Komatsu Hydraulic Excavator PC228US-3E0 PC228USLC-3E0 Shop Manual PDF

Description

Komatsu Hydraulic Excavator PC228US-3E0 PC228USLC-3E0 Shop Manual SEN01418-10 – PDF DOWNLOAD

FILE DETAILS:

Komatsu Hydraulic Excavator PC228US-3E0 PC228USLC-3E0 Shop Manual SEN01418-10 – PDF DOWNLOAD

Language : English
Pages : 951
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Komatsu Hydraulic Excavator PC228US-3E0 PC228USLC-3E0 Shop Manual SEN01418-10 – PDF DOWNLOAD

SERIAL NUMBERS

• PC228US- 40001      and up
  PC228USLC- 40001 and up

COVER 1
00 Index and foreword . 0
Index . 2
Composition of shop manual 3
Table of contents . 5
Foreword and general information 14
Safety notice . 15
How to read the shop manual . 20
Explanation of terms for maintenance standard . 22
Handling of electric equipment and hydraulic component 24
Handling of connectors newly used for engines . 33
How to read electric wire code 36
Precautions when carrying out operation . 39
Method of disassembling and connecting push-pull type coupler . 42
Standard tightening torque table 45
Conversion table 49
01 Specification 0
Specification and technical data 56
Specification dimension drawings 57
Working range diagram . 58
Specifications 59
Weight table 61
Table of fuel, coolant and lubricants . 63
10 Structure, function and maintenance standard . 0
Engine and cooling system . 67
Engine related parts 67
Radiator, oil cooler, aftercooler and fuel cooler . 68
Power train . 70
Power train . 71
Final drive . 72
Swing machinery . 74
Swing circle 76
Undercarriage and frame . 78
Track frame . 79
Idler . 81
Carrier roller 83
Track roller 84
Track shoe 85
Hydraulic system, Part 1 91
Hydraulic equipment layout drawing 92
Hydraulic tank 94
Hydraulic pump 95
Hydraulic system, Part 2 118
Control valve .119
CLSS 131
Functions and operation by valve 135
Merge-divider valve .150
Attachment circuit selector valve .173
Hydraulic drift prevention valve 175
Hydraulic system, Part 3 182
Valve control .183
PPC valve .185
PPC Accumulator .203
Return oil filter .204
Center swivel joint .205
Travel motor 206
Swing motor .216
Hydraulic cylinder 225
Work equipment 228
Dimensions of components 231
Cab and its attachments .236
Air conditioner piping 237
Electrical system .239
Engine control 240
Electrical control system .250
Monitor system 276
Sensor 294
KOMTRAX system 297
20 Standard value table . 0
Standard service value table 301
Standard value table for engine related parts .302
Standard value table for chassis 303
30 Testing and adjusting 0
Testing and adjusting, Part 1 .315
Tools for testing, adjusting, and troubleshooting .317
Sketches of special tools .322
Testing engine speed 323
Testing intake air pressure (boost pressure) 324
Checking exhaust gas color 325
Adjusting valve clearance .326
Testing compression pressure 328
Testing blow-by pressure 331
Testing engine oil pressure .332
Handling fuel system parts 333
Releasing residual pressure from fuel system 333
Testing fuel pressure .334
Reduced cylinder mode operation .337
No-injection cranking .337
Testing fuel delivery, return rate and leakage 338
Bleeding air from fuel circuit 341
Checking fuel circuit for leakage .342
Checking and adjusting air conditioner compressor belt tension 343
Replacement of fan belt .344
Testing and adjusting, Part 2 .347
Testing clearance in swing circle bearings 348
Checking and adjusting track shoe tension .349
Testing and adjusting hydraulic oil pressure in hydraulic circuit for work equipment, swing and travel 350
Testing control circuit oil pressure 354
Testing and adjusting pump PC control circuit oil pressure 355
Testing and adjusting pump LS control circuit oil pressure 358
Testing solenoid valve output pressure 363
Testing PPC valve output pressure .366
Adjusting play of work equipment and swing PPC valves .367
Inspection of locations of hydraulic drift of work equipment 368
Release of residual pressure from hydraulic circuit .370
Testing oil leakage .371
Bleeding air from each part .374
Procedure for replacing boom angle potentiometer 376
Inspection procedures for diode .377
Adjusting mirrors .378
Testing and adjusting, Part 3 .381
Special functions of machine monitor 382
Handling voltage circuit of engine controller .410
Starting KOMTRAX terminal operations 411
Indicator lamps of KOMTRAX terminal .415
Preparation work for troubleshooting of electrical system .418
Pm-clinic service .420
40 Troubleshooting 0
Failure code table and fuse locations .427
Failure code table 428
Fuse locations 431
General information on troubleshooting 435
Points to remember when troubleshooting .436
Sequence of events in troubleshooting .437
Checks before troubleshooting .438
Classification and troubleshooting steps 439
Information in troubleshooting table 440
Possible problems and troubleshooting No 442
Connection table for connector pin numbers 445
T- branch box and T- branch adapter table .481
Troubleshooting by failure code (Display of code), Part 1 .485
Failure code [AA10NX] Air cleaner Clogging 487
Failure code [AB00KE] Charge Voltage Low 488
Failure code [B@BAZG] Eng Oil Press Low .490
Failure code [B@BAZK] Eng Oil Level Low .491
Failure code [B@BCNS] Eng Water Overheat 492
Failure code [B@BCZK] Eng Water Level Low .493
Failure code [B@HANS] Hyd Oil Overheat 494
Failure code [CA111] EMC Critical Internal Failure 494
Failure code [CA115] Eng Ne and Bkup Speed Sens Error .495
Failure code [CA122] Chg Air Press Sensor High Error 496
Failure code [CA123] Chg Air Press Sensor Low Error .498
Failure code [CA131] Throttle Sensor High Error .500
Failure code [CA132] Throttle Sensor Low Error 502
Failure code [CA144] Coolant Temp Sens High Error .504
Failure code [CA145] Coolant Temp Sens Low Error 506
Failure code [CA153] Chg Air Temp Sensor High Error .508
Failure code [CA154] Chg Air Temp Sensor Low Error 510
Failure code [CA155] Chg Air Temp High Speed Derate .512
Failure code [CA187] Sens Supply 2 Volt Low Error .514
Failure code [CA221] Ambient Press Sens High Error 516
Failure code [CA222] Ambient Press Sens Low Error .518
Failure code [CA227] Sens Supply 2 Volt High Error 520
Failure code [CA234] Eng. Overspeed .521
Failure code [CA238] Ne Speed Sens Supply Volt Error 522
Failure code [CA271] IMV/PCV1 Short Error .523
Failure code [CA272] IMV/PCV1 Open Error 524
Failure code [CA322] Inj #1 (L#1) Open/Short Error 526
Failure code [CA323] Inj #5 (L#5) Open/Short Error 528
Failure code [CA324] Inj #3 (L#3) Open/Short Error 530
Failure code [CA325] Inj #6 (L#6) Open/Short Error 532
Failure code [CA331] Inj #2 (L#2) Open/Short Error 534
Failure code [CA332] Inj #4 (L#4) Open/Short Error 536
Troubleshooting by failure code (Display of code), Part 2 .539
Failure code [CA342] Calibration Code Incompatibility .541
Failure code [CA351] Injectors Drive Circuit Error 542
Failure code [CA352] Sens Supply 1 Volt Low Error .544
Failure code [CA386] Sens Supply 1 Volt High Error 546
Failure code [CA428] Water in Fuel Sensor High Error 548
Failure code [CA429] Water in Fuel Sensor Low Error .550
Failure code [CA435] Eng Oil Press Sw Error .552
Failure code [CA441] Battery Voltage Low Error 553
Failure code [CA442] Battery Voltage High Error .556
Failure code [CA449] Rail Press Very High Error .558
Failure code [CA451] Rail Press Sensor High Error .560
Failure code [CA452] Rail Press Sensor Low Error 562
Failure code [CA488] Chg Air Temp High Torque Derate 564
Failure code [CA553] Rail Press High Error 564
Failure code [CA559] Rail Press Low Error .565
Failure code [CA689] Eng Ne Speed Sensor Error 567
Failure code [CA731] Eng Bkup Speed Sens Phase Error 569
Failure code [CA757] All Continuous Data Lost Error .570
Failure code [CA778] Eng Bkup Speed Sensor Error 572
Failure code [CA1633] KOMNET Datalink Timeout Error .574
Failure code [CA2185] Throt Sens Sup Volt High Error 576
Failure code [CA2186] Throt Sens Sup Volt Low Error .577
Failure code [CA2249] Rail Press Very Low Error .578
Failure code [CA2311] IMV Solenoid Error 580
Failure code [CA2555] Grid Htr Relay Volt High Error 582
Failure code [CA2556] Grid Htr Relay Volt Low Error .584
Troubleshooting by failure code (Display of code), Part 3 .587
Failure code [D110KB] Battery Relay Drive Short Circuit .588
Failure code [D196KA] Service Return Relay Disc .590
Failure code [D196KB] Service Return Relay S/C 592
Failure code [DA22KK] Pump Solenoid Power Low Error .594
Failure code [DA25KP] 5V Sensor 1 Power Abnormality .596
Failure code [DA2RMC] CAN Discon (Pump Con Detected) 598
Failure code [DA2SKQ] Model Selection Abnormality .600
Failure code [DAFRMC] CAN Discon (Monitor Detected) .602
Failure code [DGH2KB] Hyd Oil Sensor Short 604
Failure code [DHPAMA] F Pump Press Sensor Abnormality .606
Failure code [DHPBMA] R Pump Press Sensor Abnormality .608
Failure code [DHSAMA] Sw RH PPC Press Sen. Abnormality 610
Failure code [DHSBMA] Sw LH PPC Press Sen. Abnormality 612
Troubleshooting by failure code (Display of code), Part 4 .615
Failure code [DW43KA] Travel Speed Sol Open Circuit .618
Failure code [DW43KB] Travel Speed Sol Short Circuit 620
Failure code [DW45KA] Swing Brake Sol Open Circuit 622
Failure code [DW45KB] Swing Brake Sol Short Circuit .626
Failure code [DW91KA] Travel Junction Sol Open Circuit 628
Failure code [DW91KB] Travel Junction Sol Short Circuit .630
Failure code [DW4GKA] Boom Slow Down Sol. Disc 632
Failure code [DW4GKB] Boom Slow Down Sol. S/C .634
Failure code [DWJ0KA] Merge-divider Sol Open Circuit 636
Failure code [DWJ0KB] Merge-divider Sol Short Circuit .638
Failure code [DWK0KA] 2-stage Relief Sol Open Circuit .640
Failure code [DWK0KB] 2-stage Relief Sol Short Circuit 642
Failure code [DXA0KA] PC-EPC Sol Open Circuit .644
Failure code [DXA0KB] PC-EPC Sol Short Circuit 646
Failure code [DXE0KA] LS-EPC Sol Open Circuit .648
Failure code [DXE0KB] LS-EPC Sol Short Circuit 650
Failure code [DXE4KA] Service Current EPC Open Circuit 652
Failure code [DXE4KB] Service Current EPC Short Circuit .653
Failure code [DY20KA] Wiper Working Abnormality .654
Failure code [DY20MA] Wiper Parking Abnormality .656
Failure code [DY2CKB] Washer Drive Short Circuit 658
Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit .660
Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit .662
Troubleshooting of electrical system (E-mode) .665
Before carrying out troubleshooting of electrical system 667
Information contained in troubleshooting table 669
E-1 Engine does not start .670
E-2 Auto-decelerator does not operate .673
E-3 Automatic warming-up system does not operate 675
E-4 Preheater does not operate 676
E-5 All work equipment, swing, and travel mechanism do not move .678
E-6 Power maximizing function does not operate 680
E-7 Machine monitor does not display at all .682
E-8 Machine monitor does not display some items .684
E-9 Contents of display by machine monitor are different from applicable machine 684
E-10 Fuel level monitor was lighted in red while engine running .685
E-11 Engine coolant temperature gauge does not indicate normally 686
E-12 Hydraulic oil temperature gauge does not indicate normally .688
E-13 Fuel level gauge does not indicate normally 689
E-14 Swing lock monitor does not indicate normally 690
E-15 When monitor switch is operated, monitor displays nothing 692
E-16 Windshield wiper and window washer do not operate 694
E-17 Monitoring function fails to display “boom raise” normally .698
E-18 Monitoring function fails to display “boom lower” normally .699
E-19 Monitoring function fails to display “arm IN” normally .700
E-20 Monitoring function fails to display “arm OUT” normally 701
E-21 Monitoring function fails to display “bucket CURL” normally 702
E-22 Monitoring function fails to display “bucket DUMP” normally 703
E-23 Monitoring function fails to display “swing left” normally .704
E-24 Monitoring function fails to display “swing right” normally 706
E-25 Monitoring function fails to display “travel” normally .708
E-26 Monitoring function fails to display “travel differential pressure” normally .710
E-27 Monitoring function fails to display “service” normally 712
E-28 The KOMTRAX system does not work properly 714
E-29 Air conditioner does not operate .716
E-30 Travel alarm does not sound or does not stop sounding 718
E-31 Horn does not sound 720
E-32 Attachment circuit does not change .722
Troubleshooting of hydraulic and mechanical system (H-mode) .725
System chart for hydraulic and mechanical systems .728
Information contained in troubleshooting table 730
H-1 All work equipment lack power, or travel and swing speeds are slow 731
H-2 Engine speed sharply drops or engine stalls .733
H-3 No work equipment, travel or swing move .734
H-4 Abnormal noise is heard from around hydraulic pump 734
H-5 Auto-decelerator does not work 735
H-6 Fine control mode does not function .735
H-7 Boom moves slowly or lacks power 736
H-8 Arm moves slowly or lacks power .737
H-9 Bucket moves slowly or lacks power 738
H-10 Work equipment does not move in its single operation .738
H-11 Work equipment has a bit too large hydraulic drift .739
H-12 Work equipment has big time lag 740
H-13 Other work equipment moves when relieving single circuit .740
H-14 One-touch power max. switch does not operate .740
H-15 In compound operation, work equipment with larger load moves slowly 741
H-16 In swing + boom RAISE operation, boom moves slowly .741
H-17 In swing + travel, travel speed drops sharply 741
H-18 Machine swerves in travel 742
H-19 Machine travels slowly .743
H-20 Machine cannot be easily steered or lacks power 744
H-21 Travel speed does not shift, or it is slower or faster than preset speed .745
H-22 Track shoe does not turn (on one side only) 745
H-23 Machine does not swing .746
H-24 Swing acceleration is poor, or swing speed is slow .748
H-25 Excessive overrun when stopping swing 750
H-26 There is big shock when stopping swing .751
H-27 There is big abnormal noise caused when stopping swing .751
H-28 Swing natural drift is too big .752
H-29 Attachment circuit does not change .753
H-30 Flow rate in attachment circuit cannot be adjusted .753
Troubleshooting of engine (S-mode) 755
Method of using troubleshooting chart .757
S-1 Starting performance is poor 760
S-2 Engine does not start .761
S-3 Engine does not pick up smoothly 764
S-4 Engine stops during operations 765
S-5 Engine does not rotate smoothly .766
S-6 Engine lack output (or lacks power) .767
S-7 Exhaust smoke is black (incomplete combustion) 768
S-8 Oil consumption is excessive (or exhaust smoke is blue) .769
S-9 Oil becomes contaminated quickly 770
S-10 Fuel consumption is excessive 771
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) 772
S-12 Oil pressure drops .773
S-13 Oil level rises (Entry of coolant/fuel) 774
S-14 Coolant temperature becomes too high (overheating) .775
S-15 Abnormal noise is made .776
S-16 Vibration is excessive .777
50 Disassembly and assembly . 0
General information on disassembly and assembly .779
How to read this manual .780
Coating materials list 782
Special tools list 785
Sketches of special tools .788
Engine and cooling system .793
Removal and installation of fuel supply pump assembly .794
Removal and installation of fuel injector assembly 797
Removal and installation of engine front seal .803
Removal and installation of engine rear seal 805
Removal and installation of cylinder head assembly 808
Removal and installation of radiator assembly .821
Removal and installation of hydraulic oil cooler assembly .824
Removal and installation of aftercooler assembly 826
Removal and installation of fuel cooler assembly 828
Removal and installation of engine assembly .830
Removal and installation of fuel tank assembly 832
Power train .835
Removal and installation of travel motor and final drive assembly .836
Disassembly and assembly of final drive assembly 837
Removal and installation of swing machinery assembly 845
Disassembly and assembly of swing machinery assembly 847
Removal and installation of swing circle assembly .855
Undercarriage and frame .857
Disassembly and assembly of track roller assembly .858
Disassembly and assembly of idler assembly 859
Disassembly and assembly of recoil spring .862
Expansion and installation of track shoe assembly .864
Removal and installation of revolving frame .866
Removal and installation of counterweight assembly 868
Removal and installation of maintenance counterweight (at rear of engine) .869
Removal and installation of maintenance counterweight assembly (above pump) .870
Hydraulic system 873
Removal and installation of center swivel joint assembly 874
Disassembly and assembly of center swivel joint .876
Removal and installation of hydraulic tank assembly .877
Removal and installation of work equipment pump .879
Removal and installation of control valve assembly 883
Disassembly and assembly of control valve assembly 885
Disassembly and assembly of work equipment PPC valve assembly .887
Disassembly and assembly of travel PPC valve assembly .889
Disassembly and assembly of hydraulic cylinder assembly .892
Work equipment 899
Removal and installation of work equipment assembly .900
Cab and its attachments .905
Removal and installation of operator’s cab assembly .906
Removal and installation of operator’s cab glass (Stuck glass) 908
Removal and installation of front window assembly .917
Removal and installation of floor frame assembly 918
Electrical system .923
Removal and installation of air conditioner compressor assembly .924
Removal and installation of air conditioner condenser assembly 926
Removal and installation of air conditioner unit assembly .927
Removal and installation of machine monitor assembly 929
Removal and installation of pump controller assembly 930
Removal and installation of engine controller assembly 931
Removal and installation of KOMTRAX communication modem assembly 933
90 Diagrams and drawings 0
Hydraulic diagrams and drawings .935
Hydraulic circuit diagram .937
Electrical diagrams and drawings 940
Electrical circuit diagram 942
Connector list and stereogram .949

DESCRIPTION:

Komatsu Hydraulic Excavator PC228US-3E0 PC228USLC-3E0 Shop Manual SEN01418-10 – PDF DOWNLOAD

SERIAL NUMBERS

• PC228US- 40001      and up
  PC228USLC- 40001 and up

1. Composition of shop manual
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.
q Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one
of them is required, consult KOMATSU distributors.
q Materials and specifications are subject to change without notice.
q Shop manuals are divided into the “Chassis volume” and “Engine volume”. For the engine unit, see the
engine volume of the engine model mounted on the machine.
3. Filing method
File by the brochures in the correct order of the form number printed in the shop manual composition
table.
q Revised edition mark
When a manual is revised, the ones and tens digits of the form number of each brochure is
increased by 1. (Example: 00, 01, 02 …)
q Revisions
Revised brochures are shown in the shop manual composition table.

G.B 25/12/24