Komatsu PC138USLC-10 Hydraulic Excavator Service Manual
1,421 pages · Publication SEN06062-04
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- Models
- PC138USLC-10
- Serial coverage
- 40001 and up
- Manual type
- Service Manual
- Pages
- 1,421
- Publication
- SEN06062-04
- Condition
- Brand new

What's inside
From the manual's own table of contents: 283 sections, 525 entries. See sample pages (PDF, 835 KB)
Show all 283 sections
Blade PPC valve11 topics
- 1st-line attachment PPC valve (with EPC valve)
- Solenoid valve
- Attachment circuit selector valve (for low pressure circuit)
- Attachment circuit selector valve (for high pressure circuit)
- Multi-control valve
- Anti-drop valve for boom
- Anti-drop valve for arm
- Center swivel joint
- PPC circuit accumulator
- Attachment circuit accumulator (for low pressure circuit)
- Attachment circuit accumulator (for high pressure circuit)
Work equipment2 topics
- Work equipment shim
- Bucket play adjustment shim
Cab and its attachments2 topics
- Cab mount and cab tipping stopper
- ROPS cab
Electrical system4 topics
- Electrical control system
- Machine monitor system
- KOMTRAX system
- Sensor
Standard service value table3 topics
- Standard value table for engine
- Standard value table for machine
- Standard value table for electrical system
Related information on testing and adjusting23 topics
- Tools for testing and adjusting
- Sketch of tools for testing and adjusting
- Testing engine speed
- Testing exhaust gas color
- Testing and adjusting valve clearance
- Testing compression pressure
- Testing blowby pressure
- Testing engine oil pressure
- Testing fuel pressure
- Testing fuel return rate and leakage
- Bleeding air from fuel system
- Testing fuel circuit for leakage
- Handling cylinder cutout mode operation
- Handling no-injection cranking operation
- Testing and adjusting air conditioner compressor belt tension
- Check fan belt, replace
- Check auto-tensioner, replace
- Writing compensation values at replacement of injector and engine controller
- Testing swing circle bearing clearance
- Testing and adjusting track tension
- Releasing remaining pressure from hydraulic circuit
- Testing and adjusting oil pressure in work equipment, swing, and travel circuits
- Testing oil pressure of control circuit
Failure code [CA122] Chg Air Press Sensor High Error59 topics
- Failure code [CA123] Chg Air Press Sensor Low Error
- Failure code [CA131] Throttle Sensor High Error
- Failure code [CA132] Throttle Sensor Low Error
- Failure code [CA144] Coolant Temp Sens High Error
- Failure code [CA145] Coolant Temp Sens Low Error
- Failure code [CA153] Chg Air Temp Sensor High Error
- Failure code [CA154] Chg Air Temp Sensor Low Error
- Failure code [CA187] Sensor 2 Supply Volt Low Error
- Failure code [CA221] Ambient Press Sensor High Error
- Failure code [CA222] Ambient Press Sensor Low Error
- Failure code [CA227] Sensor 2 Supply Volt High Error
- Failure code [CA234] Eng Overspeed
- Failure code [CA238] Ne Speed Sensor Supply Volt Error
- Failure code [CA239] Ne Speed Sens Supply Volt High Error
- Failure code [CA271] IMV/PCV1 Short Error
- Failure code [CA272] IMV/PCV1 Open Error
- Failure code [CA322] Inj #1(L#1) Open/Short Error
- Failure code [CA324] Inj #3(L#3) Open/Short Error
- Failure code [CA331] Inj #2(L#2) Open/Short Error
- Failure code [CA332] Inj #4(L#4) Open/Short Error
- Failure code [CA343] ECM Critical Internal Failure
- Failure code [CA351] Injectors Drive Circuit Error
- Failure code [CA352] Sensor 1 Supply Volt Low Error
- Failure code [CA356] Mass Air Flow Sensor High Error
- Failure code [CA357] Mass Air Flow Sensor Low Error
- Failure code [CA386] Sensor 1 Supply Volt High Error
- Failure code [CA435] Eng Oil Press Sw Error
- Failure code [CA441] Battery Voltage Low Error
- Failure code [CA442] Battery Voltage High Error
- Failure code [CA449] Rail Press Very High Error
- Failure code [CA451] Rail Press Sensor High Error
- Failure code [CA452] Rail Press Sensor Low Error
- Failure code [CA466] KVGT Motor Driver Position Error
- Failure code [CA515] Rail Press Sens Sup Volt High Error
- Failure code [CA516] Rail Press Sens Sup Volt Low Error
- Failure code [CA553] Rail Press High Error
- Failure code [CA555] Crankcase Press High Error 1
- Failure code [CA556] Crankcase Press High Error 2
- Failure code [CA559] Rail Press Low Error
- Failure code [CA689] Eng Ne Speed Sensor Error
- Failure code [CA691] Intake Air Temp Sens High Error
- Failure code [CA692] Intake Air Temp Sens Low Error
- Failure code [CA697] ECM Internal Temp Sensor High Error
- Failure code [CA698] ECM Int Temp Sensor Low Error
- Failure code [CA731] Eng Bkup Speed Sens Phase Error
- Failure code [CA778] Eng Bkup Speed Sensor Error
- Failure code [CA1117] Persistent Data Lost Error
- Failure code [CA1695] Sensor 5 Supply Volt High Error
- Failure code [CA1696] Sensor 5 Supply Volt Low Error
- Failure code [CA1843] Crankcase Press Sens High Error
- Failure code [CA1844] Crankcase Press Sens Low Error
- Failure code [CA1896] EGR Valve Stuck Error
- Failure code [CA1942] Crankcase Press Sens In Range Error
- Failure code [CA1961] EGR_Motor Driver IC Over Temp Error
- Failure code [CA2185] Throt Sensor Sup Volt High Error
- Failure code [CA2186] Throt Sensor Sup Volt Low Error
- Failure code [CA2249] Rail Press Very Low Error
- Failure code [CA2272] EGR Valve Pos Sens Low Error
- Failure code [CA2311] IMV Solenoid Error
Failure code [DWA2KB] Attachment Sol Short Circuit11 topics
- Failure code [DWJ0KA] Merge-divider Sol Open Circuit
- Failure code [DWJ0KB] Merge-divider Sol Short Circuit
- Failure code [DXA8KA] PC-EPC Sol Open Circuit
- Failure code [DXA8KB] PC-EPC Sol Short Circuit
- Failure code [DXE4KA] Attachment Flow EPC Open Circuit
- Failure code [DXE4KB] Attachment Flow EPC Short Circuit
- Failure code [DY20KA] Wiper Working Abnormality
- Failure code [DY20MA] Wiper Parking Abnormality
- Failure code [DY2CKB] Washer Drive Short Circuit
- Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit
- Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit
Troubleshooting of electrical system (E-mode)27 topics
- Engine does not start (Engine does not crank)
- Manual preheating system does not work
- While preheating is working, preheating monitor does not light up
- When starting switch is turned to ON position, machine monitor displays nothing
- Engine coolant temperature monitor lights up in white while engine is running
- Hydraulic oil temperature monitor lights up in white while engine is running
- Charge level monitor lights up while engine is running
- Fuel level monitor lights up in red while engine is running
- Engine coolant temperature monitor lights up in red while engine is running
- Hydraulic oil temperature monitor lights up in red while engine is running
- Engine oil pressure monitor lights up in red while engine is running
- Fuel gauge display does not move from minimum or maximum
- Fuel gauge indicates incorrect amount (indicates neither full nor empty)
- Hydraulic oil temperature gauge does not move from minimum or maximum
- Some areas of machine monitor screen are not displayed
- Function switch does not work
- Automatic warm-up system does not operate (in cold season)
- Travel speed monitor does not change while travel speed switch is operated
- Travel speed does not change while travel speed selection is changed
- Alarm buzzer does not stop sounding
- Service meter is not displayed, while starting switch is in OFF position
- Service mode cannot be selected
- Any of work equipment, swing and travel does not work
- Any of work equipment, swing and travel cannot be locked
- Alarm does not sound during travel
- Alarm does not stop sounding while machine is stopped
- Horn does not sound
Horn does not stop sounding1 topic
- operated
Time lag of work equipment is large1 topic
- slower
Swing acceleration or swing speed is low in both directions (right and left)2 topics
- direction
- left)
Engine does not crank when starting switch is turned to START position18 topics
- Engine cranks but no exhaust smoke comes out
- Engine startability is poor
- Engine does not pick up smoothly
- Engine stops during operation
- Engine runs rough or is unstable
- Engine lacks power
- Exhaust smoke is black
- Engine oil consumption is excessive
- Oil becomes contaminated quickly
- Fuel consumption is excessive
- Oil is in coolant (or coolant spurts or coolant level goes down)
- Oil pressure drops
- Fuel mixes into engine oil
- Water mixes into engine oil (milky)
- Coolant temperature rises too high (overheating)
- Unusual noise is heard
- Vibration is excessive
- Air cannot be bled from fuel circuit
Related information on disassembly and assembly31 topics
- How to read this manual
- Coating materials list
- Special tools list
- Sketches of special tools
- Removal and installation of supply pump assembly
- Removal and installation of injector assembly
- Removal and installation of cylinder head assembly
- Removal and installation of radiator assembly
- Removal and installation of hydraulic oil cooler assembly
- Removal and installation of aftercooler assembly
- Removal and installation of engine and main pump assembly
- Removal and installation of engine front oil seal
- Removal and installation of engine rear oil seal
- Removal and installation of fuel cooler assembly
- Removal and installation of fuel tank assembly
- Removal and installation of KDOC assembly
- Removal and installation of KCCV assembly
- Removal and installation of air cleaner assembly
- Removal and installation of fan belt
- Removal and installation of travel motor and final drive assembly
- Disassembly and assembly of travel motor and final drive assembly
- Removal and installation of swing motor and swing machinery assembly
- Disassembly and assembly of swing machinery assembly
- Removal and installation of swing circle assembly
- Separation and connection of track
- Removal and installation of sprocket
- Removal and installation of idler and idler cushion assembly
- Disassembly and assembly of idler assembly
- Disassembly and assembly of idler cushion assembly
- Disassembly and assembly of track roller assembly
- Removal and installation of revolving frame assembly
Anti-drop valve for arm7 topics
- Work equipment and swing PPC valve
- Travel PPC valve
- Blade PPC valve
- Boom cylinder
- Arm cylinder
- Bucket cylinder
- Blade cylinder
Air conditioner components40 topics
- Precautions for refrigerant
- Air conditioner component
- Configuration and function of refrigeration cycle
- Outline of refrigeration cycle
- Air conditioner unit
- Dual pressure switch
- Air conditioner controller
- Compressor
- Air conditioner condenser
- Sunlight sensor
- Outer temperature sensor (outside air temperature sensor)
- Procedure for testing and troubleshooting
- Circuit diagram and arrangement of connector pins
- System diagram
- Input and output signals of the air conditioner controller
- Parts and connectors layout
- Testing air leakage (duct)
- Testing with self-diagnosis function
- Testing vent (mode) changeover
- Testing FRESH/RECIRC air changeover
- Testing sunlight sensor
- Testing (dual) pressure switch for refrigerant
- Testing relays
- Troubleshooting chart 1
- Troubleshooting chart 2
- Information in troubleshooting table
- Failure code list related to air conditioner
- Failure code [879AKA] A/C Inner Sensor Open Circuit
- Failure code [879AKB] A/C Inner Sensor Short Circuit
- Failure code [879BKA] A/C Outer Sensor Open Circuit
- Failure code [879BKB] A/C Outer Sensor Short Circuit
- Failure code [879CKA] Ventilating Sensor Open Circuit
- Failure code [879CKB] Ventilating Sensor Short Circuit
- Failure code [879DKZ] Sunlight Sensor Open or Short Circuit
- Failure code [879EMC] Ventilation Damper Abnormality
- Failure code [879FMC] Air Mix Damper Abnormality
- Failure code [879GKX] Refrigerant Abnormality
- Troubleshooting for power supply system (Air conditioner does not operate)
- Troubleshooting for compressor and refrigerant system (Air is not cooled)
- abnormal)
Inside this manual
Real pages from this service manual (1,421 pages). Open the sample pages (PDF, 834 KB)
- Troubleshooting, page 741: Troubleshooting by failure code (Display of code)
- Diagram, page 1,049: 50 Disassembly and assembly
- Specifications, page 1,291: 60 Maintenance standard
- Foldout diagram: PC138USLC-10
Other manuals for this machine
Save 10% on 2 manuals, 15% on 3 or more. Other manuals for the PC138USLC-10 are listed below. Editions cover different serial number ranges: check the serial coverage and tick only the ones that match your machine.
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This is a service manual
Here's how it compares to the other manual types.
Service manual
Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.
Operator's manual
Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.
Parts manual
Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.
Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.
What it's used for
Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.
Service shops and owner/operators who repair their own equipment
Identifying correct parts and seeing how assemblies come apart and go back together
Keeping equipment running with less downtime
Factory manual, 1,421 pages
Quantity one is the manual described above.
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