Trusted Business
Verified & Licensed
Virus Free Files
100% Safe Downloads
Secure Payment
SSL Protected
Instant Delivery
Available Immediately
Sale!
Komatsu PC228US-8, PC228USLC-8 Hydraulic Excavator Shop Manual SEN05331-03 – PDF DOWNLOAD
Original price was: $54.95.$26.95Current price is: $26.95.
Komatsu PC228US-8, PC228USLC-8 Hydraulic Excavator Shop Manual
SERIAL NUMBERS 50001 and up
Instant PDF Download
Available immediately
Save to Your Device
Download & keep forever
Antivirus Scanned
100% virus-free
Trusted Worldwide
175,000+ customers
Description
Komatsu PC228US-8, PC228USLC-8 Hydraulic Excavator Shop Manual
FILE DETAILS:
Komatsu PC228US-8, PC228USLC-8 Hydraulic Excavator Shop Manual
Brands: Komatsu
Equipment Type: Hydraulic Excavator
Manuals Type: Shop Manual
Machine Model: PC228US-8, PC228USLC-8
Serial Number: 50001 and up
Book Code: SEN05331-03
Language: English
Pages: 1271
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu PC228US-8, PC228USLC-8 Hydraulic Excavator Shop Manual
How to read the shop manual:
1. Composition of shop manual
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 contains the index, foreword, safety and basic information. If any revision is made, the LIST OF REVISED PAGES will be added.
01. Specification:
This section explains the specifications of the machine.
10. Structure and function:
This section explains the structure and function of each component. It serves not only to give an understanding for the structure of each component, but also serves as reference material for troubleshooting.
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 tools and measuring methods for testing and adjusting, as well as the adjusting method of each part. The standard values and judgment criteria for “Testing and adjusting” are
explained in “Standard value table”.
40. Troubleshooting:
This section explains how to find out failed parts and how to repair them. The troubleshooting is dividedby 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.
60. Maintenance standard:
This section gives maintenance standard values of each component. The maintenance standard sub-section explains the criteria and remedies for disassembly and service.
80. Appendix:
This section explains the structure, function, testing, adjusting, and troubleshooting for the equipment not classifiable in other sections.
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 remanufacturing and repairing engine and replacing parts.
TABLE OF CONTENTS:
Komatsu PC228US-8, PC228USLC-8 Hydraulic Excavator Shop Manual
COVER ................................................................................................................ 1 Notice of revision.................................................................................................... 3 00 Index and foreword................................................................................................. 11 Table of Contents................................................................................................. 12 Table of Contents............................................................................................. 12 Forword and general information................................................................................... 22 Safety notice................................................................................................. 22 How to read the shop manual................................................................................... 27 Explanation of terms for maintenance standard................................................................. 29 Handling of hydraulic components.............................................................................. 31 Method of disconnecting and connecting push-pull type coupler................................................. 33 Handling of electric equipment................................................................................ 36 How to read electric wire code................................................................................ 46 Precautions when performing work.............................................................................. 49 Standard tightening torque table.............................................................................. 52 List of abbreviation.......................................................................................... 56 Conversion table.............................................................................................. 60 01 Specifications..................................................................................................... 65 Specifications.................................................................................................... 68 Specifications drawing........................................................................................ 68 Working range diagram......................................................................................... 69 Specifications................................................................................................ 70 Table of weight............................................................................................... 80 Table of fuel, coolant and lubricants......................................................................... 84 10 Structure and function............................................................................................. 87 Engine and cooling system......................................................................................... 89 Engine related parts.......................................................................................... 89 Cooling system................................................................................................ 90 Power train system................................................................................................ 93 Power train................................................................................................... 93 Swing circle.................................................................................................. 94 Swing machinery............................................................................................... 96 Final drive................................................................................................... 98 Undercarriage and frame........................................................................................... 100 Track frame and idler cushion................................................................................. 100 Hydraulic system.................................................................................................. 102 Hydraulic equipment layout drawing............................................................................ 102 Valve control................................................................................................. 104 Hydraulic tank................................................................................................ 105 CLSS.......................................................................................................... 107 Main pump..................................................................................................... 112 Control valve................................................................................................. 134 Function and operation by valve............................................................................... 146 Swing motor................................................................................................... 183 Travel motor.................................................................................................. 191 PPC valve..................................................................................................... 201 Solenoid valve................................................................................................ 218 Attachment circuit selector valve............................................................................. 224 Anti-drop valve............................................................................................... 228 Multi-control valve........................................................................................... 233 Center swivel joint........................................................................................... 234 Accumulator................................................................................................... 235 Work equipment.................................................................................................... 238 Work equipment................................................................................................ 238 Electrical system................................................................................................. 240 Electronic control system..................................................................................... 240 Machine monitor system........................................................................................ 278 KOMTRAX system................................................................................................ 294 Sensors....................................................................................................... 296 20 Standard value table............................................................................................... 307 Standard value table.............................................................................................. 309 Standard value table for engine............................................................................... 309 Standard value table for machine.............................................................................. 310 30 Testing and adjusting.............................................................................................. 321 Tool for testing, adjusting and troubleshooting................................................................... 323 Tools for testing, adjusting, and troubleshooting............................................................. 323 Engine and cooling system......................................................................................... 329 Testing engine speed.......................................................................................... 329 Testing intake air pressure (boost pressure).................................................................. 330 Testing exhaust gas color..................................................................................... 331 Testing and adjusting valve clearance......................................................................... 332 Testing compression pressure.................................................................................. 334 Testing blowby pressure....................................................................................... 337 Testing engine oil pressure................................................................................... 338 Handling fuel system parts.................................................................................... 339 Releasing remaining pressure from fuel system................................................................. 340 Testing fuel pressure......................................................................................... 341 Cylinder cut-out test mode.................................................................................... 344 No-injection cranking......................................................................................... 345 Checking fuel delivery, return rate and leakage............................................................... 346 Bleeding air from fuel circuit................................................................................ 349 Testing fuel circuit for leakage.............................................................................. 350 Testing and adjusting air conditioner compressor belt tension................................................. 351 Replacing fan belt............................................................................................ 352 Undercarriage and frame........................................................................................... 353 Testing swing circle bearing clearance........................................................................ 353 Checking and adjusting track tension.......................................................................... 354 Hydraulic system.................................................................................................. 355 Testing and adjusting oil pressure in work equipment, swing and travel circuits............................... 355 Testing control circuit source pressure....................................................................... 359 Testing and adjusting oil pressure in pump PC control circuit................................................. 360 Testing and adjusting oil pressure in pump LS control circuit................................................. 364 Testing solenoid valve output pressure........................................................................ 369 Testing PPC valve output pressure............................................................................. 372 Adjusting play of work equipment and swing PPC vavles......................................................... 374 Testing pump swash plate sensor............................................................................... 375 Isolating the parts causing hydraulic drift of work equipment................................................. 376 Releasing remaining pressure from hydraulic circuit........................................................... 378 Testing oil leakage amount.................................................................................... 379 Bleeding air from each part................................................................................... 381 Work equipment.................................................................................................... 383 Replacement procedure of boom angle potentiometer............................................................. 383 Cab and its attachments........................................................................................... 384 Checking cab tipping stopper.................................................................................. 384 Adjusting mirrors............................................................................................. 385 Angle adjustment of rear view camera.......................................................................... 387 Electrical system................................................................................................. 389 Speial function of machine monitor (EMMS)..................................................................... 389 Handling voltage circuit of engine controller................................................................. 445 Preparatory work for troubleshooting of electrical system..................................................... 446 Procedure for testing diodes.................................................................................. 451 Pm clinic......................................................................................................... 453 Pm clinic service............................................................................................. 453 40 Troubleshooting.................................................................................................... 459 General information on troubleshooting............................................................................ 466 Points to remember when troubleshooting....................................................................... 466 Sequence of events in troubleshooting......................................................................... 467 Checks before troubleshooting................................................................................. 468 Classification and procedures for troubleshooting............................................................. 492 Failure codes table........................................................................................... 495 Symptom and troubleshooting numbers........................................................................... 500 Information in troubleshooting table.......................................................................... 502 Troubleshooting method for open circuit in wiring harness of pressure sensor system........................... 504 Connector list and layout..................................................................................... 506 Connection table for connector pin numbers.................................................................... 518 T- branch box and T- branch adapter table..................................................................... 554 Fuse location table........................................................................................... 558 Troubleshooting by failurecode.................................................................................... 560 Failure code [989L00] Engine Controller Lock Caution 1........................................................ 560 Failure code [989M00] Engine Controller Lock Caution 2........................................................ 560 Failure code [989N00] Engine Controller Lock Caution 3........................................................ 561 Failure code [AA10NX] Air Cleaner Clogging.................................................................... 562 Failure code [AB00KE] Charge Voltage Low...................................................................... 564 Failure code [B@BAZG] Eng Oil Press Low....................................................................... 566 Failure code [B@BAZK] Eng Oil Level Low....................................................................... 567 Failure code [B@BCNS] Eng Water Overheat...................................................................... 568 Failure code [B@BCZK] Eng Water Level Low..................................................................... 570 Failure code [B@HANS] Hyd Oil Overheat........................................................................ 572 Failure code [CA111] ECM Critical Internal Failure............................................................ 573 Failure code [CA115] Eng Ne and Bkup Speed Sens Error......................................................... 573 Failure code [CA122] Chg Air Press Sensor High Error.......................................................... 574 Failure code [CA123] Chg Air Press Sensor Low Error........................................................... 576 Failure code [CA131] Throttle Sensor High Error............................................................... 578 Failure code [CA132] Throttle Sensor Low Error................................................................ 580 Failure code [CA144] Coolant Temp Sens High Error............................................................. 582 Failure code [CA145] Coolant Temp Sens Low Error.............................................................. 584 Failure code [CA153] Chg Air Temp Sensor High Error........................................................... 586 Failure code [CA154] Chg Air Temp Sensor Low Error............................................................ 588 Failure code [CA155] Chg Air Temp High Speed Derate........................................................... 590 Failure code [CA187] Sens Supply 2 Volt Low Error............................................................. 592 Failure code [CA221] Ambient Press Sens High Error............................................................ 594 Failure code [CA222] Ambient Press Sens Low Error............................................................. 596 Failure code [CA227] Sens Supply 2 Volt High Error............................................................ 598 Failure code [CA234] Eng Overspeed............................................................................ 599 Failure code [CA238] Ne Speed Sens Supply Volt Error.......................................................... 600 Failure code [CA271] IMV/PCV1 Short Error..................................................................... 602 Failure code [CA272] IMV/PCV1 Open Error...................................................................... 604 Failure code [CA322] Inj #1(L#1) Open/Short Error............................................................. 606 Failure code [CA323] Inj #5 (L#5) Open/Short Error............................................................ 608 Failure code [CA324] Inj #3(L#3) Open/Short Error............................................................. 610 Failure code [CA325] Inj #6 (L#6) Open/Short Error............................................................ 612 Failure code [CA331] Inj #2(L#2) Open/Short Error............................................................. 614 Failure code [CA332] Inj #4(L#4) Open/Short Error............................................................. 616 Failure code [CA342] Calibration Code Incompatibility......................................................... 618 Failure code [CA351] Injectors Drive Circuit Error............................................................ 619 Failure code [CA352] Sens Supply 1 Volt Low Error............................................................. 620 Failure code [CA386] Sens Supply 1 Volt High Error............................................................ 622 Failure code [CA428] Water in Fuel Sensor High Error.......................................................... 624 Failure code [CA429] Water in Fuel Sensor Low Error........................................................... 626 Failure code [CA435] Eng Oil Press Sw Error................................................................... 628 Failure code [CA441] Battery Voltage Low Error................................................................ 630 Failure code [CA442] Battery Voltage High Error............................................................... 632 Failure code [CA449] Rail Press Very High Error............................................................... 633 Failure code [CA451] Rail Press Sensor High Error............................................................. 634 Failure code [CA452] Rail Press Sensor Low Error.............................................................. 636 Failure code [CA488] Chg Air Temp High Torque Derate.......................................................... 638 Failure code [CA553] Rail Press High Error.................................................................... 639 Failure code [CA559] Rail Press Low Error..................................................................... 640 Failure code [CA689] Eng Ne Speed Sensor Error................................................................ 642 Failure code [CA731] Eng Bkup Speed Sens Phase Error.......................................................... 644 Failure code [CA757] All Continuous Data Lost Error........................................................... 645 Failure code [CA778] Eng Bkup Speed Sensor Error.............................................................. 646 Failure code [CA1633] KOMNET Datalink Timeout Error........................................................... 649 Failure code [CA2185] Throt Sens Sup Volt High Error.......................................................... 650 Failure code [CA2186] Throt Sens Sup Volt Low Error........................................................... 651 Failure code [CA2249] Rail Press Very Low Error............................................................... 652 Failure code [CA2311] IMV Solenoid Error...................................................................... 653 Failure code [CA2555] Grid Htr Relay Open Circuit Error....................................................... 654 Failure code [CA2556] Grid Htr Relay Short Circuit Error...................................................... 656 Failure code [D110KB] Battery Relay Drive Short Circuit....................................................... 658 Failure code [D19JKZ] Personal Code Relay Abnormality......................................................... 660 Failure code [D862KA] GPS Antenna Open Circuit................................................................ 662 Failure code [DA22KK] Pump Solenoid Power Low Error........................................................... 664 Failure code [DA25KP] 5V Sensor1 Power Abnormality............................................................ 666 Failure code [DA26KP] 5V Sensor2 Power Abnormality............................................................ 668 Failure code [DA29KQ] Model Selection Abnormality............................................................. 672 Failure code [DA2RMC] CAN Discon (Pump Con Detected).......................................................... 675 Failure code [DAF8KB] Camera Power Supply Short Circuit....................................................... 680 Failure code [DAFGMC] GPS Module Error........................................................................ 682 Failure code [DAFRMC] CAN Discon (Monitor Detected)........................................................... 684 Failure code [DGH2KB] Hyd Oil Sensor Short.................................................................... 688 Failure code [DHPAMA] Pump Press Sensor Abnormality........................................................... 690 Failure code [DHPBMA] R Pump Press Sensor Abnormality......................................................... 692 Failure code [DHS3MA] Arm IN PPC Sen. Abnormality............................................................. 694 Failure code [DHS4MA] Bucket CURL PPC Press Sensor Abnormality................................................ 696 Failure code [DHS8MA] Boom RAISE PPC Press Sensor Abnormality................................................. 698 Failure code [DHSAMA] Swing RH PPC Press Sensor Abnomality.................................................... 700 Failure code [DHSBMA] Swing LH PPC Press Sensor Abnomality.................................................... 702 Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality................................................ 704 Failure code [DHSFMA] Travel FW L PPC Press Sensor Abnormality................................................ 706 Failure code [DHSGMA] Travel FW R PPC Press Sensor Abnormality................................................ 708 Failure code [DHSHMA] Travel BW L PPC Press Sensor Abnormality................................................ 710 Failure code [DHSJMA] Travel BW R PPC Press Sensor Abnormality................................................ 712 Failure code [DHX1MA] Overload Sensor Abnormality............................................................. 715 Failure code [DKA0KA] Boom Angle Sensor Open Circuit.......................................................... 718 Failure code [DKA0KB] Boom Angle Sensor Power Short Circuit................................................... 720 Failure code [DKA0PH] Boom Angle Sensor Install Abnormality................................................... 722 Failure code [DKR0MA] F pump S/P sensor Abnormality........................................................... 724 Failure code [DKR1MA] R pump S/P sensor Abnormality........................................................... 726 Failure code [DV20KB] Travel Alarm Short Circuit.............................................................. 728 Failure code [DW43KA] Travel Speed Sol Open Circuit........................................................... 730 Failure code [DW43KB] Travel Speed Sol Short Circuit.......................................................... 732 Failure code [DW45KA] Swing Brake Sol Open Circuit............................................................ 734 Failure code [DW45KB] Swing Brake Sol Short Circuit........................................................... 736 Failure code [DW4GKA] Boom Slow Down Sol. Disc................................................................ 738 Failure code [DW4GKB] Boom Slow Down Sol. Short Circuit....................................................... 740 Failure code [DW4WKA] Cancel Bucket Dump Open Circuit......................................................... 742 Failure code [DW4WKB] Cancel Bucket Dump Short Circuit........................................................ 744 Failure code [DW91KA] Travel Junction Sol. Disc............................................................... 746 Failure code [DW91KB] Travel Junction Sol. S/C................................................................ 748 Failure code [DWA2KA] Attachment Sol Open Circuit............................................................. 750 Failure code [DWA2KB] Attachment Sol Short Circuit............................................................ 752 Failure code [DWK0KA] 2-stage Relief Sol Open Circuit......................................................... 754 Failure code [DWK0KB] 2-stage Relief Sol Short Circuit........................................................ 756 Failure code [DXA8KA] PC-EPC (F) Sol Open Circuit............................................................. 758 Failure code [DXA8KB] PC-EPC (F) Sol Short Circuit............................................................ 760 Failure code [DXA9KA] PC-EPC (R) Sol Open Circuit............................................................. 762 Failure code [DXA9KB] PC-EPC (R) Sol Short Circuit............................................................ 764 Failure code [DXE0KA] LS-EPC Sol Open Circuit................................................................. 766 Failure code [DXE0KB] LS-EPC Sol Short Circuit................................................................ 768 Failure code [DXE4KA] Service Current EPC Disc................................................................ 770 Failure code [DXE4KB] Service Current EPC S/C................................................................. 772 Failure code [DXE5KA] Merge-divider Main Sol Open Circuit..................................................... 774 Failure code [DXE5KB] Merge-divider Main Sol Short Circuit.................................................... 776 Failure code [DXE6KA] Merge-divider LS Sol Open Circuit....................................................... 778 Failure code [DXE6KB] Merge-divider LS Sol Short Circuit...................................................... 780 Failure code [DY20KA] Wiper Working Abnormality............................................................... 782 Failure code [DY20MA] Wiper Parking Abnormality............................................................... 784 Failure code [DY2CKA] Washer drive discon..................................................................... 786 Failure code [DY2CKB] Washer drive short...................................................................... 788 Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit......................................................... 790 Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit......................................................... 792 Troubleshooting of electrical system (E-mode)..................................................................... 795 E-1 Engine does not start (Engine does not crank)............................................................. 795 E-2 Preheater does not operate................................................................................ 800 E-3 When starting switch is turned to ON position, machine monitor displays nothing........................... 805 E-4 When starting switch is turned to ON position (before starting engine), basic check monitor lights up..... 808 E-5 Precaution monitor lights up while engine is running...................................................... 809 E-6 Emergency stop monitor lights up while engine is running.................................................. 811 E-7 Fuel level gauge does not indicate correctly.............................................................. 812 E-8 Engine coolant temperature gauge does not indicate correctly.............................................. 814 E-9 Hydraulic oil temperature gauge does not indicate correctly............................................... 816 E-10 Displays on machine monitor are different from those for actual machine.................................. 819 E-11 Some areas of machine monitor screen are not displayed................................................... 819 E-12 Function switch does not operate......................................................................... 819 E-13 Automatic warm-up system does not operate (in cold season)............................................... 820 E-14 Auto-decelerator does not operate properly............................................................... 821 E-15 Working mode does not change............................................................................. 822 E-16 Travel speed does not change............................................................................. 823 E-17 Alarm buzzer cannot be canceled.......................................................................... 824 E-18 When starting switch is turned OFF, service meter is not displayed40..................................... 824 E-19 Service mode cannot be selected.......................................................................... 825 E-20 Any of work equipment, swing and travel do not operate or cannot be locked............................... 826 E-21 Swing brake does not operate properly.................................................................... 829 E-22 One-touch power maximizing function does not operate properly............................................ 832 E-23 Travel alarm does not sound or does not stop sounding.................................................... 835 E-24 Horn does not sound or does not stop..................................................................... 836 E-25 Windshield wiper and window washer do not operate........................................................ 838 E-26 BOOM LOWER indicator is not displayed properly with monitoring function.................................. 840 E-27 ARM OUT indicator is not displayed properly with monitoring function..................................... 842 E-28 ARM IN indicator is not displayed properly with monitoring function...................................... 844 E-29 BOOM RAISE indicator is not displayed properly with monitoring function.................................. 844 E-30 BUCKET CURL indicator is not displayed properly with monitoring function................................. 844 E-31 BUCKET DUMP indicator is not displayed properly with monitoring function................................. 845 E-32 SWING indicator is not displayed properly with monitoring function....................................... 845 E-33 TRAVEL indicator is not displayed properly with monitoring function...................................... 845 E-34 ATTACHMENT indicator is not displayed properly with monitoring function.................................. 846 E-35 Attachment hydraulic circuit cannot be changed........................................................... 848 E-36 KOMTRAX system does not operate properly................................................................. 849 Troubleshooting of hydraulic and mechanical system (H-mode)....................................................... 851 Information in troubleshooting table.......................................................................... 851 System chart for hydraulic and mechanical systems............................................................. 852 Failure mode and cause table.................................................................................. 854 H- 1 All of work equipment, swing and travel work slow or lack power.......................................... 856 H- 2 Engine speed lowers significantly or engine stalls....................................................... 858 H- 3 Any of work equipment,swing and travel does not work..................................................... 859 H- 4 Unusual sound is heard from around hydraulic pump........................................................ 859 H- 5 Fine control performance or response is poor............................................................. 860 H- 6 Boom operation lacks speed or power...................................................................... 861 H- 7 Arm operation lacks speed or power....................................................................... 862 H- 8 Bucket operation lacks speed or power.................................................................... 863 H- 9 Work equipment does not move in single operation......................................................... 863 H-10 Hydraulic drift of work equipment is large............................................................... 864 H-11 Time lag of work equipment is large...................................................................... 866 H-12 Other work equipment moves when one of work equipment is relieved........................................ 866 H-13 One-touch power maximizing function does not work........................................................ 867 H-14 In combined operation of work equipment , equipment having heavier load moves slower..................... 867 H-15 In combined operation of swing and boom RAISE, boom rising speed is low.................................. 868 H-16 Travel speed drops largely in combined operation of swing and travel..................................... 868 H-17 Machine does not travel straight......................................................................... 869 H-18 Travel speed is low...................................................................................... 870 H-19 Machine is hard to steer or travel power is low.......................................................... 871 H-20 Travel speed does not change, or travel speed is too low or high......................................... 872 H-21 One of tracks does not run............................................................................... 873 H-22 Upper structure does not swing........................................................................... 874 H-23 Swing acceleration is poor or swing speed is low......................................................... 876 H-24 Upper structure overruns excessively when it stops swinging.............................................. 878 H-25 Shock is large when upper structure stops swinging....................................................... 879 H-26 Large unusual noise is heard when upper structure stops swinging40....................................... 879 H-27 Swing drift on a slope is large.......................................................................... 880 H-28 Attachment circuit cannot be changed..................................................................... 881 H-29 Oil flow in attachment circuit cannot be controlled...................................................... 881 Troubleshooting of engine (S-mode)................................................................................ 882 Method of using troubleshooting chart......................................................................... 882 S-1 Startability is poor...................................................................................... 886 S-2 Engine does not start..................................................................................... 887 S-3 Engine does not pick up smoothly.......................................................................... 890 S-4 Engine stops during operation............................................................................. 891 S-5 Engine runs rough or is unstable.......................................................................... 892 S-6 Engine lacks power........................................................................................ 893 S-7 Exhaust smoke is black (incomplete combustion)............................................................ 894 S-8 Oil consumption is excessive (or exhaust smoke is blue)................................................... 895 S-9 Oil becomes contaminated early............................................................................ 896 S-10 Fuel consumption is excessive............................................................................ 897 S-11 Oil is in coolant (or coolant spurts or coolant level goes down)......................................... 898 S-12 Oil pressure drops....................................................................................... 899 S-13 Oil level rises (coolant or fuel in oil)................................................................. 900 S-14 Coolant temperature rises too high (overheating)......................................................... 901 S-15 Unusual noise is made.................................................................................... 902 S-16 Vibration is excessive................................................................................... 903 50 Disassembly and assembly........................................................................................... 905 General information on disassembly and assembly................................................................... 908 How to read Disassembly and Assembly.......................................................................... 908 Coating materials list........................................................................................ 910 Special tools list............................................................................................ 913 Sketches of special tools..................................................................................... 917 Engine and cooling system......................................................................................... 922 Removal and installation of fuel supply pump assembly......................................................... 922 Removal and installation of fuel injector assembly............................................................ 926 Removal and installation of cylinder head assembly............................................................ 933 Removal and installation of radiator assembly................................................................. 948 Removal and installation of hydraulic oil cooler assembly..................................................... 951 Removal and installation of aftercooler assembly.............................................................. 953 Removal and installation of engine assembly................................................................... 956 Removal and installation of engine front seal................................................................. 960 Removal and installation of engine rear seal.................................................................. 962 Removal and installation of fuel cooler assembly.............................................................. 965 Removal and installation of fuel tank assembly................................................................ 967 Power train....................................................................................................... 970 Removal and installation of travel motor and final drive assembly............................................. 970 Disassembly and assembly of final drive assembly.............................................................. 971 Removal and installation of swing motor and swing machinery assembly.......................................... 979 Disassembly and assembly of swing machinery assembly.......................................................... 981 Removal and installation of swing circle assembly............................................................. 989 Undercarriage and frame........................................................................................... 990 Separation and connection of track shoe assembly.............................................................. 990 Removal and installation of idler and idler cushion assembly.................................................. 992 Disassembly and assembly of idler assembly.................................................................... 993 Disassembly and assembly of idler cushion assembly............................................................ 996 Disassembly and assembly of track roller assembly............................................................. 998 Disassembly and assembly of carrier roller assembly...........................................................1000 Removal and installation of revolving frame assembly..........................................................1003 Removal and installation of counterweight assembly............................................................1005 Removal and installation of maintenance counterweight assembly................................................1007 Hydraulic system..................................................................................................1010 Removal and installation of center swivel joint assembly......................................................1010 Disassembly and assembly of center swivel joint assembly......................................................1013 Removal and installation of hydraulic tank assembly...........................................................1015 Removal and installation of main pump assembly................................................................1017 Removal and installation of main pump input shaft oil seal....................................................1021 Removal and installation of control valve assembly............................................................1022 Disassembly and assembly of control valve assembly............................................................1027 Disassembly and assembly of work equipment PPC valve assembly.................................................1031 Disassembly and assembly of travel PPC valve assembly.........................................................1033 Work equipment....................................................................................................1036 Removal and installation of work equipment assembly...........................................................1036 Disassembly and assembly of work equipment cylinder assembly..................................................1039 Cab and its attachments...........................................................................................1046 Removal and installation of operator's cab assembly...........................................................1046 Removal and installation of operator's cab glass (adhered window glass).......................................1050 Removal and installation of front window assembly.............................................................1060 Removal and installation of floor frame assembly..............................................................1061 Removal and installation of air conditioner unit assembly.....................................................1068 Electrical system.................................................................................................1074 Removal and installation of air conditioner compressor assembly...............................................1074 Removal and installation of air conditioner condenser assembly................................................1076 Removal and installation of engine controller assembly........................................................1077 Removal and installation of pump controller assembly..........................................................1079 Removal and installation of machine monitor assembly..........................................................1082 Removal and installation of pump swash plate sensor...........................................................1084 Removal and installation of KOMTRAX terminal assembly.........................................................1085 60 Maintenance standard...............................................................................................1087 Engine and cooling system.........................................................................................1090 Engine mount..................................................................................................1090 Cooling system................................................................................................1091 Power train.......................................................................................................1092 Swing circle..................................................................................................1092 Swing machinery...............................................................................................1094 Final drive...................................................................................................1096 Sprocket......................................................................................................1098 Undercarriage and frame...........................................................................................1100 Track frame and idler cushion.................................................................................1100 Idler.........................................................................................................1102 Track roller..................................................................................................1104 Carrier roller................................................................................................1105 Track shoe....................................................................................................1106 Hydraulic system..................................................................................................1111 Hydraulic tank................................................................................................1111 Main pump.....................................................................................................1112 Control valve.................................................................................................1115 Swing motor...................................................................................................1125 Travel motor..................................................................................................1127 PPC valve.....................................................................................................1131 Solenoid valve................................................................................................1139 Attachment circuit selector valve.............................................................................1141 Anti-drop valve...............................................................................................1144 Center swivel joint...........................................................................................1146 Work equipment....................................................................................................1148 Work equipment................................................................................................1148 Dimensions of components......................................................................................1150 Work equipment cylinder.......................................................................................1154 80 Appendix...........................................................................................................1157 Air conditioner...................................................................................................1159 Precautions for refrigerant...................................................................................1159 Air conditioner component.....................................................................................1160 Configuration and function of refrigeration cycle.............................................................1162 Outline of refrigeration cycle................................................................................1164 Air conditioner unit..........................................................................................1166 Air conditioner controller....................................................................................1171 Compressor....................................................................................................1172 Condenser and Modulator.......................................................................................1173 Sensor........................................................................................................1174 Procedure for testing and troubleshooting.....................................................................1176 Circuit diagram and arrangement of connector pins.............................................................1178 System diagram................................................................................................1180 Detail of air conditioner unit................................................................................1182 Parts and connectors layout...................................................................................1184 Testing air leakage (duct)....................................................................................1188 Testing with self-diagnosis function..........................................................................1189 Testing vent (mode) changeover................................................................................1192 Testing FRESH/RECIRC air changeover...........................................................................1193 Testing inner sensor..........................................................................................1194 Testing outer sensor..........................................................................................1195 Testing sunlight sensor.......................................................................................1196 Testing (dual) pressure switch for refrigerant................................................................1197 Testing relays................................................................................................1198 Troubleshooting chart 1.......................................................................................1200 Troubleshooting chart 2.......................................................................................1202 Information in troubleshooting table..........................................................................1204 Troubleshooting for power supply and CAN communication system (Air conditioner does not operate)..............1206 Troubleshooting for compressor and refrigerant system (Air is not cooled).....................................1210 Troubleshooting for blower motor system (No air comes out or air flow is abnormal)............................1213 Troubleshooting for temperature control.......................................................................1216 Troubleshooting for vent (mode) changeover....................................................................1218 Troubleshooting for FRESH/RECIRC air changeover...............................................................1220 Troubleshooting for temperature sensor system.................................................................1222 Troubleshooting with gauge pressure...........................................................................1224 Connection of service tool....................................................................................1226 Precautions for disconnecting and connecting air conditioner piping...........................................1228 Handling of compressor oil....................................................................................1230 Desiccant replacement procedure...............................................................................1232 90 Diagrams and drawings..............................................................................................1235 Hydraulic circuit diagram.........................................................................................1237 Symbols used in hydraulic circuit diagrams....................................................................1237 Hydraulic circuit diagram.....................................................................................1241 Electrical circuit diagram........................................................................................1242 Symbols used in electric circuit diagrams.....................................................................1242 Electrical circuit diagram....................................................................................1246 Air conditioner electrical circuit diagram....................................................................1263
KOMATSU PC228US-8, PC228USLC-8 HYDRAULIC EXCAVATOR SHOP MANUAL SEN05331-03 – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
PLEASE NOTE:
- This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
- You will be directed to the download page as soon as the purchase is completed. The whole payment and downloading process will take anywhere between 2-5 minutes
- Need any other service / repair / parts manual, please feel free to contact [email protected] . We still have 50,000 manuals unlisted
1 review for Komatsu PC228US-8, PC228USLC-8 Hydraulic Excavator Shop Manual SEN05331-03 – PDF DOWNLOAD
Add a review
Misael Graham –
it was fast and easy. shocked considering most online purchases are a hassle.