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KOMATSU PC228US-2 PC228USLC-1,2 SERVICE REPAIR MANUAL (SEBM015903) KOMATSU PC228US 2 PC228USLC 1,2 – PDF DOWNLOAD
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- KOMATSU PC228US-2 PC228USLC-1,2 SERVICE REPAIR MANUAL
- PUBLICATION NUMBER:SEBM015903
- SERIAL NUMBER:
PC228USLC-1 11001 and up
PC228US-2 15001 and up
PC228USLC-2 15001 and up
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Description
KOMATSU PC228US-2 PC228USLC-1,2 SERVICE REPAIR MANUAL (SEBM015903) KOMATSU PC228US 2 PC228USLC 1,2
KOMATSU PC228US-2 PC228USLC-1,2 SERVICE REPAIR MANUAL (SEBM015903) KOMATSU PC228US 2 PC228USLC 1,2 – PDF DOWNLOAD:
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KOMATSU PC228US-2 PC228USLC-1,2 SERVICE REPAIR MANUAL (SEBM015903) KOMATSU PC228US 2 PC228USLC 1,2
- This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
- This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components.
- STRUCTURE AND FUNCTION
This 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. In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance standards. - TESTING AND ADJUSTING
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” with “Causes” are also included in this section. - DISASSEMBLY AND ASSEMBLY
This section explains the procedures for removing, installing, disassembling and assembling each component, as well as precautions for them. - MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts. The contents of this section may be described in STRUCTURE AND FUNCTION. - OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams. In addition, this section may give the specifications of attachments and options together
TABLE OF CONTENTS:
KOMATSU PC228US-2 PC228USLC-1,2 SERVICE REPAIR MANUAL (SEBM015903) KOMATSU PC228US 2 PC228USLC 1,2
COVER.................................................................................................................................................. 1 CONTENTS............................................................................................................................................... 2 01 GENERAL............................................................................................................................................. 27 SPECIFICATION DIMENSION DRAWINGS................................................................................................................... 28 SPECIFICATIONS..................................................................................................................................... 30 WEIGHT TABLE....................................................................................................................................... 36 FUEL,COOLANT AND LUBRICANTS........................................................................................................................ 42 10 STRUCTURE AND FUNCTION.............................................................................................................................. 44 ENGINE RELATED PARTS............................................................................................................................... 45 RADIATORใปOIL COOLERใปAFTERCOOLER.................................................................................................................... 46 POWER TRAIN........................................................................................................................................ 47 FINAL DRIVE........................................................................................................................................ 48 SWING CIRCLE....................................................................................................................................... 49 SWING MACHINERY.................................................................................................................................... 50 TRACK FRAMEใปRECOIL SPRING ......................................................................................................................... 51 TRACK SHOE......................................................................................................................................... 52 HYDRAULIC PIPING DRAWING .......................................................................................................................... 53 HYDRAULIC CIRCUIT DIAGRAM.......................................................................................................................... 55 HYDRAULIC TANK..................................................................................................................................... 56 HYDRAULIC PUMP..................................................................................................................................... 57 CONTROL VALVE...................................................................................................................................... 76 SELF-REDUCING PRESSURE VALVE....................................................................................................................... 87 SAFETY-SUCTION VALVE FOR SERVICE VALVE............................................................................................................. 92 SWING MOTOR........................................................................................................................................ 93 CENTER SWIVEL JOINT................................................................................................................................100 TRAVEL MOTOR.......................................................................................................................................101 VALVE CONTROL......................................................................................................................................109 WORK EQUIPMENTใปSWING PPC VALVE.....................................................................................................................110 TRAVEL PPC VALVE...................................................................................................................................114 PPC ACCUMULATOR....................................................................................................................................118 STRAIGHT-TRAVEL SYSTEM.............................................................................................................................119 LS-EPC VALVE.......................................................................................................................................120 SOLENOID VALVE.....................................................................................................................................123 BOOM HOLDING VALVE.................................................................................................................................125 WORK EQUIPMENT ...................................................................................................................................128 ACTUAL ELECTRIC WIRING DIAGRAM.....................................................................................................................129 ELECTRICAL CIRCUIT DIAGRAM.........................................................................................................................132 ENGINE CONTROL SYSTEM..............................................................................................................................134 ELECTRONIC CONTROL SYSTEM..........................................................................................................................138 MACHINE MONITORING SYSTEM..........................................................................................................................153 20 TESTING AND ADJUSTING ..............................................................................................................................159 TABLE OF JUDGEMENT STANDARD VALUE..................................................................................................................161 STANDARD VALUE TABLE FOR ELECTRICAL PARTS..........................................................................................................171 TESTING AND ADJUSTING..............................................................................................................................179 TOOLS FOR TESTING,ADJUSTING,AND TROUBLESHOOTING................................................................................................180 MEASURING ENGINE SPEED.........................................................................................................................181 MEASURING EXHAUST GAS COLOR....................................................................................................................182 ADJUSTING VALVE CLEARANCE......................................................................................................................183 MEASURING COMPRESSION PRESSURE.................................................................................................................184 MEASURING BLOW-BY PRESSURE.....................................................................................................................184 TESTING AND ADJUSTING FUEL INJECTION TIMING....................................................................................................185 MEASURING ENGINE OIL PRESSURE..................................................................................................................186 TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION..................................................................................187 MEASURING SPEED SENSOR.........................................................................................................................187 ADJUSTING ENGINE STOP SOLENOID LINKAGE.........................................................................................................188 ADJUSTING ACCELERATOR ACTUATOR CABLE...........................................................................................................189 TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT,SWING,TRAVEL CIRCUIT................................................................190 TESTING AND ADJUSTING OUTPUT PRESSURE OF PC VALVE (SERVO PISTON INPUT PRESSURE)................................................................193 TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE......................................195 MEASURING CONTROL CIRCUIT OIL PRESSURE (REDUCED PUMP DISCHARGE SELF-REDUCING PRESSURE).........................................................198 TESTING SOLENOID VALVE OUTPUT PRESSURE.........................................................................................................199 MEASURING PPC VALVE OUTPUT PRESSURE............................................................................................................202 ADJUSTING WORK EQUIPMENTใปSWING PPC VALVE.......................................................................................................203 TESTING TRAVEL DEVIATION.......................................................................................................................204 CHECKING LOCATION OF CAUSE OF HYDRAULIC DRIFT OF WORK EQUIPMENT................................................................................205 MEASURING OIL LEAKAGE OF SWING,TRAVEL MOTOR....................................................................................................207 RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT..............................................................................................207 TESTING CLEARANCE OF SWING CIRCLE BEARING......................................................................................................208 MEASURING WEAR OF SPROCKET.....................................................................................................................209 TESTING AND ADJUSTING TRACK SHOE TENSION.......................................................................................................210 BLEEDING AIR...................................................................................................................................211 PROCEDURE FOR RESETTING ELECTRICAL SYSTEM AND CHECKING OPERATION...............................................................................213 PROCEDURE FOR REPLACING POTENTIOMETER..........................................................................................................225 PROCEDURE FOR CHECKING DIODE...................................................................................................................226 TROUBLESHOOTING....................................................................................................................................227 POINTS TO REMEMBER WHEN TROUBLESHOOTING........................................................................................................228 SEQUENCE OF EVENTS IN TROUBLESHOOTING..........................................................................................................229 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE...............................................................................................230 CHECKS BEFORE TROUBLESHOOTING..................................................................................................................238 CONNECTOR TYPES AND MOUNTING LOCATIONS.........................................................................................................239 CONNECTOR ARRANGEMENT DIAGRAM..................................................................................................................242 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS.....................................................................................................247 EXPLANATIONS OF CONTROL MECHANISM OF ELECTRICAL SYSTEM.........................................................................................258 DISPLAY METHOD FOR MONITOR PANEL,CONTROLLER MONITOR PANEL,CONTROLLER DISPLAY METHOD ...........................................................261 ERROR CODE TABLE...............................................................................................................................265 METHOD OF USING TROUBLESHOOTING CHARTS.........................................................................................................266 TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)......................................................................................................268 METHOD OF USING TROUBLESHOOTING CHARTS.....................................................................................................269 S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)..............................................................................273 S-2 ENGINE DOES NOT START..................................................................................................................274 (1)ENGINE DOES NOT TURN................................................................................................................274 (2)ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED)............................................................275 (3)EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)..........................................................276 S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)...................................................................................277 S-4 ENGINE STOPS DURING OPERATIONS.........................................................................................................278 S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)..............................................................................................279 S-6 ENGINE LACKS OUTPUT (NO POWER).........................................................................................................280 S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION).........................................................................................281 S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)................................................................................282 S-9 OIL BECOMES CONTAMINATED QUICKLY.......................................................................................................283 S-10 FUEL CONSUMPTION IS EXCESSIVE.........................................................................................................284 S-11 OIL IS IN IN COOLING WATER,OR WATER SPURTS BACK,OR WATER LEVEL GOES DOWN..............................................................285 S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)............................................................................286 S-13 OIL LEVEL RISES (WATER,FUEL IN OIL)...................................................................................................287 S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)......................................................................................288 S-15 ABNORMAL NOISE IS MADE ...............................................................................................................289 S-16 VIBRATION IS EXCESSIVE................................................................................................................290 TROUBLESHOOTING OF CONTROLLER,ELECTRICAL SYSTEM(E MODE)........................................................................................291 ELECTRICAL CIRCUIT DIAGRAM FOR CONTROLLER SYSTEM...........................................................................................293 ELECTRICAL CIRCUIT DIAGRAM FOR ENGINE START,PREHEAT,STOP SYSTEM............................................................................295 ELECTRICAL CIRCUIT DIAGRAM FOR MACHINE MONITOR SYSTEM......................................................................................296 ACTION TAKEN BY SELF-DIAGNOSTIC FUNCTION AND PROBLEMS ON MACHINE ..........................................................................297 JUDGEMENT TABLE FOR CHASSIS RELATED PARTS..................................................................................................301 E-101 ERROR CODE [EE] (ABNORMALITY IN CONTROLLER POWER SOURCE SYSTEM OR COMMUNICATIONS SYSTEM) IS DISPLAYED................................303 a) ABNORMALITY IN CONTROLLER POWER SOURCE SYSTEM.......................................................................................303 b) ABNORMALITY IN COMMUNICATIONS SYSTEM................................................................................................304 E-102 ERROR CODE [31] (ABNORMALITY IN BOOM POTENTIOMETER SYSTEM) IS DISPLAYED..............................................................305 E-103 ERROR CODE [41] (ABNORMALITY IN ROTATION SENSOR SYSTEM) IS DISPLAYED.................................................................306 E-104 ERROR CODE [42] (ABNORMALITY IN FUEL CONTROL DIAL POTENTIOMETER SYSTEM) IS DISPLAYED.................................................307 E-105 ERROR CODE [44] (ABNORMALITY IN FEEDBACK POTENTIOMETER SYSTEM) IN DISPLAYED..........................................................308 E-106 ERROR CODE [54] (ABNORMALITY IN SWING HOLDING BRAKE SOLENOID SYSTEM) IS DISPLAYED....................................................309 E-107 ERROR CODE [58] (ABNORMALITY IN PUMP MERGE/DIVIDER SOLENOID SYSTEM) IS DISPLAYED.....................................................310 E-108 ERROR CODE [62] (ABNORMALITY IN ACCELERATOR MOTOR (+) RELAY SYSTEM) IS DISPLAYED.....................................................311 E-109 ERROR CODE [64] (ABNORMALITY IN 2-STAGE RELIEF SOLENOID SYSTEM) IS DISPLAYED.........................................................312 E-110 ERROR CODE [68] (ABNORMALITY IN ACCELERATOR MOTOR (-) RELAY SYSTEM) IS DISPLAYED.....................................................313 E-111 ERROR CODE [71] (ABNORMALITY IN BOOM RAISE STOP SOLENOID SYSTEM) IS DISPLAYED........................................................314 E-112 ERROR CODE [74] (ABNORMALITY IN PC-EPC SOLENOID SYSTEM) IS DISPLAYED.................................................................315 E-113 ERROR CODE [81] (ABNORMALITY IN PC-EPC SOLENOID SYSTEM) IS DISPLAYED.................................................................316 E-114 ERROR CODE [C1] (BOOM RAISE,BOOM LOWER PRESSURE SWITCHES INPUT AT SAME TIME FOR MORE THAN 3 SECONDS) IS DISPLAYED....................316 E-115 WORK EQUIPMENT DOES NOT MOVE EVEN WHEN WORK EQUIPMENT LOCK LEVER IS RELEASED.........................................................317 E-116 WORK EQUIPMENT LOCK LEVER IS AT LOCK POSITION BUT WORK EQUIPMENT MOVES...............................................................318 E-117 ELECTRICAL SYSTEM CANCEL SWITCH IS NOT TURNED ON,BUT ALARM BUZZER SOUNDS FOR 7 SECONDS AND ELECTRICAL SYSTEM CAUTION LAMP FLASHES....319 E-118 BOOM CUSHION HAS NO EFFECT...........................................................................................................320 E-119 SWING DOES NOT WORK (WHEN NO ERROR DISPLAY IS GIVEN).................................................................................321 E-120 EXCESSIVE HYDRAULIC DRIFT OF SWING...................................................................................................322 E-121 ENGINE DOES NOT START................................................................................................................323 a) STARTING MOTOR DOES NOT TURN........................................................................................................323 b) ENGINE STOP SOLENOID DOES NOT WORK..................................................................................................325 E-122 ENGINE DOES NOT STOP.................................................................................................................326 E-123 AUTO-DECELERATION IS ACTUATED EVEN WHEN AUTO-DECELERATION SWITCH IS OFF..............................................................327 E-124 AUTO-DECELERATION IS NOT ACTUATED WHEN AUTO-DECELERATION SWITCH IS SWITCHED ON.......................................................328 E-125 ENGINE ROTATION IS IRREGULAR.........................................................................................................329 E-126 WIPER DOES NOT WORK..................................................................................................................330 TROUBLESHOOTING OF CONTROLLER INPUT SIGNAL SYSTEM (F MODE).....................................................................................331 F-1 MONITOR DISPLAY DOES NOT SHOW [P1] (BOOM RAISE PRESSURE SWITCH)........................................................................332 F-2 MONITOR DISPLAY DOES NOT SHOW [P2] (BOOM LOWER PRESSURE SWITCH)........................................................................333 F-3 MONITOR DISPLAY DOES NOT SHOW [P3] (SWING PRESSURE SWITCH).............................................................................334 F-4 MONITOR DISPLAY DOES NOT SHOW [P5] (ARM IN PRESSURE SWITCH)............................................................................335 F-5 MONITOR DISPLAY DOES NOT SHOW [P7] (TRAVEL PRESSURE SWITCH)............................................................................336 F-6 MONITOR DISPLAY DOES NOT SHOW [P9] (ARM OUT,BUCKET,OFFSET PRESSURE SWITCH).............................................................337 F-7 CONTROLLER DISPLAY DOES NOT SHOW [UP] POWER MAX.SIGNAL (KNOB SWITCH SIGNAL)............................................................338 F-8 CONTROLLER DISPLAY DOES NOT SHOW [Hi] (TRAVEL SPEED BOOST SWITCH)......................................................................339 TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)....................................................................................340 TABLE OF FAILURE MODES AND CAUSES FOR HYDRAULIC AND MECHANICAL SYSTEM......................................................................341 PUMP MERGE/DIVIDER LOGIC...................................................................................................................345 H-1 SPEEDS OF ALL WORK EQUIPMENT,SWING,TRAVLE ARE SLOW OR LACK POWER.......................................................................346 H-2 THERE IS EXCESSIVE DROP IN ENGINE SPEED,OR ENGINE STALLS...............................................................................348 H-3 NO WORK EQUIPMENT,TRAVEL,SWING MOVE....................................................................................................349 H-4 ABNORMAL NOISE GENERATED (AROUND PUMP).................................................................................................349 H-5 AUTO-DECELERATION DOES NOT WORK (PPC SHUTTLE VALVE IS EQUIPPED ONLY IN TRAVEL PPC VALVE)...............................................350 H-6 FINE CONTROL ABILITY IS POOR OR RESPONSE IS POOR.......................................................................................350 H-7 BOOM IS SLOW OR LACKS POWER............................................................................................................351 H-8 ARM IS SLOW OR LACKS POWER.............................................................................................................353 H-9 BUCKET IS SLOW OR LACKS POWER..........................................................................................................355 H-10 WORK EQUIPMENT (BOOM,ARM,BUCKET) DOES NOT MOVE (BUT TRAVEL AND SWING ARE NORMAL)......................................................356 H-11 EXCESSIVE HYDRAULIC DRIFT (BOOM,ARM,OR BUCKET)........................................................................................356 H-12 EXCESSIVE TIME LAG (ENGINE AT LOW IDLING).............................................................................................357 H-13 OTHER EQUIPMENT MOVES WHEN SINGLE CIRCUIT IS RELIEVED.................................................................................357 H-14 LACK OF POWER WHEN PRESSURE RISES.....................................................................................................358 H-15 IN COMPOUND OPERATIONS,WORK EQUIPMENT WITH LARGER LOAD IS SLOW .......................................................................358 H-16 IN SWING + BOOM RAISE,BOOM RAISE IS SLOW..............................................................................................359 H-17 IN SWING + TRAVEL,TRAVEL SPEED DROPS EXCESSIVELY......................................................................................359 H-18 TRAVEL DEVIATION......................................................................................................................360 H-19 TRAVLE SPEED IS SLOW..................................................................................................................361 H-20 STEERING DOES NOT TURN EASILY OR LACKS POWER..........................................................................................363 H-21 TRAVEL SPEED DOES NOT SWITCH OR IS FASTER THAN SPECIFIED SPEED........................................................................365 H-22 TRAVEL DOES NOT MOVE (ONE SIDE ONLY)..................................................................................................365 H-23 DOES NOT SWING........................................................................................................................366 H-24 SWING ACCELERATION IS POOR OR SWING SPEED IS SLOW.....................................................................................367 H-25 EXCESSIVE OVERRUN WHEN STOPPING SWING.................................................................................................369 H-26 EXCESSIVE SHOCK WHEN STOPPING SWING (ONE DIRECTION ONLY)..............................................................................370 H-27 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING..........................................................................................370 H-28 EXCESSIVE HYDRAULIC DRIFT OF SWING ...................................................................................................371 TROUBLESHOOTING OF MACHINE MONITOR SYSTEM(M MODE)..............................................................................................372 CHASSIS MONITOR SYSTEM ELECTRICAL CIRCUIT DIAGRAM..........................................................................................373 M-1 WHEN STARTING SWITCH IS TURNED ON,NOTHING IS DISPLAYED (NOTHING LIGHTS UP FOR 3 SEC.)..................................................374 M-2 WHEN STARTING SWITCH IS TURNED ON,ALL LAMPS LIGHT UP,BUT THEY DO NOT GO OUT AFTER 3 SEC................................................374 M-3 WHEN STARTING SWITCH IS TURNED ON,SOME LAMPS DO NOT LIGHT UP FOR 3 SEC.................................................................375 a) NO GAUGES LIGHT UP..................................................................................................................375 b) ELECTRIC SYSTEM CAUTION LAMP DOES NOT LIGHT UP......................................................................................375 c) CHARGE LEVEL CAUTION LAMP DOES NOT LIGHT UP.........................................................................................375 d) ENGINE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP .................................................................................375 M-4 WHEN STARTING SWITCH IS AT ON (ENGINE STOPPED),CHARGE LEVEL CAUTION LAMP DOES NOT LIGHT UP.............................................376 M-5 WHEN STARTING SWITCH IS AT ON (ENGINE STOPPED),ENGINE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP......................................376 M-6 PREHEATING PILOT LAMP DOES NOT LIGHT UP DURING PREHEATING..............................................................................377 M-7 ENGINE OIL PRESSURE CAUTION LAMP LIGHTS UP WHEN ENGINE IS RUNNING (ENGINE OIL PRESSURE IS NORMAL)......................................377 M-8 CHARGE LEVEL CAUTION LAMP LIGHTS UP WHEN ENGINE IS RUNNING.............................................................................378 M-9 ABNORMALITY IN COOLANT TEMPERATURE SYSTEM IS DISPLAYED.................................................................................379 a) AFTER ENGINE STARTS,LEVEL STAYS AT BOTTOM AND DOES NOT GO UP........................................................................379 b) AFTER ENGINE STARTS,LEVEL GOES UP IMMEDIATELY (ENTERS RED RANGE EVEN THOUGH THERE IS NO OVERHEATING)................................379 M-10 ABNORMAL DISPLAY IS GIVEN FOR FUEL GAUGE SYSTEM.......................................................................................380 a) ALL FUEL LEVEL GAUGE SEGMENTS GO OUT................................................................................................380 b) FUEL LEVEL HAS GONE DOWN,BUT FUEL GAUGE CONTINUES TO DISPLAY FULL...................................................................380 c) EVEN WHEN FUEL TANK IS FILLED,FUEL LEVEL GAUGE DOES NOT SHOW FULL...................................................................381 M-11 WHEN STARTING SWITCH IS ON (ENGINE STOPPED),ENGINE OIL LEVEL CAUTION LAMP FLASHES.....................................................381 M-12 DEFECTIVE OPERATION OF ALARM BUZZER...................................................................................................382 a) BUZZER DOES NOT SOUND...............................................................................................................382 b) BUZZER DOES NOT STOP SOUNDING.......................................................................................................382 M-13 SERVICE METER DOES NOT MOVE WHEN ENGINE IS RUNNIGN....................................................................................383 a) WHEN CHARGE LEVEL CAUTION LAMP DOES NOT LIGHT UP....................................................................................383 b) WHEN CHARGE LEVEL CAUTION LAMP LIGHTS UP............................................................................................383 M-14 NIGHT LIGHTING DOES NOT LIGHT UP......................................................................................................384 a) COOLANT TEMPERATURE GAUGE, FUEL GAUGE,DEPTH DISPLAY DO NOT LIGHT UP.................................................................384 b) SERVICE METER DOES NOT LIGHT UP.....................................................................................................384 M-15 ELECTRIC SYSTEM CAUTION LAMP STAYS LIGHTED UP (THERE IS NO ABNORMALITY DISPLAY ON CONTROLLER,OPERATION IS NORMAL).....................385 30 DISASSEMBLY AND ASSEMBLY............................................................................................................................386 METHOD OF USING MANUAL.............................................................................................................................388 PRECAUTIONS WHEN CARRYING OUT OPERATION............................................................................................................390 SPECIAL TOOL LIST..................................................................................................................................393 SKETCHES OF SPECIAL TOOLS..........................................................................................................................396 STARING MOTOR......................................................................................................................................397 REMOVAL AND INSTALLATION.......................................................................................................................397 ALTERNATOR.........................................................................................................................................398 REMOVAL AND INSTALLATION.......................................................................................................................398 ENGINE OIL COOLER CORE.............................................................................................................................399 REMOVAL AND INSTALLATION.......................................................................................................................399 FUEL INJECTION PUMP................................................................................................................................400 REMOVAL ......................................................................................................................................400 INSTALLATION...................................................................................................................................403 WATER PUMP.........................................................................................................................................405 REMOVAL AND INSTALLATION.......................................................................................................................405 NOZZLE HOLDER......................................................................................................................................406 REMOVAL AND INSTALLATION.......................................................................................................................406 TURBOCHARGER.......................................................................................................................................407 REMOVAL AND INSTALLATION.......................................................................................................................407 THERMOSTAT.........................................................................................................................................408 REMOVAL AND INSTALLATION.......................................................................................................................408 CYLINDER HEAD .....................................................................................................................................409 REMOVAL........................................................................................................................................409 INSTALLATION...................................................................................................................................413 ENGINE,MAIN PUMP...................................................................................................................................416 REMOVAL........................................................................................................................................416 INSTALLATION...................................................................................................................................419 DAMPER.............................................................................................................................................420 REMOVAL AND INSTALLATION.......................................................................................................................420 ENGINE FRONT SEAL..................................................................................................................................421 REMOVAL AND INSTALLATION.......................................................................................................................421 ENGINE REAR SEAL...................................................................................................................................423 REMOVAL........................................................................................................................................423 INSTALLATION...................................................................................................................................424 RADIATOR,HYDRAULIC COOLER..........................................................................................................................425 REMOVAL........................................................................................................................................425 INSTALLATION...................................................................................................................................426 FUEL TANK..........................................................................................................................................427 REMOVAL........................................................................................................................................427 INSTALLATION...................................................................................................................................428 CENTER SWIVEL JOINT................................................................................................................................429 REMOVAL........................................................................................................................................429 INSTALLATION...................................................................................................................................430 CENTER SWIVEL JOINT................................................................................................................................431 DISASSEMBLY AND ASSEMBLY.......................................................................................................................431 SPROCKET...........................................................................................................................................432 REMOVAL AND INSTALLATION.......................................................................................................................432 FINAL DRIVE,TRAVEL MOTOR...........................................................................................................................433 REMOVAL AND INSTALLATION.......................................................................................................................433 FINAL DRIVE........................................................................................................................................434 DISASSEMBLY ..................................................................................................................................434 ASSEMBLY.......................................................................................................................................437 DISASSEMBLY AND ASSEMBLY OF TRAVEL MOTOR...........................................................................................................442 ASSEMBLY DRAWINGS..............................................................................................................................443 PARTS LIST.....................................................................................................................................449 TOOLS LIST FOR DISASSEMBLY AND ASSEMBLY........................................................................................................451 1.STANDARD TOOLS...........................................................................................................................451 2.MANUFACTURED TOOLS.......................................................................................................................452 DISASSEMBLY PROCEDURE..........................................................................................................................454 1.GENERAL PRECAUTIONS......................................................................................................................454 2.DISASSEMBLY PROCEDURE....................................................................................................................455 2-1.DISASSEMBLY OF BRAKE VALVE.........................................................................................................457 2-2.DISASSEMBLY OF HYDRAULIC MOTOR.....................................................................................................461 2-3.DISASSEMBLY OF REDUCTION GEAR ASSEMBLY.............................................................................................464 MAINTENANCE STANDARD...........................................................................................................................469 1.SEALS....................................................................................................................................469 2.MAINTENANCE STANDARD FOR WORM PARTS......................................................................................................469 ASSEMBLY PROCEDURE.............................................................................................................................471 1.GENERAL PRECAUTIONS......................................................................................................................471 2.ASSEMBLY PROCEDURE.......................................................................................................................472 2-1.ASSEMBLY OF BRAKE VALVE............................................................................................................472 2-2.ASSEMBLY OF REDUCTION GEAR ASSEMBLY AND HYDRAULIC MOTOR............................................................................476 PERFORMANCE TEST...............................................................................................................................491 LIST OF CLEARANCE ADJUSTMENT PARTS.............................................................................................................492 SWING MOTOR,SWING MACHINERY........................................................................................................................493 REMOVAL AND INSTALLATION ................................................................................................493 SWING MACHINERY....................................................................................................................................494 DISASSEMBLY....................................................................................................................................494 ASSEMBLY.......................................................................................................................................498 SWING MOTOR........................................................................................................................................503 REMOVAL AND INSTALLATION.......................................................................................................................503 REVOLVING FRAME....................................................................................................................................504 REMOVAL........................................................................................................................................504 INSTALLATION...................................................................................................................................505 SWING CIRCLE.......................................................................................................................................506 REMOVAL........................................................................................................................................506 INSTALLATION...................................................................................................................................507 IDLER,RECOIL SPRING................................................................................................................................508 REMOVAL AND INSTALLATION.......................................................................................................................508 RECOIL SPRING......................................................................................................................................509 DISASSEMBLY....................................................................................................................................509 ASSEMBLY.......................................................................................................................................510 IDLER..............................................................................................................................................511 DISASSEMBLY....................................................................................................................................511 ASSEMBLY.......................................................................................................................................512 TRACK ROLLER.......................................................................................................................................514 REMOVAL AND INSTALLATION.......................................................................................................................514 DISASSEMBLY....................................................................................................................................515 ASSEMBLY.......................................................................................................................................516 CARRIER ROLLER.....................................................................................................................................518 REMOVAL AND INSTALLATION.......................................................................................................................518 DISASSEMBLY....................................................................................................................................519 ASSEMBLY.......................................................................................................................................520 TRACK SHOE ........................................................................................................................................522 REMOVAL AND INSTALLATION.......................................................................................................................522 HYDRAULIC TANK.....................................................................................................................................523 REMOVAL AND INSTALLATION.......................................................................................................................523 MAIN PUMP..........................................................................................................................................524 REMOVAL........................................................................................................................................524 INSTALLATION...................................................................................................................................525 EPC VALVE..........................................................................................................................................526 REMOVAL AND INSTALLATION.......................................................................................................................526 PC VALVE...........................................................................................................................................527 REMOVAL AND INSTALLATION.......................................................................................................................527 LS VALVE...........................................................................................................................................528 REMOVAL AND INSTALLATION.......................................................................................................................528 CONTROL VALVE......................................................................................................................................529 REMOVAL........................................................................................................................................529 INSTALLATION...................................................................................................................................531 DISASSEMBLY....................................................................................................................................532 ASSEMBLY.......................................................................................................................................537 LS SELECT VALVE....................................................................................................................................543 DISASSEMBLY AND ASSEMBLY.......................................................................................................................543 PRESSURE COMPENSATION VALVE........................................................................................................................544 DISASSEMBLY....................................................................................................................................544 ASSEMBLY.......................................................................................................................................545 MAIN RELIEF VALVE..................................................................................................................................546 REMOVAL AND INSTALLATION.......................................................................................................................546 DISASSEMBLY AND ASSEMBLY.......................................................................................................................547 SOLENOID VALVE.....................................................................................................................................548 REMOVAL AND INSTALLATION.......................................................................................................................548 PUMP MERGE/DIVIDER SOLENOID VALVE..................................................................................................................549 REMOVAL AND INSTALLATION.......................................................................................................................549 2-STAGE RELIEF,TRAVEL HI/LO SOLENOID VALVE.........................................................................................................550 REMOVAL AND INSTALLATION.......................................................................................................................550 INTERFERENCE PREVENTION SOLENOID VALVE.............................................................................................................551 REMOVAL AND INSTALLATION.......................................................................................................................551 LEFT WORK EQUIPMENT PPC VALVE (FOR SWING, ARM CONTROL).............................................................................................552 REMOVAL AND INSTALLATION.......................................................................................................................552 RIGHT WORK EQUIPMENT PPC VALVE (FOR BOOM,BUCKET CONTROL)...........................................................................................553 REMOVAL AND INSTALLATION.......................................................................................................................553 WORK EQUIPMENT PPC VALVE (PPC VALVE FOR BOOM,BUCKET,ARM,SWING CONTROL).............................................................................554 DISASSEMBLY....................................................................................................................................554 ASSEMBLY.......................................................................................................................................555 TRAVEL PPC VALVE...................................................................................................................................556 REMOVAL AND INSTALLATION.......................................................................................................................556 DISASSEMBLY AND ASSEMBLY.......................................................................................................................557 PPC VALVE FOR OFFSET CONTROL.......................................................................................................................558 REMOVAL AND INSTALLATION.......................................................................................................................558 BOOM LOCK VALVE....................................................................................................................................559 REMOVAL AND INSTALLATION.......................................................................................................................559 BOOM CYLINDER......................................................................................................................................560 REMOVAL........................................................................................................................................560 INSTALLATION...................................................................................................................................561 ARM CYLINDER.......................................................................................................................................562 REMOVAL........................................................................................................................................562 INSTALLATION...................................................................................................................................563 BUCKET CYLINDER....................................................................................................................................564 REMOVAL........................................................................................................................................564 INSTALLATION...................................................................................................................................565 OFFSET CYLINDER....................................................................................................................................566 REMOVAL........................................................................................................................................566 INSTALLATION...................................................................................................................................567 HYDRAULIC CYLINDER FOR OFFSET......................................................................................................................568 DISASSEMBLY....................................................................................................................................568 ASSEMBLY.......................................................................................................................................570 HYDRAULIC CYLINDER FOR BOOM,ARM,BUCKET.............................................................................................................572 DISASSEMBLY....................................................................................................................................572 ASSEMBLY.......................................................................................................................................575 BUCKET ...........................................................................................................................................579 REMOVAL .......................................................................................................................................579 INSTALLATION...................................................................................................................................580 ARM ...............................................................................................................................................581 REMOVAL........................................................................................................................................581 INSTALLATION...................................................................................................................................582 BUCKET,ARM.........................................................................................................................................585 REMOVAL........................................................................................................................................585 INSTALLATION...................................................................................................................................586 OFFSET BRACKET.....................................................................................................................................589 REMOVAL AND INSTALLATION.......................................................................................................................589 2ND BOOM...........................................................................................................................................590 REMOVAL........................................................................................................................................590 INSTALLATION...................................................................................................................................591 1ST BOOM...........................................................................................................................................592 REMOVAL........................................................................................................................................592 INSTALLATION...................................................................................................................................594 2ND,1ST BOOM.......................................................................................................................................595 REMOVAL........................................................................................................................................595 INSTALLATION...................................................................................................................................597 OFFSET BRACKET,2ND,1ST BOOM........................................................................................................................598 REMOVAL........................................................................................................................................598 INSTALLATION...................................................................................................................................600 BOOM...............................................................................................................................................601 REMOVAL........................................................................................................................................601 INSTALLATION...................................................................................................................................602 OPERATOR'S CAB.....................................................................................................................................603 REMOVAL........................................................................................................................................603 INSTALLATION...................................................................................................................................604 FLOOR FRAME........................................................................................................................................605 REMOVAL........................................................................................................................................605 INSTALLATION...................................................................................................................................606 AIR CONDITIONER COMPRESSOR.........................................................................................................................607 REMOVAL AND INSTALLATION.......................................................................................................................607 AIR CONDITIONER CONDENSER..........................................................................................................................608 REMOVAL AND INSTALLATION.......................................................................................................................608 AIR CONDITIONER UNIT...............................................................................................................................609 REMOVAL........................................................................................................................................609 INSTALLATION...................................................................................................................................610 COUNTERWEIGHT......................................................................................................................................611 REMOVAL AND INSTALLATION.......................................................................................................................611 CONTROLLER.........................................................................................................................................612 REMOVAL AND INSTALLATION.......................................................................................................................612 MONITOR............................................................................................................................................613 REMOVAL AND INSTALLATION.......................................................................................................................613 40 MAINTENANCE STANDARD................................................................................................................................614 FINAL DRIVE........................................................................................................................................615 SWING CIRCLE.......................................................................................................................................617 SWING MACHINERY....................................................................................................................................618 TRACK FRAMEใปRECOIL SPRING..........................................................................................................................620 IDLER..............................................................................................................................................621 CARRIER ROLLER.....................................................................................................................................623 TRACK ROLLER.......................................................................................................................................624 TRACK SHOE.........................................................................................................................................625 HYDRAULIC PUMP.....................................................................................................................................630 CONTROL VALVE......................................................................................................................................631 SELF-REDUCING PRESSURE VALVE.......................................................................................................................639 SWING MOTOR........................................................................................................................................640 TRAVEL MOTOR.......................................................................................................................................641 WORK EQUIPMENTใปSWING PPC VALVE.....................................................................................................................642 TRAVEL PPC VALVE...................................................................................................................................643 SERVICE PPC VALVE..................................................................................................................................644 LS-EPC VALVE.......................................................................................................................................645 SOLENOID VALVE.....................................................................................................................................646 CENTER SWIVEL JOINT................................................................................................................................647 BOOM HOLDING VALVE.................................................................................................................................648 HYDRAULIC CYLINDER.................................................................................................................................649 WORK EQUIPMENT ...................................................................................................................................651 DIMENSION OF WORK EQUIPMENT........................................................................................................................653 90 OTHERS..............................................................................................................................................657 HYDRAULIC CIRCUIT DIAGRAM..........................................................................................................................658 PC228USLC-1....................................................................................................................................658 PC228US-2,PC228USLC-2..........................................................................................................................659 ELECTRICAL CIRCUIT DIAGRAM.........................................................................................................................660 PC228USLC-1....................................................................................................................................660 PC228US-2,PC228USLC-2..........................................................................................................................661
PLEASE NOTE:
โฆ This is the SAME exact manual used by your dealers to fix your vehicle.
โฆ The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
โฆ Any queries / doubts regarding your purchase, please feel free to contact [email protected]
