Komatsu Hydraulic Excavator PC228USLC-10 Shop Manual SEN06483-06 PDF

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Komatsu Hydraulic Excavator PC228USLC-10 Shop Manual SEN06483-06  – PDF DOWNLOAD

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Komatsu Hydraulic Excavator PC228USLC-10 Shop Manual SEN06483-06  – PDF DOWNLOAD

Language : English
Pages : 1792
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu Hydraulic Excavator PC228USLC-10 Shop Manual SEN06483-06  – PDF DOWNLOAD

• SERIAL NUMBERS 1002 and up

Cover 1
00 Index and foreword . 3
Index . 4
Foreword, safety and general information 16
Important safety notice . 16
How to read the shop manual . 23
Explanation of terms for maintenance standard . 25
Handling equipment of fuel system devices . 27
Handling of intake system parts . 28
Handling of hydraulic equipment . 29
Method of disconnecting and connecting of push-pull type coupler 31
Handling of electrical equipment 34
How to read electric wire code 42
Precautions when performing operation . 45
Practical use of KOMTRAX 50
Standard tightening torque table 51
List of abbreviation 57
Conversion table 62
01 Specification 67
Table of contents . 68
Specifications 69
Specification drawing . 69
Working range drawings 70
Specifications 71
Weight table 74
Table of fuel, coolant, and lubricants 76
10 Structure and function . 77
Table of contents . 78
Engine and cooling system . 79
Engine related parts 79
KVGT 81
EGR system piping drawing . 88
EGR system circuit diagram 90
EGR valve . 92
EGR cooler 94
KCCV layout drawing . 95
KCCV ventilator . 97
KDPF 99
Cooling system 103
Power train . 105
Power train system 105
Swing circle 107
Swing machinery . 108
Final drive . 110
Undercarriage and frame . 112
Track frame and idler cushion . 112
Hydraulic system 114
Hydraulic component layout 114
Valve control . 116
Hydraulic tank 117
CLSS 119
Main pump . 124
Control valve . 155
Swing motor . 211
Travel motor 223
PPC valve . 236
Solenoid valve 259
Attachment circuit selector valve (for high pressure circuit) . 263
Attachment circuit selector valve (for low pressure circuit) 266
Anti-drop valve 269
Center swivel joint . 277
Accumulator . 279
Work equipment 281
Work equipment 281
Work equipment shim . 282
Bucket play adjustment shim . 283
Cab and its attachments . 284
Cab mount and cab tipping stopper . 284
ROPS cab 285
Electrical system . 286
Electrical control system . 286
Machine monitor system 341
KOMTRAX system 363
Sensor 366
20 Standard value tables 387
Table of contents . 388
Standard service value table 389
Standard value table for engine . 389
Standard value table for machine 390
Standard value table for electrical system 404
30 Testing and adjusting 415
Table of contents . 416
Related information on testing and adjusting 417
Tools for testing and adjusting . 417
Sketch of tools for testing and adjusting . 421
Engine and cooling system . 422
Testing engine speed 422
Testing boost pressure 423
Testing exhaust gas color . 425
Testing and adjusting valve clearance . 427
Testing compression pressure 430
Testing blowby pressure . 434
Testing engine oil pressure . 435
Testing EGR valve and KVGT oil pressures 436
Measuring fuel pressure . 437
Measuring fuel delivery, return and leakage . 443
Bleeding air from fuel system . 448
Testing fuel circuit for leakage 450
Handling cylinder cutout mode operation . 451
Handling no-injection cranking operation 452
Testing and adjusting air conditioner compressor belt tension . 453
Replacing fan belt 455
Power train . 456
Testing swing circle bearing clearance 456
Undercarriage and frame . 457
Testing and adjusting track tension . 457
Hydraulic system 458
Releasing remaining pressure from hydraulic circuit . 458
Testing and adjusting oil pressure in work equipment, swing, and travel circuits 463
Testing oil pressure of control circuit . 467
Testing and adjusting oil pressure in pump PC control circuit . 468
Testing and adjusting oil pressure in pump LS control circuit . 472
Testing outlet pressure of solenoid valve . 480
Testing PPC valve outlet pressure . 483
Adjusting play of work equipment and swing PPC valves . 485
Testing pump swash plate sensor . 486
Isolating the parts causing hydraulic drift in work equipment . 487
Testing and adjusting travel deviation 489
Testing oil leakage . 491
Bleeding air from hydraulic circuit . 494
Testing and charging accumulator(manufactured by NOK) nitrogengas pressure for attachment (lowpressure side) . 497
Testing and charging accumulatornitrogen gas pressure for attachment(high pressure side) . 499
Replacing accumulator bladder onhigh pressure side for accumulatorpiping . 501
Work equipment 507
Testing and adjusting boom angle potentiometer 507
Cab and its attachments . 508
Testing cab tipping stopper . 508
Adjusting mirrors . 509
Electrical system . 511
Special functions of machine monitor 511
KOMTRAX terminal start-up procedure . 581
Adjusting rearview camera angle . 584
Handling voltage circuit of engine controller . 586
Handling battery disconnect switch 587
Testing diodes 588
Pm clinic . 589
Pm Clinic service . 589
40 Troubleshooting 601
Table of contents . 602
Related information on troubleshooting 609
Troubleshooting points 609
Sequence of events in troubleshooting . 611
Testing before troubleshooting 613
Inspection procedure before troubleshooting . 615
Preparation work for troubleshooting of electrical system . 634
Classification and procedure for troubleshooting 639
Symptom of probable failure and troubleshooting No. . 642
Information in troubleshooting table 645
Diagnostic procedure for wiring harness open curcuit of pressure sensor system 647
Connector list and layout . 649
Connector contact identification 660
T-branch box and T-branch adapter table . 699
Fuse location table . 704
Precautions for KDPF (KCSF and KDOC) Cleaning and Replacement . 706
Preparation of dummy temperature sensor (for KDOC and KDPF temperature sensors) . 709
Preparation of short circuit electrical connector (for failure codes [CA1883] and [CA3135]) . 710
Failure codes table . 711
Troubleshooting by failure code (Display of code) . 720
Failure code [879AKA] A/C Inner Sensor Open Circuit . 720
Failure code [879AKB] A/C Inner Sensor Short Circuit 721
Failure code [879BKA] A/C Outer Sensor Open Circuit . 722
Failure code [879BKB] A/C Outer Sensor Short Circuit 723
Failure code [879CKA] Ventilating Sensor Open Circuit . 724
Failure code [879CKB] Ventilating Sensor Short Circuit 725
Failure code [879DKZ] Sunlight Sensor Open Or Short Circuit . 726
Failure code [879EMC] Ventilation Damper Abnormality 727
Failure code [879FMC] Air Mix Damper Abnormality 728
Failure code [879GKX] Refrigerant Abnormality . 729
Failure code [989L00] Engine Controller Lock Caution 1 730
Failure code [989M00] Engine Controller Lock Caution 2 731
Failure code [989N00] Engine Controller Lock Caution 3 732
Failure code [A1U0N3] HC Desorb Request 1 . 733
Failure code [A1U0N4] HC Desorb Request 2 . 735
Failure code [AA10NX] Air Cleaner Clogging 737
Failure code [AB00KE] Charge Voltage Low 739
Failure code [B@BAZG] Eng Oil Press Low . 741
Failure code [B@BAZK] Eng Oil Level Low . 742
Failure code [B@BCNS] Eng Water Overheat 743
Failure code [B@BCZK] Eng Water Level Low . 744
Failure code [B@HANS] Hyd Oil Overheat 746
Failure code [CA115] Eng Ne and Bkup Speed Sens Error . 747
Failure code [CA122] Chg Air Press Sensor High Error 748
Failure code [CA123] Chg Air Press Sensor Low Error . 750
Failure code [CA131] Throttle Sensor High Error . 752
Failure code [CA132] Throttle Sensor Low Error 754
Failure code [CA144] Coolant Temp Sens High Error . 756
Failure code [CA145] Coolant Temp Sens Low Error 758
Failure code [CA153] Chg Air Temp Sensor High Error . 760
Failure code [CA154] Chg Air Temp Sensor Low Error 762
Failure code [CA187] Sensor 2 Supply Volt Low Error . 764
Failure code [CA221] Ambient Press Sensor High Error 766
Failure code [CA222] Ambient Press Sensor Low Error . 768
Failure code [CA227] Sensor 2 Supply Volt High Error 770
Failure code [CA234] Eng Overspeed 771
Failure code [CA238] Ne Speed Sensor Supply Volt Error 772
Failure code [CA239] Ne Speed Sens Supply Volt High Error . 773
Failure code [CA271] IMV/PCV1 Short Error . 774
Failure code [CA272] IMV/PCV1 Open Error 776
Failure code [CA295] Ambient Press Sens In Range Error 778
Failure code [CA322] Inj #1(L#1) Open/Short Error . 779
Failure code [CA323] Inj #5(L#5) Open/Short Error . 781
Failure code [CA324] Inj #3(L#3) Open/Short Error . 783
Failure code [CA325] Inj #6(L#6) Open/Short Error . 785
Failure code [CA331] Inj #2(L#2) Open/Short Error . 787
Failure code [CA332] Inj #4(L#4) Open/Short Error . 789
Failure code [CA343] ECM Critical Internal Failure 791
Failure code [CA351] Injectors Drive Circuit Error 792
Failure code [CA352] Sensor 1 Supply Volt Low Error . 793
Failure code [CA356] Mass Air Flow Sensor High Error 795
Failure code [CA357] Mass Air Flow Sensor Low Error . 797
Failure code [CA386] Sensor 1 Supply Volt High Error 799
Failure code [CA428] Water in Fuel Sensor High Error 800
Failure code [CA429] Water in Fuel Sensor Low Error . 802
Failure code [CA435] Eng Oil Press Sw Error . 804
Failure code [CA441] Battery Voltage Low Error 805
Failure code [CA442] Battery Voltage High Error . 807
Failure code [CA449] Rail Press Very High Error . 808
Failure code [CA451] Rail Press Sensor High Error . 809
Failure code [CA452] Rail Press Sensor Low Error 811
Failure code [CA488] Chg Air Temp High Torque Derate 813
Failure code [CA515] Rail Press Sens Sup Volt High Error 814
Failure code [CA516] Rail Press Sens Sup Volt Low Error . 816
Failure code [CA553] Rail Press High Error 818
Failure code [CA555] Crankcase Press High Error 1 . 819
Failure code [CA556] Crankcase Press High Error 2 . 820
Failure code [CA559] Rail Press Low Error . 821
Failure code [CA595] Turbo Speed High Error 2 . 823
Failure code [CA687] Turbo Speed Low Error 824
Failure code [CA689] Eng Ne Speed Sensor Error 826
Failure code [CA691] Intake Air Temp Sens High Error 828
Failure code [CA692] Intake Air Temp Sens Low Error . 830
Failure code [CA697] ECM Int Temp Sensor High Error . 832
Failure code [CA698] ECM Int Temp Sensor Low Error 833
Failure code [CA731] Eng Bkup Speed Sens Phase Error 834
Failure code [CA778] Eng Bkup Speed Sensor Error 836
Failure code [CA1117] Persistent Data Lost Error 841
Failure code [CA1664] KDOC Malfunction 842
Failure code [CA1691] Regeneration Ineffective 844
Failure code [CA1695] Sensor 5 Supply Volt High Error . 847
Failure code [CA1696] Sensor 5 Supply Volt Low Error 849
Failure code [CA1843] Crankcase Press Sens High Error . 851
Failure code [CA1844] Crankcase Press Sens Low Error 853
Failure code [CA1879] KDPF Delta P Sensor High Error 855
Failure code [CA1881] KDPF Delta P Sensor Low Error . 857
Failure code [CA1883] KDPF Delta P Sens In Range Error 859
Failure code [CA1921] KDPF Soot Load High Error 1 . 862
Failure code [CA1922] KDPF Soot Load High Error 2 . 865
Failure code [CA1942] Crankcase Press Sens In Range Error . 870
Failure code [CA1993] KDPF Delta Pressure Low Error . 871
Failure code [CA2185] Throt Sensor Sup Volt High Error 874
Failure code [CA2186] Throt Sensor Sup Volt Low Error . 876
Failure code [CA2249] Rail Press Very Low Error . 878
Failure code [CA2271] EGR Valve Pos Sens High Error . 879
Failure code [CA2272] EGR Valve Pos Sens Low Error 881
Failure code [CA2288] Turbo Speed High Error 1 884
Failure code [CA2311] IMV Solenoid Error 885
Failure code [CA2349] EGR Valve Solenoid Open Error . 886
Failure code [CA2353] EGR Valve Solenoid Short Error 888
Failure code [CA2357] EGR Valve Servo Error . 890
Failure code [CA2373] Exhaust Manifold Press Sens High error 891
Failure code [CA2374] Exhaust Manifold Press Sens Low error . 893
Failure code [CA2375] EGR Orifice Temp Sens High Error 895
Failure code [CA2376] EGR Orifice Temp Sens Low Error . 897
Failure code [CA2381] KVGT Pos Sens High Error 899
Failure code [CA2382] KVGT Pos Sens Low Error . 901
Failure code [CA2383] KVGT Solenoid Open Error 904
Failure code [CA2386] KVGT Solenoid Short Error . 906
Failure code [CA2387] KVGT Servo Error 908
Failure code [CA2554] Exh Manifold Press Sens In Range Error 909
Failure code [CA2555] Grid Htr Relay Volt Low Error . 910
Failure code [CA2556] Grid Htr Relay Volt High Error 912
Failure code [CA2637] KDOC Face Plugging 914
Failure code [CA2639] Manual Stationary Regeneration Request 916
Failure code [CA2961] EGR Orifice Temp High Error 1 . 919
Failure code [CA2973] Chg Air Press Sensor In Range Error . 920
Failure code [CA3133] KDPF Outlet Press Sens High Error . 921
Failure code [CA3134] KDPF Outlet Press Sens Low Error 923
Failure code [CA3135] KDPF Outlet Press Sens In Range Error . 925
Failure code [CA3251] KDOC Inlet Temp High Error 929
Failure code [CA3253] KDOC Temp Error – Non Regeneration 932
Failure code [CA3254] KDOC Outlet Temp High Error 1 . 935
Failure code [CA3255] KDPF Temp Error – Non Regeneration 938
Failure code [CA3256] KDPF Outlet Temp High Error 1 . 941
Failure code [CA3311] KDOC Outlet Temp High Error 2 . 944
Failure code [CA3312] KDPF Outlet Temp High Error 2 . 947
Failure code [CA3313] KDOC Inlet Temp Sensor Low Error 950
Failure code [CA3314] KDOC Inlet Temp Sens High Error . 953
Failure code [CA3315] KDOC Inlet Temp Sens In Range Error . 957
Failure code [CA3316] KDOC Outlet Temp Sens Low Error . 961
Failure code [CA3317] KDOC Outlet Temp Sens High Error 964
Failure code [CA3318] KDOC Outlet Temp Sens In Range Error 968
Failure code [CA3319] KDPF Outlet Temp Sens High Error 972
Failure code [CA3321] KDPF Outlet Temp Sens Low Error . 976
Failure code [CA3322] KDPF Outlet Temp Sens In Range Error 979
Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error 983
Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error . 985
Failure code [CA3741] Rail Press Valve Trip Error . 987
Failure code [D110KB] Battery Relay Drive Short Circuit . 988
Failure code [D19JKZ] Personal Code Relay Abnormality . 990
Failure code [D811MC] KOMTRAX Error . 993
Failure code [D862KA] GPS Antenna Open Circuit 994
Failure code [D8ALKA] System Operating Lamp Disconnection (KOMTRAX) . 995
Failure code [D8ALKB] System Operating Lamp Short Circuit (KOMTRAX) . 997
Failure code [D8AQKR] CAN2 Discon (KOMTRAX) . 998
Failure code [DA20MC] Pump Controller . 999
Failure code [DA22KK] Pump Solenoid Power Low Error .1000
Failure code [DA25KP] 5V Sensor 1 Power Abnormality .1002
Failure code [DA26KP] 5V Sensor 2 Power Abnormality .1005
Failure code [DA29KQ] Model Selection Abnormality .1006
Failure code [DA2LKA] System Operating Lamp Disconnection (Pump Con) 1008
Failure code [DA2LKB] System Operating Lamp Short Circuit (Pump Con) 1010
Failure code [DA2QKR] CAN2 Discon (Pump Con) 1011
Failure code [DA2RKR] CAN1 Discon (Pump Con) 1013
Failure code [DAF0MB] Monitor ROM Abnormality .1014
Failure code [DAF0MC] Monitor Error .1015
Failure code [DAF8KB] Camera Power Supply Short Circuit .1016
Failure code [DAF9KQ] Model Selection Abnormality .1018
Failure code [DAFGMC] GPS Module Error 1019
Failure code [DAFLKA] Operating Lamp Open Circuit(Monitor) 1020
Failure code [DAFLKB] System Operating Lamp Short Circuit (Monitor) .1022
Failure code [DAFQKR] CAN2 Discon (Monitor) .1023
Failure code [DAZ9KQ] A/C Model Selection Abnormality .1024
Failure code [DAZQKR] CAN2 Discon (Aircon ECU) 1025
Failure code [DB2QKR] CAN2 Discon (Engine Con) 1029
Failure code [DB2RKR] CAN1 Discon (Engine Con) 1033
Failure code [DGH2KB] Hyd Oil Sensor Short Circuit 1037
Failure code [DHA4KA] Air Cleaner Clog Sensor Open Circuit 1039
Failure code [DHPAMA] F Pump Press Sensor Abnormality .1040
Failure code [DHPBMA] R Pump Press Sensor Abnormality .1043
Failure code [DHS3MA] Arm IN PPC Sen. Abnormality .1046
Failure code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality 1048
Failure code [DHS8MA] Boom Raise PPC Press Sensor Abnormality .1051
Failure code [DHS9MA] Boom LOWER Press Sensor Abnormality .1054
Failure code [DHSAMA] Swing RH PPC Press Sensor Abnormality .1057
Failure code [DHSBMA] Swing LH PPC Press Sensor Abnormality .1060
Failure code [DHSCMA] Arm Dump PPC Press Sensor Abnormality .1063
Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality 1066
Failure code [DHSFMA] Travel Fwd LH PPC Press Sensor Abnormality 1069
Failure code [DHSGMA] Travel Fwd RH PPC Press Sensor Abnormality 1072
Failure code [DHSHMA] Travel Rev LH PPC Press Sensor Abnormality 1075
Failure code [DHSJMA] Travel Rev RH PPC Press Sensor Abnormality 1078
Failure code [DKA0KA] Failure of Boom Angle Sensor (Open circuit) .1081
Failure code [DKA0KB] Failure of Boom Angle Sensor (Short circuit) 1083
Failure code [DKA0PH] Boom Angle Sensor installation error 1085
Failure code [DKR0MA] F Pump Swash Plate Sensor Abnormality .1086
Failure code [DKR1MA] R Pump Swash Plate Sensor Abnormality .1088
Failure code [DR21KX] Camera 2 Picture Rev. Drive Abnormality .1090
Failure code [DR31KX] Camera 3 Picture Rev. Drive Abnormality .1092
Failure code [DV20KB] Travel Alarm Short Circuit 1094
Failure code [DW43KA] Travel Speed Sol Open Circuit .1096
Failure code [DW43KB] Travel Speed Sol Short Circuit 1098
Failure code [DW45KA] Swing Brake Sol Open Circuit 1100
Failure code [DW45KB] Swing Brake Sol Short Circuit .1103
Failure code [DW4GKA] Boom slow down EPC sol disconnection 1105
Failure code [DW4GKB] Boom slow down EPC sol short circuit 1107
Failure code [DW91KA] Travel Junction Sol Open Circuit 1109
Failure code [DW91KB] Travel Junction Sol Short Circuit .1111
Failure code [DWA2KA] Attachment Sol Open Circuit .1113
Failure code [DWA2KB] Attachment Sol Short Circuit 1115
Failure code [DWK0KA] 2-Stage Relief Sol Open Circuit .1117
Failure code [DWK0KB] 2-Stage Relief Sol Short Circuit 1119
Failure code [DWK2KA] Variable Back Press Sol Open Circuit 1121
Failure code [DWK2KB] Variable Back Press Sol Short Circuit .1123
Failure code [DWK8KA] Swing Press C/O Sol Open Circuit 1125
Failure code [DWK8KB] Swing Press C/O Sol Short Circuit .1127
Failure code [DXA8KA] PC-EPC (F) Sol Open Circuit .1129
Failure code [DXA8KB] PC-EPC (F) Sol Short Circuit 1131
Failure code [DXA9KA] PC-EPC (R) Sol Open Circuit .1133
Failure code [DXA9KB] PC-EPC (R) Sol Short Circuit 1135
Failure code [DXE0KA] LS-EPC Sol Open Circuit .1137
Failure code [DXE0KB] LS-EPC Sol Short Circuit 1139
Failure code [DXE4KA] Attachment Flow EPC Open Circuit 1141
Failure code [DXE4KB] Attachment Flow EPC Short Circuit .1143
Failure code [DXE5KA] Merge-divide Main Sol Open Circuit 1145
Failure code [DXE5KB] Merge-divide Main Sol Short Circuit .1147
Failure code [DXE6KA] Merge-divide LS Sol Open Circuit 1149
Failure code [DXE6KB] Merge-divide LS Sol Short Circuit .1151
Failure code [DY20KA] Wiper Working Abnormality .1153
Failure code [DY20MA] Wiper Parking Abnormality .1155
Failure code [DY2CKB] Washer Drive Short Circuit 1157
Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit .1159
Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit .1161
Troubleshooting of electrical system (E-mode) .1163
E-1 Engine does not start (Engine does not crank) .1163
E-2 Manual preheating system does not work 1168
E-3 Automatic preheating system does not work .1171
E-4 While preheating is working, preheating monitor does not light up .1173
E-5 When starting switch is turned to ON position, machine monitor displays nothing .1175
E-6 While starting switch is turned to ON position (with engine stopped), engine oil level monitor lights up in yellow 1178
E-7 While starting switch is turned to ON position (with engine stopped), radiator coolant level monitor lights up in yellow 1179
E-8 Engine coolant temperature monitor lights up in red while engine is running .1180
E-9 Hydraulic oil temperature monitor lights up in white while engine is running 1181
E-10 Charge level monitor lights up in red while engine is running 1182
E-11 Fuel level monitor lights up in red while engine is running 1183
E-12 Air cleaner clogging monitor lights up in yellow while engine is running .1184
E-13 Water separator monitor lights up in red while engine is running .1185
E-14 Engine coolant temperature monitor lights up in red while engine is running 1186
E-15 Hydraulic oil temperature monitor lights up in red while engine is running .1187
E-16 Engine oil pressure monitor lights up in red while engine is running .1188
E-17 Fuel gauge display does not move from minimum or maximum .1189
E-18 Fuel gauge indicates incorrect amount (indicates neither full nor empty) .1190
E-19 Engine coolant temperature gauge display does not move from minimum or maximum .1191
E-20 Engine coolant temperature gauge indicates incorrect temperature (indicates neither full nor empty) 1192
E-21 Hydraulic oil temperature gauge does not move from minimum or maximum 1193
E-22 Hydraulic oil temperature gauge indicates incorrect temperature (indicates neither full nor empty) .1195
E-23 Contents of display on machine monitor is different from actual machine condition 1196
E-24 Some areas of machine monitor screen are not displayed .1197
E-25 Function switch does not work 1198
E-26 Automatic warm-up system does not operate (in cold season) .1199
E-27 Auto-deceleration monitor does not light up, or does not go out, while auto-deceleration switch is operated 1200
E-28 Auto-deceleration function does not operate or is not canceled while lever is operated .1201
E-29 Working mode selection screen is not displayed while working mode selector switch is operated 1202
E-30 Setting of engine and hydraulic pump is not changed while working mode is changed 1203
E-31 Travel speed monitor does not change when travel speed switch is operated 1204
E-32 Travel speed does not change while travel speed selection is changed .1205
E-33 Alarm buzzer does not stop sounding 1206
E-34 Service meter is not displayed, while starting switch is in OFF position .1207
E-35 Service mode cannot be selected 1208
E-36 Any of work equipment, swing and travel does not work 1209
E-37 Any of work equipment, swing and travel cannot be locked .1211
E-38 Upper structure does not swing while swing parking brake cancel switch is set to CANCEL position .1213
E-39 Swing brake does not operate while swing parking brake cancel switch is set to NORMAL position .1215
E-40 One-touch power maximizing function does not operate, or indicator is not displayed on monitor .1217
E-41 One-touch power maximizing function cannot be canceled .1219
E-42 Alarm does not sound during travel .1220
E-43 Alarm does not stop sounding while machine is stopped 1222
E-44 Horn does not sound 1223
E-45 Horn does not stop sounding 1225
E-46 Wiper monitor does not light up, or does not go out, while wiper switch is operated 1226
E-47 Wiper does not operate while wiper switch is operated 1227
E-48 Window washer does not operate while window washer switch is operated 1229
E-49 Boom LOWER is not displayed correctly with monitoring function .1230
E-50 Arm OUT is not displayed correctly with monitoring function 1231
E-51 Arm IN is not displayed correctly with monitoring function .1232
E-52 Boom RAISE is not displayed correctly with monitoring function .1233
E-53 Bucket CURL is not displayed correctly with monitoring function 1234
E-54 Bucket DUMP is not displayed correctly with monitoring function 1235
E-55 Swing is not displayed correctly with monitoring function 1236
E-56 Travel is not displayed correctly with monitoring function .1237
E-57 Service is not displayed correctly with monitoring function 1238
E-58 Attachment hydraulic circuit cannot be changed .1240
E-59 KOMTRAX system does not operate normally .1241
Troubleshooting of hydraulic and mechanical system (H-mode) .1243
Information described in troubleshooting table (H-mode) .1243
System chart of hydraulic and mechanical systems 1244
Failure mode and cause table 1246
H-1 All of work equipment, swing and travel operation lacks speed or power 1254
H-2 Engine speed drops significantly or engine stalls .1257
H-3 All work equipment, swing and travel does not work 1260
H-4 Unusual sound is heard from around hydraulic pump .1261
H-5 Fine control performance or response is poor 1262
H-6 Boom speed or power is low 1264
H-7 Arm speed or power is low .1268
H-8 Bucket speed or power is low 1272
H-9 Work equipment does not move in single operation 1275
H-10 Hydraulic drift of boom is large .1276
H-11 Hydraulic drift of arm is large 1277
H-12 Hydraulic drift of bucket is large .1278
H-13 Time lag of work equipment is large 1279
H-14 When part of work equipment is relieved singly, other parts of work equipment move .1281
H-15 One-touch power maximizing function does not operate .1282
H-16 In combined operation of work equipment, equipment having heavier load moves slower 1283
H-17 In combined operations of swing and boom RAISE, boom rising speed is low .1284
H-18 In combined operations of swing and travel, travel speed drops largely .1285
H-19 Machine does not travel straight .1286
H-20 Travel speed is slow .1289
H-21 Machine is hard to steer or travel power is low 1291
H-22 Travel speed does not change, or travel speed is too slow or fast 1294
H-23 One of tracks does not run .1295
H-24 Upper structure does not swing to the right or left 1297
H-25 Upper structure swing only to the right or left 1298
H-26 Swing acceleration or swing speed is low in both directions (right and left) .1299
H-27 Swing acceleration performance is poor or swing speed is slow in only one direction 1300
H-28 Upper structure overruns excessively when it stops swinging (both right and left) 1301
H-29 Upper structure overruns excessively when it stops swinging (either right or left) .1302
H-30 Shock is large when upper structure stops swinging .1303
H-31 Large unusual noise is heard when upper structure stops swinging .1304
H-32 Swing drift on a slope is large while swing holding brake is applied .1305
H-33 Swing drift on a slope is large while swing holding brake is released 1306
H-34 Attachment hydraulic circuit cannot be changed while attachment is installed .1307
H-35 Oil flow in attachment circuit cannot be controlled 1308
Troubleshooting of engine (S-mode) 1309
Information mentioned in troubleshooting table (S mode) .1309
S-1 When starting switch is turned to START position, engine does not crank .1310
S-2 Engine cranks but no exhaust smoke comes out 1311
S-3 Fuel is being injected but engine does not start (misfiring: engine cranks but does not start) 1312
S-4 Engine startability is poor .1313
S-5 Engine does not pick up smoothly 1315
S-6 Engine stops during operation .1317
S-7 Engine runs rough or is unstable 1319
S-8 Engine lacks power 1320
S-9 Exhaust smoke is black (KDPF clogs up early) 1322
S-10 Engine oil consumption is excessive 1324
S-11 Engine oil becomes contaminated early 1325
S-12 Fuel consumption is excessive 1326
S-13 Oil is in coolant (or coolant spurts or coolant level goes down) .1327
S-14 Engine oil pressure drops 1328
S-15 Fuel is contaminated in engine oil .1329
S-16 Coolant is contaminated in engine oil (Oil becomes cloudy white) .1330
S-17 Coolant temperature rises too high (overheating) .1331
S-18 Unusual noise is heard .1332
S-19 Vibration is excessive .1333
S-20 Air cannot be bled from fuel circuit .1334
S-21 Active regeneration is executed frequently .1335
S-22 Active regeneration takes time .1336
S-23 White smoke is exhausted during active regeneration 1337
50 Disassembly and assembly .1339
Table of contents .1340
Related information on disassembly and assembly .1342
How to read this manual .1342
Coating materials list 1344
Special tools list 1348
Sketches of special tools .1354
Engine and cooling system .1360
Removal and installation of supply pump assembly 1360
Removal and installation of injector assembly .1365
Removal and installation of cylinder head assembly 1374
Removal and installation of radiator assembly .1395
Removal and installation of hydraulic oil cooler assembly .1398
Removal and installation of aftercooler assembly 1402
Removal and installation of engine assembly .1404
Removal and installation of engine front oil seal .1413
Removal and installation of engine rear oil seal 1418
Removal and installation of fuel cooler assembly 1421
Removal and installation of fuel tank assembly 1423
Removal and installation of engine hood assembly 1425
Removal and installation of KDPF assembly .1427
Disassembly and assembly of KDPF assembly .1436
Removal and installation of KCCV assembly .1444
Removal and installation of air cleaner assembly 1447
Removal and installation of EGR (Exhaust Gas Recirculation) valve assembly 1449
Removal and installation of EGR (Exhaust Gas Recirculation) cooler assembly .1451
Power train .1453
Removal and installation of travel motor and final drive assembly .1453
Disassembly and assembly of final drive .1454
Removal and installation of swing motor and swing machinery assembly 1463
Disassembly and assembly of swing machinery assembly 1465
Removal and installation of swing circle assembly .1472
Undercarriage and frame .1473
Separation and connection of track shoe assembly 1473
Removal and installation of sprocket 1476
Removal and installation of idler and idler cushion assembly 1477
Disassembly and assembly of idler assembly 1478
Disassembly and assembly of idler cushion assembly 1481
Disassembly and assembly of track roller assembly .1483
Disassembly and assembly of carrier roller assembly .1485
Removal and installation of revolving frame assembly 1488
Removal and installation of counterweight assembly 1491
Removal and installation of counterweight assembly for maintenance 1494
Hydraulic system 1495
Removal and installation of center swivel joint assembly 1495
Disassembly and assembly of center swivel joint assembly 1497
Removal and installation of hydraulic tank assembly .1499
Removal and installation of main pump assembly 1502
Removal and installation of main pump input shaft oil seal 1507
Removal and installation of control valve assembly 1508
Disassembly and assembly of control valve assembly 1515
Disassembly and assembly of work equipment PPC valve assembly .1520
Disassembly and assembly of travel PPC valve assembly .1522
Work equipment 1524
Removal and installation of work equipment assembly .1524
Disassembly and assembly of work equipment cylinder assembly 1527
Remove and install anti-Drop valve assembly for boom .1535
Remove and install anti-Drop valve assembly for arm 1537
Disassemble and assemble anti-Drop valve assembly 1539
Cab and its attachments .1541
Removal and installation of operator’s cab assembly .1541
Removal and installation of operator’s cab glass (adhered glass) 1544
Removal and installation of front window assembly .1559
Removal and installation of floor frame assembly 1565
Removal and installation of air conditioner unit assembly .1571
Removal and installation of operator’s seat .1576
Removal and installation of seat belt .1577
Removal and installation of front wiper assembly 1578
Removal and installation of air conditioner compressor assembly .1586
Removal and installation of air conditioner condenser assembly 1588
Electrical system .1590
Removal and installation of engine controller assembly 1590
Removal and installation of pump controller assembly 1591
Removal and installation of machine monitor assembly 1594
Removal and installation of pump swash plate sensor .1596
Removal and installation of mass air flow and temperature sensor 1597
Removal and installation of KOMTRAX terminal 1598
60 Maintenance standard .1599
Table of contents .1600
Engine and cooling system .1601
Engine mount 1601
Cooling system 1602
Power train .1603
Swing circle 1603
Swing machinery .1604
Final drive .1606
Sprocket 1608
Undercarriage and frame .1610
Track frame and idler cushion .1610
Idler .1612
Track roller 1614
Carrier roller 1615
Track shoe 1616
Hydraulic system 1622
Hydraulic tank 1622
Main pump .1623
Control valve .1624
Swing motor .1634
Travel motor 1636
PPC valve .1639
Solenoid valve 1649
Attachment circuit selector valve (for high-pressure circuit) .1650
Attachment circuit selector valve (for low-pressure circuit) 1651
Anti-drop valve for boom 1652
Anti-drop valve for arm .1654
Center swivel joint .1656
Work equipment 1657
Work equipment 1657
Work equipment cylinder .1666
80 Appendix .1669
Table of contents .1670
Air conditioner components 1671
Precautions for refrigerant .1671
Air conditioner component .1672
Configuration and function of refrigeration cycle .1675
Outline of refrigeration cycle 1676
Air conditioner unit 1678
Dual pressure switch 1683
Air conditioner controller 1684
Compressor 1685
Air conditioner condenser .1686
Sunlight sensor .1688
Outer temperature sensor (outside air temperature sensor) .1689
Procedure for testing and troubleshooting .1690
Circuit diagram and arrangement of connector pins .1692
System diagram 1694
Input and output signals of the air conditioner controller 1695
Air conditioner unit 1697
Parts and connectors layout .1699
Testing air leakage (duct) 1705
Testing with self-diagnosis function 1708
Testing vent (mode) changeover 1711
Testing FRESH/RECIRC air changeover .1712
Testing sunlight sensor .1713
Testing (dual) pressure switch for refrigerant 1714
Testing relays 1716
Troubleshooting chart 1 .1717
Troubleshooting chart 2 .1718
Information in troubleshooting table 1721
Failure code list related to air conditioner 1722
Failure code [879AKA] A/C Inner Sensor Open Circuit .1723
Failure code [879AKB] A/C Inner Sensor Short Circuit 1724
Failure code [879BKA] A/C Outer Sensor Open Circuit .1725
Failure code [879BKB] A/C Outer Sensor Short Circuit 1727
Failure code [879CKA] Ventilating Sensor Open Circuit .1729
Failure code [879CKB] Ventilating Sensor Short Circuit 1730
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit .1731
Failure code [879EMC] Ventilation Damper Abnormality 1733
Failure code [879FMC] Air Mix Damper Abnormality 1734
Failure code [879GKX] Refrigerant Abnormality .1735
A-1 Troubleshooting for power supply system (Air conditioner does not operate) 1736
A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled) .1738
A-3 Troubleshooting for blower motor system (No air comes out or air flow is abnormal) 1741
A-4 Troubleshooting for FRESH/RECIRC air changeover .1743
Troubleshooting with gauge pressure .1745
Connection of service tool 1748
Precautions for disconnecting and connecting refrigerant piping .1750
Handling of compressor oil 1752
Desiccant replacement .1754
90 Diagrams and drawings 1757
Table of contents .1758
Hydraulic circuit diagram .1759
Symbols in hydraulic circuit diagram 1759
Hydraulic circuit diagram .1763
Electric circuit diagram 1765
Symbols in electric circuit diagram .1765
Electrical circuit diagram 1769
Electrical circuit diagram of air conditioner unit 1781
INDEX 1783

DESCRIPTION:

Komatsu Hydraulic Excavator PC228USLC-10 Shop Manual SEN06483-06  – PDF DOWNLOAD

• SERIAL NUMBERS 1002 and up

G.B 26/12/24