Pc138uslc-10 Shop Manual

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
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
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
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
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
General information on testing and adjusting................................................................................. 30-3
Tools for testing and adjusting ............................................................................................... 30-3
Sketch of tools for testing and adjusting ................................................................................. 30-6
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
Testing and adjusting track shoe tension .............................................................................. 30-33
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
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
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
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 [CA343] ECM Critical Internal Failure.............................................................. 40-160
Failure code [CA351] Injectors Drive Circuit Error ............................................................... 40-161
Failure code [CA356] Mass Air Flow Sensor High Error ....................................................... 40-164
Failure code [CA357] Mass Air Flow Sensor Low Error ........................................................ 40-166
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 [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
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 [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
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
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
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
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
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
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
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
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
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 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 mount and cab tipping stopper ..................................................................................... 60-54
00-10 PC138USLC-10
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
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
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
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
PC138USLC-10 00-11
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
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
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
• 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
• 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
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
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
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
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
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
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
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
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
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
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
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)
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
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
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
Type 2 (ALL-C930-925-P-02-A)
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
Type 3 (ALL-C930-925-P-03-A)
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
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
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
• 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
• 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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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.
Cooling system for water leakage.
Fuel system for fuel leakage.
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
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
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
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
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

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.

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
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
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
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

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

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

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
Abbreviation Actual word spelled out

T/C Torque Converter
T/M Transmission
00-58 PC138USLC-10
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
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
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
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
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
00-64 PC138USLC-10
SHOP MANUAL
HYDRAULIC EXCAVATOR
PC138USLC-10
Model Serial Number

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
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
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
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
Type —
type type
Stroke mm 1,175 1,175
Bucket cylinder
Type —
type type
Stroke mm 885 885
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
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
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
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
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

10
10 Structure and function

3 10 Structure and function
PC138USLC-10 10-1
Table of contents

10 Structure and function ................................................................................................................... 10-1
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
Track frame ....................................................................................................................... 10-30
Idler cushion ...................................................................................................................... 10-31
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 mount and cab tipping stopper ................................................................................... 10-179
ROPS cab ....................................................................................................................... 10-180
Electrical control system ................................................................................................... 10-182
Machine monitor system ................................................................................................... 10-214
KOMTRAX system ........................................................................................................... 10-235
Sensor ............................................................................................................................ 10-252
10-2 PC138USLC-10
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
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
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
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
VFT
1. VFT motor
2. Flange bolt
3. Bracket
4. Thrust sleeve
PC138USLC-10 10-7
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
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
EGR system piping drawing
EGR system piping drawing (ENG95-A9J0-04D-K-00-A)
a EGR: Abbreviation for Exhaust Gas Recirculation

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
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
EGR system circuit diagram
EGR system circuit diagram (ENG95-A9J0-052-K-00-A)
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
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
EGR valve
EGR valve (ENG95-A9K1-041-K-00-A)

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

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
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
KCCV layout drawing
KCCV layout drawing (ENG95-A180-04D-K-00-A)
a KCCV: Abbreviation for KOMATSU Closed Crankcase Ventilation

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
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
KCCV ventilator
KCCV ventilator (ENG95-A18H-041-K-00-A)
a KCCV: Abbreviation for KOMATSU Closed Crankcase Ventilation

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
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
KDOC muffler
KDOC muffler (ENG95-A9H2-041-K-00-A)
a KDOC: Abbreviation for Komatsu Diesel Oxidation Catalyst

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
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
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
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
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
Power train system
12.Center swivel joint

13.Swing machinery
14.Swing circle
10-26 PC138USLC-10
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
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
Swing machinery
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
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
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
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
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

*2: Machines ready for installation of attachment
*3: Option
PC138USLC-10 10-33
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)

*2: Machines ready for installation of attachment
10-34 PC138USLC-10
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
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
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
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
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
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
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
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
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
Main pump
12.No. 1 check valve

13.LS valve
14.PC valve
10-44 PC138USLC-10
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
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
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
Main pump
10-48 PC138USLC-10
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
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
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
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
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
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
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
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
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
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
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
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
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
Main pump
10-62 PC138USLC-10
Main pump
PC-EPC valve (D65-C2E5-041-P-00-A)

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
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
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
Main pump
Check valve (PC138-C2YA-041-K-00-A)
PA1: 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
Main pump
Shuttle valve (PC138-C2YB-041-K-00-A)

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
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
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
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
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
Control valve
PC138USLC-10 10-71
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
Control valve
PC138USLC-10 10-73
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
Control valve
PC138USLC-10 10-75
Control valve
1. LS separation valve
2. LS bypass circuit filter
Swing valve
3. Pressure compensation valve (*1)
4. Spool
Blade valve
7. Suction safety valve
8. Suction valve
9. Spool
Left travel valve

12. Suction valve
13. Suction valve
14. Spool
16. LS check valve
17. LS bypass check valve

10-76 PC138USLC-10
Control valve
PC138USLC-10 10-77
Control valve
Right travel valve

2. Suction valve
3. Suction valve
4. Spool
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
15. Suction valve
16. Hydraulic drift prevention valve
17. Suction valve
18. Spool

10-78 PC138USLC-10
Control valve
PC138USLC-10 10-79
Control valve
Arm valve
2. Suction valve
3. Suction valve
4. Spool
6. Regeneration valve
Bucket valve
8. Suction valve
9. Suction valve
10. Spool
Service valve
15. Spool

18. Centralized safety valve filter
19. Pressure relief plug

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
Control valve
Hydraulic circuit diagram and names of valves (PC138-C030-054-K-00-A)
PC138USLC-10 10-81
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
Set pressure: 36.8 MPa {375 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}
24.Main relief valve
25.Unload valve
10-82 PC138USLC-10
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
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
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
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.
from each other, and LS circuits (LS1) and (LS2) are also divided.
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
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).
from each other, and LS circuits (LS1) and (LS2) are also divided.
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
Control valve
Introduction of LS pressure (PC138-C2A4-041-K-00-A)
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
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
Control valve
LS bypass plug (PC138-PNSH-041-K-00-A)
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
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
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
Control valve
Pressure compensation valve (PC138-L6D0-040-K-00-A)
PC138USLC-10 10-93
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
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
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
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
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
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
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
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
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
Control valve
LS separation valve (PC138-J6PA-041-K-00-A)
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
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
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
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
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
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
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
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
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
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
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
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
Swing motor
12.Valve plate
13.Center shaft
14.Center spring
15.Shuttle valve
16.Check valve
17.Swing modulating relief valve
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
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
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
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
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
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.
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
Swing motor
PC138USLC-10 10-121
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
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
Swing motor
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
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
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
Travel motor
26.Cylinder
27.Timing plate
28.Regulator valve
29.Check valve
30.Piston
PC138USLC-10 10-127
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
Travel motor
Operation of travel motor (PC138-C400-044-K-00-A)

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

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

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
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
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
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
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
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
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
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
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)
R.H. work equipment control lever

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
10-138 PC138USLC-10
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
• 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 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
• 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
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
10-142 PC138USLC-10
Travel PPC valve
Travel PPC valve (PC-C6V0-041-K-00-A)

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)
PC138USLC-10 10-143
Travel PPC valve
1. Plate
2. Case
3. Piston
4. Seal
5. Spool
6. Damper
10-144 PC138USLC-10
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 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
• 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
Travel PPC valve
(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
• 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
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
Travel PPC valve
10-148 PC138USLC-10
Blade PPC valve
Blade PPC valve (PC138-LTJ0-041-K-00-A)

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

P1: Blade valve
P2: Blade valve
1. Spool
PC138USLC-10 10-149
Blade PPC valve
2. Piston
3. Lever
4. Plate
5. Retainer
6. Body
7. Filter
10-150 PC138USLC-10
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 For explanation of operation, see "Work equipment and swing PPC valve".
PC138USLC-10 10-151
10-152 PC138USLC-10

P1: To control valve (service valve 1 port)
P2: To control valve (service valve 1 port)
1. Spool
2. Piston
3. Lever
4. Plate
5. Retainer
6. Body
7. EPC valve
PC138USLC-10 10-153
EPC valve (PC200_10-PL2B-041-K-00-A)


C: To PPC valve (R.H. attachment)
1. Valve body
2. Spool
3. Spring
4. Coil
5. Plunger
6. Push pin
7. Connector
10-154 PC138USLC-10
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
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
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
10-158 PC138USLC-10
Solenoid valve
Solenoid valve (PC138-PQPT-041-K-00-A)
PC138USLC-10 10-159
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)]
ACC: To PPC accumulator

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
Solenoid valve
For machine(s) ready for installation of attachment
PC138USLC-10 10-161
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)
ACC: To PPC accumulator

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
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
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
Attachment circuit selector valve (for low pressure
circuit)
Attachment circuit selector valve (for low pressure circuit) (PC138-PQJ3-041-K-00-A)
P1: From attachment selector solenoid valve

V: To control valve attachment 1 port
ATT: To attachment
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
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
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
Attachment circuit selector valve (for high pressure
circuit)
Attachment circuit selector valve (for high pressure circuit) (PC138-PQJ5-041-K-00-A)
P: From attachment selector solenoid valve

ACC: To accumulator
ATT: To attachment
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
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
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
Center swivel joint
Center swivel joint (PC138-J8E0-001-K-00-A)
Blade specifications (PC138-J8E0-041-K-01-A)
PC138USLC-10 10-171
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
PPC circuit accumulator
PPC circuit accumulator (PC138-PL40-041-K-00-A)
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
Attachment circuit accumulator (for low pressure circuit)
Attachment circuit accumulator (for low pressure circuit) (PC138-PL40-041-K-01-A)
1. Cap
2. Core
3. Ring
4. Lid
5. Bladder
6. Shell
Specifications (PC138-PL40-030-K-01-A)

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
Attachment circuit accumulator (for high pressure
circuit)
Attachment circuit accumulator (for high pressure circuit) (PC138-PL40-041-K-02-A)
1. Cap
2. Core
3. Lock nut
4. Gas port
5. Bladder
6. Shell
Specifications (PC138-PL40-030-K-00-A)

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
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
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
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
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
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
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
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
PC138USLC-10 10-183
10-184 PC138USLC-10
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
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
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
Engine and pump combined control function (PC138-C3W0-042-K-00-A)

2. Battery
3. Battery relay
4. Fusible link
5. Fuse box
6. Resister for PC-EPC valve
7. Pump controller
9. Machine monitor
10. Emergency pump drive switch
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
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
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
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
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
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
Auto-deceleration function (PC138-AF60-042-K-00-A)
1. Pump controller
3. Machine monitor
5. Fuel supply pump
6. Various sensors
9. Main pump
10. Control 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
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
Engine automatic warm-up function (PC138-AP13-042-K-00-A)

2. Battery
3. Battery relay
4. Fusible link
5. Fuse box
7. Pump controller
9. Machine monitor
13. Various sensors
14. Hydraulic oil temperature sensor
15. Main pump
15a. Servo
15b. LS valve
15c. PC valve
16. Control valve
17. PC-EPC valve
Input/output signal
a. CAN signal
PC138USLC-10 10-195
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
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
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).

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).

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
Hydraulic oil temperature:
torque control signal. satisfied, state before
Min. 100°C
operation is restored
Travel judgment: Any (automatic restoration).
position

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
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

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
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
Swing control function (PC138-JA01-042-K-00-A)

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
11. Main pump
12. Control valve
13. Swing motor
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
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
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
Travel control function (PC138-C7H1-042-K-00-A)
1. Pump controller
3. Machine monitor
5. Fuel supply pump
6. Various sensors
7. Oil pressure sensor of pump
9. Travel alarm
10. Main pump
11. Control valve
11c. Travel junction valve
12. Travel motor
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
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
• 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
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
PPC lock function (PC138-PX16-042-K-00-A)

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
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
System operating lamp function (PC138-AW1Q-042-K-00-A)

2. Battery
3. System operating lamp
4. Machine monitor
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
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.

2. System operating lamp
(O): OFF position

(I): ON position
10-210 PC138USLC-10
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
Oil flow adjuster function for attachment (PC138-PT24-042-K-00-A)

2. Battery
3. Battery relay
4. Fusible link
5. Fuse box
7. Pump controller
9. Machine monitor
13. Various sensors
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
10-212 PC138USLC-10
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
Machine monitor system
Machine monitor system (PC-Q170-042-K-01-A)
1. Machine monitor
2. Battery
3. Pump 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
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
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
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]
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
070-20P [CN-CM03]
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

13 (*1) —
14 (*1) —
15 (*1) —
16 (*1) —
17 (*1) —
18 (*1) —
19 (*1) —
20 (*1) —
070-8P [CN-CM04]
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) —
PC138USLC-10 10-217
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
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
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.
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
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
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.
Min. 102°C (Red) L02 changes depending
Min. 20ºC, Lights up on the temperature
— detected.
(*1) below 102ºC (Blue)
Hydraulic oil at 105°C or higher.
temperature • If background color is
Lights up
Below 20°C — white, warm up
(White)
hydraulic
components.
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
Description
Monitor
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.
(Red) L04 and L03
“L03“ is detected in engine
State of engine detected system.
system • When the
detected
sounds.
(Red) L04 and L03
“L03“ is detected in hydraulic
State of detected system.
hydraulic system • When the
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
Description
Monitor
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
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
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
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
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.
[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
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
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
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
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
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
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
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
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
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) -
12 (*1) -
13 (*1) -
14 External start signal Input/Output
15 System operation lamp Output
16 (*1) -
17 (*1) -
18 (*1) -
070-12P [CN-CK02]
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
KOMTRAX system

9 (*1) -
10 (*1) -
11 Starting switch (C) Input
12 (*1) -
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
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
KOMTRAX system

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) —
37 NE (crankshaft) speed sensor (-) C
38 (*1) —
39 (*1) —
40 SCV (-) C
41 (*1) —
42 (*1) —
43 (*1) —
44 Injector #3 (+) D
47 (*1) —
49 (*1) —
50 (*1) —
51 (*1) —
52 (*1) —
53 (*1) —
54 Injector #3 (-) C
57 (*1) —
59 GND C
DRC26-60P(2)[ECM J2(CN-CE02)]
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
KOMTRAX system

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) —
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
KOMTRAX system

57 (*1) —
58 (*1) —
59 (*1) —
60 (*1) —
DRC26-60P(3)[CN-CE03]
1 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) —
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
43 GND C
44 (*1) —
PC138USLC-10 10-241
KOMTRAX system

45 (*1) —
46 (*1) —
47 (*1) —
48 (*1) —
49 Idle validation signal 1 B
50 Idle validation signal 2 B
51 Throttle signal B
53 (*1) —
54 (*1) —
55 (*1) —
56 (*1) —
57 (*1) —
58 (*1) —
59 (*1) —
60 (*1) —
10-242 PC138USLC-10
KOMTRAX system
Pump controller (PC-C3V1-041-K-00-A)
PC138USLC-10 10-243
KOMTRAX system
Input and output signals of pump controller (PC138-C3V1-03C-K-00-A)

AMP-81P [CN-CP01]
2 Continuous power supply return Input
3 Window washer Output
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) —
44 (*1) —
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
KOMTRAX system

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
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
81 (*1) —
AMP-40P [CN-CP02]
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
KOMTRAX system

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
119 Wiper motor (+) Output
10-246 PC138USLC-10
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
KOMTRAX system
Resister for PC-EPC valve (PC138-C3VR-041-K-00-A)

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
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
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
KOMTRAX system
PPC oil pressure switch (PC-E610-041-P-00-A)
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
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
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
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
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
Sensor
VFT motor (with position sensor) (ENG95-AA56-041-K-00-A)
a VFT: Abbreviation for Variable Flow Turbocharger

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
Sensor
EGR valve (with position sensor) (ENG95-AA57-041-K-00-A)

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
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
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
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
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
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.
10-262 PC138USLC-10
Sensor
PPC oil pressure sensor (PC-E720-041-P-00-A)
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.
PC138USLC-10 10-263
10-264 PC138USLC-10
SHOP MANUAL
HYDRAULIC EXCAVATOR
PC138USLC-10
Model Serial Number

10
20 Standard value tables

4 20 Standard value tables
PC138USLC-10 20-1
Table of contents

20 Standard value tables.................................................................................................................... 20-1
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
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
Standard value table for machine
Standard value table for machine (PC138_10-0000-033-K-00-A)

Engine speed
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

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
Control effort of control lever

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
Oil pressure
for new machine
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
Swing
for new machine
• For measuring posture, see
"Swing 1"
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
"Swing 1"
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
"Swing 2"
• Engine: Stopped
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
Leakage from swing motor l/min Max. 3 Max. 6
to 55°C
• Relieve swing circuit
PC138USLC-10 20-7
Traveling
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
"Travel 2" and "Travel 3"
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
"Travel 4"
• Engine stopped
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
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
Work equipment
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
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
• 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
• 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
• 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

for new machine
"Work equipment 6"
• Engine low idle
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
"Work equipment 7"
• Engine low idle
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.
"Work equipment 8"
• Engine low idle
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
"Work equipment 9"
• Engine low idle
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

to 55°C cc/min
Center swivel joint Max. 9 Max. 50
• Relieve circuit to be
measured
20-10 PC138USLC-10
Pump performance
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
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
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
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
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
Work equipment 9: Blade time lag
20-16 PC138USLC-10
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
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.
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
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
Engine control (D37-AG10-033-K-00-A)

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
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
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
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
90°C 230 to 250 z
130°C 80 to 90 z
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
180 to 185 z
100°C
20-18 PC138USLC-10

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
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)
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
between J2 (21) and (44)
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
between CCV (3) and (2)
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
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
Machine control (PC138-E000-033-P-00-A)

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
Swing holding brake 2. Disconnect connector V03, and connect T-adapter to male side.
Resistance
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
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
Merge-divider (main) 2. Disconnect connector V05, and connect T-adapter to male side.
Resistance
2. Disconnect connector V11, and connect T-adapter to male side.
PC-EPC solenoid
Resistance
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
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
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
Travel Fwd LH PPC 2. Insert T-adapter into connector P10.
Pressure sensor 3. Turn starting switch to ON position.
Travel Fwd RH PPC 2. Insert T-adapter into connector P09.
Travel Rev LH PPC 2. Insert T-adapter into connector P27.
20-20 PC138USLC-10

Travel Rev RH PPC 2. Connect T-adapter to connector P26.
Blade RAISE PPC 2. Insert T-adapter into connector P28
pressure sensor 3. Turn starting switch to ON position.
Blade Lower PPC 2. Insert T-adapter into connector P11.
pressure sensor 3. Turn starting switch to ON position.
PC138USLC-10 20-21
Machine monitor (PC138-Q170-033-K-00-A)

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
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.
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

10
30 Testing and adjusting

5 30 Testing and adjusting
PC138USLC-10 30-1
Table of contents

30 Testing and adjusting .................................................................................................................... 30-1
General information on testing and adjusting................................................................................. 30-3
Tools for testing and adjusting ............................................................................................... 30-3
Sketch of tools for testing and adjusting ................................................................................. 30-6
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
Testing and adjusting track shoe tension .............................................................................. 30-33
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
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
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
{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
Q'ty
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)
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
Testing oil pressure of 1 {25, 60, 400, 600 kg/cm2}
K
control circuit Pressure gauge: 60 MPa {600
2 799-401-3100 Adapter 1 Size 02
Testing and adjusting 1 {25, 60, 400, 600 kg/cm2}
oil pressure in pump L Pressure gauge: 60 MPa {600
PC control circuit
799-101-5220 Nipple 4 Size: 10 x 1.25 mm
2
07002-11023 O-ring 4
1 {25, 60, 400, 600 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
Q'ty
bol
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
Testing PPC valve 1 {25, 60, 400, 600 kg/cm2}
output pressure P
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
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
M5: Sensor adapter
-: Socket
PC138USLC-10 30-7
Engine and cooling system
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.
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.
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
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
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

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
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
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

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
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
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
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

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
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

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
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

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
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 Be careful not to touch any hot parts when

installing or removing the testing tools.
30-18 PC138USLC-10
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
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,
3 Joint bolt:
3.9 to 6.9 Nm {0.4 to 0.7 kgm}
30-20 PC138USLC-10
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
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
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
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.

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.
perform inspection again from Step 1.
4. Start the engine and keep it running at low idle.
6. Start the engine and keep it running at high idle.
8. Run the engine at high idle, then load it.
a Relieve the arm circuit at the IN stroke end.
PC138USLC-10 30-23
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
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
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

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
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.
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
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
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
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
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
Power train
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
Undercarriage and frame
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
Hydraulic system
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
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
1
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.
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
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
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.
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
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
Hydraulic system
Testing oil pressure of control circuit (PC138-C010-360-K-00-A)
a Testing tools
Sym-
Part No. Part name
bol
1
K 790-261-1204 Digital hydraulic tester
2 799-401-3100 Adapter (size: 02)

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
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
1
L
799-101-5220 Nipple (10 x 1.25 mm)
2
07002-11023 O-ring

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.
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
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".
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}
tools and restore the machine.
2) Install nipple L2, and connect it to oil
pressure gauge [1].
30-40 PC138USLC-10
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
• 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
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
1
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

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.
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
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
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).
• (2): LS pressure pickup plug

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
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.

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)
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
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
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
Hydraulic system
4. After finishing the adjustment, check the LS

differential pressure again according to the
above procedure.
30-46 PC138USLC-10
Hydraulic system
Testing outlet pressure of solenoid valve (PC138-PQPT-360-K-00-A)
a Testing tools
Sym-
Part No. Part name
bol
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.
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,
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].
kg/cm2}.
a The figure shows the testing tools installed to
outlet hose (1) of the PPC lock solenoid
valve.
PC138USLC-10 30-47
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.
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].
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
1
P 790-261-1204 Digital hydraulic tester
2 799-401-3100 Adapter (size: 02)

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.
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
Hydraulic system
6. After finishing the test, remove the testing tools,

PC138USLC-10 30-49
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
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 defective.
Testing (PC-L410-360-K-00-A) • If the lowering speed does not change at
this time, the control valve is defective.
1. Checking boom cylinder and bucket cylinder
a Operate the control lever with the engine
1) Set the work equipment in the same posture
starting switch in the ON position.
as when measuring hydraulic drift, and stop
the engine. a If there is no more pressure in the
accumulator, run the engine for
a Put a weight equivalent to the rated load
approximately 10 seconds to charge the
or fill the bucket with the earth and sand.
accumulator.
[Reference] In case of the hydraulic drift is
caused by defective cylinder packing, the
reason why the drift speed becomes faster by
above mentioned operation is as follows:
1) If the work equipment is set to the above
posture (where the work equipment holding
pressure is applied to the bottom side), the
oil leaks from the bottom side to the head
side. The volume on the head side is less
than that on the bottom side by the volume of
the rod, so the pressure in the head side is
increased by the oil flowing in from the
bottom side.
2) When testing the boom cylinder, set the 2) As the inner pressure in the head side is
boom control lever to the RAISE position. increased, it is balanced with the pressure in
When testing the bucket cylinder, set the the bottom side at a certain level (which
bucket control lever to the CURL position. depends on the leak quantity), and the
• If the lowering speed is increased at this lowering speed is reduced.
time, the cylinder seal is defective. 3) If the circuit on the head side is opened to
• If the lowering speed does not change at the drain circuit by the above operation of the
this time, the control valve is defective. lever (the bottom side is closed by the check
a Operate the control lever with the engine valve at this time), the oil in the head side
starting switch in the ON position. flows in the drain circuit. As a result, the
pressure is in balanced and the lowering
a If there is no more pressure in the speed is increased.
accumulator, run the engine for 3. Testing PPC valve
approximately 10 seconds to charge the Measure the hydraulic drift of the work
accumulator. equipment when the work equipment lock lever
2. Checking arm cylinder is in the LOCK and FREE positions with the
1) Move the arm cylinder to about 100 mm accumulator charged fully.
before the IN stroke end and stop the engine.
a Operate the control lever with the engine
starting switch in the ON position.
a If there is no more pressure in the
accumulator, run the engine for
approximately 10 seconds to charge the
accumulator.
a If there is any difference in the hydraulic drift
between LOCK and FREE positions, the
PPC valve is defective (some internal
defect).
PC138USLC-10 30-51
Hydraulic system
Testing and adjusting travel deviation (PC138-0000-360-K-00-A)
Testing (PC138-0000-347-K-00-A)
1. Start the engine, increase the hydraulic oil

temperature to the operating range, and set the
machine in the traveling posture.
a To set in the traveling posture, extend the
bucket cylinder and arm cylinder fully and
hold the boom angle at 45 deg.
2. Set the working mode in P-mode and the travel
speed in Lo.
3. Run the engine at high idle and measure travel
deviation (a) in travel of 20 m after running up 10
m.
a Install oil pressure gauge and check that
discharge pressures P1 and P2 of the
hydraulic pump are even.
30-52 PC138USLC-10
Hydraulic system
Adjusting (PC138-0000-270-K-00-A)
a If travel deviation occurs, you can correct it by a Before loosening the lock nut, make a
draining a part of the discharge of the pump of matchmark between the lock nut and pump
larger discharge into the tank circuit by using the case.
adjustment plug. (Take care that the travel • Loosening angle of lock nut: Approx. 90 to
speed, work equipment speed in combined 180 deg.
operations, and relief pressure may decrease
since the pump discharge decreases if you use
this method.)
a The following is the correction method
applicable when the machine deviates in the
same direction during both forward and reverse
travels (If the deviation direction in forward
direction and reverse direction differs, the cause
of failure may be something other than the
hydraulic pump. In this case, perform
troubleshooting).
a Only when it is 200 mm or less, travel deviation
can be corrected with this method.
3. Loosen plug (3) to correct the travel deviation.
k If the adjustment plug is loosened more than
• Quantity of adjustment per turn of plug: 150
the adjustment limit, high-pressure oil may
mm (reference)
spout out. Work with extreme care.
a The plug is fully tightened when the machine
k Lower the work equipment to the ground and is shipped. Adjust by the loosening angle
stop the engine. Operate the control levers from that condition.
several times to release the remaining
a If the plug is dragged when the lock nut is
pressure in the piping, and then loosen the
loosened, tighten the plug fully once, and
oil filler cap of the hydraulic tank slowly to
then adjust it.
release the internal pressure.
a The plug may be loosened up to 2 turns (720
1. Check the travel deviation direction and the deg.) from the fully tightened condition.
positions of adjustment plugs (1) and (2). 4. While fixing plug (3) with the hexagonal wrench,
• (1): Right deviation adjustment plug (pump tighten lock nut (4).
P1 ) 3 Lock nut:
• (2): Left deviation adjustment plug (pump P2)
2.9 to 4.9 Nm {0.3 to 0.5 kgm}
a Adjust by loosening only either plug. Do not
loosen the opposite one. a After tightening the lock nut, seal the hole of
it with a vinyl tape.
5. After the adjustment, check the travel deviation
again according to the above test procedure.
2. While fixing plug (3) with a hexagonal wrench

(width across flats: 4 mm), loosen lock nut (4).
a If the lock nut is sealed with a vinyl tape,
remove the tape to work.
PC138USLC-10 30-53
Hydraulic system
Testing oil leakage (PC200_10-C000-360-P-00-A)
a Testing tools k Release the remaining pressure in the

Sym- piping on the arm cylinder head side
Part No. Part name (however, operate the lever only in the
bol
Commercially Measuring cylinder arm IN direction). For details, see
T "Releasing remaining pressure in
available
hydraulic circuit".
a Measure the oil leakage under the following
condition. 2) Disconnect hose (2) on the cylinder head
side and block the hose side by using a plug.
Testing (PC138-C000-364-K-00-A) k Be careful not to disconnect the hose
1. Testing oil leakage of boom cylinder on the cylinder bottom side.
1) Set the boom cylinder at RAISE stroke end, a Use the following parts to block the hose.
and stop the engine. 07376-70628 (Plug #06)
k Release the remaining pressure in the

piping on the boom cylinder head side
(however, operate the lever only in the
boom RAISE direction). For details,
see "Releasing remaining pressure in
hydraulic circuit".
2) Disconnect hose (1) on the cylinder head
k Be careful not to disconnect the hose

on the cylinder bottom side.
a Use the following parts to block the hose. 3) Start and run the engine at high idle, and
07376-70422 (Plug #04) relieve the circuit by moving the arm IN.
k Be careful not to operate the lever to

"Arm OUT" side.
4) 30 seconds after starting relief, measure the
amount of leakage for 1 minute.
5) After finishing the test, restore the machine.
3. Testing oil leakage of bucket cylinder
1) Set the bucket cylinder at its extension stroke
end and stop the engine.

piping on the bucket cylinder head
3) Start the engine, run it at high idle, and side (however, operate the lever only
relieve the circuit by raising the boom. in the bucket CURL direction). For
details, see "Releasing remaining
pressure in hydraulic circuit".
k Be careful not to operate the lever to
"Boom LOWER" side. 2) Disconnect hose (3) on the cylinder head
amount of leakage for 1 minute.
k Take care not to disconnect the hose
2. Testing oil leakage of arm cylinder on the cylinder bottom side.
1) Set the arm cylinder at its extension stroke a Use the following parts to block the hose.
end, and stop the engine. 07376-70522 (Plug #05)
30-54 PC138USLC-10
Hydraulic system
k Insert pin [1] between the sprocket

and the track frame to securely lock
the track.
3) Start the engine, run it at high idle, and

relieve the circuit by moving the bucket in
CURL direction.
3) Disconnect drain hose (5) of the travel motor
k Be careful not to operate the lever to and block the hose side by using a plug.
"Bucket DUMP" side.
a Use the following parts to block the hose.
amount of leakage for 1 minute. 07376-70422 (Plug #04)
4. Testing oil leakage of swing motor
1) Disconnect drain hose (4) and block the
hose side by using a plug.
a Use the following parts to block the hose.
07376-70315 (Plug #03)
4) Start the engine, run it at high idle, relieve the

travel circuit, and measure the leakage at
this time.
k Before operating the travel lever,

check the pin position and locked
direction of the travel again.
2) Set the swing lock switch to ON position.
3) Start the engine, run it at high idle, relieve the k Make signs and perform checks
swing circuit, and measure the leakage at securely, since a mistake in lever
this time. operation can cause an accident.
a 30 seconds after starting relief, measure a 30 seconds after starting relief, measure
the amount of leakage for 1 minute. the amount of leakage for 1 minute.
a After measuring once, swing the upper a Measure several times, moving the motor
structure 180 deg. and measure again. a little each time (changing the relative
4) After finishing the test, restore the machine. position between the valve plate and
5. Testing oil leakage of travel motor cylinder and that between the cylinder
and piston).
1) Remove travel motor cover.
2) Start the engine, lock the travel mechanism,
and stop the engine.
PC138USLC-10 30-55
Hydraulic system
Bleeding air from hydraulic circuit (ALL-C000-001-P-04-A)
q: Execution of work
o: Go to next procedure
Air bleeding procedure and item
1 2 3 4 5 6
Bleeding air Checking oil
from Starting the Bleeding air Bleeding air Bleeding air
level and
hydraulic engine from cylinder from swing from travel
operating
pump motor motor
machine
• Replacement of
hydraulic oil q q
q q q q
• Cleaning (See note) (See note)
strainer
• Replacing
return oil filter q o o o q
element
• Replacing or
repairing
hydraulic pump q q q o o q
• Removal of
suction piping
• Replacing or
repairing
control valve
q q o o q
• Removal of
Detail of work, remarks
control valve
piping
• Replacement
or repair of
cylinder q q o o q
• Removal of
cylinder piping
• Replacing or
repairing swing
motor
q o q o q
• Removal of
swing motor
piping
• Replacing or
repairing travel
motor
q o o q q
• Removal of
travel motor
piping
• Replacing or
repairing swivel
joint q o o o q
• Installing swivel
joint piping
Note: Bleed air from the swing motor and travel motor only when the oil in the motor cases is drained.
Bleeding air (PC138-C000-231-P-02-A)
1. Bleeding air from hydraulic pump 2) When oil without air starts to flow out, tighten
air bleeder (1).
a Keep the oil filler cap of the hydraulic tank
loosened during air bleeding work of the 3 Air bleeder: 7.8 to 9.8 Nm {0.8 to
hydraulic pump. 1.0 kgm}
1) Loosen air bleeder (1), and check that oil
oozes out from the air bleeder.
30-56 PC138USLC-10
Hydraulic system
2. Starting engine 3) Start the engine, run it at low idle, and check
When starting the engine after performing step 1, that the oil flows out of elbow (2).
keep it at low idle for 10 minutes.
a If no oil flows out of the elbow, repeat 1).
a If the automatic warm-up operation starts 4) Connect hose (1) and restore the machine.
because of low engine coolant temperature, 5. Bleeding air from travel motor
stop the engine and cancel the warm-up 1) Remove the travel motor cover and
operation with the fuel control dial. (You can disconnect motor drain hose (3).
cancel the automatic warm-up operation by 2) Start the engine, and run it at low idle, and
keeping the fuel control dial at MAX position check that the oil flows out of nipple (4).
for more than 3 seconds with the starting 3) Connect hose (3) and restore the machine.
switch ON.)
3. Bleeding air from cylinders
a When a cylinder is replaced, perform this
operation before connecting the work
equipment. In particular, the boom cylinder
does not move to the LOWER stroke end
while it is installed to the work equipment.
1) Start the engine and run it at low idle for
approximately 5 minutes.
2) While running the engine at low idle, raise
and lower the boom 4 to 5 times.
a Stop the piston rod at approximately 100
mm before stroke end to avoid relieving. 6. Check of oil level and operation
3) While running the engine at high idle, 1) Start the engine, retract the arm and bucket
perform the operation in step 2). cylinders fully, lower the work equipment to
4) While running the engine at low idle, move the ground, and stop the engine.
the piston rod to the stroke end to relieve the
circuit.
5) Bleed air from the arm and bucket cylinders
according to steps 2) to 4).
4. Bleeding air from swing motor
1) Turn the swing lock switch to ON position
and run the engine at low idle for about 5
minute.
a Bleed air from the swing motor by using
the pressure in port S.
2) Disconnect hose (2) from the swing motor
and block the hose side by using a plug.
a Use the following parts to block the hose. 2) Check the oil level by sight gauge (5) at the
07379-70628 (Plug #06) rear of the hydraulic tank.
a If the oil level is below line L, add new oil.
PC138USLC-10 30-57
Hydraulic system
a Since the oil level varies according to the

oil temperature, use the followings as a
guide.
• When oil temperature is 50ºC: Halfway
between H and L
• When oil temperature is 30 to 70ºC:
Within range between H and L
30-58 PC138USLC-10
Cab and its attachments
Checking cab tipping stopper (ALL-K138-001-K-00-A)
a Check the cab tipping stopper according to the following procedure.

Checking (PC-K138-280-K-00-A)
1. Check the tightening torque of the mounting bolt

(2) of the lock plate (1).
3 Bolt (2):
98 to 123 Nm {10 to 12.5kgm}
[Reference]
• Note that the tightening torque for mounting bolt
(4) of cab tipping stopper (3) is different from that
of a common bolt 30 mm in diameter.
3 Bolt (4):
245 to 309 Nm {25 to 31.5kgm}
PC138USLC-10 30-59
Testing, cleaning and lubricating slide door rail and roller (PC138-K160-04D-K-00-A)
Testing (PC138-K160-360-K-01-A)
If the slide door does not open or close smoothly, check slide door rail (1) and rolling surface (2) for the roller
for dirt, mud, etc.
Cleaning method of door rail

Open and close the door and remove dirt and stain from slide door rail (1) and rolling surface (2) for the roller.
Lubrication method of door rail and roller

a Do not use high-viscosity lubricating oil.
Lubricating oil recommended by manufacturer: THREEBOND PANDO 18C
1. Spray lubricating oil sufficiently to bearing (4) and rotary shaft (5) of the slide door roller.
2. After spraying the lubricating oil, check that the door opens and closes smoothly.
30-60 PC138USLC-10
Adjusting mirrors (PC138-K810-360-K-00-A)
1. Mirror installing positions
3. Adjusting mirror (B)

a Adjust mirror (B) so that the operator can see
people standing on the ground within 1 m
2. Adjusting mirror (A) around the machine.
Adjust mirror (A) so that the operator can see a (D): 1 m
person in the rear left end of the machine.
a Install the mirror to the location shown in the
following figure.
(C): 42.5 mm
a Fix mirror stay (1) while the mirror is opened
to the maximum position.
a If the mirror does not move smoothly when
adjusting, loosen mirror fixing bolt (2) and
stay mounting bolt (3).
3 Tightening torque of bolt (2):
15.7 to 19.6 Nm {1.6 to 2.0 kgm}
a Install the mirror to the location shown in the

following figure.
(E): 360 mm
(F): 15°
(G): 16 mm
a If the mirror does not move smoothly when
adjusting, loosen mirror fixing bolt (4) and
stay mounting bolt (5).
3 Tightening torque of bolt (4):
3.0 to 3.5 Nm {0.31 to 0.35 kgm}
a Adjust the mirror so that the side of the

machine is reflected in it as shown in the
following figure.
PC138USLC-10 30-61
30-62 PC138USLC-10
Electrical system
Special functions of machine monitor (PC220-Q170-042-K-01-A)
PC138USLC-10 30-63
Electrical system
Upper part of machine monitor (display portion)

(a): Multi-information display
a 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 screen display of the machine
monitor may go off for a moment. This
phenomenon is not a failure, however.
Upper part of machine monitor (switch portion)

[F1]: F1 Function switch
a The function of each function switch is indicated
by the icon which is displayed just above the
function switch on the screen of the multi-
information display panel (a).
a If the icon for a function switch is not displayed,
that function switch is not working.
Lower part of machine monitor (switch portion)

[1]: Numeral 1 input switch/Auto-deceleration switch
[2]: Numeral 2 input switch/Working mode selector
switch
[3]: Numeral 3 input switch/Travel speed selector
switch
[4]: Numeral 4 input switch/Alarm buzzer stop
switch
[5]: Numeral 5 input switch/Wiper switch
[6]: Numeral 6 input switch/Window washer switch
[7]: Numeral 7 input switch/Air conditioner switch
Switch having no numerals : Air conditioner switch
a Each switch has the function indicated by the
icon on it and the function of inputting a numeral.
a The machine monitor automatically judges which
function of each switch is currently enabled
according to the screen display of the multi-
information display panel (a).
30-64 PC138USLC-10
Electrical system
Ordinary functions and special functions of machine monitor (PC138-Q170-042-K-00-A)
The machine monitor has the ordinary functions and special functions to display the various types of
information on the multi-display.
Some items are displayed automatically according to the internal setting of the machine monitor and the
others are displayed according to the operation of the switches.
1. Ordinary functions: Operator mode
The information items in this mode are displayed ordinarily. The operator can display and set them by
operating the switches. (Display and setting of some items need special operations of the switches.)
2. Special function: Service mode
The information items in this mode are not displayed ordinarily. Each technician can display them by
operating the switches specially.
This function is used for special setting, testing, adjusting, or troubleshooting.
Operator mode (outline) Service mode

A Display of KOMATSU logo(PAGE 30-68) Monitoring/ Pre-defined(PAGE 30-82)
A Password input(PAGE 30-68) Monitoring / Custom(PAGE 30-85)
Display of check of breaker mode(PAGE 30- Abnormality record (mechanical systems)
A 68) (PAGE 30-92)
Abnormality record (electrical systems)(PAGE
A Display of check before starting(PAGE 30-68) 30-92)
Display of warning after “Check before
A starting”(PAGE 30-69) Maintenance Record(PAGE 30-94)
Display of ending of maintenance interval
A (PAGE 30-69) Maintenance mode setting(PAGE 30-95)
Display of check of working mode and travel
A speed(PAGE 30-69) Phone number entry(PAGE 30-98)
A Display of standard screen(PAGE 30-69) Default (Key-on Mode)(PAGE 30-98)
A Display of end screen(PAGE 30-70) Default value setting (Unit)(PAGE 30-99)
Display of operation screen for engine Default (With/Without Attachment)(PAGE 30-
A shutdown secondary switch(PAGE 30-70) 100)
B Selection of auto-deceleration(PAGE 30-70) Default (Camera)(PAGE 30-101)
o Testing (Cylinder Cut-out operation)(PAGE 30-
B Selection of working mode(PAGE 30-70) (Special 102)
opera- Adjustment (Pump Absorption Torque)(PAGE
B Selecting travel speed(PAGE 30-71) tion) 30-103)
Adjustment (Attachment Flow Adjustment)
B Operation to stop alarm buzzer(PAGE 30-71) (PAGE 30-104)
Adjustment (Pump calibration: Matching speed
B Operation of windshield wiper(PAGE 30-72) check)(PAGE 30-106)
B Operation of window washer(PAGE 30-72) calibration)(PAGE 30-109)
Operation of air conditioner/heater(PAGE 30- Adjustment (Pump calibration: Restore default
B 72) value)(PAGE 30-109)
Operation to display camera mode(PAGE 30-
B 72) No Injection(PAGE 30-110)
Operation to display clock and service meter KOMTRAX Settings (Terminal Status)(PAGE
B (PAGE 30-73) 30-111)
Check of maintenance information(PAGE 30- KOMTRAX Settings (GPS and Communication
B 73) Status)(PAGE 30-112)
Setting and display of user mode (including KOMTRAX Settings screen (Modem Status)
B KOMTRAX messages for user)(PAGE 30-73) (PAGE 30-112)
C Display of ECO guidance(PAGE 30-74) Service Message(PAGE 30-113)
C Display function of alarm monitor(PAGE 30-75)
Display of action level and failure code(PAGE
C 30-76)
↓(Special operation)
PC138USLC-10 30-65
Electrical system
Function of checking display of LCD (Liquid

D Crystal Display)(PAGE 30-78)
Function of checking service meter(PAGE 30-
D 78)
Function of Usage Limitation Setting/ Change
D Password(PAGE 30-78)
a Classification of operator mode

A: Display or function that is indicated or enabled 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/Function when machine monitor switch is operated
C: Display/Function when certain condition is satisfied
D: Display/Function that require special operations of switches
30-66 PC138USLC-10
Electrical system
Operator mode (outline) (PC138-Q193-042-K-01-A) Function of Usage Limitation Setting/ Change

Password(PAGE 30-78)
a Only outline of the operator mode is described in
this section.
For details of each function and display, and
their operation, see "Structure and function " or a Display pattern of operator mode
the "Operation and Maintenance Manual". The contents of display from when the starting
switch is turned to ON position to when the
a In this section, the following displays or functions standard screen appears depend on the settings
of the operator mode are explained (including and conditions of the machine.
some items which need special operations).
A: When engine start lock is enabled
B: When engine start lock is disabled
Display pattern C: When working mode at start is set to breaker
A B C D E mode (B)
Display of KOMATSU logo D: When there is abnormal item in "Check
(PAGE 30-68) 1 1 1 1 1
before starting" items
Password input(PAGE 30-68) 2 E: When there is maintenance item which
Display of check of breaker exceeded due time
mode(PAGE 30-68) 2
Display of check before starting
(PAGE 30-68) 3 2 3 2 2
Display of warning after “Check
before starting”(PAGE 30-69) 3
Display of ending of
maintenance interval(PAGE 30- 3
69)
Display of check of working
mode and travel speed(PAGE 4 3 4 4 4
30-69)
Display of standard screen
(PAGE 30-69) 5 4 5 5 5
Display of end screen(PAGE 30-70)
Display of operation screen for engine shutdown
secondary switch(PAGE 30-70)
Selection of auto-deceleration(PAGE 30-70)
Selection of working mode(PAGE 30-70)
Selecting travel speed(PAGE 30-71)
Operation to stop alarm buzzer(PAGE 30-71)
Operation of windshield wiper(PAGE 30-72)
Operation of window washer(PAGE 30-72)
Operation of air conditioner/heater(PAGE 30-72)
Operation to display camera mode(PAGE 30-72)
Operation to display clock and service meter
(PAGE 30-73)
Check of maintenance information(PAGE 30-73)
Setting and display of user mode (including
KOMTRAX messages for user)(PAGE 30-73)
Display of ECO guidance(PAGE 30-74)
Display function of alarm monitor(PAGE 30-75)
Display of action level and failure code(PAGE 30-
76)
↓ (Special operation)
Crystal Display)(PAGE 30-78)
Function of checking service meter(PAGE 30-78)
PC138USLC-10 30-67
Electrical system
Display of KOMATSU logo (PC220-Q180-044-K-01-A) a If this screen is displayed, call the person
When starting switch is turned to ON position, responsible for the operation of KOMTRAX in
KOMATSU logo is displayed for 2 seconds. your Komatsu distributor and ask for remedy.
a After the KOMATSU logo screen is displayed for
2 seconds, the screen changes to "Password
input" screen, or "Check before starting" screen.
Display of check of breaker mode (PC220-Q180-

044-K-03-A)
When the starting switch is turned ON, if the
working mode is set to the breaker mode [B], a
Password input (PC220-Q180-044-K-02-A) message to inform the operator of starting in the
After the KOMATSU logo is displayed, the screen to breaker mode is displayed on the screen.
input the engine start lock password is displayed.
k If an attachment other than the breaker is
a This screen is displayed only when the engine used while the working mode is set to the
start lock function is enabled. breaker mode [B], the machine may move
a When correct password is input, the screen unexpectedly or may not operate normally or
changes to "Check before starting" screen. the hydraulic components may be damaged.
a The machine monitor has some password a After operation to check of the breaker mode is
functions other than the engine start lock. Those finished, the screen changes to "Display of
functions are independent from one another. check before starting".
If [No] is selected: Working mode is set to
economy mode [E]
If [Yes] is selected: Working mode is set to
breaker mode [B]
a The following screen may sometimes be

displayed instead of the above "Password input"
screen.
Display of check before starting (PC220-Q180-044-K-

04-A)
When the screen changes to the check before
starting screen, the check before starting is
performed for 2 seconds.
30-68 PC138USLC-10
Electrical system
a If any abnormalities are detected in the check a The maintenance reminder function is enabled
before starting, the screen changes to "Warning or disabled by using the machine monitor in the
after the check before starting" screen or service mode.
"Overdue Maintenance" screen.
a If no abnormalities were detected in the check
before starting, display changes to "Working
Mode and Travel Speed Check" screen.
a The monitors (6 monitors) on the screen shows
the items currently subjected to the check before
starting.
Display of check of working mode and travel

speed (PC220-Q180-044-K-07-A)
If the check before starting is finished normally, the
screen for checking the working mode and travel
speed is displayed for 2 seconds.
a After the "Working mode and travel speed
check" screen is finished, the screen changes to
the "Standard" screen.
Display of warning after “Check before
starting” (PC138-Q180-044-K-01-A)
If any abnormalities are detected in "Check before
starting", the alarm monitor is displayed on the
screen.
a The following figure shows that engine oil level
monitor (a) is warning of low engine oil level.
Display of standard screen (PC220-Q180-044-K-08-A)

If the machine monitor starts normally, the standard
screen is displayed.
a Service meter (a) or clock is displayed in the top
center area of the screen (use [F4] to switch the
display of the service meter and clock).
Display of ending of maintenance a Right end of the screen displays ECO gauge (b)
interval (PC220-Q180-044-K-06-A) (turn on or off the display in the operator mode).
If the check before starting detected a maintenance
item that is near or overdue the set interval, the
maintenance monitor is displayed for 30 seconds to
urge the operator to perform maintenance.
a This screen is displayed only when the
maintenance reminder function is enabled. If the
remaining time of any item is 30 hours or less,
the yellow icon is displayed. If the remaining
time of any item is 0 hour or less, the red icon is
displayed.
PC138USLC-10 30-69
Electrical system
When you turn the engine shutdown secondary

switch to the OFF position, the KOMATSU logo
appears once and then the display is switched to
the standard screen.
Selection of auto-deceleration (PC220-AF6C-100-K-

00-A)
While the ordinary screen is displayed, if the auto-
deceleration switch is pressed, large auto-
deceleration monitor (a) is displayed for 2 seconds
and the setting of the auto-deceleration is changed.
a Each time the auto-deceleration switch is
pressed, the auto-deceleration is changed in the
order of [ON] o [OFF] o [ON].
Display of end screen (PC220-Q180-044-K-09-A)
When starting switch is turned to OFF position, the a If the auto-deceleration is set to ON, large
end screen is displayed for 5 seconds. monitor (a) and auto-deceleration monitor (b) are
displayed simultaneously.
a Another message may be displayed on the end
screen due to the message display function of a If the auto-deceleration is set to OFF, auto-
KOMTRAX. deceleration monitor (b) goes off.
Display of operation screen for engine Selection of working mode (PC220-PT5W-100-K-01-A)

shutdown secondary switch (PC220-AKHL-100-K-00-A) Select desired working mode according to the
When you turn the engine shutdown secondary following procedure.
switch to the ON position, the “Engine Shutdown 1. While the standard screen is displayed, press
Secondary Switch Activated“ screen is displayed on the working mode selector switch, and the
every screen except the end screen. working mode selection screen is displayed.
a The engine shutdown secondary switch is a Following figure shows the working mode
provided in the lower L.H. side corner of the selection screen when "with attachment" is
operator's seat. This switch is used to stop the set. (If "with attachment" is not set in service
engine when it does not stop after the starting mode, attachment mode "ATT/P", "ATT/E"
switch is turned to the OFF position. are not displayed.)
30-70 PC138USLC-10
Electrical system
2. Operate the function switches or working mode • If an attachment other than the breaker is
selector switch to select the desired working used, the machine may move unexpectedly
mode and enter the selection. or may not operate normally or the hydraulic
Function switch components may be damaged.
• [F3]: Moves to lower item • After the breaker mode is selected, the
• [F4]: Moves to upper item screen to confirm the selection of the breaker
• [F5]: Cancels selection and returns to mode is displayed (The buzzer sounds
standard screen intermittently while this screen is displayed).
• [F6]: Enters selection and returns to standard • If the setting is confirmed on this screen, the
screen screen changes to the standard screen.
Working mode selector switch If "No" is selected: Screen returns to working
• Pressed : Moves to lower item mode selecting screen
• Kept pressed : Enters selection and returns If [Yes] is selected: Working mode is set to
to standard screen breaker mode [B]
a If you do not touch any of the function
switches and working mode selector switch
for 5 seconds, the selection is determined
and the screen changes to the standard
screen.
Selecting travel speed (PC138-C6T7-100-K-00-A)

When the travel speed selector switch is pressed
while the standard screen is displayed, travel speed
large monitor (a) is displayed for 2 seconds and the
travel speed setting is changed.
3. When the ordinary screen is displayed again,
large working mode monitor (a) is displayed for 2 a Each time the switch is pressed, the travel
seconds, and then the setting of the working speed setting changes to [Lo] o [Hi] o [Lo] in
mode is changed to the selected mode. order.
a When large monitor (a) is displayed, the a When large monitor (a) is displayed, display of
display of working mode monitor (b) is travel speed monitor (b) is changed, as well.
changed, too.
Operation to stop alarm buzzer (PC220-Q576-100-K-

<Precautions for selecting breaker mode [B]> 00-A)
• If breaker mode [B] is selected, both of the While the alarm buzzer is sounding, if the alarm
control of the hydraulic pump and the setting buzzer cancel switch is pressed, the alarm buzzer
of the hydraulic circuit are changed. stops.
PC138USLC-10 30-71
Electrical system
a Even if the alarm buzzer cancel switch is

pressed, the screen display does not change.
Operation of windshield wiper (PC220-K751-100-K-00-

A)
While the ordinary screen is displayed, if the wiper
switch is pressed, large wiper monitor (a) is
displayed for 2 seconds and the wiper starts or
stops.
a The window washer does not operate if the
window limit switch is "ON".
a The wiper setting changes sequentially between
[INT] o [ON] o [OFF] o [INT] every time you
press the switch. Operation to display camera mode (PC138-Q16A-
100-K-01-A)
a When the wiper is set to INT or ON, large When [F3] is pressed, the multi-display changes to
monitor (a) is displayed and the display of wiper the camera image (Set the connection of the
monitor (b) is changed at the same time. camera in the service mode).
a If the wiper is set to OFF, large monitor (a) is not
displayed and the wiper monitor disappears.
a Up to 2 cameras can be connected. However, if

the camera mode is selected, only the image of
camera 1 is always displayed.
Operation of window washer (PC220-K7DA-100-K-00-
A)
While the ordinary screen is displayed, if the
window washer switch is pressed, the washer fluid
is splashed only while the switch is held down.
a Even if the window washer switch is pressed,
the screen display does not change.
Operation of air conditioner/heater (PC220-K500-

100-K-00-A)
While the standard screen is displayed, if the air
conditioner switch is pressed, "Air-conditioner
Setting" screen is displayed.
a While "Air-conditioner Setting" screen is
displayed, if you do not touch any switch for 5 a If any caution occurs in the camera mode, the
seconds, the screen changes to the standard corresponding caution monitor is displayed at
screen. the left top of the screen (excluding the low
hydraulic oil temperature caution).
30-72 PC138USLC-10
Electrical system
a If no control lever is operated for 10 seconds

a To reset the remaining time after finishing the
while a failure enough to display user code is
maintenance, further operations are required.
occurring in the camera mode, the screen
returns to the standard screen and displays
information about that failure.
a When 2 cameras are connected, the image for
display can be selected, or 2 images can be
displayed at the same time.
a As 2-camera image display [F4] is selected, the
image of camera 1 is displayed on the left side
of the screen and the image of camera 2 is
displayed on the right side.
Operation to display clock and service

meter (PC220-Q1MA-100-K-00-A)
While the standard screen is displayed, if [F4] is
pressed, the service meter and the clock are Setting and display of user mode (including
displayed alternately in section (a). KOMTRAX messages for user) (PC138-Q1C3-100-K-
01-A)
a When selecting the clock display, perform the To enter and display the user mode, press [F6] to
time adjustment, 12-hour or 24-hour display display the "User Menu" screen while the standard
setting, and summer time setting by using the screen is displayed.
user mode functions.
a There are following items in the user menu.

Check of maintenance information (PC138-Q1C2- “ECO Guidance“
100-K-01-A)
You can check the maintenance information on the “Machine Setting“
maintenance screen displayed by pressing [F6] “Maintenance“
while the maintenance monitor is displayed. “Monitor Setting“
If the maintenance monitor is not displayed, press “Mail Checking“
[F6] and then [F1] or [F2] to change the monitor to [KOMTRAX message]
the maintenance screen. Then you can check the
information.
PC138USLC-10 30-73
Electrical system
• There are 2 types of KOMTRAX message; one a The lamp for the guidance on deterrence of
is for the user and the other is for the technician. hydraulic relief goes out automatically after
• For user: 10 seconds has passed since it appeared, or
A message for a user sent from the KOMTRAX if the function switch [F5] is pressed.
base station is displayed on the standard screen.
Operate "Mail Checking" in the user menu to
read the message.
• For technician:
The standard screen does not display anything
when a message for the technician is received
from the KOMTRAX base station. Operate
"Service Message Display" in the service menu
of the service mode to read the message.
Display of ECO guidance (PC220-Q1L3-100-K-00-A)

When the machine is set in a certain operating
condition, the ECO Guidance screen is displayed
automatically to urge the operator to perform the
• E-mode recommendation guidance
energy-saving operation.
If light-load work continues for 10 or more
a "ECO Guidance" screen is displayed when the minutes in P- or ATT/P-mode, E-mode
following conditions are met while this display recommendation guidance is displayed. This
function is set to enabled in operator mode. function helps reduce unnecessary fuel
consumption by alerting the operator to turn on
a Conditions for display:
E-mode.
• Idle stop guidance
If no lever is operated for a period of at least 5 a The lamp for the E-mode recommendation
minutes and the engine keeps running at idle guidance goes out automatically after 10
speed during this period, the guidance on idle seconds has passed since it appeared, or if
stop is displayed on the monitor. This function the function switch [F5] is pressed.
helps reduce unnecessary fuel consumption by
alerting the operator to stop the engine while
waiting for the next operation, or during a break.
a The lamp for the idle stop guidance goes out
automatically when the lever operation is
resumed, or if the function switch [F5] is
pressed.
• Travel partial recommendation guidance

If machine travel in the travel mode Hi and the
fuel control dial at MAX continues for 2 or more
minutes, the travel partial recommendation
guidance is displayed. When traveling the
machine for a long period of time, moving the
fuel control dial from MAX to a lower position
helps reduce fuel consumption.
• Guidance on deterrence of hydraulic relief
If relieving lasts for 3 or more seconds during a The lamp for the travel partial
operation, guidance on deterrence of hydraulic recommendation guidance goes out
relief is displayed on the monitor. automatically after 10 seconds has passed
since it appeared, or if the function switch
[F5] is pressed.
30-74 PC138USLC-10
Electrical system
• Low fuel level guidance If an abnormality that displays an alarm monitor of

If the amount of time the machine can be action level "L02", "L03", or "L04" occurs, the alarm
operated that is projected from the remaining monitor is displayed at the center of the monitor until
fuel level and the latest average fuel the abnormality is eliminated.
consumption drops to less than 8 hours, the low
fuel level guidance is displayed.
a The lamp for the low fuel level guidance goes
out automatically after 10 seconds has
passed since it appeared, or if the function
switch [F5] is pressed.
Display function of alarm monitor (PC138-Q1FC-

044-K-00-A)
If an abnormality that displays the alarm monitor of
action level "L01" occurs on the standard screen or
camera mode screen, the alarm monitor is
displayed in a large size for a while and then kept
displayed at (a) inside the screen.
a When a caution occurs while the camera mode
is displayed, the alarm monitor flashes at the
upper left of the screen.
PC138USLC-10 30-75
Electrical system
Display of action level and failure code (PC220-Q1FC-100-K-00-A)

If an abnormality that displays an action level and a a Since “Error List“ cannot be displayed from the
failure code occurs on the standard screen or screen on which the camera mode is displayed,
camera mode screen, the alarm monitor lights up. move to “Error List“ from the standard screen
side.
If the alarm monitor lights up, press function switch

[F5] to display the “Error List“.
• [F1]: Moves selection to next page (screen)
(when displayed)
• [F2]: Moves selection to previous page (screen)
(when displayed)
• [F5]: Returns to the standard screen
On the “Error List“ screen, the following information
is displayed.
(a): Alarm monitor
(b): Action level (3 digits)
(c): Failure code (5 or 6 digits)
(d): Failure code name
(e): Message
(f): Telephone No. (if registered)
a This screen appears only when a trouble (failure
code) for which an action level is set occurs.
a The telephone number is displayed only when
the telephone number is registered in the
service mode.
a If multiple troubles occur simultaneously, all the
codes are displayed repeatedly in order.
a Since the information of the displayed failure
code is recorded in the "Abnormality Record" in
the service mode, check the details in the
service mode.
a “Error List“ is replaced with the standard screen
automatically after 30 seconds.
30-76 PC138USLC-10
Electrical system
a Remedies requested to operator by displayed action levels (The following table is an excerpt from the
"Operation and Maintenance Manual".)
Degree of
Action level Buzzer Alarm monitor Remedy
urgency
Stop immediately and perform
Q checking and maintenance.
High L04 Q
(Continuous) Ask your Komatsu distributor for
testing and repair services.
Stop work, move machine to safe
place, stop it, and perform checking
Q
L03 Q and maintenance.
(Intermittent)
Ask your Komatsu distributor for
testing and repair services.
I Stop the work, and then run the
engine at medium speed with no
Q load or stop it. If the condition is not
L02 Q
(Intermittent) improved, ask your Komatsu
distributor for testing and repair
services.
Some functions are restricted, but
the machine can operate. After
L01 finishing work, perform checking
Low (For 2 seconds ― Q and maintenance.
only) Ask your Komatsu distributor to
perform testing or repairs as
necessary.
PC138USLC-10 30-77
Electrical system

Crystal Display) (PC-Q1LE-100-K-00-A)
While the standard screen is displayed, if the
numeral input switches or function switches are
operated in the following manner, the entire LCD
screen turns white.
• Switch operations (simultaneous): [4] + [F2]
a When finishing the operation of the switches,
release [F2] first.
a If there is a display error in the LCD, only that
part is indicated in black.
a To return to the former screen, press any one of
the function switches. Function of Usage Limitation Setting/ Change
Reference: An LCD panel, as one of its
Password (PC220-Q19X-100-K-00-A)
Selecting the Usage Limitation Setting displays the
characteristics, sometimes shows black spots
password input screen when you proceed to setting
(spots that remain unlit) and bright spots (spots that
of the circuit breaker or attachment, or maintenance
do not go off).
resetting. Set the usage limitation according to the
If the number of the bright points and black points following procedure.
does not exceed 10, the LCD panel is not faulty or
1. While the standard screen is displayed, perform
defective.
the following operation by using the numeral
input switches.
• Switch operation (Press the switches in order
while pressing [4])
[4]+[5]o[5]o[5]
a This operation of the switches is not
accepted until 10 minutes elapse after the
starting switch is turned to the ON position.
Function of checking service meter (PC-Q1MB-

100-K-00-A)
When checking the service meter with the starting
switch in the OFF position, operate the numeral
input switches as follows to display only the service
meter section.
• Switch operations (simultaneous): [4] + [1]
a There is some time lag in start of the LCD, so 2. After the “Usage Limitation Password“ screen is
hold down the switches until the service meter is displayed, input the current password by using
displayed. the numeral input switches and confirm it by
a If you release one of the switches, the monitor using the function switch.
goes off. • [F5]: Deletes input numbers/ Returns to
Reference: After the machine monitor is used standard screen
continuously over a long period of time, blue points • [F6]: Enters input password
(points that remain lit) may appear on this screen. It a Default password: [000000]
does not indicate that the LCD panel is faulty or
defective. a When the input password is correct, the
screen changes to the next screen.
30-78 PC138USLC-10
Electrical system
a When the input password is incorrect, the

message to request inputting the password
again is displayed.
a The password for the Usage Limitation and

the engine start lock password are not
identical.
3. After the “Usage Limitation Setting“ screen is 4. Changing a password
displayed, select a setting by using the function After the “Usage Limitation New Password
switch. Input“ screen is displayed, input the new
• [F3]: Moves to lower item password by using the numeral input switches
• [F4]: Moves to upper item and confirm it by using the function switch.
• [F5]: Cancels the selection and returns the • [F5]: Deletes input numbers/ Returns the
display to the previous screen display to the preceding screen
• [F6]: Enters selection • [F6]: Enters input password
a Default password: [000000]
a When the input password is correct, the
screen changes to the next screen.
a When the input password is incorrect, the
message to request inputting the password
again is displayed.
a Set a new password of four to six digits (If it
has only three or less digits or has seven or
more digits, it is not accepted).
Selection of use/non-use of Usage limitation

After the “Usage Limitation ON/OFF“ screen is
displayed, select a setting by using the function
switch.
• Non-use: Password input screen is not
displayed
• ON: The password input screen for setting of
the circuit breaker or attachment, or
maintenance resetting appears.
• [F3]: Moves to lower item
• [F4]: Moves to upper item
• [F5]: Cancels the selection and returns the After the “Usage Limitation New Password
display to the previous screen Input“ screen is displayed once more, input the
• [F6]: Enters selection new password for the second time by using the
numeral input switches and confirm it by using
the function switch.
• [F5]: Deletes input numbers/ Returns to
standard screen
• [F6]: Enters input password
PC138USLC-10 30-79
Electrical system
a If the input password is different from the one

input before, the message to request
inputting again is displayed.
If the standard screen is displayed after the

screen to notify completion of setting is
displayed, the password is changed successfully.
30-80 PC138USLC-10
Electrical system
Service mode (PC138-Q194-100-K-00-A) a The following shows the items selectable

To change the operator mode to the service mode, with the service menu (including some items
perform the following operation. which need special operations).
This operation is always required when you use the 01 Monitoring/ Pre-defined(PAGE 30-82)
service mode. 02 Monitoring / Custom(PAGE 30-85)
1. Checking of display of screen, and switch Abnormality record (mechanical systems)
operation (PAGE 30-92)
03
While the standard screen is displayed, perform Abnormality record (electrical systems)(PAGE
the following operation with the numeral input 30-92)
switches. 04 Maintenance Record(PAGE 30-94)
• Switch operation (Press the switches in order 05 Maintenance mode setting(PAGE 30-95)
while pressing [4]) 06 Phone number entry(PAGE 30-98)
[4]+[1]o[2]o[3] Default (Key-on Mode)(PAGE 30-98)
a This switch operation is accepted only while Default value setting (Unit)(PAGE 30-99)
the standard screen is displayed. 07 Default (With/Without Attachment)(PAGE 30-
100)
Default (Camera)(PAGE 30-101)
Testing (Cylinder Cut-out operation)(PAGE 30-
08 102)
Adjustment (Pump Absorption Torque)(PAGE
30-103)
Adjustment (Attachment Flow Adjustment)
(PAGE 30-104)
09 check)(PAGE 30-106)
calibration)(PAGE 30-109)
Adjustment (Pump calibration: Restore default
value)(PAGE 30-109)
2. Selecting the service menu 10 No Injection(PAGE 30-110)
When the “Service Menu“ screen is displayed, KOMTRAX Settings (Terminal Status)(PAGE
the service mode is selected. Select a service 30-111)
menu you use by using the function switches or KOMTRAX Settings (GPS and Communication
numeral input switches. 11 Status)(PAGE 30-112)
• [F3]: Moves selection downward KOMTRAX Settings screen (Modem Status)
• [F4]: Moves selection upward (PAGE 30-112)
• [F5]: Returns the display to the standard 12 Service Message(PAGE 30-113)
screen (operator mode)
• [F6]: Enters selection
a When you input a 2-digit code by using the
numeral input switches, the corresponding
menu is directly selected. Accordingly, you
may enter the selection by using [F6].
PC138USLC-10 30-81
Electrical system
Monitoring/ Pre-defined (PC138-Q1S1-100-K-00-A)

The machine monitor can monitor the condition of a When the working mode is changed to
the machine in real time by receiving signals from breaker mode [B], the screen to confirm the
various switches, sensors, and actuators installed to change of the setting is displayed as in
various parts of the machine and the information changing the working mode on the standard
from the controllers which is controlling switches, screen.
etc.
In "Monitoring/ Pre-defined", frequently used
monitoring items in daily work are selected
beforehand.
1. Selecting menu
Select “Monitoring/Pre-defined“ on “Service
Menu“ screen.
2. Checking Monitoring/Pre-defined information

After “Monitoring/Pre-defined“ screen is
displayed, you can check the items displayed in
monitoring/pre-defined by using the function
switches.
• [F1]: Moves to next page (screen)
• [F2]: Moves to previous page (screen)
• [F4]: Selects hold or releasing hold
(If the Hold is selected, a diagonal line is
drawn on the HOLD part.)
• [F5]: Returns the display to service menu
screen
a For the items not displayed in “Monitoring/
Pre-defind“, you can freely select and check
from the "Monitoring / Custom" items.
30-82 PC138USLC-10
Electrical system
List of Monitoring/ Pre-defined items

(SI unit is the default value)
Monitoring / Pre-defined screen (1/10) Machine basics 1
Applicable
No. ID Item name Unit (SI)
component
1 01002 Engine Speed r/min ENG
2 04107 Coolant Temperature °C ENG
3 37212 Engine Oil Switch – ENG
4 18400 Intak Temperature °C ENG
5 04401 Hydr. Oil Temperature °C PUMP
6 03203 Battery Power Supply V ENG
Monitoring/ Pre-defined screen (2/10) Fuel injection system
Applicable
component
2 36400 Rail Pressure MPa ENG
3 36200 Rail Pressure Command MPa ENG
4 48000 IMV Current A ENG
5 48001 IMV Current Command A ENG
Monitoring/ Pre-defined screen (3/10) EGR, VFT actuator
Applicable
component
2 18105 EGR Opening % ENG
3 19000 VFT Opening % ENG
Monitoring / Pre-defined screen (4/10) Engine temperature system
Applicable
component
2 04107 Coolant Temperature °C ENG
3 18400 Intake Temperature °C ENG
4 18500 Charge Temperature °C ENG
Monitoring/ Pre-defined screen (5/10) intake and exhaust pressure system
Applicable
component
2 37400 Ambient Pressure kPa ENG
3 36500 Charge Pressure-A kPa ENG
4 48200 Mass Air Flow kg/min ENG
Monitoring / Pre-defined screen (6/10) Engine
Applicable
component
2 37212 Engine Oil Switch – ENG
3 48400 Crankcase Pressure kPa ENG
4 36500 Charge Pressure-A kPa ENG
PC138USLC-10 30-83
Electrical system
Monitoring/ Pre-defined screen (7/10) Pump

Applicable
component
2 01100 Pump Pressure MPa PUMP
3 01141 Service Pressure Sensor MPa PUMP
4 01300 PC-EPC Sol Current mA PUMP
5 13133 Main Pump Absorb Torque Nm PUMP
Monitoring/ Pre-defined screen (8/10) PPC pressure switch
Applicable
component
2 01900 Boom Raise – PUMP
3 01900 Boom Lower – PUMP
4 01900 Arm Curl – PUMP
5 01900 Arm Dump – PUMP
Monitoring/ Pre-defined screen (9/10) PPC pressure switch
Applicable
component
2 01900 Swing – PUMP
3 01901 Bucket Curl – PUMP
4 01901 Bucket Dump – PUMP
Monitoring /Pre-defined screen (10/10) PPC pressure
Applicable
component
2 07102 Travel Fwd LH PPC Pressure MPa PUMP
3 07103 Travel Fwd RH PPC Pressure MPa PUMP
4 07104 Travel Rev LH PPC Pressure MPa PUMP
5 07105 Travel Rev RH PPC Pressure MPa PUMP
30-84 PC138USLC-10
Electrical system
Monitoring / Custom (PC138-Q19L-100-K-00-A) a Up to 6 monitoring items are selectable at a

The machine monitor can monitor the condition of time. However, all of the 6 items may not be
the machine in real time by receiving signals from set up depending on the form of display of
various switches, sensors, and actuators installed to the selected item.
various parts of the machine and the information
from the controllers which is controlling switches,
etc. The monitoring function allows you to select a
desired monitoring item.
1. Selecting menu
Select “Monitoring/Custom“ on “Service Menu“
screen.
3. Deciding monitoring items

After selecting monitoring items, execute
monitoring with the function switch or numeral
input switch.
a Execution with function switch: Double click
or keep pressing [F6] (for approximately 2
seconds).
2. Selecting monitoring item
After the “Monitoring Selection Menu“ screen is a Execution with numeral input switch: Input
displayed, select items to be monitored by using [99999] and press [F6].
the function switches or numeral input switches. a When monitoring only two items, for example,
• [F1]: Moves selection leftward select them and confirm with [F6]. If [F6] is
• [F2]: Moves selection rightward pressed once more at this time, monitoring is
• [F3]: Moves selection downward executed.
• [F4]: Moves selection upward
• [F5]: Clears input numbers/ Returns the a If monitoring items are selected up to the limit
display to the service menu screen number, monitoring is executed
• [F6]: Enters selection automatically.
a In setting of the monitoring, each time

function switch [F2] is pressed, sequential
switching among [ENG] o [PUMP] o [MON]
o [ENG] takes place in this order. (Pressing
[F1] induces the sequential switching in the
reverse order.)
a Selection with function switches: Select an
applicable equipment by using [F1] or [F2],
select an item by using [F3] or [F4], and then
enter it by using [F6].
a Selection with numeral input switches: Enter
a 5-digit code, and the item of that code is
selected directly. Enter that item by using 4. Executing monitoring
[F6]. After the “Monitoring“ screen is displayed,
perform the necessary operation of the machine
a If the color of the selected box changes from and check the monitoring information.
yellow to red, the selection of the item of that
box is entered. a Monitoring information is indicated by value,
ON/OFF, or special display.
PC138USLC-10 30-85
Electrical system
a The unit of display can be selected in SI unit,

metric unit, or inch unit with the Default
function in the service mode.
a When the working mode is changed to

breaker mode [B], the screen to confirm the
change of the setting is displayed as in
5. Holding monitoring information changing the working mode on the standard
You can hold and release holding of the screen.
monitoring information by using the function
switches.
drawn on the HOLD portion.)
• [F5]: Returns the display to monitoring
selection menu screen
7. Saving of monitoring item

A function switch lets you save and delete the
selected monitoring item.
• [F1]: MEMORY
• [F2]: CLEAR
6. Changing machine setting mode

To change the setting of the working mode,
travel speed, or auto-deceleration during
monitoring, operate the corresponding switch
under the current condition, and the
corresponding mode is selected.
a If the setting is changed during monitoring,
the new setting is held even after the screen
returns to the ordinary screen after
monitoring is finished.
a When a monitoring item is saved, a

confirmation screen appears asking whether
the saved item should be displayed or not,
when “Monitoring“ is selected again.
a When an item is saved, it can be displayed
as many times as required unless it is
cleared.
30-86 PC138USLC-10
Electrical system
a If another item is saved while having the

previous item saved, the previously saved
item is overwritten by the latest one.
a The saved monitoring item is cleared by
using [F2]. It is also cleared when the
selection is entered by using [F6] in the
following screen.
• KOMTRAX terminal screen
• "With/Without Attachment" screen
• Functional specification screen
• Air conditioner setting screen
PC138USLC-10 30-87
Electrical system
Table of Monitoring items (PC138-Q19L-208-K-00-A)
Unit (Default: SI) Applic-

Monitoring item (Display on able
Code No. screen) Remarks
SI Metric Imperial compo-
nent
01002 Engine Speed r/min rpm rpm ENG
04107 Coolant Temperature °C °C °F ENG
48000 IMV Current A A A ENG
48001 IMV Current Command A A A ENG
03203 Battery Power Supply V V V ENG
37212 Engine Oil Pressure Switch ON, OFF ENG
36400 Rail Pressure MPa kg/cm2 psi ENG
37400 Ambient Pressure kPa kg/cm2 psi ENG
18400 Intake Temperature °C °C °F ENG
18500 Charge Temperature °C °C °F ENG
Absolute value
indication
36500 Charge Pressure-A kPa kg/cm2 psi ENG (including
atmospheric
pressure)
48200 Mass Air Flow kg/min kg/min lb/min ENG
48400 Crankcase Pressure kPa mmHg psi ENG
36700 Engine Torque Ratio % % % ENG
18700 Engine Output Torque Nm kgm lbft ENG
03000 Throttle Position Sensor Volt V V V ENG
04105 Coolant Temp Sensor Volt V V V ENG
37401 Ambient Pressure Sensor Volt V V V ENG
18401 Intake Temp Sensor Volt V V V ENG
18501 Charge Temp Sensor Volt V V V ENG
36501 Charge Pressure Sensor Volt V V V ENG
36401 Rail Pressure Sensor Volt V V V ENG
48401 Crankcase Pressure Sens Volt V V V ENG
17500 Engine Power Mode ― ENG
48900 Engine Operation Mode ― ENG
08402 Droop switch ― ENG
31701 Throttle Position % % % ENG
31706 Final Throttle Position % % % ENG
18600 Inject Fueling Command mg/st mg/st mg/st ENG
36200 Rail Pressure Command MPa kg/cm2 psi ENG
37300 Fuel Rate l/h l/h gal/h ENG
19000 VFT Opening % % % ENG
18105 EGR Opening % % % ENG
20216 ECM Build Version ― ENG
20217 Calibration Data Version ― ENG
18900 ECM Internal Temp °C °C °F ENG
20400 ECM S/N ― ENG
01601 2nd Eng. Speed Command r/min rpm rpm PUMP
01100 Pump Pressure MPa kg/cm2 psi PUMP
07102 Travel Fwd LH PPC Pressure MPa kg/cm2 psi PUMP
07103 Travel Fwd RH PPC Pressure MPa kg/cm2 psi PUMP
07104 Travel Rev LH PPC Pressure MPa kg/cm2 psi PUMP
07105 Travel Rev RH PPC Pressure MPa kg/cm2 psi PUMP
07106 Blade Raise PPC Pressure MPa kg/cm2 psi PUMP
07107 Blade Lower PPC Pressure MPa kg/cm2 psi PUMP
30-88 PC138USLC-10
Electrical system

nent
04401 Hydr. Oil Temperature °C °C °F PUMP
01300 PC-EPC Sol Current mA mA mA PUMP
01700 Attachment Sol Current mA mA mA PUMP
03200 Battery Voltage V V V PUMP
04402 Hydr. Temp. Sensor Volt V V V PUMP
01602 2nd Eng. Speed Command % % % PUMP
13113 Main Pump Absorb Torque Nm kgm lbft PUMP
01141 Service Pressure Sensor MPa kg/cm2 psi PUMP
Swing ON, OFF PUMP
Travel ON, OFF PUMP
Pressure Switch Boom Lower ON, OFF PUMP
01900
1 Boom Raise ON, OFF PUMP
Arm Curl ON, OFF PUMP
Arm Dump ON, OFF PUMP
Bucket Curl ON, OFF PUMP
Bucket Dump ON, OFF PUMP
Pressure Switch Service ON, OFF PUMP
01901
2 Travel Steering ON, OFF PUMP
Blade RAISE ON, OFF PUMP
Blade LOWER ON, OFF PUMP
Travel Junction ON, OFF PUMP
Swing Brake ON, OFF PUMP
02300 Solenoid Valve 1 Merge-divider ON, OFF PUMP
Travel Speed ON, OFF PUMP
Service Return ON, OFF PUMP
Swing Release ON, OFF PUMP
02200 Switch Input 1 Sw
Swing Brake Sw ON, OFF PUMP
Model Select 1 ON, OFF PUMP
02201 Switch Input 2
Overload Alarm ON, OFF PUMP
Key Switch
02202 Switch Input 3 ON, OFF PUMP
(ACC)
Lock Lever Sw ON, OFF PUMP
02203 Switch Input 4 Breaker Sw ON, OFF PUMP
Quick Coupler ON, OFF PUMP
Window Limit ON, OFF PUMP
SW
02204 Switch Input 5 ON, OFF
P Limit SW PUMP
WLimit SW ON, OFF PUMP
02223 Switch Input 6
20229 Pump Controller Ass'y P/N ― PUMP
20403 Pump Controller Serial No ― PUMP
20230 Pump Controller Prog. P/N ― PUMP
20212 Pump Controller Prog. Version ― PUMP
04300 Battery Charge Volt V V V MON
04200 Fuel Level Sensor Volt V V V MON
PC138USLC-10 30-89
Electrical system

nent
Key Switch ON, OFF MON
Start ON, OFF MON
04500 Monitor Input 1
Preheat ON, OFF MON
Light ON, OFF MON
Eng. Oil Level ON, OFF MON
Monitor Input 2 Battery Charge ON, OFF
04501 MON
Volt
Quick Coupler ON, OFF MON
Swing Brake Sw ON, OFF MON
ENG Shutdown
04502 Monitor Input 3 ON, OFF MON
Secondary
Seat Belt Sw ON, OFF MON
F1 ON, OFF MON
F2 ON, OFF MON
Monitor Function F3 ON, OFF MON
04503
Switches F4 ON, OFF MON
F5 ON, OFF MON
F6 ON, OFF MON
SW1 ON, OFF MON
SW2 ON, OFF MON
Monitor 1st & SW3 ON, OFF MON
04504 2nd Row
SW4 ON, OFF MON
Switches
SW5 ON, OFF MON
SW6 ON, OFF MON
SW7 ON, OFF MON
SW8 ON, OFF MON
Monitor 3rd & SW9 ON, OFF MON
04505 4th Row
SW10 ON, OFF MON
Switches
SW11 ON, OFF MON
SW12 ON, OFF MON
SW13 ON, OFF MON
Monitor 5th Row ON, OFF
04506 SW14 MON
Switches
SW15 ON, OFF MON
20227 Monitor Ass'y P/N ― MON
20402 Monitor Serial No ― MON
20228 Monitor Prog. P/N ― MON
20200 Monitor Prog. Version ― MON
55300 Aircon Compressor Status ON, OFF MON
55000 Aircon Outside Temp. Code ― MON
55100 Aircon Inside Temp. Code ― MON
55200 Aircon Mode Data(Mon) ― MON
55201 Aircon Mode Data(Aircon ECU) ― MON
Only when
20260 KOMTRAX Ass'y P/N ― MON KOMTRAX is
used
Only when
20418 KOMTRAX Serial No ― MON KOMTRAX is
used
Only when
20261 KOMTRAX Prog. P/N ― MON KOMTRAX is
used
30-90 PC138USLC-10
Electrical system

nent
Only when
20273 KOMTRAX Prog. Version ― MON KOMTRAX is
used
ID Key Controller Ass'y P/N ― Only when ID key
20262 MON
is used *
ID Key Controller Serial No ― Only when ID key
20419 MON
is used *
ID Key Controller Prog. P/N ― Only when ID key
20263 MON
is used *
a Listing order in table

The monitoring items are listed in the order of the display on the monitoring item selection menu screen.
a Unit
The display unit can be set to SI, Metric, or Imperial as required (select a desired unit from "Unit" of
"Default" in service menu).
"mg/st" in the display unit is an abbreviation for milligram/stroke.
a Applicable component
ENG: The engine controller is in charge of detecting the monitoring information.
PUMP: The pump controller is in charge of detecting the monitoring information.
MON: The machine monitor detects monitoring information.
Note 1: Instantaneous fuel consumption (Code No.: 37300) is the theoretical fuel consumption ratio. (Since it
is a theoretical value, it is slightly different from the actual fuel consumption ratio.)
*: ID key is available only for domestic specification machine.
PC138USLC-10 30-91
Electrical system
Abnormality record (mechanical (a) Occurrence order of abnormalities from latest

systems) (PC220-Q1S2-100-K-00-A) one/Total number of records
The machine monitor logs the past and currently (b): Failure code
occurring failures classifying them into the (c): Detail of failure
mechanical system abnormality and electrical (d): Number of occurrences (displayable range:
system abnormality. 0 to 65,535 times)
To check the mechanical system abnormality record, (e): Service meter reading at the first occurrence
perform the following procedures. (f): Service meter reading at the last occurrence
• [F1]: Moves selection to next page (screen)
a For the failure code list, see "40 Failure code list (when displayed)
for troubleshooting". • [F2] Moves selection to previous page
1. Selecting menu (screen) (when displayed)
Select “Abnormality Record“ on “Service Menu“ • [F5]: Returns the display to "Abnormality
screen. Record" screen
a If no abnormality is recorded, "No Error" is
displayed.
a In the mechanical systems abnormality
record screen, up to 50 cases currently
stored are displayed.
a If the number of occurrence is 1 (first
occurrence), the service meter reading at the
first occurrence and that at the last
occurrence are the same.
When the latest service meter reading is
recovered, the value at the recovery time is
2. Selecting sub menu displayed, thus the above readings may not
After the “Abnormality Record“ screen is be the same.
displayed, select “Mechanical Systems“ by using a If [E] is displayed on the left of a failure code,
the function switch or numeral input switches. the abnormality is still occurring or correction
• [F3]: Moves selection to the below item of it is not confirmed.
• [F4]: Moves selection to the above item
• [F5]: Returns the display to service menu a For all of the failure codes that the machine
screen monitor can record, see the failure code list.
item is directly selected. Accordingly, you
4. Clearing abnormality record

The contents of an abnormality record of the
mechanical system cannot be deleted.
Abnormality record (electrical

systems) (PC138-Q1S3-100-K-00-A)
3. Information displayed on "Abnormality Record" The machine monitor records the past and currently
screen occurring failures classifying them into the
On the “Mechanical Systems“ screen, the mechanical system abnormality and electrical
following information is displayed. system abnormality.
30-92 PC138USLC-10
Electrical system
To check the electrical system abnormality record, (f): Service meter reading at the last occurrence
perform the following procedures. • [F1]: Moves to next page (screen) (when
displayed)
a For the failure code list, see "40 Failure code list
• [F2] Moves to previous page (screen) (when
for troubleshooting".
displayed)
1. Selecting menu • [F3]: Moves selection downward
Select “Abnormality Record“ on “Service Menu“ • [F4]: Moves selection upward
screen. • [F5]: Returns the display to "Abnormality
Record" screen
a If no abnormality is recorded, "No Error" is
displayed.
a On the electrical systems abnormality record
screen, up to 20 cases currently stored are
displayed.
If the number of abnormality records
increases to 21 or beyond, the latest
occurrence code is displayed and the oldest
one is deleted.
a If the number of occurrence is 1 (first
2. Selecting sub menu occurrence), the service meter reading at the
After “Abnormality Record“ screen is displayed, first occurrence and that at the last
select “Electrical Systems“ by using the function occurrence are the same.
switch or numeral input switches. a If [E] is displayed on the left of a failure code,
• [F3]: Moves selection downward the abnormality is still occurring or correction
• [F4]: Moves selection upward of it is not confirmed.
• [F5]: Returns the display to service menu
screen a For all of the failure codes that the machine
• [F6]: Enters selection monitor can record, see the failure code list.

item is directly selected. Accordingly, you
4. Clearing abnormality record

1) While the “Electrical Systems“ screen is
displayed, perform the following operation by
using the numeral input switches.
3. Information displayed on "Abnormality Record" • Switch operation (Press the switches in
screen order while pressing [4])
On “Electrical Systems“ abnormality record [4] + [1] o [2] o [3]
screen, the following information is displayed.
(a) Occurrence order of abnormalities from latest
one/ Total number of records
(b): Failure code
(c): Detail of failure
(d): Number of occurrences (displayable range:
0 to 65,535 times)
(e): Service meter reading at the first occurrence
PC138USLC-10 30-93
Electrical system
a The following figure shows the screen

when an individual item is cleared (it is
slightly different from the screen when all
the item are cleared at once).
2) Check that the display on the screen

becomes the clear mode, then clear the
individual information one by one or all
together by using the function switches.
a If the screen is set in the clear mode, 4) If the screen to notify completion of clearing
graphic mark [CLEAR] is indicated above is displayed and then "Electrical System
[F2]. Abnormality Record" (clear mode) screen is
• [F2]: Clears all items displayed, the clearing of the abnormality
• [F3]: Moves selection downward record is completed.
• [F4]: Moves selection upward a After a while, the screen returns to
• [F5]: Returns the display to "Abnormality “Electrical Systems“ screen.
Record" screen
• [F6]: Clears items one by one
a To clear items one by one: Select the item
to be cleared with [F3] or [F4] and press
[F6].
a To clear all items together: Press [F2],
and all the items are cleared, regardless
of selection of the items.
a If [E] is displayed on the left of a failure
code, the clearing operation is accepted
but the item is not cleared.
Maintenance Record (PC138-Q19Z-100-K-00-A)

The machine monitor records the maintenance
information of the filters, oils, etc., which are
displayed and checked by the following operations.
When the maintenance is performed, if the data are
reset in the operator mode, the number of the times
of maintenance is recorded in this section.
1. Selecting menu
Select “Maintenance Record“ on “Service Menu“
screen.
3) After “Electrical Sys. Error Reset“ screen is

displayed, operate the function switches.
• [F5]: Returns to Electrical Systems
screen (clear mode)
Return
• [F6]: Executes clearing
30-94 PC138USLC-10
Electrical system
(b): Number of replacements up to now

(c): Service meter reading (SMR) at the last
replacement
2. Selecting maintenance record item

After the “Maintenance Record“ screen is
displayed, select an item of which the setting is
to be checked by using the function switches or
numeral input switches. Maintenance mode setting (PC138-Q1F1-100-K-00-A)
• [F1]: Moves to next page (screen) The actuating condition of the maintenance
• [F2]: Moves to previous page (screen) reminder function in the operator mode can be set
• [F3]: Moves selection downward and changed by using this menu.
• [F4]: Moves selection upward • To enable or disable the function
• [F5]: Returns the display to service menu • Change replacement interval setting (by item)
screen • To initialize all of replacement interval setting
a You may enter a 2-digit code by using the 1. Selecting menu
numeral input switches to select the item of Select “Maintenance Mode Setting“ on “Service
that code. Menu“ screen.
a The following items can be selected in the 2. Selecting sub menu

maintenance record. After the “Maintenance Mode Setting“ screen is
displayed, select an item of which the setting is
01 Engine oil change
to be changed by using the function switches or
02 Engine oil filter change numeral input switches.
03 Fuel main filter change • [F1]: Moves to next page (screen)
41 Fuel pre-filter change • [F2]: Moves to previous page (screen)
04 Hydraulic oil filter change • [F3]: Moves selection downward
05 Hydraulic tank breather change • [F4]: Moves selection upward
07 Damper case oil check and refill • [F5]: Returns the display to service menu
08 Final drive case oil change interval screen
09 Machinery case oil change • [F6]: Enters selection
10 Hydraulic oil change a When you input a 2-digit code by using the
47 KCCV filter change numeral input switches, the corresponding
3. Items displayed on Maintenance Record screen item is directly selected. Accordingly, you
The following information is displayed. may enter the selection by using [F6].
(a): Maintenance items
PC138USLC-10 30-95
Electrical system
4. Setting of Maintenance Notice Time Setting

a The following items can be selected on the
After selecting "Maintenance Notice Time
"Maintenance Mode Setting" screen.
Setting", if the screen is displayed, set with the
00 Maintenance mode change function switches.
01 Engine oil change interval
02 Engine oil filter change interval
03 Fuel main filter change interval
41 Fuel pre-filter change interval
04 Hydraulic oil filter change interval
05 Hydraulic tank breather change interval
07 Damper case oil check and refill interval
08 Final drive oil change Interval
09 Swing machinery oil change interval
10 Hydraulic oil change interval
99 Returns all to Default Values
3. Setting of maintenance mode change
After selecting “Maintenance Mode Change“ and • Default value: Maintenance notice time set
the screen is displayed, select the desired on the machine monitor (Recommended by
setting by using the function switches. the manufacturer and not changeable).
• ON: All of functions of maintenance items • Set value: Maintenance interval that can be
become effective in operator mode. freely set. Maintenance reminder function
• OFF: All of functions of maintenance items works according to this set time in operator
becomes ineffective in operator mode. mode (the time increases or decreases in
• [F3]: Moves selection downward multiples of 10 hours).
• [F4]: Moves selection upward • [F3]: Decreases set value
• [F5] Cancels selection and returns to the • [F4]: Increases set value
"Maintenance Mode Change" screen • [F5] Cancels contents of setting before entry
• [F6]: Enters selection and returns to and returns to the "Maintenance Mode
"Maintenance Mode Change" screen Change" screen
a Even if ON/OFF of each item has been set, if • [F6]: Enters setting and returns to
the above setting is changed, it overrides the Maintenance mode setting screen
individual setting.
30-96 PC138USLC-10
Electrical system
5. Setting of each maintenance item • [F5] Cancels contents of setting before entry
Select each maintenance item. After the screen and returns to the "Maintenance Mode
is displayed, set the item by using the function Change" screen
switches. • [F6]: Enters setting and returns to
• ON: Function of the selected individual "Maintenance Mode Change" screen
maintenance item becomes effective in
a When you enter by using [F6] and return to
operator mode.
the "Maintenance Mode Setting" screen by
• OFF: Function of the selected individual
using [F5] , your setting is validated.
maintenance item becomes ineffective in
operator mode. a If the set value of an item of which
• [F3]: Moves selection downward maintenance reminder function is set to "ON"
• [F4]: Moves selection upward is changed after 1 operating hour or more
• [F5]: Cancels selection and returns to the from the setup, the change is recognized as
"Maintenance Mode Change" screen a reset of the remaining time.
• [F6]: Enters selection and returns to
"Maintenance Mode Change" screen
7. Function to return all of the values to default

values
6. Setting of set value of each maintenance item After selecting “All Default Value“ and the screen
Select the set value of each maintenance item. is displayed, select the desired setting by using
After the screen is displayed, set the value by the function switches.
using the function switches.
• If the operation for this function is executed,

• Default value: Maintenance notice time set the set values of all the maintenance items
on the machine monitor (Recommended by are returned to the default values.
the manufacturer and not changeable). • [F5]: Returns the display to "Maintenance
• Set value: Maintenance interval that can be Mode Setting" screen
freely set. Maintenance reminder function • [F6]: Executes initialization
works according to this set time in operator a A while after [F6] is pressed, the initialization
mode (the time increases or decreases in completion screen is displayed. Then, when
multiples of 25 hours). the “Maintenance Mode Setting“ screen is
• [F3]: Decreases set value displayed, initialization is completed.
• [F4]: Increases set value
PC138USLC-10 30-97
Electrical system
Phone number entry (PC220-Q19A-110-K-00-A) a Up to 14 digits can be input from the left.
The telephone number, which is displayed together Input nothing in the surplus places.
with the "Occurred error list" in the operator mode, a If an input numeral is wrong, move the cursor
can be input and changed according to the following (orange background) to that digit and
procedure. overwrite it with the correct numeral.
If a telephone number is not input with this function,
a If [F6] is pressed without inputting a digit,
no telephone number is displayed in the operator
there is not information of telephone No.
mode.
Accordingly, no telephone No. is displayed in
1. Selecting menu the operator mode.
Select “Phone Number Entry“ on the “Service
Menu“ screen.
Default (Key-on Mode) (PC220-Q1F2-100-K-00-A)

2. Registering and changing phone number Use the menu of Default to check or change various
After the “Phone Number Entry“ screen is settings of the machine monitor and machine.
displayed, register or change the phone number
Use the sub menu of "key-on Mode" to set the
by using the function switch or numeral input
working mode selected and displayed on the
switches. machine monitor when the starting switch is turned
• [F2]: Deletes all input digits to ON position.
• [F3]: Moves the input position to the next left
place (if not blank) 1. Selecting menu
• [F4]: Moves the input position to the next Select “Default“ on “Service Menu“ screen.
right place (if not blank)
• [F5]: Resets input digit/Returns the display to
the service menu screen
• [F6]: Validates the entry
30-98 PC138USLC-10
Electrical system
• [F6]: Enters selection and returns the display

to Default screen
a Factory default is, "Mode at Previous Key-
off".
a If "With Attachment" is not selected, selection
of the Attachment /P-Mode and Attachment/
E-mode is disabled.
a If you change the setting to "Without
attachment" when Attachment/P-mode [P] or
Attachment/E-mode is selected, Power
mode [P] is displayed when the starting
2. Selecting sub menu switch is turned to the ON position.
After the “Default“ screen is displayed, select a If the engine is stopped with the working
“Key-on Mode“ by using the function switch or mode set to breaker mode [B] in the operator
numeral input switches. mode, Breaker Mode [B] is always displayed
a Select this item similarly to an item on the when the starting switch is turned to ON
“Service Menu“ screen. position, regardless of the above setting.
3. Selecting mode
Default value setting (Unit) (PC220-Q1F3-100-K-00-A)
After the “Key-on Mode“ screen is displayed,
Use the menu of "Default" to check or change
select the mode to be set by using the function
various settings of the machine monitor and
switches.
machine.
• Power mode: [P] is displayed when the
starting switch is set to ON position The unit selecting function is used to select the unit
• Economy mode: [E] is displayed when the of the data to be displayed in monitoring, etc.
starting switch is set to ON position 1. Selecting menu
• Lifting Operation Mode: [L] is displayed when Select “Default“ on “Service Menu“ screen.
the starting switch is turned to ON position.
• Breaker Mode: [B] is displayed when the
starting switch is turned to ON position.
• Attachment/P-mode: [ATT/P] is displayed
when the starting switch is set to the ON
position.
• Attachment/E-mode: [ATT/E] is displayed
when the starting switch is set to the ON
position.
• Mode at Previous Key-off: Final mode in
previous operation is displayed when the
starting switch is turned to ON position.
• [F3]: Moves selection to the below item
• [F4]: Moves selection to the above item 2. Selecting sub menu
• [F5]: Cancels selection and returns the After the “Default“ screen is displayed, select
display to Default screen “Unit“ by using the function switch or numeral
input switches.
PC138USLC-10 30-99
Electrical system
a Select this item similarly to an item on the

“Service Menu“ screen.
2. Selecting sub menu

After the “Default“ screen is displayed, select
3. Selecting unit “With/Without Attachment“ by using the function
After the “Unit“ screen is displayed, select the switch or numeral input switches.
unit to be set by using the function switches. a Select this item similarly to an item on the
• [F3]: Moves selection to the below item “Service Menu“ screen.
• [F5]: Cancels selection and returns the
display to Default screen
• [F6]: Enters selection and returns the display
to Default screen
a Factory default is the “SI Unit”.
3. Selecting With/Without
After the “With/Without Attachment“ screen is
displayed, select a setting by using the function
switch.
• Without Attachment: When attachment is not
installed
• With Attachment: When attachment is
Default (With/Without Attachment) (PC220-Q1F4- installed
100-K-00-A) • [F3]: Moves selection to the below item
Use the menu of Default to check or change various • [F4]: Moves selection to the above item
settings of the machine monitor and machine. • [F5]: Cancels selection and returns the
Use the sub menu of "With/Without Attachment" to display to Default screen
configure attachment setting when the attachment • [F6]: Enters selection and returns the display
is installed or removed. to Default screen
1. Selecting menu a When an attachment is installed, if this
Select “Default“ on “Service Menu“ screen. setting is not configured correctly, the
attachment setting in the operator mode
cannot be performed. As a result, the
attachment may not work normally or the
hydraulic components may be damaged.
30-100 PC138USLC-10
Electrical system
• Use: Image from connected camera is

displayed as a normal image.
(as viewed in a mirror, when used for back
monitor)
• Я: Image from connected camera is
displayed as a reverse image (as seen
directly, when used for front or side monitor)
• R: Image from connected camera is
displayed as a normal image (as viewed in a
mirror, when used for back monitor)
• [F3]: Moves selection to the below item
• [F5]: Cancels the changes prior to
confirmation
Default (Camera) (PC220-Q1F6-100-K-00-A) and returns to the Default screen
Use the menu of Default to check or change various • [F6]: Enters selection in each line
settings of the machine monitor and machine.
Use the sub menu of "Camera" to configure camera a You cannot switch camera 1 between [Я] and
setting when the camera is installed or removed. [R].
1. Selecting menu a When you enter selection in each line with
Select “Default“ on “Service Menu“ screen. [F6] and return to the "Default" screen with
[F5], your setting is validated.
a When a camera is connected, if it is not set
normally with this function, the graphic mark
of camera is not displayed at [F3] in the
operator mode. Accordingly, the image of the
camera cannot be used.
a When the camera is installed, check that the
right and left portions of the displayed image
are correct.

After the “Default“ screen is displayed, select
“Camera“ by using the function switch or
numeral input switches.
3. Selecting camera setting

After the “Camera“ screen is displayed, select a
setting by using the function switch.
• Not Use: Camera is not used
PC138USLC-10 30-101
Electrical system
Select “Diagnostic Tests“ on “Service Menu“

screen.
a If 2 or more cameras are connected, be sure

to set the use of them from camera 1 in
order. 2. Selecting sub menu
After the “Diagnostic Tests“ screen is displayed,
a The simultaneous display function of two select “Cylinder Cut-out“ using the function
images becomes effective when camera 1 switch or numeral input switches.
and camera 2 are set for use.
a Selecting method is the same as on the
3. Selecting cylinder to be cut-out

After the “Cylinder Cut-out“ screen is displayed,
select a cylinder to be cut out by using the
function switches.
• [F1]: Moves selection leftward
• [F2]: Moves selection rightward
drawn on the HOLD portion.)
• [F5]: Returns the display to "Diagnostic
Tests" screen
Testing (Cylinder Cut-out operation) (PC138-
a This operation may be performed while the
AD00-34F-K-00-A)
The operator can perform cylinder cutout mode engine is running.
operation by using the machine monitor. a When [F6] is pressed, if background (a) of
Cylinder cutout mode operation means to run the the selected cylinder number becomes white,
engine with one or more fuel injectors disabled the cylinder is cut out.
electrically to reduce the number of effective
a If the machine monitor cuts out a cylinder but
cylinders. This operation is used to identify a
the engine controller cannot cut out that
cylinder that does not output power normally
cylinder, the background (a) of the cylinder
(combustion in it is abnormal).
number becomes yellow.
1. Selecting menu
a One or more cylinders can be cut out.
30-102 PC138USLC-10
Electrical system
a During the cylinder cutout operation, the

auto-deceleration function can be enabled.
When the auto-deceleration is set to ON,
auto-deceleration monitor (b) is displayed.
[Reference]
• If a normally operating cylinder is cut out, the
following phenomena occur.
1) Lowering of engine speed
2) Fuel Inject Command (quantity) increases.
4. Releasing cut out cylinder
• If the engine is running at near high idle,
When changing a cylinder to be cut out or when
however, the engine speed may not lower for
cylinder cutout operation is finished, select a cut
the reason of engine control.
out cylinder to be reset with the function
• In this case, lower the engine speed with the
switches.
fuel control dial and judge by increase of the
a This operation may be performed while the injection rate command.
engine is running.
Adjustment (Pump Absorption Torque) (PC138-
a When [F6] is pressed, if background (a) of C201-27E-K-00-A)
the selected cylinder No. becomes blue, the You can perform various adjustments related to the
cylinder is reset. machine with the machine monitor.
a If the machine monitor releases a cut-out The sub menu of Pump Absorption Torque is used
cylinder but the engine controller cannot to finely adjust the absorption torque of the
release the cut-out cylinder, the background hydraulic pump.
(a) of the cylinder number becomes red. 1. Selecting menu
a The cut-out cylinder mode operation is not Select “Adjustment“ on “Service Menu“ screen.
automatically released after the screen
returns to the operator mode. Accordingly, be
sure to perform the releasing operation after
the cylinder cut-out mode operation is
finished.
5. Holding displayed data
Each time [F4] is pressed during the Cylinder
Cut-Out operation, the displayed data is newly
held (c) (the real-time data is kept displayed on
the left side).
While the data is held, if [F4] is pressed, the data
holding function is reset.
a The holding function is available for a
cylinder, regardless of whether it is cut out or
After the “Adjustment“ screen is displayed,
not.
select “Pump Absorption Torque“ by using the
function switch or numeral input switches.
a Selecting method is the same as on the
PC138USLC-10 30-103
Electrical system
The sub menu of "Attachment Flow Adjustment" is

used to finely adjust the oil flow rate to the
attachment in combined operations.
1. Selecting menu
Select “Adjustment“ on “Service Menu“ screen.
3. Selecting pump absorption torque setting

After the “Pump Absorption Torque“ screen is
displayed, select the desired value at the right
side by using the function switches.
• Set value: For actual torque adjustment
value, see table
• [F3]: Increases set value 2. Selecting sub menu
• [F4]: Decreases set value After the “Adjustment“ screen is displayed,
• [F6]: Confirms setting and returns to select “Attachment Flow Adjustment“ by using
Adjustment screen the function switch or numeral input switches.
a The 3-digit number in the left column does a Selecting method is the same as on the
not change since it is the code of this “Service Menu“ screen.
function.
3. Selecting distribution of oil flow

After the “Attachment Flow Adjustment“ screen
a Relationship between set value and torque is displayed, select the desired value at the right
adjustment value side by using the function switches.
Torque adjustment • Set value: For actual distribution of oil flow,
Code Set Value
value see table
000 +39.2 Nm {+4 kgm} • [F3]: Increases set value
001 +29.4 Nm {+3 kgm} • [F4]: Decreases set value
002 +19.6 Nm {+2 kgm} • [F6]: Confirms setting and returns to
003 +9.8 Nm {+1 kgm} Adjustment screen
021 004 0 Nm {0 kgm} a The 3-digit number in the left column does
005 -9.8 Nm {-1 kgm} not change since it is the code of this
006 -19.6 N {-2 kgm} function.
007 -29.4 Nm {-3 kgm}
008 -39.2 Nm {-4 kgm}
Adjustment (Attachment Flow

Adjustment) (PC138-Q1F9-100-K-00-A)
You can perform various adjustments related to the
machine with the machine monitor.
30-104 PC138USLC-10
Electrical system
a Relationship between set value and

distribution of oil flow to attachment
Distribution of flow to
Code Set Value
attachment
000 50%
001 70%
037
002 100%
003 40%
PC138USLC-10 30-105
Electrical system
Adjustment (Pump calibration: Matching speed check) (PC138-C200-280-K-00-A)

You can perform various adjustments related to the • Perform warm-up operation for at least 30
machine with the machine monitor. minutes
The pump calibration function is used to check the • Hydraulic oil temperature: 50°C
matching speed for swing relief and to set the • Working mode: P mode
matching speed to the engine properly when the • Fuel control dial: MAX position
pump or pump controller is replaced. • Swing lock switch: ON
• Air conditioner: OFF
a The pump calibration (matching speed 2. Selecting menu
calibration) is required in the following cases. Select “Adjustment“ on “Service Menu“ screen.
Pump
calibration
Replacement of engine ―
Replacement of main pump
Necessary
assembly
Replacement of pump controller Necessary
Adjustment and disassembly of
Necessary
pump PC valve
Replacement of main valve ―
Adjustment or replacement of ―
main relief valve
a A rough flow of calibration of the pump is as After “Adjustment“ screen is displayed, input
follows. "40" by using the numeral input switches and
press "F6".
In adjustment menu of service menu
a Since this function is required only when the
pump is replaced, the PC valve is adjusted or
disassembled, or the pump controller is
replaced, it is not displayed in the menu list.
4. Selection of matching speed check menu

After “Pump Calibration“ screen is displayed,
select “Matching Speed Check“ by using the
a Select this when it is required to check
abnormality or current condition of the
machine.
Selecting method is the same as on “Service
Menu“ screen.
1. Preparation for calibration
Before starting calibration, set the machine
under the following condition
30-106 PC138USLC-10
Electrical system
k When operating the work equipment,

secure full safety around the machine.
[Reference]
• The alphabet letter at the right top of the
screen indicates the following condition.
3) Perform swing relief operation. When the
D: Default
engine speed is stabilized, hold down [F1] on
F: Adjustment value at shipment from factory
the machine monitor to start checking.
(Factory shipment state (Normal))
During matching speed check, a bar is
U: User calibration value
displayed on the screen. Keep relief
5. Matching speed check (swing relief)
operation until the check is finished.
1) When “Matching Speed Check“ screen is
displayed, relieve the swing circuit and check
the matching speed by using the function
switch.
[F1]: START
[F5]: Returns to pump calibration screen
4) If the check is normally completed, the result

is displayed.
2) Operate the arm control lever or bucket

control lever under the following condition to
check the relief matching.
(Operation)
Operate according to the swing relief screen.
a Swing lever: Swing full (either RIGHT or
LEFT)
(Condition)
• Working mode: P mode If check is finished unsuccessfully, "NG" is
• Fuel control dial: MAX position displayed for the State of check and the
• Swing lock switch: ON failure cause code is displayed. Referring to
• Air conditioner: OFF the failure cause codes in Table 2, find out
and remove the cause and repeat matching
k Secure sufficient area for operation of speed check.
the work equipment during testing.
PC138USLC-10 30-107
Electrical system
Table 2. Failure cause codes

Calibration failure cause codes (Displayed in descending order of priority)
Object
Pump
Cause code Content Remedies
Calibration
of IT
A-1 q Engine speed signal is 0 rpm Check that engine is started
Check hydraulic oil temperature (Min.
A-2 q Hydraulic oil temperature is low
45°C)
Check hydraulic oil temperature (Max.
A-3 q Hydraulic oil temperature is high
55°C)
A-4 q Overheating Check for overheating
Perform troubleshooting for pump
A-6 q Pump pressure sensor is defective
pressure sensor
A-9 q PC-EPC abnormality Perform troubleshooting for PC-EPC
CAN communication is defective
A-A q Perform troubleshooting for CAN
(engine, monitor, pump)
Fuel control dial is not set to MAX
C-3 q Set fuel control dial to Max. position.
position
Perform troubleshooting for relief valve
E-2 q Pump pressure is out of standard range
and pump
E-3 q Engine speed is out of standard range Set the engine to Hi idle speed.
Perform troubleshooting for engine and
E-4 q Engine torque is out of standard range
pump
E-5 q PC-EPC current is out of standard range Perform troubleshooting for PC-EPC
current
E-7 q Working mode is not set to [P] or [ATT/P] Set working mode is to [P] or [ATT/P].
Swing lock switch is not set to ON
E-9 q Set swing lock switch to ON position.
position
E-A q Air conditioner is ON Set air conditioner to OFF position.
Emergency pump drive switch is not in Set emergency pump drive switch to
E-B q OFF postion OFF postion
30-108 PC138USLC-10
Electrical system
Adjustment (Pump calibration: Matching

speed calibration) (PC138-C200-270-K-00-A)
1. Preparation for calibration
Before starting calibration, set the machine
under the following condition
• Perform warm-up operation for at least 30
minutes
• Hydraulic oil temperature: 50°C
• Working mode: P mode
• Fuel control dial: MAX position
• Swing lock switch: ON
• Air conditioner: OFF
2. Selecting menu
Select “Adjustment“ on “Service Menu“ screen. 5. Perform the subsequent calibration procedure
according to “Matching Speed Calibration“.
Adjustment (Pump calibration: Restore

default value) (PC200_10-C200-270-K-01-A)
After the “Pump Calibration“ screen is displayed,
select “Restore to Default Setting“ by using the

After “Adjustment“ screen is displayed, input
"40" by using the numeral input switches and
press "F6".
a Since this function is required only when the
pump is replaced, the PC valve is adjusted or
disassembled, or the pump controller is
[F6]: Perform initialization
replaced, it is not displayed in the menu list.
4. Selecting matching speed calibration menu When [F6] is pressed, if the “Pump Calibration“
After “Pump Calibration“ screen is displayed, screen is displayed and alphabet letter "D" is
select “Matching Speed Calibration“ by using the indicated at the right top of the screen, initialization
function switch or numeral input switches. is completed.
PC138USLC-10 30-109
Electrical system
3. Starting no injection cranking

No Injection (PC220-AD00-25L-K-00-A) If no injection cranking (no fuel injection to every
If the engine is operated after long storage of the cylinder) is enabled, a message to notify that is
machine, it may be worn or damaged because of displayed on the screen. Under this condition,
insufficient lubrication with oil. To prevent this, the crank the engine with the starting motor.
machine monitor has a function to crank the engine
without injecting fuel to lubricate the engine before a While the screen is changing to the following
starting it. screen, the screen of "Getting Ready." is
displayed.
Set the No Injection cranking while the engine is
stopped. a Do not crank the engine for 20 seconds or
1. Selecting menu longer to protect the starting motor.
Select “No Injection“ on “Service Menu“ screen.
4. Finishing no injection cranking

2. Displaying confirmation screen After the cranking is over, turn the starting switch
When the “No Injection“ screen is displayed, the to the OFF position.
message to ask if no injection cranking should a You cannot change the screen described
be performed appears. Select the answer by above to another screen.
using the function switch. 5. Prohibiting no injection cranking
• [F5]: Do not perform (return to Service Menu Even if the operator tries to perform the no
screen) injection cranking while the engine is running,
• [F6]: Executes the message "The engine is operating" is
displayed and the no injection cranking does not
become effective.
30-110 PC138USLC-10
Electrical system
a This function can be selected even when the

engine is running. However, if you execute
the no injection cranking, a message “The
engine is operating. Please turn the key off
once.“ is displayed on the screen.
2. Selecting submenu
After the “KOMTRAX Settings” screen is
displayed, select “Terminal Status” with the
function switches or numeral input switches.
a Select this submenu as in the case of
Also, if the no injection cranking is operated selecting a menu on the "Service Menu"
when Check screen is displayed, the function screen.
does not become effective in the following
case.
• The communication between the monitor
and engine controller is not normal.
• Perform an engine start operation before
the message “No injection is possible“ is
displayed.
3. Contents displayed on the terminal status

screen
On the "Terminal Status" screen, the following
information is displayed.
• Terminal Type: Model name of the
KOMTRAX communication modem
• KOMTRAX Communication : Status of sign-
up test underway
KOMTRAX Settings (Terminal Status) (PC220-
• GMT time: Greenwich Mean Time (add 9
Q210-110-K-00-A) hours to it for Japan time)
The setting and operating status of KOMTRAX can • [F5]: Returns the display to the KOMTRAX
be checked by using the menu of "KOMTRAX settings screen
Settings".
"KOMTRAX Settings" is used to check the setting
condition of the KOMTRAX terminal.
1. Selecting the menu
Select "KOMTRAX Settings" on the "Service
Menu" screen.
PC138USLC-10 30-111
Electrical system
KOMTRAX Settings (GPS and Communication • [F5]: Returns the display to the KOMTRAX
Status) (PC220-Q210-110-K-01-A) settings screen
The setting and operating status of KOMTRAX can
be checked by using the menu of "KOMTRAX
Settings".
"GPS & Communication Status" is used to check
the positioning and communication status of the
KOMTRAX terminal.
1. Selecting the menu
Select "KOMTRAX Settings" on the "Service
Menu" screen.
KOMTRAX Settings screen (Modem

Status) (PC220-Q210-110-K-02-A)
The setting and operating conditions of KOMTRAX
can be checked through the display of KOMTRAX
Settings.
Modem information is used to check the IP address
of the KOMTRAX communication modem.
1. Selection of menu
2. Selecting sub menu Select “KOMTRAX Settings“ on “Service Menu“
After the "KOMTRAX Settings" screen is screen.
displayed, select "GPS & Communication
Status" with the function switches or numeral
input switches.
a Select this sub menu as in the case of
selecting a menu on the "Service Menu"
screen.

After the “KOMTRAX Settings“ screen is
displayed, select “Modem Status“ by using the
3. Contents displayed on GPS & Communication
Status screen
On the "GPS & Communication Status" screen,
the following items are displayed.
• Positioning: GPS positioning status
• Communication: Communication
environment and connection status of the
communication modem
• Number of message not yet sent: Number of
mails that are saved on the machine monitor
and have not yet been transmitted
30-112 PC138USLC-10
Electrical system
3. Details displayed on Modem Status screen 2. Displaying message (read only)

IP addresses (two systems) of the modem are If there is a message, its contents are displayed.
displayed. If there is no message, "No message." is
• [F5]: Returns the display to KOMTRAX displayed.
settings screen • [F5]: Returns the display to Service Menu
screen
a An IP address is a unique number assigned
to each modem that is used when a This message is different from that sent to
communication between the modem and the operator with the machine monitor in the
server is established. operator mode.
a Since this message is special for the
technician, the message monitor is not
displayed when it is received with the
machine monitor in the operator mode.
Service Message (PC220-Q210-100-K-00-A)

Special messages for the technician sent from the
KOMTRAX base station (a distributor, etc.) can be
checked with this function.
If a received message includes a setting operation, 3. Display of message (with return mail function)
a return mail can be sent by using the numeral input If a message provides the Numeric Input line
switches as well. under the text, input a proper number by using
the numeral input switches and enter it by using
1. Selecting menu
the function switch, and the information is
Select “Service Message“ on “Service Menu“
returned to the KOMTRAX base station.
screen.
• [F5]: Returns the display to KOMTRAX
settings screen
• [F6]: Enters and returns input value
a This message is different from that sent to
the operator with the machine monitor in the
operator mode.
PC138USLC-10 30-113
Electrical system
a Since this message is special for the

technician, the message monitor is not
displayed when it is received with the
machine monitor in the operator mode.
30-114 PC138USLC-10
Electrical system
Adjusting rearview camera angle (PC138-Q162-360-K-00-A)
a Adjust the camera so that persons in the area

(w) of 1 meter around the machine can be seen
by the machine monitor in the operator's cab.
2. Remove bolts (4) (2 places).

3. Remove cover (2).
If the image displayed on the monitor is out of

position, remove cover (2) of camera (1) and adjust
installed angle (A) of the rearview camera.
4. Loosen mounting bolts (5) of camera (1), and

adjust camera installing angle (A) so that the
side of camera matches the edge of bracket (B).
Angle (A): 48 deg. (+2 deg. /0)
Adjusting (PC138-Q162-270-K-01-A)
1. Remove cover (2) by inserting flat-head

screwdriver [1] in the hole in cover (3) and
pressing the internal claw.
a A part of the machine is displayed on the

monitor screen.
Adjust the image area of the counterweight
displayed on the monitor screen to 10 to 15%.
a The claw of cover (2) is made of plastic, so
be careful not to break it when removing.
PC138USLC-10 30-115
Electrical system
5. After adjusting, tighten bolts (5).

3 Camera mounting bolt:
11.8 to 14.7 Nm {1.2 to 1.5 kgm}
6. Install covers (2) and (3).
30-116 PC138USLC-10
Electrical system
Handling voltage circuit of engine controller (PC220-AP40-2A4-K-00-A)
1. Disconnecting or connecting work of the

connector between the engine controller and the
engine must be performed only when the
starting switch and disconnect switch are in the
OFF position and the system operating lamp
goes out.
k Before connecting the wiring harness

connector, be sure to completely remove
sand, dust, water, etc., inside the
connector on the controller side.
2. Perform the measuring operation with the T-
adapter inserted or connected to the connector
between the engine controller and engine when
you perform the troubleshooting.
a You may turn the starting switch to the OFF
or ON position but must not turn it to the
START position.
PC138USLC-10 30-117
Electrical system
Handling battery disconnect switch (PC138-AW1P-100-K-00-A)
1. When the battery disconnect switch is turned to

“OFF(O)“ position, be sure to remove switch key
(1).
kA hazard can result if an unauthorized

person turns switch key (1) to ON position
carelessly.
a The battery disconnect switch is installed
inside the rear left cover of the machine.
2. You can prevent an abnormal end of the
operation due to cut-off of the battery power
supply circuit while the controllers are in
operation by checking the operating status of
each controller with system operating lamp (2).
1) Before cutting off the battery power supply
circuit, turn the starting switch to “OFF“
position, and check that system operating
lamp (2) goes off, then turn the battery
disconnect switch to “OFF(O)“ position.
2) If you turn the battery disconnect switch to
“OFF(O)“ position (battery power supply
circuit is cut off) while system operating lamp
(2) lights up, Controller data lost error can
occur. Do not operate the battery disconnect
switch as long as system operating lamp (2)
lights up.
3) System operating lamp (2) goes off in 2
minutes after the starting switch is turned to
“OFF“ position.
4) System operating lamp (2) may sometimes
light up while the starting switch is turned to
“OFF“ position because KOMTRAX terminal
may maintain its communication under this
condition.
5) System operating lamp (2) 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.
• After the starting switch is turned to “OFF“
position, KOMTRAX terminal repeats the
start and stop to maintain the periodic
communication.
• The start and stop cycle (sleep cycle) of
KOMTRAX terminal varies depending on
the factors including the communication
status and machine stop time. So the
lamp can be lighting as long as
approximately an hour.
6) When you want to cut off the battery circuit
for maintenance but system operating lamp
(2) 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 (2)
goes out, turn the battery disconnect switch
immediately to “OFF(O)“ position.
30-118 PC138USLC-10
Electrical system
Testing diodes (ALL-E300-001-P-00-A)
a Test the diode array (8-pin) and the single diode

(2-pin) according to the following procedure.
a The continuity directions of the diode array are
as follows.
2. When using analog tester

1) Selects the resistance range screen.
2) Check the movement of the pointer when
performing the following connection.
1] Apply the red (+) lead of the multimeter to
a The continuity direction of the single diode is the anode (P) side of the diode and apply
indicated on the surface of the diode. the black (-) lead to the cathode (N) side.
Testing (PC220-E300-36J-P-00-A) 2] Apply the red (+) lead of the multimeter to
the cathode (N) side of the diode and
1. When using a digital tester apply the black (-) lead to the anode (P)
1) Select the diode range screen to check the side.
displayed values. 3) Evaluate the condition of the diode by the
a When an ordinary circuit tester is used, movement of the pointer.
the voltage of the internal battery is • The pointer does not move by the above
indicated. 1] connection, but it does by the 2]
2) Apply the red (+) lead of the multimeter to the connection: Normal (however, the
anode (P) side of the diode and apply the movement of the pointer (resistance)
black (-) lead to the cathode (N) side and varies by type of tester, or selection of
check the indicated value. measuring range).
3) Evaluate the condition of the diode by the • The pointer moves by either connection
indicated value. of the above 1], and 2]:
• Indicated value does not change: No Defective (internal short circuit)
continuity (defective) • The pointer moves by neither connection
• Indicated value changes: Continuity the above 1], nor 2]: Defective (internal
(normal) (note) open circuit)
Note: In the case of a silicon diode, a value in
the range from 460 to 600 mV is indicated.
• The indicated value is 0 or approximate
0:
The diode has internal short circuit
(defective).
PC138USLC-10 30-119
Pm clinic
Pm clinic (ALL-2160-001-A-00-A)
Pm Clinic service (PC138-2160-209-A-00-A)
Model Serial No. Service meter

T PC138USLC-10 h
User name Date of inspection Inspector
/ /
Specification
Main parts Attachment Shoe width
Boom T Standard T
( ) T 500 mm
T Breaker
Arm T Standard T T 600 mm
T( )
( )
T( ) T 700 mm
Bucket T Standard T
T( )
( )
Check of oil and coolant levels

T Radiator coolant When necessary T Machinery case oil
T Engine oil T Damper case oil T( )
T Hydraulic oil T Final drive case oil
Ambient temperature Altitude
°C m
Operator's comment
Result of visual inspection
Abnormality record in mechanical systems Abnormality record in electrical systems

times/ 1st time h / last times/ 1st time h / last
989EKX
time h time h
times/1st time h / last times/1st time h / last
AB00KE
time h time h
B@BAZG times/1st time h / last times/1st time h / last
time h time h
B@BAZK times/1st time h / last times/1st time h / last
time h time h
B@BCNS times/1st time h / last times/1st time h / last
time h time h
B@BCZK times/1st time h / last times/1st time h / last
time h time h
B@HANS times/1st time h / last times/1st time h / last
time h time h
times/1st time h / last times/1st time h / last
CA234
time h time h
30-120 PC138USLC-10
Pm clinic
Max. range of engine coolant temperature gauge
Water temperature gauge level Coolant temperature Color of monitor light (a)
6 105°C
Red
5 102°C
4 100°C
3 85°C Blue
2 60°C
1 30°C White
Max. range of hydraulic oil temperature gauge
Coolant temperature gauge level Coolant temperature Color of monitor light (a)
6 105°C
Red
5 102°C
4 100°C
3 85°C Blue
2 40°C
1 20°C White
PC138USLC-10 30-121
Pm clinic
Related to engine
30-122 PC138USLC-10
Pm clinic
Related to hydraulic oil
PC138USLC-10 30-123
Pm clinic
Check sheet (PC138-2160-033-A-00-A)
Check sheet (PC138USLC-10)

Date of
Model Serial No. Service meter User name Inspector
inspection
/ /
1. Engine
Testing conditions Standard
No good
Mea-
Good
value for Repair
No. Check item Fuel Work- Swing Operation of Unit sured
control ing lock new limit
work equipment item
dial mode switch machine
Engine rpm 1,950 to 1,950 to
1 speed 2,050 2,050
All control levers 0.34 to
MAX MPa
Engine oil in NEUTRAL 0.59 0.25
2 pressure {kg/
{3.5 to {2.5}
cm2}
P OFF 6.0}
Engine rpm 1,050 to 1,050 to
3 speed 1,150 1,150
All control levers MPa
MIN Min. 0.10 0.15
Engine oil in NEUTRAL
4 pressure {kg/
{Min. 1.0} {1.5}
cm2}
2. Work equipment speed
No good
Mea-
Good
value for Repair
No. Check item Fuel Work- Unit sured
control ing Testing posture, etc. new limit
item
dial mode machine
Boom Work equipment extended
1 sec. 3.4 to 4.2 Max. 4.4
RAISE fully
2 Arm IN sec. 2.9 to 3.5 Max. 4.0
Boom top face horizontal
3 Arm OUT sec. 2.4 to 3.0 Max. 3.7
Bucket Boom top face horizontal,
4 sec. 2.6 to 3.2 Max. 3.7
CURL arm cylinder retracted fully
Swing (5 MAX P Work equipment extended
sec. 24.3 to 23.3 to
5 turns) fully, swing RIGH and
30.3 31.3
LEFT
Travel ST- sec.
Either track Lo Max. 39.6 Max. 49
(running D
pushed up,
6 track idle off
ground 5 FORWARD and ST- sec.
HI Max. 22.3 Max. 27
turns) REVERSE D
3. Hydraulic drift of work equipment

No good
Mea-
Good
Fuel Work- value for Repair

No. Check item Unit sured
control ing Testing posture, etc. new limit
item
dial mode machine
Hydraulic Boom top face horizontal,
Engine stopped arm cylinder retracted mm/15
1 drift of Max. 460 Max. 700
bucket tip fully, bucket loaded min.
30-124 PC138USLC-10
Pm clinic
4. Hydraulic circuit
[1] [2] [3] [4] [5]
Testing conditions
60 MPa 60 MPa 60 MPa 60 MPa 6 MPa
No good
Pump Servo Control
Good
No. Testing tools Fuel Main Main circuit
Working Operation of LS inlet
control pump pump source
mode work equipment pres- pres-
dial A1 A2 pres-
sure sure
sure
Self-pressure All control levers
1 – – – – A
reducing valve in NEUTRAL
Main relief Arm OUT
2 B B – – –
valve relief
Unload All control levers
3 C1 C1 C2 C2 –
valve in NEUTRAL
Running R.H.
track idle off
ground D1 – D2 – –
Lever operated
halfway
4 LS valve
Running L.H.
track idle off
ground – D1 – D2 –
Lever operated
halfway
Swing locked
Right SWING E E – – –
Swing motor
MAX P relieved
5 safety
Swing locked
valve E E – – –
Left SWING
relieved
R.H. Travel
locked
F – – – –
R.H. FORWARD
relieved
R.H. Travel
locked
Main relief F – – – –
valve, travel R.H. REVERSE
motor safety relieved
6
valve, and travel L.H. Travel
junction valve locked
– F – – –
L.H. FORWARD
relieved
L.H. Travel
locked
– F – – –
L.H. REVERSE
relieved
Oil pressure to be measured Standard value for new Repair limit

Unit
machine
Standard value
A (Control circuit source pressure) 3.0 to 3.4 {31 to 35} 2.7 to 3.7 {28 to 35}
B (Work equipment relief pressure) 33.8 to 35.8 {345 to 365} 33.3 to 36.8 {340 to 375}
C (Unload pressure) MPa 1.8 to 3.8 {18 to 38} 1.8 to 3.8 {18 to 38}
D (LS differential pressure when {kg/
2.1 to 2.3 {21.5 to 23.5} 2.1 to 2.3 {21.5 to 23.5}
lever in NEUTRAL) cm2}
E (Swing relief pressure) 26.7 to 29.7 {263 to 303} 25.7 to 29.7 {263 to 303}
F (Travel relief pressure) 33.8 to 35.8 {345 to 365} 33.3 to 36.8 {340 to 375}
* Gauge selection work: Exchagne hoses of gauges [3] and [4].
PC138USLC-10 30-125
Pm clinic
[1] [2] [3a] [4a] [5]

Testing conditions
60 MPa 60 MPa 60 MPa 60 MPa 6 MPa
No good
Control
Good
No. Testing tools Servo
Fuel Main Main LS circuit
Working Operation of inlet
control pump pump pres- source
mode work equipment pres-
dial A1 A2 sure pres-
sure
sure
Arm relieved at
7 Servo piston MAX P H1 H1 H2 H2 –
OUT end
Standard value for new
Standard value
Oil pressure to be measured Unit Repair limit

machine
H1:H2 = 1:0.6
H (Seervo control pressure) –
(Oil pressure ratio)
* Gauge selection work: Replace gauges [3] and [4] with ones of 6 MPa and exchagne hoses of gauges
[3], [4], and [5].
30-126 PC138USLC-10
SHOP MANUAL
HYDRAULIC EXCAVATOR
PC138USLC-10
Model Serial Number

10
40 Troubleshooting
6 40 Troubleshooting
PC138USLC-10 40-1
40 Troubleshooting
Table of contents

40 Troubleshooting............................................................................................................................ 40-1
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
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
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 [CA221] Ambient Press Sensor High Error ...................................................... 40-142
Failure code [CA222] Ambient Press Sensor Low Error ....................................................... 40-144
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
40-2 PC138USLC-10
40 Troubleshooting
Table of contents
Failure code [CA343] ECM Critical Internal Failure.............................................................. 40-160

Failure code [CA351] Injectors Drive Circuit Error ............................................................... 40-161
Failure code [CA356] Mass Air Flow Sensor High Error ....................................................... 40-164
Failure code [CA357] Mass Air Flow Sensor Low Error ........................................................ 40-166
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 [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
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
PC138USLC-10 40-3
40 Troubleshooting
Table of contents
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 [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
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
40-4 PC138USLC-10
40 Troubleshooting
Table of contents
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
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
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
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
PC138USLC-10 40-5
40 Troubleshooting
Table of contents
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
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
40-6 PC138USLC-10
40 Troubleshooting
General information on troubleshooting
General information on troubleshooting (ALL-5100-001-A-00-A)
Troubleshooting points (ALL-5130-42A-A-00-A)
(Rev. 2011/09)
k Place the machine on a level ground, and make sure that the frame lock bar, chocks, and parking
brake are applied.
k When performing the operation with two or more service technicians, keep strictly to the agreed
signals, and do not allow any unauthorized person to come near.
k Ifthe radiator cap is removed when the engine is hot, hot water may spurt out and cause burns, so
wait for the engine to cool down before starting troubleshooting.
k Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
k Before disconnecting wiring, remove the key and turn the battery disconnect switch to OFF
position.
k When removing the plug or cap from a component which is under pressure of oil, water, or air,
always release the internal pressure first. When installing measuring equipment, be sure to
connect it properly.
Troubleshooting denotes to locate the primary cause, fix the trouble without delay and prevent its recurrence.
Despite the importance of understanding the structure and operation of the target system in troubleshooting,
you should be aware how interviewing with the operator concerned can facilitate in roughly identifying the
cause of the given undesirable symptom.
1. When performing troubleshooting, do not hurry to disassemble the components.
If components are disassembled immediately after any failure occurs:
• Parts that have no connection with the failure or other unnecessary parts will be disassembled.
• It will become impossible to find the cause of the failure.
It will also cause a waste of manhours, parts, or oil or grease, and at the same time, will also lose the
confidence of the user or operator.
For this reason, when performing troubleshooting, it is necessary to perform thorough prior investigation
and to perform troubleshooting in accordance with the fixed procedure.
2. Points to ask the user or operator
1) Have any other problems occurred apart from the problem that has been reported?
2) Was there anything strange about the machine before the failure occurred?
3) Did the failure occur suddenly, or were there problems with the machine condition before the failure?
4) Under what conditions did the failure occur?
5) Had any repairs been performed before the failure? When were these repairs performed?
6) Has the same kind of failure occurred before?
3. Check before troubleshooting
1)Is there any sign of irregularities of the machine?
2)Make checks before starting day's work.
3)Make checks of other items.
4)Check other maintenance matters which can be checked externally and are considered to be
necessary.
4. Checking failure
Check the extent of the failure by yourself, and judge whether it is a real failure or a problem with the
method of operation, etc.
a When operating the machine to reenact the troubleshooting symptoms, do not perform any inspection
or measurement that may make the problem worse.
5. Troubleshooting
Use the results of the investigation and inspection in Items 2 to 4 to narrow down the probable causes of
the failure, then use the troubleshooting flowchart to locate the failure exactly.
PC138USLC-10 40-7
40 Troubleshooting
a The basic procedure for troubleshooting is as follows.

1) Start from the simple points.
2) Start from the most likely points.
3) Investigate other related parts or information.
6. Measures to remove root cause of failure
Fixing a trouble in hand does not necessarily prevents its recurrence unless the primary cause is
eliminated. To that end, you must locate and eliminate the primary cause behind the given failure.
40-8 PC138USLC-10
40 Troubleshooting
Sequence of events in troubleshooting (ALL-5140-42A-A-00-A)
(Rev. 2011. 7)
PC138USLC-10 40-9
40 Troubleshooting
40-10 PC138USLC-10
40 Troubleshooting
Checks before troubleshooting (PC138-5150-208-A-00-A)
Judge-
No. Role ment Remedy
value
1 Check for unusual noise and smell - Correct
2 Check for dirt around engine - Remove
3 Check for water leakage around engine - Correct
4 Check for oil leakage around engine - Correct
5 Check for leakage from fuel line - Correct
6 Check of radiator for clogging - Remove
a: Engine, lubricating oil and coolant
7 Check of level and type of fuel - Refilling of oil

8 Check for foreign material in fuel - Clean and drain
9 Check of fuel pre-filter - Replace
10 Check of fuel main filter - Replace
Between
11 Check of level (in oil pan) and type of engine oil Refilling of oil
H and L
Between
12 Check of coolant level (in sub tank) Refilling of coolant
H and L
The red
piston is
not
projected
13 Check of air cleaner clogging at the Clean or replace
transpar-
ent part
of dust
indicator
14 Check for dirt around KDOC muffler - Remove
15 Check for gas leakage around KDOC muffler - Correct
1 Check for unusual noise and smell - Correct
Check for oil leakage -
b: Hydraulic and mechanical equipment
2 Correct
Between
3 Check of hydraulic oil level Refilling of oil
H and L
4 Check of hydraulic oil strainer - Clean and drain
5 Check of hydraulic oil filter - Replace
Between
6 Check of swing machinery case oil level Refilling of oil
H and L
Between Refilling of oil
7 Check of damper case oil level
H and L
8 Check of final drive case oil level - Refilling of oil
Bleed air from

9 Air bleeding - cylinder
PC138USLC-10 40-11
40 Troubleshooting
Judge-
No. Role ment Remedy
value
1 Check of battery terminal for looseness and corrosion - Retighten or replace
2 Check of alternator terminal for looseness and corrosion - Retighten or replace
3 Check of starting motor terminal for looseness and corrosion - Retighten or replace
20 to 30 Charge or replace
4 Check of battery voltage (with engine stopped)
V
Between
5 Check of battery electrolyte level Add or replace
H and L
Check of wiring harness for discoloration, burnt areas and cover
6 peeling - Repair or replace
Check for coming off of wiring harness clamp and sagging of wiring -
7 Correct
harness
c: Electrical parts
8 Check of grounding - Correct

9 Check for loose connector and damaged lock - Repair or replace
10 Check of connector pin for corrosion, bends and deformation - Repair or replace
Dry, clean or
11 Check for water and foreign material in connector -
replace
12 Check of wiring harness for open circuit and short circuit - Repair or replace
13 Check of fuse for blowout and corrosion ― Replace
After few
minutes
Check of alternator voltage (when engine speed is medium or of
14 higher) Replace
operation:
27.5 to
29.5 V
Check of battery relay operation sound (When the starting switch is
15 turned to ON or OFF position) - Replace
16 Check and cleaning of rear view camera - Clean or repair
1 Check of undercarriage - Correct
d: Exterior parts
2 Check of handrails and steps - Correct
3 Check of rear view mirrors - Clean or repair
1 Check of gauges and monitors - Clean or replace

e: Interior parts
2 Check of seat belt - Replace
40-12 PC138USLC-10
40 Troubleshooting
Inspection procedure before troubleshooting (ALL-5150-001-A-00-A)
Walk-around check (D37-5150-289-A-00-A)
Before starting the engine, look around and under Check piping between the turbocharger and KDOC
the machine to check for any loose nuts or bolts, muffler and joints of KDOC muffler for gas leakage
leakages of oil, fuel or coolant, and check the (sticking soot, etc.) If any abnormality is found,
condition of the work equipment and hydraulic repair.
system. b2. Check of work equipment, cylinders, linkage
Check the connectors for looseness, the wiring and hoses for breakage, wear and clearance
harnesses for play, and the hot parts for Check the work equipment, cylinders, linkage and
accumulated dust. hoses for cracks and excessive wear, check that
k Accumulated combustibles around hot each clearance is within the normal range, and then
engine parts such as the engine,KDOC repair any unusual parts.
muffler, and turbocharger, etc. and fuel or oil b3. Check of hydraulic equipment, hydraulic
leakages may cause a machine fire. Be sure tank, hoses and joints for oil leakage
to check thoroughly and repair any failures. Check and repair any oil leaks.
a1. and b1. Check for unusual sounds and c1. Check around battery and dirt removal
smells Check and remove any accumulated dirt and
Check for unusual sounds and smells. combustibles (dead leaves, twigs, etc.) around the
battery.
Some causes of unusual sounds and smells can
damage the machine if they are left as they are. c16. Check and cleaning of rear view camera
Therefore, stop the machine immediately when you Check the rear view camera for any defect, and
find any unusual sounds and smells. repair any failures.
a2. Check around engine and dirt removal d1. Check of undercarriage (tracks, sprockets,
Check and remove any accumulated dirt around the idlers and guards) for defect, wear, loose bolts
engine and any combustibles (dead leaves, twigs, and oil leakage from roller
etc.) on hot engine parts such as the KDOC muffler, Repair any unusual parts.
turbocharger, etc. d2. Check of handrails and steps for unusual
a3. Check for water leakage around engine conditions and loose bolts
a4. Check for oil leakage around engine Repair any unusual conditions and retighten any
Check any oil leaks from the engine and any water loose bolts.
leaks from the coolant system. If any of them is d3. Check and cleaning of rear view mirrors
unusual, perform a repair. Check and repair any unusual conditions and
a5. Check for leakage from fuel line breakage of the rear view mirrors.
Check the hoses and tubes for any fuel leaks and Clean the mirror surfaces and adjust their angles so
damages. If any of them is abnormal, perform a that the operator can see the area behind him at the
repair. operator's seat.
a6. Check of radiator and dirt removal e1. Check of gauges and monitors for unusual
Check and remove any accumulated dirt and conditions
combustibles (dead leaves, twigs, etc.) around the Check the gauges and monitors inside the operator
radiator. cab. If any of them is unusual, replace it.
For removal of dirt from the radiator, see the Clean up the surfaces.
Operation and Maintenance Manual, "Cleaning and e2. Check of seat belt and mounting hardware
testing of radiator fins, oil cooler fins, aftercooler fins,
Check the hooks, locks and hook fittings for
fuel cooler fins and air conditioner condenser fins
damage. If any of them has a problem, repair the
(machine with the air conditioner)".
damage.
a14. Check around KDOC muffler and dirt
removal
Check and remove any accumulated dirt and
combustibles (dead leaves, twigs,etc.) around
KDOC muffler.
a15. Check around KDOC muffler for gas
leakage
PC138USLC-10 40-13
40 Troubleshooting
Testing in accordance with testing procedure (PC138_10-5150-280-A-00-A)
a: Engine, lubricating oil, and coolant

a7. Check of fuel level and type
k Fuel is highly flammable and dangerous.
Never bring flames near fuel.
k When adding fuel, never spill it or let it

overflow.
k Wipe off any spilled fuel. If fuel spills over

soil or sand, remove all the fuel and soil or
sand together.
1. Turn the starting switch to ON position and

check the fuel level with fuel level gauge (1) on • If breather hole (3) in the oil filler cap is
the monitor panel. clogged, the pressure in the tank decreases
After checking, turn the switch back to OFF and fuel may not be supplied. To prevent this,
position. clean the breather hole.
2. If the fuel level is low, open fuel filler cap (F) of a9. Check of fuel prefilter
the fuel tank and add fuel through the oil filler k Immediately after the engine is stopped, its
port to the necessary level, referring to the parts and oil are still very hot, and may cause
position of float gauge (G). burn injury. Accordingly, wait until all parts
3. After adding fuel, push float gauge (G) straight have cooled down before starting the work.
down with fuel filler cap (F) and tighten fuel filler
cap (F) securely while taking care the float k High pressure is generated inside the engine
gauge (G) will not be caught in tab (2) of fuel fuel piping system when the engine is
filler cap (F). running. Stop the engine and wait at least 30
seconds until the inner pressure is released
and then replace the filter .
k Never bring flames near fuel.
a A special filter with high-efficiency filtering

properties is adopted for Komatsu genuine fuel
filter cartridges. Be sure to use Komatsu
genuine parts when replacing.
40-14 PC138USLC-10
40 Troubleshooting
a The common rail fuel injection system used on

this machine consists of more precise parts than
those in the conventional injection pump and
nozzles. If any cartridge other than a Komatsu
genuine fuel filter cartridge is used, foreign
material may enter and it may cause problems in
the injection system. Do no use substitute parts.
a During testing or maintenance of the fuel system,
take extreme care not to allow any foreign
material to enter the fuel system. If any dust or
other material sticks to any part, wash the part
thoroughly with clean fuel.
• Prepare a container to receive drained oil. 2. Open the cover on the rear right side of the
• Prepare a filter wrench. machine.
Check of water separator, and drainage of water 3. Place a container under the fuel prefilter
and sediments cartridge to receive the fuel.
1. Close the rear right side cover. 4. Loosen drain valve (2) and drain water and
sediments from transparent cup (3), and also
• The water separator is integrated with fuel drain all the fuel from filter cartridge (4).
prefilter (1). 5. Using the filter wrench, turn transparent cap (3)
2. It is possible to judge the water level and amount to remove it. (This cap is reused.)
of sediment by looking through transparent cap 6. Using the filter wrench, turn filter cartridge (4) to
(2). If there is any water or sediment collected at remove.
the bottom, place a container to catch the drain 7. Install currently removed transparent cap (3) to
water under drain hose (3). the bottom of the new filter cartridge.
3. Loosen drain valve (4) to drain the water.
4. If drain hose (3) starts to discharge fuel, close a At this time, replace O-ring (5) with a new
drain valve (4) immediately. one.
8. When installing the transparent cap, apply a thin

a If water in transparent cap (2) is frozen, drain film of oil to the O to ring, set it against the
water only after confirming that it has sealing surface of filter cartridge (4), and then
completely melted. tighten the transparent cap by turning 1/4 to 1/2
a If you cannot visually identify the presence of turn.
water due to stains on transparent cap (2), a If the transparent cap is fastened too much,
clean transparent cap (2) when replacing fuel the O-ring will be damaged and this leads to
prefilter cartridge (1). leakage of fuel. If it is too loose, fuel will also
a When you have removed drain valve (4) for leak from gaps of the O-ring. Therefore, be
the above cleaning process, coat the O-ring sure to observe the fastening angle.
with grease and tighten drain valve until it 9. Clean the filter holder, fill the new filter cartridge
touches the bottom. with clean fuel, apply a thin film of oil to the O-
Replace fuel prefilter cartridge ring, and then install the new filter cartridge on
the filter holder.
1. Turn valve (1) at the bottom of the fuel tank to
the "CLOSE" (S) position.
PC138USLC-10 40-15
40 Troubleshooting
a Be sure to add fuel through 8 small holes (A) cartridge, then check the packing surface for
on the dirty side without removing center cap damage or foreign material. If any damage or
(B). foreign material is found in the packing, replace
the cartridge with a new one, then repeat Steps
a After adding fuel, remove cap (B) and install
7 to 17.
the fuel filter.
a10. Check of main filter
a Always fill with clean fuel. Be careful not to let
k Immediately after the engine is stopped, its
any dirt or dust get into the fuel. In particular,
parts and oil are still very hot, and may cause
center portion is the clean side, so do not
burn injury. Accordingly, wait until all parts
remove cap (B) when adding fuel. Be careful
have cooled down before starting the work.
not to let dirt or dust get into the center clean
side part.
k High pressure is generated inside the engine
fuel piping system when the engine is
running. Stop the engine and wait at least 30
seconds until the inner pressure is released
and then replace the filter .
k Never bring flames near fuel.
a A special filter with high-efficiency filtering

properties is adopted for Komatsu genuine fuel
filter cartridges. Be sure to use Komatsu
genuine parts when replacing.
a The common rail fuel injection system used on
this machine consists of more precise parts than
10.When installing, tighten it by 3/4 turn after the O- those in the conventional injection pump and
ring comes in contact with the sealing surface of nozzles. If any cartridge other than a Komatsu
the filter holder. genuine fuel filter cartridge is used, foreign
a If the filter cartridge is over tightened, fuel will material may enter and it may cause problems in
leak because the O-ring is damaged. If the the injection system. Do no use substitute parts.
filter cartridge is not tightened sufficiently, a During testing or maintenance of the fuel system,
fuel will also leak through the clearance of take extreme care not to allow any foreign
the O-ring. Therefore, observe the tightening material to enter the fuel system. If any dust or
angle. other material sticks to any part, wash the part
a When using a filter wrench for tightening, thoroughly with clean fuel.
take care not to leave flaws or dents on the • Prepare a container to receive drained oil.
filter. • Prepare a filter wrench.
11.Make sure that drain valve (2) is securely 1. Turn valve (1) at the bottom of the fuel tank to
closed. the "CLOSE" (S) position.
12.Turn valve (1) on the side of fuel prefilter
cartridge to the "OPEN" (O) position.
13.After completing the replacement of filter
cartridge (4), bleed air.
14.Fill up the fuel tank with fuel (to the level where
the float is at the highest position).
15.Loosen the knob of feed pump (6), pull it out,
then pump it in and out until the movement
becomes heavy.
16.After bleeding air, push in the knob of feed pump
(6) and tighten it.
17.After replacing the filter cartridge, start the
engine and run it at low idle for 10 minutes.
Check for leakage of fuel from the filter seal
surface and transparent cap mounting face. If 2. Open the cover on the rear right side of the
there is any leakage of fuel, check the fastening machine.
condition of the filter cartridge. If the fuel still 3. Place a container under the filter cartridge to
leaks, follow Steps 2 to 6 to remove the filter receive the fuel.
40-16 PC138USLC-10
40 Troubleshooting
4. Using the filter wrench, rotate filter cartridge (2) 6. When installing the filter cartridge, tighten it by 3/
to remove. 4 turn after the O-ring comes in contact with the
sealing surface of the filter holder.
a After removing the filter cartridge, fuel falls in
drops from the filter head. a If the filter cartridge is over tightened, fuel will
In order to prevent fuel from flowing out, be leak because the O-ring is damaged. If the
sure not to leave the machine without the filter cartridge is not tightened sufficiently,
filter cartridge. fuel will also leak through the clearance of
the O-ring. Therefore, observe the tightening
angle.
7. Turn valve (1) at the fuel tank bottom to "OPEN"
(O) position.
8. Bleed air according to the following procedure.
1) Fill up the fuel tank with fuel (to the level
where the float is at the highest position).
2) Loosen feed pump knob (4) and draw it out
once, then push and pull several times until
its movement becomes stiff.
• You do not need to remove the plugs at
the head of the fuel pre-filter and fuel
main filter.
5. Clean the filter holder. Apply a thin film of oil to • If fuel is used up, bleed air by operating
the packing of the new filter cartridge and install feed pump knob (4) in the same manner.
the cartridge to the filter holder.
a Replace inside seal (3) with a new one.
3) Push in and tighten feed pump knob (4).

9. After replacing the filter cartridge, run the engine
at low idle for approximately 10 minutes.
a Do not fill the new filter cartridge with fuel. 10.Check the filter seal surface for fuel leakage. If
there is any leakage of fuel, check the fastening
a Remove cap (A) at the center, and then condition of the filter cartridge. If the fuel still
install the filter cartridge. leaks, follow Steps 1 to 4 to remove the filter
cartridge. If any damage or foreign material is
found on the O-ring, replace the cartridge with a
new one, then proceed to Step 5 and later.
a11. Check of engine oil level (in oil pan) and
type
a When checking the oil level after the engine has

been operated, wait for at least 15 minutes after
stopping the engine.
PC138USLC-10 40-17
40 Troubleshooting
a If the machine is at an angle, make it level a12. Check of coolant level (in sub tank)
before checking.
k The radiator cap does not need to be opened
a When the ambient temperature is low, water or for standard checks. When checking the
emulsified matter may stick to the oil level gauge, coolant level, check it in the sub-tank when
oil filler cap, etc. or the drained oil may be milky the engine is cooled down.
white because of water vapor in the blowby gas.
However, if the coolant level is normal, it is not a k Immediately after the engine is stopped, the
problem. coolant is still very hot and the pressure is
1. Stop the engine. accumulated in the radiator.
2. Open the engine hood. If the cap is opened under these conditions,
3. Remove oil level gauge (G) and wipe off oil on you may be scalded. If you need to remove
the gauge with a cloth. the radiator cap, wait until the temperature
4. Insert oil level gauge (G) fully and pull it out. drops before you do. Then turn the cap
slowly to release the pressure and remove it
with care.
1. Open right rear cover on the machine, check the

coolant level is within "FULL - LOW" range at
sub tank (1) (shown in the figure below), and if
coolant is insufficient, add coolant up to FULL
level through water filler port at sub tank (1).
2. After refilling with coolant, tighten the cap
securely.
3. If the sub tank is vacant, coolant may have
leaked.
If any abnormality is found in the check for
leakage, repair it immediately. If no abnormality
5. If the oil level is between lines H and L on oil
is found, check the level of the coolant in the
level gauge (G), it is at the correct level.
radiator. If it is low, add coolant to the radiator
If the oil level is below the L mark, add oil
and then to the sub-tank.
through oil filler port (F).
4. If sub tank (1) is dirty and it is difficult to check
the coolant level, clean it.
6. If the oil level is above line H, drain the extra

engine oil through drain valve (P) at the bottom
of the engine oil pan and check the oil level
again.
7. If the oil is at the correct level, tighten the oil filler
cap securely and close the engine hood.
40-18 PC138USLC-10
40 Troubleshooting
a.13 Check of air cleaner for clogging 2. Remove primary element (4).
k When using compressed air for cleaning, put a Never remove secondary element (5). If it is
on personal protective items such as removed, dirt will enter and can lead to
protective eyeglasses, gloves, dust mask, engine troubles.
etc. to protect yourself from dirt that will fly a Do not clean and reuse the secondary
out. element.
k When removing the primary element from a Replace the primary element with a new one
the air cleaner body, do not forcibly pull it out, when replacing the primary element.
otherwise it can be dangerous.
Be careful not to fall from a high location on
unsafe scaffolding as a reaction when pulling
out the primary element.
Testing
Open the rear left cover and check if the red piston
is protruding into the transparent portion of dust
indicator (1). If it is protruding, clean the air cleaner
element.
a Do not clean the element before the red piston is
projected into the transparent part of dust
indicator (1).
3. Clean the inside of the air cleaner body and
a If the element is cleaned frequently before the cover (3).
red piston is projected, the true performance of
the air cleaner will not be realized and the
cleaning effect will decrease.
4. Blow dry compressed air (0.2 MPa {2.1 kg/cm2}

and below) to the clean side (secondary element
side) of the primary element from inside along its
Cleaning of primary element pleats.
1. Open the side cover at the rear left side of the 1) Replace the primary element if it is cleaned 6
machine and disengage 4 clips (2) to remove times repeatedly or used throughout a year.
cover (3). Replace the secondary element as well at
the same time.
2) Replace both primary and secondary
elements when the red dust indicator
appears soon after cleaning the primary
element even though it has not been cleaned
6 times yet.
PC138USLC-10 40-19
40 Troubleshooting
3) Peel off a seal after cleaning the element 6. Set the cleaned primary element, then install
each time. cover (3) and fix them with mounting clips (2).
7. Press the button of dust indicator to return the
red piston.
5. After clearing the element, check it. If it has a

small hole or thin part, replace it.
a When cleaning the element, do not hit it or hit Replacement of element
anything with the element. 1. Open the side cover at the rear left side of the
machine and disengage 4 clips (2) to remove
a Do not use the element if its folds or gasket cover (3).
or seal are damaged.
a Wrap an unused element and keep it in a dry
place.
2. Remove primary element (4).

Do not remove secondary element (5) at this
time.
k When installing cover (3), check O-ring (6)

for scratches and replace it with a new
one if any.
40-20 PC138USLC-10
40 Troubleshooting
3. Clean the inside of the air cleaner body and

cover (3). b. Hydraulic and mechanical equipment
b3. Check of hydraulic oil level
k When removing the oil filler cap, the oil may

spout out. Turn it slowly to release the
internal pressure, then remove it.
1. Set the work equipment in the posture as shown

below and, after stopping the engine, check the
oil level and add new oil if necessary.
4. Remove secondary element (5), then quickly a If the work equipment posture is not as
install the new secondary element. shown below, start the engine, fully retract
the cylinder rods for arm and bucket at
k When installing cover (3), check O-ring (6) engine low idle. Then lower the boom until
for scratches and replace it with a new bucket teeth touch the ground, then stop the
one if any. engine.
5. Set new primary element (4), then install cover
(3) and fix them with clip (2).
6. Replace the seal stuck to cover (3) with a new
one.
2. Turn the starting switch to ON position within 15

seconds from the engine stop and operate
control levers (work equipment and travel) to the
travel end in each direction to release internal
7. Press the button of dust indicator to return the pressure.
red piston. 3. Open the cover on the rear right side of the
machine and check sight gauge (G). If the oil
level is between lines H and L, it is at the correct
level.
PC138USLC-10 40-21
40 Troubleshooting
a If the oil level is below line L, add oil through

oil filter port (F).
a Do not add oil above the H mark since it can
damage the hydraulic circuit or allow spurt of
oil.
a If oil is added above the H level, stop the
engine, wait for the oil temperature to cool
down, discharge excessive oil from drain
plug (P) under the suction tube.
Since the oil level varies according to the oil

temperature, use the followings as a guide.
• Before operation (oil temperature: 10 to 30°
C), the oil level should be at the center
between lines H and L.
• During normal operation (oil temperature: 50
to 80°C), the oil level should be near line H.
b4. Check of hydraulic oil strainer
k When you remove the oil filler cap, oil may

spurt out. Be careful to rotate it slowly, and
release inner pressure gradually.
1. Stop the engine and remove oil filler cap (F) of

the hydraulic tank to release the internal
pressure.
2. Remove the bolts to remove cover (1).
3. When removing the bolts, keep pressing down
cover (1) since it may be flung toward you by
spring (2).
4. Pull out rod (3) from the top, and take out spring
(2) and strainer (4).
5. Remove any dirt stuck to strainer (4), then wash
it in flushing oil. If strainer (4) is damaged,
replace it with a new one.
6. Insert and set strainer (4) in projected portion (5)
of the tank.
40-22 PC138USLC-10
40 Troubleshooting
7. While pressing down spring (2) with the 7. Set cover (1) and install it with the mounting
projection at the bottom of cover (1), install the bolts while pressing it by hand.
bolts. Tighten the mounting bolts. 8. Tighten the mounting bolts.
b.5 Check of hydraulic oil filter 9. Install oil filler cap (F).
10.To bleed air, run the engine at low idle for 10
k Immediately after the engine is stopped, its minutes.
parts and oil are still very hot, and may cause 11.Stop the engine.
burn injury. Accordingly, wait until all parts b6. Check of swing machinery case oil level
k When you remove the oil filler cap, oil may parts and oil are still very hot, and may cause
spurt out. Be careful to rotate it slowly, and burn injury. Accordingly, wait until all parts
release inner pressure gradually. have cooled down before starting the work.
1. Remove oil filler cap (F) of the hydraulic tank to 1. Swing the upper structure so that drain plug (P)
release the internal pressure. is in the middle between the right and left tracks.
2. Place a container under drain plug (P) on the
underside of the machine to catch the oil.
3. Remove oil level gauge (G) and wipe off oil on
the gauge with a cloth.
4. Fully insert oil level gauge (G) into the guide with
mark (T) directed toward the center of the swing
machinery.
5. Pull out oil level gauge (G) and check the oil
level. If the oil level is between stamped lines (H)
and (L) on the oil level gauge, it is at the correct
level.
6. If the oil does not reach the (L) mark on oil level
gauge (G), add oil through oil filler (F).
2. Remove the bolts to remove cover (1). 7. If the oil level is above line (H) of oil level gauge
When removing the bolts, keep pressing down (G), loosen drain valve (P) to drain the excessive
cover (1) since it may be flung toward you by oil.
spring (2). • When draining the oil, place an oil container
3. Remove spring (2), valve (3) and strainer (4), under drain valve (P).
and then remove element (5). 8. After checking the oil level and adding oil, install
• Check the bottom of the filter case for dirt or oil level gauge (G) and oil filler cap (F).
other material, and remove any if found. At
that time, take extreme care for any dirt or
other material not to drop into the hydraulic
tank.
4. Clean the removed parts using cleaning oil.
5. Install new element (5).
6. Place strainer (4), valve (3) and spring (2) onto
the element.
PC138USLC-10 40-23
40 Troubleshooting

1. Set plug (F) at the top so that the line between it

and plug (P) is perpendicular to the ground
surface.
2. Remove plug (G) by using a hexagonal wrench.
When the oil level reaches a point 10 mm below
the bottom of the plug hole, the correct amount
of oil is added.
3. If the oil is insufficient, add oil through plug (F)
hole. Add oil until oil overflows from the hole of
plug (G).
4. After the inspection, install plugs (F) and (G).
b8. Bleeding air

• For the bleeding air from the fuel system, see
Testing and adjusting, "Bleeding air from fuel
circuit".
• For bleeding air from the hydraulic system, see
Testing and adjusting, "Bleeding air from
hydraulic circuit".
c. Electric equipment
c1. Check of battery terminal for looseness and
corrosion
1. Open the rear left cover on the machine and
remove nut (1) from 2 places at the battery top
surface to remove battery cover (2) from 2
places.
2. Check the battery cable terminals for looseness
and corrosion.
b7. Check of final drive case oil level

k Since the oil may spurt out due to internal
pressure, rotate the plug gradually from its
side to release the internal pressure and then
remove it carefully.
40-24 PC138USLC-10
40 Troubleshooting
c4. Check of battery voltage (with engine

c2. Check of alternator terminal for looseness
stopped)
and corrosion
• Check the battery voltage by using the battery
• Remove bolts to remove bracket (1).
tester while the engine is stopped.
c5. Check of battery electrolyte level
Check before operating the machine.
k Do not use the battery if the battery
electrolyte level is below LOWER level line.
This will accelerate deterioration of the
inside of the battery and reduce the service
life of the battery. In addition, it may cause an
explosion.
k Since the battery produces combustible gas

that can explode, do not bring any open
flame near it.
• Check alternator terminal B (2) for open circuit,
looseness and corrosion. k Battery electrolyte is dangerous. Take care
that it does not come in contact with your
eyes or skin. If it does, wash it away with
water and contact your doctor.
a Do not add the battery fluid above the UPPER

LEVEL line. If done, the fluid may leak and the
coating surface may be damaged or the parts
may be corroded.
a To avoid freezing, add the purified water (such
as a commercial battery fluid) before starting the
work in the next day.
• When checking the electrolyte level through the
c3. Check of starting motor terminal for side face of the battery
looseness and corrosion 1. Open the battery room door and roll up rubber
cover (1) installed above the battery.
• Check starting motor terminal B (1) and terminal
C (2) for open circuit, looseness and corrosion.
PC138USLC-10 40-25
40 Troubleshooting
a If the fluid exceeds the UPPER LEVEL,

remove the fluid using a dropping pipette or
others until the fluid drops to the UPPER
LEVEL. When you have removed the fluid
from the battery, neutralize it with the baking
soda (sodium bicarbonate) and wash it away
with a large quantity of water.
• When electrolyte level cannot be checked
through the side face of the battery
1. Remove caps (2) from the top of battery. (As
mentioned before)
2. Observe fluid level port (3), and check the fluid
level. If the fluid level is below sleeve (4), always
2. Wipe and clean the battery surface, especially add the fluid (such as a commercial battery fluid)
around the battery level lines with a wet cloth, until it reaches the bottom of sleeve (the UPPER
and check to see that the battery fluid is LEVEL).
between the UPPER LEVEL and LOWER • (A) Correct level: Since the electrolyte level
LEVEL lines. reaches to the sleeve bottom, the shape of
a Do not clean the battery with a dry cloth the electrode plates will appear distorted due
since static electricity may cause an to the surface tension.
explosion. • (B) Low level: Electrolyte level does not
reach the bottom of sleeve, so pole plates
appear straight and not bent.
3. After adding fluid, tighten cap (2).
3. If the electrolyte level is below the center

between the U.L. and L.L. lines, remove cap (2)
and add purified water (example: commercially
available battery fluid) to the U.L. line
immediately.
4. After adding the purified water, tighten cap (2) a If the fluid exceeds the UPPER LEVEL,
securely. remove the fluid using a dropping pipette or
others until the fluid drops to the UPPER
LEVEL. When you have removed the fluid
from the battery, neutralize it with the baking
soda (sodium bicarbonate) and wash it away
with a large quantity of water.
c6. Check of wiring harness for discoloration,
burn and cover peeling
• Check the wiring harness and cables for
discoloration and burn.
a If discolored or burnt, the circuit may be shorted
or grounded.
• Check the wiring harnesses and cables for
damage and peeling of the covers.
• If any abnormality is found, repair or replace the
wiring harness or cables.
c7. Check for coming off of wiring harness
clamp and sagging of wiring harness
40-26 PC138USLC-10
40 Troubleshooting
• Check wiring harness for sagging and looseness

due to coming off of harness clamp
a In particular, carefully check the wiring harness
around the hot and movable parts.
• If removed from the clamp, secure it with the
clamp.
• Open the engine hood.

• Check the connection of engine controller (EC)
ground (T15A) and between engine controller
mounting bracket and frame (2).
c8. Check of grounding

a Be especially careful for loose ground terminals
and corrosion.
• Remove cover from the underside of the cab.
• Check the connection of ground terminals
(between cab and revolving frame (1), (T01).
c9. Check for loose connector and damaged

lock.
• Check the connection of male and female
connectors by pulling them by hand.
• If the connection is loose, secure it.
• Check the connectors for unlocking, and check

the lock and connector housing for cracking.
• Check lock screws (L) of engine controller (EC)
for looseness.
• Check the connection of ground terminals (T04) a Use a hexagonal wrench with 4 mm width
to (T08), (T010), and (T12). across flats.
a The check cannot be done without removing
the battery.
PC138USLC-10 40-27
40 Troubleshooting
c10. Check the connector pins for corrosion, • Wipe and remove any foreign material with a
bending and deformation. cloth or others, and blow the air to clean the
• Disconnect the connectors, and check their pins connector.
for corrosion, bending, sinking than other pins,
and extension of female pins.
• If pins are defective, repair or replace them.
a If the pins are not shiny, apply contact restorer to
them and connect and disconnect the
connectors several times to shine them. (If the
pins do not become shiny, connect and
disconnect the connectors 10 times)
c11. Check of connector for water and foreign
material insertion.
• Disconnect connectors, and check them for
insertion of water or foreign materials.
c12. Check of wiring harness for open or short
circuit
• Check the connection (crimped part) between
connector pins and wiring harness.
• If the line is open as shown as (A), repair or
replace the wiring harness or cables.
a If found, the seals may be damaged. Check the

seals for damage.
• If the seal is defective, repair or replace it.
• Dry the inside of the connector with a dryer.
• Visually check wiring harnesses for peeling of

harness covers and the pins for contact with
adjacent pins due to defective crimping.
c13. Check of fuse for breakage and corrosion
a When replacing a fuse, be sure to turn off the
power (turn the starting switch to OFF position)
and turn the battery disconnect switch to OFF
position.
40-28 PC138USLC-10
40 Troubleshooting
• A fusible link is a large-capacity fuse. • If the relating circuit is normal, replace the
• If a fuse is corroded and coated with white battery relay.
powder, or there is any play between the fuse
and fuse holder, replace the fuse.
• Replace each fuse with the one of the same
capacity.
Remove the cover at the rear right of the operator
seat, and the fuse holder is seen.
Open the rear left cover to gain access to fusible

links (F02), F03), (F05), and (F06).
c14. Check of alternator voltage (when engine

speed is medium or higher)
1. Open the engine hood.
2. Connect the positive (+) lead of the multimeter to
alternator terminal (B) and connect the negative
(-) lead to the chassis ground.
3. Start and warm up the engine and measure the
voltage while running the engine at a medium or
a higher speed.
• If the voltage is abnormal, repair or replace
the alternator.
c15. Check of battery relay operation sound
1. Open the rear left side cover.
2. Turn the starting switch to the ON and OFF
positions, and check whether the battery relay
operation sound is heard or not.
• If the operation sound is not heard, check the
related circuits, referring to the description of
troubleshooting for E-1 described in the E
mode troubleshooting.
PC138USLC-10 40-29
40 Troubleshooting
Preparation for troubleshooting of electrical system (PC138-C050-001-K-00-A)
a When performing troubleshooting of electrical

system of machine monitor, engine controller,
pump controller and KOMTRAX communication
modem related, expose applicable connector
portion according to the following procedure.
a For connectors whose lock method is special,
perform disconnection and connection.
Preparation
1. Machine monitor
1) Remove 3 mounting screws of cover (1).
a One of the 3 screws is covered with cap
4) Insert or connect troubleshooting T-adapters
(2).
to connectors CM01, CM02, and CM04 on
a Disconnect connector P31 of sunlight machine monitor (7).
sensor and remove cover (1).
2) Remove a mounting bolt and duct (6). 1) Open the engine hood.
3) Insert a flat-head screwdriver in slit (3) and
pull it upward to remove cover (5) while a The engine controller is mounted on the
releasing lug (4). engine.
2) Insert or connect troubleshooting T-adapters
into or to connectors J1, J2, and CE03 of
engine controller (8).
a Since the connectors is secured with
screws, loosen them before
disconnecting the connector.
a When restore them, tighten the screws to
the specified torque.
3 Screw:3 ± 1 Nm {0.3 ± 0.1 kgm}
40-30 PC138USLC-10
40 Troubleshooting
3. Pump controller a The connectors of the pump controller

1) Slide the operator's seat and seat stand to have a special locking mechanism.
the forward end. Disconnect them according to steps (a) to
2) Remove holder cup (1). (c) and connect them according to steps
3) Remove bracket (2). (d) to (f) as shown below.
4) Remove cover (3). Disconnection: (a) Unlock - (b) Slide lever
- (c) Disconnect connector.
Connection: (d) Position connector - (e)
Slide lever - (f) Lock.
5) Remove electrical components sub plate (4)

and tilt it toward the front of machine.
4. KOMTRAX communication module

1) Referring to steps (1) to (5) in 3. Pump
controller, expose KOMTRAX
communication module.
2) Connect troubleshooting T-adapters to
connectors CK01 and CK02 of KOMTRAX
communication module (1).
6) Connect test adapters to connectors CP01

and CP02 of pump controller (5).
5. Ambient pressure sensor (PAMB)

Engine Ne speed sensor (NE)
Engine Bkup speed sensor (CAM)
Engine oil pressure switch (POIL)
Crankcase pressure sensor (CCV)
Mass air flow sensor (MAF)
PC138USLC-10 40-31
40 Troubleshooting
a Disconnection and connection of connectors a Removal and installation of sensor body

Since the connectors of the ambient Since a TORX wrench is necessary when
pressure sensor, engine Ne speed sensor, removing and installing the charge (boost)
engine Bkup speed sensor and engine oil pressure and temperature sensor, see "Tools
pressure switch have a special lock for testing, adjusting, and troubleshooting".
mechanism, disconnect them in the order of 7. Supply pump IMV solenoid (SCV)
(a) to (c), and connect them in the order of
a Disconnection and connection of connectors
(d) to (f) as shown in the following figure.
The connector of the supply pump IMV
Disconnection: (a) Slide the lever, (b) unlock,
solenoid has a special locking mechanism.
and (c) disconnect the connectors.
Disconnect it according to steps (a) to (b),
Connection: (d) Connect the connectors, (e) and connect it according to steps (c) to (d) as
engage the lock, and (f) slide the lever. shown below.
Disconnection: (a) Unlock and (b) disconnect
the connectors.
Connection: (c) Connect the connectors and
(d) engage the lock.
a Removal and installation of sensor body

Since a deep socket is necessary when
performing removal and installation of engine
oil pressure switch, see "Tools for testing,
adjusting, and troubleshooting". 8. Common rail pressure sensor (PFUEL)
6. Boost pressure and temperature sensor
a Disconnection and connection of connectors
(TMAP)
The connector of the common rail pressure
a Disconnection and connection of connectors sensor has a special locking mechanism.
The connector of the boost pressure Disconnect it according to steps (a) to (b),
temperature sensor has a special locking and connect it according to steps (c) to (d) as
mechanism. Disconnect it according to steps shown below.
(a) to (b), and connect it according to steps Disconnection: (a) Unlock and (b) disconnect
(c) to (d) as shown below. the connectors.
Disconnection: (a) Unlock and (b) disconnect Connection: (c) Connect the connectors and
the connectors. (d) engage the lock.
Connection: (c) Connect the connectors and
(d) engage the lock.
40-32 PC138USLC-10
40 Troubleshooting
a Precautions for disconnection of connectors a Disconnection and connection of connectors

The direction of the lock for connector may The connector of the engine coolant
be changed toward the difficult direction temperature sensor has a special locking
(facing to the bottom or to the engine side) mechanism. Disconnect it according to steps
for unlocking depending on the position (a) to (b), and connect it according to steps
where the sensor is screwed in. (c) to (d) as shown below.
In such a case, turn the lock to the direction Disconnection: (a) Unlock and (b) disconnect
(a) by using the needle nose pliers with the connectors.
curved tip (commercially available) [1], then Connection: (c) Connect the connectors and
the lock can be canceled easily. (d) engage the lock.
Since the lock is canceled with "click" sound,
listen the sound and disconnect the
connectors.
a Removal and installation of sensor body

Since a deep socket is necessary when
removing and installing the engine coolant
a Precautions for connecting connectors temperature sensor, see "Tools for testing,
When connecting connectors, pay attention adjusting, and troubleshooting".
not to connect the connectors reverse.
Engage lock portion (e) on the harness side
to triangle notch portion (f). (Pay attention not
to take square guide portion (g) on the
opposite side of triangle notch portion (f) by
mistake.)
9. Engine coolant temperature sensor (TWTR)
PC138USLC-10 40-33
40 Troubleshooting
Classification and procedure for troubleshooting (PC220-5160-40D-A-00-A)

Classification of troubleshooting
Mode Content
Display of Troubleshooting by failure code
code
E-mode Troubleshooting electrical system
H-mode Troubleshooting hydraulic and mechanical system
S-mode Troubleshooting engine
Procedure for troubleshooting

If a problem occurs in the machine, go to the corresponding troubleshooting section according to the following
procedure.
1. Troubleshooting procedure to be taken when action level and failure code are displayed on
machine monitor:
If an action level and a failure code are displayed on the machine monitor, carry out the troubleshooting for
the corresponding [Display of code] according to the displayed failure code.
a If multiple problems occur simultaneously, all the failure codes for the problems are displayed
repeatedly in order. Record all the failure codes.
2. Troubleshooting procedure to be taken when action level and failure code are not displayed on
normal screen of machine monitor:
Check a mechanical system failure code and an electrical system failure code with the abnormality record
function of the machine monitor. (See [*1])
1) If a code is recorded, carry out troubleshooting for the corresponding [Display of code] according to the
recorded code.
a If an electrical system failure code is recorded, delete all the codes once and reproduce them, and
then see if the trouble is still detected. (See [*2])
a A failure code of the mechanical system cannot be deleted.
a If abnormality related to air conditioner is displayed in electrical system abnormality record, perform
"Check with self-diagnosis" in "Air conditioner".
2) If no failure code is recorded in the abnormality record, a failure that the machine cannot find out by
itself may have occurred in the electrical system or hydraulic and mechanical system.
In this case, check the problem which seems to be a failure again and select the same problem from
the table of "Problem which seems to be failures and troubleshooting Nos.", and then carry out
troubleshooting corresponding to that problem in the [E-mode], [H-mode], or [S-mode].
3. Actions to take after failure is repaired
Referring to following page, delete all failure codes in electrical system abnormality record.
[*1]、[*2]
1. On the normal operation screen, while pressing number key [4] in the panel switch section, press [1], [2],
and [3] in this order.
2. On the service menu screen, press switch [F3] (R) in the panel switch section twice, and then select "03
Abnormality Record".
3. Press switch [F6] in the panel switch section to confirm, and then enter the "Abnormality record" screen.
40-34 PC138USLC-10
40 Troubleshooting
4. Press switch [F6] in the panel switch section to confirm, and then enter the "Mechanical system failure
record" screen.
5. Press switch [F3] (R) in the panel switch section to check failure codes one by one and take record of all
information of all failure codes.
a A failure code of the mechanical system cannot be deleted.
6. Press switch [F5] (return) in the panel switch section to return to the "Abnormality record" screen.
7. Similarly to 2 and 3, enter the "Electrical system abnormality record" screen.
8. Press switch [F3] (R) in the panel switch section to check failure codes one by one and take record of all
information of all failure codes.
a If [E] is displayed on the left of a failure code, that failure code is "active" (the failure is still occurring or
normal resetting is not confirmed yet). If [E] is not displayed on the left of a failure code, that failure
code is "non-active" and disappears in the following clearing step. Accordingly be sure to take record
of that failure code.
9. While pressing number key [4] in the panel switch section, press [1], [2], and [3] in this order to enter the
"Clearing mode". (Same as 1)
10.Press switch [F2] (CLEAR) in the panel switch section.
11.Press switch [F6] in the panel switch section to clear all failure codes temporarily.
12.Press switch [F5] (return) in the panel switch section to return to the "Electrical system abnormality record"
screen. Check if there is any failure code still displayed and take record.
13.Press switch [F5] (return) in the panel switch section to return to the "Abnormality record" screen.
PC138USLC-10 40-35
40 Troubleshooting
14.Take record of information of all columns.

a Similarly to the electrical system abnormality record, if "E" is displayed on the left of a failure code, that
failure code is "active"
(the failure is still occurring or normal resetting is not confirmed yet).
15.Press switch [F2] (CLEAR) in the panel switch section to clear all codes temporarily. Check if "Abnormal"
is still displayed and take record. (Same as 10 in [*1] and [*2])
16.Press switch [F5] (return) in the panel switch section to return to the "Abnormality record" screen.
40-36 PC138USLC-10
40 Troubleshooting
Symptom and troubleshooting numbers (PC138-5540-441-A-00-A)
Problem and troubleshooting number

Troubleshooting
No. Problem
Index
Action level, failure code
Action level is displayed on machine monitor. If function key [F5] is pressed,
1 occurring failures list is displayed. Take actions by
The failure code is displayed on the mechanical system abnormality record screen following the
2
failure code.
3 The failure code is displayed on the electrical system abnormality record screen
Troubleshooting
No. Problem
Index
Phenomena related to engine
4 Starting performance is poor. S-4
5 Engine does not start E-1, S-1
6 When starting switch is turned to "START" position, engine is not rotated S-1, E-1
7 Engine is cranked but exhaust gas does not come out S-2
8 Fuel is injected but engine does not start S-3
9 Engine does not pick up smoothly S-5
10 Engine stops during operation S-6, H-2
11 Engine runs rough or is unstable S-7
12 Engine lacks power S-8
13 Exhaust gas color is black S-9
14 Oil consumption is increased. S-10
15 Oil becomes contaminated quickly. S-11
16 Fuel consumption is excessive S-12
17 Oil is in coolant (or coolant spurts back or coolant level goes down) S-13
18 Oil pressure drops S-14
19 Fuel in oil S-15
20 Oil is mixed with water (milkiness) S-16
21 Coolant temperature rises too high (overheating) S-17
22 Unusual noise is heard S-18
23 Vibration is excessive S-19
24 Frequency of automatic regeneration is increased S-20
25 Manual preheater does not operate. E-2
26 While preheater is operating, preheating monitor does not light up. E-3
27 Automatic warm-up system does not work (in cold weather). E-21
When auto-decelerator switch is operated, auto-decelerator monitor does not light
28 up or does not go off. E-22
29 Auto-decelerator is not operated or canceled with lever. E-23
Symptom related to work equipment, swing and travel
30 Any of work equipment, swing, and travel does not work. E-31, H-3
31 All of work equipment, swing, and travel mechanism do not lock. E-32
32 Speed or power of all work equipment, swing and travel is low. H-1
33 Engine speed lowers extremely or engine stalls. H-2, S-6
When working mode switch is operated, working mode selection screen is not
34 displayed. E-24
When working mode is changed, setting of engine and hydraulic pump is not
35 changed. E-25
36 Abnormal sound comes out from around hydraulic pump H-4
37 Fine control performance or response is low H-5
Problems related to work equipment
38 Speed or power of boom is low. H-6
PC138USLC-10 40-37
40 Troubleshooting
Troubleshooting
No. Problem
Index
39 Speed or power of arm is low. H-7
40 Speed or power of bucket is low H-8
41 Work equipment single operation does not function. H-9
42 Hydraulic drift of boom is large. H-10
43 Hydraulic drift of arm is large. H-11
44 Hydraulic drift of bucket is large. H-12
45 Time lag in work equipment operation is large. H-13
46 When attachment is installed, attachment circuit is not switched to desired one. H-32, E-51
47 Flow rate of attachment circuit cannot be adjusted H-33
Problems related to combined operation
48 Work equipment on large load side moves slower during combined operation H-14
When performing combined operation of swing and boom RAISE , boom RAISE
49 speed is slow. H-15
When performing combined operation of swing and travel , travel speed lowers
50 significantly. H-16
Problems related to travel
51 Machine deviates during travel H-17
52 Travel speed is low H-18
53 Machine is not steered well or steered-travel power is low. H-19
54 Travel speed does not switch or travel speed is too low or high. H-22, E-26, E-27
55 Travel system does not work (only one side) H-21
56 Alarm does not sound during travel. E-35
57 Alarm does not stop sounding while machine is stopped. E-36
Problems related to swing
58 Upper structure swings neither to the right nor left H-22
59 Upper structure does not swing in only one direction H-23
60 Swing acceleration is poor or swing speed is slow in both right and left directions. H-24
Swing acceleration performance is poor or swing speed is slow in only one
61 H-25
direction.
Upper structure overruns excessively when it stops swinging in both right and left
62 H-26
directions.
63 Upper structure overruns excessively when it stops swinging in only one direction. H-27
64 Large shock is made when upper structure stops swinging H-28
65 Large unusual noise is heard when upper structure stops swinging. H-29
66 While swing brake is applied, swing drift on slope is large. H-30
67 While swing brake is released, swing drift on slope is large. H-31
When swing brake cancel switch is set to CANCEL position, machine cannot
68 swing. E-33
When swing brake cancel switch is set to Normal position, swing holding brake
69 does not operate. E-34
Problems related to machine monitor
70 When starting switch is turned to ON position, machine monitor displays nothing E-4
When starting switch is turned to ON position (with engine stopped), engine oil level
71 monitor lights up in yellow. E-5
72 Engine coolant temperature monitor lights in white while engine is running. E-6
73 Hydraulic oil temperature monitor lights in white while engine is running. E-7
74 Charge level monitor lights up while engine is running. E-8
75 Fuel level monitor lights up in red while engine is running. E-9
76 Engine coolant temperature monitor lights in red while engine is running. E-10
77 Hydraulic oil temperature monitor lights in red while engine is running. E-11
78 Engine oil pressure monitor lights in red while engine is running. E-12
79 Fuel level gauge keeps indicating minimum or maximum. E-13
40-38 PC138USLC-10
40 Troubleshooting
Troubleshooting
No. Problem
Index
Fuel level gauge does not indicate actual fuel level (Indication is not minimum or
80 maximum). E-14
81 Engine coolant temperature gauge keeps indicating minimum or maximum. E-15
Engine coolant temperature gauge does not indicate actual coolant temperature
82 (Indication is not minimum or maximum). E-16
83 Hydraulic oil temperature gauge keeps indicating minimum or maximum. E-17
Hydraulic oil temperature gauge does not indicate actual oil temperature (Indication
84 is not minimum or maximum). E-18
85 Machine monitor does not display partially. E-19
86 Function switch does not operate E-20
87 Alarm buzzer cannot be canceled E-28
88 When starting switch is in OFF position, service meter is not displayed. E-29
89 Machine monitor cannot be set in service mode E-30
90 Horn does not sound. E-37
91 Horn does not stop sounding. E-38
92 When wiper switch is operated, wiper monitor does not light up or go off. E-39
93 When wiper switch is operated, windshield wiper does not operate. E-40
94 When window washer switch is operated, window washer does not operate. E-41
"Testing and
Air conditioner does not operate normally (including failure code related to air troubleshooting
95 conditioner) procedure" in
Chapter 80
96 Monitoring function does not display lever control signal normally E-42 to E-50
Others
97 KOMTRAX system does not work properly E-52
PC138USLC-10 40-39
40 Troubleshooting
Information in troubleshooting table (ALL-5170-421-A-01-A)
(Rev. 2011/12)
a The following information is summarized in the troubleshooting table. Before performing troubleshooting,
understand that information fully.
Action level Failure code
Display on Failure name displayed on the Abnormality Record screen
Display on Failure
machine of the machine monitor
machine monitor
monitor
Detail of Description of the failure detected by the machine monitor or controller
failure
Action of An action that is performed to protect the system and devices when a failure is detected by
controller the machine monitor or controller
Problem on A problem that appears as a failure on the machine as a result of an action (above) that is
machine performed by the machine monitor or controller.
Related Information on occurred failure or troubleshooting
information
No. Cause Procedure, measuring location, criteria and remarks
1 Defective — <Contents of description>
Open or short circuit in wiring • Procedure
2
harness • Measuring location
Open circuit in wiring harness
a "Between A and B" denotes measuring values such as voltage
3 (wire breakage or defective and resistance between A and B.
contact of connector)
Ground fault in wiring harness a "Between A and ground" means the measurement of voltage,
4 resistance or others between terminal A and the place which has
(contact with ground circuit) a continuity with chassis frame such as unpainted hexagonal
5 Hot short circuit head bolt or bolt hole which has no rust, etc.
• Criteria to judge probable causes (standard value), remarks
<How to use troubleshooting sheet>
• Perform troubleshooting procedures in numerical order.
• If the check result does not meet the criteria, the probable cause
described on the left column is the actual cause of the failure.
• If the check result meet the criteria and there is no specific
instruction, proceed to the next step (cause).
• If a defect is found and repaired, check that the defect has been
corrected.
<Failures in wiring harness>
Short circuit in wiring harness
6 • Open circuit
Connection of connector is defective or wiring harness is broken.
• Ground fault
A harness not to be connected to the ground (earth) circuit comes
into contact with the ground (earth) circuit or chassis accidentally.
• Hot short circuit
A harness not to be connected to the power circuit comes into
contact with the power circuit accidentally.
• Short circuit
An independent wire in the harness erroneously comes into contact
with another independent wire.
(poor insulation at connector and others)
40-40 PC138USLC-10
40 Troubleshooting

<Precautions for troubleshooting>
(1) Connector number indication method and handling of T-adapter
For troubleshooting, insert or connect T-adapters as follows unless
otherwise specified.
• When "male" or "female" is not indicated with a connector number,
disconnect the connector, and insert T-adapter between the male
and female connectors.
7 Defective controller • When "male" or "female" is indicated with a connector number,
disconnect the connector, and connect T-adapter to the male or
female connector.
(2) Pin number description sequence and tester lead handling
For troubleshooting, connect the positive (+) and negative (-) leads as
shown below unless otherwise specified.
• Connect the positive (+) lead to pin or wire indicated first.
• Connect the negative (-) lead to a pin or wire indicated second.
Related circuit diagram

This is the excerpted circuit diagram related to
troubleshooting
• The circuit diagram contains the connector Nos.,
pin Nos., and connector colors related to the
failure.
• The “/“ in a connector number is either:
1) An abbreviation (of more than three letters)
Example: T/C (Torque Converter)
2) Different connector number at male and female
sides
Example: BREAK OUT/E24
• The circuit diagram contains the destination or
source of the branch line in a wiring harness.
• The arrow (io) indicates a rough installation
position on the given machine.
• NO: Normally Open
• NC: Normally Closed
• Signal names such as GND and 24 V are included
in addition to connector numbers at junctions, etc.
in circuit diagrams.
• Except for GND and 24 V, a signal name indicated
at a junction, etc. shows that the wire is connected
to another junction or controller at where the same
signal name is indicated.
PC138USLC-10 40-41
40 Troubleshooting
Troubleshooting method for open circuit in wiring harness of pressure

sensor system (D65-E720-42A-P-00-A)
a Since the pressure sensors consist of not only resistor but also electronic circuit components such as
amplifiers they have variation in measured value and their own polarities. So troubleshooting must be
performed carefully.
Failure codes applicable to this diagnosis
• CA123: Charge air pressure sensor low error
Procedure
1. Measure and record resistance of pressure sensor unit.
1) Disconnect pressure sensor connector (1) and connect socket (2) to the sensor side connector.
2) Measure resistances R1 and R2 between pins.
a If the polarities of multimeter probes to apply are reversed, measured values may change.
Therefore, when measuring the resistances in steps 1 and 2, apply the multimeter probes to the
pressure sensor connector so that their polarities match those of the sensor.
a If the measured value is infinite, take measurements by applying the probes of the opposite
polarities and record the finite value obtained as a measured value.
a Since the measured values may be dispersed, take several measurements.
The cause of this dispersion appears to be an electric charge in a sensor. Take measurements
several times in steps 1 and 2. Consider this dispersion when judging whether or not the wiring
harness is open in step 3.
2. Measure and record the resistance of the wiring harness between the pressure sensor and engine
controller connected.
1) Since 5 V power supply to the pressure sensor is supplied to other sensors, disconnect other sensor
connectors first. (*)
2) With the pressure sensor to measure connected, disconnect connector (3) on the engine controller
side, and connect T-adapter (4) to the wiring harness side connector.
3) Connect T-box (5) to T-adapter (4) and measure resistances R1' and R2' between respective pins.
3. Judging open circuit
If there is an "apparent difference" between resistances R1 and R2 measured in step 1 and resistances
R1' and R2' measured in step 2, the "wiring harness is open".
a "Apparent difference" means a difference of 10 or more times.
40-42 PC138USLC-10
40 Troubleshooting
List of pressure sensor measuring locations and reference values
Measuring location at Measured internal

Sensor sensor pin resistance of sensor Remarks
(reference)
Charge pressure R2: between (2) and (4) Approx. 100 z Sensor is common to engine
sensor R1: between (1) and (4) Approx. 200 z models 107 and 114
*: When measuring R2', disconnect the following: (See the circuit diagram related to each failure code)
• When measuring R2' of charge pressure sensor (CA123):
Connectors of ambient air pressure sensor, CAM sensor and boost pressure sensor
Measurement record (For measuring locations, see circuit diagram related to each failure code.)
Sensor + Wiring harness
Sensor unit (Measuring location on
Sensor (Measuring location on Measured value wiring harness side Measured value
sensor pin side connetor) connector of engine
controller)
R2': Between (60) and
R2: between (2) and (4)
Charge pressure (59) (*)
sensor R1': Between (15) and
R1: between (1) and (4)
(59)
PC138USLC-10 40-43
40 Troubleshooting
Connector list and layout (PC138_10-C050-055-K-00-A)
Connector Number
Connector type Equipment name Address
No. of pins
A08 DT 6 Arm and boom angle potentiometer D-1
A09 AMP 3 Boom cylinder bottom pressure sensor E-1
A13 DT 2 Intermediate connector C-8
A40 DT 4 Camera C-9
A41 DT 4 Intermediate connector D-9
A46 DT 4 Camera 2 E-9
AB Terminal 1 Alternator terminal B H-9
AC01 YAZAKI 10 Air conditioner unit U-9
AC02 SUMITOMO 4 Air conditioner unit V-9
AC03 X 1 Air conditioner compressor solenoid clutch J-7
CAM FRAMATOME 3 CAM sensor (Bkup) AI-1
CCV FRAMATOME 3 Crankcase pressure sensor AF-5
CE03 DRC 60 Engine controller B-9
CK01 070 18 KOMTRAX controller X-8
CK02 070 12 KOMTRAX controller X-8
CM01 070 18 Machine monitor N-8
CM02 070 12 Machine monitor N-8
CM03 070 20 Machine monitor O-8
CM04 070 8 Machine monitor M-7
CN1 DT 4 Injector (#1 and #2) AE-5
CN2 DT 4 Injector (#3 and #4) AH-5
CP01 AMP 81 Pump controller X-5
CP02 AMP 40 Pump controller X-4
D01 SWP 8 Diode X-7
D02 SWP 8 Diode X-7
D03 SWP 8 Diode X-7
E01 Terminal 1 Electrical intake air heater (ribbon heater) I-8
E12 SUMITOMO 3 Alternator (terminal G,L) H-8
E24/OEM
BREAK- FRAMATOME 6 Intermediate connector (OEM BREAKOUT) AI-4
OUT
EGR V SUMITOMO 8 EGRV AH-5
F01 Terminal 20 Fuse V-9
F02 L 2 Fusible link K-8
F03 L 2 Fusible link K-8
F04 Terminal 1 Fuse K-9
H08 M 4 Intermediate connector (speaker) X-5
H09 M 8 Intermediate connector (CAB roof) X-5
H14 S 10 Intermediate connector (R.H. console harness) T-1
H15 090 22 Intermediate connector (R.H. console harness) T-1
H16 S 22 Intermediate connector (L.H. console harness) X-3
H24 X 2 Intermediate connector (heated seat) W-2
J01 SUMITOMO 20 Junction connector W-2
J02 SUMITOMO 20 Junction connector V-1
J03 SUMITOMO 20 Junction connector X-2
40-44 PC138USLC-10
40 Troubleshooting
Connector Connector type Number Equipment name

of pins Address
No.
J1(CE01) DRC 60 Engine controller AF-8
J2(CE02) DRC 60 Engine controller AF-9
K01 M 2 Pump (PC) resistor U-9
K02 DT 3 CAN terminating resistor B-8
L01 DT 2 Working lamp (boom) A-7
L03 M 2 Room lamp Z-7
L05 SWP 2 Intermediate connector AA-8
L19 DT 2 System operating lamp L-8
M01 PA 10 Radio V-2
M01A — 3 Radio V-2
M01B M 3 Intermediate connector X-6
M01C — 3 AUX jack AD-1
M02 M 2 L.H. speaker Z-9
M03 M 2 R.H speaker AA-8
M04 YAZAKI 2 Cigarette lighter X-6
M05 M 6 Wiper motor M-6
M06 YAZAKI 2 Window washer tank K-3
M07 090 2 Horn (treble tone) M-1
M09 M 2 Optional power source (1) S-9
M10 X 2 Intermediate connector (DC/DC converter) T-9
M11 DT 2 DC/DC converter —
M12 X 2 12V optional power source T-9
M13A M 2 12 V socket X-8
M13B M 2 12 V socket X-7
M14 DT 2 Travel alarm E-9
M1A X 2 Optional power source (continuous power supply) W-3
M35 DT 2 Heated seat S-9
M36 DT 2 Air suspension system S-9
M40 YAZAKI 2 Headlamp Y-5
M41 YAZAKI 2 Headlamp Y-6
N08 DT 12 Service connector V-9
NE FRAMATOME 3 Engine speed sensor AI-1
P01 X 2 Arm OUT (oil) pressure switch A-2
P02 X 2 boom RAISE hydraulic (oil) pressure switch A-2
P03 X 2 Bucket DUMP (oil) pressure switch A-2
P04 X 2 Bucket DIGGING pressure switch A-2
P05 X 2 Arm IN (oil) pressure switch A-1
P06 X 2 boom LOWER oil pressure switch A-1
P07 X 2 Swing hydraulic (oil) pressure switch (right) A-1
P08 X 2 Swing hydraulic (oil) pressure switch (left) A-1
P09 AMP 3 R.H. travel FORWARD pressure sensor C-1
P10 AMP 3 L.H. travel FORWARD pressure sensor C-1
P11 AMP 3 Blade LOWER oil pressure sensor C-1
P12 DT 6 Intermediate connector (travel,blade oil pressure sensor) B-2
P13 X 2 Intermediate connector (oil pressure switch for service) M-3
P14 X 2 Front oil pressure switch for service M-1
P15 X 2 Rear oil pressure switch for service M-2
P17 S090 2 Air conditioner Hi/Lo pressure switch O-1
P18 090 2 Air conditioner outside air temperature sensor K-4
P20 M 3 Fuel control dial P-8
P21 DT 2 Fuel level sensor D-8
P22 DT 2 Hydraulic oil temperature sensor G-9
PC138USLC-10 40-45
40 Troubleshooting
Connector Number
Connector type Equipment name Address
No. of pins
P25 AMP 3 Pump pressure sensor C-2
P26 AMP 3 R.H. travel REVERSE pressure sensor C-3
P27 AMP 3 L.H. travel REVERSE pressure sensor C-2
P28 AMP 3 Blade RAISE oil pressure sensor C-2
P29 DT 6 Intermediate connector A-3
P31 050 2 Sunlight sensor N-7
P44 DT 2 Engine oil level sensor G-1
P48 DT 4 Fuel identification sensor F-1
P49 AMP 3 Service pressure sensor D-9
P55 FRAMATOME 4 MAF sensor K-7
PAMB FRAMATOME 3 Ambient pressure sensor AI-5
PFUEL AMP 3 Common rail pressure sensor AJ-5
POIL FRAMATOME 2 Engine oil pressure switch AI-2
R01 Terminal 1 Battery relay terminal E K-5
R02 Terminal 1 Battery relay terminal BR K-4
R03 Terminal 1 Battery relay terminal M K-5
R04 Terminal 1 Battery relay terminal B K-4
R05 Relay 5 Lamp relay V-9
R06 Relay 5 Starting motor cut-off relay (PPC lock) X-6
R07 Relay 5 Starting motor cut-off relay (personal code) X-5
R12 Relay 5 Cab light relay W-9
R13 Relay 5 Relay for heated seat T-9
R15 Terminal 1 Electrical intake air heater (ribbon heater) relay K-3
R16A Terminal 1 Electrical intake air heater (ribbon heater) relay H-1
R16B Terminal 1 Electrical intake air heater (ribbon heater) relay K-2
R17 X 2 Intermediate connector K-3
R21 Relay 5 Compressor relay X-6
R22 Relay 5 Relay for arm crane W-9
R28 Terminal 1 Starting motor safety relay terminal B K-2
R29 Terminal 1 Starting motor safety relay terminal C K-2
S01 Terminal 6 Starter switch M-9
S02 SWP 6 Daytime light switch P-9
S04 SWP 6 Swing lock switch Q-9
S07 SWP 6 Revolving warning lamp switch Q-9
S10 Y090 2 R.H. knob switch (horn) M-9
S15 SWP 6 Heated seat switch Q-9
S18 SWP 6 Engine shutdown secondary switch U-1
S19 DT 2 Seat belt monitor switch W-3
S21 Terminal 6 Emergency pump drive switch X-9
S22 Terminal 6 Swing parking brake switch X-9
S25 S 10 Emergency activation switch X-9
SB Terminal 1 Starter B terminal J-7
SC Terminal 1 Starter C terminal J-7
SCV SUMITOMO 2 Supply pump flow sensor AG-6
T01 Terminal 1 Ground (floor frame) U-2
T02 Terminal 1 Ground (cab) AD-2
T03 Terminal 1 Ground (radio body) W-3
T04 Terminal 1 Ground (revolving frame) L-5
T08 Terminal 1 Ground (revolving frame) K-5
40-46 PC138USLC-10
40 Troubleshooting
Connector Connector type Number Equipment name

of pins Address
No.
T10 Terminal 1 Ground (revolving frame) K-6
T12 Terminal 1 Ground (engine cylinder block) K-5
T13 Terminal 1 Ground R-9
T15A Terminal 1 Ground (engine controller case) B-8
T15B Terminal 1 Ground (engine controller case) G-1
TMAP SUMITOMO 4 Intake air temperature sensor AJ-6
TWTR DELPHI 2 Coolant temperature sensor AF-9
V01 DT 2 PPC source pressure solenoid valve A-8
V02 DT 2 Travel Hi/Lo selecting solenoid A-8
V03 DT 2 Swing parking brake solenoid valve A-9
V04 DT 2 Travel flow solenoid valve A-9
V05 DT 2 Merge-divider valve A-9
V06 DT 2 Attachment return selector solenoid valve A-8
V10 DT 2 Cancel bucket dump solenoid C-7
V11 DT 2 PC-EPC valve G-9
V30 DT 2 Attachment oil flow adjusting EPC M-4
VFT SUMITOMO 8 VFT AJ-9
W03 X 2 Rear limit switch Z-8
PC138USLC-10 40-47
40 Troubleshooting
Layout of connectors (1/6)
40-48 PC138USLC-10
40 Troubleshooting
PC138USLC-10 40-49
40 Troubleshooting
40-50 PC138USLC-10
40 Troubleshooting
PC138USLC-10 40-51
40 Troubleshooting
40-52 PC138USLC-10
40 Troubleshooting
PC138USLC-10 40-53
40 Troubleshooting
Connector contact identification (ALL-5310-030-A-00-A)
(Rev. 2012. 09)
a The terms of male and female refer to the pins, while the terms of male housing and female housing refer
to the mating portion of the housing.
40-54 PC138USLC-10
40 Troubleshooting
PC138USLC-10 40-55
40 Troubleshooting
40-56 PC138USLC-10
40 Troubleshooting
PC138USLC-10 40-57
40 Troubleshooting
40-58 PC138USLC-10
40 Troubleshooting
PC138USLC-10 40-59
40 Troubleshooting
40-60 PC138USLC-10
40 Troubleshooting
PC138USLC-10 40-61
40 Troubleshooting
40-62 PC138USLC-10
40 Troubleshooting
PC138USLC-10 40-63
40 Troubleshooting
40-64 PC138USLC-10
40 Troubleshooting
PC138USLC-10 40-65
40 Troubleshooting
40-66 PC138USLC-10
40 Troubleshooting
PC138USLC-10 40-67
40 Troubleshooting
40-68 PC138USLC-10
40 Troubleshooting
PC138USLC-10 40-69
40 Troubleshooting
40-70 PC138USLC-10
40 Troubleshooting
PC138USLC-10 40-71
40 Troubleshooting
40-72 PC138USLC-10
40 Troubleshooting
PC138USLC-10 40-73
40 Troubleshooting
40-74 PC138USLC-10
40 Troubleshooting
PC138USLC-10 40-75
40 Troubleshooting
40-76 PC138USLC-10
40 Troubleshooting
PC138USLC-10 40-77
40 Troubleshooting
40-78 PC138USLC-10
40 Troubleshooting
PC138USLC-10 40-79
40 Troubleshooting
40-80 PC138USLC-10
40 Troubleshooting
PC138USLC-10 40-81
40 Troubleshooting
40-82 PC138USLC-10
40 Troubleshooting
PC138USLC-10 40-83
40 Troubleshooting
40-84 PC138USLC-10
40 Troubleshooting
PC138USLC-10 40-85
40 Troubleshooting
40-86 PC138USLC-10
40 Troubleshooting
PC138USLC-10 40-87
40 Troubleshooting
40-88 PC138USLC-10
40 Troubleshooting
PC138USLC-10 40-89
40 Troubleshooting
40-90 PC138USLC-10
40 Troubleshooting
PC138USLC-10 40-91
40 Troubleshooting
T-branch box and T-branch adapter table (ALL-5330-305-A-00-A)
(Rev. 2012. 09)
a The vertical column indicates a part number of T-branch box or T-branch adapter, while the horizontal
column indicates a part number of harness checker assembly.
T-adapter kit
Identification symbol
Number of pins
Out of kit
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Part number Part name
799-601-2600 T-box (for ECONO) 21 q q q q q

799-601-3100 T-box (for MS) 37 q
799-601-3200 T-box (for MS) 37 q
799-601-3380 Plate for MS (14-pin) q
799-601-3410 Adapter for BENDIX (MS) 24 MS-24P q
799-601-3470 Case q
799-601-2710 Adapter for MIC 5 MIC-5P q q q
799-601-2720 Adapter for MIC 13 MIC-13P q q q
799-601-2730 Adapter for MIC 17 MIC-17P q q q q q q
799-601-2740 Adapter for MIC 21 MIC-21P q q q q q q
799-601-2950 Adapter for MIC 9 MIC-9P q q q q
Adapter for ECONO ECONO
799-601-2750 2 q q
2P
799-601-2760 3 q q
3P
799-601-2770 4 q q
4P
799-601-2780 8 q q
8P
799-601-2790 12 q q
12P
799-601-2810 Adapter for DLI 8 DLI-8P q q
Extension cable (ECONO ECONO
799-601-2840 type) 12 q q q
12P
799-601-2850 Case q
T-box (for DRC60, q
799-601-4350 ECONO) 60
799-601-4360 Case q
799-601-7010 Adapter for X (T-adapter) 1 q q
799-601-7020 Adapter for X 2 X2P q q q q
40-92 PC138USLC-10
40 Troubleshooting
T-adapter kit
Number of pins
Out of kit
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201

799-601-7050 Adapter for SWP 6 SW6P q q q
799-601-7060 Adapter for SWP 8 SW8P q q q
799-601-7310 Adapter for SWP 12 SW12P q
799-601-7070 Adapter for SWP 14 SW14P q q
799-601-7320 Adapter for SWP 16 SW16P q
799-601-7080 Adapter for M (T-adapter) 1 q q
799-601-7090 Adapter for M 2 M2P q q q q
799-601-7340 Adapter for M 8 M8P q
799-601-7140 Adapter for S 8 S8P q q q q
799-601-7150 Adapter for S (White) 10 S10P q q q q
799-601-7160 Adapter for S (Blue) 12 S12P q q q
799-601-7170 Adapter for S (Blue) 16 S16P q q q q
799-601-7330 Adapter for S (White) 16 S16PW q
799-601-7350 Adapter for S (White) 12 S12PW q
799-601-7180 Adapter for AMP040 8 A8P q
799-601-7190 Adapter for AMP040 12 A12P q q
799-601-7210 Adapter for AMP040 16 A16P q q q q
799-601-7220 Adapter for AMP040 20 A20P q q q q
799-601-7230 Short connector for X 2 q q q q
799-601-7240 Case q q
799-601-7270 Case q
799-601-7510 Adapter for 070 10 07-10 q
799-601-7520 Adapter for 070 12 07-12 q
799-601-7530 Adapter for 070 14 07-14 q
799-601-7540 Adapter for 070 18 07-18 q
799-601-7550 Adapter for 070 20 07-20 q
799-601-7360 Adapter for relay 5 REL-5P q
799-601-7370 Adapter for relay 6 REL-6P q
799-601-7380 Adapter for JFC 2 q
799-601-9010 Adapter for DTM 2 DTM2 q q
799-601-9020 Adapter for DT 2 DT2 q q q q
799-601-9030 Adapter for DT 3 DT3 q q
799-601-9040 Adapter for DT 4 DT4 q q q q
799-601-9050 Adapter for DT 6 DT6 q q
799-601-9060 Adapter for DT (gray) 8 DT8GR q q
799-601-9070 Adapter for DT (black) 8 DT8B q q
799-601-9080 Adapter for DT (green) 8 DT8G q q
799-601-9090 Adapter for DT (Brown) 8 DT8BR q q
799-601-9110 Adapter for DT (gray) 12 DT12GR q q
PC138USLC-10 40-93
40 Troubleshooting
T-adapter kit
Number of pins
Out of kit
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
799-601-9120 Adapter for DT (black) 12 DT12B q q

799-601-9130 Adapter for DT (green) 12 DT12G q q
799-601-9140 Adapter for DT (Brown) 12 DT12BR q q
799-601-9210 Adapter for HD30-18 8 D18-8 q q
799-601-9310 Plate for HD30 (24-pin) q q q
799-601-9320 T-box (for ECONO) 24 q q q
799-601-9330 Case q
799-601-9340 Case q
799-601-9350 Adapter for DRC 40 DRC-40 q
799-601-9360 Adapter for DRC 24 DRC-24 q
799-601-9410* Socket for engine (CRI-T2) 2 G q
Adapter for engine (CRI- q q
T2)
799-601-9420 Adapter for engine (CRI- 3 A3
T3) PFUEL
Oil pressure sensor
Socket for engine (CRI-T2) q q
799-601-9430* Socket for engine(CRI-T3) 2 P
PCV
799-601-9440* Socket for engine (CRI-T2) 3 1, 2, 3 q
795-799-5520* Socket for engine (HPI-T2) 2 S q
Socket for engine (HPI-T2) q q
795-799-5530* Socket for engine (CRI-T3) 2 C
Temperature sensor
Socket for engine (HPI-T2) q q
795-799-5540* Socket for engine(CRI-T3) 2 A
TIM
795-799-5460 Cable for engine (HPI-T2) 3 q
Adapter for engine (140-T3) q q
799-601-4110 4 ITT3N
PIM
799-601-4130 T3) NE, CAM 3 FCIN
799-601-4140 T3) 3 FCIG
Ambient pressure
40-94 PC138USLC-10
40 Troubleshooting
T-adapter kit
Number of pins
Out of kit
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201

799-601-4150 T3) POIL 3 FCIB
799-601-4160 T3) 2 4160
Oil pressure switch
799-601-4180 T3) PEVA 3 4180
799-601-4190* 3 1, 2, 3L
Rail pressure
1, 2, 3,
799-601-4230* Air intake pressure/ 4
4C
temperature
799-601-4240* 3 1, 2, 3A
PAMB
799-601-4250* 3 1, 2, 3B
PIM
Socket for engine (CRI-T3) 1, 2, 3, q q
799-601-4330* 3
G G
799-601-4340* 2 2, PA
Pump actuator
Socket for engine (CRI-T3)
(95) 1, 2, 3,
799-601-4380* 4 q
Air intake pressure/ 4T
temperature
Adapter for controller q q
799-601-4260 (ENG) 4 DTP4
Adapter for controller q
799-601-4211 (ENG) 50 DRC50
Adapter for controller q
799-601-4220 (ENG) 60 DRC60
Socket for controller (95
799-601-4390* ENG) 60 q
799-601-4280* Box for controller (PUMP) 12- q

1
799-601-9720 Adapter for controller (HST) 16 HST16A q
799-601-9710 Adapter for controller (HST) 16 HST16B q
799-601-9730 Adapter for controller (HST) 26 HST26A q
2,
Multi-adapter for pins DT2
799-601-9890 3, q
to 4 and DTM2
4
*: Shows not T-adapter but socket.
PC138USLC-10 40-95
40 Troubleshooting
T-adapter kit
Number of pins
Out of kit
799-A65-4600
799-601-4620 Adapter for controller (ENG-T4) 4 799-601-4620 q

KDPF delta pressure sensor
799T-601-4611 4 799T-601-4611 q
short connector
KDPF outlet pressure sensor
799T-601-4670 4 799T-601-4670 q
short connector
KDPF dummy temperature
799T-601-4680 4 799T-601-4680 q
sensor
40-96 PC138USLC-10
40 Troubleshooting
Fuse location table (PC138_10-5530-04D-A-00-A)

Connection table of fuse box
a This connection table shows the fuse box and the devices which receive the power from the fuse box ( A
switched power supply is the power which is supplied while the starting switch is in ON position and an
unswitched power supply is the power which is supplied while the starting switch is in OFF and ON
positions).
a When performing troubleshooting related to the electrical system, check the fuses and fusible links to see
if the power is supplied properly.
Type of Power Fuse
power supply to Fuse No. Destination of power
capacity
supply fuse
1 5A Working lamp relay, emergency switch
2 30 A Solenoid valve
3 5A PPC oil pressure lock solenoid valve
4 10 A Window washer motor, cigarette lighter
5 10 A Horn
6 5A Spare
Fusible link
Switched 7 10 A –
F02 (65 A)
power 8 10 A Radio and speaker
supply 9 20 A Working lamp
10 20 A Air conditioner unit
11 10 A Headlamp (if equipped)
12 10 A Optional power supply (1)
13 20 A Optional power supply (2), power supply of 12 V
Starting 14 5A Air conditioner controller power supply
switch 15 5A Key ACC signal
16 10 A Radio backup, room lamp, system operating lamp
Continu- 17 20 A Machine monitor, pump controller
Fusible link
ous power 18 30 A Engine controller
F03 (45 A)
supply 19 5A Engine controller backup
20 10 A Optional power source (continuous power supply)
Fusible link
– 120 A Alternator (60 A)
F05 (120 A)
–
Fusible link – Preheating
120 A
F06
Locations of fusible links
* Fusible links F02, F03, F04, and F05 are accessible when the rear left cover is opened.
PC138USLC-10 40-97
40 Troubleshooting
Locations of fuse boxes and fuse No.
40-98 PC138USLC-10
40 Troubleshooting
Failure codes table (PC138_10-5520-441-A-00-A)
Failure Action Category

Failure (Displayed on screen) Controller Remarks
code level history
Failure code [879AKA] A/C Inner Sensor Electrical See Chapter
879AKA Open Circuit(PAGE 40-105) MON —
system Appendix
Failure code [879AKB] A/C Inner Sensor Electrical See Chapter
879AKB Short Circuit(PAGE 40-106) MON —
system Appendix
Failure code [879BKA] A/C Outer Sensor Electrical See Chapter
879BKA Open Circuit(PAGE 40-107) MON —
system Appendix
Failure code [879BKB] A/C Outer Sensor Electrical See Chapter
879BKB Short Circuit(PAGE 40-108) MON —
system Appendix
Failure code [879CKA] Ventilating Sensor Electrical See Chapter
879CKA Open Circuit(PAGE 40-109) MON —
system Appendix
Failure code [879CKB] Ventilating Sensor Electrical See Chapter
879CKB Short Circuit(PAGE 40-110) MON —
system Appendix
Failure code [879DKZ] Sunlight Sensor Open Electrical See Chapter
879DKZ Or Short Circuit(PAGE 40-111) MON —
system Appendix
Failure code [879EMC] Ventilation Damper Electrical See Chapter
879EMC Abnormality(PAGE 40-112) MON L01 system Appendix
Failure code [879FMC] Air Mix Damper Electrical See Chapter
879FMC Abnormality(PAGE 40-113) MON L01 system Appendix
Failure code [879GKX] Refrigerant Electrical See Chapter
879GKX Abnormality(PAGE 40-114) MON L01 system Appendix
Failure code [989L00] Engine Controller Lock Electrical
989L00 Caution 1(PAGE 40-115) MON —
system
Failure code [989M00] Engine Controller Lock Electrical
989M00 Caution 2(PAGE 40-116) MON —
system
Failure code [989N00] Engine Controller Lock Electrical
989N00 Caution 3(PAGE 40-117) MON —
system
Failure code [AB00KE] Charge Voltage Low Mechanical
AB00KE (PAGE 40-118) MON L03 system
Failure code [B@BAZG] Eng Oil Press Low Mechanical
B@BAZG ENG L03
(PAGE 40-120) system
Failure code [B@BAZK] Eng Oil Level Low Mechanical
B@BAZK MON L01
Failure code [B@BCNS] Eng Water Overheat Electrical
B@BCNS ENG L02
Failure code [CA115] Eng Ne and Bkup Electrical
CA115 Speed Sens Error(PAGE 40-123) ENG L04 system
Failure code [CA122] Chg Air Press Sensor Electrical
CA122 High Error(PAGE 40-124) ENG L03 system
Failure code [CA123] Chg Air Press Sensor Electrical
CA123 Low Error(PAGE 40-126) ENG L03 system
Failure code [CA131] Throttle Sensor High Electrical
CA131 Error(PAGE 40-128) ENG L03 system
Failure code [CA132] Throttle Sensor Low Electrical
Failure code [CA144] Coolant Temp Sens Electrical
Failure code [CA145] Coolant Temp Sens Low Electrical
Failure code [CA153] Chg Air Temp Sensor Electrical
Failure code [CA154] Chg Air Temp Sensor Electrical
Failure code [CA187] Sensor 2 Supply Volt Electrical
PC138USLC-10 40-99
40 Troubleshooting

code level history
Failure code [CA221] Ambient Press Sensor Electrical
Failure code [CA222] Ambient Press Sensor Electrical
Failure code [CA234] Eng Overspeed(PAGE Mechanical
CA234 40-147) ENG L02 system
Failure code [CA238] Ne Speed Sensor Electrical
CA238 Supply Volt Error(PAGE 40-148) ENG L01 system
Failure code [CA239] Ne Speed Sens Supply Electrical
CA239 Volt High Error(PAGE 40-149) ENG L01 system
Failure code [CA271] IMV/PCV1 Short Error Electrical
CA271 (PAGE 40-150) ENG L03 system
Failure code [CA272] IMV/PCV1 Open Error Electrical
Failure code [CA322] Inj #1(L#1) Open/Short Electrical
Failure code [CA343] ECM Critical Internal Electrical
CA343 Failure(PAGE 40-160) ENG L04 system
Failure code [CA351] Injectors Drive Circuit Electrical
Failure code [CA356] Mass Air Flow Sensor Electrical
Failure code [CA435] Eng Oil Press Sw Error Electrical
Failure code [CA441] Battery Voltage Low Electrical
Failure code [CA442] Battery Voltage High Electrical
Failure code [CA449] Rail Press Very High Electrical
Failure code [CA451] Rail Press Sensor High Electrical
Failure code [CA452] Rail Press Sensor Low Electrical
Failure code [CA466] KVGT Motor Driver Electrical
CA466 Position Error(PAGE 40-178) ENG L03 system
Failure code [CA515] Rail Press Sens Sup Electrical
CA515 Volt High Error(PAGE 40-180) ENG L03 system
Failure code [CA516] Rail Press Sens Sup Electrical
CA516 Volt Low Error(PAGE 40-182) ENG L03 system
Failure code [CA553] Rail Press High Error Electrical
40-100 PC138USLC-10
40 Troubleshooting

code level history
Failure code [CA555] Crankcase Press High Electrical
CA555 Error 1(PAGE 40-185) ENG L01 system
Failure code [CA556] Crankcase Press High Electrical
CA556 Error 2(PAGE 40-186) ENG L03 system
Failure code [CA559] Rail Press Low Error Electrical
Failure code [CA689] Eng Ne Speed Sensor Electrical
Failure code [CA691] Intake Air Temp Sens Electrical
Failure code [CA692] Intake Air Temp Sens Electrical
Failure code [CA697] ECM Internal Temp Electrical
CA697 Sensor High Error(PAGE 40-196) ENG L01 system
Failure code [CA698] ECM Int Temp Sensor Electrical
Failure code [CA731] Eng Bkup Speed Sens Electrical
CA731 Phase Error(PAGE 40-198) ENG L01 system
Failure code [CA778] Eng Bkup Speed Electrical

CA778 Sensor Error(PAGE 40-201) ENG L01 system
Failure code [CA1117] Persistent Data Lost Electrical

Failure code [CA1843] Crankcase Press Sens Electrical
Failure code [CA1896] EGR Valve Stuck Error Electrical
CA1942 In Range Error(PAGE 40-213) ENG L01 system
Failure code [CA1961] EGR_Motor Driver IC Electrical
CA1961 Over Temp Error(PAGE 40-214) ENG L03 system
Failure code [CA2185] Throt Sensor Sup Volt Electrical
Failure code [CA2186] Throt Sensor Sup Volt Electrical
Failure code [CA2249] Rail Press Very Low Electrical
Failure code [CA2272] EGR Valve Pos Sens Electrical
Failure code [CA2311] IMV Solenoid Error Electrical
Failure code [CA2349] EGR Valve Solenoid Electrical
CA2349 Open Error(PAGE 40-223) ENG L03 system
Failure code [CA2353] EGR Valve Solenoid Electrical
CA2353 Short Error(PAGE 40-225) ENG L03 system
Failure code [CA2357] EGR Valve Servo Error Electrical
Failure code [CA2765] Inj Trim Data Error Electrical
PC138USLC-10 40-101
40 Troubleshooting

code level history
CA3419 Sup Volt High Error(PAGE 40-229) ENG L03 system
CA3421 Sup Volt Low Error(PAGE 40-231) ENG L03 system
Failure code [CA3724] EGR/KVGT Motor Electrical
CA3724 Driver Power Low Error(PAGE 40-233) ENG L03 system
Failure code [CA3918] KVGT Stuck Error Electrical
Failure code [CA3919] KVGT Motor Driver IC Electrical
CA3919 Over Temp Error(PAGE 40-236) ENG L03 system
Failure code [CA3921] KVGT Servo Error 2 Electrical
CA3922 Open Error(PAGE 40-238) ENG L03 system
CA3923 Short Error(PAGE 40-240) ENG L03 system
Failure code [D110KB] Battery Relay Drive Electrical
D110KB Short Circuit(PAGE 40-242) PUMP L01 system
Failure code [D19JKZ] Personal Code Relay Electrical
D19JKZ Abnormality(PAGE 40-244) MON L03 system
Failure code [D811MC] KOMTRAX Error Electrical
D811MC (PAGE 40-247) KOMTRAX —
system
Failure code [D862KA] GPS Antenna Open Electrical
D862KA Circuit(PAGE 40-248) KOMTRAX —
system
Failure code [D8ALKA] Operating Lamp Open Electrical
D8ALKA Circuit (KOMTRAX)(PAGE 40-249) KOMTRAX —
system
Failure code [D8ALKB] Operating Lamp Short Electrical
D8ALKB Circuit (KOMTRAX)(PAGE 40-251) KOMTRAX —
system
Failure code [D8AQKR] CAN2 Discon Electrical
D8AQKR (KOMTRAX)(PAGE 40-252) MON —
system
Failure code [DA20MC] Pump Controller Electrical
DA20MC Malfunction(PAGE 40-254) PUMP —
system
Failure code [DA22KK] Pump Solenoid Power Electrical
DA22KK Low Error(PAGE 40-255) PUMP L03 system
Failure code [DA25KP] 5V Sensor 1 Power Electrical
DA25KP Abnormality(PAGE 40-257) PUMP —
system
Failure code [DA29KQ] Model Selection Electrical
DA29KQ Abnormality(PAGE 40-259) PUMP L01 system
Failure code [DA2LKA] Operating Lamp Open Electrical
DA2LKA Circuit (Pump Con)(PAGE 40-261) PUMP —
system
Failure code [DA2LKB] Operating Lamp Short Electrical
DA2LKB Circuit (Pump Con)(PAGE 40-263) PUMP —
system
Failure code [DA2QKR] CAN2 Discon (Pump Electrical
DA2QKR Con)(PAGE 40-264) MON L03 system
Failure code [DA2RKR] CAN1 Discon (Pump Electrical
DA2RKR Con)(PAGE 40-266) MON L04 system
Failure code [DAF0MB] Monitor ROM Electrical
DAF0MB Abnormality(PAGE 40-267) MON —
system
Failure code [DAF0MC] Monitor Error(PAGE Electrical
DAF0MC 40-268) MON —
system
Failure code [DAF8KB] Camera Power Electrical
DAF8KB Supply Short Circuit(PAGE 40-269) MON L03 system
Failure code [DAF9KQ] Model Selection Electrical
DAF9KQ Abnormality(PAGE 40-271) MON L03 system
Failure code [DAFGMC] GPS Module Error Electrical
DAFGMC (PAGE 40-272) KOMTRAX —
system
40-102 PC138USLC-10
40 Troubleshooting

code level history
Failure code [DAFLKA] Operating Lamp Open Electrical
DAFLKA Circuit (Monitor)(PAGE 40-273) MON —
system
Failure code [DAFLKB] Operating Lamp Short Electrical
DAFLKB Circuit (Monitor)(PAGE 40-275) MON —
system
Failure code [DAFQKR] CAN2 Discon Electrical
DAFQKR (Monitor)(PAGE 40-276) KOMTRAX —
system
Failure code [DAZ9KQ] A/C Model Selection Electrical
DAZ9KQ Abnormality(PAGE 40-277) MON —
system
Failure code [DAZQKR] CAN2 Discon (Aircon Electrical
DAZQKR ECU)(PAGE 40-278) MON L01 system
Failure code [DB2QKR] CAN2 Discon (Engine Electrical
DB2QKR Con)(PAGE 40-282) MON L03 system
Failure code [DB2RKR] CAN1 Discon (Engine Electrical
DB2RKR Con)(PAGE 40-286) MON L04 system
Failure code [DGH2KB] Hyd Oil Sensor Short Electrical
DGH2KB Circuit(PAGE 40-290) PUMP L01 system
Failure code [DHPAMA] Pump Press Sensor Electrical
DHPAMA Abnormality(PAGE 40-292) PUMP L01 system
Failure code [DHSFMA] Travel Fwd LH PPC Electrical
DHSFMA Press Sensor Abnormality(PAGE 40-294) PUMP L01 system
Failure code [DHSGMA] Travel Fwd RH PPC Electrical
DHSGMA Press Sensor Abnormality(PAGE 40-296) PUMP L01 system
Failure code [DHSHMA] Travel Rev LH PPC Electrical
DHSHMA Press Sensor Abnormality(PAGE 40-298) PUMP L01 system
Failure code [DHSJMA] Travel Rev RH PPC Electrical
DHSJMA Press Sensor Abnormality(PAGE 40-300) PUMP L01 system
Failure code [DHSKMA] Blade Raise PPC Electrical
DHSKMA Press Sensor Abnormality(PAGE 40-302) PUMP L01 system
Failure code [DHSLMA] Blade Lower PPC Electrical
DHSLMA Press Sensor Abnormality(PAGE 40-304) PUMP L01 system
Failure code [DHX1MA] Overload Sensor Electrical
DHX1MA Abnormality(PAGE 40-306) PUMP L04 system
Failure code [DR21KX] Camera 2 Picture Electrical
DR21KX Rev. Drive Abnormality(PAGE 40-307) MON L01 system
Failure code [DR31KX] Camera 3 Picture Electrical
DR31KX Rev. Drive Abnormality(PAGE 40-309) MON L01 system
Failure code [DV20KB] Travel Alarm Short Electrical
DV20KB Circuit(PAGE 40-310) PUMP L01 system
Failure code [DW43KA] Travel Speed Sol Electrical
DW43KA Open Circuit(PAGE 40-312) PUMP L01 system
Failure code [DW43KB] Travel Speed Sol Electrical
DW43KB Short Circuit(PAGE 40-314) PUMP L01 system
Failure code [DW45KA] Swing Brake Sol Electrical
Failure code [DW45KB] Swing Brake Sol Electrical
Failure code [DW91KA] Travel Junction Sol Electrical
Failure code [DW91KB] Travel Junction Sol Electrical
Failure code [DWA2KA] Attachment Sol Open Electrical
DWA2KA Circuit(PAGE 40-325) PUMP L03 system
Failure code [DWA2KB] Attachment Sol Short Electrical
DWA2KB Circuit(PAGE 40-327) PUMP L03 system
Failure code [DWJ0KA] Merge-divider Sol Electrical
DWJ0KA Open Circuit(PAGE 40-329) PUMP L01 system
PC138USLC-10 40-103
40 Troubleshooting

code level history
Failure code [DWJ0KB] Merge-divider Sol Electrical
DWJ0KB Short Circuit(PAGE 40-331) PUMP L01 system
Failure code [DXA8KA] PC-EPC Sol Open Electrical
DXA8KA Circuit(PAGE 40-333) PUMP L03 system
Failure code [DXA8KB] PC-EPC Sol Short Electrical
DXA8KB Circuit(PAGE 40-335) PUMP L03 system
Failure code [DXE4KA] Attachment Flow EPC Electrical
DXE4KA Open Circuit(PAGE 40-337) PUMP —
system
Failure code [DXE4KB] Attachment Flow EPC Electrical
DXE4KB Short Circuit(PAGE 40-339) PUMP —
system
Failure code [DY20KA] Wiper Working Electrical
DY20KA Abnormality(PAGE 40-341) PUMP —
system
Failure code [DY20MA] Wiper Parking Electrical
DY20MA Abnormality(PAGE 40-343) PUMP —
system
Failure code [DY2CKB] Washer Drive Short Electrical
DY2CKB Circuit(PAGE 40-345) PUMP —
system
Failure code [DY2DKB] Wiper Drive (Fwd) Electrical
DY2DKB Short Circuit(PAGE 40-347) PUMP —
system
Failure code [DY2EKB] Wiper Drive (Rev) Electrical
DY2EKB Short Circuit(PAGE 40-349) PUMP —
system
40-104 PC138USLC-10
40 Troubleshooting
Troubleshooting by failure code (Display of code)
Troubleshooting by failure code (Display of code) (ALL-3840-001-A-00-A)
Failure code [879AKA] A/C Inner Sensor Open Circuit (PC400-879AKA-441-A-Z0-A)
See "Failure code [879AKA] Air Conditioner Inner Sensor Open Circuit" in chapter 80 "Appendix".
a Since the inner air temperature sensor connector cannot be disconnected with the sensor installed on the
machine, the air conditioner controller or air conditioner unit must be replaced.
PC138USLC-10 40-105
40 Troubleshooting
Failure code [879AKB] A/C Inner Sensor Short Circuit (PC400-879AKB-441-A-Z0-A)
See chapter 80 Appendix "Failure code [879AKB] Air Conditioner Inner Sensor Short Circuit" .
a Since the inner air temperature sensor connector cannot be disconnected with the sensor installed on the
machine, the air conditioner controller or air conditioner unit must be replaced.
40-106 PC138USLC-10
40 Troubleshooting
Failure code [879BKA] A/C Outer Sensor Open Circuit (PC400-879BKA-441-A-Z0-A)
See chapter 80 Appendix "Failure code [879BKA] Air Conditioner Outer Sensor Open Circuit" .
PC138USLC-10 40-107
40 Troubleshooting
Failure code [879BKB] A/C Outer Sensor Short Circuit (PC400-879BKB-441-A-Z0-A)
See chapter 80 Appendix "Failure code [879BKB] Air Conditioner Outer Sensor Short Circuit" .
40-108 PC138USLC-10
40 Troubleshooting
Failure code [879CKA] Ventilating Sensor Open Circuit (PC400-879CKA-441-A-Z0-A)
See "Failure code [879CKA] Ventilating Sensor Open Circuit" in chapter 80 "Appendix".
a Since the ventilating sensor (evaporator temperature sensor) cannot be disconnected with the sensor
installed on the machine, the air conditioner controller or air conditioner unit must be replaced.
PC138USLC-10 40-109
40 Troubleshooting
Failure code [879CKB] Ventilating Sensor Short Circuit (PC400-879CKB-441-A-Z0-A)
See "Failure code [879CKB] Ventilating Sensor Short Circuit" in chapter 80 "Appendix".
a Since the ventilating sensor (evaporator temperature sensor) cannot be disconnected with the sensor
installed on the machine, the air conditioner controller or air conditioner unit must be replaced.
40-110 PC138USLC-10
40 Troubleshooting
Failure code [879DKZ] Sunlight Sensor Open Or Short Circuit (PC400-879DKZ-441-

A-Z0-A)
See chapter 80 Appendix "Failure code [879DKZ] Sunlight Sensor Open or Short Circuit".
PC138USLC-10 40-111
40 Troubleshooting
Failure code [879EMC] Ventilation Damper Abnormality (PC400-879EMC-441-A-Z0-A)
See chapter 80 Appendix "Failure code [879EMC] Ventilation Damper Abnormality".

a Since the vent select servo motor cannot be disconnected on the machine, the air conditioner controller or
air conditioner unit must be replaced.
40-112 PC138USLC-10
40 Troubleshooting
Failure code [879FMC] Air Mix Damper Abnormality (PC400-879FMC-441-A-Z0-A)
See chapter 80 Appendix "Failure code [879FMC] Air Mix Damper Abnormality".
a Since the air mix servo motor connector cannot be disconnected on the machine, the air conditioner
controller or air conditioner unit must be replaced.
PC138USLC-10 40-113
40 Troubleshooting
Failure code [879GKX] Refrigerant Abnormality (PC400-879GKX-441-A-Z0-A)
See chapter 80 Appendix "Failure code [879GKX] Refrigerant Abnormality".
40-114 PC138USLC-10
40 Troubleshooting
Failure code [989L00] Engine Controller Lock Caution 1 (PC400-989L00-400-A-Z0-A)
Action level Failure code Engine Controller Lock Caution 1

Failure
– 989L00 (Machine monitor system)
Detail of • Engine controller lock up is detected (Factor 1).
failure
Action of • None in particular
machine • If cause of failure disappears, machine becomes normal by itself.
monitor
Problem on • Engine cannot be started.
machine
• If this failure code is generated after machine monitor is replaced, user password must be
Related changed to one before replacement.
information • Method of reproducing failure code: Turn starting switch to ON position.
Replacement of machine This problem may be caused by replacement of machine monitor.
1
monitor
PC138USLC-10 40-115
40 Troubleshooting
Failure code [989M00] Engine Controller Lock Caution 2 (PC400-989M00-400-A-Z0-A)

Failure
– 989M00 (Machine monitor system)
failure
monitor
Problem on • Engine cannot be started.
machine
• If this failure code is generated after machine monitor is replaced, user password must be
Related changed to one before replacement.
Replacement of machine This problem may be caused by replacement of machine monitor.
1
monitor
If this failure code is displayed while machine monitor is not replaced,
2 Defective machine monitor machine monitor may be defective. (Since this is an internal defect,
troubleshooting cannot be performed.)
40-116 PC138USLC-10
40 Troubleshooting
Failure code [989N00] Engine Controller Lock Caution 3 (PC400-989N00-400-A-Z0-A)

Failure
– 989N00 (Machine monitor system)
failure
Action of • Tries automatic recovery.
monitor
Problem on
machine
Related • Method of reproducing failure code: Failure code cannot be reproduced since machine
information recovers when cause of failure disappears.
If this failure code is generated repeatedly, engine controller may be
1 Defective engine controller defective. (Since this is an internal defect, troubleshooting cannot be
performed.)
PC138USLC-10 40-117
40 Troubleshooting
Failure code [AB00KE] Charge Voltage Low (PC138-AB00KE-400-A-Z0-A)
Action level Failure code Charge Voltage Low

Failure
L03 AB00KE (Machine monitor system)
Detail of • While engine is running, voltage from alternator drops, and machine monitor detects that
failure battery charge voltage is low (below 7.8 V).
Action of • Displays charge level monitor red on machine monitor.
machine • Even if cause of failure disappears, machine does not become normal until starting switch
monitor is turned to OFF position.
Problem on • If machine continues to be operated, battery may not be charged.
machine
• Signal voltage of alternator can be checked by using monitoring function.
Related (Code: 04300)
information • Method of reproducing failure code: Start engine.
No. Cause Procedure, measuring location, criteria, and remarks
Loose alternator
1 terminal or open circuit 1. Turn starting switch to OFF position.
at terminal 2. Check terminal.
Defective power 1. Turn starting switch to OFF position.

generation of alternator 2. Insert T-adapter into connector E12.
2 3. Start engine.
(When system works
properly.) Between E12 (1) and Engine speed: Medium 27.5 to 29.5
Voltage
ground or above V
2. Disconnect diode D01 and connect T-adapters to male side.
3 Defective diode a Measure it with diode range of multimeter.

No
Between D01 (male) (2) (+) and (6) (-)
Continuity continuity
Between D01 (male) (6) (+) and (2) (-) Continuity
Defective wiring 2. Insert T-adapter into connector CM01.
4 harness or machine 3. Start engine.
monitor
Voltage Between CM01 (16) and ground 20 to 30 V
Open circuit in wiring a If no failure is found by check on cause 2, this check is not required.
harness
5 (wire breakage or 2. Disconnect connectors CM01 and E12, and connect T-adapter to each
defective contact of female side.
connector) Resistance Between CM01 (female) (16) and E12 (female) (1) Max. 1 z
a If no failure is found by check on cause 2, this check is not required.
Ground fault in wiring
harness
6 2. Disconnect connectors CM01 and E12, and connect T-adapter to either
(contact with ground female side.
circuit) Between CM01 (female) (16) or E12 (female) (1)
Resistance and ground Min. 1 Mz
Defective machine If no failure is found by above checks, machine monitor is defective.

7
monitor (Since this is an internal defect, troubleshooting cannot be performed.)
40-118 PC138USLC-10
40 Troubleshooting
Circuit diagram related to charge
PC138USLC-10 40-119
40 Troubleshooting
Failure code [B@BAZG] Eng Oil Press Low (PC400-BaBAZG-400-A-Z0-A)
Action level Failure code Engine Oil Pressure Low

Failure
L03 B@BAZG (Engine controller system)
Detail of • While engine is running, signal voltage from engine oil pressure sensor drops, so engine
failure controller determines that engine oil pressure is low.
Action of • Displays engine oil pressure monitor red on machine monitor.
controller
Problem on • If machine is operated as it is, engine may seize up.
machine
• Engine oil pressure sensor signal is input to engine controller and then transmitted to
machine monitor through CAN communication system.
Related • Engine oil pressure can be checked by using monitoring function.
information (Code: 37200)
• Method of reproducing failure code: Start engine.
Low engine oil pressure
1 (when system works Engine oil pressure may be low. Check it and remove cause if it is low.
properly)
If no failure is found by checks on cause 1, engine oil pressure sensor circuit
Defective engine oil
2 may be defective. Perform troubleshooting for failure codes [CA135] and
pressure sensor circuit
[CA141].
40-120 PC138USLC-10
40 Troubleshooting
Failure code [B@BAZK] Eng Oil Level Low (PC400-BaBAZK-400-A-Z0-A)
Action level Failure code Engine oil level low

Failure
L01 B@BAZK (Machine monitor system)
Detail of • While engine is running, signal voltage from engine oil level switch is not below 1 V, so
failure machine monitor determines that engine oil level is low (oil level switch is open).
Action of • Displays engine oil level monitor yellow on machine monitor.
controller
machine
• Input (ON/OFF) from engine oil level switch can be checked by using monitoring function.
Related (Code 04501: Monitor Input 2)
information • Method of reproducing failure code: Start engine
Low engine oil level
1 Check engine oil level. If it is low, remove cause.
(when system is normal)
Defective engine oil level 1. Turn starting switch to OFF position.
sensor 2. Disconnect connector P44 and connect T-adapter to male side.
2
(internal defect) Resis- Between P44 (male) (1) and ground
Max. 1 z
tance
Open circuit in wiring harness 2. Disconnect connectors CM02 and P44, and connect T-adapters to
3 (wire breakage or defective each female side.
contact of connector) Resis- Between CM02 (female) (2) and P44 (female)
(1) Max. 1 z
tance
If no failure is found by above checks, machine monitor is defective.
• Reference
2. Disconnect connectors CM01 and CM02 and connect T-adapters to
4 Defective machine monitor each female side.
Between CM02 (female) (2) and CM01 (female)
Voltage Max. 1 V
(3)
Circuit diagram related to engine oil level
PC138USLC-10 40-121
40 Troubleshooting
Failure code [B@BCNS] Eng Water Overheat (PC400-BaBCNS-400-A-Z0-A)
Action level Failure code Engine Water Overheat

Failure
L02 B@BCNS (Engine controller system)
Detail of • While engine is running, voltage from engine coolant temperature sensor drops, so engine
failure controller determines that engine coolant is overheated.
Action of • Displays engine coolant temperature monitor red on machine monitor.
controller
machine
• Signal voltage of engine coolant temperature sensor is input to engine controller that
transmits information to machine monitor through CAN communication system.
Related • Engine coolant temperature can be checked with monitoring function
information (Code: 04107 Engine coolant temperature)
Overheating of engine
1 coolant Engine coolant may overheat. Check it and remove cause if it overheats.
(when system is normal)
If no failure is found by checks on cause 1, engine coolant temperature
Defective engine coolant
2 sensor system may be defective. Carry out troubleshooting for failure
temperature sensor system
codes [CA144] and [CA145].
40-122 PC138USLC-10
40 Troubleshooting
Failure code [CA115] Eng Ne and Bkup Speed Sens Error (WA380_7-CA115-400-A-Z0-A)
Action level Failure code Engine Ne and Bkup Speed Sensor Error
Failure
L04 CA115 (Engine controller system)
Detail of • Both signals from engine Ne speed sensor and engine Bkup speed sensor are unusual.
failure
Action of • None in particular.
controller
Problem on • Engine stops.
machine • Engine does not start.
Related • Method of reproducing failure code: Start engine.
information
Poor connection of sensor Connectors of engine Ne speed sensor and Bkup sensor may be poorly
1 (incorrectly) connected. Check their connection.
connector
Defective Ne speed sensor
2 Perform troubleshooting for failure code [CA689].
system
Defective Bkup speed sensor
system
If no failure is found by above checks, engine controller is defective.
4 Defective engine controller
(Since this is an internal defect, troubleshooting cannot be performed.)
PC138USLC-10 40-123
40 Troubleshooting
Failure code [CA122] Chg Air Press Sensor High Error (D37-CA122-400-A-Z0-A)
Action level Failure code Charge Air Pressure Sensor High Error
Failure
Detail of • High voltage occurs in charge (boost) pressure sensor signal circuit.
failure
• Sets charge (boost) pressure to fixed value (400 kPa {4.1 kg/cm2}) and runs engine.
Action of • Closes EGR valve and opens VFT fully.
controller • Limits engine output and runs engine.
Problem on • Acceleration performance of engine drops.
machine • Engine output reduces.
• Signal voltage from charge pressure sensor (boost pressure sensor) can be checked with
monitoring function. (Code: 36501 (V))
• Boost pressure sensed by charge (boost) pressure sensor can be checked with
monitoring function. (Code: 36500 (kPa))
Related • Method of reproducing failure code: Turn starting switch to ON position.
information • Since female connector alone is provided for "socket" used for troubleshooting of this
sensor, it is not connectable to female connector on sensor wiring harness side and thus
not usable for check of open circuit (not designed as T-adapter).
• If sensor connector is disconnected, failure code [CA123] for "Low Error" is displayed
even in normal condition.
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "Related information on
Defective wiring troubleshooting", and check it.
1 2. Turn starting switch to ON position.
harness connector
If this failure code is not displayed, wiring harness connector is defective.
a If this failure code is displayed, perform following checks.
Defective sensor power If failure code [CA187] or [CA227] is also displayed, perform troubleshooting
2 supply system for it first.
2. Disconnect connector TMAP.
If failure code changes from [CA122] to [CA123], charge (boost) pressure
sensor is defective.
a Other failure code [CA153] for temperature sensor is also displayed.
Defective charge Ignore this code since this is displayed due to disconnection of sensor
3 (boost) pressure sensor connector.
• Reference
Sensor
Voltage Between J1 (15) and (59) 0.3 to 4.7 V
output
1. Turn starting switch to OFF position, then perform troubleshooting.
Short circuit in wiring 2. Disconnect connectors J1 and TMAP, and connect T-adapter to female
4
harness side of connector J1.
Resistance Between J1 (female) (15) and (60) Min. 1 Mz
Hot short circuit in 2. Disconnect connector TMAP, and insert T-adapter into connector J1.
5 wiring harness 3. Turn starting switch ON (with connector TMAP disconnected).
Voltage Between J1 (15) and (59) Max. 1 V
40-124 PC138USLC-10
40 Troubleshooting

Open circuit in wiring
harness If no failure is found by above checks, wiring harness probably has open
6 (wire breakage or circuit. (*)
defective contact of a To check open circuit in GND line
connector)
Defective engine If no failure is found by above checks, engine controller is defective.
7
controller (Since this is an internal defect, troubleshooting cannot be performed.)
*: Refer to "Troubleshooting method for open circuit in wiring harness of pressure sensor system" of "General
information on troubleshooting".
Circuit diagram related to charge pressure sensor
PC138USLC-10 40-125
40 Troubleshooting
Failure code [CA123] Chg Air Press Sensor Low Error (D37-CA123-400-A-Z0-A)
Action level Failure code Charge Air Pressure Sensor Low Error
Failure
Detail of • Low voltage occurs in charge (boost) pressure sensor signal circuit.
failure
• Sets charge (boost) pressure to fixed value (400 kPa {4.1 kg/cm2}) and runs engine.
Problem on • Acceleration performance of engine drops.
• Signal voltage from charge pressure sensor (boost pressure sensor) can be checked with
monitoring function. (Code: 36501 (V))
• Boost pressure sensed by charge (boost) pressure sensor can be checked with
monitoring function. (Code: 36500 (kPa))
• This failure code appears if sensor connector is disconnected.
harness connector
Defective power supply
system of charge If failure code [CA187] or [CA227] is also displayed, perform troubleshooting
2 pressure sensor (boost for it first.
pressure sensor)
Short circuit in wiring 2. Disconnect connectors J1 and TMAP, and connect T-adapter to female
3
harness side of connector J1.
Resistance Between J1 (female) (15) and (59) Min. 1 Mz
Ground fault in wiring 1. Turn starting switch to OFF position, then perform troubleshooting.
harness 2. Disconnect connectors J1 and TMAP, and connect T-adapter to female
4
(contact with ground side of connector J1.
circuit) Resistance Between J1 (female) (15) and ground Min. 1 Mz
harness
If no failure is found by above checks, wiring harness probably has open
5 (wire breakage or circuit. (*)
defective contact of
connector)
a If no failure is found by checks on causes 1 to 5 and failure is found by
check on cause 6, sensor is defective.
Defective charge 1. Turn starting switch to OFF position.
6 (boost) pressure sensor 2. Insert T-adapter into connector J1.
Sensor
output
7
*: Refer to "Troubleshooting method for open circuit in wiring harness of pressure sensor system" of "General
information on troubleshooting".
40-126 PC138USLC-10
40 Troubleshooting
Circuit diagram related to charge pressure sensor
PC138USLC-10 40-127
40 Troubleshooting
Failure code [CA131] Throttle Sensor High Error (D61-CA131-400-A-Z0-A)
Action level Failure code Throttle Sensor High Error

Failure
Detail of • High voltage appears in signal circuit of fuel dial sensor.
failure
Action of • Runs engine with signal voltage of fuel dial as fixed value (as if fuel dial is at the half
controller position)
Problem on • Engine speed cannot be controlled by using fuel control dial.
machine
• Signal voltage from fuel control dial can be checked with monitoring function.
Related (Code: 03000 “Fuel Dial Sensor Volt“)
equipment" in "Checks before troubleshooting" of "Related
information on troubleshooting", and check it.
Defective wiring harness 2. Turn starting switch to ON position.
1
connector If this failure code is not displayed, wiring harness connector is
defective.
Defective throttle sensor If failure code [CA2185] is also displayed, perform troubleshooting for it
2 power supply system first.
Defective throttle sensor (fuel
3 Between FP (male) (A) and (C) 4.0 to 6.0 kz
dial) Resis- Between FP (male) (B) and (C)
3 to 7 kz
tance
Open or short circuit in wiring 2. Disconnect connector CE03, and connect T-adapter to female side.
4
harness Resis- Between CE03 (female) (41) and (42) 4.0 to 6.0 kz
tance Between CE03 (female) (51) and (42) 3 to 7 kz
5 Short circuit in wiring harness 2. Disconnect connectors CE03 and FP, and connect T-adapter to
either female side.
Resis- Between CE03 (female) (51) and (42), or
Min. 1 Mz
tance between FP (female) (A) and (B)
Hot short circuit in wiring 2. Disconnect connector FP and connect T-adapter to female side.
harness
Voltage Between FP (female) (B) and ground Max 1 V
• Reference
2. Insert T-adapter into connector CE03.
7 Defective engine controller 3. Turn starting switch to ON position.
4. Operate fuel dial and perform troubleshooting.
Power
Between CE03 (42) and (41) 4.75 to 5.25 V
supply
Voltage
Sensor
Between CE03 (51) and (41) 0.5 to 4.5 V
output
40-128 PC138USLC-10
40 Troubleshooting
Circuit diagram related to throttle sensor
PC138USLC-10 40-129
40 Troubleshooting
Failure code [CA132] Throttle Sensor Low Error (D61-CA132-400-A-Z0-A)
Action level Failure code Throttle Sensor Low Error

Failure
Detail of • Low voltage appears in signal circuit of fuel dial sensor.
failure
Action of • Runs engine with signal voltage of fuel dial as fixed value (as if fuel dial is at the half
controller position)
machine
• Signal voltage from fuel control dial can be checked with monitoring function.
Related (Code: 03000 “Fuel Dial Sensor Volt“)
1
defective.
Defective throttle sensor If failure code [CA2186] is also displayed, perform troubleshooting for it
2 power supply system first.
Defective throttle sensor (fuel
3 Between FP (male) (A) and (C) 4.0 to 6.0 kz
dial)
Resistance Between FP (male) (B) and (C) 3 to 7 kz
Open or short circuit in wiring 2. Disconnect connector CE03, and connect T-adapter to female side.
4
harness Between CE03 (female) (41) and (42) 4.0 to 6.0 kz
Resistance
Between CE03 (female) (41) and (51) 3 to 7 kz
2. Disconnect connector CE03 and FP, and connect T-adapter to each
Open circuit in wiring harness female side.
5 (wire breakage or defective Between CE03 (female) (42) and FP
(female) (A) Max. 1 z
Between CE03 (female) (51) and FP
Resistance (female) (B) Max. 1 z
Between CE03 (female) (41) and FP
(female) (C) Max. 1 z

6 Short circuit in wiring harness 2. Disconnect connectors CE03 and FP, and connect T-adapter to
either female side.
Between CE03 (female) (51) and (41), or
Resistance between FP (female) (B) and (C) Min. 1 Mz

Ground fault in wiring harness 2. Disconnect connectors CE03 and FP, and connect T-adapter to
7 either female side.
(contact with ground circuit)
Between ground and CE03 (female) (51) or
Resistance FP (female) (B) Min. 1 Mz
8 Defective engine controller (Since this is an internal defect, troubleshooting cannot be performed.)
• Reference
40-130 PC138USLC-10
40 Troubleshooting

1.Turn starting switch to OFF position.
2.Insert T-adapter into connector CE03.
3.Turn starting switch to ON position.
4.Operate fuel dial and perform troubleshooting.
Between CE03 (42) and (41) Power supply 4.75 to 5.25 V
Voltage
Between CE03 (51) and (41) Sensor output 0.4 to 4.5 V
PC138USLC-10 40-131
40 Troubleshooting
Failure code [CA144] Coolant Temp Sens High Error (PC400-CA144-400-A-Z0-A)
Action level Failure code Coolant Temperature Sensor High Error

Failure
Detail of • High voltage occurs in engine coolant temperature sensor signal circuit.
failure
Action of • Sets coolant temperature to fixed value (90°C) and runs engine.
controller
Problem on • Engine startability is poor at low temperatures.
machine • Overheat prevention function does not work.
• Signal voltage from engine coolant temperature sensor can be checked with monitoring
function. (Code: 04105 (V))
• Temperature sensed by engine coolant temperature sensor can be checked with
monitoring function. (Code: 04107 (°C))
• Method of reproducing failure code: Turn starting switch to ON position.
Related
• Since female connector alone is provided for "socket" used for troubleshooting of this
information
k Drain approximately 10l l of coolant beforehand, because you may get scalded by
hot water spurting out from mounting location of coolant temperature sensor when
removing radiator cap during checking and replacing coolant temperature sensor.
Defective wiring harness information on troubleshooting", and check it.
connector
2. Disconnect connector TWTR, and connect to 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.
Defective coolant
2 temperature sensor 0°C 30 to 37 kz
Between TWTR (male) (A) and (B) 25°C 9.3 to 10.7 kz
Resis-
50°C 3.2 to 3.8 kz
tance a Coolant temperature-
Resistance characteristics 80°C 1.0 to 1.3 kz
95°C 700 to 800 z
2. Disconnect connector J1 and connect T-adapter to female side.
Open or short circuit in Between J1 (female) (14) and (13) (Coolant
3 wiring harness temperature: Min. 0 °C)
Resis- 700 z to 37
tance a Use Coolant temperature-Resistance kz
characteristics table for check on cause 2
as resistance criteria.
40-132 PC138USLC-10
40 Troubleshooting
Circuit diagram related to coolant temperature sensor
PC138USLC-10 40-133
40 Troubleshooting
Failure code [CA145] Coolant Temp Sens Low Error (PC400-CA145-400-A-Z0-A)
Action level Failure code Coolant Temperature Sensor Low Error

Failure
Detail of • Low voltage occurs in engine coolant temperature sensor signal circuit.
failure
Action of • Sets coolant temperature to fixed value (90°C) and runs engine.
controller
Problem on • Engine startability is poor at low temperatures.
machine • Overheat prevention function does not work.
• Signal voltage from engine coolant temperature sensor can be checked with monitoring
• Temperature sensed by engine coolant temperature sensor can be checked with
monitoring function. (Code: 04107 (°C))
Related
• If temperature sensor connector is disconnected, failure code [CA144] for high error is
information
displayed in place of this failure code.
k Drain approximately 10l l of coolant beforehand, because you may get scalded by
hot water spurting out from mounting location of coolant temperature sensor when
removing radiator cap during checking and replacing coolant temperature sensor.
equipment" in "Checks before troubleshooting" of "Related information
Defective wiring harness on troubleshooting", and check it.
connector
2. Disconnect connector TWTR, and connect to 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.
0°C 30 to 37 kz
Between TWTR (male) (A) and (B) 25°C 9.3 to 10.7 kz
Defective coolant
2 a Coolant temperature-Resistance 50°C 3.2 to 3.8 kz
temperature sensor
characteristics 80°C 1.0 to 1.3 kz
Resis- 95°C 700 to 800 z
tance Whole
coolant
Between TWTR (male) (B) and
tempera- Min. 1 Mz
ground
ture
range
Between J1 (female) (14) and (13) (Coolant
Short circuit in wiring
3 temperature: Min. 0 °C)
harness Resis-
700 z to 37 kz
tance a Use Coolant temperature-Resistance
characteristics table for check on cause 2
as resistance criteria.
Ground fault in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors J1 and TWTR, and connect T-adapter to female
4 side of connector J1.
(contact with ground
circuit) Resis- Between J1 (female) (14) and ground Min. 1 Mz
tance
40-134 PC138USLC-10
40 Troubleshooting
Circuit diagram related to coolant temperature sensor
PC138USLC-10 40-135
40 Troubleshooting
Failure code [CA153] Chg Air Temp Sensor High Error (D37-CA153-400-A-Z0-A)
Action level Failure code Charge Air Temperature Sensor High Error
Failure
Detail of • High voltage occurs in signal circuit of charge (boost) temperature sensor.
failure
• Takes charge temperature (boost temperature) to be fixed value (46°C), and runs engine.
Problem on • Engine starting performance is deteriorated at low temperatures.
• Signal voltage from charge temperature sensor (boost temperature sensor) can be
checked with monitoring function. (Code: 18501 (V))
• Temperature sensed by charge temperature sensor (boost temperature sensor) can be
checked with monitoring function. (Code: 18500 (°C))
harness connector
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 to -130°C).
-40°C 41 to 48 kz
-20°C 14 to 16 kz
Defective charge 5.4 to 6.1
2 temperature sensor 0°C
kz
Between TMAP (male) (3) and (4) 1.6 to 1.8
Resistance a Charge temperature-Resistance 30°C
kz
characteristics 560 to 600
60°C
z
230 to 250
90°C
z
130°C 80 to 90 z
Open or short circuit in Between J1 (female) (5) and (59)
3 wiring harness 80 z to 48
Resistance a Use Charge temperature-Resistance
characteristics table for check on cause 2 as kz
resistance criteria.
4
40-136 PC138USLC-10
40 Troubleshooting
Circuit diagram related to charge (boost) temperature sensor
PC138USLC-10 40-137
40 Troubleshooting
Failure code [CA154] Chg Air Temp Sensor Low Error (D37-CA154-400-A-Z0-A)
Action level Failure code Charge Air Temperature Sensor Low Error
Failure
Detail of • Low voltage occurs in signal circuit of charge (boost) temperature sensor.
failure
• Takes charge temperature (boost temperature) to be fixed value (46°C), and runs engine.
Problem on • Engine starting performance is deteriorated at low temperatures.
• Signal voltage from charge temperature sensor (boost temperature sensor) can be
checked with monitoring function. (Code: 18501 (V))
• Temperature sensed by charge temperature sensor (boost temperature sensor) can be
Related checked with monitoring function. (Code: 18500 (°C))
• If temperature sensor connector is disconnected, failure code [CA153] for "High error" is
displayed in place of this failure code.
harness connector
2. Disconnect connector TMAP and connect socket to male side.
a If charge temperature sensor has resistance of 80 z to 43 kz (-40°C to
-130°C), regard charge temperature sensor as normal.
-40°C 41 to 48 kz
-20°C 14 to 16 kz
5.4 to 6.1
Defective charge 0°C
kz
2 temperature sensor Between TMAP (male) (3) and (4) 1.6 to 1.8
30°C
a Charge temperature-Resistance kz
Resistance characteristics 560 to 600
60°C
z
230 to 250
90°C
z
130°C 80 to 90 z
Whole
Between TMAP (male) (3) and ground Min. 1 Mz
range
Short circuit in wiring Between J1 (female) (5) and (59)
3
harness 80 z to 43
Resistance a Use Charge temperature-Resistance
characteristics table for check on cause 2 as kz
resistance criteria.
harness 2. Disconnect connectors J1 and TMAP, and connect T-adapter to female
4
(contact with ground side of connector J1.
5
40-138 PC138USLC-10
40 Troubleshooting
Circuit diagram related to charge (boost) temperature sensor
PC138USLC-10 40-139
40 Troubleshooting
Failure code [CA187] Sensor 2 Supply Volt Low Error (D37-CA187-400-A-Z0-A)
Action level Failure code Sensor 2 Supply Voltage Low Error

Failure
Detail of • Low voltage occurs in sensor power supply 2 (5 V) circuit.
failure
• Ignores signals from Bkup speed sensor and controls engine by using Ne speed sensor
signals.
• Ignores signals from engine oil pressure sensor, sets engine oil pressure to fixed value
(250 kPa {2.5 kg/cm2}), and runs engine.
• Ignores signals from ambient pressure sensor, sets ambient pressure to fixed value
Action of (52.44 kPa {0.53 kg/cm2}), and runs engine.
controller • Ignores signals from charge (boost) pressure sensor, sets boost pressure to fixed value
(400 kPa {4.1 kg/cm2}), and runs engine.
• Ignores signals from crankcase pressure sensor, sets crankcase pressure to fixed value
(0 kPa), and runs engine.
• Closes EGR valve and opens VFT fully.
• Limits engine output and runs engine.
Problem on • Reduced engine output.
machine
information
harness connector
2. Disconnect following connectors one by one and turn starting switch to ON
position each time.
3. Each time troubleshooting is finished, return to step 1.
If this failure code is not displayed, disconnected sensor or engine wiring
harness is defective.
Defective sensor or a Other failure codes (many codes) are also displayed. They are generated
2 wiring harness because of disconnection of connector. Ignore failure codes other than
[CA187].
Bkup speed sensor CAM
Charge (Boost) pressure sensor TMAP
Connector Ambient pressure sensor PAMB
Crankcase pressure sensor CCV
Engine harness J1
Defective relevant
3 If other failure codes are also displayed, perform troubleshooting for them.
system
2. Disconnect connector J1 and connect T-adapter to male side.
Defective engine
4 3. Turn starting switch to ON position with connector J1 disconnected.
controller
Voltage Between ECM J1 (male) (60) and (59) 4.75 to 5.25
V
40-140 PC138USLC-10
40 Troubleshooting
Circuit diagram related to sensor power supply 2 circuit
PC138USLC-10 40-141
40 Troubleshooting
Failure code [CA221] Ambient Press Sensor High Error (D37-CA221-400-A-Z0-A)
Action level Failure code Ambient Pressure Sensor High Error

Failure
Detail of • High voltage occurs in signal circuit of ambient pressure sensor.
failure
• Sets ambient pressure to fixed value (52.44 kPa {0.53 kg/cm2}) and runs engine.
Problem on • Engine output reduces.
machine
• Signal voltage from ambient pressure sensor can be checked with monitoring function.
(Code: 37401 (V))
Related • Ambient pressure sensed by ambient pressure sensor can be checked with monitoring
information function. (Code: 37400 (kPa))
harness connector
Defective ambient
2 pressure sensor power If failure code [CA187] or [CA227] is also displayed, perform troubleshooting
supply system for it first.

2. Disconnect connector PAMB.
If failure code changes from [CA221] to [CA222], sensor is defective.
Defective ambient • Reference
3 pressure sensor 1. Turn starting switch to OFF position.
2. Insert T-adapters into connector J1 or PAMB.
Between J1 (16) and (59), or between Sensor
Voltage 0.3 to 4.7 V
PAMB (3) and (2) output
Open circuit in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors J1 and PAMB, and connect T-adapters to each
4 (wire breakage or female side.
connector)
Resistance Between J1 (female) (59) and PAMB (female) (2) Max. 1 z
2. Disconnect connectors J1 and PAMB, and connect T-adapter to either
5 female side.
harness
Between J1 (female) (60) and (16), or between
Resistance PAMB (female) (1) and (3) Min. 1 Mz

Hot short circuit in 2. Disconnect connector PAMB, and connect T-adapter to female side.
6 wiring harness 3. Turn starting switch to ON position.
Voltage Between PAMB (female) (3) and (2) Max. 1 V
7
40-142 PC138USLC-10
40 Troubleshooting
Circuit diagram related to ambient pressure sensor
PC138USLC-10 40-143
40 Troubleshooting
Failure code [CA222] Ambient Press Sensor Low Error (D37-CA222-400-A-Z0-A)
Action level Failure code Ambient Pressure Sensor Low Error

Failure
Detail of • Low voltage occurs in signal circuit of ambient pressure sensor.
failure
• Sets ambient pressure to fixed value (52.44 kPa {0.53 kg/cm2}) and runs engine.
machine
• Signal voltage from ambient pressure sensor can be checked with monitoring function.
(Code: 37401 (V))
• Ambient pressure sensed by ambient pressure sensor can be checked with monitoring
function. (Code: 37400 (kPa))
sensor, it is not usable for check of open circuit in wiring harness and voltage at sensor
connector (not designed as T-adapter).
harness connector
If failure code [CA187] or [CA227] is also displayed, perform troubleshooting
for it first.
Defective ambient 1. Turn starting switch to OFF position.
2 pressure sensor power 2. Disconnect connector PAMB, and connect T-adapter to female side.
supply system 3. Turn starting switch to ON position.
Power 4.75 to 5.25
Voltage Between PAMB (female) (1) and (2)
supply input V
2. Disconnect connectors PAMB and J1, and connect T-adapter to either
3 female side.
harness
Resistance PAMB (female) (3) and (2) Min. 1 Mz

harness 2. Disconnect connectors PAMB and J1, and connect T-adapter to either
4 female side.
Between ground and J1 (female) (16) or PAMB
circuit) Resistance (female) (3) Min. 1 Mz

2. Disconnect connectors PAMB and J1, and connect T-adapter to female
Open circuit in wiring side of connector J1.
5 Between J1 (female) (16) and PAMB (female) (3) Max. 1 z
harness
Resistance Between J1 (female) (59) and PAMB (female) (2) Max. 1 z
Between J1 (female) (60) and PAMB (female) (1) Max. 1 z
40-144 PC138USLC-10
40 Troubleshooting

a If no failure is found by checks on causes 1 to 5 and failure is found by
check on cause 6, sensor is defective.
Defective ambient 1. Turn starting switch to OFF position.
6 pressure sensor 2. Insert T-adapters into connector J1 or PAMB.
Between J1 (16) and (59), or between Sensor
PAMB (3) and (2) output
7
Circuit diagram related to ambient pressure sensor
PC138USLC-10 40-145
40 Troubleshooting
Failure code [CA227] Sensor 2 Supply Volt High Error (D37-CA227-400-A-Z0-A)
Action level Failure code Sensor 2 Supply Voltage High Error

Failure
Detail of • High voltage occurs in sensor power supply 2 (5 V) circuit.
failure
• Ignores signals from Bkup speed sensor and controls engine by using Ne speed sensor
signals.
• Ignores signals from ambient pressure sensor, sets ambient pressure to fixed value
(52.44 kPa {0.53 kg/cm2}), and runs engine.
Action of • Ignores signals from charge (boost) pressure sensor, sets boost pressure to fixed value
controller (400 kPa {4.1 kg/cm2}), and runs engine.
• Ignores signals from crankcase pressure sensor, sets crankcase pressure to fixed value
(0 kPa), and runs engine.
machine
information
Defective sensor power
supply 2 circuit
40-146 PC138USLC-10
40 Troubleshooting
Failure code [CA234] Eng Overspeed (PC400-CA234-400-A-Z0-A)
Action level Failure code Engine Overspeed

Failure
Detail of • Engine speed is above operating range.
failure
Action of • Limits fuel injection rate until engine speed lowers to operating range.
controller
Problem on • Engine speed fluctuates.
machine
Related • Engine speed can be checked by using monitoring function. (Code: 01002 (rpm))
information • Method of reproducing failure code: Run engine at full speed.
1 Use of improper fuel Fuel used may be improper. Check it.
2 Defect in related system If another failure code is displayed, perform troubleshooting for it.
Improper use Usage of machine may be improper. Instruct operator on proper use of
3
machine.
If no problem is found by checks on causes 1 and 2, engine controller is
4 Defective engine controller defective.
PC138USLC-10 40-147
40 Troubleshooting
Failure code [CA238] Ne Speed Sensor Supply Volt Error (PC400-CA238-400-A-Z0-A)
Action level Failure code Ne speed sensor supply voltage error

Failure
Detail of • Ne speed sensor power supply (5 V) circuit is defective.
failure
Action of • Controls engine by using signals of Bkup speed sensor.
controller
Problem on • Running engine stops (when Bkup (G) speed sensor is also abnormal).
machine • Stopped engine cannot be started (when Bkup(G) speed sensor is also abnormal).
information
equipment" in "Checks before troubleshooting" of "General
Defective wiring harness information on troubleshooting", and check it.
connector
If this failure code does not appear, harness connector is defective.
a If this failure code appears, perform the following.
2. Disconnect following connectors one by one and turn starting switch
to ON position each time.
3. After each troubleshooting, turn starting switch to OFF position.
If this failure code is not displayed when a sensor is disconnected,
Defective sensor or wiring sensor or engine wiring harness is defective.
2
harness
a Other failure codes are displayed, too. This is because connector is
disconnected. Ignore failure codes other than [CA238].
Sensor or harness Connector
Ne speed sensor NE
Engine wiring harness J1
3 Defective engine controller 3. Turn starting switch to ON position with engine wiring harness
disconnected.
Voltage Between J1 (male) (36) and (37) 4.75 to 5.25
V
Circuit diagram related to Ne speed sensor
40-148 PC138USLC-10
40 Troubleshooting
Failure code [CA239] Ne Speed Sens Supply Volt High Error (PC400-CA239-400-A-Z0-
A)
Action level Failure code Ne Speed Sensor Supply Voltage High Error
Failure
Detail of • High voltage appears in Ne speed sensor power supply (5 V) circuit.
failure
Action of • Controls engine by using signals from engine Bkup speed sensor.
controller
Problem on • Running engine stops (when Bkup (G) speed sensor is also defective).
machine • Stopped engine cannot be started (when Bkup (G) speed sensor is also defective).
information
1 Defective harness connector 2. Turn starting switch to ON position.
If this failure code disappears, harness connector is defective.
a If this failure code appears, perform following checks.
2. Disconnect connector NE.
2 Defective Ne speed sensor
harness is defective.
a Other failure codes (many codes) are also displayed. They are
generated because of disconnection of connector. Ignore failure
codes other than [CA239].
2. Disconnect connector J1.
3 Defective wiring harness If this failure code disappears, wiring harness is defective.
codes other than [CA239].
2. Disconnect connector J1 and connect T-adapters to male side.
4 Defective engine controller 3. Turn starting switch to ON position with engine wiring harness
disconnected.
V
Circuit diagram related to Ne speed sensor
PC138USLC-10 40-149
40 Troubleshooting
Failure code [CA271] IMV/PCV1 Short Error (D37-CA271-400-A-Z0-A)
Action level Failure code IMV/PCV1 Short Error

Failure
Detail of • Short circuit is detected in supply pump control valve (SCV) circuit.
failure
Action of
controller
machine
Related • Under normal conditions, pulse voltage of approx. 24 V is applied to SCV while engine is
information running. However, it cannot be measured by using multimeter since it is pulse voltage.
harness connector
Defective supply pump 2. Disconnect connector SCV and connect socket to male side.
2 SCV 3. Turn starting switch to ON position.
(internal short circuit) Resistance Between SCV (male) (1) and (2) 1 to 5 z
Resistance Between SCV (male) (2) and ground Min. 1 Mz
Short circuit in wiring 2. Disconnect connector J1 and connect T-adapter to female side.
3
harness Between J1 (female) (30) and (40) (SCV
Resistance resistance) 1 to 5 z
harness 2. Disconnect connectors J1 and SCV, and connect T-adapter to female side
4
(contact with ground of connector J1.
Defective engine If no abnormality is found by above diagnosis, engine controller is defective.
5
Circuit diagram related to SCV
40-150 PC138USLC-10
40 Troubleshooting
Failure code [CA272] IMV/PCV1 Open Error (D37-CA272-400-A-Z0-A)
Action level Failure code IMV/PCV1 Open Error

Failure
Detail of • Open circuit occurs in supply pump control valve (SCV) circuit.
failure
Action of
controller
machine
• Under normal conditions, pulse voltage of approx. 24 V is applied to SCV while engine is
Related running. However, it cannot be measured by using multimeter since it is pulse voltage.
harness connector
Defective supply pump 1. Turn starting switch to OFF position.
2 SCV 2. Disconnect connector SCV and connect socket to male side.
(internal open circuit) Resistance Between SCV (male) (1) and (2) 1 to 5 z
Open or short circuit in 2. Disconnect connector J1 and connect T-adapter to female side.
3 wiring harness Between J1 (female) (30) and (40) (SCV
Resistance resistance) 1 to 5 z
harness 2. Disconnect connectors J1 and SCV.
4 3. Connect T-adapter to female side of connector J1.
5
Circuit diagram related to SCV
PC138USLC-10 40-151
40 Troubleshooting
Failure code [CA322] Inj #1(L#1) Open/Short Error (D37-CA322-400-A-Z0-A)
Action level Failure code Injector #1 (L#1) Open/Short Error

Failure
Detail of • Open circuit or short circuit is detected in injector #1 circuit.
failure
Action of
controller
machine • Engine speed does not stabilize.
Related • While engine is running normally, approximately 65 V of pulse voltage is applied to
information injector (positive) side. But it is pulse voltage and cannot be measured by using
multimeter.
1
defective.
2. Disconnect connector CN1 and connect T-adapter to male side.
2 Defective injector #1 Resis- Between CN1 (male) (3) and (4)
0.4 to 1.1 z
tance
Resis- Between CN1 (male) (3) and ground
Min. 1 Mz
tance
Open circuit or ground fault in Resis-
3 wiring harness Between J1 (female) (48) and (58) 0.4 to 1.1 z
tance
Resis- Between J1 (female) (48) and ground
Min. 1 Mz
tance
Open circuit in wiring harness 2. Disconnect connectors J1 and CN1, and connect T-adapters to each
4 (wire breakage or defective female side.
contact of connector) Resis- Between J1 (female) (48) and CN1 (female) (3)
Max. 1 z
tance
Resis- Between J1 (female) (58) and CN1 (female) (4)
Max. 1 z
tance
5 harness 2. Disconnect connectors J1 and CN1, and connect T-adapters to
(contact with ground circuit) either female side.
Resis- Between J1 (female) (48) or CN1 (female) (3)
Min. 1 Mz
tance and ground
2. Disconnect connectors J1 and CN1, and connect T-adapters to
female side of connector J1.
6 Short circuit in wiring harness a Check by using multimeter in continuity mode.

Between J1 (female) (48) and each No continuity (no
pin other than pin (48) sound is heard)
Continuity
Between J1 (female) (58) and each No continuity (no
pin other than pin (58) sound is heard)
40-152 PC138USLC-10
40 Troubleshooting

Defective other cylinder If failure codes of other injectors are displayed, perform troubleshooting
7 injectors or wiring harness for them first.
Circuit diagram related to injector #1
PC138USLC-10 40-153
40 Troubleshooting

Failure
failure
Action of
controller
Related • While engine is running normally, approximately 65 V of pulse voltage is applied to injector
information (positive) side. But it is pulse voltage and cannot be measured by using multimeter.
harness connector
2 Defective injector #3
Between CN2 (male) (3) and (4) 0.4 to 1.1 z
Resistance
Between CN2 (male) (3) and ground Min. 1 Mz
Open circuit or ground 2. Disconnect connector J1 and connect T-adapter to female side.
3 fault in wiring harness Between J1 (female) (44) and (54) 0.4 to 1.1 z
Resistance
Between J1 (female) (44) and ground Min. 1 Mz
harness 1. Turn starting switch to OFF position.
4 (wire breakage or 2. Disconnect connectors J1 and CN2, and connect T-adapter to each
connector) Between J1 (female) (44) and CN2 (female) (3) Max. 1 z
Resistance
Between J1 (female) (54) and CN2 (female) (4) Max. 1 z
harness
5 2. Disconnect connectors J1 and CN2, and connect T-adapter to either
circuit) Between J1 (female) (44) or CN2 (female) (1) and
Resistance ground Min. 1 Mz

2. Disconnect connectors J1 and CN2, and connect T-adapter to the female
side of connector J1.
Short circuit in wiring a Check by using multimeter in continuity mode.
6
harness Between J1 (female) (44) and each No continuity (no sound
pin other than pin (44) is heard)
Continuity
Between J1 (female) (54) and each No continuity (no sound
Defective other cylinder
If failure codes of other injectors are displayed, perform troubleshooting for
7 injectors or wiring
them first.
harness
8
40-154 PC138USLC-10
40 Troubleshooting
PC138USLC-10 40-155
40 Troubleshooting

Failure
failure
Action of
controller
harness connector
Resistance
Resistance
4 (wire breakage or 2. Disconnect connectors J1 and CN1, and connect T-adapters to each
Resistance
harness
5 2. Disconnect connectors J1 and CN1, and connect T-adapters to either

2. Disconnect connectors J1 and CN1, and connect T-adapters to female
6
Continuity
them first.
harness
8
40-156 PC138USLC-10
40 Troubleshooting
PC138USLC-10 40-157
40 Troubleshooting

Failure
failure
Action of
controller
harness connector
Resistance
Resistance
4 (wire breakage or 2. Disconnect connectors J1 and CN2, and connect T-adapter to each
Resistance
harness
5 2. Disconnect connectors J1 and CN2, and connect T-adapter to either

2. Disconnect connectors J1 and CN2, and connect T-adapter to the female
6
Continuity
them first.
harness
8
40-158 PC138USLC-10
40 Troubleshooting
PC138USLC-10 40-159
40 Troubleshooting
Failure code [CA343] ECM Critical Internal Failure (PC400-CA343-400-A-Z0-A)
Action level Failure code ECM Critical Internal Failure

Failure
Detail of • Engine controller has internal defect.
failure
controller
Problem on • Engine continues to run normally, but it may stop during running or may not be able to
machine start if it is stopped.
• Power supply voltage of engine controller can be checked with moniitoring funtion.
Related (Code: 03203 Battery voltage)
information • Method of reproducing failure code: Turn starting switch to ON position
Defective engine controller
system
40-160 PC138USLC-10
40 Troubleshooting
Failure code [CA351] Injectors Drive Circuit Error (PC400-CA351-400-A-Z0-A)
Action level Failure code Injectors Drive Circuit Error

Failure
Detail of • Injector drive circuit is defective.
failure
Action of • Limits engine output (limits common rail pressure) and allows engine to run.
controller
Problem on • Engine output lowers.
machine
information
Check failure code (injector system failure code) that is displayed at the
1 Defect in related system
same time. If another code is displayed, perform troubleshooting for it.
Defective engine controller
system
PC138USLC-10 40-161
40 Troubleshooting

Failure
Detail of • Low voltage occurs in sensor power supply 1 (5 V) circuit.
failure
Action of • Signals from EGR valve sensor and VFT sensor are ignored.
machine
information
harness connector
2. Disconnect following connectors one by one and turn starting switch to ON
position each time.
Defective sensor or harness is defective.
2 wiring harness a Other failure codes (many codes) are also displayed. They are generated
because of disconnection of connector. Ignore failure codes other than
[CA352].
EGR valve EGR V
Connector VFT VFT
Engine harness J2
Defective relevant
system
Defective engine
4 3. Turn starting switch to ON position with connector J2 disconnected.
controller
V
40-162 PC138USLC-10
40 Troubleshooting
Circuit diagram related to sensor power supply 1 (5 V)
PC138USLC-10 40-163
40 Troubleshooting
Failure code [CA356] Mass Air Flow Sensor High Error (PC138-CA356-400-A-Z0-A)
Action level Failure code Mass Air Flow Sensor High Error
Failure
Detail of • High frequency occurs in signal circuit of mass air flow sensor.
failure
• Sets mass air flow to fixed value (10 kg/min) and runs engine.
Action of • Closes EGR valve and opens KVGT fully.
controller • Limits engine output and allows engine to run.
• Stops KDPF regeneration control.
machine
• Since sensor output is 5 V pulse voltage, it cannot be measured by using multimeter.
Related • Mass air flow sensor and intake air temperature sensor are integrated.
harness connector
Defective sensor power If failure code [CA3419] or [CA3421] is also displayed, perform
2 supply system troubleshooting for it first.
Defective mass air flow 1. Turn starting switch to OFF position.
sensor 2. Disconnect connector P55.
(internal defect)
If this failure code changes to [CA357], mass air flow sensor is defective.
1. Be ready with starting switch at OFF position.
2. Disconnect connector P55, and connect T-adapter to female side.
supply system
Power Approx. 12
Voltage Between P55 (female) (2) and (3)
supply V
2. Disconnect connectors J1 and 55, and connect T-adapters to each female
5 (wire breakage or side.
connector) a To check open circuit in GND line
Resistance Between J1 (female) (22) and P55 (female) (3) Max. 1 z
2. Disconnect connectors J1 and P55 and connect T-adapter to female side
Short circuit in wiring of connector J1.
6
harness a Check by using multimeter in continuity mode.
Between J1 (female) (23) and each pin other than
Resistance pin (23) Min. 1 Mz

7
40-164 PC138USLC-10
40 Troubleshooting
Circuit diagram related to mass air flow sensor
PC138USLC-10 40-165
40 Troubleshooting
Failure code [CA357] Mass Air Flow Sensor Low Error (PC138-CA357-400-A-Z0-A)
Action level Failure code Mass Air Flow Sensor Low Error
Failure
Detail of • Low frequency occurs in signal circuit of mass air flow sensor.
failure
• Sets mass air flow to fixed value (10 kg/min) and runs engine.
Action of • Closes EGR valve and opens KVGT fully.
controller • Limits engine output and allows engine to run.
• Stops KDPF regeneration control.
machine
• Since sensor output is 5 V pulse voltage, it cannot be measured by using multimeter.
• Mass air flow sensor and intake air temperature sensor are integrated.
Related • If sensor connector is disconnected, both this failure code and failure code [CA691] are
information displayed.
harness connector
Defective sensor power If failure code [CA3419] or [CA3421] is also displayed, perform
2 supply system troubleshooting for it first.
Defective mass air flow 1. Turn starting switch to OFF position.
sensor 2. Replace mass air flow sensor.
(internal defect)
If this failure code does not appear, original mass air flow sensor is defective.
supply system
Power Approx. 12
Voltage Between P55 (female) (2) and (3)
supply V
2. Disconnect connectors J1 and 55, and connect T-adapters to each female
side.
harness a If no failure is found by check on cause 4, this
check is not required. Max. 1 z
5 (wire breakage or Between J1 (female) (21) and P55 (female) (2)
connector) Resistance
a If no failure is found by check on cause 4, this
Between J1 (female) (22) and P55 (female) (3)
Between J1 (female) (23) and P55 (female) (1) Max. 1 z
harness 2. Disconnect connectors J1 and P55, and connect T-adapter to either
6 female side.
Between ground and J1 (female) (23) or P55

7
40-166 PC138USLC-10
40 Troubleshooting

Hot short circuit in 3. Turn starting switch to ON position.
8 wiring harness
a Ignore displayed failure codes.
Voltage Between P55 (female) (1) and (3) Max. 1 V
9
PC138USLC-10 40-167
40 Troubleshooting

Failure
Detail of • High voltage occurs in sensor power supply 1 circuit.
failure
Action of • Signals from EGR valve sensor and VFT sensor are ignored.
machine
information
Abnormally high sensor
supply voltage
40-168 PC138USLC-10
40 Troubleshooting
Failure code [CA435] Eng Oil Press Sw Error (D37-CA435-400-A-Z0-A)
Action level Failure code Engine Oil Pressure Switch Error

Failure
Detail of • Failure occurs in engine oil pressure switch signal circuit.
failure
controller
Problem on • Protection function based on engine oil pressure does not work.
machine • Engine oil pressure monitor is not displayed normally.
• Method of reproducing failure code: Turn starting switch to ON position or start engine.
• Engine oil pressure switch is in CLOSED (ON) when oil pressure is low (when engine is
stopped), but is in OPEN (OFF) when oil pressure is high (when engine is running).
• To generate this failure code, engine controller checks whether engine oil pressure switch
is in CLOSED (ON) only when engine is stopped, that is, whether signal voltage is zero or
Related not.
information • Failure of engine oil pressure switch with engine running is shown by failure code
[B@BAZG].
k When performing checking and replacement of engine oil pressure switch, open oil
filler port, and check that engine oil temperature cools down enough not to get
scalded.
harness connector
2 2. Disconnect connector POIL, and connect T-adapter to male side.
pressure switch
Resistance Between POIL (male) (1) and ground Max. 1 z
Open or short circuit in
3 2. Disconnect connector J1 and connect T-adapter to female side.
wiring harness
Resistance Between J1 (female) (31) and ground Max. 1 z
4
Circuit diagram related to engine oil pressure switch
PC138USLC-10 40-169
40 Troubleshooting
Failure code [CA441] Battery Voltage Low Error (PC138-CA441-400-A-Z0-A)
Action level Failure code Battery Voltage Low Error

Failure
Detail of • Low voltage occurs in engine controller power circuit.
failure
Action of • Sets power supply voltage tot fixed value (24 V) and runs engine.
controller
Problem on • Engine stops (if engine is running).
machine • Engine startability is poor (if engine is stopped).
Related • Power supply voltage of engine controller can be checked with monitoring function.
information (Code: 03204(V))
Loose or corroded
1 Battery terminal may be loose or corroded. Check it directly.
battery terminal
Loose terminal or partial 1. Turn starting switch to OFF position.
2 open circuit at terminal Check terminals of alternator, battery relay, ground terminal (T12), etc.
Defective wiring See descriptions of wiring harness and connectors in "c: Electrical equipment"
3 harness connector in "Checks before troubleshooting" of "Related information on
troubleshooting", and check it.
Improper battery 2. Perform troubleshooting with starting switch at OFF position and when
4 voltage starting engine.
Voltage Between battery terminals (+) and (-). 20 to 30 V
2. Insert T-adapter into connector E12.
5 Defective alternator 3. Start engine. (Engine speed: Middle or faster)
Between ground and E12 (1) or alternator R 27.5 to 29.5
Voltage
Terminal (16) V
• Reference
1. Turn starting switch to OFF position, and set battery disconnect switch to
OFF position.
Defective engine 3. Turn battery disconnect switch to ON position.
6
controller 4. Measure voltage with starting switch at OFF position and when starting
engine.
Between CE03 (1) and (21) 20 to 30 V
Voltage
40-170 PC138USLC-10
40 Troubleshooting
Circuit diagram related to battery voltage system
PC138USLC-10 40-171
40 Troubleshooting
Failure code [CA442] Battery Voltage High Error (PC400-CA442-400-A-Z0-A)
Action level Failure code Battery Voltage High Error

Failure
Detail of • High voltage (approx. 36 V or higher) appears in controller power supply circuit.
failure
Action of • Takes it that power supply voltage is at fixed value (24 V) and allows engine to run.
controller
Problem on • Engine continues to run normally, but it may stop during running or may not be able to
machine restart if it is stopped.
Related • Power supply voltage of engine controller can be checked with monitoring function.
information (Code: 03203 (V))
system of engine controller
40-172 PC138USLC-10
40 Troubleshooting
Failure code [CA449] Rail Press Very High Error (PC400-CA449-400-A-Z0-A)
Action level Failure code Rail Pressure Very High Error

Failure
Detail of • High voltage (exceeding the preset limit) occurs in common rail pressure sensor circuit.
failure
Action of • Limits engine output and allows engine to run (limits common rail pressure).
controller
machine
• Signal voltage from common rail pressure sensor can be checked with monitoring
Related • Common rail pressure sensed by common rail pressure sensor can be checked with
information monitoring function. (Code: 36400 (MPa))
Defective common rail
pressure sensor system
PC138USLC-10 40-173
40 Troubleshooting
Failure code [CA451] Rail Press Sensor High Error (PC400-CA451-400-A-Z0-A)
Action level Failure code Rail Pressure Sensor High Error

Failure
Detail of • High voltage appears in signal circuit of common rail pressure sensor.
failure
controller
Problem on • Engine output decreases.
machine
• This failure code appears if common rail pressure sensor connector is disconnected.
a If failure code [CA515] or [CA516] is also displayed, perform
troubleshooting for it first.
Defective common rail 2. Disconnect connector PFUEL, and connect T-adapter to female side
2 pressure sensor power supply of connector.
system 3. Turn starting switch to ON position.
Power
Between PFUEL (female) (1) and
Voltage supply 4.75 to 5.25
(3) V
input
2. Disconnect connectors PFUEL and J2, and connect T-adapters to
each female side of connectors.
a If power supply input is normal in check on
cause 2, this check is not required. Max. 1 z
Open circuit in wiring harness Between J2 (female) (31) and PFUEL
3 (wire breakage or defective (female) (1)
Resistance a If power supply input is normal in check on
cause 2, this check is not required. Max. 1 z
Between J2 (female) (21) and PFUEL
(female) (3)
(female) (2) (sensor output) Max. 1 z

2. Disconnect connectors PFUEL and J2.
4 Short circuit in wiring harness 3. Connect T-adapter to female side of J2.
Min. 1 Mz
Resistance Between J2 (female) (55) and (31)
40-174 PC138USLC-10
40 Troubleshooting

2. Disconnect connector PFUEL, and insert T-adapter to connector J2.
3. Turn starting switch to ON position (with connector PFUEL
Hot short circuit in wiring disconnected).
5
harness
a Pin (55) of connector J2 is connected to 5 V circuit via resistor inside
engine controller.
Voltage Between J2 (55) and (21) Approx. 5 V
a If no failure is found by checks on causes 1 to 5 and if failure is
Defective common rail found by check on cause 6, sensor is defective.
pressure sensor 1. Turn starting switch to OFF position.
6 2. Insert T-adapters into connector J2.
(improper input voltage to
engine controller) 3. Turn starting switch to ON position.
Sensor
Voltage Between J2 (55) and (21)
output 0.2 to 4.6 V
Circuit diagram related to common rail pressure sensor
PC138USLC-10 40-175
40 Troubleshooting
Failure code [CA452] Rail Press Sensor Low Error (PC400-CA452-400-A-Z0-A)
Action level Failure code Rail Pressure Sensor Low Error

Failure
Detail of • Low voltage occurs in signal circuit of common rail pressure sensor.
failure
controller
machine
• Common rail pressure sensed by common rail pressure sensor can be checked with
Related monitoring function. (Code: 36400 (MPa))
• If sensor connector is disconnected even in normal condition, failure code [CA451] for
"High Error" is generated instead of this code.
1
defective.
a If failure code [CA515] or [CA516] is also displayed, perform
troubleshooting for it first.
Defective common rail 2. Disconnect connector PFUEL, and connect T-adapter to female side
2 pressure sensor power supply of connector.
system 3. Turn starting switch to ON position.
Power
Between PFUEL (female) (1)
Voltage supply 4.75 to 5.25 V
and (3)
input
2. Disconnect connector PFUEL.
If failure code [CA452] changes to [CA451], sensor is defective.
Defective common rail • Reference
3 pressure sensor 1. Turn starting switch to OFF position.
2. Insert T-adapter into connector PFUEL or J2.
Between PFUEL (2) and (3), or Sensor
between J2 (55) and (21) output
2. Disconnect connectors J2 and PAMB, and connect T-adapters to
Open circuit in wiring harness each female side of connectors.
4 (wire breakage or defective
contact of connector) a Open circuit of 5 V circuit
Resistance (female) (1) Max. 1 z

Ground fault in wiring harness 2. Disconnect connectors J2 and PFUEL, and connect T-adapter to
5 either female side.
Between ground and PFUEL (female) (2) or Min. 1 Mz
Resistance J2 (female) (55)
40-176 PC138USLC-10
40 Troubleshooting

2. Disconnect connectors J2 and PFUEL, and connect T-adapter to
6 Short circuit in wiring harness either female side.
Between PFUEL (female) (2) and (3) or
Resistance between J2 (female) (55) and (21) Min. 1 Mz
PC138USLC-10 40-177
40 Troubleshooting
Failure code [CA466] KVGT Motor Driver Position Error (D37-CA466-400-A-Z0-A)
Action level Failure code KVGT Motor Driver Position Error

Failure
Detail of • KVGT (VFT) position error has occurred.
failure
machine
Related
information a "KVGT" in the title of this failure code refers to "VFT" on this machine.
Defective sensor power If failure code [CA352] or [CA386] is displayed, perform troubleshooting for
1 supply system failure code [CA352] or [CA386] first.
2. Disconnect connectors J3 and VFT, and connect T-adapters to each
female side.
Open circuit in wiring Between J2 (female) (30) and VFT (female) (1) Max. 1 z
2 Between J2 (female) (47) and VFT (female) (5) Max. 1 z
harness
Resistance Between J2 (female) (53) and VFT (female) (2) Max. 1 z
Between J2 (female) (43) and VFT (female) (3) Max. 1 z
2. Disconnect connectors J2 and VFT, and connect T-adapter to either
Ground fault in wiring female side.
harness Between ground and J2 (female) (53) or VFT
(female) (2) Min. 1 Mz
3
Between ground and J2 (female) (43) or VFT

2. Disconnect connectors J2 and VFT, and connect T-adapter to either
Short circuit in wiring female side.
harness Between J2 (female) (43) and (53), or between VFT
(female) (2) and (3) Min. 1 Mz
4
(Short circuit between
Between J2 (female) (53) and (52), or between VFT
wiring harnesses) Resistance (female) (2) and (4) Min. 1 Mz
Between J2 (female) (43) and (52), or between VFT
Since this is an internal sensor failure of the VFT, troubleshooting cannot be
VFT Position Sensor performed.
5
Error
Defective engine If no failure is found by above checks, engine controller may be defective.
6
40-178 PC138USLC-10
40 Troubleshooting
Circuit diagram related to VFT
PC138USLC-10 40-179
40 Troubleshooting
Failure code [CA515] Rail Press Sens Sup Volt High Error (PC400-CA515-400-A-Z0-A)
Action level Failure code Rail Pressure Sensor Supply Voltage High Error
Failure
Detail of • High voltage occurs in common rail pressure sensor power supply (5 V) circuit.
failure
Action of • Limits engine output and runs engine.
controller • Limits the common rail pressure.
machine
information
1
defective.
Defective common rail 3. Turn starting switch to ON position.
2 pressure sensor If this failure code disappears, sensor is defective.
(internal defect)
codes other than this code.
Defective wiring harness If this failure code does not appear, wiring harness may be defective.
3
Perform following troubleshooting.
Hot short circuit in wiring 2. Disconnect connector PFUEL, and connect T-adapter to female side
4 of connector.
harness
Voltage Between PFUEL (female) (1) and (3) 4.75 to 5.25
V
Voltage Between J2 (male) (31) and (21) 4.7 to 5.25 V
40-180 PC138USLC-10
40 Troubleshooting
PC138USLC-10 40-181
40 Troubleshooting
Failure code [CA516] Rail Press Sens Sup Volt Low Error (PC400-CA516-400-A-Z0-A)
Action level Failure code Rail Pressure Sensor Supply Voltage Low Error
Failure
Detail of • Low voltage appears in common rail pressure sensor power supply (5 V) circuit.
failure
Action of • Limits engine output and allows engine to run.
controller • Limits the common rail pressure.
machine
information
Defective common rail 3. Turn starting switch to ON position.
2 pressure sensor If this failure code disappears, sensor is defective.
(internal defect)
Defective wiring harness If this failure code does not appear, wiring harness may be defective.
3
Perform following troubleshooting.
Ground fault in wiring harness
4 2. Disconnect connectors J2 and PFUEL, and connect T-adapter to
(contact with ground circuit) female side of either connector.
Resis- Between ground and J2 (female) (31) or
PFUEL (female) (1) Min. 1 Mz
tance
5 Short circuit in wiring harness 2. Disconnect connectors J2 and PFUEL, and connect T-adapter to
female side of either connector.
Resis- Between J2 (female) (21) and (31), or
between PFUEL (female) (1) and (2) Min. 1 Mz
tance
2. Disconnect connector J2, and connect T-adapter to male side.
6 Defective engine controller 3. Turn starting switch to ON position.
V
40-182 PC138USLC-10
40 Troubleshooting
PC138USLC-10 40-183
40 Troubleshooting
Failure code [CA553] Rail Press High Error (PC400-CA553-400-A-Z0-A)
Action level Failure code Rail Pressure High Error

Failure
Detail of • High voltage (above the limit) appears and continued 15 or more seconds in signal circuit
failure of common rail pressure sensor.
controller
machine
Defective relevant system If other failure codes are also displayed, perform troubleshooting for
1
them.
2 Improper fuel Fuel used may be improper. Check it (the viscosity is high).
Defective electric system of Electrical system of common rail pressure sensor may be defective.
3 common rail pressure sensor Perform troubleshooting for failure codes [CA451] and [CA452].
Defective mechanical system
4 of common rail pressure Common rail pressure sensor may have mechanical failure. Check it.
sensor
The overflow valve may has a damaged spring, worn seat, or ball
5 Defective overflow valve clogging trouble. Check it.
6 Clogging of overflow piping Check overflow piping for clogging.
7 Defective pressure limiter The pressure limiter may have a mechanical failure. Check it.
40-184 PC138USLC-10
40 Troubleshooting
Failure code [CA555] Crankcase Press High Error 1 (PC400-CA555-400-A-Z0-A)
Action level Failure code Crankcase Press High Error 1

Failure
Detail of • High pressure error of crankcase pressure is detected.
failure
controller
Problem on
machine
• Signal voltage from crankcase pressure sensor can be checked with monitoring function.
(Code: 48401(V))
Related • Pressure sensed by crankcase pressure sensor can be checked with monitoring function.
information (Code: 48400 (MPa))
1 Clogged KCCV filter Replace KCCV filter with a new one.
When this failure code is not cleared after KCCV filter is replaced and
Blocked KCCV gas piping emulsion is found inside KCCV, KCCV blowby gas piping may be
2
blocked with emulsified matter. Perform troubleshooting for coolant
leaks.
Crankcase pressure sensor Crankcase pressure sensor system may be defective. Perform
3 troubleshooting for failure codes [CA1843] and [CA1844].
defective
PC138USLC-10 40-185
40 Troubleshooting
Failure code [CA556] Crankcase Press High Error 2 (PC400-CA556-400-A-Z0-A)
Action level Failure code Crankcase Pressure High Error 2

Failure
Detail of • Crankcase pressure high error (level 2) occurs.
failure
controller
machine
(Code: 48401 (V))
information (Code: 48400 (kPa))
• Method of reproducing failure code: Starting switch ON
1 Clogged KCCV filter Replace KCCV filter.
If error condition is not cleared after KCCV filter is replaced and
2 Blocked KCCV gas piping emulsion is found inside KCCV, emulsion may block KCCV blowby gas
piping. Perform troubleshooting for leakage of coolant.
Defective crankcase pressure Crankcase pressure sensor system may be defective. Perform
sensor
If error condition is not cleared after KCCV filter is replaced and failure
code of crankcase pressure high error 2 is generated in short times,
4 Increase of blowby gas
engine may be seized or turbocharger may be defective. Perform
troubleshooting for mechanical system.
40-186 PC138USLC-10
40 Troubleshooting
Failure code [CA559] Rail Press Low Error (PC138-CA559-400-A-Z0-A)
Action level Failure code Rail Pressure Low Error

Failure
Detail of • Supply pump pressure is very low (level 1).
failure
Action of • Limits the common rail pressure.
controller
machine
• Common rail pressure sensed by common rail pressure sensor can be checked with
Related monitoring function. (Code: 36400 (MPa))
Defective relevant
1 If another failure code is displayed, perform troubleshooting for it first.
system
2 Improper fuel Improper fuel may be used, so check fuel.
3 Clogging of fuel filter a If fuel filter is clogged, replace it.
a For details of troubleshooting, see Note 1.
a For check of fuel pressure in low-pressure circuit, see Testing and
Defective low-pressure adjusting, "Testing fuel pressure".
4
circuit devices Fuel pressure in low-pressure circuit
-49 to 0 MPa
(with engine running at high idle or
{-0.5 to 0 kg/cm2}
under load equivalent to rated load)
Defective electrical Electrical problem with supply pump SCV is estimated, so perform
5 system of supply pump troubleshooting for following codes: CA271 and CA272.
SCV
Defective common rail Common rail pressure sensor may be defective. Check wiring harness for
6 pressure sensor damage.
a For check of leakage from pressure limiter, see Testing and adjusting,
"Testing fuel return rate and leakage".
Defective pressure Leakage from pressure limiter
7
limiter (Engine operation equivalent to rated Max. 20 cc/min (*)
operation (with load by torque
converter stall))
a For check of limit return rate (spill) from injector, see Testing and adjusting,
"Testing fuel return rate and leakage".
Speed at rated operation Injector
(at stall) Limit return (spill) rate
8 Defective injector 1,600 rpm 190 cc/min
1,700 rpm 200 cc/min
Defective supply pump If no failure is found by checks on causes 1 to 8, supply pump may be
9
defective.
* Although upper limit is 20 cc/min, note that standard value is 0 cc/min (no leakage) in normal condition.
<How to use check sheet>
Perform above troubleshooting and fill in check results on attached "Check sheet for fuel pressure low error".
Note 1: Check low-pressure fuel circuit parts for following items.
1. Remaining quantity of fuel
2. Clogging of fuel tank breather
3. Looking and wear of fuel feed pump and clogging of filter
4. Leakage from or clogging of low-pressure fuel piping
PC138USLC-10 40-187
40 Troubleshooting
5. Clogging of fuel filter

6. Replace fuel filter when problem is not removed even if no clogging is found.
Check sheet for fuel pressure low error
Model Work No.
Machine serial No. # Date of check / /
Engine SAA4D95LE-6 Service meter h
Engine serial No. # Worker's name
No good
Good
A. Visual check
1 Fuel leakage to outside

2 Clogging of fuel tank breather
No good
Good
B. Inspection with machine monitor (02 = Abnormality record; 01 = Monitoring; 09 = Cylinder
cutout mode operation)
3 Check of failure code / / / /

Check of monitoring information
No good
Standard value
Good
Item displayed Testing conditions (Reference Measured
Code ISO unit
value) value
Minimums speed r/min 1,100 ± 50

01002 Engine speed Minimum speed r/min 2,100 ± 60
Rated speed r/min 2,050
Low idle % 0
31701 Throttle opening
High idle % 100
Last fuel injection
quantity
18600 command (relief) mg/st - - -
4
(in weight)
Last common rail
36200 pressure (arm in relief) MPa -
command
Common rail
36400 pressure (arm in relief) MPa -
Low idle CA - - -
Last injection
36300 timing command High idle CA - - -
(arm in relief) CA - - -
36500 Charge pressure (arm in relief) kPa - - ―
Engine coolant
04107 temperature Low idle °C - - -
14200 Fuel temperature Low idle °C - - -
40-188 PC138USLC-10
40 Troubleshooting
Check result of cylinder cutout mode operation (engine speed)
No good
Standard value
Good
Cutout Measured
Function Testing conditions ISO unit (Reference
cylinder value
value)
No. 1
Low idle r/min - - -
5 cylinder
Set No. 2
cylinder to cylinder
be cut out No. 3
by cylinder. cylinder Low idle r/min - - -
No. 4
cylinder
No good
Standard value
Good
C. Check of fuel circuit Measured
Testing conditions Unit (Reference
pressure value
value)
High idle or under load
Fuel pressure in low- equivalent to rated MPa 0.15 to 0.3
6 pressure circuit operation (at arm in {kg/cm2} {1.5 to 3.0}
relieved)
No good
Good
D. Check of strainers and filters
7 Visual check of fuel filter
No good
Standard value
Good
E. Check of leakage and Testing conditions (Reference Measured
Unit
return rate value) value
Engine operation
Leakage from pressure equivalent to rated
8 cc/min Max. 20 (*)
limiter operation (with load by
torque converter stall)
Arm in hydraulic relief
1,600 rpm cc/min Max. 190
cc/min Max. 200 Speed:
1,700 rpm
9 Return rate from injector 1,800 rpm cc/min Max. 210
Arm in hydraulic relief Return
rate:
* Although upper limit is 20 cc/min, note that standard value is 0 cc/min (no leakage) in normal condition.
PC138USLC-10 40-189
40 Troubleshooting
Failure code [CA689] Eng Ne Speed Sensor Error (D37-CA689-400-A-Z0-A)
Action level Failure code Engine Ne Speed Sensor Error

Failure
Detail of • Engine Ne speed sensor signal is abnormal.
failure
Action of • Controls engine by using signals from engine Bkup speed sensor.
controller
Problem on • Running engine stops (when Bkup speed sensor is also defective).
machine • Stopped engine cannot be restarted (when Bkup speed sensor is also defective).
• Since interior portion of speed sensor is configured with hall sensor and electronic circuit
rather than coil, measurements of speed sensor resistance by using mulitimeter cannot
be used to determine whether sensor is normal or not.
Related • Since speed sensor output is pulse voltage of 5 V in normal state, multimeter is not usable
information for measurement.
• Wheel (W) is mounted inside of crankshaft vibration damper and has holes for speed
sensing. Ne speed sensor detects rotating holes, and both engine speed and phase are
calculated by the engine controller.
harness connector
Defective Ne speed
2 sensor power supply If failure code [CA238] is also displayed, perform troubleshooting for it first.
system
Breakage or improper
installation (loosened) Engine Ne speed sensor may be broken or improperly installed (loose).
3
of engine Ne speed Check it.
sensor
Damage or poor (loose)
mounting of wheel for Check wheel (W) for speed sensing directly as it may be damaged or loosely
4
speed sensing mounted.

Defective Ne speed 2. Disconnect connector NE, and connect T-adapter to female side.
5 sensor power supply 3. Turn starting switch to ON position.
input Power 4.75 to 5.25
Voltage Between NE (female) (1) and (2)
supply input V
2. Disconnect connectors J1 and NE, and connect T-adapters to each female
side.
Open circuit in wiring If no failure is found by check on cause 4, this
harness check is not required. Max. 1 z
6 (wire breakage or Between J1 (female) (36) and NE (female) (1)
connector) Resistance If no failure is found by check on cause 4, this
Between J1 (female) (37) and NE (female) (2)
Between J1 (female) (26) and NE (female) (3) Max. 1 z
2. Disconnect connectors J1 and NE and connect T-adapter to either female
side.
7 Between J1 (female) (36) and (26), or between NE
harness Min. 1 Mz
(female) (1) and (3)
Resistance
Between J1 (female) (37) and (26), or between NE
40-190 PC138USLC-10
40 Troubleshooting

harness 2. Disconnect connectors J1 and NE and connect T-adapter to either female
8 side.
Between ground and J1 (female) (26) or NE

Hot short circuit in 2. Disconnect connector NE, and connect T-adapter to female side.
Voltage Between NE (female) (3) and ground Max. 1 V
If no failure is found by above checks, engine Ne speed sensor may be
Defective engine Ne
10 speed sensor defective. (Since this is an internal defect, troubleshooting cannot be
performed.)
11
Circuit diagram related to engine Ne speed sensor
• The Ne speed sensor detects the wide area of hole (W) in the wheel, and the engine controller calculates
the engine speed and signal phase.
PC138USLC-10 40-191
40 Troubleshooting
Failure code [CA691] Intake Air Temp Sens High Error (PC138-CA691-400-A-Z0-A)
Action level Failure code Intake Air Temperature Sensor High Error
Failure
Detail of • High voltage occurs in signal circuit of intake air temperature sensor.
failure
Action of • Sets intake air temperature to fixed value (25°C) and runs engine.
controller
Problem on
machine
• Mass air flow sensor and intake air temperature sensor are integrated.
Related • If sensor connector is disconnected, this failure code is displayed together with failure
information code [CA357].
harness connector
-30°C 25 to 28 kz
5.5 to 6.1
Defective intake air 0°C
kz
2 temperature sensor Between P55 (male) (3) and (4) 1.9 to 2.1
(internal defect) Resistance a Intake air temperature-Resistance 25°C
kz
characteristics 1.1 to 1.2
40°C
kz
180 to 185
100°C
z
wiring harness
180 z to 28
3 (short circuit, wire Resistance Between J1 (female) (6) and (22)
kz
breakage or defective
contact of connector) a Use Intake air temperature-Resistance characteristics table for check on
cause 2 as resistance criteria.
2. Disconnect connector P55.
Hot short circuit in 3. Insert T-adapter into connector J1, or connect T-adapter to female side of
4 wiring harness connector P55.
Between J1 (6) and (22) or between P55 (female)
Voltage Max. 5.25 V
(4) and (3)
5

6
40-192 PC138USLC-10
40 Troubleshooting
Circuit diagram related to intake air temperature sensor
PC138USLC-10 40-193
40 Troubleshooting
Failure code [CA692] Intake Air Temp Sens Low Error (PC138-CA692-400-A-Z0-A)
Action level Failure code Intake Air Temperature Sensor Low Error
Failure
Detail of • Low voltage occurs in signal circuit of intake air temperature sensor.
failure
Action of • Sets intake air temperature to fixed value (25 °C) and runs engine.
controller
Problem on
machine
Related • Mass air flow sensor and intake air temperature sensor are integrated.
harness connector
If this failure code changes to failure code [CA691], intake air temperature
• Reference
Defective intake air -30°C 25 to 28 kz
2 temperature sensor
5.5 to 6.1
(internal defect) 0°C
kz
Between P55 (male) (3) and (4) 1.9 to 2.1
25°C
a Intake air temperature-Resistance kz
Resistance characteristics 1.1 to 1.2
40°C
kz
180 to 185
100°C
z
Between P55 (male) (4) and ground Whole
(sensor body) range Min. 1 Mz

wiring harness
180 z to 28
3 (short circuit, wire Resistance Between J1 (female) (6) and (22)
kz
breakage or defective
contact of connector) a Use Intake air temperature-Resistance characteristics table for check on
cause 2 as resistance criteria.
harness 2. Disconnect connectors J1 and P55, and connect T-adapter to either
4 female side.
Between ground and J1 (female) (6) or P55

5

6
40-194 PC138USLC-10
40 Troubleshooting
Circuit diagram related to intake air temperature sensor
PC138USLC-10 40-195
40 Troubleshooting
Failure code [CA697] ECM Internal Temp Sensor High Error (PC400-CA697-400-A-Z0-
A)
Action level Failure code ECM Internal Temperature Sensor High Error
Failure
Detail of • High voltage appears in engine controller internal temperature sensor signal circuit.
failure
controller
Problem on
machine
• Temperature sensed by engine controller internal temperature sensor can be checked by
Related using monitoring function (Code: 18900(°C)).
1 Improper usage of controller Check if the controller has been used in high temperature environments.
40-196 PC138USLC-10
40 Troubleshooting
Failure code [CA698] ECM Int Temp Sensor Low Error (PC400-CA698-400-A-Z0-A)
Action level Failure code ECM Internal Temperature Sensor Low Error
Failure
Detail of • Low voltage appears in engine controller internal temperature sensor signal circuit.
failure
controller
Problem on
machine
• Temperature sensed by engine controller internal temperature sensor can be checked by

Related using monitoring function (Code: 18900(°C)).

1 Improper usage of controller Check if the controller has been used in low temperature environments.
PC138USLC-10 40-197
40 Troubleshooting
Failure code [CA731] Eng Bkup Speed Sens Phase Error (D37-CA731-400-A-Z0-A)
Action level Failure code Engine Bkup Speed Sensor Phase Error
Failure
Detail of • Phase error occurs between signals of engine Ne speed sensor and engine Bkup speed
failure sensor.
Action of • Continues to control engine by using engine Ne speed sensor signal.
controller
• Engine can not start or engine is hard to start.
Problem on • Idle speed is unstable.
machine • Exhaust gas color becomes black.
information
Damaged engine Ne
1 Engine Ne speed sensor may be damaged. Check it.
speed sensor
Damaged engine Bkup
2 Engine Bkup speed sensor may be damaged. Check it.
speed sensor
Improper installation or
damage of speed Wheel (W) on crankshaft side for speed sensing may be mounted incorrectly
3 or damaged. Check it by reading failure code [CA689].
sensing wheel on
crankshaft side
Speed detection ring on camshaft side may be installed improperly or
damaged. Check it according to following procedure.
Improper installation or 1. Rotate crankshaft clockwise when viewed from front to align wide notch
damage of speed (a) of wheel for speed sensing (W) with "1.4 TOP" (b) on cover.
4 2. Remove Bkup speed sensor.
sensing ring on
camshaft side 3. If you can see two slots on camshaft speed sensing ring (B) through
sensor mounting hole (H), ring for speed sensing is mounted correctly .
(Note that the two slots are visible only once in two turns, when #1 piston
comes to the top.)
Defective timing
adjustment of Timings of crankshaft and camshaft may not be matched each other. Check
5
crankshaft and them.
camshaft
Ground terminal may be poorly connected. Check following terminals:
Defective connection of • Ground terminal of machine ((-) terminal of battery)
6 ground terminal • Ground terminal of engine
• Ground terminal of engine controller
• Ground terminal of starting motor
40-198 PC138USLC-10
40 Troubleshooting
Circuit diagram related to engine Bkup speed sensor
PC138USLC-10 40-199
40 Troubleshooting
40-200 PC138USLC-10
40 Troubleshooting
Failure code [CA778] Eng Bkup Speed Sensor Error (PC138-CA778-400-A-Z0-A)
Action level Failure code Engine Bkup Speed (CAM) Sensor Error
Failure
Detail of • Engine Bkup speed (CAM) sensor signal is abnormal.
failure
Action of • Continues to control engine by using engine Ne speed sensor signal.
controller
Problem on • Engine startability is poor
machine • Reduced engine output.
• Since interior portion of speed sensor is configured with hall sensor and electronic circuit
rather than coil, measurements of speed sensor resistance by using mulitimeter cannot
Related be used to determine whether sensor is normal or not.
information • Since speed sensor output is pulse voltage of 5 V in normal state, multimeter is not usable
for measurement.
• This speed sensor detects groove in speed sensing ring, which is installed to camshaft, to
measure camshaft speed.
harness connector
2 supply 2 circuit for it first.
Breakage or improper
installation (loosened) Engine Bkup speed (CAM) sensor may be broken or installed improperly
3 of engine Bkup speed (loosened). Check it.
(CAM) sensor
2. Disconnect connector CAM, and connect T-adapter to female side.
Improper power supply 3. Turn starting switch to ON position.
4 input to engine Bkup Power 4.75 to 5.25
speed sensor Between CAM (female) (1) and (2)
supply V
Voltage Between CAM (female) (1) and (2) 4.75 to 5.25
V
harness 2. Disconnect connectors J1 and CAM, and connect T-adapters to each
female side.
5 (wire breakage or Between J1 (female) (60) and CAM (female) (1) Max. 1 z
connector) Resistance Between J1 (female) (59) and CAM (female) (2) Max. 1 z
Between J1 (female) (9) and CAM (female) (3) Max. 1 z
2. Disconnect connectors J1 and CAM, and connect T-adapter to either
female side.
6 Between J1 (female) (9) and (60), or between CAM
harness Min. 1 Mz
(female) (1) and (3)
Resistance
Between J1 (female) (9) and (59), or between CAM

harness 2. Disconnect connectors J1 and CAM, and connect T-adapter to either
7 female side.
Between ground and J1 (female) (9) or CAM Min. 1 Mz
circuit) Resistance (female) (3)
PC138USLC-10 40-201
40 Troubleshooting

Hot short circuit in 2. Disconnect connector CAM, and connect T-adapter to female side.
Voltage Between CAM (female) (3) and ground Max. 1 V
Loosened camshaft Remove engine Bkup speed (CAM) sensor, and check ring through hole (H).
9 speed sensing ring a If speed sensing ring (B) is loosened, see "Reference".
If no failure is found by above checks, engine Bkup speed (CAM) sensor is
Defective engine Bkup defective.
10 speed (CAM) sensor
11
Circuit diagram related to engine Bkup speed sensor
• Reference
Check of camshaft ring for looseness
Remove front cover and check camshaft ring for looseness.
a See Disassembly and assembly, "Removal and installation of engine front oil seal".
a Keep the front seal, liquid gasket LG-7 and front seal tool (795-799-6400) on hand.
Removal
1. Remove fan belt and fan, For details, see Disassembly and assembly, "Removal and installation of engine
front seal".
40-202 PC138USLC-10
40 Troubleshooting
2. Remove crankshaft pulley (1).

(DP): Dowel pin
3. Remove front cover (2).

4. Remove front seal (3).
5. Check that mounting bolt (4) of camshaft ring (5) is not loosened.
3 Mounting bolt (4):
10 ± 2 Nm {0.98 ± 0.2 kgm}
(DP): Dowel pin
Installation
a See figures shown in removal procedure section.
1. Install front cover (2).
2 Front cover:
Liquid gasket (LG-7)
2. See Disassembly and assembly, "Removal and installation of engine front oil seal".
1) install front cover (3).
PC138USLC-10 40-203
40 Troubleshooting
2) Install dowel pin (DP), and install crankshaft pulley.

3) Install fan and fan belt.
4) Install the cooling system assembly.
40-204 PC138USLC-10
40 Troubleshooting
Failure code [CA1117] Persistent Data Lost Error (PC138-CA1117-400-A-Z0-A)
Action level Failure code Persistent Data Lost Error

Failure
Detail of
• Internal defect occurred in controller.
failure
controller
• Engine continues to run normally, but it may stop during running or may not be able to
Problem on start if it is stopped.
machine • Engine controller cannot store internal data correctly.
information
Defective power supply Since the power supply circuit may be defective, carry out troubleshooting for
1 failure code [CA441].
circuit
Improper operation of
2 battery disconnect Battery disconnect switch may have been operated improperly.
switch
PC138USLC-10 40-205
40 Troubleshooting

Failure
E03 CA1695 (Engine controller system)
Detail of • High voltage error occurs in sensor power supply 5 (5V) circuit.
failure
controller
Problem on
machine
information
Cause Procedure, measuring location, criteria, and remarks
Perform troubleshooting for failure code [CA1696].
40-206 PC138USLC-10
40 Troubleshooting

Failure
Detail of • Low voltage error occurs in sensor power supply 5 (5 V) circuit.
failure
controller
machine
Related • Sensor power supply 5 (pin 52 of connector CE03) is not used.
Defective engine
controller
Voltage Between CE03 (male) (52) and (43) 4.75 to 5.25
V
Circuit diagram related to sensor power supply 5 circuit
PC138USLC-10 40-207
40 Troubleshooting
Failure code [CA1843] Crankcase Press Sens High Error (D37-CA1843-400-A-Z0-A)
Action level Failure code Crankcase Pressure Sensor High Error

Failure
Detail of • High voltage occurs in signal circuit of crankcase pressure sensor.
failure
Action of • Sets crankcase pressure to fixed value (approximately 0 kPa) and runs engine.
controller
Problem on
machine
(Code: 48401 (V))
harness connector
2 supply system for [CA187] or [CA227] first.
Defective crankcase 2. Disconnect connector CCV.
3 pressure sensor 3. Turn starting switch to ON position.
(internal defect) If failure code changes from [CA1843] to [CA1842], crankcase pressure
harness 2. Disconnect connectors J1 and CCV, and connect T-adapters to each
connector) Resistance Between J1 (female) (59) and CCV (female) (2) Max. 1 z
2. Disconnect connectors J1 and CCV, and connect T-adapter to either
5 female side.
harness
Between J1 (female) (3) and (60), or between CCV
Resistance (female) (1) and (3) Min. 1 Mz

Hot short circuit in 2. Disconnect connector CCV and connect T-adapter to female side.
Voltage Between CCV (female) (3) and (2) Max 1 V
• Reference
Defective engine 1. Turn starting switch to OFF position.
7
controller 2. Insert T-adapter into connector J1.
Sensor
output
40-208 PC138USLC-10
40 Troubleshooting
Circuit diagram related to crankcase pressure sensor
PC138USLC-10 40-209
40 Troubleshooting
Failure code [CA1844] Crankcase Press Sens Low Error (D37-CA1844-400-A-Z0-A)
Action level Failure code Crankcase Pressure Sensor Low Error

Failure
Detail of • Low voltage occurs in signal circuit of crankcase pressure sensor.
failure
Action of • Sets crankcase pressure to fixed value (approximately 0 kPa) and runs engine.
controller
Problem on
machine
(Code: 48401(V))
harness connector
for [CA187] or [CA227] first.
Defective sensor power 1. Turn starting switch to OFF position.

2 supply system 2. Disconnect connector CCV and connect T-adapter to female side.
Power 4.75 to 5.25
Voltage Between CCV (female) (1) and (2)
supply V
2. Disconnect connectors J1 and CCV, and connect T-adapters to each
female side.
Open circuit in wiring a If no failure is found by check on cause 2, this
harness Resistance check is not required. Max. 1 z
3 (wire breakage or Between J1 (female) (60) and CCV (female) (1)
connector) a If no failure is found by check on cause 2, this
Resistance check is not required. Max. 1 z
Between J1 (female) (59) and CCV (female) (2)
Resistance Between J1 (female) (3) and CCV (female) (3) Max. 1 z
harness 2. Disconnect connectors J1 and CCV, and connect T-adapter to either
4 female side.
Between ground and J1 (female) (3) or CCV

2. Disconnect connectors J1 and CCV, and connect T-adapter to either
5 female side.
harness
Between J1 (female) (3) and (59), or between CCV
Resistance (female) (2) and (3) Min. 1 Mz

Defective crankcase 2. Insert T-adapter into connector CCV.
6 pressure sensor 3. Turn starting switch to ON position.
(internal defect) Sensor 0.3 to 4.7 V
Voltage Between CCV (3) and (2)
output
40-210 PC138USLC-10
40 Troubleshooting

• Reference
7
controller 2. Insert T-adapter into connector J1.
Sensor
output
Circuit diagram related to crankcase pressure sensor
PC138USLC-10 40-211
40 Troubleshooting
Failure code [CA1896] EGR Valve Stuck Error (D37-CA1896-400-A-Z0-A)
Action level Failure code EGR Valve Stuck Error

Failure
Detail of • EGR valve stuck error has occurred (failed to learn zero point)
failure
machine
Related
information
Defective EGR
1 EGR may have mechanical failure. Check it.
mechanical system
Defective engine If no problem is found by above checks, engine controller is defective. (Since
2 this is an internal defect, troubleshooting cannot be performed.)
controller
40-212 PC138USLC-10
40 Troubleshooting
Failure code [CA1942] Crankcase Press Sens In Range Error (PC400-CA1942-400-A-

Z0-A)
Action level Failure code Crankcase Pressure Sensor In Range Error

Failure
Detail of • Output value from crankcase pressure sensor is out of normal range.
failure
controller
Problem on
machine
(Code: 48401 (V))
Defective crankcase pressure Crankcase pressure sensor system may be defective. Perform
sensor
2 Clogged KCCV filter Replace KCCV filter.
If error condition is not cleared after KCCV filter is replaced and
3 Blocked KCCV gas piping emulsion is found inside KCCV, emulsion may block KCCV blowby gas
piping. Perform troubleshooting for leakage of coolant.
If error condition is not cleared after KCCV filter is replaced and failure
code of crankcase pressure high error 2 is generated in short times,
4 Increase of blowby gas
engine may be seized or turbocharger may be defective. Perform
troubleshooting for mechanical system.
PC138USLC-10 40-213
40 Troubleshooting
Failure code [CA1961] EGR_Motor Driver IC Over Temp Error (D37-1961CA-400-A-

Z0-A)
Action level Failure code EGR Motor Driver IC Over Temperature Error
Failure
Detail of • EGR motor driver IC over temperature error occurs in engine controller.
failure
machine
Related
information
Improper use
1 environment of Check whether controller is used in high temperature environment.
controller
Defective engine If no problem is found by above checks, engine controller is defective. (Since
controller
40-214 PC138USLC-10
40 Troubleshooting
Failure code [CA2185] Throt Sensor Sup Volt High Error (PC400-CA2185-400-A-Z0-A)
Action level Failure code Throttle Sensor Supply Voltage High Error
Failure
Detail of • High voltage appears in throttle sensor power supply (5 V) circuit.
failure
• Uses throttle value obtained before failure detection to run engine if failure is detected
Action of with starting switch at ON position.
controller • Uses full throttle value to run engine if starting switch is set to ON position after failure
detection.
machine
information
N- Procedure, measuring location, criteria and remarks
Cause
o.
equipment" in "Checks before troubleshooting" of "General information
connector
If this failure code disappears, wiring harness connector is defective.
2. Disconnect connector P20, and turn starting switch to ON position.
Defective throttle sensor
2 (fuel control dial) If this failure code disappears, throttle sensor is defective.
a Other failure codes are also displayed. They are generated because of
disconnection of connector. Ignore failure codes other than [CA2185].
2. Disconnect connectors CE03 and P20, and connect T-adapter to
3 female side of CE03.
harness
Resis- Between CE03 (female) (42) and each pin other
Min. 1 Mz
tance than pin CE03 (female) (42)
Hot short circuit in wiring 1. Turn starting switch to OFF position.
4 harness 3. Turn starting switch to ON position.
(contact with 24 V circuit)
Voltage Between P20 (female) (1) and ground 4.75 to 5.25 V
If no failure is found by above checks, engine controller is defective. (Since
this is an internal defect, troubleshooting cannot be performed.)
• Reference
Power
Voltage Between CE03 (42) and (41)
supply 4.75 to 5.25 V
PC138USLC-10 40-215
40 Troubleshooting
40-216 PC138USLC-10
40 Troubleshooting
Failure code [CA2186] Throt Sensor Sup Volt Low Error (PC400-CA2186-400-A-Z0-A)
Action level Failure code Throttle Sensor Supply Voltage Low Error
Failure
Detail of • Low voltage appears in throttle sensor power supply (5 V) circuit.
failure
• Uses throttle value obtained before failure detection to run engine if failure is detected
Action of with starting switch at ON position.
controller • Uses full throttle value to run engine if starting switch is set to ON position after failure
detection.
machine
information
N- Procedure, measuring location, criteria and remarks
Cause
o.
equipment" in "Checks before troubleshooting" of "General information
connector
If this failure code disappears, wiring harness connector is defective.
2. Disconnect connector P20, and turn starting switch to ON position.
Defective throttle sensor
2 (fuel control dial) If this failure code disappears, throttle sensor is defective.
a Other failure codes are also displayed. They are generated because of
disconnection of connector. Ignore failure codes other than [CA2186].
Ground fault in wiring 2. Disconnect connectors CE03 and P20, and connect T-adapter to either
3 harness female side.
(contact with ground circuit) Resis- Between ground and CE03 (female) (42) or P20
Min. 1 Mz
tance (female) (1)
2. Disconnect connectors CE03 and P20, and connect T-adapter to
Short circuit in wiring female side of CE03.
harness
Resis- Between CE03 (female) (42) and each pin other
Min. 1 Mz
tance than pin CE03 (female) (42)
If no failure is found by above checks, engine controller is defective. (Since
this is an internal defect, troubleshooting cannot be performed.)
• Reference
Power
Voltage Between CE03 (42) and (41)
supply 4.75 to 5.25 V
PC138USLC-10 40-217
40 Troubleshooting
40-218 PC138USLC-10
40 Troubleshooting
Failure code [CA2249] Rail Press Very Low Error (PC400-CA2249-400-A-Z0-A)
Action level Failure code Rail Pressure Very Low Error

Failure
Detail of • Supply pump does not feed fuel (level 2).
failure
Action of • Limits engine output (limits common rail pressure) and allows engine to run.
controller
machine
• Signal voltage from common rail pressure sensor can be checked by using monitoring
Supply pump pressure low Perform troubleshooting for failure code [CA559].
1
error
PC138USLC-10 40-219
40 Troubleshooting
Failure code [CA2272] EGR Valve Pos Sens Low Error (D37-CA2272-400-A-Z0-A)
Action level Failure code EGR Valve Position Sensor Low Error
Failure
Detail of • EGR position error has occurred.
failure
controller • Closes EGR valve and opens VFT fully.
machine
information
harness connector
for it first.
Defective sensor power 1. Turn starting switch to OFF position.
2 supply system 2. Disconnect connector EGR V and connect T-adapter to female side.
Power 4.75 to 5.25
Voltage Between EGR V (female) (1) and (5)
supply V
2. Disconnect connectors EGR V and J2, and connect T-adapters to each
female side.
a If power supply voltage in check on cause 2 is
normal, this check is not required.
Open circuit in wiring Max. 1 z
Between J2 (female) (30) and EGR V (female)
harness (1)
3 (wire breakage or
defective contact of a If power supply voltage in check on cause 2 is
connector) Resistance normal, this check is not required.
Max. 1 z
Between J2 (female) (47) and EGR V (female)
(5)
Between J2 (female) (42) and EGR V (female) (2) Max. 1 z
2. Disconnect connectors J2 and EGR V and connect T-adapter to either
female side.
Between ground and J2 (female) (30) or EGR V
Ground fault in wiring Min. 1 Mz
(female) (1)
harness
4 Between ground and J2 (female) (42) or EGR V
(contact with ground (female) (2) Min. 1 Mz
circuit) Resistance
Between ground and J2 (female) (51) or EGR V Min. 1 Mz
(female) (4)
40-220 PC138USLC-10
40 Troubleshooting

female side.
Short circuit in wiring EGR V (female) (2) and (3) Min. 1 Mz
5
harness
Resistance EGR V (female) (2) and (4) Min. 1 Mz
EGR V (female) (3) and (4) Min. 1 Mz
Defective EGR position Sensor inside EGR may be defective.

6
sensor (Since this is an internal defect, troubleshooting cannot be performed.)
7
Circuit diagram related to EGR valve
PC138USLC-10 40-221
40 Troubleshooting
Failure code [CA2311] IMV Solenoid Error (D65-CA2311-400-A-Z0-A)
Action level Failure code IMV Solenoid Error

Failure
Detail of • Resistance value of supply pump actuator circuit is unusually high or low.
failure
controller
machine
information
1 Defective IMV solenoid Perform troubleshooting for failure codes [CA271] and [CA272].
40-222 PC138USLC-10
40 Troubleshooting
Failure code [CA2349] EGR Valve Solenoid Open Error (D37-CA2349-400-A-Z0-A)
Action level Failure code EGR Valve Solenoid Open Error

Failure
Detail of • Open circuit occurs in EGR valve motor circuit.
failure
machine
information
harness connector
2. Disconnect connector EGR V and connect T-adapter to male side.
Defective EGR valve Between EGR V (male) (6) and (7)
2 1 to 5 z
motor
Resistance Between EGR V (male) (7) and (8) 1 to 5 z
3 Between J2 (female) (3) and (4) 1 to 5 z
wiring harness
Resistance Between J2 (female) (4) and (5) 1 to 5 z
Between J2 (female) (5) and (3) 1 to 5 z
harness 2. Disconnect connectors J2 and EGR V, and connect T-adapters to each
defective contact of Between J2 (female) (3) and EGR V (female) (6) Max. 1 z
connector) Resistance Between J2 (female) (4) and EGR V (female) (7) Max. 1 z
5
PC138USLC-10 40-223
40 Troubleshooting
40-224 PC138USLC-10
40 Troubleshooting
Failure code [CA2353] EGR Valve Solenoid Short Error (D37-CA2353-400-A-Z0-A)
Action level Failure code EGR Valve Solenoid Short Error

Failure
Detail of
• Short circuit occurs in EGR valve motor circuit.
failure
machine
information
harness connector
Defective EGR valve 2. Disconnect connector EGR V and connect T-adapter to male side.
2 motor Between EGR V (male) (6) and (7) 1 to 5 z
(internal open circuit) Resistance Between EGR V (male) (7) and (8) 1 to 5 z
wiring harness
Ground fault in wiring female side.
harness Between ground and J2 (female) (3) or EGR V
4

2. Disconnect connector EGR V.
Hot short circuit in 4. Turn starting switch to OFF position.
5 wiring harness
Between J2 (3) and (47) or ground Max 5.5 V
Voltage Between J2 (4) and (47) or ground Max 5.5 V
6
PC138USLC-10 40-225
40 Troubleshooting
40-226 PC138USLC-10
40 Troubleshooting
Failure code [CA2357] EGR Valve Servo Error (D37-CA2357-400-A-Z0-A)
Action level Failure code EGR Valve Servo Error

Failure
Detail of • EGR valve servo error occurs.
failure (EGR lift sensor sends back EGR valve position value that differs from command value.)
Action of • Does not supply current to EGR valve (closes EGR valve).
controller • Fully open VFT.
machine
information
Defective relevant
system
Defective EGR valve
system
3 Defective EGR valve EGR valve may have mechanical trouble. Check it.
Defective engine If no failure is found by checks on causes 1 to 3, engine controller is defective.
4
PC138USLC-10 40-227
40 Troubleshooting
Failure code [CA2765] Inj Trim Data Error (PC400-CA2765-400-A-Z0-A)
Action level Failure code Injector Trim Data Error

Failure
Detail of • Injector trim data input to to the engine controller is not correct.
failure
Action of
controller
Problem on • Since the engine controller can not know the production variance of each injector, the
machine exhaust gas purification will be degraded.
information
1 Injector trim data mismatch a When replacing injectors, see chapter 30 Testing and adjusting,
"Injector trim".
40-228 PC138USLC-10
40 Troubleshooting
Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error (PC138-
CA3419-400-A-Z0-A)
Action level Failure code Mass Air Flow Sensor Supply Voltage High Error
Failure
Detail of • High voltage occurs in power supply (12 V) circuit of mass air flow sensor.
failure
a If signal voltage of mass air flow sensor becomes abnormal, controller takes following
measures for failure codes same as [CA356] and [CA357].
Action of
controller • Sets mass air flow to fixed value (10 kg/min) and runs engine.
• Limits engine output and allows engine to run.
machine
information
1
defective.
Defective mass air flow sensor
2 If this failure code does not appear, MAF sensor is defective.
(internal defect)
3 Defective wiring harness If this failure code does not appear, wiring harness is defective.
4 Defective engine controller Approx. 12
Voltage Between J1 (male) (21) and (22)
V
PC138USLC-10 40-229
40 Troubleshooting
40-230 PC138USLC-10
40 Troubleshooting
Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error (PC138-CA3421-
400-A-Z0-A)
Action level Failure code Mass Air Flow Sensor Supply Voltage Low Error
Failure
Detail of • High voltage occurs in power supply (12 V) circuit of mass air flow sensor.
failure
a If signal voltage of mass air flow sensor becomes abnormal, controller takes following
measures for failure codes same as [CA356] and [CA357].
Action of
controller • Sets mass air flow to fixed value (10 kg/min) and runs engine.
• Limits engine output and allows engine to run.
machine
information
1
defective.
Defective mass air flow sensor
2 If this failure code does not appear, MAF sensor is defective.
(internal defect)
Defective wiring harness or
3 If this failure code does not appear, wiring harness is defective.
connector
Ground fault in wiring harness 2. Disconnect connectors J1 and P55, and connect T-adapter to either
4 female side.
Resis- Between ground and J1 (female) (21) or P55
tance
2. Disconnect connectors J1 and P55, and connect T-adapter to either
5 Short circuit in wiring harness female side.
Resis- Between J1 (female) (21) and (22), or between
P55 (female) (2) and (3) Min. 1 Mz
tance
6 Defective engine controller Approx. 12
Voltage Between J1 (male) (21) and (22)
V
PC138USLC-10 40-231
40 Troubleshooting
40-232 PC138USLC-10
40 Troubleshooting
Failure code [CA3724] EGR/KVGT Motor Driver Power Low Error (D37-CA3724-
400-A-Z0-A)
Action level Failure code EGR/KVGT Motor Driver Power Low Error
Failure
Detail of • Low voltage error occurs in EGR/KVGT (VFT) drive power in engine controller.
failure
machine
Related a "KVGT" in the title of this failure code refers to "VFT" on this machine.
information • Power for GR valve and VFT motor driver are supplied from pin 30 of connector J2.
1
defective.
2. Disconnect following connectors one by one and turn starting switch
to ON position each time.
If this failure code is not displayed, disconnected motor or engine wiring
Defective motor or wiring harness is defective.
2
harness a Other failure codes (many codes) are also displayed. They are
codes other than this code [CA3724].
EGR valve motor driver EGR V
Connec- KVGT (VFT) motor driver VFT
tor
Engine harness J2
Defective relevant system If other failure codes are also displayed, perform troubleshooting for
3
them.
3. Turn starting switch to ON position with connector J2 disconnected.
Voltage Between J2 (male) (30) and (47) 4.75 to 5.25 V
PC138USLC-10 40-233
40 Troubleshooting
Circuit diagram related to EGR V and VFT motor driver power (5 V)
40-234 PC138USLC-10
40 Troubleshooting
Failure code [CA3918] KVGT Stuck Error (D37-CA3918-400-A-Z0-A)
Action level Failure code KVGT Stuck Error

Failure
Detail of • KVGT (VFT) stuck error has occurred.
failure (Failed to learn zero point of KVGT (VFT).)
machine
Defective KVGT
1 KVGT may have mechanical failure. Check it.
mechanical system
2
PC138USLC-10 40-235
40 Troubleshooting
Failure code [CA3919] KVGT Motor Driver IC Over Temp Error (D37-CA3919-400-A-
Z0-A)
Action level Failure code KVGT Motor Driver IC Over Temperature Error
Failure
Detail of • High KVGT (VFT) motor driver IC temperature error occurs in engine controller.
failure
machine
Improper use
1 environment of Check whether controller is used in high temperature environment.
controller
2
40-236 PC138USLC-10
40 Troubleshooting
Failure code [CA3921] KVGT Servo Error 2 (D37-CA3921-400-A-Z0-A)
Action level Failure code KVGT Servo Error 2

Failure
Detail of • KVGT (VFT) servo error has occurred.
failure (KVGT (VFT) does not follow the command value for the KVGT (VFT))
machine
information • Method of reproducing failure code: Starting switch ON
Improper use
Perform checks on causes 1 to 4 in troubleshooting for failure code [CA3922]
1 environment of
first.
controller
2 Defective VFT VFT may have mechanical failure. Check it.
3
PC138USLC-10 40-237
40 Troubleshooting
Failure code [CA3922] KVGT Motor Driver Open Error (D37-CA3922-400-A-Z0-A)
Action level Failure code KVGT Motor Driver Open Error

Failure
Detail of • Open circuit occurs in KVGT (VFT) motor driver.
failure
machine
harness connector
2. Disconnect connector VFT and connect T-adapter to male side.
2 Defective VFT motor Between VFT (male) (6) and (7) 8 to 15 z
Resistance Between VFT (male) (7) and (8) 8 to 15 z
wiring harness

harness 2. Disconnect connectors J2 and VFT, and connect T-adapters to each
female side.
4 (wire breakage or Between J2 (female) (11) and VFT (female) (6) Max. 1 z
Resistance Between J2 (female) (1) and VFT (female) (7) Max. 1 z
connector)
5
40-238 PC138USLC-10
40 Troubleshooting
PC138USLC-10 40-239
40 Troubleshooting
Failure code [CA3923] KVGT Motor Driver Short Error (D37-CA3923-400-A-Z0-A)
Action level Failure code KVGT Motor Driver Short Error

Failure
Detail of • Short circuit occurs in KVGT (VFT) motor driver.
failure
machine
harness connector
2. Disconnect connector VFT and connect T-adapter to male side.
Defective VFT motor
2 Between VFT (male) (6) and (7) 8 to 15 z
(internal open circuit)
Resistance Between VFT (male) (7) and (8) 8 to 15 z
wiring harness
2. Disconnect connectors J2 and VFT.
Ground fault in wiring Between ground and J2 (female) (11) or VFT
harness (female) (6) Min. 1 Mz
4
(contact with ground Between ground and J2 (female) (1) or VFT

2. Disconnect connector VFT.
5 wiring harness
Voltage Between J2 (1) and (47) or ground Max 5.5 V
6
40-240 PC138USLC-10
40 Troubleshooting
PC138USLC-10 40-241
40 Troubleshooting
Failure code [D110KB] Battery Relay Drive Short Circuit (PC138-D110KB-400-A-Z0-A)
Action level Failure code Battery Relay Drive Short Circuit

Failure
L01 D110KB (Pump controller system)
Detail of • Abnormal current flows when outputting 24 V to battery relay primary circuit (coil side).
failure
• Stops 24 V output to battery relay primary circuit (coil side).
Action of • Even if cause of failure disappears, machine does not become normal until starting switch
controller is turned to OFF position.
Problem on • Each controller may fail in writing of data into its ROM (non-volatile memory).
machine
• As T-adapter for pump controller connector is "socket-type box", operating voltage cannot
be measured at pump controller connector.
Related • Output state (ON/OFF) to battery relay can be checked with monitoring function.
• Method of reproducing failure code: Turn starting switch to ON position, then turn it to
OFF position.
Defective battery relay 1. Turn starting switch to OFF position.
1
(Internal short circuit) Continuity Between terminals R01 and R02 Continuity
2. Turn battery disconnect switch to OFF position (to prevent short
circuit during work).
Ground fault in wiring harness 3. Disconnect terminals R01 and R02, and disconnect connectors D01,
2 H15, and CP02.
(Contact with ground circuit)
Between terminal R02 (BR) and ground Min. 1 Mz
Resis- Between ground and terminal CP02 (female)
tance (108), R02 (harness side), D01 (female) (1) or Min. 1 Mz
(2)
If no failure is found by above checks, pump controller is defective.
• Reference
2. Insert T-adapters into connector D01.
3 Pump controller is defective.
4. Measure voltage within 0.5 second after turning staring switch to
OFF position from ON position.
Voltage Between D01 (1) and ground 20 to 30 V
40-242 PC138USLC-10
40 Troubleshooting
Circuit diagram related to battery relay
PC138USLC-10 40-243
40 Troubleshooting
Failure code [D19JKZ] Personal Code Relay Abnormality (PC138-D19JKZ-400-A-Z0-A)
Action level Failure code Personal Code Relay Abnormality

Failure
L03 D19JKZ (Machine monitor system)
Detail of • Open error or short circuit occurs in primary (coil) circuit of personal code relay.
failure
• None in particular (when open error occurred)
• Stops driving personal code relay (when short circuit occurred).
Action of • If cause of failure disappears, machine becomes normal by itself (when open error
machine occurred).
monitor • Even if cause of failure disappears, machine does not become normal until starting switch
is turned to OFF position (when short circuit occurred).
Problem on
machine
• This failure code is displayed only when engine lock function is enabled.
• Method of reproducing failure code: Turn starting switch to ON position (when open circuit
Related occurred). Failure code cannot be reproduced on the machine (when short circuit
information occurred).
• Troubleshooting for this failure code covers circuits from fuse No. 3 in fuse box F01
through primary (coil) circuit of personal code relay R07 to machine monitor.
Blown No. 3 fuse of If fuse is blown, circuit may have ground fault.
1
fuse box F01
2. Disconnect relay R07, and connect T-adapter to male side.
200 to 600
Resistance Between R07 (male) (1) and (2)
Defective personal z
2 code relay R07 1. Turn starting switch to OFF position.
2. Replace relay R07 with light relay R05.
If this failure code disappears, original personal code relay R07 is defective.
2. Remove fuse No. 3 in fuse box F01.
Open circuit, short 3. Disconnect connectors CM01 and S14, and connect T-adapter to female
3 circuit, or ground fault in side of CM01.
wiring harness 200 to 600
Between F01-3 and CM01 (female) (6)
Resistance z
Between F01-3 or CM01 (female) (6) and ground Min. 1 Mz
2.Remove fuse No. 3 in fuse box F01.
Open circuit in wiring 3.Disconnect connector CM01 and relay R07, and connect T-adapters to
4
harness each female side.
Between F01-3 and R07 (female) (1) Max. 1 z
Resistance Max. 1 z
Between R07 (female) (2) and CM01 (female) (6)
40-244 PC138USLC-10
40 Troubleshooting

2.Remove fuse No. 3 in fuse box F01.
Ground fault in wiring 3.Disconnect connector CM01 and relay R07, and connect T-adapter to
5
harness either female side.
Between F01-3 or R07 (female) (1) and ground Min. 1 Mz
Resistance Between R07 (female) (2) and ground, or between
CM01 (female) (6) and ground Min. 1 Mz

3. Disconnect connectors CM01 and relay R07, and connect T-adapter to
female side of connector CM01.
6 a Check by using multimeter in continuity mode.
harness
No
Between CM01 (female) (6) and each pin other continuity
Continuity
than (6) (No sound
is heard.)
Defective machine If no failure is found by above checks, machine monitor is defective. (Since
monitor
PC138USLC-10 40-245
40 Troubleshooting
Circuit diagram related to personal code relay
40-246 PC138USLC-10
40 Troubleshooting
Failure code [D811MC] KOMTRAX Error (PC400-D811MC-400-A-Z0-A)
Action level Failure code KOMTRAX Error

Failure
– D811MC (KOMTRAX system)
Detail of
• KOMTRAX malfunctions.
failure
Action of
controller
Problem on • KOMTRAX system does not operate properly.
machine
information
KOMTRAX is defective.
1 Malfunction of KOMTRAX
PC138USLC-10 40-247
40 Troubleshooting
Failure code [D862KA] GPS Antenna Open Circuit (PC400-D862KA-400-A-Z0-A)
Action level Failure code GPS Antenna Open Circuit

Failure
– D862KA (KOMTRAX system)
Detail of • Open circuit is detected in GPS antenna circuit.
failure
monitor
Problem on • GPS positioning cannot work.
machine
information
Probable causes are defective GPS antenna, open circuit or short circuit
Defective GPS antenna or in antenna cable, and defective connection of antenna cable connector
1
antenna cable (GPS).
Structural illustration
40-248 PC138USLC-10
40 Troubleshooting
Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX) (PC138-

D8ALKA-400-A-Z0-A)
Action level Failure code Operating Lamp Open Circuit (KOMTRAX)

Failure
– D8ALKA (KOMTRAX system)
• KOMTRAX determines that system operating lamp circuit is open because voltage of
Detail of output circuit remains at approximately 5 V or less for approximately 3 seconds after
failure starting switch is turned to ON position, during which KOMTRAX outputs no current to
system operating lamp.
controller
• While system operating lamp is lit, battery disconnect switch must not be turned to OFF
Problem on position. Turning battery disconnect switch to OFF position may destroy data stored in
machine KOMTRAX memory.
• Although KOMTRAX is not able to light up system operating lamp, no trouble will result
Related unless battery disconnect switch is turned to OFF position.
information • When controller lights up system operating lamp, output circuit voltage is at low level.
• Since no controller drives system operating lamp for approximately 3 seconds after
starting switch is turned to ON position, open circuit can be detected.
Defective fuse No. 16 in a If room lamp lights up, this check is not required.
1
fuse box F01 If fuse is blown, circuit probably has ground fault.
harness 2. Remove fuse No. 16 in fuse box F01.
2 (wire breakage or 3. Disconnect connector CK01 and connect T-adapter to female side.
connector) Resistance Between CK01 (15) and fuse F01-16 Max. 1 z
Defective KOMTRAX If no failure is found by above checks, KOMTRAX terminal is defective.
3
terminal (Since this is an internal defect, troubleshooting cannot be performed.)
PC138USLC-10 40-249
40 Troubleshooting
Circuit diagram related to system operating lamp
40-250 PC138USLC-10
40 Troubleshooting
Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX) (PC138-

D8ALKB-400-A-Z0-A)
Action level Failure code Operating Lamp Short Circuit (KOMTRAX)

Failure
- D8ALKB (KOMTRAX system)
• KOMTRAX determines that system operating lamp circuit shorts because voltage of
Detail of output circuit does not become low level while KOMTRAX outputs current to system
failure operating lamp.
controller
Problem on position. Turning battery disconnect switch to OFF position may destroy data stored in
machine KOMTRAX memory.
Related • Although KOMTRAX is not able to light up system operating lamp, no trouble will result
information unless battery disconnect switch is turned to OFF position.
• When controller lights up system operating lamp, output circuit voltage is at low level.
Short circuit in wiring 3. Disconnect connectors CM01, CP02, CK01, CE03, L19, and CC01.
1
harness Connect T-adapter to female side of connector L19.
Resistance Between L19 (female) (1) and (2) Min. 1 Mz
2
PC138USLC-10 40-251
40 Troubleshooting
Failure code [D8AQKR] CAN2 Discon (KOMTRAX) (PC138-D8AQKR-400-A-Z0-A)
Action level Failure code CAN2 Disconnection (KOMTRAX)

Failure
― D8AQKR (Detected by machine monitor.) (Machine monitor system)
Detail of • Machine monitor does not recognize KOMTRAX over CAN communication-2 line
failure (KOMNET/c).
Action of
machine • None
monitor
Problem on
• None
machine
• Start of CAN communication is recognized by each controller when ACC signal of starting
switch is received.
• 4 different failure codes, [DA2QKR], [DB2QKR], [D8AQKR], and [DAZQKR], are used for
defective CAN communication by CAN2, which are detected by machine monitor. When
all of these 4 failure codes are displayed, there may be a ground fault, short circuit, or hot
short in wiring harness (CAN communication circuit). In this case, check whether air
conditioner is operated (ON/OFF and air flow adjustment) from air conditioner operation
Related
screen since air conditioner is also controlled over CAN communication line.
information
a Air conditioner can be controlled even when failure code is displayed on screen. If air
conditioner is controlled, wiring harness (CAN communication line) does not have ground
fault, short circuit, or hot short circuit.
• Since each controller and machine monitor are connected directly to battery, they are
supplied with power even after starting switch is turned to OFF position.
• Since signal of active CAN communication line is pulse voltage, it cannot be measured by
using multimeter.
Defective fusible link 2. Disconnect fusible link F03 and connect T-adapter to female side.
1 Resistance Between F03 (female) (1) and (2) Max. 1 z
F03
a If fusible link is blown, circuit may have ground fault.
Defective fuse No. 17 in
2 2. Remove fuse No. 17 in fuse box F01.
fuse box F01
If fuse is blown, circuit probably has ground fault.
Defective power supply Perform troubleshooting for "E-52" of E mode.
3
to KOMTRAX terminal
Defective CAN
Perform checks on causes 4 to 9 in troubleshooting for failure code
4 communication 2
[DB2QKR].
system
5
6
40-252 PC138USLC-10
40 Troubleshooting
Circuit diagram related to KOMTRAX
PC138USLC-10 40-253
40 Troubleshooting
Failure code [DA20MC] Pump Controller Malfunction (PC400-DA20MC-400-A-Z0-A)
Action level Failure code Pump controller malfunction

Failure
– DA20MC (Pump controller system)
Detail of • Pump controller malfunctions.
failure
Action of
controller
Problem on • Pump controller does not function normally
machine
information
Malfunction of pump Pump controller is defective.
1
40-254 PC138USLC-10
40 Troubleshooting
Failure code [DA22KK] Pump Solenoid Power Low Error (PC138-DA22KK-400-A-Z0-A)
Action level Failure code Pump Solenoid Power Low Error

Failure
L03 DA22KK (Pump controller system)
Detail of • Power supply supply voltage of controller for driving solenoids is below 20 V.
failure
• Stops detection of failures (open circuit and short circuit) in all solenoid systems while this
Action of failure code is active.
controller • If cause of failure disappears, machine becomes normal by itself.
• No solenoid valve is energized properly, so machine does not work properly.
Problem on (Work equipment, swing, and travel systems do not work.)
machine • Hydraulic fan does not rotate in reverse direction.
• If failure code [D110KB] is displayed, perform troubleshooting for it first.
Related • As T-adapter for pump controller connector is "socket-type box", operating voltage cannot
information be measured at pump controller connector.
Defective fusible link If fusible link F02 is blown, circuit probably has ground fault (see Cause 6).
1
F02
Defective fuse No. 2 in If fuse is blown, circuit probably has ground fault (see Cause 7).
2
fuse box F01
Improper battery
3 2. After measuring voltage, measure it again when starting engine.
voltage
Voltage Between battery (+) and ground 20 to 30 V
2. Turn the battery disconnect switch to OFF position.
3. Disconnect connector CP02 and connect T-adapter to female side.
Defective wiring 4. Turn battery disconnect switch to ON position.
4
harness 5. Turn starting switch to ON position.
Between ground and each of CP02 (female) (116),
Voltage 20 to 30 V
(118) and (121)
a fusible link or fuse is blown, replace it in advance.
2.Turn the battery disconnect switch to OFF position.
3.Disconnect connector CP02 and connect T-adapter to female side.
Open circuit in wiring Between R03 and each of CP02 (female) (116),
5 Resistance (118) and (121) Max. 1 z
harness
a If no failure is found by above checks, this check is not required.
1. Disconnect connector F02 and connect T-adapter to male side
furthermore.
Between F02 (male) (2) and each of CP02 (female)
Max. 1 z
Resistance (116), (118), and (121)
Between F04 (male) (1) and terminal R03 (M) Max. 1 z
Ground fault in wiring 3. Remove wire from terminal R03.
harness 4. Disconnect connectors F02 and CP02, and connect T-adapters to female
6
(Contact with ground side of CP02 and male side of F02.
circuit) Between ground and CP02 (female)(116), (118),
(121), or F04 (male) (2) Min. 1 Mz
Resistance
Between ground and F02 (male) (1) or terminal
R03 (M) Min. 1 Mz
Pump controller is If no failure is found by above checks, pump controller is defective.

7
defective. (Since this is an internal defect, troubleshooting cannot be performed.)
PC138USLC-10 40-255
40 Troubleshooting
Circuit diagram related to solenoid power supply
40-256 PC138USLC-10
40 Troubleshooting
Failure code [DA25KP] 5V Sensor 1 Power Abnormality (PC138-DA25KP-400-A-Z0-A)
Action level Failure code 5 V Sensor 1 Power Abnormality

Failure
― DA25KP (Pump controller system)
Detail of • Voltage of 5 V sensor power supply output 1 circuit is below 2.5 V or above 6.0 V.
failure
• Stops driving 5 V sensor power supply output 1.
• Signal of pressure sensor is not input properly.
• The error code for the pressure sensor is displayed, as well.
Problem on • Travel and work equipment speeds are slow.
machine • Automatic travel speed selector function does not work (pump pressure sensor system).
• Auto-decelerator function remains activated or fine control performance of work
equipment is poor.
information
2. Disconnect connectors of the following sensors one by one and turn
starting switch ON each time.
a If this failure code goes out, disconnected sensor is defective.
a Since connector is disconnected, other failure codes appear. Ignore all
of displayed failure codes other than this one.
Defective pressure
sensor Sensor Connector
1
(Internal short circuit) Blade LOWER oil pressure sensor P11
Boom RAISE pressure sensor P28
L.H. travel FORWARD pressure sensor P10
L.H. travel REVERSE pressure sensor P27
R.H. travel FORWARD pressure sensor P09
RH. travel REVERSE pressure sensor P26
F pump pressure sensor P25
Service pressure sensor (dummy) P49
a To measure voltage before controller stops output of power.
Hot short circuit in 2. Disconnect connectors P09, P10, P11, P26, and P27.
2 wiring harness 3. Connect T-adapter to female side of connector P09.
4. Turn starting switch ON (with connector disconnected).
Voltage Between P09 (female) (3) and ground 4.5 to 5.5 V
harness 2. Disconnect connectors CP01, P09, P10, P11, P26, P27, and P49.
3 3. Connect T-adapter to female side of connector CP01.
circuit) Resistance Between CP01 (female) (6) and ground Min. 1 Mz
4
PC138USLC-10 40-257
40 Troubleshooting
Circuit diagram related to sensor power supply 1 (5 V)
40-258 PC138USLC-10
40 Troubleshooting
Failure code [DA29KQ] Model Selection Abnormality (PC138-DA29KQ-400-A-Z0-A)
Action level Failure code Model Selection Abnormality

Failure
L01 DA29KQ (Pump controller system)
Detail of • Model code signal for model which is not registered in controller is input.
failure
• Controls machine taking it that machine is default model (PC138 standard specification
Action of machine).
controller • Even if cause of failure disappears, machine does not become normal until starting switch
is turned to OFF position.
Problem on • No problem appears if machine is PC138 standard specification machine.
machine
• Pat number of pump controller assembly can be checked with monitoring function.
(Code: 20229)
• Signal status (ON/OFF) of model selection signal can be checked by using monitoring
function.
(Code: 02201)
a Without blade a Blade specification
Related
information Model selection signal 1: OFF Model selection signal 1: OFF
Model selection signal 2: OFF Model selection signal 2: OFF
Model selection signal 5: OFF Model selection signal 5: ON
2. Disconnect connectors CP01 and S29, and connect T-adapter to female
side of CP01.
a Check by using multimeter in continuity mode.
Between CP01 (female) (21) and No continuity
Short circuit in wiring each pin other than (21) (No sound is heard.)
1
harness Between CP01 (female) (40) and No continuity
each pin other than (40) (No sound is heard.)
Continuity
Pump controller with 1. Use monitoring function to display assembly part number and check
2 wrong part number whether it is identical to that listed in Parts book.
PC138USLC-10 40-259
40 Troubleshooting
Circuit diagram related to model selection abnormality
40-260 PC138USLC-10
40 Troubleshooting
Failure code [DA2LKA] Operating Lamp Open Circuit (Pump Con) (PC138-
DA2LKA-400-A-Z0-A)
Action level Failure code Operating Lamp Open Circuit (Pump Controller)
Failure
– DA2LKA (Pump controller system)
• Pump controller determines that system operating lamp circuit is open because voltage of
Detail of output circuit remains at about 5 V or below for about 3 seconds after starting switch is
failure turned to ON position, during which pump controller outputs no current to system
operating lamp.
controller
Problem on position. If the battery disconnect switch is turned OFF, the data stored in the pump
machine controller memory may be destructed.
• Although work equipment controller is not able to light up system operating lamp, no
Related trouble will result unless battery disconnect switch is turned to OFF position.
1
fuse box F01 If fuse is blown, circuit probably has ground fault.
2 (Wire breakage or 3. Disconnect connector CP02 and connect T-adapter to female side.
connector) Resistance Between CP02 (female) (100) and F01-16 Max. 1 z

3 3. Disconnect connectors CM01, CP02, CK01, CE03, and L19. Connect T-
(Contact with ground adapter to female side of connector CP02.
circuit)
Resistance Between CP02 (female) (100) and ground Min. 1 Mz
4
PC138USLC-10 40-261
40 Troubleshooting
40-262 PC138USLC-10
40 Troubleshooting
Failure code [DA2LKB] Operating Lamp Short Circuit (Pump Con) (PC138-
DA2LKB-400-A-Z0-A)
Action level Failure code Operating Lamp Short Circuit (Pump Controller)
Failure
― DA2LKB (Pump controller system)
• Pump controller determines that system operating lamp circuit shorts because voltage of
Detail of output circuit does not become Low level while pump controller outputs current to system
controller
Problem on position. If the battery disconnect switch is turned OFF, the data stored in the pump
machine controller memory may be destructed.
Related • Although work equipment controller is not able to light up system operating lamp, no
information trouble will result unless battery disconnect switch is turned to OFF position.
Short circuit in wiring 3. Disconnect connectors CM01, CP02, CK01, CE03, and L19. Connect T-
1
harness adapter to female side of connector L19.
2
PC138USLC-10 40-263
40 Troubleshooting
Failure code [DA2QKR] CAN2 Discon (Pump Con) (PC138-DA2QKR-400-A-Z0-A)
Action level Failure code CAN2 Disconnection (Pump Controller)

Failure
L03 DA2QKR (Detected by machine monitor.) (Machine monitor system)
Detail of • Machine monitor does not recognize pump controller through CAN communication 2 line
failure (KOMNET/c).
Action of
• Retains information at time of occurrence of failure.
controller
• Information to be obtained from pump controller is not displayed and special functions that
Problem on need information do not work. Or update of received data is stopped (such as failure
machine codes and monitoring codes sent from the pump controller).
switch is received.
conditioner is operated (ON/OFF and air flow adjustment) from air conditioner operation
Related screen since air conditioner is also controlled over CAN communication line.
information • This can be activated even when power supply to pump controller is OFF.
using multimeter.
Defective fusible link 2. Disconnect fusible link F03 and connect T-adapter to female side.
1 Resistance Between F03 (female) (1) and (2) Max. 1 z
F03
a If fusible link is blown, circuit may have ground fault.
Defective fuse No. 17 in
fuse box F01
If fuse is blown, circuit probably has ground fault.
Improper power supply 2. Disconnect connector CP01 and connect T-adapter to female side.
3 to pump controller 3. Turn starting switch to ON position.
Voltage
Open circuit in wiring OFF position.
3. Disconnect connectors F03 and CP01, and connect T-adapters to each
Between terminal R04 and F03 (female) (1) Max. 1 z
connector)
Between F03 (female) (2) and F01-16D Max. 1 z
Resistance
Between F01-17 and CP01 (female) (1) Max. 1 z
Between F01-17 and CP01 (female) (4) Max. 1 z
Defective CAN
5 communication 2
[DB2QKR].
system
40-264 PC138USLC-10
40 Troubleshooting

6
7
Circuit diagram related to pump controller power supply
PC138USLC-10 40-265
40 Troubleshooting
Failure code [DA2RKR] CAN1 Discon (Pump Con) (PC138-DA2RKR-400-A-Z0-A)
Action level Failure code CAN1 Disconnection (Pump Controller)

Failure
L03 DA2RKR (Detected by machine monitor.) (Machine monitor system)
Detail of • Machine monitor does not recognize pump controller through CAN communication line 1
failure (KOMNET/r).
• Retains current working mode.
Action of • Retains current selection of auto-deceleration.
controller • Retains current setting (Hi/Lo) of travel speed.
• Information to be obtained from pump controller is not displayed and special functions that
need information do not work. Or update of received data is stopped.
• Pump control is disabled.
Problem on • Hydraulic oil temperature gauge pointer disappears on machine monitor screen.
machine • Wiper operation is disabled.
• Washer operation is disabled.
• Flow rate of attachment oil pressure line cannot be controlled.
switch is received.
• When the machine monitor detects a CAN communication error in CAN1, failure code
[DB2RKR] becomes active. When failure code [DB2RKR] is displayed simultaneously on
screen, there may be a ground fault, short circuit, or hot short circuit in wiring harness
(CAN communication line).
Related • Terminal resistor of CAN1 on cab side is inside machine monitor, and that on engine side
information is led from J2 while no connector is used. (It is not in CAN communication-1 circuit
(KOMNET/r)).
using multimeter.
• This may occur even when power is not supplied to pump controller.
Defective pump
1 controller power supply
[DA2QKR].
system
Defective CAN
2 communication 1
[DB2RKR].
system
3
4
40-266 PC138USLC-10
40 Troubleshooting
Failure code [DAF0MB] Monitor ROM Abnormality (PC400-DAF0MB-400-A-Z0-A)
Action level Failure code Monitor ROM Abnormality

Failure
– DAF0MB (Machine monitor system)
Detail of • Program of machine monitor is rewritten (program error).
failure
Action of
controller
Problem on • Indication of machine monitor is unreliable.
machine • Machine monitor is incapable of normally exchanging data with controllers.
information
Machine monitor is defective.
1 Defective machine monitor
PC138USLC-10 40-267
40 Troubleshooting
Failure code [DAF0MC] Monitor Error (PC400-DAF0MC-400-A-Z0-A)
Action level Failure code Monitor Error

Failure
– DAF0MC (Machine monitor system)
Detail of
• Machine monitor malfunctions.
failure
Action of
controller
Problem on • Indication of machine monitor is unreliable.
machine • Machine monitor is incapable of normally exchanging data with controllers.
information
Machine monitor is defective.
40-268 PC138USLC-10
40 Troubleshooting
Failure code [DAF8KB] Camera Power Supply Short Circuit (PC138-DAF8KB-400-A-Z0-

A)
Action level Failure code Camera Power Supply Short Circuit

Failure
L03 DAF8KB (Machine monitor system)
Detail of • Output power supply voltage from machine monitor to camera (rated voltage is 8 V) drops
failure to 6.0 V or less or increases to 10 V or more.
Action of • Stops driving power supply voltage to camera (rated voltage is 8 V).
machine • Even if cause of failure disappears, machine does not become normal until starting switch
monitor is turned to OFF position.
Problem on • Camera image is not displayed on monitor screen.
machine
information
Defective camera 2. Disconnect camera connector A45, and turn starting switch to ON
1 position.
(internal short circuit)
After disconnecting camera connector and performing failure code
reproducing procedure, if failure code disappears, camera has internal defect.
2. Disconnect connector CM04.
Defective machine 3. Connect T-adapter to male side of connector CM04.
2
monitor 4. Turn starting switch to ON position.
Voltage Between CM04 (male) (1) and ground 6 to 10 V
harness 2. Disconnect connector CM04 and camera connector A45.
3 3. Connect T-adapter to female side of connector CM04.
circuit) Resistance Between CM04 (female) (1) and ground Min. 1 Mz
Hot short circuit in 2. Disconnect camera connector A45.
wiring harness 3. Insert T-adapter into connector CM04.
(contact with 24 V
circuit) (Disconnect camera and check that camera is not defective in advance.)
Voltage Between CM04 (1) and (5) Max. 10 V
PC138USLC-10 40-269
40 Troubleshooting
Circuit diagram related to camera power supply
40-270 PC138USLC-10
40 Troubleshooting
Failure code [DAF9KQ] Model Selection Abnormality (PC138-DAF9KQ-400-A-Z0-A)
Action level Failure code Model Selection Abnormality

Failure
L03 DAF9KQ (Machine monitor system)
Detail of • Machine model registered in machine monitor and pump controller differs.
failure (Machine monitor or pump controller of wrong part number is installed for replacement.)
Action of
controller
Problem on • Machine does not operate normally.
machine
• Signal status (ON/OFF) of model selection signal can be checked by using monitoring
function (Code: 02201).
a Without blade a Blade specification
Related Model selection signal 3: OFF Model selection signal 3: OFF
information Model selection signal 4: OFF Model selection signal 4: OFF
Model selection signal 5: OFF Model selection signal 5: ON
• Assembly part No. of pump controller program can be checked with monitoring function.
(Code: 20229)
• Assembly part No. of machine monitor program can be checked with monitoring function.
(Code: 20227)
1. Use monitoring function to display assembly part number and check
Defective machine whether it is identical to that listed in Parts book.
monitor
(Wrong machine model is programmed.)
1. Use monitoring function to display assembly part number and check
Pump controller is whether it is identical to that listed in Parts book.
2 Pump controller is defective.
defective.
(Wrong machine model is programmed.)
PC138USLC-10 40-271
40 Troubleshooting
Failure code [DAFGMC] GPS Module Error (PC400-DAFGMC-400-A-Z0-A)
Action level Failure code GPS Module Error

Failure
– DAFGMC (KOMTRAX system in machine monitor)
Detail of • Position data is not sent from GPS module (in machine monitor) to KOMTRAX
failure communication modem in 50 seconds after KOMTRAX started.
monitor
Problem on
machine
Related • Method of reproducing failure code: Turn starting switch to ON position (wait at least 50
information seconds after starting switch is turned to ON position).
GPS module in machine monitor may be defective.
40-272 PC138USLC-10
40 Troubleshooting
Failure code [DAFLKA] Operating Lamp Open Circuit (Monitor) (PC138-DAFLKA-

400-A-Z0-A)
Action level Failure code Operating Lamp Open Circuit (Monitor)

Failure
― DAFLKA (Machine monitor system)
• Machine monitor determines that system operating lamp circuit is open because voltage
Detail of of output circuit remains at approximately 5 V or less for approximately 3 seconds after
failure starting switch is turned to ON position, during which machine monitor outputs no current
to system operating lamp.
controller
Problem on position. Setting battery disconnect switch to OFF position may destroy data stored in
machine machine monitor terminal memory.
• Although machine monitor is not able to light system operating lamp, no trouble will result
Related unless battery disconnect switch is turned to OFF position.
1
fuse box F01. If fuse is blown, circuit probably has ground fault.
2 (wire breakage or 3. Disconnect connector CM01, and connect T-adapter to female side.
connector) Resistance Between CM01 (female) (8) and F01-16 Max. 1 z
3
PC138USLC-10 40-273
40 Troubleshooting
40-274 PC138USLC-10
40 Troubleshooting
Failure code [DAFLKB] Operating Lamp Short Circuit (Monitor) (PC138-DAFLKB-

400-A-Z0-A)
Action level Failure code Operating Lamp Short Circuit (Monitor)

Failure
― DAFLKB (Machine monitor system)
• Machine monitor determines that system operating lamp circuit shorts because voltage of
Detail of output circuit does not become low level while machine monitor outputs current to system
controller
Problem on position. Setting battery disconnect switch to OFF position may destroy data stored in
machine machine monitor terminal memory.
Related • Although machine monitor is not able to light system operating lamp, no trouble will result
information unless battery disconnect switch is turned to OFF position.
Short circuit in wiring 3. Disconnect connectors CM01, CP02, CK01, CE03, and L19. Connect T-
1
harness adapters to female side of connector L19.
2
PC138USLC-10 40-275
40 Troubleshooting
Failure code [DAFQKR] CAN2 Discon (Monitor) (PC138-DAFQKR-400-A-Z0-A)
Action code Failure code CAN2 Disconnection (Monitor)

Failure
- DAFQKR (KOMTRAX system)
Detail of • KOMTRAX terminal does not recognize machine monitor through CAN communication 2
failure line.
Action of
controller
Problem on • System may not function normally.
machine
switch is received.
• Failure code is transmitted to and displayed on machine monitor by CAN communication.
Accordingly, if CAN communication with machine monitor fails, failure code [DAFQKR] is
Related not displayed on machine monitor and it can be observed only through KOMTRAX
information system.
using multimeter.
Defective power supply Perform troubleshooting for "E-4" in E mode troubleshooting.
1
to machine monitor
Defective CAN Perform checks on causes 4 and after in troubleshooting for failure code
2 [DB2QKR]
communication
40-276 PC138USLC-10
40 Troubleshooting
Failure code [DAZ9KQ] A/C Model Selection Abnormality (PC138-DAZ9KQ-400-A-Z0-A)
Action level Failure code Air Conditioner Model Selection Abnormality

Failure
― DAZ9KQ (Machine monitor system)
• Machine model in machine monitor program differs from that in air conditioner controller
Detail of program.
failure (Replaced machine monitor or air conditioner controller has wrong part No.)
Action of
controller
Problem on • Machine does not operate normally.
machine
• Signal states (ON/OFF) of model selection signal can be checked by using monitoring
function (Code: 02201).
a Machines without blade a Blade specification
Related Model selection signal 5: OFF Model selection signal 5: ON
information • Model code specified by air conditioner controller program cannot be checked with
monitoring function.
• Model codes registered in machine monitor can be checked with monitoring function.
(Code: 00500)
• Air conditioner control data of machine monitor (machine model and series) can be
checked with monitoring function. (Code: 55200)
• Air conditioner control data (machine model and product series) stored in air conditioner
controller can be checked with monitoring function. (Code: 55201) (It is normal if control
data is "01" (which means PC).)
Defective machine Defective machine monitor
1
monitor (Wrong machine model is programmed.)
Defective air conditioner Defective air conditioner controller
2
controller (Wrong machine model is programmed.)
PC138USLC-10 40-277
40 Troubleshooting
Failure code [DAZQKR] CAN2 Discon (Aircon ECU) (PC138-DAZQKR-400-A-Z0-A)
Action level Failure code CAN2 Disconnection (Air Conditioner ECU)

Failure
L01 DAZQKR (Detected by machine monitor) (Machine monitor system)
Detail of • In CAN communication 2 line (KOMNET/c), machine monitor cannot recognize air
failure conditioner controller.
Action of
controller
• Function to collect information from engine controller does not work.
Problem on (Failure codes and monitoring codes that are sent by engine controller)
machine • Air conditioner cannot be operated (air does not blow out).
• Display of air conditioner operation screen of machine monitor is not correct.
switch is received.
• Four different failure codes, [DA2QKR], [DB2QKR], [D8AQKR], and [DAZQKR], are used
for defective CAN communication by CAN2, which are detected by machine monitor.
Related When all of these four failure codes are displayed, there may be a ground fault, short
information circuit, or hot short in wiring harness (CAN communication circuit).
using multimeter.
1 to air conditioner a Perform troubleshooting shown in Chapter 80 "Troubleshooting of power
controller supply system".
Defective CAN 1. Turn starting switch to OFF position.

terminating resistor 2. Disconnect connectors CM02 and K02, and connect T-adapters to each
2 male side.
(internal open or short Between K02 (male) (A) and (B) 120 ± 12 z
circuit) Resistance
Between CM02 (male) (7) and (9) 120 ± 12 z
• CAN communication line
a CAN terminating resistor of 120 z is also located in machine monitor. That
is, 2 CAN terminating resistors of 120 z are connected in parallel. When
circuit resistance is measured at connector of controller other than
machine monitor, if combined resistance is 60 z, wiring harness does not
have open circuit.
1. Turn starting switch to OFF position, and turn battery disconnect switch to
OFF position.
2. Disconnect related connectors and connect T-adapters to connectors to
be measured.
a If short circuit is found (resistance between 2 terminals is 1 z or below),
disconnect all CAN communication connectors of every controller and
Open or short circuit in check whether short circuit occurs between wiring harnesses or inside
3 wiring harness controller.
Between CM02 (female) (8) and (9) Approx. 120
z
Between CE03 (female) (17) and (18) Approx. 60
z
Between CP01 (female) (45) and (64) Approx. 60
z
Resistance Between AC01 (female) (9) and (10) Approx. 60
z
Between CK01 (female) (10) and (11) Approx. 60
z
Approx. 120
Between K02 (female) (A) and (B) z
40-278 PC138USLC-10
40 Troubleshooting

• ACC signal of starting switch (start of CAN communication is not
recognized)
OFF position.
2. Disconnect connectors to be measured and insert T-adapters into them.
3. Turn battery disconnect switch to ON position, and turn starting switch to
ON position.
Between CM01 (10) and (3) 20 to 30 V
Voltage
Between AC02 (4) and (1) 20 to 30 V
Between CK02 (3) and (1) 20 to 30 V
OFF position.
Open circuit in wiring 2. Disconnect related connectors and connect T-adapters to female side of
harness connectors to be measured.
4 (wire breakage or Between CM02 (female) (8) and CP01 (female)
(45) Max. 1 z
connector) Between CM02 (female) (9) and CP01 (female)
(64) Max. 1 z
Between CM02 (female) (8) and CE03 (female)
(17) Max. 1 z
Between CM02 (female) (9) and CE03 (female)
(18) Max. 1 z
Resistance Between CM02 (female) (8) and AC01 (female) (9) Max. 1 z
Between CM02 (female) (9) and AC01 (female)
(10) Max. 1 z
Between CM02 (female) (8) and CK01 (female)
(10) Max. 1 z
Between CM02 (female) (9) and CK01 (female)
(11) Max. 1 z
Between CE03 (female) (17) and K02 (female) (A) Max. 1 z
Between CE03 (female) (18) and K02 (female) (B) Max. 1 z
a If no failure (open circuit) is found by check on cause 3, measure
resistance at any one place in each case.
Ground fault in wiring OFF position.
harness 2. Disconnect related connectors and connect T-adapters to female side of
5
(contact with ground connectors to be measured.
circuit) Between ground and any point in CP01 (female)
(45), CM02 (female) (7), (8) or CE03 (female) (17) Min. 1 Mz
Resistance
Between ground and any point in CP01 (female)
(64), CM02 (female) (9) or CE03 (female) (18) Min. 1 Mz
a If no failure (open circuit) is found by check on cause 3, measure voltage

at any one place in each case.
OFF position.
Open circuit or hot short 2. Insert T-adapters into connectors to be measured.
circuit in wiring harness 3. Turn battery disconnect switch to ON position.
(contact with 24 V
circuit) a Voltage of CAN H and CAN L is 2.5 ± 1 V including during communication,
so regard wiring harness as normal if measured voltage is 1 to 4 V.
Between ground and either of CM02 (8), CP01
(45), CK01 (10), AC01 (2) and CE03 (17). 1 to 4 V
Voltage
Between ground and either of CM02 (9), CP01 1 to 4 V
(64), CK01 (11), AC01 (1) and CE03 (18).
PC138USLC-10 40-279
40 Troubleshooting

• If all four failure codes [DA2QKR], [DB2QKR], [D8AQKR], and [DAZQKR]
are displayed.
a To identify defective controller, repeat following steps 1. to 3. to disconnect
controllers one by one from CAN communication line.
Defective engine 1. Turn starting switch to OFF position, and set battery disconnect switch to
controller, pump OFF position.
7 controller, air 2. Disconnect CAN communication connector of engine controller (connector
conditioner unit, or CE03), pump controller (connector CP01), air conditioner unit (connector
KOMTRAX terminal AC01), and KOMTRAX terminal (connector CK01) one by one in turn.
3. Turn battery disconnect switch to ON position, turn starting switch to ON
position, then perform troubleshooting.
4. Return to step 1 to check next connector.
Has the number of displayed failure codes If YES, disconnected
decreased from four? controller is defective.
Defective air conditioner If no failure is found by above checks, air conditioner controller is defective.
8
9
10
40-280 PC138USLC-10
40 Troubleshooting
Circuit diagram related to CAN communication line 2
PC138USLC-10 40-281
40 Troubleshooting
Failure code [DB2QKR] CAN2 Discon (Engine Con) (PC138-DB2QKR-400-A-Z0-A)
Action level Failure code CAN2 Disconnection (Engine Controller)

Failure
L03 DB2QKR (Detected by machine monitor) (Machine monitor system)
Detail of • Machine monitor cannot recognize engine controller over CAN communication-2 line
failure (KOMNET/c).
Action of
controller
• Information to be obtained from engine controller is not displayed and special functions
Problem on that need information do not work. Or update of received data is stopped.
machine (Failure codes and monitoring codes that are sent by engine controller)
switch is received.
• If failure code [DB2RKR] is also displayed, engine controller may be defective (cause 2).
Related conditioner is operated (ON/OFF and air flow adjustment) from air conditioner operation
information screen since air conditioner is also controlled over CAN communication line.
using multimeter.
Defective fuse No. 15 or
1
No. 18 in fuse box F01 2. Remove fuses No. 15 and No. 18 from fuse box F01.
• When fuse is blown, engine controller may have internal short circuit.
a If fuse is not blown, this check is not required.
2 2. Disconnect connector CE03 and connect T-adapter to male side.
controller
Between CE03 (male) (1) and (21) Min. 10 z
Resistance
Between CE03 (male) (11) and (31) Min. 10 z
2. Disconnect connector CE03, and connect T-adapter to female side.
Defective power supply 3. Turn starting switch to ON position.
3 to engine controller
a If any trouble is found, perform troubleshooting for failure code [CA441].
Voltage
Defective CAN 2. Disconnect connectors CM02 and K02, and connect T-adapters to each
terminating resistor male side.
4
(internal open or short Between K02 (male) (A) and (B) 120 ± 12 z
circuit) Resistance 120 ± 12 z
Between CM02 (male) (7) and (9)
40-282 PC138USLC-10
40 Troubleshooting

have open circuit.
OFF position.
2. Disconnect related connectors and connect T-adapters to connectors to be
measured.
a If short circuit is found (resistance between 2 terminals is 1 z or below),
Open or short circuit in disconnect all CAN communication connectors of every controller and
5 wiring harness check whether short circuit occurs between wiring harnesses or inside
controller.
z
Between CE03 (female) (17) and (18) Approx. 60
z
z
Resistance
Between AC01 (female) (9) and (10) Approx. 60
z
Between CK01 (female) (10) and (11) Approx. 60
z
Between K02 (female) (A) and (B) Approx. 120
z
recognized)
OFF position.
2. Disconnect connectors to be measured and insert T-adapters into them.
ON position.
Voltage
Between AC02 (4) and (1) 20 to 30 V
Between CK02 (3) and (1) 20 to 30 V
harness 1. Turn starting switch to OFF position, and set battery disconnect switch to
6 (wire breakage or OFF position.
defective contact of 2. Disconnect related connectors and connect T-adapters to female side of
connector) connectors to be measured.
Between CM02 (female) (8) and CP01 (female) (45) Max. 1 z
Between CM02 (female) (8) and CE03 (female) (17) Max. 1 z
Between CM02 (female) (9) and CE03 (female) (18) Max. 1 z
Between CM02 (female) (8) and AC01 (female) (9) Max. 1 z
Resistance Between CM02 (female) (9) and AC01 (female) (10) Max. 1 z
Between CM02 (female) (8) and CK01 (female) (10) Max. 1 z
Between CM02 (female) (9) and CK01 (female) (11) Max. 1 z
Between CE03 (female) (17) and K02 (female) (A) Max. 1 z
Between CE03 (female) (18) and K02 (female) (B) Max. 1 z
PC138USLC-10 40-283
40 Troubleshooting

a If no failure (open circuit) is found by check on cause 5, measure
resistance at any one place in each case.
Ground fault in wiring OFF position.
harness 2. Disconnect related connectors and connect T-adapters to female side of
7
(contact with ground connectors to be measured.
circuit) Between ground and any of CP01 (female) (45),
CM02 (female) (7), (8) and CE03 (female) (17) Min. 1 Mz
Resistance
Between ground and any of CP01 (female) (64),
CM02 (female) (9) and CE03 (female) (18) Min. 1 Mz
a If no failure (open circuit) is found by check on cause 5, measure voltage at

any one place in each case.
OFF position.
Open circuit or hot short 2. Insert T-adapters into connectors to be measured.
circuit in wiring harness 3. Turn battery disconnect switch to ON position.
(contact with 24 V
circuit) a Voltage of CAN H and CAN L is 2.5 ± 1 V including during communication,
Between ground and any of CM02 (8), CP01 (45),
CK01 (10), AC01 (2) and CE03 (17) 1 to 4 V
Voltage
Between ground and any of CM02 (9), CP01 (64),
CK01 (11), AC01 (1) and CE03 (18) 1 to 4 V
• If all 4 failure codes [DA2QKR], [DB2QKR], [D8AQKR], and [DAZQKR] are
displayed
a To identify defective controller, repeat following steps 1. to 3. to disconnect
controllers one by one from CAN communication line .
Defective engine 1. Turn starting switch to OFF position, and set battery disconnect switch to
controller, pump OFF position.
9 controller, air 2. Disconnect CAN communication connector of engine controller (connector
conditioner unit, or CE03), pump controller (connector CP01), air conditioner unit (connector
KOMTRAX terminal AC01), and KOMTRAX terminal (connector CK01) one by one in turn.
3. Turn battery disconnect switch to ON position, turn starting switch to ON
position, then perform troubleshooting.
4. Return to step 1 to check next connector.
Has the number of displayed failure codes If YES, disconnected
decreased from 4? controller is defective.
10
11
40-284 PC138USLC-10
40 Troubleshooting
PC138USLC-10 40-285
40 Troubleshooting
Failure code [DB2RKR] CAN1 Discon (Engine Con) (PC138-DB2RKR-400-A-Z0-A)
Action level Failure code CAN1 Disconnection (Engine Controller)

Failure
L03 DB2RKR (Detected by machine monitor.) (Machine monitor system)
Detail of • Machine monitor does not recognize engine controller over CAN communication-1 line
failure (KOMNET/r).
• Retains current working mode.
Action of
• Retains current selection of auto-deceleration.
controller
• Information to be obtained from engine controller is not displayed and special functions
that need information do not work. Or update of received data is stopped.
Problem on • Engine cannot be controlled.
machine • Engine speed and coolant temperature cannot be detected.
• Engine coolant and hydraulic oil temperature gauge pointers disappear on machine
monitor screen.
switch is received.
• If failure code [DB2QKR] is also displayed, engine controller is probably defective (cause
1).
• Machine monitor uses failure code [DA2RKR] to indicate failure in CAN communication
over CAN 1 line. When failure code [DA2RKR] is displayed simultaneously on screen,
Related there may be a ground fault, short circuit, or hot short circuit in wiring harness (CAN
information communication line).
• Terminating resistor of CAN1 on cab side is inside machine monitor, and that on engine
side is led from J2 while no connector is used (not in CAN communication-1 line
(KOMNET/r)).
using multimeter.
Defective engine Perform checks on causes 1 to 3 in troubleshooting for failure code
1 controller system [DB2QKR].
Defective CAN 1. Turn starting switch to OFF position.
terminating resistor 2. Disconnect connectors CM02 and J2, and connect T-adapters to male side
2 of CM02 and female side of J2.
(internal open or short Between J2 (female) (24) and (25) 120 ± 12 z
circuit) Resistance
Between CM02 (male) (10) and (12) 120 ± 12 z
have open circuit.
OFF position.
2. Disconnect connectors CM02, CP01, J1, and J2 one by one, and connect
Open or short circuit in T-adapters to female side of each connector.
3 wiring harness a If short circuit is found (resistance between 2 terminals is 1 z or below),
disconnect all CAN communication connectors of every controller and
check whether short circuit occurs between wiring harnesses or inside
controller.
z
Resistance z
Approx. 120
Between J1 (female) (8) and (18) z
40-286 PC138USLC-10
40 Troubleshooting

recognized)
OFF position.
2. Disconnect connectors CM01, CP01, CE03 and insert T-adapters.
ON position.
Open circuit in wiring Voltage Between CE03 (3) and (21) 20 to 30 V
harness Between CP01 (2) and each of (24), (43), and (80) 20 to 30 V
4 (wire breakage or
defective contact of a If no failure is found by check on cause 3, this check is not required.
connector) 1. Turn starting switch to OFF position, and set battery disconnect switch to
OFF position.
2. Disconnect connectors CM02, CP01, J1 and J2, and connect T-adapters
to each female side.
Between CM02 (female) (12) and CP01 (female)
Max. 1 z
Resistance (26)
Between CM02 (female) (11) and J1 (female) (8) Max. 1 z
Between CM02 (female) (12) and J1 (female) (18) Max. 1 z
OFF position.
2. Disconnect connectors CM02, CP01, J1 and J2, and connect T-adapter to
Ground fault in wiring female side of any one.
harness Between ground and any one of CP01 (female) (7),
5 CM02 (female) (10), (11), or J1 (female) (8) Min. 1 Mz
circuit) Between J2 (female) (24) and ground Min. 1 Mz
Resistance
Between ground and any one of CP01 (female)
(26), CM02 (female) (12), or J1 (female) (18) Min. 1 Mz
a If no failure (open circuit) is found by check on cause 3, measure voltage at
any one place in each case.
OFF position.
2. Disconnect either of connectors CM02 and CP01, and connect T-adapter
to female side of connector disconnected.
Open circuit or hot short 3. Turn battery disconnect switch to ON position.
circuit in wiring harness 4. Turn starting switch to ON position.
6
(contact with 24 V
circuit) a Do not take measurements at J1 or J2.
a Voltage of CAN H and CAN L is 2.5 ± 1 V including during communication,
Between ground and any one of CP01 (female) (7),
CM02 (female) (10), (11) 1 to 4 V
Voltage
Between ground and either of CP01 (female) (26)
and CM02 (female) (12) 1 to 4 V
• If failure code [DA2RKR] is also displayed.
a Disconnect pump controller and engine controller one by one from CAN
communication line to determine which controller is defective.
Pump controller is OFF position.
7 2. Disconnect pump controller (connector CP01).
defective.
ON position.
Does either or both of failure codes [DA2RKR] and If YES, pump controller is
[DB2RKR] disappear? defective.
PC138USLC-10 40-287
40 Troubleshooting

• If failure code [DA2RKR] is also displayed.
a Disconnect pump controller and engine controller one by one from CAN
communication line to determine which controller is defective.
Defective engine OFF position.
8
controller 2. Disconnect engine controller (connector J1).
ON position.
Does either or both of failure codes [DA2RKR] and If YES, engine controller
[DB2RKR] disappear? is defective.
9
10
40-288 PC138USLC-10
40 Troubleshooting
PC138USLC-10 40-289
40 Troubleshooting
Failure code [DGH2KB] Hyd Oil Sensor Short Circuit (PC138-DGH2KB-400-A-Z0-A)
Action level Failure code Hydraulic Oil Sensor Short Circuit

Failure
L01 DGH2KB (Pump controller system)
Detail of • Signal voltage of hydraulic oil temperature sensor circuit is below 1 V, so pump controller
failure determines that circuit shorts.
Action of • If cause of failure disappears, machine becomes normal by itself.
controller
Problem on • Hydraulic oil temperature gauge indicates 50 °C.
machine
• Signal voltage from hydraulic oil temperature sensor can be checked with monitoring
function.
(Code: 04402)
Related
information k Loosen the oil filler cap of the hydraulic tank to release the pressure in the
hydraulic tank. For details, see Testing and adjusting "Releasing remaining
pressure in hydraulic circuit" when checking and replacing hydraulic oil
temperature sensor. With monitoring function (Code: 04401), check that hydraulic
oil temperature is 40 °C or lower and cool enough not to burn.
Approx. 90
10 °C
Defective hydraulic oil kz
temperature sensor Between P22 (male) (1) and (2) Approx. 35
1 30 °C
(Internal open or short a Temperature-resistance kz
circuit) Resistance characteristics of oil temperature Approx. 6.5
80 °C
sensor kz
Approx. 3.5
100 °C
kz
Between P22 (male) (2) and ground Min. 1 Mz
2. Disconnect connector P22 and connect T-adapter to female side.
Open circuit, short
a If voltage is 0 V, wiring harness has open circuit, ground fault, or short
2 circuit, or ground fault in
circuit, and if voltage is 24 V, wiring harness has hot short circuit.
wiring harness
a Voltage of approx. 5 V is applied to temperature sensor signal circuits
through resistance in pump controller.
Voltage Between P22 (female) (1) and (2) Approx. 5 V
a Use Temperature-Resistance characteristics table for troubleshooting on
Short circuit or ground cause 1 as resistance criteria.
3 fault in wiring harness
a If resistance is 1 Mz or higher, wiring harness has open circuit. If
resistance is 1 z or below, wiring harness has short circuit.
Between CP01 (female) (28) and (46) 3.5 to 90 kz
Resistance
Between CP01 (female) (28) and ground Min. 1 Mz
harness
4 2. Disconnect connectors CP01 and P22, and connect T-adapter to either
(Contact with ground female side.
circuit) Between ground and CP01 (female) (28) or P22
Resistance (female) (2) Min. 1 Mz
Pump controller is If cause is not found by above checks, pump controller is defective.
5
40-290 PC138USLC-10
40 Troubleshooting
Circuit diagram related to hydraulic oil temperature sensor
PC138USLC-10 40-291
40 Troubleshooting
Failure code [DHPAMA] Pump Press Sensor Abnormality (PC138-DHPAMA-400-A-Z0-A)
Action level Failure code Pump Pressure Sensor Abnormality

Failure
L01 DHPAMA (Pump controller system)
Detail of • Signal voltage of pump pressure sensor circuit is below 0.3 V or above 4.5 V.
failure
Action of • Controls pump taking pump pressure to be 0 MPa {0 kg/cm2}.
Problem on • Automatic travel speed selector function does not work.
machine • Straight travel performance or steering performance lowers.
a If 5 V circuit (3) and ground circuit (1) of pressure sensor are connected inversely,
pressure sensor will break. Accordingly, take extreme care when checking.
• Pump pressure can be checked by using monitoring function.
information • Method of reproducing failure code: Turn starting switch to ON position or start engine.
k Loosen the oil filler cap of the hydraulic tank to release the pressure in the
pressure in hydraulic circuit" when checking and replacing oil pressure sensor.
With monitoring function (Code: 04401), check that hydraulic oil temperature is 40 °
C or lower and cool enough not to burn.
If failure code [DA25KP] is also displayed, perform troubleshooting for it first.
Defective 5 V sensor 3. Turn starting switch to ON position.
1 power supply 1 system
a If power supply voltage is abnormal, proceed to check on cause 3.
Power
Voltage Between P25 (female) (3) and (1) 4.5 to 5.5 V
supply
Sensor
Voltage Between P25 (2) and (1) 0.5 to 4.5 V
output
a If power supply voltage is normal and sensor output voltage is abnormal, it
Defective pump is difficult to judge whether cause of failure is defective sensor, ground
2 pressure sensor fault or hot short circuit in wiring harness. Check as below.
(internal defect) 1. Turn starting switch to OFF position.
2. Replace connector P25 with connector P49 of other service pressure
sensor.
3. Turn starting switch to ON position and display "Abnormality Record"
screen of electrical system on machine monitor.
4. If E mark is not displayed for this failure code column, pump pressure
a After finishing test, restore connectors.
2. Disconnect connectors CP01 and P25, and connect T-adapters to each
female side.
harness a If power supply voltage in check on cause 1 is
3 (Wire breakage or normal, this check is not required. Max. 1 z
defective contact of Between CP01 (female) (18) and P25 (female) (1)
connector) Resistance Between CP01 (female) (11) and P25 (female) (2)
Max. 1 z
a If power supply voltage in check on cause 1 is Max. 1 z
40-292 PC138USLC-10
40 Troubleshooting

Between CP01 (female) (6) and P25 (female) (3)
harness 2. Disconnect connectors C01 and P25, and connect T-adapter to either
4 female side.
(Contact with ground
Between ground and CP01 (female) (11) or P25

Hot short circuit in
5 3. Connect T-adapter to female side of connector P25.
wiring harness
Voltage Between P25 (female) (2) and ground Max. 1 V
6
Circuit diagram related to pump pressure sensor
PC138USLC-10 40-293
40 Troubleshooting
Failure code [DHSFMA] Travel Fwd LH PPC Press Sensor

Abnormality (PC138-DHSFMA-400-A-Z0-A)
Action level Failure code Travel Forward LH PPC Pressure Sensor Abnormality
Failure
L01 DHSFMA (Pump controller system)
Detail of • Signal voltage of left travel FORWARD PPC pressure sensor is below 0.3 V or above 4.5
failure V.
Action of • Controls machine taking it that left travel FORWARD PPC pressure is 0 MPa {0 kg/cm 2}.
Problem on • Automatic deceleration does not cancel.
machine • Controllability of travel deteriorates.
• Left travel FORWARD PPC pressure can be checked with monitoring function.
Power
supply
Sensor
output
Defective left travel a If power supply voltage is normal and sensor output voltage is abnormal, it
FORWARD PPC is difficult to judge whether cause of failure is defective sensor, ground
(internal defect) 1. Turn starting switch to OFF position.
2. Replace connector P10 with connector of other PPC pressure sensor.
4. If E mark is not displayed in this failure code column, travel FORWARD LH
PPC pressure sensor is defective.
female side.
Max. 1 z
40-294 PC138USLC-10
40 Troubleshooting

harness 2. Disconnect connectors CP01 and P10, and connect T-adapter to either
4 female side.

wiring harness
6
Circuit diagram related to travel PPC pressure sensor
PC138USLC-10 40-295
40 Troubleshooting
Failure code [DHSGMA] Travel Fwd RH PPC Press Sensor

Abnormality (PC138-DHSGMA-400-A-Z0-A)
Action level Failure code Travel Forward RH PPC Pressure Sensor Abnormality
Failure
L01 DHSGMA (Pump controller system)
Detail of • Signal voltage of right travel FORWARD PPC pressure sensor is below 0.3 V or above 4.5
failure V.
Action of • Controls machine taking it that right travel FORWARD PPC pressure is 0 MPa {0 kg/cm 2}.
• Right travel FORWARD PPC pressure can be checked with monitoring function.
Power
supply
Sensor
output
Defective right travel a If power supply voltage is normal and sensor output voltage is abnormal, it
FORWARD PPC is difficult to judge whether cause of failure is defective sensor, ground
(Internal defect) 1. Turn starting switch to OFF position.
4. If E mark is not displayed in this failure code column, travel FORWARD
RH PPC pressure sensor is defective.
female side.
Max. 1 z
40-296 PC138USLC-10
40 Troubleshooting

4 female side.

wiring harness
6
PC138USLC-10 40-297
40 Troubleshooting
Failure code [DHSHMA] Travel Rev LH PPC Press Sensor

Abnormality (PC138-DHSHMA-400-A-Z0-A)
Action level Failure code Travel Reverse LH PPC Pressure Sensor Abnormality
Failure
L01 DHSHMA (Pump controller system)
Detail of • Signal voltage of left travel REVERSE PPC pressure sensor is below 0.3 V or above 4.5
failure V.
Action of • Controls machine taking it that left travel REVERSE PPC pressure is 0 MPa {0 kg/cm 2}.
• Left travel REVERSE PPC pressure can be checked with monitoring function.
Power
supply
Sensor
output
Defective left travel a If power supply voltage is normal and sensor output voltage is abnormal, it
REVERSE PPC is difficult to judge whether cause of failure is defective sensor, ground
2. Replace connector P27 with connector of another PPC pressure sensor.
4. If E mark is not displayed in this failure code column, travel REVERSE LH
female side.
Max. 1 z
40-298 PC138USLC-10
40 Troubleshooting

4 female side.

wiring harness
6
PC138USLC-10 40-299
40 Troubleshooting
Failure code [DHSJMA] Travel Rev RH PPC Press Sensor

Abnormality (PC138-DHSJMA-400-A-Z0-A)
Action level Failure code Travel Reverse RH PPC Pressure Sensor Abnormality
Failure
L01 DHSJMA (Pump controller system)
Detail of • Signal voltage of right travel REVERSE PPC pressure sensor is below 0.3 V or above 4.5
failure V.
Action of • Controls machine taking it that right travel REVERSE PPC pressure is 0 MPa {0 kg/cm 2}.
• Right travel REVERSE PPC pressure can be checked with monitoring function.
Power
supply
2. Connect T-adapter to connector P26.
Sensor
output
Defective right travel a If power supply voltage is normal and sensor output voltage is abnormal, it
REVERSE PPC is difficult to judge whether cause of failure is defective sensor, ground
4. If E mark is not displayed in this failure code column, travel REVERSE RH
2. Disconnect connectors CP01 and P26, and connect T-adapter to each
female side.
Max. 1 z
40-300 PC138USLC-10
40 Troubleshooting

4 female side.

wiring harness
6
PC138USLC-10 40-301
40 Troubleshooting
Failure code [DHSKMA] Blade Raise PPC Press Sensor

Abnormality (PC138-DHSKMA-400-A-Z0-A)
Action level Failure code Blade Raise PPC Pressure Sensor Abnormality
Failure
L01 DHSKMA (Pump controller system)
Detail of • Signal voltage of blade RAISE PPC pressure sensor circuit is below 0.3 V or above 4.5 V.
failure
Action of • Fixes blade RAISE PPC pressure at 0 MPa {0 kg/cm2} and continues control.
machine • Poor operability of blade RAISE operation
• Blade raise PPC pressure can be checked with monitoring function.
Power
supply
2. Insert T-adapter into connector P28
Sensor
output
a If power supply voltage is normal and sensor output voltage is abnormal, it
Defective blade RAISE is difficult to judge whether cause of failure is defective sensor, ground
2 PPC pressure sensor fault or hot short circuit in wiring harness. Check as below.
2. Replace connector P28 with connector of another PPC pressure sensor.
4. If E mark is not displayed again for this failure code, blade RAISE PPC
pressure sensor is defective.
female side.
Max. 1 z
40-302 PC138USLC-10
40 Troubleshooting

4 female side.

wiring harness
6
Circuit diagram related to blade RAISE PPC pressure sensor
PC138USLC-10 40-303
40 Troubleshooting
Failure code [DHSLMA] Blade Lower PPC Press Sensor

Abnormality (PC138-DHSLMA-400-A-Z0-A)
Action level Failure code Blade LOWER PPC Pressure Sensor Abnormality
Failure
L01 DHSLMA (pump controller system)
Detail of • Signal voltage of blade LOWER PPC pressure sensor circuit is below 0.3 V or above 4.5
failure V.
Action of • Fixes blade lower PPC pressure at 0 MPa {0 kg/cm2} and continues control.
machine • Poor operability of blade LOWER operation
• Blade lower PPC pressure can be checked with monitoring function.
Power
supply
Sensor
output
Defective blade a If power supply voltage is normal and sensor output voltage is abnormal, it
LOWER PPC pressure is difficult to judge whether cause of failure is defective sensor, ground
2 sensor fault or hot short circuit in wiring harness. Check as below.
4. If E mark is not displayed again for this failure code, blade LOWER PPC
pressure sensor is defective.
female side.
Max. 1 z
40-304 PC138USLC-10
40 Troubleshooting

4 female side.

wiring harness
6
Circuit diagram related to blade LOWER PPC pressure sensor
PC138USLC-10 40-305
40 Troubleshooting
Failure code [DHX1MA] Overload Sensor Abnormality (PC138-DHX1MA-400-A-Z0-A)
Action level Failure code Overload Sensor Abnormality

Failure
– DHX1MA (Pump controller system)
Detail of • Monitor (overload alarm monitor) which is not set to be displayed is displayed.
failure
Problem on
machine
information
Pump controller is Pump controller may be defective.
1
40-306 PC138USLC-10
40 Troubleshooting
Failure code [DR21KX] Camera 2 Picture Rev. Drive Abnormality (PC138-

DR21KX-400-A-Z0-A)
Action level Failure code Camera 2 Picture Reverse Drive Abnormality

Failure
L01 DR21KX (Machine monitor system)
Detail of • Voltage that is different from output voltage of machine monitor appears in camera 2
failure picture reverse drive circuit (pin 6 of connector CM04).
Action of • Does not display camera 2 image.
controller
Problem on • Camera 2 image not displayed.
machine
• Normal image is displayed when voltage of camera 2 picture reverse drive circuit (pin 6 of
Related connector CM04) is 0 V, and mirror image is displayed when voltage is 8 V (mirror image
information command of 8 V is used because camera power supply voltage is 8 V).
harness 2. Disconnect connectors CM04 and A46, and connect T-adapters to each
defective contact of Between CM04 (female) (6) and A46 (female) (3) Max. 1 z
Between CM04 (female) (8) and A46 (female) (4) Max. 1 z
harness 2. Disconnect connectors CM04 and A46, and connect T-adapter to either
2 female side.
Between ground and CM04 (female) (6) or A46

Hot short circuit in 2. Disconnect connector A46 and connect T-adapter to female side.
wiring harness 3. Turn starting switch to ON position.
3
(contact with 24 V
circuit) a Check that normal image setting is selected for camera 2.
Voltage Between A46 (female) (3) and (4) or ground Max. 4.5 V
Short circuit in wiring 2. Disconnect connector CM04 and connect T-adapter to female side.
4
harness Between CM04 (female) (6) and every pin other
Resistance than (6) Min. 1 Mz
If no failure is found by above checks, camera 2 is defective. (Since this is an
5 Defective camera 2 internal defect, troubleshooting cannot be performed.)
Defective machine If no failure is found by above checks, machine monitor is defective. (Since
monitor
PC138USLC-10 40-307
40 Troubleshooting
Circuit diagram related to camera
40-308 PC138USLC-10
40 Troubleshooting
Failure code [DR31KX] Camera 3 Picture Rev. Drive Abnormality (D155-DR31KX-

400-A-Z0-A)
a This failure code does not relate to this machine because it is not equipped with camera 3. This failure
code is provided in case where camera 3 is installed in future.
a If this failure code appears, clear failure code by referring to "Classification and procedures for
troubleshooting".
PC138USLC-10 40-309
40 Troubleshooting
Failure code [DV20KB] Travel Alarm Short Circuit (PC138-DV20KB-400-A-Z0-A)
Action level Failure code Travel Alarm Short Circuit

Failure
L01 DV20KB (Pump controller system)
Detail of • Abnormal current flows when pump controller drives travel alarm circuit.
failure
• Stops driving travel alarm circuit.
controller is set to OFF position.
Problem on
• Travel alarm does not sound.
machine
Related be measured at pump controller connector.
information • (2 persons are required for this check.)
2. Disconnect connector M14, and connect T-adapter to female side.
4. Perform troubleshooting by operating the travel lever.
k Never enter under the machine when operating travel lever.
a If voltage is normal but travel alarm does not sound, travel alarm is
Defective travel alarm defective.
1 Travel
(Internal defect)
control
lever: Max. 1 V
At
Voltage Between M14 (female) (1) and (2) NEUTRAL
Travel
control
lever: 20 to 30 V
Depressed
harness 2. Disconnect connectors CP02 and M14, and connect T-adapter to either
2 female side.
Between CP02 (female) (107) and ground, or M14
circuit) Resistance (female) (1) and ground Min. 1 Mz

2. Insert T-adapter into connector M14.
4. Perform troubleshooting by operating the travel lever.
k Never enter under the machine when operating travel lever.
Travel
Pump controller is control
3
defective. lever: Max. 1 V
At
Voltage Between M14 (1) and (2) NEUTRAL
Travel
control
lever: 20 to 30 V
Depressed
40-310 PC138USLC-10
40 Troubleshooting
Circuit diagram related to travel alarm
PC138USLC-10 40-311
40 Troubleshooting
Failure code [DW43KA] Travel Speed Sol Open Circuit (PC138-DW43KA-400-A-Z0-A)
Action level Failure code Travel Speed Solenoid Open Circuit

Failure
L01 DW43KA (Pump controller system)
• Controller output voltage to solenoid is above standard value when pump controller does
Detail of not drive travel speed selector solenoid, so pump controller determines that open circuit
failure exists in travel speed selector solenoid circuit.
Action of • None in particular (Since no current flows, solenoid is not energized.)
Problem on • "Hi" travel speed is slow. (Although "Hi" is displayed on machine monitor, actual travel
machine speed is still "Lo".)
• Controller's command (ON/OFF) to travel speed selector solenoid can be checked with
monitoring function. (As long as controller's command to solenoid is "ON", sensor status
Related displayed on monitoring screen is "ON" even if solenoid is not energized due to short
information circuit.)
(Code: 02300)
Defective travel speed 1. Turn starting switch to OFF position.
1 selector solenoid 2. Disconnect connector V02, and connect T-adapter to male side.
(Internal open circuit) Resistance Between V02 (male) (1) and (2) 20 to 60 z
Open circuit, short 2. Disconnect connector V02 and connect T-adapter to female side.
circuit, ground fault, hot 3. Turn starting switch to ON position.
2 short circuit of wiring a Shake the wiring harness by hand while measuring the voltage. If the
harness, or defective voltage drops to approximately 0 V during shaking, circuit is open around
pump controller this point.
Voltage Between V02 (female) (1) and (2) 1 to 4.5 V
Open or short circuit in 1. Turn starting switch to OFF position.
3 wiring harness 2. Disconnect connector CP02 and connect T-adapter to female side.
Between CP02 (female) (93) and each of (115),
Resistance (117), and (120) 20 to 60 z

harness 2. Disconnect connectors CP02 and V02, and connect T-adapters to each
4 (Wire breakage or female side.
defective contact of Between CP02 (female) (93) and V02 (female) (1) Max. 1 z
connector) Resistance Between V02 (female) (2) and each of CP02
(female) (115), (117), and (120) Max. 1 z

5
40-312 PC138USLC-10
40 Troubleshooting
Circuit diagram related to travel speed solenoid
PC138USLC-10 40-313
40 Troubleshooting
Failure code [DW43KB] Travel Speed Sol Short Circuit (PC138-DW43KB-400-A-Z0-A)
Action level Failure code Travel Speed Solenoid Short Circuit

Failure
L01 DW43KB (Pump controller system)
• Abnormal current flows when pump controller drives travel speed selector solenoid, so
pump controller determines that short circuit exists in travel speed selector solenoid
Detail of circuit.
failure • Controller output voltage to solenoid is above standard value when pump controller does
not drive travel speed selector solenoid, so pump controller determines that open circuit
exists in travel speed selector solenoid circuit.
• Stops driving travel speed selector solenoid.
Problem on • "Hi" travel speed is slow. (Although "Hi" is displayed on machine monitor, actual travel
machine speed is still "Lo".)
• Controller's command (ON/OFF) to travel speed selector solenoid can be checked with
Related displayed on monitoring screen is "ON" even if solenoid is not energized due to short
information circuit.)
(Code: 02300)
Defective travel speed 1. Turn starting switch to OFF position.
selector solenoid 2. Disconnect connector V02, and connect T-adapter to male side.
1
(Internal short circuit or Between V02 (male) (1) and (2) 20 to 60 z
ground fault) Resistance
Short circuit or ground
2 fault in wiring harness Between CP02 (female) (93) and each of (115),
20 to 60 z
Resistance (117), and (120)
a If no abnormality is found in check on cause 2, this check is not required.
harness
3 2. Disconnect connectors C02 and V02, and connect T-adapter to either
circuit) Between ground and CP02 (female) (93) or V02

Hot short circuit in 2. Disconnect connector V02 and connect T-adapter to female side.
Voltage Between V02 (female) (1) and ground Max. 4.5 V
5
40-314 PC138USLC-10
40 Troubleshooting
PC138USLC-10 40-315
40 Troubleshooting
Failure code [DW45KA] Swing Brake Sol Open Circuit (PC138-DW45KA-400-A-Z0-A)
Action level Failure code Swing Brake Solenoid Open Circuit

Failure
Detail of not drive swing holding brake solenoid, so pump controller determines that open circuit
failure exists in swing holding brake solenoid circuit.
• None in particular (Since no current flows, solenoid is not energized.) Swing holding brake
Action of will be applied.)
Problem on • Upper structure does not swing (swing holding brake is not released).
machine
• When solenoid and wiring harness are normal, swing operation is possible if swing brake
cancel switch is set to RELEASE position. (Note that swing holding brake is applied when
starting switch is in OFF position.)
• Keep swing brake cancel switch in release position during troubleshooting. When starting
switch is turned to ON position in this condition, normally current can flow in swing holding
brake solenoid circuit and the swing holding brake will be released.
Related • Controller's command (ON/OFF) to swing holding brake solenoid can be checked with
information monitoring function. (As long as controller's command to solenoid is "ON", sensor status
displayed on monitoring screen is "ON" even if solenoid is not energized due to open
circuit.)
(Code: 02300)
• Power for swing holding brake solenoid circuit is supplied from pin (101) of pump
controller connector C02 or fuse No.1 in fuse box F01.
Blown No. 1 fuse in fuse If fuse is blown, see failure code [DW45KB].
1
box F01
Defective swing brake 2. Disconnect connector V03, and connect T-adapters to male side.
2
solenoid
Resistance Between V03 (male) (1) and (2) 20 to 60 z
2. Remove diode arrays D01 and D03, and connect T-adapters to each male
side.
a Measure it with diode range of multimeter.
Defective diode array No
3 Between D01 (male) (3) (+) and (7) (-)
D01 or D03 continuity
Continuity
No
continuity
2. Swing lock switch OFF position
4 short circuit of wiring
harness, or defective a Shake the wiring harness by hand while measuring the voltage. If the
pump controller voltage drops to approximately 0 V during shaking, circuit is open around
this point.
2. Remove diode D01.
Open or short circuit in 3. Disconnect connector CP02, and connect T-adapter to each female side.
5 wiring harness
a Swing lock switch OFF position
Between CP02 (female) (101) and D01 (female) (7) Max. 1 z
Resistance
Between D01 (female) (3) and CP02 (female) (115) 20 to 60 z
40-316 PC138USLC-10
40 Troubleshooting

harness 2. Disconnect connectors D01, CP02, and V03, and connect T-adapters to
6 (Wire breakage or each female side.
defective contact of Between D01 (female) (3) and V03 (female) (1) Max. 1 z
connector) Resistance Between each of CP02 (female) (115), (117), (120)
and V03 (female) (2) Max. 1 z

7
PC138USLC-10 40-317
40 Troubleshooting
Circuit diagram related to swing holding brake solenoid
40-318 PC138USLC-10
40 Troubleshooting
Failure code [DW45KB] Swing Brake Sol Short Circuit (PC138-DW45KB-400-A-Z0-A)
Action level Failure code Swing Brake Solenoid Short Circuit

Failure
Detail of • Abnormal current flows when pump controller drives swing holding brake solenoid, so
failure pump controller determines that short circuit exists in swing holding brake solenoid circuit.
• Stops driving swing holding brake solenoid.
Problem on • Upper structure does not swing (swing holding brake is not released).
machine
• When solenoid and wiring harness are normal, swing operation is possible if swing brake
cancel switch is set to RELEASE position. (Note that swing holding brake is applied when
starting switch is in OFF position.)
• Keep the swing lock switch in the OFF position and the swing brake cancel switch in the
RELEASE position during troubleshooting. When starting switch is turned to ON position
in this condition, normally current can flow in swing holding brake solenoid circuit and the
swing holding brake will be released.
Related
• Controller's command (ON/OFF) to swing holding brake solenoid can be checked with
information
displayed on monitoring screen is "ON" even if solenoid is not energized due to short
circuit.)
(Code: 02300)
• Power for swing holding brake solenoid circuit is supplied from pin (101) of pump
controller connector C02 or fuse No.1 in fuse box F01.
Blown No. 1 fuse in fuse Even if fuse is blown, perform troubleshooting according to following steps to
1 identify cause.
box F01
Defective swing brake 2. Disconnect connector V03, and connect T-adapter to male side.
2
Resistance
2. Remove diode arrays D01 and D03, and connect T-adapter to each male
side.
a Measure it with diode range of multimeter.
Defective diode array No
3 Between D01 (male) (3) (+) and (7) (-)
D01 or D03 continuity
Continuity
No
continuity
Ground fault in wiring 2.Remove fuse No.1 in fuse box F01 and diode D01.
harness 3.Disconnect connectors CP02, D01, and V03.
4 4.Connect T-adapters to female side of connectors CP02 and D01.
circuit) Between CP02 (female) (101) and ground Min. 1 Mz
Resistance
Between D01 (female) (3) and ground Min. 1 Mz
2. Remove fuse No.1 in fuse box F01 and diode D01.
Short circuit in wiring 3. Disconnect connector CP02.
5
harness 4. Connect T-adapters to female side of connectors D01 and CP02.
Between D01 (female) (3) and CP02 (female)
Resistance (115), (117), or (120) 20 to 60 z

6
PC138USLC-10 40-319
40 Troubleshooting
Circuit diagram related to swing holding brake solenoid
40-320 PC138USLC-10
40 Troubleshooting
Failure code [DW91KA] Travel Junction Sol Open Circuit (PC138-DW91KA-400-A-Z0-A)
Action level Failure code Travel Junction Solenoid Open Circuit

Failure
Detail of not drive travel junction solenoid, so pump controller determines that open circuit exists in
failure travel junction solenoid circuit.
Problem on • Machine does not turn during travel.
machine
• Controller's command (ON/OFF) to travel junction solenoid can be checked with
displayed on monitoring screen is "ON" even if solenoid is not energized due to open
Related circuit.)
• Travel junction circuit is made when solenoid is de-energized.
Defective travel junction 1. Turn starting switch to OFF position.
1 solenoid 2. Disconnect connector V04, and connect T-adapter to male side.

harness 2. Disconnect connectors CP02 and V04, and connect T-adapter to each
(female) (115), (117), and (120) Max. 1 z

5
PC138USLC-10 40-321
40 Troubleshooting
Circuit diagram related to travel interconnection valve solenoid
40-322 PC138USLC-10
40 Troubleshooting
Failure code [DW91KB] Travel Junction Sol Short Circuit (PC138-DW91KB-400-A-Z0-A)
Action level Failure code Travel Junction Solenoid Short Circuit

Failure
• Abnormal current flows when pump controller drives travel junction solenoid, so pump
controller determines that short circuit exists in travel junction solenoid circuit.
Detail of • Controller output voltage to solenoid is above standard value when pump controller does
failure not drive travel junction solenoid, so pump controller determines that open circuit exists in
travel junction solenoid circuit.
• Stops driving travel junction solenoid.
Problem on • Machine does not turn during travel.
machine
• Controller's command (ON/OFF) to travel junction solenoid can be checked with
displayed on monitoring screen is "ON" even if solenoid is not energized due to short
Related circuit.)
• Travel junction circuit is made when solenoid is de-energized.
Defective travel junction 1. Turn starting switch to OFF position.
solenoid 2. Disconnect connector V04, and connect T-adapter to male side.
1
20 to 60 z
harness
3 2. Disconnect connectors CP02 and V04, and connect T-adapter to either

6
PC138USLC-10 40-323
40 Troubleshooting
Circuit diagram related to travel interconnection valve solenoid
40-324 PC138USLC-10
40 Troubleshooting
Failure code [DWA2KA] Attachment Sol Open Circuit (PC138-DWA2KA-400-A-Z0-A)
Action level Failure code Attachment Solenoid Open Circuit

Failure
L03 DWA2KA (Pump controller system)
Detail of
not drive attachment return selector solenoid, so pump controller determines that open
failure
circuit exists in attachment return selector solenoid circuit.
Problem on • Attachment return circuit does not change to 1-way circuit.
machine
• Controller's command (ON/OFF) to attachment return selector solenoid can be checked
with monitoring function. (As long as controller's command to solenoid is "ON", sensor
status displayed on monitoring screen is "ON" even if solenoid is not energized due to
Related open circuit.)
• Method of reproducing failure code: Turn starting switch to ON position and set machine
in working mode other than breaker mode (B).
Defective attachment 1. Turn starting switch to OFF position.
1 return selector solenoid 2. Disconnect connector V06, and connect T-adapter to male side.
(internal open circuit) Resistance Between V06 (male) (1) and (2) 20 to 60 z
Open circuit or ground 1. Turn starting switch to OFF position.
3 fault in wiring harness 2. Disconnect connector CP02 and connect T-adapter to female side.
Between CP02 (female) (86) and each of CP02
Resistance (female) (115), (117), (120) 20 to 60 z

connector) Resistance Between V06 (female) (2) and CP02 (female) (115),
(117), (120) Max. 1 z

5
PC138USLC-10 40-325
40 Troubleshooting
Circuit diagram related to ATT single/multiple selector solenoid
40-326 PC138USLC-10
40 Troubleshooting
Failure code [DWA2KB] Attachment Sol Short Circuit (PC138-DWA2KB-400-A-Z0-A)
Action level Failure code Attachment Solenoid Short Circuit

Failure
L03 DWA2KB (Pump controller system)
• Abnormal current flows when pump controller drives attachment return selector solenoid,
so pump controller determines that short circuit exists in attachment return selector
Detail of solenoid circuit.
not drive attachment return selector solenoid, so pump controller determines that open
circuit exists in attachment return selector solenoid circuit.
• Stops driving attachment return selector solenoid.
Problem on • Attachment return circuit does not change to 1-way circuit.
machine
• Controller's command (ON/OFF) to attachment return selector solenoid can be checked
with monitoring function. (As long as controller's command to solenoid is "ON", sensor
status displayed on monitoring screen is "ON" even if solenoid is not energized due to
Related short circuit.)
• Method of reproducing failure code: Turn starting switch ON and set machine in breaker
mode (B).
return selector solenoid 2. Disconnect connector V06, and connect T-adapter to male side.
1 (internal short circuit or Between V06 (male) (1) and (2) 20 to 60 z
Open circuit or ground 2. Disconnect connector CP02 and connect T-adapter to female side.

harness

5
PC138USLC-10 40-327
40 Troubleshooting
Circuit diagram related to ATT single/multiple selector solenoid
40-328 PC138USLC-10
40 Troubleshooting
Failure code [DWJ0KA] Merge-divider Sol Open Circuit (PC138-DWJ0KA-400-A-Z0-A)
Action level Failure code Merge-divider Solenoid Open Circuit

Failure
L01 DWJ0KA (Pump controller system)
Detail of not drive merge-divider (main) EPC solenoid solenoid, so pump controller determines that
failure open circuit exists in merge-divider (main) EPC solenoid circuit.
• Stops output command to merge-divider main solenoid and merge-divider SL solenoid to
Action of put pump in merging condition constantly.
Problem on • Single operation speed of work equipment and swing is high in fine control mode (L).
machine • Machine does not turn easily during travel.
• Drive current to merge-divider main EPC solenoid can be checked with monitoring
Related function.
Defective merge-divider 1. Turn starting switch to OFF position.
1 main EPC solenoid 2. Disconnect connector V05, and connect T-adapter to male side.
(internal open circuit) Resistance Between V05 (male) (1) and (2) 20 to 60z
Open or short circuit in 2. Disconnect connector CP02 and connect T-adapter to female side.
3 wiring harness Between CP02 (female) (112) and each of (115),

(female) (115), (117), and (120) Max. 1 z

5
PC138USLC-10 40-329
40 Troubleshooting
Circuit diagram related to pump merge-divider main solenoid
40-330 PC138USLC-10
40 Troubleshooting
Failure code [DWJ0KB] Merge-divider Sol Short Circuit (PC138-DWJ0KB-400-A-Z0-A)
Action level Failure code Merge-divider Solenoid Short Circuit

Failure
L01 DWJ0KB (Pump controller system)
• Abnormal current flows when pump controller drives merge-divider (main) EPC solenoid,
so pump controller determines that short circuit exists in merge-divider (main) EPC
Detail of solenoid circuit.
not drive merge-divider (main) EPC solenoid, so pump controller determines that open
circuit exists in merge-divider (main) EPC solenoid circuit.
• Stops output command to merge-divider main solenoid and merge-divider SL solenoid to
Action of put pump in merging condition constantly.
Problem on • Single operation speed of work equipment and swing is high in fine control mode (L).
machine • Machine does not turn easily during travel.
• Drive current to merge-divider main EPC solenoid can be checked with monitoring
function.
information • Method of reproducing failure code: Start engine and fully operate travel lever to
FORWARD or REVERSE, and travel
Defective merge-divider 1. Turn starting switch to OFF position.
main EPC solenoid 2. Disconnect connector V05, and connect T-adapter to male side.
1 (internal short circuit or Between V05 (male) (1) and (2) 20 to 60 z
20 to 60 z
harness

5
PC138USLC-10 40-331
40 Troubleshooting
Circuit diagram related to pump merge-divider main solenoid
40-332 PC138USLC-10
40 Troubleshooting
Failure code [DXA8KA] PC-EPC Sol Open Circuit (PC138-DXA8KA-400-A-Z0-A)
Action level Failure code PC-EPC Solenoid Open Circuit

Failure
L03 DXA8KA (Pump controller system)
Detail of • No current flows when pump controller drives PC-EPC solenoid, so pump controller
failure determines that open circuit exists in PC-EPC solenoid circuit.
Problem on • If pump load increases, engine speed decreases largely and engine may stall.
machine
• When solenoid and wiring harness are normal, engine can be prevented from stalling by
setting emergency pump drive switch to ON position.
Related • Drive current of PC–EPC solenoid can be checked by using monitoring function.
Incorrect operation of
1 emergency pump drive Set emergency pump drive switch at its normal position (lower side).
switch
Defective PC-EPC 1. Turn starting switch to OFF position.
2 solenoid 2. Disconnect connector V11, and connect T-adapter to male side.
2. Disconnect connector S25 and connect T-adapter to male side.
Defective emergency Switch position: Normal Max. 1 z
Between S25 (male) (3)
pump drive and (2) Switch position:
3 Min. 1 Mz
Emergency
(Internal open circuit) Resistance
Switch position: Normal Max. 1 z
Between S25 (male) (6)
and (5) Switch position:
Emergency Min. 1 Mz

Open circuit, short 2. Disconnect connector V11, and connect T-adapter to female side.
Voltage Between V11 (male) (1) and (2) Min. 20 V
5 wiring harness a Check that emergency pump drive switch is at normal position (lower
side).

Open circuit in wiring 2. Disconnect connectors CP02, S25 and V11, and connect T-adapters to
6 (Wire breakage or Between CP02 (female) (96) and S25 (female) (3) Max. 1 z
defective contact of Between S25 (female) (2) and V11 (female) (1) Max. 1 z
connector) Resistance Between S25 (female) (6) and each of CP02
(female) (115), (117), (120) Max. 1 z
Between S25 (female) (5) and V11 (female) (2) Max. 1 z
7
PC138USLC-10 40-333
40 Troubleshooting
Circuit diagram related to PC-EPC solenoid
40-334 PC138USLC-10
40 Troubleshooting
Failure code [DXA8KB] PC-EPC Sol Short Circuit (PC138-DXA8KB-400-A-Z0-A)
Action level Failure code PC-EPC Solenoid Short Circuit

Failure
L03 DXA8KB (Pump controller system)
Detail of • Abnormal current flows when pump controller drives PC-EPC solenoid, so pump
failure controller determines that short circuit exists in PC-EPC solenoid circuit.
• Stops driving PC–EPC solenoid.
Problem on • If pump load increases, engine speed decreases largely and engine may stall.
machine
• When solenoid and wiring harness are normal, engine can be prevented from stalling by
setting emergency pump drive switch to ON position.
Related • Drive current of PC–EPC solenoid can be checked by using monitoring function.
Defective PC-EPC 1. Turn starting switch to OFF position.
solenoid 2. Disconnect connector V11, and connect T-adapter to male side.
1
Defective emergency 2. Disconnect connector S25 and connect T-adapter to male side.
pump drive switch Between S25 (male) (5) and each of
2 (internal short circuit or Switch Min. 1 Mz
(2) and (3)
ground fault) Resistance position:
Between ground and each of S25
Normal Min. 1 Mz
(male) (2) and (3)
Short circuit or ground a Check that emergency pump drive switch is at normal position (lower
3 fault in wiring harness side).
3 to 14 z
Ground fault in wiring 2. Disconnect connectors CP02, S25 and V11, and connect T-adapter to any
harness female side.
4
(Contact with ground Between ground and CP02 (female) (96) or S25
circuit) (female) (3) Min. 1 Mz
Resistance
Between ground and S25 (female) (5) or V11

5
PC138USLC-10 40-335
40 Troubleshooting
Circuit diagram related to PC-EPC solenoid
40-336 PC138USLC-10
40 Troubleshooting
Failure code [DXE4KA] Attachment Flow EPC Open Circuit (PC138-DXE4KA-400-A-00-

A)
Action level Failure code Attachment Flow EPC Open Circuit

Failure
– DXE4KA (Pump controller system)
• No current flows when pump controller drives attachment flow rate adjustment (service
Detail of current) EPC solenoid, so pump controller determines that open circuit exists in
failure attachment flow rate adjustment (service current) EPC solenoid circuit.
Problem on
• Attachment does not move.
machine
• Drive current of attachment flow rate adjustment (service current) EPC solenoid can be
checked with monitoring function.
information • Method of reproducing failure code: Turn starting switch ON and set machine in breaker
mode (B)
flow rate adjustment 2. Disconnect connector V30, and connect T-adapter to male side.
1 (service current) EPC
solenoid (Internal open Resistance Between V30 (male) (1) and (2) 3 to 14 z
circuit)
Open circuit, short 2. Disconnect connector V30, and connect T-adapter to female side.

(female) (115), (117), (120) Max. 1 z

5
PC138USLC-10 40-337
40 Troubleshooting
Circuit diagram related to service flow control EPC
40-338 PC138USLC-10
40 Troubleshooting
Failure code [DXE4KB] Attachment Flow EPC Short Circuit (PC138-DXE4KB-400-A-Z0-

A)
Action level Failure code Attachment Flow EPC Short Circuit

Failure
― DXE4KB (Pump controller system)
• Abnormal current flows when pump controller drives attachment flow rate (service current)
Detail of EPC solenoid, so pump controller determines that short circuit exists in attachment flow
failure rate adjustment (service current) EPC solenoid circuit.
• Stops driving attachment flow rate adjustment EPC solenoid.
Problem on
• Attachment does not move.
machine
• Drive current of attachment flow rate adjustment (service current) EPC solenoid can be
checked with monitoring function.
information • Method of reproducing failure code: Turn starting switch ON and set machine in breaker
mode (B).
flow rate adjustment 2. Disconnect connector V30, and connect T-adapter to male side.
1 (service current) EPC
solenoid (internal short Resistance
circuit or ground fault) Between V30 (male) (1) and ground Min. 1 Mz
3 to 14 z
harness

4
PC138USLC-10 40-339
40 Troubleshooting
Circuit diagram related to service flow control EPC
40-340 PC138USLC-10
40 Troubleshooting
Failure code [DY20KA] Wiper Working Abnormality (PC138-DY20KA-400-A-Z0-A)
Action level Failure code Wiper Working Abnormality

Failure
― DY20KA (Pump controller system)
Detail of • When windshield wiper works, W signal that indicates that wiper motor reaches working
failure area upper end position is not input.
Action of • Stops working output to wiper motor.
Problem on • Wiper motor does not work.
machine
• Signal input (ON/OFF) of W contact signal that indicates wiper working area end can be
checked by using monitoring function.
(Code: 02204)
• Method of reproducing failure code: Turn starting switch to ON position and set wiper switch
to INT or ON position.
2. Disconnect connector M05 and connect T-adapter to female side.
Wiper position:
Defective wiper Working area upper Max. 1 z
end
1 motor Between M05 (female) (6) and (5)
Resis- Wiper position: Other
(Internal open circuit)
tance than working area Min. 1 Mz
upper end
Wiper position: Whole
Between M05 (female) (1) and (3) Max. 20 z
range
2. Disconnect connectors CP01 and CP02, and connect T-adapters to each
female side.
Wiper position:
Working area upper Max. 1 z
Open or short circuit
2 in wiring harness Between CP01 (female) (56) and end
Resis- ground Wiper position: Other
tance than working area Min. 1 Mz
upper end
Between CP02 (female) (114) and Wiper position: Whole
(119) range Max. 20 z

Open circuit in wiring 2. Disconnect connectors CP01, CP02, and M05.
harness 3. Connect T-adapters to female side of connectors CP01 and CP02 and male
3 (Wire breakage or side of M05.
defective contact of Between CP01 (female) (56) and M05 (male) (6) Max. 1 z
connector) Resis- Between M05 (male) (5) and ground (T01) Max. 1 z
tance Between CP02 (female) (114) and M05 (male) (1) Max. 1 z
Between CP02 (female) (119) and M05 (male) (3) Max. 1 z
4
PC138USLC-10 40-341
40 Troubleshooting
Circuit diagram related to wiper
40-342 PC138USLC-10
40 Troubleshooting
Failure code [DY20MA] Wiper Parking Abnormality (PC138-DY20MA-400-A-Z0-A)
Action level Failure code Wiper Parking Abnormality

Failure
― DY20MA (Pump controller system)
Detail of • When windshield wiper rests, P signal that indicates that wiper motor is at rest area position
failure is not input.
Action of • Stops output for resting to wiper motor.
Problem on • Wiper does not rest.
machine
• Condition of P contact signal of wiper resting area can be checked by using monitoring
function.
(Code: 02204)
• Method of reproducing failure code: Turn starting switch to ON position and set wiper switch
to INT/ONoOFF position.
Defective wiper Wiper position: Rest
Max. 1 z
area
1 motor Between M05 (female) (4) and (5)
Resis- Wiper position:
(Internal open circuit) Min. 1 Mz
tance Working area
Wiper position: Whole
range
2. Disconnect connectors CP01 and CP02, and connect T-adapter to each
female side.
Wiper position: Rest
Open or short circuit Max. 1 z
2 in wiring harness Between CP01 (female) (75) and area
Resis- ground Wiper position:
Min. 1 Mz
tance Working area
Between CP02 (female) (114) and Wiper position: Whole
(119) range Max. 20 z

Open circuit in wiring 2. Disconnect connectors CP01, CP02, and M05.
harness 3. Connect T-adapters to female side of connectors CP01 and CP02 and male
3 (Wire breakage or side of M05.
defective contact of Between CP01 (female) (75) and M05 (male) (4) Max. 1 z
connector) Resis- Between M05 (male) (5) and ground (T01) Max. 1 z
tance Between CP02 (female) (114) and M05 (male) (1) Max. 1 z
Between CP02 (female) (119) and M05 (male) (3) Max. 1 z
4
PC138USLC-10 40-343
40 Troubleshooting
40-344 PC138USLC-10
40 Troubleshooting
Failure code [DY2CKB] Washer Drive Short Circuit (PC138-DY2CKB-400-A-Z0-A)
Action level Failure code Washer Drive Short Circuit

Failure
― DY2CKB (Pump controller system)
Detail of • When outputting current to window washer motor, abnormal current flows and short circuit
failure is detected.
• Stops driving washer motor.
Problem on • Window washer does not operate.
machine
Related • Method of reproducing failure code: Turn starting switch to ON position and turn washer
information switch to ON position.
Defective fuse No. 4 in If the fuse is broken, the circuit probably has a ground fault, etc. (See failure
1 code [DY2CKA].)
fuse box F01
Defective washer motor 2. Disconnect connector M06 and connect T-adapter to male side.
2 (Internal open circuit or Between M06 (male) (1) and (2) Approx. 10
ground fault) z
Resistance Between M06 (male) (1) and ground, or between
M06 (male) (2) and ground Min. 1 Mz

2. Disconnect connector D02 and connect T-adapter to male side.
Defective assembled-
3 type diode D02 a Measure it with diode range of multimeter.
(Internal short circuit) Between D02 (male) (6) (+) and (2) (-) Continuity
Continuity No
continuity
Open or short circuit in 3. Turn starting switch to ON position.
4 wiring harness
a Ignore failure codes displayed on machine monitor.
Voltage Between CP01 (female) (3) and ground 20 to 30 V
a If no failure is found in checks on cause 4, this check is not required.
Ground fault in wiring 2.Disconnect fuse No. 4 of fuse box F01.
harness 3.Disconnect connectors M06, CP01, and D02, and connect T-adapter to
5 any one of female sides.
circuit) Between F01-4, M06 (female) (2) or D02 (female)
(2) and ground Min. 1 Mz
Resistance
Between ground and any one of CP01 (female) (3),
M06 (female) (1), or D02 (female) (6) Min. 1 Mz

2. Disconnect connectors CP01 and M06, and connect T-adapter to female
side of CP01.
Hot short circuit in 3. Disconnect fuse No. 4 of fuse box F01.
a Ignore failure codes displayed on machine monitor.
Voltage Between CP01 (female) (3) and ground Max. 4.5 V
7
PC138USLC-10 40-345
40 Troubleshooting
Circuit diagram related to window washer motor
40-346 PC138USLC-10
40 Troubleshooting
Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit (PC138-DY2DKB-400-A-Z0-A)
Action level Failure code Wiper Drive (Forward) Short Circuit

Failure
― DY2DKB (Pump controller system)
Detail of • When power to normal rotation side of wiper motor drive is supplied, short circuit was
failure detected because of abnormal current flown to the circuit.
• Stops driving wiper motor drive normal rotation side.
Problem on • Windshield wiper does not operate.
machine
information • Method of reproducing failure code: Turn starting switch to ON position and set wiper
switch to INT or ON position.
Defective wiper motor 1. Turn starting switch to OFF position.

1 (Internal short circuit or
Between M05 (female) (3) and ground Min. 1 Mz
2. Disconnect connectors CP02 and M05 and connect T-adapter to either
2 harness side.
harness
Between CP02 (female) (119) and (114), or
Resistance between M05 (male) (1) and (3) Min. 1 Mz

harness 2. Disconnect connectors CP02 and M05 and connect T-adapter to either
3 harness side.
Between CP02 (female) (119) and ground, or
circuit) Resistance between M05 (male) (3) and ground Min. 1 Mz
• Reference
Pump controller is 2. Insert T-adapter into connector M05.
defective.
4. Turn wiper switch ON and OFF, and troubleshoot.
Wiper
Max. 3 V
Voltage Between M05 (3) and (5) switch: OFF
Wiper Pulse below 3 V io
switch: ON above 20 V
PC138USLC-10 40-347
40 Troubleshooting
40-348 PC138USLC-10
40 Troubleshooting
Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit (PC138-DY2EKB-400-A-Z0-A)
Action level Failure code Wiper Drive (Reverse) Short Circuit

Failure
― DY2EKB (Pump controller system)
Detail of • When driving reverse side of wiper motor drive circuit, short circuit was detected because
failure of abnormal current flown to the circuit.
• Stops driving wiper motor drive reverse side.
Problem on • Windshield wiper does not operate.
machine
information • Method of reproducing failure code: Turn starting switch to ON position and set wiper
switch to INT or ON position.

1 (Internal short circuit or
Between M05 (female) (1) and ground Min. 1 Mz
2. Disconnect connectors CP02 and M05 and connect T-adapter to either
2 harness side.
harness
Between CP02 (female) (119) and (114), or
Resistance between M05 (male) (1) and (3) Min. 1 Mz

harness 2. Disconnect connectors CP02 and M05 and connect T-adapter to either
3 harness side.
Between CP02 (female) (114) and ground, or
circuit) Resistance between M05 (male) (1) and ground Min. 1 Mz
• Reference
Pump controller is 2. Insert T-adapter into connector M05.
defective.
4. Turn wiper switch ON and OFF, and troubleshoot.
Wiper
Max. 3 V
Voltage Between M05 (1) and (5) switch: OFF
Wiper Pulse below 3 V io
switch: ON above 20 V
PC138USLC-10 40-349
40 Troubleshooting
40-350 PC138USLC-10
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
Troubleshooting of electrical system (E-mode) (ALL-3840-001-A-01-A)
E-1 Engine does not start (Engine does not crank) (PC138-A21-400-A-Z0-A)
Failure • Engine does not start (engine does not crank).

• Engine starting circuit has following 2 start lock mechanisms.
1. Start lock by password protection of machine monitor
2. Start lock by lock lever position
Related • If failure symptom "Battery relay operation sound is not heard" appears when starting
information switch is turned to ON position, perform troubleshooting for E-1 as well.
• If failure symptom is "Machine monitor displays nothing" when starting switch is turned to
ON position, main electric power supply system may be defective. So, perform
troubleshooting for E-4 (lines connecting to fusible link F03 and fuse No. 17).
Loose terminal or open
1 Check terminals of starting motor, alternator, battery relay, and ground
circuit at terminal
terminals T04, T08, T12, etc.
Poor contact Between battery relay terminal R01 and ground
2 (grounding) between a Use machine frame as grounding point for
battery relay and frame Resistance Max. 1 z
measurement.
a Loosened or rusted terminal T08
a Be ready with starting switch at OFF position, then perform
Insufficient battery troubleshooting without turning starting switch to ON position.
3 capacity Battery voltage (2 batteries) Min. 24 V
Specific gravity of electrolyte (each
battery) Min. 1.26
Defects of engine controller power supply and ACC signal are indicated with
Defective engine
4 failure codes [DB2QKR] and [DB2RKR]. If these codes appear, perform
controller system
troubleshooting for Causes 1 to 3 of [DB2QKR] first.
Defective fuse No. 3 in If fuse is burnt out, circuit probably has ground fault. (See Cause 21.)
5
fuse box F01
1. Turn starting switch to ON position (to connect ACC).
Defective battery relay
6 system a If battery relay operation sound is not heard, go to checks on Causes 20
and after.
1. Turn starting switch to OFF position, and remove fuse No. 3 in fuse box
F01.
Defective fusible link 2. Turn starting switch to ON position (to connect ACC).
7 F02, defective wiring Between input terminal (1A) of fuse box F01-3 and
harness Voltage 20 to 30 V
ground
a If voltage is abnormal, go to check on Cause 10.
Defective starting 2. Remove fuse No. 18 (30 A) of fuse box F01. (To prevent engine from
switch, lock lever starting during troubleshooting)
switch, starting motor 3. Insert T-adapter into connector E12.
8 cut-off relay R06, 4. Turn starting switch to START position and hold it (two persons required
personal code relay for this check).
R07, battery relay, or Voltage Between E12 (1) and ground 20 to 30 V
wiring harness
a If voltage is abnormal, go to check on Cause 13 and after.
PC138USLC-10 40-351
40 Troubleshooting

a If no failure is found by check on Cause 7, this check is not required.
If fusible link is burnt out, circuit may have ground fault. In this case,
perform troubleshooting for Cause 11 first.
Defective fusible link
9 • Fuses No. 1 to 13 are connected to fusible link F02.
F02
a Connected circuit is large in scale. Accordingly, if no failure is found by
check on Cause 11, reproduce trouble and find out ground fault position by
sound and burning smell.
Open circuit 1 in wiring 1. Turn starting switch to OFF position, and turn battery disconnect switch to
harness OFF position.
10 (Wire breakage or (To prevent short circuit during troubleshooting)
defective contact of 2. Disconnect fusible link F02 and fuse No. 3 of fuse box F01.
connector) 3. Connect T-adapter to male side of connector F02.
Between battery relay (R03) and F02 (male) (1) Max. 1 z
Resistance
Between F02 (male) (2) and F01-1A Max. 1 z
Ground fault 1 in wiring OFF position.
harness 2. Disconnect fusible link F02, fuse No. 3 of fuse box F01, and battery relay
11 R03 (M terminal).
circuit) 3. Connect T-adapter to male side of connector F02.
Between ground and battery relay R03 (harness
Min. 1 Mz
Resistance side) or F02 (male) (1)
Between ground and F02 (male) (2) or F01-1A Min. 1 Mz
2.Disconnect connector H15 and connect T-adapter to male side.
3.After troubleshooting, turn starting switch to ON and START positions to
perform troubleshooting again.
Turn starting switch to
OFF position. Min. 1 Mz
Between H15 (male) (1)
Defective starting and (2) Turn starting switch to
12 switch ON position. Max. 1 z
(Internal open circuit) Turn starting switch to
Resistance and (5)
ON position. Max. 1 z
and (4) Turn starting switch to
START position. Max. 1 z

Defective lock lever 1. Turn starting switch to OFF position.
13 switch 2. Disconnect connector S14 and connect T-adapter to female side.
(Internal open circuit) Between S14 (female) Lock lever: FREE Min. 1 Mz
Resistance (1) and (3)
Lock lever: LOCK Max. 1 z
a Before performing troubleshooting, check that the head lamp lights up.
Defective starting motor
14 cut-off relay 1. Turn starting switch to OFF position.
2. Interchange starting motor cut-off relay (R06) with light relay (R05).
3. Start engine.
If engine starts, original starting motor cut-off relay is defective.
40-352 PC138USLC-10
40 Troubleshooting

a Before performing troubleshooting, check that the head lamp lights up.
Defective personal
15 code relay 1. Turn starting switch to OFF position.
2. Interchange personal code relay (R07) with light relay (R05).
3. Start engine.
If engine starts, original personal lock relay is defective.
Defective alternator 2. Turn starting switch to ON position.
16 Input from
(internal short circuit) Between alternator R terminal and
Voltage alternator Max. 1 V
ground
generation
2. Turn starting switch to START position and perform troubleshooting.
Between starting motor terminal B Power
(SB) and ground supply 20 to 30 V
Defective starting motor
17 Voltage Starting
(Internal defect) Between starting motor terminal C input to
(SC) and ground 20 to 30 V
starting
motor
If power supply and starting input to starting motor are normal but starting
motor does not rotate, starting motor is defective.
2. Disconnect connector D01 and connect T-adapter to diode.
Defective diode D01 a Measure it with diode range of multimeter.

18 (Internal open or short Between D01 (male) (1) (+) and (5) (-) No continuity
circuit) Between D01 (male) (5) (+) and (1) (-) Continuity
Between D01 (male) (2) (+) and (6) (-) No continuity
PC138USLC-10 40-353
40 Troubleshooting

• Battery relay
Between terminal R02 and D01 (female) (1) Max. 1 z
Resistance
Between D01 (female) (5) and H15 (female) (2) Max. 1 z
• Battery relay
a Check where 24 V power is reached to, and locate open section.
Between terminals R04 and R01 20 to 30 V
Voltage
Between terminal R01 and ground Max. 1 V
• Alternator and starting motor
3. Insert T-adapters into connectors H15, S14, R07, and E12.
4. Turn battery disconnect switch to ON position.
5. Turn starting switch to START position to perform troubleshooting.
a Check where 24 V power is reached to, and locate open section.
Between H15 (4) and ground 20 to 30 V
Between S14 (1) and ground 20 to 30 V
Open circuit in wiring Between S14 (3) and ground 20 to 30 V
harness
Voltage Between R07 (4) and ground 20 to 30 V
19 (Wire breakage or
Between E12 (1) and ground 20 to 30 V
connector) Between alternator terminal B and ground 20 to 30 V
Between starting motor terminal B and ground 20 to 30 V
• If fuse or fusible link is burnt out, replace it with new one.
2. Disconnect connectors H15, S14, R06, R07, and CM01.
3. Connect T-adapters to female sides of H15, R06, R07, CM01 and to male
side of S14.
4. Remove fuse F01-3.
Between H15 (female) (4) and R06 (female) (3) Max. 1 z
Between R06 (female) (5) and R07 (female) (3) Max. 1 z
Between R07 (female) (1) and S14 (male) (1) Max. 1 z
Between R07 (female) (2) and CM01 (female) (6) Max. 1 z
Between R07 (female) (4) and starting motor safety
relay terminal S Max. 1 z
Between alternator terminal B and starting motor
Resistance terminal B Max. 1 z
Between alternator terminal R and starting motor
safety relay terminal R Max. 1 z
Between alternator terminal R and D01 (female) (6) Max. 1 z
Between F01-3 and S14 (male) (1) Max. 1 z
Between S14 (male) (3) and R06 (female) (1) Max. 1 z
Between R06 (female) (2) and ground (T05) Max. 1 z
40-354 PC138USLC-10
40 Troubleshooting

Defective battery relay If voltage of terminal R03 only is unusual in battery relay checks on Cause 19,
20 battery relay is defective.
(Does not turn ON.)
2. Disconnect connectors H15, S14, R06, R07, and R17.
3. Connect T-adapters to female sides of H15, R06 and R07, and to male
side of S14.
4. Remove fuse No. 3 of fuse box F01.
Ground fault in wiring Between ground and H15 (female) (4) or R06
harness
21 Between ground and R06 (female) (5) or R07
(Contact with ground Min. 1 Mz
circuit) (female) (3)
Resistance Between ground and R07 (female) (4) or R17
Between ground and F01-3 or S14 (male) (1) Min. 1 Mz
Between ground and S14 (male) (3) or R06
wiring harness 2. Insert T-adapter into connector R17 or CM01.
(Contact with 24 V
circuit) Voltage Between ground and R17 (2) or CM01 (16) Max. 1 V
PC138USLC-10 40-355
40 Troubleshooting
Circuit diagram related to engine starting circuit
40-356 PC138USLC-10
40 Troubleshooting
E-2 Manual preheating system does not work (PC138-FEM-400-A-Z0-A)
Failure Manual preheating system does not work.

a This troubleshooting describes procedures to be followed when manual preheating does
not function to heat electrical intake air heater (ribbon heater) mounting portion.
• When only engine preheating monitor does not light up, perform troubleshooting for E-3
"While preheating is working, preheating monitor does not light up".
Related • If failure symptom "Machine monitor displays nothing" or "Battery relay does not make
information operating sound" appears when starting switch is turned to ON position, main electric
power supply system may be defective. In these cases, perform troubleshooting for E-4
and E-1 respectively.
• If fuse No. 17 in fuse box F01 is burnt out, perform troubleshooting for "Machine monitor
displays nothing".
• Before performing troubleshooting, check that no related failure code is displayed.
Defective fusible link
1 If fusible link is burnt out, circuit probably has ground fault. (See Cause 8.)
F06 (120 A)
Loose terminal or open
2 Check terminals of heater relay, battery relay, electrical intake air heater
circuit at terminal
(ribbon heater), etc.
2. Disconnect connectors CM01 and H15, and connect T-adapter to female
side of H15.
Between H15 (female) (3) and ground (coil Approx. 20
Resistance resistance of heater relay)
z
• Secondary side
Between R16B (input terminal on contact side of
Voltage 20 to 30 V
heater relay) and ground
Open and short circuit • Primary side
3 in wiring harness 1. Turn starting switch to OFF position.
a To prevent current from flowing through heater when starting switch is
3. Turn starting switch to the HEAT position (connect R1).
Voltage Between heater relay terminal R15 and ground 20 to 30 V
Between R16A (wiring harness side)
Continuity Continuity
and ground
a If no failure is found in primary side by check on Cause 3, this check is not
required.
Defective diode D02 1. Turn starting switch to OFF position.
2. Disconnect connector D02 and connect T-adapter to diode.
4 (Internal open or short
circuit) a Measure it with diode range of multimeter.
Continuity Between D02 (male) (1) (+) and (5) (-) No continuity
Continuity Between D02 (male) (5) (+) and (1) (-) Continuity
PC138USLC-10 40-357
40 Troubleshooting

a If no failure is found in primary side by check on Cause 3, this check is not
required.
Defective starting 2. Turn battery disconnect switch to OFF position.
5 3. Disconnect connector H15 and connect T-adapter to male side.
switch
4. Turn starting switch to OFF and the HEAT positions to perform
troubleshooting.
OFF Min. 1 Mz
Resistance Between H15 (male) (1) and (3)
HEAT Max. 1 z
Defective electrical 1. Turn starting switch to OFF position.
intake air heater (ribbon 2. Disconnect terminal E01.
6 heater)
Continuity Between E01 terminal and ground Continuity
Defective heater relay
If no failure is found by check on Cause 3 and heater relay operation sound is
7 (Does not turn ON) not heard, heater relay is defective.
(terminal R16A)
2. Disconnect connectors H15, CM01, D02, terminals R15, E01, and F06
Ground fault in wiring terminal of fuse.
harness Between heater relay terminal R15 (wiring harness
8 Min. 1 Mz
(Contact with ground side) and ground
circuit) Between heater relay R16B (contact side input
Resistance terminal) and ground Min. 1 Mz
Between heater terminal E01 (wiring harness side)
and ground Min. 1 Mz
40-358 PC138USLC-10
40 Troubleshooting
Circuit diagram related to engine preheating system
PC138USLC-10 40-359
40 Troubleshooting
E-3 While preheating is working, preheating monitor does not light

up (PC138-FE2-400-A-Z0-A)
Failure While preheating is working, preheating monitor does not light up.
Related • Check whether manual preheating function works first.
information
harness 2. Disconnect connectors CM01 and HDT, and connect T-adapters to each
connector) Resistance Between HIS (female) (3) and CM01 (female) (12) Max. 1 z
If no failure is found by preceding checks, machine monitor is defective.
• Reference
Defective machine 3. Disconnect heater relay terminal R16A.
2
monitor
a To prevent current from flowing through heater when starting switch is
4. Turn starting switch to HEAT.
Resistance Between CM01 (12) and (3) 20 to 30 V
40-360 PC138USLC-10
40 Troubleshooting
Circuit diagram related to engine preheating system
PC138USLC-10 40-361
40 Troubleshooting
E-4 When starting switch is turned to ON position, machine monitor

displays nothing (PC138-FEG-400-A-Z0-A)
Failure When starting switch is turned to ON position, machine monitor displays nothing.
• When starting switch is turned to ON position, machine monitor displays KOMATSU logo,
screen to input password (if set), screen to check breaker mode (if set), screen of check
before starting, screen to check working mode, screen to check travel speed, and
Related standard screen in order.
information • Depending on ambient temperature and condition of battery, battery voltage may lower
suddenly and machine monitor displays nothing temporarily when engine is started. But
this phenomenon does not mean that machine monitor is defective.
Battery disconnect
Turn starting switch to OFF position and check that battery disconnect switch
1 switch left in OFF
is in ON position.
position
a Be ready with starting switch at OFF position, then perform
Insufficient battery troubleshooting without turning starting switch to ON position.
2 capacity Battery voltage (2 batteries) Min. 24 V
Specific gravity of electrolyte (each Min. 1.26
battery)
Defective fusible link If fusible link is burnt out, circuit probably has ground fault. (See Cause 9.)
3
F03
4 Defective fuse F01-15 If fuse is burnt out, circuit probably has ground fault. (See Cause 9.)
5 Defective fuse F01-17 If fuse is burnt out, circuit probably has ground fault. (See Cause 9.)
Loose terminal or open 1. Turn starting switch to OFF position.
6
circuit at terminal Check terminals of battery relay, etc.
Defective wiring 4. Turn battery disconnect switch to ON position.
7 harness, starting switch, 5. Turn starting switch to ON position (to connect ACC).
or machine monitor Between CM01 (1) and (3) 20 to 30 V
2. Disconnect connector H15 and connect T-adapter to male side.
Defective starting 3. Turn starting switch to ON position and perform troubleshooting again.
8 switch Between H15 (male) (1) Turn starting switch to
(Internal open circuit) and (5) OFF position. Min. 1 Mz
Resistance
Between H15 (male) (1) Turn starting switch to
and (5) ON position. Max. 1 z
If no failure is found by check on Cause 7, this check is not required.
3. Disconnect fusible link F03, No. 15 and 17 fuses of fusebox F01, and
connectors H15 and CM01.
4. Connect T-adapters to male side of connector F03 and female side of H15
and CM01.
Open circuit in wiring Between battery (-) terminal and ground Max. 1 z
9 harness Between battery (+) and F03 (male) (1) Max. 1 z
(Internal open circuit) Between F03 (male) (2) and F01-16F Max. 1 z
Between F01-17 and CM01 (female) (1), (2) Max. 1 z
Resistance Between ground (T04) and each of CM01 (female)
(3) and (4) Max. 1 z
Between F01-17 and H15 (female) (1) Max. 1 z
Between H15 (female) (5) and F01-15E Max. 1 z
Between F01-15 and CM01 (female) (10) Max. 1 z
40-362 PC138USLC-10
40 Troubleshooting

If no failure is found by checks on causes 3 to 5 and 7, this check is not
required.
OFF position.
2. Disconnect fusible link F03, No. 15 and No. 17 terminals of fusebox F01,
Ground fault in wiring and connectors H15, CM01, and CP01.
harness 3. Connect T-adapters to male side of connector F03 and female side of H15
10 and CM01.
circuit) Between ground and battery (+) or F03 (male) (1) Min. 1 Mz
Between ground and F03 (male) (2) or F01-16F Min. 1 Mz
Between ground and F01-17, CM01 (female) (1),
Resistance Min. 1 Mz
(2), or H15 (female) (1)
Between ground and H15 (female) (5) or CM01
Defective machine If no failure is found by preceding checks, machine monitor is defective.

11
PC138USLC-10 40-363
40 Troubleshooting
Circuit diagram related to machine monitor power supply
40-364 PC138USLC-10
40 Troubleshooting
E-5 When starting switch is turned to ON position (with engine stopped),

engine oil level monitor lights up in yellow (PC138-FEJ-400-A-Z0-A)
When starting switch is turned to ON position (with engine stopped), engine oil level monitor
Failure lights up in yellow.
Related
information
level switch system
1 Perform troubleshooting for failure code [B@BAZK].
(machine monitor
system)
Defective machine If no failure is found by check on Cause 1, machine monitor may be defective.
2
PC138USLC-10 40-365
40 Troubleshooting
E-6 Engine coolant temperature monitor lights up in white while engine

is running (PC138-FES-400-A-Z0-A)
Failure Engine coolant temperature monitor lights up in white while engine is running.
• Signal voltage of coolant temperature sensor is input to engine controller and then the
Related data is transmitted to machine monitor through CAN communication system.
information • Coolant temperature can be checked with monitoring function.
(Code: 04107)
Insufficient warm-up of If monitor lights up in white, coolant temperature may be low (below
machine approximately 30°C). Warm up engine.
1
(When system works • Lighting up in white: Coolant temperature is low.
properly) • Lighting up in blue: Coolant temperature is proper.
If no failure is found by preceding checks, engine coolant temperature gauge
system may be defective. Perform following troubleshooting.
Defective engine
coolant temperature • E-15 Engine coolant temperature gauge display does not move from
2
gauge system minimum or maximum
• E-16 Engine coolant temperature gauge indicates incorrect temperature
(indicates neither minimum nor maximum)
40-366 PC138USLC-10
40 Troubleshooting
E-7 Hydraulic oil temperature monitor lights up in white while engine is

running (PC138-FEU-400-A-Z0-A)
Failure Hydraulic oil temperature monitor lights up in white while engine is running.
• Signal of hydraulic oil temperature sensor is input to pump controller and then data is
Related transmitted to machine monitor through CAN communication system.
information • Hydraulic oil temperature can be checked with monitoring function.
(Code: 04401)
Insufficient warm-up of If monitor lights up in white, hydraulic oil temperature may be low (below
machine approximately 20°C). Warm up engine.
1
(when system works • Lighting up in white: Hydraulic oil temperature is low.
properly) • Lighting up in blue: Hydraulic oil temperature is proper.
If no failure is found by preceding checks, hydraulic oil temperature gauge
Defective oil
temperature gauge • E-17 Hydraulic oil temperature gauge does not move from minimum or
2
system maximum
• E-18 Hydraulic oil temperature gauge indicates incorrect temperature
PC138USLC-10 40-367
40 Troubleshooting
E-8 Charge level monitor lights up while engine is running (PC138-FEP-400-A-Z0-A)
Failure Charge level monitor lights up in red while engine is running.

Related • Power-generation signal from alternator can be checked with monitoring function.
Defective alternator
1 Perform troubleshooting for failure code [AB00KE].
system
40-368 PC138USLC-10
40 Troubleshooting
E-9 Fuel level monitor lights up in red while engine is running (PC138-FEQ-400-A-
Z0-A)
Failure Fuel level monitor lights up in red while engine is running.

Related • Signal voltage of fuel sensor can be checked with monitoring function.
Low fuel level
1 (When system works Fuel level may be low. Check it and add fuel if necessary.
properly)
If no failure is found by preceding checks, fuel gauge system may be
defective. Perform following troubleshooting.
Defective fuel gauge
2 system • E-13 Fuel gauge display does not move from minimum or maximum
• E-14 Fuel gauge indicates incorrect amount (indicates neither full nor
empty)
PC138USLC-10 40-369
40 Troubleshooting
E-10 Engine coolant temperature monitor lights up in red while engine is

running (PC138-FEV-400-A-Z0-A)
Failure Engine coolant temperature monitor lights up in red while engine is running.
• Signal voltage of coolant temperature sensor is input to engine controller, and then it is
(Code: 04107)
If monitor lights up in red, coolant temperature may be high (above
Overheating of engine approximately 102°C). Cool down coolant. (Run engine at low idle.)
coolant • Lighting up in red: Coolant temperature is high (overheating).
1 • Lighting up in blue: Coolant temperature is proper.
(When system works
properly) Perform troubleshooting for "S-17 Coolant temperature rises too high
(overheating)".
If no failure is found by preceding checks, engine coolant temperature gauge
Defective engine
coolant temperature • E-15 Engine coolant temperature gauge display does not move from
2
gauge system minimum or maximum
40-370 PC138USLC-10
40 Troubleshooting
E-11 Hydraulic oil temperature monitor lights up in red while engine is

running (PC138-FEW-400-A-Z0-A)
Failure Hydraulic oil temperature monitor lights up in red while engine is running.
• Signal from hydraulic oil temperature sensor is input to pump controller and then data is
(Code: 04401)
If monitor lights up in red, hydraulic oil temperature may be high (above
Overheating of
approximately 102°C). Cool down hydraulic oil. (Run engine at low idle or stop
hydraulic oil
1 engine.)
(When system works
• Lighting up in red: Hydraulic oil temperature is high (overheating).
properly)
• Lighting up in blue: Hydraulic oil temperature is proper.
If no failure is found by preceding checks, hydraulic oil temperature gauge
Defective oil
temperature gauge • E-17 Hydraulic oil temperature gauge does not move from minimum or
2
system maximum
• E-18 Hydraulic oil temperature gauge indicates incorrect temperature
PC138USLC-10 40-371
40 Troubleshooting
E-12 Engine oil pressure monitor lights up in red while engine is

running (PC138-FEX-400-A-Z0-A)
Failure Engine oil pressure monitor lights up in red while engine is running.
• Signal of engine oil pressure sensor is input to engine controller and then the data is
information • Engine oil pressure can be checked with monitoring function.
• (Code: 37200)
Lowered engine oil
pressure Engine oil pressure may be lowered. Check engine oil pressure.
1
(When system works • Perform troubleshooting "S-14 (Oil pressure drops)".
properly)
Defective engine oil If no failure is found by check on Cause 1, engine oil pressure switch system
2 pressure system may be defective. Perform troubleshooting for failure code [CA435].
If no failure is found by check on Causes 1 to 2, machine monitor may be
Defective machine defective.
3
monitor
40-372 PC138USLC-10
40 Troubleshooting
E-13 Fuel gauge display does not move from minimum or maximum (PC138-
FGE-400-A-Z0-A)
1) While fuel is added, fuel gauge indicator does not rise from red range (E).
Failure
2) While fuel level is low, fuel gauge indicator does not lower from green range top (F)
Defective fuel level 1. Turn starting switch to OFF position.
sensor 2. Disconnect connector P21 and connect T-adapter to male side.
1 Approx. 12
(internal open or short Between P21 (male) (1) Fuel level: FULL
circuit) Resistance z
and ground
Fuel level: EMPTY 85 to 110 z
2. Disconnect connector CM01, and connect T-adapter to female side.
Open and short circuit
2 in wiring harness Approx. 12
Between CM01 (female) Fuel level: FULL
Resistance z
(15) and ground
Fuel level: EMPTY 85 to 110 z
Open circuit in wiring a If no failure is found by check on Cause 2, this check is not required.
harness
3 (wire breakage or 2. Disconnect connectors CM01 and P21 and connect T-adapters to each
connector) Resistance Between CM01 (female) (15) and P21 (female) (1) Max. 1 z
harness 2. Disconnect connectors CM01 and P21, and connect T-adapter to either
4 female side.
Between ground and CM01 (female) (15) or P21

Hot short circuit in 3. Insert T-adapter into connector CM01 or connect T-adapter to female side
5 wiring harness of connector P21.
Voltage Between ground and CM01 (15) or P21 (female) (1) Approx. 3.3
V
Defective machine If no failure is found by preceding checks, machine monitor is defective.
6 (Since this is an internal defect, troubleshooting cannot be performed.)
monitor
Circuit diagram related to fuel level sensor
PC138USLC-10 40-373
40 Troubleshooting
E-14 Fuel gauge indicates incorrect amount (indicates neither full nor
empty) (PC138-FGF-400-A-Z0-A)
1) Indication of fuel gauge is different from actual fuel level.
Failure
2) Indication of fuel gauge does not accord with indication of fuel level monitor.
Defective fuel level Perform troubleshooting for "E-13 Cause 1".
1
sensor
a Turn starting switch to ON position or start engine to perform
troubleshooting.
Fuel level: 144 l Fuel gauge level: 6
Defective machine Fuel level: 122 l Fuel gauge level: 5
2 Color of
monitor Fuel level: 99 l Fuel gauge level: 4 Blue
monitor
light (a) Fuel level: 68 l Fuel gauge level: 3
Fuel level: 52 l Fuel gauge level: 2
Fuel level: 32 l Fuel gauge level: 1 Red
Fuel gauge and fuel level monitor
40-374 PC138USLC-10
40 Troubleshooting
E-15 Engine coolant temperature gauge display does not move from
minimum or maximum (PC138-FGG-400-A-Z0-A)
1) While coolant temperature is rising normally, it does not rise from white range (C).
Failure
2) While coolant temperature is stabilized normally, it rises to red range (H).
• Signal voltage of coolant temperature sensor is input to engine controller and then the
Related data is transmitted to machine monitor through CAN communication system.
(Code: 04107)
Defective coolant
Coolant temperature sensor system may be defective. Perform
troubleshooting for failure codes [CA144] and [CA145].
system
2
Engine coolant temperature gauge and coolant temperature monitor
PC138USLC-10 40-375
40 Troubleshooting
E-16 Engine coolant temperature gauge indicates incorrect temperature

(indicates neither minimum nor maximum) (PC138-FGH-400-A-Z0-A)
1) Coolant temperature is different from indication of engine coolant temperature gauge.
Failure 2) Indication of engine coolant temperature gauge is different from indication of coolant
temperature monitor.
• Signal voltage of coolant temperature sensor is input to engine controller, and then it is
(Code: 04107)
Defective coolant
Coolant temperature sensor system may be defective. Perform
troubleshooting for failure codes [CA144] and [CA145].
system
troubleshooting.
Engine coolant
Coolant temperature
temperature gauge level:
105°C
6
Red
Engine coolant
Coolant temperature
102°C
5
Engine coolant
Defective machine Coolant temperature
2 Color of temperature gauge level:
monitor 100°C
monitor 4
light (a) Engine coolant
Coolant temperature 85°
temperature gauge level: Blue
C
3
Engine coolant
C
2
Engine coolant
temperature gauge level: White
C
1
Engine coolant temperature gauge and coolant temperature monitor
40-376 PC138USLC-10
40 Troubleshooting
E-17 Hydraulic oil temperature gauge does not move from minimum or
maximum (PC138-FGJ-400-A-Z0-A)
1) While hydraulic oil temperature is rising normally, it does not rise from white range (C).
Failure
2) While hydraulic oil temperature is stabilized normally, it rises to red range (H).
(Code: 04401)
Approx. 90
10°C
Defective hydraulic oil kz
temperature sensor Between P22 (male) (1) and (2) Approx. 35
1 30°C
(Internal open or short kz
circuit) Resistance a Thermal characteristics of oil 80°C
Approx. 6.5
temperature sensor kz
Approx. 3.5
100°C
kz
Between P22 (male) (2) and ground Min. 1 Mz
Open and short circuit Between CP01 (female) (28) and (46)
2 in wiring harness 3.5 to 90 kz
Resistance a Resistance accords with thermal characteristics
table in Cause 1.
Open circuit in wiring a If no failure is found by check on Cause 2, this check is not required.
3 (Wire breakage or 2. Disconnect connectors CP01 and P22 and connect T-adapters to each
connector) Between CP01 (female) (28) and P22 (female) (2) Max. 1 z
Resistance
Between CP01 (female) (46) and P22 (female) (1) Max. 1 z
harness
4 2. Disconnect connectors CP01 and P22, and connect T-adapter to either
circuit) Between ground and CP01 (female) (28) or P22

Hot short circuit in 3. Insert T-adapter into connector CP01 or connect T-adapter to female side
5 wiring harness of connector P22.
Voltage Between ground and CP01 (28) or P22 (female) (2) Approx. 5 V
Pump controller is If no failure is found by preceding checks, pump controller is defective.
6
PC138USLC-10 40-377
40 Troubleshooting
Circuit diagram related to hydraulic oil temperature sensor
40-378 PC138USLC-10
40 Troubleshooting
E-18 Hydraulic oil temperature gauge indicates incorrect temperature

(indicates neither minimum nor maximum) (PC138-FGK-400-A-Z0-A)
1) Hydraulic oil temperature is different from indication of hydraulic oil temperature gauge.
Failure 2) Indication of hydraulic oil temperature gauge is different from indication of hydraulic oil
temperature monitor.
(Code: 04401)
Defective hydraulic oil
1 See previous page.
temperature sensor
troubleshooting.
Hydraulic oil Hydraulic oil temperature
temperature: 105°C gauge level: 6
Red
Defective machine Hydraulic oil Hydraulic oil temperature
2 Color of
monitor temperature: 100°C gauge level: 4
monitor
light (a) Hydraulic oil Hydraulic oil temperature
temperature: 85°C gauge level: 3 Blue
temperature: 20°C gauge level: 1 White
Hydraulic oil temperature gauge and hydraulic oil temperature monitor
PC138USLC-10 40-379
40 Troubleshooting
E-19 Some areas of machine monitor screen are not displayed (PC138-FFC-400-A-
Z0-A)
Failure Some areas of machine monitor screen are not displayed.

• Liquid crystal panels sometimes allow, as one of their properties, presence of black spots
Related (spots that are not lit up) and bright spots (spots that remain constantly lit) on panel. If the
information number of bright spots and black spots does not exceed 10, liquid crystal panel is not
faulty or defective.
Defective machine a Turn starting switch to ON position, then perform troubleshooting.

1 monitor If following switch operation lights up all pixel on liquid crystal panel (entire
(Liquid crystal panel) screen turns to white), liquid crystal panel is normal.
• Operation of switches: [4] and [F2] (Press simultaneously)
Defective machine
If no failure is found by check on Cause 1, machine monitor may be defective.
2 monitor
(Monitor itself)
40-380 PC138USLC-10
40 Troubleshooting
E-20 Function switch does not work (PC138-HBC-400-A-Z0-A)
Failure Function switch does not work.

Related • Signal of function switch can be checked with monitoring function.
Defective machine Machine monitor may be defective. (Since this is an internal defect,
1 troubleshooting cannot be performed.)
monitor
PC138USLC-10 40-381
40 Troubleshooting
E-21 Automatic warm-up system does not operate (in cold season) (PC138-
FEN-400-A-Z0-A)
Failure Automatic warm-up system does not operate (in cold season).
• Automatic warm-up function increases engine speed to 1,250 rpm when coolant
temperature is below 30°C.
Related • With starting switch at ON position or after engine is started, if fuel control dial is kept at
information 70% or more of full open range for 3 seconds, automatic warm-up operation is canceled.
• If coolant temperature is below 10°C, turbocharger protection function works to keep
engine speed below 1,000 rpm for up to 20 seconds after engine is started.
troubleshooting.
a If level indication of engine coolant temperature gauge differs from actual
coolant temperature, perform following troubleshooting.
• E-15 Engine coolant temperature gauge display does not move from
minimum or maximum
Defective coolant Coolant temperature
1 temperature signal 6 (a: Red)
105°C
system Coolant temperature 5 (a: Red)
102°C
Coolant temperature 4 (a: Blue)
Coolant Monitoring code 04107 100°C
temperature
level (Coolant temperature) Coolant temperature 85° 3 (a: Blue)
C
Coolant temperature 60° 2 (a: Blue)
C
Coolant temperature 30° 1 (a: White)
C
Defective engine If no failure is found by checks on Cause 1, engine controller is defective.
2
Engine coolant temperature gauge and engine coolant temperature monitor
40-382 PC138USLC-10
40 Troubleshooting
E-22 Auto-deceleration monitor does not light up, or does not go out,
while auto-deceleration switch is operated (PC138-FFD-400-A-Z0-A)
Auto-deceleration monitor does not light up or does not go out while auto-deceleration switch
Failure is operated.
Related • Condition of signal of auto-decelerator switch can be checked with monitoring function.
monitor
PC138USLC-10 40-383
40 Troubleshooting
E-23 Auto-deceleration function does not operate or is not canceled

while lever is operated (PC138-FPM-400-A-Z0-A)
Failure Auto-deceleration function does not operate or is not canceled while lever is operated.
Related • Since set engine speed for auto-deceleration is 1,100 rpm, auto-deceleration is not
information actuated or canceled if engine speed set with fuel control dial is below this speed.
a Start engine and perform troubleshooting (with monitoring function).
a If display of monitor is incorrect, perform troubleshooting for "E-42 to 50
Monitoring function does not display *** properly".
When lever is operated:
ON
Swing
When lever is in neutral:
OFF
ON
Travel
OFF
ON
Boom LOWER
Monitoring When lever is in neutral:
code OFF
01900 ON
Boom RAISE
Defective PPC oil OFF
1 pressure signal When lever is operated:
Monitoring ON
display Arm IN
OFF
ON
Arm OUT
OFF
ON
Bucket CURL
OFF
Monitoring
ON
code Bucket DUMP
01901
OFF
ON
Service
OFF
Defective machine If no failure is found by preceding checks, machine monitor may be defective.
2
Pump controller is If no failure is found by preceding checks, pump controller may be defective.
3
Defective engine If no failure is found by preceding checks, engine controller may be defective.
4
40-384 PC138USLC-10
40 Troubleshooting
E-24 Working mode selection screen is not displayed while working

mode selector switch is operated (PC138-FFE-400-A-Z0-A)
Working mode selection screen is not displayed while working mode selector switch is
Failure operated.
Related • Signal of working mode switch can be checked with monitoring function.
monitor
PC138USLC-10 40-385
40 Troubleshooting
E-25 Setting of engine and hydraulic pump is not changed while working
mode is changed (PC138-FP9-400-A-Z0-A)
Failure Setting of engine and hydraulic pump is not changed while working mode is changed.
Related
information
monitor
Pump controller is Pump controller may be defective. (Since this is an internal defect,
defective.
40-386 PC138USLC-10
40 Troubleshooting
E-26 Travel speed monitor does not change while travel speed switch is
operated (PC138-FFF-400-A-Z0-A)
Failure Travel speed monitor does not change while travel speed switch is operated.
Related • Condition of signal of travel speed switch can be checked with monitoring function.
monitor
PC138USLC-10 40-387
40 Troubleshooting
E-27 Travel speed does not change while travel speed selection is
changed (PC138-BQ3-400-A-Z0-A)
Failure Travel speed does not change while travel speed selection is changed.
• If Cause 1 occurs, actual travel speed does not lower when travel speed selection is
Related changed to Lo.
information • As T-adapter for pump controller connector is "socket-type box", operating voltage cannot
Voltage Between V02 (female) (2) and ground Max. 1 V
2
If no failure is found by checks on Causes 1 and 2, pump controller may be
Pump controller is defective.
3
defective.
40-388 PC138USLC-10
40 Troubleshooting
E-28 Alarm buzzer does not stop sounding (PC138-KB3-400-A-Z0-A)
Failure Alarm buzzer does not stop sounding.

• Condition of signal of alarm buzzer cancel switch can be checked with monitoring
Related function.
monitor
PC138USLC-10 40-389
40 Troubleshooting
E-29 Service meter is not displayed, while starting switch is in OFF

position (PC138-FFL-400-A-Z0-A)
Failure Service meter is not displayed while starting switch is in OFF position.
• When following switches are operated while stating switch is in OFF position, service
Related meter appears at top center of screen.
information Operation of switches: [4] and [1] (press simultaneously)
When starting switch is turned to ON position, if machine monitor displays
nothing, backup power supply system may be defective. In this case, perform
Defective backup power the following troubleshooting.
1 supply system
• E-4 When starting switch is turned to ON position, machine monitor
displays nothing
2
40-390 PC138USLC-10
40 Troubleshooting
E-30 Service mode cannot be selected (PC138-HB1-400-A-Z0-A)
Failure Service mode cannot be selected.

• Operate the following switch operations, then service mode is displayed.
Related Operation of switches: [4] + [1]o[2]o[3] (While pressing [4], press [1], [2] and [3] in this
information order.)
monitor
PC138USLC-10 40-391
40 Troubleshooting
E-31 Any of work equipment, swing and travel does not work (PC138-FT5-400-A-Z0-
A)
Failure Any of work equipment, swing and travel does not work.
Related
information
Defective fuse No. 3 of If fuse is burnt out, circuit may have ground fault, etc. (See check on Cause
1 7.)
F01
Defective PPC lock 2. Disconnect connector S14 and connect T-adapter to female side.
2 switch 3. Operate lock lever and perform troubleshooting.
(Internal open circuit) FREE Max. 1 z
Resistance Between S14 (female) (1) and (2)
LOCK Min. 1 Mz
Defective PPC lock 1. Turn starting switch to OFF position.
solenoid 2. Disconnect connector V01 and connect T-adapter to male side.
3
(Internal open, short Between V01 (male) (1) and (2) 20 to 60 z
circuit, or ground fault) Resistance
2. Disconnect connector D01 and connect T-adapter to male side.
Defective diode array
4 D01 a Measure it with diode range of multimeter.
(Internal ground fault) Continuity Between D01 (male) (8) (+) and (4) (-) Continuity
No
Continuity Between D01 (male) (4) (+) and (8) (-)
continuity
2. Remove fuse No. 3.
Open or short circuit in 3. Set PPC lock switch to FREE position.
5 wiring harness
Between fuse F01-3 outlet and ground
Resistance 20 to 60 z
a Resistance of PPC lock solenoid
2.Remove fuse No. 3.
Open circuit in wiring 3.Disconnect connectors S14 and V01 and connect T-adapters to each
6
harness female side.
Between V01 (female) (2) and ground Max. 1 z
Resistance Between V01 (female) (1) and S14 (male) (2) Max. 1 z
Between fuse F01-3 outlet and S14 (male) (1) Max. 1 z
Ground fault in wiring 2.Remove fuse No. 3.
harness 3.Disconnect connectors S14, D01, V01 and then connect T-adapter to male
7
(Contact with ground side of S14 or female side of V01.
circuit) Between ground and V01 (female) (1) or S14
Min. 1 Mz
Resistance (male) (2)
Between S14 (male) (1) and ground Min. 1 Mz
40-392 PC138USLC-10
40 Troubleshooting
Circuit diagram related to PPC lock solenoid
PC138USLC-10 40-393
40 Troubleshooting
E-32 Any of work equipment, swing and travel cannot be locked (PC138-FT7-400-
A-Z0-A)
Failure Any of work equipment, swing, and travel cannot be locked.

Related
information
Defective lock lever 1. Turn starting switch to OFF position.

switch 2. Disconnect connector S14 and connect T-adapter to female side.
1
(Internal short circuit) Between S14 (female) Lock lever: LOCK Min. 1 Mz
Resistance (1) and (2)
Lock lever: FREE Max. 1 z
2. Disconnect connector V01 and connect T-adapter to female side.
wiring harness
4. Turn lock lever to LOCK position.
Voltage Between V01 (female) (2) and (1) Max. 1 V
40-394 PC138USLC-10
40 Troubleshooting
Circuit diagram related to PPC lock solenoid
PC138USLC-10 40-395
40 Troubleshooting
E-33 Upper structure does not swing while swing parking brake cancel
switch is set to CANCEL position (PC138-FGM-400-A-Z0-A)
Upper structure does not swing while swing parking brake cancel switch is set to CANCEL
Failure position.
Related • Condition of swing lock switch signal can be checked with monitoring function.
information (Pump controller system code: 02200)
Defective fuse No. 1 in If fuse is burnt out, circuit probably has ground fault. In this case, perform
1
fuse box F01 check on Cause 5 first.
Defective swing parking 2. Disconnect connector S25 and connect T-adapter to male side.
2 brake cancel switch Swing parking brake
Between S25 (male) (7) cancel switch: Normal Min. 1 Mz
(internal short circuit) Resistance and (8)
Swing parking brake
Max. 1 z
cancel switch: FREE
2. Remove diode array and connect T-adapter to male side.
(Internal short circuit) Continuity Between D01 (male) (7) (+) and (3) (-) Continuity
No
continuity
2. Remove diode array and connect T-adapter to male side.
(Internal short circuit) Continuity Between D03 (male) (5) (+) and (1) (-) Continuity
No
continuity
2. Disconnect connector V03 and connect T-adapter to female side.
Defective wiring a Swing lock switch OFF position
5
harness
Swing parking brake
Between V03 (female) 20 to 30 V
Voltage cancel switch: FREE
(1) and (2) Swing parking brake
Max. 1 V
cancel switch: Normal
harness 2. Disconnect connectors V03 and S25 and connect T-adapters to each
6 (Wire breakage or male side.
defective contact of a Swing lock switch OFF position
connector)
Between V03 (female) (1) and S25 (female) (8) Max. 1 z
Resistance
Between V03 (female) (2) and ground Max. 1 z
Ground fault in wiring a If no failure is found by check on Cause 5, this check is not required.
7 2. Disconnect connectors S25 and V03 and connect T-adapter to female side
circuit) of V03.
Resistance Between V03 (female) (1) and ground Min. 1 Mz
40-396 PC138USLC-10
40 Troubleshooting
Circuit diagram related to swing parking brake
PC138USLC-10 40-397
40 Troubleshooting
E-34 Swing brake does not operate while swing parking brake cancel
switch is set to NORMAL position (PC138-FGN-400-A-Z0-A)
Swing brake does not operate while swing parking brake cancel switch is set to NORMAL
Failure position.
Related
information
Defective swing parking 2. Disconnect connector S25 and connect T-adapter to male side.
1 brake cancel switch Swing parking brake
Between S25 (male) (7) cancel switch: Normal Min. 1 Mz
(internal short circuit) Resistance and (8)
Swing parking brake
Max. 1 z
cancel switch: FREE
wiring harness 3. Turn starting switch to ON position.
2 4. Swing lock switch: ON
(Contact with 24 V
circuit) a Measure voltage again with swing lock switch in OFF position.
40-398 PC138USLC-10
40 Troubleshooting
Circuit diagram related to swing parking brake solenoid
PC138USLC-10 40-399
40 Troubleshooting
E-35 Alarm does not sound during travel (PC138-KA4-400-A-Z0-A)
Failure Alarm does not sound during travel.

Related
information
a Be ready with starting switch OFF, then run engine to perform
troubleshooting.
a If monitoring data is not displayed normally, perform troubleshooting for "E-
49 Travel is not displayed correctly with monitoring function".
Monitoring code Item Correct display
Defective travel signal When one lever is
1
operated: ON
01901 Travel steering
OFF
When both levers
operated: ON
01900 Travel
OFF
Defective travel alarm 3. Start engine and operate travel lever.
2
(Internal defect) a If voltage is normal but travel alarm does not sound, travel alarm is
defective.
Voltage Between M14 (female) (1) and (2) 20 to 30 V
harness 2. Disconnect connectors M14 and CP02, and connect T-adapters to each
defective contact of Between CP02 (female) (107) and M14 (female) (1) Max. 1 z
Between M14 (female) (2) and ground Max. 1 z
harness 2. Disconnect connectors CP02 and M14, and connect T-adapter to either
4 female side.
Between CP02 (female) (107) and ground, or M14
circuit) Resistance (female) (1) and ground Min. 1 Mz
40-400 PC138USLC-10
40 Troubleshooting
E-36 Alarm does not stop sounding while machine is stopped (PC138-KB5-400-A-
Z0-A)
Failure Alarm does not stop sounding while machine is stopped.

Related
information
Defective travel PPC oil
pressure sensor system Perform troubleshooting for “E-49 Travel is not displayed correctly with
1
(Internal open or short monitoring function”.
circuit)
Hot short circuit in 2. Disconnect connector M14 and connect T-adapter to female side.
Voltage Between M14 (female) (1) and ground Max. 1 V
PC138USLC-10 40-401
40 Troubleshooting
E-37 Horn does not sound (PC138-KA2-400-A-Z0-A)
Failure Horn does not sound.

Related
information
If fuse F01-15 is burnt out, circuit probably has ground fault. In this case,
1 Defective fuse F01-5 perform check on Cause 7 first.
Defective horn switch 1. Turn starting switch to OFF position.

circuit) Between S10 (male) (1) Switch: OFF Min. 1 Mz
Resistance and (2)
Switch: ON Max. 1 z
Defective horn (M07) 1. Turn starting switch to OFF position.
3 (internal open or short 2. Disconnect connector M07 and connect T-adapter to male side.
circuit) Continuity Between M07 (male) (1) and (2) Continuity
Defective wiring
harness
4. Press R.H. knob switch.
Voltage Between M07 (female) (1) and (2) 20 to 30 V
Continuity Between M07 (female) (1) and ground Continuity
Open circuit in wiring a If no failure is found by check on Cause 4 or preceding check, this check is
harness not required.
5 (Wire breakage or 1. Turn starting switch to OFF position.
defective contact of 2. Remove fuse F01-5.
connector) 3. Disconnect connectors M07 and S10, and connect T-adapters to each
female side.
Between F01-5 and S10 (female) (1) Max. 1 z
Resistance Between S10 (female) (2) and M07 (female) (1) Max. 1 z
Between M07 (female) (2) and ground Max. 1 z
Ground fault in wiring a If fuse is not burnt out, this check is not required.
6 2. Remove fuse F01-5.
circuit) 3. Disconnect connector M07, and connect T-adapter to female side of M07.
Resistance Between M07 (female) (1) and ground Min. 1 Mz
Defective horn
7 If no failure is found by preceding checks, horn may be defective.
(Internal defect)
Circuit diagram related to horn
40-402 PC138USLC-10
40 Troubleshooting
E-38 Horn does not stop sounding (PC138-KB2-400-A-Z0-A)
Failure Horn does not stop sounding.

Related
information
Defective horn switch 1. Turn starting switch to OFF position.

circuit) Between S10 (male) (1) Switch: OFF Min. 1 Mz
Resistance and (2)
Switch: ON Max. 1 z
Hot short circuit in 2. Disconnect connector M07, and connect T-adapter to female side.
Voltage Between M07 (female) (2) and (1) Max. 1 V
Circuit diagram related to horn
PC138USLC-10 40-403
40 Troubleshooting
E-39 Wiper monitor does not light up, or does not go out, while wiper
switch is operated (PC138-FG4-400-A-Z0-A)
Failure Wiper monitor does not light up or does not go out while wiper switch is operated.
• Condition of wiper switch signal can be checked with monitoring function.
Related information (Code: 04504)
monitor
40-404 PC138USLC-10
40 Troubleshooting
E-40 Wiper does not operate while wiper switch is operated (PC138-FG0-400-A-Z0-A)
Failure Wiper does not operate while wiper switch is operated.

• Condition of window rear limit switch signal can be checked with monitoring function.
information • Wiper motor is troubleshooted for failure codes [DY20KA], [DY20MA], [DY2DKB], and
[DY2EKB].
Defective rear limit 2. Disconnect connector W03.
1 switch for window Front window: When
Min. 1 Mz
(internal short circuit) Between W03 (male) (1) closed
Resistance and (2) Front window: When
pulled up Max. 1 z

2 2. Disconnect connector M05 and connect T-adapter to female side.
Continuity Between M05 (female) (1) and (3) Continuity
a Wiper motor system
Open circuit in wiring See troubleshooting for [DY20KA], [DY20MA], [DY2DKB], and [DY2EKB].
harness
a Rear limit switch system
3 (Wire breakage or
defective contact of 1. Turn starting switch to OFF position.
connector) 2. Disconnect connector CP01 and connect T-adapter to female side.
3. Front window: When pulled up
Resistance Between CP01 (female) (76) and ground Max. 1 z
harness 2. Disconnect connector CP01 and connect T-adapter to female side.
4
(Contact with ground 3. Front window: When closed
circuit) Resistance Between CP01 (female) (76) and ground Min. 1 Mz
5
PC138USLC-10 40-405
40 Troubleshooting
Circuit diagram related to wiper motor
40-406 PC138USLC-10
40 Troubleshooting
E-41 Window washer does not operate while window washer switch is
operated (PC138-FH0-400-A-Z0-A)
Failure Window washer does not operate while window washer switch is operated.
• Condition of window washer switch signal can be checked with monitoring function.
information • Failure in window washer is expressed by failure code [DY2CKB].
monitor
PC138USLC-10 40-407
40 Troubleshooting
E-42 Boom Lower is not displayed correctly with monitoring

function (PC138-FFR-400-A-Z0-A)
Failure "Boom LOWER" is not displayed correctly with monitoring function.
• Monitoring code: 01900
Related • Use "short socket adapter": 799-601-7230 for 2-pin X connector in test for Cause 6.
information • As pump controller connector uses "socket-type box" T-adapter, operating voltage cannot
Defective boom 3. Start engine.
LOWER PPC oil 4. Operate R.H. work equipment control lever and perform troubleshooting.
1 pressure switch R.H. work equipment
(internal open or short Min. 1 Mz
circuit) Between P06 (male) (1) control lever: NEUTRAL
Resistance and (2) R.H. work equipment
control lever: Boom Max. 1 z
LOWER
2. Insert T-adapter in connector P06.
3. Start engine.
Defective harness or 4. Operate R.H. work equipment control lever and perform troubleshooting.
2 pump controller R.H. work equipment Approx. 7 V
control lever: NEUTRAL
Voltage Between P06 (2) and (1) R.H. work equipment
control lever: Boom Max. 1 V
LOWER
harness (wire breakage 2. Disconnect connectors CP01 and P06 and connect T-adapters to each
3 or defective contact of female side.
Resistance
Between P02 (female) (1) and ground (T06) Max. 1 z
4 harness (contact with 2. Disconnect connectors CP01 and P06, and connect T-adapter to either
ground circuit) female side.
Resistance (female) (2) Max. 1 Mz

5 wiring harness 2. Disconnect connector P06 and connect T-adapter to female side.
Voltage Between P06 (female) (2) and ground Approx. 7 V
3. Connect "short socket adapter" to female side of T-adapter.
Pump controller is 4. Turn starting switch to ON position.
6
defective. If voltage between P06 (2) and (1) is below 1 V but "Boom LOWER" is
displayed "OFF", pump controller is defective.
a After finishing test, restore connector.
40-408 PC138USLC-10
40 Troubleshooting
Circuit diagram related to boom LOWER oil pressure switch
PC138USLC-10 40-409
40 Troubleshooting
E-43 Arm OUT is not displayed correctly with monitoring function (PC138-FFS-
400-A-Z0-A)
Failure "Arm OUT" is not displayed correctly with monitoring function.

Defective Arm OUT 3. Start engine.
PPC oil pressure switch 4. Operate L.H. work equipment control lever and perform troubleshooting.
1 (internal open or short L.H. work equipment
circuit) Between P02 (male) (1) control lever: NEUTRAL Min. 1 Mz
Resistance and (2)
L.H. work equipment
Max. 1 z
control lever: Arm OUT
3. Start engine.
Defective harness or 4. Operate L.H. work equipment control lever and perform troubleshooting.
2 pump controller L.H. work equipment Approx. 7 V
Voltage Between P02 (2) and (1) control lever: NEUTRAL
L.H. work equipment
Max. 1 V
control lever: Arm OUT
Resistance

Pump controller is 3. Connect "short socket adapter" to female side of T-adapter.
defective.
If voltage between P02 (2) and (1) is below 1 V but "Arm OUT" is displayed
"OFF", pump controller is defective.
40-410 PC138USLC-10
40 Troubleshooting
Circuit diagram related to arm OUT oil pressure switch
PC138USLC-10 40-411
40 Troubleshooting
E-44 Arm IN is not displayed correctly with monitoring function (PC138-FFN-400-

A-Z0-A)
Failure "Arm IN" is not displayed correctly with monitoring function.

Defective arm IN PPC 3. Start engine.
oil pressure switch 4. Operate L.H. work equipment control lever and perform troubleshooting.
1 (internal open or short L.H. work equipment
circuit) Between P05 (male) (1) control lever: NEUTRAL Min. 1 Mz
Resistance and (2)
L.H. work equipment
Max. 1 z
control lever: Arm IN
3. Start engine.
Defective harness or 4. Operate L.H. work equipment control lever and perform troubleshooting.
2 pump controller L.H. work equipment Approx. 7 V
Voltage Between P05 (2) and (1) control lever: NEUTRAL
L.H. work equipment
Max. 1 V
control lever: Arm IN
Resistance

6
defective. If voltage between P05 (2) and (1) is below 1 V but "Arm IN" is displayed
40-412 PC138USLC-10
40 Troubleshooting
Circuit diagram related to arm IN oil pressure switch
PC138USLC-10 40-413
40 Troubleshooting
E-45 Boom Raise is not displayed correctly with monitoring

function (PC138-FFM-400-A-Z0-A)
Failure "Boom RAISE" is not displayed correctly with monitoring function.
Defective boom RAISE 3. Start engine.
PPC oil pressure switch 4. Operate R.H. work equipment control lever and perform troubleshooting.
1 (internal open or short R.H. work equipment
Min. 1 Mz
control lever: Boom Max. 1 z
RAISE
3. Start engine.
control lever: Boom Max. 1 V
RAISE
Resistance

6
defective. If voltage between P03 (2) and (1) is below 1 V but "Boom RAISE" is
40-414 PC138USLC-10
40 Troubleshooting
Circuit diagram related to boom RAISE oil pressure switch
PC138USLC-10 40-415
40 Troubleshooting
E-46 Bucket Curl is not displayed correctly with monitoring

function (PC138-FFP-400-A-Z0-A)
Failure "Bucket CURL" is not displayed correctly with monitoring function.
Related • Use "short socket adapter: 799-601-7230 for 2-pin X connector in test for Cause 6.
Defective bucket CURL 3. Start engine.
Min. 1 Mz
control lever: Bucket Max. 1 z
CURL
3. Start engine.
control lever: Bucket Max. 1 V
CURL
Resistance

defective.
If voltage between P04 (2) and (1) is below 1 V but "Bucket CURL" is
40-416 PC138USLC-10
40 Troubleshooting
Circuit diagram related to bucket CURL oil pressure switch
PC138USLC-10 40-417
40 Troubleshooting
E-47 Bucket Dump is not displayed correctly with monitoring

function (PC138-FFQ-400-A-Z0-A)
Failure "Bucket DUMP" is not displayed correctly with monitoring function.
Defective bucket DUMP 3. Start engine.
Min. 1 Mz
control lever: Bucket Max. 1 z
DUMP
3. Start engine.
control lever: Bucket Max. 1 V
DUMP
Resistance

defective.
If voltage between P01 (2) and (1) is below 1 V but "Bucket DUMP" is
40-418 PC138USLC-10
40 Troubleshooting
Circuit diagram related to bucket DUMP oil pressure switch
PC138USLC-10 40-419
40 Troubleshooting
E-48 Swing is not displayed correctly with monitoring function (PC138-FFT-400-A-

Z0-A)
Failure "Swing" is not displayed correctly with monitoring function.

2. Disconnect connectors P08 and P07, and connect T-adapters to each
male side.
Defective swing PPC oil 3. Start engine.
pressure switch 4. Operate swing lever to perform troubleshooting.
1 (internal open or short
Between P08 (male) (1) Swing lever: NEUTRAL Min. 1 Mz
circuit)
and (2) Swing lever: Right swing Max. 1 z
Resistance
Between P07 (male) (1) Swing lever: NEUTRAL Min. 1 Mz
and (2) Swing lever: Left swing Max. 1 z
2. Insert T-adapters into connectors P08 and P07.
3. Start engine.
Defective harness or 4. Operate swing lever to perform troubleshooting.
2 pump controller Swing lever: NEUTRAL Approx. 7 V
Between P08 (2) and (1)
Swing lever: Right swing Max. 1 V
Voltage
Swing lever: NEUTRAL Approx. 7 V
Between P07 (2) and (1)
Swing lever: Left swing Max. 1 V
Open circuit in wiring 2. Disconnect connectors CP01, P08, and P07, and connect T-adapters to
harness (wire breakage each female side.
3 or defective contact of Between CP01 (female) (31) and P08 (female) (2) Max. 1 z
connector) Between P08 (female) (1) and ground (T06) Max. 1 z
Resistance
Between CP01 (female) (31) and P07 (female) (2) Max. 1 z
4 harness (contact with 2. Disconnect connectors CP01, P08, and P07, and connect T-adapter to
ground circuit) any of female sides.
Between ground and CP01 (female) (31), P08
Resistance (female) (2), or P07 (female) (2) Min. 1 Mz

Hot short circuit in 2. Disconnect connectors P08 and P07 and connect T-adapter to either
5 wiring harness female side.
Between ground and P08 (female) (2) or P07
Voltage Approx. 7 V
(female) (2)
2. Disconnect connectors P08 and P07 and connect T-adapter to either
female side.
Pump controller is
6 3. Connect "short socket adapter" to female side of T-adapter.
defective.
If voltage between P08 (2) and (1) is below 1 V but "Swing" is displayed
40-420 PC138USLC-10
40 Troubleshooting
Circuit diagram related to swing PPC oil pressure switch
PC138USLC-10 40-421
40 Troubleshooting
E-49 Travel is not displayed correctly with monitoring function (PC138-FFU-400-A-

Z0-A)
Failure "Travel" is not displayed correctly with monitoring function.

Related • Monitoring code: 01901
information
Defective travel PPC oil
pressure sensor system Perform troubleshooting for failure codes [DHSFMA], [DHSGMA], [DHSHMA]
1
(Internal open or short and [DHSJMA].
circuit)
40-422 PC138USLC-10
40 Troubleshooting
E-50 Service is not displayed correctly with monitoring function (PC138-FFW-

400-A-Z0-A)
Failure Service is not displayed correctly with monitoring function.

Related • For safety, use "short socket adapter" 799-601-7230 for 2-pin X connector in tests for
information Causes 1 and 2.
k Do not check oil pressure switch connector while engine is running.
A. If monitoring function does not indicate that attachment control pedal is
operated when engine is started and attachment control pedal is depressed at
front end
2. Disconnect connector P14 and connect "short socket adapter" to male
side.
Defective PPC oil
pressure switch (P14) a After finishing test, restore connectors.
1 for front end of • If monitoring function indicates that "Service" is "ON", PPC oil pressure
attachment control switch (P14) for front end of attachment control pedal is defective (Note 1).
pedal
B. If monitoring function indicates that attachment control pedal is operated
when starting switch is turned to ON position
• If monitoring function indicates that "Service" is "OFF", PPC oil pressure
switch (P14) for front end of attachment control pedal is defective (Note 2).
A. If monitoring function does not indicate that attachment control pedal is
operated when engine is started and attachment control pedal is depressed at
rear end
2. Disconnect connector P15 and connect "short socket adapter" to male
side.
Defective PPC oil
pressure switch (P15) a After finishing test, restore connectors.
2 for rear end of • If monitoring function indicates that "Service" is "ON", PPC oil pressure
attachment control switch (P15) for rear end of attachment control pedal is defective (Note 1).
pedal
B. If monitoring function indicates that attachment control pedal is operated
when starting switch is turned to ON position
2. Disconnect P15.
• If monitoring function indicates that "Service" is "OFF", PPC oil pressure
switch (P15) for rear end of attachment control pedal is defective (Note 2).
2. Insert T-adapter into P13.
3. Start engine.
Defective wiring 4. Operate attachment control pedal, and perform troubleshooting.
3 harness or pump Attachment control
controller Between P13 (1) and (2) Approx. 7 V
pedal: NEUTRAL
Voltage Attachment control
Between P13 (1) and (2) pedal: front end or rear Max. 1 V
end
PC138USLC-10 40-423
40 Troubleshooting

Open circuit in wiring 2. Disconnect connectors CP01, P14, and P15, and connect T-adapters to
4 (Wire breakage or Between CP01 (female) (35) and P14 (female) (1) Max. 1 z
defective contact of Between CP01 (female) (35) and P15 (female) (1) Max. 1 z
harness 2. Disconnect connectors CP01, P14, and P15, and connect T-adapter to
5 any of female sides.
circuit) Between ground and CP01 (female) (35), P14
Resistance (female) (1), or P15 (female ) (1) Min. 1 Mz

2. Disconnect connectors P14 and P15, and connect T-adapter to either
Short circuit in wiring female side.
harness
Between ground and P14 (female) (1) or P15
Voltage Approx. 7 V
(female) (1)
7
Note 1: If monitoring function indicates that "attachment control pedal" is "released" while voltage between
CP01 (35) and ground is below 1 V, pump controller is defective.
Note 2: If monitoring function indicates that "attachment control pedal" is "operated" while voltage between
CP01 (35) and ground is approximately 7 V, pump controller is defective.
Circuit diagram related to attachment control pedal PPC oil pressure switch (service pressure switch)
40-424 PC138USLC-10
40 Troubleshooting
E-51 Attachment hydraulic circuit cannot be changed (PC138-HBD-400-A-Z0-A)
• Attachment circuit cannot be changed.

Failure 1) When working mode P or E is selected, crusher circuit (2-way circuit) is not selected.
2) When working mode B is selected, breaker circuit (one-way circuit) is not selected.
Related • Failures (open circuit/short circuit) of attachment oil return selector solenoid are explained
information by failure codes [DWA2KA] and [DWA2KB].
Defective attachment oil 2. Disconnect connector V06, and connect T-adapter to male side.
1 return selector solenoid
(internal short circuit) Between V06 (male) (1) and (2) 20 to 60 z
Resistance
Circuit diagram related to attachment oil return selector solenoid
PC138USLC-10 40-425
40 Troubleshooting
E-52 KOMTRAX system does not operate normally (PC138-F50-400-A-Z0-A)
Failure KOMTRAX system does not operate normally.

• Perform following troubleshooting if administrator of KOMTRAX system requests to check
Related whether failure occurs in system on machine.
information • Even when KOMTRAX system is defective, no problem appears on machine.
• Check all results of troubleshooting on service menu display of machine monitor.
Defective 2. Display "Terminal status" screen.
1
communication 1 Monitoring
Check item: Station set-up check Complete
display
2. Display "GPS & Communication Status" screen.
N ###.##.## (Latitude)
Defective positioning by Monitoring
2 Check item: Positioning E ###.##.## (Longitude)
GPS display
Positioning in Progress
If latitude and longitude are not displayed within 5 minutes under the open
sky, contact KOMTRAX service hot line.
2. Display "GPS & Communication Status" screen.
Defective Monitoring Satellite in View or No
3 communication display Check item: Communication
Satellite in View
environment If Communication Status does not display "Satellite in view" within 15 minutes
under the open sky, check whether the connector of TC330 or the antenna on
top of cab is properly connected.
Defective 2. Display "GPS & Communication Status" screen.
4
communication 2 Monitoring Check item: Number of message(s)
0 to 60 (normally 0)
display not yet sent
a Select "01 Terminal Status" from "11 KOMTRAX settings" in service menu of machine monitor.
a Select "GPS & Communication Status" from "11 KOMTRAX settings" in service menu of machine monitor.
40-426 PC138USLC-10
40 Troubleshooting
PC138USLC-10 40-427
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)
Troubleshooting of hydraulic and mechanical system (H-mode) (ALL-

3840-001-A-02-A)
Information described in troubleshooting table (H-mode) (ALL-5170-010-A-00-A)
(Rev. 2011/03)
Failure Failure symptom that appears on machine
Related Information on occurred failure or troubleshooting
information
1
2 Probable cause of failure <Contents of description>
(Each number is serial
3 number, not priority • Criteria to determine probable causes
4 sequence.) • Remarks for determination of probable cause
5
40-428 PC138USLC-10
40 Troubleshooting
mode)
System chart of hydraulic and mechanical systems (PC138-C000-054-K-00-A)
*: Only machines with ATT
PC138USLC-10 40-429
40 Troubleshooting
mode)
a This is a system chart that has been drawn up by simplifying the whole hydraulic circuit chart. Use it as a
reference material when troubleshooting the hydraulic and mechanical systems.
*: Only machines with ATT
40-430 PC138USLC-10
40 Troubleshooting
mode)
Failure mode and cause table (PC138-5340-40D-A-Z0-A)

Component causing failure
Tank Hydraulic pump
Troubleshooting code
Check valve, shuttle valve
Engine system
PC-EPC valve
Hydraulic oil
Servo piston
Piston pump
PC valve
LS valve
Strainer
Damper
Cap
Failure mode
All work equipment, and swing and travel system operate slowly or lack
q q q q q q q q H-1
power
Engine speed lowers extremely or engine stalls q q q q q q H-2
Whole work equipment
Any of work equipment, travel and swing does not work q q q H-3
Swing, travel
Unusual noise is heard from around hydraulic pump q q q q H-4
Fine control performance or response is poor q q H-5
Boom speed or power is low H-6
Arm speed or power is low H-7
Bucket speed or power is low H-8

Work equipment
Work equipment does not move in single operation H-9
Boom H-10
Hydraulic drift of work equipment is large Arm H-11
Bucket H-12
Time lag of work equipment is large H-13

In combined operation of work equipment, equipment having heavier load
H-14
moves slower
Swing +
Boom
In combined operations of swing and boom RAISE, boom rising speed is

H-15
low
Swing +
Travel
In combined operation of swing and travel, travel speed drops largely H-16
Machine does not travel straight q H-17
Travel speed is slow H-18

Travel
Machine is hard to steer or travel power is low q H-19
Travel speed does not change, or travel speed is too slow or fast H-20
One of tracks does not run H-21

Upper structure does not
H-22
swing to the right or left
Machine does not swing
Upper structure swing only
H-23
to the right or left
In both directions (right and
H-24
Swing acceleration or swing speed is low left)
Swing
In only one direction H-25
Upper structure overruns excessively when it (Both right and left) H-26
stops swinging (Either right or left) H-27
Shock is large when upper structure stops swinging H-28
Large unusual noise is heard when upper structure stops swinging H-29
PC138USLC-10 40-431
40 Troubleshooting
mode)

Tank Hydraulic pump
Check valve, shuttle valve
Engine system
PC-EPC valve
Hydraulic oil
Servo piston
Piston pump
PC valve
LS valve
Strainer
Damper
Cap
Failure mode
When parking brake works H-30
Swing drift on a slope is large
When parking brake is OFF H-31
Attachment circuit cannot be changed H-32

Attachment
Oil flow in attachment circuit cannot be controlled H-33
40-432 PC138USLC-10
40 Troubleshooting
mode)

Control valve
Pressure compensation valve
Self-pressure reducing valve
Service valve (safety valve)
Boom regeneration valve
Arm regeneration valve
Swing LS select valve
Travel junction valve
Back pressure valve

Merge-divider valve
Main relief valve
Boom lock valve

LS line orifice
Suction valve
Unload valve
Safety valve
Spool
Failure mode
All of work equipment, swing and travel operation lacks speed or
q q q H-1
power
Engine speed drops significantly or engine stalls H-2
Any of work equipment, swing and travel does not work q H-3
Swing, travel
Unusual noise is heard from around hydraulic pump H-4
Fine control performance or response is poor q H-5
Boom speed or power is low q q q q q H-6
Arm speed or power is low q q q q H-7
Bucket speed or power is low q q q H-8

Work equipment
Work equipment does not move in single operation q q H-9
Boom q q q H-10
Hydraulic drift of work equipment is large Arm q q q H-11
Bucket q q q q H-12
Time lag of work equipment is large q q H-13

In combined operation of work equipment, equipment having heavier
q H-14
load moves slower
Swing +
In combined operations of swing and boom RAISE, boom rising

Boom
q H-15
speed is low
Swing +
Travel
In combined operation of swing and travel, travel speed drops largely q q q H-16
Machine does not travel straight q q q q q H-17
Travel speed is slow q q q q q q H-18

Travel
Machine is hard to steer or travel power is low q q q q q H-19
Travel speed does not change, or travel speed is too slow or fast H-20
One of tracks does not run q q H-21

Upper structure does
not swing to the right or q q H-22
Machine does not swing left
Upper structure swing
q H-23
only to the right or left
Poor or low for both of
Swing acceleration or swing speed is low in q H-24
the right and left
Swing
both directions (right and left)

in only one direction q q H-25
stops swinging (Either right or left) q H-27
Large unusual noise is heard when upper structure stops swinging q H-29
PC138USLC-10 40-433
40 Troubleshooting
mode)

Control valve
Pressure compensation valve
Self-pressure reducing valve
Service valve (safety valve)
Boom regeneration valve
Arm regeneration valve
Swing LS select valve
Travel junction valve
Back pressure valve

Merge-divider valve
Main relief valve
Boom lock valve

LS line orifice
Suction valve
Unload valve
Safety valve
Spool
Failure mode
When parking brake
H-30
Swing drift on a slope is large works
When parking brake is
q q H-31
OFF
Attachment circuit cannot be changed q H-32
Attachment
40-434 PC138USLC-10
40 Troubleshooting
mode)

Solenoid valve Swing motor
ATT oil flow adjustment EPC valve
Travel speed selector solenoid
Swing PPC slow return valve
Work equipment lock solenoid
Swing holding brake solenoid

Pump merge-divider solenoid
ATT return selector solenoid

ATT return selector valve
PPC valve (travel lever)

PPC valve (right lever)
PPC valve (left lever)
PPC valve (service)
Shock-less valve
Parking brake
Suction valve
Piston motor
Safety valve
Check valve
Failure mode
All of work equipment, swing and travel operation lacks speed or power H-1
Engine speed drops significantly or engine stalls q H-2

Any of work equipment, swing and travel does not work H-3
Swing, travel
Fine control performance or response is poor H-5
Boom speed or power is low q H-6
Arm speed or power is low q H-7
Bucket speed or power is low q H-8

Work equipment
Work equipment does not move in single operation q q H-9
Boom H-10
Hydraulic drift of work equipment is large Arm H-11
Bucket H-12

H-14
moves slower
Swing +
Boom

H-15
low
Swing +
Travel
In combined operation of swing and travel, travel speed drops largely q H-16
Machine does not travel straight q q q H-17
Travel speed is slow q q H-18

Travel
Machine is hard to steer or travel power is low q q q H-19
Travel speed does not change, or travel speed is too slow or fast q H-20
One of tracks does not run H-21

q q q q H-22
q q q q H-23
(In both directions (right
q q q H-24
and left)
Swing
Swing acceleration or swing speed is low

In only one direction q q q q q H-25
Upper structure overruns excessively when it (Both right and left) q q H-26
stops swinging (Either right or left) q q q q q q H-27
Shock is large when upper structure stops swinging q q q q H-28
PC138USLC-10 40-435
Attachment
mode)
40-436
Failure mode

40 Troubleshooting
Attachment circuit cannot be changed
Oil flow in attachment circuit cannot be controlled

Large unusual noise is heard when upper structure stops swinging
When parking brake works
When parking brake is OFF

PPC valve (right lever)

PPC valve (left lever)

PPC valve (travel lever)
q
PPC valve (service)
q Swing PPC slow return valve
ATT return selector valve
q
ATT oil flow adjustment EPC valve
Work equipment lock solenoid
Travel speed selector solenoid
Pump merge-divider solenoid
Solenoid valve
Swing holding brake solenoid

q
ATT return selector solenoid

Piston motor
q
q
Safety valve
q
Check valve
q
q
Suction valve
Swing motor
Shock-less valve
q
Parking brake
H-33
H-32
H-31
H-30
H-29
PC138USLC-10
40 Troubleshooting
mode)

Travel motor
Counterbalance valve
Center swivel joint
Hydraulic cylinder
Swing machinery
Parking brake
Piston motor
Safety valve
Check valve
Final drive
Failure mode
All of work equipment, swing and travel operation lacks speed or power H-1
Engine speed drops significantly or engine stalls H-2

Any of work equipment, swing and travel does not work H-3
Swing, travel
Fine control performance or response is poor H-5
Boom speed or power is low q H-6
Arm speed or power is low q H-7
Bucket speed or power is low q H-8

Work equipment
Work equipment does not move in single operation H-9
Boom q H-10
Hydraulic drift of work equipment is large Arm q H-11
Bucket q H-12

H-14
moves slower
Swing +
Boom

H-15
low
Swing +
Travel
In combined operation of swing and travel, travel speed drops largely H-16
Machine does not travel straight q q q q q H-17
Travel speed is slow q q H-18

Travel
Machine is hard to steer or travel power is low q q q q H-19
Travel speed does not change, or travel speed is too slow or fast q H-20
One of tracks does not run q q q q q q H-21

q H-22
H-23
(In both directions (right
q H-24
Swing acceleration or swing speed is low and left)
In only one direction H-25
Swing
stops swinging (Either right or left) H-27
Large unusual noise is heard when upper structure stops swinging q H-29
When parking brake works H-30

When parking brake is OFF H-31
PC138USLC-10 40-437
40 Troubleshooting
mode)

Travel motor
Counterbalance valve
Center swivel joint
Hydraulic cylinder
Swing machinery
Parking brake
Piston motor
Safety valve
Check valve
Final drive
Failure mode
Attachment circuit cannot be changed H-32
Attachment
40-438 PC138USLC-10
40 Troubleshooting
mode)
H-1 All of work equipment, swing and travel operation lacks speed or
power (PC138-A8A-400-A-Z0-A)
Failure • All of work equipment, swing and travel operation lacks speed or power.
• Perform all troubleshooting with working mode set in power (P) mode.
Related • If any failure code is displayed, perform troubleshooting for that failure code first.
information (DXA8KA or DXA8KB)
• Pump pressure can be checked with monitoring function. (monitoring code: 01100)
a Be ready with engine stopped, then perform troubleshooting with engine at
Malfunction of unload high idle.
1
valve 2.8 ± 1.0 MPa
Unload pressure All levers in NEUTRAL
{28 ± 10 kg/cm2}
high idle.
Malfunction of main
2 34.8 (+2.0 /-1.0)
relief valve
Main relief pressure Arm IN hydraulic relief {355 (+20/-10) kg/
cm2}
Malfunction of main When pressure cannot be adjusted to normal level, check main relief valve for
3 malfunction (fatigue of spring) and internal defect (defective valve seat).
relief valve
high idle.
Malfunction of self- Control circuit 3.2 ± 0.5 MPa
4 pressure reducing valve source pressure All levers in NEUTRAL
{33 ± 5 kg/cm2}
a Since relief valve of self-pressure reducing valve is not adjustable, replace
self-pressure reducing valve assembly if normal pressure is not obtained.
a Be ready with engine stopped, then perform troubleshooting with engine
running at low idle and at high idle.
Engine at low idle and all levers in 2.9 MPa
Malfunction of PC-EPC
5 PC-EPC valve NEUTRAL {30 kg/cm2}
valve
output pressure Engine at high idle and all levers 3.4 MPa
in NEUTRAL {35 kg/cm2}
Replace PC-EPC valve if any failure is found.
high idle.
Oil pressure to be Oil pressure ratio
Measurement condition
measured
Pump discharge Swing lock switch: ON
Defective adjustment of 1
6 pressure Arm IN hydraulic relief
PC valve
PC valve output Swing lock switch: ON Approx. 0.6 (Approx.
pressure Arm IN hydraulic relief 3/5)
When pressure cannot be adjusted to normal level, check PC valve for
malfunction (fatigue of spring) or internal defect (stuck or seized PC spool).
PC138USLC-10 40-439
40 Troubleshooting
mode)

high idle.
Lever position and oil pressure ratio
L.H. track: Running
Oil pressure to be idle off ground in Hi
Defective adjustment of measured All levers in NEUTRAL speed setting
7
LS valve Lever moved
halfway
Pump discharge Almost same as LS valve output
pressure pressure 1
LS valve output Almost same as pump discharge Approx. 0.6 (Approx.
pressure pressure 3/5)
If normal oil pressure is not obtained after adjustment, check LS valve for
8 Malfunction of LS valve malfunction (fatigue of spring) and internal failure (stuck or seized LS spool).
Malfunction of servo
9 piston or PC valve (*) Servo piston may malfunction. Check it.
If no failure is found by above checks, piston pump may have degraded
Malfunction of piston performance, malfunction, or have internal failure.
10 pump
Check hydraulic tank strainer and return filter element for metal particles.
40-440 PC138USLC-10
40 Troubleshooting
mode)
H-2 Engine speed drops significantly or engine stalls (PC138-FPN-400-A-Z0-A)
Failure • Engine speed drops significantly or engine stalls.

Related • If any failure code is displayed, perform troubleshooting for that failure code first.
information (DXA8KA or DXA8KB)
high idle.
Malfunction of main
1 34.8 (+2.0/-1.0) MPa
relief valve
Main relief pressure Arm IN hydraulic relief {355 (+20/-10) kg/
cm2}
Malfunction of main When pressure cannot be adjusted to normal level, check main relief valve for
2 malfunction (fatigue of spring) and internal defect (defective valve seat).
relief valve
running at low idle and at high idle.
Malfunction of PC-EPC Engine at low idle and all levers in 2.9 MPa
3
valve PC-EPC valve NEUTRAL {30 kg/cm2}
output pressure Engine at high idle and all levers 3.4 MPa
in NEUTRAL {35 kg/cm2}
high idle.
Oil pressure to be Oil pressure ratio
Measurement condition
Defective adjustment of measured
4 Swing lock switch: ON
PC valve Pump discharge
pressure 1
Arm IN hydraulic relief
PC valve output Swing lock switch: ON Approx. 0.6 (Approx.
pressure Arm IN hydraulic relief 3/5)
When pressure cannot be adjusted to normal level, check PC valve for
5 Malfunction of PC valve malfunction (fatigue of spring) or internal defect (stuck or seized PC spool).

high idle.
Running track idle
Oil pressure to be off ground
measured All levers in NEUTRAL
Defective adjustment of (Lever moved
6 halfway)
LS valve
Pump discharge pressure is
Pump discharge
almost same as LS valve 1
pressure
pressure.
Pump discharge pressure is
LS valve output Approx. 0.6 (Approx.
almost same as LS valve
pressure 3/5)
pressure.
If normal oil pressure is not obtained after adjustment, check LS valve for
7 Malfunction of LS valve malfunction (fatigue of spring) and internal failure (stuck or seized LS spool).
Clogging of orifice or Check orifices and filters in pump servo devices for clogging.
8
filter in serve device
If no failure is found by above checks, piston pump may malfunction or have
Malfunction of servo internal defect.
9 piston
Check hydraulic tank strainer and return filter element for metal particles.
PC138USLC-10 40-441
40 Troubleshooting
mode)
H-3 Any of work equipment, swing and travel does not work (PC138-FT5-400-A-Z1-A)
Failure • Any of work equipment, swing and travel does not work.
Related • Perform all troubleshooting with working mode set in power (P) mode.
information
high idle.
Malfunction of work 0 MPa
1 equipment lock When locked
solenoid valve Solenoid output {0 kg/cm2}
pressure When torque converter lockup 2.84 to 3.43 MPa
clutch is disengaged {29 to 35 kg/cm2}
high idle.
2 pressure reducing valve source pressure All control levers in NEUTRAL
{33 ± 5 kg/cm2}
Piston pump may malfunction or has internal defect. Check it by following
method.
3 Defective piston pump
• Crank the engine with main oil pressure pickup port plug removed. o If
any oil flows out, piston pump is normal.
4 Defective damper Pump shaft may not rotate due to some internal defect of damper.
40-442 PC138USLC-10
40 Troubleshooting
mode)
H-4 Unusual sound is heard from around hydraulic pump (PC400-BAA-400-A-Z0-A)
Failure • Unusual sound is heard from around hydraulic pump

Related information —
Check hydraulic oil level directly.
1 Lowering of hydraulic oil level (Reference) If the hydraulic oil level is low while no hydraulic oil leaks to
the outside, it is assumed that hydraulic oil may flow in the flywheel
chamber due to a pump shaft seal damage.
2 Defective hydraulic oil Air may mix in hydraulic oil. Check it for bubbles or milky state.
Cap of the hydraulic tank cap may be clogged, causing negative
3 Clogging of hydraulic tank cap
pressure inside the tank. Check the cap.
Clogging of hydraulic tank Strainer in the hydraulic tank may be clogged, causing negative
4 pressure in the suction circuit. Check the strainer.
strainer
Clogging of hydraulic tank Check the return filter in the hydraulic tank may be clogged, especially
5 by metallic materials. Check the return filter.
return filter
If any metallic materials are detected in Cause 4 and 5 above, piston
6 Defective piston pump
pump may have internal defect.
PC138USLC-10 40-443
40 Troubleshooting
mode)
H-5 Fine control performance or response is poor (PC138-FTB-400-A-Z0-A)
Failure • Fine control performance or response is poor.

information
Clogged orifice in LS Orifice may be clogged. Check it.
1
circuit
high idle.
Oil pressure to be Travel speed
Defective adjustment of measured All levers in NEUTRAL Lever moved
2
LS valve halfway
pressure pressure 1
When pressure cannot be adjusted to normal level, check LS valve for
3 Malfunction of LS valve malfunction (fatigue of spring) or internal defect (stuck or seized LS spool).
Malfunction of servo
4 Check orifices and filters in pump servo devices for clogging.
piston
40-444 PC138USLC-10
40 Troubleshooting
mode)
H-6 Boom speed or power is low (PC138-A8B-400-A-Z0-A)
Failure Boom speed or power is low.

information • Pump pressure can be checked with monitoring function. (monitoring code: 01100)
high idle.
Malfunction of R.H. R.H. work
1 PPC valve (boom equipment NEUTRAL 0 MPa {0 kg/cm2}
circuit) PPC valve output control lever
pressure R.H. work
Boom RAISE or 2.7 MPa {28 kg/cm2}
equipment
LOWER
control lever
high idle.
Malfunction of merge- Work equipment control lever is in 0 MPa
2
divider solenoid valve Output pressure of neutral {0 kg/cm2}
solenoid valve Bucket CURL and Arm IN 2.84 to 3.43 MPa
hydraulic relief {29 to 35 kg/cm2}
a Release remaining pressure from hydraulic tank and piping, and then
perform troubleshooting with engine stopped.
Malfunction of merge- • Check for stuck or seized main spool in merge-divider valve body.
3 divider main spool (Spool must move smoothly and must not be caught.)
• Remove main spool from valve body and check it for defects and dirt.
• Take care not to let foreign matter enter valve when re-installing spool.
Malfunction of merge- • Check for stuck or seized LS spool in merge-divider valve body.
4 divider LS spool (Spool must move smoothly and must not be caught.)
• Remove LS spool from valve body and check it for defects and dirt.
Malfunction of boom • Check for stuck or seized boom spool in control valve body.
5 control valve (spool) (Spool must move smoothly and must not be caught.)
• Remove boom spool from valve body and check it for defects and dirt.
high idle.
34.8 (+2.0/-1.5) MPa
Boom relief pressure Boom RAISE hydraulic relief {355 (+20/-15) kg/
Malfunction of boom cm2}
control valve (pressure a Check hydraulic drift of boom cylinder with engine stopped.
6 compensation valve)
(boom RAISE side) Hydraulic oil temperature within
operating range, bucket with rated If visible hydraulic
Hydraulic drift drift is observed, it is
load, boom horizontal, arm
cylinder fully retracted abnormal.
a Check whether boom cylinder moves slowly when performing hydraulic

relief of other work equipment. (If boom cylinder moves, it is abnormal.)
PC138USLC-10 40-445
40 Troubleshooting
mode)

a If any failure is found in either of above check items, interchange pressure
compensation valves on RAISE and LOWER sides, and check whether
failure symptom changes.
(Pressure compensation valves have different area ratio, so be sure to
return them to their original positions after test.)
high idle.
34.8 (+2.0/-1.5) MPa
Boom relief pressure Boom LOWER hydraulic relief {355 (+20/-15) kg/
cm2}
a Check hydraulic drift of boom cylinder with engine stopped.
Malfunction of boom Hydraulic oil temperature: Within
control valve (pressure operating range, arm cylinder fully If visible hydraulic
Hydraulic drift drift is observed, it is
7 compensation valve) extended, machine raised off
ground abnormal.
(boom LOWER side)
a Check whether boom cylinder moves slowly when performing hydraulic
relief of other work equipment. (If boom cylinder moves, it is abnormal.)
compensation valves on RAISE and LOWER sides, and check whether
(Pressure compensation valves have different area ratio, so be sure to
return them to their original positions after test.)
high idle.
Boom relief pressure Boom RAISE hydraulic relief, arm 34.8 (+2.0/-1.5) MPa
and arm relief IN hydraulic relief, or arm OUT {355 (+20/-15) kg/
Malfunction of boom pressure hydraulic relief cm2}
8 control valve (safety
valve for lock valve) a Among above relief pressures, if arm IN relief pressure and boom RAISE
relief pressure are low, safety valve may be defective. Check safety valve
for damaged sealing material.
a When disassembling the safety valve, replace the safety valve assembly
with a new one since its relief pressure cannot be adjusted on the
machine.
• Check that pilot piston and poppet are seated on body in position (they are
not stuck halfway).
• Check for stuck or seized pilot piston and poppet in lock valve body (pilot
Malfunction of boom
piston and poppet must move smoothly).
9 control valve (lock
• Remove pilot piston and poppet from valve body and check them for
valve)
defects and dirt.
• Check poppet spring for fatigue and deformation.
high idle.
34.8 (+2.0/-1.5) MPa
Boom relief pressure Boom RAISE hydraulic relief {355 (+20/-15) kg/
control valve (suction
10 valve) (boom RAISE a Among above relief pressures, if only boom RAISE relief pressure is low,
side) suction valve may be defective. Check it.
• Check that check valve is seated on valve body in position (it is not stuck
halfway).
• Remove check valve from valve body and check it for defects and dirt.
• Check spring for fatigue and deformation.
40-446 PC138USLC-10
40 Troubleshooting
mode)

high idle.
34.8 (+2.0/-1.5) MPa
Boom relief pressure Boom LOWER hydraulic relief {355 (+20/-15) kg/
control valve (suction-
11 safety valve) (boom a If boom LOWER relief pressure is low, suction-safety valve may be
defective.
LOWER side)
halfway).
machine.
12 Defective boom cylinder high idle.
Leakage from boom
Boom RAISE hydraulic relief Max. 15 cc/min
cylinder
PC138USLC-10 40-447
40 Troubleshooting
mode)
H-7 Arm speed or power is low (PC138-A8C-400-A-Z0-A)
Failure • Arm speed or power is low.

high idle.
L.H. work
Malfunction of left PPC 0 MPa {0 kg/cm2}
1 equipment NEUTRAL
valve (arm circuit) PPC valve output control lever
pressure L.H. work Arm IN or OUT
equipment 2.7 MPa {28 kg/cm2}
operation
control lever
high idle.
Malfunction of pump 0 MPa
2 merge-divider solenoid Work equipment control lever is in
valve Output pressure of neutral {0 kg/cm2}
Malfunction of arm • Check for stuck or seized arm spool in control valve body.
• Remove arm spool from valve body and check it for defects and dirt.
high idle.
34.8 (+2.0/-1.5) MPa
Arm relief pressure Arm IN hydraulic relief {355 (+20/-15) kg/
cm2}
a Check hydraulic drift of arm cylinder with engine stopped.
Malfunction of arm Hydraulic oil temperature: Within If visible hydraulic
control valve (pressure Hydraulic drift operating range, bucket with rated drift is observed, it is
6 compensation valve) load, arm cylinder fully extended abnormal.
(arm IN side)
a Check whether arm cylinder moves slowly when performing hydraulic
relief of other work equipment. (If arm cylinder moves, it is abnormal.)
compensation valves on bucket CURL and DUMP sides, and check
whether failure symptom changes.
(Each area ratio is different, so be sure to restore it after checking the
symptom.)
40-448 PC138USLC-10
40 Troubleshooting
mode)

high idle.
34.8 (+2.0/-1.5) MPa
Arm relief pressure Arm OUT hydraulic relief {355 (+20/-15) kg/
cm2}
a Check hydraulic drift of arm cylinder with engine stopped.
Malfunction of arm Hydraulic oil temperature: Within If visible hydraulic
control valve (pressure Hydraulic drift operating range, bucket with rated drift is observed, it is
7 compensation valve) load, arm cylinder fully retracted abnormal.
(arm OUT side)
a Check whether arm cylinder moves slowly when performing hydraulic
relief of other work equipment. (If arm cylinder moves, it is abnormal.)
symptom.)
high idle.
34.8 (+2.0/-1.5) MPa
Arm relief pressure Arm OUT hydraulic relief {355 (+20/-15) kg/
cm2}
Malfunction of arm
8 control valve (suction a If arm OUT relief pressure is low, suction valve (check valve) may be
valve) (arm OUT side) defective. Check it.
halfway).
• Remove check valve from valve body and check it for defects and dirt.
• Check spring for setting and deformation.
high idle.
34.8 (+2.0/-1.5) MPa
Malfunction of arm cm2}
9 safety valve) (arm IN a If arm IN relief pressure is low, suction-safety valve may be defective.
side) Check it.
• Check that check valve of suction-safety valve is seated on valve body in
position (it is not stuck halfway).
a Since relief pressure cannot be adjusted with safety valve installed on
machine, replace safety valve assembly if safety valve is found to be
defective.
10 Defective arm cylinder high idle.
Leakage from arm
Arm IN hydraulic relief Max. 15 cc/min
cylinder
PC138USLC-10 40-449
40 Troubleshooting
mode)
H-8 Bucket speed or power is low (PC138-A8D-400-A-Z0-A)
Failure • Bucket speed or power is low.

high idle.
Malfunction of R.H. R.H. work
1 PPC valve (bucket equipment NEUTRAL 0 MPa {0 kg/cm2}
circuit) PPC valve output control lever
pressure R.H. work
equipment Arm IN or OUT 2.7 MPa {28 kg/cm2}
control lever
high idle.
Malfunction of pump 0 MPa
2 merge-divider solenoid Work equipment control lever is in
valve Output pressure of neutral {0 kg/cm2}
Malfunction of bucket • Check for stuck or seized bucket spool in control valve body.
• Remove bucket spool from valve body and check it for defects and dirt.
high idle.
34.8 (+2.0/-1.5) MPa
Bucket relief
pressure Bucket CURL relief {355 (+20/-15) kg/
cm2}
a Check hydraulic drift of bucket cylinder with engine stopped.
Hydraulic oil temperature: Within
operating range,
Malfunction of bucket If visible hydraulic
Hydraulic drift bucket with rated load, arm drift is observed, it is
control valve (pressure cylinder fully retracted, bucket
5 compensation valve) abnormal.
cylinder fully extended, boom top
(bucket CURL side) face horizontal
a Check whether bucket cylinder moves slowly when performing hydraulic
relief of other work equipment. (If bucket cylinder moves, it is abnormal.)
symptom.)
40-450 PC138USLC-10
40 Troubleshooting
mode)

high idle.
34.8 (+2.0/-1.5) MPa
Bucket relief
Bucket DUMP hydraulic relief {355 (+20/-15) kg/
pressure
cm2}
a Check hydraulic drift of bucket cylinder with engine stopped.
Hydraulic oil temperature: Within
Malfunction of bucket operating range,
If visible hydraulic
control valve (pressure Hydraulic drift bucket empty, arm cylinder fully drift is observed, it is
6 compensation valve) retracted, bucket cylinder fully abnormal.
(bucket DUMP side) retracted, boom top face
horizontal
a Check whether bucket cylinder moves slowly when performing hydraulic
relief of other work equipment. (If bucket cylinder moves, it is abnormal.)
symptom.)
high idle.
34.8 (+2.0/-1.5) MPa
Bucket relief
pressure Bucket CURL relief {355 (+20/-15) kg/
Malfunction of bucket cm2}
control valve (suction- • If bucket CURL relief pressure is low, suction valve may be defective.
7 safety valve) (bucket Check it.
CURL side) • Check that check valve of suction-safety valve is seated on valve body in
defective.
high idle.
34.8 (+2.0/-1.5) MPa
Bucket relief
Bucket DUMP hydraulic relief {355 (+20/-15) kg/
Malfunction of bucket pressure
cm2}
control valve (suction- • If bucket DUMP relief pressure is low, suction valve may be defective.
8 safety valve) (bucket Check it.
DUMP side) • Check that check valve of suction-safety valve is seated on valve body in
defective.
Defective bucket high idle.
9 cylinder Leakage from
bucket cylinder Bucket CURL relief Max. 15 cc/min
PC138USLC-10 40-451
40 Troubleshooting
mode)
H-9 Work equipment does not move in single operation (PC138-FTC-400-A-Z0-A)
(1) Boom does not move in single operation.

Failure (2) Arm does not move in single operation.
(3) Bucket does not move in single operation.
information
at high idle.
1 Malfunction of PPC valve Work equipment 0 MPa {0 kg/cm2}
NEUTRAL
PPC valve output control lever
pressure Work equipment 2.7 MPa {28 kg/
Operation
control lever cm2}
Malfunction of boom • Check for stuck or seized boom spool in control valve body.
2 control valve (spool)
(Spool must move smoothly and must not be caught.)
• Remove boom spool from valve body and check it for defects and dirt.
Malfunction of arm control • Check for stuck or seized arm spool in control valve body.
3 valve (spool)
4 control valve (spool)
(Reference) While work equipment is moved in single operation, if pump pressure remains at approximately 4
MPa {approximately 40 kg/cm2}, control valve spool probably stays at NEUTRAL position. (All oil from pump
is drained to tank through unload valve.)
40-452 PC138USLC-10
40 Troubleshooting
mode)
H-10 Hydraulic drift of boom is large (PC138-MS3-400-A-Z0-A)
Failure • Hydraulic drift of boom is large.

information
1 Defective boom cylinder high idle.
Leakage from boom
Boom RAISE hydraulic relief Max. 15 cc/min
cylinder
high idle.
Boom relief pressure Boom RAISE hydraulic relief or 34.8 (+2.0/-1.5) MPa
and arm relief arm IN hydraulic relief or arm {355 (+20/-15) kg/
Malfunction of boom pressure OUT hydraulic relief cm2}
2 control valve (safety
valve for lock valve) a Among above relief pressures, if arm OUT relief pressure and boom
RAISE relief pressure is low, safety valve may be defective. Check safety
valve for damaged sealing material.
machine.
• Check that pilot piston and poppet are seated on lock valve body in
position (they are not stuck halfway).
Malfunction of boom • Check for stuck or seized pilot piston and poppet in lock valve body (pilot
3 control valve (lock piston and poppet must move smoothly).
valve) • Remove pilot piston and poppet from valve body and check them for
defects and dirt.
• Check poppet spring for fatigue and deformation.
PC138USLC-10 40-453
40 Troubleshooting
mode)
H-11 Hydraulic drift of arm is large (PC138-MS4-400-A-Z0-A)
Failure • Hydraulic drift of arm is large.

information
1 Defective arm cylinder high idle.
Leakage from arm
Arm IN hydraulic relief Max. 15 cc/min
cylinder
high idle.
34.8 (+2.0/-1.5) MPa
Malfunction of arm cm2}
2 safety valve) (arm IN a Among above relief pressures, if only arm IN relief pressure is low,
side) suction-safety valve may be defective.
• Check that check valve of suction-safety valve is seated on valve body in
defective.
Malfunction of arm perform troubleshooting with engine stopped.
3 control valve (spool) • Check for stuck or seized arm spool in control valve body.
40-454 PC138USLC-10
40 Troubleshooting
mode)
H-12 Hydraulic drift of bucket is large (PC138-MS2-400-A-Z0-A)
Failure • Hydraulic drift of bucket is large.

information
Defective bucket high idle.
1 cylinder Leakage from
bucket cylinder Bucket CURL relief Max. 15 cc/min

high idle.
34.8 (+2.0/-1.5) MPa
Malfunction of bucket Bucket relief Bucket CURL or DUMP hydraulic
pressure relief {355 (+20/-15) kg/
2 control valve (suction- cm2}
safety valve)
a If relief pressure is low, suction-safety valve may be defective.
a You can replace suction-safety valve with other one and check whether
failure symptom changes for judgment.
PC138USLC-10 40-455
40 Troubleshooting
mode)
H-13 Time lag of work equipment is large (PC138-FTD-400-A-Z0-A)
Failure • Time lag of work equipment is large.

Malfunction of boom • Check for stuck or seized boom regeneration valve in control valve body.
1 control valve (Spool must move smoothly and must not be caught.)
(regeneration valve) • Check that regeneration valve (check valve ) is seated on control valve in
position (it is not stuck halfway), and then remove it from control valve
body and check it for defects and dirt.
• Check spring of check valve for fatigue and deformation.
Malfunction of arm • Check for stuck or seized arm regeneration valve in control valve body.
2 control valve (Spool must move smoothly and must not be caught.)
(regeneration valve) • Check that regeneration valve (check valve ) is seated on control valve in
position (it is not stuck halfway), and then remove it from control valve
body and check it for defects and dirt.
• Check spring of check valve for fatigue and deformation.
a Check relief pressure of each work equipment. If relief pressure only of
Malfunction of boom boom cylinder head end is unusual, suction-safety valve of boom control
3 control valve (suction- valve may malfunction.
safety valve)
Malfunction of arm arm cylinder bottom end is unusual, suction-safety valve of arm control
4 control valve (suction- valve may malfunction.
safety valve)
Malfunction of bucket bucket cylinder bottom end is unusual, suction-safety valve of bucket
5 control valve (suction- control valve may malfunction.
safety valve)
a Check whether boom cylinder moves slowly to RAISE side when
performing hydraulic relief of other work equipment. (If boom cylinder
Malfunction of boom moves, it is abnormal.)
control valve (pressure a If any failure is found in above check item, interchange pressure
6 compensation valve) compensation valves between both ports, and check whether failure
(boom RAISE side) symptom changes.
symptom.)
Malfunction of boom
control valve (pressure a Check whether boom cylinder moves slowly to LOWER side when
7 compensation valve) performing hydraulic relief of other work equipment. (If boom cylinder
(boom LOWER side) moves, it is abnormal.)
Malfunction of arm
control valve (pressure a Check whether arm cylinder moves slowly to arm IN side when performing
8 compensation valve) hydraulic relief of other work equipment. (If arm cylinder moves, it is
(arm IN side) abnormal.)
40-456 PC138USLC-10
40 Troubleshooting
mode)

Malfunction of arm
control valve (pressure a Check whether arm cylinder moves slowly to arm OUT side when
9 compensation valve) performing hydraulic relief of other work equipment. (If arm cylinder moves,
(arm OUT side) it is abnormal.)
Malfunction of bucket
control valve (pressure a Check whether bucket cylinder moves slowly to bucket CURL side when
10 compensation valve) performing hydraulic relief of other work equipment. (If bucket cylinder
(bucket CURL side) moves, it is abnormal.)
Malfunction of bucket
control valve (pressure a Check whether bucket cylinder moves slowly to bucket DUMP side when
11 compensation valve) performing hydraulic relief of other work equipment. (If bucket cylinder
(bucket DUMP side) moves, it is abnormal.)
PC138USLC-10 40-457
40 Troubleshooting
mode)
H-14 In combined operation of work equipment , equipment having

heavier load moves slower (PC138-D34-400-A-Z0-A)
Failure • In combined operation of work equipment, equipment having heavier load moves slower.
Related
information
Malfunction of control Operations
Heavier load side Smaller load side
valve on smaller load combined
side (pressure Boom RAISE and
1 Boom RAISE Arm IN
compensation valve) arm IN
(arm IN) Pressure compensation valve of control valve on smaller load side may
malfunction.
side (pressure Boom RAISE and
2 Arm OUT Boom RAISE
compensation valve) arm OUT
(boom RAISE) Pressure compensation valve of control valve on smaller load side may
malfunction.
Operations
combined
Boom RAISE and
Boom RAISE Bucket CURL
Malfunction of control bucket CURL
valve on smaller load Pressure compensation valve of control valve on smaller load side may
side (pressure malfunction.
3
compensation valve) Operations
(bucket CURL) combined
Arm OUT and bucket
Arm OUT Bucket CURL
CURL
Pressure compensation valve of control valve on smaller load side may
malfunction.
side (pressure Boom LOWER and
4 Arm OUT Boom LOWER
compensation valve) arm OUT
(boom LOWER) Pressure compensation valve of control valve on smaller load side may
malfunction.
a Pressure compensation valve is equipped with outer seal, inner seal, and LS check valve (ball).
Since slipper seal is installed to inner seal, damage on O-ring inside inner seal cannot be checked visually.
40-458 PC138USLC-10
40 Troubleshooting
mode)
H-15 In combined operation of swing and boom RAISE, boom rising

speed is low (PC138-D35-400-A-00-A)
Failure • In combined operations of swing and boom RAISE, boom rising speed is low.
Related • If boom raise single operation is also slow, troubleshoot the following first.
information • H-6 Boom speed or power is low
Malfunction or defective
1 sealing of swing control LS select valve of swing control valve may malfunction or sealing may be
valve (LS select valve) defective. Check it.
PC138USLC-10 40-459
40 Troubleshooting
mode)
H-16 In combined operation of swing and travel, travel speed drops

largely (PC138-D26-400-A-00-A)
Failure • In combined operation of swing and travel, travel speed drops largely.
Related • If travel only is also slow, troubleshoot the following first.
information • H-18 Travel speed is slow
Malfunction of pump high idle.
1 merge-divider solenoid Work equipment control lever is in 0 MPa {0 kg/cm2}
valve Main EPC output neutral
pressure 2.84 to 3.43 MPa
Bucket CURL and Arm IN {29 to 35 kg/cm2}
Malfunction of pump
2 The pump merge-divider valve of the control valve may malfunction. Check it.
merge-divider valve
Malfunction of work
equipment control valve The pressure compensation valve of the work equipment control valve may
3 (pressure malfunction. Check it.
compensation valve)
Malfunction of swing
control valve (pressure Pressure compensation valve of swing control valve may malfunction. Check
4
compensation valve) it.
Malfunction of travel
control valve (pressure Pressure compensation valve of travel control valve may malfunction. Check
5
compensation valve) it.
40-460 PC138USLC-10
40 Troubleshooting
mode)
H-17 Machine does not travel straight (PC138-FTF-400-A-Z0-A)
Failure • Machine does not travel straight.

Related • If failure codes are displayed, perform troubleshooting for them first. (DW91KA, DW91KB)
information • Travel PPC pressure can be checked with monitoring function. (monitoring code: 07102,
07103, 07104, 07105)
high idle.
1 pressure reducing valve source pressure All levers in NEUTRAL
{33 ± 5 kg/cm2}
high idle.
Malfunction of R.H. R.H. travel lever FORWARD or Min. 2.7 MPa
2 R.H. travel PPC
travel PPC valve
valve output REVERSE {Min. 28 kg/cm2}
pressure Difference in output pressures Max. 0.4 MPa
between L.H. and R.H. PPC
{Max. 4 kg/cm2}
valves
high idle.
Malfunction of L.H. L.H. travel lever FORWARD or Min. 2.7 MPa
3 L.H. travel PPC
travel PPC valve
{Max. 4 kg/cm2}
valves
4 merge-divider solenoid All levers in NEUTRAL 0 MPa {0 kg/cm2}
valve Output pressure of 2.84 to 3.43 MPa
Travel lever is operated
solenoid valve
independently. {29 to 35 kg/cm2}
high idle.
L.H. track: Running
Oil pressure to be idle off ground in Hi
Defective adjustment of measured All levers in NEUTRAL speed setting
5
LS valve Lever moved
halfway
pressure pressure 1
high idle.
Malfunction of travel Both levers in 0 MPa {0 kg/cm2}
6 junction solenoid valve NEUTRAL
Output pressure of When either
Travel levers 2.84 to 3.43 MPa
solenoid valve lever is
operated {29 to 35 kg/cm2}
PC138USLC-10 40-461
40 Troubleshooting
mode)

• Check for stuck or seized travel junction valve spool in merge-divider
Malfunction of travel valve body.
7 junction valve (spool) (Spool must move smoothly and must not be caught.)
• Remove travel junction valve spool from valve body and check it for
defects and dirt.
Malfunction of unload high idle.
8
valve 2.8 ± 1.0 MPa
Unload pressure All control levers in NEUTRAL
{28 ± 10 kg/cm2}
Malfunction of R.H. perform troubleshooting with engine stopped.
9 travel control valve • Check for stuck or seized travel spool in control valve body.
(spool) (Spool must move smoothly and must not be caught.)
• Remove travel spool from valve body and check it for defects and dirt.
Malfunction of L.H. perform troubleshooting with engine stopped.
Connect hoses from L.H. and R.H. travel motors to swivel joint changing
Defective center swivel
11 joint connecting ports with each other, and check whether direction in which
machine deviates changes.
12 Defective travel motor high idle.
Leakage from travel Travel hydraulic relief Max. 1.65 l/min
motor
13 Defective final drive a Check for unusual noise, unusual heat, and metallic powders in drained oil
to make judgment.
Defective adjustment of
Adjust travel deviation adjustment plug. For details, see Testing and adjusting,
14 travel deviation "Testing and adjusting travel deviation".
adjustment plug
40-462 PC138USLC-10
40 Troubleshooting
mode)
H-18 Travel speed is slow (PC138-D20-400-A-Z0-A)
Failure • Travel speed is slow.

07103, 07104, 07105)
Malfunction of self- high idle.
1 pressure reducing valve Control circuit 3.2 ± 0.5 MPa
source pressure All control levers in NEUTRAL
{33 ± 5 kg/cm2}
high idle.
Malfunction of R.H. R.H. travel lever FORWARD or Min. 2.7 MPa
2 R.H. travel PPC
travel PPC valve
{Max. 4 kg/cm2}
valves
high idle.
Malfunction of L.H. L.H. travel lever FORWARD or Min. 2.7 MPa
3 L.H. travel PPC
travel PPC valve
pressure Difference in output pressure Max. 0.4 MPa
{Max. 4 kg/cm2}
valves
4 merge-divider solenoid All levers in NEUTRAL 0 MPa {0 kg/cm2}
valve Output pressure of 2.84 to 3.43 MPa
Travel lever is operated
solenoid valve
independently. {29 to 35 kg/cm2}
defects and dirt.
Malfunction of pump • Check for stuck or seized main spool in merge-divider valve body.
6 merge-divider valve (Spool must move smoothly and must not be caught.)
7 • Check for stuck or seized travel spool in control valve body.
control valve (spool)
PC138USLC-10 40-463
40 Troubleshooting
mode)

high idle.
Malfunction of travel 34.8 (+2.0/-1.5) MPa
Travel relief Right travel FORWARD hydraulic
control valve (pressure pressure relief {355 (+20/-15) kg/
8 compensation valve) cm2}
(right travel FORWARD
side) a If only one of right, left, forward, and reverse is abnormal, pressure
compensation valve may malfunction.
Interchange pressure compensation valves on FORWARD and
REVERSE sides, and check whether failure symptom changes.
Malfunction of travel a Be ready with engine stopped, then perform troubleshooting with engine at
control valve (pressure high idle.
9 compensation valve) 34.8 (+2.0/-1.5) MPa
(right travel REVERSE Travel relief Right travel REVERSE hydraulic
pressure {355 (+20/-15) kg/
side) relief
cm2}
(left travel FORWARD Travel relief Left travel FORWARD hydraulic
pressure relief {355 (+20/-15) kg/
side)
cm2}
(left travel REVERSE Travel relief Left travel REVESE hydraulic
pressure {355 (+20/-15) kg/
side) relief
cm2}
Malfunction of travel If relief pressure of only 1 port is low after adjusting relief valve, suction valve
12 control valve (suction may malfunction.
valve) Check suction valve (check valve) for defects and fatigue of spring.
13 Defective travel motor high idle.
Leakage from travel Travel hydraulic relief Max. 1.65 l/min
motor
to make judgment.
40-464 PC138USLC-10
40 Troubleshooting
mode)
H-19 Machine is hard to steer or travel power is low (PC138-L18-400-A-Z0-A)
Failure • Machine is hard to steer or travel power is low.

07103, 07104, 07105)
high idle.
Malfunction of R.H.
1 R.H. travel PPC NEUTRAL 0 MPa {0 kg/cm2}
travel PPC valve
valve output R.H. travel lever FORWARD and Min. 2.7 MPa
pressure REVERSE {Min. 28 kg/cm2}
high idle.
Malfunction of L.H.
2 L.H. travel PPC NEUTRAL 0 MPa {0 kg/cm2}
travel PPC valve
valve output L.H. travel lever FORWARD and Min. 2.7 MPa
pressure REVERSE {Min. 28 kg/cm2}
high idle.
Malfunction of pump
0 MPa
3 merge-divider solenoid Travel lever in the neutral position
valve Output pressure of {0 kg/cm2}
solenoid valve Single operation of travel (either 2.84 to 3.43 MPa
or both tracks) {29 to 35 kg/cm2}
high idle.
Malfunction of travel Both levers in 0 MPa {0 kg/cm2}
4 junction solenoid valve Travel junction NEUTRAL
solenoid valve Travel levers When either
2.84 to 3.43 MPa
output pressure lever is
{29 to 35 kg/cm2}
operated
defects and dirt.
Malfunction of hydraulic The check valve of the hydraulic pump may malfunction or its sealing may be
6 pump (check valve) defective. Check it.
Malfunction of hydraulic The shuttle valve of the hydraulic pump may malfunction or its sealing may be
7 pump (shuttle valve) defective. Check it.
PC138USLC-10 40-465
40 Troubleshooting
mode)

Malfunction of R.H. perform troubleshooting with engine stopped.
Malfunction of L.H. perform troubleshooting with engine stopped.
high idle.
3.48 (+2.0/-1.5) MPa
Travel relief R.H. travel FORWARD hydraulic
pressure {355 (+20/-15) kg/
Malfunction of travel relief
cm2}
control valve (pressure
12 compensation valve) a If only 1 place of right, left, forward, and reverse is abnormal, pressure
(R.H. travel FORWARD compensation valve may malfunction.
side) Interchange pressure compensation valves on FORWARD and
REVERSE sides, and check whether failure symptom changes.
a If relief pressures of R.H. travel FORWARD and L.H. travel REVERSE are
the same and low, main relief valve of rear pump may malfunction. Check
arm relief pressure additionally.
high idle.
control valve (pressure 3.48 (+2.0/-1.5) MPa
Travel relief R.H travel REVERSE hydraulic
13 compensation valve) pressure {355 (+20/-15) kg/
relief
(R.H. travel REVERSE cm2}
side) If measured values in checks on causes (12) and (13) are the same and low,
main relief valve of rear pump may malfunction. Check arm relief pressure
additionally.
high idle.
Travel relief L.H. travel FORWARD hydraulic
14 compensation valve) (L. pressure {355 (+20/-15) kg/
relief
H. travel FORWARD cm2}
side) If relief pressures of L.H. travel FORWARD and L.H. travel REVERSE are
same and low, main relief valve of front pump may malfunction. Check bucket
relief pressure additionally.
high idle.
Travel relief L.H. travel REVESE hydraulic
15 compensation valve) (L. pressure relief {355 (+20/-15) kg/
H. travel REVERSE cm2}
side) If measured values in checks on causes (14) and (15) are same and low,
main relief valve of front pump may malfunction. Check bucket relief pressure
additionally.
Malfunction of travel If relief pressure of only 1 port is low after adjusting relief valve, suction valve
16 control valve (suction may malfunction.
valve) Check suction valve (check valve) for defects and fatigue of spring.
Connect hoses from L.H. and R.H. travel motors to swivel joint changing
Defective center swivel
17 joint connecting ports with each other, and check whether direction in which
machine deviates changes.
40-466 PC138USLC-10
40 Troubleshooting
mode)

If relief pressures of both R.H. travel FORWARD and REVERSE or those of
R.H. travel FORWARD and REVERSE are unusual in checks on causes (12)
Defective R.H. travel and (13) respectively, respective safety valves are probably defective.
18 motor (safety valve)
Interchange safety valves of L.H. and R.H. travel motors, and check whether
If relief pressures of both L.H. travel FORWARD and REVERSE are unusual
in checks on causes (14) and (15) respectively, respective safety valves may
Defective L.H. travel be defective.
19 motor (safety valve)
If pressure compensation valves are found to be normal in checks on causes
Defective R.H. travel (12) and (13), check valves may malfunction.
20 motor (check valve)
Interchange check valves on FORWARD and REVERSE sides of same travel
motor, and check whether failure symptom changes.
If pressure compensation valves are found to be normal in checks on causes
Defective L.H. travel (14) and (15), check valves may malfunction.
21 motor (check valve)
Defective R.H. travel high idle.
22
motor Leakage from travel R.H travel hydraulic relief Max. 1.65 l/min
motor
Defective L.H. travel high idle.
23
motor Leakage from travel L.H. travel hydraulic relief Max. 1.65 l/min
motor
PC138USLC-10 40-467
40 Troubleshooting
mode)
H-20 Travel speed does not change, or travel speed is too slow or
fast (PC138-BQ4-400-A-Z0-A)
Failure • Travel speed does not change, or travel speed is too slow or fast.
Related • If failure codes are displayed, perform troubleshooting for them first.(DW43KA, DW43KB)
information • Travel speed selector solenoid (ON/OFF) can be checked with monitoring function.
(monitoring code: 02300)
high idle.
Travel lever: Travel speed: 0 MPa {0 kg/cm2}
Malfunction of travel NEUTRAL Lo
1 speed solenoid valve
Output pressure of Approx. 2.84 to 3.43
solenoid valve Travel lever: MPa
Travel speed: Hi
Fine operation {Approx. 29 to 35 kg/
cm2}
If no failure is found by checks on causes (1) and (2), speed switching part of
2 motor (speed switching
travel motor may malfunction.
section)
*: Travel speed of Lo setting can be adjusted by using adjustment function of machine monitor. If it is changed
from default value, the value changes slightly.
40-468 PC138USLC-10
40 Troubleshooting
mode)
H-21 One of tracks does not run (PC138-BG1-400-A-Z0-A)
Failure • One of tracks does not run.

Related • Travel PPC pressure can be checked with monitoring function. (monitoring code: 07102,
information 07103, 07104, 07105)
high idle.
Malfunction of R.H.
1 R.H. travel lever NEUTRAL 0 MPa {0 kg/cm2}
travel PPC valve PPC valve output
FORWARD and Min. 2.7 MPa
pressure R.H. travel lever
REVERSE {Min. 28 kg/cm2}
high idle.
Malfunction of L.H.
2 L.H. travel lever NEUTRAL 0 MPa {0 kg/cm2}
travel PPC valve PPC valve output
FORWARD and Min. 2.7 MPa
pressure L.H. travel lever
REVERSE {Min. 28 kg/cm2}
Malfunction of R.H. If no failure is found by check on cause (1) and one track does not run when
3 travel control valve travel control lever is operated with pump pressure at approx. 4 MPa, check
(spool) whether spool is stuck near NEUTRAL position.
Malfunction of L.H. If no failure is found by check on cause (2) and one track does not run when
4 travel control valve travel control lever is operated with pump pressure at approx. 4 MPa, check
(spool) whether spool is stuck near NEUTRAL position.
Malfunction of R.H.
When R.H. travel lever is operated, if R.H. track does not run because of low
5 travel control valve
pump pressure, check suction valve.
(suction valve)
Malfunction of L.H.
When L.H. travel lever is operated, if L.H. track does not run because of low
6 travel control valve
pump pressure, check suction valve.
(suction valve)
high idle.
34.8 (+2.0/-1.5) MPa
Travel relief R.H. travel FORWARD and
Defective R.H. travel pressure hydraulic relief {355 (+20/-15) kg/
7 REVERSE
motor (safety valve) cm2}
If relief pressures of travel FORWARD and REVERSE are unusual to the
same degree, sealing of safety valve may be defective.
high idle.
34.8 (+2.0/-1.5) MPa
Travel relief L.H. travel FORWARD and
Defective L.H. travel pressure hydraulic relief REVERSE {355 (+20/-15) kg/
8 motor (safety valve) cm2}
If relief pressures of travel FORWARD and REVERSE are unusual to the
same degree, sealing of safety valve may be defective.
If safety valve is found to be normal in checks on cause (7), sealing of check
Defective R.H. travel valve may be defective.
9 motor (check valve) Interchange check valves on FORWARD and REVERSE sides of same travel
Defective L.H. travel If safety valve is found to be normal in checks on cause (8), sealing of check
10 motor (check valve) valve may be defective.
PC138USLC-10 40-469
40 Troubleshooting
mode)

Defective R.H. travel When running R.H. track idle off ground, if R.H. track does not run with R.H.
11 motor (parking brake) travel circuit pressure reaching relief pressure, travel parking brake may
malfunction.
Defective L.H. travel When running L.H. track idle off ground, if L.H. track does not run with L.H.
12 motor (parking brake) travel circuit pressure reaching relief pressure, travel parking brake may
malfunction.
Defective R.H. travel high idle.
13
motor Leakage from R.H. R.H. travel
R.H. travel lever hydraulic relief Max. 1.65 l/min
travel motor
Defective L.H. travel high idle.
14
motor Leakage from L.H. L.H. travel
L.H. travel lever hydraulic relief Max. 1.65 l/min
travel motor
to make judgment.
40-470 PC138USLC-10
40 Troubleshooting
mode)
H-22 Upper structure does not swing to the right or left (PC138-L41-400-A-Z0-A)
Failure • Upper structure does not swing to the right or left.

high idle.
Malfunction of swing Swing control
1 At NEUTRAL 0 MPa {0 kg/cm2}
PPC valve Swing PPC valve lever
output pressure Swing control Left swing and Min. 2.7 MPa
lever Right swing {Min. 28 kg/cm2}
high idle.
2 holding brake solenoid Swing control 0 MPa {0 kg/cm2}
Swing holding brake NEUTRAL
valve lever
solenoid output 2.84 to 3.43 MPa
Swing control Left swing and
pressure
lever Right swing {29 to 35 kg/cm2}
When no failure is found by check on cause (1), if upper structure does not
Malfunction of swing swing with swing circuit pressure reaching relief pressure, swing holding
3 motor (swing holding brake may malfunction.
brake)
(Check pump pressure by using monitoring function to make judgment.)
If no failure is found by checks on causes (1) and (2) and upper structure does
4 not swing when swing control lever is operated with pump pressure at approx.
4 MPa, check whether spool is stuck near NEUTRAL position.
high idle.
Defective swing motor 28.2 (+1.5/-2.5) MPa
5 Swing relief Swing lock Swing hydraulic
(safety valve) pressure {288 (+15/-25) kg/
switch: ON relief
cm2}
If relief pressures of left swing and right swing are same and low, sealing of
safety valve may be defective.
6 Defective swing motor high idle.
Leakage from swing Swing lock Swing hydraulic
Max. 6 l/min
motor switch: ON relief
Swing machinery may have internal failure.
Defective swing
7 machinery a Check for unusual noise, unusual heat, and metallic powders in drained oil
to make judgment.
PC138USLC-10 40-471
40 Troubleshooting
mode)
H-23 Upper structure swing only to the right or left (PC138-L42-400-A-Z0-A)
Failure • Upper structure swing only to the right or left.

information
high idle.
PPC valve Swing PPC valve lever
output pressure Swing control Left swing and Min. 2.7 MPa
If no failure is found by check on cause (1) and upper structure does not
2 swing when swing control lever is operated with pump pressure at approx. 4
MPa, check whether spool is stuck near NEUTRAL position.
high idle.
3 motor (safety valve) Swing relief Swing lock 28.2 (+1.5/-2.5) MPa
pressure switch Swing hydraulic
{288 (+15/-25) kg/
relief
(pump pressure) ON cm2}
Defective seating of Interchange shuttle valves on left and right swing sides of swing motor, and
4 swing motor (shuttle check whether failure symptom changes to make judgment.
valve) When removing valve, check it for sticking and defects.
Defective seating of Interchange check valves on left and right swing sides of swing motor, and
5 swing motor (check check whether failure symptom changes to make judgment.
40-472 PC138USLC-10
40 Troubleshooting
mode)
H-24 Swing acceleration or swing speed is low in both directions (right

and left) (PC138-L44-400-A-Z0-A)
Failure • Swing acceleration or swing speed is low in both directions (right and left).
Malfunction of swing Swing spool may malfunction.
1 control valve (spool) Check spool for getting stuck and defects.
high idle.
2 holding brake solenoid Swing control 0 MPa {0 kg/cm2}
Swing holding brake NEUTRAL
valve lever
pressure
lever right swing {29 to 35 kg/cm2}
If no failure is found by check on cause (2), swing holding brake may
3 motor (swing holding
malfunction (dragging).
brake)
high idle.
switch: ON relief
cm2}
If normal pressure is not obtained after adjustment, sealing of safety valve
may be defective.
Max. 6 l/min
Defective swing
to make judgment.
PC138USLC-10 40-473
40 Troubleshooting
mode)
H-25 Swing acceleration performance is poor or swing speed is slow in

only one direction (PC138-L45-400-A-Z0-A)
Failure • Swing acceleration performance is poor or swing speed is slow in only one direction.
information
high idle.
PPC valve PPC valve output lever
pressure Swing control Left swing and Min. 2.7 MPa
lever right swing {Min. 28 kg/cm2}
If no failure is found by check on cause (1) and upper structure does not
2 swing when swing control lever is operated with pump pressure at approx. 4
MPa, check whether spool is stuck near NEUTRAL position.
high idle.
3 motor (safety valve) Swing relief 28.2 (+1.5/-2.5) MPa
pressure Swing lock Swing hydraulic
{288 (+15/-25) kg/
switch: ON. relief
(pump pressure) cm2}
Defective seating of Interchange suction valves on left and right swing sides of swing motor, and
4 swing motor (suction check whether failure symptom changes to make judgment.
40-474 PC138USLC-10
40 Troubleshooting
mode)
H-26 Upper structure overruns excessively when it stops swinging (both

right and left) (PC138-L47-400-A-Z0-A)
Failure • Upper structure overruns excessively when it stops swinging (both right and left).
high idle.
switch: ON relief
cm2}
may be defective.
Max. 6 l/min
PC138USLC-10 40-475
40 Troubleshooting
mode)
H-27 Upper structure overruns excessively when it stops swinging

(either right or left) (PC138-L48-400-A-Z0-A)
Failure • Upper structure overruns excessively when it stops swinging (either right or left).
information
high idle.
pressure Swing control Left swing and Min. 2.7 MPa
Slow return valve for right swing PPC may malfunction. Interchange slow
return valves for left and right swings, and check whether failure symptom
Clogged slow return changes to make judgment.
2 valve for right swing
When removing slow return valve, check slow return valve strainer for
clogging.
Slow return valve for left swing PPC may malfunction. Interchange slow return
valves for left and right swings, and check whether failure symptom changes
Clogged slow return to make judgment.
3 valve for left swing PPC
When removing slow return valve, check slow return valve strainer for
clogging.
Malfunction of swing Swing spool may malfunction.
4 control valve (spool) Check spool for getting stuck and defects.
high idle.
5 motor (safety valve) Swing relief 28.2 (+1.5/-2.5) MPa
pressure Swing lock Swing hydraulic
switch: ON. relief {288 (+15/-25) kg/
(Pump pressure) cm2}
40-476 PC138USLC-10
40 Troubleshooting
mode)
H-28 Shock is large when upper structure stops swinging (PC138-L49-400-A-Z0-A)
Failure • Shock is large when upper structure stops swinging.

information
high idle.
pressure Swing control Left swing and 2.7 MPa
lever Right swing {28 kg/cm2}
Malfunction of slow Slow return valve for right swing PPC may malfunction. Interchange slow
2 return valve for right return valves for left and right swings, and check whether failure symptom
swing PPC changes to make judgment.
Malfunction of slow Slow return valve for left swing PPC may malfunction. Interchange slow return
3 return valve for left valves for left and right swings, and check whether failure symptom changes
swing PPC to make judgment.
Malfunction of swing Reverse prevention valve of swing motor may malfunction.
4 motor (reverse
prevention valve) Check for stuck spool and fatigue of spring.
PC138USLC-10 40-477
40 Troubleshooting
mode)
H-29 Large unusual noise is heard when upper structure stops

swinging (PC138-BAB-400-A-Z0-A)
Failure • Large unusual noise is heard when upper structure stops swinging.
information
Malfunction of back Back pressure valve of control valve may malfunction.
1 pressure valve Check for stuck valve, defects of valve, and fatigue of spring.
Safety valve of swing motor may malfunction.
2 motor (safety valve) If normal pressure is not obtained after adjustment, safety valve may have
internal failure.
Defective swing
to make judgment.
40-478 PC138USLC-10
40 Troubleshooting
mode)
H-30 Swing drift on a slope is large while swing parking brake is

applied (PC138-MS6-400-A-Z0-A)
Failure • Swing drift on a slope is large while swing parking brake is applied.
• When swing lock switch is set to ON position or swing parking brake cancel switch is set
Related to NORMAL position, swing brake is applied and swing system is locked by disc brake.
information • Perform all troubleshooting with working mode set in power (P) mode.
• If failure codes are displayed, perform troubleshooting for them first. (DW45KA, DW45KB)
high idle.
1 parking brake solenoid Swing control 0 MPa {0 kg/cm2}
swing parking brake At NEUTRAL
valve lever
pressure
lever Right swing {29 to 35 kg/cm2}
motor (swing parking If no failure is found by check on cause (1), swing parking brake may
2
brake) malfunction.

Max. 6 l/min
PC138USLC-10 40-479
40 Troubleshooting
mode)
H-31 Swing drift on a slope is large while swing parking brake is

released (PC138-MS7-400-A-Z0-A)
Failure • Swing drift on a slope is large while swing parking brake is released.
1 Spool of swing control valve may malfunction. Check for stuck spool.
Malfunction of swing Pressure compensation valve on right swing side of swing control valve may
control valve (pressure malfunction.
2 compensation valve on Interchange pressure compensation valves on left and right swing sides and
right swing side) check whether failure symptom changes to make judgment.
Malfunction of swing Pressure compensation valve on left swing side of swing control valve may
control valve (pressure malfunction.
3 compensation valve on Interchange pressure compensation valves on left and right swing sides and
left swing side) check whether failure symptom changes to make judgment.
high idle.
switch: ON relief
cm2}
may be defective.
Interchange suction valves on left and right swing sides of swing motor, and
Defective seal of swing check whether failure symptom changes to make judgment.
5 motor (suction valve)
When removing valve, check it for sticking and defects.
Defective sealing of Interchange check valves on left and right swing sides of swing motor, and
Malfunction of swing Reverse prevention valve of swing motor may malfunction.
7 motor (reverse
prevention valve) Check for stuck spool and fatigue of spring.
40-480 PC138USLC-10
40 Troubleshooting
mode)
H-32 Attachment hydraulic circuit cannot be changed while attachment

is installed (PC138-HBD-400-A-Z1-A)
Failure • Attachment hydraulic circuit cannot be changed while attachment is installed.
• For machines with provision for attachment, attachment circuit switches as follows
depending on selected working mode.
1. In ATT mode: The double acting circuit is selected and the safety valve is set to the
low pressure.
2. In B mode: The single acting circuit is selected and the safety valve is set to the high
Related pressure.
information
a Note that set pressure of safety valve switches only on port B side, and that on port A
side remains at low-pressure setting without switching.
• If failure codes are displayed, perform troubleshooting for them first. (DWA2KA,
DWA2KB)
high idle.
Malfunction of ATT
1 ATT selector Working mode ATT mode 0 MPa {0 kg/cm2}
selector solenoid valve
solenoid valve 2.84 to 3.43 MPa
output pressure Working mode B mode
{29 to 35 kg/cm2}
If no failure is found by check on cause (1), ATT return selector valve may
Malfunction of ATT malfunction.
2
return selector valve
Check for stuck valve spool, defects of valve, and fatigue of spring.
Defective adjustment or Safety valve of service valve may malfunction.
3 malfunction of service If normal pressure is not obtained after adjustment, safety valve may have
valve (safety valve) internal failure.
PC138USLC-10 40-481
40 Troubleshooting
mode)
H-33 Oil flow in attachment circuit cannot be controlled (PC138-HBE-400-A-Z0-A)
Failure • Oil flow in attachment circuit cannot be controlled.

• For machines with provision for attachment, oil flow rate of attachment circuit varies
depending on selected working mode.
Related • Procedure for oil flow rate adjustment differs between working modes, ATT mode and B
information mode. For details, see Operation and Maintenance Manual.
• If failure codes are displayed, perform troubleshooting for them first. (DXE4KA, DXE4KB)
high idle.
Attachment
At NEUTRAL 0 MPa {0 kg/cm2}
ATT oil flow control pedal
adjustment EPC Pressure
Malfunction of ATT oil valve output Attachment corresponding to
1 flow adjustment EPC pressure Depressed
control pedal selected oil flow
valve setting
a If output pressure of EPC valve is 0 MPa, check “Service solenoid current“
with monitoring function. (monitoring code: 01700)
If current value is 0.3 to 0.91 A, EPC valve may be defective.
Check that output pressure changes according to selected oil flow setting.
high idle.
Attachment
At NEUTRAL 0 MPa {0 kg/cm2}
Malfunction of service control pedal
2 Service PPC valve Pressure
PPC valve
output pressure Attachment corresponding to
Depressed
control pedal selected oil flow
setting
• Check that output pressure changes according to pedal stroke.
40-482 PC138USLC-10
40 Troubleshooting
Troubleshooting of engine (S-mode)
Troubleshooting of engine (S-mode) (ALL-3840-001-A-03-A)
Information mentioned in troubleshooting table (S mode) (ALL-5170-010-A-01-A)
(Rev. 2011/01)
a Troubleshooting Table collectively carries the following information. Carry out troubleshooting work after
fully grasping its contents.
Failure Problem on engine
Related Information related to the detected failure or troubleshooting
information
Probable cause Contents of check and remarks Remedy
1 <Contents of description>
2 Probable causes for
trouble (Each number is • Contents of check to judge • Actions to eliminate probable
3 serial number, not priority probable causes causes of trouble
4 sequence.) • Remarks required for
5 judgment
PC138USLC-10 40-483
40 Troubleshooting
S-1 Engine does not crank when starting switch is turned to START
position (D65-A26-400-A-Z0-A)
Failure Engine does not crank when starting switch is turned to START position.
Related • See E mode (E-1) for troubleshooting of electrical system.
information • If any failure code is displayed, perform troubleshooting for that code first.
No. Cause Point to check, remarks Remedy
Defective wiring harness in • When starting switch is turned to START Perform
1 starting circuit position, starting motor pinion is not pushed troubleshooting for E-1
out and take remedies.
• Grating noise is heard from starting motor
pinion.
(When starting switch is turned to START
position, starting motor pinion is pushed
out.)
• Starting motor pinion disengages during
operation.
position, starting motor pinion is pushed Perform
2 Defective starting motor troubleshooting for E-1
out.)
• Rattling noise is heard and starting motor and take remedies.
does not rotate.
position, starting motor pinion is pushed
out.)
(Reference: Rattling noise is caused when
starting motor pinion is repeatedly pushed
out and pulled in.)
• If grating noise is heard from starting motor
3 Broken flywheel ring gear pinion and starting motor does not rotate, Replace if damaged
visually check flywheel ring gear.
• Remove EGR cooler outlet gas piping and
check whether coolant containing
Cracked EGR cooler COOLANT flows out. Replace EGR cooler
4 (Reference: coolant in and drain water from
exhaust gas) a Water in exhaust gas can be normally engine cylinders
condensed, so check that condensate is
coolant or not.
40-484 PC138USLC-10
40 Troubleshooting
S-2 Engine cranks but no exhaust smoke comes out (D37-A27-400-A-Z0-A)
Failure Engine cranks but no exhaust smoke comes out.

Related • If any failure code is displayed, perform troubleshooting for that code first.
information
1 Insufficient fuel in tank • Fuel tank is empty. Add fuel.
Flush air breather hole
Clogged air breather hole in
2 • Air breather hole in fuel tank cap is clogged. in fuel tank cap and
fuel tank cap clean surrounding
area.
• Check used hours of fuel filter. If used
Clogged fuel filter element beyond specified hours, fuel filter element Replace fuel filter
3
may be clogged. element.
Foreign material in fuel • Rust and water are found in fuel drained Replace fuel.
4
from fuel tank.
• Air is bled during air bleeding of fuel system. Perform air bleeding.
5 Air in fuel piping system (Reference: See Testing and adjusting, Repair or replace fuel
"Bleeding air from fuel system".) piping.
• Fuel leaks from fuel piping.
Leakage from fuel piping Repair or replace fuel
6 (Reference: See Testing and adjusting,
system piping related parts.
"Testing fuel circuit for leakage".)
• Injector return rate is excessive.
Fuel leakage from injector (Reference: See Testing and adjusting, Check or replace
7 "Testing fuel discharge, return and injector.
area
leakage".)
• See Testing and adjusting, "Testing fuel Replace supply pump
8 Defective supply pump
discharge, return and leakage". or pressure limiter.
• No resistance is felt or large effort is
9 Defective priming pump Replace priming pump.
required when operating priming pump.
• Monitored common rail pressure does not Loosen injection piping
Improper air bleeding of lower even after engine is stopped. (Code: and high-pressure pipe
10 common rail or injection 36400 Common rail pressure) mounting nuts on
piping (Pressure may not decrease if air still common rail and bleed
remains.) air.
PC138USLC-10 40-485
40 Troubleshooting
S-3 Fuel is being injected but engine does not start (misfiring: engine
cranks but does not start) (D37-A28-400-A-Z0-A)
Fuel is being injected but engine does not start (incomplete combustion: engine cranks but
Failure does not start).
information
• Specific gravity of electrolyte and voltage of Add battery electrolyte
1 Defective battery
battery are low. and charge battery.
area.
4
5
from fuel tank.
• Injector return rate is excessive.
Fuel leakage from injector (Reference: See Testing and adjusting, Check or replace
8 "Testing fuel discharge, return and injector.
area
leakage".)
• Air cleaner dust indicator indicates that dust Check and clean air
10 Clogged air cleaner element
is at caution level. cleaner element.
• When preheating works, intake air heater
mounting area does not become hot.
• When preheating works or when Replace intake air
11 Defective intake air heater
temperature is low, preheating monitor does heater.
not indicate properly.
• Check valve clearance.
(Reference: See Testing and adjusting,
Worn valve or rocker arm, "Testing and adjusting valve clearance".) Replace valve or
12
etc. • When engine is cranked, unusual noise is rocker arm.
heard from around cylinder head.
• Testing compression pressure
Replace piston ring or
13 Defective piston ring (Reference: See Testing and adjusting,
piston.
"Testing compression pressure".)
• When engine is run in cylinder cutout mode
Defective injector with some cylinder cutout, engine speed
14 (clogged injector or defective does not change. Replace injector.
fuel spray) (Reference: See Testing and adjusting,
"Handling cylinder cutout mode operation".)
• Since this is an internal defect, Replace engine
15 Defective engine controller troubleshooting cannot be performed. controller.
40-486 PC138USLC-10
40 Troubleshooting
S-4 Engine startability is poor (D37-A10-400-A-Z0-A)
Failure Engine startability is poor.

• If any failure code is displayed, perform troubleshooting for that code first.
• Common rail fuel injection system (CRI) controls fuel injection timing electrically.
Related
Therefore, in some cases, engine does not start before crankshaft makes 2 turns
information
maximum even if starting operation is performed. This does not indicate any abnormality,
however.
• Specific gravity of electrolyte and voltage of Add battery electrolyte
1 Defective battery
battery are low. and charge battery.
• Fuel other than specified one is used.
• Fuel used does not accord with ambient
temperature. Use proper fuel
(Reference: If engine can start in warm specified in Operation
3 Improper fuel used
weather but does not easily start in cold and Maintenance
weather) Manual.
• Deposited wax (milky) is found in clear bowl
of fuel prefilter.
area.
5
6
from fuel tank.
• Air cleaner dust indicator indicates that dust Check and clean air
10 Clogged air cleaner element
• When preheating works, intake air heater
mounting area does not become hot.
• When preheating works or when Replace intake air
11 Defective intake air heater
temperature is low, preheating monitor does heater.
not indicate properly.
• Remove exhaust gas piping from EGR
cooler outlet and inlet, and check whether
Cracked EGR cooler Replace EGR cooler
coolant containing COOLANT flows out.
12 (Reference: Coolant enters and drain water from
exhaust gas piping.) a Water in exhaust gas can be normally engine cylinders
condensed, so check that condensate is
coolant or not.
• Some cylinder is found to be cool when
exhaust manifolds are touched by hand
immediately after engine is started.
13 Defective injector Replace injector.
with some cylinder cut out, engine speed
does not change.
PC138USLC-10 40-487
40 Troubleshooting

• Measure compression pressure (see
Standard value table).
(Reference: See Testing and adjusting, Correct contact
Defective contact between "Testing compression pressure".) between valve and
15
valve and valve seat • Check valve clearance. valve seat or replace
(Reference: See Testing and adjusting, them.
"Testing and adjusting valve clearance".)
• Check exhaust gas at KDOC muffler outlet.
"Testing exhaust gas color".)
• Measure compression pressure (see Replace piston ring or
16 Defective piston ring Standard value table). piston.
• Check piston ring and piston ring groove.
40-488 PC138USLC-10
40 Troubleshooting
S-5 Engine does not pick up smoothly (D37-A30-400-A-Z0-A)
Failure Engine does not pick-up smoothly.

information
area.
3
4
from fuel tank.
• When crankcase pressure high error (failure
code: CA555) is still displayed even after
Abnormally high crankcase KCCV filter is replaced, blowby pressure is Perform following
8 pressure probably high (see Testing and adjusting, checks on causes 10
"Testing blowby pressure"). In this case, and after.
KVGT may be seized or damaged.
does not change.
• Unusual noise is heard from VFT.
• Check whether VFT shaft rotates.
10 Seized or broken VFT Replace KVGT.
(Move VFT vanes with hand in axial and
radial directions to make judgment.)
• When engine is cranked, unusual noise is
• Check valve clearance. Adjusting valve
11 Incorrect valve clearance
(Reference: See Testing and adjusting, clearance
PC138USLC-10 40-489
40 Troubleshooting

13
40-490 PC138USLC-10
40 Troubleshooting
S-6 Engine stops during operation (D37-AF0-400-A-Z0-A)
Failure Engine stops during operation.

information
area.
3
4
from fuel tank.
Defective air intake hose
Replace air intake
9 (between air cleaner and VFT • Visually check air intake hose for breakage.
hose.
inlet)
• Check air intake manifold for internal Replace air intake
10 Defective air intake manifold breakage. manifold.
Defective boost piping and
connections Correct or replace
11 • Air leaks from boost piping.
(between VFT outlet and air boost piping.
intake manifold)
Defective exhaust gas piping • Check exhaust gas piping for damage and
exhaust gas leakage. Replace exhaust gas
12 (from exhaust manifold to (Check soot on heat insulation cover and piping.
KDOC muffler inlet) heat insulation plate.)
• Check valve and rocker arm.
Replace valve or
13 Damaged valve or rocker arm (Unusual noise is heard and engine stops
suddenly.) rocker arm.
• Metal particles are found in oil drained from
oil pan.
• Remove oil pan and check piston and
Broken or seized piston Replace piston and
14 connecting rod connecting rod.
connecting rod.
(Reference: Unusual noise is heard and
engine stops suddenly, or stops due to
overheat.)
• Metal particles are found in oil drained from
Broken or seized crankshaft oil pan. Replace crankshaft
15 bearing • Remove oil pan and check crankshaft main main bearing.
bearing.
• Check wiring harness of engine controller
Defective wiring harness of Repair wiring harness
power supply.
16 engine controller power of engine controller
(Reference: See Troubleshooting, "Failure
supply power supply.
code [CA343]".)
PC138USLC-10 40-491
40 Troubleshooting

Defective starting switch Perform
17 wiring • Check starting switch wiring harness. troubleshooting for E-1
and take remedies.
• See "H-9 Engine stalls during travel or Perform
18 Defective hydraulic system engine speed drops significantly" in H troubleshooting for H-9
mode. and take remedies.
40-492 PC138USLC-10
40 Troubleshooting
S-7 Engine runs rough or is unstable (D37-A40-400-A-Z0-A)
Failure Engine runs rough or is unstable.

information
area.
3
4
from fuel tank.
• Check boost system (between VFT outlet Repair or replace
Fuel leakage from boost
7 and aftercooler, aftercooler and air intake boost piping related
system
manifold) for fuel leakage. parts.
• Replace sensor and check whether
Defective mass air flow and symptom disappears. Replace mass air flow
8 temperature sensor (Failure code may not be generated if and temperature
sensor is covered with dust.) sensor.
PC138USLC-10 40-493
40 Troubleshooting
S-8 Engine lacks power (D37-A60-400-A-Z0-A)
Failure Engine lacks power.

information
area.
3
4
from fuel tank.
Clogged air cleaner element • Air cleaner dust indicator indicates that dust Check and clean air
8
• Check air cleaner and rectifying wire net for Correct or replace air
9 Defective air cleaner
deformation. cleaner.
Defective air intake hose
Replace air intake
10 (between air cleaner and VFT • Visually check air intake hose for breakage.
hose.
inlet)
• Check air intake manifold for internal Replace air intake
11 Defective air intake manifold breakage. manifold.
intake manifold)
Defective installation of • Air leaks from mounting part of charge Correct installation of
13 charge pressure sensor pressure sensor. charge pressure
sensor.
Defective exhaust gas piping• Check exhaust gas piping for damage and
15 Gas leakage from EGR piping • Gas leaks from EGR piping. Replace EGR piping.
Check intake and exhaust
system
• Measure boost pressure.
(between VFT outlet and air Repair or replace
intake manifold, between defective part.
"Testing boost pressure".)
exhaust manifold and KDOC
muffler inlet)
17 Seized or broken VFT Replace VFT.
40-494 PC138USLC-10
40 Troubleshooting

does not change.
21
• Open exhaust color inspection hole that is
just upstream of the KDOC muffler, and
check exhaust gas.
"Testing exhaust gas color".) Replace piston ring or
22 Defective piston ring • Measure compression pressure (see piston.
PC138USLC-10 40-495
40 Troubleshooting
S-9 Exhaust smoke is black (D37-AH5-400-A-Z0-A)
Failure Exhaust smoke is black.

information
Use proper fuel
Improper fuel used • Fuel other than specified one is used. specified in Operation
1
and Maintenance
Manual.
2
from fuel tank.
• Check air cleaner and rectifying wire net for Correct or replace air
3 Defective air cleaner
deformation. cleaner.
Defective exhaust gas piping • Check exhaust gas piping for damage and
Defective installation of Correct installation of
• Air leakage from installed position of charge
5 charge (boost) pressure charge (boost)
(boost) pressure sensor
sensor pressure sensor.
intake manifold)
• KDOC muffler is clogged. Check exhaust
Replace KDOC
7 Defective KDOC muffler pressure pressure at location just upstream
muffler.
of KDOC muffler.
8 Gas leakage from EGR piping • Gas leaks from EGR piping. Replace EGR piping.
9 Seized or broken VFT Replace VFT.
does not change.
• Measured fuel return rate is excessive.
Correct or replace fuel
11 Defective fuel return piping "Testing fuel discharge, return and
return piping.
leakage".)
• Check fuel return piping for clogging.
• Replace sensor and check whether
Defective mass air flow and symptom disappears. Replace mass air flow
12 temperature sensor (Failure code may not be generated if and temperature
sensor is covered with dust.) sensor.
40-496 PC138USLC-10
40 Troubleshooting

14
PC138USLC-10 40-497
40 Troubleshooting
S-10 Engine oil consumption is excessive (D37-B10-400-A-Z0-A)
Failure Engine oil consumption is excessive.

information
Dust sucked from air intake • When intake piping between air cleaner and Clean or replace intake
1 system engine is removed, dust is found inside. piping.
• Measured blowby pressure exceeds
standard value.
• Blowby pressure is still high after KCCV
filter element is replaced. Replace piston ring or
2 Broken or worn piston ring
• Measure compression pressure (see correct its installation.
Oil leakage from KCCV oil • Check oil leakage from KCCV oil return Correct installation of
3 return piping piping. oil piping or replace it.
4 Oil leakage outside engine • Check for oil leakage. Repair oil leaks.
Oil leakage from oil filter • Check oil filter for oil leakage. Reinstall or replace oil
5
filter.
Correct installation of
6 Oil leakage from oil piping • Check oil piping for oil leakage.
oil piping or replace it.
Retighten oil drain
7 Oil leakage from oil drain plug • Check oil drain plug for oil leakage.
plug.
8 Oil leakage from oil pan • Check oil pan for oil leakage.
oil pan or replace it.
Oil leakage from cylinder • Check cylinder head for oil leakage. cylinder head or
9
head replace it.
Worn or damaged rear oil • Oil in clutch chamber or damper chamber
10 rear oil seal or replace
seal on machine increases.
it.
• VFT blower inlet and outlet, and turbine
outlet are dirty with oil.
11 Oil leakage from VFT • Check whether VFT shaft rotates. Replace VFT.
• Oil is in coolant.
• Remove oil cooler and check for oil leakage
12 Oil leakage from oil cooler outside oil cooler. Replace oil cooler.
• Check oil cooler for oil leakage by applying
air pressure.
• Check valve guide and stem seal.
• Remove cylinder head, and check inside
Worn or damaged valve Replace valve guide or
13 guide or stem seal diameter of guide and stem seal for
damage. stem seal.
(Reference: See "Maintenance standards".)
40-498 PC138USLC-10
40 Troubleshooting
S-11 Oil becomes contaminated quickly (D37-B20-400-A-Z0-A)
Failure Oil becomes contaminated quickly.

information
Use proper fuel
Improper fuel used • Fuel other than specified one is used. specified in Operation
1
and Maintenance
Manual.
Use proper oil
Improper oil used • Oil other than specified one is used. specified in Operation
2
and Maintenance
Manual.
• Check exhaust gas color at KDOC muffler Perform
Black exhaust gas at KDOC outlet (see standard value table). troubleshooting for "S-
3 (Reference: See Testing and adjusting, 9 Exhaust smoke is
muffler outlet.
"Testing exhaust gas color".) black".
standard value. Perform following
4 Excessive blowby gas
• Blowby pressure is still high after KCCV checks.
filter element is replaced.
• Rotate VFT shaft and check for play.
Defective seal on VFT turbine (Move VFT vanes with hand in axial and Replace VFT.
5
side radial directions to make judgment.)
• Check oil level for excessive refilling.
6 Excessive refilling of oil (If oil level is excessive, oil will reach high Refill with oil to correct
temperatures and early deteriorates.) oil level.
• Visually check oil cooler element for
contamination. Clean or replace oil
7 Dirty oil cooler element
(Contaminated oil cooler element can cooler element.
increased oil temperature.)
standard value.
• Blowby pressure is still high after KCCV
filter element is replaced. Replace piston ring or
8 Broken or worn piston ring
• Measure compression pressure (see correct its installation.
• Check valve guide and stem seal.
• Remove cylinder head, and check inside
Worn or damaged valve Replace valve guide
9 diameter of guide and stem seal for
guide or stem seal and stem seal.
damage.
(Reference: See "Maintenance standards".)
PC138USLC-10 40-499
40 Troubleshooting
S-12 Fuel consumption is excessive (D37-B70-400-A-Z0-A)
Failure Fuel consumption is excessive.

information
Replace injector.
• Measure spill rate from injector.
Excessive spill of fuel from (Reference: See Testing and adjusting, Lots of dusts are is
1 injector "Testing fuel discharge, return and probably in fuel. Check
leakage".) storage management
of fuel.
• Check fuel return piping for clogging.
Correct or replace fuel
2 Clogged fuel return piping (Injection rate may be increased due to
return piping.
clogged fuel return piping.)
with some cylinder cutout, engine speed
does not change.
Fuel leakage from cylinder • Check for increased oil level. Repair defective parts.
4
head • Check for smell of diesel fuel.
• Check for increased engine oil level and
Fuel leakage from supply
5 smell of diesel fuel. Replace supply pump.
pump oil seal
• Check supply pump oil seal.
6 Fuel leakage outside engine • Check for fuel leakage outside engine. Repair defective parts.
40-500 PC138USLC-10
40 Troubleshooting
S-13 Oil is in coolant (or coolant spurts or coolant level goes down) (PC400-
B40-400-A-Z0-A)
Failure Oil is in coolant (or coolant spurts or coolant level goes down)
Related information • If any failure code is displayed, carry out troubleshooting for it first.
No. Cause Detail of work, remarks Remedy
Perform
troubleshooting for "S-
1 Milky engine oil • Engine oil level rises and oil is milky
16 Water mixes into
engine oil (milky)".
Damaged oil cooler element Replace oil cooler
2 • Check oil cooler element
element
• Coolant in radiator has excessive air
bubbles and blows back.
3 Damaged cylinder head • Overhaul engine and perform a pressure Replace cylinder head
tightness test on cylinder head to check for
abnormalities
• Coolant in radiator has excessive air
Damaged cylinder head bubbles and blows back. Replace cylinder head
4 gasket • Overhaul engine and check cylinder head gasket
gasket for abnormalities
• Engine oil level rises and oil is milky
Cracks or pitting in cylinder • Disassemble engine and check for cracks Replace cylinder block
5
block or pitting in cylinder block
PC138USLC-10 40-501
40 Troubleshooting
S-14 Oil pressure drops (PC400-10D-400-A-Z0-A)
Failure Oil pressure drops

• If any failure code is displayed, carry out troubleshooting for it first.
Related information • Confirm if machine has been operated on a slope steeper than specified in the
Operation and Maintenance Manual.
• Oil level in oil pan is low
1 Lack of oil in oil pan • Oil pressure monitor indicates low oil Add oil
pressure when operating on slopes
Defective oil pressure sensor, Replace oil pressure
• Check oil pressure sensor, wiring harness,
2 wiring harness sensor, wiring harness,
and connector
or connector
If oil is contaminated
with fuel, carry out
• Perform oil analysis and check for fuel in oil
3 Fuel in oil troubleshooting for "S-
• Engine oil smells of diesel fuel
15 Fuel mixes into
engine oil"
If oil is contaminated
• Perform oil analysis and check for water in with water, carry out
4 Water in oil oil troubleshooting for "S-
• Oil is milky 16 Water mixes into
engine oil (milky)"
• Check oil filter
(Reference: Oil filter has been used beyond
5 Clogged oil filter the specified period, oil heavily Replace oil filter
deteriorated, etc.)
• Water in oil can cause oil filter blockage
6 Clogged oil strainer • Check oil strainer Clean oil strainer
Crushed or clogged hydraulic Replace hydraulic
7 • Hydraulic piping is crushed or clogged
piping piping
• Check oil pump
8 Defective oil pump (worn or damaged gear) Replace oil pump
• Oil pump rotation is heavy or it has play
Defective regulator valve • Check valve spring for fatigue or damage Replace regulator
9
valve
• Valve and spring of oil pump relief valve is Replace oil pump relief
10 Defective oil pump relief valve fatigued, damaged. valve
Cracks in oil pump suction • Check around oil pump suction piping Replace oil pump
11 piping (cracked piping) suction piping
Defective seal between oil
12 pump and oil pump suction • Check seal Replace seal
piping
Replace boost oil
13 Defective boost oil pump • Check boost oil pump
pump
Defective boost oil pump relief • Check boost oil pump relief valve for fatigue Replace boost oil
14 or damage on valve and spring pump relief valve
valve
Oil leakage from EGR Replace EGR
15 hydraulic piping • Check EGR hydraulic piping
hydraulic piping
• Check main journal bearing
Replace main journal
16 Worn main journal bearing • Metallic powders are found in oil drained
bearing
from oil pan
• Check pin journal bearing
Replace pin journal
17 Worn pin journal bearing • Metallic powders are found in oil drained
bearing
from oil pan
Worn idler bushing, damaged Replace idler bushing
18 idler gear • Check idler bushing and idler gear
or idler gear
Breakage or falling off of Replace piston cooling
19 piston cooling nozzle • Check piston cooling nozzle
nozzle
40-502 PC138USLC-10
40 Troubleshooting
S-15 Fuel mixes into engine oil (PC400-B31-400-A-Z0-A)
Failure Fuel mixes into engine oil (smells of diluted diesel fuel)
Related information • If any failure code is displayed, carry out troubleshooting for it first.
• When exhaust manifold is touched
immediately after starting engine,
temperature of some cylinders is low
1 Defective injector • When a certain cylinder is cut out, engine Replace Injector
speed does not change
"Handling of cylinder cut-out operation".)
Fuel leakage from injector or
2 • Check injector or O-ring Replace injector O-ring
O-ring (spill circuit)
Defective seal between
• Check seal between injector and injection
3 injector and injection piping, Repair or replace
piping, and check injection piping for cracks
cracks in injection piping
• Confirm that fuel no longer mixes into oil
4 Defects in supply pump Replace supply pump
after supply pump is replaced
PC138USLC-10 40-503
40 Troubleshooting
S-16 Water mixes into engine oil (milky) (D65-B32-400-A-Z0-A)
Failure Water mixes into engine oil (milky).

• If oil mixes into coolant, perform troubleshooting for "S-13 Oil mixes into coolant".
When engine starting and stopping is frequently repeated in low ambient temperatures,
Related since KCCV is installed, condensed water vapor in blowby gas may mix into oil leading to
information milky oil or emulsified oil inside engine, but this is normal. This is not problem if coolant is
not leaking.
If coolant leakage is suspected from rapid drop of coolant level, perform following
troubleshooting procedures.
• Coolant containing COOLANT flows out
when gas piping are removed from EGR
cooler inlet and outlet.
(Check whether water contains COOLANT
or not. It can be condensed water.)
1 Cracks in EGR cooler (Reference: Note that cracks in EGR cooler Replace EGR cooler.
are caused by and preceded by drop of
coolant level of cooling system in some
cases. When replacing EGR cooler, check
cooling system piping and radiator for water
leakage.)
Damaged oil cooler element • Check oil cooler element and gasket Replace oil cooler
2 or gasket • Pressure test on oil cooler shows that water element or gasket.
leaks.
Replace cylinder head
Damaged cylinder head or • Disassemble engine to check cylinder head
3 or cylinder head
cylinder head gasket and cylinder head gasket.
gasket.
• Engine oil level increases and oil is milky.
Cracks or pitting in cylinder • Disassemble engine and check inside of Replace cylinder block.
4
block cylinder block for cracks or pitting.
40-504 PC138USLC-10
40 Troubleshooting
S-17 Coolant temperature rises too high (overheating) (D37-AL0-400-A-Z0-A)
Failure Coolant temperature rises too high (overheating).

information
Clogged radiator core • Check radiator core for clogging, and check
1 Clean radiator core.
fin for crush.
• Thermostat does not open at cracking
temperature.
2 Malfunction of thermostat a Thermostat cracking temperature: 79.4 to Replace thermostat.
83.3°C
(Full open temperature: 95°C)
• Error related to coolant temperature is Replace coolant
Defective coolant temperature sensor,
3 displayed, but measured value of radiator
temperature gauge monitor or wiring
coolant temperature is normal.
harness.
Perform
Increased fuel injection rate • Fuel injection rate is high. troubleshooting for "S-
4
12 Fuel consumption is
excessive".
5 Low coolant level • Check coolant level for lowering Refill with coolant
6 Leakage of coolant • Check water leakage from coolant piping Replace coolant piping
• Visually check water pump
(Check shaft seal for water leakage,
7 Breakage of water pump Replace water pump.
impeller for damage, and shaft for
breakage.)
Overheating due to increased
EGR ratio (EGR amount Replace mass air flow
against fresh air amount) • Check mass air flow and temperature
8 and temperature
caused by defective mass air sensor.
sensor.
flow and temperature sensor
Overheating due to increased
EGR ratio (EGR amount • Check air cleaner for deformation and Repair or replace air
9 against fresh air amount) presence. cleaner.
caused by air cleaner
deformation
Defective cylinder head or • Check radiator coolant for excessive Perform
10 cylinder head gasket bubbles and spurt back troubleshooting for "S-
13 Oil is in coolant".
• Open exhaust color inspection hole for the
KDOC muffler outlet, and check exhaust
gas.
"Testing exhaust gas color".) Replace piston ring or
11 Defective piston ring • Measure compression pressure (see piston.
PC138USLC-10 40-505
40 Troubleshooting
S-18 Unusual noise is heard (D37-BA1-400-A-Z0-A)
Failure Unusual noise is heard.

• Check whether noise source is in or outside engine before starting troubleshooting.
• Engine runs in low-temperature mode while it is not warmed up sufficiently. Accordingly,
engine sound becomes slightly larger. This does not indicate abnormality, however.
Related • When engine accelerates, it switches into acceleration mode and its sound becomes
information slightly large further for up to approximately 3 to 5 seconds. This does not indicate
abnormality, however.
• Exhaust gas leaks from piping between
cylinder head and exhaust manifold,
Exhaust gas leakage from between exhaust manifold and VFT, or Repair or replace
1 piping between VFT outlet and KDOC muffler. defective parts.
• Exhaust gas leaks from EGR piping or air
intake piping.
Vibration of exhaust piping or • Visually check for vibration. Check and retighten
2 piping brackets.
exhaust bellows
3 Seized or broken VFT (Move VFT vanes with hand in axial and Replace VFT.
Replace KDOC
4 Damage inside KDOC muffler • Check inside KDOC muffler.
muffler.
does not change.
• Check valve clearance.
6 Incorrect valve clearance (Reference: See Testing and adjusting, Adjusting valve
"Testing and adjusting valve clearance".) clearance
Seized pin bushing, front Repair or replace
7 bearing, or main bearing • Check for metal particles in oil pan.
damaged parts.
• If metal particles is found in oil pan or oil
filter, overhaul engine and check piston ring
and cylinder liner.
Worn piston ring or cylinder Replace piston ring or
8 • Measure compression pressure (see
liner cylinder liner.
• Overhaul engine and check valves and Replace valve or
9 Damaged valve or rocker arm rocker arm parts. rocker arm.
10 Damaged idler gear • Overhaul engine and check idler gear parts. Replace idler gear.
• Check fan and fan belt for damage and Repair or replace
11 Defective fan or fan belt damaged parts.
interference.
40-506 PC138USLC-10
40 Troubleshooting
S-19 Vibration is excessive (D37-BC0-400-A-Z0-A)
Failure Vibration is excessive.

• If unusual noise is heard and vibration is excessive, perform troubleshooting for "S-18
Related Unusual noise is heard", too.
information • If any failure code is displayed, perform troubleshooting for that code first.
• Visually check engine mounting bolts for
Loose engine mounting bolts Retighten bolts or
1 looseness and cushions for cracks and
or defective cushions replace cushions.
hardening.
Defective output shaft or • Check output shaft for damage and damper Replace defective
2 internal defect of damper parts.
for internal defect.
Misalignment and facial
• Measure misalignment and facial runout at
runout at connection between Replace defective
3 connection between engine and hydraulic
engine and hydraulic pump parts.
pump.
are out of standard range.
does not change.
Worn main bearing or • If metal particles are found in oil pan or oil Repair or replace
5 connecting rod bearing filter, overhaul engine. damaged parts.
• If metal particles are found in oil pan or oil Repair or replace
6 Stuck valve or rocker arm filter, open cylinder head cover and check damaged parts.
valves and rocker arms.
• If metal particles are found in oil pan or oil
Replace camshaft
7 Worn camshaft bushing filter, overhaul engine and check camshaft
bushings.
bushings.
PC138USLC-10 40-507
40 Troubleshooting
S-20 Air cannot be bled from fuel circuit (WA380_7-A29-400-A-Z0-A)
Failure Air cannot be bled from fuel circuit.

information
• Check drain valve of fuel pre-filter for
Loosened drain valve of fuel looseness.
2 pre-filter (Air enters fuel circuit from loosened drain Close drain valve.
valve.)
3
• Air is bled during air bleeding of fuel system.
Repair or replace fuel
4 Air in fuel piping system (Reference: See Testing and adjusting,
piping.
"Bleeding air from fuel system".)
"Checking fuel circuit for leakage".)
40-508 PC138USLC-10
SHOP MANUAL
HYDRAULIC EXCAVATOR
PC138USLC-10
Model Serial Number

10
50 Disassembly and assembly

7 50 Disassembly and assembly
PC138USLC-10 50-1
Table of contents

50 Disassembly and assembly ........................................................................................................... 50-1
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
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
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
50-2 PC138USLC-10
Table of contents
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
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
PC138USLC-10 50-3
General information on disassembly and assembly
General information on disassembly and assembly (ALL-3851-001-A-00-A)
How to read this manual (ALL-0320-011-A-00-A)

(Rev.2010.10)
Removal and installation of TTTT assembly • Common tools that are necessary for installation
Special tools are described as [1], [2] ... etc. and their part
• Special tools which are necessary for removal or numbers, part names and quantities are not
installation of assemblies are described as described.
A1•••X1 etc. and their part numbers, part names, • Marks shown in the installation section are
necessities, and quantities are described in the explained below.
special tool list. k: This mark indicates safety-related
• Marks used in the column of necessity are precautions which must be followed when
explained below. performing the work.
t: Tools are not substituted, must always be
equipped (used). a : This marks gives guidance or precautions
q: Tools extremely useful if available or tools when performing the work.
that can be substituted with commercially
available tool. 4 : This mark shows the weight of a part or
• For details and the sketches of the special tools, the assembled parts for a device.
see "special tool list" and "sketches of special
tools". 2 : This mark indicates a specific coating
Removal agent to be used.
• In the removal section, the work procedures, 3 : This mark indicates the specified
precautions and know-how to do the work and tightening torque.
the amount of oil and coolant to be drained are
described. 5 : This mark indicates the amount of oil or
• Common tools that are necessary for the coolant to be added.
removal work are indicated as [1], [2] ... etc. and
their part numbers, part names and quantities Disassembly and assembly of TTTT assembly
are not described. Special tools
• Marks used in the removal section are explained • Special tools which are necessary for
below. disassembly and assembly of assemblies are
described as A1•••X1 etc. and their part
k: This mark indicates safety-related numbers, part names, necessities, and
precautions which must be followed when quantities are described in the special tool list.
performing the work. • Marks used in the column of necessity are
explained below.
a : This mark gives guidance or precautions when t: Tools are not substituted, must always be
performing the work. equipped (used).
[*1]: This mark indicates that instructions or q: Tools extremely useful if available or tools
precautions for the assembly installation work are that can be substituted with commercially
given in the installation section. available tool.
• For details and the sketches of the special tools,
6 : This mark shows the amount of oil or see "special tool list" and "sketches of special
coolant to be drained. tools".
Disassembly
4 : This mark shows the weight of a part or • In the disassembly section, the work
the assembled parts for a device. procedures, precautions and know-how to do
Installation the work, and the amount of oil and coolant to be
• Unless otherwise instructed the installation of drained are described.
assemblies is to be made in the reverse order to • Common tools that are necessary for the
removal. disassembly work are indicated as [1], [2] ... etc.
• Instructions and precautions for assembly and their part numbers, part names, and
installation are shown with [*1] mark in the quantities are not described.
removal section, identifying which step the • Marks used in the disassembly section are
instructions are intended for. explained below.
50-4 PC138USLC-10
k: This mark indicates safety-related

precautions which must be followed when
performing the work.
a : This marks gives guidance or precautions

when performing the work.
6 : This mark shows the amount of oil or

coolant to be drained.
4 : This mark shows the weight of a part or

the assembled parts for a device.
Assembly
• In the assembly section, the work procedures,
precautions and the know-how to do the work,
and the amount of oil or coolant to be added are
described.
• Common tools that are necessary for the
disassembly work are indicated as [1],[2] ... etc.
and their part numbers, part names, and
quantities are not described.
• Marks used in the assembly section are
explained below.
k: This mark indicates safety-related
precautions which must be followed when
a : This mark gives guidance or precautions when

4 : This mark shows the weight of a part or

the assembled parts for a device.
2 : This mark indicates a specific coating
agent to be used.
3 : This mark indicates the specified
tightening torque.
5 : This mark indicates the amount of oil or

coolant to be added.
PC138USLC-10 50-5
Coating materials list (ALL-3540-071-A-00-A)

(Rev.2012.11)
a The recommended coating materials such as adhesives, gasket sealants, and greases used for
disassembly and assembly are listed below.
a For coating materials not listed below, use the equivalent of products shown in this manual.
Adhesive
Komatsu code Part No. Capacity Container Main features and applications
• Use to prevent rubber gaskets, rubber
LT-1A 790-129-9030 150 g Tube cushions, and cork plugs from coming
out.
• Use for plastic (except polyethylene,
20g polypropylene, tetrafluoroethylene, and
Polyethylene vinyl chloride), rubber, metal, and non-
LT-1B 790-129-9050 (2 pcs. container metal parts which require immediate
contained)
and strong adhesion.
• Features: Resistance to heat and
50 g Polyethylene chemicals
LT-2 790-129-9180
container • Use to fix and seal bolts and plugs.
Adhesive:
790-129-9060 1 kg • Use to bond and seal metal, glass and
LT-3 (Set of adhesive Can
Hardener: plastics.
and hardener)
500 g
250 g Polyethylene • Use to seal plugs for blank holes.
LT-4 790-129-9040
container
• Heat-resistant seal used to repair
Holtz MH705 790-129-9120 75 g Tube engines
• Instantaneous adhesive
50 g Polyethylene • Curing time: From 5 sec. to 3 min.
ThreeBond 1735 790-129-9140 • Use mainly to bond metals, rubbers,
container
plastics, and woods.
• Instantaneous adhesive
2g • Quick-curing type (max. strength is
Aron Alpha 201 Polyethylene
790-129-9130 (5 pcs. obtained after 30 minutes)
container
contained) • Use mainly to bond rubbers, plastics,
and metals.
• General-purpose instantaneous
adhesive with excellent resistance to
Loctite 499 428-99-80070 20 g Tube heat and impact
• Use on the bushing mounting faces of
axle supports.
• Features: Resistance to heat and
Polyethylene chemicals
Loctite 648-50 79A-129-9110 50 cc • Use for fitted portions used at high
container
temperatures.
50-6 PC138USLC-10
Liquid gasket
• Use to seal various thread portions,
LG-5 Polyethylene pipe joints, and flanges.
790-129-9080 1 kg
ThreeBond 1110F container • Use to seal taper plugs, elbows, and
nipples for hydraulic piping.
• Features: Silicon-based heat and
cold-resistant sealant
LG-6 • Use to seal thread portions and flange
790-129-9160 250 g Tube
ThreeBond 1215 surface.
• Use to seal oil pan, final drive case,
etc.
• Features: Silicon-based quick-curing
LG-7 sealant
ThreeBond 790-129-9170 150g Tube • Use to seal flywheel housing, intake
1207C manifold, oil pan, thermostat housing,
etc.
LG-8 • Features: Silicon-based, heat and
cold-resistant, vibration-resistant,
ThreeBond 419-15-18131 100 g Tube impact-resistant sealant
1207B • Use to seal transfer case, etc.
• Use for rough surfaces such as the
LG-9 circle gear top seal which is not
ThreeBond 790-129-9310 200 g Tube clamped by bolts, gaps in the weld
1206D which must be caulked, etc.
• Can be coated with paint.
LG-10 • Use as lubricant or sealant when the
ThreeBond 790-129-9320 200 g Tube radiator hoses are put on.
1206E • Can be coated with paint.
• Feature: Can be used together with
LG-11 solid gaskets.
790-129-9330 200 g Tube
ThreeBond 1121 • Use for covers of the transmission
case and steering case etc.
ThreeBond 1211 790-129-9090 100 g Tube • Liquid gasket used to repair engine
Molybdenum disulfide lubricant

• Use to prevent galling and seizure of
press-fitted portions, shrinkage-fitted
LM-P 09940-00040 200 g Tube portions, and thread portions.
• Use to lubricate linkages, bearings,
etc.
• Spray type
• Thin molybdenum disulfide films are
made on metal surfaces to prevent the
LM-S 09995-00250 190 g Can metals from galling.
• Use for the drive shaft splines, needle
bearings, pins and bolts of various
links, etc.
PC138USLC-10 50-7
Seizure prevention compound

• Feature: Seizure and galling
prevention compound with metallic
LC-G super-fine-grain, etc.
— — Can
NEVER-SEEZ • Use for the mounting bolt in the high
temperature area of the exhaust
manifold and the turbocharger, etc.
Grease
SYG2-400LI-A
G2-LI • Lithium grease with extreme pressure
SYGA-16CNLI
G0-LI (*) Various Various lubrication performance, general
SYG0-400LI-A(*) purpose type
*: For cold regions
SYG0-16CNLI(*)
• Use for parts under heavy load.
Caution:
• Do not use this grease for rolling
Molybdenum SYG2-400M 400 g x 10 Bellows-type bearings like swing circle bearings,
disulfide grease SYG2-400M-A 400 g x 20 container etc. and splines.
LM-G (G2-M) SYGA-16CNM 16 kg Can • Use this grease for work
equipment pins only when
installing them, but do not use it
afterward.
Hyper White
SYG2-400T • Higher seizure resistant, heat
Grease Bellows-type
SYG2-16CNT 400 g resistant and water resistant than
G2-T container molybdenum disulfide grease.
SYG0-400T(*) 16 kg • Not conspicuous on machine since
G0-T (*) Can
SYG0-16CNT(*) color is white.
*: For cold regions
Bio grease
G2-B SYG2-400B
SYGA-16CNB 400 g Bellows-type • Since this grease is biodegradable in
G2-BT (*) container short period, it has less impact on
*: For use at high SYG2-400BT(*) 16 kg microorganisms, animals, and plants.
Can
temperature and SYGA-16CNBT(*)
under high load
• Silicone grease with wide usable
temperature range, high resistance to
G2-S thermal-oxidative degradation and
— 200 g Tube performance to prevent deterioration
ThreeBond 1855 of rubber and plastic parts
• Use for oil seals of the transmission,
etc.
• Urea (organic system) grease with
heat resistance and long life.
G2-U-S Enclosed type.
427-12-11871 2 kg Can • Use for rubber, bearing and oil seal in
ENS grease damper.
Caution: Do not mix it with lithium
grease.
50-8 PC138USLC-10
Primer
Glass • Use to accelerate hardening of
Loctite 712 428-99-80080 100 ml
container instantaneous adhesive.
• Use as primer for painted cab
Sunstar Paint Glass sheet metal surface.
Primer 580 Super 20 ml (Effective period: 4 months after
container
manufacture)
417-926-3910
• Use as primer for cab glass
Sunstar Glass Glass surface.
20 ml
For adhering cab glass

Primer 580 Super container (Effective period: 4 months after
manufacture)
• Use as primer for painted cab
Sunstar Paint Glass sheet metal surface.
22M-54-27230 20 ml (Effective period: 4 months after
Primer 435-95 container
manufacture)
• Use as primer for black ceramic-
coated glass surface and for hard
Sunstar Glass polycarbonate-coated surface.
22M-54-27240 150 ml Steel can
Primer 435-41 (Effective period: 4 months after
manufacture)
• Use as primer for sash (Almite)
Sunstar Sash Glass (Effective period: 4 months after
22M-54-27250 20 ml
Primer GP-402 container manufacture)
Adhesive
• Use "S" in high temperature

season and "W" in low
Sunstar Penguin
Polyethylene temperature season as adhesive

Seal 580 Super 417-926-3910 320 ml for glass.
container
"S" or "W" (Effective period: 4 months after
manufacture)
• Use as adhesive for glass.

Sika Japan, Cartridge (Effective period: 6 months after
20Y-54-39850 310 ml
Sikaflex 256HV manufacture)
Ecocart • Use as adhesive for glass.
Sunstar Penguin
22M-54-27210 320 ml (Special (Effective period: 6 months after
Super 560
container) manufacture)
Caulking material
• Use to seal joints of glass parts.
Sunstar Penguin
417-926-3920 330 ml Cartridge (Effective period: 4 months after

Seal No.2505 manufacture)
• Use to seal front window.
Sekisui Silicone Cartridge (Effective period: 6 months after
20Y-54-55130 333 ml
Sealant 83 manufacture)
• Use to seal glass-to-glass joint.
GE Toshiba Translucent white seal.
Silicones 22M-54-27220 333 ml Cartridge
(Effective period: 12 months after
TOSSEAL 381 manufacture)
PC138USLC-10 50-9
Special tools list (PC138-3530-061-A-00-A)
a Tools with part number 79*T-***-**** are not supplied (to be locally manufactured).
a Necessity
t: Tools are not substituted, must always be equipped (used).
q: Tools extremely useful if available or tools that can be substituted with commercially available tools.
a New/Redesign
N: Tools with new part numbers, newly developed for this model.
R: Tools, with advanced part numbers, developed by improving existing tools for other models.
Blank: Tools already available for other models that can be used without any modification.
a Tools marked with Q in the Sketch column have the sketches. (See "Sketches of special tools")
New/Redesign
Necessity
Sketch
Sym- Details of work and
Q'ty
Work Part No. Part name
bol remarks
Removal and
Removal of supply
installation of supply 1 790-101-3000 Push puller t 1 N
pump gear
pump assembly
795T-221-1010 Push tool t 1 Q
Removal and 790-101-5201 Push tool kit t 1
Installation of engine
installation of engine 2 790-101-5271 • Plate 1
front seal
front oil seal 790-101-5221 • Grip 1
A 01010-51225 • Bolt 1
795T-221-1020 Plate t 1 Q
Removal and 790-101-5401 Push tool kit t 1
Installation of engine
installation of engine 3 790-101-5431 • Plate 1
rear seal
rear oil seal 790-101-5421 • Grip 1
01010-51240 • Bolt 1
Removal and
4 796-401-1300 Fixing jig t 1 N
installation of fan belt
1 790-201-2750 Spacer t 1 Removal of split collar
790-101-2501 Push puller kit q 1
790-101-2510 • Block 1
790-101-2550 • Leg 1
790-101-2560 • Nut 2
2 790-101-2570 • Plate 4 Removal of bearing
790-101-3101 • Bearing puller q 1
• Puller (294 kN {30
790-101-4200 ton}) q 1
Disassembly and 790-101-1102 Hydraulic pump q 1
assembly of swing F Press fit of bearing
machinery assembly 790-101-5401 Push tool kit (C) q 1
outer race
790-101-5461 • Plate 1 For main bearing
3 790-101-5441 • Plate 1 For sub bearing
790-101-5421 • Grip 1
01010-51240 • Bolt 1
Press fit of bearing
4 790-201-2850 Spacer t 1
inner race
5 790-201-2750 Spacer t 1
796T-426-1140 Push tool t 1 Q Press fit of oil seal
6
790-201-2680 Plate q 1
50-10 PC138USLC-10
New/Redesign
Necessity
Sketch
Q'ty
bol remarks
791-620-3000Remover and installer t 1

791-635-3110 • Frame 1
791-635-3120 • Support 1
791-635-3130 • Nut 1
791-635-3140 • Screw 1
791-635-3150 • Hook 1
791-635-3160 • Extension 1
791-635-3170 • Nut 4
Separation and 791-635-3180 • Screw 2 Removal and press fit
connection of track G 791-635-3190 • Screw (for fixing) 1 of master pin
shoe assembly
791-635-3210 • Pilot 1
791-630-3220 • Adapter 1
791-620-3260 • Pin pusher 1
796T-432-1010Guide t 1 Q
Cylinder (980 kN {100
790-101-1300 ton})
or t 1
790-101-1600 ton})
791-101-1102 Pump t 1
Disassembly and
assembly of idler t 1 Press fit of floating
1 791-675-1510 Installer
assembly seal
791-600-2001 Compressor (A)
or t 1
Compressor (B)
791-685-8006
791-635-3160 Extension t 1 Compression of
2 790-201-2770 Spacer t 1 spring
L 790-101-1600 t 1
Disassembly and ton})
assembly of idler 790-101-1102 Pump t 1
cushion assembly 790-201-1500 Push tool kit q 1
• Plate (outer diameter:
790-101-1590 74 mm) 1
• Plate (outer diameter: Press fit of pin dust
3
790-201-1610 79 mm) 1 seal
790-101-5021 • Grip 1
01010-50816 • Bolt 1
Installation of floating
1 790-434-1650 Installer t 1 seal (diameter: 88
Disassembly and
mm)
assembly of track M
roller assembly Sealing oil and check
2 791-601-1000 Oil pump q 1 of air leakage
PC138USLC-10 50-11
New/Redesign
Necessity
Sketch
Q'ty
bol remarks
Removal and 1 796-460-1210 Oil stopper q 1

installation of
hydraulic oil cooler
assembly
Removal and
installation of engine
and main pump
assembly
Removal and Shut off of oil in the
installation of R hydraulic tank
2 22B-60-31161 Adapter q 1
hydraulic tank
assembly
Removal and
installation of main
pump assembly
Removal and
installation of control
valve assembly
790-101-2501 Push puller q 1
790-101-2510 • Block 1
790-101-2520 • Screw 1
Disassembly and 790-101-2540 • Washer 1
assembly of center Disconnection of rotor
T 791-112-1180 • Nut 1
swivel joint assembly and shaft
790-101-2630 • Leg 2
790-101-2570 • Washer 4
790-101-2560 • Nut 2
790-101-2650 • Adapter 2
50-12 PC138USLC-10
New/Redesign
Necessity
Sketch
Q'ty
bol remarks
790-502-1003 Repair stand t 1 Disassembly and

1 assembly of cylinder
790-101-1102 Pump t 1
790-102-4300 Wrench assembly t 1 Removal and
2 installation of piston
790-102-4310 Pin t 1
790-201-1702 Push tool kit t 1
790-201-1791 • Push tool 1 Press fit of bucket
790-101-5021 • Grip 1 cylinder roll bushing
01010-50816 • Bolt 1
790-201-1811 • Push tool 1 Press fit of boom
3 cylinder roll bushing
790-101-5021 • Grip 1
01010-50816 • Bolt 1
Press fit of arm and
790-201-1821 • Push tool 1
blade cylinder roll
790-101-5021 • Grip 1 bushings
Disassembly and
assembly of work 01010-50816 • Bolt 1
equipment cylinder U 790-201-1500 Push tool kit q 1
assembly 790-201-1610 • Push tool 1 Installation of bucket
790-101-5021 • Grip 1 cylinder dust seal
01010-50816 • Bolt 1
790-201-1500 Push tool kit q 1
790-201-1620 • Push tool 1 Installation of boom
4 cylinder dust seal
790-101-5021 • Grip 1
01010-50816 • Bolt 1
790-201-1630 • Push tool 1 Installation of arm and
blade cylinder dust
790-101-5021 • Grip 1 seal
01010-50816 • Bolt 1
Expansion of piston
5 790-720-1000 Expander t 1
ring
796-720-1650 Ring t 1 Removal of bucket
6 cylinder and piston
07281-01029 Clamp t 1 ring
796-900-1200Remover t 1
796-900-1210 • Sleeve 1
792-900-1520 • Plate 1
799-900-1230 • Screw 1
Removal and
796-900-1240 • Adapter 1 Removal of boom foot
installation of work V
01643-33080 • Washer 1 pin
equipment assembly
01803-13034 • Nut 1
Puller
790-101-4000 (490 kN {50 ton} long) t 1
790-101-1102 Pump (294 kN {30 ton}) t 1
Removal and 1 793-498-1210 Lifter (suction cup) t 2 Holding glass
installation of
operator's cab glass X
(adhered window 2 22B-54-38320 Stopper rubber t 3 Fixing glass
glass)
PC138USLC-10 50-13
Sketches of special tools (PC138-3531-066-A-00-A)
A2: Push tool
A3: Plate
50-14 PC138USLC-10
F6: Push tool
G: Guide
PC138USLC-10 50-15
Removal and installation of supply pump assembly (PC138-AD70-924-K-00-A)
a Special tools
Necessity
Sym-
Q'ty
Part No. Part name
bol
A 1 790-101-3000 Push puller t 1

the work equipment to the ground, and stop
the engine.
k Place the lock lever in LOCK position.

8. Disconnect solenoid clutch connector AC03 (13)
k Turn the battery disconnect switch to OFF of the air conditioner compressor.
a The procedure in the next section is the working

procedure when the counterweight is installed.
Work for some steps are easier when the
counterweight is not installed.
Removal (PC138-AD70-520-K-00-A)
1. Open the engine cover, remove mounting bolts

(1) (4 pieces), and remove engine cover (2).
2. Remove step (3) on the top of the air conditioner
compressor and step (4).
9. Remove fan guard (14) and pulley cover (15).

10.Loosen bolts (16) (4 pieces).
11.Loosen lock nut (17) and rotate jack bolt (18) to
slide air conditioner compressor (19) in the
direction in which the compressor is loosened.
12.Remove the fan belt. For details, see "Removal
and installation of fan belt".
13.Move air conditioner compressor (19) to the
machine side.
a Do not disconnect the air conditioner hose.
3. Remove hose clamps (6) and (7) of blowby gas

outlet hose (5) of KCCV ventilator.
4. Remove bolts (9) (2 pieces) of blowby gas outlet
hose (5) that fix bracket (8), and remove blowby
gas outlet hose (5).
5. Remove clamp bolt (10), and disconnect air
conditioner hose (11) from bracket (8).
6. Remove bracket (8).
7. Disconnect clamp (12) that fixes air conditioner
hose (11) on the machine side.
14.Disconnect clamps (20) (2 pieces) of the wiring

harness.
50-16 PC138USLC-10
a Note that there is another clamp on the back

side of bracket (21) as shown in the following
figure
15.Remove bracket (21).
20.Remove fuel spray prevention caps (30) (2

pieces) of fuel high-pressure pipes (29). [*2]
21.Loosen sleeve nuts (2) (2 pieces) and remove
high-pressure fuel pipes (29). [*3]
22.Remove joint bolts (31) (2 pieces), and remove
16.Remove clamp bolt (23) (2 pieces,) and
fuel tube (32).
disconnect the wiring harness.
17.Disconnect connector (24) of crankshaft speed a When removing the fuel high-pressure pipe,
sensor (NE). be careful not to apply excessive force to the
tube.
23.Remove joint bolt (33), and disconnect fuel hose
(34). [*4]
(36).
(38). [*5]
26.Remove connector SCV (39) of the supply
pump regulator and disconnect wiring harness
(40).
18.Remove mounting bolts (25) (2 pieces), and

remove plates (26) and (27). [*1]
27.Remove mounting bolts (41) (4 pieces).

28.Remove mounting bolts (42), and remove
supply pump assembly (43) together with the
gear. [*6]
19.Remove bolts (28) (2 pieces,) and disconnect

the wiring harness.
PC138USLC-10 50-17
Installation (PC138-AD70-720-K-00-A)
• Perform installation in the reverse order of

removal.
[*1]
3 Plate mounting bolt:
8.8 to 14.7 Nm {0.9 to 1.5 kgm}
[*2]
a Face the slit of the fuel spray prevention cap
downward.
a The fuel spray prevention caps are installed so
29.Loosen nut (44). that fuel will not spout over the hot part of the
engine when it leaks by any chance.
a Do not remove the nut from the shaft.
[*3], [*4], [*5]
• Installation procedures for pipings
1. Install fuel high-pressure pipe (29).
a When installing the fuel high-pressure pipe,
be careful not to apply excessive force to the
tube.
3 Sleeve nut for fuel high-pressure pipe:
39.0 to 44.0 Nm {4.0 to 4.5 kgm}
2. Install fuel tube (32).
3. Install fuel hose (34).
3 Joint bolt:
30.Install tool A1 between the flange and gear (45) 17.6 to 19.6 Nm {1.8 to 2.0 kgm}
of the supply pump. 4. Install fuel hose (38).
3 Joint bolt:
17.6 to 19.6 Nm {1.8 to 2.0 kgm}
5. Install fuel hose (36).
[*6]
• Positioning of supply pump gear
a Match the top positions of pistons #1 and #4.
a When installing the supply pump assembly to
the front cover, align straightly the tapped
hole (a) of the gear and the tapped hole (b) of
the front cover viewing from the engine front .
31.Remove nut (44), washer (47,) and gear (45)

from shaft (46). [*7]
50-18 PC138USLC-10
a Install it with the stamp mark "C" (A) of the

gear facing the idler pulley.
[*7]
3 Gear mounting nut (44):
58.8 to 68.6 Nm {6.0 to 7.0 kgm}
PC138USLC-10 50-19
Removal and installation of injector assembly (PC138-AE60-924-K-00-A)

the engine.
k Turn the battery disconnect switch to OFF

Removal (PC138-AE60-520-K-00-A)
1. Remove mounting bolts (1) (3 pieces) to remove

cover (2) on the top of KDOC muffler.
2. Remove mounting bolts (3) (5 pieces) to remove 7. Disconnect hose (7-1).
inspection cover (4).
a To prevent the fuel from flowing back from
fuel return piping to the inside of the cylinder.
3. Open engine cover (5).

4. Remove step (6) on the top of the air conditioner
compressor and step (7). 8. Remove blowby gas outlet hose (12) and
bracket (13). [*1]
9. Remove blowby gas inlet hose (14). [*2]
a Make marks on the tube so that it can be
reconnected correctly.
10.Remove tube (15) between EGR valve and
EGR cooler. [*3]
a Make matchmarks on the tube so that it can
be reconnected correctly.
11.Disconnect aftercooler outlet hose (16). [*4]
5. Remove bolts (8) (2 pieces), clamp (9), and a Disconnect only the hose on the engine side.
bracket (10) from the area where inspection Move the hose away to a position where it is
cover (4) was removed. not an obstacle.
6. Disconnect tube (11). 12.Remove clamp (17) of the hose.
13.Move the air conditioner compressor assembly
to the machine body side. For details, see
"Removal and installation of air conditioner
compressor assembly".
50-20 PC138USLC-10
14.Disconnect connectors CN1 (18) on the intake 21.Disconnect connectors CN2 (26) on the intake
side. side.
15.Remove clamp (19). 22.Remove clamp (27).
16.Remove fuel spray prevention cap (20). 23.Remove fuel spray prevention cap (28).
17.Loosen the sleeve nut to remove fuel high- 24.Loosen the sleeve nut to remove high-pressure
pressure pipes (21). fuel pipes (29).
a When removing the fuel high-pressure pipe, a When removing the fuel high-pressure pipe,
be careful not to apply excess force to the be careful not to apply excess force to the
tube. tube.
18.Disconnect clamps (22) (3 pieces) of the wiring

harness.
19.Disconnect connector CCV (23).
a Move the wiring harness away to a position
where it is not an obstacle.
25.Remove cover (30).

26.Remove mounting bolt (31) to remove cylinder
head cover (32).
20.Remove brackets (24) and (25).
PC138USLC-10 50-21
a Read character string (M) in the order of the

arrow shown in the figure.
a Check that the noted character string (M) is
correct.
a Do not remove QR code tab (Q) attached to
the injector head.
a Do not damage QR code tab (Q) attached to
the injector head.
(Reference: The QR code or character string
indicates the difference of compensation
value for fuel injection of the injector, which is
27.Remove nuts (34) (8 pieces) for injector wiring specific to each injector.)
harness (33) from the injectors.
a Installing position of injector wiring harness
Color of injector wiring Cylinder No.
harness
White 1, 3
Black 2, 4

remove injector holders (36) (4 pieces).
a Always replace this bolt with a new bolt when
reassembling, because it is not reusable.
29.Remove injectors (37) (4 pieces).
Installation (PC138-AE60-720-K-00-A)
1. Injector assembly
a When replacing the injector assembly or
engine controller assembly, write the
character string into the engine controller
according to the following procedure. For
details, see Testing and adjusting, "Writing
compensation values at replacement of
injector and engine controller".
• Note the number of cylinder to which a new
injector is installed and character string (M)
a Before removing the injector, record the listed on the QR code tab at the top of the
cylinder number to which the injector is injector as a set.
installed and the character string (M) listed
on the QR code tab (Q) as a set. a Read character string (M) in the order of the
arrow shown in the figure.
50-22 PC138USLC-10
a Be sure to check that the noted character 5) Tighten the mounting bolt (35) of injector
string is correct. holder (36) lightly.
• Write the noted character string into the a Apply Loctite 204 to mounting bolt
engine controller. threads and bolt seat surface.
a Be sure to write the noted character string 2 Threaded portion:
into the cylinder number column of the
Liquid adhesive (Loctite No.204 or
cylinder to which the injector is installed.
equivalent)
a If the character strings are not written
a Do not overtighten this bolt.
correctly, the engine may not operate
normally. a Always use a new bolt, because it is not
(Reference: The QR code or character string reusable.
specific to each injector.)
2. Fuel high-pressure pipe
k Do not bend the fuel high-pressure pipe

to correct.
1) Install gasket (40) to injector (37).
2) Fit O-rings (41) and (42) to injector (37). k Be sure to use the genuine fuel high-
pressure pipe clamp and strictly observe
a Do not put the O-ring in spill groove (a).
the specified tightening torque.
3) Apply engine oil to O-ring (41) and head side
inserting hole of injector (37).
k Before fully tightening the fuel high-
2 O-ring and head side inserting pressure pipe, check it for the following. If
hole: the high-pressure fuel pipe has any defect,
Engine oil replace it with a new one since fuel may
4) Face the fuel inlet hole of injector (37) to the leak.
fuel inlet manifold side, and insert it into the • Make sure with visual check that the taper
cylinder head while inserting injector holder seal part of the connection ((a) part: 2 mm
(36) into (b) part of the injector. area from the tip-end) is free from
a Do not let gasket (40) at the tip of the longitudinal slits (b) or pits (c).
injector nozzle fall.
PC138USLC-10 50-23
• Be sure that part (d) (2 mm from the tip-end)

is free from steps which can be felt by your
fingernail. (Namely, this portion must be free
from fatigue.)
1) Lightly tighten the injector side of fuel high-

pressure pipes (21) and (29) to inlet
connectors (43) (4 pieces) with sleeve nut
(44).
a Also lightly tighten the common rail side
of the fuel high-pressure pipes with
sleeve nut.
2) Fully tighten mounting bolt (35) of injector
holder (36).
3 Injector holder mounting bolt:
39.0 to 49.0 Nm {4.0 to 5.0 kgm}
3) Fully tighten the mounting sleeve nut of the
fuel high-pressure pipe on the injector side.
3 Mounting sleeve nut:
39.0 to 44.0 Nm {4.0 to 4.5 kgm}
fuel high-pressure pipe on the common rail
side.
3 Mounting sleeve nut: 3. Injector wiring harness
39.0 to 44.0 Nm {4.0 to 4.5 kgm} 1) Install connectors CN1 (18) and CN2 (26).
5) Install tube clamps (19) and (27) of fuel high- 2) Tighten injector harness (33) with nut (34).
pressure pipes (21) and (29).
3 Mounting nut:
6) Install fuel spray prevention caps (20) and
(28) to the sleeve nuts of the fuel high- 2.0 to 2.4 Nm {0.20 to 0.24 kgm}
pressure pipes. a Be careful that the injector harness is not
a Face the slit of the fuel spray prevention pinched by the tool and rocker housing.
cap downward. a Installing position of injector wiring harness
a The fuel spray prevention caps are Color of injector wiring Cylinder No.
installed so that fuel will not spout over harness
the hot part of the engine when it leaks by White 1, 3
any chance. Black 2, 4
4. Perform the subsequent installation in the
reverse order to removal.
[*1], [*2]
3 Clamp (45):
3.0 to 3.5 Nm {0.30 to 0.35 kgm}
50-24 PC138USLC-10
3 Clamp (46):
3.0 to 3.5 Nm {0.30 to 0.35 kgm}
3 Clamp (47):
4.4 ± 0.49 Nm {0.45 ± 0.05 kgm}
[*3]
• Insertion position of tube (15) and the clamps
must be as shown in the following figure.
a Install the hoses and tubes to the positions
marked at removal.
3 Clamp:
• Air bleeding
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
Bleed air in the fuel system. For details, see
Testing and adjusting, "Bleeding air from fuel
system".
• Checking for fuel leakage
Check for fuel leakage. For details, see Testing
and adjusting, "Testing fuel circuit for leakage".
[*4]
• Insertion position of aftercooler outlet hose (16)
and the clamps must be as shown in the
following figure.
marked at removal.
a Check upward mark (e) of hose and install it.
3 Clamp:
10.5 ± 0.5 Nm {1.1 ± 0.05 kgm}
PC138USLC-10 50-25
Removal and installation of cylinder head assembly (PC138-A100-924-K-00-A)

the engine.

Removal (PC138-A100-520-K-00-A)

cover (2) on the top of KDOC muffler.
2. Remove mounting bolts (3) (5 pieces) to remove 7. Remove blowby gas outlet hose (12) and
inspection cover (4). bracket (13). [*1]
8. Remove blowby gas inlet hose (14). [*2]
9. Remove tube (15) between EGR valve and EGR
cooler. [*3]
10.Disconnect aftercooler outlet hose (16). [*4]
a Disconnect only the hose on the engine side.
3. Open engine cover (5). Move the hose away to a position where it is
4. Remove step (6) on the top of the air conditioner not an obstacle.
compressor and step (7). 11.Remove clamp (17) of the hose.
12.Move the air conditioner compressor assembly
to the machine body side. For details, see
"Removal and installation of air conditioner
compressor assembly".
5. Remove bolts (8) (2 pieces), clamp (9), and

bracket (10) from the area where inspection
cover (4) was removed.
6. Disconnect tube (11).
13.Remove clamp (18), and hose (19) between air

cleaner and VFT. [*5]
14.Remove tube (20). [*6]
50-26 PC138USLC-10
15.Disconnect connector VFT (21) of the wiring 20.Disconnect the water hoses (2 pieces) of KCCV
harness. ventilator (30) and the oil drain hose.
16.Remove clamp (22), and disconnect VFT 21.Remove mounting bolts (31) (2 pieces) to
assembly from the tube on the air intake outlet remove KCCV ventilator (8).
side. [*7]
22.Remove mounting bolts (32) and (33), and then

17.Remove clamp (23) and nut (24) to remove tube remove tube (34). [*9]
(25) on the exhaust outlet side. [*8]
23.Remove tubes (35) and (36).

18.Remove mounting bolt (26), and then remove
lubricating oil drain tube (27).
19.Remove mounting nut (28) to remove VFT
assembly (29).
PC138USLC-10 50-27
24.Disconnect clamp (37) of the wiring harness. 33.Disconnect connector EGR/V (52). Move wiring
25.Disconnect connector TWTR (38). Move wiring harness (53) to the counterweight side.
harness (39) away to a position where it is not
a When disconnecting the wiring harness,
an obstacle.
check the positions of each clamp.
26.Loosen clamp (40) to remove hose (41).
27.Remove fan belt (42) from the pulleys. For

details, see "Removal and installation of fan
belt".
28.Remove mounting bolt (44), and loosen bolt (45)
to move alternator (43) to the machine side.
29.Loosen clamp (46) to disconnect radiator hose

(47). [*10]
34.Remove clamp (54).

35.Remove fuel spray prevention caps (55) (4
pieces) on the common rail side.
36.Loosen the sleeve nuts on the injector side and
common rail side to remove fuel high-pressure
pipe (56).
37.Loosen clamp (57) and remove fuel tube (58).
30.Disconnect connectors CN1 (48) and CN2 (49)

on the intake side.
31.Remove fuel spray prevention cap (50) on the
injector side.
32.Disconnect ribbon heater wiring E01 (51) on the
intake side.
50-28 PC138USLC-10
38.Remove mounting bolts (59) (6 pieces) to 42.Remove cover (68). [*11]

remove fan (60) and fan pulley (61). 43.Remove mounting bolt (69) to remove cylinder
head cover (70). [*12]
39.Remove clamp (62) and move the wiring

harness away to a position where it is not an 44.Remove nuts (72) (8 pieces) for injector wiring
obstacle. harness (71) from the injectors.
a Installing position of injector wiring harness
then remove tube (64).
41.Remove mounting bolts (65) (4 pieces) and (66), Color of injector wiring Cylinder No.
and then remove water pump (67). harness
White 1, 3
Black 2, 4
a Remove injector harness connector (73) (2

pieces) from the rocker housing only when
required.
45.Remove mounting bolts (74) (19 pieces) and
remove rocker housing (75).
46.Loosen lock nuts (76) (8 pieces) and fully loosen

adjustment screws (77) (8 pieces).
PC138USLC-10 50-29
47.Remove mounting bolts (79) (7 pieces), stud a Read character string (M) in the order of the
bolts (79) (3 pieces), and rocker arm assembly arrow shown in the figure.
(80).
a Check that the noted character string (M) is
correct.
a Do not remove QR code tab (Q) attached to
the injector head.
a Do not damage QR code tab (Q) attached to
the injector head.
(Reference: The QR code or character string
specific to each injector.)
48.Remove push rods (81) (8 pieces).

49.Remove crossheads (82) (8 pieces).
a Note the mounting position and the shapes

of holes (a) and (b). (For reinstallation in the
same direction)

remove injector holders (84) (4 pieces).
a Always replace this bolt with a new bolt when
reassembling, because it is not reusable.
51.Remove injectors (85) (4 pieces).
52.Remove mounting bolt (86). Sling and remove
a Before removing the injector, record the cylinder head assembly (87).
cylinder number to which the injector is
installed and the character string (M) listed 4 Cylinder head assembly:
on the QR code tab (Q) as a set.
60 kg
50-30 PC138USLC-10
2 Mounting bolt threads:

Lubricant containing molybdenum
disulfide (LM-P)
a Finger-tighten mounting bolt (86) by 2 to 3
threads.
53.Place cylinder head assembly (87) onto the

block, and remove the intake and exhaust
manifold, heater, and connector.
a Remove the intake and exhaust manifold,
heater, and connector. For details, see
"General disassembly of engine" of Engine
Shop Manual. 4) Tighten mounting bolt (86) in the order of [1]
to [17] in the following figure and with the
Installation (PC138-A100-720-K-00-A) following procedures.
1. Install the intake and exhaust manifold, heater, F: Indicates the engine front.
and connector. For details, see "General A: Indicates the engine inlet side.
assembly of engine" of Engine Shop Manual. B: Indicates engine exhaust side.
2. Cylinder head assembly 3 Cylinder head mounting bolt:
1) Check that the cylinder head and the cylinder 1st time: 68.6 ± 9.8 Nm {7 ± 1 kgm}
block mounting face are free from dirt or 2nd time: 107.8 ± 4.9 Nm {11 ± 0.5
foreign matter and install cylinder head kgm}
gasket (88) to cylinder block assembly (89).
3rd time: Put mark (c) on the bolt
a Stamp mark "TOP" (a) on the cylinder head and cylinder head, then turn
head gasket must face the upper side bolt 90 deg. (+30 deg. / 0 deg.) to
when the gasket is installed. tighten.
a Check that pin (90) to prevent the wrong a After tightening, put a punch mark (d) on
installation of cylinder head gasket on the each bolt head to indicate the number of
upper side of the cylinder block and the tightening.
hole of cylinder head gasket are aligned.
a A bolt which already have 5 punch marks
(d) must be replaced without being
reused any more.
2) Sling cylinder head assembly (87), and

install it onto the cylinder block assembly.
4 Cylinder head assembly:

60 kg
3) Apply molybdenum disulfide lubricant to the
threads of cylinder head mounting bolts (86).
PC138USLC-10 50-31
3. Injector assembly 1) Install gasket (91) to injector (85).

a When replacing the injector assembly or 2) Fit O-rings (92) and (93) to injector (85).
engine controller assembly, write the a Do not put the O-ring in spill groove (e).
character string into the engine controller 3) Apply engine oil to O-ring (92) and head side
according to the following procedure. For inserting hole of injector (85).
details, see Testing and adjusting, "Writing
compensation values at replacement of 2 O-ring and head side inserting
injector and engine controller". hole:
• Note the number of cylinder to which a new Engine oil
injector is installed and character string (M) 4) Face the fuel inlet hole of injector (85) to the
listed on the QR code tab at the top of the fuel inlet manifold side, and insert it into the
injector as a set. cylinder head while inserting injector holder
(84) into (f) part of the injector.
a Read character string (M) in the order of
the arrow shown in the figure. a Do not let the gasket at the tip of the
injector nozzle fall.
a Be sure to check that the noted character 5) Tighten the mounting bolt (83) of injector
string is correct. holder (84) lightly.
• Write the noted character string into the
engine controller. a Apply Loctite 204 to mounting bolt
threads.
a Be sure to write the noted character string
into the cylinder number column of the 2 Threaded portion:
cylinder to which the injector is installed. Liquid adhesive (Loctite No.204 or
equivalent)
a If the character strings are not written
correctly, the engine may not operate a Do not overtighten this bolt.
normally.
a Always use a new bolt, because it is not
(Reference: The QR code or character reusable.
string indicates the difference of
compensation value for fuel injection of
the injector, which is specific to each
injector.)
50-32 PC138USLC-10
3 Rocker arm mounting bolt:

19.6 to 29.4 Nm {2.0 to 3.0 kgm}
a Loosen lock nut (76) and back off
adjustment screw (77) by sufficiently.
4) Adjust the valve clearance.
a Adjust the valve clearance. For details,
see Testing and adjusting, "Testing and
adjusting valve clearance".
5) After adjustment of valve clearance, with
adjustment screw (77) fixed, tighten lock nut
(76).
4. Push rod and crosshead 3 Lock nut:
1) Insert push rods (81) in the tappet guides. 39.2 to 49.0 Nm {4.0 to 5.0 kgm}
a The push rods for the intake and exhaust a After tightening the locknut, check the
valves are the same. valve clearance again.
a If the push rods are free from defects,
install them in the same positions as
before.
2) Install crosshead (82).
a Install the crosshead so that long hole (a)
faces the exhaust side and the short hole
(b) faces the inlet side.
6. Rocker housing assembly

1) Install rocker housing (75) with mounting bolt
(74) tightened in the order of [1] to [19] in the
following figure.
• Rocker housing tightening order
5. Rocker arm assembly

1) Install rocker arm (80).
2) Check that the ball of adjustment screw (77)
is fully put into the push rod socket.
3) Tighten rocker arm (80) with stud bolt (79)
and mounting bolt (78).
PC138USLC-10 50-33
k Before fully tightening the fuel high-

pressure pipe, check it for the following. If
the high-pressure fuel pipe has any defect,
replace it with a new one since fuel may
leak.
• Make sure with visual check that the
taper seal part of the connection ((a)
part: 2 mm area from the tip-end) is
free from longitudinal slits (b) or pits
(c).
Be sure that part (d) (2 mm from the
tip-end) is free from steps which can
2) Tighten injector harness (71) with nut (72). be felt by your fingernail. (Namely, this
portion must be free from fatigue.)
3 Mounting nut:
2.0 to 2.4 Nm {0.20 to 0.24 kgm}
a Be careful that the injector harness is not
pinched by the tool and rocker housing.
a Installing position of injector wiring
harness
Color of injector wiring Cylinder No.
harness
White 1, 3
Black 2, 4
1) Temporarily tighten the injector side of fuel

high-pressure pipe (56) to inlet connectors
(94) (4 pieces) with sleeve nut (95).
a Also temporarily tighten the common rail
side of each fuel high-pressure pipes with
sleeve nut.
2) Fully tighten mounting bolt (83) of injector
holder (84).
3 Injector holder mounting bolt:
7. Fuel high-pressure pipe 39.0 to 49.0 Nm {4.0 to 5.0 kgm}
k Do not bend the fuel high-pressure pipe

to correct.
k Be sure to use the genuine fuel high-

pressure pipe clamp and strictly observe
the specified tightening torque.

fuel high-pressure pipe on the injector side.
3 Mounting sleeve nut:
39.0 to 44.0 Nm {4.0 to 4.5 kgm}
50-34 PC138USLC-10
4) Fully tighten the mounting sleeve nut of the • Insertion position of tube (15) and the clamps
fuel high-pressure pipe on the common rail must be as shown in the following figure.
side.
3 Mounting sleeve nut: marked at removal.
39.0 to 44.0 Nm {4.0 to 4.5 kgm} 3 Clamp:
5) Install tube clamp (54) of fuel high-pressure
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
pipe (56).
6) Install fuel tube (58).
7) Install clamp (57).
8) Install fuel spray prevention cap (55) to each
sleeve nut of the fuel high-pressure pipes.
a Face the slit of the fuel spray prevention
cap downward.
a The fuel spray prevention caps are
installed so that fuel does not spout over
the hot part of the engine when it leaks by
any chance.
[*4]
and the clamps must be as shown in the
following figure.
marked at removal.
a Check mark (e) of upward hose and install it.
3 Clamp:
10.5 ± 0.5 Nm {1.1 ± 0.05 kgm}
8. Perform the subsequent installation in the
reverse order of removal.
[*1], [*2]
3 Clamp (96):
3.0 to 3.5 Nm {0.30 to 0.35 kgm}
3 Clamp (97):
3.0 to 3.5 Nm {0.30 to 0.35 kgm}
3 Clamp (98):
4.4 ± 0.49 Nm {0.45 ± 0.05 kgm}
[*3]
[*5]
PC138USLC-10 50-35
• Insertion positions of hose (19) between the air

cleaner and VFT and the clamps must be as
shown in the following figure.
marked at removal.
[*10]
• Insertion positions of radiator hose (47) and the
clamps must be as shown in the following figure.
3 Clamp:
10.8 ± 1 Nm {1.1 ± 0.1 kgm}
[*6]
3 Joint bolt:
9.8 to 12.7 Nm {1.0 to 1.3 kgm}
[*7]
3 Clamp:
5.9 to 7.8 Nm {0.6 to 0.8 kgm}
[*11]
[*8]
3 Mounting bolt:
3 Clamp:
3.6 to 4.4 Nm {0.37 to 0.45 kgm}
6.9 to 8.8 Nm {0.7 to 0.9 kgm}
[*12]
[*9]
• Tighten tube (34) in the order of [1] to [4] in the 3 Mounting bolt:
following figure and with the following 7.8 to 9.8 Nm {0.8 to 1.0 kgm}
procedures.
a Install the gasket to the mounting faces of the
both ends of tube.
3 Mounting bolt:
1st time: 9.8 to 14.7 Nm {1.0 to 1.5
kgm}
2nd time: 24.5 to 29.4 Nm {2.5 to 3.0
kgm}
3rd time: 24.5 to 29.4 Nm {2.5 to 3.0
kgm} (check)
50-36 PC138USLC-10
Removal and installation of radiator assembly (PC138-B220-924-K-00-A)
Removal (PC138-B220-520-K-00-A)
1. Remove undercover (1).
9. Remove clamp (11), and disconnect radiator

outlet hose (12). [*4]
10.Remove mounting bolt (13) and cover (14).
2. Open drain valve (2) under the radiator to drain
the coolant. [*1]
6 Radiator:
17.7 l
11.Remove mounting bolts (15) and (16) to remove

bracket (17).
3. Remove engine cover (3) and step (4).
12.Sling radiator assembly (18), and remove it. [*5]

a Be careful not to catch the bottom of the
radiator assembly when slinging it.
4. Loosen clamp (5). [*2]
4 Radiator assembly:
5. Disconnect hose (6) of the reservoir tank.
6. Loosen clamp (7). 20 kg
7. Remove bolts (8) (2 pieces), and move partition
plate (9) to the rear of engine.
8. Disconnect radiator inlet hose (10). [*3]
PC138USLC-10 50-37
a When installing the radiator assembly, be careful

not to damage the heat insulation sealant
(sponge) on the periphery while lowering.
a Check that convex portion (A) of the radiator
bottom is correctly aligned with concave portion
(B) on the machine side from the undercover
side.
Installation (PC138-B220-720-K-00-A)

removal.
[*1]
Refill with the coolant to the specified level through
the coolant filler port. Run the engine to circulate the
coolant through system. Then check the coolant
level again.
5 Radiator:
17.7 l (For details, see "Table of fuel,
coolant and lubricants")
[*2], [*3]
• Insertion position of hose (10) and the clamps
marked at removal.
3 Radiator hose clamp (5):

8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
[*4]
3 Radiator hose clamp (11):
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
[*5]
a Check that the heat insulation sealant (sponge)
on the periphery of the radiator is not damaged.
a If the heat insulation sealant (sponge) is
damaged, replace it.
50-38 PC138USLC-10
Removal and installation of hydraulic oil cooler assembly (PC138-B8P0-924-K-00-A)
a Special tools
Necessity
Sym-
Q'ty
Part No. Part name
bol
1 796-460-1210 Oil stopper q 1

R
2 22B-60-31161 Adapter q 1

the engine.
k Set the lock lever in LOCK position. 4. Remove undercover (2) at the bottom of
hydraulic oil cooler.
hydraulic circuit referring to Testing and
adjusting, "Releasing remaining pressure
from hydraulic system".

Removal (PC138-B8P0-520-K-00-A)
1. Remove the radiator assembly. For details, see

"Removal and installation of radiator assembly."
2. Remove the air cleaner assembly. For details,
see "Removal and installation of air cleaner
assembly". 5. Remove drain plug (3) to drain the remaining
3. Loosen drain plug (1) to drain the hydraulic oil. hydraulic oil from the hydraulic oil cooler.
[*1]
a Close the drain plug after draining is
6 Hydraulic tank: completed.
6. Remove bolts (4) (2 pieces).
69 l 7. Loosen mounting bolts (5) (2 pieces) and
disconnect tube (6) from the hydraulic oil cooler.
a When using tools R1 and R2, remove the

hydraulic tank strainer and stop the draining 8. Remove hose (7). [*2]
oil by using the tools R1 and R2. 9. Disconnect hose (8) from the aftercooler. [*3]
a Make marks on the tube so that it can be
reconnected correctly.
PC138USLC-10 50-39
a Refill with oil to the specified level through the oil

filler port. Run the engine to circulate the oil
through the piping. Then check the oil level
again.
5 Hydraulic tank:
69 l (specified capacity: 120 l For details,
see "Table of fuel, coolant and
lubricants")
3 Drain plug:
58.8 to 78.4 Nm {6.0 to 8.0 kgm}
10.Remove mounting bolts (9) (2 pieces) to [*2]
disconnect tube (10). • Insertion position of hose (7) and the clamps

remove hydraulic oil cooler assembly (12) while
3 Clamp:
sliding it to the counterweight side. [*4]
10.8 ± 1 Nm {1.1 ± 0.1 kgm}
a Be careful not to catch the bottom of the [*3]
hydraulic oil cooler assembly when removing
it.
marked at removal.
a Check mark (a) of upward hose and install it.
Installation (PC138-B8P0-720-K-00-A)

removal.
[*1]
a Check that the drain plug is tightened before 3 Clamp:
refilling. 10.5 ± 0.5 Nm {1.1 ± 0.05 kgm}
[*4]
50-40 PC138USLC-10
a Check that the heat insulation sealant (sponge)

on the periphery of the hydraulic oil cooler is not
damaged.
a If the heat insulation sealant (sponge) is
damaged, replace it.
a When installing the hydraulic oil cooler assembly,
be careful not to damage the heat insulation
sealant (sponge) on the periphery while
lowering.
PC138USLC-10 50-41
Removal and installation of aftercooler assembly (PC138-A9A0-924-K-00-A)
Removal (PC138-A9A0-520-K-00-A)

assembly".
2. Loosen clamps (1) (2 pieces) to disconnect hose
(2). [*1]
a Make matchmarks on the hose end and tube
so that they can be reconnected correctly.
3. Loosen MIKALOR clamps (3) (2 pieces) to
disconnect hose (4). [*2]
a Make matchmarks on the hose end and tube
so that they can be reconnected correctly.
3 Clamp:
10.5 ± 0.5 Nm {1.1 ± 0.05 kgm}
[*2]
1. Install the disconnected hoses according to the
a Be sure to use new MIKALOR clamp (3).
1) Align hose to its original position (marked
position).
2) Set bridge (BR) under clamp tightening bolt
and tighten MIKALOR clamp (3) so that
overlap dimension (b) between bridge (BR)
and band is following dimension.
4. Remove mounting bolts (5), and pull up Dimension (b): Min. 5 mm
aftercooler assembly (6) from the engine cover 2 Clamp tightening bolt threaded
side. portion (BC):
a Be careful not to make the aftercooler fin Lubricating oil (ThreeBond
interfere with other machines. PANDO18B)
a Impact wrench is not allowed to use.
a Tighten it until dimension BDG becomes
as shown below.
BDG: 0 to 2 mm
Installation (PC138-A9A0-720-K-00-A)

removal.
[*1]
• Insertion position of hose (2) and the clamps • Insertion position of hose (4) and the clamps
must be as shown in the following figure. must be as shown in the following figure.
a Install the hoses and tubes to the positions a Install the hoses and tubes to the
marked at removal. positions marked at removal.
a Check mark (a) of upward hose and install it.
50-42 PC138USLC-10
PC138USLC-10 50-43
Removal and installation of engine and main pump assembly (PC138-R400-924-K-

00-A)
a Special tools 3. Loosen drain plug (3) under the hydraulic tank to
drain the hydraulic oil. [*2]
Necessity
Sym-
Q'ty
Part No. Part name 6 Hydraulic tank:
bol
69 l
1 796-460-1210 Oil stopper q 1
R
2 22B-60-31161 Adapter q 1

the engine.
k Set the lock lever in LOCK position.

k Turn the battery disconnect switch to OFF hydraulic tank strainer and stop the draining
position, and remove the key. oil by using the tools R1 and R2.
Removal (PC138-R400-520-K-00-A)
4. Remove engine cover (4), step (5), cover (6) on

the top of KDOC muffler, step (7), and inspection
cover (8).
2. Open drain valve (2) under the radiator to drain
the coolant. [*1]
6 Radiator:
17.7 l
5. Remove the counterweight assembly. For

details, see "Removal and installation of
counterweight assembly [For machines with
additional counterweight]" or "Removal and
50-44 PC138USLC-10
installation of counterweight assembly [For 21.Remove mounting bolts (36) (2 pieces) to

machines without additional counterweight]". remove KCCV ventilator (37).
6. Remove bolts (9) (3 pieces) of the bracket and 22.Disconnect connector E24 (38).
remove frame (10). 23.Disconnect connectors J1 (CE01) (39), J2
7. Disconnect air conditioner hose clamp (11). (CE02) (40), and CE03 (41).
8. Disconnect hose (12) and move it toward the 24.Remove mounting bolts (42), (43), and (44) (6
machine side together with bracket (13). [*3] pieces in total) and remove frame (45).
9. Remove fan guard (14) and pulley cover (15).
a Mounting bolts (44) (2 pieces) are indicated
10.Disconnect solenoid clutch connector AC03
on the back side of the figure.
(16).
11.Loosen bolts (17) (4 pieces).
12.Loosen lock nut (18) and rotate jack bolt (19) to
slide air conditioner compressor (20) in the
direction in which the compressor is loosened.
13.Remove the fan belt. For details, see "Removal
and installation of fan belt".
14.Disconnect clamp (21), and move air conditioner
compressor (20) to the machine side.
15.Disconnect hoses (22), (23), and (24). [*4]
25.Disconnect radiator lower hose (46).

16.Disconnect connector K02 (25). 26.Disconnect heater hoses (47).
17.Disconnect clamps (26) and (27). 27.Disconnect fuel hoses (48) and (49).
18.Disconnect camera wiring (28) from the frame. 28.Disconnect engine ground cable (50).
19.Disconnect fuel hoses (29), (30), and (31) from 29.Disconnect starter C terminal SC (51) and
the frame. starter B terminal SB (52). [*6]
20.Disconnect hoses (32), (33), (34) and (35) of 30.Disconnect connector E01of the ribbon heater.
KCCV ventilator. [*5] 31.Disconnect clamps (4 pieces) of wiring
a Disconnect hoses (33), (34), and (35) on the harnesses (54) and disconnect the wiring
KCCV ventilator side. harness.
PC138USLC-10 50-45
32.Remove rubber cover (55). 37.Disconnect hoses (64) (6 pieces) of the main
33.Remove mounting bolts (56) to remove heat pump.
insulation plate (57). 38.Disconnect connectors V11 (65) and P22 (66).
39.Remove clamp (67).
40.Remove mounting bolts (68) (4 pieces) to
remove suction tube (69).
34.Loosen clamp (58) and remove mounting bolts

(59) (4 pieces) to remove tube (60) between
KDOC muffler and VFT.
41.Remove mounting bolts (70) to remove engine
oil filter assembly (71) together with the bracket.
a Tie the engine oil filter assembly to some
portion of the engine.
35.Remove water drain tube (61) of KDOC muffler.

a The tube is inserted only. Therefore, pull out
it directly downward. Do not pull out forcibly.
Otherwise, the insertion hole may be
damaged. 42.Remove mounting bolts (72) (6 pieces) to
36.Remove U-bolts (62) (2 pieces) to remove remove fan (73) and fan pulley (74).
KDOC muffler (63) from the top of the machine
body.
50-46 PC138USLC-10
43.Loosen clamp (75) to disconnect tube (76). 47.Sling engine and main pump assembly (82), and
remove them.
4 Engine and main pump assembly:

600 kg
44.Disconnect connector E12 (78) and R terminal

AB (79) of alternator (77).
Installation (PC138-R400-720-K-00-A)

removal.
[*1]
a Refill with the coolant to the specified level
through the coolant filler port. Run the engine to
circulate the coolant through system. Then
check the coolant level again.
5 Radiator:
45.Disconnect connector P44 (80).
17.7 l (For details, see "Table of fuel,
[*2]
a Check that the drain plug is tightened before
refilling.
again.
5 Hydraulic tank:
46.Remove mounting bolts (81) (4 pieces) of the see "Table of fuel, coolant and
engine assembly. lubricants")
PC138USLC-10 50-47
3 Drain plug: a Install the hoses and tubes to the positions

58.8 to 78.4 Nm {6.0 to 8.0 kgm} marked at removal.
a Bleeding air (hydraulic system) a Check mark (e) of upward hose and install it.
Bleed air from the hydraulic pump circuit. For 3 Clamp:
details, see Testing and adjusting, "Bleeding air 10.5 ± 0.5 Nm {1.1 ± 0.05 kgm}
[*3], [*5]
3 Clamp (83) of hose (12):
3.0 to 3.5 Nm {0.30 to 0.35 kgm}
3.0 to 3.5 Nm {0.30 to 0.35 kgm}
4.4 ± 0.49 Nm {0.45 ± 0.05 kgm}
3 Joint bolt of hoses (33) and (35):

3.3 ± 0.49 Nm {0.34 ± 0.05 kgm}
• Insertion positions of hose (24) between the air
[*4]
cleaner and VFT and the clamps must be as
• Insertion positions of radiator hose (22) and the shown in the following figure.
clamps must be as shown in the following figure.
a Install the hoses and tubes to the positions marked at removal.
marked at removal.
3 Clamp:
3 Radiator hose clamp:
10.8 ± 1 Nm {1.1 ± 0.1 kgm}
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
[*6]
and the clamps must be as shown in the 3 Starter C terminal SC (51):
following figure. 2.6 to 4.6 Nm {0.27 to 0.47 kgm}
50-48 PC138USLC-10
3 Starter B terminal SB (52):

17.7 to 24.5 Nm {1.8 to 2.5 kgm}
PC138USLC-10 50-49
Removal and installation of engine front oil seal (PC138-A350-924-K-00-A)
a Special tools
Necessity
Sym-
Q'ty
Part No. Part name
bol
795T-221-1010 Push tool t 1

A 2 790-101-5271 • Plate 1
790-101-5221 • Grip 1
01010-51225 • Bolt 1
Removal (PC138-A350-520-K-00-A)
1. Remove the engine assembly. For details, see Installation (PC138-A350-720-K-00-A)

"Removal and installation of engine and main a Before installing the front oil seal, check that the
pump assembly". end corner and the lip sliding surface of the
2. Remove mounting bolt (1) to remove idler pulley crankshaft are free from a flaw, burr, fin, and
assembly (2). rust.
1. By using tool A2, install front oil seal (6).
2. After press fitting the front oil seal, fill the space
between oil seal lips with approximately 2 cc of
grease.
2 Front oil seal:
Grease (G2-LI)
3. Remove mounting bolt (3) to remove plate (4)

and crank pulley assembly (5). [*1]
• Perform subsequent installation in the

reverse order of removal.
[*1]
3 Crank pulley mounting bolt:
343 to 402 Nm {35 to 41 kgm}
4. Remove front oil seal (6).
50-50 PC138USLC-10
Removal and installation of engine rear oil seal (PC138-A510-924-K-00-A)
a Special tools 1) Screw a slide hammer, etc. in the metal ring

of rear oil seal (5), and pull out the rear oil
Necessity
seal by using the the impact of the slide
Sym-
Q'ty
Part No. Part name hammer.
bol
a Before pulling out the seal, drive the seal
795T-221-1020 Plate t 1 inward a little to separate it from the housing
790-101-5401 Push tool kit t 1 for easy removal.
A 3 790-101-5431 • Plate 1 a Do not use a drill, etc. as metal chips may
790-101-5421 • Grip 1 enter the engine.
01010-51240 • Bolt 1
Removal (PC138-A510-520-K-00-A)
1. Remove main pump assembly. For details, see

"Removal and installation of main pump
assembly".
2. Removal of flywheel
1) Remove mounting bolts (1) (6 pieces), and
remove coupling (2). [*1]
Installation (PC138-A510-720-K-00-A)
a Before installing the rear oil seal, check that the

end corner and the lip sliding surface of the
crankshaft are free from a flaw, burr, fin, and
rust.
1. Install rear oil seal (5) by using tool A3.
2. After press-fitting the rear oil seal, fill the space
between oil seal lips with approximately 3 cc of
2) Sling flywheel (3). grease.
3) Remove flywheel (3) mounting bolts (5 2 Rear oil seal:
pieces) but leave the remaining one. [*2]
Grease (G2-LI)
4) Remove the remaining mounting bolt (4) (1
piece), sling flywheel (3), and remove it.
4 Flywheel:
40 kg
a Be careful not to remove the guide bolt.
3. Removal of rear oil seal
PC138USLC-10 50-51
3. Rotate the flywheel 1 turn, and measure the

difference between the maximum and
minimum readings of the dial gauge pointer.
a When the flywheel rotated 1 turn, check
that the dial gauge indicates the same
value as it of the starting rotation.
• Perform subsequent installation in the reverse

order of removal.
[*1]
3 Coupling mounting bolt:
98 to 122.6 Nm {10 to 12.5 kgm}
[*2]
• Tighten the flywheel mounting bolts according to • Measurement of facial runout of flywheel
the following procedure. a Standard value: Max. 0.30 mm
1. Apply engine oil to the threaded portions of 1. Similarly to the measurement of radial runout,
mounting bolts. set dial gauge [2] so that its probe is at a right
2 Mounting bolt threads: angle with the end face (b) near the outer
circumference of the flywheel.
Engine oil
2. Tighten the mounting bolts twice in order a Perform the measurement with the
according to the following torque. crankshaft pulled to either the front or
rear side of the engine to prevent errors
3 Mounting bolt:
caused by backlash.
1st time: 58.8 to 117.7 Nm {6.0 to 2. Rotate the flywheel one turn, and measure
12.0 kgm} the difference between the maximum and
2nd time: 186.3 to 196.1 Nm {19.0 minimum readings of the dial gauge pointer.
to 20.0 kgm}
• The following figure shows the tightening order.
• Measurement of radial runout of flywheel

a Standard value: Max. 0.30 mm
1. Install dial gauge [1] to the flywheel housing.
2. Set the probe of the dial gauge at a right
angle to the spigot joint portion (a) or outside
of the flywheel.
50-52 PC138USLC-10
Removal and installation of fuel cooler assembly (PC220-B7W0-924-K-00-A)
a If the fuel is too much, drain the fuel in order to

stop the fuel flow from the fuel tank return hose.
Removal (PC138-B7W0-520-K-00-A)

assembly".
2. Disconnect inlet hose (2) and outlet hose (3) of
fuel cooler assembly (1). [*1]
a Be sure to use spanners, etc. separately for
the hose adapter and nipple head, and rotate
the hose adapter in the loosening direction to
disconnect the hoses.
a If a force is applied to the fuel cooler when
loosening, the tube of the fuel cooler may be
damaged.
fuel cooler assembly (1).
Installation (PC138-B7W0-720-K-00-A)

removal.
[*1]
a Be sure to use spanners, etc. separately for the
hose adapter and nipple head, and strongly
tighten the hose adapter and nipple head in the
tightening direction respectively.
a If a force is applied to the fuel cooler when
tightening, the tube of the fuel cooler may be
damaged.
PC138USLC-10 50-53
Removal and installation of fuel tank assembly (PC220-AD10-924-K-00-A)
k Park the machine on a level ground, swing

the upper structure by 90 deg., lower the
work equipment to the ground stably, and
stop the engine.
k Set the lock lever in the Lock position.
k Turn the battery disconnect switch to the

OFF position and remove the key.
Removal (PC138-AD10-520-K-00-A)
1. Open cover (1) at the rear right of the machine,

and open fuel drain valve (2) to drain the fuel.
6 When filled up with fuel:

200 l
6. Disconnect return hose (8) between the fuel

cooler and fuel tank.
7. Remove connectors P21 (9) and P49 (10), and
remove wiring harness (11).
8. Sling stay (12) on the right side of the machine,

2. Disconnect fuel level sensor connector P21 (3). and remove mounting bolts (13) (8 pieces).
3. Remove engine oil filter assembly (4) together 9. Sling stay (12) and remove it.
with the bracket. 10.Remove covers (14) and (15) on the right side of
the fuel tank.
a Move the engine oil filter assembly away to a 11.Remove steps (16) and (17).
position where it is not an obstacle.
4. Disconnect reservoir tank assembly (5).
5. Disconnect fuel pre-filter assembly (6) and travel
alarm assembly (7) together with the bracket.
a Disconnect bolt (8) of the hose clamp.
50-54 PC138USLC-10
15.Remove cover (22) at the bottom of the fuel

tank.
16.Disconnect hoses (23) and (24).

17.Remove mounting bolts (25) (4 pieces). [*1]

remove bracket (18) at the rear of the hydraulic
tank.
18.Sling fuel tank assembly (26), and remove it.
4 Fuel tank assembly:

110 kg
13.Remove wiring and hose mounting bracket (20).

14.Remove mounting bracket (21) at the front of the
fuel tank.
PC138USLC-10 50-55
Installation (PC138-AD10-720-K-00-A)

removal.
[*1]
2 Mounting bolt:
Liquid adhesive (LT-2)
3 Mounting bolt:
235 to 285 Nm {24 to 29 kgm}
50-56 PC138USLC-10
Removal and installation of KDOC assembly (PC138-A9H2-924-K-00-A)

the engine.

Removal (PC138-A9H2-520-K-00-A)
1. Remove cover (1) on the top of KDOC muffler.

2. Remove step (2) and inspection cover (3) on the
front of the machine. 5. Open cover (8) at the rear right of the machine.
3. Remove mounting bolts (4) (4 pieces), and

6. Remove water drain tube (9) of KDOC muffler.
remove insulation plate (5) from the top of
KDOC muffler. a The tube is inserted only. Therefore, pull out
damaged.
7. Remove U-bolts (10) (2 pieces) to remove
KDOC muffler (11) from the top of the machine
body. [*1]
4. Remove bolt (7) to disconnect tube (6) between

KDOC muffler and VFT from the inspection
cover on the front of the machine.
Installation (PC138-A9H2-720-K-00-A)

removal.
[*1]
3 Mounting nut:
14 ± 1 Nm {1.43 ± 0.1 kgm}
PC138USLC-10 50-57
Removal and installation of KCCV assembly (PC220-A180-924-K-00-A)
removal.
[*1], [*2]
k After the engine is stopped, its parts are still
hot. Accordingly, wait until they have cooled 3 Clamp:
down before starting the work. 3.0 to 3.5 Nm {0.30 to 0.35 kgm}
Removal (PC138-A180-520-K-00-A)
2. Remove clamp (2), and disconnect hose (3). [*1]

3. Remove clamp (4), and disconnect hose (5). [*2]
4. Disconnect hoses (6), (7), and (8).
5. Remove mounting bolts (11) (2 pieces) to

remove KCCV ventilator and bracket assembly.
KCCV ventilator (10).
50-58 PC138USLC-10
Removal and installation of air cleaner assembly (PC220-A910-924-K-00-A)

Removal (PC138-A910-520-K-00-A)
1. Open engine cover (1) and disconnect hose (2)

and connector P55 (3) of the dust indicator
2. Loosen clamp (4) to disconnect hose (5). [*1]
3. Open cover (6) at the rear left of the machine.

4. Disconnect hose (7) from tube (A).
5. Remove mounting bolts (8) (2 pieces), and 9. Remove mounting bolts (14) (4 pieces) to
remove air intake bracket (9). remove air cleaner (10) from bracket (11). [*2]
6. Remove mounting bolts (12) of bracket (11) of
air cleaner (10).
8. Remove air cleaner (10) together with bracket
(11).
a Be careful not to damage the air conditioner
condenser.

removal.
[*1]
marked at removal.
PC138USLC-10 50-59
3 Clamp:
10.8 ± 1 Nm {1.1 ± 0.1 kgm}
[*2]
a When the following parts are removed from
removed air cleaner (10), install them to a new
air cleaner.
• Nipple (15)
• Tube (16)
• Eyejoint (17)
• Seal washer (18) (2 pieces)
a Fix nipple (15) by using spanners, and then
tighten eyejoint (17).
If overtightening the eyejoint, the air cleaner may
be damaged.
3 Nipple (15):
4.9 to 6.9 Nm {0.5 to 0.7 kgm}
3 Eyejoint (17):
9.8 to 12.7 Nm {1.0 to 1.3 kgm}
50-60 PC138USLC-10
Removal and installation of fan belt (PC138-B430-924-K-00-A)
a Special tools
Necessity
Sym-
Q'ty
Part No. Part name
bol
A 4 796-401-1300 Fixing jig t 1

the engine.

4. Apply a wrench to portion (c) (width across flats:
k Turn the battery disconnect switch to OFF 12.7 mm) of auto tensioner (2), and rotate it to
position, and remove the key. the opposite to the winding-up direction to
decrease the tension of fan belt (4).
Removal (PC138-B430-520-K-00-A)
1. Remove undercover (1). k Be sure that wrench is set securely to

portion (c) of auto tensioner assembly (2)
before rotating it. (Since the spring force
of auto tensioner assembly (2) is strong,
the wrench might come off and induce
personal injury if it is rotated when not
securely attached.)
k Return auto tensioner (2) to its original

position slowly and carefully.
k Be careful not to get your fingers caught

between the pulley and fan belt (4) during
work.
2. Install collar [1] for the guide of fixing jig A4 to
spacer (3) of auto tensioner (2).
3. Insert holding bracket [2] to collar [1], and
temporarily tighten it with nut [3].
At this time, install the dent portion (a) of the
holding bracket to protruding portion (b) of auto
tensioner (2).
5. Tighten nut [3] at the position where the belt

tension was reduced.
a Check that holding bracket [2] is inserted
between protrusions (b) and (d) of auto
tensioner (2), and that the end surface of
collar [1] and that of nut [3] become flush at
this time.
6. Check that holding bracket [2] is clipped
between protrusions (b) and (d) and fixed when
auto tensioner (2) is slowly returned.
PC138USLC-10 50-61
k If holding bracket [2] is insufficiently

clipped between protrusions (b) and (d), it
may be removed. Therefore, securely
tighten nut [3].
7. Remove fan belt (4).
Installation (PC138-B430-720-K-00-A)

removal.
50-62 PC138USLC-10
Power train system
Power train system (ALL-C100-001-K-50-A)
Removal and installation of travel motor and final drive assembly (PC138-DF10-
924-K-00-A)

the engine.


Removal (PC138-DF10-520-K-00-A)
Installation (PC138-DF10-720-K-00-A)

1. Separate the track. For details, see "Separation
removal.
and connection of track shoe assembly".
[*1]
2. Remove the sprocket. For details, see "Removal
and installation of sprocket". 2 Threaded portion of travel motor and
3. Remove the travel motor cover. final drive assembly mounting bolt:
4. Disconnect travel motor hoses (2) (4 pieces). Adhesive (LT-2)
3 Travel motor and final drive assembly
mounting bolt:
235 to 285 Nm {23.5 to 29.5 kgm}
• Refilling of oil
Refill with oil to the specified level through the oil
through the system. Then check the oil level
again.
a Bleed air from the travel motor. For details, see
Testing and adjusting, "Bleeding air from
hydraulic system".
5. Sling travel motor and final drive assembly (3),
and remove them. [*1]
a Take extreme care not to damage the nipple
seal of hose mounting portion.
4 Travel motor and final drive assembly:

150 kg
PC138USLC-10 50-63
Power train system
Disassembly and assembly of travel motor and final drive assembly (PC138-
DF10-926-K-00-A)
a Component part drawing
50-64 PC138USLC-10
Power train system
PC138USLC-10 50-65
Power train system
50-66 PC138USLC-10
Power train system
Part name list

No. Part name
No. Part name
Hub 161 Piston
1
Spindle 162 Shoe
2
167 Pivot
3 Carrier A
171 Dowel pin
4 Sun gear A
185 Spring
5 Planetary gear A
201 Valve seat
6 Pin
202 Valve
7 Carrier B
Sun gear B 203 Relief valve
8
Planetary gear B 204 Collar
9
205 Plug
10 Pin
206 Spring
11 Thrust washer A
207 O-ring
12 Thrust washer B
208 Ring
13 thrust plate
209 O-ring
14 Cover
Coupling 210 Ring
15
211 O-ring
16 Pin
212 O-ring
17 Pin
22 Lock washer 213 Shim
301 Rear flange
23 Shim
24 Ball bearing 323 Spool
Bearing 324 Plug
27
28 Bearing 325 Spring retainer
29 Floating seal 326 Plug
30 Plug 327 Valve
O-ring 328 Spring
31
32 O-ring 329 Orifice
O-ring 330 Spring
33
Dowel pin 331 O-ring
34
Hexagonal socket head bolt 336 O-ring
35
Ring 341 Dowel pin
36
343 Hexagonal socket head bolt
102 Shaft
103 Swash plate 352 Plug
104 Cylinder block 353 Seal ball
354 Hexagonal socket head plug
105 Piston
106 Shoe 357 Plug
107 Retainer plate 358 O-ring
108 Thrust ball 359 O-ring
109 Timing plate 363 Spool
110 Washer 366 Spring
112 Piston 376 Orifice
113 Spring 377 Filter
114 Spring 378 Seal ball
115 Disc 379 Plug
116 Plate 380 Plug
132 Oil seal 381 Piston
135 O-ring 383 O-ring
139 O-ring 384 Hexagonal socket head plug
145 THS snap ring 396 Hexagonal socket head plug
149 Ball bearing 398 Hexagonal socket head plug
150 Ball bearing 399 Plate
151 Needle
PC138USLC-10 50-67
Power train system
a Maintenance outline
Tool
• Standard tool
No. Part name Model, dimension Q'ty
2.5 (M5), 3 (M6), 4 (NPTF 1/16)
1 Hexagonal wrench 5 (PF 1/8), 6 (PF 1/4) each 1
8 (M10, PF 3/8), 10 (M12, PF 1/2)
2 Socket wrench handle Daruma type 1
Dial type: 50 N
Dial type: 100 N
3 Torque wrench each 1
Dial type: 300 N
Dial type: 560 N
4 Torque wrench adapter — each 1
5 Socket wrench Width across flats: 24.41 mm 1
6 Extension bar 150 mm 1
7 Hammer Various each 1
8 Plastic hammer L: 400 mm 1
9 Flat-head screwdriver L: 50, 150 mm each 1
10 Snap ring pliers For shaft and hole each 1
11 Pincers 200 mm 1
Slinging load: Min. 2,940 N (300 kg) 1 unit
Eyebolt (M16) (2)
12 Slinging tool Eyebolt (M12) (3)
Eyebolt (PF 1/2) (2)
Wire with hook (1)
13 Container General pad W 450 x D 300 x H 120 mm 2
14 Leather gloves — 1 unit
• Bolts
No. Part name Model, dimension Q'ty
1 Hexagonal socket head bolt M12 (P1.5 x 40 mm) 2
• Equipment
Application, part Model, dimension Q'ty
Part name
number
Disassembly and
General work stand — 1
assembly
Parts cleaning Cleaning tank Simple cleaning, finishing of cleaning 1
(24) Press performance: Min. 9,800 N
(1,000 kg)
24, 104, 149 Press work stand 1
(200 kg)
(200 kg)
Heating performance: Min. 100°C
149 Heating tank 1
Volume: Min. 500 x 500 x 500
Drying after parts Air pressure: 0.29 to 0.49 MPa {3 to 5 kg/
Compressed air —
cleaning cm2}
50-68 PC138USLC-10
Power train system
• Manufacture tool
Work stand [1]
• Fix during disassembly and assembly of
travel motor.
Jig [5]
• Install lock washer [22] to the groove of
spindle [2].
No.1 holder [2]

• Install spring (114), washer (110), and THS
snap ring (145) to cylinder block (104).
• Remove spring (114) from cylinder block
(104).
Push tool [6]

• Press-fit ball bearing (24) to hub (1).
No.2 holder [3]

• Remove ball bearing (114) from shaft (104).
Steel bar [7]

• Remove ball bearing (114) from hub (1).
Push tool [4]

• Press-fit oil seal (132) to spindle (2).
PC138USLC-10 50-69
Power train system
Eyebolt [8] No.2 installation jig [11]

• Sling travel motor, spindle (2), and hub (1). • Install floating seal (29) to hub (1) and
Application Dimension (A): spindle (2).
Hub M16
Hub M10
Spindle M16
Travel motor M16
No.3 installation jig [12]

• Install floating seal (29) to spindle (2).
Spatula [9]
• Remove timing plate (109) from rear flange
(301).
Pin punch [13]

• Remove the outer race from ball bearing
(24).
No.1 installation jig [10]

• Install floating seal (29) to hub (1).
50-70 PC138USLC-10
Power train system
Tightening torque
Width
Part Nominal number
Part name across flats Q'ty Tightening torque (Nm {kgm})
number of parts
(mm)
30, 357 Plug PF 1/2 10 4 98.1 ± 19.6 {10.0 ± 2.0}
Hexagonal socket head M10 (P1.5) 66.7 ± 3.92 {6.8 ± 0.4}
35 8 12
bolt
203 Sleeve PF 1/2 24 (socket) 2 98.1 ± 19.6 {10.0 ± 2.0}
205 Plug PF 1/4 6 2 29.4 ± 4.90 {3.0 ± 0.5}
324 Plug M36 (P1.5) 41 (socket) 2 441 ± 39.2 {45.0 ± 4.0}
Hexagonal socket head M12 (P1.75) 102 ± 15.7 {10.4 ± 1.6}
343 10 10
bolt
352 Plug PF 1/8 5 3 12.3 ± 2.45 {1.25 ± 0.25}
Hexagonal socket head 9.81 ± 1.96 {1.0 ± 0.2}
354 NPTF 1/16 4 5
bolt
380 Plug PF 3/8 8 2 58.8 ± 9.81 {6.0 ± 1.0}
396 PT 1/4 6 2
bolt
398 PT 1/8 5 5
bolt
Weight table
Part Weight (kg)
Part name
number
— Travel motor assembly 150
1 Hub 50
2 Spindle 30
3 and Carrier (A) assembly 15
others
7 and Carrier (B) assembly 25
others
301 and Rear flange assembly 15
others
PC138USLC-10 50-71
Power train system
Disassembly (PC138-DF10-530-K-00-A)
Preparation items a For the part number that is not described in the
1. Preparation before disassembly figure of this manual, see "Component parts
figure".
1) Preparation of work stand
1. Cleaning of travel motor assembly
• Prepare the work stand for disassembly
and assembly of the travel motor. 1) Install eyebolts [8] (2 pieces) to the mounting
• Prepare the robust work stand that can bolt hole of spindle (2).
be used for disassembly and assembly of a Install eyebolts [8] (2 pieces)
the travel motor internal parts and on symmetrically.
which the parts can be put.
• Spread a rubber or vinyl sheet on the
work stand.
2) Prepare the above tools and equipment.
2. General precautions for working
k Oil is applied to the internal parts during

disassembly and the parts is is slippery.
Handle the parts carefully to prevent the
parts from falling. Otherwise, personal
injury may occur and the parts may be
damaged.
k Flammable material such as JIS No.1

2) Sling the travel motor assembly and move it
kerosene is used for cleaning the parts.
to the cleaning tank.
Handle the material carefully because it
may ignite and cause fire or burn.
4 Travel motor assembly:
1) Get full understanding of the testing items 150 kg
and the existing abnormal conditions before 3) Use a brush to securely clean the travel
disassembly. Proceed with the disassembly motor assembly.
work according to the procedures.
2) Handle the parts carefully because they are a Soil or sand is entered into the area
manufactured very precisely. Do not hit them between hub (1) and spindle (2) (floating
each other and drop them. seal mounting portion). Therefore,
3) When disassembling, do not tap forcibly and securely clean the assembly.
pry. Otherwise, burr may be generated and
damages may be occurred. The parts may
not be assembled and the performance may
be deteriorated.
4) If the disassembled parts are left during the
work, the parts may be rusted due to the
humidity and dusts. In such a case, be sure
to protect the parts from rust or dusts.
5) When disassembling, make a match mark on
the mating surfaces of the parts.
6) To prevent from the parts being damaged or
lost during disassembly, order and store the
removed parts.
7) Do not reuse the disassembled or removed 2. Setting travel motor
seals. Replace them with new ones. 1) Sling the travel motor assembly and set it to
8) The illustration in this section is the typical work stand [1].
model. It may be different from the actual
machine. However, the disassembly a Set the travel motor assembly while
procedure is the same. aligning the bolt hole of hub (1) with the
hole of work stand [1].
50-72 PC138USLC-10
Power train system
2) Install the hexagonal socket head bolts (2 4. Removal of cover

pieces) symmetrically. 1) Invert the travel motor assembly so that the
final drive faces upward.
k Install hexagonal socket head bolts 2) Remove bolt (35). Sealant is applied to the
(38) (2 pieces) securely. (To prevent mating surfaces of cover (14) and hub (1).
the travel motor assembly from Therefore, put a backing metal to the
removing when inverting it) protruding portion of the cover and tap it in
diagonally upper direction to remove the
cover.
k When tapping the cover in diagonally

upper direction, the cover may leap
and fall. Take care not to drop the
cover to the foot, etc.
3. Draining oil in final drive case

1) Place the travel motor assembly sideways so
that the drain plug faces downward.
2) Loosen plug (30) of the oil filler port to
release pressure from the case, and then
lightly tighten the plug. (See "Component
parts figure".)
3) Install eyebolts [8] to port (k) and lift cover
a If the internal case is pressurized, the oil (14) to remove it from hub (1).
may spout when loosening the drain plug.
3) If the does not come out sufficiently, slowly
loosen the drain plug.
a Remove O-ring (31) of plug (30). Do not
reuse it. (See "Component parts figure".)
a Set the oil pan under the travel motor to
receive the oil.
6 Final drive case:

2.1 l
5. Removal of sun gear A
PC138USLC-10 50-73
Power train system
1) After removing thrust plate (13), remove sun

gear A (4).
7. Removal of sun gear B

1) Install eyebolts [8] to the slinging tap (7
places) of carrier B (3) to remove the carrier
assembly.
4 Carrier assembly:
25 kg
a Set the center shafts of the hub and
carrier assembly vertically and slowly
sling the assembly to prevent the hub
internal teeth from being damaged by the
end face of planetary gear B (9). (See
"Component parts figure".)
2) Remove sun gear B (8) from carrier B (7).

places) of carrier A (3) to remove the carrier
assembly.
sling the assembly to prevent the hub
internal teeth from being damaged by the
end face of planetary gear A (5). (See
8. Removal of lock washer

1) Fix hub (1) to work stand [1] with hexagonal
socket head bolts.
6. Removal of coupling
1) Remove coupling (15) from shaft (102). (See
50-74 PC138USLC-10
Power train system
2) Put a flat-head screwdriver, etc. into the a If the floating seal sticks due to mud, etc.,
clearance between lock washers (22) (2 use a flat-head screwdriver to remove
pieces) and tap it in diagonally lower according to this procedure.
direction by using a hammer to remove the
lock washers.
11.Removal of ball bearing

1) Lightly and evenly drive in pin punch [13] to
9. Removal of hub
remove ball bearings (24) at 3 or 4 places on
1) Remove the hexagonal socket head bolts circumference of the outer race.
that fix work stand [1] and hub (1).
2) Install eyebolts [8] to hub (1) and sling the a If driving in the inner race, the truck
hub. surface of the ball bearing may be
damaged and the bearing cannot be
4 Hub (1) : reused. Do not drive in the inner race
unless it is replaced.
50 kg
a Ball bearing (24) may fall if hub (1)
a Slowly and gradually sling the hub in
removes from the mating portion. Protect
parallel with the shaft of spindle (2).
the hub by spreading the rubber sheet on
the floor.
k If slinging the hub diagonally, the more
power is required and the slinging
tools or eyebolts may be damaged.
Therefore, use a press to remove the
hub instead of slinging the hub
forcibly.
12.Removal of rear flange

1) Invert the travel motor assembly so that the
travel motor faces upward.
a The following work is preparation for
disassembling the internal rear flange.
10.Removal of floating seal
a Loosen the plug so that it can be rotated
1) Put a finger to the internal diameter of by hand.
floating seal (29) to remove it upward.
a Do not loosen the plug when not
a Wear gloves to remove the floating seal disassembling the internal rear flange.
because the finger may be cut by the 2) Loosen plugs (324) (2 pieces).
edge of the seal.
PC138USLC-10 50-75
Power train system
a If plug (324) is loosened, spring (328) a If forcibly prying and patting rear flange
works. Be careful when loosing because (301), timing plate (109) may fall and may
the plug and spring may leap out. (See be damaged. (See "Component parts
"Component parts figure".) figure".)
3) Loosen plugs (380) (2 pieces), (352) (2 7) Remove dowel pins (34) (2 pieces) from
pieces), and (357). spindle (2).
4) Remove relief valve assembly (18) (2 8) Remove O-rings (32) (1 piece) and (33) (2
pieces). pieces) from spindle (2).
a Do not reuse removed O-rings (207), a Do not reuse removed O-rings (32) and
(209), and (212) and rings (208) and (33).
(210). (See "Component parts figure".)
13.Disassembly of rear flange

5) Remove hexagonal socket head bolts (301) 1) Set rear flange (301) on the work stand so
(10 pieces) from rear flange (343). that mating surface (a) to the spindle faces
6) Remove rear flange (301) from spindle (2). upward.
a Lift rear flange (301) slowly and straight 2) Remove timing plate (109) from rear flange
by both hands to remove it. (301).
50-76 PC138USLC-10
Power train system
a If timing plate (109) is firmly contacted

due to oil, insert spatula [9] to the groove
on rear flange (301) side to remove the
plate. (See "4) Manufacture tools" in
"Tool".)
a Sharp tools such as a flat-head
screwdriver may damage mating surface
(a). Do not use them.
2) Remove spring remove retainers (325) (2

pieces) and springs (328) (2 pieces) from
rear flange (301).
3) Remove spool (323) from rear flange (301).
a Spool (323) can be removed by inclining
rear flange (301). Pinch the tip of the
spool to remove it.
3) Remove ball bearing (150) from rear flange

(301).
4) Remove O-rings (336) (2 pieces) from plugs

(324) (2 pieces).
a Do not reuse removed O-rings (336).
4) Remove dowel pin (341) from rear flange
(301).
15.Disassembly of 2-stage speed selector spool

1) Remove plug (357) from rear flange (301).
14.Disassembly of brake valve 2) Remove O-ring (359) from plug (357).
1) Remove plugs (324) (2 pieces) from rear
flange (301).
(See "Component parts figure".)
PC138USLC-10 50-77
Power train system
3) Remove spring (366) and spool (363) from 17.Disassembly of seal ball
rear flange (301). (See "Component parts 1) Remove plugs (352) (2 pieces) from rear
figure".) flange (301).
(352) (2 pieces). (See "Component parts
figure".)
16.Disassembly of piston
1) Remove plugs (380) (2 pieces) from rear
flange (301).
(380) (2 pieces). (See "Component parts
3) Remove seal balls (353) (2 pieces) from rear
figure".)
flange (301).
a If it is difficult to remove the seal balls,
use a magnet, etc. to remove it.
3) Remove piston (381) from rear flange (301).

18.Disassembly of parking brake
1) Blow in compressed air through oil passage
(b) for parking brake of spindle (2) to remove
piston (112).
50-78 PC138USLC-10
Power train system
k If strongly blowing in compressed air, 4) Rotate cylinder block (104) 2 or 3 times

it is dangerous because piston (112) alternately to disconnect the swash plate
may leap out. Slowly blow in (103) and shoe (106) tightly contacted each
compressed air. Use protective cover other due to the oil. (See "Component parts
(19) to secure the safety. figure".)
5) Remove cylinder block (104) from shaft
2) Remove O-rings (135) and (139) from piston
(102).
(112).
a Be careful not to drop the parts (piston
a Do not reuse removed O-rings (135) and
(105), shoe (106), etc.) in cylinder block
(139).
(104) into spindle (2) due to the tight
contact between swash plate (103) and
shoe (106). (See "Component parts
figure".)
6) Remove piston assembly (piston (105), shoe

(106), and retainer plate (107)) as a whole.
a Remove retainer plate (107) by both
hands.
a Piston (105) integrates with shoe (106)
because they are tied at the spherical
portion of the piston. Therefore, they
cannot be separated each other.
19.Disassembly of travel motor a To replace piston (105) and shoe (106),

replace them together. (Called as piston
1) Rotate spindle (2) 90°, and it faces sideways.
assembly hereafter.)
a The oil is drained from spindle (2).
Prepare the oil container under it.
2) Drain the oil from spindle (2).
3) Remove plates (116) (4 pieces) and discs
(115) (3 pieces) from spindle (2).
7) Remove piston assemblies (piston (105) and

shoe (106)) (9 units) from retainer plate
(107).
PC138USLC-10 50-79
Power train system
3) Remove THS snap ring (145) from the snap

ring groove of cylinder block (104).
k If suddenly loosening the press, it is

dangerous because spring (114) leaps
out. Therefore, slowly loosen the
press.
8) Remove thrust ball (108) from cylinder block

(104).
9) Remove needles (151) (3 pieces) from

cylinder block (104).
4) Remove THS snap ring (145), washer (110),

spring (114), and washer (110) from cylinder
block (104). (See "Component parts figure".)
20.Removal of spring inside cylinder block

1) Set cylinder block (104) on the press stand.
a Remove spring (114) only for
replacement.
a To remove spring (114), align the center
of No.1 holder [2] and that of washer 21.Removal of swash plate
(110), and prevent cylinder block (104)
1) Rotate spindle (2) 90 deg. so that it faces
from being damaged.
sideways. Remove swash plate (103) from
a Cover cylinder block (104) with vinyl shaft (102).
sheet (20) to protect from damages
during the work.
2) Set No.1 holder [2] to upper side washer
(110) and hold it by using the press.
50-80 PC138USLC-10
Power train system
a When removing swash plate (103), pivot 22.Removal of ball bearing

(167) may be attached. Be careful not to
a Remove the ball bearing only for
remove it. (See "Component parts
replacement.
figure".)
1) Set No.2 holder [3] on the press stand and
set shaft (102) to the inside.
2) Hold shaft (102) by using the press to pull out
it from ball bearing (149).
a Do not reuse ball bearing (149).
2) Remove shaft (102) from spindle (2).

a At this time, remove ball bearing (149)
together. (See "Component parts figure".)
a Lightly tap shaft (102) by using a hammer
from the final drive side to remove the ball 23.Removal of spindle components
bearing easily.
1) Remove shaft (23) from spindle (2).
3) Remove pivots (167) (2 pieces) and dowel
pins (171) (2 pieces) from spindle (2). (See
2) Remove floating seal (29) from spindle (2).
4) Remove spring (185) and 2-stage speed

selector piston assembly (piston (161) and
shoe (162)) from spindle (2). (See
3) Remove oil seal (132) from spindle (2).

a Do not reuse removed floating seal (29)
and oil seal (132). (See "Component
parts figure".)
PC138USLC-10 50-81
Power train system
3) Blow with compressed air to dry the inside of

hub (1) and spindle (2) in dust-free and
moisture-free place.
4) Naturally dry the travel motor parts and gears
in dust-free and moisture-free place.
a After drying the parts, apply power train
oil (TO30).
24.Simple cleaning of parts

1) Hub (1), spindle (2) cover (14), and rear
flange (301) are distinguished from other
parts (called as built-in parts hereafter). (See
2) Put hub (1), spindle (2) cover (14), and rear
flange (301) in the cleaning tank to clean
them.
a Soil and sand attached to the outside of
the parts. Therefore, securely clean them.
3) Put the built-in parts in the simple cleaning
container that contains JIS No.1 kerosene.
k Flammable material such as JIS No.1

kerosene is used for cleaning the parts.
Handle the material carefully because
it may ignite and cause fire or burn.
a If cleaning the parts in the kerosene at
first, they are damaged. Soak them in the
kerosene and then clean them when
dusts and oil are loosened and float.
25.Finishing of cleaning
1) Put the parts in the finishing cleaning
container that contains JIS No.1 kerosene
and rotate the parts slowly to clean them up
to the inside.
2) Wipe the kerosene off the parts with clean
cloth.
50-82 PC138USLC-10
Power train system
a Testing parts
When disassembling and testing the travel motor, perform the maintenance according to the following
standard. The moving and sliding parts are precision parts. Be careful not to damage them.
1. Handling seals
If the seals (O-ring, oil seal, and floating seal) are disassembled once, be sure to replace all of them with
new ones regardless of damages.
2. Maintenance standard of wear parts
1) Replace all the visibly and significantly worn parts with new ones.
2) If the parts are abnormal as described below, replace all of them with new ones.
Part
Standard Allowable
Part name Phenomenon
value value
number
• Significantly and visibly damaged
• Pitching occurs on the tooth surface of the ring
1 Hub — —
gear.
• Abnormal wear such as scuffing is found.
• Significantly and visibly damaged
2 Spindle — —
• Abnormal wear such as scuffing is found.
3, 7
and Carrier assembly • Abnormal wear such as scuffing is found. — —
others
4 Sun gear A
8 Sun gear B • Pitching occurs on the tooth surface.
• Flaking phenomenon is found on the rail surface — —
5 Planetary gear A of the bearing.
9 Planetary gear B
• Impression is found.
Ball bearing • Flaking phenomenon is found on the rail surface — —
24
of the ball bearing.
• Uneven wear is found.
• Sliding portions of spool (323), (363) and piston
301 Rear flange — —
(381) are damaged.
• Mating face with oil seal (132) wears.
102 Shaft — —
• Spline wears.
103 Swash plate • Seizure phenomenon is found. — —
• Spline wears.
• Inner bore significantly wears.
104 Cylinder block — —
• The sliding surface with timing plate (109) is
damaged or unevenly wears.
• Clearance is found between piston (105) and
105 Piston assembly Clearance Clearance
(106) in direction of the shaft.
106 (piston + shoe) 0.05 mm 0.15 mm
• Shoe (106) abnormally and unevenly wears.
• The sliding surface with shoe (106) unevenly
wears.
107 Retainer plate — —
• The sliding surface with thrust ball (108) is
damaged and unevenly wears.
• The spherical sliding surface with retainer plate
108 Thrust ball — —
(107) unevenly wears.
• Seizure phenomenon and uneven wear are
109 Timing plate — —
found on the sliding surface.
Braking Braking
115 Disc • Uneven wear is found on both end surface. torque torque
• Specified torque is not found.
116 Plate • Seizure phenomenon is found. Min. 206 Nm Min. 206 Nm
{21.0 kgm} {21.0 kgm}
—
105 Piston • Periphery is damaged. —
PC138USLC-10 50-83
Power train system
Part
Standard Allowable
Part name Phenomenon
value value
number
• Impression is found.
149 • Flaking phenomenon is found on the rail surface
Ball bearing — —
150 of the bearing.
• Wear is found.
2-stage speed
161 • Abnormal wear is found on periphery.
piston assembly — —
162 • The shoe abnormally and unevenly wears.
(piston + shoe)
323 • Uneven wear is found on periphery.
Spool — —
363 • Periphery is damaged.
381 Piston • Periphery is damaged. — —
50-84 PC138USLC-10
Power train system
Assembly (PC138-DF10-710-K-00-A)
• Perform installation in the reverse order to a When replacing the above parts for
removal. reassembling, be sure to use the ones
Preparation items adjusted in "Adjustment of individual part".
1. Preparation before assembling Using the parts that are not adjusted may
Prepare the same tools and equipment as the cause malfunction and premature damage to
preparation items in "Disassembly" section. the travel motor.
2. General precautions for working
1) Same as "2. General precautions for
working" in "Disassembly" section.
2) Before assembling, clean all the parts,
remove metal particles and foreign matter,
and check that there are no burrs and
scratches. If there are burrs and scratches,
remove them by using the oil abrasive wheel.
3) Do not reuse the O-ring, oil seal, and floating
seal. Replace them with new ones.
4) Pass the tap (M10, P1.5) into the screw hole
of hub (1), and remove the remaining
adhesive.
Clean the screw hole and degrease it, and
then blow with compressed air to dry it.
Replace hexagonal socket head bolt (35)
with a new one.
5) When installing the O-ring, oil seal, and
floating seal, lightly grease, and perform the
work carefully to prevent them from being
damaged.
6) Be sure to apply power train oil (TO30) to the
moving and sliding surfaces of each part of
the travel motor for assembling.
7) Do not wear cloth gloves during the
assembly work.
(This is because to prevent the malfunction
due to entry of particles of the cloth glove
fiber)
8) For tightening the bolts and plugs, see
"Tightening torque table".
9) After completion of assembly, immediately
install the plugs to all the ports to prevent
dusts from entering.
10)The illustration in this section is the typical
model. It may be different from the actual
machine. However, the assembly procedure
is the same.
3. Assembly procedures
a Preload adjustment of bearing is necessary
when reassembling after parts replacement.
Check that the following parts are replaced
with new ones.
Hub (1)
Spindle (2)
Ball bearing (24)
PC138USLC-10 50-85
Power train system
1. Assembly of hub 2 O-ring:

1) Set hub (1) on cylinder (21) on the press Grease (G2-LI)
table.
a Remove the O-ring and lightly apply
2) Install ball bearing (24) to hub (1) and press-
grease to the periphery.
fit the bearing by using push tool [6].
2) Set No.3 installation jig [12] and then No.2
3) Rotate hub (1) reversely and install ball
installation jig [11] to spindle (2) in order, and
bearing (24) to the opposite side similarly.
push until No.2 installation jig [11] hits No.3
a Check the direction of ball bearing (24), installation jig [12].
and then install it.
a Remove No.3 installation jig [12] and
No.2 installation jig [11].
a Check that the parallelism of the end
surface of spindle (2) and the seal
surface of floating seal (29) is 1 mm or
less.
4) Apply grease to the O-ring of floating seal

(29), and install it to hub (1).
2 O-ring:
Grease (G2-LI)
a Remove the O-ring, and lightly apply
grease to the periphery. 3) Install eyebolts [8] (2 pieces) to the mounting
5) Set No.1 installation jig [10] and then No.2 bolt hole of spindle (2).
installation jig [11] to hub (1) in order, and a Install eyebolts [8] (2 pieces)
push until No.2 installation jig [11] contacts to symmetrically.
No.1 installation jig [10]. 4) Sling spindle (2) and install hexagonal socket
a Remove No.1 installation jig [10] and head bolts (37) to the work stand
No.2 installation jig [11]. symmetrically.
a Check that the parallelism of the end 4 Spindle (2):

surface of hub (1) and the seal surface of
30 kg
floating seal (29) is 1 mm or less.
a Securely tighten hexagonal socket head
bolts (2 pieces). (This is because to
prevent the travel motor assembly from
removing when rotating it reversely)
2. Assembly of spindle
1) Apply grease to the O-ring of floating seal
(29), and install it to spindle (2).
50-86 PC138USLC-10
Power train system
3. Adjustment of preload of ball bearing

a When hub (1), ball bearing (24), and spindle
(2) have been replaced, adjust the preload. If
the preload is not correct, the ball bearing
may be damaged early. (See "Component
parts figure".)
1) Temporarily install lock washer (22) to
spindle (2) and measure dimension (c).
4. Installation of hub
1) Lower hub (1) so that the center shaft of
spindle (2) becomes straight and press-fit the
hub to ball bearing (24). (See "Component
parts figure".)
4 Hub (1):
50 kg
2) Fix hub (1) to work stand [1] with hexagonal
2) Measure installation width (d) of ball bearing socket head bolts.
(24). 3) Lightly tap ball bearing (24) on the final drive
a Rotate hub (1) and ball bearing (24) a few side by using a hammer to reduce the
times to reduce the flotation, and then flotation of the ball bearing. (See
measure the width. "Component parts figure".)
3) Select shim (23) so that clearance (e) is

+0.13 to +0.17 mm.
• Clearance (e) = Dimension (c) - (d)
Thickness Thickness
Code (mm) Code (mm)
A 0.9 G 1.5
B 1.0 H 1.6
C 1.1 I 1.7
D 1.2 J 1.8
E 1.3 K 1.9
F 1.4 L 2.0
4) Install shim (23) to spindle (2).
4) Invert the work stand and install lock washer
(22) to the groove of spindle (2).
PC138USLC-10 50-87
Power train system
5) Use jig [5] to push lock washer (22) to the 2) Install dowel pins (171) (2 pieces) to the pin
groove of spindle (2). hole of spindle (2). (See "Component parts
figure".)
a Sufficiently push lock washer (22) so that
3) Install pivots (167) (2 pieces) to dowel pins
carrier B (7) does not interfere with the
(167). (See "Component parts figure".)
lock washer when the carrier is installed.
(See "Component parts figure".) 2 Spherical portion of pivot (167):
6) Remove the hexagonal socket head bolts of Grease (G2-LI)
hub (1) that fix the work stand. (See 4) Install spring (185) to piston assembly (piston
"Component parts figure".) (161) and shoe (162)). (See "Component
7) Rotate hub (1) 2 or 3 turns. parts figure".)
a The sliding surface of floating seal (29) 2 Spring (185):
fits in and prevent oil from leaking. (See
Grease (G2-LI)
5) Apply power train oil (TO30) to the sliding
8) Rotate the work stand reversely so that the
surface of the piston assembly and install it
to the piston holes of spindle (2).
6) Install dowel pins (171) (2 pieces) to the pin
holes on the mating surfaces of the rear
flange of spindle (2). (See "Component parts
figure".)
5. Assembly of inner spindle

1) By using push tool [4], press-fit oil seal (132)
to spindle (2).
2 Lip of oil seal (132):
6. Installation of shaft
Grease (G2-LI)
1) Heat ball bearing (149) by using the heating
a Check the installation direction of oil seal tank and press-fit it to shaft (102).
(132), and then install it. Heating of ball bearing (149): 100 - 10 °C, for
10 minutes
k Heating and installing ball bearing

(149) may cause burn. Be sure to wear
leather gloves during the work.
50-88 PC138USLC-10
Power train system
2) Rotate the travel motor assembly 90 deg. so 7. Assembly of cylinder block

that it faces sideways and install shaft (102) 1) Install washer (110), spring (114), washer
to spindle (2). (110), and THS snap ring (145) to cylinder
block (104) in order.
a Face the sharp side of washer (110) on
THS snap ring (145) side upward.
a Face the sharp side of THS snap ring
upward. (See "Component parts figure".)
2) Set cylinder block (104) on the press stand.
3) Set No.1 holder [2] to upper side washer
(110) and hold it by using the press.
4) Remove THS snap ring (145) to the snap
ring groove of cylinder block (104).
k If the tip of the snap ring pliers

3) Press shaft (102) by using the press to removes from the hole of THS snap
press-fit it to ball bearing (149). ring (145), it is dangerous because
THS snap ring (145) leap out. Be
a When installing shaft (102), be careful not
careful when installing it.
to damage the lip of previously-installed
oil seal (132). a To push spring (114), align the center of
No.1 holder [2] with that of washer (110),
a Damage of oil seal (132) lip may cause oil
and prevent cylinder block (104) from
leakage and premature damage to the
being damaged.
travel motor.
(See "Component parts figure".) a Cover cylinder block (104) with vinyl
4) Install swash plate (103) to shaft (102). sheet (20) to protect from damages
during the work.
2 Sliding surfaces of spindle (2) and
swash plate (103):
Grease (G2-LI)
a Align pivots (167) (2 pieces) with the
installation hole position on swash plate
side, and install them. (See "Component
parts figure".)
PC138USLC-10 50-89
Power train system
3) Install piston assemblies (piston (105) and

shoe (106)) (9 units) to retainer plate (107).
a After installation, soak the parts as a unit
in power train oil (TO30).
4) Install piston assembly (piston (105), shoe

(106), and retainer plate (107)) to cylinder
block (104) together.
a Install retainer plate (107) by both hands.
a Securely align retainer plate (107) with
the spherical portion of thrust ball (108)
8. Assembly of travel motor
1) Install needles (151) (3 pieces) to cylinder
block (104).
5) Install cylinder block (104) to shaft (102).

a Align spline of shaft (102) to install
cylinder block (104).
2) Install thrust ball (108) to cylinder block
(104).
6) After installation of cylinder block (104),

rotate cylinder block (104) by hand to check
50-90 PC138USLC-10
Power train system
that there is no play of the block around shaft

(102).
a Test if any play is found.
a After installation of cylinder block (104),
do not lift cylinder block (104). (If the
cylinder block is lifted, thrust ball (108)
removes and does not rotate correctly.)
10.Assembly of 2-stage speed selector spool

1) Install spring (366) and spool (363) to rear
flange (301). (See "Component parts figure".)
2) Install O-ring (359) to plug (357).
2 O-ring (359):
Grease (G2-LI)
9. Assembly of parking brake

1) Rotate the travel motor assembly 90deg. so
that the travel motor faces upward.
2) Install disc (115) and plate (116) alternately
to cylinder block (104). (See "Component
parts figure".)
a Soak disc (115) in power train oil (TO30)
in advance.
3) Install and temporarily tighten plug (357) to

rear flange (301).
3) Install O-rings (135) and (139) to piston

(112).
2 O-rings (135) and (139):
Grease (G2-LI)
4) Install piston (112) to spindle (2).
11.Assembly of seal ball
a If it is difficult to install piston (112), lightly 1) Install O-rings (358) (2 pieces) to plugs (352)
tap by using a plastic hammer to install it. (2 pieces). (See "Component parts figure".)
a Be careful not to damage O-rings (135) 2 O-ring (358):
and (139) when installing them.
Grease (G2-LI)
2) Install seal balls (353) (2 pieces) to rear
flange (301).
PC138USLC-10 50-91
Power train system
3) Temporarily tighten plugs (352) (2 pieces) to 13.Assembly of brake valve

rear flange (301). 1) Install spool (323) to rear flange (301).
2 Spool (323):
Power train oil (TO30)
a Carefully insert spool (323) to the center
of the spool hole of rear flange (301).
a Damaging spool (323) and the spool
holes of rear flange (301) during insertion
may cause the oil leakage and
deterioration of the travel motor
performance.
2) Install O-rings (336) (2 pieces) to plugs (342)
(2 pieces).
12.Assembly of piston 2 O-ring (336):
1) Install O-rings (383) (2 pieces) to plugs (380) Grease (G2-LI)
(2 pieces). (See "Component parts figure".) 3) Install washers (325) (2 pieces) and springs
2 O-ring (383): (328) (2 pieces) to plugs (324) (2 pieces).
Grease (G2-LI)
2) Install piston (381) to rear flange (301).
3) Temporarily tighten plugs (380) (2 pieces) to

rear flange (301).
50-92 PC138USLC-10
Power train system
4) Screw in plugs (324) (2 pieces) to rear flange 3) Use the dowel pin as a guide to install timing
(301). plate (109) to rear flange (301).
a Be careful not to deform spring (328) 2 Mating surfaces of rear flange
when screwing in plug (324). (301) and timing plate (109):
Grease (G2-LI)
a Check that timing plate (109) and rear
flange (301) are tightly contacted by
grease.
a Prevent timing plate (109) from falling
when installing rear flange (301) to
spindle (2). (See "Component parts
figure".)
14.Assembly of rear flange

1) Install ball bearing (150) to rear flange (301).
2 Ball bearing (150):
Grease (G2-LI)
4) Install springs (113) (10 pieces) to rear flange

(301).
2 Spring (113):
Grease (G2-LI)
a Sufficiently apply grease to prevent the
springs from falling when installing rear
flange.
2) Install dowel pin (341) to the pin hole of rear

flange (301).
PC138USLC-10 50-93
Power train system
4) Install rear flange (301) to spindle (2).

a To install rear flange (301), align it with
the positions of dowel pins (34). (See
5) Temporarily tighten hexagonal socket head
bolts (343) (10 pieces) to spindle (2).
15.Installation of rear flange

1) Install O-rings (33) (2 piece) and (32) (1
piece) to spindle (1).
a Do not apply grease to the O-rings (32)
and (33). (Grease may leak from the
mating surfaces of rear flange (301) and
spindle (2) during operation. This 6) Tighten hexagonal socket head bolts (343)
phenomenon may be mistaken as oil (10 pieces).
leakage.) (See "Component parts
figure".) 3 Hexagonal socket head bolt (343):
2) Add oil to spindle (2). 102 ± 15.7 Nm {10.4 ± 1.6 kgm}
5 Inside of spindle (2) (power train

oil):
1.0 l (TO30)
7) Tighten plug (324) (2 pieces).

3 Plug (324):
441 ± 39.2 Nm {45.0 ± 4.0 kgm}
3) Install dowel pins (34) (2 pieces) to spindle
(2).
8) Tighten plugs (380) (2 pieces), (352) (2

pieces), and (357).
50-94 PC138USLC-10
Power train system
3 Plug (380): a Set the center shafts of the hub and

58.8 ± 9.81 Nm {6.0 ± 1.0 kgm} carrier assembly vertically and slowly
lower and install the assembly to prevent
3 Plug (352): the hub internal teeth from being
12.3 ± 2.45 Nm {1.25 ± 0.25 kgm} damaged by the end face of planetary
gear B (9). (See "Component parts
3 Plug (357):
figure".)
98.1 ± 19.6 Nm {10.0 ± 2.0 kgm}
16.Installation of relief valve assembly a Lower so that ports (f) of planetary gear B
(9) and rear flange (301) are as shown in
1) Tighten relief valve assemblies (18) (2
the following figure.
pieces).
Port (f): For hydraulic piping
3 Relief valve assembly (18):
Hole (g): For 2-stage speed piston
98.1 ± 19.6 Nm {10.0 ± 2.0 kgm}
18.Installation of coupling
17.Assembly of sun gear B
1) Install coupling (15) to shaft (102). (See
1) Invert the work stand so that the final drive "Component parts figure".)
faces upward.
2) Install sun gear B (8) to carrier B (7). (See
places) of carrier B (7), and install the sun
gear while lowering the carrier assembly.
4 Carrier assembly:
25 kg
19.Assembly of sun gear A
PC138USLC-10 50-95
Power train system

places) of carrier A (3), and install the sun
gear while lowering the carrier assembly.
lower and install the assembly to prevent
the hub internal teeth from being
damaged by the end face of planetary
gear B (5).
20.Installation of cover
1) Apply liquid adhesive to mating surfaces (h)
with cover (14) of hub (1).
2 Mating surface (h):
equivalent)
a Apply the liquid adhesive without gap.
2) Install sun gear A (4) while aligning it with the

spline of coupling (15). (See "Component
parts figure".)
a If the spline of sun gear A (4) interferes
with the tooth tip of planetary gear A (5)
and installation cannot be performed,
slowly sling the carrier assembly until sun
gear B (8) removes from the gear
coupling and then install sun gear A (4).
2) Install eyebolts [8] to port (k) and cover (14)

to hub (1) while aligning the bolt hole
position.
3) Install thrust plate (13) to carrier A (3).
3) Tighten hexagonal socket head bolts (35).

2 Mounting bolt:
equivalent)
50-96 PC138USLC-10
Power train system
3 Mounting bolt: 3) Install eyebolts [8] to the screw hole of

66.7 ± 3.92 Nm {6.8 ± 0.4 kgm} spindle (2) to sling and remove the travel
motor assembly.
4 Travel motor assembly:

150 kg
a Performance check test
• After completion of the travel motor maintenance,
perform the performance check test according to
the following procedure.
1. Required instruments
No. Part name Q'ty
Pressure gauge (3.43 MPa {35 kg/
1 cm2}) 2
21.Adding oil 2 Female cylinder (5 l) 1
1) Add oil through oil filler port (j). 3 Stopwatch 1
2. Test procedure
5 Final drive case: 1) Removal of travel motor and piping
2.1 l Install the travel motor to the machine and
perform the piping. However, do not install
the track shoe.
(For performance test (operation without
load) of the travel motor)
a Perform the piping so that a pressure
gauge (main circuit) can be installed or
drain amount of the hydraulic motor can
be measured.
a Slowly install the travel motor with the bolt
holes instead of tapping by using a
hammer.
2) Running-in of travel motor
2) Tighten plugs (30) (3 places). Travel
motor Running Running
Selection Pressure
3 Plug (30): speed direction time
98.1 ± 19.6 Nm {10.0 ± 2.0 kgm} Low
speed 10 rpm 1 minute
running Right or longer
No load respec-
High and left
speed 20 rpm tively
running
3) Performance check test of travel motor
Preparation for running-in before test
a Perform running-in until reaching the
1] following temperatures
• Reduction gear hub external temperature:
40 to 80 °C
2] Check test
22.Removal of travel motor
1) Invert the travel motor assembly so that the
2) Remove travel motor mounting bolts from
work stand [1]. (See "Component parts
figure".)
PC138USLC-10 50-97
Power train system
a Measure the following items at low speed

to determine pass or fail.
• Passing standard - Travel motor drive
pressure difference
Max. 1.57 MPa {16 kg/cm2} / 10 rpm
• Hydraulic motor drain amount
Max. 1.2 l/min. / 10 rpm
a Test result
Accepted: Track shoe can be installed.
Unaccepted: Disassemble and adjust
again.
50-98 PC138USLC-10
Power train system
Removal and installation of swing motor and swing machinery

assembly (PC220-J120-924-K-00-A)
k Park the machine on a level ground, lower
the engine.

hydraulic circuit. For details, see Testing and
adjusting, “Releasing remaining pressure
from hydraulic circuit”.
a Note connector numbers and installed positions

before disconnecting wiring and hoses.
a Fit a plug or flange to the disconnected hydraulic
hose to prevent oil from flowing out. 4. Use the forcing screw for forcing tap (A) to
Removal (PC138-J120-520-K-00-A)
disconnect swing motor and swing machinery
assembly (9).
step (2).
5. Sling swing motor and swing machinery

assembly (9), and remove them. [*1]
2. Disconnect hoses (3) to (7).
a Be careful not to interfere with peripheral
hoses when slinging.
4 Swing motor and swing machinery

assembly:
105 kg
3. Remove mounting bolts (8) (13 pieces).
Installation (PC138-J120-720-K-00-A)

removal.
[*1]
PC138USLC-10 50-99
Power train system
3 Swing machinery mounting bolt:

303.8 to 362.6 Nm {31.0 to 37.0 kgm}
again.
5 Hydraulic tank:
lubricants")
a Bleeding air (hydraulic system)
Bleed air from the hydraulic pump circuit. For details,
see Testing and adjusting, "Bleeding air from
hydraulic system".
50-100 PC138USLC-10
Power train system
Disassembly and assembly of swing machinery assembly (PC138-J120-926-K-00-A)
a Special tools 6) Sling swing motor assembly (4), and remove

it.
Necessity
Sym-
Q'ty
Part No. Part name
bol
1 790-201-2750 Spacer t 1
790-101-2501 Push puller kit q 1
790-101-2510 • Block 1
790-101-2550 • Leg 1
790-101-2560 • Nut 2
2 790-101-2570 • Plate 4
790-101-3101 • Bearing puller q 1
• Puller
790-101-4200 (294 kN {30 ton}) q 1
3. No.1 carrier and No.2 sun gear assembly
F 790-101-1102 Hydraulic pump q 1
790-101-5401 Push tool kit (C) q 1 1) Remove No.1 sun gear (5).
2) Remove No.1 carrier and No.2 sun gear
790-101-5461 • Plate 1
assembly (6).
3 790-101-5441 • Plate 1
790-101-5421 • Grip 1
01010-51240 • Bolt 1
4 790-201-2850 Spacer t 1
5 790-201-2750 Spacer t 1
796T-426-1140 Push tool t 1
6
790-201-2680 Plate q 1
Disassembly (PC138-J120-530-K-01-A)
1. Draining oil
Remove the drain plug to drain the oil in the
swing machinery.
6 Swing machinery case: 3) Disassembly of No.1 carrier and No.2 sun

2.5 l gear assembly
2. Swing motor assembly 1] Remove snap ring (7) to remove thrust
1) Remove U-bolt (1). washer (8), gear (9), bearing (10), and
2) Remove bracket mounting bolts (2-1) (2 thrust washer (11).
pieces) and remove bracket (2).
3) Remove oil filler pipe (3).
4) Remove swing motor mounting bolts (3-1)
(11 pieces).
2] Drive in pin (12) to remove shaft (13).

a After removing the shaft, remove pin
(12).
5) By using forcing screws [1], disconnect 3] Remove snap ring (14) and remove No.2
swing motor assembly (4). sun gear (15) from carrier (16).
PC138USLC-10 50-101
Power train system
3) Remove split collar (28).
4. Ring gear
Remove ring gear (17).
7. Shaft assembly
5. No.2 carrier assembly
1) Set the shaft and case assembly (30) on
1) Remove spacer (18).
block [2], and remove shaft assembly (31) by
2) Remove No.2 carrier assembly (19).
using push tool [3] and the press.
2) Remove bearing (29).
3) Disassembly of No.2 carrier assembly

1] Drive in pin (20) to remove shaft (21) from 3) By using tool F2, remove bearing (32) and
carrier (22). collar (33) from shaft (34).
a After removing the shaft, remove pin
(20).
2] Remove thrust washer (23), gear (24),
bearing (25), and thrust washer (26).
8. Oil seal, bearing outer race

1) Remove oil seal (35) from case (36).
6. Retainer, collar
1) Remove retainer (27).
2) Set the shaft and case assembly on the
press, push split collar (28) by using push
tool F1, and press-fit bearing (29).
50-102 PC138USLC-10
Power train system
2) By using puller [4], remove bearings outer 3) Set case (39) to shaft assembly (31).
races (37) and (38) from case (36). 4) By using push tool F5 and press, press-fit
bearing (29) up to the position where the split
collar is inserted.
a Press-fitting force: Max. 11,760 N {1,200
kg}
a Gradually press-fit the bearing while
rotating the case.
Assembly (PC138-J120-710-K-01-A)
1. Bearing outer race

By using the push tool F3, press-fit outer races
(37) and (38) to cage (36).
5) Install split collar (28).

6) Screw in the bolt (12mm, P = 1.75) to the
case and measure the tangential force in the
rotating direction by using push-pull scale [5].
a Tangential force: Max. 176.4 N {18 kg}
a Tangential force indicates the maximum
value at the beginning of rotation.
2. Shaft assembly
1) Install the O-ring to the inside of collar (33)
and install it to shaft (34).
2) By using push tool F4 and press, press-fit
bearing (32).
3. Oil seal
PC138USLC-10 50-103
Power train system
By using tool F6, press-fit oil seal (35).

a Use a new oil seal.
a When press-fitting the oil seal, lightly apply
liquid gasket to the internal diameter of the
case and completely wipe off the protruded
liquid.
Be careful not to apply liquid gasket to the oil
seal lip.
2 Liquid gasket:
LG-5
a Apply a grease evenly without surge to the oil 3] Align the pin hole in shaft (21) with the
seal lip. hole in the carrier, and tap the shaft by
2 Oil seal lip: using a plastic hammer to install it.
Grease (G2-LI or G2-S) a Install the shaft while rotating the
planetary gear and be careful not to
damage the thrust washer.
4] Insert pin (20).
a Use a new pin.
a Insert the narrow side of pin groove
(b).
a After inserting the pin, peen portion (a)
of the carrier pin side (2 places).
4. Retainer
Install retainer (27).
5. No.2 carrier assembly

1) Assembly of No.2 carrier assembly
1] Install bearing (25) to gear (24).
2] Attach thrust washers (23) and (26) for
the top and bottom and set the gear
assembly on carrier (22).
2) Install No.2 carrier assembly (19) to the shaft

and case assembly.
3) Install spacer (18).
50-104 PC138USLC-10
Power train system
6. Ring gear
Install O-ring (40) to the shaft and case
assembly, and install it to ring gear (17).
7. No.1 carrier and No.2 sun gear assembly

1) Assembly of No.1 carrier and No.2 sun gear
assembly
1] Align the pin hole in shaft (13) with the
hole in the carrier, and tap the shaft by
using a plastic hammer to install it.
2] Insert pin (12).
a Use a new pin.
a Insert the narrow side of pin groove
4] Install thrust washer (11), bearing (10),
(b).
gear (9) and thrust washer (8) to install
a After inserting the pin, peen portion (a) snap ring (7).
of the carrier pin side (2 places).
a Use a new snap ring.
a Check that step (c) between the shaft
a When installing the snap ring, do not
and carrier is Max. 0.2 mm.
expand the mating part 11mm or more.
3] Install No.1 carrier (16) to No.2 sun gear
Otherwise, the snap ring deforms.
(15) and install snap ring (14).
a Install snap ring (d) so that edge side
a Install snap ring (d) so that edge side
(e) and drooping side (f) are as shown
(e) and drooping side (f) are as shown
in the figure.
in the figure.
a Check that the snap ring is securely
fitted.
PC138USLC-10 50-105
Power train system
8. Swing motor assembly

1) Install the snap ring to the output shaft of the
swing motor.
a Use a new snap ring.
2) Install swing motor assembly (4).
3) Install oil filler pipe (3) to the swing motor.
4) Install bracket (2) and U-bolt (1).
3 U-bolt mounting nut:
10.8 to 26.5 Nm {1.1 to 2.7 kgm}
5) Install swing motor mounting bolts (3-1) (11
pieces) and bracket mounting bolts (2-1) (2
pieces).
2) Install No.1 carrier and No.2 sun gear
assembly (6) to the shaft and case assembly. a The length of the bracket mounting bolts
3) Install No. 1 sun gear (5). (2 pieces) are different each other.
a Install No. 1 sun gear (5) so that step (h) 3 Bracket mounting bolts and swing
is as shown in the figure. motor mounting bolt:
4) Install O-ring (41) to the ring gear. 988 to 122.5 Nm {10 to 12.5 kgm}
9. Refilling of oil
Tighten the drain plug and supply power train oil
TO30 through the oil filler port.
5 Swing machinery case:

2.5 l
50-106 PC138USLC-10
Power train system
Removal and installation of swing circle assembly (PC138-J110-924-K-00-A)

the engine.

Removal (PC138-J110-520-K-00-A)
1. Remove the revolving frame assembly. For

revolving frame assembly".
2. Sling swing circle assembly (1), and remove the
mounting bolts (38 pieces) of the inner race. [*1]
3. Remove swing circle assembly (1). [*2]
4 Swing circle assembly:

170 kg
Installation (PC138-J110-720-K-00-A)

removal.
[*1]
2 Inner race mounting bolt (A) (38 pieces):
Adhesive (LT-2)
3 Inner race mounting bolt (A) (38 pieces):
245 to 308.9 Nm {25 to 31.5 kgm}
[*2]
a Sling swing circle assembly (1), and direct "S"
mark of the inner ring soft zone of the inner race
toward the position shown in the figure to install
the track frame.
2 Amount of grease (G2-LI) of swing circle:
9.1 l
PC138USLC-10 50-107
Separation and connection of track (PC138-DTL0-924-K-00-A)
a Special tools
Necessity
Sym-
Q'ty
Part No. Part name
bol
Remover and
791-620-3000 t 1
installer
791-635-3110 • Frame 1
791-635-3120 • Support 1
791-635-3130 • Nut 1
791-635-3140 • Screw 1
791-635-3150 • Hook 1
3. Remove shoes (5) (2 pieces) on the top and
791-635-3160 • Extension 1
front side of master pin (1) from track (4). [*2]
791-635-3170 • Nut 4
791-635-3180 • Screw 2 a Loosen each of 4 bolts by 1 or 2 turns. Check
G 791-635-3190 • Screw (for fixing) 1 that they can be unscrewed smoothly, and
791-635-3210 • Pilot 1 then remove them.
791-630-3220 • Adapter 1 a If a bolt does not turn smoothly and it is
791-620-3260 • Pin pusher 1 unscrewed forcibly, the threads of the bolt
796T-432- and link may be damaged.
Guide t 1
1010
Cylinder
790-101-1300 (980 kN {100 ton})
or t 1
790-101-1600 Cylinder
(686 kN {70 ton})
791-101-1102 Pump t 1
Separation (PC138-DTL0-520-K-00-A)
1. Move master pin (1) to the top of idler (2).
4. Remove master pin (1) by using tool G. [*3]

a Push master pin (1) by using guide pin [1].
2. Lower the work equipment to the ground, loosen

lubricator (3) and slacken the track tension. [*1]
k Since the internal pressure of the

adjustment cylinder is very high, do not
loosen the lubricator more than one turn.
If the grease does not come out 5. Move the installed position of guide pin [1] and
sufficiently, travel the machine in the place block [2], etc. at the bottom of track (4) in
forward and reverse directions. front of the idler to support it.
6. Pull out guide pin [1] and remove block [2], etc.
to easily separate track (4).
50-108 PC138USLC-10
7. Travel the machine slowly in reverse to separate

track (4). [*4]
3. Drive in guide pin [1] into link (7).
Installation (PC138-DTL0-720-K-00-A)
1. Pull the wire [3] by the forklift, work equipment,

etc., slowly travel the machine forward to wind
track (4) with the wire [3]
4. Perform subsequent installation in the reverse of

separation.
[*1]
a Adjust the track tension. For details, see Testing
and adjusting, "Testing and adjusting track
tension".
2. Wind track shoe (4) by using bar [4], hammer [5],
etc. and align the pin mounting hole position of [*2]
link (7). a Tighten the shoe bolts and nuts in the order as
a Place block [2], etc. at the bottom of track shown in the following figure.
shoes (4) in front of the idler to support it. 1. Assemble so that (R) side of shoe nut (6) tightly
contacts the seat surface on the link side.
a If installing the opposite side, the nut corner
interferes with the link seat surface, and nuts
float. This may cause the bolts to loosen.
2. Tighten the bolt to the following torque.
PC138USLC-10 50-109
a Check that the mating surfaces tightly

contact and then retighten the bolt.
a Tighten the bolt in the order shown in the
figure.
Triple
grouser shoe Road liner Remarks
196 ± 20 Nm 176 ± 20 Nm
1st time {20 ± 2 kgm} {18 ± 2 kgm} —
90 deg. ± 10 60 deg. ± 5 Angle
2nd time deg. deg. tightening
a When installing the dust seal, apply grease (G2-

LI) to the mating surfaces of the seal and
bushing.
a Apply grease (G2-LI-1) to the inside diameter of
the master bushing and then press-fit the master
pin.
a If the rubber parts of the road liner (rubber pad
type) are worn and damaged and the mounting
bolt heads are damaged, replace the shoes with
new ones immediately. If the head of a bolt is
crushed, that bolt cannot be removed.
[*3]
a Press-fit the master pin by using tool G so that
projection (a) of the master pin is the following
dimension.
• Projection (a): 3 ± 2 mm
50-110 PC138USLC-10
Removal and installation of sprocket (PC220-DT60-924-K-00-A)
Removal (PC138-DT60-520-K-00-A)
1. Separate the track shoe assembly. For details,

see "Separation and connection of track shoe
assembly".
2. Swing the work equipment 90 deg. and raise the
machine off the ground by using the work
equipment to set block [1] between the track
frame and track shoe.
3. Remove mounting bolts (15 pieces) to sling

sprocket (1), and remove it. [*1]
4 Sprocket:
35 kg
Installation (PC138-DT60-720-K-00-A)

removal.
[*1]
2 Threaded portion of sprocket mounting
bolt:
Adhesive (LT-2)
3 Sprocket mounting bolt:
323.6 to 362.8 Nm {33 to 37 kgm}
PC138USLC-10 50-111
Removal and installation of idler and idler cushion assembly (PC220-DTA0-924-K-00-

A)
Removal (PC138-DTA0-520-K-00-A)
1. Separate the track shoe assembly. For details,

see "Separation and connection of track shoe
assembly".
2. Pull idler and idle cushion assembly (1) forward
and remove it while slinging it.
4 Idler and idler cushion assembly:

155 kg
3. Disconnect idler cushion assembly (3) from idler

(2).
4 Idler assembly:
80 kg
4 Idler cushion assembly:

75 kg
Installation (PC138-DTA0-720-K-00-A)

removal.
50-112 PC138USLC-10
Disassembly and assembly of idler assembly (PC138-DT90-926-K-00-A)
a Special tools
Necessity
Sym-
Q'ty
Part No. Part name
bol
L 1 791-675-1510 Installer t 1
Disassembly (PC138-DT90-530-K-00-A)
1. Remove dowel pin (1) to remove support (2).

2. Remove floating seal (3) from support (2) and
idler (4).
3. Pull out idler (4) from shaft (5) and support (7)
assembly. 5. Remove dowel pin (8) to remove support (7)
a Oil of 90 cc is filled and sealed. Drain it at this from shaft (5).
time or spread a cloth to keep the ground 6. Remove bushings (9) and (10) from idler (4).
clean.
4. Remove floating seal (6) on the opposite side
from idler (4), shaft (5), and support (7)
assembly.
Assembly (PC138-DT90-710-K-00-A)
1. Press-fit bushings (9) and (10) to idler (4).
2. Install O-ring and install support (7) to shaft (5).

3. Install floating seal (6) to idler (4), shaft (5), and
support (7) assembly by using tool L1.
a Apply grease to the sliding surface of the
floating seal to prevent dirt, etc. from
attaching.
a Degrease the mating surfaces of the floating
seal and O-ring.
PC138USLC-10 50-113
a Check that the inclination is less than 1 mm

and projection dimension (a) is within the
range between 6 and 10 mm after the
floating seal is inserted.
5. Add the oil between shaft (5) and idler (4).
5 Sealed oil:
90 to 105 cc (E030)
6. Install floating seal (3) to idler (4) and support (2)

by using tool L1.
attaching on the contact surface of the
floating seal.
a Degrease the mating surfaces of the floating
seal and O-ring.
4. Install shaft (5) and support (7) assembly to idler
(4).
50-114 PC138USLC-10
7. Install O-ring and install support (2) with dowel

pin (1).
PC138USLC-10 50-115
Disassembly and assembly of idler cushion assembly (PC138-DTBP-926-K-00-A)
a Special tools
Necessity
Sym-
Q'ty
Part No. Part name

bol
791-600-2001 Compressor (A)

or t 1
Compressor (B)
791-685-8006
791-635-3160 Extension t 1
2 790-201-2770 • Spacer t 1
Cylinder
790-101-1600 t 1
(686 kN {70 ton})
L 790-101-1102 Pump t 1
• Plate (outer
790-201-1590 diameter: 74 mm) 1
3 • Plate (outer
790-201-1610 diameter: 79 mm) 1
790-101-5021 • Grip 1
01010-50816 • Bolt 1
50-116 PC138USLC-10
Disassembly (PC138-DTBP-530-K-00-A)
1. Remove lock plate (1) and remove seat (2) and 2) Slowly apply hydraulic pressure to compress
valve (3). the spring and then tighten nut (6).
a Do not remove grease fitting (17) from valve a Compress the spring until the nut is
(3). loose.
2. Remove yoke and piston assembly (5) from
a Slowly release hydraulic pressure to
recoil spring
relieve tension of the spring.
assembly (4).
3) Remove pilot (8) and spring (7).
3. Disassembly of recoil spring assembly (4)
4) Remove snap ring (10), dust seal (11), and
1) Set recoil spring assembly (4) to tool L2. bushing (12) from cylinder (9).
4. Disassembly of yoke and piston assembly
k Since the load at installed length of the 1) Remove snap ring (14) to remove U-packing
spring is large and dangerous, set the (15).
recoil spring assembly securely to the 2) Remove wear ring (16) from yoke and piston
tool. (13).
• Load at installed length of spring:
84,300 N {8,600 kg}
PC138USLC-10 50-117
Assembly (PC138-DTBP-710-K-00-A)
1. Assembly of yoke and piston assembly a Install the valve so that grease fitting (17)
1) Install wear ring (16) to yoke and piston (13). faces outward.
2) Install U-packing (15) and fix it with snap ring 5. Fill the inside of the cylinder with approximately
(14). 120 cc of grease from the grease fitting.
2. Assembly of recoil spring assembly 2 Cylinder inside:
1) By using tool [1], press-fit bushing (12) to Grease (G2-LI)
cylinder (9).
2) By using tool L3, press-fit dust seal (11) to
cylinder (9).
3) Install cylinder (9) and pilot (8) to spring (7)

and set them to tool L2.
4) Apply hydraulic pressure slowly to compress
the spring and to tighten nut (6) so that the
installed length of the spring becomes
dimension "a".
a Standard installed length (a) of spring:
390 mm
5) Remove recoil spring assembly (4) from tool

L2.
3. Install yoke and piston assembly (5) to recoil
spring
assembly (4).
2 Sliding surface of yoke and piston,
wear ring:
Grease (G2-LI)
4. Apply valve (3) and seat (2) and fix them by
using lock plate (1).
50-118 PC138USLC-10
Disassembly and assembly of track roller assembly (PC138-DTD0-926-K-00-A)
a Special tools a Oil of 145 to 155 cc is filled and sealed. Drain

it at this time or spread a cloth to keep the
Necessity
ground clean.
Sym-
Q'ty
Part No. Part name 4. Remove floating seal (6) on the opposite side
bol
from roller (4) and shaft (5).
1 790-434-1650 Installer t 1
M
2 791-601-1000 Oil pump q 1
Disassembly (PC138-DTD0-530-K-00-A)
1. Remove pin (1) to remove collar (2).
5. Remove collar (8) from shaft (5).

6. Remove bushings (9) and (10) from roller (4).
Assembly (PC138-DTD0-710-K-00-A)
1. Using push tool [1], press-fit bushings (9) and

(10) to roller (4).
2. Remove floating seal (3) from collar (2) and 2. Press-fit shaft (5) to collar (8).
roller (4). 3. Using tool M1, install floating seal (6) to shaft (5).
a Clean, degrease and dry the mating surface
(hatched area) of the floating seal and O-
ring.
attaching.
3. Pull out roller (4) from shaft (5).
PC138USLC-10 50-119
8. Install collar (2) to shaft (5) and install pin (1).
4. Install floating seals (6) and (3) to roller (4) by

using tool M1. 9. Apply standard pressure to the roller oil filler port
by using tool M2 to check the air leakage of the
a For precautions for installation of floating
seal.
seals (6b), (6d), (3b), and (3d), see mark a
in section 3. • Standard pressure: 0.1 MPa {1 kg/cm2}
5. Install drive shaft (5) to roller (4). a Check method: Retain the standard pressure
for 10 seconds. Do not allow the gauge
pointer to lower.
6. Invert roller (4) and shaft (5) assembly.

7. Install floating seal (3) to collar (2) by using tool
M1. 10.After refilling the track roller assembly with the
a For precautions for installation of floating oil by using tool M2, tighten plug (11).
seals (3a) and (3c), see mark a in section 3.
5 Track roller oil:
145 to 155 cc (EO30)
3 Plug (11):
10 to 20 Nm {1 to 2 kgm}
50-120 PC138USLC-10
PC138USLC-10 50-121
Removal and installation of revolving frame assembly (PC138-H110-924-K-00-A)
Removal (PC138-H110-520-K-00-A)
1. Remove the work equipment assembly. For

details, see "Removal and installation of work
equipment assembly".
2. Disconnect boom cylinder hoses (1) and (2).
a Be sure to install the plugs to the
disconnected hoses.
3. Remove covers (3) and (4).
4. Sling the boom cylinder, and remove pin (5) on
the bottom side.
a Since shims are installed, check their
quantity and mounting positions in advance. 11.Remove mounting bolts (15) (2 pieces) at the
[*1] front and rear must be remained. [*2]
5. Sling boom cylinder assembly (6) and remove it. 12.Sling revolving frame assembly (16), and loosen
remaining mounting bolts (15).
4 Boom cylinder assembly:
a Adjust the balance by using a crane, and
120 kg remove the remaining bolts carefully.
6. Remove operator's cab assembly (7). For details,
see "Removal and installation of operator's cab a Be careful not to interfere with the center
assembly". swivel joint, etc., and slowly sling the bolts to
remove them.
4 Revolving frame assembly:

6,100 kg
7. From center swivel joint, disconnect drain hose

(8), hoses (9) and (10) between the control valve
and left travel motor.
8. Disconnect hoses (11) and (12) between control
valve and right travel motor. Installation (PC138-H110-720-K-00-A)
9. Disconnect hose (13) between the solenoid
valve (acceleration) and right and left travel • Perform installation in the reverse order of
motors. removal.
10.Disconnect plate (14) from the revolving frame. [*1]
50-122 PC138USLC-10
2 Inner surface of bushing when

assembling pin:
Hyper White Grease (G2-T)
2 Greasing after assembling pin:
Hyper White Grease (G2-T)
k Never insert your fingers in the holes, when
aligning mounting holes for the pin.
a Install the same (number and position) shims as

those before installation of the boom cylinder.
a Adjust the frame clearance between the
installation portion on the boom cylinder bottom
side and frame to 0.5 mm or less by using
shims.
[*2]
2 Mating surfaces of the swing circles:
Liquid gasket (LG-6)
2 Threaded portion of revolving frame
mounting bolt:
3 Revolving frame mounting bolt:
343 to 382 Nm {35 to 39 kgm}
• Refilling with oil (hydraulic tank)
Refill with oil to the specified level through the oil
through the system. Then check the oil level
again.
• Bleeding air
Bleed air. For details, see Testing and adjusting,
"Bleeding air from hydraulic system".
PC138USLC-10 50-123
Removal and installation of counterweight assembly [For machines with

additional counterweight] (PC138-H700-924-K-00-A)
the engine.

Removal (PC138-H700-520-K-00-A)
1. Remove rearview camera assembly.

1) Insert flat-head screwdriver [1] to the hole of
cover (1) and remove cover (1) while 3) Disconnect connector A40 (4).
pressing the internal claw. 4) Remove bolt (5), and rearview camera
assembly (6).
a The claw of cover (1) is made of plastic,
so be careful not to break it when
removing.
2. Remove covers (7) and (8) on the top of the

engine.
2) Remove bolts (2) to remove cover (3). 3. Remove bolts (9) (2 pieces) and move fuel main
filter (10) to the engine side.
4. Disconnect hose (11).
50-124 PC138USLC-10
a To prevent interference with the machine,

slide the counterweight assembly backward
and horizontally at first, and sling it.
4 Counterweight assembly (15):

3,100 kg
5. Remove caps (2 pieces) on top of the additional

counterweight assembly.
6. By using eyebolts (M20 x 2.5) (2 pieces), sling
the additional counterweight assembly.
7. Remove mounting bolts (12) and (12-1) (width
across flats of each bolt: 55 mm), and sling
additional counterweight assembly (13) to
remove it. [*1]
4 Additional counterweight assembly

(13):
510 kg
Installation (PC138-H700-720-K-00-A)

removal.
[*1]
a Install additional counterweight assembly
1. Attach X and Y surfaces to the insert boss of the
counterweight.
2. Lightly tighten mounting bolts (12-1) on the
upper surface.
2 Mounting bolt (12-1):
Adhesive (LT-2)
3. Adjust the position so that clearance (a) is 10 ± 3
mm and tighten mounting bolt (12) on the side.
Adhesive (LT-2)
8. Remove caps (2 pieces) on top of the 3 Mounting bolt (12):
counterweight assembly. 1,860 to 3,040 Nm {190 to 310 kgm}
9. By using eyebolts (M36 x 3.0) (3 pieces), sling 4. Tighten mounting bolts (12-1).
the counterweight assembly.
10.Remove mounting bolt (14) (width across flats: 3 Mounting bolt (12-1):
65 mm), and sling counterweight assembly (15) 1,860 to 3,040 Nm {190 to 310 kgm}
to remove it. [*2]
PC138USLC-10 50-125
a Adjust the mounting positions of the covers (17)

and (18) on both sides so that the step of
counterweight assembly (15) in rightward and
leftward direction is 5 ± 2 mm.
[*2]
a Install counterweight assembly (15) so that the
front and rear clearance of revolving frame (16)
is as the following dimension.
• Left side clearance (b) = 11 ± 3 mm
• Right side clearance (c) = 19 ± 3 mm
Adhesive (LT-2)
3,430 to 4,212 Nm {350 to 430 kgm}
(Target: 3,626 Nm {370 kgm})
50-126 PC138USLC-10
Hydraulic system
Removal and installation of center swivel joint assembly (PC220-J8E0-924-K-00-A)
k Park the machine on a level ground, lower

the engine.

hydraulic circuit. For details, see Testing and
from hydraulic circuit".
a Note connector numbers and installed positions

before disconnecting wiring and hoses.
a Fit a plug or flange in the place of the hydraulic
hose is disconnected from to prevent oil from 8. Remove drain hose (16).
flowing out. 9. Remove hose (17) (4 pieces) between the
control valve and center swivel joint.
Removal (PC138-J8E0-520-K-00-A) 10.Remove hose (18) (2 pieces) between the
control valve and center swivel joint.
step (2). a Hose (18) is only for machines with blade.
inspection cover (4).
3. Remove attachment circuit return filter assembly
(5) together with the bracket.
a Filter (5) is only for the machines equipped
with the attachment.
11.The cotter pin that installs plate (19) is on the

back side of A portion. Remove the cotter pin to
disconnect plate (19) from the center swivel joint
assembly (20).
a Remove the cotter pin only on the center
swivel joint side.
4. Disconnect hoses (7) to (10) between R.H travel 12.Disconnect hose (21) from the solenoid valve.
motor and center swivel joint.
5. Disconnect hoses (11) to (14) between L.H
travel motor and center swivel joint.
6. Remove elbow (6).
7. Disconnect hose (15) between the blade and
center swivel joint.
a Hose (15) is only for machines with blade.
PC138USLC-10 50-127
Hydraulic system
13.Remove mounting bolts (22) (4 pieces), sling a Bleeding air (hydraulic system)
center swivel joint assembly (20), and remove it. Bleed air from the hydraulic pump circuit. For
[*1] details, see Testing and adjusting, "Bleeding air
4 Center swivel joint assembly:
30 kg (standard specification)
45 kg (machines with blade)
Installation (PC138-J8E0-720-K-00-A)

removal.
[*1]
Adhesive (LT-2)
3 Mounting bolt of center swivel joint
assembly:
98.0 to 123.0 Nm {10.0 to 12.5 kgm}
again.
5 Hydraulic tank:
lubricants")
50-128 PC138USLC-10
Hydraulic system
Disassembly and assembly of center swivel joint assembly (PC138-J8E0-926-K-00-A)
a Special tools
Necessity
Sym-
Q'ty
Part No. Part name
bol
790-101-2501 Push puller q 1

790-101-2510 • Block 1
790-101-2520 • Screw 1
790-101-2540 • Washer 1
T 791-112-1180 • Nut 1
790-101-2630 • Leg 2
790-101-2570 • Washer 4
790-101-2560 • Nut 2 Assembly (PC138-J8E0-710-K-00-A)
790-101-2650 • Adapter 2 1. Install slipper seal (7) and O-ring (6) to swivel
Disassembly (PC138-J8E0-530-K-00-A) rotor (4).
2. Set swivel shaft (5) to the block and install swivel
1. Remove cover (1). rotor (4) by using the push tool while tapping it
2. Remove snap ring (2). by using a hammer.
3. Pull out swivel rotor (4) and ring (3) from swivel
shaft (5) by using tool T. 2 Mating surfaces of rotor and shaft
4. Remove O-ring (6) and slipper seal (7) from the Grease (G2-LI)
swivel shaft.
a Be careful not to damage slipper seal (7) and
O-ring (6) when installing the rotor.
3. Install ring (3) and fix it with snap ring (2).
4. Install cover (1) together with the O-ring.
3 Mounting bolt:
31.3 ± 2.9 Nm {3.2 ± 0.3 kgm}
PC138USLC-10 50-129
Hydraulic system
Removal and installation of hydraulic tank assembly (PC138-PM30-924-K-00-A)
a Special tools 3. Remove mounting bolts (3) (4 pieces) to

disconnect suction hose (4) from the main
Necessity
pump.
Sym-
Q'ty
Part No. Part name
bol
1 796-460-1210 Oil stopper q 1

R
2 22B-60-31161 Adapter q 1

the engine.

4. Remove the fuel tank. For details, see "Removal
and installation of fuel tank assembly".
5. Loosen clamp (5) and disconnect wiring harness
Removal (PC138-PM30-520-K-00-A) (6).
6. Disconnect hose (7).
1. Loosen drain plug (1) to drain the hydraulic oil.
[*1]
6 Hydraulic tank:
69 l
7. Disconnect hoses (7) to (15) at the front of the

hydraulic tank.
a Hose (15) is only for the machines ready for
installation of attachment.

hydraulic tank strainer and stop the draining
oil by using the tools R1 and R2.
8. Disconnect hose (16) between the oil coolers.

a Disconnect hose clamps (17).
2. Disconnect sensor (2).
50-130 PC138USLC-10
Hydraulic system
12.Remove mounting bracket (26) at the front of the

fuel tank.
9. Disconnect breather hose (18) on the right side

of the hydraulic tank.
13.Remove mounting bolts (20) (4 pieces) from the
bottom of the machine. [*2]
10.Remove step (19).
14.Sling hydraulic tank assembly (21) and remove

it. Put it on the block, etc.
a Move the assembly to the fuel tank side
before slinging, and pay attention to safety in
the surrounding area of the suction hose
when slinging.
4 Hydraulic tank assembly:

110 kg

remove bracket (24) at the rear of the hydraulic
tank.
PC138USLC-10 50-131
Hydraulic system
a Reference
Air hose insertion length
• Tank side: 92 mm
• Pump side: 85 mm
a Set bridge (BR) under clamp mounting bolt, and
adjust overlap (b) between bridge (BR) and
band to Min. 5 mm.
• b dimension: Min. 5 mm
2 Clamp tightening bolt threaded portion
(BC):
Lubricating oil (ThreeBond PANDO18B)
15.Remove clamp (22) and disconnect suction
hose (23). [*3] a Impact wrench is not allowed to use.
• When reusing hose
a Align clamp position to trace of clamp left on
hose.
3 Clamp bolt:
Min. 6 Nm {0.6 kgm}
• When hose is new
a Tighten it until dimension BDG becomes as
shown below.
• BDG: 14 to 17 mm
Installation (PC138-PM30-720-K-00-A)

removal.
[*1]
refilling.
again.
5 Hydraulic tank:
lubricants")
3 Drain plug:
58.8 to 78.4 Nm {6.0 to 8.0 kgm}
[*2]
3 Mounting bolt:
245 to 309 Nm {25.0 to 31.5 kgm}
[*3]
a Be sure to use new MIKALOR clamp.
a Align hose to its original position (marked
position).
50-132 PC138USLC-10
Hydraulic system
Removal and installation of main pump assembly (PC138-C200-924-K-00-A)
a Special tools
Necessity
Sym-
Q'ty
Part No. Part name
bol
1 796-460-1210 Oil stopper q 1

R
2 22B-60-31161 Adapter q 1

the engine.
k Set the lock lever in LOCK position. 2. Open the cover at the rear right of the machine,
remove rubber cover (3) of KDOC muffler and
heat insulation plate (4).
3. Disconnect clamp (5).
disconnect the fuel main filter and bracket
assembly (7).
position, and remove the key. a Move the fuel main filter and bracket
assembly away to a position where they are
Removal (PC138-C200-520-K-00-A) not obstacles.
1. Loosen drain plug (1) to drain the hydraulic oil. 5. Disconnect oil filter and bracket assembly (8).
[*1] a Move the oil filter and bracket assembly
away to a position where they are not
6 Hydraulic tank: obstacles.
69 l 6. Disconnect travel alarm connector M14 (9).
7. Disconnect fuel prefilter assembly (10) and
travel alarm assembly (11) together with the
bracket.
a Disconnect bolt (12) of the hose clamp.
8. Disconnect reservoir tank assembly (13).
9. Disconnect oil filler hose (14) of PTO gear case.

PC138USLC-10 50-133
Hydraulic system

disconnect suction tube (24) from main pump
(25).
13.Remove water drain tube (26) of KDOC muffler.
a The tube is inserted only. Therefore, pull out
damaged.
14.Remove undercover (27).
10.Disconnect EPC solenoid wiring connector V11

(15) and oil temperature sensor wiring connector
P22 (16).
15.Loosen drain plug (29) of PTO gear case (28)

and drain the power train oil. [*2]
6 PTO gear case:

0.75 l
11.Disconnect hoses (17) to (22).
a Record the installed positions of the hoses.
16.Disconnect clamps (30) and (31).

a To remove mounting bolt on the bottom of the
main pump easily.
50-134 PC138USLC-10
Hydraulic system
4) Pull up main pump (25) by using chain block

[2] and loosen wire rope [1].
5) Remove wire rope [1] from main pump (25).
17.Remove the main pump according to the

1) Sling main pump (25) by using wire rope [1],
etc. to remove mounting bolts (33) (11 6) Install wire rope [1] from outside of the
pieces). counterweight to main pump (25).
a By covering the sides of KDOC muffler by a Put template [3], etc. to protect the
using the template, etc., the muffler can counterweight from damages by the wire
be protected from damages. rope.
2) Sling main pump (25) and slowly disconnect
it from the engine.
4 Main pump assembly:

110 kg
7) Move it outside up to the position where

chain block [2] almost contacts the
counterweight.
8) Slowly lower it by using chain block [2] and
remove the chain block from the main pump
3) Move the main pump forward up to the (25).
position where wire rope [1] almost contacts 9) Lower the main pump (25) on the block, etc. ,
the counterweight. and remove it.
PC138USLC-10 50-135
Hydraulic system
Installation (PC138-C200-720-K-00-A)

removal.
[*1]
refilling.
again.
5 Hydraulic tank:
lubricants")
[*2]
5 PTO gear case:

0.75 l
6 PTO gear case drain plug:

26.5 to 43.1 Nm {2.7 to 4.4 kgm}
a Bleeding air (hydraulic system)
Bleed air from the hydraulic pump circuit. For
details, see Testing and adjusting, "Bleeding air
50-136 PC138USLC-10
Hydraulic system
Removal and installation of control valve assembly (PC138-C030-924-K-00-A)
a Special tools
Necessity
Sym-
Q'ty
Part No. Part name
bol
1 796-460-1210 Oil stopper q 1

R
2 22B-60-31161 Adapter q 1

the engine.
k Set the lock lever in LOCK position. 2. Remove stay (2), cover (3), and step (4).

a Note the connector numbers and installed

positions before disconnecting wiring harnesses
and hoses.
a Install a plug or flange in the place where a
hydraulic hose is disconnected to prevent oil 3. Disconnect hoses (5) to (12) of the solenoid
from flowing out. valve.
a The removal and installation procedures in this a The band color of the hoses are as shown
section are based on the "Machines equipped below.
with attachment and machines equipped with
Hose (5): Red/Green (PPC source pressure)
multi pattern valve".
Hose (6): Red (Travel HI/LO)
Removal (PC138-C030-520-K-00-A)
Hose (7): Red/Red (Swing parking brake)
1. Loosen drain plug (1) to drain the hydraulic oil. Hose (8): No band (Merge-divider selector
[*1] signal)
Hose (9): No band (Travel junction valve)
6 Hydraulic tank:
Hose (10): No band (Attachment selector
69 l valve)
Hose (11): No band (Pilot pressure)
Hose (12): No band (PC-EPC source
pressure)

PC138USLC-10 50-137
Hydraulic system
Connector (23): V02 (Travel junction solenoid

valve)
Connector (24): V05 (Merge-divider selector
solenoid valve)
Connector (25): V06 (Attachment return selector
solenoid valve)
Connector (25a): V10 (Bucket DUMP solenoid)
Connector (26): P29 (Intermediate connector)
5. Remove mounting bolts (27) disconnect
together with bracket (28).
6. Disconnect wiring harness (29).
a When disconnecting the wiring harness,
4. Disconnect the following connectors (13) to (26). disconnect frame (30) up to the position
Connector (13): P25 (Pump pressure sensor) where it is an obstacle.
Connector (14): P26 (R.H. travel REVERSE 7. Remove frame assembly (30).
pressure sensor)
Connector (15): P27 (L.H. travel REVERSE
pressure sensor)
Connector (16): P28 (Blade RAISE pressure
sensor)
Connector (17): P09 (R.H. travel FORWARD

pressure sensor)
Connector (18): P10 (L.H. travel FORWARD
pressure sensor)
Connector (19): P11 (Blade LOWER oil pressure
sensor)
Connector (20): V01 (PPC source pressure lock

solenoid valve)
Connector (21): V02 (Travel HI/LO solenoid 8. Disconnect pressure switch connectors (31) to
valve) (37).
Connector (22): V03 (Swing parking brake Connector (31): P01 (Bucket DUMP switch)
solenoid valve) Connector (32): P02 (Arm OUT switch)
50-138 PC138USLC-10
Hydraulic system
Connector (33): P03 (Boom RAISE switch) 11.Disconnection of wiring and hoses of multi
Connector (34): P04 (Bucket CURL switch) pattern valve assembly (if equipped)
Connector (35): P05 (Arm IN switch) 1) Disconnect connectors (40) and (41).
Connector (36): P06 (Boom LOWER switch) Connector (40): P08 (Left Swing switch)
Connector (37): P07 (Right Swing switch) Connector (41): P67 (Right Swing switch)
9. Disconnect wiring harness (38), and remove
frame (39). a Connector P67 (41) is connected to
connector P07 (37).
a Connector P08 of the machine that is not
equipped with the multi pattern valve
assembly is located under connector P07
in the mounting bracket.
10.Disconnect pressure switch connectors (60) to

(62).
a Right side of control valve
Connector (60): P64 (Bucket CURL switch)
Connector (61): P65 (Arm IN switch) 2) Disconnect hoses (42) to (47) on the rear
Connector (62): P66 (Boom LOWER switch) side of the multi pattern valve.
a Left side of control valve

Connector (63): P61 (Bucket DUMP switch)
Connector (64): P62 (Arm OUT switch)
Connector (65): P63 (Arm RAISE switch)
3) Disconnect hoses (48) to (53) on the right

side of the multi pattern valve.
PC138USLC-10 50-139
Hydraulic system
4) Disconnect hoses (54) to (57) on the left side 13.Disconnect hoses (74) to (79).
of the multi pattern valve.
a Left side of control valve (upper)
Hose (74): No band
Hose (75): Red/Red/Red
Hose (76): Red
Hose (77): Orange
Hose (78): Yellow
Hose (79): Yellow
5) Remove mounting bolts (58), and remove

multi pattern valve (59) together with the
bracket.

a Left side of control valve (lower)
Hose (80): Black/Yellow
Hose (81): Brown/Yellow
Hose (82): Red/Black

a Right side of control valve
Hose (66): Blue/Blue/Blue
Hose (67): No band
Hose (68): Yellow
Hose (69): Green/Yellow
Hose (70): Orange/Yellow
Hose (71): Blue/Yellow
Hose (72): Blue
Hose (73): No band 15.Disconnect hoses (83) to (88).
50-140 PC138USLC-10
Hydraulic system
a Rear side of control valve (upper)

Hose (83): Brown
Hose (84): Blue/Blue
Hose (85): Red
Hose (86): Blue
Hose (87): Orange
Hose (88): Green
18.Remove mounting bolts (101) (4 pieces) to sling

control valve assembly (102), and remove it.
4 Control valve assembly:

155 kg

a Rear side of control valve (middle)
Hose (89): No band
Hose (90): Black
Hose (91): Orange
Hose (92): (No band on the control valve
side, Blue/Red only on the main pump side)
Installation (PC138-C030-720-K-00-A)
17.Disconnect hoses (95) to (100). • Perform installation in the reverse order of

removal.
a Rear side of control valve (middle)
Hose (95): Brown/Yellow a Check that the drain plug is tightened before
refilling.
Hose (96): Orange/Yellow
Hose (97): Red/Black a Refill with oil to the specified level through the oil
Hose (98): Blue/Yellow through the piping. Then check the oil level
Hose (99): White again.
Hose (100): Brown
PC138USLC-10 50-141
Hydraulic system
5 Hydraulic tank:
lubricants")
3 Drain plug:
58.8 to 78.4 Nm {6.0 to 8.0 kgm}
50-142 PC138USLC-10
Hydraulic system
Disassembly and assembly of control valve assembly (PC138-C030-926-K-00-A)
a This section explains only the precautions for assembling the control valve.
PC138USLC-10 50-143
Hydraulic system
Assembly of control valve assembly (PC138-C030-530-K-00-A)
a The figure shows related items only. 4. Apply grease (G2-LI) to periphery (c) of filter
(6).
a For the excluded figures, see "Structure,
5. Tighten plug (7).
function and maintenance standard, Control
valve". 3 Plug (7):
a For the tightening torque of the bolts and plugs 245 to 304 Nm {25 to 31 kgm}
of the control valve assembly, see "Maintenance
standard, Control valve".
• Apply engine oil on the sliding surfaces on the
parts before assembling them.
2 Mating face:
Liquid seal (SEALEND 242 or
equivalent)
• Installation of cover (1):
Tighten nuts (2) 3 times in order of [1] to [4].
3 1st time: 58.8 to 68.6 Nm {6 to 7 kgm}
2nd time: 78.5 to 88.3 Nm {8 to 9 kgm}
3rd time: 98.1 to 113 Nm {10 to 11.5
kgm}
a Projection from nut end to stud end: 0.5 to 3
mm
• Assembly of safety valve circuit filter
3 Centralized safety valve filter (3):
107.8 to 147 Nm {11 to 15 kgm}
3 Pressure relief plug (4):
19.6 to 24.5 Nm {2 to 2.5 kgm}
3 Suction safety valve (5):
176.6 to 196.2 Nm {18 to 20 kgm}
• Assembly of pump circuit filter

1. Install filters (6) (2 places) to the top and
bottom blocks.
2. When installing filter (6) to plug (7), apply
grease (G2-LI) to the inside diameter of the
plug to prevent removal.
3. Assemble filter (6) so that punch portion (a)
is in oil flow direction (d).
50-144 PC138USLC-10
Hydraulic system
Disassembly and assembly of work equipment PPC valve assembly (PC138-

PL28-926-K-00-A)
a Figure of structure
Disassembly (PC138-PL28-530-K-00-A)
1. Remove nut (15) to remove disc (13) and boot

(14).
2. Remove bolt (11) to remove plate (9).
a Do not remove joint (12) except when
replacing.
3. Remove seal (16) and collar (17).
4. Pull out piston (8) and remove retainer (18),
springs (7), (6), (5), and shim (4).
a For springs (7) and (5), check the installed
positions (hydraulic port) and put distinction
tag, etc. to prevent the installation error,
since 2 types of spring whose load at
installed length is different are installed (2
pieces each).
5. Pull out valve (19) from body (1).
a Do not remove plugs (2) and (3).
PC138USLC-10 50-145
Hydraulic system
Assembly (PC138-PL28-710-K-00-A)
a Carefully clean and inspect the parts to prevent 5. Apply grease to the sliding surface of joint (12)
failure due to dust, rust, and scratch, etc., and and to the contact surfaces of disc (13) and
then take extreme care when assembling them. piston (8).
1. When installing piston (8), apply grease to the 2 Joint sliding surface:
periphery of the piston and inner periphery of the
Grease (G2-LI)
body hole.
• b portion: Apply 7 to 10 ml l of
2 For inside of body hole on periphery grease (G2-L1) to the periphery.
of piston: • c portion: Apply gear oil 0.2 to 0.4
Grease (G2-LI) mll to the joint and pin sliding
2. When installing spring (5), install the end surface surfaces (4 places).
of the smaller end turn diameter to shim (4) side.
• End turn diameter of spring (inside diameter)
Small diameter: 4.9 mm
Large diameter: 5.4 mm
3. Carefully install springs (6) and (7) since the
different springs are used for each oil pressure
port.
• All installation heights: 34 mm
• Load at installed length
Spring (6) (P1 and P2): 29 N {3 kg}
Spring (7) (P3 and P4) 17.7 N {1.8 kg}
3 Bolt (11):
11.8 to 14.7 Nm {1.2 to 1.5 kgm} • Contact parts of disc and piston:
4. When installing joint (12) to body (1), apply
0.3 to 0.8 cc/place
Loctite according to the following procedure.
1) When installing the joint, apply 1 drop a Install disc (13). For details, see Testing and
(approx. 0.02 g) of Loctite to the body female adjusting, "Adjusting play of work equipment
threads (2 places). Degrease and dry the and swing PPC valves".
joint male threads and body female threads a Play of lever:
thoroughly by using dry solvent and then
0.5 to 3mm (200 mm away from lever
install them. rotational center)
2) Loctite dropping positions are as followings.
3 Nut (15):
2 Body female threads:
69 to 88 Nm {7 to 9 kgm}
Loctite No. 648
3 Joint (10):
39 to 49 Nm {4 to 5 kgm}
50-146 PC138USLC-10
Hydraulic system
Disassembly and assembly of travel PPC valve assembly (PC138-C6V0-926-K-00-A)
Disassembly (PC138-C6V0-530-K-00-A) a When installing spring (4), install the end surface
1. Remove screws (22) to remove damper of the smaller end turn diameter to shim (3) side.
assembly (21). • End turn diameter of spring (inside diameter)
2. Remove mounting bolt (14) to remove case (10), Small diameter: 4.9 mm
shaft (12) and lever (11) as a unit. Large diameter: 5.55 mm
3. Remove mounting bolts (16) to remove plate
(13). a Apply grease to the contact surfaces of lever
(11) and piston (7) and to the contact surfaces of
a Check the installed position and thickness of damper (21) and pin (23).
washer (17).
2 Grease (G2-LI):
a Pull out pin (24) from body (1).
Contact surfaces of lever and piston: 0.3
4. Remove seal (8) and seat (9).
to 0.8 cc/place
5. Pull out piston (7) and remove retainer (5),
springs (6), (4), and shim (3). Contact surfaces of damper and pin: 0.3
to 0.8 cc/place
a Check the thickness and number of shims (3)
at each installed position, and then store a Install washer (17) of t = 1.6. If the difference
them. between the right and left at the lever full stroke
6. Pull out valve (2) from body (1). is larger than 0.7 deg., change the washer
thickness to 0.7 deg. or smaller. (If the washer
thickness becomes thinner by 0.3mm, the full
stroke angle adds by 0.39 deg.)
• Washer thickness t (mm) = 1.0, 1.3, 1.6, 1.9,
2.2
1. Tightening torque of each part is as following.
3 Screw (22):
0.44 to 0.59 Nm {0.045 to 0.06 kgm}
3 Bolt (14):
25 to 30 Nm {2.5 to 3.2 kgm}
3 Bolt (16):
27 to 34 Nm {2.8 to 3.5 kgm}
Assembly (PC138-C6V0-710-K-00-A)
• Only precautions for assembly is described.

a Carefully clean and inspect the parts to prevent
failure due to dust and scratch, etc., and then
take extreme care when assembling them.
a When assembling piston (7), apply grease (G2-
LI) to the piston periphery and inner periphery of
the body hole.
PC138USLC-10 50-147
Hydraulic system
50-148 PC138USLC-10
Work equipment
Removal and installation of work equipment assembly (PC138-L410-924-K-00-A)
a Special tools
Necessity
Sym-
Q'ty
Part No. Part name
bol
796-900-1200 Remover t 1
796-900-1210 • Sleeve 1
792-900-1520 • Plate 1
799-900-1230 • Screw 1
796-900-1240 • Adapter 1
V 01643-33080 • Washer 1
01803-13034 • Nut 1 3. Disconnect connectors A08 (6) and A13 (7).
Puller (490 kN {50 4. Disconnect clamp (8).
790-101-4000 ton} long) t 1
Pump (294 kN {30
790-101-1102 ton}) t 1
k Park the machine on a level ground, fully

extend the arm and bucket, and set the block
to the tip of the arm. Lower the bucket end to
the ground.

from hydraulic system". 5. Disconnect hoses (9) to (16).
a Plug the disconnected hoses for starting the
k Turn the battery disconnect switch to OFF engine.
a The removal and installation procedures in this

section are based on the "Arm crane
specification".
Removal (PC138-L410-520-K-00-A)
1. Remove stay (1) to remove steps (2) and (3).
6. Disconnect grease hose (17).

7. Remove lock bolt (18).
a Sling the boom cylinder assembly.
8. Remove plate (19) and push pin (20) to the
opposite side until it is removed from the cylinder
head. [*1]
2. Remove step (4) and cover (5) of the boom quantity and mounting positions in advance.
mounting part. 9. Lower boom cylinder (21) on the block, etc.
PC138USLC-10 50-149
Work equipment
a Insert the key, turn the battery disconnect

switch to ON position, start the engine, and
retract the boom cylinder piston.
a Turn the battery disconnect switch to OFF
13.Sling work equipment assembly (28), and pull

out boom foot pin (22) by using tool V.
a Disconnect the work equipment assembly
from the revolving frame. Slowly sling it and
remove it by using a crane.
4 Work equipment assembly:

1,960 kg
10.Remove plug (23) of boom foot pin (22).

11.Remove mounting bolts (24) to remove plate
(25).
14.Remove the boom cylinder according to the
1) Sling boom cylinder assembly (29).
12.Set tool V to boom foot pin (22).

a Disconnect hose (26) and bracket (27) and
move them away to a position where they
are not obstacles, then the work is easier. 2) Disconnect hose (30) and bracket (31).
a Prevent them from interfering with the
boom cylinder assembly being lowered
on the block, etc.
50-150 PC138USLC-10
Work equipment
3) Disconnect grease hose (32).

a When pulling out boom cylinder foot pin
4) Remove lock bolt (33).
(38), pay attention to the followings to
5) Remove plate (34) and push pin (35) to the
prevent the hoses from being damaged.
opposite side until it is removed from the
cylinder head. a Lower the hose by hand to prevent it from
interfering with portion (a) between the
plate and hose of boom cylinder foot pin
quantity and mounting positions in
(38).
advance.
a Lower the hose by hand to prevent it from

interfering with portion (b) between the
pin and hose until the boom cylinder foot
pin is pulled out.
6) Remove lock bolt (36).

7) Remove plate (37), and pull out boom
cylinder foot pin (38).
8) Sling boom cylinder assembly (39), and

remove it.
4 Boom cylinder assembly:

120 kg
PC138USLC-10 50-151
Work equipment
a Standard shim thickness: 0.5 mm, 1.0 mm, and

2.0 mm
Installation (PC138-L410-720-K-00-A)

removal.
[*1]
filler port of the hydraulic tank. Run the engine to
2 Inner surface of bushing when circulate the oil through the piping. Then check
assembling pin: the oil level again.
Molybdenum disulfide lubricant (LM-P) a Bleeding air (hydraulic system)
2 Greasing after assembling pin: Bleed air from the hydraulic pump circuit. For
Grease (LM-G) details, see Testing and adjusting, "Bleeding air
a Adjust clearance (c) between cylinder rod (40)

and plate (41) to 1.0 mm or less by using shims.
a Standard shim thickness: 1.0 mm
[*2]
2 Inner surface of bushing when
assembling pin:
Molybdenum disulfide lubricant (LM-P)
2 Greasing after assembling pin:
Grease (LM-G)
a Adjust clearance (d) between boom (42) and

plate (43) to 0.5 mm or less by using shims.
50-152 PC138USLC-10
Work equipment
Disassembly and assembly of work equipment cylinder assembly (PC138-

PPZ0-926-K-00-A)
a Special tools a Place a container, etc. under the cylinder

to receive oil.
Necessity
Sym-
Q'ty
Part No. Part name
bol
790-502-1003 Repair stand t 1

1
790-101-1102 Pump t 1
790-102-4300 Wrench assembly t 1
2
790-102-4310 Pin t 1
790-201-1791 • Push tool (*1) 1
790-101-5021 • Grip 1
01010-50816 • Bolt 1
790-201-1811 • Push tool (*2) 1 4) Disassemble the piston rod assembly
3 according to the following procedure.
790-101-5021 • Grip 1
01010-50816 • Bolt 1 1] Set piston rod assembly (2) on tool U1.
790-201-1821 • Push tool (*3) 1
790-101-5021 • Grip 1
U 01010-50816 • Bolt 1
790-201-1610 • Push tool (*4) 1
790-101-5021 • Grip 1
01010-50816 • Bolt 1
790-201-1620 • Push tool (*5) 1
4
790-101-5021 • Grip 1
01010-50816 • Bolt 1
790-201-1500 Push tool kit q 1 2] Remove lock screw (3) of the piston
790-201-1630 • Push tool (*6) 1 assembly.
790-101-5021 • Grip 1 Screw size
01010-50816 • Bolt 1 M12 x pitch 1.75: Boom, Arm,
5 790-720-1000 Expander t 1 Blade
Ring t M10 x pitch 1.5: Bucket
796-720-1650 1
6
07281-01029 Clamp t 1
(*1): Press fit of bucket cylinder roll bushing
(*2): Press fit of boom cylinder roll bushing
(*3): Press fit of arm and blade cylinder roll bushings
(*4): Installation of bucket cylinder dust seal
(*5): Installation of boom cylinder dust seal
(*6): Installation of arm and blade cylinder dust seal
Disassembly (PC138-PPZ0-530-K-00-A)
1. Piston rod assembly

1) Remove the piping from the cylinder
assembly.
2) Remove the mounting bolt and disconnect
head assembly (1).
3) Pull out piston rod assembly (2).
PC138USLC-10 50-153
Work equipment
a If screw (3) is punched securely and • Only for arm cylinder

hard to remove, tighten it further once.
a Since cap (8) is made of nylon, screw
Then tap its threaded portion with tap
in the screw, etc. and pull up the cap
(a) and remove the screw.
by using pliers.
3] By using tool U2, remove piston

2. Disassembly of piston assembly
assembly (4).
1) Remove ring (11).
• When tool U2 is not used, use drilled
2) Remove wear ring (12).
holes (10 mm: 2 places) to loosen
3) Remove piston ring (13).
the piston assembly.
4) Remove the O-ring and backup ring (14).
4] Remove plunger (5).

3. Disassembly of cylinder head assembly
• Arm cylinder, boom cylinder
1) Remove the O-ring and backup ring (15).
5] Remove collar (6).
2) Remove snap ring (16) and remove dust seal
• Arm cylinder, boom cylinder (17).
6] Remove head assembly (7). 3) Remove rod packing (18).
4) Remove buffer ring (19).
5) Remove bushing (20).
7] Remove cap (8), remove balls (9) (11

pieces), and remove cushion plunger
(10).
50-154 PC138USLC-10
Work equipment
Assembly (PC138-PPZ0-710-K-01-A)
a Take care not to damage packings, dust seals,

O-rings, etc.
a When installing the backup ring, do not install it
forcibly. Warm it in hot water (temperature is
approximately 50 to 60°C), and then install it.
1. Assembly of cylinder head assembly
1) Press-fit bushing (20) by using tool U3.
2) Install buffer ring (19).
3) Install rod packing (18).
4) By using tool U4, install dust seal (17) and
secure it with snap ring (16). 3) Install the backup ring and O-ring (14).
5) Install the backup ring and O-ring (15). 4) Install wear ring (12).
5) Install ring (11).
a Take care not to expand the ring mating
part excessively.
2 Link groove:
Grease (G2-LI)
3. Piston rod assembly

1) Set piston rod assembly (2) on tool U1.
2. Assembly of piston assembly

1) By using tool U5, expand piston ring (13).
a Set the piston ring on tool U5, and rotate
the handle 8 to 10 turns to expand the
piston ring.
2) Compress piston ring (13) by using tool U6.
2) Install head assembly (7).

3) Install the O-ring and backup ring to collar
(6).
4) Install plunger (5).
PC138USLC-10 50-155
Work equipment
a Make sure that the plunger end has a 3] Punch the threaded portions (2 places)
certain play. with a punch.
5) Set cushion plunger (10) on the piston rod,
install balls (9) (11 pieces), and fix them with
cap (8).
• Only for arm cylinder
6) Assemble piston assembly (4) according to
the following procedure.
• When reusing the rod and piston
assembly (2)
a Clean them thoroughly and remove all
chips and dirt.
1] Screw in piston assembly (4), and tighten
it until the screw holes are aligned by
using tool U2. • When either or both of the rod and piston
a Remove burrs and sharp edges from assembly (2) are new
threaded part by using a file. a Put the marks of the cap (8) holes to the
end surface of the rod with bottom
cushion.
• Only for arm cylinder
1] Screw in piston assembly (4) until it
reaches rode (2) end (b), and then tighten
by using tool U2.
3 Piston assembly (4):
294 ± 29.4 Nm {30 ± 3.0 kgm}
a After tightening the piston, make sure
that plunger (5) hits.
• Only for boom and arm cylinder
2] Tighten screw (3). 2] Make one threaded hole for tightening

screw (3).
2 Threaded part of screw (3):
a Drill a hole in horizontal into the V-
Loctite No. 262 groove where piston (4) and the
3 Screw (3) threads of rod (2) mesh with each
Boom, arm, blade: other.
66.2 ± 7.35 Nm {6.75 ± 0.75 a For the cylinder with bottom cushion,
kgm} avoid cap (8) holes when drilling the
Bucket: hole.
30.9 ± 3.4 Nm {3.15 ± 0.35 kgm} • Drilling dimensions (mm)
50-156 PC138USLC-10
Work equipment
Cylinder Tap drill Tap hole Tap

Tapping
diameter depth depth
Boom,
arm, 10.3 27 12 x 1.75 20
blade
Bucket 8.5 27 10 x 1.5 20
8) Tighten head assembly (1) with the mounting

bolt.
3 Mounting bolt:
Cylinder name Tightening torque
Bucket 172 ± 25 Nm {17.5 ± 2.5 kgm}
3] After making the hole, remove all chips Arm 270 ± 39 Nm {27.5 ± 4.0 kgm}
and dirt, and clean the hole thoroughly. Boom 172 ± 25 Nm {17.5 ± 2.5 kgm}
4] Tighten screw (3). Blade 270 ± 39 Nm {27.5 ± 4.0 kgm}
2 Threaded part of screw (3): 9) Install piping.
Loctite No. 262
3 Screw (3)
Boom, arm, blade:
66.2 ± 7.35 Nm {6.75 ± 0.75
kgm}
Bucket:
30.9 ± 3.4 Nm {3.15 ± 0.35 kgm}
5] Punch 4 parts of the threaded portion with
a punch.
7) Install piston rod assembly (2).

2 Seal:
Grease (G2-LI)
a Set ring mating part (c) in horizontal
position and align the cylinder tube with
the shaft core to insert it.
a After insertion, check that the ring is not
damaged or removed, and then fully push
it.
PC138USLC-10 50-157
Removal and installation of operator's cab assembly (PC138-K000-924-K-00-A)

completely lower the work equipment to the
ground,and stop the engine.

Removal (PC138-K000-520-K-00-A)
1. Remove floor mat (1).

2. Remove machine monitor assembly (2). For
machine monitor assembly".
3. Remove covers (3) to (6). 8. Remove cover (12).
4. Remove ducts (7) and (8).
5. Loosen right console (9) and move it inside.
9. Disconnect connector M04 (13).

10.Remove cover (14) and duct (15).
6. Disconnect connector M05 (10). 11.Disconnect cover (16).
a Note that the pump controller is installed on
the back side of cover (16), and remove it
carefully.
7. Disconnect window washer hose (11).
13.Disconnect connectors CK01 (18) and CK02

(19).
14.Disconnect radio antenna cable (22).
15.Disconnect connectors M01B (23), H09 (24),
and H08 (25).
50-158 PC138USLC-10
3) Remove mounting bolts (28) of lock plate to

remove plate (29). [*2]
4) Remove mounting bolts (30) of operator's
cab tipping stopper. [*3]
16.Removal of operator's cab mounting bolts and

nuts
1) Remove mounting bolts (26b) (6 pieces
marked with *) and nuts (26n) (4 pieces 17.Sling operator's cab assembly (31), and remove
marked with #) in the operator's cab. [*1] it.
a Nut (26n) is tightened together with the a When removing operator's cab assembly,
floor frame. check that all the wiring and piping are
disconnected before removing.
4 Operator's cab assembly:

400 kg
2) Remove left side cover (27).
Installation (PC138-K000-720-K-00-A)

removal.
[*1]
PC138USLC-10 50-159
3 Mounting bolt (26b):

54 to 123 Nm {5.5 to 12.5 kgm}
3 Mounting bolt (26n):
147 to 309 Nm {15 to 31.5 kgm}
[*2]
3 Mounting bolt:
98 to 123 Nm {10.0 to 12.5 kgm}
[*3]
3 Mounting bolt:
245 to 309 Nm {25.0 to 31.5 kgm}
50-160 PC138USLC-10
Removal and installation of operator's cab door (PC138-K160-924-K-00-A)
a This section explains only precautions for

installation of the operator's cab door.
1. Check that step (1) between cab side and door

side is Max. ±3 mm when closing the door.
a When the step is not Max. ±3 mm, adjust the
mounting position of upper roller (2)
rightward and leftward (3) to the machine.
3 Upper roller mounting bolt:
34 to 74 Nm {3.5 to 7.5 kgm}
2. Check that clearance (4) between cab and door
side is Max. 5±2 mm.
a When the clearance is not Max. 5±2 mm,
adjust the mounting position of center roller
(5) in longitudinal direction of the machine.
3 Center roller mounting bolt:
14.7 to 34.3 Nm {1.5 to 3.5 kgm}
3. Check that vertical step (6) of the door is Max.
±3 mm.
a When the step is not Max. ±3 mm, adjust the
mounting position of center roller (5) in
vertical direction of the machine.
4. Check that there is clearance (8) between the
cab and lower bracket (7).
a If the cab and lower bracket interfere each
other, slide the lower bracket mounting
position downward for adjustment.
3 Lower bracket mounting bolt:
14.7 to 34.3 Nm {1.5 to 3.5 kgm}
5. Check that stopper (9) tightly contacts with inner
surface (11) of the door when the door is closed.
a Deflection of the stopper is approximately 0.5
mm.
a When the stopper is not tightly contact with
the inner surface of the door, loosen nut (10)
and adjust the stopper mounting position.
3 Stopper mounting bolt threads:
59 to 74 Nm {6 to 7.5 kgm}
6. Check that the center of the striker (12) is at
center (13) of the lock assembly groove when
the door is closed.
a When the striker center is not at the center of

the lock assembly groove, adjust the striker
mounting position.
PC138USLC-10 50-161
3 Striker mounting bolt: a If it is not on the latch, adjust rear striker (15)
54 to 74 Nm {5.5 to 7.5 kgm} mounting position.
7. Check that dovetails (14a) and (14b) at the top 12.Check that stopper (16) reaches center (18) of
and bottom of the front side of the door are supporting portion (17) on the door side.
installed to the cab side simultaneously when a When the center position is not aligned,
closing the door. loosen the nut with the door locked, and
a When the dovetails at the top and bottom of adjust the stopper mounting position
the front side of the door are not installed to rightward and leftward (19) to the machine to
the cab side simultaneously, adjust the align the center. Then, tighten the nut at the
dovetail mounting positions. position where the stopper deflection is 2
8. Check that dovetails (14c) and (14d) at the top mm.
and bottom of the rear side of the door are 3 Stopper mounting bolt:
installed to the cab side simultaneously when
98 to 123 Nm {10 to 12.5 kgm}
closing the door.
a When the dovetails at the top and bottom of
the rear side of the door are not installed to
the cab side simultaneously, adjust the
dovetail mounting positions.
3 Dovetail mounting bolt:
9.8 to 14.7 Nm {1 to 1.5 kgm}
2 Dovetail mounting bolt:
Adhesive (LT-2)
9. Check that there is not clearance between the

door trim and cab when the door is closed,
10.Check that the door smoothly opens and closes 13.Check that the door opens and closes smoothly
without play. without unusual noise or interference.
11.Check that the door on the latch when the 14.Apply grease to the rails (top, center, and
dovetails at the top and bottom of the door are bottom), dovetails (front and rear), and stopper.
installed.
50-162 PC138USLC-10
2 Dove tails, stopper:

Grease (G2-L1)
PC138USLC-10 50-163
Removal and installation of operator's cab glass (adhered glass) (PC138-K183-

924-K-00-A)
a Special tools
Necessity
Sym-
Q'ty
Part No. Part name
bol
1 793-498-1210 Lifter (suction cup) t 2

X
2 22B-54–38320 Stopper rubber t 3
a There are some figures not applicable to the

related machine model. However, the
replacement procedure is basically the same.
a Among the window glasses on 4 sides of the
operator's cab glasses, the stuck type is 5
glasses from (1) to (5) in the figure.
a This section describes the replacement
procedure of the stuck glass.
a Always remove front window assembly (6) when
front window glasses (5) is to be replaced. (If the
front glass is installed to the operator's cab, it
cannot be replaced.)
a For replacement procedure of the front window
assembly, see "Removal and installation of front
window assembly".
50-164 PC138USLC-10
a Figure of structure
(1): R.H. window glass

(2): L.H. rear window glass
(3): Upper door window glass
(4): Lower door window glass
(5): Front window glass
(6): Front window assembly (front window glass + front frame)
(7): Dam rubber
(16): Center trim seal
PC138USLC-10 50-165
Removal (PC138-K183-520-K-00-A)
a Remove the window glass to be replaced

1. By using seal cutter [1], cut off the adhesive
between damaged window glass (9) and
operator' cab (sheet metal) (8).
2. Remove the window glass.
a When a seal cutter is not available, drill a

hole in the adhesive and dam rubber with a
gimlet, then pass one end of an ultrafine wire
(such as piano wire) [2] through the hole. Clip
both ends of the ultrafine wire passed
through the hole with pliers [3] (or wind the
wire around pliers), then cut off the adhesive
and dam rubber by shuttling the wire.
Since the wire may be broken by the
frictional heat, apply lubricant to it.
(Figure shows the operator's cab on a wheel
loader.)
a If the window glass is broken in small pieces,

it may be removed with knife [4] and a flat-
head screwdriver.
a While widening the cut with a flat-head
screwdriver, cut the adhesive and dam
rubber with knife [4].
loader.)
50-166 PC138USLC-10
1. Remove the remaining adhesive and dam a Make sure to use primer within 2 hours from
rubber from the sheet metal (adhesion surfaces) opening its cap.
of the operator's cab by using a knife and
a Even when putting the lid again immediately
scraper [5].
after opening, be sure to use it within 24
a Do not scrape excessively and damage the hours from opening. (A primer must be
coating surface. Even if the adhesive and disposed when 24 hours have elapsed from
dam rubber are left on the sheet metal opening.)
surface, it is OK as long as they do not 1) Stir both primers for paint surface and glass
prevent the bonding effect of new adhesive. thoroughly before use.
(If the coating surfaces are damaged,
adhesion will be lowered.) a If a primer was chilled-stored in a
depository, leave it at least half a day in
room temperature before stirring it. (If you
loader.)
open the lid of a primer immediately after
having been chilled-stored, dew will
condense on the surface of primer. So
allow a sufficient period of time for the
primer to be settled in the room
temperature.)
2) When reusing a brush (11) for applying a
primer, clean it with white gasoline before
use.
a After cleaning, check again that the brush
is free from stains or fouling.
a Provide a brush for the primer for paint
surface and another for glass.
2. By using white gasoline, remove oil, dusts and
stains from bonding surfaces on operator's cab
(8) and window glass (9).
a Clean them thoroughly since insufficient
cleaning induces defective adhesion.
a Clean all the black part on the back of the
window glass.
a After cleaning, leave them for more than 5
minutes for natural drying.
3) Apply primer for paint surface uniformly to

the mounting position of the dam rubber of
operator's cab (8) and the portion outside of
it to which adhesive is applied.
2 Primer for surface to be coated:
SUNSTAR paint surface primer
580 SUPER
a Primer is applied for up to 2 times.
(Application more than 2 times cause
3. Apply primer (10).
degradation.)
a Since useful life of primer is 4 months from
a Area to be coated: Entire area of
the date of production, do not use an
dimension (a).
overdue primer (10).
• Primer coating dimension (a): 25 mm
PC138USLC-10 50-167
2 Primer for glass:

SUNSTAR Glass Primer 580
SUPER
a Primer is applied for up to 2 times.
(Application beyond 2 times cause
degradation.)
a Area to be coated: Apply the primer to the

entire area of installation position (d)
which is a periphery of whole area of
window glass relative to dam rubber (7)
mounting position and operator's cab (8).
a For right side window glass (1), apply the a Do not apply the primer to about 5 mm of
primer only to the mounting position of the border area between the black and
the dam rubber in the outer periphery transparent portions on the window glass.
side and the portion to which adhesive is a After coating, leave the coated surface for
applied outside. more than 5 minutes (but no longer than
• Part of (b) 8 hours) for natural drying.
a After coating, leave the coated surface for a Be careful not to use wrong primer for
more than 5 minutes (but no longer than coating. If a wrong primer such as paint
8 hours) for natural drying. surface primer is applied, wipe it out
completely using white gasoline.
a Be careful not to use wrong primer for
coating. If a wrong primer such as glass
primer is applied, wipe it out completely
using white gasoline.
4. Attach dam rubber (double-coated adhesion

tape) (7) along the inner edge of window glass
mounting surface.
4) Apply a glass primer to the mounting surface
a Do not remove the release tape on glass-
of window glass (9).
adhering side of the dam rubber until
installation of the window glass is started.
50-168 PC138USLC-10
a When sticking the dam rubber, do not touch

the cleaned surface.
a Be sure that the dam rubber in each sticking
corner sticks thoroughly to the corner.
2) Attach dam rubber (7) for left side rear

window glass (2) to the position indicated in
the figure.
a When bonding dam rubber (7) around a

window, be careful to prevent its overlapping
in the meeting area of the starting and ending
points. Or provide a clearance of 5 mm or so
in meeting area (e).
1) Attach dam rubber (7) for right side window
glass (1) to the position indicated in the
figure.
3) Attach dam rubbers (7) for door upper

window glass (3) and door lower window
glass (4) to the position indicated in the
figure.
(Figure shows the door upper window glass)
a Attach additional dam rubber (7a) for right

side window glass (1).
• Right side window glass additional dam
rubber mounting position:
(f): 140 mm
(g): 500 mm
(Figure shows the door lower window glass.)
PC138USLC-10 50-169
4) Attach dam rubber (7) for front window glass

(5) to the position indicated in the figure.
a Dam rubber: 1,004 mm x 2
5. Position the new window glass.

1) Check clearance between a window glass
• The details of the mounting positions are and operator's cab in the right, left, top and
as follows: bottom. Then adjust the window glass
(h): Mount it along the inner end surface position so that the clearance is even in
of left and right front frames (17). every direction.
(i): Recess it from the front frame (17) end 2) Attach tape [6] between window glass (9)
surface by "3.0 mm." and operator' cab (8), and draw a line (n) on
the tape for the position alignment.
a Apply tapes [6] at 3 positions, right side
window glass, rear left side window glass,
and door lower window glasses (top and
bottom) , for position alignment.
3) Cut the tape at a position between window
glass (9) and operator's cab (8) by using a
cutter knife, and remove the window glass.
a Do not remove the tapes left on the
window glass and the operator's cab until
the window glass is installed
50-170 PC138USLC-10
a Since useful life of adhesive is 4 months from

the date of production, do not use an
overdue adhesive.
a Adhesives must be stored at 25°C or lower in
a dark and cool place.
a Never heat an adhesive more than 30°C.
a When reusing the adhesive, remove
hardened adhesive at the nozzle tip
completely.
1) Break aluminum dehumidification membrane
(13) at the mouth of adhesive cartridge (12)
a The left/right and top/bottom mounting and attach there the dedicated nozzle.
positions for positioning of front window
glass (5) are as shown below.
(m) part (right): Protruded from the frame
end surface by "3.8 mm."
(o) part (top): Recessed from the frame
end surface by "3.0 mm."
2) Cut the tip of adhesive nozzle (14) to

dimensions (q) and (r) shown in the figure.
• Dimension (q): 10 mm
• Dimension (r): 15 mm
3) Set adhesive cartridge (12) on caulking gun

[7].
6. Apply adhesive.
a 2 types of adhesives must be selectively
used depending on the season.
2 Adhesive (summer):
SUNSTAR Penguin Seal 580 SUPER
"S"
2 Adhesive (winter):
SUNSTAR Penguin Seal 580 SUPER
"W"
PC138USLC-10 50-171
4) Remove the protective tape on the glass- 7. Install window glass.

bonding side of dam rubber. 1) Install the window glass (9) aligning it to the
5) Apply adhesive (15) to the outside portion of lines drawn on the tapes in the process of
dam rubber (7) on the operator's cab. step 5 above.
a Since the window glass cannot be
removed and adhered again, adhere it
with utmost care.
a Adhere the glass within 5 minutes after
applying the adhesive.
a Apply adhesive (15) to dam rubber (7) of

operator's cab (8) according to the
dimensions (s) and (t) indicated in the
figure.
• Dimension (s): 10 mm
• Dimension (t): 15 mm
2) After bonding window glass (9), press down
a Height of applied adhesive (15) must be entire circumference of the window glass
thicker than that of dam rubber (7). until it firmly sticks to dam rubber.
a Height of applied adhesive must be even. a Especially, press the corners of the
window glass firmly.
a For right side window glass, apply the
primer to the outside of the dam rubber in a Pulling window glass (9) from inside of
the outside perimeter side. the operator's cab by using of the suction
cup X1 will facilitate your work.
(Figure shows the operator's cab of
PC200-7.)
50-172 PC138USLC-10
(Figure shows the operator's cab of PC200-

7.)
a Attach a center trim seal(16) to the lower

part of front window glass (5) after
mounting it. (Figure shows the operator's cab of PC200-
Also, caulk the entire periphery of the U- 7.)
shaped part between the glass and
center trim seal to eliminate any gap.
a When caulking, shape the adhesive on
the left and right end surfaces using a
rubber spatula.
2 Adhesive: Sika Japan
Sikaflex 256HV
2) Make the window glass and dam rubber stick

together by clamping them with expanded
styrene foam [9] and rubber band [10], and
cure them in that state.
(Figure shows the operator's cab of PC200-
7.)
9. Clean the remaining primer and adhesive on the

window glass and operator's cab after
completing the installation of the window glass.
8. Fix the window glass.
1) For right window glass (1) after installing it in a Wipe off adhesives before it is dried up by
the operator's cab, install sheet X2 for using white gasoline.
fixation in 2 portions (v) at the bottom of the a After cleaning the glass, do not give an
glass. impact to it.
10.Cure the adhered window glass.
PC138USLC-10 50-173
1) Keep the stopper rubbers, styrene foam

blocks, and rubber bands installed for 10
hours of curing period.
(Ambient temperature 20°C / Humidity 60 %)
2) Before actual operation of the machine, let it
cure for 14 hours after the stopper rubbers,
styrene foam blocks, and rubber bands are
removed, and for a total of 24 hours after the
adhesive is applied.
50-174 PC138USLC-10
Removal and installation of front window assembly (PC138-K181-924-K-00-A)
k Lower the work equipment to the ground,

Removal (PC138-K181-520-K-00-A)
a To replace the front window glass, the front

window assembly must be removed from the
operator's cab. Procedure for installing and
removing the front window assembly (front
frame + front glass) are described as following.
1. Fix the rear locks (right and left) with the front
window assembly put up to the ceiling.
2. Remove lower left block (1) and lower right block
(2).
3. Unlock the lock at the rear of the cab.

4. Carefully and slightly lower front window
assembly (3) and remove rollers (4) and (5) out
from the removal portion (lowest end of the rail)
of the lower right and lower left blocks removed
in above step 2.
5. Remove upper right and lower left rollers (6) and
(7) by twisting front window assembly (3)
rightward and leftward to remove front window
assembly (3).
a For (6) and (7), see the right figure.

removal.
PC138USLC-10 50-175
Removal and installation of floor frame assembly (PC138-H1H0-924-K-00-A)

6 Radiator:
the work equipment to the ground, stop the
engine, and set the lock lever in LOCK 17.7 l
position.

k If you drain the coolant or disconnect the

heater hose when the coolant is still hot, you
may be scalded. Wait until the coolant
temperature drops before starting the work.

gets in your eyes, you may lose your sight.
And if it touches your skin, you may suffer
from frostbite. Be sure to put on protective 3. Removal of exterior package
eyeglasses, gloves and working clothes with 1) Remove stay (2).
long sleeves while collecting the refrigerant 2) Remove cover (3) and step (4).
or filling the air conditioner circuit with the
refrigerant.
a Never release the refrigerant (R134a) to the

atmosphere.
persons can work.)
and hoses.
a The removal and installation procedures in this 3) Remove covers (5), (6), and (7).
section are based on the "Machines equipped
with attachment and machines equipped with
multi pattern valve".
Removal (PC138-H1H0-520-K-00-A)
4. Disconnection of wiring and hoses around

solenoid valve
1) Disconnect bucket dump solenoid wiring
connector V10 (8).
2. Open coolant drain valve (2) to drain the coolant.

[*1]
50-176 PC138USLC-10
2) Disconnect connectors (10) to (20) around

the solenoid valve connected to wiring
harness (9).
(10): V01 (PPC source pressure solenoid
valve)
(11): V02 (Travel HI/LO solenoid valve)
(12): V03 (Swing parking brake solenoid
valve)
(13): V04 (Travel junction valve solenoid
valve)
(14): V05 (Merge-divider selector solenoid
valve)
(15): V06 (Attachment return selector
solenoid valve) 5. Disconnection of wiring of pressure switch and
(16): P25 (Pump pressure sensor) pressure sensor connector
(17): P26 (R.H. travel REVERSE pressure 1) Disconnect connectors (24) to (31)
sensor) connected to wiring harness (23).
(18): P27 (L.H. travel REVERSE pressure (24): P01 (Bucket DUMP switch)
sensor) (25): P02 (Arm OUT switch)
(19): P28 (Blade RAISE pressure sensor) (26): P03 (Boom RAISE switch)
(20): P29 (Intermediate connector) (27): P04 (Bucket CURL switch)
3) Remove the harness mounting clamp and (28): P05 (Arm IN switch)
disconnect wiring harness (9) from solenoid (29): P06 (Boom LOWER switch)
valve mounting frame assembly (21). (30): P07 (Right Swing switch)
4) Disconnect PPC source pressure hose (22) (31): P08 (Left Swing switch)
(color band: red/green). (If the multi pattern valve is equipped.)
(32): P67 (Right Swing switch)
(If the multi pattern valve is equipped.)
a Connector P67 is connected to connector
P07.
a Connector P08 of the machine that is not
equipped with the multi pattern valve
assembly is located under connector P07
in the mounting bracket.
(33): P12 (Intermediate connector)
2) Remove the wiring harness mounting clamp
and disconnect wiring harness (23) from
pressure switch connector mounting bracket
(34).
PC138USLC-10 50-177
a Left side of control valve (operator's cab

side)
4) Disconnect harness connectors (42) to (44).
(42): P61 (Bucket DUMP switch)
(43): P62 (Arm OUT switch)
(44): P63 (Boom RAISE switch)
5) Disconnect hose (45) of the attachment.
(If the attachment is equipped.)
(Color band: Red/Red/Red)
6. Disconnection of wiring and hoses of control

valve assembly
a Right side of control valve (inspection cover
side)
1) Disconnect hose (35) of the attachment.
(If the attachment is equipped.)
(Band color: Blue/Blue/Blue)
2) Disconnect connectors (36) to (38).
(36): P64 (Bucket CURL switch)
(37): P65 (Arm IN switch) 6) Disconnect travel sensor connectors (46) to
(38): P66 (Boom LOWER switch) (48).
(46): P09 (R.H. travel FORWARD pressure
sensor)
(47): P10 (L.H. travel FORWARD pressure
sensor)
(48): P11 (Blade LOWER oil pressure
sensor)
3) Disconnect hoses (39) to (41).

(39): Green/Yellow
(40): Orange/Yellow
(41): Yellow/Blue
7) Disconnect hoses (49) to (51).

(49): Black/Yellow
50-178 PC138USLC-10
(50): Brown/Yellow a For the machine not equipped with the multi
(51): Red/Black pattern valve, disconnect the hoses (8
pieces) installed to the solenoid valve
mounting frame as shown in step 4-4) (photo
No. CPP27503) in the following order.
Red (Bucket DUMP)
Orange (Arm OUT)
Yellow (Boom RAISE)
Blue (Bucket CURL)
Green (Arm IN)
Black (Boom LOWER)
White (Left SWING)
Brown (Right SWING)
7. Disconnect hoses (52) to (59) (8 pieces) from 8. Disconnect PPC drain hose (60).
the multi pattern valve assembly. (if equipped)
a Left side of multi pattern valve
(52): Brown
(53): Green
(54): White
(55): Orange
9. Disconnect connectors A13 (61) and A08 (62).
a Rear side of multi pattern valve

(56): Black
(57): Yellow
(58): Blue
(59): Red
10.Disconnect boom bottom pressure sensor

connector P46 (63).
11.Remove clamp (64) and disconnect the wiring
harness.
PC138USLC-10 50-179
12.Disconnect connector (65).

13.Remove clamp (66) to disconnect buzzer wiring.
a How to remove the clamp (66)

Put flat-head screwdriver [1] to portion (a), lift
whole of clamp (66) while pushing portion (a),
and remove the clamp from plate (b)
14.Remove the operator's cab assembly. For

operator's cab assembly."
15.Disconnection of wiring and clamps under floor
1) Disconnect the wiring harness and hose
clamps (67) to (78).
16.Disconnect high/low pressure switch wiring
connector (79) of the air conditioner compressor.
17.Disconnect air conditioner hoses (80) and (81).
[*2]
18.Disconnect heater hoses (82) and (83).
50-180 PC138USLC-10
4 Floor frame assembly:

210 kg
19.Pull out wiring harness fixing pad (84) and wiring

harness (85).
Installation (PC138-H1H0-720-K-00-A)

removal.
[*1]
a Refill with the coolant to the specified level
through the coolant filler port. Run the engine to
circulate the coolant through system. Then
check the coolant level again.
5 Radiator:
20.Disconnect grounding cable (86). 17.7 l (For details, see "Table of fuel,
[*2]
• Filling of refrigerant (air conditioner gas: R134a)
Refill the air conditioner circuit with refrigerant
(air conditioner gas: R134a).
• Filling quantity: 800 ± 50 g
• Refilling of air conditioner compressor oil
See "Filling of compressor oil" of "Others".
a When installing the air conditioner piping, be
careful not to allow invasion of dirt, dusts and
water into the hose.
a Check that the O-rings are fitted to the joints
21.Sling floor frame assembly (87), and remove it. when connecting the air conditioner piping.
a Check that all the wiring connectors and a Once an O-ring is used, it is deformed and
wiring clamps are disconnected before deteriorated. Accordingly, do not reuse it.
slinging.
a When removing the O-rings, use a soft tool so
a Pull out the wiring on the control valve side that the piping is not damaged.
while gradually slinging floor frame assembly
(87). a Check that the O-ring is not damaged or
deteriorated.
a When pulling out the wiring on the control
valve side, obstacles may catch the wire in a Apply compressor oil (DENSO: ND-OIL8) for
the middle of pulling out and it may become refrigerant (R134a) to O-ring.
difficult to pull out the wiring. In this case, do 3 Hose clamp (M6 bolt):
not pull the wire forcibly. Pull out the wiring
8 to 12 Nm {0.8 to 1.2 kgm}
while avoiding the obstacles.
PC138USLC-10 50-181
50-182 PC138USLC-10
Removal and installation of air conditioner unit assembly (PC138-K500-924-K-00-A)
k Place the machine on a level ground,

completely lower the work equipment to the
ground, stop the engine, and set the lock
lever in LOCK position.

k If you drain the coolant or disconnect the

heater hose when the coolant is still hot, you
may be scalded. Wait until the coolant
temperature drops before starting the work.
k If refrigerant gas (air conditioner gas: R134a) 5. Remove floor mat (7).
gets in your eyes, you may lose your sight. 6. Remove machine monitor assembly (8). For
And if it touches your skin, you may suffer details, see "Removal and installation of
from frostbite. Be sure to put on protective machine monitor assembly".
eyeglasses, gloves and working clothes with 7. Remove covers (8) to (10).
long sleeves while collecting the refrigerant 8. Remove clips (11) (2 pieces) to pull down ducts
or filling the air conditioner circuit with the (12) and (13) in the direction of arrow.
refrigerant.
a Never release the refrigerant (air conditioner

gas: R134a) to the atmosphere.
persons can work.)
and hoses.
Removal (PC138-K500-520-K-00-A)
1. Remove side cover (1).
10.Remove cover (15) and duct (16).

2. Disconnect high- and low-pressure switch wiring 11.Remove covers (17) and (18).
connector (2) of the air conditioner compressor.
3. Disconnect air conditioner hoses (3) and (4). [*1]
4. Disconnect heater hoses (5) and (6).
PC138USLC-10 50-183
12.Disconnect connectors ACECU (19), AC01 (20), 2) Remove mounting bolts (29) (3 pieces) of
and AC02 (21). machine monitor cover (28), and lightly
13.Disconnect clamps (22) and (23). loosen mounting bolt (30).
14.Remove cover (24). 3) Rotate machine monitor cover (28) in the

direction of arrow having mounting bolt (30)
as a fulcrum.
a Fix it at the position where it does not
interfere with right side duct (31).
4) Remove front mounting bolt (32) of right side
duct (31).
15.Remove the right side duct according to the

1) Remove cable clip (25), and disconnect
cable (26) from duct lever (27).
a Insert a flat-head screwdriver between
the cable and clip, and lower it to remove
the cable clip. 5) Remove rear mounting bolt (33) of right side
duct (31).
50-184 PC138USLC-10
6) Pull out right side duct (31) in the direction of 19.Remove mounting bolts (36) (3 places each on
arrow to remove it. the front and rear sides) of air conditioner unit
(37) to remove the air conditioner unit.
16.Remove cover mounting bolts (34) (3 pieces

each on the right and left sides). 20.Pull out air conditioner unit assembly (37) in the
direction of arrow to remove it.
a Check that all the wiring harnesses and
hoses are disconnected before removing.
17.Install forcing screws [1] (1 piece on the right

side, 2 pieces on the left side).
18.Tighten forcing screws [1] evenly on the right
and left sides, and lift sheet mounting bracket
(35) to secure clearance (a) between the bracket
and floor.
Clearance (a): 90 mm
a Secure clearance (a) to prevent the
interference when pulling out the air
conditioner unit assembly.
PC138USLC-10 50-185

removal.
See Air conditioner, "Filling of compressor oil".
[*1]
a When installing the hose for the air conditioner
when connecting the air conditioner piping.
a Once an O-ring is used, it is deformed and
deteriorated. Accordingly, do not reuse it.
a Check that the O-ring is not damaged or
deteriorated.
a Apply compressor oil (DENSO: ND-OIL8) for
refrigerant (R134a) to O-ring.
3 Hose clamp (M6 bolt):
8 to 12 Nm {0.8 to 1.2 kgm}
50-186 PC138USLC-10
Removal and installation of air conditioner compressor assembly (PC138-

K590-924-K-00-A)

the engine.


from frostbite. Be sure to put on protective
eyeglasses, gloves and working clothes with 4. Disconnect air conditioner hoses (5) and (6). [*2]
long sleeves while collecting the refrigerant a Plug the hoses to prevent any dirt, dust and
or filling the air conditioner circuit with the water from entering.
refrigerant.
a Be careful not to damage or lose O-ring.
a Never release the refrigerant (air conditioner 5. Disconnect solenoid clutch connector AC03 (7)
gas: R134a) to the atmosphere. of the air conditioner compressor.

persons can work.)
Removal (PC138-K590-520-K-00-A)
1. Collect the refrigerant (air conditioner gas:

R134a) from the air conditioner circuit. [*1]
a Refrigerant to be collected: 800 ± 50 g
2. Open engine cover (1) and remove step (2)
6. Remove air conditioner compressor belt (12)

according to the following procedure. [*3]
1) Loosen 4 bolts (8).
2) Loosen lock nut (9) and rotate jack bolt (10)
to slide air conditioner compressor (11) in the
direction (B) in which the compressor is
loosened.
3) Reduce the tension of air conditioner
compressor belt (12) to remove the belt.
7. Remove mounting bolts (13) (4 pieces) and
remove air conditioner compressor assembly
3. Remove fan guard (3) and pulley cover (4). (11). [*4]
PC138USLC-10 50-187
a See Testing and adjusting, "Testing and

adjusting air conditioner compressor belt
tension".
3 Lock nut (9):
108 to 132 Nm {11 to 13.5 kgm}
59 to 74 Nm {6.0 to 7.5 kgm}
[*4]
24.5 to 29.4 Nm {2.5 to 3.0 kgm}

removal.
[*1]
See Air conditioner, "Filling of compressor oil".
[*2]
circuit, be careful not to allow invasion of dirt,
deteriorated.
8 to 12 Nm {0.8 to 1.2 kgm}
[*3]
50-188 PC138USLC-10
Removal and installation of air conditioner condenser assembly (PC138-K580-

924-K-00-A)


from frostbite. Be sure to put on protective
eyeglasses, gloves and working clothes with
long sleeves while collecting the refrigerant
or filling the air conditioner circuit with the
refrigerant.
a Never release the refrigerant (air conditioner

gas: R134a) to the atmosphere. 5. Remove mounting bolts (5) (2 pieces) to remove
disconnect switch (6).
persons can work.)
Removal (PC138-K580-520-K-00-A)
1. Collect the refrigerant (air conditioner gas:

R134a) from the air conditioner circuit. [*1]
a Refrigerant to be collected: 800 ± 50 g
assembly".
3. Disconnect connector L19 (1) of the operating
lamp from the cover on the left rear of the 6. Remove bolts (7) and (9) to disconnect hoses
machine. (8) and (10). [*2]
4. Remove mounting bolts (2) and (3) to remove air a Plug the hose to prevent dust and water from
cleaner bracket (4). entering.
a Be careful not to damage or lose O-ring.

remove air conditioner condenser assembly (12).
[*3]
a Be careful not to damage the core portion of
the air conditioner condenser when
removing.
PC138USLC-10 50-189
[*3]
a Remove air conditioner condenser assembly
with the cushion.
Adhesive (LT-2)
3 Mounting bolt:
12.5 ± 2.5 Nm {1.27 ± 0.25 kgm}

removal.
[*1]
a Filling quantity: 800 ± 50 g
See "Handling of compressor oil" of "Others".
[*2]
deteriorated.
8 to 12 Nm {0.8 to 1.2 kgm}
50-190 PC138USLC-10
Removal and installation of operator's seat (PC138-K2Q0-924-K-00-A)

the work equipment to the ground in a stable
posture, and stop the engine.

k Removal and installation work must be done

by a pair of workers.

and hoses.
Removal (PC138-K2Q0-520-K-00-A)
1. Pull lever (1) to your side and move operator's

seat (2) backward.
2. Remove mounting bolts (3) (4 pieces).
a Move the operator's seat forward, and
remove mounting bolts (2 pieces) at the rear.
3. Disconnect connector S19 (4) at the rear of the

operator's seat.
4. Remove operator's seat (2) while slowly lifting it
by 2 persons.
4 Operator's seat assembly:

30 kg
Installation (PC138-K2Q0-720-K-00-A)

removal.
PC138USLC-10 50-191
Removal and installation of seat belt (PC138-K2Q3-924-K-00-A)

the engine.

Removal (PC138-K2Q3-520-K-00-A)
1. Remove the operator's seat. For details, see

"Removal and installation of operator's seat".
2. Remove mounting bolts (2) (one each on right
and left sides) of seat belt (1), and remove seat
belt (1). [*1]
Installation (PC138-K2Q3-720-K-00-A)

removal.
50-192 PC138USLC-10
Removal and installation of front wiper assembly (PC138-K710-924-K-00-A)

the engine.
k Place the work equipment lock lever in LOCK

position.

Removal (PC138-K710-520-K-00-A)
1. Check that wiper blade (1) is stowed in the right

stay.
2. While holding grips (2) on the right and left of the

front window, pull lever (3) forward to release the
lock.
3. Pull up lower grip (4) by left hand and upper grip

(5) by right hand, and push them to lock catch
(6) at the rear of the cab to lock.
4. Check that lever (3) is securely at LOCK

position.
PC138USLC-10 50-193
a Check that the arrow on lock case (7) is

aligned with that of lever (3).
8. Disconnect connector P31 (14) inside of cover

(12).
5. Hold and pull up knob (8) to remove lower

window (9).
9. Remove covers (15) and (16).
6. Remove cover (10) and floor mat (11).

a Insert a flat-head screwdriver to slit (18) at
the lower left and pull it up to remove the
7. Remove cover (12). cover while avoiding protrusion (19).
a 1 out of the mounting screws (4 pieces) is
covered with cap (13).
50-194 PC138USLC-10
13.Move harness (23) and disconnect connector

M05 (24).
14.Open cap (25) and remove nut (26) to remove

wiper arm (27)
15.Remove cap (28), nut (29), washer (30) and
packing (31).
11.Remove duct (20).

remove wiper motor assembly (33).
12.Remove the mounting bolt of bracket (21), and

move it backward together with machine monitor
(22).
a The connector of the machine monitor needs
not to be disconnect .
1. Install wiper motor assembly (33).

PC138USLC-10 50-195
2. Install packing (31) and washer (30), and tighten

nut (29).
a When installing washer (30), direct the
chamfered side toward the front of the cab.
3 Nut (29):
10.8 to 12.7 Nm {1.10 to 1.30 kgm}
5. To check the wiper arm operation, preform the

following works.
1) Connect connectors M05 (24) and P31 (14).
3. Install cap (28) and wiper arm (27).

a Install wiper arm (27) so that clearance (a)
between washer nozzle (34) and wiper blade
(35) is the following dimension.
• Dimension (a): 22 mm
4. Tighten nut (26) to close cap (25).
3 Nut (26):
11.8 to 15.7 Nm {1.20 to 1.60 kgm}
2) Hold knob (8) and install lower window (9).
50-196 PC138USLC-10
5) When the bottom of the front window

reaches the top of lower window, push the
top of the front window to front lock catches
(36) and engage the lock.
3) While holding grips (2) on the right and left of

the front window set to the ceiling, pull down
lever (3) to release the lock.
6) Check that lever (3) is securely at LOCK

position.
a Check that the arrow on lock case (7) is
aligned with that of lever (3).
4) Securely hold lower grip (4) by left hand and

upper grip (5) by right hand, and slowly push
down them forward.
7) Turn battery disconnect switch to ON

position.
8) Check that the work equipment lock lever is
in LOCK position and start the engine.
9) Check the operation of the wiper arm with the
front window dried.
1] Press wiper switch (37) 3 times
continuously, and check that wiper arm
(27) swings one round-trip, and then is
stowed in the right stay.
2] Perform step 1] again.
a Between steps 1] and 2], the rotation
direction of the motor crank is different.
Therefore, check the operation 2
times.
3] When the tip of wiper blade (35) is at the
highest position by pressing wiper switch
(37), check that clearance (b) between
trim seal (38) and wiper is the following
dimension.
• Dimension (b): Max. 130 mm
PC138USLC-10 50-197
and stopper (41) do not interfere each

other (clicks in case of interference).
• When the tip of wiper blade (35) is at
the lowest position, wiper blade (35)
and front window seal (42) do not
interfere each other.
10)Check the operation of the wiper arm when

the front window is wet with washer fluid.
1] Hold down window washer switch (39) for
a few seconds to wet the front window
sufficiently, and then release the switch.
2] Check that wiper arm (27) swings 2
round-trips and then is stowed in the right 11)In case of abnormality as results of the
stay. above checks, adjust the wiper arm
3] Perform step 1] again. installation as described in step 3.
4] Check that wiper arm (27) swings odd 6. Perform the subsequent installation in the
number of round-trips and then is stowed reverse order to removal.
in the right stay.
5] Hold down window washer switch (39) to
operate the wiper and check the
followings.
• When the tip of wiper blade (35) is at
the highest position, wiper slider (40)
50-198 PC138USLC-10
Electrical system
Removal and installation of engine controller assembly (PC138-AP70-924-K-00-A)

the engine.

Removal (PC138-AP70-520-K-00-A)
2. Disconnect connectors J1 (CE01) (3), J2 (CE02)

(4), and CE03 (5) of engine controller (2). [*1]
3. Remove mounting bolts (6) (4 pieces) and
remove engine controller (2).
Installation (PC138-AP70-720-K-00-A)

removal.
[*1]
3 Hexagonal socket head bolt:
3 ± 1 Nm {0.31 ± 0.1 kgm}
PC138USLC-10 50-199
Electrical system
Removal and installation of pump controller assembly (PC138-C3V1-924-K-00-A)

the engine.


and hoses.
Removal (PC138-C3V1-520-K-00-A)
1. Move operator's seat (1) to the forward end and

tilt the backrest forward. 8. Disconnect the wiring as follows.
2. Remove cover (2) at the rear inside the cab. • Connector D01 (12)
• Connector D02 (13)
• Connector D03 (14)
• Connector R21 (15): Compressor relay
• Connectors R06 (16) and R07 (17): starting
motor cut-off relay
• Connector S25 (18): Emergency activation
switch
9. Remove air conditioner controller (19) together
with the bracket.
3. Disconnect the cigarette lighter connector M04

of wiring harness (3).
5. Disconnect fuse box (5).

6. Disconnect the wiring as follows.
• Connector R05 (6): Light relay
• Connector R12 (7): Light relay (if equipped)
• Connector R22 (8): For arm crane
specification machine
• Connector N08 (9): Service connector
7. Remove mounting bolts (10) (4 pieces) to pull
remove pump controller (21).
out bracket (11).
50-200 PC138USLC-10
Electrical system
Installation (PC138-C3V1-720-K-00-A)
• Perform installation in the reverse order to

removal.
PC138USLC-10 50-201
Electrical system
Removal and installation of machine monitor assembly (PC138-Q170-924-K-00-A)

the engine.


and hoses.
Removal (PC138-Q170-520-K-00-A)
1. Pull up front window assembly (1) to the ceiling,

and lock it. 6. Remove duct (10) (1 bolt).
a Be sure that the assembly is certainly locked.
2. Remove front lower window (2).
3. Remove rubber panel (3) (2 bolts).
7. Insert a flat-head screwdriver in slit (7), and pull

it upward to remove cover (9) while avoiding
protrusion (8).
4. Remove 3 mounting screws of cover (4).
a One of the 3 screws is covered with cap (5).
a Claw (17) is attached to the back side of

cover (9).
5. Disconnect connector P31 (6) of sunlight sensor
and then remove cover (4).
50-202 PC138USLC-10
Electrical system
8. Loosen mounting bolts (19) of cover and duct

assembly (18).
a By loosening mounting bolt (19), the machine
monitor mounting bolt can be removed
easily.
Installation (PC138-Q170-720-K-00-A)

removal.
9. Remove mounting bolts (11) (4 pieces) of

machine monitor (12).
10.Disconnect connectors (13) to (16).

a By disconnecting connector (15) in advance,
other connectors can be disconnected easily.
• Connector (13): Machine monitor (CM01)
• Connector (14): Machine monitor (CM02)
• Connector (15): Machine monitor (unused)
(CM03)
• Connector (16): Machine monitor (for camera
connection) (CM03)
PC138USLC-10 50-203
Electrical system
Removal and installation of mass air flow and temperature sensor (PC138-
A96H-924-K-00-A)

the engine.

Removal (PC138-A96H-520-K-00-A)
2. Disconnect connector P55 (2) between the air

cleaner and hose.
3. Remove mounting bolts (3) to remove mass air
flow and temperature sensor (4).
Installation (PC138-A96H-720-K-00-A)

removal.
50-204 PC138USLC-10
Electrical system
Removal and installation of KOMTRAX terminal assembly (PC138-Q210-924-K-00-A)

the engine.


and hoses.
Removal (PC138-Q210-520-K-00-A)
1. Move operator's seat (1) to the forward end and

tilt the backrest forward. 6. Disconnect connectors CK01 (7) and CK02 (8).
2. Remove cover (2) at the rear inside the cab. 7. Disconnect GPS antenna wiring (9) and
communication antenna wiring (10).
remove KOMTRAX terminal (12).
3. Disconnect the cigarette lighter connector M04

of wiring harness (3).
Installation (PC138-Q210-720-K-00-A)

removal.
5. Remove mounting bolts (5) (4 pieces) to pull out

forward together with bracket (6).
PC138USLC-10 50-205
Electrical system
50-206 PC138USLC-10
SHOP MANUAL
HYDRAULIC EXCAVATOR
PC138USLC-10
Model Serial Number

10
60 Maintenance standard
8 60 Maintenance standard
PC138USLC-10 60-1
Table of contents

60 Maintenance standard................................................................................................................... 60-1
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 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 mount and cab tipping stopper ..................................................................................... 60-54
Work equipment ....................................................................................................................... 60-55
Work equipment................................................................................................................. 60-55
Boom cylinder.................................................................................................................... 60-64
Arm cylinder ...................................................................................................................... 60-65
Bucket cylinder .................................................................................................................. 60-66
Blade cylinder .................................................................................................................... 60-67
60-2 PC138USLC-10
Engine mount
Engine mount (PC138-H320-034-K-00-A)
PC138USLC-10 60-3
PTO
PTO (PC138-D400-034-K-00-A)
a PTO: Abbreviation for Power Take Off
60-4 PC138USLC-10
Cooling system
Cooling system (PC138-B000-034-K-00-A)
PC138USLC-10 60-5
Swing circle
Swing circle (PC138-J110-034-K-00-A)
Unit: mm
No. Item Criteria Remedy
Axial clearance of Standard clearance Allowable clearance
bearing
1 Replace
(when mounted on 0.5 to 1.6 2.6
machine)
60-6 PC138USLC-10
Swing machinery
Swing machinery (PC138-J130-034-K-00-A)
Unit: mm
Backlash between Standard clearance Allowable clearance
1 swing motor shaft and
No. 1 sun gear 0.07 to 0.18 0.4
Backlash between No.
2 1 sun gear and No. 1 0.13 to 0.31 0.6
planetary gear
3 1 planetary gear and 0.15 to 0.34 0.7
ring gear
4 1 planetary carrier and 0.14 to 0.34 0.7
No. 2 sun gear
Replace
5 2 sun gear and No. 2 0.13 to 0.31 0.6
planetary gear
6 2 planetary gear and 0.15 to 0.34 0.7
ring gear
7 2 planetary carrier and 0.08 to 0.19 0.4
swing pinion
Backlash between
8 swing pinion and swing 0.13 to 1.16 2.3
circle
Standard Repair limit Repair by
Outside diameter of oil Tolerance
dimension hard chrome
9 seal contact surface of
0 plating or
swing pinion collar 145 144.8
-0.100 replace
PC138USLC-10 60-7
Sprocket
Sprocket (PC138-DT60-034-K-00-A)
Unit: mm
Standard Repair limit
Tolerance
dimension
1 Tip outside diameter
+1.0
542.8 530 Rebuild by
-2.0
2 Root outside diameter 607.5 — 595 build-up
welding or
3 Width of tooth tip 27 — 22 replace
4 Width of tooth root 42 ±1.5 39
Thickness of tooth +0.465
5 109.4 103
bottom -1.160
60-8 PC138USLC-10
Track frame
Track frame (PC138-DT20-034-K-00-A)
Unit: mm
Standard dimension Repair limit Rebuild by
Track build-up
84 89 welding
Vertical width frame
1 of idler guide Rebuild by
Idler build-up
support 82 77 welding or
replace
Rebuild by
Track build-up
185 193
frame welding
Horizontal
2 width of idler Rebuild by
guide Idler build-up
support 183 175 welding or
replace
PC138USLC-10 60-9
Idler cushion
Idler cushion (PC138-DTBP-034-K-00-A)
Unit: mm
Standard dimension Repair limit
Load at Load at
Installed
Free length installed Free length installed
1 Recoil spring length Replace
length length
93.2 kN 83.0 kN
513.3 390 500
{9,500 kg} {8,460 kg}
60-10 PC138USLC-10
Idler
Idler (PC138-DT90-034-K-00-A)
Unit: mm
Outside diameter of Standard dimension Repair limit
1 protrusion 527 —
Outside diameter of Rebuild by
2 489 477
tread build-up
Thickness of tread welding or
3 (Center of width of 15 9 replace
tread)
4 Level difference of tread 19 25
5 Overall width of idler 115 — —
Rebuild by
build-up
6 Width of tread 31.5 36.5 welding or
replace
Standard Tolerance Standard Allowable
Clearance between dimension Shaft Hole clearance clearance
7 shaft and bushing -0.250 +0.074 0.250 to
54 —
-0.280 0 0.354
Tolerance Standard Allowable
Standard
interfer- interfer- Replace
Interference between dimension Shaft Hole
8 ence ence bushing
idler and bushing
+0.117 +0.030 0.057 to
61 —
+0.087 0 0.117
Clearance between Standard clearance Allowable clearance
9 bushing and support
0.36 to 0.76 —
(Total on both sides)
PC138USLC-10 60-11
Track roller
Track roller (PC138-DTD0-034-K-00-A)
Unit: mm
1 flange Rebuild by
158 —
build-up
Outside diameter of welding or
2 130 120
tread replace
3 Thickness of tread 38 33
4 Overall width of roller 176 — —
5 Width of tread 35 — Rebuild by
build-up
6 Width of flange 26.5 — welding or
replace
7 shaft and bushing -0.220 +0.190 0.250 to
50 —
-0.240 +0.030 0.430
Tolerance Standard Allowable
Standard Replace
interfer- interfer-
Interference between dimension Shaft Hole bushing
8 ence ence
roller and bushing
+0.190 0.110 to
54 ±0.030 —
+0.140 0.220
Axial play of roller Standard dimension Repair limit
9
(total on both sides) 0.5 to 0.9 —
60-12 PC138USLC-10
Carrier roller
Carrier roller (PC138-DTJ0-034-K-00-A)
Unit: mm
1
tread 116 106 Rebuild by
Thickness of tread build-up
(Measure at 10 mm welding or
2 17.7 12.7 replace
from outside end face of
roller)
3 Width of tread 123 — —
4 shaft and bushing +0.055 +0.261 0.145 to
40 —
+0.035 +0.200 0.226 Replace
Tolerance Standard Allowable bushing
Standard
interfer- interfer-
Interference between dimension Shaft Hole
5 ence ence
collar and bushing
+0.061 +0.025 0.011 to
47 —
+0.036 0 0.061
Interference between +0.055 +0.005 0.030 to
6 40 —
shaft and collar +0.035 -0.020 0.075
Replace
Standard clearance Allowable clearance
7 Axial play of roller
0.36 to 0.54 —
PC138USLC-10 60-13
Track shoe
Track shoe (PC138-DTL0-034-K-00-A)

Triple grouser shoe, road liner, and rubber pad shoe
a Part P shows the link in which the bushing is press-fitted.

*1: Triple grouser shoe, rubber pad shoe
*2: Road liner
60-14 PC138USLC-10
Track shoe
Unit: mm
1 Link pitch
175.3 178.3
Turn 180
Outside diameter of Standard dimension Invert deg. or
2 bushing 50.6 46.6 replace
Thickness of bushing
3 (center of bushing) 9 5
4 Link height
90 85 Repair or
Thickness of link replace
5 (bushing press-fit part) 23.9 18.9
6 102.4
7 Shoe bolt pitch 86.4 Replace
8 57
Inside
9 52.4
width
Overall Repair or
10 Link 35 replace
width
Tread
11 30.1
width
12 Protrusion of pin 3
Protrusion of regular
13 bushing 3.75
Adjust or
14 Overall length of pin 168
replace
15 Overall length Regular 94.3
16 of bushing Master 86.7
17 Thickness of spacer —
18 Bushing 58.8 to 176.5 kN {6 to 18 ton}
Regular
19 Press-fitting 98.1 to 235.4 kN {10 to 24 ton}
pin —
force
(*1) Master
98.1 to 235.4 kN {10 to 24 ton}
20 pin
Tightening torque Retightening angle
(Nm {kgm}) (deg.)
a: • Triple grouser
shoe 196 ± 20
Regular 90 ± 10
link • Rubber pad {20 ± 2}
shoe
21 Shoe bolt Retighten
176 ± 20
• Road liner 60 ± 5
{18 ± 2}
Tightening torque Retightening angle Lower limit torque
b:
Master (Nm {kgm}) (deg.) (Nm {kgm})
link —
— —
PC138USLC-10 60-15
Track shoe
Unit: mm
Standard Tolerance Standard
Interference between dimension Shaft Hole interference
22 bushing and link +0.387 +0.074
50.2 0.273 to 0.387
+0.347 0
Interference between +0.150 -0.188
23 regular pin and link 32 0.238 to 0.400
+0.050 -0.250
Clearance between dimension Shaft Hole clearance
24 regular pin and bushing +0.150 +0.830 Adjust or
32 0.180 to 0.780 replace
+0.050 +0.330
(*1) Interference between dimension Shaft Hole interference
25 master pin and link +0.060 -0.188
32 0.208 to 0.310
+0.020 -0.250
(*1) Clearance between dimension Shaft Hole clearance
26 master pin and bushing -0.200 +0.830
32 0.530 to 1.130
-0.300 +0.330
*1: For dry track.
60-16 PC138USLC-10
Track shoe
Triple grouser shoe (PC138-DTL8-034-K-00-A)
Unit: mm
1 Grouser height
20 10
2 Overall height of shoe 29.5 19.5
3 Plate thickness 9.5 Rebuild by
build-up
4 Lower base length of 20 welding or
5 grouser 20 replace
6 14
Upper base length of
7 grouser 13
8 15
PC138USLC-10 60-17
Track shoe
Road liner (PC138-DTLK-034-K-00-A)
Unit: mm
1 Grouser height Replace
58 21
60-18 PC138USLC-10
Hydraulic tank
Hydraulic tank (PC138-PM30-034-K-00-A)
PC138USLC-10 60-19
Main pump
Main pump (PC138-C200-034-K-00-A)
60-20 PC138USLC-10
Main pump
PC138USLC-10 60-21
Main pump
PC-EPC valve (D65-C2E5-034-P-00-A)

60-22 PC138USLC-10
Control valve
Control valve (PC138-C030-034-K-00-A)
PC138USLC-10 60-23
Control valve
60-24 PC138USLC-10
Control valve
Unit: mm
Free length Installed Load at Load at
x Outside installed Free length installed
1 Suction valve spring length
diameter length length
5.49 N 4.41 N
46.8 x 7.5 40.6 —
{0.56 kg} {0.45 kg}
135 N 108 N
2 Piston return spring 72.7 x 20.6 42.5 —
{13.8 kg} {11.0 kg}
5.1 N 4.12 N
3 Suction valve spring 39.2 x 4.45 33.5 —
{0.52 kg} {0.42 kg}
141 N 113 N
4 Spool return spring 41.8 x 19 38.5 —
{14.4 kg} {11.5 kg}
41.44 x 137 N 110 N
5 Spool return spring 38.5 — Replace
19.3 {13.96 kg} {11.2 kg}
spring if
27.14 x 55.9 N 44.7 N damaged or
6 Spool return spring 25.5 —
25.8 {5.7 kg} {4.56 kg} deformed
60.2 N 48.2 N
7 Spool return spring 32.4 x 11 31.4 —
{6.137 kg} {4.91 kg}
76.78 x 485 N 388 N
8 Spool return spring 70 —
20.9 {49.5 kg} {39.6 kg}
221 N 177 N
9 Spool return spring 45.7 x 28 43 —
{22.55 kg} {18.04 kg}
222 N 178 N
{22.6 kg} {18.1 kg}
230 N 184 N
{23.5 kg} {18.8 kg}
203 N 163 N
{20.7 kg} {16.6 kg}
PC138USLC-10 60-25
Control valve
60-26 PC138USLC-10
Control valve
Unit: mm
1 Check valve spring length Replace
spring if
5.88 N 4.71 N damaged or
41.5 x 8.5 31.5 —
{0.6 kg} {0.48 kg} deformed
2.94 N 2.35 N
2 Check valve spring 20.3 x 13.7 16 —
{0.3 kg} {0.24 kg}
PC138USLC-10 60-27
Control valve
60-28 PC138USLC-10
Control valve
Unit: mm
1 Check valve spring length Replace
spring if
21.9 x 5 15.8 —
0.98 N 0.78 N
2 Retainer spring 9.1 x 4.2 7.4 —
{0.1 kg} {0.08 kg}
PC138USLC-10 60-29
Control valve
60-30 PC138USLC-10
Control valve
Unit: mm
1 Spool return spring length
15.7 N 12.6 N
19.26 x 7.5 14 —
{1.6 kg} {1.28 kg}
1.96 N 1.57 N
2 Check valve spring 21.9 x 5 15.8 — Replace
{0.2 kg} {0.16 kg}
spring if
3 Valve return spring 58.9 x 13 53 —
98.1 N 78.5 N
4 Spool return spring 49.8 x 18.8 33 —
{10 kg} {8 kg}
13.7 N 11.0 N
5 Check valve spring 16.4 x 8.9 11.5 —
{1.4 kg} {1.12 kg}
Cooler bypass valve 135 N 108 N
6 72.7 x 20.6 42.5 —
spring {13.8 kg} {11 kg}
PC138USLC-10 60-31
Control valve
60-32 PC138USLC-10
Control valve
Unit: mm
Free length Installed Load at Load at Replace
x Outside installed Free length installed spring if
1 Valve spring length
diameter length length damaged or
5.88 N 4.71 N deformed
41.5 x 8.5 31.5 —
{0.6 kg} {0.48 kg}
PC138USLC-10 60-33
Swing motor
Swing motor (PC138-J610-034-K-00-A)
60-34 PC138USLC-10
Swing motor
PC138USLC-10 60-35
Swing motor
Unit: mm
1 Shuttle valve spring length Replace
spring if
13.0 x 6.5 9.5 —
0.88 N 0.69 N
2 Check valve spring 43.3 x 6 36.5 —
{0.09 kg} {0.07 kg}
60-36 PC138USLC-10
Travel motor
Travel motor (PC138-C400-034-K-00-A)
PC138USLC-10 60-37
Work equipment and swing PPC valve (PC200_10-PL28-034-K-00-A)
60-38 PC138USLC-10
PC138USLC-10 60-39
Unit:mm
Centering spring x Outside installed Free length installed
1 length
(for ports P3 and P4) diameter length length
If damaged
17.7 N 14.1 N or deformed,
42.5 x 15.5 34.0 —
{1.80 kg} {1.44 kg} replace
Centering spring 29.4 N 23.5 N spring
2 44.5 x 15.5 34.0 —
(for ports P1 and P2) {3.0 kg} {2.40 kg}
16.7 N 13.3 N
3 Metering spring 26.5 x 8.15 24.9 —
{1.70 kg} {1.36 kg}
60-40 PC138USLC-10
Travel PPC valve
Travel PPC valve (PC-C6V0-034-K-00-A)
PC138USLC-10 60-41
Travel PPC valve
60-42 PC138USLC-10
Travel PPC valve
Unit:mm
x Outside installed Free length installed If damaged
1 Centering spring length
diameter length length or deformed,
48.57 x 108 N 86.3 N replace
32.5 —
15.5 {11 kg} {8.8 kg} spring
26.53 x 16.7 N 13.3 N
2 Metering spring 24.9 —
8.15 {1.7 kg} {1.36 kg}
PC138USLC-10 60-43
Blade PPC valve
Blade PPC valve (PC138-LTJ0-034-K-00-A)
(Blade specification)
60-44 PC138USLC-10
Blade PPC valve
Unit: mm
1 Centering spring length Replace
spring if
42.36 x 147 N 118 N damaged or
32.5 —
15.5 {15 kg} {12.0 kg} deformed
16.7 N 13.3 N
2 Metering spring 22.73 x 8.1 22 —
{1.7 kg} {1.36 kg}
PC138USLC-10 60-45
1st-line attachment PPC valve (with EPC valve) (PC200_10-PL29-034-K-00-A)

60-46 PC138USLC-10
Unit:mm
x Outside installed Free length installed If damaged
1 Centering spring length
diameter length length or deformed,
125 N 100 N replace
33.9 x 15.3 28.4 —
{12.7 kg} {10.2 kg} spring
16.7 N 13.3 N
2 Metering spring 22.7 x 8.10 22.0 —
{1.70 kg} {1.36 kg}
PC138USLC-10 60-47
EPC valve (PC200_10-PL2B-034-K-00-A)
(If equipped)
EPC: Abbreviation for Electromagnetic Proportional Control
Unit: mm
Load at Load at Replace
Installed PPC valve
Free length installed Free length installed
1 Metering spring length assembly if
length length
damaged or
3.1 N 2.5 N
9.5 8.4 — deformed
{0.32 kg} {0.26 kg}
60-48 PC138USLC-10
Solenoid valve
Solenoid valve (PC138-PQPT-034-K-00-A)
PC138USLC-10 60-49
Solenoid valve
For machine(s) ready for installation of attachment
60-50 PC138USLC-10
circuit)
Attachment circuit selector valve (for low pressure circuit) (PC138-PQJ3-034-K-00-A)
Unit: mm
245.2 N 196 N deformed
58.11 x 23 53.5 —
{25 kg} {20.0 kg}
PC138USLC-10 60-51
circuit)
Attachment circuit selector valve (for high pressure circuit) (PC138-PQJ5-034-K-00-A)
Unit: mm
28.7 N 22.9 N deformed
33.4 x 11.2 27.3 —
{2.93 kg} {2.34 kg}
60-52 PC138USLC-10
Center swivel joint
Center swivel joint (PC138-J8E0-034-K-00-A)
Blade specifications (PC138-J8E0-034-K-02-A)
Unit: mm
Allowable
Clearance between Standard dimension Standard clearance
1 clearance Replace
rotor and shaft
90 0.056 to 0.105 0.111
PC138USLC-10 60-53
Cab mount and cab tipping stopper
Cab mount and cab tipping stopper (PC138-K138-034-K-00-A)
60-54 PC138USLC-10
Work equipment
Work equipment (PC138-L410-034-K-00-A)
PC138USLC-10 60-55
Work equipment
60-56 PC138USLC-10
Work equipment
Unit: mm
Criteria
No. Item Standard Tolerance Standard Allowable Remedy
dimension Shaft Hole clearance clearance
Clearance between
mounting pin and -0.030 +0.143 0.093 to Replace pin
1 70 0.8 or bushing
bushing of revolving -0.100 +0.063 0.243
frame and boom
Inside diameter of hole
to insert bushing on +0.054 Build up by
2 boom side at joint of 85 — — — welding, then
revolving frame and 0 work
boom
Clearance between
3 70 0.8 or bushing
bushing of boom and -0.100 +0.070 0.229
arm
+0.054 Build up by
to insert bushing on arm — — —
4 85 welding, then
side at joint of boom and 0 work
arm
Clearance between
5 60 0.8 or bushing
bushing of arm and -0.080 +0.074 0.209
bucket
+0.046 Build up by
6 75 welding, then
side at joint of arm and 0 work
bucket
Clearance between -0.030 +0.133 0.105 to Replace pin
7 mounting pin and 60 0.8 or bushing
bushing of arm and link -0.080 +0.075 0.213
+0.046 Build up by
8 75 welding, then
side at joint of arm and 0 work
link
Clearance between -0.030 +0.132 0.105 to
9 mounting pin and 65 0.8
bushing of links -0.080 +0.075 0.212
Clearance between
mounting pin and -0.030 +0.130 0.108 to
10 60 0.8 Replace pin
bushing of link and -0.080 +0.078 0.210 or bushing
bucket
Clearance between
mounting pin and -0.030 +0.190 0.120 to
11 70 1.5
bushing of track frame -0.100 +0.090 0.290
and blade
PC138USLC-10 60-57
Work equipment
Unit: mm
Criteria
Greasing Width of boss Width of hinge Remedy
No. Item Standard
interval Standard Standard
Tolerance Tolerance clearance
dimension dimension
0 +3.0
561 565 4.5 to 7.5
-0.5 +0.5
Joint of L12: Insert plastic shim 2.0 mm thick (1). Adjust by combining
revolving metallic shims 2.0 mm thick (1), 1.0 mm thick (1), and 0.5 mm
12 thick (1)
frame and
boom 500 hours R12: Insert plastic shim 2.0 mm thick (1) Adjust
clearance to
a Be sure to insert one plastic shim 2.0 mm thick (1) each on 0.5 mm or
the right and left boom sides. less by using
(*1) +3 shims
80 ±1.2 81.5 0.3 to 5.7
Joint of 0
13 revolving L13: —
frame and
boom 500 hours R13: Adjust by combining shims 2.0 mm thick (1) and 1.0 mm
cylinder thick (1).
0
420 — — —
Joint of -0.5
boom and L14: Insert shim 1.0 mm thick (2)
14 boom Adjust
500 hours R14: Insert shim 1.0 mm thick (2)
cylinder clearance to
a Insert shims on both sides of pin evenly. 1.0 mm or
+1 less by using
Joint of 80 ±1.2 81.5 0.3 to 3.7 shims
0
15 boom and L15: —
arm cylinder 500 hours
R15: Insert shim 1.0 mm thick (1)
-0.2 +0.5 Adjust
Joint of 226 226 0.2 to 1.2 clearance to
-0.7 0
16 boom and 0.5 mm or
L16: Adjust by using shim 1.0 mm thick (1) or 0.5 mm thick (1)
arm 500 hours less by using
R16: — shims
+1
Joint of arm 80 ±1.2 81.5 0.3 to 3.7
0
17 cylinder and L17: — Adjust
arm 500 hours clearance to
R17: Adjust by using shim 2.0 mm thick (1) or 1.0 mm thick (2)
1.0 mm or
+1
Joint of arm 75 ±1.2 76.5 0.3 to 3.7 less by using
0 shims
18 and bucket L18: —
cylinder 500 hours
R18: Insert shim 1.0 mm thick (1)
+1.0 +2.2
258 262 3.0 to 7.7 Adjust
-1.5 0
clearance to
Joint of arm L19: —
19 0.5 mm or
and bucket (*2) R19: Adjust by combining shims 1.0 mm thick (8) and 0.5 mm less by using
100 hours thick (4). shims
60-58 PC138USLC-10
Work equipment
Unit: mm
Criteria
Greasing Width of boss Width of hinge Remedy
No. Item Standard
interval Standard Standard
Tolerance Tolerance clearance
dimension dimension
0
222.5 — — —
–0.5
Joint of arm
20 L20: Adjust by combining shims 2.0 mm thick (1) and 1.0 mm
and link
500 hours thick (1)
R20: —
— — — — — Adjust
L21: — clearance to
Joint of
21 1.0 mm or
links 500 hours R21: Adjust by combining shims 2.0 mm thick (1) and 1.0 mm less by using
thick (1) shims
0
259 261 ±1 1.0 to 3.1
-0.1
Joint of link
22 L20: Adjust by combining shims 2.0 mm thick (1) and 1.0 mm
and bucket
500 hours thick (2)
R20: —
0 +1
Joint of 80 85 5.0 to 7.0
-1 0
23 track frame
L23: Insert shim 1.0 mm thick (4)
and blade 500 hours
R23: —
Joint of +2 Adjust
80 ±1.2 83 1.8 to 6.2 clearance to
blade and 0
24 blade L24: — 1.0 mm or
cylinder 500 hours less by using
L24: Insert shim 1.0 mm thick (2) shims
Joint of +1
80 ±1.2 85 3.8 to 7.2
track frame 0
25 and blade
L25: Insert shim 1.0 mm thick (4)
cylinder 500 hours
R25: —
*1: The criteria are for the R.H. boom cylinder. The shim adjustment position of the L.H. boom cylinder is
reverse to R.H.
*2: Use split-type iron shims.
a The number in ( ) after each shim thickness indicates the number of prepared shim.
PC138USLC-10 60-59
Work equipment
Dimensions of arm (PC138-L412-034-K-00-A)
60-60 PC138USLC-10
Work equipment
Unit: mm
Tolerance
No. Measuring point Standard dimension
Shaft Hole
-0.030 +0.100
1 — 70
-0.100 0
+1.0
Arm side 81.5
2 0
Cylinder head side 80 ±1.2
+0.5
Boom side 226
0
3
-0.2
Arm side 226
-0.7
-0.030 +0.100
4 — 70
-0.100 0
5 — 264 ±2.0
6 — 213.5 ±1.0
7 — 640.6 ±0.5
8 — 2,491 —
9 — 2,101.9 ±1.5
10 — 290.4 ±0.5
11 — 487 ±0.2
12 — 415 ±0.5
13 — 374.9 —
14 — 1,246.2 —
-0.030 +0.200
15 — 60
-0.080 0
0
Link side 259
16 -0.1
Bucket side 261 ±1.0
-0.030 +0.200
17 — 60
-0.080 0
0
Bare arm 226
-0.5
18
+1.0
Arm with bushing fitted 258
-1.5
Min. 1,378 —
19
Max. 2,263 —
PC138USLC-10 60-61
Work equipment
Dimensions of bucket (PC138-LBK0-034-K-00-A)
60-62 PC138USLC-10
Work equipment
Unit: mm
No. Measuring point Standard dimension Tolerance
1 — 371.3 ±0.5
2 — 51.6 ±0.5
3 — 97.9 dig. —
4 — 374.9 —
5 — 1,231.6 —
6 — 190.2 —
7 — 5 dig. —
8 — 0 dig. —
+0.2
9 — 60
0
10 — 64 —
+0.25
11 — 80
0
12 — 261 ±1.0
13 — 50 —
14 — 85 —
+1.0
15 — 380
0
16 — 18 —
17 — 110 —
18 — 130 —
19 — 132 —
20 — 108 —
+2.0
21 — 274
0
22 — 51 —
23 — 34 —
24 — 106.7 —
25 — 127.3 —
26 — 74 —
27 — 68 —
PC138USLC-10 60-63
Boom cylinder
Boom cylinder (PC138-L541-034-K-01-A)
Unit: mm
Clearance between dimension Shaft Hole clearance clearance Replace
1 piston rod and bushing bushing
-0.030 +0.259 0.093 to
70 0.435
-0.076 +0.063 0.335
Clearance between -0.030 +0.190
piston rod support shaft 0.120 to
2 70 1.0
and bushing -0.100 +0.090 0.290
Replace pin
Clearance between or bushing
-0.030 +0.190 0.120 to
3 cylinder bottom support 70 1.0
shaft and bushing -0.100 +0.090 0.290
Tightening torque of
4 172 ± 24.5 Nm {17.5 ± 2.5 kgm}
cylinder head bolt
5 294 ± 29.4 Nm {30.0 ± 3.0 kgm} Retighten
cylinder piston
6 cylinder piston lock 58.9 to 73.6 Nm {6.0 to 7.5 kgm}
screw
60-64 PC138USLC-10
Arm cylinder
Arm cylinder (PC138-L950-034-K-00-A)
Unit: mm
-0.030 +0.279 0.095 to
75 0.455
-0.076 +0.065 0.355
2 70 1.0
and bushing -0.100 +0.090 0.290
Replace pin
-0.030 +0.190 0.120 to
4 270 ± 39 Nm {27.5 ± 4.0 kgm}
cylinder head bolt
5 294 ± 29.4 Nm {30.0 ± 3.0 kgm}
cylinder piston
Tightening torque of Retighten
screw
7 83.4 to 102.9 Nm {8.5 to 10.5 kgm}
plug
PC138USLC-10 60-65
Bucket cylinder
Bucket cylinder (PC138-LCD0-034-K-00-A)
Unit: mm
-0.030 +0.250 0.085 to
65 0.426
-0.076 +0.055 0.326
2 65 1.0
and bushing -0.080 +0.070 0.250
Replace pin
-0.030 +0.170 0.100 to
4 172 ± 24.5 Nm {17.5 ± 2.5 kgm}
cylinder head bolt
5 294 ± 29.4 Nm {30.0 ± 3.0 kgm} Retighten
cylinder piston
screw
60-66 PC138USLC-10
Blade cylinder
Blade cylinder (PC138-LRL1-034-K-00-A)
(Blade specification)
Unit: mm
-0.030 +0.279 0.095 to
75 0.455
-0.076 +0.065 0.355
2 70 1.0
and bushing -0.100 +0.090 0.290
Replace pin
-0.030 +0.190 0.120 to
4 270 ± 39 Nm {27.5 ± 4.0 kgm}
cylinder head bolt
5 294 ± 29.4 Nm {30.0 ± 3.0 kgm} Retighten
cylinder piston
screw
PC138USLC-10 60-67
Blade cylinder
60-68 PC138USLC-10
SHOP MANUAL
HYDRAULIC EXCAVATOR
PC138USLC-10
Model Serial Number

10
80 Appendix
9 80 Appendix
PC138USLC-10 80-1
80 Appendix
Table of contents

80 Appendix...................................................................................................................................... 80-1
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
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
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
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
80-2 PC138USLC-10
80 Appendix
Precautions for refrigerant
Air conditioner components (ALL-K500-001-K-02-A)
Precautions for refrigerant (ALL-K512-012-K-00-A)
k Collect the refrigerant (air conditioner gas: R134a) from the air conditioner circuit before
disconnecting the air conditioner hoses to replace the air conditioner unit or condenser, the air
conditioner compressor, receiver drier, etc.
a Ask a qualified person for collecting, adding and filling operations of the refrigerant (air conditioner gas:
R134a). (Only registered person can work.)
a Never release the refrigerant (R134a) to the atmosphere.
k If refrigerant gas (R134a) gets in your eyes, you may lose your sight. And if it touches your skin,
you may suffer from frostbite. Put on protective eyeglasses, gloves and working clothes with long
sleeves while collecting the refrigerant or filling the air conditioner circuit with the refrigerant.
PC138USLC-10 80-3
80 Appendix
Air conditioner component
Air conditioner component (PC138-K500-04D-K-00-A)
80-4 PC138USLC-10
80 Appendix
1. Compressor
2. Condenser
3. Modulator (with desiccating agent)
4. Hot water piping
5. Hot water return piping
6. Refrigerant piping
7. Dual pressure switch
8. Sight glass
9. Outside air temperature sensor
10. Air conditioner unit
11. Recirculation air filter
12. Fresh air filter
13. Machine monitor
14. Sunlight sensor
A. Front vent
B. Rear vent
C. Foot area vent
D. Defroster vent
PC138USLC-10 80-5
80 Appendix
E: Recirculation air inlet

F: Fresh air inlet
Specifications (PC138-K500-030-K-00-A)
Refrigerant R134a
Refrigerant refill amount (g) 800 ± 50
80-6 PC138USLC-10
80 Appendix
Configuration and function of refrigeration cycle
Configuration and function of refrigeration cycle (ALL-K500-042-K-00-A)
Cycle Compression Condensation Expansion Evaporation

(Component) (Compressor) (Condenser) (Expansion valve) (Evaporator)
In operator's cab In operator's cab
Engine
Location compartment Front of radiator (Built in air conditioner (Built into air
unit) conditioner unit)
Circulates Lowers temperature
By evaporating
refrigerant gas and Condenses and pressure of
refrigerant, absorb
increases its refrigerant to refrigerant liquid and
heat from the air
temperature and discharge heat gas for easy
around the evaporator,
Function pressure so that it absorbed in evaporation with
and cools the
can be liquefied evaporator. throttle. Controls flow
surrounding air.
easily in condenser. (condensation of rate, too.
(Evaporation of
(Compression of refrigerant) (Throttle action of
refrigerant)
refrigerant) refrigerant)
Gas o gas Gas o liquid Liquid, gas o gas
State of Liquid o liquid, gas
refrigerant Adiabatic Constant pressure Constant pressure
Adiabatic expansion
compression change change
PC138USLC-10 80-7
80 Appendix
Outline of refrigeration cycle
Outline of refrigeration cycle (ALL-K500-04A-K-00-A)
• The refrigerating cycle performs the following four processes. The refrigerant is liquefied and gasified
repeatedly while it is circulated in the cycle.
Compression (Compressor)
• The compressor sucks in the refrigerant that has been vaporized in the evaporator and compresses it into
a state where it can be easily liquefied at the ambient temperature.
• The gaseous refrigerant sucked into the compressor cylinder is compressed to a temperature and
pressure at which it can be easily liquefied when cooled to the ambient temperature.
Condensation (Condenser)
• The condenser cools and liquefies the high pressure and high-temperature gaseous refrigerant sent from
the compressor.
• The heat released to the outside from the condenser is called condensation heat.
• The amount of condensation heat is the sum total of the heat absorbed by the evaporator from the air in
the cab and the quantity of the work applied (the value converted into a heat quantity) by compression of
the compressor.
• The refrigerant liquefied in the condenser is dehydrated in the modulator and cooled further in the sub-cool
section to increase the cooling efficiency.
• In the compression cycle, the gaseous refrigerant and liquid refrigerant coexist.
• The temperature (condensation temperature) and the pressure (condensation pressure) at which the
gaseous refrigerant is liquefied are proportional to each other.
(The condensation pressure varies depending on the condensation temperature of the refrigerant)
Expansion (Expansion valve)

• The expansion valve reduces the liquid refrigerant pressure to a level where liquid refrigerant can be
easily evaporated by the throttle action (*1).
• The action of reducing the liquid refrigerant pressure to a level where it can be easily evaporated before it
is sent to the evaporator is called expansion.
• The expansion valve, which reduces the refrigerant pressure, also adjusts the refrigerant flow rate
simultaneously.
• The quantity of the liquid refrigerant that can be evaporated in the evaporator depends on the amount of
heat (refrigeration load) to be removed under the specific evaporation temperature (evaporation pressure).
• The expansion valve controls the refrigerant feed rate so that the optimum quantity of liquid refrigerant is
supplied to the evaporator.
*1: Throttle action
• If there is a narrow section in the passage through which liquid is flowing at a constant rate, a resistance to
the flow will be generated.
The liquid expands when it passes through the narrow section and rushes into the passage where the
sectional area is larger, and consequently, its pressure and temperature are reduced.
• No heat is transferred from or to the outside during the throttle action.
Evaporation (Evaporator)
• The evaporator evaporates the liquid refrigerant (superheated vapor).
• The refrigerant evaporates, while absorbing an amount of heat necessary for evaporation (evaporation
heat) from the air around the cooling fins (air in the cab).
• After the heat has been removed, the cooled air is sent into the cab by the blower fan, reducing the
temperature inside the cab.
• The mist refrigerant that has been sent from the expansion valve coexists with the evaporated refrigerant
in the evaporator
• The temperature (evaporation temperature) and the pressure (evaporation pressure) at which the liquid
refrigerant is evaporated are proportional to each other.
• The compressor sucks in the evaporated refrigerant in order to keep the pressure level in the evaporator
as low as possible so that the liquid refrigerant can be evaporated at a much lower temperature.
Relationship between refrigerant and defective air conditioning

• The refrigerant circulates in the refrigeration circuit while repeating the refrigeration cycle to expel the heat
from inside the cab.
80-8 PC138USLC-10
80 Appendix
Outline of refrigeration cycle
• If there is an insufficient quantity of refrigerant, all of it will be evaporated while it is passing through the
evaporator. This causes evaporator efficiency to deteriorate, which will result in defective air conditioning.
• If there is excessive refrigerant, not all of it will be evaporated and part of it will be sucked into the
compressor in liquid form, which will cause the compressor to compress the liquid and may damage the
components.
• If water gets into the refrigeration circuit, it will freeze at a small hole in the expansion valve, lower the
refrigerant flow, and may result in defective air conditioning.
PC138USLC-10 80-9
80 Appendix
Air conditioner unit
Air conditioner unit (PC138-K540-041-K-00-A)
80-10 PC138USLC-10
80 Appendix
A: Refrigerant inlet (from condenser)

B: Refrigerant outlet (to compressor)
C: Hot water inlet
D: Hot water outlet
1. Evaporator
2. Heater core
3. Expansion valve
4. Blower fan and blower motor
5. Air mix servomotor
6. Air mix door
7. Vent (mode) changeover servomotor
8. Mode changeover door
9. FRESH/RECIRC air changeover servomotor
11. Power transistor
12. Evaporator temperature sensor
13. Inner sensor (inside air temperature sensor)
14. Recirculation air filter
a “Doors“ are sometimes called “dampers“.
Function (PC138-K540-042-K-00-A)
• The air conditioner unit consists of evaporator (1) and heater core (2), and is used to cool down or warm
up the air in the cab.
Temperature control
• When the temperature control switch on the machine monitor is operated, the set temperature data is sent
to the air conditioner controller that is located at the rear of the operator's seat. The air conditioner
controller controls air mix servomotor (5) to change the angle of air mix door (6) so that the set
temperature is reached
Over-cooling (Freezing) prevention

• Evaporator temperature sensor (12) varies the resistance of its resistor according to temperature.
• The air conditioner controller converts the change in resistance of evaporator temperature sensor (12) into
the change in voltage to determine the temperature of evaporator (1).
• The air conditioner controller performs control to prevent freezing of the evaporator (1) by operating the
compressor clutch relay (*) to stop the compressor.
*: See "Parts and connectors layout" for details regarding the compressor clutch relay.
Air flow adjustment

• When the air flow adjusting switch on the machine monitor is operated, the set air flow data is sent to the
air conditioner controller. The air conditioner controller controls blower motor (4) by using power transistor
(11) in order to adjust the air flow.
Vent (mode) changeover

• When a vent switch on the machine monitor is operated, mode data is sent to the air conditioner controller.
The air conditioner controller controls vent (mode) changeover servomotor (7) to adjust the opening and
closing angles of mode changeover doors so that the selected vents are available.
FRESH/RECIRC air changeover

• When the FRESH/RECIRC air selector switch on the machine monitor is operated, the set data of
FRESH/RECIRC air changeover is sent to the air conditioner controller. The air conditioner controller
controls FRESH/RECIRC air changeover servomotor (9) to open or close FRESH/RECIRC air
changeover door (10).
PC138USLC-10 80-11
80 Appendix
Automatic mode of air conditioner

• Inside air temperature sensor (13) detects the temperature inside operator's cab based on changes in
resistance. The air conditioner controller converts the change in resistance of inside air temperature
sensor (13) into the change in voltage to determine the room temperature.
The air conditioner controller checks the voltage of inside air temperature sensor (13) and controls the
room temperature so that it matches the setting made on the machine monitor.
The air conditioner controller also takes into consideration data from the sunlight sensor and the outer
sensor (outside air temperature sensor) when adjusting the room temperature.
Functions of major components (ALL-K540-001-K-00-A)
a For details of the numbers in the following sentence, see “Air conditioner unit”.
Evaporator (ALL-K549-042-K-00-A)
• Evaporator (1) is cooled by the low-pressure, low-temperature refrigerant gas being sent from expansion
valve (3).
• Air from blower motor (4) is cooled and dehumidified when passing through the evaporator fins.
Heater core (ALL-K547-042-K-00-A)

• Heater core (2) is warmed by the hot water (engine coolant) being sent from the engine. Air from blower
motor (4) is warmed when passing through fins of the heater core (2).
Evaporator temperature sensor (PC138-K5FF-042-K-00-A)

• Evaporator temperature sensor (12) is installed to evaporator (1) with the holder. Its resistance changes in
accordance with the temperature change of the evaporator. The air conditioner controller determines the
temperature of evaporator (1) from voltage changes of evaporator temperature sensor (12) to prevent
freeze of the evaporator.
Servomotor (ALL-K5D2-042-K-00-A)
a Servomotors are used to adjust the temperature (air mix) and to perform vent (mode) changeover.
• When a switch on the machine monitor is operated, the air conditioner controller applies 24V power
between servomotor terminal B (6) and servomotor terminal A (7). (Rotation direction switches according
to the polarity of supply voltage.) )
• The servomotor contains a variable resistor, and its resistance value changes as the motor rotates.
• The air conditioner controller applies a voltage of 5 V to the variable resistor and determines the motor
rotation angle from the potential difference.
• When the door (damper) reaches the position specified by each switch, the air conditioner controller stops
the supply of current to the servomotor, then the corresponding door stops.
• When the air conditioner controller cannot recognize the potential difference that corresponds to the
command to the servomotor, it generates a air conditioner failure code to inform the machine monitor of
failure in air conditioner system. Failure code [879EMC] or [879FMC] is displayed on the electrical system
failure record screen of the machine monitor.
a FRESH/RECIRC air changeover servo motor does not feature a variable resistance, and therefore,
does not have a self-diagnosis function.
80-12 PC138USLC-10
80 Appendix
a Do not try to drive a servomotor by supplying power directly between servomotor terminals (6) and (7)
during inspection.
Expansion valve (ALL-K548-041-K-00-A)
A: When evaporator outlet temperature is high

B: When evaporator outlet temperature is low
C: From capacitor (high-pressure refrigerant)
D: To compressor (low-pressure refrigerant)
1. Expansion valve
1a. Needle valve
1a-1. Diaphragm
1a-2. Thermoprobe
1b. Spring
2. Refrigerant gas
3. Evaporator
Outline
• The expansion valve(1) converts high-pressure and high-temperature liquid refrigerant from the receiver
drier to low-pressure, low-temperature misty refrigerant through the throttle action.
• It controls the flow rate of refrigerant by changing the level of throttling depending on the temperature in
the cab.
Structure (ALL-K548-042-K-00-A)
• Box-type expansion valve (1) consists of needle valve (1a), spring (1b), etc.
• Refrigerant gas (2) is sealed in the diaphragm chamber (hatched area) outside diaphragm (1a-1) of
needle valve (1a).
• The opening level of needle valve (1a) is determined based on the balance between the reaction force
exerted by spring (1b) in a rightward direction, and force (Fg) of refrigerant gas (2) pushing needle valve
(1a) through diaphragm (1a-1) in a leftward direction.
PC138USLC-10 80-13
80 Appendix
• The refrigerant flow rate flowing from the receiver drier to evaporator (3) is determined based on the
opening level of needle valve (1a).
Operation (ALL-K548-044-K-00-A)
• Thermoprobe (1a-2) senses the refrigerant temperature after it passes through the evaporator (3).
• After the refrigerant passes through evaporator (3), its temperature is transferred to the refrigerant gas (2)
in the diaphragm chamber (hatched area) through the thermoprobe (1a-2).
• The pressure of the refrigerant gas (2) sealed in the diaphragm chamber (hatched area) changes in
response to the temperature change of the thermoprobe (1a-2), which therefore changes the force (Fg)
pushing the needle valve (1a).
• The opening level of the needle valve (1a) is determined based on the balance between the reaction force
exerted by the spring (1b) in a rightward direction, and the force (Fg) of the refrigerant gas (2) pushing the
needle valve (1a) through the diaphragm (1a-1) in a leftward direction.
• The temperature of the air blown out of the air vent is adjusted depending on the flow rate of refrigerant
circulating in the evaporator (3).
When evaporator (3) outlet temperature is high: [When not cooled yet: Condition (A) in the figure]
• The pressure of the refrigerant gas (2) in the diaphragm chamber is high and the volume is increased.
• The force (Fg) of the refrigerant gas (2) pushing the needle valve (1a) is increased, and the needle valve
(1a) moves leftward.
• As a result, the opening level of the needle valve (1a) is increased and the refrigerant flow rate to the
evaporator (3) is increased to improve cooling capacity. (Condition (A) in previous figure)
When evaporator (3) outlet temperature is low: [When cooled already: Condition (B) in the figure]
• The pressure of the refrigerant gas (2) in the diaphragm chamber is low and the volume is decreased.
• The force (Fg) of the refrigerant gas (2) pushing the needle valve (1a) is reduced, and the needle valve
(1a) is moved rightward by the reaction force of spring (1b).
• The opening level of the needle valve (1a) is reduced and the refrigerant flow rate to the evaporator (3) is
reduced to lower the cooling capacity. (Condition (B) in previous figure)
80-14 PC138USLC-10
80 Appendix
Dual pressure switch
Dual pressure switch (ALL-K5FG-044-K-00-A)
a The dual pressure switch is mounted on the air conditioner hose under the floor.
• The dual pressure switch turns “OFF“ when the refrigerant circuit pressure becomes abnormally low or
abnormally high.
• When the dual pressure switch turns "OFF", the air conditioner controller turns the compressor clutch
relay “OFF“. As a result, the compressor's magnet clutch is released and air conditioner components are
protected.
Function (ALL-K5FG-042-K-00-A)
a LA or lower: Abnormally low pressure

a HA or higher: Abnormally high pressure
LA: 0.20 MPa {2 kg/cm2}
LB: 0.02 MPa {0.2 kg/cm2}
HA: 3.14 MPa {32 kg/cm2}
HB: 0.59 MPa {6 kg/cm2}
PC138USLC-10 80-15
80 Appendix
Air conditioner controller
Air conditioner controller (ALL-K5G4-041-K-00-A)
a See "System Diagrams" for details regarding input/output signals.
80-16 PC138USLC-10
80 Appendix
Compressor
Compressor (ALL-K590-041-K-00-A)
A: Refrigerant inlet (from air conditioner unit)

B: Refrigerant outlet (to condenser)
1. Pulley
2. Magnetic clutch
3. Relief valve
Specification (ALL-K590-044-K-00-A)
Number of cylinders - Bore x Stroke (mm) 10 - 32 x 20.8

Piston capacity (cc/rev) 157.3
Max. allowable speed (rpm) 6,000
Compressor oil DENSO: ND-OIL8 (For R134a)
Compressor oil refill capacity (cc) 180
Function (ALL-K590-042-K-00-A)
• The compressor circulates the refrigerant and compresses the gaseous refrigerant from the evaporator
into a misty refrigerant at high pressure and high temperature so that it will be easily regenerated
(liquefied) at the normal temperature.
• Calling into account of the evaporator temperature and refrigerant pressure, the air conditioner controller
activates magnetic clutch (2) built in the compressor.
• When magnetic clutch (2) is engaged, the power of the engine rotates the compressor shaft along with
pulley (1) to drive the compressor.
PC138USLC-10 80-17
80 Appendix
Air conditioner condenser
Air conditioner condenser (ALL-K580-041-K-00-A)
A: Refrigerant inlet (from compressor)

B: Refrigerant outlet (to air conditioner unit)
1. Condenser
2. Modulator
3. Desiccating agent
4. Filter
5. Seal cap
6. O-ring
7. Snap ring
Specification (ALL-K580-044-K-00-A)
Fin pitch (mm) 4.0

Total heat dissipation surface (m2) 3.58
Max. working pressure (MPa{kg/cm2}) 3.53{36}
Weight of desiccating agent (g) 290
Function (ALL-K580-042-K-00-A)
• The condensation section of condenser (1) cools and liquefies the high-pressure and high-temperature
misty refrigerant sent from the compressor.
• The sub-cooling section of condenser (1) further cools the liquid refrigerant that came through modulator
(2) to enhance the cooling efficiency.
• Modulator (2) stores high-pressure and high-temperature liquid refrigerant sent from the condenser. If
bubbles are mixed in the liquid refrigerant depending on heat radiation condition of the condenser, the
refrigerant is liquefied completely.
• Filter (4) and desiccating agent (3) built in modulator (2) eliminate foreign substances in the circulation
circuit and water in the refrigerant.
80-18 PC138USLC-10
80 Appendix
Air conditioner condenser
a If its cooling fins are crushed or clogged with dirt and dust, heat exchange efficiency lowers. Accordingly,
the condenser cannot liquefy the refrigerant entirely. The circuit pressure in the refrigerant cycle increases
resulting in unnecessary load on the engine and poor cooling effect. Take care not to crush the fins in
handling and daily maintenance of the condenser.
a Refer to "Desiccant replacement procedure" when replacing desiccating agent (3) in modulator (2).
PC138USLC-10 80-19
80 Appendix
Sunlight sensor
Sunlight sensor (ALL-K5FH-041-K-00-A)
1. Connector
2. Sensor
Function (ALL-K5FH-042-K-00-A)
• The sunlight sensor is mounted on top of the machine monitor.

• It detects the strength of incident sunlight and sends signals to the air conditioner controller.
• When performing automatic air conditioning, the air conditioner controller controls the blower motor and
the air mix servomotor with the data of the sunlight sensor in order to adjust the temperature and air flow.
80-20 PC138USLC-10
80 Appendix
Outer temperature sensor (outside air temperature
sensor)
Outer temperature sensor (outside air temperature sensor) (ALL-K55C-041-K-00-A)
1. Connector
2. Sensor
Function (PC138-K55C-042-K-00-A)
• The outside air temperature sensor is installed on the top of the battery.
• The outside air temperature sensor has feature of change in resistance by temperature change, therefore,
can detect the ambient temperature.
• The air conditioner controller determines the ambient temperature by converting the changes in the
resistance of the outer sensor resistor into voltage changes.
• Only when the air conditioner is on AUTO mode, the air conditioner controller controls the blower motor
and the air mix servomotor with the data of the outer sensor in order to adjust the temperature and air flow.
PC138USLC-10 80-21
80 Appendix
Procedure for testing and troubleshooting
Procedure for testing and troubleshooting (ALL-K500-422-K-00-A)
The air conditioner is provided with self-diagnosis functionality in order to provide for inspection of its main
components. Specifically, the operation of sensors and servomotors can be examined.
If a troubled section is detected, every part of that section must be inspected.
1. After basic check, find the troubled section according to the detected trouble of the air conditioner.
2. Narrow down the sections with the self-diagnosis function (See “Check with self-diagnosis”).
If, however, the entire air conditioner unit fails to operate, inspect for problems with the supply of power to
the air conditioner controller and with CAN communication between the machine monitor and the air
conditioner controller.
If any part of the air conditioner unit can operate, it will indicate that the air conditioner controller is
receiving power normally and that CAN communication between the machine monitor and the air
conditioner controller is normal.
3. After finding out the troubled section, inspect the component parts in that section and repair the troubled
part.
Basic testing and troubleshooting sequence
*1: By error display or abnormal display on "Electrical Systems" screen on the machine monitor.
*2: Simple checking of refrigerant volume through sight glass.
Start up the engine, set the air conditioner switch to ON, and then wait for five minutes before proceeding with
the inspection.
A) If the continuous stream of bubbles can be seen, the system contains insufficient refrigerant.
B) If the bubbles can be seen intermittently, the refrigerant volume is sufficient.
80-22 PC138USLC-10
80 Appendix
Procedure for testing and troubleshooting
C) If no bubbles can be seen (i.e., the liquid is perfectly clear), the system contains too much refrigerant or no
refrigerant at all.
The above should be treated as general guidelines as certain exceptions do exist.
See "Troubleshooting with gauge pressure" and use gauge pressure to determine whether or not the
condition is normal.
S: Sight glass condition
R: Receiver drier internal condition
LR: Liquid refrigerant
*3: If any leakage of refrigerant is occurring, the compressor oil circulating within the air conditioner circuit will
definitely be leaking from the same point.
In such a case, retighten in accordance with the table of retightening torques from "Precautions for
disconnecting and connecting air conditioner piping."
*4: Start the engine and perform the check with the air conditioner switch set to ON.
PC138USLC-10 80-23
80 Appendix
Circuit diagram and arrangement of connector pins
Circuit diagram and arrangement of connector pins (PC138-K500-051-K-01-A)
80-24 PC138USLC-10
80 Appendix
Circuit diagram and arrangement of connector pins
a Diffuser servomotor means vent (mode) changeover servomotor.

a SERVOMOTOR OF INSIDE/OUTSIDE AIR means FRESH/RECIRC air changeover servomotor.
a Frost sensor means evaporator temperature sensor.
PC138USLC-10 80-25
80 Appendix
System diagram
System diagram (PC220-K5F0-051-K-00-A)
a This air conditioner unit is auto temperature control type.
80-26 PC138USLC-10
80 Appendix
Input and output signals of the air conditioner controller
Input and output signals of the air conditioner controller (ALL-K5G4-03C-K-00-A)
Controller connector: AMP 025 - 32PM

Wiring harness connector: ACECU
AMP025 - 32PF
Input/Output
Pin No. Symbol Signal name
signal
1 +Bback Backup power supply Input
2 – (*1) –
3 SS Sunlight sensor Input
4 THOUT Outside air temperature sensor Input
5 THF Evaporator temperature sensor Input
6 THI Inside air temperature sensor Input
7 POT5 V Servomotor potentiometer power supply (5 V) Output
8 BWFB Blower feedback signal Input
9 PTRB Power transistor control signal Output
10 CAN_H CAN communication signal (H) Input/output
11 CAN_L CAN communication signal (L) Input/output
12 – (*1) –
13 MRFA Fresh/recirculated air servomotor terminal A Output
14 MRFB Fresh/recirculated air servomotor terminal B Output
15 MAMA Air mix servomotor terminal A Output
16 MAMB Air mix servomotor terminal B Output
17 +24 V 24 V power supply Input
18 – (*1) –
19 SAM Air mix servomotor potentiometer signal Input
20 SVI Vent (mode) changeover servomotor potentiometer signal Input
21 PRESS SW Dual pressure switch Input
22 – (*1) –
23 – (*1) –
24 – (*1) –
25 GNDS Sensor GND Input
26 GND GND Input
27 – (*1) –
28 – (*1) –
29 RLCC Compressor clutch relay Output
30 – (*1) –
31 MV1A Vent (mode) changeover servomotor terminal A Output
32 MV1B Vent (mode) changeover servomotor terminal B Output
Function (ALL-K5G4-042-K-00-A)
• Operation of air conditioner controller

1. Performing CAN communication with the machine monitor, the air conditioner controller controls the air
conditioner unit by inputting switches associated with air conditioning.
2. The air conditioner controller controls three servomotors located inside the air conditioner unit in order to
adjust the temperature (airmix), perform vent (mode) changeover, and perform FRESH/RECIRC air
changeover.
3. The air conditioner controller controls the ON/OFF condition of the compressor clutch relay (i.e., a switch
for activating the compressor).
4. The air conditioner controller controls the air flow volume using the power transistor.
a The power transistor has an overcurrent prevention fuse in it.
PC138USLC-10 80-27
80 Appendix
Input and output signals of the air conditioner controller
5. The air conditioner controller detects the evaporator temperature using the evaporator temperature
sensor.
6. In order to prevent freezing of the evaporator, the air conditioner controller controls the compressor by
turning the compressor clutch relay ON and OFF.
a When the dual pressure switch detects a pressure abnormality (i.e., turns OFF), the air conditioner
controller turns the compressor clutch relay OFF, and therefore, the compressor stops operating.
7. When performing automatic air conditioning, the air conditioner controller controls the inside (air)
temperature to the set temperature and adjust the air flow according to the data from the sunlight sensor,
the outside air temperature sensor, and the inside air temperature sensor.
8. The air conditioner controller has the self-diagnosis function. If any abnormality is detected, the controller
notifies it to the machine monitor by the CAN communication. Then, failure code [879***] is displayed on
the "Electrical Systems" screen of the electrical system on the machine monitor.
80-28 PC138USLC-10
80 Appendix
Air conditioner unit (PC138-K500-04D-K-02-A)
1. Foot door
3. Inner sensor (inside air temperature sensor)
PC138USLC-10 80-29
80 Appendix
4. Expansion valve
A: Recirculation air port
B: Fresh air port
ACECU: Control amplifier connector

[1]: Blower (fan) motor connector
[2]*: Power transistor (PTR) connector
[3]*: Blowing out (Mode) servomotor connector
[4]*: Temperature control (air mix) servomotor connector
[5]: FRESH/RECIRC air changeover servomotor connector
[6]: Inner sensor (inside air temperature sensor) connector
[7]: Evaporator temperature sensor connector
*: Although shown in the circuit diagram, these connectors cannot be seen from outside.
a Connectors [1], [5], and [7] also cannot be seen with the air conditioner unit assembled.
80-30 PC138USLC-10
80 Appendix
Parts and connectors layout
Parts and connectors layout (PC138-K500-055-K-00-A)
• Three fuses related to the air conditioner are located in the fuse box at the rear left of the operator's seat.
• The air conditioner unit is installed in the rear cover at the rear side of the operator's seat.
k Park the machine on a level surface, lower the work equipment to the ground so that it is stable,
k Turn the battery disconnect switch to “OFF“ position, and remove the key.
a Note the connector numbers and installed positions before disconnecting wiring harnesses and hoses.
Item to be
Connector No. Remarks Location
referred
AC01 Intermediate connector Rear left of the cab 2.
AC02 Intermediate connector Rear left of the cab 2.
AC03 Air conditioner compressor Engine 7.
ACECU Air conditioner controller Rear left of the cab 2.
CM01* Machine monitor Front side of the cab 5.
CM02 Machine monitor Front side of the cab 5.
F01 Fuse box Rear left of the cab 1.
P17 Dual pressure switch Under cab 6.
P18 Outside air temperature sensor Cooling unit 8.
P31 Sunlight sensor Machine monitor 4.
R21 Relay Rear left of the cab 2.
[1] Blower motor Air conditioner unit –
[2] Power transistor Air conditioner unit 3.
[3] Vent (mode) servomotor Air conditioner unit –
[4] Temperature control (air mix) servomotor Air conditioner unit –
[5]* FRESH/RECIRC air changeover servomotor Air conditioner unit 3.
[6]* Inside air temperature sensor Air conditioner unit 3.
[7]* Evaporator temperature sensor (frost sensor) Air conditioner unit 3.
*: Connectors not identified in the troubleshooting
Details (PC138-K500-04D-K-01-A)
1. Fuses in fuse box F01

Open the cover of fuse box at the rear left of the operator's seat.
• No. 10 (20 A): Fuse for power supply to blower (fan) and air conditioner compressor
• No. 14 (5 A): Fuse for air conditioner unit, air conditioner controller and primary side power supply of
electromagnetic clutch relay of air conditioner compressor
• No. 19 (5 A): Fuse for power supply (backup power supply) to air conditioner controller

1) Remove holder cup (1).
PC138USLC-10 80-31
80 Appendix
2) Remove bracket (2).

3) Remove cover (3).
4) Remove electrical components sub plate (4) and tilt it toward the front of machine.
• AC01: Air conditioner unit connector for connecting machine monitor and CAN communication
(communication lines shared with engine controller and pump controller), compressor, pressure switch,
sunlight sensor, ambient temperature sensor, and relay (primary side)
• AC02: Air conditioner unit connector for power supply, ground, and relay (secondary side)
• ACECU: Air conditioner controller connector
• R21: Air conditioner compressor solenoid clutch relay connector
80-32 PC138USLC-10
80 Appendix

1) Remove floor mat (6).
2) Remove covers (7) to (9).
3) Remove pin (P1) and remove ducts (10) to (13).

a Pin (P1) is also provided under duct (11).
4) Using bolt B, raise seat bracket (14).

• A/C U: Air conditioner unit
[6]: Inside air temperature sensor connector
PC138USLC-10 80-33
80 Appendix
4. Sunlight sensor
P31: Sunlight sensor connector
5. Machine monitor
• CM01 to CM04: Machine monitor connector
a Connector CM04: (for camera connection)
6. Dual pressure switch

1) Remove cover (1).
80-34 PC138USLC-10
80 Appendix
2) Remove toolbox (2).
• P17: Dual pressure switch connector

7. Air conditioner compressor
a Open the engine hood.
• ACC: Air compressor
• AC03: Air conditioner compressor connector
• E: Ground
PC138USLC-10 80-35
80 Appendix
8. Outer temperature sensor (outside air temperature sensor)

Open the cover on the rear left side of the machine.
P18: Outside air temperature sensor connector
80-36 PC138USLC-10
80 Appendix
Testing air leakage (duct)
Testing air leakage (duct) (ALL-K5D0-001-K-00-A)
k Place the machine on a level ground, lower the work equipment to the ground and stop the engine.
k Turn the battery disconnect switch to the OFF position and remove the key.
Testing (PC138-K5D0-360-K-00-A)
1. Pull up front window assembly (1) to the ceiling and lock it.
a Make sure that the assembly is certainly locked.
2. Remove front lower window (2).
4. Remove cover (4) first, and then remove cover (5).
6. Remove cap (7).

a Disconnect connector P31 of the sunlight sensor from rear of cover (8).
8. Remove cup holder (9).

10.Remove rear cover (11).
11.Remove duct cover (12).
PC138USLC-10 80-37
80 Appendix
12.Check the duct.

1) Rear duct
Check duct (13) for disconnection.
2) Check defroster duct (14) and face duct (15) for disconnection.
3) Check defroster duct (16) for disconnection.
4) Fresh air duct

Check pin (P) and duct (17) for disconnection.
80-38 PC138USLC-10
80 Appendix
PC138USLC-10 80-39
80 Appendix
Testing with self-diagnosis function
Testing with self-diagnosis function (ALL-Q19Y-001-K-00-A)
Testing outline (ALL-Q19Y-360-K-00-A)
The air conditioner controller performs various self-diagnosis such as inside air temperature sensor, outside
air temperature sensor, evaporator temperature sensor, temperature control system, vent (mode) changeover
system, sunlight sensor, and refrigerant pressure with the dual pressure switch. If an error is detected on the
temperature control system, vent (mode) changeover system, or refrigerant, the machine monitor
momentarily shows a warning screen and then "Air conditioner system state monitor" lights up continuously.
a The machine monitor displays the system state monitor "!" when an error occurs in the communication
between the machine monitor and the air conditioner controller.
a The system performs self-diagnosis of various sensors. If any failure is detected, a failure code is
displayed on the “Electrical Systems Abnormality Record“ screen in the service mode of the machine
monitor.
a Once a failure is detected in the self-diagnosis, the error condition is not canceled even if the failed part
returns to normal.
Turning the starting switch “OFF“ clears a failure.
a FRESH/RECIRC air changeover servomotor is not checked in the self-diagnosis.
How to open the electrical system abnormality record screen in service mode
of the machine monitor (PC220-Q19Y-100-K-00-A)
• Overview of machine monitor operating procedure
Standard screen
Press [1], [2], and [3] in this order while holding down O [4].
Service menu (Mode)
Press O [F3] twice. Press [F6].
03 Abnormality Record
Press O [F3] once. Press [F6].
02 Electrical systems abnormality record screen
• Detailed description of machine monitor operating procedure
1. On the normal operation screen, while pressing number key [4], press [1], [2], and [3] in this order.
2. Validate the selection by pressing [F6].
80-40 PC138USLC-10
80 Appendix
3. Press [F3] twice on the Service Menu screen to select 03 “Abnormality Record“.
5. Press [F3] once on the Failure Record screen to select 02 “Electrical System Abnormality Record“.
a For details, see the failure code list related to air conditioner.
Failure code Failure (Displayed on screen) Remarks
Air Conditioner Inner Sensor Open
879AKA
Circuit
*
Air Conditioner Inner Sensor Short
879AKB
Circuit
Air Conditioner Outer Sensor Open
879BKA
Circuit
Air Conditioner Outer Sensor Short
879BKB
Circuit
879CKA Ventilating Sensor Open Circuit
*
879CKB Ventilating Sensor Short Circuit
Sunlight Sensor Open or Short
879DKZ
Circuit
PC138USLC-10 80-41
80 Appendix
Failure code Failure (Displayed on screen) Remarks

879EMC Ventilation Damper Abnormality *
879FMC Air Mix Damper Abnormality *
879GKX Refrigerant Abnormality
Air Conditioner Model Selection
DAZ9KQ Abnormality See Chapter 40, "Troubleshooting
CAN2 Disconnection (Air by failure code" **
DAZQKR Conditioner ECU)
*: Troubleshooting cannot be performed while the controller is mounted on the machine since the connector
cannot be checked.
**: Troubleshooting is not performed by the air conditioner unit but by the machine monitor.
a The air conditioner inner sensor means the inside (air) temperature sensor.
a The air conditioner outer sensor means the outside (air) temperature sensor.
a The ventilating sensor means the evaporator temperature sensor (frost sensor).
a The ventilation damper means the vent (mode) changeover damper (door).
a The air mix damper means the temperature adjustment (air mix) damper (door).
80-42 PC138USLC-10
80 Appendix
Testing vent (mode) changeover
Testing vent (mode) changeover (ALL-K5FR-001-K-00-A)
Testing (PC138-K5FR-360-K-00-A)
The vents (mode) are switched by changing the angle of the 2 doors (dampers) at the inside of the air
conditioner unit and the door (damper) inside the duct. The angles of the doors (dampers) are changed by
using a mode changeover servo motor but this motor cannot be seen from the outside. The mode changeover
servo motor is still not visible from the outside even when the air conditioner unit is removed. Therefore,
visually check the opening and closing of the foot door (damper) and the lever angle of the defroster/face
changeover door (damper) in the duct.
a To reset the self-diagnosis system (to clear the "A/C Controller Error" displayed on the air conditioner
screen of the machine monitor), the starting switch must be turned OFF (While "A/C Controller Error" is
displayed with self-diagnosis system, no signals are output to the servomotor).
1. Remove front window (1).
3. Remove covers (3) to (5).
4. Check the connection of cable (6) and lever (L).

(Check whether it is securely in place.)
5. Check clip (7) for coming off.
6. Start the engine and turn on the air conditioner power.
7. Press the face and defroster selector switch on the air conditioner screen of the machine monitor and
visually check that lever (L) moves smoothly between the face mode (F) and defroster mode (D) shown in
the figure.
8. Press the foot and defroster selector switch on the air conditioner screen of the machine monitor and
visually check that foot door (8) opens and closes.
9. Stop the engine.
PC138USLC-10 80-43
80 Appendix
Testing FRESH/RECIRC air changeover
Testing FRESH/RECIRC air changeover (ALL-K5D2-001-K-00-A)
Testing (PC138-K5D2-360-K-00-A)
FRESH/RECIRC air is selected by changing the FRESH/RECIRC air changeover door (damper) angle in the
air conditioner unit with the FRESH/RECIRC air changeover servo motor. Check the opening and closing
operation of the door visually.
a The system does not have self-diagnosis function for FRESH/RECIRC air changeover servo motor.
1. Open cover (1) and remove outside air filter (2).
2. Start the engine and turn on the air conditioner power.

3. Press FRESH/RECIRC air selector switch on the machine monitor's air conditioner control screen, and
then check the opening and closing operation of FRESH/RECIRC air changeover door (4) by using mirror
(3).
a As the connector for FRESH/RECIRC air changeover servo motor is located on the floor of the air
conditioner unit, its connection condition cannot be checked.
80-44 PC138USLC-10
80 Appendix
Testing sunlight sensor
Testing sunlight sensor (PC220-K5FH-001-K-00-A)
Testing (PC220-K5FH-360-K-01-A)
1. Remove the machine monitor cover. For details, see "Testing air leakage (duct)", Steps 6 and 7.
2. Check connector P31 at the rear of the sunlight sensor. (Check whether the connector is coming off.)
3. Disconnect connector P31, remove the sunlight sensor, and measure the voltage between the terminals
on the sensor side using a circuit tester in voltage range.
• Approximate voltage of sunlight sensor unit
0.55 V: Direct sunlight
0.45 V: Cloudy
0.4 V: Indoors
PC138USLC-10 80-45
80 Appendix
Testing (dual) pressure switch for refrigerant
Testing (dual) pressure switch for refrigerant (PC220-K5FG-001-K-00-A)
Testing (PC138-K5FG-360-K-00-A)
• If [879GKX] "Refrigerant Abnormal" is displayed by the self-diagnosis (on "03 Air-conditioning System"
screen of "Abnormality Record" in the machine monitor), test the dual pressure switch connector P17.
• To reset the self-diagnosis system (detection of abnormality), the starting switch must be turned OFF.
• The dual pressure switch is ON when the refrigerant pressure is normal, and OFF when it is abnormal.
a If ambient temperature drops to 0 °C or below, refrigerant pressure will also subsequently decrease.
Accordingly, there is a possibility that the dual pressure switch is OFF. In such a case, the dual pressure
switch unit is not defective but normal.
1. Referring to “Parts and connectors layout“ “6. Dual pressure switch“, remove the tool box.
2. Disconnect the dual pressure switch connector P17.
3. Check if the resistance between the switch-side terminals of connector P17 are shorted (ON). (If not
shorted (OFF), dual pressure switch is detecting an abnormal refrigerant pressure.)
a If the dual pressure switch is OFF, attach a pressure gauge to the high-pressure line of the air
conditioner compressor and check the refrigerant pressure. See "Connection of service tool" and
"Troubleshooting with gauge pressure".
a If the refrigerant pressure is normal, the dual pressure switch is defective.
• (Dual) pressure switch
LA: 0.20 MPa {2 kg/cm2}

LB: 0.02 MPa {0.2 kg/cm2}
HA: 3.14 MPa {32 kg/cm2}
HB: 0.59 MPa {6 kg/cm2}
k When replacing the dual pressure switch, refrigerant must be collected in advance.
80-46 PC138USLC-10
80 Appendix
Testing (dual) pressure switch for refrigerant
a If resistance between the switch-side terminals from connector P17 is shorted (ON), perform
"Troubleshooting for compressor and refrigerant system".
PC138USLC-10 80-47
80 Appendix
Testing relays
Testing relays (PC220-K5FE-001-K-00-A)
Testing (PC138-K5FE-360-K-00-A)
a If air conditioner compressor is normal (air is cooled), skip the test.

• Compressor clutch relay R21:
Turns the air conditioner compressor (clutch) ON/OFF.
a See Step 2 in "Parts and connectors layout".
1. Check the condition of contact of connector R21. (Check whether it is securely in place.)
2. Turn the starting switch ON (engine stopped), turn on the main power to the air conditioner, then turn the
air conditioner switch ON. The compressor relay is turned on if the air conditioner status is normal. Check
that a click is heard.
a The air conditioner controller will not turn on the compressor clutch relay in the following cases.
• When the evaporator temperature is 3 °C or below (indicated by the evaporator temperature sensor)
• When the dual pressure switch detects abnormal pressure (the dual pressure switch is OFF)
• Checking relay unit

a Since no T-adapter is available, it is impossible to check the relay while the voltage is applied to the coil
actually.
Compressor clutch relay (R21), air conditioner compressor connector (AC03)
• Coil resistance between terminals (1) and (2) is 300 to 500 z
• While voltage (20 to 30 VDC) is not applied between terminals (1) (+) and (2), terminals (3) and (4) are
connected.
• While voltage (20 to 30 VDC) is applied between terminals (1) (+) and (2), terminals (3) and (5) are
connected.
80-48 PC138USLC-10
80 Appendix
Troubleshooting chart 1
Troubleshooting chart 1 (PC220-3840-421-A-00-A)
Numbers in T represent the item numbers in the troubleshooting quick reference table.
1. Lowered cooling performance
2. Lowered heating performance
PC138USLC-10 80-49
80 Appendix
Troubleshooting chart 2 (PC220-3840-421-A-01-A)
1. During cooling, the blower fan motor does not operate or the rotation speed does not match the air flow
setting.
Probable cause Check method Remedy
Check the connector for disconnection. Repair broken parts
Wire breakage or defective and connect
connection See "Parts and connectors layout". correctly
Operate the fan switches in order and check the fan
Defective blower fan motor speed. Replace
See "Air conditioner unit".
Defective power transistor Operate the fan switches in order and check the fan
Replace
(PTR) speed.
2. During cooling, the blower fan motor is normal but the flow of air is very light.
Large duct resistance Check the filter for clogging and the duct for crushing. Repair
Air leakage through duct Check duct joints.
Repair
joints See "Testing air leakage (duct)".
Obstruction at evaporator Check evaporator for stain and obstruction Remove obstruction
inlet and clean
Defective evaporator Evaporator is frozen.
temperature sensor, Sensor fixing clip inspection, sensor contaminated
defective contact of Repair or replace
evaporator temperature Inspect the air conditioner hose around the pressure
switch for frost.
sensor, defective expansion
valve* (when freezing has advanced even further)
*: The evaporator temperature sensor and expansion valve are located inside the air conditioner unit.
3. Pressure abnormality (high-pressure/low-pressure) during cooling.
Repair leaking part,
then charge with
Insufficient refrigerant
proper quantity of
Check the refrigerant volume through sight glass. refrigerant again
Specifically, perform checking with the gauge manifold Collect refrigerant,
connected. then fill up with
Overcharge with refrigerant
proper quantity of
refrigerant again
Normal pressure range
Low-pressure: Approx. 0.13 to 0.2 MPa {1.3 to 2.0 kg/
cm2 }
Judgment by pressure at See Troubleshooting
inlet/outlet of compressor High pressure: Approx. 1.5 to 1.7 MPa {15 to 17 kg/cm2 with gauge pressure
}
Temperature in operator's cab: 30 to 35 °C , Engine
speed: Approx. 1,500 rpm
80-50 PC138USLC-10
80 Appendix
4. During cooling, the compressor will not operate smoothly, or at all.

a See "Troubleshooting of compressor system (Air is not cooled)".
Troubled
part
Deflection of belt is large.
Compressor See "Checking and adjusting air
belt
Slack of belt conditioner compressor belt tension" in Adjust tension
the "Testing and adjusting" in Chapter
30.
Trouble in compressor Slip of belt Repair or replace
Compressor Insufficient compressor oil See "Handling
Heating of compressor
Seizing on compressor compressor oil".
Drop of battery voltage Slip of clutch Charge battery
Open or short circuit in coil Inspect with multimeter (10 to 20 z) Replace
Magnet
Check ground cable and joints.
clutch Wire breakage or defective
connection of ground wire See "Troubleshooting for compressor Repair
and refrigerant system".
Defective compressor clutch
Relay See "Testing relays" Replace
relay
See
Refrigerant Low/high pressure (Operation See "Troubleshooting with gauge "Troubleshooting
pressure of pressure switch) pressure". with gauge
pressure".
See "Troubleshooting for compressor
Pressure and refrigerant system".
Defective pressure switch Replace
switch See "Testing refrigerant (dual) pressure
switch".
5. During heating, blower fan motor is normal but air flow alone is insufficient.
Large duct resistance Check the filter for clogging and the duct for crushing. Repair
Air leakage through duct Check the duct joints by referring to "Testing air leakage
Repair
joints (duct)."
Clogging of heater core fins Check heater core fins for clogging Clean
6. Engine coolant temperature or volume abnormalities during heating or cooling
Low engine coolant Warm up engine, and then check engine coolant
temperature temperature Find out cause
Low engine coolant level Check coolant level in radiator Add coolant
Insufficient circulation of Check engine coolant piping for clogging.
engine coolant Bleed air and correct
(Hose, pipe and core)
The connection of IN and
OUT heater hoses is in Check the destination of heater hoses Correct
reverse.
7. Fan speed abnormalities during cooling
See "Replacing fan belt" in "Testing and adjusting" in
Fan speed is low Replace
Chapter 30.
PC138USLC-10 80-51
80 Appendix
8. Other abnormalities
Probable cause Check method Remarks
Temperature cannot be Select manual mode and change temperature setting.
controlled
Vent (mode) changeover is Common to cooling
See "Testing vent (mode) changeover".
not possible. and heating
FRESH/RECIRC air cannot
See "Testing FRESH/RECIRC air changeover".
be changed over
Excessive compressor oil See "Handling of compressor oil".
Cooling only
Water leakage into the cab Clogging of drain hole
80-52 PC138USLC-10
80 Appendix
Information in troubleshooting table
Information in troubleshooting table (ALL-5170-421-A-03-A)

Information in troubleshooting table
Failure Failure symptom that appears on machine
Related information Information on occurred failure or troubleshooting
Cause Procedure, measuring location, criteria and remarks
[Information described]
• Procedure
• Measuring location
1
a "Between A and B" denotes measuring voltage or resistance, etc.
Probable cause of failure between A and B.
(Perform troubleshooting • Criteria to determine probable causes
according to these.) • Remarks for judgment of Good or No good
[Notes on troubleshooting]
2 (1) pin number description sequence and tester lead handling
For troubleshooting, connect the plus (+) and minus (-) tester leads
as shown below unless otherwise specified.
• Connect the plus (+) lead to a pin or harness indicated in the
front.
• Connect the minus (-) lead to a pin or harness indicated in the
rear.
3 Defective — (2) Example of troubleshooting done by testing multiple items
a Normal in 1 but abnormal in 2
At this time, "Defective component" shown at left 3 is applied.
a If a wiring harness is burnt, replace it.

[Defective wiring harness]
• Open circuit
Connection of connector is defective or wiring harness is broken.
• Ground fault
A harness not to be connected to the ground (earth) circuit comes into contact with the ground (earth)
circuit or chassis accidentally.
• Hot short circuit
A harness not to be connected to the power (24V) circuit comes into contact with the power (24V) circuit
accidentally.
• Short circuit
An independent wire in the harness abnormally comes into contact with another independent wire. (poor
insulation at connector and others)
Related circuit diagram

This is the extracted circuit diagram related to failure
• Indicates connector No., and pin No.
• See "Circuit diagram and arrangement of connector pins" and "Parts and connectors layout" for
connector location
• The circuit diagram shows the size and colors of wires.
W: White, B: Black, R: Red, G: Green, Y: Yellow, L: Blue, V: Purple, P: Pink, O: Orange, Br: Brown, Gr:
Gray, Sb: Sky blue, Lg: Light green, Dg: Dark green, Ch: Dark brown
a When there are two colors
Example: WY: Yellow line on white background
a The number before the wire color indicates the wire size.
• N.C.: Normally closed (Normally ON)
• [1], [2], ... are numbers of unlabeled connectors.
• The arrow (io) indicates their rough installation position on the machine.
PC138USLC-10 80-53
80 Appendix
Failure code list related to air conditioner
Failure code list related to air conditioner (PC138-K500-441-K-00-A)

Applicable History
Failure Failure (Displayed on screen) Action
compo- category Remarks
code level
nent
Air Conditioner Inner Sensor Electrical Troubleshooting cannot be
879AKA Open Circuit MON –
system performed while the controller
is mounted on the machine
Air Conditioner Inner Sensor Electrical
879AKB MON – since the connector cannot
Short Circuit system
be checked.
Air Conditioner Outer Sensor Electrical
879BKA Open Circuit MON –
system
Air Conditioner Outer Sensor Electrical
879BKB MON –
Ventilating Sensor Open Electrical Troubleshooting cannot be
879CKA MON –
Circuit system performed while the controller
Ventilating Sensor Short Electrical
879CKB MON – since the connector cannot
Circuit system
be checked.
Sunlight Sensor Open or Electrical
879DKZ MON –
Ventilation Damper Electrical Troubleshooting cannot be
879EMC Abnormality MON L01 system performed while the controller
Electrical
879FMC Air Mix Damper Abnormality MON L01 since the connector cannot
system
be checked.
Electrical
879GKX Refrigerant Abnormality MON L01 system
Air Conditioner Model Electrical
DAZ9KQ Selection Abnormality MON –
system See Chapter 40,
"Troubleshooting by failure
CAN2 Disconnection (Air Electrical
DAZQKR Conditioner ECU) MON L01 code" **
system
**: Troubleshooting is not performed by the air conditioner unit but by the machine monitor.
a The air conditioner inner sensor means the inside (air) temperature sensor.
a The air conditioner outer sensor means the outside (air) temperature sensor.
a The ventilating sensor means the evaporator temperature sensor (frost sensor).
a The ventilation damper means the vent (mode) changeover damper (door).
a The air mix damper means the temperature adjustment (air mix) damper (door).
a Troubleshooting for the troubles which do not display failure codes
• Troubleshooting for power supply system (Air conditioner does not operate)
• Troubleshooting for compressor and refrigerant system (Air is not cooled)
• Troubleshooting for blower motor system (No air comes out or air flow is abnormal)
• Troubleshooting for FRESH/RECIRC air changeover
80-54 PC138USLC-10
80 Appendix
Failure code [879AKA] A/C Inner Sensor Open Circuit
Failure code [879AKA] A/C Inner Sensor Open Circuit (PC138-879AKA-400-A-Z0-A)
Action level Failure code Open circuit in air conditioner inside air temperature sensor
Failure
― 879AKA (Machine monitor system)
Detail of • Air conditioner controller detected open circuit in inside (air) temperature sensor.
failure
• The air conditioner controller sends information about the inside (air) temperature sensor
Action of open circuit to the machine monitor via CAN communication.
controller • Stops the air conditioner if it is in automatic mode.
• The air conditioner does not operate in automatic mode because of a short circuit in the
Problem on air conditioner inside air temperature sensor.
machine (The air conditioner can be operated in manual mode)
Related
• Check whether this failure code is displayed on the electrical system abnormality record
information
screen in service mode of the machine monitor.
Defective inside air 2. Disconnect connector [6].
temperature sensor
1 Approx. 1.6
(Replacement of air Between connector [6] (male) (1) and 0 °C
kz
conditioner unit) Resistance (2)
Approx. 5
25 °C
kz
Defective air conditioner Air conditioner controller may be defective. (Since this is an internal defect,
controller
Defective air conditioner Air conditioner unit may be defective. (Since this is an internal defect,
unit
Circuit diagram related to air conditioner inside air temperature sensor
PC138USLC-10 80-55
80 Appendix
Failure code [879AKB] A/C Inner Sensor Short Circuit
Failure code [879AKB] A/C Inner Sensor Short Circuit (PC138-879AKB-400-A-Z0-A)
Action level Failure code Short circuit in air conditioner inside air temperature sensor
Failure
― 879AKB (Machine monitor system)
Detail of • Air conditioner controller detected short circuit in inside (air) temperature sensor.
failure
• The air conditioner controller sends information about the inside (air) temperature sensor
Action of short circuit to the machine monitor via CAN communication.
controller • Stops the air conditioner if it is in automatic mode.
• The air conditioner does not operate in automatic mode because of a short circuit in the
Problem on air conditioner inside air temperature sensor.
machine (The air conditioner can be operated in manual mode)
Related
information
Defective internal air 2. Disconnect connector [6].
sensor
1 Approx. 1.6
(Defective air Between connector [6] (male) (1) and 0 °C
kz
conditioner unit) Resistance (2)
Approx. 5
25 °C
kz
Defective air conditioner Air conditioner controller may be defective. (Since this is an internal defect,
controller
Defective air conditioner Air conditioner unit may be defective. (Since this is an internal defect,
unit
Circuit diagram related to air conditioner inside air temperature sensor
80-56 PC138USLC-10
80 Appendix
Failure code [879BKA] A/C Outer Sensor Open Circuit
Failure code [879BKA] A/C Outer Sensor Open Circuit (PC138-879BKA-400-A-Z0-A)
Action level Failure code Open circuit in air conditioner outside air temperature sensor
Failure
― 879BKA (Machine monitor system)
Detail of • An open circuit is detected in the air conditioner controller outside air temperature sensor
failure
• The air conditioner controller sends information about the outside air temperature sensor
Action of open circuit to the machine monitor via CAN communication.
controller • When the air conditioner is in Auto mode, the controller continues controlling the air
conditioner irrespective of any data received from the external air temperature sensor.
• Due to an open circuit in the outside air temperature sensor of the air conditioner, external
Problem on air temperature is not taken into consideration for the air conditioner in Auto mode.
machine (The air conditioner is not affected in the manual mode)
• For each connector, see "Parts and connectors layout".
Related • Since T-adapter is not provided for the connector ACECU of the air conditioner controller
information and the pin size is small, use the intermediate connector for troubleshooting (T-adapter is
also not provided for the intermediate connector, however, the pin size is larger).
• When replacing the air conditioner wiring harness between connector ACECU of the air
conditioner controller and the intermediate connector, you must replace the entire air
conditioner unit.
Defective outside air 2. Disconnect connector P18.
1 temperature sensor Approx. 1.7
Resistance Between P18 (male) (1) and (2) 25 °C
kz
2. Disconnect connector AC01.
2 wiring harness a If normal, the resistance is the same as above.
Approx. 1.7
Resistance Between AC01 (female) (3) and (4) 25 °C
kz
3 (wire breakage or 2. Disconnect connectors P18 and AC01.
defective contact of Between AC01 (female) (4) and P18A (female) (1) Max. 1 z
Between AC01 (female) (3) and P18 (female) (2) Max. 1 z
If no failures are found by the above checks, the air conditioner controller may
Defective air conditioner be defective. (Since this is an internal defect, troubleshooting cannot be
4
controller performed.)
If no failures are found by the above checks, the air conditioner unit may be
Defective air conditioner defective. (Since this is an internal defect, troubleshooting cannot be
5
unit performed.)
PC138USLC-10 80-57
80 Appendix
Failure code [879BKA] A/C Outer Sensor Open Circuit
Circuit diagram related to air conditioner outside air temperature sensor
80-58 PC138USLC-10
80 Appendix
Failure code [879BKB] A/C Outer Sensor Short Circuit
Failure code [879BKB] A/C Outer Sensor Short Circuit (PC138-879BKB-400-A-Z0-A)
Action level Failure code Short circuit in air conditioner outside air temperature sensor
Failure
― 879BKB (Machine monitor system)
Detail of • The air conditioner controller detected short circuit in the outside air temperature sensor.
failure
• The air conditioner controller sends information about the short circuit of the outside air
Action of temperature sensor to the machine monitor via CAN communication.
controller • When the air conditioner is in Auto mode, the controller continues controlling the air
conditioner irrespective of any data received from the external air temperature sensor.
• Due to a short circuit in the outside air temperature sensor of the air conditioner, outside
Problem on air temperature is not taken into consideration for the air conditioner in Auto mode.
machine (The air conditioner is not affected in the manual mode)
conditioner unit.
Defective outside air 2. Disconnect connector P18.
1 temperature sensor Approx. 1.7
Resistance Between P18 (male) (1) and (2) 25°C
kz
2. Disconnect connector AC01.
2 wiring harness a If normal, the resistance is the same as above.
Approx. 1.7
Resistance Between AC01 (female) (3) and (4) 25°C
kz
Short circuit in wiring 1. Turn starting switch to OFF position.
3 2. Disconnect connectors P18 and AC01.
harness
Between AC01 (female) (3) and (4), or between
Resistance P18 (female) (1) and (2) Min. 1 Mz
harness 2. Disconnect connectors P18 and AC01.
4
(Contact with ground Between ground and AC01 (female) (4) or P18
5
6
unit performed.)
PC138USLC-10 80-59
80 Appendix
Failure code [879BKB] A/C Outer Sensor Short Circuit
Circuit diagram related to air conditioner outside air temperature sensor
80-60 PC138USLC-10
80 Appendix
Failure code [879CKA] Ventilating Sensor Open Circuit
Failure code [879CKA] Ventilating Sensor Open Circuit (D155-879CKA-400-A-00-A)
Action level Failure code Open circuit in evaporator temperature (frost) sensor
Failure
- 879CKA (Machine monitor system)
Detail of • Air conditioner controller detected open circuit in evaporator temperature (frost) sensor.
failure
• The air conditioner controller sends information about the evaporator temperature (frost)
Action of sensor open circuit to the machine monitor via CAN communication.
controller • Stops the air conditioner.
Problem on • The air conditioner does not operate due to an open circuit in the evaporator temperature
machine (frost) sensor.
Related screen in service mode of the machine monitor.
information • Troubleshooting cannot be performed since the connector portion of the evaporator
temperature (frost) sensor cannot be checked while the air conditioner unit is installed on
the machine.
Defective air conditioner Air conditioner controller may be defective. (Since this is an internal
1 defect, troubleshooting cannot be performed.)
controller
Air conditioner unit may be defective. (Since this is an internal defect,
2 Defective air conditioner unit troubleshooting cannot be performed.)
PC138USLC-10 80-61
80 Appendix
Failure code [879CKB] Ventilating Sensor Short Circuit
Failure code [879CKB] Ventilating Sensor Short Circuit (D155-879CKB-400-A-00-A)
Action level Failure code Short circuit in evaporator temperature (frost) sensor
Failure
- 879CKB (Machine monitor system)
Detail of • Air conditioner controller detected short circuit in evaporator temperature (frost) sensor.
failure
• The air conditioner controller sends information about the evaporator temperature (frost)
Action of sensor short circuit to the machine monitor via CAN communication.
controller • Stops the air conditioner.
Problem on • The air conditioner does not operate due to a short circuit in the evaporator temperature
machine (frost) sensor.
• Method of reproducing failure code: Starting switch ON
information • Troubleshooting cannot be performed since the connector portion of the evaporator
temperature (frost) sensor cannot be checked while the air conditioner unit is installed on
the machine.
controller
80-62 PC138USLC-10
80 Appendix
Failure code [879DKZ] Sunlight Sensor Open or Short
Circuit
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit (PC138-879DKZ-400-A-

Z0-A)
Action level Failure code Sunlight Sensor Open or Short Circuit

Failure
― 879DKZ (Machine monitor system)
Detail of • The air conditioner controller detects open circuit or short circuit in the sunlight sensor
failure
• The air conditioner controller sends information about open or short circuit of the sunlight
Action of sensor to the machine monitor via CAN communication.
controller • When the air conditioner is on Auto mode, the controller continues controlling the air
conditioner neglecting data from the sunlight sensor.
• Due to an open circuit or a short circuit in the sunlight sensor for the air conditioner, the
Problem on amount of sunshine is not taken into consideration for the air conditioner in Auto mode.
machine (The air conditioner in manual mode is not affected by this failure.)
conditioner unit.
1. See "Testing sunlight sensor".
Direct Approx.
Defective sunlight sunlight 0.55 V
1 Approx.
sensor Voltage Between sunlight sensor terminals Cloudy
0.45 V
Approx. 0.4
Indoor
V
harness 2. Disconnect connector P31.
2 (Wire breakage or a See "Testing sunlight sensor".
defective contact of Between P31 (female) (1) and AC01 (female) (1) Max. 1 z
Between P31 (female) (2) and AC01 (female) (2) Max. 1 z
3
4
unit performed.)
PC138USLC-10 80-63
80 Appendix
Failure code [879DKZ] Sunlight Sensor Open or Short
Circuit
Circuit diagram related to sunlight sensor
80-64 PC138USLC-10
80 Appendix
Failure code [879EMC] Ventilation Damper Abnormality
Failure code [879EMC] Ventilation Damper Abnormality (D155-879EMC-400-A-00-A)
Action level Failure code Abnormality in vent (mode) changeover damper servomotor
Failure
L01 879EMC (Machine monitor system)
Detail of • Air conditioner controller judged from potentiometer voltage of servomotor that vent
failure (mode) changeover damper servomotor is not operating.
Action of • The air conditioner controller sends information about the abnormality in vent (mode)
controller changeover damper to the machine monitor via CAN communication.
Problem on • Vent (mode) cannot be changed but air conditioner can be operated.
machine
information • Troubleshooting cannot be performed since the connector portion of vent (mode)
changeover damper servomotor cannot be checked while the air conditioner unit is
installed on the machine.
controller
PC138USLC-10 80-65
80 Appendix
Failure code [879FMC] Air Mix Damper Abnormality
Failure code [879FMC] Air Mix Damper Abnormality (D155-879FMC-400-A-00-A)
Action level Failure code Abnormality in air mix (temperature control) damper
Failure servomotor
L01 879FMC
(Machine monitor system)
Detail of • The air conditioner controller judged from the potentiometer voltage of the servomotor that
failure the air mix (temperature regulation) damper servomotor is not operating.
Action of • The air conditioner controller sends information about the air mix damper abnormality to
controller the machine monitor via CAN communication.
Problem on • The air conditioner does not operate since temperature cannot be regulated.
machine
Related
information
• Troubleshooting cannot be performed since the connector portion of the air mix damper
servomotor cannot be checked while the air conditioner unit is installed on the machine.
controller
80-66 PC138USLC-10
80 Appendix
Failure code [879GKX] Refrigerant Abnormality
Failure code [879GKX] Refrigerant Abnormality (PC138-879GKX-400-A-Z0-A)
Action level Failure code Refrigerant (dual) pressure switch abnormality

Failure
L01 879GKX (Machine monitor system)
Detail of • Air conditioner controller detected that dual pressure switch was OFF (abnormal).
failure
• The air conditioner controller sends information about the refrigerant pressure abnormality
to the machine monitor via CAN communication.
Action of • The air conditioner controller turns OFF compressor clutch relay, since refrigerant
controller pressure is abnormal.
(The air compressor stops.)
Problem on • The air conditioner (for cooling) does not work.
machine
conditioner unit.
Cause Procedure, measuring location, criteria, and remarks
1. See "Testing (dual) pressure switch for refrigerant".
Defective refrigerant
1 (dual) pressure switch k Before replacing the dual pressure switch, be sure to collect
refrigerant. See "Precautions for refrigerant".
harness 2. Disconnect connectors AC01 and P17.
2 (Wire breakage or Between P17 (female) (1) and AC01 (female) (5) Max. 1 z
defective contact of Resistance Between P17 (female) (2) and ground
connector) Max. 1 z
a Looseness and rust of T06
3
4
unit performed.)
Circuit diagram related to (dual) pressure switch for refrigerant
PC138USLC-10 80-67
80 Appendix
A-1 Troubleshooting for power supply system (Air
conditioner does not operate)
A-1 Troubleshooting for power supply system (Air conditioner does not
operate) (PC138-FJ0-400-A-Z0-A)
Failure Air conditioner does not operate due to power supply system failure.
Problem on • [DAZQKR] is displayed on the operation screen of machine monitor.　
machine • No air blows out (Blower motor does not rotate).
• If failure code [DAZQKR] is displayed on the machine monitor, perform this
troubleshooting first.
a The machine monitor, engine controller, pump controller, and air conditioner controller are
connected via CAN communication.
• [DAZQKR] is displayed on the operation screen of machine monitor in the following
cases. 1) and 2) of these will be covered here.
1. The air conditioner controller is receiving no power.
2. The air conditioner controller is broken.
3. No communication is possible between the air conditioner controller and the machine
monitor.
a For 3), see failure code [DAZQKR].
• Turn the starting switch ON, and check whether failure code [DAZQKR] for an abnormality
Related in CAN communication is displayed. An abnormality in CAN communication refers to the
information state in which CAN communication between the air conditioner controller on the air
conditioner unit and the machine monitor is disabled.
• Referring to "Parts and connectors layout", check fuse No. 14 (5A) in fuse box F01 for
breakage.
• Ground cable of air conditioner is connected in machine wiring harness together with
electrical equipment of machine.
• In cases where fuses are blown when the A/C switch is pressed, see "Troubleshooting for
compressor and refrigerant system."
• Since T-adapter is not provided for the connector ACECU of the air conditioner controller
and the pin size is small, use the intermediate connector for troubleshooting (T-adapter is
conditioner unit.
Defective wiring 2. Turn the battery disconnect switch to OFF position.
1 harness (ground) 3. Disconnect connector AC02.
Between (1) (black) on harness side of connector
Resistance AC02 and chassis ground Max. 1 z

2 Blown fuse 2. Referring to "Parts and connectors layout", check fuse No. 14 (5A) in fuse
box F01 for breakage.
a If fuse described in Related information is blown, replace it.
Defective wiring 3. Disconnect connector AC02.
3
harness 4. Turn battery disconnect switch to ON position.
Between connector AC02 (female) (4) (blue) and 20 to 30 V
Voltage
(1) (black)
80-68 PC138USLC-10
80 Appendix
A-1 Troubleshooting for power supply system (Air
conditioner does not operate)

a If a fuse is blown again in the above test, perform the following procedure.
Ground fault in wiring 1.Turn starting switch to OFF position.
harness 2.Turn the battery disconnect switch to OFF position.
4 3.Disconnect connector AC02.
circuit) 4.Remove fuse No. 14 in fuse box F04.
Between ground and connector AC02 (female) (4)
Resistance (blue) or F01-14 Min. 1 Mz

2.Turn the battery disconnect switch to OFF position.
Open circuit in wiring 3.Disconnect connector AC02.
5
harness 4.Remove fuse No. 14 in fuse box F01.
Between connector AC02 (female) (4) (red) and
Resistance Max. 1 z
F01-14
Defective air conditioner Replace the air conditioner controller.
6
controller
Defective air conditioner If no failure is found by the above checks, the air conditioner unit may be
7
unit defective.
8
monitor
Circuit diagram related to power supply system
PC138USLC-10 80-69
80 Appendix
A-2 Troubleshooting for compressor and refrigerant
system (Air is not cooled)
A-2 Troubleshooting for compressor and refrigerant system (Air is not

cooled) (PC138-FKE-400-A-Z0-A)
Failure Air is not cooled due to compressor or refrigerant system failure.
• When engine is started and A/C switch is pressed on air conditioner screen of machine
Problem on monitor, air is not cooled as displayed on screen.
machine • Air conditioner compressor does not operate.
• Referring to inspection by self-diagnosis function, display the "Electrical Systems" screen
on the machine monitor to check whether an inappropriate refrigerant is being used by
confirming that failure code [879GKX] is displayed. If an inappropriate refrigerant is being
used, the compressor will not be turned on, and air will not be cooled.
a Abnormal refrigerant pressure indicates that "Signal ((21) of connector ACECU) from the
dual pressure switch is not grounded".
• In certain cases, the air conditioner will not turn on at 3 °C or lower (normal).
Related • When air does not come out, see "Troubleshooting of blower motor system".
information • For each connector and fuse, see "Parts and connectors layout".
a A T-adapter is provided only for the connector AC03.
conditioner unit.
a This troubleshooting is performed when failure code [879GKX] is
displayed on the "Electrical Systems" screen of the machine monitor.
See failure code [879GKX].
Defective dual pressure a In certain cases, the dual pressure switch may be operating normally and
1 switch system set to OFF position, therefore, if abnormality is indicated (i.e., switch OFF),
attach a pressure gauge to the air conditioner compressor and check the
refrigerant pressure. (See "Troubleshooting with gauge pressure.")
k Before replacing pressure switch, collect refrigerant.
2. Disconnect the connector AC03 from the air conditioner compressor and
connect a T-adapter to the male side.
Defective air conditioner a Ensure connection of air conditioner compressor ground cable (E).
2 compressor (See "Parts and connectors layout".)
Between connector AC03 (male) (1) and the
Approx. 15
Resistance chassis ground (i.e., air conditioner compressor coil
resistance) z
• Referring to "Testing relays", check sound when compressor clutch relay
is turned ON.
Clicking sound is heard: A
a When A above is abnormal and B below is abnormal and C is normal (if
the relay is normal), go to cause 4.
Defective compressor 2. Disconnect connector R21.
3 clutch relay (does not 3. Use a wire to short-circuit (3) (yellow) and (5) (blue) of connector R21
turn ON) (wiring harness side). (This forces the compressor to operate without
using the relay.)
Air is cooled: B
2. Disconnect connector R21 and troubleshoot in that condition.
Between R21 (male) (1) and (2) (coil Approx. 300
Resistance resistance) C
to 500 z
80-70 PC138USLC-10
80 Appendix

2. Disconnect connector R21.
a Make sure that result of check of cause 2 is normal (air conditioner
compressor is normal).
Between connector R21 (female) (5) and F01-10
Open circuit in wiring Max. 1 z
4 (Pressure switch is turned ON)
harness
Between connector R21 (female) (3) and chassis
Approx. 15
Resistance ground z
(Air conditioner compressor coil resistance)
Between F01-14 and AC01 (female) (7) 300 to 500
a Relay coil resistance z
Ground fault in wiring a If the fuse is not blown, skip troubleshooting.

5 2. Disconnect connectors AC03 and R21, and connect a T-adapter to the
circuit) female side of AC03.
Resistance Between AC03 (female) (1) and chassis ground Min. 1 Mz
2. Disconnect connectors AC01, AC02, and R21.
6 a Ensure that test result for cause 2 is normal.
harness
Between wiring harness side (2) of connector R21
Resistance and AC02 (female) (2), (3), and (4) Min. 1 Mz

2. Disconnect connector R21.
Defective air conditioner 3. Turn starting switch to ON position.
7 4. Display the air conditioner operation screen on the machine monitor and
controller
press the A/C switch.
Voltage Between connector R21 (female) (2) and ground Max. 1 V
Defective machine 1. Turn starting switch to ON position.
8 monitor 2. Display the air conditioner operation screen on the machine monitor.
(defective switch) Press A/C switch. "A/C ON" is displayed
9
unit defective.
PC138USLC-10 80-71
80 Appendix
Circuit diagram related to compressor and refrigerant system
80-72 PC138USLC-10
80 Appendix
A-3 Troubleshooting for blower motor system (No air
comes out or air flow is abnormal)
A-3 Troubleshooting for blower motor system (No air comes out or air
flow is abnormal) (PC138-FK3-400-A-Z0-A)
Failure No air comes out or air flow is abnormal due to blower motor system failure.
• LCD of machine monitor on air conditioner operation screen lights up normally but air
Problem on does not come out.
machine • Air flow does not match fan switch setting on air conditioner operation screen.
• This failure is not checked with self-diagnosis function.
• During cooling, if the air flow becomes abnormal after a certain time, the evaporator may
be frozen.
This may be due to the followings.
1. Defective compressor clutch relay (remains turned ON) (see Item 3-A of
"Troubleshooting for compressor and refrigerant system")
2. Evaporator temperature sensor mounting holder has come off (replace air conditioner
unit).
3. Improper adjustment of expansion valve (replace air conditioner unit)
• When air comes out, fuses and motor are normal, and failure of wiring harness is unlikely.
Related • For each connector and power transistor, see "Parts and connectors layout".
information • When air comes out but air flow is abnormal during heating, the power transistor is
defective. In this case replace the air conditioner unit. (The power transistor may also be
defective when no air comes out.)
a The power transistor and the blower motor cannot be replaced.
conditioner unit.
Defective fuse No. 10 in If fuse is blown, circuit probably has ground fault.
1
fuse box F01
harness 2. Disconnect connector AC02.
2 (wire breakage or 3. Remove fuse No. 10 in fuse box F01.
connector) Resistance Between AC02 (female) (2) and F01-10 Max. 1 z
3
(contact with ground 3. Remove fuse No. 10 in fuse box F01.
circuit) Resistance Between AC02 (female) (2) or F01-10 and ground Max. 1 z
4
5
unit defective.
PC138USLC-10 80-73
80 Appendix
A-3 Troubleshooting for blower motor system (No air
comes out or air flow is abnormal)
Circuit diagram related to blower motor system
80-74 PC138USLC-10
80 Appendix
A-4 Troubleshooting for FRESH/RECIRC air changeover
A-4 Troubleshooting for FRESH/RECIRC air changeover (PC138-FKF-400-A-Z0-A)
Failure FRESH/RECIRC air changeover does not work.

• When FRESH/RECIRC air selector switch of machine monitor is operated, recirculated or
Problem on fresh air does not change over.
machine (FRESH/RECIRC air changeover door (damper) does not rotate)
• FRESH/RECIRC air changeover is not checked with self-diagnosis function.
• Referring to "Testing FRESH/RECIRC air changeover", operate the FRESH/RECIRC air
selector switch and check operation of FRESH/RECIRC air changeover door (damper).
a The T-adapter is not prepared for the connector.
Related and the pin size is small, use the intermediate connector for troubleshooting (T-adapter is
information also not provided for the intermediate connector, however, the pin size is larger).
conditioner unit.
• Troubleshooting cannot be performed since the connector portion of the servomotor
cannot be checked while it is installed on machine.
Defective fuse No. 19 in If fuse is blown, circuit probably has ground fault.
1
fuse box F01.
2 (wire breakage or 3. Remove fuse No. 19 in fuse box F01.
connector) Resistance Between F01-19 and AC02 (female) (3) Max. 1 z

Between F01-19 and ground, or between AC02
circuit) Resistance (female) (3) and ground Max. 1 z
4
5
unit performed.)
Defective machine 1. Turn starting switch to ON position.
monitor 2. Display the air conditioner operation screen on the machine monitor.
6
(defective switch) Display of Recirc/Fresh
Press FRESH/RECIRC air selector switch. changes.
PC138USLC-10 80-75
80 Appendix
A-4 Troubleshooting for FRESH/RECIRC air changeover
Circuit diagram related to FRESH/RECIRC air changeover
80-76 PC138USLC-10
80 Appendix
Troubleshooting with gauge pressure
Troubleshooting with gauge pressure (PC220-3840-362-A-00-A)
Perform troubleshooting according to the high and low gauge pressures of the cooling cycle. For details, see
"Connection of service tool".
a The gauge pressure varies largely with the weather condition and operating condition of the machine.
Check the gauge pressure under the pressure measurement conditions.
• Pressure of high-pressure line is too high: Min. approx. 2.5 MPa {25 kg/cm 2}
• Pressure of high-pressure line is too low: Max. approx. 1 MPa {10 kg/cm 2}
• Pressure of low-pressure line is too high: Min. approx. 0.3 MPa {3 kg/cm 2}
• Pressure of low-pressure line is too low: Max. approx. 0.05 MPa {0.5 kg/cm 2}
a Dual pressure switch turns "OFF" to protect the air conditioner circuit if the pressure of the high-pressure
or low-pressure line is abnormal.
[Measurement condition for pressure]
Item Condition value
Ambient temperature 25 to 50 °C
Engine speed 1,500 rpm
Air conditioner switch ON
Fan switch HI
Set temperature Cool-Max
• Dual pressure switch
a The switch is normally "ON", and becomes "OFF" when it detects abnormal pressure for compressor
operation.
LA: 0.20 MPa {2 kg/cm2}

LB: 0.02 MPa {0.2 kg/cm2}
HA: 3.14 MPa {32 kg/cm2}
HB: 0.59 MPa {6 kg/cm2}
PC138USLC-10 80-77
80 Appendix
Indicated gauge pressure Cause Check method Remedy

Air conditioner cycle is operating normally.
If any problem (poor cooling) is recognized, the cause
is in other system.
Pressure is normal Pressure of high-pressure line: Approx. 1.5 to -1.7 ―
MPa {15 to 17 kg/cm2}
Pressure of low-pressure line: Approx. 0.13 to 0.2
MPa {1.3 to 2.0 kg/cm2}
Collect refrigerant, then fill
Bubbles can be seen
Insufficient refrigerant up with proper quantity of
through sight glass. *1, *3
refrigerant again. *2
Temperature difference is
recognized between inlet
Clogging of receiver drier and outlet pipes of Replace *2
receiver drier.
Tank is frosty.
Clogging of expansion Expansion valve is frosty. Clean or replace *2
valve
Gas leakage at
<Pressure of both high- Low-pressure line gauge Replace *2
thermoprobe of expansion
pressure and low- reads vacuum.
valve
pressure lines are too
Evaporator is frozen.
low>
Flow rate of refrigerant is Repair or replace
Low-pressure line gauge Defective evaporator
reduced due to freezing.
reads vacuum temperature sensor or Replace receiver drier.
defective contact of (If air conditioner is set to
sensor (coming off of Cool Max. and HI fan
up with proper quantity of
mounting clip) speed modes, later its
cooling performance
lowers.)
Piping between receiver
drier and compressor is
clogged or crushed.
Clogged or crushed piping Clean or replace *2
If clogged completely, low-
pressure line gauge reads
vacuum
Filling of too much
Connect gauge manifold. up with proper quantity of
refrigerant
Check condenser for dirt, Clean condenser, repair
Defective cooling of fins for clogging or fins, or repair or replace
condenser crushing, and cooling fan cooling fan *2
<Pressure of both high- for defective rotation.
pressure and low- Defective adjustment of
pressure lines are too expansion valve Bubbles can be seen
high> Replace *2
(Valve is excessively through sight glass. *3
opened.)
Evacuate air from air
Air sucked in cooling Bubbles can be seen conditioner and then fill up
cycle parts through sight glass. *3 with proper quantity of
80-78 PC138USLC-10
80 Appendix
Indicated gauge pressure Cause Check method Remedy

<Pressure of high- Piping between Remarkable temperature Clean inside of cooling
pressure line is too high compressor and difference is recognized cycle parts or replace
and that of low-pressure condenser is Clogged or across clogged part. them.*2
line is too low> crushed.
Pressures of high-
pressure and low-
<Pressure of high- pressure lines are almost
Defective compressor
pressure line is too low the same while
(compression trouble of Replace *2
and that of low-pressure compressor is running.
compressor)
line is too high>
Compressor has seized
and is extremely hot.
*1: If refrigerant leaks, compressor oil in the air conditioner circuit always leaks, too. So perform the check
mainly on pipe joints and dirty parts with oil.
*2:
k When replacing cooling cycle parts, be sure to collect refrigerant. For details, see "Precautions for
refrigerant". After replacing parts, fill the air conditioner circuit with refrigerant.
*3: Sight glass is on the air conditioner hose near the condenser.
PC138USLC-10 80-79
80 Appendix
Connection of service tool
Connection of service tool (PC300-K500-061-K-00-A)
k Park the machine on a level surface, lower the work equipment to the ground so that it is stable,
k Turn the battery disconnect switch to OFF position, and remove the key.
a Following service tool kit is used for work with refrigerant R134a.
Symbol Part No. Part name
X 799-703-1200 Service tool kit
a Use the service tool kit for R134a.

Service tool kit X
(1): Gauge manifold
(2): Red high-pressure line charging hose
(3): Blue low-pressure line charging hose
(4): Large diameter quick joint (for high-pressure line)
(5): Small diameter quick joint (for low-pressure line)
(a): Note that the threads are coarse and the hoses are relatively easy to loosen.
Connect the gauge manifold, hoses and other service tools according to the following procedure.
1. Close high-pressure line valve (6) and low-pressure line valve (7) of gauge manifold (1).
2. Connect red high-pressure line charging hose (2) to the gauge manifold (HI side) and blue low-pressure
line charging hose (3) to the gauge manifold (LO side).
3. Connect quick joints (4) and (5) to each hose.
4. Connect quick joints (4) and (5) to service valves (8) and (9) of high- and low-pressure piping respectively.
80-80 PC138USLC-10
80 Appendix
Connection of service tool
A: From operator's cab

B: To condenser
PC138USLC-10 80-81
80 Appendix
Precautions for disconnecting and connecting
refrigerant piping
Precautions for disconnecting and connecting refrigerant piping (PC138-K5B0-

924-K-00-A)
k When replacing the air conditioner unit, air conditioner compressor, condenser or receiver drier,
etc., collect the refrigerant (air conditioner gas: R134a) from the air conditioner circuit before
disconnecting the air conditioner hoses.
a Ask a qualified person for collecting, adding and filling operations of the refrigerant (air conditioner gas:
R134a). (Only registered persons can work.)
a Never release the refrigerant (air conditioner gas: R134a) to the atmosphere.
k If refrigerant gas (air conditioner gas: R134a) gets in your eyes, you may lose your sight. And if it
touches your skin, you may suffer from frostbite. Put on protective eyeglasses, gloves and
working clothes with long sleeves while collecting the refrigerant or filling the air conditioner
circuit with the refrigerant.
Disconnection
k Although the refrigerant (air conditioner gas: R134a) used on the machine's air conditioner is less
destructive to the ozone layer for environmentally friendliness, it is not allowed to be released into
the atmosphere as is. Whenever disconnecting the air conditioner gas circuit, be sure to recover
the refrigerant gas to reuse it.
a Ask a qualified person for collection and charge of the refrigerant (air conditioner gas: R134a).
a Never release the refrigerant (air conditioner gas: R134a) to the atmosphere.
k If the refrigerant (air conditioner gas: R134a) gets in your eyes, you may lose your sight. Also, if
your skin is exposed to the gas, you may suffer from frostbite. Accordingly, put on protective
eyeglasses, gloves and working suits with long sleeves while you are collecting or filling
refrigerant.
• When loosening the nuts fixing air conditioner hoses and tubes, be sure to use 2 wrenches; use one
wrench to fix and use the other one to loosen the nut.
• For the disconnected air conditioner piping, plug ends to prevent dirt, dust, and water from entering the
hose.
Connection
• Once an O-ring is used, it is deformed and deteriorated. Accordingly, do not reuse it.
• When removing it, use a soft tool (such as a toothpick) so that the piping will not be damaged.
• Check that the O-ring is not damaged or deteriorated.
• Apply compressor oil (ND–OIL8) for refrigerant (R134a) to the O-ring. (See item 4 of "Handling of
compressor oil".)
a However, do not apply oil to the threaded portion of a bolt, nut or union.
• Check that the O-rings are fitted to the joints when connecting the air conditioner piping.
• 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.
80-82 PC138USLC-10
80 Appendix
Precautions for disconnecting and connecting
refrigerant piping
Table of tightening torque for refrigerant pipe joint.

Thread size Tightening torque: Nm {kgm}
8 to 12 {0.8 to 1.2} (compressor)
M6 x 1.0
4 to 7 {0.4 to 0.7} (condenser)
1. Engine
2. Compressor
3. Condenser
4. Modulator
PC138USLC-10 80-83
80 Appendix
Handling of compressor oil
Handling of compressor oil (PC138-K594-212-K-Z0-A)

Check compressor oil amount
• Although compressor oil (ND–OIL8) differs from engine oil in that it does not need frequent checking or
filling, the following types of problem can occur if the amount in the system is excessive or too insufficient.
Condition Content
Insufficient oil Lubrication trouble and seizure of compressor
Lowered cooling performance
Excess oil
(Excess oil stick to parts and lower heat exchange performance)
• Accordingly, compressor oil (ND–OIL8) must be filled to the specified level, similarly to refrigerant.
Filling of compressor oil

a Refrigerant may be dangerous if not handled with care. Discharging refrigerant into the atmosphere is
harmful to the environment. Before disconnecting air conditioner hoses, refer to "Precautions for
disconnecting and connecting refrigerant piping" and ask a qualified person for the work.
a If oil for use with CFC–12 (R–12) is used, lubrication trouble will occur and the compressor may be broken
or seized. Be sure to use the oil (ND–OIL8) for R134a.
a Oil (ND–OIL8) for use with R134a is extremely hygroscopic, and therefore, put the cap the oil container
immediately after use to limit contact with air.
Avoid damp places for storage and store the oil can in a ventilated place.
a Do not allow oil for use with R134a to come into contact with acrylic plastic or polystyrene surfaces (except
a baked finish) as it may dissolve these plastics.
If any of the following is true, check the oil level and add oil as necessary.
• Refrigerant is lost in a short time due to a large leakage.
• The compressor had a problem and was replaced.
(Refer to "Replacement of compressor" in this section.)
• Component(s) of the refrigeration cycle such as air conditioner unit, condenser, modulator, or refrigerant
pipings has been changed.
Quantity of oil to be added when cycle part is replaced
Air conditioner part Quantity to be added
Air conditioner unit, evaporator Approx. 40 cc
Condenser (including modulator) Approx. 60 cc
Modulator (desiccating agent) Approx. 20 cc
Hose (between compressor and cab) Approx. 30 cc
Hose (between compressor and condenser) Approx. 20 cc
Hose (between cab and condenser) Approx. 10 cc
Replacement of compressor
In case of compressor seizure or breakage
• Metal chips will circulate through the air conditioner circuit and contaminate the compressor oil extremely.
• Flush the refrigerant circuit and replace the compressor and condenser (modulator).
80-84 PC138USLC-10
80 Appendix
Handling of compressor oil
• Compressor oil will be drained from the air conditioner circuit by flushing.
• Install the new compressor, which is filled with the specified amount (180 cc) of compressor oil.
Other cases
a A new compressor is filled with 180 cc of compressor oil.
1. Prepare an oil container and drain oil from the old compressor.
2. Measure the quantity of the drained oil with a measuring cylinder, and note the quantity.
3. Drain below-mentioned quantity of oil from the new compressor.

Quantity to be drained = 180 cc - "Noted quantity"
Example: If 30 cc was drained from the removed compressor, the quantity to be drained from the new
compressor would be 150 cc (i.e., 180 - 30 cc).
Applying compressor oil to O-rings

• Whenever connecting piping or hoses, the compressor oil (ND–OIL8) must be applied to O-rings in order
to prevent the leakage of refrigerant.
PC138USLC-10 80-85
80 Appendix
Desiccant replacement
Desiccant replacement (ALL-K523-923-K-00-A)
a Prepare desiccating agent replacement kit (20Y-810-1250).
k When replacing the desiccating agent, be sure to collect the refrigerant from the air conditioning
cycle. If the desiccating agent is replaced without collecting the refrigerant, the refrigerant may
blind you or cap (C) may fly out and injure you because of the refrigerant pressure in the cycle.
1. Condenser
2. Modulator
a The desiccanting agent is in modulator (2).
Taking out desiccanting agent (D)

1. Remove snap ring (SR) from modulator (2).
2. Hold boss (B) of cap (C) with pliers etc. to remove it from modulator (2).
a Cap (C) may be hard to remove. When removing it, exercise care not to damage or deform the seal or
modulator (2).
3. Remove filter (F) from modulator (2).
4. Remove desiccanting agent (D) from modulator (2).
a Replace snap ring (SR), cap (C), O-ring (OR), filter (F), and desiccanting agent (D) with the new parts
in the desiccanting agent replacement kit.
80-86 PC138USLC-10
80 Appendix
Installing new desiccanting agent (D)

1. Apply compressor oil (ND-OIL8) to the periphery of O-ring (OR) of cap (C).
2. Install filter (F) to cap (C).
3. Insert desiccanting agent (D) in modulator (2).

4. Install cap (C) with filter (F) to modulator (2).
5. Fit snap ring (SR) to modulator (2) to fix cap (C).
a If snap ring (SR) is not fitted to the groove in modulator (2) securely, cap (C) may be come off.
PC138USLC-10 80-87
80 Appendix
80-88 PC138USLC-10
SHOP MANUAL
HYDRAULIC EXCAVATOR
PC138USLC-10
Model Serial Number

10
90 Diagrams and drawings

10 90 Diagrams and drawings
PC138USLC-10 90-1
Table of contents

90 Diagrams and drawings................................................................................................................. 90-1
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
90-2 PC138USLC-10
Symbols in hydraulic circuit diagram
Hydraulic circuit diagram (ALL-C000-001-K-90-A)
Symbols in hydraulic circuit diagram (PC220-0000-007-K-00-A)
(Rev. 2010/03)
PC138USLC-10 90-3
90-4 PC138USLC-10
PC138USLC-10 90-5
90-6 PC138USLC-10
Hydraulic circuit diagram Hydraulic circuit diagram
PC138USLC-10
PC138USLC-10
a This figure covers the equipment and devices that are unavailable as optional items in some areas.
PC138USLC-10 90-7
Symbols in electric circuit diagram
Electric circuit diagram (ALL-0000-001-K-90-A)
Symbols in electric circuit diagram (PC220-0000-008-K-00-A)
(Rev. 2010/03)
PC138USLC-10 90-9
90-10 PC138USLC-10
PC138USLC-10 90-11
90-12 PC138USLC-10
Electrical circuit diagram (1/6) Electrical circuit diagram (1/6)
PC138USLC-10
PC138USLC-10
PC138USLC-10 90-13
PC138USLC-10
PC138USLC-10
PC138USLC-10 90-15
PC138USLC-10
PC138USLC-10
PC138USLC-10 90-17
PC138USLC-10
PC138USLC-10
PC138USLC-10 90-19
PC138USLC-10
PC138USLC-10
PC138USLC-10 90-21
PC138USLC-10
PC138USLC-10
PC138USLC-10 90-23
Electrical circuit diagram for air conditioner unit Electrical circuit diagram for air conditioner unit
PC138USLC-10
PC138USLC-10
a In the drawing, full line shows air conditioner wiring harness, and dashed line shows cab and chassis wiring harness. (For the detail of cab and chassis harness, see "Electrical circuit diagram")
a In the drawing, dot and dash line shows machine monitor wiring, and using twisted line (AVSS 0.5 x 2, pitch 45 mm or less).
PC138USLC-10 90-25
INDEX
INDEX
1st-line attachment PPC valve (with EPC Configuration and function of refrigeration
valve)............................................. 10-151, 60-46 cycle ............................................................ 80-7
Connection of service tool ............................. 80-80
Connector contact identification ..................... 40-54
A Connector list and layout ............................... 40-44
A-1 Troubleshooting for power supply system Control valve ...................................... 10-68, 60-23
(Air conditioner does not operate) ................. 80-68 Conversion table .......................................... 00-59
A-2 Troubleshooting for compressor and Cooling system.....................................10-23, 60-5
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
D
A-04 Troubleshooting for FRESH/RECIRC air Desiccant replacement.................................. 80-86
changeover ................................................ 80-75 Disassembly and assembly of center swivel
Adjusting play of work equipment and swing joint assembly........................................... 50-129
PPC valves ................................................ 30-50 Disassembly and assembly of control valve
Adjusting rearview camera angle ................. 30-115 assembly.................................................. 50-143
Air conditioner component ............................... 80-4 Disassembly and assembly of idler assembly 50-113
Air conditioner condenser .............................. 80-18 Disassembly and assembly of idler cushion
Air conditioner controller ................................ 80-16 assembly.................................................. 50-116
Air conditioner unit .............................. 80-10, 80-29 Disassembly and assembly of swing
Arm cylinder ................................................. 60-65 machinery assembly ................................. 50-101
Attachment circuit accumulator (for high Disassembly and assembly of track roller
pressure circuit) ........................................ 10-175 assembly.................................................. 50-119
Attachment circuit accumulator (for low Disassembly and assembly of travel motor and
pressure circuit) ........................................ 10-174 final drive assembly..................................... 50-64
Attachment circuit selector valve (for high Disassembly and assembly of travel PPC
pressure circuit) .............................. 10-168, 60-52 valve assembly ......................................... 50-147
Attachment circuit selector valve (for low Disassembly and assembly of work equipment
pressure circuit) .............................. 10-165, 60-51 cylinder assembly ..................................... 50-153
Disassembly and assembly of work equipment
PPC valve assembly ................................. 50-145
B Dual pressure switch..................................... 80-15
Blade cylinder............................................... 60-67
Blade PPC valve .............................. 10-149, 60-44
Bleeding air from fuel system ......................... 30-21
E
Bleeding air from hydraulic circuit ................... 30-56 E-1 Engine does not start (Engine does not
Boom cylinder .............................................. 60-64 crank) ...................................................... 40-351
Bucket cylinder ............................................. 60-66 E-2 Manual preheating system does not work .....40-
Bucket play adjustment shim ....................... 10-178 357
E-3 While preheating is working, preheating
monitor does not light up............................ 40-360
C E-4 When starting switch is turned to ON
Cab mount and cab tipping stopper .... 10-179, 60-54 position, machine monitor displays nothing.. 40-362
Carrier roller ................................................. 60-13 E-5 When starting switch is turned to ON
Center swivel joint............................. 10-171, 60-53 position (with engine stopped), engine oil
Checking and adjusting air conditioner level monitor lights up in yellow .................. 40-365
compressor belt tension............................... 30-26 E-6 Engine coolant temperature monitor lights
Checking cab tipping stopper......................... 30-59 up in white while engine is running.............. 40-366
Circuit diagram and arrangement of connector E-7 Hydraulic oil temperature monitor lights up
pins ........................................................... 80-24 in white while engine is running .................. 40-367
Classification and procedure for E-8 Charge level monitor lights up while engine
troubleshooting ........................................... 40-34 is running ................................................. 40-368
CLSS........................................................... 10-37 E-9 Fuel level monitor lights up in red while
Coating materials list....................................... 50-6 engine is running....................................... 40-369
Compressor ................................................. 80-17
PC138USLC-10 1
INDEX
E-10 Engine coolant temperature monitor E-37 Horn does not sound ........................... 40-402
lights up in red while engine is running ........ 40-370 E-38 Horn does not stop sounding ............... 40-403
E-11 Hydraulic oil temperature monitor lights E-39 Wiper monitor does not light up, or does
up in red while engine is running................. 40-371 not go out, while wiper switch is operated .... 40-404
E-12 Engine oil pressure monitor lights up in E-40 Wiper does not operate while wiper
red while engine is running......................... 40-372 switch is operated ..................................... 40-405
E-13 Fuel gauge display does not move from E-41 Window washer does not operate while
minimum or maximum ............................... 40-373 window washer switch is operated .............. 40-407
E-14 Fuel gauge indicates incorrect amount E-42 Boom Lower is not displayed correctly
(indicates neither full nor empty) ................. 40-374 with monitoring function ............................. 40-408
E-15 Engine coolant temperature gauge E-43 Arm OUT is not displayed correctly with
display does not move from minimum or monitoring function.................................... 40-410
maximum ................................................. 40-375 E-44 Arm IN is not displayed correctly with
E-16 Engine coolant temperature gauge monitoring function.................................... 40-412
indicates incorrect temperature (indicates E-45 Boom Raise is not displayed correctly
neither minimum nor maximum) ................. 40-376 with monitoring function ............................. 40-414
E-17 Hydraulic oil temperature gauge does not E-46 Bucket Curl is not displayed correctly with
move from minimum or maximum ............... 40-377 monitoring function.................................... 40-416
E-18 Hydraulic oil temperature gauge indicates E-47 Bucket Dump is not displayed correctly
incorrect temperature (indicates neither with monitoring function ............................. 40-418
minimum nor maximum) ............................ 40-379 E-48 Swing is not displayed correctly with
E-19 Some areas of machine monitor screen monitoring function.................................... 40-420
are not displayed....................................... 40-380 E-49 Travel is not displayed correctly with
E-20 Function switch does not work ............. 40-381 monitoring function.................................... 40-422
E-21 Automatic warm-up system does not E-50 Service is not displayed correctly with
operate (in cold season) ............................ 40-382 monitoring function.................................... 40-423
E-22 Auto-deceleration monitor does not light E-51 Attachment hydraulic circuit cannot be
up, or does not go out, while auto- changed ................................................... 40-425
deceleration switch is operated .................. 40-383 E-52 KOMTRAX system does not operate
E-23 Auto-deceleration function does not normally ................................................... 40-426
operate or is not canceled while lever is EGR cooler .................................................. 10-15
operated................................................... 40-384 EGR system circuit diagram .......................... 10-12
E-24 Working mode selection screen is not EGR system piping drawing........................... 10-10
displayed while working mode selector switch EGR valve ................................................... 10-13
is operated ............................................... 40-385 Electrical circuit diagram................................ 90-13
E-25 Setting of engine and hydraulic pump is Electrical circuit diagram of air conditioner unit 90-25
not changed while working mode is changed .....40- Electrical control system.............................. 10-182
386 Engine control .............................................. 20-18
E-26 Travel speed monitor does not change Engine mount ................................................. 60-3
while travel speed switch is operated .......... 40-387 Engine related parts ........................................ 10-3
E-27 Travel speed does not change while Explanation of terms for maintenance standard ...00-
travel speed selection is changed ............... 40-388 22
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
F
E-30 Service mode cannot be selected......... 40-391 Failure code [879AKA] A/C Inner Sensor Open
E-31 Any of work equipment, swing and travel Circuit ............................................ 40-105, 80-55
does not work ........................................... 40-392 Failure code [879AKB] A/C Inner Sensor Short
E-32 Any of work equipment, swing and travel Circuit ............................................ 40-106, 80-56
cannot be locked....................................... 40-394 Failure code [879BKA] A/C Outer Sensor
E-33 Upper structure does not swing while Open Circuit ................................... 40-107, 80-57
swing parking brake cancel switch is set to Failure code [879BKB] A/C Outer Sensor Short
CANCEL position ...................................... 40-396 Circuit ............................................ 40-108, 80-59
E-34 Swing brake does not operate while Failure code [879CKA] Ventilating Sensor
swing parking brake cancel switch is set to Open Circuit ............................................. 40-109
NORMAL position ..................................... 40-398 Failure code [879CKB] Ventilating Sensor
E-35 Alarm does not sound during travel....... 40-400 Short Circuit ............................................. 40-110
E-36 Alarm does not stop sounding while Failure code [879DKZ] Sunlight Sensor Open
machine is stopped ................................... 40-401 or Short Circuit............................................ 80-63
2 PC138USLC-10
INDEX
Failure code [879DKZ] Sunlight Sensor Open Failure code [CA221] Ambient Press Sens
Or Short Circuit ..........................................40-111 High Error................................................. 40-142
Failure code [879EMC] Ventilation Damper Failure code [CA222] Ambient Press Sens Low
Abnormality .............................................. 40-112 Error ........................................................ 40-144
Failure code [879FMC] Air Mix Damper Failure code [CA2249] Rail Press Very Low
Abnormality .............................................. 40-113 Error 2...................................................... 40-219
Failure code [879GKX] Refrigerant Failure code [CA227] Sensor 2 Supply Volt
Abnormality .................................... 40-114, 80-67 High Error................................................. 40-146
Failure code [989L00] Engine Controller Lock Failure code [CA2272] EGR Valve Pos Sens
Caution 1 ................................................. 40-115 Low Error ................................................. 40-220
Failure code [989M00] Engine Controller Lock Failure code [CA2311] IMV Solenoid Error .... 40-222
Caution 2 ................................................. 40-116 Failure code [CA234] Eng Overspeed........... 40-147
Failure code [989N00] Engine Controller Lock Failure code [CA2349] EGR Valve Solenoid
Caution 3 ................................................. 40-117 Open Error ............................................... 40-223
Failure code [AB00KE] Charge Voltage Low . 40-118 Failure code [CA2357] EGR Valve Servo Error ....40-
Failure code [B@BAZG] Eng Oil Press Low .. 40-120 227
Failure code [B@BAZK] Eng Oil Level Low ... 40-121 Failure code [CA2360] EGR Valve Solenoid
Failure code [B@BCNS] Eng Water Overheat .....40- Short Error................................................ 40-225
122 Failure code [CA238] Ne Speed Sensor
Failure code [CA1117] Persistent Data Lost Supply Volt Error ....................................... 40-148
Error ........................................................ 40-205 Failure code [CA239] Ne Speed Sens Supply
Failure code [CA115] Eng Ne and Bkup Speed Volt High Error .......................................... 40-149
Sens Error ................................................ 40-123 Failure code [CA271] IMV/PCV1 Short Error . 40-150
Failure code [CA122] Chg Air Press Sensor Failure code [CA272] IMV/PCV1 Open Error . 40-151
High Error................................................. 40-124 Failure code [CA2765] Inj Trim Data Error ..... 40-228
Failure code [CA123] Chg Air Press Sensor Failure code [CA322] Inj #3(L#3) Open/Short
Low Error ................................................. 40-126 Error ........................................................ 40-152
Failure code [CA131] Throttle Sensor High Failure code [CA324] Inj #3(L#3) Open/Short
Error ........................................................ 40-128 Error ........................................................ 40-154
Failure code [CA132] Throttle Sensor Low Failure code [CA331] Inj #2(L#2) Open/Short
Error ........................................................ 40-130 Error ........................................................ 40-156
Failure code [CA144] Coolant Temp Sens High Failure code [CA332] Inj #4(L#4) Open/Short
Error Failure code [CA144] Coolant Temp Error ........................................................ 40-158
Sens High Error ........................................ 40-132 Failure code [CA3419] Mass Air Flow Sensor
Failure code [CA145] Coolant Temp Sens Low Sup Volt High Error.................................... 40-229
Error Failure code [CA145] Coolant Temp Failure code [CA3421] Mass Air Flow Sensor
Sens Low Error ......................................... 40-134 Sup Volt Low Error .................................... 40-231
Failure code [CA153] Chg Air Temp Sensor Failure code [CA343] ECM Critical Internal
High Error................................................. 40-136 Failure ..................................................... 40-160
Failure code [CA154] Chg Air Temp Sensor Failure code [CA351] Injectors Drive Circuit
Low Error ................................................. 40-138 Error ........................................................ 40-161
Failure code [CA1695] Sensor 5 Supply Volt Failure code [CA352] Sensor 1 Supply Volt
High Error................................................. 40-206 Low Error ................................................. 40-162
Failure code [CA1696] Sensor 5 Supply Volt Failure code [CA356] Mass Air Flow Sensor
Low Error ................................................. 40-207 High Error................................................. 40-164
Failure code [CA1843] Crankcase Press Sens Failure code [CA357] Mass Air Flow Sensor
High Error................................................. 40-208 Low Error ................................................. 40-166
Failure code [CA1844] Crankcase Press Sens Failure code [CA3724] EGR/KVGT Motor
Low Error ................................................. 40-210 Driver Power Low Error ............................. 40-233
Failure code [CA187] Sensor 2 Supply Volt Failure code [CA386] Sensor 1 Supply Volt
Low Error ................................................. 40-140 High Error................................................. 40-168
Failure code [CA1896] EGR Valve Stuck Error ....40- Failure code [CA3918] KVGT Stuck Error ..... 40-235
212 Failure code [CA3919] KVGT Motor Driver IC
Failure code [CA1942] Crankcase Press Sens Over Temp Error ........................... 40-214, 40-236
In Range Error .......................................... 40-213 Failure code [CA3921] KVGT Servo Error 2 .. 40-237
Failure code [CA2185] Throt Sensor Sup Volt Failure code [CA3922] KVGT Motor Driver
High Error................................................. 40-215 Open Error ............................................... 40-238
Failure code [CA2186] Throt Sensor Sup Volt Failure code [CA3923] KVGT Motor Driver
Low Error ................................................. 40-217 Short Error................................................ 40-240
PC138USLC-10 3
INDEX
Failure code [CA435] Eng Oil Press Sw Error......40- Failure code [DA2LKA] Operating Lamp Open
169 Circuit (Pump Con).................................... 40-261
Failure code [CA441] Battery Voltage Low Failure code [DA2LKB] Operating Lamp Short
Error ........................................................ 40-170 Circuit (Pump Con).................................... 40-263
Failure code [CA442] Battery Voltage High Failure code [DA2QKR] CAN2 Discon (Pump
Error ........................................................ 40-172 Con) ........................................................ 40-264
Failure code [CA449] Rail Press Very High Failure code [DA2RKR] CAN1 Discon (Pump
Error ........................................................ 40-173 Con) ........................................................ 40-266
Failure code [CA451] Rail Press Sensor High Failure code [DAF0MB] Monitor ROM
Error ........................................................ 40-174 Abnormality .............................................. 40-267
Failure code [CA452] Rail Press Sensor Low Failure code [DAF0MC] Monitor Error ........... 40-268
Error ........................................................ 40-176 Failure code [DAF8KB] Camera Power Supply
Failure code [CA466] KVGT Motor Driver Short Circuit ............................................. 40-269
Position Error............................................ 40-178 Failure code [DAF9KQ] Model Selection
Failure code [CA515] Rail Press Sens Sup Volt Abnormality .............................................. 40-271
High Error Failure code.............................. 40-180 Failure code [DAFGMC] GPS Module Error .. 40-272
Failure code [CA516] Rail Press Sens Sup Volt Failure code [DAFLKA] Operating Lamp Open
Low Error ................................................. 40-182 Circuit (Monitor) ........................................ 40-273
Failure code [CA553] Rail Press High Error 1 40-184 Failure code [DAFLKB] Operating Lamp Short
Failure code [CA555] Crankcase Press High Circuit (Monitor) ........................................ 40-275
Error 1...................................................... 40-185 Failure code [DAFQKR] CAN2 Discon
Failure code [CA556] Crankcase Press High (Monitor) .................................................. 40-276
Error 2...................................................... 40-186 Failure code [DAZ9KQ] A/C Model Selection
Failure code [CA559] Rail Press Low Error ... 40-187 Abnormality .............................................. 40-277
Failure code [CA689] Eng Ne and Speed Failure code [DAZQKR] CAN2 Discon (Aircon
Sensor Error Failure code .......................... 40-190 ECU) ....................................................... 40-278
Failure code [CA691] Intake Air Temp Sens Failure code [DB2QKR] CAN2 Discon (Engine
High Error................................................. 40-192 Con) ........................................................ 40-282
Failure code [CA692] Intake Air Temp Sens Failure code [DB2RKR] CAN1 Discon (Engine
Low Error ................................................. 40-194 Con) ........................................................ 40-286
Failure code [CA697] ECM Internal Temp Failure code [DGH2KB] Hyd Oil Sensor Short
Sensor High Error ..................................... 40-196 Circuit ...................................................... 40-290
Failure code [CA698] ECM Int Temp Sensor Failure code [DHPAMA] Pump Press Sensor
Low Error ................................................. 40-197 Abnormality .............................................. 40-292
Failure code [CA731] Eng Bkup Speed Sens Failure code [DHSFMA] Travel Fwd LH PPC
Phase Error .............................................. 40-198 Press Sensor Abnormality ......................... 40-294
Failure code [CA778] Eng Bkup Speed Sensor Failure code [DHSGMA] Travel Fwd RH PPC
Error ........................................................ 40-201 Press Sensor Abnormality ......................... 40-296
Failure code [D110KB] Battery Relay Drive Failure code [DHSHMA] Travel Rev LH PPC
Short Circuit ............................................. 40-242 Press Sensor Abnormality ......................... 40-298
Failure code [D19JKZ] Personal Code Relay Failure code [DHSJMA] Travel Rev RH PPC
Abnormality .............................................. 40-244 Press Sensor Abnormality ......................... 40-300
Failure code [D811MC] KOMTRAX Error ...... 40-247 Failure code [DHSKMA] Blade Raise PPC
Failure code [D862KA] GPS Antenna Open Press Sensor Abnormality ......................... 40-302
Circuit ...................................................... 40-248 Failure code [DHSLMA] Blade Lower PPC
Failure code [D8ALKA] Operating Lamp Open Press Sensor Abnormality ......................... 40-304
Circuit (KOMTRAX)................................... 40-249 Failure code [DHX1MA] Overload Sensor
Failure code [D8ALKB] Operating Lamp Short Abnormality .............................................. 40-306
Circuit (KOMTRAX)................................... 40-251 Failure code [DR21KX] Camera 2 Picture Rev.
Failure code [D8AQKR] CAN2 Discon Drive Abnormality...................................... 40-307
(KOMTRAX) ............................................. 40-252 Failure code [DR31KX] Camera 3 Picture Rev.
Failure code [DA20MC] Pump Controller Drive Abnormality...................................... 40-309
Malfunction............................................... 40-254 Failure code [DV20KB] Travel Alarm Short
Failure code [DA22KK] Pump Solenoid Power Circuit ...................................................... 40-310
Low Error ................................................. 40-255 Failure code [DW43KA] Travel Speed Sol
Failure code [DA25KP] 5V Sensor 1 Power Open Circuit ............................................. 40-312
Abnormality .............................................. 40-257 Failure code [DW43KB] Travel Speed Sol
Failure code [DA29KQ] Model Selection Short Circuit ............................................. 40-314
Abnormality .............................................. 40-259
4 PC138USLC-10
INDEX
Failure code [DW45KA] Swing Brake Sol Open H-6 Boom speed or power is low .................. 40-445
Circuit ...................................................... 40-316 H-7 Arm speed or power is low..................... 40-448
Failure code [DW45KB] Swing Brake Sol Short H-8 Bucket speed or power is low ................ 40-450
Circuit ...................................................... 40-319 H-9 Work equipment does not move in single
Failure code [DW91KA] Travel Junction Sol operation.................................................. 40-452
Open Circuit ............................................. 40-321 H-10 Hydraulic drift of boom is large ............. 40-453
Failure code [DW91KB] Travel Junction Sol H-11 Hydraulic drift of arm is large ................ 40-454
Short Circuit ............................................. 40-323 H-12 Hydraulic drift of bucket is large............ 40-455
Failure code [DWA2KA] Attachment Sol Open H-13 Time lag of work equipment is large...... 40-456
Circuit ...................................................... 40-325 H-14 In combined operation of work equipment
Failure code [DWA2KB] Attachment Sol Short , equipment having heavier load moves
Circuit ...................................................... 40-327 slower ...................................................... 40-458
Failure code [DWJ0KA] Merge-divider Sol H-15 In combined operation of swing and
Open Circuit ............................................. 40-329 boom RAISE, boom rising speed is low....... 40-459
Failure code [DWJ0KB] Merge-divider Sol H-16 In combined operation of swing and
Short Circuit ............................................. 40-331 travel, travel speed drops largely ................ 40-460
Failure code [DXA8KA] PC-EPC Sol Open H-17 Machine does not travel straight........... 40-461
Circuit ...................................................... 40-333 H-18 Travel speed is slow............................ 40-463
Failure code [DXA8KB] PC-EPC Sol Short H-19 Machine is hard to steer or travel power
Circuit ...................................................... 40-335 is low ....................................................... 40-465
Failure code [DXE4KA] Attachment Flow EPC H-20 Travel speed does not change, or travel
Open Circuit ............................................. 40-337 speed is too slow or fast ............................ 40-468
Failure code [DXE4KB] Attachment Flow EPC H-21 One of tracks does not run................... 40-469
Short Circuit ............................................. 40-339 H-22 Upper structure does not swing to the
Failure code [DY20KA] Wiper Working right or left ................................................ 40-471
Abnormality .............................................. 40-341 H-23 Upper structure swing only to the right or
Failure code [DY20MA] Wiper Parking left ........................................................... 40-472
Abnormality .............................................. 40-343 H-24 Swing acceleration or swing speed is low
Failure code [DY2CKB] Washer Drive Short in both directions (right and left).................. 40-473
Circuit ...................................................... 40-345 H-25 Swing acceleration performance is poor
Failure code [DY2DKB] Wiper Drive (Fwd) or swing speed is slow in only one direction. 40-474
Short Circuit ............................................. 40-347 H-26 Upper structure overruns excessively
Failure code [DY2EKB] Wiper Drive (Rev) when it stops swinging (both right and left) .. 40-475
Short Circuit ............................................. 40-349 H-27 Upper structure overruns excessively
Failure code [879CKA] Ventilating Sensor when it stops swinging (either right or left) ... 40-476
Open Circuit ............................................... 80-61 H-28 Shock is large when upper structure
Failure code [879CKB] Ventilating Sensor stops swinging .......................................... 40-477
Short Circuit ............................................... 80-62 H-29 Large unusual noise is heard when upper
Failure code [879EMC] Ventilation Damper structure stops swinging ............................ 40-478
Abnormality ................................................ 80-65 H-30 Swing drift on a slope is large while swing
Failure code [879FMC] Air Mix Damper parking brake is applied ............................. 40-479
Abnormality ................................................ 80-66 H-31 Swing drift on a slope is large while swing
Failure code list related to air conditioner ........ 80-54 parking brake is released ........................... 40-480
Failure codes table ....................................... 40-99 H-32 Attachment hydraulic circuit cannot be
Failure mode and cause table ...................... 40-431 changed while attachment is installed ......... 40-481
Fuse location table........................................ 40-97 H-33 Oil flow in attachment circuit cannot be
controlled ................................................. 40-482
Handling battery disconnect switch .............. 30-118
H Handling cylinder cutout mode operation ........ 30-24
H-1 All of work equipment, swing and travel Handling equipment of fuel system devices..... 00-24
operation lacks speed or power .................. 40-439 Handling no injection cranking operation......... 30-25
H-2 Engine speed drops significantly or engine Handling of compressor oil ............................ 80-84
stalls ........................................................ 40-441 Handling of electrical equipment .................... 00-31
H-3 Any of work equipment, swing and travel Handling of hydraulic equipment .................... 00-26
does not work ........................................... 40-442 Handling of intake system parts ..................... 00-25
H-4 Unusual sound is heard from around Handling voltage circuit of engine controller .. 30-117
hydraulic pump ......................................... 40-443 How to open the electrical system abnormality
H-5 Fine control performance or response is record screen in service mode of the machine
poor ......................................................... 40-444 monitor....................................................... 80-40
PC138USLC-10 5
INDEX
How to read electric wire code ....................... 00-39 PTO ......................................................10-5, 60-4
How to read the shop manual ........................ 00-20
How to read this manual .................................. 50-4
Hydraulic circuit diagram ................................. 90-7
R
Hydraulic component layout........................... 10-32 Releasing remaining pressure from hydraulic
Hydraulic tank .................................... 10-35, 60-19 circuit ......................................................... 30-34
Removal and installation of air conditioner
compressor assembly ............................... 50-187
I Removal and installation of air conditioner
Idler ............................................................. 60-11 condenser assembly ................................. 50-189
Idler cushion....................................... 10-31, 60-10 Removal and installation of air conditioner unit
Important safety notice .................................. 00-13 assembly.................................................. 50-183
Information described in troubleshooting table Removal and installation of center swivel joint
(H-mode).................................................. 40-428 assembly.................................................. 50-127
Information in troubleshooting table ...... 40-40, 80-53 Removal and installation of control valve
Information mentioned in troubleshooting table assembly.................................................. 50-137
(S mode) .................................................. 40-483 Removal and installation of counterweight
Inspection procedure before troubleshooting... 40-13 assembly [For machines with additional
Isolating the parts causing hydraulic drift in counterweight] .......................................... 50-124
work equipment .......................................... 30-51 Removal and installation of cylinder head
assembly.................................................... 50-26
Removal and installation of engine and main
K pump assembly .......................................... 50-44
KCCV layout drawing .................................... 10-17 Removal and installation of engine controller
KCCV ventilator............................................ 10-19 assembly.................................................. 50-199
KDOC muffler............................................... 10-21 Removal and installation of engine front oil
KOMTRAX system ..................................... 10-235 seal ........................................................... 50-50
Removal and installation of engine rear oil seal ...50-
51
L Removal and installation of fan belt ................ 50-61
List of abbreviation........................................ 00-54 Removal and installation of floor frame
assembly.................................................. 50-176
Removal and installation of front window
M assembly.................................................. 50-175
Machine monitor system.............................. 10-214 Removal and installation of front wiper
Main pump ......................................... 10-41, 60-20 assembly.................................................. 50-193
Method of disconnecting and connecting of Removal and installation of fuel cooler
push-pull type coupler ................................. 00-28 assembly.................................................... 50-53
Multi-control valve....................................... 10-170 Removal and installation of fuel tank assembly....50-
54
Removal and installation of hydraulic oil cooler
O assembly.................................................... 50-39
Outer temperature sensor.............................. 80-21 Removal and installation of hydraulic tank
Outline of refrigeration cycle ............................ 80-8 assembly.................................................. 50-130
Removal and installation of idler and idler
cushion assembly ..................................... 50-112
P Removal and installation of injector assembly . 50-20
Parts and connectors layout .......................... 80-31 Removal and installation of KCCV assembly ... 50-58
Pm Clinic service ........................................ 30-120 Removal and installation of KDOC assembly .. 50-57
Power train system ....................................... 10-25 Removal and installation of KOMTRAX
PPC circuit accumulator .............................. 10-173 terminal assembly ..................................... 50-205
Practical use of KOMTRAX............................ 00-47 Removal and installation of machine monitor
Precautions for disconnecting and connecting assembly.................................................. 50-202
refrigerant piping ......................................... 80-82 Removal and installation of main pump
Precautions for refrigerant ............................... 80-3 assembly.................................................. 50-133
Precautions when performing operation.......... 00-42 Removal and installation of mass air flow and
Preparation for troubleshooting of electrical temperature sensor ................................... 50-204
system ....................................................... 40-30 Removal and installation of operator's cab
Procedure for testing and troubleshooting ....... 80-22 assembly.................................................. 50-158
6 PC138USLC-10
INDEX
Removal and installation of operator's cab door...50- Sprocket ........................................................ 60-8

161 Standard tightening torque table .................... 00-48
Removal and installation of operator's cab Standard value table for electrical system ....... 20-17
glass (adhered glass) ................................ 50-164 Standard value table for engine........................ 20-3
Removal and installation of operator's seat ... 50-191 Standard value table for machine ..................... 20-4
Removal and installation of pump controller Sunlight sensor............................................. 80-20
assembly.................................................. 50-200 Swing circle..........................................10-27, 60-6
Removal and installation of seat belt............. 50-192 Swing machinery ..................................10-28, 60-7
Removal and installation of sprocket .............50-111 Swing motor ..................................... 10-113, 60-34
Removal and installation of supply pump Symbols in electric circuit diagram.................... 90-9
assembly.................................................... 50-16 Symbols in hydraulic circuit diagram................. 90-3
Removal and installation of swing circle Symptom of probable failure and
assembly.................................................. 50-107 troubleshooting No. ..................................... 40-37
Removal and installation of swing motor and System chart of hydraulic and mechanical
swing machinery assembly .......................... 50-99 systems ................................................... 40-429
Removal and installation of travel motor and System component parts............................. 10-238
final drive assembly..................................... 50-63 System diagram ........................................... 80-26
Removal and installation of work equipment
assembly.................................................. 50-149
Replacing fan belt ......................................... 30-27
T
ROPS cab.................................................. 10-180 T-branch box and T-branch adapter table........ 40-92
Table of fuel, coolant, and lubricants ............... 01-11
Testing air leakage (duct)............................... 80-37
S Testing and adjusting oil pressure in pump LS
S-1 Engine does not crank when starting control circuit .............................................. 30-42
switch is turned to START position.............. 40-484 Testing and adjusting oil pressure in pump PC
S-2 Engine cranks but no exhaust smoke control circuit .............................................. 30-39
comes out ................................................ 40-485 Testing and adjusting oil pressure in work
S-3 Fuel is being injected but engine does not equipment, swing, and travel circuits............. 30-35
start (misfiring: engine cranks but does not Testing and adjusting track shoe tension......... 30-33
start) ........................................................ 40-486 Testing and adjusting travel deviation ............. 30-52
S-4 Engine startability is poor....................... 40-487 Testing and adjusting valve clearance ............ 30-10
S-5 Engine does not pick up smoothly .......... 40-489 Testing before troubleshooting ....................... 40-11
S-6 Engine stops during operation................ 40-491 Testing blowby pressure ................................ 30-15
S-7 Engine runs rough or is unstable ............ 40-493 Testing compression pressure ....................... 30-12
S-8 Engine lacks power............................... 40-494 Testing diodes ............................................ 30-119
S-9 Exhaust smoke is black ......................... 40-496 Testing (dual) pressure switch for refrigerant ... 80-46
S-10 Engine oil consumption is excessive..... 40-498 Testing engine oil pressure ............................ 30-16
S-11 Engine oil becomes contaminated early 40-499 Testing engine speed ...................................... 30-8
S-12 Fuel consumption is excessive............. 40-500 Testing exhaust gas color ................................ 30-9
S-13 Oil is in coolant (or coolant spurts or Testing FRESH/RECIRC air changeover ........ 80-44
coolant level goes down) ........................... 40-501 Testing fuel circuit for leakage ........................ 30-23
S-14 Oil pressure drops............................... 40-502 Testing fuel pressure ..................................... 30-17
S-15 Fuel mixes into engine oil .................... 40-503 Testing fuel return rate and leakage ................ 30-18
S-16 Water mixes into engine oil (milky)........ 40-504 Testing oil leakage ........................................ 30-54
S-17 Coolant temperature rises too high Testing oil pressure of control circuit ............... 30-38
(overheating) ............................................ 40-505 Testing outlet pressure of solenoid valve......... 30-47
S-18 Unusual noise is heard ........................ 40-506 Testing PPC valve output pressure................. 30-48
S-19 Vibration is excessive.......................... 40-507 Testing relays ............................................... 80-48
S-20 Air cannot be bled from fuel circuit ........ 40-508 Testing sunlight sensor.................................. 80-45
Sensor....................................................... 10-252 Testing swing circle bearing clearance............ 30-32
Separation and connection of track .............. 50-108 Testing vent (mode) changeover .................... 80-43
Sequence of events in troubleshooting ............. 40-9 Testing with self-diagnosis function................. 80-40
Sketches of special tools ............................... 50-14 Testing, cleaning and lubricating slide door rail
Solenoid valve.................................. 10-159, 60-49 and roller .................................................... 30-60
Special functions of machine monitor.............. 30-63 Tools for testing and adjusting.......................... 30-3
Special tools list............................................ 50-10 Track frame ..........................................10-30, 60-9
Specification drawing ...................................... 01-3 Track roller ................................................... 60-12
Specifications ................................................. 01-5 Track shoe ................................................... 60-14
PC138USLC-10 7
INDEX
Travel motor ..................................... 10-125, 60-37

Travel PPC valve .............................. 10-143, 60-41
Troubleshooting chart 1................................. 80-49
Troubleshooting chart 2................................. 80-50
Troubleshooting method for open circuit in
wiring harness of pressure sensor system ..... 40-42
Troubleshooting points .................................... 40-7
Troubleshooting with gauge pressure ............. 80-77
V
Valve control ................................................ 10-34
VFT ............................................................... 10-6
W
Weight table ................................................... 01-9
Work equipment ............................... 10-176, 60-55
Work equipment and swing PPC valve ...10-136, 60-
38
Work equipment shim ................................. 10-177
Working range drawings.................................. 01-4
Writing compensation values at replacement of
injector and engine controller ....................... 30-28
8 PC138USLC-10
PC138USLC-10 HYDRAULIC EXCAVATOR
Form No. SEN06062-01
©2012 KOMATSU
All Rights Reserved
Printed in Japan 11–12

Pc138uslc-10 Shop Manual

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Pc138uslc-10 Shop Manual

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SEN06062-01

HYDRAULIC PC138USLC -10

PC138USLC- 40001 and up

00 Index and foreword

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

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

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

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

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

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

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

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

General precautions knowledge of welding perform the work. When

k Slinging with one rope may cause turning

Precautions for using mobile crane

Precautions for using overhead traveling crane

• Before starting work, check the wire ropes, Nominal

Manufacturer Part name

For tightening torques, see "Others",

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

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

KDPF is a system for purifying soot in exhaust

To prevent pollution, pay full attention to the way to

Some kinds of rubber and plastics may produce

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

Composition of shop manual

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

the parts can not be used any longer. This value

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

Use care for working environment

How to clean parts when dirt is stuck

Precautions for replacing fuel filter cartridge

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

Be careful of working environment

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

Be careful of working environment

Disassembly and maintenance work in the field

Plugging of opening (prevention of flowing out

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

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

Precautions for handling electric equipment

Handling wiring harnesses and connectors

Main failures occurring in wiring harness

blow it with compressed air and spray it with

High-pressure water entering connector

Entry of water, mud or dirt when disconnecting a

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

3. Action to take after removing connectors

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

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

3. Perform a continuity test on the connector.

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

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

Push lock type (3) (AMP-3)

a If the lock is located on the underside, use

Example) Injection pressure control valve of

Connection Handling controller

• Cover the control connectors with tape or a vinyl

temperature even for a short period of time.

• Precautions when performing arc welding

Precautions for troubleshooting electrical

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

Type, symbol, and material

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