Komatsu Hydraulic Excavator PC228US-3E0 PC228USLC-3E0 Shop Manual SEN01418-12 PDF

Description

Komatsu Hydraulic Excavator PC228US-3E0 PC228USLC-3E0 Shop Manual SEN01418-12 –  PDF DOWNLOAD

FILE DETAILS:

Komatsu Hydraulic Excavator PC228US-3E0 PC228USLC-3E0 Shop Manual SEN01418-12 –  PDF DOWNLOAD

Language : English
Pages : 968
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Komatsu Hydraulic Excavator PC228US-3E0 PC228USLC-3E0 Shop Manual SEN01418-12 –  PDF DOWNLOAD

SERIAL NUMBERS

• PC228US- 40001     and up
  PC228USLC- 40001 and up

Cover . 1
00 Index and foreword . 0
Index . 3
Composition of shop manual 4
Table of contents . 6
Foreword and general information 15
Safety notice . 16
How to read the shop manual . 21
Explanation of terms for maintenance standard . 23
Handling of electric equipment and hydraulic component 25
Handling of connectors newly used for engines . 34
How to read electric wire code 37
Precautions when carrying out operation . 40
Method of disassembling and connecting push-pull type coupler . 43
Standard tightening torque table 46
Conversion table 50
01 Specification 0
Specification and technical data 57
Specification dimension drawings 58
Working range diagram . 59
Specifications 60
Weight table 62
Table of fuel, coolant and lubricants . 64
10 Structure, function and maintenance standard . 0
Engine and cooling system . 67
Engine related parts 68
Radiator, oil cooler, aftercooler and fuel cooler . 69
Power train . 71
Power train . 72
Final drive . 74
Swing machinery . 76
Swing circle 78
Undercarriage and frame . 81
Track frame . 82
Idler . 84
Carrier roller 86
Track roller 87
Track shoe 88
Hydraulic system, Part 1 95
Hydraulic equipment layout drawing 96
Hydraulic tank 98
Hydraulic pump 100
Hydraulic system, Part 2 123
Control valve .124
CLSS 136
Functions and operation by valve 140
Merge-divider valve .155
Attachment circuit selector valve .178
Hydraulic drift prevention valve 180
Hydraulic system, Part 3 187
Valve control .188
PPC valve .190
PPC Accumulator .208
Return oil filter .209
Center swivel joint .210
Travel motor 211
Swing motor .221
Hydraulic cylinder 230
Work equipment 233
Work equipment 234
Dimensions of components 236
Cab and its attachments .241
Air conditioner piping 242
Electrical system .245
Engine control 246
Electrical control system .256
Monitor system 282
Sensor 300
KOMTRAX system 303
20 Standard value table . 0
Standard service value table 307
Standard value table for engine related parts .308
Standard value table for chassis 309
30 Testing and adjusting 0
Testing and adjusting, Part 1 .321
Tools for testing, adjusting, and troubleshooting .323
Sketches of special tools .328
Testing engine speed 329
Testing intake air pressure (boost pressure) 330
Checking exhaust gas color 331
Adjusting valve clearance .332
Testing compression pressure 334
Testing blow-by pressure 337
Testing engine oil pressure .338
Handling fuel system parts 339
Releasing residual pressure from fuel system 339
Testing fuel pressure .340
Reduced cylinder mode operation .343
No-injection cranking .343
Testing fuel delivery, return rate and leakage 344
Bleeding air from fuel circuit 347
Checking fuel circuit for leakage .348
Checking and adjusting air conditioner compressor belt tension 349
Replacement of fan belt .350
Testing and adjusting, Part 2 .353
Testing clearance in swing circle bearings 354
Checking and adjusting track shoe tension .355
Testing and adjusting hydraulic oil pressure in hydraulic circuit for work equipment, swing and travel 356
Testing control circuit oil pressure 360
Testing and adjusting pump PC control circuit oil pressure 361
Testing and adjusting pump LS control circuit oil pressure 364
Testing solenoid valve output pressure 369
Testing PPC valve output pressure .372
Adjusting play of work equipment and swing PPC valves .373
Inspection of locations of hydraulic drift of work equipment 374
Release of residual pressure from hydraulic circuit .376
Testing oil leakage .377
Bleeding air from each part .380
Procedure for replacing boom angle potentiometer 382
Inspection procedures for diode .383
Adjusting mirrors .384
Testing and adjusting, Part 3 .387
Special functions of machine monitor 388
Handling voltage circuit of engine controller .416
Starting KOMTRAX terminal operations 417
Indicator lamps of KOMTRAX terminal .421
Preparation work for troubleshooting of electrical system .424
Pm-clinic service .426
40 Troubleshooting 0
Failure code table and fuse locations .433
Failure code table 434
Fuse locations 437
General information on troubleshooting 441
Points to remember when troubleshooting .442
Sequence of events in troubleshooting .443
Checks before troubleshooting .444
Classification and troubleshooting steps 445
Information in troubleshooting table 446
Possible problems and troubleshooting No 448
Connection table for connector pin numbers 451
T- branch box and T- branch adapter table .487
Troubleshooting by failure code (Display of code), Part 1 .491
Failure code [AA10NX] Air cleaner Clogging 493
Failure code [AB00KE] Charge Voltage Low 494
Failure code [B@BAZG] Eng Oil Press Low .496
Failure code [B@BAZK] Eng Oil Level Low .497
Failure code [B@BCNS] Eng Water Overheat 498
Failure code [B@BCZK] Eng Water Level Low .499
Failure code [B@HANS] Hyd Oil Overheat 500
Failure code [CA111] EMC Critical Internal Failure 500
Failure code [CA115] Eng Ne and Bkup Speed Sens Error .501
Failure code [CA122] Chg Air Press Sensor High Error 502
Failure code [CA123] Chg Air Press Sensor Low Error .504
Failure code [CA131] Throttle Sensor High Error .506
Failure code [CA132] Throttle Sensor Low Error 508
Failure code [CA144] Coolant Temp Sens High Error .510
Failure code [CA145] Coolant Temp Sens Low Error 512
Failure code [CA153] Chg Air Temp Sensor High Error .514
Failure code [CA154] Chg Air Temp Sensor Low Error 516
Failure code [CA155] Chg Air Temp High Speed Derate .518
Failure code [CA187] Sens Supply 2 Volt Low Error .520
Failure code [CA221] Ambient Press Sens High Error 522
Failure code [CA222] Ambient Press Sens Low Error .524
Failure code [CA227] Sens Supply 2 Volt High Error 526
Failure code [CA234] Eng. Overspeed .527
Failure code [CA238] Ne Speed Sens Supply Volt Error 528
Failure code [CA271] IMV/PCV1 Short Error .529
Failure code [CA272] IMV/PCV1 Open Error 530
Failure code [CA322] Inj #1 (L#1) Open/Short Error 532
Failure code [CA323] Inj #5 (L#5) Open/Short Error 534
Failure code [CA324] Inj #3 (L#3) Open/Short Error 536
Failure code [CA325] Inj #6 (L#6) Open/Short Error 538
Failure code [CA331] Inj #2 (L#2) Open/Short Error 540
Failure code [CA332] Inj #4 (L#4) Open/Short Error 542
Troubleshooting by failure code (Display of code), Part 2 .545
Failure code [CA342] Calibration Code Incompatibility .547
Failure code [CA351] Injectors Drive Circuit Error 548
Failure code [CA352] Sens Supply 1 Volt Low Error .550
Failure code [CA386] Sens Supply 1 Volt High Error 552
Failure code [CA428] Water in Fuel Sensor High Error 554
Failure code [CA429] Water in Fuel Sensor Low Error .556
Failure code [CA435] Eng Oil Press Sw Error .558
Failure code [CA441] Battery Voltage Low Error 559
Failure code [CA442] Battery Voltage High Error .562
Failure code [CA449] Rail Press Very High Error .564
Failure code [CA451] Rail Press Sensor High Error .566
Failure code [CA452] Rail Press Sensor Low Error 568
Failure code [CA488] Chg Air Temp High Torque Derate 570
Failure code [CA553] Rail Press High Error 570
Failure code [CA559] Rail Press Low Error .571
Failure code [CA689] Eng Ne Speed Sensor Error 573
Failure code [CA731] Eng Bkup Speed Sens Phase Error 575
Failure code [CA757] All Continuous Data Lost Error .576
Failure code [CA778] Eng Bkup Speed Sensor Error 578
Failure code [CA1633] KOMNET Datalink Timeout Error .580
Failure code [CA2185] Throt Sens Sup Volt High Error 582
Failure code [CA2186] Throt Sens Sup Volt Low Error .583
Failure code [CA2249] Rail Press Very Low Error .584
Failure code [CA2311] IMV Solenoid Error 586
Failure code [CA2555] Grid Htr Relay Volt High Error 588
Failure code [CA2556] Grid Htr Relay Volt Low Error .590
Troubleshooting by failure code (Display of code), Part 3 .593
Failure code [D110KB] Battery Relay Drive Short Circuit .594
Failure code [D196KA] Service Return Relay Disc .596
Failure code [D196KB] Service Return Relay S/C 598
Failure code [DA22KK] Pump Solenoid Power Low Error .600
Failure code [DA25KP] 5V Sensor 1 Power Abnormality .602
Failure code [DA2RMC] CAN Discon (Pump Con Detected) 604
Failure code [DA2SKQ] Model Selection Abnormality .606
Failure code [DAFRMC] CAN Discon (Monitor Detected) .608
Failure code [DGH2KB] Hyd Oil Sensor Short 610
Failure code [DHPAMA] F Pump Press Sensor Abnormality .612
Failure code [DHPBMA] R Pump Press Sensor Abnormality .614
Failure code [DHSAMA] Sw RH PPC Press Sen. Abnormality 616
Failure code [DHSBMA] Sw LH PPC Press Sen. Abnormality 618
Troubleshooting by failure code (Display of code), Part 4 .621
Failure code [DW43KA] Travel Speed Sol Open Circuit .624
Failure code [DW43KB] Travel Speed Sol Short Circuit 626
Failure code [DW45KA] Swing Brake Sol Open Circuit 628
Failure code [DW45KB] Swing Brake Sol Short Circuit .632
Failure code [DW91KA] Travel Junction Sol Open Circuit 634
Failure code [DW91KB] Travel Junction Sol Short Circuit .636
Failure code [DW4GKA] Boom Slow Down Sol. Disc 638
Failure code [DW4GKB] Boom Slow Down Sol. S/C .640
Failure code [DWJ0KA] Merge-divider Sol Open Circuit 642
Failure code [DWJ0KB] Merge-divider Sol Short Circuit .644
Failure code [DWK0KA] 2-stage Relief Sol Open Circuit .646
Failure code [DWK0KB] 2-stage Relief Sol Short Circuit 648
Failure code [DXA0KA] PC-EPC Sol Open Circuit .650
Failure code [DXA0KB] PC-EPC Sol Short Circuit 652
Failure code [DXE0KA] LS-EPC Sol Open Circuit .654
Failure code [DXE0KB] LS-EPC Sol Short Circuit 656
Failure code [DXE4KA] Service Current EPC Open Circuit 658
Failure code [DXE4KB] Service Current EPC Short Circuit .659
Failure code [DY20KA] Wiper Working Abnormality .660
Failure code [DY20MA] Wiper Parking Abnormality .662
Failure code [DY2CKB] Washer Drive Short Circuit 664
Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit .666
Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit .668
Troubleshooting of electrical system (E-mode) .671
Before carrying out troubleshooting of electrical system 673
Information contained in troubleshooting table 675
E-1 Engine does not start .676
E-2 Auto-decelerator does not operate .679
E-3 Automatic warming-up system does not operate 681
E-4 Preheater does not operate 682
E-5 All work equipment, swing, and travel mechanism do not move .684
E-6 Power maximizing function does not operate 686
E-7 Machine monitor does not display at all .688
E-8 Machine monitor does not display some items .690
E-9 Contents of display by machine monitor are different from applicable machine 690
E-10 Fuel level monitor was lighted in red while engine running .691
E-11 Engine coolant temperature gauge does not indicate normally 692
E-12 Hydraulic oil temperature gauge does not indicate normally .694
E-13 Fuel level gauge does not indicate normally 695
E-14 Swing lock monitor does not indicate normally 696
E-15 When monitor switch is operated, monitor displays nothing 698
E-16 Windshield wiper and window washer do not operate 700
E-17 Monitoring function fails to display “boom raise” normally .704
E-18 Monitoring function fails to display “boom lower” normally .705
E-19 Monitoring function fails to display “arm IN” normally .706
E-20 Monitoring function fails to display “arm OUT” normally 707
E-21 Monitoring function fails to display “bucket CURL” normally 708
E-22 Monitoring function fails to display “bucket DUMP” normally 709
E-23 Monitoring function fails to display “swing left” normally .710
E-24 Monitoring function fails to display “swing right” normally 712
E-25 Monitoring function fails to display “travel” normally .714
E-26 Monitoring function fails to display “travel differential pressure” normally .716
E-27 Monitoring function fails to display “service” normally 718
E-28 The KOMTRAX system does not work properly 720
E-29 Air conditioner does not operate .722
E-30 Travel alarm does not sound or does not stop sounding 724
E-31 Horn does not sound 726
E-32 Attachment circuit does not change .728
Troubleshooting of hydraulic and mechanical system (H-mode) .731
System chart for hydraulic and mechanical systems .734
Information contained in troubleshooting table 736
H-1 All work equipment lack power, or travel and swing speeds are slow 737
H-2 Engine speed sharply drops or engine stalls .739
H-3 No work equipment, travel or swing move .740
H-4 Abnormal noise is heard from around hydraulic pump 740
H-5 Auto-decelerator does not work 741
H-6 Fine control mode does not function .741
H-7 Boom moves slowly or lacks power 742
H-8 Arm moves slowly or lacks power .743
H-9 Bucket moves slowly or lacks power 744
H-10 Work equipment does not move in its single operation .744
H-11 Work equipment has a bit too large hydraulic drift .745
H-12 Work equipment has big time lag 746
H-13 Other work equipment moves when relieving single circuit .746
H-14 One-touch power max. switch does not operate .746
H-15 In compound operation, work equipment with larger load moves slowly 747
H-16 In swing + boom RAISE operation, boom moves slowly .747
H-17 In swing + travel, travel speed drops sharply 747
H-18 Machine swerves in travel 748
H-19 Machine travels slowly .749
H-20 Machine cannot be easily steered or lacks power 750
H-21 Travel speed does not shift, or it is slower or faster than preset speed .751
H-22 Track shoe does not turn (on one side only) 751
H-23 Machine does not swing .752
H-24 Swing acceleration is poor, or swing speed is slow .754
H-25 Excessive overrun when stopping swing 756
H-26 There is big shock when stopping swing .757
H-27 There is big abnormal noise caused when stopping swing .757
H-28 Swing natural drift is too big .758
H-29 Attachment circuit does not change .759
H-30 Flow rate in attachment circuit cannot be adjusted .759
Troubleshooting of engine (S-mode) 761
Method of using troubleshooting chart .763
S-1 Starting performance is poor 766
S-2 Engine does not start .767
S-3 Engine does not pick up smoothly 770
S-4 Engine stops during operations 771
S-5 Engine does not rotate smoothly .772
S-6 Engine lack output (or lacks power) .773
S-7 Exhaust smoke is black (incomplete combustion) 774
S-8 Oil consumption is excessive (or exhaust smoke is blue) .775
S-9 Oil becomes contaminated quickly 776
S-10 Fuel consumption is excessive 777
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) 778
S-12 Oil pressure drops .779
S-13 Oil level rises (Entry of coolant/fuel) 780
S-14 Coolant temperature becomes too high (overheating) .781
S-15 Abnormal noise is made .782
S-16 Vibration is excessive .783
50 Disassembly and assembly . 0
General information on disassembly and assembly .785
How to read this manual .786
Coating materials list 788
Special tools list 791
Sketches of special tools .794
Engine and cooling system .799
Removal and installation of fuel supply pump assembly .800
Removal and installation of fuel injector assembly 803
Removal and installation of engine front seal .809
Removal and installation of engine rear seal 811
Removal and installation of cylinder head assembly 814
Removal and installation of radiator assembly .827
Removal and installation of hydraulic oil cooler assembly .830
Removal and installation of aftercooler assembly 832
Removal and installation of fuel cooler assembly 834
Removal and installation of engine assembly .836
Removal and installation of fuel tank assembly 838
Power train .841
Removal and installation of travel motor and final drive assembly .842
Disassembly and assembly of final drive assembly 843
Removal and installation of swing machinery assembly 851
Disassembly and assembly of swing machinery assembly 853
Removal and installation of swing circle assembly .861
Undercarriage and frame .863
Disassembly and assembly of track roller assembly .864
Disassembly and assembly of idler assembly 865
Disassembly and assembly of recoil spring .868
Expansion and installation of track shoe assembly .870
Removal and installation of revolving frame .872
Removal and installation of counterweight assembly 874
Removal and installation of maintenance counterweight (at rear of engine) .875
Removal and installation of maintenance counterweight assembly (above pump) .876
Hydraulic system 879
Removal and installation of center swivel joint assembly 880
Disassembly and assembly of center swivel joint .882
Removal and installation of hydraulic tank assembly .883
Removal and installation of work equipment pump .885
Removal and installation of control valve assembly 889
Disassembly and assembly of control valve assembly 891
Disassembly and assembly of work equipment PPC valve assembly .893
Disassembly and assembly of travel PPC valve assembly .895
Disassembly and assembly of hydraulic cylinder assembly .898
Work equipment 905
Removal and installation of work equipment assembly .906
Cab and its attachments .911
Removal and installation of operator’s cab assembly .912
Removal and installation of operator’s cab glass (Stuck glass) 914
Removal and installation of front window assembly .923
Removal and installation of floor frame assembly 924
Electrical system .929
Removal and installation of air conditioner compressor assembly .930
Removal and installation of air conditioner condenser assembly 932
Removal and installation of air conditioner unit assembly .933
Removal and installation of machine monitor assembly 935
Removal and installation of pump controller assembly 936
Removal and installation of engine controller assembly 937
Removal and installation of KOMTRAX communication modem assembly 939
90 Diagrams and drawings 0
Hydraulic diagrams and drawings .941
Hydraulic circuit diagram .943
Electrical diagrams and drawings 947
Electrical circuit diagram 949
Air conditioner electric circuit diagram 963
Connector list and stereogram .965

DESCRIPTION:

Komatsu Hydraulic Excavator PC228US-3E0 PC228USLC-3E0 Shop Manual SEN01418-12 –  PDF DOWNLOAD

SERIAL NUMBERS

• PC228US- 40001     and up
  PC228USLC- 40001 and up

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)
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 25/12/24