Вы находитесь на странице: 1из 1388

SEN06062-01

HYDRAULIC PC138USLC -10


EXCAVATOR
SERIAL NUMBERS 40001 and up
SHOP MANUAL

HYDRAULIC EXCAVATOR
PC138USLC-10
Model Serial Number

PC138USLC- 40001 and up


10

00 Index and foreword


1 00 Index and foreword

PC138USLC-10 00-1
00 Index and foreword
Index

Index (ALL-0310-001-A-00-A)
00 Index and foreword ....................................................................................................................... 00-1
Index ......................................................................................................................................... 00-2
Foreword, safety and general information ................................................................................... 00-13
Important safety notice ....................................................................................................... 00-13
How to read the shop manual.............................................................................................. 00-20
Explanation of terms for maintenance standard .................................................................... 00-22
Handling equipment of fuel system devices .......................................................................... 00-24
Handling of intake system parts........................................................................................... 00-25
Handling of hydraulic equipment.......................................................................................... 00-26
Method of disconnecting and connecting of push-pull type coupler ......................................... 00-28
Handling of electrical equipment.......................................................................................... 00-31
How to read electric wire code............................................................................................. 00-39
Precautions when performing operation ............................................................................... 00-42
Practical use of KOMTRAX ................................................................................................. 00-47
Standard tightening torque table.......................................................................................... 00-48
List of abbreviation ............................................................................................................. 00-54
Conversion table ................................................................................................................ 00-59
01 Specification................................................................................................................................. 01-1
Table of contents ........................................................................................................................ 01-2
Specifications............................................................................................................................. 01-3
Specification drawing ........................................................................................................... 01-3
Working range drawings ....................................................................................................... 01-4
Specifications ...................................................................................................................... 01-5
Weight table ........................................................................................................................ 01-9
Table of fuel, coolant, and lubricants .................................................................................... 01-11
10 Structure and function ................................................................................................................... 10-1
Table of contents ........................................................................................................................ 10-2
Engine and cooling system .......................................................................................................... 10-3
Engine related parts ............................................................................................................. 10-3
PTO.................................................................................................................................... 10-5
VFT .................................................................................................................................... 10-6
EGR system piping drawing ................................................................................................ 10-10
EGR system circuit diagram ................................................................................................ 10-12
EGR valve......................................................................................................................... 10-13
EGR cooler........................................................................................................................ 10-15
KCCV layout drawing ......................................................................................................... 10-17
KCCV ventilator ................................................................................................................. 10-19
KDOC muffler .................................................................................................................... 10-21
Cooling system .................................................................................................................. 10-23
Power train............................................................................................................................... 10-25
Power train system............................................................................................................. 10-25
Swing circle ....................................................................................................................... 10-27
Swing machinery ............................................................................................................... 10-28
Undercarriage and frame........................................................................................................... 10-30
Track frame ....................................................................................................................... 10-30
Idler cushion ...................................................................................................................... 10-31
Hydraulic system ...................................................................................................................... 10-32
Hydraulic component layout ................................................................................................ 10-32
Valve control...................................................................................................................... 10-34
Hydraulic tank.................................................................................................................... 10-35
CLSS ................................................................................................................................ 10-37
Main pump ........................................................................................................................ 10-41
Control valve ..................................................................................................................... 10-68
Swing motor .................................................................................................................... 10-113
Travel motor .................................................................................................................... 10-125
Work equipment and swing PPC valve............................................................................... 10-136
Travel PPC valve ............................................................................................................. 10-143
Blade PPC valve .............................................................................................................. 10-149

00-2 PC138USLC-10
00 Index and foreword
Index

1st-line attachment PPC valve (with EPC valve) ................................................................. 10-151


Solenoid valve ................................................................................................................. 10-159
Attachment circuit selector valve (for low pressure circuit).................................................... 10-165
Attachment circuit selector valve (for high pressure circuit) .................................................. 10-168
Multi-control valve ............................................................................................................ 10-170
Center swivel joint ............................................................................................................ 10-171
PPC circuit accumulator ................................................................................................... 10-173
Attachment circuit accumulator (for low pressure circuit)...................................................... 10-174
Attachment circuit accumulator (for high pressure circuit) .................................................... 10-175
Work equipment ..................................................................................................................... 10-176
Work equipment............................................................................................................... 10-176
Work equipment shim....................................................................................................... 10-177
Bucket play adjustment shim............................................................................................. 10-178
Cab and its attachments .......................................................................................................... 10-179
Cab mount and cab tipping stopper ................................................................................... 10-179
ROPS cab ....................................................................................................................... 10-180
Electrical system .................................................................................................................... 10-182
Electrical control system ................................................................................................... 10-182
Machine monitor system ................................................................................................... 10-214
KOMTRAX system ........................................................................................................... 10-235
Sensor ............................................................................................................................ 10-252
20 Standard value tables.................................................................................................................... 20-1
Table of contents ........................................................................................................................ 20-2
Standard service value table........................................................................................................ 20-3
Standard value table for engine ............................................................................................. 20-3
Standard value table for machine .......................................................................................... 20-4
Standard value table for electrical system............................................................................. 20-17
30 Testing and adjusting .................................................................................................................... 30-1
Table of contents ........................................................................................................................ 30-2
General information on testing and adjusting................................................................................. 30-3
Tools for testing and adjusting ............................................................................................... 30-3
Sketch of tools for testing and adjusting ................................................................................. 30-6
Engine and cooling system .......................................................................................................... 30-8
Testing engine speed ........................................................................................................... 30-8
Testing exhaust gas color ..................................................................................................... 30-9
Testing and adjusting valve clearance .................................................................................. 30-10
Testing compression pressure............................................................................................. 30-12
Testing blowby pressure ..................................................................................................... 30-15
Testing engine oil pressure ................................................................................................. 30-16
Testing fuel pressure .......................................................................................................... 30-17
Testing fuel return rate and leakage ..................................................................................... 30-18
Bleeding air from fuel system .............................................................................................. 30-21
Testing fuel circuit for leakage ............................................................................................. 30-23
Handling cylinder cutout mode operation.............................................................................. 30-24
Handling no-injection cranking operation.............................................................................. 30-25
Checking and adjusting air conditioner compressor belt tension ............................................. 30-26
Replacing fan belt .............................................................................................................. 30-27
Writing compensation values at replacement of injector and engine controller ......................... 30-28
Power train............................................................................................................................... 30-32
Testing swing circle bearing clearance ................................................................................. 30-32
Undercarriage and frame........................................................................................................... 30-33
Testing and adjusting track shoe tension .............................................................................. 30-33
Hydraulic system ...................................................................................................................... 30-34
Releasing remaining pressure from hydraulic circuit .............................................................. 30-34
Testing and adjusting oil pressure in work equipment, swing, and travel circuits....................... 30-35
Testing oil pressure of control circuit .................................................................................... 30-38
Testing and adjusting oil pressure in pump PC control circuit.................................................. 30-39
Testing and adjusting oil pressure in pump LS control circuit .................................................. 30-42
Testing outlet pressure of solenoid valve .............................................................................. 30-47

PC138USLC-10 00-3
00 Index and foreword
Index

Testing PPC valve output pressure ...................................................................................... 30-48


Adjusting play of work equipment and swing PPC valves....................................................... 30-50
Isolating the parts causing hydraulic drift in work equipment................................................... 30-51
Testing and adjusting travel deviation................................................................................... 30-52
Testing oil leakage ............................................................................................................. 30-54
Bleeding air from hydraulic circuit ........................................................................................ 30-56
Cab and its attachments ............................................................................................................ 30-59
Checking cab tipping stopper .............................................................................................. 30-59
Testing, cleaning and lubricating slide door rail and roller ....................................................... 30-60
Adjusting mirrors ................................................................................................................ 30-61
Electrical system ...................................................................................................................... 30-63
Special functions of machine monitor ................................................................................... 30-63
Adjusting rearview camera angle ....................................................................................... 30-115
Handling voltage circuit of engine controller........................................................................ 30-117
Handling battery disconnect switch .................................................................................... 30-118
Testing diodes ................................................................................................................. 30-119
Pm clinic ................................................................................................................................ 30-120
Pm Clinic service ............................................................................................................. 30-120
40 Troubleshooting............................................................................................................................ 40-1
Table of contents ........................................................................................................................ 40-2
General information on troubleshooting ........................................................................................ 40-7
Troubleshooting points ......................................................................................................... 40-7
Sequence of events in troubleshooting................................................................................... 40-9
Checks before troubleshooting ............................................................................................ 40-11
Inspection procedure before troubleshooting ........................................................................ 40-13
Preparation for troubleshooting of electrical system............................................................... 40-30
Classification and procedure for troubleshooting ................................................................... 40-34
Symptom and troubleshooting numbers ............................................................................... 40-37
Information in troubleshooting table ..................................................................................... 40-40
Troubleshooting method for open circuit in wiring harness of pressure sensor system .............. 40-42
Connector list and layout .................................................................................................... 40-44
Connector contact identification........................................................................................... 40-54
T-branch box and T-branch adapter table ............................................................................. 40-92
Fuse location table ............................................................................................................. 40-97
Failure codes table............................................................................................................. 40-99
Troubleshooting by failure code (Display of code) ...................................................................... 40-105
Failure code [879AKA] A/C Inner Sensor Open Circuit ........................................................ 40-105
Failure code [879AKB] A/C Inner Sensor Short Circuit......................................................... 40-106
Failure code [879BKA] A/C Outer Sensor Open Circuit........................................................ 40-107
Failure code [879BKB] A/C Outer Sensor Short Circuit ........................................................ 40-108
Failure code [879CKA] Ventilating Sensor Open Circuit ....................................................... 40-109
Failure code [879CKB] Ventilating Sensor Short Circuit ....................................................... 40-110
Failure code [879DKZ] Sunlight Sensor Open Or Short Circuit ..............................................40-111
Failure code [879EMC] Ventilation Damper Abnormality ...................................................... 40-112
Failure code [879FMC] Air Mix Damper Abnormality ........................................................... 40-113
Failure code [879GKX] Refrigerant Abnormality .................................................................. 40-114
Failure code [989L00] Engine Controller Lock Caution 1...................................................... 40-115
Failure code [989M00] Engine Controller Lock Caution 2..................................................... 40-116
Failure code [989N00] Engine Controller Lock Caution 3 ..................................................... 40-117
Failure code [AB00KE] Charge Voltage Low....................................................................... 40-118
Failure code [B@BAZG] Eng Oil Press Low ....................................................................... 40-120
Failure code [B@BAZK] Eng Oil Level Low ........................................................................ 40-121
Failure code [B@BCNS] Eng Water Overheat .................................................................... 40-122
Failure code [CA115] Eng Ne and Bkup Speed Sens Error .................................................. 40-123
Failure code [CA122] Chg Air Press Sensor High Error ....................................................... 40-124
Failure code [CA123] Chg Air Press Sensor Low Error ........................................................ 40-126
Failure code [CA131] Throttle Sensor High Error................................................................. 40-128
Failure code [CA132] Throttle Sensor Low Error ................................................................. 40-130
Failure code [CA144] Coolant Temp Sens High Error .......................................................... 40-132

00-4 PC138USLC-10
00 Index and foreword
Index

Failure code [CA145] Coolant Temp Sens Low Error ........................................................... 40-134
Failure code [CA153] Chg Air Temp Sensor High Error ........................................................ 40-136
Failure code [CA154] Chg Air Temp Sensor Low Error......................................................... 40-138
Failure code [CA187] Sensor 2 Supply Volt Low Error ......................................................... 40-140
Failure code [CA221] Ambient Press Sensor High Error ...................................................... 40-142
Failure code [CA222] Ambient Press Sensor Low Error ....................................................... 40-144
Failure code [CA227] Sensor 2 Supply Volt High Error......................................................... 40-146
Failure code [CA234] Eng Overspeed ................................................................................ 40-147
Failure code [CA238] Ne Speed Sensor Supply Volt Error ................................................... 40-148
Failure code [CA239] Ne Speed Sens Supply Volt High Error............................................... 40-149
Failure code [CA271] IMV/PCV1 Short Error ...................................................................... 40-150
Failure code [CA272] IMV/PCV1 Open Error ...................................................................... 40-151
Failure code [CA322] Inj #1(L#1) Open/Short Error ............................................................. 40-152
Failure code [CA324] Inj #3(L#3) Open/Short Error ............................................................. 40-154
Failure code [CA331] Inj #2(L#2) Open/Short Error ............................................................. 40-156
Failure code [CA332] Inj #4(L#4) Open/Short Error ............................................................. 40-158
Failure code [CA343] ECM Critical Internal Failure.............................................................. 40-160
Failure code [CA351] Injectors Drive Circuit Error ............................................................... 40-161
Failure code [CA352] Sensor 1 Supply Volt Low Error ......................................................... 40-162
Failure code [CA356] Mass Air Flow Sensor High Error ....................................................... 40-164
Failure code [CA357] Mass Air Flow Sensor Low Error ........................................................ 40-166
Failure code [CA386] Sensor 1 Supply Volt High Error......................................................... 40-168
Failure code [CA435] Eng Oil Press Sw Error ..................................................................... 40-169
Failure code [CA441] Battery Voltage Low Error ................................................................. 40-170
Failure code [CA442] Battery Voltage High Error................................................................. 40-172
Failure code [CA449] Rail Press Very High Error................................................................. 40-173
Failure code [CA451] Rail Press Sensor High Error............................................................. 40-174
Failure code [CA452] Rail Press Sensor Low Error ............................................................. 40-176
Failure code [CA466] KVGT Motor Driver Position Error ...................................................... 40-178
Failure code [CA515] Rail Press Sens Sup Volt High Error .................................................. 40-180
Failure code [CA516] Rail Press Sens Sup Volt Low Error ................................................... 40-182
Failure code [CA553] Rail Press High Error ........................................................................ 40-184
Failure code [CA555] Crankcase Press High Error 1 ........................................................... 40-185
Failure code [CA556] Crankcase Press High Error 2 ........................................................... 40-186
Failure code [CA559] Rail Press Low Error......................................................................... 40-187
Failure code [CA689] Eng Ne Speed Sensor Error .............................................................. 40-190
Failure code [CA691] Intake Air Temp Sens High Error ........................................................ 40-192
Failure code [CA692] Intake Air Temp Sens Low Error......................................................... 40-194
Failure code [CA697] ECM Internal Temp Sensor High Error................................................ 40-196
Failure code [CA698] ECM Int Temp Sensor Low Error........................................................ 40-197
Failure code [CA731] Eng Bkup Speed Sens Phase Error ................................................... 40-198
Failure code [CA778] Eng Bkup Speed Sensor Error........................................................... 40-201
Failure code [CA1117] Persistent Data Lost Error................................................................ 40-205
Failure code [CA1695] Sensor 5 Supply Volt High Error....................................................... 40-206
Failure code [CA1696] Sensor 5 Supply Volt Low Error ....................................................... 40-207
Failure code [CA1843] Crankcase Press Sens High Error.................................................... 40-208
Failure code [CA1844] Crankcase Press Sens Low Error .................................................... 40-210
Failure code [CA1896] EGR Valve Stuck Error.................................................................... 40-212
Failure code [CA1942] Crankcase Press Sens In Range Error ............................................. 40-213
Failure code [CA1961] EGR_Motor Driver IC Over Temp Error............................................. 40-214
Failure code [CA2185] Throt Sensor Sup Volt High Error ..................................................... 40-215
Failure code [CA2186] Throt Sensor Sup Volt Low Error...................................................... 40-217
Failure code [CA2249] Rail Press Very Low Error ............................................................... 40-219
Failure code [CA2272] EGR Valve Pos Sens Low Error ....................................................... 40-220
Failure code [CA2311] IMV Solenoid Error ......................................................................... 40-222
Failure code [CA2349] EGR Valve Solenoid Open Error ...................................................... 40-223
Failure code [CA2353] EGR Valve Solenoid Short Error ...................................................... 40-225
Failure code [CA2357] EGR Valve Servo Error ................................................................... 40-227
Failure code [CA2765] Inj Trim Data Error .......................................................................... 40-228

PC138USLC-10 00-5
00 Index and foreword
Index

Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error ........................................ 40-229
Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error ......................................... 40-231
Failure code [CA3724] EGR/KVGT Motor Driver Power Low Error........................................ 40-233
Failure code [CA3918] KVGT Stuck Error........................................................................... 40-235
Failure code [CA3919] KVGT Motor Driver IC Over Temp Error ............................................ 40-236
Failure code [CA3921] KVGT Servo Error 2........................................................................ 40-237
Failure code [CA3922] KVGT Motor Driver Open Error ........................................................ 40-238
Failure code [CA3923] KVGT Motor Driver Short Error ........................................................ 40-240
Failure code [D110KB] Battery Relay Drive Short Circuit...................................................... 40-242
Failure code [D19JKZ] Personal Code Relay Abnormality.................................................... 40-244
Failure code [D811MC] KOMTRAX Error............................................................................ 40-247
Failure code [D862KA] GPS Antenna Open Circuit ............................................................. 40-248
Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX) ...................................... 40-249
Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX) ...................................... 40-251
Failure code [D8AQKR] CAN2 Discon (KOMTRAX) ............................................................ 40-252
Failure code [DA20MC] Pump Controller Malfunction .......................................................... 40-254
Failure code [DA22KK] Pump Solenoid Power Low Error..................................................... 40-255
Failure code [DA25KP] 5V Sensor 1 Power Abnormality...................................................... 40-257
Failure code [DA29KQ] Model Selection Abnormality .......................................................... 40-259
Failure code [DA2LKA] Operating Lamp Open Circuit (Pump Con) ....................................... 40-261
Failure code [DA2LKB] Operating Lamp Short Circuit (Pump Con) ....................................... 40-263
Failure code [DA2QKR] CAN2 Discon (Pump Con) ............................................................. 40-264
Failure code [DA2RKR] CAN1 Discon (Pump Con) ............................................................. 40-266
Failure code [DAF0MB] Monitor ROM Abnormality.............................................................. 40-267
Failure code [DAF0MC] Monitor Error ................................................................................ 40-268
Failure code [DAF8KB] Camera Power Supply Short Circuit ................................................ 40-269
Failure code [DAF9KQ] Model Selection Abnormality .......................................................... 40-271
Failure code [DAFGMC] GPS Module Error........................................................................ 40-272
Failure code [DAFLKA] Operating Lamp Open Circuit (Monitor) ........................................... 40-273
Failure code [DAFLKB] Operating Lamp Short Circuit (Monitor)............................................ 40-275
Failure code [DAFQKR] CAN2 Discon (Monitor) ................................................................. 40-276
Failure code [DAZ9KQ] A/C Model Selection Abnormality.................................................... 40-277
Failure code [DAZQKR] CAN2 Discon (Aircon ECU) ........................................................... 40-278
Failure code [DB2QKR] CAN2 Discon (Engine Con) ........................................................... 40-282
Failure code [DB2RKR] CAN1 Discon (Engine Con) ........................................................... 40-286
Failure code [DGH2KB] Hyd Oil Sensor Short Circuit .......................................................... 40-290
Failure code [DHPAMA] Pump Press Sensor Abnormality ................................................... 40-292
Failure code [DHSFMA] Travel Fwd LH PPC Press Sensor Abnormality ............................... 40-294
Failure code [DHSGMA] Travel Fwd RH PPC Press Sensor Abnormality .............................. 40-296
Failure code [DHSHMA] Travel Rev LH PPC Press Sensor Abnormality ............................... 40-298
Failure code [DHSJMA] Travel Rev RH PPC Press Sensor Abnormality ............................... 40-300
Failure code [DHSKMA] Blade Raise PPC Press Sensor Abnormality .................................. 40-302
Failure code [DHSLMA] Blade Lower PPC Press Sensor Abnormality .................................. 40-304
Failure code [DHX1MA] Overload Sensor Abnormality ........................................................ 40-306
Failure code [DR21KX] Camera 2 Picture Rev. Drive Abnormality ........................................ 40-307
Failure code [DR31KX] Camera 3 Picture Rev. Drive Abnormality ........................................ 40-309
Failure code [DV20KB] Travel Alarm Short Circuit............................................................... 40-310
Failure code [DW43KA] Travel Speed Sol Open Circuit ....................................................... 40-312
Failure code [DW43KB] Travel Speed Sol Short Circuit ....................................................... 40-314
Failure code [DW45KA] Swing Brake Sol Open Circuit ........................................................ 40-316
Failure code [DW45KB] Swing Brake Sol Short Circuit ........................................................ 40-319
Failure code [DW91KA] Travel Junction Sol Open Circuit .................................................... 40-321
Failure code [DW91KB] Travel Junction Sol Short Circuit..................................................... 40-323
Failure code [DWA2KA] Attachment Sol Open Circuit.......................................................... 40-325
Failure code [DWA2KB] Attachment Sol Short Circuit.......................................................... 40-327
Failure code [DWJ0KA] Merge-divider Sol Open Circuit....................................................... 40-329
Failure code [DWJ0KB] Merge-divider Sol Short Circuit....................................................... 40-331
Failure code [DXA8KA] PC-EPC Sol Open Circuit............................................................... 40-333
Failure code [DXA8KB] PC-EPC Sol Short Circuit............................................................... 40-335

00-6 PC138USLC-10
00 Index and foreword
Index

Failure code [DXE4KA] Attachment Flow EPC Open Circuit ................................................ 40-337
Failure code [DXE4KB] Attachment Flow EPC Short Circuit................................................. 40-339
Failure code [DY20KA] Wiper Working Abnormality ............................................................ 40-341
Failure code [DY20MA] Wiper Parking Abnormality............................................................. 40-343
Failure code [DY2CKB] Washer Drive Short Circuit ............................................................. 40-345
Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit ...................................................... 40-347
Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit ....................................................... 40-349
Troubleshooting of electrical system (E-mode) .......................................................................... 40-351
E-1 Engine does not start (Engine does not crank) .............................................................. 40-351
E-2 Manual preheating system does not work..................................................................... 40-357
E-3 While preheating is working, preheating monitor does not light up .................................. 40-360
E-4 When starting switch is turned to ON position, machine monitor displays nothing............. 40-362
E-5 When starting switch is turned to ON position (with engine stopped), engine oil level
monitor lights up in yellow.................................................................................... 40-365
E-6 Engine coolant temperature monitor lights up in white while engine is running ................. 40-366
E-7 Hydraulic oil temperature monitor lights up in white while engine is running ..................... 40-367
E-8 Charge level monitor lights up while engine is running ................................................... 40-368
E-9 Fuel level monitor lights up in red while engine is running .............................................. 40-369
E-10 Engine coolant temperature monitor lights up in red while engine is running .................. 40-370
E-11 Hydraulic oil temperature monitor lights up in red while engine is running ...................... 40-371
E-12 Engine oil pressure monitor lights up in red while engine is running .............................. 40-372
E-13 Fuel gauge display does not move from minimum or maximum .................................... 40-373
E-14 Fuel gauge indicates incorrect amount (indicates neither full nor empty)........................ 40-374
E-15 Engine coolant temperature gauge display does not move from minimum or
maximum ........................................................................................................... 40-375
E-16 Engine coolant temperature gauge indicates incorrect temperature (indicates neither
minimum nor maximum) ...................................................................................... 40-376
E-17 Hydraulic oil temperature gauge does not move from minimum or maximum ................. 40-377
E-18 Hydraulic oil temperature gauge indicates incorrect temperature (indicates neither
minimum nor maximum) ...................................................................................... 40-379
E-19 Some areas of machine monitor screen are not displayed............................................ 40-380
E-20 Function switch does not work................................................................................... 40-381
E-21 Automatic warm-up system does not operate (in cold season)...................................... 40-382
E-22 Auto-deceleration monitor does not light up, or does not go out, while auto-deceleration
switch is operated ............................................................................................... 40-383
E-23 Auto-deceleration function does not operate or is not canceled while lever is
operated ............................................................................................................ 40-384
E-24 Working mode selection screen is not displayed while working mode selector switch is
operated ............................................................................................................ 40-385
E-25 Setting of engine and hydraulic pump is not changed while working mode is
changed............................................................................................................. 40-386
E-26 Travel speed monitor does not change while travel speed switch is operated ................ 40-387
E-27 Travel speed does not change while travel speed selection is changed......................... 40-388
E-28 Alarm buzzer does not stop sounding......................................................................... 40-389
E-29 Service meter is not displayed, while starting switch is in OFF position.......................... 40-390
E-30 Service mode cannot be selected .............................................................................. 40-391
E-31 Any of work equipment, swing and travel does not work............................................... 40-392
E-32 Any of work equipment, swing and travel cannot be locked .......................................... 40-394
E-33 Upper structure does not swing while swing parking brake cancel switch is set to
CANCEL position................................................................................................ 40-396
E-34 Swing brake does not operate while swing parking brake cancel switch is set to NORMAL
position .............................................................................................................. 40-398
E-35 Alarm does not sound during travel ............................................................................ 40-400
E-36 Alarm does not stop sounding while machine is stopped.............................................. 40-401
E-37 Horn does not sound ................................................................................................ 40-402
E-38 Horn does not stop sounding..................................................................................... 40-403
E-39 Wiper monitor does not light up, or does not go out, while wiper switch is
operated ............................................................................................................ 40-404
E-40 Wiper does not operate while wiper switch is operated ................................................ 40-405

PC138USLC-10 00-7
00 Index and foreword
Index

E-41 Window washer does not operate while window washer switch is operated ................... 40-407
E-42 Boom Lower is not displayed correctly with monitoring function .................................... 40-408
E-43 Arm OUT is not displayed correctly with monitoring function......................................... 40-410
E-44 Arm IN is not displayed correctly with monitoring function ............................................ 40-412
E-45 Boom Raise is not displayed correctly with monitoring function..................................... 40-414
E-46 Bucket Curl is not displayed correctly with monitoring function...................................... 40-416
E-47 Bucket Dump is not displayed correctly with monitoring function................................... 40-418
E-48 Swing is not displayed correctly with monitoring function.............................................. 40-420
E-49 Travel is not displayed correctly with monitoring function ............................................. 40-422
E-50 Service is not displayed correctly with monitoring function ........................................... 40-423
E-51 Attachment hydraulic circuit cannot be changed.......................................................... 40-425
E-52 KOMTRAX system does not operate normally ............................................................ 40-426
Troubleshooting of hydraulic and mechanical system (H-mode) .................................................. 40-428
Information described in troubleshooting table (H-mode) ..................................................... 40-428
System chart of hydraulic and mechanical systems............................................................. 40-429
Failure mode and cause table ........................................................................................... 40-431
H-1 All of work equipment, swing and travel operation lacks speed or power ......................... 40-439
H-2 Engine speed drops significantly or engine stalls .......................................................... 40-441
H-3 Any of work equipment, swing and travel does not work ................................................ 40-442
H-4 Unusual sound is heard from around hydraulic pump .................................................... 40-443
H-5 Fine control performance or response is poor ............................................................... 40-444
H-6 Boom speed or power is low ....................................................................................... 40-445
H-7 Arm speed or power is low .......................................................................................... 40-448
H-8 Bucket speed or power is low...................................................................................... 40-450
H-9 Work equipment does not move in single operation....................................................... 40-452
H-10 Hydraulic drift of boom is large .................................................................................. 40-453
H-11 Hydraulic drift of arm is large ..................................................................................... 40-454
H-12 Hydraulic drift of bucket is large ................................................................................. 40-455
H-13 Time lag of work equipment is large ........................................................................... 40-456
H-14 In combined operation of work equipment , equipment having heavier load moves
slower................................................................................................................ 40-458
H-15 In combined operation of swing and boom RAISE, boom rising speed is low ................. 40-459
H-16 In combined operation of swing and travel, travel speed drops largely .......................... 40-460
H-17 Machine does not travel straight ................................................................................ 40-461
H-18 Travel speed is slow ................................................................................................. 40-463
H-19 Machine is hard to steer or travel power is low ............................................................ 40-465
H-20 Travel speed does not change, or travel speed is too slow or fast ................................. 40-468
H-21 One of tracks does not run ........................................................................................ 40-469
H-22 Upper structure does not swing to the right or left ........................................................ 40-471
H-23 Upper structure swing only to the right or left .............................................................. 40-472
H-24 Swing acceleration or swing speed is low in both directions (right and left) .................... 40-473
H-25 Swing acceleration performance is poor or swing speed is slow in only one
direction............................................................................................................. 40-474
H-26 Upper structure overruns excessively when it stops swinging (both right and
left).................................................................................................................... 40-475
H-27 Upper structure overruns excessively when it stops swinging (either right or left) ........... 40-476
H-28 Shock is large when upper structure stops swinging.................................................... 40-477
H-29 Large unusual noise is heard when upper structure stops swinging .............................. 40-478
H-30 Swing drift on a slope is large while swing parking brake is applied............................... 40-479
H-31 Swing drift on a slope is large while swing parking brake is released............................. 40-480
H-32 Attachment hydraulic circuit cannot be changed while attachment is installed................ 40-481
H-33 Oil flow in attachment circuit cannot be controlled ....................................................... 40-482
Troubleshooting of engine (S-mode)......................................................................................... 40-483
Information mentioned in troubleshooting table (S mode)..................................................... 40-483
S-1 Engine does not crank when starting switch is turned to START position......................... 40-484
S-2 Engine cranks but no exhaust smoke comes out........................................................... 40-485
S-3 Fuel is being injected but engine does not start (misfiring: engine cranks but does not
start).................................................................................................................. 40-486
S-4 Engine startability is poor ............................................................................................ 40-487

00-8 PC138USLC-10
00 Index and foreword
Index

S-5 Engine does not pick up smoothly ............................................................................... 40-489


S-6 Engine stops during operation ..................................................................................... 40-491
S-7 Engine runs rough or is unstable ................................................................................. 40-493
S-8 Engine lacks power .................................................................................................... 40-494
S-9 Exhaust smoke is black .............................................................................................. 40-496
S-10 Engine oil consumption is excessive .......................................................................... 40-498
S-11 Oil becomes contaminated quickly ............................................................................. 40-499
S-12 Fuel consumption is excessive .................................................................................. 40-500
S-13 Oil is in coolant (or coolant spurts or coolant level goes down)...................................... 40-501
S-14 Oil pressure drops .................................................................................................... 40-502
S-15 Fuel mixes into engine oil.......................................................................................... 40-503
S-16 Water mixes into engine oil (milky) ............................................................................. 40-504
S-17 Coolant temperature rises too high (overheating) ........................................................ 40-505
S-18 Unusual noise is heard ............................................................................................. 40-506
S-19 Vibration is excessive ............................................................................................... 40-507
S-20 Air cannot be bled from fuel circuit ............................................................................. 40-508
50 Disassembly and assembly ........................................................................................................... 50-1
Table of contents ........................................................................................................................ 50-2
General information on disassembly and assembly........................................................................ 50-4
How to read this manual ....................................................................................................... 50-4
Coating materials list ............................................................................................................ 50-6
Special tools list ................................................................................................................. 50-10
Sketches of special tools .................................................................................................... 50-14
Engine and cooling system ........................................................................................................ 50-16
Removal and installation of supply pump assembly............................................................... 50-16
Removal and installation of injector assembly....................................................................... 50-20
Removal and installation of cylinder head assembly.............................................................. 50-26
Removal and installation of radiator assembly ...................................................................... 50-37
Removal and installation of hydraulic oil cooler assembly ...................................................... 50-39
Removal and installation of aftercooler assembly .................................................................. 50-42
Removal and installation of engine and main pump assembly ................................................ 50-44
Removal and installation of engine front oil seal .................................................................... 50-50
Removal and installation of engine rear oil seal..................................................................... 50-51
Removal and installation of fuel cooler assembly .................................................................. 50-53
Removal and installation of fuel tank assembly ..................................................................... 50-54
Removal and installation of KDOC assembly ........................................................................ 50-57
Removal and installation of KCCV assembly ........................................................................ 50-58
Removal and installation of air cleaner assembly .................................................................. 50-59
Removal and installation of fan belt...................................................................................... 50-61
Power train system ................................................................................................................... 50-63
Removal and installation of travel motor and final drive assembly ........................................... 50-63
Disassembly and assembly of travel motor and final drive assembly....................................... 50-64
Removal and installation of swing motor and swing machinery assembly ................................ 50-99
Disassembly and assembly of swing machinery assembly................................................... 50-101
Removal and installation of swing circle assembly .............................................................. 50-107
Undercarriage and frame......................................................................................................... 50-108
Separation and connection of track.................................................................................... 50-108
Removal and installation of sprocket...................................................................................50-111
Removal and installation of idler and idler cushion assembly ............................................... 50-112
Disassembly and assembly of idler assembly ..................................................................... 50-113
Disassembly and assembly of idler cushion assembly......................................................... 50-116
Disassembly and assembly of track roller assembly ............................................................ 50-119
Removal and installation of revolving frame assembly ......................................................... 50-122
Removal and installation of counterweight assembly [For machines with additional
counterweight].................................................................................................... 50-124
Hydraulic system .................................................................................................................... 50-127
Removal and installation of center swivel joint assembly ..................................................... 50-127
Disassembly and assembly of center swivel joint assembly ................................................. 50-129
Removal and installation of hydraulic tank assembly ........................................................... 50-130

PC138USLC-10 00-9
00 Index and foreword
Index

Removal and installation of main pump assembly ............................................................... 50-133


Removal and installation of control valve assembly ............................................................. 50-137
Disassembly and assembly of control valve assembly......................................................... 50-143
Disassembly and assembly of work equipment PPC valve assembly.................................... 50-145
Disassembly and assembly of travel PPC valve assembly ................................................... 50-147
Work equipment ..................................................................................................................... 50-149
Removal and installation of work equipment assembly ........................................................ 50-149
Disassembly and assembly of work equipment cylinder assembly........................................ 50-153
Cab and its attachments .......................................................................................................... 50-158
Removal and installation of operator's cab assembly........................................................... 50-158
Removal and installation of operator's cab door .................................................................. 50-161
Removal and installation of operator's cab glass (adhered glass) ......................................... 50-164
Removal and installation of front window assembly ............................................................. 50-175
Removal and installation of floor frame assembly................................................................ 50-176
Removal and installation of air conditioner unit assembly..................................................... 50-183
Removal and installation of air conditioner compressor assembly......................................... 50-187
Removal and installation of air conditioner condenser assembly .......................................... 50-189
Removal and installation of operator's seat......................................................................... 50-191
Removal and installation of seat belt .................................................................................. 50-192
Removal and installation of front wiper assembly ................................................................ 50-193
Electrical system .................................................................................................................... 50-199
Removal and installation of engine controller assembly ....................................................... 50-199
Removal and installation of pump controller assembly......................................................... 50-200
Removal and installation of machine monitor assembly ....................................................... 50-202
Removal and installation of mass air flow and temperature sensor ....................................... 50-204
Removal and installation of KOMTRAX terminal assembly .................................................. 50-205
60 Maintenance standard................................................................................................................... 60-1
Table of contents ........................................................................................................................ 60-2
Engine and cooling system .......................................................................................................... 60-3
Engine mount ...................................................................................................................... 60-3
PTO.................................................................................................................................... 60-4
Cooling system .................................................................................................................... 60-5
Power train................................................................................................................................. 60-6
Swing circle ......................................................................................................................... 60-6
Swing machinery ................................................................................................................. 60-7
Sprocket.............................................................................................................................. 60-8
Undercarriage and frame............................................................................................................. 60-9
Track frame ......................................................................................................................... 60-9
Idler cushion ...................................................................................................................... 60-10
Idler .................................................................................................................................. 60-11
Track roller ........................................................................................................................ 60-12
Carrier roller ...................................................................................................................... 60-13
Track shoe ........................................................................................................................ 60-14
Hydraulic system ...................................................................................................................... 60-19
Hydraulic tank.................................................................................................................... 60-19
Main pump ........................................................................................................................ 60-20
Control valve ..................................................................................................................... 60-23
Swing motor ...................................................................................................................... 60-34
Travel motor ...................................................................................................................... 60-37
Work equipment and swing PPC valve................................................................................. 60-38
Travel PPC valve ............................................................................................................... 60-41
Blade PPC valve ................................................................................................................ 60-44
1st-line attachment PPC valve (with EPC valve) ................................................................... 60-46
Solenoid valve ................................................................................................................... 60-49
Attachment circuit selector valve (for low pressure circuit)...................................................... 60-51
Attachment circuit selector valve (for high pressure circuit) .................................................... 60-52
Center swivel joint .............................................................................................................. 60-53
Cab and its attachments ............................................................................................................ 60-54
Cab mount and cab tipping stopper ..................................................................................... 60-54

00-10 PC138USLC-10
00 Index and foreword
Index

Work equipment ....................................................................................................................... 60-55


Work equipment................................................................................................................. 60-55
Boom cylinder.................................................................................................................... 60-64
Arm cylinder ...................................................................................................................... 60-65
Bucket cylinder .................................................................................................................. 60-66
Blade cylinder .................................................................................................................... 60-67
80 Appendix...................................................................................................................................... 80-1
Table of contents ........................................................................................................................ 80-2
Air conditioner components ......................................................................................................... 80-3
Precautions for refrigerant..................................................................................................... 80-3
Air conditioner component .................................................................................................... 80-4
Configuration and function of refrigeration cycle...................................................................... 80-7
Outline of refrigeration cycle.................................................................................................. 80-8
Air conditioner unit ............................................................................................................. 80-10
Dual pressure switch .......................................................................................................... 80-15
Air conditioner controller ..................................................................................................... 80-16
Compressor....................................................................................................................... 80-17
Air conditioner condenser ................................................................................................... 80-18
Sunlight sensor .................................................................................................................. 80-20
Outer temperature sensor (outside air temperature sensor) ................................................... 80-21
Procedure for testing and troubleshooting ............................................................................ 80-22
Circuit diagram and arrangement of connector pins............................................................... 80-24
System diagram................................................................................................................. 80-26
Input and output signals of the air conditioner controller ......................................................... 80-27
Air conditioner unit ............................................................................................................. 80-29
Parts and connectors layout................................................................................................ 80-31
Testing air leakage (duct) .................................................................................................... 80-37
Testing with self-diagnosis function ...................................................................................... 80-40
Testing vent (mode) changeover.......................................................................................... 80-43
Testing FRESH/RECIRC air changeover.............................................................................. 80-44
Testing sunlight sensor ....................................................................................................... 80-45
Testing (dual) pressure switch for refrigerant......................................................................... 80-46
Testing relays .................................................................................................................... 80-48
Troubleshooting chart 1 ...................................................................................................... 80-49
Troubleshooting chart 2 ...................................................................................................... 80-50
Information in troubleshooting table ..................................................................................... 80-53
Failure code list related to air conditioner.............................................................................. 80-54
Failure code [879AKA] A/C Inner Sensor Open Circuit .......................................................... 80-55
Failure code [879AKB] A/C Inner Sensor Short Circuit........................................................... 80-56
Failure code [879BKA] A/C Outer Sensor Open Circuit.......................................................... 80-57
Failure code [879BKB] A/C Outer Sensor Short Circuit .......................................................... 80-59
Failure code [879CKA] Ventilating Sensor Open Circuit ......................................................... 80-61
Failure code [879CKB] Ventilating Sensor Short Circuit ......................................................... 80-62
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit ................................................ 80-63
Failure code [879EMC] Ventilation Damper Abnormality ........................................................ 80-65
Failure code [879FMC] Air Mix Damper Abnormality ............................................................. 80-66
Failure code [879GKX] Refrigerant Abnormality .................................................................... 80-67
A-1 Troubleshooting for power supply system (Air conditioner does not operate) ..................... 80-68
A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled) ........................ 80-70
A-3 Troubleshooting for blower motor system (No air comes out or air flow is
abnormal) ............................................................................................................ 80-73
A-4 Troubleshooting for FRESH/RECIRC air changeover ...................................................... 80-75
Troubleshooting with gauge pressure................................................................................... 80-77
Connection of service tool................................................................................................... 80-80
Precautions for disconnecting and connecting refrigerant piping............................................. 80-82
Handling of compressor oil.................................................................................................. 80-84
Desiccant replacement ....................................................................................................... 80-86
90 Diagrams and drawings................................................................................................................. 90-1
Table of contents ........................................................................................................................ 90-2

PC138USLC-10 00-11
00 Index and foreword
Index

Hydraulic circuit diagram ............................................................................................................. 90-3


Symbols in hydraulic circuit diagram ...................................................................................... 90-3
Hydraulic circuit diagram....................................................................................................... 90-7
Electric circuit diagram ................................................................................................................ 90-9
Symbols in electric circuit diagram ......................................................................................... 90-9
Electrical circuit diagram ..................................................................................................... 90-13
Electrical circuit diagram of air conditioner unit...................................................................... 90-25
Index.................................................................................................................................................................... 1

00-12 PC138USLC-10
00 Index and foreword
Foreword, safety and general information

Foreword, safety and general information (ALL-0370-001-A-00-A)

Important safety notice (ALL-1120-012-A-01-A)

(Rev. 2012/10)
• Appropriate servicing and repair are extremely important to ensure safe operation of the machine. The
shop manual describes the effective and safe servicing and repair methods recommended by Komatsu.
Some of these methods require the use of the special tools designed by Komatsu for the specific purpose.
• The symbol mark k is used for such matters that require special cautions during the work. The work
indicated by the caution mark should be performed according to the instructions with special attention to
the cautions. Should hazardous situation occur or be anticipated during such work, be sure to keep safe
first and take every necessary measure.

General precautions knowledge of welding perform the work. When


performing welding work, always wear welding
k Inappropriate handling causes an extreme gloves, apron, shielding goggles, cap, etc.
danger. Read and understand what is • Before starting work, warm up your body
described in the operation and maintenance thoroughly to start work under good condition.
manual before operating the machine. Read • Avoid continuing work for long hours and take
and understand what is described in this rests with proper intervals to keep your body in
manual before starting the work. good condition. Take a rest in a specified safe
place.
• Before performing any greasing or repairs, read
all the safety labels stuck to the machine. For Safety points
the locations of the safety labels and detailed 1 Good arrangement
explanation of precautions, see the operation 2 Correct work clothes
and maintenance manual.
3 Observance of work standard
• Locate a place in the repair workshop to keep
4 Practice of making and checking signals
the tools and removed parts. Always keep the
Prohibition of operation and handling by
tools and parts in their correct places. Always 5
unlicensed workers
keep the work area clean and make sure that Safety check before starting work
6
there is no dirt, water or oil on the floor. Smoke
Wearing protective goggles (for cleaning or
only in the areas provided for smoking. Never 7 grinding work)
smoke while working.
Wearing shielding goggles and protectors (for
• When performing any work, always wear the 8 welding work)
safety shoes and helmet. Do not wear loose
9 Good physical condition and preparation
work cloths, or clothes with buttons missing.
Precautions against work which you are not
1. Always wear the protective eyeglasses when 10 used to or you are used to too much
hitting parts with a hammer.
2. Always wear the protective eyeglasses when Preparation
grinding parts with a grinder, etc. • Before adding oil or making any repairs, place
• When performing any work with two or more the machine on a firm and level ground, and
workers, always agree on the working procedure apply the parking brake and chock the wheels or
before starting. While working, always keep tracks to prevent the machine from moving.
conversations of the work between your fellow • Before starting work, lower the work equipment
workers and your self on any step of the work. (blade, ripper, bucket, etc.) to the ground. If it is
During the work, hang the warning tag of not possible to lower the equipment to the
"UNDER WORKING" in the operator's ground, insert the lock pin or use blocks to
compartment. prevent the work equipment from falling. And be
• Only qualified workers must perform the work sure to lock all the work equipment control levers
and operation which require license or and hang a warning tag on them.
qualification. • When performing the disassembling or
• Keep the tools in good condition. And learn the assembling work, support the machine securely
correct way to use the tools, and use the proper with blocks, jacks, or stands before starting the
ones among them. Before starting the work, work.
thoroughly check the tools, lift truck, service • Remove all of mud and oil from the steps or
vehicle, etc. other places used to get on and off the machine
• If welding repairs is required, always have a completely. Always use the handrails, ladders of
trained and experienced welder with good

PC138USLC-10 00-13
00 Index and foreword
Foreword, safety and general information

steps when getting on or off the machine. Never • When removing piping, prevent the fuel or oil
jump on or off the machine. When the scaffold is from spilling out. If any fuel or oil drips onto the
not provided, use steps or stepladder to secure floor, wipe it off immediately. Fuel or oil on the
your footing. floor can cause you to slip and can even cause
fires.
Precautions during work • As a general rule, do not use gasoline to wash
• For the machine equipped with the battery parts. Do not use gasoline to clean the electrical
disconnect switch, check that the system parts, in particular.
operating lamp is turned off before starting the • Reinstall the parts removed to their original
work. Then, turn the battery disconnect switch to places. Replace the damaged parts and the
OFF (Q) position and remove the switch key. For parts which must not be used with new ones.
the machine not equipped with the battery When installing the hoses and wiring harnesses,
disconnect switch, remove the cable from the be careful that they are not damaged by
battery before starting the work. Be sure to contacting with other parts when the machine is
remove the negative end (-) of the battery cable operated.
first. • When connecting the high pressure hoses and
• Release the remaining pressure in the circuits tubes, make sure that they are not twisted. The
completely before the work when the parts in the damaged high pressure hoses and tubes are
circuits of oil, fuel, coolant and air are very dangerous when they are installed. So, be
disconnected or removed. When the cap of the extremely careful when connecting the high
oil filter, drain plug or oil pressure pickup plug is pressure pipings. In addition, check that their
removed, loose them slowly to prevent the oil connections are correct.
from spurting out. • When assembling or installing the parts, be sure
• When removing or installing the checking plug or to tighten the bolts to the specified torque. When
the piping in the fuel circuit, wait 30 seconds or installing the protective parts such as guards, or
longer after the engine is shut down and start the parts which vibrate violently or rotate at high
the work after the remaining pressure is speeds, be sure to check that they are installed
released from the fuel circuit. correctly.
• Immediately after the engine is shut down, the • When aligning 2 holes, never insert your fingers
coolant and oil in the circuits are hot. Be careful or hand into the holes. Align the holes with care
not to get scalded by the hot coolant and oil. so that your fingers are not caught in the hole.
Start the work after checking that the coolant • When measuring hydraulic pressure, check that
and oil are cooled down sufficiently. the measuring tools are correctly installed.
• Start the work after the engine is shut down. Be • Pay attention to safety when removing and
sure to shut down the engine when working on installing the tracks of the track type machines.
or around the rotating parts in particular. When When removing the track, it separates suddenly.
checking the machine without shutting down the The workers should not stand at either end of
engine (measuring oil pressure, rotational speed, the track.
oil or coolant temperature), take extreme care • If the engine is operated for a long time in a
not to get caught in the rotating parts or the closed place which is not ventilated well, you
working equipment. may suffer from gas poisoning. Accordingly,
• The hoist or crane must be used to sling the open the windows and doors to ventilate the
components weighing 25 kg or heavier. Check place well.
the slings (wire rope, nylon sling, chain and
hook) for damage before the work. Use the Precautions for slinging work and making
slings with ample capacity and install them to signals
the proper places. Operate the hoist or crane • Only one appointed worker must make signals
slowly to prevent the component from hitting any and co-worker must communicate with each
other part. Do not work with any part still raised other frequently. The appointed signaler must
by the hoist or crane. make specified signals clearly at the place
• When removing the part which is under internal where the signaler is well seen from the
pressure or reaction force of the spring, always operator's seat and where the signaler can see
leave 2 bolts in diagonal positions. Loosen those the working condition easily. The signaler must
2 bolts gradually and alternately and release the always stand in front of the load and guide the
pressure, then, remove the part. operator safely.
• When removing the part, be careful not to break 1. Do not stand under the load.
or damage the electrical wiring. The damaged 2. Do not step on the load.
wiring may cause electrical fires. • Check the slings before starting sling work.

00-14 PC138USLC-10
00 Index and foreword
Foreword, safety and general information

• Keep putting on the gloves during sling work. • Use the specified eye bolts and fix wire ropes,
(Put on the leather gloves, if available.) chains, etc. to them with shackles, etc.
• Measure the weight of the load by the eye and • Apply wire ropes to the middle part of the hook.
check its center of gravity.
a Slinging near the tip of the hook may cause
• Use the proper sling according to the weight of
the rope to slip off the hook during hoisting.
the load and method of slinging. If too thick wire
The strength of the hook is maximum at its
ropes are used to sling a light load, the load may
central part.
slip and fall.
• Do not sling a load with 1 wire rope only. If do so,
the load may rotate or the sling gets loose and
the sling may slip off. Install 2 or more wire ropes
symmetrically.

k Slinging with one rope may cause turning


of the load during hoisting, untwisting of
the rope, or slipping of the rope from its
original slinging position on the load,
which can result in a dangerous accident.
• Hanging angle must be 60 degrees or smaller as
a rule.
• When hanging a heavy load (25kg or heavier), • Do not use twisted or kinked wire ropes.
the hanging angle of the rope must be narrower • When slinging up a load, observe the following.
than that of the hook.
1. Wind up the rope slowly until the wire rope
a When slinging a load with 2 ropes or more, tensions. When putting your hands on the
the larger the hanging angle is, the larger the wire ropes, do not grasp them but press them
tension of each rope. The figure bellow down from above. If you grasp them, your
shows the variation of allowable load in kN fingers may be caught.
{kg} when hoisting is made with 2 ropes, 2. After the wire ropes are stretched, stop the
each of which is allowed to sling up to 9.8 kN crane and check the condition of the slung
{1000kg} a load vertically, at various hanging load, wire ropes, and pads.
angles. When the 2 ropes sling a load 3. If the load is unstable or the wire rope or
vertically, up to19.6 kN {2000 kg} of total chains are twisted, lower the load and lift it
weight can be suspended. This weight is up again.
reduced to 9.8 kN {1000 kg} when the 2 4. Do not lift up the load at an angle.
ropes make a hanging angle of 120 degrees. • When lowering a load, pay attention to the
If the two ropes sling a 19.6 kN {2000 kg} following.
load at a hanging angle of 150 degrees, each 1. When lifting down a load, stop it temporarily
rope is subjected to a force as large as 39.2 at 30 cm above the floor, and then lower it
kN {4000 kg}. slowly.
2. Check that the load is stable, and then
remove the sling.
3. Remove kinks and dirt from the wire ropes
and chains used for the sling work, and put
them in the specified place.

Precautions for using mobile crane


a Read the Operation and Maintenance Manual of
the crane carefully in advance and operate the
crane safely.

Precautions for using overhead traveling crane


k The hoist or crane must be used to sling the
• When installing wire ropes to an angular load,
components weighing 25 kg or heavier. A
apply pads to protect the wire ropes. If the load
part weighing 25 kg or heavier in
is slippery, apply proper material to prevent the
"disassembly and assembly" section is
wire rope from slipping.
indicated with the symbol of 4 .

PC138USLC-10 00-15
00 Index and foreword
Foreword, safety and general information

• Before starting work, check the wire ropes, Nominal


diameter of rope Allowable load
brake, clutch, controller, rails, over winding
prevention device, ground fault circuit interrupter mm kN ton
for electric shock prevention, crane collision 50 221.6 22.6
prevention device, and energizing warning lamp, 60 318.3 32.4
and check the following safety items.
• Observe the signals for sling work. a The allowable load is calculated as one sixth of
• Operate the hoist at a safe place. the breaking load of the rope to be used (safety
• Be sure to check the directions of the direction coefficient: 6).
indication plate (north, south, east and west) and
the operating button. Precautions for disconnecting and connecting
hoses and tubes in air conditioner circuit
• Do not sling a load at an angle. Do not move the
crane while the slung load is swinging. Disconnection
• Do not raise or lower a load while the crane is
k When replacing the air conditioner unit, air
moving longitudinally or laterally.
• Do not drag a sling. conditioner compressor, condenser or
• When lifting up a load, stop it just after it leaves receiver drier, etc., collect the refrigerant (air
the ground and check safety, and then lift it up. conditioner gas: R134a) from the air
• Consider the travel route in advance and lift up a conditioner circuit before disconnecting the
load to a safe height. air conditioner hoses.
• Place the control switch in a position where it will
a Ask a qualified person for collecting, adding and
not be an obstacle to work and passage.
filling operations of the refrigerant (air
• After operating the hoist, do not swing the
conditioner gas: R134a). (Only registered
control switch.
persons can work.)
• Remember the position of the main switch so
that you can turn off the power immediately in an a Never release the refrigerant (air conditioner
emergency. gas: R134a) to the atmosphere.
• Shut down the main switch when the hoist stops
k If refrigerant gas (air conditioner gas: R134a)
because of a blackout. When turning on a switch
which is turned OFF by the ground fault circuit gets in your eyes, you may lose your sight.
interrupter for electric shock prevention, check And if it touches your skin, you may suffer
that the devices related to that switch are not in from frostbite. Put on protective eyeglasses,
operating condition. gloves and working clothes with long
• If you find an obstacle around the hoist, stop the sleeves while collecting the refrigerant or
operation. filling the air conditioner circuit with the
• After finishing the work, stop the hoist at the refrigerant.
specified position and raise the hook to at least 2
• When loosening the nuts fixing air conditioner
meters above the floor. Do not leave the sling
hoses and tubes, be sure to use 2 wrenches;
attached to the hook.
use one wrench to fix and use the other one to
Selecting wire ropes loosen the nut.
• Select adequate ropes depending on the weight
Connection
of the parts to be hoisted, referring to the table
• When installing the hose for the air conditioner
below
circuit, take care not to allow invasion of dirt,
Wire rope (JIS G3525, 6 x 37 - Type A)
dusts and water into the hose.
(Standard Z twist wire ropes without galvanizing) • Check that the O-rings are fitted to the joints
Nominal when connecting the air conditioner piping.
diameter of rope Allowable load • Once an O-ring is used, it is deformed and
mm kN ton deteriorated. Accordingly, do not reuse it.
10 8.8 0.9 • When removing the O-rings, use a soft tool so
that the piping is not damaged.
12 12.7 1.3
• Check that the O-ring is not damaged or
14 17.3 1.7
deteriorated.
16 22.6 2.3 • Apply compressor oil for refrigerant (R134a) to
18 28.6 2.9 the O-ring.
20 35.3 3.6
25 55.3 5.6 a However, do not apply oil to the threaded
portion of a bolt, nut or union.
30 79.6 8.1
40 141.6 14.4

00-16 PC138USLC-10
00 Index and foreword
Foreword, safety and general information

Manufacturer Part name


DENSO ND-OIL8
VALEO THERMAL ZXL100PG (equivalent to
SYSTEMS PAG46)
SANDEN SP-10
• When tightening nuts of the air conditioner
hoses and tubes, be sure to use 2 wrenches.
Use one wrench to fix and tighten the nut with
the other wrench to the specified torque (Use a
torque wrench for tightening).
a Example of fitting of O-ring
• An O-ring is fitted to every joint of the air
conditioner piping.

For tightening torques, see "Others",


"Precautions for disconnection and connection
of air conditioner piping".

PC138USLC-10 00-17
00 Index and foreword
Foreword, safety and general information

Fire prevention (ALL-0000-001-K-27-A)

Action if fire occurs (ALL-0000-17A-K-01-A)


• Turn the starting switch to OFF position to stop
the engine.
• Use the handrails and steps to get off the
machine.
• Do not jump off the machine. You may fall or
suffer serious injury.
• The fume generated by a fire contains harmful 9 J D 0 1 7 2 0
materials which have a bad influence on a
human body when they are sucked.
Don't breathe a fume.
• After a fire, there may be harmful compounds
left. If it touches your skin it may have a bad
influence on your body.
Be sure to wear rubber gloves when handle the
materials left after the fire.
The material of the gloves, which is
recommended is polychloroprene (Neoprene) or
polyvinyl chloride (in the lower temperature 9 J D 0 1 7 2 1
environment).
When wearing cotton-work-gloves, wear rubber • Fire caused by accumulation or attachment
gloves under them. of flammable material
• Remove any dry leaves, chips, pieces of
Prevent fire (ALL-0000-17B-K-03-A) paper, coal dust, or any other flammable
• Fire caused by fuel, oil, coolant or window materials accumulated or attached to or
washer fluid around the engine exhaust manifold, muffler,
Do not bring any flame or fire close to flammable or battery, or on the undercovers.
substances such as fuel, oil, coolant or window • To prevent fires from being caught, remove
washer fluid.There is danger that they may catch any flammable materials such as dry leaves,
fire. Always observe the following. chips, pieces of paper, coal dust, or any
• Do not smoke or use any flame near fuel or other flammable materials accumulated
other flammable substances. around the cooling system (radiator, oil
• Shut down the engine before adding fuel. cooler) or on the undercover.
• Do not leave the machine when adding fuel • Fire coming from electric wiring
or oil. Short circuits in the electrical system can cause
• Tighten all the fuel and oil caps securely. fire. Always observe the following.
• Be careful not to spill fuel on overheated • Keep all the electric wiring connections clean
surfaces or on parts of the electrical system. and securely tightened.
• After adding fuel or oil, wipe up any spilled • Check the wiring every day for looseness or
fuel or oil. damage. Reconnect any loose connectors or
• Put greasy rags and other flammable refasten wiring clamps. Repair or replace any
materials into a safe container to maintain damaged wiring.
safety at the workplace. • Fire caused by piping
• When washing parts with oil, use a non- Check that all the clamps for the hoses and
flammable oil. Do not use diesel oil or tubes, guards, and cushions are securely fixed
gasoline.There is danger that they may catch in position.
fire. If they are loose, they may vibrate during
• Do not weld or use a cutting torch to cut any operation and rub against other parts.There is
pipes or tubes that contain flammable liquids. danger that this may lead to damage to the
• Determine well-ventilated areas for storing oil hoses and cause high-pressure oil to spurt out,
and fuel. Keep the oil and fuel in the leading to fire and serious personal injury or
specified place and do not allow death.
unauthorized persons to enter. • Fire around the machine due to highly heated
• When performing grinding or welding work exhaust gas
on the machine, move any flammable This machine is equipped with KDPF (Komatsu
materials to a safe place before starting. Diesel Particulate Filter).

00-18 PC138USLC-10
00 Index and foreword
Foreword, safety and general information

KDPF is a system for purifying soot in exhaust


gas.Its exhaust gas discharged during
purification process (regeneration) can be at
higher temperature than that from existing
models. Do not bring any flammable material
close to the outlet of the exhaust pipe.
• When there are thatched houses, dry leaves
or pieces of paper near the work site, set the
system to disable the regeneration before
starting work to prevent fire hazards due to
highly heated exhaust gas.
See the operation and maintenance manual
for the setting procedure.
• Explosion caused by lighting equipment
• When checking fuel, oil, battery electrolyte,
or coolant, always use lighting equipment
with anti-explosion specifications.
• When taking the electrical power for the
lighting equipment from the machine itself,
follow the instructions in the operation and
maintenance manual.
Dispose of waste materials (ALL-0000-99A-K-
02-A)

To prevent pollution, pay full attention to the way to


dispose of waste materials.
• Always put the oil and coolant drained from the
machine in containers. Never drain the oil and
coolant directly onto the ground or dump into the
sewage system, rivers, the sea, or lakes.
• Observe the related laws and regulations when
disposing of harmful objects such as oil, fuel,
coolant, solvent, filters, and batteries.

Some kinds of rubber and plastics may produce


poisonous gas harmful to human body when they
are burned.
• As for rubber, plastics, or parts (hoses, cables,
and wiring harnesses, etc.) which contain those
materials, ask the industrial waste treatment
firms for their disposals in accordance with the
local regulations.

PC138USLC-10 00-19
00 Index and foreword
Foreword, safety and general information

How to read the shop manual (ALL-0320-010-A-01-A)

(Rev. 2012/10)
• Some attachments and optional parts described in this shop manual may not be arranged for certain
areas. Contact your Komatsu distributor if one or some of them are required.
• Materials and specifications are subject to change without notice.
• The shop manuals are available for "Machine part" and "Engine part". For the engine, see the shop
manual for the same model of the engine as the one which is mounted on the machine.

Composition of shop manual


• This shop manual describes the technical information required for the services performed in a workshop.
The shop manual is divided into the following chapters for the convenience of use.
00. Index and foreword
• This section includes the index, foreword, safety and basic information.
01. Specification
• This section explains the specifications of the machine.
10. Structure and function
• This section explains the structure and function of the machine. The section of "Structure and function"
serves not only to give an understanding for the structure of each component, but also serves as
reference material for troubleshooting.
20. Standard value table
• The standard values for a new machine and trouble shooting are indicated. This standard value table is
used for testing and adjusting, and determining a failure at troubleshooting.
30. Testing and adjusting
• This section describes the measuring tools and how to measure, and how to adjust various parts. As for
the standard value and failure criterion, see the standard value table.
40. Troubleshooting
• This section describes the troubleshooting in a suspected area when a failure occurs and the remedy for
the failure. Troubleshooting is described by each failure mode.
50. Disassembly and assembly
• This section explains the procedures for removing, installing, disassembling, and assembling each part or
component and the special tools for the works as well as precautions for doing them safely. In addition,
tightening torque, and quantity and weight of coating material, oil, grease, and coolant required for the
works are also explained.
60. Maintenance standard
• This section describes the maintenance standard values for each component. This section gives the
criterion values for each component and required remedy at disassembly or maintenance.
80. Appendix
• The structure and function, testing and adjusting, and troubleshooting for all of the other components or
equipment which can not be separately classified are explained together in the appendix.
90. Diagrams and drawings
• This section gives hydraulic circuit diagrams and electrical circuit diagrams.

00-20 PC138USLC-10
00 Index and foreword
Foreword, safety and general information

Symbol
Important safety and quality portions are marked with the following symbols so that the shop manual is used
practically.
Symbol Item Remarks
Safety The special safety precautions required for performing work are
k described.
The special technical precautions or other precautions for preserving
a Caution standards required when performing work are described.
The weight of part or component and the cautions required when
4 Weight selecting hoisting wire or when working posture is important are
indicated.
Tightening The tightening torques that require special attention during assembly
3 torque work are indicated.
The places to be coated with adhesives, grease, etc. during assembling
2 Coat
are indicated.
Oil, coolant The places where oil, coolant, etc. must be added and the quantity to be
5 added are indicated.
Places where oil, coolant, etc. must be drained and the quantity to be
6 Drain
drained are indicated.

Unit
• In this shop manual, the units are indicated with International System of units (SI).
• For reference, Gravitational System of units which is used to be used is indicated in parentheses of { }.

PC138USLC-10 00-21
00 Index and foreword
Foreword, safety and general information

Explanation of terms for maintenance standard (ALL-0330-006-A-01-A)

(Rev. 2012/10)
• The chapter of maintenance standard shows judgement criteria to determine the products to be replaced
or to be reused. The judgement criteria are described by using the following terms.

Standard dimension and tolerance • When some parts are repaired, the value of
• To be accurate, the finished dimension of a part performance/function is set to the standard
is slightly different from one to another. value.
• The finished dimension of a part specifies the
allowable difference from the standard
dimension which is set first.
• The dimension set as the standard is called the
standard dimension and the range of difference
from this standard dimension is called the
"tolerance".
• An indication example of a standard dimension
and tolerance is shown in the following table.
(The standard dimension is entered on the left
side and the tolerance is entered with a positive
or negative symbol on the right side)
Example:
Standard dimension Tolerance
-0.022
120
-0.126
• The tolerance may be indicated in the text and a
table as "standard dimension (upper limit of
tolerance/lower limit of tolerance)."
Example: 120(-0.022/-0.126)
• Usually, the dimension of a hole and the
dimension of a shaft to be inserted into the hole
are indicated by the same standard dimension
and different tolerances of the hole and shaft.
The tightness of fit is decided by the tolerance.
• An indication example of a shaft and hole is
shown in the following table.
Standard interference
(The standard dimension is entered on the left
• When the diameter of a hole of a part shown in
side and the tolerance of the shaft is entered
with a positive or negative symbol at the center the given standard dimension and tolerance
table is smaller than that of the shaft to be
and that of the hole on the right side)
inserted, the difference between those
Standard Tolerance diameters is called the "interference".
dimension Shaft Hole • Subtract the maximum dimension of the hole
-0.030 +0.046 from the minimum dimension of the shaft and
60
-0.076 0 call it (A). Subtract the minimum dimension of
the hole from the maximum dimension of the
Standard clearance and standard value shaft and call it (B). The range between (A) and
• The clearance made when new parts are (B) is the "standard interference".
assembled is called the standard clearance, • After repairing or replacing some parts, measure
which is indicated by the range from the the dimension of their hole and shaft and check
minimum clearance to the maximum clearance. that the interference is in the standard range.
• When some parts are repaired, the clearance is
generally adjusted to the standard clearance. Repair limit and allowable value or allowable
• The values indicating performance and function dimension
of new products or equivalent are called the • The dimensions of parts change because of the
"standard value", which is indicated by a range wear or deformation while they are used. When
or a target value. the dimension changes exceeding certain value,

00-22 PC138USLC-10
00 Index and foreword
Foreword, safety and general information

the parts can not be used any longer. This value


is called "repair limit".
• If a part is worn to the repair limit, it must be
replaced or repaired.
• The performance and function of the products
lower while they are used. When the value of the
performance and function lowers exceeding a
certain limit and it influences the operation etc.,
this value is called the allowable value or
allowable dimension.
• A product whose dimension is out of the
allowable value, must be repaired. However,
since the allowable values are generally
estimated through various tests or experiences
in most cases, the judgement must be made in
consideration of the operating condition and
customer's requirement.

Allowable clearance
• Parts can be used until the clearance between
them is increased to a certain limit. The limit at
which those parts cannot be used is called the
"allowable clearance".
• If the clearance between the parts exceeds the
allowable clearance, they must be replaced or
repaired.

Allowable interference
• The allowable maximum interference between
the hole of a part and the shaft of another part to
be assembled is called the "allowable
interference".
• The allowable interference shows the repair limit
of the part of smaller tolerance.
• The parts whose interferences are out of the
allowable interference must be replaced or
repaired.

PC138USLC-10 00-23
00 Index and foreword
Foreword, safety and general information

Handling equipment of fuel system devices (PC-AD00-2A4-K-00-A)

(Rev. 2012/01)
• The common rail fuel injection system (CRI)
consists of more precise parts than the parts
used in the conventional fuel injection pump and
nozzle. If foreign material enters this system, it
may cause a failure. Use special care to prevent
entry of the foreign material when servicing the
fuel system.

Use care for working environment


• Avoid filter change or repairing the machine in
rain or high winds, or at places where there is a
lot of dust.
Sealing openings
• Plug the pipes and the openings of the
components which are removed with the caps,
tapes, vinyl bags, etc. to prevent foreign material
from entering. Never perform repair works under
the condition that the openings are left as they
are or plugged with cloths as foreign material
may enter or environment may be polluted by
the oil leaked. Do not discard the waste oil
somewhere or other. Hand it over to your
customer for disposal, or dispose it by yourself.

How to clean parts when dirt is stuck


• If any dirt or dust sticks the parts of the fuel
system, clean it off thoroughly with clean fuel.

Precautions for replacing fuel filter cartridge


• Be sure to use the Komatsu genuine fuel filter
cartridge.
• The common rail fuel injection system (CRI)
consists of more precise parts than the parts
used in the conventional fuel injection pump and
nozzle. In order to prevent foreign material from
entering this system, the filter employs a
specially high performance of filter element. If a
filter element other than the genuine one is used,
the fuel system may have a failure. Accordingly,
never use such a filter element.

00-24 PC138USLC-10
00 Index and foreword
Foreword, safety and general information

Handling of intake system parts (PC220-A900-2A4-K-00-A)

(Rev.2012/01)
• The Komatsu Variable Geometry Turbocharger
(KVGT) consists of more precise parts (variable
mechanism) than the parts used in the
conventional turbocharger. If foreign material
enters this system, it may cause a failure. Use
special care to prevent entry of the foreign
material when servicing the air intake system.

Be careful of working environment


• Avoid the repair work of the machine in rain or
strong wind or at the places where there is a lot
of dust.
Sealing openings
• Plug the pipes and the openings of the
components which are removed, with the caps,
tapes, vinyl bags, etc. to prevent foreign material
from entering. Never perform repair works under
the condition that the openings are left open or
plugged with rag since foreign material may
enter.

PC138USLC-10 00-25
00 Index and foreword
Foreword, safety and general information

Handling of hydraulic equipment (ALL-C000-2A4-P-01-A)

(Rev. 2012/10)
• With the increase in pressure and precision of the hydraulic components, the most common cause of a
failure is dirt (foreign material) in the hydraulic circuit. Therefore, the special care must be taken when
adding hydraulic oil,or when disassembling or assembling the hydraulic components.

Be careful of working environment


• Avoid adding hydraulic oil, replacing filters, or
repairing the machine in rain or high winds, or at
places where there is a lot of dust.

Disassembly and maintenance work in the field


• When disassembly or maintenance work of the
hydraulic is performed in the field, there is
danger of dust entering the components. It is
also difficult to check the performance of the
components after repairs, so it is desirable to
use the component exchange service. The
disassembly and assembly of the hydraulic
components must be performed in the specially
arranged dustproof workshop and the Preventing intrusion of foreign materials during
performance test of the components must be refilling operations.
performed with the special testing equipment. • Care must be taken when adding hydraulic oil so
that foreign material does not enter. Keep the oil
filler port and the area around it, oil supply pump
and oil container clean. If an oil cleaning device
is used, it is possible to remove the dirt that is
collected during storage. It is a surer means.

Plugging of opening (prevention of flowing out


of oil)
• Plug the pipes and the openings of the
components which are removed (when plugs
are not prepared, seal with caps, tapes, vinyl
bags, etc.) to prevent entry of foreign material Replacing hydraulic oil while its temperature is
and flowing out of oil. Never leave the openings high
• When the hydraulic oil is warm, it flows easily. In
of the pipes and hoses without being covered or
addition, sludge can also be drained from the
plugged with cloth as foreign material may enter
them or environment may be polluted by the oil circuit together with the oil. So, it is better to
leaked. Do not discard the waste oil somewhere change the hydraulic oil while it is warm. When
or other. Hand it over to your customer for changing the hydraulic oil, the old oil must be
disposal, or dispose it by yourself. drained as much as possible. (Drain the oil not
only from the hydraulic tank, but also from the
filter housing and the drain plug hole in the
circuit.) If the old oil is left in the system, the
contaminant and sludge in the oil mix with the
new oil and shorten the life of the new hydraulic
oil.

00-26 PC138USLC-10
00 Index and foreword
Foreword, safety and general information

Flushing operations
• After disassembling the equipment or when
changing the hydraulic oil with new one, flush
the system to remove the contaminant and
sludge left in the hydraulic circuit as well as the
oil which includes them. Normally, flushing is
performed twice. Primary flushing is performed
by use of the flushing oil and the secondary
flushing is performed by use of the specified
hydraulic oil.

Cleaning operations
• After repairing the hydraulic equipment (pump,
control valve, etc.) or when the machine is in
operation, perform oil cleaning to remove the
sludge or contaminant in the hydraulic oil circuit.
The oil cleaning equipment can remove the ultra
fine (approximately 3 μm) particles that the filter
built in the hydraulic equipment can not remove.
So, it is an extremely effective device.

PC138USLC-10 00-27
00 Index and foreword
Foreword, safety and general information

Method of disconnecting and connecting of push-pull type coupler (ALL-


C930-001-P-00-A)
(Rev. 2012/01)

k Loosen the oil filler cap of the hydraulic tank slowly to release the remaining pressure in the
hydraulic tank.

k Even if the remaining pressure is released from the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly, prepare an oil container.

Type 1 (ALL-C930-925-P-01-A)

Disconnection Connection
1. Hold adapter (1) and push hose joint (2) into 1. Hold hose adapter (1) or hose (5) and insert it in
mating adapter (3). (Fig. 1) mating adapter (3) aligning them with each other.
(Fig. 4)
a It can be pushed in by approximately 3.5mm.
a Do not hold rubber cap part (4).
a Do not hold rubber cap portion (4).
2. After inserting the hose fitting in the adapter on
2. While pushing hose joint (2) into adapter (3),
the other side perfectly, pull it back to check the
push rubber cap (4) against adapter (3) until
connecting condition. (Fig. 4)
"click" is heard. (Fig. 2)
3. Hold hose adapter (1) or hose (5) and pull it out. a When the hose fitting is pulled back, the
(Fig. 3) rubber cap will move toward the hose,
however, it is not a problem.
a Since some hydraulic oil flows out, prepare
an oil container.

00-28 PC138USLC-10
00 Index and foreword
Foreword, safety and general information

Type 2 (ALL-C930-925-P-02-A)

Disconnection Connection
1. While holding the fitting, push body (7) in straight 1. While holding the fitting, push body (7) in straight
until sliding prevention ring (6) hits contact until sliding prevention ring (6) hits contact
surface (a) at the hexagonal part on the male surface (a) at the hexagonal part on the male
side. (Fig. 6) side to connect it. (Fig. 9)
2. While keeping the condition of Step 1, turn lever
(8) to the right (clockwise). (Fig. 7)
3. While keeping the conditions of Steps 1 and 2,
pull out whole body (7) to disconnect it. (Fig. 8)

PC138USLC-10 00-29
00 Index and foreword
Foreword, safety and general information

Type 3 (ALL-C930-925-P-03-A)

Disconnection Connection
1. While holding the fitting, push body (9) in straight 1. While holding the fitting, push body (9) in straight
until sliding prevention ring (8) hits contact until sliding prevention ring (8) hits contact
surface (b) at the hexagonal portion on the male surface (a) at the hexagonal portion on the male
side. (Fig. 10) side to connect them. (Fig. 13)
2. While keeping the condition of Step 1, push
cover (10) straight until it hits contact surface (b)
of the hexagonal portion on the male side. (Fig.
11)
3. While keeping the conditions of Steps 1 and 2,
pull out whole body (9) to disconnect it. (Fig. 12)

00-30 PC138USLC-10
00 Index and foreword
Foreword, safety and general information

Handling of electrical equipment (ALL-E000-2A4-P-01-A)

(Rev. 2012/10)

• To maintain the performance of the machine over a long period, and to prevent failures or troubles before
they occur, correct "operation", "maintenance and inspection" "troubleshooting", and "repairs" must be
performed. This section deals particularly with correct repair procedures for mechatronics components
and is aimed at improving the quality of repairs. For this purpose, it describes the working procedures in
"Handling of electrical equipment".

Precautions for handling electric equipment

Handling wiring harnesses and connectors


• Wiring harnesses consist of wires connecting
one component to another component,
connectors used for connecting and
disconnecting one wire from another wire, and
protectors or tubes used for protecting the wires.
• Compared with other electrical components
fitted in boxes or cases, wiring harnesses are
more likely to be affected by the direct effects of
rain water, heat, or vibration. Furthermore,
during inspection and repair operations, they are
frequently removed and installed again, so they Defective crimping or soldering of connectors
are likely to suffer deformation or damage. For
this reason, it is necessary to be extremely • The pins of the male and female connectors are
careful when handling the wiring harnesses. attached to wires by crimping or soldering. If
excessive force is applied to the wire, the joining
area may become loose, which may result in a
defective connection or breakage.

Main failures occurring in wiring harness


Defective contact of connectors (defective
contact between male and female connectors) Disconnections in wiring
• Problems with defective contact are likely to • If the wiring harness is pulled to disconnect the
occur because the male connector is not connector, or the components are lifted with a
properly inserted into the female connector,or crane while the wiring harness is still connected,
because one or both of connectors are or a heavy object hits the wiring harness, the
deformed or the position is not correctly aligned, crimping of the connector may separate, or the
or because there is corrosion or oxidization of soldering may be damaged, or the wiring
the contact surfaces. The corroded or oxidized harness may be broken.
contact surfaces may become shiny again (and
contact may become normal) by connecting and
disconnecting the connectors approximately 10
times.

PC138USLC-10 00-31
00 Index and foreword
Foreword, safety and general information

blow it with compressed air and spray it with


electrical contact restorer.
a When wiping the joint portion of the
connector, be careful not to apply excessive
force or deform the pins.
a If there is oil or water in the compressed air, it
causes the contacts to become dirtier. So,
remove the oil and water from the
compressed air completely before cleaning
the connector with the compressed air.

High-pressure water entering connector


• The connector is designed to make it difficult for
water to enter (drip-proof structure), but if high-
pressure water is sprayed directly on the
connector, water may enter the connector,
depending on the direction of the water jet.
Accordingly, take care not to spray water over
the connector.
The connector is designed to prevent water from
entering, but once water does enter, it is difficult
to drain it. If water should get into the connector,
the pins will be short-circuited by the water. So if
any water gets in, immediately dry the connector Removing, installing, and drying connectors
and wiring harnesses
or take other appropriate action before passing
Disconnecting connectors
electricity through it.
1. Hold the connectors when disconnecting.
• Disconnect connectors by holding the
connector bodies. For the connectors held by
a screw, loosen the screw fully, then hold the
male and female connectors with each hand
respectively and pull them apart horizontally.
For the connectors with lock stopper, press
down the stopper with your thumb and pull
the connectors apart.
a Never pull the connector with one hand.

Entry of water, mud or dirt when disconnecting a


connector
• If any water, mud or dirt is stuck to the outside
surface of a connector, it can enter inside the
connector when the connector is disconnected.
Before disconnecting the connector, wipe off any
stuck water or dirt by using a piece of dry cloth
or blow it with compressed air.
Oil, mud or dirt stuck to connector
• If any oil or grease is stuck to the connector and
an oil film is formed on the mating surface of the 2. When removing from clips
male and female pins, the oil prevents electricity • Both of the connector and clip have stoppers,
from passing through, resulting in defective which are engaged with each other when the
contact. If any oil or grease, mud or dirt is stuck connector is connected.
to the connector, wipe it off with a dry cloth or

00-32 PC138USLC-10
00 Index and foreword
Foreword, safety and general information

• Check that there is no oil, dirt or water stick


to the connector pins (joint portion).
• Check that the connector pins are free from
deformation, defective contact, corrosion, or
damage.
• Check that external surfaces of the
connectors are free from damage or
breakage.
a If any oil, water or dirt is stuck to the
connector, wipe it off with a dry cloth. If any
water is inside the connector, warm the
connector and the inside of the wiring
• When removing a connector from a clip, pull harness with a dryer. But be careful not to
the connector in a parallel direction to the clip make it too hot as it causes short circuit.
for removing stoppers. a If there is any damage or breakage, replace
a If the connector is pried up and down or the connector.
to the right and left, the housing may 2. Fix the connector securely.
break. • Align the connectors correctly, and fit them
securely. For the connectors with the lock
stopper, push in the connectors until "click" is
heard.

3. Action to take after removing connectors


• After removing the connector, cover it with
the vinyl bag to prevent entry of dust, dirt,oil
or water in the contact portion. 3. Correct the protrusion of the boot and
misalignment of the wiring harness
a If the machine is left disassembled for a • For connectors fitted with the boot, correct
long time, it is particularly easy for any extrusion of the boot. In addition, if the
improper contact to occur, so always wiring harness or the clamp is out of the
cover the connector. position, put it in its original position.
a If the connector cannot be corrected
easily, remove the clamp and adjust the
position.

Connecting connectors
1. Check the connector visually.

PC138USLC-10 00-33
00 Index and foreword
Foreword, safety and general information

• If the connector clamp is removed, be sure to Drying wiring harness


return it to its original position. And check • If there is any oil or dirt on the wiring harness,
that it is securely installed. wipe it off with a dry cloth. Avoid washing by
using steam. If the wire harness must be
washed in water, do not apply high pressure
water or steam directly to the wiring harness. If
water gets directly on the connector, do as
follows.
1. Disconnect the connector and wipe off the water
with a dry cloth.
a If the connector is to be blown with dry
compressed air, there is a risk that oil in the
air may cause defective contact of the
conditioner, remove oil and water in the air
before starting air blow.
Handling of Deutsch connector (DT8-pin, DT12-
pin)
Disconnection
1. While pressing locks (a) and (b) from each side
respectively, pull out female connector (2).

2. Dry the inside of the connector with a dryer.


If water gets inside the connector, use a dryer to
dry the connector.
a Hot air from the dryer can be used, but
regulate the time to use hot air in order to
prevent the connector or related parts from
Connection becoming too hot, as it causes deformation
1. Push in female connector (2) horizontally until or damage to the connector.
the lock clicks. (Arrow: x)
2. Since locks (a) and (b) may not be set
completely, push in female connector (2) with
curving movement until the locks are set
normally. (Arrow: x, y, and z)
a Lock (a) in the figure is pulled down (not set
completely), and lock (b) is set completely.

3. Perform a continuity test on the connector.


After drying, leave the wiring harness
disconnected and perform a continuity test to
check for any short circuits between pins caused
by water.
a After the connector is completely dried, blow
the contact restorer and reassemble them.

00-34 PC138USLC-10
00 Index and foreword
Foreword, safety and general information

2. While pressing lock (L2), pull out connector (1).


Handling of connectors used on engine

Slide, lock type (Type 1) (FRAMATOME-3,


FRAMATOME-2)
Disconnection
1. Slide lock (L1) to the right.
2. While pressing lock (L2), pull out connector (1)
toward you.
a In the case that even if lock (L2) is pressed,
connector (1) cannot be pulled out toward
you unless part A floats, float part A with a
small flat-head screwdriver while pressing
lock (L2), and then pull out connector (1)
toward you.
a Lock (L2) is located in the back of connector
(1).

Connection
1. Insert the connector securely until a click is
heard. Connection
1. Insert the connector securely until a click is
Slide, lock type (Type 2) (FRAMATOME-24) heard.
Disconnection
1. Slide down lock (red) (L1). Pull lock type (PACKARD-2)
Disconnection
1. Disconnect the connector (2) by pulling lock (B)
(on the wiring harness side) of connector (2)
outward.

PC138USLC-10 00-35
00 Index and foreword
Foreword, safety and general information

Connection Connection
1. Insert the connector securely until a click is 1. Insert the connector securely until a click is
heard. heard.
Push lock type (1) (BOSCH-3) Push lock type (2) (SUMITOMO-4)
Disconnection Disconnection
1. While pressing lock (C), pull out connector (3) in 1. While pressing lock (C), pull out connector (4) in
the direction of the arrow. the direction of the arrow.
• 114 series Connection
1. Insert the connector securely until a click is
heard.

• 107 series

Push lock type (3) (AMP-3)


Disconnection
1. While pressing lock (E), pull out connector (5) in
the direction of the arrow.
Example) Fuel pressure sensor in common rail:
PFUEL etc (AMP-3)

a If the lock is located on the underside, use


flat-head screwdriver [1] since you cannot
insert your fingers.
While pushing up lock (C) of the connector
with flat-head screwdriver [1], pull out
connector (3) in the direction of the arrow.

00-36 PC138USLC-10
00 Index and foreword
Foreword, safety and general information

Example) Injection pressure control valve of


supply pump: PCV (SUMITOMO-2)

Connection
1. Insert the connector to the end while aligning its
Example) Speed sensor of supply pump: G grove to the other.
(SUMITOMO-3) 2. Turn housing (H1) in the direction of the arrow
until it "clicks".
a Pull the connector straight up.

Connection Handling controller


• The electronic circuits for control including the
1. Insert the connector securely until a click is
microcomputers are assembled in the controller.
heard.
These electronic circuits in the controller must
Turn-housing type (Round green connector) be handled with care as they control the
(CANNON-4) machine.
Disconnection • Do not place objects on top of the controller.
1. Turn housing (H1) in the direction of the arrow.
a Unlock the connector by turning housing (H1).
When the lock is release the housing is felt
tight to turn.
2. Pull out housing (H1) in the direction of the
arrow.
a Housing (H1) is left on the wiring harness
side.

• Cover the control connectors with tape or a vinyl


bag. Never touch the connector contacts.
• During rainy weather, do not leave the controller
in a place where it is exposed to rain.
• Do not place the controller on oil, water, or soil,
or in a place that can be heated to a high

PC138USLC-10 00-37
00 Index and foreword
Foreword, safety and general information

temperature even for a short period of time.


(Place it on a suitable dry stand.)

• Precautions when performing arc welding


When performing arc welding on the machine
body, disconnect all the wiring harness
connectors connected to the controller. Put the
arc welding ground to the place close to the
welding point.

Precautions for troubleshooting electrical


circuits
• Be sure to turn the starting switch to the "OFF"
position before disconnecting or connecting the
connectors.
• Before performing troubleshooting, check all the
related connectors for loose connection.
a Check the related connectors for their
performance by disconnecting and
connecting them several times.
• Be sure to connect all the disconnected
connectors before proceeding to the next step.
a If the starting switch is turned to the "ON"
position with the connectors disconnected,
the failure which is not related to the part
which is actually failed.
• When performing the troubleshooting for the
circuit (measurement of voltage, resistance,
continuity, current, etc.), shake the related wiring
harnesses and connectors several times and
check that the multimeter reading does not
change.
a If there is any value change on the
multimeter, there may be a defective contact
in the circuit.

00-38 PC138USLC-10
00 Index and foreword
Foreword, safety and general information

How to read electric wire code (ALL-E500-030-P-00-A)


(Rev. 2012/10)
• In the electrical circuit diagram, material, thickness and color of each electric wire are indicated by
symbols. The wire code is helpful in understanding the electrical circuit diagram.
Example) AEX 0.85 L: Indicates blue, heat-resistant, low-voltage wire for automobile, having nominal No. of
0.85
Indicates type of wire by symbol.
Type, symbol, and material of wire are shown in Table 1.
AEX
(Since the use of AV and AVS wires depends on size (nominal No.), their symbols are not
indicated on the diagram.)
Indicates size of wire by nominal No.
0.85
Size (Nominal No.) is shown in Table 2.
Indicates color of wire by color code.
L
Color codes are shown in Table 3.

Type, symbol, and material


• AV and AVS are different in thickness and outside diameter of the coating. CAVC has a circular
compressed conductor. It differs from AV and AVS in the outside diameter of conductor and thickness of
the coating. And AEX is similar to AV in thickness and outside diameter of the coating but different from AV
and AVS in material of the coating.
(Table 1)
Temperature
Type Sym- Conductor Example of use
Insulator material range (°C) in
bol material
use
Low-voltage For large current wiring
wire for AV
automobile (nominal No. 5 and above)
Thin-cover
low-voltage
General wiring
wire for AVS
automobile (nominal No. 3 and lower)
Soft polyvinyl chloride -30 to +60
(Type 1) Annealed
Thin-cover copper for
low-voltage electric For mid- to small-size
wire for CAVS appliance excavators
automobile (nominal No. 1.25 and lower)
(Type 2)
Heat- General wiring for extremely
resistant low- Heat-resistant cross cold weather specification
voltage wire AEX linked polyethylene -50 to +110
for Wiring at high ambient
automobile temperature place

PC138USLC-10 00-39
00 Index and foreword
Foreword, safety and general information

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/ 20/ 30/ 11/ 50/ 16/ 37/ 26/ 58/ 41/ 65/
7/0.32
Diameter of 0.18 0.18 0.32 0.18 0.32 0.26 0.32 0.26 0.32 0.32
strand
Conductor Cross-
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 —
Coating D

AV Standard — — — — — — — 4.6
AEX Standard 2.0 2.2 2.7 3.0 3.1 — 3.8 4.6

Nominal No. 8 15 20 30 40 50 60 85 100


Number of
strands/ 108/ 127/ 169/ 217/
50/0.45 84/0.45 41/0.80 70/0.80 85/0.80
Diameter of 0.80 0.80 0.80 0.80
strand
Conductor Cross-
sectional 7.95 13.36 20.61 35.19 42.73 54.29 63.84 84.96 109.1
area (mm2)
d (approx.) 3.7 4.8 6.0 8.0 8.6 9.8 10.4 12.0 13.6
AVS Standard — — — — — — — — —
Coating D

AV Standard 5.5 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
AEX Standard 5.3 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6

Nominal No. 0.5f 0.5 0.75f 0.85 1.25f 1.25


Number of
strands/ 7/round 11/round 16/round
— — —
Diameter of compression compression compression
strand
Conductor Cross-
sectional — 0.56 — 0.88 — 1.29
area (mm2)
d (approx.) — 0.9 — 1.1 — 1.4
Coating D

CAVS Standard — 1.6 — 1.8 — 2.1

a "f" of nominal No. denotes "flexible".

00-40 PC138USLC-10
00 Index and foreword
Foreword, safety and general information

Color codes table


(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

a 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.
Examples)
GW means that the background is "Green" and marking is "White".

Types of circuits and color codes


Type of wire AVS, AV, CAVS 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 — — — — — — —

PC138USLC-10 00-41
00 Index and foreword
Foreword, safety and general information

Precautions when performing operation (ALL-1160-927-A-00-A)

(Rev. 2012/10)
• When performing "testing and adjusting" of the machine, "removal and installation" and "disassembly and
assembly" of the components, observe the following general cautions.

Precautions for removal and disassembly work


• If the coolant contains antifreeze, dispose of it correctly as chemicals. Do not drain the coolant to the
sewage rashly.
• After disconnecting the hoses or tubes, plug them to prevent dirt or dust from entering.
• When draining oil, prepare a container with sufficient capacity.
• Check the match marks which indicate the installing position, and put match marks on the places where
they seem necessary before removal of the components to prevent any mistake when assembling.
• To prevent any excessive force from being applied to the wiring, always hold the connectors when
disconnecting the connectors. Do not pull the wires.
• Attach the tags to wires and hoses to show their installing positions to prevent any mistake when
installing.
• Check the number and thickness of the shims, and keep them in a safe place.
• When hoisting the components, prepare the slings with sufficient strength.
• When using forcing screws to remove any component, tighten the forcing screws uniformly and
alternately.
• Before removing any component, clean the surrounding area and cover the component to prevent any
foreign material from entering after removal.
• After disconnecting the piping or removing a pipe joint, install the following plugs.
a The O-rings in the table are emergency parts used for disassembly or transportation of the machine.
When assembling, confirm the part numbers in the parts book and use the parts conforming to the
using condition.
Disconnection of face seal type hoses and tubes

Hose side Pipe joint side


Nominal No. O-ring (3)
Plug (1) Nut (2)
02 07376-70210 02789-00210 02896-11008
03 07376-70315 02789-00315 02896-11009
04 07376-70422 02789-00422 02896-11012
05 07376-70522 02789-00522 02896-11015
06 07376-70628 02789-00628 02896-11018

00-42 PC138USLC-10
00 Index and foreword
Foreword, safety and general information

Disconnection of taper seal type hoses and tubes

Hose side Pipe joint side


Nominal No.
Plug (1) Nut (2)
02 07376-50210 07222-00210
03 07376-50315 07222-00312
04 07376-50422 07222-00414
05 07376-50522 07222-00515
06 07376-50628 07222-00616
10 07376-51034 07222-01018
12 07376-51234 07222-01219
14 07376-51443 07222-01422

Disconnection of split flange type hoses and tubes

No- Bolt pitch (mm) Hose side Tube side


minal Split flange Sleeve head O-ring (4) Bolt (5) Washer (6)
a b Flange (1)
No. (2) (3)
07379- 01010-
04 38.1 17.5 07371-30400 07378-10400 07000-12021 01643-50823
00400 80825
07379- 01010-
05 42.9 19.8 07371-30500 07378-10500 07000-13022 01643-50823
00500 80830
07379- 07372-
06 47.6 22.2 07371-30640 07378-10600 07000-13025 01643-51032
00640 51035
07379- 07372-
10 52.4 26.2 07371-31049 07378-11000 07000-13032 01643-51032
01044 51035
07379- 07372-
58.7 30.2 07371-31255 07378-11200 07000-13038 01643-51032
01250 51035
12
07379- 01010-
66.7 31.8 07371-51260 07378-11210 07000-13038 01643-51232
01260 81245
07379- 07372-
14 69.9 35.8 07371-31465 07378-11400 07000-13048 01643-51232
01460 51240

PC138USLC-10 00-43
00 Index and foreword
Foreword, safety and general information

No- Bolt pitch (mm) Hose side Tube side


minal Split flange Sleeve head O-ring (4) Bolt (5) Washer (6)
a b Flange (1)
No. (2) (3)
07379- 01010-
79.4 36.5 07371-51470 07378-11410 07000-13048 01643-31445
01470 81455
07379- 07372-
77.8 42.8 07371-32076 07378-12000 07000-12060 01643-51232
02071 51240
20
07379- 01010-
96.8 44.5 07371-52080 07378-12010 07000-12060 01643-31845
02080 81865
07379- 07372-
24 88.9 50.8 07371-12484 07378-12400 07000-12070 01643-51232
02484 51240
07379- 07372-
30 106.4 62 07371-13010 07378-13000 07000-12085 01643-51645
03010 51650
07372-
34 120.6 69.8 07379-03411 07371-13411 07378-13400 07000-12100 01643-51645
51650
07379- 07372-
40 130.2 77.8 07371-14012 07378-14000 07000-12110 01643-51645
04012 51650
07372-
50 152.4 92 07379-05011 07371-15011 07378-15000 07000-12135 01643-51645
51655

Removal of pipe joints of O-ring boss type

Nominal No. Plug (1) O-ring (2)


08 07040-10807 07002-10823
10 07040-11007 07002-11023
12 07040-11209 07002-11223
14 07040-11409 07002-11423
16 07040-11612 07002-11623
18 07040-11812 07002-11823
20 07040-12012 07002-12034
24 07040-12412 07002-12434
30 07041-13012 07002-13034
33 07040-13316 07002-13334
36 07041-13612 07002-13634
42 07040-14220 07002-14234
52 07040-15223 07002-15234

Removal of pipe joints of taper pipe thread type

00-44 PC138USLC-10
00 Index and foreword
Foreword, safety and general information

Nominal Plug (1)


Nominal No.
thread size Square head type (A) Hexagonal socket head (B)
01 R 1/ 8 07042-00108 07043-00108
02 R 1/ 4 07042-00211 07043-00211
03 R 3/ 8 07042-00312 07043-00312
04 R 1/ 2 07042-00415 07043-00415
06 R 3/ 4 07042-00617 07043-00617
10 R1 07042-01019 07043-01019
12 R1 1/4 07042-01222 07043-01222
14 R1 1/2 07042-01422 07043-01422
20 R2 07042-02026 07043-02026

Precautions for installation and assembly work


• Tighten the bolts and nuts (sleeve nuts) to the specified torque (KES), unless otherwise specified.
• Install the hoses without twist and interference, and securely fasten the clamps located in-between if they
are.
• Replace all of the gaskets, O-rings, cotter pins, and lock plates with new parts.
• Bend the cotter pins and lock plates securely.
• When applying adhesive, clean and degrease the part, and apply 2 to 3 drops of adhesive to the threaded
portion.
• When applying liquid gasket, clean and degrease the surface, and apply it uniformly after making sure that
the surface is free from dirt or damage.
• Clean all of the parts, and repair any damage, dents, burrs, or rust found on them.
• Coat the rotating parts and sliding parts with engine oil.
• Coat the surfaces of the press-fitting parts with molybdenum disulfide lubricant (LM-P).
• After installing the snap ring, check that the snap ring is settled in the ring groove completely.
• When connecting wiring harness connectors, clean the connectors to remove oil, dirt, or water, then
connect them securely.
• Use the eye bolts with no fatigue and deformation and screw them in securely. Match the directions of the
eyes and the hook.
• When installing split flanges, tighten the bolts uniformly and alternately to prevent excessive tightening on
one side.
• As a rule, apply liquid gasket (LG-5) or liquid sealant (LS-2) to the threaded portion of each taper male
screws which receives pressure.
However, if the threaded portion is difficult to degrease, you may use a seal tape.
• When winding a seal tape onto a right-handed taper male screw, wind it clockwise in the advancing
direction of the threads, seeing from the screw end and starting at the third thread.
a If you wind the seal tape in the opposite direction, it becomes loose and comes off or its end part is
pushed out, and that can cause oil leakage.

PC138USLC-10 00-45
00 Index and foreword
Foreword, safety and general information

a When the hydraulic cylinder is used for the first time after reassembly of the hydraulic equipment such as
the hydraulic cylinder, pump, etc. and piping after removing them for repair, be sure to perform air bleeding
of the hydraulic circuit according to the following procedure.
1. Start and run the engine at low idle.
2. Repeat the operation to extend and retract each cylinder of the work equipment to approximately 100
mm before the stroke end four to five times.
3. Operate the hydraulic cylinder 3 to 4 times to the end of its stroke.
a After the completion of repair and when operating the machine which is stored long term, perform the air
bleeding with the same procedure as the one described above.

Precautions at the time of completing work


Refilling of coolant, oil and grease
• When the coolant is drained, tighten the drain valve securely, then refill the coolant reservoir with the
coolant Komatsu recommends to the specified level. Start the engine to circulate the coolant in the piping,
and add the coolant to the specified level again.
• When the hydraulic components are removed and installed, refill the oil reservoir with the oil Komatsu
recommends to the specified level. Start the engine to circulate the oil in the piping, and add the oil to the
specified level again.
• If the hydraulic piping or hydraulic equipment is removed, be sure to bleed air from the system after
rebuilding the parts, by referring to "Testing and adjusting".
• Supply the specified amount of grease to the work equipment parts.
Testing installed condition of cylinder heads and manifolds
• Check the cylinder head and intake and exhaust manifold mountings for looseness.
• If any bolt is loose, retighten it.
a For the tightening torques, see the "Disassembly and assembly".
Testing of engine piping for damage and looseness
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints
Intake and exhaust for air suction and exhaust gas leakage.
system
If any part is loosely installed or damaged, retighten the bolts or repair the parts.
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints
Cooling system for water leakage.
If any part is loosely installed or damaged, retighten the bolts or repair the parts.
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints
Fuel system for fuel leakage.
If any part is loosely installed or damaged, retighten the bolts or repair the parts.
Check of KDPF or muffler and exhaust pipe for damage and looseness
• Visually check the KDPF or muffler, exhaust pipe and their mounting parts for a crack and damage. If any
part is damaged, replace it.
• Check the mounting bolts, nuts, and clamps of the KDPF or muffler, exhaust pipe and their mounting parts
for looseness.
If any part is loosely installed, retighten the bolts.
Check of KDPF or muffler function
• Check the KDPF or the muffler for unusual noise comparing to the noise when they are new.
If any unusual noise is heard, repair KDPF or muffler, referring to "Troubleshooting" and "Disassembly and
assembly".

00-46 PC138USLC-10
00 Index and foreword
Foreword, safety and general information

Practical use of KOMTRAX (ALL-Q210-13V-K-00-A)


(Rev. 2012/10)
KOMTRAX system transmits various machine information by use of the radio communication and KOMTRAX
operator can refer this information in the office and provide various services to the customers.
When KOMTRAX is installed on the machine, the machine information can be checked through the
KOMTRAX system and the testing and troubleshooting can be performed efficiently.
(KOMTRAX may not be installed on the machine in some countries or areas.)

Merit of using KOMTRAX


• The working place of the machine can be checked in the map on PC.
• Operation information such as service meter reading, operating hours, fuel consumption, occurred caution
and failure code can be checked.
• The hours used and replacement time of consumable parts of the machine such as fuel filter, hydraulic oil
filter, hydraulic oil and engine oil can be checked.
• The information of machine working condition (idling time, traveling time, digging time, relieving time, etc.)
can be checked and the machine operating condition can be presumed with these information.
• Various reports such as "Fuel saving operation support", "Summary of operation", etc. can be generated
and utilized as an advice tool for the user and operator.

How to use KOMTRAX practically


With KOMTRAX, following support activities will be available.
1. Quick response to sudden request of repair
1) When receiving a repair request from a user, check the displayed caution and failure code, etc. through
KOMTRAX.
2) Arrange the necessary tools, replacement parts, etc, immediately in accordance with the displayed
failure code.
3) By using the map of KOMTRAX, find the location of the failed machine and visit the customer there.
2. Proactive maintenance
1) Check the service summary screen of KOMTRAX, and find the machine which has high priority failure
code indicated by a red or yellow flag.
2) Check the condition of the machine with the customer and make a plan to visit.
3) Arrange necessary tools, replacement parts, etc, immediately in accordance with the displayed failure
code.
3. Practice of periodic maintenance and periodic inspection service
1) Check the service summary screen of KOMTRAX, and find the machine of which the usage limits for
the consumable parts indicated by red flags are over.
2) Submit an estimate sheet for the consumable parts to be replaced and the labor cost for the
replacement work to the customer.
3) Propose the periodic inspection (PM clinic, etc.) according to the service meter reading.

How to operate KOMTRAX


For the operating method of each screen of KOMTRAX, see "KOMTRAX basic operation manual".

PC138USLC-10 00-47
00 Index and foreword
Foreword, safety and general information

Standard tightening torque table (ALL-M140-03B-P-01-A)

(Rev. 2012/10)

Table of tightening torque for bolts and nuts


Unless otherwise specified, tighten the metric bolts and nuts to the torque shown in the table below.

Thread diameter Width across flats


Tightening torque (Nm {kgm})
(mm) (mm)
10
6 11.8 to 14.7 {1.2 to 1.5}
(*2) 10
13
8 27 to 34 {2.8 to 3.5}
(*2) 12
17
10 59 to 74 {6.0 to 7.5}
(*1, *2) 14
19
12 98 to 123 {10.0 to 12.5}
(*1, *2) 17
14 22 157 to 196 {16 to 20}
24
16 245 to 309 {25 to 31.5}
(*1) 22
18 27 343 to 427 {35 to 43.5}
20 30 490 to 608 {50 to 62}
22 32 662 to 829 {67.5 to 84.5}
24 36 824 to 1,030 {84 to 105}
27 41 1,180 to 1,470 {120 to 150}
30 46 1,520 to 1,910 {155 to 195}
33 50 1,960 to 2,450 {200 to 250}
36 55 2,450 to 3,040 {250 to 310}
39 60 2,890 to 3,630 {295 to 370}
*1: Split flange bolt.
*2: Flanged bolt.

00-48 PC138USLC-10
00 Index and foreword
Foreword, safety and general information

a Tighten the following flanged bolt on which “7“ is stamped on its top to the tightening torque shown in the
following table.

Thread diameter Width across flats


Tightening torque (Nm {kgm})
(mm) (mm)
6 10 5.9 to 9.8 {0.6 to 1.0}
8 12 13.7 to 23.5 {1.4 to 2.4}
10 14 34.3 to 46.1 {3.5 to 4.7}
12 17 74.5 to 90.2 {7.6 to 9.2}

Unless otherwise specified, tighten the unified coarse threaded bolts and nuts to the torque shown in the table
below.

Type of bolt A B
Nominal No. - Tightening torque (Nm {kgm}) Tightening torque (Nm {kgm})
threads per inch,
type of thread Range Target Range Target
1/4-20UNC 9.8 to 14.7 {1 to 1.5} 12.7 {1.3} 2.9 to 3.9 {0.3 to 0.4} 3.43 {0.35}
5/16-18UNC 24.5 to 34.3 {2.5 to 3.5} 29.4 {3} 6.9 to 8.8 {0.7 to 0.9} 7.8 {0.8}
3/8-16UNC 44.1 to 58.8 {4.5 to 6} 52.0 {5.3} 9.8 to 14.7 {1 to 1.5} 11.8 {1.2}
7/16-14UNC 73.5 to 98.1 {7.5 to 10} 86.3 {8.8} 19.6 to 24.5 {2 to 2.5} 21.6 {2.2}
1/2-13UNC 108 to 147 {11 to 15} 127 {13} 29.4 to 39.2 {3 to 4} 34.3 {3.5}
9/16-12UNC 157 to 216 {16 to 22} 186 {19} 44.1 to 58.8 {4.5 to 6} 51.0 {5.2}
5/8-11UNC 226 to 294 {23 to 30} 265 {27} 63.7 to 83.4 {6.5 to 8.5} 68.6 {7}
3/4-10UNC 392 to 530 {40 to 54} 461 {47} 108 to 147 {11 to 15} 127 {13}
7/8-9UNC 637 to 853 {65 to 87} 745 {76} 177 to 235 {18 to 24} 206 {21}
1-8UNC 883 to 1,196 {90 to 122} 1,040 {106} 245 to 333 {25 to 34} 284 {29}
1 1/8-7UNC 1,187 to 1,608 {121 to 164} 1,393 {142} 333 to 451 {34 to 46} 392 {40}
1 1/4-7UNC 1,598 to 2,157 {163 to 220} 1,873 {191} 451 to 608 {46 to 62} 530 {54}
1 1/2-6UNC 2,354 to 3,177 {240 to 324} 2,765 {282} 657 to 892 {67 to 91} 775 {79}

PC138USLC-10 00-49
00 Index and foreword
Foreword, safety and general information

Unless otherwise specified, tighten the unified fine threaded bolts and nuts to the torque shown in the table
below.

Type of bolt A B
Nominal No. - Tightening torque (Nm {kgm}) Tightening torque (Nm {kgm})
threads per inch,
type of thread Range Target Range Target
1/4-28UNF 14.7 to 19.6 {1.5 to 2} 17.7 {1.8} 3.9 to 4.9 {0.4 to 0.5} 4.41 {0.45}
5/16-24UNF 34.3 to 39.2 {3.5 to 4} 37.3 {3.8} 7.8 to 9.8 {0.8 to 1} 8.8 {0.9}
3/8-24UNF 53.9 to 68.6 {5.5 to 7} 61.8 {6.3} 14.7 to 19.6 {1.5 to 2} 16.7 {1.7}
7/16-20UNF 83.4 to 108 {8.5 to 11} 96.1 {9.8} 24.5 to 29.4 {2.5 to 3} 26.5 {2.7}
1/2-20UNF 127 to 167 {13 to 17} 147 {15} 34.3 to 49.0 {3.5 to 5} 41.2 {4.2}
9/16-18UNF 186 to 245 {19 to 25} 216 {22} 49.0 to 68.6 {5 to 7} 58.6 {6}
5/8-18UNF 255 to 343 {26 to 35} 294 {30} 73.5 to 98.1 {7.5 to 10} 83.4 {8.5}
3/4-16UNF 441 to 598 {45 to 61} 520 {53} 127 to 167 {13 to 17} 147 {15}
7/8-14UNF 716 to 961 {73 to 98} 843 {86} 196 to 265 {20 to 27} 226 {23}
1-14UNF 1,020 to 1,373 {104 to 140} 1,196 {122} 284 to 382 {29 to 39} 333 {34}
1 1/8-12UNF 1,353 to 1,844 {138 to 188} 1,598 {163} 382 to 520 {39 to 53} 451 {46}
1 1/4-12UNF 1,804 to 2,432 {184 to 248} 2,118 {216} 510 to 686 {52 to 70} 598 {61}
1 1/2-12UNF 2,707 to 3,658 {276 to 373} 3,177 {324} 765 to 1,030 {78 to 105} 892 {91}

Table of tightening torque for O-ring boss piping joints


a Unless otherwise specified, tighten the pipe joint for O-ring boss to the torque shown in the table below.

Thread Width Tightening torque (Nm {kgm})


Nominal No. diameter across flats
(mm) (mm) Range Target
02 14 Varies 35 to 63 {3.5 to 6.5} 44 {4.5}
— 18 depending 59 to 98 {6.0 to 10.0} 78 {8.0}
03, 04 20 on type of 84 to 132 {8.5 to 13.5} 103 {10.5}
05, 06 24 connector. 128 to 186 {13.0 to 19.0} 157 {16.0}

00-50 PC138USLC-10
00 Index and foreword
Foreword, safety and general information

Thread Width Tightening torque (Nm {kgm})


Nominal No. diameter across flats
(mm) (mm) Range Target
10, 12 33 363 to 480 {37.0 to 49.0} 422 {43.0}
14 42 746 to 1,010 {76.0 to 103} 883 {90.0}

Table of tightening torque for O-ring boss plugs


a Unless otherwise specified, tighten the plug for O-ring boss to the torque shown in the table below.

Thread Width Tightening torque (Nm {kgm})


Nominal No. diameter across flats
(mm) (mm) Range Target
08 8 14 5.88 to 8.82 {0.6 to 0.9} 7.35 {0.75}
10 10 17 9.8 to 12.74 {1.0 to 1.3} 11.27 {1.15}
12 12 19 14.7 to 19.6 {1.5 to 2.0} 17.64 {1.8}
14 14 22 19.6 to 24.5 {2.0 to 2.5} 22.54 {2.3}
16 16 24 24.5 to 34.3 {2.5 to 3.5} 29.4 {3.0}
18 18 27 34.3 to 44.1 {3.5 to 4.5} 39.2 {4.0}
20 20 30 44.1 to 53.9 {4.5 to 5.5} 49.0 {5.0}
24 24 32 58.8 to 78.4 {6.0 to 8.0} 68.6 {7.0}
30 30 32 93.1 to 122.5 {9.5 to 12.5} 107.8 {11.0}
33 33 — 107.8 to 147.0 {11.0 to 15.0} 127.4 {13.0}
36 36 36 127.4 to 176.4 {13.0 to 18.0} 151.9 {15.5}
42 42 — 181.3 to 240.1 {18.5 to 24.5} 210.7 {21.5}
52 52 — 274.4 to 367.5 {28.0 to 37.5} 323.4 {33.0}

Table of tightening torque for hose (taper seal type and face seal type)
a Unless otherwise specified, tighten the hose fittings (taper seal type and face seal type) to the torque
shown in the table below.
a The table is applied to the threads coated with engine oil (wet threads)

PC138USLC-10 00-51
00 Index and foreword
Foreword, safety and general information

Tightening torque (Nm {kgm}) Taper seal Face seal


Width
Nominal across Nominal No. - Thread root
No. of flats Thread size threads per diameter
Range Target
hose (mm) (mm) inch, type of (mm)
thread (reference)
34 to 54 {3.5 to 5.5} 44 {4.5} — 9/16-18UN 14.3
02 19
34 to 63 {3.5 to 6.5} 44 {4.5} 14 — —
22 54 to 93 {5.5 to 9.5} 74 {7.5} — 11/16-16UN 17.5
03
24 59 to 98 {6.0 to 10.0} 78 {8.0} 18 — —
04 27 84 to 132 {8.5 to 13.5} 103 {10.5} 22 13 /16-16UN 20.6
05 32 128 to 186 {13.0 to 19.0} 157 {16.0} 24 1 -14UNS 25.4
06 36 177 to 245 {18.0 to 25.0} 216 {22.0} 30 1 3/16-12UN 30.2
(10) 41 177 to 245 {18.0 to 25.0} 216 {22.0} 33 — —
(12) 46 197 to 294 {20.0 to 30.0} 245 {25.0} 36 — —
(14) 55 246 to 343 {25.0 to 35.0} 294 {30.0} 42 — —

Table of tightening torque for face seal joints


a The tightening torque table below applies to the seal joint (sleeve nut type)
a The table is applied to the threads coated with engine oil (wet threads).

Tightening torque (Nm {kgm}) Face seal


Outer Width
diameter of across flats Nominal No. - Thread root
pipe (mm) (mm) Range Target threads per inch, diameter (mm)
type of thread (reference)
8 19 14 to 16 {1.4 to 1.6} 15 {1.5} 9/16-18UN 14.3
10 22 24 to 27 {2.4 to 2.7} 25.5 {2.6} 11/16-16UN 17.5
12 24 {27} 43 to 47 {4.4 to 4.8} 45 {4.6} 13/16-16UN 20.6
15 {16} 30 {32} 60 to 68 {6.1 to 6.8} 64 {6.5} 1 -14UNS 25.4
22 {20} 36 90 to 95 {9.2 to 9.7} 92.5 {9.4} 1 3/16-12UN 30.2
Reference: The face seal joint of the dimension in ( ) is also used, depending on the specification.

Tightening torque table for bolts and nuts on 102,107 and 114 series engines
a Unless otherwise specified, tighten the metric threads bolts and nuts used on the 102, 107 and 114 series
engines to the torques shown in the table below.
Thread diameter (mm) Tightening torque (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 —

00-52 PC138USLC-10
00 Index and foreword
Foreword, safety and general information

Tightening torque table for 102, 107, and 114 series engines (joint bolts)
a Unless otherwise specified, tighten the metric joint bolts used on the 102, 107, and 114 series engines to
the torque shown in the table below.

Thread diameter (mm) Tightening torque (Nm {kgm})


6 8 ± 2 {0.81 ± 0.20}
8 10 ± 2 {1.02 ± 0.20}
10 12 ± 2 {1.22 ± 0.20}
12 24 ± 4 {2.45 ± 0.41}
14 36 ± 5 {3.67 ± 0.51}

Tightening torque table for tapered screws on 102,107, and 114 series engines (National taper pipe
thread (NPT))
a Unless otherwise specified, tighten the National taper pipe threaded (NPT) screws used on the 102, 107,
and 114 series engines to the torques shown in the table below.
Material of female screw In cast iron or steel In aluminum
Nominal thread size Tightening torque (Nm {kgm}) Tightening torque (Nm {kgm})
1/16 15 ± 2 {1.53 ± 0.20} 5 ± 1 {0.51 ± 0.10}
1/ 8 20 ± 2 {2.04 ± 0.20 15 ± 2 {1.53 ± 0.20}
1/ 4 25 ± 3 {2.55 ± 0.31} 20 ± 2 {2.04 ± 0.20}
3/ 8 35 ± 4 {3.57 ± 0.41} 25 ± 3 {2.55 ± 0.31}
1/ 2 55 ± 6 {5.61 ± 0.61} 35 ± 4 {3.57 ± 0.41}
3/ 4 75 ± 8 {7.65 ± 0.82} 45 ± 5 {4.59 ± 0.51}

PC138USLC-10 00-53
00 Index and foreword
Foreword, safety and general information

List of abbreviation (ALL-0360-005-A-00-A)


(Rev. 2012/10)
• This list of abbreviations includes the abbreviations used in the text of the shop manual for parts,
components, and functions whose meaning is not immediately clear. The spelling is given in full with an
outline of the meaning.
• Abbreviations that are used in general society may not be included.
• Special abbreviations which appear infrequently are noted in the text (marked with a).
• This list of abbreviations consists of 2 parts. The first part is a list of the abbreviations used in the text of
the manual, and the second part is a list of the abbreviations used in the circuit diagrams.

List of abbreviations used in the shop manual


Purpose of use (major
Abbrevia- Actual word spelled applicable machine (*), or Explanation
tion out equipment/device)
Function with which when the tires skid
Anti-skid Brake Travel and brake (wheels stop rotating), the brakes are
ABS System released, and when the wheels start to rotate,
(HD, HM)
the brakes are applied again.
Automatic Idling
AISS Engine Automatic setting function of idle speed
Setting System
Function that a lever can perform the steering
Advanced Joystick Steering operations, shifting gear speed operation and
AJSS Steering System changing direction operation instead of a
(WA)
steering wheel.
Function that the retarder works automatically
Automatic Retarder Travel and brake with a certain braking force when the
ARAC
Accelerator Control (HD, HM) accelerator pedal is released while the
machine travels downhill.
Function that the retarder works automatically
with a certain braking force so that the
Automatic Retarder Travel and brake machine travels with the speed not exceeding
ARSC Speed Control (HD, HM) the speed set by the operator when the
accelerator pedal is released while the
machine travels downhill.
Function with which, when the rear wheels
Automatic Spin Travel and brake spin on soft ground surfaces, this function
ASR Regulator (HD, HM) automatically uses the optimum braking force
to drive both wheels.
A device that can be fixed onto a machine in
ATT Attachment Work equipment
order to enable it to do different jobs.
Brake Valve that bypasses part of the brake cooling
Brake cooling oil oil to reduce the load on the hydraulic pump
BCV
control valve (HD) when the retarder is not being used.
Controller Area Communication and One of communication standards that is used
CAN
Network electronic control in the network on the machine
Crankcase Depression Regulator valve that is installed to the KCCV
CDR Engine ventilator It is not used independently and
Regulator
described CDR valve.
System that can simultaneously actuate
Closed-center Load multiple actuators regardless of the load
CLSS Oil pressure
Sensing System (provides better combined operation
comparing to OLSS).
Function to maintain optimum fuel injection
amount and fuel injection timing by using
CRI Common Rail Injection Engine
engine controller to perform electronic control
of supply pump, common rail, and injector.
Electronic control device that uses the signals
Electronic Control from the sensors on the machine to indicate
ECM Electronic control system
Module the optimum actuation to the actuators .
(Same as ECU)

00-54 PC138USLC-10
00 Index and foreword
Foreword, safety and general information

Purpose of use (major


Abbrevia- Actual word spelled applicable machine (*), or Explanation
tion out equipment/device)
Transmission Proportional electromagnetic valve that
Electronic Control
ECMV gradually increases oil pressure to engage
Modulation Valve (D, HD, WA, etc.)
clutch and reduces transmission shock.
System that ensures smooth high-speed
Electronically Travel travel by using hydraulic spring effect of
ECSS Controlled Suspension
(WA) accumulator to absorb vibration of machine
System
during travel
Electronic control device that uses the signals
from the sensors on the machine to indicate
ECU Electronic Control Unit Electronic control system the optimum actuation to the actuators .
(Same as ECM)
Function to recirculate part of exhaust gas to
Exhaust Gas Engine combustion chamber in order to reduce
EGR
Recirculation combustion temperature and to control
emission of NOx.
Equipment System that allows data (filter, oil replacement
Management interval, malfunctions on machine, failure
EMMS Machine monitor
Monitoring System code, and failure history) from each sensor on
the machine to be checked on monitor.
Electromagnetic Electromagnetic proportional control
EPC Oil pressure Mechanism that actuator works in proportion
Proportional Control
to current
Structure that protects operator's head from
Falling Object Cab and canopy falling objects. (Structure to protect operator)
FOPS
Protective Structure
Performance standardized in ISO 3449
Forward-Neutral- Operation
F-N-R Forward - NEUTRAL - REVERSE
Reverse
Communication Global Positioning System Satellite
Global Positioning
GPS System (KOMTRAX 、KOMTRAX positioning system that is used to determine
Plus) the current location on the earth
Steering function that uses a combination of
Hydrostatic Steering Steering hydraulic motor and bevel shaft to control
HSS System difference in travel speed of right and left
(D) tracks to turn machine without using steering
clutch.
Hydraulic transmission system that uses a
Hydro Static Transmission combination of hydraulic pump and hydraulic
HST motor to shift gear steplessly without using
Transmission (D, WA)
gears.
Valve that adjusts fuel intake amount at inlet
Inlet Metering Actuator Engine port of pump in order to control fuel discharge
IMA
amount of supply pump. Same meaning as
IMV
Valve adjusting fuel intake amount at inlet port
IMV Inlet Metering Valve Engine of pump in order to control fuel discharge
amount of supply pump. Described IMV (IMA)
This mechanism separates oil in blowby gas
Komatsu Closed Engine and returns it to the intake side to afterburn it
KCCV
Crankcase Ventilation there. It primarily consists of filters.
Komatsu Catalyzed This filter captures soot in exhaust gas.
KCSF Engine
Soot Filter It is built in to KDPF.
The catalyst used for purifying exhaust gas.
Komatsu Diesel
KDOC Engine This is built in KDPF or assembled with the
Oxidation Catalyst
muffler.
This component contains KDOC (catalyst)
Komatsu Diesel Engine and KCSF (soot filter) for purifying exhaust
KDPF
Particulate Filter gas.

PC138USLC-10 00-55
00 Index and foreword
Foreword, safety and general information

Purpose of use (major


Abbrevia- Actual word spelled applicable machine (*), or Explanation
tion out equipment/device)
It is installed in place of the currently used
muffler.
Function that recovers the drive force of the
wheels by braking automatically with the
Komatsu Traction Travel and brake optimum force and at the same time activates
KTCS Control System the inter-axle differential lock when the wheels
(HM system)
idle while the machine travels on the soft
ground road.
Komatsu Variable
The turbocharger on which the cross-section
KVGT Geometry Engine
area of the exhaust passage is made variable.
Turbocharger
Liquid Display Image display equipment such
LCD Liquid Crystal Display Machine monitor as the monitor which assembles in the liquid
crystal element.
Light Emitting Diode Semi-conductor element
LED Light Emitting Diode Electronic parts that emits light when the voltage is applied in
the normal direction.
Local Interconnect Communication and One of communication standards that is used
LIN
Network electronic control in the network on the machine
Function that detects differential pressure of
LS Load Sensing Oil pressure pump and controls discharge amount
according to load.
Low Voltage Communication and One of communication standards that is used
LVDS Differential Signaling electronic control in the network on the machine
It means the intake air flow of the engine. It is
Engine not used independently but used together with
MAF Mass Air Flow
the sensor. The mass air flow sensor may be
called MAF sensor.
Service that allows transmission and
Multimedia Messaging reception of short messages consisting of
MMS Communication characters or voice or images between cell
Service
phones.
Device actuated to open electric or hydraulic
NC Normally Closed Electric and hydraulic circuits that are normally closed if not
actuated.
Device actuated to close electric or hydraulic
NO Normally Open Electric and hydraulic
circuits that are normally open if not actuated.
Open-center Load Hydraulic system that can operate multiple
OLSS Oil pressure actuators at the same time, regardless of the
Sensing System
load.
Pressure
PC Oil pressure A function used to correct oil pressure.
Compensation
System in which a controller instantly
Palm command control Steering analyses data from each lever, pedal, and
PCCS system dial, and performs optimum electronic control
(D)
of the engine and transmission.
Valve installed at inlet port of pump to adjust
Pre-stroke Control Engine fuel intake amount in order to control fuel
PCV
Valve discharge amount of supply pump.
Proportional pressure control Mechanism that
Proportional Pressure Oil pressure actuator works in proportion to hydraulic
PPC
Control pressure
Piston Pump and Oil pressure
PPM Piston pump and motor.
Motor (D, PC, etc.)
PTO Power Take Off Power transmission Power take-off mechanism
Power Tilt and power Work equipment Function that performs hydraulic control of the
PTP tilt and pitch of the bulldozer blade.
Pitch dozer (D)

00-56 PC138USLC-10
00 Index and foreword
Foreword, safety and general information

Purpose of use (major


Abbrevia- Actual word spelled applicable machine (*), or Explanation
tion out equipment/device)
Structure that protects operator fastening seat
belt from being crushed when machine tips
Roll-Over Protective Cab and canopy over (Structure to protect operator when
ROPS:
Structure machine tips over)
Performance standardized in ISO 3471
Abbreviation for "International system of units"
International unit
SI Unit Unit system that is employed worldwide, and
system
"one unit against one factor"
Actuator that moves a part with a movable iron
SOL Solenoid Electric core in the coil (solenoid), which is moved by
energizing the coil.
2-Way Valve Hydraulic and electric Solenoid valve that switches the direction of
TWV
flow.
Variable Flow Turbocharger variable in route of exhaust
VFT Engine
Turbocharger passage.
*1: Code for applicable machine family
D: Bulldozer
HD: Dump truck
HM: Articulated dump truck
PC: Hydraulic excavator
WA: Wheel loader
List of abbreviations used in the circuit diagrams
Abbreviation Actual word spelled out
A/C Air Conditioner
A/D Analogue-to-Digital
A/M Air Mix Damper
ACC Accessory
ADD Additional
AUX Auxiliary
BR Battery Relay
CW Clockwise
CCW Counter Clockwise
ECU Electronic Control Unit
ECM Electronic Control Module
ENG Engine
EXGND External Ground
F.G. Frame Ground
GND Ground
IMA Inlet Metering Actuator
NC No Connection
S/T
Steering
STRG
SIG Signal
SOL Solenoid
STD Standard
OPT
Option
OP
PRESS Pressure
SPEC Specification
SW Switch
TEMP Temperature

PC138USLC-10 00-57
00 Index and foreword
Foreword, safety and general information

Abbreviation Actual word spelled out


T/C Torque Converter
T/M Transmission

00-58 PC138USLC-10
00 Index and foreword
Foreword, safety and general information

Conversion table (ALL-2150-931-A-00-A)


(Rev. 2012/10)

Method of using the conversion table


• The unit conversion table enables the simple conversion in the figures between the different units. For
further details of the method of use of the conversion table, see the examples given below.
Example: Method of using the conversion table to convert a unit from millimeters to inches
Conversion of 55 mm into inches
1. Locate the number 50 in the vertical column at the left side, take this as (A), and then draw a horizontal
line from (A).
2. Locate the number 5 in the row across the top, take this as (B), then draw a vertical line down from (B).
3. Take the point where the 2 lines cross as (C). This point (C) gives the value when converting the unit from
millimeters to inches. Therefore, 55 mm = 2.165 in.
Conversion of 550 mm into inches
1. The number 550 does not appear in the table, so divide it by 10 (move the decimal point one place to the
left) to get 55 mm.
2. Then convert 55 mm to 2.165 in by the same procedure as above.
3. The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point
one place to the right) to get the original value. This gives 550 mm = 21.65 in. Therefore, 550 mm = 21.65
in.
Millimeters to inches
(B)
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
(C)
50 1.969 2.008 2.017 2.087 2.126 2.165 2.205 2.244 2.283 2.323
(A)
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 2.847 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

PC138USLC-10 00-59
00 Index and foreword
Foreword, safety and general information

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 2.847 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

Kilograms to pounds
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

l to U.S. Gallons
1 l = 0.2642 U.S.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
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

00-60 PC138USLC-10
00 Index and foreword
Foreword, safety and general information

l to U.K. Gallons
1 l = 0.21997 U.K.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.699 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
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

PC138USLC-10 00-61
00 Index and foreword
Foreword, safety and general information

kg/cm2 to lb/in22
1 kg/cm2 = 14.2233 lb/in22
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

00-62 PC138USLC-10
00 Index and foreword
Foreword, safety and general information

Temperature
Conversion of Fahrenheit to Celsius
• A simple way to convert a Fahrenheit temperature reading into a Celsius temperature reading or vice
versa is to see the number in the center column of the following table. The figures on the following table
show the temperatures in both Fahrenheit and Celsius.
• When converting from Fahrenheit to Celsius degrees, consider the center column to be a table of
Fahrenheit temperatures and read the corresponding Celsius temperature in the column at the left.
• When converting from Celsius to Fahrenheit degrees, consider the center column to be a table of Celsius
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
-28.3 -19 -2.2 -8.9 16 60.8 10.6 51 123.8 30.0 86 186.8
-27.8 -18 -0.4 -8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
-27.2 -17 1.4 -7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
-26.7 -16 3.2 -7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
-26.1 -15 5.0 -6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
-25.6 -14 6.8 -6.1 21 69.8 13.3 56 132.8 32.8 91 195.8
-25.0 -13 8.6 -5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
-24.4 -12 10.4 -5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
-23.9 -11 12.2 -4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
-23.3 -10 14.0 -3.9 25 77.0 15.6 60 140.0 35.0 95 203.0
-22.8 -9 15.8 -3.3 26 78.8 16.1 61 141.8 35.6 96 204.8
-22.2 -8 17.6 -2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
-21.7 -7 19.4 -2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
-21.1 -6 21.2 -1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
-20.6 -5 23.0 -1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
-20.0 -4 24.8 -0.6 31 87.8 18.9 66 150.8 40.6 105 221.0
-19.4 -3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
-18.9 -2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
-18.3 -1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
-17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
-17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0
-16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
-16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
-15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
-15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
-14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0
-13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
-13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
-12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
-12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0

PC138USLC-10 00-63
00 Index and foreword
Foreword, safety and general information

00-64 PC138USLC-10
SHOP MANUAL

HYDRAULIC EXCAVATOR
PC138USLC-10
Model Serial Number

PC138USLC- 40001 and up


10

01 Specification
2 01 Specification

PC138USLC-10 01-1
01 Specification
Table of contents

Table of contents (ALL-0310-002-A-00-A)


01 Specification................................................................................................................................. 01-1
Table of contents ........................................................................................................................ 01-2
Specifications............................................................................................................................. 01-3
Specification drawing ........................................................................................................... 01-3
Working range drawings ....................................................................................................... 01-4
Specifications ...................................................................................................................... 01-5
Weight table ........................................................................................................................ 01-9
Table of fuel, coolant, and lubricants .................................................................................... 01-11

01-2 PC138USLC-10
01 Specification
Specification drawing

Specifications (ALL-2111-001-A-00-A)

Specification drawing (ALL-2110-001-A-00-A)

PC138USLC-10 (PC138_10-2110-931-A-00-A)

Item Unit PC138USLC-10


Machine weight
Blade mountable specification 14,600
kg
Blade specification 15,450
Bucket capacity m3 0.5
Engine model — Komatsu SAA4D95LE-6 diesel engine
Engine rated horsepower
• SAE J1995 (gross) 72.6 {97.3}/2,050 {2,050}
kW {HP}/min-1
• ISO 14396 72.6 {97.3}/2,050 {2,050}
{rpm}
• ISO 9249/SAE J1349 (net) 69.7 {93.5}/2,050 {2,050}
Overall length
A Blade mountable specification mm 7,390
A’ Blade specification mm 8,040
B Overall height mm 2,850
C Overall width (overall width of track) mm 2,590
C’ Overall width of upper structure mm 2,490
D Shoe width mm 600
E Tail swing radius mm 1,545
F Overall length of track mm 3,870
G Distance between tumbler centers mm 3,140
H Cab height mm 2,815
Min. ground clearance mm 395
Travel speed (Lo/Hi) km/h 2.9/5.1
Continuous swing speed min-1 {rpm} 11.0 {11.0}

a The engine rated horsepower is indicated in the net value and gross value. The gross denotes the
flywheel horsepower measured on the basic engine unit, while the net denotes the value measured of an
engine under the condition essentially the same as that when it is installed on a machine.

PC138USLC-10 01-3
01 Specification
Working range drawings

Working range drawings (ALL-2110-001-A-02-A)

PC138USLC-10 (PC138_10-2110-931-A-01-A)

Item Unit PC138USLC-10


A Max. digging reach mm 8,300
B Max. digging depth mm 5,480
C Max. digging height mm 9,340
D Max. vertical wall digging depth mm 4,900
E Max. dumping height mm 6,840
Min. swing radius of work
F mm 1,980
equipment
Max. digging reach at ground mm 8,180
G
level
H Max. blade lift above ground (*1) mm 470
Max. blade drop below ground
I mm 490
(*1)
*1: The values show the blade specification.

01-4 PC138USLC-10
01 Specification
Specifications

Specifications (ALL-2111-001-A-01-A)

PC138USLC-10 (PC138_10-2111-931-A-00-A)

PC138USLC-10
Machine model Blade mountable Reinforced blade
Unit specification specification
Serial No. 40001 and up
Bucket capacity m3 0.50 0.50
Machine weight kg 14,600 15,450

Performance
Working ranges
Max. digging depth mm 5,480 5,480
Max. vertical wall digging depth mm 4,900 4,900
Max. digging reach mm 8,300 8,300
Max. digging reach at ground level mm 8,180 8,180
Max. digging height mm 9,340 9,340
Max. dumping height mm 6,840 6,840
Max. blade lift above ground mm — 470
Max. blade drop below ground mm — 490
Max. digging force (bucket) kN {kg} 93.2 {9,500} 93.2 {9,500}
Continuous swing speed min-1 {rpm} 11.0 {11.0} 11.0 {11.0}
Swing operation max. slope angle deg. 20 20
Travel speed (Lo/Hi) km/h 2.9/5.1 2.9/5.1
Gradeability deg. 35 35
Ground pressure (standard shoe) kPa {kg/cm2} 35.3 {0.36} 37.3 {0.38}

Dimensions
Overall length (for transport) mm 7,390 8,040
Overall width mm 2,590 2,590
Overall height (for transport) mm 2,850 2,850
Overall height (for operation) mm 2,830 2,830
Ground clearance of upper structure (*1) mm 900 900
Min. ground clearance mm 395 395
Tail swing radius mm 1,545 1,545
Min. swing radius of work equipment mm 1,980 1,980
Max. height of work equipment in min.
mm 6,770 6,770
swing radius posture
Overall width of track mm 2,590 2,590
Overall length of track mm 3,870 3,870
Distance between tumbler centers mm 3,140 3,140
Track gauge mm 1,990 1,990
Machine cab height mm 2,140 2,140
Blade width x height mm — 2,590 x 590
*1: The values are for machines with triple grouser shoes.

PC138USLC-10 01-5
01 Specification
Specifications

PC138USLC-10
Machine model Blade mountable Reinforced blade
Unit specification specification
Serial No. 40001 and up

Engine
Model — SAA4D95LE-6
4-cycle, water-cooled, in-line, vertical, direct
Type — injection, with variable geometry turbocharger
and air-cooled aftercooler
No. of cylinders - bore x stroke mm 4 - 95 x 115
Total piston displacement l {cc} 3.26 {3,260}
Performance
Rated horsepower
• SAE J1995 (gross) 72.6 {97.3}/2,050 {2,050}
kW {HP}/min-1
• ISO 14396 72.6 {97.3}/2,050 {2,050}
{rpm}
• ISO 9249/SAE J1349 (net) 69.7 {93.5}/2,050 {2,050}
Nm {kgm}/min-1
Max. torque 383 {39.1}/1,500 {1,500}
{rpm}
Max. speed with no load
• When mounted on machine 2,000 {2,000}
min-1 {rpm}
• Basic engine 2,150 {2,150}
Min. speed with no load min-1 {rpm} 1,100 {1,100}
Fuel consumption rate at rated
g/kWh {g/HPh} 226 {169}
horsepower
Starting motor — 24 V, 4.5 kW
Alternator — 24 V, 35 A
Battery (*2) — 12 V, 72 Ah x 2 pieces
Radiator model — CF90-4
Type of aftercooler core — Corrugated aluminum
*2: The battery capacity (Ah) is indicated in the 5-hour rate.
a The engine rated horsepower is indicated in the net value and gross value. The gross denotes the
flywheel horsepower measured on the basic engine unit, while the net denotes the value measured of an
engine under the condition essentially the same as that when it is installed on a machine.

Undercarriage
Carrier roller — 2 (each side)
Track roller — 8 (each side)
Track shoe

• Assembly type triple grouser shoe 46 on each side



• Assembly type road liner 46 on each side

01-6 PC138USLC-10
01 Specification
Specifications

PC138USLC-10
Machine model Blade mountable Reinforced blade
Unit specification specification
Serial No. 40001 and up

Hydraulic system
Hydraulic pump
Type x quantity — Variable displacement piston type x 1 pc.
Discharge l/min 121 x 2 (at 2,050 rpm)
Set pressure MPa {kg/cm2} 34.8 {355}
Control valve
Type x quantity — 7-spool type x 1 pc.
Operating method — Hydraulic assist type
Travel motor
Variable displacement piston type x 2 pcs.
Type x quantity —
(with brake valve and parking brake)
Swing motor
Fixed displacement piston type x 1 pc.
Type x quantity —
(with safety valve and parking brake)
Boom cylinder
Double-acting piston Double-acting piston
Type —
type type
Cylinder bore mm 105 105
Piston rod diameter mm 70 70
Stroke mm 1,055 1,055
Max. distance between pins mm 2,555 2,555
Min. distance between pins mm 1,500 1,500
Arm cylinder
Double-acting piston Double-acting piston
Type —
type type
Cylinder bore mm 110 110
Piston rod diameter mm 75 75
Stroke mm 1,175 1,175
Max. distance between pins mm 2,798 2,798
Min. distance between pins mm 1,623 1,623
Bucket cylinder
Double-acting piston Double-acting piston
Type —
type type
Cylinder bore mm 95 95
Piston rod diameter mm 65 65
Stroke mm 885 885
Max. distance between pins mm 2,263 2,263
Min. distance between pins mm 1,378 1,378
Blade cylinder
Double-acting piston
Type — —
type
Cylinder bore mm — 110
Piston rod diameter mm — 75
Stroke mm — 181
Max. distance between pins mm — 870
Min. distance between pins mm — 689

PC138USLC-10 01-7
01 Specification
Specifications

PC138USLC-10
Machine model Blade mountable Reinforced blade
Unit specification specification
Serial No. 40001 and up
Hydraulic tank — Box-shaped sealed type
Hydraulic oil filter — Tank return side
Hydraulic oil cooler — Air-cooled type (CF40)

01-8 PC138USLC-10
01 Specification
Weight table

Weight table (ALL-2120-001-A-01-A)

PC138USLC-10 (PC138_10-2120-931-A-00-A)

k This weight table is prepared for your reference when handling or transporting the components.
Unit: kg
PC138USLC-10
Machine model Blade mountable
Blade specification
specification
Serial No. 40001 and up
Engine assembly (excluding coolant and oil) 594 594
• Engine (excluding coolant and oil) 450 450
• Engine mount 34 34
• Damper 5.5 5.5
• Main pump 104 104
Cooling assembly (excluding coolant, oil, and
fuel) 108 108
• Radiator (excluding coolant) 18.3 18.3
• Oil cooler (excluding oil) 11.9 11.9
• Aftercooler 5.3 5.3
• Fuel cooler (excluding fuel) 0.8 0.8
Revolving frame 1,485 1,485
Operator's cab 385 385
Operator's seat 39 39
Fuel tank assembly (excluding fuel) 98.5 98.5
Hydraulic tank and filter assembly (excluding
hydraulic oil) 76 76
Control valve 100 100
Counterweight 3,100 3,100
Additional counterweight 500 500
Swing motor (including brake valve) 20 20
Swing circle 152.6 152.6
Swing machinery 71.6 71.6
Center swivel joint 43.6 43.6
Track frame assembly (excluding track shoes) 2,680 2,680
• Track frame 1,600 1,600
• Idler assembly 79 x 2 79 x 2
• Recoil spring assembly 71 x 2 71 x 2
• Carrier roller 12 x 4 12 x 4
• Track roller 22 x 16 22 x 16
• Travel motor (including reduction gear) 145 x 2 145 x 2
• Sprocket 33.1 x 2 33.1 x 2
Track shoe assembly
Triple grouser shoe (500 mm) 805 x 2 805 x 2
Triple grouser shoe (600 mm) 895 x 2 895 x 2
Triple grouser shoe (700 mm) 995 x 2 995 x 2
Rubber pad shoe (500 mm) 800 x 2 800 x 2
Rubber pad shoe (600 mm) 895 x 2 895 x 2
Road liner (500 mm) 870 x 2 870 x 2
Boom assembly 820 820
Arm assembly 356 356
Bucket link assembly 85.6 85.6
Bucket assembly
980 mm wide (including side cutter) 399
399

PC138USLC-10 01-9
01 Specification
Weight table

Unit: kg
PC138USLC-10
Machine model Blade mountable
Blade specification
specification
Serial No. 40001 and up
Blade assembly
Reinforced blade (BOC type, including BOC) — 688
Blade (welded edge type) — 668
Reinforced wide blade (BOC type, including
— 702
BOC)
Wide blade (welded edge type) — 682
Boom cylinder assembly 105.5 x 2 105.5 x 2
Arm cylinder assembly 126.6 126.6
Bucket cylinder assembly 79.2 79.2
Blade cylinder assembly — 62.5 x 2

a BOC: Abbreviation for Bolt On Cutting edge

01-10 PC138USLC-10
01 Specification
Table of fuel, coolant, and lubricants

Table of fuel, coolant, and lubricants (PC138-RA19-05A-K-01-A)

a For details of notes (Note 1, Note 2...) in the table, see the Operation and Maintenance Manual.

Unit: l
PC138USLC–10
Applicable portion
Specified quantity Refill capacity
Engine oil pan 12.5 11.5
Swing machinery case 2.5 2.5
Final drive case (each of right and left) 2.1 2.1
PTO gear case 0.75 0.75
Hydraulic oil system 120 69
Cooling system 17.7 —
Fuel tank 200 —

PC138USLC-10 01-11
01 Specification
Table of fuel, coolant, and lubricants

01-12 PC138USLC-10
SHOP MANUAL

HYDRAULIC EXCAVATOR
PC138USLC-10
Model Serial Number

PC138USLC- 40001 and up


10

10 Structure and function


3 10 Structure and function

PC138USLC-10 10-1
10 Structure and function
Table of contents

Table of contents (ALL-0310-002-A-00-A)


10 Structure and function ................................................................................................................... 10-1
Table of contents ........................................................................................................................ 10-2
Engine and cooling system .......................................................................................................... 10-3
Engine related parts ............................................................................................................. 10-3
PTO.................................................................................................................................... 10-5
VFT .................................................................................................................................... 10-6
EGR system piping drawing ................................................................................................ 10-10
EGR system circuit diagram ................................................................................................ 10-12
EGR valve......................................................................................................................... 10-13
EGR cooler........................................................................................................................ 10-15
KCCV layout drawing ......................................................................................................... 10-17
KCCV ventilator ................................................................................................................. 10-19
KDOC muffler .................................................................................................................... 10-21
Cooling system .................................................................................................................. 10-23
Power train............................................................................................................................... 10-25
Power train system............................................................................................................. 10-25
Swing circle ....................................................................................................................... 10-27
Swing machinery ............................................................................................................... 10-28
Undercarriage and frame........................................................................................................... 10-30
Track frame ....................................................................................................................... 10-30
Idler cushion ...................................................................................................................... 10-31
Hydraulic system ...................................................................................................................... 10-32
Hydraulic component layout ................................................................................................ 10-32
Valve control...................................................................................................................... 10-34
Hydraulic tank.................................................................................................................... 10-35
CLSS ................................................................................................................................ 10-37
Main pump ........................................................................................................................ 10-41
Control valve ..................................................................................................................... 10-68
Swing motor .................................................................................................................... 10-113
Travel motor .................................................................................................................... 10-125
Work equipment and swing PPC valve............................................................................... 10-136
Travel PPC valve ............................................................................................................. 10-143
Blade PPC valve .............................................................................................................. 10-149
1st-line attachment PPC valve (with EPC valve) ................................................................. 10-151
Solenoid valve ................................................................................................................. 10-159
Attachment circuit selector valve (for low pressure circuit).................................................... 10-165
Attachment circuit selector valve (for high pressure circuit) .................................................. 10-168
Multi-control valve ............................................................................................................ 10-170
Center swivel joint ............................................................................................................ 10-171
PPC circuit accumulator ................................................................................................... 10-173
Attachment circuit accumulator (for low pressure circuit)...................................................... 10-174
Attachment circuit accumulator (for high pressure circuit) .................................................... 10-175
Work equipment ..................................................................................................................... 10-176
Work equipment............................................................................................................... 10-176
Work equipment shim....................................................................................................... 10-177
Bucket play adjustment shim............................................................................................. 10-178
Cab and its attachments .......................................................................................................... 10-179
Cab mount and cab tipping stopper ................................................................................... 10-179
ROPS cab ....................................................................................................................... 10-180
Electrical system .................................................................................................................... 10-182
Electrical control system ................................................................................................... 10-182
Machine monitor system ................................................................................................... 10-214
KOMTRAX system ........................................................................................................... 10-235
Sensor ............................................................................................................................ 10-252

10-2 PC138USLC-10
10 Structure and function
Engine related parts

Engine and cooling system (ALL-R401-001-K-00-A)

Engine related parts (PC138-A001-041-K-00-A)

1. KDOC muffler
2. KCCV ventilator
3. Engine controller
4. Mass air flow and temperature sensor
5. Dust indicator
6. Air cleaner (*1)
7. Auto-tensioner
8. VFT

PC138USLC-10 10-3
10 Structure and function
Engine related parts

9. EGR cooler
10.Engine oil filter
11.Air conditioner compressor
12.Fuel filter
13.Rear engine mount (*2)
14.Front engine mount (*2)

*1: For details, see Engine Shop Manual.


*2: The crankshaft pulley side of the engine mount is the front and the flywheel side is the rear.

10-4 PC138USLC-10
10 Structure and function
PTO

PTO (PC138-D400-041-K-00-A)

a PTO: Abbreviation for Power Take Off

1. Flywheel
2. Coupling
3. Main pump shaft
4. Drain plug
5. Oil filler plug
6. Oil level plug
Specifications (PC138-D400-030-K-00-A)

Type of PTO Wet type


Oil used for PTO TO30
Quantity of PTO oil (l) 0.75

PC138USLC-10 10-5
10 Structure and function
VFT

VFT (ENG95-AA10-041-K-00-A)

a VFT: Abbreviation for Variable Flow Turbocharger


a The shape is subject to machine models.

A: Air intake inlet


B: Air intake outlet
C: Exhaust inlet
D: Exhaust outlet

10-6 PC138USLC-10
10 Structure and function
VFT

1. VFT motor
2. Flange bolt
3. Bracket
4. Thrust sleeve

PC138USLC-10 10-7
10 Structure and function
VFT

5. Bracket
6. O-ring
7. Insert
8. Oil deflector
9. Thrust bearing
10. Thrust ring
11. Bearing housing
12. Bearing
13. Piston ring
14. Turbine wheel
15. Turbine insert
16. Turbine housing assembly
17. Pin
18. Seal ring
19. Snap ring
20. O-ring
21. Snap ring
22. Piston ring
23. Compressor cover assembly
24. Compressor wheel
25. Lock nut
26. Flange bolt
27. Flange bolt
28. Connector assembly
29. Snap ring
30. Snap ring
31. Lock plate
32. Flange bolt
E: Oil inlet
F: Oil outlet
Specifications (ENG95-AA10-030-K-00-A)

Model: TD04M4t-VFT
Applicable exhaust temperature: Max. 700°C (turbine inlet)
Rotation direction: Clockwise (seen from intake air inlet)

10-8 PC138USLC-10
10 Structure and function
VFT

Operation (ENG95-AA10-044-K-00-A)

1. Large scroll
2. Small scroll
3. Fixed vane
4. Flow control valve fully closed
5. Flow control valve fully open
A: When flow control valve is fully closed (small flow rate)
B: When flow control valve is fully open (large flow rate)
• The turbine housing of the VFT consists of large scroll (1) and small scroll (2).
• Fixed vane (3) is installed between large scroll (1) and small scroll (2) for flow rectification.
• The flow rate into large scroll (1) side is controlled by opening (5) or closing (4) the flow control valve.
• The position of the flow control valve is controlled by the actuator which is driven by the command from
the engine controller.

PC138USLC-10 10-9
10 Structure and function
EGR system piping drawing

EGR system piping drawing (ENG95-A9J0-04D-K-00-A)

a EGR: Abbreviation for Exhaust Gas Recirculation


a The shape is subject to machine models.

1. VFT
2. EGR valve
3. Intake air connector
4. Mixing connector
5. Exhaust manifold
6. EGR cooler
Function (ENG95-A9J0-042-K-00-A)

• EGR valve (driven with electric motor)


Controls the gas flow from exhaust side to intake side. Since the exhaust pressure is higher than the boost
pressure, the exhaust gas flows into the intake side.
• EGR cooler

10-10 PC138USLC-10
10 Structure and function
EGR system piping drawing

Cools the exhaust gas.


The engine coolant is used for cooling.
• Intake air connector
Returns the air from the air-cooled aftercooler and the exhaust gas from the EGR valve to the intake side.
• Sensors
Control the EGR according to the operating condition.
Troubleshoot the system.
• Control each part of the EGR circuit and control the EGR rate according to the operating condition to clean
the exhaust gas constantly.
• Monitor the condition of the EGR circuit and perform troubleshooting to prevent a serious failure.

PC138USLC-10 10-11
10 Structure and function
EGR system circuit diagram

EGR system circuit diagram (ENG95-A9J0-052-K-00-A)

a EGR: Abbreviation for Exhaust Gas Recirculation

1. Air cleaner
2. KDOC muffler
3. Mass air flow and temperature sensor (MAF)
4. Electric actuator (VFT)
5. EGR cooler
6. EGR valve
7. Electric actuator (EGR valve)
8. Ambient pressure sensor
9. Aftercooler
10. Exhaust manifold
11. Air intake manifold
12. Charge (boost) pressure and temperature sensor
13. Engine controller
C: Blower impeller
T: Turbine impeller
Operation (ENG95-A9J0-044-K-00-A)

• The engine controller outputs signals so that EGR valve (6) opens properly according to the engine load to
realize both clean exhaust gas and low fuel consumption.
• If EGR valve (6) opens, a part of the exhaust gas (EGR gas) flows from exhaust manifold (10) into EGR
cooler (5) through the EGR piping.
• The exhaust gas cooled by EGR cooler (5) flows through EGR valve (6), merges with the intake air in the
air intake connector, and flows into intake manifold (11).

10-12 PC138USLC-10
10 Structure and function
EGR valve

EGR valve (ENG95-A9K1-041-K-00-A)

a EGR: Abbreviation for Exhaust Gas Recirculation


a The shape is subject to machine models.

1. DC motor assembly (brushless motor with built-in position sensor)


2. DC motor shaft
3. Rod
4. Filter
5. Housing
6. Valve seat
7. Valve
8. Seal
9. Spring
A: EGR gas inlet (from EGR cooler)
B: EGR gas outlet (to intake manifold)

Structure
• Small-sized EGR valve driven with a DC motor.
• The DC motor has a position sensor in it to sense the valve position.
• Since 2 valves are combined to cancel the EGR gas pressure, the operating effort is small.

PC138USLC-10 10-13
10 Structure and function
EGR valve

Operation (ENG95-A9K1-044-K-00-A)

A: EGR gas inlet (from EGR cooler)


B: EGR gas outlet (to air intake manifold)
• DC motor shaft (2) of the DC motor converts rotary motion into linear motion. Accordingly, valve (7) is
opened or closed by turning the motor.
Open valve: The DC motor is turned and DC motor shaft (2) is pushed out to push rod (3) and open valve (7).
When valve (7) opens, the EGR gas flows into the air intake manifold.
Close valve: The DC motor is turned in reverse and DC motor shaft (2) is pulled in, then rod (3) is pushed
back by spring (9) and valve (7) closes.

10-14 PC138USLC-10
10 Structure and function
EGR cooler

EGR cooler (ENG95-A9L0-041-K-00-A)

a EGR: Abbreviation for Exhaust Gas Recirculation


a The shape is subject to machine models.

1. Tube
2. Shell
A: EGR gas inlet
B: Air vent
C: Coolant outlet
D: EGR gas outlet
E: Coolant inlet

1. Flat tube
2. Inner fin
Operation (ENG95-A9L0-044-K-00-A)

• The EGR gas enters from (A) and flows through 9 flat tubes (1).

PC138USLC-10 10-15
10 Structure and function
EGR cooler

• Coolant enters from (E) and flows around flat tube (1) in the shell and then goes out from (C).
• The EGR gas is effectively cooled by flat tubes (1) with inner fins (2) and flows out from EGR gas outlet
(D).

10-16 PC138USLC-10
10 Structure and function
KCCV layout drawing

KCCV layout drawing (ENG95-A180-04D-K-00-A)

a KCCV: Abbreviation for KOMATSU Closed Crankcase Ventilation


a The shape is subject to machine models.

1. Breather
2. Crankcase pressure sensor
3. VFT
4. CDR valve
5. KCCV ventilator
6. Check valve
A: Blowby gas (from breather)
B: Blowby gas from which engine oil was removed (to VFT)
C: Engine oil from which blowby gas was removed (to oil pan)
• In the past, blowby gas (A) was discharged into the atmosphere as it was. Since the emission regulations
has become strict and blowby gas must be controlled now, the blowby gas intake recirculation system is
employed.
• Blowby gas (A) contains ingredients of the engine oil. If it is recirculated to VFT (3) as it is, it causes the
following problems. To prevent this, a filter is installed to KCCV ventilator (5) to remove the engine oil.
1. Lowering of performance of turbocharger and aftercooler caused by sticking engine oil
2. Abnormal combustion in engine
3. Malfunction of each sensor caused by sticking engine oil

PC138USLC-10 10-17
10 Structure and function
KCCV layout drawing

Operation (ENG95-A180-044-K-00-A)

a The left side of the following figure shows the traditional flow of blowby gas that has been discharged to
the atmosphere. The right side shows the flow of blowby gas recirculated to the intake system by the
KCCV ventilator.

1. Air cleaner
2. VFT
3. Aftercooler
4. Cylinder block (crankcase)
5. Breather
6. KCCV ventilator
7. Oil pan
• Engine oil is removed from blowby gas (A) in cylinder block (4) by the filter in KCCV ventilator (6), and
then the cleaned gas (B) is recirculated to the intake side of the VFT.
• Removed engine oil (C) flows through a check valve and falls to the oil pan.

10-18 PC138USLC-10
10 Structure and function
KCCV ventilator

KCCV ventilator (ENG95-A18H-041-K-00-A)

a KCCV: Abbreviation for KOMATSU Closed Crankcase Ventilation


a The shape is subject to machine models.

1. Case
2. Filter
3. CDR valve
4. Relief valve
A: Blowby gas inlet (from breather)
B: Blowby gas outlet (to VFT intake side)
C: Oil drain port (to oil pan)
Function (ENG95-A18H-042-K-00-A)

• If the blowby gas is returned to the intake side of the VFT, the crankcase pressure becomes negative and
dust may be sucked in through the crankshaft seal. To prevent this, the blowby pressure is controlled by
using the CDR valve (regulator valve) and crankcase pressure sensor.
• If the filter of the KCCV ventilator is clogged, the crankcase pressure increases to cause oil leakage. To
prevent this, the crankcase pressure sensor (installed separately) senses clogging of the filter.
• There are 2 types of the filter; one is the top load type (taken out upward) and the other is the bottom load
type (taken out downward).
Operation (ENG95-A18H-044-K-00-A)

• Blowby gas enters (A) and engine oil mist is separated when it flows through filter (2).
• The separated oil flows along the case wall to oil drain port (C), and then flows into the oil pan.
• When the crankcase pressure becomes negative, the CDR valve operates to prevent the crankcase
pressure from becoming excessively negative.
• The crankcase pressure sensor senses the blowby gas pressure (crankcase pressure).
• If the engine controller judges from the value sensed by the crankcase pressure sensor that the filter is
clogged, it displays failure code CA555 and then displays CA556 if the pressure increases further.

PC138USLC-10 10-19
10 Structure and function
KCCV ventilator

• Relief valve (4) is installed inside case (1) and operates to protect the KCCV ventilator and engine when
filter (2) is blocked.
CDR valve (ENG95-A18A-041-K-00-A)

a CDR: Abbreviation for Crankcase Depression Regulator

1. Diaphragm
2. Spring
A: Crankcase side
B: VFT side (intake side)
• The CDR valve is a regulator valve which prevents excessive negative crankcase pressure (P1).
• Normally, diaphragm (1) is pushed up by spring (2) and blowby gas flows from crankcase side (A) to VFT
side (intake side) (B).
• When intake air flow at the VFT side (intake side) (B) increases and crankcase pressure (P1) decreases,
force of spring (2) yields to ambient pressure (P2). The diaphragm shuts the passage and temporarily
blocks the flow.
• Then, when blowby gas accumulates in the crankcase and pressure (P1) recovers, the diaphragm is
pushed up again and blowby gas starts to flow again.

10-20 PC138USLC-10
10 Structure and function
KDOC muffler

KDOC muffler (ENG95-A9H2-041-K-00-A)

a KDOC: Abbreviation for Komatsu Diesel Oxidation Catalyst


a The shape is subject to machine models.

1. DOC unit
2. Silencer unit
3. Exhaust gas outlet piping
4. Exhaust gas inlet piping
5. Drain piping

Structure
• The KDOC muffler consists of inlet piping (4) to lead in the exhaust gas from the engine, DOC unit (1) to
store the oxidation catalyst, silencer unit (2) having silencing function and containing a "dam" to prevent
rain water from flowing into the DOC unit from exhaust gas outlet piping, outlet piping (3) to discharge the
exhaust gas, and drain piping (5) to drain water from the silencer unit. Those components are welded
together into one unit.
• DOC unit (1) consists of ceramic honeycomb with oxidation catalyst.
• The ceramic honeycomb is protected with a mat made of special fibers to prevent breakage of the ceramic
under the vibrations from the engine and chassis.

PC138USLC-10 10-21
10 Structure and function
KDOC muffler

Function (ENG95-A9H2-042-K-00-A)

A: Flow of exhaust gas


1. DOC unit
2. Silencer unit
• The KDOC muffler is installed to meet the latest very severe emission regulations. It oxidizes SOF
(soluble organic fraction in minute particle in exhaust gas), HC (hydrocarbon not combusted), and CO
(carbon monoxide) contained in the engine exhaust gas to clean the exhaust gas. It also has a silencer to
reduce the exhaust noise.
• Function of DOC unit
(1) Oxidization of SOF (soluble organic fraction)
(2) Oxidization of HC (hydrocarbon)
(3) Oxidization of CO (carbon monoxide)
• Function of silencer unit
Reduction of exhaust noise

10-22 PC138USLC-10
10 Structure and function
Cooling system

Cooling system (PC138-B000-041-K-00-A)

1. Oil cooler outlet


2. Oil cooler
3. Radiator
4. Radiator cap
5. Reservoir tank
6. Aftercooler
7. Fuel cooler inlet
8. Fuel cooler
9. Fuel cooler outlet
10.Air conditioner condenser

PC138USLC-10 10-23
10 Structure and function
Cooling system

11.Radiator inlet hose


12.Aftercooler outlet hose
13.Aftercooler inlet hose
14.Radiator outlet hose
15.Drain plug
16.Shroud
17.Oil cooler inlet
Specifications (PC138-B000-030-K-00-A)

Radiator Oil cooler Aftercooler Fuel cooler


Core type Corrugated Drawn cup
CF90-4 CF91
aluminum
Fin pitch (mm) 3.5/2 3.5/2 4.0/2 4.0/2
Total heat
dissipation area (m2) 47.81 13.34 6.1 0.99
Cracking pressure
49.0 ± 14.7 {0.5 ±
of pressure valve — — —
0.15}
(kPa {kg/cm })
2

Cracking pressure
of vacuum valve -4.9 to 0 {-0.05 to 0} — — —
(kPa {kg/cm2})

10-24 PC138USLC-10
10 Structure and function
Power train system

Power train (ALL-C100-001-K-00-A)

Power train system (PC138-C100-041-K-00-A)

1. Idler
2. Control valve
2a. Self-pressure reducing valve
2b. Merge-divider valve
2c. Travel junction valve
3. PPC lock solenoid valve
4. 2-stage travel speed selector solenoid valve
5. Swing parking brake solenoid valve
6. Merge-divider solenoid valve
7. Travel junction solenoid valve
8. Travel motor
9. Main pump
10.Engine
11.Swing motor

PC138USLC-10 10-25
10 Structure and function
Power train system

12.Center swivel joint


13.Swing machinery
14.Swing circle

10-26 PC138USLC-10
10 Structure and function
Swing circle

Swing circle (PC138-J110-041-K-00-A)

1. Greasing port of swing circle pinion


2. Grease fitting of swing circle bearing
3. Outer race
4. Ball
5. Seal
6. Inner race (number of teeth: 90)

a. Position of inner race soft zone


b. Position of outer race soft zone
Specifications (PC138-J110-030-K-00-A)

Reduction ratio 90/11 = 8.182


Grease G2-LI
Quantity of grease (l) 9.1

PC138USLC-10 10-27
10 Structure and function
Swing machinery

Swing machinery (PC138-J130-041-K-00-A)

1. Swing pinion (number of teeth: 11)


2. Swing machinery case
3. No. 2 planetary carrier
4. No. 2 sun gear (number of teeth: 17)
5. Ring gear (number of teeth: 61)
6. No. 1 planetary carrier
7. No. 1 sun gear (number of teeth: 14)
8. Swing motor
9. Oil filler pipe
10.Oil level gauge
11.No. 1 planetary gear (number of teeth: 24)
12.No. 2 planetary gear (number of teeth: 22)
13.Drain plug

10-28 PC138USLC-10
10 Structure and function
Swing machinery

Specifications (PC138-J130-030-K-00-A)

Reduction ratio ((14 + 61)/14) x ((17 + 61)/17) = 24.58


Swing reduction ratio 24.58 x 8.182 = 201.11
Swing speed
11.0
(rpm)

PC138USLC-10 10-29
10 Structure and function
Track frame

Undercarriage and frame (ALL-DT00-001-K-00-A)

Track frame (PC138-DT20-041-K-00-A)

1. Idler
2. Track frame
3. Carrier roller
4. Sprocket
5. Travel motor
6. Track roller
7. Center guard
8. Track shoe
Specifications (PC138-DT20-030-K-00-A)

Model PC138USLC–10
Number of carrier rollers (each side) 2
Number of track rollers (each side) 8

Standard shoe
• Shoe width (mm) 600
• Link pitch (mm) 175.3
• Number of shoes (each side) 46

10-30 PC138USLC-10
10 Structure and function
Idler cushion

Idler cushion (PC138-DTBP-041-K-00-A)

1. Idler
2. Support
3. Rod
4. Cylinder
5. Recoil spring
6. U-packing
7. Pilot
8. Nut
9. Valve
10.Grease fitting
Specifications (PC138-DTBP-030-K-00-A)

Grease G2-LI
Quantity of grease (cc) 135

PC138USLC-10 10-31
10 Structure and function
Hydraulic component layout

Hydraulic system (ALL-C000-001-K-00-A)

Hydraulic component layout (PC138-C000-04D-K-00-A)


Exterior

1. Bucket cylinder
2. Arm cylinder
3. Boom cylinder
4. Travel motor
5. Blade cylinder (*1)

*1: Blade specification

10-32 PC138USLC-10
10 Structure and function
Hydraulic component layout

Upper structure

1. Main pump
2. Attachment circuit return filter (*2)
3. Oil cooler
4. Blade PPC valve (*1)
5. R.H. work equipment EPC valve
6. L.H. work equipment and swing PPC valve
7. Travel PPC valve
8. 1st-line attachment PPC valve (*2)
9. Attachment circuit accumulator (for low pressure) (*2)
10.Center swivel joint
11.Multi-control valve (*3)
12.Control valve
13.Swing motor
14.Solenoid valve
15.Attachment circuit selector valve (for low pressure) (*2)
16.PPC circuit accumulator
17.Hydraulic tank

*1: Blade specification


*2: Machines ready for installation of attachment
*3: Option

PC138USLC-10 10-33
10 Structure and function
Valve control

Valve control (PC138-PK01-041-K-00-A)

1. Junction block
2. Solenoid valve
3. PPC circuit accumulator
4. Control valve
5. R.H. work equipment EPC valve
6. Blade PPC valve (*1)
7. Blade control lever (*1)
8. R.H. work equipment control lever (for operation of boom and bucket)
9. L.H. work equipment control lever (for operation of arm and swing)
10.L.H. work equipment and swing PPC valve
11.Lock lever
12.Travel levers
13.Travel pedal
14.Travel PPC valve
15.1st-line attachment PPC valve (*2)
16.1st-line attachment control pedal (*2)
17.Lock pin (*2)

*1: Blade specification


*2: Machines ready for installation of attachment

10-34 PC138USLC-10
10 Structure and function
Hydraulic tank

Hydraulic tank (PC138-PM30-041-K-00-A)

1. Hydraulic tank
2. Oil filler cap with breather
3. Sight gauge
4. Drain plug
5. Filter element
6. Bypass valve
7. Suction strainer
Specifications (PC138-PM30-030-K-00-A)

Hydraulic tank capacity (l) 99


Hydraulic oil in tank (l) 69
Bypass valve set pressure (MPa {kg/cm2}) 0.15 ± 0.03 {1.53 ± 0.3}

PC138USLC-10 10-35
10 Structure and function
Hydraulic tank

Oil filler cap (PC138-AD1C-041-K-00-A)

1. Filter element
2. Bottom plate
3. Gasket
4. Seam valve
5. Spring

Prevention of negative pressure in tank


• Since the hydraulic tank is pressurized and sealed, if the oil level in it decreases, negative pressure is
generated in it. At this time, seam valve (4) is opened by the differential pressure between the tank
pressure and the ambient pressure to prevent generation of negative pressure.
(Set pressure of air intake valve: -0.49 to 0 kPa {-0.005 to 0 kg/cm 2})

Prevention of pressure rise in tank


• While the hydraulic circuit is in operation, the pressure in the hydraulic tank increases as the oil level and
the temperature in the hydraulic tank rise according to the operation of the hydraulic cylinders. If the
pressure in the tank exceeds the set pressure, bottom plate (2) is pushed up to release the pressure in the
tank and prevent pressure rise.
(Set pressure of exhaust valve: 16.7 ± 6.86 kPa {0.17 ± 0.07 kg/cm2 })

10-36 PC138USLC-10
10 Structure and function
CLSS

CLSS (ALL-PNJ1-001-K-00-A)

a CLSS: Abbreviation for Closed center Load Sensing System


Structure of CLSS (PC138-PNJ1-041-K-00-A)

a CLSS: Abbreviation for Closed center Load Sensing System

Features
• Fine controllability not influenced by load
• Control performance that allows digging even under fine control operation condition
• Ease of combined operation ensured by the flow dividing performance that is determined by the opening
areas of spools during combined operations
• Energy saving by variable discharge pump control

Configuration
• CLSS consists of variable capacity piston pump, control valves, and respective actuators.
• The main pump consists of a pump body, PC valve, and LS valve.

PC138USLC-10 10-37
10 Structure and function
CLSS

Basic principle

Pump swash plate angle control


• The pump swash plate angle (pump discharge) is so controlled that LS differential pressure (dPLS), which
is the differential pressure between pump discharge pressure (PP) and control valve outlet LS pressure
(PLS) (actuator load pressure), is kept constant.
LS differential pressure (dPLS) = Pump discharge pressure (PP) - LS pressure (PLS)

• The pump swash plate shifts toward the maximum angle position if LS differential pressure (dPLS) is
lower than the set pressure of the LS valve (when the actuator load pressure is high).
• The pump swash plate shifts toward the minimum angle position if LS differential pressure (dPLS) is
higher than the set pressure of the LS valve (when the actuator load pressure is low).

10-38 PC138USLC-10
10 Structure and function
CLSS

LS differential pressure (d
d PLS) and pump swash plate angle

a See "Main pump" for the explanation of the operation.

Pressure compensation control

PC138USLC-10 10-39
10 Structure and function
CLSS

• A pressure compensation valve is installed to the outlet port side of the control valve to balance the load.
• When actuators are operated in combined operations, the pressure difference (dP) between the upstream
(inlet port) and downstream (outlet port) of the spool of each valve is kept the same among them
regardless of the level of the load (pressure).
• The flow of oil from the pump is divided (compensated) in proportion to the areas of openings (S1) and
(S2) of each valve.

10-40 PC138USLC-10
10 Structure and function
Main pump

Main pump (PC138-C200-041-K-00-A)

BMP: Breather mounting port


Im: PC mode selector current
OCP: Oil check port

PC138USLC-10 10-41
10 Structure and function
Main pump

P1T: Travel deviation adjustment orifice


P2T: Travel deviation adjustment orifice
PA1: Pump discharge port
PA1C: Pump discharge pressure pickup port
PA2: Pump discharge port
PA2C: Pump discharge pressure pickup port
PB: Pump pressure inlet port
Pd1: Case drain port
Pd2: Drain plug
Pen: Control pressure pickup port
PEPB: EPC source pressure pickup port
PEPC: EPC source pressure input port
PLS: Load pressure input port
PLSC: Load pressure pickup port
PM: PC mode selector pressure pickup port
PS: Pump suction port

1. Main pump
2. PC–EPC valve

10-42 PC138USLC-10
10 Structure and function
Main pump

1. Shaft
2. Cradle
3. Case
4. Rocker cam
5. Shoe
6. Piston
7. Cylinder block
8. Valve plate
9. End cap
10.Shuttle valve
11.No. 2 check valve

PC138USLC-10 10-43
10 Structure and function
Main pump

12.No. 1 check valve


13.LS valve
14.PC valve

10-44 PC138USLC-10
10 Structure and function
Main pump

Structure
• Cylinder block (7) is supported to shaft (1) by spline (S).
• Shaft (1) is supported by each bearing (9),(10) at the front and rear.
• The tip of piston (6) is shaped as a concave sphere and crimped together with shoe (5).
• Piston (6) and shoe (5) form a spherical bearing.
• Rocker cam (4) has flat surface (A), and shoe (5) is always pressed against this surface while sliding in a
circular pattern.
• Rocker cam (4) rocks on cylindrical surface (B) of cradle (2) fixed to the case. High-pressure oil is supplied
between them to form a static pressure bearing.
• Piston (6) moves relatively in the axial direction in each cylinder chamber of cylinder block (7).
• Cylinder block (7) rotates relatively to valve plate (8) while sealing the pressurized oil.
• This surface maintains the oil pressure balance at a suitable level.
• The pressurized oil is sucked in and discharged from each cylinder chamber in cylinder block (7) through
valve plate (8).

Features of double pump system


• In the conventional single pump system, the oil pressure loss due to pressure compensation valve is large
and the lowering of travel speed becomes large during steering operation.
• Since the double pump system has each independent circuit for the right and left travel, the oil pressure
loss due to pressure compensation valve is small and the lowering of travel speed becomes small during
steering operation.
• The double pump has more simple structure than the tandem pump.

PC138USLC-10 10-45
10 Structure and function
Main pump

Function (PC138-C200-042-K-00-A)

• It converts the rotation and torque of the engine transmitted to shaft (1) into hydraulic pressure and
discharges pressurized oil according to the load.
• It is possible to change the discharge by changing the swash plate angle.
Operation (PC138-C200-044-K-00-A)

• Cylinder block (7) rotates together with shaft (1) and shoe (5) slides on plane (A).
• Rocker cam (4) moves along cylindrical surface (B). As a result, angle (a) between center line (X) of
rocker cam (4) and the axis of cylinder block (7) changes.
• Angle (a) is called the swash plate angle.

• While angle (a) is made between center line (X) of rocker cam (4) and the axis of cylinder block (7), plane
(A) works as a cam for shoe (5).
• Piston (6) slides inside cylinder block (7) and a difference is made between volumes (E) and (F) in cylinder
block (7).
• Oil in amount of (F) minus (E) is sucked in and discharged from each piston (6).
• Oil is discharged while cylinder block (7) rotates and the volume of chamber (E) decreases.
• Oil is sucked in when the volume of chamber (F) increases.

• When center line (X) of rocker cam (4) matches the axis of cylinder block (7) (the swash plate angle is
zero), the difference between volumes (E) and (F) inside cylinder block (7) is zero.
• Pressurized oil is not sucked or discharged, namely pumping action is not performed. (Actually, however,
the swash plate angle does not become 0 degrees)

10-46 PC138USLC-10
10 Structure and function
Main pump

Control of discharge
• When swash plate angle (a) is increased, the difference between volumes (E) and (F) is increased, then
the discharge is increased.
• Swash plate angle (a) is changed by servo piston (12).
• Servo piston (12) moves in a linear reciprocating motion according to the signal pressure from the PC
valve and LS valve.
• This linear reciprocating motion is transmitted to rocker cam (4) through slider (13).
• Being supported by cradle (2) on the cylindrical surface, rocker cam (4) slides on the surface while
continuing revolving movement.
• The area of servo piston (12) for receiving the pressure are not identical on the right side and left side.
Main pump discharge pressure (output pressure of the check valve) (PP) is always transmitted to the
pressure chamber of the small diameter piston side.
• Output pressure (Pen) of LS valve is supplied to the chamber receiving the pressure at the large diameter
piston end.
• The movement of servo piston (12) is controlled by the relationship of pressure between small diameter
piston side (PP) and large diameter side (Pen) and by the ratio of the area receiving the pressure between
small diameter piston and large diameter piston.

PC138USLC-10 10-47
10 Structure and function
Main pump

10-48 PC138USLC-10
10 Structure and function
Main pump

LS valve (PC138-C2J0-041-K-00-A)

a LS: Abbreviation for Load Sensing

PA: Pump port


PDP: Drain port
PLP: LS control pressure output port
PLS: LS pressure input port
PP: Pump port
PPL: Control pressure input port

1. Sleeve
2. Piston
3. Spool
4. Spring
5. Seat
6. Sleeve
7. Plug
8. Lock nut

Function (PC138-C2J0-042-K-00-A)
• The LS valve detects the load and controls the pump discharge.
• This valve controls pump discharge (Q) according to differential pressure (dPLS) [ = (PP) — (PLS)] (called
LS differential pressure) between pump discharge pressure (PP) and control valve outlet port pressure
(PLS).
• This valve receives main pump pressure (PP) and pressure (PLS) (called the LS pressure) coming from
the control valve output.

PC138USLC-10 10-49
10 Structure and function
Main pump

Operation (PC138-C2J0-044-K-00-A)

When control valve is at “Neutral“ position

• The LS valve is a 3-way selector valve, and LS pressure (PLS) (actuator load pressure) on the outlet of
the control valve is transmitted to spring chamber (B), and pump discharge pressure (PP) is transmitted to
port (H) of sleeve (8).
• Magnitude of the force resulting from this LS pressure (PLS), force of spring (4) and the pump discharge
pressure (PP) determine the position of spool (6).
• Before the engine is started, servo piston (12) is pushed to the left. (See figure below.)
• When the control lever is in “NEUTRAL“ position when the engine is started, LS pressure (PLS) is set to 0
MPa {0 kg/cm2}. (It is interconnected to the drain circuit through the control valve spool)

10-50 PC138USLC-10
10 Structure and function
Main pump

• Spool (6) is pushed to the left, and port (C) and port (D) are connected.
• Pump discharge pressure (PP) is transmitted to the larger diameter end of pump from the port (K).
• The same pump discharge pressure (PP) is transmitted to the smaller diameter end at port (J).
• According to the area difference of servo piston (12), the servo piston is moved in the direction (left) which
makes the swash plate angle minimum. (See figure above)

When pump discharge is increased

• When the difference between pump discharge pressure (PP) and LS pressure (PLS), in other words, LS
differential pressure (dPLS) becomes smaller [for example, when the area of opening of the control valve
becomes larger and pump discharge pressure (PP) drops], spool (6) is pushed to the right by the
combined force of LS pressure (PLS) and the force of spring (4).

PC138USLC-10 10-51
10 Structure and function
Main pump

• As spool (6) moves, ports (D) and (E) are interconnected and also connected to the PC valve.
• Since the PC valve is connected to the drain port, the pressure between ports (D) and (K) becomes drain
pressure (PT). (The operation of the PC valve is described later.)
• The pressure at the large end of servo piston (12) becomes drain pressure (PT) and pump pressure (PP)
is constantly transmitted to port (J) at the small end. Accordingly, servo piston (12) is pushed to the right
and moves the swash plate in the direction to increase the discharge.

When pump discharge is decreased

• When servo piston (12) moves to the left (in the direction of smaller discharge), LS differential pressure
(dPLS) becomes larger [for example, when the area of opening of the control valve becomes smaller and
pump discharge pressure (PP) rises], pump discharge pressure (PP) pushes spool (6) to the left.
• When spool (6) moves, pump discharge pressure (PP) is transmitted to the large diameter end of the
piston through port (C), port (D) and port (K).
• Pump discharge pressure (PP) is transmitted to port (J) of the small piston diameter end as well, but
because of the difference in area between the large and the small piston diameter ends of servo piston
(12), servo piston (12) is pushed to the right As a result, the swash plate angle is decreased.

10-52 PC138USLC-10
10 Structure and function
Main pump

When servo piston is balanced

• The symbols (A1), (A0) and (Pen) respectively represent the area receiving the pressure at the large end
of the piston, the area receiving the pressure at the small end and the pressure transmitted to the large
diameter end of the piston.
• When main pump pressure (PP) of the LS valve is balanced with the combined force of LS pressure (PLS)
and spring (4) and (A0) x (PP) = (A1) x (Pen), servo piston (12) stops at the current position.
• The pump swash plate is held at an intermediate position. [The swash plate stops at a position where the
opening between ports (D) and (E) of spool (6) and that between ports (C) and (D) are approximately
equal]
• The relation between the area receiving the pressure at both ends of servo piston (12) is (A0) : (A1) = 1 : 2,
so the pressure applied to both ends of the piston when it is balanced becomes (PP) : (Pen) C 2 : 1.
• The position where spool (6) is balanced and stopped is the standard center, and the force of spring (4) is
adjusted so that it is determined when (PP) - (PLS) = 2.2 MPa {22.5 kg/cm 2}.

PC138USLC-10 10-53
10 Structure and function
Main pump

PC valve (PC138-C2K0-041-K-00-A)

a PC: Abbreviation for Pressure Compensation

PA: Pump port


PA2: Pump pressure pilot port
PDP: Drain port
PM: Mode selector pressure pilot port
PPL: Control pressure output port (to PC valve)
PPL2: Control pressure output port (to LS valve)

1. Plug
2. Servo piston assembly
3. Pin
4. Spool
5. Retainer
6. Seat
7. Cover
8. Wiring

Function (PC138-C2K0-042-K-00-A)
• When pump discharge pressures (PP1) (check valve pressure) and (PP2) (shuttle valve output pressure)
are high, the PC valve limits the oil flow to a certain level according to the discharge pressure, regardless
of the control valve stroke, to prevent the pump absorption horsepower from exceeding the engine
horsepower.
• When the load increases and pump discharge pressure (PP) increases accordingly during operation, this
valve reduces the pump discharge.
• When the pump discharge pressure decreases, this valve increases the pump discharge.
• The relationship between average discharge pressure of the front and rear pumps [(PP1 + PP2]/2 and
pump discharge (Q) in this case is shown below as a parameter of the current value given to the PC-EPC
valve solenoid.
• The controller counts the actual engine speed.
• When the load increases and the engine speed decreases, this valve decreases the pump discharge to
recover the engine speed.
• When the load increases and the engine speed decreases below the set value, the command current from
the controller to the PC-EPC valve solenoid increases according to the engine speed drop to decrease the
pump swash plate angle.

10-54 PC138USLC-10
10 Structure and function
Main pump

Operation (PC138-C2K0-044-K-00-A)

When pump controller is normal

When actuator load is small and pump discharge pressure (PP1) and (PP2) are low

PC138USLC-10 10-55
10 Structure and function
Main pump

Action of PC-EPC valve solenoid (1)


• Command current (X) from the pump controller flows to the PC-EPC valve solenoid (1).
• This command current (X) acts on the PC-EPC valve to generate signal pressure to vary the force pushing
piston (2).
• Spool (3) stops at a position where the set pressures of springs (4) and (6) is balanced with the combined
force of pump pressures (PP1) (self pressure) and (PP2) (the other pump pressure) to push spool (3).
• Depending on this position, the pressure output from the PC valve [port (C) pressure] varies.
• The amperage of the command current (X) depends on the type of work (lever operation), working mode
selection, engine speed setting, and the actual engine speed.

Action of spring
• The reaction force of springs (4) and (6) in the PC valve depends on the position of the swash plate.
• When servo piston (9) moves to the left, spring (6) is compressed.
• When the servo piston moves to the left further, it touches seat (5) and spring (6) is fixed.
• After this point, only spring (4) operates.
• When servo piston (9) compresses or stretches springs (4) and (6), the reaction force varies.
• When the command current (X) input to PC-EPC valve solenoid (1) varies, the thrust pushing piston (2)
varies.

10-56 PC138USLC-10
10 Structure and function
Main pump

• The spring forces of springs (4) and (6) also vary due to the PC-EPC valve solenoid command current (X).
• Port (C) on the PC valve is connected to port (E) on the LS valve.
• Self pressure (PP1) is transmitted into small diameter side of servo piston (9) and port (B), and other pump
pressure (PP2) is transmitted to port (A).
• When pump pressures (PP1) and (PP2) are low, spool (3) is at the left.
• Port (C) and port (D) are connected, and the pressure transmitted to the LS valve becomes drain pressure
(PT).
• When port (E) of the LS valve is connected to port (G), the pressure from port (J) transmitted to the large
diameter side of the piston becomes drain pressure (PT), and servo piston (9) moves to the right.
• The pump discharge goes to increase.
• The movement of servo piston (9) lets springs (4) and (6) expand, and the reaction force of springs
decreases.
• When the reaction force of springs decreases, spool (3) moves to the left. Ports (C) and (D) are blocked,
while pump discharge pressure port (B) is connected to port (C).
• Since the pressure in port (C) and the pressure at the large diameter side of the piston increase, servo
piston (9) stops moving to the right.
• Stop position of servo piston (9) (= pump discharge) is determined by a position where the thrust
generated by pressures (PP1) and (PP2) on spool (3) and the thrust by PC-EPC valve solenoid and the
force of springs (4) and (6) are balanced.

PC138USLC-10 10-57
10 Structure and function
Main pump

When actuator load is large and pump discharge pressure (PP) is high

Function
• When the load is large and pump discharge pressures (PP1) and (PP2) are high, the thrust moving spool
(3) to the left increases, and spool (3) comes to a position shown in above figure.
• The pressure from port (C) to the LS valve becomes approximately half of pump pressure (PP2), because
a part of the pressure from port (B) flows into port (D) through the LS valve and port (C), as shown in
above figure.

Operation
• When ports (E) and (G) of the LS valve are connected, the pressure is transmitted from port (J) to the
large diameter end of servo piston (9), and servo piston (9) stops moving.
• When main pump pressure (PP) increases more and spool (3) moves further to the left, pump pressure
(PP1) flows to port (C) to minimize the pump discharge.
• When servo piston (9) moves to the left, springs (4) and (6) are compressed, and push back spool (3).
• The pressure in port (C) (=J) decreases, and the movement of servo piston (9) to the right stops.
• At this time, servo piston (9) stops at a position further to the left than the position when pump pressures
(PP1) and (PP2) are low.

10-58 PC138USLC-10
10 Structure and function
Main pump

• The relationship between pump average pressure (PP1 + PP2)/2 and the position of servo piston (9) is
indicated by a bent line since springs (4) and (6) are a 2-stage spring.
• The relationship between pump average pressure (PP1 + PP2)/2 and pump average discharge (Q)
becomes as shown in the following figure.

• If command current (X) sent to PC-EPC valve solenoid (1) increases further, the relationship between
pump average pressure (PP1 + PP2)/2 and pump discharge (Q) is translated in proportion to the thrust of
PC-EPC valve solenoid.
• The thrust of PC-EPC valve solenoid (1) is added to the leftward thrust caused by the pump pressure
applied to spool (3), so the relationship between pump average pressure (PP1 + PP2)/2 and pump
discharge (Q) moves from (A) to (B) as the command current (X) is increased.

PC138USLC-10 10-59
10 Structure and function
Main pump

When the emergency pump drive switch is turned “ON“ due to failure on the pump controller

When the main pump is under light load

• If there is a failure in the pump controller, the emergency pump drive switch is turned to "ON" position to
switch the control to the resistor side.
• In this case, the power is directly supplied from the battery. The current, however, is too large as is, so the
resistor is set in between to control the current flowing to PC-EPC valve solenoid (1).
• The current becomes constant, so the force pushing piston (2) is also constant.
• When pump discharge pressures (PP1) and (PP2) are low, spool (3) is balanced at right position, since
the combined force of PC-EPC valve solenoid (1) and pump discharge pressure is smaller than the spring
set pressure.
• Port (C) is connected to the drain passage of port (D), and the large diameter end of servo piston (9) is
also connected to the drain passage through the LS valve.
• Since the pressure on the small diameter end of servo piston (9) is larger, the piston moves in the direction
to make the discharge larger.

10-60 PC138USLC-10
10 Structure and function
Main pump

When the main pump is under heavy load

• Similarly to the preceding section, when the emergency pump drive switch is at "ON" position, command
current (X) sent to PC-EPC valve solenoid (1) becomes constant.
• For this reason, the force of piston (2) pushing spool (3) is constant.
• When main pump pressures (PP1) and (PP2) increase, spool (3) moves to the left from the position where
the load of the main pumps is smaller, and is balanced at the position shown in the above figure.
• Since the pressure from port (A) flows into port (C), servo piston (9) moves to the left (smaller pump
discharge) and stops at a position to the further to the left than when the load on the pump is light.
• The curves of pump discharge pressure (PP) and pump discharge (Q) are determined as shown in the
figure below by the electric current value sent to the PC-EPC valve solenoid through the resistor even
when the emergency pump driving switch is turned to "ON" position.
• The curves resulting when the emergency pump drive switch is turned to "ON" position are situated further
to the left (B) than when the pump controller is normal (A).

PC138USLC-10 10-61
10 Structure and function
Main pump

10-62 PC138USLC-10
10 Structure and function
Main pump

PC-EPC valve (D65-C2E5-041-P-00-A)

a PC: Abbreviation for Pressure Compensation


a EPC: Abbreviation for Electromagnetic Proportional Control

C: To PC valve
P: From pump
T: To tank

1. Connector
2. Coil
3. Body
4. Spring
5. Spool
6. Rod
7. Plunger

Function (D65-C2E5-042-P-00-A)
• The EPC valve consists of the proportional solenoid and the hydraulic valve.
• When signal current (i) from the controller is received, an EPC output pressure proportional to the
amperage of current is generated and output to the PC valve.

PC138USLC-10 10-63
10 Structure and function
Main pump

Operation (D65-C2E5-044-P-00-A)

When signal current is zero (coil de-energized)

• When the signal current from the controller is not flowing through coil (1), coil (1) is de-energized.
• Spool (2) is pushed to the left side by spring (3).
• Port (P) is closed, and the pressurized oil from the pilot pump does not flow to the PC valve.
• The pressurized oil from the PC valve is drained to the tank through port (C) and port (T).

10-64 PC138USLC-10
10 Structure and function
Main pump

When signal current is minute (coil is energized)

• When a small signal current flows through coil (1), coil (1) is energized and a thrust pushing plunger (4) to
the right is generated.
• Rod (5) pushes spool (2) to the right, and the pressurized oil flows from port (P) to port (C).
• The pressure at port (C) increases and the total of the force applied to the surface of spool (2) and the
reaction force of spring (3) becomes larger than the thrust of plunger (4).
• Spool (2) is pushed to the left to throttle the passage between ports (P) and (C).
• Port (C) connects to port (T).
• Spool (2) moves to a position where the thrust of plunger (4) becomes equal to the total of the pressure in
port (C) and the reaction force of spring (3).
• The circuit pressure between the EPC valve and the PC valve is controlled in proportion to the amperage
of the signal current.

When signal current is maximum (coil is energized)

• Coil (1) is energized when signal current is supplied to coil (1).


• As the amperage of signal current is maximum, the thrust of plunger (4) is also maximized.
• Spool (2) is pushed to the right by rod (5).
• The pressurized oil flows from port (P) to port (C) at the maximum rate, and the circuit pressure between
the EPC valve and PC valve is maximized.
• Since port (T) is closed, no pressurized oil flows to the tank.

PC138USLC-10 10-65
10 Structure and function
Main pump

Check valve (PC138-C2YA-041-K-00-A)

PA1: Main pump discharge pressure


PA2: Main pump discharge pressure
PP1: Check valve output pressure

1. Poppet valve
2. Poppet valve

Function (PC138-C2YA-042-K-00-A)
• 2 check valves are used as a set to output the higher one of the 2 main pump discharge pressures.

Operation (PC138-C2YA-044-K-00-A)

When (PA1) > (PA2)


• Main pump discharge pressures (PA1) and (PA2) act on poppet valves (1) and (2). Since (PA1) > (PA2),
poppet valve (2) is kept closed and (PA1) is output to (PP1).

When (PA1) < (PA2)


• Reversely to the above, poppet valve (1) is kept closed and (PA2) is output to (PP1).

10-66 PC138USLC-10
10 Structure and function
Main pump

Shuttle valve (PC138-C2YB-041-K-00-A)

PA1: Main pump discharge pressure


PA2: Main pump discharge pressure
PP2: Shuttle valve output pressure

1. Poppet valve
2. Poppet valve
3. Pin

Function (PC138-C2YB-042-K-00-A)
• This valve chooses and outputs the lower one of the discharge pressures of the 2 main pumps.

Operation (PC138-C2YB-044-K-00-A)
• 2 main pump discharge pressures (PA1) and (PA2) act on poppet valves (1) and (2) respectively.
• Since poppet valves (1) and (2) operate through pin (3), poppet valve (1) on the high pressure side closes
and poppet valve (2) on the low pressure side opens.

PC138USLC-10 10-67
10 Structure and function
Control valve

Control valve (PC138-C030-041-K-00-A)

a In this section, only the 8-spool valve (blade valve + service valve) is shown.

10-68 PC138USLC-10
10 Structure and function
Control valve

A1: To swing motor


A2: To blade cylinder bottom
A3: To L.H. travel motor
A4: To R.H. travel motor
A5: To boom cylinder bottom
A6: To arm cylinder head
A7: To bucket cylinder head
A8: To attachment
B1: To swing motor
B2: To blade cylinder head
B3: To L.H. travel motor
B4: To R.H. travel motor
B5: To boom cylinder head
B6: To arm cylinder bottom
B7: To bucket cylinder bottom
A8: To attachment
BP1: From R.H. work equipment PPC valve (boom “RAISE“)
LS: From pump LS valve
LS1: LS1 pressure pickup port
LS2: LS2 pressure pickup port
LS3: LS3 pressure pickup port
P1: From main pump
P2: From main pump
PA1: From L.H. work equipment PPC valve (swing LEFT)
PA2: From blade PPC valve (blade “LOWER“)
PA3: From travel PPC valve (left travel FORWARD)
PA4: From travel PPC valve (right travel FORWARD)
PA5: From R.H. work equipment PPC valve (boom “RAISE“)
PA6: From L.H. work equipment PPC valve (arm “OUT“)
PA7: From R.H. work equipment PPC valve (bucket “DUMP“)
PA8: From R.H. attachment PPC valve
PB1: From L.H. work equipment PPC valve (swing RIGHT)
PB2: From blade PPC valve (blade RAISE)
PB3: From travel PPC valve (left travel REVERSE)
PB4: From travel PPC valve (right travel REVERSE)
PB5: From R.H. work equipment PPC valve (boom “LOWER“)
PB6: From L.H. work equipment PPC valve (arm “IN“)
PB7: From R.H. work equipment PPC valve (bucket “CURL“)
PB8: From R.H. attachment PPC valve
PMAX: Pump pressure pickup sensor port
PP: To main pump
PP1: PP1 pressure pickup port
PP2: PP2 pressure pickup port
PPI1: Pump 1 pressure pickup port
PPI2: Pump 2 pressure pickup port
PR: To solenoid valve and EPC valve
PRI: PR pressure pickup port

PC138USLC-10 10-69
10 Structure and function
Control valve

PS: From merge-divider solenoid valve


PST: From travel junction solenoid valve
TB: To hydraulic tank
TC: To oil cooler
TS1: To hydraulic tank
TS2: To hydraulic tank
TSW: To swing motor

1. Cover
2. Service valve
3. Bucket valve
4. Arm valve
5. Boom valve
6. Right travel valve
7. Left travel valve
8. Blade valve
9. Swing valve
10.Block
11.LS check valve
12.Travel junction valve + LS check valve
13.Arm regeneration valve
14.Boom hydraulic drift prevention valve
15.Merge-divider valve block

10-70 PC138USLC-10
10 Structure and function
Control valve

PC138USLC-10 10-71
10 Structure and function
Control valve

1. Centralized safety valve filter


2. Suction safety valve (service)
3. Suction valve (bucket)
4. Suction valve (arm)
5. Suction valve (boom)
6. Back pressure check valve
7. Suction valve (right travel)
8. Suction valve (left travel)
9. Suction valve (blade)
10.Suction safety valve (blade)
11.Suction valve (left travel)
12.Suction valve (right travel)
13.Main relief valve
14.Suction valve (boom)
15.Suction valve (arm)
16.Suction valve (bucket)
17.Suction safety valve (service)
18.Suction-safety valve
19.Spool (service)
20.Spool (bucket)
21.Spool (arm)
22.Spool (boom)
23.Spool (right travel)
24.Spool (left travel)
25.Spool (blade)
26.Spool (swing)
27.Unload valve
28.Unload valve

10-72 PC138USLC-10
10 Structure and function
Control valve

PC138USLC-10 10-73
10 Structure and function
Control valve

1. LS separation valve
2. Oil cooler bypass valve
3. PP circuit filter
4. Pressure compensation valve (service) (*1)
5. Pressure compensation valve (bucket) (*1)
6. Pressure compensation valve (arm) (*1)
7. Pressure compensation valve (boom) (*1)
8. Pressure compensation valve (right travel) (*1)
9. Pressure compensation valve (left travel) (*1)
10.Pressure compensation valve (blade) (*1)
11.Pressure compensation valve (swing) (*1)
12.Pressure compensation valve (swing) (*2)
13.Pressure compensation valve (blade) (*2)
14.Pressure compensation valve (left travel) (*2)
15.Pressure compensation valve (right travel) (*2)
16.Merge-divider valve spool
17.Pressure compensation valve (boom) (*2)
18.Pressure compensation valve (arm) (*2)
19.Pressure compensation valve (bucket) (*2)
20.Pressure compensation valve (service) (*2)

*1: Pressure reducing valve


*2: Flow control valve

10-74 PC138USLC-10
10 Structure and function
Control valve

PC138USLC-10 10-75
10 Structure and function
Control valve

1. LS separation valve
2. LS bypass circuit filter

Swing valve
3. Pressure compensation valve (*1)
4. Spool
5. Pressure compensation valve (*2)

Blade valve
6. Pressure compensation valve (*1)
7. Suction safety valve
8. Suction valve
9. Spool
10. Pressure compensation valve (*2)

Left travel valve


11. Pressure compensation valve (*1)
12. Suction valve
13. Suction valve
14. Spool
15. Pressure compensation valve (*2)
16. LS check valve

17. LS bypass check valve

*1: Flow control valve


*2: Pressure reducing valve

10-76 PC138USLC-10
10 Structure and function
Control valve

PC138USLC-10 10-77
10 Structure and function
Control valve

Right travel valve


1. Pressure compensation valve (*1)
2. Suction valve
3. Suction valve
4. Spool
5. Pressure compensation valve (*2)
6. LS check valve
7. Travel junction valve

8. Unload valve
9. LS bypass plug
10. Merge-divider valve spool
11. Main relief valve
12. Oil cooler bypass valve
13. Back pressure check valve

Boom valve
14. Pressure compensation valve (*1)
15. Suction valve
16. Hydraulic drift prevention valve
17. Suction valve
18. Spool
19. Pressure compensation valve (*2)

*1: Flow control valve


*2: Pressure reducing valve

10-78 PC138USLC-10
10 Structure and function
Control valve

PC138USLC-10 10-79
10 Structure and function
Control valve

Arm valve
1. Pressure compensation valve (*1)
2. Suction valve
3. Suction valve
4. Spool
5. Pressure compensation valve (*2)
6. Regeneration valve

Bucket valve
7. Pressure compensation valve (*1)
8. Suction valve
9. Suction valve
10. Spool
11. Pressure compensation valve (*2)

Service valve
12. Pressure compensation valve (*1)
13. Suction safety valve
14. Suction safety valve
15. Spool
16. Pressure compensation valve (*2)

17. Suction safety valve


18. Centralized safety valve filter
19. Pressure relief plug

*1: Flow control valve


*2: Pressure reducing valve

Structure
• The control valves of the following types are available.
7-spool valve (blade)
8-spool valve (blade + service valve)
• The control valve consists of a 6-spool valve (integrated), service valve, and blade valve, and the merge-
divider valve, variable back pressure valve, and boom hydraulic drift prevention valve are installed to it.
• Since all the valves are fixed in one unit with connecting bolts and their passages are connected internally,
the whole unit is compact in size and easy to service.
• This control valve has a simple structure of 1 spool for 1 work equipment.

10-80 PC138USLC-10
10 Structure and function
Control valve

Hydraulic circuit diagram and names of valves (PC138-C030-054-K-00-A)

PC138USLC-10 10-81
10 Structure and function
Control valve

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. Pressure compensation valve
10.Suction valve
11.LS separation valve
12.Merge-divider valve
13.Arm regeneration valve
14.Self-pressure reducing valve
15.Travel junction valve
16.Back pressure check valve
17.Oil cooler bypass valve
18.LS bypass plug
19.Boom hydraulic drift prevention valve
20.Suction-safety valve
Set pressure: 36.8 MPa {375 kg/cm2}
21.Suction-safety valve
Set pressure: 24.5 MPa {250 kg/cm2}
22.2-stage suction-safety valve
1st stage set pressure: 24.5 MPa {250 kg/cm2}
2nd stage set pressure: 17.2 MPa {175 kg/cm2}
23.Suction-safety valve
Set pressure: 35.8 MPa {365 kg/cm2}
24.Main relief valve
Set pressure: 34.8 MPa {355 kg/cm2}
25.Unload valve
Set pressure: 5.9 MPa {60 kg/cm2}

10-82 PC138USLC-10
10 Structure and function
Control valve

Unload valve (PC138-PQD5-041-K-00-A)


When control valve is at hold

Function
• This valve releases discharge (Q) for the minimum pump swash plate angle into the tank circuit when the
control valve is held. At this time, the pump circuit pressures (P1) and (P2) are set with springs (2) in the
valve. The LS circuit pressures (LS1) and (LS2) are 0 MPa {0 kg/cm2}.
• Since the merge-divider spool is at the merge position, pump circuit pressures (P1) and (P2) are merged.
LS circuit pressures (LS1), (LS2), and (LS3) are also merged.

Operation
• Pump circuit pressures (P1) and (P2) act on pump pressure receiving faces (SA) of spool (1).
• LS circuit pressures (LS1) and (LS2) act on pump pressure receiving faces (SB). [(P1) = (P2), (LS1) =
(LS2)]
• When the control valve is held, LS circuit pressures (LS1) and (LS2) are 0, thus only the pump circuit
pressures (P1) and (P2) act on the valve, and (P1) and (P2) are set with only the reaction force of springs
(2).
• When pump circuit pressures (P1) and (P2) increase to the set pressure of springs (2), spools (1) move to
the left and pump circuit pressures (P1) and (P2) are supplied to tank circuit (T) through the notches of
spools (1) .

PC138USLC-10 10-83
10 Structure and function
Control valve

When work equipment valve is operated

Function
• When the work equipment valve is operated, if the actuator demand flow exceeds the pump discharge
with the swash plate at the minimum angle, the unload valve blocks the flow to tank circuit (T) and allows
all of pump discharge (Q) to flow to the actuator circuit.
• Since the merge-divider spool is at the merge position, pump circuit pressures (P1) and (P2) are merged.
LS circuit pressures (LS1), (LS2), and (LS3) are also merged.

Operation
• When the work equipment valve is operated largely, LS circuit pressures (LS1) and (LS2) are generated
and applied to faces (SB) of spools (1). Pump circuit pressures (P1) and (P2) act on pump pressure
receiving faces (SA).
• LS circuit pressures (LS1) and (LS2) act on pump pressure receiving faces (SB). [(P1) = (P2), (LS1) =
(LS2)]
• Since the differential pressure between pump circuit pressures [(P1) and (P2)] and LS circuit pressures
[(LS1) and (LS2)] does not reach the set pressure of springs (2), spools (1) are pushed to the right by
springs (2).
• Pump circuits (P1) and (P2) are disconnected from tank circuit (T) and all of pump discharge (Q) flows to
the actuator circuit.

10-84 PC138USLC-10
10 Structure and function
Control valve

When fine control operation of right and left travel valves is performed

Function
• When the differential pressure between pump circuit pressures [(P1) and (P2)] and LS circuit pressures
[(LS1) and (LS2)] reaches the set pressure of springs (2), spools (1) open and excessive oil (pump
maximum discharge - demand flow) flows to tank circuit (T).
• Since the merge-divider spool is at the divide position, pump circuit pressures (PP1) and (PP2) are divided
from each other, and LS circuits (LS1) and (LS2) are also divided..
• The pump swash plate angle becomes its maximum, and the maximum flow is discharged. (For details,
see the section of merge-divider valve.)

Operation
• When the right and left control valves are controlled finely, LS circuit pressures (LS1) and (LS2) are
generated and applied to faces (SB) of spools (1). [(P1), (P2), (LS1), and (LS2) are divided]
When the differential pressure between pump circuit pressures [(P1) and (P2)] and LS circuit pressures
[(LS1) and (LS2)] reaches the set pressure of springs (2), spools (1) move to the left to connect pump
circuits pressures (P1) and (P2) to tank circuit (T) and allow the excessive oil (pump maximum discharge -
demand flow) to flow.
• The excess oil other than the demand flow in accordance with the stroke of the right and left travel valves
(pump maximum discharge - demand flow) is supplied to tank circuit (T).

PC138USLC-10 10-85
10 Structure and function
Control valve

When right and left travel valves are operated

Function
• When the right and left travel valves are operated and the demand flow of the right and travel circuits
becomes maximum, draining into tank circuit (T) is stopped and all of pump discharge (Q) is supplied to
the right and left travel circuits.
• Since the merge-divider spool is at the divide position, pump circuit pressures (PP1) and (PP2) are divided
from each other, and LS circuits (LS1) and (LS2) are also divided.
• The pump swash plate angle becomes its maximum, and the maximum flow is discharged. (For details,
see the section of merge-divider valve.)

Operation
• When the right and left control valves are controlled finely, LS circuit pressures (LS1) and (LS2) are
generated and applied to faces (SB) of spools (1). [(P1), (P2), (LS1), and (LS2) are divided]
• Since the open areas of the right and left travel valve spools are large, the differential pressure between
pump circuit pressures [(P1) and (P2)] and LS circuit pressures [(LS1) and (LS2)] is small.
• Since the differential pressure between pump circuit pressures [(P1) and (P2)] and LS circuit pressures
[(LS1) and (LS2)] does not reach the set pressure of springs (2), spools (1) are pushed to the right by
springs (2).
• Pump circuits (P1) and (P2) are disconnected from tank circuit (T) and all of pump discharge (Q) flows to
the actuator circuit.

10-86 PC138USLC-10
10 Structure and function
Control valve

When travel valve on one side is operated

Function
• The operated side supplies a demand flow to the travel circuit according to the stroke of the travel valve,
and the non-operated side supplies all of pump discharge (Q) to the tank circuit (T).
• Since the merge-divider spool is at the divide position, pump circuit pressures (PP1) and (PP2) are divided
from each other, and LS circuits (LS1) and (LS2) are also divided.
• The pump swash plate angle becomes its maximum, and the maximum flow is discharged. (For details,
see the section of merge-divider valve.)

Operation
When left travel valve is operated full stroke and right travel valve is held
• When the left control valve is operated full stroke, LS circuit pressures (LS1) and (LS2) are generated and
LS circuit pressure (LS1) is applied to faces (SB) of spools (1).
Since the open area of the left travel valve spool is large, the differential pressure between pump circuit
pressures [(P1) and (P2)] and LS circuit pressures [(LS1) and (LS2)] is small.
• Since the differential pressure between pump circuit pressure (P1) and LS circuit pressure (LS1) does not
reach the spring load of springs (2), spools(1) are pushed to the right by springs (2).
• Pump circuit pressure (P1) is disconnected from tank circuit (T) and all of pump discharge (QP1) on the
(P1) side flows into the left travel circuit.
• Since the right travel valve is held, LS circuit pressure (LS2) is not generated, only pump circuit pressure
(P2) acts on the valve.
• When pump circuit pressure (P2) increase to the set pressure of springs (2), spools (1) move to the left
and all of pump discharge (QP2) on the (P2) side flows into tank circuit (T).

PC138USLC-10 10-87
10 Structure and function
Control valve

Introduction of LS pressure (PC138-C2A4-041-K-00-A)

a LS: Abbreviation for Load Sensing

Function
• LS pressure is the actuator load pressure on the outlet side of the control valve.
• Actually, the work equipment valve reduces pump discharge pressure (PP) with pressure reducing valve
(3) of the pressure compensation valve to the same value of pressure as actuator circuit pressure (A), and
then supplies it to LS circuit (PLS).
• In the travel valve, actuator circuit pressure (A) is supplied directly to LS circuit (PLS).

Operation

Work equipment valve

• When spool (1) is operated, pump discharge pressure (PP) flows from flow control valve (2) and notch (a)
in the spool through bridge passage (b) to actuator circuit (A).
• Pressure reducing valve (3) also moves to the right, so pump discharge pressure (PP) is reduced due to
the pressure loss at notch (c) and then transmitted to LS circuit (PLS). Pump delivery pressure (PP) is
further sent to spring chamber (PLSS).
• LS circuit (PLS) is connected to tank circuit (T) from LS bypass valve (4). (See "LS bypass valve".)
• The areas at both ends of pressure reducing valve (3) are the same [(SA) = (SLS)], and actuator circuit
pressure (PA) acts on the (SA) end. The reduced pump discharge pressure (PP) acts on (SLS) the other
end.

10-88 PC138USLC-10
10 Structure and function
Control valve

• Pressure reducing valve (3) is balanced at a position where actuator circuit pressure (PA) and the
pressure of spring chamber (PLSS) are the same. Pump discharge pressure (PP) reduced at notch (c)
becomes actuator circuit pressure (A) and is transmitted into LS circuit (PLS).

Travel valve

• When spool (1) is operated, pump discharge pressure (PP) flows from flow control valve (2) and notch (a)
in the spool through bridge passage (b) to actuator circuit pressure (A).
• Actuator circuit pressure (PA) (= A) is transmitted through check valve (5) to LS circuit (PLS).
a In the travel circuit, unlike in the work equipment circuit, actuator circuit pressure (PA) is supplied directly
to LS circuit (PLS).

PC138USLC-10 10-89
10 Structure and function
Control valve

LS bypass plug (PC138-PNSH-041-K-00-A)

a LS: Abbreviation for Load Sensing

Function
• Release the remaining pressure in the LS circuit (PLS).
• Decrease the rising speed of the pressure in the LS circuit (PLS) to prevent a sudden change of the oil
pressure.
• Generate pressure loss in the throttle quantity of the pressure reducing valve with the discarded throttled
flow from LS bypass plug (2).
• Decrease the effective LS circuit differential pressure to improve the dynamic stability of the actuator.

10-90 PC138USLC-10
10 Structure and function
Control valve

Operation

When work equipment valve is operated


(including simultaneous operation of work equipment and travel)

• Since merge-divider spool (1) is located at the merge position, the pressurized oil in LS circuits (PLS1),
(PLS2), and (PLS3) flows from filter (a) at the end of LS bypass plug (2) through orifice (b) into tank circuit
(T).

PC138USLC-10 10-91
10 Structure and function
Control valve

When right or left travel valve is operated


(including operation of one side travel)

• Since merge-divider spool (1) is located at the divide position, LS circuits (PLS1) and (PLS2) are divided
from each other.
• The pressurized oil in LS circuit (PLS1) flows through filter (a) at the end of LS bypass plug (2) and orifice
(b) to tank circuit (T).
• The pressurized oil in LS circuit (PLS2) flows through filter (c) at the end of LS bypass plug (3) and orifice
(d) to tank circuit (T).

10-92 PC138USLC-10
10 Structure and function
Control valve

Pressure compensation valve (PC138-L6D0-040-K-00-A)

PC138USLC-10 10-93
10 Structure and function
Control valve

Function
• Oil flow rate to be supplied from pump to each actuators is equivalent when the load applied to actuators
in operation is equivalent.
• If pressure compensation valve is not equipped, operating speed of a certain actuator with smaller load
becomes faster than it of other actuators with larger load. It is because oil supplied from pump flows more
to actuators with lower load when load of a certain actuator increased.
• Pressure compensation valve decreases flow rate going to actuator with smaller load by LS pressure
(PLS) of actuators with the largest load during combined operations. Thus, flow rate going to actuator with
larger load is compensated to secure the operating speed not influenced by the load pressure.

Operation
• When load pressure (Ab) of the other actuator (upper side in the above figure) increases during combined
operation, flow to the actuator circuit (Aa) on this side (lower side in the above figure) is going to increase.
• In this case, LS circuit pressure (PLS) of the other actuator side (top in the above figure) is applied to
spring chamber (PLS1) on this side (below in the above figure) and pushes pressure reducing valve (1)
and flow control valve (2) to the left.
• Flow control valve (2) reduces the open area between pump circuit (PP) and spool upstream (PPA) to
generate a pressure loss between (PP) and (PPA).
• The flow control valve (2) and the pressure reducing valve (1) balance each other at the place where the
pressure difference between (PA) and (PLS) which applies to the both end surfaces of the pressure
reducing valve (1) becomes the same as the pressure loss between (PP) and (PPA) around the flow
control valve.
• The pressure differences between upstream pressure (PPA) and downstream pressure (PA) of both
spools operated for combined operation becomes the same and the pump delivery is divided in proportion
to the opening area of notch (a) of each spool.

10-94 PC138USLC-10
10 Structure and function
Control valve

Surface area ratio of pressure compensation valve

S1: Area of flow control valve (2) - Area of piston (3)


S2: Area of pressure reducing valve (1) - Area of piston (3)
PP: Pump discharge pressure
PPB: Upstream pressure at notch of spool
PLS: LS circuit pressure
PA: Actuator circuit pressure
A: Actuator operating pressure

Function
• The pressure compensation valve finely adjusts the ratio of area (S1) on the left side of flow control valve
(2) to area (S2) on the right side of pressure reducing valve (1) ((S2)/(S1)) to decide the compensation
characteristics according to the characteristics of each actuator.

Surface area ratio (S2):(S1) and compensation characteristics


• The flow division ratio varies with the surface area ratio of portions (S1) and (S2) of the pressure
compensation valve. Surface area ratio = (S2)/(S1)
• When the surface area ratio is 1:
[(PP) - (PPB)] C [(PLS) - (PA (= A))], thus oil flow is supplied evenly in accordance with the open area
ratio of the spool.
• When the surface area ratio is more than 1:
[(PP) - (PPB)] > [(PLS) - (PA (= A))], thus less oil flow is supplied to the compensated side for the open
area ratio of the spool.

PC138USLC-10 10-95
10 Structure and function
Control valve

• When the surface area ratio is less than 1:


[(PP) - (PPB)] < [(PLS) - (PA (= A))], thus more oil flow is supplied to the compensated side for the
open area ratio of the spool.

10-96 PC138USLC-10
10 Structure and function
Control valve

Boom regeneration circuit (PC138-L511-040-K-00-A)


When cylinder bottom pressure is higher than the head pressure (when hydraulically drifts, etc.)

Function
• During the boom “LOWER“ operation, if bottom pressure (A) of boom cylinder (1) is higher than head
pressure (B) and the boom drifts hydraulically, regeneration circuit (a) increases the oil flow to the head
side to increase the cylinder rod speed.

Operation
• If the boom drifts hydraulically during the boom “LOWER“ operation, bottom pressure (A) of boom cylinder
(1) is higher than head pressure (B).
• A part of the return oil on the bottom side flows through the notch of boom spool (2) to regeneration circuit
(a) and opens check valve (3).
• Then, the above oil flows from check valve (3) to the head side of boom cylinder (1) to increase the boom
“LOWER“ speed.

PC138USLC-10 10-97
10 Structure and function
Control valve

When cylinder head pressure is higher than the bottom pressure (when digging, etc.)

Function
• During the boom “LOWER“ operation, if head pressure (B) of boom cylinder (1) is higher than bottom
pressure (A) and the boom is loaded, check valve (3) closes to disconnect the head side and bottom side.

Operation
• If the boom is loaded during the boom “LOWER“ operation, head pressure (B) of boom cylinder (1) is
higher than bottom pressure (A).
• Check valve (3) is closed by head pressure (B) and spring (4), and circuits on head side and bottom side
are disconnected.

10-98 PC138USLC-10
10 Structure and function
Control valve

Arm regeneration circuit (PC138-L911-040-K-00-A)


When cylinder bottom pressure is higher than the head pressure (when hydraulically drifts, etc.)

Function
• During the arm “IN“ operation, if head pressure (A) of arm cylinder (1) is higher than bottom pressure (B)
and the arm drifts hydraulically, regeneration circuit (a) increases the oil flow to the bottom side to increase
the cylinder speed.

Operation
• If the arm drifts hydraulically during the arm “IN“ operation, head pressure (A) of arm cylinder (1) is higher
than bottom pressure (B).
• A part of the return oil on the bottom side flows through the notch of arm spool (2) to regeneration circuit
(a) and opens check valve (3).
• Then, the above oil flows from check valve (3) to the bottom side of arm cylinder (1) to increase the arm
“IN“ speed.

PC138USLC-10 10-99
10 Structure and function
Control valve

When cylinder head pressure is higher than the bottom pressure (when digging, etc.)

Function
• During the arm “IN“ operation, if bottom pressure (B) of arm cylinder (1) is higher than head pressure (A)
and the arm is loaded, check valve (3) closes to disconnect the head side and bottom side.

Operation
• If the arm is loaded during the arm “IN“ operation, bottom pressure (B) of arm cylinder (1) is higher than
head pressure (A).
• Check valve (3) is closed by bottom pressure (B) and spring (4), and circuits on head side and bottom side
are disconnected.

10-100 PC138USLC-10
10 Structure and function
Control valve

Merge-divider valve (PC138-PP30-040-K-00-A)


Operation

When merged [(PS) = 0 MPa {0 kg/cm2}]

• Merge-divider spool (3) merges pump discharge pressures (P1) and (P2), and merges (LS1), (LS2), and
(LS3).
• As a result, (P1) = (P2) and (LS1) = (LS2) = (L3), and the pump swash plate is controlled with the
differential pressure between (P) circuit and (LS) circuit.

PC138USLC-10 10-101
10 Structure and function
Control valve

When divided [(PS) = 30 MPa {0 kg/cm2}]

• Merge-divider spool (3) divides pump discharge pressures (P1) and (P2), and divides (LS1), (LS2), and
(LS3).
• Merge-divider spool (3) supplies the higher one of (P1) and (P2) to the output port of LS circuit.
• Since the differential pressure between (P) circuit and (LS) circuit is lost, the pump swash plate angle is
maximized.

10-102 PC138USLC-10
10 Structure and function
Control valve

LS separation valve (PC138-J6PA-041-K-00-A)

a LS: Abbreviation for Load Sensing

Function
• This valve prevents high LS circuit pressure of the swing circuit from flowing into the LS circuit of the work
equipment valve during the combined operations of swing and boom “RAISE“.
• This valve improves the operability of the work equipment during swing operation by securing the pump
discharge.

Operation

When normally operated

• Since pilot port (BP1) is blocked during the operations other than boom “RAISE“, no pilot pressure acts on
it normally.
• At this time, pump discharge pressure (PP) pushes valve (1) open and flows into pressure reducing valve
(4) of the swing valve. When the swing operation is performed, pressure (PLS) is generated in the LS
circuit according to the load pressure and sent to the pump LS valve.

PC138USLC-10 10-103
10 Structure and function
Control valve

In compound operation of swing and boom “RAISE“

• When the swing and boom “RAISE“ operations are performed simultaneously, the signal of boom “RAISE“
PPC circuit is transmitted to pilot port (BP1).
• At this time, the pilot pressure acts on piston (2). When it reaches the set pressure of spring (3), piston (2)
moves to the left, valve (1) closes, and pump discharge pressure (PP) to pressure reducing valve (4) of
the swing valve is blocked.
• Pressure (PLS) in the LS circuit is not generated by the swing pressure, but only pressure (PLS) in the LS
circuit generated by the boom “RAISE“ operation is transmitted to the pump LS valve.
• The pump discharge is controlled by pressure (PLS) in the LS circuit generated by the boom RAISE
operation.
• The level of the pilot pressure is determined by the stroke of the control lever.

10-104 PC138USLC-10
10 Structure and function
Control valve

Self-pressure reducing valve (PC138-PL30-042-K-00-A)


Function
• It reduces the main pump discharge pressure and provides it as control pressure to the solenoid valves,
EPC valves, etc.

Operation

If normal

• When pressure (PR) exceeds the set pressure, poppet (1) opens.
• The pressurized oil flows from port (PR) to orifice (a) in spool (4), and then flows through the opening of
poppet (1) to seal drain port (TS).
• Differential pressure is generated over orifice (a) in spool (4) and spool (4) moves to close the opening
between ports (P) and (PR).
• Pressure (P) is reduced and adjusted to constant pressure (set pressure) by the opening area at this time
and supplied as pressure (PR).

When abnormal high pressure occurs


• If pressure (PR) of the self-pressure reducing valve becomes abnormal, ball (6) compresses spring (5)
and separates from the seat.
• The pressurized oil flows through port (PR) to (TS) to reduce pressure (PR).
• Thus, the hydraulic components such as the PPC valves and solenoid valves are protected from abnormal
pressure.

PC138USLC-10 10-105
10 Structure and function
Control valve

Travel junction valve (PC138-C6C0-042-K-00-A)


Function
• The travel junction valve interconnects the right and left travel circuits to equalize the oil flow supplied to
the right and left travel motors and secure straight travel.
• During steering operation, the right and left travel circuits are disconnected by external pilot pressure
(PST) to secure high steering performance.

Operation

When pilot pressure is applied

10-106 PC138USLC-10
10 Structure and function
Control valve

• When the pilot pressure from the travel junction solenoid valve reaches the set pressure of spring (2),
travel junction spool (1) moves to the left stroke end.
At this time, L.H. travel circuit port (PTL) and R.H. travel circuit port (PTR) are disconnected.

PC138USLC-10 10-107
10 Structure and function
Control valve

Boom hydraulic drift prevention valve (PC138-L6C0-042-K-00-A)


Function
• While the boom is not operated with the R.H. work equipment control lever, this valve prevents the
pressurized oil on the bottom side of the boom cylinder from leaking through spool (1) to cause hydraulic
drift of the boom.
Operation

Boom“RAISE“operation

• When the control lever is operated to perform the boom “RAISE“ operation, poppet (5) is moved up by the
pressurized oil from the control lever.
• The pressurized oil from the control lever flows through the opening of poppet (5) to the bottom side of the
boom cylinder.

10-108 PC138USLC-10
10 Structure and function
Control valve

Boom“NEUTRAL“operation

• When the R.H. work equipment control lever is returned to “NEUTRAL“ position during “RAISE“ operation,
the holding pressure on the bottom side of the boom cylinder is blocked by poppet (5) and the pressurized
oil flowing in through orifice (a) is blocked by pilot spool (3), thus the boom is held.

PC138USLC-10 10-109
10 Structure and function
Control valve

Boom“LOWER“operation

• When the control lever is operated to perform the boom “LOWER“ operation, pilot spool (3) is pushed by
the pilot pressure from the PPC valve and the pressurized oil in chamber (b) in the poppet is drained.
• The pressure in port (Ab) is increased by the pressurized oil on the bottom side of the boom cylinder, but
the pressure in chamber (b) is decreased by orifice (a).
• When the pressure in chamber (b) is lower than that in port (Aa), poppet (5) opens.
• When poppet (5) opens, the pressurized oil from port (Ab) flows into port (Aa), and then to the control
valve.

10-110 PC138USLC-10
10 Structure and function
Control valve

Back pressure check valve (PC138-PQ81-041-K-00-A)

Function (PC138-PQ81-042-K-00-A)
• This valve applies back pressure to the drain circuit to prevent negative pressure of each actuator (motor,
cylinder, etc.)

Operation (PC138-PQ81-044-K-00-A)
• Pressure (PA) in the drain circuit of the control valve acts on the left side of piston (2) to move piston (2) to
the right.
• Piston (2) balances so that the back pressure is as follows.
• (PA) - (PB) = Reaction force of spring (3) / Pressure receiving area (S1) of piston (2)

PC138USLC-10 10-111
10 Structure and function
Control valve

Oil cooler bypass valve (PC138-B8PB-041-K-00-A)

Function (PC138-B8PB-042-K-00-A)
• The oil cooler bypass valve prevents breakage of oil cooler (4) when the return oil flow from the control
valve increases and oil cooler inlet pressure (PB) increases consequently.
• The oil cooler bypass valve drains the return oil from the control valve directly to the tank without via oil
cooler (4).

Operation (PC138-B8PB-044-K-00-A)
• Oil cooler inlet pressure (PB) acts on the underside of piston (1) to move up piston (1).
• Piston (1) balances so that the oil cooler inlet pressure (PB) is as follows.
• (PB) - (PT) = Reaction force of spring (5) / Pressure receiving area (S2) of piston (1)

10-112 PC138USLC-10
10 Structure and function
Swing motor

Swing motor (PC138-J610-041-K-00-A)

B: From swing parking brake solenoid valve


MA: From control valve (left swing port)
MB: From control valve (right swing port)
S: From control valve (back pressure check valve)
T: To hydraulic tank

1. Reverse prevention valve


2. Safety valve

PC138USLC-10 10-113
10 Structure and function
Swing motor

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

10-114 PC138USLC-10
10 Structure and function
Swing motor

12.Valve plate
13.Center shaft
14.Center spring
15.Shuttle valve
16.Check valve
17.Swing modulating relief valve
Specifications (PC138-J610-030-K-00-A)

Model KMF45ABE-5
Theoretical displacement (cm3/rev) 45.3
Safety valve set pressure (MPa {kg/cm2}) 26 {265}
Rated speed (rpm) 2,111
Parking brake releasing pressure (MPa {kg/cm2}) 1.1 {11}

PC138USLC-10 10-115
10 Structure and function
Swing motor

Swing parking brake (PC138-J6A0-044-K-00-A)


Operation

Solenoid valve“de-energized“
• When the swing parking brake solenoid valve is de-energized, the pressurized oil from the self-pressure
reducing valve is blocked.
• Port (B) is connected to tank circuit (T).
• Brake piston (8) is pushed down by brake spring (1).
• Discs (5) and plates (6) are pressed and the brake operates.

10-116 PC138USLC-10
10 Structure and function
Swing motor

Solenoid valve“energized“
• When the swing parking brake solenoid valve is energized, the valve is changed.
• The pressurized oil from the self-pressure reducing valve flows into brake chamber (a) through port (B).
• The pressurized oil in brake chamber (a) compresses brake spring (1) and moves up brake piston (8).
• Discs (5) and plates (6) separate and the brake is released.

PC138USLC-10 10-117
10 Structure and function
Swing motor

Relief valve (PC220-J6B1-041-K-00-A)


• The relief valve portion consists of check valves (2) and (3), shuttle valves (4) and (5), and relief valve (1).

Function (PC220-J6B1-044-K-00-A)
• When the swing is stopped, control valve (6) blocks the motor outlet circuit, but the motor rotation is
continued by inertial force.
• If the pressure of motor outlet circuit becomes abnormally high, it may cause damage to the motor.
• In order to prevent the motor damage, the relief valve relieves the abnormally high pressure to port (S)
from the motor outlet (high-pressure side).

Operation (PC138-J6B1-044-K-00-A)

When starting swing

• When the control lever is operated to “Swing RIGHT“, the pressurized oil from the pump is supplied
through control valve (6) to port (MA).
• The pressure in port (MA) increases and generates starting torque in the motor, and the motor starts to
rotate.
• The pressurized oil from the motor output returns from port (MB) through control valve (6) to the tank.

10-118 PC138USLC-10
10 Structure and function
Swing motor

When stopping swing

• When the control lever is returned from “Swing RIGHT“ to “NEUTRAL“, the pressurized oil from the pump
is not supplied to port (MA).
• Since the return circuit to the tank for the pressurized oil from the motor outlet is closed by control valve (6),
the pressure in port (MB) increases.
• Rotation resistance is generated in the motor and the brake starts to work.
• When the pressure in port (MB) exceeds that in port (MA), it pushes shuttle valve (4).
• The pressure in chamber (C) becomes the same with port (MB) and increases to the set pressure of relief
valve (1).
• High braking torque is applied to the motor to stop.
• While relief valve (1) is in operation, the relieved pressurized oil and the pressurized oil from port (S) are
supplied to port (MA) through check valve (3).
• Cavitation in port (MA) is prevented.

PC138USLC-10 10-119
10 Structure and function
Swing motor

Swing modulating relief valve function (PC138-J6B3-042-K-00-A)


• The swing motor relief valve has characteristics of preventing sudden increase of the relief pressure to
reduce shocks generated when the machine stops and starts swinging.

Operation (PC138-J6B3-044-K-00-A)

When circuit pressure is (P0)


• The relief valve does not operate.

When circuit pressure rises abruptly


• When circuit pressure reaches (P1), pressure acts on the area difference between (D1) and (D3) [(D1 >
(D3)] and presses spring (4), thus valve (3) starts opening.
• At this time, pressure acts on the area difference between (D1) and (D2) [(D2) > (D1)], thus seat (1)
follows valve (3).
• The relief passage to port (S) for the oil in chamber (a) compressed by movement of seat (1) is narrowed
by ball (2), thus seat (1) moves slower than valve (3).
• Accordingly, the relief pressure increases gradually from (P1) to (P2) during the time before seat (1)
reaches sleeve (5).

10-120 PC138USLC-10
10 Structure and function
Swing motor

PC138USLC-10 10-121
10 Structure and function
Swing motor

Swing motor reverse prevention valve (PC-J6B2-041-K-00-A)

MA: From control valve (left swing port)


MB: From control valve (right swing port)

10-122 PC138USLC-10
10 Structure and function
Swing motor

T1: To hydraulic tank


T2: To hydraulic tank

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)

Explanatory drawing of effects

Function (PC220-J6B2-042-K-00-A)
• At the stop of swing operation, the upper structure may swing back. This is due to inertia of the mass of
the upper structure, the backlash and rigidity of the swing machinery system, and compressibility of the
hydraulic oil. This valve prevents such movement.
• The valve contributes to prevention of load spillage when the swing is stopped and also contributes to
reduction in the cycle time (enhances the positioning performance, enabling you to proceed to the next
work quicker than ever).

PC138USLC-10 10-123
10 Structure and function
Swing motor

Operation (PC220-J6B2-044-K-00-A)

When brake pressure is generated in port (MB)

• Pressure (MB) is led to chamber (d) through notch (g).


• As (D1 > D2) holds in regards to circle areas of spool (5), spring (6) is compressed and spool (5) is moved
to the left.
• Port (MB) and chamber (e) are interconnected to each other.
• Since pressure (MA) is lower than the set pressure of spring (3), spool (2) does not move and the
pressurized oil is blocked. Thus the braking force is ensured.

When motor reversing pressure is generated in port (MA)

• The trapped pressure in port (MB) turns the motor in the opposite direction. (1st reverse rotation)
• Reversing pressure is generated in port (MA). Pressure (MA) is transmitted to chamber (a).
• As (D3 > D4) holds in regard to circle areas of spool (2), spring (3) is compressed and spool (2) is moved
to the right.
• Port (MA) and chamber (b) are interconnected to each other.
• Port (b) is interconnected to port (f) through the drilled hole (h) in spool (5). This bypasses the reversing
pressure in port (MA) to port (T), thereby preventing the 2nd reverse rotation of the motor.

10-124 PC138USLC-10
10 Structure and function
Travel motor

Travel motor (PC138-C400-041-K-00-A)

L.H. travel motor


A: From center swivel joint (port B2)
B: From center swivel joint (port D2)
D: To center swivel joint (port DR2)
P: From center swivel joint (port E2)

R.H. travel motor


A: From center swivel joint (port C2)
B: From center swivel joint (port A2)
D: To center swivel joint (port DR2)
P: From center swivel joint (port E2)

1. Oil filler plug


2. Oil level plug
3. Drain plug

PC138USLC-10 10-125
10 Structure and function
Travel motor

1. Plug
2. Check valve
3. Counterbalance valve
4. Sleeve
5. Relief valve
6. End cover
7. Brake piston
8. Disc
9. Plate
10.Swash plate
11.Pivot
12.Bearing
13.Hub
14.No. 2 planetary gear
15.No. 1 planetary gear
16.Cover
17.No. 1 sun gear
18.No. 1 planetary carrier
19.No. 2 sun gear
20.No. 2 planetary carrier
21.Regulator piston
22.Shaft
23.Piston
24.Floating seal
25.Spindle

10-126 PC138USLC-10
10 Structure and function
Travel motor

26.Cylinder
27.Timing plate
28.Regulator valve
29.Check valve
30.Piston

PC138USLC-10 10-127
10 Structure and function
Travel motor

Structure

Reduction gear system


• Reduction gear (1) consists of 2-stage planetary gear mechanism and reduces the high speed rotation of
hydraulic motor (2) into low-speed and high-torque rotation.

Hydraulic motor
• Hydraulic motor (2) is a swash plate type axial piston motor. It converts the energy of the pressurized oil
sent from the main pump into rotary motion.

Brake valve
• Brake valve (3) consists of valves of various types and has the following functions.
Function of stopping hydraulic motor (2) smoothly
Function of preventing running away of hydraulic motor (2)
Function of preventing generation of abnormal pressure when hydraulic motor (2) is stopped suddenly

2-stage travel speed selector mechanism


• 2-stage travel speed selector mechanism (4) consists of the regulator valve and regulator piston and
changes the rotation speed to 2 levels by changing the displacement of hydraulic motor (2).

Parking brake
• Parking brake (5) is a multiple disc type brake and integrated with hydraulic motor (2).

Specifications (PC138-C400-030-K-00-A)

Model GM21VA-A
At min. swash plate angle 44.2
Theoretical displacement (cm3/rev)
At max. swash plate angle 79.1
Rated pressure (MPa {kg/cm2}) 34.81 {355}
At min. swash plate angle 2,609
Rated speed (rpm)
At max. swash plate angle 1,486
Parking brake releasing pressure (MPa {kg/cm2}) 0.76 {7.71}
Travel speed selector pressure (MPa {kg/cm2}) 2.94 {30}
Reduction ratio 54.0

10-128 PC138USLC-10
10 Structure and function
Travel motor

Operation of travel motor (PC138-C400-044-K-00-A)


At low engine speed (motor swash plate angle is maximum)

1. 2-stage travel speed selector solenoid valve


2. Regulator valve
3. Spring
4. Check valve
5. Regulator piston
6. Swash plate
7. Parking brake piston
8. Hydraulic pump
9. Travel control valve
10.Merge-divider valve
11.Self-pressure reducing valve
12.Brake valve

• When 2-stage travel speed selector solenoid valve (1) is de-energized, the pressurized oil from self-
pressure reducing valve (11) does not flow into port (P).
• Regulator valve (2) is pressed down by spring (3).
• The pressurized oil from the control valve passes through check valve (4) but its passage to regulator
piston (5) is blocked by regulator valve (2).
• At this time, the oil in chamber (C) is drained through oil passage (e) of regulator valve (2) and port (D).
• Swash plate (6) is set to the maximum angle, and consequently the motor capacity becomes maximum
and the machine travels at low speed.

PC138USLC-10 10-129
10 Structure and function
Travel motor

At high engine speed (motor swash plate angle is minimum)

1. 2-stage travel speed selector solenoid valve


2. Regulator valve
3. Spring
4. Check valve
5. Regulator piston
6. Swash plate
7. Parking brake piston
8. Hydraulic pump
9. Travel control valve
10.Merge-divider valve
11.Self-pressure reducing valve
12.Brake valve

• When 2-stage travel speed selector solenoid valve (1) is energized, the pressurized oil from self-pressure
reducing valve (11) flows into port (P).
• Regulator valve (2) is pushed up by the pressurized oil flowing into port (P).
• The pressurized oil from the control valve passes through check valve (4), then flows through oil passage
(f) of regulator valve (2) into chamber (C) and moves regulator piston (5) to the left.
• Swash plate (6) is set to the minimum angle, and consequently the motor capacity becomes minimum and
the machine travels at high speed.

10-130 PC138USLC-10
10 Structure and function
Travel motor

Brake valve (PC138-C4Q0-044-K-00-A)


When supplied

• When the travel lever is operated, pressurized oil from the control valve is supplied to port (A). It pushes
open check valve (1a) and flows through port (C) and hydraulic motor to port (D).
• When the pressurized oil flowing into chamber (G) through orifice (f) exceeds the set pressure of spring (3),
counterbalance valve (2) moves to the right, and the ports (D) and (B) are connected.
• At this time, parking brake piston (4) is pressed down by the pressurized oil which flows through ports (A)
and (E). As a result, the parking brake is released and the hydraulic motor rotates.

PC138USLC-10 10-131
10 Structure and function
Travel motor

When shut off

• When travel lever is returned to “NEUTRAL“ position, the pressurized oil from the control valve is blocked
and counterbalance valve (2) is moved to the left by spring (3).
• When the oil in chamber (G) flows through orifice (f) to port (A), the throttle effect of orifice (f) generates
back pressure, which controls the speed of counterbalance valve (2) moving to the left.
• Counterbalance valve (2) throttles the return circuit gradually with the moving speed and notch to stop the
hydraulic motor slowly.

10-132 PC138USLC-10
10 Structure and function
Travel motor

When traveling downhill

• If the machine runs away during downhill travel, the hydraulic motor rotates idle and the oil pressure in port
(C) drops, and the oil pressure in port (G) also drops through orifice (f).
• When the oil pressure in chamber (G) decreases below the set pressure of spring (3), counterbalance
valve (2) moves to the left.
• When the oil in chamber (J) flows through orifice (h) to port (B), the throttle effect of orifice (h) generates
back pressure, which controls the speed of counterbalance valve (2) moving to the right.
• When ports (D) and (B) are throttled and the oil pressure in port (D) increases, resistance is applied to the
rotation of the hydraulic motor to prevent running away of the machine.
• Counterbalance valve (2) moves to a position where the pressure generated by the machine weight and
the pressure in port (A) are balanced with the pressure in port (B). As a result, the outlet circuit is throttled
to control the rotation speed according to the pump discharge.

PC138USLC-10 10-133
10 Structure and function
Travel motor

Relief valve (PC138-C4J0-044-K-00-A)

When started

• The pressurized oil from the control valve flows through ports (A) and (C) to the hydraulic motor to give a
rotational force to the motor.
• When the oil pressure in port (C) increases above the set pressure, relief valve (1a) moves up to release
the pressurized oil into port (D).
• The pressurized oil from the control valve flows through ports (A) and (C), relief valve (1a), and sleeve (2a)
to chamber (E) to move piston (3) to the right.
• When piston (3) reaches the stroke end, the pressure between relief valve (1a) and chamber (E)
increases and relief valve (1a) closes the oil passages to ports (C) and (D).
• Relief valve (1a) controls the pressure in port (C) on the inlet side of the hydraulic motor to start the
hydraulic motor smoothly.

10-134 PC138USLC-10
10 Structure and function
Travel motor

When stopped

• When the pressurized oil from the control valve is blocked, ports (A) and (C), and ports (B) and (D) are
disconnected respectively, and the hydraulic motor continues rotation by the inertial force.
• When the oil pressure in port (D) increases above the set pressure, relief valve (1b) moves up to release
the pressurized oil into port (C) to prevent cavitation.
• The pressurized oil in port (D) flows through relief valve (1b) and sleeve (2b) to chamber (F) to move
piston (3) to the left.
• When piston (3) reaches the stroke end, the pressure between relief valve (1b) and chamber (F) increases
and relief valve (1b) closes the oil passages to ports (C) and (D).
• Relief valve (1b) controls the pressure in port (D) on the outlet side of the hydraulic motor to stop the
hydraulic motor smoothly.

PC138USLC-10 10-135
10 Structure and function
Work equipment and swing PPC valve

Work equipment and swing PPC valve (PC-PL28-041-K-00-A)

a PPC: Abbreviation for Proportional Pressure Control

10-136 PC138USLC-10
10 Structure and function
Work equipment and swing PPC valve

L.H. work equipment control lever


P: From self-pressure reducing valve
P1: To control valve (arm OUT port)
P2: To control valve (arm IN port)
P3: To control valve (LEFT swing port)
P4: To control valve (RIGHT swing port)
T: To hydraulic tank

R.H. work equipment control lever


P: From self-pressure reducing valve
P1: To control valve (boom LOWER port)
P2: To control valve (boom RAISE port)
P3: To control valve (bucket CURL port)
P4: To control valve (bucket DUMP port)
T: To hydraulic oil tank

PC138USLC-10 10-137
10 Structure and function
Work equipment and swing PPC valve

10-138 PC138USLC-10
10 Structure and function
Work equipment and swing PPC valve

1. Spool
2. Piston
3. Disc
4. Nut (for lever connection)
5. Joint
6. Plate
7. Retainer
8. Valve body
9. Filter
Operation (PC-PL28-044-K-00-A)
When control lever is in NEUTRAL position
• Ports (A) and (B) of the control valve and ports (P1) and (P2) of the PPC valve are connected to drain
chamber (D) through fine control hole (f) in spool (1).

When control lever is in fine control range

(When moved from NEUTRAL to fine control range)


• When piston (4) is pushed by disc (5), retainer (9) is pushed and spool (1) is also pushed by metering
spring (2) and moves downward.
• When fine control hole (f) is disconnected from drain chamber (D), it is connected to pump pressure
chamber (PP) at almost the same time.
• The pilot pressure from the main pump is transmitted from port (P1) to port (A) through the fine control
hole (f).
• When the pressure in port (P1) becomes higher, spool (1) is pushed back and fine control hole (f) is
disconnected from pump pressure chamber (PP). At almost the same time, it is connected to drain
chamber (D) to release the pressure in port (P1).
• Accordingly, spool (1) moves up and down until the force of metering spring (2) is balanced with the force
exerted by the pressure in port (P1).

PC138USLC-10 10-139
10 Structure and function
Work equipment and swing PPC valve

• The positional relationship between spool (1) and valve body (10) [fine control hole (f) is located between
drain chamber (D) and pump pressure chamber (PP)] does not change until retainer (9) comes in contact
with spool (1).
• Metering spring (2) is compressed in proportion to the control lever travel.
• In addition, the pressure in port (P1) increases in proportion to the control lever travel.
• Accordingly, the control valve spool moves to a position at which the pressure in port (A) [equal to the
pressure in port (P1)] is balanced with the reaction force of the control valve spool return spring.

When control lever is in fine control range

(When returned to fine control range)


• When disc (5) begins to return, spool (1) is pushed up by the force of centering spring (3) and the force
exerted by the pressure in port (P1).
• Fine control hole (f) is connected to drain chamber (D), and the pressurized oil in port (P1) is released.
• If the pressure in port (P1) is excessively reduced, spool (1) is depressed by metering spring (2).
• Fine control hole (f) is disconnected from drain chamber (D), and at almost the same time, it is connected
to pump pressure chamber (PP).
• The pump pressure is supplied until the pressure at port (P1) recovers to the level corresponding to the
lever position.
• When the spool of the control valve returns, the pressurized oil in drain chamber (D) flows in through fine
control hole (f') in the valve on the side that is not operated. The oil passes through port (P2) and flows into
port (B) to replenish the port with pressurized oil.

10-140 PC138USLC-10
10 Structure and function
Work equipment and swing PPC valve

When control lever is moved to stroke end


• Disc (5) depresses piston (4), and retainer (9) depresses spool (1).
• Fine control hole (f) is disconnected from drain chamber (D), and it is connected to pump pressure
chamber (PP).
• The pilot pressure oil from the self-pressure reducing valve passes through fine control hole (f) and flows
from port (P1) to port (A) and pushes the control valve spool.
• The oil returning from port (B) flows from port (P2) into drain chamber (D) through fine control hole (f').

PC138USLC-10 10-141
10 Structure and function
Work equipment and swing PPC valve

10-142 PC138USLC-10
10 Structure and function
Travel PPC valve

Travel PPC valve (PC-C6V0-041-K-00-A)

a PPC: Abbreviation for Proportional Pressure Control

P: From self-pressure reducing valve


P1: To control valve (L.H. travel REVERSE port)
P2: To control valve (L.H. travel FORWARD port)
P3: To control valve (R.H. travel REVERSE port)
P4: To control valve (R.H. travel FORWARD port)
T: To hydraulic tank

PC138USLC-10 10-143
10 Structure and function
Travel PPC valve

1. Plate
2. Case
3. Piston
4. Seal
5. Spool
6. Damper

10-144 PC138USLC-10
10 Structure and function
Travel PPC valve

Operation (PC-C6V0-044-K-00-A)
When control lever is in NEUTRAL position
• Ports (A) and (B) of the control valve and ports (P1) and (P2) of the PPC valve are connected to drain
chamber (D) through fine control hole (f) in spool (1).

When control lever is in fine control range

(When moved from NEUTRAL to fine control range)


• When piston (4) is pushed by lever (5), retainer (9) is pushed and spool (1) is also pushed by metering
spring (2) and moves downwards.
• When fine control hole (f) is disconnected from drain chamber (D), it is connected to pump pressure
chamber (PP) at almost the same time.
• The pilot pressure from the control pump is transmitted from port (P1) to port (A) through the fine control
hole (f).
• When the pressure in port (P1) becomes higher, spool (1) is pushed back and fine control hole (f) is
disconnected from pump pressure chamber (PP). At almost the same time, it is connected to drain
chamber (D) to release the pressure in port (P1).
• Accordingly, spool (1) moves up and down until the force of metering spring (2) is balanced with the force
exerted by the pressure in port (P1).
• The positional relationship between spool (1) and valve body (10) [fine control hole (f) is located between
drain chamber (D) and pump pressure chamber (PP)] does not change until retainer (9) comes in contact
with spool (1).
• Metering spring (2) is compressed in proportion to the control lever travel.
• In addition, the pressure in port (P1) increases in proportion to the control lever travel.
• Accordingly, the control valve spool moves to a position at which the pressure in port (A) [equal to the
pressure in port (P1)] is balanced with the reaction force of the control valve spool return spring.

PC138USLC-10 10-145
10 Structure and function
Travel PPC valve

When control lever is in fine control range

(When returned to fine control range)


• When lever (5) starts to return, spool (1) is pushed up by the force of centering spring (3) and the force
exerted by the pressure in port (P1).
• Fine control hole (f) is connected to drain chamber (D), and the pressurized oil in port (P1) is released.
• If the pressure in port (P1) is excessively reduced, spool (1) is depressed by metering spring (2).
• Fine control hole (f) is disconnected from drain chamber (D), and at almost the same time, it is connected
to pump pressure chamber (PP).
• The pump pressure is supplied until the pressure at port (P1) recovers to the level corresponding to the
lever position.
• When the spool of the control valve returns, the pressurized oil in drain chamber (D) flows in through fine
control hole (f') in the valve on the side that is not operated. The oil passes through port (P2) and flows into
port (B) to replenish the port with pressurized oil.

10-146 PC138USLC-10
10 Structure and function
Travel PPC valve

When control lever is moved to stroke end


• Lever (5) depresses piston (4), and retainer (9) depresses spool (1).
• Fine control hole (f) is disconnected from drain chamber (D), and it is connected to pump pressure
chamber (PP).
• The pilot pressure oil from the self-pressure reducing valve passes through fine control hole (f) and flows
from port (P1) to port (A) and pushes the control valve spool.
• The oil returning from port (B) flows from port (P2) into drain chamber (D) through fine control hole (f').

PC138USLC-10 10-147
10 Structure and function
Travel PPC valve

10-148 PC138USLC-10
10 Structure and function
Blade PPC valve

Blade PPC valve (PC138-LTJ0-041-K-00-A)

a PPC: Abbreviation for Proportional Pressure Control


a For explanation of operation, see "Work equipment and swing PPC valve".

P: From self-pressure reducing valve


P1: Blade valve
P2: Blade valve
T: To hydraulic tank

1. Spool

PC138USLC-10 10-149
10 Structure and function
Blade PPC valve

2. Piston
3. Lever
4. Plate
5. Retainer
6. Body
7. Filter

10-150 PC138USLC-10
10 Structure and function
1st-line attachment PPC valve (with EPC valve)

1st-line attachment PPC valve (with EPC valve) (PC200_10-PL29-041-K-00-A)

(Machines ready for installation of attachment)


a PPC: Abbreviation for Proportional Pressure Control
a EPC: Abbreviation for Electromagnetic Proportional Control
a For explanation of operation, see "Work equipment and swing PPC valve".

PC138USLC-10 10-151
10 Structure and function
1st-line attachment PPC valve (with EPC valve)

10-152 PC138USLC-10
10 Structure and function
1st-line attachment PPC valve (with EPC valve)

P: From self-pressure reducing valve


P1: To control valve (service valve 1 port)
P2: To control valve (service valve 1 port)
T: To hydraulic tank

1. Spool
2. Piston
3. Lever
4. Plate
5. Retainer
6. Body
7. EPC valve

PC138USLC-10 10-153
10 Structure and function
1st-line attachment PPC valve (with EPC valve)

EPC valve (PC200_10-PL2B-041-K-00-A)

(Machines ready for installation of attachment)


a EPC: Abbreviation for Electromagnetic Proportional Control

P: From self-pressure reducing valve


C: To PPC valve (R.H. attachment)
T: To hydraulic tank

1. Valve body
2. Spool
3. Spring
4. Coil
5. Plunger
6. Push pin
7. Connector

10-154 PC138USLC-10
10 Structure and function
1st-line attachment PPC valve (with EPC valve)

Function (PC-PL2B-042-K-00-A)
• The EPC valve consists of the proportional solenoid portion and the hydraulic valve.
• When a signal current (i) from the pump controller is received, the EPC output pressure proportional to the
amperage of current is generated and output to the control valve.

Operation (PC200_10-PL2B-044-K-00-A)

When signal current is zero amp. (coil is de-energized)


• Since the signal current from the controller does not flow through coil (4), coil (4) is de-energized.
• Spool (2) is pushed to the left by spring (3).
• Port (P) is blocked, so the pressurized oil from the front pump does not flow to the control valve.
• The pressurized oil from the control valve is drained to the tank through port (C) and port (T).

PC138USLC-10 10-155
10 Structure and function
1st-line attachment PPC valve (with EPC valve)

When signal current is minute (coil is energized)


• When minute signal current flows through coil (4), coil (4) is energized and the thrust pushing plunger (5)
lightward is generated.
• Push pin (6) pushes spool (2) to the light, and the pressurized oil from port (P) flows to port (C).
• The pressure in port (C) increases and the combined force of the force applied on surface (a) of spool (2)
and the reaction force of spring (3) become larger than the thrust of plunger (5).
• Spool (2) is pressed to the left, so port (P) is disconnected from port (C) and port (C) is connected to port
(T).
• Spool (2) moves to a position where the thrust of plunger (5) is equal to the total of the force exerted by the
pressure in port (C) and the force of spring (3).
• Thus, the circuit pressure between the EPC valve and the control valve is controlled in proportion to the
amperage of the signal current.

10-156 PC138USLC-10
10 Structure and function
1st-line attachment PPC valve (with EPC valve)

When signal current is maximum (coil is energized)


• Coil (4) is energized when the signal current flows through coil (4).
• As the signal current is the maximum, the thrust of plunger (5) is also maximized.
• Spool (2) is pushed to the light by push pin (4).
• The pressurized oil flows from port (P) to port (C) at the maximum rate, and the circuit pressure between
the EPC valve and control valve is maximized.
• Port (T) is blocked, so no pressurized oil flows to the hydraulic tank.

PC138USLC-10 10-157
10 Structure and function
1st-line attachment PPC valve (with EPC valve)

10-158 PC138USLC-10
10 Structure and function
Solenoid valve

Solenoid valve (PC138-PQPT-041-K-00-A)

PC138USLC-10 10-159
10 Structure and function
Solenoid valve

P1: From self-pressure reducing valve


A1: To PPC valve
A2: To center swivel joint [port (P)]
A3: To swing motor [port (B)]
A4: To control valve [port (PS)]
A5: To control valve [port (PST)]
T: To hydraulic tank
ACC: To PPC accumulator

1. PPC lock solenoid valve


2. 2-stage travel speed selector solenoid valve
3. Swing parking brake solenoid valve
4. Merge-divider solenoid valve
5. Travel junction solenoid valve

Solenoid valve
6. Coil (ON/OFF type)
7. Push pin
8. Valve spool
9. Sleeve
10. Block
11. Plug

Check valve
12. Plunger
13. Plug

10-160 PC138USLC-10
10 Structure and function
Solenoid valve

For machine(s) ready for installation of attachment

PC138USLC-10 10-161
10 Structure and function
Solenoid valve

P1: From self-pressure reducing valve


A1: To PPC valve
A2: To center swivel joint [port (P)]
A3: To swing motor [port (B)]
A4: To control valve [port (PS)]
A5: To control valve [port (PST)]
A6: To attachment circuit selector valve (for low pressure)
T: To hydraulic tank
ACC: To PPC accumulator

1. PPC lock solenoid valve


2. 2-stage travel speed selector solenoid valve
3. Swing parking brake solenoid valve
4. Merge-divider solenoid valve
5. Travel junction solenoid valve
6. Attachment selector solenoid valve

Solenoid valve
7. Coil (ON/OFF type)
8. Push pin
9. Valve spool
10. Sleeve
11. Block
12. Plug

Check valve
13. Plunger
14. Plug

10-162 PC138USLC-10
10 Structure and function
Solenoid valve

Operation (ALL-PQPT-044-K-00-A)

Operation of check valve

• This valve is installed between port (P) and the PPC solenoid valve. When the engine is stopped, plunger
(1) is pushed back to the left by the reaction force of spring (2), so the passage between ports (ACC) and
(P) is blocked, keeping the pressure in the accumulator.
• When the engine is running, plunger (1) is pushed to the right with the pilot pressure that is sent to port (P),
so port (P) is connected to port (ACC).

Operation of solenoid valve

When solenoid valve is “de-energized“ (circuit is blocked)

• Coil (1) is de-energized when no signal current flows through coil (1).
• Spool (2) is pushed back to the left by reaction force of spring (3).
• As the passage between ports (P) and (A) is blocked, the pilot pressure is not fed to the actuator through
port (A). At the same time, the passage to port (T) is made, so the oil from the actuator is drained to the
hydraulic tank.

PC138USLC-10 10-163
10 Structure and function
Solenoid valve

When solenoid valve is “energized“ (circuit is made)

• Coil (1) is energized when the signal current flows through coil (1).
• Spool (2) is pushed to the right by push pin (4).
• The passage between ports (P) and (A) is made, so the pilot pressure flows to the actuator through port
(A). At the same time, the passage to port (T) is blocked, so the oil from the actuator does not flow to the
hydraulic tank.

10-164 PC138USLC-10
10 Structure and function
Attachment circuit selector valve (for low pressure
circuit)

Attachment circuit selector valve (for low pressure circuit) (PC138-PQJ3-041-K-00-A)

(Machines ready for installation of attachment)

P1: From attachment selector solenoid valve


V: To control valve attachment 1 port
ATT: To attachment
T: To hydraulic tank
TS: To hydraulic tank
ACC: Plug

1. Spool
Function (PC220-PQJ3-042-K-00-A)

• For a machine equipped with a breaker, this valve serves to interconnect between the main circuit from the
control valve to the breaker and the accumulator.
• For a machine equipped with other attachment (crusher, etc.), this valve serves to disconnect the main
circuit from the accumulator.

PC138USLC-10 10-165
10 Structure and function
Attachment circuit selector valve (for low pressure
circuit)

Operation (PC138-PQJ3-044-K-00-A)
When attachment other than breaker is installed

• Spool (1) is pressed to the left side with the force of spring (2).
• Since ports (ATT) and (V) are interconnected to each other and port (ATT) is disconnected from port (T),
the attachment is interconnected to the control valve.

10-166 PC138USLC-10
10 Structure and function
Attachment circuit selector valve (for low pressure
circuit)

When breaker is installed

• Pilot pressure (PI) from the attachment circuit selector solenoid valve compresses spring (2), and
consequently spool (1) moves to the right stroke end.
• Ports (ATT) and (V) are disconnected from each other and port (ATT) is interconnected to port (T).
• The pressurized oil returning from the breaker returns directly to the hydraulic tank through port (T) without
through the control valve.

PC138USLC-10 10-167
10 Structure and function
Attachment circuit selector valve (for high pressure
circuit)

Attachment circuit selector valve (for high pressure circuit) (PC138-PQJ5-041-K-00-A)

(Machines ready for installation of attachment)

P: From attachment selector solenoid valve


ACC: To accumulator
ATT: To attachment
T: To hydraulic tank

1. Spool
Function (PC220-PQJ5-042-K-00-A)

• For a machine equipped with a breaker, this valve allows the oil from the breaker to return directly to the
hydraulic tank without passing through the main valve.
• For a machine equipped with other attachment (crusher, etc.), this valve serves to interconnect the
attachment to the main valve.
Operation (PC138-PQJ5-044-K-00-A)
When attachment other than breaker is installed

10-168 PC138USLC-10
10 Structure and function
Attachment circuit selector valve (for high pressure
circuit)

• Spool (1) is pressed to the left side with the force of spring (2).
• Since port (ATT) and port (ACC) are disconnected, no oil flows into the accumulator.

When breaker is installed

• Pilot pressure (P) from the attachment circuit selector solenoid valve compresses spring (2), and
consequently spool (1) moves to the right stroke end.
• Since port (ATT) and port (ACC) are interconnected, oil flows into the accumulator and absorbs the oil
pulsation.

PC138USLC-10 10-169
10 Structure and function
Multi-control valve

Multi-control valve (PC138-PKP0-041-K-00-A)

(if equipped)

(1) ISO pattern


(2) Backhoe pattern

Drawing for operation pattern selection (port names correspond to symbols in the drawing)

10-170 PC138USLC-10
10 Structure and function
Center swivel joint

Center swivel joint (PC138-J8E0-001-K-00-A)

Blade specifications (PC138-J8E0-041-K-01-A)

PC138USLC-10 10-171
10 Structure and function
Center swivel joint

A1: From control valve (right travel REVERSE port) [port (B4)]
A2: To R.H. travel motor REVERSE [port (A)]
B1: From control valve (left travel FORWARD port) [port (A3)]
B2: To L.H. travel motor FORWARD [port (A)]
C1: From control valve (right travel FORWARD port) [port (A4)]
C2: To R.H. travel motor FORWARD [port (B)]
D1: From control valve (left travel REVERSE port) [port (B3)]
D2: To L.H. travel motor REVERSE [port (B)]
E1: From 2-stage travel selector solenoid valve
E2: To R.H. and L.H travel motors [port (P)]
F1: From control valve (blade “LOWER“)
F2: To R.H. and L.H. blade cylinder bottoms
G1: From control valve (blade “RAISE“)
G2: To R.H. and L.H. blade cylinder heads
DR1: To hydraulic tank
DR2: From R.H. and L.H travel motors [port (D)]

1. Cover
2. Rotor
3. Slipper seal
4. Dust seal
5. Shaft

10-172 PC138USLC-10
10 Structure and function
PPC circuit accumulator

PPC circuit accumulator (PC138-PL40-041-K-00-A)

a PPC: Abbreviation for Proportional Pressure Control

1. Gas plug
2. Shell
3. Poppet
4. Holder
5. Bladder
6. Oil port
Specifications (PC-PL40-030-K-00-A)

Gas to be used Nitrogen gas


Volume of gas (cc) 300
Charged pressure 1.18 {12}
(MPa {kg/cm2}) (at 80°C)
Max. operating pressure
6.86 {70}
(MPa {kg/cm2})

Function (PC-PL40-042-K-01-A)

• This accumulator is installed to the solenoid valve. Even if the engine is stopped while the work equipment
is raised, pilot oil pressure can be supplied to the work equipment control valve with the pressure of the
compressed nitrogen gas in the accumulator to operate the spool and lower the work equipment by its
own weight.

PC138USLC-10 10-173
10 Structure and function
Attachment circuit accumulator (for low pressure circuit)

Attachment circuit accumulator (for low pressure circuit) (PC138-PL40-041-K-01-A)

(Machines ready for installation of attachment)

1. Cap
2. Core
3. Ring
4. Lid
5. Bladder
6. Shell
Specifications (PC138-PL40-030-K-01-A)

Gas to be used Nitrogen gas


Volume of gas (cc) 480
Charged pressure 0.1 {1.0}
(MPa {kg/cm2}) (At 80°C)
Max. pressure used
6.86 {70}
(MPa {kg/cm2})

Function (PC138-PL40-042-K-02-A)

• This accumulator is installed to the attachment piping to absorb the oil pulsation generated by the breaker
work into the compressed nitrogen gas in it for protection of the hydraulic component and piping.

10-174 PC138USLC-10
10 Structure and function
Attachment circuit accumulator (for high pressure
circuit)

Attachment circuit accumulator (for high pressure circuit) (PC138-PL40-041-K-02-A)

(Machines ready for installation of attachment)

1. Cap
2. Core
3. Lock nut
4. Gas port
5. Bladder
6. Shell
Specifications (PC138-PL40-030-K-00-A)

Gas to be used Nitrogen gas


Volume of gas (cc) 500
Charged pressure 5.88 {60}
(MPa {kg/cm2}) (At 80°C)
Max. pressure used
20.6 {210}
(MPa {kg/cm2})

Function (PC138-PL40-042-K-02-A)

• This accumulator is installed to the attachment piping to absorb the oil pulsation generated by the breaker
work into the compressed nitrogen gas in it for protection of the hydraulic component and piping.

PC138USLC-10 10-175
10 Structure and function
Work equipment

Work equipment (ALL-L000-001-K-00-A)

Work equipment (PC138-L410-041-K-00-A)

1. Bucket
2. Bucket link
3. Bucket cylinder
4. Arm
5. Arm cylinder
6. Boom
7. Boom cylinder
8. Blade cylinder
9. Blade

10-176 PC138USLC-10
10 Structure and function
Work equipment shim

Work equipment shim (PC138-L413-040-K-00-A)


Structure
• There are 2 types of work equipment shims, the iron shim and plastic shim.
• The work equipment shims are inserted to adjust the clearance of each joint of the work equipment to the
standard value.
Function
Iron shim
• The purpose of the iron shim is to reduce the play in the right and left direction of the work equipment.
a Depending on the size of clearance, it may be required to insert the shim into either of the right and left
sides and insert no shim on the other side.

Plastic shim
• The purpose of the plastic shim is to reduce the play in the right and left direction of the work equipment
and prevent a creak and scuffing caused by rubbing of the end faces of steel parts of a joint.

PC138USLC-10 10-177
10 Structure and function
Bucket play adjustment shim

Bucket play adjustment shim (PC138-LBKB-040-K-00-A)


Structure
• Split-type iron shims are used for the joint of the arm and bucket.
• The play in the joint can be adjusted by adjusting the number of the shims.
a When the play is large, you can reduce it by removing one or more shims.

10-178 PC138USLC-10
10 Structure and function
Cab mount and cab tipping stopper

Cab and its attachments (ALL-K000-001-K-00-A)

Cab mount and cab tipping stopper (PC138-K138-041-K-00-A)

1. Mount seat
2. Front damper
3. Rear damper
4. Cab tipping stopper

Structure
• Dampers (2) and (3) are installed to 2 places each at the front and rear of the cab to fix the cab and floor
frame to the revolving frame.
• Dampers (2) and (3) are oil-filled type and used to absorb vibration.
• Cab tipping stopper (4) is installed to 1 place at the rear to fix the cab when the machine tips over.
• Dampers (2) and (3) are different types and installed to different locations as shown in the following
identification table.
Location of damper Identification color
Front left Blue
Front right Blue
Rear left Green
Rear right Green

PC138USLC-10 10-179
10 Structure and function
ROPS cab

ROPS cab (PC138-K000-041-K-00-A)

a ROPS: Abbreviation for Roll-Over Protective Structure

1. Front window
2. Wiper
3. Headlamp
4. Ceiling window
5. KOMTRAX GPS antenna
6. Radio antenna
7. KOMTRAX communication antenna
8. Air conditioner fresh air filter
9. Door
10.Mirror
Function (PC220-K000-042-K-00-A)

• ROPS cab is a structure which protects the operator fastening a seat belt not to be crushed when the
machine tips over.

10-180 PC138USLC-10
10 Structure and function
ROPS cab

Take wiring harness out of cab (PC138-K16F-520-K-00-A)

1. Grommet

Structure
• 2 grommets (1) are installed to take the wiring out of the cab.

PC138USLC-10 10-181
10 Structure and function
Electrical control system

Electrical system (ALL-RA1D-001-K-01-A)

Electrical control system (PC220-C050-001-K-00-A)

General system drawing (PC138-C050-051-K-00-A)

a Devices marked with "*1" in the figure are optional.

10-182 PC138USLC-10
10 Structure and function
Electrical control system

PC138USLC-10 10-183
10 Structure and function
Electrical control system

10-184 PC138USLC-10
10 Structure and function
Electrical control system

Engine control function (PC220-AK60-042-K-00-A)

1. Battery disconnect switch


2. Battery
3. Battery relay
4. Fusible link
5. Fuse box
6. Starting switch
7. Engine shutdown secondary switch
8. Engine controller
9. Lock lever
10. PPC lock switch
11. Starting motor cut-off relay (for PPC lock)
12. Starting motor cut-off relay (for personal code)
13. Fuel control dial
14. Safety relay
15. Starting motor
16. Fuel supply pump
17. Sensors
18. Machine monitor
19. KOMTRAX terminal
20. Pump controller

Function
• The neutral safety circuit is employed to secure safety when the engine is started.
a The engine does not start until the lock lever is set to the “LOCK“ position.
• The KOMTRAX engine cut circuit is employed to disable the engine from starting when the KOMTRAX
terminal receives an engine cut command issued through external operation.
• When you cannot stop the engine due to stuck starting switch (6), engine shutdown secondary switch (7)
is usable for stopping the engine.

Starting the engine


• If starting switch (6) is turned to “ON“ position , engine controller (8) sends command current to fuel supply
pump (16).

PC138USLC-10 10-185
10 Structure and function
Electrical control system

For this reason, a fail-safe mechanism is provided with the electrical system to stop the engine when an
electrical failure occurs.
• If starting switch (6) is turned to “START“ position when lock lever (9) is in the “LOCK“ position, starting
current is supplied to starting motor (15) and the engine starts.
If lock lever (9) is in the “FREE“ position, starting motor cut-off relay (11) cuts off the starting current to
starting motor (15), thus the engine does not start. This is the neutral safety mechanism.
• 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-off relay (12) to cut off the starting current to starting motor
(15), therefore the engine does not start.

Engine speed control


• Upon receipt of the throttle signals from fuel control dial (13) and pump controller (20), engine controller (8)
selects lower throttle signal, and sends command current to fuel supply pump (16).
Fuel supply pump (16) adjusts the fuel injection rate to control the engine speed.

Engine stop
• If starting switch (6) is turned to “OFF“ position, the current from ACC terminal of starting switch (6) to
engine controller (8) is cut off, and consequently the command current to fuel supply pump (16) is cut off.
Fuel supply pump (16) stops fuel feed, decreasing the engine speed until the engine stops.

Stopping the engine with engine shutdown secondary switch


• If engine shutdown secondary switch (7) is turned to “Stop Engine“ position, the current from ACC terminal
of starting switch (6) to engine controller (8) is forcibly cut off.
Above induces the same state as when starting switch (6) is turned to “OFF“ position, stopping the engine.

10-186 PC138USLC-10
10 Structure and function
Electrical control system

Engine and pump combined control function (PC138-C3W0-042-K-00-A)

1. Battery disconnect switch


2. Battery
3. Battery relay
4. Fusible link
5. Fuse box
6. Resister for PC-EPC valve
7. Pump controller
8. Engine controller
9. Machine monitor
10. Emergency pump drive switch
11. Fuel control dial
12. Fuel supply pump
13. Various sensors
14. Oil pressure sensor of pump
15. Oil pressure sensor
16. Oil pressure switch
17. Main pump
17a. Servo
17b. LS valve
17c. PC valve
18. Control valve
18a. Merge-divider valve
18b. Self-pressure reducing valve
19. PC-EPC valve

PC138USLC-10 10-187
10 Structure and function
Electrical control system

Input/output signal
a: CAN signal
b: PC-EPC valve drive signal
c: Solenoid valve GND
d: Oil pressure sensor signal
e: Oil pressure switch signal
f: Throttle signal
g: Fuel supply pump control signal
h: Various sensor signals

Function
• This function allows the operator to select one from the 6 working modes of P, E, L, B, ATT/P, and ATT/E
by using the working mode selector switch on machine monitor (9).
• The operator can select the most appropriate engine torque (T) and pump absorption torque according to
the contents of work.
• If “Without Attachment“ is set for the attachment by “With/Without Attachment“ in “Default“ of the service
mode, the available modes are 4 of P, E, L, and B.
• Pump controller (7) calculates the pump absorption upper limit torque according to the engine speed set
with the working mode and fuel control dial (11) and the actual engine speed, and controls the pump so
that the engine speed is kept around the matching point set in each mode even when heavy load is
applied.
• When the engine speed decreases, the pump controller reduces the pump absorption torque to prevent
the engine from stalling.

10-188 PC138USLC-10
10 Structure and function
Electrical control system

Control method in each mode


P, E, ATT/P, and ATT/E modes
Matching point
Working mode Matching point
P and ATT/P
69.7 kW/2,050 rpm
• During travel
{93.5 HP/2,050 rpm}
64.9 kW/1,950 rpm
• During work (arm “IN“)
{87 HP/1,950 rpm}
66.8 kW/1,950 rpm
• During work (other than arm “IN“)
{89.6 HP/1,950 rpm}
58.9 kW/1,850 rpm
E and ATT/E
{78.9 HP/1,850 rpm}

• In mode P, E, ATT/P, or ATT/E, the engine speed is kept around the matching point set in each mode.
• When the pump load increases and the pressure becomes higher, engine speed (N) decreases. At this
time, controller decreases pump discharge (Q) to increase the engine speed to around the matching point.
On the contrary, when the load decreases and the pressure becomes lower, controller increases pump
discharge so that the engine speed becomes around the matching point.

PC138USLC-10 10-189
10 Structure and function
Electrical control system

B and L mode
Working mode Partial output
B 75%
L 70%
Matching point
Working mode Matching point
50.9 kW/1,760 rpm
B
{68.2 HP/1,760 rpm}
47.8 kW/1,550 rpm
L
{64.1 HP/1,550 rpm}
• In B mode or L mode, engine output is kept constant.
• The controller controls pump absorption torque and decreases the engine speed so that the engine torque
is kept constant along the equal engine horsepower curve .
• The controller controls pump discharge (Q) so that the engine torque is kept constant along the equal
engine horsepower curve.

10-190 PC138USLC-10
10 Structure and function
Electrical control system

Control function when traveling


• When the machine travels in P mode or ATT/P mode, engine speed (N) increases.
• Engine speed (N) and pump absorption torque do not change when the machine travels in mode E, ATT/E,
B, or L.

PC138USLC-10 10-191
10 Structure and function
Electrical control system

Control function when emergency pump drive switch is “ON“


• If the controller has trouble and the main pump does not operate normally and the machine does not work,
the operator can operate the machine temporarily with the absorption torque equivalent to E mode by
operating emergency pump drive switch (1).
At this time, since a constant current flows from the battery to the PC-EPC valve, only the PC-EPC valve
senses oil pressure.
a: Emergency (when abnormal)
b: Normal (when normal)
a Emergency pump switch (1) is alternative type. If the operator work with this switch at the “Emergency (a)“
position while the machine is normal, action level “E02“ appears on the display.

10-192 PC138USLC-10
10 Structure and function
Electrical control system

Auto-deceleration function (PC138-AF60-042-K-00-A)

1. Pump controller
2. Engine controller
3. Machine monitor
4. Fuel control dial
5. Fuel supply pump
6. Various sensors
7. Oil pressure sensor
8. Oil pressure switch
9. Main pump
10. Control valve
10a. Merge-divider valve
10b. Self-pressure reducing valve
11. PPC lock solenoid valve
Input/output signal
a. CAN signal
b. Oil pressure sensor signal
c. Oil pressure switch signal
d. Throttle signal
e. Fuel supply pump control signal
f. Oil pressure sensor signal

PC138USLC-10 10-193
10 Structure and function
Electrical control system

Function
• When all the control levers are set to “NEUTRAL“ positions while waiting for a dump truck or next work,
the engine speed decreases to the control speed automatically to improve the fuel economy and reduce
the noise.
• If any control lever is operated, the engine speed returns immediately to the speed set with fuel control dial
(4).

Operation

When control lever is at NEUTRAL


• While the engine is running at about 1,100 rpm or higher speed, when all the control levers are set to
“NEUTRAL“ positions (A) for 4 seconds or more (E), engine speed is decreased and kept to engine
control speed (D) until any control lever is “operated“ (B).

When control lever is in operation


• While the engine speed is kept at engine control speed (D), when any control lever is operated, the engine
speed increases immediately to fuel control dial set speed (C).

A: All control levers in “NEUTRAL“


B: Control lever “operated“
C: Fuel control dial set speed
D: Engine control speed (approx. 1,100 rpm)
E: 4 sec
F: Max. 2 sec
G: Max. 1 sec

10-194 PC138USLC-10
10 Structure and function
Electrical control system

Engine automatic warm-up function (PC138-AP13-042-K-00-A)

1. Battery disconnect switch


2. Battery
3. Battery relay
4. Fusible link
5. Fuse box
6. Resister for PC-EPC valve
7. Pump controller
8. Engine controller
9. Machine monitor
10. Emergency pump drive switch
11. Fuel control dial
12. Fuel supply pump
13. Various sensors
14. Hydraulic oil temperature sensor
15. Main pump
15a. Servo
15b. LS valve
15c. PC valve
16. Control valve
16a. Merge-divider valve
16b. Self-pressure reducing valve
17. PC-EPC valve
Input/output signal
a. CAN signal

PC138USLC-10 10-195
10 Structure and function
Electrical control system

b. PC-EPC valve drive signal


c. Solenoid valve ground
d. Hydraulic oil temperature signal
e. Throttle signal
f. Fuel supply pump control signal
g. Various sensor signals

10-196 PC138USLC-10
10 Structure and function
Electrical control system

Function
• When the coolant temperature is low after the engine is started, the engine speed is increased
automatically to warm up the engine.
• The engine automatic warm-up function has 2 kinds; “Heater warm-up“ and “Normal warm-up“, either of
which is used according to the purpose.
• The purpose of the heater warm-up is to increase the coolant temperature to improve the effect of the
heat.
• The purpose of the normal warm-up is to heat the engine to prevent damage on the engine caused by low
temperature.

Operating conditions 1
Machine specification: Air conditioner specification
Air conditioner: Blower “ON“
Coolant temperature: Below 55ºC
Ambient temperature: Below 5°C
Manual stationary regeneration: OFF
Soot accumulation level: Max. 2 g/l
O O
When any of operating conditions 1 is not satisfied When all of operating conditions 1 are satisfied
Heater warm-up is disabled (normal warm-up) Heater warm-up is enabled
Operating conditions 2
(Operates when all of the following conditions are O
satisfied)
Coolant temperature: Below 30ºC
O
Engine speed: Max. 1,200 rpm
O O
Operation Operates

Engine speed: 1,200 rpm Engine speed: Min. 1,300 rpm

O O
Condition for cancellation Condition for cancellation
(Canceled when any of the following conditions is (Canceled when any of the following conditions is
satisfied) satisfied)
Coolant temperature: Min. 30ºC
Automat-
ic Warm-up operation time: Min. 10 Coolant temperature: Min. 60ºC
minutes
Ambient temperature: Min. 10°C
Fuel control dial: Held at 70% of full
Manual speed (Max.) for 3 seconds.

O O
Canceled
Engine speed: Any

PC138USLC-10 10-197
10 Structure and function
Electrical control system

Overheat prevention function (PC138-B717-042-K-00-A)

a For the system circuit diagram, see "Engine automatic warm-up function".
• When the coolant temperature or the hydraulic oil temperature increases too high during work, the pump
load is reduced and the engine speed is lowered to prevent overheat and protect the engine and hydraulic
components.

Operating condition Operation and remedy Condition for cancellation


Working mode: P, ATT/P, Coolant temperature: Below
ATT/E 95ºC
Coolant temperature: Min. Engine speed: Kept as it is
Hydraulic oil temperature:
95ºC o • Pump absorption torque is o Below 95°C
or lowered and engine load is
reduced according to the • When above condition is
Hydraulic oil temperature: torque control signal. satisfied, state before
Min. 95°C operation is restored
Travel judgment: OFF (automatic restoration).

Operating condition Operation and remedy Condition for cancellation


Working mode: P, ATT/P, Coolant temperature: Below
ATT/E 98ºC
Coolant temperature: Min. Hydraulic oil temperature:
98ºC o Engine speed: Kept as it is o Below 98°C
or • Travel speed: Decreased • When above condition is
Hydraulic oil temperature: satisfied, state before
Min. 98°C operation is restored
Travel judgment: ON (automatic restoration).

Operating condition Operation and remedy Condition for cancellation


Working mode: P, ATT/P,
ATT/E Coolant temperature: Below
100ºC
Coolant temperature: Min. Engine speed: Kept as it is
100ºC Hydraulic oil temperature:
o • Pump absorption torque is o Below 100°C
or lowered and engine load is
reduced according to the • When above condition is
Hydraulic oil temperature:
torque control signal. satisfied, state before
Min. 100°C
operation is restored
Travel judgment: Any (automatic restoration).
position

Operating condition Operation and remedy Condition for cancellation


Working mode: P, E, ATT/P,
ATT/E, B Coolant temperature: Below
Engine speed: Kept as it is 102ºC
Coolant temperature: Min.
102ºC • Pump absorption torque is Hydraulic oil temperature:
o o Below 102°C
or lowered and engine load is
reduced according to the • When above condition is
Hydraulic oil temperature: torque control signal. satisfied, state before
Min. 102°C • Alarm monitor: Lights up operation is restored
Travel judgment: Any (automatic restoration).
position

10-198 PC138USLC-10
10 Structure and function
Electrical control system

Operating condition Operation and remedy Condition for cancellation


Coolant temperature: Below
Working mode: All modes 105ºC
Coolant temperature: Min. Hydraulic oil temperature:
105ºC Below 105°C
o Engine speed: Low idle o
or Fuel control dial: Return to low
Alarm monitor: Lights up
Hydraulic oil temperature: idle (MIN) position.
Min. 105°C Alarm buzzer: Sounds
• When above condition is
Travel judgment: Any satisfied, state before
position operation is restored
(manual restoration).

PC138USLC-10 10-199
10 Structure and function
Electrical control system

Turbocharger protection function (PC138-AA90-042-K-00-A)

a For the system circuit diagram, see "Engine automatic warm-up function".
• This function limits the engine speed to prevent seizure of the turbocharger when the engine speed is
increased suddenly just after the engine is started.
• The control time is controlled according to the coolant temperature.

Operating condition Operation


o Limits the engine speed
Engine oil pressure: Below 50 kPa {0.51 kg/cm2}
(See the following figure)

A: Starting of engine
B: Turbocharger protection time (Approximately 0 to 20 seconds)
C: Modulation time (Approximately 1.5 seconds)
D: 500 rpm
E: 1,100 rpm
F: 2,000 rpm (*1)

*1:
Working mode: P mode
Fuel control dial: Full speed (Max.) position
When travel lever is operated

10-200 PC138USLC-10
10 Structure and function
Electrical control system

Swing control function (PC138-JA01-042-K-00-A)

1. Battery disconnect switch


2. Battery
3. Battery relay
4. Fusible link
5. Fuse box
6. Swing parking brake cancel switch
7. Swing lock switch
8. Pump controller
9. Machine monitor
10. Oil pressure switch
11. Main pump
12. Control valve
12a. Merge-divider valve
12b. Self-pressure reducing valve
13. Swing motor
14. Swing parking brake solenoid valve

Input/output signal
a. Swing parking brake cancel switch signal
b: Swing parking brake solenoid valve drive signal
c. CAN signal
d. Swing lock switch signal
e. Oil pressure switch signal

Function
Swing lock & swing holding brake function
• With the swing lock (manual) function, the operator can lock the swing at any place by setting swing lock
switch (1) to “ON“ position.
• The swing parking brake (automatic) is interlocked with the swing operation and prevents hydraulic drift
after swing is stopped.
• To reduce the load on the swing device during digging work, the swing parking brake is released when the
attachment control pedal is operated.

PC138USLC-10 10-201
10 Structure and function
Electrical control system

Swing lock switch OFF ON


Swing lock Lights up
Goes out
monitor
Function Swing parking brake Swing lock
• If the L.H. control lever or attachment • The swing parking brake operates to
control pedal is set to “NEUTRAL“ lock the swing.
position, the swing parking brake • Even if the L.H. control lever is operated
operates 5 seconds later. to swing, the swing parking brake is not
Operation
• If the L.H. control lever or attachment released and swing cannot be
control pedal is “operated“, the swing performed.
parking brake is released and the upper
structure can swing freely.

A: Operate L.H. control lever or attachment control pedal (Swing parking brake is “released“)
B: Set L.H. control lever or attachment control pedal to “NEUTRAL“ position
C: Swing parking brake “operates“
D: Approx. 5 seconds

10-202 PC138USLC-10
10 Structure and function
Electrical control system

Swing holding brake cancel function


• If the swing parking brake does not operate normally and the upper structure cannot swing because of
trouble in the controller, etc., the operator can swing by releasing the swing parking brake with swing
parking brake cancel switch (2).
a: Release (when abnormal)
b: Normal (when normal)
Swing parking Released Normal
brake cancel
(When controller is abnormal) (When controller is normal)
switch
Swing lock switch ON OFF ON OFF
Swing parking brake Swing parking brake
Swing brake Swing lock operates Swing lock operates
is released (*1) operates
*1: Operation of hydraulic brake by safety valve
a When swing lock switch is set to “ON“ position, the swing parking brake is not released even if swing
parking brake cancel switch (2) is set to “RELEASE (a)“ position.
a While the swing parking brake is released, only the hydraulic brake is applied by the safety valve. If swing
is stopped on a slope, the hydraulic drift may occur. Take care.
a Swing parking brake cancel switch (2) is alternate type. When it is set to the “RELEASE (a)“ position, the
swing lock monitor on the machine monitor flashes.

PC138USLC-10 10-203
10 Structure and function
Electrical control system

Travel control function (PC138-C7H1-042-K-00-A)

1. Pump controller
2. Engine controller
3. Machine monitor
4. Fuel control dial
5. Fuel supply pump
6. Various sensors
7. Oil pressure sensor of pump
8. Oil pressure sensor
9. Travel alarm
10. Main pump
11. Control valve
11a. Merge-divider valve
11b. Self-pressure reducing valve
11c. Travel junction valve
12. Travel motor
13. 2-stage travel speed selector solenoid valve
14. Travel junction solenoid valve
15. Merge-divider solenoid valve

Input/output signal
a. Oil pressure sensor signal
b. CAN signal
c. Merge-divider solenoid valve drive signal
d. Travel junction solenoid valve drive signal

10-204 PC138USLC-10
10 Structure and function
Electrical control system

e. 2-stage travel speed selector solenoid valve drive signal


f. Oil pressure sensor signal
g. Travel alarm operation signal
h. Throttle signal
i. Fuel supply pump control signal
j. Various sensor signals

Function
Travel speed selector function
1. “Manual“ change of travel speed
• The operator can change the travel speed by setting the travel speed selector switch to “Hi“ or “Lo“
position to change the motor capacity.
Lo Hi
Travel speed selector switch
(Low speed) (High speed)
Motor capacity (cc/rev) 79.1 44.2
Motor capacity Max. Min.
Travel speed (km/h) 2.9 5.1
2. “Automatic“ change of travel speed
1) Automatic change in accordance with engine speed
• When the engine speed is set to 1,500 rpm or below with fuel control dial (4), the travel speed is set
to “Lo“ automatically.
2) Automatic change in accordance with pump discharge pressure
• While traveling with the travel speed selector switch at “Hi“ position, if the load increases on a slope,
etc., and the travel pressure is 32.4 MPa {330 kg/cm2} or higher for 0.02 seconds or more, the
motor capacity is changed automatically and the travel speed is changed to a low speed (a speed
equivalent to “Lo“) (however, travel speed selector switch is kept at “Hi“ position).
• While traveling at low speed set by the automatic travel speed change with load, when the load
decreases on a flat or downhill slope and the travel pressure is 17.7 MPa {180 kg/cm 2} or less for
0.1 seconds or more, the motor capacity is changed automatically and the travel speed is returned
to the set speed of “Hi“.

A: 17.7 MPa {180 kg/cm2}


B: 32.4 MPa {330 kg/cm2}
C: 0.1 seconds or more
D: 0.02 seconds or more
Pump control function when traveling
a For details, see "Engine and pump combined control function".

Travel junction function


• When the travel lever is operated, the pilot pressure is sensed to judge if the machine is driven straight or
steered.

PC138USLC-10 10-205
10 Structure and function
Electrical control system

• When the machine is driven straight, a signal is sent to the travel junction solenoid valve to set the flow
rates to the right and left travel motors to almost the same level to prevent travel deviation and improve the
straight travel performance.
• When the machine is steered, the signal to the travel junction solenoid valve is cut out to set the flow rates
to the right and left travel motors independently to improve the travel performance during steering.

Pump merge-dividing function


• It detects the pilot pressure when the travel lever is operated and judges whether the lever is operated to
travel.
• When operating travel, a signal is sent to the merge-divider solenoid valve to divide the pump discharge,
then traveling performance can be improved.

Judgment of travel Judgment of Judgment of work equipment and blade Merge-


Pattern operation steering operation control operation divider
valve
When stopped or
when speed is slow
(All of the following
conditions are
satisfied)
• P1 = Max. 1.6
1 {16} — — Merge
• P2 = Max. 1.6
{16}
• P3 = Max. 1.6
{16}
• P4 = Max. 1.6
{16}
(All of the following conditions are
When traveling satisfied)
forward • When no work equipment is operated
2 (All of the following (work equipment PPC oil pressure Divide
conditions are switch is “OFF“)
satisfied) • When no blade operated (P5 = Max.
When speed is 0.3 {3})
normal • The absolute
value of P1 - P2 (Any of the following condition is satisfied)
(Any of the
= Max. 0.3 {3} • When work equipment is operated
following condition
• The absolute (work equipment PPC oil pressure
3 is satisfied) Merge
value of P3 - P4 switch is “ON“)
• P1 = Max. 1.8 = Max. 0.3 {3} • When blade operated (P5 = Min. 0.5
{18} {5})
• P2 = Max. 1.8
{18} (All of the following conditions are
When machine is satisfied)
• P3 = Max. 1.8 steered
{18} • When no work equipment is operated
• P4 = Max. 1.8 (Any of the (work equipment PPC oil pressure
{18} following condition switch is “OFF“)
(*1)
is satisfied) • When blade is not operated deeply (P5 Divide
4 = Max. 2.0 {20})
• P1 - P2 = Min.
0.5 {5} • When pivot turn is not performed
• P3 - P4 = Min. Example) Right forward travel pivot turn
0.5 {5} (P1 = Max. 2.0 {20} or P2, P4 = Min.
0.5 {5})

10-206 PC138USLC-10
10 Structure and function
Electrical control system

Judgment of travel Judgment of Judgment of work equipment and blade Merge-


Pattern operation steering operation control operation divider
valve
(Any of the following condition is satisfied)
• When no work equipment is operated
(work equipment PPC oil pressure
switch is “OFF“)
5 • When blade is operated deeply (P5 = Merge
Max. 2.2 {22})
• When pivot turn is performed
Example) Right forward travel pivot turn
(P1 = Max. 2.2 {22} and P2, P4 = Min.
0.3 {3})
*1. When the work equipment is operated in the condition of pattern 4, the merge-divider valve switches to
merge as in the pattern 5. After switching to pattern 5, it does not return to pattern 4 even if the operation of
work equipment is stopped.
P1: Left FORWARD PPC pressure (MPa {kg/cm2})
P2: Right FORWARD PPC pressure (MPa {kg/cm2})
P3: Left REVERSE PPC pressure (MPa {kg/cm2})
P4: Right REVERSE PPC pressure (MPa {kg/cm2})
P5: Blade PPC pressure (MPa {kg/cm2})

PC138USLC-10 10-207
10 Structure and function
Electrical control system

PPC lock function (PC138-PX16-042-K-00-A)

a PPC: Abbreviation for Proportional Pressure Control

1. Battery disconnect switch


2. Battery
3. Battery relay
4. Fusible link
5. Fuse box
6. Starting switch
7. Lock lever
8. PPC lock switch
9. Main pump
10. Control valve
10a. Merge-divider valve
10b. Self-pressure reducing valve
11. PPC lock solenoid valve
Function
• PPC lock switch (8) is interlocked with lock lever (7). When lock lever (7) is set to “LOCK“ position, PPC
lock switch (8) is turned to OFF position.
• When PPC lock switch (8) is turned to “OFF“ position, the current flowing into PPC lock solenoid valve (11)
is cut out and the work equipment and machine body do not move even if any control lever or pedal is
operated.

10-208 PC138USLC-10
10 Structure and function
Electrical control system

System operating lamp function (PC138-AW1Q-042-K-00-A)

1. Battery disconnect switch


2. Battery
3. System operating lamp
4. Machine monitor
5. Engine controller
6. Pump controller
7. KOMTRAX terminal
Function
• You can prevent an abnormal end due to cut-off of the battery power supply circuit while the controllers are
in operation by checking the operating status of machine monitor (4), controllers (5), (6), and (7) with
system operating lamp (3).
a Before cutting off the battery power supply circuit, turn the starting switch to “OFF“ position, and check that
system operating lamp (3) goes off, then turn battery disconnect switch (1) to “OFF“ position.
a If you turn battery disconnect switch (1) to “OFF“ position (battery power supply circuit is cut off) while
system operating lamp (3) is ON, data lost error of machine monitor (4), controllers (5), (6), and (7) can
occur. Do not operate battery disconnect switch (1) while system operating lamp (3) is ON.
a System operating lamp (3) goes off in 2 minutes after the starting switch is turned to “OFF“ position.
a System operating lamp (3) may sometimes light up while the starting switch is turned to “OFF“ position
because KOMTRAX terminal (7) may maintain its communication under this condition.

ON/OFF of system operating lamp


• Voltage of 24 V is always applied to one end of the system operating lamp (LED) (3).
• When any of machine monitor (4), controllers (5), (6), and (7) is in operation, the controller outputs low
voltage (0 V), and a current flows in the diode to turn ON system operating lamp (3).
• When all of machine monitor (4), controllers (5), (6), and (7) are stopped, the controller outputs high
voltage (24 V), and no current flows in the diode, thus system operating lamp (3) goes off.
a System operating lamp (3) may look slightly luminous in the dark after it is turned off. It is due to the minute
leakage of current and not an abnormal phenomenon.
• KOMTRAX terminal (7) performs communication periodically even if the starting switch is kept in “OFF“
position, thus it starts and stops repeatedly.
• The start and stop cycle (sleep cycle) of KOMTRAX terminal (7) varies the conditions including the
communication status and machine stop time, and the lamp may keep lighting for up to approximately one
hour
a When you want to cut off the battery circuit for maintenance but system operating lamp (3) keeps on
lighting up, turn the starting switch to ON position, and then turn it to OFF position, and the lamp goes off
in 2 minutes.
After system operating lamp (3) goes off, turn battery disconnect switch (1) immediately to “OFF“ position.

PC138USLC-10 10-209
10 Structure and function
Electrical control system

Battery disconnect switch function (PC138-AW1P-042-K-00-A)

a Battery disconnect switch (1) and system operating lamp (2) are installed inside the cover at rear left of the
machine.

1. Battery disconnect switch


2. System operating lamp

(O): OFF position


(I): ON position

10-210 PC138USLC-10
10 Structure and function
Electrical control system

Function
• Usually, battery disconnect switch (1) is used instead of disconnecting the cable from the negative
terminal of the battery in the following cases.
1. When storing the machine for a long period (more than 1 month)
2. When servicing or repairing the electrical system
3. When performing electric welding
4. When handling the battery
5. When replacing a fuse, etc.
• When battery disconnect switch (1) is turned to OFF position (the contact is opened), all the continuous
power supplies for the components, including the starting switch B terminal and controllers, are all cut out,
and the condition is the same as the condition when the battery is not connected. Accordingly, all the
electric system of the machine is disabled.
• System operating lamp (2) lights up when the controller is turned ON. Even if the starting switch is in OFF
position, the lamp lights up while the KOMTRAX terminal is performing communication.

Precautions for using battery disconnect switch


• Do not turn OFF battery disconnect switch (1) while system operating lamp (2) is lit.
If battery disconnect switch (1) is turned OFF while system operating lamp (2) is lit, the data in the
controller may be lost and the controller may be damaged seriously.
• Do not turn OFF battery disconnect switch (1) while the engine is running or immediately after the engine
is stopped.
If battery disconnect switch (1) is turned OFF while the alternator is generating power, the generated
current has nowhere to go, leading to overvoltage in the electrical system of the machine, which may
cause serious damage to the electrical system, including the electric devices and controllers.
• If battery disconnect switch (1) is turned OFF for a long period, the machine monitor and the clock of the
radio may be initialized. In this case, re-setting is required.

PC138USLC-10 10-211
10 Structure and function
Electrical control system

Oil flow adjuster function for attachment (PC138-PT24-042-K-00-A)

(Machines ready for installation of attachment)

1. Battery disconnect switch


2. Battery
3. Battery relay
4. Fusible link
5. Fuse box
6. Resister for PC-EPC valve
7. Pump controller
8. Engine controller
9. Machine monitor
10. Emergency pump drive switch
11. Fuel control dial
12. Fuel supply pump
13. Various sensors
14. Oil pressure switch
15. Main pump
15a. Servo
15b. LS valve
15c. PC valve
16. Control valve
16a. Self-pressure reducing valve
16b. Merge-divider valve
17. Attachment selector solenoid valve
18. PPC lock solenoid valve

10-212 PC138USLC-10
10 Structure and function
Electrical control system

19. Attachment flow adjustment EPC valve


20. PC-EPC valve
21. Attachment circuit selector valve (for high pressure side)
22. Attachment circuit selector valve (for low pressure side)
23. Attachment
24. Accumulator
Input/output signal
a. PC-EPC valve drive signal
b. Solenoid valve ground
c. CAN signal
d. Attachment selector solenoid valve drive signal
e. Attachment flow adjustment EPC valve drive signal
f. Oil pressure switch signal
g. Throttle signal
h. Fuel supply pump control signal
i. Various sensor signals

Function
• The flow rate to the attachment when the attachment control pedal is depressed fully is controlled by
setting the working mode and flow rate with machine monitor (9).
• The operation of the attachment changes as shown in the following table, depending on the working
mode.
Working mode Operation of attachment
ATT/P and ATT/E Double action
B Single action

PC138USLC-10 10-213
10 Structure and function
Machine monitor system

Machine monitor system (PC-Q170-042-K-01-A)

1. Machine monitor
2. Battery
3. Pump controller
4. Engine controller
5. Air conditioner controller
6. KOMTRAX terminal
7. Sensors and switches
8. Wiper motor and window washer motor
9. Camera
Input and output signals
a. Power supply
b. CAN signal
c. Sensor and switch signals
d. Drive signal
e. Camera signal

Function
• The monitor system keeps the operator informed of all machine functions, by monitoring the machine
conditions by using the sensors and switches installed in various parts of the machine and processing
them instantly to display on the machine monitor.

10-214 PC138USLC-10
10 Structure and function
Machine monitor system

The information displayed on the machine monitor falls into the following types:
1. Alarm when the machine has trouble
2. Machine status display (coolant temperature, hydraulic oil temperature, fuel level, etc.)
3. Display of camera image
• The switches on the machine monitor have an operating function to control the machine.
Machine monitor (PC-Q180-042-K-01-A)

Function
• The machine monitor has monitor display function, mode selection function and switch function for
electrical parts etc. Also it has an alarm buzzer.
• The machine monitor has a CPU (Central Processing Unit) in it to process, display, and output the
information.
• The machine monitor consists of a display and switches: the display is of LCD type, and the switches are
of flat sheet switch.
• If a failure occurs in the machine monitor itself, controller or wiring circuit between monitor and controller,
the monitor does not display properly.

Precautions on the machine monitor display


• One of the features of liquid crystal display panels is that there may be black spots (spots that do not light
up) or white spots (spots that stay lit up) on the screen. If there are fewer than 10 black or white spots, this
is not a failure or a defect. Products having 10 or less black or bright spots conform the product
specification; such the condition is quite normal.
• When the engine is started, the battery voltage may drop suddenly, depending on the ambient
temperature and the condition of the battery. In this case, the machine monitor display may go off for a
moment. However, this phenomenon is not a failure.
• Continuous operation of the machine monitor may display blue bright spots on the screen having a black
background; it is quite normal.
Blue bright spots can never be a problem as the screen has usually blue or white background. (White in
the LCD is made up of red, green and blue.)

PC138USLC-10 10-215
10 Structure and function
Machine monitor system

Input and output signals of machine monitor (PC138-Q180-03C-K-00-A)


070-18P [CN-CM01]
Pin No. Signal name Input/output signal
1 Continuous power supply (24 V) Input
2 Continuous power supply (24 V) Input
3 GND (continuous power supply) —
4 GND (continuous power supply) —
5 External starting signal Input
6 Starting motor cut-off relay (for personal code) Output
7 (*1) —
8 System operating lamp Input/Output
9 Lamp switch Input
10 Starting switch (ACC) Input
11 Starting switch (C) Input
12 Preheating Input
13 Engine shutdown secondary switch Input
14 (*1) —
15 Fuel level sensor Input
16 Charge level (Alternator terminal R) Input
17 (*1) —
18 (*1) —
*1: Never connect these pins. Malfunctions or failures may occur.
070-12P [CN-CM02]
Pin No. Signal name Input/output signal
1 Seat belt alarm switch Input
2 Engine oil level sensor Input
3 (*1) —
4 (*1) —
5 Swing lock switch Input
6 Buzzer sound signal Input
7 CAN (C) terminating resistor terminal —
8 CAN (C)_H Input/Output
9 CAN (C)_L Input/Output
10 CAN (R) terminating resistor terminal —
11 CAN (R)_H Input/Output
12 CAN (R)_L Input/Output
*1: Never connect these pins. Malfunctions or failures may occur.
070-20P [CN-CM03]
Pin No. Signal name Input/output signal
1 (*1) —
2 (*1) —
3 (*1) —
4 (*1) —
5 (*1) —
6 (*1) —
7 (*1) —
8 (*1) —
9 (*1) —
10 (*1) —
11 (*1) —
12 (*1) —

10-216 PC138USLC-10
10 Structure and function
Machine monitor system

Pin No. Signal name Input/output signal


13 (*1) —
14 (*1) —
15 (*1) —
16 (*1) —
17 (*1) —
18 (*1) —
19 (*1) —
20 (*1) —
*1: Never connect these pins. Malfunctions or failures may occur.
070-8P [CN-CM04]
Pin No. Signal name Input/output signal
1 Power supply for camera (8 V) Output
2 Camera NTSC signal 1 Input
3 Camera NTSC signal 2 Input
4 (*1) —
5 GND (power supply for camera) —
6 Select camera 2 normal/mirror image Output
7 (*1) —
8 GND (shield) —
*1: Never connect these pins. Malfunctions or failures may occur.

PC138USLC-10 10-217
10 Structure and function
Machine monitor system

Display (PC138-Q1LA-042-K-03-A)

a Camera image screen (F) shows the image when multiple cameras are mounted.
A: Standard screen
B: Check before starting screen
C: Maintenance due time warning screen
D: Warning screen
E: Guidance screen
F: Camera image screen

10-218 PC138USLC-10
10 Structure and function
Machine monitor system

1. Message monitor
2. Engine stop monitor
3. Seat belt monitor
4. Air conditioner monitor
5. Wiper monitor
6. Swing lock monitor
7. Engine preheating monitor
8. Service meter
9. Auto-deceleration monitor
10.Working mode monitor
11.Travel speed monitor
12.Fuel level gauge
13.Fuel level monitor
14.ECO gauge
15.Fuel consumption gauge
16.Hydraulic oil temperature monitor
17.Hydraulic oil temperature gauge
18.Engine coolant temperature monitor
19.Engine coolant temperature gauge
20.Engine oil level monitor
21.Engine oil pressure monitor
22.Charge level monitor
23.Clock
24.Maintenance due time warning monitor
25.System state monitor
26.Action level monitor
27.ECO guidance

PC138USLC-10 10-219
10 Structure and function
Machine monitor system

Gauges (PC138-Q1LA-042-K-00-A)

Gauge Item displayed Description Remarks


Temperature Background • Indicates
Range
(°C) color corresponding
(*1) W1 105 Red temperature range.
• Alarm buzzer sounds
Engine coolant W2 102 Red
at 105°C or higher.
temperature W3 100 Blue • If background color is
gauge W4 85 Blue white, warm up
W5 60 Blue engine.
W6 30 White
Temperature Background • Indicates
Range
(°C) color corresponding
(*1) H1 105 Red temperature range.
• Alarm buzzer sounds
Hydraulic oil H2 102 Red
at 105°C or higher.
temperature H3 100 Blue • If background color is
gauge H4 85 Blue white, warm up
H5 40 Blue hydraulic
H6 20 White components.
Range Quantity (l) Background • Indicates
color corresponding level
F1 144 Blue range.
(*1) F2 121 Blue
Fuel level gauge F3 98 Blue
F4 67 Blue
F5 52 Blue
F6 32 Red
Segment Load level • Indicates
Light to instantaneous fuel
Green 1 to 8 consumption
medium
(average of fuel
(*2) consumption by 3
seconds) in 10 steps.
ECO gauge (Displays when “ECO
Orange 9, 10 Heavy Guidance“ o
“Configurations” o
“ECO Gauge“ on user
menu is set to “ON“.)
• Indicates
accumulated engine
operating hours
(alternator is
Service meter 00000.0 h to 99999.9 h generating).
(Press F4 switch to
change to clock
display.)

10-220 PC138USLC-10
10 Structure and function
Machine monitor system

Gauge Item displayed Description Remarks


• Displays time.
• 12-hour system display (AM/PM) (Press F4 switch to
Clock • 24-hour system display change to service
meter display.)
• Indicates average
fuel consumption.
(Display can be
(*2) changed by setting
• 1 Day another item in “ECO
Fuel Guidance“ o
• Split Time
consumption “Configurations” o
• None
gauge “Average Fuel
Consumption
Display“ on user
menu.)
*1: If the gauge signal is not available due to an open circuit in the CAN communication line, the gauge
pointer disappears.
*2: The display can be changed by selecting another item in “ECO Guidance“ o "Configurations" on the user
menu.

PC138USLC-10 10-221
10 Structure and function
Machine monitor system

Alarm monitor (PC138-Q1LA-042-K-01-A)


Description
Monitor
Symbol Item displayed display Action level Remarks
Range
(Background monitor
color)
Lights up • Background color
Min. 102°C (Red) L02 changes depending
Min. 30ºC, Lights up on the temperature
(*1) — detected.
below 102ºC (Blue)
Engine coolant • Alarm buzzer sounds
temperature at 105°C or higher.
Lights up • If background color is
Below 30°C —
(White) white, warm up
engine.
Lights up • Background color
Min. 102°C (Red) L02 changes depending
Min. 20ºC, Lights up on the temperature
— detected.
(*1) below 102ºC (Blue)
• Alarm buzzer sounds
Hydraulic oil at 105°C or higher.
temperature • If background color is
Lights up
Below 20°C — white, warm up
(White)
hydraulic
components.
Lights up • Background color
Below 41 l —
(*1) (Red) changes depending
Lights up on the remaining fuel
Fuel level Min. 41 l —
(Blue) level.
When charge • Monitor lights up and
is defective alarm buzzer sounds
(Charge Lights up when abnormality is
(*1) L03 detected while engine
voltage < (Red)
Battery charge Battery is running.
voltage)
When normal Goes out —
When • Monitor lights up and
abnormal alarm buzzer sounds
(*1) Lights up when abnormality is
(When below (Red) L03
Engine oil specified detected while engine
pressure pressure) is running.
When normal Goes out —
When • Monitor lights up
abnormal when abnormality is
Lights up (*3) detected while engine
(*1) (Below (Yellow)
specified L01 is stopped.
Engine oil level
level)

When normal Goes out

10-222 PC138USLC-10
10 Structure and function
Machine monitor system

Description
Monitor
Symbol Item displayed display Action level Remarks
Range
(Background monitor
color)
When • The display changes
maintenance Lights up depending on how

due time is (Red) long it has been since
over the maintenance due
time was over
Maintenance • After starting switch is
(*2) turned to “ON“
due time warning
When Lights up position, monitor
maintenance — lights up if condition
(Yellow)
notice time is for lighting it up is
over satisfied, and then
goes out in 30
seconds.
When action • Monitor lights up
level “L04“ or Lights up when abnormality is
(Red) L04 and L03
“L03“ is detected in machine
State of system detected system.
• When the
When action Lights up (*3) background color is
level “L01“ is (Yellow) L01 red, the alarm buzzer
detected
sounds.
When action • Monitor lights up
level “L04“ or Lights up when abnormality is
(Red) L04 and L03
“L03“ is detected in engine
State of engine detected system.
system • When the
When action Lights up (*3) background color is
level “L01“ is (Yellow) L01 red, the alarm buzzer
detected
sounds.
When action • Monitor lights up
level “L04“ or Lights up when abnormality is
(Red) L04 and L03
“L03“ is detected in hydraulic
State of detected system.
hydraulic system • When the
When action Lights up (*3) background color is
level “L01“ is (Yellow) L01 red, the alarm buzzer
detected
sounds.
• Monitor lights up and
Engine When engine Lights up alarm buzzer sounds
overspeed overspeed is (Red) L02 when engine
detected overspeed is
detected.
• Monitor lights up
When air Lights up (*3) when abnormality is
State of air
conditioner is (Yellow) detected in air
conditioner L01
abnormal conditioner system.

PC138USLC-10 10-223
10 Structure and function
Machine monitor system

Description
Monitor
Symbol Item displayed display Action level Remarks
Range
(Background monitor
color)
When action Lights up • Monitor lights up
level “L04“ is (Red) L04 when abnormality is
detected detected in machine.
When action Lights up When the
level “L03“ is (Red) L03 background color is
detected red, the alarm buzzer
Action level
When action Lights up sounds.
level “L02“ is (Red) L02
detected
When action Lights up (*3)
level “L01“ is (Yellow)
detected L01

*1: This is included in the check before starting items. After the staring switch is turned to “ON“ position, the
monitor lights up for 2 seconds, and changes to the standard screen if no failure is found.
*2: The notice time is changeable from the items in “Maintenance Mode Setting“.
*3: Lights up for 2 seconds, and then goes out.

10-224 PC138USLC-10
10 Structure and function
Machine monitor system

Pilot monitor (PC138-Q1LA-042-K-02-A)


Symbol Item displayed Description Remarks
• Operates automatically at • Indicates the
low temperature. operation state of
Automatic (Lights up for preheater.
preheating approximately 30 seconds
at longest)
• Goes off after engine is
started.
Elapsed time
after turning
Preheating Monitor
starting switch
display
to “HEAT
(Preheat)“
Manual
preheating 0 to 30 Lights up
seconds
30 to 40
Flashes
seconds
40 seconds or
longer Goes out
Swing parking Monitor • Indicates the
Swing lock
brake cancel display operation state of
switch
switch swing lock.
Swing lock OFF OFF Goes out
ON OFF Lights up
OFF ON Flashes
ON ON Flashes
• Indicates the
INT: Intermittent operation
operation state of
Wiper ON: Continuous operation front window wiper.
Goes out: Stopped
• Indicates the
Lights up: ON operation state of air
Air conditioner conditioner and
Goes out: OFF
blower.
• Indicates whether
Lights up: Not fastened seat belt is fastened.
Seat belt
Goes off: Fastened

• Indicates the
Lights up: When engine is stopped operation state of
Engine stopped engine.
Goes off: While engine is running

• Indicates the state of


Message Lights up: There is unread message. message.
(Unread) Goes off: No message

Message • Indicates the state of


(No return Lights up: There is an already-read message message.
message, but return message for it is not sent yet.
already-read Goes off: No message
message)

PC138USLC-10 10-225
10 Structure and function
Machine monitor system

Symbol Item displayed Description Remarks


• Indicates the
Auto- Lights up: ON operation state of
deceleration auto-decelerator.
Goes out: OFF

P: Heavy-duty operation • Indicates the set


E: Low-fuel consumption operation working mode.
L: Fine control operation
Working mode B: Breaker operation
ATT/P: 2-way attachment operation
ATT/E: 2-way attachment operation with low
fuel consumption
• Indicates the set
Lo: Low-speed travel travel speed.
Travel speed
Hi: High-speed travel

• Idle stop guidance • Indicates the


• Deterrence guidance of hydraulic relief guidance to support
• E-mode (recommended) guidance operation of the
ECO guidance
• Reduce engine speed (recommended) machine.
guidance
• Low fuel level guidance

10-226 PC138USLC-10
10 Structure and function
Machine monitor system

Switches (PC138-Q1C0-042-K-00-A)

No. Name Function Operation


Switches between ON and OFF of • When the working mode is “L“ and
Auto-deceleration the auto-deceleration. after the engine is started, the auto-
1 switch
Lights up: ON deceleration function is kept “OFF“.
[Numeral key pad: 1] OFF io ON
Goes out: OFF
P: Heavy-duty operation
E: Low-fuel consumption operation
(*1)
L: Fine control operation
Working mode selector Displays working mode selection
2 switch B: Breaker operation
screen.
[Numeral key pad: 2] ATT/P: 2-way attachment operation
ATT/E: 2-way attachment operation with
low fuel consumption
Travel speed selector Selects travel speed. • Changes as follows in order.
3 switch Lo lights up: Low-speed travel Lo (low speed) o Hi (high speed) o
[Numeral key pad: 3] Lo (low speed)
Hi lights up: High-speed travel
Stops the alarm buzzer. • The alarm buzzer stops sounding.
Buzzer cancel switch • When abnormality which turns on the
4 (Some alarm buzzer does not stop
[Numeral key pad: 4] alarm buzzer is detected again, the
even if the switch is pressed.) alarm buzzer sounds.
Operates front window wiper. • Each time the switch is pressed,
(*2) operation of the wiper chagnes.
INT: Intermittent operation
5 Wiper switch INT (intermittent) o ON (continuous)
ON: Continuous operation o OFF (stopped) o INT (intermittent)
[Numeral key pad: 5]
Goes out: Stopped

PC138USLC-10 10-227
10 Structure and function
Machine monitor system

No. Name Function Operation


ON: Washer fluid spouts out and the
wiper operates continuously.
[When wiper is stopped]
(*2) OFF: When the switch is released, the
wiper continues to operate for 2 cycles,
6 Window washer switch Sprays washer fluid to the front
window. then stops.
[Numeral key pad: 6]
[When wiper is intermittent operation]
OFF: When the switch is released, the
wiper continues to operate for 2 cycles,
then returns to intermittent operation.
Fan switch (increase) • The air flow increases immediately
7a Adjusts the air flow of the air after the air conditioner adjustment
[Numeral key pad: 7]
conditioner in six levels. screen appears.
(Low, Medium 1, Medium 2, • The air flow decreases immediately
7b Fan switch (decrease) Medium 3, Medium 4, High) after the air conditioner adjustment
screen appears.
Temperature control • The preset temperature increases
8a switch (High) Adjusts the temperature inside the immediately after the air conditioner
[Numeral key pad: 8] air-conditioned cab. adjustment screen appears.
Temperature control (18.0ºC to 32.0ºC: Settable by • The preset temperature decreases
8b switch (low) 0.5ºC) immediately after the air conditioner
[Numeral key pad: 0] adjustment screen appears.
• Automatically controls the air flow, air
(*3) Operates the air conditioner and air vent, and FRESH/RECIRC air
blower with automatic operation. changeover according to the set
9 Auto switch
AUTO lights up: Automatic temperature, immediately after the air
[Numeral key pad: 9] operation conditioner adjustment screen
appears.
Switches between ON and OFF of • Switches to the air conditioner
(*4) the air conditioner. adjustment screen, and pressing it
10 A/C lights up: Manual operation again switches ON/OFF.
Air conditioner switch
OFF io ON
Goes out: Stopped
• Switches to the air conditioner
FRESH/RECIRC air adjustment screen, and pressing it
11 Selects FRESH/RECIRC air.
selector switch again switches FRESH/RECIRC.
RECIRC io FRESH
Selects air vent mode from 6 • Switches to the air conditioner
modes. adjustment screen, and pressing it
1. Front and rear again switches air vent mode.
1o2o3o4o5o1
12 Vent selector switch 2. Front, rear, and foot
3. Foot
4. Foot and defroster
5. Defroster
Stops fan and air conditioner. • The fan and air conditioner stop.
13 OFF switch
Goes out: OFF
14a Guidance icon
See "Guidance icon and function switch." section.
14b Function switch
*1: When the working mode is changed, the auto-decelerator function is turned “ON“.
*2: Windshield wiper and window washer do not operate while the front window is open, even if the switch is
pressed.
*3: If temperature is set to 18.0°C or 32.0°C, the air flow from the fan is always set to “HIGH“ and does not
change even if the set temperature is reached.
*4: When the fan is stopped, the air conditioner does not start even if the switch is pressed.

10-228 PC138USLC-10
10 Structure and function
Machine monitor system

Guidance icon and function switch (PC138-Q1C1-042-K-00-A)


• Functions available with the function switch vary depending on the guidance icon displayed above the
switch.
• No function is available if no guidance icon appears above the function switch.
• The following is the list of guidance icons and the functions displayed above the function switches.
Guidance
Item Function
icon
Selects user menu screen.
Information transmitted can be checked with background colors.
Select user menu screen • Gray: When condition is normal
• Red: When maintenance due time is exceeded
• Yellow: When maintenance notice time is exceeded
• Green: When there is unread KOMTRAX message

Select clock or service


Selects clock or service meter
meter

Select camera image Selects camera image

Enters selected item or set item.


Information transmitted can be checked with background colors.
Enter
• Gray: When condition is normal
• Green: When ECO guidance is displayed

Return Returns to previous screen or status.

Moves selection to the above item.


Move selected item (Moves selection to the bottom item when at the top item)
Holds the monitoring.
Moves selection to the below item.
Move selected item (Moves selection to the top item when at the bottom item)
Cancels holding of the monitoring.
Green arrow: Moves to the right tab.
Move selected item White arrow: Moves to the right.
(Moves selection to the leftmost item when at the rightmost item)
Green arrow: Moves to the left tab.
Move selected item White arrow: Moves to the left.
(Moves selection to the rightmost item when at the leftmost item)

Moves selection to the above page.


Move selected item
(Moves selection to the bottom page when at the top page)

Moves selection to the below page.


Move selected item
(Moves selection to the top page when at the bottom page)

Clear Clears selected item or displayed item.

PC138USLC-10 10-229
10 Structure and function
Machine monitor system

Guidance
Item Function
icon

Returns selected item to default value.


Return to default setting
(Used for screen adjustment)

Set Executes setting.

Executes starting.
Start (Used for starting split fuel consumption measurement for fuel
consumption display)

Executes stopping.
Stop (Used for stopping split fuel consumption measurement for fuel
consumption display)

Save Saves setting.

Select name setting screen Selects name setting screen.

Select ATT1 oil flow setting Selects the 1-attachment oil flow setting screen.
screen (Effective only when installation of 2-attachment systems is set)

Select ATT2 oil flow setting Selects the 2-attachment oil flow setting screen.
screen (Effective only when installation of 2-attachment systems is set)

Holds value of monitoring item.


Hold
(Used during monitoring)

Cancels held value of monitoring item.


Cancel holding
(Used during monitoring)

Change "Average Fuel


Changes graph on "Average Fuel Consumption Logs" screen.
Consumption Logs" screen

Select oil flow setting Selects the attachment and breaker oil flow setting screen.
screen

Selects "Occurred Error List" screen.


Select "Occurred Error Information transmitted can be checked with background colors.
List" screen • Red: When action level of L2, L3, or L4 is displayed.
• Yellow: When action level of L0 is displayed.

Display image of camera Selects image of camera No. 1.


No. 1

10-230 PC138USLC-10
10 Structure and function
Machine monitor system

Guidance
Item Function
icon

Display image of camera Selects image of camera No. 2.


No. 2

Display images of cameras


No. 1 and No. 2 Displays images of cameras No. 1 and No. 2 simultaneously.
simultaneously

PC138USLC-10 10-231
10 Structure and function
Machine monitor system

Operator mode functions (PC138-Q193-042-K-00-A)


• The functions with which the operator can display or set by operating switches in normally displayed
screen.
Display and setting of some functions require special operation of the switch.
• Items available in the operator mode are as follows:
Category Display order (*2)
Item
(*1) V W X Y Z
Display of KOMATSU logo 1 1 1 1 1
Display of password input 2 — — — —
Display to check breaker mode — — 2 — —
Display of Check before starting 3 2 3 2 2
Display of warning after check before starting — — — 3 —
A — — — —
Display of maintenance due time over 3
Display to check working mode and travel speed 4 3 4 4 4
Display of standard screen 5 4 5 5 5
Display of engine shutdown secondary switch screen
Display of end screen
Selection of auto-deceleration
Selection of working mode
Selection of travel speed
Stop operation of alarm buzzer
Operation of windshield wiper
Operation of window washer
Operation of air conditioner
B Operation to display camera mode
Operation to display clock and service meter
Check of maintenance information
Setting and display of user menu
• ECO Guidance
• Machine Setting
• Maintenance
• Monitor Setting
• Display of message (including KOMTRAX messages for user)
Display of ECO guidance
C Display of caution monitor
Display of action level and failure code
Checking function by LCD (Liquid Crystal Display)
D Function to check service meter
Function of usage limitation setting/change password
*1: The operator mode items are classified as follows.
A: Display from the time when the starting switch is turned to “ON“ position to the time when display changes
to the standard screen, and display after starting switch is turned to “OFF“ position
B: Display when the machine monitor switch is operated
C: Display when condition is satisfied
D: Display that requires special operations of switches

*2: Display sequence from the time when the starting switch is turned to ON position to the time when the
standard screen appears varies depending on the settings and conditions of the machine as follows:
V: When the engine start lock is set ON
W: When the engine start lock is set OFF
X: When the working mode is set to “Breaker Mode (B)“ at start of engine
Y: When any abnormality is detected by the check before starting

10-232 PC138USLC-10
10 Structure and function
Machine monitor system

Z: When any item is detected as the maintenance due time is over.

a For how to operate the operator mode functions, see the Operation and Maintenance Manual or "Operator
mode (Outline)" section in Testing and adjusting.
a For the operating method of the engine start lock function, see Password setting and canceling manual.

PC138USLC-10 10-233
10 Structure and function
Machine monitor system

Service mode functions (PC138-Q194-042-K-00-A)


• These functions are not displayed normally. A technician can display and set them special operation of
switches.
This function is used for special setting, testing, adjusting, or troubleshooting.
• Items available in the service mode are as follows:
Monitoring/Pre-defined
Monitoring/Custom
Abnormality Record Mechanical Systems
Electrical Systems
Maintenance Record
Maintenance Mode Setting
Phone Number Entry
Default Key-on Mode
Unit
With/Without Attachment
Camera
Diagnostic Tests Cylinder Cut-out
Regeneration for Service
Adjustment Pump Absorption Torque
Attachment Flow Adjustment
No Injection
KOMTRAX Settings Terminal Status
GPS & Communication Status
Modem Status
Service Message

a For operating method of the service mode functions, see "Service mode" section in Testing and adjusting.

10-234 PC138USLC-10
10 Structure and function
KOMTRAX system

KOMTRAX system (PC-Q210-042-K-00-A)

• The KOMTRAX system consists of the KOMTRAX terminal, communication antenna and GPS antenna.
• This system transmits various machine information by use of the radio communication. This system allows
the KOMTRAX operator to refer the information and provide various services to the customers.
• Information transmittable from the KOMTRAX system are as follows.
1. Operation map
2. Service meter reading
3. Location information
4. Abnormality record
a To provide the services, you need to make an arrangement for starting the KOMTRAX service separately.

PC138USLC-10 10-235
10 Structure and function
KOMTRAX system

KOMTRAX terminal (PC220-Q220-042-K-00-A)

Type: TC330

1. GPS antenna connection


2. Machine harness connection (070-18P)
3. Machine harness connection (070-12P)
4. Communication antenna connection

Input and output signals (PC220-Q220-03C-K-00-A)


070-18P[CN-CK01]
Pin No. Signal name Input/Output signal
1 (*1) -
2 (*1) -
3 (*1) -
4 (*1) -
5 (*1) -
6 (*1) -
7 (*1) -
8 (*1) -
9 (*1) -
10 CAN (C)_H Input/Output
11 CAN (C)_L Input/Output
12 (*1) -
13 (*1) -
14 External start signal Input/Output
15 System operation lamp Output
16 (*1) -
17 (*1) -
18 (*1) -
*1: Never connect these pins. Malfunctions or failures may occur.
070-12P [CN-CK02]
Pin No. Signal name Input/Output signal
1 GND -
2 GND -
3 Starting switch (ACC) Input
4 Alternator (R) Input
5 (*1) -
6 Power supply Input
7 Power supply Input
8 (*1) -

10-236 PC138USLC-10
10 Structure and function
KOMTRAX system

Pin No. Signal name Input/Output signal


9 (*1) -
10 (*1) -
11 Starting switch (C) Input
12 (*1) -
*1: Never connect these pins. Malfunctions or failures may occur.

Function (PC-Q220-042-K-00-A)
• This terminal utilizes satellite communications technology.
• The terminal is an equipment which transmits various machine information obtained through network
signals and input signals, as well as GPS positioning data. The terminal can transmit data via the
communication antenna.
• The status of the terminal can be checked by using the menu of “KOMTRAX setting“ in the service mode
of the machine monitor .
• Use of KOMTRAX terminal must be limited for the countries in which such communication is allowed.
• This terminal has LED lamps and 7-segment lamp indicator used for testing and troubleshooting on its
display section.
a When commencing operation of the KOMTRAX system or changing the country in which the system is
used, you must give notice about the name of the country to Komatsu Ltd.
a When operating the system in Japan, install a terminal dedicated for use in Japan.

PC138USLC-10 10-237
10 Structure and function
KOMTRAX system

System component parts (ALL-RA1C-001-K-00-A)

Engine controller (PC220-AP70-041-K-00-A)

Input and output signals of engine controller (ENG95-AP70-03C-K-00-A)


• The symbols in the signal category column of the input/output signal table are as follows.
A: Power supply
B: Input
C: Ground/Shield/Return
D: Output
E: Communication
DRC26-60P(1)[ECM J1(CN-CE01)]
Pin No. Signal name Signal category
1 (*1) —
2 (*1) —
3 Crankcase pressure sensor B
4 (*1) —
5 Charge temperature sensor B
6 Intake temperature MAF sensor B
7 (*1) —
8 CAN_B (+) (KOMNET/r) E
9 Bkup (camshaft) speed sensor (+) B
10 (*1) —
11 (*1) —
12 (*1) —
13 GND C
14 Coolant temperature sensor B
15 Charge pressure sensor B
16 Ambient pressure sensor B

10-238 PC138USLC-10
10 Structure and function
KOMTRAX system

Pin No. Signal name Signal category


17 (*1) —
18 CAN_B (-) (KOMNET/r) E
19 (*1) —
20 (*1) —
21 Sensor power supply (12 V) A
22 GND C
23 Mass air flow (MAF) sensor B
24 (*1) —
25 (*1) —
26 Ne (crankshaft) speed sensor (+) B
27 (*1) —
28 (*1) —
29 (*1) —
30 SCV (+) D
31 Engine oil pressure switch B
32 (*1) —
33 (*1) —
34 (*1) —
35 (*1) —
36 Sensor power supply (5 V) A
37 NE (crankshaft) speed sensor (-) C
38 (*1) —
39 (*1) —
40 SCV (-) C
41 (*1) —
42 (*1) —
43 (*1) —
44 Injector #3 (+) D
45 Injector #2 (+) D
46 Injector #4 (+) D
47 (*1) —
48 Injector #1 (+) D
49 (*1) —
50 (*1) —
51 (*1) —
52 (*1) —
53 (*1) —
54 Injector #3 (-) C
55 Injector #2 (-) C
56 Injector #4 (-) C
57 (*1) —
58 Injector #1 (-) C
59 GND C
60 Sensor power supply (5 V) A
*1: Never connect these pins. Malfunctions or failures may occur.
DRC26-60P(2)[ECM J2(CN-CE02)]
Pin No. Signal name Signal category
1 VFT motor (V) B
2 VFT motor (U) B
3 EGR valve motor (W) B
4 EGR valve motor (V) B

PC138USLC-10 10-239
10 Structure and function
KOMTRAX system

Pin No. Signal name Signal category


5 EGR valve motor (U) B
6 (*1) —
7 (*1) —
8 (*1) —
9 (*1) —
10 (*1) —
11 VFT motor B
12 (*1) —
13 (*1) —
14 (*1) —
15 (*1) —
16 (*1) —
17 (*1) —
18 GND C
19 (*1) —
20 (*1) —
21 GND C
22 (*1) —
23 (*1) —
24 CAN_B (+) E
25 CAN_B (-) E
26 (*1) —
27 (*1) —
28 (*1) —
29 (*1) —
30 Sensor power supply (5 V) A
31 Sensor power supply (5 V) A
32 (*1) —
33 (*1) —
34 (*1) —
35 (*1) —
36 (*1) —
37 (*1) —
38 (*1) —
39 (*1) —
40 (*1) —
41 EGR valve sensor (V) D
42 EGR valve sensor (W) D
43 VFT sensor (V) D
44 Common rail pressure sensor B
45 (*1) —
46 (*1) —
47 GND C
48 (*1) —
49 (*1) —
50 (*1) —
51 EGR valve sensor (U) D
52 VFT sensor (U) D
53 VFT sensor (W) D
54 (*1) —
55 Common rail pressure sensor B
56 (*1) —

10-240 PC138USLC-10
10 Structure and function
KOMTRAX system

Pin No. Signal name Signal category


57 (*1) —
58 (*1) —
59 (*1) —
60 (*1) —
*1: Never connect these pins. Malfunctions or failures may occur.
DRC26-60P(3)[CN-CE03]
Pin No. Signal name Signal category
1 Continuous power supply (24 V) A
2 Continuous power supply (24 V) A
3 Starting switch ACC signal B
4 Electrical intake air heater relay (+) D
5 (*1) —
6 (*1) —
7 (*1) —
8 (*1) —
9 System operating lamp D
10 (*1) —
11 Continuous power supply (24 V) A
12 Continuous power supply (24 V) A
13 GND C
14 (*1) —
15 (*1) —
16 (*1) —
17 CAN_A (+) (KOMNET/c) E
18 CAN_A (-) (KOMNET/c) E
19 GND C
20 (*1) —
21 GND C
22 GND C
23 (*1) —
24 (*1) —
25 (*1) —
26 (*1) —
27 (*1) —
28 (*1) —
29 (*1) —
30 (*1) —
31 GND C
32 GND C
33 (*1) —
34 (*1) —
35 (*1) —
36 (*1) —
37 (*1) —
38 (*1) —
39 (*1) —
40 (*1) —
41 GND C
42 Sensor power supply (5 V) A
43 GND C
44 (*1) —

PC138USLC-10 10-241
10 Structure and function
KOMTRAX system

Pin No. Signal name Signal category


45 (*1) —
46 (*1) —
47 (*1) —
48 (*1) —
49 Idle validation signal 1 B
50 Idle validation signal 2 B
51 Throttle signal B
52 Sensor power supply (5 V) A
53 (*1) —
54 (*1) —
55 (*1) —
56 (*1) —
57 (*1) —
58 (*1) —
59 (*1) —
60 (*1) —
*1: Never connect these pins. Malfunctions or failures may occur.

10-242 PC138USLC-10
10 Structure and function
KOMTRAX system

Pump controller (PC-C3V1-041-K-00-A)

PC138USLC-10 10-243
10 Structure and function
KOMTRAX system

Input and output signals of pump controller (PC138-C3V1-03C-K-00-A)


AMP-81P [CN-CP01]
Pin No. Signal name Input/output signal
1 Continuous power supply (24 V) Input
2 Continuous power supply return Input
3 Window washer Output
4 Continuous power supply (24 V) Input
5 Continuous power supply return Input
6 Potentiometer power supply (5 V) Output
7 CAN (R)_H Input/Output
8 Service oil pressure sensor Input
9 (*1) —
10 R.H. lever potentiometer signal 2 Input
11 Oil pressure sensor of pump Input
12 (*1) —
13 Boom “LOWER“ PPC oil pressure switch Input
14 Arm “IN “PPC oil pressure switch Input
15 Left travel REVERSE PPC oil pressure sensor Input
16 Overload sensor Input
17 (*1) —
18 GND (analog signal) —
19 (*1) —
20 Swing lock switch Input
21 (*1) —
22 (*1) —
23 Breaker switch Input
24 Starting switch ACC signal Input
25 (*1) —
26 CAN (R)_L Input/Output
27 (*1) —
28 Hydraulic oil temperature sensor Input
29 L.H. lever potentiometer signal 2 Input
30 (*1) —
31 Swing PPC oil pressure switch Input
32 Boom “RAISE“ PPC oil pressure switch Input
33 (*1) —
34 Left travel FORWARD PPC oil pressure sensor Input
35 Service PPC oil pressure switch Input
36 (*1) —
37 GND (digital signal) —
38 (*1) —
39 Swing parking brake cancel switch Input
40 (*1) —
41 (*1) —
42 (*1) —
43 Starting switch ACC signal Input
44 (*1) —
45 CAN (C)_H Input/Output
46 GND (analog signal) —
47 (*1) —
48 R.H. lever potentiometer signal 2 Input
49 (*1) —
50 Bucket “DUMP“ PPC oil pressure switch Input

10-244 PC138USLC-10
10 Structure and function
KOMTRAX system

Pin No. Signal name Input/output signal


51 Arm “OUT “PPC oil pressure switch Input
52 Blade “LOWER“ PPC oil pressure switch Input
53 Right travel REVERSE oil pressure sensor Input
54 Quick coupler alarm Output
55 (*1) —
56 Wiper motor reverse (W) Input
57 Overload alarm actuation switch Input
58 Blade specification switch Input
59 (*1) —
60 (*1) —
61 Starting switch C signal Input
62 External starting signal Input
63 Potentiometer power supply (5 V) Output
64 CAN (C)_L Input/Output
65 (*1) —
66 (*1) —
67 L.H. lever potentiometer signal 1 Input
68 (*1) —
69 Bucket “CURL“ PPC oil pressure switch Input
70 (*1) —
71 Blade “RAISE“ PPC oil pressure switch Input
72 Right travel FORWARD PPC oil pressure sensor Input
73 (*1) —
74 (*1) —
75 Wiper motor stop (P) Input
76 Cab front window open limit switch Input
77 (*1) —
78 (*1) —
79 PPC lock switch Input
80 Starting switch ACC signal Input
81 (*1) —
*1: Never connect these pins. Malfunctions or failures may occur.
AMP-40P [CN-CP02]
Pin No. Signal name Input/output signal
82 (*1) —
83 (*1) —
84 (*1) —
85 Travel junction solenoid valve Output
86 Attachment selector solenoid valve Output
87 2nd attachment L.H. EPC valve Output
88 (*1) —
89 (*1) —
90 (*1) —
91 (*1) —
92 (*1) —
93 Travel speed increase solenoid valve Output
94 (*1) —
95 2nd attachment R.H. EPC valve Output
96 Pump PC-EPC valve Output
97 Attachment flow adjustment EPC valve Output
98 (*1) —

PC138USLC-10 10-245
10 Structure and function
KOMTRAX system

Pin No. Signal name Input/output signal


99 (*1) —
100 System-in-use signal Output
101 Swing parking brake solenoid valve Output
102 Attachment L.H. EPC valve Output
103 (*1) —
104 (*1) —
105 (*1) —
106 (*1) —
107 Travel alarm Output
108 Battery relay drive Output
109 (*1) —
110 Attachment R.H. EPC valve Output
111 (*1) —
112 Merge-divider selector solenoid valve Output
113 (*1) —
114 Wiper motor (-) Output
115 GND (solenoid) Input
116 Solenoid power supply Input
117 GND (solenoid) Input
118 Solenoid power supply Input
119 Wiper motor (+) Output
120 GND (solenoid) Input
121 Solenoid power supply Input
*1: Never connect these pins. Malfunctions or failures may occur.

10-246 PC138USLC-10
10 Structure and function
KOMTRAX system

Fuel control dial (PC-AGJ7-041-K-01-A)

1. Knob
2. Dial
3. Spring
4. Ball
5. Potentiometer
6. Connector

Function (PC-AGJ7-042-K-00-A)
• This dial is installed in the right console box. Turning knob (1) causes potentiometer (5) shaft to rotate.
• As the potentiometer shaft is turned, the resistance of the variable resistor in potentiometer (5) changes
and a throttle signal is sent to the engine controller.
• The hatched areas in the graph are abnormality detection areas. If the throttle voltage is within the area,
the engine speed drops down to low idle.

PC138USLC-10 10-247
10 Structure and function
KOMTRAX system

Resister for PC-EPC valve (PC138-C3VR-041-K-00-A)

a PPC: Abbreviation for Proportional Pressure Control


a EPC: Abbreviation for Electromagnetic Proportional Control

1. Resistance
2. Connector

Specifications (PC138-C3VR-030-K-00-A)
Resistance: 30 z

Function (PC138-C3VR-042-K-00-A)

• This resistor allows a proper current to flow to EPC valve, according to the condition, when the emergency
pump drive switch or emergency work equipment operation switch is turned to “ON“ position.
a No current flows normally.

10-248 PC138USLC-10
10 Structure and function
KOMTRAX system

CAN terminating resistor (PC220-Q2V1-041-K-00-A)

a CAN: Abbreviation for Controller Area Network

1. Connector (with built-in resistor)

Specifications (PC220-Q2V1-030-K-00-A)
Resistance: 120 z

Function (PC220-Q2V1-042-K-00-A)
• This resistance controls the reflection of the high-frequency signals at the end of CAN communication line
not to generate noise on the CAN communication signals sending and receiving between controllers.
a If this resistance is missing, an error occurs on CAN communication and the machine cannot be
operated.

PC138USLC-10 10-249
10 Structure and function
KOMTRAX system

Engine oil pressure switch (PC-ABK6-041-K-00-A)

1. Connector
2. Sensor
3. O-ring

Specifications (PC220-ABK6-030-K-00-A)
Contact type: Normally closed

Function (ENG95-ABK6-042-K-00-A)
• This oil pressure sensor is installed to the cylinder block, senses the engine oil pressure, and turns “ON“
when the engine oil pressure decreases below the specified pressure.

10-250 PC138USLC-10
10 Structure and function
KOMTRAX system

PPC oil pressure switch (PC-E610-041-P-00-A)

a PPC: Abbreviation for Proportional Pressure Control

1. Plug
2. Switch
3. Connector

Specifications (PC220-E610-030-P-00-A)
Contact type: Normally open
Operating (ON) pressure: 490 ± 98.1 kPa {5.0 ± 1.0 kg/cm2}
Resetting (OFF) pressure: 294 ± 49.0 kPa {3.0 ± 0.5 kg/cm2}

Function (PC138-E610-042-P-00-A)
• This sensor is installed to 8 places of the junction block, senses the PPC oil pressure while each actuator
is operated, and turns the switch “ON“ when the PPC oil pressure exceeds the specified pressure.

PC138USLC-10 10-251
10 Structure and function
Sensor

Sensor (ALL-E700-001-P-00-A)

Ambient pressure sensor (ENG-AAP2-041-K-00-A)

1. Connector
2. Sensor

Function (ENG95-AAP2-042-K-00-A)
• This sensor is installed to the bracket on the side of the cylinder block, senses the ambient pressure, and
outputs it as a variable voltage.

10-252 PC138USLC-10
10 Structure and function
Sensor

Charge (boost) pressure and temperature sensor (ENG-AAM7-041-K-00-A)

1. Connector
2. Sensor
3. O-ring

Function (ENG-AAM7-042-K-00-A)
• This sensor is installed to the engine intake manifold. It detects the engine intake air pressure and its
temperature, and outputs signals as a variable voltage for pressure, and as variable resistance for
temperature.
a "Charge pressure and temperature" are the engine intake air pressure and temperature of a turbocharged
engine. These are also referred to as "boost pressure and temperature" or "intake air pressure and
temperature".

Output characteristics

PC138USLC-10 10-253
10 Structure and function
Sensor

Coolant temperature sensor (ENG-BA87-041-K-00-A)

1. Connector
2. Sensor
3. O-ring

Function (ENG-BA87-042-K-00-A)
• This sensor, installed on the cylinder head of the engine, converts the temperature variation into the
resistance variation, and outputs the corresponding signals.
Ne (crankshaft) speed sensor (ENG-AG42-041-K-00-A)

1. O-ring
2. Sensor
3. Connector

Function (ENG-AG42-042-K-00-A)
• This sensor, installed to the crankshaft pulley on the engine front cover, outputs the pulse voltage due to
the gear rotation.

10-254 PC138USLC-10
10 Structure and function
Sensor

Bkup (camshaft) speed sensor (ENG-AG62-041-K-00-A)

1. O-ring
2. Sensor
3. Connector

Function (ENG95-AG62-042-K-00-A)

Common rail pressure sensor (ENG95-AE28-041-K-00-A)

1. Common rail pressure


2. Sensor
3. Connector

Function (ENG-AE28-042-K-00-A)
• This sensor, installed to the common rail in the engine, detects the fuel pressure to output the
corresponding variable voltage.

PC138USLC-10 10-255
10 Structure and function
Sensor

VFT motor (with position sensor) (ENG95-AA56-041-K-00-A)

a VFT: Abbreviation for Variable Flow Turbocharger


a The shape is subject to machine models.

1. VFT motor (brushless motor with built-in position sensor)


2. Turbine portion
3. Connector

Function (ENG95-AA56-042-K-00-A)
• Controls the flow control valve with a DC motor.
• The VFT motor has a position sensor in it to sense the valve position.

10-256 PC138USLC-10
10 Structure and function
Sensor

EGR valve (with position sensor) (ENG95-AA57-041-K-00-A)

a EGR: Abbreviation for Exhaust Gas Recirculation


a The shape is subject to machine models.

1. EGR valve motor (with built-in position sensor)


2. Connector
3. Body

Function (ENG95-AA57-042-K-00-A)
• Small-sized EGR valve driven with a DC motor.
• The EGR valve motor has a position sensor in it to sense the valve position.

PC138USLC-10 10-257
10 Structure and function
Sensor

Mass air flow and temperature sensor (ENG-A96H-041-K-00-A)

1. Connector
2. O-ring
3. Sensor

Function (ENG-A96H-042-K-00-A)
• This sensor is installed to the outlet side of air cleaner, converts the variations of intake air flow and
temperature into the resistance variation, and outputs the corresponding signals.
a The “MAF (Mass Air Flow)“ means the “intake air flow“.
Crankcase pressure sensor (ENG-A18C-041-K-00-A)

1. Connector
2. Sensor
3. O-ring

Function (ENG95-A18C-042-K-00-A)
• This sensor is installed to the breather top, senses the crankcase pressure (blowby pressure), and outputs
it as a variable voltage.

10-258 PC138USLC-10
10 Structure and function
Sensor

Engine oil level sensor (ENG-AB45-041-K-00-A)

1. Connector
2. Bracket
3. Float
4. Switch

Function (ENG-AB45-042-K-00-A)
• This sensor, installed on the side face of the oil pan, turns “OFF“ by the lowered float, if the oil level
becomes lower than specified.

PC138USLC-10 10-259
10 Structure and function
Sensor

Fuel level sensor (PC-AD41-041-K-00-A)

1. Connector
2. Float
3. Arm
4. Valve body
5. Spring
6. Variable resistor

Function (PC-AD41-042-K-00-A)
• This sensor is installed on the side face of the fuel tank. The float moves up and down according to the
fuel level.
• The movement of the float activates the variable resistor through the arm. As a result, the source voltage
is changed according to the resistance change due to the arm angle change and is output as a signal.

10-260 PC138USLC-10
10 Structure and function
Sensor

Hydraulic oil temperature sensor (PC-PMT1-041-K-00-A)

1. Connector
2. Plug
3. Thermistor

Function (PC138-PMT1-042-K-00-A)
• This sensor is installed to the suction piping of the main pump and outputs a resistance change signal of
the thermistor for the temperature change.

PC138USLC-10 10-261
10 Structure and function
Sensor

Oil pressure sensor of pump (PC138-C3WJ-041-K-00-A)

1. O-ring
2. Sensor
3. Connector

Function (PC138-C3WJ-042-K-00-A)
• This sensor is installed to the control valve, senses the main pump pressure, and outputs it as a variable
voltage.

Output characteristics

10-262 PC138USLC-10
10 Structure and function
Sensor

PPC oil pressure sensor (PC-E720-041-P-00-A)

a PPC: Abbreviation for Proportional Pressure Control

1. O-ring
2. Sensor
3. Connector

Function (PC138-E720-042-P-00-A)
• The PPC oil pressure sensor is installed to the control valve joint of the blade pilot circuit, senses the pilot
pressure, and outputs a variable voltage for it.

Output characteristics

PC138USLC-10 10-263
10-264 PC138USLC-10
SHOP MANUAL

HYDRAULIC EXCAVATOR
PC138USLC-10
Model Serial Number

PC138USLC- 40001 and up


10

20 Standard value tables


4 20 Standard value tables

PC138USLC-10 20-1
20 Standard value tables
Table of contents

Table of contents (ALL-0310-002-A-00-A)


20 Standard value tables.................................................................................................................... 20-1
Table of contents ........................................................................................................................ 20-2
Standard service value table........................................................................................................ 20-3
Standard value table for engine ............................................................................................. 20-3
Standard value table for machine .......................................................................................... 20-4
Standard value table for electrical system............................................................................. 20-17

20-2 PC138USLC-10
20 Standard value tables
Standard value table for engine

Standard service value table (ALL-A000-001-K-00-A)

Standard value table for engine (PC138_10-A000-033-K-00-A)

Machine model PC138USLC-10


Engine SAA4D95LE-6
Standard value
Item Measurement condition Unit for new Repair limit
machine
Max. speed rpm 2,150 ± 60 ―
Engine speed (*) • Coolant temperature: 75 to Min. speed rpm 1,100 ± 50 ―
94°C
Rated speed rpm 2,050 ―
At sudden Bosch
Max. 0.5 Max. 2.0
acceleration index
Exhaust gas color • Coolant temperature: 75 to
94°C Bosch
At max. speed Max. 0.5 Max. 1.5
index
• Coolant temperature: Intake valve mm 0.35 ―
Valve clearance Normal temperature Exhaust valve mm 0.50 ―
Compression • Engine oil temperature: 40 to 60°C MPa Min. 2.9 2.0
pressure • Engine speed: 320 to 360 rpm {kg/cm2} {Min. 30} {20}
kPa
• Coolant temperature: 75 to 94°C Max. 0.98 1.47
Blowby pressure {mmH2-
• Arm IN relief {Max. 100} {150}
O}
0.29 to 0.69 0.21
• Coolant temperature: 75 to High idle
Engine oil MPa {3.0 to 7.0} {2.1}
pressure 94°C
{kg/cm2} Min. 0.15 0.13
• EO15W40–LA oil Low idle
{Min. 1.5} {1.3}
Engine oil
• Whole speed range (inside oil pan) °C 80 to 115 120
temperature
Automatic Automatic
adjustment adjustment
Fan belt tension ― mm
(Auto- (Auto-
tensioner) tensioner)
Air conditioner • Between compressor pulley and fan pulley
compressor belt • Deflection when pressed with finger at 60 mm 6 to 9 6 to 9
tension N {6.1 kg}
(*): The values of the max. speed and rated speed are the speed during digging work.
Reference: During travel
Max. speed: 2,150 rpm
Rated speed: 2,050 rpm

PC138USLC-10 20-3
20 Standard value tables
Standard value table for machine

Standard value table for machine (PC138_10-0000-033-K-00-A)


Engine speed
Machine model PC138USLC-10
Standard value Repair limit
Item Measurement condition Unit
for new machine
• Hydraulic oil temperature: 45
to 55°C
• Coolant temperature: 75 to
When pump is relieved 94°C rpm 1,950 ± 100 1,950 ± 100
• Engine: High idle
• Power mode (P)
• Arm OUT relief

Travel of control lever


Machine model PC138USLC-10
Standard value Repair limit
Item Measurement condition Unit
for new machine
NEUTRAL
Boom control lever o RAISE/ 85 ± 9 85 ± 17
LOWER
NEUTRAL
Arm control lever 85 ± 9 85 ± 17
o IN/OUT
NEUTRAL
Bucket control lever o CURL/ 85 ± 9 85 ± 17
DUMP
NEUTRAL
Swing control lever o Swing
85 ± 9 85 ± 17
• At center of LEFT/
lever knob RIGHT
• Tip of pedal NEUTRAL
Blade control lever • Read value to o RAISE/ mm 48 ± 5 48 ± 10
end of travel. LOWER
• Engine: NEUTRAL
Stopped o
FOR-
Travel control lever WARD/ 115 ± 12 115 ± 23
REVERSE
(Right and
left)
Work
equipment/
3 to 5 5 to 0
Play of control lever Swing/
Blade
Travel 10 ± 3 10 ± 5

20-4 PC138USLC-10
20 Standard value tables
Standard value table for machine

Control effort of control lever


Machine model PC138USLC-10
Standard value Repair limit
Item Measurement condition Unit
for new machine
15.7 ± 4 Max. 24.5
Boom control lever
{1.6 ± 0.4} {Max. 2.53}
15.7 ± 4 Max. 24.5
Arm control lever • Engine: High idle
• Hydraulic oil temperature: 45 {1.6 ± 0.4} {Max. 2.53}
to 55°C 12.7 ± 3 Max. 21.6
Bucket control lever
• For control lever, measure by {1.3 ± 0.3} {Max. 2.2}
hooking push-pull scale to N 12.7 ± 3 Max. 21.6
Swing control lever center of grip
• For control pedal, measure {kg} {1.3 ± 0.3} {Max. 2.2}
by hooking push-pull scale to 29.4 ± 6 Max. 35.4
Blade control lever
pedal end {3.0 ± 0.63} {Max. 3.6}
• Read max. value through 24.5 ± 5.9 Max. 39.2
Travel control lever travel end.
{2.5 ± 0.6} {Max. 4.0}
74.5 ± 18.6 Max. 107.6
Travel pedal
{7.6 ± 1.9} {Max. 11}

PC138USLC-10 20-5
20 Standard value tables
Standard value table for machine

Oil pressure
Machine model PC138USLC-10
Standard value Repair limit
Item Measurement condition Unit
for new machine
• Hydraulic oil temperature: 45
to 55°C
• Engine high idle MPa
1.8 to 3.8 1.8 to 3.8
Unload pressure • Power mode (P) {kg/
• Hydraulic pump output {18 to 38} {18 to 38}
cm2}
pressure with all control
levers in NEUTRAL position
34.8 (+2.0 /
34.8 ± 1.0
Boom relief pressure -1.5)
{355 ± 10}
{355 (+20 / -15)}
34.8 (+2.0 /
34.8 ± 1.0
Arm relief pressure -1.5)
{355 ± 10}
• Hydraulic oil temperature: 45 {355 (+20 / -15)}
to 55°C 34.8 (+2.0 /
34.8 ± 1.0
Bucket relief pressure • Engine high idle -1.5)
• Power mode (P) {355 ± 10}
{355 (+20 / -15)}
• Hydraulic pump outlet
28.2 (+1.5 /
pressure with all 28.2 ± 1.5
Swing relief pressure -2.5)
measurement circuits {288 ± 15}
relieved {288 (+15 / -25)}
34.8 (+2.0 /
34.8 (± 1.0)
Blade RAISE relief pressure MPa -1.5)
355 (± 10)
{kg/ {355 (+20 / -15)}
cm2} 34.8 ± 1.0 34.8 (+2.0/-1.5)
Blade LOWER relief pressure Target {355 ± 10} {355 (+20 / -15)}
• Hydraulic oil temperature: 45 value 34.8 (+2.0 /
(Range) 34.8 ± 1.0
Travel relief pressure to 55°C -1.5)
• Engine high idle {355 ± 10}
{355 (+20 / -15)}
• Hydraulic pump outlet
Control circuit source pressure with all 3.2 ± 0.2 3.2 ± 0.5
pressure measurement circuits {33 ± 2} {33 ± 5}
relieved
• Oil temperature: All control 2.8 ± 1.0 -
45 to 55°C levers in
{28 ± 10} {-}
• Engine: High NEUTRAL
idle Running
LS differential pressure a LS differential track idle off
pressure = ground 2.2 ± 0.1 -
Pump outlet Travel lever {22.5 ± 1} {-}
pressure – LS operated
pressure halfway

20-6 PC138USLC-10
20 Standard value tables
Standard value table for machine

Swing
Machine model PC138USLC-10
Standard value Repair limit
Item Measurement condition Unit
for new machine
• For measuring posture, see
"Swing 1"
• Engine: High idle
• Hydraulic oil temperature: 45
to 55°C
Overswing • Overswing of swing circle deg. 100 ± 20 100 ± 30
after 1 swing
• Bucket: With rated load (450
kg)
• Value inside ( ): Overswing at
outside of swing circle
• For measuring 2.8 ± 0.3 Max. 3.5
posture, see 90 deg.
(3.4 ± 0.3) (Max. 4.0)
"Swing 1"
• Engine: High
idle
• Hydraulic oil
Time required to start temperature: 45
to 55°C sec.
swinging 4.0 ± 0.4 Max. 6.2
• Time required to 180 deg.
pass 90° and (4.9 ± 0.5) (Max. 6.4)
180 deg. points
after starting
swing
• Value in ( ): With
rated load
• For measuring posture, see
"Swing 1"
• Engine: High idle
Time required to finish
• Hydraulic oil temperature: 45 sec. 27.3 ± 3 27.3 ± 4
swinging
to 55°C
• Time required to complete 5
swing after 1 swing
• For measuring posture, see
"Swing 2"
• Engine: Stopped
• Hydraulic oil temperature: 45
to 55°C
• Bucket: With rated load (450
kg)
• Set machine on 15 deg. deg. 0 0
Swing drift on slope slope, and set upper
(mm) (0) (0)
structure at 45 deg. to uphill
side.
• Make matchmark between
swing circle outer race and
track frame
• Distance between
matchmarks made in 15
minutes
• Engine: High idle
• Hydraulic oil temperature: 45
Leakage from swing motor l/min Max. 3 Max. 6
to 55°C
• Relieve swing circuit

PC138USLC-10 20-7
20 Standard value tables
Standard value table for machine

Traveling
Machine model PC138USLC-10
Standard value Repair limit
Item Measurement condition Unit
for new machine
• For measuring Lo Max. 39.6 Max. 49
posture, see
"Travel 1"
• Engine: High
idle
• Hydraulic oil
temperature: 45
Travel speed (idle running) to 55°C sec.
• Time required to Hi Max. 22.3 Max. 27
complete 5
turns after 1
turn with track
of one side
raised off
ground
• For measuring Lo Max. 31.0 Max. 35
posture, see
"Travel 2"
• Engine: High
idle
Travel speed (actual running) • Hydraulic oil sec.
temperature: 45 Hi Max. 14.5 Max. 17
to 55°C
• Time required to
travel 20 m after
running up 10 m
• For measuring posture, see
"Travel 2" and "Travel 3"
• Engine: High idle
• Hydraulic oil temperature: 45
Travel deviation to 55°C mm Max. 200 Max. 220
• Travel deviation in travel of
20 m after running up 10 m
and more on level ground
• Firm and level ground
• For measuring posture, see
"Travel 4"
• Engine stopped
• Hydraulic oil temperature: 45
to 55°C
Machine drift on slope mm 0 0
• Place machine on slope of
12deg. with sprocket on
uphill side.
• Travel distance by machine
drift on slope for 5 minutes
• Engine: High idle
• Hydraulic oil temperature: 45
Leakage from travel motor to 55°C l/min Max. 1.1 Max. 1.7
• Lock shoes and relieve travel
circuit

20-8 PC138USLC-10
20 Standard value tables
Standard value table for machine

Work equipment
Machine model PC138USLC-10
Standard value Repair limit
Item Measurement condition Unit
for new machine
• Whole work • For measuring posture, see
equipment "Work equipment 1"
(Hydraulic drift of • Measure extension amount Max. 460 Max. 700
bucket tooth tip) and retraction amount of
• Boom cylinder each cylinder and hydraulic
(Retraction amount of drift of bucket tooth tip. Max. 10 Max. 12
cylinder) • Level and flat ground
• Arm cylinder • Bucket: With rated load (450
(Extension amount of kg)
Max. 80 Max. 90
• Lever in NEUTRAL
Hydraulic drift

cylinder)
• Engine stopped
• Hydraulic oil temperature: 45
mm
to 55°C
• Bucket cylinder • Measure immediately after
(Retraction amount of setting Max. 22 Max. 40
cylinder) • Measure hydraulic drift every
5 minutes and judge at 15
minutes
• Engine: Stopped
• Hydraulic oil temperature: 45
• Blade
to 55°C
(Hydraulic drift of Max. 31 Max. 47
• Measure hydraulic drift of
blade tip)
blade tip from max. raising
position for 15 minutes
• For measuring 3.8 ± 0.4 Max. 4.4
• Boom posture, see RAISE (To just before (To just before
Bucket tooth on "Work equipment cushion) cushion)
ground 2"
IO • Engine: High idle
Max. extension of • Hydraulic oil LOWER 3.1 ± 0.3 Max. 4.2
cylinder temperature: 45 to
55°C
• For measuring 3.2 ± 0.3 Max. 4.0
• Arm posture, see IN (To just before (To just before
Max. extension of "Work equipment cushion) cushion)
3"
Work equipment speed

cylinder
• Engine: High idle 2.7 ± 0.3 Max. 3.7
IO • Hydraulic oil
Max. retraction OUT (To just before (To just before
temperature: 45 to cushion) cushion)
55°C sec.
• For measuring CURL 2.9 ± 0.3 Max. 3.7
• Bucket posture, see
Max. extension of "Work equipment
cylinder 4"
• Engine: High idle DUMP 2.3 ± 0.2 Max. 2.9
IO • Hydraulic oil
Max. retraction temperature: 45 to
55°C
• For measuring RAISE 1.2 ± 0.3 Max. 2.5
• Blade posture, see
Max. extension of "Work equipment
cylinder 5"
• Engine: High idle LOWER Max. 2.5
IO 1.3 ± 0.3
• Hydraulic oil
Blade on ground
temperature: 45 to
55°C

PC138USLC-10 20-9
20 Standard value tables
Standard value table for machine

Machine model PC138USLC-10


Standard value Repair limit
Item Measurement condition Unit
for new machine
• For measuring posture, see
"Work equipment 6"
• Engine low idle
• Hydraulic oil temperature: 45
to 55°C
Boom • With arm and bucket Max. 3 Max. 3
cylinders retracted fully, lower
boom from max. raising
position and measure time
taken to raise the machine
after bucket reaches ground
• For measuring posture, see
"Work equipment 7"
• Engine low idle
• Hydraulic oil temperature: 45
to 55°C
Arm • With arm top side horizontal Max. 2 Max. 2
and bucket cylinder retracted
fully, move arm IN and
measure time to start it again
Time lag

after it stops on lower side


sec.
• For measuring posture, see
"Work equipment 8"
• Engine low idle
• Hydraulic oil temperature: 45
to 55°C
Bucket • With boom top side Max. 2 Max. 2
horizontal and arm cylinder
retracted fully, CURL bucket
and measure time to start it
again after it stops on lower
side
• For measuring posture, see
"Work equipment 9"
• Engine low idle
• Hydraulic oil temperature: 45
to 55°C
Blade • Lower blade from max. Max. 2 Max. 2
raising position and measure
time taken to raise the
machine after blade reaches
ground
Each cylinder Max. 3.3 Max. 15
Internal leakage

• Engine: High idle


• Hydraulic oil temperature: 45
to 55°C cc/min
Center swivel joint Max. 9 Max. 50
• Relieve circuit to be
measured

20-10 PC138USLC-10
20 Standard value tables
Standard value table for machine

Pump performance
Machine model PC138USLC-10
Discharge Discharge
Item Measurement condition Unit Standard Repair limit
value
• Pump speed (rpm): 2,050 rpm
• PC-EPC current value (mA): 350 mA
• Test pump discharge pressure (MPa {kg/
cm2})
PA1 Q Q
Performance of
• Discharge pressure of other pump (MPa l/min
hydraulic pump (See graph) (See graph)
{kg/cm2})
PA2
• Average discharge pressure (MPa {kg/
cm2})
: Pp=(PA1+PA2)÷2

a Bring pump discharge pressure PA1 and PA2 as close as possible to the average pressure when
measuring.
Avoid measuring the near turning point of the graph because the error increases there.
a When measuring with the pump mounted on the machine, if it is impossible to set the engine speed to the
specified speed by using the fuel control dial, take the pump discharge and the engine speed at the time of
measurement, and use them as a base for calculating the pump discharge at the specified speed.
a Pump discharge Q in the graph indicates the discharge from one pump.

PC138USLC-10 20-11
20 Standard value tables
Standard value table for machine

Machine posture and procedure for measuring performance (PC138_10-0000-321-K-00-A)

Control valve: Spool travel

Swing 1: Overswing, time required to start swinging, time required to finish swinging

Swing 2: Swing drift on slope

20-12 PC138USLC-10
20 Standard value tables
Standard value table for machine

Travel 1: Travel speed (idle running)

Travel 2: Travel speed (actual run), Travel deviation

Travel 3: Travel deviation

Travel 4: Machine drift on a slope

PC138USLC-10 20-13
20 Standard value tables
Standard value table for machine

Work equipment 1: Hydraulic drift of the work equipment

Work equipment 2: Boom speed

Work equipment 3: Arm speed

Work equipment 4: Bucket speed

20-14 PC138USLC-10
20 Standard value tables
Standard value table for machine

Work equipment 5: Blade speed

Work equipment 6: Boom time lag

Work equipment 7: Arm time lag

Work equipment 8: Bucket time lag

PC138USLC-10 20-15
20 Standard value tables
Standard value table for machine

Work equipment 9: Blade time lag

20-16 PC138USLC-10
20 Standard value tables
Standard value table for electrical system

Standard value table for electrical system (D155-E000-001-P-00-A)

Controller (PC138-RA1E-033-K-00-A)
Equipment name Procedure, measuring location, criteria and remarks
a Check ground terminal T12 for looseness and rust.
1. Turn starting switch to OFF position.
2. Turn battery disconnect switch to OFF position.
Continuous 3. Disconnect connector CE03, and connect T-adapter to female side.
Engine power 4. Turn battery disconnect switch to ON position.
controller supply 5. Turn starting switch to ON position.
voltage
a If any trouble is found, perform troubleshooting for failure code [CA441].
Between CE03 (female) (1) and (21) 20 to 30 V
Voltage
Between CE03 (female) (11) and (31) 20 to 30 V
a Check ground terminal T04 for looseness and rust.
1. Turn starting switch to OFF position.
Continuous 2. Turn battery disconnect switch to OFF position.
power 3. Disconnect connector CP01 and connect T-adapter to female side.
supply 4. Turn battery disconnect switch to ON position.
voltage 5. Turn starting switch to ON position.
Between CP01 (female) (1) and (2) 20 to 30 V
Voltage
HST Between CP01 (female) (4) and (5) 20 to 30 V
controller 1. Turn starting switch to OFF position.
2. Turn battery disconnect switch to OFF position.
Solenoid 3. Disconnect connector CP02 and connect T-adapter to female side.
power 4. Turn battery disconnect switch to ON position.
supply 5. Turn starting switch to ON position.
voltage Between CP02 (female) (116) and ground 20 to 30 V
Voltage Between CP02 (female) (118) and ground 20 to 30 V
Between CP02 (female) (121) and ground 20 to 30 V
1. Turn starting switch to OFF position.
2. Turn battery disconnect switch to OFF position.
Continuous 3. Insert T-adapter into connector CM01.
Machine power 4. Turn battery disconnect switch to ON position.
monitor supply 5. Turn starting switch to ON position (to connect ACC).
voltage Between CM01 (1) and (3) 20 to 30 V
Voltage Between CM01 (2) and (4) 20 to 30 V
Between CM01 (10) and (4) (ACC line) 20 to 30 V

PC138USLC-10 20-17
20 Standard value tables
Standard value table for electrical system

Engine control (D37-AG10-033-K-00-A)

Equipment name Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Disconnect connector EGR V , and connect T-adapter to male side.
EGR valve solenoid Between EGR V (male) (6) and (7) 1 to 5 z
Resistance Between EGR V (male) (7) and (8) 1 to 5 z
Between EGR V (male) (8) and (6) 1 to 5 z
1. Turn starting switch to OFF position.
VFT solenoid 2. Disconnect connector VFT and connect T-adapter to male side.
(In the monitor display Between VFT (male) (6) and (7) 8 to 15 z
KVGT) Resistance Between VFT (male) (7) and (8) 8 to 15 z
Between VFT (male) (8) and (6) 8 to 15 z
1. Turn starting switch to OFF position.
2. Disconnect connector TWTR, and connect socket to male side.
a Regard coolant temperature sensor as normal if its resistance is 700 z to 37
kz when coolant temperature is min. 0°C.
Coolant temperature
sensor 0°C 30 to 37 kz
Between TWTR (male) (A) and
(B) 25°C 9.3 to 10.7 kz
Resistance 50°C 3.2 to 3.8 kz
a Coolant temperature- 80°C 1.0 to 1.3 kz
Resistance characteristics
95°C 700 to 800 z
1. Turn starting switch to OFF position.
2. Disconnect connector TMAP, and connect socket to male side.
a Regard charge temperature sensor as normal if its resistance is 80 z to 48
kz.
-40°C 41 to 48 kz
Charge temperature
sensor -20°C 14 to 16 kz
Between TMAP (male) (3) and
(4) 0°C 5.4 to 6.1 kz
Resistance 30°C 1.6 to 1.8 kz
a Charge temperature- 60°C 560 to 600 z
Resistance characteristics
90°C 230 to 250 z
130°C 80 to 90 z
1. Turn starting switch to OFF position.
2. Disconnect connector P55 and connect T-adapter to male side.
-30°C 25 to 28 kz
Intake air temperature 0°C 5.5 to 6.1 kz
Between P55 (male) (3) and (4)
sensor 25°C 1.9 to 2.1 kz
Resistance a Intake air temperature-
40°C 1.1 to 1.2 kz
Resistance characteristics
180 to 185 z
100°C

20-18 PC138USLC-10
20 Standard value tables
Standard value table for electrical system

Equipment name Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
Charge (Boost) pressure 2. Insert T-adapter into connector J1.
sensor 3. Turn starting switch to ON position.
Voltage Between J1 (15) and (59) Sensor output 0.3 to 4.7 V
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector J1.
Ambient pressure sensor 3. Turn starting switch to ON position.
Between J1 (16) and (59) or
Voltage Sensor output 0.3 to 4.7 V
between PAMB (3) and (2)
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector PFUEL or J2
Common rail pressure 3. Turn starting switch to ON position.
sensor
Between PFUEL (2) and (3) or
Voltage Sensor output 0.2 to 4.6 V
between J2 (21) and (44)
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector J1 or CCV.
Crankcase pressure 3. Turn starting switch to ON position.
sensor
Between J1 (3) and (59) or
Voltage Sensor output 0.3 to 4.7 V
between CCV (3) and (2)
1. Turn starting switch to OFF position.
2. Disconnect connector FP, and connect T-adapter to male side.
Throttle sensor (fuel dial) Between FP (male) (A) and (C) 4.0 to 6.0 kz
Resistance Between FP (male) (B) and (C) 3 to 7 kz
Between FP (male) (A) and (B) 3 to 7 kz
1. Turn starting switch to OFF position.
Engine oil pressure switch 2. Disconnect connector POIL , and connect T-adapter to male side.
Resistance Between POIL (male) (1) and ground Max. 1 z

PC138USLC-10 20-19
20 Standard value tables
Standard value table for electrical system

Machine control (PC138-E000-033-P-00-A)


Equipment name Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
Travel speed selector 2. Disconnect connector V02, and connect T-adapter to male side.
solenoid Between V02 (male) (1) and (2) 20 to 60 z
Resistance
Between V02 (male) (1) and ground Min. 1 Mz
1. Turn starting switch to OFF position.
Swing holding brake 2. Disconnect connector V03, and connect T-adapter to male side.
solenoid Between V03 (male) (1) and (2) 20 to 60 z
Resistance
Between V03 (male) (1) and ground Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector V04, and connect T-adapter to male side.
Travel junction solenoid
Between V04 (male) (1) and (2) 20 to 60 z
Resistance
Between V04 (male) (1) and ground Min. 1 Mz
1. Turn starting switch to OFF position.
Attachment return 2. Disconnect connector V06, and connect T-adapter to male side.
selector solenoid Between V06 (male) (1) and (2) 20 to 60 z
Resistance
Between V06 (male) (1) and ground Min. 1 Mz
1. Turn starting switch to OFF position.
Merge-divider (main) 2. Disconnect connector V05, and connect T-adapter to male side.
solenoid Between V05 (male) (1) and (2) 3 to 14 z
Resistance
Between V05 (male) (1) and ground Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector V11, and connect T-adapter to male side.
PC-EPC solenoid
Between V11 (male) (1) and (2) 3 to 14 z
Resistance
Between V11 (male) (1) and ground Min. 1 Mz
1. Turn starting switch to OFF position.
Attachment oil flow 2. Disconnect connector V30, and connect T-adapter to male side.
adjustment EPC solenoid Between V30 (male) (1) and (2) 3 to 14 z
Resistance
Between V30 (male) (1) and ground Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector P22 and connect T-adapter to male side.
Hydraulic oil temperature Between P22 (male) (1) and (2) 10°C Approx. 90 kz
sensor 30°C Approx. 35 kz
Resistance a Temperature of oil
temperature sensor – 80°C Approx. 6.5 kz
Resistance characteristics 100°C Approx. 3.5 kz
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector P25.
Pump pressure sensor
3. Turn starting switch to ON position.
Voltage Between P25 (2) and (1) Sensor output 0.5 to 4.5 V
1. Turn starting switch to OFF position.
Travel Fwd LH PPC 2. Insert T-adapter into connector P10.
Pressure sensor 3. Turn starting switch to ON position.
Voltage Between P10 (2) and (1) Sensor output 0.5 to 4.5 V
1. Turn starting switch to OFF position.
Travel Fwd RH PPC 2. Insert T-adapter into connector P09.
Pressure sensor 3. Turn starting switch to ON position.
Voltage Between P09 (2) and (1) Sensor output 0.5 to 4.5 V
1. Turn starting switch to OFF position.
Travel Rev LH PPC 2. Insert T-adapter into connector P27.
Pressure sensor 3. Turn starting switch to ON position.
Voltage Between P27 (2) and (1) Sensor output 0.5 to 4.5 V

20-20 PC138USLC-10
20 Standard value tables
Standard value table for electrical system

Equipment name Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
Travel Rev RH PPC 2. Connect T-adapter to connector P26.
Pressure sensor 3. Turn starting switch to ON position.
Voltage Between P26 (2) and (1) Sensor output 0.5 to 4.5 V
1. Turn starting switch to OFF position.
Blade RAISE PPC 2. Insert T-adapter into connector P28
pressure sensor 3. Turn starting switch to ON position.
Voltage Between P28 (2) and (1) Sensor output 0.5 to 4.5 V
1. Turn starting switch to OFF position.
Blade Lower PPC 2. Insert T-adapter into connector P11.
pressure sensor 3. Turn starting switch to ON position.
Voltage Between P11 (2) and (1) Sensor output 0.5 to 4.5 V

PC138USLC-10 20-21
20 Standard value tables
Standard value table for electrical system

Machine monitor (PC138-Q170-033-K-00-A)


Equipment name Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
Defective power 2. Insert T-adapter into connector E12.
generation of alternator 3. Start engine.
(when system is normal) Engine speed:
Voltage Between E12 (1) and ground Medium or 27.5 to 29.5 V
above
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector CM01.
3. Disconnect heater relay terminal R16A.
Preheating a To prevent current from flowing through heater when starting switch is
turned to HEAT position
4. Turn starting switch to HEAT position.
Voltage Between CM01 (12) and (3) 20 to 30 V
1. Turn starting switch to OFF position.
2. Disconnect connector P21 and connect T-adapter to male side.
Between P21 (male) (1) and FULL Approx. 12 z
Fuel level sensor
ground
Resistance Approx. 85 to
a Fuel level sensor EMPTY
110 z
characteristics

20-22 PC138USLC-10
SHOP MANUAL

HYDRAULIC EXCAVATOR
PC138USLC-10
Model Serial Number

PC138USLC- 40001 and up


10

30 Testing and adjusting


5 30 Testing and adjusting

PC138USLC-10 30-1
30 Testing and adjusting
Table of contents

Table of contents (ALL-0310-002-A-00-A)


30 Testing and adjusting .................................................................................................................... 30-1
Table of contents ........................................................................................................................ 30-2
General information on testing and adjusting................................................................................. 30-3
Tools for testing and adjusting ............................................................................................... 30-3
Sketch of tools for testing and adjusting ................................................................................. 30-6
Engine and cooling system .......................................................................................................... 30-8
Testing engine speed ........................................................................................................... 30-8
Testing exhaust gas color ..................................................................................................... 30-9
Testing and adjusting valve clearance .................................................................................. 30-10
Testing compression pressure............................................................................................. 30-12
Testing blowby pressure ..................................................................................................... 30-15
Testing engine oil pressure ................................................................................................. 30-16
Testing fuel pressure .......................................................................................................... 30-17
Testing fuel return rate and leakage ..................................................................................... 30-18
Bleeding air from fuel system .............................................................................................. 30-21
Testing fuel circuit for leakage ............................................................................................. 30-23
Handling cylinder cutout mode operation.............................................................................. 30-24
Handling no-injection cranking operation.............................................................................. 30-25
Checking and adjusting air conditioner compressor belt tension ............................................. 30-26
Replacing fan belt .............................................................................................................. 30-27
Writing compensation values at replacement of injector and engine controller ......................... 30-28
Power train............................................................................................................................... 30-32
Testing swing circle bearing clearance ................................................................................. 30-32
Undercarriage and frame........................................................................................................... 30-33
Testing and adjusting track shoe tension .............................................................................. 30-33
Hydraulic system ...................................................................................................................... 30-34
Releasing remaining pressure from hydraulic circuit .............................................................. 30-34
Testing and adjusting oil pressure in work equipment, swing, and travel circuits....................... 30-35
Testing oil pressure of control circuit .................................................................................... 30-38
Testing and adjusting oil pressure in pump PC control circuit.................................................. 30-39
Testing and adjusting oil pressure in pump LS control circuit .................................................. 30-42
Testing outlet pressure of solenoid valve .............................................................................. 30-47
Testing PPC valve output pressure ...................................................................................... 30-48
Adjusting play of work equipment and swing PPC valves....................................................... 30-50
Isolating the parts causing hydraulic drift in work equipment................................................... 30-51
Testing and adjusting travel deviation................................................................................... 30-52
Testing oil leakage ............................................................................................................. 30-54
Bleeding air from hydraulic circuit ........................................................................................ 30-56
Cab and its attachments ............................................................................................................ 30-59
Checking cab tipping stopper .............................................................................................. 30-59
Testing, cleaning and lubricating slide door rail and roller ....................................................... 30-60
Adjusting mirrors ................................................................................................................ 30-61
Electrical system ...................................................................................................................... 30-63
Special functions of machine monitor ................................................................................... 30-63
Adjusting rearview camera angle ....................................................................................... 30-115
Handling voltage circuit of engine controller........................................................................ 30-117
Handling battery disconnect switch .................................................................................... 30-118
Testing diodes ................................................................................................................. 30-119
Pm clinic ................................................................................................................................ 30-120
Pm Clinic service ............................................................................................................. 30-120

30-2 PC138USLC-10
30 Testing and adjusting
General information on testing and adjusting

General information on testing and adjusting (ALL-3831-001-A-00-A)

Tools for testing and adjusting (PC138-5320-304-A-00-A)

Testing/Adjusting item Sym-

Q'ty
Part No. Part name Remarks
bol
1 799-201-9002 Handy smoke checker 1
Testing exhaust gas
A Commercially Bosch index: 0 to 9
color 2 Smoke meter 1
available
Adjusting valve Commercially Feeler gauge
B 1
clearance available
1 795-502-1590 Compression gauge 1 0 to 7 MPa {0 to 70 kg/cm2}
2 795-502-1800 Adapter 1 For 95LE-6 engine
Testing compression 3 6275-11-3880 Gasket 1
pressure C
4 6275-11-3890 O-ring 2
Commercially Inside diameter of hose: Approx.
5 Hose 1
available 15 mm
1 799-201-1504 Blowby checker 1 0 to 5 kPa {0 to 500 mmH2O}
Testing blowby
pressure D 2 799T-201-3210 Plug 1 Hose inside diameter: 24 mm
3 799T-201-3220 Cap 2 Pipe outside diameter: 25.4 mm
Pressure gauge: 2.5, 6, 40, 60
799-101-5002 Hydraulic tester 1 MPa
1 {25, 60, 400, 600 kg/cm2}
Pressure gauge: 60 MPa {600
Testing engine oil 790-261-1204 Digital hydraulic tester 1 kg/cm2}
pressure E
2 Pressure gauge: 1.0 MPa {10 kg/
799-401-2320 Gauge 1 cm2}
6732-81-3170 Adapter 1
3
07002-11023 O-ring 1
Pressure gauge: 2.5, 6, 40, 60
799-101-5002 Hydraulic tester 1 MPa
{25, 60, 400, 600 kg/cm2}
1 799-101-5160 • Nipple 1 R1/8
799-101-5150 • Hose 1
Testing fuel pressure F Pressure gauge: 60 MPa {600
790-261-1204 Digital hydraulic tester 1 kg/cm2}
795-471-1450 Adapter 1
2
07005-00812 Seal washer 1
Pressure gauge: 1.0 MPa {10 kg/
3 799-401-2320 Gauge 1 cm2}
1 6151-51-8490 Spacer 1
2 6206-71-1770 Joint 1
3 07005-01012 Seal washer 1
Commercially
4 Hose 1 Inside diameter: approx. 6.5 mm
Testing fuel return available
rate and leakage G Commercially
5 Hose 1 Inside diameter: approx. 12 mm
available
Commercially Measuring cylinder
6 1
available
Commercially Stopwatch
7 1
available
Replacing fan belt U 796-401-1300 Fixing jig 1

PC138USLC-10 30-3
30 Testing and adjusting
General information on testing and adjusting

Testing/Adjusting item Sym-

Q'ty
Part No. Part name Remarks
bol
Commercially Lap top type personal Windows XP SP2/VISTA/
1 computer 1
available Windows7
Writing compensation 2 Cu 3886388 INSITE ver. 7.4 –
values at 795-799-5730 INSITE 5 kit –
replacement of X Commercially • Cable (USB) 1
injector and engine 3 available or
controller • Cable (RS232) 1
795-799-5740
795-799-5720 • Cable 1
4 799-601-4510 Cable (12P) 1
Testing swing circle Commercially
H Dial gauge 1
bearing clearance available
Developer for dye
Testing fuel circuit for Commercially penetrant (color
leakage Y 1
available checker)
Pressure gauge: 2.5, 6, 40, 60
799-101-5002 Hydraulic tester 1 MPa
Testing and adjusting 1 {25, 60, 400, 600 kg/cm2}
oil pressure in work
J Pressure gauge: 60 MPa {600
equipment, swing, 790-261-1204 Digital hydraulic tester 1 kg/cm2}
and travel circuits
799-101-5220 Nipple 1 Size: 10 x 1.25 mm
2
07002-11023 O-ring 1
Pressure gauge: 2.5, 6, 40, 60
799-101-5002 Hydraulic tester 1 MPa
Testing oil pressure of 1 {25, 60, 400, 600 kg/cm2}
K
control circuit Pressure gauge: 60 MPa {600
790-261-1204 Digital hydraulic tester 1 kg/cm2}
2 799-401-3100 Adapter 1 Size 02
Pressure gauge: 2.5, 6, 40, 60
799-101-5002 Hydraulic tester 1 MPa
Testing and adjusting 1 {25, 60, 400, 600 kg/cm2}
oil pressure in pump L Pressure gauge: 60 MPa {600
790-261-1204 Digital hydraulic tester 1 kg/cm2}
PC control circuit
799-101-5220 Nipple 4 Size: 10 x 1.25 mm
2
07002-11023 O-ring 4
Pressure gauge: 2.5, 6, 40, 60
799-101-5002 Hydraulic tester 1 MPa
1 {25, 60, 400, 600 kg/cm2}
Pressure gauge: 60 MPa {600
790-261-1204 Digital hydraulic tester 1 kg/cm2}
Differential pressure
2 799-401-2701 gauge 1 50 MPa {500 kg/cm2}
799-101-5220 Nipple 4 Size: 10 x 1.25 mm
3
07002-11023 O-ring 4
Testing and adjusting Pressure range: 50 MPa {500 Kg/
oil pressure in pump M 796T-440-1101 Sensor adapter 1 cm2}
LS control
796-440-1150 • Wiring harness 1
796T-440-1160 • Nipple 1
4 799-401-2350 • Washer 1
790-261-1130 • Coupling 1
07002-61823 • O-ring 1
Pressure range: 50 MPa {500 Kg/
7861-93-1812 • Pressure sensor 1 cm2}
Pressure range: 5 MPa {50 Kg/
5 796T-440-1200 Sensor adapter 1 cm2}

30-4 PC138USLC-10
30 Testing and adjusting
General information on testing and adjusting

Testing/Adjusting item Sym-

Q'ty
Part No. Part name Remarks
bol
Pressure gauge: 2.5, 6, 40, 60
799-101-5002 Hydraulic tester 1 MPa
Testing output 1 {25, 60, 400, 600 kg/cm2}
pressure of solenoid N Pressure gauge: 60 MPa {600
valve 790-261-1204 Digital hydraulic tester 1 kg/cm2}
799-401-3100 Adapter 1 Size: 02
2
02896-11008 O-ring 1
Pressure gauge: 2.5, 6, 40, 60
799-101-5002 Hydraulic tester 1 MPa
Testing PPC valve 1 {25, 60, 400, 600 kg/cm2}
output pressure P
Pressure gauge: 60 MPa {600
790-261-1204 Digital hydraulic tester 1 kg/cm2}
2 799-401-3100 Adapter 1 Size 02
Testing oil leakage Commercially Measuring cylinder
T 1
available
Testing coolant
temperature and oil – 799-101-1502 Digital thermometer 1 -99.9 to 1,299°C
temperature
Testing operating – 79A-264-0021 Push-pull scale 1 0 to 294 N {0 to 30 kg}
effort and depressing
effort
– 79A-264-0091 Push-pull scale 1 0 to 490 N {0 to 50 kg}
Testing stroke and Commercially
– Ruler 1
hydraulic drift available
Testing work Commercially Stopwatch
– 1
equipment speed available
Testing voltage and – Commercially
Multimeter 1
resistance available
Removal and
installation of engine 19 mm deep socket
– 795T-981-1010 Socket 1
coolant temperature (MITOLOY 4ML-19 or equivalent)
sensor

PC138USLC-10 30-5
30 Testing and adjusting
General information on testing and adjusting

Sketch of tools for testing and adjusting (PC138-3531-061-A-00-A)

Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.
M4: Sensor adapter

M4: Nipple

30-6 PC138USLC-10
30 Testing and adjusting
General information on testing and adjusting

Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.
M5: Sensor adapter

-: Socket

PC138USLC-10 30-7
30 Testing and adjusting
Engine and cooling system

Engine and cooling system (ALL-R401-001-K-00-A)

Testing engine speed (PC138-A000-360-K-00-A)

a Check the engine speed with the monitoring 4) Operate the L.H. work equipment control
function of the machine monitor. lever to relieve the arm circuit at the OUT
stroke end, and measure the engine speed.
a Measure the engine speed under the following
5. Measuring the engine speed when auto-
conditions.
deceleration is activated
• Coolant temperature: 75 to 94°C
1) Start the engine, set the fuel control dial to
• Hydraulic oil temperature: 45 to 55°C
high idle (MAX) position, and turn the auto-
Testing (PC138-A000-388-K-00-A) deceleration function ON.
2) Set all the levers and pedals for work
1. Preparation
equipment control, swing control, and travel
Operate the machine monitor so that it can
in neutral and test the engine speed when
monitor the engine speed.
the auto-decelerator operates.
a For the machine monitor operating method,
a The engine speed automatically lowers to a
see the section of "Special functions of
certain level approximately 5 seconds after
machine monitor".
all the levers and pedals are set to
a Monitoring code: 01002 “Engine speed“ NEUTRAL position. This level is the auto-
deceleration speed.

2. Testing low idle speed


1) Start the engine, and set the fuel control dial
to low idle (MIN) position.
2) Set all the levers and pedals for work
equipment control, swing control, and travel
in neutral, and test the engine speed.
3. Testing high idle speed
1) Start the engine, and set the fuel control dial
to high idle (MAX) position.
2) Set the working mode in Power Mode (P)
and set the auto-deceleration to OFF.
3) Set the swing lock switch to ON position.
4) Set all the levers and pedals for work
equipment control, swing control, and travel
in neutral, and test the engine speed.
4. Measuring engine speed at pump relief
1) Start the engine, and operate the arm to the
stroke end where the arm cylinder is fully
extended.
2) Set the swing lock switch to OFF position.
3) Set the fuel control dial to high idle (MAX)
position, and set the working mode to Power
mode (P).

30-8 PC138USLC-10
30 Testing and adjusting
Engine and cooling system

Testing exhaust gas color (PC138-A900-360-K-01-A)

a Testing tools
Sym-
Part No. Part name
bol
1 799-210-9001 Handy smoke checker
A Commercially
2 Smoke meter
available

k Place the machine on a level ground and


lower the work equipment to the ground.

k Be careful not to touch any hot part when


installing or removing the testing tools.

a Measure the exhaust gas color under the 2) Connect the probe hose, accelerator switch
following conditions. outlet and air hose to smoke meter A2.
• Coolant temperature: 75 to 94°C a The supplied air pressure must be 1.5
MPa {15 kg/cm2} or below.
a If an air source and a electric power source are
3) Connect the power cable to an AC 100 V
not available in the field, use handy smoke
receptacle.
checker A1. When recording official data, etc.,
use smoke meter A2. a Before connecting the power cable, make
Testing (PC138-A900-385-K-00-A)
sure that the power switch of the smoke
meter is turned OFF.
1. Checking with handy smoke checker A1 4) Loosen the cap nut of the suction pump and
1) Fit a sheet of filter paper to handy smoke place the filter paper.
checker A1.
a Place the filter paper securely so that the
2) Insert the exhaust gas intake pipe into
exhaust gas does not leak.
exhaust pipe (1).
5) Turn the power switch of smoke meter A2
3) Start the engine, accelerate it quickly and run
ON.
it at high idle, and operate the handle of
handy smoke checker A1 to absorb the
exhaust gas into the filter paper.
a Suction time: 1.4 ± 0.2 second

6) Start the engine, accelerate it quickly or run it


at high idle, and depress the accelerator
pedal of the smoke meter A2 to collect
exhaust gas on the filter paper.
4) Remove the filter paper and compare it with 7) Place the contaminated filter paper on the
the attached scale for judgment. clean filter paper (at least 10 sheets) in the
5) After finishing the test, remove the testing filter paper holder and read the indicated
tools, and restore the machine. value.
2. Testing with smoke meter A2 8) After finishing the test, remove the testing
1) Insert probe [1] of smoke meter A2 into the tools, and restore the machine.
outlet of exhaust pipe (1), and fix it to the
exhaust pipe with clip.

PC138USLC-10 30-9
30 Testing and adjusting
Engine and cooling system

Testing and adjusting valve clearance (PC138-A700-360-K-00-A)

a Tools for testing and adjusting


Sym-
Part No. Part name
bol
Commercially Feeler gauge
B
available

k Place the machine on a level ground and


lower the work equipment to the ground.

a Adjust the valve clearance under the following


conditions.
• Coolant temperature: Normal temperature
Testing (PC138-A700-361-K-00-A) 8. Rotate crankshaft pulley (15) forward and match
1. Remove engine hood (1), stay (2), and cover (3). compression top dead center mark (a) to large
slit (b) of ring (16).

2. Remove blowby hose (4), bracket (5), clamp (6),


and aftercooler hose (7). a At the compression top dead center, the
rocker arm of No.1 cylinder can be moved by
hand by the distance equivalent to the valve
clearance. If you cannot move the rocker arm
with your hand, the No.1 piston is not at its
compression top dead center. In that case,
rotate the crankshaft one more turn.
9. Check the valve clearances marked with q in
the valve arrangement drawing.

3. Remove connector (9) of crankcase pressure


sensor (8).
4. Remove sensor mounting bolt (10) to remove
crankcase pressure sensor (8).
5. Loosen clamp (11) to remove breather hose
(12).
6. Remove breather (13) from cylinder head cover
(14).
7. Remove cylinder head covers (14).
10.Insert feeler gauge B into the clearance between
rocker arm (19) and valve stem (20) to check the
valve clearance.

30-10 PC138USLC-10
30 Testing and adjusting
Engine and cooling system

Adjusting (PC138-A700-27D-K-00-A)

After testing, adjust the valve clearance according


to the following procedure, if necessary.
1. While fixing adjustment screw (17), loosen lock
nut (18).
2. Insert feeler gauge B in the clearance between
rocker arm (19) and valve stem (20), and adjust
the valve clearance with adjustment screw (17).
a With feeler gauge B inserted, turn the
adjustment screw (17) until feeler gauge B
can move lightly.
3. With adjustment screw (17) fixed, tighten lock
nut (18).
3 Lock nut (18):
39.2 to 49 Nm {4 to 5 kgm}
a After tightening lock nut (18), check the valve
clearance again.

4. After finishing the adjustment, remove the


adjusting tools, and restore the machine.
3 Cylinder head cover mounting nut:
8.82 ± 0.98 Nm {0.9 ± 0.1 kgm}

PC138USLC-10 30-11
30 Testing and adjusting
Engine and cooling system

Testing compression pressure (PC138-A000-360-K-01-A)

a Testing tools
Sym-
Part No. Part name
bol
1 795-502-1590 Compression gauge
2 795-502-1800 Adapter
3 6275-11-3880 Gasket
C
4 6275-11-3890 O-ring
Commercially Hose, inside diameter:
5 approximately 15 mm
available

k Place the machine on a level ground and


lower the work equipment to the ground.
4. Remove harness clamps (8, 9, 10, and 11).
k Turn the battery connect switch to OFF
position, and remove the key.

k When testing the compression pressure, be


careful not to burn yourself by touching the
exhaust manifold or KDPF, or get caught in a
rotating part.

a Measure the compression pressure under the


following conditions.
• Engine oil temperature: 40 to 60°C
Testing (PC138-A000-36B-K-00-A)

1. Remove the cylinder head cover and set the 5. Remove clamps (13 and 14) of high-pressure
piston in the target cylinder of testing to the pipe (12) and fuel spray prevention cap (15), and
compression top dead center. For details, see then remove high-pressure pipe.
"Testing and adjusting valve clearance".
a Confirm the compression top dead center of
the cylinder by checking that you can move
both of the intake rocker arm exhaust rocker
arm by the distance equivalent to the valve
clearance.
2. Remove EGR stay (1) EGR valve connector (2),
heater terminal (3), and injector connector (for
No. 3 and 4).

6. Drain the fuel and its level lowers to 1/4 (about


50 l: F5 of the fuel level gauge).
a It is because it may flow back from the return
circuit when the engine is cranked.

3. Remove clamps (5, 6, and 7) of the air


conditioner connector and move the wiring
harness.

30-12 PC138USLC-10
30 Testing and adjusting
Engine and cooling system

11.Install hose C5 to the disconnected part of the


7. Loosen injector terminal nuts (18), and remove
tube on the common rail side to drain the
the terminals from injector (17).
injected fuel into a container.
a Insulate the terminals with tape etc. so that 12.Return the engine parts disconnected for testing
they do not touch each other. the compression pressure to their original
Remove the holder to remove injector (17). positions to enable cranking.
13.Set the machine monitor to “No Injection“.
a Turn the battery disconnect switch to ON
position, then turn the starting switch to ON
position.
a For the method to set to “No Injection“, see
"Special functions of machine monitor".

k If the engine is not set to the "No-Injection


cranking", it may start during
measurement and cause personal injury.
Accordingly, be sure to set the engine in
this mode.
8. Install gasket G3 to the tip of adapter C2 and
insert them into the mounting portion of injector
(17).
9. Fix adapter C2 with injector mounting holders
(19).
3 Mounting bolt:
39 to 49 Nm {4.0 to 5.0 kgm}
a Tighten the mounting bolt while the fulcrum of
the holder is seated perfectly.

k Do not reuse the holder mounting bolt.

14.Crank the engine by using the starting motor


and measure the compression pressure.
a Read the compression pressure when the
gauge pointer stands still.
15.After finishing the test, remove the testing tools,
and restore the machine.
a Install injector (17) and spill hose connector
according to the following procedure.
1) Fit O-ring (C4) and gasket (C3) to injector
(17).
a Do not fit O-ring (C4) to groove "a".
10.Connect compression gauge C1 to adapter C2.

PC138USLC-10 30-13
30 Testing and adjusting
Engine and cooling system

a Install gasket (C3) so that it does not fall


from the end of injector (17) due to its
own weight.
Apply grease, if necessary.

2) When inserting injector (17) into the head,


apply engine oil to the O-ring and insertion
hole on the head.
3) Be sure to use a new injector holder bolt.
a Do not reuse the injector holder bolt since
the engine oil may enter into the fuel
return circuit.

30-14 PC138USLC-10
30 Testing and adjusting
Engine and cooling system

Testing blowby pressure (PC138-A000-360-K-02-A)

a Testing tools
Sym-
Part No. Part name
bol
1 799-201-1504 Blowby checker
D 2 799T-201-3210 Plug
3 799T-201-3220 Cap

k Place the machine on a level ground and


lower the work equipment to the ground.

a Measure the blowby pressure under the


following conditions.
• Coolant temperature: 75 to 94°C 6. After finishing the test, remove the testing tools
• Hydraulic oil temperature: 45 to 55°C and restore the machine.
Testing (PC138-A000-36C-K-00-A)

1. Open the engine hood.


2. Disconnect KCCV gas outlet hose (1), block the
hose by using plug D2, and block KCCV hose
insertion pipe by using cap D3.
3. Disconnect KCCV gas inlet hose (2), block
KCCV hose insertion pipe by using cap D3,
install tool and adapter [1] of the blowby checker
to hose (2), and connect gauge [3].

4. Start the engine, set the working mode to the


Power Mode (P), and turn the swing lock switch
ON.
a If the swing lock switch is turned to ON
position, the main relief valve is set for high-
pressure relief.
5. Measure the blowby pressure when the
hydraulic relief is made by arm IN operation at
engine high idle.
a Read the blowby gas pressure when the
gauge pointer stands still.

PC138USLC-10 30-15
30 Testing and adjusting
Engine and cooling system

Testing engine oil pressure (PC138-AB00-360-K-00-A)

a Testing tools
Sym-
Part No. Part name
bol
799-101-5002 Hydraulic tester
1
790-261-1204 Digital hydraulic tester
E 2 799-401-2320 Gauge
6732-81-3170 Adapter
3
07002-11023 O-ring

k Place the machine on a level ground and


lower the work equipment to the ground.

a Measure the engine oil pressure under the 5. After finishing the test, remove the testing tools,
following condition. and restore the machine.
• Coolant temperature: 75 to 94°C
3 Oil pressure pickup plug:
Testing (PC138-AB00-362-K-00-A) 20 to 22 Nm {2.0 to 2.2 kgm}
1. Open the side cover of the engine compartment,
and remove oil pressure pickup port plug (1)
from the engine block.

2. Install O-ring to adapter E3, and connect gauge


E2 to hose [2] by using nipple [1] and hose [2] of
hydraulic tester E1.

3. Start the engine, and turn the auto-decelerator


OFF.
4. Measure the oil pressure with the engine at low
idle and high idle.

30-16 PC138USLC-10
30 Testing and adjusting
Engine and cooling system

Testing fuel pressure (PC138-AE20-360-K-01-A)

a Testing tools 2) Install adapter F2 and nipple [1] of hydraulic


Sym- tester F1, and connect them to oil pressure
Part No. Part name gauge [2].
bol
799-101-5002 Hydraulic tester a Use the oil pressure gauge of 2.5 MPa
1
790-261-1204 Digital hydraulic tester {25 kg/cm2}.
Adapter
F 795-471-1450
2 (8 x 1.25 mm o R1/8)
07005-00812 Seal washer
3 799-401-2320 Gauge

k Place the machine on a level ground, and


lower the work equipment to the ground.

a Measure only the fuel pressure in the low-


pressure circuit from the priming pump through
the supply pump to the fuel main filter, and in the
return circuit between the supply pump/common
rail/ injector and fuel tank.
3) Start the engine, and measure the pressure
k Testing of the high-pressure circuit
in the fuel low-pressure circuit with the
connecting the supply pump, the common
engine at high idle.
rail and the injector can not be performed
due to the extremely high pressure a The pressure in the fuel low-pressure
generated there. circuit is normal when it is within the
following standard range.
a Before the fuel circuit is tested and its parts are
Engine speed Fuel pressure
removed or installed, the remaining pressure in
883 to 1,471 kPa
the fuel circuit must be released completely. High idle
Accordingly, observe the following. {9 to 15 kg/cm2}
4) After finishing the test, remove the testing
k Before testing the fuel system or removing/
tools, and restore the machine.
installing its parts, wait at least 30 seconds
after stopping the engine until the remaining 3 Fuel pressure pickup plug:
pressure in the fuel circuit is released. (Do 7.8 to 9.8 Nm {0.8 to 1.0 kgm}
not start the work just after stopping the
engine since there is remaining pressure.)

Testing (PC138-AE20-362-K-00-A)

1. Check of pressure in fuel low-pressure circuit


1) Open the engine hood,and remove fuel
pressure pickup plug (1) on the fuel main
filter.

PC138USLC-10 30-17
30 Testing and adjusting
Engine and cooling system

Testing fuel return rate and leakage (PC138-AE20-360-K-00-A)

A: Measuring position of leakage from pressure a Testing tools


limiter Sym-
Part No. Part name
B: Measuring position of return rate from injector bol
1. Fuel tank 1 6151-51-8490 Spacer
2. Pre-filter 2 6206-71-1770 Joint
3 07005-01012 Seal washer
3. Priming pump
Commercially
4. Fuel filter 4 Hose
available
5. Feed pump G Commercially
5 Hose
available
6. SCV (Suction control valve)
Commercially Measuring cylinder
7. Common rail pressure 6
available
8. Injector Commercially Stopwatch
7
available
9. Pressure limiter
10. Supply pump a Since fuel flows out during the test, prepare an
11. Fuel cooler oil pan of approximately 20 (container to catch
the fuel) l.
k Place the machine on a level ground, and
lower the work equipment to the ground.

k Be careful not to touch any hot parts when


installing or removing the testing tools.

30-18 PC138USLC-10
30 Testing and adjusting
Engine and cooling system

Testing (PC138-AE20-363-K-00-A)

1. Preparation
1) Remove the air compressor.
2) Remove injector return tube (3) and pressure
limiter return tube (4) connected to joint bolt
(2) of return block (1).

8) Return the air compressor.


Preparation is completed.
2. Testing leakage from pressure limiter
1) Arrange the route of test hose G4 so that it
does not sag, and put its end in a oil pan
(container to catch the fuel).
3) Insert spacers G1 (2 pieces) into the return
2) Start the engine, and run it at 1,600 rpm with
block side, and tighten the removed joint bolt
no load.
again.
3) After the engine speed is stabilized, measure
a Be sure to install seal washers G3 (3 the leakage for 1 minute by using measuring
pieces) to each end of spacers G1. cylinder G6.
a Measuring duration can be 20 seconds if
the leaked amount is multiplied by 3 after
the measurement.
a Leakage from the pressure limiter is
normal when it is within the following
standard value range.
Engine speed (rpm) Leakage
(cc/min)
At rated horsepower
operation Max. 20

4) Remove the joint bolt on the cylinder head


side of injector return tube (3), set joint G2,
and tighten the joint bolt again.
5) Connect test hose G4 to the end of joint G2.

4) Stop the engine after the measurement is


over.
3. Testing fuel return rate from injector
a While you are measuring the fuel return rate
6) Set joint G2 to pressure limiter (5), and from the injector, keep the hose on the
tighten the removed joint bolt again. pressure limiter side connected and its end in
7) Connect test hose G4 to the end of joint G2. the oil pan (container to catch the fuel).

PC138USLC-10 30-19
30 Testing and adjusting
Engine and cooling system

1) Start the engine, and run it at the rated


horsepower.
2) After the engine speed is stabilized, measure
the return rate for 1 minute by using
measuring cylinder G6.
a You may measure the return rate for 20
seconds and multiply it by 3 to judge.
a If the error of no-pressure feed occurs on
the supply pump, the engine speed may
not rise. In this case, record the engine
speed during the test as well.
a Return (spill) rate from the injector is
normal if it is within the following standard
value range.
Engine speed at rated Limit return (spill) rate (cc/
horsepower (rpm) min)
1,600 190
1,700 200
1,800 210
1,900 220
2,000 230

3) Stop the engine after the measurement is


over.
4. After finishing the test, remove the testing tools,
and restore the machine.
3 Joint bolt:
3.9 to 6.9 Nm {0.4 to 0.7 kgm}

30-20 PC138USLC-10
30 Testing and adjusting
Engine and cooling system

Bleeding air from fuel system (ALL-AD00-001-K-00-A)

a If fuel is used up or if a fuel circuit part is


removed and installed, bleed air from the fuel
circuit according to the following procedure.
k Park the machine on a level ground and
lower the work equipment to the ground.
Bleeding air (PC138-AD00-231-K-00-A)

1. Fill the fuel tank with fuel.


a Supply fuel until the float of sight gauge
reaches to the highest position.
2. Open the side cover of the pump room.
3. Loosen knob (1) of the feed pump and pull it out,
and move it back and forth.
a Move the knob until its movement becomes
heavy.
a You may not remove the plug on the top
surface of the main fuel filter.

4. After bleeding air, push knob (1) in and tighten it.

PC138USLC-10 30-21
30 Testing and adjusting
Engine and cooling system

a Air bleeding route of fuel circuit


Fuel tank o prefilter o feed pump o main filter o metering unit o fuel tank

1. Fuel tank
2. Fuel prefilter
3. Priming pump
4. Fuel filter
5. Feed pump
6. SCV (Suction control valve)
7. Common rail
8. Injector
9. Supply pump
10. Fuel cooler

30-22 PC138USLC-10
30 Testing and adjusting
Engine and cooling system

Testing fuel circuit for leakage (PC138-AD00-360-K-00-A)

a Testing tools 9. Stop the engine and check the fuel piping and
Sym- devices for fuel leakage.
Part No. Part name
bol a Check the high-pressure circuit for fuel
Developer leakage focusing on the area to which color
Commercially
Y for dye penetrant check checker Y is sprayed.
available
(color checker)
a If any fuel leakage is detected, repair it and
k Very high pressure is generated in the high- perform inspection again from Step 1.
pressure circuit of the fuel system. If fuel a If no fuel leakage is detected, inspection is
leaks while the engine is running, it presents completed.
a serious danger that could result in a fire.
After testing the fuel system and removing or
installing the tools for the test, test it for fuel
leakage according to the following procedure.

k Place 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.
Testing (PC138-AD00-364-K-00-A)

1. Spray color checker (developer) Y to the fuel


supply pump, common rail, fuel injectors, and
joints of the high-pressure fuel piping.
2. Start the engine, keep its speed at 1,000 rpm or
below, and stop it when its speed is stabilized.
3. Stop the engine and check the fuel piping and
devices for fuel leakage.
a Check the high-pressure circuit for fuel
leakage focusing on the area to which color
checker Y is sprayed.
a If any fuel leakage is detected, repair it and
perform inspection again from Step 1.
4. Start the engine and keep it running at low idle.
5. Stop the engine and check the fuel piping and
devices for fuel leakage.
a Check the high-pressure circuit for fuel
leakage focusing on the area to which color
checker Y is sprayed.
a If any fuel leakage is detected, repair it and
perform inspection again from Step 2.
6. Start the engine and keep it running at high idle.
7. Stop the engine and check the fuel piping and
devices for fuel leakage.
a Check the high-pressure circuit for fuel
leakage focusing on the area to which color
checker Y is sprayed.
a If any fuel leakage is detected, repair it and
perform inspection again from Step 2.
8. Run the engine at high idle, then load it.
a Relieve the arm circuit at the IN stroke end.

PC138USLC-10 30-23
30 Testing and adjusting
Engine and cooling system

Handling cylinder cutout mode operation (PC400-AD00-34F-K-00-A)

a The cylinder cut-out test mode operation means


to run the engine with the fuel injectors of one or
more cylinders disabled electrically to reduce the
number of active cylinders. The purposes and
effects of this operation are as follows.
1. This mode is used to find out a cylinder which
does not output power properly (or, combustion
in it is abnormal).
2. When a cylinder is selected for the Cylinder Cut-
out Mode operation, if the engine speed and
output do not change from the normal operation
(all-cylinder operation), that cylinder has one or
more defects.
The following problems can be considered:
• Compression leak from cylinder head gasket
• Defective injection from injector
• Defective piston, piston ring or cylinder liner
• Defective valve mechanism (valve operating
system)
• Defective electrical system
3. The injector of each cylinder is separately
controlled electronically in the common rail fuel
injection system, so the cylinder cut-out test can
be performed easily by the simple operations of
the switches compared with the mechanical fuel
injection system. This allows to find out a
defective cylinder easily.

30-24 PC138USLC-10
30 Testing and adjusting
Engine and cooling system

Handling no-injection cranking operation (PC-A000-25L-K-00-A)

a No-injection cranking means to crank the engine


by using the starting motor while all the
injections are stopped electrically. The purpose
and effect of this operation are as follows.
Before the engine is started after it or the
machine has been stored for a long period, the
no-injection cranking is performed to lubricate
the engine parts and protect them from seizure.

PC138USLC-10 30-25
30 Testing and adjusting
Engine and cooling system

Checking and adjusting air conditioner compressor belt tension (ALL-K5A0-001-


K-00-A)

k Park the machine on a level ground and 4. When the belt tension becomes appropriate,
lower the work equipment to the ground. tighten bolts (1) (4 pieces).

Testing (PC138-K5A0-285-K-01-A)
3 Bolt (1):
34 to 74 Nm {3.5 to 7.5 kgm}
1. Open the engine hood and remove step (1),
5. After tightening nut (2) until it touches boss (5),
compressor guard (2), and cover (3).
then tighten it further in direction (B) to prevent it
from loosening.
3 Nut (1):
108 to 132 Nm {11.0 to 13.5 kgm}
6. Check again if the belt tension is appropriate.
Adjust it again if the tension is not within the
proper range.
a Check each pulley for breakage, wear of the
V-groove, and contact of the V-belt with V-
groove.
a If the V-belt is elongated exceeding the
adjustment allowance or it has a cut or a
2. Press the belt at the intermediate point between crack, replace it with a new one.
the fan pulley and compressor pulley with your
finger and measure deflection (a). a When the V-belt is replaced, check and
adjust its tension again after running the
• Belt pressing force: 60 N {6.2 kg}
engine for an hour.
• Belt deflection
a: 6 to 9 mm

7. After finishing testing and adjusting, restore the


machine.
3. After finishing the test, restore the machine.
Adjusting (PC138-K5A0-27C-K-01-A)

a If the belt deflection is improper, adjust it


according to the following procedure.
1. Loosen bolts (1) (4 pieces).
a Do not loosen bolts (1) too much.
2. Loosen nut (2) in direction (A).
a Nut (2) is provided to prevent loosening of
jack bolt (3).
3. Tighten jack bolt (3) and slide compressor (4) in
direction (A), then the compressor belt is tensed.
a To loosen the belt, loosen jack bolt (3) and
slide compressor (4) in direction (B).

30-26 PC138USLC-10
30 Testing and adjusting
Engine and cooling system

Replacing fan belt (PC138-B430-360-K-00-A)

a Replacing tools k Make sure that it is securely inserted into


Sym- part (A) of tensioner assembly (1) before
Part No. Part name turning the wrench. (The spring of
bol
U 796-401-1300 Fixing jig tensioner assembly (1) is strong. If the
wrench is loosely inserted, the wrench
a The auto-tensioner is provided for the fan belt. may accidentally come off while being
Thus, usual checking and adjusting the belt is turned, and it is extremely dangerous.)
not necessary.
k After removing fan belt (3), return
a When replacing the fan belt, remove the air
conditioner compressor belt beforehand. tensioner assembly (1) to its original
position slowly and carefully.
k Place the machine on a level ground and
lower the work equipment to the ground. k Be careful not to get your fingers caught
between the pulley and fan belt (3) during
Replace (PC138-B430-923-K-00-A) work.
1. Remove the engine undercover.
2. Install fixing jig guide collar [1] to spacer (2) of
auto-tensioner (1).
3. Insert holding bracket [2] into collar [1] and
tighten it lightly with nut [3].
At this time, fit hollow part "a" of holding bracket
[2] to protruding part "b" of auto-tensioner (1).

5. Replace fan belt (3).


• Check each pulley for breakage and crack.

4. Apply the wrench to portion (C) (width across


flats: 12.7 mm) of tensioner assembly (1), and
turn it in the direction opposite to the tightening
direction to decrease the tension of fan belt (3).

PC138USLC-10 30-27
30 Testing and adjusting
Engine and cooling system

Writing compensation values at replacement of injector and engine


controller (PC400-AP70-001-K-00-A)
a Equipment needed for writing compensation
values
Sy-
mb- Part No. Part name
ol
Commer-
Laptop computer: Windows XP
1 cially
SP2/ VISTA/ Windows 7
available
2 Cu3886388 INSITE ver 7.4
Cu4919416 INLINE 5 kit
Commer-
cially
X available • Cable (USB)
3 or • Cable (RS232) a Service connector (1) (CN-N08) is installed in
795-799- the panel in the rear left side of the cab.
5740
795-799-
• Cable
5720
799-601- Cable (12P)
4
4510

a To install the INSITE program to the computer,


insert the software DVD-ROM into the DVD
drive of the computer and follow the menu.
a For writing, use INSITE v7.4 Feature Pack 1 or
after.
a If a problem (shutdown or open circuit) occurs in
the computer or cables, a serious error may
arise in the engine controller. Be careful when Start INSITE
connecting the cables. 1. Boot the PC.
a When connecting the INSITE system to the 2. Turn the starting switch to ON position, and
engine controller, do not interrupt the battery supply power from the battery to the engine
power supply to the engine controller. A power controller.
loss breaks the connection with the INSITE 3. Double-click the icon on the PC shown in the
system. figure below.

Connecting PC (PC138-AP70-270-K-00-A)

1. Check that the starting switch is turned to OFF


position.

k The starting switch must be turned to


OFF position when the personal computer
is connected or disconnected.
2. Connect INLINE 5 kit X3 and cable X4 to
personal computer X1, and then connect the
cable to service connector (CN-N08).

4. Establish communication with the engine


controller.
1) Select "Connect to ECM".
• Section A: Make sure that "INLINE 5 USB
(J1939) Connection" is indicated.

30-28 PC138USLC-10
30 Testing and adjusting
Engine and cooling system

2) Select "Connect". 2) Select "High Pressure Common Rail Injector


• Section B: Confirm that "None" is Setup".
displayed. • Section G: Make sure that "High
Pressure Common Rail Injector Setup" is
indicated.

a C: Connection-in-process screen
D: Screen after the connection is 3) Input the new data to "New Bar code"
complete (illustration does not move) column.
E: Communication status is displayed a Replacement of the injector and engine
(illustration moves during communication) controller is performed.
Replace injector.
• When the injector is replaced, write the
injector compensation value written on
the new injector in the engine controller.
• If the compensation value is not correctly
written, an engine trouble can result.
• The character string on the injector top
face is read.
Read from the top line, from left to right.
(Reading order of character string)

5. Execute the injector trim function and data


writing.
1) Select "Advanced ECM Data".
• Section F: Make sure that "Advanced
ECM Data" is indicated.

PC138USLC-10 30-29
30 Testing and adjusting
Engine and cooling system

Replacing engine controller 5) After writing data, turn the starting switch to
• When the engine controller is replaced, OFF position and select "OK".
write the injector compensation value • Section K: Select "OK."
written on the old engine controller to the
new engine controller.
• If the compensation value is not correctly
written, an engine trouble can result.
• Compensation value information provided
on the back of engine controller
a: String of characters
b: QR code

• Screen while data processing is


continued (wait for 30 seconds)

• Section H: "New Barcode" column

6) After data processing is over, turn the


starting switch to ON position and select
"OK".
• Section L: Select "OK."

4) Execute writing to the engine controller.


After entering the injector data, select "Apply".
• I: Entry of data of the target injector.
Examples)
Enter data of No.1 cylinder injector
corresponding to "Cylinder1".
• Section J: Select "Apply."

30-30 PC138USLC-10
30 Testing and adjusting
Engine and cooling system

7) Screen that indicates data writing is over. 6. Disconnect and end the communication with the
Select "OK". engine controller.
• Section M: Select "OK." • Section Q: Select "Disconnect from ECM."

8) Screen that appears when data writing ends 7. Turn the starting switch to OFF position, then
successfully. "Success" is displayed on the boot the PC again (turn the starting switch to ON
screen. position) to make sure that an error is not
• Section N: Make sure that "success" is present on the monitor.
indicated. a Related error code:
CA2765: Inj Trim Data Error
8. When replacing the injector, clear the values on
the compensation values sheet on the back of
the engine controller.
a Clear the former data characters of the
replaced injector on the compensation
values sheet that is provided on the back of
the controller. (Draw strike through)
a Record the former data of the replaced
injector in the maintenance register.
9. When the engine controller is replaced,
inconsistency may result between the data
a Screen that appears for faulty data writing recorded on the sheet on the back of the
• Section P: Indicates that writing is controller and that recorded in the register when
faulty. replacement of an injector or engine controller
• If the following appears instead of the was done before. In such case, you must use
screen of item 8) after the operation of the compensation character strings contained in
item 7), it is suspected that the the maintenance record information or import
entered new data is inappropriate. the compensation value information described
(Check the data again and repeat its on the top face of every injector installed on the
entry.) cylinders, in the same way as you did in the
above when you replaced the injector.

PC138USLC-10 30-31
30 Testing and adjusting
Power train

Power train (ALL-C100-001-K-00-A)

Testing swing circle bearing clearance (PC138-J117-360-K-00-A)

a Testing tools 5. Under this condition, read dial gauge H.


Sym- a The value indicated by dial gauge H is the
Part No. Part name
bol bearing clearance.
Commercially Dial gauge
H
available

k Be careful not to put you hand or foot under


the undercarriage during the test.

Testing (PC138-J117-365-K-00-A)

1. Fix dial gauge H to outer race (1) or inner race


(2) of the swing circle and put the probe to inner
race (2) or outer race (1) on the opposite side.
a Set dial gauge H at the front or rear of the
machine.

6. Return the machine to the condition in step 2,


and check that dial gauge H indicates 0 again.
a If the dial gauge does not indicate 0, repeat
steps 3 to 5.

2. Set the work equipment in the maximum reach


posture, and set the bucket end to the height of
the under surface of the revolving frame.
a At this time, the front of the upper structure
lowers and the rear rises.
3. Set dial gauge H to the zero point.

4. Set the arm at about a right angle to the ground,


and lower the boom until the track shoe at the
front of the machine rises 150 to 200 mm above
the ground.
a At this time, the front of the upper structure
rises and the rear lowers.

30-32 PC138USLC-10
30 Testing and adjusting
Undercarriage and frame

Undercarriage and frame (ALL-DT00-001-K-00-A)

Testing and adjusting track shoe tension (ALL-DTL0-001-K-00-A)

Testing (PC200_10-DTL0-285-K-00-A) a You can add grease until dimension (b)


between the idler guide and the track
1. Run the engine at low idle and move the
machine forward by the length of track on frame end becomes 0 mm. If the tension
is still low, the pins and bushings will
ground, and then stop slowly.
become excessively worn. In this case,
2. Place square bar [1] on the track shoes between
turn 180 deg. , or replace the pins and
the idler and the 1st carrier roller.
bushings.
a As the square bar [1], use an angle steel, etc.
which deflects less.
3. Measure maximum clearance (a) between steel
bar [1] and track shoe.
• Standard maximum clearance (a): 10 to 30
mm

2. Decreasing tension
1) Loosen valve (2) to discharge grease, and
then tighten it.

k Do not loosen the valve more than one


turn. Otherwise, the valve jumps out
Adjusting (PC220-DTL0-27C-K-00-A) because of the high-pressure grease
inside.
a If the track tension is improper, adjust it
according to the following procedure. 2) To check that the tension is proper, run the
1. Increasing tension engine at low idle and move the machine
forward by the length of track on ground,
1) Add grease through grease fitting (1) by
then stop slowly.
using a grease gun.
3) After adjusting, check the track tension again
2) To check that the tension is proper, run the
according to the above procedure.
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 tension again
according to the above procedure.

PC138USLC-10 30-33
30 Testing and adjusting
Hydraulic system

Hydraulic system (ALL-C000-001-K-00-A)

Releasing remaining pressure from hydraulic circuit (ALL-C000-001-P-02-A)

Releasing remaining pressure (PC138- 3) Start the engine, and run it at low idle for 5
C000-22A-K-00-A) seconds to raise the pressure in the
1. Releasing remaining pressure from hydraulic accumulator.
tank a The engine does not start unless the lock
lever is set to LOCK position.
k The hydraulic tank is sealed and 4) Repeat above steps 2) and 3) two to three
pressurized. Therefore, when removing a times, and all remaining pressure is released
hose or a plug connected to the hydraulic from the piping completely.
tank, release the remaining pressure in 3. Releasing remaining pressure from swing motor
the hydraulic tank according to the circuit
following procedure.
a The remaining pressure in the swing motor
1) Lower the work equipment to the ground in a circuit can be released by performing the
stable posture and stop the engine. same operation as that described in
2) Loosen oil filler cap (1) of the hydraulic tank preceding "Releasing remaining pressure in
gradually to release the air in the tank. hydraulic cylinder circuit" (Operate the lever
to SWING only, however).
4. Releasing remaining pressure from travel motor
circuit
a The control valve spool of the travel motor
circuit is an open type circuit, so the
remaining pressure in the circuit can be
released by performing the same operation
as that described in preceding "Releasing
remaining pressure in hydraulic tank".

2. Releasing remaining pressure in hydraulic


cylinder circuit

k When disconnecting a pipe between a


hydraulic cylinder and the control valve,
release the remaining pressure from the
piping according to the following
procedure.
1) Release the remaining pressure in the
hydraulic tank. For details, see preceding
"Releasing remaining pressure in hydraulic
tank".
a Leave the oil filler cap of the hydraulic
tank removed.
2) Turn the starting switch to ON position and
set the work equipment lock lever to FREE
position, and then operate the right and left
work equipment control levers forward and
backward, and to the right and left.
a The control valve is operated by the
pressure in the accumulator. The
pressure in the accumulator is used up,
however, after the work equipment
control levers are operated two to three
times.

30-34 PC138USLC-10
30 Testing and adjusting
Hydraulic system

Testing and adjusting oil pressure in work equipment, swing, and travel
circuits (PC138-C000-360-K-00-A)
a Testing tools
Sym-
Part No. Part name
bol
799-101-5002 Hydraulic tester
1
790-261-1204 Digital hydraulic tester
J
799-101-5220 Nipple (10 x 1.25 mm)
2
07002-11023 O-ring

k Place the machine on a level ground, lower


the work equipment to the ground, and
release the remaining pressure in the
hydraulic circuit. For details, see "Releasing
remaining pressure in hydraulic circuit".
2) Install nipple J2 and connect oil pressure
Testing (PC138-C000-362-K-00-A) gauge [1] of hydraulic tester J1.

a The oil pressures (pump discharge pressures) of a Use the oil pressure gauge of 60 MPa
the work equipment, swing, and travel circuits {600 kg/cm2}.
can be checked with the monitoring function of
the machine monitor (For details, see SPECIAL
FUNCTIONS OF MACHINE MONITOR).
• Monitoring code: 01100 “Pump pressure“
a Measure the oil pressure in the work equipment,
swing, and travel circuits under the following
condition.
• Hydraulic oil temperature: 45 to 55°C
1. Preparation
1) Open the pump room side cover, and remove
oil pressure pickup plugs (1) and (2).
• (1): Pump discharge pressure port (1) 2. Testing unload pressure
pickup plug
1) Start the engine, set the working mode to
• (2): Pump discharge pressure port (2)
power mode (P), and turn the auto
pickup plug
deceleration OFF.
2) Run the engine at high idle, set all of control
levers and pedals of work equipment, swing,
and travel in neutral, and measure the oil
pressure.
a The oil pressure at which the unload
valve unloads is displayed.

3. Testing work equipment relief pressure

PC138USLC-10 30-35
30 Testing and adjusting
Hydraulic system

1) Start the engine, and operate the cylinder to 6. Work after finishing test
be measured to the stroke end. After finishing the test, remove the testing tools
2) Set the working mode to Power Mode (P). and restore the machine.
3) Run the engine at high idle, operate the right
3 Oil pressure pickup plug:
and left work equipment control levers to
relieve the cylinder, and measure the oil 20 to 27 Nm {2.0 to 2.8 kgm}
pressure.
Measuring method by using machine monitor
a The pressure at which the main relief
a The oil pressures in the work equipment, swing,
valve of the control valve cracks is
and travel circuits (pump discharge pressures)
displayed (however, when the boom is
can be checked from the “Monitoring / Pre-
lowered, the boom LOWER safety-
defined“ or “Monitoring / Custom“ screen of the
suction valve relieves).
machine monitor.
4. Testing swing relief pressure
1. Start the engine, and set the machine monitor to
1) Start the engine, set the working mode to the
“Monitoring / Pre-defined“ or “Monitoring /
Power Mode (P), and turn the swing lock
Custom“ screen.
switch ON.
2) Run the engine at high idle, operate the left a For the setting method, see "Special
work equipment control lever to relieve the functions of machine monitor".
swing motor circuit, and measure the oil • Monitoring code: 01100 “Pump pressure“
pressure. • “Monitoring / Pre-defined (07/10)“ screen
a The pressure when the safety valve of the
swing motor relieved is displayed.
a The swing relief pressure is lower than
the main relief pressure.
5. Testing travel relief pressure
1) Run the engine, and lock the travel
mechanism.

k Insert pin [2] between the sprocket


and the track frame to securely lock
the track.

• “Monitoring / Custom“

2) Set the working mode to Power Mode (P).


3) Run the engine at high idle, operate the
travel lever and pedal to relieve the travel
motor circuit, and measure the oil pressure. 2. Increase the hydraulic oil temperature to 45 to
55°C and measure the pump discharge
k Before operating the travel lever pressure.
(pedal), check the pin position and
locked direction of the travel again. a For the measuring procedure, see
"Measuring method by using oil pressure
a The pressure when the main relief valve gauge".
of the control valve cracks is displayed.
The travel circuit is always relieved at
high pressure.

30-36 PC138USLC-10
30 Testing and adjusting
Hydraulic system

2. Adjustment of swing relief pressure


Adjusting (PC138-C000-270-K-00-A)
a If the swing relief pressure is not normal,
a You cannot adjust the unload valve and boom
adjust safety valve (6) of the swing motor
LOWER safety-suction valve.
according to the following procedure.
1. Adjustment of work equipment and travel relief
pressure
a If the work equipment and travel relief
pressure is not normal, adjust main relief
valve (3) of the control valve according to the
following procedure.
a When adjusting the main relief valve, remove
the side cover of the control valve.

1) While fixing adjustment screw (7), loosen


lock nut (8).
2) Turn adjustment screw (7) to adjust the set
pressure.
a When the adjustment screw is:
• turned clockwise, the set pressure
increases.
• turned counterclockwise, the set
1) Remove the left side cover of the control pressure decreases.
valve.
2) While fixing holder (4), loosen lock nut (5). a Quantity of pressure adjustment per turn
3) Turn holder (4) to adjust the set pressure. of adjustment screw:
6.71 MPa {68.4 kg/cm2}
a When the holder is
3) While fixing adjustment screw (7), tighten
• turned clockwise, the set pressure lock nut (8).
increases.
• turned counterclockwise, the set 3 Lock nut:
pressure decreases. 78 to 103 Nm {8 to 10.5 kgm}
a Quantity of adjustment per turn of holder:
Approx. 20.5 MPa {Approx. 209 kg/cm2}
4) While fixing holder (4), tighten lock nut (5).
3 Lock nut:
49 to 58. 8 Nm {5 to 6 kgm}

4) After finishing the adjustment, check the oil


pressure again according to the above
procedure.

5) After finishing the adjustment, check the oil


pressure again according to the above
procedure.

PC138USLC-10 30-37
30 Testing and adjusting
Hydraulic system

Testing oil pressure of control circuit (PC138-C010-360-K-00-A)

a Testing tools
Sym-
Part No. Part name
bol
799-101-5002 Hydraulic tester
1
K 790-261-1204 Digital hydraulic tester
2 799-401-3100 Adapter (size: 02)

k Place the machine on a level ground, lower


the work equipment to the ground, and
release the remaining pressure in the
hydraulic circuit. For details, see "Releasing
remaining pressure in hydraulic circuit".
5. After finishing the test, remove the testing tools
a Measure the control circuit oil pressure under and restore the machine.
the following condition.
• Hydraulic oil temperature: 45 to 55°C a The control circuit pressure may be tested at oil
pressure pickup port plug (2) on the hydraulic
Testing (PC138-C010-362-K-00-A) pump.
1. Open the front cover of the control valve, and
remove solenoid valve inlet hose (1).

a Do not adjust the relief valve for the control


2. Install adapter K2, and connect oil pressure circuit pressure.
gauge [1] of hydraulic tester K1.
a Use the oil pressure gauge of 5.9 MPa {60
kg/cm2}.

3. Start the engine, set the working mode to power


mode (P), and turn the auto deceleration OFF.
4. Run the engine at high idle, set all of control
levers and pedals of work equipment, swing,
and travel in neutral, and measure the oil
pressure.

30-38 PC138USLC-10
30 Testing and adjusting
Hydraulic system

Testing and adjusting oil pressure in pump PC control circuit (PC138-C2A3-360-K-


00-A)

a Testing tools
Sym-
Part No. Part name
bol
799-101-5002 Hydraulic tester
1
790-261-1204 Digital hydraulic tester
L
799-101-5220 Nipple (10 x 1.25 mm)
2
07002-11023 O-ring

k Place the machine on a level ground, lower


the work equipment to the ground, and
release the remaining pressure in the
hydraulic circuit. For details, see "Releasing
remaining pressure in hydraulic circuit".
2) Install nipple L2 and connect it to oil pressure
Testing (PC138-C2A3-362-K-00-A) gauge [1] of hydraulic tester QL.

a Before testing the oil pressure in the pump PC


control circuit, check that the oil pressure in the
work equipment, swing, and travel circuits and
the source pressure of the control circuit are
proper.
a Measure the oil pressure in the pump PC control
circuit under the following condition.
• Hydraulic oil temperature: 45 to 55°C
1. Measurement of PC valve output pressure
(servo piston inlet pressure)
a To measure the PC valve output pressure
(servo piston inlet pressure), measure the
a Install nipple L2 to the test portion of plug
pump discharge pressure simultaneously
(2), and connect them to oil pressure
and compare them.
gauge [1] by using hose [2] of hydraulic
1) Open the pump room side cover, and remove tester L1.
oil pressure pickup plugs (1) and (2).
a Use the oil pressure gauge of 60 MPa
• (1): Pump discharge pressure pickup port
{600 kg/cm2}.
• (2): PC valve output pressure pickup plug

3) Start the engine, and operate the arm


cylinder to arm IN stroke end.
4) Set the working mode to Power Mode (P).
5) Run the engine at high idle, operate the left
work equipment control lever to relieve the
arm cylinder circuit at IN end, and measure
the oil pressure.

PC138USLC-10 30-39
30 Testing and adjusting
Hydraulic system

a Use the oil pressure gauge of 5.9 MPa


{60 kg/cm2}.

a Measuring condition and judgment


method: If the oil pressure is as shown in
the table below, the PC valve is normal. 3) Start the engine, and set the working mode
Oil pressure to be Operation of Oil pressure to power mode (P).
measured lever ratio 4) Run the engine at low idle and high idle, set
Pump discharge all of control levers and pedals of work
pressure 1 equipment, swing, and travel in neutral, and
Arm IN relief Approx. 0.6 measure the oil pressure.
PC valve output
pressure (Approx. 3/5)

a If the PC valve or servo piston is


abnormal, the PC valve output pressure
(servo piston inlet pressure) is the "same
as the pump discharge pressure" or
approximately "0".
6) After finishing the test, remove the testing
tools and restore the machine.
2. Measuring PC-EPC valve output pressure
1) Open the pump room side cover, and remove
oil pressure pickup plug (3).
• (3): PC-EPC valve output pressure
pickup plug a Measuring condition and judgment
method: If the output pressure is as
shown in the table below, PC-EPC valve
is normal.
Engine Operation of Output pressure
lever
Approx. 2.9 MPa
Low idle {Approx. 30 kg/
All control levers cm2}
and pedals in
Approx. 3.4 MPa
NEUTRAL
High idle {Approx. 35 kg/
cm2}
5) After finishing the test, remove the testing
tools and restore the machine.
2) Install nipple L2, and connect it to oil
pressure gauge [1].

30-40 PC138USLC-10
30 Testing and adjusting
Hydraulic system

Adjusting (PC138-C2A3-270-K-00-A)
Adjustment of pump PC valve
a When the phenomena shown below occur and
PC valve (4) seems to be defective, adjust it
according to the following procedure.
• When the working load increases, the engine
speed drops largely.
• The engine speed is normal but the work
equipment speed is low.
a The width across flats of the lock nut for the PC
valve is 13 mm and that (inside width) of the
adjustment screw is 4 mm. 4. After finishing the adjustment, check the PC
valve output pressure (servo piston inlet
Do not rotate any other lock nut or adjustment
pressure) again according to the above
screw than the above, since it affects the
procedure.
hydraulic pump performance.

1. Loosen lock nut (5).


a Before loosening the lock nut, make a
matchmark on its end surface so that you
can see the position before the adjustment
(you can return to the original position by
rotating in reverse).
2. Adjust by rotating adjustment screw (6)
clockwise or counterclockwise.
a Rotate the adjustment screw
• clockwise when the work equipment
speed is low (to increase the pump
absorption torque), or
• counterclockwise when the engine speed
is low (to decrease the pump absorption
torque).
3. Tighten lock nut (5).
3 Lock nut:
27 to 34 Nm {2.8 to 3.5 kgm}

PC138USLC-10 30-41
30 Testing and adjusting
Hydraulic system

Testing and adjusting oil pressure in pump LS control circuit (PC138-C2A4-360-K-00-


A)

a Testing tools
Sym-
Part No. Part name
bol
799-101-5002 Hydraulic tester
1
790-261-1204 Digital hydraulic tester
Differential pressure
2 799-401-2701 gauge
799-101-5220 Nipple (10 x 1.25 mm)
3
07002-11023 O-ring
796T-440-1101 Sensor adapter
M
796-440-1150 • Wiring harness
796T-440-1160 • Nipple
4 799-401-2350 • Washer
790-261-1130 • Coupling
07002-61823 • O-ring
7861-93-1812 • Pressure sensor
5 796T-440-1200 Sensor adapter

k Place the machine on a level ground, lower


the work equipment to the ground, and
release the remaining pressure in the
hydraulic circuit. For details, see "Releasing
remaining pressure in hydraulic circuit".

Testing (PC138-C2A4-362-K-00-A)

a Before testing the oil pressure in the pump LS 2) Install nipple M3, and connect it to oil
control circuit, check that the oil pressure in the pressure gauge [1] of hydraulic tester M1.
work equipment, swing, and travel circuits and
the source pressure of the control circuit are
proper.
a Test the oil pressure in the pump LS control
circuit under the following condition.
• Hydraulic oil temperature: 45 to 55°C
1. Measuring LS valve output pressure (servo
piston inlet pressure)
a To measure LS valve output pressure (servo
piston inlet pressure), measure the pump
discharge pressure simultaneously, and
compare them.
1) Open the pump room side cover, and remove a Install nipple M3 to the test portion of plug
oil pressure pickup plugs (1) and (2). (2), and connect them to oil pressure
gauge [1] by using hose [2] of hydraulic
• (1): Pump discharge pressure pickup port
tester M1.
• (2): LS valve output pressure pickup plug
a Use the oil pressure gauge of 60 MPa
{600 kg/cm2}.

30-42 PC138USLC-10
30 Testing and adjusting
Hydraulic system

Operation of lever
All control Travel lever at half
levers and stroke
pedals in
NEUTRAL (Track runs idle)
Pump
Set measured value

Oil pressure to be measured


discharge
pressure to 1

Almost
same
LS valve pressure Approx. 3/5 of
output
3) Start the engine, raise the track to be tested above pressure
pressure
off the ground by using the work equipment,
and prepare for running track idle off the
ground.

k Provide a enough work space to run 6) After finishing the test, remove the testing
the track idle off the ground. tools, and restore the machine.
2. Testing LS differential pressure
4) Set the working mode in power mode (P) and
the travel speed in Hi. a To obtain the LS differential pressure,
5) Run the engine at high idle, set all of control measure the pump discharge pressure and
levers and pedals of work equipment, swing, LS pressure (actuator load pressure)
and travel in NEUTRAL, and measure the oil simultaneously, and calculate the difference.
pressure while running the track idle off 1) Remove connector V5 (port A4) of the
ground by operating the travel lever. solenoid valve.
Purpose: To stabilize the LS differential
k Run the raised track idle off the pressure by removing the connector and
ground, paying enough attention to keeping the merge-divider valve in the merge
the surroundings for safety. state.
2) Open the pump room side cover and remove
a Do not operate the travel lever full stroke oil pressure pickup plugs (1) and (2).
(limit it to about a half stroke).
• (1): Pump discharge pressure pickup port
• (2): LS pressure pickup plug

a Measuring condition and judgment


method: If the oil pressure is as shown in 3) Install nipple M3 to the plug, and connect
the table below, the LS valve is normal. them to differential pressure gauge M2 or oil
pressure gauge [1] of hydraulic tester M1.

PC138USLC-10 30-43
30 Testing and adjusting
Hydraulic system

a When using differential pressure gauge 5) Set the working mode in power mode (P),
M2: and the travel speed in Hi.
Connect the pump discharge pressure to 6) Run the engine at high idle, set all of control
the high-pressure side (reverse side), and levers and pedals of work equipment, swing,
connect the LS pressures to the low- and travel in NEUTRAL, and measure the oil
pressure side (lower side). The pressure while running the track idle off
differential pressure gauge needs 12 V ground by operating the travel lever.
DC power, so connect it to a battery.
k Run the raised track idle, paying
a When using the oil pressure gauge enough attention to the surroundings
(component of M1): for safety.
Use the oil pressure gauge of 60 MPa
{600 kg/cm2} with the graduation by 1.0 a Do not operate the travel lever full stroke
MPa {10 kg/cm2}. Since the differential (limit it to about a half stroke).
pressure is 3.9 MPa {40 kg/cm2} at
maximum, use the same gauge
throughout the measurement,
reconnecting it properly.
• The figure shows the pump discharge
pressure side.

a Measuring condition and judgment


method: If the pressure is as shown in the
table below, the LS valve is normal.
LS differential
Operation of lever
pressure
All control levers and 2.8 ± 1.0 MPa
• The figure shows the LS pressure side. pedals in NEUTRAL (28 ± 10 kg/cm2 )
Travel lever at half stroke
2.2 ± 0.1 MPa
(Either track running idle off
(22.5 ± 1 kg/cm2 )
ground)
7) After finishing the test, remove the testing
tools, and restore the machine. Connect
disconnected connector V5 of the solenoid
valve to restore it.
Testing oil pressure with sensor
adapter (special tool) (PC138-TA11-362-P-00-A)
Select "Monitoring / Pre-defined" or "Monitoring /
Custom" on the machine monitor to monitor the
4) Start the engine, raise the track to be tested service pressure.
off the ground by using the work equipment, a For the machine monitor operating method, see
and prepare for running track idle off the the section of "Special functions of machine
ground. monitor".
• When testing circuit P1: R.H. track
a Monitoring code: 01141 “Service Pressure
• When testing circuit P2: L.H. track
Sensor“
k Provide a enough work space to run • "Monitoring/Pre-defined" screen
the track idle off the ground.

30-44 PC138USLC-10
30 Testing and adjusting
Hydraulic system

3. Start the engine and increase the hydraulic oil


• "Monitoring" item
temperature to the operating range.
4. Monitor the oil pressure with the engine at low
idle or high idle.
5. After finishing the test, remove the testing tools
and restore the machine.
Adjusting (PC138-C2A4-270-K-00-A)
Adjustment of LS valve
a If the LS differential pressure is abnormal, adjust
the LS valve according to the following
procedure.
• (3): LS valve

1. Open the right side cover of the machine, and


connect service oil pressure connector (1) (P49)
to sensor adapter assembly M4 (Pressure
range: 50 MPa {500 kg/cm2}).
a When monitoring by using sensor adapter
M5 (Pressure range: 5 MPa {50 kg/cm2}),
Note that the value displayed on the monitor
needs to be divided by 10.

1. While fixing adjustment screw (4), loosen lock


nut (5).
2. Turn adjustment screw (4) to adjust the
differential pressure.
a When the adjustment screw is:
• turned clockwise, the pressure is
increased.
• turned counterclockwise, the pressure is
decreased.
2. Remove the oil pressure pickup nipple of the
measurement portion, install nipple M2, and a Quantity of pressure adjustment
connect it to sensor adapter assembly M4. per turn of adjustment screw (LS pressure):
1.1 MPa {10.8 kg/cm2}
3. While fixing adjustment screw (4), tighten lock
nut (5).
3 Lock nut:
49 to 68.6 Nm {5 to 7 kgm}

PC138USLC-10 30-45
30 Testing and adjusting
Hydraulic system

4. After finishing the adjustment, check the LS


differential pressure again according to the
above procedure.

30-46 PC138USLC-10
30 Testing and adjusting
Hydraulic system

Testing outlet pressure of solenoid valve (PC138-PQPT-360-K-00-A)

a Testing tools
Sym-
Part No. Part name
bol
799-101-5002 Hydraulic tester
1
N 790-261-1204 Digital hydraulic tester
2 799-401-3100 Adapter (size: 02)

k Lower the work equipment to the ground and


stop the engine. Operate the control levers
several times to release the remaining
pressure in the piping, and then loosen the
oil filler cap of the hydraulic tank slowly to
release the internal pressure. 4. Start the engine.
5. Run the engine at high idle, operate each control
a Before testing the solenoid valve output lever and switch, turn the solenoid valve ON or
pressure, check that the control circuit source OFF, and measure the output pressure.
pressure is normal.
a For the conditions for turning the solenoid
a Measure the solenoid valve outlet pressure valve ON/OFF, see the operation table of
under the following conditions: each solenoid valve.
• Hydraulic oil temperature: 45 to 55°C
a You can check the operating condition of the
Testing (PC138-PQPT-362-K-00-A) solenoid valve with the monitoring function of
1. Remove the right side cover of the control valve the machine monitor (For details, see
and disconnect outlet hoses (1) to (5) of the SPECIAL FUNCTIONS OF MACHINE
solenoid valves to be tested. MONITOR).
No. Solenoid valve to be tested • Monitoring code: 02300 solenoid 1
1 PPC lock solenoid valve a If the output pressure is as shown in the table,
2 Travel speed selector solenoid valve the solenoid valve is normal.
3 Swing parking brake solenoid valve Solenoid valve Output pressure
4 Merge-divider valve OFF (de-energized) 0 MPa {0 kg/cm2}
5 Travel junction solenoid valve ON (energized) 2.9 MPa {30 kg/cm2}
6 ATT return selector solenoid valve 6. After finishing the test, remove the testing tools,
and restore the machine.

2. Install adapter N2, and connect the


disconnected hose again.
3. Install nipple [1] of hydraulic tester N1, and
connect them to oil pressure gauge [2].
a Use the oil pressure gauge of 5.9 MPa {60
kg/cm2}.
a The figure shows the testing tools installed to
outlet hose (1) of the PPC lock solenoid
valve.

PC138USLC-10 30-47
30 Testing and adjusting
Hydraulic system

Testing PPC valve output pressure (PC138-PW11-360-K-00-A)

Connecting points of PPC piping a Measure the solenoid valve output pressure
under the following conditions.
• Hydraulic oil temperature: 45 to 55°C
Testing (PC138-PW11-362-K-00-A)

1. Disconnect the hose of PPC circuit to be tested.


a For the hose to be disconnected, see
"Connecting points of PPC piping".
2. Install adapter P2, and connect the
disconnected hose again.
3. Install nipple [1] of hydraulic tester P1, and
connect them to oil pressure gauge [2].
a Use the oil pressure gauge of 5.9 MPa {60
kg/cm2}.
a The above figure shows the connecting points of
PPC piping to the control valve of 1-attachment a The figure shows the testing tools installed to
specification. hose of the R.H. travel forward PPC circuit.
The colors in ( ) are the colors of the bands
installed for piping identification.
a The following figure shows the testing points of
the steering signal pressure of the travel PPC
valve.
When testing the steering signal pressure,
remove the lower cover (front side) of the
operator's cab.

4. Start the engine, and set the working mode to


power mode (P).
5. Run the engine at high idle, set the control
levers in NEUTRAL and travel end, and
measure the oil pressure at each position.

a Testing tools
Sym-
Part No. Part name
bol
799-101-5002 Hydraulic tester
1
P 790-261-1204 Digital hydraulic tester
2 799-401-3100 Adapter (size: 02)

k Place the machine on a level ground, lower


the work equipment to the ground, and a If the output pressure is as shown in the
release the remaining pressure in the following table, PPC valve is normal.
hydraulic circuit. For details, see "Releasing
remaining pressure in hydraulic circuit". Operation of lever Output pressure
NEUTRAL 0 MPa {0 kg/cm2}
a Before testing PPC valve output pressure, check Almost same as control circuit
that the control circuit source pressure is normal. Travel end source pressure (See
standard value table)

30-48 PC138USLC-10
30 Testing and adjusting
Hydraulic system

6. After finishing the test, remove the testing tools,


and restore the machine.

PC138USLC-10 30-49
30 Testing and adjusting
Hydraulic system

Adjusting play of work equipment and swing PPC valves (ALL-PL28-001-K-00-A)

a If the right and left work equipment levers have


large play, adjust them according to the following
procedure.
a The play of the lever measured at a position of
200 mm from the pivot must be 0.5 to 3 mm.
Adjusting (PC-PL28-270-K-00-A)

1. Remove boot (1).


2. Loosen lock nut (2) and tighten disc (3) until it
comes in contact with the heads of pistons (4) (4
pieces).
a At this time, do not move the pistons.
3. While fixing disc (3), tighten lock nut (2) to the
specified torque.
3 Locknut: 68 to 88 Nm (7 to 9 kgm)
4.
a Apply gear oil and grease (G2–L1) to the
rocking portions of the joint.
(Portion J):
Apply grease (G2–L1) of 7 to 10 ml all
around.
(Portion P):
Apply gear oil of 0.2 to 0.4 ml to the sliding
parts (4 places) of the joints and pins.

5. Install boot (1).

30-50 PC138USLC-10
30 Testing and adjusting
Hydraulic system

Isolating the parts causing hydraulic drift in work equipment (ALL-L410-001-K-00-A)

a If the work equipment (cylinder) drifts 2) Operate the arm control lever to the arm IN
hydraulically, perform check to see if the position.
problem is in the cylinder seal or control valve • If the lowering speed is increased at this
according to the following procedure. time, the cylinder seal is defe