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Komatsu PC238USLC-11 Shop Manual
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Komatsu PC238USLC-11 Shop Manual

Hydraulic excavator
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SEN06635-02
HYDRAULIC
PC238USLC
-11
EXCAVATOR
5001
SERIAL NUMBERS
and up

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Summary of Contents for Komatsu PC238USLC-11

  • Page 1 SEN06635-02 HYDRAULIC PC238USLC EXCAVATOR 5001 SERIAL NUMBERS and up...
  • Page 2 Find manuals at https://best-manuals.com...
  • Page 3 00 INDEX AND FOREWORD PC238USLC-11 00-1 Find manuals at https://best-manuals.com...
  • Page 4 ENGINE SYSTEM ..........................10-40 LAYOUT DRAWING OF ENGINE SYSTEM ................... 10-40 ENGINE CONTROL SYSTEM ....................... 10-42 AUTO-DECELERATION SYSTEM ....................10-45 ENGINE AUTOMATIC WARM-UP SYSTEM .................. 10-47 OVERHEAT PREVENTION SYSTEM .................... 10-49 TURBOCHARGER PROTECTION SYSTEM ................. 10-52 00-2 PC238USLC-11 Find manuals at https://best-manuals.com...
  • Page 5 CONTENTS ............................20-2 ABBREVIATION LIST ..........................20-3 STANDARD VALUE TABLE FOR ENGINE ..................... 20-9 STANDARD VALUE TABLE FOR ENGINE: PC238USLC-11 ............20-9 STANDARD VALUE TABLE FOR MACHINE..................20-14 STANDARD VALUE TABLE FOR MACHINE: PC238USLC-11............20-14 MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE ......20-28 30 TESTING AND ADJUSTING ........................
  • Page 6 ADJUST KomVision CAMERA ANGLE ..................30-245 ADJUST KomVision RELATED ITEMS ..................30-247 HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER ............30-264 HANDLE BATTERY DISCONNECT SWITCH ................30-265 TEST DIODES ..........................30-266 Pm CLINIC............................30-267 Pm CLINIC SERVICE ........................30-267 40 TROUBLESHOOTING ..........................40-1 00-4 PC238USLC-11 Find manuals at https://best-manuals.com...
  • Page 7 FAILURE CODE [AS00R4]......................40-197 FAILURE CODE [AS00R5]......................40-198 FAILURE CODE [AS00R6]......................40-199 FAILURE CODE [AS00ZK]......................40-200 FAILURE CODE [AS10KM]......................40-201 FAILURE CODE [AS10NR] ......................40-202 FAILURE CODE [AS10NT] ......................40-203 FAILURE CODE [B@BAZG] ......................40-204 FAILURE CODE [B@BAZK]......................40-206 FAILURE CODE [B@BCNS] ......................40-208 PC238USLC-11 00-5 Find manuals at https://best-manuals.com...
  • Page 8 FAILURE CODE [CA595] ......................40-307 FAILURE CODE [CA687] ......................40-309 FAILURE CODE [CA689] ......................40-311 FAILURE CODE [CA691] ......................40-314 FAILURE CODE [CA692] ......................40-316 FAILURE CODE [CA697] ......................40-318 FAILURE CODE [CA698] ......................40-319 FAILURE CODE [CA731] ......................40-320 FAILURE CODE [CA778] ......................40-322 00-6 PC238USLC-11 Find manuals at https://best-manuals.com...
  • Page 9 FAILURE CODE [CA2639] ......................40-436 FAILURE CODE [CA2771] ......................40-438 FAILURE CODE [CA2777] ......................40-443 FAILURE CODE [CA2976] ......................40-446 FAILURE CODE [CA3133] ......................40-448 FAILURE CODE [CA3134] ......................40-450 FAILURE CODE [CA3135] ......................40-452 FAILURE CODE [CA3142] ......................40-455 FAILURE CODE [CA3143] ......................40-456 PC238USLC-11 00-7 Find manuals at https://best-manuals.com...
  • Page 10 FAILURE CODE [CA3583] ......................40-589 FAILURE CODE [CA3596] ......................40-591 FAILURE CODE [CA3649] ......................40-595 FAILURE CODE [CA3681] ......................40-598 FAILURE CODE [CA3682] ......................40-603 FAILURE CODE [CA3713] ......................40-608 FAILURE CODE [CA3717] ......................40-611 FAILURE CODE [CA3718] ......................40-612 FAILURE CODE [CA3725] ......................40-613 00-8 PC238USLC-11 Find manuals at https://best-manuals.com...
  • Page 11 FAILURE CODE [CA5179] ......................40-744 FAILURE CODE [CA5181] ......................40-746 FAILURE CODE [CA5383] ......................40-748 FAILURE CODE [D110KB]......................40-750 FAILURE CODE [D19JKZ] ......................40-752 FAILURE CODE [D811MC] ......................40-755 FAILURE CODE [D862KA]......................40-756 FAILURE CODE [D8ALKA] ......................40-757 FAILURE CODE [D8ALKB] ......................40-759 FAILURE CODE [D8AQKR] ......................40-761 PC238USLC-11 00-9...
  • Page 12 FAILURE CODE [DHSDMA] ......................40-873 FAILURE CODE [DHSFMA]......................40-875 FAILURE CODE [DHSGMA] ......................40-877 FAILURE CODE [DHSHMA] ......................40-879 FAILURE CODE [DHSJMA] ......................40-881 FAILURE CODE [DHX1MA] ......................40-883 FAILURE CODE [DKR0MA] ......................40-884 FAILURE CODE [DKR1MA] ......................40-887 FAILURE CODE [DKULKA]......................40-890 FAILURE CODE [DKULKB]......................40-892 FAILURE CODE [DKULKY]......................40-894 00-10 PC238USLC-11...
  • Page 13 FAILURE CODE [DXE7KB]......................40-992 FAILURE CODE [DXE7KY]......................40-994 FAILURE CODE [DXE8KA]......................40-996 FAILURE CODE [DXE8KB]......................40-998 FAILURE CODE [DXE8KY]......................40-1000 FAILURE CODE [DXE9KA]......................40-1002 FAILURE CODE [DXE9KB]......................40-1004 FAILURE CODE [DXE9KY]......................40-1006 FAILURE CODE [DXEAKA] ......................40-1008 FAILURE CODE [DXEAKB] ......................40-1010 FAILURE CODE [DXEAKY] ......................40-1012 FAILURE CODE [DY20KA] ......................40-1014 PC238USLC-11 00-11...
  • Page 14 E-32 ALARM BUZZER CANNOT BE CANCELED ..............40-1069 E-33 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION.................................40-1070 E-34 SERVICE MODE CANNOT BE SELECTED ...............40-1071 E-35 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE ..40-1072 00-12 PC238USLC-11...
  • Page 15 H-15 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE ......40-1153 H-16 ATTACHMENT CIRCUIT CANNOT BE CHANGED............40-1154 H-17 OIL FLOW IN ATTACHMENT CIRCUIT CANNOT BE CHANGED ........40-1155 H-18 IN COMBINED OPERATION OF WORK EQUIPMENT, EQUIPMENT HAVING HEAVIER LOAD MOVES SLOWER ........................40-1156 PC238USLC-11 00-13...
  • Page 16 S-22 ACTIVE REGENERATION TAKES TIME................40-1210 S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION......40-1211 S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE ..............40-1212 S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR) ............40-1214 S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES)......40-1215 50 DISASSEMBLY AND ASSEMBLY......................50-1 00-14 PC238USLC-11...
  • Page 17 REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY...........50-385 DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY ..............50-387 DISASSEMBLE AND ASSEMBLE OF IDLER CUSHION ASSEMBLY ..........50-392 DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY ..........50-395 REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY ............50-398 REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY............50-403 PC238USLC-11 00-15...
  • Page 18 MAINTENANCE STANDARD OF TRIPLE SHOE................60-30 MAINTENANCE STANDARD OF ROAD LINER ................60-31 MAINTENANCE STANDARD OF FLAT SHOE................60-32 HYDRAULIC SYSTEM.......................... 60-33 MAINTENANCE STANDARD OF HYDRAULIC TANK ..............60-33 MAINTENANCE STANDARD OF MAIN PUMP................60-34 MAINTENANCE STANDARD OF LS-EPC VALVE ................. 60-35 00-16 PC238USLC-11...
  • Page 19 METHOD FOR TESTING SUNLIGHT SENSOR................80-51 TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT..............80-52 METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT......80-52 TEST RELAYS............................80-54 METHOD FOR TESTING RELAYS ....................80-54 AIR CONDITIONER TROUBLESHOOTING CHART 1 ................. 80-55 PC238USLC-11 00-17...
  • Page 20 ELECTRICAL CIRCUIT DIAGRAM (2/9)..................90-23 ELECTRICAL CIRCUIT DIAGRAM (3/9)..................90-25 ELECTRICAL CIRCUIT DIAGRAM (4/9)..................90-27 ELECTRICAL CIRCUIT DIAGRAM (5/9)..................90-29 ELECTRICAL CIRCUIT DIAGRAM (6/9)..................90-31 ELECTRICAL CIRCUIT DIAGRAM (7/9)..................90-33 ELECTRICAL CIRCUIT DIAGRAM (8/9)..................90-35 ELECTRICAL CIRCUIT DIAGRAM (9/9)..................90-37 INDEX..................................1 00-18 PC238USLC-11...

  • Page 21: Abbreviation List

    It is written as CDR valve and is not Regulator used independently. This is a system that can actuate multiple actua- Closed-center Load CLSS Hydraulic system tors simultaneously regardless of the load (pro- Sensing System vides better combined operation than OLSS). PC238USLC-11 00-19...
  • Page 22 (D Series) combination of hydraulic motor and bevel shaft. Transmission Hydraulic transmission system that uses a com- Hydro Static Transmis- bination of hydraulic pump and hydraulic motor sion (D, WA) without using gears for stepless gear shifting. 00-20 PC238USLC-11...
  • Page 23 Inlet Metering Valve Engine pump combustion discharged volume. (Same as IMA) This is a mechanism that burns the blowby gas Komatsu Closed Crank- again by separating oil from blowby gas and re- KCCV Engine case Ventilation turning it to the intake side. It primarily consists of filters.
  • Page 24 This is an actuator that consists of a solenoid and Solenoid Electrical system an iron core that is operated by the magnetic force when the solenoid is energized. 00-22 PC238USLC-11...
  • Page 25 Abbreviation Actual word spelled out Air Conditioner Analogue-to-Digital Air Mix Damper Accessory Additional Auxiliary Battery Relay Clockwise Counter Clockwise Electronic Control Unit Electronic Control Module Engine EXGND External Ground F.G. Frame Ground Ground Inlet Metering Actuator No Connection PC238USLC-11 00-23...
  • Page 26 ABBREVIATION LIST 00 INDEX AND FOREWORD Abbreviation Actual word spelled out Steering STRG Signal Solenoid Standard Option PRESS Pressure SPEC Specification Switch TEMP Temperature Torque Converter Transmission 00-24 PC238USLC-11...

  • Page 27: Troubleshooting

    REMARK • Some of the attachments and options described in this shop manual may not be available in some areas. If they are required, consult your Komatsu distributor. • The materials and specifications are subject to change without notice. • Shop Manuals are available for "machine part" and "engine part". For the engine unit, see the shop manual for the machine which has the same engine model.

  • Page 28: Signal Word

    REMARK Remark This signal word contains useful information to know. Unit International System of Units (SI) is used in this manual. For reference, units that have been used in the past are given in { }. 00-26 PC238USLC-11...

  • Page 29: Safety Matters

    Appropriate servicing and repair are extremely important to ensure safe operation of the machine. The shop manuals describe the effective and safe servicing and repair methods recommended by Komatsu. Some of the servicing and repair methods require the use of special tools designed by Komatsu for special purpos- •...

  • Page 30: Precautions During Work

    Then, disconnect the quick release battery terminal (-). REMARK For the machine without the system operating lamp, turn the starting switch to OFF position, wait for two minutes or more before starting the work. Disconnect the quick release battery terminal (-). 00-28 PC238USLC-11...
  • Page 31 • Do not use gasoline to wash parts as a general rule. Do not use gasoline to clean electrical parts, in partic- ular. PC238USLC-11 00-29...
  • Page 32 • Hanging angle must be 60 ° or smaller as a rule. • When slinging a heavy load (25 kg or heavier), the hanging angle of the rope must be narrower than that of the hook. 00-30 PC238USLC-11...
  • Page 33 Precautions for using mobile crane REMARK Read Operation and Maintenance Manual of the crane carefully in advance and operate the crane safely. Precautions for using overhead traveling crane When raising a heavy component (heavier than 25 kg), use a hoist or crane. PC238USLC-11 00-31...
  • Page 34 Wire rope (JIS G3525 6x37-A type) (Standard Z twist wire ropes without galvanizing) Nominal diameter of rope ( mm) Allowable load ( kN { t} ) 8.8 {0.9} 12.7 {1.3} 17.3 {1.7} 22.6 {2.3} 28.6 {2.9} 35.3 {3.6} 55.3 {5.6} 79.6 {8.1} 141.6 {14.4} 221.6 {22.6} 318.3 {32.4} 00-32 PC238USLC-11...
  • Page 35 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). PC238USLC-11 00-33...
  • Page 36 • The figure shows an example of fitting of O-ring. • An O-ring is fitted to every joint of the air conditioner piping. For tightening torques, see THE OTHER INFORMATION, "Pre- cautions for disconnection and connection of air conditioner piping". 00-34 PC238USLC-11...
  • Page 37 Fire around the machine due to highly heated exhaust gas Some models and specifications may be equipped with KDPF (Komatsu Diesel Particulate Filter). KDPF is a system for purifying exhaust gas by removing soot in exhaust gas. In the process of purification (re- generation), the temperature of discharged exhaust gas may be higher than that of conventional models.
  • Page 38 • 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, follow the instructions in the Operation and Maintenance Manual. 00-36 PC238USLC-11...
  • Page 39 Be sure to wear rubber gloves when handling the materials left after the fire. The material of the gloves, which is recommended is polychloroprene (Neoprene) or polyvinyl chloride (in the lower temperature environment). When wearing cotton work gloves, wear rubber gloves under them. PC238USLC-11 00-37...
  • Page 40 Avoid exposure to burning rubber or plastics which produce a toxic gas that is harmful to people. • When disposing of parts made of rubber or plastics (hoses, cables, and harnesses), always comply with the local regulations for disposing industrial waste products. 00-38 PC238USLC-11...
  • Page 41 This machine is equipped with the following two exhaust gas treatment systems: • Komatsu Diesel Particulate Filter (hereafter KDPF): A device which captures soot in the exhaust gas to pu- rify exhaust gas. This process performs the combustion of soot referred to as "regeneration".
  • Page 42 If it gets on your skin, thoroughly wash it off with water. Never relocate or modify the exhaust gas after-treatment device. The harmful gas may be exhausted and it can cause serious damage to the environment as well as violation of laws. 00-40 PC238USLC-11...
  • Page 43 Do not discard the oil inconsiderately. Ask the customer for disposal or bring it back to dispose it ap- propriately. REMARK Cover the places tightly with caps, tapes, or plastic bags if it is hard to provide the plugs. PC238USLC-11 00-41...
  • Page 44 Cleaning operation Perform oil cleaning to remove the contaminants and sludges in the hydraulic circuit after repair of the hydraulic device (pump, or control valve) or during operation of the machine. 00-42 PC238USLC-11...
  • Page 45 00 INDEX AND FOREWORD PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT REMARK The oil cleaning equipment can remove the ultra fine (approxi- mately 3 μm) particles that the filter built in the hydraulic equip- ment cannot remove. So, it is very effective device. PC238USLC-11 00-43...
  • Page 46 When disassembling the machine, check the part number by referring to the Parts Book and use the appropriate parts according to the usage conditions. REMARK The part numbers of O-ring shown in the table indicate the temporary part number when disassembling and transporting the machine. 00-44 PC238USLC-11...
  • Page 47 Introduction of parts for the disconnection of the taper seal type hoses and tubes Hose side Pipe joint side Nominal No. Plug (1) Nut (2) 07376-50210 07222-00210 07376-50315 07222-00312 07376-50422 07222-00414 07376-50522 07222-00515 07376-50628 07222-00616 07376-51034 07222-01018 07376-51234 07222-01219 07376-51443 07222-01422 PC238USLC-11 00-45...
  • Page 48 07379-03010 07371-13010 07378-13000 07000-12085 07372-51650 01643-51645 120.6 69.8 07379-03411 07371-13411 07378-13400 07000-12100 07372-51650 01643-51645 130.2 77.8 07379-04012 07371-14012 07378-14000 07000-12110 07372-51650 01643-51645 152.4 07379-05011 07371-15011 07378-15000 07000-12135 07372-51655 01643-51645 Introduction of parts for the removal of O-ring boss type joint 00-46 PC238USLC-11...
  • Page 49 Precautions for installation and assembling work • Tighten the bolts and nuts (sleeve nuts) to the specified torque (KES) unless otherwise specified. • Install the hoses without twist and interference. If there is any in-between clamp, securely fasten it. PC238USLC-11 00-47...
  • Page 50 Perform the operation to extend and retract each cylinder of the work equipment and stop it at approximate- ly 100 mm before the stroke end for 4 or 5 times. Perform the operation to extend and retract each cylinder of the work equipment and stop it at the stroke end for 3 or 4times. 00-48 PC238USLC-11...
  • Page 51 When the coolant is drained, be sure that the drain valve is securely tightened, then refill the coolant reser- voir 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.
  • Page 52 • Parts which connects the above, or etc. Check that there is no unusual noise by comparing to it of the time when the machine was new. If there is any unusual noise, repair KDPF or muffler, referring to "TROUBLESHOOTING" and "DISASSEMBLY AND ASSEMBLY". 00-50 PC238USLC-11...
  • Page 53 The pins of the male and female connectors are attached to wires by crimping or soldering. If excessive force is applied to the wire, the jointed portion (1) may become loose, and it may result in a defective connection or breakage. PC238USLC-11 00-51...
  • Page 54 • If there is oil or water in the compressed air, it causes the contacts to become dirtier. Use clean air which any oil and water has been removed from. 00-52 PC238USLC-11...
  • Page 55 If a filter oth- er than a Komatsu genuine filter is used, fuel system contamination and damage may occur. Therefore Komatsu recommends using only Komatsu fuel filters and install them following the procedures in the shop manual.
  • Page 56 Plug the removed pipes and the openings of the removed components with the caps, tapes, plastic bags, etc. to prevent foreign material from entering. NOTICE Do not expose the openings or stuff it, otherwise foreign material may enter it. 00-54 PC238USLC-11...
  • Page 57 To 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, ask KOMTRAX key person in your Komatsu distributor. PC238USLC-11 00-55...
  • Page 58 Provide an oil container to receive a quantity of hydraulic oil which may flow out. Connection Hold hose adapter (1) or hose (5), and insert it in mating adapter (3), aligning the axis. REMARK Do not hold rubber cap portion (4). 00-56 PC238USLC-11...
  • Page 59 While keeping the condition of step 1, turn lever (3) to the right (clockwise). While keeping the conditions of steps 1 and 2, pull out whole body (2) to disconnect it. REMARK Provide an container to receive a quantity of hydraulic oil which may flow out. PC238USLC-11 00-57...
  • Page 60 While keeping the conditions of steps 1 and 2, pull out whole body (2) to disconnect it. REMARK Provide an container to receive a quantity of hydraulic oil which may flow out. 00-58 PC238USLC-11...
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5001