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Komatsu Hydraulic Excavator Pc138 Us 8 Shop Manual
Komatsu Hydraulic Excavator Pc138 Us 8 Shop Manual
HYDRAULIC PC138US -8
EXCAVATOR
PC138USLC -8
PC138US- 20001
SERIAL NUMBERS and up
PC138USLC- 20001
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SEN01977-12
PC138US-8
PC138USLC-8
PC138US, USLC-8 1
SEN01977-12 00 Index and foreword
Shop Manual, contents binder, binder label and tabs ............................................................ SEN01968-12
01 Specification.................................................................................................................... SEN01970-02
Specification and technical data...................................................................................... SEN01979-02
2 PC138US, USLC-8
00 Index and foreword SEN01977-12
PC138US, USLC-8 3
SEN01977-12 00 Index and foreword
Table of contents 1
00 Index and foreword
Index SEN01977-12
Composition of shop manual....................................................................................................... 2
Table of contents ......................................................................................................................... 4
01 Specification
Specification and technical data SEN01979-02
Specification dimension drawing ................................................................................................. 2
Working range diagram ............................................................................................................... 3
Specifications .............................................................................................................................. 4
Weight table ................................................................................................................................ 10
Table of fuel, coolant and lubricants ............................................................................................ 14
4 PC138US, USLC-8
00 Index and foreword SEN01977-12
PC138US, USLC-8 5
SEN01977-12 00 Index and foreword
40 Troubleshooting
Failure code table and fuse locations SEN02461-03
Failure code table........................................................................................................................ 2
Fuse locations ............................................................................................................................. 6
General information on troubleshooting SEN02462-01
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
Connection table for connector pin numbers............................................................................... 11
T- branch box and T- branch adapter table ................................................................................. 47
Troubleshooting by failure code, Part 1 SEN02463-02
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 ........................................................................................ 31
Failure code [CA238] Ne speed sensor sup. volt. error .............................................................. 32
Failure code [CA271] IMV/PCV1 short error ............................................................................... 34
Failure code [CA272] IMV/PCV1 open error ............................................................................... 35
Failure code [CA322] Injector #1 (L #1) system open/short error ............................................... 36
Failure code [CA324] Injector #3 (L/B #3) system open/short error ............................................ 38
Failure code [CA331] Injector #2 (L/B #2) system open/short error ............................................ 40
Failure code [CA332] Injector #4 (L/B #4) system open/short error ............................................ 42
6 PC138US, USLC-8
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PC138US, USLC-8 11
SEN01977-12 00 Index and foreword
© 2012 KOMATSU
All Rights Reserved
Printed in Japan 10-12
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
Komatsu Hydraulic Excavator Pc138 Us 8 Shop Manual
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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
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