Komatsu PC228USLC-10 Hydraulic Excavator Shop Manual UENBM00320 PDF

Description

Komatsu PC228USLC-10 Hydraulic Excavator Shop Manual UENBM00320 – PDF DOWNLOAD

FILE DETAILS:

Komatsu PC228USLC-10 Hydraulic Excavator Shop Manual UENBM00320 – PDF DOWNLOAD 

Language : English
Pages : 1753
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Komatsu PC228USLC-10 Hydraulic Excavator Shop Manual UENBM00320 – PDF DOWNLOAD 

SERIAL NUMBERS 1149 and up

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
Center swivel joint 269
Accumulator 271
Work equipment 273
Work equipment 273
Work equipment shim 274
Bucket play adjustment shim 275
Cab and its attachments 276
Cab mount and cab tipping stopper 276
ROPS cab 277
Electrical system 278
Electrical control system 278
Machine monitor system 333
KOMTRAX system 355
Sensor 358
20 Standard value tables 379
Table of contents 380
Standard service value table 381
Standard value table for engine 381
Standard value table for machine 382
Standard value table for electrical system 396
30 Testing and adjusting 407
Table of contents 408
Related information on testing and adjusting 409
Tools for testing and adjusting 409
Sketch of tools for testing and adjusting 413
Engine and cooling system 414
Testing engine speed 414
Testing boost pressure 415
Testing exhaust gas color 417
Testing and adjusting valve clearance 419
Testing compression pressure 422
Testing blowby pressure 426
Testing engine oil pressure 427
Testing EGR valve and KVGT oil pressures 428
Measuring fuel pressure 429
Measuring fuel delivery, return and leakage 435
Bleeding air from fuel system 440
Testing fuel circuit for leakage 442
Handling cylinder cutout mode operation 443
Handling no-injection cranking operation 444
Checking and adjusting air conditioner compressor belt tension 445
Replacing fan belt 447
Power train 448
Testing swing circle bearing clearance 448
Undercarriage and frame 449
Testing and adjusting track tension 449
Hydraulic system 450
Releasing remaining pressure from hydraulic circuit 450
Testing and adjusting oil pressure in work equipment, swing, and travel circuits 455
Testing oil pressure of control circuit 459
Testing and adjusting oil pressure in pump PC control circuit 460
Testing and adjusting oil pressure in pump LS control circuit 464
Testing outlet pressure of solenoid valve 472
Testing PPC valve outlet pressure 475
Adjusting play of work equipment and swing PPC valves 477
Testing pump swash plate sensor 478
Isolating the parts causing hydraulic drift in work equipment 479
Testing and adjusting travel deviation 481
Testing oil leakage 483
Bleeding air from hydraulic circuit 486
Work equipment 489
Testing and adjusting boom angle potentiometer 489
Cab and its attachments 490
Checking cab tipping stopper 490
Adjusting mirrors 491
Electrical system 493
Special functions of machine monitor 493
KOMTRAX terminal start-up procedure 563
Adjusting rearview camera angle 566
Handling voltage circuit of engine controller 568
Handling battery disconnect switch 569
Testing diodes 570
Pm clinic 571
Pm Clinic service 571
40 Troubleshooting 583
Table of contents 584
Related information on troubleshooting 591
Troubleshooting points 591
Sequence of events in troubleshooting 593
Testing before troubleshooting 595
Inspection procedure before troubleshooting 597
Preparation work for troubleshooting of electrical system 616
Classification and procedure for troubleshooting 621
Symptom of probable failure and troubleshooting No 624
Information in troubleshooting table 627
Diagnostic procedure for wiring harness open curcuit of pressure sensor system 629
Connector list and layout 631
Connector contact identification 642
T-branch box and T-branch adapter table 680
Fuse location table 685
Precautions for KDPF (KCSF and KDOC) Cleaning and Replacement 687
Preparation of dummy temperature sensor (for KDOC and KDPF temperature sensors) 690
Preparation of short circuit electrical connector (for failure codes [CA1883] and [CA3135]) 691
Failure codes table 692
Troubleshooting by failure code (Display of code) 701
Failure code [879AKA] A/C Inner Sensor Open Circuit 701
Failure code [879AKB] A/C Inner Sensor Short Circuit 702
Failure code [879BKA] A/C Outer Sensor Open Circuit 703
Failure code [879BKB] A/C Outer Sensor Short Circuit 704
Failure code [879CKA] Ventilating Sensor Open Circuit 705
Failure code [879CKB] Ventilating Sensor Short Circuit 706
Failure code [879DKZ] Sunlight Sensor Open Or Short Circuit 707
Failure code [879EMC] Ventilation Damper Abnormality 708
Failure code [879FMC] Air Mix Damper Abnormality 709
Failure code [879GKX] Refrigerant Abnormality 710
Failure code [989L00] Engine Controller Lock Caution 1 711
Failure code [989M00] Engine Controller Lock Caution 2 712
Failure code [989N00] Engine Controller Lock Caution 3 713
Failure code [A1U0N3] HC Desorb Request 1 714
Failure code [A1U0N4] HC Desorb Request 2 716
Failure code [AA10NX] Air Cleaner Clogging 718
Failure code [AB00KE] Charge Voltage Low 720
Failure code [B@BAZG] Eng Oil Press Low 722
Failure code [B@BAZK] Eng Oil Level Low 723
Failure code [B@BCNS] Eng Water Overheat 724
Failure code [B@BCZK] Eng Water Level Low 725
Failure code [B@HANS] Hyd Oil Overheat 727
Failure code [CA115] Eng Ne and Bkup Speed Sens Error 728
Failure code [CA122] Chg Air Press Sensor High Error 729
Failure code [CA123] Chg Air Press Sensor Low Error 731
Failure code [CA131] Throttle Sensor High Error 733
Failure code [CA132] Throttle Sensor Low Error 735
Failure code [CA144] Coolant Temp Sens High Error 737
Failure code [CA145] Coolant Temp Sens Low Error 739
Failure code [CA153] Chg Air Temp Sensor High Error 741
Failure code [CA154] Chg Air Temp Sensor Low Error 743
Failure code [CA187] Sensor 2 Supply Volt Low Error 745
Failure code [CA221] Ambient Press Sensor High Error 747
Failure code [CA222] Ambient Press Sensor Low Error 749
Failure code [CA227] Sensor 2 Supply Volt High Error 751
Failure code [CA234] Eng Overspeed 752
Failure code [CA238] Ne Speed Sensor Supply Volt Error 753
Failure code [CA239] Ne Speed Sens Supply Volt High Error 754
Failure code [CA271] IMV/PCV1 Short Error 755
Failure code [CA272] IMV/PCV1 Open Error 757
Failure code [CA295] Ambient Press Sens In Range Error 759
Failure code [CA322] Inj #1(L#1) Open/Short Error 760
Failure code [CA323] Inj #5(L#5) Open/Short Error 762
Failure code [CA324] Inj #3(L#3) Open/Short Error 764
Failure code [CA325] Inj #6(L#6) Open/Short Error 766
Failure code [CA331] Inj #2(L#2) Open/Short Error 768
Failure code [CA332] Inj #4(L#4) Open/Short Error 770
Failure code [CA343] ECM Critical Internal Failure 772
Failure code [CA351] Injectors Drive Circuit Error 773
Failure code [CA352] Sensor 1 Supply Volt Low Error 774
Failure code [CA356] Mass Air Flow Sensor High Error 776
Failure code [CA357] Mass Air Flow Sensor Low Error 778
Failure code [CA386] Sensor 1 Supply Volt High Error 780
Failure code [CA428] Water in Fuel Sensor High Error 781
Failure code [CA429] Water in Fuel Sensor Low Error 783
Failure code [CA435] Eng Oil Press Sw Error 785
Failure code [CA441] Battery Voltage Low Error 786
Failure code [CA442] Battery Voltage High Error 788
Failure code [CA449] Rail Press Very High Error 789
Failure code [CA451] Rail Press Sensor High Error 790
Failure code [CA452] Rail Press Sensor Low Error 792
Failure code [CA488] Chg Air Temp High Torque Derate 794
Failure code [CA515] Rail Press Sens Sup Volt High Error 795
Failure code [CA516] Rail Press Sens Sup Volt Low Error 797
Failure code [CA553] Rail Press High Error 799
Failure code [CA555] Crankcase Press High Error 1 800
Failure code [CA556] Crankcase Press High Error 2 801
Failure code [CA559] Rail Press Low Error 802
Failure code [CA595] Turbo Speed High Error 2 804
Failure code [CA687] Turbo Speed Low Error 805
Failure code [CA689] Eng Ne Speed Sensor Error 807
Failure code [CA691] Intake Air Temp Sens High Error 809
Failure code [CA692] Intake Air Temp Sens Low Error 811
Failure code [CA697] ECM Int Temp Sensor High Error 813
Failure code [CA698] ECM Int Temp Sensor Low Error 814
Failure code [CA731] Eng Bkup Speed Sens Phase Error 815
Failure code [CA778] Eng Bkup Speed Sensor Error 817
Failure code [CA1117] Persistent Data Lost Error 822
Failure code [CA1664] KDOC Malfunction 823
Failure code [CA1691] Regeneration Ineffective 825
Failure code [CA1695] Sensor 5 Supply Volt High Error 828
Failure code [CA1696] Sensor 5 Supply Volt Low Error 830
Failure code [CA1843] Crankcase Press Sens High Error 832
Failure code [CA1844] Crankcase Press Sens Low Error 834
Failure code [CA1879] KDPF Delta P Sensor High Error 836
Failure code [CA1881] KDPF Delta P Sensor Low Error 838
Failure code [CA1883] KDPF Delta P Sens In Range Error 840
Failure code [CA1921] KDPF Soot Load High Error 1 843
Failure code [CA1922] KDPF Soot Load High Error 2 846
Failure code [CA1942] Crankcase Press Sens In Range Error 851
Failure code [CA1993] KDPF Delta Pressure Low Error 852
Failure code [CA2185] Throt Sensor Sup Volt High Error 855
Failure code [CA2186] Throt Sensor Sup Volt Low Error 857
Failure code [CA2249] Rail Press Very Low Error 859
Failure code [CA2271] EGR Valve Pos Sens High Error 860
Failure code [CA2272] EGR Valve Pos Sens Low Error 862
Failure code [CA2288] Turbo Speed High Error 1 865
Failure code [CA2311] IMV Solenoid Error 866
Failure code [CA2349] EGR Valve Solenoid Open Error 867
Failure code [CA2353] EGR Valve Solenoid Short Error 869
Failure code [CA2357] EGR Valve Servo Error 871
Failure code [CA2373] Exhaust Manifold Press Sens High error 872
Failure code [CA2374] Exhaust Manifold Press Sens Low error 874
Failure code [CA2375] EGR Orifice Temp Sens High Error 876
Failure code [CA2376] EGR Orifice Temp Sens Low Error 878
Failure code [CA2381] KVGT Pos Sens High Error 880
Failure code [CA2382] KVGT Pos Sens Low Error 882
Failure code [CA2383] KVGT Solenoid Open Error 885
Failure code [CA2386] KVGT Solenoid Short Error 887
Failure code [CA2387] KVGT Servo Error 889
Failure code [CA2554] Exh Manifold Press Sens In Range Error 890
Failure code [CA2555] Grid Htr Relay Volt Low Error 891
Failure code [CA2556] Grid Htr Relay Volt High Error 893
Failure code [CA2637] KDOC Face Plugging 895
Failure code [CA2639] Manual Stationary Regeneration Request 897
Failure code [CA2961] EGR Orifice Temp High Error 1 900
Failure code [CA2973] Chg Air Press Sensor In Range Error 901
Failure code [CA3133] KDPF Outlet Press Sens High Error 902
Failure code [CA3134] KDPF Outlet Press Sens Low Error 904
Failure code [CA3135] KDPF Outlet Press Sens In Range Error 906
Failure code [CA3251] KDOC Inlet Temp High Error 910
Failure code [CA3253] KDOC Temp Error – Non Regeneration 913
Failure code [CA3254] KDOC Outlet Temp High Error 1 916
Failure code [CA3255] KDPF Temp Error – Non Regeneration 919
Failure code [CA3256] KDPF Outlet Temp High Error 1 922
Failure code [CA3311] KDOC Outlet Temp High Error 2 925
Failure code [CA3312] KDPF Outlet Temp High Error 2 928
Failure code [CA3313] KDOC Inlet Temp Sensor Low Error 931
Failure code [CA3314] KDOC Inlet Temp Sens High Error 934
Failure code [CA3315] KDOC Inlet Temp Sens In Range Error 938
Failure code [CA3316] KDOC Outlet Temp Sens Low Error 942
Failure code [CA3317] KDOC Outlet Temp Sens High Error 945
Failure code [CA3318] KDOC Outlet Temp Sens In Range Error 949
Failure code [CA3319] KDPF Outlet Temp Sens High Error 953
Failure code [CA3321] KDPF Outlet Temp Sens Low Error 957
Failure code [CA3322] KDPF Outlet Temp Sens In Range Error 960
Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error 964
Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error 966
Failure code [CA3741] Rail Press Valve Trip Error 968
Failure code [D110KB] Battery Relay Drive Short Circuit 969
Failure code [D19JKZ] Personal Code Relay Abnormality 971
Failure code [D811MC] KOMTRAX Error 974
Failure code [D862KA] GPS Antenna Open Circuit 975
Failure code [D8ALKA] System Operating Lamp Disconnection (KOMTRAX) 976
Failure code [D8ALKB] System Operating Lamp Short Circuit (KOMTRAX) 978
Failure code [D8AQKR] CAN2 Discon (KOMTRAX) 979
Failure code [DA20MC] Pump Controller 980
Failure code [DA22KK] Pump Solenoid Power Low Error 981
Failure code [DA25KP] 5V Sensor 1 Power Abnormality 983
Failure code [DA26KP] 5V Sensor 2 Power Abnormality 986
Failure code [DA29KQ] Model Selection Abnormality 987
Failure code [DA2LKA] System Operating Lamp Disconnection (Pump Con) 989
Failure code [DA2LKB] System Operating Lamp Short Circuit (Pump Con) 991
Failure code [DA2QKR] CAN2 Discon (Pump Con) 992
Failure code [DA2RKR] CAN1 Discon (Pump Con) 994
Failure code [DAF0MB] Monitor ROM Abnormality 995
Failure code [DAF0MC] Monitor Error 996
Failure code [DAF8KB] Camera Power Supply Short Circuit 997
Failure code [DAF9KQ] Model Selection Abnormality 999
Failure code [DAFGMC] GPS Module Error 1000
Failure code [DAFLKA] Operating Lamp Open Circuit(Monitor) 1001
Failure code [DAFLKB] System Operating Lamp Short Circuit (Monitor) 1003
Failure code [DAFQKR] CAN2 Discon (Monitor) 1004
Failure code [DAZ9KQ] A/C Model Selection Abnormality 1005
Failure code [DAZQKR] CAN2 Discon (Aircon ECU) 1006
Failure code [DB2QKR] CAN2 Discon (Engine Con) 1010
Failure code [DB2RKR] CAN1 Discon (Engine Con) 1014
Failure code [DGH2KB] Hyd Oil Sensor Short Circuit 1018
Failure code [DHA4KA] Air Cleaner Clog Sensor Open Circuit 1020
Failure code [DHPAMA] F Pump Press Sensor Abnormality 1021
Failure code [DHPBMA] R Pump Press Sensor Abnormality 1024
Failure code [DHS3MA] Arm IN PPC Sen Abnormality 1027
Failure code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality 1029
Failure code [DHS8MA] Boom Raise PPC Press Sensor Abnormality 1032
Failure code [DHS9MA] Boom LOWER Press Sensor Abnormality 1035
Failure code [DHSAMA] Swing RH PPC Press Sensor Abnormality 1038
Failure code [DHSBMA] Swing LH PPC Press Sensor Abnormality 1041
Failure code [DHSCMA] Arm Dump PPC Press Sensor Abnormality 1044
Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality 1047
Failure code [DHSFMA] Travel Fwd LH PPC Press Sensor Abnormality 1050
Failure code [DHSGMA] Travel Fwd RH PPC Press Sensor Abnormality 1053
Failure code [DHSHMA] Travel Rev LH PPC Press Sensor Abnormality 1056
Failure code [DHSJMA] Travel Rev RH PPC Press Sensor Abnormality 1059
Failure code [DKA0KA] Failure of Boom Angle Sensor (Open circuit) 1062
Failure code [DKA0KB] Failure of Boom Angle Sensor (Short circuit) 1064
Failure code [DKA0PH] Boom Angle Sensor installation error 1066
Failure code [DKR0MA] F Pump Swash Plate Sensor Abnormality 1067
Failure code [DKR1MA] R Pump Swash Plate Sensor Abnormality 1069
Failure code [DR21KX] Camera 2 Picture Rev Drive Abnormality 1071
Failure code [DR31KX] Camera 3 Picture Rev Drive Abnormality 1073
Failure code [DV20KB] Travel Alarm Short Circuit 1075
Failure code [DW43KA] Travel Speed Sol Open Circuit 1077
Failure code [DW43KB] Travel Speed Sol Short Circuit 1079
Failure code [DW45KA] Swing Brake Sol Open Circuit 1081
Failure code [DW45KB] Swing Brake Sol Short Circuit 1084
Failure code [DW4GKA] Boom slow down EPC sol disconnection 1086
Failure code [DW4GKB] Boom slow down EPC sol short circuit 1088
Failure code [DW91KA] Travel Junction Sol Open Circuit 1090
Failure code [DW91KB] Travel Junction Sol Short Circuit 1092
Failure code [DWA2KA] Attachment Sol Open Circuit 1094
Failure code [DWA2KB] Attachment Sol Short Circuit 1096
Failure code [DWK0KA] 2-Stage Relief Sol Open Circuit 1098
Failure code [DWK0KB] 2-Stage Relief Sol Short Circuit 1100
Failure code [DWK2KA] Variable Back Press Sol Open Circuit 1102
Failure code [DWK2KB] Variable Back Press Sol Short Circuit 1104
Failure code [DWK8KA] Swing Press C/O Sol Open Circuit 1106
Failure code [DWK8KB] Swing Press C/O Sol Short Circuit 1108
Failure code [DXA8KA] PC-EPC (F) Sol Open Circuit 1110
Failure code [DXA8KB] PC-EPC (F) Sol Short Circuit 1112
Failure code [DXA9KA] PC-EPC (R) Sol Open Circuit 1114
Failure code [DXA9KB] PC-EPC (R) Sol Short Circuit 1116
Failure code [DXE0KA] LS-EPC Sol Open Circuit 1118
Failure code [DXE0KB] LS-EPC Sol Short Circuit 1120
Failure code [DXE4KA] Attachment Flow EPC Open Circuit 1122
Failure code [DXE4KB] Attachment Flow EPC Short Circuit 1124
Failure code [DXE5KA] Merge-divide Main Sol Open Circuit 1126
Failure code [DXE5KB] Merge-divide Main Sol Short Circuit 1128
Failure code [DXE6KA] Merge-divide LS Sol Open Circuit 1130
Failure code [DXE6KB] Merge-divide LS Sol Short Circuit 1132
Failure code [DY20KA] Wiper Working Abnormality 1134
Failure code [DY20MA] Wiper Parking Abnormality 1136
Failure code [DY2CKB] Washer Drive Short Circuit 1138
Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit 1140
Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit 1142
Troubleshooting of electrical system (E-mode) 1144
E-1 Engine does not start (Engine does not crank) 1144
E-2 Manual preheating system does not work 1149
E-3 Automatic preheating system does not work 1152
E-4 While preheating is working, preheating monitor does not light up 1154
E-5 When starting switch is turned to ON position, machine monitor displays nothing 1156
E-6 While starting switch is turned to ON position (with engine stopped), engine oil level monitor lights up in yellow 1159
E-7 While starting switch is turned to ON position (with engine stopped), radiator coolant level monitor lights up in yellow 1160
E-8 Engine coolant temperature monitor lights up in red while engine is running 1161
E-9 Hydraulic oil temperature monitor lights up in white while engine is running 1162
E-10 Charge level monitor lights up in red while engine is running 1163
E-11 Fuel level monitor lights up in red while engine is running 1164
E-12 Air cleaner clogging monitor lights up in yellow while engine is running 1165
E-13 Water separator monitor lights up in red while engine is running 1166
E-14 Engine coolant temperature monitor lights up in red while engine is running 1167
E-15 Hydraulic oil temperature monitor lights up in red while engine is running 1168
E-16 Engine oil pressure monitor lights up in red while engine is running 1169
E-17 Fuel gauge display does not move from minimum or maximum 1170
E-18 Fuel gauge indicates incorrect amount (indicates neither full nor empty) 1171
E-19 Engine coolant temperature gauge display does not move from minimum or maximum 1172
E-20 Engine coolant temperature gauge indicates incorrect temperature (indicates neither full nor empty) 1173
E-21 Hydraulic oil temperature gauge does not move from minimum or maximum 1174
E-22 Hydraulic oil temperature gauge indicates incorrect temperature (indicates neither full nor empty) 1176
E-23 Contents of display on machine monitor is different from actual machine condition 1177
E-24 Some areas of machine monitor screen are not displayed 1178
E-25 Function switch does not work 1179
E-26 Automatic warm-up system does not operate (in cold season) 1180
E-27 Auto-deceleration monitor does not light up, or does not go out, while auto-deceleration switch is operated 1181
E-28 Auto-deceleration function does not operate or is not canceled while lever is operated 1182
E-29 Working mode selection screen is not displayed while working mode selector switch is operated 1183
E-30 Setting of engine and hydraulic pump is not changed while working mode is changed 1184
E-31 Travel speed monitor does not change when travel speed switch is operated 1185
E-32 Travel speed does not change while travel speed selection is changed 1186
E-33 Alarm buzzer does not stop sounding 1187
E-34 Service meter is not displayed, while starting switch is in OFF position 1188
E-35 Service mode cannot be selected 1189
E-36 Any of work equipment, swing and travel does not work 1190
E-37 Any of work equipment, swing and travel cannot be locked 1192
E-38 Upper structure does not swing while swing parking brake cancel switch is set to CANCEL position 1194
E-39 Swing brake does not operate while swing parking brake cancel switch is set to NORMAL position 1196
E-40 One-touch power maximizing function does not operate, or indicator is not displayed on monitor 1198
E-41 One-touch power maximizing function cannot be canceled 1200
E-42 Alarm does not sound during travel 1201
E-43 Alarm does not stop sounding while machine is stopped 1203
E-44 Horn does not sound 1204
E-45 Horn does not stop sounding 1206
E-46 Wiper monitor does not light up, or does not go out, while wiper switch is operated 1207
E-47 Wiper does not operate while wiper switch is operated 1208
E-48 Window washer does not operate while window washer switch is operated 1210
E-49 Boom LOWER is not displayed correctly with monitoring function 1211
E-50 Arm OUT is not displayed correctly with monitoring function 1212
E-51 Arm IN is not displayed correctly with monitoring function 1213
E-52 Boom RAISE is not displayed correctly with monitoring function 1214
E-53 Bucket CURL is not displayed correctly with monitoring function 1215
E-54 Bucket DUMP is not displayed correctly with monitoring function 1216
E-55 Swing is not displayed correctly with monitoring function 1217
E-56 Travel is not displayed correctly with monitoring function 1218
E-57 Service is not displayed correctly with monitoring function 1219
E-58 Attachment hydraulic circuit cannot be changed 1221
E-59 KOMTRAX system does not operate normally 1222
Troubleshooting of hydraulic and mechanical system (H-mode) 1224
Information described in troubleshooting table (H-mode) 1224
System chart of hydraulic and mechanical systems 1225
Failure mode and cause table 1227
H-1 All of work equipment, swing and travel operation lacks speed or power 1235
H-2 Engine speed drops significantly or engine stalls 1238
H-3 All work equipment, swing and travel does not work 1241
H-4 Unusual sound is heard from around hydraulic pump 1242
H-5 Fine control performance or response is poor 1243
H-6 Boom speed or power is low 1245
H-7 Arm speed or power is low 1249
H-8 Bucket speed or power is low 1253
H-9 Work equipment does not move in single operation 1256
H-10 Hydraulic drift of boom is large 1257
H-11 Hydraulic drift of arm is large 1258
H-12 Hydraulic drift of bucket is large 1259
H-13 Time lag of work equipment is large 1260
H-14 When part of work equipment is relieved singly, other parts of work equipment move 1262
H-15 One-touch power maximizing function does not operate 1263
H-16 In combined operation of work equipment, equipment having heavier load moves slower 1264
H-17 In combined operations of swing and boom RAISE, boom rising speed is low 1265
H-18 In combined operations of swing and travel, travel speed drops largely 1266
H-19 Machine does not travel straight 1267
H-20 Travel speed is slow 1270
H-21 Machine is hard to steer or travel power is low 1272
H-22 Travel speed does not change, or travel speed is too slow or fast 1275
H-23 One of tracks does not run 1276
H-24 Upper structure does not swing to the right or left 1278
H-25 Upper structure swing only to the right or left 1279
H-26 Swing acceleration or swing speed is low in both directions (right and left) 1280
H-27 Swing acceleration performance is poor or swing speed is slow in only one direction 1281
H-28 Upper structure overruns excessively when it stops swinging (both right and left) 1282
H-29 Upper structure overruns excessively when it stops swinging (either right or left) 1283
H-30 Shock is large when upper structure stops swinging 1284
H-31 Large unusual noise is heard when upper structure stops swinging 1285
H-32 Swing drift on a slope is large while swing holding brake is applied 1286
H-33 Swing drift on a slope is large while swing holding brake is released 1287
H-34 Attachment hydraulic circuit cannot be changed while attachment is installed 1288
H-35 Oil flow in attachment circuit cannot be controlled 1289
Troubleshooting of engine (S-mode) 1290
Information mentioned in troubleshooting table (S mode) 1290
S-1 When starting switch is turned to START position, engine does not crank 1291
S-2 Engine cranks but no exhaust smoke comes out 1292
S-3 Fuel is being injected but engine does not start (misfiring: engine cranks but does not start) 1293
S-4 Engine startability is poor 1294
S-5 Engine does not pick up smoothly 1296
S-6 Engine stops during operation 1298
S-7 Engine runs rough or is unstable 1300
S-8 Engine lacks power 1301
S-9 Exhaust smoke is black (KDPF clogs up early) 1303
S-10 Engine oil consumption is excessive 1305
S-11 Engine oil becomes contaminated early 1306
S-12 Fuel consumption is excessive 1307
S-13 Oil is in coolant (or coolant spurts or coolant level goes down) 1308
S-14 Engine oil pressure drops 1309
S-15 Fuel is contaminated in engine oil 1310
S-16 Coolant is contaminated in engine oil (Oil becomes cloudy white) 1311
S-17 Coolant temperature rises too high (overheating) 1312
S-18 Unusual noise is heard 1313
S-19 Vibration is excessive 1314
S-20 Air cannot be bled from fuel circuit 1315
S-21 Active regeneration is executed frequently 1316
S-22 Active regeneration takes time 1317
S-23 White smoke is exhausted during active regeneration 1318
50 Disassembly and assembly 1319
Table of contents 1320
Related information on disassembly and assembly 1322
How to read this manual 1322
Coating materials list 1324
Special tools list 1328
Sketches of special tools 1334
Engine and cooling system 1340
Removal and installation of supply pump assembly 1340
Removal and installation of injector assembly 1345
Removal and installation of cylinder head assembly 1354
Removal and installation of radiator assembly 1375
Removal and installation of hydraulic oil cooler assembly 1378
Removal and installation of aftercooler assembly 1382
Removal and installation of engine assembly 1384
Removal and installation of engine front oil seal 1393
Removal and installation of engine rear oil seal 1398
Removal and installation of fuel cooler assembly 1401
Removal and installation of fuel tank assembly 1403
Removal and installation of engine hood assembly 1405
Removal and installation of KDPF assembly 1407
Disassembly and assembly of KDPF assembly 1416
Removal and installation of KCCV assembly 1424
Removal and installation of air cleaner assembly 1427
Removal and installation of EGR (Exhaust Gas Recirculation) valve assembly 1429
Removal and installation of EGR (Exhaust Gas Recirculation) cooler assembly 1431
Power train 1433
Removal and installation of travel motor and final drive assembly 1433
Disassembly and assembly of final drive 1434
Removal and installation of swing motor and swing machinery assembly 1443
Disassembly and assembly of swing machinery assembly 1445
Removal and installation of swing circle assembly 1452
Undercarriage and frame 1453
Separation and connection of track shoe assembly 1453
Removal and installation of sprocket 1456
Removal and installation of idler and idler cushion assembly 1457
Disassembly and assembly of idler assembly 1458
Disassembly and assembly of idler cushion assembly 1461
Disassembly and assembly of track roller assembly 1463
Disassembly and assembly of carrier roller assembly 1465
Removal and installation of revolving frame assembly 1468
Removal and installation of counterweight assembly 1471
Removal and installation of counterweight assembly for maintenance 1474
Hydraulic system 1475
Removal and installation of center swivel joint assembly 1475
Disassembly and assembly of center swivel joint assembly 1477
Removal and installation of hydraulic tank assembly 1479
Removal and installation of main pump assembly 1482
Removal and installation of main pump input shaft oil seal 1487
Removal and installation of control valve assembly 1488
Disassembly and assembly of control valve assembly 1495
Disassembly and assembly of work equipment PPC valve assembly 1500
Disassembly and assembly of travel PPC valve assembly 1502
Work equipment 1504
Removal and installation of work equipment assembly 1504
Disassembly and assembly of work equipment cylinder assembly 1507
Cab and its attachments 1515
Removal and installation of operator’s cab assembly 1515
Removal and installation of operator’s cab glass (adhered glass) 1518
Removal and installation of front window assembly 1533
Removal and installation of floor frame assembly 1539
Removal and installation of air conditioner unit assembly 1545
Removal and installation of operator’s seat 1550
Removal and installation of seat belt 1551
Removal and installation of front wiper assembly 1552
Removal and installation of air conditioner compressor assembly 1558
Removal and installation of air conditioner condenser assembly 1560
Electrical system 1562
Removal and installation of engine controller assembly 1562
Removal and installation of pump controller assembly 1563
Removal and installation of machine monitor assembly 1566
Removal and installation of pump swash plate sensor 1568
Removal and installation of mass air flow and temperature sensor 1569
Removal and installation of KOMTRAX terminal 1570
60 Maintenance standard 1571
Table of contents 1572
Engine and cooling system 1573
Engine mount 1573
Cooling system 1574
Power train 1575
Swing circle 1575
Swing machinery 1576
Final drive 1578
Sprocket 1580
Undercarriage and frame 1582
Track frame and idler cushion 1582
Idler 1584
Track roller 1586
Carrier roller 1587
Track shoe 1588
Hydraulic system 1594
Hydraulic tank 1594
Main pump 1595
Control valve 1596
Swing motor 1606
Travel motor 1608
PPC valve 1611
Solenoid valve 1621
Attachment circuit selector valve (for high-pressure circuit) 1622
Attachment circuit selector valve (for low-pressure circuit) 1623
Center swivel joint 1624
Work equipment 1625
Work equipment 1625
Work equipment cylinder 1634
80 Appendix 1637
Table of contents 1638
Air conditioner components 1639
Precautions for refrigerant 1639
Air conditioner component 1640
Configuration and function of refrigeration cycle 1643
Outline of refrigeration cycle 1644
Air conditioner unit 1646
Dual pressure switch 1651
Air conditioner controller 1652
Compressor 1653
Air conditioner condenser 1654
Sunlight sensor 1656
Outer temperature sensor (outside air temperature sensor) 1657
Procedure for testing and troubleshooting 1658
Circuit diagram and arrangement of connector pins 1660
System diagram 1662
Input and output signals of the air conditioner controller 1663
Air conditioner unit 1665
Parts and connectors layout 1667
Testing air leakage (duct) 1673
Testing with self-diagnosis function 1676
Testing vent (mode) changeover 1679
Testing FRESH/RECIRC air changeover 1680
Testing sunlight sensor 1681
Testing (dual) pressure switch for refrigerant 1682
Testing relays 1684
Troubleshooting chart 1 1685
Troubleshooting chart 2 1686
Information in troubleshooting table 1689
Failure code list related to air conditioner 1690
Failure code [879AKA] A/C Inner Sensor Open Circuit 1691
Failure code [879AKB] A/C Inner Sensor Short Circuit 1692
Failure code [879BKA] A/C Outer Sensor Open Circuit 1693
Failure code [879BKB] A/C Outer Sensor Short Circuit 1695
Failure code [879CKA] Ventilating Sensor Open Circuit 1697
Failure code [879CKB] Ventilating Sensor Short Circuit 1698
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit 1699
Failure code [879EMC] Ventilation Damper Abnormality 1701
Failure code [879FMC] Air Mix Damper Abnormality 1702
Failure code [879GKX] Refrigerant Abnormality 1703
A-1 Troubleshooting for power supply system (Air conditioner does not operate) 1704
A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled) 1706
A-3 Troubleshooting for blower motor system (No air comes out or air flow is abnormal) 1709
A-4 Troubleshooting for FRESH/RECIRC air changeover 1711
Troubleshooting with gauge pressure 1713
Connection of service tool 1716
Precautions for disconnecting and connecting refrigerant piping 1718
Handling of compressor oil 1720
Desiccant replacement 1722
90 Diagrams and drawings 1725
Table of contents 1726
Hydraulic circuit diagram 1727
Symbols in hydraulic circuit diagram 1727
Hydraulic circuit diagram 0
Electric circuit diagram 1733
Symbols in electric circuit diagram 1733
Electrical circuit diagram 0
Electrical circuit diagram of air conditioner unit 0
UENBM00320-MA2 pdf 0
Hydraulic circuit diagram 0
Electrical circuit diagram (1/6) 0
PC228USLC-10 0
a This figure covers the equipment and devices that are unavailable as optional items in some areas 0
Electrical circuit diagram (1/6) 0
PC228USLC-10 0
Electrical circuit diagram (2/6) 0
PC228USLC-10 0
a This figure covers the equipment and devices that are unavailable as optional items in some areas 0
Electrical circuit diagram (2/6) 0
PC228USLC-10 0
Electrical circuit diagram (3/6) 0
PC228USLC-10 0
a This figure covers the equipment and devices that are unavailable as optional items in some areas 0
Electrical circuit diagram (3/6) 0
PC228USLC-10 0
Electrical circuit diagram (4/6) 0
PC228USLC-10 0
a This figure covers the equipment and devices that are unavailable as optional items in some areas 0
Electrical circuit diagram (4/6) 0
PC228USLC-10 0
Electrical circuit diagram (5/6) 0
PC228USLC-10 0
a This figure covers the equipment and devices that are unavailable as optional items in some areas 0
Electrical circuit diagram (5/6) 0
PC228USLC-10 0
Electrical circuit diagram (6/6) 0
PC228USLC-10 0
a This figure covers the equipment and devices that are unavailable as optional items in some areas 0
Electrical circuit diagram (6/6) 0
PC228USLC-10 0
Electrical circuit diagram of air conditioner unit 0
PC228USLC-10 0
a In the drawing, full line shows air conditioner wiring harness, and dashed line shows cab and chassis wiring harness (For the detail of cab and chassis harness, see “Electrical circuit diagram”) 0
a In the drawing, dot and dash line shows machine monitor wiring, and using twisted line (AVSS 0 5 x 2, pitch 45 mm or less) 0
a This figure covers the equipment and devices that are unavailable as optional items in some areas 0
Electrical circuit diagram for air conditioner unit 0
PC228USLC-10 0
UENBM00320-MA2 pdf 0
Hydraulic circuit diagram 1731
Electrical circuit diagram (1/6) 1737
PC228USLC-10 1737
a This figure covers the equipment and devices that are unavailable as optional items in some areas 1737
Electrical circuit diagram (1/6) 1737
PC228USLC-10 1737
Electrical circuit diagram (2/6) 1738
PC228USLC-10 1738
a This figure covers the equipment and devices that are unavailable as optional items in some areas 1738
Electrical circuit diagram (2/6) 1738
PC228USLC-10 1738
Electrical circuit diagram (3/6) 1739
PC228USLC-10 1739
a This figure covers the equipment and devices that are unavailable as optional items in some areas 1739
Electrical circuit diagram (3/6) 1739
PC228USLC-10 1739
Electrical circuit diagram (4/6) 1740
PC228USLC-10 1740
a This figure covers the equipment and devices that are unavailable as optional items in some areas 1740
Electrical circuit diagram (4/6) 1740
PC228USLC-10 1740
Electrical circuit diagram (5/6) 1741
PC228USLC-10 1741
a This figure covers the equipment and devices that are unavailable as optional items in some areas 1741
Electrical circuit diagram (5/6) 1741
PC228USLC-10 1741
Electrical circuit diagram (6/6) 1742
PC228USLC-10 1742
a This figure covers the equipment and devices that are unavailable as optional items in some areas 1742
Electrical circuit diagram (6/6) 1742
PC228USLC-10 1742
Electrical circuit diagram of air conditioner unit 1743
PC228USLC-10 1743
a In the drawing, full line shows air conditioner wiring harness, and dashed line shows cab and chassis wiring harness (For the detail of cab and chassis harness, see “Electrical circuit diagram”) 1743
a In the drawing, dot and dash line shows machine monitor wiring, and using twisted line (AVSS 0 5 x 2, pitch 45 mm or less) 1743
a This figure covers the equipment and devices that are unavailable as optional items in some areas 1743
Electrical circuit diagram for air conditioner unit 1743
PC228USLC-10 1743
Blank Page 1732

DESCRIPTION:

Komatsu PC228USLC-10 Hydraulic Excavator Shop Manual UENBM00320 – PDF DOWNLOAD 

SERIAL NUMBERS 1149 and up

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.

IMAGES PREVIEW OF THE MANUAL:

S.V 22/12/24