KOMATSU HYDRAULIC EXCAVATOR Galeo PC228US-3E0 PC228USLC-3E0 Shop Manual UEN01418-03 PDF

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KOMATSU HYDRAULIC EXCAVATOR Galeo PC228US-3E0 PC228USLC-3E0 Shop Manual UEN01418-03-PDF DOWNLOAD

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KOMATSU HYDRAULIC EXCAVATOR Galeo PC228US-3E0 PC228USLC-3E0 Shop Manual UEN01418-03-PDF DOWNLOAD

Language : English
Pages :186
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

KOMATSU HYDRAULIC EXCAVATOR Galeo PC228US-3E0 PC228USLC-3E0 Shop Manual UEN01418-03-PDF DOWNLOAD

SERIAL NUMBERS PC228US- 40001 and up PC228USLC-40001

Table of contents 1
00 Index and foreword
Index UEN01420-03
Composition of shop manual 2
Table of contents 4
Foreword and general information UEN01421-00
Foreword and general information 2
Safety notice 2
How to read the shop manual 6
Explanation of terms for maintenance standard 8
Handling electric equipment and hydraulic component 10
How to read electric wire code 18
Method of disassembling and connecting push-pull type coupler 21
Standard tightening torque table 24
Conversion table 28
01 Specification
Specification and technical data UEN01423-00
Specification and technical data 2
Specification dimension drawings 2
Working range diagram 3
Specifications 4
Weight table 6
Table of fuel, coolant and lubricants 8
10 Structure, function and maintenance standard
Engine and cooling system UEN01425-00
Engine and cooling system 2
Engine related parts 2
Radiator, oil cooler, aftercooler and fuel cooler 3
Power train UEN01426-00
Power train 2
Power train 2
Final drive 4
Swing machinery 6
Swing circle 8
Undercarriage and frame UEN01427-00
Undercarriage and frame 2
Track frame 2
Idler 4
Carrier roller 6
Track roller 7
Track shoe 8
Hydraulic system, Part 1 UEN01428-00
Hydraulic system, Part 1 2
Hydraulic equipment layout drawing 2
Hydraulic tank 4
Hydraulic pump 6
Hydraulic system, Part 2 UEN01429-00
Hydraulic system, Part 2 2
Control valve 2
CLSS 14
Functions and operation by valve 18
00 Index and foreword UEN01420-03
PC228US, USLC-3E0 5
Merge-divider valve 33
Attachment circuit selector valve 56
Hydraulic drift prevention valve 58
Hydraulic system, Part 3 UEN01430-01
Hydraulic system, Part 3 2
Valve control 2
PPC valve 4
PPC Accumulator 22
Return oil filter 23
Center swivel joint 24
Travel motor 25
Swing motor 35
Hydraulic cylinder 44
Quick coupler control valve 46
Work equipment UEN01431-00
Work equipment 2
Dimensions of components 4
Cab and its attachments UEN01432-00
Cab and its attachments 2
Air conditioner piping 2
Electrical system UEN01433-00
Electrical system 2
Engine control 2
Electrical control system 12
Monitor system 38
Sensor 56
KOMTRAX terminal system 59
20 Standard value table
Standard service value table UEN01441-00
Standard service value table 2
Standard value table for engine related parts 2
Standard value table for chassis 3
30 Testing and adjusting
Testing and adjusting, Part 1 UEN01879-00
Testing and adjusting, Part 1 2
Tools for testing, adjusting, and troubleshooting 2
Measuring engine speed 5
Measuring intake air pressure (boost pressure) 6
Checking exhaust gas color 7
Adjusting valve clearance 8
Measuring compression pressure 10
Measuring blow-by pressure 12
Measuring engine oil pressure 13
Handling fuel system parts 14
Releasing residual pressure from fuel system 14
Measuring fuel pressure 15
Measuring fuel return rate and leakage 17
Bleeding air from fuel circuit 20
Checking fuel circuit for leakage 22
Checking and adjusting air conditioner compressor belt tension 23
Testing and adjusting, Part 2 UEN01880-01
Testing and adjusting, Part 2 3
Measurement of clearance in swing circle bearings 3
UEN01420-03 00 Index and foreword
6 PC228US, USLC-3E0
Checking and adjusting track shoe tension 4
Inspection and adjustment of hydraulic oil pressure in hydraulic circuit for
work equipment, swing and travel 5
Measurement of control circuit oil pressure 9
Inspection and adjustment of pump PC control circuit oil pressure 10
Inspection and adjustment of pump LS control circuit oil pressure 13
Measurement of solenoid valve output pressure 18
Measurement of PPC valve output pressure 21
Adjustment of work equipment and swing PPC valve 23
Inspection of locations of hydraulic drift of work equipment 24
Release of residual pressure from hydraulic circuit 26
Measuring oil leakage 27
Bleeding air from each part 30
Procedure for replacing boom angle potentiometer 32
Inspection procedures for diode 33
Adjusting mirrors 34
Measuring and adjusting quick coupler control valve output pressure 36
Testing and adjusting, Part 3 UEN01881-00
Testing and adjusting, Part 3 2
Special functions of machine monitor 2
Handling voltage circuit of engine controller 30
Procedure for turning on KOMTRAX terminal 31
KOMTRAX terminal lamp indications 34
Preparation work for troubleshooting of electrical system 37
40 Troubleshooting
Failure code table and fuse locations UEN01882-00
Failure code table and fuse locations 2
Failure code table 2
Fuse locations 5
General information on troubleshooting UEN01883-00
General information on troubleshooting 2
Points to remember when troubleshooting 2
Sequence of events in troubleshooting 3
Checks before troubleshooting 4
Classification and troubleshooting steps 5
Information in troubleshooting table 6
Possible problems and troubleshooting No 8
Wiring table for connector pin numbers 11
T-adapter box and T-adapter table 40
Troubleshooting by failure code (Display of code), Part 1 UEN01884-00
Troubleshooting by failure code (Display of code), Part 1 3
Failure code [A000N1] Eng Hi Out of Std 3
Failure code [AA10NX] Air cleaner Clogging 4
Failure code [AB00KE] Charge Voltage Low 6
Failure code [B@BAZG] Eng Oil Press Low 8
Failure code [B@BAZK] Eng Oil Level Low 9
Failure code [B@BCNS] Eng Water Overheat 10
Failure code [B@BCZK] Eng Water Level Low 12
Failure code [B@HANS] Hydr Oil Overheat 13
Failure code [CA111] EMC Critical Internal Failure 13
Failure code [CA115] Eng Ne and Bkup Speed Sens Error 14
Failure code [CA122] Chg Air Press Sensor High Error 16
Failure code [CA123] Chg Air Press Sensor Low Error 18
Failure code [CA131] Throttle Sensor High Error 20
Failure code [CA132] Throttle Sensor Low Error 22
Failure code [CA144] Coolant Temp Sens High Error 24
00 Index and foreword UEN01420-03
PC228US, USLC-3E0 7
Failure code [CA145] Coolant Temp Sens Low Error 26
Failure code [CA153] Chg Air Temp Sensor High Error 28
Failure code [CA154] Chg Air Temp Sensor Low Error 30
Failure code [CA155] Chg Air Temp High Speed Derate 32
Failure code [CA187] Sens Supply 2 Volt Low Error 34
Failure code [CA221] Ambient Press Sens High Error 36
Failure code [CA222] Ambient Press Sens Low Error 38
Failure code [CA227] Sens Supply 2 Volt High Error 40
Failure code [CA234] Eng Overspeed 41
Failure code [CA238] Ne Speed Sens Supply Volt Error 42
Failure code [CA271] IMV/PCV1 Short Error 43
Failure code [CA272] IMV/PCV1 Open Error 44
Failure code [CA322] Inj #1 Open/Short Error 46
Failure code [CA323] Inj #5 Open/Short Error 48
Failure code [CA324] Inj #3 Open/Short Error 50
Troubleshooting by failure code (Display of code), Part 2 UEN01885-00
Troubleshooting by failure code (Display of code), Part 2 4
Failure code [CA325] Inj #6 Open/Short Error 4
Failure code [CA331] Inj #2 Open/Short Error 6
Failure code [CA332] Inj #4 Open/Short Error 8
Failure code [CA342] Calibration Code Incompatibility 10
Failure code [CA351] Injectors Drive Circuit Error 12
Failure code [CA352] Sens Supply 1 Volt Low Error 14
Failure code [CA386] Sens Supply 1 Volt High Error 16
Failure code [CA428] Water in Fuel Sensor High Error 18
Failure code [CA429] Water in Fuel Sensor Low Error 20
Failure code [CA435] Eng Oil Press Sw Error 22
Failure code [CA441] Engine Controller Battery Voltage Low Error 23
Failure code [CA442] Engine Controller Battery Voltage High Error 26
Failure code [CA449] Rail Press Very High Error 28
Failure code [CA451] Rail Press Sensor High Error 30
Failure code [CA452] Rail Press Sensor Low Error 32
Failure code [CA488] Chg Air Temp High Torque Derate 34
Failure code [CA553] Rail Press High Error 34
Failure code [CA559] Rail Press Low Error 35
Failure code [CA689] Eng Ne Speed Sensor Error 36
Failure code [CA731] Eng Bkup Speed Sens Phase Error 38
Failure code [CA757] All Continuous Data Lost Error 40
Failure code [CA778] Eng Bkup Speed Sensor Error 42
Failure code [CA1633] KOMNET Datalink Timeout Error 44
Failure code [CA2185] Throt Sens Sup Volt High Error 46
Failure code [CA2186] Throt Sens Sup Volt Low Error 47
Failure code [CA2249] Rail Press Very Low Error 48
Failure code [CA2311] IMV Solenoid Error 50
Failure code [CA2555] Grid Htr Relay Volt High Error 52
Failure code [CA2556] Grid Htr Relay Volt Low Error 54
Troubleshooting by failure code (Display of code), Part 3 UEN01886-00
Troubleshooting by failure code (Display of code), Part 3 2
Failure code [D110KB] Battery Relay Drive S/C 2
Failure code [D196KA] Service Return Relay Disc 4
Failure code [D196KB] Service Return Relay S/C 6
Failure code [DA22KK] Pump Solenoid Power Low Error 8
Failure code [DA25KP] Press Sensor Power Abnormality 10
Failure code [DA2RMC] Pump Comm Abnormality 12
Failure code [DA2SKQ] Model Selection Abnormality 14
Failure code [DAFRMC] Monitor Comm Abnormality 16
Failure code [DGH2KB] Hydr Oil Sensor Short 18
UEN01420-03 00 Index and foreword
8 PC228US, USLC-3E0
Failure code [DHPAMA] F Pump Press Sensor Abnormality 20
Failure code [DHPBMA] R Pump Press Sensor Abnormality 22
Failure code [DHSAMA] Sw RH PPC Press Sen Abnormality 24
Failure code [DHSBMA] Sw LH PPC Press Sen Abnormality 26
Troubleshooting by failure code (Display of code), Part 4 UEN01887-00
Troubleshooting by failure code (Display of code), Part 4 4
Failure code [DW43KA] Travel Speed Sol Disc 4
Failure code [DW43KB] Travel Speed Sol S/C 6
Failure code [DW45KA] Swing Brake Sol Disc 9
Failure code [DW45KB] Swing Brake Sol S/C 12
Failure code [DW91KA] Travel Junction Sol Disc 14
Failure code [DW91KB] Travel Junction Sol S/C 16
Failure code [DW4GKA] Disconnection in boom RAISE throttle EPC solenoid 18
Failure code [DW4GKB] Short circuit in boom RAISE throttle EPC solenoid 20
Failure code [DWJ0KA] Merge-divider Sol Disc 22
Failure code [DWJ0KB] Merge-divider Sol S/C 24
Failure code [DWK0KA] 2-stage Relief Sol Disc 26
Failure code [DWK0KB] 2-stage Relief Sol S/C 28
Failure code [DXA0KA] PC-EPC Sol Disc 30
Failure code [DXA0KB] PC-EPC Sol S/C 32
Failure code [DXE0KA] LS-EPC Sol Disc 34
Failure code [DXE0KB] LS-EPC Sol S/C 36
Failure code [DXE4KA] Service Current EPC Disc 38
Failure code [DXE4KB] Service Current EPC S/C 39
Failure code [DY20KA] Wiper Working Abnormality 40
Failure code [DY20MA] Wiper Parking Abnormality 42
Failure code [DY20MA] Wiper Parking Abnormality 42
Failure code [DY2CKB] Washer Drive S/C 44
Failure code [DY2DKB] Wiper Drive (For) S/C 46
Failure code [DY2EKB] Wiper Drive (Rev) S/C 48
Troubleshooting of electrical system (E-mode) UEN01888-00
Troubleshooting of electrical system (E-mode) 3
Before carrying out troubleshooting of electrical system 3
Information contained in troubleshooting table 4
E-1 Engine does not start 5
E-2 Auto-decelerator does not operate 8
E-3 Automatic warming-up system does not operate 10
E-4 Preheater does not operate 12
E-5 All work equipment, swing, and travel mechanism do not move 14
E-6 Power maximizing function does not operate 16
E-7 Machine monitor does not display at all 18
E-8 Machine monitor does not display some items 20
E-9 Contents of display by machine monitor are different from applicable machine 20
E-10 Fuel level monitor was lighted in red while engine running 21
E-11 Engine coolant temperature gauge does not indicate normally 22
E-12 Hydraulic oil temperature gauge does not indicate normally 24
E-13 Fuel level gauge does not indicate normally 25
E-14 Swing lock monitor does not indicate normally 26
E-15 When monitor switch is operated, monitor displays nothing 28
E-16 Windshield wiper and window washer do not operate 30
E-17 Monitoring function fails to display “boom raise” normally 34
E-18 Monitoring function fails to display “boom lower” normally 35
E-19 Monitoring function fails to display “arm IN” normally 36
E-20 Monitoring function fails to display “arm OUT” normally 37
E-21 Monitoring function fails to display “bucket CURL” normally 38
E-22 Monitoring function fails to display “bucket DUMP” normally 39
E-23 Monitoring function fails to display “swing left” normally 40
00 Index and foreword UEN01420-03
PC228US, USLC-3E0 9
E-24 Monitoring function fails to display “swing right” normally 42
E-25 Monitoring function fails to display “travel” normally 44
E-26 Monitoring function fails to display “travel differential pressure” normally 46
E-27 Monitoring function fails to display “service” normally 48
E-28 KOMTRAX system does not operate normally 50
E-29 Air conditioner does not operate 52
E-30 Travel alarm does not sound or does not stop sounding 54
E-31 Horn does not sound 56
E-32 Attachment circuit does not change 58
Troubleshooting of hydraulic and mechanical system (H-mode) UEN01889-01
Troubleshooting of hydraulic and mechanical system (H-mode) 4
System chart for hydraulic and mechanical systems 4
Information contained in troubleshooting table 6
H-1 All work equipment lack power, or travel and swing speeds are slow 7
H-2 Engine speed sharply drops or engine stalls 9
H-3 No work equipment, travel or swing move 10
H-4 Abnormal noise is heard from around hydraulic pump 10
H-5 Auto-decelerator does not work 11
H-6 Fine control mode does not function 11
H-7 Boom moves slowly or lacks power 12
H-8 Arm moves slowly or lacks power 13
H-9 Bucket moves slowly or lacks power 14
H-10 Work equipment does not move in its single operation 14
H-11 Work equipment has a bit too large hydraulic drift 15
H-12 Work equipment has big time lag 16
H-13 Other work equipment moves when relieving single circuit 16
H-14 One-touch power max switch does not operate 16
H-15 In compound operation, work equipment with larger load moves slowly 17
H-16 In swing + boom RAISE operation, boom moves slowly 17
H-17 In swing + travel, travel speed drops sharply 17
H-18 Machine swerves in travel 18
H-19 Machine travels slowly 19
H-20 Machine cannot be easily steered or lacks power 20
H-21 Travel speed does not shift, or it is slower or faster than preset speed 21
H-22 Track shoe does not turn (on one side only) 21
H-23 Machine does not swing 22
H-24 Swing acceleration is poor, or swing speed is slow 24
H-25 Excessive overrun when stopping swing 26
H-26 There is big shock when stopping swing 27
H-27 There is big abnormal noise caused when stopping swing 27
H-28 Swing natural drift is too big 28
H-29 Attachment circuit does not change 29
H-30 Flow rate in attachment circuit cannot be adjusted 29
Quick coupler 30
Troubleshooting of engine (S-mode) UEN01890-00
Troubleshooting of engine (S-mode) 4
Method of using troubleshooting chart 4
S-1 Starting performance is poor 8
S-2 Engine does not start 9
S-3 Engine does not pick up smoothly 12
S-4 Engine stops during operations 13
S-5 Engine does not rotate smoothly 14
S-6 Engine lack output (or lacks power) 15
S-7 Exhaust smoke is black (incomplete combustion) 16
S-8 Oil consumption is excessive (or exhaust smoke is blue) 17
S-9 Oil becomes contaminated quickly 18
S-10 Fuel consumption is excessive 19
UEN01420-03 00 Index and foreword
10 PC228US, USLC-3E0
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) 20
S-12 Oil pressure drops 21
S-13 Oil level rises (Entry of coolant/fuel) 22
S-14 Coolant temperature becomes too high (overheating) 23
S-15 Abnormal noise is made 24
S-16 Vibration is excessive 25
50 Disassembly and assembly
General information on disassembly and assembly UEN01923-00
General information on disassembly and assembly 2
How to read this manual 2
Coating materials list 4
Special tool list 7
Sketches of special tools 10
Engine and cooling system UEN01924-00
Engine and cooling system 2
Removal and installation of fuel supply pump assembly 2
Removal and installation of fuel injector assembly 4
Removal and installation of engine front seal 8
Removal and installation of engine rear seal 10
Removal and installation of cylinder head assembly 13
Removal and installation of radiator assembly 24
Removal and installation of hydraulic oil cooler assembly 27
Removal and installation of aftercooler assembly 29
Removal and installation of fuel cooler assembly 31
Removal and installation of engine assembly 33
Removal and installation of fuel tank assembly 35
Power train UEN01925-00
Power train 2
Removal and installation of travel motor and final drive assembly 2
Disassembly and assembly of travel motor and final drive assembly 3
Removal and installation of swing motor and swing machinery assembly 11
Disassembly and assembly of swing motor and swing machinery assembly 13
Removal and installation of swing circle assembly 21
Undercarriage and frame UEN01926-00
Undercarriage and frame 2
Disassembly and assembly of track roller assembly 2
Disassembly and assembly of idler assembly 3
Disassembly and assembly of recoil spring 6
Expansion and installation of track shoe assembly 8
Removal and installation of revolving frame 10
Removal and installation of counterweight assembly 12
Removal and installation of maintenance counterweight (at rear of engine) 13
Removal and installation of maintenance counterweight assembly (above pump) 14
Hydraulic system UEN01927-01
Hydraulic system 2
Removal and installation of center swivel joint assembly 2
Disassembly and assembly of center swivel joint 4
Removal and installation of hydraulic tank assembly 5
Removal and installation of work equipment pump 7
Removal and installation of control valve assembly 11
Disassembly and assembly of control valve assembly 13
Disassembly and assembly of work equipment PPC valve assembly 15
Disassembly and assembly of travel PPC valve assembly 17
Disassembly and assembly of hydraulic cylinder assembly 19
Disassembly and Assembly of Quick Coupler Valve 25
00 Index and foreword UEN01420-03
PC228US, USLC-3E0 11
Work equipment UEN01928-00
Work equipment 2
Removal and installation of work equipment assembly 2
Cab and its attachments UEN01929-00
Cab and its attachments 2
Removal and installation of operator’s cab assembly 2
Removal and installation of operator’s cab glass (Stuck glass) 4
Removal and installation of front window assembly 14
Removal and installation of floor frame assembly 15
Electrical system UEN01930-00
Electrical system 2
Removal and installation of air conditioner compressor assembly 2
Removal and installation of air conditioner condenser assembly 3
Removal and installation of air conditioner unit assembly 4
Removal and installation of machine monitor assembly 6
Removal and installation of pump controller assembly 7
Removal and installation of engine controller assembly 8
Removal and installation of KOMTRAX communication modem assembly 10
90 Diagrams and drawings
Hydraulic diagrams and drawings UEN01439-00
Hydraulic circuit diagram 3
Electrical diagrams and drawings UEN01440-01
Electrical circuit diagram (1/7) 3
Electrical circuit diagram (2/7) 5
Electrical circuit diagram (3/7) 7
Electrical circuit diagram (4/7) 9
Electrical circuit diagram (5/7) 11
Electrical circuit diagram (6/7) 13
Electrical circuit diagram (7/7) 15

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S.M 18/12/24