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KOMATSU PC228USLC-10 HYDRAULIC EXCAVATOR SHOP MANUAL – PDF DOWNLOAD
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KOMATSU PC228USLC-10 HYDRAULIC EXCAVATOR SHOP MANUAL SEN06483-12 – PDF DOWNLOAD
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KOMATSU PC228USLC-10 HYDRAULIC EXCAVATOR SHOP MANUAL SEN06483-12 – PDF DOWNLOAD
Language : English
Pages : 1846
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
KOMATSU PC228USLC-10 HYDRAULIC EXCAVATOR SHOP MANUAL SEN06483-12 – PDF DOWNLOAD
Cover........................................................................................................................................ 1 00 Index and foreword ................................................................................................................... 3 Index ............................................................................................................................... 4 Foreword, safety and general information ............................................................................................ 16 Important safety notice ......................................................................................................... 16 How to read the shop manual ..................................................................................................... 23 Explanation of terms for maintenance standard ................................................................................... 25 Handling equipment of fuel system devices ....................................................................................... 27 Handling of intake system parts ................................................................................................. 28 Handling of hydraulic equipment ................................................................................................. 29 Method of disconnecting and connecting of push-pull type coupler ................................................................ 31 Handling of electrical equipment ................................................................................................ 34 How to read electric wire code .................................................................................................. 42 Precautions when performing operation ........................................................................................... 45 Practical use of KOMTRAX ........................................................................................................ 50 Standard tightening torque table ................................................................................................ 51 List of abbreviation ............................................................................................................ 57 Conversion table ................................................................................................................ 62 01 Specification ........................................................................................................................ 67 Table of contents ................................................................................................................... 68 Specifications ...................................................................................................................... 69 Specification drawing ........................................................................................................... 69 Working range drawings .......................................................................................................... 70 Specifications .................................................................................................................. 71 Weight table .................................................................................................................... 74 Table of fuel, coolant, and lubricants .......................................................................................... 76 10 Structure and function ............................................................................................................... 77 Table of contents ................................................................................................................... 78 Engine and cooling system ........................................................................................................... 79 Engine related parts ............................................................................................................ 79 KVGT ............................................................................................................................ 81 EGR system piping drawing ....................................................................................................... 88 EGR system circuit diagram ...................................................................................................... 90 EGR valve ....................................................................................................................... 92 EGR cooler ...................................................................................................................... 94 KCCV layout drawing ............................................................................................................. 95 KCCV ventilator ................................................................................................................. 97 KDPF ............................................................................................................................ 99 Cooling system .................................................................................................................. 103 Power train ......................................................................................................................... 105 Power train system .............................................................................................................. 105 Swing circle .................................................................................................................... 107 Swing machinery ................................................................................................................. 108 Final drive ..................................................................................................................... 110 Undercarriage and frame ............................................................................................................. 112 Track frame and idler cushion ................................................................................................... 112 Hydraulic system .................................................................................................................... 114 Hydraulic component layout ...................................................................................................... 114 Valve control ................................................................................................................... 116 Hydraulic tank .................................................................................................................. 117 CLSS ............................................................................................................................ 119 Main pump ....................................................................................................................... 124 Control valve ................................................................................................................... 155 Swing motor ..................................................................................................................... 211 Travel motor .................................................................................................................... 223 PPC valve ....................................................................................................................... 236 Solenoid valve .................................................................................................................. 259 Attachment circuit selector valve (for high pressure circuit) ................................................................... 263 Attachment circuit selector valve (for low pressure circuit) .................................................................... 266 Anti-drop valve.................................................................................................................. 269 Center swivel joint ............................................................................................................. 277 Accumulator ..................................................................................................................... 279 Work equipment ...................................................................................................................... 281 Work equipment .................................................................................................................. 281 Work equipment shim ............................................................................................................. 282 Bucket play adjustment shim ..................................................................................................... 283 Cab and its attachments ............................................................................................................. 284 Cab mount and cab tipping stopper ............................................................................................... 284 ROPS cab ........................................................................................................................ 285 Electrical system ................................................................................................................... 286 Electrical control system ....................................................................................................... 286 Machine monitor system .......................................................................................................... 341 KOMTRAX system .................................................................................................................. 363 Sensor .......................................................................................................................... 366 20 Standard value tables ................................................................................................................ 387 Table of contents ................................................................................................................... 388 Standard service value table ........................................................................................................ 389 Standard value table for engine ................................................................................................. 389 Standard value table for machine ................................................................................................ 390 Standard value table for electrical system ...................................................................................... 404 30 Testing and adjusting ................................................................................................................ 415 Table of contents ................................................................................................................... 416 Related information on testing and adjusting ........................................................................................ 417 Tools for testing and adjusting ................................................................................................. 417 Sketch of tools for testing and adjusting ....................................................................................... 421 Engine and cooling system ........................................................................................................... 422 Testing engine speed ............................................................................................................ 422 Testing boost pressure .......................................................................................................... 423 Testing exhaust gas color ....................................................................................................... 425 Testing mass air flow and temperature sensor..................................................................................... 427 Testing and adjusting valve clearance ........................................................................................... 429 Testing compression pressure .................................................................................................... 432 Testing blowby pressure ......................................................................................................... 436 Testing engine oil pressure ..................................................................................................... 437 Testing EGR valve and KVGT oil pressures ........................................................................................ 438 Measuring fuel pressure ......................................................................................................... 439 Measuring fuel delivery, return and leakage ..................................................................................... 445 Bleeding air from fuel system ................................................................................................... 450 Testing fuel circuit for leakage ................................................................................................ 452 Handling cylinder cutout mode operation ......................................................................................... 453 Handling no-injection cranking operation ........................................................................................ 454 Testing and adjusting air conditioner compressor belt tension ................................................................... 455 Replacing fan belt .............................................................................................................. 457 Power train ......................................................................................................................... 458 Testing swing circle bearing clearance .......................................................................................... 458 Undercarriage and frame ............................................................................................................. 459 Testing and adjusting track tension ............................................................................................. 459 Hydraulic system .................................................................................................................... 460 Releasing remaining pressure from hydraulic circuit ............................................................................. 460 Testing and adjusting oil pressure in work equipment, swing, and travel circuits ................................................ 465 Testing oil pressure of control circuit ......................................................................................... 469 Testing and adjusting oil pressure in pump PC control circuit ................................................................... 470 Testing and adjusting oil pressure in pump LS control circuit ................................................................... 474 Testing outlet pressure of solenoid valve ....................................................................................... 482 Testing PPC valve outlet pressure ............................................................................................... 485 Adjusting play of work equipment and swing PPC valves ........................................................................... 487 Testing pump swash plate sensor ................................................................................................. 488 Isolating the parts causing hydraulic drift in work equipment ................................................................... 489 Testing and adjusting travel deviation .......................................................................................... 491 Testing oil leakage ............................................................................................................. 493 Bleeding air from hydraulic circuit ............................................................................................. 496 Testing and charging accumulator(manufactured by NOK) nitrogengas pressure for attachment (lowpressure side)..................... 499 Testing and charging accumulatornitrogen gas pressure for attachment(high pressure side)......................................... 501 Replacing accumulator bladder onhigh pressure side for accumulatorpiping......................................................... 503 Work equipment ...................................................................................................................... 509 Testing and adjusting boom angle potentiometer .................................................................................. 509 Cab and its attachments ............................................................................................................. 510 Testing cab tipping stopper ..................................................................................................... 510 How to Examine and Adjust Slide Door............................................................................................. 511 Adjusting mirrors ............................................................................................................... 537 Electrical system ................................................................................................................... 539 Special functions of machine monitor ............................................................................................ 539 KOMTRAX terminal start-up procedure ............................................................................................. 609 Adjusting rearview camera angle ................................................................................................. 612 Handling voltage circuit of engine controller ................................................................................... 614 Handling battery disconnect switch .............................................................................................. 615 Testing diodes .................................................................................................................. 616 Pm clinic ........................................................................................................................... 617 Pm Clinic service ............................................................................................................... 617 40 Troubleshooting ...................................................................................................................... 629 Table of contents ................................................................................................................... 630 Related information on troubleshooting .............................................................................................. 637 Troubleshooting points .......................................................................................................... 637 Sequence of events in troubleshooting ........................................................................................... 639 Testing before troubleshooting .................................................................................................. 641 Inspection procedure before troubleshooting ..................................................................................... 643 Preparation work for troubleshooting of electrical system ....................................................................... 662 Classification and procedure for troubleshooting ................................................................................ 667 Symptom of probable failure and troubleshooting No. ............................................................................. 670 Information in troubleshooting table ............................................................................................ 673 Diagnostic procedure for wiring harness open curcuit of pressure sensor system .................................................. 675 Connector list and layout ....................................................................................................... 677 Connector contact identification ................................................................................................ 688 T-branch box and T-branch adapter table ......................................................................................... 727 Fuse location table ............................................................................................................. 732 Precautions for KDPF (KCSF and KDOC) Cleaning and Replacement ................................................................... 734 Preparation of dummy temperature sensor (for KDOC and KDPF temperature sensors) ................................................. 737 Preparation of short circuit electrical connector (for failure codes [CA1883] and [CA3135]) ..................................... 738 Failure codes table ............................................................................................................. 739 Troubleshooting by failure code (Display of code) ................................................................................... 748 Failure code [879AKA] A/C Inner Sensor Open Circuit ............................................................................. 748 Failure code [879AKB] A/C Inner Sensor Short Circuit ............................................................................ 749 Failure code [879BKA] A/C Outer Sensor Open Circuit ............................................................................. 750 Failure code [879BKB] A/C Outer Sensor Short Circuit ............................................................................ 751 Failure code [879CKA] Ventilating Sensor Open Circuit ........................................................................... 752 Failure code [879CKB] Ventilating Sensor Short Circuit .......................................................................... 753 Failure code [879DKZ] Sunlight Sensor Open Or Short Circuit ..................................................................... 754 Failure code [879EMC] Ventilation Damper Abnormality ............................................................................ 755 Failure code [879FMC] Air Mix Damper Abnormality ................................................................................ 756 Failure code [879GKX] Refrigerant Abnormality ................................................................................... 757 Failure code [989L00] Engine Controller Lock Caution 1 .......................................................................... 758 Failure code [989M00] Engine Controller Lock Caution 2 .......................................................................... 759 Failure code [989N00] Engine Controller Lock Caution 3 .......................................................................... 760 Failure code [A1U0N3] HC Desorb Request 1 ....................................................................................... 761 Failure code [A1U0N4] HC Desorb Request 2 ....................................................................................... 763 Failure code [AA10NX] Air Cleaner Clogging ...................................................................................... 765 Failure code [AB00KE] Charge Voltage Low ........................................................................................ 767 Failure code [B@BAZG] Eng Oil Press Low ......................................................................................... 769 Failure code [B@BAZK] Eng Oil Level Low ......................................................................................... 770 Failure code [B@BCNS] Eng Water Overheat ........................................................................................ 771 Failure code [B@BCZK] Eng Water Level Low ....................................................................................... 772 Failure code [B@HANS] Hyd Oil Overheat .......................................................................................... 774 Failure code [CA115] Eng Ne and Bkup Speed Sens Error ........................................................................... 775 Failure code [CA122] Chg Air Press Sensor High Error ............................................................................ 776 Failure code [CA123] Chg Air Press Sensor Low Error ............................................................................. 778 Failure code [CA131] Throttle Sensor High Error ................................................................................. 780 Failure code [CA132] Throttle Sensor Low Error .................................................................................. 782 Failure code [CA144] Coolant Temp Sens High Error ............................................................................... 784 Failure code [CA145] Coolant Temp Sens Low Error ................................................................................ 786 Failure code [CA153] Chg Air Temp Sensor High Error ............................................................................. 788 Failure code [CA154] Chg Air Temp Sensor Low Error .............................................................................. 790 Failure code [CA187] Sensor 2 Supply Volt Low Error ............................................................................. 792 Failure code [CA221] Ambient Press Sensor High Error ............................................................................ 794 Failure code [CA222] Ambient Press Sensor Low Error ............................................................................. 796 Failure code [CA227] Sensor 2 Supply Volt High Error ............................................................................ 798 Failure code [CA234] Eng Overspeed .............................................................................................. 799 Failure code [CA238] Ne Speed Sensor Supply Volt Error .......................................................................... 800 Failure code [CA239] Ne Speed Sens Supply Volt High Error ....................................................................... 801 Failure code [CA271] IMV/PCV1 Short Error ....................................................................................... 802 Failure code [CA272] IMV/PCV1 Open Error ........................................................................................ 804 Failure code [CA295] Ambient Press Sens In Range Error .......................................................................... 806 Failure code [CA322] Inj #1(L#1) Open/Short Error ............................................................................... 807 Failure code [CA323] Inj #5(L#5) Open/Short Error ............................................................................... 809 Failure code [CA324] Inj #3(L#3) Open/Short Error ............................................................................... 811 Failure code [CA325] Inj #6(L#6) Open/Short Error ............................................................................... 813 Failure code [CA331] Inj #2(L#2) Open/Short Error ............................................................................... 815 Failure code [CA332] Inj #4(L#4) Open/Short Error ............................................................................... 817 Failure code [CA343] ECM Critical Internal Failure .............................................................................. 819 Failure code [CA351] Injectors Drive Circuit Error .............................................................................. 820 Failure code [CA352] Sensor 1 Supply Volt Low Error ............................................................................. 821 Failure code [CA356] Mass Air Flow Sensor High Error ............................................................................ 823 Failure code [CA357] Mass Air Flow Sensor Low Error ............................................................................. 825 Failure code [CA386] Sensor 1 Supply Volt High Error ............................................................................ 827 Failure code [CA428] Water in Fuel Sensor High Error ............................................................................ 828 Failure code [CA429] Water in Fuel Sensor Low Error ............................................................................. 830 Failure code [CA435] Eng Oil Press Sw Error ..................................................................................... 832 Failure code [CA441] Battery Voltage Low Error .................................................................................. 833 Failure code [CA442] Battery Voltage High Error ................................................................................. 835 Failure code [CA449] Rail Press Very High Error ................................................................................. 836 Failure code [CA451] Rail Press Sensor High Error ............................................................................... 837 Failure code [CA452] Rail Press Sensor Low Error ................................................................................ 839 Failure code [CA488] Chg Air Temp High Torque Derate ............................................................................ 841 Failure code [CA515] Rail Press Sens Sup Volt High Error ........................................................................ 842 Failure code [CA516] Rail Press Sens Sup Volt Low Error ......................................................................... 844 Failure code [CA553] Rail Press High Error ...................................................................................... 846 Failure code [CA555] Crankcase Press High Error 1 ............................................................................... 847 Failure code [CA556] Crankcase Press High Error 2 ............................................................................... 848 Failure code [CA559] Rail Press Low Error ....................................................................................... 849 Failure code [CA595] Turbo Speed High Error 2 ................................................................................... 851 Failure code [CA687] Turbo Speed Low Error ...................................................................................... 852 Failure code [CA689] Eng Ne Speed Sensor Error .................................................................................. 854 Failure code [CA691] Intake Air Temp Sens High Error ............................................................................ 856 Failure code [CA692] Intake Air Temp Sens Low Error ............................................................................. 858 Failure code [CA697] ECM Int Temp Sensor High Error ............................................................................. 860 Failure code [CA698] ECM Int Temp Sensor Low Error .............................................................................. 861 Failure code [CA731] Eng Bkup Speed Sens Phase Error ............................................................................ 862 Failure code [CA778] Eng Bkup Speed Sensor Error ................................................................................ 864 Failure code [CA1117] Persistent Data Lost Error ................................................................................ 869 Failure code [CA1664] KDOC Malfunction .......................................................................................... 870 Failure code [CA1691] Regeneration Ineffective .................................................................................. 872 Failure code [CA1695] Sensor 5 Supply Volt High Error ........................................................................... 875 Failure code [CA1696] Sensor 5 Supply Volt Low Error ............................................................................ 877 Failure code [CA1843] Crankcase Press Sens High Error ........................................................................... 879 Failure code [CA1844] Crankcase Press Sens Low Error ............................................................................ 881 Failure code [CA1879] KDPF Delta P Sensor High Error ............................................................................ 883 Failure code [CA1881] KDPF Delta P Sensor Low Error ............................................................................. 885 Failure code [CA1883] KDPF Delta P Sens In Range Error .......................................................................... 887 Failure code [CA1921] KDPF Soot Load High Error 1 ............................................................................... 890 Failure code [CA1922] KDPF Soot Load High Error 2 ............................................................................... 893 Failure code [CA1942] Crankcase Press Sens In Range Error ....................................................................... 898 Failure code [CA1993] KDPF Delta Pressure Low Error ............................................................................. 899 Failure code [CA2185] Throt Sensor Sup Volt High Error .......................................................................... 902 Failure code [CA2186] Throt Sensor Sup Volt Low Error ........................................................................... 904 Failure code [CA2249] Rail Press Very Low Error ................................................................................. 906 Failure code [CA2271] EGR Valve Pos Sens High Error ............................................................................. 907 Failure code [CA2272] EGR Valve Pos Sens Low Error .............................................................................. 909 Failure code [CA2288] Turbo Speed High Error 1 .................................................................................. 912 Failure code [CA2311] IMV Solenoid Error ........................................................................................ 913 Failure code [CA2349] EGR Valve Solenoid Open Error ............................................................................. 914 Failure code [CA2353] EGR Valve Solenoid Short Error ............................................................................ 916 Failure code [CA2357] EGR Valve Servo Error ..................................................................................... 918 Failure code [CA2373] Exhaust Manifold Press Sens High error .................................................................... 919 Failure code [CA2374] Exhaust Manifold Press Sens Low error ..................................................................... 921 Failure code [CA2375] EGR Orifice Temp Sens High Error .......................................................................... 923 Failure code [CA2376] EGR Orifice Temp Sens Low Error ........................................................................... 925 Failure code [CA2381] KVGT Pos Sens High Error .................................................................................. 927 Failure code [CA2382] KVGT Pos Sens Low Error ................................................................................... 929 Failure code [CA2383] KVGT Solenoid Open Error .................................................................................. 932 Failure code [CA2386] KVGT Solenoid Short Error ................................................................................. 934 Failure code [CA2387] VGT Servo Error ........................................................................................... 936 Failure code [CA2554] Exh Manifold Press Sens In Range Error .................................................................... 939 Failure code [CA2555] Grid Htr Relay Volt Low Error ............................................................................. 942 Failure code [CA2556] Grid Htr Relay Volt High Error ............................................................................ 944 Failure code [CA2637] KDOC Face Plugging ........................................................................................ 946 Failure code [CA2639] Manual Stationary Regeneration Request .................................................................... 948 Failure code [CA2961] EGR Orifice Temp High Error 1 ............................................................................. 951 Failure code [CA2973] Chg Air Press Sensor In Range Error ....................................................................... 952 Failure code [CA3133] KDPF Outlet Press Sens High Error ......................................................................... 953 Failure code [CA3134] KDPF Outlet Press Sens Low Error .......................................................................... 955 Failure code [CA3135] KDPF Outlet Press Sens In Range Error ..................................................................... 957 Failure code [CA3251] KDOC Inlet Temp High Error ................................................................................ 961 Failure code [CA3253] KDOC Temp Error - Non Regeneration ........................................................................ 964 Failure code [CA3254] KDOC Outlet Temp High Error 1 ............................................................................. 967 Failure code [CA3255] KDPF Temp Error - Non Regeneration ........................................................................ 970 Failure code [CA3256] KDPF Outlet Temp High Error 1 ............................................................................. 973 Failure code [CA3311] KDOC Outlet Temp High Error 2 ............................................................................. 976 Failure code [CA3312] KDPF Outlet Temp High Error 2 ............................................................................. 979 Failure code [CA3313] KDOC Inlet Temp Sensor Low Error .......................................................................... 982 Failure code [CA3314] KDOC Inlet Temp Sens High Error ........................................................................... 985 Failure code [CA3315] KDOC Inlet Temp Sens In Range Error ....................................................................... 989 Failure code [CA3316] KDOC Outlet Temp Sens Low Error ........................................................................... 993 Failure code [CA3317] KDOC Outlet Temp Sens High Error .......................................................................... 996 Failure code [CA3318] KDOC Outlet Temp Sens In Range Error ......................................................................1000 Failure code [CA3319] KDPF Outlet Temp Sens High Error ..........................................................................1004 Failure code [CA3321] KDPF Outlet Temp Sens Low Error ...........................................................................1008 Failure code [CA3322] KDPF Outlet Temp Sens In Range Error ......................................................................1011 Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error ..................................................................1015 Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error ...................................................................1017 Failure code [CA3741] Rail Press Valve Trip Error ...............................................................................1019 Failure code [D110KB] Battery Relay Drive Short Circuit .........................................................................1020 Failure code [D19JKZ] Personal Code Relay Abnormality ...........................................................................1022 Failure code [D811MC] KOMTRAX Error .............................................................................................1025 Failure code [D862KA] GPS Antenna Open Circuit ..................................................................................1026 Failure code [D8ALKA] System Operating Lamp Disconnection (KOMTRAX) .............................................................1027 Failure code [D8ALKB] System Operating Lamp Short Circuit (KOMTRAX) .............................................................1029 Failure code [D8AQKR] CAN2 Discon (KOMTRAX) .....................................................................................1030 Failure code [DA20MC] Pump Controller ...........................................................................................1031 Failure code [DA22KK] Pump Solenoid Power Low Error .............................................................................1032 Failure code [DA25KP] 5V Sensor 1 Power Abnormality .............................................................................1034 Failure code [DA26KP] 5V Sensor 2 Power Abnormality .............................................................................1037 Failure code [DA29KQ] Model Selection Abnormality ...............................................................................1038 Failure code [DA2LKA] System Operating Lamp Disconnection (Pump Con) ............................................................1040 Failure code [DA2LKB] System Operating Lamp Short Circuit (Pump Con) ............................................................1042 Failure code [DA2QKR] CAN2 Discon (Pump Con) ....................................................................................1043 Failure code [DA2RKR] CAN1 Discon (Pump Con) ....................................................................................1045 Failure code [DAF0MB] Monitor ROM Abnormality ...................................................................................1046 Failure code [DAF0MC] Monitor Error .............................................................................................1047 Failure code [DAF8KB] Camera Power Supply Short Circuit .........................................................................1048 Failure code [DAF9KQ] Model Selection Abnormality ...............................................................................1050 Failure code [DAFGMC] GPS Module Error ..........................................................................................1051 Failure code [DAFLKA] Operating Lamp Open Circuit(Monitor) ......................................................................1052 Failure code [DAFLKB] System Operating Lamp Short Circuit (Monitor) .............................................................1054 Failure code [DAFQKR] CAN2 Discon (Monitor) .....................................................................................1055 Failure code [DAZ9KQ] A/C Model Selection Abnormality ...........................................................................1056 Failure code [DAZQKR] CAN2 Discon (Aircon ECU) ..................................................................................1057 Failure code [DB2QKR] CAN2 Discon (Engine Con) ..................................................................................1061 Failure code [DB2RKR] CAN1 Discon (Engine Con) ..................................................................................1065 Failure code [DGH2KB] Hyd Oil Sensor Short Circuit ..............................................................................1069 Failure code [DHA4KA] Air Cleaner Clog Sensor Open Circuit ......................................................................1071 Failure code [DHPAMA] F Pump Press Sensor Abnormality ...........................................................................1072 Failure code [DHPBMA] R Pump Press Sensor Abnormality ...........................................................................1075 Failure code [DHS3MA] Arm IN PPC Sen. Abnormality ...............................................................................1078 Failure code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality ..................................................................1080 Failure code [DHS8MA] Boom Raise PPC Press Sensor Abnormality ...................................................................1083 Failure code [DHS9MA] Boom LOWER Press Sensor Abnormality .......................................................................1086 Failure code [DHSAMA] Swing RH PPC Press Sensor Abnormality .....................................................................1089 Failure code [DHSBMA] Swing LH PPC Press Sensor Abnormality .....................................................................1092 Failure code [DHSCMA] Arm Dump PPC Press Sensor Abnormality .....................................................................1095 Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality ..................................................................1098 Failure code [DHSFMA] Travel Fwd LH PPC Press Sensor Abnormality ................................................................1101 Failure code [DHSGMA] Travel Fwd RH PPC Press Sensor Abnormality ................................................................1104 Failure code [DHSHMA] Travel Rev LH PPC Press Sensor Abnormality ................................................................1107 Failure code [DHSJMA] Travel Rev RH PPC Press Sensor Abnormality ................................................................1110 Failure code [DKA0KA] Failure of Boom Angle Sensor (Open circuit) ...............................................................1113 Failure code [DKA0KB] Failure of Boom Angle Sensor (Short circuit) ..............................................................1115 Failure code [DKA0PH] Boom Angle Sensor installation error ......................................................................1117 Failure code [DKR0MA] F Pump Swash Plate Sensor Abnormality .....................................................................1118 Failure code [DKR1MA] R Pump Swash Plate Sensor Abnormality .....................................................................1120 Failure code [DR21KX] Camera 2 Picture Rev. Drive Abnormality ...................................................................1122 Failure code [DR31KX] Camera 3 Picture Rev. Drive Abnormality ...................................................................1124 Failure code [DV20KB] Travel Alarm Short Circuit ................................................................................1126 Failure code [DW43KA] Travel Speed Sol Open Circuit .............................................................................1128 Failure code [DW43KB] Travel Speed Sol Short Circuit ............................................................................1130 Failure code [DW45KA] Swing Brake Sol Open Circuit ..............................................................................1132 Failure code [DW45KB] Swing Brake Sol Short Circuit .............................................................................1135 Failure code [DW4GKA] Boom slow down EPC sol disconnection ......................................................................1137 Failure code [DW4GKB] Boom slow down EPC sol short circuit ......................................................................1139 Failure code [DW91KA] Travel Junction Sol Open Circuit ..........................................................................1141 Failure code [DW91KB] Travel Junction Sol Short Circuit .........................................................................1143 Failure code [DWA2KA] Attachment Sol Open Circuit ...............................................................................1145 Failure code [DWA2KB] Attachment Sol Short Circuit ..............................................................................1147 Failure code [DWK0KA] 2-Stage Relief Sol Open Circuit ...........................................................................1149 Failure code [DWK0KB] 2-Stage Relief Sol Short Circuit ..........................................................................1151 Failure code [DWK2KA] Variable Back Press Sol Open Circuit ......................................................................1153 Failure code [DWK2KB] Variable Back Press Sol Short Circuit .....................................................................1155 Failure code [DWK8KA] Swing Press C/O Sol Open Circuit ..........................................................................1157 Failure code [DWK8KB] Swing Press C/O Sol Short Circuit .........................................................................1159 Failure code [DXA8KA] PC-EPC (F) Sol Open Circuit ...............................................................................1161 Failure code [DXA8KB] PC-EPC (F) Sol Short Circuit ..............................................................................1163 Failure code [DXA9KA] PC-EPC (R) Sol Open Circuit ...............................................................................1165 Failure code [DXA9KB] PC-EPC (R) Sol Short Circuit ..............................................................................1167 Failure code [DXE0KA] LS-EPC Sol Open Circuit ...................................................................................1169 Failure code [DXE0KB] LS-EPC Sol Short Circuit ..................................................................................1171 Failure code [DXE4KA] Attachment Flow EPC Open Circuit ..........................................................................1173 Failure code [DXE4KB] Attachment Flow EPC Short Circuit .........................................................................1175 Failure code [DXE5KA] Merge-divide Main Sol Open Circuit ........................................................................1177 Failure code [DXE5KB] Merge-divide Main Sol Short Circuit .......................................................................1179 Failure code [DXE6KA] Merge-divide LS Sol Open Circuit ..........................................................................1181 Failure code [DXE6KB] Merge-divide LS Sol Short Circuit .........................................................................1183 Failure code [DY20KA] Wiper Working Abnormality .................................................................................1185 Failure code [DY20MA] Wiper Parking Abnormality .................................................................................1187 Failure code [DY2CKB] Washer Drive Short Circuit ................................................................................1189 Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit ...........................................................................1191 Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit ...........................................................................1193 Troubleshooting of electrical system (E-mode) .......................................................................................1195 E-1 Engine does not start (Engine does not crank) ...............................................................................1195 E-2 Manual preheating system does not work ......................................................................................1200 E-3 Automatic preheating system does not work ...................................................................................1203 E-4 While preheating is working, preheating monitor does not light up ...........................................................1205 E-5 When starting switch is turned to ON position, machine monitor displays nothing .............................................1207 E-6 While starting switch is turned to ON position (with engine stopped), engine oil level monitor lights up in yellow ..........1210 E-7 While starting switch is turned to ON position (with engine stopped), radiator coolant level monitor lights up in yellow ....1211 E-8 Engine coolant temperature monitor lights up in red while engine is running .................................................1212 E-9 Hydraulic oil temperature monitor lights up in white while engine is running ................................................1213 E-10 Charge level monitor lights up in red while engine is running ..............................................................1214 E-11 Fuel level monitor lights up in red while engine is running ................................................................1215 E-12 Air cleaner clogging monitor lights up in yellow while engine is running ...................................................1216 E-13 Water separator monitor lights up in red while engine is running ...........................................................1217 E-14 Engine coolant temperature monitor lights up in red while engine is running ................................................1218 E-15 Hydraulic oil temperature monitor lights up in red while engine is running .................................................1219 E-16 Engine oil pressure monitor lights up in red while engine is running .......................................................1220 E-17 Fuel gauge display does not move from minimum or maximum ...................................................................1221 E-18 Fuel gauge indicates incorrect amount (indicates neither full nor empty) ...................................................1222 E-19 Engine coolant temperature gauge display does not move from minimum or maximum .............................................1223 E-20 Engine coolant temperature gauge indicates incorrect temperature (indicates neither full nor empty) ........................1224 E-21 Hydraulic oil temperature gauge does not move from minimum or maximum ......................................................1225 E-22 Hydraulic oil temperature gauge indicates incorrect temperature (indicates neither full nor empty) .........................1227 E-23 Contents of display on machine monitor is different from actual machine condition ..........................................1228 E-24 Some areas of machine monitor screen are not displayed .....................................................................1229 E-25 Function switch does not work ..............................................................................................1230 E-26 Automatic warm-up system does not operate (in cold season) .................................................................1231 E-27 Auto-deceleration monitor does not light up, or does not go out, while auto-deceleration switch is operated ................1232 E-28 Auto-deceleration function does not operate or is not canceled while lever is operated .....................................1233 E-29 Working mode selection screen is not displayed while working mode selector switch is operated ..............................1234 E-30 Setting of engine and hydraulic pump is not changed while working mode is changed ..........................................1235 E-31 Travel speed monitor does not change when travel speed switch is operated ..................................................1236 E-32 Travel speed does not change while travel speed selection is changed .......................................................1237 E-33 Alarm buzzer does not stop sounding ........................................................................................1238 E-34 Service meter is not displayed, while starting switch is in OFF position ...................................................1239 E-35 Service mode cannot be selected ............................................................................................1240 E-36 Any of work equipment, swing and travel does not work ......................................................................1241 E-37 Any of work equipment, swing and travel cannot be locked ...................................................................1243 E-38 Upper structure does not swing while swing parking brake cancel switch is set to CANCEL position ...........................1245 E-39 Swing brake does not operate while swing parking brake cancel switch is set to NORMAL position .............................1247 E-40 One-touch power maximizing function does not operate, or indicator is not displayed on monitor .............................1249 E-41 One-touch power maximizing function cannot be canceled .....................................................................1251 E-42 Alarm does not sound during travel .........................................................................................1252 E-43 Alarm does not stop sounding while machine is stopped ......................................................................1254 E-44 Horn does not sound ........................................................................................................1255 E-45 Horn does not stop sounding ................................................................................................1257 E-46 Wiper monitor does not light up, or does not go out, while wiper switch is operated ........................................1258 E-47 Wiper does not operate while wiper switch is operated ......................................................................1259 E-48 Window washer does not operate while window washer switch is operated ......................................................1261 E-49 Boom LOWER is not displayed correctly with monitoring function .............................................................1262 E-50 Arm OUT is not displayed correctly with monitoring function ................................................................1263 E-51 Arm IN is not displayed correctly with monitoring function .................................................................1264 E-52 Boom RAISE is not displayed correctly with monitoring function .............................................................1265 E-53 Bucket CURL is not displayed correctly with monitoring function ............................................................1266 E-54 Bucket DUMP is not displayed correctly with monitoring function ............................................................1267 E-55 Swing is not displayed correctly with monitoring function ..................................................................1268 E-56 Travel is not displayed correctly with monitoring function .................................................................1269 E-57 Service is not displayed correctly with monitoring function ................................................................1270 E-58 Attachment hydraulic circuit cannot be changed .............................................................................1272 E-59 KOMTRAX system does not operate normally ...................................................................................1273 Troubleshooting of hydraulic and mechanical system (H-mode) .........................................................................1275 Information described in troubleshooting table (H-mode) .........................................................................1275 System chart of hydraulic and mechanical systems ................................................................................1276 Failure mode and cause table ....................................................................................................1278 H-1 All of work equipment, swing and travel operation lacks speed or power ......................................................1286 H-2 Engine speed drops significantly or engine stalls ...........................................................................1289 H-3 All work equipment, swing and travel does not work ..........................................................................1292 H-4 Unusual sound is heard from around hydraulic pump ...........................................................................1293 H-5 Fine control performance or response is poor ................................................................................1294 H-6 Boom speed or power is low ..................................................................................................1296 H-7 Arm speed or power is low ...................................................................................................1300 H-8 Bucket speed or power is low ................................................................................................1304 H-9 Work equipment does not move in single operation ............................................................................1307 H-10 Hydraulic drift of boom is large ...........................................................................................1308 H-11 Hydraulic drift of arm is large ............................................................................................1309 H-12 Hydraulic drift of bucket is large .........................................................................................1310 H-13 Time lag of work equipment is large ........................................................................................1311 H-14 When part of work equipment is relieved singly, other parts of work equipment move .........................................1313 H-15 One-touch power maximizing function does not operate .......................................................................1314 H-16 In combined operation of work equipment, equipment having heavier load moves slower ........................................1315 H-17 In combined operations of swing and boom RAISE, boom rising speed is low ...................................................1316 H-18 In combined operations of swing and travel, travel speed drops largely .....................................................1317 H-19 Machine does not travel straight ...........................................................................................1318 H-20 Travel speed is slow .......................................................................................................1321 H-21 Machine is hard to steer or travel power is low ............................................................................1323 H-22 Travel speed does not change, or travel speed is too slow or fast ..........................................................1326 H-23 One of tracks does not run .................................................................................................1327 H-24 Upper structure does not swing to the right or left ........................................................................1329 H-25 Upper structure swing only to the right or left ............................................................................1330 H-26 Swing acceleration or swing speed is low in both directions (right and left) ...............................................1331 H-27 Swing acceleration performance is poor or swing speed is slow in only one direction ........................................1332 H-28 Upper structure overruns excessively when it stops swinging (both right and left) ..........................................1333 H-29 Upper structure overruns excessively when it stops swinging (either right or left) .........................................1334 H-30 Shock is large when upper structure stops swinging .........................................................................1335 H-31 Large unusual noise is heard when upper structure stops swinging ...........................................................1336 H-32 Swing drift on a slope is large while swing holding brake is applied .......................................................1337 H-33 Swing drift on a slope is large while swing holding brake is released ......................................................1338 H-34 Attachment hydraulic circuit cannot be changed while attachment is installed ...............................................1339 H-35 Oil flow in attachment circuit cannot be controlled ........................................................................1340 Troubleshooting of engine (S-mode) ..................................................................................................1341 Information mentioned in troubleshooting table (S mode) .........................................................................1341 S-1 When starting switch is turned to START position, engine does not crank .....................................................1342 S-2 Engine cranks but no exhaust smoke comes out ................................................................................1343 S-3 Fuel is being injected but engine does not start (misfiring: engine cranks but does not start) ..............................1344 S-4 Engine startability is poor .................................................................................................1345 S-5 Engine does not pick up smoothly ............................................................................................1347 S-6 Engine stops during operation ...............................................................................................1349 S-7 Engine runs rough or is unstable ............................................................................................1351 S-8 Engine lacks power ..........................................................................................................1352 S-9 Exhaust smoke is black (KDPF clogs up early) ................................................................................1354 S-10 Engine oil consumption is excessive ........................................................................................1356 S-11 Engine oil becomes contaminated early ......................................................................................1357 S-12 Fuel consumption is excessive ..............................................................................................1358 S-13 Oil is in coolant (or coolant spurts or coolant level goes down) ...........................................................1359 S-14 Engine oil pressure drops ..................................................................................................1360 S-15 Fuel is contaminated in engine oil .........................................................................................1361 S-16 Coolant is contaminated in engine oil (Oil becomes cloudy white) ...........................................................1362 S-17 Coolant temperature rises too high (overheating) ...........................................................................1363 S-18 Unusual noise is heard .....................................................................................................1364 S-19 Vibration is excessive .....................................................................................................1365 S-20 Air cannot be bled from fuel circuit .......................................................................................1366 S-21 Active regeneration is executed frequently .................................................................................1367 S-22 Active regeneration takes time .............................................................................................1368 S-23 White smoke is exhausted during active regeneration ........................................................................1369 50 Disassembly and assembly .............................................................................................................1371 Table of contents ...................................................................................................................1372 Related information on disassembly and assembly .....................................................................................1374 How to read this manual .........................................................................................................1374 Coating materials list ..........................................................................................................1376 Special tools list ..............................................................................................................1380 Sketches of special tools .......................................................................................................1386 Engine and cooling system ...........................................................................................................1392 Removal and installation of supply pump assembly ................................................................................1392 Removal and installation of injector assembly ...................................................................................1397 Removal and installation of cylinder head assembly ..............................................................................1406 Removal and installation of radiator assembly ...................................................................................1427 Removal and installation of hydraulic oil cooler assembly .......................................................................1430 Removal and installation of aftercooler assembly ................................................................................1434 Removal and installation of engine assembly .....................................................................................1436 Removal and installation of engine front oil seal ...............................................................................1445 Removal and installation of engine rear oil seal ................................................................................1450 Removal and installation of fuel cooler assembly ................................................................................1453 Removal and installation of fuel tank assembly ..................................................................................1455 Removal and installation of engine hood assembly ................................................................................1457 Removal and installation of KDPF assembly .......................................................................................1459 Disassembly and assembly of KDPF assembly .......................................................................................1468 Removal and installation of KCCV assembly .......................................................................................1476 Removal and installation of air cleaner assembly ................................................................................1479 Removal and installation of EGR (Exhaust Gas Recirculation) valve assembly ......................................................1481 Removal and installation of EGR (Exhaust Gas Recirculation) cooler assembly .....................................................1483 Power train .........................................................................................................................1485 Removal and installation of travel motor and final drive assembly ...............................................................1485 Disassembly and assembly of final drive .........................................................................................1486 Removal and installation of swing motor and swing machinery assembly ............................................................1495 Disassembly and assembly of swing machinery assembly ............................................................................1497 Removal and installation of swing circle assembly ...............................................................................1504 Undercarriage and frame .............................................................................................................1505 Separation and connection of track shoe assembly ................................................................................1505 Removal and installation of sprocket ............................................................................................1508 Removal and installation of idler and idler cushion assembly ....................................................................1509 Disassembly and assembly of idler assembly ......................................................................................1510 Disassembly and assembly of idler cushion assembly ..............................................................................1513 Disassembly and assembly of track roller assembly ...............................................................................1515 Disassembly and assembly of carrier roller assembly .............................................................................1517 Removal and installation of revolving frame assembly ............................................................................1520 Removal and installation of counterweight assembly ..............................................................................1523 Removal and installation of counterweight assembly for maintenance ..............................................................1526 Hydraulic system ....................................................................................................................1527 Removal and installation of center swivel joint assembly ........................................................................1527 Disassembly and assembly of center swivel joint assembly ........................................................................1529 Removal and installation of hydraulic tank assembly .............................................................................1531 Removal and installation of main pump assembly ..................................................................................1534 Removal and installation of main pump input shaft oil seal ......................................................................1539 Removal and installation of control valve assembly ..............................................................................1540 Disassembly and assembly of control valve assembly ..............................................................................1547 Disassembly and assembly of work equipment PPC valve assembly ...................................................................1552 Disassembly and assembly of travel PPC valve assembly ...........................................................................1554 Work equipment ......................................................................................................................1556 Removal and installation of work equipment assembly .............................................................................1556 Disassembly and assembly of work equipment cylinder assembly ....................................................................1559 Remove and install anti-Drop valve assembly for boom.............................................................................1567 Remove and install anti-Drop valve assembly for arm..............................................................................1569 Disassemble and assemble anti-Drop valve assembly................................................................................1571 Cab and its attachments .............................................................................................................1573 Removal and installation of operator's cab assembly .............................................................................1573 Remove and Install Slide Door....................................................................................................1576 Removal and installation of operator's cab glass (adhered glass) ................................................................1580 Removal and installation of front window assembly ...............................................................................1595 Removal and installation of floor frame assembly ................................................................................1601 Removal and installation of air conditioner unit assembly .......................................................................1607 Removal and installation of operator's seat .....................................................................................1612 Removal and installation of seat belt ...........................................................................................1613 REMOVE AND INSTALL WORK EQUIPMENT CONTROL LEVER ASSEMBLY.........................................................................1615 Removal and installation of front wiper assembly ................................................................................1630 Removal and installation of air conditioner compressor assembly .................................................................1638 Removal and installation of air conditioner condenser assembly ..................................................................1640 Electrical system ...................................................................................................................1642 Removal and installation of engine controller assembly ..........................................................................1642 Removal and installation of pump controller assembly ............................................................................1643 Removal and installation of machine monitor assembly ............................................................................1646 Removal and installation of pump swash plate sensor .............................................................................1648 Removal and installation of mass air flow and temperature sensor ................................................................1649 Removal and installation of KOMTRAX terminal ....................................................................................1650 60 Maintenance standard .................................................................................................................1651 Table of contents ...................................................................................................................1652 Engine and cooling system ...........................................................................................................1653 Engine mount ....................................................................................................................1653 Cooling system ..................................................................................................................1654 Power train .........................................................................................................................1655 Swing circle ....................................................................................................................1655 Swing machinery .................................................................................................................1656 Final drive .....................................................................................................................1658 Sprocket ........................................................................................................................1660 Undercarriage and frame .............................................................................................................1662 Track frame and idler cushion ...................................................................................................1662 Idler ...........................................................................................................................1664 Track roller ....................................................................................................................1666 Carrier roller ..................................................................................................................1667 Track shoe ......................................................................................................................1668 Hydraulic system ....................................................................................................................1674 Hydraulic tank ..................................................................................................................1674 Main pump .......................................................................................................................1675 Control valve ...................................................................................................................1676 Swing motor .....................................................................................................................1686 Travel motor ....................................................................................................................1688 PPC valve .......................................................................................................................1691 Solenoid valve ..................................................................................................................1701 Attachment circuit selector valve (for high-pressure circuit) ...................................................................1702 Attachment circuit selector valve (for low-pressure circuit) ....................................................................1703 Anti-drop valve for boom........................................................................................................1704 Anti-drop valve for arm.........................................................................................................1706 Center swivel joint .............................................................................................................1708 Work equipment ......................................................................................................................1709 Work equipment ..................................................................................................................1709 Work equipment cylinder .........................................................................................................1718 80 Appendix .............................................................................................................................1721 Table of contents ...................................................................................................................1722 Air conditioner components ..........................................................................................................1723 Precautions for refrigerant .....................................................................................................1723 Air conditioner component .......................................................................................................1724 Configuration and function of refrigeration cycle ...............................................................................1727 Outline of refrigeration cycle ..................................................................................................1728 Air conditioner unit ............................................................................................................1730 Dual pressure switch ............................................................................................................1735 Air conditioner controller ......................................................................................................1736 Compressor ......................................................................................................................1737 Air conditioner condenser .......................................................................................................1738 Sunlight sensor .................................................................................................................1740 Outer temperature sensor (outside air temperature sensor) .......................................................................1741 Procedure for testing and troubleshooting .......................................................................................1742 Circuit diagram and arrangement of connector pins ...............................................................................1744 System diagram ..................................................................................................................1746 Input and output signals of the air conditioner controller ......................................................................1747 Air conditioner unit ............................................................................................................1749 Parts and connectors layout .....................................................................................................1751 Testing air leakage (duct) ......................................................................................................1757 Testing with self-diagnosis function ............................................................................................1760 Testing vent (mode) changeover ..................................................................................................1763 Testing FRESH/RECIRC air changeover .............................................................................................1764 Testing sunlight sensor .........................................................................................................1765 Testing (dual) pressure switch for refrigerant ..................................................................................1766 Testing relays ..................................................................................................................1768 Troubleshooting chart 1 .........................................................................................................1769 Troubleshooting chart 2 .........................................................................................................1770 Information in troubleshooting table ............................................................................................1773 Failure code list related to air conditioner ....................................................................................1774 Failure code [879AKA] A/C Inner Sensor Open Circuit .............................................................................1775 Failure code [879AKB] A/C Inner Sensor Short Circuit ............................................................................1776 Failure code [879BKA] A/C Outer Sensor Open Circuit .............................................................................1777 Failure code [879BKB] A/C Outer Sensor Short Circuit ............................................................................1779 Failure code [879CKA] Ventilating Sensor Open Circuit ...........................................................................1781 Failure code [879CKB] Ventilating Sensor Short Circuit ..........................................................................1782 Failure code [879DKZ] Sunlight Sensor Open or Short Circuit .....................................................................1783 Failure code [879EMC] Ventilation Damper Abnormality ............................................................................1785 Failure code [879FMC] Air Mix Damper Abnormality ................................................................................1786 Failure code [879GKX] Refrigerant Abnormality ...................................................................................1787 A-1 Troubleshooting for power supply system (Air conditioner does not operate) ..................................................1788 A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled) ...................................................1790 A-3 Troubleshooting for blower motor system (No air comes out or air flow is abnormal) ..........................................1793 A-4 Troubleshooting for FRESH/RECIRC air changeover .............................................................................1795 Troubleshooting with gauge pressure .............................................................................................1797 Connection of service tool ......................................................................................................1800 Precautions for disconnecting and connecting refrigerant piping .................................................................1802 Handling of compressor oil ......................................................................................................1804 Desiccant replacement ...........................................................................................................1806 90 Diagrams and drawings ................................................................................................................1809 Table of contents ...................................................................................................................1810 Hydraulic circuit diagram ...........................................................................................................1811 Symbols in hydraulic circuit diagram ............................................................................................1811 Hydraulic circuit diagram .......................................................................................................1815 Electric circuit diagram ............................................................................................................1817 Symbols in electric circuit diagram .............................................................................................1817 Electrical circuit diagram ......................................................................................................1821 Electrical circuit diagram of air conditioner unit ..............................................................................1833 INDEX....................................................................................................................................1835
DESCRIPTION:
KOMATSU PC228USLC-10 HYDRAULIC EXCAVATOR SHOP MANUAL SEN06483-12 – PDF DOWNLOAD
Composition of shop manual
• This shop manual describes the technical information required for the services performed in a workshop. The shop manual is divided into the following chapters for the convenience of use.
00. Index and foreword
• This section includes the index, foreword, safety and basic information.
01. Specification
• This section explains the specifications of the machine.
10. Structure and function
• This section explains the structure and function of the machine. The section of “Structure and function” 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
• The standard values for a new machine and trouble shooting are indicated. This standard value table is used for testing and adjusting, and determining a failure at troubleshooting.
30. Testing and adjusting
• This section describes the measuring tools and how to measure, and how to adjust various parts. As for the standard value and failure criterion, see the standard value table.
40. Troubleshooting
• This section describes the troubleshooting in a suspected area when a failure occurs and the remedy for the failure. Troubleshooting is described by each failure mode.
50. Disassembly and assembly
• This section explains the procedures for removing, installing, disassembling, and assembling each part or component and the special tools for the works as well as precautions for doing them safely. In addition, tightening torque, and quantity and weight of coating material, oil, grease, and coolant required for the works are also explained.
60. Maintenance standard
• This section describes the maintenance standard values for each component. This section gives the criterion values for each component and required remedy at disassembly or maintenance.
80. Appendix
• The structure and function, testing and adjusting, and troubleshooting for all of the other components or equipment which can not be separately classified are explained together in the appendix.
90. Diagrams and drawings
• This section gives hydraulic circuit diagrams and electrical circuit diagrams.
S.S 24/12/24
