Komatsu Hydraulic Excavator PC238USLC Repair Service Manual
Komatsu Hydraulic Excavator PC238USLC Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavator PC238USLC, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu Hydraulic Excavator PC238USLC-11 workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
PRODUCT DETAILS:
Total Pages: 2,841 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
SEN06635-04 - Komatsu Hydraulic Excavator PC238USLC-11 Shop Manual.pdf
MAIN SECTIONS
COVER...1
00 INDEX AND FOREWORD...3
INDEX...4
ABBREVIATION LIST...21
FOREWORD, SAFETY, BASIC INFORMATION...27
HOW TO READ THE SHOP MANUAL...27
SAFETY NOTICE FOR OPERATION...29
PRECAUTIONS TO PREVENT FIRE...37
ACTIONS IF FIRE OCCURS...39
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS...40
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS...41
PRECAUTIONS FOR DEF...42
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING...42
PRECAUTIONS FOR ADDING...42
PRECAUTIONS FOR STORING...42
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE...42
THE OTHER PRECAUTIONS...42
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT...43
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS...46
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT...53
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT...55
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT...56
PRACTICAL USE OF KOMTRAX...57
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER...58
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER...58
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER...59
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER...60
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS...62
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR...66
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR...67
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL...69
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH...70
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE...72
HOW TO READ ELECTRICAL WIRE CODE...73
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD...77
STANDARD TIGHTENING TORQUE TABLE...80
CONVERSION TABLE...87
01 SPECIFICATIONS...93
CONTENTS...94
ABBREVIATION LIST...95
SPECIFICATIONS...101
SPECIFICATION DRAWING...101
SPECIFICATION DRAWING: PC238USLC-11...101
WORKING RANGE DRAWINGS...103
WORKING RANGE: PC238USLC-11...103
SPECIFICATIONS...104
SPECIFICATIONS: PC238USLC-11...104
WEIGHT TABLE...107
WEIGHT TABLE: PC238USLC-11...107
FUEL, COOLANT, LUBRICANTS (FOR NORTH AMERICA)...109
USE OF FUEL, COOLANT AND LUBRICANTS TO ACCORDING TO AMBIENT TEMPERATURE...109
10 STRUCTURE AND FUNCTION...111
CONTENTS...112
ABBREVIATION LIST...115
UREA SCR SYSTEM...121
LAYOUT DRAWING OF UREA SCR SYSTEM...121
UREA SCR SYSTEM DIAGRAM...126
FUNCTION OF UREA SCR SYSTEM...127
FUNCTION OF AdBlue/DEF SYSTEM...127
INDUCEMENT STRATEGY...129
COMPONENT PARTS OF UREA SCR SYSTEM...137
AdBlue/DEF MIXING TUBE...137
SCR ASSEMBLY...138
AdBlue/DEF TANK...140
AdBlue/DEF PUMP...142
AdBlue/DEF INJECTOR...143
AdBlue/DEF HOSE...144
AdBlue/DEF TANK HEATING VALVE...145
BOOT-UP SYSTEM...146
LAYOUT DRAWING OF BOOT-UP SYSTEM...146
SYSTEM OPERATING LAMP SYSTEM...148
SYSTEM OPERATING LAMP SYSTEM DIAGRAM...148
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM...148
BATTERY DISCONNECT SWITCH...149
FUNCTION OF BATTERY DISCONNECT SWITCH...149
ENGINE SYSTEM...150
LAYOUT DRAWING OF ENGINE SYSTEM...150
SPECIFICATIONS OF ENGINE SYSTEM...151
FUNCTION OF ENGINE SYSTEM...151
ENGINE CONTROL SYSTEM...152
ENGINE CONTROL SYSTEM DIAGRAM...152
FUNCTION OF ENGINE CONTROL SYSTEM...153
AUTO-DECELERATION SYSTEM...155
AUTO-DECELERATION SYSTEM DIAGRAM...155
FUNCTION OF AUTO-DECELERATION SYSTEM...155
OPERATION OF AUTO-DECELERATION SYSTEM...156
ENGINE AUTOMATIC WARM-UP SYSTEM...157
ENGINE AUTOMATIC WARM-UP SYSTEM DIAGRAM...157
FUNCTION OF ENGINE AUTOMATIC WARM-UP SYSTEM...158
OVERHEAT PREVENTION SYSTEM...159
OVERHEAT PREVENTION SYSTEM DIAGRAM...159
FUNCTION OF OVERHEAT PREVENTION SYSTEM...160
TURBOCHARGER PROTECTION SYSTEM...162
TURBOCHARGER PROTECTION SYSTEM DIAGRAM...162
FUNCTION OF TURBOCHARGER PROTECTION SYSTEM...163
AUTOMATIC IDLE STOP SYSTEM...164
AUTOMATIC IDLE STOP SYSTEM DIAGRAM...164
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM...164
COMPONENT PARTS OF ENGINE SYSTEM...167
VGT...167
EGR SYSTEM...172
EGR VALVE...174
EGR COOLER...176
KCCV SYSTEM...178
KCCV VENTILATOR...180
KDPF...182
COOLING SYSTEM...186
LAYOUT DRAWING OF COOLING SYSTEM...186
SPECIFICATIONS OF COOLING SYSTEM...187
FAN SPEED CONTROL SYSTEM OF FAN CLUTCH...188
FAN SPEED CONTROL SYSTEM DIAGRAM OF FAN CLUTCH...188
FUNCTION OF FAN SPEED CONTROL SYSTEM OF FAN CLUTCH...189
ENGINE OUTPUT CONTROL SYSTEM OF FAN CLUTCH...190
ENGINE OUTPUT CONTROL SYSTEM DIAGRAM OF FAN CLUTCH...190
FUNCTION OF ENGINE OUTPUT CONTROL SYSTEM OF FAN CLUTCH...190
COMPONENT PARTS OF COOLING SYSTEM...192
FAN CLUTCH...192
CONTROL SYSTEM...193
LAYOUT DRAWING OF CONTROL SYSTEM...193
MACHINE MONITOR SYSTEM...196
MACHINE MONITOR SYSTEM DIAGRAM...196
FUNCTION OF MACHINE MONITOR SYSTEM...196
KomVision SYSTEM...198
LAYOUT DRAWING OF KomVision SYSTEM...198
KomVision SYSTEM DIAGRAM...200
FUNCTION OF KomVision SYSTEM...200
KOMTRAX SYSTEM...202
KOMTRAX SYSTEM DIAGRAM...202
FUNCTION OF KOMTRAX SYSTEM...202
COMPONENT PARTS OF CONTROL SYSTEM...203
MACHINE MONITOR...203
KomVision CONTROLLER...222
KomVision CAMERA...226
KOMTRAX TERMINAL...227
PUMP CONTROLLER...229
RESISTOR FOR PC-EPC VALVE...234
CAN TERMINATING RESISTOR...235
ENGINE CONTROLLER...236
FUEL CONTROL DIAL...243
HYDRAULIC SYSTEM...245
LAYOUT DRAWING OF HYDRAULIC SYSTEM...245
CLSS...249
STRUCTURE OF CLSS...249
OPERATION OF UNLOAD VALVE AND LS PRESSURE...251
PUMP SWASH PLATE ANGLE (OIL FLOW) CONTROL...252
PRESSURE COMPENSATION CONTROL...265
ENGINE AND PUMP COMBINED CONTROL SYSTEM...268
ENGINE AND PUMP COMBINED CONTROL SYSTEM DIAGRAM...268
FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM...270
PUMP AND VALVE CONTROL SYSTEM...275
PUMP AND VALVE CONTROL SYSTEM DIAGRAM...275
FUNCTION OF PUMP AND VALVE CONTROL SYSTEM...276
COMPONENT PARTS OF HYDRAULIC SYSTEM...278
HYDRAULIC TANK...278
MAIN PUMP...280
CONTROL VALVE...306
WORK EQUIPMENT SYSTEM...364
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM...364
ONE-TOUCH POWER MAXIMIZING SYSTEM...369
ONE-TOUCH POWER MAXIMIZING SYSTEM DIAGRAM...369
FUNCTION OF ONE-TOUCH POWER MAXIMIZING SYSTEM...370
PPC LOCK SYSTEM...371
PPC LOCK SYSTEM DIAGRAM...371
FUNCTION OF PPC LOCK SYSTEM...371
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM...372
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM DIAGRAM...372
FUNCTION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM...372
OPERATION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM...373
OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT...374
ATTACHMENT OIL FLOW ADJUSTER SYSTEM DIAGRAM...374
FUNCTION OF OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT...375
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM...376
WORK EQUIPMENT AND SWING PPC VALVE...376
1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE)...382
2ND-LINE ATTACHMENT PPC VALVE...387
SOLENOID VALVE...389
BOOM ANGLE POTENTIOMETER...393
ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE)...394
ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE)...396
PILOT CIRCUIT ACCUMULATOR...398
ATTACHMENT CIRCUIT ACCUMULATOR...399
SWING SYSTEM...400
LAYOUT DRAWING OF SWING SYSTEM...400
SWING CONTROL SYSTEM DIAGRAM...404
FUNCTION OF SWING CONTROL SYSTEM...404
COMPONENT PARTS OF SWING SYSTEM...408
SWING MOTOR...408
SWING MACHINERY...420
SWING CIRCLE...422
TRAVEL SYSTEM...423
LAYOUT DRAWING OF TRAVEL SYSTEM...423
TRAVEL CONTROL SYSTEM DIAGRAM...427
FUNCTION OF TRAVEL CONTROL SYSTEM...428
COMPONENT PARTS OF TRAVEL SYSTEM...429
TRAVEL MOTOR...429
FINAL DRIVE...442
TRAVEL PPC VALVE...444
CENTER SWIVEL JOINT...448
UNDERCARRIAGE AND FRAME...450
LAYOUT DRAWING OF UNDERCARRIAGE...450
SPECIFICATIONS OF UNDERCARRIAGE...451
WORK EQUIPMENT...452
STRUCTURE OF WORK EQUIPMENT...452
FUNCTION OF WORK EQUIPMENT...453
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM...454
FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM...454
BUCKET CLEARANCE ADJUSTMENT SHIM...455
FUNCTION OF BUCKET CLEARANCE ADJUSTMENT SHIM...455
CAB AND ITS ATTACHMENTS...456
ROPS CAB...456
STRUCTURE OF ROPS CAB...456
FUNCTION OF ROPS CAB...456
CAB MOUNT...457
STRUCTURE OF CAB MOUNT...457
FUNCTION OF CAB MOUNT...457
CAB TIPPING STOPPER...458
STRUCTURE OF CAB TIPPING STOPPER...458
FUNCTION OF CAB TIPPING STOPPER...458
TAKE WIRING HARNESS OUT OF CAB...459
20 STANDARD VALUE TABLE...461
CONTENTS...462
ABBREVIATION LIST...463
STANDARD VALUE TABLE FOR ENGINE...469
STANDARD VALUE TABLE FOR ENGINE: PC238USLC-11...469
STANDARD VALUE TABLE FOR MACHINE...474
Japanese Only...474
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE...488
30 TESTING AND ADJUSTING...493
CONTENTS...494
ABBREVIATION LIST...497
RELATED INFORMATION ON TESTING AND ADJUSTING...503
TOOLS FOR TESTING AND ADJUSTING...503
SKETCH OF TOOLS FOR TESTING AND ADJUSTING...509
ENGINE AND COOLING SYSTEM...510
TEST ENGINE SPEED...510
METHOD FOR TESTING ENGINE SPEED...510
TEST BOOST PRESSURE...513
METHOD FOR TESTING BOOST PRESSURE ON MACHINE MONITOR...513
METHOD FOR TESTING BOOST PRESSURE...514
TEST EXHAUST GAS COLOR...516
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER...516
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER...517
TEST AND ADJUST VALVE CLEARANCE...519
METHOD FOR TESTING VALVE CLEARANCE...519
