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Komatsu PC228US-3E0, PC228USLC-3E0 Hydraulic Excavator Service Manual

952 pages · Publication SEN01418-10

$99.61
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Models
PC228US-3E0, PC228USLC-3E0
Serial coverage
40001 and up
Manual type
Service Manual
Pages
952
Publication
SEN01418-10
Condition
Brand new
Komatsu PC228US-3E0, PC228USLC-3E0 Hydraulic Excavator Service Manual, publication SEN01418-10

What's inside

From the manual's own table of contents: 181 sections, 331 entries. See sample pages (PDF, 839 KB)

Composition of shop manual
Safety notice
How to read the shop manual
Explanation of terms for maintenance standard
Handling of electric equipment and hydraulic component
Handling of connectors newly used for engines
How to read electric wire code
Precautions when carrying out operation
Method of disassembling and connecting push-pull type coupler
Standard tightening torque table
Conversion table
Specification dimension drawings
Working range diagram
Specifications
Weight table
Table of fuel, coolant and lubricants
Engine related parts
Radiator, oil cooler, aftercooler and fuel cooler
Power train
Final drive
Swing machinery
Swing circle
Track frame
Idler
Show all 181 sections
Carrier roller
Track roller
Track shoe
Hydraulic equipment layout drawing
Hydraulic tank
Hydraulic pump
Control valve
CLSS
Functions and operation by valve
Merge-divider valve
Attachment circuit selector valve
Hydraulic drift prevention valve
Valve control
PPC valve
PPC Accumulator45 topics
  • Return oil filter
  • Center swivel joint
  • Travel motor
  • Swing motor
  • Hydraulic cylinder
  • Dimensions of components
  • Air conditioner piping
  • Engine control
  • Electrical control system
  • Monitor system
  • Sensor
  • KOMTRAX system
  • Standard value table for engine related parts
  • Standard value table for chassis
  • Tools for testing, adjusting, and troubleshooting
  • Sketches of special tools
  • Testing engine speed
  • Testing intake air pressure (boost pressure)
  • Checking exhaust gas color
  • Adjusting valve clearance
  • Testing compression pressure
  • Testing blow-by pressure
  • Testing engine oil pressure
  • Handling fuel system parts
  • Releasing residual pressure from fuel system
  • Testing fuel pressure
  • Reduced cylinder mode operation
  • No-injection cranking
  • Testing fuel delivery, return rate and leakage
  • Bleeding air from fuel circuit
  • Checking fuel circuit for leakage
  • Checking and adjusting air conditioner compressor belt tension
  • Replacement of fan belt
  • Testing clearance in swing circle bearings
  • Checking and adjusting track shoe tension
  • swing and travel
  • Testing control circuit oil pressure
  • Testing and adjusting pump PC control circuit oil pressure
  • Testing and adjusting pump LS control circuit oil pressure
  • Testing solenoid valve output pressure
  • Testing PPC valve output pressure
  • Adjusting play of work equipment and swing PPC valves
  • Inspection of locations of hydraulic drift of work equipment
  • Release of residual pressure from hydraulic circuit
  • Testing oil leakage
Bleeding air from each part
Procedure for replacing boom angle potentiometer
Inspection procedures for diode
Adjusting mirrors
Special functions of machine monitor
Handling voltage circuit of engine controller
Starting KOMTRAX terminal operations
Indicator lamps of KOMTRAX terminal
Preparation work for troubleshooting of electrical system
Pm-clinic service
Failure code table
Fuse locations
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
Connection table for connector pin numbers
T- branch box and T- branch adapter table
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] 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 (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 Error55 topics
  • 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 Volt High Error
  • Failure code [CA2556] Grid Htr Relay Volt Low Error
  • Failure code [D110KB] Battery Relay Drive Short Circuit
  • 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] 5V Sensor 1 Power Abnormality
  • Failure code [DA2RMC] CAN Discon (Pump Con Detected)
  • Failure code [DA2SKQ] Model Selection Abnormality
  • Failure code [DAFRMC] CAN Discon (Monitor Detected)
  • Failure code [DGH2KB] Hyd 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
  • 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 [DW91KA] Travel Junction Sol Open Circuit
  • Failure code [DW91KB] Travel Junction Sol Short Circuit
  • Failure code [DW4GKA] Boom Slow Down Sol. Disc
  • Failure code [DW4GKB] Boom Slow Down Sol. S/C
  • Failure code [DWJ0KA] Merge-divider Sol Open Circuit
  • Failure code [DWJ0KB] Merge-divider Sol Short Circuit
  • Failure code [DWK0KA] 2-stage Relief Sol Open Circuit
  • Failure code [DWK0KB] 2-stage Relief Sol Short Circuit
  • Failure code [DXA0KA] PC-EPC Sol Open Circuit
  • Failure code [DXA0KB] PC-EPC 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 Open Circuit
Failure code [DXE4KB] Service Current EPC Short Circuit
Failure code [DY20KA] Wiper Working Abnormality
Failure code [DY20MA] Wiper Parking Abnormality
Failure code [DY2CKB] Washer Drive Short Circuit
Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit
Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit
Before carrying out troubleshooting of electrical system
Information contained in troubleshooting table
Engine does not start
Auto-decelerator does not operate
Automatic warming-up system does not operate
Preheater does not operate
All work equipment, swing, and travel mechanism do not move
Power maximizing function does not operate
Machine monitor does not display at all
Machine monitor does not display some items
Contents of display by machine monitor are different from applicable machine
Fuel level monitor was lighted in red while engine running
Engine coolant temperature gauge does not indicate normally
Hydraulic oil temperature gauge does not indicate normally
Fuel level gauge does not indicate normally
Swing lock monitor does not indicate normally
When monitor switch is operated, monitor displays nothing
Windshield wiper and window washer do not operate
Monitoring function fails to display “boom raise” normally
Monitoring function fails to display “boom lower” normally
Monitoring function fails to display “arm IN” normally
Monitoring function fails to display “arm OUT” normally
Monitoring function fails to display “bucket CURL” normally
Monitoring function fails to display “bucket DUMP” normally
Monitoring function fails to display “swing left” normally
Monitoring function fails to display “swing right” normally
Monitoring function fails to display “travel” normally
Monitoring function fails to display “travel differential pressure” normally
Monitoring function fails to display “service” normally
The KOMTRAX system does not work properly
Air conditioner does not operate
Travel alarm does not sound or does not stop sounding
Horn does not sound
Attachment circuit does not change
System chart for hydraulic and mechanical systems
All work equipment lack power, or travel and swing speeds are slow
Engine speed sharply drops or engine stalls
No work equipment, travel or swing move
Abnormal noise is heard from around hydraulic pump
Auto-decelerator does not work
Fine control mode does not function
Boom moves slowly or lacks power
Arm moves slowly or lacks power
Bucket moves slowly or lacks power
Work equipment does not move in its single operation
Work equipment has a bit too large hydraulic drift
Work equipment has big time lag50 topics
  • Other work equipment moves when relieving single circuit
  • One-touch power max. switch does not operate
  • In compound operation, work equipment with larger load moves slowly
  • In swing + boom RAISE operation, boom moves slowly
  • In swing + travel, travel speed drops sharply
  • Machine swerves in travel
  • Machine travels slowly
  • Machine cannot be easily steered or lacks power
  • Travel speed does not shift, or it is slower or faster than preset speed
  • Track shoe does not turn (on one side only)
  • Machine does not swing
  • Swing acceleration is poor, or swing speed is slow
  • Excessive overrun when stopping swing
  • There is big shock when stopping swing
  • There is big abnormal noise caused when stopping swing
  • Swing natural drift is too big
  • Attachment circuit does not change
  • Flow rate in attachment circuit cannot be adjusted
  • Method of using troubleshooting chart
  • Starting performance is poor
  • Engine does not start
  • Engine does not pick up smoothly
  • Engine stops during operations
  • Engine does not rotate smoothly
  • Engine lack output (or lacks power)
  • Exhaust smoke is black (incomplete combustion)
  • Oil consumption is excessive (or exhaust smoke is blue)
  • Oil becomes contaminated quickly
  • Fuel consumption is excessive
  • Oil is in coolant (or coolant spurts back or coolant level goes down)
  • Oil pressure drops
  • Oil level rises (Entry of coolant/fuel)
  • Coolant temperature becomes too high (overheating)
  • Abnormal noise is made
  • Vibration is excessive
  • How to read this manual
  • Coating materials list
  • Special tools list
  • 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
  • Removal and installation of travel motor and final drive assembly
Disassembly and assembly of final drive assembly
Removal and installation of swing machinery assembly
Disassembly and assembly of swing machinery assembly
Removal and installation of swing circle assembly
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)
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
Removal and installation of work equipment assembly
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
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
Hydraulic circuit diagram
Electrical circuit diagram
Connector list and stereogram

Inside this manual

Real pages from this service manual (952 pages). Open the sample pages (PDF, 838 KB)

Sample pages from the Komatsu PC228US-3E0, PC228USLC-3E0 Hydraulic Excavator Service Manual: Troubleshooting, Diagram, Specifications, Foldout diagram
  • Troubleshooting, page 573: Failure code [CA778] Eng Bkup Speed Sensor Error
  • Diagram, page 699: E-17 Monitoring function fails to display “boom raise” normally
  • Specifications, page 881: 50 Disassembly and assembly
  • Foldout diagram: Electrical circuit diagram (2/7)

Other manuals for this machine

Save 10% on 2 manuals, 15% on 3 or more. Other manuals for the PC228US-3E0, PC228USLC-3E0 are listed below. Editions cover different serial number ranges: check the serial coverage and tick only the ones that match your machine.

This manual: Service Manual SEN01418-10$99.61
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Details

This is a service manual

Here's how it compares to the other manual types.

This manual

Service manual

Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.

Operator's manual

Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.

Parts manual

Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.

Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.

What it's used for

Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.

Service shops and owner/operators who repair their own equipment

Identifying correct parts and seeing how assemblies come apart and go back together

Keeping equipment running with less downtime

Factory manual, 952 pages

Quantity one is the manual described above.

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