Komatsu PC228US-8 PC228USLC-8 Hydraulic Excavator Shop Manual (SEN05331-05)

Description

Komatsu PC228US-8 PC228USLC-8 Hydraulic Excavator Shop Manual — SEN05331-05

Issued February 2017 as the 5th revision, the Komatsu PC228US-8 PC228USLC-8 Hydraulic Excavator Shop Manual (document number SEN05331-05) is the complete workshop-level reference for the PC228US-8 and PC228USLC-8 machines from serial number 50001 and up. Covering engine and cooling, power train, undercarriage, hydraulics, work equipment, electrical and air conditioning systems, it delivers the testing, adjusting, troubleshooting, disassembly, assembly and maintenance standard procedures needed to keep these excavators running to specification.

File Details

• Manual type: Shop Manual (service, repair, troubleshooting)
• Brand: Komatsu
• Models covered: PC228US-8, PC228USLC-8
• Serial number range: 50001 and up
• Document number: SEN05331-05
• Revision: 5th revision
• Publication date: February 2017
• Language: English
• File format: PDF
• Pages: 1,279

IMAGES PREVIEW

Chapters Covered

• 00 — Index and Foreword: safety notice, how to read the shop manual, explanation of terms for maintenance standard, handling of hydraulic components, method of disconnecting and connecting push-pull type coupler, handling of electric equipment, how to read electric wire code, precautions when performing work, standard tightening torque table, list of abbreviations, conversion table
• 01 — Specification: specifications drawing, working range diagram, specifications, table of weight, table of fuel, coolant and lubricants
• 10 — Structure and Function: engine and cooling system, power train, swing circle, swing machinery, final drive, undercarriage and frame, track frame and idler cushion, hydraulic system (equipment layout, valve control, hydraulic tank, CLSS, main pump, control valve, function and operation by valve, swing motor, travel motor, PPC valve, solenoid valve, attachment circuit selector valve, anti-drop valve, multi-control valve, center swivel joint, accumulator), work equipment, electrical system (electronic control system, machine monitor system, KOMTRAX system, sensors)
• 20 — Standard Value Table: standard value table for engine, standard value table for machine
• 30 — Testing and Adjusting: tools for testing, adjusting and troubleshooting, engine and cooling system testing and adjusting, fuel system handling and testing, undercarriage and frame, hydraulic system testing (work equipment, swing and travel circuit oil pressure, control circuit source pressure, pump PC control circuit, pump LS control circuit, solenoid valve output pressure, PPC valve output pressure, pump swash plate sensor, hydraulic drift isolation, oil leakage amount, air bleeding), work equipment, cab and attachments, electrical system special function of machine monitor (EMMS), handling voltage circuit of engine controller, preparatory work for troubleshooting of electrical system, procedure for testing diodes, Pm clinic
• 40 — Troubleshooting: general information, failure codes table, troubleshooting by failure code, E-mode (electrical system), H-mode (hydraulic and mechanical system), S-mode (engine)
• 50 — Disassembly and Assembly: engine and cooling system, power train, undercarriage and frame, hydraulic system, work equipment, cab and attachments, electrical system
• 60 — Maintenance Standard: engine and cooling system, power train, undercarriage and frame, hydraulic system, work equipment
• 80 — Appendix: air conditioner — precautions for refrigerant, components, refrigeration cycle, air conditioner unit, controller, compressor, condenser and modulator, sensors, testing and troubleshooting, connection of service tool, handling of compressor oil, desiccant replacement
• 90 — Diagrams and Drawings: hydraulic circuit diagram (4 sheets), electrical circuit diagram, air conditioner electrical circuit diagram

As a whole, this manual gives a technician a fully cross-referenced working set: structure-and-function explanations establish how each system is built and how it operates, the standard value tables define the acceptable numeric ranges, the testing and adjusting chapter tells you which gauge to connect where and what reading to expect, and the troubleshooting chapters — organized by failure code, electrical symptom, hydraulic/mechanical symptom and engine symptom — narrow down the cause step by step. The disassembly and assembly chapter supplies the special tools, tightening torques, coating materials and component weights needed to remove and refit parts without damaging them, while the maintenance standard chapter gives the wear limits that tell you when a part is serviceable and when it must be replaced or rebuilt.

Covered Models and Engines

• Komatsu PC228US-8 hydraulic excavator
• Komatsu PC228USLC-8 hydraulic excavator
• Serial numbers 50001 and up
• Komatsu SAA6D107E-1 diesel engine — 4-cycle, water-cooled, in-line vertical, direct injection with turbocharger and air-cooled aftercooler, 6 cylinders, 107 mm bore × 124 mm stroke, 6.69 L displacement

The same manual serves both the standard PC228US-8 and the PC228USLC-8 long-crawler variant, including the North America specification, so it covers the machine-weight, track-roller-count and shoe-width differences documented between the two models.

What You Can Do With This Shop Manual

The depth of the SEN05331-05 manual means it supports a wide range of jobs, not just routine maintenance:

• Verify hydraulic relief pressures in the work equipment, swing and travel circuits and adjust the main relief valves when they drift out of range
• Test and adjust the pump PC control circuit and LS control circuit, including the PC valve, LS valve, PC-EPC valve and LS-EPC valve
• Check pump swash plate sensor output, PPC valve output pressure and control circuit source pressure
• Isolate the source of hydraulic drift on a boom, arm or bucket before pulling a cylinder apart
• Test the engine for speed, boost pressure, exhaust gas colour, valve clearance, compression pressure, blow-by pressure and oil pressure
• Diagnose faults by failure code — the troubleshooting section includes dedicated procedures for engine controller, sensor, injector, solenoid, EPC valve, CAN communication and monitor-related codes, plus electrical (E-mode), hydraulic/mechanical (H-mode) and engine (S-mode) symptom-based procedures
• Use the machine monitor’s special functions (EMMS) — monitoring, abnormality record, maintenance record, calibration of pump swash plate sensors, boom potentiometer initialization, cylinder cut-out and no-injection cranking
• Disassemble and reassemble the final drive, swing machinery, swing motor, travel motor, control valve, PPC valve, centre swivel joint, idler, track roller, carrier roller, work equipment cylinders and hydraulic tank — with special tool references, torque values, coating materials and component weights
• Service the air conditioner — component layout, self-diagnosis, pressure gauge troubleshooting and desiccant replacement
• Read the hydraulic circuit diagrams and electrical circuit diagrams to trace connections on the machine

Why Correct Procedures and Specifications Matter on the PC228US-8 / PC228USLC-8

Hydraulic excavators are unforgiving of guesswork. Relief pressures set too high can damage cylinders, hoses and pumps; LS differential pressure set outside the standard range degrades fine control and combined operation; an incorrectly installed anti-drop valve or work equipment cylinder bolt can leak under load; and engine sensors that are out of calibration quietly derate the machine. A failure code like CA559 Rail Press Low Error or DHPAMA Pump Press Sensor Abnormality only leads to a fix when the technician follows the wiring harness, connector pin numbers and criteria given for that code. Using the measured values printed in this manual — torque figures, wear limits, pressure ranges, adjustment values — turns a repair from a gamble into a procedure.

Instant PDF Delivery

The Komatsu PC228US-8 PC228USLC-8 Hydraulic Excavator Shop Manual SEN05331-05 is delivered as a downloadable PDF immediately after payment. There is no physical shipment to wait for, no shipping cost, and no risk of a lost paper copy. Open it on a laptop, tablet or phone in the workshop, print the pages you need for the job in front of you, and keep the full 1,279-page reference on hand for every future service, repair and diagnostic task on your PC228US-8 or PC228USLC-8.