Komatsu GALEO PC228US-3E0,PC228USLC-3E0 Shop Manual UEN01418-04 PDF
$34.95
Komatsu GALEO PC228US-3E0,PC228USLC-3E0 Shop Manual UEN01418-04 – PDF DOWNLOAD
SERIAL NUMBERS
- PC228US- 40001 and up
- PC228USLC-40001 and up
Description
Komatsu GALEO PC228US-3E0,PC228USLC-3E0 Shop Manual UEN01418-04 – PDF DOWNLOAD
FILE DETAILS:
Komatsu GALEO PC228US-3E0,PC228USLC-3E0 Shop Manual UEN01418-04 – PDF DOWNLOAD
Language : English
Pages : 946
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Komatsu GALEO PC228US-3E0,PC228USLC-3E0 Shop Manual UEN01418-04 – PDF DOWNLOAD
SERIAL NUMBERS
- PC228US- 40001 and up
- PC228USLC-40001 and up
00 Index and foreword 3
Composition of shop manual . 4
Table of contents 6
00 Index and foreword 15
Foreword and general information . 16
Safety notice 16
How to read the shop manual 20
Explanation of terms for maintenance standard 22
Handling electric equipment and hydraulic component 24
How to read electric wire code . 32
Method of disassembling and connecting push-pull type coupler 35
Standard tightening torque table . 38
Conversion table . 42
01 Specification . 49
Specification and technical data . 50
Specification dimension drawings . 50
Working range diagram 51
Specifications . 52
Weight table . 54
Table of fuel, coolant and lubricants 56
10 Structure, function and maintenance standard 59
Engine and cooling system 60
Engine related parts . 60
Radiator, oil cooler, aftercooler and fuel cooler 61
10 Structure, function and maintenance standard 63
Power train 64
Power train 64
Final drive 66
Swing machinery 68
Swing circle . 70
10 Structure, function and maintenance standard 73
Undercarriage and frame 74
Track frame 74
Idler 76
Carrier roller . 78
Track roller . 79
Track shoe . 80
10 Structure, function and maintenance standard 87
Hydraulic system, Part 1 . 88
Hydraulic equipment layout drawing . 88
Hydraulic tank . 90
Hydraulic pump . 92
10 Structure, function and maintenance standard 115
Hydraulic system, Part 2 .116
Control valve 116
CLSS .128
Functions and operation by valve .132
Merge-divider valve 147
Attachment circuit selector valve 170
Hydraulic drift prevention valve .172
10 Structure, function and maintenance standard 179
Hydraulic system, Part 3 .180
Valve control 180
PPC valve 182
PPC Accumulator 200
Return oil filter 201
Center swivel joint 202
Travel motor .203
Swing motor 213
Hydraulic cylinder .222
Quick coupler control valve 224
10 Structure, function and maintenance standard 227
Work equipment .228
Work equipment .228
Dimensions of components .230
10 Structure, function and maintenance standard 235
Cab and its attachments 236
Air conditioner piping .236
10 Structure, function and maintenance standard 239
Electrical system 240
Engine control .240
Electrical control system 250
Monitor system .276
Sensor .294
KOMTRAX terminal system 297
20 Standard value table 301
Standard service value table .302
Standard value table for engine related parts 302
Standard value table for chassis .303
Flow control characteristics of PC valve (STD) .312
30 Testing and adjusting .315
Testing and adjusting, Part 1 316
Tools for testing, adjusting, and troubleshooting 316
Measuring engine speed .319
Measuring intake air pressure (boost pressure) .320
Checking exhaust gas color .321
Adjusting valve clearance 322
Measuring compression pressure .324
Measuring blow-by pressure .326
Measuring engine oil pressure 327
Handling fuel system parts .328
Releasing residual pressure from fuel system .328
Measuring fuel pressure 329
Measuring fuel return rate and leakage .331
Bleeding air from fuel circuit .334
Checking fuel circuit for leakage 336
Checking and adjusting air conditioner compressor belt tension .337
30 Testing and adjusting .339
Testing and adjusting, Part 2 341
Measurement of clearance in swing circle bearings 341
Checking and adjusting track shoe tension 342
Inspection and adjustment of hydraulic oil pressure in hydraulic circuit for work equipment, swing and travel 343
Measurement of control circuit oil pressure 347
Inspection and adjustment of pump PC control circuit oil pressure 348
Inspection and adjustment of pump LS control circuit oil pressure 351
Measurement of solenoid valve output pressure 356
Measurement of PPC valve output pressure .359
Adjustment of work equipment and swing PPC valve .361
Inspection of locations of hydraulic drift of work equipment .362
Release of residual pressure from hydraulic circuit 364
Measuring oil leakage 365
Bleeding air from each part 368
Procedure for replacing boom angle potentiometer .370
Inspection procedures for diode 371
Adjusting mirrors 372
Measuring and adjusting quick coupler control valve output pressure 374
30 Testing and adjusting .377
Testing and adjusting, Part 3 378
Special functions of machine monitor .378
Handling voltage circuit of engine controller 406
Procedure for turning on KOMTRAX terminal 407
KOMTRAX terminal lamp indications 410
Preparation work for troubleshooting of electrical system 413
40 Troubleshooting .421
Failure code table and fuse locations 422
Failure code table .422
Fuse locations .425
40 Troubleshooting .427
General information on troubleshooting .428
Points to remember when troubleshooting 428
Sequence of events in troubleshooting 429
Checks before troubleshooting 430
Classification and troubleshooting steps .431
Information in troubleshooting table .432
Possible problems and troubleshooting No .434
Wiring table for connector pin numbers .437
T-adapter box and T-adapter table 466
40 Troubleshooting .471
Troubleshooting by failure code (Display of code), Part 1 473
Failure code [A000N1] Eng. Hi Out of Std .473
Failure code [AA10NX] Air cleaner Clogging .474
Failure code [AB00KE] Charge Voltage Low .476
Failure code [B@BAZG] Eng. Oil Press. Low 478
Failure code [B@BAZK] Eng. Oil Level Low .479
Failure code [B@BCNS] Eng. Water Overheat 480
Failure code [B@BCZK] Eng. Water Level Low .482
Failure code [B@HANS] Hydr Oil Overheat 483
Failure code [CA111] EMC Critical Internal Failure .483
Failure code [CA115] Eng Ne and Bkup Speed Sens Error 484
Failure code [CA122] Chg Air Press Sensor High Error .486
Failure code [CA123] Chg Air Press Sensor Low Error 488
Failure code [CA131] Throttle Sensor High Error 490
Failure code [CA132] Throttle Sensor Low Error .492
Failure code [CA144] Coolant Temp Sens High Error 494
Failure code [CA145] Coolant Temp Sens Low Error .496
Failure code [CA153] Chg Air Temp Sensor High Error 498
Failure code [CA154] Chg Air Temp Sensor Low Error .500
Failure code [CA155] Chg Air Temp High Speed Derate 502
Failure code [CA187] Sens Supply 2 Volt Low Error 504
Failure code [CA221] Ambient Press Sens High Error .506
Failure code [CA222] Ambient Press Sens Low Error 508
Failure code [CA227] Sens Supply 2 Volt High Error .510
Failure code [CA234] Eng. Overspeed 511
Failure code [CA238] Ne Speed Sens Supply Volt Error .512
Failure code [CA271] IMV/PCV1 Short Error 513
Failure code [CA272] IMV/PCV1 Open Error .514
Failure code [CA322] Inj #1 Open/Short Error .516
Failure code [CA323] Inj #5 Open/Short Error .518
Failure code [CA324] Inj #3 Open/Short Error .520
40 Troubleshooting .523
Troubleshooting by failure code (Display of code), Part 2 526
Failure code [CA325] Inj #6 Open/Short Error .526
Failure code [CA331] Inj #2 Open/Short Error .528
Failure code [CA332] Inj #4 Open/Short Error .530
Failure code [CA342] Calibration Code Incompatibility 532
Failure code [CA351] Injectors Drive Circuit Error .534
Failure code [CA352] Sens Supply 1 Volt Low Error 536
Failure code [CA386] Sens Supply 1 Volt High Error .538
Failure code [CA428] Water in Fuel Sensor High Error .540
Failure code [CA429] Water in Fuel Sensor Low Error 542
Failure code [CA435] Eng Oil Press Sw Error 544
Failure code [CA441] Engine Controller Battery Voltage Low Error .545
Failure code [CA442] Engine Controller Battery Voltage High Error 548
Failure code [CA449] Rail Press Very High Error 550
Failure code [CA451] Rail Press Sensor High Error 552
Failure code [CA452] Rail Press Sensor Low Error .554
Failure code [CA488] Chg Air Temp High Torque Derate .556
Failure code [CA553] Rail Press High Error .556
Failure code [CA559] Rail Press Low Error 557
Failure code [CA689] Eng Ne Speed Sensor Error .558
Failure code [CA731] Eng Bkup Speed Sens Phase Error .560
Failure code [CA757] All Continuous Data Lost Error 562
Failure code [CA778] Eng Bkup Speed Sensor Error .564
Failure code [CA1633] KOMNET Datalink Timeout Error 566
Failure code [CA2185] Throt Sens Sup Volt High Error .568
Failure code [CA2186] Throt Sens Sup Volt Low Error 569
Failure code [CA2249] Rail Press Very Low Error 570
Failure code [CA2311] IMV Solenoid Error .572
Failure code [CA2555] Grid Htr Relay Volt High Error .574
Failure code [CA2556] Grid Htr Relay Volt Low Error 576
40 Troubleshooting .579
Troubleshooting by failure code (Display of code), Part 3 580
Failure code [D110KB] Battery Relay Drive S/C 580
Failure code [D196KA] Service Return Relay Disc 582
Failure code [D196KB] Service Return Relay S/C .584
Failure code [DA22KK] Pump Solenoid Power Low Error 586
Failure code [DA25KP] Press. Sensor Power Abnormality 588
Failure code [DA2RMC] Pump Comm. Abnormality .590
Failure code [DA2SKQ] Model Selection Abnormality 592
Failure code [DAFRMC] Monitor Comm. Abnormality 594
Failure code [DGH2KB] Hydr Oil Sensor Short 596
Failure code [DHPAMA] F Pump Press Sensor Abnormality 598
Failure code [DHPBMA] R Pump Press Sensor Abnormality 600
Failure code [DHSAMA] Sw RH PPC Press Sen. Abnormality .602
Failure code [DHSBMA] Sw LH PPC Press Sen. Abnormality .604
40 Troubleshooting .607
Troubleshooting by failure code (Display of code), Part 4 610
Failure code [DW43KA] Travel Speed Sol. Disc .610
Failure code [DW43KB] Travel Speed Sol. S/C 612
Failure code [DW45KA] Swing Brake Sol. Disc 615
Failure code [DW45KB] Swing Brake Sol. S/C .618
Failure code [DW91KA] Travel Junction Sol. Disc 620
Failure code [DW91KB] Travel Junction Sol. S/C .622
Failure code [DW4GKA] Disconnection in boom RAISE throttle EPC solenoid 624
Failure code [DW4GKB] Short circuit in boom RAISE throttle EPC solenoid 626
Failure code [DWJ0KA] Merge-divider Sol. Disc 628
Failure code [DWJ0KB] Merge-divider Sol. S/C .630
Failure code [DWK0KA] 2-stage Relief Sol. Disc .632
Failure code [DWK0KB] 2-stage Relief Sol. S/C 634
Failure code [DXA0KA] PC-EPC Sol. Disc .636
Failure code [DXA0KB] PC-EPC Sol. S/C 638
Failure code [DXE0KA] LS-EPC Sol. Disc .640
Failure code [DXE0KB] LS-EPC Sol. S/C 642
Failure code [DXE4KA] Service Current EPC Disc .644
Failure code [DXE4KB] Service Current EPC S/C 645
Failure code [DY20KA] Wiper Working Abnormality 646
Failure code [DY20MA] Wiper Parking Abnormality 648
Failure code [DY2CKB] Washer Drive S/C .650
Failure code [DY2DKB] Wiper Drive (For) S/C 652
Failure code [DY2EKB] Wiper Drive (Rev) S/C 654
40 Troubleshooting .657
Troubleshooting of electrical system (E-mode) 659
Before carrying out troubleshooting of electrical system .659
Information contained in troubleshooting table .660
E-1 Engine does not start 661
E-2 Auto-decelerator does not operate 664
E-3 Automatic warming-up system does not operate .666
E-4 Preheater does not operate .668
E-5 All work equipment, swing, and travel mechanism do not move 670
E-6 Power maximizing function does not operate .672
E-7 Machine monitor does not display at all 674
E-8 Machine monitor does not display some items 676
E-9 Contents of display by machine monitor are different from applicable machine .676
E-10 Fuel level monitor was lighted in red while engine running 677
E-11 Engine coolant temperature gauge does not indicate normally .678
E-12 Hydraulic oil temperature gauge does not indicate normally 680
E-13 Fuel level gauge does not indicate normally .681
E-14 Swing lock monitor does not indicate normally .682
E-15 When monitor switch is operated, monitor displays nothing .684
E-16 Windshield wiper and window washer do not operate .686
E-17 Monitoring function fails to display “boom raise” normally 690
E-18 Monitoring function fails to display “boom lower” normally 691
E-19 Monitoring function fails to display “arm IN” normally 692
E-20 Monitoring function fails to display “arm OUT” normally .693
E-21 Monitoring function fails to display “bucket CURL” normally .694
E-22 Monitoring function fails to display “bucket DUMP” normally .695
E-23 Monitoring function fails to display “swing left” normally 696
E-24 Monitoring function fails to display “swing right” normally .698
E-25 Monitoring function fails to display “travel” normally 700
E-26 Monitoring function fails to display “travel differential pressure” normally 702
E-27 Monitoring function fails to display “service” normally .704
E-28 KOMTRAX system does not operate normally 706
E-29 Air conditioner does not operate 708
E-30 Travel alarm does not sound or does not stop sounding .710
E-31 Horn does not sound .712
E-32 Attachment circuit does not change 714
40 Troubleshooting .717
Troubleshooting of hydraulic and mechanical system (H-mode) 720
System chart for hydraulic and mechanical systems 720
Information contained in troubleshooting table .722
H-1 All work equipment lack power, or travel and swing speeds are slow .723
H-2 Engine speed sharply drops or engine stalls 725
H-3 No work equipment, travel or swing move 726
H-4 Abnormal noise is heard from around hydraulic pump .726
H-5 Auto-decelerator does not work .727
H-6 Fine control mode does not function 727
H-7 Boom moves slowly or lacks power .728
H-8 Arm moves slowly or lacks power 729
H-9 Bucket moves slowly or lacks power .730
H-10 Work equipment does not move in its single operation 730
H-11 Work equipment has a bit too large hydraulic drift 731
H-12 Work equipment has big time lag .732
H-13 Other work equipment moves when relieving single circuit 732
H-14 One-touch power max. switch does not operate 732
H-15 In compound operation, work equipment with larger load moves slowly .733
H-16 In swing + boom RAISE operation, boom moves slowly 733
H-17 In swing + travel, travel speed drops sharply .733
H-18 Machine swerves in travel .734
H-19 Machine travels slowly 735
H-20 Machine cannot be easily steered or lacks power .736
H-21 Travel speed does not shift, or it is slower or faster than preset speed 737
H-22 Track shoe does not turn (on one side only) .737
H-23 Machine does not swing 738
H-24 Swing acceleration is poor, or swing speed is slow 740
H-25 Excessive overrun when stopping swing .742
H-26 There is big shock when stopping swing 743
H-27 There is big abnormal noise caused when stopping swing 743
H-28 Swing natural drift is too big 744
H-29 Attachment circuit does not change 745
H-30 Flow rate in attachment circuit cannot be adjusted 745
Quick coupler 746
40 Troubleshooting .749
Troubleshooting of engine (S-mode) .752
Method of using troubleshooting chart 752
S-1 Starting performance is poor .756
S-2 Engine does not start 757
S-3 Engine does not pick up smoothly .760
S-4 Engine stops during operations .761
S-5 Engine does not rotate smoothly 762
S-6 Engine lack output (or lacks power) 763
S-7 Exhaust smoke is black (incomplete combustion) .764
S-8 Oil consumption is excessive (or exhaust smoke is blue) 765
S-9 Oil becomes contaminated quickly .766
S-10 Fuel consumption is excessive .767
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) .768
S-12 Oil pressure drops 769
S-13 Oil level rises (Entry of coolant/fuel) .770
S-14 Coolant temperature becomes too high (overheating) 771
S-15 Abnormal noise is made 772
S-16 Vibration is excessive 773
50 Disassembly and assembly 775
General information on disassembly and assembly 776
How to read this manual 776
Coating materials list .778
Special tool list 781
Sketches of special tools 784
50 Disassembly and assembly 787
Engine and cooling system 788
Removal and installation of fuel supply pump assembly 788
Removal and installation of fuel injector assembly .790
Removal and installation of engine front seal 794
Removal and installation of engine rear seal .796
Removal and installation of cylinder head assembly .799
Removal and installation of radiator assembly 810
Removal and installation of hydraulic oil cooler assembly 813
Removal and installation of aftercooler assembly .815
Removal and installation of fuel cooler assembly .817
Removal and installation of engine assembly 819
Removal and installation of fuel tank assembly .821
50 Disassembly and assembly 823
Power train 824
Removal and installation of travel motor and final drive assembly 824
Disassembly and assembly of travel motor and final drive assembly 825
Removal and installation of swing motor and swing machinery assembly .833
Disassembly and assembly of swing motor and swing machinery assembly .835
Removal and installation of swing circle assembly 843
50 Disassembly and assembly 845
Undercarriage and frame 846
Disassembly and assembly of track roller assembly 846
Disassembly and assembly of idler assembly .847
Disassembly and assembly of recoil spring 850
Expansion and installation of track shoe assembly 852
Removal and installation of revolving frame 854
Removal and installation of counterweight assembly .856
Removal and installation of maintenance counterweight (at rear of engine) 857
Removal and installation of maintenance counterweight assembly (above pump) 858
50 Disassembly and assembly 861
Hydraulic system .862
Removal and installation of center swivel joint assembly .862
Disassembly and assembly of center swivel joint 864
Removal and installation of hydraulic tank assembly 865
Removal and installation of work equipment pump 867
Removal and installation of control valve assembly .871
Disassembly and assembly of control valve assembly .873
Disassembly and assembly of work equipment PPC valve assembly 875
Disassembly and assembly of travel PPC valve assembly 877
Disassembly and assembly of hydraulic cylinder assembly 879
Disassembly and Assembly of Quick Coupler Valve 885
50 Disassembly and assembly 887
Work equipment .888
Removal and installation of work equipment assembly 888
50 Disassembly and assembly 893
Cab and its attachments 894
Removal and installation of operator’s cab assembly 894
Removal and installation of operator’s cab glass (Stuck glass) .896
Removal and installation of front window assembly 906
Removal and installation of floor frame assembly .907
50 Disassembly and assembly 911
Electrical system 912
Removal and installation of air conditioner compressor assembly 912
Removal and installation of air conditioner condenser assembly .913
Removal and installation of air conditioner unit assembly 914
Removal and installation of machine monitor assembly .916
Removal and installation of pump controller assembly .917
Removal and installation of engine controller assembly .918
Removal and installation of KOMTRAX communication modem assembly .920
90 Diagrams and drawings .923
Hydraulic diagrams and drawings 925
Hydraulic circuit diagram 925
90 Diagrams and drawings .929
Electrical diagrams and drawings .931
Electrical circuit diagram (1/7) .931
Electrical circuit diagram (2/7) .933
Electrical circuit diagram (3/7) .935
Electrical circuit diagram (4/7) .937
Electrical circuit diagram (5/7) .939
Electrical circuit diagram (6/7) .941
Electrical circuit diagram (7/7) .943
DESCRIPTION:
Komatsu GALEO PC228US-3E0,PC228USLC-3E0 Shop Manual UEN01418-04 – PDF DOWNLOAD
SERIAL NUMBERS
- PC228US- 40001 and up
- PC228USLC-40001 and up
This shop manual contains the necessary technical information for services performed in a workshop.
For ease of understanding, the manual is divided into the following sections.
00. Index and foreword
This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification
This section explains the specifications of the machine.
10. Structure, function and maintenance standard
This section explains the structure, function, and maintenance standard values of each component.
The structure and function sub-section explains the structure and function of each component. It
serves not only to give an understanding of the structure, but also serves as reference material for
troubleshooting. The maintenance standard sub-section explains the criteria and remedies for disassembly
and service.
20. Standard value table
This section explains the standard values for new machine and judgement criteria for testing,
adjusting, and troubleshooting. This standard value table is used to check the standard values in
testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting
This section explains measuring instruments and measuring methods for testing and adjusting, and
method of adjusting each part. The standard values and judgement criteria for testing and adjusting
are explained in Testing and adjusting.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is
divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also
explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly
This section explains the special tools and procedures for removing, installing, disassembling, and
assembling each component, as well as precautions for them. In addition, tightening torque and
quantity and weight of coating material, oil, grease, and coolant necessary for the work are also
explained.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
q Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q Engine volume
This section explains the method of reproducing, repairing, and replacing parts.
2. Revision and distribution
Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most
up-to-date information before you start any work.
G.B 26/12/24
