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Komatsu PC228US-8, PC228USLC-8 Hydraulic Excavator Service Manual

1,281 pages · Publication SEN05331-05

$129.71
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Models
PC228US-8, PC228USLC-8
Serial coverage
50001 and up
Manual type
Service Manual
Pages
1,281
Publication
SEN05331-05
Condition
Brand new
Komatsu PC228US-8, PC228USLC-8 Hydraulic Excavator Service Manual, publication SEN05331-05

What's inside

From the manual's own table of contents: 11 sections, 441 entries. See sample pages (PDF, 778 KB)

Notice of revision
Index and Foreword12 topics
  • Foreword 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
Specification5 topics
  • Specifications
  • Specifications drawing
  • Working range diagram
  • Table of weight
  • Table of fuel, coolant and lubricants
Structure and function33 topics
  • 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
  • Electrical system
  • Electronic control system
  • Machine monitor system
  • KOMTRAX system
  • Sensors
Standard value table2 topics
  • Standard value table for engine
  • Standard value table for machine
Testing and adjusting44 topics
  • Tool for testing, adjusting and troubleshooting
  • Tools for testing, adjusting, and troubleshooting
  • 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
  • Testing swing circle bearing clearance
  • Checking and adjusting track tension
  • 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
  • Replacement procedure of boom angle potentiometer
  • Cab and its attachments
  • Checking cab tipping stopper
  • Adjusting mirrors
  • Angle adjustment of rear view camera
  • 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
Troubleshooting223 topics
  • 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-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 displayed
  • 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)
  • 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-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 swinging
  • 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
Disassembly and assembly56 topics
  • General information on disassembly and assembly
  • How to read Disassembly and Assembly
  • Coating materials list
  • Special tools list
  • Sketches of special tools
  • 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
  • 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
  • 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
  • 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
  • Removal and installation of work equipment assembly
  • Removal and installation of anti-drop valve assembly for boom
  • Removal and installation of anti-drop valve assembly for arm
  • Disassembly and assembly of anti-drop valve assembly
  • Disassembly and assembly of work equipment cylinder assembly
  • 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
  • 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
Maintenance standard8 topics
  • Engine mount
  • Sprocket
  • Idler
  • Track roller
  • Carrier roller
  • Track shoe
  • Dimensions of components
  • Work equipment cylinder
Appendix38 topics
  • 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
  • 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
Diagrams and drawings9 topics
  • 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
  • Air conditioner electrical circuit diagram

Inside this manual

Real pages from this service manual (1,281 pages). Open the sample pages (PDF, 778 KB)

Sample pages from the Komatsu PC228US-8, PC228USLC-8 Hydraulic Excavator Service Manual: Troubleshooting, Diagram, Specifications, Foldout diagram
  • Troubleshooting, page 605: Troubleshooting by failurecode
  • Diagram, page 700: Troubleshooting by failurecode
  • Specifications, page 947: Engine and cooling system
  • Foldout diagram: PC228US-8,PC228USLC-8

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Details
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, 1,281 pages

Quantity one is the manual described above.

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