Komatsu Excavator PC138US-10 service & repair manual

Description Komatsu Excavator PC138US-10 service & repair manual

Komatsu Hydraulic Excavator PC138US-10 pdf workshop service repair manual

Serial number F40003 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
Foreword, safety and general information
Important safety notice
Fire prevention
Dispose of waste materials
How to read the shop manual
Explanation of terms for maintenance standard
Handling equipment of fuel system devices
Handling of intake system parts
Handling of hydraulic equipment
Method of disconnecting and connecting of push-pull type coupler
Handling of electrical equipment
How to read electric wire code
Precautions when performing operation
Practical use of KOMTRAX
Standard tightening torque table
List of abbreviation
Conversion table

Specification
Specification drawing
Working range drawings
Weight table
Table of fuel, coolant, and lubricants

Structure and function
Engine and cooling system
Engine related parts
PTO
VFT
EGR system piping drawing
EGR system circuit diagram
EGR valve
EGR cooler
KCCV layout drawing
KCCV ventilator
CDR valve
KDOC muffler
Cooling system
Power train
Power train system
Swing circle
Swing machinery
Undercarriage and frame
Track frame
Idler cushion
Hydraulic system
Hydraulic component layout
Valve control
Hydraulic tank
CLSS
Main pump
Control valve
Swing motor
Travel motor
Work equipment and swing PPC valve
Travel PPC valve
Blade PPC valve
2-piece boom PPC valve
1st-line attachment PPC valve (with EPC valve)
Solenoid valve
Attachment circuit selector valve (for low pressure circuit)
Quick coupler control valve
Center swivel joint
PPC circuit accumulator
Attachment circuit accumulator (for low pressure circuit)
Work equipment
Work equipment
Work equipment shim
Bucket play adjustment shim
Cab and its attachments
Cab mount and cab tipping stopper
ROPS cab
Take wiring harness out of cab
Electrical system
Electrical control system
Engine control function
Engine and pump combined control function
Autodeceleration function
Engine automatic warmup function
Overheat prevention function
Turbocharger protection function
Travel control function
PPC lock function
System operating lamp function
Battery disconnect switch function
Oil flow adjuster function for attachment
Machine monitor system
Display
KOMTRAX system
Sensor

Standard value tables
Standard value table for engine
Standard value table for machine
Machine posture and procedure for measuring performance
Standard value table for electrical system

Testing and adjusting
General information on testing and adjusting
Tools for testing and adjusting
Sketch of tools for testing and adjusting
Engine and cooling system
Testing engine speed
Testing exhaust gas color
Testing and adjusting valve clearance
Testing compression pressure
Testing blowby pressure
Testing engine oil pressure
Testing fuel pressure
Testing fuel return rate and leakage
Bleeding air from fuel system
Testing fuel circuit for leakage
Handling cylinder cutout mode operation
Handling noinjection cranking operation
Checking and adjusting air conditionercompressor belt tension
Replacing fan belt
Writing compensation values at replacement of injector and engine controller
Power train
Testing swing circle bearing clearance
Undercarriage and frame
Testing and adjusting track shoe tension
Hydraulic system
Releasing remaining pressure from hydraulic circuit
Testing and adjusting oil pressure in work equipment, swing, and travel circuits
Testing oil pressure of control circuit
Testing and adjusting oil pressure in pump PC control circuit
Testing and adjusting oil pressure in pump LS control circuit
Testing oil pressure with sensor adapter (special tool
Testing outlet pressure of solenoid valve
Testing PPC valve output pressure
Adjusting play of work equipment and swing PPC valves
Isolating the parts causing hydraulic drift in work equipment
Testing and adjusting travel deviation
Testing oil leakage
Bleeding air from hydraulic circuit
Cab and its attachments
Checking cab tipping stopper
Testing, cleaning and lubricating slide door rail and roller
Electrical system
Special functions of machine monitor
Ordinary functions and special functions of machine monitor
Adjusting rearview camera angle
Handling voltage circuit of engine controller
Handling battery disconnect switch
Testing diodes
Pm clinic
Pm Clinic service

Troubleshooting
General information on troubleshooting
Troubleshooting points
Sequence of events in troubleshooting
Inspection procedure before troubleshooting
Testing in accordance with testing procedure
Preparation for troubleshooting of electrical system
Classification and procedure for troubleshooting
Symptom and troubleshooting numbers
Information in troubleshooting table
Troubleshooting method for open circuit in wiring harness of pressure sensor system
Connector list and layout
Connector contact identification
Tbranch box and T-branch adapter table
Fuse location table
Failure codes table
Troubleshooting by failure code (Display of code)
Troubleshooting of electrical system (E-mode)
Troubleshooting of hydraulic and mechanical system (H-mode)
Troubleshooting of engine (S-mode)

Disassembly and assembly
General information on disassembly and assembly
How to read this manual
Coating materials list
Special tools list
Sketches of special tools
Engine and cooling system
Removal and installation of supply pump assembly
Removal and installation of injector assembly
Removal and installation of cylinder head assembly
Removal and installation of radiator assembly
Removal and installation of hydraulic oil cooler assembly
Removal and installation of aftercooler assembly
Removal and installation of engine and main pump assembly
Removal and installation of engine front oil seal
Removal and installation of engine rear oil seal
Removal and installation of fuel cooler assembly
Removal and installation of fuel tank assembly
Removal and installation of KDOC assembly
Removal and installation of KCCV assembly
Removal and installation of air cleaner assembly
Removal and installation of fan belt
Power train system
Removal and installation of travel motor and final drive assembly
Disassembly and assembly of travel motor and final drive assembly
Removal and installation of swing motor and swing machinery assembly
Disassembly and assembly of swing machinery assembly
Removal and installation of swing circle assembly
Undercarriage and frame
Separation and connection of track
Removal and installation of sprocket
Removal and installation of idler and idler cushion assembly
Disassembly and assembly of idler assembly
Disassembly and assembly of idler cushion assembly
Disassembly and assembly of track roller assembly
Removal and installation of revolving frame assembly
Removal and installation of counterweight assembly [For machines with additional counterweight]
Hydraulic system
Removal and installation of center swivel joint assembly
Disassembly and assembly of center swivel joint assembly
Removal and installation of hydraulic tank assembly
Removal and installation of main pump assembly
Removal and installation of control valve assembly
Disassembly and assembly of control valve assembly
Disassembly and assembly of work equipment PPC valve assembly
Disassembly and assembly of travel PPC valve assembly
Work equipment
Removal and installation of work equipment assembly (with standard boom)
Removal and installation of work equipment assembly (with 2-piece boom)
Removal and installation of 1st boom assembly
Removal and installation of 2nd boom
Removal and installation of arm
Removal and installation of boom cylinders (with 2-piece boom)
Removal and installation of 2-piece boom cylinder
Disassembly and assembly of work equipment cylinder assembly
Cab and its attachments
Removal and installation of operator's cab assembly
Removal and installation of operator's cab door
Removal and installation of operator's cab glass (adhered glass)
Removal and installation of front window assembly
Removal and installation of floor frame assembly
Removal and installation of air conditioner unit assembly
Removal and installation of air conditioner compressor assembly
Removal and installation of air conditioner condenser assembly
Removal and installation of operator's seat
Removal and installation of seat belt
Removal and installation of front wiper assembly
Electrical system
Removal and installation of engine controller assembly
Removal and installation of pump controller assembly
Removal and installation of machine monitor assembly
Removal and installation of mass air flow and temperature sensor
Removal and installation of KOMTRAX terminal assembly

Maintenance standard
Engine and cooling system
Engine mount
PTO
Cooling system
Power train
Swing circle
Swing machinery
Sprocket
Undercarriage and frame
Track frame
Idler cushion
Idler
Track roller
Carrier roller
Track shoe
Triple grouser shoe
Road liner
Hydraulic system
Hydraulic tank
Main pump
Control valve
Swing motor
Travel motor
Work equipment and swing PPC valve
Travel PPC valve
Blade PPC valve
2-piece boom PPC valve
1st-line attachment PPC valve (with EPC valve)
EPC valve
Solenoid valve
Attachment circuit selector valve (for low pressure circuit)
Center swivel joint
Cab and its attachments
Cab mount and cab tipping stopper
Work equipment
Work equipment (standard boom specification)
Work equipment (2-piece boom specification)
Dimensions of arm
Dimensions of bucket
Boom cylinder (for standard boom)
Arm cylinder (for standard boom)
Bucket cylinder
Blade cylinder
Boom cylinder (for 2-piece boom)
Arm cylinder (for 2-piece boom)
2-piece boom cylinder
80 Appendix
Air conditioner components
Precautions for refrigerant
Air conditioner component
Configuration and function of refrigeration cycle
Outline of refrigeration cycle
Air conditioner unit
Dual pressure switch
Air conditioner controller
Compressor
Air conditioner condenser
Sunlight sensor
Outer temperature sensor (outside air temperature sensor)
Circuit diagram and arrangement of connector pins
System diagram
Input and output signals of the air conditioner controller
Air conditioner unit
Parts and connectors layout
Testing air leakage (duct)
Testing with selfdiagnosis function
Testing vent (mode) changeover
Testing FRESH/RECIRC air changeover
Testing sunlight sensor
Testing (dual) pressure switch for refrigerant
Testing relays
Troubleshooting chart
Information in troubleshooting table
Failure code list related to air conditioner
Failure code [879AKA] A/C Inner Sensor Open Circuit
Failure code [879AKB] A/C Inner Sensor Short Circuit
Failure code [879BKA] A/C Outer Sensor Open Circuit
Failure code [879BKB] A/C Outer Sensor Short Circuit
Failure code [879CKA] Ventilating Sensor Open Circuit
Failure code [879CKB] Ventilating Sensor Short Circuit
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit
Failure code [879EMC] Ventilation Damper Abnormality
Failure code [879FMC] Air Mix Damper Abnormality
Failure code [879GKX] Refrigerant Abnormality
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 with gauge pressure
Connection of service tool
Precautions for disconnecting and connecting refrigerant piping
Handling of compressor oil
Desiccant replacement

Diagrams and drawings
Hydraulic circuit diagram
Symbols in hydraulic circuit diagram
Electric circuit diagram

Engine SAA4D95LE-6 workshop service manual