Komatsu Excavator PC138E-11 service & repair manual

Description Komatsu Excavator PC138E-11 service & repair manual

Komatsu Hydraulic Excavator PC138E-11 pdf workshop service & repair manual

Serial numbers:
1 and up

Technical documentation, specifications, troubleshooting, maintenance, electrical diagrams, hydraulic schematics, adjusting, assembly, disassembly, removal, installation instructions and other information

SERVICE MANUAL CONTENT:
Index and Foreword
Abbreviation List
Foreword, Safety, Basic Information
How to Read the Shop Manual
Safety Notice for Operation
Precautions for BatteryPowered Hydraulic Excavator
Precautions to Prevent Fire
Precautions When You Discard Waste Materials
Precautions When You Handle Hydraulic Equipment
Precautions When You Disconnect and Connect Pipings
Precautions When You Handle Electrical Equipment
Precautions for Maintenance of Power Electronics Components
Precautions Against High Voltage and High Temperature
Procedure for Inspection and Maintenance of Power Electronics Components
Precautions for Normal Inspection and Maintenance
Precautions When Machine Falls over and Power Electronics Components Have Damage
Precautions for Machine Not to be Put in Water
Practical Use of KOMTRAX
Disconnect and Connect Push-Pull Type Coupler
Precautions for Disconnection and Connection of Connectors
How to Disconnect and Connect Deutsch Connector
How to Disconnect and Connect Slide Lock Type Connector
How to Disconnect and Connect Connector with Lock to Pull
How to Disconnect and Connect Connector with Lock to Push
How to Disconnect and Connect Connector with Housing to Rotate
How to Disconnect and Connect High Voltage Wiring Connector of Power Electronics Components
How to Read the Codes for Electric Cable
Explanation of Terms for Maintenance Standard
Standard Tightening Torque Table
Conversion Table

Specifications
Specification Drawing
Working Range Drawings
Weight Table
Coolant, Lubricant

Structure and Function
Boot-up System
Layout Drawing of Boot-up System
System Operating Lamp System
Auxiliary Battery Disconnect Switch
Function of Electric Motor Shutdown Secondary Switch
Electric Drive System
Layout Drawing of Electric Drive System
System Diagram of Electric Drive System
Structure of Electric Drive System
Worker Protection System When You Disassemble Power Electronics Components
High Voltage Wiring (Power Cable)
Component Parts of Electric Drive System
Electric Motor System
Layout Drawing of Electric Motor System
Electric Motor Control System
Auto-Deceleration System
Overheat Prevention System
Component Parts of Electric Motor System
Cooling System
Layout Drawing of Cooling System
Fan Speed Control System of Electric Fan
Component Parts of Cooling System
Control System
Layout Drawing of Control System
Machine Monitor System
KomVision System
KOMTRAX System
Component Parts of Control System
Hydraulic System
Layout Drawing of Hydraulic System
CLSS
Electric Motor and Pump Combined Control System
Component Parts of Hydraulic System
Work Equipment System
Layout Drawing of Work Equipment System
Structure of Valve Control
PPC Lock System
Work Equipment and Travel Automatic Lock System
Attachment Oil Flow Adjuster System
Component Parts of Work Equipment System
Swing System
Layout Drawing of Swing System
Swing Control System Diagram
Component Parts of Swing System
Travel System
Layout Drawing of Travel System
System Diagram of Travel Control System
Component Parts of Travel System
Undercarriage and Frame
Layout Drawing of Undercarriage
Idler Cushion
Work Equipment
Structure of Work Equipment
Function of Work Equipment
Work Equipment Clearance Adjustment Shim
Bucket Clearance Adjustment Shim
CAB Related Parts
ROPS CAB
CAB Mount
Remove Wiring Harness Out of Cab

Standard Value Table
Standard Value Table for Electric Motor
Standard Value Table for Electric Motor: PC138E-11
Standard Value Table for Machine
Standard Value Table for Machine: PC138E-11
Machine Posture and Procedures to Measure Performance

Testing and Adjusting
Precautions Before Work
Related Information on Testing and Adjusting
Differences In Machine Monitor Symbols
Tools for Testing and Adjusting
Sketch of Tools for Testing and Adjusting
Motor and Cooling System
Examine Electric Motor Speed
Examine and Adjust Air Conditioner Compressor Belt Tension
Electric Drive System
Precautions for Electric Drive System
Replace Desiccant for Main Battery
Bleed Air from Coolant Circuit of Main Battery
Examine Water Level of Hot Water Heater and Add Water
Bleed Air from Water Circuit of Hot Water Heater
Power Train
Examine Swing Circle Bearing Clearance
Undercarriage and Frame
Examine and Adjust Track Tension
Hydraulic System
Release Remained Pressure in Hydraulic Circuit
Examine and Adjust Oil Pressure in Work Equipment, Swing, Travel, and Blade Circuits
Examine Oil Pressure of Control Circuit
Examine and Adjust Oil Pressure in Pump PC Control Circuit
Examine and Adjust Oil Pressure in Pump LS Control Circuit
Examine Outlet Pressure of Solenoid Valve
Examine PPC Valve Outlet Pressure
Examine Attachment Circuit Oil Pressure
Adjust Play of Work Equipment and Swing PPC Valves
Examine and Adjust Travel Deviation
Examine Parts Which Cause Hydraulic Drift of Work Equipment
Examine Oil Leakage
Bleed Air from Hydraulic System
Examine and Charge Accumulator (Made by Eagle Industry Co, Ltd) Nitrogen Gas Pressure for Attachment
CAB Related Parts
Examine CAB Tipping Stopper
Adjust Mirrors
How to Examine and Adjust Slide Door
Electrical System
Set and Operate Machine Monitor
How to Start Up KOMTRAX System
How to Stop Use of KOMTRAX System
Adjust KomVision Camera Angle
Adjust KomVision Related Function
Set Region of Bluetooth® Compatible Radio
Handle Voltage Circuit of Power Management Controller
Handle Auxiliary Battery Disconnect Switch
Handle MSD of High Voltage Junction Box
Handle MSD of Main Battery
Examine Diodes
Pm Clinic
Pm Clinic Service

Troubleshooting
Precautions Before Work
Related Information to Troubleshooting
General Troubleshooting Points
Sequence of Events in Troubleshooting
Checks Before Troubleshooting
Inspection Procedure Before Troubleshooting
Test in Accordance with Testing Procedure
Preparation for Troubleshooting of Electrical System
Procedure for Troubleshooting
Symptom and Troubleshooting Numbers
Information Shown in Troubleshooting Table
Connector List and Layout
Connector Contact Connection Table
T-Branch Box and T-Branch Adapter Table
Fuse Location Table
Failure Code Table
Troubleshooting by Failure Code (Display of Code)
Troubleshooting of Electrical System (E-Mode)
Troubleshooting for Hydraulic and Mechanical Systems (H-Mode)

Disassembly and Assembly
Precautions Before Work
Related Information on Disassembly and Assembly
How to Read This Manual
Coating Materials List
Special Tool List
Sketches of Special Tools
Prepare
Drain and Add Coolant
Drain and Add Hydraulic Oil
Collect and Refill Refrigerant
Electric Motor and Cooling System
Remove and Install Air Conditioner Compressor Belt
Remove and Install Hydraulic Oil Cooler Assembly
Remove and Install Hood Assembly
Remove and Install Air Conditioner Compressor Assembly
Remove and Install Air Conditioner Condenser Assembly
Remove and Install Electric Fan Assembly
Remove and Install BTMS
Power Train
Remove and Install Travel Motor and Final Drive Assembly
Disassemble and Assemble Travel Motor and Final Drive Assembly
Remove and Install Swing Motor and Swing Machinery Assembly
Disassemble and Assemble Swing Machinery Assembly
Remove and Install Swing Circle Assembly
Undercarriage and Frame
Separate and Connect Track Assembly
Remove and Install Sprocket
Remove and Install Idler and Idler Cushion Assembly
Disassemble and Assemble Idler Assembly
Disassemble and Assemble Idler Cushion Assembly
Disassemble and Assemble Track Roller Assembly
Remove and Install Revolving Frame Assembly
Remove and Install Counterweight Assembly
Hydraulic System
Remove and Install Center Swivel Joint Assembly
Disassemble and Assemble Center Swivel Joint Assembly
Remove and Install Hydraulic Tank Assembly
Remove and Install Main Pump Assembly
Remove and Install Control Valve Assembly
Disassemble and Assemble Control Valve Assembly
Disassemble and Assemble Work Equipment PPC Valve Assembly
Disassemble and Assemble Travel PPC Valve Assembly
Work Equipment
Remove and Install Blade Assembly
Remove and Install Work Equipment Assembly
Remove and Install Boom Anti-Drop Valve Assembly
Remove and Install Arm Anti-Drop Valve Assembly
Disassemble and Assemble Anti-Drop Valve Assembly
Disassemble and Assemble Work Equipment Cylinder Assembly
CAB Related Parts
Remove and Install Operator Cab Assembly
Remove and Install Operator Cab Door
Remove and Install Operator Cab Glass (Adhered Glass)
Remove and Install Front Window Assembly
Remove and Install Floor Frame Assembly
Remove and Install Air Conditioner Unit Assembly
Remove and Install Operator Seat
Remove and Install Seat Belt
Remove and Install Work Equipment Control Lever Assembly
Remove and Install Front Wiper Assembly
Remove and Install Lower Wiper Assembly
Remove and Install Hot Water Heater Assembly
Electrical System
Remove and Install Pump Controller Assembly
Remove and Install KomVision Controller Assembly
Remove and Install Machine Monitor Assembly
Remove and Install KomVision Camera
Remove and Install Gateway Function Controller Assembly
Remove and Install Communication Terminal Wiring Harness
Remove and Install Communication Terminal
Remove and Install Power Management Controller Assembly
Remove and Install Electric Motor Assembly
Remove and Install Main Battery MSD
Remove and Install Main Battery
Remove and Install Desiccant for Main Battery
Remove and Install Inverter
Remove and Install HVJB
Remove and Install Power Distribution Unit
Remove and Install DC-DC Converter
Remove and Install Charging Port
Remove and Install Telemetry
Remove and Install Main Battery Integration Controller

Maintenance Standard
Explanation of Terms for Maintenance Standard
Electric Motor and Cooling System
Maintenance Standard for Electric Motor
Maintenance Standard for Electric Motor Terminal
Maintenance Standard for Inverter Mount
Maintenance Standard for Cooling System
Maintenance Standard for Main Battery
Maintenance Standard for BTMS
Maintenance Standard for Coupling
Electric Devices
Maintenance Standard for HVJB Mount
Maintenance Standard for DC-DC Converter Mount
Maintenance Standard for Power Distribution Unit Mount
Maintenance Standard for Charging Port Mount
Maintenance Standard for Heater
Power Train
Maintenance Standard for Swing Circle
Maintenance Standard for Swing Machinery
Maintenance Standard for Sprocket
Undercarriage and Frame
Maintenance Standard for Track Frame and Idler Cushion
Maintenance Standard for Idler
Maintenance Standard for Track Roller
Maintenance Standard for Carrier Roller
Maintenance Standard for Track Shoes
Maintenance Standard for Triple Shoes
Maintenance Standard for Road Liner
Hydraulic System
Maintenance Standard for Hydraulic Tank
Maintenance Standard for Main Pump
Maintenance Standard for PCEPC Valve
Maintenance Standard for Swing Motor
Maintenance Standard for Travel Motor
Maintenance Standard for Control Valve
Maintenance Standard for Boom AntiDrop Valve
Maintenance Standard for Arm AntiDrop Valve
Maintenance Standard for Work Equipment and Swing PPC Valve
Maintenance Standard for Blade PPC Valve
Maintenance Standard for Travel PPC Valve
Maintenance Standard for 1st-Line Attachment PPC Valve (with EPC Valve)
Maintenance Standard for Solenoid Valve
Maintenance Standard for Variable Back Pressure Solenoid Valve
Maintenance Standard for Attachment Circuit Selector Valve (For Low Pressure)
Maintenance Standard for Attachment Circuit Accumulator (For Low Pressure Circuit)
Maintenance Standard for Arm OUT Quick Return Valve
Maintenance Standard for Center Swivel Joint
Work Equipment
Maintenance Standard for Work Equipment Linkage
Maintenance Standard for Boom Cylinder
Maintenance Standard for Arm Cylinder
Maintenance Standard for Bucket Cylinder
Maintenance Standard for Blade Cylinder
CAB Related Parts
Maintenance Standard for CAB Mount

Appendix
Precautions Before Work
Air Conditioner System
Precautions for Refrigerant
Air Conditioner Component
Specifications of Air Conditioner
Structure and Function of Refrigeration Cycle
Outline of Refrigeration Cycle
Component Parts of Air Conditioner System
Component Parts of Air Conditioner Unit
Air Conditioner Controller
Compressor
Condenser
Air Conditioner Related Sensors
Explanation of Procedure for Test of and Troubleshooting of Air Conditioner
Circuit Diagram and Configuration of Connector Pins of Air Conditioner
System Diagram of Air Conditioner
Input and Output Signals of Air Conditioner Controller
Locations of Air Conditioner Parts and Layout of Connectors
Examine Air Leakage (Duct)
How to Examine Air Leakage (Duct)
Examine Air Conditioner with SelfDiagnosis Function
Open the Electrical System Abnormality Record Screen in Service Mode of Machine Monitor
Examine Vent (Mode) Changeover
How to Examine Vent (Mode) Changeover
Examine Fresh/Recirc Air Changeover
How to Examine Fresh/Recirc Air Changeover
Examine Sunlight Sensor
How to Examine Sunlight Sensor
Examine Refrigerant (Dual) Pressure Switch
How to Examine Refrigerant (Dual) Pressure Switch
Examine Relay
How to Examine Relay
Air Conditioner Troubleshooting Chart
Information Shown in Troubleshooting Table
A-1 Troubleshooting for Power Supply System (Air Conditioner Does Not Operate)
A-2 Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled)
A-3 Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal)
A-4 Troubleshooting for Fresh/Recirc Air Changeover
Troubleshooting by Gauge Pressure
Connect Service Tool
How to Connect Service Tool
Precautions for Disconnection and Connection of Air Conditioner Piping
Handle Compressor Oil
How to Replace Desiccant

Circuit Diagrams
How to Read the Codes for Electric Cable
Hydraulic Circuit Diagram
Symbols Used in Hydraulic Circuit Diagram
Hydraulic Circuit Diagram
Hydraulic Circuit Diagram (at Boom RAISE Operation)
Hydraulic Circuit Diagram (at Left Swing Operation)
Hydraulic Circuit Diagram (at Boom RAISE and Left Swing Operation)
Electrical Circuit Diagram
Symbols Used in Electric Circuit Diagram