Service manual Komatsu PC228US-8, PC228USLC-8 50001 & Up | SEN05331-05

Komatsu PC228US-8, PC228USLC-8 50001 & Up SEN05331-05 (Preview)

Cover
Notice of revision
00 Index and foreword
Table of Contents
Table of Contents
Forword and general information
Safety notice
How to read the shop manual
Explanation of terms for maintenance standard
Handling of hydraulic components
Method of disconnecting and connecting push-pull type coupler
Handling of electric equipment
How to read electric wire code
Precautions when performing work
Standard tightening torque table
List of abbreviation
Conversion table
01 Specifications
Specifications
Specifications drawing
Working range diagram
Specifications
Table of weight
Table of fuel, coolant and lubricants
10 Structure and function
Engine and cooling system
Engine related parts
Cooling system
Power train system
Power train
Swing circle
Swing machinery
Final drive
Undercarriage and frame
Track frame and idler cushion
Hydraulic system
Hydraulic equipment layout drawing
Valve control
Hydraulic tank
CLSS
Main pump
Control valve
Function and operation by valve
Swing motor
Travel motor
PPC valve
Solenoid valve
Attachment circuit selector valve
Anti-drop valve
Multi-control valve
Center swivel joint
Accumulator
Work equipment
Work equipment
Electrical system
Electronic control system
Machine monitor system
KOMTRAX system
Sensors
20 Standard value table
Standard value table
Standard value table for engine
Standard value table for machine
30 Testing and adjusting
Tool for testing, adjusting and troubleshooting
Tools for testing, adjusting, and troubleshooting
Engine and cooling system
Testing engine speed
Testing intake air pressure (boost pressure)
Testing exhaust gas color
Testing and adjusting valve clearance
Testing compression pressure
Testing blowby pressure
Testing engine oil pressure
Handling fuel system parts
Releasing remaining pressure from fuel system
Testing fuel pressure
Cylinder cut-out test mode
No-injection cranking
Checking fuel delivery, return rate and leakage
Bleeding air from fuel circuit
Testing fuel circuit for leakage
Testing and adjusting air conditioner compressor belt tension
Replacing fan belt
Undercarriage and frame
Testing swing circle bearing clearance
Checking and adjusting track tension
Hydraulic system
Testing and adjusting oil pressure in work equipment, swing and travel circuits
Testing control circuit source pressure
Testing and adjusting oil pressure in pump PC control circuit
Testing and adjusting oil pressure in pump LS control circuit
Testing solenoid valve output pressure
Testing PPC valve output pressure
Adjusting play of work equipment and swing PPC vavles
Testing pump swash plate sensor
Isolating the parts causing hydraulic drift of work equipment
Releasing remaining pressure from hydraulic circuit
Testing oil leakage amount
Bleeding air from each part
Work equipment
Replacement procedure of boom angle potentiometer
Cab and its attachments
Checking cab tipping stopper
Adjusting mirrors
Angle adjustment of rear view camera
Electrical system
Speial function of machine monitor (EMMS)
Handling voltage circuit of engine controller
Preparatory work for troubleshooting of electrical system
Procedure for testing diodes
Pm clinic
Pm clinic service
40 Troubleshooting
General information on troubleshooting
Points to remember when troubleshooting
Sequence of events in troubleshooting
Checks before troubleshooting
Classification and procedures for troubleshooting
Failure codes table
Symptom and troubleshooting numbers
Information in troubleshooting table
Troubleshooting method for open circuit in wiring harness of pressure sensor system
Connector list and layout
Connection table for connector pin numbers
T- branch box and T- branch adapter table
Fuse location table
Troubleshooting by failurecode
Failure code [989L00] Engine Controller Lock Caution 1
Failure code [989M00] Engine Controller Lock Caution 2
Failure code [989N00] Engine Controller Lock Caution 3
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] Hyd Oil Overheat
Failure code [CA111] ECM 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(L#1) Open/Short Error
Failure code [CA323] Inj #5 (L#5) Open/Short Error
Failure code [CA324] Inj #3(L#3) Open/Short Error
Failure code [CA325] Inj #6 (L#6) Open/Short Error
Failure code [CA331] Inj #2(L#2) Open/Short Error
Failure code [CA332] Inj #4(L#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] Battery Voltage Low Error
Failure code [CA442] 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 Open Circuit Error
Failure code [CA2556] Grid Htr Relay Short Circuit Error
Failure code [D110KB] Battery Relay Drive Short Circuit
Failure code [D19JKZ] Personal Code Relay Abnormality
Failure code [D862KA] GPS Antenna Open Circuit
Failure code [DA22KK] Pump Solenoid Power Low Error
Failure code [DA25KP] 5V Sensor1 Power Abnormality
Failure code [DA26KP] 5V Sensor2 Power Abnormality
Failure code [DA29KQ] Model Selection Abnormality
Failure code [DA2RMC] CAN Discon (Pump Con Detected)
Failure code [DAF8KB] Camera Power Supply Short Circuit
Failure code [DAFGMC] GPS Module Error
Failure code [DAFRMC] CAN Discon (Monitor Detected)
Failure code [DGH2KB] Hyd Oil Sensor Short
Failure code [DHPAMA] Pump Press Sensor Abnormality
Failure code [DHPBMA] R Pump Press Sensor Abnormality
Failure code [DHS3MA] Arm IN PPC Sen. Abnormality
Failure code [DHS4MA] Bucket CURL PPC Press Sensor Abnormality
Failure code [DHS8MA] Boom RAISE PPC Press Sensor Abnormality
Failure code [DHSAMA] Swing RH PPC Press Sensor Abnomality
Failure code [DHSBMA] Swing LH PPC Press Sensor Abnomality
Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality
Failure code [DHSFMA] Travel FW L PPC Press Sensor Abnormality
Failure code [DHSGMA] Travel FW R PPC Press Sensor Abnormality
Failure code [DHSHMA] Travel BW L PPC Press Sensor Abnormality
Failure code [DHSJMA] Travel BW R PPC Press Sensor Abnormality
Failure code [DHX1MA] Overload Sensor Abnormality
Failure code [DKA0KA] Boom Angle Sensor Open Circuit
Failure code [DKA0KB] Boom Angle Sensor Power Short Circuit
Failure code [DKA0PH] Boom Angle Sensor Install Abnormality
Failure code [DKR0MA] F pump S/P sensor Abnormality
Failure code [DKR1MA] R pump S/P sensor Abnormality
Failure code [DV20KB] Travel Alarm Short Circuit
Failure code [DW43KA] Travel Speed Sol Open Circuit
Failure code [DW43KB] Travel Speed Sol Short Circuit
Failure code [DW45KA] Swing Brake Sol Open Circuit
Failure code [DW45KB] Swing Brake Sol Short Circuit
Failure code [DW4GKA] Boom Slow Down Sol. Disc.
Failure code [DW4GKB] Boom Slow Down Sol. Short Circuit
Failure code [DW4WKA] Cancel Bucket Dump Open Circuit
Failure code [DW4WKB] Cancel Bucket Dump Short Circuit
Failure code [DW91KA] Travel Junction Sol. Disc.
Failure code [DW91KB] Travel Junction Sol. S/C
Failure code [DWA2KA] Attachment Sol Open Circuit
Failure code [DWA2KB] Attachment Sol Short Circuit
Failure code [DWK0KA] 2-stage Relief Sol Open Circuit
Failure code [DWK0KB] 2-stage Relief Sol Short Circuit
Failure code [DXA8KA] PC-EPC (F) Sol Open Circuit
Failure code [DXA8KB] PC-EPC (F) Sol Short Circuit
Failure code [DXA9KA] PC-EPC (R) Sol Open Circuit
Failure code [DXA9KB] PC-EPC (R) Sol Short Circuit
Failure code [DXE0KA] LS-EPC Sol Open Circuit
Failure code [DXE0KB] LS-EPC Sol Short Circuit
Failure code [DXE4KA] Service Current EPC Disc.
Failure code [DXE4KB] Service Current EPC S/C
Failure code [DXE5KA] Merge-divider Main Sol Open Circuit
Failure code [DXE5KB] Merge-divider Main Sol Short Circuit
Failure code [DXE6KA] Merge-divider LS Sol Open Circuit
Failure code [DXE6KB] Merge-divider LS Sol Short Circuit
Failure code [DY20KA] Wiper Working Abnormality
Failure code [DY20MA] Wiper Parking Abnormality
Failure code [DY2CKA] Washer drive discon
Failure code [DY2CKB] Washer drive short
Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit
Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit
Troubleshooting of electrical system (E-mode)
E-1 Engine does not start (Engine does not crank)
E-2 Preheater does not operate
E-3 When starting switch is turned to ON position, machine monitor displays nothing
E-4 When starting switch is turned to ON position (before starting engine), basic check monitor lights up.
E-5 Precaution monitor lights up while engine is running
E-6 Emergency stop monitor lights up while engine is running
E-7 Fuel level gauge does not indicate correctly
E-8 Engine coolant temperature gauge does not indicate correctly
E-9 Hydraulic oil temperature gauge does not indicate correctly
E-10 Displays on machine monitor are different from those for actual machine
E-11 Some areas of machine monitor screen are not displayed
E-12 Function switch does not operate
E-13 Automatic warm-up system does not operate (in cold season)
E-14 Auto-decelerator does not operate properly
E-15 Working mode does not change
E-16 Travel speed does not change
E-17 Alarm buzzer cannot be canceled
E-18 When starting switch is turned OFF, service meter is not displayed40
E-19 Service mode cannot be selected
E-20 Any of work equipment, swing and travel do not operate or cannot be locked
E-21 Swing brake does not operate properly
E-22 One-touch power maximizing function does not operate properly
E-23 Travel alarm does not sound or does not stop sounding
E-24 Horn does not sound or does not stop
E-25 Windshield wiper and window washer do not operate
E-26 BOOM LOWER indicator is not displayed properly with monitoring function
E-27 ARM OUT indicator is not displayed properly with monitoring function
E-28 ARM IN indicator is not displayed properly with monitoring function
E-29 BOOM RAISE indicator is not displayed properly with monitoring function
E-30 BUCKET CURL indicator is not displayed properly with monitoring function
E-31 BUCKET DUMP indicator is not displayed properly with monitoring function
E-32 SWING indicator is not displayed properly with monitoring function
E-33 TRAVEL indicator is not displayed properly with monitoring function
E-34 ATTACHMENT indicator is not displayed properly with monitoring function
E-35 Attachment hydraulic circuit cannot be changed
E-36 KOMTRAX system does not operate properly
Troubleshooting of hydraulic and mechanical system (H-mode)
Information in troubleshooting table
System chart for hydraulic and mechanical systems
Failure mode and cause table
H- 1 All of work equipment, swing and travel work slow or lack power
H- 2 Engine speed lowers significantly or engine stalls
H- 3 Any of work equipment,swing and travel does not work
H- 4 Unusual sound is heard from around hydraulic pump
H- 5 Fine control performance or response is poor
H- 6 Boom operation lacks speed or power
H- 7 Arm operation lacks speed or power
H- 8 Bucket operation lacks speed or power
H- 9 Work equipment does not move in single operation
H-10 Hydraulic drift of work equipment is large
H-11 Time lag of work equipment is large
H-12 Other work equipment moves when one of work equipment is relieved
H-13 One-touch power maximizing function does not work
H-14 In combined operation of work equipment , equipment having heavier load moves slower.
H-15 In combined operation of swing and boom RAISE, boom rising speed is low
H-16 Travel speed drops largely in combined operation of swing and travel
H-17 Machine does not travel straight
H-18 Travel speed is low
H-19 Machine is hard to steer or travel power is low
H-20 Travel speed does not change, or travel speed is too low or high
H-21 One of tracks does not run
H-22 Upper structure does not swing
H-23 Swing acceleration is poor or swing speed is low
H-24 Upper structure overruns excessively when it stops swinging
H-25 Shock is large when upper structure stops swinging
H-26 Large unusual noise is heard when upper structure stops swinging40
H-27 Swing drift on a slope is large
H-28 Attachment circuit cannot be changed
H-29 Oil flow in attachment circuit cannot be controlled
Troubleshooting of engine (S-mode)
Method of using troubleshooting chart
S-1 Startability is poor
S-2 Engine does not start
S-3 Engine does not pick up smoothly
S-4 Engine stops during operation
S-5 Engine runs rough or is unstable
S-6 Engine 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 early
S-10 Fuel consumption is excessive
S-11 Oil is in coolant (or coolant spurts or coolant level goes down)
S-12 Oil pressure drops
S-13 Oil level rises (coolant or fuel in oil)
S-14 Coolant temperature rises too high (overheating)
S-15 Unusual noise is made
S-16 Vibration is excessive
50 Disassembly and assembly
General information on disassembly and assembly
How to read Disassembly and Assembly
Coating materials list
Special tools list
Sketches of special tools
Engine and cooling system
Removal and installation of fuel supply pump assembly
Removal and installation of fuel injector assembly
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 engine assembly
Removal and installation of engine front seal
Removal and installation of engine rear seal
Removal and installation of fuel cooler assembly
Removal and installation of fuel tank assembly
Power train
Removal and installation of travel motor and final drive assembly
Disassembly and assembly of final drive assembly
Removal and installation of swing motor and swing machinery assembly
Disassembly and assembly of swing machinery assembly
Removal and installation of swing circle assembly
Undercarriage and frame
Separation and connection of track shoe assembly
Removal and installation of idler and idler cushion assembly
Disassembly and assembly of idler assembly
Disassembly and assembly of idler cushion assembly
Disassembly and assembly of track roller assembly
Disassembly and assembly of carrier roller assembly
Removal and installation of revolving frame assembly
Removal and installation of counterweight assembly
Removal and installation of maintenance counterweight assembly
Hydraulic system
Removal and installation of center swivel joint assembly
Disassembly and assembly of center swivel joint assembly
Removal and installation of hydraulic tank assembly
Removal and installation of main pump assembly
Removal and installation of main pump input shaft oil seal
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
Work equipment
Removal and installation of work equipment assembly
Removal and installation of antidropvalve assembly for boom
Removal and installation of antidropvalve assembly for arm
Disassembly and assembly ofanti-drop valve assembly
Disassembly and assembly of work equipment cylinder assembly
Cab and its attachments
Removal and installation of operator’s cab assembly
Removal and installation of operator’s cab glass (adhered window glass)
Removal and installation of front window assembly
Removal and installation of floor frame assembly
Removal and installation of air conditioner unit assembly
Electrical system
Removal and installation of air conditioner compressor assembly
Removal and installation of air conditioner condenser assembly
Removal and installation of engine controller assembly
Removal and installation of pump controller assembly
Removal and installation of machine monitor assembly
Removal and installation of pump swash plate sensor
Removal and installation of KOMTRAX terminal assembly
60 Maintenance standard
Engine and cooling system
Engine mount
Cooling system
Power train
Swing circle
Swing machinery
Final drive
Sprocket
Undercarriage and frame
Track frame and idler cushion
Idler
Track roller
Carrier roller
Track shoe
Hydraulic system
Hydraulic tank
Main pump
Control valve
Swing motor
Travel motor
PPC valve
Solenoid valve
Attachment circuit selector valve
Anti-drop valve
Center swivel joint
Work equipment
Work equipment
Dimensions of components
Work equipment cylinder
80 Appendix
Air conditioner
Precautions for refrigerant
Air conditioner component
Configuration and function of refrigeration cycle
Outline of refrigeration cycle
Air conditioner unit
Air conditioner controller
Compressor
Condenser and Modulator
Sensor
Procedure for testing and troubleshooting
Circuit diagram and arrangement of connector pins
System diagram
Detail of air conditioner unit
Parts and connectors layout
Testing air leakage (duct)
Testing with self-diagnosis function
Testing vent (mode) changeover
Testing FRESH/RECIRC air changeover
Testing inner sensor
Testing outer sensor
Testing sunlight sensor
Testing (dual) pressure switch for refrigerant
Testing relays
Troubleshooting chart 1
Troubleshooting chart 2
Information in troubleshooting table
Troubleshooting for power supply and CAN communication system (Air conditioner does not operate)
Troubleshooting for compressor and refrigerant system (Air is not cooled)
Troubleshooting for blower motor system (No air comes out or air flow is abnormal)
Troubleshooting for temperature control
Troubleshooting for vent (mode) changeover
Troubleshooting for FRESH/RECIRC air changeover
Troubleshooting for temperature sensor system
Troubleshooting with gauge pressure
Connection of service tool
Precautions for disconnecting and connecting air conditioner piping
Handling of compressor oil
Desiccant replacement procedure
90 Diagrams and drawings
Hydraulic circuit diagram
Symbols used in hydraulic circuit diagrams
Hydraulic circuit diagram (1/4)
Hydraulic circuit diagram (2/4)
Hydraulic circuit diagram (3/4)
Hydraulic circuit diagram (4/4)
Electrical circuit diagram
Symbols used in electric circuit diagrams
Electrical circuit diagram
Air conditioner electrical circuit diagram