Komatsu PC228US-3E0 & PC228USLC-3E0 Hydraulic Excavator Shop Manual SEN01418-04 – PDF Download

Description

Komatsu PC228US-3E0 & PC228USLC-3E0 Shop Manual — Form No. SEN01418-04

This is the complete Komatsu PC228US-3E0 and PC228USLC-3E0 Hydraulic Excavator Shop Manual, published under Form No. SEN01418-04 and applicable to machines from serial number 40001 and up. It is the same comprehensive service documentation used in professional workshops, covering the SAA6D107E-1 engine, the full hydraulic system, electrical control systems, undercarriage, power train, work equipment, and cab. Every major chapter is included: specifications, structure and function, standard value tables, testing and adjusting, troubleshooting, disassembly and assembly, and complete hydraulic and electrical diagrams.

File Details

• Manual Type: Shop Manual (Hydraulic Excavator)
• Brand: Komatsu
• Models Covered: PC228US-3E0, PC228USLC-3E0
• Serial Numbers: 40001 and up
• Language: English
• File Format: PDF
• Document Number: SEN01418-04
• Date: 2007
• Page Count: 925

Chapters Covered

• 00 Index and foreword
• 01 Specification
• 10 Structure, function and maintenance standard
• 20 Standard value table
• 30 Testing and adjusting
• 40 Troubleshooting
• 50 Disassembly and assembly
• 90 Diagrams and drawings

00 Index and foreword

Safety notices, how to read the shop manual, explanation of terms for maintenance standards, handling of electric equipment and hydraulic components, connector types used on engines, how to read electric wire codes, precautions for operation, push-pull coupler disassembly and connection, standard tightening torque tables, and conversion tables.

01 Specification

Specification dimension drawings, working range diagram, full specifications, weight table for major components, and the table of fuel, coolant and lubricants. Covers the PC228US-3E0 and PC228USLC-3E0 with dimensions, performance figures, engine data, undercarriage details, hydraulic pump and motor specifications, and cylinder data.

10 Structure, function and maintenance standard

Detailed explanation of structure, function, and maintenance standards across every major system. Engine and cooling system (including damper assembly, radiator, oil cooler, aftercooler, fuel cooler). Power train (final drive, swing machinery, swing circle). Undercarriage and frame (track frame, idler, carrier roller, track roller, track shoe). Hydraulic system Parts 1–3 (hydraulic tank, hydraulic pump, control valve, CLSS, merge-divider valve, attachment circuit selector valve, drift prevention valve, PPC valve, center swivel joint, travel motor, swing motor, hydraulic cylinders). Work equipment dimensions. Cab and air conditioner piping. Electrical system including engine control, electrical control system, monitor system, sensors, and KOMTRAX terminal.

20 Standard value table

Standard value table for engine related parts (engine speed, intake pressure, exhaust gas color, valve clearance, compression pressure, blow-by pressure, oil pressure, fan belt tension) and chassis standard values (spool stroke, control lever travel, operating force, hydraulic pressures, swing and travel performance, work equipment speed and hydraulic drift, internal leakage).

30 Testing and adjusting

Tools for testing, adjusting and troubleshooting. Measuring engine speed, intake air pressure (boost pressure), exhaust gas color, valve clearance adjustment, compression pressure testing, blow-by pressure measurement, engine oil pressure, fuel system handling and pressure measurement, fuel return rate and leakage, air bleeding, fuel circuit leakage checks, air conditioner compressor belt tension. Part 2 covers swing circle bearing clearance, track shoe tension, hydraulic oil pressure in work equipment / swing / travel circuits, control circuit oil pressure, pump PC and LS control circuit oil pressure, solenoid valve output pressure, PPC valve output pressure, PPC valve adjustment, hydraulic drift inspection, residual pressure release, oil leakage measurement, air bleeding, boom angle potentiometer replacement, diode inspection, and mirror adjustment. Part 3 covers special functions of the machine monitor, handling the engine controller voltage circuit, KOMTRAX terminal procedures and lamp indications, and preparation work for electrical system troubleshooting.

40 Troubleshooting

Failure code table and fuse locations. General information on troubleshooting with points to remember, sequence of events, checks before troubleshooting, classification and steps, and the troubleshooting table structure. Troubleshooting by failure code in four parts, covering engine codes (A000N1, AA10NX, AB00KE, B@BAZG, CA111 through CA2556), pump controller and machine monitor codes (D110KB through DHSBMA), and solenoid codes (DW43KA through DY2EKB). Electrical system troubleshooting (E-mode) with 32 specific symptom-based procedures. Hydraulic and mechanical system troubleshooting (H-mode) with 30 procedures. Engine troubleshooting (S-mode) with 16 symptom-based procedures.

50 Disassembly and assembly

General information on disassembly and assembly including how to read the manual, coating materials list, special tool list, and sketches of special tools. Engine and cooling system procedures for fuel supply pump, fuel injectors, front and rear seals, cylinder head, radiator, oil cooler, aftercooler, fuel cooler, engine assembly, and fuel tank. Power train procedures for travel motor and final drive, swing motor and swing machinery, and swing circle. Undercarriage and frame procedures for track roller, idler, recoil spring, track shoe, revolving frame, counterweight, and maintenance counterweights. Hydraulic system procedures for center swivel joint, hydraulic tank, work equipment pump, control valve, PPC valves, and hydraulic cylinders. Work equipment removal and installation. Cab and attachments including operator’s cab, stuck glass, front window, and floor frame. Electrical system procedures for air conditioner compressor, condenser, unit, machine monitor, pump controller, engine controller, and KOMTRAX modem.

90 Diagrams and drawings

Hydraulic circuit diagram, electrical circuit diagram, and connector arrangement diagram with full pin-out tables for every connector on the machine.

Everything You Need for PC228US-3E0 & PC228USLC-3E0 Service

Whether you are performing routine maintenance, diagnosing a fault code, overhauling a hydraulic pump, or tearing down a travel motor, this Komatsu PC228US-3E0 and PC228USLC-3E0 Shop Manual gives you the exact procedures, torque values, and specifications Komatsu specifies for these machines. The troubleshooting chapters guide you through every E-mode, H-mode, and S-mode symptom with the same structured approach a factory technician uses. The standard value tables let you judge wear limits and adjustment points with confidence. The disassembly and assembly chapters break down every major component — engine, radiator, hydraulic tank, control valve, travel motor, swing motor, cylinders, cab, and more — with special tool references, tightening torques, and coating material specifications. The diagrams section delivers the complete hydraulic and electrical schematics, including connector pin arrangements so you can trace any circuit on the machine.

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This Komatsu PC228US-3E0 and PC228USLC-3E0 Shop Manual is delivered as an instant PDF download after purchase. No shipping, no waiting. Open it on any computer, tablet, or smartphone, or print the pages you need for the workshop. The file is fully self-contained, with all 925 pages organized exactly as Komatsu structured the original documentation — covering serial numbers 40001 and up.