Komatsu PC228US-3E0, PC228USLC-3E0 40001 & Up UEN01418-02 (Preview)
00 Index and foreword
Composition of shop manual
Table of contents
00 Index and foreword
Foreword and general information
Safety notice
How to read the shop manual
Explanation of terms for maintenance standard
Handling electric equipment and hydraulic component
How to read electric wire code
Method of disassembling and connecting push-pull type coupler
Standard tightening torque table
Conversion table
01 Specification
Specification and technical data
Specification dimension drawings
Working range diagram
Specifications
Weight table
Table of fuel, coolant and lubricants
10 Structure, function and maintenance standard
Engine and cooling system
Engine related parts
Radiator, oil cooler, aftercooler and fuel cooler
10 Structure, function and maintenance standard
Power train
Power train
Final drive
Swing machinery
Swing circle
10 Structure, function and maintenance standard
Undercarriage and frame
Track frame
Idler
Carrier roller
Track roller
Track shoe
10 Structure, function and maintenance standard
Hydraulic system, Part 1
Hydraulic equipment layout drawing
Hydraulic tank
Hydraulic pump
10 Structure, function and maintenance standard
Hydraulic system, Part 2
Control valve
CLSS
Functions and operation by valve
Merge-divider valve
Attachment circuit selector valve
Hydraulic drift prevention valve
10 Structure, function and maintenance standard
Hydraulic system, Part 3
Valve control
PPC valve
PPC Accumulator
Return oil filter
Center swivel joint
Travel motor
Swing motor
Hydraulic cylinder
10 Structure, function and maintenance standard
Work equipment
Work equipment
Dimensions of components
10 Structure, function and maintenance standard
Cab and its attachments
Air conditioner piping
10 Structure, function and maintenance standard
Electrical system
Engine control
Electrical control system
Monitor system
Sensor
KOMTRAX terminal system
20 Standard value table
Standard service value table
Standard value table for engine related parts
Standard value table for chassis
Flow control characteristics of PC valve (STD)
30 Testing and adjusting
Testing and adjusting, Part 1
Tools for testing, adjusting, and troubleshooting
Measuring engine speed
Measuring intake air pressure (boost pressure)
Checking exhaust gas color
Adjusting valve clearance
Measuring compression pressure
Measuring blow-by pressure
Measuring engine oil pressure
Handling fuel system parts
Releasing residual pressure from fuel system
Measuring fuel pressure
Measuring fuel return rate and leakage
Bleeding air from fuel circuit
Checking fuel circuit for leakage
Checking and adjusting air conditioner compressor belt tension
30 Testing and adjusting
Testing and adjusting, Part 2
Measurement of clearance in swing circle bearings
Checking and adjusting track shoe tension
Inspection and adjustment of hydraulic oil pressure in hydraulic circuit for work equipment, swing and travel
Measurement of control circuit oil pressure
Inspection and adjustment of pump PC control circuit oil pressure
Inspection and adjustment of pump LS control circuit oil pressure
Measurement of solenoid valve output pressure
Measurement of PPC valve output pressure
Adjustment of work equipment and swing PPC valve
Inspection of locations of hydraulic drift of work equipment
Release of residual pressure from hydraulic circuit
Measuring oil leakage
Bleeding air from each part
Procedure for replacing boom angle potentiometer
Inspection procedures for diode
Adjusting mirrors
30 Testing and adjusting
Testing and adjusting, Part 3
Special functions of machine monitor
Handling voltage circuit of engine controller
Procedure for turning on KOMTRAX terminal
KOMTRAX terminal lamp indications
Preparation work for troubleshooting of electrical system
40 Troubleshooting
Failure code table and fuse locations
Failure code table
Fuse locations
40 Troubleshooting
General information on troubleshooting
Points to remember when troubleshooting
Sequence of events in troubleshooting
Checks before troubleshooting
Classification and troubleshooting steps
Information in troubleshooting table
Possible problems and troubleshooting No.
Wiring table for connector pin numbers
T-adapter box and T-adapter table
40 Troubleshooting
Troubleshooting by failure code (Display of code), Part 1
Failure code [A000N1] Eng. Hi Out of Std
Failure code [AA10NX] Air cleaner Clogging
Failure code [AB00KE] Charge Voltage Low
Failure code [B@BAZG] Eng. Oil Press. Low
Failure code [B@BAZK] Eng. Oil Level Low
Failure code [B@BCNS] Eng. Water Overheat
Failure code [B@BCZK] Eng. Water Level Low
Failure code [B@HANS] Hydr Oil Overheat
Failure code [CA111] EMC Critical Internal Failure
Failure code [CA115] Eng Ne and Bkup Speed Sens Error
Failure code [CA122] Chg Air Press Sensor High Error
Failure code [CA123] Chg Air Press Sensor Low Error
Failure code [CA131] Throttle Sensor High Error
Failure code [CA132] Throttle Sensor Low Error
Failure code [CA144] Coolant Temp Sens High Error
Failure code [CA145] Coolant Temp Sens Low Error
Failure code [CA153] Chg Air Temp Sensor High Error
Failure code [CA154] Chg Air Temp Sensor Low Error
Failure code [CA155] Chg Air Temp High Speed Derate
Failure code [CA187] Sens Supply 2 Volt Low Error
Failure code [CA221] Ambient Press Sens High Error
Failure code [CA222] Ambient Press Sens Low Error
Failure code [CA227] Sens Supply 2 Volt High Error
Failure code [CA234] Eng. Overspeed
Failure code [CA238] Ne Speed Sens Supply Volt Error
Failure code [CA271] IMV/PCV1 Short Error
Failure code [CA272] IMV/PCV1 Open Error
Failure code [CA322] Inj #1 Open/Short Error
Failure code [CA323] Inj #5 Open/Short Error
Failure code [CA324] Inj #3 Open/Short Error
40 Troubleshooting
Troubleshooting by failure code (Display of code), Part 2
Failure code [CA325] Inj #6 Open/Short Error
Failure code [CA331] Inj #2 Open/Short Error
Failure code [CA332] Inj #4 Open/Short Error
Failure code [CA342] Calibration Code Incompatibility
Failure code [CA351] Injectors Drive Circuit Error
Failure code [CA352] Sens Supply 1 Volt Low Error
Failure code [CA386] Sens Supply 1 Volt High Error
Failure code [CA428] Water in Fuel Sensor High Error
Failure code [CA429] Water in Fuel Sensor Low Error
Failure code [CA435] Eng Oil Press Sw Error
Failure code [CA441] Engine Controller Battery Voltage Low Error
Failure code [CA442] Engine Controller Battery Voltage High Error
Failure code [CA449] Rail Press Very High Error
Failure code [CA451] Rail Press Sensor High Error
Failure code [CA452] Rail Press Sensor Low Error
Failure code [CA488] Chg Air Temp High Torque Derate
Failure code [CA553] Rail Press High Error
Failure code [CA559] Rail Press Low Error
Failure code [CA689] Eng Ne Speed Sensor Error
Failure code [CA731] Eng Bkup Speed Sens Phase Error
Failure code [CA757] All Continuous Data Lost Error
Failure code [CA778] Eng Bkup Speed Sensor Error
Failure code [CA1633] KOMNET Datalink Timeout Error
Failure code [CA2185] Throt Sens Sup Volt High Error
Failure code [CA2186] Throt Sens Sup Volt Low Error
Failure code [CA2249] Rail Press Very Low Error
Failure code [CA2311] IMV Solenoid Error
Failure code [CA2555] Grid Htr Relay Volt High Error
Failure code [CA2556] Grid Htr Relay Volt Low Error
40 Troubleshooting
Troubleshooting by failure code (Display of code), Part 3
Failure code [D110KB] Battery Relay Drive S/C
Failure code [D196KA] Service Return Relay Disc.
Failure code [D196KB] Service Return Relay S/C
Failure code [DA22KK] Pump Solenoid Power Low Error
Failure code [DA25KP] Press. Sensor Power Abnormality
Failure code [DA2RMC] Pump Comm. Abnormality
Failure code [DA2SKQ] Model Selection Abnormality
Failure code [DAFRMC] Monitor Comm. Abnormality
Failure code [DGH2KB] Hydr Oil Sensor Short
Failure code [DHPAMA] F Pump Press Sensor Abnormality
Failure code [DHPBMA] R Pump Press Sensor Abnormality
Failure code [DHSAMA] Sw RH PPC Press Sen. Abnormality
Failure code [DHSBMA] Sw LH PPC Press Sen. Abnormality
40 Troubleshooting
Troubleshooting by failure code (Display of code), Part 4
Failure code [DW43KA] Travel Speed Sol. Disc.
Failure code [DW43KB] Travel Speed Sol. S/C
Failure code [DW45KA] Swing Brake Sol. Disc.
Failure code [DW45KB] Swing Brake Sol. S/C
Failure code [DW91KA] Travel Junction Sol. Disc.
Failure code [DW91KB] Travel Junction Sol. S/C
Failure code [DW4GKA] Disconnection in boom RAISE throttle EPC solenoid
Failure code [DW4GKB] Short circuit in boom RAISE throttle EPC solenoid
Failure code [DWJ0KA] Merge-divider Sol. Disc
Failure code [DWJ0KB] Merge-divider Sol. S/C
Failure code [DWK0KA] 2-stage Relief Sol. Disc.
Failure code [DWK0KB] 2-stage Relief Sol. S/C
Failure code [DXA0KA] PC-EPC Sol. Disc.
Failure code [DXA0KB] PC-EPC Sol. S/C
Failure code [DXE0KA] LS-EPC Sol. Disc.
Failure code [DXE0KB] LS-EPC Sol. S/C
Failure code [DXE4KA] Service Current EPC Disc.
Failure code [DXE4KB] Service Current EPC S/C
Failure code [DY20KA] Wiper Working Abnormality
Failure code [DY20MA] Wiper Parking Abnormality
Failure code [DY2CKB] Washer Drive S/C
Failure code [DY2DKB] Wiper Drive (For) S/C
Failure code [DY2EKB] Wiper Drive (Rev) S/C
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
Before carrying out troubleshooting of electrical system
Information contained in troubleshooting table
E-1 Engine does not start
E-2 Auto-decelerator does not operate
E-3 Automatic warming-up system does not operate
E-4 Preheater does not operate
E-5 All work equipment, swing, and travel mechanism do not move
E-6 Power maximizing function does not operate
E-7 Machine monitor does not display at all
E-8 Machine monitor does not display some items
E-9 Contents of display by machine monitor are different from applicable machine
E-10 Fuel level monitor was lighted in red while engine running
E-11 Engine coolant temperature gauge does not indicate normally
E-12 Hydraulic oil temperature gauge does not indicate normally
E-13 Fuel level gauge does not indicate normally
E-14 Swing lock monitor does not indicate normally
E-15 When monitor switch is operated, monitor displays nothing
E-16 Windshield wiper and window washer do not operate
E-17 Monitoring function fails to display “boom raise” normally
E-18 Monitoring function fails to display “boom lower” normally
E-19 Monitoring function fails to display “arm IN” normally
E-20 Monitoring function fails to display “arm OUT” normally
E-21 Monitoring function fails to display “bucket CURL” normally
E-22 Monitoring function fails to display “bucket DUMP” normally
E-23 Monitoring function fails to display “swing left” normally
E-24 Monitoring function fails to display “swing right” normally
E-25 Monitoring function fails to display “travel” normally
E-26 Monitoring function fails to display “travel differential pressure” normally
E-27 Monitoring function fails to display “service” normally
E-28 KOMTRAX system does not operate normally
E-29 Air conditioner does not operate
E-30 Travel alarm does not sound or does not stop sounding
E-31 Horn does not sound
E-32 Attachment circuit does not change
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-mode)
System chart for hydraulic and mechanical systems
Information contained in troubleshooting table
H-1 All work equipment lack power, or travel and swing speeds are slow
H-2 Engine speed sharply drops or engine stalls
H-3 No work equipment, travel or swing move
H-4 Abnormal noise is heard from around hydraulic pump
H-5 Auto-decelerator does not work
H-6 Fine control mode does not function
H-7 Boom moves slowly or lacks power
H-8 Arm moves slowly or lacks power
H-9 Bucket moves slowly or lacks power
H-10 Work equipment does not move in its single operation
H-11 Work equipment has a bit too large hydraulic drift
H-12 Work equipment has big time lag
H-13 Other work equipment moves when relieving single circuit
H-14 One-touch power max. switch does not operate
H-15 In compound operation, work equipment with larger load moves slowly
H-16 In swing + boom RAISE operation, boom moves slowly
H-17 In swing + travel, travel speed drops sharply
H-18 Machine swerves in travel
H-19 Machine travels slowly
H-20 Machine cannot be easily steered or lacks power
H-21 Travel speed does not shift, or it is slower or faster than preset speed
H-22 Track shoe does not turn (on one side only)
H-23 Machine does not swing
H-24 Swing acceleration is poor, or swing speed is slow
H-25 Excessive overrun when stopping swing
H-26 There is big shock when stopping swing
H-27 There is big abnormal noise caused when stopping swing
H-28 Swing natural drift is too big
H-29 Attachment circuit does not change
H-30 Flow rate in attachment circuit cannot be adjusted
40 Troubleshooting
Troubleshooting of engine (S-mode)
Method of using troubleshooting chart
S-1 Starting performance is poor
S-2 Engine does not start
S-3 Engine does not pick up smoothly
S-4 Engine stops during operations
S-5 Engine does not rotate smoothly
S-6 Engine lack output (or lacks power)
S-7 Exhaust smoke is black (incomplete combustion)
S-8 Oil consumption is excessive (or exhaust smoke is blue)
S-9 Oil becomes contaminated quickly
S-10 Fuel consumption is excessive
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)
S-12 Oil pressure drops
S-13 Oil level rises (Entry of coolant/fuel)
S-14 Coolant temperature becomes too high (overheating)
S-15 Abnormal noise is made
S-16 Vibration is excessive
50 Disassembly and assembly
General information on disassembly and assembly
How to read this manual
Coating materials list
Special tool list
Sketches of special tools
50 Disassembly and assembly
Engine and cooling system
Removal and installation of fuel supply pump assembly
Removal and installation of fuel injector assembly
Removal and installation of engine front seal
Removal and installation of engine rear seal
Removal and installation of cylinder head assembly
Removal and installation of radiator assembly
Removal and installation of hydraulic oil cooler assembly
Removal and installation of aftercooler assembly
Removal and installation of fuel cooler assembly
Removal and installation of engine assembly
Removal and installation of fuel tank assembly
50 Disassembly and assembly
Power train
Removal and installation of travel motor and final drive assembly
Disassembly and assembly of travel motor and final drive assembly
Removal and installation of swing motor and swing machinery assembly
Disassembly and assembly of swing motor and swing machinery assembly
Removal and installation of swing circle assembly
50 Disassembly and assembly
Undercarriage and frame
Disassembly and assembly of track roller assembly
Disassembly and assembly of idler assembly
Disassembly and assembly of recoil spring
Expansion and installation of track shoe assembly
Removal and installation of revolving frame
Removal and installation of counterweight assembly
Removal and installation of maintenance counterweight (at rear of engine)
Removal and installation of maintenance counterweight assembly (above pump)
50 Disassembly and assembly
Hydraulic system
Removal and installation of center swivel joint assembly
Disassembly and assembly of center swivel joint
Removal and installation of hydraulic tank assembly
Removal and installation of work equipment pump
Removal and installation of control valve assembly
Disassembly and assembly of control valve assembly
Disassembly and assembly of work equipment PPC valve assembly
Disassembly and assembly of travel PPC valve assembly
Disassembly and assembly of hydraulic cylinder assembly
50 Disassembly and assembly
Work equipment
Removal and installation of work equipment assembly
50 Disassembly and assembly
Cab and its attachments
Removal and installation of operator’s cab assembly
Removal and installation of operator’s cab glass (Stuck glass)
Removal and installation of front window assembly
Removal and installation of floor frame assembly
50 Disassembly and assembly
Electrical system
Removal and installation of air conditioner compressor assembly
Removal and installation of air conditioner condenser assembly
Removal and installation of air conditioner unit assembly
Removal and installation of machine monitor assembly
Removal and installation of pump controller assembly
Removal and installation of engine controller assembly
Removal and installation of KOMTRAX communication modem assembly
90 Diagrams and drawings
Hydraulic diagrams and drawings
Hydraulic circuit diagram
90 Diagrams and drawings
Electrical diagrams and drawings
Electrical circuit diagram
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