Name: Komatsu Galeo PC138US-8
Brand: Komatsu
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SEN02551-00 10 Structure, function and maintenance standard

8 PC138US, USLC-8

Hydraulic cylinder 1

Boom cylinder

Arm cylinder

Bucket cylinder

Table of Contents6
Index and Foreword16
Safety Notice16
How to Read the Shop Manual21
Explanation of Terms for Maintenance Standard23
Handling of Electric Equipment and Hydraulic Component25
Handling of Connectors Newly Used for Engines34
How to Read Electric Wire Code37
Precautions When Carrying out Operation40
Method of Disassembling and Connecting Push-Pull Type Coupler43
Standard Tightening Torque Table46
Conversion Table50
Specification57
- Specification Dimension Drawings58
- Working Range Diagram59
- Specifications60
- List of Weights66
- Table of Fuel, Coolant and Lubricants70
Structure, Function and Maintenance Standard73
- Engine and Cooling System SEN02545-0173
  - Engine Mount74
  - Pto75
  - Cooling System76
- Power Train SEN02546-0179
  - Power Train79
  - Swing Circle81
  - Swing Machinery82
  - Track Frame86
  - Structure, Function and Maintenance Standard86
  - Idler Cushion88
  - Idler90
  - Track Roller91
  - Carrier Roller92
  - Sprocket93
  - Track Shoe94
- Hydraulic System, Part 1101
  - Hydraulic Equipment Layout Drawing102
  - Structure, Function and Maintenance Standard102
  - Valve Control104
  - Hydraulic Tank and Filter106
  - Hydraulic Pump108
- Hydraulic System, Part 2135
  - Control Valve136
  - Clss148
  - Functions and Operation by Valve152
- Hydraulic System, Part 3183
  - PPC Valve184
  - Structure, Function and Maintenance Standard184
- Swing Motor201
- Travel Motor209
- Center Swivel Joint218
- Solenoid Valve222
- PPC Accumulator226
- Holding Valve228
- Multi-Control Valve233
- Work Equipment235
- Dimensions of Components238
- Hydraulic Cylinder242
- Air Conditioner246
- Electronic Control System260
- Structure, Function and Maintenance Standard260
- Monitor System293
- KOMTRAX System307
- Sensor309
Standard Value Table317
- Standard Value Table for Engine Related Parts318
- Standard Value Table for Chassis Related Parts319
Testing and Adjusting Testing and Adjusting, Part329
- Tools for Testing, Adjusting, and Troubleshooting331
- Testing and Adjusting331
- Testing Engine Speed334
- Testing Exhaust Temperature335
- Checking Exhaust Gas Color336
- Adjusting Valve Clearance337
- Testing Compression Pressure339
- Testing Blow-By Pressure341
- Testing Engine Oil Pressure342
- Handling Fuel System Parts343
- Releasing Residual Pressure from Fuel System343
- Testing Fuel Pressure344
- Testing Fuel Return Rate and Fuel Leakage345
- Bleeding Air from Fuel Circuit347
- Checking Fuel Circuit for Leakage349
- Testing and Adjusting Alternator Belt Tension350
- Testing Swing Circle Bearing Clearance351
- Pc138Us, Uslc-8351
- Checking and Adjusting Air Conditioner Compressor Belt Tension352
- Checking and Adjusting Track Shoe Tension353
- Testing and Adjusting Oil Pressure in Work Equipment, Swing, and Travel Circuits355
- Testing Control Circuit Basic Pressure358
- Testing and Adjusting Oil Pressure in Pump PC Control Circuit359
- Testing and Adjusting Oil Pressure in Pump LS Control Circuit362
- Testing Solenoid Valve Output Pressure366
- Testing PPC Valve Output Pressure367
- Adjusting Play of Work Equipment and Swing PPC Valves369
- Checking Parts Which Cause Hydraulic Drift of Work Equipment370
- Testing and Adjusting Travel Deviation372
- Releasing Residual Pressure from Hydraulic Circuit374
- Testing Oil Leakage375
- Bleeding Air from each Part378
  - Checking Cab Tipping Stopper380
  - Adjusting Mirrors380
- Testing and Adjusting, Part 2383
  - Special Functions of Machine Monitor384
- Testing and Adjusting, Part 3437
  - Handling Voltage Circuit of Engine Controller438
  - Testing and Adjusting438
  - Preparation Work for Troubleshooting of Electrical System439
  - Procedure for Testing Diodes444
  - Pm Clinic Service445
Troubleshooting451
- Failure Code Table452
- Fuse Locations456
- Points to Remember When Troubleshooting460
- Troubleshooting460
- Sequence of Events in Troubleshooting461
- Checks before Troubleshooting462
- Classification and Procedures for Troubleshooting463
- Information in Troubleshooting Table464
- Phenomena Looking Like Troubles and Troubleshooting Nos466
- Wiring Table for Connector Pin Numbers469
- T-Adapter Box and T-Adapter Table502
- Troubleshooting by Failure Code, Part 1506
  - Failure Code [989L00] Engine Controller Lock Caution 1508
  - Failure Code [989M00] Engine Controller Lock Caution 2508
  - Failure Code [989N00] Engine Controller Lock Caution 3509
  - Failure Code [AB00KE] Charge Voltage Low511
  - Troubleshooting511
  - Failure Code [B@BAZG] Eng Oil Press. Low513
  - Failure Code [B@BAZK] Eng Oil Level Low513
  - Failure Code [B@BCNS] Eng Coolant Overheat514
  - Failure Code [B@HANS] Hydr Oil Overheat514
  - Failure Code [CA111] ECM Critical Internal Failure515
  - Failure Code [CA115] Eng. Ne and Bkup Speed Sensor Error518
  - Failure Code [CA122] Charge Air Press Sensor High Error519
  - Failure Code [CA123] Charge Air Press Sensor Low Error521
  - Failure Code [CA131] Throttle Sensor High Error523
  - Failure Code [CA132] Throttle Sensor Low Error525
  - Failure Code [CA144] Coolant Temp. Sensor High Error526
  - Failure Code [CA145] Coolant Temp. Sensor Low Error527
  - Pc138Us, Uslc-8527
  - Failure Code [CA153] Charge Air Temp. Sensor High Error528
  - Failure Code [CA154] Charge Air Temp. Sensor Low Error529
  - Failure Code [CA187] Sensor Sup. 2 Volt. Low Error529
  - Failure Code [CA221] Ambient Air Press. Sensor High Error531
  - Failure Code [CA222] Ambient Air Press. Sensor Low Error533
  - Failure Code [CA227] Sensor Sup. 2 Volt. High Error535
  - Failure Code [CA234] Eng. Overspeed537
  - Failure Code [CA238] Ne Speed Sensor Sup. Volt. Error539
  - Failure Code [CA271] IMV/PCV1 Short Error541
  - Failure Code [CA272] IMV/PCV1 Open Error542
  - Failure Code [CA322] Injector #1 (L #1) System Open/Short Error543
  - Failure Code [CA324] Injector #3 (L #3) System Open/Short Error545
  - Failure Code [CA331] Injector #2 (L #2) System Open/Short Error547
  - Failure Code [CA332] Injector #4 (L #4) System Open/Short Error549
- Troubleshooting by Failure Code, Part 2552
  - Failure Code [CA351] Inj. Drive Circuit Error554
  - Troubleshooting554
- Failure Code [CA352] Sensor Sup. 1 Volt. Low Error557
- Failure Code [CA386] Sensor Sup. 1 Volt. High Error559
- Failure Code [CA435] Abnormality in Engine Oil Pressure Switch561
- Failure Code [CA441] Battery Voltage Low Error562
- Failure Code [CA442] Battery Voltage High Error562
- Failure Code [CA449] Rail Press. very High Error563
- Failure Code [CA451] Rail Press. Sensor High Error565
- Failure Code [CA452] Rail Press. Sensor Low Error567
- Failure Code [CA553] Rail Press. High Error567
- Failure Code [CA559] Rail Press. Low Error568
- Failure Code [CA689] Eng. Ne Speed Sensor Error571
- Failure Code [CA731] Eng. Bkup Speed Sensor Phase Error573
- Failure Code [CA757] All Persistent Data Lost Error573
- Failure Code [CA778] Eng. Bkup Speed Sensor Error575
- Failure Code [CA1633] KOMNET Datalink Timeout Error577
- Pc138Us, Uslc-8577
- Failure Code [CA2185] Throttle Sens. Sup. Volt. High Error579
- Failure Code [CA2186] Throttle Sens. Sup. Volt. Low Error581
- Failure Code [CA2249] Rail Press. very Low Error581
- Failure Code [CA2311] Abnormality in IMV Solenoid582
- Failure Code [D110KB] Battery Relay Drive Short583
- Failure Code [D19JKZ] Personal Code Relay Abnormality585
- Failure Code [D862KA] GPS Antenna Discon587
- Failure Code [DA22KK] Pump Solenoid Power Low Error589
- Failure Code [DA25KP] 5V Sensor 1 Power Abnormality591
- Failure Code [DA26KP] 5V Sensor 2 Power Abnormality594
Troubleshooting by Failure Code, Part 3596
- Failure Code [DA2RMC] CAN Discon (Pump Controller Detected)599
- Failure Code [DAF8KB] Short Circuit in Camera Power Supply601
- Failure Code [DAFGMC] GPS Module Error603
- Failure Code [DAFRMC] CAN Discon (Monitor Detected)605
- Failure Code [DGH2KB] Hydr Oil Sensor Short607
- Failure Code [DHPAMA] Pump Press Sensor Abnormality609
- Failure Code [DHSFMA] Travel Left Forward PPC Press Sensor Abnormality611
- Failure Code [DHSGMA] Travel Right Forward PPC Press Sensor Abnormality613
- Failure Code [DHSHMA] Travel Left Reverse PPC Press Sensor Abnormality615
- Failure Code [DHSJMA] Travel Right Reverse PPC Press Sensor Abnormality617
- Failure Code [DHSKMA] Blade Raise PPC Press Sensor Abnormality619
- Failure Code [DHSLMA] Blade Lower PPC Press Sensor Abnormality621
- Failure Code [DHX1MA] Overload Sensor Abnormality (Analog)623
- Failure Code [DV20KB] Travel Alarm S/C624
- Failure Code [DW43KA] Travel Speed Sol Discon625
- Failure Code [DW43KB] Travel Speed Sol Short626
- Failure Code [DW45KA] Swing Brake Sol Discon627
- Failure Code [DW45KB] Swing Brake Sol Short629
- Failure Code [DW91KA] Travel Junction Sol Discon631
- Failure Code [DW91KB] Travel Junction Sol Short632
- Failure Code [DWJ0KA] Merge-Divider Sol Discon633
- Failure Code [DWJ0KB] Merge-Divider Sol Short634
Troubleshooting by Failure Code, Part 4636
- Failure Code [DXA8KA] PC-EPC Sol Discon637
- Failure Code [DXA8KB] PC-EPC Sol Short639
- Failure Code [DXE4KA] Service Current EPC Discon641
- Failure Code [DXE4KB] Service Current EPC Short642
- Failure Code [DY20KA] Wiper Working Abnormality643
- Failure Code [DY20MA] Wiper Parking Abnormality645
- Failure Code [DY2CKA] Washer Drive Discon647
- Failure Code [DY2CKB] Washer Drive Short649
Failure Code [DY2DKB] Wiper Drive (For) Short651
Failure Code [DY2EKB] Wiper Drive (Rev) Short653
Before Carrying out Troubleshooting of Electrical System658
Information in Troubleshooting Table660
When Starting Switch Turned ON, Machine Monitor Displays Nothing661
When Starting Switch Turned on (before Starting Engine), Basic Check Item Lights up663
Engine Does Not Start (Engine Does Not Turn)664
Preheater Does Not Operate667
Automatic Warm-Up System Does Not Operate (in Cold Season)669
All Work Equipment, Swing, and Travel Mechanism Do Not Move or Cannot be Locked670
Precaution Lights up While Engine Is Running672
Emergency Stop Item Lights up While Engine Is Running675
Engine Coolant Temperature Gauge Does Not Indicate Normally676
Hydraulic Oil Temperature Gauge Does Not Indicate Normally677
Fuel Level Gauge Does Not Indicate Normally679
Contents of Display by Machine Monitor Are Different from Applicable Machine681
Function Switch Does Not Work681
Machine Monitor Does Not Display some Items681
Auto-Decelerator Does Not Operate Normally682
Working Mode Does Not Change683
Travel Speed Does Not Change684
Alarm Buzzer Cannot be Stopped685
Windshield Wiper and Window Washer Do Not Operate686
Swing Holding Brake Does Not Operate Normally689
Travel Alarm Does Not Sound or Does Not Stop Sounding691
Air Conditioner Does Not Operate Normally (Including Air Conditioner Abnormality Record)692
Machine Monitor Cannot be Set in Service Mode704
While Starting Switch Is in off Position, Service Meter Is Not Displayed704
Monitoring Function Does Not Display Lever Control Signal Normally705
KOMTRAX System Does Not Operate Normally721
Information Contained in Troubleshooting Table725
System Chart for Hydraulic and Mechanical Systems726
Speed or Power of All Work Equipment, Swing, and Travel Are Low728
Engine Speed Sharply Drops or Engine Stalls729
Abnormal Noise Is Heard from Around Hydraulic Pump730
No Work Equipment, Travel and Swing Move730
Fine Control Mode Does Not Function731
Speed or Power of Boom Is Low732
Speed or Power of Arm Is Low733
Speed or Power of Bucket Is Low734
Work Equipment Does Not Move in Its Single Operation735
Hydraulic Drift of Work Equipment Is Large736
Boom RAISE Speed Is Low in Compound Operation of Swing + Boom RAISE737
Time Lag of Work Equipment Is Large737
Work Equipment Loaded more Is Slower During Compound Operation737
Travel Speed Lowers Largely During Compound Operation of Work Equipment/Swing + Travel738
Machine Deviates During Travel739
Travel Speed Is Low740
Machine Cannot be Steered Easily or Steering Power Is Low741
Track Does Not Move (Only Either Side)742
Travel Speed Does Not Change or It Is Kept Low or High742
Machine Does Not Swing743
Swing Acceleration or Swing Speed Is Low744
Excessive Overrun When Stopping Swing745
When Upper Structure Stops Swinging, It Makes Large Shock746
- When Upper Structure Stops Swinging, It Makes Large Sound746
- Hydraulic Drift of Swing Is Large747
- Flow Rate in Attachment Circuit Cannot be Adjusted748
- Method of Using Troubleshooting Chart754
- Starting Performance Is Poor758
- Engine Does Not Start759
- Engine Does Not Pick up Smoothly762
- Engine Stops During Operations763
- Engine Does Not Rotate Smoothly764
- Engine Lacks Output (or Lacks Power)765
- Exhaust Smoke Is Black (Incomplete Combustion)766
- Oil Consumption Is Excessive (or Exhaust Smoke Is Blue)767
- Oil Becomes Contaminated Quickly768
- Fuel Consumption Is Excessive769
- Oil Is in Coolant (or Coolant Spurts Back or Coolant Level Goes Down)770
- Oil Pressure Drops771
- Oil Level Rises (Entry of Coolant or Fuel)772
- Coolant Temperature Becomes too High (Overheating)773
- Abnormal Noise Is Made774
- Vibration Is Excessive775
Disassembly and Assembly778
- How to Read this Manual778
- List of Adhesives780
- Special Tool List783
- Sketche of Special Tool787
- Removal and Installation of Fuel Supply Pump Assembly790
- Removal and Installation of Fuel Injector Assembly792
- Removal and Installation of Front Oil Seal795
- Removal and Installation of Rear Oil Seal797
- Removal and Installation of Cylinder Head Assembly800
- Removal and Installation of Radiator Assembly807
- Removal and Installation of Aftercooler Assembly809
- Removal and Installation of Work Equipment Oil Cooler Assembly811
- Removal and Installation of Engine and Work Equipment Pump Assembly814
- Removal and Installation of Fuel Tank Assembly819
- Removal and Installation of Travel Motor and Final Drive Assembly824
- Removal and Installation of Swing Motor and Swing Machinery Assembly826
- Disassembly and Assembly of Swing Machinery Assembly828
- Removal and Installation of Swing Circle Assembly834
- Disassembly and Assembly of Track Roller838
- Disassembly and Assembly of Idler Assembly841
- Disassembly and Assembly of Recoil Spring844
- Removal and Installation of of Track Shoe Assembly847
- Removal and Installation of Sprocket849
- Removal and Installation of Revolving Frame Assembly850
- Removal and Installation of Counterweight Assembly (Machine Without Add-On Weight)852
- Removal and Installation of Counterweight Assembly (Machine with Add-On Weight)854
- Removal and Installation of Center Swivel Joint Assembly858
- Disassembly and Assembly of Center Swivel Joint Assembly860
  - Removal and Installation of Hydraulic Tank Assembly861
  - Removal and Installation of Hydraulic Pump Assembly864
  - Removal and Installation of Control Valve Assembly868
  - Disassembly and Assembly of Control Valve Assembly873
  - Disassembly and Assembly of Work Equipment PPC Valve Assembly883
  - Disassembly and Assembly of Travel PPC Valve Assembly886
  - Disassembly and Assembly of Hydraulic Cylinder Assembly888
  - Removal and Installation of Work Equipment Assembly896
  - Removal and Installation of Operator Cab Assembly902
  - Removal and Installation of Operator's Cab Glass (Stuck Glass)904
  - Removal and Installation of Front Window Assembly913
  - Removal and Installation of Floor Frame Assembly914
  - Removal and Installation of Air Compressor Assembly924
  - Removal and Installation of Air Conditioner Condenser925
  - Removal and Installation of Air Compressor Unit Assembly926
  - Removal and Installation of Machine Monitor Assembly929
  - Removal and Installation of Pump Controller Assembly930
  - Removal and Installation of Engine Controller Assembly931
  - Removal and Installation of KOMTRAX Communications Module932
Diagrams and Drawings935
- Hydraulic Circuit Diagram935
- Electrical Circuit Diagram941
- Connectors Table and Arrangement Drawing941

Brand	Komatsu
Model	Galeo PC138US-8
Category	Excavators
Language	English

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