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DKP8P8EM Download Komatsu Pc138us 8 Pc138uslc 8 Excavator Manual
DKP8P8EM Download Komatsu Pc138us 8 Pc138uslc 8 Excavator Manual
HYDRAULIC
EXCAVATOR
PC138US -8
PC138USLC -8
PC138US- 20001
SERIAL NUMBERS and up
PC138USLC- 20001
SEN01977-02
PC138US-8
PC138USLC-8
PC138US, USLC-8 1
SEN01977-02 00 Index and foreword
01 Specification SEN01970-01
Specification and technical data SEN01979-01
40 Troubleshooting SEN01974-01
Failure code table and fuse locations SEN02461-01
General information on troubleshooting SEN02462-00
Troubleshooting by failure code, Part 1 SEN02463-01
Troubleshooting by failure code, Part 2 SEN02464-01
Troubleshooting by failure code, Part 3 SEN02465-01
Troubleshooting by failure code, Part 4 SEN02466-00
Troubleshooting of electrical system (E-mode) SEN02467-00
2 PC138US, USLC-8
00 Index and foreword SEN01977-02
PC138US, USLC-8 3
SEN01977-02 00 Index and foreword
Table of contents 1
00 Index and foreword
Index SEN01977-02
Composition of shop manual....................................................................................................... 2
Table of contents ......................................................................................................................... 4
01 Specification
Specification and technical data SEN01979-01
Specification dimension drawings ............................................................................................... 2
Working range diagram ............................................................................................................... 3
Specifications .............................................................................................................................. 4
List of weights.............................................................................................................................. 10
Table of fuel, coolant and lubricants ............................................................................................ 14
4 PC138US, USLC-8
00 Index and foreword SEN01977-02
PC138US, USLC-8 5
SEN01977-02 00 Index and foreword
40 Troubleshooting
Failure code table and fuse locations SEN02461-01
Failure code table........................................................................................................................ 2
Fuse locations ............................................................................................................................. 6
General information on troubleshooting SEN02462-00
Points to remember when troubleshooting.................................................................................. 2
Sequence of events in troubleshooting ....................................................................................... 3
Checks before troubleshooting.................................................................................................... 4
Classification and procedures for troubleshooting ...................................................................... 5
Information in troubleshooting table ............................................................................................ 6
Phenomena looking like troubles and troubleshooting Nos. ....................................................... 8
Wiring table for connector pin numbers....................................................................................... 11
T-adapter box and T-adapter table .............................................................................................. 44
Troubleshooting by failure code, Part 1 SEN02463-01
Failure code [989L00] Engine controller lock caution 1............................................................... 3
Failure code [989M00] Engine controller lock caution 2.............................................................. 3
Failure code [989N00] Engine controller lock caution 3 .............................................................. 4
Failure code [AB00KE] Charge voltage low ................................................................................ 6
Failure code [B@BAZG] Eng oil press. low................................................................................. 8
Failure code [B@BAZK] Eng oil level low ................................................................................... 8
Failure code [B@BCNS] Eng coolant overheat........................................................................... 9
Failure code [B@HANS] Hydr oil overheat ................................................................................. 9
Failure code [CA111] ECM critical internal failure ....................................................................... 10
Failure code [CA115] Eng. Ne and Bkup speed sensor error ..................................................... 13
Failure code [CA122] Charge air press sensor high error........................................................... 14
Failure code [CA123] Charge air press sensor low error ............................................................ 16
Failure code [CA131] Throttle sensor high error ......................................................................... 18
Failure code [CA132] Throttle sensor low error........................................................................... 20
Failure code [CA144] Coolant temp. sensor high error ............................................................... 21
Failure code [CA145] Coolant temp. sensor low error ................................................................ 22
Failure code [CA153] Charge air temp. sensor high error........................................................... 23
Failure code [CA154] Charge air temp. sensor low error ............................................................ 24
Failure code [CA187] Sensor sup. 2 volt. low error..................................................................... 24
Failure code [CA221] Ambient air press. sensor high error ........................................................ 26
Failure code [CA222] Ambient air press. sensor low error.......................................................... 28
Failure code [CA227] Sensor sup. 2 volt. high error ................................................................... 30
Failure code [CA234] Eng. overspeed ........................................................................................ 32
Failure code [CA238] Ne speed sensor sup. volt. error .............................................................. 34
Failure code [CA271] IMV/PCV1 short error ............................................................................... 36
Failure code [CA272] IMV/PCV1 open error ............................................................................... 37
Failure code [CA322] Injector #1 (L #1) system open/short error ............................................... 38
Failure code [CA324] Injector #3 (L/B #3) system open/short error ............................................ 40
Failure code [CA331] Injector #2 (L/B #2) system open/short error ............................................ 42
Failure code [CA332] Injector #4 (L/B #4) system open/short error ............................................ 44
Troubleshooting by failure code, Part 2 SEN02464-01
Failure code [CA351] Inj. drive circuit error ................................................................................. 3
6 PC138US, USLC-8
00 Index and foreword SEN01977-02
PC138US, USLC-8 7
SEN01977-02 00 Index and foreword
8 PC138US, USLC-8
00 Index and foreword SEN01977-02
H-24 When upper structure stops swinging, it makes large sound ............................................. 24
H-25 Hydraulic drift of swing is large........................................................................................... 25
H-26 Flow rate in attachment circuit cannot be adjusted ............................................................ 26
Troubleshooting of engine (S-mode) SEN02469-01
Method of using troubleshooting chart ........................................................................................ 4
S-1 Starting performance is poor ................................................................................................ 8
S-2 Engine does not start............................................................................................................ 9
S-3 Engine does not pick up smoothly........................................................................................ 12
S-4 Engine stops during operations ............................................................................................ 13
S-5 Engine does not rotate smoothly .......................................................................................... 14
S-6 Engine lacks output (or lacks power).................................................................................... 15
S-7 Exhaust smoke is black (incomplete combustion)................................................................ 16
S-8 Oil consumption is excessive (or exhaust smoke is blue) .................................................... 17
S-9 Oil becomes contaminated quickly ....................................................................................... 18
S-10 Fuel consumption is excessive........................................................................................... 19
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) ................................. 20
S-12 Oil pressure drops .............................................................................................................. 21
S-13 Oil level rises (Entry of coolant or fuel)............................................................................... 22
S-14 Coolant temperature becomes too high (overheating) ....................................................... 23
S-15 Abnormal noise is made ..................................................................................................... 24
S-16 Vibration is excessive ......................................................................................................... 25
PC138US, USLC-8 9
SEN01977-02 00 Index and foreword
10 PC138US, USLC-8
00 Index and foreword SEN01977-02
PC138US, USLC-8 11
SEN01977-02 00 Index and foreword
© 2007 KOMATSU
All Rights Reserved
Printed in Japan 10-07 (02)
12 PC138US, USLC-8
SEN01978-01
PC138US-8
PC138USLC-8
PC138US, USLC-8 1
SEN01978-01 00 Index and foreword
2 PC138US, USLC-8
00 Index and foreword SEN01978-01
3) When disassembling or assembling, sup- 8) When removing piping, stop the fuel or oil
port the machine with blocks, jacks, or from spilling out. If any fuel or oil drips
stands before starting work. onto the floor, wipe it up immediately. Fuel
4) Remove all mud and oil from the steps or or oil on the floor can cause you to slip
other places used to get on and off the and can even start fires.
machine. Always use the handrails, lad- 9) As a general rule, do not use gasoline to
ders or steps when getting on or off the wash parts. Do not use it to clean electri-
m a c h i n e . N e v e r j u m p o n o r o ff t h e cal parts, in particular.
machine. If it is impossible to use the 10) Be sure to assemble all parts again in their
handrails, ladders or steps, use a stand to original places. Replace any damaged
provide safe footing. parts and parts which must not be reused
with new parts. When installing hoses and
3. Precautions during work wires, be sure that they will not be dam-
1) Before disconnecting or removing compo- aged by contact with other parts when the
nents of the oil, water, or air circuits, first machine is operated.
release the pressure completely from the 11) When installing high pressure hoses,
circuit. When removing the oil filler cap, a make sure that they are not twisted. Dam-
drain plug, or an oil pressure pickup plug, aged tubes are dangerous, so be
loosen it slowly to prevent the oil from extremely careful when installing tubes for
spurting out. high pressure circuits. In addition, check
2) The coolant and oil in the circuits are hot t h a t c o n n e c t i n g pa r ts a r e c o r r e c t l y
when the engine is stopped, so be careful installed.
not to get scalded. Wait for the oil and 12) When assembling or installing parts,
coolant to cool before carrying out any always tighten them to the specified
work on the oil or water circuits. torques. When installing protective parts
3) Before starting work, stop the engine. such as guards, or parts which vibrate vio-
When working on or around a rotating lently or rotate at high speed, be particu-
part, in particular, stop the engine. When l a r ly c a r e fu l t o c he c k t h a t t h e y ar e
checking the machine without stopping installed correctly.
the engine (measuring oil pressure, 13) When aligning 2 holes, never insert your
revolving speed, temperature, etc.), take fingers or hand. Be careful not to get your
extreme care not to get rolled or caught in fingers caught in a hole.
rotating parts or moving parts. 14) When measuring hydraulic pressure,
4) Before starting work, remove the leads check that the measuring tools are cor-
from the battery. Always remove the lead rectly assembled.
from the negative (–) terminal first. 15) Take care when removing or installing the
5) When raising a heavy component (heavier tracks of track-type machines. When
than 25 kg), use a hoist or crane. Before removing the track, the track separates
starting work, check that the slings (wire suddenly, so never let anyone stand at
ropes, chains, and hooks) are free from either end of the track.
damage. Always use slings which have 16) If the engine is operated for a long time in
ample capacity and install them to proper a place which is not ventilated well, you
places. Operate the hoist or crane slowly may suffer from gas poisoning. Accord-
to prevent the component from hitting any ingly, open the windows and doors to ven-
other part. Do not work with any part still tilate well.
raised by the hoist or crane.
6) When removing a cover which is under
internal pressure or under pressure from a
spring, always leave 2 bolts in diagonal
positions. Loosen those bolts gradually
and alternately to release the pressure,
and then remove the cover.
7) When removing components, be careful
not to break or damage the electrical wir-
ing. Damaged wiring may cause electrical
fires.
PC138US, USLC-8 3
SEN01978-01 00 Index and foreword
4 PC138US, USLC-8
00 Index and foreword SEN01978-01
q If the load is unstable or the wire rope 13) If the hoist stops because of a power fail-
or chains are twisted, lower the load ure, turn the power switch OFF. When
and lift it up again. turning on a switch which was turned OFF
q Do not lift up the load slantingly. by the electric shock prevention earth
13) When lifting down a load, observe the fol- leakage breaker, check that the devices
lowing. related to that switch are not in operation
q When lifting down a load, stop it tem- state.
porarily at 30 cm above the floor, and 14) If you find an obstacle around the hoist,
then lower it slowly. stop the operation.
q Check that the load is stable, and 15) After finishing the work, stop the hoist at
then remove the sling. the specified position and raise the hook
q Remove kinks and dirt from the wire to at least 2 m above the floor. Do not
ropes and chains used for the sling leave the sling installed to the hook.
work, and put them in the specified
place. 7. Selecting wire ropes
1) Select adequate ropes depending on the
5. Precautions for using mobile crane weight of parts to be hoisted, referring to
a Read the Operation and Maintenance the table below.
Manual of the crane carefully in advance
and operate the crane safely. Wire ropes
(Standard “Z” twist ropes without galvanizing)
6. Precautions for using overhead hoist crane (JIS G3525, No. 6, Type 6X37-A)
k When raising a heavy part (heavier Nominal
Allowable load
than 25 kg), use a hoist, etc. In Disas- diameter of rope
sembly and assembly, the weight of a mm kN ton
part heavier than 25 kg is indicated 10 8.8 0.9
after the mark of 4. 12 12.7 1.3
1) Before starting work, inspect the wire 14 17.3 1.7
ropes, brake, clutch, controller, rails, over
16 22.6 2.3
wind stop device, electric shock preven-
18 28.6 2.9
tion earth leakage breaker, crane collision
20 35.3 3.6
prevention device, and power application
warning lamp, and check safety. 25 55.3 5.6
2) Observe the signs for sling work. 30 79.6 8.1
3) Operate the hoist at a safe place. 40 141.6 14.4
4) Check the direction indicator plates (east, 50 221.6 22.6
west, south, and north) and the directions 60 318.3 32.4
of the control buttons without fail.
5) Do not sling a load slantingly. Do not move a The allowable load is one-sixth of the
the crane while the slung load is swinging. breaking strength of the rope used
6) Do not raise or lower a load while the (Safety coefficient: 6).
crane is moving longitudinally or laterally.
7) Do not drag a sling.
8) When lifting up a load, stop it just after it
leaves the ground and check safety, and
then lift it up.
9) Consider the travel route in advance and
lift up a load to a safe height.
10) Place the control switch on a position
where it will not be an obstacle to work
and passage.
11) After operating the hoist, do not swing the
control switch.
12) Remember the position of the main switch
so that you can turn off the power immedi-
ately in an emergency.
PC138US, USLC-8 5
SEN01978-01 00 Index and foreword
2) Connection
1] When installing the air conditioner cir-
cuit hoses and tubes, take care that
dirt, dust, water, etc. will not enter
them.
2] When connecting the air conditioner
hoses and tubes, check that O-rings
(1) are fitted to their joints.
3] Check that each O-ring is not dam-
aged or deteriorated.
4] When connecting the refrigerant pip-
ing, apply compressor oil for refriger-
ant (R134a) (DENSO: ND-OIL8,
ZEXEL: ZXL100PG (equivalent to
PAG46)) to its O-rings.
6 PC138US, USLC-8
00 Index and foreword SEN01978-01
q Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one
of them is required, consult KOMATSU distributors.
q Materials and specifications are subject to change without notice.
q Shop manuals are divided into the “Chassis volume” and “Engine volume”. For the engine unit, see the
engine volume of the engine model mounted on the machine.
01. Specification
This section explains the specifications of the machine.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is
divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also
explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
q Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q Engine volume
This section explains the method of reproducing, repairing, and replacing parts.
PC138US, USLC-8 7
SEN01978-01 00 Index and foreword
3. Filing method
File by the brochures in the correct order of the form number printed in the shop manual composition
table.
q Revisions
Revised brochures are shown in the shop manual composition table.
4. Symbols
Important safety and quality portions are marked with the following symbols so that the shop manual will
be used practically.
4
Weight of parts of component or parts. Caution necessary when
Weight
selecting hoisting wire, or when working posture is important, etc.
3
Tightening Places that require special attention for tightening torque during
torque assembly.
5
Oil, coolant Places where oil, etc. must be added, and capacity.
6
Drain Places where oil, etc. must be drained, and quantity to be drained.
5. Units
In this shop manual, the units are indicated with International System of units (SI). For reference, con-
ventionally used Gravitational System of units is indicated in parentheses { }.
8 PC138US, USLC-8
00 Index and foreword SEN01978-01
Example:
Standard size Tolerance
–0.022
120
–0.126
Example:
Tolerance
Standard size
Shaft Hole
–0.030 +0.046
60
–0.076 +0
PC138US, USLC-8 9
SEN01978-01 00 Index and foreword
10 PC138US, USLC-8
00 Index and foreword SEN01978-01
PC138US, USLC-8 11
SEN01978-01 00 Index and foreword
3) Disconnections in wiring
If the wiring is held and the connectors are
pulled apart, or components are lifted with
a crane with the wiring still connected, or a
heavy object hits the wiring, the crimping
of the connector may separate, or the sol-
dering may be damaged, or the wiring
may be broken.
12 PC138US, USLC-8
00 Index and foreword SEN01978-01
PC138US, USLC-8 13
SEN01978-01 00 Index and foreword
2) Connecting connectors
1] Check the connector visually.
Check that there is no oil, dirt, or
water stuck to the connector pins
(mating portion).
Check that there is no deformation,
defective contact, corrosion, or dam-
age to the connector pins.
Check that there is no damage or
breakage to the outside of the con-
nector.
a If there is any oil, water, or dirt
stuck to the connector, wipe it off
with a dry cloth. If any water has
got inside the connector, warm
the inside of the wiring with a
dryer, but be careful not to make
it too hot as this will cause short
circuits.
a If there is any damage or break-
age, replace the connector.
2] Fix the connector securely.
Align the position of the connector
correctly, and then insert it securely.
For connectors with the lock stopper,
push in the connector until the stop-
per clicks into position.
3] Correct any protrusion of the boot and
any misalignment of the wiring har-
ness.
For connectors fitted with boots, cor-
rect any protrusion of the boot. In
addition, if the wiring harness is mis-
aligned, or the clamp is out of posi-
tion, adjust it to its correct position.
a If the connector cannot be cor-
rected easily, remove the clamp
and adjust the position.
q If the connector clamp has been
removed, be sure to return it to
its original position. Check also
that there are no loose clamps.
14 PC138US, USLC-8
00 Index and foreword SEN01978-01
3) Heavy duty wire connector (DT 8-pole, 12- q Disconnection q Connection (Example of
pole) incomplete setting of (a))
Disconnection (Left of figure)
While pressing both sides of locks (a)
and (b), pull out female connector (2).
Connection (Right of figure)
1] Push in female connector (2) horizon-
tally until the lock clicks.
Arrow: 1)
2] Since locks (a) and (b) may not be set
completely, push in female connector
(2) while moving it up and down until
the locks are set normally.
Arrow: 1), 2), 3)
a Right of figure: Lock (a) is pulled
down (not set completely) and
lock (b) is set completely.
(1): Male connector
(2): Female connector
(a), (b): Locks
PC138US, USLC-8 15
SEN01978-01 00 Index and foreword
16 PC138US, USLC-8
00 Index and foreword SEN01978-01
4. Handling controller
1) The controller contains a microcomputer
and electronic control circuits. These con-
trol all of the electronic circuits on the
machine, so be extremely careful when
handling the controller.
2) Do not place objects on top of the control-
ler.
3) Cover the control connectors with tape or
a vinyl bag. Never touch the connector
contacts with your hand.
4) During rainy weather, do not leave the
controller in a place where it is exposed to
rain.
5) Do not place the controller on oil, water, or
soil, or in any hot place, even for a short
time. (Place it on a suitable dry stand).
6) Precautions when carrying out arc welding
When carrying out arc welding on the
body, disconnect all wiring harness con-
nectors connected to the controller. Fit an
arc welding ground close to the welding
point.
PC138US, USLC-8 17
SEN01978-01 00 Index and foreword
3. Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from
entering. If the opening is left open or is
blocked with a rag, there is danger of dirt
entering or of the surrounding area being
made dirty by leaking oil so never do this. Do
not simply drain oil out onto the ground, but
collect it and ask the customer to dispose of it,
or take it back with you for disposal.
18 PC138US, USLC-8
00 Index and foreword SEN01978-01
6. Flushing operations
After disassembling and assembling the equip-
ment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit. Normally, flushing is
carried out twice: primary flushing is carried
out with flushing oil, and secondary flushing is
carried out with the specified hydraulic oil.
7. Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the
machine, carry out oil cleaning to remove the
sludge or contaminants in the hydraulic oil cir-
cuit. The oil cleaning equipment is used to
remove the ultra fine (about 3 m) particles that
the filter built in the hydraulic equipment can-
not remove, so it is an extremely effective
device.
PC138US, USLC-8 19
SEN01978-01 00 Index and foreword
20 PC138US, USLC-8
00 Index and foreword SEN01978-01
q 114 engine
q 107 engine
PC138US, USLC-8 21
SEN01978-01 00 Index and foreword
Example)
Injection pressure control valve of fuel
supply pump: PCV (SUMITOMO-2)
Example)
Speed sensor of fuel supply pump:
G (SUMITOMO-3)
a Pull the connector straight up.
22 PC138US, USLC-8
00 Index and foreword SEN01978-01
In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by sym-
bols. The electric wire code is helpful in understanding the electric circuit diagram.
Example: AEX 0.85 L - - - Indicates blue, heat-resistant, low-voltage wire for automobile, having nomi-
nal No. of 0.85
Indicates color of wire by color code.
Color codes are shown in Table 3.
(Table 1)
Using
Sym-
Type Material temperature Example of use
bol
range (°C)
Low-voltage Conduc- Annealed copper for elec-
General wiring
wire for AV tor tric appliance
(Nominal No. 5 and above)
automobile Insulator Soft polyvinyl chloride
Thin-cover Conduc- Annealed copper for elec- –30 to +60
low-voltage tor tric appliance General wiring
AVS
wire for (Nominal No. 3 and below)
automobile Insulator Soft polyvinyl chloride
Heat-resis- Conduc- Annealed copper for elec-
General wiring in extremely
tant low-volt- tor tric appliance
AEX –50 to +110 cold district, wiring at high-tem-
age wire for Heat-resistant crosslinked
Insulator perature place
automobile polyethylene
PC138US, USLC-8 23
SEN01978-01 00 Index and foreword
2. Dimensions
(Table 2)
Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5
Number of
strands/Diam- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32
eter of strand
Conductor
Sectional
0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23
area (mm2)
d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0
AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6 –
Cov-
AV Standard – – – – – – – 4.6
er D
AEX Standard 2.0 2.2 2.7 3.0 3.1 – 3.8 4.6
24 PC138US, USLC-8
00 Index and foreword SEN01978-01
(Table 3)
Color Code Color of wire Color Code Color of wire
B Black LgW Light green & White
Br Brown LgY Light green & Yellow
BrB Brown & Black LR Blue & Red
BrR Brown & Red LW Blue & White
BrW Brown & White LY Blue & Yellow
BrY Brown & Yellow O Orange
Ch Charcoal P Pink
Dg Dark green R Red
G Green RB Red & Black
GB Green & Black RG Red & Green
GL Green & Blue RL Red & Blue
Gr Gray RW Red & White
GR Green & Red RY Red & Yellow
GW Green & White Sb Sky Blue
GY Green & Yellow Y Yellow
L Blue YB Yellow & Black
LB Blue & Black YG Yellow &Green
Lg Light green YL Yellow & Blue
LgB Light green & Black YR Yellow & Red
LgR Light green & Red YW Yellow & White
Remarks: In a color code consisting of 2 colors, the first color is the color of the background and
the second color is the color of the marking.
Example: “GW” means that the background is Green and marking is White.
(Table 4)
Type of wire AVS or AV AEX
Charge R WG – – – – R –
Ground B – – – – – B –
Start R – – – – – R –
Light RW RB RY RG RL – D –
Instrument Y YR YB YG YL YW Y Gr
Signal G GW GR GY GB GL G Br
L LW LR LY LB – L –
Type of
Br BrW BrR BrY BrB – – –
circuit
Lg LgR LgY LgB LgW – – –
O – – – – – – –
Others Gr – – – – – – –
P – – – – – – –
Sb – – – – – – –
Dg – – – – – – –
Ch – – – – – – –
PC138US, USLC-8 25
SEN01978-01 00 Index and foreword
3) If the part is not under hydraulic pressure, the following corks can be used.
Nominal Dimensions
Part Number
number D d L
06 07049-00608 6 5 8
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12
12 07049-01215 12 10 15
14 07049-01418 14 11.5 18
16 07049-01620 16 13.5 20
18 07049-01822 18 15 22
20 07049-02025 20 17 25
22 07049-02228 22 18.5 28
24 07049-02430 24 20 30
27 07049-02734 27 22.5 34
26 PC138US, USLC-8
00 Index and foreword SEN01978-01
a When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other
hydraulic equipment removed for repair, always bleed the air as follows:
1) Start the engine and run at low idle.
2) Operate the work equipment control lever to operate the hydraulic cylinder 4 – 5 times, stopping the
cylinder 100 mm from the end of its stroke.
3) Next, operate the hydraulic cylinder 3 – 4 times to the end of its stroke.
4) After doing this, run the engine at normal speed.
a When using the machine for the first time after repair or long storage, follow the same procedure.
PC138US, USLC-8 27
SEN01978-01 00 Index and foreword
28 PC138US, USLC-8
00 Index and foreword SEN01978-01
Type 1
1. Disconnection
1) Hold adapter (1) and push hose joint (2)
into mating adapter (3). (Fig. 1)
a The adapter can be pushed in about
3.5 mm.
a Do not hold rubber cap portion (4).
2) After hose joint (2) is pushed into adapter
(3), press rubber cap portion (4) against
adapter (3) until it clicks. (Fig. 2)
3) Hold hose adapter (1) or hose (5) and pull
it out. (Fig. 3)
a Since some hydraulic oil flows out,
prepare an oil receiving container.
2. Connection
1) Hold hose adapter (1) or hose (5) and
insert it in mating adapter (3), aligning
them with each other. (Fig. 4)
a Do not hold rubber cap portion (4).
2) After inserting the hose in the mating
adapter perfectly, pull it back to check its
connecting condition. (Fig. 5)
a When the hose is pulled back, the
rubber cap portion moves toward the
hose about 3.5 mm. This does not
indicate abnormality, however.
PC138US, USLC-8 29
SEN01978-01 00 Index and foreword
Type 2
1. Disconnection
1) Hold the tightening portion and push body
(7) straight until sliding prevention ring (6)
contacts contact surface (a) of the hexag-
onal portion at the male end. (Fig. 6)
2) While holding the condition of Step 1), turn
lever (8) to the right (clockwise). (Fig. 7)
3) While holding the condition of Steps 1)
and 2), pull out whole body (7) to discon-
nect it. (Fig. 8)
2. Connection
q Hold the tightening portion and push body
(7) straight until sliding prevention ring (6)
contacts contact surface (a) of the hexag-
onal portion at the male end. (Fig. 9)
30 PC138US, USLC-8
00 Index and foreword SEN01978-01
Type 3
1. Disconnection
1) Hold the tightening portion and push body
(9) straight until sliding prevention ring (8)
contacts contact surface (b) of the hexag-
onal portion at the male end. (Fig. 10)
2) While holding the condition of Step 1),
push cover (10) straight until it contacts
contact surface (b) of the hexagonal por-
tion at the male end. (Fig. 11)
3) While holding the condition of Steps 1)
and 2), pull out whole body (9) to discon-
nect it. (Fig. 12)
2. Connection
q Hold the tightening portion and push body
(9) straight until the sliding prevention ring
contacts contact surface (b) of the hexag-
onal portion at the male end. (Fig. 13)
PC138US, USLC-8 31
SEN01978-01 00 Index and foreword
a Fig. A a Fig. B
32 PC138US, USLC-8
00 Index and foreword SEN01978-01
PC138US, USLC-8 33
SEN01978-01 00 Index and foreword
5. Table of tightening torques for hoses (taper seal type and face seal type)
a Unless there are special instructions, tighten the hoses (taper seal type and face seal type) to the
torque below.
a Apply the following torque when the threads are coated (wet) with engine oil.
6. Table of tightening torques for 102, 107 and 114 engine series (Bolts and nuts)
a Unless there are special instructions, tighten the metric bolts and nuts of the 102, 107 and 114
engine series to the torque below.
Tightening torque
Thread size
Bolts and nuts
mm Nm kgm
6 10 ± 2 1.02 ± 0.20
8 24 ± 4 2.45 ± 0.41
10 43 ± 6 4.38 ± 0.61
12 77 ± 12 7.85 ± 1.22
14 — —
7. Table of tightening torques for 102, 107 and 114 engine series (Eye joints)
a Unless there are special instructions, tighten the metric eye joints of the 102, 107 and 114 engine
series to the torque below.
34 PC138US, USLC-8
00 Index and foreword SEN01978-01
8. Table of tightening torques for 102, 107 and 114 engine series (Taper screws)
a Unless there are special instructions, tighten the taper screws (unit: inch) of the 102, 107 and 114
engine series to the torque below.
PC138US, USLC-8 35
SEN01978-01 00 Index and foreword
Conversion table 1
Method of using the conversion table
The conversion table in this section is provided to enable simple conversion of figures. For details of the
method of using the conversion table, see the example given below.
Example: Method of using the conversion table to convert from millimeters to inches
36 PC138US, USLC-8
00 Index and foreword SEN01978-01
Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
PC138US, USLC-8 37
SEN01978-01 00 Index and foreword
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
kgm to ft.lb
1 kgm = 7.233 ft.lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
38 PC138US, USLC-8
00 Index and foreword SEN01978-01
kg/cm2 to lb/in2
1 kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1,010 1,024 1,038 1,053 1,067 1,081 1,095 1,109 1,124
80 1,138 1,152 1,166 1,181 1,195 1,209 1,223 1,237 1,252 1,266
90 1,280 1,294 1,309 1,323 1,337 1,351 1,365 1,380 1,394 1,408
100 1,422 1,437 1,451 1,465 1,479 1,493 1,508 1,522 1,536 1,550
110 1,565 1,579 1,593 1,607 1,621 1,636 1,650 1,664 1,678 1,693
120 1,707 1,721 1,735 1,749 1,764 1,778 1,792 1,806 1,821 1,835
130 1,849 1,863 1,877 1,892 1,906 1,920 1,934 1,949 1,963 1,977
140 1,991 2,005 2,020 2,034 2,048 2,062 2,077 2,091 2,105 2,119
150 2,134 2,148 2,162 2,176 2,190 2,205 2,219 2,233 2,247 2,262
160 2,276 2,290 2,304 2,318 2,333 2,347 2,361 2,375 2,389 2,404
170 2,418 2,432 2,446 2,460 2,475 2,489 2,503 2,518 2,532 2,546
180 2,560 2,574 2,589 2,603 2,617 2,631 2,646 2,660 2,674 2,688
190 2,702 2,717 2,731 2,745 2,759 2,773 2,788 2,802 2,816 2,830
200 2,845 2,859 2,873 2,887 2,901 2,916 2,930 2,944 2,958 2,973
210 2,987 3,001 3,015 3,030 3,044 3,058 3,072 3,086 3,101 3,115
220 3,129 3,143 3,158 3,172 3,186 3,200 3,214 3,229 3,243 3,257
230 3,271 3,286 3,300 3,314 3,328 3,343 3,357 3,371 3,385 3,399
240 3,414 3,428 3,442 3,456 3,470 3,485 3,499 3,513 3,527 3,542
PC138US, USLC-8 39
SEN01978-01 00 Index and foreword
Temperature
Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centi-
grade temperature reading or vice versa is to enter the accompanying table in the center (boldface column)
of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
When convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of Fahren-
heit temperatures and read the corresponding Centigrade temperature in the column at the left.
When convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of Centi-
grade values, and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8°F
°C °F °C °F °C °F °C °F
–40.4 –40 –40.0 –11.7 11 51.8 7.8 46 114.8 27.2 81 177.8
–37.2 –35 –31.0 –11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
–34.4 –30 –22.0 –10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
–31.7 –25 –13.0 –10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
–28.9 –20 –4.0 –9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
40 PC138US, USLC-8
00 Index and foreword SEN01978-01
PC138US, USLC-8 41
SEN01978-01
© 2007 KOMATSU
All Rights Reserved
Printed in Japan 10-07 (02)
42
SEN01979-01
PC138US-8
PC138USLC-8
01 Specification
Specification and technical data
Specification dimension drawings ................................................................................................................... 2
Working range diagram................................................................................................................................... 3
Specifications .................................................................................................................................................. 4
List of weights ............................................................................................................................................... 10
Table of fuel, coolant and lubricants.............................................................................................................. 14
PC138US, USLC-8 1
SEN01979-01 01 Specification
a There are net value and gross value for displaying engine rate output. Gross value is measurement of
engine alone, and net value is measurement with close to on-board conditions.
2 PC138US, USLC-8
01 Specification SEN01979-01
PC138US, USLC-8 3
SEN01979-01 01 Specification
Specifications 1
PC138US-8
Machine model
Standard specification Reinforced blade specification
Serial No. 20001 and up
Bucket capacity m3 0.50 0.50
Operating weight kg 13,400 14,050
Max. digging depth mm 5,480 5,480
Max. vertical wall depth mm 4,900 4,900
Working ranges
The values are based on the machine with the triple grouser shoe.
4 PC138US, USLC-8
01 Specification SEN01979-01
1
PC138USLC-8
Standard specification Reinforced blade specification
20001 and up
0.50 0.50
14,500 15,150
5,480 5,480
4,900 4,900
8,300 8,300
8,180 8,180
9,340 9,340
6,840 6,840
— 470
— 490
93.2{9,500} 93.2{9,500}
11.0 11.0
19.0 19.0
2.9/5.1 2.9/5.1
35 35
35.3{0.36} 37.3{0.38}
7,390 8,040
2,590 2,590
2,850 2,850
2,830 2,830
900 900
395 395
1,545 1,545
1,980 1,980
6,770 6,770
2,590 2,590
3,870 3,870
3,140 3,140
1,990 1,990
2,145 2,145
— 2,590 x 590
PC138US, USLC-8 5
SEN01979-01 01 Specification
PC138US-8
Machine model
Standard specification Reinforced blade specification
Serial No. 20001 and up
Model SAA4D95LE-5
4-cycle, water-cooled, in-line, vertical, direct injection, with
Type
turbocharger and air cooled aftercooler
No. of cylinders-bore x stroke mm 95 x 115
Piston displacement l{cc} 3.260{3,260}
Rated horsepower
• Net [ISO 9249/SAE J1349] kW{HP}/rpm 68.4{91.7}/2,200
• Gross [SAE J1995] 72.1{96.6}/2,200
Performance
6 PC138US, USLC-8
01 Specification SEN01979-01
PC138USLC-8
Standard specification Reinforced blade specification
20001 and up
SAA4D95LE-5
4-cycle, water-cooled, in-line, vertical, direct injection, with
turbocharger and air cooled aftercooler
95 x 115
3.260{3,260}
68.4{91.7}/2,200
72.1{96.6}/2,200
350{35.7}/1,500
2,300
1,100
224{167}
24 V, 4.5 kW
24 V, 35 A
12 V, 64 Ah x 2
4-array aluminum mesh core
Aluminum mesh core
2 on each side
8 on each side
Assembly-type triple grouser shoe, 46 on each side
Assembly-type road liner, 46 on each side
34.8{355}
6-spool type x 1
Hydraulic type
PC138US, USLC-8 7
SEN01979-01 01 Specification
PC138US-8
Machine model
Standard specification Reinforced blade specification
Serial No. 20001 and up
Type Reciprocating piston type Reciprocating piston type
Boom cylinder
8 PC138US, USLC-8
01 Specification SEN01979-01
PC138USLC-8
Standard specification Reinforced blade specification
20001 and up
Reciprocating piston type Reciprocating piston type
105 105
70 70
1,055 1,055
2,555 2,555
1,500 1,500
Reciprocating piston type Reciprocating piston type
110 110
75 75
1,175 1,175
2,798 2,798
1,623 1,623
Reciprocating piston type Reciprocating piston type
95 95
65 65
885 885
2,263 2,263
1,378 1,378
— Reciprocating piston type
— 110
— 75
— 181
— 870
— 689
PC138US, USLC-8 9
SEN01979-01 01 Specification
List of weights 1
k This weight table is prepared for your reference when handling or transporting the components.
Unit: kg
PC138US-8
Machine model
Standard specification Blade specification
Serial No. 20001 and up
Engine assembly (excl. coolant and oil) 458 458
• Engine (excl. coolant and oil) 332 332
• Engine mount 18.1 18.1
• PTO 5.5 5.5
• Hydraulic pump 102 102
• • Filter (for KA specification) (6 x 2) (6 x 2)
Cooling assembly (excl. coolant and oil) 82.2 82.2
• Radiator (excl. coolant) 7.9 7.9
• Oil cooler (excl. oil) 10.2 10.2
• Aftercooler 8.1 8.1
• Fuel cooler (excl. fuel) 0.7 0.7
Revolving frame 1,400 1,400
Operator cab 375 375
Operator seat 38 38
Fuel cooler (excl. fuel) 90.6 90.6
Hydraulic tank (excl. hydraulic oil) 79.5 79.5
Control valve 95 99
Counterweight 3,240 2,855
Added counterweight 500 500
Swing motor (incl. brake valve) 20 20
Swing circle 152.6 152.6
Swing machinery 71.6 71.6
Center swivel joint 28.6 43.6
Track frame assembly (excl. track shoe) 2,300 2,410
• Track frame 1,305 1,415
• Idler assembly 79 x 2 79 x 2
• Recoil spring assembly 69 x 2 69 x 2
• Carrier roller 16.5 x 2 16.5 x 2
• Track roller 22 x 14 22 x 14
• Travel motor (with final drive) 145 x 2 145 x 2
• Sprocket 33.1 x 2 33.1 x 2
Track shoe assembly
• Triple grouser shoe (500 mm) 755 x 2 755 x 2
• Triple grouser shoe (600 mm) 840 x 2 840 x 2
• Triple grouser shoe (700 mm) 930 x 2 930 x 2
• Triple grouser shoe (750 mm) 975 x 2 975 x 2
• Single grouser shoe (510 mm) 860 x 2 860 x 2
• City pad shoe (500 mm) 750 x 2 750 x 2
• City pad shoe (600 mm) — —
• Road liner (500 mm) 810 x 2 810 x 2
10 PC138US, USLC-8
01 Specification SEN01979-01
Unit: kg
PC138USLC-8
Standard specification Blade specification
20001 and up
458 458
332 332
18.1 18.1
5.5 5.5
102 102
(6 x 2) (6 x 2)
82.2 82.2
7.9 7.9
10.2 10.2
8.1 8.1
0.7 0.7
1,400 1,400
375 375
39 39
90.6 90.6
79.5 79.5
95 99
3,240 2,855
500 500
20 20
152.6 152.6
71.6 71.6
28.6 43.6
2,540 2,680
1,460 1,600
79 x 2 79 x 2
71 x 2 71 x 2
16.5 x 4 16.5 x 4
22 x 16 22 x 16
145 x 2 145 x 2
33.1 x 2 33.1 x 2
805 x 2 805 x 2
895 x 2 895 x 2
995 x 2 995 x 2
— —
— —
800 x 2 800 x 2
895 x 2 895 x 2
870 x 2 870 x 2
PC138US, USLC-8 11
SEN01979-01 01 Specification
Unit: kg
PC138US-8
Machine model
Standard specification Blade specification
Serial No. 20001 and up
Boom assembly 820 820
Arm assembly 356 356
Bucket link assembly 85.6 85.6
Bucket assembly
• 955 mm width (incl. side cutter) — —
• 980 mm width (incl. side cutter) 399 399
Blade assembly
• Reinforced blade (BOC type, incl. BOC) — 688
• Blade (edge-welding type) — 668
• Reinforced wide blade (BOC type, incl. BOC) — 702
• Wide blade (edge-welding type) — 682
Boom cylinder assembly 101.3 x 2 101.3 x 2
Arm cylinder assembly 125.3 125.3
Bucket cylinder assembly 77.8 77.8
Blade cylinder assembly — 59.5 x 2
12 PC138US, USLC-8
01 Specification SEN01979-01
Unit: kg
PC138USLC-8
Standard specification Blade specification
20001 and up
820 820
356 356
85.6 85.6
— —
399 399
— 688
— 668
— 702
— 682
101.3 x 2 101.3 x 2
125.3 125.3
77.8 77.8
— 59.5 x 2
PC138US, USLC-8 13
SEN01979-01 01 Specification
14 PC138US, USLC-8
01 Specification SEN01979-01
Unit: l
Reservoir Specified capacity Refill capacity
Engine oil pan 11.5 11.0
Swing machinery case 2.5 2.5
Final drive case (each side) 2.1 2.1
PTO case 0.75 0.75
Hydraulic system 120 69
Fuel tank 195 —
Cooling system 12.4 —
PC138US, USLC-8 15
SEN01979-01 01 Specification
© 2007 KOMATSU
All Rights Reserved
Printed in Japan 02-07 (02)
16 PC138US, USLC-8
SEN02545-01
HYDRAULIC EXCAVATOR
PC138US-8
PC138USLC-8
PC138US, USLC-8 1
SEN02545-01 10 Structure, function and maintenance standard
Engine mount 1
2 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02545-01
PTO 1
a PTO: Abbreviation for Power Take Off
1. Flywheel
2. Coupling
3. Hydraulic pump shaft
4. Drain plug
5. Oil filler plug
6. Oil level plug
PC138US, USLC-8 3
SEN02545-01 10 Structure, function and maintenance standard
Cooling system 1
4 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02545-01
Specifications
PC138US, USLC-8 5
SEN02545-01 10 Structure, function and maintenance standard
© 2007 KOMATSU
All Rights Reserved
Printed in Japan 02-07 (02)
6 PC138US, USLC-8
SEN02546-01
HYDRAULIC EXCAVATOR
PC138US-8
PC138USLC-8
PC138US, USLC-8 1
SEN02546-01 10 Structure, function and maintenance standard
Power train 1
2 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02546-01
Swing circle 1
Unit: mm
No. Item Criteria Remedy
Basic clearance Clearance limit
1 Bearing clearance Replace
0.5 – 1.6 2.6
PC138US, USLC-8 3
SEN02546-01 10 Structure, function and maintenance standard
Swing machinery 1
4 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02546-01
Unit: mm
No. Item Criteria Remedy
Backlash between swing motor Standard clearance Clearance limit
1
shaft and No. 1 sun gear 0.07 – 0.18 0.4
Backlash between No. 1 sun
2 0.13 – 0.31 0.6
gear and No. 1 planetary gear
Backlash between No. 1 plane-
3 0.15 – 0.34 0.7
tary gear and ring gear
Backlash between No. 1 plane-
4 0.14 – 0.34 0.7
tary carrier and No. 2 sun gear
Replace
Backlash between No. 2 sun
5 0.13 – 0.31 0.6
gear and No. 2 planetary gear
Backlash between No. 2 plane-
6 0.15 – 0.34 0.7
tary gear and ring gear
Backlash between No. 2 plane-
7 0.08 – 0.19 0.4
tary carrier and swing pinion
Back lash between swing pinion
8 0.13 – 1.16 2.3
and swing circle
Outside diameter of oil seal Standard size Tolerance Repair limit Repair by hard
9 contacting surface on swing 0 chrome-plating
pinion collar 145 144.8 or replace
-0.100
PC138US, USLC-8 5
SEN02546-01 10 Structure, function and maintenance standard
© 2007 KOMATSU
All Rights Reserved
Printed in Japan 02-07 (02)
6 PC138US, USLC-8
SEN02547-01
HYDRAULIC EXCAVATOR
PC138US-8
PC138USLC-8
PC138US, USLC-8 1
SEN02547-01 10 Structure, function and maintenance standard
Track frame 1
PC138US-8
Unit: mm
No. Item Criteria Remedy
Standard size Repair limit
Track Rebuilding
84 89
1 Length at idler guide frame
Idler Rebuilding or
82 77
support replace
Track
185 193 Rebuilding
frame
2 Width at idler guide
Idler Rebuilding or
183 175
support replace
3. Idler 7. Sprocket
4. Track frame 8. Track roller
5. Carrier roller 9. Idler cushion
6. Travel motor 10. Track shoe
2 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02547-01
PC138USLC-8
Unit: mm
No. Item Criteria Remedy
Standard size Repair limit
Track Rebuilding
84 89
1 Length at idler guide frame
Idler Rebuilding or
82 77
support replace
Track
185 193 Rebuilding
frame
2 Width at idler guide
Idler Rebuilding or
183 175
support replace
3. Idler
4. Track frame
5. Carrier roller
6. Travel motor
7. Sprocket
8. Track roller
9. Idler cushion
10. Track shoe
PC138US, USLC-8 3
SEN02547-01 10 Structure, function and maintenance standard
Idler cushion 1
PC138US-8
Unit: mm
No. Item Criteria Remedy
Standard size Repair limit
Installed Installed Installed
Free length Free length
1 Recoil spring length load load Replace
84.3 kN 75.0 kN
501.4 390 489
{8,600 kg} {7,650 kg}
2. Idler Specifications
3. Support
Grease G2-LI
4. Rod
5. Recoil spring Grease quantity (cc) 118
6. Cylinder
7. U-packing
8. Pilot
9. Nut
10. Valve
11. Grease fitting
4 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02547-01
PC138USLC-8
Unit: mm
No. Item Criteria Remedy
Standard size Repair limit
Installed Installed Installed
Free length Free length
1 Recoil spring length load load Replace
93.2 kN 83.0 kN
513.3 390 500
{9,500 kg} {8,460 kg}
2. Idler Specifications
3. Support
4. Rod Grease G2-LI
5. Recoil spring Grease quantity (cc) 135
6. Cylinder
7. U-packing
8. Pilot
9. Nut
10. Valve
11. Grease fitting
PC138US, USLC-8 5
SEN02547-01 10 Structure, function and maintenance standard
Idler 1
Unit: mm
No. Item Criteria Remedy
Standard size Repair limit
1 Outside diameter of projection
527 —
Rebuilding or
2 Outside diameter of tread 489 477
replace
3 Tread depth 19 25
4 Width of projection 52 42
5 Overall width 115 107 —
Rebuilding or
6 Tread width 31.5 36.5
replace
Standard Tolerance Standard Clearance
Clearance between idler shaft size Shaft Hole clearance limit
7
and bushing -0.250 +0.074 0.250 –
54 1.5
-0.280 0 0.354
Tolerance Standard
Standard Interfer-
interfer- Replace
Interference between bushing size Shaft Hole ence limit
8 ence
and idler
+0.117 +0.030 0.057 –
61 —
+0.087 0 0.117
Side clearance of idler Standard clearance Clearance limit
9
(each side) 0.18 – 0.38 1.5
Tread thickness Basic dimension Repair limit Rebuilding or
10
(at tread center) 15 9 replace
— Oil capacity 90 cc (engine oil: SAE30CD) —
6 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02547-01
Track roller 1
Unit: mm
No. Item Criteria Remedy
Standard size Repair limit
1 Outside diameter of projection
158 — Rebuilding or
2 Outside diameter of tread 130 120 replace
3 Flange width 26.5 —
4 Overall width 176 — —
Rebuilding or
5 Tread width 35 —
replace
Standard Tolerance Standard Clearance
Clearance between Shaft and size Shaft Hole clearance limit
6
bushing -0.220 +0.190 0.250 –
50 1.5
-0.240 +0.030 0.430
Tolerance Standard
Standard Interfer-
interfer- Replace
Interference between roller and size Shaft Hole ence limit
7 ence
bushing
+0.190 0.110 –
54 ± 0.030 —
+0.140 0.220
Side clearance of track roller Standard clearance Clearance limit
8
(each side) 0.41 – 0.90 1.5
Tread thickness Standard size Repair limit Rebuilding or
9
(at tread center) 38 33 replace
— Oil capacity 145 – 155 cc (engine oil: SAE30CD) —
PC138US, USLC-8 7
SEN02547-01 10 Structure, function and maintenance standard
Carrier roller 1
Unit: mm
No. Item Criteria Remedy
Standard size Repair limit Rebuilding or
1 Outside diameter of tread
116 106 replace
2 Tread width 123 — —
Standard Tolerance Standard Clearance
Clearance between shaft and size Shaft Hole clearance limit
3
bushing +0.055 +0.261 0.145 –
40 —
+0.035 +0.200 0.226
Tolerance Standard
Standard Interfer-
interfer- Replace
Interference between collar and size Shaft Hole ence limit
4 ence
bushing
+0.061 +0.025 0.011 –
47 —
+0.036 0 0.061
Side clearance of carrier roller Standard clearance Clearance limit
5
(each side) 0.363 – 0.537 1.5
Tread thickness Standard size Repair limit
Rebuilding or
6 (at 10 mm from roller outer
17.7 12.7 replace
edge)
— Oil capacity 68 – 76 cc (engine oil: SAE30CD) —
8 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02547-01
Sprocket 1
Unit: mm
No. Item Criteria Remedy
Standard size Tolerance Repair limit
1 Wear on tooth bottom diameter +1.0
542.8 530
-2.0
2 Wear on tooth tip diameter 607.5 — 595 Rebuilding or
3 Wear on tooth tip width 27 — 22 replace
4 Wear on tooth bottom width 42 ±1.5 39
+0.465
5 Thickness at tooth bottom 109.4 103
-1.160
PC138US, USLC-8 9
SEN02547-01 10 Structure, function and maintenance standard
Track shoe 1
Triple grouser shoe, road liner, city pad shoe
10 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02547-01
Unit: mm
No. Item Criteria Remedy
Standard size Repair limit
1 Link pitch
175.3 178.3
Reverse or
Standard size Reverse
2 Bushing external diameter replace
50.6 46.6
3 Bushing thickness 9 5
Standard size Repair limit Repair or
4 Link height
90 85 replace
Link thickness (bushing press fit
5 23.9 18.9
part)
6 102.4 Replace
7 Shoe bolt pitch 86.4
8 57
9 Internal width 52.4
Repair or
10 Link Overall width 35
replace
11 Tread width 30.1
12 Pin projection 3
13 Regular bushing projection 3.75
14 Pin overall length 168 Adjust or
Bushing overall length (master replace
15 86.7
bushing)
16 Spacer thickness —
17 Bushing 58.8 – 176.5 kN {6 – 18 ton}
18 Regular pin 98.1 – 235.4 kN {10 – 24 ton}
Press-fit force —
19
Master pin 98.1 – 235.4 kN {10 – 24 ton}
(*)
PC138US, USLC-8 11
SEN02547-01 10 Structure, function and maintenance standard
Unit: mm
No. Item Criteria Remedy
Tightening torque (Nm {kgm}) Retightening angle (degree)
• Triple grouser
shoe
196 ± 20
a. Regu- • City pad shoe 90 ± 10
{20 ± 2}
lar link • Single grouser
20 Shoe bolt shoe Retighten
176 ± 20
• Road liner 60 ± 5
{18 ± 2}
Tightening torque Retightening angle Torque lower limit
b. Mas- (Nm {kgm}) (degree) (Nm {kgm})
ter link
— — —
Tolerance Standard
Standard size
Interference between bushing Shaft Hole interference
21
and link +0.387 +0.074
50.2 0.273 – 0.387
+0.347 +0.074
Interference between regular +0.150 -0.188
22 32 0.238 – 0.400
pin and link +0.050 -0.250
Tolerance Standard
Standard size
Clearance between regular pin Shaft Hole clearance
23
and bushing +0.150 +0.830 Adjust or
32 0.180 – 0.780
+0.050 +0.330 replace
Tolerance Standard
Standard size
24 Interference between master Shaft Hole interference
(*) pin and link +0.060 +0.188
32 0.208 – 0.310
+0.020 -0.250
Tolerance Standard
Standard size
25 Clearance between master pin Shaft Hole clearance
(*) and bushing -0.200 +0.830
32 0.530 – 1.130
-0.300 +0.330
26 Grouser height (road liner) 58 21 Replace
12 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02547-01
Unit: mm
No. Item Criteria Remedy
Standard size Repair limit
1 Grouser overall height
20 10
2 Shoe overall height 29.5 19.5
3 Plate thickness 9.5
Rebuilding or
4 20
Grouser bottom length replace
5 20
6 14
7 Grouser tip length 13
8 15
PC138US, USLC-8 13
SEN02547-01 10 Structure, function and maintenance standard
Single shoe
Unit: mm
No. Item Criteria Remedy
Standard size Repair limit
1 Grouser overall height
50 20.5
2 Shoe overall height 62 32.5 Rebuilding or
3 Plate thickness 12 replace
4 Grouser bottom length 25
5 Grouser tip length 14
14 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02547-01
PC138US, USLC-8 15
SEN02547-01 10 Structure, function and maintenance standard
© 2007 KOMATSU
All Rights Reserved
Printed in Japan 02-07 (02)
16 PC138US, USLC-8
SEN02548-01
HYDRAULIC EXCAVATOR
PC138US-8
PC138USLC-8
PC138US, USLC-8 1
SEN02548-01 10 Structure, function and maintenance standard
2 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02548-01
PC138US, USLC-8 3
SEN02548-01 10 Structure, function and maintenance standard
Valve control 1
4 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02548-01
PC138US, USLC-8 5
SEN02548-01 10 Structure, function and maintenance standard
6 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02548-01
Breather
1. Filter element
2. Bottom plate
3. Gasket
4. Seam valve
5. Spring
PC138US, USLC-8 7
SEN02548-01 10 Structure, function and maintenance standard
Hydraulic pump 1
Type: HPD56+56
8 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02548-01
Outline
q This pump consists of a variable-displacement
swash plate type piston pump, PC valve, LS
valve and EPC valve.
1. Main pump
2. LS valve
3. PC valve
4. PC-EPC valve
5. Shuttle valve
6. No. 1 check valve
7. No. 2 check valve
PC138US, USLC-8 9
SEN02548-01 10 Structure, function and maintenance standard
10 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02548-01
PC138US, USLC-8 11
SEN02548-01 10 Structure, function and maintenance standard
Operation of pump
q Cylinder block (7) rotates together with shaft q As center line (X) of rocker cam (4) matches
(1), and shoe (5) slides on flat surface (A). the axial direction of cylinder block (7) (swash
q When this happens, rocker cam (4) moves plate angle (a) = 0), the difference between
along cylindrical surface (B), so angle (a) volumes (E) and (F) inside cylinder block (7)
between center line (X) of rocker cam (4) and becomes 0.
the ax ial di rec tio n of cy li nder b loc k (7) q Suction and discharge of pressurized oil is not
changes. carried out in this state. Namely pumping
q (a) is named the swash plate angle. action is not performed. (Actually, however, the
swash plate angle is not set to 0)
12 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02548-01
Control of delivery
q If the swash plate angle (a) becomes larger,
the difference between volumes (E) and (F)
b ec o me s l ar g er a nd pu m p d el i v e r y ( Q )
increases.
q Servo piston (12) is used for changing swash
plate angle (a).
q Servo piston (12) carries out linear reciprocal
movement according to the signal pressure
from the PC and LS valves.
q This linear movement is transmitted to rocker
cam (4) via slider (13).
q Being supported by cradle (2) on the cylindrical
surface, rocker cam (4) slides on the surface
while continuing revolving movement.
q Space of the pressure receiving area of servo
piston (12) are not identical on the left side and
right side. Main pump discharge pressure
(check valve output pressure) (PP) is always
brought to the pressure chamber of the small
diameter piston side.
q Output pressure (PEN) of the LS valve is
brought to the chamber receiving the pressure
at the large diameter piston end.
q The relationship in the size of pressure (PP) at
the small diameter piston end and pressure
(PEN) at the large diameter piston end, and
the ratio between the area receiving the pres-
sure of the small diameter piston and the large
diameter piston controls the movement of
servo piston (12).
PC138US, USLC-8 13
SEN02548-01 10 Structure, function and maintenance standard
LS valve
Function
q The LS (load sensing) valve detects the load
and controls the delivery.
q This valve controls main pump delivery (Q)
according to differential pressure ( PLS) [=
(PP) — (PLS)], called the LS differential pres-
sure (the difference between main pump pres-
sure (PP) and control valve outlet port pressure
(PLS)).
q Main pump pressure (PP), pressure (PLS)
(called the LS pressure) coming from the con-
trol valve output enters this valve.
14 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02548-01
Operation
q The LS valve is a 3-way selector valve, with q Pump pressure (PP) is conducted to the larger
pressure (PLS) (LS pressure) from the outlet diameter end from the port (K).
port of the control valve brought to spring q The same pump pressure (PP) is conducted to
chamber (B), and main pump discharge pres- the smaller diameter end from the port (J).
sure (PP) brought to port (H) of sleeve (8). q According to the difference in the areas on
q Magnitude of the force resulting from this LS servo piston (12), the pressure moves in such
pressure (PLS), force of spring (4) and the that the swash plate angle may be minimized.
pump delivery pressure (check valve output
pressure) (PP) determine the position of spool
(6).
q Before the engine is started, servo piston (12)
is pushed to the left. (See the diagram on the
right)
q If the control lever is at the neutral position
when the engine is started, LS pressure (PLS)
will be set to 0 MPa {0 kg/cm2}. (It is intercon-
nected to the drain circuit via the control valve
spool)
q Spool (6) is pushed to the left, and port (C) and
port (D) will be connected.
PC138US, USLC-8 15
SEN02548-01 10 Structure, function and maintenance standard
16 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02548-01
PC138US, USLC-8 17
SEN02548-01 10 Structure, function and maintenance standard
q Let us take the area receiving the pressure at q Force of spring (4) is adjusted in such that the
the large diameter end of the piston as (A1), position of the balanced stop of this spool (6)
the area receiving the pressure at the small may be determined when (PP) — (PLS) = 2.2
diameter end as (A0), and the pressure flowing MPa {22.5 kg/cm2} at the median of the speci-
into the large diameter end of the piston as fied value.
(PEN).
q If the main pump pressure (PP) of the LS valve
and the combined force of spring (4) and LS
pressure (PLS) are balanced, and the relation-
ship is (A0) × (PP) = (A1) × (PEN), servo pis-
ton (12) will stop in that position.
q The swash plate of the pump will be held at the
intermediate position. [Spool (6) will be
stopped at a position where the distance of the
opening from port (D) to port (E) and the dis-
tance from port (C) to port (D) is almost the
same.]
q At this point, the relationship between the pres-
sure receiving areas across servo piston (12)
is (A0) : (A1) = 1 : 2, so the pressure applied
across the piston when it is balanced becomes
(PP) : (PEN) C 2 : 1.
18 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02548-01
PC valve
Function
q When the pump discharge pressure (PP1) q If the engine speed goes below the specified
(check valve output pressure) and (PP2) (shut- value because of increased load, the controller
tle valve output pressure) are high, the PC sends a command current to PC-EPC valve
valve controls the pump so that the volume of solenoid in order to reduce the slope angle in
oil beyond the discharge pressure-based spe- proportion to reduction in the engine speed.
cific flowrate may not be conducted however
you may increase the control valve stroke.
Namely it is intended at controlling the horse
power for the pumps so that it may not exceed
the engine hose power.
q If the pump discharge pressure (PP1) increases
due to increased load during operation, this
valve decreases the pump delivery.
q And if the pump delivery pressure goes low, it
increases the pump delivery.
q In this case, relation between the mean average
discharge pressure of the pump [(PP1) +
(PP2)]/2 and the pump delivery (Q) will
becomes as shown in the diagram if the relation
is represented as the parameter of the current
value to be given to PC-EPC valve solenoid.
q The controller continues counting the actual
engine speed.
q If the engine speed is slowed down due to
increased load, the controller reduces the
pump delivery to recover the speed.
PC138US, USLC-8 19
SEN02548-01 10 Structure, function and maintenance standard
Operation
1) When the load on the actuator is small and pump discharge pressures (PP1) and (PP2) are low
20 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02548-01
PC138US, USLC-8 21
SEN02548-01 10 Structure, function and maintenance standard
Action of spring
q Load of springs (4) and (6) on the PC valve is q Spring load of springs (4) and (6) is also
determined by the swash plate position. affected by the command current (X) to PC-
q As servo piston (9) moves to left, spring (6) is EPC valve solenoid.
retracted. q Port (C) of the PC valve is connected to port
q If the servo piston moves further, it will be con- (E) of the LS valve.
tacted again seat (5) and spring (6) will be q Check valve output pressure (PP1) enters port
fixed. (B) and the small diameter end of servo piston
q After that, spring (4) alone will operate. (9), and shuttle valve output pressure (PP2)
q The spring load is changed by servo piston (9) enters port (A).
as it extends or compresses springs (4) and q When pump pressures (PP1) and (PP2) are
(6). small, spool (3) will be positioned in the right
q If the command current (X) to PC-EPC valve side.
solenoid (1) changes, so does the force push- q Port (C) and (D) are connected, and the pres-
ing piston (2). sure entering the LS valve becomes drain
pressure (PT).
22 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02548-01
PC138US, USLC-8 23
SEN02548-01 10 Structure, function and maintenance standard
Outline Operation
q When the load is large and pump discharge q When port (E) and port (G) of the LS valve are
pressures (PP1) and (PP2) are high, the force connected, this pressure from port (J) enters
pushing spool (3) to the left becomes larger the large diameter end of servo piston (9),
and spool (3) will be moved to the position stopping servo piston (9).
shown in above figure. q If main pump pressure (PP) increases further
q Part of the pressure to be conducted from port and spool (3) moves further to the left, main
(C) to LS valve flows from port (A) to port (C) pump pressure (PP1) flows to port (C) and acts
and (D) through LS valve. At the end this flow, to make the pump delivery the minimum.
level of this pressure becomes approximately q When servo piston (9) moves to the left,
half of the main pump pressure (PP). springs (4) and (6) are compressed and push
back spool (3).
q When spool (3) moves to the right, the opening
of port (C) and port (D) becomes larger.
24 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02548-01
PC138US, USLC-8 25
SEN02548-01 10 Structure, function and maintenance standard
2. As the emergency pump drive switch is turned on due to failure on the pump
controller
q If there is a failure in the pump controller, the q If the main pump pressures (PP1) and (PP2)
emergency pump drive switch is turned on to are low, the combined force of the pump pres-
hand the control to the resistor side. sure and the PC-EPC valve solenoid (1) is
q In this case, the power is directly supplied from weaker than the spring set force, so spool (3)
the battery. The current, however, is too large is balanced at a position to the right.
as is, so the resistor is set in between to con- q The port (C) is connected to the drain pressure
trol the current flowing to PC-EPC valve sole- of the port (D), and the large diameter end of
noid (1). the servo piston (9) also becomes the drain
q The current becomes constant, so the force pressure (PT) through the LS valve.
pushing piston (2) is also constant. q Since the pressure on the small diameter end
of the piston is large, servo piston (9) moves in
the direction to make the delivery larger.
26 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02548-01
PC138US, USLC-8 27
SEN02548-01 10 Structure, function and maintenance standard
28 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02548-01
PC-EPC valve
C : To PC valve
P : From self pressure reducing valve
T : To tank
1. Connector
2. Coil
3. Body
4. Spring
5. Spool
6. Rod
7. Plunger
PC138US, USLC-8 29
SEN02548-01 10 Structure, function and maintenance standard
Function Operation
q The EPC valve consists of the proportional
solenoid portion and the hydraulic valve por- 1. When signal current is 0 (coil is de-
tion. energized)
q When it receives signal current (i) from the q When there is no signal current flowing from
controller, it generates the EPC output pres- the controller to coil (2), coil (2) is de-ener-
sure in proportion to the size of the signal, and gized.
outputs it to the PC valve. q Spool (5) is pushed to the left by spring (4).
q Port (P) closes and the pressurized oil from the
self pressure reducing valve does not flow to
the PC valve.
q The pressurized oil from the PC valve is
drained to the tank through port (C) and port
(T).
30 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02548-01
PC138US, USLC-8 31
SEN02548-01 10 Structure, function and maintenance standard
Check valve
Function Operation
q A set of 2 check valves is used to select and 1. When (PA1) > (PA2)
output the higher discharge pressure of the 2 q Discharge pressures (PA1) and (PA2) of the
main pumps. main pumps are applied to poppet valves (1)
and (2). Since (PA1) > (PA2), however, poppet
valve (2) is kept closed and (PA1) is output to
(PP1).
32 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02548-01
Shuttle valve
1. Poppet valve
2. Poppet valve
3. Pin
Function Operation
q The shuttle valve selects and outputs the lower q The discharge pressures (PA1) and (PA2) of
discharge pressure of the 2 main pumps. the 2 main pumps are applied to poppet valves
(1) and (2) respectively.
q Since poppet valves (1) and (2) push each
other through pin (3), either one of them
receiving higher pressure is closed and the
other one receiving lower pressure is opened.
q Accordingly, lower discharge pressure of the 2
main pumps is output.
PC138US, USLC-8 33
SEN02548-01 10 Structure, function and maintenance standard
© 2007 KOMATSU
All Rights Reserved
Printed in Japan 02-07 (02)
34 PC138US, USLC-8
SEN02549-02
HYDRAULIC EXCAVATOR
PC138US-8
PC138USLC-8
PC138US, USLC-8 1
SEN02549-02 10 Structure, function and maintenance standard
Control valve 1
Outline
The control valves of the following types are set.
q 6-spool valve (Without service valve)
q 7-spool valve (6-spool valve + service valve)
q 7-spool valve (Blade)
q 8-spool valve (Blade + service valve)
q 8-spool valve (6-spool valve + 2 service valves)
q 9-spool valve (Blade + 2 service valves)
The appearance and section of only the 8-spool valve (blade + service valve) are shown here.
2 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02549-02
PC138US, USLC-8 3
SEN02549-02 10 Structure, function and maintenance standard
4 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02549-02
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length
Installed Installed Installed
× Outside Free length
28 Suction valve spring length load load
diameter
5.49 N 4.41 N
46.8 × 7.5 40.6 —
{0.56 kg} {0.45 kg}
135 N 108 N
29 Piston return spring 72.7 × 20.6 42.5 —
{13.8 kg} {11.0 kg}
5.1 N 4.12 N
30 Suction valve spring 39.2 × 4.45 33.5 —
{0.52 kg} {0.42 kg}
141 N 113 N
31 Spool return spring 41.8 × 19 38.5 —
{14.4 kg} {11.5 kg}
137 N 110 N
32 Spool return spring 41.44 × 19.3 38.5 — If damaged or
{13.96 kg} {11.2 kg}
deformed,
55.9 N 44.7 N replace spring
33 Spool return spring 27.14 × 25.8 25.5 —
{5.7 kg} {4.56 kg}
60.2 N 48.2 N
34 Spool return spring 32.4 × 11 31.4 —
{6.137 kg} {4.91 kg}
423 N 338 N
35 Spool return spring 76.78 × 20.9 70 —
{43.1 kg} {34.5 kg}
221 N 177 N
36 Spool return spring 45.7 × 28 43 —
{22.55 kg} {18.04 kg}
222 N 178 N
37 Spool return spring 42.4 × 28 39 —
{22.6 kg} {18.1 kg}
230 N 184 N
38 Spool return spring 45.6 × 28 43 —
{23.5 kg} {18.8 kg}
203 N 163 N
39 Spool return spring 45.81 × 28 43 —
{20.7 kg} {16.6 kg}
PC138US, USLC-8 5
SEN02549-02 10 Structure, function and maintenance standard
6 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02549-02
1 LS selector valve
2. Cooler bypass valve
3. Pressure compensation valve R (Service)
4. Pressure compensation valve R (Bucket)
5. Pressure compensation valve R (Arm)
6. Pressure compensation valve R (Boom)
7. Pressure compensation valve R (Right travel)
8. Pressure compensation valve R (Left travel)
9. Pressure compensation valve R (Blade)
10. Pressure compensation valve R (Swing)
11. Pressure compensation valve F (Swing)
12. Pressure compensation valve F (Blade)
13. Pressure compensation valve F (Left travel)
14. Pressure compensation valve F (Right travel)
15. Merge-divider valve spool
16. Pressure compensation valve F (Boom)
17. Pressure compensation valve F (Arm)
18. Pressure compensation valve F (Bucket)
19. Pressure compensation valve F (Service)
PC138US, USLC-8 7
SEN02549-02 10 Structure, function and maintenance standard
8 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02549-02
1. LS selector valve
Swing valve
2. Pressure compensation valve F
3. Spool
4. Pressure compensation valve R
5. Swing bleed valve
Blade valve
6. Suction safety valve
7. Suction valve
8. Spool
9. Pressure compensation valve R
10. Pressure compensation valve F
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length
Installed Installed Installed
x Outside Free length
17 Check valve spring length load load
diameter
If damaged or
3.92 N 3.14 N
23.3 × 12.5 23 — deformed,
{0.4 kg} {0.32 kg}
replace spring
1.96 N 1.57 N
18 Check valve spring 21.9 × 5 15.8 —
{0.2 kg} {0.16 kg}
0.98 N 0.78 N
19 Retainer spring 9.1 × 4.2 7.4 —
{0.1 kg} {0.08 kg}
PC138US, USLC-8 9
SEN02549-02 10 Structure, function and maintenance standard
10 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02549-02
7. Unload valve
8. LS bypass valve
9. Merge-divider valve spool
10. Main relief valve
11. Cooler bypass valve
12. Lift check valve
Boom valve
13. Pressure compensation valve F
14. Suction valve
15. Hydraulic drift prevention valve
16. Suction valve
17. Spool
18. Pressure compensation valve R
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length
Installed Installed Installed
x Outside Free length
19 Spool return spring length load load
diameter
15.7 N 12.6 N
19.26 × 7.5 14 —
{1.6 kg} {1.28 kg}
1.96 N 1.57 N
20 Check valve spring 21.9 × 5 15.8 — If damaged or
{0.2 kg} {0.16 kg}
deformed,
83.4 N 66.7 N replace spring
21 Valve return spring 58.9 × 13 53 —
{8.5 kg} {6.8 kg}
98.1 N 78.5 N
22 Spool return spring 49.8 × 18.8 33 —
{10 kg} {8 kg}
13.7 N 11.0 N
23 Check valve spring 16.4 × 8.9 11.5 —
{1.4 kg} {1.12 kg}
135 N 108 N
24 Spool return valve spring 72.7 × 20.6 42.5 —
{13.8 kg} {11 kg}
PC138US, USLC-8 11
SEN02549-02 10 Structure, function and maintenance standard
12 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02549-02
Arm valve
1. Pressure compensation valve F
2. Suction valve
3. Suction valve
4. Spool
5. Pressure compensation valve R
6. Regeneration valve
Bucket valve
7. Pressure compensation valve F
8. Suction valve
9. Suction valve
10. Spool
11. Pressure compensation valve R
Service valve
12. Pressure compensation valve F
13. Suction safety valve
14. Suction safety valve
15. Spool
16. Pressure compensation valve R
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length
Installed Installed Installed If damaged or
× Outside Free length
19 Valve spring length load load deformed,
diameter
replace spring
5.88 N 4.71 N
41.5 × 8.5 31.5 —
{0.6 kg} {0.48 kg}
PC138US, USLC-8 13
SEN02549-02 10 Structure, function and maintenance standard
CLSS 1
Outline of CLSS 1
Features Configuration
CLSS stands for Closed center Load Sensing Sys- q CLSS is configured with variable capacity
tem, which has the following characteristics: piston pumps, control valves, and respective
actuators.
q Fine control not influenced by load q The hydraulic pump is configured with pump
q Controllability enabling digging even with fine body, PC valve and LS valve.
control
q Ease of compound operation ensured by flow
divider function using area of opening of spool
during compound operations
q Energy saving using variable pump control
14 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02549-02
Basic principle 1
1. Pump swash plate angle control
q The pump swash plate angle (pump delivery) q The pump swash plate angle shifts toward the
is controlled so that LS differential pressure maximum position if LS differential pressure
( P L S ) ( t h e d i ff e r e n c e b e t w e e n p u m p ( PLS) is lower than the set pressure of the
pressure PP and control valve outlet port LS LS valve (when the actuator load pressure is
pressure PLS) (load pressure of actuator) is high).
constant. q If it becomes higher than the set pressure
q [LS differential pressure ( PLS) = Pump (when the actuator load pressure is low), the
discharge pressure (PP) — LS pressure (PLS)] pump swash plate angle shifts toward the
minimum position.
PC138US, USLC-8 15
SEN02549-02 10 Structure, function and maintenance standard
16 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02549-02
PC138US, USLC-8 17
SEN02549-02 10 Structure, function and maintenance standard
18 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02549-02
1. Swing valve
2. Blade valve
3. Left travel valve
4. Right travel valve
5. Boom valve
6. Arm valve
7. Bucket valve
8. Service valve
9. Swing spool
10. Blade spool
11. Left travel spool
12. Right travel spool
13. Boom spool
14. Arm spool
15. Bucket spool
16. Service spool
17. Pressure compensation valve
18. Suction valve
19. LS service valve
20. Merge-divider valve
21. Arm regeneration valve
22. Self pressure reducing valve
23. Travel junction valve
24. Lift check valve
25. Cooler bypass valve
26. Boom hydraulic drift prevention valve
27. Swing bleeding valve
28. Suction safety valve
Set pressure: 36.8 MPa {375 kg/cm²}
29. Suction safety valve
Set pressure: 24.5 MPa {250 kg/cm²}
30. Suction safety valve
Set pressure: 35.8 MPa {365 kg/cm²}
31. Main relief valve
Set pressure: 34.8 MPa {355 kg/cm²}
32. Unload valve
PC138US, USLC-8 19
SEN02549-02 10 Structure, function and maintenance standard
Unload valve
1. When control valve is at HOLD
Operation
q Pump discharge pressures (P1) and (P2) are
applied to pump pressure receiving (SA) face
of unload spool (1).
q LS pressures (LS1) and (LS2) are applied to
LS pressure receiving (SB) face. [(P1) = (P2),
(LS1) = (LS2)]
20 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02549-02
Function Operation
q When any work equipment valve is operated if q When any work equipment valve is operated
the demand flow for the actuator becomes for a long stroke, LS pressures (LS1) and
greater than the pump discharge from the min- (LS2) are generated and act on the face (SB)
imum swash plate angle, the oil flow to tank cir- of unload spool (1) [(P1) = (P2), (LS1) = (LS2)].
cuit (T) is cut off, and all pump delivery (Q) q For this reason, the difference between pump
flows to the actuator circuit. discharge pressure (P1) and (P2) and LS pres-
q Since the pump merge-divider valve is at the sure (LS1) and (LS2) does not reach the load
merge position, pump discharge pressures of spring (2), so spool (1) is pushed to the right
(P1) and (P2) are merged. LS pressures (LS1), by spring (2).
(LS2), and (LS3) are also merged. q As a result, pump discharge pressures (P1)
and (P2) and tank circuit (T) are shut off, and
all pump delivery (Q) flows to the actuator cir-
cuit.
PC138US, USLC-8 21
SEN02549-02 10 Structure, function and maintenance standard
Function Operation
q When the difference between pump discharge q When fine control is carried out on both travel
pressure (P1) and (P2) and LS pressure (LS1) valves, LS pressures (LS1) and (LS2) are gen-
and (LS2) reaches the load of spring (2), erated and act on the face (SB) of spool (1)
unload spool (1) opens, so excessive oil (maxi- [(P1), (P2), (LS1), and (LS2) are separated].
mum pump delivery - demand flow) flows into q When the difference between pump discharge
the tank circuit. pressure (P1) and (P2) and LS pressure (LS1)
q Since the pump merge-divider valve is at the and (LS2) reaches the load of spring (2), spool
separate position, pump discharge pressures (1) moves to the left, and pump discharge
(P1) and (P2) are separated. LS pressures pressures (P1) and (P2) are connected to tank
(LS1) and (LS2) are also separated. circuit (T) and the excessive oil (maximum
q The swash plate angle of the pump becomes pump delivery - demand flow) flows.
maximum, so the pump delivery becomes q In other words, the excessive oil (maximum
maximum. (For details, see the sections on the pump delivery - demand flow) above the
pump merge-divider valve.) strokes of both travel valves flows into tank cir-
cuit (T).
22 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02549-02
Function Operation
q During operation of both travel valves, when q When both travel valves are operated to the
the demand flow becomes maximum, the oil stroke ends, LS pressures (LS1) and (LS2) are
flow to tank circuit (T) is cut off, and all pump generated and act on the face (SB) of unload
delivery (Q) flows to both travel circuits. spool (1) [(P1), (P2), (LS1), and (LS2) are sep-
q Since the pump merge-divider spool is at the arated].
separate position, pump discharge pressures q The area of the openings of both travel valve
(P1) and (P2) are separated. LS pressures spools is large, so LS pressures (LS1) and
(LS1) and (LS2) are also separated. (LS2) are not so different from pump discharge
q The swash plate angle of the pump becomes pressures (P1) and (P2).
maximum, so the pump delivery becomes q For this reason, the difference between pump
maximum. (For details, see the sections on the discharge pressure (P1) and (P2) and LS pres-
pump merge-divider valve .) sure (LS1) and (LS2) does not reach the load
of spring (2), so spool (1) is pushed to the right
by spring (2).
q As a result, pump discharge pressures (P1)
and (P2) and tank circuit (T) are shut off, and
all pump delivery (Q) flows to the actuator cir-
cuit.
PC138US, USLC-8 23
SEN02549-02 10 Structure, function and maintenance standard
24 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02549-02
PC138US, USLC-8 25
SEN02549-02 10 Structure, function and maintenance standard
Merge-divider valve
1. When oil is merged: (PS) = 0 kg/cm2
Function
q Pump discharge pressures (P1) and (P2) are
merged in pump merge-divider spool (3).
(LS1), (LS2), and (LS3) are also merged.
q At this time, (P1) = (P2) and (LS1) = (LS2) =
(LS3) and the pump swash plate is controlled
by the difference between (P) and (LS).
26 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02549-02
Function
q Pump discharge pressures (P1) and (P2) are
divided in pump merge-divider spool (3).
(LS1), (LS2), and (LS3) are also divided.
q At this time, higher one of (P1) and (P2) is
applied through pump merge-divider spool (3)
to the output port of the LS pressure.
q As a result, there is not difference between (P)
and (LS) and the pump swash plate is set to
the maximum position.
PC138US, USLC-8 27
SEN02549-02 10 Structure, function and maintenance standard
Introduction of LS pressure
1. Work equipment valve
28 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02549-02
2. Travel valve
Operation
q When spool (1) is operated, pump discharge
pressure (PP) flows from flow control valve (2)
through notch (a) in the spool and bridge pas-
sage (b) to actuator circuit (A).
q Actuator circuit pressure (PA) (= A) is intro-
duced through the check valve (5) into LS cir-
cuit (PLS).
PC138US, USLC-8 29
SEN02549-02 10 Structure, function and maintenance standard
LS bypass valve
1. When work equipment valve is operated
(including compound operation of work equipment + travel)
Function Operation
q The LS bypass valve releases the remaining q Since pump merge-divider spool (1) is at the
pressure of LS pressure (PLS). merge position, the hydraulic oil in LS circuits
q This lowers the rising speed of LS pressure (PLS1), (PLS2), and (PLS3) flows from tip filter
(PLS). In addition, the discarded throttled flow (a) of LS bypass valve (2) through orifice (b) to
causes a pressure loss in the throttled flow in tank circuit (T).
the reducing valve, and that lowers the effec-
tive LS differential pressure to improve the sta-
bility.
30 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02549-02
Operation q The hydraulic oil (PLS2) flows from tip filter (c)
q Since pump merge-divider spool (1) is at the of LS bypass valve (3) through orifice (d) to
separate position, LS circuits (PLS1) and tank circuit (T).
(PLS2) are separated.
q The hydraulic oil (PLS1) flows from tip filter (a)
of LS bypass valve (2) through orifice (b) to
tank circuit (T).
PC138US, USLC-8 31
SEN02549-02 10 Structure, function and maintenance standard
32 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02549-02
Function
q When the load pressure becomes lower than
another actuator and the flow is going to
increase during a compound operation, this
valve compensates the load pressure. [At the
time, the load pressure of another actuator
under compound operation (the upper side) is
higher than that of the actuator on this side
(the lower side)].
Operation
q When the load pressure (Ab) of another actua-
tor side (the upper side) rises during a com-
pound operation, the flow in the actuator circuit
(Aa) on this side (the lower side) is apt to
increase.
q In this case, the LS pressure (PLS) of another
actuator is applied to the spring chamber
(PLS1) and pushes the pressure reducing
valve (1) and the flow control valve (2) to the
left side.
q The flow control valve (2) throttles the opening
area between the pump circuit (PP) and the
spool upstream (PPA) and causes a pressure
loss between (PP) and (PPA).
q The flow control valve (2) and the pressure
reducing valve (1) balance each other where
the pressure difference between (PA) applied
to the both end faces of the pressure reducing
valve (1) and (PLS) becomes the same as the
pressure loss between (PP) before and after
the flow control valve (2) and (PPA).
q So, the pressure differences between the
upstream pressures (PPA) and the down-
stream pressures (PA) of the both spools
under compound operation become the same,
and the pump flow is distributed in proportion
to the opening area of each spool notch (a).
PC138US, USLC-8 33
SEN02549-02 10 Structure, function and maintenance standard
34 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02549-02
Operation
q When the boom is lowered and falls due to its
own weight, the bottom side pressure (A) in the
boom cylinder (1) will rise above the head side
pressure (B).
PC138US, USLC-8 35
SEN02549-02 10 Structure, function and maintenance standard
Function q At the time, the head side pressure (B) and the
q When the head pressure (B) of the cylinder (1) spring (4) close the check valve (3), and the
is higher than the bottom pressure (A) while circuits on the head side and the bottom side
the boom is lowered and the boom is in the are interrupted.
load process, the check valve (3) will be
closed, and the circuits on the head side and
the bottom side will be interrupted.
Operation
q When the boom is lowered and is in the load
process, the head side pressure (B) of the
boom cylinder (1) rises above the bottom side
pressure (A).
36 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02549-02
Operation
q When the arm falls for digging due to its own
weight, the head side pressure (A) in the arm
cylinder (1) will rise above the bottom side
pressure (B).
PC138US, USLC-8 37
SEN02549-02 10 Structure, function and maintenance standard
2. At arm in process
Function
q When the bottom pressure (B) of the cylinder
(1) rises above the head pressure (A) and the
arm enters the digging process, the check
valve (3) will be closed and the circuits on the
head side and the bottom side will be inter-
rupted.
Operation
q When the arm is in the digging process, the
bottom side pressure (B) of the arm cylinder
(1) will rise, close the check valve (3) and inter-
rupt the circuits on the head side and the bot-
tom side.
38 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02549-02
Function Operation
q While the boom lever is not operated, the q If the boom is raised out, the main pressure
hydraulic drift prevention valve prevents pres- from the control valve pushes up poppet (5).
surized oil from leaking from the boom bottom As a result, the main pressure from the control
through spool (1) to prevent the boom from valve flows through the valve into the boom
drifting hydraulically. cylinder bottom.
PC138US, USLC-8 39
SEN02549-02 10 Structure, function and maintenance standard
Operation
q If the control lever is returned to the neutral
position while the boom is raised out, the hold-
ing pressure in the boom cylinder bottom and
arm cylinder head is blocked by poppet (5) and
the pressurized oil flowing in through orifice (a)
is blocked by pilot spool (3). Accordingly, the
boom is held.
40 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02549-02
Operation
q If the boom is lowered, pilot pressure (P1) from
the PPC valve pushes pilot spool (3) and the
pressurized oil in chamber (b) in the poppet is
drained.
q The pressurized oil in port (Ab) is raised by the
pressurized oil from the boom cylinder bottom,
but the pressurized oil in chamber (b) is low-
ered by orifice (a).
q If the pressure in chamber (b) is lowered below
the pressure in port (Aa), poppet (5) opens and
the pressurized oil from port (Ab) flows through
port (Aa) into the control valve.
PC138US, USLC-8 41
SEN02549-02 10 Structure, function and maintenance standard
42 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02549-02
LS select valve
1. During normal operation
Function
q At the time of simultaneous operation of swing
+ boom RAISE, this valve prevents high swing
LS pressure from entering the LS circuit (PLS)
and also prevents the boom RAISE speed
from reducing by securing the pump flow at the
time of swing drive.
Operation
q The pilot pressure is not generally applied to
the pilot port (BP) except for boom RAISE
operation.
q In this state, the pump discharge pressure
(PP) pushes the valve (1) to open it and is led
to the pressure reducing valve (4) of the swing
valve. At the time of swing operation, there
occurs the LS pressure (PLS) suitable for the
load pressure, and the pressure is led to the
pump LS valve.
PC138US, USLC-8 43
SEN02549-02 10 Structure, function and maintenance standard
Operation
q At the simultaneous operation of swing + boom
RAISE, the signal pressure of the PPC circuit
is led to the pilot port (BP).
q When this pilot pressure (BP) is applied to the
piston (2) and reaches a pressure that is stron-
ger than the spring (3), the piston (2) will be
pushed to the left side, the valve (1) will close
and the pump discharge pressure (PP) will not
come to flow to the pressure reducing valve (4)
of the swing valve.
q Then, the swing pressure does not cause LS
pressure (PLS), but the LS pressure (PLS)
caused by the boom RAISE pressure is led to
the pump LS valve, and the pump delivery is
controlled with the boom RAISE LS pressure.
q The pilot pressure (BP) depends on the control
lever stroke.
44 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02549-02
Function Operation
q This valve connects both travel circuits to each When pilot pressure is turned ON
other so that hydraulic oil will be supplied q If the pilot pressure from the travel junction
evenly to both travel motors and the machine solenoid valve becomes higher than the force
will travel straight. of spring (2), travel junction spool (1) moves to
q When the machine is steered, outside pilot the left stroke end and the junction circuit
pressure (PST) closes the travel junction valve between port (PTL) (Left travel circuit) and
to secure high steering performance. (PTR) (Right travel circuit) is closed.
PC138US, USLC-8 45
SEN02549-02 10 Structure, function and maintenance standard
46 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02549-02
Function Function
q The lift check valve generates back pressure in q The cooler bypass valve protects oil cooler (4)
the drain circuit to prevent negative pressure from breakage when the return flow rate from
on each actuator (motor, cylinder, etc.) the control valve increases and oil cooler inlet
pressure (PB) increases.
Operation q The cooler bypass valve returns the return oil
q Drain circuit pressure (PA) of the control valve to the tank directly without passing it through
acts on the left side of piston (2) to move the oil cooler (4).
piston to the right.
q The piston is so balanced that the back pres- Operation
sure will be as follows. q Oil cooler inlet pressure (PB) acts on the
q (PA) – (PB) = Force of spring (3) / Area of pis- underside of piston (1) to push up the piston.
ton (2) at diameter (d1) q Piston (1) is so balanced that oil cooler inlet
[(PB) C 0 kg/cm²] pressure (PB) will be as follows.
q (PB) – (PT) = Force of spring (5) / Area of pis-
ton (1) at diameter (d2)
[(PT) C 0 kg/cm²]
PC138US, USLC-8 47
SEN02549-02 10 Structure, function and maintenance standard
© 2007 KOMATSU
All Rights Reserved
Printed in Japan 10-07 (02)
48 PC138US, USLC-8
SEN02550-01
HYDRAULIC EXCAVATOR
PC138US-8
PC138USLC-8
PC138US, USLC-8 1
SEN02550-01 10 Structure, function and maintenance standard
PPC valve 1
Work equipment and swing PPC valve 1
2 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02550-01
PC138US, USLC-8 3
SEN02550-01 10 Structure, function and maintenance standard
1. Spool
2. Piston
3. Disc
4. Nut (for lever connection)
5. Joint
6. Plate
7. Retainer
8. Body
9. Filter
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length
Installation Installation Installation
Centering spring × Outside Free length
10 length load load
(for ports P3 and P4) diameter
If damaged or
42.48 × 17.7 N 14.1 N
34 — deformed,
15.5 {1.8 kg} {1.44 kg}
replace spring.
Centering spring 44.45 × 29.4 N 23.5 N
11 34 —
(for ports P1 and P2) 15.5 {3 kg} {2.40 kg}
16.7 N 13.3 N
12 Metering spring 26.9 × 8 24.9 —
{1.7 kg} {1.36 kg}
4 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02550-01
PC138US, USLC-8 5
SEN02550-01 10 Structure, function and maintenance standard
6 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02550-01
PC138US, USLC-8 7
SEN02550-01 10 Structure, function and maintenance standard
8 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02550-01
1. Plate
2. Body
3. Piston
4. Seal
5. Valve
6. Damper
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length
Installation Installation Installation
× Outside Free length
7 Centering spring length load load If damaged or
diameter
deformed,
48.57 × 108 N 86.3 N replace spring.
32.5 —
15.5 {11 kg} {8.8 kg}
26.53 × 16.7 N 13.3 N
8 Metering spring 24.9 —
8.15 {1.7 kg} {1.36 kg}
PC138US, USLC-8 9
SEN02550-01 10 Structure, function and maintenance standard
10 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02550-01
PC138US, USLC-8 11
SEN02550-01 10 Structure, function and maintenance standard
a For the details of operation, see the paragraph of "Work equipment and swing PPC valve".
12 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02550-01
1. Spool
2. Piston
3. Lever
4. Plate
5. Retainer
6. Body
7. Filter
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length
Installation Installation Installation
× Outside Free length
8 Centering spring length load load If damaged or
diameter
deformed,
42.36 × 147 N 118 N replace spring.
32.5 —
15.5 {15 kg} {12.0 kg}
16.7 N 13.3 N
9 Metering spring 22.73 × 8.1 22 —
{1.7 kg} {1.36 kg}
PC138US, USLC-8 13
SEN02550-01 10 Structure, function and maintenance standard
a For the details of operation, see the paragraph of "Work equipment and swing PPC valve".
14 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02550-01
1. Spool
2. Piston
3. Lever
4. Plate
5. Retainer
6. Block
7. Body
8. EPC valve
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length
Installation Installation Installation
× Outside Free length
9 Centering spring length load load If damaged or
diameter
deformed,
125 N 100 N replace spring.
33.9 × 15.3 28.4 —
{12.7 kg} {10.2 kg}
16.7 N 13.3 N
10 Metering spring 22.7 × 8.10 22 .0 —
{1.70 kg} {1.36 kg}
PC138US, USLC-8 15
SEN02550-01 10 Structure, function and maintenance standard
1. EPC valve
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
If damaged or
Installation Installation Installation
Free length Free length deformed,
8 Return spring length load load
replace EPC
3.1 N valve assembly.
9.0 8.4 — —
{0.32 kg}
16 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02550-01
Function Operation
q The EPC valve consists of the proportional
solenoid portion and the hydraulic valve por- 1) When signal current is 0
tion. (coil is de-energized)
q When it receives signal current (i) from the q When there is no signal current flowing from
pump controller, it generates the EPC output the controller to coil (14), coil (14) is de-ener-
pressure in proportion to the size of the signal, gized.
and outputs it to the control valve. q Spool (11) is pushed to the right by spring (12).
q Port (P) closes and the pressurized oil from the
front pump does not flow to the control valve.
q The pressurized oil from the control valve is
drained to the tank via port (C) and port (T).
PC138US, USLC-8 17
SEN02550-01 10 Structure, function and maintenance standard
18 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02550-01
Swing motor 1
Type: KMF45ABE-5
PC138US, USLC-8 19
SEN02550-01 10 Structure, function and maintenance standard
20 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02550-01
1. Brake spring
2. Drive shaft
3. Spacer
4. Case
5. Disc
6. Plate
7. Brake ring
8. Brake piston
9. Housing
10. Piston
11. Cylinder block
12. Valve plate
13. Center shaft
14. Center spring
15. Check valve
16. Shuttle valve
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length
Installation Installation Installation
× Outside Free length
17 Check valve spring length load load If damaged or
diameter
deformed,
6.96 N 5.59 N replace spring.
66.5 × 25.6 45.0 —
{0.71 kg} {0.57 kg}
7.45 N 5.98 N
18 Shuttle valve spring 24.5 × 11.6 14.5 —
{0.76 kg} {0.61 kg}
PC138US, USLC-8 21
SEN02550-01 10 Structure, function and maintenance standard
Operation Operation
q As the swing holding brake solenoid valve is q As the swing holding brake solenoid valve is
de-energized, the pressurized oil from the self energized, the valve is switched.
pressure reducing valve is shut off. q The pressurized oil from the self pressure
q Port (B) is connected to tank circuit (T). reducing valve is conducted brake chamber (a)
q Brake piston (8) is pushed down by brake via port (B).
spring (1). q After entering chamber (a), the pressurized oil
q Disc (5) and plate (6) are pushed together, and compresses brake spring (1) and pushes
the brake is applied. brake piston (8) up.
q Disc (5) is separated from plate (6), releasing
the brake.
22 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02550-01
PC138US, USLC-8 23
SEN02550-01 10 Structure, function and maintenance standard
24 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02550-01
1. Valve body
2. Spool (MA side)
3. Spring (MA side)
4. Plug (MA side)
5. Spool (MB side)
6. Spring (MB side)
7. Plug (MB side)
PC138US, USLC-8 25
SEN02550-01 10 Structure, function and maintenance standard
26 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02550-01
Travel motor 1
PC138US, USLC-8 27
SEN02550-01 10 Structure, function and maintenance standard
28 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02550-01
Specifications
Type GM21VA-A
Stroke volume Hi 44.2
(cm³/rev) Lo 79.1
Rated speed Hi 2,609
(rpm) Lo 1,486
Brake releasing pressure 0.76
(MPa{kg/cm²}) {7.71}
Hi-Lo switching pressure 2.94
(MPa{kg/cm²}) {30}
Reduction ratio 54.0
Outline
3. Brake valve
Consists of various valves. Provides the follow-
ing functions: stops the hydraulic motor
smoothly, prevents runway of hydraulic motor,
prevents generation of abnormally high pres-
sure when the hydraulic motor is stopped sud-
denly.
PC138US, USLC-8 29
SEN02550-01 10 Structure, function and maintenance standard
Operation
Operation of motor
At low speed (the motor swash plate angle is maximized.)
1. 2nd travel speed select solenoid valve q Since 2nd travel speed select solenoid valve
2. Regulator valve (1) is de-energized, the pressurized oil from
3. Spring self pressure reduction valve (11) is not fed to
4. Check valve port (P).
5. Regulator piston q Regulator valve (2) is pushed down with spring
6. Swash plate (3) reaction force.
7. Parking brake piston q The main pressurized oil, sent from the control
8. Hydraulic pump valve through check valve (4), is controlled by
9. Travel control valve regulator valve (2) and used to shuts off the cir-
10. Pump merge-divider valve cuit to regular piston (5).
11. Self pressure reducing valve q The pressurized oil in control chamber (C) is
12. Brake valve drained from port (D) through oil passage (e) of
regulator valve (2).
q Swash plate (7) reaches its maximum tilt
angle, and the machine travels at low speed
with the maximum motor capacity.
30 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02550-01
1. 2nd travel speed select solenoid valve q When 2nd travel speed select solenoid valve
2. Regulator valve (1) is energized, the pressurized oil from self
3. Spring pressure reduction valve (11) is fed to port (P).
4. Check valve q Regulator valve (2) is pushed up with the pres-
5. Regulator piston surized oil that is sent to port (P).
6. Swash plate q The main pressurized oil from the control valve
7. Parking brake piston passes through check valve (4), and passes
8. Hydraulic pump through oil passage (F) in regulator valve (2) to
9. Travel control valve control chamber (C), and is used to push to
10. Pump merge-divider valve regular piston (5) to the left.
11. Self pressure reducing valve q Swash plate (7) reaches its minimum tilt angle,
12. Brake valve and the machine travels at high speed with the
minimum motor capacity.
PC138US, USLC-8 31
SEN02550-01 10 Structure, function and maintenance standard
Brake valve
Operation when pressure oil is supplied Operation when pressure is shut off
q When the travel lever is operated, the pressur- q When the travel lever is returned to its neutral
ized oil from the control valve is fed to port (A) position, the hydraulic oil circuit from the con-
and check valve (1) is opened. The oil is fur- trol valve is closed. And counterbalance valve
ther sent from port (C) to port (D) through the (2) starts to return to the left by spring (3) reac-
motor. tion force.
q At the same time, when the pressure of the q The hydraulic oil in chamber (G) tends to flow
hydraulic oil that entered in chamber (G) to port (A) through orifice (f). However, the
through orifice (f) exceeds spring (3) reaction back pressure is generated by closing of orifice
force, counterbalance valve (2) moves to the (f), controlling the return speed of counterbal-
right, opening ports (D) and (B), and the motor ance valve (2) to the right.
becomes ready to rotate. q The motor tends to rotate by inertia even when
q As ports (A) and (E) also open, parking brake the hydraulic oil from the control valve is
piston (4) is pressed down by the hydraulic stopped.During this time, the oil return circuit is
pressure. This releases the parking brake and gradually closed by controlling the movement
the motor starts to rotate. speed of counterbalance valve (2) and by
using its cutout portion. By this, the motor is
smoothly stopped.
32 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02550-01
PC138US, USLC-8 33
SEN02550-01 10 Structure, function and maintenance standard
Relief valve
q The pressurized oil from the control valve is q When the hydraulic oil from the control valve is
fed from port (A) to port (C). As port (C) is con- stopped, ports (A) and (C) are closed. At the
nected to the motor, the pressure drives the same time, ports (D) and (B) are closed, but
motor to rotate. the motor continues to rotate by the inertia.
q When the hydraulic pressure at port (C) q When the hydraulic pressure at port (D)
exceeds the specified value, relief valve (1a) is exceeds the specified value, relief valve (1b) is
pushed up and the hydraulic oil is fed to port pushed up and the hydraulic oil is fed to port
(D).However, relief valve (1b) is kept closed (C).The hydraulic pressure applied to port (D)
independent from the hydraulic pressure at at the outlet side is fed to port (C) at the inlet
port (C). side, and it is used to prevent the oil cavitation.
q The hydraulic oil is fed from port (C) to cham- q The hydraulic oil from port (D) passes through
ber (E) through the oil passages of relief valve the oil passages of relief valve (1b) and sleeve
(1a) and sleeve (2a). By this pressure, piston (2b), and sent to chamber (F). By this pres-
(3) is moved to the right. sure, piston (3) is moved to the left.
q When piston (3) reaches its stroke end posi- q When piston (3) reaches its stroke end posi-
tion, the hydraulic pressure from relief valve tion, the hydraulic pressure from relief valve
(1a) to chamber (E) increases. Therefore, (1b) to chamber (F) increases. Therefore, ports
ports (C) and (D) are closed by relief valve (D) and (C) are closed by relief valve (1b).
(1a). q The hydraulic pressure at port (D) at the outlet
q The hydraulic pressure at port (C) at the inlet side is controlled so that the motor is smoothly
side is controlled so that the motor is smoothly stopped.
started to rotate.
34 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02550-01
PC138US, USLC-8 35
SEN02550-01 10 Structure, function and maintenance standard
A1: From control valve (R.H. travel FORWARD) A2: To R.H. travel motor port B
B1: From control valve (L.H. travel FORWARD) B2: To L.H. travel motor port A
C1: From control valve (R.H. travel REVERSE) C2: To R.H. travel motor port A
D1: From control valve (L.H. travel REVERSE) D2: To L.H. travel motor port B
E1: From 2nd travel speed select solenoid valve E2: To L.H. and R.H. travel motor port P
DR1: To hydraulic tank DR2: From L.H. and R.H. travel motor port D
1. Cover 4. O-ring
2. Body 5. Shaft
3. Slipper seal
36 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02550-01
Unit: mm
No. Item Criteria Remedy
Clearance between rotor and Standard size Standard clearance Clearance limit
1 Replace
shaft 80 0.056 – 0.105 0.111
PC138US, USLC-8 37
SEN02550-01 10 Structure, function and maintenance standard
Blade specification
(if equipped)
A1: From control valve (R.H. travel REVERSE) A2: To R.H. travel motor port A
B1: From control valve (L.H. travel FORWARD) B2: To L.H. travel motor port A
C1: From control valve (R.H. travel FORWARD) C2: To R.H. travel motor port B
D1: From control valve (L.H. travel REVERSE) D2: To L.H. travel motor port B
E1: From 2nd travel speed select solenoid valve E2: To L.H. and R.H. travel motor port P
F1: From control valve (blade LOWER) F2: To L.H. and R.H. blade cylinder bottom
G1: From control valve (blade RAISE) G2: To L.H. and R.H. blade cylinder head
DR1: To hydraulic tank DR2: From L.H. and R.H. travel motor port D
38 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02550-01
Unit: mm
No. Item Criteria Remedy
clearance between rotor and Standard size Standard clearance Clearance limit
1 Replace
shaft 80 0.056 – 0.105 0.111
PC138US, USLC-8 39
SEN02550-01 10 Structure, function and maintenance standard
Solenoid valve 1
40 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02550-01
Solenoid valve
6. Coil (ON/OFF type)
7. Push pin q Installed between port (P) and PPC solenoid
8. Valve spool valve. When the engine is stopped, plunger (1)
9. Sleeve is pushed back to the left with spring (2) reac-
10. Block tion force, and ports (ACC) and (P) are closed
11. Plug to maintain the pressure in the accumulator.
q When the engine is running, plunger (1) is
Check valve pushed to the right with the pilot pressure that
12. Plunger is sent to port (P), and ports (P) and (ACC) are
13. Plug interconnected.
PC138US, USLC-8 41
SEN02550-01 10 Structure, function and maintenance standard
Solenoid valve
When solenoid valve is “de-energized“ (circuit When solenoid valve is “energized“ (circuit is
is closed) connected)
q Coil (1) is de-energized when no signal current q Coil (1) is energized when signal current is
is supplied to coil (1). supplied to coil (1).
q Spool (2) is pushed back to the left with spring q Spool (2) is pushed to the right with push pin
(3) reaction force. (4).
q As ports (P) and (A) are closed, the pilot pres- q As ports (P) and (A) are opened, the pilot pres-
sure is not fed to the actuator through port (A). sure is fed to the actuator through port (A).
At the same time, port (T) is opened, allowing At the same time, port (T) is closed, shutting off
the oil from the actuator to drain to the hydrau- the oil from the actuator to the hydraulic tank.
lic tank.
42 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02550-01
PC138US, USLC-8 43
SEN02550-01 10 Structure, function and maintenance standard
PPC accumulator 1
For PPC circuit
1. Gas plug
2. Shell
3. Poppet
4. Holder
5. Bladder
6. Oil port
Outline
q Mounted on the solenoid valve. If the engine is
stopped with the work equipment is kept at an
elevated position, the pilot pressure is supplied
to the control valve by the pressure of the com-
pressed nitrogen gas in the accumulator.
Therefore, the spool can be operated to lower
the work equipment by its own weight.
Specifications
Gas to be used: Nitrogen gas
Gas capacity: 300 cc
Sealed gas pressure:
1.18 MPa {12 kg/cm²} (at 80°C)
Maximum operating pressure:
6.86 MPa {70 kg/cm²}
44 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02550-01
For breaker
(Machine ready for attachment)
For low pressure For high pressure
1. Cap 1. Cap
2. Core 2. Core
3. Guard rubber 3. Locknut
4. Ring 4. Gas port
5. Lid 5. Bladder
6. Bladder 6. Shell
7. Shell
Outline Outline
q Connected to the attachment piping. When the q Connected to the attachment piping. When the
breaker operates, the oil pulsation is absorbed breaker operates, the oil pulsation is absorbed
by the pressure of compressed nitrogen gas of by the pressure of compressed nitrogen gas of
the accumulator, to protect the hydraulic sys- the accumulator, to protect the hydraulic sys-
tem devices and piping. tem devices and piping.
Specifications Specifications
Gas to be used: Nitrogen gas Gas to be used: Nitrogen gas
Gas capacity: 480 cc Gas capacity: 500 cc
Sealed gas pressure: 0.1 MPa {1 kg/cm²} (at 80°C) Sealed gas pressure:
Maximum operating pressure: 0.69 MPa {7 kg/cm²} 5.88 MPa {60 kg/cm²} (at 80°C)
Maximum operating pressure:
20.6 MPa {210 kg/cm²}
PC138US, USLC-8 45
SEN02550-01 10 Structure, function and maintenance standard
Holding valve 1
(For boom and arm)
46 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02550-01
1. Pilot spool
2. Safety valve
3. Check valve
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length
Installation Installation Installation
× Outside Free length
4 Check valve spring length load load
diameter
If damaged or
12.7 N 10.2 N
20.8 × 12.2 13.5 — deformed,
{1.3 kg} {1.04 kg}
replace spring.
58.8 N 47.1 N
5 Spool return spring 41.1 × 9.6 35.0 —
{6.0 kg} {4.8 kg}
78.5 N 62.8 N
6 Spool return spring 41.9 × 25.8 41.0 —
{8.0 kg} {6.4 kg}
PC138US, USLC-8 47
SEN02550-01 10 Structure, function and maintenance standard
Function
q Prevents the pressurized oil from reversing
from the work equipment cylinder in order to
prevents sudden drift of the work equipment at
breaking of the piping between the control
valve and the work equipment cylinder.
Operation
1. When the work equipment lever is in neu-
tral
48 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02550-01
PC138US, USLC-8 49
SEN02550-01 10 Structure, function and maintenance standard
50 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02550-01
Multi-control valve 1
(if equipped)
Control pattern switching diagram (Port names correspond to the marks on the above figures.)
PC138US, USLC-8 51
SEN02550-01 10 Structure, function and maintenance standard
© 2007 KOMATSU
All Rights Reserved
Printed in Japan 02-07 (02)
52 PC138US, USLC-8
SEN02551-00
HYDRAULIC EXCAVATOR
PC138US-8
PC138USLC-8
PC138US, USLC-8 1
SEN02551-00 10 Structure, function and maintenance standard
Work equipment 1
Unit: mm
No. Item Criteria Remedy
Standard Tolerance Standard Clearance
Clearance between mounting size clearance limit
Shaft Hole
1 pin and bushing of boom and
revolving frame -0.030 +0.143 0.093 –
70 0.8
-0.100 +0.063 0.245
Clearance between mounting
-0.030 +0.145 0.095 –
2 pin and bushing of boom and 70 0.8
-0.100 +0.065 0.245
arm
Clearance between mounting
-0.030 +0.129 0.104 –
3 pin and bushing of arm and 60 0.8
-0.080 +0.074 0.209
bucket Replace pin and
Clearance between mounting -0.030 +0.133 0.105 – bushing
4 60 0.8
pin and bushing of arm and link -0.080 +0.075 0.213
Clearance between mounting -0.030 +0.132 0.105 –
5 65 0.8
pin and bushing of link and link -0.080 +0.075 0.212
Clearance between mounting
-0.030 +0.130 0.108 –
6 pin and bushing of link and 60 0.8
-0.080 +0.078 0.210
bucket
Clearance between mounting
-0.030 +0.190 0.120 –
7 pin and bushing of blade and 70 1.5
-0.100 +0.090 0.290
track frame
2 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02551-00
PC138US, USLC-8 3
SEN02551-00 10 Structure, function and maintenance standard
Dimensions of components 1
Arm
4 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02551-00
Unit: mm
PC138US-8, PC138USLC-8
No. Tolerance
Measurement point Standard size
Shaft Hole
-0.030 +0.100
1 — 70
-0.100 0
+1.0
Arm side 81.5
2 0
Cylinder head side 80 ±1.2
+0.5
Boom side 226
0
3
-0.2
Arm side 226
-0.7
-0.030 +0.100
4 — 70
-0.100 0
5 — 264 ±2.0
6 — 213.5 ±1.0
7 — 640.6 ±0.5
8 — 2,491 —
9 — 2,101.9 ±1.5
10 — 290.4 ±0.5
11 — 487 ±0.2
12 — 415 ±0.5
13 — 374.9 —
14 — 1,241.3 —
-0.030 +0.200
15 — 60
-0.080 0
0
Link side 259
16 -1.0
Bucket side 261 ±1.0
-0.030 +0.200
17 — 60
-0.080 0
0
Arm side 226
-0.5
18
+2.0
Bucket side 274
0
Min. 1,378 —
19
Max. 2,263 —
PC138US, USLC-8 5
SEN02551-00 10 Structure, function and maintenance standard
Bucket
6 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02551-00
Unit: mm
PC138US-8, PC138USLC-8
No.
Measurement point Standard size Tolerance
1 — 371.3 ±0.5
2 — 51.6 ±0.5
3 — 97.9° —
4 — 374.9 —
5 — 1,226.6 —
6 — 190.2 —
7 — 5° —
8 — 0° —
+0.2
9 — 60
0
10 — 64 —
+0.25
11 — 80
0
12 — 261 ±1.0
13 — 50 —
14 — 85 —
+1.0
15 — 380
0
16 — 18 —
17 — 110 —
18 — 130 —
19 — 132 —
20 — 108 —
+2.0
21 — 274
0
22 — 51 —
23 — 34 —
24 — 100.5 —
25 — 115.3 —
26 — 74 —
27 — 65 —
PC138US, USLC-8 7
SEN02551-00 10 Structure, function and maintenance standard
Hydraulic cylinder 1
Boom cylinder
Arm cylinder
Bucket cylinder
8 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02551-00
Blade cylinder
Unit: mm
No. Item Criteria Remedy
Cylinder Standard Tolerance Standard Clearance
name size Shaft Hole clearance limit
-0.030 +0.259 0.093 –
Boom 70 0.435
-0.076 +0.063 0.335
Clearance between
1 piston rod and bush- -0.030 +0.279 0.095 –
Arm 75 0.455
ing -0.076 +0.065 0.355
-0.030 +0.250 0.085 –
Bucket 65 0.426
-0.076 +0.055 0.326
-0.030 +0.279 0.095 –
Blade 75 0.455
-0.076 +0.065 0.355
-0.030 +0.190 0.120 –
Boom 70 1.0
-0.100 +0.090 0.290
-0.030 +0.190 0.120 – Replace bush-
Clearance between Arm 70 1.0 ing
-0.100 +0.090 0.290
2 piston rod support
shaft and bushing -0.030 +0.170 0.100 –
Bucket 65 1.0
-0.080 +0.070 0.250
-0.030 +0.190 0.120 –
Blade 70 1.0
-0.100 +0.090 0.290
-0.030 +0.190 0.120 –
Boom 70 1.0
-0.100 +0.090 0.290
Clearance between -0.030 +0.190 0.120 –
Arm 70 1.0
cylinder bottom -0.100 +0.090 0.290
3
support shaft and -0.030 +0.170 0.100 –
bushing Bucket 65 1.0
-0.080 +0.070 0.250
-0.030 +0.190 0.120 –
Blade 70 1.0
-0.100 +0.090 0.290
PC138US, USLC-8 9
SEN02551-00 10 Structure, function and maintenance standard
© 2007 KOMATSU
All Rights Reserved
Printed in Japan 01-07 (02)
10 PC138US, USLC-8
SEN02552-01
HYDRAULIC EXCAVATOR
PC138US-8
PC138USLC-8
PC138US, USLC-8 1
SEN02552-01 10 Structure, function and maintenance standard
Air conditioner 1
Air conditioner piping diagram
2 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02552-01
Specifications
PC138US, USLC-8 3
SEN02552-01 10 Structure, function and maintenance standard
1. Engine
2. Compressor
3. Condenser
3a. Receiver
4. Sight glass
5. Air conditioner unit
6. Dual pressure switch
Unit: Nm{kgm}
No. Item Criteria Remedy
Compressor refrigerant piping 7.85 – 11.8 {0.8 – 1.2}
7
lock bolt (Screw size: M6 × 1.0)
Condenser refrigerant piping 3.92 – 6.86 {0.4 – 0.7}
8 Retighten
lock bolt (Screw size: M6 × 1.0)
Air conditioner unit refrigerant 7.85 – 11.8 {0.8 – 1.2}
9
piping connector lock bolt (Screw size: M6 × 1.0)
4 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02552-01
PC138US, USLC-8 5
SEN02552-01 10 Structure, function and maintenance standard
6 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02552-01
PC138US, USLC-8 7
SEN02552-01 10 Structure, function and maintenance standard
8 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02552-01
PC138US, USLC-8 9
SEN02552-01 10 Structure, function and maintenance standard
Compressor
Specifications
Number of cylinders - bore x
stroke 10-32 x 20.8
(mm)
Piston capacity
129.2
(cc/rev)
Allowable maximum speed
6,000
(rpm)
Refrigerant oil to be used Denso: ND-OIL 8
Refrigerant oil capacity
180
(cc)
10 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02552-01
Condenser
PC138US, USLC-8 11
SEN02552-01 10 Structure, function and maintenance standard
Sunlight sensor
Outline
q The external air temperature sensor is installed
Outline
in the battery room at the rear left of the
q The sunlight sensor is installed on top of the machine.
machine monitor of the air duct. q It senses the external air temperature and
q It senses intensity of the sun light and sends sends signals to the air conditioner controller.
signals to the air conditioner controller. The The signal sent to the air conditioner controller
signal sent to the air conditioner controller is is used to control the compressor. As the
used to control the blower motor and compres- result, temperature of the air blown out of the
sor. grill is adjusted depending on the volume of
refrigerant circulated in the evaporator.
Output characteristics
12 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02552-01
PC138US, USLC-8 13
SEN02552-01 10 Structure, function and maintenance standard
© 2007 KOMATSU
All Rights Reserved
Printed in Japan 02-07 (02)
14 PC138US, USLC-8
SEN02553-01
HYDRAULIC EXCAVATOR
PC138US-8
PC138USLC-8
PC138US, USLC-8 1
SEN02553-01 10 Structure, function and maintenance standard
2 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02553-01
PC138US, USLC-8 3
SEN02553-01 10 Structure, function and maintenance standard
1. Battery Function
2. Battery relay 1. The neutral safety circuit is employed to
3. Fusible link secure safety when the engine is started.
4. Fuse box q The engine does not start until the lock
5. Starting switch lever is set in the “LOCK“ position.
6. Engine controller
7. Lock lever 2. The KOMTRAX engine cut circuit is employed
8. PPC lock switch to disable the engine from starting when the
9. Starting motor cut-out relay (for PPC lock) KOMTRAX terminal receives an engine cut
10. Starting motor cut-out relay (for personal code) command issued through external operation.
11. Fuel control dial
12. Safety relay
13. Starting motor
14. Fuel supply pump
15. Sensors
16. Engine controller power cut-off relay A
17. Engine controller power cut-off relay B
18. Machine monitor
19. KOMTRAX terminal
4 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02553-01
Starting engine
q When starting switch (5) is turned “ON“, engine
controller (6) sends command current to fuel
supply pump (14).
For this reason, a fail-safe mechanism is pro-
vided with the electrical system to stop the
engine when an electrical failure occurs.
q When starting switch (5) is turned to “START“
with lock lever (7) set in the “LOCK“ position, a
starting current is supplied to starting motor
(13) causing the engine to start.
However, as the neutral safety mechanism is
provided, the engine will not start if lock lever
(7) is set in the “FREE“ position at this time;
starting motor cut-out relay (9) cuts off the
starting current to starting motor (13).
q Upon receipt of the engine cut-off command
from the external source, KOMTRAX terminal
(19) sends the signal to machine monitor (18).
Machine monitor (18) causes starting motor
cut-out relay (10) to cut off the starting current
to starting motor (13), therefore the engine
does not start.
Stopping engine
q When starting switch (5) is turned “OFF“, the
current from the ACC terminal of starting
switch (5) to engine controller (6) is cut off, and
consequently the command current to fuel sup-
ply pump (14) is cut off.
Fuel supply pump (14) stops fuel feed, causing
the engine speed to go down and the engine
stops.
PC138US, USLC-8 5
SEN02553-01 10 Structure, function and maintenance standard
6 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02553-01
Function
q A function that selects working mode with the
working mode selector switch in the machine
monitor. 5 modes (P, E, L, ATT, B) are avail-
able, allowing the operator to select appropri-
ate engine torque (T) and pump absorption
torque depending on the work. In the default
setting of the service mode, only 3 modes (P,
E, L) are available in which “Without“ is
selected for the attachment.
q According to the pump absorption torque set at
each mode, based on the engine governor set
speed with the fuel control dial and the actual
engine speed, the controller controls so that
the pump absorbs all torques at each engine
output point.
q When the engine speed is lowered, the con-
troller prevents the engine from stopping by
throttling the pump absorption torque.
PC138US, USLC-8 7
SEN02553-01 10 Structure, function and maintenance standard
8 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02553-01
Modes B and L
q Matching point:
Working mode Matching point
50.9 kW/1,870 rpm
B
{68.2 HP/1,870 rpm}
47.8 kW/1,640 rpm
L
{64.1 HP/1,640 rpm}
PC138US, USLC-8 9
SEN02553-01 10 Structure, function and maintenance standard
Control function during travel Control function with emergency pump drive
q Traveling the machine in P or ATT mode switch “ON“
increases engine speed (N). q If the controller gets out of order and no work is
q Traveling the machine in E, L or B mode does possible because the hydraulic pump does not
not change engine speed (N) or pump absorp- work properly, operating emergency pump
tion torque. drive switch (1) temporarily enables to main-
tain functions of the machine with absorption
torques quite similar to those in the Mode E.
In this case, a constant current flows from the
battery to the PC-EPC valve, and the valve
detects the oil pressure only.
a. Emergency
b: Normal
a Emergency pump drive switch (1) is of the
alternative type. If the machine is operated
after the switch is set to “Emergency (a)“ even
though the machine is normal, the user code
“E02“ will be shown on the display.
10 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02553-01
PC138US, USLC-8 11
SEN02553-01 10 Structure, function and maintenance standard
Auto-decelerator function
12 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02553-01
Function
q When all the control levers are set to NEU-
TRAL for waiting for a dump track or work, the
engine speed is automatically reduced to a
control speed, and fuel consumption and noise
are lowered.
q When any control lever is operated, the engine
speed returns immediately to the speed that is
set with the fuel control dial.
Operation
When control levers are set in neutral
q If all the control levers are set to NEUTRAL for
4 seconds or more with the engine speed
exceeding approx. 1,400 rpm, the engine
speed lowers down to the control speed
(approx. 1,400 rpm) and is held until the con-
trol lever is operated again.
PC138US, USLC-8 13
SEN02553-01 10 Structure, function and maintenance standard
14 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02553-01
Function
q Raises the engine speed automatically to warm up the engine if the coolant temperature is low after
start-up of the engine.
Operational conditions (all required) Operation
Coolant temperature: Max. 30°C o
Engine speed: 1,300 rpm
Fuel control dial: Max. 70% of full rotation
O
Release conditions (either one required) Release
Coolant temperature: Min. 30°C
Automatic
Duration of automatic warming-up: Min. 10 minutes o
Engine speed: Any
Fuel control dial: Held at Min. 70% of full rotation for Min. 3 sec-
Manual
onds
q Prevents overheat to protect the engine by reducing load on the pump if the coolant or hydraulic oil tem-
perature becomes too high.
Operational conditions Operation and actions taken Release conditions
Coolant temperature: Max. 95°C
Working mode: P, ATT Engine speed: Remains same
Coolant temperature: Min. 95°C o • Sends torque control signal to o Hydraulic oil temperature: Max. 95°C
• The original conditions are restored if
Hydraulic oil temperature: Min. 95°C lower the pump absorption torque
above requirements are met (auto-
Traveling status check: OFF and reduce the engine load. matic restoration).
Working mode: P, ATT Engine speed: Remains same Coolant temperature: Max. 100°C
Coolant temperature: Min. 100°C o • Sends torque control signal to o Hydraulic oil temperature: Max. 100°C
• The original conditions are restored if
Hydraulic oil temperature: Min. 100°C lower the pump absorption torque
above requirements are met (auto-
Traveling status check: Any and reduce the engine load. matic restoration).
PC138US, USLC-8 15
SEN02553-01 10 Structure, function and maintenance standard
q When the engine is started at low temperatures and the engine speed is increased sharply, the turbo-
charger may be seized. Controlling the engine speed prevents this problem.
q Duration of engine speed control depends on the coolant temperature.
Operational conditions Operating
o Turbocharger protection
Engine oil pressure: Max. 50 kPa {0.51 kg/cm2}
(See the following figure)
A: Start engine
B: Duration of turbocharger protection (approx. 0
– 20 sec)
C: Modulating time (approx. 1.5 sec)
D: 500 rpm
E: 1,100 rpm
F: 2,300 rpm (*1)
16 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02553-01
PC138US, USLC-8 17
SEN02553-01 10 Structure, function and maintenance standard
Function
Swing lock
OFF ON
switch
Swing lock and swing holding brake functions
Swing lock
q Turning swing lock switch (1) to “ON“ locks the OFF ON
monitor
swing lock (manual lock) at any position.
Function Swing holding brake Swing lock
q Interlocked with the swing operation, the swing
holding brake (auto lock) prevents hydraulic • When the L.H. work • The swing hold-
drift from occurring after the swing stops. equipment control ing brake works to
q Interlocked with the arm retract operation, the lever is set to NEU- lock the swing.
TRAL, the swing • Even if the L.H.
swing holding brake is released to reduce the holding brake works work equipment
load on the swing equipment during excavation in 5 sec. control lever is
work. • When the L.H. work operated for
Operation equipment control swing, the swing
lever is operated for holding brake
swing or the arm cannot be
lever is operated for released, and no
retract, the swing swing is possible.
holding brake is
released allowing
free swing opera-
tion.
18 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02553-01
PC138US, USLC-8 19
SEN02553-01 10 Structure, function and maintenance standard
20 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02553-01
Function
PC138US, USLC-8 21
SEN02553-01 10 Structure, function and maintenance standard
*1. If the work equipment etc. is operated in pattern 4, the pump merge-divider valve is set to the merge
mode of pattern 5. Even if the work equipment operation is stopped after the pump merge-divider valve
is set in pattern 5, the pump merge-divider valve is not returned to pattern 4.
22 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02553-01
1. Battery Function
2. Battery relay q Interlocked with the lock lever, the PPC lock
3. Fusible link switch is turned “OFF“ when operating the lock
4. Fuse box lever to “LOCK“ position.
5. Starting switch q When the PPC lock switch is turned “OFF“, the
6. Lock lever current to the PPC lock solenoid valve is cut-
7. PPC lock switch off, causing neither the work equipment nor
8. Hydraulic pump machine moves even if levers or pedal is oper-
9. Control valve ated.
9a. Pump merge-divider valve
9b. Self pressure reducing valve
10. PPC lock solenoid valve
PC138US, USLC-8 23
SEN02553-01 10 Structure, function and maintenance standard
24 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02553-01
PC138US, USLC-8 25
SEN02553-01 10 Structure, function and maintenance standard
System components
Engine controller
DTP-4P [CN-CE03]
Signal
Pin No. Signal name
classification
1 GND C
2 NC —
3 Constant power supply (24 V) A
4 NC —
26 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02553-01
DRC-60P(1) [CN-CE01]
Signal Signal
Pin No. Signal name Pin No. Signal name
classification classification
1 NC — 31 NC —
2 NC — 32 Engine oil pressure switch B
3 NC — 33 NC —
4 NC — 34 NC —
5 NC — 35 NC —
6 NC — 36 Sensor power supply (5 V) A
7 NC — 37 Camshaft speed sensor B
8 NC — 38 NC —
9 NC — 39 NC —
10 Fuel supply pump regulator (+) B 40 NC —
11 Boost temperature sensor B 41 NC —
12 NC — 42 Crankshaft speed sensor B
13 NC — 43 NC —
14 Fuel supply pump regulator (–) C 44 Crankshaft speed sensor GND C
15 NC — 45 Injector #2 (+) D
16 NC — 46 NC —
17 NC — 47 Coolant temperature sensor GND C
18 NC — 48 Sensor GND C
19 Boost pressure sensor B 49 Coolant temperature sensor D
20 Ambient pressure sensor B 50 NC —
21 NC — 51 Injector #4 (–) C
22 NC — 52 NC —
23 NC — 53 Injector #1 (–) C
24 NC — 54 NC —
25 NC — 55 Injector #3 (+) D
26 Crankshaft speed sensor (5 V) A 56 Injector #4 (+) D
27 NC — 57 Injector #1 (+) D
28 NC — 58 Injector #2 (–) C
29 Common rail pressure sensor B 59 Injector #3 (–) C
30 NC — 60 NC —
DRC-60P(2) [CN-CE02]
Pin No. Signal name Signal Pin No. Signal name Signal
classification classification
1 CAN(+) E 31 NC —
Engine controller power cut-off relay
2 NC — 32 C
GND
3 NC — 33 NC —
4 NC — 34 NC —
5 NC — 35 Fuel control dial (+) B
6 NC — 36 NC —
7 NC — 37 NC —
8 NC — 38 NC —
9 NC — 39 NC —
10 NC — 40 NC —
11 NC — 41 NC —
12 NC — 42 NC —
13 NC — 43 NC —
14 NC — 44 NC —
15 NC — 45 Starting switch ACC signal B
16 NC — 46 NC —
17 NC — 47 NC —
18 NC — 48 NC —
19 NC — 49 NC —
20 NC — 50 NC —
21 CAN (–) E 51 NC —
22 NC — 52 NC —
23 NC — 53 NC —
24 NC — 54 NC —
25 NC — 55 Engine controller power cut-off relay D
26 NC — 56 NC —
27 Fuel control dial (5 V) A 57 NC —
28 Fuel control dial (–) C 58 NC —
29 NC — 59 NC —
30 NC — 60 NC —
PC138US, USLC-8 27
SEN02553-01 10 Structure, function and maintenance standard
Pump controller
28 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02553-01
PC138US, USLC-8 29
SEN02553-01 10 Structure, function and maintenance standard
1. Knob
2. Dial
3. Spring
4. Ball
5. Potentiometer
6. Connector
Function
q Installed in the right console box. Potentiome-
ter (5) is installed inside knob (1). Turning knob
(1) causes potentiometer (5) shaft to rotate.
q This rotation changes the resistance of the
variable resistor within potentiometer (5), and a
throttle signal is sent to the controller.
q The hatched areas in the graph are error
detection areas. If the throttle voltage is within
the area, the engine drops down to low idle.
30 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02553-01
Resistor
1. Resistance
2. Connector
Specifications
For PC-EPC valve: 30 z
Function
q Sends an electric current to each EPC valve
that is appropriate for each condition, when the
emergency pump drive switch is turned to
“ON“.
a No electric current flows in the normal condi-
tion.
PC138US, USLC-8 31
SEN02553-01 10 Structure, function and maintenance standard
1. Connector
2. Sensor
3. O-ring
Specifications
Contact type: Normal close
Function
q Installed in the cylinder block. Detects engine
oil pressure, and turns the switch “ON“ when
the pressure goes below the specified value.
32 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02553-01
1. Plug
2. Switch
3. Connector
Specifications
Contact type: Normal open
Operating pressure to make contact point ON:
490 ± 98.1 kPa {5.0 ± 1.0 kg/cm2}
Operating pressure to break contact point OFF:
294 ± 49.0 kPa {3.0 ± 0.5 kg/cm2}
Function
q Installed (8 places) in the connecting valve.
Detects the PPC oil pressure when each actu-
ator is operated, and turns the switch “ON“
when the pressure exceeds the specified
value.
PC138US, USLC-8 33
SEN02553-01 10 Structure, function and maintenance standard
34 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02553-01
Monitor system 1
PC138US, USLC-8 35
SEN02553-01 10 Structure, function and maintenance standard
Machine monitor
36 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02553-01
070-12P(1) [CN-CM02]
Input/output Input/output
Pin No. Signal name Pin No. Signal name
signal signal
1 Engine oil pressure sensor Input 7 GND (machine signal) —
2 Engine oil level sensor Input 8 CAN terminal signal —
3 Radiator coolant level sensor Input 9 CAN_H Input/output
4 Air cleaner clogging sensor Input 10 CAN_L Input/output
5 Swing lock switch Input 11 USB data (–) Input/output
6 Spare Input 12 USB data (+) Input/output
070-18P(2) [CN-CM03]
Input/output Input/output
Pin No. Signal name Pin No. Signal name
signal signal
For communication terminal, RS232C For communication terminal, RS232C
1 Input 10 Input
CD CTS
For communication terminal, RS232C For communication terminal, RS232C
2 Input 11 Input
RXD RI
For communication terminal, RS232C GND (communication terminal power
3 — 12 —
SG supply)
GND (communication terminal con- Communication terminal status signal
4 — 13 Input
trol signal) CH1
Communication terminal selection Communication terminal power sup-
5 Input 14 Output
signal ply control signal
For communication terminal, RS232C Communication terminal control sig-
6 Output 15 Output
RTS nal CH1
For communication terminal, RS232C Communication terminal control sig-
7 Output 16 Output
TXD nal CH2
For communication terminal, RS232C Communication terminal status signal
8 Output 17 Input
DTR CH2
For communication terminal, RS232C Communication terminal power sup-
9 Input 18 Output
DSR ply (12 V)
070-12P(2) [CN-CM04]
Input/output Input/output
Pin No. Signal name Pin No. Signal name
signal signal
GND (peripheral equipment power
1 — 7 Reserved —
supply)
2 Peripheral equipment control signal Output 8 Reserved —
GND (for peripheral equipment,
3 — 9 Reserved —
RS232C)
4 For peripheral equipment, RS232C TXD Output 10 Reserved —
For peripheral equipment, RS232C
5 Input 11 Reserved —
RXD
Peripheral equipment power supply
6 Reserved — 12 Output
(12 V)
B60-8P [CN-CM05]
Input/output Input/output
Pin No. Signal name Pin No. Signal name
signal signal
1 Camera power supply (8 V) Output 5 GND (Camera power supply) —
2 Camera NTSC signal 1 Input 6 GND (Camera signal 1) —
3 Camera NTSC signal 2 Input 7 GND (Camera signal 2) —
4 Camera NTSC signal 3 Input 8 GND (Camera signal 3) —
PC138US, USLC-8 37
SEN02553-01 10 Structure, function and maintenance standard
Display
38 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02553-01
PC138US, USLC-8 39
SEN02553-01 10 Structure, function and maintenance standard
*2: Included in the star-up check. After the staring switch is turned “ON“, the monitor turns ON for 2 sec-
onds, and changes to a normal operation screen if no error is found.
40 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02553-01
PC138US, USLC-8 41
SEN02553-01 10 Structure, function and maintenance standard
Switches
*1: When the working mode is changed, the auto-decelerator function turns “ON“.
42 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02553-01
*2: When the temperature is set at 18.0°C or 32.0°C, the fan speed is kept at “High“. Even if the set tem-
perature is reached, the fan speed remains the same.
*3: When the fan is set at Stop, the air conditioner does not start even if the switch is pressed.
PC138US, USLC-8 43
SEN02553-01 10 Structure, function and maintenance standard
Guidance
Function switch Item Function
icon
1 Clear Clears selected/displayed item.
Moves selection down one page.
2 Move selection
(To the top page from the bottom page.)
3 Set Sets function.
F1 Starts function.
4 Start (Used for starting measurement of spilt fuel consump-
tion.)
Stops function.
5 Stop (Used for stopping measurement of spilt fuel con-
sumption.)
Sets selected item back to default.
1 Default
(Used for screen adjustment.)
F2 Moves selection up one page.
2 Move selection
(To the bottom page from the top page.)
3 Clear Clears selected/displayed item.
1 Camera image Switches to camera image.
Moves selection down one item.
2 Move selection (To the top item from the bottom item.) Releases hold-
F3
ing of the monitor.
Moves selection to the left.
3 Move selection
(To the rightmost item from the leftmost item.)
1 Switching clock/service meter Switches clock/service meter display.
Moves selection up one item.
2 Move selection (To the bottom item from the top item.) Holds the mon-
F4
itor.
Moves selection to the right.
3 Move selection
(To the leftmost item from the rightmost item.)
44 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02553-01
Guidance
Function switch Item Function
icon
1 Selecting maintenance screen Selects maintenance screen.
F5
2 Return Returns to the previous screen or condition.
1 Selecting user mode screen Selects user mode screen.
F6
2 Fix Fixes selected/displayed item.
PC138US, USLC-8 45
SEN02553-01 10 Structure, function and maintenance standard
*1: The items available in the operator mode fall into the following categories.
A: Display from the time starting switch is turned “ON“ until the ordinary screen appears. Display after
the starting switch is turned “OFF“.
B: Display when the switch of machine monitor is operated.
C: Display when a certain condition is satisfied
D: Display when special switch operation is necessary.
*2: For the category A, the order in which items are displayed varies depending on the setting and condi-
tions of the machine as follows:
W: When the engine start lock is set on
X: When the engine start lock is set off
Y: When an error is detected during start-up check.
Z: When a maintenance overdue is detected.
a For how to operate the operator mode functions, see the Operation and Maintenance Manual or “Spe-
cial functions of machine monitor“ in Testing and adjusting.
a For how to set the engine start lock on/off, see “Password setting/cancel manual“.
46 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02553-01
Oil flow setting for breaker Oil flow setting for attachment
q Oil flow for the breaker can be changed in the q Oil flow for the compound attachment can be
“Breaker/attachment setting“ of the user mode. changed in the “Breaker/attachment setting“ of
q Oil flow level can be set as follows: the user mode.
q Oil flow level can be set as follows:
Oil flow level Quantity (l/min) Remarks
1 60 Oil flow level Quantity (l/min) Remarks
2 70 1 30
3 80 2 85
4 90 3 105
5 100 4 130
6 110 5 155
7 120 6 175
10 150
11 160 Language setting
12 170
13 180
14 190
15 200
PC138US, USLC-8 47
SEN02553-01 10 Structure, function and maintenance standard
a For how to operate the service mode functions, see “Special functions of machine monitor“ in Testing
and adjusting.
48 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02553-01
KOMTRAX system 1
PC138US, USLC-8 49
SEN02553-01 10 Structure, function and maintenance standard
KOMTRAX terminal
TH300
q The KOMTRAX system uses satellite commu- Input and output signals
nication technology.
AMP-14P [CN-CK01]
1. Communication antenna connection Pin No. Signal name
Input/output
2. Machine harness connection (AMP-14P) signal
3. Machine harness connection (AMP-10P) A1 Power supply (5 V) Input
A2 NC —
Outline
A3 NC —
q The KOMTRAX terminal sends various machine
information based on the network signals and A4 Selection of power supply voltage Output
input signals obtained through the machine A5 NC —
monitor, as well as GPS position data, via wire- A6 NC —
less communication. The KOMTRAX terminal
A7 GND Input
can sends information via communication
antenna. A8 GND Input
q Conditions of the KOMTRAX terminal can be A9 NC —
checked with the “Display of KOMTRAX set- A10 NC —
ting“ in the service mode of the machine moni-
A11 NC —
tor.
q Use of KOMTRAX terminal must be limited for A12 NC —
the countries in which such communication is A13 NC —
allowed. A14 NC —
AMP-10P [CN-CK02]
Input/output
Pin No. Signal name
signal
B1 RS232C DCD Output
B2 RS232C RXD Output
B3 RS232C TXD Input
B4 RS232C DTR Input
B5 RS232C SGND Input
B6 RS232C DSR Output
B7 NC —
B8 NC —
B9 NC —
B10 NC —
50 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02553-01
Sensor 1
Atmospheric pressure sensor
1. Connector
2. Pressure inlet port
Function
q Installed in the bracket on the side face of the cylinder block. Detects the ambient pressure and outputs
variable voltage.
1. Connector
2. Sensor
3. O-ring
Function
q Installed in the intake manifold. Detects the boost pressure and boost temperature, and outputs signal
as a variable voltage for pressure, and a resistance change for temperature.
PC138US, USLC-8 51
SEN02553-01 10 Structure, function and maintenance standard
1. Connector
2. Sensor
3. O-ring
Function
q Installed in the water pump. Detects the temperature change and outputs signal as a resistance change.
1. Connector
2. Sensor
3. O-ring
Function
q The crankshaft speed sensor is installed in the gear of the flywheel, and the camshaft speed sensor is
installed in the gear of the camshaft. Each of the sensors outputs a pulse voltage according to the gear
rotation.
52 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02553-01
1. Common rail
2. Sensor
3. Connector
Function
q Installed in the common rail. Detects the fuel pressure and outputs variable voltage.
1. Connector 3. Float
2. Bracket 4. Switch
Function
q The engine oil level sensor is installed to the side of the oil pan. If the oil level lowers below the specified
level, the float lowers and the switch is turned “OFF“.
PC138US, USLC-8 53
SEN02553-01 10 Structure, function and maintenance standard
1. Connector 5. Spring
2. Float 6. Contact
3. Arm 7. Spacer
4. Body
Function
q This sensor is installed on the side face of the fuel tank. The float moves up and down according to the
fuel level.
The float moves the variable resistor through the arm. The resistance changes according to the operat-
ing angle and signal voltage is generated from the source voltage according to the change of the resis-
tance.
54 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02553-01
1. Connector
2. Plug
3. Thermistor
Function
q Installed in the suction pipe of the hydraulic pump. Detects the temperature change and outputs signal
as a resistance change of the thermistor.
Function
q The pump oil pressure sensor is installed in the
control valve. Detects the pump discharge
pressure and outputs variable voltage.
PC138US, USLC-8 55
SEN02553-01 10 Structure, function and maintenance standard
Function
q The PPC oil pressure sensor is installed in the
control valve connecting part of the pilot circuit
for travel and blade operation. Detects the pilot
pressure and outputs variable voltage.
56 PC138US, USLC-8
10 Structure, function and maintenance standard SEN02553-01
PC138US, USLC-8 57
SEN02553-01 10 Structure, function and maintenance standard
© 2007 KOMATSU
All Rights Reserved
Printed in Japan 02-07 (02)
58 PC138US, USLC-8
SEN02457-01
PC138US-8
PC138USLC-8
PC138US, USLC-8 1
SEN02457-01 20 Standard value table
Engine SAA4D95LE-5
• Arm IN relief
0.34 – 0.59 0.25
SAE30 Oil
• At sudden {3.5 – 6.0} {2.5}
Oil pressure acceleration 0.29 – 0.49 0.2
SAE10W Oil
(Hydraulic oil MPa {3.0 – 5.0} {2.1}
temperature: {kg/cm2} Min. 0.18 0.15
Min. 80°C) SAE30 Oil
{Min. 1.8} {1.5}
• Low idle
Min. 0.15 0.13
SAE10W Oil
{Min. 1.5} {1.3}
• Whole speed range
Oil temperature °C 80 – 115 120
(inside oil pan)
• Between fan pulley and
alternator pulley
Fan belt tension • Deflection when pressed with mm 6 – 10 —
finger force of approx.
60 N {6.1 kg}
• Between fan pulley and
Air conditioner compressor pulley
compressor belt • Deflection when pressed with mm 12 – 15 12 – 15
tension finger force of approx.
60 N {6.1 kg}
2 PC138US, USLC-8
20 Standard value table SEN02457-01
45 – 55°C
• Engine oil pressure:
At 1-pump relief rpm 2,050 ± 100 —
Within operating range
• Engine water temperature:
Within operating range
• Center of No
Boom control lever 100 ± 11 100 ± 21
lever knob RAISE, LOWER
• Tip of pedal
Arm control lever • Read max. N o IN, OUT 85 ± 11 85 ± 21
value to end
of travel No
Bucket control lever 100 ± 11 100 ± 21
Travel of control levers
PC138US, USLC-8 3
SEN02457-01 20 Standard value table
4 PC138US, USLC-8
20 Standard value table SEN02457-01
PC138US, USLC-8 5
SEN02457-01 20 Standard value table
Max. 15 Max. 23
retraction of • Bucket: Rated load (450 kg)
cylinder) • Levers at HOLD
Arm cylinder • Engine stopped
(amount of • Hydraulic oil temperature:
Max. 50 Max. 75
extension of 45 – 55°C
cylinder) • Start testing immediately after mm
Bucket cylinder setting.
(amount of • Test hydraulic drift every 5
minutes, and judge from results Max. 40 Max. 60
retraction of
cylinder) for 15 minutes.
• Engine stopped
• Hydraulic oil temperature:
Blade (hydraulic 45 – 55°C
drift at tip of • Set blade at maximum lifting Max. 31 Max. 47
blade) height and test downward
movement at edge of blade for
Work equipment
15 minutes.
Boom • For testing posture, see 3.8 ± 0.3 Max. 4.4
RAISE
O
Cylinder fully 3.1 ± 0.3 Max. 4.2
extended
• For testing posture, see 3.2 ± 0.3 Max. 4.0
Arm
Work equipment 3 (Until touching (Until touching
IN
Cylinder fully
Work equipment speed
6 PC138US, USLC-8
20 Standard value table SEN02457-01
equipment 8
• Engine at low idle
• Hydraulic oil temperature:
45 – 55°C
Bucket • Set top surface of boom Max. 2 Max. 2
horizontal, retract arm cylinder
fully, then extend bucket
cylinder and test time taken for
bucket to start moving again
after stopping at bottom.
• For testing posture, see Work
equipment 9
• Engine at low idle
• Hydraulic oil temperature:
45 – 55°C
Blade Max. 2 Max. 2
• Lower blade from maximum
height and test time taken from
point where blade contacts
ground to point where chassis
rises from ground.
• Hydraulic oil temperature:
Internal leakage level
PC138US, USLC-8 7
SEN02457-01 20 Standard value table
P1 + P2
As desired P1 P2 See graph See graph
2
a As far as possible, bring pump discharge pressure P1 and P2 as close as possible to the average pres-
sure when testing.
The error is large near the point where the graph curves, so avoid testing at this point.
a When testing with the pump mounted on the machine, if it is impossible to set the engine speed to the
specified speed with the fuel control dial, take the pump discharge amount and the engine speed at the
point of test, and use them as a base for calculating the pump discharge amount at the specified speed.
a Pump delivery Q in the graph is the delivery from 1 side of the pump.
8 PC138US, USLC-8
20 Standard value table SEN02457-01
Posture of machine for testing performance and Travel 2: Travel speed (actual run), travel deviation
test procedure
Swing 1: Swing brake angle, time taken to start
swing, time taken to swing
PC138US, USLC-8 9
SEN02457-01 20 Standard value table
10 PC138US, USLC-8
20 Standard value table SEN02457-01
PC138US, USLC-8 11
SEN02457-01 20 Standard value table
© 2007 KOMATSU
All Rights Reserved
Printed in Japan 02-07 (02)
12 PC138US, USLC-8
SEN02458-01
PC138US-8
PC138USLC-8
PC138US, USLC-8 1
SEN02458-01 30 Testing and adjusting
2 PC138US, USLC-8
30 Testing and adjusting SEN02458-01
Q'ty
Testing/Adjusting item Part No. Part name Remarks
bol
Exhaust temperatures R 799-101-1502 Digital thermometer 1 -99.9 – 1,299°C
1 799-201-9001 Handy smoke checker 1 Bosch index: 0 – 9
Checking exhaust gas
A Commercially
color 2 Smoke meter 1
available
1 795-799-1131 Gear 1
Adjusting valve clearance B Commercially Intake: 0.35 mm
2 Thickness gauge 1
available Exhaust: 0.57 mm
1 795-502-1590 Compression gauge 1 0 – 6.9 MPa {0 – 70 kg/cm2}
Testing compression pres-
C 795-471-1420 Adapter 1
sure 2 For 95E-5 engine
6261-11-3880 Gasket 1
Testing blow-by pressure D 1 799-201-1504 Blow-by checker 1 0 – 5 kPa {0 – 500 mmH2O}
Pressure gauge:
799-101-5002 Hydraulic tester 1 2.5, 5.9, 39.2, 58.8 MPa
1 {25, 60, 400, 600 kg/cm2}
Testing engine oil pres-
E Pressure gauge:58.8 MPa
sure 799-261-1204 Digital hydraulic tester 1
{600 kg/cm2}
Pressure gauge:0.98 MPa
2 799-401-2320 Gauge 1
{10 kg/cm2}
Pressure gauge:
799-101-5002 Hydraulic tester 1 2.5, 5.9, 39.2, 58.8 MPa
1 {25, 60, 400, 600 kg/cm2}
Pressure gauge:58.8 MPa
790-261-1204 Digital hydraulic tester 1
Testing fuel pressure F {600 kg/cm2}
795-471-1450 Adapter 1 Size: 8 x 1.25 mm
2
07005-00812 Washer 1
Pressure gauge:0.98 MPa
3 799-401-2320 Gauge 1
{10 kg/cm2}
1 6151-51-8490 Spacer 1 ø14
2 6164-81-5750 Joint 1 ø14
3 07042-20108 Plug 1
Commercially
4 Hose 1 Internal dimensions: Approx. 6 mm
available
Testing fuel return rate
G Commercially
and leakage 5 Hose 1 Internal dimensions: Approx. 12 mm
available
Commercially
6 Measuring cylinder 1
available
Commercially
7 Stopwatch 1
available
Testing swing circle bear- Commercially
H Dial gauge 1
ing clearance available
Pressure gauge:
799-101-5002 Hydraulic tester 1 2.5, 5.9, 39.2, 58.8 MPa
Testing and adjusting oil 1 {25, 60, 400, 600 kg/cm2}
pressure in work equip- Pressure gauge: 58.8 MPa
J
ment, swing, and travel 790-261-1204 Digital hydraulic tester 1
{600 kg/cm2}
circuits
799-101-5220 Nipple 2 Size: 10 x 1.25 mm
2
07002-11023 O-ring 2
PC138US, USLC-8 3
SEN02458-01 30 Testing and adjusting
Sym-
Q'ty
Testing/Adjusting item Part No. Part name Remarks
bol
Pressure gauge:
799-101-5002 Hydraulic tester 1 2.5, 5.9, 39.2, 58.8 MPa
1 {25, 60, 400, 600 kg/cm2}
Testing basic pressure of Pressure gauge: 58.8 MPa
K
control circuit 790-261-1204 Digital hydraulic tester 1
{600 kg/cm2}
799-101-5220 Nipple 2 Size: 10 x 1.25 mm
2
07002-11023 O-ring 2
Pressure gauge:
799-101-5002 Hydraulic tester 1 2.5, 5.9, 39.2, 58.8 MPa
1 {25, 60, 400, 600 kg/cm2}
Testing and adjusting oil
pressure in pump PC con- L Pressure gauge: 58.8 MPa
790-261-1204 Digital hydraulic tester 1
trol circuit {600 kg/cm2}
799-101-5220 Nipple 2 Size: 10 x 1.25 mm
2
07002-11023 O-ring 2
Pressure gauge:
799-101-5002 Hydraulic tester 1 2.5, 5.9, 39.2, 58.8 MPa
1 {25, 60, 400, 600 kg/cm2}
Testing and adjusting oil Pressure gauge: 58.8 MPa
790-261-1204 Digital hydraulic tester 1
pressure in pump LS con- M {600 kg/cm2}
trol circuit Differential pressure
2 799-401-2701 1 49 MPa {500 kg/cm2}
gauge
799-101-5220 Nipple 2 Size: 10 x 1.25 mm
3
07002-11023 O-ring 2
Pressure gauge:
799-101-5002 Hydraulic tester 1 2.5, 5.9, 39.2, 58.8 MPa
Testing solenoid valve out- 1 {25, 60, 400, 600 kg/cm2}
N
put pressure Pressure gauge: 58.8 MPa
790-261-1204 Digital hydraulic tester 1
{600 kg/cm2}
2 799-401-3100 Adapter 1 Size: 02
Pressure gauge:
799-101-5002 Hydraulic tester 1 2.5, 5.9, 39.2, 58.8 MPa
Testing PPC valve output 1 {25, 60, 400, 600 kg/cm2}
P
pressure Pressure gauge: 58.8 MPa
790-261-1204 Digital hydraulic tester 1
{600 kg/cm2}
2 799-401-3100 Adapter 1 Size: 02
Commercially
Testing oil leakage Q Measuring cylinder 1
available
799-601-4100
or T-adapter assembly 1
799-601-4200
799-601-4130 • T-adapter 1 CAM
799-601-4160 • T-adapter 1 Ne sensor
Troubleshooting for 799-601-4220 • T-adapter 1 Engine controller
engine controller/sensors/ S 799-601-4240 • Socket 1 For ambient pressure sensor
actuators
799-601-4190 • Socket 1 Common rall pressure sensor
799-601-4340 • Socket 1 Injector
795-799-5530 • Socket 1 Engine water temprature sensor
799-601-4380 Socket 1 Boost pressure sensor
799-601-4390 Socket 1 Engine controller
4 PC138US, USLC-8
30 Testing and adjusting SEN02458-01
Sym-
Q'ty
Testing/Adjusting item Part No. Part name Remarks
bol
799-601-4100
or
799-601-4200
or T-adapter assembly 1
799-601-9000
or
799-601-9200
799-601-9020 • Adapter for DT 1 For DT2P
For DT3P (Does not include 799-601-
799-601-9030 • Adapter for DT 1
4100 and 799-601-4200)
For DT6P (Does not include 799-601-
799-601-9050 • Adapter for DT 1
4100 and 799-601-4200)
Troubleshooting for chas- For DT12P (Does not include 799-
799-601-9110 • Adapter for DT 1
sis sensors/wiring har- T 601-4100 and 799-601-4200)
nesses For HD30P (Does not include 799-
799-601-9220 • Adapter for HD30 1
601-4100 and 799-601-4200)
799-601-7000
or
799-601-7100
or T-adapter kit 1
799-601-7400
or
799-601-8000
For SW6P (Does not include 799-
799-601-7050 • Adapter for SWP 1
601-8000)
799-601-7090 • Adapter for M 1 For M2P
799-601-7110 • Adapter for M 1 For M3P
Testing coolant tempera-
799-101-1502 Digital thermometer 1 -99.9 – 1,299°C
ture and oil temperature
—
Testing operating effort 79A-264-0021 Push-pull scale 1
and depressing force 79A-264-0091 Push-pull scale 1
Testing stroke and hydrau- Commercially
— Ruler 1
lic drift available
Testing work equipment Commercially
— Stopwatch 1
speed available
Testing voltage and resis- Commercially
— Circuit tester 1
tance available
a For the model names and part Nos. of the T-boxes and T-adapters used for troubleshooting for the
machine monitor, controllers, sensors, actuators, electrical equipment, and wiring harnesses, see "Trou-
bleshooting (General information on troubleshooting), List of T-boxes and T-adapters".
PC138US, USLC-8 5
SEN02458-01 30 Testing and adjusting
6 PC138US, USLC-8
30 Testing and adjusting SEN02458-01
Testing exhaust temperature 1 4. Run the engine and test the exhaust tempera-
ture over the speed range.
a Testing tools for exhaust temperature
Symbol Part No. Part name
R 799-101-1502 Digital thermometer
PC138US, USLC-8 7
SEN02458-01 30 Testing and adjusting
8 PC138US, USLC-8
30 Testing and adjusting SEN02458-01
Adjusting valve clearance 1 3. Remove plate (5) on the starting motor and
insert gear B1.
a Adjusting tools for valve clearance
Symbol Part No. Part name
1 795-799-1131 Gear
B Commercially
2 Thickness gauge
available
PC138US, USLC-8 9
SEN02458-01 30 Testing and adjusting
5. Adjust the valve clearances marked with q in 7. After finishing adjustment, remove the adjust-
the valve arrangement drawing according to ing tools and return the removed parts.
the following procedure. k Take care not to forget remove gear B1.
3 Cylinder head cover mounting nut:
8.82 ± 0.98 Nm {0.9 ± 0.1 kgm}
10 PC138US, USLC-8
30 Testing and adjusting SEN02458-01
PC138US, USLC-8 11
SEN02458-01 30 Testing and adjusting
12 PC138US, USLC-8
30 Testing and adjusting SEN02458-01
PC138US, USLC-8 13
SEN02458-01 30 Testing and adjusting
14 PC138US, USLC-8
30 Testing and adjusting SEN02458-01
PC138US, USLC-8 15
SEN02458-01 30 Testing and adjusting
16 PC138US, USLC-8
30 Testing and adjusting SEN02458-01
Testing fuel return rate and fuel a Lay test hose G4 so that it will not
leakage 1 slacken and put its end in the oil pan.
1. Preparation work
1) Remove tube (3) and spill hose (4)
between common rail (1) and return block
(2).
PC138US, USLC-8 17
SEN02458-01 30 Testing and adjusting
2. Testing leakage from pressure limiter 3. Testing return rate from injector
1) Lay test hose G4 so that it will not slacken a While testing the return rate from the
and put its end in the oil pan. injector, keep the test hose on the pres-
2) Start the engine and keep its speed at sure limiter side connected and keep its
1,600 rpm with no load. end in the oil pan.
3) After the engine speed is stabilized, test 1) Run the engine at the rated output.
the leakage in 1 minute with measuring 2) After the engine speed is stabilized, test
cylinder G6. the return rate in 1 minute with measuring
a You may test for 20 seconds and cylinder G6.
judge by multiplying the result by 3. a You may test for 20 seconds and
a If the leakage from the pressure lim- judge by multiplying the result by 3.
iter is in the following standard range, a If the supply pump pressure is low,
it is normal. the engine speed may not rise. In this
case, record the engine speed, too,
Engine speed Leakage during the test.
(rpm) (cc/min)
a If the return rate (spill) from the injec-
1,600 Max. 20 tor is in the following standard range,
it is normal.
Rated output Limit of return rate
speed (rpm) (spill) (cc/min)
1,600 190
1,700 200
1,800 210
1,900 220
2,000 230
18 PC138US, USLC-8
30 Testing and adjusting SEN02458-01
PC138US, USLC-8 19
SEN02458-01 30 Testing and adjusting
1. Fuel tank
2. Priming pump
3. Pre-filter with water separator
4. Main filter
5. Feed pump
6. IMV (Inlet Metering Valve)
7. Overflow valve
8. Rail
9. Injector
10. Safety valve
11. High pressure pump
20 PC138US, USLC-8
30 Testing and adjusting SEN02458-01
Checking fuel circuit for leakage 1 9. Check the fuel piping and devices for fuel leak-
age.
k Very high pressure is generated in the high- a Check mainly around the high-pressure
pressure circuit of the fuel system. If fuel circuit parts coated with the color checker
leaks while the engine is running, it is dan- for fuel leakage.
gerous since it can catch fire. a If any fuel leakage is detected, repair it
After checking the fuel system or removing and check again from step 2.
its parts, check it for fuel leakage according a If no fuel leakage is detected, check is
to the following procedure. completed.
k Stop the machine on a level ground and
lower the work equipment to the ground.
a Clean and degrease the engine and the parts
around it in advance so that you can check it
easily for fuel leakage.
PC138US, USLC-8 21
SEN02458-01 30 Testing and adjusting
22 PC138US, USLC-8
30 Testing and adjusting SEN02458-01
Testing swing circle bearing 4. Set the arm almost perpendicular to the
clearance 1 ground and lower the boom until the front track
shoe floats.
a Testing tools for swing circle bearing clearance a At this time the front of the upper structure
Symbol Part No. Part name rises and the rear lowers.
Commercially
H Dial gauge 5. Under this condition, read dial gauge H.
available
a The value indicated by dial gauge H is the
clearance of the bearing.
a When testing the swing circle bearing clear-
a For the standard value, see Structure,
ance installed to the machine, perform the fol-
function and maintenance standard,
lowing procedure.
k
"Swing circle".
Stop the machine on a level ground and
lower the work equipment to the ground.
k Do not put your hands or feet under the
undercarriage during test.
PC138US, USLC-8 23
SEN02458-01 30 Testing and adjusting
k Stop the machine on a level ground and 1. Loosen bolts (1) and (2) and locknut (6).
lower the work equipment to the ground.
2. Move compressor (3) and bracket (4) as a set
Checking with adjustment bolt (5) to adjust the belt ten-
1. Open the engine hood, press the intermediate sion.
point of the belt between the fan pulley and
compressor pulley with a finger, and test 3. After positioning compressor (3), tighten bolts
deflection (a) of the belt. (1) and (2) and locknut (6).
q Belt pressing force: 60 N {6.1 kg} a Check each pulley for breakage, wear of
the V-groove, and contact of the V-belt
and V-groove.
a If the V-belt is so lengthened that the
adjustment allowance is eliminated or it
has a cut or a crack, replace it.
a If the belt is replaced, adjust their tension
again after operating the machine for 1
hour.
a After tightening the bolts, check the belt
tension again according the above proce-
dure.
24 PC138US, USLC-8
30 Testing and adjusting SEN02458-01
PC138US, USLC-8 25
SEN02458-01 30 Testing and adjusting
2. Decreasing tension
1) Loosen valve (1) to discharge grease, and
then tighten it.
k Do not loosen the valve more than
1 turn. If it is loosened more, it
may jump out because of the high-
pressure grease in it.
2) To check that the tension is normal, run
the engine at low idle and move the
machine forward by the length of track on
ground, then stop slowly.
3) After adjusting, check the track shoe ten-
sion again according to the above proce-
dure.
26 PC138US, USLC-8
30 Testing and adjusting SEN02458-01
Testing
a The oil pressure in the work equipment, swing,
and travel circuits (pump discharge pressure)
can be checked with monitoring function of the
machine monitor, too (For details, see "Special
functions of machine monitor").
q Monitoring code: 01100 pump pressure
a Test the oil pressure in the work equipment,
swing, and travel circuits under the following
condition.
q Hydraulic oil temperature: Within operat-
ing range
PC138US, USLC-8 27
SEN02458-01 30 Testing and adjusting
3. Testing work equipment relief pressure 2) Set the working mode in the power mode
1) Start the engine and move the cylinder to (P).
be tested to the stroke end. 3) Run the engine at high idle, operate the
2) Set the working mode in the power mode travel lever and pedal to relieve the travel
(P). motor, and test the oil pressure.
3) Run the engine at high idle, operate the k Before operating the travel lever
right and left work equipment control and pedal, check the position and
levers to relieve the cylinder, and test the locking direction of the locked
oil pressure. sprocket again.
a The pressure tested when the main a The pressure tested when the main
relief valve is relieved is indicated (If relief valve of the control valve is
t he boo m is l owe r ed si ng ly, t he relieved is indicated. The travel circuit
safety-suction valve of the control is always relieved at high pressure.
valve for lowering the boom is
relieved). 6. Work after finishing test
After finishing test, remove the testing tools
4. Testing swing relief pressure and return the removed parts.
1) Start the engine, set the working mode in 3 Oil pressure pickup plug:
the power mode (P), and turn the swing 20 – 27 Nm {2.0 – 2.8 kgm}
lock switch ON.
2) Run the engine at high idle, operate the
left work equipment control lever to relieve
the swing motor, and test the oil pressure.
a The pressure tested when the swing
motor relief valve is relieved is indi-
cated.
a The swing relief pressure is lower
than the main relief pressure.
28 PC138US, USLC-8
30 Testing and adjusting SEN02458-01
PC138US, USLC-8 29
SEN02458-01 30 Testing and adjusting
Testing control circuit basic 3. Start the engine, set the working mode in the
pressure 1 power mode (P), and turn the auto-decelerator
OFF.
a Testing tools for control circuit basic pressure
Symbol Part No. Part name 4. Run the engine at high idle, set all the levers
and pedals for work equipment control, swing
799-101-5002 Hydraulic tester
1 control, and travel in neutral, and test the oil
790-261-1204 Digital hydraulic tester pressure.
K
799-101-5220 Nipple (10 × 1.25 mm)
2
07002-11023 O-ring
1. Remove the control valve cover and oil pres- 5. After finishing test, remove the testing tools
sure pickup plug (1). and return the removed parts.
30 PC138US, USLC-8
30 Testing and adjusting SEN02458-01
Testing
a Before testing the oil pressure in the PC con-
trol circuit, check that the oil pressure in the
work equipment, swing, and travel circuits and
the basic pressure of the control circuit are nor-
mal.
a Test the oil pressure in the pump PC control
circuit under the following condition.
q Hydraulic oil temperature: Within operating
range
1. Testing PC valve output pressure (servo a Install nipple L2 to the inspection part
piston inlet pressure) of plug (2) and connect it to oil pres-
a Test the PC valve output pressure (servo sure gauge [1] by hose [2] of hydrau-
piston inlet pressure) and pump discharge lic tester L1.
pressure simultaneously and compare a Use the oil pressure gauges of 58.8
them. MPa {600 kg/cm2}.
1) Open the side cover of the pump room
and remove oil pressure pickup plugs (1)
and (2).
q (1): Pump discharge pressure pickup
plug
q (2): PC valve output pressure pickup
plug
PC138US, USLC-8 31
SEN02458-01 30 Testing and adjusting
5) Run the engine at high idle, operate the 2) Install nipples L2 and connect them to oil
left work equipment control lever to relieve pressure gauges [1].
the arm circuit at the IN stroke end, and a Use the oil pressure gauges of 5.9
test the oil pressure. MPa {60 kg/cm2}.
a Testing condition and method of judg- 3) Start the engine and set the working mode
ment: If the pressures are in the fol- in the power mode (P).
lowing ratio, the PC valve is normal. 4) Run the engine at high idle and low idle,
set all the levers and pedals for work
Tested oil Operation of Ratio of oil
pressure lever pressures equipment control, swing control, and
travel in neutral, and test the oil pressure
Pump discharge
1 at each speed.
pressure
Arm IN relief
PC valve output Approx. 0.6
pressure (Approx. 3/5)
32 PC138US, USLC-8
30 Testing and adjusting SEN02458-01
Adjusting
Adjusting pump PC valve
a If the following phenomenon occurs and PC
valve (4) seems to be defective, adjust PC
valve (4) according to the following procedure.
q As the working load increases, the engine
speed lowers remarkably.
q The engine speed is normal but the work
equipment speed is low.
a The width across flats of the PC valve locknut
is 13 mm and that of the adjustment screw
(inside width) is 4 mm.
Do not turn any other locknuts or adjustment
screws since they affects the hydraulic pump
performance. 4. After finishing adjustment, check again that the
PC valve output pressure (servo piston inlet
pressure) is normal according to the above
described test procedure.
PC138US, USLC-8 33
SEN02458-01 30 Testing and adjusting
k Stop the machine on a level ground and 2) Install nipple M3 and connect it to oil pres-
lower the work equipment to the ground. sure gauge [1] of hydraulic tester M1.
Then, release the residual pressure from
the hydraulic circuit. For details, see
"Releasing residual pressure from hydrau-
lic circuit".
Testing
a Before testing the oil pressure in the LS control
circuit, check that the oil pressure in the work
equipment, swing, and travel circuits and the
basic pressure of the control circuit are normal.
a Test the oil pressure in the pump LS control cir-
cuit under the following condition.
q Hydraulic oil temperature: Within operating
range
a Install nipple M3 to the inspection part
1. Testing LS valve output pressure (servo of plug (2) and connect it to oil pres-
piston inlet pressure) sure gauge [1] by hose [2] of hydrau-
a Test the LS valve output pressure (servo lic tester M1.
piston inlet pressure) and pump discharge a Use the oil pressure gauges of 58.8
pressure simultaneously and compare MPa {600 kg/cm2}.
them.
1) Open the side cover of the pump room
and remove oil pressure pickup plugs (1)
and (2).
q (1): Pump discharge pressure pickup
plug
q (2): LS valve output pressure pickup
plug
34 PC138US, USLC-8
30 Testing and adjusting SEN02458-01
4) Set the working mode in the power mode 2) Open the side cover of the pump room
(P) and set the travel speed in the High and remove oil pressure pickup plugs (1)
position. and (2).
5) Run the engine at high idle, set all the q (1): Pump discharge pressure pickup
levers and pedals for work equipment con- plug
trol, swing control, and travel in neutral, q (2): LS pressure pickup plug
and test the oil pressure at each speed.
Then, operate the travel lever to run the
track shoe idle and test the oil pressure.
k While checking the safety around
the machine extremely, run the
track shoe pushed up idle.
a Do not operate the travel lever to the
stroke end (but stop it halfway).
PC138US, USLC-8 35
SEN02458-01 30 Testing and adjusting
q The figure shows the LS pressure side. a Testing condition and method of judg-
ment: If the pressures are in the fol-
lowing ratio, the LS valve is normal.
LS differential
Operation of levers
pressure
All control levers and pedals 2.8 ± 1.0 MPa
in neutral {28 ± 10 kg/cm2}
Travel lever moved halfway 2.2 ± 0.1 MPa
(No-load travel operation of
one side) {22.5 ± 1 kg/cm2}
36 PC138US, USLC-8
30 Testing and adjusting SEN02458-01
Adjusting
Adjusting LS valve
a If the LS differential pressure is abnormal,
adjust the LS valve according to the following
procedure.
q (3): Pump LS valve
PC138US, USLC-8 37
SEN02458-01 30 Testing and adjusting
Testing solenoid valve output 2. Install adapter N2 and connect the discon-
pressure 1 nected hose again.
a Testing tools for solenoid valve output pressure 3. Install nipple [1] of hydraulic tester N1 and con-
Symbol Part No. Part name nect it to oil pressure gauge [2].
a Use the oil pressure gauge of 5.9 MPa {60
799-101-5002 Hydraulic tester
1 kg/cm2}.
N 790-261-1204 Digital hydraulic tester a The figure shows the testing tools con-
2 799-401-3100 Adapter (Size: 02) nected to outlet hose (1) of the PPC lock
solenoid valve.
k Stop the machine on a level ground and
lower the work equipment to the ground.
Then, release the residual pressure from
the hydraulic circuit. For details, see
"Releasing residual pressure from hydrau-
lic circuit".
a Before testing the solenoid valve output pres-
sure, check that the basic pressure of the con-
trol circuit is normal.
a Test the solenoid valve output pressure under
the following condition.
q Hydraulic oil temperature: Within operating
range
1. Remove the control valve left side cover and 4. Start the engine.
disconnect outlet hoses (1) – (5) of the sole-
noid valve to be checked. 5. Run the engine at high idle, operate the control
No. Solenoid valve to be tested levers and switches to turn the solenoid valve
ON or OFF, and test the oil pressure.
1 PPC lock solenoid valve
a For the conditions for turning the solenoid
2 Travel speed shifting solenoid valve valve ON and OFF, see the operation
3 Swing holding brake solenoid valve table of each solenoid valve.
4 Merge-divider valve a The operating condition of the solenoid
valve can be checked with the monitoring
5 Travel junction solenoid valve
function of the machine monitor (For
details, see "Special functions of machine
a When testing with hose (1), remove the
monitor").
undercover (rear side) of the operator's
q Monitoring code: 02300 Solenoid 1
cab.
a If the output pressure is as follows, the
solenoid valve is normal.
Solenoid valve Output pressure
OFF
0 MPa {0 kg/cm2}
(Demagnetization)
ON (Excitation) 2.9 MPa {30 kg/cm2}
38 PC138US, USLC-8
30 Testing and adjusting SEN02458-01
Testing PPC valve output a Testing tools for PPC valve output pressure
pressure 1 Symbol Part No. Part name
Connecting points of PPC piping 799-101-5002 Hydraulic tester
1
P 790-261-1204 Digital hydraulic tester
2 799-401-3100 Adapter (Size: 02)
PC138US, USLC-8 39
SEN02458-01 30 Testing and adjusting
40 PC138US, USLC-8
30 Testing and adjusting SEN02458-01
PC138US, USLC-8 41
SEN02458-01 30 Testing and adjusting
42 PC138US, USLC-8
30 Testing and adjusting SEN02458-01
PC138US, USLC-8 43
SEN02458-01 30 Testing and adjusting
Inspection
1. Run the engine and heighten the hydraulic oil
temperature to the operating range and set the
machine in the travel posture.
a To set the machine in the travel posture,
extract the bucket cylinder and arm cylin-
der fully and set the boom angle to 45°.
44 PC138US, USLC-8
30 Testing and adjusting SEN02458-01
PC138US, USLC-8 45
SEN02458-01 30 Testing and adjusting
46 PC138US, USLC-8
30 Testing and adjusting SEN02458-01
1. Testing oil leakage from boom cylinder hose on the cylinder bottom side.
1) Move the boom cylinder to the RAISE a Use the following part to block the
stroke end and stop the engine. hose side.
k Release the residual pressure from
07376-70522 (Plug #05)
the piping on the boom cylinder
head side. For details, see "Releas-
ing residual pressure from hydrau-
lic circuit" (Operate the lever in the
boom RAISE direction only, how-
ever).
2) Disconnect hose (1) on the cylinder head
side and block it with a plug.
k Take care not to disconnect the
hose on the cylinder bottom side.
a Use the following part to block the
hose side.
07379-00640 (Flange #06)
PC138US, USLC-8 47
SEN02458-01 30 Testing and adjusting
3. Testing oil leakage from bucket cylinder 4. Testing oil leakage from swing motor
1) Move the bucket cylinder to the CURL 1) Disconnect 2 drain hoses (4) and block
stroke end and stop the engine. the hose side with plugs.
k Release the residual pressure from a Use the following parts to block the
the piping on the bucket cylinder hose side.
head side. For details, see Releas- 07376-70315 (Plug #03)
ing residual pressure from hydrau-
lic circuit (Operate the lever in the
bucket CURL direction only, how-
ever).
2) Disconnect hose (3) on the cylinder head
side and block it with a plug.
k Take care not to disconnect the
hose on the cylinder bottom side.
a Use the following part to block the
hose side.
07376-70422 (Plug #04)
48 PC138US, USLC-8
30 Testing and adjusting SEN02458-01
5. Testing oil leakage from travel motor 5) After finishing test, return the removed
1) Remove the travel motor cover. parts.
2) Run the engine, lock the travel mecha-
nism, and stop the engine.
k Put pin [1] between the sprocket
and track frame to lock the travel
mechanism securely.
PC138US, USLC-8 49
SEN02458-01 30 Testing and adjusting
Note: Bleed air from the swing motor and travel motor only when the oil in the motor cases is drained.
50 PC138US, USLC-8
30 Testing and adjusting SEN02458-01
3) While running the engine at high idle, per- 6. Checking oil level and starting work
form step 2). 1) Run the engine, retract the arm cylinder
4) While running the engine at low idle, move and bucket cylinder to the stroke ends,
the piston rod to the stroke end and lower the work equipment to the ground,
relieve the oil. and stop the engine.
5) Bleed air from the arm cylinder and bucket
cylinder according to steps 2) – 4).
PC138US, USLC-8 51
SEN02458-01 30 Testing and adjusting
52 PC138US, USLC-8
30 Testing and adjusting SEN02458-01
PC138US, USLC-8 53
SEN02458-01 30 Testing and adjusting
© 2007 KOMATSU
All Rights Reserved
Printed in Japan 02-07 (02)
54 PC138US, USLC-8
SEN02459-00
PC138US-8
PC138USLC-8
PC138US, USLC-8 1
SEN02459-00 30 Testing and adjusting
2 PC138US, USLC-8
30 Testing and adjusting SEN02459-00
PC138US, USLC-8 3
SEN02459-00 30 Testing and adjusting
Page Page
t Operator mode (Outline) Service mode
6p 19p
A Display of KOMATSU logo 6p Monitoring 20p
A Display of inputting password 7p Mechanical Systems 25p
Abnormality
A Display of check before starting 7p Electrical Systems 26p
Record
A Display of warning after check before starting 7p Air-conditioning System 32p
A Display of ending of maintenance interval 7p Maintenance Record 33p
A Display of check of working mode and travel speed 8p Maintenance Mode Change 34p
A Display of ordinary screen 8p Phone Number Entry 36p
A Display of end screen 8p Key-on Mode 37p
B Selection of auto-deceleration 8p Unit 38p
O (Special operation)
4 PC138US, USLC-8
30 Testing and adjusting SEN02459-00
PC138US, USLC-8 5
SEN02459-00 30 Testing and adjusting
6 PC138US, USLC-8
30 Testing and adjusting SEN02459-00
PC138US, USLC-8 7
SEN02459-00 30 Testing and adjusting
Selection of auto-deceleration
While the ordinary screen is displayed, if the auto-
Display of ordinary screen deceleration switch is pressed, large auto-deceler-
If the machine monitor starts normally, the ordinary ation monitor (a) is displayed for 2 seconds and the
screen is displayed. setting of the auto-deceleration is changed.
a Service meter (a) or a clock is displayed at the a Each time the auto-deceleration switch is
center upper section of the screen (The ser- pressed, the auto-deceleration is turned ON
vice meter or clock is selected with [F4]). and OFF alternately.
a ECO gauge (b) is displayed at the right end of a If the auto-deceleration is turned ON, large
the screen (It is turned ON and OFF in the ser- monitor (a) and auto-deceleration monitor (b)
vice mode). are displayed simultaneously.
a If the auto-deceleration is turned OFF, auto-
deceleration monitor (b) goes off.
8 PC138US, USLC-8
30 Testing and adjusting SEN02459-00
PC138US, USLC-8 9
SEN02459-00 30 Testing and adjusting
10 PC138US, USLC-8
30 Testing and adjusting SEN02459-00
PC138US, USLC-8 11
SEN02459-00 30 Testing and adjusting
12 PC138US, USLC-8
30 Testing and adjusting SEN02459-00
PC138US, USLC-8 13
SEN02459-00 30 Testing and adjusting
14 PC138US, USLC-8
30 Testing and adjusting SEN02459-00
a Remedies given by displayed user codes to operator to take (The following table is an excerpt from the
Operation and Maintenance Manual)
User code Failure mode Action
When emergency pump drive switch is at the up (emergency)
E02 Pump control system error position, normal operations become possible, but have
inspection carried out immediately.
Move the swing brake cancel switch up to release the brake.
When applying the swing brake, operate the swing lock switch
E03 Swing brake system error manually. Depending on the cause of the problem, it may not
be possible to release it. In any case, have inspection carried
out immediately.
Engine controller power source error
E10 Engine controller drive system circuit error Have inspection carried out immediately.
(engine stopped)
Engine controller system error Operate machine to a safe posture and have inspection carried
E11
Output reduced to protect engine out immediately.
Operate machine to a safe posture and have inspection carried
E14 Abnormality in throttle system
out immediately.
Engine sensor (coolant temperature, fuel Operations are possible, but have inspection carried out
E15
pressure, oil pressure) system error immediately.
Operations are possible, but have inspection carried out
E20 Abnormality in travel system
immediately.
Operate machine to a safe posture and have inspection carried
E0E Network error
out immediately.
PC138US, USLC-8 15
SEN02459-00 30 Testing and adjusting
16 PC138US, USLC-8
30 Testing and adjusting SEN02459-00
Function of changing attachment/maintenance 3. After the New password input screen is dis-
password played, input a new password with the numeral
When changing the attachment/maintenance pass- input switches and confirm it with the function
word used for the attachment setting function and switch.
maintenance setting function, follow these proce- a Set a new password of 4 – 6 digits (If it
dures. has only 3 or less digits or has 7 or more
1. While the ordinary screen is displayed, perform digits, it is not accepted).
the following operation with the numeral input q [F5]: Reset input numeral/Return to ordi-
switches. nary screen
q Operation of switches (While pressing [4], q [F6]: Confirm input numeral
perform the operation in order):
[4] + [5] o [5] o [5]
a This operation of the switches is not
accepted until 10 minutes pass after the
starting switch is turned on.
PC138US, USLC-8 17
SEN02459-00 30 Testing and adjusting
18 PC138US, USLC-8
30 Testing and adjusting SEN02459-00
PC138US, USLC-8 19
SEN02459-00 30 Testing and adjusting
Monitoring
The machine monitor can monitor the condition of
the machine in real time by receiving signals from
various switches, sensors, and actuators installed
to many parts of the machine and the information
from the controllers which are controlling switches,
etc.
1. Selecting menu
Select "Monitoring" on the service menu
screen.
20 PC138US, USLC-8
30 Testing and adjusting SEN02459-00
PC138US, USLC-8 21
SEN02459-00 30 Testing and adjusting
22 PC138US, USLC-8
30 Testing and adjusting SEN02459-00
PC138US, USLC-8 23
SEN02459-00 30 Testing and adjusting
24 PC138US, USLC-8
30 Testing and adjusting SEN02459-00
PC138US, USLC-8 25
SEN02459-00 30 Testing and adjusting
26 PC138US, USLC-8
30 Testing and adjusting SEN02459-00
PC138US, USLC-8 27
SEN02459-00 30 Testing and adjusting
28 PC138US, USLC-8
30 Testing and adjusting SEN02459-00
PC138US, USLC-8 29
SEN02459-00 30 Testing and adjusting
30 PC138US, USLC-8
30 Testing and adjusting SEN02459-00
PC138US, USLC-8 31
SEN02459-00 30 Testing and adjusting
32 PC138US, USLC-8
30 Testing and adjusting SEN02459-00
PC138US, USLC-8 33
SEN02459-00 30 Testing and adjusting
34 PC138US, USLC-8
30 Testing and adjusting SEN02459-00
PC138US, USLC-8 35
SEN02459-00 30 Testing and adjusting
1. Selecting menu
Select "Phone Number Entry" on the "Service
Menu" screen.
36 PC138US, USLC-8
30 Testing and adjusting SEN02459-00
3. Selecting mode
After the "Key-on Mode" screen is displayed,
select the mode to be set with the function
switches.
q Power Mode: [P] is displayed when key is
ON
q Economy Mode: [E] is displayed when key
is ON
q Lifting Mode: [L] is displayed when key is
ON
q Breaker Mode: [B] is displayed when key
is ON
q Attachment Mode: [ATT] is displayed
when key is ON
PC138US, USLC-8 37
SEN02459-00 30 Testing and adjusting
1. Selecting menu
Select "Default" on the "Service Menu" screen.
3. Selecting unit
After the "Unit" screen is displayed, select the
unit to be set with the function switches.
q [F3]: Move to lower unit
q [F4]: Move to upper unit
q [F5]: Cancel selection and return to
"Default" screen
q [F6]: Confirm selection and return to
"Default" screen
38 PC138US, USLC-8
30 Testing and adjusting SEN02459-00
3. Selecting With/Without
After the "With/Without Attachment" screen is
displayed, select the setting with the function
switches.
q Without Attachment:
When attachment is not installed
q With Attachment:
When attachment is installed
q [F3] : Move to lower item
q [F4] : Move to upper item
q [F5] : Cancel selection and return to
Default screen
q [F6] : Confirm selection and return to
Default screen
PC138US, USLC-8 39
SEN02459-00 30 Testing and adjusting
40 PC138US, USLC-8
30 Testing and adjusting SEN02459-00
PC138US, USLC-8 41
SEN02459-00 30 Testing and adjusting
1. Selecting menu
Select "Default" on the "Service Menu" screen.
42 PC138US, USLC-8
30 Testing and adjusting SEN02459-00
PC138US, USLC-8 43
SEN02459-00 30 Testing and adjusting
44 PC138US, USLC-8
30 Testing and adjusting SEN02459-00
Cylinder Cut-Out
The operator can perform "Cylinder Cut-Out" oper-
ation with the machine monitor.
"Cylinder Cut-Out" operation means to run the
engine with 1 or more fuel injectors disabled electri-
cally to reduce the number of effective cylinders.
This operation is used to find out a cylinder which
does not output power normally (combustion in it is
abnormal).
1. Selecting menu
Select "Cylinder Cut-Out" on the "Service
Menu" screen.
PC138US, USLC-8 45
SEN02459-00 30 Testing and adjusting
[Reference] No Injection
q If a normally operating cylinder is Cut-Out, If the engine is operated after long storage of the
the following phenomena occur. machine, it may be worn or damaged because of
1) Lowering of engine speed insufficient lubrication with oil. To prevent this, the
2) Increase of final injection rate com- function to lubricate the engine before starting it by
mand (quantity) cranking it without injecting fuel is installed.
q If the engine is running near the high idle, Set the no-injection cranking while the engine is
however, the engine speed may not lower stopped.
for the reason of engine control.
q In this case, lower the engine speed with 1. Selecting menu
the fuel control dial and judge by increase Select "No Injection" on the "Service Menu"
of the injection rate command. screen.
46 PC138US, USLC-8
30 Testing and adjusting SEN02459-00
PC138US, USLC-8 47
SEN02459-00 30 Testing and adjusting
2. Starting test
After the screen of "Fuel Consumption" is dis-
played, start test with the function switches.
q [F1]: Start
q [F2]: Clear 4. Finishing test
q [F5]: Return to Service menu screen Press [F1], and test is finished and the data
a When the screen of Fuel consumption is are displayed on the finishing date and time
displayed, if a data is indicated, it is the side.
data of the previous test. This data is not
an obstacle to new test and can be reset 5. Displaying fuel consumption
by pressing [F2]. If the test is finished, the hourly fuel consump-
a If [F1] is pressed, the data is displayed on tion calculated from the fuel consumption cal-
the starting date and time side and test culated by the engine controller and the
starts. elapsed time are displayed.
48 PC138US, USLC-8
30 Testing and adjusting SEN02459-00
PC138US, USLC-8 49
SEN02459-00 30 Testing and adjusting
KOMTRAX Settings (GPS & Communication Status) 3. Contents of display of GPS & communication
The setting condition and operating condition of status
KOMTRAX can be checked with "KOMTRAX Set- On the screen of "GPS & Communication Sta-
tings". tus", the following items are displayed.
GPS & communication status is used to check the q Positioning: Positioning condition of GPS
condition of positioning and communication of the q Communication: Communication environ-
KOMTRAX terminal. ment of communication MODEM and con-
necting condi tion of c ommunication
1. Selecting menu MODEM
Select "KOMTRAX Settings" on the "Service q Number of message not yet sent: Number
Menu" screen. of mails which are saved in machine mon-
itor and not transmitted yet
q [F5]: Return to KOMTRAX settings screen
50 PC138US, USLC-8
30 Testing and adjusting SEN02459-00
1. Selecting menu
Select "KOMTRAX Settings" on the "Service
Menu" screen.
PC138US, USLC-8 51
SEN02459-00 30 Testing and adjusting
52 PC138US, USLC-8
30 Testing and adjusting SEN02459-00
PC138US, USLC-8 53
SEN02459-00 30 Testing and adjusting
© 2007 KOMATSU
All Rights Reserved
Printed in Japan 01-07 (02)
54 PC138US, USLC-8
SEN02460-01
PC138US-8
PC138USLC-8
PC138US, USLC-8 1
SEN02460-01 30 Testing and adjusting
2 PC138US, USLC-8
30 Testing and adjusting SEN02460-01
1. Machine monitor
1) Remove 2 mounting bolts and cover (1).
a One of the mounting bolts is installed
in the cover on the right of the day-
light sensor.
a While removing the mounting bolts,
disconnect connector P31 of the day-
light sensor.
a The following figure shows the model 2. Engine controller
of the arm crane specification 1) Open the engine hood.
equipped with a level. If the machine a The engine controller is mounted on
which you are working on has the arm the engine (on the counterweight
crane specification, remove level (2). side).
2) Insert or connect troubleshooting T-adapt-
ers in or to connectors CE01, CE02, and
CE03 of engine controller (5).
a Connectors CE01 and CE02 are fixed
with screws. When disconnecting
them, loosen the screws.
a When returning connectors CE01 and
CE02, tighten the screws to the spec-
ified torque.
3 Screw: 3 ± 1 Nm {0.3 ± 0.1 kgm}
PC138US, USLC-8 3
SEN02460-01 30 Testing and adjusting
4 PC138US, USLC-8
30 Testing and adjusting SEN02460-01
PC138US, USLC-8 5
SEN02460-01 30 Testing and adjusting
6. Boost pressure and temperature sensor 7. Supply pump IMV solenoid (Fuel regulator)
(Boost press & IMT) a Disconnection and connection of con-
a Disconnection and connection of con- nector
nector The connector of the supply pump IMV
The connector of the boost pressure and solenoid has a special locking mecha-
temperature sensor has a special locking nism. Disconnect it according to steps (a)
mechanism. Disconnect it according to – (b) and connect it according to steps (c)
steps (a) – (b) and connect it according to – (d) as shown below.
steps (c) – (d) as shown below. Disconnection: (a) Unlock – (b) Discon-
Disconnection: (a) Unlock – (b) Discon- nect connector.
nect connector. Connection: (c) Connect connector – (d)
Connection: (c) Connect connector – (d) Lock.
Lock.
6 PC138US, USLC-8
30 Testing and adjusting SEN02460-01
PC138US, USLC-8 7
SEN02460-01 30 Testing and adjusting
8 PC138US, USLC-8
30 Testing and adjusting SEN02460-01
Pm Clinic service 1
Model name Serial No. Service meter
T PC138US-8 h
User's name Date of execution Inspector
/ /
Specifications
Main components Attachments Shoe width
Boom T Standard T ( ) T Breaker T 500 mm T( )
Arm T Standard T ( ) T( ) T 600 mm
Bucket T Standard T ( ) T( ) T 700 mm
Check of oil/coolant level
T Radiator coolant When necessary
T Machinery case oil
T Engine oil T Damper case oil
T( )
T Hydraulic oil T Final drive case oil
Ambient temperature Altitude
°C m
Operator's opinion
Mechanical equipment system fault history Electrical equipment system fault history
989EKX times/1st time h/last h times/1st time h/last h
AB00KE times/1st time h/last h times/1st time h/last h
B@BAZG times/1st time h/last h times/1st time h/last h
B@BAZK times/1st time h/last h times/1st time h/last h
B@BCNS times/1st time h/last h times/1st time h/last h
B@HANS times/1st time h/last h times/1st time h/last h
CA234 times/1st time h/last h times/1st time h/last h
Max. range of engine coolant temperature gauge Max. range of hydraulic oil temperature gauge
PC138US, USLC-8 9
SEN02460-01 30 Testing and adjusting
1. Engine
Checking condition
Standard Mea-
Service limit
Good
Fuel Work- Auto-
Bad
No. Check item Operation of work Unit value for new sured
control ing decel- value
equipment machine value
dial mode eration
1 Engine speed rpm 2,090 – 2,210 2,090 – 2,210
Engine oil MAX All levers in neutral MPa 0.34 – 0.59 0.25
2
pressure {kg/cm2} {3.47 – 6.02} {2.5}
P OFF
3 Engine speed rpm 1,050 – 1,150 1,050 – 1,150
Engine oil MIN All levers in neutral MPa Min. 0.10 0.07
4
pressure {kg/cm2} {Min. 1.0} {0.7}
Good
Fuel Work-
Bad
No. Check item Unit value for new sured
control ing Checking posture, etc. value
machine value
dial mode
1 Boom RAISE Work equipment extended fully sec 3.5 – 4.1 Max. 4.4
2 Arm IN sec 2.9 – 3.5 Max. 4.0
Boom top horizontal
3 Arm OUT sec 2.4 – 3.0 Max. 3.7
Boom top horizontal
4 Bucket CURL sec 2.6 – 3.2 Max. 3.7
MAX P Arm cylinder retracted fully
Work equipment extended fully
5 Swing (5 turns) sec 25.3 – 29.3 23.3 – 31.3
Swing right and left
One side of track LO STD sec Max. 39.5 Max. 49
Travel
6 pushed up and turned
(5 idle turns) HI STD sec Max. 22.3 Max. 27
forward and backward
Fuel Work-
Bad
10 PC138US, USLC-8
30 Testing and adjusting SEN02460-01
4. Hydraulic circuit
[1] [2] [3] [4] [5]
Checking condition
600K 600K 600K 600K 60K
Good
Bad
No. Checked part Fuel Work-
Pump Pump Pump Pump
control ing Operation of work equipment Control
main 1 main 2 LS 1 LS 2
dial mode
Self pressure A
1 All lever in neutral — — — —
reducing valve
B B
2 Main relief valve Arm out relief — — —
C1 C1 C2 C2
3 Unload valve All levers in neutral —
Checked oil pressure Unit Standard value for new machine Service limit value
A (Control circuit basic pressure) 3.0 – 3.4 {31 – 35} 2.7 – 3.7 {28 – 35}
Standard value
B (Work equipment relief pressure) 33.8 – 35.8 {345 – 365} 33.8 – 36.8 {345 – 375}
C (Unload pressure) MPa 1.8 – 3.8 {18 – 38} 1.8 – 3.8 {18 – 38}
D (LS differential pressure) {kg/cm2} 2.1 – 2.3 {21.5 – 23.5} 2.1 – 2.3 {21.5 – 23.5}
E (Swing relief pressure) 28.2 – 30.2 {288 – 308} 26.7 – 30.7 {273 – 313}
F (Travel relief pressure) 33.8 – 35.8 {345 – 365} 32.8 – 36.8 {335 – 375}
Checked oil pressure Unit Standard value for new machine Service limit value
Standard value
H1 : H2 = 1 : 0.6
H (Servo control pressure) —
(Oil pressure ratio)
PC138US, USLC-8 11
SEN02460-01 30 Testing and adjusting
* Gauge changing work: Change [3] and [4] to 60K and change hoses of [3], [4], and [5].
[1] [2] [3b] [4b] [5a]
Checking condition
600K 600K 60K 60K 60K
Good
Bad
No. Check item Fuel Work-
F pump R pump F pump R pump
control ing Operation of work equipment LS-EPC
main main (F) (R)
dial mode
J1 J1
MIN — — —
P
J2 J2
— — —
J3 J3
8 PC-EPC valve E All levers in neutral — — —
MAX
J4 J4
L — — —
J5 J5
B — — —
Checked oil pressure Unit Standard value for new machine Service limit value
Standard value
12 PC138US, USLC-8
30 Testing and adjusting SEN02460-01
PC138US, USLC-8 13
SEN02460-01 30 Testing and adjusting
© 2007 KOMATSU
All Rights Reserved
Printed in Japan 02-07 (02)
14 PC138US, USLC-8
SEN02461-01
PC138US-8
PC138USLC-8
40 Troubleshooting 1
Failure code table and fuse locations
Failure code table ........................................................................................................................................... 2
Fuse locations................................................................................................................................................. 6
PC138US, USLC-8 1
SEN02461-01 40 Troubleshooting
2 PC138US, USLC-8
40 Troubleshooting SEN02461-01
PC138US, USLC-8 3
SEN02461-01 40 Troubleshooting
4 PC138US, USLC-8
40 Troubleshooting SEN02461-01
PC138US, USLC-8 5
SEN02461-01 40 Troubleshooting
Fuse locations 1
Connection table of fuse box
a This connection table shows the devices to which each power supply of the fuse box supplies power (A
switch power supply is a device which supplies power while the starting switch is in the ON position and
a constant power supply is a device which supplies power while the starting switch is in the OFF and ON
positions).
a When carrying out troubleshooting related to the electrical system, you should check the fuses and fus-
ible links to see if the power is supplied normally.
Fuse
Type of power supply Fusible link Fuse No. Destination of power
capacity
1 10A Emergency operating circuit
2 30A Solenoid valve
F02
Switch power supply 3 15A Cigarette lighter
(45A)
4 10A Windshield washer
5 10A Horn
6 5A Working lamp relay, horn relay
7 10A Rotary lamp (If equipped)
F02
Switch power supply 8 20A Working lamp
(45A)
9 10A Radio, speaker
10 5A Air conditioner
11 20A Air conditioner unit
F02 12 10A Optional power supply (1)
Switch power supply
(45A) 13 10A Optional power supply (2), power supply of 12 volt
14 10A Spare
15 5A Air conditioner
F03 16 10A Radio backup, room lamp
Constant power supply
(45A) 17 20A Machine monitor, pump controller, starting switch
18 30A Engine controller
Starting switch 19 5A Engine controller
Switch power supply
ACC 20 5A PPC oil pressure lock solenoid
6 PC138US, USLC-8
40 Troubleshooting SEN02461-01
PC138US, USLC-8 7
SEN02461-01 40 Troubleshooting
© 2007 KOMATSU
All Rights Reserved
Printed in Japan 02-07 (02)
8 PC138US, USLC-8
SEN02462-00
PC138US-8
PC138USLC-8
40 Troubleshooting 1
General information on troubleshooting
Points to remember when troubleshooting ..................................................................................................... 2
Sequence of events in troubleshooting........................................................................................................... 3
Checks before troubleshooting ....................................................................................................................... 4
Classification and procedures for troubleshooting .......................................................................................... 5
Information in troubleshooting table................................................................................................................ 6
Phenomena looking like troubles and troubleshooting Nos. ........................................................................... 8
Wiring table for connector pin numbers .........................................................................................................11
T-adapter box and T-adapter table................................................................................................................ 44
PC138US, USLC-8 1
SEN02462-00 40 Troubleshooting
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to pre-
vent reoccurrence of the failure. When carrying out troubleshooting, and important point is of course to
understand the structure and function. However, a short cut to effective troubleshooting is to ask the operator
various questions to form some idea of possible causes of the failure that would produce the reported symp-
toms.
1. When carrying out troubleshooting, do not 4) Other maintenance items can be checked
hurry to disassemble the components. externally, so check any item that is con-
If components are disassembled immediately sidered to be necessary.
any failure occurs:
q Parts that have no connection with the fail- 4. Confirming failure
ure or other unnecessary parts will be dis- Confirm the extent of the failure yourself, and
assembled. judge whether to handle it as a real failure or
q It will become impossible to find the cause as a problem with the method of operation, etc.
of the failure. a When operating the machine to reenact
It will also cause a waste of manhours, parts, the troubleshooting symptoms, do not
or oil or grease, and at the same time, will also carry out any investigation or measure-
lose the confidence of the user or operator. For ment that may make the problem worse.
this reason, when carrying out troubleshooting,
it is necessary to carry out thorough prior 5. Troubleshooting
investigation and to carry out troubleshooting Use the results of the investigation and inspec-
in accordance with the fixed procedure. tion in Items 2 – 4 to narrow down the causes
of failure, then use the troubleshooting table or
2. Points to ask user or operator troubleshooting flowchart to locate the position
1) Have any other problems occurred apart of the failure exactly.
from the problem that has been reported? a The basic procedure for troubleshooting is
2) Was there anything strange about the as follows.
machine before the failure occurred? 1] Start from the simple points.
3) Did the failure occur suddenly, or were 2] Start from the most likely points.
there problems with the machine condition 3] Investigate other related parts or
before this? information.
4) Under what conditions did the failure
occur? 6. Measures to remove root cause of failure
5) Had any repairs been carried out before Even if the failure is repaired, if the root cause
the failure? When were these repairs car- of the failure is not repaired, the same failure
ried out? will occur again.To prevent this, always investi-
6) Has the same kind of failure occurred gate why the problem occurred. Then, remove
before? the root cause.
2 PC138US, USLC-8
40 Troubleshooting SEN02462-00
PC138US, USLC-8 3
SEN02462-00 40 Troubleshooting
4 PC138US, USLC-8
40 Troubleshooting SEN02462-00
1. Procedure for troubleshooting to be taken when user code and failure code are displayed on
machine monitor:
If a user code and a failure code are displayed on the machine monitor, carry out the troubleshooting for
the corresponding "Display of code" according to the displayed failure code.
2. When electrical system error code or mechanical system error code is recorded in abnormality
record:
If a user code and a failure code are not displayed on the machine monitor, check a mechanical system
failure code and an electrical system failure code with the abnormality record function of the machine
monitor.
If a code is recorded, carry out troubleshooting for the corresponding "Display of code" according to
the recorded code.
a If an electrical system failure code is recorded, delete all the codes and reproduce them, and then
see if the trouble is still detected.
a An error code of the mechanical system cannot be deleted.
a If a trouble is displayed in the air conditioner abnormality record or heater abnormality record by the
abnormality record function, carry out the corresponding troubleshooting in E-mode.
3. When user code and failure code is not displayed and no failure code is recorded in abnormality
record:
If a user code and failure code are not displayed on the machine monitor and no failure code is recorded
in the abnormality record, a trouble that the machine cannot find out by itself may have occurred in the
electrical system or hydraulic and mechanical system.
In this case, check the phenomenon looking like a trouble again and select the same phenomenon from
the table of "Phenomena looking like troubles and troubleshooting Nos.", and then carry out trouble-
shooting corresponding to that phenomenon in the "E-mode", "H-mode", or "S-mode".
PC138US, USLC-8 5
SEN02462-00 40 Troubleshooting
6 PC138US, USLC-8
40 Troubleshooting SEN02462-00
PC138US, USLC-8 7
SEN02462-00 40 Troubleshooting
8 PC138US, USLC-8
40 Troubleshooting SEN02462-00
Troubleshooting
No. Phenomena looking like troubles Display
E-mode H-mode S-mode
of code
34 Hydraulic drift of work equipment is large H-10
35 Time lag of work equipment is large H-11
Flow rate in attachment circuit cannot be adjusted (when attachment is
36 H-26
installed)
Phenomena related to compound operation
37 Work equipment loaded more is slower during compound operation H-12
Boom RAISE speed is low in compound operation of swing + boom
38 H-13
RAISE
Travel speed lowers largely during compound operation of work
39 H-14
equipment/swing + travel
Phenomena related to travel
40 Machine deviates during travel H-15
41 Travel speed is low H-16
42 Machine cannot be steered easily or steering power is low H-17
43 Travel speed does not change or it is kept low or high E-17 H-18
44 Track does not move (Only either side) H-19
45 Travel alarm does not sound or does not stop sounding E-21
Phenomena related to swing
46 Machine does not swing H-20
47 Swing acceleration or swing speed is low H-21
48 Excessive overrun when stopping swing H-22
49 When upper structure stops swinging, it makes large shock H-23
50 When upper structure stops swinging, it makes large sound H-24
Swing holding brake does not operate normally
51 E-20 H-25
Hydraulic drift of swing is large
Phenomena related to machine monitor
52 When starting switch turned ON, machine monitor displays nothing E-1
When starting switch turned ON (before starting engine), basic check
53 E-2
item lights up
54 Precaution lights up while engine is running E-7
55 Emergency stop item lights up while engine is running E-8
56 Engine coolant temperature gauge does not indicate normally E-9
57 Hydraulic oil temperature gauge does not indicate normally E-10
58 Fuel level gauge does not indicate normally E-11
Contents of display by machine monitor are different from applicable
59 E-12
machine
60 Machine monitor does not display some items E-13
61 Function switch does not work E-14
62 Alarm buzzer cannot be stopped E-18
63 Windshield wiper and window washer do not operate E-19
Air conditioner does not operate normally (including air conditioner
64 E-22
abnormality record)
65 While starting switch is in OFF position, service meter is not displayed E-23
66 Machine monitor cannot be set in service mode E-24
67 Monitoring function does not display lever control signal normally E-25
PC138US, USLC-8 9
SEN02462-00 40 Troubleshooting
Troubleshooting
No. Phenomena looking like troubles Display
E-mode H-mode S-mode
of code
Other phenomena
68 KOMTRAX system does not operate normally E-26
10 PC138US, USLC-8
40 Troubleshooting SEN02462-00
a The terms of male and female refer to the pins, while the terms of male housing and female housing
refer to the mating portion of the housing.
PC138US, USLC-8 11
SEN02462-00 40 Troubleshooting
12 PC138US, USLC-8
40 Troubleshooting SEN02462-00
PC138US, USLC-8 13
SEN02462-00 40 Troubleshooting
14 PC138US, USLC-8
40 Troubleshooting SEN02462-00
PC138US, USLC-8 15
SEN02462-00 40 Troubleshooting
16 PC138US, USLC-8
40 Troubleshooting SEN02462-00
PC138US, USLC-8 17
SEN02462-00 40 Troubleshooting
18 PC138US, USLC-8
40 Troubleshooting SEN02462-00
PC138US, USLC-8 19
SEN02462-00 40 Troubleshooting
20 PC138US, USLC-8
40 Troubleshooting SEN02462-00
PC138US, USLC-8 21
SEN02462-00 40 Troubleshooting
22 PC138US, USLC-8
40 Troubleshooting SEN02462-00
PC138US, USLC-8 23
SEN02462-00 40 Troubleshooting
24 PC138US, USLC-8
40 Troubleshooting SEN02462-00
PC138US, USLC-8 25
SEN02462-00 40 Troubleshooting
26 PC138US, USLC-8
40 Troubleshooting SEN02462-00
PC138US, USLC-8 27
SEN02462-00 40 Troubleshooting
28 PC138US, USLC-8
40 Troubleshooting SEN02462-00
PC138US, USLC-8 29
SEN02462-00 40 Troubleshooting
30 PC138US, USLC-8
40 Troubleshooting SEN02462-00
PC138US, USLC-8 31
SEN02462-00 40 Troubleshooting
32 PC138US, USLC-8
40 Troubleshooting SEN02462-00
PC138US, USLC-8 33
SEN02462-00 40 Troubleshooting
34 PC138US, USLC-8
40 Troubleshooting SEN02462-00
PC138US, USLC-8 35
SEN02462-00 40 Troubleshooting
36 PC138US, USLC-8
40 Troubleshooting SEN02462-00
PC138US, USLC-8 37
SEN02462-00 40 Troubleshooting
38 PC138US, USLC-8
40 Troubleshooting SEN02462-00
PC138US, USLC-8 39
SEN02462-00 40 Troubleshooting
40 PC138US, USLC-8
40 Troubleshooting SEN02462-00
PC138US, USLC-8 41
SEN02462-00 40 Troubleshooting
42 PC138US, USLC-8
40 Troubleshooting SEN02462-00
PC138US, USLC-8 43
SEN02462-00 40 Troubleshooting
a The vertical column indicates a part number of T-branch box or T-branch adapter while the horizontal
column indicates a part number of harness checker assembly.
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4100
799-601-4200
Out of kit
Identification
Part No. Part name
symbol
44 PC138US, USLC-8
40 Troubleshooting SEN02462-00
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4100
799-601-4200
Out of kit
Identification
Part No. Part name
symbol
PC138US, USLC-8 45
SEN02462-00 40 Troubleshooting
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4100
799-601-4200
Out of kit
Identification
Part No. Part name
symbol
46 PC138US, USLC-8
SEN02462-00 40 Troubleshooting
© 2007 KOMATSU
All Rights Reserved
Printed in Japan 01-07 (02)
48 PC138US, USLC-8
SEN02463-01
PC138US-8
PC138USLC-8
40 Troubleshooting 1
Troubleshooting by failure code, Part 1
Failure code [989L00] Engine controller lock caution 1 .................................................................................. 3
Failure code [989M00] Engine controller lock caution 2 ................................................................................. 3
Failure code [989N00] Engine controller lock caution 3.................................................................................. 4
Failure code [AB00KE] Charge voltage low.................................................................................................... 6
Failure code [B@BAZG] Eng oil press. low .................................................................................................... 8
Failure code [B@BAZK] Eng oil level low ....................................................................................................... 8
Failure code [B@BCNS] Eng coolant overheat .............................................................................................. 9
Failure code [B@HANS] Hydr oil overheat ..................................................................................................... 9
Failure code [CA111] ECM critical internal failure ......................................................................................... 10
Failure code [CA115] Eng. Ne and Bkup speed sensor error ....................................................................... 13
Failure code [CA122] Charge air press sensor high error ............................................................................ 14
Failure code [CA123] Charge air press sensor low error.............................................................................. 16
Failure code [CA131] Throttle sensor high error........................................................................................... 18
Failure code [CA132] Throttle sensor low error ............................................................................................ 20
Failure code [CA144] Coolant temp. sensor high error................................................................................. 21
Failure code [CA145] Coolant temp. sensor low error .................................................................................. 22
PC138US, USLC-8 1
SEN02463-01 40 Troubleshooting
Failure code [CA153] Charge air temp. sensor high error ............................................................................ 23
Failure code [CA154] Charge air temp. sensor low error.............................................................................. 24
Failure code [CA187] Sensor sup. 2 volt. low error....................................................................................... 24
Failure code [CA221] Ambient air press. sensor high error .......................................................................... 26
Failure code [CA222] Ambient air press. sensor low error............................................................................ 28
Failure code [CA227] Sensor sup. 2 volt. high error ..................................................................................... 30
Failure code [CA234] Eng. overspeed .......................................................................................................... 32
Failure code [CA238] Ne speed sensor sup. volt. error ................................................................................ 34
Failure code [CA271] IMV/PCV1 short error ................................................................................................. 36
Failure code [CA272] IMV/PCV1 open error ................................................................................................. 37
Failure code [CA322] Injector #1 (L #1) system open/short error ................................................................. 38
Failure code [CA324] Injector #3 (L #3) system open/short error ................................................................. 40
Failure code [CA331] Injector #2 (L #2) system open/short error ................................................................. 42
Failure code [CA332] Injector #4 (L #4) system open/short error ................................................................. 44
2 PC138US, USLC-8
40 Troubleshooting SEN02463-01
PC138US, USLC-8 3
SEN02463-01 40 Troubleshooting
4 PC138US, USLC-8
40 Troubleshooting SEN02463-01
PC138US, USLC-8 5
SEN02463-01 40 Troubleshooting
6 PC138US, USLC-8
40 Troubleshooting SEN02463-01
PC138US, USLC-8 7
SEN02463-01 40 Troubleshooting
8 PC138US, USLC-8
40 Troubleshooting SEN02463-01
PC138US, USLC-8 9
SEN02463-01 40 Troubleshooting
10 PC138US, USLC-8
40 Troubleshooting SEN02463-01
PC138US, USLC-8 11
SEN02463-01 40 Troubleshooting
12 PC138US, USLC-8
40 Troubleshooting SEN02463-01
PC138US, USLC-8 13
SEN02463-01 40 Troubleshooting
14 PC138US, USLC-8
40 Troubleshooting SEN02463-01
PC138US, USLC-8 15
SEN02463-01 40 Troubleshooting
16 PC138US, USLC-8
40 Troubleshooting SEN02463-01
PC138US, USLC-8 17
SEN02463-01 40 Troubleshooting
18 PC138US, USLC-8
40 Troubleshooting SEN02463-01
PC138US, USLC-8 19
SEN02463-01 40 Troubleshooting
20 PC138US, USLC-8
40 Troubleshooting SEN02463-01
PC138US, USLC-8 21
SEN02463-01 40 Troubleshooting
22 PC138US, USLC-8
40 Troubleshooting SEN02463-01
PC138US, USLC-8 23
SEN02463-01 40 Troubleshooting
24 PC138US, USLC-8
40 Troubleshooting SEN02463-01
PC138US, USLC-8 25
SEN02463-01 40 Troubleshooting
26 PC138US, USLC-8
40 Troubleshooting SEN02463-01
PC138US, USLC-8 27
SEN02463-01 40 Troubleshooting
28 PC138US, USLC-8
40 Troubleshooting SEN02463-01
PC138US, USLC-8 29
SEN02463-01 40 Troubleshooting
30 PC138US, USLC-8
40 Troubleshooting SEN02463-01
PC138US, USLC-8 31
SEN02463-01 40 Troubleshooting
32 PC138US, USLC-8
40 Troubleshooting SEN02463-01
PC138US, USLC-8 33
SEN02463-01 40 Troubleshooting
34 PC138US, USLC-8
40 Troubleshooting SEN02463-01
PC138US, USLC-8 35
SEN02463-01 40 Troubleshooting
36 PC138US, USLC-8
40 Troubleshooting SEN02463-01
PC138US, USLC-8 37
SEN02463-01 40 Troubleshooting
38 PC138US, USLC-8
40 Troubleshooting SEN02463-01
PC138US, USLC-8 39
SEN02463-01 40 Troubleshooting
40 PC138US, USLC-8
40 Troubleshooting SEN02463-01
PC138US, USLC-8 41
SEN02463-01 40 Troubleshooting
42 PC138US, USLC-8
40 Troubleshooting SEN02463-01
PC138US, USLC-8 43
SEN02463-01 40 Troubleshooting
44 PC138US, USLC-8
40 Troubleshooting SEN02463-01
PC138US, USLC-8 45
SEN02463-01 40 Troubleshooting
© 2007 KOMATSU
All Rights Reserved
Printed in Japan 02-07 (02)
46 PC138US, USLC-8
SEN02464-01
PC138US-8
PC138USLC-8
40 Troubleshooting 1
Troubleshooting by failure code, Part 2
Failure code [CA351] Inj. drive circuit error..................................................................................................... 3
Failure code [CA352] Sensor sup. 1 volt. low error ........................................................................................ 6
Failure code [CA386] Sensor sup. 1 volt. high error ....................................................................................... 8
Failure code [CA435] Abnormality in engine oil pressure switch .................................................................. 10
Failure code [CA441] Battery voltage low error .............................................................................................11
Failure code [CA442] Battery voltage high error ............................................................................................11
Failure code [CA449] Rail press. very high error .......................................................................................... 12
Failure code [CA451] Rail press. sensor high error ...................................................................................... 14
Failure code [CA452] Rail press. sensor low error ....................................................................................... 16
Failure code [CA553] Rail press. high error.................................................................................................. 16
Failure code [CA559] Rail press. low error ................................................................................................... 17
Failure code [CA689] Eng. Ne speed sensor error ....................................................................................... 20
Failure code [CA731] Eng. Bkup speed sensor phase error......................................................................... 22
Failure code [CA757] All persistent data lost error ....................................................................................... 22
Failure code [CA778] Eng. Bkup speed sensor error ................................................................................... 24
Failure code [CA1633] KOMNET datalink timeout error ............................................................................... 26
PC138US, USLC-8 1
SEN02464-01 40 Troubleshooting
2 PC138US, USLC-8
40 Troubleshooting SEN02464-01
PC138US, USLC-8 3
SEN02464-01 40 Troubleshooting
4 PC138US, USLC-8
40 Troubleshooting SEN02464-01
PC138US, USLC-8 5
SEN02464-01 40 Troubleshooting
6 PC138US, USLC-8
40 Troubleshooting SEN02464-01
PC138US, USLC-8 7
SEN02464-01 40 Troubleshooting
8 PC138US, USLC-8
40 Troubleshooting SEN02464-01
PC138US, USLC-8 9
SEN02464-01 40 Troubleshooting
10 PC138US, USLC-8
40 Troubleshooting SEN02464-01
PC138US, USLC-8 11
SEN02464-01 40 Troubleshooting
12 PC138US, USLC-8
40 Troubleshooting SEN02464-01
PC138US, USLC-8 13
SEN02464-01 40 Troubleshooting
14 PC138US, USLC-8
40 Troubleshooting SEN02464-01
PC138US, USLC-8 15
SEN02464-01 40 Troubleshooting
16 PC138US, USLC-8
40 Troubleshooting SEN02464-01
PC138US, USLC-8 17
SEN02464-01 40 Troubleshooting
B. Check with machine monitor (Fault history function, monitoring function, and reduced cylinder mode function) Good NG
3 Check of failure code / / / /
Check of monitoring information
Standard value
Code Displayed item Checking condition Unit Measured value Good NG
(Reference value)
Low idle rpm 1,100 ± 50
*1 Engine speed High idle rpm 2,300 ± 60
Equivalent to rating rpm 2,200
Low idle % 0
*2 Throttle opening degree
High idle % 100
*3 Fuel injection command Equivalent to rating mm3 — — —
18 PC138US, USLC-8
40 Troubleshooting SEN02464-01
*1 – *10:
See Testing and adjusting, "Special functions of machine monitor", Monitoring items table.
*: A limit value is the value mentioned above, but a standard value in normalcy is "0 cc/min. (no leak)".
Rating or equivalent:
Relieve the circuit under the following condition.
1) Engine: Full throttle
2) Mode: P
3) Boom: Raise
PC138US, USLC-8 19
SEN02464-01 40 Troubleshooting
Related
• Method of reproducing failure code: Start engine.
information
20 PC138US, USLC-8
40 Troubleshooting SEN02464-01
PC138US, USLC-8 21
SEN02464-01 40 Troubleshooting
Related
• Method of reproducing failure code: Start engine.
information
22 PC138US, USLC-8
40 Troubleshooting SEN02464-01
PC138US, USLC-8 23
SEN02464-01 40 Troubleshooting
Related
• Method of reproducing failure code: Start engine.
information
24 PC138US, USLC-8
40 Troubleshooting SEN02464-01
PC138US, USLC-8 25
SEN02464-01 40 Troubleshooting
26 PC138US, USLC-8
40 Troubleshooting SEN02464-01
PC138US, USLC-8 27
SEN02464-01 40 Troubleshooting
28 PC138US, USLC-8
40 Troubleshooting SEN02464-01
PC138US, USLC-8 29
SEN02464-01 40 Troubleshooting
30 PC138US, USLC-8
40 Troubleshooting SEN02464-01
PC138US, USLC-8 31
SEN02464-01 40 Troubleshooting
32 PC138US, USLC-8
40 Troubleshooting SEN02464-01
PC138US, USLC-8 33
SEN02464-01 40 Troubleshooting
34 PC138US, USLC-8
40 Troubleshooting SEN02464-01
PC138US, USLC-8 35
SEN02464-01 40 Troubleshooting
Configuration drawing
36 PC138US, USLC-8
40 Troubleshooting SEN02464-01
PC138US, USLC-8 37
SEN02464-01 40 Troubleshooting
38 PC138US, USLC-8
40 Troubleshooting SEN02464-01
PC138US, USLC-8 39
SEN02464-01 40 Troubleshooting
40 PC138US, USLC-8
40 Troubleshooting SEN02464-01
Hot short (Short circuit with Wiring harness between C01 (female) (17)
3
24V circuit) in wiring harness – P05 (female) (2), P05 (female) (1) – J03 –
ground (T08) Voltage Max. 1 V
[Bucket DUMP PPC pressure sensor sys-
tem]
Wiring harness between C01 (female) (16)
– P07 (female) (2), P07 (female) (1) – J03 –
ground (T08) Voltage Max. 1 V
[Boom RAISE PPC pressure sensor sys-
tem]
Wiring harness between C01 (female) (16)
– P08 (female) (2), P08 (female) (1) – J03 –
ground (T08) Voltage Max. 1 V
[Swing RIGHT PPC pressure sensor sys-
tem]
Wiring harness between C01 (female) (9) –
J07 – P25 (female) (3) Voltage Max. 1 V
[Pump pressure sensor system]
If causes 1 – 3 are not detected, pump controller may be defective.
4 Defective pump controller
(Since trouble is in system, troubleshooting cannot be carried out.)
PC138US, USLC-8 41
SEN02464-01 40 Troubleshooting
42 PC138US, USLC-8
40 Troubleshooting SEN02464-01
PC138US, USLC-8 43
SEN02464-01 40 Troubleshooting
© 2007 KOMATSU
All Rights Reserved
Printed in Japan 02-07 (02)
44 PC138US, USLC-8
SEN02465-01
PC138US-8
PC138USLC-8
40 Troubleshooting 1
Troubleshooting by failure code, Part 3
Failure code [DA2RMC] CAN discon (Pump controller detected)................................................................... 4
Failure code [DAF8KB] Short circuit in camera power supply ........................................................................ 6
Failure code [DAFGMC] GPS module error.................................................................................................... 8
Failure code [DAFRMC] CAN discon (Monitor detected).............................................................................. 10
Failure code [DGH2KB] Hydr oil sensor short .............................................................................................. 12
Failure code [DHPAMA] Pump press sensor abnormality............................................................................. 14
Failure code [DHSFMA] Travel left forward PPC press sensor abnormality ................................................. 16
Failure code [DHSGMA] Travel right forward PPC press sensor abnormality .............................................. 18
Failure code [DHSHMA] Travel left reverse PPC press sensor abnormality ................................................ 20
Failure code [DHSJMA] Travel right reverse PPC press sensor abnormality ............................................... 22
Failure code [DHSKMA] Blade raise PPC press sensor abnormality ........................................................... 24
Failure code [DHSLMA] Blade lower PPC press sensor abnormality........................................................... 26
Failure code [DHX1MA] Overload sensor abnormality (Analog)................................................................... 28
Failure code [DV20KB] Travel alarm S/C...................................................................................................... 29
Failure code [DW43KA] Travel speed sol discon.......................................................................................... 30
Failure code [DW43KB] Travel speed sol short ............................................................................................ 31
PC138US, USLC-8 1
SEN02465-01 40 Troubleshooting
2 PC138US, USLC-8
40 Troubleshooting SEN02465-01
PC138US, USLC-8 3
SEN02465-01 40 Troubleshooting
4 PC138US, USLC-8
40 Troubleshooting SEN02465-01
PC138US, USLC-8 5
SEN02465-01 40 Troubleshooting
6 PC138US, USLC-8
40 Troubleshooting SEN02465-01
PC138US, USLC-8 7
SEN02465-01 40 Troubleshooting
8 PC138US, USLC-8
40 Troubleshooting SEN02465-01
PC138US, USLC-8 9
SEN02465-01 40 Troubleshooting
10 PC138US, USLC-8
40 Troubleshooting SEN02465-01
PC138US, USLC-8 11
SEN02465-01 40 Troubleshooting
12 PC138US, USLC-8
40 Troubleshooting SEN02465-01
PC138US, USLC-8 13
SEN02465-01 40 Troubleshooting
14 PC138US, USLC-8
40 Troubleshooting SEN02465-01
PC138US, USLC-8 15
SEN02465-01 40 Troubleshooting
16 PC138US, USLC-8
40 Troubleshooting SEN02465-01
PC138US, USLC-8 17
SEN02465-01 40 Troubleshooting
18 PC138US, USLC-8
40 Troubleshooting SEN02465-01
PC138US, USLC-8 19
SEN02465-01 40 Troubleshooting
20 PC138US, USLC-8
40 Troubleshooting SEN02465-01
PC138US, USLC-8 21
SEN02465-01 40 Troubleshooting
22 PC138US, USLC-8
40 Troubleshooting SEN02465-01
PC138US, USLC-8 23
SEN02465-01 40 Troubleshooting
24 PC138US, USLC-8
40 Troubleshooting SEN02465-01
PC138US, USLC-8 25
SEN02465-01 40 Troubleshooting
26 PC138US, USLC-8
40 Troubleshooting SEN02465-01
PC138US, USLC-8 27
SEN02465-01 40 Troubleshooting
28 PC138US, USLC-8
40 Troubleshooting SEN02465-01
PC138US, USLC-8 29
SEN02465-01 40 Troubleshooting
30 PC138US, USLC-8
40 Troubleshooting SEN02465-01
PC138US, USLC-8 31
SEN02465-01 40 Troubleshooting
32 PC138US, USLC-8
40 Troubleshooting SEN02465-01
PC138US, USLC-8 33
SEN02465-01 40 Troubleshooting
34 PC138US, USLC-8
40 Troubleshooting SEN02465-01
PC138US, USLC-8 35
SEN02465-01 40 Troubleshooting
36 PC138US, USLC-8
40 Troubleshooting SEN02465-01
PC138US, USLC-8 37
SEN02465-01 40 Troubleshooting
38 PC138US, USLC-8
40 Troubleshooting SEN02465-01
PC138US, USLC-8 39
SEN02465-01 40 Troubleshooting
© 2007 KOMATSU
All Rights Reserved
Printed in Japan 02-07 (02)
40 PC138US, USLC-8
SEN02466-00
PC138US-8
PC138USLC-8
40 Troubleshooting 1
Troubleshooting by failure code, Part 4
Failure code [DXA8KA] PC-EPC sol discon ................................................................................................... 2
Failure code [DXA8KB] PC-EPC sol short...................................................................................................... 4
Failure code [DXE4KA] Service current EPC discon ...................................................................................... 6
Failure code [DXE4KB] Service current EPC short ........................................................................................ 7
Failure code [DY20KA] Wiper working abnormality ........................................................................................ 8
Failure code [DY20MA] Wiper parking abnormality ...................................................................................... 10
Failure code [DY2CKA] Washer drive discon ............................................................................................... 12
Failure code [DY2CKB] Washer drive short.................................................................................................. 14
Failure code [DY2DKB] Wiper drive (for) short ............................................................................................. 16
Failure code [DY2EKB] Wiper drive (rev) short ............................................................................................ 18
PC138US, USLC-8 1
SEN02466-00 40 Troubleshooting
2 PC138US, USLC-8
40 Troubleshooting SEN02466-00
PC138US, USLC-8 3
SEN02466-00 40 Troubleshooting
4 PC138US, USLC-8
40 Troubleshooting SEN02466-00
PC138US, USLC-8 5
SEN02466-00 40 Troubleshooting
6 PC138US, USLC-8
40 Troubleshooting SEN02466-00
PC138US, USLC-8 7
SEN02466-00 40 Troubleshooting
8 PC138US, USLC-8
40 Troubleshooting SEN02466-00
PC138US, USLC-8 9
SEN02466-00 40 Troubleshooting
10 PC138US, USLC-8
40 Troubleshooting SEN02466-00
PC138US, USLC-8 11
SEN02466-00 40 Troubleshooting
12 PC138US, USLC-8
40 Troubleshooting SEN02466-00
PC138US, USLC-8 13
SEN02466-00 40 Troubleshooting
14 PC138US, USLC-8
40 Troubleshooting SEN02466-00
PC138US, USLC-8 15
SEN02466-00 40 Troubleshooting
16 PC138US, USLC-8
40 Troubleshooting SEN02466-00
PC138US, USLC-8 17
SEN02466-00 40 Troubleshooting
18 PC138US, USLC-8
40 Troubleshooting SEN02466-00
PC138US, USLC-8 19
SEN02466-00 40 Troubleshooting
© 2007 KOMATSU
All Rights Reserved
Printed in Japan 01-07 (02)
20 PC138US, USLC-8
SEN02467-00
PC138US-8
PC138USLC-8
40 Troubleshooting 1
Troubleshooting of electrical system
(E-mode)
Before carrying out troubleshooting of electrical system ................................................................................ 3
Information in troubleshooting table................................................................................................................ 5
E-1 When starting switch turned ON, machine monitor displays nothing ....................................................... 6
E-2 When starting switch turned ON (before starting engine), basic check item lights up.............................. 8
E-3 Engine does not start (Engine does not turn) ........................................................................................... 9
E-4 Preheater does not operate.................................................................................................................... 12
E-5 Automatic warm-up system does not operate (in cold season).............................................................. 14
E-6 All work equipment, swing, and travel mechanism do not move or cannot be locked ........................... 16
E-7 Precaution lights up while engine is running .......................................................................................... 18
E-8 Emergency stop item lights up while engine is running.......................................................................... 21
E-9 Engine coolant temperature gauge does not indicate normally ............................................................. 22
E-10 Hydraulic oil temperature gauge does not indicate normally................................................................ 23
E-11 Fuel level gauge does not indicate normally ........................................................................................ 25
E-12 Contents of display by machine monitor are different from applicable machine .................................. 27
PC138US, USLC-8 1
SEN02467-00 40 Troubleshooting
2 PC138US, USLC-8
40 Troubleshooting SEN02467-00
PC138US, USLC-8 3
SEN02467-00 40 Troubleshooting
4 PC138US, USLC-8
40 Troubleshooting SEN02467-00
PC138US, USLC-8 5
SEN02467-00 40 Troubleshooting
E-1 When starting switch turned ON, machine monitor displays nothing 1
Trouble • When starting switch turned ON, machine monitor displays nothing.
• When starting switch is turned ON, machine monitor displays KOMATSU logo, screen to input pass-
word (if set), screen to check breaker mode (if set), screen of check before starting, screen to check
Related
working mode and travel speed, and ordinary screen in order.
information
• When the engine is started, the battery voltage may lower suddenly, depending on the ambient tem-
perature and the condition of the battery.
6 PC138US, USLC-8
40 Troubleshooting SEN02467-00
PC138US, USLC-8 7
SEN02467-00 40 Troubleshooting
8 PC138US, USLC-8
40 Troubleshooting SEN02467-00
PC138US, USLC-8 9
SEN02467-00 40 Troubleshooting
10 PC138US, USLC-8
40 Troubleshooting SEN02467-00
PC138US, USLC-8 11
SEN02467-00 40 Troubleshooting
(2) When starting switch is turned to HEAT position, intake air heater mounting part does not become
Trouble
warm.
Related • Check that engine can be turned with starting motor (If engine cannot be turned, carry out trouble-
information shooting for E-1 Engine does not start (Engine does not turn)).
12 PC138US, USLC-8
40 Troubleshooting SEN02467-00
PC138US, USLC-8 13
SEN02467-00 40 Troubleshooting
E-5 Automatic warm-up system does not operate (in cold season) 1
Trouble • Automatic warm-up system does not operate (in cold season).
• When engine coolant temperature is below 30°C automatic warm-up system raises engine speed to
1,300 rpm.
• If fuel control dial is opened more than 70% for 3 seconds when starting switch is turned ON or after
Related
engine is started, automatic warm-up system is turned OFF. (Automatic warm-up system stops
information
automatically after operating for 10 minutes.)
• If engine coolant temperature is below 10°C turbocharger protection function operates to keep the
engine speed at low idle.
14 PC138US, USLC-8
SEN02467-00 40 Troubleshooting
E-6 All work equipment, swing, and travel mechanism do not move or
cannot be locked 1
Trouble (1) All work equipment, swing, and travel mechanism do not move.
Related
information
16 PC138US, USLC-8
40 Troubleshooting SEN02467-00
Trouble (2) All work equipment, swing, and travel mechanism cannot be locked.
Related
information
PC138US, USLC-8 17
SEN02467-00 40 Troubleshooting
18 PC138US, USLC-8
40 Troubleshooting SEN02467-00
PC138US, USLC-8 19
SEN02467-00 40 Troubleshooting
20 PC138US, USLC-8
40 Troubleshooting SEN02467-00
PC138US, USLC-8 21
SEN02467-00 40 Troubleshooting
(3) Display of coolant temperature gauge is different from actual engine coolant temperature.
Trouble (4) Display of engine coolant temperature gauge is different from display of engine coolant tempera-
ture monitor.
• Signals of engine coolant temperature sensor are input to engine controller and then transmitted to
Related machine monitor through communication system.
information • Engine coolant temperature can be checked with monitoring function.
(Code: 04107 Engine coolant temperature)
22 PC138US, USLC-8
40 Troubleshooting SEN02467-00
PC138US, USLC-8 23
SEN02467-00 40 Troubleshooting
(3) Display of hydraulic oil temperature gauge is different from actual hydraulic oil temperature.
Trouble (4) Display of hydraulic oil temperature gauge is different from display of hydraulic oil temperature
monitor.
• Signals of hydraulic oil temperature sensor are input to pump controller and then transmitted to
Related machine monitor through communication system.
information • Hydraulic oil temperature can be checked with monitoring function.
(Code: 04401 Hydraulic oil temperature)
24 PC138US, USLC-8
40 Troubleshooting SEN02467-00
PC138US, USLC-8 25
SEN02467-00 40 Troubleshooting
(3) Display of fuel level gauge is different from actual fuel level.
Trouble
(4) Display of fuel level gauge is different from display of fuel level monitor.
Related • Signal voltage of fuel level sensor can be checked with monitoring function.
information (Code: 04200 Fuel level sensor voltage)
26 PC138US, USLC-8
40 Troubleshooting SEN02467-00
PC138US, USLC-8 27
SEN02467-00 40 Troubleshooting
28 PC138US, USLC-8
40 Troubleshooting SEN02467-00
Trouble (2) When working mode is changed, setting of engine and hydraulic pump is not changed.
Related
information
PC138US, USLC-8 29
SEN02467-00 40 Troubleshooting
Trouble (2) When travel speed is shifted, actual travel speed does not change.
Related
• If cause 1 occurs, actual travel speed does not lower when travel speed is shifted to Lo.
information
30 PC138US, USLC-8
40 Troubleshooting SEN02467-00
PC138US, USLC-8 31
SEN02467-00 40 Troubleshooting
Trouble (2) When wiper switch is operated, wiper does not operate.
Related • Condition of window rear limit switch signal can be checked with monitoring function.
information (Code: 02204 Switch input 5)
32 PC138US, USLC-8
40 Troubleshooting SEN02467-00
PC138US, USLC-8 33
SEN02467-00 40 Troubleshooting
Trouble (3) When window washer switch is operated, window washer does not operate.
Related • Condition of window washer switch signal can be checked with monitoring function.
information (Code: 04504 Monitor 1st, 2nd line switches)
34 PC138US, USLC-8
SEN02467-00 40 Troubleshooting
(2) When swing lock switch is turned ON, swing lock does not operate. (Hydraulic drift of swing occurs
Trouble
on slope.)
Related
information
36 PC138US, USLC-8
40 Troubleshooting SEN02467-00
PC138US, USLC-8 37
SEN02467-00 40 Troubleshooting
E-21 Travel alarm does not sound or does not stop sounding 1
• Alarm does not sound during travel.
Trouble
• Alarm does not stop sounding while machine is stopped.
Related
information
38 PC138US, USLC-8
40 Troubleshooting SEN02467-00
Trouble (2) When air conditioner switch is operated, air conditioner does not operate at all.
Related
information
PC138US, USLC-8 39
SEN02467-00 40 Troubleshooting
Trouble (3) Air does not come out (Air flow is insufficient).
Related
information
40 PC138US, USLC-8
40 Troubleshooting SEN02467-00
PC138US, USLC-8 41
SEN02467-00 40 Troubleshooting
42 PC138US, USLC-8
40 Troubleshooting SEN02467-00
(5) Air conditioner abnormality record: Communication condition “CAN disconnection”, Communica-
Trouble
tion condition “Abnormal”
• While abnormality in communication is being detected, “CAN disconnection” is displayed.
• If abnormality in communication has been detected and reset, “Abnormality” is displayed.
Related
• If “CAN disconnection” is displayed as communication condition, communication cannot be carried
information
out normally. Accordingly, condition of other items is not displayed.
• Method of reproducing abnormality record: Turn starting switch ON.
PC138US, USLC-8 43
SEN02467-00 40 Troubleshooting
Trouble (7) Air conditioner abnormality record: Internal air sensor “Abnormality”
• If “CAN disconnection” is displayed as communication condition, communication cannot be carried
Related out normally. Accordingly, this condition is not displayed.
information • Method of reproducing abnormality record: Turn starting switch ON + Turn air conditioner (A/C)
switch ON.
44 PC138US, USLC-8
40 Troubleshooting SEN02467-00
Trouble (8) Air conditioner abnormality record: External air sensor “Unused”
• External air sensor is not used in air conditioner system of this machine.
Related
• If “CAN disconnection” is displayed as communication condition, communication cannot be carried
information
out normally. Accordingly, this condition is not displayed.
Trouble (9) Air conditioner abnormality record: Air flow sensor “Abnormality”
• If “CAN disconnection” is displayed as communication condition, communication cannot be carried
Related out normally. Accordingly, this condition is not displayed.
information • Method of reproducing abnormality record: Turn starting switch ON + Turn air conditioner (A/C)
switch ON.
PC138US, USLC-8 45
SEN02467-00 40 Troubleshooting
46 PC138US, USLC-8
40 Troubleshooting SEN02467-00
Trouble (11) Air conditioner abnormality record: Air outlet damper “Abnormality”
• If “CAN disconnection” is displayed as communication condition, communication cannot be carried
Related out normally. Accordingly, this condition is not displayed.
information • Method of reproducing abnormality record: Turn starting switch ON + Turn air conditioner (A/C)
switch ON.
PC138US, USLC-8 47
SEN02467-00 40 Troubleshooting
48 PC138US, USLC-8
40 Troubleshooting SEN02467-00
PC138US, USLC-8 49
SEN02467-00 40 Troubleshooting
50 PC138US, USLC-8
40 Troubleshooting SEN02467-00
PC138US, USLC-8 51
SEN02467-00 40 Troubleshooting
E-25 Monitoring function does not display lever control signal normally 1
Trouble (1) Boom raise operation is not displayed normally by monitoring function.
Related
• Monitoring code: 01900 Pressure switch 1
information
52 PC138US, USLC-8
40 Troubleshooting SEN02467-00
PC138US, USLC-8 53
SEN02467-00 40 Troubleshooting
Trouble (2) Arm curl operation is not displayed normally by monitoring function.
Related
• Monitoring code: 01900 Pressure switch 1
information
54 PC138US, USLC-8
40 Troubleshooting SEN02467-00
PC138US, USLC-8 55
SEN02467-00 40 Troubleshooting
Trouble (3) Bucket curl operation is not displayed normally by monitoring function.
Related
• Monitoring code: 01901 Pressure switch 2
information
56 PC138US, USLC-8
40 Troubleshooting SEN02467-00
PC138US, USLC-8 57
SEN02467-00 40 Troubleshooting
Trouble (4) Bucket dump operation is not displayed normally by monitoring function.
Related
• Monitoring code: 01901 Pressure switch 2
information
58 PC138US, USLC-8
40 Troubleshooting SEN02467-00
PC138US, USLC-8 59
SEN02467-00 40 Troubleshooting
Trouble (5) Boom lower operation is not displayed normally by monitoring function.
Related
• Monitoring code: 01900 Pressure switch 1
information
60 PC138US, USLC-8
40 Troubleshooting SEN02467-00
PC138US, USLC-8 61
SEN02467-00 40 Troubleshooting
Trouble (6) Arm dump operation is not displayed normally by monitoring function.
Related
• Monitoring code: 01900 Pressure switch 1
information
62 PC138US, USLC-8
40 Troubleshooting SEN02467-00
PC138US, USLC-8 63
SEN02467-00 40 Troubleshooting
64 PC138US, USLC-8
40 Troubleshooting SEN02467-00
PC138US, USLC-8 65
SEN02467-00 40 Troubleshooting
66 PC138US, USLC-8
40 Troubleshooting SEN02467-00
PC138US, USLC-8 67
SEN02467-00 40 Troubleshooting
a Select “Terminal Status” from “12 Display of a Select “GPS & Communication Status” from
KOMTRAX setting” in the service menu of the “12 Display of KOMTRAX setting” in the ser-
machine monitor. vice menu of the machine monitor.
68 PC138US, USLC-8
SEN02467-00 40 Troubleshooting
© 2007 KOMATSU
All Rights Reserved
Printed in Japan 01-07 (02)
70 PC138US, USLC-8
SEN02468-01
PC138US-8
PC138USLC-8
40 Troubleshooting 1
Troubleshooting of hydraulic and
mechanical system (H-mode)
Information contained in troubleshooting table ............................................................................................... 3
System chart for hydraulic and mechanical systems ...................................................................................... 4
H-1 Speed or power of all work equipment, swing, and travel are low ........................................................... 6
H-2 Engine speed sharply drops or engine stalls............................................................................................ 7
H-3 No work equipment, travel and swing move ............................................................................................ 8
H-4 Abnormal noise is heard from around hydraulic pump............................................................................. 8
H-5 Fine control mode does not function ........................................................................................................ 9
H-6 Speed or power of boom is low .............................................................................................................. 10
H-7 Speed or power of arm is low..................................................................................................................11
H-8 Speed or power of bucket is low ............................................................................................................ 12
H-9 Work equipment does not move in its single operation.......................................................................... 13
H-10 Hydraulic drift of work equipment is large ............................................................................................ 14
H-11 Time lag of work equipment is large..................................................................................................... 15
H-12 Work equipment loaded more is slower during compound operation .................................................. 15
PC138US, USLC-8 1
SEN02468-01 40 Troubleshooting
H-13 Boom RAISE speed is low in compound operation of swing + boom RAISE....................................... 15
H-14 Travel speed lowers largely during compound operation of work equipment/swing + travel ............... 16
H-15 Machine deviates during travel............................................................................................................. 17
H-16 Travel speed is low............................................................................................................................... 18
H-17 Machine cannot be steered easily or steering power is low ................................................................. 19
H-18 Travel speed does not change or it is kept low or high ........................................................................ 20
H-19 Track does not move (Only either side)................................................................................................ 20
H-20 Machine does not swing....................................................................................................................... 21
H-21 Swing acceleration or swing speed is low ............................................................................................ 22
H-22 Excessive overrun when stopping swing.............................................................................................. 23
H-23 When upper structure stops swinging, it makes large shock ............................................................... 24
H-24 When upper structure stops swinging, it makes large sound ............................................................... 24
H-25 Hydraulic drift of swing is large............................................................................................................. 25
H-26 Flow rate in attachment circuit cannot be adjusted .............................................................................. 26
2 PC138US, USLC-8
40 Troubleshooting SEN02468-01
2
Possible causes Cause for presumed
and standard failure <Contents>
value in normal (The attached No. for • The standard values in normalcy by which to judge "good"
3
state filing and reference or "no good" about presumed causes.
purpose only. It does not • References for making judgement of "good" or "no good"
stand for any priority)
4
PC138US, USLC-8 3
SEN02468-01 40 Troubleshooting
4 PC138US, USLC-8
40 Troubleshooting SEN02468-01
a This is a system chart that has been drawn up by simplifying the whole hydraulic circuit chart. Use it as
a reference material when troubleshooting the hydraulic and mechanical systems.
PC138US, USLC-8 5
SEN02468-01 40 Troubleshooting
H-1 Speed or power of all work equipment, swing, and travel are low 1
Trouble • Speed or power of all work equipment, swing, and travel are low.
Related
• Conduct the troubleshooting in working mode P.
information
6 PC138US, USLC-8
40 Troubleshooting SEN02468-01
PC138US, USLC-8 7
SEN02468-01 40 Troubleshooting
8 PC138US, USLC-8
40 Troubleshooting SEN02468-01
PC138US, USLC-8 9
SEN02468-01 40 Troubleshooting
10 PC138US, USLC-8
40 Troubleshooting SEN02468-01
PC138US, USLC-8 11
SEN02468-01 40 Troubleshooting
12 PC138US, USLC-8
40 Troubleshooting SEN02468-01
PC138US, USLC-8 13
SEN02468-01 40 Troubleshooting
Trouble • Hydraulic drift of work equipment is large. (2) Hydraulic drift of arm is large.
Related
• Conduct the troubleshooting in working mode P.
information
Trouble • Hydraulic drift of work equipment is large. (3) Hydraulic drift of bucket is large.
Related
• Conduct the troubleshooting in working mode P.
information
14 PC138US, USLC-8
40 Troubleshooting SEN02468-01
PC138US, USLC-8 15
SEN02468-01 40 Troubleshooting
16 PC138US, USLC-8
40 Troubleshooting SEN02468-01
PC138US, USLC-8 17
SEN02468-01 40 Troubleshooting
18 PC138US, USLC-8
40 Troubleshooting SEN02468-01
PC138US, USLC-8 19
SEN02468-01 40 Troubleshooting
20 PC138US, USLC-8
40 Troubleshooting SEN02468-01
Trouble • Machine does not swing. (2) Machine does not swing in only one direction.
Related
• Conduct the troubleshooting in working mode P.
information
PC138US, USLC-8 21
SEN02468-01 40 Troubleshooting
22 PC138US, USLC-8
40 Troubleshooting SEN02468-01
PC138US, USLC-8 23
SEN02468-01 40 Troubleshooting
24 PC138US, USLC-8
40 Troubleshooting SEN02468-01
Trouble • Hydraulic drift of swing is large. (2) When swing holding brake is released
• If the swing holding brake release is in the emergency position, the swing holding brake is released
Related
and the upper structure is held with only hydraulic pressure.
information
• Conduct the troubleshooting in working mode P.
PC138US, USLC-8 25
SEN02468-01 40 Troubleshooting
26 PC138US, USLC-8
40 Troubleshooting SEN02468-01
PC138US, USLC-8 27
SEN02468-01 40 Troubleshooting
© 2007 KOMATSU
All Rights Reserved
Printed in Japan 02-07 (02)
28 PC138US, USLC-8
SEN02469-01
PC138US-8
PC138USLC-8
40 Troubleshooting 1
Troubleshooting of engine (S-mode)
Method of using troubleshooting chart............................................................................................................ 4
S-1 Starting performance is poor .................................................................................................................... 8
S-2 Engine does not start ............................................................................................................................... 9
S-3 Engine does not pick up smoothly.......................................................................................................... 12
S-4 Engine stops during operations .............................................................................................................. 13
S-5 Engine does not rotate smoothly ............................................................................................................ 14
S-6 Engine lacks output (or lacks power) ..................................................................................................... 15
S-7 Exhaust smoke is black (incomplete combustion).................................................................................. 16
S-8 Oil consumption is excessive (or exhaust smoke is blue) ...................................................................... 17
S-9 Oil becomes contaminated quickly ......................................................................................................... 18
S-10 Fuel consumption is excessive............................................................................................................. 19
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) ................................................... 20
S-12 Oil pressure drops ................................................................................................................................ 21
S-13 Oil level rises (Entry of coolant or fuel)................................................................................................. 22
S-14 Coolant temperature becomes too high (overheating) ......................................................................... 23
PC138US, USLC-8 1
SEN02469-01 40 Troubleshooting
2 PC138US, USLC-8
40 Troubleshooting SEN02469-01
PC138US, USLC-8 3
SEN02469-01 40 Troubleshooting
Items listed in the [Questions] and [Check items] and related to the [Causes] are marked with E, Q, and w.
E : Causes to be referred to for questions and check items
Q : Causes related to questions and check items
w : Causes highly probable among ones marked with Q
a When narrowing the "causes", apply the items marked with w before those marked with Q.
When narrowing the causes, do not apply the items marked with E. (If no items have other marks and
the causes cannot be narrowed, however, you may apply them.)
4 PC138US, USLC-8
40 Troubleshooting SEN02469-01
PC138US, USLC-8 5
SEN02469-01 40 Troubleshooting
6 PC138US, USLC-8
40 Troubleshooting SEN02469-01
There is a causal relationship between 3 items in the [Questions] and [Check items] sections and 5 items in
the [Causes] section.
The method of pinpointing the "cause" from the causal relationship and approaching the "troubleshooting" is
explained according to Step 1 – Step 3 shown below.
PC138US, USLC-8 7
SEN02469-01 40 Troubleshooting
Defective injector
nomenon does not indicate a trouble, however.
Carry out troubleshooting according to “No-pressure feed by supply pump (*1)” indicated q
by code
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not
q
change
When starting switch is turned to HEAT, intake air heater mount does not become warm q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Clean
Clean
Remedy
8 PC138US, USLC-8
40 Troubleshooting SEN02469-01
on E-mode
When terminal B and terminal C of starting switch are connected, q
engine starts
Turn starting switch OFF,
When terminal B and terminal C at safety relay outlet are
connect cord, and carry out q
connected, engine starts
troubleshooting at ON
Even if terminal B and terminal C at safety relay outlet are
connected, engine does not start q
Replace
Replace
Replace
Replace
Correct
Remedy —
PC138US, USLC-8 9
SEN02469-01 40 Troubleshooting
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Add
Remedy
10 PC138US, USLC-8
40 Troubleshooting SEN02469-01
c) Exhaust smoke comes out but engine does not start Causes
(fuel is being injected)
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Remedy
PC138US, USLC-8 11
SEN02469-01 40 Troubleshooting
Black
When engine is cranked, abnormal sound is generated around cylinder head w
When engine is cranked, interference sound is generated around turbocharger w
High idle speed under no load is normal, but speed suddenly drops when load is applied Q w
There is hunting from engine (rotation is irregular) Q Q Q
Blow-by gas is excessive w
Replace
Replace
Correct
Correct
Adjust
Clean
Clean
Clean
Remedy
12 PC138US, USLC-8
40 Troubleshooting SEN02469-01
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Clean
Clean
Add
Remedy
—
PC138US, USLC-8 13
SEN02469-01 40 Troubleshooting
Remedy
14 PC138US, USLC-8
40 Troubleshooting SEN02469-01
(air leakage)
Confirm recent repair history
Degree of use of machine Operated for long period E E E E
Suddenly Q w Q Q Q Q
Questions
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Adjust
Clean
Clean
Remedy
PC138US, USLC-8 15
SEN02469-01 40 Troubleshooting
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change q
Carry out troubleshooting according to “Abnormality in coolant temperature sensor (*2)”
q
indicated by code
Confirm with monitoring function q q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Clean
Remedy
16 PC138US, USLC-8
40 Troubleshooting SEN02469-01
Turbocharger
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Clean
Remedy
PC138US, USLC-8 17
SEN02469-01 40 Troubleshooting
See S-7
Inspect oil cooler directly q
Inspect oil filter directly q
Spring of oil filter safety valve is hitched or broken q
Inspect turbocharger lubrication drain tube directly q
Replace
Replace
Replace
Replace
Replace
Replace
Clean
Clean
Remedy —
18 PC138US, USLC-8
40 Troubleshooting SEN02469-01
Carry out troubleshooting according to “No-pressure feed by supply pump (*1)” indicated by code q
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change q
If spill hose from injector is disconnected, much fuel spills q
Carry out troubleshooting according to “Abnormality in coolant temperature sensor (*2)” indicated
q
by code
Confirm with monitoring function q q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Remedy
PC138US, USLC-8 19
SEN02469-01 40 Troubleshooting
S-11 Oil is in coolant (or coolant spurts back or coolant level goes
down) 1
General causes why oil is in coolant Causes
q Internal leakage in lubrication system
Suddenly rose Q Q
Oil level
Gradually rose Q Q
Hard water is being used as coolant Q Q
Oil level has risen and oil is milky Q Q w
Check
items
Replace
Replace
Replace
Replace
Remedy
20 PC138US, USLC-8
40 Troubleshooting SEN02469-01
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Add
Remedy —
PC138US, USLC-8 21
SEN02469-01 40 Troubleshooting
Remedy
22 PC138US, USLC-8
40 Troubleshooting SEN02469-01
Sudden overheated Q w Q
Condition overheating
Always tends to overheat Q w w Q
Rises quickly Q w
Coolant temperature gauge
Does not go down from red range w
Radiator coolant level monitor indicates drop of coolant level w
Engine oil level has risen, oil is milky w Q
Fan belt tension is low w
When fan pulley is turned, it has play w
Milky oil is floating on coolant w
There are excessive air bubbles in radiator, coolant spurts back w
When light bulb is held behind radiator core, no light passes through w
Check items
Radiator shroud, inside of underguard side are clogged with dirt or mud w w
Coolant is leaking because of cracks in hose or loose clamps w
Coolant flows out from radiator overflow hose w
Fan belt whines under sudden acceleration w
Hydraulic oil temperature enters red range faster than engine coolant
w
temperature
on H-mode
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Add
Remedy —
PC138US, USLC-8 23
SEN02469-01 40 Troubleshooting
Gradually occurred Q Q
Condition of abnormal noise
Suddenly occurred Q Q Q
Non-specified fuel is being used Q
Oil must be added more frequently w
Metal particles are found when oil filter is drained w w
Air leaks between turbocharger and cylinder head w
When engine is cranked, interference sound is generated around turbocharger w
When engine is cranked, abnormal sound is generated around cylinder head w w
When engine is cranked, beat noise is generated around muffler w
When exhaust manifold is touched immediately after starting engine, temperature of
Check items
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Remedy
24 PC138US, USLC-8
40 Troubleshooting SEN02469-01
Suddenly increased Q Q
Condition of vibration
Gradually increased Q Q Q
Non-specified oil is being used Q Q
Metal particles are found when oil filter is drained w w
Metal particles are found when oil pan is drained w w
Oil pressure is low at low idle Q Q
Check items
Replace
Replace
Replace
Remedy
PC138US, USLC-8 25
SEN02469-01 40 Troubleshooting
© 2007 KOMATSU
All Rights Reserved
Printed in Japan 02-07 (02)
26 PC138US, USLC-8
SEN02709-00
HYDRAULIC EXCAVATOR
PC138US-8
PC138USLC-8
PC138US, USLC-8 1
SEN02709-00 50 Disassembly and assembly
1) Necessity of work.
t : Special tools that cannot be substi- a: This mark gives guidance or precautions when
tuted and should always be used doing the procedure.
(installed). [*1] : This mark shows that there are instructions or
q : Special tools that will be useful if avail- precautions for installing parts.
able and are substitutable with com- 6 : This mark shows the amount of oil or coolant
mercially available tools. to be drained.
2) Distinction of new and existing special 4 : Weight of part or component
tools
N: Tools newly developed for this
model. They respectively have a Installation
new part number. q Except where otherwise instructed, installation
R: Tools with upgraded part numbers. of parts is done in the reverse order of removal.
They are remodeled from already q Instructions and precautions for installing parts
available tools for other models. are shown with [*1] mark in the "Removal" sec-
Blank: Tools already available for other tion, identifying which step the instructions are
models. They can be used without intended for.
any modification. q Marks shown in the "Installation" section stand
3) Circle mark Q in sketch column: for the following.
q The sketch of the special tool is pre- k : Precautions related to safety in execution
sented in the section of "Sketches of of work.
special tools". a: This mark gives guidance or precautions when
q Part No. of special tools starting with doing the procedure.
2 : Type of coating material
* *** ****
79 T- - :
means that they can not be supplied 3 : Tightening torque
5
from Komatsu in Japan (i.e. locally : Quantity of oil or coolant to be added
made parts ).
Sketches of special tools
a General tools that are necessary for
q Various special tools are illustrated for the con-
removal or installation are described as
venience of local manufacture.
[1], [2]•••etc. and their part names, part
numbers and quantities are not described.
2 PC138US, USLC-8
50 Disassembly and assembly SEN02709-00
PC138US, USLC-8 3
SEN02709-00 50 Disassembly and assembly
List of adhesives
a The recommended coating materials such as adhesives, gasket sealants, and greases used for disas-
sembly and assembly are listed below.
a For coating materials not listed below, use the equivalent of products shown in this list.
Cate- Komatsu
Part No. Q'ty Container Main features and applications
gory code
• Used to prevent rubber gaskets, rubber cushions, and
LT-1A 790-129-9030 150 g Tube
cork plugs from coming out.
• Used for plastic (except polyethylene, polypropylene,
20 g Polyethylene tetrafluoroethylene and vinyl chloride), rubber, metal,
LT-1B 790-129-9050
(2 pcs.) container and non-metal parts which require immediate and
strong adhesion.
Polyethylene • Features: Resistance to heat and chemicals.
LT-2 09940-00030 50 g
container • Used to fix and seal bolts and plugs.
790-129-9060 Adhesive:
(Set of 1 kg
LT-3 Can • Used to stick and seal metal, glass, and plastics.
adhesive and Hardener:
hardener) 500 g
Adhesive
Polyethylene
LT-4 790-129-9040 250 g • Used to seal plugs.
container
Holtz MH
790-129-9120 75 g Tube • Heat-resistant seal used to repair engines.
705
• Quick-setting adhesive.
ThreeBond Polyethylene • Setting time: Within 5 sec. to 3 min.
790-129-9140 50 g
1735 container • Used mainly to stick metals, rubbers, plastics, and
woods.
• Quick-setting adhesive.
Aron-alpha Polyethylene • Quick-setting type.
790-129-9130 2g
201 container (max. strength is obtained after 30 minutes)
• Used mainly to stick rubbers, plastics, and metals.
Loctite Polyethylene • Features: Resistance to heat and chemicals.
79A-129-9110 50 cc
648-50 container • Used for fitted portions used at high temperatures.
• Used to stick or seal gaskets and packings of power
LG-1 790-129-9010 200 g Tube
train case, etc.
• Used to seal various threaded portions, pipe joints,
Polyethylene and flanges.
LG-5 790-129-9080 1 kg
container • Used to seal tapered plugs, elbows, and nipples of
hydraulic piping.
• Features: Silicon-based heat and cold-resistant seal-
Gasket sealant
ant.
LG-6 790-129-9020 200 g Tube
• Used to seal flange surfaces and threaded portions.
• Used to seal oil pan, final drive case, etc.
• Features: Silicon-based quick-setting sealant.
LG-7 790-129-9070 1 kg Tube • Used to seal flywheel housing, intake manifold, oil
pan, thermostat housing, etc.
ThreeBond
790-129-9090 100 g Tube • Gasket sealant used to repair engine.
1211
• Features: Silicon-based, heat and cold-resistant,
ThreeBond
419-15-18131 100 g Tube vibration-resistant, impact-resistant sealant.
1207B
• Used to seal transfer case, etc.
4 PC138US, USLC-8
50 Disassembly and assembly SEN02709-00
Cate- Komatsu
Part No. Q'ty Container Main features and applications
gory code
molybdenum disulfide
ing part.
22M-54-27230 20 ml
painting plane container (Term of validity: 4 months after manufac-
435-95 turing)
• To be used as primer for black ceramic
Sunstar
coated plane of glass side and polycarbon-
primer for
22M-54-27240 150 ml Steel can ate hard coat plane.
glass
(Term of validity: 4 months after manufac-
435-41
turing)
Sunstar • To be used as primer for sash (Alumite
primer for Glass surface treatment)
22M-54-27250 20 ml
sash container (Term of validity: 4 months after manufac-
GP-402 turing)
PC138US, USLC-8 5
SEN02709-00 50 Disassembly and assembly
Cate- Komatsu
Part No. Q'ty Container Main features and applications
gory code
• "S" and "W" are used as glass adhesive
Sunstar pen- compound in high temperature (April -
guin seal 580 Polyethylene October) and in low temperature (October
417-926-3910 320 ml
Adhesive compound
6 PC138US, USLC-8
50 Disassembly and assembly SEN02709-00
New/remodel
Necessity
Sym-
Component Part No. Part Name Nature of work, remarks
Sketch
bol
Q’ty
790-101-5201 Push tool (Kit) t 1
790-101-5271 • Plate 1
Engine front oil seal 1 Instllation front oil seal
790-101-5221 • Grip 1
01010-51225 • Bolt 1
Engine rear oil seal A 2 795-931-1100 Seal puller assembly q 1 Removal rear oil seal
790-101-5401 Push tool (Kit) t 1
790-101-5431 • Plate 1
Engine rear oil seal 3 Instllation rear oil seal
790-101-5421 • Grip 1
01010-51240 • Bolt 1
796-460-1210 Oil stopper q 1 Stop oil supply from hydraulic
Hydraulic oil tank D
795-799-1131 Adapter q 1 tank
790-101-4200 Puller q 1
(294 kN {30 ton})
Swing machinery F 790-101-1102 Hydraulic oil pump q 1
790-101-5401 Push tool (Kit) (C) q 1 Instllation Bearing outer race
790-101-5461 • Plate 1 For main bearing
3 790-101-5441 • Plate 1 For sub bearing
790-101-5421 • Grip 1
01010-51240 • Bolt 1
4 790-201-2850 Spacer t 1
Instllation Bearing inner race
5 790-201-2750 Spacer t 1
796T-426-1140 Push tool t 1 Q
6 Instllation oil seal
790-201-2680 Plate q 1
PC138US, USLC-8 7
SEN02709-00 50 Disassembly and assembly
New/remodel
Necessity
Sym-
Component Part No. Part Name Nature of work, remarks
Sketch
bol
Q’ty
1 791-675-1510 Installer t 1 Application of floating seal
791-600-2001 Compressor (A) 1
or t
791-685-8006 Compressor (B) 1
791-635-3160 Extension t 1
2 790-201-2770 t 1 Compression of spring
• Spacer
Cylinder
790-101-1600 (686 kN {70 ton}) t 1
Disassembly, assembly
of idler recoil spring L 790-101-1102 Pump t 1
790-201-1500 Push tool (Kit) q 1
790-201-1590 • Plate 1
(Periphery ø74)
3 790-201-1610 • Plate 1 Press fit of piston dust seal
(Periphery ø79)
790-101-5021 • Grip 1
01010-50816 • Bolt 1
1 790-434-1650 Installer t 1 Application of floating seal ø88
Disassembly, assembly M
of track roller Sealing of oil and checking of
2 791-601-1000 Oil pump q 1 air leak
791-616-1110 Frame t 1
791-616-1121 Plate t 1
791-616-1131 Plate t 1
791-616-1150 Guide t 1
791-616-1160 Adapter t 1
791T-616-1280 Adapter t 1 Q
791-620-3530 Push t 1
Expansion, installation 791-620-3260 Push t 1 Removal, pressfit of master
of track shoe R pin
791-620-3270 Guide t 1
01011-62260 Bolt t 2
01643-62260 Washer t 2
01011-61455 Bolt t 3
01643-31445 Washer t 3
Cylinder
790-105-1100 (297 kN {30 ton}) t 1
790-101-1102 Pump t 1
790-101-2501 Push puller q 1
790-101-2510 • Block 1
790-101-2520 • Screw 1
790-101-2540 • Washer 1
Disassembly of center T 791-112-1180 • Nut 1 Disconnection of rotor from
swivel joint shaft
790-101-2630 • Leg 2
790-101-2570 • Washer 4
790-101-2560 • Nut 2
791-112-2650 • Adapter 2
8 PC138US, USLC-8
50 Disassembly and assembly SEN02709-00
New/remodel
Necessity
Sym-
Component Part No. Part Name Nature of work, remarks
Sketch
bol
Q’ty
790-502-1003 Repair stand t 1 Disassembly, assembly of cyl-
1 inder
790-101-1102 Pump t 1
790-102-4300 Wrench assembly t 1 Removal, installation of
2 piston
790-201-4310 Pin t 1
790-201-1702 Push tool (Kit) t 1
790-201-1791 • Push tool 1 Press fit of bucket cylinder roll
790-101-5021 • Grip 1 bushings
01010-50816 • Bolt 1
790-201-1702 Push tool (Kit) t 1
790-201-1811 • Push tool 1 Press fit of boom cylinder roll
3 bushings
790-101-5021 • Grip 1
01010-50816 • Bolt 1
790-201-1702 Push tool (Kit) t 1
790-201-1821 • Push tool 1 Press fit of arm and blade cyl-
790-101-5021 • Grip 1 inder roll bushings
01010-50816 • Bolt 1
790-201-1500 Push tool (Kit) q 1
790-201-1620 • Push tool 1 Application of boom cylinder
4
790-101-5021 • Grip 1 dust seal
01010-50816 • Bolt 1
790-201-1500 Push tool (Kit) q 1
790-201-1630 • Push tool 1 Application of arm and blade
790-101-5021 • Grip 1 cylinder dust seal
01010-50816 • Bolt 1
5 790-720-1000 Expander t 1 Extension of piston ring
796-720-1660 Ring t 1 Bucket cylin- Removal,
6 der installation of
Arm, boom, piston ring
07281-01159 Clamp t 1 blade cylinder
792-785-1100 Remover t 1
Operator’s cab glass 1 793-498-1210 Lifter (Suction cup) t 2 Removal and installation oper-
X
(stuck glass) 2 20Y-54-13180 Adapter t 2 atiors cab glass (stuck glass)
PC138US, USLC-8 9
SEN02709-00 50 Disassembly and assembly
New/remodel
Necessity
Sym-
Component Part No. Part Name Nature of work, remarks
Sketch
bol
Q’ty
799-703-1200 Service tool (Kit) t 1
Vacuum pump
Floor frame assembly 799-703-1100 (100V) t 1
airconditioner com-
pressor assembly air- Vacuum pump Charging of air-conditioning
conditioner condenser X 3 799-703-1111 (220V) t 1 gas
assembly aircondi-
tioner unit assembly Vacuum pump
790-703-1121 (240V) t 1
10 PC138US, USLC-8
50 Disassembly and assembly SEN02709-00
F6 Push tool
R Adapter
PC138US, USLC-8 11
SEN02709-00 50 Disassembly and assembly
© 2007 KOMATSU
All Rights Reserved
Printed in Japan 02-07 (02)
12 PC138US, USLC-8
SEN02710-00
HYDRAULIC EXCAVATOR
PC138US-8
PC138USLC-8
PC138US, USLC-8 1
SEN02710-00 50 Disassembly and assembly
Removal and installation of fuel 6) Loosen sleeve nuts (12) and (13) and
remove high pressure pipe (14). [*2]
supply pump assembly 1 7) Remove the pin and disconnect spill hose
(15).
Removal
k
8) Remove joint bolts (16), (17) and (18) and
Disconnect the negative (–) terminal of the
remove fuel tubes (19) and (20). [*3]
battery beforehand.
2 PC138US, USLC-8
50 Disassembly and assembly SEN02710-00
[*1]
a Set the boot slit facing outward and downward.
a The boot is designed with fire safety to prevent
fuel from splashing onto the hot engine if fuel
leaks.
[*2]
k Never bens a high-pressure pipe for the
convenience sake.
k The clamp used for fixing a high-pressure
pipe must be a genuine Komatsu part and it
must be tightened to the specified torque.
k Be sure to install the boot to the sleeve nut
2) Remove 3 nuts (26) and remove supply after installing the high-pressure pipe.
pump (27) from pump holder (28). a Before installing a high-pressure pipe, confirm
the following points. If any abnormality was
found, replace it with new one. Otherwise,
leakage of fuel can result.
q No visible striations (b) or patchy dents (c) in
the taper seal portion of the connection ( (a)
portion: area 2 mm inside the tip).
q No deformation in portion (d) (at the end of the
taper seal portion: 2 mm inside the tip).
[*3]
3 Joint bolts (16) and (17):
24.5 – 34.3 Nm {2.5 – 3.51 kgm}
[*4]
a For mounting bolt (22), install M6 bolt with LT-
2A.
[*5]
3 Pump gear mount nut:
65 – 75 Nm {6.6 – 7.6 kgm}
PC138US, USLC-8 3
SEN02710-00 50 Disassembly and assembly
4 PC138US, USLC-8
50 Disassembly and assembly SEN02710-00
[*2]
k Never bend a high-pressure pipe for the
convenience sake.
k The clamp used for fixing a high-pressure
pipe must be a genuine Komatsu part and it
must be tightened to the specified torque.
k Be sure to install the boot to the sleeve nut
after installing the high-pressure hose.
a Before Installing a high-pressure pipe, confirm
the following points. If any abnormality was
found, replace it with new one. Otherwise,
leakage of fuel can result.
q No visible striations (b) or patchy dents (c) in
the taper seal portion of the connection ( (a)
portion: area 2mm inside the tip).
q No deformation in portion (d) (at the end of the
taper seal portion: 2 mm inside the tip).
[*3]
3 Holder mounting bolt (13):
27 – 30 Nm {2.8 – 3.1 kgm}
PC138US, USLC-8 5
SEN02710-00 50 Disassembly and assembly
[*4]
q When reusing injector, always replace Oring
(15) and gasket (16) with new ones.
6 PC138US, USLC-8
50 Disassembly and assembly SEN02710-00
Removal and installation of front 3. Loosen fan belt adjust bolt (3) and remove fan
belt (4). [*1]
oil seal 1
4. Remove engine speed sensor connector (5).
Special tools
5. Remove speed sensor mounting bolt (6) and
New/Remodel
remove speed sensor (7). [*2]
Necessity
Sym-
Part No. Part name
bol
6. Remove crankshaft pulley mounting bolt (8)
Q'ty
and remove crankshaft pulley (9). [*3]
790-101-5201 Push tool (kit) t 1
790-101-5271 • Plate 1
A 1
790-101-5221 • Grip 1
01010-51225 • Bolt 1
Removal
1. Remove the engine assembly, referring to
"Removal and installation of engine assembly."
PC138US, USLC-8 7
SEN02710-00 50 Disassembly and assembly
Installation
1. Use tool A1 (outside diameter of 80 mm) to
press front oil seal (10) in gear case (11).
1) Check the crankshaft end corner and the
oil seal lip sliding surface for flaws, burrs,
scars, or rust, before installing the oil seal.
2) Fill about 2 cc of grease to between the oil
seal lips.
2 Front oil seal: grease (G2-LI)
[*1]
Confirm the direction of the fan.
[*2]
2 Speed sensor mounting bolt (6):
7.0 – 11 Nm {0.7 – 1.1 kgm}
[*3]
2 Crankshaft pulley mounting bolt (8):
343 – 402 Nm {35 – 41 kgm}
8 PC138US, USLC-8
50 Disassembly and assembly SEN02710-00
New/Remodel
Necessity
Sym-
Part No. Part name
bol
Q'ty
Seal puller assem-
2 795-931-1100 q 1
bly
790-101-5401 • Push tool (kit) t 1
A
790-101-5431 • Plate 1
3
790-101-5421 • Grip 1
01010-51240 • Bolt 1
4) Loosen flywheel mounting bolt (4).
k Leave 3 threads or 4 engaged to
prevent the flywheel from suddenly
Removal
k
shooting out in the following pro-
Disconnect the negative (–) terminal of the
cedure.
battery beforehand.
5) Pull out the flywheel by prying with a bar,
etc.
1. Remove the work equipment pump assembly,
6) Checking that flywheel (3) is manually
referring to "Removal and Installation of Work
removable, remove the flywheel mounting
Equipment Pump Assembly."
bolt (4).
7) Lift flywheel (3) and remove it.
2. Removal of the flywheel
4 Flywheel: 25 kg
1) Remove coupling mounting bolt (1) and
remove coupling (2). [*1]
PC138US, USLC-8 9
SEN02710-00 50 Disassembly and assembly
[*2]
q Tighten the flywheel mounting bolts according
to the following procedure:
1) Apply engine oil EO#30 to the bolt threads.
2 Mounting bolt threads:
Engine oil (EO30)
2) Tighten the bolts in the order of 1 to 6 as
shown in the diagram (CPP14824).
3) Tighten the bolts each in two actions by
applying torque as specified in the order of
item 2) above.
3 Mounting bolt:
Unit: Nm{kgm}
procedure target range
1st time 88.2 {9.0} 58.7 – 117.7 {6.0 – 12.0}
2nd time 191.3 {19.5} 186.4 – 196.2 {19.0 – 20.0}
10 PC138US, USLC-8
50 Disassembly and assembly SEN02710-00
[*3]
q Measuring radial runout of flywheel
1) Install dial gauge [2] to the flywheel hous-
ing.
2) Set the probe of the dial gauge at right
angles to the spigot joint (a) or the outer
periphery of the flywheel.
3) Rotate the crank shaft one full turn and
measure the difference of the maximum
values of runout of the needle.
a Check that the position of needle
remains in its original position after
the flywheel is rotated one full turn.
Radial runout: Max. 0.15 mm
PC138US, USLC-8 11
SEN02710-00 50 Disassembly and assembly
Removal and installation of 4. Disconnect aftercooler hose (11) from the air
intake connector (12) side.
cylinder head assembly 1
Removal
k Disconnect the negative (–) terminal of the
battery beforehand.
12 PC138US, USLC-8
50 Disassembly and assembly SEN02710-00
PC138US, USLC-8 13
SEN02710-00 50 Disassembly and assembly
2) Remove 2 clamp mounting bolts (44) and 13. Removal of turbocharger and exhaust man-
remove clamp (45). [*10] ifold assembly
1) Remove cover (52).
14 PC138US, USLC-8
50 Disassembly and assembly SEN02710-00
4) Remove mounting bolts (56) and discon- 14. Removal of water pump
nect turbocharger lubricant inlet port tube 1) Disconnect coolant temperature sensor
(57). [*12] connector TWTR (64).
5) Remove 2 mounting bolts (58) and discon- 2) Disconnect radiator upper hose (65),
nect turbocharger lubricant return tube heater hoses (66) and (67) and radiator
(59). lower hose (68).
6) Remove 3 mounting bolts (60) and discon- 3) Remove fan belt (69).
nect connector (61) between the turbo- 4) Remove 6 fan pulley mounting bolts (70).
charger and aftercooler hose from the 5) Remove fan pulley assembly (71).
turbocharger.
7) Remove 8 exhaust manifold mounting
bolts (62). [*13]
8) Lift turbocharger and exhaust manifold
assembly (63) and remove them.
4 Turbocharger and exhaust manifold
assembly: 15 kg
PC138US, USLC-8 15
SEN02710-00 50 Disassembly and assembly
16 PC138US, USLC-8
50 Disassembly and assembly SEN02710-00
[*10]
q Install the clamp mounting bolts between the
turbocharger and muffler according to the fol-
3 Sleeve nut on the supply pump side: lowing procedure:
18 – 23 Nm {1.9 – 2.3 kgm} 3 Clamp mounting bolt:
3 Sleeve nut on the common rail side: 1st time: 39.2 – 49 Nm {4 – 5 kgm}
25.5 – 29.4 Nm { 2.6 – 3.0 kgm} 2nd time: 68.6 - 122.5 Nm {7 – 12.5 kgm}
[*11]
3 Cylinder head cover mounting nut:
7.84 – 9.8 Nm {0.8 – 1.0 kgm}
[*12]
3 Lubricant inlet port tube mounting bolt:
34.3 – 53.9 Nm {3.5 – 5.5 kgm}
[*13]
q Exhaust manifold mounting procedure:
1) Attach the guide bolt to the cylinder head
and set the gasket.
a Install the manifold with the gasket
face stamped 6205 on the side of the
manifold.
PC138US, USLC-8 17
SEN02710-00 50 Disassembly and assembly
[*14]
a One (1) of the water pump mounting bolts is
tightened together with the alternator mounting
bracket.
[*15] [*16]
a Before installing rocker arm assembly (77),
loosen lock nut (74) and fully loosen adjust-
ment screw (75).
a When installing rocker arm assembly (77), (In the diagram, (F) indicates the front of engine,
tighten the mounting bolts alternately by (R) the rear and (b) a plastic region turning angle
checking that the adjustment screw ball fits to tightening bolt.)
the push rod socket.
3 Rocker arm mounting bolt (76):
19.6– 29.4 Nm {2.0– 3.0 kgm}
q For adjustment of the valve clearance, refer to
"Adjusting valve clearance" in Testing and
adjusting.
[*17]
q Tightening procedure for the cylinder head
mounting bolt
Apply molybdenum disulphide lubricant (LM-P)
to the threads of cylinder head mounting bolt,
and tighten the bolts in the order shown in the
diagram.
3 Cylinder head mounting bolt:
1st time: 68.6 ± 9.8 Nm {7.0 ± 1.0 kgm}
2nd time: 107.8 ± 4.9 Nm {11.0 ± 0.5 kgm}
3rd time: Mark the bolt head and cylin-
der head, and turn the cylinder
head by 90° (+30/0°) to tighten.
a After tightening, stamp a punch mark (n),
indicating the number of tightening, on the
bolt head.
a If a bolt has 5 punch marks, do not reuse.
Replace it with a new one.
18 PC138US, USLC-8
50 Disassembly and assembly SEN02710-00
PC138US, USLC-8 19
SEN02710-00 50 Disassembly and assembly
Installation
q Carry out the installation in the reverse order of
removal.
[*1]
5 Coolant: 12.4 l
[*2] [*3]
3 Radiator hose clamp bolt:
(Both upper and lower hoses)
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
[*4]
a When installing the radiator assembly, align
the convex portion (a) on the bottom of the
radiator assembly with the concave portion (b)
on the machine.
20 PC138US, USLC-8
50 Disassembly and assembly SEN02710-00
Removal and installation of 4. Loosen 2 clamps (6) and disconnect the air
aftercooler upper hose (7).
aftercooler assembly 1
5. Remove 2 mounting bolts (8) and remove plate
Removal
k
(9).
Disconnect the negative (–) terminal of the
battery beforehand.
6. Remove 2 air aftercooler mounting bolts (10).
1. Remove lower cover (1).
PC138US, USLC-8 21
SEN02710-00 50 Disassembly and assembly
Installation
q Carry out the installation in the reverse order of
removal.
[*1]
a Take care not to damage sponge on the sides
when installing the aftercooler.
a When installing the radiator assembly, align
the convex portion (a) on the bottom of the air
aftercooler with the concave portion (b) on the
machine.
22 PC138US, USLC-8
50 Disassembly and assembly SEN02710-00
Removal and installation of work a When using tool D to stop oil, remove the
hydraulic oil tank strainer in advance.
equipment oil cooler assembly 1
Special tools
New/Remodel
Necessity
Sym-
Part No. Part name
bol
Q'ty
796-460-1210 Oil stopper q 1
D
795-799-1131 Adapter q 1
Removal
k Stop the machine on a level place and
4. Remove lower cover (2).
lower it to the ground. Stop the engine and
set the lock lever to locked position.
k Disconnect the negative (–) terminal of the
battery beforehand.
k Loosen the hydraulic oil tank cap gradually
to release the pressure in the tank.
2. Remove the air aftercooler assembly referring 5. Remove 2 oil cooler lower mounting bolts (3)
to "Removal and Installation of Air Aftercooler and disconnect lower hose (4).
Assembly."
PC138US, USLC-8 23
SEN02710-00 50 Disassembly and assembly
6. Remove air cleaner (5). 11. Pull out oil cooler assembly (11). [*2]
24 PC138US, USLC-8
50 Disassembly and assembly SEN02710-00
Installation
q Carry out the installation in the reverse order of
removal.
[*1]
3 Hydraulic oil drain plug (13):
58.8 – 78.4 Nm {6 – 8 kgm}
Target: 68.6 Nm {7 kgm}
5 Hydraulic tank: 69 l
(Specified capacity: 120 l)
PC138US, USLC-8 25
SEN02710-00 50 Disassembly and assembly
Removal and installation of 3. Open fuel drain valve (3) to drain fuel.
engine and work equipment pump
assembly 1
Special tools
New/Remodel
Necessity
Sym-
Part No. Part name
bol
Q'ty
796-460-1210 Oil stopper q 1
D
795-799-1131 Adapter q 1
26 PC138US, USLC-8
50 Disassembly and assembly SEN02710-00
5. Remove covers (5), (6) and (7). 8) Remove frame mounting bolts (20), (21)
and (22).
6. Open covers (8) and (9).
PC138US, USLC-8 27
SEN02710-00 50 Disassembly and assembly
28 PC138US, USLC-8
50 Disassembly and assembly SEN02710-00
13. Remove 4 bracket mounting bolts (51) and dis- 3) Disconnect 6 hoses (56) to (61).
connect engine oil filter and bracket assembly
(52).
a Tie the assembly with a string to keep it
out of the way.
PC138US, USLC-8 29
SEN02710-00 50 Disassembly and assembly
[*2]
3 Hydraulic oil drain plug (13):
58.8 – 78.4 Nm {6 – 8 kgm}
Target: 68.6 Nm {7 kgm}
5 Hydraulic tank: 69 l
(Specified capacity: 120 l)
[*3]
3 Hose clamps between the turbocharger and
air cleaner: 10.8 ± 1 Nm {1.1 ± 0.1 kgm}
[*4]
3 Aftercooler hose clamp:
10.8 ± 0.5 Nm {1.1 ± 0.05 kgm}
[*5][*6]
3 Radiator hose clamp bolt:
(Both upper and lower hoses)
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
[*7]
3 Starting motor wiring terminal (42):
17.7 – 24.5 Nm {1.8 – 2.5 kgm}
3 Starting motor wiring terminal (42a):
2.6 – 4.6 Nm {0.27 – 0.47 kgm}
3 Connector mounting bolt:
10 ± 2 Nm {1.02 ± 0.2 kgm}
[*8]
3 Engine mounting bolt:
245 – 309 Nm {25 – 31.5 kgm}
30 PC138US, USLC-8
50 Disassembly and assembly SEN02710-00
5. Disconnect water separator and bracket 2) Remove wiring and hose mounting brack-
assembly (5). ets (13).
3) Remove fuel tank front mounting brackets
6. Disconnect reservoir tank (6). (14).
PC138US, USLC-8 31
SEN02710-00 50 Disassembly and assembly
[*1]
2 Fuel tank mounting bolt:
liquid adhesive (LT–2)
3 Fuel tank mounting bolt:
235 – 285 Nm {23.5 – 29.5 kgm}
32 PC138US, USLC-8
50 Disassembly and assembly SEN02710-00
PC138US, USLC-8 33
SEN02710-00 50 Disassembly and assembly
© 2007 KOMATSU
All Rights Reserved
Printed in Japan 02-07 (02)
34 PC138US, USLC-8
SEN02711-00
HYDRAULIC EXCAVATOR
PC138US-8
PC138USLC-8
PC138US, USLC-8 1
SEN02711-00 50 Disassembly and assembly
2 PC138US, USLC-8
50 Disassembly and assembly SEN02711-00
Installation
q Carry out installation in the reverse order to
removal.
[*1]
2 Thread of travel motor mounting bolt :
Thread tightener (LT-2)
3 Sprocket mounting bolt :
323.6 – 362.8 Nm {33 – 37 kgm}
[*2]
2 Thread of travel motor and final drive
assembly mounting bolt :
Thread tightener (LT-2)
3 Travel motor and final drive assembly
mounting bolt :
235 – 285 Nm {23.5 – 29.5 kgm}
a Bleed the air from the travel motor.
For details, see Testing and adjusting,
"Bleeding air from travel motor".
PC138US, USLC-8 3
SEN02711-00 50 Disassembly and assembly
4 PC138US, USLC-8
50 Disassembly and assembly SEN02711-00
Installation
q Carry out the installation in the reverse order of
removal.
q Bleeding air
a Bleed air from the piping, referring to
"Bleeding air from each part" in Testing
and adjusting.
[*1]
3 Wing machinery mounting bolt:
277 ± 31.9 Nm {28.25 ± 3.25 kgm}
PC138US, USLC-8 5
SEN02711-00 50 Disassembly and assembly
New/Remodel
Sym-
Necessity
Part No. Part name
bol
Sketch
Q'ty
1 790-201-2750 Spacer t 1
790-101-5201 Push puller (Kit) q 1
790-101-2510 • Block 1
4) Disconnect swing motor assembly (4)
790-101-2550 • Leg 1
using forcing screw [1].
790-101-2560 • Nut 2 5) Lift and remove swing motor assembly (4).
2 790-101-2570 • Plate 4
790-101-3101 Bearing puller q 1
Puller
790-101-4200 q 1
(294 kN {30 ton})
Hydraulic oil
F 790-101-1102 q 1
pump
790-101-5401 Push tool (Kit) (C) q 1
790-101-5461 • Plate 1
3 790-101-5441 • Plate 1
790-101-5421 • Grip 1
01010-51240 • Bolt 1
4 790-201-2850 Spacer t 1 3. Carrier No. 1 and Sun gear No. 2 assembly
1) Remove sun gear No. 1 (5).
5 790-201-2750 Spacer t 1
2) Remove carrier No. 1 and sun gear No. 2
796T-426-1140 Push tool t 1 Q assembly (6).
6
790-201-2680 Plate q 1
Disassembly
1. Oil drain
Remove the drain plug and drain oil from the
swing machinery.
6 Swing machinery case: 2.5 l
6 PC138US, USLC-8
50 Disassembly and assembly SEN02711-00
4. Ring gear
Remove ring gear (17).
PC138US, USLC-8 7
SEN02711-00 50 Disassembly and assembly
8 PC138US, USLC-8
50 Disassembly and assembly SEN02711-00
2. Shaft assembly
1) Install O-ring to inside collar (33) and
install to shaft (34).
2) Use push tool F4 to press bearing (32)
with the press. 3. Oil seal
Using tool F6 to press oil seal (35).
a Replace the oil seal with a new one.
2 Circumference of oil seal: LG-6
a Be careful not to allow LG-6 to attach to
the lip and shaft.
2 Oil seal lip portion: Grease (G2-LI)
PC138US, USLC-8 9
SEN02711-00 50 Disassembly and assembly
6. Ring gear
Install O-ring (40) to the shaft and case assem-
bly, and install ring gear (17).
10 PC138US, USLC-8
50 Disassembly and assembly SEN02711-00
PC138US, USLC-8 11
SEN02711-00 50 Disassembly and assembly
12 PC138US, USLC-8
50 Disassembly and assembly SEN02711-00
PC138US, USLC-8 13
SEN02711-00 50 Disassembly and assembly
© 2007 KOMATSU
All Rights Reserved
Printed in Japan 02-07 (02)
14 PC138US, USLC-8
SEN02712-00
HYDRAULIC EXCAVATOR
PC138US-8
PC138USLC-8
PC138US, USLC-8 1
SEN02712-00 50 Disassembly and assembly
Disassembly and assembly of 3. Pull out roller (4) from shaft (5).
a It is filled with 75 – 85 cc of oil, so drain the
track roller 1 oil at this point or lay a cloth to prevent the
area from becoming dirty.
Special tools
4. Remove floating seal (6) (on opposite side)
New/Remodel
from roller (4) and shaft (5).
Necessity
Sym-
Part No. Part name
bol
Q'ty
1 790-434-1650 Installer t 1
M
2 791-601-1000 Oil pump q 1
Disassembly
1. Remove pin (1), then remove collar (2).
8 5
6
10
4
9
3
2
11
CLP00790
2 PC138US, USLC-8
50 Disassembly and assembly SEN02712-00
1
2
PC138US, USLC-8 3
SEN02712-00 50 Disassembly and assembly
10. Using tool M2, fill track roller assembly with oil,
then tighten plug (11).
5 Track roller oil: 75 – 85 cc (EO30-CD)
4 PC138US, USLC-8
50 Disassembly and assembly SEN02712-00
New/Remodel
Necessity
Sym-
Part No. Part name
bol
Q'ty
L 1 791-675-1510 Installer t 1
Disassembly
1. Remove dowel pin (1), then remove support 5. Remove dowel pin (8), then remove support
(2). (7) from shaft (5).
2. Remove floating seal (3) from support (2) and 6. Remove bushings (9) and (10) from idler (4).
idler (4).
PC138US, USLC-8 5
SEN02712-00 50 Disassembly and assembly
2. Fit O-ring and install support (7) to shaft (5) 5. Add oil between shaft (5) and idler (4).
with dowel pin (8). 5 Oil: 90 – 105 cc (EO30)
6 PC138US, USLC-8
50 Disassembly and assembly SEN02712-00
PC138US, USLC-8 7
SEN02712-00 50 Disassembly and assembly
New/Remodel
Necessity
Sym-
Part No. Part name
bol
Q'ty
791-600-2001 Compressor (A) 1
or t
791-685-8006 Compressor (B) 1
791-635-3160 Extension t 1
L 2
790-201-2770 • Spacer t 1
Cylinder
790-101-1600 t 1
(686 kN {70 ton})
790-101-1102 Pump t 1
Disassembly
8 PC138US, USLC-8
50 Disassembly and assembly SEN02712-00
PC138US, USLC-8 9
SEN02712-00 50 Disassembly and assembly
Assembly
4. Fit valve (3) and seat (2), and secure with lock
plate (1).
a Install the valve so that the direction of the
3) Assemble cylinder (9) and pilot (8) to fitting (17) is to the outside.
spring (7), and set to tool L2.
4) Apply hydraulic pressure slowly to com- 5. Fill inside of cylinder with a approximately 120
press spring, and tighten nut (6) so that cc of grease.
installed length of spring is dimension 2 Inside cylinder: Grease (G2-LI)
(a).
a Installed length (a) of spring: 390 mm
10 PC138US, USLC-8
50 Disassembly and assembly SEN02712-00
New/Remodel
4. Remove tool R, pull out temporary pin, and
Necessity
Sym-
Part No. Part name remove dust seal, then drive machine in
bol
reverse to lay out track (2). [*3]
Q'ty
791-616-1110 Frame t 1
791-616-1121 Plate t 1
791-616-1131 Plate t 1
791-616-1150 Guide t 1
791-616-1160 Adapter t 1
791T-616-1280 Adapter t 1
791-620-3530 Push t 1
791-620-3260 Push t 1
R
791-620-3270 Guide t 1
01011-62260 Bolt t 2
01643-62260 Washer t 2
01011-61455 Bolt t 3
01643-31445 Washer t 3
Cylinder
790-105-1100 t 1
(297 kN {30 ton})
790-101-1102 Pump t 1
Removal
1. Lower work equipment to ground, then loosen
lubricator (1), and relieve track tension. [*1]
k The adjustment cylinder is under
extremely high pressure. Never loosen
the lubricator more than one turn. If
the grease does not come out, move
the machine backwards and forwards.
PC138US, USLC-8 11
SEN02712-00 50 Disassembly and assembly
Installation
[*1]
a Adjust the track tension.
For details, see Testing and adjusting, "Testing
and adjusting track tension".
[*2]
a Use tool R and press fit the master pin so that
the protrusion of the master pin is dimension
(a).
Protrusion (a) of master pin: 5.5 ± 2 mm
[*3]
a When assembling the dust seal, coat the bush-
ing contact surface with grease (G2-LI).
12 PC138US, USLC-8
50 Disassembly and assembly SEN02712-00
PC138US, USLC-8 13
SEN02712-00 50 Disassembly and assembly
Removal and installation of 7. Disconnect drain hose (8) and hoses (9) and
(10) between control valve and left travel motor
revolving frame assembly 1 from center swivel joint.
Removal
k
8. Disconnect hoses (11) and (12) between con-
Disconnect the negative (–) terminal of the
trol valve and right travel motor.
battery.
9. Disconnect hoses (13) between solenoid valve
1. Remove the work equipment assembly by
(Boost) and both travel motors.
referring to "Removal of work equipment
assembly".
10. Disconnect plate (14) from revolving frame.
2. Disconnect boom cylinder hoses (1) (right) and
(2) (left).
a Be sure to apply the blind plug to the dis-
connected hose.
14 PC138US, USLC-8
50 Disassembly and assembly SEN02712-00
[*2]
2 Swing circle contacting face:
Liquefied gasket (LG-1)
2 Revolving frame mounting bolt screw:
Liquefied adhesive (LT-2)
3 Revolving frame mounting bolt:
277.5 ± 32.4 Nm {28.3 ± 3.3 kgm}
q Bleeding air
Bleed the air. For details , see Testing and
adjusting, "Bleeding air from each part".
PC138US, USLC-8 15
SEN02712-00 50 Disassembly and assembly
16 PC138US, USLC-8
50 Disassembly and assembly SEN02712-00
Installation
q Carry out installation in the reverse order to
removal.
[*1]
2 Counterweight mounting bolt:
Adhesive (LT-2)
3 Counterweight mounting bolt:
3,430 – 4,212 Nm {350 – 430 kgm}
Target: 3,626 Nm {370 kgm}
PC138US, USLC-8 17
SEN02712-00 50 Disassembly and assembly
2. Remove the 2 monitor camera mounting bolts 7. Lift off counterweight assembly (6).
to remove the monitor camerai1j. a First, move the counterweight assembly
horizontally toward the rear so that it will
3. Remove mounting bolt (2) on the top of the not interfere with the machine body, and
add-on weight. then lift it up.
4 Counterweight assembly
4. Sling add-on weight (3) and remove 2 mount- : 3,300 kg (Standard specification)
ing bolts (4) from its side. : 2,900 kg (Blade specification)
18 PC138US, USLC-8
50 Disassembly and assembly SEN02712-00
Installation
q Carry out installation in the reverse order to
removal.
[*1]
Installation procedure for add-on weight
1) Put faces (X) and (Y) to the insert boss of the
counterweight.
2) Install top bolt (2) and tighten it lightly.
2 Add-on weight mounting bolt:
Adhesive (LT-2)
3) Adjust clearance (a) to 10 ± 3 and install side
bolts (4).
2 Add-on weight mounting bolt:
Adhesive (LT-2)
3 Add-on weight mounting bolt:
1,860 – 3,040 Nm {190 – 310 kgm}
[*2]
2 Counterweight mounting bolt:
Adhesive (LT-2)
3 Counterweight mounting bolt:
3,430 – 4,212 Nm {350 – 430 kgm}
Target: 3,626 Nm {370 kgm}
PC138US, USLC-8 19
SEN02712-00 50 Disassembly and assembly
© 2007 KOMATSU
All Rights Reserved
Printed in Japan 02-07 (02)
20 PC138US, USLC-8
SEN02713-00
HYDRAULIC EXCAVATOR
PC138US-8
PC138USLC-8
PC138US, USLC-8 1
SEN02713-00 50 Disassembly and assembly
2. Remove filter and bracket assembly (3). (for 9. Disconnect hoses (for changing the speed)
attachment specification) (18) and (19) between both travel motors and
swivel joint.
2 PC138US, USLC-8
50 Disassembly and assembly SEN02713-00
Installation
q Installation is performed in the opposite way to
removal.
[*1]
2 Mounting bolt screw:
Liquefied adhesive (LT-2)
3 Mounting bolt:
98.1 – 123.0 Nm {10.0 – 12.5 kgm}
q Bleeding air
Bleed air from the swing motor. For details,
see Testing and adjusting, "Bleeding air from
each part".
PC138US, USLC-8 3
SEN02713-00 50 Disassembly and assembly
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
790-101-2501 Push puller q 1
790-101-2510 • Block 1
790-101-2520 • Screw 1
790-101-2540 • Washer 1
Assembly
T 791-112-1180 • Nut 1 1. Fit slipper seals (7) and O-rings (6) to swivel
790-101-2630 • Leg 2 rotor.
790-101-2570 • Washer 4
2. Set swivel shaft (5) to block, then fit it by using
790-101-2560 • Nut 2 push tool and hitting swivel rotor (4) lightly with
791-112-2650 • Adapter 2 plastic hammer.
2 Contact surfaces of rotor and shaft
: Grease (G2-LI)
Disassembly a When installing the rotor, take care not to
1. Remove cover (1). damage the slipper seals and O-rings.
2. Remove snap ring (2). 3. Install ring (3) and secure with snap ring (2).
3. Using tool T, pull out swivel rotor (4) and ring 4. Fit O-ring and install cover (1).
(3) from swivel shaft (5). 3 Swivel joint mounting bolt :
31.3 ± 2.9 Nm {3.2 ± 0.3 kgm}
4. Remove O-rings (6) and slipper seals (7) from
swivel shaft (5).
4 PC138US, USLC-8
50 Disassembly and assembly SEN02713-00
Removal and installation of a When using tool D to stop oil, remove the
hydraulic oil tank strainer in advance.
hydraulic tank assembly 1
Special tools
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
796-460-1210 Oil Stopper q 1
D
795-799-1131 Adapter q 1
Removal
k Park the machine on a level place and lower
2. Removal of exterior parts
the work equipment stably to the ground.
1) Removal handrail(2)
Stop the engine and set the lock lever to
2) Removal cover(3) – (6).
locked position.
k Release the remaining pressure from the
hydraulic circuit, referring to "Bleeding
residual pressure from hydraulic circuit" in
"Testing and adjusting."
k Disconnect the negative (–) terminal of the
battery beforehand.
PC138US, USLC-8 5
SEN02713-00 50 Disassembly and assembly
3) Remove engine oil filter bracket (9). 7. Removal of hydraulic oil tank mounting bracket
a Move the filter assembly close to the and mounting bolts.
engine. 1) Remove fuel tank rear mounting brackets
4) Disconnect hose (10) from radiator. (23).
5) Disconnect fuel level sensor wire (11).
5. Disconnect swing machinery oil level pipe 4) Remove 4 hydraulic oil front mounting
clamp (20). bolts (26). [*2]
6 PC138US, USLC-8
50 Disassembly and assembly SEN02713-00
[*1]
3 Drain plug (1): 58.8 – 78.4 Nm {6 – 8kgm}
Target: 68.6 Nm {7 kgm}
5 Hydraulic oil tank: 69 l
(Capacity: 120 l)
[*2]
2 Thread of hydraulic oil tank mounting bolt:
Adhesive (LT-2)
3 Hydraulic oil tank mounting bolt (27):
245 – 309 Nm {25 – 31.5 kgm}
PC138US, USLC-8 7
SEN02713-00 50 Disassembly and assembly
Removal and installation of a When using tool D to stop oil, remove the
hydraulic oil tank strainer in advance.
hydraulic pump assembly 1
Special tools
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
796-460-1210 Oil Stopper q 1
D
795-799-1131 Adapter q 1
Removal
k Park the machine on a level place and lower
2. Remove covers (2) and (3).
the work equipment stably to the ground.
Stop the engine and set the lock lever to
locked position.
k Release the remaining pressure from the
hydraulic circuit, referring to "Bleeding
residual pressure from hydraulic circuit" in
"Testing and adjusting."
k Disconnect the negative (-) terminal of the
battery beforehand.
8 PC138US, USLC-8
50 Disassembly and assembly SEN02713-00
PC138US, USLC-8 9
SEN02713-00 50 Disassembly and assembly
10. Removal procedures of work equipment 4) Install wire rope [2] to the work equipment
pump pump from outside the counterweight.
Remove work equipment pump by pulling it a Apply rubber plates or cloth [3] to the
toward the front according to the following pro- counterweight to prevent it from being
cedures. damaged by wire rope.
1) Shift the pump closer to the front end until
wire rope [2] almost makes contact with
the counterweight.
10 PC138US, USLC-8
50 Disassembly and assembly SEN02713-00
PC138US, USLC-8 11
SEN02713-00 50 Disassembly and assembly
Removal and installation of a When using tool D to stop oil, remove the
hydraulic tank strainer in advance.
control valve assembly 1
Special tools
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
796-460-1210 Oil Stopper q 1
D
795-799-1131 Adapter q 1
Removal
k Park the machine on a level place and lower
2. Removal of exterior parts
the work equipment stably to the ground.
1) Removal handrail(2)
Stop the engine and set the lock lever to
2) Removal cover (3) and (6).
locked position.
k Release the remaining pressure from the
hydraulic circuit, referring to "Bleeding
residual pressure from hydraulic circuit" in
"Testing and adjusting."
k Disconnect the negative (–) terminal of the
battery beforehand.
1. Loosen hydraulic drain plug(1) and drain the 3. Removal of solenoid valve frame
hydraulic. [*1] 1) Disconnect hoses (5) to (12).
6 Hydraulic oil tank: 69 l (Index No. , Color band , Hose Name)
(Capacity: 120 l) (5); (Red-Green) PPC basic pressure
(6); (Red) Travel HI/LO
(7); (Red-Red) Swing paring brake
(8); (–) Merge-divider valve selection
signal
(9); (–) Travel junction valve
(10); (–) P1Pilot pressure
(11); (–) Travel junction valve
(12); (–) Pilot pressure #3
12 PC138US, USLC-8
50 Disassembly and assembly SEN02713-00
PC138US, USLC-8 13
SEN02713-00 50 Disassembly and assembly
14 PC138US, USLC-8
50 Disassembly and assembly SEN02713-00
PC138US, USLC-8 15
SEN02713-00 50 Disassembly and assembly
16 PC138US, USLC-8
50 Disassembly and assembly SEN02713-00
PC138US, USLC-8 17
SEN02713-00 50 Disassembly and assembly
The appearance and section of only the 8-spool valve (blade + service valve) are shown here.
18 PC138US, USLC-8
50 Disassembly and assembly SEN02713-00
PC138US, USLC-8 19
SEN02713-00 50 Disassembly and assembly
20 PC138US, USLC-8
50 Disassembly and assembly SEN02713-00
PC138US, USLC-8 21
SEN02713-00 50 Disassembly and assembly
22 PC138US, USLC-8
50 Disassembly and assembly SEN02713-00
PC138US, USLC-8 23
SEN02713-00 50 Disassembly and assembly
24 PC138US, USLC-8
50 Disassembly and assembly SEN02713-00
PC138US, USLC-8 25
SEN02713-00 50 Disassembly and assembly
NN1. Pressure compensation valve F (Arm) NN12. Pressure compensation valve F (Service)
NN2. Suction valve (Arm) NN13. Safety-suction valve
NN3. Suction valve (Arm) NN14. Safety-suction valve
NN4. Spool (Arm) NN15. Spool (Service)
NN5. Pressure compensation valve R (Arm) NN16. Pressure compensation valve (Service)
NN6. Hydraulic drift prevention valve (Arm) NN17. Safety-suction valve
NN7. Pressure compensation valve F (Bucket) NN18. Pressure release plug
NN8. Suction valve (Bucket)
NN9. Suction valve (Bucket) F: Flow control valve
NN10. Spool (Bucket) R: Pressure reducing valve
NN11. Pressure compensation valve R (Bucket)
26 PC138US, USLC-8
50 Disassembly and assembly SEN02713-00
PC138US, USLC-8 27
SEN02713-00 50 Disassembly and assembly
Assembly
a When assembling, clean and inspect the parts
closely and take care fully so that dirt, rust,
flaw, etc. will not cause a trouble.
28 PC138US, USLC-8
50 Disassembly and assembly SEN02713-00
6. When installing joint (10) to body (1), apply 9. Installation of disc (12)
LOCTITE as shown below. 1) Install disc (12) so that each bolt (9) will be
1) When installing the joint, apply 1 drop the center of each side of disc (12) and
(approx. 0.02 g) of LOCTITE (No. 262) they will not interfere with each other dur-
each to 2 places of the female screw (A) ing compound operation. (Error: ± 3 °)
of the body. Before installing the joint, 2) When installing disc (12), adjust it so that
thoroughly degrease and dry its male the play of the lever end will be 0.5 – 3
screw and the female screw of the body mm (at 200 mm from the center of rotation
with DRYSOL. of the lever).
2) Drop LOCTITE to the following positions. 3) Fixing disc (12) with [1], tighten nut (13).
2 Female screw (A) of body: a At this time, give play to body (1) or plate
LOCTITE No. 262 (14) and lock with [2].
3 Joint (10): 39 – 49 Nm {4 – 5 kgm} 3 Nut (13):
93.1 – 112.7 Nm {9.5 – 11.5 kgm}
PC138US, USLC-8 29
SEN02713-00 50 Disassembly and assembly
30 PC138US, USLC-8
50 Disassembly and assembly SEN02713-00
Assembly
a When assembling, clean and inspect the parts
closely and take care fully so that dirt, rust,
flaw, etc. will not cause a trouble.
PC138US, USLC-8 31
SEN02713-00 50 Disassembly and assembly
New/Remodel
and assembly of offset cylinder assembly".
Necessity
Sym-
Part No. Part name
1. Piston rod assembly
Sketch
bol
1) Remove the piping from the cylinder
Q'ty
assembly.
790-502-1003 Repair stand t 1
1 2) Remove the mounting bolt to disconnect
790-101-1102 Pump t 1 head assembly (1).
790-102-4300 Wrench assembly t 1 3) Remove piston rode assembly (2).
2 a Place an oil pan or the like under the
790-201-4310 Pin t 1
cylinder to receive oil.
790-201-1702 Push tool (Kit) t 1
4) Disassemble the piston rod assembly with
790-201-1791 • Push tool 1 the following procedure.
790-101-5021 • Grip 1 1] Set piston rod assembly (2) on tool
U1.
01010-50816 • Bolt 1
790-201-1702 Push tool (Kit) t 1
790-201-1811 • Push tool 1
3
790-101-5021 • Grip 1
01010-50816 • Bolt 1
790-201-1702 Push tool (Kit) t 1
790-201-1821 • Push tool 1
790-101-5021 • Grip 1
U 01010-50816 • Bolt 1
790-201-1500 Push tool (Kit) q 1
790-201-1610 • Push tool 1
790-101-5021 • Grip 1
01010-50816 • Bolt 1
790-201-1500 Push tool (Kit) q 1
790-201-1620 • Push tool 1
4
790-101-5021 • Grip 1
01010-50816 • Bolt 1
790-201-1500 Push tool (Kit) q 1
790-201-1630 • Push tool 1
790-101-5021 • Grip 1
01010-50816 • Bolt 1
5 790-720-1000 Expander t 1
796-720-1660 Ring t 1
6
07281-01159 Clamp t 1
32 PC138US, USLC-8
50 Disassembly and assembly SEN02713-00
2] Remove piston assembly lock screw 6] Remove the head assembly (7).
(3).
Screw size
M12 x 1.75 pitch:
Boom, arm and blade
M10 x 1.5 pitch: Bucket
PC138US, USLC-8 33
SEN02713-00 50 Disassembly and assembly
34 PC138US, USLC-8
50 Disassembly and assembly SEN02713-00
PC138US, USLC-8 35
SEN02713-00 50 Disassembly and assembly
36 PC138US, USLC-8
50 Disassembly and assembly SEN02713-00
PC138US, USLC-8 37
SEN02713-00 50 Disassembly and assembly
© 2007 KOMATSU
All Rights Reserved
Printed in Japan 02-07 (02)
38 PC138US, USLC-8
SEN02714-00
PC138US-8
PC138USLC-8
PC138US, USLC-8 1
SEN02714-00 50 Disassembly and assembly
Removal and installation of work 3. Disconnect working lamp wiring connector (6)
and clamp (7).
equipment assembly 1
4. Remove guard (8).
Special tools
5. Disconnect hoses (9) (Arm cylinder bottom),
New/Remodel
(10) (Bucket cylinder bottom), (11) (Arm cylin-
Necessity
Sym-
Part No. Part name der head), and (12) (Bucket cylinder head).
bol
a Since the engine will be started, be sure to
Q'ty
plug the disconnected hoses.
792-785-1100 Remover t 1
796-270-1110 • Adapter 1
V 1 • Puller
790-101-4000 1
(490 kN {50 ton})
790-101-1102 • Pump 1
Removal
k Fully extend the work equipment and set a
block at the arm end and lower the bucket
tip to the ground.
k Disconnect the cable from the negative (–)
terminal of the battery.
6. Disconnect grease tube (13).
1. Remove handrail (1), then remove covers (2)
and (3). 7. Remove lock bolt (14). [*1]
2. Remove undercovers (4) and (5) from boom 8. Remove plate and push out pin (15) to the
mounting section. opposite side until it is removed from cylinder
head. [*2]
a Check the number and location of the
shims.
2 PC138US, USLC-8
50 Disassembly and assembly SEN02714-00
[*1]
a When tightening the locknut, tighten so that the
clearance (a) between the plate and nut is 0.5
– 1.5 mm.
[*2]
2 Inside surface of bushing when assembling
pin:
Molybdenum disulphide lubricant (LM-P)
2 Grease after assembling pin :
Grease (LM-G)
k When aligning the position of the pin hole,
never insert your fingers in the pin hole.
a Adjust the shim thickness so that clearance (b)
between cylinder rod (21) and plate (22) is less
than 1 mm.
a Standard shim thickness: 1.0 mm
PC138US, USLC-8 3
SEN02714-00 50 Disassembly and assembly
[*3]
2 Inside surface of bushing when assembling
pin :
Molybdenum disulphide lubricant (LM-P)
2 Grease after assembling pin :
Grease (LM-G)
k When aligning the position of the pin hole,
never insert your fingers in the pin hole.
a Adjust the shim thickness so that clearance (c)
between boom (23) and bracket (24) is less
than 0.5 mm.
a Standard shim thickness: 0.5, 1.0, 2.0 mm
q Bleeding air
Bleed the air.
For details, see Testing and adjusting, "Bleed-
ing air from hydraulic cylinder".
4 PC138US, USLC-8
50 Disassembly and assembly SEN02714-00
PC138US, USLC-8 5
SEN02714-00 50 Disassembly and assembly
© 2007 KOMATSU
All Rights Reserved
Printed in Japan 02-07 (02)
6 PC138US, USLC-8
SEN02715-00
PC138US-8
PC138USLC-8
PC138US, USLC-8 1
SEN02715-00 50 Disassembly and assembly
2 PC138US, USLC-8
50 Disassembly and assembly SEN02715-00
13. Removal of operator cab mounting bolts and 14. Lift and remove operator cab assembly (27).
nuts. a Before removing the operator cap assem-
1) Remove 6 mounting bolts (22b) (marked bly, make sure that all wiring and piping
with *) and 4 nuts (22n) (marked with #) are disconnected.
from inside the operator cab. 4 Operator cab assembly: 380 kg
a Nuts (22n) tightens floor frame
together.
Installation
2) Remove L.H. side cover (23). q Carry out the installation in the reverse order of
removal.
PC138US, USLC-8 3
SEN02715-00 50 Disassembly and assembly
* Amoung the panes of window glass on the 4 ( 1 ): Right side window glass
sides of the operator’s cab, 5 panes (1) – (5) ( 2 ): Left side rear window glass
are stuck. ( 3 ): Door upper window glass
In this section, the procedure for replacing the ( 4 ): Door lower window glass
stuck glass is explained. ( 5 ): Front window glass
When replacing front window glass (5), remove ( 6 ): Front window assembly
front window assembly (6). (It is impossible to (Front window glass + Front frame)
replace only the front window glass while the ( 7 ): Both-sided adhesive tape
front window assembly is installed to the oper- (16): Center trim seal
ator’s cab.)
For the procedure for replacing the front win-
dow assembly, see "Removal and installation
of front window assembly".
4 PC138US, USLC-8
50 Disassembly and assembly SEN02715-00
New/Remodel
a Widening the cut with a screwdriver, cut the
Necessity
Sym- adhesive and both-sided adhesive tape with
Part No. Part name
bol knife [4].
Q'ty
(The figure shows the operator’s cab of a wheel
1 793-498-1210 Lifter (Suction cup) t 2
X loader.)
2 20Y-54-13180 Adapter t 2
Removal
a Remove the window glass to be replaced accor-
ing to the following procedure.
PC138US, USLC-8 5
SEN02715-00 50 Disassembly and assembly
Installation
1. Using a knife and scraper [5], remove the
remaining adhesive and both-sided adhesive
tape from the metal sheets (glass sticking sur-
faces) of the operator’s cab.
a Remove the adhesive and both-sided
adhesive tape to a degree that they will
not affect adhesion of the new adhesive.
Take care not to scratch the painted sur-
fac e s. (If th e pai nt ed s urf ac es are
scratched, adhesion will be lowered.)
(The figure shows the operator’s cab of a
wheel loader.)
3. Apply primer (10).
a The using limit of primer (10) is 4 months
after the date of manufacture. Do not use
primer (10) after this limit.
a Use the primer within 2 hours after
unpacking it.
a Even if the primer is packed again just
after it is unpacked, use it within 24 hours
after it is unpacked for the first time. (Dis-
c ar d t h e p r i m e r 2 4 ho u r s a ft e r i t i s
packed.)
1) Stir the primers for paint and glass suffi-
ciently before using them.
2. Remove oil, dust, dirt, etc. from the sticking a If the primer has been stored in a
surfaces of cab (8) and window glass (9) with refrigerator, leave it at the room tem-
white gasoline. perature for at least half a dry before
a If the sticking surfaces are not cleaned stirring it. (If the primer is unpacked
well, the glass may not be stuck perfectly. just after taken out of the refrigertor,
a Clean the all back part on the back side of water will be condensed. Accord-
the window glass. ingly, leave the primer at the room
a After cleaning the sticking surfaces, leave temperature for a sufficient time.)
them for at least 5 minutes to dry. 2) When reusing primer brush (11), wash it in
white gasoline.
a After washing the brush, check it
again for dirt and foreign matter.
a Prepare respective brushes for the
paint primer glass primer.
6 PC138US, USLC-8
50 Disassembly and assembly SEN02715-00
3) Evenly apply paint primer to the surfaces a As for right side window glass (1),
to stick both-sided adhesive tapes and the apply the primer to only the periphery
surfaces out of those surfaces on opera- of the glass to stick the both-sided
tor’s cab (8) which will be coated with the adhesive tapes and the areas out of it
adhesive. to apply the adhesive.
2 Paint primer: q Part (b)
SUNSTAR PAINT PRIMER a After applying the primer, leave it for
580 SUPER or equivalant at least 5 minutes (within 8 hours) to
a Do not apply the primer more than 2 dry.
times. (If it is applied more than 2 a Never apply wring primer. If the glass
times, its performance will be low- primer is applied by mistake, wipe it
ered.) off with white gasoline.
a Parts to be coated with primer: Apply 4) Evenly apply glass primer to the sticking
the primer all over dimension (a). surfaces of window glass (9).
q Dimension to apply primer (a): 25 mm 2 Glass primer:
SUNSTAR GLASS PRIMER
580 SUPER or equivalant
a Do not apply the primer more than 2
times. (If it is applied more than 2
times, its performance will be low-
ered.)
PC138US, USLC-8 7
SEN02715-00 50 Disassembly and assembly
a Parts to be coated with primer: Apply a When sticking both-sided adhesive tape
the primer to the sticking surfaces of (7) around a frame, do not lap its finishing
window glass (9) and all over dimen- end over the starting end but make clear-
sion (d) which will be on both-sided ance e of about 5 mm between them.
adhesive tape (7) and operator’s cab 1) Stick both-sided adhesive tape (7) for right
(8). side window glass (1) as shown in the fig-
a Do not apply the primer to the ure.
boarder about 5 mm wide between
the black part and transparent part of
the glass.
a After applying the primer, leave it for
at least 5 minutues (within 8 hours) to
dry.
a Never apply wring the primer. If the
glass primer is applied by mistake,
wipe it off with white gasoline.
8 PC138US, USLC-8
50 Disassembly and assembly SEN02715-00
3) Stick both-sided adhesive tape (7) for door q Details of the sticking positions are as
upper window glass (3) and lower window follows.
glass (4) as shown in the figure. (h): Stick to inside end of right and left
(The figure shows the door upper window front frames (17).
glass.) (j) : Retract by "3.0 mm" from the end
of front frame (17).
PC138US, USLC-8 9
SEN02715-00 50 Disassembly and assembly
a When positioning front window glass 1) Break aluminum seal (13) of the outlet of
(5), set its horizontal and vertical posi- adhesive cartridge (12) and install the
tions as shown below. nozzle.
Part (m) (Right side): Project by "3.8
mm" from the
frame end.
Part (o) (Upper side): Retract by "3.0
mm" from the
frame end.
10 PC138US, USLC-8
50 Disassembly and assembly SEN02715-00
4) Remove the release tape of the both- 7. Install the window glass.
sided adhesive tape on the glass side. 1) Install window glass (9), matching it to the
5) Apply adhesive (15) to the outside of both- lines of the positioning tapes drawn in step
sided adhesive tape (7) of the operator’s 5.
cab. a Sine the window glass cannot be
removed and stuck again, stick it very
carefully.
a Stick the glass within 5 minutes after
applying the adhesive.
2) After sticking window glass (9), press all
around it until it is stuck to the both-sided
adhesive tape.
a Press the corners of the window glass
firmly.
a You can perform this work efficiently
by pulling window glass (9) from
inside of the operator’s cab with suc-
tion cup X1.
(The figure shows the operator's cab
a Apply adhesive (15) to dimensions s
of PC200-7.)
and t of both-sided adhesive tape (7)
of operator’s cab (8).
q Dimension (s): 10 mm
q Dimension (t) : 15 mm
a Apply adhesive (15) higher than both-
sided adhesive tape (7).
a Apply the adhesive evenly.
PC138US, USLC-8 11
SEN02715-00 50 Disassembly and assembly
a After installing front window glass (5), (The figure shows the operator's cab of PC200-
install the center trim seal to its bot- 7.)
tom. Then, apply caulking material all
a r ou nd t he g la s s to fi ll par t ( U)
between the glass and center trim
seal.
a When caulking, neatly arrange the
form of the adhesive at the right and
left ends with a rubber spatula.
2 Adhesive:
Sikaflex 256HV manufactured
by Sika Japan
12 PC138US, USLC-8
50 Disassembly and assembly SEN02715-00
Removal
1. Raise the front window assembly to the ceiling
and fix it with the rear locks (on both sides).
[*1]
PC138US, USLC-8 13
SEN02715-00 50 Disassembly and assembly
New/Remodel
Necessity
Sym-
Part No. Part name
bol
Q'ty
799-703-1200 Service tool (Kit) t 1
Vacuum pump
799-703-1100 t 1
(100V)
Vacuum pump
X 3 799-703-1111 t 1
(220V)
2. Open the coolant drain valve (2) and drain
Vacuum pump
799-703-1121 t 1 coolant.
(240V)
6 Coolant: 12.4 l
799-703-1401 Gas leak detector t 1
Removal
k Park the machine on a level place and lower
the work equipment stably to the ground.
Stop the engine and set the lock lever to
locked position.
k Release the remaining pressure from the
hydraulic circuit, referring to "Bleeding
residual pressure from hydraulic circuit" in
Testing and adjusting.
k Disconnect the negative (–) terminal of the
battery beforehand.
3. Removal of exterior parts
a Fasten tags to respective connecters and pip- 1) Remove handrail (2).
ing for identification to prevent any mistakes 2) Remove covers (3) and (4).
when re-installing.
14 PC138US, USLC-8
50 Disassembly and assembly SEN02715-00
3) Remove covers (111), (112) and (113). 2) Disconnect wiring connectors (8) to (16)
around the solenoid valves connected to
wring (7).
(8) : V01 (PPC basic pressure)
(9) : V02 (Travel HI/LO)
(10): V03 (Swing paring brake)
(11) : V04 (Travel junction valve)
(12): V05 (Merge-divider valve selection
signal)
(13): P25 (Pump pressure sensor)
(14): P26 (Travel right rear pressure sen-
sor)
(15): P27 (Travel left rear pressure sensor)
(16): P29 (Dummy)
3) Remove wiring mounting clamp and dis-
4. Disconnecting wiring and hoses around the
connect wiring (7) from solenoid valve
solenoid valve
mounting frame assembly (17).
1) Disconnect bucket damp solenoid wiring
4) Disconnect PPC basic pressure hose (18)
connector V10 (5) and travel alarm M14
(color band: Red-Green).
(6).
PC138US, USLC-8 15
SEN02715-00 50 Disassembly and assembly
5. Disconnecting pressure switch and pressure 6. Disconnection of control valve assembly wiring
sensor connector wiring and hoses
1) Disconnect wiring connectors (20) to (29) (R.H. side of control valve-inspection cover
connected to wiring (19). side-)
(20): P01 (Bucket dump switch) 1) Disconnect hose (31) to the attachment.
(21): P02 (Arm dump switch) (Machine with the attachment)
(22): P03 (Boom raise switch) (Band color: Blue-Blue)
(23): P04 (Bucket digging switch) 2) Disconnect wiring connectors (32) to (34).
(24): P05 (Boom digging switch) (32): P64 (Bucket digging switch)
(25): P06 (Boom lower switch) (33): P65 (Arm digging switch)
(26): P07 (Right swing switch) (34): P66 (Boom lower switch)
(27): P08 (Left swing switch)
(Multi-valve-installed machine)
(28): P67 (Right swing switch)
(Multi-valve-installed machine)
a Connector P67 is connected to con-
nector P07.
a For a machine without the multi-
valve, connector P08 is positioned
under P07 of the pressure switch con-
nector mounting bracket.
(29): P12 (Pressure sensor)
16 PC138US, USLC-8
50 Disassembly and assembly SEN02715-00
(Operator cab side) 7. Disconnect 8 hoses (47) to (54) from the oper-
5) Disconnect wiring connectors (39) to (41). ation pattern select valve assembly. (Machine
(39): P61 (Bucket dump switch) with the select valve)
(40): P62 (Arm dump switch) (From the upper side of operator cab)
(41): P63 (Boom raise switch) (47): Brown (Swing right)
6) Disconnect hose (42) to the attachment. (48): Green (Arm digging)
(Machine with the attachment) (49): White (Swing left)
(Color band: Red-Red) (50): Orange (Arm dump)
(From the upper side of the hydraulic tank)
(51): Yellow (Boom raise)
(52): Black (Boom lower)
(53): Red (Bucket dump)
(54): Blue (Bucket digging)
a For a machine without the operation pat-
tern select valve, disconnect 8 hoses
installed in the following order from the top
to the solenoid valve installation frame as
s hown i n Procedure 4- 4 (Photo No.
CPP15287).
Red (Bucket dump)
Orange (Arm dump)
Yellow (Boom raise)
7) Disconnect travel switch connectors (38) Blue (Bucket digging)
and (39). Green (Arm digging)
(43): (Black-Yellow) Black (Boom lower)
(44): (Brown-Yellow) White (Swing left)
8) Disconnect travel motor hoses (40) and Brown (Swing right)
(41).
(Color band)
(45): (Black-Yellow)
(46): (Brown-Yellow)
PC138US, USLC-8 17
SEN02715-00 50 Disassembly and assembly
8. Disconnect PPC drain hose (55). 12. Disconnect buzzer wiring connector (60).
18 PC138US, USLC-8
50 Disassembly and assembly SEN02715-00
PC138US, USLC-8 19
SEN02715-00 50 Disassembly and assembly
[*1]
a Care must be exercised in the installation so
that dusts, dirt or water may not enter the hose
of the air conditioner circuit.
a Make sure that O-ring is installed to the pipe
joint section of the air conditioner hoses before
installing
a Check the O-ring for scratches or degradation.
a When installing O-ring, apply the compressor
oil (Denso: ND-OIL8 or ZEXEL: ZXL100PG
(PAG46 or equivalent)).
16. Lift and remove floor frame assembly (82). 3 Mounting bolt:
a Before lifting the floor frame assembly, 8 – 12 Nm {0.8 – 1.2 kgm}
check that every wiring connector and
clamp is disconnected. q Filling of air conditioner gas
a Pull out the control valve wiring while lift- Using tool X3, fill the air conditioner circuit with
ing floor frame assembly (82) little by little. the air conditioner gas (R134a).
a When pulling out the wiring on the control a Filling capacity: 800 (+50/0) g
valve side, it may catch obstacles on the
way to resist smooth removal. Do not pull
by force. Manage to evade obstacles
patiently.
4 Floor frame assembly:
Approx. 210 kg
20 PC138US, USLC-8
50 Disassembly and assembly SEN02715-00
PC138US, USLC-8 21
SEN02715-00 50 Disassembly and assembly
© 2007 KOMATSU
All Rights Reserved
Printed in Japan 02-07 (02)
22 PC138US, USLC-8
SEN02716-00
PC138US-8
PC138USLC-8
PC138US, USLC-8 1
SEN02716-00 50 Disassembly and assembly
New/Remodel
q Precautions when installing piping
a Care must be exercised in the installation so
Necessity
Sym-
Part No. Part name
bol that dusts, dirt or water may not enter the hose
of the air conditioner circuit.
Q'ty
a When jointing the air conditioner piping, apply
799-703-1200 Service tool (Kit) t 1
compressor oil (Denso ND-01L8 equivalent) to
Vacuum pump the threaded portions.
799-703-1100 t 1
(100V) 3 Mounting bolt:
Vacuum pump 8 – 12 Nm {0.8 – 1.2 kgm}
X 3 799-703-1111 t 1
(220V)
Vacuum pump q Filling of air conditioner gas
799-703-1121 t 1 Using tool X3, fill the air conditioner circuit with
(240V)
799-703-1401 Gas leak detector t 1 the air conditioner gas (R134a).
[*2]
Removal 3 Air compressor mounting bolt:
k Stop the machine on a level place and 24.5 – 29 Nm {2.5 – 3.0 kgm}
lower the work equipment to the ground.
Stop the engine and set the lock lever to
locked position.
k Disconnect the negative (–) terminal of the
battery beforehand.
k Bleed the air conditioner gas using the spe-
cial tool.
2 PC138US, USLC-8
50 Disassembly and assembly SEN02716-00
New/Remodel
Necessity
Sym-
Part No. Part name
bol
Q'ty
799-703-1200 Service tool (Kit) t 1
Vacuum pump
799-703-1100 t 1
(100V)
Vacuum pump
X 3 799-703-1111 t 1
(220V)
Vacuum pump
799-703-1121 t 1
(240V)
799-703-1401 Gas leak detector t 1
Removal
k Lower the work equipment to the ground
completely.
k Remove the negative (–) terminal from the
battery.
Installation
q Carry out installation in reverse oder to
remaval.
PC138US, USLC-8 3
SEN02716-00 50 Disassembly and assembly
Removal and installation of air 2. Disconnect wiring connector (2) of the air con-
ditioner high and low pressure switch.
compressor unit assembly 1
Special tools 3. Disconnect air conditioner hoses (3) and (4).
New/Remodel
4. Disconnect heater hoses (5) and (6).
Necessity
Sym-
Part No. Part name
bol
Q'ty
799-703-1200 Service tool (Kit) t 1
Vacuum pump
799-703-1100 t 1
(100V)
Vacuum pump
X 3 799-703-1111 t 1
(220V)
Vacuum pump
799-703-1121 t 1
(240V)
799-703-1401 Gas leak detector t 1
4 PC138US, USLC-8
50 Disassembly and assembly SEN02716-00
10. Remove cover (16). 15. Remove 3 cover mounting bolts (24) on the left
and right.
11. Remove duct (17).
PC138US, USLC-8 5
SEN02716-00 50 Disassembly and assembly
Installation
q Carry out the installation in the reverse order of
removal.
[*1]
q Precautions when installing piping
a Care must be exercised in the installation so
that dusts, dirt or water may not enter the hose
of the air conditioner circuit.
6 PC138US, USLC-8
50 Disassembly and assembly SEN02716-00
PC138US, USLC-8 7
SEN02716-00 50 Disassembly and assembly
Installation
q Carry out the installation in the reverse order of
removal.
8 PC138US, USLC-8
50 Disassembly and assembly SEN02716-00
PC138US, USLC-8 9
SEN02716-00 50 Disassembly and assembly
Installation
q Carry out the installation in the reverse order of
removal.
10 PC138US, USLC-8
50 Disassembly and assembly SEN02716-00
PC138US, USLC-8 11
SEN02716-00 50 Disassembly and assembly
© 2007 KOMATSU
All Rights Reserved
Printed in Japan 02-07 (02)
12 PC138US, USLC-8
SEN01980-00
PC138US-8
PC138USLC-8
PC138US, USLC-8 1
Hydraulic circuit diagram Hydraulic circuit diagram
PC138US-8
PC138US-8
SEN01980-00
PC138US, USLC-8 3
Hydraulic circuit diagram Hydraulic circuit diagram
PC138US-8
PC138US-8 (Blade specification and machine ready for attachment)
(Blade specification and machine ready for attachment)
SEN01980-00
PC138US, USLC-8 5
Hydraulic circuit diagram Hydraulic circuit diagram
PC138USLC-8 (KA specification)
PC138USLC-8 (KA specification) (Blade specification and machine ready for attachment)
(Blade specification and machine ready for attachment)
SEN01980-00
PC138US, USLC-8 7
Hydraulic circuit diagram Hydraulic circuit diagram
PC138US-8 (KUK specification)
PC138US-8 (KUK specification) (Blade specification and machine ready for attachment)
(Blade specification and machine ready for attachment)
SEN01980-00
PC138US, USLC-8 9
SEN01980-00 90 Diagrams and drawings
© 2007 KOMATSU
All Rights Reserved
Printed in Japan 01-07 (02)
12 PC138US, USLC-8
SEN01981-01
PC138US-8
PC138USLC-8
PC138US, USLC-8 1
SEN01981-01 90 Diagrams and drawings
2 PC138US, USLC-8
Electrical circuit diagram PC138US, USLC-8 Electrical circuit diagram
PC138US, USLC-8
SEN01981-01
PC138US, USLC-8 3
Connectors table and arrangement drawing PC138US, USLC-8 Connectors table and arrangement drawing
PC138US, USLC-8
Type of Type of
Connector No. Model connector Component name Address Connector No. Model connector Component name Address
A08 DT-T 6 Intermediate connector F-9 P32 YAZAKI 2 Air conditioner daylight sensor H-1
A13 DT-T 2 Intermediate connector F-9 P44 DT-T 2 Engine oil level sensor H-9
AB Terminal 1 Alternator (Terminal B) H-9 P61 X 2 Pressure switch(Buket dump) -
AC01 YAZAKI 10 Air conditioner unit AB-4 P62 X 2 - -
AC02 X 1 Air conditioner compressor electromagnetic clutch J-9 P63 X 2 - -
ACC Terminal 1 Starter switch - P64 X 2 - -
AR SUMITOMO 3 Alternator H-9 P65 X 2 - -
B Terminal 1 Starter switch - P66 X 2 - -
BNC - 1 Orbcomm - P67 X 2 - -
BR Terminal 1 Starter switch - PAMB AMP 3 Ambient pressure sensor AF-5
BR Terminal 1 Battery relay L-7 PFUEL BOSCH 3 Common rall pressure sensor AG-5
C Terminal 1 Starter switch - POIL FRAMA TOME 1 Engine oil pressure switch (Low pressure) AD-6
C01 AMP 81 CH700 controller Z-4 PREG BOSCH 2 Supply pump solenoid (IMV) AD-7
C02 AMP 39 CH700 controller Z-5 PTIM BOSCH 4 Boost pressur/temp. AD-8
CAN FRAMA TOME 3 Engine Bkup speed sensor AF-1 R1 Terminal 1 Starter switch -
CE01 DRC 60 Engine controller AE-9 R05 RELAY 5 Relay for light X-9
CE02 DRC 60 Engine controller K-9 R06 RELAY 5 Relay for Starter cut(Ppc lock) Z-5
CE03 DTP 4 Engine controller L-8 R07 RELAY 5 Relay for Starter cut(Personal cood) Z-4
CK01 AMP 14 KOMTRAX communication module AB-7 R10 RELAY 5 Relay for OPT. light Y-8
CK02 AMP 10 KOMTRAX communication module AA-7 R14 Terminal 1 Ribon heater relay M-5
CM01 070 18 Machine monitor O-6 R15 Terminal 1 Ribon heater relay N-5
CM02 070 12 Machine monitor O-6 R16 Terminal 1 Ribon heater relay N-5
CM03 070 18 Machine monitor O-5 R17 X 2 - H-1
CM05 B60 8 Machine monitor - R18 Terminal 1 - J-1
CN1 DT 2 Injector #1 AF-9 R19 Terminal 1 - J-1
CN2 DT 2 Injector #2 AF-9 R20 RELAY 4 Blower relay AB-4
CN3 DT 2 Injector #3 AG-9 R21 RELAY 4 Compressor relay AB-5
CN4 DT 2 Injector #4 AG-9 R23 RELAY 5 Relay for CM2100(1) AB-4
D01 SWP 8 Battery relay AA-7 R24 RELAY 5 Relay for CM2100(2) AB-4
D02 SWP 8 Ribbon heater relay/washer motor Z-6 RB Terminal 1 Battery relay L-7
D03 SWP 8 Monitor light switch Z-6 RE Terminal 1 Battery relay L-6
D10 - 2 Diode AB-7 RM Terminal 1 Battery relay L-7
D11 - 2 Diode AB-7 S02 SWP 6 Light switch R-8
E01 Terminal 1 Ribbon heater I-9 S04 SWP 6 Swing lock switch R-8
E10 Terminal 1 Starting motor I-9 S07 SWP 6 Beacon S-8
F01 - 20 Fuse X-9 S10 Y090 2 Right knob switch Q-7
F02 L 2 Fuse(45A) L-6 S14 M 3 PPC hydraulic lock switch W-9
F03 L 2 Fuse(450A) L-6 S21 - 5 Emergency pump drive switch Y-8
F04 Terminal 1 Fuse L-4 S22 - 5 Emergency swing parking brake release Y-8
F05 Terminal 1 Fuse(50A) K-1 S25 090 16 Intermediate connector AA-7
F06 Terminal 1 Fuse(120A) L-4 T01 Terminal 1 Floor frame W-1
GT5 - 1 Antenna F-1 T02 Terminal 1 Cab GND L-5
H08 M 4 Intermediate connector Y-5 T03 Terminal 1 GND X-2
H09 M 8 Intermediate connector Y-5 T04 Terminal 1 Floor frame G-1
H15 S090 22 Intermediate connector T-9 T05 Terminal 1 Revolving frame G-1
H16 S 12 Intermediate connector Y-3 T06 Terminal 1 GND AF-5
J01 SUMITOMO 20 Junction connector (Pink) T-9 T07 Terminal 1 GND AE-5
J02 SUMITOMO 20 Junction connector (Pink) U-9 T08 Terminal 1 Revolving frame I-1
J03 SUMITOMO 20 Junction connector (Pink) U-9 T09 Terminal 1 Revolving frame I-1
J04 SUMITOMO 20 Junction connector (Black) U-9 T10 Terminal 1 Revolving frame I-1
J05 SUMITOMO 20 Junction connector (Green) V-9 T11 Terminal 1 Revolving frame H-1
J06 SUMITOMO 20 Junction connector (Black) V-9 T12 Terminal 1 Revolving frame H-1
J07 SUMITOMO 20 Junction connector (Pink) V-9 T14 Terminal 1 Revolving frame V-1
K01 M 2 Pump resistor Z-7 TNC - 1 FOMA L-5
K02 DT-T 3 CAN terminal resistance K-9 TWTR PACKARD 2 Engine water temperature sensor AE-9
L01 - 2 Working lamp (Boom) B-9 V01 DT-T 2 PPC lock solenoid valve C-9
L03 M 2 Cab light I-9 V02 DT-T 2 Travel speed shifting solenoid valve C-9
M01 PA 9 Radio X-2 V03 DT-T 2 Swing holding brake solenoid valve C-9
M02 M 2 Speaker(left) J-9 V04 DT-T 2 Travel junction solenoid valve B-8
M03 M 2 Speaker(right) I-9 V05 DT-T 2 Confluece solenoid valve A-8
M04 - 2 Cigar lighter O-6 V10 DT-T 2 Bucket dump lock solenoid valve E-9
M05 M 6 Wiper motor "E-1,O-5" V11 DT-T 2 PC-EPC valve G-9
M06 KES 2 Window washer motor K-1 V30 DT-T 2 Att current Q-1
M07 090 2 Horn (High tone) E-1 W03 M 2 Limit switch J-9
M09 M 2 Optional power supply connector (1) S-9 - TAJIMI 8 Rear view camera -
M10 M 2 Optional power supply connector (2) W-2
M11 M 4 DC/DC converter -
M12 M 2 12V outlet -
M13 M 2 Optional power supply connector (12 V) -
M14 DT-T 2 Travel alarm D-9
M40 X 2 Head light(STD) G-9
M41 X 2 Head light(OPT) E-9
N08 DT-T 12 Service coneeector X-9
N10 SUMITOMO 4 Air conditioner unit AB-3
NE FRAMA TOME 3 NE sensor AF-1
P01 X 2 Pressure switch(Buket dump) A-6
P02 X 2 Pressure switch(Arm dump) A-5
P03 X 2 Pressure switch(Boom UP) A-5
P04 X 2 Pressure switch(Buket digging) A-5
P05 X 2 Pressure switch(Arm digging) A-5
P06 X 2 Pressure switch(Boom down) A-5
P07 X 2 Pressure switch(Left swing) A-4
P08 X 2 Pressure switch(Right swing) A-4
P09 AMP 3 - C-1
P10 AMP 3 - D-1
P11 AMP 3 - D-1
P12 DT-T 6 Intermediate connector B-1
P13 X 2 Intermediate connector R-1
P14 X 2 Pressure switch(Service) Q-1
P15 X 2 Pressure switch(Service) Q-1
P17 S 090 2 A/C HI/LO pressure switch T-1
P20 M 3 Fuel dial Q-9
P21 X 1 Fuel level sensor F-9
P22 DT-T 2 Hydraulic oil temperature sensor G-9
P25 AMP 3 Pump pressure sensor A-6
P26 AMP 3 - A-6
P27 AMP 3 - A-6
P28 AMP 3 - A-1
P29 DT-T 6 Intermediate connector A-7
P31 YAZAKI 2 Sunshine sensor O-6
SEN01981-01
PC138US, USLC-8 5
90 Diagrams and drawings SEN01981-01
PC138US, USLC-8 7
SEN01981-01 90 Diagrams and drawings
© 2007 KOMATSU
All Rights Reserved
Printed in Japan 02-07 (02)
8 PC138US, USLC-8