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Komatsu PC228US-3 PC228USLC-3 Hydraulic Excavator Operation & Maintenance Manual – PDF DOWNLOAD
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Komatsu PC228US-3 PC228USLC-3 Hydraulic Excavator Operation & Maintenance Manual
Book Code : UEAM002603
SERIAL NUMBER:
PC228US-3 – 31936 and up
PC228USLC-3 – 31959 and up
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Description
Komatsu PC228US-3 PC228USLC-3 Hydraulic Excavator Operation & Maintenance Manual SN 31936, 31959 and up
FILE DETAILS:
Komatsu PC228US-3 PC228USLC-3 Hydraulic Excavator Operation & Maintenance Manual
Size :8.87 MB
Format : PDF
Language : English
Number of Pages : 324 pages
Brand: Komatsu
Type of machine: Hydraulic Excavator
Type of document: Operation & Maintenance Manual
Model: PC228US-3 PC228USLC-3
Serial: 31936, 31959 and up
KOMATSU PC228US-3 PC228USLC-3 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu PC228US-3 PC228USLC-3 Hydraulic Excavator Operation & Maintenance Manual
FOREWORD:
This manual provides rules and guidelines which will help you use this machine safely and effectively. The precautions in this manual must be followed at all times when performing operation and maintenance. Most accidents are caused by the failure to follow fundamental safety rules forthe operation and maintenance of machines. Accidents can be prevented by knowing beforehand conditions that may cause hazard when performing operation and maintenance.
TABLE OF CONTENTS:
Komatsu PC228US-3 PC228USLC-3 Hydraulic Excavator Operation & Maintenance Manual
FOREWORD.............................................................................................. 3 FOREWORD.......................................................................................... 4 SAFETY INFORMATION................................................................................ 5 Noise emission levels......................................................................... 7 Vibration levels.............................................................................. 7 Guide to Reduce Vibration Levels on Machine............................................... 8 INTRODUCTION...................................................................................... 10 DIRECTIONS OF MACHINE......................................................................... 10 PRODUCT INFORMATION............................................................................... 11 MACHINE SERIAL NUMBER PLATE AND ITS LOCATION.................................................. 11 ENGINE SERIAL NUMBER PLATE AND ITS LOCATION................................................... 11 SERVICE METER LOCATION........................................................................ 12 YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR................................................... 12 MACHINE SERIAL NUMBER PLATE................................................................... 13 FOREWORD...................................................................................... 14 SAFETY........................................................................................ 14 OPERATION..................................................................................... 15 MAINTENANCE................................................................................... 17 SPECIFICATIONS................................................................................ 19 ATTACHMENTS AND OPTIONS....................................................................... 19 INDEX......................................................................................... 21 SAFETY................................................................................................ 23 SAFETY INFORMATION................................................................................ 24 SAFETY LABELS..................................................................................... 26 LOCATION OF SAFETY LABELS..................................................................... 27 SAFETY LABELS................................................................................. 28 SAFETY INFORMATION................................................................................ 34 SAFETY MACHINE OPERATION.......................................................................... 43 STARTING ENGINE............................................................................... 43 OPERATION..................................................................................... 45 TRANSPORTATION................................................................................ 51 BATTERY....................................................................................... 52 TOWING........................................................................................ 54 LIFTING OBJECTS WITH BUCKET................................................................... 55 SAFETY MAINTENANCE INFORMATION.................................................................... 56 OPERATION............................................................................................. 63 MACHINE VIEW ILLUSTRATIONS........................................................................ 64 OVERALL MACHINE VIEW.......................................................................... 64 CONTROLS AND GAUGES........................................................................... 65 DETAILED CONTROLS AND GAUGES...................................................................... 66 MONITORING SYSTEM............................................................................. 66 Basic Operation Of Machine Monitor........................................................ 67 Basic Check Monitors...................................................................... 69 Caution Monitors.......................................................................... 71 Emergency Monitors........................................................................ 73 Meter Display Portion..................................................................... 75 Monitor Switches Portion.................................................................. 79 SWITCHES...................................................................................... 89 CONTROL LEVERS AND PEDALS..................................................................... 94 SUN ROOF...................................................................................... 96 Opening................................................................................... 96 Closing................................................................................... 96 WINDSHIELD.................................................................................... 97 SLIDING DOOR..................................................................................103 ASHTRAY.......................................................................................103 CONTROLLERS...................................................................................103 REAR UNDERVIEW MIRROR.........................................................................104 EMERGENCY ESCAPE HAMMER.......................................................................104 CAP WITH LOCK.................................................................................105 HOT AND COOL BOX..............................................................................106 AIR CONDITIONER CONTROLS......................................................................107 Air Conditioner Control Panel.............................................................107 Use Air Conditioner With Care.............................................................112 Air Conditioner Maintenance...............................................................112 AUXILIARY ELECTRIC POWER......................................................................113 24V power source..........................................................................113 12V power source..........................................................................113 FUSE..........................................................................................114 FUSIBLELINK...................................................................................115 TOOL BOX......................................................................................115 GREASE GUN HOLDER.............................................................................115 ACCUMULATOR...................................................................................116 Releasing Hydraulic Pressure With Accumulator.............................................116 MACHINE OPERATIONS AND CONTROLS...................................................................117 BEFORE STARTING ENGINE........................................................................117 Walk-Around Checks........................................................................117 Checks Before Starting....................................................................118 Adjustment................................................................................125 Seat Belt.................................................................................127 Operations Before Starting Engine.........................................................129 STARTING ENGINE...............................................................................132 Normal Starting...........................................................................132 Starting Engine In Cold Weather...........................................................134 AFTER STARTING ENGINE.........................................................................136 Breaking-In The New Machine...............................................................136 Warming-Up Operation......................................................................136 In Cold Weather Areas.....................................................................140 STOPPING THE ENGINE...........................................................................145 MACHINE OPERATION.............................................................................146 Preparations For Moving The Machine Off...................................................146 Moving Machine Forward....................................................................147 Moving Machine Backward...................................................................148 Stopping Machine..........................................................................149 STEERING THE MACHINE..........................................................................150 Steering..................................................................................150 SWINGING......................................................................................152 WORK EQUIPMENT CONTROLS AND OPERATIONS........................................................153 WORKING MODE..................................................................................155 PROHIBITED OPERATIONS.........................................................................156 GENERAL OPERATION INFORMATION.................................................................158 TRAVELING ON SLOPES...........................................................................159 ESCAPE FROM MUD...............................................................................161 Stuck One Side Of Track...................................................................161 Stuck Both Sides Of Tracks................................................................161 RECOMMENDED APPLICATIONS......................................................................162 Backhoe Work..............................................................................162 Shovel Work...............................................................................162 Ditching Work.............................................................................162 Loading Work..............................................................................163 BUCKET REPLACEMENT AND INVERSION..............................................................164 Replacement...............................................................................164 Inversion.................................................................................165 PARKING MACHINE...............................................................................167 CHECK AFTER SHUT OFF ENGINE...................................................................168 MACHINE INSPECTION AFTER DAILY WORK...........................................................168 LOCKING.......................................................................................169 TRANSPORTATION....................................................................................170 TRANSPORTATION PROCEDURE......................................................................170 LOADING AND UNLOADING WITH TRAILER............................................................171 Loading...................................................................................172 Securing Machine..........................................................................174 Unloading.................................................................................177 LIFTING MACHINE...............................................................................179 COLD WEATHER OPERATION............................................................................180 COLD WEATHER OPERATION INFORMATION............................................................180 Fuel And Lubricants.......................................................................180 AFTER DAILY WORK COMPLETION...................................................................182 AFTER COLD WEATHER SEASON.....................................................................182 LONG TERM STORAGE.................................................................................183 BEFORE STORAGE................................................................................183 DURING STORAGE................................................................................183 AFTER STORAGE.................................................................................184 STARTING MACHINE AFTER LONG-TERM STORAGE......................................................184 TROUBLES AND ACTIONS..............................................................................185 RUNNING OUT OF FUEL...........................................................................185 PHENOMENA THAT ARE NOT FAILURES...............................................................185 TOWING THE MACHINE............................................................................186 LIGHTWEIGHT TOWING HOLE.......................................................................186 SEVERE JOB CONDITION..........................................................................187 DISCHARGED BATTERY............................................................................187 Battery Removal And Installation..........................................................188 Battery Charges...........................................................................188 Starting Engine With Booster Cables.......................................................189 OTHER TROUBLE.................................................................................191 Electrical System.........................................................................191 Chassis...................................................................................192 Engine....................................................................................193 Electronic Control System.................................................................195 Point Of Contact To Telephone When Error Occurs...........................................196 MAINTENANCE...........................................................................................197 MAINTENANCE INFORMATION...........................................................................198 LUBRICANTS, COOLANT AND FILTERS...................................................................200 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC........................................200 Oil.......................................................................................200 Fuel......................................................................................200 Cooling System Coolant....................................................................201 Grease....................................................................................201 Carrying out KOWA (Komatsu Oil Wear Analysis).............................................201 Oil And Fuel Storage......................................................................202 Filters...................................................................................202 ELECTRIC SYSTEM MAINTENANCE...................................................................203 WEAR PARTS........................................................................................204 WEAR PARTS LIST...............................................................................204 LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS.......................................................205 PROPER SELECTION..............................................................................205 TIGHTENING TORQUE SPECIFICATIONS..................................................................209 TIGHTENING TORQUE LIST........................................................................209 SAFETY CRITICAL PARTS.............................................................................210 SAFETY CRITICAL PARTS LIST....................................................................210 MAINTENANCE SCHEDULE..............................................................................211 MAINTENANCE SCHEDULE CHART....................................................................211 MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER....................................................213 MAINTENANCE PROCEDURE.............................................................................214 INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)................................214 INITIAL 1000 HOURS MAINTENANCE (ONLY AFTER THE FIRST 1000 HOURS)..............................214 WHEN REQUIRED.................................................................................215 CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT..............................................215 CLEAN INSIDE OF COOLING SYSTEM............................................................219 CHECK AND TIGHTEN TRACK SHOE BOLTS........................................................221 CHECK AND ADJUST TRACK TENSION............................................................222 CHECK ELECTRICAL INTAKE AIR HEATER........................................................224 REPLACE BUCKET TEETH (VERTICAL PIN TYPE)..................................................225 REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)................................................228 ADJUST BUCKET CLEARANCE...................................................................229 CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID................................................230 CHECK AND ADJUST AIR CONDITIONER..........................................................231 WASH WASHABLE FLOOR.......................................................................232 BLEEDING AIR FROM HYDRAULIC SYSTEM........................................................235 METHOD FOR RELEASING INTERNAL PRESSURE IN HYDRAULIC CIRCUIT...............................237 CHECK NITROGEN GAS CHARGE PRESSURE IN ACCUMULATOR (control circuit).......................238 CHECK BEFORE STARTING.........................................................................239 EVERY 100 HOURS MAINTENANCE...................................................................240 LUBRICATING...............................................................................240 EVERY 250 HOURS MAINTENANCE...................................................................241 LUBRICATING...............................................................................241 LUBRICATE SWING CIRCLE....................................................................243 CHECK OIL LEVEL IN SWING MACHINERY CASE, ADD OIL..........................................243 CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL..............................................244 CHECK LEVEL OF BATTERY ELECTROLYTE........................................................245 CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST.....................................247 EVERY 500 HOURS MAINTENANCE...................................................................248 REPLACE FUEL FILTER CARTRIDGE.............................................................248 CHECK SWING PINION GREASE LEVEL, ADD GREASE...............................................249 CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS, CONDENSER FINS AND AFTER COOLER FINS....250 CLEAN INTERNAL AND EXTERNAL AIR FILTERS OF AIR CONDITIONER................................251 REPLACE BREATHER ELEMENT IN HYDRAULIC TANK................................................252 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE.........................253 EVERY 1000 HOURS MAINTENANCE..................................................................255 REPLACE HYDRAULIC OIL FILTER ELEMENT......................................................255 CHANGE OIL IN SWING MACHINERY CASE........................................................256 CHECK OIL LEVEL IN DAMPER CASE, ADD OIL...................................................257 CHECK ALL TIGHTENING PARTS OF TURBOCHARGER................................................257 CHECK PLAY TURBOCHARGER ROTOR.............................................................257 REPLACE CORROSION RESISTOR CARTRIDGE......................................................258 CHECK FAN BELT TENSION AND REPLACE FAN BELT...............................................258 CHECK NITROGEN GAS CHARGE PRESSURE IN ACCUMULATOR (for breaker)...........................258 EVERY 2000 HOURS MAINTENANCE..................................................................259 CHANGE OIL IN FINAL DRIVE CASE............................................................259 CLEAN HYDRAULIC TANK STRAINER.............................................................260 CLEAN, CHECK TURBOCHARGER.................................................................260 CHECK ALTERNATOR, STARTING MOTOR..........................................................260 CHECK ENGINE VALVE CLEARANCE, ADJUST......................................................260 CHECK VIBRATION DAMPER....................................................................261 EVERY 4000 HOURS MAINTENENCE..................................................................262 CHECK WATER PUMP..........................................................................262 EVERY 5000 HOURS MAINTENANCE..................................................................262 CHANGE OIL IN HYDRAULIC TANK..............................................................262 SPECIFICATIONS........................................................................................265 SPECIFICATIONS....................................................................................266 EXPLANATION OF LIFTING CAPACITY CHART (PC228US-3, PC228USLC-3)................................268 ATTACHMENTS AND OPTIONS...............................................................................271 ATTACHMENTS AND OPTIONS - GENERAL INFORMATION.....................................................272 SAFETY FIRST..................................................................................272 ATTACHMENT INSTALLATION.......................................................................273 BUCKET WITH HOOK..................................................................................274 HOOK CONDITION................................................................................274 OPERATIONS WITH CARE..........................................................................274 PROHIBITED OPERATIONS.........................................................................274 AIR CONDITIONER...................................................................................275 AIR CONDITIONER CONTROL PANEL.................................................................275 AIR CONDITIONER CONTROLS......................................................................280 AIR CONDITIONER MAINTENANCE...................................................................280 MACHINE READY FOR ATTACHMENT......................................................................281 LOCATIONS.....................................................................................281 HYDRAULIC CIRCUIT.............................................................................285 Switching Hydraulic Circuit...............................................................285 Adjusting Oil Flow........................................................................286 Switching Between Breaker and General Attachment..........................................286 Hydraulic Circuit Connection..............................................................286 Oil Flow Path.............................................................................287 Replace Additional Breaker Filter Element.................................................288 ATTACHMENT REMOVAL AND INSTALLATION...........................................................289 Attachment Removal........................................................................289 Attachment Installation...................................................................290 ATTACHMENT OPERATIONS.........................................................................291 When Using Breaker........................................................................291 When Using General Attachment Such As Crusher.............................................292 LONG TERM STORAGE.............................................................................293 SPECIFICATIONS................................................................................293 ATTACHMENT GUIDE..................................................................................294 ATTACHMENT COMBINATIONS.......................................................................294 TRACK SHOES SELECTION.........................................................................295 BUCKET TEETH SELECTION........................................................................296 Teeth Selection...........................................................................296 Selection Guide For Horizontal Or Vertical Pin Type Tooth.................................296 HANDLING OF RUBBER PAD SHOE AND ROAD LINER....................................................297 Working Environment.......................................................................297 Working Conditions........................................................................297 Storage And Maintenance...................................................................298 Extent Of Damage To Rubber................................................................298 Check Road Liner..........................................................................298 Replace Road Liner........................................................................298 RECOMMENDED ATTACHMENT OPERATIONS.................................................................299 HYDRAULIC BREAKER.............................................................................299 BLADE.............................................................................................304 DETAILED CONTROLS.............................................................................304 Blade Control Lever.......................................................................304 BLADE CONTROL AND OPERATION...................................................................304 PROHIBITED OPERATIONS.........................................................................305 Avoid Hitting Blade.......................................................................305 Folding in Work Equipment.................................................................305 Support Blade on Both Sides...............................................................305 Blade During Backhoe Operation............................................................306 EVERY 100 HOURS MAINTENANCE...................................................................306 Lubricating...............................................................................306 2-PIECE BOOM......................................................................................307 DETAILED CONTROLS.............................................................................307 WORK EQUIPMENT CONTROLS AND OPERATIONS........................................................310 GENERAL OPERATION INFORMATION.................................................................311 WORK POSSIBLE USING 2-PIECE BOOM..............................................................312 Independent Operations....................................................................312 Slope Finishing Work......................................................................312 Excavating Under Front of Machine.........................................................312 Leveling Work.............................................................................312 EVERY 100 HOURS MAINTENANCE...................................................................313 Lubricating...............................................................................313 EVERY 250 HOURS MAINTENANCE...................................................................314 Lubricating...............................................................................314 BUCKET COMBINATIONS...........................................................................317 INDEX.................................................................................................319 <A>...............................................................................................321 <B>...............................................................................................321 <C>...............................................................................................321 <D>...............................................................................................321 <E>...............................................................................................321 <F>...............................................................................................321 <G>...............................................................................................321 <H>...............................................................................................321 <I>...............................................................................................321 <L>...............................................................................................321 <M>...............................................................................................321 <O>...............................................................................................322 <P>...............................................................................................322 <R>...............................................................................................322 <S>...............................................................................................322 <T>...............................................................................................322 <W>...............................................................................................322 <Y>...............................................................................................322
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