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KOMATSU PC228US -3E0 PC228USLC-3E0 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL (SN:40001 & UP) – PDF DOWNLOAD
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- KOMATSU PC228US -3E0 PC228USLC-3E0 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL
- SERIAL NUMBERS PC228US- 40001
PC228USLC- 40001 and up - SERIAL NUMBER:SEN01418-10
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KOMATSU PC228US -3E0 PC228USLC-3E0 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL (SN:40001 & UP)
KOMATSU PC228US -3E0 PC228USLC-3E0 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL (SN:40001 & UP) – PDF DOWNLOAD:
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KOMATSU PC228US -3E0 PC228USLC-3E0 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL (SN:40001 & UP)
- This shop manual contains the necessary technical information for services performed in a workshop. For ease of understanding, the manual is divided into the following sections.
- 00. Index and foreword
This section explains the shop manuals list, table of contents, safety, and basic information. - 01. Specification
This section explains the specifications of the machine. - 10. Structure, function and maintenance standard
This section explains the structure, function, and maintenance standard values of each component. The structure and function sub-section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. The maintenance standard sub-section explains the criteria and remedies for disassembly and service. - 20. Standard value table
This section explains the standard values for new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting. - 30. Testing and adjusting
This section explains measuring instruments and measuring methods for testing and adjusting, and method of adjusting each part. The standard values and judgement criteria for testing and adjusting are explained in Testing and adjusting. - 40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also explained in the Chassis volume and Engine volume. In this case, see the Chassis volume. - 50. Disassembly and assembly
This section explains the special tools and procedures for removing, installing, disassembling, and assembling each component, as well as precautions for them. In addition, tightening torque and quantity and weight of coating material, oil, grease, and coolant necessary for the work are also explained. - 90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
Engine volume
This section explains the method of reproducing, repairing, and replacing parts
TABLE OF CONTENTS:
KOMATSU PC228US -3E0 PC228USLC-3E0 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL (SN:40001 & UP)
COVER ............................................................................................................ 1 00 Index and foreword............................................................................................. 0 Index......................................................................................................... 2 Composition of shop manual................................................................................ 3 Table of contents......................................................................................... 5 Foreword and general information.............................................................................. 14 Safety notice............................................................................................. 15 How to read the shop manual............................................................................... 20 Explanation of terms for maintenance standard............................................................. 22 Handling of electric equipment and hydraulic component.................................................... 24 Handling of connectors newly used for engines............................................................. 33 How to read electric wire code............................................................................ 36 Precautions when carrying out operation................................................................... 39 Method of disassembling and connecting push-pull type coupler............................................. 42 Standard tightening torque table.......................................................................... 45 Conversion table.......................................................................................... 49 01 Specification.................................................................................................. 0 Specification and technical data.............................................................................. 56 Specification dimension drawings.......................................................................... 57 Working range diagram..................................................................................... 58 Specifications............................................................................................ 59 Weight table.............................................................................................. 61 Table of fuel, coolant and lubricants..................................................................... 63 10 Structure, function and maintenance standard................................................................... 0 Engine and cooling system..................................................................................... 67 Engine related parts...................................................................................... 67 Radiator, oil cooler, aftercooler and fuel cooler......................................................... 68 Power train................................................................................................... 70 Power train............................................................................................... 71 Final drive............................................................................................... 72 Swing machinery........................................................................................... 74 Swing circle.............................................................................................. 76 Undercarriage and frame....................................................................................... 78 Track frame............................................................................................... 79 Idler..................................................................................................... 81 Carrier roller............................................................................................ 83 Track roller.............................................................................................. 84 Track shoe................................................................................................ 85 Hydraulic system, Part 1...................................................................................... 91 Hydraulic equipment layout drawing........................................................................ 92 Hydraulic tank............................................................................................ 94 Hydraulic pump............................................................................................ 95 Hydraulic system, Part 2......................................................................................118 Control valve.............................................................................................119 CLSS......................................................................................................131 Functions and operation by valve..........................................................................135 Merge-divider valve.......................................................................................150 Attachment circuit selector valve.........................................................................173 Hydraulic drift prevention valve..........................................................................175 Hydraulic system, Part 3......................................................................................182 Valve control.............................................................................................183 PPC valve.................................................................................................185 PPC Accumulator...........................................................................................203 Return oil filter.........................................................................................204 Center swivel joint.......................................................................................205 Travel motor..............................................................................................206 Swing motor...............................................................................................216 Hydraulic cylinder........................................................................................225 Work equipment................................................................................................228 Dimensions of components..................................................................................231 Cab and its attachments.......................................................................................236 Air conditioner piping....................................................................................237 Electrical system.............................................................................................239 Engine control............................................................................................240 Electrical control system.................................................................................250 Monitor system............................................................................................276 Sensor....................................................................................................294 KOMTRAX system............................................................................................297 20 Standard value table........................................................................................... 0 Standard service value table..................................................................................301 Standard value table for engine related parts.............................................................302 Standard value table for chassis..........................................................................303 30 Testing and adjusting.......................................................................................... 0 Testing and adjusting, Part 1.................................................................................315 Tools for testing, adjusting, and troubleshooting.........................................................317 Sketches of special tools.................................................................................322 Testing engine speed......................................................................................323 Testing intake air pressure (boost pressure)..............................................................324 Checking exhaust gas color................................................................................325 Adjusting valve clearance.................................................................................326 Testing compression pressure..............................................................................328 Testing blow-by pressure..................................................................................331 Testing engine oil pressure...............................................................................332 Handling fuel system parts................................................................................333 Releasing residual pressure from fuel system..............................................................333 Testing fuel pressure.....................................................................................334 Reduced cylinder mode operation...........................................................................337 No-injection cranking.....................................................................................337 Testing fuel delivery, return rate and leakage............................................................338 Bleeding air from fuel circuit............................................................................341 Checking fuel circuit for leakage.........................................................................342 Checking and adjusting air conditioner compressor belt tension............................................343 Replacement of fan belt...................................................................................344 Testing and adjusting, Part 2.................................................................................347 Testing clearance in swing circle bearings................................................................348 Checking and adjusting track shoe tension.................................................................349 Testing and adjusting hydraulic oil pressure in hydraulic circuit for work equipment, swing and travel....350 Testing control circuit oil pressure......................................................................354 Testing and adjusting pump PC control circuit oil pressure................................................355 Testing and adjusting pump LS control circuit oil pressure................................................358 Testing solenoid valve output pressure....................................................................363 Testing PPC valve output pressure.........................................................................366 Adjusting play of work equipment and swing PPC valves.....................................................367 Inspection of locations of hydraulic drift of work equipment..............................................368 Release of residual pressure from hydraulic circuit.......................................................370 Testing oil leakage.......................................................................................371 Bleeding air from each part...............................................................................374 Procedure for replacing boom angle potentiometer..........................................................376 Inspection procedures for diode...........................................................................377 Adjusting mirrors.........................................................................................378 Testing and adjusting, Part 3.................................................................................381 Special functions of machine monitor......................................................................382 Handling voltage circuit of engine controller.............................................................410 Starting KOMTRAX terminal operations......................................................................411 Indicator lamps of KOMTRAX terminal.......................................................................415 Preparation work for troubleshooting of electrical system.................................................418 Pm-clinic service.........................................................................................420 40 Troubleshooting................................................................................................ 0 Failure code table and fuse locations.........................................................................427 Failure code table........................................................................................428 Fuse locations............................................................................................431 General information on troubleshooting........................................................................435 Points to remember when troubleshooting...................................................................436 Sequence of events in troubleshooting.....................................................................437 Checks before troubleshooting.............................................................................438 Classification and troubleshooting steps..................................................................439 Information in troubleshooting table......................................................................440 Possible problems and troubleshooting No..................................................................442 Connection table for connector pin numbers................................................................445 T- branch box and T- branch adapter table.................................................................481 Troubleshooting by failure code (Display of code), Part 1.....................................................485 Failure code [AA10NX] Air cleaner Clogging................................................................487 Failure code [AB00KE] Charge Voltage Low..................................................................488 Failure code [B@BAZG] Eng Oil Press Low...................................................................490 Failure code [B@BAZK] Eng Oil Level Low...................................................................491 Failure code [B@BCNS] Eng Water Overheat..................................................................492 Failure code [B@BCZK] Eng Water Level Low.................................................................493 Failure code [B@HANS] Hyd Oil Overheat....................................................................494 Failure code [CA111] EMC Critical Internal Failure........................................................494 Failure code [CA115] Eng Ne and Bkup Speed Sens Error.....................................................495 Failure code [CA122] Chg Air Press Sensor High Error......................................................496 Failure code [CA123] Chg Air Press Sensor Low Error.......................................................498 Failure code [CA131] Throttle Sensor High Error...........................................................500 Failure code [CA132] Throttle Sensor Low Error............................................................502 Failure code [CA144] Coolant Temp Sens High Error.........................................................504 Failure code [CA145] Coolant Temp Sens Low Error..........................................................506 Failure code [CA153] Chg Air Temp Sensor High Error.......................................................508 Failure code [CA154] Chg Air Temp Sensor Low Error........................................................510 Failure code [CA155] Chg Air Temp High Speed Derate.......................................................512 Failure code [CA187] Sens Supply 2 Volt Low Error.........................................................514 Failure code [CA221] Ambient Press Sens High Error........................................................516 Failure code [CA222] Ambient Press Sens Low Error.........................................................518 Failure code [CA227] Sens Supply 2 Volt High Error........................................................520 Failure code [CA234] Eng. Overspeed.......................................................................521 Failure code [CA238] Ne Speed Sens Supply Volt Error......................................................522 Failure code [CA271] IMV/PCV1 Short Error.................................................................523 Failure code [CA272] IMV/PCV1 Open Error..................................................................524 Failure code [CA322] Inj #1 (L#1) Open/Short Error........................................................526 Failure code [CA323] Inj #5 (L#5) Open/Short Error........................................................528 Failure code [CA324] Inj #3 (L#3) Open/Short Error........................................................530 Failure code [CA325] Inj #6 (L#6) Open/Short Error........................................................532 Failure code [CA331] Inj #2 (L#2) Open/Short Error........................................................534 Failure code [CA332] Inj #4 (L#4) Open/Short Error........................................................536 Troubleshooting by failure code (Display of code), Part 2.....................................................539 Failure code [CA342] Calibration Code Incompatibility.....................................................541 Failure code [CA351] Injectors Drive Circuit Error........................................................542 Failure code [CA352] Sens Supply 1 Volt Low Error.........................................................544 Failure code [CA386] Sens Supply 1 Volt High Error........................................................546 Failure code [CA428] Water in Fuel Sensor High Error......................................................548 Failure code [CA429] Water in Fuel Sensor Low Error.......................................................550 Failure code [CA435] Eng Oil Press Sw Error...............................................................552 Failure code [CA441] Battery Voltage Low Error............................................................553 Failure code [CA442] Battery Voltage High Error...........................................................556 Failure code [CA449] Rail Press Very High Error...........................................................558 Failure code [CA451] Rail Press Sensor High Error.........................................................560 Failure code [CA452] Rail Press Sensor Low Error..........................................................562 Failure code [CA488] Chg Air Temp High Torque Derate......................................................564 Failure code [CA553] Rail Press High Error................................................................564 Failure code [CA559] Rail Press Low Error.................................................................565 Failure code [CA689] Eng Ne Speed Sensor Error............................................................567 Failure code [CA731] Eng Bkup Speed Sens Phase Error......................................................569 Failure code [CA757] All Continuous Data Lost Error.......................................................570 Failure code [CA778] Eng Bkup Speed Sensor Error..........................................................572 Failure code [CA1633] KOMNET Datalink Timeout Error.......................................................574 Failure code [CA2185] Throt Sens Sup Volt High Error......................................................576 Failure code [CA2186] Throt Sens Sup Volt Low Error.......................................................577 Failure code [CA2249] Rail Press Very Low Error...........................................................578 Failure code [CA2311] IMV Solenoid Error..................................................................580 Failure code [CA2555] Grid Htr Relay Volt High Error......................................................582 Failure code [CA2556] Grid Htr Relay Volt Low Error.......................................................584 Troubleshooting by failure code (Display of code), Part 3.....................................................587 Failure code [D110KB] Battery Relay Drive Short Circuit...................................................588 Failure code [D196KA] Service Return Relay Disc...........................................................590 Failure code [D196KB] Service Return Relay S/C............................................................592 Failure code [DA22KK] Pump Solenoid Power Low Error.......................................................594 Failure code [DA25KP] 5V Sensor 1 Power Abnormality.......................................................596 Failure code [DA2RMC] CAN Discon (Pump Con Detected)......................................................598 Failure code [DA2SKQ] Model Selection Abnormality.........................................................600 Failure code [DAFRMC] CAN Discon (Monitor Detected).......................................................602 Failure code [DGH2KB] Hyd Oil Sensor Short................................................................604 Failure code [DHPAMA] F Pump Press Sensor Abnormality.....................................................606 Failure code [DHPBMA] R Pump Press Sensor Abnormality.....................................................608 Failure code [DHSAMA] Sw RH PPC Press Sen. Abnormality....................................................610 Failure code [DHSBMA] Sw LH PPC Press Sen. Abnormality....................................................612 Troubleshooting by failure code (Display of code), Part 4.....................................................615 Failure code [DW43KA] Travel Speed Sol Open Circuit.......................................................618 Failure code [DW43KB] Travel Speed Sol Short Circuit......................................................620 Failure code [DW45KA] Swing Brake Sol Open Circuit........................................................622 Failure code [DW45KB] Swing Brake Sol Short Circuit.......................................................626 Failure code [DW91KA] Travel Junction Sol Open Circuit....................................................628 Failure code [DW91KB] Travel Junction Sol Short Circuit...................................................630 Failure code [DW4GKA] Boom Slow Down Sol. Disc............................................................632 Failure code [DW4GKB] Boom Slow Down Sol. S/C.............................................................634 Failure code [DWJ0KA] Merge-divider Sol Open Circuit......................................................636 Failure code [DWJ0KB] Merge-divider Sol Short Circuit.....................................................638 Failure code [DWK0KA] 2-stage Relief Sol Open Circuit.....................................................640 Failure code [DWK0KB] 2-stage Relief Sol Short Circuit....................................................642 Failure code [DXA0KA] PC-EPC Sol Open Circuit.............................................................644 Failure code [DXA0KB] PC-EPC Sol Short Circuit............................................................646 Failure code [DXE0KA] LS-EPC Sol Open Circuit.............................................................648 Failure code [DXE0KB] LS-EPC Sol Short Circuit............................................................650 Failure code [DXE4KA] Service Current EPC Open Circuit....................................................652 Failure code [DXE4KB] Service Current EPC Short Circuit...................................................653 Failure code [DY20KA] Wiper Working Abnormality...........................................................654 Failure code [DY20MA] Wiper Parking Abnormality...........................................................656 Failure code [DY2CKB] Washer Drive Short Circuit..........................................................658 Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit.....................................................660 Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit.....................................................662 Troubleshooting of electrical system (E-mode).................................................................665 Before carrying out troubleshooting of electrical system..................................................667 Information contained in troubleshooting table............................................................669 E-1 Engine does not start.................................................................................670 E-2 Auto-decelerator does not operate.....................................................................673 E-3 Automatic warming-up system does not operate..........................................................675 E-4 Preheater does not operate............................................................................676 E-5 All work equipment, swing, and travel mechanism do not move...........................................678 E-6 Power maximizing function does not operate............................................................680 E-7 Machine monitor does not display at all...............................................................682 E-8 Machine monitor does not display some items...........................................................684 E-9 Contents of display by machine monitor are different from applicable machine..........................684 E-10 Fuel level monitor was lighted in red while engine running...........................................685 E-11 Engine coolant temperature gauge does not indicate normally..........................................686 E-12 Hydraulic oil temperature gauge does not indicate normally...........................................688 E-13 Fuel level gauge does not indicate normally..........................................................689 E-14 Swing lock monitor does not indicate normally........................................................690 E-15 When monitor switch is operated, monitor displays nothing............................................692 E-16 Windshield wiper and window washer do not operate....................................................694 E-17 Monitoring function fails to display “boom raise” normally...........................................698 E-18 Monitoring function fails to display “boom lower” normally...........................................699 E-19 Monitoring function fails to display “arm IN” normally...............................................700 E-20 Monitoring function fails to display “arm OUT” normally..............................................701 E-21 Monitoring function fails to display “bucket CURL” normally..........................................702 E-22 Monitoring function fails to display “bucket DUMP” normally..........................................703 E-23 Monitoring function fails to display “swing left” normally...........................................704 E-24 Monitoring function fails to display “swing right” normally..........................................706 E-25 Monitoring function fails to display “travel” normally...............................................708 E-26 Monitoring function fails to display “travel differential pressure” normally.........................710 E-27 Monitoring function fails to display “service” normally..............................................712 E-28 The KOMTRAX system does not work properly............................................................714 E-29 Air conditioner does not operate.....................................................................716 E-30 Travel alarm does not sound or does not stop sounding................................................718 E-31 Horn does not sound..................................................................................720 E-32 Attachment circuit does not change...................................................................722 Troubleshooting of hydraulic and mechanical system (H-mode)...................................................725 System chart for hydraulic and mechanical systems.........................................................728 Information contained in troubleshooting table............................................................730 H-1 All work equipment lack power, or travel and swing speeds are slow....................................731 H-2 Engine speed sharply drops or engine stalls...........................................................733 H-3 No work equipment, travel or swing move...............................................................734 H-4 Abnormal noise is heard from around hydraulic pump....................................................734 H-5 Auto-decelerator does not work........................................................................735 H-6 Fine control mode does not function...................................................................735 H-7 Boom moves slowly or lacks power......................................................................736 H-8 Arm moves slowly or lacks power.......................................................................737 H-9 Bucket moves slowly or lacks power....................................................................738 H-10 Work equipment does not move in its single operation.................................................738 H-11 Work equipment has a bit too large hydraulic drift...................................................739 H-12 Work equipment has big time lag......................................................................740 H-13 Other work equipment moves when relieving single circuit.............................................740 H-14 One-touch power max. switch does not operate.........................................................740 H-15 In compound operation, work equipment with larger load moves slowly..................................741 H-16 In swing + boom RAISE operation, boom moves slowly...................................................741 H-17 In swing + travel, travel speed drops sharply........................................................741 H-18 Machine swerves in travel............................................................................742 H-19 Machine travels slowly...............................................................................743 H-20 Machine cannot be easily steered or lacks power......................................................744 H-21 Travel speed does not shift, or it is slower or faster than preset speed.............................745 H-22 Track shoe does not turn (on one side only)..........................................................745 H-23 Machine does not swing...............................................................................746 H-24 Swing acceleration is poor, or swing speed is slow...................................................748 H-25 Excessive overrun when stopping swing................................................................750 H-26 There is big shock when stopping swing...............................................................751 H-27 There is big abnormal noise caused when stopping swing...............................................751 H-28 Swing natural drift is too big.......................................................................752 H-29 Attachment circuit does not change...................................................................753 H-30 Flow rate in attachment circuit cannot be adjusted...................................................753 Troubleshooting of engine (S-mode)............................................................................755 Method of using troubleshooting chart.....................................................................757 S-1 Starting performance is poor..........................................................................760 S-2 Engine does not start.................................................................................761 S-3 Engine does not pick up smoothly......................................................................764 S-4 Engine stops during operations........................................................................765 S-5 Engine does not rotate smoothly.......................................................................766 S-6 Engine lack output (or lacks power)...................................................................767 S-7 Exhaust smoke is black (incomplete combustion)........................................................768 S-8 Oil consumption is excessive (or exhaust smoke is blue)...............................................769 S-9 Oil becomes contaminated quickly......................................................................770 S-10 Fuel consumption is excessive........................................................................771 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)................................772 S-12 Oil pressure drops...................................................................................773 S-13 Oil level rises (Entry of coolant/fuel)..............................................................774 S-14 Coolant temperature becomes too high (overheating)...................................................775 S-15 Abnormal noise is made...............................................................................776 S-16 Vibration is excessive...............................................................................777 50 Disassembly and assembly....................................................................................... 0 General information on disassembly and assembly...............................................................779 How to read this manual...................................................................................780 Coating materials list....................................................................................782 Special tools list........................................................................................785 Sketches of special tools.................................................................................788 Engine and cooling system.....................................................................................793 Removal and installation of fuel supply pump assembly.....................................................794 Removal and installation of fuel injector assembly........................................................797 Removal and installation of engine front seal.............................................................803 Removal and installation of engine rear seal..............................................................805 Removal and installation of cylinder head assembly........................................................808 Removal and installation of radiator assembly.............................................................821 Removal and installation of hydraulic oil cooler assembly.................................................824 Removal and installation of aftercooler assembly..........................................................826 Removal and installation of fuel cooler assembly..........................................................828 Removal and installation of engine assembly...............................................................830 Removal and installation of fuel tank assembly............................................................832 Power train...................................................................................................835 Removal and installation of travel motor and final drive assembly.........................................836 Disassembly and assembly of final drive assembly..........................................................837 Removal and installation of swing machinery assembly......................................................845 Disassembly and assembly of swing machinery assembly......................................................847 Removal and installation of swing circle assembly.........................................................855 Undercarriage and frame.......................................................................................857 Disassembly and assembly of track roller assembly.........................................................858 Disassembly and assembly of idler assembly................................................................859 Disassembly and assembly of recoil spring.................................................................862 Expansion and installation of track shoe assembly.........................................................864 Removal and installation of revolving frame...............................................................866 Removal and installation of counterweight assembly........................................................868 Removal and installation of maintenance counterweight (at rear of engine).................................869 Removal and installation of maintenance counterweight assembly (above pump)...............................870 Hydraulic system..............................................................................................873 Removal and installation of center swivel joint assembly..................................................874 Disassembly and assembly of center swivel joint...........................................................876 Removal and installation of hydraulic tank assembly.......................................................877 Removal and installation of work equipment pump...........................................................879 Removal and installation of control valve assembly........................................................883 Disassembly and assembly of control valve assembly........................................................885 Disassembly and assembly of work equipment PPC valve assembly.............................................887 Disassembly and assembly of travel PPC valve assembly.....................................................889 Disassembly and assembly of hydraulic cylinder assembly...................................................892 Work equipment................................................................................................899 Removal and installation of work equipment assembly.......................................................900 Cab and its attachments.......................................................................................905 Removal and installation of operator’s cab assembly.......................................................906 Removal and installation of operator’s cab glass (Stuck glass)............................................908 Removal and installation of front window assembly.........................................................917 Removal and installation of floor frame assembly..........................................................918 Electrical system.............................................................................................923 Removal and installation of air conditioner compressor assembly...........................................924 Removal and installation of air conditioner condenser assembly............................................926 Removal and installation of air conditioner unit assembly.................................................927 Removal and installation of machine monitor assembly......................................................929 Removal and installation of pump controller assembly......................................................930 Removal and installation of engine controller assembly....................................................931 Removal and installation of KOMTRAX communication modem assembly..........................................933 90 Diagrams and drawings.......................................................................................... 0 Hydraulic diagrams and drawings...............................................................................935 Hydraulic circuit diagram.................................................................................937 Electrical diagrams and drawings..............................................................................940 Electrical circuit diagram................................................................................942 Connector list and stereogram.............................................................................949
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