SEN05331-05

HYDRAULIC PC228US -8
EXCAVATOR
PC228USLC -8
SERIAL NUMBERS 50001 and up
 Notice of revision

Notice of revision
5th revision 2017/02
The affected pages are indicated by the use of the
Mark Indication Action required
following marks. It is requested that necessary ac-
tions must be taken to these pages according to the Q Page to be newly added Add
list below.
q Page to be replaced Replace

() Page to be deleted Discard

List of revised pages

Revision Revision Revision Revision
Mark Page Mark Page Mark Page Mark Page
number number number number
q 1 (05) 00-26 (02) 01-21 10-40
2 (04) 00-27 (02) 01-22 10-41
3 (03) 00-28 (02) 10-1 10-42
4 (02) 00-29 (02) 10-2 10-43
q 5 (05) 00-30 (02) 10-3 10-44
q 6 (05) 00-31 (02) 10-4 10-45
q 7 (05) 00-32 (02) 10-5 10-46
8 (02) 00-33 (02) 10-6 10-47
00-1 00-34 (02) 10-7 10-48 (02)
00-2 (02) 00-35 (02) 10-8 10-49
00-3 (01) 00-36 (02) 10-9 10-50
00-3-1 (01) 00-37 (02) 10-10 10-51
00-3-2 (01) 00-38 (02) 10-11 10-52 (02)
00-3-3 (01) 00-39 (02) 10-12 10-53 (02)
00-3-4 (01) 00-40 (02) 10-13 10-54
00-3-5 (02) 00-41 (02) 10-14 10-55
00-3-6 (04) 00-42 (02) 10-15 10-56
00-3-7 (04) 00-43 (02) 10-16 10-57
q 00-3-8 (05) 00-44 (02) 10-17 10-58
00-4 (02) 00-45 (02) 10-18 10-59
00-5 (02) 00-46 (02) 10-19 10-60
00-6 (02) 01-1 10-20 10-61
00-7 (02) 01-2 10-21 10-62 (02)
00-8 (02) 01-3 10-22 10-63
00-9 (02) 01-4 (02) 10-23 10-64 (02)
00-10 (02) 01-5 10-24 10-65
00-11 (02) 01-6 (02) 10-25 10-66
00-12 (02) 01-7 10-26 (02) 10-67
00-13 (02) 01-8 (02) 10-27 (02) 10-68
00-14 (02) 01-9 (02) 10-28 (02) 10-69 (02)
00-15 (02) 01-10 10-29 10-70
00-16 (02) 01-11 (02) 10-30 10-71
00-17 (02) 01-12 (02) 10-31 (02) 10-72
00-18 (02) 01-13 10-32 10-73
00-19 (02) 01-14 (02) 10-33 (02) 10-74
00-20 (02) 01-15 10-34 (02) 10-75
00-21 (02) 01-16 10-35 10-76
00-22 (02) 01-17 10-36 10-77
00-23 (02) 01-18 (02) 10-37 10-78
00-24 (02) 01-19 10-38 10-79
00-25 (02) 01-20 10-39 10-80 (02)

PC228US-8,PC228USLC-8 1
(05)
Notice of revision

Revision Revision Revision Revision

Mark Page Mark Page Mark Page Mark Page
number number number number
10-81 10-133 10-185 30-3 (01)
10-82 10-134 10-186 30-4 (02)
10-83 10-135 10-187 30-5 (01)
10-84 10-136 10-188 30-6 (01)
10-85 10-137 10-189 30-6-1 (02)
10-86 10-138 (02) 10-190 30-6-2 (02)
10-87 10-139 10-191 30-7 (01)
10-88 10-140 (02) 10-192 30-8 (01)
10-89 10-141 10-193 30-9 (01)
10-90 10-142 10-194 30-10 (01)
10-91 10-143 10-195 30-11 (01)
10-92 10-144 (02) 10-196 (02) 30-12 (01)
10-93 10-145 10-197 (02) 30-13 (01)
10-94 10-146 10-198 (02) 30-14 (01)
10-95 10-147 10-199 30-15 (01)
10-96 10-148 (03) 10-200 30-16 (01)
10-97 10-149 10-201 30-17 (01)
10-98 10-150 10-202 30-18 (01)
10-99 10-151 10-203 30-19 (01)
10-100 10-152 10-204 30-20 (01)
10-101 10-153 10-205 (02) 30-21 (01)
10-102 10-154 10-206 30-22 (01)
10-103 10-155 10-207 30-23 (01)
10-104 10-156 10-208 30-24 (01)
10-105 10-157 10-209 30-25 (01)
10-106 10-158 10-210 30-26 (01)
10-107 10-159 10-211 (02) 30-27 (01)
10-108 10-160 10-212 30-28 (01)
10-109 10-161 10-213 30-29 (01)
10-110 10-162 10-214 30-30 (01)
10-111 10-163 10-215 30-31 (01)
10-112 10-164 10-216 30-32 (01)
10-113 10-165 10-217 (02) 30-33 (01)
10-114 10-166 10-218 30-34 (01)
10-115 (02) 10-167 10-219 30-35 (01)
10-116 (02) 10-168 10-220 30-36 (01)
10-117 10-169 20-1 (01) 30-37 (01)
10-118 10-170 (03) 20-2 (01) 30-38 (01)
10-119 10-171 (02) 20-3 (01) 30-39 (01)
10-120 10-172 20-4 (01) 30-40 (01)
10-121 10-173 20-5 (01) 30-41 (01)
10-122 10-174 20-6 (01) 30-42 (01)
10-123 (02) 10-175 20-7 (01) 30-43 (01)
10-124 10-176 20-8 (01) 30-44 (01)
10-125 10-177 20-9 (01) 30-45 (01)
10-126 10-178 20-10 (01) 30-46 (01)
10-127 10-179 20-11 (01) 30-47 (01)
10-128 10-180 20-12 (01) 30-48 (01)
10-129 10-181 20-13 (01) 30-49 (01)
10-130 10-182 20-14 (01) 30-50 (01)
10-131 10-183 30-1 (01) 30-51 (02)
10-132 10-184 30-2 (01) 30-52 (01)

2 PC228US-8,PC228USLC-8
(04)
 Notice of revision

Revision Revision Revision Revision

Mark Page Mark Page Mark Page Mark Page
number number number number
30-53 (01) 30-105 (01) 40-21 (01) 40-73 (01)
30-54 (01) 30-106 (01) 40-22 (01) 40-74 (01)
30-55 (01) 30-107 (01) 40-23 (01) 40-75 (01)
30-56 (01) 30-108 (01) 40-24 (01) 40-76 (01)
30-57 (01) 30-109 (01) 40-25 (01) 40-77 (01)
30-58 (01) 30-110 (01) 40-26 (01) 40-78 (01)
30-59 (01) 30-111 (01) 40-27 (01) 40-79 (01)
30-60 (01) 30-112 (01) 40-28 (01) 40-80 (01)
30-61 (01) 30-113 (01) 40-29 (01) 40-81 (01)
30-62 (01) 30-114 (01) 40-30 (01) 40-82 (01)
30-63 (01) 30-115 (01) 40-31 (01) 40-83 (01)
30-64 (01) 30-116 (01) 40-32 (01) 40-84 (01)
30-65 (01) 30-117 (01) 40-33 (01) 40-85 (01)
30-66 (01) 30-118 (01) 40-34 (01) 40-86 (01)
30-67 (01) 30-119 (01) 40-35 (01) 40-87 (01)
30-68 (02) 30-120 (01) 40-36 (01) 40-88 (01)
30-69 (01) 30-121 (01) 40-37 (01) 40-89 (01)
30-70 (01) 30-122 (01) 40-38 (01) 40-90 (01)
30-71 (01) 30-123 (01) 40-39 (01) 40-91 (01)
30-72 (01) 30-124 (01) 40-40 (01) 40-92 (01)
30-73 (01) 30-125 (01) 40-41 (01) 40-93 (01)
30-74 (01) 30-126 (01) 40-42 (01) 40-94 (01)
30-75 (01) 30-127 (01) 40-43 (01) 40-95 (01)
30-76 (01) 30-128 (01) 40-44 (01) 40-96 (01)
30-77 (01) 30-129 (01) 40-45 (01) 40-97 (01)
30-78 (01) 30-130 (01) 40-46 (01) 40-98 (01)
30-79 (01) 30-131 (01) 40-47 (01) 40-99 (01)
30-80 (01) 30-132 (01) 40-48 (01) 40-100 (01)
30-81 (01) 30-133 (01) 40-49 (01) 40-101 (01)
30-82 (01) 30-134 (01) 40-50 (01) 40-102 (01)
30-83 (01) 30-135 (01) 40-51 (01) 40-103 (01)
30-84 (01) 30-136 (01) 40-52 (01) 40-104 (01)
30-85 (01) 40-1 (01) 40-53 (01) 40-105 (01)
30-86 (01) 40-2 (01) 40-54 (01) 40-106 (01)
30-87 (01) 40-3 (01) 40-55 (01) 40-107 (01)
30-88 (01) 40-4 (01) 40-56 (01) 40-108 (01)
30-89 (01) 40-5 (01) 40-57 (01) 40-109 (01)
30-90 (01) 40-6 (01) 40-58 (01) 40-110 (01)
30-91 (01) 40-7 (01) 40-59 (01) 40-111 (01)
30-92 (01) 40-8 (01) 40-60 (01) 40-112 (01)
30-93 (01) 40-9 (01) 40-61 (01) 40-113 (01)
30-94 (01) 40-10 (01) 40-62 (01) 40-114 (01)
30-95 (01) 40-11 (01) 40-63 (01) 40-115 (01)
30-96 (01) 40-12 (01) 40-64 (01) 40-116 (01)
30-97 (01) 40-13 (01) 40-65 (01) 40-117 (01)
30-98 (01) 40-14 (01) 40-66 (01) 40-118 (01)
30-99 (01) 40-15 (01) 40-67 (01) 40-119 (01)
30-100 (01) 40-16 (01) 40-68 (01) 40-120 (01)
30-101 (01) 40-17 (01) 40-69 (01) 40-121 (01)
30-102 (01) 40-18 (01) 40-70 (01) 40-122 (01)
30-103 (01) 40-19 (01) 40-71 (01) 40-123 (01)
30-104 (01) 40-20 (01) 40-72 (01) 40-124 (01)

PC228US-8,PC228USLC-8 3
(03)
Notice of revision

Revision Revision Revision Revision

Mark Page Mark Page Mark Page Mark Page
number number number number
40-125 (01) 40-177 (01) 40-229 (01) 40-281 (01)
40-126 (01) 40-178 (01) 40-230 (01) 40-282 (01)
40-127 (01) 40-179 (01) 40-231 (01) 40-283 (01)
40-128 (01) 40-180 (01) 40-232 (01) 40-284 (01)
40-129 (01) 40-181 (01) 40-233 (01) 40-285 (01)
40-130 (01) 40-182 (01) 40-234 (01) 40-286 (01)
40-131 (01) 40-183 (01) 40-235 (01) 40-287 (01)
40-132 (01) 40-184 (01) 40-236 (01) 40-288 (01)
40-133 (01) 40-185 (01) 40-237 (01) 40-289 (01)
40-134 (01) 40-186 (01) 40-238 (01) 40-290 (01)
40-135 (01) 40-187 (01) 40-239 (01) 40-291 (01)
40-136 (01) 40-188 (01) 40-240 (01) 40-292 (01)
40-137 (01) 40-189 (01) 40-241 (01) 40-293 (01)
40-138 (01) 40-190 (01) 40-242 (01) 40-294 (01)
40-139 (01) 40-191 (01) 40-243 (01) 40-295 (01)
40-140 (01) 40-192 (01) 40-244 (01) 40-296 (01)
40-141 (01) 40-193 (01) 40-245 (01) 40-297 (01)
40-142 (01) 40-194 (01) 40-246 (01) 40-298 (01)
40-143 (01) 40-195 (01) 40-247 (01) 40-299 (01)
40-144 (01) 40-196 (01) 40-248 (01) 40-300 (01)
40-145 (01) 40-197 (01) 40-249 (01) 40-301 (01)
40-146 (01) 40-198 (01) 40-250 (01) 40-302 (01)
40-147 (01) 40-199 (01) 40-251 (01) 40-303 (01)
40-148 (01) 40-200 (01) 40-252 (01) 40-304 (01)
40-149 (01) 40-201 (01) 40-253 (01) 40-305 (01)
40-150 (01) 40-202 (01) 40-254 (01) 40-306 (01)
40-151 (01) 40-203 (01) 40-255 (01) 40-307 (01)
40-152 (01) 40-204 (01) 40-256 (01) 40-308 (01)
40-153 (01) 40-205 (01) 40-257 (01) 40-309 (01)
40-154 (01) 40-206 (01) 40-258 (01) 40-310 (01)
40-155 (01) 40-207 (01) 40-259 (01) 40-311 (01)
40-156 (01) 40-208 (01) 40-260 (01) 40-312 (01)
40-157 (01) 40-209 (01) 40-261 (01) 40-313 (01)
40-158 (01) 40-210 (01) 40-262 (01) 40-314 (01)
40-159 (01) 40-211 (01) 40-263 (01) 40-315 (01)
40-160 (01) 40-212 (01) 40-264 (01) 40-316 (01)
40-161 (01) 40-213 (01) 40-265 (01) 40-317 (01)
40-162 (01) 40-214 (01) 40-266 (01) 40-318 (01)
40-163 (01) 40-215 (01) 40-267 (01) 40-319 (01)
40-164 (01) 40-216 (01) 40-268 (01) 40-320 (01)
40-165 (01) 40-217 (01) 40-269 (01) 40-321 (01)
40-166 (01) 40-218 (01) 40-270 (01) 40-322 (01)
40-167 (01) 40-219 (01) 40-271 (01) 40-323 (01)
40-168 (01) 40-220 (01) 40-272 (01) 40-324 (01)
40-169 (01) 40-221 (01) 40-273 (01) 40-325 (01)
40-170 (01) 40-222 (01) 40-274 (01) 40-326 (01)
40-171 (01) 40-223 (01) 40-275 (01) 40-327 (01)
40-172 (01) 40-224 (01) 40-276 (01) 40-328 (01)
40-173 (01) 40-225 (01) 40-277 (01) 40-329 (01)
40-174 (01) 40-226 (01) 40-278 (01) 40-330 (01)
40-175 (01) 40-227 (01) 40-279 (01) 40-331 (01)
40-176 (01) 40-228 (01) 40-280 (01) 40-332 (01)

4 PC228US-8,PC228USLC-8
(03)
(02)
 Notice of revision

Revision Revision Revision Revision

Mark Page Mark Page Mark Page Mark Page
number number number number
40-333 (01) 40-379 (01) 40-425 (01) 50-25 (02)
40-334 (01) 40-380 (01) 40-426 (01) 50-26 (02)
40-335 (01) 40-381 (01) 40-427 (01) 50-27 (02)
40-336 (01) 40-382 (01) 40-428 (01) 50-28 (02)
40-337 (01) 40-383 (01) 40-429 (01) 50-29 (02)
40-338 (01) 40-384 (01) 40-430 (01) 50-30 (02)
40-339 (01) 40-385 (01) 40-431 (01) 50-31 (02)
40-340 (01) 40-386 (01) 40-432 (01) 50-32 (02)
40-341 (01) 40-387 (01) 40-433 (01) 50-33 (02)
40-342 (01) 40-388 (01) 40-434 (01) 50-34 (02)
40-343 (01) 40-389 (01) 40-435 (01) 50-35 (02)
40-344 (01) 40-390 (01) 40-436 (01) 50-36 (02)
40-345 (01) 40-391 (01) 40-437 (01) 50-37 (02)
40-346 (01) 40-392 (01) 40-438 (01) 50-38 (02)
40-347 (01) 40-393 (01) 40-439 (01) 50-39 (02)
40-348 (01) 40-394 (01) 40-440 (01) 50-40 (02)
40-349 (01) 40-395 (01) 40-441 (01) 50-41 (02)
40-350 (01) 40-396 (01) 40-442 (01) 50-42 (02)
40-351 (01) 40-397 (01) 40-443 (01) 50-43 (02)
40-352 (01) 40-398 (01) 40-444 (01) 50-44 (02)
40-353 (01) 40-399 (01) 40-445 (01) 50-45 (02)
40-354 (01) 40-400 (01) 40-446 (01) 50-46 (02)
40-355 (01) 40-401 (01) 50-1 (02) 50-47 (02)
40-356 (01) 40-402 (01) 50-2 (04) 50-48 (02)
40-357 (01) 40-403 (01) 50-3 (04) 50-49 (02)
40-358 (01) 40-404 (01) 50-4 (02) 50-50 (02)
40-359 (01) 40-405 (01) 50-5 (02) 50-51 (02)
40-360 (01) 40-406 (01) 50-6 (02) 50-52 (02)
40-361 (01) 40-407 (01) 50-7 (02) 50-53 (02)
40-362 (01) 40-408 (01) 50-8 (02) 50-54 (02)
40-363 (01) 40-409 (01) 50-9 (02) 50-55 (02)
40-364 (01) 40-410 (01) 50-10 (02) 50-56 (02)
40-365 (01) 40-411 (01) 50-11 (02) 50-57 (02)
40-366 (01) 40-412 (01) 50-12 (02) 50-58 (02)
40-367 (01) 40-413 (01) 50-13 (02) 50-59 (02)
40-368 (01) 40-414 (01) 50-14 (02) 50-60 (02)
40-369 (01) 40-415 (01) 50-15 (02) 50-61 (02)
40-370 (01) 40-416 (01) 50-16 (02) 50-62 (02)
40-371 (01) 40-417 (01) 50-17 (02) 50-63 (02)
40-372 (01) 40-418 (01) 50-18 (02) 50-64 (02)
40-373 (01) 40-419 (01) 50-19 (02) 50-65 (02)
40-374 (01) 40-420 (01) 50-20 (02) 50-66 (02)
40-375 (01) 40-421 (01) 50-21 (02) 50-67 (02)
40-376 (01) 40-422 (01) 50-22 (02) 50-68 (02)
40-377 (01) 40-423 (01) 50-23 (02) 50-69 (02)
40-378 (01) 40-424 (01) 50-24 (02) 50-70 (02)

PC228US-8,PC228USLC-8 5
(05)
Notice of revision

Revision Revision Revision Revision

Mark Page Mark Page Mark Page Mark Page
number number number number
50-71 (02) 50-117 (02) 50-157 (02) 60-21
50-72 (02) 50-118 (02) 50-158 (02) 60-22
50-73 (02) 50-119 (02) 50-159 (02) 60-23
50-74 (02) 50-120 (02) 50-160 (02) 60-24
50-75 (02) 50-121 (02) 50-161 (02) 60-25
50-76 (02) 50-122 (02) 50-162 (02) 60-26 (02)
50-77 (02) 50-123 (02) 50-163 (02) 60-27 (02)
50-78 (02) 50-124 (02) 50-164 (02) 60-28
50-79 (02) 50-125 (02) 50-165 (02) 60-29
50-80 (02) 50-126 (02) 50-166 (02) 60-30
50-81 (02) 50-127 (02) 50-167 (02) 60-31
50-82 (02) 50-128 (02) 50-168 (02) 60-32 (02)
50-83 (02) 50-129 (02) 50-169 (02) 60-33
50-84 (02) 50-130 (02) 50-170 (02) 60-34
50-85 (02) 50-131 (02) 50-171 (02) 60-35
50-86 (02) 50-132 (02) 50-172 (02) 60-36
50-87 (02) 50-133 (02) 50-173 (02) 60-37
50-88 (02) 50-134 (02) 50-174 (02) 60-38
50-89 (02) 50-134-1 (04) 50-175 (02) 60-39
50-90 (02) 50-134-2 (04) 50-176 (02) 60-40
50-91 (02) 50-134-3 (04) 50-177 (02) 60-41
50-92 (02) 50-134-4 (04) 50-178 (02) 60-42
50-93 (02) 50-134-5 (04) 50-179 (02) 60-43 (02)
50-94 (02) 50-134-6 (04) 50-180 (02) 60-44
50-95 (02) 50-135 (02) 50-181 (02) 60-45 (02)
50-96 (02) 50-136 (02) 50-182 (02) 60-46 (02)
50-97 (02) 50-137 (02) 60-1 60-47
50-98 (02) 50-138 (02) 60-2 60-48
50-99 (02) 50-139 (02) 60-3 60-49
50-100 (02) 50-140 (02) 60-4 60-50
50-101 (02) 50-141 (02) 60-5 60-51
50-102 (02) 50-142 (02) 60-6 60-52
50-103 (02) 50-143 (02) 60-7 60-53
50-104 (02) 50-144 (02) 60-8 60-54
50-105 (02) 50-145 (02) 60-9 60-55
50-106 (02) 50-146 (02) 60-10 60-56
50-107 (02) 50-147 (02) 60-11 60-57
50-108 (02) 50-148 (02) 60-12 60-58
50-109 (02) 50-149 (02) 60-13 60-59
50-110 (02) 50-150 (02) 60-14 60-60
50-111 (02) 50-151 (02) 60-15 60-61
50-112 (02) 50-152 (02) 60-16 60-62
50-113 (02) 50-153 (02) 60-17 (02) 60-63
50-114 (02) 50-154 (02) 60-18 60-64
50-115 (02) 50-155 (02) 60-19 60-65
50-116 (02) 50-156 (02) 60-20 60-66

6 PC228US-8,PC228USLC-8
(05)
 Notice of revision

Revision Revision Revision Revision

Mark Page Mark Page Mark Page Mark Page
number number number number
60-67 80-48 (01) 90-19
60-68 80-49 (01) 90-20
60-69 80-50 (01) 90-21
60-70 80-51 (01) 90-22
80-1 (01) 80-52 (01) 90-23
80-2 (01) 80-53 (01) 90-24
80-3 (01) 80-55 (01) 90-25
80-4 (01) 80-56 (01) 90-26
80-5 (01) 80-57 (01) 90-27
80-6 (01) 80-58 (01) 90-28
80-7 (01) 80-59 (01) 90-29
80-8 (01) 80-60 (01) 90-30
80-9 (01) 80-61 (01) 90-31
80-10 (01) 80-62 (01) 90-32
80-11 (01) 80-63 (01) 90-33
80-12 (01) 80-64 (01) 90-34
80-13 (01) 80-65 (01) 90-35
80-14 (01) 80-66 (01) 90-36
80-15 (01) 80-67 (01) 90-37
80-16 (01) 80-68 (01) 90-38
80-17 (01) 80-69 (01) 90-39
80-18 (01) 80-70 (01) 90-40
80-19 (01) 80-71 (01) 90-41
80-20 (01) 80-72 (01) 90-42
80-21 (01) 80-73 (01) 90-43
80-22 (01) 80-74 (01) 90-44
80-23 (01) 80-75 (01) 90-45
80-24 (01) 80-76 (01) 90-46
80-25 (01) 80-77 (01) 90-47
80-26 (01) 80-78 (01) 1 (04)
80-27 (01) 90-1 2 (04)
80-28 (01) q 90-2 (05) 3 (04)
80-29 (01) 90-3 4 (04)
80-30 (01) 90-4 5 (04)
80-31 (01) 90-5 6 (04)
80-32 (01) 90-6 7 (02)
80-33 (01) q 90-7 (05) q Colophon (05)
80-34 (01) Q 90-7-2 (05)
80-35 (01) Q 90-7-4 (05)
80-36 (01) Q 90-7-6 (05)
80-37 (01) 90-8
80-38 (01) 90-9
80-39 (01) 90-10
80-40 (01) 90-11
80-41 (01) 90-12
80-42 (01) 90-13
80-43 (01) 90-14
80-44 (01) 90-15
80-45 (01) 90-16
80-46 (01) 90-17
80-47 (01) 90-18

PC228US-8,PC228USLC-8 7
(05)
Notice of revision

8 PC228US-8,PC228USLC-8
(03)
(02)
 0-1

PC228US-8,PC228USLC-8

HYDRAULIC EXCAVATOR
Shop Manual 0-1

PC228US-8
PC228USLC-8

Machine model Serial number

PC228US-8 50001 and up
PC228USLC-8 50001 and up

00 Index and foreword 0 -1

PC228US-8,PC228USLC-8 00-1
Table of Contents

Table of Contents 0 -2
Notice of revision .................................................................................................................... 1

00 Index and Foreword

Table of contents .................................................................................................................... 00 - 2
Table of contents ................................................................................................................. 00 - 2
Foreword and general information .......................................................................................... 00- 4
Safety notice ........................................................................................................................ 00- 4
How to read the shop manual .............................................................................................. 00- 9
Explanation of terms for maintenance standard .................................................................. 00- 11
Handling of hydraulic components....................................................................................... 00- 13
Method of disconnecting and connecting push-pull type coupler ........................................ 00- 15
Handling of electric equipment............................................................................................. 00- 18
How to read electric wire code............................................................................................. 00- 28
Precautions when performing work...................................................................................... 00- 31
Standard tightening torque table.......................................................................................... 00- 34
List of Abbreviation .............................................................................................................. 00- 38
Conversion table .................................................................................................................. 00- 42

01 Specification
Specifications.......................................................................................................................... 01- 4
Specifications drawing ......................................................................................................... 01- 4
Working range diagram........................................................................................................ 01- 5
Specifications....................................................................................................................... 01- 6
Table of weight..................................................................................................................... 01- 16
Table of fuel, coolant and lubricants .................................................................................... 01- 20

10 Structure and function

Engine and cooling system ..................................................................................................... 10- 3
Engine related parts............................................................................................................. 10- 3
Cooling system .................................................................................................................... 10- 4
Power train system ................................................................................................................. 10- 7
Power train........................................................................................................................... 10- 7
Swing circle.......................................................................................................................... 10- 8
Swing machinery.................................................................................................................. 10- 10
Final drive ............................................................................................................................ 10- 12
Undercarriage and frame ........................................................................................................ 10- 14
Track frame and idler cushion.............................................................................................. 10- 14
Hydraulic system..................................................................................................................... 10- 16
Hydraulic equipment layout drawing .................................................................................... 10- 16
Valve control ........................................................................................................................ 10- 18
Hydraulic tank ...................................................................................................................... 10- 19
CLSS.................................................................................................................................... 10- 21
Main pump ........................................................................................................................... 10- 26
Control valve ........................................................................................................................ 10- 48
Function and operation by valve .......................................................................................... 10- 60
Swing motor ......................................................................................................................... 10- 97
Travel motor......................................................................................................................... 10- 105
PPC valve ............................................................................................................................ 10- 115
Solenoid valve...................................................................................................................... 10- 132
Attachment circuit selector valve ......................................................................................... 10- 138
Anti-drop valve ..................................................................................................................... 10- 142
Multi-control valve ................................................................................................................ 10- 147

00-2 PC228US-8,PC228USLC-8
(02)
 Table of Contents

Center swivel joint................................................................................................................ 10- 148

Accumulator......................................................................................................................... 10- 149
Work equipment...................................................................................................................... 10- 152
Work equipment................................................................................................................... 10- 152
Electrical system ..................................................................................................................... 10- 154
Electronic control system..................................................................................................... 10- 154
Machine monitor system...................................................................................................... 10- 192
KOMTRAX system............................................................................................................... 10- 208
Sensors................................................................................................................................ 10- 210

20 Standard value table

Standard value table ............................................................................................................... 20- 3
Standard value table for engine........................................................................................... 20- 3
Standard value table for machine ........................................................................................ 20- 4

30 Testing and adjusting

Tool for testing, adjusting and troubleshooting ....................................................................... 30- 3
Tools for testing, adjusting, and troubleshooting ................................................................. 30- 3
Engine and cooling system ..................................................................................................... 30- 7
Testing engine speed .......................................................................................................... 30- 7
Testing intake air pressure (boost pressure) ....................................................................... 30- 8
Testing exhaust gas color.................................................................................................... 30- 9
Testing and adjusting valve clearance................................................................................. 30- 10
Testing compression pressure............................................................................................. 30- 12
Testing blowby pressure...................................................................................................... 30- 15
Testing engine oil pressure.................................................................................................. 30- 16
Handling fuel system parts .................................................................................................. 30- 17
Releasing remaining pressure from fuel system.................................................................. 30- 18
Testing fuel pressure ........................................................................................................... 30- 19
Cylinder cut-out test mode................................................................................................... 30- 22
No-injection cranking ........................................................................................................... 30- 23
Checking fuel delivery, return rate and leakage .................................................................. 30- 24
Bleeding air from fuel circuit ................................................................................................ 30- 27
Testing fuel circuit for leakage ............................................................................................. 30- 28
Testing and adjusting air conditioner compressor belt tension............................................ 30- 29
Replacing fan belt ................................................................................................................ 30- 30
Undercarriage and frame ........................................................................................................ 30- 31
Testing swing circle bearing clearance................................................................................ 30- 31
Checking and adjusting track tension .................................................................................. 30- 32
Hydraulic system .................................................................................................................... 30- 33
Testing and adjusting oil pressure in work equipment, swing and travel circuits................. 30- 33
Testing control circuit source pressure ................................................................................ 30- 37
Testing and adjusting oil pressure in pump PC control circuit ............................................. 30- 38
Testing and adjusting oil pressure in pump LS control circuit.............................................. 30- 42
Testing solenoid valve output pressure ............................................................................... 30- 47
Testing PPC valve output pressure ..................................................................................... 30- 50
Adjusting play of work equipment and swing PPC vavles ................................................... 30- 52
Testing pump swash plate sensor ....................................................................................... 30- 53
Isolating the parts causing hydraulic drift of work equipment .............................................. 30- 54
Releasing remaining pressure from hydraulic circuit ........................................................... 30- 56
Testing oil leakage amount.................................................................................................. 30- 57
Bleeding air from each part.................................................................................................. 30- 59
Work equipment...................................................................................................................... 30- 61
Replacement procedure of boom angle potentiometer........................................................ 30- 61

PC228US-8,PC228USLC-8 00-3
(01)
Table of Contents

Cab and its attachments ......................................................................................................... 30- 62

Checking cab tipping stopper............................................................................................... 30- 62
Adjusting mirrors .................................................................................................................. 30- 63
Angle adjustment of rear view camera................................................................................. 30- 65
Electrical system ..................................................................................................................... 30- 67
Speial function of machine monitor (EMMS)........................................................................ 30- 67
Handling voltage circuit of engine controller ........................................................................ 30- 123
Preparatory work for troubleshooting of electrical system ................................................... 30- 124
Procedure for testing diodes ................................................................................................ 30- 129
Pm clinic.................................................................................................................................. 30- 131
Pm clinic service .................................................................................................................. 30- 131

40 Troubleshooting
General information on troubleshooting .................................................................................. 40- 8
Points to remember when troubleshooting .......................................................................... 40- 8
Sequence of events in troubleshooting................................................................................ 40- 9
Checks before troubleshooting ............................................................................................ 40- 10
Classification and procedures for troubleshooting ............................................................... 40- 34
Failure codes table............................................................................................................... 40- 37
Symptom and troubleshooting numbers .............................................................................. 40- 42
Information in troubleshooting table..................................................................................... 40- 44
Troubleshooting method for open circuit in wiring harness of pressure sensor system ...... 40- 46
Connector list and layout ..................................................................................................... 40- 48
Connection table for connector pin numbers ....................................................................... 40- 60
T- branch box and T- branch adapter table ......................................................................... 40- 96
Fuse location table............................................................................................................... 40- 100
Troubleshooting by failurecode ............................................................................................... 40- 102
Failure code [989L00] Engine Controller Lock Caution 1 .................................................... 40- 102
Failure code [989M00] Engine Controller Lock Caution 2 ................................................... 40- 102
Failure code [989N00] Engine Controller Lock Caution 3.................................................... 40- 103
Failure code [AA10NX] Air Cleaner Clogging ...................................................................... 40- 104
Failure code [AB00KE] Charge Voltage Low ....................................................................... 40- 106
Failure code [B@BAZG] Eng Oil Press Low........................................................................ 40- 108
Failure code [B@BAZK] Eng Oil Level Low......................................................................... 40- 109
Failure code [B@BCNS] Eng Water Overheat .................................................................... 40- 110
Failure code [B@BCZK] Eng Water Level Low ................................................................... 40- 112
Failure code [B@HANS] Hyd Oil Overheat.......................................................................... 40- 114
Failure code [CA111] ECM Critical Internal Failure ............................................................. 40- 115
Failure code [CA115] Eng Ne and Bkup Speed Sens Error ................................................ 40- 115
Failure code [CA122] Chg Air Press Sensor High Error ...................................................... 40- 116
Failure code [CA123] Chg Air Press Sensor Low Error ....................................................... 40- 118
Failure code [CA131] Throttle Sensor High Error ................................................................ 40- 120
Failure code [CA132] Throttle Sensor Low Error ................................................................. 40- 122
Failure code [CA144] Coolant Temp Sens High Error ......................................................... 40- 124
Failure code [CA145] Coolant Temp Sens Low Error.......................................................... 40- 126
Failure code [CA153] Chg Air Temp Sensor High Error ...................................................... 40- 128
Failure code [CA154] Chg Air Temp Sensor Low Error ....................................................... 40- 130
Failure code [CA155] Chg Air Temp High Speed Derate .................................................... 40- 132
Failure code [CA187] Sens Supply 2 Volt Low Error ........................................................... 40- 134
Failure code [CA221] Ambient Press Sens High Error ........................................................ 40- 136
Failure code [CA222] Ambient Press Sens Low Error ......................................................... 40- 138
Failure code [CA227] Sens Supply 2 Volt High Error .......................................................... 40- 140
Failure code [CA234] Eng Overspeed ................................................................................. 40- 141
Failure code [CA238] Ne Speed Sens Supply Volt Error..................................................... 40- 142

00-3-1 PC228US-8,PC228USLC-8
(01)
 Table of Contents

Failure code [CA271] IMV/PCV1 Short Error....................................................................... 40- 144

Failure code [CA272] IMV/PCV1 Open Error ...................................................................... 40- 146
Failure code [CA322] Inj #1(L#1) Open/Short Error ............................................................ 40- 148
Failure code [CA323] Inj #5 (L#5) Open/Short Error ........................................................... 40- 150
Failure code [CA324] Inj #3(L#3) Open/Short Error ............................................................ 40- 152
Failure code [CA325] Inj #6 (L#6) Open/Short Error ........................................................... 40- 154
Failure code [CA331] Inj #2(L#2) Open/Short Error ............................................................ 40- 156
Failure code [CA332] Inj #4(L#4) Open/Short Error ............................................................ 40- 158
Failure code [CA342] Calibration Code Incompatibility ....................................................... 40- 160
Failure code [CA351] Injectors Drive Circuit Error............................................................... 40- 161
Failure code [CA352] Sens Supply 1 Volt Low Error ........................................................... 40- 162
Failure code [CA386] Sens Supply 1 Volt High Error .......................................................... 40- 164
Failure code [CA428] Water in Fuel Sensor High Error ....................................................... 40- 166
Failure code [CA429] Water in Fuel Sensor Low Error........................................................ 40- 168
Failure code [CA435] Eng Oil Press Sw Error ..................................................................... 40- 170
Failure code [CA441] Battery Voltage Low Error................................................................. 40- 172
Failure code [CA442] Battery Voltage High Error ................................................................ 40- 174
Failure code [CA449] Rail Press Very High Error................................................................ 40- 175
Failure code [CA451] Rail Press Sensor High Error............................................................ 40- 176
Failure code [CA452] Rail Press Sensor Low Error............................................................. 40- 178
Failure code [CA488] Chg Air Temp High Torque Derate ................................................... 40- 180
Failure code [CA553] Rail Press High Error ........................................................................ 40- 181
Failure code [CA559] Rail Press Low Error ......................................................................... 40- 182
Failure code [CA689] Eng Ne Speed Sensor Error ............................................................. 40- 184
Failure code [CA731] Eng Bkup Speed Sens Phase Error.................................................. 40- 186
Failure code [CA757] All Continuous Data Lost Error ......................................................... 40- 187
Failure code [CA778] Eng Bkup Speed Sensor Error.......................................................... 40- 188
Failure code [CA1633] KOMNET Datalink Timeout Error.................................................... 40- 191
Failure code [CA2185] Throt Sens Sup Volt High Error ...................................................... 40- 192
Failure code [CA2186] Throt Sens Sup Volt Low Error ....................................................... 40- 193
Failure code [CA2249] Rail Press Very Low Error............................................................... 40- 194
Failure code [CA2311] IMV Solenoid Error.......................................................................... 40- 195
Failure code [CA2555] Grid Htr Relay Open Circuit Error ................................................... 40- 196
Failure code [CA2556] Grid Htr Relay Short Circuit Error ................................................... 40- 198
Failure code [D110KB] Battery Relay Drive Short Circuit .................................................... 40- 200
Failure code [D19JKZ] Personal Code Relay Abnormality .................................................. 40- 202
Failure code [D862KA] GPS Antenna Open Circuit............................................................. 40- 204
Failure code [DA22KK] Pump Solenoid Power Low Error ................................................... 40- 206
Failure code [DA25KP] 5V Sensor1 Power Abnormality ..................................................... 40- 208
Failure code [DA26KP] 5V Sensor2 Power Abnormality ..................................................... 40- 210
Failure code [DA29KQ] Model Selection Abnormality ......................................................... 40- 214
Failure code [DA2RMC] CAN Discon (Pump Con Detected) .............................................. 40- 217
Failure code [DAF8KB] Camera Power Supply Short Circuit .............................................. 40- 222
Failure code [DAFGMC] GPS Module Error ........................................................................ 40- 224
Failure code [DAFRMC] CAN Discon (Monitor Detected) ................................................... 40- 226
Failure code [DGH2KB] Hyd Oil Sensor Short .................................................................... 40- 230
Failure code [DHPAMA] Pump Press Sensor Abnormality.................................................. 40- 232
Failure code [DHPBMA] R Pump Press Sensor Abnormality .............................................. 40- 234
Failure code [DHS3MA] Arm IN PPC Sen. Abnormality ...................................................... 40- 236
Failure code [DHS4MA] Bucket CURL PPC Press Sensor Abnormality ............................. 40- 238
Failure code [DHS8MA] Boom RAISE PPC Press Sensor Abnormality.............................. 40- 240
Failure code [DHSAMA] Swing RH PPC Press Sensor Abnomality .................................... 40- 242
Failure code [DHSBMA] Swing LH PPC Press Sensor Abnomality .................................... 40- 244
Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality ............................. 40- 246

PC228US-8,PC228USLC-8 00-3-2
(01)
Table of Contents

Failure code [DHSFMA] Travel FW L PPC Press Sensor Abnormality ............................... 40- 248
Failure code [DHSGMA] Travel FW R PPC Press Sensor Abnormality .............................. 40- 250
Failure code [DHSHMA] Travel BW L PPC Press Sensor Abnormality............................... 40- 252
Failure code [DHSJMA] Travel BW R PPC Press Sensor Abnormality ............................... 40- 254
Failure code [DHX1MA] Overload Sensor Abnormality ....................................................... 40- 257
Failure code [DKA0KA] Boom Angle Sensor Open Circuit .................................................. 40- 260
Failure code [DKA0KB] Boom Angle Sensor Power Short Circuit ....................................... 40- 262
Failure code [DKA0PH] Boom Angle Sensor Install Abnormality ........................................ 40- 264
Failure code [DKR0MA] F pump S/P sensor Abnormality ................................................... 40- 266
Failure code [DKR1MA] R pump S/P sensor Abnormality ................................................... 40- 268
Failure code [DV20KB] Travel Alarm Short Circuit .............................................................. 40- 270
Failure code [DW43KA] Travel Speed Sol Open Circuit...................................................... 40- 272
Failure code [DW43KB] Travel Speed Sol Short Circuit ...................................................... 40- 274
Failure code [DW45KA] Swing Brake Sol Open Circuit ....................................................... 40- 276
Failure code [DW45KB] Swing Brake Sol Short Circuit ....................................................... 40- 278
Failure code [DW4GKA] Boom Slow Down Sol. Disc. ......................................................... 40- 280
Failure code [DW4GKB] Boom Slow Down Sol. Short Circuit ............................................. 40- 282
Failure code [DW4WKA] Cancel Bucket Dump Open Circuit .............................................. 40- 284
Failure code [DW4WKB] Cancel Bucket Dump Short Circuit .............................................. 40- 286
Failure code [DW91KA] Travel Junction Sol. Disc............................................................... 40- 288
Failure code [DW91KB] Travel Junction Sol. S/C................................................................ 40- 290
Failure code [DWA2KA] Attachment Sol Open Circuit......................................................... 40- 292
Failure code [DWA2KB] Attachment Sol Short Circuit......................................................... 40- 294
Failure code [DWK0KA] 2-stage Relief Sol Open Circuit..................................................... 40- 296
Failure code [DWK0KB] 2-stage Relief Sol Short Circuit..................................................... 40- 298
Failure code [DXA8KA] PC-EPC (F) Sol Open Circuit......................................................... 40- 300
Failure code [DXA8KB] PC-EPC (F) Sol Short Circuit......................................................... 40- 302
Failure code [DXA9KA] PC-EPC (R) Sol Open Circuit ........................................................ 40- 304
Failure code [DXA9KB] PC-EPC (R) Sol Short Circuit ........................................................ 40- 306
Failure code [DXE0KA] LS-EPC Sol Open Circuit............................................................... 40- 308
Failure code [DXE0KB] LS-EPC Sol Short Circuit ............................................................... 40- 310
Failure code [DXE4KA] Service Current EPC Disc.............................................................. 40- 312
Failure code [DXE4KB] Service Current EPC S/C............................................................... 40- 314
Failure code [DXE5KA] Merge-divider Main Sol Open Circuit ............................................. 40- 316
Failure code [DXE5KB] Merge-divider Main Sol Short Circuit ............................................. 40- 318
Failure code [DXE6KA] Merge-divider LS Sol Open Circuit ................................................ 40- 320
Failure code [DXE6KB] Merge-divider LS Sol Short Circuit................................................. 40- 322
Failure code [DY20KA] Wiper Working Abnormality............................................................ 40- 324
Failure code [DY20MA] Wiper Parking Abnormality ............................................................ 40- 326
Failure code [DY2CKA] Washer drive discon ...................................................................... 40- 328
Failure code [DY2CKB] Washer drive short......................................................................... 40- 330
Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit ..................................................... 40- 332
Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit...................................................... 40- 334
Troubleshooting of electrical system (E-mode)....................................................................... 40- 337
E-1 Engine does not start (Engine does not crank) ............................................................. 40- 337
E-2 Preheater does not operate........................................................................................... 40- 342
E-3 When starting switch is turned to ON position, machine monitor displays nothing ....... 40- 347
E-4 When starting switch is turned to ON position (before starting engine), basic check monitor lights up.
............................................................................................................................................. 40- 350
E-5 Precaution monitor lights up while engine is running .................................................... 40- 351
E-6 Emergency stop monitor lights up while engine is running ........................................... 40- 353
E-7 Fuel level gauge does not indicate correctly ................................................................. 40- 354
E-8 Engine coolant temperature gauge does not indicate correctly .................................... 40- 356
E-9 Hydraulic oil temperature gauge does not indicate correctly......................................... 40- 358

00-3-3 PC228US-8,PC228USLC-8
(01)
 Table of Contents

E-10 Displays on machine monitor are different from those for actual machine ................. 40- 361
E-11 Some areas of machine monitor screen are not displayed ......................................... 40- 361
E-12 Function switch does not operate ............................................................................... 40- 361
E-13 Automatic warm-up system does not operate (in cold season) .................................. 40- 362
E-14 Auto-decelerator does not operate properly................................................................ 40- 363
E-15 Working mode does not change ................................................................................. 40- 364
E-16 Travel speed does not change.................................................................................... 40- 365
E-17 Alarm buzzer cannot be canceled............................................................................... 40- 366
E-18 When starting switch is turned OFF, service meter is not displayed........................... 40- 366
E-19 Service mode cannot be selected ............................................................................... 40- 367
E-20 Any of work equipment, swing and travel do not operate or cannot be locked ........... 40- 368
E-21 Swing brake does not operate properly ...................................................................... 40- 371
E-22 One-touch power maximizing function does not operate properly .............................. 40- 374
E-23 Travel alarm does not sound or does not stop sounding ............................................ 40- 377
E-24 Horn does not sound or does not stop ........................................................................ 40- 378
E-25 Windshield wiper and window washer do not operate ................................................ 40- 380
E-26 BOOM LOWER indicator is not displayed properly with monitoring function.............. 40- 382
E-27 ARM OUT indicator is not displayed properly with monitoring function ...................... 40- 384
E-28 ARM IN indicator is not displayed properly with monitoring function .......................... 40- 386
E-29 BOOM RAISE indicator is not displayed properly with monitoring function ................ 40- 386
E-30 BUCKET CURL indicator is not displayed properly with monitoring function.............. 40- 386
E-31 BUCKET DUMP indicator is not displayed properly with monitoring function ............. 40- 387
E-32 SWING indicator is not displayed properly with monitoring function ........................... 40- 387
E-33 TRAVEL indicator is not displayed properly with monitoring function ......................... 40- 387
E-34 ATTACHMENT indicator is not displayed properly with monitoring function .............. 40- 388
E-35 Attachment hydraulic circuit cannot be changed......................................................... 40- 390
E-36 KOMTRAX system does not operate properly ............................................................ 40- 391
Troubleshooting of hydraulic and mechanical system (H-mode) ............................................ 40- 393
Information in troubleshooting table..................................................................................... 40- 393
System chart for hydraulic and mechanical systems........................................................... 40- 394
Failure mode and cause table ............................................................................................. 40- 396
H- 1 All of work equipment, swing and travel work slow or lack power ............................... 40- 398
H- 2 Engine speed lowers significantly or engine stalls....................................................... 40- 400
H- 3 Any of work equipment,swing and travel does not work .............................................. 40- 401
H- 4 Unusual sound is heard from around hydraulic pump ................................................. 40- 401
H- 5 Fine control performance or response is poor ............................................................. 40- 402
H- 6 Boom operation lacks speed or power......................................................................... 40- 403
H- 7 Arm operation lacks speed or power ........................................................................... 40- 404
H- 8 Bucket operation lacks speed or power ....................................................................... 40- 405
H- 9 Work equipment does not move in single operation .................................................... 40- 405
H-10 Hydraulic drift of work equipment is large ................................................................... 40- 406
H-11 Time lag of work equipment is large ........................................................................... 40- 408
H-12 Other work equipment moves when one of work equipment is relieved ..................... 40- 408
H-13 One-touch power maximizing function does not work ................................................ 40- 409
H-14 In combined operation of work equipment , equipment having heavier load moves slower.
............................................................................................................................................. 40- 409
H-15 In combined operation of swing and boom RAISE, boom rising speed is low ............ 40- 410
H-16 Travel speed drops largely in combined operation of swing and travel ...................... 40- 410
H-17 Machine does not travel straight ................................................................................. 40- 411
H-18 Travel speed is low ..................................................................................................... 40- 412
H-19 Machine is hard to steer or travel power is low........................................................... 40- 413
H-20 Travel speed does not change, or travel speed is too low or high.............................. 40- 414
H-21 One of tracks does not run.......................................................................................... 40- 415
H-22 Upper structure does not swing .................................................................................. 40- 416

PC228US-8,PC228USLC-8 00-3-4
(01)
Table of Contents

H-23 Swing acceleration is poor or swing speed is low ....................................................... 40- 418
H-24 Upper structure overruns excessively when it stops swinging .................................... 40- 420
H-25 Shock is large when upper structure stops swinging .................................................. 40- 421
H-26 Large unusual noise is heard when upper structure stops swinging........................... 40- 421
H-27 Swing drift on a slope is large ..................................................................................... 40- 422
H-28 Attachment circuit cannot be changed ........................................................................ 40- 423
H-29 Oil flow in attachment circuit cannot be controlled ...................................................... 40- 423
Troubleshooting of engine (S-mode) ...................................................................................... 40- 424
Method of using troubleshooting chart................................................................................. 40- 424
S-1 Startability is poor.......................................................................................................... 40- 428
S-2 Engine does not start .................................................................................................... 40- 429
S-3 Engine does not pick up smoothly................................................................................. 40- 432
S-4 Engine stops during operation....................................................................................... 40- 433
S-5 Engine runs rough or is unstable................................................................................... 40- 434
S-6 Engine lacks power ....................................................................................................... 40- 435
S-7 Exhaust smoke is black (incomplete combustion)......................................................... 40- 436
S-8 Oil consumption is excessive (or exhaust smoke is blue) ............................................. 40- 437
S-9 Oil becomes contaminated early ................................................................................... 40- 438
S-10 Fuel consumption is excessive.................................................................................... 40- 439
S-11 Oil is in coolant (or coolant spurts or coolant level goes down) .................................. 40- 440
S-12 Oil pressure drops ....................................................................................................... 40- 441
S-13 Oil level rises (coolant or fuel in oil)............................................................................. 40- 442
S-14 Coolant temperature rises too high (overheating) ....................................................... 40- 443
S-15 Unusual noise is made ................................................................................................ 40- 444
S-16 Vibration is excessive.................................................................................................. 40- 445

50 Disassembly and assembly

General information on disassembly and assembly ............................................................... 50- 4
How to read Disassembly and Assembly............................................................................. 50- 4
Coating materials list............................................................................................................ 50- 6
Special tools list ................................................................................................................... 50- 9
Sketches of special tools ..................................................................................................... 50- 13
Engine and cooling system ..................................................................................................... 50- 18
Removal and installation of fuel supply pump assembly ..................................................... 50- 18
Removal and installation of fuel injector assembly .............................................................. 50- 22
Removal and installation of cylinder head assembly ........................................................... 50- 29
Removal and installation of radiator assembly .................................................................... 50- 44
Removal and installation of hydraulic oil cooler assembly................................................... 50- 47
Removal and installation of aftercooler assembly................................................................ 50- 49
Removal and installation of engine assembly...................................................................... 50- 52
Removal and installation of engine front seal ...................................................................... 50- 56
Removal and installation of engine rear seal ....................................................................... 50- 58
Removal and installation of fuel cooler assembly ................................................................ 50- 61
Removal and installation of fuel tank assembly ................................................................... 50- 63
Power train.............................................................................................................................. 50- 66
Removal and installation of travel motor and final drive assembly ...................................... 50- 66
Disassembly and assembly of final drive assembly............................................................. 50- 67
Removal and installation of swing motor and swing machinery assembly .......................... 50- 75
Disassembly and assembly of swing machinery assembly ................................................. 50- 77
Removal and installation of swing circle assembly .............................................................. 50- 85
Undercarriage and frame ........................................................................................................ 50- 86
Separation and connection of track shoe assembly ............................................................ 50- 86
Removal and installation of idler and idler cushion assembly.............................................. 50- 88
Disassembly and assembly of idler assembly ..................................................................... 50- 89

00-3-5 PC228US-8,PC228USLC-8
(02)
 Table of Contents

Disassembly and assembly of idler cushion assembly ........................................................ 50- 92

Disassembly and assembly of track roller assembly ........................................................... 50- 94
Disassembly and assembly of carrier roller assembly ......................................................... 50- 96
Removal and installation of revolving frame assembly........................................................ 50- 99
Removal and installation of counterweight assembly .......................................................... 50- 101
Removal and installation of maintenance counterweight assembly .................................... 50- 103
Hydraulic system .................................................................................................................... 50- 106
Removal and installation of center swivel joint assembly .................................................... 50- 106
Disassembly and assembly of center swivel joint assembly................................................ 50- 109
Removal and installation of hydraulic tank assembly .......................................................... 50- 111
Removal and installation of main pump assembly............................................................... 50- 113
Removal and installation of main pump input shaft oil seal ................................................. 50- 117
Removal and installation of control valve assembly ............................................................ 50- 118
Disassembly and assembly of control valve assembly ........................................................ 50- 123
Disassembly and assembly of work equipment PPC valve assembly ................................. 50- 127
Disassembly and assembly of travel PPC valve assembly ................................................. 50- 129
Work equipment...................................................................................................................... 50- 132
Removal and installation of work equipment assembly ....................................................... 50- 132
Removal and installation of anti-drop valve assembly for boom.......................................... 50- 134-1
Removal and installation of anti-drop valve assembly for arm ............................................ 50- 134-4
Disassembly and assembly of anti-drop valve assembly .................................................... 50- 134-6
Disassembly and assembly of work equipment cylinder assembly ..................................... 50- 135
Cab and its attachments ......................................................................................................... 50- 142
Removal and installation of operator's cab assembly.......................................................... 50- 142
Removal and installation of operator's cab glass (adhered window glass).......................... 50- 146
Removal and installation of front window assembly ............................................................ 50- 156
Removal and installation of floor frame assembly ............................................................... 50- 157
Removal and installation of air conditioner unit assembly ................................................... 50- 164
Electrical system ..................................................................................................................... 50- 170
Removal and installation of air conditioner compressor assembly ...................................... 50- 170
Removal and installation of air conditioner condenser assembly ........................................ 50- 172
Removal and installation of engine controller assembly...................................................... 50- 173
Removal and installation of pump controller assembly........................................................ 50- 175
Removal and installation of machine monitor assembly...................................................... 50- 178
Removal and installation of pump swash plate sensor........................................................ 50- 180
Removal and installation of KOMTRAX terminal assembly ................................................. 50- 181

60 Maintenance standard
Engine and cooling system ..................................................................................................... 60- 4
Engine mount....................................................................................................................... 60- 4
Cooling system .................................................................................................................... 60- 5
Power train.............................................................................................................................. 60- 6
Swing circle.......................................................................................................................... 60- 6
Swing machinery ................................................................................................................. 60- 8
Final drive ............................................................................................................................ 60- 10
Sprocket............................................................................................................................... 60- 12
Undercarriage and frame ........................................................................................................ 60- 14
Track frame and idler cushion ............................................................................................. 60- 14
Idler...................................................................................................................................... 60- 16
Track roller........................................................................................................................... 60- 18
Carrier roller......................................................................................................................... 60- 19
Track shoe ........................................................................................................................... 60- 20
Hydraulic system .................................................................................................................... 60- 25
Hydraulic tank ...................................................................................................................... 60- 25

PC228US-8,PC228USLC-8 00-3-6
(04)
Table of Contents

Main pump ........................................................................................................................... 60- 26

Control valve ........................................................................................................................ 60- 29
Swing motor ......................................................................................................................... 60- 39
Travel motor......................................................................................................................... 60- 41
PPC valve ............................................................................................................................ 60- 45
Solenoid valve...................................................................................................................... 60- 53
Attachment circuit selector valve ......................................................................................... 60- 55
Anti-drop valve ..................................................................................................................... 60- 58
Center swivel joint................................................................................................................ 60- 60
Work equipment...................................................................................................................... 60- 62
Work equipment................................................................................................................... 60- 62
Dimensions of components.................................................................................................. 60- 64
Work equipment cylinder ..................................................................................................... 60- 68

80 Appendix
Air conditioner ......................................................................................................................... 80- 3
Precautions for refrigerant ................................................................................................... 80- 3
Air conditioner component ................................................................................................... 80- 4
Configuration and function of refrigeration cycle.................................................................. 80- 6
Outline of refrigeration cycle ................................................................................................ 80- 8
Air conditioner unit ............................................................................................................... 80- 10
Air conditioner controller ...................................................................................................... 80- 15
Compressor ......................................................................................................................... 80- 16
Condenser and Modulator ................................................................................................... 80- 17
Sensor.................................................................................................................................. 80- 18
Procedure for testing and troubleshooting ........................................................................... 80- 20
Circuit diagram and arrangement of connector pins ............................................................ 80- 22
System diagram ................................................................................................................... 80- 24
Detail of air conditioner unit ................................................................................................. 80- 26
Parts and connectors layout ................................................................................................ 80- 28
Testing air leakage (duct) .................................................................................................... 80- 32
Testing with self-diagnosis function ..................................................................................... 80- 33
Testing vent (mode) changeover ......................................................................................... 80- 36
Testing FRESH/RECIRC air changeover ............................................................................ 80- 37
Testing inner sensor ............................................................................................................ 80- 38
Testing outer sensor ............................................................................................................ 80- 39
Testing sunlight sensor ........................................................................................................ 80- 40
Testing (dual) pressure switch for refrigerant ...................................................................... 80- 41
Testing relays....................................................................................................................... 80- 42
Troubleshooting chart 1 ....................................................................................................... 80- 44
Troubleshooting chart 2 ....................................................................................................... 80- 46
Information in troubleshooting table..................................................................................... 80- 48
Troubleshooting for power supply and CAN communication system (Air conditioner does not
operate)................................................................................................................................ 80- 50
Troubleshooting for compressor and refrigerant system (Air is not cooled) ........................ 80- 54
Troubleshooting for blower motor system (No air comes out or air flow is abnormal) ......... 80- 57
Troubleshooting for temperature control.............................................................................. 80- 60
Troubleshooting for vent (mode) changeover ...................................................................... 80- 62
Troubleshooting for FRESH/RECIRC air changeover ......................................................... 80- 64
Troubleshooting for temperature sensor system ................................................................. 80- 66
Troubleshooting with gauge pressure.................................................................................. 80- 68
Connection of service tool.................................................................................................... 80- 70
Precautions for disconnecting and connecting air conditioner piping .................................. 80- 72
Handling of compressor oil .................................................................................................. 80- 74

00-3-7 PC228US-8,PC228USLC-8
(04)
 Table of Contents

Desiccant replacement procedure ....................................................................................... 80- 76

90 Diagrams and drawings

Hydraulic circuit diagram ........................................................................................................ 90- 3
Symbols used in hydraulic circuit diagrams ......................................................................... 90- 3
Hydraulic circuit diagram (1/4) ............................................................................................. 90- 7
Hydraulic circuit diagram (2/4) ............................................................................................. 90- 7-2
Hydraulic circuit diagram (3/4) ............................................................................................. 90- 7-4
Hydraulic circuit diagram (4/4) ............................................................................................. 90- 7-6
Electrical circuit diagram ......................................................................................................... 90- 9
Symbols used in electric circuit diagrams............................................................................ 90- 9
Electrical circuit diagram...................................................................................................... 90- 13
Air conditioner electrical circuit diagram .............................................................................. 90- 47

Index ....................................................................................................................................... 1

PC228US-8,PC228USLC-8 00-3-8
(05)
Foreword and general information
Safety notice

Foreword and general information 0 -4

Safety notice 0 -4
(Rev. 2010/03)
Important safety notice

Appropriate servicing and repair are extremely important to ensure safe operation of the machine.
The shop manuals describe the effective and safe servicing and repair methods recommended by Ko-
matsu. Some of the servicing and repair methods require use of special tools designed by Komatsu
for special purposes.
The symbol mark "k" is indicated for such matters that require special precautions. The work indi-
cated with the warning mark should be performed according to the instructions with special attention
to the precautions. Should a hazardous situation occur or be anticipated during such work, be sure
to keep safe first and take every necessary measure.
6) Keep all tools in good condition, learn the
1. General precautions correct way to use them, and use the proper
k Inappropriate handling creates an ex- ones. Before starting work, thoroughly check
treme danger. Read and understand what the tools, machine, forklift truck, service car,
is described in the Operation and Mainte- etc.
nance Manual before operating the ma- 7) If welding repairs are needed, always have a
chine. Read and understand what is trained and experienced welder perform the
described in this manual before starting work. When performing welding work, always
work. wear welding gloves, apron, shielding
1) Before performing any greasing or repairs, goggles, cap and other clothes suited for
read all the safety labels stuck to the welding work.
machine. For the locations of the safety 8) Before starting work, warm up your body
labels and detailed explanation of precau- thoroughly to start work under good condi-
tions, see the Operation and Maintenance tion.
Manual. 9) Avoid continuing work for long hours and
2) Locate a place in the repair workshop to keep take rests at proper intervals to keep your
tools and removed parts. Always keep the body in good condition and at the provided
tools and parts in their correct places. Always place.
keep the work area clean and make sure that
there is no dirt, water, or oil on the floor. Safety points
Smoke only in the areas provided for 1 Good arrangement
smoking. Never smoke while working. 2 Correct work clothes
3) When performing any operation, always 3 Following work standard
wear safety shoes and helmet. Do not wear 4 Making and checking signals
Prohibition of operation and handling by unli-
loose work clothes, or clothes with buttons 5
censed workers
missing. 6 Safety check before starting work
q Always wear the safety glasses when hit- Wearing protective goggles (for cleaning or grind-
ting parts with a hammer. 7
ing work)
q Always wear the safety glasses when Wearing shielding goggles and protectors (for
8
grinding parts with a grinder, etc. welding work)
4) When performing any operation with two or 9 Good physical condition and preparation
more workers, always agree on the operating Precautions against work which you are not used
10
procedure before starting. Always inform to or you are used to too much
your fellow workers before starting any step
of the operation. Before starting work, hang
UNDER REPAIR warning tag in the oper-
ator's compartment.
5) Only qualified workers must perform the work
and operation which require license or quali-
fication.

00-4 PC228US-8,PC228USLC-8
(02)
 Foreword and general information
Safety notice

2. Preparation work 6) When removing a cover which is under

1) Before adding oil or making any repairs, park internal pressure or under pressure by a
the machine on a hard and level ground, and spring, always leave two bolts in diagonal
apply the parking brake and chock the positions. Loosen those bolts gradually and
wheels or tracks to prevent the machine from alternately to release the pressure, and then
moving. remove the cover.
2) Before starting work, lower the work equip- 7) When removing components, be careful not
ment (blade, ripper, bucket, etc.) to the to break or damage the electrical wiring.
ground. If this is not possible, insert the lock Damaged wiring may cause electrical fires.
pin or use blocks to prevent the work equip- 8) When removing piping, stop the fuel or oil
ment from falling. In addition, be sure to lock from spilling out. If any fuel or oil drips onto
all the control levers and hang warning tag on the floor, wipe it off immediately. Fuel or oil
them. on the floor can cause you to slip and can
3) When disassembling or assembling, support even cause fires.
the machine with blocks, jacks, or stands 9) As a general rule, do not use gasoline to
before starting the work. wash parts. Do not use it to clean electrical
4) Remove all mud and oil from the steps or parts, in particular.
other places used to get on and off the 10)Be sure to assemble all parts again in their
machine. Always use the handrails, ladders original places. Replace any damaged parts
or steps when getting on or off the machine. and parts which must not be reused with new
Never jump on or off the machine. If it is parts. When installing hoses and wires, be
impossible to use the handrails, ladders or sure that they will not be damaged by contact
steps, use a stand to provide safe footing. with other parts when the machine is oper-
ated.
3. Precautions during work 11)When installing high pressure hoses and
1) Before disconnecting or removing compo- tubes, make sure that they are not twisted.
nents for the oil, water, or air circuits, first Damaged hoses and tubes are dangerous,
release the pressure completely from the so be extremely careful when installing
circuit. When removing the oil filler cap, a hoses and tubes for high pressure circuits. In
drain plug, or an oil pressure pickup plug, addition, check that connections of them are
loosen it slowly to prevent the oil from correct.
spurting out. 12)When assembling or installing parts, always
2) The coolant and oil in the circuits are hot tighten them to the specified torques. When
when the engine is shut down, so be careful installing protective parts such as guards, or
not to get scalded. Wait for the oil and coolant parts which vibrate violently or rotate at high
to cool before performing any work on the oil speeds, be particularly careful to check that
or water circuits. they are installed correctly.
3) Before starting work, shut down the engine. 13)When aligning two holes, never insert your
When working on or around a rotating part, in fingers or hand. Be careful not to get your
particular, shut down the engine. When fingers caught in a hole.
checking the machine without shutting down 14)When measuring hydraulic pressure, check
the engine (measuring oil pressure, revolving that the measuring tools are correctly
speed, temperature, etc.), take extreme care installed.
not to get caught in rotating parts or moving 15)Take care when removing or installing the
parts. tracks of track-type machines. When
4) Before starting work, remove the cables from removing the track, the track separates
the battery. Always remove the cable from suddenly, so never let anyone stand at either
the negative (–) terminal first. end of the track.
5) When raising a heavy component (heavier 16)If the engine is operated for a long time in a
than 25 kg), use a hoist or crane. Before place which is not ventilated well, you may
starting work, check that the slings (wire suffer from gas poisoning. Accordingly, open
ropes, chains, and hooks) are free from the windows and doors to ventilate well.
damage. Always use slings which have
ample capacity and install them to proper
places. Operate the hoist or crane slowly to
prevent the component from hitting any other
part. Do not work with any part still raised by
the hoist or crane.

PC228US-8,PC228USLC-8 00-5
(02)
Foreword and general information
Safety notice

4. Precautions for slinging work and making signals

1) Only one appointed worker must make
signals and co-workers must communicate
with each other frequently. The appointed
signaler must make specified signals clearly
at a place where he is well seen from the
operator's seat and where he can see the
working condition easily. The signaler must
always stand in front of the load and guide
the operator safely.
q Do not stand under the load.
q Do not step on the load.
2) Check the slings before starting sling work.
3) Keep putting on gloves during sling work.
(Put on leather gloves, if available.)
4) Measure the weight of the load by the eye 8) When installing wire ropes to an angular
and check its center of gravity. load, apply pads to protect the wire ropes. If
5) Use proper sling according to the weight of the load is slippery, apply proper material to
the load and method of slinging. If too thick prevent the wire rope from slipping.
wire ropes are used to sling a light load, the 9) Use the specified eyebolts and fix wire ropes,
load may slip and fall. chains, etc. to them with shackles, etc.
6) Do not sling a load with one wire rope alone. 10)Apply wire ropes to the middle portion of the
If it is slung so, It may rotate and may slip out hook.
of the rope. Install two or more wire ropes q Slinging near the tip of the hook may
symmetrically.
k Slinging with one rope may cause
cause the rope to slip off the hook during
hoisting. The hook has the maximum
turning of the load during hoisting, un- strength at the middle portion.
twisting of the rope, or slipping of the
rope from its original winding position
on the load, which can result in a dan-
gerous accident.
7) Limit the hanging angle to 60 degree, as a
rule.
Do not sling a heavy load with ropes forming
a wide hanging angle from the hook.
When hoisting a load with two or more ropes,
the force subjected to each rope will increase
with the hanging angle. The table below
shows the variation of allowable load in kN
{kg} when hoisting is made with two ropes,
each of which is allowed to sling up to 9.8 kN
{1,000 kg} vertically, at various hanging
angles. When the two ropes sling a load verti- 11)Do not use twisted or kinked wire ropes.
cally, up to 19.6 kN {2,000 kg} of total weight 12)When lifting up a load, observe the following.
can be suspended. This weight is reduced to q Wind in the crane slowly until wire ropes

9.8 kN {1,000 kg} when the two ropes make are stretched. When settling the wire
a hanging angle of 120 degree. If the two ropes with the hand, do not grasp them
ropes sling a 19.6 kN {2,000 kg} load at a but press them from above. If you grasp
lifting angle of 150 degree, each of them is them, your fingers may be caught.
subjected to a force as large as 39.2 kN q After the wire ropes are stretched, stop

{4,000 kg}. the crane and check the condition of the

slung load, wire ropes, and pads.

00-6 PC228US-8,PC228USLC-8
(02)
 Foreword and general information
Safety notice

qIf the load is unstable or the wire rope or 13)If the hoist stops because of a power failure,
chains are twisted, lower the load and lift turn the power switch OFF. When turning on
it up again. a switch which was turned OFF by the
q Do not lift up the load at an angle. ground fault circuit interrupter, check that the
13)When lowering a load, observe the following. devices related to that switch are not in oper-
q When lifting down a load, stop it tempo- ating condition.
rarily at 30 cm above the floor, and then 14)If you find an obstacle around the hoist, stop
lower it slowly. the operation.
q Check that the load is stable, and then re- 15)After finishing the work, stop the hoist at the
move the sling. specified position and raise the hook to at
q Remove kinks and dirt from the wire least 2 m above the floor. Do not leave the
ropes and chains used for the sling work, sling installed to the hook.
and put them in the specified place.
7. Selecting wire ropes
5. Precautions for using mobile crane 1) Select adequate ropes depending on the
a Read the Operation and Maintenance Manu- weight of parts to be hoisted, referring to the
al of the crane carefully in advance and oper- table below.
ate the crane safely. Wire ropes
(Standard "Z" twist ropes without galvanizing)
6. Precautions for using overhead traveling (JIS G3525, No. 6, Type 6X37-A)
crane Nominal diameter Allowable load
k A hoist crane or similar device must be
of rope
mm kN ton
used for lifting a heavy load (25 kg or
10 8.8 0.9
more). The weight of a part that is 25 kg or 12 12.7 1.3
more is indicated with the symbol "4" in 14 17.3 1.7
"Disassembly and assembly". 16 22.6 2.3
1) Before starting work, inspect the wire ropes, 18 28.6 2.9
brake, clutch, controller, rails, over wind stop 20 35.3 3.6
device, ground fault circuit interrupter, crane 25 55.3 5.6
30 79.6 8.1
collision prevention device, and power appli-
40 141.6 14.4
cation warning lamp, and check safety. 50 221.6 22.6
2) Observe the signals for sling work. 60 318.3 32.4
3) Operate the hoist at a safe place.
a The allowable load is one-sixth of the
4) Check the direction indicator plates (east,
breaking strength of the rope to be used
west, south, and north) and the directions of
(Safety coefficient: 6).
the control buttons without fail.
5) Do not sling a load at an angle. Do not move
the crane while the slung load is swinging.
6) Do not raise or lower a load while the crane
is moving longitudinally or laterally.
7) Do not drag a sling.
8) When lifting up a load, stop it just after it
leaves the ground and check safety, and
then lift it up.
9) Consider the travel route in advance and lift
up a load to a safe height.
10)Place the control switch in a position where it
will not be an obstacle to work and passage.
11)After operating the hoist, do not swing the
control switch.
12)Remember the position of the main switch so
that you can turn off the power immediately in
an emergency.

PC228US-8,PC228USLC-8 00-7
(02)
Foreword and general information
Safety notice

8. Precautions for disconnecting and a For tightening torque, see the precau-
connecting hoses and tubes in an air condi- tions for installation in each section of
tioner circuit "Disassembly and assembly".
1) Disconnection
k Although the refrigerant (refrigerant
gas: R134a) used on the machine's air
conditioner is less destructive to the
ozone layer for environmentally friend-
liness, it is not allowed to be released
into the atmosphere as is. Whenever
disconnecting the air conditioner gas
circuit, be sure to recover the refriger-
ant gas to reuse it.
a Ask a qualified person for collection and
charge of the refrigerant (R134a).
a Never release the refrigerant (R134a) to
the atmosphere.
k If the refrigerant gas gets in your eyes
or contacts your skin, you may lose
your sight or your skin may be frozen.
Whenever recovering or adding refrig-
erant gas, you must put on safety
glasses, safety gloves and long
sleeved clothes.
The refrigerant gas must be recovered
and added by a qualified person.

2) Connection
1] When installing the air conditioner circuit
hoses and tubes, take care that dirt, dust,
water, etc. will not enter them.
2] When connecting the air conditioner
hoses and tubes, check that O-rings (1)
are fitted to their joints.
3] Check that O-ring (1) is free from flaw and
deterioration.
4] When connecting the refrigerant piping,
apply compressor oil for refrigerant
(R134a) (DENSO: ND-OIL8, VALEO
THERMAL SYSTEMS: ZXL100PG
(equivalent to PAG46)) to its O-rings.
a Example of O-ring (Fitted to every
joint of hoses and tubes)

00-8 PC228US-8,PC228USLC-8
(02)
 Foreword and general information
How to read the shop manual

How to read the shop manual 0 -9

(Rev. 2010/03)

q Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one of them is
required, consult KOMATSU distributors.
q Materials and specifications are subject to change without notice.
q Shop manuals are divided into the "Chassis volume" and "Engine volume". For the engine unit, see the engine vol-
ume of the engine model mounted on the machine.

1. Composition of shop manual

This shop manual contains the necessary technical information for services performed in a workshop. For
ease of understanding, the manual is divided into the following sections.

00. Index and foreword

This section contains the index, foreword, safety and basic information. If any revision is made, the LIST
OF REVISED PAGES will be added.

01. Specification
This section explains the specifications of the machine.

10. Structure and function

This section explains the structure and function of each component. It serves not only to give an under-
standing for the structure of each component, but also serves as reference material for troubleshooting.

20. Standard value table

This section explains the standard values for new machine and judgement criteria for testing, adjusting,
and troubleshooting. This standard value table is used to check the standard values in testing and adjust-
ing and to judge parts in troubleshooting.

30. Testing and adjusting

This section explains measuring tools and measuring methods for testing and adjusting, as well as the
adjusting method of each part. The standard values and judgment criteria for "Testing and adjusting" are
explained in "Standard value table".

40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is divided
by failure modes. The "S mode" of the troubleshooting related to the engine may be also explained in the
Chassis volume and Engine volume. In this case, see the Chassis volume.

50. Disassembly and assembly

This section explains the special tools and procedures for removing, installing, disassembling, and assem-
bling each component, as well as precautions for them. In addition, tightening torque, and quantity and
weight of coating material, oil, grease, and coolant necessary for the work are also explained.

60. Maintenance standard

This section gives maintenance standard values of each component. The maintenance standard sub-sec-
tion explains the criteria and remedies for disassembly and service.

80. Appendix
This section explains the structure, function, testing, adjusting, and troubleshooting for the equipment not
classifiable in other sections.

90. Diagrams and drawings (chassis volume) /Repair and replacement of parts (engine volume)
q Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q Engine volume
This section explains the method of remanufacturing and repairing engine and replacing parts.

PC228US-8,PC228USLC-8 00-9
(02)
Foreword and general information
How to read the shop manual

2. Revision and distribution

Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most
up-to-date information before you start any work.

3. Filing method
File the revised or added pages in the correct order of the page numbers printed in the LIST OF REVISED
PAGES.

q Revision number
When a manual is revised, revision number of each page is increased by 1.
(Example: (01), (02), (03)...)

q Revisions
The revised pages are shown in the LIST OF REVISED PAGES.

4. Symbol
Important safety and quality portions are marked with the following symbols so that the shop manual will be
used practically.

Symbol Item Description

k
Special safety precautions which are necessary when performing work are
Safety
described.

Special technical precautions or other precautions for preserving standards which

a Caution
are necessary when performing work are described.

4
Weight of parts of component or parts are indicated. Caution necessary when
Weight
selecting hoisting wire, or when working posture is important, etc. are described.

3
Places that require special attention for tightening torque during assembly are
Tightening torque
indicated.

2 Coat Places to be coated with adhesives, etc. during assembly are indicated.

5 Oil, coolant Places where oil, etc. must be added, and capacity are indicated.

6 Drain Places where oil, etc. must be drained, and quantity to be drained are indicated.

5. Unit
In this shop manual, the units are indicated with International System of units (SI).
For reference, conventionally used Gravitational System of units is indicated in parentheses { }.

00-10 PC228US-8,PC228USLC-8
(02)
 Foreword and general information
Explanation of terms for maintenance standard

Explanation of terms for maintenance standard 0 -1

(Rev. 2010/03)
The maintenance standard chapter explains the criteria for replacing or reusing products and parts in the ma-
chine maintenance work. The following terms are used to explain the criteria.

1. Standard dimension and tolerance q When some parts are repaired, the value of
q To be accurate, the finished dimension of performance/function is set to the standard
parts is slightly different from one to another. value.
q To specify the finished dimension of a part, a
certain dimension is set for the part and an al-
lowable difference from that dimension is in-
dicated.
q The above dimension set is called the "stan-
dard dimension" and the range of difference
from the standard dimension is called the
"tolerance".
q The tolerance with the symbols of + or – is in-
dicated on the right side of the standard di-
mension.

Example:
Standard dimension Tolerance
-0.022
120
-0.126
a The tolerance may be indicated in the text
and a table as [standard dimension (upper
limit of tolerance/lower limit of tolerance)].
Example) 120 (–0.022/–0.126)

q Usually, the dimension of a hole and the di-

mension of the shaft to be inserted into that
hole are indicated by the same standard di-
mension and different tolerances of the hole
and shaft. The tightness of fit is decided by
the tolerance.
q Indication of dimension of rotating shaft and
hole and their related drawing.
3. Standard interference
Example: q When the diameter of a hole of a part shown
Standard dimen- Tolerance
in the given standard dimension and toler-
sion Shaft Hole
-0.030 +0.046
ance table is smaller than that of the shaft to
60 be inserted, the difference between those di-
-0.076 0
ameters is called the "interference".
q The range (between A and B) from the differ-
2. Standard clearance and standard value ence (A) between the minimum dimension of
q The clearance made when new parts are as-
the shaft and the maximum dimension of the
sembled is called the "standard clearance", hole to the difference (B) between the maxi-
which is indicated by the range from the min- mum dimension of the shaft and the mini-
imum clearance to the maximum clearance. mum dimension of the hole is the “standard
q When some parts are repaired, the clearance
interference”.
is generally adjusted to the standard clear- q After repairing or replacing some parts, mea-
ance. sure the dimension of their hole and shaft
q The values indicating performance and func-
and check that the interference is in the stan-
tion of new products or equivalent are called dard range.
the "standard value", which is indicated by a
range or a target value.

PC228US-8,PC228USLC-8 00-11
(02)
Foreword and general information
Explanation of terms for maintenance standard

4. Repair limit and allowable value or allowable

dimension
q The dimension of a part changes because of
wear and deformation while it is used. The
limit of changed dimension is called the "re-
pair limit".
q If a part is worn to the repair limit, it must be
replaced or repaired.
q The performance and function of a product
lowers while it is used. A value with which the
product can be used without causing a prob-
lem is called the "allowable value" or "allow-
able dimension".
q If a product deviates from the allowable val-
ue, it must be checked or repaired. However,
since most of the allowable values are esti-
mated from various tests or experiences in
most cases, it must be judged after consider-
ing the operating condition and customer's
requirement.

5. Allowable clearance
q Parts can be used until the clearance be-
tween them is increased to a certain limit.
The limit at which those parts cannot be used
is called the "allowable clearance".
q If the clearance between the parts exceeds
the allowable clearance, they must be re-
placed or repaired.

6. Allowable interference
q The allowable maximum interference be-
tween the hole of a part and the shaft of an-
other part to be assembled is called the
"allowable interference".
q The allowable interference shows the repair
limit of the part of smaller tolerance.
q If the interference between the parts exceeds
the allowable interference, they must be re-
placed or repaired.

00-12 PC228US-8,PC228USLC-8
(02)
 Foreword and general information
Handling of hydraulic components

Handling of hydraulic components 0 -13

(Rev. 2010/03)
With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt
(foreign material) in the hydraulic circuit. Therefore, special precaution is required when adding hydraulic oil,
or when disassembling or assembling hydraulic components.

1. Be careful of the operating environment

Avoid adding hydraulic oil, replacing filters, or
repairing the machine in rain or high winds, or at
places where there is a lot of dust.

2. Disassembly and maintenance work in the

field
If disassembly or maintenance work is
performed on hydraulic components in the field,
there is danger of dust entering the components.
It is also difficult to check the performance after
repairs, so it is desirable to use unit exchange.
Disassembly and maintenance of hydraulic
components should be performed in a specially
prepared dustproof workshop, and the perfor-
mance should be checked with special test
equipment.

3. Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from
entering. If the opening is left open or is blocked
with a rag, there is danger of dirt entering or of
the surrounding area being made dirty by
leaking oil so never do this. Do not simply drain
oil out onto the ground, but collect it and ask the
customer to dispose of it, or take it back with you
for disposal.

4. Preventing intrusion of foreign materials

during refilling operations.
Be careful not to let any dirt or dust get in when
refilling with hydraulic oil. Always keep the oil
filler and the area around it clean, and also use
clean pumps and oil containers. If an oil cleaning
device is used, it is possible to filter out the dirt
that has been collected during storage, so this is
an even more effective method.

PC228US-8,PC228USLC-8 00-13
(02)
Foreword and general information
Handling of hydraulic components

5. Replacing hydraulic oil while its temperature is high

When hydraulic oil or other oil is warm, it flows
easily. In addition, the sludge can also be
drained out easily from the circuit together with
the oil, so it is best to change the oil when it is still
warm. When changing the oil, as much as
possible of the old hydraulic oil must be drained
out. (Drain the oil from the hydraulic tank; also
drain the oil from the filter and from the drain plug
hole in the circuit.) If any old oil is left, the
contaminants and sludge in it will mix with the
new oil and will shorten the life of the hydraulic
oil.

6. Flushing operations
After disassembling and assembling the equip-
ment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit. Normally, flushing is
performed twice. Primary flushing is performed
by use of flushing oil and secondary flushing is
performed by use of the specified hydraulic oil.

7. Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the machine,
perform oil cleaning to remove the sludge or
contaminants in the hydraulic oil circuit. The oil
cleaning equipment can remove the ultra fine
(about 3 m) particles that the filter built in the
hydraulic equipment cannot remove, so it is an
extremely effective device.

00-14 PC228US-8,PC228USLC-8
(02)
 Foreword and general information
Method of disconnecting and connecting push-pull type coupler

Method of disconnecting and connecting push-pull type coupler 0 -15

(Rev. 2010/03)
k Before performing the following work, loosen the oil filler cap of the hydraulic tank gradually to
release the remaining pressure in the hydraulic tank.
k Even if the remaining pressure is released from the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly, prepare an oil container.

Type 1 0 -15

1. Disconnection
1) Hold adapter (1) and push hose joint (2) into
mating adapter (3). (Fig. 1)
a The adapter can be pushed in about 3.5
mm.
a Do not hold rubber cap portion (4).
2) With hose joint (2) pushed into adapter (3),
press rubber cap portion (4) against adapter
(3) until it clicks. (Fig. 2)
3) Hold hose adapter (1) or hose (5) and pull it
out. (Fig. 3)
a Since some hydraulic oil flows out, pre-
pare an oil container.

2. Connection
1) Hold hose adapter (1) or hose (5) and insert
it in mating adapter (3), aligning them with
each other. (Fig. 4)
a Do not hold rubber cap portion (4).
2) After inserting the hose fitting in the adapter
on the other side perfectly, pull it back to
check the connecting condition (Fig. 5)
a When the hose is pulled back, the rubber
cap portion moves toward the hose about
3.5 mm. This does not indicate abnormal-
ity, however.

PC228US-8,PC228USLC-8 00-15
(02)
Foreword and general information
Method of disconnecting and connecting push-pull type coupler

Type 2 0 -16

1. Disconnection
1) Hold the tightening portion and push body (7)
straight until sliding prevention ring (6)
contacts contact surface (a) of the hexagonal
portion at the male end. (Fig. 6)
2) While holding the condition of Step 1), turn
lever (8) to the right (clockwise). (Fig. 7)
3) While holding the condition of Steps 1) and
2), pull out whole body (7) to disconnect it.
(Fig. 8)

2. Connection
q Hold the tightening portion and push body (7)
straight until sliding prevention ring (6) con-
tacts contact surface (a) of the hexagonal
portion at the male end. (Fig. 9)

00-16 PC228US-8,PC228USLC-8
(02)
 Foreword and general information
Method of disconnecting and connecting push-pull type coupler

Type 3 0 -17

1. Disconnection
1) Hold the tightening portion and push body (9)
straight until sliding prevention ring (8)
contacts contact surface (b) of the hexagonal
portion at the male end. (Fig. 10)
2) While holding the condition of Step 1), push
cover (10) straight until it contacts contact
surface (b) of the hexagonal portion at the
male end. (Fig. 11)
3) While holding the condition of Steps 1) and
2), pull out whole body (9) to disconnect it.
(Fig. 12)

2. Connection
q Hold the tightening portion and push body (9)
straight until sliding prevention ring (8) con-
tacts contact surface (b) of the hexagonal
portion at the male end. (Fig. 13)

PC228US-8,PC228USLC-8 00-17
(02)
Foreword and general information
Handling of electric equipment

Handling of electric equipment 0 -18

(Rev. 2010/03)
To maintain the performance of the machine over a long period, and to prevent failures or other troubles be-
fore they occur, correct "operation", "maintenance and inspection", "troubleshooting", and "repairs" must be
performed. This section deals particularly with correct repair procedures for mechatronics and is aimed at im-
proving the quality of repairs. For this purpose, it gives sections on "Handling electric equipment".

Points to remember when handling electric equipment 0 -18

1. Handling wiring harnesses and connectors
Wiring harnesses consist of wires connecting
one component to another component, connec-
tors used for connecting and disconnecting one
wire from another wire, and protectors or tubes
used for protecting the wires.
Compared with other electrical components
fitted in boxes or cases, wiring harnesses are
more likely to be affected by the direct effects of
rain water, heat, or vibration. Furthermore,
during inspection and repair operations, they are
frequently removed and installed again, so they
are likely to suffer deformation or damage. For
this reason, it is necessary to be extremely
careful when handling wiring harnesses.
2. Main failures occurring in wiring harnesses
1) Defective contact of connectors (defective
contact between male and female connec-
tors)
Problems with defective contact are likely to
occur because the male connector is not
properly fitted into the female connector, or
because one or both of the connectors is
deformed or the position is not correctly
aligned, or because there is corrosion or
oxidization of the contact surfaces. The
corroded or oxidized contact surfaces may
become shiny again (and contact may
become normal) by connecting and discon-
necting the connector about ten times.
2) Defective crimping or soldering of connectors
The pins of the male and female connectors
are attached to wires by crimping or
soldering. If excessive force is applied to the
wire, the joint is separated and causes a
defective contact or the wire is broken.

00-18 PC228US-8,PC228USLC-8
(02)
 Foreword and general information
Handling of electric equipment

3) Disconnections in wiring
If the harness is pulled to disconnect the
connector, or components are lifted with a
crane with the harness still connected, or a
heavy object hits the harness, the crimping of
the connector may separate, or the soldering
may be damaged, or the harness may be
broken.

4) High-pressure water entering connector

The connector is designed to make it difficult
for water to enter (drip-proof structure), but if
high-pressure water is sprayed directly on
the connector, water may enter the
connector, depending on the direction of the
water jet.
Accordingly, take care not to spray water
over the connector.
The connector is designed to prevent water
from entering, but at the same time, if water
does enter, it is difficult for it to be drained.
Therefore, if water should get into the
connector, the pins will be short-circuited by
the water, so if any water gets in, immediately
dry the connector or take other appropriate
action before passing electricity through it.
5) Oil or dirt stuck to connector
If oil or grease are stuck to the connector and
an oil film is formed on the mating surface of
the male and female pins, the oil will not let
the electricity pass, so there will be defective
contact. If there is oil or grease stuck to the
connector, wipe it off with a dry cloth or blow
it to dry with compressed air and spray it with
electric contact cleaner.
a When wiping the joint portion of the con-
nector, be careful not to apply excessive
force or deform the pins.
a If there is oil or water in the compressed
air, the contacts will become even dirtier,
so remove the oil and water from the com-
pressed air completely before cleaning
with compressed air.

PC228US-8,PC228USLC-8 00-19
(02)
Foreword and general information
Handling of electric equipment

3. Removing, installing, and drying connectors

and wiring harnesses
1) Disconnecting connectors
1] Hold the connectors when disconnecting.
When disconnecting the connectors, hold
the connectors. For connectors held by a
screw, loosen the screw fully, then hold
the male and female connectors in each
hand and pull apart. For connectors
which have a lock stopper, press down
the stopper with your thumb and pull the
connectors apart.
a Never pull with one hand.

2] When removing from clips

q Both of the connector and clip have
stoppers, which are engaged with
each other when the connector is in-
stalled.

q When removing a connector from a

clip, pull the connector in a parallel di-
rection to the clip for removing stop-
pers.
a If the connector is pried up and down
or to the left or right, the housing may
break.

3] Action to take after removing connectors

After removing a connector, cover it with
a vinyl bag to prevent the entry of dust,
dirt, oil, or water to the contact portion.
a If the machine is left disassembled for
a long time, it is particularly easy for
improper contact to occur, so always
cover the connector.

00-20 PC228US-8,PC228USLC-8
(02)
 Foreword and general information
Handling of electric equipment

2) Connecting connectors
1] Check the connector visually.
Check that no oil, dirt, or water is stuck to
connector pins (joint portion).
Check that connector pins are free from
deformation, defective contact, corrosion,
or damage.
Check that external surfaces of the
connectors are free from damage or
breakage.
a If there is any oil, water, or dirt stuck to
the connector, wipe it off with a dry
cloth. If any water has got inside the
connector, warm the inside of the con-
nector and harness with a dryer, but
be careful not to make them too hot as
this will cause short circuits.
a If there is any damage or breakage,
replace the connector.
2] Fix the connector securely.
Position the connectors correctly, and
then fit them securely. For connectors
with the lock stopper, push in the
connector until the stopper clicks into
position.
3] Correcting protrusion of the boot and
misalignment of the wiring harness
For connectors fitted with the boot,
correct any extrusion of the boot. In addi-
tion, if the wiring harness is moved in
laying, or the clamp is out of position,
correct it to its right position.
a If the connector cannot be corrected
easily, remove the clamp and adjust
the position.
q If the connector clamp is removed, be
sure to return it to its original position.
Check also that there are no loose
clamps.

PC228US-8,PC228USLC-8 00-21
(02)
Foreword and general information
Handling of electric equipment

3) Deutsch connector (DT 8-pin, 12-pin)

Disconnection (Left of figure) q Disconnection q Connection (Example of
While pressing locks (a) and (b), pull out the incomplete setting of
female connector (2). (a))
Connection (Right of figure)
1] Push in female connector (2) horizontally
until the lock clicks.
Arrow: 1)
2] Since locks (a) and (b) may not be set
completely, push in female connector (2)
while moving it up and down until the
locks are set normally.
Arrow: 1), 2), 3)
a Right of figure: Lock (a) is pulled down
(not set completely) and lock (b) is set
completely.
(1): Male connector
(2): Female connector
(a), (b): Locks

00-22 PC228US-8,PC228USLC-8
(02)
 Foreword and general information
Handling of electric equipment

4) Drying wiring harness

If there is any oil or dirt on the wiring harness,
wipe it off with a dry cloth. Avoid washing it in
water or using steam. If the connector must
be washed in water, do not use high-pres-
sure water or steam directly on the wiring
harness. If water gets directly on the
connector, do as follows.
1] Disconnect the connector and wipe off
the water with a dry cloth.
a If the connector is to be blown with dry
compressed air, there is the risk that
oil in the air may cause defective con-
tact, remove oil and water in the air
before starting air blow.

2] Dry the inside of the connector with a

dryer.
If water gets inside the connector, use a
dryer to dry the connector.
a Hot air from the dryer can be used, but
regulate the time that the hot air is
used in order not to make the connec-
tor or related parts too hot, as this will
cause deformation or damage to the
connector.

3] Perform a continuity test on the

connector.
After drying, leave the wiring harness
disconnected and perform a continuity
test to check for any short circuits
between pins caused by water.
a After completely drying the connector,
blow it with electric contact cleaner
and reassemble.

PC228US-8,PC228USLC-8 00-23
(02)
Foreword and general information
Handling of electric equipment

4. Handling of connectors used on engine

a Mainly, following engines are object for following connectors.
q 95E-5
q 107E-1
q 114E-3
q 125E-5
q 140E-5
q 170E-5
q 12V140E-3

1) Slide, lock type (FRAMATOME-3, FRAM- Examples)

ATOME-2) Intake air temperature sensor in
q 95/107/114/125/140/170/12V140 Series intake manifold: TIM
q Various pressure sensors and NE Fuel temperature sensor: TFUEL
speed sensor Oil temperature sensor: TOIL
Examples) Coolant temperature sensor: TWTR,
Intake air pressure sensor in intake etc.
manifold: PIM (125/170/12V140
series) Disconnection
Oil pressure sensor: POIL Disconnect the connector by pulling lock (B)
(125/170/12V140 series) (on the wiring harness side) of connector (2)
Oil pressure switch (95/107/114 outward.
series)
Ne speed sensor on flywheel housing:
NE (95/107/114/125/140/170/12V140
series)
Ambient pressure sensor: PAMB
(125/170/12V140 series)

Disconnection
1] Slide lock L1 to the right.
2] While pressing lock L2, pull out connector
(1) toward you.
a Even if lock L2 is pressed, connector
(1) cannot be pulled out toward you, if
part (A) does not float. In this case,
float part (A) with a small screwdriver Connection
while pressing lock L2, and then pull Insert the connector straight until it "clicks".
out connector (1) toward you.

Connection
Insert the connector straight until it "clicks".
2) Pull lock type (PACKARD-2)
q 95/107/114/125/140/170/12V140 Series
q Various temperature sensors

00-24 PC228US-8,PC228USLC-8
(02)
 Foreword and general information
Handling of electric equipment

3) Push lock type (1) While pressing up lock (C) of the connector
q 95/107/114 series with flat-head screwdriver [1], pull out
Example) Fuel pressure sensor in connector (3) in the direction of the arrow.
common rail (BOSCH-03)

Disconnection
While pressing lock (C), pull out connector
(3) in the direction of the arrow.

q 114 series

Connection
Insert the connector straight until it "clicks".

4) Push lock type (2)

q 107/114 series
Example) Intake air pressure/tempera-
ture sensor in intake manifold (SUMI-
q 107 series TOMO-04)

Disconnection
While pressing lock (D), pull out connector
(4) in the direction of the arrow.

a If the lock is located on the underside, use

flat-head screwdriver [1] since you cannot
insert your fingers.

Connection
Insert the connector straight until it "clicks".

PC228US-8,PC228USLC-8 00-25
(02)
Foreword and general information
Handling of electric equipment

5) Push lock type (3) Example) Intake air pressure sensor in

q 95/125/140/170/12V140 series intake manifold.
(CANNON-04): PIM, etc.
Disconnection
While pressing lock (E) of the connector, pull
out connector (5) in the direction of the arrow. Disconnection
Example) Fuel pressure sensor in common 1] Turn housing (H1) in the direction of the
rail: PFUEL etc. (AMP-3) arrow.
a When connector is unlocked, housing
(H1) becomes heavy to turn.
2] Pull out housing (H1) in the direction of
the arrow.
a Housing (H1) is left on the wiring har-
ness side.

Example) Injection pressure control valve of

fuel supply pump: PCV (SUMITOMO-2)

Connection
1] Insert the connector to the end, while
setting its groove.
2] Turn housing (H1) in the direction of the
arrow until it "clicks".

Examples) Speed sensor of fuel supply

pump: G (SUMITOMO-3)
a Pull the connector straight up.

Connection
Insert the connector straight until it "clicks".
6) Turn-housing type (Round green
connector)
q 140 series

00-26 PC228US-8,PC228USLC-8
(02)
 Foreword and general information
Handling of electric equipment

5. Handling controller
1) The controller contains a microcomputer and
electronic control circuits. These control all of
the electronic circuits on the machine, so be
extremely careful when handling the
controller.
2) Do not place objects on top of the controller.
3) Cover the control connectors with tape or a
vinyl bag. Never touch the connector
contacts with your hand.
4) During rainy weather, do not leave the
controller in a place where it is exposed to
rain.
5) Do not place the controller on oil, water, or
soil, or in a place that can be heated to a high
temperature even for a short time. (Place it
on a suitable dry stand.)
6) Precautions when performing arc welding
When performing arc welding on the
machine body, disconnect all of the wiring
harness connectors connected to the
controller. Fit an arc welding ground to the
place close to the welding point.

6. Points to remember when troubleshooting

electric circuits
1) Be sure to turn the power OFF before discon-
necting or connecting connectors.
2) Before performing troubleshooting, check all
the related connectors for loose connection.
a Disconnect and connect the related con-
nectors several times to check.
3) Be sure to connect any disconnected
connectors before going on to the next step.
a If the power is turned ON with the connec-
tors still disconnected, unnecessary
warning will be displayed.
4) When performing troubleshooting of circuits
(measuring the voltage, resistance, conti-
nuity, or current), wag the related wiring
harnesses and connectors several times and
check that there is no change in the reading
of the tester.
a If there is any change, there may be de-
fective contact in the circuit.

PC228US-8,PC228USLC-8 00-27
(02)
Foreword and general information
How to read electric wire code

How to read electric wire code 0 -28

(Rev. 2010/03)
In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by symbols.
The electric wire code is helpful in understanding the electric circuit diagram.

Example: AEX 0.85 L --- Indicates blue, heat-resistant, low-voltage wire for automobile, having nominal No.
of 0.85

Indicates color of wire by color code.

Color codes are shown in Table 3.

Indicates size of wire by nominal No.

Size (Nominal No.) is shown in Table 2.

Indicates type of wire by symbol.

Type, symbol, and material of wire are shown in Table 1.
(Since the use of AV and AVS wires depends on size (nominal No.), their symbols
are not indicated on the diagram.)

1. Type, symbol, and material

AV and AVS are different only in thickness and outside diameter of the cover. CAVS has a circular
compressed conductor. It differs from AV and AVS in the outside diameter and thickness of the cover. And
AEX is similar to AV in thickness and outside diameter of the cover but different from AV and AVS in mate-
rial of the cover.

(Table 1)
Tempera-
Type Symbol Material ture range Example of use
for use ( °C)
Annealed copper for electric
Low-voltage Conductor
appliance General wiring
wire for automo- AV
(nominal No. 5 and above)
biles Insulator Soft polyvinyl chloride
Thin low-volt- Annealed copper for electric
Conductor
age wire for appliance General wiring
AVS -30 – +60
automobile (nominal No. 3 and below)
Insulator Soft polyvinyl chloride
(type 1)
Thin low-volt- Annealed copper for electric
Conductor
age wire for appliance For mid- to small-size excavators
CAVS
automobile (nominal No. 1.25 and below)
Insulator Soft polyvinyl chloride
(type 2)
Annealed copper for electric General wiring in extremely cold
Heat resistant Conductor
appliance weather district, wiring at high
low-voltage wire AEX -50 – +110
Heat-resistant crosslinked ambient temperature place
for automobiles Insulator
polyethylene

00-28 PC228US-8,PC228USLC-8
(02)
 Foreword and general information
How to read electric wire code

2. Dimensions

(Table 2)
Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5
Number of
strands/Diame- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32
ter of strand
Conduc- Sectional area
tor 0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23
(mm2)

d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0

AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6 –

Cover D

AV Standard – – – – – – – 4.6

AEX Standard 2.0 2.2 2.7 3.0 3.1 – 3.8 4.6

Nominal No. 8 15 20 30 40 50 60 85 100

Number of
strands/Diame- 50/0.45 84/0.45 41/0.80 70/0.80 85/0.80 108/0.80 127/0.80 169/0.80 217/0.80
ter of strand
Conduc- Sectional area
tor 7.95 13.36 20.61 35.19 42.73 54.29 63.84 84.96 109.1
(mm2)

d (approx.) 3.7 4.8 6.0 8.0 8.6 9.8 10.4 12.0 13.6

AVS Standard – – – – – – – – –
Cover D

AV Standard 5.5 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6

AEX Standard 5.3 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6

Nominal No. 0.5f 0.5 0.75f 0.85 1.25f 1.25

Number of 7/Circular com- 11/Circular com- 16/Circular com-
strands/Diame- – – –
ter of strand pressed pressed pressed
Conduc- Sectional area
tor – 0.56 – 0.88 – 1.29
(mm2)

d (approx.) – 0.9 – 1.1 – 1.4

Cover D

CAVS Standard – 1.6 – 1.8 – 2.1

"f" of nominal No. denotes "flexible".

PC228US-8,PC228USLC-8 00-29
(02)
Foreword and general information
How to read electric wire code

3. Color codes table

(Table 3)
Color Code Color of wire Color Code Color of wire
B Black LgW Light green & White
Br Brown LgY Light green & Yellow
BrB Brown & Black LR Blue & Red
BrR Brown & Red LW Blue & White
BrW Brown & White LY Blue & Yellow
BrY Brown & Yellow O Orange
Ch Charcoal P Pink
Dg Dark green R Red
G Green RB Red & Black
GB Green & Black RG Red & Green
GL Green & Blue RL Red & Blue
Gr Gray RW Red & White
GR Green & Red RY Red & Yellow
GW Green & White Sb Sky Blue
GY Green & Yellow Y Yellow
L Blue YB Yellow & Black
LB Blue & Black YG Yellow & Green
Lg Light green YL Yellow & Blue
LgB Light green & Black YR Yellow & Red
LgR Light green & Red YW Yellow & White

Remarks: In a color code consisting of 2 colors, the first color is the color of the background and the second
color is the color of the marking.
Example: "GW" means that the background is "Green" and marking is "White".

4. Types of circuits and color codes

(Table 4)
Type of wire AVS, AV, CAVS AEX
Charge R WG – – – – R –
Ground B – – – – – B –
Start R – – – – – R –
Light RW RB RY RG RL – D –
Instrument Y YR YB YG YL YW Y Gr
Signal G GW GR GY GB GL G Br
L LW LR LY LB – L –
Type of cir-
Br BrW BrR BrY BrB – – –
cuit
Lg LgR LgY LgB LgW – – –
O – – – – – – –
Others Gr – – – – – – –
P – – – – – – –
Sb – – – – – – –
Dg – – – – – – –
Ch – – – – – – –

00-30 PC228US-8,PC228USLC-8
(02)
 Foreword and general information
Precautions when performing work

Precautions when performing work 0 -31

(Rev. 2010/03)
When removing, installing, disassembling or assembling a unit, be sure to follow the general precautions giv-
en below.

1. Precautions for removal work

q If the coolant contains antifreeze, dispose of it correctly as chemicals.
q After disconnecting hoses or tubes, cover them or fit plugs to prevent dirt or dust from entering.
q When draining oil, prepare a container of adequate size to catch the oil.
q Check the match marks showing the installation position, and put match marks in the necessary places
before removal to prevent any mistake when assembling.
q To prevent any excessive force from being applied to the wiring, always hold the connectors when dis-
connecting the connectors. Do not pull the wires.
q Attach the tags to wires and hoses to show their installation position to prevent any mistake when in-
stalling.
q Check the number and thickness of the shims, and keep them in a safe place.
q When slinging component, be sure to use lifting equipment of ample strength.
q When using forcing screws to remove any component, tighten the forcing screws uniformly and alter-
nately.
q Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from
entering after removal.
a Precautions when handling piping during disassembly
Put the following plugs into the piping after disconnecting it during disassembly operations.
1) Face seal type hoses and tubes
Nominal
Plug (nut end) Sleeve nut (elbow end)
number
02 07376 - 70210 02789 - 20210
03 07376 - 70315 02789 - 20315
04 07376 - 70422 02789 - 20422
05 07376 - 70522 02789 - 20522
06 07376 - 70628 02789 - 20628
10 07376 - 71034 07221 - 21034
12 07376 - 71234 07221 - 21234

2) Split flange type hoses and tubes

Nominal
Flange (hose end) Sleeve head (tube end) Split flange
number
04 07379 - 00400 07378 - 10400 07371 - 30400
05 07379 - 00500 07378 - 10500 07371 - 30500

3) If the part is not under hydraulic pressure, the following corks can be used.
Nominal Dimensions
Part No.
number D d L
06 07049 - 00608 5 6 8
08 07049 - 00811 8 6.5 11
10 07049 - 01012 10 8.5 12
12 07049 - 01215 12 10 15
14 07049 - 01418 14 11.5 18
16 07049 - 01620 16 13.5 20
18 07049 - 01822 18 15 22
20 07049 - 02025 20 17 25
22 07049 - 02228 22 18.5 28
24 07049 - 02430 24 20 29
27 07049 - 02734 27 22.5 34

PC228US-8,PC228USLC-8 00-31
(02)
Foreword and general information
Precautions when performing work

2. Precautions for installation work

q Tighten all of the bolts and nuts (sleeve nuts) to the specified torque (KES).
q Install the hoses without twisting or interference and fix them with intermediate clamps, if available.
q Replace all of the gaskets, O-rings, cotter pins, and lock plates with new parts.
q Bend the cotter pins and lock plates securely.
q When coating with adhesive, clean and degrease the part, and coat the threaded portion with two to
three drops of adhesive.
q When coating with liquid gasket, clean and degrease the surface, and apply it uniformly after making
sure that the surface is free from dirt or damage.
q Clean all of the parts, and correct any damage, dents, burrs, or rust found on them.
q Coat the rotating parts and sliding parts with engine oil.
q When press-fitting parts, coat the surface with molybdenum disulfide lubricant (LM-P).
q After installing the snap rings, check that the snap ring is settled in the ring groove completely.
q When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect
them securely.
q When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align
the direction of the hook.
q When installing split flanges, fasten them uniformly and alternately to prevent excessive tightening on
one side.
a When operating the hydraulic cylinders for the first time after reassembling the cylinders, hydraulic
pumps and other hydraulic component removed for repair, be sure to bleed the air as follows:
1] Start and run the engine at low idle.
2] Operate the work equipment control lever to operate the hydraulic cylinder four to five times, stop-
ping the piston at 100 mm off the end of its stroke.
3] Next, operate the hydraulic cylinder three to four times to the end of its stroke.
a When using the machine for the first time after repair or long storage, follow the same procedure.

3. Precautions for completing work

1) Refilling of coolant, oil and grease
q If the coolant is drained, close the drain valve, and add coolant to the specified level. Run the engine
to circulate the coolant through the system. Then add the coolant again if necessary.
q If the hydraulic component is removed and installed again, add engine oil to the specified level. Run
the engine to circulate the oil through the system. Then add the oil again if necessary.
q If the hydraulic piping or hydraulic equipment are removed, be sure to bleed air from the system
after reassembling the parts, by referring to "Testing and adjusting".
q Supply the specified amount of grease (molybdenum disulfide grease) to the work equipment parts.

2) Checking cylinder head and manifolds mountings for looseness

Check the cylinder head and intake and exhaust manifold mountings for looseness.
If any part is loosened, retighten it.
q For the tightening torques, see the "Disassembly and assembly".

3) Checking engine piping for damage and looseness

Intake and exhaust system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for air suction and
exhaust gas leakage.
If any part is loosened or damaged, retighten or repair it.
Cooling system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for coolant leak-
age.
If any part is loosened or damaged, retighten or repair it.
Fuel system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for fuel leakage.
If any part is loosened or damaged, retighten or repair it.

00-32 PC228US-8,PC228USLC-8
(02)
 Foreword and general information
Precautions when performing work

4) Checking muffler, exhaust pipe and their mounts for damage and looseness
1] Visually check the muffler, exhaust pipe and their mounts for a crack and damage.
If any part is damaged, replace it.
2] Check the mounting bolts and nuts of the muffler, exhaust pipe and their mounts for looseness.
If any part is loosened, retighten it.
5) Checking muffler function
Check the muffler for unusual sound and sound different from that of a new muffler.
If any unusual sound is heard, repair the muffler, referring to "Troubleshooting" and "Disassembly and
assembly".

PC228US-8,PC228USLC-8 00-33
(02)
Foreword and general information
Standard tightening torque table

Standard tightening torque table 0 -34

(Rev. 2010/03)
1. Table of tightening torques for bolts and nuts
a Unless otherwise specified, tighten metric nuts and bolts to the torque shown in the following table.

1) The following table applies to the bolts in Fig. A.

Thread diam- Width across
Tightening torque
eter of bolt flats
mm mm Nm kgm
6 10(10) 11.8 –14.7 1.2 – 1.5
8 13(12) 27 – 34 2.8 – 3.5
10 17(14) 59 – 74 6.0 – 7.5
12 19(17) 98 – 123 10.0 – 12.5
14 22 157 – 196 16 – 20
16 24 245 – 309 25 – 31.5
18 27 343 – 427 35 – 43.5
20 30 490 – 608 50 – 62
22 32 662 – 829 67.5 – 84.5
24 36 824 – 1,030 84 – 105
27 41 1,180 – 1,470 120 – 150
30 46 1,520 – 1,910 155 – 195
33 50 1,960 – 2,450 200 – 250
36 55 2,450 – 3,040 250 – 310
39 60 2,890 – 3,630 295 – 370
a Values with ( ) in the "Width across flats" column are for (*) marked bolt (flange bolt) shown in Fig. A.

2) The following table applies to the bolts in Fig. B.

Thread diam- Width across
Tightening torque
eter of bolt flats
mm mm Nm kgm
6 10 5.9 – 9.8 0.6 – 1.0
8 12 13.7 – 23.5 1.4 – 2.4
10 14 34.3 – 46.1 3.5 – 4.7
12 17 74.5 – 90.2 7.6 – 9.2

Fig. A Fig. B

a Values with ( ) are applied to (*) marked bolt (flange bolt) as the width across flats.

00-34 PC228US-8,PC228USLC-8
(02)
 Foreword and general information
Standard tightening torque table

2. Table of tightening torque for split flanged bolts

a Unless otherwise specified, tighten split flanged bolts to the torque shown in the following table.
Thread diam- Width across
Tightening torque
eter of bolt flats
mm mm Nm kgm
10 14 59 – 74 6.0 – 7.5
12 17 98 – 123 10.0 – 12.5
16 22 235 – 285 23.5 – 29.5

3. Table of tightening torque for O-ring boss piping joints

a Unless otherwise specified, tighten O-ring boss piping joints to the torque shown in the following table.
Thread diam- Width across
Tightening torque (Nm {kgm})
Nominal No. eter flats
mm mm Range Target
02 14 35 – 63 {3.5 – 6.5} 44 {4.5}
Varies
03, 04 20 84 – 132 {8.5 – 13.5} 103 {10.5}
depending on
05, 06 24 128 – 186 {13.0 – 19.0} 157 {16.0}
type of con-
10, 12 33 363 – 480 {37.0 – 49.0} 422 {43.0}
nector.
14 42 746 – 1,010 {76.0 – 103} 883 {90.0}

4. Table of tightening torque for O-ring boss plugs

a Unless otherwise specified, tighten O-ring boss plugs to the torque shown in the following table.
Thread diam- Width across
Tightening torque (Nm {kgm})
Nominal No. eter flats
mm mm Range Target
08 8 14 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75}
10 10 17 9.8 – 12.74 {1.0 – 1.3} 11.27 {1.15}
12 12 19 14.7 – 19.6 {1.5 – 2.0} 17.64 {1.8}
14 14 22 19.6 – 24.5 {2.0 – 2.5} 22.54 {2.3}
16 16 24 24.5 – 34.3 {2.5 – 3.5} 29.4 {3.0}
18 18 27 34.3 – 44.1 {3.5 – 4.5} 39.2 {4.0}
20 20 30 44.1 – 53.9 {4.5 – 5.5} 49.0 {5.0}
24 24 32 58.8 – 78.4 {6.0 – 8.0} 68.6 {7.0}
30 30 32 93.1 – 122.5 { 9.5 – 12.5} 107.8 {11.0}
33 33 – 107.8 – 147.0 {11.0 – 15.0} 127.4 {13.0}
36 36 36 127.4 – 176.4 {13.0 – 18.0} 151.9 {15.5}
42 42 – 181.3 – 240.1 {18.5 – 24.5} 210.7 {21.5}
52 52 – 274.4 – 367.5 {28.0 – 37.5} 323.4 {33.0}

PC228US-8,PC228USLC-8 00-35
(02)
Foreword and general information
Standard tightening torque table

5. Table of tightening torque for hoses (taper seal type and face seal type)
a Unless otherwise specified, tighten the hose fittings (taper seal type and face seal type) to the torque
shown in the following table.
a Apply the following torque when the threads are coated with engine oil (wetted).
Tightening torque (Nm {kgm}) Taper seal Face seal
Nominal Width Nominal No.
Thread diame-
number of across Thread size –Number of
Range Target ter (mm) (Ref-
hose flats (mm) (mm) threads, type of
erence)
thread
34 – 54 {3.5 – 5.5} 44 {4.5} – 9/16 – 18UN 14.3
02 19
34 – 63 {3.5 – 6.5} 44 {4.5} 14 – –
22 54 – 93 {5.5 – 9.5} 74 {7.5} – 11/16 – 16UN 17.5
03
24 59 – 98 {6.0 – 10.0} 78 {8.0} 18 – –
04 27 84 – 132 {8.5 – 13.5} 103 {10.5} 22 13/16 – 16UN 20.6
05 32 128 – 186 {13.0 – 19.0} 157 {16.0} 24 1 – 14UNS 25.4
06 36 177 – 245 {18.0 – 25.0} 216 {22.0} 30 1-3/16 – 12UN 30.2
(10) 41 177 – 245 {18.0 – 25.0} 216 {22.0} 33 – –
(12) 46 197 – 294 {20.0 – 30.0} 245 {25.0} 36 – –
(14) 55 246 – 343 {25.0 – 35.0} 294 {30.0} 42 – –

6. Table of tightening torque for face seal joints

a Tighten the face seal joints (sleeve nut type) made of plated steel pipes for low pressure service to be
used for engines etc. to the torque shown in the following table.
a Apply the following torque to the face seal joint while their threaded parts are coated with engine oil
(wetted).
Tightening torque (Nm {kgm}) Face seal
Outer diam- Width across Nominal No.
Thread diameter
eter of pipe flats –Number of
Range Target (mm)
(mm) (mm) threads, type of
(Reference)
thread
8 19 14 – 16 {1.4 – 1.6} 15 {1.5} 9/16 – 18UN 14.3
10 22 24 – 27 {2.4 – 2.7} 25.5 {2.6} 11/16 – 16UN 17.5
12 24 (27) 43 – 47 {4.4 – 4.8} 45 {4.6} 13/16 – 16UN 20.6
15 (16) 30 (32) 60 – 68 {6.1 – 6.8} 64 {6.5} 1 – 14UNS 25.4
22 (20) 36 90 – 95 {9.2 – 9.7} 92.5 {9.4} 1 – 3/16 – 12UN 30.2
Reference: The face seal joints of the dimensions in ( ) are also used, depending on the specification.

00-36 PC228US-8,PC228USLC-8
(02)
 Foreword and general information
Standard tightening torque table

7. Table of tightening torque for 102, 107 and 114 engine series (bolts and nuts)
a Unless otherwise specified, tighten the metric bolts and nuts used for the 102, 107 and 114 engine se-
ries to the torque shown in the following table.
Tightening torque
Thread size
Bolts and nuts
mm Nm kgm
6 10 ± 2 1.02 ± 0.20
8 24 ± 4 2.45 ± 0.41
10 43 ± 6 4.38 ± 0.61
12 77 ± 12 7.85 ± 1.22
14 – –

8. Table of tightening torque for 102, 107 and 114 engine series (eye joints)
a Unless otherwise specified, tighten the metric eye joints used for the 102, 107 and 114 engine series
to the torque shown in the following table.
Thread size Tightening torque
mm Nm kgm
6 8±2 0.81 ± 0.20
8 10 ± 2 1.02 ± 0.20
10 12 ± 2 1.22 ± 0.20
12 24 ± 4 2.45 ± 0.41
14 36 ± 5 3.67 ± 0.51

9. Table of tightening torque for 102, 107 and 114 engine series (taper screws)
a Unless otherwise specified, tighten NPT screws used for the 102, 107 and 114 engine series to the
torque shown in the following table.
Tightening torque
Material In cast iron or steel In aluminum
Thread size (inch) Nm kgm Nm kgm
1/16 15 ± 2 1.53 ± 0.20 5±1 0.51 ± 0.10
1/8 20 ± 2 2.04 ± 0.20 15 ± 2 1.53 ± 0.20
1/4 25 ± 3 2.55 ± 0.31 20 ± 2 2.04 ± 0.20
3/8 35 ± 4 3.57 ± 0.41 25 ± 3 2.55 ± 0.31
1/2 55 ± 6 5.61 ± 0.61 35 ± 4 3.57 ± 0.41
3/4 75 ± 8 7.65 ± 0.82 45 ± 5 4.59 ± 0.51

PC228US-8,PC228USLC-8 00-37
(02)
Foreword and general information
List of Abbreviation

List of Abbreviation 0 -38

(Rev. 2010/03)
q This list of abbreviations includes the abbreviations used in the text of the shop manual for parts, compo-
nents, and functions whose meaning is not immediately clear. The spelling is given in full with an outline
of the meaning.
q Abbreviations that are used in general society may not be included.
q Special abbreviations that appear infrequently are marked in the text with an *.
q This list of abbreviations consists of two parts. The first part is a list of abbreviations used in the text of the
manual, and the second part is a list of abbreviations used in circuit diagrams.
List of abbreviations used in the shop manual
Purpose of use (major
Abbrevia-
Full Spelling applicable machine (*), or Explanation
tion
component/system)
With this function, when the tires skid (wheels stop
Travel and brake
A.B.S. Anti-skid Brake System rotating), the brakes are released, and when the
(HD, HM)
wheels start to rotate, the brakes are applied again.
Automatic Idling Setting
A.I.S.S. Engine This function automatically sets the idle speed.
System
Instead of a steering wheel, a lever is used to per-
Advanced Joystick Steer- Steering
A.J.S.S. form the steering operations as well as to shift gear
ing System (WA)
and change direction (forward or reverse).
When the machine is traveling downhill, if the
Automatic Retarder Travel and brake accelerator pedal is released, this function auto-
A.R.A.C.
Accelerator Control (HD, HM) matically applies the retarder with a constant brak-
ing force.
When the machine is traveling downhill, if the
accelerator pedal is released, this function auto-
Automatic Retarder Travel and brake
A.R.S.C. matically applies the retarder to ensure that the
Speed Control (HD, HM)
machine speed does not accelerate above the
speed set by the operator.
When the rear wheels spin on soft ground sur-
Travel and brake
A.S.R. Automatic Spin Regulator faces, this function automatically uses the optimum
(HD, HM)
braking force to drive both wheels.
A device that can be fixed onto a machine in order
ATT. Attachment Work equipment
to enable it to do different jobs.
When the retarder is not being used, this valve
Brake Cooling oil control Brake
B.C.V. bypasses part of the brake cooling oil to reduce the
Valve (HD)
load on the hydraulic pump.
Communication and elec- Communications standard standardized as
C.A.N. Controller Area Network
tronic control ISO11898.
System that can simultaneously actuate multiple
Closed-center Load
C.L.S.S. Hydraulic actuators regardless of the load (provides better
Sensing System
ease of combined operation than O.L.S.S.).
Uses engine controller to perform electronic control
of supply pump, common rail, and injector. Func-
C.R.I. Common Rail Injection Engine
tions to maintain optimum fuel injection amount
and fuel injection timing.
Electronic control device that uses the signals from
Electronic Control Mod-
E.C.M. Electronic control system the sensors on the machine to indicate to the actu-
ule
ators the optimum actuation. (same as ECU)
Proportional electromagnetic valve that gradually
Electronic Control Modu- Transmission
E.C.M.V. increases oil pressure to engage clutch and
lation Valve (D, HD, WA, etc.)
reduces transmission shock.
System that ensures smooth high-speed travel by
Electronically Controlled Travel
E.C.S.S. using hydraulic spring effect of accumulator to
Suspension System (WA)
absorb vibration of machine during travel
Electronic control device that uses the signals from
E.C.U. Electronic Control Unit Electronic control system the sensors on the machine to indicate to the actu-
ators the optimum actuation. (same as ECM)
Functions to recirculate part of exhaust gas to com-
Exhaust Gas Recircula-
E.G.R. Engine bustion chamber in order to reduce combustion
tion
temperature, controls emission of Nox.

00-38 PC228US-8,PC228USLC-8
(02)
 Foreword and general information
List of Abbreviation

Purpose of use (major

Abbrevia-
Full Spelling applicable machine (*), or Explanation
tion
component/system)
System that allows data (filter, oil replacement
Equipment Management interval, malfunctions on machine, failure code,
E.M.M.S. Machine monitor
Monitoring System and failure history) from each sensor on the
machine to be checked on monitor.
Control system that moves an actuator in propor-
Electromagnetic Propor-
E.P.C. Hydraulic tion to the amperage of an electric current passing
tional Control
through the solenoid.
F-N-R Forward-Neutral-Reverse Operation Position of the gear shift lever or switch.
System that is used to determine the current loca-
Global Positioning Sys- Communication tion on the Earth of a ship, car, machine, etc. by
G.P.S.
tem (KOMTRAX, VHMS) receiving the radio wave signals transmitted from
the navigation satellites.
Steering function that uses a combination of
Hydrostatic Steering Sys- Steering hydraulic motor and bevel shaft to control differ-
H.S.S.
tem (D) ence in travel speed of right and left tracks to turn
machine without using steering clutch.
Hydraulic transmission system that uses a combi-
Hydro Static Transmis- Transmission
H.S.T. nation of hydraulic pump and hydraulic motor to
sion (D, WA)
shift gear steplessly without using gears.
Valve installed at inlet port of pump to adjust fuel
I.M.A. Inlet Metering Actuator Engine intake amount in order to control fuel discharge
amount of supply pump. Same as IMV.
Valve installed at inlet port of pump to adjust fuel
I.M.V. Inlet Metering Valve Engine intake amount in order to control fuel discharge
amount of supply pump. Described as IMV (IMA).
Image display device made up of a large number of
L.C.D. Liquid Crystal Display Machine monitor
pixels filled with liquid crystal.
Semiconductor element that emits light when the
L.E.D. Light Emitting Diode Electronic parts voltage is applied in forward direction, positive volt-
age to anode and negative voltage to cathode.
Function that senses differential pressure of pump
L.S. Load Sensing Hydraulic
and controls discharge amount according to load.
Service that allows transmission and reception of
Multimedia Messaging
M.M.S. Communication short messages consisting of characters or voice
Service
or images between cell phones.
Device actuated to open electric or hydraulic cir-
N.C. Normally Closed Electric and hydraulic
cuits that are normally closed if not actuated.
Device actuated to close electric or hydraulic cir-
N.O. Normally Open Electric and hydraulic
cuits that are normally open if not actuated.
Open-center Load Sens- Hydraulic system that can operate multiple actua-
O.L.S.S. Hydraulic
ing System tors at the same time, regardless of the load.
P.C. Pressure Control Hydraulic Controlling the oil pressure.
System in which a controller instantly analyses
Palm Command Control Steering data from each lever, pedal, and dial, and performs
P.C.C.S.
System (D) optimum electronic control of the engine and trans-
mission.
Valve installed at inlet port of pump to adjust fuel
P.C.V. Pump Control Valve Engine intake amount in order to control fuel discharge
amount of supply pump.
Proportional Pressure Control system that moves an actuator in propor-
P.P.C. Hydraulic
Control tion to the oil pressure.
Hydraulic
P.P.M. Piston Pump and Motor Piston pump and motor.
(D, PC, etc.)
P.T.O. Power Take Off Power transmission A device to take off power of the engine.
Power Tilt and power Work equipment Function that performs hydraulic control of the tilt
P.T.P.
Pitch dozer (D) and pitch of the bulldozer blade.

PC228US-8,PC228USLC-8 00-39
(02)
Foreword and general information
List of Abbreviation

Purpose of use (major

Abbrevia-
Full Spelling applicable machine (*), or Explanation
tion
component/system)
International System of Units (abbreviated SI from
the French Le Systeme Internationale d’Unites) is
the modern form of the metric system, and is the
Le Systeme International world’s most widely used system of measurement.
S.I. Unit
d’ Unites There’re seven base units: meter (m), kilogram
(kg), second (s), ampere (A), kelvin (K), candela
(cd), and mole (mol). The derived units include
Pascal (Pa), Newton (N), etc.
Solenoid is a loop of wire. However, as a matter of
fact in engineering, it refers to an actuator consists
of a solenoid and an iron core that is moved by the
SOL. Solenoid Electric
magnetic force when the solenoid is energized.
The word solenoid also often refers to a solenoid
valve.
T.W.V. Two Way Valve Hydraulic and electric Solenoid valve that switches over direction of flow.
Communications system that transmits machine
data, such as the present position of the machine,
Monitoring and communica- daily or aggregate hours of operation, fuel con-
Vehicle Health Monitoring
V.H.M.S. tion sumption, radiator coolant temperature, oil or filter
System
(D, HD, PC, WA : Large size) replacement interval, to make it possible to collect
and check this data from a distant place (Devel-
oped for use on large machines used in mines).
*: Code for machine family
D: bulldozer
HD: dump truck
HM: articulate dump truck
PC: hydraulic excavator
WA: wheel loader

00-40 PC228US-8,PC228USLC-8
(02)
 Foreword and general information
List of Abbreviation

List of abbreviations used in the circuit diagrams

Abbreviation Full Spelling
A/C Air Conditioner
A/D Analogue-to-Digital
A/M Air Mix damper
ACC Accessory
ADD Additional
AUX Auxiliary
BR Battery Relay
CW Clockwise
CCW Counter Clockwise
ECU Electronic Control Unit
ECM Electronic Control Module
ENG Engine
EXGND External Ground
F.G. Frame Ground
GND Ground
IMA Inlet Metering Actruator
NC No Connection
S/T
Steering
STRG
SIG Signal
SOL Solenoid
STD Standard
OPT
Option
OP
SW Switch
T/C Torque Converter
T/M Transmission

PC228US-8,PC228USLC-8 00-41
(02)
Foreword and general information
Conversion table

Conversion table 0 -42

(Rev. 2010/03)
Method of using the conversion table 0 -42
The conversion table in this section is provided to enable simple conversion of figures. For details of the meth-
od of using the conversion table, see the example given below.

Example: Method of using the conversion table to convert from millimeters to inches

1. Convert 55 mm into inches.

1) Locate the number 50 in the vertical column at the left side, take this as (A), and then draw a horizontal
line from (A).
2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down
from (B).
3) Take the point where the 2 lines cross as (C). This point (C) gives the value when converting from milli-
meters to inches. Therefore, 55 mm = 2.165 inches.

2. Convert 550 mm into inches.

1) The number 550 does not appear in the table, so divide it by 10 (move the decimal point one place to
the left) to convert it to 55 mm.
2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point
one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.

Millimeters to inches (B)

1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
(C)
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
(A)
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.847 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898

00-42 PC228US-8,PC228USLC-8
(02)
 Foreword and general information
Conversion table

Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929

50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.847 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898

Kilogram to pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 52.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03

50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26

Liters to U.S. Gallons

1 l = 0.2642 U.S.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944

50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153

PC228US-8,PC228USLC-8 00-43
(02)
Foreword and general information
Conversion table

Liters to U.K. Gallons

1 l = 0.21997 U.K.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.699 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778

50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777

kgm to ft.lb
1 kgm = 7.233 ft.lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4

50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1

100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7

150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4

00-44 PC228US-8,PC228USLC-8
(02)
 Foreword and general information
Conversion table

kg/cm2 to lb/in2
1 kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9

50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1,010 1,024 1,038 1,053 1,067 1,081 1,095 1,109 1,124
80 1,138 1,152 1,166 1,181 1,195 1,209 1,223 1,237 1,252 1,266
90 1,280 1,294 1,309 1,323 1,337 1,351 1,365 1,380 1,394 1,408

100 1,422 1,437 1,451 1,465 1,479 1,493 1,508 1,522 1,536 1,550
110 1,565 1,579 1,593 1,607 1,621 1,636 1,650 1,664 1,678 1,693
120 1,707 1,721 1,735 1,749 1,764 1,778 1,792 1,806 1,821 1,835
130 1,849 1,863 1,877 1,892 1,906 1,920 1,934 1,949 1,963 1,977
140 1,991 2,005 2,020 2,034 2,048 2,062 2,077 2,091 2,105 2,119

150 2,134 2,148 2,162 2,176 2,190 2,205 2,219 2,233 2,247 2,262
160 2,276 2,290 2,304 2,318 2,333 2,347 2,361 2,375 2,389 2,404
170 2,418 2,432 2,446 2,460 2,475 2,489 2,503 2,518 2,532 2,546
180 2,560 2,574 2,589 2,603 2,617 2,631 2,646 2,660 2,674 2,688
190 2,702 2,717 2,731 2,745 2,759 2,773 2,788 2,802 2,816 2,830

200 2,845 2,859 2,873 2,887 2,901 2,916 2,930 2,944 2,958 2,973
210 2,987 3,001 3,015 3,030 3,044 3,058 3,072 3,086 3,101 3,115
220 3,129 3,143 3,158 3,172 3,186 3,200 3,214 3,229 3,243 3,257
230 3,271 3,286 3,300 3,314 3,328 3,343 3,357 3,371 3,385 3,399
240 3,414 3,428 3,442 3,456 3,470 3,485 3,499 3,513 3,527 3,542

PC228US-8,PC228USLC-8 00-45
(02)
Foreword and general information
Conversion table

Temperature 0 -46

Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centi-
grade temperature reading or vice versa is to enter the accompanying table in the center (boldface column)
of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
When convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of Fahrenheit
temperatures and read the corresponding Centigrade temperature in the column at the left.
When convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of Centigrade
values, and read the corresponding Fahrenheit temperature on the right.
1 °C = 33.8°F
°C °F °C °F °C °F °C °F
-40.4 -40 -40.0 -11.7 11 51.8 7.8 46 114.8 27.2 81 177.8
-37.2 -35 -31.0 -11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
-34.4 -30 -22.0 -10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
-31.7 -25 -13.0 -10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
-28.9 -20 -4.0 -9.4 15 59.0 10.0 50 122.0 29.4 85 185.0

-28.3 -19 -2.2 -8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

-27.8 -18 -0.4 -8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
-27.2 -17 1.4 -7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
-26.7 -16 3.2 -7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
-26.1 -15 5.0 -6.7 20 68.0 12.8 55 131.0 32.2 90 194.0

-25.6 -14 6.8 -6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

-25.0 -13 8.6 -5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
-24.4 -12 10.4 -5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
-23.9 -11 12.2 -4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
-23.3 -10 14.0 -3.9 25 77.0 15.6 60 140.0 35.0 95 203.0

-22.8 -9 15.8 -3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

-22.2 -8 17.6 -2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
-21.7 -7 19.4 -2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
-21.1 -6 21.2 -1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
-20.6 -5 23.0 -1.1 30 86.0 18.3 65 149.0 37.8 100 212.0

-20.0 -4 24.8 -0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

-19.4 -3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
-18.9 -2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
-18.3 -1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
-17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0

-17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0

-16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
-16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
-15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
-15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0

-14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

-13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
-13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
-12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
-12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0

00-46 PC228US-8,PC228USLC-8
(02)
SEN0533404-00 01-

PC228US-8,PC228USLC-8

HYDRAULIC EXCAVATOR
Shop Manual 01-

PC228US-8
PC228USLC-8

Machine model Serial number

PC228US-8 50001 and up
PC228USLC-8 50001 and up

01 Specifications 01-

PC228US-8,PC228USLC-8 01-1
Contents

Contents 01-2
01 Specifications
Specifications.......................................................................................................................... 01- 4
Specifications drawing ......................................................................................................... 01- 4
Working range diagram........................................................................................................ 01- 5
Specifications....................................................................................................................... 01- 6
Table of weight..................................................................................................................... 01- 16
Table of fuel, coolant and lubricants .................................................................................... 01- 20

01-2 PC228US-8,PC228USLC-8
 Contents

PC228US-8,PC228USLC-8 01-3
Specifications
Specifications drawing

Specifications 01-4
Specifications drawing 01-4

PC228USLC-8
Item Unit PC228US-8 Standard North America
specification specification
Machine weight kg 21,800 23,000 24,900
Bucket capacity m3 0.8 0.8 0.8
Engine model – Komatsu SAA6D107E-1 diesel engine
Engine rated output
q Net [ISO 9249/SAE J1349] kW {HP}/rpm 110 {148}/2,000
q Gross [SAE J1995] kW {HP}/rpm 116 {155}/2,000
A Overall length mm 8,700 8,890 8,890
B Overall height mm 3,050 3,050 3,065
Overall width mm 2,980 3,080 3,180
C Upper structure width mm 2,980 2,980 2,980
D Overall track width mm 2,800 3,080 3,180
E Shoe width mm 600 700 800
F Tail swing radius mm 1,680 1,680 1,810
G Overall crawler length mm 4,070 4,450 4,450
Distance between tumbler cen-
H mm 3,275 3,655 3,655
ters
Min. ground clearance mm 440 440 440
Traveling speed (Low/Med/High) km/h 3.0/4.1/5.5 3.0/4.1/5.5 3.0/4.1/5.5
Continuous swing speed rpm 11.0 11.0 11.0

a The engine rated horsepower is indicated in the net value and gross value. Gross value is the rated horse-
power measured of the bear engine. While, net value is the value measured of an engine under the same
condition essentially as the condition that it is installed on the machine.

01-4 PC228US-8,PC228USLC-8
(02)
 Specifications
Working range diagram

Working range diagram 01-5

PC228USLC-8
Item Unit PC228US-8 North America
Standard specification
specification
A Max. digging reach mm 9,875 9,875 9,875
B Max. digging depth mm 6,620 6,620 6,620
C Max. digging height mm 10,700 10,700 10,700
Max. vertical wall digging
D mm 5,980 5,980 5,980
depth
E Max. dumping height mm 7,825 7,825 7,825
F Min. dumping height mm 2,940 2,940 2,940
G Max. reach at ground level mm 9,700 9,700 9,700

PC228US-8,PC228USLC-8 01-5
Specifications
Specifications

Specifications 01-6
PC228US-8 01-6
Machine model PC228US-8
Serial number 50001 and up
Bucket capacity m3 0.8
Machine weight kg 21,800
Max. digging depth mm 6,620
Working ranges

Max. vertical wall digging depth mm 5,980

Max. digging reach mm 9,875
Max. reach at ground level mm 9,700
Max. digging height mm 10,700
Performance

Max. dumping height mm 7,825

Max. digging force
138 {14,100}
(when one-touch power max. function kN{kg}
(149 {15,200})
is turned on)
Continuous swing speed rpm 11.0
Swing operation max. slope angle deg. 20
Traveling speed (Low/Med/High) km/h 3.2/4.1/5.5
Gradeability deg. 35
Ground pressure (Standard shoe) kPa {kg/cm2} 50 {0.51}
Overall length mm 8,700
Overall width mm 2,980
Overall height (During transportation)
mm 3,050
(*)
Overall height (for work) mm 3,025
Ground clearance of upper structure
mm 1,060
bottom
Min. ground clearance mm 440
Dimensions

Tail swing radius mm 1,680

Min. swing radius of work equipment mm 2,310
Maximum height at minimum swing
mm 8,250
radius of work equipment
Overall track width mm 2,800
Overall crawler length mm 4,070
Track gauge mm 2,200
Distance between tumbler centers mm 3,275
Machine cab height mm 2,285
Width of standard shoe mm 600
* : Including grouser height (26 mm)

01-6 PC228US-8,PC228USLC-8
(02)
 Specifications
Specifications

Machine model PC228US-8

Serial number 50001 and up
Model SAA6D107E-1
4-cycle, water-cooled, in-line and vertical type, direct
Type injection type with turbocharger and air-cooled after-
cooler
Number of cylinders – bore x stroke mm 6 – 107 x 124
Total piston displacement l {cc} 6.69 {6,690}
Rated horsepower
q Net[ISO 9249/SAE J1349] kW {HP}/rpm 110 {148}/2,000
q Gross[SAE J1995] kW {HP}/rpm 116 {155}/2,000
Performance

Nm/rpm
Engine

Max. torque 609/1,500 {62.1/1,500}

{kgm/rpm}
Max. high idle speed
q At mounted on machine rpm 1,900 ± 70
q At bear engine rpm 2,060 ± 50
Min. low idle speed rpm 1,050 ± 25
Min. fuel consumption ratio g/kWh {g/HPh} 215 {158}
Starting motor 24 V, 4.5 kW
Alternator 24 V, 35 A
Battery (*1) 12 V, 110 Ah x 2
Radiator type Corrugated aluminum, 4 array
Undercarriage

Carrier roller 2 on each side

Track roller 7 on each side
Assembly-type with triple grouser shoes, 45 on each
Track shoe
side
*1. Battery capacity (Ah) is based on 5-hour rate.
a The engine rated horsepower is indicated in the net value and gross value. Gross value is the rated horsepower
measured of the bear engine. While, net value is the value measured of the engine under the same condition es-
sentially as the condition that it is installed on the machine.

PC228US-8,PC228USLC-8 01-7
Specifications
Specifications

Machine model PC228US-8

Serial number 50001 and up
Hydraulic motor Control valve Hydraulic pump

Type x quantity Variable displacement piston type (HPV95+95) x 2

Delivery l/min 218.4 x 2

Set pressure MPa {kg/cm2} 37.2 {380}

Type x quantity 6-spool type x 1

Operating method Hydraulic

Variable displacement piston type (HMV110-2) x 2

Travel motor
(with brake valve and parking brake)
Hydraulic system

Fixed displacement piston type (KMF125AB-5) x 1

Swing motor
(with safety valve and parking brake)

Boom Arm (*2) Bucket

Double acting Double acting Double acting
Type
Hydraulic cylinder

piston piston piston

Cylinder inner diameter mm 120 135 115
Piston rod diameter mm 85 95 80
Stroke mm 1,385 1,490 1,120

Max. pin-to-pin distance mm 3,255 3,565 2,800

Min. pin-to-pin distance mm 1,870 2,075 1,680

Hydraulic tank Box-shaped, closed type

Hydraulic oil filter Tank return side
Hydraulic oil cooler Air cooled (CF40-1)
*2. With head side cushion and bottom side cushion.

01-8 PC228US-8,PC228USLC-8
(02)
 Specifications
Specifications

PC228USLC-8 (standard specification) 01-9

Machine model PC228USLC-8 (standard specification)
Serial number 50001 and up
Bucket capacity m3 0.8
Machine weight kg 23,000
Max. digging depth mm 6,620
Working ranges

Max. vertical wall digging depth mm 5,980

Max. digging reach mm 9,875
Max. reach at ground level mm 9,700
Max. digging height mm 10,700
Performance

Max. dumping height mm 7,825

Max. digging force
138 {14,100}
(when one-touch power max. function kN{kg}
(149 {15,200})
is turned on)
Continuous swing speed rpm 11.0
Swing operation max. slope angle deg. 20
Traveling speed (Low/Med/High) km/h 3.0/4.1/5.5
Gradeability deg. 35
Ground pressure (Standard shoe) kPa {kg/cm2} 41 {0.42}
Overall length mm 8,890
Overall width mm 3,080
Overall height (During transportation)
mm 3,050
(*)
Overall height (for work) mm 3,025
Ground clearance of upper structure
mm 1,060
bottom
Min. ground clearance mm 440
Dimensions

Tail swing radius mm 1,680

Min. swing radius of work equipment mm 2,310
Maximum height at minimum swing
mm 8,250
radius of work equipment
Overall track width mm 3,080
Overall crawler length mm 4,450
Track gauge mm 2,380
Distance between tumbler centers mm 3,655
Machine cab height mm 2,285
Width of standard shoe mm 700
*: Grouser height (26 mm) included.

PC228US-8,PC228USLC-8 01-9
(02)
Specifications
Specifications

Machine model PC228USLC-8 (standard specification)

Serial number 50001 and up
Model SAA6D107E-1
4-cycle, water-cooled, in-line and vertical type, direct
Type injection type with turbocharger and air-cooled after-
cooler
No. of cylinders - bore x stroke mm 6 – 107 x 124
Total piston displacement l {cc} 6.69 {6,690}
Rated horsepower
q Net[ISO 9249/SAE J1349] kW {HP}/rpm 110 {148}/2,000
q Gross[SAE J1995] kW {HP}/rpm 116 {155}/2,000
Performance

Nm/rpm
Engine

Max. torque 609/1,500 {62.1/1,500}

{kgm/rpm}
Max. high idle speed
q At mounted on machine rpm 1,900 ± 70
q At bear engine rpm 2,060 ± 50
Min. low idle speed rpm 1,050 ±25
Min. fuel consumption ratio g/kWh {g/HPh} 215 {158}
Starting motor 24 V, 4.5 kW
Alternator 24 V, 35 A
Battery (*1) 12 V, 110 Ah x 2
Radiator type Aluminum wave type, 4 rows
Undercarriage

Carrier roller 2 on each side

Track roller 9 on each side
Assembly-type with triple grouser shoes, 49 on each
Track shoe
side
*1. Battery capacity (Ah) is based on 5-hour rate.
a The engine rated horsepower is indicated in the net value and gross value. Gross value is the rated horsepower
measured of the bear engine. While, net value is the value measured of the engine under the same condition es-
sentially as the condition that it is installed on the machine.

01-10 PC228US-8,PC228USLC-8
 Specifications
Specifications

Machine model PC228USLC-8 (standard specification)

Hydraulic motor Control valve Hydraulic pump Serial number 50001 and up
Type x quantity Variable displacement piston type (HPV95+95) x 2
Delivery l/min 218.4 x 2

Set pressure MPa {kg/cm2} 37.2 {380}

Type x quantity 6-spool type x 1

Operating method Hydraulic

Variable displacement piston type (HMV110-2) x 2

Travel motor
(with brake valve and parking brake)
Hydraulic system

Fixed displacement piston type (KMF125AB-5) x 1

Swing motor
(with safety valve and parking brake)

Boom Arm (*2) Bucket

Double acting Double acting Double acting
Type
Hydraulic cylinder

piston piston piston

Cylinder inner diameter mm 120 135 115
Piston rod diameter mm 85 95 80
Stroke mm 1,385 1,490 1,120
Max. pin-to-pin distance mm 3,255 3,565 2,800
Min. pin-to-pin distance mm 1,870 2,075 1,680
Hydraulic tank Box-shaped closed type
Hydraulic oil filter Tank return side
Hydraulic oil cooler Air cooled (CF40-1)
*2. With head side cushion and bottom side cushion.

PC228US-8,PC228USLC-8 01-11
(02)
Specifications
Specifications

PC228USLC-8 (North America specification) 01- 2

Machine model PC228USLC-8 (North America specification)
Serial number 50001 and up
Bucket capacity m3 0.8
Machine weight kg 24,900
Max. digging depth mm 6,620
Working ranges

Max. vertical wall digging depth mm 5,980

Max. digging reach mm 9,875
Max. reach at ground level mm 9,700
Max. digging height mm 10,700
Performance

Max. dumping height mm 7,825

Max. digging force
138 {14,100}
(when one-touch power max. func- kN{kg}
(149 {15,200})
tion is turned on)
Continuous swing speed rpm 11.0
Swing operation max. slope angle deg. 20
Traveling speed (Low/Med/High) km/h 3.0/4.1/5.5
Gradeability deg. 35
Ground pressure (Standard shoe) kPa {kg/cm2} 39 {0.40}
Overall length mm 8,890
Overall width mm 3,080
Overall height (During transportation)
mm 3,065
(*)
Overall height (for work) mm 3,040
Ground clearance of upper structure
mm 1,075
bottom
Min. ground clearance mm 440
Dimensions

Tail swing radius mm 1,810

Min. swing radius of work equipment mm 2,310
Maximum height at minimum swing
mm 8,250
radius of work equipment
Overall track width mm 3,180
Overall crawler length mm 4,450
Track gauge mm 2,380
Distance between tumbler centers mm 3,655
Machine cab height mm 2,300
Width of standard shoe mm 800
*: Grouser height (26 mm) included.

01-12 PC228US-8,PC228USLC-8
(02)
 Specifications
Specifications

Machine model PC228USLC-8 (North America specification)

Serial number 50001 and up
Model SAA6D107E-1
4-cycle, water-cooled, in-line and vertical type, direct
Type injection type with turbocharger and air-cooled after-
cooler
No. of cylinders - bore x stroke mm 6 – 107 x 124
Total piston displacement l {cc} 6.69 {6,690}
Rated horsepower
q Net[ISO 9249/SAE J1349] kW {HP}/rpm 110 {148}/2,000
q Gross[SAE J1995] kW {HP}/rpm 116 {155}/2,000
Performance

Nm/rpm
Engine

Max. torque 609/1,500 {62.1/1,500}

{kgm/rpm}
Max. high idle speed
q At mounted on machine rpm 1,900 ± 70
q At bear engine rpm 2,060 ± 50
Min. low idle speed rpm 1,050 ± 25
Min. fuel consumption ratio g/kWh {g/HPh} 215 {158}
Starting motor 24 V, 4.5 kW
Alternator 24 V, 35 A
Battery (*1) 12 V, 110 Ah x 2
Radiator type Aluminum wave type, 4 rows
Undercarriage

Carrier roller 2 on each side

Track roller 9 on each side
Assembly-type with triple grouser shoes, 49 on each
Track
side
*1. Battery capacity (Ah) is based on 5-hour rate.
a The engine rated horsepower is indicated in the net value and gross value. Gross value is the rated horsepower
measured of the bear engine. While, net value is the value measured of the engine under the same condition es-
sentially as the condition that it is installed on the machine.

PC228US-8,PC228USLC-8 01-13
Specifications
Specifications

Machine model PC228USLC-8 (North America specification)

Serial number 50001 and up
Hydraulic motor Control valve Hydraulic pump

Type x quantity Variable displacement piston type (HPV95+95) x 2

Delivery l/min 218.4 x 2

Set pressure MPa {kg/cm2} 37.2 {380}

Type x quantity 6-spool type x 1

Operating method Hydraulic

Variable displacement piston type (HMV110-2) x 2

Travel motor
(with brake valve and parking brake)
Hydraulic system

Fixed displacement piston type (KMF125AB-5) x 1

Swing motor
(with safety valve and parking brake)

Boom Arm (*2) Bucket

Double acting Double acting Double acting
Type
Hydraulic cylinder

piston piston piston

Cylinder inner diameter mm 130 135 115
Piston rod diameter mm 90 95 80
Stroke mm 1,385 1,490 1,120
Max. pin-to-pin distance mm 3,255 3,565 2,800
Min. pin-to-pin distance mm 1,870 2,075 1,680
Hydraulic tank Box-shaped closed type
Hydraulic oil filter Tank return side
Hydraulic oil cooler Air cooled (CF40-1)
*2. With head side cushion and bottom side cushion.

01-14 PC228US-8,PC228USLC-8
(02)
 Specifications
Specifications

PC228US-8,PC228USLC-8 01-15
Specifications
Table of weight

Table of weight 01- 6

k This weight table is prepared for your reference when handling or transporting the components.
PC228US-8 01- 6
Unit: kg
Machine model PC228US-8
Serial number 50001 and up
Engine assembly 735
q Engine 575
q Damper 6
q Main pump 154
Radiator and oil cooler assembly 126
Hydraulic tank and filter assembly (Not including hydraulic
146
oil)
Fuel tank assembly (Not including fuel) 131
Revolving frame 1,872
Operator's cab 445
Operator's seat 27
Counterweight 6,060
Swing machinery 224
Control valve 265
Swing motor 51.5
Travel motor 98 x 2
Center swivel joint 30.3
Track frame assembly (Not including piping) 4,269
q Track frame 2,260
q Swing circle 267
q Idler 101 x 2
q Idler cushion 118 x 2
q Carrier roller 14 x 4
q Track roller 36 x 14
q Final drive (including travel motor and sprocket) 372 x 2
Track shoe assembly
q Triple grouser shoe (600 mm) 1,215 x 2
q Triple grouser shoe (700 mm) 1,405 x 2
q Triple grouser shoe (800 mm) 1,530 x 2
Boom assembly 1,500
Arm assembly 633
Bucket assembly 632
Boom cylinder assembly 167 x 2
Arm cylinder assembly 223
Bucket cylinder assembly 133
Bucket link (large) assembly 52

01-16 PC228US-8,PC228USLC-8
 Specifications
Table of weight

Unit: kg
Machine model PC228US-8
Serial number 50001 and up
Bucket link (small) assembly 22 x 2
Boom pin 42 + 8 x 2 + 28 + 10 + 26
Arm pin 12 + 8
Bucket pin 20 x 2
Bucket link pin 13 x 2

PC228US-8,PC228USLC-8 01-17
Specifications
Table of weight

PC228USLC-8 01- 8
Unit: kg
PC228USLC-8
Machine model
Standard specification North America specification
Serial number 50001 and up
Engine assembly 735 735
q Engine 575 575
q Damper 6 6
q Main pump 154 154
Radiator and oil cooler assembly 126 126
Hydraulic tank and filter assembly (Not including
146 146
hydraulic oil)
Fuel tank assembly (Not including fuel) 131 131
Revolving frame 1,872 1,980
Operator's cab 445 445
Operator's seat 27 27
Counterweight 6,060 7,400
Swing machinery 224 224
Control valve 265 265
Swing motor 51.5 51.5
Travel motor 98 x 2 98 x 2
Center swivel joint 30.3 30.3
Track frame assembly (Not including piping) 4,797 4,797
q Track frame 2,644 2,644
q Swing circle 267 267
q Idler 101 x 2 101 x 2
q Idler cushion 118 x 2 118 x 2
q Carrier roller 14 x 4 14 x 4
q Track roller 36 x 18 36 x 18
q Final drive (including travel motor and sprocket) 372 x 2 372 x 2
Track shoe assembly
q Triple grouser shoe (600 mm) 1,395 x 2 1,395 x 2
q Triple grouser shoe (700 mm) 1,530 x 2 1,530 x 2
q Triple grouser shoe (800 mm) 1,670 x 2 1,670 x 2
q Road liner (rubber pad type)(600 mm) – 1,600 x 2
Boom assembly 1,500 1,500
Arm assembly 633 633
Bucket assembly 632 632
Boom cylinder assembly 167 x 2 191 x 2
Arm cylinder assembly 223 223
Bucket cylinder assembly 133 133
Bucket link (large) assembly 52 52

01-18 PC228US-8,PC228USLC-8
(02)
 Specifications
Table of weight

Unit: kg
PC228USLC-8
Machine model
Standard specification North America specification
Serial number 50001 and up
Bucket link (small) assembly 22 x 2 22 x 2
Boom pin 42 + 8 x 2 + 28 + 10 + 26 42 + 8 x 2 + 28 + 10 + 26
Arm pin 12 + 8 12 + 8
Bucket pin 20 x 2 20 x 2
Bucket link pin 13 x 2 13 x 2

PC228US-8,PC228USLC-8 01-19
Specifications
Table of fuel, coolant and lubricants

Table of fuel, coolant and lubricants 01-20

a For details of the notes (Notes 1, Note 2... ) in the table, see the Operation and Maintenance Manual.

01-20 PC228US-8,PC228USLC-8
 Specifications
Table of fuel, coolant and lubricants

Unit: l
PC228US-8, PC228USLC-8
Reservoir
Specified capacity Refill capacity
Engine oil pan 25.4 23.1
Swing machinery case 7.1 7.1
Final drive case (right and left respectively) 5.4 5.2
Damper case 0.65 0.65
Hydraulic oil system 185 126
Cooling system 21 –
Fuel tank 320 –

PC228US-8,PC228USLC-8 01-21
Specifications
Table of fuel, coolant and lubricants

01-22 PC228US-8,PC228USLC-8
SEN0533406-00 10-1

PC228US-8,PC228USLC-8

HYDRAULIC EXCAVATOR
Shop Manual 10-1

PC228US-8
PC228USLC-8

Machine model Serial number

PC228US-8 50001 and up
PC228USLC-8 50001 and up

10 Structure and function 10-1

PC228US-8,PC228USLC-8 10-1
Contents

Contents 10-2
10 Structure and function
Engine and cooling system ..................................................................................................... 10- 3
Engine related parts............................................................................................................. 10- 3
Cooling system .................................................................................................................... 10- 4
Power train system ................................................................................................................. 10- 7
Power train........................................................................................................................... 10- 7
Swing circle.......................................................................................................................... 10- 8
Swing machinery.................................................................................................................. 10- 10
Final drive ............................................................................................................................ 10- 12
Undercarriage and frame ........................................................................................................ 10- 14
Track frame and idler cushion.............................................................................................. 10- 14
Hydraulic system..................................................................................................................... 10- 16
Hydraulic equipment layout drawing .................................................................................... 10- 16
Valve control ........................................................................................................................ 10- 18
Hydraulic tank ...................................................................................................................... 10- 19
CLSS.................................................................................................................................... 10- 21
Main pump ........................................................................................................................... 10- 26
Control valve ........................................................................................................................ 10- 48
Function and operation by valve .......................................................................................... 10- 60
Swing motor ......................................................................................................................... 10- 97
Travel motor......................................................................................................................... 10- 105
PPC valve ............................................................................................................................ 10- 115
Solenoid valve...................................................................................................................... 10- 132
Attachment circuit selector valve ......................................................................................... 10- 138
Anti-drop valve ..................................................................................................................... 10- 142
Multi-control valve ................................................................................................................ 10- 147
Center swivel joint................................................................................................................ 10- 148
Accumulator ......................................................................................................................... 10- 149
Work equipment...................................................................................................................... 10- 152
Work equipment................................................................................................................... 10- 152
Electrical system ..................................................................................................................... 10- 154
Electronic control system ..................................................................................................... 10- 154
Machine monitor system ...................................................................................................... 10- 192
KOMTRAX system............................................................................................................... 10- 208
Sensors................................................................................................................................ 10- 210

10-2 PC228US-8,PC228USLC-8
 Engine and cooling system
Engine related parts

Engine and cooling system 10-3

Engine related parts 10-3

1.Muffler Outline 10-3

2.Damper assembly A damper assembly is wet type.
2a.Drive plate
2b.Torsion spring Specification 10-3
2c.Stopper pin Oil type TO30
2d.Friction plate Oil capacity (l) 0.65
3.Rear engine mount
4.Front engine mount
5.Vibration damper

PC228US-8,PC228USLC-8 10-3
Engine and cooling system
Cooling system

Cooling system 10-4

10-4 PC228US-8,PC228USLC-8
 Engine and cooling system
Cooling system

1. Aftercooler 10. Reservoir tank

2. Oil cooler 11. Accumulator (for oil cooler circuit)
3. Radiator inlet hose 12. Oil cooler outlet
4. Radiator cap 13. Oil cooler inlet
5. Radiator 14. Aftercooler outlet tube
6. Condenser 15. Radiator outlet hose
7. Fuel cooler inlet 16. Aftercooler inlet hose
8. Fuel cooler 17. Shroud
9. Fuel cooler outlet 18. Fan guard

Specification 10-5
Radiator Oil cooler Aftercooler Fuel cooler

Corrugated alumi-
Corrugated alumi-
Core type num CF40-1 Drawn cup
num
4 array

Fin pitch (mm) 3.5 / 2 3.5 / 2 3.5 / 2 4.0 / 2

Total heat dissipation area (m2) 32.60 7.87 x 2 14.05 0.59

Pressure valve cracking pres-

sure 68.6 ± 14.7
– – –
{0.7 ± 0.15}
(kPa {kg/cm2})
Vacuum valve cracking pressure -4.9 – 0
– – –
(kPa {kg/cm2}) {-0.05 – 0}

PC228US-8,PC228USLC-8 10-5
Engine and cooling system
Cooling system

10-6 PC228US-8,PC228USLC-8
 Power train system
Power train

Power train system 10-7

Power train 10-7

1. Idler 8. Attachment selector solenoid valve

2. Control valve (Machine ready for installing attachment)
2a. Self-pressure reducing valve 9. Final drive
2b. Pump merge-divider valve 10. Travel motor
2c. Travel junction valve 11. Main pump
3. PPC lock solenoid valve 12. Engine
4. Travel junction solenoid valve 13. Swing motor
5. Swing brake solenoid valve 14. Center swivel joint
6. Travel speed increase solenoid valve 15. Swing machinery
7. 2-stage relief solenoid valve 16. Swing circle

PC228US-8,PC228USLC-8 10-7
Power train system
Swing circle

Swing circle 10-8

Standard specification 10-8

1. Swing circle pinion grease filler port a. Outer race soft zone position
2. Swing circle bearing grease fitting b. Inner race soft zone position
3. Outer race
4. Ball Specification 10-8
5. Seal Reduction ratio -96 / 13 = -7.385
6. Inner race (number of teeth: 96) Grease G2-LI
Amount of grease (l) 14.5

10-8 PC228US-8,PC228USLC-8
 Power train system
Swing circle

North America specification 10-9

1. Swing circle pinion grease filler port a. Outer race soft zone position
2. Swing circle bearing grease fitting b. Inner race soft zone position
3. Outer race
4. Ball Specification 10-9
5. Seal Reduction ratio -96 / 13 = -7.385
6. Inner race (number of teeth: 96) Grease G2-LI
Amount of grease (l) 20.5

PC228US-8,PC228USLC-8 10-9
Power train system
Swing machinery

Swing machinery 10-10

10-10 PC228US-8,PC228USLC-8
 Power train system
Swing machinery

1. Swing pinion (number of teeth: 13) Specification 10-1

2. No. 2 planetary carrier Reduction
((17 + 58) / 17) x ((18 + 58) / 18) =18.627
3. No. 2 sun gear (number of teeth: 18) ratio
4. No. 2 planetary gear (number of teeth: 19) Swing
reduction 18.627 x 7.385 = 137.557
5. No. 1 planetary carrier
ratio
6. No. 1 planetary gear (number of teeth: 20) Swing
7. Swing motor speed 11.0
8. No. 1 sun gear (number of teeth: 17) (rpm)
9. Ring gear (number of teeth: 58)
10. Swing machinery case
11. Drain plug
12. Oil level gauge
13. Oil filler port cap

PC228US-8,PC228USLC-8 10-11
Power train system
Final drive

Final drive 10-12

10-12 PC228US-8,PC228USLC-8
 Power train system
Final drive

1. Level plug Specification 10-13

2. No. 1 planetary gear (number of teeth: 48) Reduction -((11 + 109)/11) x ((20 + 96)/20) + 1 =
3. Drain plug ratio -62.273
4. No. 1 sun gear (number of teeth: 11)
5. No. 2 sun gear (number of teeth: 20)
6. No. 1 planetary carrier
7. Cover
8. Ring gear (number of teeth: 109, 96)
9. No. 2 planetary carrier
10. Retainer
11. Hub
12. Sprocket
13. Floating seal
14. Travel motor
15. No. 2 planetary gear (number of teeth: 37)

PC228US-8,PC228USLC-8 10-13
Undercarriage and frame
Track frame and idler cushion

Undercarriage and frame 10-14

Track frame and idler cushion 10-14
a The following figure shows PC228US-8.

10-14 PC228US-8,PC228USLC-8
 Undercarriage and frame
Track frame and idler cushion

1. Idler
2. Track frame
3. Carrier roller
4. Final drive
5. Track roller
6. Track shoe
7. Center guard
8. Idler cushion
9. Front guard

Outline 10-15
q The dimensions and the number of track rollers
depend on the model, but the basic structure is
not different.
q Number of track rollers

Model Q'ty (each side)

PC228US-8 7
PC228USLC-8 9

Standard shoe
Model PC228US-8 PC228USLC-8
Shoe width (mm) 600 700
Link pitch (mm) 190 190
Number of shoes (each side) 45 49

PC228US-8,PC228USLC-8 10-15
Hydraulic system
Hydraulic equipment layout drawing

Hydraulic system 10-16

Hydraulic equipment layout drawing 10-16

10-16 PC228US-8,PC228USLC-8
 Hydraulic system
Hydraulic equipment layout drawing

1. Bucket cylinder
2. Arm cylinder
3. Attachment selector valve (for high pressure) (*2)
4. Accumulator (for high pressure) (*2)
5. Main pump
6. Swing motor
7. Oil cooler
8. Travel motor
9. Accumulator (for oil cooler circuit)
10. L.H. work equipment PPC valve
11. Center swivel joint
12. Travel PPC valve
13. Attachment PPC valve
14. R.H. work equipment PPC valve
15. Boom anti-drop valve
16. Boom cylinder
17. Accumulator (for PPC circuit)
18. Solenoid valve
19. Control valve
20. Pilot oil filter
21. Return oil filter (*2)
22. Hydraulic tank
23. Attachment selector valve (for low pressure) (*2)
24. Boom cushion EPC valve
25. Multi-control valve (*1)
26. Accumulator (for low pressure) (*2)

*1: If equipped
*2: Machine ready for installing attachment

PC228US-8,PC228USLC-8 10-17
Hydraulic system
Valve control

Valve control 10-18

1. Control valve 9. Travel PPC valve

2. R.H. work equipment PPC valve 10. Attachment PPC valve (*2)
3. R.H. work equipment lever (for boom and bucket 11. Attachment pedal (*2)
control) 12. Boom cushion EPC valve
4. L.H. work equipment lever (for arm and swing 13. Multi-control valve (*1)
control) 14. Relay block
5. L.H. work equipment PPC valve 15. Accumulator (for PPC circuit)
6. Lock lever 16.Solenoid valve
7. Travel lever 17. Lock pin (*2)
8. Travel pedal

*1: If equipped
*2: Machine ready for installing attachment

10-18 PC228US-8,PC228USLC-8
 Hydraulic system
Hydraulic tank

Hydraulic tank 10-19

1. Filler cap Specification 10-19

2. Breather Hydraulic tank capacity (l) 165
3. Hydraulic tank
Amount of oil in hydraulic tank
4. Main pump 126
(l)
5. Drain plug Bypass valve set pressure 0.15 ± 0.03
6. Sight gauge
(MPa {kg/cm2} {1.5 ± 0.3}
7. Filter element
8. Bypass valve
9. Strainer
10. Suction strainer

PC228US-8,PC228USLC-8 10-19
Hydraulic system
Hydraulic tank

Oil filler cap 10-20 Breather 10-20

1. Filter element 1. Nut

2. Bottom plate 2. Cover
3. Gasket 3. Filter element
4. Seam valve 4. Case
5. Spring 5. Valve assembly
6. Body
Prevention of negative pressure in tank 10-20
q The hydraulic tank is sealed and pressurized. Prevention of negative pressure in tank 10-20
When the oil level in the hydraulic tank drops, q The hydraulic tank is sealed and pressurized.
negative pressure is generated in the tank. To When the oil level in the hydraulic tank drops,
prevent this negative pressure generation, seam negative pressure is generated in the tank.
valve (4) is opened to draw the atmosphere to To prevent this negative pressure generation,
the tank. valve assembly (5) is opened to draw the atmo-
(Suction valve set pressure: sphere to the tank.
0 – 0.49 kPa {0 – 0.005 kg/cm2}) (Suction valve set pressure:
1.96 ± 0.29 kPa {0.02 ± 0.003 kg/cm2})
Prevention of pressure rise in tank 10-20
q When the hydraulic circuit is working, the pres- Prevention of pressure rise in tank 10-20
sure in the hydraulic tank increases as the hy- q When the hydraulic circuit is working, the pres-
draulic cylinders operate and the oil level and sure in the hydraulic tank increases as the hy-
temperature increase in the tank. draulic cylinders operate and the oil level and
If the pressure in the tank rises above the set temperature increase in the tank.
value, bottom plate (2) is pushed up to release If the pressure in the tank rises above the set
the pressure in the tank. value, valve assembly (5) is pushed up to
(Relief valve set pressure: release the pressure in the tank.
16.7 ± 6.86 kPa {0.17 ± 0.07 kg/cm2 }) (Relief valve set pressure:
16.7 ± 2.45 kPa {0.17 ± 0.025 kg/cm2})

10-20 PC228US-8,PC228USLC-8
 Hydraulic system
CLSS

CLSS 10-21
a CLSS: Abbreviation for Closed center Load Sensing System

Outline of CLSS 10-21

Features 10-21 Configuration 10-21

q Fine control not influenced by load q CLSS is configured with variable capacity piston
q Fine control performance allowing for digging pumps, control valves, and respective actuators.
even with fine control operation q The Main pump is configured with pump unit, PC
q Ease of combined operation ensured by the flow valve and LS valve.
divider function according to the open areas of
spools during combined operations
q Energy saving due to the control of variable
pumps

PC228US-8,PC228USLC-8 10-21
Hydraulic system
CLSS

Basic principle 10-2

Pump swash plate angle control 10-2 q If it becomes higher than the set pressure (when
q The pump swash plate angle (pump delivery) is the actuator load pressure is low), the pump
controlled so that LS differential pressure swash plate angle shifts toward the minimum po-
(dPLS), the difference between pump (pressure sition.
(PP) and LS pressure (PLS)) (load pressure of
actuator), at control valve outlet is constant. LS differential pressure (dPLS) and pump swash
q [LS differential pressure (dPLS) = Pump delivery plate angle 10-2
pressure (PP) – LS pressure (PLS)]

a For details of functions, see the “Main pump”.

q The pump swash plate angle shifts toward the

maximum position if LS differential pressure
(dPLS) is lower than the set pressure of the LS
valve (when the actuator load pressure is high).

10-22 PC228US-8,PC228USLC-8
 Hydraulic system
CLSS

Pressure compensation control 10-23

q A pressure compensation valve is installed to

the outlet port side of each control valve to bal-
ance the load pressures.
q When actuators are operated simultaneousely,
the pressure difference (dP) between the up-
stream (inlet port) and downstream (outlet port)
of the spool of each valve becomes the same re-
gardless the size of the load (pressure).
q The flow of oil from the pump is divided (com-
pensated) in proportion to the areas of openings
(S1) and (S2) of each valve.

PC228US-8,PC228USLC-8 10-23
Hydraulic system
CLSS

System diagram 10-24

a The illustration shows the condition when actuator (7) is in relief condition at its stroke end in the merge
mode.

1. Front pump 9. LS circuit

2. Rear pump 10. Tank circuit
3. Main relief valve 11. Valve
4. Unload valve 12. Spring
5. Merge-divider valve 13. LS bypass valve
6. Control valve 14. LS valve
7. Actuator 15. PC valve
8. Pump circuit

10-24 PC228US-8,PC228USLC-8
 Hydraulic system
CLSS

PC228US-8,PC228USLC-8 10-25
Hydraulic system
Main pump

Main pump 10-26

Type: HPV95+95

10-26 PC228US-8,PC228USLC-8
(02)
 Hydraulic system
Main pump

Outline 10-27
q This pump consists of two variable capacity
swash plate piston pumps, PC valve, LS valve,
EPC valve, and swash plate sensor.

IMF: Front PC mode selector current

IMR: Rear PC mode selector current
ISIG: LS set pressure selector current
PAF: Front pump delivery port
PAR: Rear pump delivery port
PBF: Pump pressure input port
PD1F: Air bleeder
PD1R: Case drain port
PD2F: Drain plug
PD2R: Drain plug
PENF: Front control pressure pickup port
PENR: Rear control pressure pickup port
PEPC: EPC source pressure port
PEPCC: EPC source pressure pickup port
PFC: Front pump delivery pressure pickup port
PLSF: Front load pressure input port
PLSFC: Front load pressure pickup port
PLSR: Rear load pressure input port
PLSRC: Rear load pressure pickup port
PMF: Front PC mode selector pressure pickup port
PMR: Rear PC mode selector pressure pickup port
PRC: Rear pump delivery pressure pickup port
PS: Pump suction port
PSIG: LS set selector pressure pickup port

1. Front pump
2. Rear pump
3. LS valve
4. PC valve
5. LS-EPC valve
6. PC-EPC valve

PC228US-8,PC228USLC-8 10-27
(02)
Hydraulic system
Main pump

1. Front shaft
2. Cradle
3. Front case
4. Rocker cam
5. Shoe
6. Piston
7. Cylinder block
8. Valve plate
9. End cap
10. Rear shaft
11. Rear case
12. PC valve
13. Servo piston

10-28 PC228US-8,PC228USLC-8
(02)
 Hydraulic system
Main pump

Function 10-29 q Piston (6) in each cylinder of cylinder block (7)

q The pump converts the engine torgue transmit- reciprocates in the axial direction.
ted to its shaft (1) into oil pressure and delivers q Cylinder block (7) seals the pressurized oil to
pressurized oil corresponding to the load. valve plate (8) and perfroms relative rotation.
q It is possible to change the delivery by changing q This surface is designed so that the oil pressure
the swash plate angle. balance is maintained at a suitable level.
q The oil is sucked into and discharged from each
Structure 10-29 cylinder in cylinder block (7) through valve plate
q Cylinder block (7) is supported by shaft (1) on
(8).
splined area (14).
q Shaft (1) is supported by each bearing (15) at the
front and rear.
q The tip of piston (6) has a spherical hollow in
which shoe (5) is being held by crimping.
q Piston (6) and shoe (5) form a spherical bearing.
q Rocker cam (4) has flat surface (A), and shoe (5)
is always pressed against this surface while slid-
ing in a circular pattern.
q Rocker cam (4) conducts high pressure oil to cyl-
inder surface (B) with cradle (2), which is se-
cured to the case, and forms a static pressure
bearing when it slides.

PC228US-8,PC228USLC-8 10-29
Hydraulic system
Main pump

Operation of pump 10-30

q Cylinder block (7) rotates together with shaft (1) q As center line (X) of rocker cam (4) matches the
and shoe (5) slides on plane (A). axis of cylinder block (7) (swash plate angle = 0),
q Rocker cam (4) moves along cylindrical face (B). the difference between volumes (E) and (F) in-
As a result, angle (a) between center line (X) of side cylinder block (7) equals 0.
rocker cam (4) and the axis of cylinder block (7) q The hydraulic oil is not sucked or discharged.
changes. (Actually, however, the swash plate angle does
q Angle (a) is called the swash plate angle. not become to 0)

q If swash plate angle (a) is made between center

line (X) of rocker cam (4) and the axis of cylinder
block (7), plane (A) functions as a cam against
shoe (5).
q Piston (6) reciprocates inside cylinder block (7)
and a difference is made between volumes (E)
and (F) of cylinder chamber in cylinder block (7).
q Each piston (6) sucks and discharges oil by (F)
– (E).
q If cylinder block (7) rotates and the volume of
chamber (E) is decreased, the oil is discharged
from chamber (E) during this process.
q The volume of chamber (F) is increased and the
oil is sucked in chamber (F) during this process.

10-30 PC228US-8,PC228USLC-8
 Hydraulic system
Main pump

Control of delivery 10-31

q If swash plate angle (a) increases, the difference
between volumes (E) and (F) increases, and
pump delivery (Q) increases.
q Swash plate angle (a) is changed by servo pis-
ton (12).
q Servo piston (12) reciprocates straight according
to the signal pressure from the PC and LS
valves.
q This linear reciprocating movement is transmit-
ted to rocker cam (4) through slider (13).
q Being supported by cradle (2) on the cylindrical
surface, rocker cam (4) slides on the surface
while continuing revolving movement.
q Output pressure (PEN) of LS valve is supplied to
the chamber receiving the pressure at the large
diameter piston end.
q The areas receiving the pressure on the right
and left sides of servo piston (12) are different
from each other, and delivery pressure (self
pressure) (PP) of the main pump is constantly
applied to the pressure chamber of the small di-
ameter piston side.
q The movement of servo piston (12) is controlled
by the relationship of pressure between small di-
ameter piston side (PP) and large diameter pis-
ton side (PEN) and by the ratio of the areas
receiving the pressure of the small diameter pis-
ton and large diameter piston.

PC228US-8,PC228USLC-8 10-31
(02)
Hydraulic system
Main pump

LS valve 10-32

PA: Pump port q The relation between the pump delivery (Q) and
PDP: Drain port the differential pressure (dPLS)[= (PP) – (PLS)]
PLP: LS control pressure output port between the main pump pressure (PP) and LS
PLS: LS pressure input port pressure (PLS) is changed by the LS set pres-
PP: Pump port sure selector current (ISIG) as shown in the fig-
PPL: Control pressure input port ure below.
PSIG: LS mode selector pilot port q When the (ISIG) changes from 0 A to 1 A, the
spring setting force will change accordingly, to
1. Sleeve let the center of the standard value range of the
2. Piston pump delvery selector point vary within the
3. Spool range from 0.27 MPa {2.78 kg/cm2} to 1.7 MPa
4. Spring
{17.75 kg/cm2}.
5. Seat
6. Sleeve
7. Plug
8. Locknut

Function 10-32
q The LS (load sensing) valve detects the load of
the actuator and controls the discharge amount.
q This valve controls pump delivery (Q) with the
differential pressure (dPLS) [= (PP) - (PLS)]
(called the LS differential pressure) between
pump delivery pressure (PP) and control valve
outlet pressure (PLS).
q This valve receives main pump delivery pres-
sure (PP), pressure (PLS) (called the LS pres-
sure) coming from the control valve output, and
pressure (PSIG) (called the LS set selector pres-
sure) from the proportional solenoid valve.

10-32 PC228US-8,PC228USLC-8
 Hydraulic system
Main pump

Operation 10-3

When control valve is in “NEUTRAL” position 10-3

q The LS valve is a 3-way selector valve, and LS q Pump pressure (PP) is conducted to the larger
pressure (PLS) (actuator load pressure) on the diameter end of the pump from the port (K).
outlet of control valve is transmitted to spring q The same pump pressure (PP) is conducted to
chamber (B), and pump delivery pressure (PP) is the smaller diameter end of the pump at the port
transmitted to port (H) of sleeve (8). (J).
q Magnitude of the force resulting from this LS q According to the area difference of servo piston
pressure (PLS), force of spring (4) and the pump (12), the servo piston is moved to the right, in the
discharge pressure (self pressure) (PP) deter- direction which makes the swash plate angle
mine the position of spool (6). minimum (See the figure above).
q However, magnitude of the output pressure
(PSIG) (called the LS selector pressure) of the
EPC valve for the LS valve entering port (G) also
changes the position of spool (6). (Setting force
of the spring is changed.)
q Before the engine is started, servo piston (12) is
pushed to the left. (See the figure on the right)
q If the control lever is in the neutral position when
the engine is started, LS pressure (PLS) is set to
0 MPa {0 kg/cm2}. (It is interconnected to the
drain circuit via the control valve spool)
q Spool (6) is pushed to the right, and port (C) and
port (D) will be connected.

PC228US-8,PC228USLC-8 10-33
(02)
Hydraulic system
Main pump

When pump delivery is increased 10-34

q When the difference between pump delivery q At this time, when the output pressure from the
pressure (PP) and LS pressure (PLS), in other EPC valve for the LS valve enters port (G), a
words, LS differential pressure (dPLS) decreas- force is applied on piston (7) to move the piston
es (for example, when the control valve open to the right.
area increases and pump delivery pressure (PP) q It piston (7) is pushed to the right, setting force of
decreases), the combined force of LS pressure spring (4) is weakened, changing the LS differ-
(PLS) and the force of spring (4) pushes spool ential pressure (dPLS) [Difference between oil
(6) to the left. pressures (PLS) and (PP)] when ports (D) and
q As spool (6) moves, ports (D) and (E) are inter- (E) of spool (6) are connected.
connected and also connected to the PC valve.
q Since the PC valve and drain port are connect-
ed, the pressure between ports (D) and (K) be-
comes drain pressure (PT). (PC valve operation
will be explained later.)
q The pressure on the large diameter piston side
of servo piston (12) becomes drain pressure
(PT), and pump pressure (PP) is constantly ap-
plied to port (J) on the small diameter side. Ac-
cordingly, servo piston (12) is pushed to the left
and the swash plate is moved to increase the de-
livery.

10-34 PC228US-8,PC228USLC-8
(02)
 Hydraulic system
Main pump

When pump delivery is decreased 10-35

q When servo piston (12) moves to the right (the

direction that reduces pump delivery) and LS dif-
ferential pressure (dPLS) increases (for exam-
ple, when the control valve open area decreases
and pump delivery pressure (PP) increases), the
force caused by pump delivery pressure (PP)
pushes spool (6) to the right.
q The movement of spool (6) transmits pump de-
livery pressure (PP) to the large diameter end of
the piston through port (C) , port (D) and port (K).
q Although pump delivery pressure (PP) is applied
to port (J) on the small diameter piston side, ser-
vo piston (12) is pushed to the right by the area
difference between the large diameter piston
side and small diameter piston side of servo pis-
ton (12). As the result, the swash plate angle be-
comes smaller.
q When the LS set selector pressure (PSIG) en-
ters port (G), the spring (4) setting force is weak-
ened.

PC228US-8,PC228USLC-8 10-35
Hydraulic system
Main pump

When servo piston is balanced 10-36

q The symbols (A1), (A0) and (PEN) represent the q The force of spring (4) is adjusted so that spool
area receiving the pressure at the large diameter (6) can be balanced at the specified center when
end of the piston, the area receiving the pressure (PP) - (PLS) = 1.7 MPa {17.75 kg/cm2}.
at the small diameter end and the pressure con- q When (PSIG) [LS-EPC valve output pressure, 0
ducted to the large diameter end of the piston,
to 2.9 MPa {0 to 30 kg/cm2}]is applied to port (G),
respectively.
the balanced position will change in proportion to
q When the force generated by main pump pres-
the (PSIG) pressure within a range of (PP) -
sure (PP) of the LS valve is balanced with the
combined force of LS pressure (PLS) and spring (PLS) = 1.7 MPa {17.75 kg/cm2} to 0.27 MPa
(4), and the relationship becomes (A0) x (PP) = {2.78 kg/cm2}.
(A1) x (PEN), servo piston (12) stops in that po-
sition.
q The swash plate of the pump is held at the inter-
mediate position. [Spool (6) is stopped at a posi-
tion where the opening area from port (D) to port
(E) and the distance from port (C) to port (D) is
almost the same.]
q The relationship between the area receiving the
pressure at both ends of servo piston (12) is
(A0):(A1) = 3:5, and the pressures applied to
both ends of the piston when the piston is bal-
anced is (PP):(PEN)C 5:3.

10-36 PC228US-8,PC228USLC-8
 Hydraulic system
Main pump

PC valve 10-37

PA: Pump port q If the engine speed is slowed down due to in-
PA2: Pump pressure pilot port creased load, the controller reduces the pump
PDP: Drain port delivery to recover the speed.
PM: Mode selector pressure pilot port q When the load increases and the engine speed
PPL: Control pressure output port (to LS valve) decreases below a preset value, the controller
increases the command current to the PC-EPC
1. Plug valve solenoid depending on the amount of en-
2. Servo piston assembly gine speed decrease, to decrease the swash
3. Pin plate angle.
4. Spool
5. Retainer
6. Seat
7. Cover
8. Wiring

Function 10-37
q The PC valve limits the oil flow to a certain level
(depends on the delivery pressure) even if the
travel of the control valve is increased extremely.
This is to ensure the horsepower absorbed by
the pump not to exceed the engine horsepower,
when pump delivery pressures (PP1) (self pres-
sure) and (PP2) (other pump's pressure) are
high.
q If the pump delivery pressure increases due to
increased load during work, this valve decreases
the pump delivery.
q And if the pump delivery pressure goes low, it in-
creases the pump delivery.
q The relation between the average delivery pres-
sure of front and rear pumps [(PP1)+(PP2)]/2
and pump delivery (Q) is as shown in the figure,
as a parameter for each current (X) values ap-
plied to the PC-EPC valve solenoid.
q The controller continues counting the actual en-
gine speed.

PC228US-8,PC228USLC-8 10-37
Hydraulic system
Main pump

Operation 10-38

When the pump controller is normal 10-38

When load on the actuator is small and pump pressures (PP1) and (PP2) are low 10-38

Work of PC-EPC valve solenoid (1) 10-38 a Other pump’s pressure denotes the pressure of
q Command current (X) from the pump controller the pump situated on the opposite side.
flows to the PC-EPC valve solenoid (1). For the front pump pressure, the other pump's
q This command current (X) acts on the PC-EPC pressure is that of the rear pump.
valve to generate signal pressure to vary the And for the rear pump pressure, the other
force pushing piston (2). pump's pressure is that of the front pump.
q Spool (3) stops at a position when the combined
forces of springs (4) and (6), pump pressure
(PP1) (self pressure), and pump pressure (PP2)
(other pump's pressure) acting on spool (3) are
balanced.
q Depending on this position, the pressure output
from the PC valve [port (C) pressure] varies.
q The amperage of the command current (X) de-
pends on the type of work (lever operation), work
mode selection, engine speed setting, and the
actual engine speed.

10-38 PC228US-8,PC228USLC-8
 Hydraulic system
Main pump

Action of spring 10-39 q When pressures (PP1) and (PP2) are low, spool
q The spring force of springs (4) and (6) in the PC (3) is on the left.
valve depends on the position of the swash q Port (C) and port (D) are connected, and the
plate. pressure entering the LS valve will be drain pres-
q When servo piston (9) moves to the right, spring sure (PT).
(6) is compressed. q When port (E) of the LS valve is connected to
q When the piston moves further to the right, the port (G), the pressure from port (J) entering the
piston comes in contact with seat (5) and spring large diameter side of the pistion becomes drain
(6) is fixed. pressure (PT), and servo piston (9) moves to the
q Then, only spring (4) operates. left.
q When servo piston (9) compresses or decom- q The pump delivery goes to increase.
presses springs (4) and (6), the spring load var- q The movement of servo piston (9) lets springs
ies. (4) and (6) to expand, and the spring force de-
q When the command current (X) input to PC-EPC creases.
valve solenoid (1) varies, the thrust pushing pis- q When the spring force decreases, spool (3) is
ton (2) varies. moves to the right. Ports (C) and (D) are
q The spring loads of springs (4) and (6) are also blocked, while pump delivery pressure port (B) is
varied by the PC-EPC valve solenoid command connected to port (C).
current (X). q Since the pressure in port (C) and the pressure
q Port (C) on the PC valve is connected to port (E) at the large diameter side of the piston increase,
on the LS valve. servo piston (9) stops moving to the left.
q Self pressure (PP1) enters the small diameter
side of servo piston (9) port (B), and other
pump's pressure (PP2) enters port (A).

PC228US-8,PC228USLC-8 10-39
Hydraulic system
Main pump

q Accordingly, the stop position (= pump delivery)

of servo piston (9) is determined by the position
where the thrust caused by pressures (PP1) and
(PP2), the thrust generated by the PC-EPC
valve solenoid, and the force of springs (4) and
(6) acting on the spool (3) are balanced.

10-40 PC228US-8,PC228USLC-8
 Hydraulic system
Main pump

When load on the actuator is large and pump pressures (PP1) and (PP2) are high 10-41

Outline 10-41 q When spool (3) moves to the left, the openings
q When the load is large and the pump delivery of ports (C) and (D) widen.
pressures (PP1) and (PP2) are high, the thrust q The pressure in port (C) (=J) decreases, and the
moving spool (3) to the right increases, and movement of servo piston (9) to the right stops.
spool (3) comes to a position as shown above. q Servo pistion (9) will stop at a position further to
q The pressure from port (C) to the LS valve will be the right than the position when pump pressures
about half of pump pressure (PP2), because a (PP1) and (PP2) are low.
part of the pressure from port (B) flows through
the LS valve and port (C) to port (D), as shown
above.

Operation 10-41
q When ports (E) and (G) of the LS vave are con-
nected, the pressure enters from port (J) to the
large diameter side of servo piston (9), and servo
piston (9) stops moving.
q When pump pressure (PP2) increases more and
spool (3) moves further to the right, pump pres-
sure (PP1) flows to port (C) to minimize the
pump delivery.
q When servo piston (9) moves to the right,
springs (4) and (6) are compressed, and spool
(3) is pushed back.

PC228US-8,PC228USLC-8 10-41
Hydraulic system
Main pump

q The relation between the average pump pres-

sure [(PP1)+(PP2)]/2 and servo piston (9) posi-
tion are plotted as a bent line because two
springs (4) and (6) are used.
q The relation between the average pump pres-
sure (PP1+PP2)/2 and average pump delivery
(Q) is shown below.

q When the command current (X) input to PC-EPC

valve solenoid (1) increases, the plotted line in-
dicating the relation between the average pump
pressure (PP1+PP2)/2 and average pump deliv-
ery (Q) makes parallel translation by a distance
proportional to the PC-EPC valve solenoid
thrust.
q Since PC-EPC valve solenoid (1) thrust is added
to the thrust pressing spool (3) to the right, the
curve indicating relation between the average
pump pressure (PP1+PP2)/2 and average pump
delivery (Q) shifts from (A) to (B) as the com-
mand current (X) is increased.

10-42 PC228US-8,PC228USLC-8
 Hydraulic system
Main pump

When the pump controller malfunctions and the emergency pump drive switch is at "ON" position 10-43

When load on the main pump is small 10-43

q If the pump controller fails, turn "ON" the emer-

gency pump drive switch and select the resistor
side.
q In this case, power must be taken directly from
the battery, however, a resistor is needed to con-
trol the current supplied to PC-EPC valve sole-
noid (1).
q Since the current is constant, the thrust applied
to piston (2) is constant.
q When main pump pressures (PP1) and (PP2)
are low, the combined force of PC-EPC valve so-
lenoid (1) thrust and the pump pressure is small-
er than the force of springs. Spool (3) stays
balanced at the left.
q Port (C) is connected to port (D) at drain pres-
sure, and the pressure at the large diameter side
of servo pistion (9) comes to drain pressure (PT)
through the LS valve.
q Since the pressure at the small diameter side of
the piston is large, servo piston (9) moves in the
direction to increase the delivery.

PC228US-8,PC228USLC-8 10-43
Hydraulic system
Main pump

When load on the main pump is large 10-4

q As mentioned before, when the emergency

pump drive switch is turned "ON", the command
current (X) sent to PC-EPC valve solenoid (1) is
constant.
q Therefore, the thrust applied by piston (2) to
spool (3) coms to constant.
q When main pump pressures (PP1) and (PP2) in-
crease, spool (3) moves to a position further to
the right than when the main pump load is small,
and stays balanced as shown above.
q Since the pressure from port (B) flows into port
(C), servo piston (9) moves to the right (delevery
decreases), and stops at a position further to the
right than when the pump load is small.
q When the emergency pump drive switch is
turned "ON", the curve indicating the relation be-
tween the pump pressure (PP) and delivery (Q)
is plotted in accordance with the current supplied
through the resistor to the PC-EPC valve sole-
noid.
q When the emergency pump drive switch is
turned "ON", the curve is plotted as (B), which is
shifted toward the left than curve (A) for a normal
pump controller.

10-44 PC228US-8,PC228USLC-8
 Hydraulic system
Main pump

LS (PC)-EPC valve 10-45

C: To LS(PC) valve
P: From self-pressure reducing valve
T: To hydraulic tank

1. Connector
2. Coil
3. Body
4. Spring
5. Spool
6. Rod
7. Plunger

PC228US-8,PC228USLC-8 10-45
Hydraulic system
Main pump

Function 10-46 Operation 10-46

q The EPC valve consists of the proportional sole-
noid and the hydraulic valve . When signal current is zero (coil de-energized) 10-46
q When a signal current (i) from the controller is re-
ceived, an EPC output pressure proportional to
the amperage of current is generated and output
to the LS (PC) valve.

q When the signal current from the controller is not

flowing through coil (2), coil (2) is de-energized.
q Spool (5) is pushed to the left side by spring (4).
q Port (P) is closed, and the pressurized oil from
the self pressure reducing valve does not flow to
the LS (PC) valve.
q The pressurized oil from the LS (PC) valve flows
through port (C) and then port (T), and is drained
to the tank.

10-46 PC228US-8,PC228USLC-8
 Hydraulic system
Main pump

When signal current is small (coil energized) 10-47 When signal current is maximum (coil ener-
gized) 10-47

q When a small signal current flows through coil

(2), coil (2) is energized and a thrust pushing q Coil (2) is energized when signal current is sup-
plunger (7) to the right is generated. plied to coil (2).
q Rod (6) pushes spool (5) to the right, and the q As the amperage of signal current is maximum,
pressurized oil flows from port (P) to port (C). the thrust of plunger (7) is also maximized.
q The pressure at port (C) increases and the total q Spool (5) is pushed to the right by rod (6).
of the force applied to the surface of spool (5) q The pressurized oil flows from port (P) to port (C)
and load of spring (4) becomes larger than the at the maximum rate, and the circuit pressure
thrust of plunger (7). between the EPC valve and LS (PC) valve is
q Spool (5) is pushed to the left, and ports (C) and maximized.
(D) are blocked. q Port (T) closes, and no pressurized oil flows to
q Port (C) connects to port (T). the tank.
q Spool (5) moves to a position where the thrust of
plunger (7) becomes equal to the total of the
pressure at port (C) and the load of spring (4).
q The circuit pressure between the EPC valve and
LS (PC) valve is controlled in proportion to the
amperage of signal current.

PC228US-8,PC228USLC-8 10-47
Hydraulic system
Control valve

Control valve 10-48

Outline 10-48
The control valves of the following types are set.
q 6-spool valve (without service valve)
q 7-spool valve (6-spool valve with service valve)
q 8-spool valve (6-spool valve with two service valves)

q This control valve consists of a 6-spool valve (unit type) and a set of service valve. A merge-divider valve,
a back pressure valve and a boom hydraulic drift prevention valve are installed to it.
q Since all the valves are assembled together with connecting bolts and their passes are connected to each
other inside the assembly, the assembly is compact and easy to maintain.
q With one spool provided for one work equipment, this control valve is simple in structure.
q As for outside views and sectional views, only the 8-spool valve (6-spool valve + 2 service valves) is
shown.

A1: To bucket cylinder head P7: From L.H. work equipment PPC valve (swing
A2: To L.H. travel motor RIGHT)
A3: To boom cylinder bottom P8: From L.H. work equipment PPC valve (swing
A4: To swing motor LEFT)
A5: To R.H. travel motor P9: From travel PPC valve (R.H. travel reverse)
A6: To arm cylinder head P10: From travel PPC valve (R.H. travel forward)
A-1: To attachment 1 P11: From L.H. work equipment PPC valve (arm
A-2: To attachment 2 OUT)
ATT: From attachment P12: From L.H. work equipment PPC valve (arm IN)
B1: To bucket cylinder bottom P-1: From R.H. attachment PPC valve
B2: To L.H. travel motor P-2: From R.H. attachment PPC valve
B3: To boom cylinder head P-3: From L.H. attachment PPC valve
B4: To swing motor P-4: From L.H. attachment PPC valve
B5: To R.H. travel motor PLS1: To rear pump LS valve
B6: To arm cylinder bottom PLS2: To front pump LS valve
B-1: To attachment 1 PLSC: LS pressure pickup port
B-2: To attachment 2 PP1: From rear pump
BP1: From LS select solenoid valve PP2: From front pump
BP5: From attachment selector solenoid valve PP1S: Pressure sensor mounting port
C: To tank PPC: Pilot source pressure pickup port
IS1: From controller PP2S: Pressure sensor mounting port
IS2: From controller PPS2: To front pump LS valve
P1: From R.H. work equipment PPC valve (bucket PR: To solenoid valve, PPC valve, and EPC valve
DUMP) PST: From travel junction valve solenoid valve
P2: From R.H. work equipment PPC valve (bucket PX1: From 2-stage relief solenoid valve
CURL) PX2: From 2-stage relief solenoid valve
P3: From travel PPC valve (L.H. travel reverse) T: To tank
P4: From travel PPC valve (L.H. travel forward) T1: To tank
P5: From R.H. work equipment PPC valve (boom TS: To tank
RAISE) TSW: From swing motor
P6: From R.H. work equipment PPC valve (boom
LOWER)

1. 8-spool valve 6. Pump merge-divider valve

2. Cover A 7. Boom hydraulic drift prevention valve
3. Cover B 8. Arm check valve
4. Service valve 1 9. Arm quick return valve
5. Service valve 2

10-48 PC228US-8,PC228USLC-8
(02)
 Hydraulic system
Control valve

General view 10-49

PC228US-8,PC228USLC-8 10-49
Hydraulic system
Control valve

Sectional view 10-50

(1/5)

10-50 PC228US-8,PC228USLC-8
 Hydraulic system
Control valve

1. Pressure compensation valve (arm OUT)

2. Pressure compensation valve (R.H. travel REVERSE)
3. Pressure compensation valve (RIGHT swing)
4. Pressure compensation valve (Boom RAISE)
5. Pressure compensation valve (L.H. travel REVERSE)
6. Pressure compensation valve (Bucket DUMP)
7. Pressure compensation valve (Service 1)
8. Pressure compensation valve (Service 2)
9. Pressure compensation valve (Bucket CURL)
10. Pressure compensation valve (L.H. travel FORWARD)
11. Pressure compensation valve (Boom LOWER)
12. Pressure compensation valve (LEFT swing)
13. Pressure compensation valve (R.H. travel FORWARD)
14. Pressure compensation valve (arm IN)
15. Main relief valve
16. Unload valve
17. Main relief valve
18. Spool (Service 2)
19. Spool (Service 1)
20. Spool (Bucket)
21. Spool (L.H. travel)
22. Spool (Boom)
23. Spool (Swing)
24. Spool (R.H. travel)
25. Spool (Arm)

PC228US-8,PC228USLC-8 10-51
Hydraulic system
Control valve

(2/5)

10-52 PC228US-8,PC228USLC-8
(02)
 Hydraulic system
Control valve

1. Suction valve (arm OUT)

2. Suction valve (R.H. travel REVERSE)
3. Suction valve (Boom RAISE)
4. Suction valve (L.H. travel REVERSE)
5. Suction safety valve (Bucket DUMP)
6. Suction safety valve (Service 1)
7. Suction safety valve (Service 2)
8. Suction 2-stage safety valve (Service)
9. Suction safety valve (Bucket CURL)
10. Suction valve (L.H. travel FORWARD)
11. Suction safety valve (Boom LOWER)
12. Suction valve (R.H. travel FORWARD)
13. Suction safety valve (arm IN)
14. LS shuttle valve (Arm)
15. LS shuttle valve (R.H. travel)
16. LS select valve
17. LS shuttle valve (Boom)
18. LS shuttle valve (Left travel)
19. LS shuttle valve (Bucket)
20. LS shuttle valve (Service 1)
21. LS shuttle valve (Service 2)
22. LS check valve

PC228US-8,PC228USLC-8 10-53
(02)
Hydraulic system
Control valve

(3/5)

10-54 PC228US-8,PC228USLC-8
 Hydraulic system
Control valve

1. Unload valve
2. Safety valve (Boom RAISE)
3. Main relief valve
4. Back pressure valve

Arm valve 10-5

5. Arm check valve
6. LS shuttle valve
7. Quick return valve
8. Pressure compensation valve (IN)
9. Spool
10. Suction safety valve (IN)
11. Cooler check valve
12. Regeneration circuit check valve
13. Suction valve (OUT)
14. Pressure compensation valve (OUT)

Right travel valve 10-5

15. LS shuttle valve
16. Pressure compensation valve (FORWARD)
17. Spool
18. Suction valve (FORWARD)
19. Suction valve (REVERSE)
20. Pressure compensation valve (REVERSE)

Swing valve 10-5

21. LS select valve
22. Pressure compensation valve (L.H.)
23. Spool
24. Pressure compensation valve (R.H.)

PC228US-8,PC228USLC-8 10-55
Hydraulic system
Control valve

(4/5)

10-56 PC228US-8,PC228USLC-8
 Hydraulic system
Control valve

1. Return spring
2. Merge-divider valve (for LS)
3. Valve (Sequence valve)
4. Spring (Sequence valve)
5. Merge-divider valve (Main)
6. Return spring

Boom valve 10-57

7. Drift prevention valve
8. LS shuttle valve
9. Pressure compensation valve (LOWER)
10. Spool
11. Suction safety valve (LOWER)
12. Regeneration circuit check valve
13. Suction valve (RAISE)
14. Pressure compensation valve (RAISE)

Left travel valve 10-57

15. Merge-divider valve (travel junction valve)
16. Return spring
17. LS shuttle valve
18. Pressure compensation valve (FORWARD)
19. Spool
20. Suction valve (FORWARD)
21. Suction valve (REVERSE)
22. Pressure compensation valve (REVERSE)

Bucket valve 10-57

23. LS shuttle valve
24. Pressure compensation valve (CURL)
25. Spool
26. Suction safety valve (Curl)
27. Suction safety valve (DUMP)
28. Pressure compensation valve (DUMP)

PC228US-8,PC228USLC-8 10-57
Hydraulic system
Control valve

(5/5)

Service valve 1 10-58 Service valve 2 10-58

1. LS shuttle valve 6. LS shuttle valve
2. Pressure compensation valve 7. Pressure compensation valve
3. Spool 8. Spool
4. Suction 2-stage safety valve 9. Suction safety valve
5. Suction safety valve 10. Unload valve
11. Main relief valve
12. LS bypass plug

10-58 PC228US-8,PC228USLC-8
 Hydraulic system
Control valve

PC228US-8,PC228USLC-8 10-59
Hydraulic system
Function and operation by valve

Function and operation by valve 10-60

Hydraulic circuit diagram and valve names 10-60

10-60 PC228US-8,PC228USLC-8
 Hydraulic system
Function and operation by valve

1. Arm valve 27. Arm quick return valve

2. Right travel valve 28. Arm check valve
3. Swing valve (For centralized safety valve circuit)
4. Boom valve 29. Self-pressure reducing valve
5. Left travel valve 30. Travel junction valve
6. Bucket valve 31. Back pressure valve
7. Service valve 1 32. Cooler check valve
8. Service valve 2 33. Boom drift prevention valve
9. Arm spool 34. Main relief valve (for attachment, bucket, left
10. R.H. travel spool travel and boom circuits)
11. Swing spool Set pressure: 34.9 ± 0.5 MPa {355.5 ± 5 kg/cm2}
12. Boom spool With power max. ON: 37.5 ± 0.5 MPa {382 ± 5
13. L.H. travel spool
kg/cm2}
14. Bucket spool
35. Main relief valve (for arm, right travel and swing
15. Service spool 1
circuits)
16. Service spool 2
17. Pressure compensation valve Set pressure: 34.9 ± 0.5 MPa {355.5 ± 5 kg/cm2}
18. Suction valve With power max. ON: 37.5 ± 0.5 MPa {382 ± 5
19. Check valve(for boom regeneration circuit) kg/cm2}
20. Check valve(for arm regeneration circuit) 36. Unload valve (bucket side)
21. EPC valve (for pump merge-divider valve main Cracking pressure: 2.5 ± 0.5 MPa {26 ± 5
spool changeover) kg/cm2}
22. EPC valve (for pump merge-divider valve LS 37. Unload valve (arm side)
spool changeover) Cracking pressure: 2.5 ± 0.5 MPa {26 ± 5
23. LS shuttle valve kg/cm2}
24. LS bypass plug 38. Suction-safety valve
25. LS select valve
Set pressure: 24.5 ± 0.5 MPa {250 ± 5 kg/cm2}
26. Merge-divider valve
39. Suction-safety valve
Set pressure: 38.2 ± 0.5 MPa {390 ± 5 kg/cm2}
40. Suction 2-stage safety valve
Set pressure: 1st stage: 24.5 ± 0.5 MPa {250 ± 5
kg/cm2}
2nd stage: 20.6 ± 0.5 MPa {210 ± 5
kg/cm2}

PC228US-8,PC228USLC-8 10-61
Hydraulic system
Function and operation by valve

Unload valve 10-62

When unload valve is actuated 10-62

1. LS circuit q When operating actuators within the pump deliv-

2. Valve ery with the swash plate angle at the minimum,
3. Pump circuit the delivery pressure with swash plate angle at
4. Tank circuit the minimum is controlled to the LS pressure
5. Spring plus P1 pressure.
q The LS differential pressure (dPLS) with the
Function 10-62 swash plate angle at the minimum becomes P1
q When all control valves are at HOLD, this valve pressure.
serves to drain as same amount of oil as the Operation of relief valve 10-62
pump delivery with swash plate angle at the min- q When the cylinder reaches its stroke end, the
imum. main relief valve opens.
q The pump pressure becomes the pressure cor- q The pump delivery (Q) is relieved to the tank.
responding to the set load of spring (5) in the (See the system diagram)
valve (referred to as P1). q As no flow is at upstream and downstream of the
q As the LS pressure oil is drained from the LS by- spool, the pump delivery pressure (PP) and LS
pass valve, the LS pressure comes to be that LS pressure (PLS) are approximately the same, and
pressure C tank pressureC 0 MPa {0 kg/cm2}. the LS differential pressure (dPLS) is 0 MPa
{0 kg/cm2}.
Operation 10-62 q As LS differential pressure (dPLS) is lower than
q Pressure of pump circuit (3) is received by the the LS set pressure of LS valve, LS valve oper-
end of valve (2). ates to make the pump swash plate angle maxi-
q As the control valve is in neutral, the pressure in mum.
LS circuit (1) is 0 MPa {0 kg/cm2}. q Mechanically, operation of PC valve has priority

q Pressurized oil of pump circuit (3) stops at valve over that of LS valve.
(2), and the pressure rises as no relief is avail- q The pump is maintained at the minimum swash

able. plate angle due to PC valve cut-off function.

q When the force exerted by this pressure be-
comes larger than the force of spring (5), valve
(2) moves to the left.
q Ports (b) and (c) are connected, and the pump
pressure oil flows to tank circuit (4)
q The pressurized oil of LS circuit (1) passes from
orifice (a) through port (c) and is drained to tank
circuit (4).
q When this valve is actuated, the LS pressure is
nearly equal to the tank pressure.
q When unloading, the pressure difference, pump
delivery pressure minus LS circuit pressure, is
greater than pump LS control pressure. This is
the signal to control the pump swash plate angle
to the minimum.

10-62 PC228US-8,PC228USLC-8
(02)
 Hydraulic system
Function and operation by valve

Introduction of LS pressure 10-63

1. Main pump
2. Main spool
3. Pressure compensation valve
4. Valve
5. Check valve
6. LS circuit
7. LS shuttle valve

Function 10-63
q The upstream pressure (spool meter-in down-
stream pressure) of pressure compensation
valve (3) is introduced and led to LS shuttle valve
(7) as the LS pressure.
q The pressure compensation valve connects to
port (B) of actuator through valve (4), taking that
the LS pressure is nearly equal to the actuator
negative pressure.
q In main spool (2), leading hole (a) with a small di-
ameter also acts as an orifice.

Operation 10-63
q When main spool (2) is operated, the pump pres-
sure enters port (c) through leading hole (a) and
is led to the LS circuit.
q When the pump pressures rises to reach the
load pressure of port (B), check valve (5) opens
and the pressurized oil flows.

PC228US-8,PC228USLC-8 10-63
Hydraulic system
Function and operation by valve

LS bypass plug 10-64

1. Main pump
2. Main spool
3. Pressure compensation valve
4. LS shuttle valve
5. LS bypass plug
6. LS circuit

Function 10-64
q This plug relieves residual pressure in LS pres-
sure circuit (6) from orifices (a) and (b).
q This plug serves to slow down the rising rate of
the LS pressure to prevent a sudden change of
hydraulic pressure.
q Depending on the bypass flow from LS bypass
plug (5), a pressure loss is generated due to the
circuit resistance from orifice (c) of main spool
(2) to LS shuttle valve (4).
q Effective LS differential pressure drops to im-
prove a dynamic stability of the actuator.

10-64 PC228US-8,PC228USLC-8
(02)
 Hydraulic system
Function and operation by valve

Pressure compensation valve 10-65

When the work equipment is operated independently and the load pressure is the maximum 10-65
(When the load pressure is higher than other work equipment during a combined operation)

1. Main pump q As principle, port (C) and spring chamber (E) are
2. Valve not interconnected in an integrated pressure
3. Shuttle valve compensation valve.
4. Piston q If high peak pressure is generated at port (C),
5. Spring valve (7) does not collide with the valve cham-
6. LS shuttle valve ber.
q With a bucket valve, etc., port (C) and spring
Function 10-65 chamber (E) are designed to interconnect before
q Pressure compensation valve works as the load valve (7) is seated.
check valve.
q If the pump pressure (LS pressure) is lower than
the load pressure at port (c), shuttle valve (3) in
pressure compensation valve piston (4) inter-
connects spring chamber (E) and port (C).
q The force of spring (5) operates piston (4) and
valve (2) to the closing direction.

Integrated pressure compensation valve 10-65

q When a high peak pressure or continuous and
repetitive peak pressure (as in breaker opera-
tion) is generated in the actuator circuit, valve (2)
may collide with valve chamber seat (C), produc-
ing high stress in the parts.
q To prevent this, a pressure compensation valve
with integrated valve (2) and piston (4) is used.
q With this machine, this valve is adopted for the
bucket valve (cylinder bottom) and the service
valve.

PC228US-8,PC228USLC-8 10-65
Hydraulic system
Function and operation by valve

When compensated 10-6

(When the load pressure is lower than other work equipment during a combined operation)

Function 10-6
q The pressure compensation valve closes by the
LS pressure of port (D), and the spool meter-in
downstream pressure of port (B) becomes
equivalent to the maximum pressure of other
work equipment.
q Since the spool meter-in upstream pressure of
port (A) is the pump pressure, the spool meter-in
differential pressure [upstream pressure (port
(A) pressure)] – downstream pressure [(port (B)
pressure)] becomes equivalent to all the spools
in operation.
q Pump flow is divided according to the ratio of the
meter-in opening areas.

Operation 10-6
q Spring chamber (E) is interconnected to port (D).
q Piston (4) and valve (2) is moved in the closing
direction (to the right) by the LS circuit pressure
of port (F) from other work equipment.
q Valve upstream pressure (= spool meter-in
downstream pressure) of port (B) is controlled
with the LS pressure.

10-66 PC228US-8,PC228USLC-8
 Hydraulic system
Function and operation by valve

Area ratio of pressure compensation valve 10-67

Function 10-67
q The condition of oil flow division changes ac-
cording to the area ratio of pressure compensa-
tion valve portions (A1) and (A2). Area ratio =
(A2)/(A1)
q When area ratio = 1: As the spool meter-in
downstream pressure is equal to the maximum
load pressure, the oil flow is divided in the ratio
as same as the opening area ratio.
q When area ratio is more than 1: As the spool me-
ter-in downstream pressure is higher than the
maximum load pressure, the oil flow is divided in
a ratio lower than the opening area ratio.
q When area ratio is below 1: As the spool me-
ter-in downstream pressure is lower than the
maximum load pressure, the oil flow is divided in
a ratio higher than the opening area ratio.

PC228US-8,PC228USLC-8 10-67
Hydraulic system
Function and operation by valve

Shuttle valve in pressure compensation valve 10-68

When holding pressure at port (A) becomes higher than LS pressure in spring chamber (B) 10-68

1. Main pump
2. Valve
3. Shuttle valve
4. Piston
5. Pressure compensation valve

Function 10-68
q Shuttle valve (3) is pressed to the right side by
the pressure of port (A). As a result, port (A) is
disconnected from port (C).
q Holding pressure at port (A) is led to the spring
chamber (B) to push piston (4) to the left so that
piston (4) is not separated from valve (2).

10-68 PC228US-8,PC228USLC-8
 Hydraulic system
Function and operation by valve

When traveling 10-69

Outline 10-69
q Since no holding pressure is generated at port
(A) of the travel circuit, a pressure compensation
valve without shuttle valve (5) is adopted.

PC228US-8,PC228USLC-8 10-69
(02)
Hydraulic system
Function and operation by valve

Boom regeneration circuit 10-70

When cylinder head pressure is lower than bottom pressure (hydraulic drift, etc.) 10-70

1. Main pump Operation 10-70

2. Boom spool q When the cylinder head pressure is lower than
3. Pressure compensation valve the bottom pressure, some of pressurized oil (A)
4. Suction-safety valve from the cylinder bottom flows to drain circuit (B)
5. Suction valve from the notch of boom spool (2).
6. Check valve q The remaining oil flows to regeneration circuit
7. LS shuttle valve (C), opens check valve (6) and flows to the cylin-
der bottom through circuit (D).
Function 10-70 q Flow from regeneration circuit (C) and pump (1)
q The regeneration circuit from the cylinder bottom merges in circuit (E).
to the cylinder head is installed to increase flow
to the cylinder head when the boom is lowered.

10-70 PC228US-8,PC228USLC-8
 Hydraulic system
Function and operation by valve

When cylinder head pressure is higher than bottom pressure (digging operation, etc.) 10-71

Function 10-71
q Check valve (6) provided to regeneration circuit
(C) closes to shut off the flow from the cylinder
bottom to the head.

PC228US-8,PC228USLC-8 10-71
Hydraulic system
Function and operation by valve

Arm regeneration circuit 10-72

When cylinder head pressure is higher than bottom pressure 10-72

1. Main pump Operation 10-72

2. Arm spool q When the cylinder head pressure is higher than
3. Pressure compensation valve the bottom pressure, some of pressurized oil (A)
4. Suction-safety valve from the cylinder head flows to drain circuit (B)
5. Suction valve from the notch of arm spool (2).
6. Check valve q The remaining flow goes to the regeneration cir-
7. LS shuttle valve cuit (C), opens check valve (6), and flows to the
cylinder bottom through circuit (D).
Function 10-72 q Flow from regeneration circuit (C) and pump (1)
q The regeneration circuit from the cylinder head merges in circuit (E).
to cylinder bottom is installed to increase the flow
to the cylinder (pump delivery flow + regenera-
tion flow) during arm IN operation in order to ac-
celerate the cylinder speed.

10-72 PC228US-8,PC228USLC-8
 Hydraulic system
Function and operation by valve

When cylinder head pressure is lower than bottom pressure 10-73

Function 10-73
q Check valve (6) provided to regeneration circuit
(C) closes to shut off the flow from the cylinder
bottom to the head.

PC228US-8,PC228USLC-8 10-73
Hydraulic system
Function and operation by valve

Merge-divider valve 10-74

When pump flow are merged [pump merge-divider valve changeover signals (IS1) and (IS2) are OFF]10-74

1. Main spool Operation 10-74

2. Spring q As changeover signal (IS1) is OFF, the output
3. LS spool pressure of EPC valve becomes 0 MPa
4. Spring {0 kg/cm2}.
5. LS circuit (bucket side) q Main spool (1) is pressed to the right by spring
6. LS circuit (bucket side) (2). As a result ports (E) and (F) are connected.
7. LS circuit (arm side) q Pressurized oils (P1) and (P2) from the two
8. LS circuit (arm side) pumps are merged by ports (E) and (F), and sent
9. EPC valve (for main spool changeover) to the required control valves.
10. EPC valve (for LS spool changeover) q As changeover signal (IS2) is OFF, LS spool (3)
is also pressed to the right by spring (4). As a re-
Function 10-74 sult, ports (A) and (D) are connected, and ports
q This valve merges or divides (distribute to each (B) and (C) are connected.
control valve group) the pressurized oils (P1) q LS pressures introduced from each control valve
and (P2) from the two pumps. spool to LS circuit (5), (6), (7) and (8) are routed
q This valve merges and divides LS circuit pres- to all pressure compensation valves.
sures.

10-74 PC228US-8,PC228USLC-8
 Hydraulic system
Function and operation by valve

When pump flow are divided [pump merge-divider valve changeover signals (IS1) and (IS2) are ON] 10-75

Operation 10-75
q As changeover signal (IS1) is ON, main spool (1)
is moved to the left by the pressure from EPC
valve. As a result, ports (E) and (F) are discon-
nected.
q The pressurized oils from the two pumps are
sent to respective control valve groups.
P1 pressure: to bucket, left travel, boom
P2 pressure: to swing, right travel, arm
q When changeover signal (IS2) becomes ON, LS
spool (3) is also moved to the left by the pressure
from the EPC valve. As a result, ports (A) and
(C) are connected, and other ports are discon-
nected.
q The LS pressure introduced from each control
valve spool to LS circuits (5), (6), (7) and (8) is
routed to respective control valves.

PC228US-8,PC228USLC-8 10-75
Hydraulic system
Function and operation by valve

LS selector valve 10-76

Function 10-76 Operation 10-76

q This valve prevents high LS pressure from the
swing valve from entering the LS circuits of work When pilot pressure (BP) is not developed 10-76
equipment valves when the swing and work q As pilot pressure (BP) is not developed, piston
equipment are in combined operation. (3) is pressed to the left by spring (2).
q This valve prevents high pressure generated at q When the swing is operated, swing LS pressure
swing drive to improve operability of work equip- (P1) enters port (A) after passing swing spool
ment. (5).
q Valve (1) is pressed to the left side, and ports (A)
and (B) are connected.
q Swing LS pressure (P1) is routed to LS shuttle
valves (8).

When pilot pressure (BP) is developed 10-76

q When pilot pressure (BP) is developed, spring
(2) is compressed by the BP pressure and piston
(3) is moved to the right.
q Valve (1) is pressed to the right, and ports (A)
and (B) are disconnected.
q Swing LS pressure (P1) stops flowing to LS shut-
tle valves (8).
q If swing LS pressure (P1) rises, other LS circuits

a The illustration shows the condition when swing are not affected.
and right travel are in combined operation. [(BP)
pressure is developed]
1. Valve
2. Spring
3. Piston
4. Piston
5. Swing spool
6. R.H. travel spool
7. Arm spool
8. LS shuttle valve
9. LS circuit

10-76 PC228US-8,PC228USLC-8
 Hydraulic system
Function and operation by valve

Self-pressure reducing valve 10-7

Function 10-7
q This valve serves to reduce the delivery pres-
sure of main pump and provide it as the control
pressure for solenoid valves, EPC valves, etc.

Operation 10-7

While engine is stopped 10-7

q Poppet (11) is pressed by spring (12) against the
seat, so port (PR) is disconnected from port
(TS).
q As valve (14) is pressed to the left by spring (13),
ports (P2) and (TS) are disconnected.
q Valve (7) is pressed to the left by spring (8), so
port (P2) is disconnected from port (A2).

PC228US-8,PC228USLC-8 10-77
Hydraulic system
Function and operation by valve

When control valve is in NEUTRAL and when When load pressure (P2) is high 10-78
load pressure (P2) is low 10-78 q As load pressure (A2) increases with the opera-
a When load pressure (A2) is lower than output tion of digging, etc, the pump delivery increases
pressure (PR) of the self-pressure reducing accordingly.
valve q Pressure (P2) increases, and [Force (fd (area) x
P2] becomes larger than [force of spring (8) +
q Force of spring (8) and the force exerted by the force (fd (area) x PR pressure)] holds. As a re-
PR pressure (0 MPa {0 kg/cm2}, when engine is sult, valve (7) moves to the right stroke end.
stopped), are applied to valve (7) in the direction q As a result, opening between ports (P2) and (A2)

to disconnect the circuit ports (P2) and (A2). increases, and the passage resistance reduces,
q When pressurized oil flows in from port (P2), reducing the engine horsepower loss.
valve (7) balance when [Force (fd area x P2 q When pressure (PR) rises above the set pres-

pressure) = force of spring (8) + force (fd area x sure, poppet (11) opens.
PR pressure)] holds. q Pressurized oil flows from port (PR) to orifice (a)

q The opening of valve (7) is adjusted so that pres- in spool (14), then flows to seal drain port (TS)
sure (P2) is at a constant level over pressure from poppet (11) opening.
(PR). q Differential pressure is generated across orifice

q When pressure (PR) rises above the set pres- (a) in spool (14) and then spool (14) moves to
sure, poppet (11) opens. close the opening between ports (P2) and (PR).
q Pressurized oil flows from port (PR) to orifice (a) q Pressure (P2) is reduced by the opening at this

in spool (14), then flows to seal drain port (TS) time and adjusted to a constant pressure (the set
from poppet (11) opening. pressure) and supplied as pressure (PR).
q Differential pressure is generated across orifice
(a) in spool (14) and then spool (14) moves to
close the passage between ports (P2) and (PR).
q Pressure (P2) is reduced by the opening at this
time and adjusted to a constant pressure (the set
pressure) and supplied as pressure (PR).

10-78 PC228US-8,PC228USLC-8
 Hydraulic system
Function and operation by valve

When abnormally high pressure is generated 10-79

q If pressure (PR) of self-pressure reducing valve
becomes abnormally high, ball (16) contracts
spring (15) and separates from the seat.
q The pressurized oil is allowed to flow to (TS)
from port (PR) to lower pressure (PR).
q As a result, components such as PPC valves
and solenoid valves are protected from abnor-
mal pressure.

PC228US-8,PC228USLC-8 10-79
Hydraulic system
Function and operation by valve

Travel junction valve 10-80

When pilot pressure is developed 10-80

Function 10-80 Operation 10-80

q This valve connects the L.H. and R.H. travel cir- q Pilot pressure (PST) from the travel junction so-
cuits through travel junction valve so that the hy- lenoid valve compresses spring (1), and travel
draulic oil will be supplied evenly to both travel junction spool (2) moves to the left stroke end.
motors to ensure machine's straight travel per- q Junction circuit between port (PTL) (L.H. travel
formance. circuit) and port (PTR) (R.H. travel circuit) is
q During steering operation, good steering perfor- closed.
mance is maintained by disconnecting the travel
circuits by external pilot pressure (PST).

10-80 PC228US-8,PC228USLC-8
(02)
 Hydraulic system
Function and operation by valve

When pilot pressure is not developed 10-81

Operation 10-81
q When pilot pressure (PST) from the solenoid q If the oil flow rates to the L.H. and R.H. travel mo-
valve is 0 MPa {0 kg/cm2}, the travel junction tors become different from each other, the oil
spool (2) is pressed to the right by the force of flows through the route between port (PTL), the
spring (1). As a result, port (PTL) connects to opening of travel junction spool (2), and port
port (PTR). (PTR) so that the oil flow rates to both motors are
equalized again.

PC228US-8,PC228USLC-8 10-81
Hydraulic system
Function and operation by valve

Travel PPC shuttle valve 10-82

When travel lever is in NEUTRAL 10-82

Function 10-82 Operation 10-82

q In the case that boom RAISE, arm IN or OUT, q The oil in the stroke limiting signal chamber (a) is
bucket CURL or DUMP operation is performed drained through orifices (5) and (6) of respective
when going a steep uphill, the oil flow to each pistons (3) and (4) in the travel spring case and
cylinder is restricted by limiting the stroke of travel PPC valve.
each spool of boom, arm and bucket valve, by q When conducting boom (or arm IN or OUT,
using the pilot pressure of travel PPC valve. dump, bucket CURL or DUMP) operation, spool
q The limit the stroke of the boom, arm or bucket (1) moves to the left until it contacts with the end
spool, the pilot pressure of travel PPC valve acts face of spring case (2) (st0).
on the spool through the internal circuit of re-
spective control valves.

10-82 PC228US-8,PC228USLC-8
 Hydraulic system
Function and operation by valve

Travel operation 10-83

Operation 10-83 q Maximum stroke of the spool is limited to (st1) for

q When running the right track in reverse (or for- the amount of movement (st2) of piston (8) to the
ward), the pilot pressure from the PPC valve right.
pushes spool (7) to the left (or right).
q Spool (7) pushes piston (3) to close orifice (5).
As a result, the drain circuit from stroke limiting
signal chamber (a) to the travel PPC valve is
blocked off.
q When running the right track in reverse (or for-
ward), the pilot pressure from PPC valve is ap-
plied through orifice (6) of piston (4) to the left
end face of piston (8) to push it to the right.
q When conducting boom raise (or arm IN or OUT,
bucket CURL or DUMP) operation, spool (1)
moves to the left.

PC228US-8,PC228USLC-8 10-83
Hydraulic system
Function and operation by valve

Boom drift prevention valve 10-84

At boom RAISE operation 10-84

Function 10-84
q This valve prevents the boom from lowering un-
der its weight due to the leak of oil in the boom
cylinder bottom through spool (1) while the boom
lever is not operated.

Operation 10-84
q When conducting boom RAISE operation, the
pressurized oil from the control valve is applied
to the ring-shaped area, which OD is the poppet
(5) diameter (d1) and which ID is the seat diam-
eter (d2), in the direction from right to left.
q The force contracts spring (4) and poppet (5)
moves to the left.
q As a result, pressurized oil from the control valve
passes through the opening of poppet (5) and
flows to the bottom end of the boom cylinder.

10-84 PC228US-8,PC228USLC-8
 Hydraulic system
Function and operation by valve

When boom lever is in NEUTRAL 10-85

Operation 10-85
q This explanation applies to the case that the
boom lever is returned to NEUTRAL with the
boom raised.
q Pressurized oil flown inside poppet (5) from ori-
fice (a) of poppet (5) is blocked by pilot piston
(2).
q The holding pressure of boom cylinder bottom
acts on the ring-shaped area (S), whose OD is
outside diameter (d1) of poppet (5) and whose
ID is seat diameter (d2), to move it to the right.
q The sum of this force and the force of spring (4)
closes poppet (5).
q Pressurized oil from the control valve and the
holding pressure oil of the boom cylinder bottom
are blocked.

PC228US-8,PC228USLC-8 10-85
Hydraulic system
Function and operation by valve

At boom LOWER operation 10-86

Operation 10-86
q When boom LOWER operation is performed, the
pilot pressure from the PPC valve presses pilot
piston (2).
q Pressurized oil in chamber (b) inside the poppet
is drained through orifice (c).
q The pressurized oil in the boom bottom flows in
the sequence of orifice (a), o chamber (b), o or-
ifice (c) o drain (T), and the pressurized oil in
chamber (b) lowers.
q When the pressure in chamber (b) lowers, the
pressure at port (B) opens poppet (5).
q Pressurized oil from port (B) is led to port (A) and
then flows to the control valve.

10-86 PC228US-8,PC228USLC-8
 Hydraulic system
Function and operation by valve

Arm drift prevention valve 10-87

(if equipped)

At arm OUT operation 10-87

Function 10-87
q This valve prevents the arm from drifting due to
the leak of oil in the arm cylinder head through
spool (1) while the arm lever is not operated.

Operation 10-87
q When conducting arm OUT operation, the pres-
surized oil from the control valve is applied to the
ring-shaped area, whose OD is the poppet (5) di-
ameter (d1) and whose ID is the seat diameter
(d2), in the direction from right to left.
q This force contracts spring (4) and poppet (5)
moves to the left.
q As a result, pressurized oil from the control valve
passes through the opening of poppet (5) and
flows to the arm cylinder head.

PC228US-8,PC228USLC-8 10-87
Hydraulic system
Function and operation by valve

When arm lever is in NEUTRAL 10-8

Operation 10-8
q This explanation applies to the case that the arm
lever is returned to NEUTRAL with the arm at
arm OUT position.
q Pressurized oil flown into poppet (5) from orifice
(a) of poppet (5) is blocked by pilot piston (2).
q The holding pressure of arm cylinder head acts
on ring-shaped area (S), whose OD is the out-
side diameter (d1) of poppet (5) and whose ID is
seat diameter (d2) to move it to the right.
q The sum of this force and the force of spring (4)
closes poppet (5).
q Pressurized oil from the control valve and the
holding pressure oil of the arm cylinder head are
blocked.

10-88 PC228US-8,PC228USLC-8
 Hydraulic system
Function and operation by valve

At arm IN operation 10-89

Operation 10-89
q When conducting arm IN operation, the pilot
pressure from the PPC valve pushes pilot piston
(2).
q Pressurized oil in chamber (b) inside the poppet
is drained through orifice (c).
q The pressurized oil in arm head flows in the se-
quence of orifice (a), o chamber (b), o orifice (c)
o drain (T), and the pressurized oil in chamber
(b) lowers.
q When the pressure in chamber (b) lowers, the
pressure at port (B) opens poppet (5).
q Pressurized oil from port (B) is led to port (A) and
then flows to the control valve.

PC228US-8,PC228USLC-8 10-89
Hydraulic system
Function and operation by valve

When abnormally high pressure is generated 10-90

Operation 10-90
q If abnormally high pressure is generated in the q If arm drift prevention valve (if equipped) is in-
boom cylinder bottom circuit, the pressurized oil stalled to the arm cylinder head circuit, the oil of
in port (B) pushes check valve (6) open, then the boom cylinder bottom circuit pressure or arm
safety valve (3) works. cylinder head circuit pressure, whichever higher
pressure, pushes check valve (6) or (6A) open to
actuate safety valve (3).

10-90 PC228US-8,PC228USLC-8
 Hydraulic system
Function and operation by valve

Quick return valve 10-91

At arm OUT operation 10-91

Function 10-91 q (Force received by area fd2 > Force received by

q Large amount of oil is returned from the cylinder area fd1 + Force of spring)
bottom when conducting arm OUT operation. q Valve (2) is moved to the left and pressurized oil
q The valve reduces this pressure loss. is routed from port (A) to port (B).
q From port (B), the pressurized oil is drained di-
Operation 10-91 rectly to the tank.
q When conducting arm OUT operation, the pilot
pressure from the PPC valve pushes pilot piston
(1).
q Pressurized oil in chamber (b) inside the valve is
drained through orifice (c).
q The pressurized oil in the arm bottom flows in the
sequence of orifice (a) o chamber (b) o orifice
(c) o drain (T), and the pressure in chamber (b)
lowers.
q If the pressure of chamber (b) drops lower than
that of port (A), the force receved by the pres-
sure receiving portion [fd2 area (S2) (seat diam-
eter area)] on the side of port (A) exceeds the
sum of the force receved by pressure receiving
portion [fd1 area (S1)] on the chamber (b) side
of valve (2) and the spring force.

PC228US-8,PC228USLC-8 10-91
Hydraulic system
Function and operation by valve

When arm lever is in NEUTRAL 10-92

Operation 10-92
q When arm lever is returned from arm OUT to
NEUTRAL, the pilot pressure from PPC valve
becomes 0 MPa {0 kg/cm2}.
q The pressurized oil that is routed and drained
through orifice (a) in valve (2) is blockd by pilot
piston (1).
q The holding pressure of the arm bottom is ap-
plied to the ring-shaped area with sectional area
of (S2 -S1) of valve (2) in the direction from left
to right.
q Valve (2) is closed by the total of this force and
the force of spring (3), so port (A) is disconnect-
ed from port (B).

10-92 PC228US-8,PC228USLC-8
 Hydraulic system
Function and operation by valve

Back pressure valve 10-93

Function 10-93 When engine is running 10-93

q This valve develops back pressure to the drain q The output pressure of self-pressure reducing
circuit to prevent generation of negative pres- valve is led through inside of control valve to
sure on each actuator (motors, cylinders, etc.). spring chamber (c) of back pressure valve (3).
q Output pressure (PR) introduced to spring
Operation 10-93 chamber (c) acts on the left end face of valve (1)
(area of fd) to push valve (1) to the right.
While engine is stopped 10-93 q At this time, pressure (PA) of drain circuit (a) of
q Pressurized oil is not fed to the self pressure re- the control valve acts on the right end face of
ducing valve from the pump, and valve (1) is valve (1) (area of fd1) to push valve (1) to the
pressed to the right by the force of spring (2). left.
q Drain circuit (a) of the control valve is connected q Valve (1) balances so that the back pressure
to port (T) through orifice (b) of valve (1). (PA) satisfies the equation below.
(Area of fd) x PR + force of spring (2)
PA=
Area of fd1

PC228US-8,PC228USLC-8 10-93
Hydraulic system
Function and operation by valve

Main relief valve 10-94

1. Spring
2. Poppet

Function 10-94
q The set pressure of relief valve can be set in two
stages.
q When power is needed, pilot pressure (P) is de-
veloped and the set pressure becomes
high-pressure setting.

Operation 10-94
q The set pressure of the relief valve depends on
the load at installed length of spring (1). (1st
stage)
q There is no need to conduct each setting for 1st
and 2nd stages. When 1st stage is set, 2nd
stage is set automatically.

When pilot pressure (P) is not developed: Low

pressure setting 10-94
Set pressure is determined by the load at installed
length of spring (1).

When pilot pressure (P) is developed: High pres-

sure setting 10-94
The load at installed length of spring (1) is added
with the force exerted by pilot pressure (P) applied
to the area of poppet (2) of diameter (d1), raising the
set pressure to higher level.

10-94 PC228US-8,PC228USLC-8
 Hydraulic system
Function and operation by valve

2-stage suction-safety valve 10-95

[Installed to port (B) of the service valve]

1. Spring
2. Piston
3. Spring
4. Holder
When pilot pressure is not developed (High
Function 10-95 pressure setting) 10-95
q This valve serves to provide the safety valve set q As pilot pressure (P) is not developed, piston (2)
pressure in two stages, and make the low-pres- is pressed to the left by spring (3). [Load at in-
sure setting smaller. stalled length of pring (1) < Load at installed
q This valve relieves high load applied to the cylin- length of spring (3)]
der without lever operation. q When the load at installed length of spring (1) is
q This valve improves work efficiency and reduces the maximum, the set pressure is at high-pres-
machine body vibration. sure setting.
q Passage (B) is interconnected to the drain circuit
Operation 10-95 via passage (C) and chamber (D).
q The safety valve set pressure is determined by
the load at installed length of spring (1).

PC228US-8,PC228USLC-8 10-95
Hydraulic system
Function and operation by valve

When pilot pressure is developed (Low pressure

setting) 10-96
q When pilot pressure (P) is developed, the pilot
pressure is led to portion (A) through passage
(B).
q The pilot pressure acts on the pressure receiving
diameter at portion (A) [(d2)– (d1)] of piston (2).
q This pilot pressure contracts spring (3), and pis-
ton (2) moves to the right until it contacts with
holder (4).
q Spring (1) stretches, the force of spring is re-
duced, and the set pressure lowers.
q The amount of pressurized oil for piston stroke is
drained through passage (C) and chamber (D) .

10-96 PC228US-8,PC228USLC-8
 Hydraulic system
Swing motor

Swing motor 10-97

Type: KMF125AB-5

MA: From left swing port of control valve Specification 10-97

MB: From right swing port of control valve Theoretical delivery
B: From swing holding brake solenoid valve 125
(cm3/rev)
S: From control valve (back pressure valve)
Safety valve set pressure
T: To hydraulic tank 28.4 {290}
(MPa {kg/cm2})
1. Reversal prevention valve Rated speed: (rpm) 1,694
2. Safety valve
Brake release pressure
1.6 {16}
(MPa {kg/cm2}

PC228US-8,PC228USLC-8 10-97
Hydraulic system
Swing motor

10-98 PC228US-8,PC228USLC-8
 Hydraulic system
Swing motor

1. Brake spring
2. Drive shaft
3. Spacer
4. Case
5. Disc
6. Plate
7. Brake piston
8. Housing
9. Piston
10. Cylinder block
11. Valve plate
12. Center shaft
13. Center spring
14. Check valve
15. Shuttle valve

PC228US-8,PC228USLC-8 10-99
Hydraulic system
Swing motor

Swing brake 10-10

Operation 10-10

When solenoid valve is "de-energized" 10-10 When solenoid valve is "energized" 10-10

q As the swing brake is de-energized, the pressur- q As the swing brake solenoid valve is energized,
ized oil from the self pressure reducing valve is the valve is switched
blocked. q The pressurized oil from self-pressure reducing
q Port (B) is connected to tank circuit (T). valve enters port (B), and flows into brake cham-
q Brake piston (7) is pushed downward by brake ber (a).
spring (1). q After entering chamber (a), the pressurized oil
q Disc (5) and plate (6) are pushed against each compresses brake spring (1) and moves brake
other to apply the brake. piston (7) upward.
q Disc (5) is separated from plate (6), releasing the
brake.

10-100 PC228US-8,PC228USLC-8
 Hydraulic system
Swing motor

Relief valve portion 10-101 When swing is stopped 10-101

Outline 10-101
q The relief valve portion consists of check valves
(2) and (3), shuttle valves (4) and (5), and relief
valve (1).

Function 10-101
q When the swing is stopped, control valve (6)
blocks the motor outlet circuit, but the motor ro-
tation is continued by inertial force.
q The motor outlet pressure, therefore, is abnor-
mally increased, resulting in damaging the mo-
tor.
q In order to prevent the motor damages, the relief
valve relieves the abnormally high pressure to
port (S) from the motor outlet (high-pressure
side) of the motor.

Operation 10-101

When swinging is started 10-101

q When the swing control lever is returned to NEU-

TRAL, the supply of pressurized oil from the
pump to port (MA) is stopped.
q The pressurized oil from the motor outlet cannot
return to the tank since the return circuit to the
tank is blocked by control valve (6). Thus, pres-
sure on port (MB) increases.
q Rotation resistance is generated on the motor
and hence the brake starts working.
q When the pressure at port (MB) comes to be
higher than that at port (MA), shuttle valve (4) is
pressed.
q The pressure in chamber (C) becomes the same
as that of port (MB), and is increased to the set
pressure of relief valve (1).
q A high braking torque works on the motor, there-
by stopping the motor.
q When relief valve (1) is actuated, the relieved
pressurized oil and the pressurized oil from port
(S) are fed to port (MA) through the check valve
q When the swing control lever is moved to the (3).
right swing, the pressurized oil from the pump is q Thus, cavitations is prevented from generating
supplied to port (MA) through control valve (6). on port (MA).
q The pressure on port (MA) rises, the starting
torque is generated in the motor, and the motor
starts to rotate.
q The pressurized oil from the outlet of the motor
passes from port (MB) through the control valve
(6) and returns to the tank.

PC228US-8,PC228USLC-8 10-101
Hydraulic system
Swing motor

Reversal prevention valve 10-102

10-102 PC228US-8,PC228USLC-8
 Hydraulic system
Swing motor

MA: From left swing port of control valve

MB: From right swing port of control valve
T1: To hydraulic tank
T2: To hydraulic tank

1. Valve body
2. Spool (MA side)
3. Spring (MA side)
4. Plug (MA side)
5. Spool (MB side)
6. Spring (MB side)
7. Plug (MB side)

Explanatory drawing of effects 10-103

PC228US-8,PC228USLC-8 10-103
Hydraulic system
Swing motor

Function 10-104 When motor is stopped temporarily 10-104

q At the stop of swing operation, the upper struc-
ture may swing back. This is due to inertia of the
mass of the upper structure, the backlash and ri-
gidity of the swing machinery system, and com-
pressibility of the hydraulic oil. This valve
prevents such movement.
q The valve contributes in preventing spill of load
when the swing is stopped and also contributes
in reducing cycle time (enhances the positioning
performance, enabling you to proceed to the
next work quicker than ever).

Operation 10-104

When brake pressure is generated port (MB) 10-104 q The motor starts to turn in the opposite direction
by trapped pressure generated in port (MB). (1st
reverse turn)
q Reversing pressure is generated in port (MA).
(MA) pressure is provided to chamber (a).
q As (fD3 > fD4) holds in regards to circle areas
of spool (2), spring (3) is compressed and spool
(2) is moved to the left.
q Port (MA) connects to chamber (b).
q Ports (b) (f) are interconnected through the
drilled hole (h) in spool (5). This interconnection
bypasses the reversing pressure on port (MA) to
port (T), thereby preventing the reverse rotation
of the 2nd time.

q (MB) pressure is led to chamber (d) through

notch (g).
q As (fD1 > fD2) holds in regards to circle areas
of spool (5), spring (6) is compressed and spool
(5) is moved to the left.
q Port (MB) connects to chamber (e).
q Since (MA) pressure is lower than the set pres-
sure of spring (3), spool (2) does not move and
the pressurized oil is blocked. Thus the braking
force is ensured.

10-104 PC228US-8,PC228USLC-8
 Hydraulic system
Travel motor

Travel motor 10-105

Type: HMV110-2

PA: Left travel motor: From left travel reverse port of Specification 10-105
control valve Theoretical delivery Min. 74
Right travel motor: From right travel forward port (cm3/rev) Max. 110.7
of control valve (Rated pressure: MPa {kg/cm2}) 37.3 {380}
PB: Left travel motor: From left travel forward port of Rated speed (rpm)
Min. 2,980
control valve Max. 1,485
Right travel motor: From right travel reverse port Brake release pressure
1.18 {12}
of control valve (MPa {kg/cm2}
P: From travel speed acceleration valve Travel speed selector pressure
0.85 {8.7}
T: To hydraulic tank (MPa {kg/cm2}
B: Plug (Brake release pressure port)
MA: Port PA oil pressure pickup port
MB: Port PB oil pressure pickup port

PC228US-8,PC228USLC-8 10-105
Hydraulic system
Travel motor

10-106 PC228US-8,PC228USLC-8
 Hydraulic system
Travel motor

1. Regulator piston
2. Regulator valve
3. Motor case
4. Suction-safety valve
5. Check valve
6. Output shaft
7. Rocker cam
8. Retainer guide
9. Pin
10. Retainer
11. Piston
12. Cylinder block
13. Valve plate
14. Counterbalance valve spool
15. Ring
16. Brake piston
17. Plate
18. Disc
19. Ball retainer

PC228US-8,PC228USLC-8 10-107
Hydraulic system
Travel motor

Operation of motor 10-108

At low-speed travel setting (motor swash plate angle is at maximum) 10-108

q When the solenoid valve is de-energized, the pi- q The pressurized oil in regulator piston (15) flows
lot pressure oil from the self-pressure reducing through orifice (c) in regulator valve (9), and is
valve does not flow to port (P). drained into motor case.
q Regulator valve (9) is pressed to the right by q Rocker cum (4) tilts in the direction achieving the
spring (10). maximum swash plate angle, and the resultant
q The pressurized oil from the control valve push- maximized motor capacity realizes the
es check valve (22) open and is led to end cover low-speed travel setting.
(8), but it is blocked by regulator valve (9).
q The fulcrum (a) of the rocker cum is located ec-
centric to the point of action (b) for the combined
force of piston thrusts of cylinder (6).
q The combined force of piston thrusts act as a
moment to tilt rocker cum (4) in the direction
achieving the maximum swash plate angle.

10-108 PC228US-8,PC228USLC-8
 Hydraulic system
Travel motor

At high-speed travel setting (motor swash plate angle is at minimum) 10-109

q When the solenoid valve is energized, the pilot

pressure oil from the self-pressure reducing
valve flows to port (P).
q Regulator valve (9) is pressed to the left.
q The pressurized oil from the control valve flows
through passage (d) of regulator valve (9), and
enters regulator piston (15).
q Regulator valve (15) is pressed to the right.
q Rocker cum (4) tilts in the direction achieving the
minimum swash plate angle, and the resultant
minimized motor capacity realizes the high
speed travel setting.

PC228US-8,PC228USLC-8 10-109
Hydraulic system
Travel motor

Operation of parking brake 10-1 0

When starting traveling 10-1 0

q When the travel lever is operated, the pressur-

ized oil from the pump activates counterbalance
valve spool (19) to make the parking brake cir-
cuit.
q The oil enters chamber (e) of brake piston (12),
compresses spring (11), and pushes piston (12)
to the left.
q As pressing forces between plate (13) and disc
(14) are eliminated, they are separated and the
brake is released.

10-110 PC228US-8,PC228USLC-8
 Hydraulic system
Travel motor

When stopping traveling 10-1 1

q When travel lever is in NEUTRAL, counterbal-

ance valve spool (19) returns to the neutral posi-
tion, and the parking brake circuit is blocked.
q The pressurized oil in chamber (e) of brake pis-
ton (12) is drained to the case through orifice (f)
of brake piston (12).
q Brake piston (12) is pressed to the right by spring
(11).
q Plate (13) and disc (14) are pressed each other,
and the brake is applied.
q When brake piston (12) is returned, the flow of
pressurized oil is restricted by slow return valve
(22).
q The restriction of the return flow of pressurized
oil delays the application of the parking brake.
The parking brake is applied after the machine
has stopped.

PC228US-8,PC228USLC-8 10-111
Hydraulic system
Travel motor

Brake valve 10-1 2

q Brake valve is comprised of suction safety valve Operation when pressurized oil is supplied 10-1 2
(18A) and counterbalance valve (18).
q Functions and operations of respective compo-
nents are as follows.

Counterbalance valve, check valve 10-1 2

Function 10-1 2

q If the travel lever is operated, the pressurized oil

is supplied from the control valve to port (PA).
q The oil opens suction-safety valve (18A), and
flows from motor inlet port (MA) to motor outlet
port (MB).
q As motor outlet is blocked by suction-safety
valve (18B) and spool (19), the pressure of suc-
q When the machine travels down a slope, its trav- tion side increases.
el speed tends to get faster than the motor (en-
gine) speed because of the downward force
generated from its own weight.
q If the machine travels with the engine at low
speed, the motor may run idle, and the machine
runs out of control ; it is in a very dangerous sit-
uation.
q These valves are used to prevent above by con-
trolling the machine to travel according to the en-
gine speed (pump delivery).

10-112 PC228US-8,PC228USLC-8
 Hydraulic system
Travel motor

Brake operation at travelling downhill 10-1 3

q The pressurized oil of suctionside flows through

orifices (E1) and (E2) of spool (19) to cham- q If the machine start to run away is sensed while
ber(S1). it travels down a slop, the motor runs idle and the
q When the pressure in chamber (S1) comes to be inlet side pressure decreases.
higher than the spool changeover pressure, q The pressure in chamber (S1) decreases, as the
spool (19) is pressed to the right. oil is drained through orifices (E1) and (E2).
q Port (MB) connects to port (PB), and the motor q When the pressure in chamber (S1) becomes
outlet opens and the motor rotates. lower than the spool changeover pressure, spool
(19) is returned to the left by spring (20), restrict-
ing the outlet port (MB).
q The pressure in the outlet port rises, generating
rotation resistance on the motor to prevent the
machine from a runaway.
q The spool moves to the position where the force
exerted by the pressure at outlet port (MB) bal-
ances the sum of the force due to the machine
weight and the force exerted by the inlet pres-
sure.
q Restricting the oil flow from the outlet circuit al-
lows the machine to travel a the travel speed cor-
responding to the pump delivery.

PC228US-8,PC228USLC-8 10-113
Hydraulic system
Travel motor

Suction-safety valve 10-1 4

Function 10-1 4
q As long as the machine is stopped (or it is travels
down a slope), the counterbalance valve blocks
the inlet and outlet circuits of the motor.
q Since the motor is rotated by inertial force, pres-
sure in the motor outlet port is abnormally in-
creased, potentially resulting in damages on the
motor and piping.
q The safety valve releases this abnormal pres-
sure to the inlet port of the motor in order to pre-
vent damages to the equipment.
q When the pressure comes to be more than the
Operation 10-1 4
set pressure of suction-safety valve, poppet (1)
opens.
When stopping traveling (or downhill) (right
q The pressurized oil flows through slot (A1) of
turn) 10-1 4
spool (19) to the chamber of opposite side circuit
(MA).
q At the time of left turn, it makes reverse opera-
tion for right turn.

When starting traveling (or constant travel) 10-1 4

q As the pressure at motor inlet (PA) decreases,

the pressure in chamber (S1) also decreases.
q When it becomes lower than the spool change-
over pressure, spool (19) is returned to the left
by spring (20), restricting the outlet passage
q If the travel lever is operated, the pressurized oil
(B1).
from the pump moves spool (19) to the right.
q As motor tends to keep rotating by inertial force,
q As the passage to suction-safety valve is
the pressure at outlet (MB) increases.
changed to that the oil flow through slot (B2) of
spool (19), the differential pressure increases.
q The pump pressure rises and the large drawbar
pull is obtained.

10-114 PC228US-8,PC228USLC-8
 Hydraulic system
PPC valve

PPC valve 10-1 5

a PPC: Abbreviation for Proportional Pressure Control

Work equipment and swing PPC valve 10-1 5

P: From self-pressure reducing valve P4: Left side: To control valve (right swing port)
P1: Left side: To control valve (arm OUT port) Right side: To control valve (bucket DUMP port)
Right side: To control valve (boom LOWER port) T: To hydraulic tank
P2: Left side: To control valve (arm IN port)
Right side: To control valve (boom RAISE port)
P3: Left side: To control valve (left swing port)
Right side: To control valve (bucket CURL port)

PC228US-8,PC228USLC-8 10-115
(02)
Hydraulic system
PPC valve

10-116 PC228US-8,PC228USLC-8
(02)
 Hydraulic system
PPC valve

1. Spool
2. Piston
3. Disc
4. Nut (for lever connection)
5. Joint
6. Plate
7. Retainer
8. Body
9. Filter

PC228US-8,PC228USLC-8 10-117
Hydraulic system
PPC valve

Operation 10-1 8 q The positional relationship between spool (1)

and valve body (10) [where fine control hole (f) is
At neutral 10-1 8 between drain chamber (D) and pump pressure
q Ports (A) and (B) of the control valve and ports chamber (PP)] does not change until retainer (9)
(P1) and (P2) of the PPC valve are connected to comes in contact with spool (1).
drain chamber (D) through fine control hole (f) in q Metering spring (2) is compressed in proportion
spool (1). to the control lever travel.
q In addition, the pressure at port (P1) increases in
proportion to the control lever travel.
q In this way, the control valve spool moves to a
position where the pressure of port (A) (same as
pressure at port (P1)) and the force of the return
spring of the control valve spool are balanced.

When control lever is in fine control range 10-1 8

(fine control from neutral) 10-1 8
q When piston (4) is pushed by disc (5), retainer
(9) is pushed and spool (1) is also pushed down
through metering spring (2).
q When fine control hole (f) is disconnected from
drain chamber (D), it is connected to pump pres-
sure chamber (PP) at almost the same time.
q The pilot pressure oil of control pump is led from
port (P1) through fine control hole (f) to port (A).
q When the pressure at port (P1) becomes higher,
spool (1) is pushed back and fine control hole (f)
is shut off from pump pressure chamber (PP). At
almost the same time, it is connected to drain
chamber (D) to release the pressure at port (P1).
q As a result, spool (1) moves up and down until
the force of metering spring (2) is balanced with
the force exerted by the pressure at port (P1).

10-118 PC228US-8,PC228USLC-8
 Hydraulic system
PPC valve

When control lever is in fine control range 10-1 9 At full stroke 10-1 9
(When returning control lever) 10-1 9 q Disc (5) depresses pistion (4), and retainer (9)
q When disc (5) begins to return, spool (1) is depress spool (1).
pushed up by the force of centering spring (3) q Fine control hole (f) is disconnected from drain
and the force exerted by the pressure at port chamber (D), and it is connected to pump pres-
(P1). sure chamber (PP).
q Because of this, fine control hole (f) is connected q The pilot oil flows from self pressure redusing
to drain chamber (D), and the pressurized oil at valve through fine control hole (f) and port (P1)
port (P1) is released. into port (A) and pushes the control valve spool.
q If the pressure at port (P1) is excessively re- q The oil returning from port (B) flows through port
duced, spool (1) is depressed by metering spring (P2) and fine control hole (f') into drain chamber
(2). (D).
q Fine control hole (f) is disconnected from drain
chamber (D), and at almost the same time, it is
connected to pump pressure chamber (PP).
q The pump pressure is provided until the pres-
sure at port (P1) is recovered to the extent that
the pressure is equal to a pressure for the lever
position.
q When the spool of the control valve returns, the
oil in drain chamber (D) flows in through fine con-
trol hole (f') in the valve on the side that is not in
operation. The oil passes through port (P2) and
enters (B) chamber to replenish the port with
pressurized oil.

PC228US-8,PC228USLC-8 10-119
Hydraulic system
PPC valve

Travel PPC valve 10-120

P: From self-pressure reducing valve

P1: To control valve (left reverse travel port)
P2: To control valve (left forward travel port)
P3: To control valve (right reverse travel port)
P4: To control valve (right forward travel port)
T: To hydraulic tank

10-120 PC228US-8,PC228USLC-8
 Hydraulic system
PPC valve

1. Plate
2. Body
3. Piston
4. Seal
5. Valve
6. Damper

PC228US-8,PC228USLC-8 10-121
Hydraulic system
PPC valve

Operation 10-12 q The positional relationship between spool (1)

and valve body (10) [where fine control hole (f) is
At neutral 10-12 between drain chamber (D) and pump pressure
q Ports (A) and (B) of the control valve and ports chamber (PP)] does not change until retainer (9)
(P1) and (P2) of the PPC valve are connected to comes in contact with spool (1).
drain chamber (D) through fine control hole (f) in q Metering spring (2) is compressed in proportion
spool (1). to the control lever travel.
q In addition, the pressure at port (P1) increases in
proportion to the control lever travel.
q In this way, the control valve spool moves to a
position where the pressure of port (A) (same as
pressure at port (P1)) and the force of the return
spring of the control valve spool are balanced.

When control lever is in fine control range 10-12

(fine control from neutral) 10-12
q When piston (4) is pushed by lever (5), retainer
(9) is pushed and spool (1) is also pushed down
through metering spring (2).
q When fine control hole (f) is disconnected from
drain chamber (D), it is connected to pump pres-
sure chamber (PP) at almost the same time.
q The pilot pressure oil of control pump is led from
port (P1) through fine control hole (f) to port (A).
q When the pressure at port (P1) becomes higher,
spool (1) is pushed back and fine control hole (f)
is shut off from pump pressure chamber (PP). At
almost the same time, it is connected to drain
chamber (D) to release the pressure at port (P1).
q As a result, spool (1) moves up and down until
the force of metering spring (2) is balanced with
the force exerted by the pressure at port (P1).

10-122 PC228US-8,PC228USLC-8
 Hydraulic system
PPC valve

When control lever is in fine control range 10-123 At full stroke 10-123
(When returning control lever) 10-123 q Lever (5) depresses piston (4), and retainer (9)
q When lever (5) begins to return, spool (1) is depresses spool (1).
pushed up by the force of centering spring (3) q Fine control hole (f) is disconnected from drain
and the force exerted by the pressure at port chamber (D), and it is connected to pump pres-
(P1). sure chamber (PP).
q Because of this, fine control hole (f) is connected q The pilot oil flows from self pressure reducing
to drain chamber (D), and the pressurized oil at valve through fine control hole (f) and port (P1)
port (P1) is released. into port (A) and pushes the control valve spool.
q If the pressure at port (P1) is excessively re- q The oil returning from port (B) flows through port
duced, spool (1) is depressed by metering spring (P2) and fine control hole (f') into drain chamber
(2). (D).
q Fine control hole (f) is disconnected from drain
chamber (D), and at almost the same time, it is
connected to pump pressure chamber (PP).
q The pump pressure is provided until the pres-
sure at port (P1) is recovered to the extent that
the pressure is equal to a pressure for the lever
position.
q When the spool of the control valve returns, the
oil in drain chamber (D) flows in through fine con-
trol hole (f') in the valve on the side that is not in
operation. The oil passes through port (P2) and
enters chamber (B) to replenish the port with
pressurized oil.

PC228US-8,PC228USLC-8 10-123
(02)
Hydraulic system
PPC valve

Right attachment PPC valve 10-124

(with EPC valve) 10-124

a For the details of operation, see the section of " Work equipment and swing PPC valve" .

10-124 PC228US-8,PC228USLC-8
 Hydraulic system
PPC valve

P: From self-pressure reducing valve

P1: To control valve (service valve 1 port)
P2: To control valve (service valve 1 port)
T: To hydraulic tank

1. Spool
2. Piston
3. Lever
4. Plate
5. Retainer
6. Block
7. Body
8. EPC valve

PC228US-8,PC228USLC-8 10-125
Hydraulic system
PPC valve

EPC valve 10-126

P: From self-pressure reducing valve 1. Body

C: To right attachment PPC valve 2. Plug
T: To hydraulic tank 3. Spool
4. Push pin
5. Coil
6. Plunger
7. Connector

10-126 PC228US-8,PC228USLC-8
 Hydraulic system
PPC valve

Function 10-127 Operation 10-127

q The EPC valve consists of the proportional sole-
noid portion and the hydraulic valve portion. When signal current is zero (coil de-energized) 10-127
q When a signal current (i) from pump controller is q When the singal current from controller does not
received, an EPC output pressure proportional flow through coil (14), the coil (14) is de-ener-
to the amperage of current is generated and out- gized.
put to control valve. q Spool (11) is pushed to the right by spring (12).
q Port (P) is closed, and the pressurized oil from
front pump does not flow to the control valve.
q The pressurized oil from the control valve flows
through port (C) and then port (T), and is drained
to the tank.

PC228US-8,PC228USLC-8 10-127
Hydraulic system
PPC valve

When signal current is small (coil energized) 10-128 When signal current is maximum (coil ener-
q When small signal current flows through coil (5), gized) 10-128
coil (5) is energized and the thrust pushing q Coil (5) is energized when signal current is sup-
plunger (6) leftward is generated. plied to the coil).
q Push pin (4) pushes spool (2) to the left, and the q As the signal curent is the maximum, the thrust
pressurized oil flows from port (P) to port (C). of plunger (6) is also maximized
q The pressure at port (C) increases and the force q Spool (2) is pushed to the left side by push pin
applied to surface (a) of spool (2) plus force of (4).
spring (3) becomes larger than the thrust of q The pressurized oil flows from port (P) to port (C)
plunger (6). at the maximum rate, and the cuircuit pressure
q Spool (2) is pressed to the right side, and port (P) between EPC valve and control valve is maxi-
is disconnected from ports (C), while port (C) is mized.
is connected to ports (T). q Port (T) closes, and there is no flow to the hy-
q Spool (2) changes its vertical position so that the draulic oil tank.
thrust of plunger (6) is equal to the pressure at
port (C) plus the force of spring (3).
q The circuit pressure between the EPC valve and
the control valve is controlled in proportion to the
amperage of the signal current.

10-128 PC228US-8,PC228USLC-8
 Hydraulic system
PPC valve

PC228US-8,PC228USLC-8 10-129
Hydraulic system
PPC valve

Left attachment PPC valve 10-130

(if equipped) 10-130

a For the details of operation, see the section of " Work equipment and swing PPC valve" .

10-130 PC228US-8,PC228USLC-8
 Hydraulic system
PPC valve

P: From self-pressure reducing valve

P1: To control valve (service valve 2 port)
P2: To control valve (service valve 2 port)
T: To hydraulic tank

1. Spool
2. Piston
3. Lever
4. Plate
5. Retainer
6. Body

PC228US-8,PC228USLC-8 10-131
Hydraulic system
Solenoid valve

Solenoid valve 10-132

a The figure shows the type for a machine ready for installing attachments.

10-132 PC228US-8,PC228USLC-8
 Hydraulic system
Solenoid valve

P1: From self-pressure reducing valve Operation 10-13

A1: To PPC valve
A2: To control valve, port PST Check valve operation 10-13
A3: To swing motor, port B
A4: To travel motor, port P
A5: To control valve, port PX1 and PX2
A6: To attachment circuit selector valve
T: To hydraulic tank
ACC: To accumulator (for PPC circuit)

1. PPC lock solenoid valve

2. Travel junction solenoid valve
3. Swing brake solenoid valve
4. Travel speed increase solenoid valve
5. 2-stage relief solenoid valve
6. Attachment selector solenoid valve
(Machine ready for installing attachment)
q This valve is installed between port (P) and PPC
Solenoid valve 10-13
7. Coil (ON/OFF type) solenoid valve. When the engine is stopped,
8. Push pin plunger (1) is pushed back to the left with spring
9. Valve spool (2) reaction force, and the path between ports
10. Sleeve (ACC) and (P) is closed to maintain the pressure
11. Block in the accumulator.
12. Plug q When the engine is running, plunger (1) is
pushed to the right with the pilot pressure that is
Check valve 10-13 sent to port (P), and ports (P) and (ACC) are in-
13. Plunger terconnected.
14. Plug

PC228US-8,PC228USLC-8 10-133
Hydraulic system
Solenoid valve

Solenoid valve operation 10-134

When solenoid valve is "de-energized" (circuit When solenoid valve is "energized" (circuit is
is closed) 10-134 open) 10-134

q Coil (1) is de-energized when no signal current is q Coil (1) is energized when signal current is sup-
supplied to coil (1). plied to coil (1).
q Spool (2) is pushed back to the left by reaction q Spool (2) is pushed to the right by push pin (4).
force of spring (3). q The path between ports (P) and (A) opens, and
q As the path between ports (P) and (A) is closed, the pilot pressure is fed to the actuator through
the pilot pressure is not fed to the actuator port (A).
through port (A). At the same time, the path to port (T) is closed,
At the same time, the path to port (T) is open, shutting off the oil from the actuator to the
draining the oil from the actuator to the hydraulic hydraulic tank.
tank.

10-134 PC228US-8,PC228USLC-8
 Hydraulic system
Solenoid valve

Boom RAISE cushion EPC valve 10-135

P: From R.H. work equipment PPC valve (boom

RAISE)
C: To control valve, boom RAISE port
T: To hydraulic tank

1. Body
2. Spool
3. Push pin
4. Coil
5. Plunger
6. Connector

PC228US-8,PC228USLC-8 10-135
Hydraulic system
Solenoid valve

Function 10-136 Operation 10-136

q The EPC valve consists of the proportional sole-
noid portion and the hydraulic valve. When signal current is zero (coil de-energized) 10-136
q When a signal current (i) from the pump control-
ler is received, the EPC output pressure propor-
tional to the amperage of current is generated
and output to the control valve.

q When the singal current from the controller does

not flow through coil (1), coil (1) is de-energized.
q Spool (2) is pushed to the right by spring (3).
q Port (P) is closed, and the pressurized oil from
the work equipment PPC valve does not flow to
the control valve.
q The pressurized oil from the control valve flows
through port (C) and then port (T), and is drained
to the hydraulic tank.

10-136 PC228US-8,PC228USLC-8
 Hydraulic system
Solenoid valve

When signal current is small (coil energized) 10-137 When signal current is maximum (coil ener-
gized) 10-137

q When a small signal current flows through coil

(5), coil (5) is energized and a thrust pushing q Coil (5) is energized when signal current is sup-
plunger (6) leftward is generated. plied to the coil.
q Push pin (4) pushes spool (2) to the left side, and q As the amperage of signal curent is maximum,
pressurized oil flows from port (P) to port (C). the thrust of plunger (6) is also maximized.
q The pressure at port (C) increases and the total q Spool (2) is pushed to the left side by push pin
of the force applied to surface (a) of spool (2) (4).
and the force of spring (3) becomes larger than q Pressurized oil flows from port (P) to port (C) at
the thrust of plunger (6). the maximum rate, and the circuit pressure be-
q Spool (2) is pressed to the right side, and ports tween EPC valve and control valve is maxi-
(P) and (C) are disconnected, while ports (C) mized.
and (T) are connected. q Port (T) closes, and there is no flow to the hy-
q Spool (2) changes its axial position so that the draulic oil tank.
thrust of plunger (6) is equal to the total pressure
of the pressure at port (C) and the force of spring
(3).
q The circuit pressure between the EPC valve and
the control valve is controlled in proportion to the
size of the signal current.

PC228US-8,PC228USLC-8 10-137
Hydraulic system
Attachment circuit selector valve

Attachment circuit selector valve 10-138

High-pressure side

PI: From attachment selector solenoid valve

ACC: To accumulator
ATT: To attachment
TS: To hydraulic tank
1. Spool

10-138 PC228US-8,PC228USLC-8
(02)
 Hydraulic system
Attachment circuit selector valve

Function 10-139 When a breaker is installed 10-139

q When a breaker is installed, the oil from the
breaker returns to the hydraulic tank directly
without passing through the main valve.
q When other attachments (crusher, etc.) are in-
stalled, the attachment and the main valve are
interconnected.

Operation 10-139

When attachments other than a breaker is in-

stalled 10-139

q Pilot pressure (PI) from the attachment circuit

selector solenoid valve will compress spring (2),
and spool (1) will move to the right to its stroke
end.
q Port (ATT) is disconnected from port (V), and
ports (ATT) and (T) are interconnected.
q Pressurized oil returning from the breaker re-
turns directly to the hydraulic tank via port (T)
without passing through the control valve.

q Spool (1) is pressed to the left by the force of

spring (2).
q Ports (ATT) and (V) are interconnected and port
(ATT) is disconnected from port (T). Attachment
is thus interconnected to the control valve.

PC228US-8,PC228USLC-8 10-139
Hydraulic system
Attachment circuit selector valve

Low-pressure side

PI: From attachment selector solenoid valve

V: To control valve attachment 1 port
ACC: To accumulator
ATT: To attachment
T: To hydraulic tank
TS: To hydraulic tank

1. Spool

10-140 PC228US-8,PC228USLC-8
(02)
 Hydraulic system
Attachment circuit selector valve

Function 10-141 When a breaker is installed 10-141

q When a breaker is installed, the main circuit from
the control valve to the breaker will be connected
to the accumulator.
q When an attachment other than a breaker
(crusher, etc.) is installed, the main circuit is
blocked from the accumulator.

Operation 10-141

When attachments other than a breaker is in-

stalled 10-141

q Pilot pressure (PI) from the attachment circuit

selector solenoid valve will compress spring (2),
and spool (1) will move to the right to its stroke
end.
q Port (ATT) and port (ACC) will be connected and
oil will flow to the accumulator, where the oil pul-
sation is absorbed.

q Spool (1) is pressed to the left by the force of

spring (2).
q Port (ATT) and port (ACC) will be blocked and oil
will not flow to the accumulator.

PC228US-8,PC228USLC-8 10-141
Hydraulic system
Anti-drop valve

Anti-drop valve 10-142

For boom and arm cylinder 10-142
(if equipped)

10-142 PC228US-8,PC228USLC-8
 Hydraulic system
Anti-drop valve

CY: To work equipment cylinder

PCY: For pressure pickup port and equalizer circuit
PI: From PPC valve
T: To hydraulic tank
V: From control valve

1. Pilot spool
2. Spring (1st stage of spool)
3. Spring (2nd stage of spool)
4. Safety valve
5. Check valve
6. Spring

PC228US-8,PC228USLC-8 10-143
Hydraulic system
Anti-drop valve

Function 10-14
q This valve prevents the pressurized oil from re-
versing from the work equipment cylinder in or-
der to prevent sudden drift of the work
equipment at breaking of the piping between the
control valve and the work equipment cylinder.

Operation 10-14

When the work equipment is in neutral 10-14

When there are no damages in the piping 10-14

q Check valve (5) is closed under the holding pres-
sure of the cylinder led from port (CY) to cham-
ber (b).
q The pilot pressure from the PPC valve to port

(PI) is 0 MPa {0 kg/cm2}.

q Spool (1) is pressed to the left by the forces of
springs (2) and (3).
q Chambers (a) and (b) are shut off.
q No pressurized oil flows between the control
valve and the work equipment cylinder.
q Accordingly, the work equipment is held in posi-
tion.
q If the work equipment cylinder has abnormally
high pressure, safety valve (4) is actuated by the
holding pressure of the work equipment cylinder.
q Chambers (b) of L.H. and R.H. anti-drop valves
for the boom are interconnected by port (PCY).
q Chambers (b) have the same pressure even if
the L.H. and R.H. anti-drop valves have a differ-
ence in leakage.

When the piping is damaged 10-14

q If piping (A) is broken between the control valve
and the work equipment cylinder, chambers (a)
and (b) are shut off similarly to the case when the
piping is not damaged.
q Pressure for the work equipment cylinder is held
to prevent a sudden drop of the work equipment.

10-144 PC228US-8,PC228USLC-8
(02)
 Hydraulic system
Anti-drop valve

When pressurized oil flows from the main

valve to the cylinder 10-145

When there are no damages in the piping 10-145

q Pressure of the oil led to chamber (a) from the
control valve becomes higher than the combined
force of pressure from work equipment cylinder
circuit chamber (b) and spring (6).
q Check valve (5) opens and chambers (a) and (b)
are interconnected.
q Pressurized oil flows from the control valve to the
work equipment cylinder.

When the piping is damaged 10-145

q If piping (A) between the control valve and the
work equipment cylinder is broken, the pressur-
ized oil in chamber (a) flows outside from the
damaged portion.
q Pressure force in chamber (a) drops.
q Pressure force in chamber (a) drops lower than
the combined pressure force of chamber (b) and
spring (6).
q Check valve (5) closes and chambers (a) and (b)
are shut off.
q Pressure for the work equipment cylinder is held
to prevent a sudden drop of the work equipment.

PC228US-8,PC228USLC-8 10-145
Hydraulic system
Anti-drop valve

When oil returns from the work equipment

cylinder to the main valve 10-146

When there are no damages in the piping 10-146

q Holding pressure of the work equipment cylinder
is led to chamber (b) and check valve (5) closes.
q Pilot pressure from the PPC valve is led to port
(PI) and pilot pressure gets larger than force of
spring (3) (area of d).
q Spool (1) moves to the right to the standby posi-
tion. (1st stage of stroke)
q At this point, chambers (a) and (b) are not inter-
connected.
q Pilot pressure further rises, and pilot pressure
gets larger than force of spring (2) (area of d).
q Spool (1) moves to the right further, and cham-
bers (a) and (b) are interconnected. (2nd stage
of stroke)
q Pressurized oil returns to the control valve from
the work equipment cylinder.

When the piping is damaged 10-146

q If piping (A) bursts between the control valve and
the work equipment cylinder.
q Pressurized oil in chamber (a) flows out of the
bursted portion but resupplied from chamber (b).
q Since pressurized oil flows via opening (c) of
spool (1), a sudden drop of the cylinder is pre-
vented.

10-146 PC228US-8,PC228USLC-8
 Hydraulic system
Multi-control valve

Multi-control valve 10-147

2-way type 10-147
(if equipped)

(1) ISO pattern

(2) Backhoe pattern

Control pattern switching diagram (Port names correspond to the marks on the above figures.)

PC228US-8,PC228USLC-8 10-147
Hydraulic system
Center swivel joint

Center swivel joint 10-148

A1: To L.H. travel motor reverse travel port PB 1. Cover

A2: From control valve L.H. reverse travel port 2. Slipper seal
B1: To L.H. travel motor forward travel port PA 3. Rotor
B2: From control valve L.H. forward travel port 4. Dust seal
C1: To R.H. travel motor reverse travel port PA 5. O-ring
C2: From control valve R.H. reverse travel port 6. Cover
D1: To R.H. travel motor forward travel port PB 7. Shaft
D2: From control valve R.H. forward travel port
E1: To L.H. and R.H. travel motor port P
E2: From travel speed increase solenoid valve
DR1: From L.H. and R.H. travel motor port T
DR2: To hydraulic tank

10-148 PC228US-8,PC228USLC-8
(03)
 Hydraulic system
Accumulator

Accumulator 10-149
For PPC circuit 10-149
1. Gas plug
2. Shell
3. Poppet
4. Holder
5. Bladder
6. Oil port

Outline 10-149
q The accumulator is installed on the solenoid
valve. If the engine is stopped with the work
equipment is kept at an elevated position, the pi-
lot pressure is supplied to the control valve by
the pressure of the compressed nitrogen gas in
the accumulator. Therefor, the spool can be op-
erated to lower the work equipment by its own
weight.

Specification 10-149
Gas to be used Nitrogen gas
Gas capacity (cc) 300
Sealed gas pressure 1.18 {12}
(MPa {kg/cm2} (at 80 °C)
Maximum operating pres-
sure 6.86 {70}
(MPa {kg/cm2}

PC228US-8,PC228USLC-8 10-149
Hydraulic system
Accumulator

For oil cooler circuit 10-150

1. Gas plug
2. Poppet
3. Holder
4. Bladder
5. Film
6. Shell
7. Oil port

Outline 10-150
q The accumulator installed between the work
equipment control valve and the oil cooler ab-
sorbs the oil pulsation genereted by work equip-
ment operation, to protect the oil cooler.

Specification 10-150
Gas to be used Nitrogen gas
Gas capacity (cc) 500
Sealed gas pressure 0.10 {1}
(MPa {kg/cm2} (at 80 °C)
Maximum operating pres-
sure 1.47 {15}
(MPa {kg/cm2}

10-150 PC228US-8,PC228USLC-8
 Hydraulic system
Accumulator

For breaker 10-151

(for machine with provision for attachment) 10-151
1. Cap
2. Core
3. Gas port
4. Bladder
5. Shell
6. Valve
7. Oil port

Outline 10-151
q The accumulator is installed in the attachment oil
circuit. When the breaker operates, the oil pul-
sation is absorbed by the pressure of com-
pressed nitrogen gas in the accumulator. This
protects the hydraulic components and piping.

Specification 10-151
Gas to be used Nitrogen gas
Gas capacity (cc) 1,000
For
0.10 {1}
Sealed gas pres- low-pres- (at 20 °C)
sure sure
For
(MPa {kg/cm2} high-pres-
8.83 {90}
(at 20 °C)
sure
Maximum operating pressure
29.4 {300}
(MPa {kg/cm2}

PC228US-8,PC228USLC-8 10-151
Work equipment
Work equipment

Work equipment 10-152

Work equipment 10-152

1. Bucket
2. Bucket link
3. Bucket cylinder
4. Arm
5. Arm cylinder
6. Boom
7. Boom cylinder

10-152 PC228US-8,PC228USLC-8
 Work equipment
Work equipment

PC228US-8,PC228USLC-8 10-153
Electrical system
Electronic control system

Electrical system 10-154

Electronic control system 10-154
General system drawing 10-154
a Items marked with "*1" in drawing may or may not be installed.

10-154 PC228US-8,PC228USLC-8
 Electrical system
Electronic control system

PC228US-8,PC228USLC-8 10-155
Electrical system
Electronic control system

Engine control function 10-156

1. Battery Function 10-156

2. Battery relay 1. The neutral safety circuit is employed to secure
3. Fusible link safety when the engine is started.
4. Fuse box q The engine does not start until the lock lever
5. Starting switch is set to the LOCK position.
6. Engine controller
7. Lock lever 2. The KOMTRAX engine cut circuit is employed to
8. PPC lock switch disable the engine from starting when the
9. Starting motor cutout relay (for PPC lock) KOMTRAX terminal receives an engine cut
10. Starting motor cutout relay (for personal code) command issued through external operation.
11. Fuel control dial (if equipped)
12. Safety relay
13. Starting motor
14. Supply pump
15. Sensors
16. Engine controller power cutoff relay A
17. Engine controller power cutoff relay B
18. Machine monitor
19. KOMTRAX terminal (if equipped)

10-156 PC228US-8,PC228USLC-8
 Electrical system
Electronic control system

Start engine 10-157

q When starting switch (5) is turned to ON position,
engine controller (6) sends a command current
to supply pump (14).
For this reason, a fail-safe mechanism is
provided with the electrical system to stop the
engine when an electrical failure occurs.
q When starting switch (5) is turned to START with
lock lever (7) set to LOCK position, a starting
current is supplied to starting motor (13) causing
the engine to start.
However, as the neutral safety mechanism is
provided, the engine will not start if lock lever (7)
is set to FREE position at this time; starting
motor cut-out relay (9) cuts off the starting
current to starting motor (13).
q Upon receipt of the engine cutoff command from
the external source, KOMTRAX terminal (19)
sends the signal to machine monitor (18). Ma-
chine monitor (18) causes starting motor cut-out
relay (10) to cut off the starting current to starting
motor (13), therefore the engine does not start.
(if equipped)

Engine speed control 10-157

q Upon receipt of a fuel control dial (11) control
signal, engine controller (6) sends a command
current to supply pump (14) to adjust the fuel in-
jection amount to control the engine speed.

Engine stopped 10-157

q When starting switch (5) is turned to OFF posi-
tion, the current from the ACC terminal of start-
ing switch (5) to engine controller (6) is cut off,
and consequently the command current to sup-
ply pump (14) is cut off.
Supply pump (14) stops fuel feed, causing the
engine speed to go down and the engine stops.

PC228US-8,PC228USLC-8 10-157
Electrical system
Electronic control system

Engine and pump combined control function 10-158

1. Battery 20. Control valve

2. Battery relay 20a. Self-pressure reducing valve
3. Fusible link 20b. Pump merge-divider valve
4. Fuse box 20c. Travel junction valve
5. Resistor 21. Front pump PC-EPC valve
6. Pump controller 22. Rear pump PC-EPC valve
7. Engine controller 23. LS-EPC valve
8. Machine monitor
9. Emergency pump drive switch Input/Output signal 10-158
10. Fuel control dial a. Front pump PC-EPC valve drive signal
11. Supply pump b. Rear pump PC-EPC valve drive signal
12. Sensors c. Solenoid valve GND
13. One-touch power maximizing switch d. CAN signal
14. Front pump oil pressure sensor e. LS-EPC valve drive signal
15. Rear pump oil pressure sensor f. Oil pressure sensor signal
16. Oil pressure sensor g. One-touch power maximizing switch signal
17. Oil pressure switch h. Oil pressure switch signal
18. Front pump i. Throttle signal
18a. Servo j. Supply pump control signal
18b. LS valve k. Sensor signals
18c. PC valve
19. Rear pump
19a. Servo
19b. LS valve
19c. PC valve

10-158 PC228US-8,PC228USLC-8
 Electrical system
Electronic control system

Function 10-159
q This function is for selecting one of the five work-
ing modes of P, E, L, ATT and B with the working
mode selector switch of the machine monitor.
The most suitable combination of engine torque
(T) and pump absorption torque can be selected
for the contents of work. If "Without" is selected
for the attachment on the initial setting (Default)
screen of the service mode, one of the three
modes of P, E and L is selectable.
q According to the pump absorption torque set at
each mode, based on the engine governor set
speed by the fuel control dial and the actual en-
gine speed, the controller controls so that the
pump absorbs all torques at each engine horse-
power point.
q When the engine speed is lowered, the control-
ler reduces the power consumed by the pump in
order to prevent engine stall.

PC228US-8,PC228USLC-8 10-159
Electrical system
Electronic control system

Control method in each mode 10-160

P mode, E mode, and ATT mode 10-160

q Matching point

Working mode Max. matching point

106.6 kW/1,800 rpm
P, ATT Working
{143 HP/1,800 rpm}
91.9 kW/1,800 rpm
E
{123 HP/1,800 rpm}

q In P, E, or ATT modes, the engine speed is al-

ways controlled so that it is kept around the
matching point specified for each mode.
q If the load on the pump and oil pressure in-
crease, the engine speed (N) will decrease. The
controller will decrease the pump delivery (Q) to
increase the engine speed to near the matching
point. If the load on the pump and oil pressure
decrease, the pump delivery will be increased to
keep the engine speed near the matching point.
q The controller calculates the pump delivery
based on servo piston stroke signals sent from
the swash plate sensor installed on the pump.
q The controller lowers the engine matching speed
(Nm) at low loads (low delivery and torque) in ac-
cordance with the pump absorption torque and
delivery.
q Variable matching of engine speeds contributes
to minimize fuel consumption.

10-160 PC228US-8,PC228USLC-8
 Electrical system
Electronic control system

B mode and L mode 10-161

Working mode Partial horsepower
B 75 %
L 70 %

q Matching point:
Working mode Max. matching point
80.9 kW/1,800 rpm
B mode
{108 HP/1,800 rpm}
73.5 kW/1,800 rpm
L mode
{99 HP/1,800 rpm}

q In B or L mode, engine horsepower is controlled

to a constant level.
q The controller controls the pump absorption
torque to decrease the engine speed while keep-
ing the engine torque at a constant level along
the equal engine horsepower curve.
q The controller adjusts the pump delivery (Q) to
keep the engine torque constant along the en-
gine horsepower curve.

PC228US-8,PC228USLC-8 10-161
Electrical system
Electronic control system

Control function during travel 10-162 Function to control when emergency pump
q The engine speed (N) rises when traveling in P drive switch is turned on 10-162
or ATT mode. q If the controller gets out of order and no work is
q When traveling in E or B mode, the work mode possible because the main pump does not work
remains unchanged, while the pump absorption properly, operating emergency pump drive
torque and engine speed (N) rise to the values switch (1) temporarily enables to maintain func-
as same as for P mode traveling. tions of the machine with absorption torques
q When traveling in L mode, the work mode and quite similar to those in the E mode.
engine speed (N) remains unchanged, while the In this case, a constant current flows from the
pump absorption torque rises. battery to the PC-EPC valve, so the oil pressure
sensing by the PC-EPC valve only is performed.
a: Emergency (when abnormal)
b: Normal
a Emergency pump drive switch (1) is of the alter-
native type. If the machine is operated after the
switch is set to "Emergency (a)" even though the
machine is normal, the user code "E02" will be
shown on the display.

10-162 PC228US-8,PC228USLC-8
 Electrical system
Electronic control system

Pump and valve control function 10-163

1. Battery 16. Front pump PC-EPC valve

2. Battery relay 17. Rear pump PC-EPC valve
3. Fusible link 18. LS-EPC valve
4. Fuse box 19. Pump merge-divider EPC valve (for main spool)
5. Resistor 20. Pump merge-divider EPC valve (for LS spool)
6. Pump controller 21. Travel junction solenoid valve
7. Engine controller 22. 2-stage relief solenoid valve
8. Machine monitor
9. Emergency pump drive switch Input/Output signal 10-163
10. Fuel control dial a. Front pump PC-EPC valve drive signal
11. Supply pump b. Rear pump PC-EPC valve drive signal
12. Sensors c. Solenoid valve GND
13. Front pump d. CAN signal
13a. Servo e. LS-EPC valve drive signal
13b. LS valve f. Pump merge-divider EPC valve (for main spool)
13c. PC valve drive signal
14. Rear pump g. Pump merge-divider EPC valve (for LS spool)
14a. Servo drive signal
14b. LS valve h. Travel junction solenoid valve drive signal
14c. PC valve i. 2-stage relief solenoid valve drive signal
15. Control valve j. Throttle signal
15a. Self-pressure reducing valve k. Supply pump control signal
15b. Pump merge-divider valve l. Sensor signals
15c. Travel junction valve
15d. Main relief valve

PC228US-8,PC228USLC-8 10-163
Electrical system
Electronic control system

Function 10-164 2-stage relief function 10-164

q The LS control function, cutoff function, and q The normal relief pressure is 34.8 MPa
2-stage relief function work together to maintain {355 kg/cm2}, however, this increases to approx.
the optimum matching under various working
37.2 MPa {380 kg/cm2} when the 2-stage relief
conditions.
function operates.
Operating conditions for 2-stage relief Relief pres-
LS control function 10-164
function sure
q According to the actuator operation, the output
q During travel
pressure from the LS-EPC valve to LS valve var- q When swing lock switch is turned to 34.8 MPa
ies in order to change the selector point for pump the ON position {355 kg/cm2}
delivery amount [LS differential pressure (DLS) q When the boom is lowered O
setting] in the LS valve. q When one-touch power maximizing 37.2 MPa
q The build-up time of pump delivery amount will function is turned on {380 kg/cm2}
be optimized, and the ease of combined opera- q When L mode is selected

tion and fine control will be improved.

A: 0 MPa {0 kg/cm2}
B: EPC pressure (Psig) = 1.8 MPa {18 kg/cm2}

Cutoff function 10-164

q PC-EPC current (J) is increased and the flow at
relief is decreased to minimize fuel consumption.
Operating condition for turning on cutoff function
When the one-touch power maximizing function is not
activated and the average of front pump and rear pump
oil pressure sensor values is 27.9 MPa {285 kg/cm2} or
higher.
However, this will not operate when traveling in P mode,
when in the arm crane mode, or when the swing lock
switch is "ON".

A: PC-EPC current at cutoff

10-164 PC228US-8,PC228USLC-8
 Electrical system
Electronic control system

Power maximizing function 10-165

1. Battery 18. Control valve

2. Battery relay 18a. Self-pressure reducing valve
3. Fusible link 18b. Pump merge-divider valve
4. Fuse box 18c. Travel junction valve
5. Resistor 18d. Main relief valve
6. Pump controller 19. Front pump PC-EPC valve
7. Engine controller 20. Rear pump PC-EPC valve
8. Machine monitor 21. 2-stage relief solenoid valve
9. Emergency pump drive switch
10. Fuel control dial Input/Output signal 10-165
11. Fuel supply pump a. Front pump PC-EPC valve drive signal
12. Sensors b. Rear pump PC-EPC valve drive signal
13. One-touch power maximizing switch c. Solenoid valve GND
14. Front pump oil pressure sensor d. CAN signal
15. Rear pump oil pressure sensor e. 2-stage relief solenoid valve drive signal
16. Front pump f. Pump oil pressure sensor signal
16a. Servo g. One-touch power maximizing switch signal
16b. LS valve h. Throttle signal
16c. PC valve i. Supply pump control signal
17. Rear pump j. Sensor signals
17a. Servo
17b. LS valve
17c. PC valve

PC228US-8,PC228USLC-8 10-165
Electrical system
Electronic control system

Function 10-16
q By operating the one-touch power maximizing
switch on the L.H. work equipment control lever
knob, the power is maximized for a limited time.
q This can be used when extra digging force is
needed for a while, for example, when digging
out a rock during excavating work.
q When the one-touch power maximizing switch is
pressed in P mode, E mode, or ATT mode, the
hydraulic force will be increased by approx. 7%,
and the horsepower will be increased by approx.
3% to boost the digging force.
The functions are automatically set as follows.
Function Setting
Engine and pump combined Matching at rated output
control point
34.8 MPa {355 kg/cm2}
2-stage relief function O
37.2 MPa {380 kg/cm2}
Cutoff function Cancel
a The power is increased while the one-touch
power maximizing switch is pressed. The func-
tion is automatically deactivated when the switch
is continuously pressed for more than 8.5 sec-
onds.

10-166 PC228US-8,PC228USLC-8
 Electrical system
Electronic control system

Auto-deceleration function 10-167

1. Pump controller Input/Output signal 10-167

2. Engine controller a. CAN signal
3. Machine monitor b. Oil pressure switch signal
4. Fuel control dial c. Oil pressure sensor signal
5. Supply pump d. Throttle signal
6. Sensors e. Supply pump control signal
7. Oil pressure switch f. Sensor signals
8. Oil pressure sensor
9. Main pump
10. Control valve
10a. Self-pressure reducing valve
10b. Pump merge-divider valve
10c. Travel junction valve
11. PPC lock solenoid valve

PC228US-8,PC228USLC-8 10-167
Electrical system
Electronic control system

Function 10-168
q When all the control levers are set to NEUTRAL
for waiting for a dump truck or work, the engine
speed is automatically reduced to a controlled
speed, and fuel consumption and noise are low-
ered.
q When any control lever is operated, the engine
speed returns immediately to the speed that is
set by the fuel control dial.

Operation 10-168
Control lever in NEUTRAL 10-168
q If all the control levers are kept in neutral for 4
seconds with the engine speed higher than ap-
prox. 1,050 rpm, the engine speed is decreased
to the controlled speed (approx. 1,050 rpm) and
held until any control lever is operated.

When any control lever is operated 10-168

q With the engine speed at the controlled speed
(approx. 1,050 rpm), when any control lever is
operated, the engine speed increases immedi-
ately to the speed that is set by the fuel control
dial.

A: All work equipment control levers in NEUTRAL

B: Work equipment control levers OPERATED
C: Fuel control dial set speed
D: Controlled engine speed (approx. 1,050 rpm)
E: 4 sec.
F: Max. 2 sec.
G: Max. 1 sec.

10-168 PC228US-8,PC228USLC-8
 Electrical system
Electronic control system

Engine automatic warm-up function 10-169

1. Battery 17. Control valve

2. Battery relay 17a. Self-pressure reducing valve
3. Fusible link 17b. Pump merge-divider valve
4. Fuse box 17c. Travel junction valve
5. Resistor 18. Front pump PC-EPC valve
6. Pump controller 19. Rear pump PC-EPC valve
7. Engine controller
8. Machine monitor Input/Output signal 10-169
9. Air conditioner unit a. Front pump PC-EPC valve drive signal
10. Emergency pump drive switch b. Rear pump PC-EPC valve drive signal
11. Fuel control dial c. Solenoid valve GND
12. Supply pump d. CAN signal
13. Sensors e. Hydraulic oil temperature signal
14. Hydraulic oil temperature sensor f. Throttle signal
15. Front pump g. Supply pump control signal
15a. Servo h. Sensor signals
15b. LS valve
15c. PC valve
16. Rear pump
16a. Servo
16b. LS valve
16c. PC valve

PC228US-8,PC228USLC-8 10-169
Electrical system
Electronic control system

Function 10-170
q Increases the engine speed automatically to warm up the engine if the coolant temperature is too low after
the engine starts.
q Has two different modes; "Heater warm-up" mode and "Normal warm-up" mode, automatically selected
depending on the purpose.
q Heater warm-up function warms up the coolant temperature for warmer air from blower.
q Normal warm-up function warms up the engine to prevent it from being damaged by operating in low tem-
perature.

Operating conditions 1
Machine specification: with air conditioner
Air conditioner: blower "ON"
Coolant temperature: Max. 55 °C
Ambient temperature: below 5 °C
Manual stationary regeneration: OFF
Soot accumulation amount: Max. 2 g/l
O O
If any of operating conditions 1 is not satisfied When all of operating conditions 1 are satisfied
Heater warm-up is disabled (normal warm-up) Heater warm-up is enabled
Operational conditions 2
O
(all required)
Coolant temperature: Max. 30 °C
O
Engine speed: Max. 1,200 rpm
O O
Operation Operation
Engine speed: 1,200 rpm Engine speed: 1,300 rpm
O O
Cancellation conditions Cancellation cod. CAN signalnditions
(either one required) (either one required)
Coolant temperature: Min. 30 °C
Auto
Duration of automatic warming-up: Min. 10 minutes Coolant temperature: Min. 60 °C
Ambient temperature: min. 10 °C
Man- Fuel control dial: held at over 70% of maximum
ual speed for 3 seconds or more
O O
Cancellation
Engine speed: as desired

10-170 PC228US-8,PC228USLC-8
(03)
 Electrical system
Electronic control system

Overheat prevention function 10-171

a See "Engine automatic warm-up function" section for system circuit diagram.

q Prevents overheat to protect the engine and hydraulic components by reducing load on the pump and low-
ering the engine speed if the coolant or hydraulic oil temperature becomes too high.
Operating condition Operation and actions taken Conditions for cancellation
Hydraulic oil temperature: Max. 95 °C
Working mode: travel
o Engine speed: Remains unchanged. o q The original conditions are restored if
Hydraulic oil temperature:
Travel speed: Down above requirements are met (automatic
Min. 95 °C
restoration).

Operating condition Operation and actions taken Conditions for cancellation

Working mode: P, ATT, E
Coolant temperature: Max. 100 °C
Engine speed: Remains unchanged.
Coolant temperature: Min. Hydraulic oil temperature: Max. 100 °C
o q Sends torque control signal to lower the o
100 °C q The original conditions are restored if
pump absorption torque and reduce the
or above requirements are met (automatic
load on the engine.
Hydraulic oil temperature: restoration).
Min. 100 °C

Operating condition Operation and actions taken Conditions for cancellation

Working mode: P, ATT, E, B, L
Engine speed: Remains unchanged. Coolant temperature: Max. 102 °C
Coolant temperature: Min. Alarm monitor: Lights up Hydraulic oil temperature: Max. 102 °C
o o
102 °C q Sends torque control signal to lower the q The original conditions are restored if
or pump absorption torque and reduce the above requirements are met (automatic
Hydraulic oil temperature: load on the engine. restoration).
Min. 102 °C

Operating condition Operation and actions taken Conditions for cancellation

Working mode: all modes Coolant temperature: Max. 105 °C
Hydraulic oil temperature: Max. 105 °C
Coolant temperature: Min. Engine speed: Low idle Fuel control dial: Returns to low idle (MIN) posi-
o o
105 °C Alarm monitor: Lights up tion.
or Alarm buzzer: Sounds q The original conditions are restored if
Hydraulic oil temperature: above requirements are met (manual resto-
Min. 105 °C ration).

Operating condition Operation and actions taken Conditions for cancellation

Coolant temperature:
95 – below 99 °C Coolant temperature: Max. 95 °C
o Pump absorption torque decreased o
or or
0 – 19.6 Nm {0 – 2 kgm}
Hydraulic oil temperature: Hydraulic oil temperature: Max. 95 °C
95 – below 99 °C

Operating condition Operation and actions taken Conditions for cancellation

Coolant temperature:
90 – below 95 °C Coolant temperature: Max. 90 °C
o Pump absorption torque decreased o
or or
0 – 39.2 Nm {0 – 4 kgm}
Hydraulic oil temperature: Hydraulic oil temperature: Max. 90 °C
90 – below 95 °C

PC228US-8,PC228USLC-8 10-171
(02)
Electrical system
Electronic control system

Turbocharger protection function 10-172

a See "Engine automatic warm-up function" section for system circuit diagram.

q When the engine is started at low temperatures and the engine speed is increased sharply, the turbo-
charger may be seized. Controlling the engine speed prevents this problem.
q Duration of engine speed control depends on the coolant temperature.
Operating condition Operation
2 o Turbocharger protection
Engine oil pressure: below 50 kPa {0.51 kg/cm } (See the following figure)

A: Start engine
B: Duration of turbocharger protection (approxi-
mately 0 – 20 sec.)
C: Modulating time (approx. 1 sec.)
D: 600 rpm
E: 1,050 rpm
F: 1,950 rpm(*1)

*1. Working mode: P mode

Fuel control dial: Full speed (MAX) position
Travel lever operated

10-172 PC228US-8,PC228USLC-8
 Electrical system
Electronic control system

Swing control function 10-173

1. Battery Input/Output signal 10-173

2. Battery relay a. Swing brake cancel signal
3. Fusible link b. Swing brake solenoid valve drive signal
4. Fuse box c. CAN signal
5. Swing brake cancel switch d. Solenoid valve GND
6. Swing lock switch e. Oil pressure switch signal
7. Pump controller f. Oil pressure sensor signal
8. Machine monitor
9. Oil pressure switch
10. Oil pressure sensor
11. Main pump
12. Control valve
12a. Self-pressure reducing valve
12b. Pump merge-divider valve
12c. Travel junction valve
13. Swing motor
14. Swing brake solenoid valve

PC228US-8,PC228USLC-8 10-173
Electrical system
Electronic control system

Function 10-174

Swing lock and swing brake function 10-174

q On machines with swing lock (manual), swing Swing lock When the travel steering
ON
can be locked at any position by turning swing switch signal is OFF
lock switch (1) to "ON" position. Swing lock
Off ON
q Interlocked with the swing operation, the swing monitor
brake (auto lock) prevents hydraulic drift from Function Swing Brake Swing lock
occurring after the swing stops.
q When the L.H. and q Swing brake ap-
q Interlocked with the L.H. and R.H. work equip-
R.H. work equipment plies and lock the
ment control levers and attachment control ped- control levers and at- swing.
als operations, the swing brake is canceled to tachment control ped- q Even if the L.H.
reduce the load on the swing equipment during als are set to work equipment
NEUTRAL, the swing control lever is op-
excavation work.
brake works in approx. erated for swing,
5 sec. the swing brake
Operation q When the L.H. and cannot be can-
R.H. work equipment celed, and the up-
control levers or at- per structure does
tachment control ped- not swing.
als are operated, the
swing brake is can-
celed and the upper
structure becomes
free to swing.

A: When a work equipment control lever or attach-

ment control pedal is operated
(Swing brake "CANCEL" )
B: When work equipment control levers and attach-
ment control pedals are in "NEUTRAL"
C: Swing brake "OPERATED"
D: Approx. 5 sec.

10-174 PC228US-8,PC228USLC-8
 Electrical system
Electronic control system

Swing brake release function 10-175

q If the controller gets out of order and no swing is
possible because the swing brake does not work
properly, operating swing brake cancel switch
(2) releases the swing brake and allows swing
operation.
a: Release (Emergency)
b: Normal
Swing Release Normal
brake can- (When controller has (When the controller is
cel switch trouble) normal)
Swing lock
ON OFF ON OFF
switch
Swing
Swing
Swing Swing lock brake is Swing lock
brake
brake works released works
works
(*1)
*1:Hydraulic brake by the safety valve.

a Even if swing brake cancel switch is set to CAN-

CEL, swing brake is not be released while swing
lock switch is set to "ON".
a When the swing brake is canceled, only the hy-
draulic brake with the safety valve is effective for
holding the upper structure. So, note that, when
the swing stops on a slope, a hydraulic drift may
occur.
a Swing brake cancel switch (2) is of the alterna-
tive type. When the switch is turned to CANCEL
(a) position, the swing lock monitor in the ma-
chine monitor will blink.

PC228US-8,PC228USLC-8 10-175
Electrical system
Electronic control system

Travel control function 10-176

1. Pump controller 14. Travel motor

2. Engine controller 15. Travel speed increase solenoid valve
3. Machine monitor 16. Travel junction solenoid valve
4. Fuel control dial 17. LS-EPC valve
5. Supply pump
6. Sensors Input/Output signal 10-176
7. Front pump oil pressure sensor a. Oil pressure sensor signal
8. Rear pump oil pressure sensor b. CAN signal
9. Oil pressure sensor c. LS-EPC valve drive signal
10. Travel alarm d. Solenoid valve GND
11. Front pump e. Travel junction solenoid valve drive signal
11a. Servo f. Travel speed increase solenoid valve drive signal
11b. LS valve g. Oil pressure sensor signal
11c. PC valve h. Travel alarm buzzer operation signal
12. Rear pump i. Throttle signal
12a. Servo j. Supply pump control signal
12b. LS valve k. Sensor signals
12c. PC valve
13. Control valve
13a. Self-pressure reducing valve
13b. Pump merge-divider valve
13c. Travel junction valve

10-176 PC228US-8,PC228USLC-8
 Electrical system
Electronic control system

Function 10-17

Travel speed selection function 10-17

1. Travel speed "Manual" change
q Setting the travel speed selector switch to
"Hi", "Mi" or "Lo" changes the motor capacity,
which changes the machine travel speed.
Travel speed Mi
Lo Hi
selector switch (medium
(low speed) (high speed)
speed)
Motor capacity (%) 75 65 100
Travel speed
3.0 4.1 5.5
(km/h)
Travel motor
Max. Min. Min.
swash plate angle

2. Travel speed "Automatic" change A: 17.7 MPa {180 kg/cm2}

1) Automatic change corresponding to engine B: 33.3 MPa {340 kg/cm2}
speed C: Min. 0.5 sec.
q When the engine speed is lowered to be- D: Min. 0.5 sec.
low 1,500 rpm by the fuel control dial, the
travel speed will not change from "Mi" to Function to control pump during travel 10-17
"Hi" while the machine is traveling with a See " Pump and engine combined control func-
the travel speed selector switch set to tion" for details.
"Mi", and will change from "Hi" to "Mi"
while it is traveling with the travel speed Travel junction function 10-17
selector switch set to "Hi". q The controller detects the pilot pressure generat-

2) Automatic change by pump delivery pressure ed by travel control lever operation, and judges
q If the travel circuit oil pressure increases the operator’s intention, the straight travel or
on an uphill with the travel speed selector steered travel.
switch in "Hi", and the travel circuit oil q When traveling straight, a signal is sent to the

pressure exceeding 33.3 MPa travel junction solenoid valve to supply almost
2
{340 kg/cm } continues for 0.5 seconds the same oil flow to the L.H. and R.H. travel mo-
or more, the travel motor capacity is tors.
q When the steering is operated, the signal to the
switched to that for low speed travel (cor-
responds to "Lo") automatically (the travel travel junction solenoid valve is shut off. This
speed switch position remains in "Hi"). separates the pump flow to the right and left trav-
q If the travel circuit oil pressure decreases
el motors from each other and enhances the
on a flat or downhill during low speed trav- traction while steering.
el (caused by the automatic speed
change due to increase in the load on the
travel oil circuit), and the travel circuit oil
pressure below 17.7 MPa {180 kg/cm2}
continues for 0.5 seconds or more, the
travel motor capacity is switched back to
that for high speed travel (Hi) automati-
cally.

PC228US-8,PC228USLC-8 10-177
Electrical system
Electronic control system

PPC lock function 10-178

1. Battery Function 10-178

2. Battery relay q Interlocked with the lock lever, the PPC lock
3. Fusible link switch is turned off when the lock lever is set to
4. Fuse box LOCK position.
5. Starting switch q When the PPC lock switch is turned off, the cur-
6. Lock lever rent to the PPC lock solenoid valve is shut off,
7. PPC lock switch causing neither the work equipment nor machine
8. Main pump moves even if levers or pedal is operated.
9. Control valve
9a. Self-pressure reducing valve
9b. Pump merge-divider valve
9c. Travel junction valve
10. PPC lock solenoid valve

10-178 PC228US-8,PC228USLC-8
 Electrical system
Electronic control system

Boom RAISE cushion function 10-179

1. Battery Emergency work equipment drive function 10-179

2. Battery relay q If the controller gets out of order and the work

3. Fusible link equipment becomes inoperable, boom RAISE

4. Fuse box can be temporarily enabled by operating the
5. Resistor emergency work equipment drive switch (1).
6. Emergency work equipment drive switch a: Emergency (controller failure)
7. Pump controller b: Normal
8. Machine monitor
9. Boom angle potentiometer a Emergency work equipment drive switch (1) is of
10. Main pump the alternative type. If the the switch is set to
11. Control valve "Emergency (a)" when the user code "E06" is
11a. Self-pressure reducing valve shown on the display, the work equipment will
11b. Pump merge-divider valve become operable.
11c. Travel junction valve a The electrical control system does not work, so
12. Boom RAISE cushion EPC valve do not operate the machine for normal work with
13. Boom cylinder emergency work equipment drive switch (1) in
"Emergency (a)".
Input/Output signal 10-179
a. CAN signal
b. Boom RAISE cushion EPC valve drive signal
c. Solenoid valve GND
d. Boom angle signal

Cushion function 10-179

q The boom end cushion function reduces the
boom speed before the boom reaches its stroke
end in order to lessen the shock at this point, and
prevents spillage of the load and reduces the im-
pact applied to the machine and cylinder.
q When the boom enters the cushion range, the pi-
lot pressure, which is fed from the PPC valve to
the control valve, is reduced and then cut off by
the EPC valve, and the boom is stopped.

PC228US-8,PC228USLC-8 10-179
Electrical system
Electronic control system

Oil flow adjuster function for attachment 10-180

(for machine with provision for attachment) 10-180

10-180 PC228US-8,PC228USLC-8
 Electrical system
Electronic control system

1. Battery Input/Output signal 10-181

2. Battery relay a. Front pump PC-EPC valve drive signal
3. Fusible link b. Rear pump PC-EPC valve drive signal
4. Fuse box c. Solenoid valve GND
5. Resistor d. CAN signal
6. Pump controller e. Attachment selector solenoid valve drive signal
7. Engine controller f. Oil flow adjuster EPC valve drive signal for attach-
8. Machine monitor ment
9. Emergency pump drive switch g. Oil pressure switch signal
10. Oil pressure switch h. Throttle signal
11. Fuel control dial i. Supply pump control signal
12. Supply pump j. Sensor signals
13. Sensors
14. Front pump Function 10-181
14a. Servo q Setting of the working mode and oil flow rate on
14b. LS valve the machine monitor controls the oil flow to the
14c. PC valve attachment when the attachment control pedal is
15. Rear pump fully depressed.
15a. Servo
15b. LS valve
15c. PC valve
16. Control valve
16a. Self-pressure reducing valve
16b. Pump merge-divider valve
16c. Travel junction valve
17. Attachment selector solenoid valve
18. PPC lock solenoid valve
19. Oil flow adjuster EPC valve for attachment
20. Front pump PC-EPC valve
21. Rear pump PC-EPC valve
22. Attachment circuit selector valve (high pressure
side)
23. Attachment circuit selector valve (low pressure
side)
24. Attachment
25. Accumulator

PC228US-8,PC228USLC-8 10-181
Electrical system
Electronic control system

Component 10-182

Engine controller 10-182

Input/Output signal 10-182

q The following is the list of the symbols used for signal classification in the input/output signal table.
A: Power supply
B: Input
C: Ground/Shield/Return
D: Output
E: Communication

DTP-4P [ CN-CE03 ]
Signal
Pin No. Signal name classifica-
tion
1 GND -
2 NC (*) –
3 Unswitched power supply (24 V) A
4 NC (*) –
*: Never connect any cable to NC, or malfunctions or failures will occur.

10-182 PC228US-8,PC228USLC-8
 Electrical system
Electronic control system

DRC-60P [ CN-CE01 ]
Signal Signal
Pin No. Signal name classifi- Pin No. Signal name classifi-
cation cation
1 NC (*) – 31 NC (*) –
2 IMA power supply D 32 IMA return C
3 Ambient pressure sensor B 33 Sensor power supply (5 V) A
4 NC (*) – 34 NC (*) –
5 NC (*) – 35 NC (*) –
6 CAN (-) E 36 NC (*) –
7 NC (*) – 37 Sensor power supply (5 V) A
8 CAN (+) E 38 GND C
9 NC (*) – 39 NC (*) –
10 NC (*) – 40 NC (*) –
11 NC (*) – 41 NC (*) –
12 NC (*) – 42 NC (*) –
13 NC (*) – 43 NC (*) –
14 Water-in-fuel sensor B 44 Boost pressure sensor B
15 Coolant temperature sensor B 45 Injector #1 (+) D
16 Sensor power supply (5 V) A 46 Injector #5 (+) D
17 Engine oil pressure switch B 47 Sensor GND C
18 NC (*) – 48 Crankshaft speed sensor (-) C
19 NC (*) – 49 NC (*) –
20 NC (*) – 50 NC (*) –
21 NC (*) – 51 Injector #2 (–) C
22 NC (*) – 52 Injector #3 (–) C
23 Intake air temperature sensor B 53 Injector #1 (–) C
24 NC (*) – 54 Injector #2 (+) D
25 Common rail pressure sensor B 55 Injector #3 (+) D
26 Camshaft speed sensor (+) B 56 Injector #4 (+) D
27 Crankshaft speed sensor (+) B 57 Injector #6 (+) D
28 NC (*) – 58 Injector #4 (–) C
29 NC (*) – 59 Injector #6 (–) C
30 NC (*) – 60 Injector #5 (–) C
*: Never connect any cable to NC, or malfunctions or failures will occur.

PC228US-8,PC228USLC-8 10-183
Electrical system
Electronic control system

DRC-50P[ CN-CE02 ]
Signal
Signal
Pin No. Signal name classifi- Pin No. Signal name
category
cation
1 NC (*) – 26 NC (*) –
2 NC (*) – 27 NC (*) –
3 NC (*) – 28 NC (*) –
4 NC (*) – 29 NC (*) –
5 NC (*) – 30 NC (*) –
6 NC (*) – 31 NC (*) –
7 NC (*) – 32 NC (*) –
8 NC (*) – 33 DIS_SEL0 (GND) C
9 Fuel control dial (+) B 34 NC (*) –
10 NC (*) – 35 NC (*) –
11 NC (*) – 36 NC (*) –
12 NC (*) – 37 NC (*) –
13 NC (*) – 38 NC (*) –
14 NC (*) – 39 Starting switch ACC signal B
Electrical intake air heater relay
15 NC (*) – 40 D
drive
16 NC (*) – 41 NC (*) –
Electrical intake air heater relay
17 NC (*) – 42 C
return
18 NC (*) – 43 NC (*) –
19 NC (*) – 44 NC (*) –
20 NC (*) – 45 NC (*) –
21 NC (*) – 46 CAN (+) E
22 Fuel control dial (5 V) A 47 CAN (-) E
23 Fuel control dial (–) C 48 NC (*) –
24 NC (*) – 49 Engine controller power cutoff relay D
25 NC (*) – 50 NC (*) –
*: Never connect any cable to NC, or malfunctions or failures will occur.

10-184 PC228US-8,PC228USLC-8
 Electrical system
Electronic control system

Pump controller 10-185

PC228US-8,PC228USLC-8 10-185
Electrical system
Electronic control system

Input/Output signal 10-186

AMP-81P [CN-C01]
Input/Ou Input/Ou
Pin No. Signal name tput sig- Pin No. Signal name tput sig-
nal nal
1 Unswitched power supply (24 V) Input 42 NC (*) –
2 Unswitched power return Input 43 Starting switch ACC signal Input
3 Window washer Output 44 NC (*) –
Input/out
4 Unswitched power supply (24 V) Input 45 CAN_H
put
5 Unswitched power return Input 46 GND (analog signal) Input
6 NC (*) – 47 NC (*) –
7 NC (*) – 48 NC (*) –
8 Potentiometer power supply (5 V) Output 49 Front pump oil pressure sensor Input
9 Potentiometer power supply (5 V) Output 50 Rear pump swash plate sensor Input
10 NC (*) – 51 NC (*) –
11 Arm potentiometer Input 52 Attachment oil pressure switch Input
Boom cylinder head oil pressure
12 Input 53 Boom RAISE oil pressure sensor Input
sensor
Left forward travel oil pressure sen-
13 NC (*) – 54 Input
sor
Right forward travel oil pressure
14 Boom LOWER oil pressure switch Input 55 Input
sensor
15 Arm OUT oil pressure switch Input 56 Wiper motor reverse (W) Input
16 Swing left oil pressure sensor Input 57 Cab front window open limit switch Input
17 Arm IN pressure sensor Input 58 Model Selection 4 Input
18 GND (analog signal) Input 59 NC (*) –
19 Swing lock switch Input 60 Starting switch C signal Input
20 NC (*) – 61 NC (*) –
21 Model Selection 2 Input 62 External drive signal Input
22 NC (*) – 63 NC (*) –
Input/out
23 NC (*) – 64 CAN_L
put
24 Starting switch ACC signal Input 65 NC (*) –
25 NC (*) – 66 NC (*) –
26 NC (*) – 67 Boom potentiometer Input
27 NC (*) – 68 Rear pump oil pressure sensor Input
28 NC (*) – 69 NC (*) –
29 Hydraulic oil temperature sensor Input 70 GND (analog signal) Input
30 Front pump swash plate sensor Input 71 NC (*) –
Boom cylinder bottom oil pressure
31 Input 72 Swing right oil pressure sensor Input
sensor
32 NC (*) – 73 Bucket CURL oil pressure sensor Input
33 NC (*) – 74 NC (*) –
34 Bucket DUMP oil pressure sensor Input 75 Wiper motor stop (P) Input
Left travel reverse oil pressure sen-
35 Input 76 NC (*) –
sor
Right travel reverse oil pressure
36 Input 77 Model Selection 3 Input
sensor
37 NC (*) – 78 Overload alarm effective signal Input
38 Swing brake cancel switch Input 79 Starting switch ACC signal Input
39 Model Select 5 Input 80 Arm crane relay monitoring Input
40 Model Select 1 Input 81 NC (*) –
One-touch power maximizing
41 Input
switch
*: Never connect any cable to NC, or malfunctions or failures will occur.

10-186 PC228US-8,PC228USLC-8
 Electrical system
Electronic control system

AMP-40P [CN-C02]
Input/Ou Input/Ou
Pin No. Signal name tput sig- Pin No. Signal name tput sig-
nal nal
82 NC (*) – 102 NC (*) –
83 NC (*) – 103 NC (*) –
84 NC (*) – 104 Rear pump PC-EPC valve Output
85 NC (*) – 105 Boom RAISE cushion EPC valve Output
86 Attachment selector solenoid Output 106 NC (*) –
87 Travel speed increase solenoid Output 107 Travel alarm Output
88 LS-EPC valve Output 108 Battery relay drive Output
Pump merge-divider EPC valve
89 Output 109 2-stage relief solenoid Output
(LS)
90 NC (*) – 110 Travel junction SOL Output
91 NC (*) – 111 NC (*) –
Pump merge-divider EPC valve
92 NC (*) – 112 Output
(main)
93 Arm crane relay drive signal Output 113 NC (*) –
Bucket DUMP operation lock sole-
94 Output 114 Wiper motor (-) Output
noid
95 NC (*) – 115 GND (solenoid) Input
96 Front pump PC-EPC valve Output 116 Solenoid power supply Input
Oil flow adjuster EPC for attach-
97 Output 117 GND (solenoid) Input
ment
98 NC (*) – 118 Solenoid power supply Input
99 NC (*) – 119 Wiper motor (+) Output
100 NC (*) – 120 GND (solenoid) Input
101 Swing brake solenoid Output 121 Solenoid power supply Input
*: Never connect any cable to NC, or malfunctions or failures will occur.

PC228US-8,PC228USLC-8 10-187
Electrical system
Electronic control system

Fuel control dial 10-18

1. Knob
2. Dial
3. Spring
4. Ball
5. Potentiometer
6. Connector

Function 10-18
q This dial is installed in the right console box.
Turning knob (1) causes potentiometer (5) shaft
to rotate.
q As the potentiometer shaft is turned, the resis-
tance of the variable resistor in potentiometer (5)
changes and a throttle signal is sent to the en-
gine controller.
q The hatched areas in the graph are error detec-
tion areas. If the throttle voltage is within the ar-
ea, the engine speed drops down to low idle.

10-188 PC228US-8,PC228USLC-8
 Electrical system
Electronic control system

Resistor 10-189

1. Resistance
2. Connector

Specifications 10-189
For PC-EPC valve: 20 z
For boom RAISE cushion EPC valve: 20 z

Function 10-189
q When the emergency pump drive switch or the
emergency work equipment drive switch is
turned to ON position, this resistor sends an
electric current to each PC-EPC valve that is ap-
propriate for each condition.
a No electric current flows in the normal condition.

PC228US-8,PC228USLC-8 10-189
Electrical system
Electronic control system

Engine oil pressure switch 10-190

1. Connector
2. Sensor
3. O-ring

Specifications 10-190
Contact type: Normally closed

Function 10-190
q This oil pressure switch is installed in the cylin-
der block. It detects engine oil pressure, and
turns the switch on when the pressure goes be-
low the specified value.

10-190 PC228US-8,PC228USLC-8
 Electrical system
Electronic control system

PPC oil pressure switch 10-191

1. Plug
2. Switch
3. Connector

Specifications 10-191
Type of contacts: Normally open
Operating pressure to make contact point ON: 490
± 98.1 kPa {5.0 ± 1.0 kg/cm2}
Operating pressure to break contact point OFF: 294
± 49.0 kPa {3.0 ± 0.5 kg/cm2}

Function 10-191
q Two of these sensors are installed to the relay
block in the pilot circuit between the PPC valve
and control valve. They detect the PPC oil pres-
sure when each actuator is operated, and turn
the switch on when the pressure exceeds the
specified value.

PC228US-8,PC228USLC-8 10-191
Electrical system
Machine monitor system

Machine monitor system 10-192

1. Machine monitor Outline 10-192

2. Battery q The monitor system keeps the operator informed

3. Pump controller of all machine functions, by monitoring the ma-

4. Engine controller chine conditions by using the sensors and
5. Air conditioner controller switches installed in various parts of the ma-
6. KOMTRAX terminal chine and processing them instantly to display
7. Sensors and switches on the machine monitor.
8. Wiper motor and window washer motor The information displayed on the machine
monitor falls into the following types:
Input/output signal 10-192 1. Alarm when the machine has problem
a. Power supply 2. Machine condition display (coolant tempera-
b. CAN signal ture, hydraulic oil temperature, and fuel level)
c. Sensor and switch signals q The switches on the machine monitor controls
d. Drive signal the machine.

10-192 PC228US-8,PC228USLC-8
 Electrical system
Machine monitor system

Machine monitor 10-193

Outline 10-193 Precautions on the machine monitor display 10-193

q The machine monitor has monitor display func- q The LCD panel may has black points (points
tion, mode selection function and switch function which are not lighted) and bright points (points
for electrical parts etc. Also it has an alarm buzz- which do not go off) for the reason of its charac-
er. teristics. If the number of the bright points and
q The machine monitor has a CPU (Central Pro- black points does not exceed 10, it does not in-
cessing Unit) in it to process, display, and output dicate a failure or a defect.
the information. q When the engine is started, the battery voltage
q The machine monitor consists of a display and may drop suddenly depending on ambient tem-
switches: the display is of LCD type, and the peratures and battery conditions. In this case,
switches are of flat sheet switch. the machine monitor display may go off for a mo-
q If an error occurs in the machine monitor itself, ment. However, this phenomenon is not a fail-
controller or wiring circuit between monitor and ure.
controller, the monitor does not display properly. q Continuous operation of the machine monitor
may display blue bright spots on the screen hav-
ing a black background; it is quite normal.
Blue points can never be a problem as the
screen has usually blue or white background.
(White in the LCD is made up of red, green and
blue.)

PC228US-8,PC228USLC-8 10-193
Electrical system
Machine monitor system

Input/output signal 10-194

070-18P(1) [CN-CM01]
Input/Output Input/Output
Pin No. Signal name Pin No. Signal name
signal signal
1 Unswitched power supply (24 V) Input 10 NC (*) –
2 Unswitched power supply (24 V) Input 11 Battery charge Input
3 GND (unswitched power supply ) – 12 GND (machine analog signal) –
4 GND (unswitched power supply ) – 13 Lamp switch Input
5 Wake-up Input/output 14 Starting switch ACC signal Input
Starting motor cut-out relay (for per-
6 Output 15 Starting switch C signal Input
sonal code)
7 NC (*) – 16 Preheating Input
8 NC (*) – 17 NC (*) –
9 Fuel level Input 18 NC (*) –

*: Never connect any cable to NC, or malfunctions or failures will occur.

070-12P(1) [CN-CM02]
Input/Output Input/Output
Pin No. Signal name Pin No. Signal name
signal signal
1 NC (*) – 7 NC (*) –
2 Engine oil level sensor Input 8 CAN terminal –
3 Coolant level sensor Input 9 CAN_H Input/output
4 Air cleaner clogging sensor Input 10 CAN_L Input/output
5 Swing lock switch Input 11 NC (*) –
6 NC (*) – 12 NC (*) –

*: Never connect any cable to NC, or malfunctions or failures will occur.

070-18P(2) [CN-CM03]
Input/Output Input/Output
Pin No. Signal name Pin No. Signal name
signal signal
RS232C CD for communication termi- For communication terminal: RS232C
1 Input 10 Input
nal CTS
RS232C RXD for communication ter- For communication terminal: RS232C
2 Input 11 Input
minal RI
RS232C SG for communication termi- GND (communication terminal power
3 – 12 –
nal supply)
GND (communication terminal control Communication terminal status signal
4 – 13 Input
signal) CH1
Communication terminal selection sig- Communication terminal power supply
5 Input 14 Output
nal control signal
For communication terminal: RS232C Communication terminal control signal
6 Output 15 Output
RTS CH1
For communication terminal: RS232C Communication terminal control signal
7 Output 16 Output
TXD CH2
For communication terminal: RS232C Communication terminal status signal
8 Output 17 Input
DTR CH2
For communication terminal: RS232C Communication terminal power supply
9 Input 18 Output
DSR (12 V)

10-194 PC228US-8,PC228USLC-8
 Electrical system
Machine monitor system

070-12P(2) [CN-CM04]
Input/Output Input/Output
Pin No. Signal name Pin No. Signal name
signal signal
1 NC (*) – 7 NC (*) –
2 NC (*) – 8 NC (*) –
3 NC (*) – 9 NC (*) –
4 NC (*) – 10 NC (*) –
5 NC (*) – 11 NC (*) –
6 NC (*) – 12 NC (*) –

*: Never connect any cable to NC, or malfunctions or failures will occur.

B60-8P [CN-CM05]
Input/Output Input/Output
Pin No. Signal name Pin No. Signal name
signal signal
1 Camera power supply (8 V) Output 5 GND (Camera power supply) –
2 Camera NTSC signal 1 Input 6 GND (Camera signal 1) –
3 Camera NTSC signal 2 Input 7 GND (Camera signal 2) –
4 Camera NTSC signal 3 Input 8 GND (Camera signal 3) –

PC228US-8,PC228USLC-8 10-195
Electrical system
Machine monitor system

Display 10-196

A: Standard screen
B: All indicators light-up screen
q If problems indicated by monitors (15) to (20) occur after starting the engine, the corresponding monitors
are displayed from the left top in the order of occurrence of the problems.
q If a problem indicated by monitors (15) to (20) occurs while working, the relevant monitor is displayed in
large size for two seconds and then displayed in small size.
q If the hydraulic oil temperature goes High or Low while a monitor is being displayed at the central portion
of the screen, at whitch the hydraulic oil temperature monitor is to be displayed, the screen displays only
hydraulic oil temperature monitor (2b).
C: Screen with maintenance time reminder

10-196 PC228US-8,PC228USLC-8
(02)
 Electrical system
Machine monitor system

Display
NO. Display item Description Remarks
category
Range Tempera- Background q Indicates corresponding temperature
ture (°C) color range.
W1 105 Red q Alarm buzzer sounds when the tem-
(*1) W2 102 Red perature exceeds 105 °C.
1a Gauge
Engine coolant W3 100 Blue q If the monitor background appears
temperature W4 85 Blue white, warm-up the engine.
W5 60 Blue
W6 30 White
1b Caution See the column "Gauge".
Tempera- Background q Indicates corresponding temperature
Range
ture (°C) color range.
H1 105 Red q Alarm buzzer sounds when the tem-
(*1) H2 102 Red perature exceeds 105 °C.
2a Gauge
Hydraulic oil H3 100 Blue q If the monitor background appears
temperature H4 85 Blue white, warm-up the hydraulic compo-
H5 40 Blue nents.
H6 20 White
2b Caution See the column "Gauge".
Background q Indicates corresponding fuel level.
Range Quantity (l)
color
F1 230 Blue
F2 195 Blue
3a Gauge (*1)
F3 160 Blue
Fuel level
F4 80 Blue
F5 60 Blue
F6 40 Red
3b Cautions See the column "Gauge".
Segment Load level q Indicates average load per minute on a
Light to scale of 1 to 10.
Green 1– 8
medium
4 ECO gauge
(Indicates when " Default (ECO display
Orange 9,10 Heavy is set to active)" of the service mode is
" ON" .)
q Indicates accumulated engine operat-
ing hours (the alternator is running).
Service meter reading 00000h - 99999h
(F4 switch changes it for clock dis-
5 play.)
q Displays time.
q 12-hour display (AM/PM)
Clock (F4 switch changes it for service meter
q 24-hour display
display.)
Background (If KOMTRAX is installed.)
Condition
color q The condition of the message is dis-
6 Message
Green There is unread message. played.
Blue There is unsent message. (OFF when no message exists.)
Light ON: ON q Indicates air conditioner and air blower
7 Air conditioner
Light OFF: OFF operating status.
INT: Intermittent q Indicates front glass wiper operating
8 Pilot Wiper ON: Continuous condition.
Light OFF:Stop
Swing lock Swing brake Monitor dis- q Indicates swing lock operating status.
switch cancel switch play
OFF OFF OFF
9 Swing lock
ON OFF ON
OFF ON Blink
ON ON Blink
*1: If the gauge signal is not available due to open circuit in CAN communication line, the gauge pointer goes off.

PC228US-8,PC228USLC-8 10-197
(02)
Electrical system
Machine monitor system

Display
NO. Display item Description Remarks
category
Elapsed time after turning q Indicates preheat operating status.
Monitor dis-
the starting switch to
play
"HEAT (preheat)".
10 Preheating
0 – 30 sec. ON
30 – 40 sec. Blink
After 40 sec. or longer OFF
One-touch q Indicates the operating status of
power max. Monitor display one-touch power maximizing function.
switch
One-touch
11 ON
power max.
ON (Goes off if pressed for
8.5 seconds)
Pilot
OFF Off
Auto-decelera- Light ON: ON q Indicates auto-decelerator operating
12
tor Light OFF: OFF status.
P: Heavy-duty operation q Displays working mode.
E: Low-fuel consumption operation
L: Fine operation
13 Working mode
B: Breaker operation
ATT: Double-acting attachment opera-
tion
Lo: Low speed q Displays travel speed setting.
14 Travel speed Med: Medium speed
Hi: High speed
(*2) Light ON: Abnormal range (below the q When an error is detected with the en-
15 Radiator coolant specified value) gine stopped, the monitor lights up on
level Light OFF: Normal range the screen.
Light ON: Defective battery charge q When an error is detected with the en-
(*2)
16 (Charge voltage < Battery voltage) gine running, the monitor lights up on
Battery charge
Light OFF: Normal range the screen.
(*2) Light ON: Abnormal range (below the q The monitor lights up on the screen
17 Engine oil pres- specified value) and alarm buzzer sounds, when an er-
sure Light OFF: Normal range ror is detected with the engine running.
Light ON: Abnormal range (below the q When an error is detected with the en-
(*2)
18 specified value) gine stopped, the monitor lights up on
Engine oil level
Light OFF: Normal range the screen.
Caution
(*2) Light ON: Abnormal range (above the q When an error is detected with the en-
19 Air cleaner clog- specified value) gine running, the monitor lights up on
ging Light OFF: Normal range the screen.
Light ON: Abnormal range (water level q When an error is detected with the en-
(*2)
20 is above the specified) gine running, the monitor lights up on
Water separator
Light OFF: Normal range the screen.
Background q The display changes depending on the
Condition
color time to/after the replacement.
There is a maintenance q After the starting switch is turned to ON
Maintenance item which is 30 hours or position, the monitor turns on if the
21 Yellow
time less left before next monitor light-up conditions are met,
replacement. and then goes off in 30 seconds.
There is a replacement
Red
overdue item.
*2: Included in the start-up check. After the staring switch is turned to ON position, the monitor turns on for two seconds,
and changes to the standard screen if no error is found.

10-198 PC228US-8,PC228USLC-8
(02)
 Electrical system
Machine monitor system

PC228US-8,PC228USLC-8 10-199
Electrical system
Machine monitor system

Switches 10-20

NO. Model Function Operation

Turns the auto-decelerator function q When the working mode is in "L" , the
Auto-deceleration switch ON/OFF. auto-decelerator does not work.
1
[Numeric keypad: 1] Light ON: ON
OFF io ON
Light OFF: OFF
P: Heavy-duty operation
(*1)
E: Low-fuel consumption operation
Working mode Displays the working mode selector
2 L: Fine operation
selector switch screen.
B: Breaker operation
[Numeric keypad: 2]
ATT: Double attachment operation
Changes the travel speed. o Lo (Low speed) o Mi (Medium speed) o
Travel speed
Lo light ON: Low speed Hi (High speed) o
3 selector switch
Mi light ON: Medium speed I O
[Numeric keypad: 3]
Hi light ON: High speed i i i i i i
Buzzer cancel Stops the alarm buzzer. q Stops the alarm buzzer.
4 switch (Some alarm buzzer does not stop even if q The alarm buzzer resumes sounding
[Numeric keypad: 4] the switch is pressed.) when another error is detected.
Operates the front window glass wiper. o INT o ON o OFF o
(*2)
INT: Intermittent (Intermit- (Continu-
5 Wiper switch I (Stop) O
ON: Continuous tent) ous)
[Numeric keypad: 5]
Light OFF: Stop i i i
ON: Washer fluid is sprayed and wiper
works continuously.
[When wiper stops]
(*2)
OFF: Wiper works twice and stops after the
Window washer Sprays washer fluid onto the front window
6 switch is released.
switch glass.
[When wiper operates intermittently]
[Numeric keypad: 6]
OFF: Wiper works twice continuously and
returns to intermittent operation after the
switch is released.

10-200 PC228US-8,PC228USLC-8
 Electrical system
Machine monitor system

NO. Model Function Operation

q The air flow increases immediately after
Fan switch (increase)
7a Controls the flow rate of the air condi- the air conditioner adjustment screen
[Numeric keypad: 7]
tioner in 6 levels. appears.
(Low, Medium 1, Medium 2, Medium 3, q The air flow decreases immediately after
7b Fan switch (decrease) Medium 4, High) the air conditioner adjustment screen
appears.
Temperature control q The preset temperature increases im-
8a switch (UP) mediately after the air conditioner ad-
Controls the temperature inside the cab.
[Numeric keypad: 8] justment screen appears.
(18.0 °C – 32.0 °C: adjustable at every
Temperature control q The preset temperature decreases im-
0.5 °C)
8b switch (DOWN) mediately after the air conditioner ad-
[Numeric keypad: 0] justment screen appears.
q Automatically controls the air flow, air
(*3) Auto-runs the air conditioner and air vent, fresh/recirculated air change ac-
9 Auto switch blower. cording to the temperature setting, im-
[Numeric keypad: 9] AUTO light ON: Auto run mediately after the air conditioner
adjustment screen appears.
q Switches to the air conditioner adjust-
Turns the air conditioner ON/OFF.
(*4) ment screen, and pressing it again
10 AC ON lights-up: manual operation
Air conditioner switch switches ON/OFF.
Light OFF:Stop
OFF io ON
q Switches to the air conditioner adjust-
FRESH/RECIRC air ment screen, and pressing it again
11 Changes the FRESH/RECIRC.
selector switch switches FRESH/RECIRC.
RECIRC io FRESH
q Switches to the air conditioner adjust-
Selects the air vent mode from 6 modes.
ment screen, and pressing it again
1. Front
switches air vent mode.
2. Front and rear
Modes 5 and 6 are not available with
12 Vent selector switch 3. Front and rear foot
auto mode.
4. Foot
o1o2o3o4o5o6o
5. Foot and defroster
I O
6. Defroster
i i i i i i
Stop the fan and air conditioner.
13 OFF switch q The fan and air conditioner stop.
Light OFF: OFF
14a Guidance icon
a See "Guidance icon and function switch." section.
14b Function switch
*1: When the working mode is changed, the auto-decelerator function turns "ON".
*2: When the front window is open, the windshield wiper and the washer do not operate even if the switch is
pressed.
*3: When the temperature is set to 18.0 °C or 32.0 °C, the fan speed is kept at "High". Even if the set temper-
ature is reached, the flow rate remains fixed at "High".
*4: When the fan is set to Stop, the air conditioner does not start even if the switch is pressed.

PC228US-8,PC228USLC-8 10-201
Electrical system
Machine monitor system

Guidance icon and function switch 10-202

q Functions available with the function switch vary depending on the guidance icon displayed above the
switch.
q No function is available if no guidance icon appears above the function switch.
q The following is the list of guidance icons and the functions displayed above the function switches.

10-202 PC228US-8,PC228USLC-8
 Electrical system
Machine monitor system

Guidance
Function switch Role Function
icon
1 Clear Clears selected/displayed item.

2 Display No. 1 camera screen Selects No. 1 camera screen.

Moves selectable item page down one page.
3 Change selectable items
(To the top page from the bottom page.)
F1 4 Set Performs setting.
Starts function.
5 Start (Used for starting measurement of spilt fuel consump-
tion.)
Stops operation.
6 Stop (Used for stopping measurement of spilt fuel consump-
tion.)
Sets selected item back to default.
1 Return to default setting
(Used for screen adjustment.)
2 Display No. 2 camera screen Selects No. 2 camera screen.
F2
Moves selectable item page up one page.
3 Change selectable items
(To the bottom page from the top page.)
4 Clear Clears selected/displayed item.

1 Switching to camera screen Switches to camera screen.

2 Display No. 3 camera screen Selects No. 3 camera screen.

F3 Moves selectable item down one item.
3 Select item (To the top item from the bottom item.)
Releases holding of the monitor.
Moves selectable item to the left.
4 Select item
(To the rightmost item from the leftmost item.)
1 Switching clock/service meter Switches clock/service meter display.
Display No. 1 and No. 2 camera Display both images of No.1 and No.2 cameras simul-
2
screens taneously.
F4 Moves selectable item up one item.
3 Select item (To the bottom item from the top item.)
Holds the monitor.
Moves selectable item to the right.
4 Select item
(To the leftmost item from the rightmost item.)
Selection of maintenance
1 Switches to the maintenance screen.
F5 screen
2 Return Returns to the previous screen or status.

1 Select user mode screen Switches to the user mode screen.

F6
2 Enter Enters selected/set item.

PC228US-8,PC228USLC-8 10-203
Electrical system
Machine monitor system

Operator mode function 10-204

q The operator can select the information to be displayed on the standard screen and the function to be
used, by operating the switches. Note that some information displays and function selections require the
special operations of the switches.
q Items available in the operator mode are as follows:
Category Display order (*2)
Item
(*1) V W X Y Z
KOMATSU logo screen 1 1 1 1 1
Password input screen 2 - - - -
Breaker mode check screen - - 2 - -
Start-up check screen 3 2 3 2 2
A Warning after "start-up check" screen - - - 3 -
Overdue replacement item screen - - - - 3
Working mode and travel speed check screen 4 3 4 4 4
Display of standard screen 5 4 5 5 5
Display of end screen
Selection of auto-deceleration
Selection of working mode
Selection of travel speed
Operation to stop alarm buzzer
Operation of windshield wiper
Operation of windshield washer
Operation of air conditioner
Operation to display camera mode
B Switching between clock display and service meter display
Check of maintenance information
Entering user mode
q Breaker/Attachment Settings
q User Messages (including KOMTRAX messages for user)
q Screen Adjustment
q Clock Adjustment
q Language
q Economy Mode Adjustment
Display of energy-saving guidance
C Display of caution monitor
Displaying user code and failure code
Function of checking display of LCD (Liquid Crystal Display)
D Function of checking service meter
Function of changing attachment/maintenance password
*1: The items available in the operator mode fall into the following categories.
A: Display from the time starting switch is turned to ON position until the standard screen appears. Display after the
starting switch is turned to OFF position.
B: Display when the switch on the machine monitor is operated.
C: Display when a certain condition is satisfied
D: Display to requires special operation of the switches.
*2: For the category A, the order in which items are displayed varies depending on the settings and conditions of the
machine as follows:
V: When engine start lock is set effective
W: When engine start lock is disabled
X: When working mode at start is set to "Breaker Mode (B)"
Y: When an error is detected during start-up check.
Z: When a replacement time overdue is detected.

a For how to operate the operator mode functions, see the Operation and Maintenance Manual or "Special functions
of machine monitor" section in Testing and adjusting.
a For how to set the engine start lock on/off, see " Password setting/cancel manual" .

10-204 PC228US-8,PC228USLC-8
 Electrical system
Machine monitor system

Oil flow setting for breaker 10-205 Oil flow setting for attachment 10-205

q Oil flow for the breaker can be changed in the q Oil flow for the 2-way attachment can be
"Breaker/attachment setting" of the user mode. changed in the " Breaker/attachment setting" of
q Oil flow level can be set as follows: the user mode.
Flow level Flow rate (l/min) Remarks q Oil flow level can be set as follows:
1 70 Flow level Flow rate (l/min) Remarks
2 80 1 30
3 90 2 90
4 100 3 115
5 110 4 140
6 120 5 170
7 130 6 250
8 140 7 350
9 150 8 430 Default
10 160
11 170 Language setting 10-205
12 180 Default
13 190
14 200
15 210

q The language used in the machine monitor can

be changed in the " Language setting" of the
user mode.
q The available languages are as follows:
English, Japanese, Chinese, French, Spanish,
Portuguese, Italian, German, Russian, Turkish,
Indonesan, and Thai.

PC228US-8,PC228USLC-8 10-205
(02)
Electrical system
Machine monitor system

Economy mode adjustment 10-206

q Fuel consumption can be improved by adjusting

the engine output power at "Economy Mode Ad-
justment" in user mode.
q The level can be selected from 4 stages,
E0/E1/E2/E3. The larger, the number of stage
becomes, the more the fuel consumption im-
proves, while the production reduces.

10-206 PC228US-8,PC228USLC-8
 Electrical system
Machine monitor system

Service mode function 10-207

q The functions in this mode are not displayed on the standard screen. The arrangements for the information
display and various setting can be made only by the technician through the special operation of the switch-
es.
This mode is used for special setting, testing, adjusting, or troubleshooting.
q Items available in the service mode are as follows:
Monitoring
Mechanical Systems
Abnormality Record Electrical Systems
Air-conditioning System
Maintenance Record
Maintenance Mode Change
Phone Number Entry
Key-on Mode
Unit
With/Without Attachment
Default
Attachment/Maintenance Password
Camera
ECO Display
Pump Absorption Torque (F)
Pump Absorption Torque (R)
Low Speed
Adjustment Attachment Flow Adjustment
Initialize boom potentiometer
Calib F pump swash plate sensor
Calib R pump swash plate sensor
Cylinder Cut-Out
No Injection
Fuel Consumption
Terminal Status
KOMTRAX Settings GPS & Communication Status
Modem S/N
Service Message
a For how to operate the service mode functions, see "Special functions of machine monitor" section in Test-
ing and adjusting.

PC228US-8,PC228USLC-8 10-207
Electrical system
KOMTRAX system

KOMTRAX system 10-208

(if equipped)

q The KOMTRAX system consists of the

KOMTRAX terminal, communication antenna,
machine monitor and GPS antenna.
q This system sends various information on the
machine via wireless communication. It allows
operators of the KOMTRAX to obtain the ma-
chine information from the office and to provide
various services with the customers.
q The information available from the KOMTRAX
system are as follows:
1. Operation map
2. Service meter reading
3. Location information
4. Failure history
and others.
a To provide the services, you need to make an ar-
rangement for starting the KOMTRAX service
separately.

10-208 PC228US-8,PC228USLC-8
 Electrical system
KOMTRAX system

KOMTRAX terminal 10-209

Model: TH300
q The KOMTRAX system utilizes satellite communications technology.

1. Communication antenna connection Outline 10-209

2. Machine harness connection (AMP-14P) q The terminal is a radio communication equip-
3. Machine harness connection (AMP-10P) ment which transmits various machine informa-
tion obtained by the machine monitor through
Input/output signal network signals and input signals, as well as
AMP-14P [CN-CK01] GPS positioning data. The terminal can transmit
Pin No. Signal name
Input/Output data via the communication antenna.
signal q The status of the terminal can be monitored on
A1 Power supply (12 V) Input
A2 NC (*) - the machine monitor when it is in the service
A3 NC (*) - mode "KOMTRAX setting display".
A4 Power supply voltage switching Output q Use of KOMTRAX terminal must be limited for
A5 NC (*) - the countries in which such communication is al-
A6 NC (*) -
A7 GND - lowed.
A8 GND -
A9 NC (*) - a When commencing operation of the KOMTRAX
A10 NC (*) -
system or changing the country in which the sys-
A11 NC (*) -
A12 NC (*) - tem is used, you must give notice to Komatsu
A13 NC (*) - Ltd..
A14 NC (*) - a When operating the system in Japan, install a
*: Never connect any cable to NC, or malfunctions or failures
terminal dedicated for use in Japan.
will occur.

AMP-10P [CN-CK02]
Input/Output
Pin No. Signal name
signal
B1 RS232C DCD Output
B2 RS232C RXD Output
B3 RS232C TXD Input
B4 RS232C DTR Input
B5 RS232C SGND -
B6 RS232C DSR Output
B7 NC (*) -
B8 NC (*) -
B9 NC (*) -
B10 NC (*) -
*: Never connect any cable to NC, or malfunctions or failures
will occur.

PC228US-8,PC228USLC-8 10-209
Electrical system
Sensors

Sensors 10-210
Ambient pressure sensor 10-210

1. Connector 2. Pressure intake port

Function 10-210
q This sensor, installed to the air intake cover at the engine top side, senses the atmospheric pressure to
output the corresponding variable voltage.

Boost pressure/temperature sensor 10-210

1. Connector 3. O-ring
2. Sensor

Function 10-210
q This sensor is installed in the intake manifold. It detects the boost pressure and intake air temperature,
and outputs signal as a variable voltage for pressure, and a resistance change for temperature.

10-210 PC228US-8,PC228USLC-8
 Electrical system
Sensors

Coolant temperature sensor 10-21

1. Connector 3. O-ring
2. Sensor

Function 10-21
q This sensor, installed on the cylinder head, converts the temperature variation into the change in resis-
tance, and outputs the corresponding signals.

Crankshaft speed sensor 10-21

Camshaft speed sensor 10-21

1. Connector 3. O-ring
2. Sensor

Function 10-21
q Crankshaft speed sensor and camshaft speed sensor are installed to the adjacency of the gear and the
ring on the cooling fan side of crankshaft and camshaft, respectively, and output pulse voltages due to
gear rotations.

PC228US-8,PC228USLC-8 10-211
(02)
Electrical system
Sensors

Common rail pressure sensor 10-212

1. Common rail 3. Connector

2. Sensor

Function 10-212
q The sensor is installed in the common rail. It detects the fuel pressure and outputs variable voltage signal.

Engine oil level sensor 10-212

1. Connector 3. Float
2. Bracket 4. Switch

Function 10-212
q This sensor is installed on the side face of the oil pan, and turns "OFF" by the lowered float, if the oil level
becomes lower than specified.

10-212 PC228US-8,PC228USLC-8
 Electrical system
Sensors

Fuel level sensor 10-213

1. Connector 5. Spring
2. Float 6. Contact
3. Arm 7. Spacer
4. Body

Function 10-213
q This sensor is installed on the side face of the fuel tank. The float moves up and down according to the
fuel level.
The movement of the float rotate the shaft of the variable resistor through the arm. As a result, the source
voltage is changed according to the resistance change due to the arm angle change and is output as a
signal.

PC228US-8,PC228USLC-8 10-213
Electrical system
Sensors

Coolant level sensor 10-214

1. Float 3. Connector
2. Sensor 4. Reservoir tank

Function 10-214
q This sensor is integrated with reservoir tank, and turns "OFF" by the lowered float, if the coolant level be-
comes lower than specified.

10-214 PC228US-8,PC228USLC-8
 Electrical system
Sensors

Hydraulic oil temperature sensor 10-215

1. Connector 3. Thermistor
2. Plug

Function 10-215
q This sensor, installed on the suction pipe of main pump, senses the temperature variation as the change
in thermistor resistance, and outputs the corresponding signals.

Front pump oil pressure sensor 10-215

Rear pump oil pressure sensor 10-215

1. O-ring Output characteristics 10-215

2. Sensor
3. Connector

Function 10-215
q Front pump oil pressure sensor and rear pump
oil pressure sensor are installed to the control
valves, detect the delivery pressures of pumps,
and output the corresponding variable voltages.

PC228US-8,PC228USLC-8 10-215
Electrical system
Sensors

PPC oil pressure sensor 10-216

1. O-ring Output characteristics 10-216

2. Sensor
3. Connector

Function 10-216
q PPC oil pressure sensors, 6 of which are in-
stalled to interconnect blocks in the pilot circuit
between control valves and PPC valve, and 4 of
which are installed to travel PPC valves, detect
the pilot pressures, and output the correspond-
ing variable voltage.

Air cleaner clogging sensor 10-216

1. Boss 4. Wire
2. Switch 5. Connector
3. Conduit

Function 10-216
q The sensor is installed on the air cleaner outlet side. It turns "ON", if the air cleaner is clogged and the
pressure level drops to the specified level (negative pressure).

10-216 PC228US-8,PC228USLC-8
 Electrical system
Sensors

Front pump swash plate sensor 10-217

Rear pump swash plate sensor 10-217

1. Sensor case Output characteristics 10-217

2. Spool q The relation between stroke and output voltage
3. Lead wire is as shown in the graph below.
4. Connector

L: Operation stroke (9 mm)

Function 10-217
q These sensors are installed to the front pump
side and the rear pump side of main pump, de-
tect the stroke of servo pistons, and output the
corresponding variable voltages.
q The output voltages are sent to the pump con-
troller which converts the voltages into the pump
swash plate angles (oil flow) to process them.

q The relation between oil flow of pump and output

voltage is as shown in the graph below.

PC228US-8,PC228USLC-8 10-217
(02)
Electrical system
Sensors

Water-in-fuel sensor 10-218

1. Connector 3. Sensor
2. Conduit

Function 10-218
q This sensor is installed to the cup of fuel prefilter, and outputs a signal when detecting water exists in the
fuel.

10-218 PC228US-8,PC228USLC-8
 Electrical system
Sensors

Boom angle potentiometer 10-219

1. Shaft Output characteristics 10-219

2. Housing
3. Bearing
4. Brush
5. Variable resistor
6. Connector

Function 10-219
q This potentiometer is installed to the boom foot,
and detects the boom angle.
q Based on the boom angle, the potentiometer
converts the supply voltage into signal voltage
depending on the resistance value of the vari-
able resistor.

PC228US-8,PC228USLC-8 10-219
Electrical system
Sensors

10-220 PC228US-8,PC228USLC-8
SEN0533408-00 20-1

PC228US-8,PC228USLC-8

HYDRAULIC EXCAVATOR
Shop Manual 20-1

PC228US-8
PC228USLC-8

Machine model Serial number

PC228US-8 50001 and up
PC228USLC-8 50001 and up

20 Standard value table 20-1

PC228US-8,PC228USLC-8 20-1
(01)
Contents

Contents 20-2
20 Standard value table
Standard value table ............................................................................................................... 20- 3
Standard value table for engine ........................................................................................... 20- 3
Standard value table for machine ........................................................................................ 20- 4

20-2 PC228US-8,PC228USLC-8
(01)
 Standard value table
Standard value table for engine

Standard value table 20-3

Standard value table for engine 20-3

PC228US-8
Machine model
PC228USLC-8
Engine SAA6D107E-1
Standard
Item Measurement conditions Unit Repair limit
value
High idle rpm 1,900 ± 70 1,900 ± 70
q Coolant temperature:
Engine speed Low idle rpm 1,050 ± 25 1,050 ± 25
Within operating range
Rated speed rpm 2,000 2,000

q Coolant temperature: Within operating range kPa Min. 133 103

Boost pressure
q Arm IN relief + One-touch power max. {mmHg} {Min. 1,000} {775}

Discolor-
At sudden acceler-
ation Max. 25 35
ation
q Coolant temperature: %
Exhaust gas color
Within operating range Discolor-
Rated hosepower ation Max. 12 22
%
Intake
mm 0.25 0.152 – 0.381
Valve
Valve clearance q Normal temperature
Exhaust
mm 0.51 0.381 – 0.762
Valve
Compression pres- MPa Min. 2.41 1.69
Compression pres- q Engine oil temperature: 40 - sure {kg/cm2} {Min. 24.6} {17.2}
sure 60 °C Engine
rpm 250 – 280 250 – 280
speed

q Coolant temperature: Within operating range kPa Max. 0.98 1.96

Blowby pressure
q Arm IN relief + One-touch power max. {mmH2O} {Max. 100} {200}

High kPa Min. 0.29 0.25

q Engine oil temperature: idle {kg/cm2} {Min. 3.0} {2.5}
Engine oil pressure Min. 80 °C
q SAE30 Oil Low kPa Min. 0.10 0.07
idle {kg/cm2} {Min. 1.0} {0.7}
Oil temperature q Whole speed range (inside oil pan) °C 80 – 110 120
q Between fan pulley and alternator pulley
Auto-ten- Auto-
Fan belt tension q Deflection when pressed with thum at approx. 98 mm
sioner tentioner
N {10 kg}
q Between compressor pulley and fan pulley
Air conditioner com-
q Deflection when pressed with thum at approx. 60 mm 6.3 – 8.7 6.3 – 8.7
pressor belt tension
N {6.1 kg}

PC228US-8,PC228USLC-8 20-3
(01)
Standard value table
Standard value table for machine

Standard value table for machine 20-4

PC228US-8
Machine model
PC228USLC-8
Category

Item Measurement conditions Unit Standard value Repair limit

q Coolant temperature: Within operating range

q Hydraulic oil
Speed at 2-pump temperature: Within operating range
rpm 1,920 ± 100 1,920 ± 100
relief q Engine at high speed
q Power mode (P)
q Arm IN relief
Engine speed

q Coolant temperature: Within operating range

q Hydraulic oil
Speed at 2-pump
temperature: Within operating range
relief + One-touch rpm 1,950 ± 100 1,950 ± 100
q Engine at high speed
power maximizing
q Power mode (P)
q Arm IN relief + Left knob switch in ON position
q Engine at high speed
Speed when
q Auto-deceleration switch in ON position
auto-deceleration rpm 1,050 ± 100 1,050 ± 100
q All control levers in NEUTRAL
is operated
position
RAISE mm 11.5 ± 0.5 11.5 ± 0.5
Boom control valve
Travel of control valve spool

LOWER mm 9.5 ± 0.5 9.5 ± 0.5

IN mm 11.5 ± 0.5 11.5 ± 0.5
Arm control valve
q Engine stopped OUT mm 9.5 ± 0.5 9.5 ± 0.5
Bucket control q For measuring point, see "Con- CURL
trol valve". mm 9.5 ± 0.5 9.5 ± 0.5
valve DUMP
Swing control Left swing
mm 9.5 ± 0.5 9.5 ± 0.5
valve Right swing
Travel control Forward
mm 9.5 ± 0.5 9.5 ± 0.5
valve Reverse
Boom control lever mm 85 ± 10 85 ± 10
Travel of control lever

Arm control lever q Engine stopped mm 85 ± 10 85 ± 10

Bucket control q At center of control lever grip
mm 85 ± 10 85 ± 10
lever q Read Max. value through travel end.
Swing control lever (except lever play in NEUTRAL position) mm 85 ± 10 85 ± 10
Travel control lever mm 115 ± 12 115 ± 12
Work equip-
Play of control mm Max. 15 Max. 20
ment
levers
Travel mm Max. 20 Max. 25

20-4 PC228US-8,PC228USLC-8
(01)
 Standard value table
Standard value table for machine

PC228US-8
Machine model
PC228USLC-8
Operating effort of control lever and pedal Category

Item Measurement conditions Unit Standard value Repair limit

N 15.7 ± 3.9 Max. 24.5

Boom control lever
{kg} {1.6 ± 0.4} {Max. 2.5}
N 15.7 ± 3.9 Max. 24.5
Arm control lever
{kg} {1.6 ± 0.4} {Max. 2.5}
q Hydraulic oil
Bucket control N 12.7 ± 2.9 Max. 21.6
temperature: Within operating range
lever {kg} {1.3 ± 0.3} {Max. 2.2}
q Engine at high speed
q Control lever: At center of grip N 12.7 ± 2.9 Max. 21.6
Swing control lever
q Pedal: At tip of pedal {kg} {1.3 ± 0.3} {Max. 2.2}
q Read Max. value through travel end. N 24.5 ± 5.9 Max. 39.2
Travel control lever
{kg} {2.5 ± 0.6} {Max. 4.0}

Travel control N 74.5 ± 18.6 Max. 107.6

pedal {kg} {7.6 ± 1.9} {Max. 11}
q Hydraulic oil
temperature: Within operating range
q Engine at high speed MPa 3.5 ± 1.0 3.5 ± 1.0
Unload pressure
q Power mode (P) {kg/cm2} {36 ± 10} {36 ± 10}
q Hydraulic pump output pressure with all con-
trol levers in NEUTRAL position
At normal MPa 34.8 ± 1.0 33.3 – 36.8
Boom relief pres- relief {kg/cm2} {355 ± 10} {340 – 375}
sure At power MPa 37.3 ± 1.0 36.3 – 39.2
q Hydraulic oil maximizing {kg/cm2} {380 ± 10} {370 – 400}
temperature: Within operating
range At normal MPa 34.8 ± 1.0 33.3 – 36.8
q Engine at high speed relief {kg/cm2} {355 ± 10} {340 – 375}
Arm relief pressure
q Power mode (P) At power MPa 37.3 ± 1.0 36.3 – 39.2
q Hydraulic pump output pressure maximizing {kg/cm2} {380 ± 10} {370 – 400}
with all measurement circuits re-
At normal MPa 34.8 ± 1.0 33.3 – 36.8
lieved
Bucket relief pres- relief {kg/cm2} {355 ± 10} {340 – 375}
Oil pressure

sure At power MPa 37.3 ± 1.0 36.3 – 39.2

maximizing {kg/cm2} {380 ± 10} {370 – 400}
Swing relief pres- q Hydraulic oil MPa 30.3 ± 1.5 28.4 – 32.3
sure temperature: Within operating range {kg/cm2} {310 ± 15} {290 – 330}
q Engine at high speed
Travel relief pres- q Power mode (P) MPa 38.7 (+1.0/-2.0) 36.8 – 40.2
sure q Hydraulic pump output pressure with all mea- {kg/cm2} {395 (+10/-20)} {375 – 410}
surement circuits relieved
q Hydraulic oil
temperature: Within operating range MPa
Control circuit 3.23 (+0.2/-0.3) 2.75 – 3.43
q Engine at high speed 2}
source pressure {kg/cm {33 (+2/-3)} {28 – 35}
q Self-pressure reducing valve output pressure
with all control levers in NEUTRAL position
q Hydraulic oil When all
temperature: Within operating control MPa 3.5 ± 1.0 3.5 ± 1.0
range levers in 2}
{kg/cm {36 ± 10} {36 ± 10}
q Engine at high speed NEUTRAL
LS differential
q Power mode (P) position
pressure
q Travel speed: Hi
When travel MPa
q Run either track idle. 1.8 ± 0.1 1.8 ± 0.1
levers at 2}
q LS differential pressure = Pump {kg/cm {18 ± 1} {18 ± 1}
half travel
pressure – LS pressure

PC228US-8,PC228USLC-8 20-5
(01)
Standard value table
Standard value table for machine

PC228US-8
Machine model
PC228USLC-8
Category

Item Measurement conditions Unit Standard value Repair limit

q Hydraulic oil
temperature: Within operating range
q Engine at high speed
deg. Max. 100 Max. 130
Overrun of swing q Power mode (P)
(mm) (–) (–)
q Swing circle misalignment amount when stop-
ping after one turn
q For measuring posture, see "Swing 1".
q Hydraulic oil
temperature: Within operating
90° sec. 3.1 ± 0.3 Max. 3.7
range
q Engine at high speed
Time required to q Power mode (P)
start swinging q Time required to swing from
swing start position to 90 de- 180° sec. 4.4 ± 0.4 Max. 5.5
grees and 180 degrees
q For measuring posture, see
"Swing 1".
q Hydraulic oil
Swing

temperature: Within operating range

q Engine at high speed
Time required to
q Power mode (P) sec. 27.3 (+3.6/-1.7) Max. 33
finish swinging
q Time required for five more turns after making
initial one turn
q For measuring posture, see "Swing 1".
q Hydraulic oil
temperature: Within operating range
q Engine stopped
q On slope of 15 degrees, set upper structure
Swing drift on a
crosswise and make matchmark on inner race mm 0 0
slope
and outer race of swing circle.
q Matchmark misalignment amount during 5
minutes
q For measuring posture, see "Swing 2".
q Power mode (P)
q Engine at high speed
Leakage from q Hydraulic oil
l/min Max. 5 Max. 10
swing motor temperature: Within operating range
q Swing lock switch: ON
q Relieve swing circuit.

20-6 PC228US-8,PC228USLC-8
(01)
 Standard value table
Standard value table for machine

PC228US-8
Machine model
PC228USLC-8
Category

Item Measurement conditions Unit Standard value Repair limit

Power mode (P) q STD LC STD LC

Engine at high speed q
Lo 51.3 ± 55.9 ± 46.2 – 50.3 –
q Hydraulic oil temperature: 45 -
55 °C 5.1 5.6 60.5 66.0
Travel speed (idle run- q Raise either track of the ground 37.5 ± 40.8 ± 33.8 – 36.7 –
Mi sec.
ning) and measure time required to 3.8 4.1 45.0 49.0
move five turns idle after finishing
one turn. 26.5 ± 28.9 ± 25.2 – 26.0 –
q For measuring posture, see "Trav- Hi
1.3 1.4 29.9 32.7
el 1".
q Power mode (P)
q Engine at high speed Lo 24.0 ± 2.4 21.6 – 26.4
q Hydraulic oil temperature: 45 -
Travelspeed (actual 55 °C Mi 17.6 ± 1.8 15.8 – 19.3
sec.
running) q Measure time required to travel 20
m after run-up of at least 10 m on
a level ground. Hi 13.1 ± 0.7 12.4 – 13.7
q For testing posture, see "Travel 2".
Travel

q Power mode (P)

q Engine at high speed
q Hydraulic oil temperature: 45 - 55 °C
q Measure deviation made during travel of 20
Travel deviation m after run-up of at least 10 m on a level mm Max. 150 Max. 250
ground.
a Use a hard and level ground.
a Measure dimension X.
q For measuring posture, see "Travel 2 and 3"
q Engine stopped
q Hydraulic oil temperature: 45 - 55 °C
q Park machine on slope of 12° with sprocket
Hydraulic drift of travel mm 0 0
faced to the uphill side.
q Travel distance by travel drift in 5 minutes
q For measuring posture, see "Travel 4".

q Engine at high speed

Leakage from travel q Hydraulic oil temperature: 45 - 55 °C
l/min 13.6 27.2
motor q Lock shoes and relieve travel circuit.
q For measuring posture, see "Travel 5".
Whole work
equipment q Measure extraction or retraction distance of
Max. 600 Max. 900
Hydraulic drift in work equipment

(Drop at bucket each cylinder and drop distance of bucket

tooth tip) tooth tip in posture "Work equipment 1".
q Bucket: Full of earth and sand or rated load
Boom cylinder
Work equipment

(14.1 kN {1,440 kg})

(Retraction of cyl- q Measure on level and flat surface. Max. 18 Max. 27
inder) q Set lever to NEUTRAL.
mm
q Engine stopped
Arm cylinder
q Hydraulic oil temperature: 45 - 55 °C
(Extension of cyl- Max. 160 Max. 240
q Start measurement just after setting.
inder)
q Measure drop distance every 5 minutes and
Bucket cylinder judge after 15 minutes.
q For measuring posture, see "Work equip-
(Retraction of cyl- Max. 40 Max. 58
inder) ment 1".

PC228US-8,PC228USLC-8 20-7
(01)
Standard value table
Standard value table for machine

PC228US-8
Machine model
PC228USLC-8
Category

Item Measurement conditions Unit Standard value Repair limit

q Power mode (P) Demoli- Demoli-

q Engine at high speed tion tion
Boom and STD STD
q Hydraulic oil temperature: 45 - 55 °C specifica- specifica-
bucket

RAISE
q Emergency work equipment actuation tion tion
tooth
switch:
touched on
Emergency (upper) 3.7 ± 4.1 ±
k
ground Max. 5.2 Max. 5.2
Since boom raise stroke end cush- 0.4 0.4
I
ion function is not activated , large
O
impacts are made at stroke end.
Boom cylin-

LOWER
Therefore, perform the measure-
der fully 2.8 ± 3.1±
ment on level and hard ground. Max. 4.4 Max. 4.4
Work equipment speed

extended 0.3 0.3

q For testing posture, see "Work equip-
ment 2".
Arm
3.5 ± 4.5 ±
cylinder
IN
sec. Max. 4.5 Max. 5.2
q Power mode (P) 0.3 0.4
fully
q Engine at high speed
retracted
q Hydraulic oil temperature: 45 - 55 °C
I
q For measuring posture, see "Work
OUT

O 2.7 ± 0.3 Max. 3.5

equipment 3".
Fully
extracted
Bucket
CURL

2.6 ± 2.8 ±
cylinder Max. 3.3 Max 3.4
q Power mode (P) 0.3 0.3
fully
q Engine at high speed
retracted
q Hydraulic oil temperature: 45 - 55 °C
I
DUMP
Work equipment

q For measuring posture, see "Work 1.9 ± 2.2 ±

O Max. 2.7 Max. 2.9
equipment 4". 0.2 0.2
Fully
extracted
q Power mode (P)
q Time required to raise machine at the
ground after bucket touches ground
Boom q Engine at low speed Max. 1.0 Max.1.2
q Hydraulic oil temperature: 45 - 55 °C
q For measuring posture, see "Work equip-
ment 5".

q Power mode (P)

Time lag

q Period of time while arm stops momentarily

q Engine at low speed. sec.
Arm Max.2.0 Max.2.8
q Hydraulic oil temperature: 45 - 55 °C
q For measuring posture, see "Work equip-
ment 6".
q Power mode (P)
q Period of time while the bucket stops mo-
mentarily
Bucket q Engine at low speed Max. 1.0 Max. 3.6
q Hydraulic oil temperature: 45 - 55 °C
q For measuring posture, see "Work equip-
ment 7".
Internal leackage

Cylinders 4.5 20
q Hydraulic oil temperature: 45 - 55 °C
cc/min
q Engine at high speed
Center .
q Relieve the circuit to be measured. 10 50
swivel joint

20-8 PC228US-8,PC228USLC-8
(01)
 Standard value table
Standard value table for machine

PC228US-8
Machine model
PC228USLC-8
Characteristics of PC flow control Pump swash plate sensor Ease of combined operation Category

Item Measurement conditions Unit Standard value Repair limit

q Engine at high speed

Travel deviation
q Hydraulic oil temperature: 45 - 55 °C
during work equip-
a Use a hard and level ground. mm Max. 200 Max. 220
ment operation +
a Measure dimension X.
travel
q For measuring posture, see "Travel 3".

All control
q Hydraulic oil levers in
V 1.57 ± 0.20 1.57 ± 0.63
temperature: Within operating NEUTRAL
Pump swash plate range condition
sensor output volt- q Engine at high speed When run-
age q Power mode (P) ning track
q Travel speed: Hi idle V 3.75 ± 0.20 3.75 ± 0.63
q Run either track idle (lever at
travel end)

q Hydraulic oil
temperature: Within operating range
q Engine at high speed
q Power mode (P)
Time required for q Bucket rated load
swinging from 0 to 4.0 ± 0.4
90° with boom (0.8 m3: 14,110 N {1,440 kg}) sec.
(Reference value)
q On hard and level ground, set arm vertically
RASIE
and lower back of bucket to ground
q Time required for turning from 0 to 90° with
boom raised
q For measuring posture, see "Combind 1".

Hydraulic pump
– See "Performance of hydraulic pump" (next page).
delivery

PC228US-8,PC228USLC-8 20-9
(01)
Standard value table
Standard value table for machine

PC228US-8
Machine model
PC228USLC-8
Category

Item Measurement conditions Unit Standard value Repair limit

q Pump speed (rpm): 2,000

q PC-EPC current value (mA): 440
Hydraulic pump

q Test pump delivery pressure (MPa {kg/cm2}):

Performance of P1 Q Q
q Delivery pressure of another pump (MPa l/min
hydraulic pump (See graph) (See graph)
{kg/cm2}): P2
q Average delivery pressure (MPa {kg/cm2}):
Pp=(P1+P2)÷2
a Bring pump delivery pressure P1 and P2 as close as possible to the average pressure when measuring.
Avoid measuring the near turning point of the graph because the error increases there.
a When measuring with the pump mounted on the machine, if it is impossible to set the engine speed to the
specified speed by using the fuel control dial, take the pump delivery and the engine speed at the time of
measurement, and use them as a base for calculating the pump delivery the specified speed.

20-10 PC228US-8,PC228USLC-8
(01)
 Standard value table
Standard value table for machine

Posture of machine for measuring performance Travel 1: Travel speed (idle running)
and measurement procedure 20-1

Spool travel

Travel 2: Travel speed (actual running) and travel

deviation

Swing 1: Overrun of swing, time required to start

swing and time required to finish swing

Travel 3: Travel deviation

Swing 2: Swing drift on a slope

PC228US-8,PC228USLC-8 20-11
(01)
Standard value table
Standard value table for machine

Travel 4: Hydraulic drift of travel Work equipment 2: Work equipment speed (boom)

Travel 5: Leakage from travel motor Work equipment 3: Work equipment speed (arm)

Work equipment 1:Hydraulic drift in work equipment Work equipment 4: Work equipment speed (bucket)

20-12 PC228US-8,PC228USLC-8
(01)
 Standard value table
Standard value table for machine

Work equipment 5: Time lag (boom) Combined 1: Ease of combined operation

Work equipment 6: Time lag (arm)

Work equipment 7: Time lag (bucket)

PC228US-8,PC228USLC-8 20-13
(01)
Standard value table
Standard value table for machine

20-14 PC228US-8,PC228USLC-8
(01)
SEN0533410-00 30-1

PC228US-8,PC228USLC-8

HYDRAULIC EXCAVATOR
Shop Manual 30-1

PC228US-8
PC228USLC-8

Machine model Serial number

PC228US-8 50001 and up
PC228USLC-8 50001 and up

30 Testing and adjusting 30-1

PC228US-8,PC228USLC-8 30-1
(01)
Contents

Contents 30-2
30 Testing and adjusting
Tool for testing, adjusting and troubleshooting ....................................................................... 30- 3
Tools for testing, adjusting, and troubleshooting ................................................................. 30- 3
Engine and cooling system ..................................................................................................... 30- 7
Testing engine speed........................................................................................................... 30- 7
Testing intake air pressure (boost pressure) ....................................................................... 30- 8
Testing exhaust gas color .................................................................................................... 30- 9
Testing and adjusting valve clearance................................................................................. 30- 10
Testing compression pressure............................................................................................. 30- 12
Testing blowby pressure ...................................................................................................... 30- 15
Testing engine oil pressure.................................................................................................. 30- 16
Handling fuel system parts................................................................................................... 30- 17
Releasing remaining pressure from fuel system.................................................................. 30- 18
Testing fuel pressure ........................................................................................................... 30- 19
Cylinder cut-out test mode ................................................................................................... 30- 22
No-injection cranking ........................................................................................................... 30- 23
Checking fuel delivery, return rate and leakage................................................................... 30- 24
Bleeding air from fuel circuit................................................................................................. 30- 27
Testing fuel circuit for leakage ............................................................................................. 30- 28
Testing and adjusting air conditioner compressor belt tension ............................................ 30- 29
Replacing fan belt ................................................................................................................ 30- 30
Undercarriage and frame ........................................................................................................ 30- 31
Testing swing circle bearing clearance ................................................................................ 30- 31
Checking and adjusting track tension .................................................................................. 30- 32
Hydraulic system..................................................................................................................... 30- 33
Testing and adjusting oil pressure in work equipment, swing and travel circuits................. 30- 33
Testing control circuit source pressure ................................................................................ 30- 37
Testing and adjusting oil pressure in pump PC control circuit ............................................. 30- 38
Testing and adjusting oil pressure in pump LS control circuit.............................................. 30- 42
Testing solenoid valve output pressure ............................................................................... 30- 47
Testing PPC valve output pressure ..................................................................................... 30- 50
Adjusting play of work equipment and swing PPC vavles ................................................... 30- 52
Testing pump swash plate sensor ....................................................................................... 30- 53
Isolating the parts causing hydraulic drift of work equipment .............................................. 30- 54
Releasing remaining pressure from hydraulic circuit ........................................................... 30- 56
Testing oil leakage amount .................................................................................................. 30- 57
Bleeding air from each part.................................................................................................. 30- 59
Work equipment...................................................................................................................... 30- 61
Replacement procedure of boom angle potentiometer........................................................ 30- 61
Cab and its attachments ......................................................................................................... 30- 62
Checking cab tipping stopper............................................................................................... 30- 62
Adjusting mirrors .................................................................................................................. 30- 63
Angle adjustment of rear view camera................................................................................. 30- 65
Electrical system ..................................................................................................................... 30- 67
Speial function of machine monitor (EMMS)........................................................................ 30- 67
Handling voltage circuit of engine controller ........................................................................ 30- 123
Preparatory work for troubleshooting of electrical system ................................................... 30- 124
Procedure for testing diodes ................................................................................................ 30- 129
Pm clinic.................................................................................................................................. 30- 131
Pm clinic service .................................................................................................................. 30- 131

30-2 PC228US-8,PC228USLC-8
(01)
 Tool for testing, adjusting and troubleshooting
Tools for testing, adjusting, and troubleshooting

Tool for testing, adjusting and troubleshooting 30-3

Tools for testing, adjusting, and troubleshooting 30-3

Q'ty
Testing and adjusting item Symbol Part number Part name Remarks
Testing intake air pressure
R 799-201-2202 Boost gauge kit 1 -101 – 200 kPa {-760 – 1,500 mmHg}
(boost pressure)
1 799-201-9001 Handy smoke checker 1
Testing exhaust gas color A Commercially Bosch index: 0 to 9
2 Smoke meter 1
available
1 795-799-1131 Gear 1
Adjustment of valve clear-
B Commercially
ance 2 Feeler gauge 1 Intake: 0.25 mm, Exhaust: 0.51 mm
available
1 795-502-1590 Compression gauge 1 0 – 7 MPa {0 – 70 kg/cm2}
Testing compression pres- 2 795-799-6700 Puller 1 For 107E-1 engine
C
sure 3 795-790-4410 Adapter 1 For 107E-1 engine
4 6754-11-3130 Gasket 1 For 107E-1 engine
1 799-201-1504 Blowby checker 1 0 – 5 kPa {0 – 500 mmH2O}
Testing blow-by pressure D
2 795-790-3300 Blow-by testing tool 1 for 107E-1 engine
Pressure gauge: 2.5, 6, 40, 60MPa
799-101-5002 Hydraulic tester 1
{25, 60, 400, 600 kg/cm2}
1
Testing engine oil pressure E Pressure gauge: 60 MPa
790-261-1204 Digital hydraulic tester 1
{600 kg/cm2}
2 799-401-2320 Hydraulic tester 1 Pressure gauge: 1.0 MPa {10 kg/cm2}
Pressure gauge: 2.5, 6, 40, 60MPa
799-101-5002 Hydraulic tester 1
{25, 60, 400, 600 kg/cm2}
1
Pressure gauge: 60 MPa
790-261-1204 Digital hydraulic tester 1
{600 kg/cm2}
795-790-4430 Adapter 1
Testing fuel pressure F 2 10 x 1.0 mm o R1/8
6215-81-9710 O-ring 1
3 799-401-2320 Gauge 1 Pressure gauge: 1.0 MPa {10 kg/cm2}
4 795-790-5110 Screw 1
5 799-201-2202 Boost gauge kit 1
6 796T-501-1110 Adapter 1 Size: 12 x 1.5 mm
1 795-790-4700 Tester kit 1
2 795-790-6700 Adapter 1
6754-71-5340 Connector 1
3
6754-71-5350 Washer 1
Commercially
4 Measuring cylinder 1
Testing fuel discharge, available
G
return rate and leakage Commercially
5 Stopwatch 1
available
Commercially
6 Hose 1 Internal dimension 14 mm
available
Commercially
7 Hose 1 Internal dimension 8 mm
available
Testing swing circle bear- Commercially
H Dial gauge 1
ing clearance available
Pressure gauge: 2.5, 6, 40, 60 MPa
799-101-5002 Hydraulic tester 1
Measuring and adjusting {25, 60, 400, 600 kg/cm2}
1
oil pressure in work equip- Pressure gauge: 60 MPa
J 790-261-1204 Digital hydraulic tester 1
ment, swing, and travel cir- {600 kg/cm2}
cuits 799-101-5220 Nipple 2
2 Size: 10 x 1.25 mm
07002-11023 O-ring 2
Pressure gauge: 2.5, 6, 40, 60 MPa
799-101-5002 Hydraulic tester 1
{25, 60, 400, 600 kg/cm2}
1
Testing basic pressure of Pressure gauge: 60 MPa
K 790-261-1204 Digital hydraulic tester 1
control circuit {600 kg/cm2}
799-101-5220 Nipple 1
2 Size: 10 x 1.25 mm
07002-11023 O-ring 1

PC228US-8,PC228USLC-8 30-3
(01)
Tool for testing, adjusting and troubleshooting
Tools for testing, adjusting, and troubleshooting

Q'ty
Testing and adjusting item Symbol Part number Part name Remarks
Pressure gauge: 2.5, 6, 40, 60 MPa
799-101-5002 Hydraulic tester 1
{25, 60, 400, 600 kg/cm2}
Measuring and adjusting 1
Pressure gauge: 60 MPa
oil pressure in pump PC L 790-261-1204 Digital hydraulic tester 1
control circuit {600 kg/cm2}
799-101-5220 Nipple 4
2 Size: 10 x 1.25 mm
07002-11023 O-ring 4
Pressure gauge: 2.5, 6, 40, 60 MPa
799-101-5002 Hydraulic tester 1
{25, 60, 400, 600 kg/cm2}
1
Pressure gauge: 60 MPa
Pump LS control 790-261-1204 Digital hydraulic tester 1
Testing and adjusting cir- M {600 kg/cm2}
cuit oil pressure 799-101-5220 Nipple 4
2 Size: 10 x 1.25 mm
07002-11023 O-ring 4
Differential pressure
3 799-401-2701 1 50 MPa {500 kg/cm2}
gauge
Pressure gauge: 2.5, 6, 40, 60 MPa
799-101-5002 Hydraulic tester 1
{25, 60, 400, 600 kg/cm2}
1
Testing solenoid valve out- Pressure gauge: 60 MPa
N 790-261-1204 Digital hydraulic tester 1
put pressure {600 kg/cm2}
799-401-3100 Adapter 1 Size: 02
2
02896-11008 O-ring 1
Pressure gauge: 2.5, 6, 40, 60 MPa
799-101-5002 Hydraulic tester 1
{25, 60, 400, 600 kg/cm2}
1
Pressure gauge: 60 MPa
Testing PPC valve output 790-261-1204 Digital hydraulic tester 1
P {600 kg/cm2}
pressure
799-401-3100 Adapter 1 Size: 02
2
799-401-3200 Adapter 1 Size: 03
3 796T-562-1110 Adapter 1 Size: 12 x 1.5 mm
Commercially
Testing oil leakage Q Measuring cylinder 1
available
Measuring coolant temper-
– 799-101-1502 Digital thermometer 1 -99.9 – 1,299 °C
ature and oil temperature
Testing operating effort 79A-264-0021 Push-pull scale 1 0 – 294 N {0 – 30 kg}
–
and depressing effort 79A-264-0091 Push-pull scale 1 0 – 490 N {0 – 50 kg}
Measuring stroke and Commercially
– Ruler 1
hydraulic drift available
Testing work equipment Commercially
– Stopwatch 1
speed available
Measuring voltage and Commercially
– Multimeter 1
resistance available
Removal and installation
Commercially Hexlobe (TORX) 3.26 mm TORX wrench
of boost pressure and tem- – 1
available wrench (KTC Q4T15 or equivalent)
perature sensors
Removal and installation
of engine oil pressure sen- – 795-799-6210 Socket 1 27 mm deep socket
sor
Removal and installation
19 mm deep socket
of engine coolant tempera- – 795T-981-1010 Socket 1
(MITOLOY 4ML-19 or equivalent)
ture sensor

30-4 PC228US-8,PC228USLC-8
(02)
 Tool for testing, adjusting and troubleshooting
Tools for testing, adjusting, and troubleshooting

Q'ty
Testing and adjusting item Symbol Part number Part name Remarks
799-601-4101
or T-adapter assembly 1
799-601-4201
For DRC60, ECONO
799-601-4350 q T-box 1
(Not included in Kit No. 799-601-4201)
Engine (CRI-T3) water temperature
sensor
For (PACKARD 2P)
Engine (CRI-T3) fuel temperature sen-
795-799-5530 q Socket 1 sor
For (PACKARD 2P)
Engine (CRI-T3) oil temperature sen-
sor
For (PACKARD 2P)
Engine (CRI-T3) ambient pressure
799-601-4140 q Socket 1 sensor
For (AMP 3P)
Engine (CRI-T3) boost pressure sen-
799-601-4230 q Socket 1 sor and boost temperature sensor
Troubleshooting for For (SUMITOMO 4P)
Engine (CRI-T3) G (Backup)
engine, 799-601-4330 q Socket 1
– For sensor (SUMITOMO 3P)
controller sensor,
For engine (CRI-T3) supply pump
and actuator
799-601-4340 q Socket 1 PCV 1 and PCV 2 sensors (SUMI-
TOMO 3P)
Engine (CRI-T3) NE sensor
799-601-4130 q T-adapter 1
For (FRAMATOME 3P)
Engine (CRI-T3) common rail fuel
799-601-4190 q T-adapter 1 pressure
For sensor (AMP 3P)
For engine controller DRC26-50P
799-601-4211 q T-adapter 1
(Not included in Kit No. 799-601-4201)
For engine controller DRC26-60P
799-601-4220 q T-adapter 1
(Not included in Kit No. 799-601-4201)
For engine controller DTP-4P
799-601-4260 q Adapter for DTP 1 (Included in Kit Nos. 799-601-9000
and 799-601-9100, too)
For DT 4P (Included in Kit Nos.
799-601-9040 q T-adapter 1 799-601-9000 and 799-601-9200, too)

For DT 2P (Included in Kit Nos.

799-601-9020 q T-adapter 1 799-601-9000 and 799-601-9200, too)

799-601-9000
or
799-601-9100 T-adapter assembly
or
799-601-9300
799-601-9320 q T-box 1 For ECONO (Max. 24P)
799-601-4101 q T-adapter assembly
799-601-4350 q T-box 1 For DRC60, ECONO (Max. 60P)
Troubleshooting for 799-601-7000
machine or
–
wiring harness 799-601-7100
or T-adapter assembly
799-601-7400
or
799-601-8000
For ECONO (Max. 21P)
799-601-2600 q T-box 1
(Not included in Kit No. 799-601-7000)
799-601-7210 q T-adapter 1 For AMP040 16P
799-601-7220 q T-adapter 1 For AMP040 20P
799-601-7090 q T-adapter 1 For M 2P

PC228US-8,PC228USLC-8 30-5
(01)
Tool for testing, adjusting and troubleshooting
Tools for testing, adjusting, and troubleshooting

Q'ty
Testing and adjusting item Symbol Part number Part name Remarks
799-601-7120 q T-adapter 1 For M 4P
799-601-7130 q T-adapter 1 For M 6P
799-601-7340 q T-adapter 1 For M 8P (Kit No. is not registered)
799-601-7140 q T-adapter 1 For S 8P
For S 12P (white) (Kit No. is not regis-
799-601-7350 q T-adapter 1
tered)
799-601-7170 q T-adapter 1 For S 16P (blue)
For S 16P (white) (Kit No. is not regis-
799-601-7330 q T-adapter 1
tered)
For SWP 8P
799-601-7060 q T-adapter 1
(Not included in Kit No. 799-601-8000)
For SWP 12P
799-601-7310 q T-adapter 1
(Not included in Kit No. 799-601-8000)
For SWP 14P
799-601-7070 q T-adapter 1
(Not included in Kit No. 799-601-8000)
For SWP 16P (Kit No. is not regis-
799-601-7320 q T-adapter 1
tered)
799-601-7010 q T-adapter 1 For X 1P
799-601-7020 q T-adapter 1 For X 2P
799-601-7040 q T-adapter 1 For X 4P
799-601-7500 T-adapter assembly
Troubleshooting for
799-601-7520 q T-adapter 1 For AMP070 12P
machine
– 799-601-9000
wiring harness
or T-adapter assembly
799-601-9200
For DT 4P (Included in Kit Nos.
799-601-9040 q T-adapter 1
799-601-4101 and 799-601-4201, too)
799-601-9020 q T-adapter 1 For DT 2P
799-601-9030 q T-adapter 1 For DT 3P
799-601-9050 q T-adapter 1 For DT 6P
799-601-9110 q T-adapter 1 For DT 12P (gray)
799-601-9120 q T-adapter 1 For DT 12P (black)
799-601-9130 q T-adapter 1 For DT 12P (green)
799-601-9140 q T-adapter 1 For DT 12P (brown)
For HD36 24-21P
799-601-9270 q T-adapter 1 (Not include in Kit No. 799-601-9200)
(Include in Kit No. 799-601-9100, too)
799-601-9300 T-adapter assembly
799-601-9360 q T-adapter 1 For pump controller DRC26-24P
799-601-9350 q T-adapter 1 For pump controller DRC26-40P
799-601-7360 T-adapter 1 For 5P-relay (Kit No. is not registered)
799-601-7370 T-adapter 1 For 6P-relay (Kit No. is not registered)
For AMP 3P (Pressure sensor)
799-601-9420 T-adapter 1 (Included in Kit Nos. 799-601-4101
and 799-601-4201, too)

30-6 PC228US-8,PC228USLC-8
(01)
 Tool for testing, adjusting and troubleshooting
Tools for testing, adjusting, and troubleshooting

Note: Komatsu will not be held responsible for special tools manufactured according to these sketches.

-: Socket

F6 Adapter

PC228US-8,PC228USLC-8 30-6-1
(02)
Tool for testing, adjusting and troubleshooting
Tools for testing, adjusting, and troubleshooting

Note: Komatsu will not be held responsible for special tools manufactured according to these sketches.

P3 Adapter

30-6-2 PC228US-8,PC228USLC-8
(02)
 Engine and cooling system
Testing engine speed

Engine and cooling system 30-7

Testing engine speed 30-7

a Test the engine speed with the monitoring func- 3) Operate the left work equipment control lever
tion of the machine monitor. to relieve the arm circuit at the IN stroke end
a Measure the engine speed under the following and test the engine speed.
conditions.
q Engine coolant temperature: within operating 5. Testing speed (around rated speed) at
range 2-pomp relief + one-touch power maximizing
q Hydraulic oil temperature: within operating function
range 1) Start the engine and operate the arm cylinder
to the IN stroke end.
1. Preparation work 2) Set the fuel control dial to the full speed
Operate the machine monitor so that the engine (MAX) position and set the working mode to
speed can be monitored. the Power Mode (P).
a For the operating method of the machine 3) While operating the left work equipment
monitor, see “Special functions of machine control lever to relieve the arm circuit at the
monitor”. IN stroke end and pressing the one-touch
a Monitoring code: 01002 Engine speed power maximizing switch, test the engine
speed.
a The one-touch power maximizing function is
reset automatically in approximately 8.5 sec-
onds even if the switch is kept pressed. Ac-
cordingly, test the engine speed in that
preiod.
a You may check with the swing lock switch
ON (In this case, you do not need to operate
the power maximizing switch.)

6. Testing auto-deceleration speed

1) Start the engine, set the fuel control dial to
the high idle position (MAX), and set the
auto-decelerator to ON.
2) Set all the control levers and pedals for work
2. Testing low idle speed
equipment, swing, and travel to the neutral
1) Start the engine and set the fuel control dial
position and measure the engine speed
to the low idle (MIN) position.
when the auto-deceleration operates.
2) Set all the control levers and pedals for work
a The engine speed lowers to a certain level
equipmentl, swing, and travel to the neutral
approximately 5 seconds after all the levers
positon and test the engine speed.
and pedals are set to neutral. This level is the
auto-deceleration speed.
3. Testing high idle speed
1) Start the engine and set the fuel control dial
to the full speed (MAX) position.
2) Set the working mode in the Power Mode (P)
and set the auto-deceleration to OFF.
3) Set all control the levers and pedals for work
equipment, swing, and travel to the neutral
position and test the engine speed.

4. Testing 2-pomp relief speed

1) Start the engine and operate the arm cylinder
to the IN stroke end.
2) Set the fuel control dial to the full speed
(MAX) position and set the working mode to
the Power Mode (P).

PC228US-8,PC228USLC-8 30-7
(01)
Engine and cooling system
Testing intake air pressure (boost pressure)

Testing intake air pressure (boost pressure) 30-8

a Boost pressure can be checked with monitoring 3. Run the engine at middle or higher speed and
code (36500). bleed oil from the hose.
a Testing tools for intake air pressure (boost pres- a Insert the hose connector into the gauge half-
sure) way to open the self-seal on the hose side re-
Symbol Part number Part name peatedly, and the oil will be purged.
R 799-201-2202 Boost gauge kit a If Pm kit (A) is available, you may use the
k Stop the machine on the level ground and air-bleeding coupling (790-261-1130) in that
lower the work equipment to the ground. kit.
a Test the intake air pressure under the following a If oil is left in the hose, the gauge does not
conditions. work. Accordingly, be sure to purge the oil.
q Engine coolant temperature: within operating
range 4. Set the working mode to the Power Mode (P)
q Hydraulic oil temperature: within operating
and set swing lock switch to ON position.
range a If the swing lock switch is turned to the ON
position, the main relief valve is set for
1. Open the engine hood and remove intake air high-pressure relief.
pressure pickup plug (1) from the intake air
connector. 5. While running the engine at full speed, relieve
the arm circuit at the IN and measure the intake
air pressure.

2. Install nipple [1] of boost pressure gauge kit R

and connect it to gauge [2].
6. After finishing test remove the testing tools and
return the removed parts.

30-8 PC228US-8,PC228USLC-8
(01)
 Engine and cooling system
Testing exhaust gas color

Testing exhaust gas color 30-9

a Testing tools for exhaust gas color

Symbol Part number Part name
1 799-201-9001 Handy smoke checker
A Commercially
2 Smoke meter
available
k Stop the machine on the level ground and
lower the work equipment to the ground.
k Be careful not to touch any hot part when re-
moving or installing the testing tools.
a Test the exhaust gas color under the following
conditions.
q Engine coolant temperature: within operating
range
a If an air source and an electric power source are
not available in the field, use handy smoke 2) Connect the probe hose, plug of the acceler-
checker A1. When recording official data, use ator switch, and air hose to smoke meter A2.
smoke meter A2. a Limit the supplied air pressure to 1.5 MPa
{15 kg/cm2} or below.
1. Testing by using handy smoke checker A1
3) Connect the power cable to an AC recep-
1) Stick a sheet of filter paper to smoke checker
tacle.
A1.
a Check that the smoke meter power switch
2) Insert the exhaust gas intake pipe in exhaust
is in the OFF position, before connecting
pipe (1).
the power cable to the receptacle.
3) Start the engine and operate the handle of
4) Loosen the cap nut of the suction pump and
smoke checker A1 when the engine is accel-
place the filter paper.
erated suddenly and when it is running at
a Place the filter paper securely so that the
high idle so that the filter paper absorbs the
exhaust gas does not leak.
exhaust gas.
5) Turn on the power switch of smoke meter A2.
a Absorbing time: 1.4 ± 0.2 sec.

6) Start the engine and depress the accelerator

4) Remove the filter paper and compare it with
pedal of smoke meter A2 when the engine is
the attached scale for judgement.
accelerated suddenly and when it is running
5) After finishing test remove the testing tools
at high idle in order to collect the exhaust gas
and return the removed parts.
into the filter paper.
7) Put the polluted filter paper on non-polluted
2. Checking by using smoke meter A2
filter paper (more than 10 sheets) in the filter
1) Insert probe [1] of smoke meter A2 in the
paper holder, and read the indicated value.
outlet of the exhaust pipe (1) and fix it to the
8) After finishing test remove the testing tools
exhaust pipe by using a clip.
and return the removed parts.

PC228US-8,PC228USLC-8 30-9
(01)
Engine and cooling system
Testing and adjusting valve clearance

Testing and adjusting valve clearance 30-10

a Valve clearance testing and adjustment tools 3. Remove cylinder head cover (4).
Symbol Part number Part name a Remove aeration hose (5) also.
1 795-799-1131 Gear
B Commercially
2 Feeler gauge
available
k Stop the machine on the level ground and
lower the work equipment to the ground.
a Test and adjust the valve clearance under the
following condition.
q Engine coolant temperature: normal temper-
ature

1. Open the engine hood and remove plate (1).

4. Remove plug (6) located above the starting

motor and insert gear B1.

2. Remove breather connector (2) and muffler

cover plate (3) at the rear of the cylinder head
cover.
a Connector (2) has an O-ring, so take care not
to fall the O-ring.

30-10 PC228US-8,PC228USLC-8
(01)
 Engine and cooling system
Testing and adjusting valve clearance

5. Rotate the crankshaft in the normal direction by 7. Adjust the valve clearance according to the
using gear B1 to match wide slit (b) in the speed following procedure.
sensing ring with top (a) of the projection of the 1) While fixing adjustment screw (7), loosen
front cover. locknut (8).
a When seen from the air conditioner compres- 2) Insert feeler gauge B2 in the clearance
sor side, top (a) of the projection must be between rocker arm (9) and crosshead (10)
within the range of wide slit (b). and adjust the valve clearance with adjust-
a If top (a) of the projection and yellow paint of ment screw (7).
wide slit (b) can be checked, you may match a With the feeler gauge inserted, turn the
them. adjustment screw to a degree that you
k If this positioning is applied, note that the can move the feeler gauge with some re-
No. 1 or No. 6 cylinder is not at the com- sistance.
pression top dead center (TDC). 3) While fixing adjustment screw (7), tighten
locknut (8).
3 Locknut:
24 ± 4 Nm {2.45 ± 0.41 kgm}
a After tightening the locknut, check the
valve clearance again.

6. Check the movement of the rocker arm of the

No. 1 cylinder to determine the valve to be
adjusted.
a If you can move the rocker arm of air intake
valves (IN) with the hand by the valve clear-
ance, adjust the valves marked with Q in the 8. Rotate the crankshaft in the normal direction by
valve arrangement drawing. one turn according to step 5 and match wide slit
a If you can move the rocker arm of exhaust (b) with top (a) of the projection.
valves (EX) by hand by the valve clearance
amount, adjust the valves marked with q in 9. Adjust the clearances of the other valves
the valve arrangement drawing. according to steps 6 - 7.
a Valve arrangement drawing a If the valves marked with Q in the valve ar-
rangement drawing were adjusted in steps 6
and 7, adjust the valves marked with q.
a If the valves marked with q in the valve ar-
rangement drawing were adjusted in steps 6
- 7, adjust the other valves marked with Q.

10. After completing adjustment, remove the

adjusting tools and return the removed parts.
k Be sure to remove gear B1.
3 Cylinder head cover mounting nut:
24 ± 4 Nm {2.45 ± 0.41 kgm}

PC228US-8,PC228USLC-8 30-11
(01)
Engine and cooling system
Testing compression pressure

Testing compression pressure 30-12

a Testing tools for compression pressure 3. Disconnect high pressure fuel tube (3).
Symbol Part number Part name
1 795-502-1590 Compression gauge
2 795-799-6700 Puller
C
3 795-790-4410 Adapter
4 6754-11-3130 Gasket
k Stop the machine on the level ground and
lower the work equipment to the ground.
a Test the intake air pressure under the following
condition.
q Engine oil temperature: 40 - 60 °C
k When testing the compression pressure,
take care not to burn yourself on the exhaust
manifold, muffler, ect. or get caught in a rota-
tion part.
4. Loosen injector terminal nuts (4) and remove the
1. Open the engine hood and remove cylinder
harness terminals from the injector.
head cover (1).
a For the removal procedure, see "Adjusting
5. Set the cylinder to be tested to the compression
valve clearance".
top dead center.
a See "Adjusting valve clearance" for the bar-
2. Disconnect injector harness connector (2) and
ring method.
shift the harness.
6. Remove rocker arm assembly (5).

30-12 PC228US-8,PC228USLC-8
(01)
 Engine and cooling system
Testing compression pressure

7. Remove retainer (6) and remove fuel inlet 14. Adjust the valve clearances.
connector (7). a See "Adjusting valve clearance".

8. Remove holder (8).

9. Remove injector (9).

a Remove the injector by using tool C2 and uti-
lizing impacts of the slide hammer.
a Do not hold the upper part of the injector and
pry the injector out.

15. Operate the machine monitor to set the engine to

the cylinder cutout mode operation.
a See the section of "Special functions of ma-
chine monitor".
k If engine is not set to the cutout mode op-
eration and set all the cylinders to inac-
tivs, the engine starts during testing, and
that is dangerous. Be sure to set the en-
gine to the all-cylinder cutout mode oper-
ation.

16. Rotate the crankshaft by the starting motor and

test the compression pressure.
a Read the pressure gauge pointer when it is
stabilized.

17. After finishing testing, remove the testing tools

and return the removed parts.
a Install the injector and high-pressure fuel
tube according to the following procedure.
1) Set the injector to the cylinder head, while
10. Install gasket C4 to the end of adapter C3 and matching projection a with notch b.
insert them into the injector mounting bore. a Set the injector with the above mating po-
sition toward the fuel inlet connector
11. Fix adapter C3 by using the injector holder. pass-through.
a Tighten the holder mounting bolts alternately.
3 Injector holder mounting bolt :
8 ± 0.8 Nm {0.8 ± 0.08 kgm}

12. Connect gauge assembly C1 to adapter C3.

a If a small amount of oil is applied to the con-
necting portions of the adapter and gauge,
air will not leak easily.

13. Install rocker arm assembly (5).

3 Rocker arm assembly mounting bolt :
36 ± 5 Nm {3.67 ± 0.51 kgm}

PC228US-8,PC228USLC-8 30-13
(01)
Engine and cooling system
Testing compression pressure

2) Tighten injector holder mounting bolts (10) by 18. After installing the rocker arm assembly, adjust
3 – 4 turns. the valve clearance. For details, see "Adjusting
3) Set fuel inlet connector (7). valve clearance".
a Press it in until you feel the O-ring clicks 3 Rocker arm assembly mounting bolt :
in. 36 ± 5 Nm {3.67 ± 0.51 kgm}
4) Loosely install the inlet connector (7) by
using retainer (6). 19. Tighten the injector terminal nuts with the
3 Inlet connector retainer : following torque.
15 ± 5.0 Nm {1.5 ± 0.5 kgm} 3 Terminal nut :
5) Tighten injector holder mounting bolts (10) 1.5 ± 0.25 Nm {0.15 ± 0.025 kgm}
alternately. a Check that the injector wiring harness does
3 Injector holder mounting bolt : not interfere with the rocker arm.
8 ± 0.8 Nm {0.8 ± 0.08 kgm}
6) Tighten retainer (6) of the fuel inlet 20. Tighten the head cover mounting nuts to the
connector. following torque.
3 Inlet connector retainer : 3 Head cover mounting nut :
50 ± 5.0 Nm {5.1 ± 0.5 kgm} 24 ± 4 Nm {2.45 ± 0.41 kgm}

7) Tighten the high pressure fuel tube (3) sleeve

nuts from the head side first, and then the
common rail side.
3 Sleeve nut:
35 ± 3.5 Nm {3.6 ± 0.4 kgm}

30-14 PC228US-8,PC228USLC-8
(01)
 Engine and cooling system
Testing blowby pressure

Testing blowby pressure 30-15

a Testing tools for blowby pressure

Symbol Part number Part name
1 799-201-1504 Blowby checker
D
2 795-790-3300 Blowby testing tool
k Stop the machine on the level ground and
lower the work equipment to the ground.
a Test the blowby pressure under the following
conditions.
q Engine coolant temperature: within operating
range
q Hydraulic oil temperature: within operating
range

1. Install tool and adapter [1] of blowby checker D1

or blowby tool D2 to breather hose (1) and 4. After finishing test remove the testing tools and
connect gauge [2]. return the removed parts.

2. Start the engine, set the working mode to the

Power Mode (P), and turn the swing lock switch
ON.
a If the swing lock switch is turned ON, the
main relief valve is set for high-pressure re-
lief.

3. While running the engine at full speed, relieve

the arm circuit by arm IN operation and test the
blowby pressure.
a Read the gauge for blowby pressure when
the pointer is stabilized.

PC228US-8,PC228USLC-8 30-15
(01)
Engine and cooling system
Testing engine oil pressure

Testing engine oil pressure 30-16

a Testing tools for engine oil pressure 3. Start the engine and turn the auto-decelerator
Symbol Part number Part name OFF.
799-101-5002 Hydraulic tester
1
E 790-261-1204 Digital hydraulic tester 4. Test the oil pressure during low idle and high
2 799-401-2320 Hydraulic tester idle.
k Stop the machine on the level ground and
lower the work equipment to the ground.
a Measure the engine oil pressure under the fol-
lowing condition.
q Engine coolant temperature: within operating
range

1. Open the side cover of the pump room and

remove oil pressure pickup port plug (1) from the
engine oil filter head.

5. After finishing test remove the testing tools and

return the removed parts.

2. Install nipple [1] of hydraulic tester E1 and

connect hydraulic tester E2.

30-16 PC228US-8,PC228USLC-8
(01)
 Engine and cooling system
Handling fuel system parts

Handling fuel system parts 30-17

a Precautions in Inspection and Maintenance of

Fuel System
The common rail fuel injection system (CRI)
consists of more precise parts than the conven-
tional fuel injection pump and nozzles. If foreign
matter enters this system, it can cause a trouble.
During inspection and maintenance of the fuel
system, pay more attention to foreign matters
than in case of usual fuel injection system and
wash the system carefully with clean fuel if dusts
enter the system.
a Precautions for replacing fuel filter cartridge
Be sure to use the Komatsu genuine fuel filter
cartridge.
The common rail fuel injection system (CRI)
consists of more precise parts than the conven-
tional fuel injection pump and nozzles. It
employs a high-efficiency special filter to prevent
foreign matter from entering it. If a filter other
than the genuine one is used, the fuel system
may have a trouble. Accordingly, never use such
a filter.

PC228US-8,PC228USLC-8 30-17
(01)
Engine and cooling system
Releasing remaining pressure from fuel system

Releasing remaining pressure from fuel system 30-18

a Pressure is generated in the low-pressure circuit

and high-pressure circuit of the fuel system while
the engine is running.
Low-pressure circuit: Feed pump – Fuel main
filter – Supply pump
High-pressure circuit: Supply pump – Common
rail – Injector
a The pressure in both low-pressure circuit and
high-pressure circuit lowers to a safety level au-
tomatically 30 seconds after the engine is
stopped.
a Before the fuel circuit is checked and its parts
are removed, the remaining pressure in the fuel
circuit must be released completely. According-
ly, observe the following.
k Before checking the fuel system or removing
its parts, wait at least 30 seconds after stop-
ping the engine until the pressure remaining
in the fuel circuit is released. (Do not start the
work just after stopping the engine because
there is the remaining pressure.)

30-18 PC228US-8,PC228USLC-8
(01)
 Engine and cooling system
Testing fuel pressure

Testing fuel pressure 30-19

a Testing tools for fuel pressure

Symbol Part number Part name
799-101-5002 Hydraulic tester
1
790-261-1204 Digital hydraulic tester
Adapter
795-790-4430
2 (10 x 1.0 mm o R1/8)
6215-81-9710 O-ring
F
3 799-401-2320 Gauge
4 795-790-5110 Screw
5 799-201-2202 Boost gauge kit
Adapter
6 796T-501-1110
(12 x 1.5 mm o R1/8)
k Stop the machine on the level ground and
lower the work equipment to the ground.
a Test only the fuel pressure in the low-pressure
circuit from the feed pump through the fuel main 3) Run the engine at low idle and measure the
filter to the supply pump and the return circuit pressure in the low-pressure fuel circuit.
from the supply pump/common rail/injector to a If the pressure in the low-pressure fuel cir-
fuel tank. cuit is in the following range, it is normal.
k The pressure in the high-pressure circuit 0.5 – 1.3MPa
from the supply pump through the common At low idle
{5.1 – 13.3 kg/cm2}
rail to the injectors is very high, so it cannot 0.3 – 1.1MPa
be tested. During cranking
{3.1 – 11.3 kg/cm2}
k If the engine cannot be started, you
1. Testing pressure in low-pressure fuel circuit
1) Open the engine hood and remove fuel pres- may perform the measurement while
sure pickup port plug (1) from the fuel main rotating the engine by the starting mo-
filter head. tor. However, do not crank the engine
for more than 20 seconds continuous-
ly for protection of the starting motor.

2) Install adapter F2 and nipple [1] of the

hydraulic tester F1 and connect them to
gauge of boost gauge kit F3. 4) After finishing test remove the testing tools
a Use the oil pressure gauge of 2.5 MPa and return the removed parts.
3 Fuel pressure pickup port plug:
{25 kg/cm2}.
10 ± 2 Nm {1.0–0.2 kgm}

PC228US-8,PC228USLC-8 30-19
(01)
Engine and cooling system
Testing fuel pressure

2. Testing pressure in fuel return circuit

1) Open the engine hood and remove fuel pres-
sure pickup port plug (2) from the fuel return
block.

4) After finishing test remove the testing tools

and return the removed parts.
3 Fuel pressure pickup port plug:
24 ± 4 Nm {2.4 ± 0.4 kgm}
2) Install adapter F6 and nipple [1] of the
hydraulic tester F1 and connect them to 3. Testing pressure in negative pressure fuel
gauge F3. circuit
1) Open the engine hood and remove joint bolt
(2) of fuel hose (1) between the prefilter and
supply pump from supply pump (3).

3) Run the engine at low idle and measure the

pressure in the fuel return circuit.
a If the pressure in the fuel return circuit is
in the following range, it is normal.
At low idle Max. 0.02 MPa
During cranking {Max. 0.19 kg/cm2}
k If the engine cannot be started, you may
perform the measurement while rotating
the engine by the starting motor. However,
do not crank the engine continuously for
more than 20 seconds for protection of the
starting motor.

30-20 PC228US-8,PC228USLC-8
(01)
 Engine and cooling system
Testing fuel pressure

2) Using tool F4 instead of joint bolt (2), connect

fuel hose (1) to supply pump (3).
a When installing tool F4, install the seal
rings to both sides of eye joint of the fuel
hose.
3 Tool F4:
19.6 – 29.4 Nm {2.0 – 3.0 kgm}
3) Connect tool F5 to F4.

4) Run the engine and measure the circuit

negative pressure at high idle.
Standard negative pressure in circuit: Max.
-50.7 kPa {-380 mmHg}
5) If the negative pressure is higher than the
criteria, the fuel prefilter may be clogged. In
this case, replace the fuel prefilter and
measure the pressure again.
6) After finishing test, remove the testing instru-
ments and return the removed parts.
3 Joint bolt (2):
19.6 – 29.4 Nm {2.0 – 3.0 kgm}

PC228US-8,PC228USLC-8 30-21
(01)
Engine and cooling system
Cylinder cut-out test mode

Cylinder cut-out test mode 30-2

a The cylinder cut-out test mode operation means

to run the engine with the fuel injectors of one or
more cylinders disabled electrically to reduce the
number of active cylinders. The purposes and
effects of this operation are as follows.
1. This mode is used to find out a cylinder which
does not output power properly (or, combustion
in it is abnormal).
2. When a cylinder is cut out, if the engine speed
and output power do not change from the normal
operation (all-cylinder operation), that cylinder
has one or more defects.
The following problems can be considered:
Gas leakage through the cylinder head gas-
ket
Defective injection from injector
Defective piston or piston ring
Defective valve mechanism
Defective electrical system
3. The injector of each cylinder is separately
controlled electronically in the common rail fuel
injection system, so the cylinder cut-out test can
be performed easily by the simple operations of
the switches compared with the mechanical fuel
injection system. This allows to find out a defec-
tive cylinder easily.

30-22 PC228US-8,PC228USLC-8
(01)
 Engine and cooling system
No-injection cranking

No-injection cranking 30-23

a No-injection cranking means to crank the engine

by using the starting motor while all the injections
are stopped electrically. The purpose and effect
of this operation are as follows.
Before the engine is started after it or the
machine has been stored for a long period, the
no-injection cranking is performed to lubricate
the engine parts and protect them from seizure.

PC228US-8,PC228USLC-8 30-23
(01)
Engine and cooling system
Checking fuel delivery, return rate and leakage

Checking fuel delivery, return rate and leakage 30-24

a Tools for inspecting fuel delivery, return, and

leakage rates
Symbol Part number Part name
1 795-790-4700 Tester kit
2 795-790-6700 Adapter
6754-71-5340 Connector
3
6754-71-5350 Washer
Commercially
4 Measuring cylinder
available
G
Commercially
5 Stopwatch
available
Commercially
6 Hose (inner diameter 14 mm)
available
Commercially
7 Hose (inner diameter 8 mm)
available
a Prepare a container of approximately 20 l to re- 3) Crank the engine for 30 seconds and
ceive the fuel flowing out during the test. measure the discharged fuel by using
measuring cylinder G4.
k Stop the machine on the level ground and a Do not crank the engine for more than 30
lower the work equipment to the ground. seconds to protect the starting motor in
any case other than this test.
1. Testing supply pump delivery a If the supply pump delivery is in the fol-
1) Loosen clamp (2) of discharge tube (1) of the lowing standard range, it is normal.
supply pump and disconnect tube (1). At cranking speed (125
75 cc or more
rpm)
At cranking speed (150
90 cc or more
rpm)

2) Install test hose G6 to the nipple on the

discharge side of the supply pump.
a Tie the hose with a wire etc.
a Adjust the route of the test hose so that it
4) Remove the measuring tools after the
does not slacken and put its end in an
measurement and return the removed parts
container.
to their original position.
3 Tube sleeve nut:
35 ± 4 Nm {3.6 ± 0.4 kgm}
3 Clamp mounting bolt:
10 ± 2 Nm {1.0 ± 0.2 kgm}

2. Testing supply pump return rate

1) Open the engine hood and disconnect return
hose (1) of the supply pump.
a The return hose is connected by a quick
coupler.

30-24 PC228US-8,PC228USLC-8
(01)
 Engine and cooling system
Checking fuel delivery, return rate and leakage

5) After finishing test remove the testing tools

and return the removed parts.
a When measuring the leakage from the
pressure limiter or finishing the measure-
ment: Return the removed parts to their
original positions.
a If the return rate from the injector is mea-
sured next, keep the engine as it is and
put the test hose end in the container.

3. Testing leakage from pressure limiter

1) Open the engine hood and disconnect return
hose (2) of the pressure limiter.
2) Install connector G3 and cap nut [1] of tester a Keep the seal washer attached to the
kit G1 to the return hose to stop the fuel from connector bolt.
flowing out.
3) Connect test hose [2] of tester kit G1 to the
supply pump.
a Adjust the route of the test hose so that it
does not slacken and put its end in an
container.

2) Install removed connector bolt (3) and cap

nut [1] of tester kit G1 to the return hose to
stop the fuel from flowing out.
3) Install connector G3 to the common rail and
connect test hose [2] of tester kit G1.
a Adjust the route of the test hose so that it
4) While running the engine at low idle, does not slacken and put its end in an
measure the return rate in 1 minute by using container.
measuring cylinder G4.
a If the return rate from the supply pump is
in the following range, it is normal.
At low idle Max. 1,000 cc
During cranking Max. 140 cc

4) While running the engine at low idle,

measure the leakage in 1 minute by using
measuring cylinder G4.
a If the leakage from the pressure limiter is
in the following range, it is normal.

PC228US-8,PC228USLC-8 30-25
(01)
Engine and cooling system
Checking fuel delivery, return rate and leakage

0 cc 3) Install connector bolt [3] of adapter G2

At low idle
(No leakage) instead of the removed connector bolt and
connect test hose [4].
a Adjust the route of the test hose so that it
does not slacken and put its end in an
container.

5) After finishing test remove the testing tools

and return the removed parts.
3 Joint bolt:
24 ± 4 Nm {2.4 ± 0.4 kgm}
4) While running the engine at low idle,
measure the return rate in 1 minute by using
4. Testing return rate from injector
measuring cylinder G4.
a The fuel return rate from the injector is tested
a If the return rate from the injector is in the
while the return hose of the pressure limiter is
following range, it is normal.
connected. Accordingly, before testing the
At low idle Max. 180 cc
return rate from the injector, check that the
During cranking 90 cc or less
leakage from the pressure limiter is normal.
1) Referring to “Measuring return rate from k If the engine cannot be started, you
supply pump”, set the supply pump for test. may perform the measurement while
a The injector return hose of the cylinder rotating the engine by the starting mo-
head is difficult to disconnect, so work on tor. However, do not crank the engine
the return block side. for more than 30 seconds continuous-
k The fuel returning from the supply ly for protection of the starting motor.
pump flows out during measurement
of the return rate from the injector.
Keep the test hose end in the contain-
er.
2) Remove connector bolt (4) of the return
block.
a Keep the seal washer installed to the re-
turn hose.

5) After finishing test remove the testing tools

and return the removed parts.
3 Joint bolt:
24 ± 4 Nm {2.4 ± 0.4 kgm}

30-26 PC228US-8,PC228USLC-8
(01)
 Engine and cooling system
Bleeding air from fuel circuit

Bleeding air from fuel circuit 30-27

a If fuel is used up or if a fuel circuit part is removed

and installed, bleed air from the fuel circuit ac-
cording to the following procedure.
k Stop the machine on the level ground and
lower the work equipment to the ground.

1. Fill fuel in the fuel tank to full.

a Add fuel until float in the sight gauge rises to
the maximum position.

2. Open the side cover of the pump room.

3. Loosen knob (1) of the feed pump and pull it out,

and then operate it forward and backward.
a Operate the knob until it becomes heavy.
a The plug at the top of the fuel main filter head
does not need to be removed.

4. After bleeding air, push in and tighten knob (1).

PC228US-8,PC228USLC-8 30-27
(01)
Engine and cooling system
Testing fuel circuit for leakage

Testing fuel circuit for leakage 30-28

k Very high pressure is generated in the a Check mainly around the high-pressure cir-
high-pressure circuit of the fuel system. If cuit parts coated with the color checker for
fuel leaks while the engine is running, it pres- fuel leakage.
ents a serious danger that could result in a a If any fuel leakage is detected, repair it and
fire. check again from step 1.
After checking the fuel system or removing a If no fuel leakage is detected, check is com-
its parts, check it for fuel leakage according pleted.
to the following procedure.
k Stop the machine on the level ground and
lower the work equipment to the ground.
a Clean and degrease the engine and the parts
around it in advance so that you can check it
easily for fuel leakage.

1. Spray color checker (fuel leak detector) over the

fuel supply pump, common rail, fuel injectors,
and joints of the high-pressure fuel piping.

2. Start the engine, keep its speed at 1,000 rpm or

below, and stop it when its speed is stabilized.

3. Stop the engine and check the fuel piping and

devices for fuel leakage.
a Check mainly around the high-pressure cir-
cuit parts coated with the color checker for
fuel leakage.
a If any fuel leakage is detected, repair it and
check again from step 1.

4. Run the engine at low idle.

5. Stop the engine and check the fuel piping and

devices for fuel leakage.
a Check mainly around the high-pressure cir-
cuit parts coated with the color checker for
fuel leakage.
a If any fuel leakage is detected, repair it and
check again from step 1.

6. Run the engine at high idle.

7. Stop the engine and check the fuel piping and

devices for fuel leakage.
a Check mainly around the high-pressure cir-
cuit parts coated with the color checker for
fuel leakage.
a If any fuel leakage is detected, repair it and
check again from step 1.

8. Run the engine at high idle and load it.

a Relieve the arm circuit at the IN stroke end.

9. Stop the engine and check the fuel piping and

devices for fuel leakage.

30-28 PC228US-8,PC228USLC-8
(01)
 Engine and cooling system
Testing and adjusting air conditioner compressor belt tension

Testing and adjusting air conditioner compressor belt tension 30-29

k Stop the machine on the level ground and Adjust 30-29

lower the work equipment to the ground. a If the belt deflection amount is not proper, adjust
it in the following manner.
Testing 30-29
1. Open the engine hood and remove plate (1) and 1. Loosen bolts (3) and (4).
belt guard (2) at the top of the air conditioner
compressor. 2. Move compressor (5) and bracket (6) together to
adjust the belt tension.

3. After positioning compressor (5), tighten bolts

(3) and (4).
a Check each pulley for breakage, wear of the
V-groove, and contact of the V-belt and
V-groove.
a If the V-belt is elongated exceeding the ad-
justment allowance or it has a cut or a crack,
replace it.
a If the belt is replaced, adjust and check the
tension again after operating the machine for
one hour.
a After tightening the bolts, check the belt ten-
2. Press the middle point of the belt between the sion again according to the above procedure.
fan pulley and compressor pulley with a thumb
and measure deflection (a).
q Belt pressing force: 60 N {6.2 kg}
q Deflection of belt: 6.6 - 8.9 mm

4. After finishing checking and adjusting, return the

removed parts.

PC228US-8,PC228USLC-8 30-29
(01)
Engine and cooling system
Replacing fan belt

Replacing fan belt 30-30

a The auto-tensioner is provided for the fan belt.

Thus, testing and adjustment of the belt is usual-
ly not necessary.
a Disconnect the air conditioner compressor belt
before replacing the fan belt.

1. Insert a wrench to the portion A (width across

flats: 12.7 mm) of the tensioner (3), and rotate it
to the opposite to the winding-up direction to
decrease the fan belt (2) tension.
k Make sure that the wrench is secured at
the portion (A) of the tensioner assembly
(3) before rotating it. (The spring of the
tensioner assembly (3) is strong. If the
wrench is applied improperly, the wrench
may accidentally come off while being ro-
tated and it is extremely dangerous.)
k After removing the fan belt (2), return the
tensioner assembly (3) slowly with care.
k Be careful not to get your fingers caught
between the pulley and fan belt (2) during
work.

2. Replace the fan belt (2).

q Check each pulley for breakage and crack.

30-30 PC228US-8,PC228USLC-8
(01)
 Undercarriage and frame
Testing swing circle bearing clearance

Undercarriage and frame 30-31

Testing swing circle bearing clearance 30-31

a Swing circle bearing clearance measurement 4. Set the arm almost perpendicular to the ground
tools and lower the boom until the front part of the
Symbol Part number Part name tracks float by 150 - 200 mm.
a At this time the front of the upper structure
Commercially
H Dial gauge rises and the rear lowers.
available
a Follow the steps explained below when measur- 5. Under this condition, read dial gauge H.
ing clearance in the swing circle bearing on the a The value indicated by dial gauge H is the
actual machine. clearance of the bearing.
k Be careful not to put a hand or foot under the
undercarriage, while taking measurement.

1. Fix dial gauge H to outer race (1) or inner race

(2) of the swing circle and apply the probe to the
end face of inner race (2) or outer race (1).
a Set dial gauge H to the front or rear of the
machine.

6. Return the machine to the condition of step 2

and check that dial gauge H indicates 0.
a If zero value is not indicated, repeat the steps
3 through 5.

2. Set the work equipment to the maximum reach

position and set the bucket tip to the height of the
underside of the revolving frame.
a At this time the front of the upper structure
lowers and the rear rises.

3. Set dial gauge H to the 0 point.

PC228US-8,PC228USLC-8 30-31
(01)
Undercarriage and frame
Checking and adjusting track tension

Checking and adjusting track tension 30-32

Testing 30-32 a You may add grease until dimension (b)

1. Run the engine at low idle and move the between the idler guide and track frame
machine forward by the length of track on end becomes 0 mm. If the tension is still
ground, and then stop slowly. low, the pins and bushings are worn ex-
cessively. In this case, reverse or replace
2. Place square bar [1] on the track shoes between the pins and bushings.
the idler and the 1st carrier roller.
a As the square bar [1], use an angle steel, etc.
which deflects less.

3. Measure maximum clearance (a) between

square bar [1] and track shoe.
q Standard max. clearance (a): 10 - 30 mm

2. Decreasing tension
1) Loosen valve (2) to discharge grease, and
then tighten it.
k Do not loosen the valve more than 1
turn. Otherwise, the valve may jump
out because of the high-pressure
grease inside.
Adjust 30-32 2) To check that the tension is proper, run the
a If the track tension is improper, adjust it accord- engine at low idle and move the machine
ing to the following procedure. forward by the length of track on ground, then
stop slowly.
1. Increasing tension 3) After adjusting, check the track tension again
1) Add grease through grease fitting (1) by according to the above procedure.
using a grease gun.
2) To check that the tension is proper, run the
engine at low idle and move the machine
forward by the length of track on ground, then
stop slowly.
3) After adjusting, check the track tension again
according to the above procedure.

30-32 PC228US-8,PC228USLC-8
(01)
 Hydraulic system
Testing and adjusting oil pressure in work equipment, swing and travel circuits

Hydraulic system 30-3

Testing and adjusting oil pressure in work equipment, swing and travel
circuits 30-3

a Instruments for inspecting and adjusting oil pres-

sure in work equipment, swing, and travel cir-
cuits
Symbol Part number Part name
799-101-5002 Hydraulic tester
1
790-261-1204 Digital hydraulic tester
J
799-101-5220 Nipple (10 x 1.25 mm)
2
07002-11023 O-ring

k Stop the machine on the level ground and

lower the work equipment to the ground.
Then, release the remaining pressure from
the hydraulic circuit. For details, see “Re- 2) Install nipples J2 and connect it to oil pres-
leasing remaining pressure from hydraulic sure gauges [1] of hydraulic tester J1.
circuit”. a Use an oil pressure gauge with the ca-
pacity of 60 MPa {600 kg/cm2}.
Testing 30-3
a The oil pressure in the work equipment, swing,
and travel circuits (pump discharge pressure)
can be checked also by using monitoring func-
tion of the machine monitor. (For details, see
"Special functions of machine monitor").
q Monitoring code: 01100 F pump pressure
q Monitoring code: 01101 R pump pressure
a Measure the oil pressure in the work equipment,
swing, and travel circuits under the following
condition.
q Hydraulic oil temperature: within operating
range

1. Preparation work
k Lower the work equipment to the ground 3) Start the engine and keep it running until the
and stop the engine. Operate the control hydraulic oil temperature rises to the oper-
lever several times to release the remain- ating range.
ing pressure in the piping, and loosen the
oil filler cap of the hydraulic tank gradual-
ly to release the internal pressure of the
tank.
1) Open the side cover of the pump room,
remove the undercover of the pump, and
remove oil pressure pickup port plugs (1) and
(2).
q (1): Rear pump discharge pressure pick-
up port plug
q (2): The front pump oil pressure pickup
port plug is installed to the delivery block
that is located at the section below the fig-
ure (not shown in the figure due to limita-
tion of the camera angle).

PC228US-8,PC228USLC-8 30-33
(01)
Hydraulic system
Testing and adjusting oil pressure in work equipment, swing and travel circuits

2. Combination of pump, actuator, and valve 3. Measuring unload pressure

a When the oil flow from the pumps is divided, 1) Start the engine, set the working mode to the
the front pump and rear pump actuate each Power Mode (P), and turn the auto-deceler-
actuator independently as shown on the ta- ator OFF.
ble. Note that the relieved valve varies de- 2) Set all control levers and pedals to the
pending on the actuator. neutral and measure the oil pressure while
a When the work equipment circuit or swing cir- running the engine at full speed.
cuit is relieved singly, the oil flows from the a Hydraulic oil pressure when the unload
pumps are merged. When the travel circuit is valve unloads is displayed.
relieved singly, the oil flows from the pumps
are divided.
a The actuators in the table are arranged in the
order that the control valves are viewed from
the front of the machine. (As for the service
valve, the table shows an example in which
an attachment is installed.)
Pump Actuator Valve relieved
(R unload valve) (R main relief valve)
Service Safety valve
Rear Bucket R main relief valve
Left travel R main relief valve
Boom R main relief valve 4. Testing work equipment relief pressure
(Pump merge-divider valve) (Travel junction valve)
1) Start the engine and move the cylinder to be
measured to the stroke end.
(Self-pressure reducing valve) 2) Set the working mode to the Power Mode (P).
Swing Swing motor safety valve 3) Measure hydraulic oil pressure when the
Front Right cylinder is relieved while the engine is
F main relief valve running at full speed.
travel
Arm F main relief valve
a The pressure at the time when the main
relief valve is relieved is displayed.
(F unload valve) (F main relief valve) a If the one-touch power maximizing switch
(Centralized safety valve) (Back pressure valve) is not pressed, the low relief pressure is
obtained. If the former is pressed, the
high relief pressure is obtained.
a If the swing lock switch is set to the ON
position, the 2-stage relief valve is kept
ON and the high relief pressure is ob-
tained. Therefore, keep the swing lock
switch at the OFF position.

30-34 PC228US-8,PC228USLC-8
(01)
 Hydraulic system
Testing and adjusting oil pressure in work equipment, swing and travel circuits

5. Testing swing relief pressure 7. Work after finishing testing

1) Start the engine, set the working mode to the After finishing test remove the testing tools and
Power Mode (P), and turn the swing lock return the removed parts.
switch ON. 3 Oil pressure pickup port plug:
2) Measure hydraulic oil pressure when the 20 – 27 Nm {2.0 – 2.8 kgm}
engine is running at full speed and the swing Adjust 30-35
circuit is relieved. a The unload valve cannot be adjusted.
a Hydraulic oil pressure when the swing 1. Adjusting work equipment and travel relief
motor safety valve is relieved is dis- pressure
played. a If the relief pressure of the work equipment
a The swing motor relief pressure is lower circuit and travel circuit is abnormal, adjust
than that of the main relief valve. main relief valves (3) and (4) of the main re-
lief valve according to the following proce-
6. Testing travel relief pressure dure.
1) Run the engine and lock the travel mecha- q (3): Front main relief valve
nism. q (4): Rear main relief valve
k Put pin [2] between the sprocket and a When adjusting the main relief valve on the
track frame to lock the travel mecha- front pump, remove the cover under the con-
nism securely. trol valve.
a When adjusting the main relief valve for the
rear pump circuit, remove the fuel tank cover.
a Adjust only the low relief pressure of the main
relief valve. If the low relief pressure is adjust-
ed, the high relief pressure is set automati-
cally.
a The low relief pressure is the pressure under
the following condition: the 2-stage relief so-
lenoid valve is not enerhized selenid on the
and the pilot pressure is not applied to the se-
lector port.

2) Set the working mode to the Power Mode (P).

3) Measure the pressure when the engine is
running at full speed and the travel circuit is
relieved.
k Before operating the travel lever (ped-
al), check the pin position and locked
direction of the travel again.
a The pressure at the time when the main
relief valve is relieved is displayed. The
travel circuit is always relieved at high
pressure. 1) Disconnect the pilot hose.
2) While fixing holder (6), loosen locknut (7).
3) Turn holder (6) to adjust the pressure.
a If the holder is
q Turned to the right, the pressure rises.
q Turned to the left, the pressure low-
ers.
a Pressure of adjustment per turn of holder:
Approx. 20.5 MPa {Approx. 209 kg/cm2}
4) While fixing holder (6), tighten locknut (7).
3 Lock nut:
49 – 58.8 Nm {5 – 6 kgm}

PC228US-8,PC228USLC-8 30-35
(01)
Hydraulic system
Testing and adjusting oil pressure in work equipment, swing and travel circuits

2) While fixing adjustment screw (13), loosen

locknut (14).
3) Adjust the pressure by rotating adjustment
screw (13).
a Turn the adjustment screw
q Turned to the right, the pressure rises.
q Turned to the left, the pressure low-
ers.
a Quantity of pressure adjustment per turn
of adjustment screw:
6.71 MPa {68.4 kg/m2}
4) While fixing adjustment screw (13), tighten
locknut (14).
3 Lock nut:

5) Connect the pilot hose. 78–103 Nm {8.0–10.5 kgm}

6) After finishing adjustment, check the
hydraulic pressure again according to the
above measurement procedure.

2. Adjusting swing relief pressure

a If the swing relief pressure is improper, adjust
swing motor safety valve (12) according to
the following procedure.
1) Preparation work
Remove step plates (8) and (9) and plates
(10) and (11).

5) After finishing adjustment, check the

hydraulic pressure again according to the
above measurement procedure.

30-36 PC228US-8,PC228USLC-8
(01)
 Hydraulic system
Testing control circuit source pressure

Testing control circuit source pressure 30-37

a Testing tools for control circuit pressure 4. Measure hydraulic oil pressure, when the engine
Symbol Part number Part name is running at full speed and all the control levers
are set to the neutal.
799-101-5002 Hydraulic tester
1
790-261-1204 Digital hydraulic tester
K
799-101-5220 Nipple (10 x 1.25 mm)
2
07002-11023 O-ring

k Lower the work equipment to the ground and

stop the engine. Operate the control lever
several times to release the remaining pres-
sure in the piping, and loosen the oil filler cap
of the hydraulic tank gradually to release the
internal pressure of the tank.

1. Remove oil pressure pickup port plug (1).

5. After finishing test remove the testing tools and
return the removed parts.
a The control circuit source pressure may be
tested at oil pressure pickup port plug (2) on
the hydraulic pump.

2. Install nipple K2 and connect it to oil pressure

gauges [1] of hydraulic tester K1.
a Use the oil pressure gauge of 6.0 MPa
{60 kg/cm2}.
a Do not adjust the relief valve for control circuit
source pressure.

3. Start the engine and keep it running until the

hydraulic oil temperature rises to the operating
range.

PC228US-8,PC228USLC-8 30-37
(01)
Hydraulic system
Testing and adjusting oil pressure in pump PC control circuit

Testing and adjusting oil pressure in pump PC control circuit 30-38

a Testing and adjusting tools for pump PC control 2) Install nipples L2 and connect it to oil pres-
circuit oil pressure sure gauges [1] of hydraulic tester L1.
Symbol Part number Part name a Use an oil pressure gauge with the ca-
pacity of 60 MPa {600 kg/cm2}.
799-101-5002 Hydraulic tester
1 q The figure shows the pump discharge
790-261-1204 Digital hydraulic tester pressure side.
L
799-101-5220 Nipple (10 x 1.25 mm)
2
07002-11023 O-ring

Testing 30-38
a Before testing the oil pressure in the pump PC
control circuit, check that the oil pressure in the
work equipment, swing, and travel circuits and
the source pressure of the control circuit are
proper.
k Lower the work equipment to the ground and
stop the engine. Operate the control lever
several times to release the remaining pres-
sure in the piping, and loosen the oil filler cap
of the hydraulic tank gradually to release the q The figure shows the PC valve output
internal pressure of the tank. pressure side.

1. Testing PC valve output pressure (servo

piston inlet pressure)
a Measure the PC valve output pressure (ser-
vo piston inlet pressure) and pump discharge
pressure simultaneously and compare them.
1) Remove pressure pickup port plugs (1), (2),
(3) and (4).
q (1): Front pump delivery pressure pickup
port plug
q (2): Rear pump delivery pressure pickup
port plug
q (3):Front PC valve output pressure pickup
port plug
q (4): Output pressure pickup port plug of
rear PC valve
The pressure pickup port plug of the deliver
block under the pump may be used to
measure the discharge pressure.

30-38 PC228US-8,PC228USLC-8
(01)
 Hydraulic system
Testing and adjusting oil pressure in pump PC control circuit

3) Start the engine and keep it running until the

hydraulic oil temperature rises to the oper-
ating range.

2) Install nipples L2 and connect it to oil pres-

sure gauges [1] of hydraulic tester L1.
a Use the oil pressure gauge of 6.0 MPa
{60 kg/cm2}.
4) Measure the pump discharge pressure and
PC valve output pressure (pressure at servo
piston inlet) at the same time after setting the
machine to the following conditions with the
engine running at full speed.
q Working mode: P-mode
q Swing lock switch: ON
(Turning 2-stage relief ON switches to
high-pressure relief)
q Work equipment, swing and travel: Arm
IN relief
a Judgment method:
If the ratio between the pump discharge
pressure and the PC valve output pres-
sure (servo piston output pressure)
reaches the following value, the pres- 3) Start the engine and keep it running until the
sures are proper. hydraulic oil temperature rises to the oper-
Measured oil Ratio of oil pres-
ating range.
pressure sures
Pump discharge
1
pressure
PC valve output
Approx. 0.6 (3/5)
pressure

a If the PC valve or the servo piston is de-

fective, the PC valve output pressure
(servo piston output pressure) comes to
the same pressure as the pump dis-
charge pressure, or almost 0.

2. Testing PC-EPC valve output pressure

1) Open the side cover of the pump room and
remove oil pressure pickup port plugs (5) and
(6).
q (5): output pressure pickup port plug of
front PC-EPC valve
q (6): output pressure pickup port plug of
rear PC-EPC valve

PC228US-8,PC228USLC-8 30-39
(01)
Hydraulic system
Testing and adjusting oil pressure in pump PC control circuit

4) Measure the hydraulic oil pressure with all Adjust 30-40

the control levers set to the neutral and the a If either of the following problem occurs and the
engine running at full speed and at low idle. PC valve seems to be defective, adjust PC
a You can assume that the PC-EPC valve valves (7) and (8) according to the procedure
output pressure is normal when the fol- shown below.
lowing changes are observed. q As the work load increases, the engine

Engine Control lever Pressure speed decreases remarkably.

q The engine speed is normal but the work
Low 2.9 MPa
equipment speed is low.
idle {30 kg/cm2} q (7): Front pump PC valve
Neutral
Full 0 MPa q (8): Rear pump PC valve
speed {0 kg/cm2} a The width across flats of the PC valve locknut is
13 mm and that (inside width) of the adjusting
5) After finishing test remove the testing tools
screw is 4 mm.
and return the removed parts.
Do not turn any locknuts and adjustment screws
other than the above because doing so affects
the hydraulic pump performance.

1. Loosen locknut (9).

a Before loosening the locknut, make a match
mark on the end face of the adjustment screw
to indicate the original position of the adjust-
ment screw (so that you can return the ad-
justment screw to the original position if you
turn it in the opposite direction).

2. Adjust the pressure by rotating adjustment

screw (10) to the right or left.
a Turn the adjustment screw
q If the work equipment speed is low, turn it
to the right.
(The pump absorption torque will
increase.)
q If the engine speed lowers when the work
load increases, turn it to the right. (The
pump absorption torque will decrease.)

30-40 PC228US-8,PC228USLC-8
(01)
 Hydraulic system
Testing and adjusting oil pressure in pump PC control circuit

3. Tighten lock nut (9).

3 Lock nut:
27.5 – 34.3 Nm {2.8 – 3.5 kgm}

4. After the adjustment, make sure that the PC

valve output pressure (servo piston inlet pres-
sure) is normal according to the measurement
steps explained earlier.

PC228US-8,PC228USLC-8 30-41
(01)
Hydraulic system
Testing and adjusting oil pressure in pump LS control circuit

Testing and adjusting oil pressure in pump LS control circuit 30-42

a Testing and adjusting tools for pump LS control

circuit oil pressure
Symbol Part number Part name
799-101-5002 Hydraulic tester
1
790-261-1204 Digital hydraulic tester
M 790-101-5220 Nipple (10 x 1.25 mm)
2
07002-11023 O-ring
3 799-401-2701 Differential pressure gauge

Testing 30-42
a Before testing the oil pressure in the pump LS
control circuit, check that the oil pressure in the
2) Install nipple M2 and connect it to oil pres-
work equipment, swing, and travel circuits and
sure gauge [1] of hydraulic tester M1.
the source pressure of the control circuit are
a Use an oil pressure gauge with the ca-
proper.
k Lower the work equipment to the ground and
pacity of 60 MPa {600 kg/cm2}.
q The figure shows the pump discharge
stop the engine. Operate the control lever
several times to release the remaining pres- pressure side.
sure in the piping, and loosen the oil filler cap
of the hydraulic tank gradually to release the
internal pressure of the tank.

1. Testing LS valve output pressure (servo

piston inlet pressure)
a Measure the LS valve output pressure (servo
piston inlet pressure) and the pump dis-
charge pressure simultaneously and com-
pare them.
1) Remove pressure pickup port plugs (1), (2),
(3) and (4).
q (1): Front pump delivery pressure pickup
port plug
q (2): Rear pump delivery pressure pickup q The figure shows the LS valve output
port plug side.
q (3):Front PC valve output pressure pickup
port plug
q (4): Rear PC valve pressure pickup port
plug
The pressure pickup port plug of the deliver
block under the pump may be used to
measure the discharge pressure.

30-42 PC228US-8,PC228USLC-8
(01)
 Hydraulic system
Testing and adjusting oil pressure in pump LS control circuit

3) Run the engine and raise the hydraulic oil 2. Testing LS differential pressure
temperature to the operating range and raise a To obtain the LS differential pressure, mea-
the track to be tested off the ground by using sure the pump discharge pressure and LS
the work equipment. pressure (actuator load pressure) at the
q When measuring front circuit: Right track same time and calculate the difference.
q When measuring rear circuit: Left track 1) Open the side cover of the pump room,
k Provide a working area of sufficient remove the undercover of the pump, and
space, as the raised track must be run remove pressure pickup port plugs (1), (2),
idle. (5), and (6).
q (1): Front pump delivery pressure pickup
port plug
q (2): Rear pump delivery pressure pickup
port plug

4) Measure the pump discharge pressure and

PC valve output pressure (pressure at servo
piston inlet) at the same time after setting the
machine to the following conditions with the
engine running at full speed. q (5): Front pump LS pressure pickup port
q Working mode: P-mode plug
q Work equipment, swing and travel: When q (6): Rear pump LS pressure pickup port
all levers are at neutral and when a travel plug
lever is at half stroke (to run a track idle).
a Run the raised track idle, paying enough
attention to the surroundings for safety.
a Measurement conditions and judgment
method:
If the ratio between the pump discharge
pressure and LS valve output pressure
(servo piston input pressure) reaches the
following value, the pressures are correct.
Position of levers and pedals
All levers and Travel lever set
pedals are at at half stroke
neutral (Track runs idle)
Pump
Measured oil pressure

Measure value
dis-
is regarded as
charge
1.
pressure Almost same
pressure
LS valve
Approx. 3/5 of
out put
the above
pressure

5) After finishing test remove the testing tools

and return the removed parts.

PC228US-8,PC228USLC-8 30-43
(01)
Hydraulic system
Testing and adjusting oil pressure in pump LS control circuit

2) Install nipple M2 and connect it to the differ-

ential pressure gauge M3 or hydraulic tester
M1.
a When using differential pressure gauge:
Connect the pump delivery pressure hose
to the high pressure side (back side) and
connect the LS pressure hose to the low
pressure side (lower side).
The differential pressure gauge needs 12
V DC power, so connect a battery to it.
a When using the oil pressure gauge:
Use the oil pressure gauge of 60 MPa
{600 kg/cm2} with the graduation by 1
MPa {10 kg/cm2}.
The differential pressure is approximately 4) While running the engine at full speed under
4 MPa {40 kg/cm2} at the maximum, so the following condition, measure the pump
perform the measurement by using a discharge pressure and LS pressure (actu-
gauge alternately. ator load pressure) simultaneously.
q Working mode: P-mode
q The figure shows the pump discharge
q Travel speed: Hi
pressure side.
q Work equipment, swing and travel: When
all levers are at neutral and when travel
lever is at half stroke (to run a track idle)
a Run the raised track idle, paying enough
attention to the surroundings for safety.
a Calculating LS differential pressure
(when the pressure gauge is used):
LS differential pressure = pump outlet
port pressure – LS pressure
a If the LS differential pressure is as fol-
lows, it is normal.
LS differential
Operation of lever
pressure
Unload pressure
When all control levers in
(See standard
neutral
q The figure shows the LS pressure side. value table)
Standard LS dif-
When a travel lever is moved ferential pres-
halfway (Raised track runs sure
idle) (See standard
value table)

5) After finishing test remove the testing tools

and return the removed parts.

3) Run the engine and raise the hydraulic oil

temperature to the operating range and raise
up the track to be tested.
q When measuring front circuit: right track
q When measuring rear circuit: left track
k Provide a working area of sufficient
space, as the raised track must be run
idle.

30-44 PC228US-8,PC228USLC-8
(01)
 Hydraulic system
Testing and adjusting oil pressure in pump LS control circuit

3. Testing LS-EPC valve output pressure

1) Remove pressure pickup port plug (7).

5) After finishing test remove the testing tools

2) Install nipple M2 and connect it to oil pres- and return the removed parts.
sure gauge [1] of hydraulic tester M1. Adjust 30-45
a Use the oil pressure gauge of 6.0 MPa a If the LS differential pressure is improper, adjust
{60 kg/cm2}. LS valves (8) and (9) according to the following
procedure.
q (8): Front pump LS valve
q (9): Rear pump LS valve

3) Start the engine and keep it running until the

hydraulic oil temperature rises to the oper-
ating range.

4) Measure the oil pressure when the engine is 1. While fixing adjusting screw (10), loosen locknut
running at full speed and the travel speed (11).
switch and travel control lever are operated.
a If the LS-EPC valve output pressure 2. Turn adjusting screw (10) to adjust the pressure.
changes as follows, it is normal. a Turn the adjustment screw
q Turned to the right, the differential pres-
Travel speed Travel lever Hydraulic
sure rises.
Approx. 2.9 q Turned to the left, the differential pressure
MPa
Low Neutral lowers.
{Approx.
a Amount of adjustment (LS differential pres-
30 kg/cm2} sure) per turn of adjustment screw:
Fine travel lever 0 MPa Quantity of pressure adjustment (LS differen-
High
control (Note) {0 kg/cm2}
tial pressure): 1.1 MPa {10.8 kg/cm2}
Note: Operate the travel lever to a degree
that the PPC oil pressure switch is just 3. While fixing adjustment screw (10), tighten
turned on (position before the tracks start locknut (11).
moving). 3 Lock nut:
49 – 64 Nm {5 – 7 kgm}

PC228US-8,PC228USLC-8 30-45
(01)
Hydraulic system
Testing and adjusting oil pressure in pump LS control circuit

4. After finishing adjustment, check that the LS

valve output pressure (servo piston inlet pres-
sure) is correct according to the testing proce-
dure described above.

30-46 PC228US-8,PC228USLC-8
(01)
 Hydraulic system
Testing solenoid valve output pressure

Testing solenoid valve output pressure 30-47

a Tools for measuring solenoid valve outlet pres- a Use the oil pressure gauge of 6.0 MPa
sure {60 kg/cm2}.
Symbol Part number Part name a The figure shows the testing tools installed to
the outlet hose of PPC lock solenoid valve.
799-101-5002 Hydraulic tester
1
790-261-1204 Digital hydraulic tester
N
799-401-3100 Adapter (Size: 02)
2
02896-11008 O-ring

k Lower the work equipment to the ground and

stop the engine. Operate the control lever
several times to release the remaining pres-
sure in the piping, and loosen the oil filler cap
of the hydraulic tank gradually to release the
internal pressure of the tank.
a Check that the control circuit basic oil pressure is
correct before testing the solenoid valve outlet
pressure.
a Measure the solenoid valve outlet pressure un- 4. Start the engine.
der the following conditions:
q Hydraulic oil temperature: within operating
range

1. Disconnect outlet hoses (1) to (6) of the solenoid

valves to be measured.
NO. Solenoid valve to be tested
1 PPC lock solenoid valve
2 Travel junction solenoid valve
3 Swing brake solenoid valve
4 Travel speed selector solenoid valve
5 2-stage relief solenoid valve
ATT return selector solenoid valve 5. While running the engine at full speed, operate
6
(for the machine with the attachment) each control lever and each switch to energize
and de-energize each solenoid valve, and
measure the pressure.
a For the conditions for energizing or de-ener-
gizing the solenoid, see the operation table of
each solenoid valve.
a The operating status of each solenoid valve
can be checked by using the monitoring func-
tion of the machine monitor. (For details, see
"Special functions of machine monitor")
q Monitoring code: 02300 Solenoid 1
q Monitoring code: 02301 Solenoid 2
a If the output pressure is as shown in the ta-
ble, the solenoid valve is normal.
Solenoid valve Outlet pressure
OFF (de-energized) 0 MPa {0 kg/cm2}
2. Install adapter N2 and connect the disconnected ON (energized) 2.9 MPa {30 kg/cm2}
hose again.

3. Install nipple [2] and connect it to pressure 6. After finishing test remove the testing tools and
gauge [3]. return the removed parts.

PC228US-8,PC228USLC-8 30-47
(01)
Hydraulic system
Testing solenoid valve output pressure

Solenoid valve ON-OFF control 30-48

Solenoid valve ON (energized) OFF (de-energized)
(1) PPC lock Free Lock operates
(2) Swing brake Brake is released. Brake is applied.
Motor swash plate Motor swash plate
(3) Travel speed selector
angle is set to Min. angle is set to Max.
Pressure is not
(4) 2-stage relief Pressure is increased.
increased.
(5) Travel junction Cut Connected
Single action, low Double action, high
(6) ATT selector
pressure pressure

(1) Operation table of PPC lock solenoid valve 30-48

Operating condition Operation
Lock OFF
PPC lock lever
Released ON

(2) Operation table of swing brake solenoid valve 30-48

Operating condition Operation
All are OFF. OFF
Signals of work equipment and swing (Work equipment includes attachment.)
Any one is ON. ON

(3) Operation table of travel speed selector solenoid valve 30-48

Operating condition Operation
Overheat 2nd setting is ON.
Arm crane is installed.
Fuel control dial is at 1,500 rpm or below.
OFF
Travel speed switch is at Lo.
Travel signal is OFF.
When F or R pump pressure is 33.3 MPa
Travel speed switch: Mi,
Hi {340 kg/cm2} or above.
Travel signal is ON.
When F or R pump pressure is 17.6 MPa
{180 kg/cm2} or below. ON
Other than the above conditions

30-48 PC228US-8,PC228USLC-8
(01)
 Hydraulic system
Testing solenoid valve output pressure

(4) Operation table of 2-stage relief solenoid valve 30-49

Operating condition Operation
Overheat 1st setting is ON.
Overheat 2nd setting is ON. OFF
When all the signals for work equipment, swing and travel are OFF.
Swing lock switch is ON.
Travel signal is ON.
When L mode is selected. ON
When the boom LOWER signal is ON
Signals other than the
When the working mode "swing only" are ON.
When one-touch power max. switch is ON.
is P or E.
"Swing only " is ON.
OFF
Other than above conditions

(5) Operation table of travel junction solenoid valve 30-49

Operating condition Operation
Travel steering signal is ON.
When " travel only" signal When F or R pump pressure is 24.5 MPa ON
Travel steering signal is is ON. {250 kg/cm2} or above.
OFF.
Other than the above conditions OFF

(6) Operation table of ATT return selector solenoid valve (for the machine with attachment) 30-49
Operating condition Operation
Working mode: Other than B OFF
Working mode: B ON

PC228US-8,PC228USLC-8 30-49
(01)
Hydraulic system
Testing PPC valve output pressure

Testing PPC valve output pressure 30-50

a Testing tools for PPC valve outlet pressure q The circuits marked with * can be checked by us-
Symbol Part number Part name ing the monitoring function of the machine mon-
itor.
799-101-5002 Hydraulic tester a The circuit to be tested (1) to (8) are installed to
1
790-261-1204 Digital hydraulic tester the PPC relay block and (9) to (12) are installed
to the reverse side of the cab.
P 799-401-3100 Adapter (Size: 02)
2
799-401-3200 Adapter (Size: 03)
3 796T-562-1110 Adapter (12 x 1.5 mm)

a Check that the control circuit source pressure is

correct before testing the PPC valve outlet pres-
sure.
a Test the PPC valve outlet pressure under the fol-
lowing condition.
Hydraulic oil temperature: within operating range
a The outlet pressure of the following PPC valve
can be checked by using the monitoring function
of the machine monitor.
(For details, see "Special functions of machine
monitor")
Monitoring code: 07400 Boom RAISE PPC pres-
sure
Monitoring code: 07200 Arm IN PPC pressure
Monitoring code: 07300 Bucket CURL PPC
pressure
Monitoring code: 07301 Bucket DUMP PPC
pressure
Monitoring code: 09001 Swing LEFT PPC pres-
sure
Monitoring code: 09002 Swing RIGHT PPC
pressure
Monitoring code: 07102 Travel LEFT
FORWARD PPC pressure
Monitoring code: 07103 Travel RIGHT 1. Disconnect hydraulic hose (2) of the PPC circuit,
FORWARD PPC pressure install adapter P2, and connect hydraulic hose
Monitoring code: 07104 Travel LEFT REVERSE (2) again.
PPC pressure
Monitoring code: 07105 Travel RIGHT
REVERSE PPC pressure
No. Circuit to be tested No. Circuit to be tested
1 * Bucket CURL (White) 7 * Right swing (Red)
Boom LOWER
2 8 Arm DUMP (Yellow)
(Brown)
* Left swing (Not Travel left forward
3 9
installed) (Red)
Travel right forward
4 * Arm IN (Blue) 10
(Green)
* Bucket DUMP Travel right reverse
5 11
(Black) (Blue)
Travel left reverse
6 * Boom RAISE (Green) 12
(Not installed)
q The colors in ( ) are the colors of the bands in-
stalled for piping identification.

30-50 PC228US-8,PC228USLC-8
(01)
 Hydraulic system
Testing PPC valve output pressure

2. Install nipple [1] of hydraulic tester P1 to adapter 4. Measure the pressure when the engine is
P2 or P3 and connect oil pressure gauge [2]. running at full speed and the control lever of the
a Use the oil pressure gauge of 6.0 MPa circuit to be measured is kept at the neutral posi-
{60 kg/cm2}. tion and at the full stroke.
a The figure shows the testing tools installed to a If PPC valve output pressure is at the level
the position for the boom LOWER PPC oil shown below, it is correct.
pressure switch installation. Operation of lever Pressure
At neutral 0 MPa {0 kg/cm2}
Almost the same pressure
as the control circuit-
At full stroke
source pressure (See
“Standard values table”)

5. After finishing test remove the testing tools and

return the removed parts.

a The figure shows the testing tools installed to

the position for the RIGHT travel reverse
PPC oil pressure switch installation.

3. Start the engine and set the working mode to the

Power Mode (P).

PC228US-8,PC228USLC-8 30-51
(02)
Hydraulic system
Adjusting play of work equipment and swing PPC vavles

Adjusting play of work equipment and swing PPC vavles 30-52

a If the right and left work equipment levers have

large play, adjust them according to the following
procedure.
a The play of the lever measured at a position of
200 mm from the pivot must be 0.5 - 3 mm.

1. Remove the work equipment and swing PPC

valve assembly.

2. Remove boot (1).

3. Loosen locknut (2) and tighten disc (3) until it

touches the heads of four pistons (4).
a Do not move the piston while doing this work.

4. Fix the position of disc (3) and tighten locknut (2)

to the specified torque.
3 Lock nut: 69 –88 Nm {7 –9 kgm}

5. Install boot (1).

6. Install the work equipment and swing PPC valve

assembly.

30-52 PC228US-8,PC228USLC-8
(01)
 Hydraulic system
Testing pump swash plate sensor

Testing pump swash plate sensor 30-53

Testing 30-53
a Before testing pump swash plate sensor, check
that oil pressure in work equipment, swing, and
travel circuits, control circuit source pressure,
and no-load travel speed are correct.
a Test pump swash plate sensor under the follow-
ing conditions.
q Hydraulic oil temperature: within operating
range
q Working mode: P-mode

Testing output voltage of pump swash plate

sensor 30-53
a Output voltage of pump swash plate sensor can a Testing condition and judgment: If the volt-
be checked by the monitoring function of ma- ages are as shown in the table, pump swash
chine monitor. plate sensor is correct.
(For the operating method, see " Special func- Pump swash plate
Operation of lever
tions of machine monitor" .) sensor voltage
q Monitoring code: All control levers and pedals
1.57 ± 0.63 V
01138 F pump swash plate sensor voltage are at neutral.
Travel lever is at stroke end.
01140 R pump swash plate sensor voltage 3.75 ± 0.63 V
(Track runs idle.)
1) Start the engine and raise the track on the
side to be tested, by using the work equip-
ment, and prepare for running the track idle.
q When testing front pump: right track
q When testing rear pump: left track

k Provide a working area of sufficient

space, as the raised track must be run
idle.

2) Set the working mode to the Power Mode (P)

and set the travel speed to the High.
3) Set the swing lock switch to ON position.
4) While running the engine at full speed, set all
the levers and pedals for work equipment,
swing, and travel to the neutral, and then set
the travel lever to stroke end in order to run a
track idle, and measure the voltage during
each operation.

k While taking care of safety around the ma-

chine, run the raised track idle.

PC228US-8,PC228USLC-8 30-53
(01)
Hydraulic system
Isolating the parts causing hydraulic drift of work equipment

Isolating the parts causing hydraulic drift of work equipment 30-54

a If the work equipment (cylinder) drifts hydrauli- 2. Testing arm cylinder

cally, perform check to see if the problem is in 1) Move the arm cylinder to about 100 mm
the cylinder seal or control valve according to the before the IN stroke end and stop the engine.
following procedure.

1. Testing boom cylinder and bucket cylinder

1) Set the work equipment in the same posture
as when measuring hydraulic drift, and stop
the engine.
a Put a weight equivalent to the rated load
or fill the bucket with the earth and sand.

2) Operate the arm control lever to the arm IN

position.
q If the lowering speed is increased at this
time, the cylinder seal is defective.
q If the lowering speed does not change at
this time, the control valve is defective.

a Operate the control lever while the start-

2) When testing the boom cylinder, set the ing switch is in the ON position.
boom control lever to the RAISE position. a If there is no more pressure in the accu-
When testing the bucket cylinder, set the mulator, run the engine for approx. 10
bucket control lever to the CURL position. seconds to charge the accumulator.
q If the lowering speed is increased at this
time, the cylinder seal is defective. [Reference] If the cause of the hydraulic drift is
q If the lowering speed does not change at a defect in the seal, the speed of down-
this time, the control valve is defective. ward movement in the above operation
will become faster for the following
a Operate the control lever while the start- reasons.
ing switch is in the ON position. 1) If the work equipment is set to the above
a If there is no more pressure in the accu- posture (where the work equipment holding
mulator, run the engine for approx. 10 pressure is applied to the bottom side), the oil
seconds to charge the accumulator. leaks from the bottom side to the head side.
The volume on the head side is less than that
on the bottom side by the volume of the rod,
so the pressure in the head side is increased
by the oil flowing in from the bottom side.
2) As the pressure in the head side is increased,
it is balanced with the pressure in the bottom
side at a certain level (which depends on the
leak quantity), and the lowering speed is
lowered.
3) If the circuit on the head side is opened to the
drain circuit by the above operation of the
lever (the bottom side is closed by the check
valve at this time), the oil in the head side
flows in the drain circuit. As a result, the pres-
sure is inbalanced and the lowering speed is
increased.

30-54 PC228US-8,PC228USLC-8
(01)
 Hydraulic system
Isolating the parts causing hydraulic drift of work equipment

3. Testing boom lock valve

1) Set the work equipment at the maximum
reach with the boom top in level and stop the
engine.
k Set the work equipment lock lever to
LOCK position and release the pres-
sure in the hydraulic tank.
k Do not allow anyone to come under the
work equipment during the work.
2) Disconnect drain hose (1) of the control
valve, and install an oil stopper plug in the
hose.
q Oil stopper plug: 07376-70210
a Leave the port in control valve open.
a If oil flows out of the open port when the
work equipment lowers by its own weight,
the boom lock valve is defective (sealing
is defective).

4. Testing PPC valve

Measure the hydraulic drift of the work equip-
ment when the work equipment lock lever is in
the LOCK and FREE positions with the accumu-
lator charged fully.
a Operate the control lever while the starting
switch is in the ON position.
a If there is no more pressure in the accumula-
tor, run the engine for approx. 10 seconds to
charge the accumulator.
a If there is a difference in the lowering dis-
tance between the LOCK position and FREE
position, the PPC valve is defective (it has an
internal defect).

PC228US-8,PC228USLC-8 30-55
(01)
Hydraulic system
Releasing remaining pressure from hydraulic circuit

Releasing remaining pressure from hydraulic circuit 30-56

1. Releasing remaining pressure from 3. Releasing remaining pressure from swing

hydraulic tank motor circuit
k The hydraulic tank is airtight and pressur- a Release the remaining pressure from the
ized, so release the remaining pressure swing motor circuit by performing the proce-
from it when removing a hose or a plug dure for 2 (Releasing remaining pressure
connected to it. from hydraulic cylinder circuit).
1) Lower the work equipment to the ground in a
stable posture and stop the engine. 4. Releasing remaining pressure from travel
2) Loosen oil filler cap (1) of the hydraulic tank motor circuit
gradually to release the air in the tank. a The control valve spool of the travel motor
circuit is open, so the pressure in this circuit
can be released by perfoming the operation
for "Release remaining pressure from hy-
draulic tank".

2. Releasing remaining pressure from

hydraulic cylinder circuit
k When disconnecting a pipe between a hy-
draulic cylinder and the control valve, re-
lease the remaining pressure from the
piping according to the following proce-
dure.
1) Release the remaining pressure from the
hydraulic tank. For details, see "Releasing
remaining pressure from hydraulic tank" .
a Leave the oil filler cap of the hydraulic
tank removed.
2) Set the starting switch to ON position and set
the lock lever to the FREE position, and then
operate the right and left work equipment
control levers forward, backward, to the right,
and to the left.
a The control valve is operated by the pres-
sure in the accumulator. The pressure in
the accumulator is used up, however, af-
ter the work equipment control levers are
operated 2 to 3 times.
3) Start the engine and run it at low idle for 5
seconds to raise the pressure in the accumu-
lator.
a The engine does not start unless the lock
lever is set to the LOCK position.
4) Repeat steps 2) and 3) above 2 to 3 times,
and the remaining pressure in the piping is
released completely.

30-56 PC228US-8,PC228USLC-8
(01)
 Hydraulic system
Testing oil leakage amount

Testing oil leakage amount 30-57

a Testing tools for oil leakage 2. Testing oil leakage from arm cylinder
Symbol Part number Part name 1) Move the arm cylinder to the arm IN stroke
end and stop the engine.
k Release the remaining pressure from
Commercially
Q Measuring cylinder
available
the piping on the arm cylinder head
a Test the oil leakage under the following condi- side. For details, see "Releasing re-
tion. maining pressure from hydraulic cir-
q Hydraulic oil temperature: within operating cuit" (Operate the lever to arm IN only,
range however).
2) Disconnect hose (2) on the cylinder head
1. Testing oil leakage from boom cylinder side and block the hose end by a flange.
1) Extend the boom cylinder to the boom RAISE k Take care not to disconnect the hose
stroke end and stop the engine. on the cylinder bottom side.
k Release the remaining pressure from a Use the following part to block the hose
the piping on the boom cylinder head end.
side. For details, see "Releasing re- 07379-00640 (Flange #06)
maining pressure from hydraulic cir-
cuit" (Operate the lever to the boom
RAISE direction only, however).
2) Disconnect hoses (1) on the cylinder head
side and block the hose end by a flange.
k Take care not to disconnect the hoses
on the cylinder bottom side.
a Use the following part to block the hose
end.
07379-00640 (Flange #06)

3) Run the engine at full speed and relieve the

arm circuit by moving the arm IN.
k Take care not to "move the arm OUT".
4) Start measuring the oil leakage 30 seconds
after relieving is started, and measure the
leak for 1 minute.
5) After finishing measuring, return the machine
status as it was.

3. Testing oil leakage from bucket cylinder

1) Move the bucket cylinder to the bucket CURL
3) Run the engine at full speed and relieve the stroke end and stop the engine.
boom circuit by raising the boom. k Release the remaining pressure from
k Take care not to "lower the boom". the piping on the bucket cylinder head
4) Start measuring the oil leakage 30 seconds side. For details, see "Releasing re-
after relieving is started, and measure the maining pressure from hydraulic cir-
leak for 1 minute. cuit" (Operate the lever in the bucket
5) After finishing measuring, return the machine CURL direction only, however).
status as it was. 2) Disconnect hose (3) on the cylinder head
side and block the hose end by a flange.
k Take care not to disconnect the hose
on the cylinder bottom side.
a Use the following part to block the hose
end.
07379-00640 (Flange #06)

PC228US-8,PC228USLC-8 30-57
(01)
Hydraulic system
Testing oil leakage amount

5. Testing oil leakage from travel motor

1) Remove the travel motor cover.
2) Run the engine, lock the travel mechanism,
and stop the engine.
k Insert pin [1] between the sprocket and
the track frame to securely lock the
track.

3) Run the engine at full speed and relieve the

bucket circuit by curling the bucket.
k Take care not to perform "bucket
DUPM operation".
4) Start measuring the oil leakage 30 seconds
after relieving is started, and measure the
leak for 1 minute.
5) After finishing measuring, return the machine 3) Disconnect drain hose (5) of the travel motor
status as it was. and block the hose end by a plug.
a Use the following part to block on the
4. Testing oil leakage from swing motor hose end.
1) Remove the upper cover (steel) of the swing 07376-70422 (Plug #04)
motor.
2) Disconnect two drain hoses (4) and block the
hose side end by plugs.
a Use the following part to block the hose
end.
07376-70522 (Plug #05)

4) Run the engine at full speed, relieve the

travel circuit, and measure the oil leakage.
k Before operating the travel lever,
check the pin position and locked di-
rection of the travel again.
k Wrong operation of the lever can
cause the personal injury. Make the
3) Turn the swing lock switch to ON position. signals and checks securely.
4) Run the engine at full speed and relieve the a Start measuring the oil leakage 30 sec-
swing circuit by swinging. onds after relieving is started, and mea-
a Start measuring the oil leakage 30 sec- sure the leak t for 1 minute.
onds after relieving is started, and mea- a Take measurement several times, mov-
sure the leak for for 1 minute. ing the motor a little each time (i.e.
a After measuring one time, swing 180°, change the position of the valve plate and
and then measure the leak again. cylinder, and that of the cylinder and pis-
5) After finishing testing, return the machine ton each time).
status as it was. 5) After finishing testing, return the machine
status as it was.

30-58 PC228US-8,PC228USLC-8
(01)
 Hydraulic system
Bleeding air from each part

Bleeding air from each part 30-59

q: Execution of work
o: Go to next proce-
dure
Air bleeding procedure and item
1 2 3 4 5 6
Checking
Bleeding air
Bleeding air Bleeding air Bleeding air oil level
from Run
from cylin- from swing from travel and
hydraulic engine
der motor motor starting
pump
work
q Replacing hydraulic oil q q
q q q q
q Cleaning strainer (See note) (See note)
q Replacing return filter element q o o o q
q Replacing or repairing hydraulic
pump q q q o o q
Nature of work, remarks

q Removing suction piping

q Replacing or repairing control valve
q q o o q
q Removing control valve piping
q Replacing and repairing cylinder
q q o o q
q Removing cylinder piping
q Replacing or repairing swing motor
q o q o q
q Removing swing motor piping
q Replacing or repairing travel motor
q o o q q
q Removing travel motor piping
q Replacing or repairing swivel joint
q o o o q
q Installing swivel joint piping

Note: Bleed air from the swing motor and travel motor only when the oil in the motor cases is drained.

1. Bleeding air from hydraulic pump 2. Starting engine

a Keep the oil filler cap of the hydraulic tank When running the engine after performing step
loosened while the air is bled from the hy- 1, let it low-idle for 10 minutes.
draulic pump. a If the automatic warm-up operation starts be-
1) Loosen air bleeder (1) and check that oil cause of low engine coolant temperature,
oozes out through the air bleeder. stop the engine and cancel the warm-up op-
2) After oil containing no bubbles flows out, eration by operaring the fuel control dial.
tighten air bleeder (1). (With the starting switch at the ON position,
3 Air bleeder: hold the fuel control dial at the MAX position
7.8 – 9.8 Nm {0.8 – 1.0 kgm} for 3 seconds, and the automatic warm-up
operation is canceled)

3. Bleeding air from cylinder

a If a cylinder is replaced, bleed air from it be-
fore connection to the work equipment. In
particular, the boom cylinder does not move
to the lowering stroke end, if it is installed to
the work equipment.
1) Run the engine at low idle for approximately
5 minutes.
2) While running the engine at low speed, raise
and lower the boom 4 to 5 times.
a Stop the piston rod approximately 100
mm before each stroke end. Do not cause
the relief.

PC228US-8,PC228USLC-8 30-59
(01)
Hydraulic system
Bleeding air from each part

3) While running the engine at full speed, 7. Checking oil level and starting work
perform step 2). 1) Run the engine, retract the arm cylinder and
4) While running the engine at low idle speed, bucket cylinder to the stroke ends, lower the
move the piston rod to the stroke end and work equipment to the ground, and stop the
relieve the oil. engine.
5) Bleed air from the arm cylinder and bucket
cylinder according to steps 2) to 4).

4. Bleeding air from swing motor

1) Start the engine and run it at low idle.
2) Swing to the right and left slowly to bleed air.

5. Bleeding air from travel motor

1) Start the engine and run it at low idle.
2) Loosen air bleeder (2) and check that oil
oozes out from it.
3) After oil containing no bubbles flows out,
tighten air bleeder (2).
3 Air bleeder:
27.5–35.3 Nm {2.8–3.6 kgm}
2) Check the oil level by sight gauge (3) on the
rear side of the hydraulic tank.
a The oil level is acceptable if it is situated
between H and L lines.
a If the oil level is below line L, it is insuffi-
cient. Add oil.

6. Bleeding air from swivel joint

1) Start the engine and run it at low idle.
2) Raise a track and run it idle slowly (forward
and reverse directions) to bleed air. Apply the
same procedure to the right and left tracks.

30-60 PC228US-8,PC228USLC-8
(01)
 Work equipment
Replacement procedure of boom angle potentiometer

Work equipment 30-61

Replacement procedure of boom angle potentiometer 30-61

a Perform the removal and installation of the boom

angle potentiometer according to the following
procedure.
a If the boom angle potentiometer is replaced, the
initial set value recorded in the pump controller
agree with the new potentiometer. Be sure to
perform the initial setting operation after install-
ing the new boom angle potentiometer.

Removal 30-61
1. Remove the potentiometer cover.
2. Disconnect connector A53 (1).
3. Remove lever (2) from the boom and fix it to
plate (3).
a Fix the lever to the plate so that the lever
does not move unexpectedly.
4. Remove plate (3) and potentiometer as a unit.
5. Remove lever (2) and remove potentiometer
assembly (4) from plate (3).
a Do not swing the potentiometer assembly by
gripping the lever or move the lever unneces-
sary.

Connection 30-61
1. Carry out installation in the reverse order to the
removal.
2. Set the machine monitor to the service mode
and perform initial setting for the boom angle
potentiometer.
a For adjustment procedure, see "Special func-
tions of monitor panel" (Adjustment in service
mode [07]).

PC228US-8,PC228USLC-8 30-61
(01)
Cab and its attachments
Checking cab tipping stopper

Cab and its attachments 30-62

Checking cab tipping stopper 30-62

a Check the cab tipping stopper according to the 2. Check the tightening torque of the mounting bolt
following procedure. (2) of the lock plate (1).
3 Bolt (2):
1. Remove additional lower cover (5) at the rear of 98 – 123 Nm {10 – 12.5 kgm}
the operator cab.
[Reference]
q Note that the tightening torque for mounting bolt
(4) of cab tipping stopper (3) is different from that
of a common bolt 30 mm in diameter.
3 Bolt (4):
245 – 309 Nm {25 – 31.5 kgm}

30-62 PC228US-8,PC228USLC-8
(01)
 Cab and its attachments
Adjusting mirrors

Adjusting mirrors 30-63

1. Mirror Installetion position

q Adjust the mirror so that the side of the ma-

chine is reflected in it as shown below.

2. Adjusting mirror (a)

Adjust mirror (a) so that the operator can see a 3. Adjusting mirror (b)
person at the left rear end of the machine. Adjust mirror ((b)) so that the operator can see a
a If the mirror is folded, set it to the normal po- person at the right rear end of the machine.
sition before adjusting. a Install the mirror as shown below.
a Install the mirror as shown below. (L): 45°, (M): 15 mm
(G): 10°, (H): 30°, (J): 35 mm, (K): 15 mm a If the mirror is hard to adjust, loosen mirror
a If the mirror is hard to adjust, loosen mirror bolts (3).
bolts (2). 3 Bolt:
a Fix mirror stay (1) while the mirror is opened 6.0–7.0 Nm {0.61–0.71 kgm}
to the maximum position.
3 Bolt:
6.0–7.0 Nm {0.61–0.71 kgm}

q Adjust the mirror so that the side of the ma- chine is reflected in it as shown below.

PC228US-8,PC228USLC-8 30-63
(01)
Cab and its attachments
Adjusting mirrors

4. Adjusting mirror (c)

Adjust the mirror so that the operator can see
persons on the ground at 1 meter around the
machine (hatched area).
a If the mirror is hard to adjust, loosen mirror
screw (4).
3 Bolt: 3.0 – 3.5 Nm {0.31 – 0.35 kgm}
q Dimension W: 1,000 mm

q When installing the mirror, secure clearance

(N) so that the mirror does not interfere with
the mirror stay.
(N): Min. 10 mm

30-64 PC228US-8,PC228USLC-8
(01)
 Cab and its attachments
Angle adjustment of rear view camera

Angle adjustment of rear view camera 30-65

a Adjust the camera so that persons in area (w) at 1. Remove cover (2) by inserting flat-head screw-
1 meter around the machine is displayed on the driver [1] in the hole in cover (3) and pressing the
machine monitor in the operator cab. internal pawl.

a Claw of cover (2) is made of plastic, it is eas-

If the image displayed on the monitor is out of posi- ily damaged while removing, therefore take
tion, remove cover (2) of camera (1) and adjust the special care at work.
installation angle (A) of the rear view camera.

2. Remove two bolts (4).

3. Remove cover (2).

PC228US-8,PC228USLC-8 30-65
(01)
Cab and its attachments
Angle adjustment of rear view camera

4. Loosen mounting bolts (5) of camera (1) and

adjust installtion angle (A) of camera so that the
side line of camera is matched with the corner
(B) of the bracket.
Angle (A): 48°(+2°/0)

a A part of the machine is displayed on the

monitor screen.
Adjust the camera so that the image of the
counterweight will occupy about 10 to 15% of
the monitor screen.

5. After adjusting, tighten bolts (5).

3 Camera mounting bolt :
11.8–14.7 Nm {1.2–1.5 kgm}

6. Install covers (2) and (3).

30-66 PC228US-8,PC228USLC-8
(01)
 Electrical system
Speial function of machine monitor (EMMS)

Electrical system 30-67

Speial function of machine monitor (EMMS) 30-67

PC228US-8,PC228USLC-8 30-67
(01)
Electrical system
Speial function of machine monitor (EMMS)

Upper part of machine monitor (diaplay portion)30-68

(a): Multi-display
a When the engine is started, the battery voltage
may lower suddenly, depending on the ambient
temperature and the condition of the battery.
In this case, the machine monitor goes off for a
moment. This phenomenon is not a failure,
however.

Upper part of machine monitor (switches por-

tion) 30-68
[F1]: F1 function switch
[F2]: F2 function switch
[F3]: F3 function switch
[F4]: F4 function switch
[F5]: F5 function switch
[F6]: F6 function switch
a The function of each function switch is indicated
by graphic mark in the multi-display (a) above
that function switch.
a If the graphic mark of a function switch is not dis-
played, that function switch is not working.

Lower part of machine monitor (switches por-

tion) 30-68
[1]: Numeral 1 input switch/Auto-deceleration switch
[2]:Numeral 2 input switch/Working mode selector
switch
[3]: Numeral 3 input switch/Travel speed selector
switch
[4]: Numeral 4 input switch/Alarm buzzer stop switch
[5]:Numeral 5 input switch/Wiper switch
[5]:Numeral 6 input switch/Wind washer switch
[7]:Numeral 7 input switch/Air conditioner or heater
switch
[8]:Numeral 8 input switch/Air conditioner or heater
switch
[9]:Numeral 9 input switch/Air conditioner or heater
switch
[0]: Numeral 0 input switch/Air conditioner or heater
switch
Switch having no numerals: Air conditioner or heat-
er switch
a Each switch has the function indicated by graph-
ic mark and the function of inputting a numeral.
a The machine monitor automatically judges
which function of each switch is currently effec-
tive, according to the display condition of
multi-display.

Reference
For the setup procedure after replacing the machine
monitor assembly, see Service News(AT07196).

30-68 PC228US-8,PC228USLC-8
(02)
 Electrical system
Speial function of machine monitor (EMMS)

t Ordinary functions and special functions of machine monitor 30-69

The machine monitor has the ordinary functions and special functions and displays information of various
types on the multi-display.
Some items are displayed automatically according to the internal setting of the machine monitor and the oth-
ers are displayed according to the operation of the switches.
1. Ordinary functions: Operator mode
The information items in this mode are displayed ordinarily. The operator can display and set them by
operating the switches (Display and setting of some items need special operations of the switches).
2. Special function: Service mode
The information items in this mode are not displayed ordinarily. Each technician can display them by oper-
ating the switches specially.
This mode is used for special setting, testing, adjusting, or troubleshooting. While normal operation screen
is displayed.
Page Page
Operator mode (outline) Service mode
30-71 30-83
A Display of KOMATSU logo 30-71 Monitoring 30-84
Mechanical system failure his-
A Display of inputting password 30-72 30-90
Abnormality tory
A Display of check of breaker mode 30-72 Record Electrical system failure history 30-91
A Display of check before starting 30-72 Air conditioner failure history 30-93
A Display of warning after check before starting 30-72 Maintenance history 30-94
A Display of overdue maintenance 30-73 Change of maintenance mode 30-95
Working mode and travel speed check
A 30-73 Telephone number registration 30-97
screen
A Display of standard screen 30-73 Key-on Mode 30-98
A Display of end screen 30-74 Unit 30-99
B Selection of auto-deceleration 30-74 With/Without Attachment 30-100
Attachment/Maintenance Pass-
B Selection of working mode 30-74 Default 30-101
o word
B Selection of travel speed 30-75 Camera 30-102
(Special operation)

B Operation to stop alarm buzzer 30-75

ECO Display 30-103
B Operation of wiper 30-76
B Operation of window washer 30-76 Pump Absorption Torque (F) 30-104
B Operation of air conditioner 30-76 Pump Absorption Torque (R) 30-105
B Operation to display camera mode 30-76 Low Speed 30-106
Attachment Flow Adjustment 30-107
Boom potentiometer compensa-
Adjustment 30-108
tion
Switching between clock display and service
B 30-77 F pump swash plate sensor cali-
meter display 30-110
bration
R pump swash plate sensor cali-
30-113
bration
B Check of maintenance information 30-77 Cylinder Cut-Out 30-115
Entering user mode
B 30-77 No Injection 30-116
(including KOMTRAX messages for user)
C Display function of energy-saving guidance 30-78 Fuel Consumption 30-118
Terminal Status 30-119
C Display of caution monitor 30-78
KOMTRAX GPS & Communication Status 30-120
Displaying function of user code and failure Settings
C 30-79 MODEM IP address 30-121
code
O (Special operation) Display of service message 30-122
Function of checking display of LCD (Liquid
D 30-81
Crystal Display)
D Function of checking service meter 30-81
Function of changing attachment/mainte-
D 30-81
nance password

PC228US-8,PC228USLC-8 30-69
(01)
Electrical system
Speial function of machine monitor (EMMS)

a Classification of operator mode

A: Screen or function that is displayed or enabled from the time when the starting switch is turned to ON
position to the time when screen changes to the standard screen, and screen after starting switch is turned
to OFF position
B:Display/Function when switch of machine monitor is operated
C:Display/Function when certain condition is satisfied
D:Screen or function that needs special operation of switches to be displayed or enabled

30-70 PC228US-8,PC228USLC-8
(01)
 Electrical system
Speial function of machine monitor (EMMS)

t Operator mode (outline) 30-71 Display of KOMATSU logo 30-71

a Only outline of the operator mode is described in When starting switch is turned ON, KOMATSU logo
this section. is displayed for 2 seconds.
For details of contents/operation of each func- a After the KOMATSU logo is displayed for two
tion/display, see the “Structure, function and seconds, the screen changes to "Password in-
maintenance standard”, or Operation and Main- put" screen, or "Check before starting" screen.
tenance Manual.
a The following are the displays or functions of the
operator mode explained in this section (includ-
ing some items which need special operations).
Display pattern
A B C D E
Display of KOMATSU logo 1 1 1 1 1
Display of inputting password 2 – – – –
Display of check of breaker mode – – 2 – –
Display of check before starting 3 2 3 2 2
Display of warning after check before – – – 3 –
starting
Display of overdue maintenance – – – – 3
Working mode and travel speed check 4 3 4 4 4
screen
Display of standard screen 5 4 5 5 5 a The following screen may be displayed instead
Display of end screen of the above “Display of inputting password
Selection of auto-deceleration screen”.
Selection of working mode a If this screen is displayed, call the person re-
Selection of travel speed sponsible to operation of KOMTRAX in your Ko-
Operation to stop alarm buzzer matsu distributor and ask for remedy.
Operation of windshield wiper
Operation of windshield washer
Operation of air conditioner
Operation to diaplay camera mode
Switching between clock display and service meter dis-
play
Check of maintenance information
Entering user mode
(including KOMTRAX messages for user)
Display of energy-saving guidance
Display of caution monitor
Displaying user code and failure code
O (Special operation)
Function of checking display of LCD (Liquid Crystal Dis-
play)
Function of checking service meter
Function of changing attachment/maintenance pass-
word
a Display pattern of operator mode
The contents of display from the time when
starting switch is turned ON to time when screen
changes to ordinary screen depends on the
setting and condition of the machine.
A: When engine start lock is set effective
B: When engine start lock is set ineffective
C: When working mode at start is set to Breaker
mode (B)
D: When there is abnormal item in
check-before-starting items
E: When there is maintenance item which is not
maintained after specified interval

PC228US-8,PC228USLC-8 30-71
(01)
Electrical system
Speial function of machine monitor (EMMS)

Display of inputting password 30-72 Display of check before starting 30-72

After the KOMATSU logo is displayed, the screen to When the screen changes to the check-before-start-
input the engine start lock password is displayed. ing screen, the check before starting is carried out
a This screen is displayed only when the engine for 2 seconds.
start lock function is set effective. a If any abnormality is detected by the check be-
a If the password is input normally, the screen fore starting, the screen changes to "Display of
changes to "Display of check before starting". warning after check before starting" or "Display
a The machine monitor has some password func- of overdue maintenance".
tions other than the engine start lock. Those a If no abnormality is detected by the check before
functions are independent from one another. starting, the screen changes to "Working mode
and travel speed check" screen.
a The monitors (2 pieces) displayed on the screen
are the items under the check before starting.

Display of check of breaker mode 30-72

When the starting switch is turned ON, if the working
mode is set to the breaker mode [B], a message to
inform the operator of starting in the breaker mode Display of warning after check before starting 30-72
is displayed on the screen. If any abnormality is detected by the check before
k If an attachment other than the breaker is starting, the warning monitor is displayed on the
used while the working mode is set to the screen.
breaker mode [B], the machine may move un- a The following figure shows that the engine oil
expectedly or may not operate normally or pressure monitor (a) that warns of low engine oil
the hydraulic components may be damaged. pressure.
a After the check operation of the breaker mode is
finished, the screen changes to "display of check
before starting".
If [No] is selected: Working mode is set to
economy mode [E]
If [Yes] is selected: Working mode is set to
breaker mode [B]

30-72 PC228US-8,PC228USLC-8
(01)
 Electrical system
Speial function of machine monitor (EMMS)

Display of overdue maintenance 30-73 Display of standard screen 30-73

When the check before starting is carried out, if a If the machine monitor starts normally, the standard
maintenance item is near or after the end of the set screen is displayed.
interval, the maintenance monitor is displayed for 30 a Service meter (a) or a clock is displayed at the
seconds to urge the operator to maintenance. center upper section of the screen (use [F4] to
a This screen is displayed only when the mainte- switch the display between the service meter
nance function is enabled. and clock).
If the remaining time of any item is 30 H or less, a ECO gauge (b) is displayed at the right end of
the yellow icon is displayed. If the remaining time the screen (specify display or non-display of the
of any item is 0 H or less, the red icon is ECO gauge in the service mode).
displayed.
a The maintenance reminder function is enabled
or disabled by using the machine monitor in the
service mode.
a After this screen display is finished, the screen
changes to "Working mode and travel speed
check" screen.

Working mode and travel speed check screen 30-73

If the check before starting is finished successfully,
the screen to check the working mode and travel
speed is displayed for 2 seconds.
a After the “Working mode and travel speed
check” screen is finished, the screen changes to
the "Standard” screen.

PC228US-8,PC228USLC-8 30-73
(01)
Electrical system
Speial function of machine monitor (EMMS)

Display of end screen 30-74 Selection of working mode 30-74

When starting switch is turned OFF, the end screen Select a working mode according to the following
is displayed for 5 seconds. procedure.
a Another message may be displayed on the end 1. While the standard screen is displayed, press
screen, depending on the message display func- the working mode selector switch, and the
tion of KOMTRAX. working mode selection screen is displayed.

Selection of auto-deceleration 30-74 2. Operate the function switches or working mode

While the standard screen is displayed, if the au- selector switch to select the desired working
to-deceleration switch is pressed, large auto-decel- mode and enter the selection.
eration monitor (a) is displayed for 2 seconds and Function switch
the setting of the auto-deceleration is changed. q [F3]: Move to lower working mode
a Each time the auto-deceleration switch is q [F4]: Move to upper working mode
pressed, the auto-deceleration is turned ON and q [F5]: Cancel selection and return to standard
OFF alternately. screen
a If the auto-deceleration is set to ON, large moni- q [F6]: Confirm selection and return to stan-
tor (a) and auto-deceleration monitor (b) are dis- dard screen
played simultaneously. Working mode selector switch
a If the auto-deceleration is set to OFF, auto-de- q Press: Move to lower working mode
celeration monitor (b) goes off. q Hold down:Confirm selection and return to
standard screen
a If you do not touch any of the function switch-
es and working mode selector switch for 5
seconds, the selection is determined and the
screen changes to the ordinary screen.

30-74 PC228US-8,PC228USLC-8
(01)
 Electrical system
Speial function of machine monitor (EMMS)

3. When the standard screen is displayed again, Selection of travel speed 30-75
large working mode monitor (a) is displayed for While the standard screen is displayed, if the travel
2 seconds, and then the setting of the working speed shifting switch is pressed, large travel speed
mode is changed to the selected mode. monitor (a) is displayed for 2 seconds and the set-
a When large monitor (a) is displayed, the dis- ting of the travel speed is changed.
play of working mode monitor (b) is changed, a Each time the travel speed shifting switch is
too. pressed, the travel speed changes in the order of
[Lo], [Mi], [Hi] and [Lo].
a When large monitor (a) is displayed, the display
of travel speed monitor (b) is changed, too.

<Precautions for selecting breaker mode [B]>

q If breaker mode [B] is selected, both of the
control of the hydraulic pump and the setting
of the hydraulic circuit are changed. Operation to stop alarm buzzer 30-75
q If an attachment other than the breaker is While the alarm buzzer is sounding, if the alarm
used, the machine may move unexpectedly buzzer cancel switch is pressed, the alarm buzzer
or may not operate normally or the hydraulic stops.
components may be damaged. a Even if the alarm buzzer cancel switch is
q After the breaker mode is selected, the pressed, the screen does not change.
screen to confirm the selection of the breaker
mode is displayed (The buzzer sounds inter-
mittently while this screen is displayed).
q If the setting is confirmed on this screen, the
screen changes to the standard screen.
If "No" is selected: Screen returns to working
mode selecting screen
If [Yes] is selected: Working mode is set to
breaker mode [B]

PC228US-8,PC228USLC-8 30-75
(01)
Electrical system
Speial function of machine monitor (EMMS)

Operation of wiper 30-76 Operation of air conditioner 30-76

While the standard screen is displayed, if the wiper While the standard screen is displayed, if the air
switch is pressed, large wiper monitor (a) is dis- conditioner switch is pressed, the air conditioner ad-
played for 2 seconds and the wiper starts or stops. justment screen is displayed.
a The window washer does not operate if the win- a While the air conditioner adjustment screen is
dow limit switch is "ON". displayed, if you do not touch any switch for 5
a Each time the wiper switch is pressed, the wiper seconds, the screen changes to the standard
setting is changed in the order of INT, ON, OFF, screen.
and INT.
a When the wiper is set to INT or ON, large moni-
tor (a) is displayed and the display of wiper mon-
itor (b) is changed, too.
a If the wiper is set to OFF, large monitor (a) is not
displayed and the wiper monitor disappears.

Operation to display camera mode 30-76

If [F3] is pressed, the multi-display changes to the
camera image (Set the connection of the camera in
the service mode).

Operation of window washer 30-76

While the standard screen is displayed, if the win-
dow washer switch is pressed, the washer fluid is
splashed only while the switch is held down.
a Even if the window washer switch is pressed, the
screen does not change.

a Up to three cameras can be connected. If the

camera mode is selected, however, only the im-
age of camera 1 is always displayed.

30-76 PC228US-8,PC228USLC-8
(01)
 Electrical system
Speial function of machine monitor (EMMS)

a If any caution occurs in the camera mode, the Check of maintenance information 30-7
corresponding caution monitor is displayed at While the maintenance monitor or ordinary screen is
the left top of the screen (excluding the low hy- displayed, if [F5] is pressed, the Maintenance List
draulic oil temperature caution). screen is displayed.

a If no control lever is operated for 10 seconds a To reset the remaining time after finishing main-
while a failure enough to diaplay user code is oc- tenance, more operations are necessary.
curring in the camera mode, the screen returns
to the standard screen and displays information
about that failure.
a When two or more cameras are connected, the
image of one of them or the images of two of
them can be displayed.
a As 2-camera image display [F4] is selected, the
image of camera 1 is displayed on the left side of
the screen and the image of camera 2 is dis-
played on the right side.
The image of camera 3 is displayed only singly.
a If 2-camera image display operation is made,
the images are displayed frame by frame at in-
tervals of approximately 1 second on the right
and left side of the screen.
Entering user mode 30-7
(including KOMTRAX messages for user)
Switching between clock display and service
To enter the user mode, press [F6] to display the
meter display 30-7
"User Menu" screen while the standard screen is
While the standard screen is displayed, if [F4] is
displayed.
pressed, the service meter and the clock are dis-
played alternately in section (a).
a When selecting the clock display, perform the
time adjustment, 12-hour or 24-hour display set-
ting, and summer time setting by using the user
mode functions.

PC228US-8,PC228USLC-8 30-77
(01)
Electrical system
Speial function of machine monitor (EMMS)

a There are following items in the user menu. Display of energy-saving guidance 30-78
Breaker/attachment setting When the machine is set in a certain operating con-
Message display dition, the energy-saving guidance screen is dis-
Screen adjustment played automatically to urge the operator to the
Clock adjustment energy-saving operation.
Language setting a The energy-saving guidance is displayed when
Economy mode adjustment the following condition is satisfied while the dis-
a The breaker/attachment setting menu is dis- play setting is set effective in the service mode.
played only when "With attachment" is set in the a Condition for display:
service mode. "Engine is running" and "All levers have been in
neutral for 5 minutes"and "Caution (Note) or user
code is not indicated"
Note: Excluding hydraulic oil low temperature
caution.
a If any lever or pedal is operated, or [F5] is
pressed, the screen returns to the standard
screen.

[KOMTRAX message]
q There are two types of KOMTRAX message;
one is for the user and the other is for the ser-
vice.
q For user:
A message transmitted from the KOMTRAX
base station for the user. If it is received, the
message monitor is displayed on the standard
screen. To see the contents of the message, Display of caution monitor 30-78
operate "User Message" in the above user While the standard screen or the camera image
menu. screen is displayed, if a problem enough to display
q For service:
a caution monitor occurs, the caution monitor is dis-
This is a message sent from the KOMTRAX played large for a moment and then displayed at
base station for the technician. Even if it is section (a) on the screen.
received, no sign is displayed on the standard a On the camera mode screen, the caution moni-
screen. To read the message, select "Service tor flashes at the left upper of the screen when a
message display" on the service menu in the caution item is detected.
service mode.

30-78 PC228US-8,PC228USLC-8
(01)
 Electrical system
Speial function of machine monitor (EMMS)

Display function of user code and failure code 30-79

While the standard screen or the camera mode
screen is displsyed, if an abnormality which displays
a user code and a failure code occurs, all the infor-
mation of the abnormality is displayed.
(a): User code (three digits)
(b): Failure code (five or six digits)
(c): Telephone mark
(d): Telephone No.
a This screen is displayed only when an abnormal-
ity (failure code) for which a user code is set oc-
curs.
a The telephone mark and telephone number are
displayed only when the telephone number is
registered in the service mode.
a If multiple abnormalities occur simultaneously,
all the codes are displayed repeatedly in order.
a Since the information of the displayed failure
code is recorded in the abnormality record in the
service mode, check the details in the service
mode.

a When the caution monitor is also displayed, the

telephone mark is not displayed.

PC228US-8,PC228USLC-8 30-79
(01)
Electrical system
Speial function of machine monitor (EMMS)

a Remedies that the displayed user codes prompt the operator to take (The following table is an excerpt from
the Operation and Maintenance Manual)

User code Failure mode Action

If the emergency pump drive switch is set to the rear (emergency)

E02 Pump control system error position, normal operations become possible, but have inspection car-
ried out immediately.
E03 Swing brake system error Have inspection carried out immediately.
The work equipment can be raised by setting the work equipment
E06 Electric system error emergency operation switch to the ON position. In that instance, how-
ever, call on your Komatsu distributor for inspection immediately.
Defective engine controller
power source
E10 Engine controller drive system Have inspection carried out immediately.
circuit error
(Engine stopps)
Engine controller system error Operate machine to a safe posture and have inspection carried out
E11
Output reduced to protect engine immediately.
Problem in throttle system Operate machine to a safe posture and have inspection carried out
E14
(Abnormality in fuel control dial) immediately.
Engine sensor (coolant tempera-
Normal operation is possible. Have the machine inspected immedi-
E15 ture, fuel pressure, oil pressure)
ately, however.
system error
Operate machine to a safe posture and have inspection carried out
E20 Problem in travel system
immediately.
Operate machine to a safe posture and have inspection carried out
E0E Network error
immediately.
Stop crane work immediately.
If there is any abnormality, ask your KOMATSU distributor for testing
E50 Arm crane system error and repair.
If another working mode is selected, the machine can perform digging
work.

30-80 PC228US-8,PC228USLC-8
(01)
 Electrical system
Speial function of machine monitor (EMMS)

Function of checking display of LCD (Liquid

Crystal Display) 30-81
While the standard screen is displayed, if the follow-
ing numeral input switch and function switch are op-
erated as follows, all the LCD (Liquid Crystal
Display) lights up in white.
q Operation of switches (simultaneous): "4" + "F2"
a When finishing the operation of the switches, re-
lease "F2" first.
a If there is a display error in the LCD, only that
part is indicated in black.
a The LCD panel sometimes has black points
(points which are not lighted) and bright points
(points which do not go off) for the reason of its
Function of changing attachment/maintenance
characteristics.
password 30-81
If the number of the bright points and black
When changing the attachment/maintenance pass-
points does not exceed 10, those points are not
word that is necessary for using the attachment set-
a failure or a defect.
ting function and maintenance setting function,
a To return to the former screen, press any one of
perform the following procedures.
the function switches.
1. While the standard screen is displayed, perform
the following operation with the numeral input
switches.
q Operation of switches (While pressing [4],
perform the operation in order):
[4]+[5]o[5]o[5]
a This operation of the switches is not accept-
ed until 10 minutes pass after the starting
switch is turned to ON position.

Function of checking service meter 30-81

To check the service meter while the starting switch
is in OFF position, operate the numeral input switch-
es as follows. At this time, only the service meter
section appears.
q Operation of switches (simultaneous): "4"+ "1"
a There is some time lag in start of the LCD, so
hold down the switches until the LCD displays
normally.
2. After the Attachment/Maintenance PASSWORD
a In the case of a machine monitor that has been
screen is displayed, input the current password
used a long period of time, the machine monitor
with the numeral input switches and confirm it
may display blue bright spots (spots which do
with the function switch.
not go off) on this screen; it is quite normal.
q [F5]: Delete input numeral/Return to ordinary
screen
q [F6]: Confirm input numeral
a Default password: [000000]
a If the input password is correct, the screen
changes to the next screen.
a If the input password is incorrect, the mes-
sage to request inputting the password again
is displayed.

PC228US-8,PC228USLC-8 30-81
(01)
Electrical system
Speial function of machine monitor (EMMS)

4. After the New password input screen is

displayed again, input a new password again by
using the numeral input switches and confirm it
by using the function switch.
q [F5]: Delete input numeral/Return to stan-
dard screen
q [F6]: Confirm input numeral
a If a password different from the password in-
put before is input, the message to input
again is displayed.

3. After the "New Password" screen is displayed,

input a new password with the numeral input
switches and confirm it with the function switch.
a Set a new password of 4 to 6 digits (If it has
only 3 or less digits or has 7 or more digits, it
is not accepted).
q [F5]: Delete input numeral/Return to stan-
dard screen
q [F6]: Confirm input numeral

5. If the screen to notify completion of setting is

displayed and then the standard screen is
displayed, the password has been changed
successfully

30-82 PC228US-8,PC228USLC-8
(01)
 Electrical system
Speial function of machine monitor (EMMS)

t Service mode 30-83 a The items which can be selected in the ser-
To change the operator mode to the service mode, vice menu are as follows (including some
perform the following operation. items which need special operations).
This operation is always required when you use the 01 Monitoring
service mode. Mechanical system abnormality
record
1. Check of display of screen and operation of 02 Abnormality Electrical system abnormality
switches Record record
While the standard screen is displayed, perform Air conditioning system abnor-
mality record
the following operation with the numeral input
03 Maintenance Record
switches. 04 Maintenance Mode Change
q Operation of switches (While pressing [4], 05 Phone Number Entry
perform the operation in order): Key-on Mode
[4]+[1]o[2]o[3] Unit
a This operation of the switches is accepted With/Without Attachment
only while the ordinary screen is displayed. 06 Default Attachment/Maintenance Pass-
word
Camera
ECO Display
Pump Absorption Torque (F)
Pump Absorption Torque (R)
Low Speed
Attachment Flow Adjustment
07 Adjustment Boom potentiometer initialization
F pump swash plate sensor cali-
bration
R pump swash plate sensor cali-
bration
08 Cylinder Cut-Out
09 No Injection
10 Fuel Consumption
Terminal Status
11 KOMTRAX
GPS & Communication Status
2. Selection of service menu Settings
Modem S/N
When the "Service Menu" screen is displayed, 12 Service message display
the service mode is selected. Select a service
menu you use by using the function switches or
numeral input switches.
q [F3]: Move to lower item
q [F4]: Move to upper item
q [F5]: Return to standard screen (operator
mode)
q [F6]: Confirm selection
a You may enter a 2-digit code with the numer-
al input switches to select the menu of that
code and confirm it with [F6].

PC228US-8,PC228USLC-8 30-83
(01)
Electrical system
Speial function of machine monitor (EMMS)

Monitoring 30-84
The machine monitor can monitor the condition of
the machine in real time by receiving signals from
various switches, sensors, and actuators installed to
many parts of the machine and the information from
the controllers which are controlling switches, etc.

1. Selection of menu
Select "Monitoring" on the "Service Menu"
screen.

3. Deciding monitoring items

After selecting monitoring items, execute moni-
toring with the function switch or numeral input
switch.
a Execution with function switch: Doubleclick
or keep presssing [F6] (for approximately 2
seconds).
a Execution with numeral input switch: Input
[99999] and press [F6].
a When monitoring only two items, for exam-
2. Selecting monitoring items ple, select them and confirm with [F6]. If [F6]
After the "Monitoring selection menu screen" is is pressed once more at this time, monitoring
displayed, select items to be monitored by using is executed.
the function switches or numeral input switches. a If monitoring items are selected up to the limit
q [F1]: Move to next page (screen) number, monitoring is executed automatical-
q [F2]: Move to previous page (screen) ly.
q [F3]: Move to lower item
q [F4]: Move to upper item
q [F5]: Delete input numeral/Return to service
menu screen
q [F6]: Confirm selection
a Selection with function switches: Select an
item with [F3] or [F4] and determine it with
[F6].
a Selection with numeral input switches: Enter
a 5-digit code, and the item of that code is se-
lected directly. Confirm that item with [F6].
a If the color of the selected box changes from
yellow to red, selection of the item of that box
is confirmed.
a Up to six monitoring items can be selected at
a time. You may not able to set up to six
items, however, depending on the display
form of the selected items.

30-84 PC228US-8,PC228USLC-8
(01)
 Electrical system
Speial function of machine monitor (EMMS)

4. Executing monitoring 6. Changing machine setting mode

After the "Executing monitoring screen" is To change the setting of the working mode,
displayed, perform the necessary operation of travel speed, or auto-deceleration during moni-
the machine and check the monitoring informa- toring, operate the corresponding switch under
tion. the current condition, and the mode setting
a Monitoring information is indicated by value, screen is displayed.
ON/OFF, or special display. While this screen is displayed, if the corre-
a The unit of display can be selected in SI unit, sponding switch is operated further, the corre-
metric unit, or inch unit with the Default func- sponding mode is changed.
tion in the service mode. a After finishing changing the setting, press
[F6] to return to the monitoring information
screen.
a If the setting is changed during monitoring,
the new setting is held even after the screen
returns to the standard screen after monitor-
ing is finished.

5. Holding monitoring information

The monitoring information can be held and
released with the function switches.
q [F3]: Release holding
q [F4]: Hold information (displayed data is
fixed) a If the working mode is changed to breaker
q [F5]: Return to monitoring selection menu mode [B], the screen to confirm the change of
screen the setting is displayed as in changing the
working mode on the standard screen.

PC228US-8,PC228USLC-8 30-85
(01)
Electrical system
Speial function of machine monitor (EMMS)

Monitoring items list

Unit (Initial setting: ISO) Comp
Code onent
Monitoring item (Display on screen) Remarks
No. ISO meter inch in
charge
00200 Controller Model Select – PUMP
00201 Machine ID – ENG
01002 Engine speed r/min rpm rpm ENG
01601 2nd Eng. Speed Command r/min rpm rpm PUMP
01100 F Pump Pressure MPa 2 psi PUMP
kg/cm
01101 R Pump Pressure MPa kg/cm2 psi PUMP
07400 Boom Raise PPC Pressure MPa kg/cm2 psi PUMP
07200 Arm Curl PPC Pressure MPa kg/cm2 psi PUMP
07300 Bucket Curl PPC Pressure MPa kg/cm2 psi PUMP
07301 Bucket Dump PPC Pressure MPa kg/cm2 psi PUMP
09001 Swing left PPC Pressure MPa kg/cm2 psi PUMP
09002 Swing right PPC Pressure MPa kg/cm2 psi PUMP
07102 Travel FW L PPC Pressure MPa kg/cm2 psi PUMP
07103 Travel FW R PPC Pressure MPa kg/cm2 psi PUMP
07104 Travel BW L PPC Pressure MPa kg/cm2 psi PUMP
07105 Travel BW R PPC Pressure MPa kg/cm2 psi PUMP
04107 Coolant Temperature °C °C °F ENG
04401 Hydr. Oil Temperature °C °C °F PUMP
01300 PC-EPC Sol. Curr. (F) mA mA mA PUMP
01302 PC-EPC Sol. Curr. (R) mA mA mA PUMP
01500 LS-EPC Sol. Curr. mA mA mA PUMP
08000 Merge-divider Sol. Curr. (Main) mA mA mA PUMP
08001 Merge-divider Sol. Curr. (LS) mA mA mA PUMP
01700 Service Sol. Curr. mA mA mA PUMP
01800 Boom slow down EPC current mA mA mA PUMP
03200 Battery Voltage V V V PUMP
03203 Battery Power Supply V V V ENG
04300 Battery Charge Vol. V V V MON
36400 Rail Pressure MPa kg/cm2 psi ENG
37400 Ambient Pressure kPa kg/cm2 psi ENG
18500 Charge Temperature °C °C °F ENG
Absolute value indication
36500 Boost Pressure kPa kg/cm2 psi ENG (including atmospheric pres-
sure)
36700 Engine Torque Ratio % % % ENG
18700 Engine Output Torque Nm kgm lbft ENG
03000 Fuel Dial Pos Sens Volt V V V ENG
04200 Fuel Level Sensor Vol. V V V MON

30-86 PC228US-8,PC228USLC-8
(01)
 Electrical system
Speial function of machine monitor (EMMS)

Unit (Initial setting: ISO) Comp

Code onent
Monitoring item (Display on screen) Remarks
No. ISO meter inch in
charge
04105 Eng. Water Temp. Vol. Lo V V V ENG
04402 Hydr. Temp. Sonser Vol. V V V PUMP
37401 Ambient Press Sens Volt V V V ENG
18501 Charge Temp Sens Volt V V V ENG
36501 Charge Press Sens Volt V V V ENG
36401 Rail Pressure Sens Volt V V V ENG
17500 Engine Power Mode – ENG
31701 Throttle Position % % % ENG
31706 Final Throttle Position % % % ENG
18600 Inject Fueling Command mg/st mg/st mg/st ENG
36200 Rail Press Command MPa kg/cm2 psi ENG
36300 Injection Timing Command CA CA CA ENG
37300 Fuel Rate l/h l/h gal/h ENG
01602 2nd Eng. Speed Command % % % PUMP
13113 Main Pump Absorb Torque Nm kgm lbft PUMP
01137 F pump delivery cc/rev cc/rev cc/rev PUMP
01138 F pump sw plate sensor volt V V V PUMP
01139 R pump delivery cc/rev cc/rev cc/rev PUMP
01140 R pump sw plate sensor volt V V V PUMP
15900 Boom Bottom Pressure MPa kg/cm2 psi PUMP
06004 Boom Angle Potentio Voltage V V V PUMP
Swing ON, OFF PUMP
Travel ON, OFF PUMP
Pressure Switch Boom Lower ON, OFF PUMP
01900
1 Boom Raise ON, OFF PUMP
Arm Curl ON, OFF PUMP
Arm Dump ON, OFF PUMP
Bucket Curl ON, OFF PUMP
Pressure Switch Bucket Dump ON, OFF PUMP
01901
2 Service ON, OFF PUMP
Travel Steering ON, OFF PUMP
Travel Junction ON, OFF PUMP
Swing Brake ON, OFF PUMP
02300 Solenoid Valve 1 Merge-divider ON, OFF PUMP
2-Stage Relief ON, OFF PUMP
Travel Speed ON, OFF PUMP
02301 Solenoid Valve 2 Service Return ON, OFF PUMP
Lever Sw. ON, OFF PUMP
02200 Switch Input 1 Swing Release Sw. ON, OFF PUMP
Swing Brake Sw. ON, OFF PUMP

PC228US-8,PC228USLC-8 30-87
(01)
Electrical system
Speial function of machine monitor (EMMS)

Unit (Initial setting: ISO) Comp

Code onent
Monitoring item (Display on screen) Remarks
No. ISO meter inch in
charge
Model Select 1 ON, OFF PUMP
Model Select 2 ON, OFF PUMP
Model Select 3 ON, OFF PUMP
02201 Switch Input 2
Model Select 4 ON, OFF PUMP
Model Select 5 ON, OFF PUMP
Overload Alarm ON, OFF PUMP
02202 Switch Input 3 Key Switch (ACC) ON, OFF PUMP
Window Limit SW. ON, OFF PUMP
02204 Switch Input 5 P Limit SW. ON, OFF PUMP
W Limit SW. ON, OFF PUMP
Key Switch ON, OFF MON
Start ON, OFF MON
04500 Monitor input 1 Preheat ON, OFF MON
Light ON, OFF MON
Rad. Level ON, OFF MON
Air cleaner ON, OFF MON
04501 Monitor Input 2 Eng. Oil Level ON, OFF MON
Battery Charge ON, OFF MON
04502 Monitor Input 3 Swing Brake Sw. ON, OFF MON
F1 ON, OFF MON
F2 ON, OFF MON

Monitor Func- F3 ON, OFF MON

04503
tion Switches F4 ON, OFF MON
F5 ON, OFF MON
F6 ON, OFF MON
SW1 ON, OFF MON
SW2 ON, OFF MON
Monitor 1st & SW3 ON, OFF MON
04504 2nd Row
Switches SW4 ON, OFF MON
SW5 ON, OFF MON
SW6 ON, OFF MON
SW7 ON, OFF MON
SW8 ON, OFF MON
Monitor 3rd & SW9 ON, OFF MON
04505 4th Row
Switches SW10 ON, OFF MON
SW11 ON, OFF MON
SW12 ON, OFF MON

30-88 PC228US-8,PC228USLC-8
(01)
 Electrical system
Speial function of machine monitor (EMMS)

Unit (Initial setting: ISO) Comp

Code onent
Monitoring item (Display on screen) Remarks
No. ISO meter inch in
charge
SW13 ON, OFF MON
Monitor 5th Row
04506 SW14 ON, OFF MON
Switches
SW15 ON, OFF MON
18800 Water In Fuel ON, OFF ENG WIF: Water In Fuel
20216 ECM Build Version – ENG
20217 ECM CAL Data Ver – ENG
18900 ECM Internal Temp °C °C °F ENG
20400 ECM Serial No – ENG
20227 Monitor Ass'y P/N – MON
20402 Monitor Serial No – MON
20228 Monitor Prog. P/N – MON
20229 Pump Con. Ass'y P/N – PUMP
20403 Pump Con. Serial No – PUMP
20230 Pump Con. Prog. P/N – PUMP

a Listing order of items in table

The items are listed in the order of display on the monitoring item selection menu screen.
a Unit
The display unit can be set to ISO, meter, or inch freely (Set it with unit selecting in "Default" setting of the
service menu).
"CA" in the display unit is an abbreviation for crankshaft angle.
"mg/st" in the display unit is an abbreviation for milligram/stroke.
a Component in charge
MON: The machine monitor is in charge of detection of monitoring information.
ENG: The engine controller is in charge of detection of monitoring information.
PUMP: The pump controller is in charge of detection of monitoring information.

Note 1:The momentary fuel consumption (monitoring code: 37300) is the theoretical fuel consumption (be-
cause it is a theoretical value, it is a little different from the actual fuel consumption).

PC228US-8,PC228USLC-8 30-89
(01)
Electrical system
Speial function of machine monitor (EMMS)

Abnormality Record (Mechanical Systems) 30-90 3. Information displayed on "Abnormality Record"

The machine monitor classifies and logs the failures screen
which occurred in the past or which are occurring at On the "Mechanical Systems" screen, the
present into the electrical system abnormality, me- following information is displayed.
chanical system abnormality, and Air-conditioning (a): Occurrence order of abnormalities from
System abnormality. latest one/Total number of abnormalities in the
To check the mechanical system abnormality re- log
cord, perform the following procedures. (b): Failure code
a For the failure code list, see "40 Failure code list (c): Failure
for troubleshooting". (d): Number of occurrences (limit of display: 0 -
1. Selection of menu 65,535 times)
Select "Abnormality Record" on the "Service (e): SMR at first occurrence
Menu" screen. (f): SMR at last occurrence
q [F1]: Move to next page (screen) (if dis-
played)
q [F2]: Move to previous page (screen) (if dis-
played)
q [F5]: Return to Abnormality Record screen
a If no abnormality is recorded, "No abnormal-
ity record" is displayed.
a If the number of occurrences is one (first oc-
currence), the service meter reading at the
first occurrence and that at the last occur-
rence are the same.
a If [E] is displayed on the left of a failure code,
the abnormality is still occurring or restora-
tion has not been confirmed.
a For all the failure codes that the machine
2. Selecting sub menu
monitor can record, see the "Failure code ta-
After the "Abnormality Record" screen is
ble".
displayed, select "Mechanical Systems" with the
function switches or numeral input switches.
q [F3]: Move to lower item
q [F4]: Move to upper item
q [F5]: Return to Service Menu screen
q [F6]: Confirm selection
a You may enter a 2-digit code with the numer-
al input switches to select the item of that
code and confirm it with [F6].
a The following figure shows the display for the
machines with air conditioner.
As for machines with heater and heaterless
machines, the character string of "03
Air-conditioning System" is different or is not
displayed respectively.
4. Clearing abnormality record
A contents of the mechanical system abnor-
mality record cannot be clearing.

30-90 PC228US-8,PC228USLC-8
(01)
 Electrical system
Speial function of machine monitor (EMMS)

Abnormality Record (Electrical Systems) 30-91 3. Information displayed on "Abnormality Record"

The machine monitor classifies and logs the failures screen
which occurred in the past or which are occurring at On the "Electrical Systems" screen, the following
present into the electrical system abnormality, me- information is displayed.
chanical system abnormality, and Air-conditioning (a): Occurrence order of abnormalities from
System abnormality. latest one/Total number of abnormalities in the
To check the electrical system abnormality record, log
perform the following procedures. (b): Failure code
a For the failure code list, see "40 Failure code list (c): Failure
for troubleshooting". (d): Number of occurrences (limit of display: 0 -
1. Selection of menu 65,535 times)
Select "Abnormality Record" on the "Service (e): SMR at first occurrence
Menu" screen. (f): SMR at last occurrence
q [F1]: Move to next page (screen) (if dis-
played)
q [F2]: Move to previous page (screen) (if dis-
played)
q [F3]: Move to lower item
q [F4]: Move to upper item
q [F5]: Return to Abnormality Record screen
a If no abnormality is recorded, "No abnormal-
ity record" is displayed.
a If the number of occurrences is one (first oc-
currence), the service meter reading at the
first occurrence and that at the last occur-
rence are the same.
a If [E] is displayed on the left of a failure code,
the abnormality is still occurring or restora-
2. Selecting sub menu
tion of it has not been confirmed.
After the "Abnormality Record" screen is
a For all the failure codes that the machine
displayed, select "Electrical Systems" with the
monitor can record, see the "Failure code ta-
function switches or numeral input switches.
ble".
q [F3]: Move to lower item
q [F4]: Move to upper item
q [F5]: Return to Service Menu screen
q [F6]: Confirm selection
a You may enter a 2-digit code with the numer-
al input switches to select the item of that
code and confirm it with [F6].

PC228US-8,PC228USLC-8 30-91
(01)
Electrical system
Speial function of machine monitor (EMMS)

4. Clearing abnormality record 3) After the "Electrical Sys. Error Reset" screen
1) While the "Electrical Systems" screen is is displayed, operate the function switches.
displayed, perform the following operation q [F5]: Return to Electrical systems screen
with the numeral input switches. (clear mode)
q Operation of switches (While pressing [4], q [F6]: Execute clearing
perform the operation in order): a The following figure shows the screen
[4]+[1]o[2]o[3] displayed when the items are cleared one
by one (which is a little different from the
screen displayed when all the items are
cleared together).

2) Check that the screen is set in the clear

mode, and then clear the items one by one or
together with the function switches.
a If the screen is set in the clear mode, 4) If the screen to notify completion of clearing
graphic mark [CLEAR] is indicated above is displayed and then the "Electrical
[F2]. Systems" (clear mode) screen is displayed,
q [F2]: Clear all items the clearing of the abnormality record is
q [F3]: Move to lower item completed.
q [F4]: Move to upper item a After a while, the screen returns to the
q [F5]: Return to Abnormality Record "Electrical Systems" screen.
screen
q [F6]: Clear selected item
a To clear items one by one: Select the item
to be cleared with [F3] or [F4] and press
[F6].
a To clear all items together: Press [F2],
and all the items are cleared, regardless
of selection of the items.
a If [E] is displayed on the left of a failure
code, the clearing operation is accepted
but the information is not reset.

30-92 PC228US-8,PC228USLC-8
(01)
 Electrical system
Speial function of machine monitor (EMMS)

Abnormality Record (Air-conditioning System) 30-93 3. Information displayed on "Abnormality Record"

The machine monitor classifies and logs the failures screen
which occurred in the past or which are occurring at On the "Air-conditioning System" screen, the
present into the electrical system abnormality, me- following information is displayed.
chanical system abnormality, and Air-conditioning (a): System or component name
System abnormality. (b): Number of failure occurrences
To check the air-conditioning abnormality record or (c): Status display (Normal or abnormal)
heater abnormality record, perform the following q [F2]: Delete "Abnormality record"
procedures. q [F5]: Return to Abnormality record screen
If [E] is displayed on the left of a status
1. Selection of menu display, the abnormality is still occurring or
Select "Abnormality Record" on the "Service retoration of it has not been confirmed.
Menu" screen. If "CAN disconnection" is displayed for CAN
Status, communication cannot be carried out
normally. Accordingly, the statuses of other
items are not displayed.

2. Selecting sub menu

After the "Abnormality Record" screen is
displayed, select "Air-conditioning System" by
using the function switches or numeral input 4. Clearing abnormality record
switches. While the "Air-conditioning system" screen is
q [F3]: Move to lower item displayed, press [F2], and the number of occur-
q [F4]: Move to upper item rences of abnormality is cleared. If it is confirmed
q [F5]: Return to Service Menu screen at this time that the system is restored, the stauts
q [F6]: Confirm selection display changes to Normal.
You may enter a 2-digit code with the
numeral input switches to select the item of
that code and confirm it with [F6].

PC228US-8,PC228USLC-8 30-93
(01)
Electrical system
Speial function of machine monitor (EMMS)

Maintenance Record 30-94 a The following items can be selected in the

The machine monitor records the maintenance in- maintenance record.
formation of the filters, oils, etc., which are displayed 01 Engine oil change
and checked by the following operations. 02 Engine oil filter change
When maintenance is performed, if the remaining 03 Fuel main filter change
time is reset in the operator mode, the number of 41 Change of fuel pre-filter
04 Hydraulic oil filter change
maintenance times is recorded in this record.
05 Hydraulic tank breather change
06 Corrosion resistor change
1. Selection of menu 07 Damper case service
Select "Maintenance Record" on the "Service 08 Final drive case oil change
Menu" screen. 09 Machinery case oil change
10 Hydraulic oil change
42 Oil cooler accumulator change

3. Items displayed on maintenance record screen

The following items are displayed.
(a): Maintenance item
(b): Number of replacements up to now
(c): SMR at previous replacement

2. Selecting maintenance record item

After the "Maintenance Record" screen is
displayed, select an item to be checked by using
the function switches or numeral input switches.
q [F1]: Move to next page (screen)
q [F2]: Move to previous page (screen)
q [F3]: Move to lower item
q [F4]: Move to upper item
q [F5]: Return to Service Menu screen
a You may enter a 2-digit code with the numer-
al input switches to select the item of that
code.

30-94 PC228US-8,PC228USLC-8
(01)
 Electrical system
Speial function of machine monitor (EMMS)

Change of maintenance mode 30-95 a The following items can be selected on the
The actuating condition of the maintenance remind- change of maintenance mode screen.
er function in the operation mode can be set and 00 Maintenance mode on/off
changed by using this menu. 01 Engine oil change int.
q To enable or disable the function 02 Engine oil filter change int.
q To change set replacement interval (by item)
03 Fuel main filter change int.
41 Fuel pre-filter change int.
q To initialize all set replacement intervals
04 Hyd oil filter change int.
05 Hyd tank breather change int.
1. Selection of menu 06 Corrosion resistor change int.
Select of "Maintenance Mode Change" on the 07 Damper case service int.
"Service Menu" screen. 08 Final drive case oil change int.
09 Machinery case oil change int.
10 Hydraulic oil change int.
42 Oil cooler accumulator change int.
99 Initialize all items

3. Details of setting of maintenance mode ON/OFF

After selecting "Maintenance Mode On/Off", if
the screen is displayed, select ON or OFF with
the function switches.
q ON: Maintenance reminder functions of all
maintenance items are enabled in operator
mode
q OFF: Maintenance reminder functions of all
maintenance items are disabled in operator
mode
2. Selecting sub menu q [F3]: Move to lower item
After the "Maintenance Mode Change" screen is q [F4]: Move to upper item
displayed, select an item of wiich the setting is to q [F5]: Cancel selection and return to Mainte-
be changed by using the function switches or nance Mode Change screen
numeral input switches. q [F6]: Confirm selection and return to Mainte-
q [F1]: Move to next page (screen)
nance Mode Change screen
q [F2]: Move to previous page (screen)
a Even if ON/OFF of each item has been set, if
q [F3]: Move to lower item
the above setting is changed, it overrides the
q [F4]: Move to upper item
individual setting.
q [F5]: Return to Service Menu screen
q [F6]: Confirm selection
a You may enter a 2-digit code with the numer-
al input switches to select the item of that
code and confirm it with [F6].

PC228US-8,PC228USLC-8 30-95
(01)
Electrical system
Speial function of machine monitor (EMMS)

4. Setting of each maintenance item

After selecting each maintenance item, if the
screen is displayed, set the item with the function
switches.

5. Function of initializing all items

After selecting "Use Default Value" and the
screen is displayed, set with the function
q Initial value: Maintenance interval set in ma- switches.
chine monitor (Recommended by manufac-
turer and not changeable).
q Set value: Maintenance interval which can be
set freely. Maintenance reminder function in
operator mode works according to this set
time (which is increased or decreased by 50
hours).
q ON: Maintenance reminder function of this
item is enabled in operator mode.
q OFF: Maintenance reminder function of this
item is disabled in operator mode.
q [F3]: Reduce set value (in upper column) or
select OFF (in lower column).
q [F4]: Increase set value (in upper column) or
q If this function is executed, the set values of
select ON (in lower column).
all the maintenance items are initialized.
q [F5]: Cancel setting before confirmation and
q [F5]: Return to “Maintenance Mode Change”
return to “Maintenance Mode Change”
screen
screen.
q [F6]: Perform initialization
q [F6]: Confirm setting of upper or lower col-
a A while after [F6] is pressed, the initialization
umn
completion screen is displayed. Then, return
a After the settings of the upper and lower col-
to the "Maintenance Mode Change" screen
umns are confirmed with [F6] and the screen
to complet the initialization.
changes to the Maintenance Mode Change
screen with [F5], the settings are effective.
a If the set value of an item of which mainte-
nance reminder function is set to "ON" is
changed after one operating hours or more
from the setup, the change is recognized as
a reset of the remaining time.

30-96 PC228US-8,PC228USLC-8
(01)
 Electrical system
Speial function of machine monitor (EMMS)

Telephone number registration 30-97 a Up to 14 digits can be input from the left. In-
The telephone number to be displayed together with put nothing in the surplus positions.
the user code and failure code in the operator mode a If an input numeral is wrong, move the cursor
can be registered or changed according to the fol- (orange background) to that digit and over-
lowing procedure. write it with the correct numeral.
If a telephone No. is not input by using this function, a If [F6] is pressed without inputting a digit,
no telephone No. is displayed in the operator mode. there is not information of telephone No. Ac-
cordingly, no telephone No. is displayed in
1. Selection of menu the operator mode.
Select "Phone Number Entry" on the "Service
Menu" screen.

2. Registering and changing phone number

After the "Phone Number Entry" screen is
displayed, register or change the phone number
q [F2]: Delete all input digits.
q [F3]: Move to left position (if not blank)
q [F4]: Move to right position (if not blank)
q [F5]: Reset input digit/Return to Service
Menu screen
q [F6]:Confirm input

PC228US-8,PC228USLC-8 30-97
(01)
Electrical system
Speial function of machine monitor (EMMS)

Default (Key-on Mode) 30-98 3. Selecting mode

Use the menu of “Default” to check or change vari- After the "Key-on Mode" screen is displayed,
ous settings of the machine monitor and machine. select the mode to be set by using the function
Use the sub menu of "key-on Mode" to set the work- switches.
ing mode selected and displayed on the machine q Power Mode: [P] is displayed when the start-
monitor when the starting switch is turned to ON po- ing switch is turned to ON position.
sition. q Economy Mode: [E] is displayed when the
starting switch is turned to ON position.
1. Selection of menu q Lifting Mode: [L] is displayed when the start-
Select "Default" on the "Service Menu" screen. ing switch is turned to ON position.
q Breaker Mode: [B] is displayed when the
starting switch is turned to ON position.
q Attachment Mode: [ATT] is displayed when
the starting switch is turned to ON position.
q Mode at Previous Key-off: Final mode in pre-
vious operation is displayed when the start-
ing switch is turned to ON position.
q [F3]: Move to lower item
q [F4]: Move to upper item
q [F5]: Cancel selection and return to Default
screen
q [F6]: Confirm selection and return to Default
screen
a Factory default is, "Mode at Previous
Key-off".
2. Selecting sub menu
a If "With Attachment" is not selected for the at-
After the "Default" screen is displayed, select
tachment setting, the Attachment Mode can-
"Key-on Mode" by using the function switches or
not be selected.
numeral input switches.
a For the machine selecting Attachment Mode
a Select this item similarly to an item on the
[ATT], if the attachment setting is changed to
"Service Menu" screen.
"Without Attachment", Power Mode [P] is se-
lected and displayed when the starting switch
is turned to ON position.
a If the engine is stopped with the working
mode set to breaker mode [B] in the operator
mode, Breaker Mode [B] is always displayed
when the starting switch is turned to ON po-
sition, regardless of the above setting.

30-98 PC228US-8,PC228USLC-8
(01)
 Electrical system
Speial function of machine monitor (EMMS)

Default (Unit) 30-9 3. Selecting unit

Use the menu of “Default” to check or change vari- After the "Unit" screen is displayed, select the
ous settings of the machine monitor and machine. unit to be set by using the function switches.
Use the sub menu of "Unit" to select the unit of the q [F3]: Move to lower item
data displayed for monitoring, etc. q [F4]: Move to upper item
q [F5]: Cancel selection and return to Default
1. Selection of menu screen
Select "Default" on the "Service Menu" screen. q [F6]: Confirm selection and return to Default
screen
a Factory default is the “SI Unit”.

2. Selecting sub menu

After the "Default" screen is displayed, select
"Unit" by using the function switches or numeral
input switches.
a Select this item similarly to an item on the
"Service Menu" screen.

PC228US-8,PC228USLC-8 30-99
(01)
Electrical system
Speial function of machine monitor (EMMS)

Default (With/Without Attachment) 30-10 3. Selecting With/Without

Use the menu of “Default” to check or change vari- After the "With/Without Attachment" screen is
ous settings of the machine monitor and machine. displayed, select the setting by using the func-
Use the sub menu of "With/Without Attachment" to tion switches.
configure attachment setting when the attachment q Without Attachment: When attachment is not
is installed or removed. installed
q With Attachment: When attachment is in-
1. Selection of menu stalled
Select "Default" on the "Service Menu" screen. q [F3]: Move to lower item
q [F4]: Move to upper item
q [F5]: Cancel selection and return to Default
screen
q [F6]: Confirm selection and return to Default
screen
a When an attachment is installed, if this set-
ting is not configured correctly, the attach-
ment setting in the operator mode cannot be
performed. As a result, the attachment may
not work normally or the hydraulic compo-
nents may be damaged.

2. Selecting sub menu

After the "Default" screen is displayed, select
"With/Without Attachment" by using the function
switches or numeral input switches.
a Select this item similarly to an item on the
"Service Menu" screen.

30-100 PC228US-8,PC228USLC-8
(01)
 Electrical system
Speial function of machine monitor (EMMS)

Default (Attachment/Maintenance Password) 30-101 3. Selecting Disable/Enable

Use the menu of “Default” to check or change vari- After the Attachment/Maintenance Password
ous settings of the machine monitor and machine. screen is displayed, select the setting by using
Use the sub menu of "Attachment/Maintenance the function switches.
Password" to set the password screen to be dis- q Disable: Password screen is not displayed
played when the functions related to the attachment q Enable: Password screen is displayed
and maintenance are used in the operator mode. q [F3]: Move to lower item
q [F4]: Move to upper item
1. Selection of menu q [F5]: Cancel selection and return to Default
Select "Default" on the "Service Menu" screen. screen
q [F6]: Confirm selection and return to Default
screen

2. Selecting sub menu

After the "Default" screen is displayed, select
"Attachment/Maintenance Password" by using 4. Displaying “Attachment/Maintenance Password”
the function switches or numeral input switches. screen
a Select this item similarly to an item on the When the following operation is performed, the
"Service Menu" screen. password screen is displayed in the operator
mode.
q Maintenance mode: When the Maintenance
list screen is changed to the maintenance in-
terval reset screen.
q User mode: On the User Menu screen, the
menu of "Breaker/Attachment settings" is se-
lected and the screen is changed to the "At-
tachment Settings" screen.

5. Changing attachment/maintenance password

The password can be changed with the special
switch operatin in the operator mode.
a See Attachment/Maintenance password
changing function in the operator mode.
a Default password: [000000]
a If the password setting is changed from En-
able to Disable, the password is reset to the
default.
When Enable is set again, be sure to set a
new password.
a The attachment/maintenance password is
different from the engine start lock password.

PC228US-8,PC228USLC-8 30-101
(01)
Electrical system
Speial function of machine monitor (EMMS)

Default (Camera) 30-102 q [F5]: Cancel settings before confirmation and

Use the menu of “Default” to check or change vari- return to Default screen
ous settings of the machine monitor and machine. q [F6]: Confirm selection of each column
Use the sub menu of "Camera" to configure camera a When "Camera" screen is displayed, camera
setting when the camera is installed or removed. 1 is always ready for setting.
a After confirming the setting of each column
1. Selection of menu with [F6], return to the "Default" screen with
Select "Default" on the "Service Menu" screen. [F5], and the setting is effective.
a If a camera is connected but not configured
normally with this function, the graphic mark
of camera is not displayed above [F3] in the
operator mode. Accordingly, the image of the
camera cannot be screen.
a If the camera is installed, check that the right
and left portions of the displayed image are
correct.

2. Selecting sub menu

After the "Default" screen is displayed, select
"Camera" by using the function switches or
numeral input switches.
a Select this item similarly to an item on the
"Service Menu" screen.

3. Selecting camera setting

After the "Camera" screen for setting is
displayed, select the setting by using the func-
tion switches.
q OFF: Camera is not configured.
q Original Image: Image from connected cam-
era is displayed normally (A mirror image, se-
lect this setting for rearview monitor back
monitor).
q Reverse Image: Image from connected cam-
era is displayed in reverse (View is displayed
as seen directly, select this setting for a front
or side monitor.)
q [F3]: Move to left item
q [F4]: Move to right item

30-102 PC228US-8,PC228USLC-8
(01)
 Electrical system
Speial function of machine monitor (EMMS)

Default (ECO Display) 30-103 a If ECO Mark is set to ON, ECO mark is dis-
Use the menu of “Default” to check or change vari- played when the screen changes to the stan-
ous settings of the machine monitor and machine. dard screen. Even if ECO Guidance is set to
Use the sub menu of "ECO Display" to set the ECO ON, however, ECO Guidance screen is not
mark and ECO guidance to be displayed. displayed if the condition for display is not
satisfied on the standard screen.
1. Selection of menu
Select "Default" on the "Service Menu" screen.

a ECO mark (a)

2. Selecting sub menu

After the "Default" screen is displayed, select
"ECO Display" by using the function switches or
numeral input switches
a Select this item similarly to an item on the
"Service Menu" screen.

a ECO Guidance screen

3. Selecting display setting

After the "ECO Display" screen is displayed,
select the setting by using the function switches.
q ON: Display ECO
q OFF: Do not display ECO
q [F3]: Move to left item
q [F4]: Move to right item
q [F5]: Cancel settings before confirmation and
return to Default screen
q [F6]: Confirm selection of each column
a After confirming the setting of the upper and
lower columns with [F6], return to the "De-
fault" screen with [F5], and the setting is ef-
fective.

PC228US-8,PC228USLC-8 30-103
(01)
Electrical system
Speial function of machine monitor (EMMS)

Adjustment (Pump Absorption Torque (F)) 30-104

The machine monitor allows for adjustment of vari-
ous items related to the machine.
The sub menu of Pump Absorption Torque (F) is
used to finely adjust the absorption torque of the
front hydraulic pump.

1. Selection of menu
Select "Adjustment" on the "Service Menu"
screen.

a Relationship between set value and torque

adjustment value
Set
Code Torque adjustment value
value
000 +39.2 Nm {+4 kgm}
001 +29.4 Nm {+3 kgm}
002 +19.6 Nm {+2 kgm}
003 +9.8 Nm {+1 kgm}
021 004 0 Nm {0 kgm}
2. Selecting sub menu 005 -9.8 Nm {-1 kgm}
After the "Adjustment" screen is displayed,
select "Pump Absorption Torque (F)" by using 006 -19.6 Nm {-2 kgm}
the function switches or numeral input switches. 007 -29.4 Nm {-3 kgm}
a Select this item similarly to an item on the
008 -39.2 Nm {-4 kgm}
"Service Menu" screen.

3. Selecting pump absorption torque setting

After the "Pump Absorption Torque (F)" screen
is displayed, select a set value in the right
column by using the function switches.
q Set value: For actual torque adjustment val-
ue, see table
q [F3]: Increase set value.
q [F4]: Decrease set value.
q [F6]: Confirm setting and return to Adjust-
ment screen
a The 3-digit number in the left column do not
change since it is the code of this function.

30-104 PC228US-8,PC228USLC-8
(01)
 Electrical system
Speial function of machine monitor (EMMS)

Adjustment (Pump Absorption Torque (R)) 30-105 3. Selecting pump absorption torque setting
The machine monitor allows for adjustment of vari- After the "Pump Absorption Torque (R)" screen
ous items related to the machine. is displayed, select a set value in the right
The sub menu of Pump Absorption Torque (R) is column by using the function switches.
used to finely adjust the absorption torque of the q Set value: For actual torque adjustment val-
rear hydraulic pump. ue, see table
q [F3]: Increase set value.
1. Selection of menu q [F4]: Decrease set value.
Select "Adjustment" on the "Service Menu" q [F6]: Confirm setting and return to Adjust-
screen. ment screen
a The 3-digit number in the left column do not
change since it is the code of this function.

2. Selecting sub menu

After the “Adjustment” screen is displayed,
select “Pump Absorption Torque (R)” by using a Relationship between set value and torque
the function switches or numeral input switches. adjustment value
a Select this item similarly to an item on the Set
"Service Menu" screen. Code Torque adjustment value
value
000 +39.2 Nm {+4 kgm}
001 +29.4 Nm {+3 kgm}
002 +19.6 Nm {+2 kgm}
003 +9.8 Nm {+1 kgm}
022 004 0 Nm {0 kgm}
005 -9.8 Nm {-1 kgm}
006 -19.6 Nm {-2 kgm}
007 -29.4 Nm {-3 kgm}
008 -39.2 Nm {-4 kgm}

PC228US-8,PC228USLC-8 30-105
(01)
Electrical system
Speial function of machine monitor (EMMS)

Adjustment (travel low speed setting) 30-106 3. Selecting low speed

The machine monitor allows for adjustment of vari- After the "Low Speed" screen for setting is
ous items related to the machine. displayed, select a set value in the right column
The sub menu of Low Speed is used to finely adjust by using the function switches.
the travel speed at Low setting. q Set value code: For the actual travel speed at
Low setting, see the following table.
1. Selection of menu q [F3]: Increase set value.
Select "Adjustment" on the "Service Menu" q [F4]: Decrease set value.
screen. q [F6]: Confirm setting and return to Adjust-
ment screen
a The 3-digit number in the left column do not
change since it is the code of this function.

2. Selecting sub menu

After the "Adjustment" screen is displayed,
select "Low speed" by using the function
switches or numeral input switches. a Relationship between set value and travel
a Select this item similarly to an item on the speed at Low setting
"Service Menu" screen. Set
Code Travel speed at Low
value
000 3.0 km/h
001 2.8 km/h
020
002 3.2 km/h
003 3.4 km/h

30-106 PC228US-8,PC228USLC-8
(01)
 Electrical system
Speial function of machine monitor (EMMS)

Adjustment (Attachment Flow Adjustment) 30-107 3. Selecting distribution of oil flow

The machine monitor allows for adjustment of vari- After the screen of "Attachment Flow Adjust-
ous items related to the machine. ment" is displayed, select a set value in the right
The sub menu of "Attachment Flow Adjustment" is column by using the function switches.
used to finely adjust the oil flow rate to the attach- q Set value: For actual distribution of oil flow,
ment in combined operation. see table
1. Selection of menu q [F3]: Increase set value.
Select "Adjustment" on the "Service Menu" q [F4]: Decrease set value.
screen. q [F6]: Confirm setting and return to Adjust-
ment screen
a The 3-digit number in the left column do not
change since it is the code of this function.

2. Selecting sub menu

After the "Adjustment" screen is displayed,
select "Attachment Flow Adjustment" by using
the function switches or numeral input switches. a Relationship between set value and distribu-
a Select this item similarly to an item on the tion of oil flow to attachment
"Service Menu" screen. Set Distribution of flow to attach-
Code
value ment
000 50%
001 70%
044
002 100%
003 40%

PC228US-8,PC228USLC-8 30-107
(01)
Electrical system
Speial function of machine monitor (EMMS)

Adjustment (Boom potentiometer initialization) 30-108 3. When the "Initialize boom potentiometer" screen
When the boom potentiometer or boom is removed is displayed, initialize the boom potentiometer by
and installed, or when the boom stroke end elec- using the work equipment control lever and func-
tronic cushion function does not work normally, ini- tion switches.
tialize the boom potentiometer according to the q [F1]: SET
following procedure. q [F2]: Clear
1. Selection of menu q [F6]: Confirm settings.
Select "Adjustment" on the "Service Menu"
screen.

4. Operate the right work equipment control lever

to raise the boom to the maximum height.
2. Selecting sub menu a Take care not to allow the boom to lower.
After the "Adjustment" screen is displayed, a The arm may be at any position.
select "Initialize boom potentiometer" by using q Fig. 1: Posture for initialization of boom po-
the function switches or numeral input switches. tentiometer
a Select this item similarly to an item on the
"Service Menu" screen.

30-108 PC228US-8,PC228USLC-8
(01)
 Electrical system
Speial function of machine monitor (EMMS)

5. Press [F1] to save the adjusted value of the

boom angle potentiometer.
a "OK" is displayed for State of adjustment and
the angle indication on the screen to updated
to the adjusted values.

a To do the initialization again, press [F2] to de-

lete the adjusted value and then perform the
procedure again from step 1).
a If the installed angle of the potentiometer de-
viates 10 or more degrees from the standard
value in the controller, the buzzer sounds for
approximately one seconds and the adjusted
value is not saved. ("NG" is displayed for
State of adjustment.) In this case, check the
installed condition of the potentiometer and
perform the procedure again from step 1).

6. Press [F6] to confirm the setting.

a If the setting is accepted, the screen returns
to the Adjustment screen.

PC228US-8,PC228USLC-8 30-109
(01)
Electrical system
Speial function of machine monitor (EMMS)

Adjustment (Calibration of front pump swash In adjustment menu of service menu

plate sensor) 30-1 0
The machine monitor allows for adjustment of vari-
ous items related to the machine.
The sub menu of Calib F pump swach plate sensor
is used to calibrate the sensor installed on the actual
machine to eliminate deviation of the sensor signal
made when the front pump swash plate sensor is re-
moved and installed or replaced with new one.

a The pump swash plate sensor needs to be ad-

justed in the following cases.
Calibra- Calibra-
tion of tion of rear
front pump pump
swash swash
plate sen- plate sen-
sor sor
Removal and installation or
replacement of front pump Necessary –
swash plate sensor
Removal and installation or
replacement of rear pump – Necessary
swash plate sensor
Replacement of main pump
Necessary Necessary
assembly
Replacement of pump controller Necessary Necessary
Adjustment and disassembly of
Necessary –
front pump PC valve
Adjustment and disassembly of
– Necessary
pump PC valve
a Before calibrating the pump swash plate sensor, 1. Preparation for calibration
check the pump swash plate sensor to confirm Before starting calibration, set the machine
that the pump swash plate sensor is normal. under the following condition.
a A rough flow of calibration of the pump swash q Hydraulic oil temperature: 50 °C
plate sensor is as follows. q Working mode: P mode
q Travel speed setting: Hi

2. Selection of menu
Select "Adjustment" on the "Service Menu"
screen.

30-110 PC228US-8,PC228USLC-8
(01)
 Electrical system
Speial function of machine monitor (EMMS)

3. Selecting sub menu

After the "Adjustment" screen is displayed, k Provide a enough work space to run
select "Calib F pump swash plate sensor" by the track idle off the ground.
using the function switches or numeral input k Be careful about safety around the ma-
switches. chine while running the track idle off
a Select this item similarly to an item on the the ground.
"Service Menu" screen.

3) When the speed of hte track running idle is

stabilized, hold down [F1] of the machine
4. Calibration of front pump swash plate sensor for monitor to start calibration.
the maximum angle A bar is displayed during calibration.
1) After the "Calib F pump swash plate sensor Keep running the track idle until calibration is
max" is displayed, calibrate the front pump finished.
swash plate sensor for the maximum angle
by running track idle off the ground and oper-
ating the function switches.
[F1]: Start
[F2]: Clear
[F5]: Return to Adjustment screen
[F6]: Confirm setting.

4) Calibration is finished successfully, "OK" is

displayed for the State of adjustment to show
that calibration for the maximum angle is
completed.
Press [F6] to go to calibration for the
maximum angle.

2) Raise the right track off ground by using the

work equipment and move the right travel
lever to the stroke end to run the right track
idle off the ground.
q Fuel control dial: Max. position
q Right travel lever: Full stroke
Travel direction may be set in either of
forward and reverse.
q Swing lock switch may be set in either of
ON and OFF.

PC228US-8,PC228USLC-8 30-111
(01)
Electrical system
Speial function of machine monitor (EMMS)

If calibration is finished unsuccessfully, "NG"

is displayed for the State of adjustment and 2) Wait under the following conditions:
the failure cause code is displayed. Referring q All levers: Neutral
to the failure cause codes in Table 1, find out Fuel control dial may be at any position.
and remove the cause and repeat calibration.
3) Hold down [F1] of the machine monitor to
start calibration.
A bar is displayed during calibration.
Keep all the levers in NEUTRAL until calibra-
tion is finished.

a The calibration value can be initialized by

holding down CLEAR button [F2].
If the calibration value is initialized,
"READY" is displayed for the State of
adjustment on the screen.

5. Calibration of front pump swash plate sensor for 4) Calibration is finished successfully, "OK" is
the minimum angle displayed for the State of adjustment to show
1) After the "Calib F pump swash plate sensor that calibration for the minimum angle is
min" is displayed, set all the levers in completed.
NEUTRAL and perform calibration the front Press [F6] to return to the Adjustment
pump swash plate sensor for the minimum screen.
angle with the function switches.
[F1]: Start
[F2]: Clear
[F5]: Return to Adjustment screen
[F6]: Confirm setting

30-112 PC228US-8,PC228USLC-8
(01)
 Electrical system
Speial function of machine monitor (EMMS)

If calibration is finished unsuccessfully, "NG" Adjustment (Calibration of rear pump swash

is displayed for the State of adjustment and plate sensor) 30-1 3
the failure cause code is displayed. Referring 1. Preparation for calibration
to the failure cause codes in Table 1, find out Before starting calibration, set the machine
and remove the cause and press [F6] to under the following condition
repeat the calibration for the minimum angle. q Hydraulic oil temperature: 50 °C
q Working mode: P mode
q Travel speed setting: Hi

2. Selection of menu
Select "Adjustment" on the "Service Menu"
screen.

a The calibration value can be initialized by

holding down CLEAR button [F2].
If the calibration value is initialized,
"READY" is displayed for the State of
adjustment on the screen.

3. Selecting sub menu

After the "Adjustment" screen is displayed,
select "Calib R pump swash plate sensor" by
using the function switches or numeral input
switches.
a Select this sub menu as in the case of select-
ing a menu on the "Service Menu" screen.

4. Perform the subsequent calibration procedure

according to "Calibration of front pump swash
plate sensor".

PC228US-8,PC228USLC-8 30-113
(01)
Electrical system
Speial function of machine monitor (EMMS)

Table 1. Failure cause codes

Calibration failure cause codes (Displayed in descending order of priority)
Cause code Object Content Remedy
A-1 Engine speed signal is 0 rpm Check that engine is started
A-2 Hydraulic oil temperature is low Check hydraulic oil temperature (Min. 45 °C)
A-3 Hydraulic oil temperature is high Check hydraulic oil temperature (Min. 90 °C)
A-4 Common Engine overheats Check for overheat
Perform troubleshooting for pump pressure
A-6 Pump pressure sensor (F, R) is defective
sensor
Perform troubleshooting for pump swash
A-7 Pump swash plate (F, R) sensor is defective
plate sensor
B-1 Calibration for Pump pressure of calibrated pump is above Test unload pressure
the minimum standard value
B-3 angle Lever is not in NEUTRAL Check that all levers are in NEUTRAL
Pump pressure of calibrated pump is below Perform troubleshooting for H-18 Travel
C-1
standard value speed is low
C-2 Travel speed setting is not Hi Check that travel speed setting is Hi
C-3 Fuel control dial is not set to Max. position Set fuel control dial to Max. position
C-4 Calibration for Both tracks are running Check that one travel lever is operated
the maximum
Check that work equipment lever are in NEU-
C-5 angle Oil flow from two pumps are not divided
TRAL
Perform troubleshooting for travel PPC pres-
C-6 Travel PPC pressure sensor is defective
sure sensor
Travel PPC pressure is below standard Perform troubleshooting for H-18 Travel
C-7
value speed is low
Output voltage of pump swash plate sensor Perform troubleshooting for pump swash
FF Common
is out of calibration range plate sensor

30-114 PC228US-8,PC228USLC-8
(01)
 Electrical system
Speial function of machine monitor (EMMS)

Cylinder Cut-Out 30-1 5

The machine monitor allows for running the engine
in "Cylinder Cut-Out" mode.
"Cylinder Cut-Out" operation means to run the en-
gine with 1 or more fuel injectors disabled electrical-
ly to reduce the number of effective cylinders. This
operation is used to locate a cylinder which does not
output power normally (combustion in it is abnor-
mal).

1. Selection of menu
Select "Cylinder Cut-out" on the "Service Menu"
screen.

3. Resetting Cut-Out cylinder

When changing a cylinder to be cut out or when
Cylinder Cut-Out operation is finished, select a
cut-out cylinder to be reset with the function
switches.
a This operation may be performed while the
engine is running.
a When [F6] is pressed, if background (a) of
the selected cylinder No. becomes blue, the
cylinder is reset.
a If the machine monitor resets a cut-out cylin-
der but the engine controller cannot reset
that cut-out cylinder, the background (a) of
2. Selecting cylinder to be disabled the cylinder No. becomes red.
After the "Cylinder Cut-Out" screen is displayed, a The cut-out cylinder is not automatically reset
select a cylinder to be cut out by using the func- even after returning to the operator mode.
tion switches. Accordingly, be sure to perform the resetting
q [F1]: Move selection mark (R) to left operation after the Cylinder Cut-Out opera-
q [F2]: Move selection mark (R) to right tion is finished.
q [F3]: Reset holding
q [F4]: Hold 4. Function of holding displayed information
q [F5]: Return to Service Menu screen Each time [F4] is pressed during the Cylinder
q [F6]: Confirm selection Cut-Out operation, the displayed data is newly
a This operation may be performed while the held (c) (the real-time data is kept displayed on
engine is running. the left side).
a When [F6] is pressed, if background (a) of If [F3] is pressed with the condition of hold, the
the selected cylinder No. becomes white, the holding function is canceled.
cylinder is cut out. a The holding function is available for a cylin-
a If the machine monitor cuts out a cylinder but der, regardless of whether it is cut out or not.
the engine controller cannot cut out that cyl-
inder, the background (a) of the cylinder No.
becomes yellow.
a One or more cylinders can be cut-out.
a During the cylinder Cut-Out operation, the
auto-deceleration function can be enabled. If
the auto-deceleration is set to ON, auto-de-
celeration monitor (b) is displayed.

PC228US-8,PC228USLC-8 30-115
(01)
Electrical system
Speial function of machine monitor (EMMS)

[Reference] No Injection 30-1 6

q If a normal cylinder is cut-out, the following phe- If the engine is operated after long storage of the
nomena occur. machine, it may be worn or damaged because of in-
1) Lowering of engine speed sufficient lubrication with oil. To prevent this, the ma-
2) Increase of final injection rate command chine monitor allows for cranking the engine without
(quantity) injecting fuel to lubricate the engine before starting
q If the engine is running near the high idle, how- it.
ever, the engine speed may not lower for the Set the no-injection cranking while the engine is
reason of engine control. stopped.
q In this case, lower the engine speed with the fuel
control dial and judge by increase of the injection 1. Selection of menu
rate command. Select "No Injection" on the "Service Menu"
screen.

2. Displaying check screen

When the "No injection" screen is displayed, the
the message to ask if no injection cranking
should be performed appears. Answer with the
function switch.
q [F5]: Do not perform (return to Service Menu
screen)
q [F6]: Perform
a Before the following screen is displayed, the
message of "Communication between con-
trollers is being checked" appears.

30-116 PC228US-8,PC228USLC-8
(01)
 Electrical system
Speial function of machine monitor (EMMS)

3. Starting no injection cranking 5. Prohibiting no injection cranking

If no injection cranking (fuel injection in no cylin- If the operator tries to perform the no injection
ders) becomes effective, "No Injection." is cranking while the engine is running, the
displayed on the screen. Under this condition, message "Engine is running" is displayed and
crank the engine with the starting motor. the no injection cranking is not enabled.
a Before the following screen is displayed, the a This function can be selected even while the
message of "Setting is being prepared" ap- engine is running. If the no injection cranking
pears. is performed, however, the message of "En-
a Limit the cranking time to 20 seconds to pro- gine is running" is displayed on the screen.
tect the starting motor.

4. Finishing no injection cranking

After completing the no injection cranking opera-
tion, press [F6], and the message "Finished" is
displayed and the screen returns to the "Service
Menu" screen automatically.

PC228US-8,PC228USLC-8 30-117
(01)
Electrical system
Speial function of machine monitor (EMMS)

Fuel Consumption 30-1 8 3. Display and function during measurement

Use this function to calculates the hourly fuel con- Clock mark (a) flashes during measurement.
sumption from the actual fuel consumption in a mea- a While the fuel consumption is being tested,
suring period and indicate it. the operator can work with the operator
mode and other functions. Test is not fin-
1. Selection of menu ished until [F1] is pressed again on this
Select "Fuel Consumption" on the "Service screen (even if the starting switch is turned to
Menu" screen. OFF positon, this function is kept effective,
although fuel consumption is tested only
while the engine is running).

2. Starting measurement
After the screen of "Fuel Consumption" is
displayed, start measurement by using the func- 4. Finishing measurement
tion switches. Press [F1], and measurement is finished and the
q [F1]: Start data are displayed in the Stop Time column.
q [F2]: Clear
q [F5]: Return to Service Menu screen 5. Displaying fuel consumption
a When the screen of "Fuel Consumption" is If the test is finished, the hourly fuel consumption
displayed, if a data is indicated, it is the data calculated from the fuel consumption calculated
of the previous measurement. This data is by the engine controller and the elapsed time are
not an obstacle to new measurement and displayed.
can be deleted by pressing [F2].
a If [F1] is pressed, the data is displayed in the
Start Time columun and measurement starts.

a The display unit of the fuel consumption

changes according to the unit set with the
Default (Unit) function.
SI and metric unit: l/h, Imoerial unit: gal/h

30-118 PC228US-8,PC228USLC-8
(01)
 Electrical system
Speial function of machine monitor (EMMS)

KOMTRAX Settings (Terminal Status) 30-1 9 3. Contents displayed on Terminal Status screen
The setting and operating status of KOMTRAX can On the "Terminal Status" screen, the following
be checked by using the menu of "KOMTRAX Set- items are displayed.
tings". q Terminal type: Model name of KOMTRAX
"KOMTRAX Settings" is used to check the setting communication MODEM
condition of the KOMTRAX terminal. q KOMTRAX communication: Executing condi-
tion of station opening inspection
1. Selection of menu q GMT time: Greenwich Mean Time
Select "KOMTRAX Settings" on the "Service q [F5]: Return to KOMTRAX Settings screen
Menu" screen.

2. Selecting sub menu

After the "KOMTRAX Settings" screen is
displayed, select "Terminal Status" by using the
function switches or numeral input switches.
a Select this item similarly to an item on the
"Service Menu" screen.

PC228US-8,PC228USLC-8 30-119
(01)
Electrical system
Speial function of machine monitor (EMMS)

KOMTRAX Settings (GPS & Communication Sta- 3. Contents of display of “GPS & Communication
tus) 30-120 Status”
The setting and operating status of KOMTRAX can On the "GPS & Communication Status" screen,
be checked by using the menu of "KOMTRAX Set- the following items are displayed.
tings". q Positioning: Positioning condition of GPS
"GPS & Communication Status" is used to check the q Communication: Communication environ-
positioning and communication status of the ment of communication MODEM and con-
KOMTRAX terminal. necting condition of communication MODEM
q Number of message not yet sent: Number of
1. Selection of menu mails which are saved in machine monitor
Select "KOMTRAX Settings" on the "Service and not transmitted yet
Menu" screen. q [F5]: Return to KOMTRAX settings screen

2. Selecting sub menu

After the "KOMTRAX Settings" screen is
displayed, select “GPS & Communication
Status” with the function switches or numeral
input switches.
a Select this item similarly to an item on the
"Service Menu" screen.

30-120 PC228US-8,PC228USLC-8
(01)
 Electrical system
Speial function of machine monitor (EMMS)

KOMTRAX Setting (MODEM S/N) 30-121 3. Contents displayed on Modem S/N screen
The setting and operating status of KOMTRAX can The serial No. of TH300 Modem is displayed.
be checked by using the menu of "KOMTRAX Set- q [F5]: Return to KOMTRAX Settings screen
tings".
Modem S/N is used to check the serial No. of the
KOMTRAX communication modem.

1. Selecting menu
Select "KOMTRAX Settings" on the "Service
Menu" screen.

2. Selecting sub menu

After the "KOMTRAX Settings" screen is
displayed, select "Modem S/N" with the function
switches or numeral input switches.
a Select this item similarly to an item on the
"Service Menu" screen.

PC228US-8,PC228USLC-8 30-121
(01)
Electrical system
Speial function of machine monitor (EMMS)

Service Message 30-12 3. Display of message (with return mail function)

Special messages for the technician sent from the If a message provides the Numeric Input line
KOMTRAX base station (a distributor, etc.) can be under the text, input a proper number by using
checked with this function. the numeral input switches and enter it by using
If a received message has return mail setting, a re- the function switch, and the information is
turn mail can be sent by using the numeral input returned to the KOMTRAX base station.
switches. q [F5]: Return to KOMTRAX Settings screen
q [F6]: To enter and return input value
1. Setection of menu a This message is different from that is sent for
Select "Service Message" on the Service Menu the operator in the operator mode
screen. a Since this message is special for the techni-
cian, the message monitor is not displayed
when it is received with the machine monitor
in the operator mode.

2. Display of message (read-only)

If there is a message, its contents are displayed.
If there is no message, "No message" is
displayed.
q [F5]: Return to Service Menu screen
a This message is different from that is sent for
the operator in the operator mode
a Since this message is special for the techni-
cian, the message monitor is not displayed
when it is received with the machine monitor
in the operator mode.

30-122 PC228US-8,PC228USLC-8
(01)
 Electrical system
Handling voltage circuit of engine controller

Handling voltage circuit of engine

controller 30-123

1. Before disconnecting or connecting the engine

harness connector from/to the engine controller,
be sure to turn the starting switch to OFF posi-
tion.

2. If a T-adapter is inserted in or connected to the

connector between the engine controller and
engine harness for troubleshooting, do not start
the engine.
a You may turn the starting switch to the OFF
or ON position, but must not turn it to the
START position.

PC228US-8,PC228USLC-8 30-123
(01)
Electrical system
Preparatory work for troubleshooting of electrical system

Preparatory work for troubleshooting of electrical system 30-124

a When carrying out troubleshooting of an electric 4) Insert or connect troubleshooting T-adapters

circuit related to the machine monitor, engine to connectors CM01, CM02, and CM03 on
controller, pump cont roller, or KOMTRAX com- machine monitor (4).
munication MODEM, expose the related con- a Connectors CM02 and CM03 are of the
nectors according to the following procedure. same type. When returning them, check
a Disconnect and connect the connectors, which the mark plates on the mounting brackets
have a special locking device, according to the and take care not to make a wrong con-
following procedure. nection.

1. Machine monitor
1) Remove two mounting bolts and cover (1).
a One of the mounting bolts is installed in
the cover on the right of the sunlight sen-
sor.
a While removing the mounting bolts, dis-
connect connector P31 of the sunlight
sensor.
2) Remove cover (2).
a The cover is fixed with the clip, so pull it
up to remove..
a While removing the mounting bolts, dis-
connect connector M04 of the cigarette
lighter. 2. Engine controller
1) Open the engine hood and remove the
compressor assembly from the air condi-
tioner.
a The engine controller is mounted on the
engine (on the counterweight side).
2) Insert or connect troubleshooting T-adapters
to connectors CE01, CE02, and CE03 on
engine controller (5).
a Connectors CE01 and CE02 are fixed by
screws. When disconnecting them, loos-
en the screws.
a When returning connectors CE01 and
CE02, tighten the screws to the specified
torque.
3) Remove a mounting bolt and duct (3). 3 Screw:
3 ± 1 Nm {0.3 ± 0.1 kgm}

30-124 PC228US-8,PC228USLC-8
(01)
 Electrical system
Preparatory work for troubleshooting of electrical system

3. Pump controller
1) Slide the operator's seat and seat stand to
the forward end.
2) Remove mounting bolts and cool &amp; hot
box (6).
3) Remove plate (7).
4) Remove duct (8).
5) Remove pump controller cover (9).

a The connectors of the pump controller

have a special locking mechanism. Dis-
connect them according to steps (a) to (c)
and connect them according to steps (d)
to (f) as shown below.
Disconnection: (a) Unlock o (b) Slide
lever o (c) Disconnect
connector.
Connection:(d) Position connector o (e)
Slide lever o (f) Lock.

4. KOMTRAX communication module

1) Slide the operator's seat and seat stand to
the forward end.
2) Remove mounting bolts and cool &amp; hot
box (6).
3) Remove plate (7).

6) Connect troubleshooting adapters to connec-

tors C01 and C02 of pump controller (10).
a Connect the adapters to only the wiring
harness.

PC228US-8,PC228USLC-8 30-125
(01)
Electrical system
Preparatory work for troubleshooting of electrical system

a Disconnection and connection of connector

4) Connect troubleshooting T-adapters to The connectors of the engine Ne speed
connectors CK01 and CK02 of KOMTRAX sensor, engine Bkup speed sensor, engine
communication module (13). oil pressure switch have a special locking
a Cable (14) is for the communication an- mechanism. Disconnect them according to
tenna. steps (a) to (c) and connect them according
to steps (d) to (f) as shown below.
Disconnection: (a) Slide lever o (b) Unlock
o (c) Disconnect connector.
Connection: (d) Connect connector o (e)
Lock o (f) Slide lever.

5. Engine Ne speed sensor (CRANK SENSOR)

Engine Bkup speed sensor (CAM SENSOR)
Engine oil pressure switch (OIL PRESSURE
SWITCH)

a Removal and installation of sensor

A deep socket is necessary for removal and
installation of the engine oil pressure switch.
See "Tools for testing, adjusting and trouble-
shooting".

6. Boost pressure temperature and sensor

(BOOST PRES & IMT)
a Disconnection and connection of connector
The connector of the boost pressure temper-
ature and sensor has a special locking mech-
anism. Disconnect it according to steps (a) to
(b), and connect it according to steps (c) to
(d) as shown below.
Disconnection: (a) Unlock o (b) Disconnect
connector.
Connection: (c) Connect connector o (d)
Lock.

30-126 PC228US-8,PC228USLC-8
(01)
 Electrical system
Preparatory work for troubleshooting of electrical system

a Removal and installation of sensor a Precautions for disconnecting connector

A Torx wrench is necessary for removal and The direction of the lock on the connector
installation of the boost pressure tempera- varies depending on position at which the
ture and sensor. See "Tools for testing, tightening of the sensor has been stopped
adjusting and troubleshooting". and the lock may be in a direction in which it
is difficult to unlock (lock faces the engine or
7. Supply pump IMV solenoid (FUEL REGU- downward).
LATOR) In this case, pinch the lock in direction (a) by
a Disconnection and connection of connector bent-longnose pliers [1] (commercially avail-
The connector of the supply pump IMV sole- able), and the lock is unlocked.
noid has a special locking mechanism. The lock clicks when it is unlocked, so
Disconnect it according to steps (a) to (b), disconnect the connector after a click is
and connect it according to steps (c) to (d) as heard.
shown below.
Disconnection: (a) Unlock o (b) Disconnect
connector.
Connection: (c) Connect connector o (d)
Lock.

a Precautions for connecting connector

Take care not to connect the connector
reversely.
Engage lock (e) on the wiring harness side
with triangular projection (f) on the sensor
8. Common rail pressure sensor (FUEL RAIL side (Do not engage lock (e) with square
PRESS) guide (g) on the opposite side of triangular
a Disconnection and connection of connector projection (f)).
The connector of the common rail pressure
sensor has a special locking mechanism.
Disconnect it according to steps (a) to (b),
and connect it according to steps (c) to (d) as
shown below.
Disconnection: (a) Unlock o (b) Disconnect
connector.
Connection: (c) Connect connector o (d)
Lock.

PC228US-8,PC228USLC-8 30-127
(01)
Electrical system
Preparatory work for troubleshooting of electrical system

9. Engine coolant temperature sensor

(COOLANT TEMP)
a Disconnection and connection of connector
The connector of the engine coolant temper-
ature sensor has a special locking device.
Disconnect it in the order of steps (a) to (b)
and connect it in the order of steps (c) to (d)
as shown below.
Disconnection: (a) Unlock o (b) Disconnect
connector.
Connection: (c) Connect connector o (d)
Lock.

a Removal and installation of sensor

A deep socket is necessary for removal and
installation of the engine coolant temperature
sensor. See Testing and adjusting, “Trouble-
shooting tools table”.

30-128 PC228US-8,PC228USLC-8
(01)
 Electrical system
Procedure for testing diodes

Procedure for testing diodes 30-129

a Test the diode assay (8-pin) and the single diode

(2-pin) according to the following procedure.
a The conducting directions of the diode array are
as follows.

2. When using analog multimeter

1) Set the multimeter in the resistance range.
2) Apply the leads of the multimeter as
explainedbelow and check the movement of
a The conducting direction of the single diode is in- the pointer.
dicated on the surface of the diode. 1] Apply the red (+) lead of the multimeter to
the anode (P) of the diode and apply the
black (–) lead to the cathode (N).
2] Apply the red (+) lead of the multimeter to
the cathode (N) of the diode and apply the
black (–) lead to the anode (P).
3) Evaluate the condition of the diode by the
movement of the pointer.
q The pointer does not move in i] but moves
in ii): The diode is normal (The moving
range (resistance) depends on the type
and selected range of the multimeter,
however).
q The pointer moves in both i] and ii]: The
diode is defective (internal short circuit).
q The pointer moves in neither of i] and ii]:
1. When using digital multimeter
The diode is defective (internal open cir-
1) Set the multimeter to the diode range and
cuit).
read the indicated value.
a When an ordinary circuit tester is used,
the voltage of the internal battery is indi-
cated.
2) Apply the red (+) lead of the multimeter to the
anode (P) of the diode and apply the black (–)
lead to the cathode (N), and check the indi-
cated value.
3) Evaluate the condition of the diode by the
indicated value.
q The indicated value does not change:
The diode does not have continuity (De-
fective).
q The indicated value changes: The diode
has continuity (Normal).
Note: In the case of a silicon diode, a value in
the range from 460 to 600 is indicated.

PC228US-8,PC228USLC-8 30-129
(01)
Electrical system
Procedure for testing diodes

30-130 PC228US-8,PC228USLC-8
(01)
 Pm clinic
Pm clinic service

Pm clinic 30-131
Pm clinic service 30-131
Model Serial No. Service meter reading
T PC228US-8
h
T PC228USLC-8
Customer name Date of check Inspector
/ /
Specification
Main components Attachments Shoe width
Boom T Standard T ( ) T Breaker T 600 mm
Arm T Standard T ( ) T( ) T 700 mm
Bucket T Standard T ( ) T( ) T( )
Check of oil/coolant level
T Radiator coolant When necessary
T Machinery case oil
T Engine oil T Damper case oil
T( )
T Hydraulic oil T Final drive case oil
Ambient temperature Height above sea level

°C m

Operator's comment

Visual check result

Mechanical system abnormality record Electrical Systems

989EKX __times/ 1st at ___hrs. / last at ___hrs. __times/ 1st at ___hrs. / last at ___hrs.
AA10NX __times/ 1st at ___hrs. / last at ___hrs. __times/ 1st at ___hrs. / last at ___hrs.
AB00KE __times/ 1st at ___hrs. / last at ___hrs. __times/ 1st at ___hrs. / last at ___hrs.
B@BAZG __times/ 1st at ___hrs. / last at ___hrs. __times/ 1st at ___hrs. / last at ___hrs.
B@BAZK __times/ 1st at ___hrs. / last at ___hrs. __times/ 1st at ___hrs. / last at ___hrs.
B@BCNS __times/ 1st at ___hrs. / last at ___hrs. __times/ 1st at ___hrs. / last at ___hrs.
B@BCZK __times/ 1st at ___hrs. / last at ___hrs. __times/ 1st at ___hrs. / last at ___hrs.
B@HANS __times/ 1st at ___hrs. / last at ___hrs. __times/ 1st at ___hrs. / last at ___hrs.
CA234 __times/ 1st at ___hrs. / last at ___hrs. __times/ 1st at ___hrs. / last at ___hrs.

Highest reading on engine coolant temperature Highest reading on hydraulic oil temperature
gauge 30-131 gauge 30-131

PC228US-8,PC228USLC-8 30-131
(01)
Pm clinic
Pm clinic service

Check items related to engine 30-132

30-132 PC228US-8,PC228USLC-8
(01)
 Pm clinic
Pm clinic service

Check items related to hydraulic pressure 30-13

PC228US-8,PC228USLC-8 30-133
(01)
Pm clinic
Pm clinic service

Check sheet (PC228US-8, PC228USLC-8)

Model Serial No. Service meter Customer name Date of check Inspector
reading
/ /

1. Engine
Testing conditions Standard
Mea-

Good
Fuel Work- Auto- Left Operation of value for Service limit

NG
No. Check item Unit sured
control ing decel- knob work equip- new value
value
dial mode erator switch ment machine
1 Engine speed All levers in rpm 1830 - 1970 1830 - 1970
Engine oil MAX the neutral MPa Min. 0.29 0.25
2
pressure position {kg/cm2} {Min. 3.0} {2.5}
OFF
3 Engine speed All levers in rpm 1025 - 1075 1025 - 1075
Engine oil MIN OFF the neutral MPa Min. 0.10 0.07
4
pressure
P
position {kg/cm2} {Min. 1.0} {0.7}
5 Engine speed rpm 1820 - 2020 1820 - 2020
Blowby pres- ON Arm IN relief kPa Max. 0.98 1.96
6
sure {mmH2O} {Max. 100} {200}
MAX
All levers in
7 Engine speed ON OFF the neutral rpm 950 - 1150 950 - 1150
position

2. Work equipment speed

Testing conditions Standard
Mea-

Good
Fuel Work- value for Service limit

NG
No. Check item Unit sured
control ing Work equipment posture, etc. new value
value
dial mode machine
Boom
1 PC228US 3.3 - 4.1 Max. 5.2
RAISE
Work equipment
P Demoli- sec.
extended fully
tion speci- 3.6 - 4.4 Max. 5.2
fication
PC228US 3.1 - 3.9 Max. 4.5
Demoli-
sec.
tion speci- 4.1 - 4.9 Max. 5.2
fication
E
PC228US 3.3 - 4.1 Max. 4.5
Demoli-
sec.
2 Arm IN tion speci- 4.3 - 5.3 Max. 6.0
Horizontal boom top fication
face PC228US
Demoli-
sec. 5.7 - 6.9 Max. 7.7
tion speci-
MAX fication
L
PC228US
Demoli-
sec. 2.4 - 3.0 Max. 3.5
tion speci-
fication
3 Arm OUT Horizontal boom top PC228US 2.3 - 3.9 Max. 3.3
surface and fully Demoli-
Bucket sec.
4 retracted arm cylin- tion speci- 2.5 - 3.1 Max. 3.4
CURL
der fication
Swing (5 Work equipment extended fully
5 sec. 25.6 - 30.9 Max. 33
turns) P Swing right and left
STD 46.2 - 56.4 46.2 - 60.5
LO sec.
LC 50.3 - 61.5 50.3 - 66
Travel One track raised and
STD 33.7 - 41.3 33.8 - 45.0
6 (five turns run idle forward and MI sec.
LC 36.7 - 44.9 36.7 - 49
idle running) reverse
STD 25.2 - 27.8 25.2 - 29.9
HI sec.
LC 27.5 - 30.3 26 - 32.7

30-134 PC228US-8,PC228USLC-8
(01)
 Pm clinic
Pm clinic service

3. Hydraulic drift of work equipment

Testing conditions
Standard Mea-

Good
Work- Service limit

NG
No. Check item Fuel con- Unit value for new sured
ing Work equipment posture, etc. value
trol dial machine value
mode
Drop amount of Boom top horizontal, Arm cylinder mm/15
1 Engine stopped Max. 600 Max. 900
bucket tip retracted fully, Bucket loaded min

4. Hydraulic circuit
[1] [2] [3] [4] [5]
Testing conditions 60 MPa 60 MPa 60 MPa 60 MPa 6 MPa
{600 kg/cm2} {600 kg/cm2} {600 kg/cm2} {600 kg/cm2} {60 kg/cm2}

Good
NG
No. Check item
Fuel Work- Left
Operation of R pump
control ing knob F pump main F pump LS R pump LS Control
work equipment main
dial mode switch
Self-pres-
All levers in the
1 sure reduc- – – – – A
neutral position
ing valve
OFF
Main relief
2 valve (low B B B B –
pressure)
Arm OUT relief
Main relief
3 valve (low ON C C C C –
pressure)
Unload All levers in the
4 D1 D1 D2 D2 –
valve neutral position
Right track run
idle, Lever E1 – E2 – –
moved halfway
5 LS valve
Left track run
idle, Lever – E1 – E2 –
moved halfway
MAX P Swing lock
switch ON, Right F F – – –
Swing
swing relief
6 motor
Swing lock
safety valve
switch ON, Left F F – – –
swing relief
OFF
Right track
locked ,Right
G – – – –
track forward
relief
Main relief
Right track
valve,
locked , Right
travel motor G – – – –
track reverse
7 safety
relief
valve,
Left track locked,
travel junc-
Left track for- – G – – –
tion valve
ward relief
Left track locked,
Left track – G – – –
reverse relief
Measured oil pressure Unit Standard value for new machine Service limit value
A (Control circuit source
2.93 - 3.43 {30 - 35} 2.75 - 3.43 {28 - 35}
pressure)
Standard value

B (Work equipment relief

33.8 - 35.8 {345 - 365} 33.3 - 36.8 {340- 375}
pressure, low)
C (Work equipment relief MPa
36.3 - 38.3 {370 - 390} 36.3 - 39.2 {370 - 400}
pressure, high) {kg/cm2}
D (Unload pressure) D1 - D2 = 2.5 - 4.5 {26 - 46} D1 - D2 = 2.5 - 4.5 {26 - 46}
E (LS differential pressure) E1 - E2 = 1.7 - 1.9 {17 - 19} E1 - E2 = 1.7 - 1.9 {17 - 19}
F (Swing relief pressure) 28.8 - 31.8 {295 - 325} 28.4 - 32.3 {290 - 330}
G (Travel relief pressure) 36.7 - 39.7 {375 - 405} 36.8 - 40.2 {375 - 410}

PC228US-8,PC228USLC-8 30-135
(01)
Pm clinic
Pm clinic service

* Gauge connection changing work: Exchange hoses of gauges [3] and [4].
[1] [2] [3a] [4a] [5]
Testing conditions 60 MPa 60 MPa 60 MPa 60 MPa 6 MPa

Good
Check {600 kg/cm2} {600 kg/cm2} {600 kg/cm2} {600 kg/cm2} {60 kg/cm2}

NG
No.
item Fuel Work- Left Operation of
F pump R pump F pump R pump
control ing knob work equip- Control
main main servo servo
dial mode switch ment
Servo pis- Arm OUT H1 H1 H2 H2
8 MAX P OFF –
ton relief
Measured oil pressure Unit Standard value for new machine Service limit value
Standard value

H1: H2 = 1 : 0.6
H (Servo control pressure) –
(Oil pressure ratio)

* Gauge connection changing work: Replace gauges [3] and [4] with 60K and exchange hoses of
[3], [4], and [5].
[1] [2] [3b] [4b] [5a]
Testing conditions 60 MPa 60 MPa 60 MPa 60 MPa 6 MPa
{600 kg/cm2} {600 kg/cm2} {600 kg/cm2} {600 kg/cm2} {60 kg/cm2}

Good
Opera-

NG
No. Check item
Fuel Work- Left tion of
F pump R pump
control ing knob work F pump (F) R pump (R) LS-EPC
main main
dial mode switch equip-
ment
PC-EPC(F) MIN P All levers – – J1 J1 –
valve in the – – J2 J2 –
9 E – – J3 J3 –
PC-EPC L neutral – – J4 J4 –
(R) valve B position – – J5 J5 –
Travel K1
speed:
Lo,
– – – –
Travel
lever in
neutral
MAX OFF
Travel K2
LS-EPC speed:
10 P
valve Mi, Travel – – – –
lever
operated
Travel K3
speed:
Hi, Travel – – – –
lever
operated
Measured oil pressure Unit Standard value for new machine Service limit value
J1 (PC-EPC valve output
Approx. 2.9 {Approx. 30}
pressure 1)
J2 (PC-EPC valve output
Approx. 0.7 {Approx. 7}
pressure 2)
J3 (PC-EPC valve output
Approx. 0.78 {Approx. 8}
Standard value

pressure 3)
J4 (PC-EPC valve output
MPa Approx. 1.7 {Approx. 17.5}
pressure 4)
J5 (PC-EPC valve output {kg/cm2} Approx. 1.57 {Approx. 16}
pressure 5)
K1 (LS-EPC valve output
Approx. 2.45 {Approx. 25}
pressure 1)
K2 (LS-EPC valve output
Approx. 0.74 {Approx. 7.5}
pressure 2)
K3 (LS-EPC valve output
pressure 3) 0 {0 kg/cm2}

30-136 PC228US-8,PC228USLC-8
(01)
SEN0533412-00 40-1

PC228US-8,PC228USLC-8

HYDRAULIC EXCAVATOR
Shop Manual 40-1

PC228US-8
PC228USLC-8

Machine model Serial number

PC228US-8 50001 and up
PC228USLC-8 50001 and up

40 Troubleshooting 40-1

PC228US-8,PC228USLC-8 40-1
(01)
Contents

Contents 40-2
40 Troubleshooting
General information on troubleshooting .................................................................................. 40- 8
Points to remember when troubleshooting .......................................................................... 40- 8
Sequence of events in troubleshooting................................................................................ 40- 9
Checks before troubleshooting ............................................................................................ 40- 10
Classification and procedures for troubleshooting ............................................................... 40- 34
Failure codes table............................................................................................................... 40- 37
Symptom and troubleshooting numbers .............................................................................. 40- 42
Information in troubleshooting table..................................................................................... 40- 44
Troubleshooting method for open circuit in wiring harness of pressure sensor system ...... 40- 46
Connector list and layout ..................................................................................................... 40- 48
Connection table for connector pin numbers ....................................................................... 40- 60
T- branch box and T- branch adapter table ......................................................................... 40- 96
Fuse location table............................................................................................................... 40- 100
Troubleshooting by failurecode ............................................................................................... 40- 102
Failure code [989L00] Engine Controller Lock Caution 1 .................................................... 40- 102
Failure code [989M00] Engine Controller Lock Caution 2 ................................................... 40- 102
Failure code [989N00] Engine Controller Lock Caution 3.................................................... 40- 103
Failure code [AA10NX] Air Cleaner Clogging ...................................................................... 40- 104
Failure code [AB00KE] Charge Voltage Low ....................................................................... 40- 106
Failure code [B@BAZG] Eng Oil Press Low........................................................................ 40- 108
Failure code [B@BAZK] Eng Oil Level Low......................................................................... 40- 109
Failure code [B@BCNS] Eng Water Overheat .................................................................... 40- 110
Failure code [B@BCZK] Eng Water Level Low ................................................................... 40- 112
Failure code [B@HANS] Hyd Oil Overheat.......................................................................... 40- 114
Failure code [CA111] ECM Critical Internal Failure ............................................................. 40- 115
Failure code [CA115] Eng Ne and Bkup Speed Sens Error ................................................ 40- 115
Failure code [CA122] Chg Air Press Sensor High Error ...................................................... 40- 116
Failure code [CA123] Chg Air Press Sensor Low Error ....................................................... 40- 118
Failure code [CA131] Throttle Sensor High Error ................................................................ 40- 120
Failure code [CA132] Throttle Sensor Low Error ................................................................. 40- 122
Failure code [CA144] Coolant Temp Sens High Error ......................................................... 40- 124
Failure code [CA145] Coolant Temp Sens Low Error.......................................................... 40- 126
Failure code [CA153] Chg Air Temp Sensor High Error ...................................................... 40- 128
Failure code [CA154] Chg Air Temp Sensor Low Error ....................................................... 40- 130
Failure code [CA155] Chg Air Temp High Speed Derate .................................................... 40- 132
Failure code [CA187] Sens Supply 2 Volt Low Error ........................................................... 40- 134
Failure code [CA221] Ambient Press Sens High Error ........................................................ 40- 136
Failure code [CA222] Ambient Press Sens Low Error ......................................................... 40- 138
Failure code [CA227] Sens Supply 2 Volt High Error .......................................................... 40- 140
Failure code [CA234] Eng Overspeed ................................................................................. 40- 141
Failure code [CA238] Ne Speed Sens Supply Volt Error..................................................... 40- 142
Failure code [CA271] IMV/PCV1 Short Error....................................................................... 40- 144
Failure code [CA272] IMV/PCV1 Open Error....................................................................... 40- 146
Failure code [CA322] Inj #1(L#1) Open/Short Error............................................................. 40- 148
Failure code [CA323] Inj #5 (L#5) Open/Short Error............................................................ 40- 150
Failure code [CA324] Inj #3(L#3) Open/Short Error............................................................. 40- 152
Failure code [CA325] Inj #6 (L#6) Open/Short Error............................................................ 40- 154
Failure code [CA331] Inj #2(L#2) Open/Short Error............................................................. 40- 156
Failure code [CA332] Inj #4(L#4) Open/Short Error............................................................. 40- 158
Failure code [CA342] Calibration Code Incompatibility........................................................ 40- 160

40-2 PC228US-8,PC228USLC-8
(01)
 Contents

Failure code [CA351] Injectors Drive Circuit Error............................................................... 40- 161

Failure code [CA352] Sens Supply 1 Volt Low Error ........................................................... 40- 162
Failure code [CA386] Sens Supply 1 Volt High Error .......................................................... 40- 164
Failure code [CA428] Water in Fuel Sensor High Error ....................................................... 40- 166
Failure code [CA429] Water in Fuel Sensor Low Error........................................................ 40- 168
Failure code [CA435] Eng Oil Press Sw Error ..................................................................... 40- 170
Failure code [CA441] Battery Voltage Low Error................................................................. 40- 172
Failure code [CA442] Battery Voltage High Error ................................................................ 40- 174
Failure code [CA449] Rail Press Very High Error................................................................ 40- 175
Failure code [CA451] Rail Press Sensor High Error............................................................ 40- 176
Failure code [CA452] Rail Press Sensor Low Error............................................................. 40- 178
Failure code [CA488] Chg Air Temp High Torque Derate ................................................... 40- 180
Failure code [CA553] Rail Press High Error ........................................................................ 40- 181
Failure code [CA559] Rail Press Low Error ......................................................................... 40- 182
Failure code [CA689] Eng Ne Speed Sensor Error ............................................................. 40- 184
Failure code [CA731] Eng Bkup Speed Sens Phase Error.................................................. 40- 186
Failure code [CA757] All Continuous Data Lost Error ......................................................... 40- 187
Failure code [CA778] Eng Bkup Speed Sensor Error.......................................................... 40- 188
Failure code [CA1633] KOMNET Datalink Timeout Error.................................................... 40- 191
Failure code [CA2185] Throt Sens Sup Volt High Error ...................................................... 40- 192
Failure code [CA2186] Throt Sens Sup Volt Low Error ....................................................... 40- 193
Failure code [CA2249] Rail Press Very Low Error............................................................... 40- 194
Failure code [CA2311] IMV Solenoid Error.......................................................................... 40- 195
Failure code [CA2555] Grid Htr Relay Open Circuit Error ................................................... 40- 196
Failure code [CA2556] Grid Htr Relay Short Circuit Error ................................................... 40- 198
Failure code [D110KB] Battery Relay Drive Short Circuit .................................................... 40- 200
Failure code [D19JKZ] Personal Code Relay Abnormality .................................................. 40- 202
Failure code [D862KA] GPS Antenna Open Circuit............................................................. 40- 204
Failure code [DA22KK] Pump Solenoid Power Low Error ................................................... 40- 206
Failure code [DA25KP] 5V Sensor1 Power Abnormality ..................................................... 40- 208
Failure code [DA26KP] 5V Sensor2 Power Abnormality ..................................................... 40- 210
Failure code [DA29KQ] Model Selection Abnormality ......................................................... 40- 214
Failure code [DA2RMC] CAN Discon (Pump Con Detected) .............................................. 40- 217
Failure code [DAF8KB] Camera Power Supply Short Circuit .............................................. 40- 222
Failure code [DAFGMC] GPS Module Error ........................................................................ 40- 224
Failure code [DAFRMC] CAN Discon (Monitor Detected) ................................................... 40- 226
Failure code [DGH2KB] Hyd Oil Sensor Short .................................................................... 40- 230
Failure code [DHPAMA] Pump Press Sensor Abnormality.................................................. 40- 232
Failure code [DHPBMA] R Pump Press Sensor Abnormality .............................................. 40- 234
Failure code [DHS3MA] Arm IN PPC Sen. Abnormality ...................................................... 40- 236
Failure code [DHS4MA] Bucket CURL PPC Press Sensor Abnormality ............................. 40- 238
Failure code [DHS8MA] Boom RAISE PPC Press Sensor Abnormality.............................. 40- 240
Failure code [DHSAMA] Swing RH PPC Press Sensor Abnomality .................................... 40- 242
Failure code [DHSBMA] Swing LH PPC Press Sensor Abnomality .................................... 40- 244
Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality ............................. 40- 246
Failure code [DHSFMA] Travel FW L PPC Press Sensor Abnormality ............................... 40- 248
Failure code [DHSGMA] Travel FW R PPC Press Sensor Abnormality .............................. 40- 250
Failure code [DHSHMA] Travel BW L PPC Press Sensor Abnormality............................... 40- 252
Failure code [DHSJMA] Travel BW R PPC Press Sensor Abnormality ............................... 40- 254
Failure code [DHX1MA] Overload Sensor Abnormality ....................................................... 40- 257
Failure code [DKA0KA] Boom Angle Sensor Open Circuit.................................................. 40- 260
Failure code [DKA0KB] Boom Angle Sensor Power Short Circuit ....................................... 40- 262
Failure code [DKA0PH] Boom Angle Sensor Install Abnormality ........................................ 40- 264
Failure code [DKR0MA] F pump S/P sensor Abnormality ................................................... 40- 266

PC228US-8,PC228USLC-8 40-3
(01)
Contents

Failure code [DKR1MA] R pump S/P sensor Abnormality ................................................... 40- 268
Failure code [DV20KB] Travel Alarm Short Circuit .............................................................. 40- 270
Failure code [DW43KA] Travel Speed Sol Open Circuit...................................................... 40- 272
Failure code [DW43KB] Travel Speed Sol Short Circuit ...................................................... 40- 274
Failure code [DW45KA] Swing Brake Sol Open Circuit ....................................................... 40- 276
Failure code [DW45KB] Swing Brake Sol Short Circuit ....................................................... 40- 278
Failure code [DW4GKA] Boom Slow Down Sol. Disc. ......................................................... 40- 280
Failure code [DW4GKB] Boom Slow Down Sol. Short Circuit ............................................. 40- 282
Failure code [DW4WKA] Cancel Bucket Dump Open Circuit .............................................. 40- 284
Failure code [DW4WKB] Cancel Bucket Dump Short Circuit .............................................. 40- 286
Failure code [DW91KA] Travel Junction Sol. Disc............................................................... 40- 288
Failure code [DW91KB] Travel Junction Sol. S/C................................................................ 40- 290
Failure code [DWA2KA] Attachment Sol Open Circuit......................................................... 40- 292
Failure code [DWA2KB] Attachment Sol Short Circuit......................................................... 40- 294
Failure code [DWK0KA] 2-stage Relief Sol Open Circuit..................................................... 40- 296
Failure code [DWK0KB] 2-stage Relief Sol Short Circuit..................................................... 40- 298
Failure code [DXA8KA] PC-EPC (F) Sol Open Circuit......................................................... 40- 300
Failure code [DXA8KB] PC-EPC (F) Sol Short Circuit......................................................... 40- 302
Failure code [DXA9KA] PC-EPC (R) Sol Open Circuit ........................................................ 40- 304
Failure code [DXA9KB] PC-EPC (R) Sol Short Circuit ........................................................ 40- 306
Failure code [DXE0KA] LS-EPC Sol Open Circuit............................................................... 40- 308
Failure code [DXE0KB] LS-EPC Sol Short Circuit ............................................................... 40- 310
Failure code [DXE4KA] Service Current EPC Disc.............................................................. 40- 312
Failure code [DXE4KB] Service Current EPC S/C............................................................... 40- 314
Failure code [DXE5KA] Merge-divider Main Sol Open Circuit ............................................. 40- 316
Failure code [DXE5KB] Merge-divider Main Sol Short Circuit ............................................. 40- 318
Failure code [DXE6KA] Merge-divider LS Sol Open Circuit ................................................ 40- 320
Failure code [DXE6KB] Merge-divider LS Sol Short Circuit................................................. 40- 322
Failure code [DY20KA] Wiper Working Abnormality............................................................ 40- 324
Failure code [DY20MA] Wiper Parking Abnormality ............................................................ 40- 326
Failure code [DY2CKA] Washer drive discon ...................................................................... 40- 328
Failure code [DY2CKB] Washer drive short......................................................................... 40- 330
Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit ..................................................... 40- 332
Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit...................................................... 40- 334
Troubleshooting of electrical system (E-mode)....................................................................... 40- 337
E-1 Engine does not start (Engine does not crank) ............................................................. 40- 337
E-2 Preheater does not operate........................................................................................... 40- 342
E-3 When starting switch is turned to ON position, machine monitor displays nothing ....... 40- 347
E-4 When starting switch is turned to ON position (before starting engine), basic check monitor lights up.
............................................................................................................................................. 40- 350
E-5 Precaution monitor lights up while engine is running .................................................... 40- 351
E-6 Emergency stop monitor lights up while engine is running ........................................... 40- 353
E-7 Fuel level gauge does not indicate correctly ................................................................. 40- 354
E-8 Engine coolant temperature gauge does not indicate correctly .................................... 40- 356
E-9 Hydraulic oil temperature gauge does not indicate correctly......................................... 40- 358
E-10 Displays on machine monitor are different from those for actual machine.................. 40- 361
E-11 Some areas of machine monitor screen are not displayed ......................................... 40- 361
E-12 Function switch does not operate................................................................................ 40- 361
E-13 Automatic warm-up system does not operate (in cold season)................................... 40- 362
E-14 Auto-decelerator does not operate properly................................................................ 40- 363
E-15 Working mode does not change.................................................................................. 40- 364
E-16 Travel speed does not change .................................................................................... 40- 365
E-17 Alarm buzzer cannot be canceled ............................................................................... 40- 366
E-18 When starting switch is turned OFF, service meter is not displayed........................... 40- 366

40-4 PC228US-8,PC228USLC-8
(01)
 Contents

E-19 Service mode cannot be selected ............................................................................... 40- 367

E-20 Any of work equipment, swing and travel do not operate or cannot be locked ........... 40- 368
E-21 Swing brake does not operate properly ...................................................................... 40- 371
E-22 One-touch power maximizing function does not operate properly .............................. 40- 374
E-23 Travel alarm does not sound or does not stop sounding ............................................ 40- 377
E-24 Horn does not sound or does not stop ........................................................................ 40- 378
E-25 Windshield wiper and window washer do not operate ................................................ 40- 380
E-26 BOOM LOWER indicator is not displayed properly with monitoring function.............. 40- 382
E-27 ARM OUT indicator is not displayed properly with monitoring function ...................... 40- 384
E-28 ARM IN indicator is not displayed properly with monitoring function .......................... 40- 386
E-29 BOOM RAISE indicator is not displayed properly with monitoring function ................ 40- 386
E-30 BUCKET CURL indicator is not displayed properly with monitoring function.............. 40- 386
E-31 BUCKET DUMP indicator is not displayed properly with monitoring function ............. 40- 387
E-32 SWING indicator is not displayed properly with monitoring function ........................... 40- 387
E-33 TRAVEL indicator is not displayed properly with monitoring function ......................... 40- 387
E-34 ATTACHMENT indicator is not displayed properly with monitoring function .............. 40- 388
E-35 Attachment hydraulic circuit cannot be changed......................................................... 40- 390
E-36 KOMTRAX system does not operate properly ............................................................ 40- 391
Troubleshooting of hydraulic and mechanical system (H-mode) ............................................ 40- 393
Information in troubleshooting table..................................................................................... 40- 393
System chart for hydraulic and mechanical systems........................................................... 40- 394
Failure mode and cause table ............................................................................................. 40- 396
H- 1 All of work equipment, swing and travel work slow or lack power ............................... 40- 398
H- 2 Engine speed lowers significantly or engine stalls....................................................... 40- 400
H- 3 Any of work equipment,swing and travel does not work .............................................. 40- 401
H- 4 Unusual sound is heard from around hydraulic pump ................................................. 40- 401
H- 5 Fine control performance or response is poor ............................................................. 40- 402
H- 6 Boom operation lacks speed or power......................................................................... 40- 403
H- 7 Arm operation lacks speed or power ........................................................................... 40- 404
H- 8 Bucket operation lacks speed or power ....................................................................... 40- 405
H- 9 Work equipment does not move in single operation .................................................... 40- 405
H-10 Hydraulic drift of work equipment is large ................................................................... 40- 406
H-11 Time lag of work equipment is large ........................................................................... 40- 408
H-12 Other work equipment moves when one of work equipment is relieved ..................... 40- 408
H-13 One-touch power maximizing function does not work ................................................ 40- 409
H-14 In combined operation of work equipment , equipment having heavier load moves slower.
............................................................................................................................................. 40- 409
H-15 In combined operation of swing and boom RAISE, boom rising speed is low ............ 40- 410
H-16 Travel speed drops largely in combined operation of swing and travel ...................... 40- 410
H-17 Machine does not travel straight ................................................................................. 40- 411
H-18 Travel speed is low ..................................................................................................... 40- 412
H-19 Machine is hard to steer or travel power is low........................................................... 40- 413
H-20 Travel speed does not change, or travel speed is too low or high.............................. 40- 414
H-21 One of tracks does not run.......................................................................................... 40- 415
H-22 Upper structure does not swing .................................................................................. 40- 416
H-23 Swing acceleration is poor or swing speed is low....................................................... 40- 418
H-24 Upper structure overruns excessively when it stops swinging .................................... 40- 420
H-25 Shock is large when upper structure stops swinging .................................................. 40- 421
H-26 Large unusual noise is heard when upper structure stops swinging .......................... 40- 421
H-27 Swing drift on a slope is large ..................................................................................... 40- 422
H-28 Attachment circuit cannot be changed........................................................................ 40- 423
H-29 Oil flow in attachment circuit cannot be controlled...................................................... 40- 423
Troubleshooting of engine (S-mode) ...................................................................................... 40- 424
Method of using troubleshooting chart................................................................................. 40- 424

PC228US-8,PC228USLC-8 40-5
(01)
Contents

S-1 Startability is poor.......................................................................................................... 40- 428

S-2 Engine does not start .................................................................................................... 40- 429
S-3 Engine does not pick up smoothly................................................................................. 40- 432
S-4 Engine stops during operation....................................................................................... 40- 433
S-5 Engine runs rough or is unstable................................................................................... 40- 434
S-6 Engine lacks power ....................................................................................................... 40- 435
S-7 Exhaust smoke is black (incomplete combustion)......................................................... 40- 436
S-8 Oil consumption is excessive (or exhaust smoke is blue) ............................................. 40- 437
S-9 Oil becomes contaminated early ................................................................................... 40- 438
S-10 Fuel consumption is excessive.................................................................................... 40- 439
S-11 Oil is in coolant (or coolant spurts or coolant level goes down) .................................. 40- 440
S-12 Oil pressure drops ....................................................................................................... 40- 441
S-13 Oil level rises (coolant or fuel in oil)............................................................................. 40- 442
S-14 Coolant temperature rises too high (overheating) ....................................................... 40- 443
S-15 Unusual noise is made ................................................................................................ 40- 444
S-16 Vibration is excessive.................................................................................................. 40- 445

40-6 PC228US-8,PC228USLC-8
(01)
 Contents

PC228US-8,PC228USLC-8 40-7
(01)
General information on troubleshooting
Points to remember when troubleshooting

General information on troubleshooting 40-8

Points to remember when troubleshooting 40-8
(Rev. 2010/03)
k Stop the machine in a level place, and check that the lock pin, blocks, and parking brake are se-
curely fitted.
k When carrying out the operation with two or more service technitians, keep strictly to the agreed
signals, and do not allow any unauthorized person to come near.
k If the radiator cap is removed when the engine is hot, hot water may spurt out and cause burns, so
wait for the engine to cool down before starting troubleshooting.
k Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
k When disconnecting wiring, always disconnect the negative (–) terminal of the battery first.
k When removing the plug or cap from a component which is under pressure from oil, water, or air,
always release the internal pressure first. When installing measuring equipment, be sure to con-
nect it properly.

The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to pre-
vent reoccurrence of the failure. When carrying out troubleshooting, an important point is of course to under-
stand the structure and function. However, a short cut to effective troubleshooting is to ask the operator
various questions to form some idea of possible causes of the failure that would produce the reported symp-
toms.

1. When carrying out troubleshooting, do not hurry 3) Make checks of other items.
to disassemble the components. 4) Check other maintenance matters which can
If components are disassembled immediately be checked externally and are considered to
after any failure occurs: be necessary.
q Parts that have no connection with the failure
or other unnecessary parts will be disassem- 4. Confirming failure
bled. Confirm the extent of the failure yourself, and
q It will become impossible to find the cause of judge whether to handle it as a real failure or as
the failure. a problem with the method of operation, etc.
It will also cause a waste of manhours, parts, or a When operating the machine to reenact the
oil or grease, and at the same time, will also lose troubleshooting symptoms, do not perform
the confidence of the user or operator. any inspection or measurement that may
For this reason, when carrying out trouble- make the problem worse.
shooting, it is necessary to carry out thorough
prior investigation and to carry out trouble- 5. Troubleshooting
shooting in accordance with the fixed procedure. Use the results of the investigation and inspec-
tion in Items 2 to 4 to narrow down the causes of
2. Points to ask the user or operator failure, then use the troubleshooting flowchart to
1) Have any other problems occurred apart locate the failure exactly.
from the problem that has been reported? a The basic procedure for troubleshooting is as
2) Was there anything strange about the follows.
machine before the failure occurred? 1] Start from the simple points.
3) Did the failure occur suddenly, or were there 2] Start from the most likely points.
problems with the machine condition before 3] Investigate other related parts or informa-
the failure? tion.
4) Under what conditions did the failure occur?
5) Had any repairs been carried out before the 6. Measures to remove root cause of failure
failure? When were these repairs carried Even if the immediate failure is removed, the
out? same failure may occur again, unless the root
6) Has the same kind of failure occurred cause of the failure is repaired. To prevent this,
before? always investigate why the cause of the failure
occurred. Then, remove the root cause.
3. Check before troubleshooting
1) Is there any sign of irregularities of the
machine?
2) Make checks before starting day's work.

40-8 PC228US-8,PC228USLC-8
(01)
 General information on troubleshooting
Sequence of events in troubleshooting

Sequence of events in troubleshooting 40-9

(Rev.2007.12)

PC228US-8,PC228USLC-8 40-9
(01)
General information on troubleshooting
Checks before troubleshooting

Checks before troubleshooting 40-10

No. Item Criterion Remedy

1 Check for unusual sounds and smells – Repair

2 Check for dirt around engine – Remove

3 Check for water leakage around engine – Repair

4 Check for oil leakage around engine – Repair

a: Engine, lubricating oil and coolant

5 Check for leakage from fuel line – Repair

6 Check of radiator for clogging – Remove

7 Check of level and type of fuel – Refill with fuel

8 Check for foreign matter in fuel – Clean and drain

9 Check of fuel pre-filter – Replace

10 Check of fuel main filter – Replace

11 Check of level (in oil pan) and type of engine oil Between H – L Refill with oil

12 Check of coolant level (in sub tank) Between H – L Refill with coolant
No air cleaner
13 Check of air cleaner for clogging clogging moni- Clean or replace
tor on screen
1 Check for abnormal sounds and smells – Repair

2 Check for oil leakage – Repair

b: Hydraulic and mechanical equipment

3 Check of hydraulic oil level Between H – L Refill with oil

4 Check of hydraulic oil strainer – Clean and drain

5 Check of hydraulic oil filter – Replace

6 Check of swing machinery case oil level Between H – L Refill with oil

7 Check of damper case oil level Between H – L Refill with oil

8 Check of final drive case oil level – Refill with oil

9 Performing air bleeding – Air bleeding

40-10 PC228US-8,PC228USLC-8
(01)
 General information on troubleshooting
Checks before troubleshooting

No. Item Criterion Remedy

1 Check of battery terminal for looseness and corrosion – Retighten or replace

2 Check of alternator terminal for looseness and corrosion – Retighten or replace

3 Check of starting motor terminal for looseness and corrosion – Retighten or replace

4 Check of battery voltage (with engine stopped) 20 – 30 V Charge or replace

5 Check of battery electrolyte level Between H – L Add or replace

6 Check of wiring harness for discoloration, burn and cover peeling – Repair or replace
c: Electrical equipment

7 Check of wiring harness for release from clamp and sagging – Repair

8 Check of grounding – Repair

9 Check for loose connector and damaged lock – Repair or replace

10 Check of connector pin for corrosion, bending and deformation – Repair or replace

11 Check for water and foreign matter in connector – Dry, clean or replace

12 Check of wiring harness for open or short circuit – Repair or replace

13 Check of fuse for blowout and corrosion – Replace

After several min-
Check of alternator voltage (When engine speed is medium or
14 utes operation: Replace
higher)
27.5 – 29.5 V
Check of battery relay operation sound (when the starting switch is
15 – Replace
turned and ON or OFF position)

16 Check and cleaning of rear view camera – Clean or repair

e: Interior parts d: Exterior parts

1 Check of undercarriage – Repair

2 Check of handrails and steps – Repair

3 Check of rear view mirrors – Clean or repair

1 Check of gauges and monitors – Clean or replace

2 Check of seat belt – Repair

PC228US-8,PC228USLC-8 40-11
(01)
General information on troubleshooting
Checks before troubleshooting

Testing procedure before troubleshooting 40-12

Walk-around check 40-12

Before starting the engine, look around and under the machine to check for any loose nuts or bolts, leakages
of oil, fuel or coolant, and check the condition of the work equipment and hydraulic system.
Check the connectors for looseness, the wiring harnesses for play, and the hot parts for accumulated dust.

k Accumulated combustibles around hot engine parts such as the engine muffler and turbocharger,
etc. and fuel or oil leakages may cause a machine fire. Be sure to check thoroughly and repair any
abnormalities.
a a1 and a2, ---, b1, b2, --- refer to the symbols in the table on the previous page.

a1. and b1. Check for unusual sounds and b3. Check of hydraulic equipment, hydraulic
smells tank, hoses and joints for oil leakage
Check for unusual sounds and smells. Check and repair any oil leaks.
Some causes of unusual sounds and smells can
damage the machine if they are left as they are. c1. Check for dirt around battery
Therefore, stop the machine immediately when Check for and remove any accumulated dirt and
you find any abnormality. combustibles (dead leaves, twigs, etc.) around
the battery.
a2. Check for dirt around engine
Check for and remove any accumulated dirt c16. Check and cleaning of rear view camera
around the engine and any combustibles (dead Check the rear view camera for any defect, and
leaves, twigs, etc.) on hot engine parts such as repair any failures.
the engine muffler, turbocharger, etc.
d1. Check of undercarriage (track, sprocket,
a3. Check for water leakage around engine idler and guard) for defect, wear, loose bolts and
a4. Check for oil leakage around engine oil leakage from roller
Check for any oil leaks from the engine and any Repair any failures.
water leaks from the cooling system. If any of
them is defective, carry out a repair. d2. Check of handrails and steps for defect and
loose bolts
a5. Check for leakage from fuel line Repair any failures and retighten any loose
Check for any fuel leaks and damaged hoses bolts.
and tubes. If any of them is defective, carry out a
repair. d3. Check and cleaning of rear view mirrors
Check for and repair any defective and broken
a6. Check of radiator for clogging rear view mirrors.
Check for and remove any accumulated dirt and Clean the mirror surfaces and adjust their angles
combustibles (dead leaves, twigs, etc.) around so that the operator can see the area behind him
the radiator. at the operator's seat.
For removal of dirt from the radiator, see the
Operation and Maintenance Manual, "Cleaning e1. Check of gauges and monitors for defect
and testing of radiator fins, oil cooler fins, after- Check the gauges and monitors inside the oper-
cooler fins, fuel cooler fins and air conditioner ator cab. If any of them is defective, replace it.
condenser fins (machine with the air condi- Clean up the surfaces.
tioner)".
e2. Check of seat belt and mounting hardware
b2. Check of work equipment, cylinders, linkage Check the hooks, locks and hook fittings for
and hoses for breakage, wear and clearance damage. If any of them has a problem, repair it.
Check the work equipment, cylinders, linkage
and hoses for cracks and excessive wear, check
that the clearances in them are within the normal
range, and then repair any failures.

40-12 PC228US-8,PC228USLC-8
(01)
 General information on troubleshooting
Checks before troubleshooting

Test according to testing procedure 40-13

a. Engine, lubricating oil and coolant 40-13

a7. Check of level and type of fuel

k Fuel is flammable and dangerous. Do not
bring any open flame near fuel.
k When adding fuel, take care not to let it over-
flow.
k Wipe off any spilt fuel. If fuel has spilt over
dirt and sand, remove the dirt and sand, too.
1. Turn the starting switch to the ON position and
check the fuel level with fuel level gauge (1) on
the monitor panel.
After checking, return the switch to the OFF posi-
tion.
q If breather hole (3) in the oil filler cap is
clogged, the pressure in the tank decreases
and fuel may not be supplied. To prevent this,
clean the breather hole.

2. If the fuel level is low, open oil filler cap (F) of the
fuel tank and add fuel through the oil filler port to
the necessary level, referring to the position of
float gauge (G).
3. After adding the fuel, push float gauge (G)
straight down using oil filler cap (F) and tighten
oil filler cap (F) securely while taking care not to
pinch float gauge (G) with pawls (2) of the oil
filler cap (F).

PC228US-8,PC228USLC-8 40-13
(01)
General information on troubleshooting
Checks before troubleshooting

a8. Check for foreign matter in fuel a9. Check of fuel pre-filter
1. Open the side cover on the rear right side of the k Immediately after the engine is stopped, its
machine. parts and oil will still be very hot and may
2. Put a container under drain valve (1) to receive burn your hands on contact. Therefore, wait
the drained fuel. until they have cooled down before starting
3. Turn drain valve (1) to "OPEN" position (O) to the work.
discharge the sediment and water in the bottom k High pressure is generated in the engine fuel
together with the fuel. piping system while the engine is running.
4. When only the clean fuel flows out, turn drain Wait for at least 30 seconds after stopping
valve (1) to "CLOSE" position (S). the engine until the internal pressure de-
5. Close the side cover. creases, and then replace the filter.
k Do not bring any open flame near the filter.
a Komatsu genuine fuel filter cartridges use a spe-
cial filter with a high filtration efficiency. When re-
placing, be sure to use a Komatsu genuine
cartridge.

a The common rail fuel injection system of this ma-

chine consists of parts that are more precise
compared with the conventional injection pump
and nozzle. If a fuel filter cartridge other than Ko-
matsu genuine one is used, foreign matter may
enter, which can cause a trouble in the injection
system. Never use a substitute.

a When testing and servicing the fuel system, be

extremely careful that no foreign matter enters. If
any dirt sticks, remove it completely by using fu-
el.
q Prepare a container to receive the fuel.
q Prepare the filter wrench.

Check of water separator, and drainage of water

and sediments
1. Turn valve (1) at the bottom of the fuel tank to
"CLOSE" (S) position.

2. Open the side cover on the rear right side of the

machine.
q The water separator is integrated with fuel
pre-filter (1).

40-14 PC228US-8,PC228USLC-8
(01)
 General information on troubleshooting
Checks before troubleshooting

3. Transparent cap (2) lets you identify the water a If water in transparent cap (2) is frozen, the
level and presence/absence of sediments. If water separator monitor may not light up.
water or sediments are found, place a container And after the engine starts, if the frozen water
under drain hose (3) to receive the drained water is melted into water due to the increased tem-
and sediments. perature surrounding fuel pre-filter (1), water
4. Loosen drain valve (4) to drain the water. separator monitor may suddenly light up.
Drain water frequently during the cold sea-
5. If drain hose (3) starts to discharge fuel, close son even if water separator monitor (5) is not
drain valve (4) immediately. lit up.
a If water in transparent cap (2) is frozen, drain
water only after confirming that it has com-
pletely melted.
a If you cannot visually identify the presence of
water due to stains on transparent cap (2),
clean transparent cap (2) when replacing fuel
pre-filter cartridge (1).
a When you have removed drain valve (4) for
the above cleaning process, coat the O-ring
with grease and tighten drain valve until it
touches the bottom.

a The sensor is installed in this machine for de-

tecting accumulation of water in transparent
cap (2).
a If water separator monitor (5) lights up in red
on the machine monitor, it indicates that wa-
ter is accumulated in transparent cap (2).
Drain water from the cap.

PC228US-8,PC228USLC-8 40-15
(01)
General information on troubleshooting
Checks before troubleshooting

Replacing fuel pre-filter cartridge 9. When installing the transparent cap, apply a thin
1. Turn valve (1) at the bottom of the fuel tank to the film of oil to the O-ring, set it against the sealing
"CLOSE" (S) position. surface of filter cartridge (4), and then tighten the
transparent cap by turning 1/4 to 1/2 turn.
a If the transparent cap is over tightened, fuel
will leak because the O-ring will have been
damaged. If the transparent cap is not tight-
ened sufficiently, fuel will also leak through
the clearance of the O-ring. Therefore, ob-
serve the tightening angle.
10. Clean the filter holder, fill the new filter cartridge
with clean fuel, apply a thin film of oil to the
O-ring , and then install the new filter cartridge
on the filter holder.
a Be sure to add fuel through 8 small holes (A)
on the dirty side without removing center cap
(B).
a After filling with the fuel, remove cap (B) at
2. Open the side cover on the rear right side of the
the center before installing the fuel pre-filter.
machine.
a Add clean fuel and take care that dirt is not
3. Place a container under the fuel pre-filter
mixed in it. Be sure to add fuel without remov-
cartridge to receive the fuel.
ing cap (B) to prevent dirt from entering the
4. Loosen drain valve (2) and drain water and sedi-
clean side of the central part.
ments from transparent cup (3), and also drain
all the fuel from filter cartridge (4).
5. Disconnect connector (5). Wrap the removed
connector with a vinyl bag and the like to protect
it from being exposed to fuel, oil and water.
6. Using the filter wrench, rotate transparent cap
(3) to remove. (This cap is reused.)
7. Using the filter wrench, rotate filter cartridge (4)
to remove.
8. Install currently removed transparent cap (3) to
the bottom of the new filter cartridge.
a At this time, replace O-ring (6) with a new
one.

11. When installing the fuel pre-filter cartridge,

tighten it by 3/4 turn after the O-ring come in
contact with the sealing surface of the filter
holder.
a If the filter cartridge is over tightened, fuel will
leak because the O-ring is damaged. If the fil-
ter cartridge is not tightened sufficiently, fuel
will also leak through the clearance of the
O-ring. Therefore, observe the tightening an-
gle.
a When using a filter wrench for tightening,
take care not to leave flaws or dents on the
filter.
12. Make sure that drain valve (2) is securely closed.

40-16 PC228US-8,PC228USLC-8
(01)
 General information on troubleshooting
Checks before troubleshooting

13. Remove the vinyl bag wrapping connector (5) a10. Check of main filter
and connect connector (5). k Immediately after the engine is stopped, its
a If connector (5) is exposed to water, the sen- parts and oil will still be very hot and may
sor may malfunction, lighting up the water burn your hands on contact. Therefore, wait
separator monitor. Whenever disconnecting until they have cooled down before starting
connector (5), take care not to allow the con- the work.
nector to come in contact with water. k High pressure is generated in the engine fuel
a If connector (5) does come in contact with piping system while the engine is running.
water, dry it completely prior to connecting it. Wait for at least 30 seconds after stopping
the engine until the internal pressure de-
creases, and then replace the filter.
k Do not bring any open flame near the filter.
a Komatsu genuine fuel filter cartridges use a spe-
cial filter with a high filtration efficiency. When re-
placing, be sure to use a Komatsu genuine
cartridge.

a The common rail fuel injection system of this ma-

chine consists of parts that are more precise
compared with the conventional injection pump
and nozzle. If a fuel filter cartridge other than Ko-
matsu genuine one is used, foreign matter may
enter, which can cause a trouble in the injection
system. Never use a substitute.

a When testing and servicing the fuel system, be

extremely careful that no foreign matter enters. If
any dirt sticks, remove it completely by using fu-
el.
q Prepare a container to receive the fuel.
q Prepare the filter wrench.

1. Turn valve (1) at the bottom of the fuel tank to the

"CLOSE" (S) position.

2. Open the engine hood.

3. Place a container under the filter cartridge to
receive the fuel.

PC228US-8,PC228USLC-8 40-17
(01)
General information on troubleshooting
Checks before troubleshooting

4. Using the filter wrench, rotate filter cartridge (2) a If the filter cartridge is over tightened, fuel will
to remove. leak because the O-ring is damaged. If the fil-
ter cartridge is not tightened sufficiently, fuel
will also leak through the clearance of the
O-ring. Therefore, observe the tightening an-
gle.
7. Turn valve (1) at the fuel tank bottom to "OPEN"
(O) position.
8. Bleed air according to the following procedure.
1) Fill the fuel tank up with the fuel (until the float
is in the upper limit position).
2) Loosen feed pump knob (4) and draw it out
once, then push and pull several times until
its movement becomes stiff.
q You do not need to remove the plugs at
the head of the fuel pre-filter and fuel
main filter.
5. Clean the filter holder. Apply a thin film of oil to
q If fuel is used up, bleed air by operating
the packing of the new filter cartridge and install
feed pump knob (4) in the same manner.
the cartridge to the filter holder.
a Replace inside seal (3) with a new one.

3) Push in and tighten feed pump knob (4).

a Do not fill the new filter cartridge with fuel.
9. After replacing the filter cartridge, run the engine
a Remove cap (A) at the center before install-
at low idle for approximately 10 minutes.
ing the filter cartridge.
10. Check the filter sealing surface for fuel leakage.
If fuel is leaking, check whether the filter
cartridge is appropriately tightened. If fuel
leakage recurs after the check, remove the filter
cartridge by following the steps 1 to 4 and check
the O-ring for damage or foreign matter being
caught. If any of the above problems are
detected on the O-ring, replace the cartridge
with a new one. Then, perform step 5 and after.

6. When installing the filter cartridge, tighten it by

3/4 turn after the O-ring comes in contact with
the sealing surface of the filter holder.

40-18 PC228US-8,PC228USLC-8
(01)
 General information on troubleshooting
Checks before troubleshooting

a11. Check of level (in oil pan) and type of en- 6. If the oil level is above line H, drain the extra
gine oil engine oil through drain valve (P) at the bottom
k Immediately after the engine is stopped, its of the engine oil pan and check the oil level
parts and oil will still be very hot and may again.
burn your hands on contact. Therefore, wait 7. If the oil is at the correct level, tighten the oil filler
until they have cooled down before starting cap securely and close the engine hood.
the work.
a If the engine has been operated, wait for at least
15 minutes after stopping it, and check the oil
level.
a When checking, set the machine in a horizontal
position.
1. Stop the engine.
2. Open the engine hood.
3. Remove oil level gauge (G) and wipe off oil on
the gauge with a cloth.
4. Insert oil level gauge (G) fully and pull it out.

5. If the oil level is between stamped lines H and L

on oil level gauge (G), it is at the correct level.
If the oil level is below line L, add oil through oil
filler port (F).

PC228US-8,PC228USLC-8 40-19
(01)
General information on troubleshooting
Checks before troubleshooting

a12. Check of coolant level (in sub tank) a13. Check of air cleaner for clogging
k You do not need to open the radiator cap in k When using compressed air for cleaning, put
the ordinary check. Check the coolant on the on personal protective items such as safety
sub tank side after the engine has cooled glasses, gloves, dust mask, etc. to protect
down. yourself from dirt that will fly out.
k Immediately after the engine is stopped, the k Removing the outer element from the air
coolant will be hot and pressure will have ac- cleaner body forcibly is dangerous .
cumulated in the radiator. When working in high places or on unstable
If the cap is opened under these conditions, footing, you may fall off due to the reaction
you may be scalded. If you need to remove when you pull out the outer element.
the radiator cap, wait until the temperature
drops before you do. Then rotate the cap Checking
slowly to release the pressure and remove it Clean the air cleaner element if air cleaner clogging
with care. monitor (1) on the monitor panel lights up.
1. Open the side cover at the rear left side of the
machine and check whether the coolant level is
between lines FULL and LOW on sub tank (1)
(see following figure). If there is not enough
coolant, add it through the coolant filler port of
sub tank (1) until the level reaches line FULL.
2. After adding the coolant, tighten the cap
securely.
3. If the sub tank is vacant, coolant may have
leaked.
After checking, repair any failures immediately. If
no failure is found, check the coolant level in the
radiator. If the level is low, add coolant to the
radiator first and then to the sub tank.
4. When you cannot identify the coolant level due
a Do not clean the element until the air cleaner
to stains inside sub tank (1), clean the sub tank.
clogging monitor lights up on the monitor panel.
If the element is cleaned frequently before the air
cleaner clogging monitor on the monitor panel
lights up, the true performance of the air cleaner
will not be realized and the filtration efficiency will
decrease.
a If the outer element is checked or cleaned while
the engine is running, the dirt sticking to it will fall
into the inner element side more frequently and
enter and damage the engine. Be sure to stop
the engine before cleaning.

40-20 PC228US-8,PC228USLC-8
(01)
 General information on troubleshooting
Checks before troubleshooting

Cleaning of outer element

a Do not leave or store the element in direct sun-
light before or after cleaning it.
a Replace the outer element after cleaning it six
times or after using it for 1 year. When replacing
the outer element, replace the inner element,
too.
a If the air cleaner clogging monitor (1) lights up
soon after cleaning when the outer element has
not been cleaned up to six times, replace both
the inner and outer elements.
1. Open the side cover at the rear left side of the
engine and disengage four hooks (2) to remove
cover (3).
5. If dirt has piled up on vacuator valve (4) installed
on cover (3), remove it.

2. Hold and pull out outer element (5) while

swinging it up, down and laterally and rotating
element to the left and right.
6. Blow dry compressed air (Max. 0.69 MPa
a Never remove inner element (6). If it is re-
moved, dirt will enter and can lead to engine {7 kg/cm2}) along the inside pleats of the outer
troubles. element.
a Do not use a screwdriver or another tool. 7. Next, blow air along the outside pleats, and blow
a After removing outer element (5), check that again along the inside pleats.
the inner element has not come off or tilted. If
the inner element is tilted, push it in straight
by hand.
3. After removing outer element (5), cover the inner
element (6) with a clean cloth or tape to prevent
dirt from sticking to it.
4. Remove any dirt adhered to the inside of air
cleaner body (7) and cover (3) with a piece of
clean cloth, etc.
a When cleaning the element, do not tap it or
bump it against other objects.

PC228US-8,PC228USLC-8 40-21
(01)
General information on troubleshooting
Checks before troubleshooting

a After cleaning, light up the inside of the ele- 11. Install cover (3) according to the following proce-
ment to check it. If the element has a small dure.
hole or a thin component, replace it. 1) Set cover (3) to the element.
a Be sure to install cover (3) so that vacua-
tor (4) is at the bottom (A).

8. Remove the cloth or tape covering inner element

(6).
9. Check and remove any dirt, oil, etc. sticking to
the sealing surface of the cleaned or new
2) Hitch the tips of hooks (2) to the projection of
element.
the air cleaner body to lock.
a If the element or O-ring used for more than
a Hitch hooks (2) diagonally (top and bot-
one year is cleaned and reused, it can cause
tom, or right and left) to lock.
a trouble. Therefore, do not reuse it.
a After installing cover (3), check for clear-
a Do not use the element if its pleats, gasket or
ance between the air cleaner body and
seal is damaged.
cover (3). If there is any clearance, re-
10. Push the outer element straight into the air
move and install cover (3) correctly.
cleaner body while swinging it up, down and
laterally.
a Install the air cleaner element with its bottom
(end with no hole) (C) on cover (3) side.
If the air cleaner element is installed in
reverse, it may be broken and the engine
may be damaged seriously.

12. Peel off a seal after cleaning the element each

time.

40-22 PC228US-8,PC228USLC-8
(01)
 General information on troubleshooting
Checks before troubleshooting

Replacement of element
1. Remove outer element (5). For details, see
"Cleaning of outer element".
2. Remove inner element (6) and install new inner
element (6) quickly to air cleaner body (7).
a Do not clean or reuse the inner element.
When replacing the outer element, also re-
place the inner element.

5. Install cover (3). For details, see "Cleaning of

outer element".
6. Replace seal (9) of cover (3) with a new one.

a Install the air cleaner element with its bottom

(end with no hole) (B) on cover (3) side.
If the air cleaner element is installed in
reverse, it may be broken and the engine
may be damaged seriously.
a If the outer element and cover are installed
while the inner element is not installed se-
curely, the outer element may be broken. In-
stall the inner element securely.

3. Push the outer element straight into the air

cleaner body while swinging it up, down and
laterally.
a Install the air cleaner element with its bottom
(end with no hole) (B) on cover (3) side.
If the air cleaner element is installed in
reverse, it may be broken and the engine
may be damaged seriously.
4. Replace O-ring (8) of cover (3) with a new one.

PC228US-8,PC228USLC-8 40-23
(01)
General information on troubleshooting
Checks before troubleshooting

b. Hydraulic and mechanical equipment 40-24

b3. Check of hydraulic oil level

k Immediately after the engine is stopped, its
parts and oil will still be very hot and may
burn your hands on contact. Therefore, wait
until they have cooled down before starting
the work.
k If the oil filler cap is removed quickly, the oil
may spurt out. Therefore, rotate the oil filler
cap slowly to release the internal pressure
and remove it with care.
1. Set the work equipment in the posture as shown
below and, after stopping the engine, check the
oil level and add new oil if necessary.
a If the work equipment posture is not as
shown below, fully retract the cylinder rod for
the arm and bucket while running the engine
at low speed. Then lower the boom and stop
the engine when the bucket teeth touch the
ground.

2. Turn the starting switch to the ON position within

15 seconds after stopping the engine and
operate each control lever (work equipment and
travel) to the stroke end in each direction to
release the internal pressure.
3. Sit down on the operator's seat and check sight
gauge (G) through the right window. If the oil Since the oil level fluctuates according to the oil
level is between lines H and L, there is sufficient temperature, note the following when checking
oil. it.
a If the oil level is below line L, add oil through q Before operation (oil temperature: 10 -
oil filter port (F). 30 °C), the oil level should be at the center
a Do not add oil to above line H. If too much is between lines H and L.
added, it may damage the hydraulic circuit q During normal operation (oil temperature: 50
and spurt out. - 80 °C), the oil level should be near line H.
a If the oil level is higher than line H, swing the
upper structure so that drain plug (P) at the
bottom of the tank comes between the left
and right tracks, and stop the engine. After
the hydraulic oil has cooled, remove cover (1)
to drain excessive oil through drain plug (P).

40-24 PC228US-8,PC228USLC-8
(01)
 General information on troubleshooting
Checks before troubleshooting

b4. Check of hydraulic oil strainer b5. Check of hydraulic oil filter
k Immediately after the engine is stopped, its k Immediately after the engine is stopped, its
parts and oil will still be very hot and may parts and oil will still be very hot and may
burn your hands on contact. Therefore, wait burn your hands on contact. Therefore, wait
until they have cooled down before starting until they have cooled down before starting
the work. the work.
k If the oil filler cap is removed quickly, the oil k If the oil filler cap is removed quickly, the oil
may spurt out. Therefore rotate the oil filler may spurt out. Therefore rotate the oil filler
cap slowly to release the internal pressure cap slowly to release the internal pressure
and remove it with care. and remove it with care.
1. Stop the engine and remove oil filler cap (F) of
the hydraulic tank to release the internal pres- 1. On a level and firm ground, set the work equip-
sure. ment to the posture as shown below and stop the
2. Remove the bolts to remove cover (1). engine.
When removing the bolts, keep pressing down
cover (1) since it may be flung toward you by
spring (2).
3. Pull out rod (3) from the top, and take out spring
(2) and strainer (4).
4. Remove dirt from strainer (4) and clean it using
cleaning oil. If strainer (4) is damaged, replace it
with a new one.
5. Insert and set strainer (4) in projected portion (5)
of the tank.
6. While pressing down spring (2) with the projec-
tion at the bottom of cover (1), install the bolts.
7. Tighten the mounting bolts.
2. Remove oil filler cap (F) of the hydraulic tank to
release the internal pressure.

3. Remove the bolts to remove cover (1).

When removing the bolts, keep pressing down
cover (1) since it may be flung toward you by
spring (2).
4. Remove spring (2), valve (3), strainer (4) and
then remove element (5).
q Check the bottom of the filter case and re-
move dirt if there is. At this time, take extreme
care that dirt does not enter the hydraulic
tank.

PC228US-8,PC228USLC-8 40-25
(01)
General information on troubleshooting
Checks before troubleshooting

5. Clean the removed parts using cleaning oil. 6. After checking the oil level and adding oil, install
6. Install new element (5). oil level gauge (G) and oil filler cap (F).
7. Set strainer (4), valve (3) and spring (2) on the
element.
8. Set cover (1) and install it with the mounting bolts
while pressing it with your hand.
9. Tighten the mounting bolts.

10. Install oil filler cap (F).

11. Run the engine at a low speed for 10 minutes to
bleed air.
12. Stop the engine.

b6. Check of swing machinery case oil level

k Immediately after the engine is stopped, its
parts and oil will still be very hot and may
burn your hands on contact. Therefore, wait
until they have cooled down before starting
the work.
1. Remove oil level gauge (G) and wipe off oil on
the gauge with a cloth.
2. Insert oil level gauge (G) fully into the guide.
3. Pull out oil level gauge (G) and check the oil
level. If the oil level is between stampde lines (H)
and (L) on the oil level gauge, there is sufficient
oil.
4. If the oil level is below line (L) on oil level gauge
(G), remove the cap of oil filter port (F) and add
oil. When adding oil, remove oil level gauge (G).
5. If the oil level is above line (H) of oil level gauge
(G), loosen drain valve (P) to drain the excessive
oil.
q When draining the oil, place an oil container
under drain valve (P).

40-26 PC228US-8,PC228USLC-8
(01)
 General information on troubleshooting
Checks before troubleshooting

b7. Check of damper case oil level 4. Tighten plug (P).

k Before checking the oil level, you must stop 5. Supply oil through the hole for plug (F).
the machine in a level place and wait for at 6. If oil flows out from the hole for plug (F), install
least 30 minutes after the engine is stopped. plug (F).
1. Open the side cover on the rear right side of the 3 Tightening torque of Plugs (P) and (F):
machine. 68.6 ± 9.8 Nm {7 ± 1 kgm}
2. Remove plug (G) and check the oil level. If the oil a Plug (F) is provided in two locations. To add
level is near the lower edge of the plug hole, oil, use the hole that is easier to use or the in-
there is sufficient oil. If the oil level is insufficient, ternal gear can not be seen throught it.
remove plug (F) and add oil through the hole of
plug (F) up to the lower edge of the hole for plug
(G).
a Since an excessive oil can cause overheat, it
must be drained to the specified oil level.
3. Install plug (G) and plug (F).
4. Close the side cover.

b8. Check of final drive case oil level

k Since the oil may spurt out due to internal
pressure, rotate the plug gradually from its
side to release the internal pressure and then
remove it carefully.
k Immediately after the engine is stopped, its
parts and oil will still be very hot and may
burn your hands on contact. Therefore, wait
b9. Performing air bleeding
until they have cooled down before starting
q For the procedure for bleeding air from the fuel
the work.
system, see Testing and adjusting, "Bleeding air
q Refill capacity (right and left, respectively): 5.2 l
from fuel circuit".
q Prepare the handle.
q For the procedure for bleeding air from the hy-
1. Set the final drive with TOP mark at the top, and
draulic equipment, see Testing and adjusting,
the straight line connecting the mark and plug (p)
"Bleeding air from each part".
is vertical to the ground surface.
2. Place the fuel receiving container under plug (P).
3. Remove plug (P) and (F) using the handle to
drain oil.
a Check the O-ring attached to the plug for
damage. Replace it, if any.

PC228US-8,PC228USLC-8 40-27
(01)
General information on troubleshooting
Checks before troubleshooting

c. Electrical equipment 40-28

c1. Check of battery terminal for looseness and

corrosion
1. Open the side cover on the rear left side of the
machine and remove battery cover (1).
2. Check the battery cable terminals for looseness
and corrosion.

c2. Check of alternator terminal for looseness

and corrosion
q Remove covers (1) and (2).
q Check alternator terminal B (3) for open circuit,
looseness and corrosion.

c3. Check of starting motor terminal for loose-

ness and corrosion
q Check starting motor terminal B (4) and terminal
C (5) for open circuit, looseness and corrosion.

40-28 PC228US-8,PC228USLC-8
(01)
 General information on troubleshooting
Checks before troubleshooting

c4. Check of battery voltage (with engine 3. After adding the purified water, tighten cap (2)
stopped) securely.
Test the battery voltage by using the battery tester
while the engine is stopped.

c5. Check of battery electrolyte level

Check before operating the machine.
k Do not use the battery while its electrolyte
level is below LOWER LEVEL. If it is used un-
der that condition, its inside will deteriorate,
its service life will be shortened and it may
lead to an explosion.
k Since the battery produces combustible gas
that can explode, do not bring any open
flame near it.
k Battery electrolyte is dangerous. Take care
that it does not come in contact with your
a If you have added purified water above the
eyes or skin. If it does, wash it away with wa-
U.L. line, take some of it out using a syringe
ter and contact your doctor.
or similar tool. Neutralize the liquid that has
a Do not add battery electrolyte beyond the UP-
been taken out with sodium bicarbonate or
PER LEVEL mark. Excessive addition can
other suitable liquid, and wash it out with a
cause electrolyte leakage that damages the
large amount of water.
painted surface and corrodes the parts.
q When electrolyte level cannot be checked
a As purified water (example: commercially avail-
through the side face of the battery
able battery fluid) added to the battery may
1. Remove cap (2) on the top of the battery.
freeze, add it before starting work for the day so
(Described previously)
that it does not freeze.
2. Look into electrolyte level opening (3) to check
q When checking the electrolyte level through the
the electrolyte level. If the electrolyte level is
side face of the battery
below sleeve (4), be sure to add purified water
1. Clean around the electrolyte level lines using a
(example: commercially available battery fluid)
cloth soaked in water, and check that the electro-
up to the sleeve bottom (U.L. line).
lyte level is between UPPER LEVEL (U.L.) and
q (A) Correct level: Since the electrolyte level
LOWER LEVEL (L.L.)
reaches to the sleeve bottom, the shape of
a Do not clean the battery with a dry cloth since
the electrode plates will appear distorted due
static electricity may cause an explosion.
to the surface tension.
q (B) Low: Since the electrolyte level does not
reach the sleeve bottom, the shape of the
electrode plates will appear straight.
3. After adding the purified water, tighten cap (2).

2. If the electrolyte level is below the center

between the U.L. and L.L. lines, remove cap (2)
and add purified water (example: commercially
available battery fluid) to the U.L. line immedi-
ately.

PC228US-8,PC228USLC-8 40-29
(01)
General information on troubleshooting
Checks before troubleshooting

a If you have added purified water above the c7. Check of wiring harness for release from
U.L. line, take some of it out using a syringe clamp and sagging
or similar tool. Neutralize the liquid that has q Check the wiring harnesses for sagging and
been taken out with sodium bicarbonate or loosening caused by holease from a clamp.
other suitable liquid, and wash it out with a a In particular, carefully check the wiring harness
large amount of water. around the hot and movable parts.
q If any part is off the clamp, resecure it to the
c6. Check of wiring harness for discoloration, clamp.
burn and cover peeling
q Check the wiring harness and cables for discol-
oration and burn.
a Discoloration and burn indicate that short circuit
or ground fault is in the circuit.
q Check the wiring harnesses and cables for dam-
age and peeling of the covers.
q If any failures are discovered, repair or replace
the wiring harness or cable.

c8. Check of grounding

a Check the ground terminal for looseness and
rust in particular.
q Remove cover (1).

q Check the connection of ground terminals (2),

(3), (T01) and (T14).

40-30 PC228US-8,PC228USLC-8
(01)
 General information on troubleshooting
Checks before troubleshooting

q Cab ground strap T02

a Since (T02) is situated at the bottom on the rear
left side of the cab and connected to (T01), it is
not particularly necessary to check it.

q Check ground terminals (T04) - ( T10) for con-

nection.

c9. Check for loose connector and damaged

lock
q Pull the male and female connectors of the con-
nector by the hand to check the connection.
q If the connection is defective, connect them se-
curely.

q Open the engine hood.

a To check the connection of ground strap of the
engine, remove the counterweight.
q Check the connection of ground strap (4) of en-
gine controller (EC).

q Check that the connector is not unlocked and

check its lock and housing for cracks.
q Check lock screws (L) of engine controller (EC)
for looseness.
a Use a hexagonal wrench with 4 mm width
across flats.

PC228US-8,PC228USLC-8 40-31
(01)
General information on troubleshooting
Checks before troubleshooting

c10. Check of connector pin for corrosion, bend- q Remove foreign matter in the connector by using
ing and deformation a cloth or other material, and blow compressed
q Disconnect the connector and check the pins for air against the inside of the connector.
corrosion, bending and recession. Check that
the female pins have not expanded.
q If any pin is found to be damaged, repair or re-
place it.
a If the pins are not shiny, apply contact restorer to
them and connect and disconnect several times
to shine them. (If the pins do not become shiny,
connect and disconnect the connector 10 times)

c11. Check for water and foreign matter in con-

nector
q Disconnect the connector and check for water,
dirt, sand, etc. in it.

c12. Check of wiring harness for open or short

circuit
q Check the connection (crimped parts) between
each connector pin and wiring harness.
q If any open circuit is in wiring harness or connec-
tor as (A) in the figuer, repair or replace them.

a If sand or foreign matter is in the connector,

check the seal for damage.
q If the seal is defective, repair or replace it.
q Dry the moisture in the connector by using a dri-
er.

q Check that any pin does not contact any adja-

cent pin due to peeling of the wire cover, defec-
tive crimping of the pin, etc.

c13. Check of fuse for blowout and corrosion

a When replacing a fuse, be sure to turn off the
power (turn the starting switch to the OFF posi-
tion).
q A fusible link is a large-capacity fuse.
q If a fuse is corroded and coated with white pow-
der, or there is any play between the fuse and
fuse holder, replace the fuse.
q Replace each fuse with the one of the same ca-
pacity.

40-32 PC228US-8,PC228USLC-8
(01)
 General information on troubleshooting
Checks before troubleshooting

Remove the cover at the left rear of the operator

seat, and the fuse holder is seen.

Open the battery inspection cover and pull up the vi-

nyl cover. You will find fusible links (F04) and (F05)
there.

c14. Check of alternator voltage (when engine

speed is medium or higher)
1. Open the engine hood.
2. Connect the positive (+) lead of the multimatter
to alternator terminal (B) and connect the nega-
tive (-) lead to the chassis ground.
3. Start and warm up the engine and measure the
voltage while running the engine at a medium or
a higher speed.
q If the voltage is out of the normal range ab-
normal, repair or replace the alternator.

c15. Check of battery relay operation sound

1. Open the battery cover.
2. Check whether the battery relay operation sound
is heard when starting switch is turned to
ON/OFF position.
q If the operation sound is not heard, check the
related circuits, referring to E-1 described in
the E mode troubleshooting.
q If the related circuits are normal, replace the
battery relay.

PC228US-8,PC228USLC-8 40-33
(01)
General information on troubleshooting
Classification and procedures for troubleshooting

Classification and procedures for troubleshooting 40-34

Classification for troubleshooting 40-34

Mode Contents
Display of code Troubleshooting by failure code
E-mode Troubleshooting of electrical system
H-mode Troubleshooting of hydraulic and mechanical systems
S-mode Troubleshooting of engine

Procedure for troubleshooting 40-34

If a problem occurs on the machine, proceed to the appropriate troubleshooting section according to the fol-
lowing procedure.
1. Procedure for troubleshooting when user code and failure code are displayed on machine
monitor:
If a user code and a failure code are displayed on the machine monitor, perform the troubleshooting for
the corresponding "Display of code".
a If multiple failure codes are displayed simultaneously, all the codes are displayed repeatedly in order.
Note down all the codes.
2. Procedure for troubleshooting when a user code and a failure code are not displayed on machine
monitou:
Check the mechanical system failure code and the electrical system failure code by using the abnormailty
record function of the machine monitor. (See [*1].)
1) If failure code (s) is (are) recorded, perform troubleshooting for the failure code described in Trouble-
shooting [Display of code].
a If electrical system failure code (s) is (are) recorded, delete all the codes and reproduce them in
order to see if the problem remains unsolved. (See [*2].)
a The failure code of the mechanical system cannot be deleted.
a If an air conditioner system failure is recorded in the abnormality record , perform "Inspection by
self-diagnosis function " in "Air conditioner ". (See [*3].)
2) If no failure code is found in the abnormality record, a problem that the machine monitor cannot find
out by itself may have occurred in the electrical system or hydraulic and mechanical system.
In this case, check the phenomenon which is assumed to show a trouble again and select the same
phenomenon from the list on the next page, and then perform troubleshooting corresponding to that
phenomenon in the "E-mode", "H-mode", or "S-mode".

3. Action to take after trouble is eliminated

Referring to the next page, clear all the failure codes in the electrical system abnormality record.

40-34 PC228US-8,PC228USLC-8
(01)
 General information on troubleshooting
Classification and procedures for troubleshooting

[*1], [*2] 5. Press the [F3] switch (R) on the panel switch
1. While pressing numerical key [4] of the panel section to see if the next failure code is displayed
switch section with the standard screen and note down all the failure codes.
displayed, press [1], [2] and [3] in order. a A mechanical system failure code cannot be
cleared.
6. Press [F5] switch (Return) on the panel switch
section to return to the "Abnormality Record"
screen.
7. Select the "Electrical Systems " screen similarly
to steps 2 and 3.
8. Press the [F3] switch (R) on the panel switch
section to see if the next failure code is displayed
and note down all of the failure codes.
a "E" on the left of a failure code indicates that
the failure code is "active" (the failure re-
mains or restoration to the normal condition
has not been verified). A failure code having
no "E" on its left is a "inactive" one. Since it
2. On the Service Menu screen, press [F3] switch disappears at the following clear step, be
(R) on the panel switch section once to select sure to note it down.
"02 Abnormality Record". 9. While pressing numerical key [4] on the panel
3. Press [F6] switch ( ) on the panel switch to switch section, press [1], [2] and [3] in this order
confirm and go to "Abnormality Record" screen. to select the "Clear mode". (Same as step 1)
10. Press [F2] switch(CLEAR) on the panel switch
section.
11. Press [F6] switch ( ) on the panel switch to clear
all the failure codes temporarily.
12. Press [F5] switch (Return) on the panel switch
section to return to the "Electrical Systems"
abnormality record screen. See if any failure
code is still displayed and note down displayed
ones.
13. Press [F5] switch (Return) on the panel switch
section to return to the "Abnormality Record"
screen.

4. Press [F6] switch ( ) on the panel switch to

confirm and go to "Mechanical system" screen.

PC228US-8,PC228USLC-8 40-35
(01)
General information on troubleshooting
Classification and procedures for troubleshooting

[*3]
a For the method of accessing the "Abnormality
Record" screen, see steps 1 to 3 in [*1] and [*2].
1. On the "Abnormality Record" screen, press [F3]
switch (R) on the panel switch section twice to
select "03 Air-conditioning System".
2. Press [F6] switch ( ) on the panel switch to
confirm and enter the "Air conditioner abnor-
mality record" screen.

3. Note down the information in all the columns.

a "E" on the left of a failure code (same as in
the "Electrical Systems" abnormality record)
indicates that the failure code is "active" (the
failure remains or its restoration to the normal
condition has not been verified).
4. Press [F2] switch (CLEAR) on the panel switch
section to clear all the codes. Check whether any
failure code is still displayed and note down
displayed ones. (Same as step 10 of [*1] and
[*2])
5. Press [F5] switch (Return) on the panel switch
section to return to the "Abnormality Record"
screen.

40-36 PC228US-8,PC228USLC-8
(01)
 General information on troubleshooting
Failure codes table

Failure codes table 40-37

Reference
Component Category of
Failure code Failure (Displayed on screen) User code document
in charge record
page
Electrical
989L00 Engine Controller Lock Caution 1 MON – 40-102
system
Electrical
989M00 Engine Controller Lock Caution 2 MON – 40-102
system
Electrical
989N00 Engine Controller Lock Caution 3 MON – 40-103
system
Mechanical
AA10NX Air Cleaner Clogging MON – 40-104
system
Mechanical
AB00KE Charge Voltage Low MON – 40-106
system
Mechanical
B@BAZG Eng Oil Press Low ENG – 40-108
system
Mechanical
B@BAZK Eng Oil Level Low MON – 40-109
system
Mechanical
B@BCNS Eng Water Overheat ENG – 40-110
system
Mechanical
B@BCZK Eng Water Level Low MON – 40-112
system
Mechanical
B@HANS Hyd Oil Overheat MON – 40-114
system
Electrical
CA111 EMC Critical Internal Failure ENG E10 1-115
system
Electrical
CA115 Eng Ne and Bkup Speed Sens Error ENG E10 40-115
system
Electrical
CA122 Chg Air Press Sensor High Error ENG E11 40-116
system
Electrical
CA123 Chg Air Press Sensor Low Error ENG E11 40-118
system
Electrical
CA131 Throttle Sensor High Error ENG E14 40-120
system
Electrical
CA132 Throttle Sensor Low Error ENG E14 40-122
system
Electrical
CA144 Coolant Temp Sens High Error ENG E15 40-124
system
Electrical
CA145 Coolant Temp Sens Low Error ENG E15 40-126
system
Electrical
CA153 Chg Air Temp Sensor High Error ENG E15 40-128
system
Electrical
CA154 Chg Air Temp Sensor Low Error ENG E15 40-130
system
Electrical
CA155 Chg Air Temp High Speed Derate ENG E11 40-132
system
Electrical
CA187 Sens Supply 2 Volt Low Error ENG E15 40-134
system
Electrical
CA221 Ambient Press Sens High Error ENG E11 40-136
system
Electrical
CA222 Ambient Press Sens Low Error ENG E11 40-138
system
Electrical
CA227 Sens Supply 2 Volt High Error ENG E15 40-140
system
Electrical
CA234 Eng Overspeed ENG – 40-141
system
Electrical
CA238 Ne Speed Sens Supply Volt Error ENG E15 40-142
system
Electrical
CA271 IMV/PCV1 Short Error ENG E10 40-144
system
Electrical
CA272 IMV/PCV1 Open Error ENG E10 40-146
system
Electrical
CA322 Inj #1 (L#1) Open/Short Error ENG E11 40-148
system

PC228US-8,PC228USLC-8 40-37
(01)
General information on troubleshooting
Failure codes table

Electrical
CA323 Inj #5 (L#5) Open/Short Error ENG E11 40-150
system
Electrical
CA324 Inj #3 (L#3) Open/Short Error ENG E11 40-152
system
Electrical
CA325 Inj #6 (L#6) Open/Short Error ENG E11 40-154
system
Electrical
CA331 Inj #2 (L#2) Open/Short Error ENG E11 40-156
system
Electrical
CA332 Inj #4 (L#4) Open/Short Error ENG E11 40-158
system
Electrical
CA342 Calibration Code Incompatibility ENG E10 40-160
system
Electrical
CA351 Injectors Drive Circuit Error ENG E10 40-161
system
Electrical
CA352 Sens Supply 1 Volt Low Error ENG E15 40-162
system
Electrical
CA386 Sens Supply 1 Volt High Error ENG E15 40-164
system
Electrical
CA428 Water in Fuel Sensor High Error ENG E15 40-166
system
Electrical
CA429 Water in Fuel Sensor Low Error ENG E15 40-168
system
Electrical
CA435 Eng Oil Press Sw Error ENG E15 40-170
system
Electrical
CA441 Battery Voltage Low Error ENG E10 40-172
system
Electrical
CA442 Battery Voltage High Error ENG E10 40-174
system
Electrical
CA449 Rail Press Very High Error ENG E11 40-175
system
Electrical
CA451 Rail Press Sensor High Error ENG E11 40-176
system
Electrical
CA452 Rail Press Sensor Low Error ENG E11 40-178
system
Electrical
CA488 Chg Air Temp High Torque Derate ENG E11 40-180
system
Electrical
CA553 Rail Press High Error ENG E15 40-181
system
Electrical
CA559 Rail Press Low Error ENG E15 40-182
system
Electrical
CA689 Eng Ne Speed Sensor Error ENG E15 40-184
system
Electrical
CA731 Eng Bkup Speed Sens Phase Error ENG E15 40-186
system
Electrical
CA757 All Continuous Data Lost Error ENG E10 40-187
system
Electrical
CA778 Eng Bkup Speed Sensor Error ENG E15 40-188
system
Electrical
CA1633 KOMNET Datalink Timeout Error ENG E0E 40-191
system
Electrical
CA2185 Throt Sens Sup Volt High Error ENG E14 40-192
system
Electrical
CA2186 Throt Sens Sup Volt Low Error ENG E14 40-193
system
Electrical
CA2249 Rail Press Very Low Error ENG E11 40-194
system
Electrical
CA2311 IMV Solenoid Error ENG E11 40-195
system
Electrical
CA2555 Grid Htr Relay Open Circuit Error ENG E15 40-196
system
Electrical
CA2556 Grid Htr Relay Short Circuit Error ENG E15 40-198
system
Electrical
D110KB Battery Relay Drive Short Circuit PUMP – 40-200
system

40-38 PC228US-8,PC228USLC-8
(01)
 General information on troubleshooting
Failure codes table

Electrical
D19JKZ Personal Code Relay Abnormality KOMTRAX E01 40-202
system
Electrical
D862KA GPS Antenna Open Circuit KOMTRAX – 40-204
system
Electrical
DA22KK Pump Solenoid Power Low Error PUMP E0E 40-206
system
Electrical
DA25KP 5 V Sensor1 Power Abnormality PUMP – 40-208
system
Electrical
DA26KP 5 V Sensor2 Power Abnormality PUMP – 40-210
system
Electrical
DA29KQ Model Selection Abnormality PUMP – 40-214
system
Electrical
DA2RMC CAN Discon (Pump Con Detected) PUMP E0E 40-217
system
Electrical
DAF8KB Camera Power Supply Short Circuit MON – 40-222
system
Electrical
DAFGMC GPS Module Error KOMTRAX – 40-224
system
Electrical
DAFRMC CAN Discon (Monitor Detected) MON E0E 40-226
system
Electrical
DGH2KB Hyd Oil Sensor Short PUMP – 40-230
system
Electrical
DHPAMA F Pump Press Sensor Abnormality PUMP – 40-232
system
Electrical
DHPBMA R Pump Press Sensor Abnormality PUMP – 40-234
system
Electrical
DHS3MA Arm Curl PPC Press Sensor Abnormality PUMP – 40-236
system
Electrical
DHS4MA Bucket Curl PPC Press Sensor Abnormality PUMP – 40-238
system
Electrical
DHS8MA Boom Raise PPC Press Sensor Abnormality PUMP – 40-240
system
Electrical
DHSAMA Swing RH PPC Press Sensor Abnormality PUMP – 40-242
system
Electrical
DHSBMA Swing LH PPC Press Sensor Abnormality PUMP – 40-244
system
Electrical
DHSDMA Bucket Dump PPC Press Sensor Abnormality PUMP – 40-246
system
Electrical
DHSFMA Travel FW L PPC Press Sensor Abnormality PUMP E20 40-248
system
Electrical
DHSGMA Travel FW R PPC Press Sensor Abnormality PUMP E20 40-250
system
Electrical
DHSHMA Travel BW L PPC Press Sensor Abnormality PUMP E20 40-252
system
Electrical
DHSJMA Travel BW R PPC Press Sensor Abnormality PUMP E20 40-254
system
Electrical
DHX1MA Overload Sensor Abnormality PUMP – 40-257
system
Electrical
DKA0KA Boom Angle Sensor Open Circuit PUMP E50 40-260
system
Electrical
DKA0KB Boom Angle Sensor Power Short Circuit PUMP E50 40-262
system
Electrical
DKA0PH Boom Angle Sensor Install Abnormality PUMP E50 40-264
system
Electrical
DKR0MA F pump S/P sensor Abnormality PUMP – 40-266
system
Electrical
DKR1MA R pump S/P sensor Abnormality PUMP – 40-268
system
Electrical
DV20KB Travel Alarm Short Circuit PUMP – 40-270
system
Electrical
DW43KA Travel Speed Sol Open Circuit PUMP – 40-272
system
Electrical
DW43KB Travel Speed Sol Short Circuit PUMP – 40-274
system

PC228US-8,PC228USLC-8 40-39
(01)
General informationontroubleshooting
Failure codes table

Electrical
DW45KA Swing Brake Sol Open Circuit PUMP E03 40-276
system
Electrical
DW45KB Swing Brake Sol Short Circuit PUMP E03 40-278
system
Electrical
DW4GKA Boom Slow Down Sol. Disc. PUMP E06 40-280
system
Electrical
DW4GKB Boom Slow Down Sol. S/C PUMP E06 40-282
system
Electrical
DW4WKA Cancel Bucket Dump Sol Open Circuit PUMP E50 40-284
system
Electrical
DW4WKB Cancel Bucket Dump Sol Short Circuit PUMP E50 40-286
system
Electrical
DW91KA Travel Junction Sol Open Circuit PUMP – 40-288
system
Electrical
DW91KB Travel Junction Sol Short Circuit PUMP – 40-290
system
Electrical
DWA2KA Attachment Sol Open Circuit PUMP – 40-292
system
Electrical
DWA2KB Attachment Sol Short Circuit PUMP – 40-294
system
Electrical
DWK0KA 2-stage Relief Sol Open Circuit PUMP – 40-296
system
Electrical
DWK0KB 2-stage Relief Sol Short Circuit PUMP – 40-298
system
Electrical
DXA8KA PC-EPC (F) Sol Open Circuit PUMP E02 40-300
system
Electrical
DXA8KB PC-EPC (F) Sol Short Circuit PUMP E02 40-302
system
Electrical
DXA9KA PC-EPC (R) Sol Open Circuit PUMP E02 40-304
system
Electrical
DXA9KB PC-EPC (R) Sol Short Circuit PUMP E02 40-306
system
Electrical
DXE0KA LS-EPC Sol Open Circuit PUMP – 40-308
system
Electrical
DXE0KB LS-EPC Sol Short Circuit PUMP – 40-310
system
Electrical
DXE4KA Service Current EPC Open Circuit PUMP – 40-312
system
Electrical
DXE4KB Service Current EPC Short Circuit PUMP – 40-314
system
Electrical
DXE5KA Merge-divider Main Sol Open Circuit PUMP – 40-316
system
Electrical
DXE5KB Merge-divider Main Sol Short Circuit PUMP – 40-318
system
Electrical
DXE6KA Merge-divider LS Sol Open Circuit PUMP – 40-320
system
Electrical
DXE6KB Merge-divider LS Sol Short Circuit PUMP – 40-322
system
Electrical
DY20KA Wiper Working Abnormality PUMP – 40-324
system
Electrical
DY20MA Wiper Parking Abnormality PUMP – 40-326
system
Electrical
DY2CKA Washer Drive Open Circuit PUMP – 40-328
system
Electrical
DY2CKB Washer Drive Short Circuit PUMP – 40-330
system
Electrical
DY2DKB Wiper Drive (Fwd) Short Circuit PUMP – 40-332
system
Electrical
DY2EKB Wiper Drive (Rev) Short Circuit PUMP – 40-334
system

40-40 PC228US-8,PC228USLC-8
(01)
 General information on troubleshooting
Failure codes table

a In this table, failure codes are arranged in the order of characters from numeric to alphabelic character.
a A component in charge means a controller or the machine monitor that is in charge of the system check.
MON: Machine monitor
ENG: Engine controller
PUMP: Pump controller
KOMTRAX: KOMTRAX part of machine monitor
a The failure codes that do not have user codes in the user code columns are not displayed on the standard
screen even if a failure code is generated. They are just recorded in the abnormality record (electrical sys-
tem and mechanical system) on the service menu.
a The category of record column shows in which system each failure is classified, the electrical equipment
system or mechanical equipment system, when it is recorded in the abnormality record.
For details, see "Troubleshooting by failure code (Display of code)".

PC228US-8,PC228USLC-8 40-41
(01)
General information on troubleshooting
Symptom and troubleshooting numbers

Symptom and troubleshooting numbers 40-42

Symptom and troubleshooting number
Troubleshooting
No. Symptom of failure Reference document
Index
page
User code, failure code
1 User code and failure code are displayed on machine monitor
The failure code is displayed on the mechanical system abnormality
2 Take actions by following the failure code.
record screen
The failure code is displayed on the electrical system abnormality
3
record screen
The failure code is displayed on the air conditioner or heater abnor- "Inspection by self-diagnosis function" in
4
mality record screen Chapter 80

Troubleshooting
No. Symptom of failure Reference document
Index
page
Symptom related to engine
5 Startability is poor S-1 40-428
6 Engine does not start E-1, S-2 40-337,40-429
7 Engine does not pick up smoothly S-3 40-432
8 Engine stops during operation S-4, H-2 40-433,40-400
9 Engine runs rough or is unstable (hunts) S-5 40-434
10 Engine lacks power S-6 40-435
11 Exhaust smoke is black (incomplete combustion) S-7 40-436
12 Oil consumption is too much (or exhaust smoke is blue) S-8 40-437
13 Oil becomes contaminated early S-9 40-438
14 Fuel consumption is excessive S-10 40-439
15 Oil is in coolant (or coolant spurts back or coolant level goes down) S-11 40-440
16 Oil pressure drops S-12 40-441
17 Oil level rises (coolant or fuel in oil) S-13 40-442
18 Coolant temperature rises too high (Overheating) S-14 40-443
19 Unusual noise is heard S-15 40-444
20 Vibration is excessive S-16 40-445
21 Preheater does not operate E-2 40-342
22 Automatic warm-up system does not operate (in cold season) E-13 40-362
23 Auto-decelerator does not operate normally E-14 40-363
Symptom related to work equipment, swing and travel
24 Any of work equipment, swing, and travel does not work E-20, H-3 40-368,40-401
25 All of work equipment, swing and travel work slow or lack power H-1 40-398
26 Engine speed lowers significantly or engine stalls H-2, S-6 40-400,40-435
27 Working mode does not change E-15 40-364
28 Unusual sound is heard from around hydraulic pump H-4 40-401
29 Fine control performance or response is poor H-5 40-402
Symptom related to work equipment
30 Speed or power of boom is low H-6 40-403
31 Speed or power of arm is low H-7 40-404
32 Speed or power of bucket is low H-8 40-405
33 Work equipment does not move in single operation H-9 40-405
34 Hydraulic drift of work equipment is large H-10 40-406
35 Time lag of work equipment operation is large H-11 40-408

40-42 PC228US-8,PC228USLC-8
(01)
 General information on troubleshooting
Symptom and troubleshooting numbers

Troubleshooting
No. Symptom of failure Reference document
Index
page
36 Other wok equipment moves when one of work equipment is relieved H-12 40-408
37 One-touch power maximizing function does not work. H-13, E-22 40-409,40-374
38 Attachment circuit can not be changed H-28, E-35 40-423,40-390
39 Oil flow in attachment circuit cannot be changed H-29 40-423
Symptom related to combined operation
In combined operation of work equipment, equipment having heavier
40 H-14 40-409
load moves slower
In combined operations of swing and boom RAISE, boom rising speed
41 H-15 40-409
is low
42 Travel speed drops largely in combined operation of swing and travel H-16 40-410
Symptom related to travel
43 Machine does not travel straight H-17 40-411
44 Travel speed is low. H-18 40-412
45 Machine is hard to steer or travel power is low H-19 40-413
46 Travel speed does not change or travel speed is too low or high H-20, E-16 40-414,40-365
47 One of tracks does not run H-21 40-415
48 Travel alarm does not sound or does not stop sounding E-23 40-377
Symptom related to swing
49 Upper structure does not swing H-22 40-416
50 Swing acceleration is poor or swing speed is low H-23 40-418
51 Upper structure overruns excessively when it stops swinging H-24 40-420
52 Shock is larger when upper structure stops swinging H-25 40-421
53 Large unsual noise is heard when upper structure stops swinging H-26 40-421
Swing brake does not operate properly
54 H-27, E-21 40-422,40-371
Swing drift on a slope is large
Symptom is related to machine monitor
When starting switch is turned to ON position, machine monitor dis-
55 E-3 40-347
plays nothing
When starting switch is turned ON (before starting engine), basic
56 E-4 40-350
check monitor lights up
57 Precaution monitor lights up while engine is running. E-5 40-351
58 Emergency stop monitor lights up while engine is running E-6 40-353
59 Engine coolant temperature gauge does not indicate correctly E-8 40-356
60 Hydraulic oil temperature gauge does not indicate correctly E-9 40-358
61 Fuel level gauge does not indicate correctly E-7 40-354
Contents of display on machine monitor is different from that of actual
62 E-10 40-361
machine
63 Some areas of machine monitor are not displayed E-11 40-361
64 Function switch does not work E-12 40-361
65 Alarm buzzer cannot be stopped E-17 40-366
66 While starting switch is in OFF position, service meter is not displayed E-18 40-366
67 Service mode can not be selected E-19 40-367
68 Horn does not sound or does not stop E-24 40-378
69 Windshield wiper and window washer do not operate E-25 40-380
Air conditioner does not operate normally (including air conditioner "Testing and troubleshooting procedure" in
70
fault record) Chapter 80
71 Monitoring function does not display lever control signal normally E-26 – 34 40-382 – 40-388
Others
72 KOMTRAX system does not work properly E-36 40-391

PC228US-8,PC228USLC-8 40-43
(01)
General information on troubleshooting
Information in troubleshooting table

Information in troubleshooting table 40-4

(Rev. 2010/03)
a The following information is summarized in the troubleshooting table and the related electrical circuit dia-
gram. Before performing troubleshooting, understand that information fully.
User code Failure code
Display on Failure name displayed on the Abnormality Record screen of the
Display on machine Failure
machine moni- machine monitor
monitor
tor
Detail of failure Description of the failure detected by the machine monitor or controller
Action of
Action to be taken to protect the system and equipment when the machine monitor or controller detects
machine moni-
a trouble
tor or controller
Problem on
Problem that appears on machine as result of action (above) taken by machine monitor or controller
machine
Related infor-
Information related to detected failure or troubleshooting
mation
Cause Procedure, measuring location, criteria and remarks
<Details of description>
q Procedure
q Measuring location
1 Defective component a "Between A and B" means the measurement of voltage, resistance or oth-
ers between terminals A and B.
q Criteria to judge probable causes (normal value)
q Remarks for judgment
<How to use troubleshooting sheet>
Open or short circuit in wiring q Perform troubleshooting procedures in numerical order.
2 q If the check result does not meet the criteria, the probable cause described
harness
on the left column is the actual cause of the failure.
q If the check result shows no abnormality, and unless otherwise specified, pro-
ceed to the next step (next cause item).
q Check that the failure is fixed after a failure was found and repaired.
Open circuit in wiring harness <Failures in wiring harness>
3 (wire breakage or defective con- q Open circuit in wiring
tact of connector) The connector connection is defective or the wire is broken.
q Ground fault
A harness not connected to ground circuit contacts the ground wiring or
machine.
q Hot short circuit
Ground fault in wiring harness A harness not connected to the power circuit (24 V) contacts with the power
4
(contact with ground circuit) circuit.
q Short circuit
An independent wire in the harness contacts with other wire.
(Poor insulation at connector and others)
<Precautions for troubleshooting>
Hot short circuit (1) Connector number indication method and handling of T-adapter
5
(contact with 24 V circuit) For troubleshooting, insert or connect T-adapter as follows unless otherwise
specified.
q When "male" or "female" is not indicated with a connector number, dis-
connect the connector, and insert T-adapter between the male and fe-
male connectors.
q When "male" or "female" is indicated with a connector number, discon-
6 Short circuit in wiring harness
nect the connector, and connect T-adapter only to either male or femae
connector.
(2) Description sequence of pin number and handling of tester lead
For troubleshooting, connect the positive (+) and negative (-) leads as shown
below unless otherwise specified.
q Connect the positive (+) lead to pin or wire indicated first.
7 Defective controller q Connect the negative (-) lead to a pin or wire indicated second.

40-44 PC228US-8,PC228USLC-8
(01)
 General information on troubleshooting
Information in troubleshooting table

Related circuit diagram 40-45

This is the excerpted circuit diagram related to trouble-

shooting
q The circuit diagram contains the connector Nos., pin
Nos., and connector colors related to the failure.
q The circuit diagram contains the destination or source of
the branch line in a wiring harness.
q Arrow (io): Roughly shows the location on the ma-
chine.
q NO: Normally Open
q NC: Normally Closed

PC228US-8,PC228USLC-8 40-45
(01)
General information on troubleshooting
Troubleshooting method for open circuit in wiring harness of pressure sensor system

Troubleshooting method for open circuit in wiring harness of pressure

sensor system 40-46

a Since pressure sensors consisting not only of resistor but also electronic circuit components such as am-
plifiers have variation in measured value and its own polarities. So troubleshooting must be performed
carefully.

Failure codes applicable to this diagnosis

q CA123: Charge air pressure sensor low error
q CA451: Common rail pressure sensor high error

Procedure
1. Measure and record resistance of pressure sensor unit.
1) Disconnect pressure sensor connector (1) and connect socket (2) to the sensor side connector.
2) Measure resistances R1 and R2 between pins.
a If polarities of multimeter probes to apply are reversed, measured values may change. Therefore,
when measuring resistances in steps 1 and 2, apply the multimeter probes to the pressure sensor
connector so that their polarities match these of the sensor.
a If measured value is infinite, take measurements by applying the probes of opposite polarities and
record the finite value obtained as a measured value.
a Since measured values may be dispersed, take several measurements.
Cause of this dispersion appears to be a charge in a sensor. Repeat steps 1 and 2 several times.
Consider this dispersion when judging whether the wiring harness is open in step 3.

2. Measure and record resistance with the wiring harness between the pressure sensor and engine controller
connected.
1) Since 5 V power supply to the pressure sensor is supplied to other sensors, disconnect other sensor
connectors first. (*)
2) With the pressure sensor to measure connected, disconnect connector (3) on engine controller side,
and connect T-adapter (4) to the harness side connector.
3) Connect T-box (5) to T-adapter (4) and measure resistances R1' and R2' between respective pins.

3. Judging open circuit

If there is an "apparent difference" between resistances R1 and R2 measured in step 1 and resistances
R1' and R2' measured in step 2, "wiring harness is open".
a "Apparent difference" means a difference of 10 or more times.

40-46 PC228US-8,PC228USLC-8
(01)
 General information on troubleshooting
Troubleshooting method for open circuit in wiring harness of pressure sensor system

List of pressure sensor measuring locations and reference values

Measuring location at sen-
Sensor Measured internal resis- Remarks
sor pin
tance of sensor (reference)
Charge pressure sen- R2: between (2) and (4) Approx. 100 z Sensor is common to engine models
sor R1: between (1) and (4) Approx. 200 z 107 and 114
Sensor is common to engine models
R2: Between (3) and (1) Approx. 23 kz
Common rail pressure 107 and 114
sensor R1: Between (1) (+) and If polarities are inverted, resistance is
Approx. 10 Mz
(2) (-) infinite

*: In addition to the above, when measuring R2', disconnect the following: (See circuit diagram related to each
failure code)
q When measuring R2' of charge pressure sensor (CA123):
Connectors of common rail pressure sensor, CAM sensor and water-in-fuel sensor (water sepa-
rator)
q When measuring R2' of common rail pressure sensor (CA451):
Connectors of charge pressure sensor, CAM sensor and water-in-fuel sensor (water separator)

Measurement record (For measuring locations, see circuit diagram related to each failure code.)
Sensor + Wiring harness
Sensor unit
(Measuring location on wir-
Sensor (Measuring location on sen- Measured value Measured value
ing harness side connector
sor pin side connetor)
of engine controller)
R2': Between (37) and (47)
Charge pressure sen- R2: between (2) and (4)
(*)
sor
R1: between (1) and (4) R1': Between (44) and (47)
R2': Between (37) and (47)
R2: Between (3) and (1)
Common rail pressure (*)
sensor R1: Between (1) (+) and R1': between (47)(+) and
(2) (-) (25)(-)

PC228US-8,PC228USLC-8 40-47
(01)
General information on troubleshooting
Connector list and layout

Connector list and layout 40-48

PC228US-8, PC228USLC-8
Number
Connector No. Type Equipment name Layout address
of pins
A08 SWP 12 Intermediate connector Q1
A13 DT 2 Intermediate connector (working lamp) I2
A15 DT 2 Rear working lamp (if equipped) I8
A40 DT 4 Intermediate connector (camera) H8
A41 DT 4 Intermediate connector N4
A42 DT 4 Intermediate connector N5
A43 S 8 Intermediate connector R9
A53 DT 3 Boom angle potentiometer G8
A54 DT 3 Front pump swash plate sensor J9
A55 DT 3 Rear pump swash plate sensor K9
AB Terminal 1 Alternator (B terminal) AH9
AC01 YAZAKI 10 Air conditioner unit W6
AC02 X 1 Air conditioner compressor electromagnetic clutch AF3
AMB. AIR PRES-
– 3 Ambient pressure sensor AE2
SURE
BOOST PRESS &
– 3 Boost pressure and temperature sensor AG5
IMT
C01 AMP 81 Pump controller V4
C02 AMP 40 Pump controller V4
CAM SENSOR – 3 Engine Bkup speed sensor AF1
CE02 DRC 50 Engine controller AF1
CE03 DTP 4 Engine controller AG1
CK01 AMP 14 KOMTRAX terminal V7
CK02 AMP 10 KOMTRAX terminal V6
CM01 070 18 Machine monitor M8
CM02 070 12 Machine monitor M7
CM03 070 18 Machine monitor N7
CM04 070 12 Machine monitor (unconnected) –
CM05 MITSUMI 8 Machine monitor (for camera connection) O8
COOLANT TEMP – 2 Engine coolant temperature sensor AE3
CP3 PUMP REGU-
– 2 Supply pump solenoid (IMV) AJ2
LATOR
CRANK SENSOR – 3 Engine Ne speed sensor AF1
D01 SWP 8 Diode array W7
D02 SWP 8 Diode array W7
D03 SWP 8 Diode array W8
D10 M 2 Diode X7
D11 M 2 Diode X8
E01 Terminal 1 Electrical intake air heater AF4
W.I.F [E06] DT 2 Intermediate connector AI1
E08 X 1 Intermediate connector AH9
E10 D 1 Intermediate connector AG6
E12 SUMITOMO 3 Alternator (terminal IG, L) AI9
ECM [CE01] DRC 30 Engine controller AG1

40-48 PC228US-8,PC228USLC-8
(01)
 General information on troubleshooting
Connector list and layout

Number
Connector No. Type Equipment name Layout address
of pins
F01 – – Fuse box T9
F04 L mode 2 Fusible link (65 A) K6
F05 M 2 Fusible link (30A) K5
FUEL RAIL
– 3 Common rail pressure sensor AJ5
PRESS
GT5 070 1 Machine monitor (GPS antenna) N6
H08 M 4 Intermediate connector V3
H09 M 8 Intermediate connector V4
H15 090 22 Intermediate connector R9
H16 S090 12 Intermediate connector V3
INJECTOR CYL 1 Terminal 2 Injector #1 AE4
INJECTOR CYL
DT 4 Injector #1, 2 AE3
1&2
INJECTOR CYL 2 Terminal 2 Injector #2 AF4
INJECTOR CYL 3 Terminal 2 Injector #3 AG4
INJECTOR CYL
DT 4 Injector #3, 4 AG5
3&4
INJECTOR CYL 4 Terminal 2 Injector #4 AG5
INJECTOR CYL 5 Terminal 2 Injector #5 AH5
INJECTOR CYL
DT 4 Injector #5, 6 AI6
5&6
INJECTOR CYL 6 Terminal 2 Injector #6 AH5
J01 – 20 Junction connector (black) S9
J02 – 20 Junction connector (black) S9
J03 – 20 Junction connector (green) T9
J04 – 20 Junction connector (green) S9
J05 – 20 Junction connector (pink) T9
J06 – 20 Junction connector (orange) T9
K01 M 2 Pump (PC) resistor X8
K02 DT 3 CAN terminating resistor AH1
K03 M 2 Boom RAISE resistor X8
L03 – 2 Room lamp AD9
Intermediate connector (machines with revolving warning
L05 SWP 2 AC9
lamp)
Revolving warning lamp [machines with revolving warn-
L15 DT 2 AA9
ing lamp]
M01 PA 9 Radio V1
M02 M 2 Speaker (R.H.) AC9
M03 M 2 Speaker (L.H.) AB9
M04 – 2 Cigarette lighter O8
M05 M 5 Wiper motor N5
M06 KESO 2 Wind washer motor C1
M07 090 2 Horn (high tone) H2
M08 090 2 Horn (low tone) H2
M09 M 2 Optional power supply connector (1) R9
M10 M 2 Optional power supply connector (2) U1, AC1
M11 M 4 DC/DC converter (option) AC2
M12 M 2 Optional power supply connector (12 V) AC1
M13 M 2 Power supply socket (12 V) AD3

PC228US-8,PC228USLC-8 40-49
(01)
General information on troubleshooting
Connector list and layout

Number
Connector No. Type Equipment name Layout address
of pins
M14 DT 2 Travel alarm K6
M40 X 2 Headlamp [machines with headlamps] Z8
M41 X 2 Headlamp [machines with headlamps] Y7
M9A DT 2 Working lamp (L.H. side of boom) F8
M9B DT 2 Working lamp (R.H. side of boom) E7
N08 DT 12 Service connector U9
N10 SUMITOMO 4 Air conditioner unit W6
OIL PRESSURE
Terminal 2 Engine oil pressure switch (low pressure) AI1
SWITCH
P01 AMP 3 Bucket CURL PPC pressure sensor B3
P02 X 2 Boom LOWER PPC pressure switch B3
P03 AMP 3 Swing LEFT pressure sensor B3
P04 AMP 3 Arm In pressure sensor B2
P05 AMP 3 Bucket DUMP PPC pressure sensor B2
P06 AMP 3 Boom RAISE PPC pressure sensor B2
P07 AMP 3 Swing RIGHT pressure sensor B1
P08 X 2 Arm DUMP PPC pressure switch B1
P09 AMP 3 R.H. travel PPC pressure sensor (forward) O1
P10 AMP 3 L.H. travel PPC pressure sensor (forward) P1
P13 X 2 Intermediate connector N4
Attachment pedal front PPC oil pressure switch
P14 X 2 N1
[machines with provision for attachment]
Attachment pedal rear PPC oil pressure switch [machines
P15 X 2 N3
with provision for attachment]
Attachment pedal front PPC oil pressure switch
P16 X 2 –
[machines with provision for attachment]
P17 S090 2 Air conditioner high/low pressure switch N5
P20 M 3 Fuel control dial P9
P21 X 1 Fuel level sensor AE8
P22 D 2 Hydraulic oil temperature sensor K7
P23 DT 2 Air cleaner clogging switch K5
P24 X 2 Radiator coolant level switch K4
P25 AMP 3 Front pump pressure sensor B6
P26 AMP 3 Rear pump pressure sensor A7
P27 AMP 3 R.H. travel PPC pressure sensor (reverse) O1
P28 AMP 3 L.H. travel PPC pressure sensor (reverse) P1
Attachment pedal rear PPC oil pressure switch [machines
P30 X 2 –
with provision for attachment]
P31 – 2 Sunlight sensor M9
P32 YAZAKI 2 Air conditioner outside air temperature sensor K4
P44 DT 2 Engine oil temperature sensor AI8
P47 DT 2 Water-in-fuel sensor AE6
R01 Terminal 1 Battery relay (terminal E) S1
R02 Terminal 1 Battery relay (terminal BR) S1
R03 Terminal 1 Battery relay (terminal M) T1
R04 Terminal 1 Battery relay (terminal B) T1

40-50 PC228US-8,PC228USLC-8
(01)
 General information on troubleshooting
Connector list and layout

Number
Connector No. Type Equipment name Layout address
of pins
R05 Relay 6 Working lamp relay U9
R06 Relay 6 Starting motor cut-out relay (PPC lock) W7
R07 Relay 6 Starting motor cut-out relay (Personal code) V4
R08 Relay 6 Horn relay V5
R10 Relay 6 Rear lamp relay [machines with rear lamp] U9
R12 Relay 6 Cab lamp relay [machines with cab lamp] V5
R15 Terminal 1 Electrical intake air heater relay (coil circuit) R1
R16 Terminal 1 Electrical intake air heater relay (switch circuit) R1
R17 X 2 Starting motor safety relay (terminal S, R) S1
R18 Relay 6 Auto preheater relay V5
R20 Relay 4 Air conditioner blower relay V5
R21 Relay 4 Air conditioner compressor relay V5
R23 Relay 6 Engine controller relay (1) X7
R24 Relay 6 Engine controller relay (2) X7
R28 Terminal 1 Starting motor safety relay (terminal C) S1
S01 Terminal 5 Starting switch P9
S02 SWP 5 Light switch Q9
S04 SWP 5 Swing lock switch Q9
Revolving warning lamp switch [machines with revolving
S07 SWP 5 Q9
warning lamp]
S10 Y090 2 R.H. knob switch (horn) P9
S11 Y090 2 L.H. knob switch U1
S14 M 3 PPC oil pressure lock switch V2
S21 Terminal 12 Emergency pump drive switch V8
S22 Terminal 5 Swing brake release switch V8
S23 Terminal 5 Emergency work equipment operation switch V7
Intermediate connector (R.H. console emergency drive
S25 090 16 X9
switch)
S26 SWP 5 Emergency work equipment operation switch W9
S30 S 8 Model selection connector W9
SB Terminal 1 Starting motor (terminal B) AF7
SC Terminal 1 Starting motor (terminal C) AF7
T01 Terminal 1 Ground (floor frame) U1
T02 Terminal 1 Ground (cab) AD2
T03 M 1 Intermediate connector V1
T03A Terminal 1 Radio body ground V1
T04 Terminal 1 Ground (revolving frame) J2
T05 Terminal 1 Ground (revolving frame) J2
T06 Terminal 1 Ground (revolving frame) J2
T07 Terminal 1 Ground (revolving frame) K2
T08 Terminal 1 Ground (revolving frame) K1
T09 Terminal 1 Ground (revolving frame) K1
T10 Terminal 1 Ground (revolving frame) L1
T12 Terminal 1 Ground (engine block) AH1
T14 Terminal 1 Ground (floor frame) T1

PC228US-8,PC228USLC-8 40-51
(01)
General information on troubleshooting
Connector list and layout

Number
Connector No. Type Equipment name Layout address
of pins
TOOL PORT – 3 Communication connector AE2
V01 DT 2 PPC lock solenoid valve C9
V02 DT 2 Travel junction solenoid valve B9
V03 DT 2 Swing brake solenoid valve B9
V04 DT 2 Travel speed selector solenoid valve B9
V05 DT 2 2-stage relief solenoid valve A9
Attachment return selector solenoid valve [machines with
V06 DT 2 A9
provision for attachment]
V09 D 2 Boom RAISE throttle EPC valve E2
V11 D 2 F-PC-EPC valve J8
V12 D 2 R-PC-EPC valve J7
V19 D 2 LS-EPC valve J8
V23 D 2 Pump merge-divider EPC valve (main) D8
V24 D 2 Pump merge-divider EPC valve (LS) D9
Oil flow adjuster EPC valve for attachment [machines
V30 DT 2 N4
with provision for attachment]
W03 X 2 Window rear limit switch AC9

40-52 PC228US-8,PC228USLC-8
(01)
 General information on troubleshooting
Connector list and layout

PC228US-8,PC228USLC-8 40-53
(01)
General information on troubleshooting
Connector list and layout

Layout of connector (1/6)

40-54 PC228US-8,PC228USLC-8
(01)
 General information on troubleshooting
Connector list and layout

(2/6)

PC228US-8,PC228USLC-8 40-55
(01)
General information on troubleshooting
Connector list and layout

(3/6)

40-56 PC228US-8,PC228USLC-8
(01)
 General information on troubleshooting
Connector list and layout

(4/6)

PC228US-8,PC228USLC-8 40-57
(01)
General information on troubleshooting
Connector list and layout

(5/6)

40-58 PC228US-8,PC228USLC-8
(01)
 General information on troubleshooting
Connector list and layout

(6/6)

PC228US-8,PC228USLC-8 40-59
(01)
General information on troubleshooting
Connection table for connector pin numbers

Connection table for connector pin numbers 40-60

(Rev. 2009. 04)
a The terms of male and female refer to the pins, while the terms of male housing and female housing refer
to the mating portion of the housing.

40-60 PC228US-8,PC228USLC-8
(01)
 General information on troubleshooting
Connection table for connector pin numbers

PC228US-8,PC228USLC-8 40-61
(01)
General information on troubleshooting
Connection table for connector pin numbers

40-62 PC228US-8,PC228USLC-8
(01)
 General information on troubleshooting
Connection table for connector pin numbers

PC228US-8,PC228USLC-8 40-63
(01)
General information on troubleshooting
Connection table for connector pin numbers

40-64 PC228US-8,PC228USLC-8
(01)
 General information on troubleshooting
Connection table for connector pin numbers

PC228US-8,PC228USLC-8 40-65
(01)
General information on troubleshooting
Connection table for connector pin numbers

40-66 PC228US-8,PC228USLC-8
(01)
 General information on troubleshooting
Connection table for connector pin numbers

PC228US-8,PC228USLC-8 40-67
(01)
General information on troubleshooting
Connection table for connector pin numbers

40-68 PC228US-8,PC228USLC-8
(01)
 General information on troubleshooting
Connection table for connector pin numbers

PC228US-8,PC228USLC-8 40-69
(01)
General information on troubleshooting
Connection table for connector pin numbers

40-70 PC228US-8,PC228USLC-8
(01)
 General information on troubleshooting
Connection table for connector pin numbers

PC228US-8,PC228USLC-8 40-71
(01)
General information on troubleshooting
Connection table for connector pin numbers

40-72 PC228US-8,PC228USLC-8
(01)
 General information on troubleshooting
Connection table for connector pin numbers

PC228US-8,PC228USLC-8 40-73
(01)
General information on troubleshooting
Connection table for connector pin numbers

40-74 PC228US-8,PC228USLC-8
(01)
 General information on troubleshooting
Connection table for connector pin numbers

PC228US-8,PC228USLC-8 40-75
(01)
General information on troubleshooting
Connection table for connector pin numbers

40-76 PC228US-8,PC228USLC-8
(01)
 General information on troubleshooting
Connection table for connector pin numbers

PC228US-8,PC228USLC-8 40-77
(01)
General information on troubleshooting
Connection table for connector pin numbers

40-78 PC228US-8,PC228USLC-8
(01)
 General information on troubleshooting
Connection table for connector pin numbers

PC228US-8,PC228USLC-8 40-79
(01)
General information on troubleshooting
Connection table for connector pin numbers

40-80 PC228US-8,PC228USLC-8
(01)
 General information on troubleshooting
Connection table for connector pin numbers

PC228US-8,PC228USLC-8 40-81
(01)
General information on troubleshooting
Connection table for connector pin numbers

40-82 PC228US-8,PC228USLC-8
(01)
 General information on troubleshooting
Connection table for connector pin numbers

PC228US-8,PC228USLC-8 40-83
(01)
General information on troubleshooting
Connection table for connector pin numbers

40-84 PC228US-8,PC228USLC-8
(01)
 General information on troubleshooting
Connection table for connector pin numbers

PC228US-8,PC228USLC-8 40-85
(01)
General information on troubleshooting
Connection table for connector pin numbers

40-86 PC228US-8,PC228USLC-8
(01)
 General information on troubleshooting
Connection table for connector pin numbers

PC228US-8,PC228USLC-8 40-87
(01)
General information on troubleshooting
Connection table for connector pin numbers

40-88 PC228US-8,PC228USLC-8
(01)
 General information on troubleshooting
Connection table for connector pin numbers

PC228US-8,PC228USLC-8 40-89
(01)
General information on troubleshooting
Connection table for connector pin numbers

40-90 PC228US-8,PC228USLC-8
(01)
 General information on troubleshooting
Connection table for connector pin numbers

PC228US-8,PC228USLC-8 40-91
(01)
General information on troubleshooting
Connection table for connector pin numbers

40-92 PC228US-8,PC228USLC-8
(01)
 General information on troubleshooting
Connection table for connector pin numbers

PC228US-8,PC228USLC-8 40-93
(01)
General information on troubleshooting
Connection table for connector pin numbers

40-94 PC228US-8,PC228USLC-8
(01)
 General information on troubleshooting
Connection table for connector pin numbers

PC228US-8,PC228USLC-8 40-95
(01)
General information on troubleshooting
T- branch box and T- branch adapter table

T- branch box and T- branch adapter table 40-96

(Rev. 2009. 03)
a The vertical column indicates a part number of T-branch box or T-branch adapter while the horizontal col-
umn indicates a part number of harness checker assembly.

T-adapter kit

Number of pins

799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identificati
Part No. Part name
on symbol

799-601-2600 T-box (for ECONO) 21 q q q q q

799-601-3100 T-box (for MS) 37 q
799-601-3200 T-box (for MS) 37 q
799-601-3380 Plate for MS (14-pin) q
799-601-3410 Adapter for BENDIX (MS) 24 MS-24P q
799-601-3420 Adapter for BENDIX (MS) 24 MS-24P q
799-601-3430 Adapter for BENDIX (MS) 17 MS-17P q
799-601-3440 Adapter for BENDIX (MS) 17 MS-17P q
799-601-3450 Adapter for BENDIX (MS) 5 MS-5P q
799-601-3460 Adapter for BENDIX (MS) 10 MS-10P q
799-601-3510 Adapter for BENDIX (MS) 5 MS-5P q
799-601-3520 Adapter for BENDIX (MS) 17 MS-17P q
799-601-3530 Adapter for BENDIX (MS) 19 MS-19P q
799-601-2910 Adapter for BENDIX (MS) 14 MS-14P q
799-601-3470 Case q
799-601-2710 Adapter for MIC 5 MIC-5P q q q
799-601-2720 Adapter for MIC 13 MIC-13P q q q
799-601-2730 Adapter for MIC 17 MIC-17P q q q q q q
799-601-2740 Adapter for MIC 21 MIC-21P q q q q q q
799-601-2950 Adapter for MIC 9 MIC-9P q q q q
799-601-2750 Adapter for ECONO 2 ECONO2P q q
799-601-2760 Adapter for ECONO 3 ECONO3P q q
799-601-2770 Adapter for ECONO 4 ECONO4P q q
799-601-2780 Adapter for ECONO 8 ECONO8P q q
ECONO12
799-601-2790 Adapter for ECONO 12
P
q q
799-601-2810 Adapter for DLI 8 DLI-8P q q
799-601-2820 Adapter for DLI 12 DLI-12P q q
799-601-2830 Adapter for DLI 16 DLI-16P q q
ECONO12
799-601-2840 Extension cable (ECONO type) 12
P
q q q
799-601-2850 Case q
799-601-4350 T-box (for DRC 60, ECONO) 60 q
799-601-4360 Case q
799-601-7010 Adapter for X (T-adapter) 1 q q
799-601-7020 Adapter for X 2 X2P q q q q
799-601-7030 Adapter for X 3 X3P q q q q
799-601-7040 Adapter for X 4 X4P q q q q
799-601-7050 Adapter for SWP 6 SW6P q q q
799 -601-7060 Adapter for SWP 8 SW8P q q q
799-601-7310 Adapter for SWP 12 SW12P q
799-601-7070 Adapter for SWP 14 SW14P q q
799-601-7320 Adapter for SWP 16 SW16P q
799-601-7080 Adapter for M (T-adapter) 1 - q q
799 -601-7090 Adapter for M 2 M2P q q q q
799-601-7110 Adapter for M 3 M3P q q q q
799-601-7120 Adapter for M 4 M4P q q q q
799-601-7130 Adapter for M 6 M6P q q q q
799-601-7340 Adapter for M 8 M8P q

40-96 PC228US-8,PC228USLC-8
(01)
 General information on troubleshooting
T- branch box and T- branch adapter table

T-adapter kit

Number of pins

799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identificati
Part No. Part name
on symbol

799-601-7140 Adapter for M 8 S8P q q q q

799-601-7150 Adapter for S (White) 10 S10P q q q q
799-601-7160 Adapter for S (Blue) 12 S12P q q q
799-601-7170 Adapter for S (Blue) 16 S16P q q q q
799-601-7330 Adapter for S (White) 16 S16PW q
799-601-7350 Adapter for S (White) 12 S12PW q
799-601-7180 Adapter for AMP040 8 A8P q
799-601-7190 Adapter for AMP040 12 A12P q q
799-601-7210 Adapter for AMP040 16 A16P q q q q
799-601-7220 Adapter for AMP040 20 A20P q q q q
799-601-7230 Short connector for X 2 – q q q q
799-601-7240 Case q q
799-601-7270 Case q
799-601-7510 Adapter for 070 10 07-10 q
799-601-7520 Adapter for 070 12 07-12 q
799-601-7530 Adapter for 070 14 07-14 q
799-601-7540 Adapter for 070 18 07-18 q
799-601-7550 Adapter for 070 20 07-20 q
799-601-7360 Adapterfor relay 5 REL-5P q
799-601-7370 Adapterfor relay 6 REL-6P q
799-601-7380 Adapter for JFC 2 – q
799-601-9010 Adapter for DTM 2 DTM2 q q
799-601- 9020 Adapter for DT 2 DT2 q q q q
799-601-9030 Adapter for DT 3 DT3 q q
799-601-9040 Adapter for DT 4 DT4 q q q q
799-601-9050 Adapter for DT 6 DT6 q q
799-601-9060 Adapter for DT (Gray) 8 DT8GR q q
799-601-9070 Adapter for DT (Black) 8 DT8B q q
799-601-9080 Adapter for DT (Green) 8 DT8G q q
799-601-9090 Adapter for DT (Brown) 8 DT8BR q q
799-601-9110 Adapter for DT (Gray) 12 DT12GR q q
799-601-9120 Adapter for DT (Black) 12 DT12B q q
799-601-9130 Adapter for DT (Green) 12 DT12G q q
799-601-9140 Adapter for DT (Brown) 12 DT12BR q q
799-601-9210 Adapter for HD30-18 8 D18-8 q q
799-601-9220 Adapter for HD30-18 14 D18-14 q q
799-601-9230 Adapter for HD30-18 20 D18-20 q q
799-601-9240 Adapter for HD30-18 21 D18-21 q q
799-601-9250 Adapter for HD30-24 9 D24-9 q q
799-601-9260 Adapter for HD30-24 16 D24-16 q q
799-601-9270 Adapter for HD30-24 21 D24-21 q q
799-601-9280 Adapter for HD30-24 23 D24-23 q q
799-601-9290 Adapter for HD30-24 31 D24-31 q q
799-601-9310 Plate for HD30 (24-pin) q q q
799-601-9320 T-box (for ECONO) 24 q q q
799-601-9330 Case q
799-601-9340 Case q
799-601-9350 Adapter for DRC 40 DRC-40 q
799-601-9360 Adapter for DRC 24 DRC-24 q
799-601-9410* Socket for engine (CRI-T2) 2 G q
Adapter for engine (CRI-T2)
799-601-9420 Adapter for engine (CRI-T3) PFUEL 3 A3 q q
Oil pressure sensor
Socket for engine (CRI-T2)
799-601-9430*
Socket for engine(CRI-T3) PCV
2 P q q

PC228US-8,PC228USLC-8 40-97
(01)
General information on troubleshooting
T- branch box and T- branch adapter table

T-adapter kit

Number of pins

799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identificati
Part No. Part name
on symbol

799-601-9440* Socket for engine (CRI-T2) 3 1, 2, 3 q

795-799-5520* Socket for engine (HPI-T2) 2 S q
Socket for engine (HPI-T2)
795-799-5530* Socket for engine (CRI-T3) 2 C q q
Temperature sensor
Socket for engine (HPI-T2)
795-799-5540*
Socket for engine(CRI-T3) TIM
2 A q q
795-799-5460 Cable for engine (HPI-T2) 3 – q
795-799-5470 Cable for engine (HPI-T2) 3 – q
795-799-5480 Cable for engine (HPI-T2) 3 – q
799-601-4110 Adapter for engine (140-T3) PIM 4 ITT3N q q
799-601-4130 Adapter for engine (CRI-T3) NE, CAM 3 FCIN q q
Adapter for engine (CRI-T3)
799-601-4140
Atomosphere pressure
3 FCIG q q
799-601-4150 Adapter for engine (CRI-T3) POIL 3 FCIB q q
Adapter for engine (CRI-T3)
799-601-4160
Oil pressure switch
2 4160 q q
799-601-4180 Adapter for engine (CRI-T3) PEVA 3 4180 q q
Socket for engine (CRI-T3)
799-601-4190*
Common rail pressure
3 1, 2, 3 L q q
Socket for engine (CRI-T3)
799-601-4230*
Air intake pressure/temperature
4 1, 2, 3, 4 C q q
799-601-4240* Socket for engine (CRI-T3) PAMB 3 1, 2, 3 A q q
799-601-4250* Socket for engine (CRI-T3) PIM 3 1, 2, 3 B q q
799-601-4330* Socket for engine (CRI-T3) G 3 1, 2, 3, G q q
Socket for engine (CRI-T3)
799-601-4340*
Pump actuator
2 2, PA q q
Socket for engine (CRI-T3)(95)
799-601-4380*
Air intake pressure/temperature
4 1, 2, 3, 4T q
799 -601-4260 Adapter for controller (ENG) 4 DTP4 q q
799 -601-4211 Adapter for controller (ENG) 50 DRC50 q
799-601-4220 Adapter for controller (ENG) 60 DRC60 q
799-601-4390* Socket for controller (95 ENG) 60 – q
799-601-4280* Box for controller (PUMP) 121 – q
799-601-9720 Adapter for controller (HST) 16 HST16A q
799-601-9710 Adapter for controller (HST) 16 HST16B q
799-601-9730 Adapter for controller (HST) 26 HST26A q
2,
799-601-9890 Multi-adapter for DT2 – 4 and DTM2 3, – q
4
“*” Shows not T-adapter but socket.

40-98 PC228US-8,PC228USLC-8
(01)
 General information on troubleshooting
T- branch box and T- branch adapter table

PC228US-8,PC228USLC-8 40-99
(01)
General information on troubleshooting
Fuse location table

Fuse location table 40-10

Connection table of fuse box 40-10

a This connection table shows the fuse box and the devices which receive the power from the fuse box (
switching power supply is the power which is supplied while the starting switch is in ON position and the
unswitched power supply is the power which is supplied while the starting switch is in OFF and ON posi-
tions).
a When performing troubleshooting related to the electrical system, check the fuses and fusible links to see
if the power is supplied properly.
Type of Power supply Fuse
Fuse No. Destination of power
power supply to fuse capacity
Lamp relay, rear lamp relay, cab lamp relay
PC-EPC (F) solenoid valve, PC-EPC (R) solenoid valve
[When emergency pump drive switch is operated]
Swing brake solenoid valve
1 10 A
[When swing brake release switch is operated]
Boom RAISE throttle EPC valve
[when boom RAISE throttle release switch is operated in
emergency]
2 30 A Pump controller (Solenoid power supply)
PPC oil pressure lock solenoid valve
Switching Fusible link 3 10 A Starting motor cut-out relay (PPC lock)
power F04 Starting motor cut-out relay (Personal code)
4 10 A Window washer motor, cigarette lighter
supply (60 A)
5 10 A Horn, horn relay
6 10 A Heater relay, electrical intake air heater
7 10 A Revolving warning lamp (if equipped)
8 20 A Working lamp
9 10 A Radio, speaker, L.H. knob switch (pump controller input)
10 5A Air conditioner
11 20 A A/C unit blower motor, A/C compressor
12 10 A (Spare)
13 10 A Headlamp
14 10 A Optional power supply (1)
15 10 A Travel alarm, optional power supply (2)
16 10 A Radio backup and room lamp
Fusible link
Unswitched 17 20 A Machine monitor, pump controller and starting switch
F05
power supply 18 5A Air conditioner
(30A)
19 30 A Engine controller
Switching
Starting switch
power 20 5A ACC for engine controller
ACC
supply

40-100 PC228US-8,PC228USLC-8
(01)
 General information on troubleshooting
Fuse location table

Locations of fusible link 40-101 Location of fuse box and fuse number 40-101

* The two fusible links (F04) and (F05) are accessi-

ble when the plastic cover is lifted.

PC228US-8,PC228USLC-8 40-101
(01)
Troubleshooting by failurecode
Failure code [989L00] Engine Controller Lock Caution 1

Troubleshooting by failurecode 40-102

Failure code [989L00] Engine Controller Lock Caution 1 40-102
User code Failure code Engine controller lock caution 1
Failure
(Machine monitor system)
— 989L00
Detail of failure q Engine controller lock is detected (Factor 1).
Action of
q None in particular
machine moni-
q If cause of failure disappears, machine becomes normal by itself.
tor
Problem on
q Engine cannot be started.
machine

q If this failure code is displayed after machine monitor is replaced, user password must be changed
Related infor-
to one before replacement.
mation
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

Replacement of
1 This problem may be caused by replacement of machine monitor.
machine monitor

Failure code [989M00] Engine Controller Lock Caution 2 40-102

User code Failure code Engine controller lock caution 2
Failure
(Machine monitor system)
— 989M00
Detail of failure q Engine controller lock is detected (Factor 2).
Action of
q None in particular
machine moni-
q If cause of failure disappears, machine becomes normal by itself.
tor
Problem on
q Engine cannot be started.
machine
q If this failure code is displayed after machine monitor is replaced, user password must be changed
Related infor-
to one before replacement.
mation
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

Replacement of
1 This problem may be caused by replacement of machine monitor.
machine monitor
If this failure code is displayed while machine monitor is not replaced, machine monitor
Defective machine mon-
2 may be defective. (Since this is an internal failure, troubleshooting cannot be per-
itor
formed.)

40-102 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [989N00] Engine Controller Lock Caution 3

Failure code [989N00] Engine Controller Lock Caution 3 40-103

User code Failure code Engine controller lock caution 3
Failure
(Machine monitor system)
— 989N00
Detail of failure q Engine controller lock is detected (Factor 3).
Action of
q Tries automatic resetting.
machine moni-
q If cause of failure disappears, machine becomes normal by itself.
tor
Problem on
machine
Related infor- q Method of reproducing failure code: Failure code cannot be reproduced since machine recovers
mation by cause of failure disappears.

Cause Procedure, measuring location, criteria and remarks

If this failure code is displayed repeatedly, engine controller may be defective.
1 Defective engine controller
(Since this is internal failure, troubleshooting cannot be performed.)

PC228US-8,PC228USLC-8 40-103
(01)
Troubleshooting by failurecode
Failure code [AA10NX] Air Cleaner Clogging

Failure code [AA10NX] Air Cleaner Clogging 40-104

User code Failure code Air cleaner clogging
Failure
(Machine monitor system)
– AA10NX
q Air cleaner clogging switch signal voltage was not 1 V or less while engine was running, and ma-
Detail of failure
chine monitor detected clogging of air cleaner (open of switch contacts).
Action of con-
q Displays clogging of air cleaner monitor red on machine monitor.
troller
Problem on
q If machine is operated as it is, engine may be damaged.
machine
q Input signal status (ON/OFF) from air cleaner clogging switch can be checked by using monitoring
Related infor- function.
mation (Code: 04501 Monitor input 2)
q Method of reproducing failure code: Start engine.

Cause Procedure, measuring location, criteria and remarks

Air cleaner clogging Air cleaner may be clogged. Check it for clogging and then clean or replace if
1
(When system is normal) clogged.
1. Turn starting switch to OFF position.
2. Disconnect connector P23 and connect T-adapter to male side.
3. Start engine.
Defective air cleaner clogging Air cleaner
2
switch (internal open circuit) When normal *1 Resistance Max. 1 z
Between P23 (male) (1)
and (2) Air cleaner
When clogged *2 Resistance Min. 1 Mz

1. Turn starting switch to OFF position.

2. Disconnect connectors CM02 and P23, and connect T-adapter to each
Open circuit in wiring harness
female side.
3 (wire breakage or defective con-
tact of connector) Between CM02 (female) (4) and P23 (female) (1) Resistance Max. 1 z
Between P23 (female) (2) and ground Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Insert T-adapters into connectors CM01 and CM02.
3. Start engine.
4 Defective machine monitor Air cleaner
When normal Voltage Max. 1 V
Between CM02 (4) and
CM01 (3) Air cleaner
When clogged Voltage 7 – 11 V

q Air cleaner suction resistance

*1: Max. -3,430 Pa {-350 mmH2O}
*2: -7,470±490 Pa {-762 ± 50 mmH2O}

40-104 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [AA10NX] Air Cleaner Clogging

Circuit diagram related to air cleaner clogging sensor 40-105

PC228US-8,PC228USLC-8 40-105
(01)
Troubleshooting by failurecode
Failure code [AB00KE] Charge Voltage Low

Failure code [AB00KE] Charge Voltage Low 40-106

User code Failure code Charge voltage low
Failure
(Machine monitor system)
— AB00KE

Detail of failure q While engine is running, signal voltage of alternator detects low charge voltage (below 7.8 V).

Action of q Displays charge level monitor red on machine monitor.

machine moni- q Even if cause of failure disappears, machine does not become normal until starting switch is turned
tor to OFF position.
Problem on
q If machine is operated as it is, battery may not be charged.
machine

q Signal voltage of alternator can be checked by using monitoring function.

Related infor-
(Code: 04300 Charge voltage)
mation
q Method of reproducing failure code: Start engine.

Cause Procedure, measuring location, criteria and remarks

Loose alternator terminal or open 1. Turn starting switch to OFF position.
1
circuit at terminal 2. Check terminal.
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector E12.
Defective generation by alternator a Connector E08 may be used for diagnosis.
2 3. Start engine.
(When system is normal)
Between E12 (1) and Engine speed: medium 27.5 - 29.5
Voltage
ground or higher V

1. Turn starting switch to OFF position.

Defective wiring harness or 2. Insert T-adapter into connector CM01.
3 3. Start engine.
machine monitor
Between CM01 (11) and ground Voltage 20 – 30 V
a If no failure is found by checks on cause 2, this check is not required.
Open circuit in wiring harness 1. Turn starting switch to OFF position.
4 (wire breakage or defective con- 2. Disconnect connectors CM01 and E12, and connect T-adapter to each
tact of connector) female side.
Between CM01 (female) (11) and E12 (female) (1) Resistance Max. 1 z
a If no failure is found by checks on cause 2, this check is not required.
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors CM01 and E02, and connect T-adapter to female
5
(contact with ground circuit) side of either of them.
Between CM01 (female) (11) or E12 (female) (1)
Resistance Min. 1 Mz
and ground
If no failure is found by above checks, machine monitor is defective. (Since
6 Defective machine monitor
this is internal failure, troubleshooting cannot be performed.)

40-106 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [AB00KE] Charge Voltage Low

Electrical diagram related to charging cricuit 40-107

PC228US-8,PC228USLC-8 40-107
(01)
Troubleshooting by failurecode
Failure code [B@BAZG] Eng Oil Press Low

Failure code [B@BAZG] Eng Oil Press Low 40-108

User code Failure code Engine oil pressure low
Failure
(Engine controller system)
— B@BAZG
q While engine is running, engine controller detects engine oil pressure drop (sensor contact is
Detail of failure
closed) from signal voltage of engine oil pressure switch.
Action of con- q Displays engine oil pressure monitor red on machine monitor.
troller q If cause of failure disappears, machine becomes normal by itself.
Problem on
q If machine is operated as it is, engine may be damaged.
machine
q Signal from engine oil pressure switch is input to engine controller. If engine oil pressure switch is
Related infor- closed (turned ON) while engine is running, engine controller transmitts this signal to machine
mation monitor to display this failure code.
q Method of reproducing failure code: Start engine.

Cause Procedure, measuring location, criteria and remarks

Dropped engine oil pres-
1 sure (when system is nor- Engine oil pressure may be low. Check it and remove cause if it is low.
mal)
If no failure is found by check on causes, engine oil pressure monitor system may be
Defective engine oil pres-
2 defective. Perform troubleshooting for "E-6 Emergency stop lamp lights up while
sure monitor system
engine is running".

40-108 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [B@BAZK] Eng Oil Level Low

Failure code [B@BAZK] Eng Oil Level Low 40-109

User code Failure code Eng oil level low

Failure
(Machine monitor system)
- B@BAZK
q While engine is running, signal voltage from engine oil level switch does not remain below 1 V, so
Detail of failure
machine monitor determines that engine oil level is low (oil level switch is open).
Action of con-
q Displays engine oil level monitor red on machine monitor.
troller
Problem on
q If machine is operated as it is, engine may seize up.
machine
q Input (ON/OFF) from engine oil level switch can be checked by using monitoring function.
Related infor-
(Code: 04501 Monitor input 2)
mation
q Method of reproducing failure code: Start engine

Cause Procedure, measuring location, criteria and remarks

Lowered engine oil level (when
1 Check engine oil level. If it is low, remove cause.
system is normal)
1. Turn starting switch to OFF position.
Defective engine oil level switch 2. Disconnect connector P44.
2 3. Turn starting switch to ON position.
(internal failure)
Between P44 (male) (1) and ground Resistance Max. 1 z
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Disconnect connectors CM02 and P44, and connect T-adapter to each
3 (wire breakage or defective con- female side.
tact of connector)
Between CM02 (female) (2) and P44 (female) (1) Resistance Max. 1 z
If no failure is found by above checks, machine monitor is defective.
q Reference
1. Turn starting switch to OFF position.
4 Defective machine monitor 2. Insert T-adapters into connectors CM01 and CM02.
3. Turn starting switch to ON position.
Between CM02 (2) and CM01 (3) Voltage Max. 1 V

Circuit diagram related to engine oil level

switch 40-109

PC228US-8,PC228USLC-8 40-109
(01)
Troubleshooting by failurecode
Failure code [B@BCNS] Eng Water Overheat

Failure code [B@BCNS] Eng Water Overheat 40-1 0

User code Failure code Engine coolant overheat
Failure
(Engine controller system)
— B@BCNS
q While engine is running, engine controller detects overheating of engine coolant (above approx.
Detail of failure
102 °C), from signal of engine coolant temperature sensor.
Action of con- q Displays engine coolant temperature monitor red on machine monitor.
troller q If cause of failure disappears, machine becomes normal by itself.
Problem on
q If machine is operated as it is, engine may seize up.
machine

q Signal of engine coolant temperature sensor is input to engine controller and then data is transmit-
ted to machine monitor through CAN communication system.
Related infor-
q Engine coolant temperature can be checked by using monitoring function.
mation
(Code: 04107 Engine coolant temperature)
q Method of reproducing failure code: Start engine.

Cause Procedure, measuring location, criteria and remarks

Overheating of engine cool-
1 Engine coolant may overheat. Check it and remove cause if it overheats.
ant (when system is normal)
If no failure is found by check on cause 1, engine coolant temperature gauge sys-
Defective engine coolant
2 tem may be defective. Perform troubleshooting for "E-8 Engine coolant temperature
temperature gauge system
gauge does not indicate normally."

40-110 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [B@BCNS] Eng Water Overheat

PC228US-8,PC228USLC-8 40-111
(01)
Troubleshooting by failurecode
Failure code [B@BCZK] Eng Water Level Low

Failure code [B@BCZK] Eng Water Level Low 40-1 2

User code Failure code Radiator coolant level low

Failure
(Machine monitor system)
- B@BCZK
q While starting switch is at ON position (with engine stopped) or engine is running, radiator coolant
Detail of failure level switch signal voltage does not remain below 1 V, so machine monitor determines taht that ra-
diator coolant level is low (sensor contact is open).
Action of con-
q Displays radiator coolant level monitor red on machine monitor.
troller
Problem on
q If machine is operated as it is, engine may overheat.
machine
q Input (ON/OFF) from radiator coolant level switch can be checked by using monitoring function.
Related infor-
(Code: 04500 Monitor input 1)
mation
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

Lowered radiator coolant level Check radiator sub tank for lowering of coolant level. If coolant level is low, add
1
(when system is normal) coolant.
1. Turn starting switch to OFF position.
2. Disconnect connector P24 and connect T-adapter to male side.
Defective coolant level switch Between
2 FULL and Resistance Max. 1 z
(internal failure)
Between P24 (male) (1) and (2) LOW lines
Below LOW
Resistance Min. 1 Mz
line
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Disconnect connectors CM02 and P24, and connect T-adapter to each
3 (wire breakage or defective con- female side.
tact) a Add coolant.
Between CM02 (female) (3) and P24 (female) (1) Resistance Max. 1 z
If no failure is found by above checks, machine monitor is defective.
q Reference
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector CM02.
3. Turn starting switch to ON position.
4 Defective machine monitor Between
FULL and Voltage Max. 1 V
Between CM02 (3) and CM01 (3) LOW lines
Below LOW
Voltage 7 – 11 V
line

40-112 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [B@BCZK] Eng Water Level Low

Circuit diagram related to radiator coolant level switch 40-1 3

PC228US-8,PC228USLC-8 40-113
(01)
Troubleshooting by failurecode
Failure code [B@HANS] Hyd Oil Overheat

Failure code [B@HANS] Hyd Oil Overheat 40-1 4

User code Failure code Hydraulic oil overheat
Failure
(Pump controller system)
— B@HANS
q While engine is running, pump controller detects overheating of hydraulic oil (above approx.
Detail of failure
102 °C), from signal of hydraulic oil temperature sensor.
Action of con- q Displays hydraulic oil temperature monitor in red on machine monitor.
troller q If cause of failure disappears, machine becomes normal by itself.
Problem on
q If machine is operated as it is, hydraulic components may be damaged.
machine
q Signal of hydraulic oil temperature sensor is input to pump controller and then the data is transmit-
ted to machine monitor through CAN communication system.
Related infor- q Hydraulic oil temperature can be checked by using monitoring function
mation (Code: 04401 Hydraulic oil temperature)
q See "E-9 Hydraulic oil temperature gauge does not display normally" in E-mode.
q Method of reproducing failure code: Start engine.

Cause Procedure, measuring location, criteria and remarks

Overheating of hydraulic oil
1 Hydraulic oil may overheat. Check it and remove cause if it overheats
(when system is normal)
Defective hydraulic oil tempera- If no failure is found by check on cause 1, hydraulic oil temperature sensor
2
ture gauge system system may be defective. Perform troubleshooting for failure code [DGH2KB].

40-114 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [CA111] ECM Critical Internal Failure

Failure code [CA111] ECM Critical Internal Failure 40-1 5

User code Failure code Engine controller has internal failure

Failure
(Engine controller system)
E10 CA111
Detail of failure q Memory or power supply circuit in engine controller is defective.
Action of con-
q None in particular
troller
Problem on
q Engine may stop during operation or may not be able to start.
machine
q Power supply voltage of engine controller can be checked by using moniitoring funtion.
Related infor-
(Code: 03203 Battery voltage)
mation
q Method of reproducing failure code: Start engine.

Cause Procedure, measuring location, criteria and remarks

1 Defect in related system If another failure code is displayed, perform troubleshooting for it.

2 Perform troubleshooting for failure code [CA441].

Failure code [CA115] Eng Ne and Bkup Speed Sens Error 40-1 5

User code Failure code Engine Ne and Bkup speed sensor error
Failure
(Engine controller system)
E10 CA115
Detail of failure q Signals from both engine Ne speed sensor and engine Bkup speed sensor are abnormal.
Action of con-
q None in particular
troller
Problem on q Engine stops.
machine q Engine does not start
Related infor-
q Method of reproducing failure code: Start engine.
mation

Cause Procedure, measuring location, criteria and remarks

Defective connection of sensorConnectors of Ne speed sensor and Bkup speed sensor may be connected
1
connector defectively (or to wrong connection). Check them directly.
Perform troubleshooting for troubleshooting Nos. 1 to 10 of failure code
2 Defective Ne speed sensor system
[CA689].
Defective Bkup speed sensor sys-
3 Perform troubleshooting for failure code [CA778].
tem
If no failure is found by above checks, engine controller is defective. (Since
4 Defective engine controller
this is internal failure, troubleshooting cannot be performed.)

PC228US-8,PC228USLC-8 40-115
(01)
Troubleshooting by failurecode
Failure code [CA122] Chg Air Press Sensor High Error

Failure code [CA122] Chg Air Press Sensor High Error 40-1 6

User code Failure code Boost pressure sensor high error

Failure
(Engine controller system)
E11 CA122
Detail of failure q High voltage appears in signal circuit of boost pressure & temperature sensor.
Action of con-
q Takes charge pressure to be at fixed value and allows engines to run.
troller
Problem on
q Engine output lowers.
machine
q Input voltage from boost pressure sensor can be checked by using monitoring function.
(Code: 36501 (V))
q Boost pressure from boost pressure sensor can be checked by using monitoring function.
Related infor-
(Code: 36500 (kPa))
mation
q Method of reproducing failure code: Turn starting switch to ON position.
q If sensor connector is disconnected, code [CA123] for "Low Error" is displayed, even in normal con-
dition.

Cause Procedure, measuring location, criteria and remarks

See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 in "Checks before troubleshooting" of "General information on troubleshoot-
tor
ing", and check them directly.
Defective sensor power supply 2
2 If failure code [CA227] is also displayed, perform troubleshooting for it first.
line
1. Turn starting switch to OFF position.
2. Disconnect connector BOOST PRESS & IMT.
3. Turn starting switch to ON position.
Defective boost pressure & tem- If failure code changes from [CA122] to [CA123] ,boost pressure sensor is
3
perature sensor defective.
a Failure code [CA153] for temperature sensor is displayed at the same time.
Ignore this failure code since it appears because of disconnection of
sensor.
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM and BOOST PRESS & IMT, and connect
4 Short circuit in wiring harness T-adapter to female side of ECM.
Between ECM (female) (37) and (44) Resistance Min. 100 kz
1. Turn starting switch to OFF position.
2. Disconnect connector BOOST PRESS & IMT, and connect T-adapter to
Hot short circuit in wiring harness connector ECM.
5 3. Turn starting switch to ON position (with connector BOOST PRESS & IMT
(contact with 24 V circuit)
disconnected).
Between ECM (44) and (47) Voltage Max. 1 V
If no failure is found by above checks, engine controller is defective. (Since
6 Defective engine controller
this is internal failure, troubleshooting cannot be performed.)

40-116 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [CA122] Chg Air Press Sensor High Error

Circuit diagram related to boost pressure sensor 40-1 7

PC228US-8,PC228USLC-8 40-117
(01)
Troubleshooting by failurecode
Failure code [CA123] Chg Air Press Sensor Low Error

Failure code [CA123] Chg Air Press Sensor Low Error 40-1 8

User code Failure code Boost pressure sensor low error

Failure
(Engine controller system)
E11 CA123
Detail of failure q Low voltage appears in pressure signal circuit of boost pressure & temperature sensor.
Action of con-
q Takes charge pressure to be at fixed value and allows engine to run.
troller
Problem on
q Engine output lowers.
machine
q Input voltage from boost pressure sensor can be checked by using monitoring function.
(Code: 36501 (V))
q Boost pressure from boost pressure sensor can be checked by using monitoring function.
(Code: 36500 (kPa))
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation
q Since troubleshooting "socket" for this sensor features female connector alone, it is not usable for
checking open circuit in wiring harness and voltage at sensor connector (not designed as a
T-adapter).
q If sensor connector is disconnected, this failure code is displayed.

Cause Procedure, measuring location, criteria and remarks

See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 in "Checks before troubleshooting" of "General information on troubleshoot-
tor
ing", and check them directly.
Defective power supply system of If failure code [CA187] or [CA227] is displayed, perform troubleshooting for it
2
boost pressure sensor first.
1. Turn starting switch to OFF position.
2. Disconnect connectors CAM SENSOR, FUEL RAIL PRESS, BOOST
PRESS & IMT and ECM.
3 Short circuit in wiring harness 3. Connect T-adapter to female side of ECM.
Between ECM (female) (37) and (47) Resistance Min. 100 kz
Between ECM (female) (44) and (47) Resistance Min. 100 kz
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors ECM and BOOST PRESS & IMT, and connect
4 T-adapter to female side of ECM.
(contact with ground circuit)
Between ECM (female) (44) and ground Resistance Min. 100 kz
If no failure is found by above checks, there may be open circuit in wiring har-
5 Open circuit in wiring harness
ness. (*)
a If no failure is found by checks on 1 - 5 and check result of cause 6 is ab-
normal, sensor is defective.
Defective boost pressure & tem-
1. Turn starting switch to OFF position.
perature sensor
6 2. Insert T-adapter to connector ECM.
(improper input voltage to engine
3. Turn starting switch to ON position.
controller)
Sensor out-
Between ECM (44) and (47) Voltage 0.3 - 4.7 V
put
If no failure is found by above checks, engine controller is defective. (Since
7 Defective engine controller
this is internal failure, troubleshooting cannot be performed.)

*: See "Troubleshooting method for open circuit in wiring harness of pressure sensor system" of "Related in-
formation of troubleshooting".

40-118 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [CA123] Chg Air Press Sensor Low Error

Circuit diagram related to boost pressure sensor 40-1 9

PC228US-8,PC228USLC-8 40-119
(01)
Troubleshooting by failurecode
Failure code [CA131] Throttle Sensor High Error

Failure code [CA131] Throttle Sensor High Error 40-120

User code Failure code Throttle sensor high error

Failure
(Engine controller system)
E14 CA131
Detail of failure q High voltage appears in fuel control dial circuit.
q Uses throttle value obtained before failure detection and allows engine to run when failure is de-
Action of con-
tected with starting switch at ON position.
troller
q Uses full throttle value to run engine if starting switch is set to ON position after detecting failure.
Problem on
q Engine speed cannot be controlled by using fuel control dial.
machine
q Signal voltage from fuel control dial can be checked by using monitoring function.
Related infor-
(Code: 03000 Fuel control dial voltage)
mation
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 of "Checks before troubleshooting" in "General information on troubleshoot-
tor
ing" , and check them directly.
Defective throttle sensor power
2 If failure code [CA2185] is also displayed, perform troubleshooting for it first.
supply system
1. Turn starting switch to OFF position.
2. Disconnect connector P20 and connect T-adapter to male side.
Defective fuel control dial (throttle Between P20 (male) (1) and (3) Resistance 4.0 - 6.0 kz
3
sensor)
Between P20 (male) (2) and (3) Resistance 0.25 - 5.0 kz
Between P20 (male) (1) and (2) Resistance 0.25 - 5.0 kz
1. Turn starting switch to OFF position.
2. Disconnect connector CE02, and connect T-adapter to female side.
Open or short circuit in wiring har-
4
ness Between CE02 (famale) (22) and (23) Resistance 4.0 - 6.0 kz
Between CE02 (famale) (9) and (23) Resistance 0.25 - 5.0 kz
a If no failure is found by checks on cause 4, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors CE02 and P20, and connect T-adapter to female
5 Short circuit in wiring harness side of either connector.
Between CE02 (female) (9) and (22), or between
Resistance Min. 1 Mz
P20 (female) (1) and (2)
1. Turn starting switch to OFF position.
Hot short in wiring harness 2. Disconnect connector P20, and connect T-adapter to female side.
6 3. Turn starting switch to ON position.
(contact with 24 V circuit)
Between P20 (female) (2) and ground Voltage Max. 1 V
If no failure is found by above checks, engine controller is defective. (Since
this is internal failure, troubleshooting cannot be performed.)
q Reference
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector CE02.
7 Defective engine controller 3. Turn starting switch to ON position.
4. Operate fuel control dial and perform troubleshooting.
Power sup-
Between CE02 (22) and (23) Voltage 4.75 – 5.25V
ply
Sensor out-
Between CE02 (9) and (23) Voltage 0.5 – 4.5 V
put

40-120 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [CA131] Throttle Sensor High Error

Circuit diagram related to throttle sensor 40-121

PC228US-8,PC228USLC-8 40-121
(01)
Troubleshooting by failurecode
Failure code [CA132] Throttle Sensor Low Error

Failure code [CA132] Throttle Sensor Low Error 40-12

User code Failure code Throttle sensor low error

Failure
(Engine controller system)
E14 CA132
Detail of failure q Low voltage appears in fuel control dial circuit.
q Uses throttle value obtained before failure detection and allows engine to run when failure is de-
Action of con-
tected with starting switch at ON position.
troller
q Uses full throttle value to run engine if starting switch is set to ON position after detecting failure.
Problem on
q Engine speed cannot be controlled by using fuel control dial.
machine
q Signal voltage from fuel control dial can be checked by using monitoring function.
Related infor-
(Code: 03000 Fuel control dial votage)
mation
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

See the descriptions of wiring harness and connectors in "c: Electrical equip-
Defective wiring harness connec-
1 ment" of "Checks before troubleshooting" in "General information on trouble-
tor
shooting" , and check them directly.
Defective throttle sensor power
2 If failure code [CA2186] is also displayed, perform troubleshooting for it first.
supply system
1. Turn starting switch to OFF position.
2. Disconnect connector P20 and connect T-adapter to male side.
Defective fuel control dial (throttle Between P20 (male) (1) and (3) Resistance 4.0 - 6.0 kz
3
sensor)
Between P20 (male) (2) and (3) Resistance 0.25 - 5.0 kz
Between P20 (male) (1) and (2) Resistance 0.25 - 5.0 kz
1. Turn starting switch to OFF position.
2. Disconnect connector CE02, and connect T-adapter to female side.
Open or short circuit in wiring har-
4
ness Between CE02 (famale) (22) and (23) Resistance 4.0 - 6.0 kz
Between CE02 (famale) (9) and (23) Resistance 0.25 - 5.0 kz
a If no failure is found by checks on cause 4, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors CE02 and P20, and connect T-adapter to each
female side.
Open circuit in wiring harness
Between CE02 (female) (22) and P20
5 (wire breakage or defective con- Resistance Max. 1 z
(female) (1)
tact of connector)
Between CE02 (female) (9) and P20 (female)
Resistance Max. 1 z
(2)
Between CE02 (female) (23) and P20
Resistance Max. 1 z
(female) (3)
a If no failure is found by checks on cause 4, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors CE02 and P20, and connect T-adapter to female
6 Short circuit in wiring harness side of either connector.
Between CE02 (female) (9) and (23), or
between P20 (female) (2) and (3) Resistance Min. 1 Mz

1. Turn starting switch to OFF position.

2. Disconnect connectors CE02 and P20, and connect T-adapter to female
Ground fault of wiring harness side of either connector.
7
(contact with ground circuit)
Between CE02 (female) (9) or P20 (female)
Resistance Min. 1 Mz
(2) and ground

40-122 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [CA132] Throttle Sensor Low Error

Cause Procedure, measuring location, criteria and remarks

If no failure is found by above checks, engine controller is defective. (Since
this is internal failure, troubleshooting cannot be performed.)
q Reference
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector CE02.
8 Defective engine controller
3. Turn starting switch to ON position.
4. Operate fuel control dial and perform troubleshooting.
Between CE02 (22) and (23) Power supply Voltage 4.75 – 5.25V
Between CE02 (9) and (23) Sensor output Voltage 0.5 – 4.5 V

Circuit diagram related to throttle sensor 40-123

PC228US-8,PC228USLC-8 40-123
(01)
Troubleshooting by failurecode
Failure code [CA144] Coolant Temp Sens High Error

Failure code [CA144] Coolant Temp Sens High Error 40-124

User code Failure code Coolant temperature sensor high error

Failure
(Engine controller system)
E0E CA144
Detail of failure q High voltage appears in signal circuit of coolant temperature sensor .
Action of con-
q Takes coolant temperature to be at fixed value and allows engine to run.
troller
Problem on q Engine does not start easily at low temperature.
machine q Overheat prevention function does not work.
q Input voltage from engine coolant temperature sensor can be checked by using monitoring func-
tion.
(Code: 04105 (V))
q Temperature sensed by engine coolant temperature sensor can be checked by using monitoring
function.
Related infor-
(Code: 04107 (°C))
mation
q Method of reproducing failure code: Turn starting switch to ON position.
q This failure code is displayed if temperature sensor connector is disconnected.
q Since troubleshooting "socket" for this sensor features the female connector alone, it is not con-
nectable to wiring harness side female connector and thus not usable for checking open circuit (not
designed as a T-adapter).

Cause Procedure, measuring location, criteria and remarks

See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 in "Checks before troubleshooting" of "General information on troubleshoot-
tor
ing", and check them directly.
1. Turn starting switch to OFF position.
2. Disconnect connector COOLANT TEMP, and connect socket to male side.
a If coolant temperature sensor has resistance of 700 z - 37 kz with coolant
temperature above 0 °C, regard coolant temperature sensor as normal.
0 °C Resistance 30 - 37 kz
Defective coolant temperature
2 Between COOLANT
sensor 25 °C Resistance 9.3 - 10.7 kz
TEMP (male) (A) and (B)
a Coolant tempera- 50 °C Resistance 3.2 - 3.8 kz
ture- Resistance
80 °C Resistance 1.0 - 1.3 kz
characteristics
95 °C Resistance 700 – 800 z
1. Turn starting switch to OFF position.
2. Disconnect connector ECM and connect T-adapter to female side.
Open or short circuit in wiring har- Between ECM (female) (15) and (38) (Coolant tem-
3 perature: Min. 0°C)
ness Resis-
a Use "Coolant temperature-Resistance charac- 700 z – 37 kz
tance
teristics" table shown above as resistance crite-
ria.
If no failure is found by above checks, engine controller is defective. (Since
4 Defective engine controller
this is internal failure, troubleshooting cannot be performed.)

40-124 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [CA144] Coolant Temp Sens High Error

Circuit diagram related to coolant temperature sensor 40-125

PC228US-8,PC228USLC-8 40-125
(01)
Troubleshooting by failurecode
Failure code [CA145] Coolant Temp Sens Low Error

Failure code [CA145] Coolant Temp Sens Low Error 40-126

User code Failure code Coolant temperature sensor low error

Failure
(Engine controller system)
E0E CA145
Detail of failure q Low voltage appears in signal circuit of coolant temperature sensor .
Action of con-
q Takes coolant temperature to be at fixed value and allows engine to run.
troller
Problem on q Engine does not start easily at low temperature.
machine q Overheat prevention function does not work.
q Input voltage from engine coolant temperature sensor can be checked by using monitoring func-
tion.
(Code: 04105 (V))
q Temperature sensed by engine coolant temperature sensor can be checked by using monitoring
Related infor-
function.
mation
(Code: 04107(°C) )
q Method of reproducing failure code: Turn starting switch to ON position.
q If temperature sensor connector is disconnected, this failure code is not displayed but failure code
[CA144] for "High Error" is displayed.

Cause Procedure, measuring location, criteria and remarks

See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 in "Checks before troubleshooting" of "General information on troubleshoot-
tor
ing", and check them directly.
1. Turn starting switch to OFF position.
2. Disconnect connector COOLANT TEMP, and connect socket to male side.
a If coolant temperature sensor has resistance of 700 z - 37 kz with coolant
temperature above 0 °C, regard coolant temperature sensor as normal.
0 °C Resistance 30 – 37 kz
Between COOLANT
Defective coolant temperature 25 °C Resistance 9.3 – 10.7 kz
2 TEMP (male) (A) and (B)
sensor a Coolant tempera- 50 °C Resistance 3.2 – 3.8 kz
ture- Resistance
80 °C Resistance 1.0 – 1.3 kz
characteristics
95 °C Resistance 700 – 800 z
Whole cool-
Between (B) and ground ant temper- Resistance Min. 100 kz
ature range
1. Turn starting switch to OFF position.
2. Disconnect connector ECM and connect T-adapter to female side.
Between ECM (female) (15) and (38) (Coolant tem-
3 Short circuit in wiring harness perature: Min. 0 °C)
Resis-
a Use "Coolant temperature-Resistance charac- 700 z – 37 kz
tance
teristics" table shown above as resistance crite-
ria.
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM and COOLANT TEMP, and connect
Ground fault in wiring harness
4 T-adapter to female side of ECM.
(contact with ground circuit)
Resis-
Between ECM (female) (15) and ground Min. 100 kz
tance
If no failure is found by above checks, engine controller is defective. (Since
5 Defective engine controller
this is internal failure, troubleshooting cannot be performed.)

40-126 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [CA145] Coolant Temp Sens Low Error

Circuit diagram related to coolant temperature sensor 40-127

PC228US-8,PC228USLC-8 40-127
(01)
Troubleshootingby
Troubleshooting byfailurecode
failurecode
Failure code
Failure code [CA153]
[CA153] Chg
Chg Air
Air Temp
Temp Sensor
Sensor High
High Error
Error

Failure code [CA153] Chg Air Temp Sensor High Error 40-128

User code Failure code Boost temperature sensor high error

Failure
(Engine controller system)
E0E CA153
Detail of failure q High voltage appears in temperature signal circuit of boost pressure & temperature sensor.
Action of con-
q Takes boost temperature to be at fixed value and allows engine to run.
troller
Problem on
q Engine protection function based on boost temperature does not work.
machine
q Input voltage from boost temperature sensor can be checked by using monitoring function.
(Code: 18501 (V))
q Temperature sensed by boost temperature sensor can be checked by using monitoring function.
(Code: 18500(°C))
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation
q Since troubleshooting "socket" for this sensor features female connector alone, it is not connect-
able to wiring harness side female connector and thus not usable for checking open circuit (not de-
signed as a T-adapter).
q This failure code is displayed if temperature sensor connector is disconnected.

Cause Procedure, measuring location, criteria and remarks

See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 in "Checks before troubleshooting" of "General information on troubleshoot-
tor
ing", and check them directly.
1. Turn starting switch to OFF position.
2. Disconnect connector BOOST PRESS & IMT, and connect socket to male
side.
-40 °C Resistance 41 – 48 kz
-20 °C Resistance 14 – 16 kz
Between BOOST
Defective boost temperature sen-
2 PRESS & IMT (male) (3) 0 °C Resistance 5.4 – 6.1 kz
sor
and (4)
30 °C Resistance 1.6 – 1.8 kz
a Boost temperature
-Resistance chari- 60 °C Resistance 560 – 600 z
acteristic
90 °C Resistance 230 – 250 z
130 °C Resistance 80 – 90 z
1. Turn starting switch to OFF position.
2. Disconnect connector ECM and connect T-adapter to female side.
Open or short circuit in wiring har-
3 Between ECM (female) (23) and (47)
ness 80 z –
a Use "boost temperature-Resistance characteris- Resistance
48 kz
tics" table shown above as resistance criteria.
If no failure is found by above checks, engine controller is defective. (Since
4 Defective engine controller
this is internal failure, troubleshooting cannot be performed.)

40-128 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [CA153] Chg Air Temp Sensor High Error

Circuit diagram related to boost temperature sensor 40-129

PC228US-8,PC228USLC-8 40-129
(01)
Troubleshooting by failurecode
Failure code [CA154] Chg Air Temp Sensor Low Error

Failure code [CA154] Chg Air Temp Sensor Low Error 40-130

User code Failure code Boost temperature sensor low error

Failure
(Engine controller system)
E0E CA154
Detail of failure q Low voltage appears in temperature signal circuit of boost pressure & temperature sensor.
Action of con-
q Takes boost temperature to be at fixed value and allows engine to run.
troller
Problem on
q Engine protection function based on boost temperature does not work.
machine
q Input voltage from boost temperature sensor can be checked by using monitoring function.
(Code: 18501 (V))
q Temperature sensed by boost temperature sensor can be checked by using monitoring function.
Related infor-
(Code: 18500 (°C))
mation
q If temperature sensor connector is disconnected, this failure code is not displayed but failure code
[CA153] for "High Error" is displayed.
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 in "Checks before troubleshooting" of "General information on troubleshoot-
tor
ing", and check them directly.
1. Turn starting switch to OFF position.
2. Disconnect connector BOOST PRESS & IMT, and connect socket to male
side.

-40 °C Resistance 41 – 48 kz
-20 °C Resistance 14 – 16 kz
Defective boost temperature sen- Between BOOST
2
sor PRESS & IMT (male) (3) 0 °C Resistance 5.4 – 6.1 kz
and (4)
30 °C Resistance 1.6 – 1.8 kz
a Boost temperature
-Resistance chari- 60 °C Resistance 560 – 600 z
acteristic
90 °C Resistance 230 – 250 z
130 °C Resistance 80 – 90 z
1. Turn starting switch to OFF position.
2. Disconnect connector ECM and connect T-adapter to female side.
3 Short circuit in wiring harness Between ECM (female) (23) and (47)
80 z –
a Use "boost temperature-Resistance characteris- Resistance
48 kz
tics" table shown above as resistance criteria.
a If no failure is found by checks on cause 3, this check is not required.
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors ECM and BOOST PRESS & IMT, and connect
4
(contact with ground circuit) T-adapter to female side of ECM.
Between ECM (female) (23) and ground Resistance Min. 100 kz
If no failure is found by above checks, engine controller is defective. (Since
5 Defective engine controller
this is internal failure, troubleshooting cannot be performed.)

40-130 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [CA154] Chg Air Temp Sensor Low Error

Circuit diagram related to boost temperature sensor 40-131

PC228US-8,PC228USLC-8 40-131
(01)
Troubleshooting by failurecode
Failure code [CA155] Chg Air Temp High Speed Derate

Failure code [CA155] Chg Air Temp High Speed Derate 40-132

User code Failure code Boost temperature high enough for speed derate
Failure
(Engine controller system)
E11 CA155
q Boost temperature sensed by boost pressure & temperature sensor exceeds upper limit of control
Detail of failure
temperature.
Action of con-
q Limits engine output and allows engine to run.
troller
Problem on q Engine output lowers.
machine q Engine stops.
q Boost temperature can be checked by using monitoring function.
Related infor-
(Code: 18500 Boost temperature)
mation
q Method of reproducing failure code: Start engine.

Cause Procedure, measuring location, criteria and remarks

Aftercooler cooling performance may degrade. Directly check the following
points:
Lowered cooling performance of
1 q Looseness and damage of fan belt
aftercooler
q Insufficient cooling air
q Clogging of aftercooler fins
Abnormal rise of turbocharger out- Outlet temperature of turbocharger may be abnormally high. Check related
2
let temperature parts directly.
Defective boost temperature sen- If no failure is found by above checks, boost temperature sensor system may
3
sor be defective. Perform troubleshooting for failure codes [CA153] and [CA154].

40-132 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [CA155] Chg Air Temp High Speed Derate

PC228US-8,PC228USLC-8 40-133
(01)
Troubleshooting by failurecode
Failure code [CA187] Sens Supply 2 Volt Low Error

Failure code [CA187] Sens Supply 2 Volt Low Error 40-134

User code Failure code Sensor power supply 2 voltage low error
Failure
(Engine controller system)
E0E CA187
Detail of failure q Low voltage appears in sensor power supply 2 circuit.

Action of con- q Takes boost pressure & temperature set to be at fixed values and allows engine to run.
troller q Run engine with engine output limited.

Problem on q Engine output lowers.

machine q Engine starting performance becomes deteriorated.
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation

Cause Procedure, measuring location, criteria and remarks

See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 in "Checks before troubleshooting" of "General information on troubleshoot-
tor
ing", and check them directly.
1. Turn starting switch to OFF position.
2. Disconnect following connectors sequentially one by one and turn starting
switch to ON position each time.
3. After each troubleshooting, return to 1.
If this failure code is not displayed when a connector is disconnected, that sen-
sor or engine wiring harness is defective.
a Other failure codes are displayed, too. This is because of disconnection of
connector. Ignore failure codes other than [CA187].
2 Defective sensor or wiring harness
Sensor or harness Connector
Boost pressure & temperature sen-
BOOST PRESS & IMT
sor
Common rail pressure sensor FUEL RAIL PRESS
Bkup sensor CAM SENSOR
Engine wiring harness ECM
1. Turn starting switch to OFF position.
2. Disconnect connector ECM and connect T-adapter to male side.
3 Defective engine controller 3. Turn starting switch to ON position with connector ECM disconnected.

Between ECM (male) (37) and (47) Voltage 4.75 - 5.25 V

40-134 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [CA187] Sens Supply 2 Volt Low Error

Circuit diagram related to sensor power supply 2 40-135

PC228US-8,PC228USLC-8 40-135
(01)
Troubleshooting by failurecode
Failure code [CA221] Ambient Press Sens High Error

Failure code [CA221] Ambient Press Sens High Error 40-136

User code Failure code Ambient pressure sensor high error

Failure
(Engine controller system)
E11 CA221
Detail of failure q High voltage appears in signal circuit of ambient pressure sensor.
Action of con-
q Takes ambient pressure to be at fixed value and allows engine to run.
troller
Problem on q Engine output lowers.
machine q Engine starting performance becomes deteriorated.
q Input voltage from ambient pressure sensor can be checked by using monitoring function.
(Code: 37401 (V))
Related infor- q Ambient pressure sensed by ambient pressure sensor can be checked by using monitoring func-
mation tion.
(Code: 37400 (kPa))
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 in "Checks before troubleshooting" of "General information on troubleshoot-
tor
ing", and check them directly.
Defective sensor power supply 1 If failure code [CA352] or [CA386] is displayed simultaneously, perform trou-
2
system bleshooting for it first.
1. Turn starting switch to OFF position.
2. Disconnect connector AMB. AIR PRESSURE.
3 Defective ambient pressure sensor 3. Turn starting switch to ON position.

If failure code changes from [CA221] to [CA222], sensor is defective.

1. Turn starting switch to OFF position.
2. Disconnect connectors ECM and AMB. AIR PRESSURE, and connect
4 Short circuit in wiring harness T-adapter to female side of either one.
Between ECM (female) (33) and (3), or between
Resistance Min. 100 kz
AMB. AIR PRESSURE (female) (1) and (3)
1. Turn starting switch to OFF position.
2. Disconnect connector AMB. AIR PRESSURE.
3. Connect T-adapter to female side of connector AMB. AIR PRESSURE or
Hot short circuit in wiring harness insert T-adapter in connector ECM.
5 4. Turn starting switch to ON position (with connector AMB. AIR PRESSURE
(contact with 24 V circuit)
disconnected).
Between ECM (3) and (38), or between AMB. AIR
Voltage Max. 1 V
PRESSURE (female) (3) and (2)
If no failure is found by above checks, engine controller is defective. (Since
6 Defective engine controller
this is internal failure, troubleshooting cannot be performed.)

40-136 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [CA221] Ambient Press Sens High Error

Circuit diagram related to ambient pressure sensor 40-137

PC228US-8,PC228USLC-8 40-137
(01)
Troubleshooting by failurecode
Failure code [CA222] Ambient Press Sens Low Error

Failure code [CA222] Ambient Press Sens Low Error 40-138

User code Failure code Ambient pressure sensor low error

Failure
(Engine controller system)
E11 CA222
Detail of failure q Low voltage appears in signal circuit of ambient pressure sensor.
Action of con-
q Takes ambient pressure to be at fixed value and allows engine to run.
troller
Problem on q Engine output lowers.
machine q Engine starting performance becomes deteriorated.
q Input voltage from ambient pressure sensor can be checked by using monitoring function.
(Code: 37401 (V))
q Ambient pressure sensed by ambient pressure sensor can be checked by using monitoring func-
Related infor-
tion.
mation
(Code: 37400 (kPa))
q If sensor connector is disconnected, this failure code is displayed.
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 in "Checks before troubleshooting" of "General information on troubleshoot-
tor
ing", and check them directly.
If failure code [CA352] or [CA386] is also displayed, perform troubleshooting
for it first.
1. Turn starting switch to OFF position.
Defective power supply line of 2. Disconnect connector AMB. AIR PRESSURE and connect T-adapter to
2
ambient pressure sensor female side.
3. Turn starting switch to ON position.
Between AMB. AIR PRESSURE 4.75 –
Power input Voltage
(female) (1) and (2) 5.25 V
1. Turn starting switch to OFF position.
2. Disconnect connectors AMB. AIR PRESSURE and ECM, and connect
T-adapter to each female side.
a If power supply input in checks on cause 2 is nor-
mal, this check is not required.
Resistance Max. 10 z
Short circuit in wiring harness Between ECM (female) (33) and AMB. AIR
3 (wire breakage or defective con- PRESSURE (female) (1)
tact of connector) a If power supply input in checks on cause 2 is nor-
mal, this check is not required.
Resistance Max. 10 z
Between ECM (female) (38) and AMB. AIR
PRESSURE (female) (2)
Between ECM (female) (3) and AMB. AIR PRES-
Resistance Max. 10 z
SURE (female) (3) (sensor output)
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM and AMB. AIR PRESSURE, and connect
Ground fault in wiring harness T-adapter to female side of either one.
4
(contact with ground circuit)
Between ECM (female) (3) and ground, or between
Resistance Min. 100 kz
AMB. AIR PRESSURE (female) (3) and ground
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM and AMB. AIR PRESSURE, and connect
5 Short circuit in wiring harness T-adapter to female side of either one.
Between ECM (female) (3) and (38), or between
Resistance Min. 100 kz
AMB. AIR PRESSURE (female) (2) and (3)

40-138 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [CA222] Ambient Press Sens Low Error

Cause Procedure, measuring location, criteria and remarks

a If no failure is found by checks on causes 1 to 5 and check result for cause
6 is abnormal, sensor is defective.
Defective ambient pressure sensor 1. Turn starting switch to OFF position.
6 (improper input voltage to engine 2. Insert T-adapter to connector ECM.
controller) 3. Turn starting switch to ON position.
Sensor out-
Between ECM (3) and (38) Voltage 0.5 – 4.5 V
put
If no failure is found by above checks, engine controller is defective. (Since
7 Defective engine controller
this is internal failure, troubleshooting cannot be performed.)

Circuit diagram related to ambient pressure sensor 40-139

PC228US-8,PC228USLC-8 40-139
(01)
Troubleshooting by failurecode
Failure code [CA227] Sens Supply 2 Volt High Error

Failure code [CA227] Sens Supply 2 Volt High Error 40-140

User code Failure code Sensor power supply 2 voltage high error
Failure
(Engine controller system)
E0E CA227
Detail of failure q High voltage appears in sensor power supply 2 circuit.
Action of con- q Takes boost pressure and charge temperature to be at fixed values and allows engine to run.
troller q Runs engine with output and limited.
Problem on q Engine output lowers.
machine q Engine starting performance becomes deteriorated.
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation

Cause Procedure, measuring location, criteria and remarks

Perform troubleshooting for failure code [CA187].

40-140 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [CA234] Eng Overspeed

Failure code [CA234] Eng Overspeed 40-141

User code Failure code Engine overspeed

Failure
(Engine controller system)
– CA234
Detail of failure q Engine speed exceeded upper limit of control speed .
Action of con-
q Stops injection until engine speed lowers to normal level.
troller
Problem on
q Engine speed fluctuates.
machine
q Engine speed can be checked by using monitoring function.
Related infor-
(Code: 01002 Engine speed)
mation
q Method of reproducing failure code: Run engine at high idle.

Cause Procedure, measuring location, criteria and remarks

1 Use of improper fuel Fuel used may be improper. Check it directly

2 Improper use Machine may be used improperly. Instruct operator on proper way to use.

If no failure is found by checks on causes 1 and 2, engine controller may be

3 Defective engine controller
defective. (Since this is internal failure, troubleshooting cannot be performed.)

PC228US-8,PC228USLC-8 40-141
(01)
Troubleshooting by failurecode
Failure code [CA238] Ne Speed Sens Supply Volt Error

Failure code [CA238] Ne Speed Sens Supply Volt Error 40-142

User code Failure code Ne speed power supply voltage error

Failure
(Engine controller system)
E0E CA238
Detail of failure q Low voltage appears in power supply circuit of engine Ne speed sensor.
Action of con-
q Controls the engine with signal from engine Bkup speed sensor.
troller
q Running engine stops (when Bkup speed sensor is also defective).
Problem on q Stopped engine cannot be started (when Bkup speed sensor is also defective).
machine q Starting performance is poor
q Engine hunts.
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation

Cause Procedure, measuring location, criteria and remarks

See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 in "Checks before troubleshooting" of "General information on troubleshoot-
tor
ing", and check them directly.
1. Turn starting switch to OFF position.
2. Disconnect following connectors one by one and turn starting switch to ON
position each time.
3. After each troubleshooting, return to step 1.
If this failure code is not displayed when sensor is disconnected, sensor or
engine wiring harness is defective.
2 Defective sensor or wiring harness a Other failure codes are displayed, too. This is because of disconnection of
connector. Ignore failure codes other than [CA238].
Sensor or harness Connector
Ne speed sensor CRANK SENSOR
Engine wiring harness ECM
1. Turn starting switch to OFF position.
2. Disconnect connector ECM and connect T-adapter to male side.
3 Defective engine controller 3. Turn starting switch to ON position with connector ECM disconnected.
4.75 –
Between ECM (male) (16) and (48) Voltage
5.25 V

Circuit diagram related to engine Ne speed sensor 40-142

40-142 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [CA238] Ne Speed Sens Supply Volt Error

PC228US-8,PC228USLC-8 40-143
(01)
Troubleshooting by failurecode
Failure code [CA271] IMV/PCV1 Short Error

Failure code [CA271] IMV/PCV1 Short Error 40-14

User code Failure code Short circuit in IMV/PCV1

Failure
(Engine controller system)
E10 CA271
Detail of failure q Short circuit is detected in drive circuit of supply pump actuator.
Action of con-
q None in particular
troller
q Engine speed does not increase from low idle.
Problem on
q Engine output lowers.
machine
q Common rail fuel pressure rises above command value.
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation

Cause Procedure, measuring location, criteria and remarks

See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 in "Checks before troubleshooting" of "General information on troubleshoot-
tor
ing", and check them directly.
1. Turn starting switch to OFF position.
2. Disconnect connector CP3 PUMP REGULATOR.
2 Defective supply pump actuator 3. Turn starting switch to ON position.
If failure code changes from [CA271] to [CA272] , supply pump actuator is
defective.
1. Turn starting switch to OFF position.
2. Disconnect connector ECM and connect T-adapter to female side.
Short circuit or ground fault in wir-
3
ing harness Between ECM (female) (2) and (32) Resistance 1–5z
Between ECM (female) (2) and ground Resistance Min. 100 kz
a If no failure is found by checks on cause 3, this check is not required.
1. Turn starting switch to OFF position.
4 Short circuit in wiring harness 2. Disconnect connectors ECM and CP3 PUMP REGULATOR and connect
T-adapter to female side of ECM.
Between ECM (female) (2) and (32) Resistance Min. 100 kz
a If no failure is found by checks on cause 3, this check is not required.
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors ECM and CP3 PUMP REGULATOR and connect
5
(contact with ground circuit) T-adapter to female side of ECM.
Between ECM (female) (2) and ground Resistance Min. 100 kz
If no failure is found by above checks, engine controller is defective. (Since
6 Defective engine controller
this is internal failure, troubleshooting cannot be performed.)

40-144 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [CA271] IMV/PCV1 Short Error

Circuit diagram related to IMV/PCV1 40-145

PC228US-8,PC228USLC-8 40-145
(01)
Troubleshooting by failurecode
Failure code [CA272] IMV/PCV1 Open Error

Failure code [CA272] IMV/PCV1 Open Error 40-146

User code Failure code Open circuit in IMV/PCV1

Failure
(Engine controller system)
E10 CA272
Detail of failure q Open circuit is detected in drive circuit of supply pump actuator.
Action of con-
q None in particular
troller
Problem on q Engine runs but its speed does not stabilize.
machine q Common rail fuel pressure rises above command value.
q Method of reproducing failure code: Turn starting switch to ON position.
Related infor- q Since troubleshooting "socket" for this sensor features female connector alone, it is not connect-
mation able to harness side female connector and thus not usable for checking open circuit (not designed
as a T-adapter).

Cause Procedure, measuring location, criteria and remarks

See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 in "Checks before troubleshooting" of "General information on troubleshoot-
tor
ing", and check them directly.
1. Turn starting switch to OFF position.
2. Disconnect connector CP3 PUMP REGULATOR.
2 Defective supply pump actuator
Between CP3 PUMP REGULATOR (male) (1) and
Resistance Max. 5 z
(2)
1. Turn starting switch to OFF position.
Open or short circuit in wiring har- 2. Disconnect connector ECM and connect T-adapter to female side.
3
ness
Between ECM (female) (2) and (32) Resistance Max. 5 z

1.Turn starting switch to OFF position.

2.Disconnect connector CP3 PUMP REGULATOR.
3.Insert T-adapter to connector ECM.
Hot short circuit in wiring harness 4.Turn starting switch to ON position and perform troubleshooting after one
4
(contact with 24 V circuit) minute or longer (with connector CP3 PUMP REGULATOR disconnected).
a Average voltage is displayed because of PWM.

Between ECM (2) and (32) Voltage Max. 3 V

If no failure is found by above checks, engine controller is defective. (Since
5 Defective engine controller
this is internal failure, troubleshooting cannot be performed.)

40-146 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [CA272] IMV/PCV1 Open Error

Circuit diagram related to IMV/PCV1 40-147

PC228US-8,PC228USLC-8 40-147
(01)
Troubleshooting by failurecode
Failure code [CA322] Inj #1(L#1) Open/Short Error

Failure code [CA322] Inj #1(L#1) Open/Short Error 40-148

User code Failure code Open or short circuit in injector #1 (L/B#1)

Failure
(Engine controller system)
E11 CA322
Detail of failure q Open or short circuit is detected in drive circuit of No. 1 injector.
Action of con-
q None in particular
troller
Problem on q Combustion becomes irregular or engine hunts.
machine q Engine output lowers.
q Method of reproducing failure code: Start engine.
Related infor-
q While engine is running normally, pulse voltage of approx. 65 V is applied to injector (+) side but
mation
cannot be measured by using multimeter because it cannot measure pulse voltages.

Cause Procedure, measuring location, criteria and remarks

See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 in "Checks before troubleshooting" of "General information on troubleshoot-
tor
ing", and check them directly.
1. Turn starting switch to OFF position.
2. Disconnect connector INJECTOR CYL 1&2 and connect T-adapter to male
side.
2 Defective No. 1 injector
Between INJECTOR CYL 1&2 (male) (3) and (4) Resistance Max. 2 z
Between INJECTOR CYL 1&2 (male) (3) and
Resistance Min. 100 kz
ground
1. Turn starting switch to OFF position.
2. Disconnect connector ECM and connect T-adapter to female side.
Open circuit or ground fault in wir-
3
ing harness Between ECM (female) (45) and (53) Resistance Max. 2 z
Between ECM (female) (45) and ground Resistance Min. 100 kz
a If no failure is found by checks on cause 3, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM and INJECTOR CYL 1&2 and connect
Open circuit in wiring harness
T-adapter to each female side.
4 (wire breakage or defective con-
Between ECM (female) (45) and INJECTOR CYL
tact of connector) Resistance Max. 2 z
1&2 (female) (3)
Between ECM (female) (53) and INJECTOR CYL
Resistance Max. 2 z
1&2 (female) (4)
a If no failure is found by checks on cause 3, this check is not required.
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors ECM and INJECTOR CYL 1&2 and connect
5 T-adapter to female side of either one.
(contact with ground circuit)
Between ECM (female) (45) or INJECTOR CYL
Resistance Min. 100 kz
1&2 (female) (3) and ground
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM and INJECTOR CYL 1&2 and connect
T-adapter to female side of ECM.
a Check by using multimeter in continuity mode.
6 Short circuit in wiring harness
Between ECM (female) (45) and each pin other No continuity (no sound
than (45) is heard.)
Between ECM (female) (53) and each pin other No continuity (no sound
than (53) is heard.)
Defective other cylinder injectors If failure codes for other injectors are displayed, perform troubleshooting for
7
or wiring harness them, too.
If no failure is found by checks on causes 1 to 7, engine controller is defective.
8 Defective engine controller
(Since this is internal failure, troubleshooting cannot be performed.)

40-148 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [CA322] Inj #1(L#1) Open/Short Error

Circuit diagram related to injector #1 40-149

PC228US-8,PC228USLC-8 40-149
(01)
Troubleshooting by failurecode
Failure code [CA323] Inj #5 (L#5) Open/Short Error

Failure code [CA323] Inj #5 (L#5) Open/Short Error 40-150

User code Failure code Open or short circuit in injector #5 (L/B #5)
Failure
(Engine controller system)
E11 CA323
Detail of failure q Open or short circuit is detected in drive circuit of No. 5 injector.
Action of con-
q None in particular
troller
Problem on q Combustion becomes irregular or engine hunts.
machine q Engine output lowers.
q Method of reproducing failure code: Start engine.
Related infor-
q While engine is running normally, pulse voltage of approx. 65 V is applied to injector (+) side but
mation
cannot be measured by using multimeter because it cannot measure pulse voltages.

Cause Procedure, measuring location, criteria and remarks

See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 in "Checks before troubleshooting" of "General information on troubleshoot-
tor
ing", and check them directly.
1. Turn starting switch to OFF position.
2. Disconnect connector INJECTOR CYL 5&6 and connect T-adapter to male
side.
2 Defective No. 5 injector
Between INJECTOR CYL 5&6 (male) (3) and (4) Resistance Max. 2 z
Between INJECTOR CYL 5&6 (male) (3) and
Resistance Min. 100 kz
ground
1. Turn starting switch to OFF position.
2. Disconnect connector ECM and connect T-adapter to female side.
Open circuit or ground fault in wir-
3
ing harness Between ECM (female) (46) and (60) Resistance Max. 2 z
Between ECM (female) (46) and ground Resistance Min. 100 kz
a If no failure is found by checks on cause 3, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM and INJECTOR CYL 5&6 and connect
Open circuit in wiring harness
T-adapter to each female side.
4 (wire breakage or defective con-
Between ECM (female) (46) and INJECTOR CYL
tact of connector) Resistance Max. 2 z
5&6 (female) (3)
Between ECM (female) (60) and INJECTOR CYL
Resistance Max. 2 z
5&6 (female) (4)
a If no failure is found by checks on cause 3, this check is not required.
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors ECM and INJECTOR CYL 5&6 and connect
5 T-adapter to female side of either one.
(contact with ground circuit)
Between ECM (female) (46) or INJECTOR CYL
Resistance Min. 100 kz
5&6 (female) (3) and ground
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM and INJECTOR CYL 5&6 and connect
T-adapter to female side of ECM.
a Check by using multimeter in continuity mode.
6 Short circuit in wiring harness
Between ECM (female) (46) and each pin other No continuity (no sound
than (46) is heard.)
Between ECM (female) (60) and each pin other No continuity (no sound
than (60) is heard.)
Defective other cylinder injectors If failure codes for other injectors are displayed, perform troubleshooting for
7
or wiring harness them, too.
If no failure is found by above checks, engine controller is defective. (Since
8 Defective engine controller
this is internal failure, troubleshooting cannot be performed.)

40-150 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [CA323] Inj #5 (L#5) Open/Short Error

Circuit diagram related to injector #5 40-151

PC228US-8,PC228USLC-8 40-151
(01)
Troubleshooting by failurecode
Failure code [CA324] Inj #3(L#3) Open/Short Error

Failure code [CA324] Inj #3(L#3) Open/Short Error 40-152

User code Failure code Open or short circuit in injector #3 (L/B #3)
Failure
(Engine controller system)
E11 CA324
Detail of failure q Open or short circuit is detected in drive circuit of No. 3 injector.
Action of con-
q None in particular
troller
Problem on q Combustion becomes irregular or engine hunts.
machine q Engine output lowers.
q Method of reproducing failure code: Start engine.
Related infor-
q While engine is running normally, pulse voltage of approx. 65 V is applied to injector (+) side but
mation
cannot be measured by using multimeter because it cannot measure pulse voltages.

Cause Procedure, measuring location, criteria and remarks

See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 in "Checks before troubleshooting" of "General information on troubleshoot-
tor
ing", and check them directly.
1. Turn starting switch to OFF position.
2. Disconnect connector INJECTOR CYL 3&4 and connect T-adapter to male
side.
2 Defective No. 3 injector
Between INJECTOR CYL 3&4 (male) (3) and (4) Resistance Max. 2 z
Between INJECTOR CYL 3&4 (male) (3) and
Resistance Min. 100 kz
ground
1. Turn starting switch to OFF position.
2. Disconnect connector ECM and connect T-adapter to female side.
Open circuit or ground fault in wir-
3
ing harness Between ECM (female) (55) and (52) Resistance Max. 2 z
Between ECM (female) (55) and ground Resistance Min. 100 kz
a If no failure is found by checks on cause 3, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM and INJECTOR CYL 3&4 and connect
Open circuit in wiring harness
T-adapter to each female side.
4 (wire breakage or defective con-
Between ECM (female) (55) and INJECTOR CYL
tact of connector) Resistance Max. 2 z
3&4 (female) (3)
Between ECM (female) (52) and INJECTOR CYL
Resistance Max. 2 z
3&4 (female) (4)
a If no failure is found by checks on cause 3, this check is not required.
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors ECM and INJECTOR CYL 3&4 and connect
5 T-adapter to female side of either one.
(contact with ground circuit)
Between ECM (female) (55) or INJECTOR CYL
Resistance Min. 100 kz
3&4 (female) (3) and ground
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM and INJECTOR CYL 3&4 and connect
T-adapter to female side of ECM.
a Check by using multimeter in continuity mode.
6 Short circuit in wiring harness
Between ECM (female) (55) and each pin other No continuity (no sound
than (55) is heard.)
Between ECM (female) (52) and each pin other No continuity (no sound
than (52) is heard.)
Defective other cylinder injectors If failure codes for other injectors are displayed, perform troubleshooting for
7
or wiring harness them, too.
If no failure is found by above checks, engine controller is defective. (Since
8 Defective engine controller
this is internal failure, troubleshooting cannot be performed.)

40-152 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [CA324] Inj #3(L#3) Open/Short Error

Circuit diagram related to injector #3 40-153

PC228US-8,PC228USLC-8 40-153
(01)
Troubleshooting by failurecode
Failure code [CA325] Inj #6 (L#6) Open/Short Error

Failure code [CA325] Inj #6 (L#6) Open/Short Error 40-154

User code Failure code Open or short circuit in injector #6 (L/B #6)
Failure
(Engine controller system)
E11 CA325
Detail of failure q Open or short circuit is detected in drive circuit of No. 6 injector.
Action of con-
q None in particular
troller
Problem on q Combustion becomes irregular or engine hunts.
machine q Engine output lowers.
q Method of reproducing failure code: Start engine.
Related infor-
q While engine is running normally, pulse voltage of apporx. 65 V is applied to injector (+) side but
mation
cannot be measured by using multimeter because it cannot measure pulse voltages.

Cause Procedure, measuring location, criteria and remarks

See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 in "Checks before troubleshooting" of "General information on troubleshoot-
tor
ing", and check them directly.
1. Turn starting switch to OFF position.
2. Disconnect connector INJECTOR CYL 5&6 and connect T-adapter to male
side.
2 Defective injector No. 6
Between INJECTOR CYL 5&6 (male) (1) and (2) Resistance Max. 2 z
Between INJECTOR CYL 5&6 (male) (1) and
Resistance Min. 100 kz
ground
1. Turn starting switch to OFF position.
2. Disconnect connector ECM and connect T-adapter to female side.
Open circuit or ground fault in wir-
3
ing harness Between ECM (female) (57) and (59) Resistance Max. 2 z
Between ECM (female) (57) and ground Resistance Min. 100 kz
a If no failure is found by checks on cause 3, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM and INJECTOR CYL 5&amp;6, and connect
Open circuit in wiring harness
T-adapters to each female side.
4 (wire breakage or defective con-
Between ECM (female) (57) and INJECTOR CYL
tact of connector) Resistance Max. 2 z
5&6 (female) (1)
Between ECM (female) (59) and INJECTOR CYL
Resistance Max. 2 z
5&6 (female) (2)
a If no failure is found by checks on cause 3, this check is not required.
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors ECM and INJECTOR CYL 5&6 and connect
5 T-adapter to female side of either one.
(contact with ground circuit)
Between ECM (female) (57) or INJECTOR CYL
Resistance Min. 100 kz
5&6 (female) (1) and ground
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM and INJECTOR CYL 5&6 and connect
T-adapter to female side of ECM.
a Check by using multimeter in continuity mode.
6 Short circuit in wiring harness
Between ECM (female) (57) and each pin other No continuity (no sound
than (57) is heard.)
Between ECM (female) (59) and each pin other No continuity (no sound
than (59) is heard.)
Defective other cylinder injectors If failure codes for other injectors are displayed, perform troubleshooting for
7
or wiring harness them, too.
If no failure is found by above checks, engine controller is defective. (Since
8 Defective engine controller
this is internal failure, troubleshooting cannot be performed.)

40-154 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [CA325] Inj #6 (L#6) Open/Short Error

Circuit diagram related to injector #6 40-15

PC228US-8,PC228USLC-8 40-155
(01)
Troubleshooting by failurecode
Failure code [CA331] Inj #2(L#2) Open/Short Error

Failure code [CA331] Inj #2(L#2) Open/Short Error 40-156

User code Failure code Open or short circuit in injector #2 (L/B#2)

Failure
(Engine controller system)
E11 CA322
Detail of failure q Open or short circuit is detected in drive circuit of No. 2 injector.
Action of con-
q None in particular
troller
Problem on q Combustion becomes irregular or engine hunts.
machine q Engine output lowers.
q Method of reproducing failure code: Start engine.
Related infor-
q While engine is running normally, pulse voltage of approx. 65 V is applied to injector (+) side but
mation
cannot be measured by using multimeter because it cannot measure pulse voltages.

Cause Procedure, measuring location, criteria and remarks

See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 in "Checks before troubleshooting" of "General information on troubleshoot-
tor
ing", and check them directly.
1. Turn starting switch to OFF position.
2. Disconnect connector INJECTOR CYL 1&2 and connect T-adapter to male
side.
2 Defective No. 2 injector
Between INJECTOR CYL 1&2 (male) (1) and (2) Resistance Max. 2 z
Between INJECTOR CYL 1&2 (male) (2) and
Resistance Min. 100 kz
ground
1. Turn starting switch to OFF position.
2. Disconnect connector ECM and connect T-adapter to female side.
Open circuit or ground fault in wir-
3
ing harness Between ECM (female) (54) and (51) Resistance Max. 2 z
Between ECM (female) (54) and ground Resistance Min. 100 kz
a If no failure is found by checks on cause 3, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM and INJECTOR CYL 1&2 and connect
Open circuit in wiring harness
T-adapter to each female side.
4 (wire breakage or defective con-
Between ECM (female) (54) and INJECTOR CYL
tact of connector) Resistance Max. 2 z
1&2 (female) (2)
Between ECM (female) (51) and INJECTOR CYL
Resistance Max. 2 z
1&2 (female) (1)
a If no failure is found by checks on cause 3, this check is not required.
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors ECM and INJECTOR CYL 1&2 and connect
5 T-adapter to female side of either one.
(contact with ground circuit)
Between ECM (female) (54) or INJECTOR CYL
Resistance Min. 100 kz
1&2 (female) (2) and ground
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM and INJECTOR CYL 1&2 and connect
T-adapter to female side of ECM.
a Check by using multimeter in continuity mode.
6 Short circuit in wiring harness
Between ECM (female) (54) and each pin other No continuity (no sound
than (54) is heard.)
Between ECM (female) (51) and each pin other No continuity (no sound
than (51) is heard.)
Defective other cylinder injectors If failure codes for other injectors are displayed, perform troubleshooting for
7
or wiring harness them, too.
If no failure is found by above checks, engine controller is defective. (Since
8 Defective engine controller
this is internal failure, troubleshooting cannot be performed.)

40-156 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [CA331] Inj #2(L#2) Open/Short Error

Circuit diagram related to injector #2 40-157

PC228US-8,PC228USLC-8 40-157
(01)
Troubleshooting by failurecode
Failure code [CA332] Inj #4(L#4) Open/Short Error

Failure code [CA332] Inj #4(L#4) Open/Short Error 40-158

User code Failure code Open or short circuit in injector #4 (L/B #4 )

Failure
(Engine controller system)
E11 CA332
Detail of failure q Open or short circuit is detected in drive circuit of No. 4 injector.
Action of con-
q None in particular
troller
Problem on q Combustion becomes irregular or engine hunts.
machine q Engine output lowers.
q Method of reproducing failure code: Start engine.
Related infor-
q While engine is running normally, pulse voltage of approx. 65 V is applied to injector (+) side but
mation
cannot be measured by using multimeter because it cannot measure pulse voltages.

Cause Procedure, measuring location, criteria and remarks

See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 in "Checks before troubleshooting" of "General information on troubleshoot-
tor
ing", and check them directly.
1. Turn starting switch to OFF position.
2. Disconnect connector INJECTOR CYL 3&4 and connect T-adapter to male
side.
2 Defective No. 4 injector
Between INJECTOR CYL 3&4 (male) (1) and (2) Resistance Max. 2 z
Between INJECTOR CYL 3&4 (male) (2) and
Resistance Min. 100 kz
ground
1. Turn starting switch to OFF position.
2. Disconnect connector ECM and connect T-adapter to female side.
Open circuit or ground fault in wir-
3
ing harness Between ECM (female) (56) and (58) Resistance Max. 2 z
Between ECM (female) (56) and ground Resistance Min. 100 kz
a If no failure is found by checks on cause 3, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM and INJECTOR CYL 3&4 and connect
Open circuit in wiring harness
T-adapter to each female side.
4 (wire breakage or defective con-
Between ECM (female) (56) and INJECTOR CYL
tact of connector) Resistance Max. 2 z
3&4 (female) (2)
Between ECM (female) (58) and INJECTOR CYL
Resistance Max. 2 z
3&4 (female) (1)
a If no failure is found by checks on cause 3, this check is not required.
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors ECM and INJECTOR CYL 3&4 and connect
5 T-adapter to female side of either one.
(contact with ground circuit)
Between ECM (female) (56) or INJECTOR CYL
Resistance Min. 100 kz
3&4 (female) (2) and ground
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM and INJECTOR CYL 3&4 and connect
T-adapter to female side of ECM.
a Check by using multimeter in continuity mode.
6 Short circuit in wiring harness
Between ECM (female) (56) and each pin other No continuity (no sound
than (56) is heard.)
Between ECM (female) (58) and each pin other No continuity (no sound
than (58) is heard.)
Defective other cylinder injectors If failure codes for other injectors are displayed, perform troubleshooting for
7
or wiring harness them, too.
If no failure is found by above checks, engine controller is defective. (Since
8 Defective engine controller
this is internal failure, troubleshooting cannot be performed.)

40-158 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [CA332] Inj #4(L#4) Open/Short Error

Circuit diagram related to injector #4 40-159

PC228US-8,PC228USLC-8 40-159
(01)
Troubleshooting by failurecode
Failure code [CA342] Calibration Code Incompatibility

Failure code [CA342] Calibration Code Incompatibility 40-160

User code Failure code Calibration code incompatible

Failure
(Engine controller system)
E10 CA342
Detail of failure q Matching error occurred in engine controller data.
Action of con-
q None in particular
troller
Problem on
q Machine continues normal operation, or engine is stopped and cannot be restarted.
machine
q Method of reproducing failure code: Turn starting switch to ON position.
Related infor-
q Power supply voltage of engine controller can be checked by using moniitoring funtion.
mation
(Code: 03203 (V))

Cause Procedure, measuring location, criteria and remarks

1 Defect in related system If another failure code is displayed, perform troubleshooting for it.

Defective power supply voltage

2 Perform troubleshooting for failure code [CA441].
system

40-160 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [CA351] Injectors Drive Circuit Error

Failure code [CA351] Injectors Drive Circuit Error 40-161

User code Failure code Injectors drive circuit error

Failure
(Engine controller system)
E10 CA351
Detail of failure q There is error in drive power circuit of injector.
Action of con-
q Runs engine with engine output limited.
troller
q Exhaust smoke becomes black.
Problem on q Combustion becomes irregular.
machine q Engine output lowers.
q Engine cannot be started.
q Method of reproducing failure code: Start engine.
Related infor-
q Power supply voltage of engine controller can be checked by using moniitoring funtion.
mation
(Code: 03203 (V))

Cause Procedure, measuring location, criteria and remarks

1 Defect in related system If another failure code is displayed, perform troubleshooting for it.

Defective power supply voltage

2 Perform troubleshooting for failure code [CA441].
system

PC228US-8,PC228USLC-8 40-161
(01)
Troubleshooting by failurecode
Failure code [CA352] Sens Supply 1 Volt Low Error

Failure code [CA352] Sens Supply 1 Volt Low Error 40-162

User code Failure code Sensor power supply 1 low error

Failure
(Engine controller system)
E0E CA352
Detail of failure q Low voltage appears in sensor power supply 1 circuit.
Action of con-
q Takes ambient pressure to be at fixed value and allows engine to run.
troller
Problem on q Engine output lowers.
machine q Engine starting performance becomes deteriorated.
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation

Cause Procedure, measuring location, criteria and remarks

See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 in "Checks before troubleshooting" of "General information on troubleshoot-
tor
ing", and check them directly.
1. Turn starting switch to OFF position.
2. Disconnect following connectors one by one and turn starting switch to ON
position each time.
3. After each troubleshooting, return to step 1.
If this failure code is not displayed when sensor is disconnected, sensor or
engine wiring harness is defective.
2 Defective sensor or wiring harness a Other failure codes are displayed as well. This is because connector is un-
plugged. Ignore all failure codes other than [CA352].
Sensor or harness Connector
Ambient pressure sensor AMB. AIR PRESSURE
Engine wiring harness ECM
1. Turn starting switch to OFF position.
2. Disconnect connector ECM and connect T-adapter to male side.
3 Defective engine controller 3. Turn starting switch to ON position with connector ECM disconnected.
Between ECM (male) (33) and (38) Voltage 4.75 - 5.25V

40-162 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [CA352] Sens Supply 1 Volt Low Error

Circuit diagram related to sensor power supply 1 40-163

PC228US-8,PC228USLC-8 40-163
(01)
Troubleshooting by failurecode
Failure code [CA386] Sens Supply 1 Volt High Error

Failure code [CA386] Sens Supply 1 Volt High Error 40-164

User code Failure code Sensor power supply 1 high error

Failure
(Engine controller system)
E0E CA386
Detail of failure q High voltage appears in sensor power supply 1 circuit.
Action of con-
q Takes ambient pressure to be at fixed value and allows engine to run.
troller
Problem on q Engine output lowers.
machine q Engine starting performance becomes deteriorated.
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation

Cause Procedure, measuring location, criteria and remarks

Perform troubleshooting for failure code [CA352]

40-164 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [CA386] Sens Supply 1 Volt High Error

PC228US-8,PC228USLC-8 40-165
(01)
Troubleshooting by failurecode
Failure code [CA428] Water in Fuel Sensor High Error

Failure code [CA428] Water in Fuel Sensor High Error 40-16

User code Failure code Water-in-fuel sensor high error

Failure
(Engine controller system)
E0E CA428
Detail of failure q High voltage appears in signal circuit of water-in-fuel sensor installed to fuel pre-filter.
Action of con-
q None in particular
troller
Problem on
q Water separator monitor is not displayed correctly.
machine
q Signal (ON/OFF) from water-in-fuel sensor can be checked by using monitoring function.
Related infor-
(Code: 18800)
mation
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 in "Checks before troubleshooting" of "General information on troubleshoot-
tor
ing", and check them directly.
1. Turn starting switch to OFF position.
Defective water-in-fuel sensor 2. Disconnect connector P47, and connect T-adapter to female side.
2 a If water is in water separator, drain it.
installed to fuel pre-filter
Between P47 (female) (1) and (2) Resistance Min. 100 kz
1. Turn starting switch to OFF position.
Open or short circuit in wiring har- 2. Disconnect connector ECM and connect T-adapter to female side.
3
ness Between ECM (female) (14) and (47)
Resistance Min. 100 kz
(Resistance of water-in-fuel sensor)
a If no failure is found by checks on cause 3, this check is not required.
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Disconnect connectors ECM and P47, and connect T-adapter to each
4 (wire breakage or defective con- female side.
tact of connector) Between ECM (female) (14) and P47 (female) (1) Resistance Max. 10 z
Between ECM (female) (47) and P47 (female) (2) Resistance Max. 10 z
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM and P47, and connect T-adapters to female
side of ECM.
5 Short circuit in wiring harness
a Check by using multimeter in continuity mode.
Between ECM (female) (14) and each pin other No continuity (no sound
than (14) is heard.)
If no failure is found by above checks, engine controller is defective. (Since
6 Defective engine controller
this is internal failure, troubleshooting cannot be performed.)

40-166 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [CA428] Water in Fuel Sensor High Error

Circuit diagram related to water-in-fuel sensor 40-167

PC228US-8,PC228USLC-8 40-167
(01)
Troubleshooting by failurecode
Failure code [CA429] Water in Fuel Sensor Low Error

Failure code [CA429] Water in Fuel Sensor Low Error 40-168

User code Failure code Water-in-fuel sensor low error

Failure
(Engine controller system)
E0E CA429
Detail of failure q Low voltage appears in signal circuit of water-in-fuel sensor installed to fuel pre-filter.
Action of con-
q None in particular
troller
Problem on
q Water separator monitor is not displayed correctly.
machine
q Signal (ON/OFF) from water-in-fuel sensor can be checked by using monitoring function.
Related infor-
(Code: 18800)
mation
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 in "Checks before troubleshooting" of "General information on troubleshoot-
tor
ing", and check them directly.
1. Turn starting switch to OFF position.
2. Disconnect connector P47, and connect T-adapter to female side.
Defective water-in-fuel sensor a If water is in water separator, drain it.
2
installed to fuel pre-filter Between P47 (female) (1) and (2) Resistance Min. 100 kz
Between P47 (female) (1) and ground Resistance Min. 100 kz
1. Turn starting switch to OFF position.
2. Disconnect connector ECM and connect T-adapter to female side.
Short circuit or ground fault in wir-
3 Between ECM (female) (14) and (47)
ing harness Resistance Min. 100 kz
(Resistance of water-in-fuel sensor)
Between ECM (female) (14) and ground Resistance Min. 100 kz
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM and P47, and connect T-adapters to female
side of ECM.
4 Short circuit in wiring harness
a Check by using multimeter in continuity mode.
Between ECM (female) (14) and each pin other No continuity (no sound
than (14) is heard.)
a If no failure is found by checks on cause 3, this check is not required.
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors ECM and P47, and connect T-adapter to female
5
(contact with ground circuit) side of either one.
Between ECM (female) (14) and ground or between
Resistance Min. 100 kz
P47 (female) (1) and ground
If no failure is found by above checks, engine controller is defective. (Since
6 Defective engine controller
this is internal failure, troubleshooting cannot be performed.)

40-168 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [CA429] Water in Fuel Sensor Low Error

Circuit diagram related to water-in fuel sensor 40-169

PC228US-8,PC228USLC-8 40-169
(01)
Troubleshooting by failurecode
Failure code [CA435] Eng Oil Press Sw Error

Failure code [CA435] Eng Oil Press Sw Error 40-170

User code Failure code Engine oil pressure switch error

Failure
(Engine controller system)
E0E CA435
Detail of failure q Abnormality is detected in signal circuit of engine oil pressure switch.
Action of con-
q None in particular
troller
Problem on q Engine protection function based on engine oil pressure does not work.
machine q Engine oil pressure monitor is not displayed correctly.
q Method of reproducing failure code: Turn starting switch to ON position or start engine.
q Engine oil pressure switch is closed (ON) when oil pressure is low (when engine is stopped), but is
Related infor- open (OFF) when high (when engine is running).
mation q To generate this failure code, engine controller checks if engine oil pressure switch is closed (ON),
that is, if signal voltage is at GND level or not only while engine is stopped.
q When engine is running, engine oil pressure switch error is shown by failure code [B@BAZG].

Cause Procedure, measuring location, criteria and remarks

See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 in "Checks before troubleshooting" of "General information on troubleshoot-
tor
ing", and check them directly.
1. Turn starting switch to OFF position.
2. Disconnect connector OIL PRESSURE SWITCH and connect T-adapter to
Defective engine oil pressure
2 male side.
switch
Between OIL PRESSURE SWITCH (male) (1) and
Resistance Max. 10 z
ground
1. Turn starting switch to OFF position.
Open or short circuit in wiring har- 2. Disconnect connector ECM and connect T-adapter to female side.
3
ness
Between ECM (female) (17) and ground Resistance Max. 10 z
If no failure is found by above checks, engine controller is defective. (Since
4 Defective engine controller
this is internal failure, troubleshooting cannot be performed.)

Circuit diagram related to engine oil pressure switch 40-170

40-170 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [CA435] Eng Oil Press Sw Error

PC228US-8,PC228USLC-8 40-171
(01)
Troubleshooting by failurecode
Failure code [CA441] Battery Voltage Low Error

Failure code [CA441] Battery Voltage Low Error 40-172

User code Failure code Battery voltage low error

Failure
(Engine controller system)
E10 CA441
Detail of failure q Low voltage appears in controller power supply circuit.
Action of con-
q None in particular
troller
Problem on q Engine stops.
machine q Starting performance is poor
q Method of reproducing failure code: Turn starting switch to ON position.
Related infor-
q Power supply voltage of engine controller can be checked by using moniitoring funtion.
mation
(Code: 03203 (V))

Cause Procedure, measuring location, criteria and remarks

1 Loose or corroded battery terminal Battery cable terminal may be loose or corroded. Check it directly.

Loose terminal or partial open cir- 1. Turn starting switch to OFF position.
2
cuit at terminal Check terminals of alternator, battery relay, ground terminal (T12), etc.
See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
3 in "Checks before troubleshooting" of "General information on troubleshoot-
tor
ing", and check them directly.
1. Turn starting switch to OFF position.
2. Perform troubleshooting with starting switch at OFF position and at engine
4 Improper battery voltage cranking.
Between battery terminals (+) and (-). Voltage 20 – 30 V
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector E12.
5 Defective alternator 3. Start engine (Engine speed: Middle or faster).
Between E12 (1) and ground Voltage 27.5 – 29.5 V
If no failure is found by above checks, engine controller is defective. (Since
this is internal failure, troubleshooting cannot be performed.)
q Reference
1. Turn starting switch to OFF position and disconnect ground cable.
2. Insert T-adapter in connector CE03.
3. Connect ground cable.
6 Defective engine controller
4. Measure voltage with starting switch at ON position and when starting
engine.
Between CE03 (3) and
Starting switch: ON Voltage 20 – 30 V
(1)
Between CE03 (3) and
Starting switch: START Voltage Min. 12 V
(1)

40-172 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [CA441] Battery Voltage Low Error

Circuit diagram related to engine controller power supply 40-173

PC228US-8,PC228USLC-8 40-173
(01)
Troubleshooting by failurecode
Failure code [CA442] Battery Voltage High Error

Failure code [CA442] Battery Voltage High Error 40-174

User code Failure code Battery voltage high error

Failure
(Engine controller system)
E10 CA442
Detail of failure q High voltage (36 V or higher) appears in controller power supply circuit.
Action of con-
q None in particular
troller
Problem on q Engine continues to run normally, but it may stop during running or may not be able to start if it is
machine stopped.
q Method of reproducing failure code: Turn starting switch to ON position.
Related infor-
q Power supply voltage of engine controller can be checked by using moniitoring funtion.
mation
(Code: 03203 (V))

Cause Procedure, measuring location, criteria and remarks

Perform troubleshooting for failure code [CA441].

40-174 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [CA449] Rail Press Very High Error

Failure code [CA449] Rail Press Very High Error 40-175

User code Failure code Common rail pressure high error

Failure
(Engine controller system)
E11 CA449
Detail of failure q High pressure error (2) occurs in common rail circuit.
Action of con-
q Limits engine output and allows engine to run.
troller
Problem on q Engine sound becomes large when no or light load is applied.
machine q Engine output lowers.
q Common rail pressure can be checked by using monitoring function.
Related infor-
(Code: 36400 Common rail pressure)
mation
q Method of reproducing failure code: Start engine.

Cause Procedure, measuring location, criteria and remarks

1 Defect in related system If another failure code is displayed, perform troubleshooting for it.

Air may be in low-pressure circuit. Check it directly according to following pro-

cedure.
2 Air in low pressure circuit 1. Remove fuel pressure pickup port plug (outlet side) of fuel main filter.
2. Operate feed pump of fuel pre-filter.
3. Check fuel and air from pressure pickup plug for leakage level.
a For check of pressure in fuel return circuit, see Testing and adjusting, "Test-
ing fuel pressure".
3 Defect in fuel return circuit parts Max. 0.02 MPa
Fuel return circuit pres- Engine at low idle or
sure cranking {Max. 0.19 kg/cm2}
Defective common rail pressure
4 Perform troubleshooting for failure codes [CA451] and [CA452]
sensor system
a For check of leakage from pressure limiter, see Testing and adjusting,
"Checking fuel return rate and leakage".
5 Defective pressure limiter
Leakage from pressure
At low idle 0 cc (no leakage)
limiter
6 Defective supply pump If no failure is found by above checks, supply pump may be defective.

PC228US-8,PC228USLC-8 40-175
(01)
Troubleshooting by failurecode
Failure code [CA451] Rail Press Sensor High Error

Failure code [CA451] Rail Press Sensor High Error 40-176

User code Failure code Common rail pressure sensor high error
Failure
(Engine controller system)
E11 CA451
Detail of failure q High voltage appears in signal circuit of common rail pressure sensor.
Action of con-
q Limits engine output and allows engine to run.
troller
Problem on q Engine speed or output lowers.
machine q Engine does not start
q Signal voltage of common rail pressure sensor can be checked with monitoring function.
(Code: 36401 Common rail pressure sensor volt)
q Method of reproducing failure code: Turn starting switch to ON position.
Related infor-
q This failure code is displayed if common rail pressure sensor connector is disconnected.
mation
q Since troubleshooting "socket" for this sensor features female connector alone, it is not usable for
checking open circuit in wiring harness and voltage at sensor connector (not designed as a
T-adapter).

Cause Procedure, measuring location, criteria and remarks

See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 in "Checks before troubleshooting" of "General information on troubleshoot-
tor
ing", and check them directly.
Defective common rail pressure If failure code [CA227] or [CA187] is also displayed, perform troubleshooting
2
sensor power supply line for it first.
1. Turn starting switch to OFF position.
2. Disconnect connectors CAM SENSOR, FUEL RAIL PRESS, BOOST
3 Short circuit in wiring harness PRESS & IMT and ECM.
3. Connect T-adapter to female side of ECM.
Between ECM (female) (25) and (37) Resistance Min. 100 kz
1. Turn starting switch to OFF position.
2. Disconnect connector FUEL RAIL PRESS, and connect T-adapter to
connector ECM.
Hot short circuit in wiring harness 3. Turn starting switch to ON position (with connector FUEL RAIL PRESS
4
(contact with 24 V circuit) disconnected).
a Pin (25) of ECM is connected to 5V line via resistor inside engine controller.
Between ECM (25) and (47) Voltage Approx. 5 V
If no failure is found by above checks, there may be open circuit in wiring har-
5 Open circuit in wiring harness
ness. (*)
a If no failure is found by checks on causes 1 to 5 and check result for cause
6 is abnormal, sensor is defective.
Defective common rail pressure
1. Turn starting switch to OFF position.
sensor
6 2. Insert T-adapter to connector ECM.
(improper input voltage to engine
3. Turn starting switch to ON position.
controller)
Sensor out-
Between ECM (25) and (47) Voltage 0.2 – 4.6 V
put
If no failure is found by above checks, engine controller is defective. (Since
7 Defective engine controller
this is internal failure, troubleshooting cannot be performed.)

*: See "Troubleshooting method for open circuit in wiring harness of pressure sensor system" of "Related in-
formation of troubleshooting".

40-176 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [CA451] Rail Press Sensor High Error

Circuit diagram related to common rail pressure sensor 40-17

PC228US-8,PC228USLC-8 40-177
(01)
Troubleshooting by failurecode
Failure code [CA452] Rail Press Sensor Low Error

Failure code [CA452] Rail Press Sensor Low Error 40-178

User code Failure code Common rail pressure sensor low error
Failure
(Engine controller system)
E11 CA452
Detail of failure q Low voltage appears in signal circuit of common rail pressure sensor.
Action of con-
q Limits engine output and allows engine to run.
troller
Problem on q Engine speed or output lowers.
machine q Engine does not start
q Signal voltage of common rail pressure sensor can be checked with monitoring function.
(Code: 36401 Common rail pressure sensor volt)
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation
q If sensor connector is disconnected even in normal condition, failure code [CA451] for "High Error"
is displayed.

Cause Procedure, measuring location, criteria and remarks

See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 in "Checks before troubleshooting" of "General information on troubleshoot-
tor
ing", and check them directly.
Defective common rail pressure If failure code [CA187] (ground fault in sensor power supply line) or [CA227] is
2
sensor power supply line indicated, perform troubleshooting for it first.
a Check that failure code [CA187] (Ground fault in sensor power supply line)
is not displayed.
Defective common rail pressure 1. Turn starting switch to OFF position.
3 2. Disconnect connector FUEL RAIL PRESS.
sensor
3. Turn starting switch to ON position.
If failure code [CA452] changes to [CA451] , sensor is defective.
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors ECM and FUEL RAIL PRESS, and connect
4 T-adapter to female side of ECM.
(contact with ground circuit)
Between ECM (female) (25) and ground Resistance Min. 100 kz
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM and FUEL RAIL PRESS, and connect
5 Short circuit in wiring harness T-adapter to female side of ECM.
Between ECM (female) (25) and (47) Resistance Min. 100 kz
If no failure is found by above checks, engine controller is defective. (Since
6 Defective engine controller
this is internal failure, troubleshooting cannot be performed.)

40-178 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [CA452] Rail Press Sensor Low Error

Circuit diagram related to common rail pressure sensor 40-179

PC228US-8,PC228USLC-8 40-179
(01)
Troubleshooting by failurecode
Failure code [CA488] Chg Air Temp High Torque Derate

Failure code [CA488] Chg Air Temp High Torque Derate 40-180

User code Failure code Boost temperature high error

Failure
(Engine controller system)
E11 CA488
q Temperature signal from boost pressure & temperature sensor exceeds upper limit of control tem-
Detail of failure
perature.
Action of con-
q Limits engine output and allows engine to run.
troller
Problem on
q Engine output lowers.
machine
q Boost temperature can be checked by using monitoring function.
Related infor-
(Code: 18500 Boost temperature)
mation
q Method of reproducing failure code: Start engine.

Cause Procedure, measuring location, criteria and remarks

Cooling performance of aftercooler may degrade. Directly check following
points:
Lowered cooling performance of
1 q Looseness and breakage of fan belt
aftercooler
q Insufficient cooling air
q Clogging of aftercooler fins
Abnormal rise of turbocharger out- Outlet temperature of turbocharger may be abnormally high. Check related
2
let temperature parts directly.
3 Defective engine controller Perform troubleshooting for failure codes [CA153] and [CA154].

40-180 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [CA553] Rail Press High Error

Failure code [CA553] Rail Press High Error 40-181

User code Failure code Common rail pressure high error

Failure
(Engine controller system)
E0E CA553
Detail of failure q High pressure error appears (1) in common rail circuit.
Action of con-
q None in particular
troller
Problem on q Engine sound becomes large without load or with light load.
machine q Engine output lowers.
q Common rail pressure can be checked by using monitoring function.
Related infor-
(Code: 36400 Common rail pressure)
mation
q Method of reproducing failure code: Start engine.

Cause Procedure, measuring location, criteria and remarks

1 Defect in related system If another failure code is displayed, perform troubleshooting for it.

Connection of ground terminal may be defective. Check following terminals

directly.
Defective connection of ground q Ground terminal of machine ((–) terminal of battery)
2
terminal q Ground terminal of engine
q Ground terminal of engine controller
q Ground terminal of starting motor
Defective O-ring of supply pump
3 O-ring of supply pump actuator may be damaged. Check it directly.
actuator
Defective common rail pressure
4 Perform troubleshooting for failure codes [CA451] and [CA452]
sensor system

PC228US-8,PC228USLC-8 40-181
(01)
Troubleshooting by failurecode
Failure code [CA559] Rail Press Low Error

Failure code [CA559] Rail Press Low Error 40-182

User code Failure code Common rail pressure low error

Failure
(Engine controller system)
E0E CA559
Detail of failure q Low pressure appears in common rail circuit.
Action of con-
q None in particular
troller
q Engine does not start at all or does not start easily.
Problem on
q Exhaust smoke becomes black.
machine
q Engine output lowers.
q Common rail pressure can be checked by using monitoring function.
Related infor-
(Code: 36400 Common rail pressure)
mation
q Method of reproducing failure code: Start engine.

Cause Procedure, measuring location, criteria and remarks

1 Use of improper fuel Check fuel used directly (for high viscosity).
Fuel may leak to outside. Check it directly (Check visually while running
2 Fuel leakage to outside
engine at low idle).
a For more information on troubleshooting, see Note 1.
a For check of fuel pressure in low-pressure circuit, see Testing and adjust-
ing, "Testing fuel pressure".
Negative pressure at fuel
At high idle Max. -50.7 MPa
supply pump inlet (outlet
(if engine can be started) {Max. -380 mmHg}
3 Defect in low pressure circuit parts side of fuel pre-filter)
During cranking 0.3 – 1.1 MPa
(if engine cannot be
Inlet pressure of fuel started) {3.1 – 11.3 kg/cm2}
main filter 0.5 – 1.3 MPa
At low idle
(if engine can be started) {5.1 – 13.3 kg/cm2}
a For check of leakage through pressure limiter, see Testing and adjusting,
“Checking fuel return rate and leakage”.
4 Defective pressure limiter
Leakage from pressure
At low idle 0 cc (no leakage)
limiter
a For check of return rate from injector, see Testing and adjusting, “Checking
fuel return rate and leakage”.
Defective injector During cranking
5 (including high-pressure piping in (if engine cannot be Max. 90 cc/min
cylinder head) Return rate from injector started)
At low idle
Max. 180 cc/min
(if engine can be started)
a For check of return rate from supply pump, see Testing and adjusting,
“Checking fuel return rate and leakage”.
During cranking
6 Defective supply pump (if engine cannot be Max. 140 cc/min
Return rate from supply started)
pump
At low idle
Max. 1,000 cc/min
(if engine can be started)
Defective common rail pressure
7 Perform troubleshooting for failure codes [CA451] and [CA452]
sensor system
Note 1: Check the low-pressure line parts for the following.
1) Fuel level
2) Clogging of fuel tank breather
3) Leakage or clogging of low-pressure fuel piping
4) Clogging of fuel pre-filter
5) Clogging of fuel main filter
6) Replace the fuel filter if the problem is not removed after clearing the clog.

40-182 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [CA559] Rail Press Low Error

PC228US-8,PC228USLC-8 40-183
(01)
Troubleshooting by failurecode
Failure code [CA689] Eng Ne Speed Sensor Error

Failure code [CA689] Eng Ne Speed Sensor Error 40-184

User code Failure code Engine Ne speed sensor error

Failure
(Engine controller system)
E0E CA689
Detail of failure q Signal from engine Ne speed sensor is abnormal.
Action of con-
q Continues to control engine by using signal from engine Bkup speed sensor.
troller
q Engine hunts.
Problem on
q Starting performance is poor.
machine
q Engine output lowers.
q Method of reproducing failure code: Start engine.
q Since inside of speed sensor is not composed of coil but Hall sensor and electronic circuit, speed
sensor cannot be determined to be normal by measuring its resistance with multimeter.
Related infor-
q Since speed sensor output is 5 V pulse voltage during normal operation, it cannot be measured
mation
with multimeter.
q Speed sensor senses passing slotted hole in speed sensing wheel that is installed on inside of
crankshaft vibration damper and rotated by crankshaft.

Cause Procedure, measuring location, criteria and remarks

See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 in "Checks before troubleshooting" of "General information on troubleshoot-
tor
ing", and check them directly.
Defective Ne speed sensor power
2 If failure code [CA238] is also displayed, perform troubleshooting for it first.
supply line
Breakage or improper installation
Engine Ne speed sensor may be broken or may have improper installation
3 (looseness) of engine Ne speed
(looseness). Check it directly.
sensor
1. Turn starting switch to OFF position.
2. Disconnect connector CRANK SENSOR and connect T-adapter to female
Defective Ne speed sensor power side.
4
supply input 3. Turn starting switch to ON position.
Between CRANK SENSOR (female)
Power input Voltage 4.75 - 5.25V
(1) and (2)
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM and CRANK SENSOR.
a If no failure is found by checks on cause 4, this
check is not required. Resis-
Max. 10 z
Open circuit in wiring harness Between ECM (female) (16) and CRANK tance
5 (wire breakage or defective con- SENSOR (female) (1)
tact of connector) a If no failure is found by checks on cause 4, this
check is not required. Resis-
Max. 10 z
Between ECM (female) (48) and CRANK tance
SENSOR (female) (2)
Between ECM (female) (27) and CRANK SENSOR Resis-
Max. 10 z
(female) (3) tance
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM and CRANK SENSOR.
Between ECM (female) (16) and (27) or CRANK Resis-
6 Short circuit in wiring harness Min. 100 kz
SENSOR (female) (1) and (3) tance
Between ECM (female) (27) and (48) or CRANK Resis-
Min. 100 kz
SENSOR (female) (2) and (3) tance
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors ECM and CRANK SENSOR.
7
(contact with ground circuit) Between ECM (female) (27) or CRANK SENSOR Resis-
Min. 100 kz
(female) (3) and ground tance

40-184 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [CA689] Eng Ne Speed Sensor Error

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Hot short circuit in wiring harness 2. Disconnect connector CRANK SENSOR.
8 3. Turn starting switch to ON position.
(contact with 24 V circuit)
Between CRANK SENSOR (female) (3) and ground Voltage Max. 1 V
Damage or loose mounting of
9 Check speed sensing wheel directly.
wheel for speed sensing
If no failure is found by above checks, Ne speed sensor is defective. (Since
10 Defective Ne speed sensor
this is internal failure, troubleshooting cannot be performed.)
If no failure is found by above checks, engine controller is defective. (Since
11 Defective engine controller
this is internal failure, troubleshooting cannot be performed.)

Circuit diagram related to engine Ne speed sensor 40-185

PC228US-8,PC228USLC-8 40-185
(01)
Troubleshooting by failurecode
Failure code [CA731] Eng Bkup Speed Sens Phase Error

Failure code [CA731] Eng Bkup Speed Sens Phase Error 40-186

User code Failure code Engine Bkup speed sensor phase error
Failure
(Engine controller system)
E0E CA731
q Phase error is detected between signals from engine Ne speed sensor and engine Bkup speed
Detail of failure
sensor
Action of con-
q Continues to control engine by using signal from engine Ne speed sensor.
troller
q Engine does not start at all or does not start easily.
Problem on
q Idle speed is unstable.
machine
q Exhaust smoke becomes black.
Related infor-
q Method of reproducing failure code: Start engine.
mation

Cause Procedure, measuring location, criteria and remarks

Breakage of engine Ne speed sen-
1 Engine Ne speed sensor may be broken. Check it directly.
sor
Breakage of engine Bkup speed
2 Engine Bkup speed sensor may be broken. Check it directly.
sensor
Speed sensing wheel on crankshaft side may be installed defectively or bro-
ken. Check it according to following procedure.
Defective installation or breakage 1. Align paint mark (M1) on damper with Ne speed sensor top (M2).
3 of speed sensing wheel on crank- a Do not align with mark of No. 1 cylinder compression top dead center.
shaft side (Approx. 80 ° before compression top dead center)
2. If center of oblong hole (WS) of speed sensing wheel aligns with Ne speed
sensor top (M2), installation is correct.
Speed sensing ring on camshaft side may be installed defectively or broken.
Check it according to the following procedure.
1. Align paint mark (M1) on damper with Ne speed sensor top (M2).
Defective installation or breakage
a Do not align with mark of No. 1 cylinder compression top dead center.
4 of speed sensing ring on camshaft
(Approx. 80 ° before compression top dead center)
side
2. Remove Bkup speed sensor.
3. If you can see double-slot part (with one crest) (B) on speed sensing ring
through sensor mounting hole (H), speed sensing ring is installed correctly.
Defective timing of crankshaft and
5 Timing of crankshaft and camshaft may be defective. Check it directly.
camshaft
Connection at ground terminal may be defective. Check following terminals
directly.
Defective connection at ground q Ground terminal of machine ((-) terminal of battery)
6
terminal q Ground terminal of engine
q Ground terminal of engine controller
q Ground terminal of starting motor

40-186 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [CA757] All Continuous Data Lost Error

Failure code [CA757] All Continuous Data Lost Error 40-187

User code Failure code All continuous data lost error

Failure
(Engine controller system)
E10 CA757
Detail of failure q All data in engine controller are lost.
Action of con-
q None in particular
troller
Problem on q Engine may stop and may not be started again.
machine q Monitoring function of machine monitor (engine controller system) may not work normally.
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation

Cause Procedure, measuring location, criteria and remarks

1 Defect in related system If another failure code is displayed, perform troubleshooting for it.

2 Perform troubleshooting for failure code [CA441].

PC228US-8,PC228USLC-8 40-187
(01)
Troubleshooting by failurecode
Failure code [CA778] Eng Bkup Speed Sensor Error

Failure code [CA778] Eng Bkup Speed Sensor Error 40-18

User code Failure code Engine Bkup speed sensor error

Failure
(Engine controller system)
E0E CA778
Detail of failure q Singal from engine Bkup speed (cam) sensor is abnormal.
Action of con-
q Continues to control engine by using signal from engine Ne speed sensor.
troller
Problem on q Starting performance is poor.
machine q Engine output lowers.
q Method of reproducing failure code: Start engine.
q Since inside of speed sensor is not coil but Hall sensor and electronic circuit, speed sensor cannot
Related infor- be determined to be normal by measuring its resistance with multimeter.
mation q Since speed sensor outputs 5 V pulse voltage during normal operation, it cannot be measured by
using multimeter.
q Speed sensor scans rotating slot of speed sensing ring mounted on the camshaft.

Cause Procedure, measuring location, criteria and remarks

See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 in "Checks before troubleshooting" of "General information on troubleshoot-
tor
ing", and check them directly.
Defective sensor power supply 2
2 If failure code [CA187] or [CA227] is also displayed, troubleshoot it first.
line
Damage or incorrect (loose) instal-
Engine Bkup speed (cam) sensor directly as it may be damaged or incorrectly
3 lation of engine Bkup speed (cam)
(loosely) installed. Check it directly.
sensor
1. Turn starting switch to OFF position.
2. Disconnect connector CAM SENSOR , and connect T-adapter to female
Defective power supply input to side.
4
engine Bkup speed sensor 3. Turn starting switch to ON position.
Between CAM SENSOR (female) (1) Power sup-
Voltage 4.75 - 5.25V
and (2) ply
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM and CAM SENSOR, and connect T-adapter to
each female side.
Open circuit in wiring harness Between ECM (female) (37) and CAM SENSOR Resis-
Max. 10 z
5 (wire breakage or defective con- (female) (1) tance
tact of connector) Between ECM (female) (47) and CAM SENSOR Resis-
Max. 10 z
(female) (2) tance
Between ECM (female) (26) and CAM SENSOR Resis-
Max. 10 z
(female) (3) tance
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM and CAM SENSOR, and connect T-adapter to
female side of either connector.
6 Short circuit in wiring harness Between ECM (female) (26) and (37) or CAM SEN- Resis-
Min. 100 kz
SOR (female) (1) and (3) tance
Between ECM (female) (26) and (47) or CAM SEN- Resis-
Min. 100 kz
SOR (female) (2) and (3) tance
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM and CAM SENSOR, and connect T-adapter to
Ground fault in wiring harness female side of either connector.
7
(contact with ground circuit)
Between ECM (female) (26) or CAM SENSOR Resis-
Min. 100 kz
(female) (3) and ground tance
1. Turn starting switch to OFF position.
2. Disconnect connector CAM SENSOR, and connect T-adapter to female
Hot short circuit in wiring harness side.
8
(contact with 24 V circuit) 3. Turn starting switch to ON position.
Between CAM SENSOR (female) (3) and ground Voltage Max. 1 V

40-188 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [CA778] Eng Bkup Speed Sensor Error

Cause Procedure, measuring location, criteria and remarks

Remove engine Bkup speed (cam) sensor, and check ring directly through
hole (H).
9 Loose speed sensing ring
a If speed sensing ring (B) is loosely installed, follow instructions given in the
"Reference" column.
Defective engine Bkup speed If no failure is found by above checks, engine Bkup speed (cam) sensor is
10
(cam) sensor defective. (Since this is internal failure, troubleshooting cannot be performed.)
If no failure is found by above checks, engine controller is defective. (Since
11 Defective engine controller
this is internal failure, troubleshooting cannot be performed.)

Circuit diagram related to engine Bkup speed sensor 40-189

PC228US-8,PC228USLC-8 40-189
(01)
Troubleshooting by failurecode
Failure code [CA778] Eng Bkup Speed Sensor Error

Reference for troubleshooting for CA778 (107 5. Check mounting bolt (4) of camshaft ring (5) for
series engine) looseness.
Checking camshaft ring for loose installation 3 Mounting bolt (4):
Remove the front cover and check the camshaft ring 10 ± 2 Nm
for looseness. (DP): Dowel pin
a See "Removal and installation of front seal" in
Disassembly and assembly.
a Keep the front seal, liquid gasket LG-7 and front
seal tool (795-799-6400) on hand.
Removal 40-190
1. Remove the fan and fan belt. For details, see
"Removal and installation of front seal" in Disas-
sembly and assembly.
2. Remove damper assembly (1).
(DP): Dowel pin

Connection 40-190
a See the figures in "Removal" for installation.
1. Install front cover (2).
3 Front cover:
Liquid gasket (LG-7)
2. Install the front seal according to the following
procedure. For details, see "Removal and instal-
lation of front seal" in Disassembly and
assembly.
1) Install front seal (3).
3. Remove front cover (2). 2) Install the damper with the dowel pin (DP)
4. Remove front seal (3). assembly.
(RING): Ring 3) Install fan belt, and install the fan.
4) Install the cooling system assembly.

40-190 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [CA1633] KOMNET Datalink Timeout Error

Failure code [CA1633] KOMNET Datalink Timeout Error 40-191

User code Failure code KOMNET datalink timeout error
Failure
(Engine controller system)
E0E CA1633
q Engine controller detects communication error in KOMNET communication circuit between engine
Detail of failure
controller and pump controller or machine monitor.
Action of con- q Allows engine to run in default mode or keeps control conditions at the time of failure detection.
troller q If cause of failure disappears, machine becomes normal by itself.
q Machine may not operate normally because informations which are exchanged through KOMNET
Problem on
communication are not transmitted properly.
machine
(Failure symptom depends on failed section.)
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation

Cause Procedure, measuring location, criteria and remarks

Perform troubleshooting for failure code [DA2RMC].

PC228US-8,PC228USLC-8 40-191
(01)
Troubleshooting by failurecode
Failure code [CA2185] Throt Sens Sup Volt High Error

Failure code [CA2185] Throt Sens Sup Volt High Error 40-192

User code Failure code Throttle sensor volaget high error

Failure
(Engine controller system)
E14 CA2185
Detail of failure q High voltage (5.25 V or higher) appears in throttle sensor power supply circuit.
Action of con-
q Gets throttle position by using signal other than throttle sensor signal and allows engine to run.
troller
Problem on
q Engine speed cannot be controlled by fuel control dial.
machine
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation

Cause Procedure, measuring location, criteria and remarks

See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 in "Checks before troubleshooting" of "General information on troubleshoot-
tor
ing", and check them directly.
1. Turn starting switch to OFF position.
2. Disconnect connector P20, and turn starting switch to ON position.
Defective throttle sensor (fuel con-
2 If this failure code is not displayed, throttle sensor is defective.
trol dial)
a Other failure codes are displayed, too. This is because of disconnection of
connector. Ignore failure codes other than [CA2185].
1. Turn starting switch to OFF position.
2. Disconnect connectors CE02, CE03 and P20, and connect T-adapters to
each female side of connectors CE02 and CE03.
3 Short circuit in wiring harness Between CE02 (female) (22) and each pin other Resis-
Min. 1 Mz
than (22) tance
Resis-
Between CE02 (female) (22) and CE03 (female) (3) Min. 1 Mz
tance
1. Turn starting switch to OFF position.
Hot short circuit in wiring harness 2. Disconnect connector P20, and connect T-adapter to female side.
4 3. Turn starting switch to ON position.
(contact with 24 V circuit)
Between P20 (female) (1) and ground Voltage 4.75 - 5.25V
1. Turn starting switch to OFF position.
2. Disconnect connector CE02, and connect T-adapter to male side.
5 Defective engine controller 3. Turn starting switch to ON position with wiring harness disconnected.
Between CE02 (male) (22) and (23) Voltage 4.75 - 5.25V

Circuit diagram related to throttle sensor 40-192

40-192 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [CA2186] Throt Sens Sup Volt Low Error

Failure code [CA2186] Throt Sens Sup Volt Low Error 40-193

User code Failure code Throttle sensor voltage low error

Failure
(Engine controller system)
E14 CA2186
Detail of failure q Low voltage appears in throttle sensor power supply circuit.
Action of con-
q Gets throttle position by using signal other than throttle sensor signal and allows engine to run.
troller
Problem on
q Engine speed cannot be controlled by fuel control dial.
machine
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation

Cause Procedure, measuring location, criteria and remarks

See the descriptions of wiring harness and connectors in "c: Electrical equip-
Defective wiring harness connec-
1 ment" of "Checks before troubleshooting" in "General information on trouble-
tor
shooting" , and check them directly.
1. Turn starting switch to OFF position.
2. Disconnect connector P20, and turn starting switch to ON position.
Defective throttle sensor (fuel con-
2 If this failure code is not displayed, throttle sensor is defective.
trol dial)
a Other failure code is displayed too. This is because of disconnection of con-
nector. Ignore failure codes other than [CA2186].
1. Turn starting switch to OFF position.
2. Disconnect connectors CE02 and P20, and connect T-adapter to female
Ground fault of wiring harness
3 side of either connector.
(contact with ground circuit)
Between CE02 (female) (22) or P20 (female) (1) Resis-
Min. 1 Mz
and ground tance
1. Turn starting switch to OFF position.
2. Disconnect connectors CE02 and P20, and connect T-adapter to female
side of connector CE02.
4 Short circuit in wiring harness 3. Turn starting switch to ON position.
Between CE02 (female) (22) and each pin other Resis-
Min. 1 Mz
than (22) tance
1. Turn starting switch to OFF position.
2. Disconnect connector CE02, and connect T-adapter to male side.
5 Defective engine controller 3. Turn starting switch to ON position with wiring harness disconnected.
Between CE02 (male) (22) and (23) Voltage 4.75 - 5.25V

Circuit diagram related to throttle sensor 40-193

PC228US-8,PC228USLC-8 40-193
(01)
Troubleshooting by failurecode
Failure code [CA2249] Rail Press Very Low Error

Failure code [CA2249] Rail Press Very Low Error 40-194

User code Failure code Common rail pressure very low error
Failure
(Engine controller system)
E11 CA2311
Detail of failure q Low pressure appears in common rail circuit.
Action of con-
q Limits engine output and allows engine to run.
troller
q Starting performance is poor.
Problem on
q Exhaust gas becomes black.
machine
q Engine output lowers.
q Common rail pressure can be checked by using monitoring function.
Related infor-
(Code: 36400 Common rail pressure)
mation
q Method of reproducing failure code: Start engine.

Cause Procedure, measuring location, criteria and remarks

Perform troubleshooting for failure code [CA559] .

40-194 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [CA2311] IMV Solenoid Error

Failure code [CA2311] IMV Solenoid Error 40-195

User code Failure code IMV solenoid error
Failure
(Engine controller system)
E11 CA2311
Detail of failure q Resistance of supply pump actuator circuit is abnormally high or low.
Action of con-
q None in particular
troller
Problem on
q Engine output lowers.
machine
Related infor-
q Method of reproducing failure code: Start engine.
mation

Cause Procedure, measuring location, criteria and remarks

Perform troubleshooting for failure codes [CA271] and [CA272].

PC228US-8,PC228USLC-8 40-195
(01)
Troubleshooting by failurecode
Failure code [CA2555] Grid Htr Relay Open Circuit Error

Failure code [CA2555] Grid Htr Relay Open Circuit Error 40-196

User code Failure code Intake air heater relay open circuit
Failure
(Engine controller system)
E0E CA2555
Detail of failure q Open circuit is detected in drive circuit (primary circuit) of preheater relay.
Action of con-
q None in particular
troller
Problem on q Intake air heater does not work in auto preheating (degraded starting performance at low temper-
machine ature and emission of white smokes)
q Temperature sensed by boost temperature sensor can be checked by using monitoring function.
(Code: 18500)
q Method of reproducing failure code: Turn starting switch to ON position (when boost temperature
Related infor- is below -4 °C)
mation q Troubleshooting for this failure code covers circuit starting from engine controller to primary circuit
(coil) of preheater relay R18.
q For troubleshooting related to heater relay and secondary circuit of preheater relay R18, see E-2
in Troubleshooting [E-mode].

Cause Procedure, measuring location, criteria and remarks

See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 in "Checks before troubleshooting" of "General information on troubleshoot-
tor
ing", and check them directly.
1. Turn starting switch to OFF position.
2. Disconnect relay R18, and connect T-adapter to male side.

Between R18 (male) (1) and (2) Resistance 200 – 400 z

2 Defective preheater relay R18
1. Turn starting switch to OFF position.
2. Replace relay R18 with another one.
3. Turn starting switch to ON position.
If this failure code disappears, original preheater relay R18 is defective.
1. Turn starting switch to OFF position.
2. Disconnect connector CE02, and connect T-adapter to female side.
Open or short circuit in wiring har-
3 Between CE02 (female) (40) and (42)
ness
a Resistance of preheater relay R18 coil resis- Resistance 200 – 400 z
tance
a If no failure is found by checks on cause 3, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connector CE02 and relay R18, and connect T-adapter to each
4 Open circuit in wiring harness female side.
Between CE02 (female) (40) and R18 (female) (1) Resistance Max. 1 z
Between R18 (female) (2) and CE02 (42) Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect connector CE02 and relay R18, and connect T-adapter to
female side of CE02.
5 Short circuit in wiring harness a Check by using multimeter in continuity mode.
Between CE02 (female) (40) and each pin other No continuity
than (40) (No sound is heard)
If no failure is found by above checks, engine controller is defective. (Since
6 Defective engine controller
this is internal failure, troubleshooting cannot be performed.)

40-196 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [CA2555] Grid Htr Relay Open Circuit Error

Circuit diagram related to intake air heater relay 40-197

PC228US-8,PC228USLC-8 40-197
(01)
Troubleshooting by failurecode
Failure code [CA2556] Grid Htr Relay Short Circuit Error

Failure code [CA2556] Grid Htr Relay Short Circuit Error 40-198

User code Failure code Intake air heater relay short circuit
Failure
(Engine controller system)
E0E CA2556
Detail of failure q Short circuit is detected in drive circuit (primary circuit) of preheater relay.
Action of con-
q None in particular
troller
Problem on q Intake air heater does not work in auto preheating (degraded starting performance at low temper-
machine ature and emission of white smokes)
q Temperature sensed by boost temperature sensor can be checked by using monitoring function.
(Code: 18500 )
q Method of reproducing failure code: Turn starting switch to ON position (when boost temperature
Related infor- is below -4 °C)
mation q Troubleshooting for this failure code covers circuit starting from engine controller to primary circuit
(coil) of preheater relay R18.
q For troubleshooting related to heater relay and secondary circuit of preheater relay R18, see E-2
in Troubleshooting [E-mode].

Cause Procedure, measuring location, criteria and remarks

See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 in "Checks before troubleshooting" of "General information on troubleshoot-
tor
ing", and check them directly.
1. Turn starting switch to OFF position.
2. Disconnect relay R18, and connect T-adapter to male side.

Between R18 (male) (1) and (2) Resistance 200 – 400 z

2 Defective preheater relay R18
1. Turn starting switch to OFF position.
2. Replace relay R18 with another one.
3. Turn starting switch to ON position.
If this failure code disappears, original preheater relay R18 is defective.
1. Turn starting switch to OFF position.
2. Disconnect connector CE02 and relay R18, and connect T-adapter to
3 Ground fault in wiring harness female side of either connector.
Between CE02 (female) (40) or R18 (female) (1)
Resistance Min. 1 Mz
and ground
1. Turn starting switch to OFF position.
2. Disconnect connector CE02 and relay R18, and connect T-adapter to
female side of CE02.
4 Short circuit in wiring harness a Check by using multimeter in continuity mode.
Between CE02 (female) (40) and each pin other No continuity
than (40) (No sound is heard)
If no failure is found by above checks, engine controller is defective. (Since
5 Defective engine controller
this is internal failure, troubleshooting cannot be performed.)

40-198 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [CA2556] Grid Htr Relay Short Circuit Error

Circuit diagram related to intake air heater relay 40-19

PC228US-8,PC228USLC-8 40-199
(01)
Troubleshooting by failurecode
Failure code [D110KB] Battery Relay Drive Short Circuit

Failure code [D110KB] Battery Relay Drive Short Circuit 40-20

User code Failure code Battery relay output system short circuit
Failure
(Pump controller system)
– D110KB
Detail of failure q Abnormal current flows when outputting 24 V to battery relay primary circuit (coil side).
q Stops 24 V output to battery relay primary circuit (coil side).
Action of con-
q Even if cause of failure disappears, machine does not become normal until starting switch is turned
troller
to OFF position.
Problem on
q Machine may have a trouble in writing data into ROM (non-volatile memory) of each controller.
machine
q As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be mea-
sured at pump controller connector.
Related infor- q Output (ON/OFF) to battery relay can be checked by using monitoring function.
mation (Code: 03700 Controller output 1)
q Method of reproducing failure code: During 0.5 second afer turning starting switch from ON to OFF
position

Cause Procedure, measuring location, criteria and remarks

Defective battery relay 1. Turn starting switch to OFF position.

1
(internal short circuit) Between terminal RE and terminal BR Continuity
1. Turn starting switch to OFF position.
2. Disconnect negative battery cable (in order not to make short circuit).
3. Disconnect connector R01, terminal R02, and connectors D01, H15 and
C02.
Ground fault of wiring harness Between terminal R02 (BR) and ground Resistance Min. 1 Mz
2
(contact with ground circuit)
Between any of terminal R02 (harness side), D01
Resistance Min. 1 Mz
(female) (1) or (2) and ground
Between C02 (female) (108) or D01 (female) (5)
Resistance Min. 1 Mz
and ground
If no failure is found by above checks, pump controller is defective.
q Reference
1. Turn starting switch to OFF position.
2. Insert T-adapter in connector D01.
3 Defective pump controller 3. Turn starting switch to ON position.
4. Measure voltage during 4 to 7seconds after turning starting switch from ON
to OFF position
Between D01 (5) and ground Voltage 20 – 30 V

40-200 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [D110KB] Battery Relay Drive Short Circuit

Circuit diagram related to battery relay 40-201

PC228US-8,PC228USLC-8 40-201
(01)
Troubleshooting by failurecode
Failure code [D19JKZ] Personal Code Relay Abnormality

Failure code [D19JKZ] Personal Code Relay Abnormality 40-202

User code Failure code Personal code relay malfunction
Failure
(KOMTRAX system in machine monitor)
E01 D19JKZ
Detail of failure q Open circuit error or short circuit error is detected in primary (coil) circuit of personal code relay.
q None in particular (for open circuit error)
Action of q Stops output to personal code relay (for short circuit error).
machine moni- q If cause of failure disappears, machine becomes normal by itself (for open circuit error).
tor q Even if cause of failure disappears, machine does not become normal until starting switch is turned
to OFF position (when short circuit is detected).
Problem on
machine
q This failure code may be generated only when engine lock function is enabled.
q Method of reproducing failure code: Turn starting switch to ON position (for open circuit error). Fail-
Related infor-
ure code cannot be reproduced (for short circuit error).
mation
q Troubleshooting for this failure code covers circuit starting from No. 3 of fuse F01, through primary
(coil) circuit of personal code relay R07, to machine monitor.

Cause Procedure, measuring location, criteria and remarks

1 Blown No. 3 of fuse F01 When fuse is blown, ground fault may have probably occurred in circuit.
1. Turn starting switch to OFF position.
2. Disconnect relay R07, and connect T-adapter to male side.
Between R07 (male) (1) and (2) Resistance 100 – 500 z
2 Defective personal code relay R07 1. Turn starting switch to OFF position.
2. Replace relay R07 with another one.
3. Turn starting switch to ON position.
If this failure code disappears, original personal code relay R07 is defective.
1. Turn starting switch to OFF position.
2. Remove fuse No. 3 of fuse box F01.
Open circuit ?short circuit or 3. Disconnect connector CM01 and connect T-adapter to female side.
3
ground fault in wiring harness Between F01-3 and CM01 (female) (6) Resistance 100 – 500 z
Between F01-3 or CM01 (female) (6) and ground Resistance Min. 1 Mz
a If no failure is found by checks on cause 3, this check is not required.
1. Turn starting switch to OFF position.
2. Remove fuse No. 3 of fuse box F01.
4 Open circuit in wiring harness 3. Disconnect connector CM01 and relay R07, and connect T-adapters to
each female side.
Between F01-3 and R07 (female) (1) Resistance Max. 1 z
Between R07 (female) (2) and CM01 (female) (6) Resistance Max. 1 z
a If no failure is found by checks on cause 3, this check is not required.
1. Turn starting switch to OFF position.
2. Remove fuse No. 3 of fuse box F01.
3. Disconnect connector CM01 and relay R07, and connect T-adapter to
5 Ground fault in wiring harness female side of either one.
Between F01-3 or R07 (female) (1) and ground Resistance Min. 1 Mz
Between R07 (female) (2) or CM01 (female) (6)
Resistance Min. 1 Mz
and ground
1. Turn starting switch to OFF position.
2. Remove fuse No. 3 of fuse box F01.
3. Disconnect connectors CM01 and relay R07, and connect T-adapter to
6 Short circuit in wiring harness female side of connector CM01.
a Check by using multlmeter in continuity mode.
Between CM01 (female) (6) and each pin other No continuity
than pin (6) (No sound is heard)
If no failure is found by the above checks, machine monitor (KOMTRAX sec-
Defective machine monitor
7 tion) is defective. (Since this is internal failure, troubleshooting cannot be per-
(KOMTRAX section)
formed.)

40-202 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [D19JKZ] Personal Code Relay Abnormality

Circuit diagram related to personal code relay 40-203

PC228US-8,PC228USLC-8 40-203
(01)
Troubleshooting by failurecode
Failure code [D862KA] GPS Antenna Open Circuit

Failure code [D862KA] GPS Antenna Open Circuit 40-204

User code Failure code GPS antenna open circuit
Failure
(KOMTRAX system in machine monitor)
— D862KA
Detail of failure q Open circuit is detected in GPS antenna circuit.
Action of
q None in particular
machine moni-
q If cause of failure disppears, machine becomes normal by itself.
tor
Problem on
q GPS positioning cannot work.
machine
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation

Cause Procedure, measuring location, criteria and remarks

Defective GPS antenna or Probable causes are defective GPS antenna, open circuit or short circuit in antenna
1
antenna cable cable, and defective connection of antenna cable connector (GPS).

Structural illustration 40-204

40-204 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [D862KA] GPS Antenna Open Circuit

PC228US-8,PC228USLC-8 40-205
(01)
Troubleshooting by failurecode
Failure code [DA22KK] Pump Solenoid Power Low Error

Failure code [DA22KK] Pump Solenoid Power Low Error 40-206

User code Failure code Pump solenoid power supply voltage low error (input)
Failure
(Pump controller system)
E0E DA22KK
Detail of failure q Solenoid power supply voltage of controller is below 20 V.
q Stops generation of failure codes (open circuit and short circuit) for all solenoid systems while this
Action of con-
failure code is active.
troller
q If cause of failure disappears, machine becomes normal by itself.
Problem on
q No solenoid valve is driven properly, so machine does not work properly.
machine
q As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be mea-
Related infor- sured at pump controller connector.
mation q If failure code D110KB] is displayed, troubleshoot it first.
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

Defective fusible link F04 or fuse
1 If fusible link or fuse is blown, circuit probably has ground fault. (See Cause 5.)
No. 2 of fuse box F01
1. Turn starting switch to OFF position.
2 Improper battery voltage 2. After measuring voltage, measure it again when starting engine.
Between battery (+) and ground Voltage 20 – 30 V
1. Turn starting switch to OFF position and disconnect battery ground cable.
2. Disconnect connector C02 and connect T-adapter to female side.
3 Defective wiring harness 3. Connect battery ground cable and turn starting switch to ON position.
Between each of (116), (118) and (121) of C02 and
Voltage 20 – 30 V
ground
a If no failure is found by checks on cause 3, this check is not required.
1. Turn starting switch to OFF position and disconnect battery ground cable.
2. Remove fusible link F02 and fuse (2) in fuse box F01.
3. Disconnect connector C02 and connect T-adapter to female side.
4 Open circuit in wiring harness Between each of (116), (118) and (121) of C02
Resistance Max. 1 z
(female) and F01-2
Between F01-1A and F04 (male) (2) Resistance Max. 1 z
Between F04 (male) (1) and terminal R03 Resistance Max. 1 z
a If no failure is found by checks on cause 3, this check is not required.
1. Turn starting switch to OFF position and disconnect battery ground cable.
2. Remove fusible link F04 and fuse No. 2 of fuse box F01.
3. Disconnect connector C02 and connect T-adapter to female side.
Ground fault in wiring harness
5 Between each of (116), (118) and (121) of C02
(contact with ground circuit) Resistance Min. 1 Mz
(female) or F01-2 and ground
Between F01-1A or F04 (male) (2) and ground Resistance Min. 1 Mz
Between F04 (male) (1) or terminal R03 and ground Resistance Min. 1 Mz
If no failure is found by above checks, pump controller is defective. (Since this
6 Defective pump controller
is internal failure, troubleshooting cannot be performed.)

40-206 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [DA22KK] Pump Solenoid Power Low Error

Circuit diagram related to solenoid power supply 40-207

PC228US-8,PC228USLC-8 40-207
(01)
Troubleshooting by failurecode
Failure code [DA25KP] 5V Sensor1 Power Abnormality

Failure code [DA25KP] 5V Sensor1 Power Abnormality 40-208

User code Failure code 5 V sensor power supply output 1 circuit defective
Failure
(Pump controller system)
– DA25KP
Detail of failure q Voltage of 5 V sensor power supply output 1 circuit is below 2.5 V or above 6.0 V.
q Stops output from 5 V sensor power supply output 1 circuit.
Action of con-
q Even if cause of failure disappears, machine does not become normal until starting switch is turned
troller
to OFF position.
q Automatic travel speed selector function does not work (pump pressure sensor system).
Problem on
q Auto-decelerator keeps working and is not canceled or fine control performance of work equipment
machine
is lowered (PPC pressure sensor system).
q As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be mea-
Related infor-
sured at pump controller connector.
mation
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect following sensors one by one, and turn starting switch to ON
position for each troubleshooting.
a If this failure code disappears, disconnected sensor is defective.
3. After each troubleshooting, turn starting swith to OFF position.
Sensor Connector
Bucket CURL PPC pressure sensor P01
Bucket DUMP PPC pressure sensor P05
Arm IN pressure sensor P04
Defective pressure sensor Boom RAISE PPC pressure sensor P06
1
(internal short circuit)
Swing RIGHT PPC pressure sensor P07
Swing LEFT PPC pressure sensor P03
F Pump pressure sensor P25
R Pump pressure sensor P26
R.H. travel FORWARD PPC pressure sensor P09
R.H. travel REVERSE PPC pressure sensor P27
L.H. travel FORWARD PPC pressure sensor P10
L.H. travel REVERSE PPC pressure sensor P28
a Measure voltage before controller stops output.
1. Turn starting switch to OFF position.
2. Disconnect connectors P01, P03 to P07, P09, P10 and P25 to P28.
Hot short circuit in wiring harness 3. Connect T-adapter to female side of either of disconnected connectors
2 (e.g. P07).
(contact with 24 V circuit)
4. Turn starting switch to ON position (with connectors P01, P03 to P07, P09,
P10 and P25 to P28 disconnected).
Between P07 (female) (3) and ground Voltage 4.5 – 5.5 V
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors C01, P01, P03 to P07, P09, P10 and P25 to P28.
3
(contact with ground circuit) 3. Connect T-adapter to female side of connector C01.
Between C01 (female) (9) and ground Resistance Min. 1 Mz
If no failure is found by above checks, pump controller is defective. (Since this
4 Defective pump controller
internal failure, troubleshooting cannot be performed.)

40-208 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [DA25KP] 5V Sensor1 Power Abnormality

Circuit diagram related to 5 V sensor power supply 1 circuit 40-209

PC228US-8,PC228USLC-8 40-209
(01)
Troubleshooting by failurecode
Failure code [DA26KP] 5V Sensor2 Power Abnormality

Failure code [DA26KP] 5V Sensor2 Power Abnormality 40-210

User code Failure code 5 V sensor power supply output 2 circuit defective
Failure
(Pump controller system)
– DA26KP
Detail of failure q Voltage of 5 V sensor power supply output 2 circuit is below 2.5 V or above 6.0 V.
q Stops output from 5 V sensor power supply output 2 circuit.
Action of con-
q Even if cause of failure disappears, machine does not become normal until starting switch is turned
troller
to OFF position.
Problem on
q All overload alarm functions do not operate normally (for overload specification machine).
machine
q As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be mea-
Related infor-
sured at pump controller connector.
mation
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect following sensors one by one, and turn starting switch to ON
position for each troubleshooting.
a If this failure code disappears, disconnected sensor is defective.
Defective pressure sensor 3. After each troubleshooting, turn starting swith to OFF position.
1
(internal short circuit)
Sensor Connector
Boom angle potentiometer A53
Boom cylinder bottom pressure sensor * Y09*
a Measure voltage before controller stops output.
1. Turn starting switch to OFF position.
2. Disconnect connectors A53 and Y09*.
Hot short circuit in wiring harness 3. Connect T-adapter to female side of connector A53.
2
(contact with 24 V circuit) 4. Turn starting switch to ON position (with connectors A53 and Y09* discon-
nected).
Between A53 (female) (C) and ground Voltage 4.5 – 5.5 V
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors C01, A53, and Y09*.
3 3. Connect T-adapter to female side of connector C01.
(contact with ground circuit)
Between C01 (female) (8) and ground Resistance Min. 1 Mz
If no failure is found by above checks, pump controller is defective. (Since this
4 Defective pump controller
internal failure, troubleshooting cannot be performed.)
*: Connector Y09 is installed to only machine with overload alarm specification.

40-210 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [DA26KP] 5V Sensor2 Power Abnormality

Circuit diagram related to 5 V sensor power supply 2 circuit (Standard specification) 40-21

PC228US-8,PC228USLC-8 40-211
(01)
Troubleshooting by failurecode
Failure code [DA26KP] 5V Sensor2 Power Abnormality

Circuit diagram related to 5 V sensor power supply 2 circuit (Overload alarm specification machine) 40-212

40-212 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [DA26KP] 5V Sensor2 Power Abnormality

PC228US-8,PC228USLC-8 40-213
(01)
Troubleshooting by failurecode
Failure code [DA29KQ] Model Selection Abnormality

Failure code [DA29KQ] Model Selection Abnormality 40-214

User code Failure code Model selection error
Failure
(Pump controller system)
— DA29KQ
Detail of failure q Model code of input signal is not registered in controller.
q Controls machine, taking it that machine is default model (PC228).
Action of con-
q Even if cause of failure disappears, machine does not become normal until starting switch is turned
troller
to OFF position.
Problem on
q Because pump controller recognizes machine as "PC228", no particular problem occurs.
machine
q Model code input to pump controller can be checked by using monitoring function.
(Code: 00200 Controller model code)
Related infor-
q Condition of model selection signal can be checked by using monitoring function.
mation
(Code: 02201 Switch Input 2)
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connector S30 and connect T-adapter to female side.
Between S30 (female) (1) and (2) Resistance Min. 1 Mz
Defective model selection connec-
1 tor (Internal open circuit or short Between S30 (female) (3) and (4) Resistance Min. 1 Mz
circuit) Between S30 (female) (7) and (8) Resistance Min. 1 Mz
Between S30 (female) (2) and (8) Resistance Max. 1 z
Between S30 (female) (3) and (8) Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect connector C01 and connect T-adapter to female side.
2 Open circuit in wiring harness
Between C01 (female) (21) and ground Resistance Max. 1 z
Between C01 (female) (77) and ground Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect connector C01 and connect T-adapter to female side.

3 Short circuit in wiring harness Between C01 (female) (39) and C01 (21) Resistance Min. 1 Mz
Between C01 (female) (40) and C01 (21) Resistance Min. 1 Mz
Between C01 (female) (58) and C01 (21) Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector C01 and connect T-adapter to female side.
Ground fault in wiring harness Between C01 (female) (40) and ground Resistance Min. 1 Mz
4
(contact with ground circuit)
Between C01 (female) (58) and ground Resistance Min. 1 Mz
Between C01 (female) (39) and ground Resistance Min. 1 Mz
If no failure is found by above checks, pump controller is defective. (Since this
5 Defective pump controller
is internal failure, troubleshooting cannot be performed.)

40-214 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [DA29KQ] Model Selection Abnormality

Circuit diagram related to model selection signal 40-215

PC228US-8,PC228USLC-8 40-215
(01)
Troubleshooting by failurecode
Failure code [DA29KQ] Model Selection Abnormality

40-216 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [DA2RMC] CAN Discon (Pump Con Detected)

Failure code [DA2RMC] CAN Discon (Pump Con Detected) 40-217

User code Failure code CAN communication disabled (detected by pump controller)
Failure
(Pump controller system)
E0E DA2RMC
q Pump controller has failed CAN communication with machine monitor or engine controller.
Detail of failure
1) CAN communication line or ACC line of starting switch is abnormal.
q Fixes engine output to that of P mode to limit pump absorption torque to certain value.
Action of con- q Continues to control machine by using information obtained through CAN communication just be-
troller fore detection of error.
q If cause of failure disappears, machine becomes normal by itself.
q Engine output lowers. (Pump absorption torque decreases.)
q If actuator load increases, engine may stall.
Problem on
q Information may not be transmitted normally through CAN communication lines and machine may
machine
not operate normally.
(Failure symptom depends on failed section.)
q Method of reproducing failure code: Turn starting switch to ON position.
q Start of CAN communication is recognized by each controller when ACC signal of starting switch
is received.
q Failure code is sent to machine monitor through CAN communication. Accordingly, if failure code
[DA2RMC] is displayed on machine monitor, CAN communication between pump controller and
machine monitor is normal. That is, there can not be short circuit, ground fault or hot short circuit in
CAN communication line.
Related infor- q Since air conditioner is also controlled via CAN communication, check whether you can control air
mation conditioner (such as power on/off and air flow rate control) on "Air conditioner" screen.) (air condi-
tioner can be controlled even if failure code [DA2RMC] is displayed.)
q If failure code [DAFRMC] is also displayed, engine controller may be defective.
q If failure code [DY20KA], [DY20MA] or [DW43KA] is displayed, pump controller may be defective.
q Since each controller and machine monitor are connected to battery directly, they receive un-
switched power even while starting switch is at OFF position.
q Since signal of active CAN communication line is pulse voltage, it cannot be measured by using
multimeter.

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Remove fuses F01-18 (30 A fuse) and F01-20 (5 A fuse).
1 Blown fuse F01-18 or 20
a If fuse is blown, controller may have internal short circuit.

a If fuse is not blown, this check is not required.

1. Turn starting switch to OFF position.
Defective engine controller 2. Disconnect connector CE03, and connect T-adapter to male side.
2 a If measured resistance is below 10 z, engine controller is defective (inter-
(internal short circuit)
nal short circuit).
Between CE03 (male) (3) and (1) Resistance Min. 10 z
a Check ground terminal T12 for looseness and rust.
1. Turn starting switch to OFF position.
2. Disconnect connector CE03, and connect T-adapter to female side.
a If fuse F01-18 is blown, replace it.
Improper power supply to engine
3 3. Turn starting switch to ON position.
controller
Between CE03 (female) (3) and (1) Voltage 20 – 30 V
a If abnormality is found, perform troubleshooting for Detail of failure 2) "En-
gine controller power supply circuit is defective."
1. Turn starting switch to OFF position.
2. Disconnect connectors K02 and CM02, and connect T-adapter to each
Defective CAN terminating resistor
male side.
4 (open or short circuit in internal
wiring) Between K02 (male) (A) and (B) Resistance 120 ± 12 z
Between CM02 (male) (8) and (10) Resistance 120 ± 12 z

PC228US-8,PC228USLC-8 40-217
(01)
Troubleshooting by failurecode
Failure code [DA2RMC] CAN Discon (Pump Con Detected)

Cause Procedure, measuring location, criteria and remarks

q CAN communication line
a CAN terminating resistor of 120 z is also installed inside machine monitor.
Since 120 z resistors are connected in parallel, if combined resistance
measured at connector of controller other than machine monitor is 60 z,
CAN communication line has no open circuit.
1. Turn starting switch to OFF position and disconnect ground cable.
2. Disconnect connectors CE02, C01, N10, K02 and CM02 one by one, and
connect T-adapter to female side of connector disconnected.
a If short circuit occurs (if resistance between terminals is 1 z or less), dis-
connect all of connectors CE02, C01, N10, K02 and CM02. Then, check
Open or short circuit in wiring har- whether failure is short circuit between wiring harnesses or within control-
5
ness ler.
Approx.
Between CE02 (female) (46) and (47) Resistance
60 z
Approx.
Between C01 (female) (45) and (64) Resistance
60 z
Approx.
Between N10 (female) (1) and (2) Resistance
60 z
Approx.
Between K02 (female) (A) and (B) Resistance
120 z
Approx.
Between CM02 (female) (9) and (10) Resistance
120 z
a If no failure is found by checks on cause 5 , this check is not required.
1. Turn starting switch to OFF position and disconnect ground cable.
2. Disconnect connectors CE02, C01, N10, K02 and CM02, and connect
T-adapter to each female side.
Between C01 (female) (45) and each of CM02
Resistance Max. 1 z
(female) (9) and (8).
Between C01 (female) (64) and CM02 (female) (10) Resistance Max. 1 z
Between C01 (female)( 45) and CE02 (female) (46) Resistance Max. 1 z
Between C01 (female) (64) and CE02 (female) (47) Resistance Max. 1 z
Between C01 (female) (45) and N10 (female) (1) Resistance Max. 1 z
Between C01 (female) (64) and N10 (female) (2) Resistance Max. 1 z
Between CE02 (female) (46) and K02 (female) (A) Resistance Max. 1 z
Between CE02 (female) (47) and K02 (female) (B) Resistance Max. 1 z
Open circuit in wiring harness q ACC signal from starting switch
6 (Wire breakage or defective con- 1. Turn starting switch to OFF position and disconnect ground cable.
tact of connector) 2. Insert T-adapters into connectors CE02, C01 and CM01.
3. Connect battery ground cable and turn starting switch to ON position.
Between CE02 (39) and ground Voltage 20 – 30 V
Between each of C01 (24), (43) and (79) and C01
Voltage 20 – 30 V
(2)
Between CM01 (14) and (3) Voltage 20 – 30 V
a If no failure is found by above checks, this check is not required.
1. Turn starting switch to OFF position and disconnect ground cable.
2. Disconnect connectors CE02, COL and CM01 one by one, and connect
T-adapter to connector disconnected.
Between starting switch (ACC) and each of C01
Resistance Max. 1 z
(female) (24), (43) and (79).
Between starting switch (ACC) and CM01 (female)
Resistance Max. 1 z
(14)
Between starting switch (ACC) and CE02 (female)
Resistance Max. 1 z
(45)
If no failure is found by above checks and if failure code [DAFRMC] is also dis-
7 Defective engine controller played on machine monitor, engine controller is defective.
(Since this is an internal failure, troubleshooting cannot be performed.)

40-218 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [DA2RMC] CAN Discon (Pump Con Detected)

Cause Procedure, measuring location, criteria and remarks

If no failure is found by above checks, pump controller is defective.
8 Defective pump controller
(Since this is an internal failure, troubleshooting cannot be performed.)

Circuit diagram related to CAN communication line 40-219

PC228US-8,PC228USLC-8 40-219
(01)
Troubleshooting by failurecode
Failure code [DA2RMC] CAN Discon (Pump Con Detected)

Detail of failure 2) Engine controller power supply circuit is defective.

Cause Procedure, measuring location, criteria and remarks

1 Loose or corroded battery terminal Battery terminal may be loosened or corroded. Check it directly.

Remove fuse F01-19 (30 A fuse).

2 Defective fuse F01-19
a If fuse is blown, controller may have internal short circuit.
Defective wiring harness connec-
3
tor
1. Turn starting switch to OFF position.
2. Perform troubleshooting with starting switch at OFF position and at engine
4 Improper battery voltage cranking.
Between battery (2 pieces) terminal (+) and (-) Voltage 20 – 30 V
1. Turn starting switch to OFF position.
2. Exchange relays (R23 and R24 one by one) for engine controller power
Defective relays (R23 and R24) for supply with other relays.
5
engine controller power supply 3. Turn starting switch to ON position.
If this failure code disappeas, original relay is defective.
1. Turn starting switch to OFF position.
2. Remove diode arrays D10 and D11 and connect T-adapters to each male
side.
a Measure by using multimeter in diode range.
6 Defective diode D10 and D11 Between D10 (male) (2) (+) and (1) (-) Continuity
Between D10 (male) (1) (+) and (2) (-) No continuity
Between D11 (male) (2) (+) and (1) (-) Continuity
Between D11 (male) (1) (+) and (2) (-) No continuity
1. Turn starting switch to OFF position.
2. Remove fuse F01-19 (30 A fuse).
3. Disconnect connectors each of R23, R24, CE02, CE03, D10 and D11, and
connect T-adapters to each female side.
Between F01-19 and each of R23 (female) (1) and
Resistance Max. 1 z
R24 (female) (3)
Between each of R23 (female) (5) and R24 (female)
Resistance Max. 1 z
(5) and CE03 (female) (3)
Open circuit in wiring harness Between CE03 (female) (1) and ground (T12)
7 (wire breakage or defective con- Resistance Max. 1 z
a Corroded or loosened ground terminal (T12)
tact of connector)
Between CE02 (female) (33) and each of R23
Resistance Max. 1 z
(female) ( 2) and R24 (female) (2)
Between each of R23 (female) (1) and R24 (female)
(1) and each of D10 (female) (1) and D11 (female) Resistance Max. 1 z
(1)
Between battery relay R04 and each of R23
Resistance Max. 1 z
(female) (3) and R24 (female) (3)
Between CE02 (female) (49) and D11 (female) (2) Resistance Max. 1 z
1. Turn starting switch to OFF position and disconnect ground cable from
battery.
2. Remove fuse F01-19 (30 A fuse).
3. Disconnect connectors R23, R24, CE02 and CE03, and connect T-adapter
Ground fault in wiring harness
8 to female side of either one of them.
(contact with ground circuit)
Between any of F01-19 ,R23 (female) (3) or R24
Resistance Min. 1 Mz
(female) (3) and ground
Between any of R23 (female) (5), R24 (female) (5)
Resistance Min. 1 Mz
or CE03 (female) (3) and ground

40-220 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [DA2RMC] CAN Discon (Pump Con Detected)

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position and disconnect ground cable from
battery.
2. Disconnect connectors CE02 and CE03, and connect T-adapters to each
female side.
9 Short circuit in wiring harness Between CE03 (female) (3) and (1) Resistance Min. 1 Mz
Between CE03 (female) (3) and CE02 (female)
Resistance Min. 1 Mz
(each pin)
Between CE03 (female) (1) and CE02 (female)
Resistance Min. 1 Mz
(each pin)

Circuit diagram related to engine controller power supply 40-2 1

PC228US-8,PC228USLC-8 40-221
(01)
Troubleshooting by failurecode
Failure code [DAF8KB] Camera Power Supply Short Circuit

Failure code [DAF8KB] Camera Power Supply Short Circuit 40-2 2

User code Failure code Camera power supply short circuit
Failure
(Machine monitor system)
– DAF8KB
q Output power supply voltage (Rating: 8 V) from machine monitor to camera is below 6.0 V or above
Detail of failure
10 V.
Action of q Stops output of power supply voltage (Rating: 8 V) to camera.
machine q Even if cause of failure disappears, machine does not become normal until starting switch is turned
monitor to OFF position.
Problem on
q Camera image is not displayed on monitor screen.
machine
Related
q Method of reproducing failure code: Turn starting switch to ON position.
information

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Defective camera (internal short 2. Disconnect camera connector(s), and turn starting switch to ON position.
1
circuit) Disconnect camera connectors and perform failure code reproducing proce-
dure. If failure code disappears, camera is defective.
1. Turn starting switch to OFF position.
2. Disconnect connector CM05.
2 Defective machine monitor 3. Connect T-adapter to male side of connector CM05.
4. Turn starting switch to ON position.
Between CM05 (male) (1) and ground Voltage 6 – 10 V
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connector CM05 and camera connector(s).
3 3. Connect T-adapter to female side of connector CM05.
(contact with ground circuit)
Between CM05 (female) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect camera connector(s).
3. Insert T-adapter into connector CM05.
Hot short circuit in wiring harness 4. Turn starting switch to ON position.
4
(contact with 24 V circuit) (Disconnect camera connector(s) and check that camera is not defective in
advance.)
Between CM05 (1) and (7) Voltage Max. 10 V

40-222 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [DAF8KB] Camera Power Supply Short Circuit

Circuit diagram related to camera power supply 40-2 3

PC228US-8,PC228USLC-8 40-223
(01)
Troubleshooting by failurecode
Failure code [DAFGMC] GPS Module Error

Failure code [DAFGMC] GPS Module Error 40-2 4

User code Failure code GPS module error
Failure
(KOMTRAX system in machine monitor)
– DAFGMC
q Position data is not sent from GPS module (in machine monitor) to KOMTRAX communication mo-
Detail of failure
dem in 50 seconds after KOMTRAX started.
Action of
q None in particular
machine moni-
q If cause of failure disppears, machine becomes normal by itself.
tor
Problem on
machine
Related infor- q Method of reproducing failure code: Turn starting switch to ON position (At least 50 seconds after
mation starting switch is turned to ON position).

Cause Procedure, measuring location, criteria and remarks

GPS module of machine monitor may be defective. (Since this is an internal failure,
1 Defective machine monitor
troubleshooting cannot be performed.)

40-224 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [DAFGMC] GPS Module Error

PC228US-8,PC228USLC-8 40-225
(01)
Troubleshooting by failurecode
Failure code [DAFRMC] CAN Discon (Monitor Detected)

Failure code [DAFRMC] CAN Discon (Monitor Detected) 40-2 6

User code Failure code CAN communication disabled (detected by machine monitor)
Failure
(Machine monitor system)
E0E DAFRMC

Detail of failure q Machine monitor has failed CAN communication with pump controller or engine controller.

Action of
machine moni- q If cause of failure disappears, machine becomes normal by itself.
tor
q Engine output lowers. (Pump absorption torque decreases.)
q If actuator load increases, engine may stall.
Problem on
q Information may not be transmitted normally through CAN communication lines and machine may
machine
not operate normally.
(Failure symptom depends on failed section.)
q Method of reproducing failure code: Turn starting switch to ON position.
q Start of CAN communication is recognized by each controller when ACC signal of starting switch
is received.
q Since air conditioner is also controlled via CAN communication, check whether you can control air
conditioner (such as power ON/OFF and air flow rate control) on "Air conditioner "screen. (Air con-
ditioner can be controlled even if failure code is displayed on monitor screen.)
Related infor- If air conditioner can be controlled, there is no possibility of ground fault or short circuit or hot short
mation circuit in wiring harness (CAN communication line)
q If failure code [DA2RMC] is also displayed, engine controller may be defective.
q If failure code [DY20KA], [DY20MA] or [DW43KA] is displayed, pump controller may be defective.
q Since each controller and machine monitor are connected to battery directly, they receive un-
switched power even while starting switch is at OFF position.
q Since signal of active CAN communication line is pulse voltage, it cannot be measured by using
multimeter.

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Remove fuses F01-18 (30 A fuse) and F01-20 (5 A fuse).
1 Blown fuse F01-18 or 20
a If fuse is blown, controller may have internal short circuit.

a If fuse is not blown, this check is not required.

1. Turn starting switch to OFF position.
Defective engine controller 2. Disconnect connector CE03, and connect T-adapter to male side.
2 a If measured resistance is below 10 z, engine controller is defective (internal
(internal short circuit)
short circuit).
Between CE03 (male) (3) and (1) Resistance Min. 10 z
a Check ground terminal T12 for looseness and rust.
1. Turn starting switch to OFF position.
2. Disconnect connector CE03, and connect T-adapter to female side.
a If fuse F01-18 is blown, replace it.
Improper power supply to engine
3 3. Turn starting switch to ON position.
controller
Between CE03 (female) (3) and (1) Voltage 20 – 30 V
a If failure is found, perform troubleshooting for failure code [DA2RMC] (Detail
of failure 2) "Engine controller power supply circuit is defective").
1. Turn starting switch to OFF position.
2. Disconnect connectors K02 and CM02, and connect T-adapter to each male
Defective CAN terminating resistor
side.
4 (open or short circuit in internal
wiring) Between K02 (male) (A) and (B) Resistance 120 ± 12 z
Between CM02 (male) (8) and (10) Resistance 120 ± 12 z

40-226 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [DAFRMC] CAN Discon (Monitor Detected)

Cause Procedure, measuring location, criteria and remarks

q CAN communication line
a CAN terminating resistor of 120 z is also installed inside machine monitor.
Since 120 z resistors are connected in parallel, if combined resistance mea-
sured at connector of controller other than machine monitor is 60 z, CAN
communication line has no open circuit.
1. Turn starting switch to OFF position and disconnect ground cable.
2. Disconnect connectors CE02, C01, N10, K02 and CM02 one by one, and
connect T-adapter to female side of connector disconnected.
Open or short circuit in wiring har- a If short circuit occurs (if resistance between terminals is 1 z or less), discon-
5 nect all of connectors CE02, C01, N10 ,K02 and CM02. Then, check wheth-
ness
er failure is short circuit between wiring harnesses or within controller.
Between CE02 (female) (46) and (47) Resistance Approx. 60 z
Between C01 (female) (45) and (64) Resistance Approx. 60 z
Between N10 (female) (1) and (2) Resistance Approx. 60 z
Approx.
Between K02 (female) (A) and (B) Resistance
120 z
Approx.
Between CM02 (female) (9) and (10) Resistance
120 z
a If no failure is found by checks on cause 5 , this check is not required.
1. Turn starting switch to OFF position and disconnect ground cable.
2. Disconnect connectors CE02, C01, N10, K02 and CM02 one by one, and
connect T-adapter to each female side.
Between C01 (female) (45) and each of CM02
Resistance Max. 1 z
(female) (9) and (8).
Between C01 (female) (64) and CM02 (female)
Resistance Max. 1 z
(10)
Between C01 (female)( 45) and CE02 (female)
Resistance Max. 1 z
(46)
Between C01 (female) (64) and CE02 (female)
Resistance Max. 1 z
(47)
Between C01 (female) (45) and N10 (female) (1) Resistance Max. 1 z
Between C01 (female) (64) and N10 (female) (2) Resistance Max. 1 z
Between CE02 (female) (46) and K02 (female)
Resistance Max. 1 z
(A)
Between CE02 (female) (47) and K02 (female)
Open circuit in wiring harness Resistance Max. 1 z
(B)
6 (wire breakage or defective con- q ACC signal from starting switch
tact of connector) 1. Turn starting switch to OFF position and disconnect ground cable.
2. Insert T-adapters into connectors CE02, C01 and CM01.
3. Connect battery ground cable and turn starting switch to ON position.
Between CE02 (39) and ground Voltage 20 – 30 V
Between each of C01 (24), (43) and (79) and C01
Voltage 20 – 30 V
(2)
Between CM01 (14) and (3) Voltage 20 – 30 V
a If no failure is found by above checks, this check is not required.
1. Turn starting switch to OFF position and disconnect ground cable.
2. Disconnect connectors CE02, C01, N10, K02 and CM02 one by one, and
connect T-adapter to each female side.
Between starting switch (ACC) and each of C01
Resistance Max. 1 z
(female) (24), (43) and (79).
Between starting switch (ACC) and CM01
Resistance Max. 1 z
(female) (14)
Between starting switch (ACC) and CE02
Resistance Max. 1 z
(female) (45)

PC228US-8,PC228USLC-8 40-227
(01)
Troubleshooting by failurecode
Failure code [DAFRMC] CAN Discon (Monitor Detected)

Cause Procedure, measuring location, criteria and remarks

a If failure code [DA2RMC] is displayed on machine monitor, or you can con-
trol air conditioner on " Air conditioner " screen, this check is not required.
a If no failure is found by checks on cause 5 (no open circuit), measure resis-
tance at one connector. Disconnect one of connectors CE02, C01, and
Ground fault in wiring harness CM02 and connect T-adapter to female side of connector disconnected.
7
(contact with ground circuit) Between C01 (female) (45), CM02 (female) (8),
Resistance Min. 1 Mz
(9) or CE02 (female) (46) and ground
Between C01 (64), CM02 (10) or CE02 (47) and
Resistance Min. 1 Mz
ground
a If failure code [DA2RMC] is displayed on machine monitor, or you can con-
trol air conditioner on " Air conditioner " screen, this check is not required.
a If no failure is found by checks on cause 5 (no open circuit), measure voltage
at one connnector.
1. Turn starting switch to OFF position and disconnect ground cable.
2. Insert T-adapter into connector CE02, C01 or CM02.
Short circuit or hot short circuit in 3. Connect ground cable.
8 wiring harness (contact with 24 V 4. Turn starting switch to ON position.
circuit) a CAN_H and CAN_L lines are considered to be normal if their voltage are be-
tween 1 to 4 V although their normal voltage is 2.5 ± 1 V.
Between C01 (45), CM02 (8), (9) or CE02 (46)
Voltage 1–4V
and ground
Between C01 (64), CM02 (10) or CE02 (47) and
Voltage 1–4V
ground

If no failure is found by above checks and if failure code [DA2RMC] is also dis-
9 Defective engine controller
played, engine controller is defective. (Since this is internal failure, trouble-
shooting cannot be performed.)
If no failure is found by above checks, and if failure code [DA2RMC] is not dis-
played or if air conditioner cannot be controlled, locate defective controller as
follows.
A. Procedure for judging by operation of air conditioner
q Step 1
1. Turn starting switch to OFF position and disconnect ground cable.
2. Disconnect engine controller (connector CE02) and pump controller
(connector C01).
3. Connect battery ground cable and turn starting switch to ON position.
4. Operate air conditioner.
a If air conditioner can be controlled, go to step 2.

NO Defective air conditioner unit

Can air conditioner be controlled?
Either of removed control-
YES
lers is defective
Defective engine controller, pump q Step 2
10
controller or air conditioner unit 1. Turn starting switch to OFF position and disconnect ground cable.
2. Disconnect either engine controller (connector CE02) or pump controller
(connector C01).
3. Connect ground cable, turn starting switch to ON position and perform trou-
bleshooting.
4. Return to Step 1, to troubleshoot other controller.
Removed controller is defec-
Can air conditioner be controlled? YES
tive
B. Procedure for juding by display of failure code [DA2RMC]
(When air conditioner is not installed)
1. Turn starting switch to OFF position and disconnect ground cable.
2. Disconnect engine controller (connector CE03).
3. Connect battery ground cable and turn starting switch to ON position.
NO Defective pump controller
Is failure code [DA2RMC] displayed?
YES Defective engine controller

40-228 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [DAFRMC] CAN Discon (Monitor Detected)

Cause Procedure, measuring location, criteria and remarks

If no failure is found by above checks, machine monitor is defective.
11 Defective machine monitor
(Since this is an internal failure, troubleshooting cannot be performed.)

Circuit diagram related to CAN communication line 40-2 9

PC228US-8,PC228USLC-8 40-229
(01)
Troubleshooting by failurecode
Failure code [DGH2KB] Hyd Oil Sensor Short

Failure code [DGH2KB] Hyd Oil Sensor Short 40-230

User code Failure code Hydraulic oil temperature sensor short circuit
Failure
(Pump controller system)
– DGH2KB
Detail of failure q Signal voltage of hydraulic oil temperature sensor circuit is below 1 V and ground fault is detected.
Action of con-
q If cause of failure disappears, machine becomes normal by itself.
troller
Problem on q While hydraulic oil temperature rises normally, indicator of hydraulic oil temperature gauge does
machine not move from top of white range (bottom of green range).
q Signal voltage of hydraulic oil temperature sensor can be checked by using monitoring function.
Related infor-
(Code: 04402: Hydraulic oil temperature sensor voltage)
mation
q Method of reproducing failure code: Start engine.

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connector P22 and connect T-adapter to male side.
10°C Resistance Approx. 90 kz
Defective hydraulic oil
temperature sensor Between P22 (male) (1) and (2) 30°C Resistance Approx. 35 kz
(internal open or short a Temperature-resistance character-
1
istics of oil temperature sensor 80°C Resistance Approx. 6.5 kz
circuit)
100°C Resistance Approx. 3.5 kz
Between P22 (male) (2) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector P22 and connect T-adapter to female side.
Open circuit, short cir- 3. Turn starting switch to ON position.
cuit, ground fault or hot a If voltage is 0 V, wiring harness has open circuit, ground fault, or short circuit, and if
2 voltage is 24 V, wiring harness has hot short circuit.
short circuit in wiring
harness a Voltage of about 5 V is applied to temperature sensor signal lines through resistor in
pump controller.
Between P22 (female) (1) and (2) Voltage Approx. 5 V
1. Turn starting switch to OFF position.
2. Disconnect connector C01 and connect T-adapter to female side.
a Use temperature-resistance characteristics table for troubleshooting on cause 1.
Short circuit or ground a If resistance is above 1 Mz, wiring harness has open circuit. If resistance is below 1 z,
3
fault in wiring harness wiring harness has short circuit.
Between C01 (female) (29) and (46) Resistance 3.5 – 90 kz
Between C01 (female) (29) and ground Resistance Min. 1 Mz
a If no failure is found by checks cause 2, this check is not required.
1. Turn starting switch to OFF position.
Ground fault in wiring
2. Disconnect connectors C01 and P22, and connect T-adapter to female side of either
4 harness (contact with
one.
ground circuit)
Between C01 (female) (29) and ground, or between
Resistance Min. 1 Mz
P22 (female) (2) and ground
Defective pump con- If no failure is found by above checks, pump controller is defective. (Since this is internal
5
troller failure, troubleshooting cannot be performed.)

40-230 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [DGH2KB] Hyd Oil Sensor Short

Circuit diagram related to hydraulic oil temperature sensor 40-231

PC228US-8,PC228USLC-8 40-231
(01)
Troubleshooting by failurecode
Failure code [DHPAMA] Pump Press Sensor Abnormality

Failure code [DHPAMA] Pump Press Sensor Abnormality 40-232

User code Failure code Front pump pressure sensor malfunction
Failure
(Pump controller system)
– DHPAMA
Detail of failure q Signal voltage of front pump pressure sensor circuit is below 0.3 V or above 4.5 V.
Action of con- q Controls machine taking front pump pressure to be 0 MPa {0 kg/cm2}.
troller q If cause of failure disappears, machine becomes normal by itself.
Problem on q
Automatic travel speed selector function does not work.
machine q
Straight travel performance or steering performance lowers.
a If 5 V circuit (3) and ground circuit (1) of pressure sensor are connected to reverse polarities, pres-
sure sensor is damaged. Accordingly, take extreme care when checking.
q As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be mea-
Related infor-
sured at pump controller connector.
mation
q Front pump pressure can be checked by using monitoring function.
(Code: 01100 F pump pressure).
q Method of reproducing failure code: Turn starting switch to ON position or start engine.

Cause Procedure, measuring location, criteria and remarks

If failure code [DA25KP] is also displayed, perform troubleshooting for it first.

1. Turn starting switch to OFF position.

Defective 5V sensor power supply 2. Disconnect connector P25, and connect T-adapter to female side.
1
1 system 3. Turn starting switch to ON position.
a If power supply voltage is unusual, proceed to cause 3.
Power sup-
Between P25 (female) (3) and (1) Voltage 4.5 – 5.5 V
ply
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector P25.
3. Turn starting switch to ON position.
Sensor out-
Between P25 (2) and (1) Voltage 0.5 – 4.5 V
put
a If power supply voltage is normal and sensor output voltage is unusual, it is
difficult to judge whether cause is defective sensor, ground fault or hot short
Defective front pump pressure circuit in harness. Check as follows.
2
sensor (internal failure) 1. Turn starting switch to OFF position.
2. Replace connector P25 with connector P26 of R pump PPC pressure
sensor.
3. Turn starting switch to ON position and display "Abnormality Record"
screen of electrical system on machine monitor.
4. If E mark is not displayed for this failure code, front pump pressure sensor
is defective.
a After finishing test, return connectors as they were.
1. Turn starting switch to OFF position.
2. Disconnect connectors C01 and P25, and connect T-adapters to each
female side.
a If power supply voltage in checks 1 is normal,
Open circuit in wiring harness this check is not required. Resistance Max. 1 z
3 (Wire breakage or defective con- Between C01 (female) (18) and P25 (female) (1)
tact of connector)
Between C01 (female) (49) and P25 (female) (2) Resistance Max. 1 z
a If power supply voltage in checks 1 is normal,
this check is not required. Resistance Max. 1 z
Between C01 (female) (9) and P25 (female) (3)
1. Turn starting switch to OFF position.
2. Disconnect connectors C01 and P25, and connect T-adapter to female side
Ground fault in wiring harness
4 of either connector.
(contact with ground circuit)
Between C01 (female) (49) or P25 (female) (2) and
Resistance Min. 1 Mz
ground

40-232 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [DHPAMA] Pump Press Sensor Abnormality

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connector P25.
Hot short circuit in wiring harness 3. Connect T-adapter to female side of connector P25.
5
(short to 5 V or 24 V circuit) 4. Turn starting switch to ON position.
Between P25 (female) (2) and ground Voltage Max. 1 V
If no failure is found by above checks, pump controller is defective. (Since this
6 Defective pump controller
is internal failure, troubleshooting cannot be performed.)

Circuit diagram related to front pump pressure sensor 40-23

PC228US-8,PC228USLC-8 40-233
(01)
Troubleshooting by failurecode
Failure code [DHPBMA] R Pump Press Sensor Abnormality

Failure code [DHPBMA] R Pump Press Sensor Abnormality 40-234

User code Failure code Rear pump pressure sensor malfunction
Failure
(Pump controller system)
– DHPAMA
Detail of failure q Signal voltage of rear pump pressure sensor circuit is below 0.3 V or above 4.5 V.
Action of con- q Controls machine taking rear pump pressure to be 0 MPa {0 kg/cm2}.
troller q If cause of failure disappears, machine becomes normal by itself.
Problem on q
Automatic travel speed selector function does not work.
machine q
Straight travel performance or steering performance lowers.
a If 5 V circuit (3) and ground circuit (1) of pressure sensor are connected to reverse polarities, pres-
sure sensor is damaged. Accordingly, take extreme care when checking.
q As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be mea-
Related infor-
sured at pump controller connector.
mation
q Rear pump pressure can be checked by using monitoring function.
(Code: 01101 R pump pressure)
q Method of reproducing failure code: Turn starting switch to ON position or start engine.

Cause Procedure, measuring location, criteria and remarks

If failure code [DA25KP] is also displayed, perform troubleshooting for it first.

1. Turn starting switch to OFF position.

Defective 5V sensor power supply 2. Disconnect connector P25, and connect T-adapter to female side.
1
1 system 3. Turn starting switch to ON position.
a If power supply voltage is unusual, proceed to cause 3.
Power sup-
Between P26 (female) (3) and (1) Voltage 4.5 – 5.5 V
ply
1. Turn starting switch to OFF position.
2. Connect T-adapter to connector P26.
3. Turn starting switch to ON position.
Sensor out-
Between P26 (2) and (1) Voltage 0.5 – 4.5 V
put
a If power supply voltage is normal and sensor output voltage is unusual, it is
difficult to judge whether cause is defective sensor, ground fault or hot short
Defective rear pump pressure sen- circuit in harness. Check as follows.
2
sor (internal defect) 1. Turn starting switch to OFF position.
2. Replace connector P26 with connector P25 of front pump PPC pressure
sensor.
3. Turn starting switch to ON position and display "Abnormality Record"
screen of electrical system on machine monitor.
4. If E mark is not displayed for this failure code, rear pump pressure sensor
is defective.
a After finishing test, return connectors as they were.
1. Turn starting switch to OFF position.
2. Disconnect connectors C01 and P26, and connect T-adapters to female
sides of them.
a If power supply voltage in checks 1 is normal,
Open circuit in wiring harness this check is not required. Resistance Max. 1 z
3 (Wire breakage or defective con- Between C01 (female) (18) and P26 (female) (1)
tact of connector)
Between C01 (female) (68) and P26 (female) (2) Resistance Max. 1 z
a If power supply voltage in checks 1 is normal,
this check is not required. Resistance Max. 1 z
Between C01 (female) (9) and P26 (female) (3)
1. Turn starting switch to OFF position.
2. Disconnect connectors C01 and P26, and connect T-adapter to female side
Ground fault in wiring harness
4 of either connector.
(contact with ground circuit)
Between C01 (female) (68) or P26 (female) (2) and
Resistance Min. 1 Mz
ground

40-234 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [DHPBMA] R Pump Press Sensor Abnormality

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connector P26.
Hot short circuit in wiring harness 3. Connect T-adapter to female side of connector P26.
5
(short to 5 V or 24 V circuit) 4. Turn starting switch to ON position.
Between P26 (female) (2) and ground Voltage Max. 1 V
If no failure is found by above checks, pump controller is defective. (Since this
6 Defective pump controller
is internal failure, troubleshooting cannot be performed.)

Circuit diagram related to rear pump pressure sensor 40-235

PC228US-8,PC228USLC-8 40-235
(01)
Troubleshooting by failurecode
Failure code [DHS3MA] Arm IN PPC Sen. Abnormality

Failure code [DHS3MA] Arm IN PPC Sen. Abnormality 40-236

User code Failure code Arm IN PPC sensor system malfunction
Failure
(Pump controller system)
— DHS3MA
Detail of failure q Signal voltage of arm IN PPC pressure sensor circuit is below 0.3 V or above 4.5 V.
Action of con- q Controls machine taking arm IN PPC pressure to be 0 MPa {0 kg/cm2}.
troller q If cause of failure disappears, machine becomes normal by itself.
Problem on q
Automatic deceleration cannot be canceled.
machine q
Arm IN performance lowers.
a If 5 V circuit (3) and ground circuit (1) of pressure sensor are connected to reverse polarities, pres-
sure sensor is damaged. Accordingly, take extreme care when checking.
q As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be mea-
Related infor-
sured at pump controller connector.
mation
q Arm IN PPC pressure can be checked by using monitoring function.
(Code: 07200 Arm IN PPC pressure)
q Method of reproducing failure code: Turn starting switch to ON position or start engine.

Cause Procedure, measuring location, criteria and remarks

If failure code [DA25KP] is also displayed, perform troubleshooting for it first.

1. Turn starting switch to OFF position.

Defective 5V sensor power supply 2. Disconnect connector P04 and connect T-adapter to female side.
1
1 system 3. Turn starting switch to ON position.
a If power supply voltage is unusual, proceed to cause 3.
Power sup-
Between P04 (female) (3) and (1) Voltage 4.5 – 5.5 V
ply
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector P04
3. Turn starting switch to ON position.
Sensor out-
Between P04 (2) and (1) Voltage 0.5 – 4.5 V
put
a If power supply voltage is normal and sensor output voltage is unusual, it is
difficult to judge whether cause is defective sensor, ground fault or hot short
Defective arm IN PPC pressure
2 circuit in harness. Check as follows.
sensor (internal failure)
1. Turn starting switch to OFF position.
2. Replace connector P04 with connector of other PPC pressure sensor.
3. Turn starting switch to ON position and display "Abnormality Record"
screen of electrical system on machine monitor.
4. If E mark is not displayed for this failure code, arm IN PPC pressure sensor
is defective.
a After finishing test, return connectors as they were.
1. Turn starting switch to OFF position.
2. Disconnect connectors C01 and P04, and connect T-adapters to each
female side.
a If power supply voltage in checks 1 is normal,
Open circuit in wiring harness this check is not required. Resistance Max. 1 z
3 ( wire preakage or defective con- Between C01 (female) (18) and P04 (female) (1)
tact of connector)
Between C01 (female) (17) and P04 (female) (2) Resistance Max. 1 z
a If power supply voltage in checks 1 is normal,
this check is not required. Resistance Max. 1 z
Between C01 (female) (9) and P04 (female) (2)
1. Turn starting switch to OFF position.
2. Disconnect connectors C01 and P04, and connect T-adapter to female side
Ground fault in wiring harness
4 of either connector.
(contact with ground circuit)
Between C01 (female) (17) or P04 (female) (2) and
Resistance Min. 1 Mz
ground

40-236 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [DHS3MA] Arm IN PPC Sen. Abnormality

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connector P04.
Hot short circuit in wiring harness 3. Connect T-adapter to female side of connector P04.
5
(short to 24 V circuit) 4. Turn starting switch to ON position.
Between P04 (female) (2) and ground Voltage Max. 1 V
If no failure is found by above checks, pump controller is defective. (Since this
6 Defective pump controller
is internal failure, troubleshooting cannot be performed.)

Circuit diagram related to arm IN PPC pressure sensor 40-237

PC228US-8,PC228USLC-8 40-237
(01)
Troubleshooting by failurecode
Failure code [DHS4MA] Bucket CURL PPC Press Sensor Abnormality

Failure code [DHS4MA] Bucket CURL PPC Press Sensor Abnormality 40-238
User code Failure code Bucket CURL PPC pressure sensor system malfunction
Failure
(Pump controller system)
— DHS4MA
Detail of failure q Signal voltage of bucket CURL PPC pressure sensor circuit is below 0.3 V or above 4.5 V.
Action of con- q Controls machine taking bucket CURL PPC pressure to be 0 MPa {0 kg/cm2}.
troller q If cause of failure disappears, machine becomes normal by itself.
Problem on q
Automatic deceleration cannot be canceled.
machine q
Bucket CURL performance lowers.
a If 5 V circuit (3) and ground circuit (1) of pressure sensor are connected to reverse polarities, pres-
sure sensor is damaged. Accordingly, take extreme care when checking.
q As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be mea-
Related infor-
sured at pump controller connector.
mation
q Bucket CURL PPC pressure can be checked by using monitoring function.
(Code: 07300 Bucket CURL PPC pressure)
q Method of reproducing failure code: Turn starting switch to ON position or start engine.

Cause Procedure, measuring location, criteria and remarks

If failure code [DA25KP] is also displayed, perform troubleshooting for it first.

1. Turn starting switch to OFF position.

Defective 5V sensor power supply 2. Disconnect connector P01 and connect T-adapter to female side.
1
1 system 3. Turn starting switch to ON position.
a If power supply voltage is unusual, proceed to cause 3.
Power sup-
Between P01 (female) (3) and (1) Voltage 4.5 – 5.5 V
ply
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector P01.
3. Turn starting switch to ON position.
Sensor out-
Between P01 (2) and (1) Voltage 0.5 – 4.5 V
put
a If power supply voltage is normal and sensor output voltage is unusual, it is
Defective bucket CURI PPC pres- difficult to judge whether cause is defective sensor, ground fault or hot short
2 circuit in harness. Check as follows.
sure sensor (internal failure)
1. Turn starting switch to OFF position.
2. Replace connector P01 with connector of other PPC pressure sensor.
3. Turn starting switch to ON position and display "Abnormality Record"
screen of electrical system on machine monitor.
4. If E mark is not displayed for this failure code, bucket CURL PPC pressure
sensor is defective.
a After finishing test, return connectors as they were.
1. Turn starting switch to OFF position.
2. Disconnect connectors C01 and P01, and connect T-adapters to each
female side.
a If power supply voltage in checks 1 is normal,
Open circuit in wiring harness this check is not required. Resistance Max. 1 z
3 (wire preakage or defective con- Between C01 (female) (18) and P01 (female) (1)
tact of connector)
Between C01 (female) (73) and P01 (female) (2) Resistance Max. 1 z
a If power supply voltage in checks 1 is normal,
this check is not required. Resistance Max. 1 z
Between C01 (female) (9) and P01 (female) (3)
1. Turn starting switch to OFF position.
2. Disconnect connectors C01 and P01, and connect T-adapter to female side
Ground fault in wiring harness
4 of either connector.
(contact with ground circuit)
Between C01(female) (73) and ground, or between
Resistance Min. 1 Mz
P01 (female) (2) and ground

40-238 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [DHS4MA] Bucket CURL PPC Press Sensor Abnormality

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connector P01.
Hot short circuit in wiring harness 3. Connect T-adapter to female side of connector P01.
5
(short to 24 V circuit) 4. Turn starting switch to ON position.
Between P01 (female) (2) and ground Voltage Max. 1 V
If no failure is found by above checks, pump controller is defective. (Since this
6 Defective pump controller
is internal failure, troubleshooting cannot be performed.)

Circuit diagram related to bucket CURL PPC pressure sensor 40-239

PC228US-8,PC228USLC-8 40-239
(01)
Troubleshooting by failurecode
Failure code [DHS8MA] Boom RAISE PPC Press Sensor Abnormality

Failure code [DHS8MA] Boom RAISE PPC Press Sensor Abnormality 40-240
User code Failure code Boom RAISE PPC pressure sensor system malfunction
Failure
(Pump controller system)
— DHS8MA
Detail of failure q Signal voltage of boom RAISE PPC pressure sensor circuit is below 0.3 V or above 4.5 V.
Action of con- q Controls machine taking boom RAISE PPC pressure to be 0 MPa {0 kg/cm2}.
troller q If cause of failure disappears, machine becomes normal by itself.
Problem on q
Automatic deceleration cannot be canceled.
machine q
Boom RAISE performance lowers.
a If 5 V circuit (3) and ground circuit (1) of pressure sensor are connected to reverse polarities, pres-
sure sensor is damaged. Accordingly, take extreme care when checking.
q As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be mea-
Related infor-
sured at pump controller connector.
mation
q Boom RAISE PPC pressure can be checked by using monitoring function.
(code: 07400 Boom RAISE PPC pressure)
q Method of reproducing failure code: Turn starting switch to ON position or start engine.

Cause Procedure, measuring location, criteria and remarks

If failure code [DA25KP] is also displayed, perform troubleshooting for it first.
1.
Turn starting switch to OFF position.
Defective 5V sensor power 2.
Disconnect connector P06 and connect T-adapter to female side.
1 3.
Turn starting switch to ON position.
supply 1 system
a
If power supply voltage is unusual, proceed to cause 3.
Power sup-
Between P06 (female) (3) and (1) Voltage 4.5 – 5.5 V
ply
1. Turn starting switch to OFF position.
2. Insert T-adapter in connector P06.
3. Turn starting switch to ON position.
Sensor out-
Between P06 (2) and (1) Voltage 0.5 – 4.5 V
put
a If power supply voltage is normal and sensor output voltage is unusual, it is difficult
Defective boom RAISE PPC to judge whether cause is defective sensor, ground fault or hot short circuit in har-
2 pressure sensor (internal fail- ness. Check as follows.
ure) 1. Turn starting switch to OFF position.
2. Replace connector P06 with connector of other PPC pressure sensor.
3. Turn starting switch to ON position and display "Abnormality Record" screen of
electrical system on machine monitor.
4. If E mark is not displayed for this failure code, boom RAISE PPC pressure sensor
is defective.
a After finishing test, return connectors as they were.
1. Turn starting switch to OFF position.
2. Disconnect connectors C01 and P06, and connect T-adapters to female sides of
them.
Open circuit in wiring har- a If power supply voltage in checks 1 is normal, this
ness (Wire breakage or check is not required. Resistance Max. 1 z
3 Between C01 (female) (18) and P06 (female) (1)
defective contact of connec-
tor) Between C01 (female) (53) and P06 (female) (2) Resistance Max. 1 z
a If power supply voltage in checks 1 is normal, this
check is not required. Resistance Max. 1 z
Between C01 (female) (53) and P06 (female) (3)
1. Turn starting switch to OFF position.
Ground fault in wiring har- 2. Disconnect connectors C01 and P06, and connect T-adapter to female side of
4 ness (contact with ground either connector.
circuit) Between C01(female) (53) and ground, or between P06
Resistance Min. 1 Mz
(female) (2) and ground

40-240 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [DHS8MA] Boom RAISE PPC Press Sensor Abnormality

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connector P06.
Hot short in wiring harness 3. Connect T-adapter to female side of connector P06.
5
(short to 24 V circuit) 4. Turn starting switch to ON position.
Between P06 (female) (2) and ground Voltage Max. 1 V
If no failure is found by above checks, pump controller is defective. (Since this is
6 Defective pump controller
internal failure, troubleshooting cannot be performed.)

Circuit diagram related to boom RAISE PPC pressure sensor 40-241

PC228US-8,PC228USLC-8 40-241
(01)
Troubleshooting by failurecode
Failure code [DHSAMA] Swing RH PPC Press Sensor Abnomality

Failure code [DHSAMA] Swing RH PPC Press Sensor Abnomality 40-242

User code Failure code Swing RIGHT PPC pressure sensor system malfunction
Failure
(Pump controller system)
– DHSAMA
Detail of failure q Signal voltage of swing RIGHT PPC pressure sensor is below 0.3 V or above 4.5 V.
Action of con- q Controls machine taking swing RIGHT PPC pressure to be 0 MPa {0 kg/cm2}.
troller q If cause of failure disappears, machine becomes normal by itself.
Problem on q
Automatic deceleration cannot be canceled.
machine q
Swing RIGHT performance lowers.
a If 5 V circuit (3) and ground circuit (1) of pressure sensor are connected to reverse polarities, pres-
sure sensor is damaged. Accordingly, take extreme care when checking.
q As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be mea-
Related infor-
sured at pump controller connector.
mation
q Swing RIGHT PPC pressure can be checked by using monitoring function.
(Code 09002: Swing RIGHT PPC pressure)
q Method of reproducing failure code: Turn starting switch to ON position or start engine.

Cause Procedure, measuring location, criteria and remarks

If failure code [DA25KP] is also displayed, perform troubleshooting for it first.

1. Turn starting switch to OFF position.

Defective 5V sensor power supply 2. Disconnect connector P07, and connect T-adapter to female side.
1
1 system 3. Turn starting switch to ON position.
a If power supply voltage is unusual, proceed to cause 3.
Power sup-
Between P07 (female) (3) and (1) Voltage 4.5 – 5.5 V
ply
1. Turn starting switch to OFF position.
2. Connect T-adapter to connector P07.
3. Turn starting switch to ON position.
Sensor out-
Between P07 (2) and (1) Voltage 0.5 – 4.5 V
put
a If power supply voltage is normal and sensor output voltage is unusual, it is
difficult to judge whether cause is defective sensor, ground fault or hot short
Defective swing RIGHT PPC pres-
2 circuit in harness. Check as follows.
sure sensor (internal failure)
1. Turn starting switch to OFF position.
2. Replace connector P07 with connector of other PPC pressure sensor.
3. Turn starting switch to ON position and display "Abnormality Record"
screen of electrical system on machine monitor.
4. If E mark is not displayed for this failure code, swing RIGHT PPC pressure
sensor is defective.
a After finishing test, return connectors as they were.
1. Turn starting switch to OFF position.
2. Disconnect connectors C01 and P07, and connect T-adapters to each
female side.
a If power supply voltage in checks 1 is normal,
Open circuit in wiring harness this check is not required. Resistance Max. 1 z
3 (wirie breakage or defective con- Between C01 (female) (18) and P07 (female) (1)
tact of connector)
Between C01 (female) (72) and P07 (female) (2) Resistance Max. 1 z
a If power supply voltage in checks 1 is normal,
this check is not required. Resistance Max. 1 z
Between C01 (female) (9) and P07 (female) (3)
1. Turn starting switch to OFF position.
2. Disconnect connectors C01 and P07, and connect T-adapter to female side
Ground fault in wiring harness
4 of either connector.
(contact with ground circuit)
Between C01 (female) (72) or P07 (female) (2) and
Resistance Min. 1 Mz
ground

40-242 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [DHSAMA] Swing RH PPC Press Sensor Abnomality

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connector P07.
Hot short circuit in wiring harness 3. Connect T-adapter to female side of connector P07.
5
(short to 5 V/24 V circuit) 4. Turn starting switch to ON position.
Between P07 (female) (2) and ground Voltage Max. 1 V
If no failure is found by above checks, pump controller is defective. (Since this
6 Defective pump controller
is internal failure, troubleshooting cannot be performed.)

Circuit diagram related to swing RIGHT PPC pressure sensor 40-243

PC228US-8,PC228USLC-8 40-243
(01)
Troubleshooting by failurecode
Failure code [DHSBMA] Swing LH PPC Press Sensor Abnomality

Failure code [DHSBMA] Swing LH PPC Press Sensor Abnomality 40-24

User code Failure code Defective swing LEFT PPC pressure sensor
Failure
(Pump controller system)
– DHSBMA
Detail of failure q Signal voltage of swing LEFT PPC pressure sensor is below 0.3 V or above 4.5 V.
Action of con- q Controls machine taking swing LEFT PPC pressure to be 0 MPa {0 kg/cm2}.
troller q If cause of failure disappears, machine becomes normal by itself.
Problem on q
Automatic deceleration cannot be canceled.
machine q
Swing LEFT performance lowers.
a If 5 V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor
will be broken. Accordingly, take extreme care when checking.
q As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be mea-
Related infor-
sured at pump controller connector.
mation
q Swing LEFT PPC pressure can be checked with monitoring function.
(Code 09001: Swing LEFT PPC pressure)
q Method of reproducing failure code: Turn starting switch to ON position or start engine.

Cause Procedure, measuring location, criteria and remarks

If failure code [DA25KP] is also displayed, perform troubleshooting for it first.

1. Turn starting switch to OFF position.

Defective 5V sensor power supply 2. Disconnect connector P03 and connect T-adapter to female side.
1
1 system 3. Turn starting switch to ON position.
a If power supply voltage is abnormal, proceed to cause 3.
Power sup-
Between P03 (female) (3) and (1) Voltage 4.5 – 5.5 V
ply
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector P03.
3. Turn starting switch to ON position.
Sensor out-
Between P03 (2) and (1) Voltage 0.5 – 4.5 V
put
a If power supply voltage is normal and sensor output voltage is abnormal, it
Defective swing LEFT PPC pres- is difficult to judge whether cause is defective sensor, ground fault or hot
2 sure sensor short circuit of harness. Check as follows.
(Internal failure) 1. Turn starting switch to OFF position.
2. Replace connector P03 with connector of another PPC pressure sensor.
3. Turn starting switch to ON position and display "Abnormality Record"
screen of electrical system on machine monitor.
4. If E mark is not displayed in this failure code column, swing LEFT PPC
pressure sensor is defective.
a After finishing test, return connectors as they were.
1. Turn starting switch to OFF position.
2. Disconnect connectors C01 and P03, and connect T-adapters to each
female side of them.
a If power supply voltage in checks 1 is normal,
Open circuit in wiring harness this check is not required. Resistance Max. 1 z
3 (Wire breakge or defective contact Between C01 (female) (18) and P03 (female) (1)
of connector)
Between C01 (female) (16) and P03 (female) (2) Resistance Max. 1 z
a If power supply voltage in checks 1 is normal,
this check is not required. Resistance Max. 1 z
Between C01 (female) (9) and P03 (female) (3)
1. Turn starting switch to OFF position.
2. Disconnect connectors C01 and P03, and connect T-adapter to female side
Ground fault in wiring harness
4 of either connector.
(Contact with ground circuit)
Between ground and C01 (female) (16) or P03
Resistance Min. 1 Mz
(female) (2)

40-244 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [DHSBMA] Swing LH PPC Press Sensor Abnomality

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connector P03.
Hot short circuit in wiring harness 3. Connect T-adapter to female side of connector P03.
5
(Contact with 5 V/24 V circuit) 4. Turn starting switch to ON position.
Between P03 (female) (2) and ground Voltage Max. 1 V
If no abnormality is found by above checks, pump controller is defective.
6 Defective pump controller
(Since this is an internal failure, troubleshooting cannot be performed.)

Circuit diagram related to swing LEFT PPC pressure sensor 40-245

PC228US-8,PC228USLC-8 40-245
(01)
Troubleshooting by failurecode
Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality

Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality 40-246
User code Failure code Bucket DUMP PPC pressure sensor failure
Failure
(Pump controller system)
— DHSDMA
Detail of failure q Signal voltage of bucket DUMP PPC pressure sensor is below 0.3 V or above 4.5 V.
Action of con- q Controls machine taking bucket DUMP PPC pressure to be 0 MPa {0 kg/cm2}.
troller q If cause of failure disappears, machine becomes normal by itself.
Problem on q
Automatic deceleration cannot be canceled.
machine q
Bucket dump performance lowers.
a If 5 V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor
will be broken. Accordingly, take extreme care when checking.
q As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be mea-
Related infor-
sured at pump controller connector.
mation
q Bucket DUMP PPC pressure can be checked with monitoring function.
(Code: 07301 Bucket DUMP PPC pressure)
q Method of reproducing failure code: Turn starting switch to ON position or start engine.

Cause Procedure, measuring location, criteria and remarks

If failure code [DA25KP] is also displayed, carry out troubleshooting for it first.

1. Turn starting switch to OFF position.

Defective 5V sensor power supply 2. Disconnect connector P05 and connect T-adapter to female side.
1
1 system 3. Turn starting switch to ON position.
a If power supply voltage is abnormal, proceed to cause 3.
Power sup-
Between P05 (3) and (1) Voltage 4.5 – 5.5 V
ply
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector P05.
3. Turn starting switch to ON position.
Sensor out-
Between P05 (2) and (1) Voltage 0.5 – 4.5 V
put
a If power supply voltage is normal and sensor output voltage is abnormal, it
is difficult to judge whether cause is defective sensor, ground fault or hot
Defective bucket DUMP PPC pres-
2 short circuit of harness. Check as follows.
sure sensor (Internal failure)
1. Turn starting switch to OFF position.
2. Replace connector P05 with connector of another PPC pressure sensor.
3. Turn starting switch to ON position and display "Abnormality Record"
screen of electrical system on machine monitor.
4. If E mark is not displayed in this failure code column, bucket DUMP PPC
pressure sensor is defective.
a After finishing test, return connectors as they were.
1. Turn starting switch to OFF position.
2. Disconnect connectors C01 and P05, and connect T-adapters to each
female side of them.
a If power supply voltage in checks 1 is normal,
Open circuit in wiring harness this check is not required. Resistance Max. 1 z
3 (Wire breakge or defective contact Between C01 (female) (18) and P05 (female) (1)
of connector)
Between C01 (female) (34) and P05 (female) (2) Resistance Max. 1 z
a If power supply voltage in checks 1 is normal,
this check is not required. Resistance Max. 1 z
Between C01 (female) (9) and P05 (female) (3)
1. Turn starting switch to OFF position.
2. Disconnect connectors C01 and P05, and connect T-adapter to female side
Ground fault in wiring harness
4 of either of them.
(Contact with ground circuit)
Between ground and C01 (female) (34) or P05
Resistance Min. 1 Mz
(female) (2)

40-246 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connector P05.
Hot short circuit in wiring harness 3. Connect T-adapter to female side of connector P05.
5
(Contact with 24 V circuit) 4. Turn starting switch to ON position.
Between P05 (female) (2) and ground Voltage Max. 1 V
If no abnormality is found by above checks, pump controller is defective.
6 Defective pump controller
(Since this is an internal failure, troubleshooting cannot be performed.)

Circuit diagram related to bucket DUMP PPC pressure sensor 40-247

PC228US-8,PC228USLC-8 40-247
(01)
Troubleshooting by failurecode
Failure code [DHSFMA] Travel FW L PPC Press Sensor Abnormality

Failure code [DHSFMA] Travel FW L PPC Press Sensor Abnormality 40-248

User code Failure code Left travel FORWARD PPC pressure sensor abnormality
Failure
(Pump controller system)
E20 DHSFMA
Detail of failure q Signal voltage of left travel FORWARD PPC pressure sensor is below 0.3 V or above 4.5 V.
Action of con- q Controls machine taking left travel FORWARD PPC pressure to be 0 MPa {0 kg/cm2}.
troller q If cause of failure disappears, machine becomes normal by itself.
Problem on q
Automatic deceleration cannot be canceled.
machine q
Travel performance is poor.
a If 5 V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor
will be broken. Accordingly, take extreme care when checking.
q As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be mea-
Related infor-
sured at pump controller connector.
mation
q Left travel FORWARD PPC pressure can be checked with monitoring function.
(Code: 07102 Left travel FORWARD PPC pressure)
q Method of reproducing failure code: Turn starting switch to ON position or start engine.

Cause Procedure, measuring location, criteria and remarks

If failure code [DA25KP] is also displayed, perform troubleshooting for it first.

1. Turn starting switch to OFF position.

Defective 5V sensor power supply 2. Disconnect connector P10 and connect T-adapter to female side.
1
1 system 3. Turn starting switch to ON position.
a If power supply voltage is abnormal, proceed to cause 3.
Power sup-
Between P10 (female) (3) and (1) Voltage 4.5 – 5.5 V
ply
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector P10.
3. Turn starting switch to ON position.
Sensor out-
Between P10 (2) and (1) Voltage 0.5 – 4.5 V
put
a If power supply voltage is normal and sensor output voltage is abnormal, it
Defective left travel FORWARD is difficult to judge whether cause is defective sensor, ground fault or hot
2 PPC pressure sensor (Internal fail- short circuit of harness. Check as follows.
ure) 1. Turn starting switch to OFF position.
2. Replace connector P10 with connector of another PPC pressure sensor.
3. Turn starting switch to ON position and display "Abnormality Record"
screen of electrical system on machine monitor.
4. If E mark is not displayed in this failure code column, left travel FORWARD
PPC pressure sensor is defective.
a After finishing test, return connectors as they were.
1. Turn starting switch to OFF position.
2. Disconnect connectors C01 and P10, and connect T-adapters to each
female side of them.
a If power supply voltage in checks 1 is normal,
Open circuit in wiring harness this check is not required. Resistance Max. 1 z
3 (Wire breakage or defective con- Between C01 (female) (18) and P10 (female) (1)
tact of connector)
Between C01 (female) (54) and P10 (female) (2) Resistance Max. 1 z
a If power supply voltage in checks 1 is normal,
this check is not required. Resistance Max. 1 z
Between C01 (female) (9) and P10 (female) (3)
1. Turn starting switch to OFF position.
2. Disconnect connectors C01 and P10, and connect T-adapter to female side
Ground fault in wiring harness
4 of either connector.
(Contact with ground circuit)
Between ground and C01 (female) (54) or P10
Resistance Min. 1 Mz
(female) (2)

40-248 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [DHSFMA] Travel FW L PPC Press Sensor Abnormality

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connector P10.
Hot short circuit in wiring harness 3. Connect T-adapter to female side of connector P10.
5
(Contact with 5 V/24 V circuit) 4. Turn starting switch to ON position.
Between P10 (female) (2) and ground Voltage Max. 1 V
If no abnormality is found by above checks, pump controller is defective.
6 Defective pump controller
(Since this is an internal failure, troubleshooting cannot be performed.)

Circuit diagram related to travel PPC pressure sensor 40-249

PC228US-8,PC228USLC-8 40-249
(01)
Troubleshooting by failurecode
Failure code [DHSGMA] Travel FW R PPC Press Sensor Abnormality

Failure code [DHSGMA] Travel FW R PPC Press Sensor Abnormality 40-250

User code Failure code Right travel FORWARD PPC pressure sensor abnormality
Failure
(Pump controller system)
E20 DHSGMA
Detail of failure q Signal voltage of right travel FORWARD PPC pressure sensor is below 0.3 V or above 4.5 V.
Action of con- q Controls machine taking right travel FORWARD PPC pressure to be 0 MPa {0 kg/cm2}.
troller q If cause of failure disappears, machine becomes normal by itself.
Problem on q
Automatic deceleration cannot be canceled.
machine q
Poor operatability of travel operation
a If 5 V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor
will be broken. Accordingly, take extreme care when checking.
q As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be mea-
Related infor-
sured at pump controller connector.
mation
q Right travel FORWARD PPC pressure can be checked with monitoring function.
(Code: 07103 Right travel FORWARD PPC pressure)
q Method of reproducing failure code: Turn starting switch to ON position or start engine.

Cause Procedure, measuring location, criteria and remarks

If failure code [DA25KP] is also displayed, perform troubleshooting for it first.

1. Turn starting switch to OFF position.

Defective 5V sensor power supply 2. Disconnect connector P09, and connect T-adapter to female side.
1
1 system 3. Turn starting switch to ON position.
a If power supply voltage is abnormal, proceed to cause 3.
Power sup-
Between P09 (female) (3) and (1) Voltage 4.5 – 5.5 V
ply
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector P09.
3. Turn starting switch to ON position.
Sensor out-
Between P09 (2) and (1) Voltage 0.5 – 4.5 V
put
a If power supply voltage is normal and sensor output voltage is abnormal, it
Defective right travel FORWARD is difficult to judge whether cause is defective sensor, ground fault or hot
2 PPC pressure sensor short circuit of harness. Check as follows.
(Internal failure) 1. Turn starting switch to OFF position.
2. Replace connector P09 with connector of another PPC pressure sensor.
3. Turn starting switch to ON position and display "Abnormality Record"
screen of electrical system on machine monitor.
4. If E mark is not displayed in this failure code column, right travel
FORWARD PPC pressure sensor is defective.
a After finishing test, return connectors as they were.
1. Turn starting switch to OFF position.
2. Disconnect connectors C01 and P09, and connect T-adapters to each
female side of them.
a If power supply voltage in checks 1 is normal,
Open circuit in wiring harness this check is not required. Resistance Max. 1 z
3 (Wire breakage or defective con- Between C01 (female) (18) and P09 (female) (1)
tact of connector)
Between C01 (female) (55) and P09 (female) (2) Resistance Max. 1 z
a If power supply voltage in checks 1 is normal,
this check is not required. Resistance Max. 1 z
Between C01 (female) (9) and P09 (female) (3)
1. Turn starting switch to OFF position.
2. Disconnect connectors C01 and P09, and connect T-adapter to female side
Ground fault in wiring harness
4 of either connector.
(Contact with ground circuit)
Between C01 (female) (55) or P09 (female) (2) and
Resistance Min. 1 Mz
ground

40-250 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [DHSGMA] Travel FW R PPC Press Sensor Abnormality

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connector P09.
Hot short circuit in wiring harness 3. Connect T-adapter to female side of connector P09.
5
(Contact with 5 V/24 V circuit) 4. Turn starting switch to ON position.
Between P09 (female) (2) and ground Voltage Max. 1 V
If no abnormality is found by above checks, pump controller is defective.
6 Defective pump controller
(Since this is an internal failure, troubleshooting cannot be performed.)

Circuit diagram related to travel PPC pressure sensor 40-251

PC228US-8,PC228USLC-8 40-251
(01)
Troubleshooting by failurecode
Failure code [DHSHMA] Travel BW L PPC Press Sensor Abnormality

Failure code [DHSHMA] Travel BW L PPC Press Sensor Abnormality 40-252

User code Failure code Left travel REVERSE PPC pressure sensor abnormality
Failure
(Pump controller system)
E20 DHSHMA
Detail of failure q Signal voltage of left travel REVERSE PPC pressure sensor is below 0.3 V or above 4.5 V.
Action of con- q Controls machine taking left travel REVERSE PPC pressure to be 0 MPa {0 kg/cm2}.
troller q If cause of failure disappears, machine becomes normal by itself.
Problem on q
Automatic deceleration cannot be canceled.
machine q
Poor operatability of travel operation
a If 5 V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor
will be broken. Accordingly, take extreme care when checking.
q As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be mea-
Related infor-
sured at pump controller connector.
mation
q Left travel REVERSE PPC pressure can be checked with monitoring function.
(Code: 07104 Left travel REVERSE PPC pressure)
q Method of reproducing failure code: Turn starting switch to ON position or start engine.

Cause Procedure, measuring location, criteria and remarks

If failure code [DA25KP] is also displayed, perform troubleshooting for it first.

1. Turn starting switch to OFF position.

Defective 5V sensor power supply 2. Disconnect connector P28 and connect T-adapter to female side.
1
1 system 3. Turn starting switch to ON position.
a If power supply voltage is abnormal, proceed to cause 3.
Power sup-
Between P28 (female) (3) and (1) Voltage 4.5 – 5.5 V
ply
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector P28
3. Turn starting switch to ON position.
Sensor out-
Between P28 (2) and (1) Voltage 0.5 – 4.5 V
put
a If power supply voltage is normal and sensor output voltage is abnormal, it
Defective left travel REVERSE is difficult to judge whether cause is defective sensor, ground fault or hot
2 PPC pressure sensor short circuit of harness. Check as follows.
(Internal failure) 1. Turn starting switch to OFF position.
2. Replace connector P28 with connector of another PPC pressure sensor.
3. Turn starting switch to ON position and display "Abnormality Record"
screen of electrical system on machine monitor.
4. If E mark is not displayed in this failure code column, left travel REVERSE
PPC pressure sensor is defective.
a After finishing test, return connectors as they were.
1. Turn starting switch to OFF position.
2. Disconnect connectors C01 and P28, and connect T-adapters to each
female side of them.
a If power supply voltage in checks 1 is normal,
Open circuit in wiring harness this check is not required. Resistance Max. 1 z
3 (Wire breakage or defective con- Between C01 (female) (18) and P28 (female) (1)
tact of connector)
Between C01 (female) (35) and P28 (female) (2) Resistance Max. 1 z
a If power supply voltage in checks 1 is normal,
this check is not required. Resistance Max. 1 z
Between C01 (female) (9) and P28 (female) (3)
1. Turn starting switch to OFF position.
2. Disconnect connectors C01 and P28, and connect T-adapter to female side
Ground fault in wiring harness
4 of either connector.
(Contact with ground circuit)
Between ground and C01 (female) (35) or P28
Resistance Min. 1 Mz
(female) (2)

40-252 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [DHSHMA] Travel BW L PPC Press Sensor Abnormality

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connector P28.
Hot short circuit in wiring harness 3. Connect T-adapter to female side of connector P28.
5
(Contact with 5 V/24 V circuit) 4. Turn starting switch to ON position.
Between P28 (female) (2) and ground Voltage Max. 1 V
If no abnormality is found by above checks, pump controller is defective.
6 Defective pump controller
(Since this is an internal failure, troubleshooting cannot be performed.)

Circuit diagram related to travel PPC pressure sensor 40-253

PC228US-8,PC228USLC-8 40-253
(01)
Troubleshooting by failurecode
Failure code [DHSJMA] Travel BW R PPC Press Sensor Abnormality

Failure code [DHSJMA] Travel BW R PPC Press Sensor Abnormality 40-254

User code Failure code Right travel REVERSE PPC pressure sensor abnormality
Failure
(Pump controller system)
E20 DHSJMA
Detail of failure q Signal voltage of right travel REVERSE PPC pressure sensor is below 0.3 V or above 4.5 V.
Action of con- q Controls machine taking right travel REVERSE PPC pressure to be 0 MPa {0 kg/cm2}.
troller q If cause of failure disappears, machine becomes normal by itself.
Problem on q
Automatic deceleration cannot be canceled.
machine q
Poor operatability of travel operation
a If 5 V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor
will be broken. Accordingly, take extreme care when checking.
q As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be mea-
Related infor-
sured at pump controller connector.
mation
q Right travel REVERSE PPC pressure can be checked with monitoring function.
(Code: 07105 Right travel REVERSE PPC pressure)
q Method of reproducing failure code: Turn starting switch to ON position or start engine.

Cause Procedure, measuring location, criteria and remarks

If failure code [DA25KP] is also displayed, perform troubleshooting for it first.

1. Turn starting switch to OFF position.

Defective 5V sensor power supply 2. Disconnect connector P27, and connect T-adapter to female side.
1
1 system 3. Turn starting switch to ON position.
a If power supply voltage is abnormal, proceed to cause 3.
Power sup-
Between P27 (female) (3) and (1) Voltage 4.5 – 5.5 V
ply
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector P27.
3. Turn starting switch to ON position.
Sensor out-
Between P27 (2) and (1) Voltage 0.5 – 4.5 V
put
a If power supply voltage is normal and sensor output voltage is abnormal, it
Defective right travel REVERSE is difficult to judge whether cause is defective sensor, ground fault or hot
2 PPC pressure sensor short circuit of harness. Check as follows.
(Internal failure) 1. Turn starting switch to OFF position.
2. Replace connector P27 with connector of another PPC pressure sensor.
3. Turn starting switch to ON position and display "Abnormality Record"
screen of electrical system on machine monitor.
4. If E mark is not displayed in this failure code column, right travel REVERSE
PPC pressure sensor is defective.
a After finishing test, return connectors as they were.
1. Turn starting switch to OFF position.
2. Disconnect connectors C01 and P27, and connect T-adapters to each
female side of them.
a If power supply voltage in checks 1 is normal,
Open circuit in wiring harness this check is not required. Resistance Max. 1 z
3 (Wire breakage or defective con- Between C01 (female) (18) and P27 (female) (1)
tact of connector)
Between C01 (female) (36) and P27 (female) (2) Resistance Max. 1 z
a If power supply voltage in checks 1 is normal,
this check is not required. Resistance Max. 1 z
Between C01 (female) (9) and P27 (female) (3)
1. Turn starting switch to OFF position.
2. Disconnect connectors C01 and P27, and connect T-adapter to female side
Ground fault in wiring harness
4 of either connector.
(Contact with ground circuit)
Between C01 (female) (36) or P27 (female) (2) and
Resistance Min. 1 Mz
ground

40-254 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [DHSJMA] Travel BW R PPC Press Sensor Abnormality

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connector P27.
Hot short circuit in wiring harness 3. Connect T-adapter to female side of connector P27.
5
(Contact with 5 V/24 V circuit) 4. Turn starting switch to ON position.
Between P27 (female) (2) and ground Voltage Max. 1 V
If no abnormality is found by above checks, pump controller is defective.
6 Defective pump controller
(Since this is an internal failure, troubleshooting cannot be performed.)

Circuit diagram related to travel PPC pressure sensor 40-25

PC228US-8,PC228USLC-8 40-255
(01)
Troubleshooting by failurecode
Failure code [DHSJMA] Travel BW R PPC Press Sensor Abnormality

40-256 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [DHX1MA] Overload Sensor Abnormality

Failure code [DHX1MA] Overload Sensor Abnormality 40-257

Standard specification 40-257

User code Failure code Overload Sensor Abnormality (Analog)

Failure
(Pump controller system)
- DHX1MA
Detail of failure q Monitor (overload alarm monitor) which is not set to be displayed is displayed.
Action of con- q None in particular
troller q If cause of failure disappears, machine becomes normal by itself.
Problem on
machine
Related informa-
q Method of reproducing failure code: Turn starting switch to ON position.
tion

Cause Procedure, measuring location, criteria and remarks

Defective pump control- Pump controller may be defective. (Since this is an internal failure, troubleshooting can-
1
ler not be performed.)

Overload alarm specification 40-257

Detail of failure q Signal voltage of boom bottom pressure sensor circuit is below 0.3 V or above 4.5 V.
q Continues outputting overload alarm.
Action of con-
q Even if cause of failure disappears, machine does not become normal until starting switch is turned
troller
to OFF position.
Problem on
q Overload alarm is kept indicated on machine monitor, regardless of actual load.
machine
q This failure code is detected for only overload alarm specification (pin 78 of connector C01 is GND).
a If 5 V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor
Related infor- will be broken. Accordingly, take extreme care when checking.
mation q Boom cylinder bottom pressure can be checked with monitoring function.
(Code: 15900 Boom bottom pressure)
q Method of reproducing failure code: Turn starting switch to ON position or start engine.

Cause Procedure, measuring location, criteria and remarks

If failure code [DA26KP] is also displayed, troubleshoot it first.

1. Turn starting switch to OFF position.

Defective 5 V sensor power supply 2. Disconnect connector Y09 and connect T-adapter to female side.
1
2 line 3. Turn starting switch to ON position.
a If power supply voltage is abnormal, proceed to cause 3.
Power sup-
Between Y09 (female) (3) and (1) Voltage 4.5 – 5.5 V
ply
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector Y09.
3. Turn starting switch to ON position.
Defective boom bottom pressure Between Y09 (2) and (1) Sensor out-
Voltage 0.5 – 4.5 V
2 sensor put
a If power supply voltage is normal and sensor output voltage is abnormal, it
(Internal failure)
is difficult to judge whether cause is defective sensor, ground fault or hot
short circuit of harness. Check as follows.
q Check for causes 4 and 5 first. If result is normal, boom bottom pressure
sensor is defective.

PC228US-8,PC228USLC-8 40-257
(01)
Troubleshooting by failurecode
Failure code [DHX1MA] Overload Sensor Abnormality

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connectors C01 and Y09, and connect T-adapters to female
sides of them.
a If power supply voltage in checks 1 is normal,
Open circuit in wiring harness this check is not required. Resistance Max. 1 z
3 (Wire breakage or defective con- Between C01 (female) (70) and Y09 (female) (1)
tact of connector)
Between C01 (female) (31) and Y09 (female) (2) Resistance Max. 1 z
a If power supply voltage in checks 1 is normal,
this check is not required. Resistance Max. 1 z
Between C01 (female) (8) and Y09 (female) (3)
1. Turn starting switch to OFF position.
2. Disconnect connectors C01 and Y09, and connect T-adapter to female side
Ground fault in wiring harness
4 of either connector.
(Contact with ground circuit)
Between C01 (female) (31) or Y09 (female) (2) and
Resistance Min. 1 Mz
ground
1. Turn starting switch to OFF position.
2. Disconnect connector Y09.
Hot short circuit in wiring harness 3. Connect T-adapter to female side of connector Y09.
5
(Contact with 5 V/24 V circuit) 4. Turn starting switch to ON position.
Between Y09 (female) (2) and ground Voltage Max. 1 V
If no abnormality is found by above checks, pump controller is defective.
6 Defective pump controller
(Since this is an internal failure, troubleshooting cannot be performed.)

40-258 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [DHX1MA] Overload Sensor Abnormality

Circuit diagram related to boom bottom pressure sensor (overload alarm specification) 40-259

PC228US-8,PC228USLC-8 40-259
(01)
Troubleshooting by failurecode
Failure code [DKA0KA] Boom Angle Sensor Open Circuit

Failure code [DKA0KA] Boom Angle Sensor Open Circuit 40-260

User code Failure code Boom angle sensor abnormality (open circuit)
Failure
(Pump controller system)
E40 DKA0KA
Detail of failure q The signal voltage of boom angle sensor circuit is below 0.3 V.
q Turns OFF an output to boom LOWER EPC.
q Turns OFF an output to boom RAISE EPC.
Action of con-
q Turns OFF an output to arm IN EPC.
troller
q Even if cause of failure disappears, machine does not become normal until starting switch is turned
to OFF position.
Problem on
q Machine monitor does not display working radius, actual load and lifting height.
machine
q If the Arm Crane mode (L) is selected on an arm crane model, user code [E50] is displayed.
q Turning the emergency operating switch of work equipment to ON, work equipment can be operat-
ed.
Related infor- q As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be mea-
mation sured at pump controller connector.
q The signal voltage of boom angle sensor can be checked with monitoring function.
(Code: 15100 Boom angle)
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

Defective 5 V sensor power sup-
1 If failure code [DA26KP] is also displayed, troubleshoot it first.
ply 2 line
Defective installation of boom
2 If failure code [DKA0PH] is also displayed, troubleshoot it first.
angle sensor
1. Turn starting switch to OFF position.
2. Disconnect connector A53 and connect T-adapter to male side.
Defective boom angle sensor Between A53 (male) (A) and (C) Resistance 4.0 - 6.0 kz
3
(Internal open circuit in wiring)
Between A53 (male) (B) and (C) Resistance 0.25 - 5.0 kz
Between A53 (male) (B) and (A) Resistance 0.25 - 5.0 kz
1. Turn starting switch to OFF position.
2. Disconnect connectors C01, Y09, Y13 and Y11, and connect T-adapters to
Open or short circuit in wiring har- female side of them.
4
ness Between C01 (female) (8) and (18) Resistance 4.0 - 6.0 kz
Between C01 (female) (67) and (18) Resistance 0.25 - 5.0 kz
a If no abnormality is found in checks on cause 4, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors C01 and A53, and connect T-adapters to each
Open circuit in wiring harness female side of them.
5 (Wire breakage or defective con- Between C01 (female) (18) and A53 (female)
Resistance Max. 1 z
tact of connector) (A)
Between C01 (female) (67) and A53 (female)
Resistance Max. 1 z
(B)
Between C01 (female) (8) and A53 (female) (C) Resistance Max. 1 z
a If no abnormality is found in checks on cause 4, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors C01 and A53, and connect T-adapter to female side
6 Short circuit in wiring harness
of either connector.
Between C01 (female) (67) and each of (18)
Resistance Min. 1 Mz
and (70), or between A53 (female) (B) and (A)
1. Turn starting switch to OFF position.
2. Disconnect connectors C01 and A53, and connect T-adapter to female side
Ground fault in wiring harness
7 of either connector.
(Contact with ground circuit)
Between ground and C01 (female) (67) or A53
Resistance Min. 1 Mz
(female) (B)

40-260 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [DKA0KA] Boom Angle Sensor Open Circuit

Cause Procedure, measuring location, criteria and remarks

If cause is not found by above checks, pump controller is defective.
8 Defective pump controller
(Since this is an internal failure, troubleshooting cannot be performed.)

Circuit diagram related to boom angle sensor 40-261

PC228US-8,PC228USLC-8 40-261
(01)
Troubleshooting by failurecode
Failure code [DKA0KB] Boom Angle Sensor Power Short Circuit

Failure code [DKA0KB] Boom Angle Sensor Power Short Circuit 40-262
User code Failure code Boom angle sensor abnormality (power short circuit)
Failure
(Pump controller system)
E40 DKA0KB
Detail of failure q The signal voltage of boom angle sensor circuit is above 4.7 V.
q Turns OFF an output to boom LOWER EPC.
q Turns OFF an output to boom RAISE EPC.
Action of con-
q Turns OFF an output to arm IN EPC.
troller
q Even if cause of failure disappears, machine does not become normal until starting switch is turned
to OFF position.
Problem on
q Machine monitor does not display working radius, actual load and lifting height.
machine
q If the Arm Crane mode (L) is selected on an arm crane model, user code [E50] is displayed.
q Turning the emergency operating switch of work equipment to ON, work equipment can be operat-
ed.
Related infor- q As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be mea-
mation sured at pump controller connector.
q The signal voltage of boom angle sensor can be checked with monitoring function.
(Code: 15100 Boom angle)
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

Defective 5 V sensor power sup-
1 If failure code [DA26KP] is also displayed, troubleshoot it first.
ply 2 line
Defective installation of boom
2 If failure code [DKA0PH] is also displayed, troubleshoot it first.
angle sensor
1. Turn starting switch to OFF position.
2. Disconnect connector A53 and connect T-adapter to male side.
Defective boom angle sensor Between A53 (male) (A) and (C) Resistance 4.0 - 6.0 kz
3
(Internal short circuit)
Between A53 (male) (B) and (C) Resistance 0.25 - 5.0 kz
Between A53 (male) (B) and (A) Resistance 0.25 - 5.0 kz
1. Turn starting switch to OFF position.
2. Disconnect connectors C01, Y09, Y11 and Y13, and connect T-adapters to
Open or short circuit in wiring har- female side of them.
4
ness Between C01 (female) (8) and (18) Resistance 4.0 - 6.0 kz
Between C01 (female) (67) and (18) Resistance 0.25 - 5.0 kz
a If no abnormality is found in checks on cause 4, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors C01 and A53, and connect T-adapter to female side
5 Short circuit in wiring harness
of either connector.
Between C01 (female) (67) and (8), or
Resistance Max. 1 Mz
between A53 (female) (C) and (B)
1. Turn starting switch to OFF position.
Hot short circuit in wiring harness 2. Disconnect connector A53 and connect T-adapter to female side.
6 3. Turn starting switch to ON position.
(Contact with 24 V circuit)
Between A53 (female) (B) and ground Voltage Max. 1 V
If no abnormality is found by the above checks, the pump controller is defec-
7 Defective pump controller
tive. (Since this is an internal failure, troubleshooting cannot be performed.)

40-262 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [DKA0KB] Boom Angle Sensor Power Short Circuit

Circuit diagram related to boom angle sensor 40-263

PC228US-8,PC228USLC-8 40-263
(01)
Troubleshooting by failurecode
Failure code [DKA0PH] Boom Angle Sensor Install Abnormality

Failure code [DKA0PH] Boom Angle Sensor Install Abnormality 40-264

User code Failure code Defective installation of boom angle sensor
Failure
(Pump controller system)
E40 DKA0PH
q The boom angle sensor signal is more than the maximum angle by 5 °or more, or less than the
Detail of failure
minimum angle by 5 °or more.
Action of con-
q If cause of failure disappears, machine becomes normal by itself.
troller
Problem on
q Machine monitor does not display working radius, actual load and lifting height.
machine
q If the Arm Crane mode (L) is selected on an arm crane model, user code [E50] is displayed.
q Turning the emergency operating switch of work equipment to ON, work equipment can be operat-
Related infor- ed.
mation q The signal voltage of boom angle sensor can be checked with monitoring function.
(Code: 15100 Boom angle)
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

Defective installation of boom The boom angle sensor may be installed incorrectly. Check for a mounting
1
angle sensor error, and correct it if abnormal.
If cause 1 is not found, the pump controller may be defected. (Since this is an
2 Defective pump controller
internal failure, troubleshooting cannot be performed.)

40-264 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [DKA0PH] Boom Angle Sensor Install Abnormality

Circuit diagram related to boom angle sensor 40-265

PC228US-8,PC228USLC-8 40-265
(01)
Troubleshooting by failurecode
Failure code [DKR0MA] F pump S/P sensor Abnormality

Failure code [DKR0MA] F pump S/P sensor Abnormality 40-26

User code Failure code F pump swash plate sensor abnormality
Failure
(Pump controller system)
— DKR0MA
Detail of failure q Signal voltage of F pump swash plate sensor circuit is below 0.4 V or above 4.6 V.
Action of con-
q If cause of failure disappears, machine becomes normal by itself.
troller
q
Automatic deceleration cannot be canceled.
Problem on
q
One-touch power maximizing function does not work.
machine
q Engine is not so controlled that low-load matching speed is lowered.
a If 5 V circuit (A) and ground circuit (B) of swash plate sensor are connected inversely, sensor will
be broken. Accordingly, take extreme care when checking.
q As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be mea-
Related infor-
sured at pump controller connector.
mation
q Voltage from front pump swash plate sensor can be checked with monitoring function.
(Code: 01138 F pump swash plate sensor voltage)
q Method of reproducing failure code: Turn starting switch to ON position or start engine.

Cause Procedure, measuring location, criteria and remarks

If failure code [DA25KP] is also displayed, carry out troubleshooting for it first.

1. Turn starting switch to OFF position.

Defective 5V sensor power supply 2. Disconnect connector A54 and connect T-adapter to female side.
1
1 system 3. Turn starting switch to ON position.
a If power supply voltage is abnormal, proceed to cause 3.
Power sup-
Between A54 (female) (A) and (B) Voltage 4.5 – 5.5 V
ply
1. Turn starting switch to OFF position.
2. Disconnect connector A54 and connect T-adapter to male side.
Approx.
Between A54 (male) (A) and (B) Resistance
6 kz
Approx.
Between A54 (female) (B) and (C) Resistance
6 kz
Approx.
Between A54 (female) (A) and (C) Resistance
170 z
Between A54 (male) (C) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector A54.
Defective F pump swash plate
3. Turn starting switch to ON position.
2 sensor Sensor out-
(Internal failure) Between A54 (female) (C) and (B) Voltage Approx. 3 V
put
a If power supply voltage is normal and sensor output voltage is abnormal, it
is difficult to judge whether cause is defective sensor, ground fault or hot
short circuit of harness. Check as follows.
1. Turn starting switch to OFF position.
2. Replace connector A54 with connector A55.
3. Turn starting switch to ON position and display "Abnormality Record"
screen of electrical system on machine monitor.
4. If E mark is not displayed in this failure code column, F pump swash plate
sensor is defective.
a After finishing test, return connectors as they were.

40-266 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [DKR0MA] F pump S/P sensor Abnormality

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connectors C01 and A54, and connect T-adapters to each
female side of them.
a If power supply voltage in checks 1 is normal,
Open circuit in wiring harness this check is not required. Resistance Max. 1 z
3 (Wire breakage or defective con- Between C01 (female) (9) and A54 (female) (A)
tact of connector) a If power supply voltage in checks 1 is normal,
this check is not required. Resistance Max. 1 z
Between C01 (female) (18) and A54 (female) (B)
Between C01 (female) (30) and A54 (female) (C) Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect connectors C01 and A54, and connect T-adapter to female side
Ground fault in wiring harness
4 of either connector.
(Contact with ground circuit)
Between C01 (female) (30) or A54 (female) (C) and
Resistance Min. 1 Mz
ground
1. Turn starting switch to OFF position.
2. Disconnect connector A54.
Hot short circuit in wiring harness 3. Connect T-adapter to female side of connector A54.
5
(Contact with 24 V circuit) 4. Turn starting switch to ON position.
Between A54 (female) (C) and ground Voltage Max. 1 V
If no abnormality is found by above checks, pump controller is defective.
6 Defective pump controller
(Since this is an internal failure, troubleshooting cannot be performed.)

Circuit diagram related to F and R pump swash plate sensors 40-267

PC228US-8,PC228USLC-8 40-267
(01)
Troubleshooting by failurecode
Failure code [DKR1MA] R pump S/P sensor Abnormality

Failure code [DKR1MA] R pump S/P sensor Abnormality 40-268

User code Failure code R pump swash plate sensor abnormality
Failure
(Pump controller system)
— DKR1MA
Detail of failure q Signal voltage of R pump swash plate sensor circuit is below 0.4 V or above 4.6 V.
Action of con-
q If cause of failure disappears, machine becomes normal by itself.
troller
q
Automatic deceleration cannot be canceled.
Problem on
q
One-touch power maximizing function does not work.
machine
q Engine is not so controlled that low-load matching speed is lowered.
a If 5 V circuit (A) and ground circuit (B) of swash plate sensor are connected inversely, sensor will
be broken. Accordingly, take extreme care when checking.
q As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be mea-
Related infor-
sured at pump controller connector.
mation
q Voltage from rear pump swash plate sensor can be checked with monitoring function.
(Code: 01140 R pump swash plate sensor voltage)
q Method of reproducing failure code: Turn starting switch to ON position or start engine.

Cause Procedure, measuring location, criteria and remarks

If failure code [DA25KP] is also displayed, carry out troubleshooting for it first.

1. Turn starting switch to OFF position.

Defective 5V sensor power supply 2. Disconnect connector A55 and connect T-adapter to female side.
1
1 system 3. Turn starting switch to ON position.
a If power supply voltage is abnormal, proceed to cause 3.
Power sup-
Between A55 (female) (A) and (B) Voltage 4.5 – 5.5 V
ply
1. Turn starting switch to OFF position.
2. Disconnect connector A55 and connect T-adapter to male side.
Approx.
Between A55 (male) (A) and (B) Resistance
6 kz
Approx.
Between A55 (female) (B) and (C) Resistance
6 kz
Approx.
Between A55 (female) (A) and (C) Resistance
170 z
Between A55 (male) (C) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector A55.
Defective R pump swash plate
3. Turn starting switch to ON position.
2 sensor Sensor out-
(Internal defect) Between A55 (C) and (B) Voltage Approx. 3 V
put
a If power supply voltage is normal and sensor output voltage is abnormal, it
is difficult to judge whether cause is defective sensor, ground fault or hot
short circuit of harness. Check as follows.
1. Turn starting switch to OFF position.
2. Replace connector A55 with connector A54.
3. Turn starting switch to ON position and display "Abnormality Record"
screen of electrical system on machine monitor.
4. If E mark is not displayed in this failure code column, R pump swash plate
sensor is defective.
a After finishing test, return connectors as they were.

40-268 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [DKR1MA] R pump S/P sensor Abnormality

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connectors C01 and A55, and connect T-adapters to each
female side of them.
a If power supply voltage in checks 1 is normal,
Open circuit in wiring harness this check is not required. Resistance Max. 1 z
3 (Wire breakage or defective con- Between C01 (female) (9) and A55 (female) (A)
tact of connector) a If power supply voltage in checks 1 is normal,
this check is not required. Resistance Max. 1 z
Between C01 (female) (18) and A55 (female) (B)
Between C01 (female) (50) and A55 (female) (C) Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect connectors C01 and A55, and connect T-adapter to female side
Ground fault in wiring harness
4 of either connector.
(Contact with ground circuit)
Between C01 (female) (50) or A55 (female) (C) and
Resistance Min. 1 Mz
ground
1. Turn starting switch to OFF position.
2. Disconnect connector A55.
Hot short circuit in wiring harness 3. Connect T-adapter to female side of connector A55.
5
(Contact with 24 V circuit) 4. Turn starting switch to ON position.
Between A55 (female) (C) and ground Voltage Max. 1 V
If no abnormality is found by above checks, pump controller is defective.
6 Defective pump controller
(Since this is an internal failure, troubleshooting cannot be performed.)

Circuit diagram related to F and R pump swash plate sensors 40-269

PC228US-8,PC228USLC-8 40-269
(01)
Troubleshooting by failurecode
Failure code [DV20KB] Travel Alarm Short Circuit

Failure code [DV20KB] Travel Alarm Short Circuit 40-270

User code Failure code Travel Alarm Short Circuit
Failure
(Pump controller system)
– DV20KB
Detail of failure q When outputting current to travel alarm circuit, abnormal current flows.
q Stops outputting current to travel alarm circuit.
Action of con-
q Even if cause of failure disappears, machine does not become normal until starting switch is turned
troller
to OFF position.
Problem on
q Travel alarm does not sound.
machine
q Operation (ON or OFF) of travel alarm can be checked with monitoring function.
Related infor- (Code: 03701 Controller output 2)
mation q As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be mea-
sured at pump controller connector.

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connector M14, and connect T-adapter to female side.
3. Turn starting switch to ON position.
4. Operate travel lever and perform troubleshooting.
Travel lever:
Voltage Max. 1 V
Defective travel alarm NEUTRAL
1 Between M14 (female) (1)
(Internal failure) Travel lever:
and (2) FOR-
Voltage 20 – 30 V
WARD/REVER
SE
a If the above voltage is normal but travel alarm does not sound, travel alarm
is defective.
1. Turn starting switch to OFF position.
2. Disconnect connectors C02 and M14, and connect T-adapter to female side
Ground fault in wiring harness of either connector.
2
(Contact with ground circuit)
Between C02 (female) (107) or M14 (female)
Resistance Min. 1 Mz
(1) and ground
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector M14.
3. Turn starting switch to ON position.
4. Operate travel lever and perform troubleshooting.
Travel lever:
3 Defective pump controller Voltage Max. 1 V
NEUTRAL
Between M14 (1) and (2) Travel lever:
FOR-
Voltage 20 – 30 V
WARD/REVER
SE

40-270 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [DV20KB] Travel Alarm Short Circuit

Circuit diagram related to travel alarm 40-271

PC228US-8,PC228USLC-8 40-271
(01)
Troubleshooting by failurecode
Failure code [DW43KA] Travel Speed Sol Open Circuit

Failure code [DW43KA] Travel Speed Sol Open Circuit 40-272

User code Failure code Travel speed solenoid system open circuit
Failure
(Pump controller system)
– DW43KA
q When outputting current to travel speed selector solenoid, no current flows and open circuit is de-
Detail of failure
tected.
Action of con- q None in particular (Since no current flows, solenoid does not operate).
troller q If cause of failure disappears, machine becomes normal by itself.
Problem on q "Hi" travel speed is slow. (Although "Hi" is diaplayed on machine monitor, actual travel speed is still
machine "Lo".)
q Controller's command (ON/OFF) to travel speed selector solenoid can be checked with monitoring
function. (If controller sends solenoid ON command, monitoring display is ON even if solenoid is
Related infor-
not switched ON due to open circuit.)
mation
(Code: 02300 Solenoid 1)
q Method of reproducing failure code: Start engine, set travel speed to High and operate travel lever.

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Defective travel speed selector 2. Disconnect connector V04, and connect T-adapter to male side.
1
solenoid (Internal open circuit)
Between V04 (male) (1) and (2) Resistance 20 – 60 z
1. Turn starting switch to OFF position.
2. Disconnect connector C02 and connect T-adapter to female side.
Between C02 (female) (87) and (115) or (117) or
Resistance 20 – 60 z
(120)
Open circuit in wiring harness a If above check result is normal, this check is not required.
2 (Wire breakage or defective con- 1. Turn starting switch to OFF position.
tact of connector) 2. Disconnect connectors C02 and V04, and connect T-adapters to each
female side of them.
Between C02 (female) (87) and V04 (female) (1) Resistance Max. 1 z
Between V02 (female) (2) and C02 (female) (115)
Resistance Max. 1 z
or (117) or (120)
If no abnormality is found by above checks, pump controller is defective.
3 Defective pump controller
(Since this is an internal failure, troubleshooting cannot be performed.)

40-272 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [DW43KA] Travel Speed Sol Open Circuit

Circuit diagram related to travel speed solenoid 40-273

PC228US-8,PC228USLC-8 40-273
(01)
Troubleshooting by failurecode
Failure code [DW43KB] Travel Speed Sol Short Circuit

Failure code [DW43KB] Travel Speed Sol Short Circuit 40-274

User code Failure code Travel speed solenoid short circuit
Failure
(Pump controller system)
– DW43KB
q When outputting current to travel speed selector solenoid, abnormal current flows and short circuit
Detail of failure
is detected.
q Stops outputting current to travel speed selector solenoid.
Action of con-
q Even if cause of failure disappears, machine does not become normal until starting switch is turned
troller
to OFF position.
Problem on q "Hi" travel speed is slow. (Although "Hi" is diaplayed on machine monitor, actual travel speed is still
machine "Lo".)
q Controller's command (ON/OFF) to travel speed selector solenoid can be checked with monitoring
function. (If controller sends solenoid ON command, monitoring display is ON even if solenoid is
Related infor-
not switched ON due to short circuit.)
mation
(Code: 02300 Solenoid 1)
q Method of reproducing failure code: Start engine, set travel speed to High and operate travel lever.

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Defective travel speed 2. Disconnect connector V04, and connect T-adapter to male side.
1 selector solenoid (Internal
Between V04 (male) (1) and (2) Resistance 20 – 60 z
short circuit, ground fault)
Between V04 (male) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector C02 and connect T-adapter to female side.
Short circuit or ground fault
2
in wiring harness Between C02 (female) (87) and (115) or (117) or (120) Resistance 20 – 60 z
Between C02 (female) (87) and ground Resistance Min. 1 Mz
a If no abnormality is found in check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
Ground fault in wiring har-
2. Disconnect connectors C02 and V04, and connect T-adapter to female side of
3 ness
either connector.
(Contact with ground circuit)
Between C02 (female) (87) or V04 (female) (1) and
Resistance Min. 1 Mz
ground
If no abnormality is found by above checks, pump controller is defective. (Since this
4 Defective pump controller
is an internal failure, troubleshooting cannot be performed.)

40-274 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [DW43KB] Travel Speed Sol Short Circuit

Circuit diagram related to travel speed solenoid 40-275

PC228US-8,PC228USLC-8 40-275
(01)
Troubleshooting by failurecode
Failure code [DW45KA] Swing Brake Sol Open Circuit

Failure code [DW45KA] Swing Brake Sol Open Circuit 40-276

User code Failure code Swing brake solenoid open circuit
Failure
(Pump controller system)
E03 DW45KA
q When stops outputting current to swing brake solenoid, controller solenoid output voltage is above
Detail of failure
standard value and open circuit is detected.
Action of con- q None in particular. (Since no current flows, solenoid does not work. Swing brake is kept applied.)
troller q If cause of failure disappears, machine becomes normal by itself.
Problem on
q Machine cannot swing (Swing brake is not released)
machine
q If solenoid and wiring harness are normal, swing operation is possible by setting swing brake re-
lease switch to RELEASE position. (However, swing brake is not released while upper structure is
stopped. Swing brake continues to be applied.)
q Set swing brake release switch to RELEASE position during troubleshooting. When starting switch
is turned to ON position in this condition, normally current can flow in swing brake solenoid circuit
and break can be released.
Related infor-
q Controller's command (ON/OFF) to swing brake solenoid can be checked with monitoring function.
mation
(If controller sends solenoid ON command, monitoring display is ON even if solenoid is not
switched ON due to open circuit.)
(Code: 02300 Solenoid 1)
q Method of reproducing failure code: Turn starting switch to ON position.
q Swing brake solenoid circuit is powered from pin (101) of pump controller connector C02 or pin (1)
of fuse box F01.

Cause Procedure, measuring location, criteria and remarks

Blown No. 1 of fuse F01 (right top
1 If fuse has blown out, see [DW45KB].
fuse)
1. Turn starting switch to OFF position.
2 Defective swing brake solenoid 2. Disconnect connector V03, and connect T-adapter to male side.
Between V03 (male) (1) and (2) Resistance 20 – 60 z
1. Turn starting switch to OFF position.
2. Remove diode arrays D01 and D03, and connect T-adapters to their male
side.
a Check the continuity in diode range.
3 Defective diode array D01 or D03 Between D01 (male) (3) (+) and (7) (-) No continuity
Between D01 (male) (7) (+) and (3) (-) Continuity
Between D03 (male) (3) (+) and (7) (-) No continuity
Between D03 (male) (7) (+) and (3) (-) Continuity
1. Turn starting switch to OFF position.
2. Remove diode D01.
3. Disconnect connector C02 and connect T-adapter to each female side of
them.
a Swing lock switch OFF
Between C02 (female) (101) and D01 (female) (7) Resistance Max. 1 z
Open circuit in wiring harness
Between D01 (female) (3) and C02 (female) (115) Resistance 20 – 60 z
4 (Wire breakage or defective con-
tact of connector) a If no abnormality is found by above check, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors D01, C02, and V03, and connect T-adapter to each
female side of them.
Between D01 (female) (3) and V03 (female) (1) Resistance Max. 1 z
Between V03 (female) (2) and C02 (female) (115)
Resistance Max. 1 z
or (117) or (120)
If no abnormality is found by above checks, pump controller is defective.
5 Defective pump controller
(Since this is an internal failure, troubleshooting cannot be performed.)

40-276 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [DW45KA] Swing Brake Sol Open Circuit

Circuit diagram related to swing brake solenoid 40-27

PC228US-8,PC228USLC-8 40-277
(01)
Troubleshooting by failurecode
Failure code [DW45KB] Swing Brake Sol Short Circuit

Failure code [DW45KB] Swing Brake Sol Short Circuit 40-278

User code Failure code Swing brake solenoid short circuit
Failure
(Pump controller system)
E03 DW45KB
q When outputting current to swing brake solenoid, abnormal current flows in circuit and short circuit
Detail of failure
is detected.
q Stops outputting current to swing brake solenoid.
Action of con-
q Even if cause of failure disappears, machine does not become normal until starting switch is turned
troller
to OFF position.
Problem on
q Machine cannot swing (Swing brake is not released)
machine
q If solenoid and wiring harness are normal, swing operation is possible by setting swing brake re-
lease switch to RELEASE position. (However, swing brake is not released while upper structure is
stopped. Swing brake continues to be applied.)
q Keep swing lock switch in OFF position and swing holding brake release switch in RELEASE posi-
tion during troubleshooting. When starting switch is turned to ON position in this condition, normally
current can flow in swing brake solenoid circuit and brake can be released.
Related infor-
q Controller's command (ON/OFF) to swing brake solenoid can be checked with monitoring function.
mation
(If controller sends solenoid ON command, monitoring display is ON even if solenoid is not
switched ON due to short circuit.)
(Code: 02300 Solenoid 1)
q Method of reproducing failure code: Turn starting switch to ON position.
q Swing brake solenoid circuit is powered from pin (101) of pump controller connector C02 or pin (1)
of fuse box F01.

Cause Procedure, measuring location, criteria and remarks

Blown No. 1 of fuse F01 (right top Even if fuse is blown, perform troubleshooting according to following steps to
1
fuse) identify cause.
1. Turn starting switch to OFF position.
2. Disconnect connector V03, and connect T-adapter to male side.
2 Defective swing brake solenoid
Between V03 (male) (1) and (2) Resistance 20 – 60 z
Between V03 (male) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Remove diode arrays D01 and D03, and connect T-adapters to their male
side.
a Check the continuity in diode range.
3 Defective diode array D01 or D03 Between D01 (male) (3) (+) and (7) (-) No continuity
Between D01 (male) (7) (+) and (3) (-) Continuity
Between D03 (male) (3) (+) and (7) (-) No continuity
Between D03 (male) (7) (+) and (3) (-) Continuity
1. Turn starting switch to OFF position.
2. Remove No. 1 of fuse F01 (right top fuse, 10 A) and diode D01.
3. Disconnect connectors C02, D01 and V03.
Ground fault in wiring harness
4 4. Connect T-adapters to female sides of connectors C02 and D01.
(Contact with ground circuit)
Between C02 (female) (101) and ground Resistance Min. 1 Mz
Between D01 (female) (3) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Remove No. 1 of fuse F01 (right top fuse, 10 A) and diode D01.
3. Disconnect connector C02.
5 Short circuit in wiring harness 4. Connect T-adapters to female sides of connectors D01 and C02.
Between D01 (female) (3) and C02 (female) (115)
Resistance 20 – 60 z
or (117) or (120)
If no abnormality is found by above checks, pump controller is defective.
6 Defective pump controller
(Since this is an internal failure, troubleshooting cannot be performed.)

40-278 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [DW45KB] Swing Brake Sol Short Circuit

Circuit diagram related to swing brake 40-279

PC228US-8,PC228USLC-8 40-279
(01)
Troubleshooting by failurecode
Failure code [DW4GKA] Boom Slow Down Sol. Disc.

Failure code [DW4GKA] Boom Slow Down Sol. Disc. 40-280

User code Failure code Boom RAISE throttle EPC solenoid open circuit
Failure
(Pump controller system)
E41 DW4GKA
q When outputting current to boom RAISE throttle EPC solenoid, no current flows and open circuit is
Detail of failure
detected.
Action of con-
q If cause of failure disappears, machine becomes normal by itself.
troller
Problem on
q Boom RAISE does not function.
machine
q Turning the emergency operating switch of work equipment to ON, work equipment can be operat-
ed.
Related infor-
q Drive current of boom RAISE throttle EPC solenoid can be checked with monitoring function.
mation
(Code: 01800 Boom RAISE throttle EPC solenoid current)
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

Defective boom RAISE throttle 1. Turn starting switch to OFF position.

1 EPC solenoid (Internal short cir- 2. Disconnect connector V09, and connect T-adapter to male side.
cuit or ground fault) Between V09 (male) (1) and (2) Resistance 5 – 25 z
1. Turn starting switch to OFF position.
2. Disconnect connector S26, and connect T-adapter to male side.
a Measure work equipment emergency operation switch at normal posi-
Defective work equipment emer-
2 tion (lower side).
gency operation switch
Between S26 (male) (2) and (3) Resistance Max. 1 z
Between S26 (male) (5) and (6) Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect connector C02 and connect T-adapter to each female side of
them.
a Measure work equipment emergency operation switch at normal posi-
tion (lower side).
Between C02 (female) (105) and (115)
Open circuit in wiring harness (Resistance of boom RAISE throttle EPC solenoid Resistance 5 – 25 z
3 (Wire breakage or defective con- coil)
tact) a If no failure is found by above checks, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors C02 and V09, and connect T-adapters to each
female side of them.
Between C02 (female) (105) and V09 (female) (2) Resistance Max. 1 z
Between C02 (female) (115) and V09 (female) (1) Resistance Max. 1 z
4 Defective pump controller If cause is not found by above checks, pump controller is defective.

40-280 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [DW4GKA] Boom Slow Down Sol. Disc.

Circuit diagram related to boom RAISE throttle EPC solenoid 40-281

PC228US-8,PC228USLC-8 40-281
(01)
Troubleshooting by failurecode
Failure code [DW4GKB] Boom Slow Down Sol. Short Circuit

Failure code [DW4GKB] Boom Slow Down Sol. Short Circuit 40-282
User code Failure code Boom throttle EPC solenoid short circuit
Failure
(Pump controller system)
E41 DW4GKB
q When outputting current to boom RAISE throttle EPC solenoid, abnormal current flows and short
Detail of failure
circuit is detected.
q Stops outputting current to boom RAISE throttle EPC.
Action of con-
q Even if cause of failure disappears, machine does not become normal until starting switch is turned
troller
to OFF position.
Problem on
q Boom RAISE does not function.
machine
q Turning the emergency operating switch of work equipment to ON, work equipment can be operat-
ed.
Related infor-
q Drive current of boom raise adjust EPC solenoid can be checked with monitoring function.
mation
(Code: 01800 Boom RAISE throttle EPC solenoid current)
q Method of reproducing failure code: Start engine and operate lever to boom RAISE.

Cause Procedure, measuring location, criteria and remarks

Defective boom RAISE throttle 1. Turn starting switch to OFF position.

1 EPC solenoid (Internal short cir- 2. Disconnect connector V09, and connect T-adapter to male side.
cuit or ground fault) Between V09 (male) (1) and (2) Resistance 5 – 25 z
1. Turn starting switch to OFF position.
2. Disconnect connector S26, and connect T-adapter to male side.
a Measure work equipment emergency operation switch at normal posi-
Defective work equipment emer-
2 tion (lower side).
gency operation switch
Between S26 (male) (2) and (3) Resistance Max. 1 z
Between S26 (male) (5) and (6) Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect connectors C02 and V09, and connect T-adapters to each
female side of them.
Ground fault in wiring harness
3 a Measure work equipment emergency operation switch at normal posi-
(Contact with ground circuit)
tion (lower side).
Between C02 (female) (105) or V09 (female) (1)
Resistance Min. 1 Mz
and ground
1. Turn starting switch to OFF position.
2. Disconnect connectors C02 and V09, and connect T-adapter to female side
of either of them.
4 Short circuit in wiring harness a Measure work equipment emergency operation switch at normal posi-
tion (lower side).
Between C02 (female) (105) and (115), or between
Resistance Min. 1 Mz
V09 (female) (1) and (2)
5 Defective pump controller If cause is not found by above checks, pump controller is defective.

40-282 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [DW4GKB] Boom Slow Down Sol. Short Circuit

Circuit diagram related to boom RAISE throttle EPC solenoid 40-283

PC228US-8,PC228USLC-8 40-283
(01)
Troubleshooting by failurecode
Failure code [DW4WKA] Cancel Bucket Dump Open Circuit

Failure code [DW4WKA] Cancel Bucket Dump Open Circuit 40-284

User code Failure code Bucket DUMP prohibit EPC solenoid open circuit
Failure
(Pump controller system)
E50 DW4WKA
q When stop outputting current to bucket DUMP prohibit EPC solenoid, controller solenoid output
Detail of failure
voltage is above standard value and open circuit is detected.
Action of con- q None in particular (Since no current flows, solenoid does not operate).
troller q If cause of failure disappears, machine becomes normal by itself.

Problem on
q Bucket DUMP does not work.
machine
q This failure code is subject to be displayed only when arm crane mode (L) is selected for arm crane
Related infor- specification machine.
mation q Method of reproducing failure code: Turn starting switch to ON position and select arm crane mode
(L).

Cause Procedure, measuring location, criteria and remarks

Defective bucket DUMP prohibit 1. Turn starting switch to OFF position.

1 EPC solenoid (Internal open cir- 2. Disconnect connector Y08 and connect T-adapter to male side.
cuit) Between Y08 (male) (1) and (2) Resistance 20 – 60 z
1. Turn starting switch to OFF position.
Open or short circuit in wiring har- 2. Disconnect connector C02 and connect T-adapter to female side.
2
ness Between C02 (male) (94) and (115)
Resistance 20 – 60 z
(Resistance of EPC solenoid coil)
a If no failure is found by above checks, this check is not required.
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Disconnect connectors C02 and Y08 and connect T-adapter to each female
3 (Wire breakage or defective con- side of them.
tact) Between C02 (female) (94) and Y08 (female) (1) Resistance Max. 1 z
Between C02 (female) (115) and Y08 (female) (2) Resistance Max. 1 z
4 Defective pump controller If cause is not found by above checks, pump controller is defective.

40-284 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [DW4WKA] Cancel Bucket Dump Open Circuit

Circuit diagram related to bucket DUMP prohibit EPC solenoid 40-285

PC228US-8,PC228USLC-8 40-285
(01)
Troubleshooting by failurecode
Failure code [DW4WKB] Cancel Bucket Dump Short Circuit

Failure code [DW4WKB] Cancel Bucket Dump Short Circuit 40-286

User code Failure code Bucket DUMP prohibit EPC solenoid short circuit
Failure
(Pump controller system)
– DW4WKB
q When outputting current to bucket DUMP prohibit EPC solenoid, abnormal current flows in circuit
Detail of failure
and short circuit is detected.
q Stops outputting current to bucket DUMP prohibit EPC solenoid.
Action of con-
q Even if cause of failure disappears, machine does not become normal until starting switch is turned
troller
to OFF position.
Problem on
q Bucket DUMP does not work.
machine
q This failure code is detected only when other than arm crane mode (L) is set for the machine with
Related infor- arm crane specification.
mation q Method of reproducing failure code: Turn starting switch to ON position and select arm crane mode
(L).

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Defective bucket DUMP prohibit 2. Disconnect connector Y08 and connect T-adapter to male side.
1 EPC solenoid (Internal short cir-
Between Y08 (male) (1) and (2) Resistance 20 – 60 z
cuit or ground fault)
Between Y08 (male) (2) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
Open or short circuit in wiring har- 2. Disconnect connector C02 and connect T-adapter to female side.
2
ness Between C02 (male) (94) and (115)
Resistance 20 – 60 z
(Resistance of EPC solenoid coil)
1. Turn starting switch to OFF position.
2. Disconnect connectors C02 and Y08, and connect T-adapter to female side
Ground fault in wiring harness
3 of either of them.
(Contact with ground circuit)
Between C02 (female) (94) or Y08 (female) (1) and
Resistance Min. 1 Mz
ground
4 Defective pump controller If cause is not found by above checks, pump controller is defective.

40-286 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [DW4WKB] Cancel Bucket Dump Short Circuit

Circuit diagram related to bucket DUMP prohibit EPC solenoid 40-287

PC228US-8,PC228USLC-8 40-287
(01)
Troubleshooting by failurecode
Failure code [DW91KA] Travel Junction Sol. Disc.

Failure code [DW91KA] Travel Junction Sol. Disc. 40-28

User code Failure code Travel interconnection solenoid open circuit
Failure
(Pump controller system)
– DW91KA
q When stop outputting current to travel interconnection valve solenoid, controller solenoid output
Detail of failure
voltage is above standard value and open circuit is detected.
Action of con- q None in particular (Since no current flows, solenoid does not operate).
troller q If cause of failure disappears, machine becomes normal by itself.
Problem on
q Machine is not steered easily during travel.
machine
q Controller's command (ON/OFF) to travel junction valve solenoid can be checked with monitoring
function. (If controller sends solenoid ON command, monitoring display is ON even if solenoid is
Related infor-
not switched ON due to open circuit.)
mation
(Code: 02300 Solenoid 1)
q Method of reproducing failure code: Start engine and steer machine with right and left travel levers.

Cause Procedure, measuring location, criteria and remarks

Defective travel interconnection 1. Turn starting switch to OFF position.

1 solenoid 2. Disconnect connector V02, and connect T-adapter to male side.
(Internal open circuit) Between V02 (male) (1) and (2) Resistance 20 – 60 z
1. Turn starting switch to OFF position.
Open or short circuit in wiring har- 2. Disconnect connector C02 and connect T-adapter to female side.
2
ness Between C02 (female) (110) and (115) or (117) or
Resistance 20 – 60 z
(120)
a If no abnormality is found in checks on cause 2, this check is not required.
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Disconnect connectors C02 and V02, and connect T-adapters to each
3 (Wire breakage or defective con- female side of them.
tact of connector) Between C02 (female) (110) and V02 (female) (1) Resistance Max. 1 z
Between V02 (female) (2) and C02 (female) (115)
Resistance Max. 1 z
or (117) or (120)
If no abnormality is found by above checks, pump controller is defective.
4 Defective pump controller
(Since this is an internal failure, troubleshooting cannot be performed.)

40-288 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [DW91KA] Travel Junction Sol. Disc.

Circuit diagram related to travel interconnection valve solenoid 40-289

PC228US-8,PC228USLC-8 40-289
(01)
Troubleshooting by failurecode
Failure code [DW91KB] Travel Junction Sol. S/C

Failure code [DW91KB] Travel Junction Sol. S/C 40-290

User code Failure code Travel interconnection solenoid short circuit
Failure
(Pump controller system)
– DW91KB
q When outputting current to travel interconnection valve solenoid, abnormal current flows in circuit
Detail of failure
and short circuit is detected.
q Stop outputting current to travel junction solenoid.
Action of con-
q Even if cause of failure disappears, machine does not become normal until starting switch is turned
troller
to OFF position.
Problem on
q Machine is not steered easily during travel.
machine
q Controller's command (ON/OFF) to travel junction valve solenoid can be checked with monitoring
function. (If controller sends solenoid ON command, monitoring display is ON even if solenoid is not
Related infor-
switched ON due to short circuit.)
mation
(Code: 02300 Solenoid 1)
q Method of reproducing failure code: Start engine and steer machine with right and left travel levers.

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Defective travel interconnec-
2. Disconnect connector V02, and connect T-adapter to male side.
tion solenoid
1
(Internal short circuit or Between V02 (male) (1) and (2) Resistance 20 – 60 z
ground fault)
Between V02 (male) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector C02 and connect T-adapter to female side.
Short circuit or ground fault
2
in wiring harness Between C02 (female) (110) and (115) or (117) or (120) Resistance 20 – 60 z
Between C02 (female) (110) and ground Resistance Min. 1 Mz
a If no abnormality is found in checks on cause 2, this check is not required.
1. Turn starting switch to OFF position.
Ground fault in wiring har-
2. Disconnect connectors C02 and V02, and connect T-adapter to female side of
3 ness
either of them.
(Contact with ground circuit)
Between C02 (female) (110) or V02 (female) (1) and
Resistance Min. 1 Mz
ground
If no abnormality is found by above checks, pump controller is defective. (Since this
4 Defective pump controller
is an internal failure, troubleshooting cannot be performed.)

40-290 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [DW91KB] Travel Junction Sol. S/C

Circuit diagram related to travel interconnection valve solenoid 40-291

PC228US-8,PC228USLC-8 40-291
(01)
Troubleshooting by failurecode
Failure code [DWA2KA] Attachment Sol Open Circuit

Failure code [DWA2KA] Attachment Sol Open Circuit 40-292

User code Failure code Attachment single/multiple selector solenoid open circuit
Failure
(Pump controller system)
– DWA2KA
q When outputting current to attachment return selector solenoid, no current flows and open circuit
Detail of failure
is detected.
Action of con- q None in particular (Since no current flows, solenoid does not operate).
troller q If cause of failure disappears, machine becomes normal by itself.
Problem on
q Hydraulic circuit for attachment does not change to single-acting circuit.
machine
q Controller's command (ON/OFF) to attachment return selector solenoid can be checked with mon-
itoring function. (If controller sends solenoid ON command, monitoring display is ON even if sole-
Related infor- noid is not switched ON due to open circuit.)
mation (Code: 02301 Solenoid 2)
q Method of reproducing failure code: Turn starting switch ON and set machine in mode other than
breaker mode (B).

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Defective attachment return selec- 2. Disconnect connector V06, and connect T-adapter to male side.
1
tor solenoid (Internal open circuit)
Between V06 (male) (1) and (2) Resistance 20 – 60 z
1. Turn starting switch to OFF position.
Open circuit or ground fault in wir- 2. Disconnect connector C02 and connect T-adapter to female side.
2
ing harness Between C02 (female) (86) and C02 (female) (115)
Resistance 20 – 60 z
or (117) or (120)
a If no abnormality is found in checks on cause 2, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors C02 and V06, and connect T-adapters to each
Open circuit in wiring harness
female side of them.
3 (Wire breakage or defective con-
tact of connector) Between C02 (female) (86) and V06 (female) (1) Resistance Max. 1 z
Between V06 (female) (2) and C02 (female) (115)
Resistance Max. 1 z
or (117) or (120)
If no abnormality is found by above checks, pump controller is defective.
4 Defective pump controller
(Since this is an internal failure, troubleshooting cannot be performed.)

40-292 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [DWA2KA] Attachment Sol Open Circuit

Circuit diagram related to ATT single/multiple selector solenoid 40-293

PC228US-8,PC228USLC-8 40-293
(01)
Troubleshooting by failurecode
Failure code [DWA2KB] Attachment Sol Short Circuit

Failure code [DWA2KB] Attachment Sol Short Circuit 40-294

User code Failure code Attachment single/multiple selector solenoid short circuit
Failure
(Pump controller system)
– DWA2KB
q When outputting current to attachment return selector solenoid, abnormal current flows in circuit
Detail of failure
and short circuit is detected.
q Stops outputting current to attachment return selector solenoid.
Action of con-
q Even if cause of failure disappears, machine does not become normal until starting switch is turned
troller
to OFF position.
Problem on
q Hydraulic circuit for attachment does not change to single-acting circuit.
machine
q Controller's command (ON/OFF) to attachment return selector solenoid can be checked with mon-
itoring function. (If controller sends solenoid ON command, monitoring display is ON even if sole-
Related infor-
noid is not switched ON due to short circuit.)
mation
(Code: 02301 Solenoid 2)
q Method of reproducing failure code: Turn starting switch ON and set machine in breaker mode (B).

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Defective attachment return selec- 2. Disconnect connector V06, and connect T-adapter to male side.
1 tor solenoid (Internal short circuit,
Between V06 (male) (1) and (2) Resistance 20 – 60 z
ground fault)
Between V06 (male) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
Open circuit or ground fault in wir- 2. Disconnect connector C02 and connect T-adapter to female side.
2
ing harness Between C02 (female) (86) and (115) or (117) or
Resistance 20 – 60 z
(120)
a If no abnormality is found in checks on cause 2, this check is not required.
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors C02 and V06, and connect T-adapter to female side
3 of either of them.
(Contact with ground circuit)
Between C02 (female) (86) or V06 (female) (1) and
Resistance Min. 1 Mz
ground
If no abnormality is found by above checks, pump controller is defective.
4 Defective pump controller
(Since this is an internal failure, troubleshooting cannot be performed.)

40-294 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [DWA2KB] Attachment Sol Short Circuit

Circuit diagram related to ATT single/multiple selector solenoid 40-295

PC228US-8,PC228USLC-8 40-295
(01)
Troubleshooting by failurecode
Failure code [DWK0KA] 2-stage Relief Sol Open Circuit

Failure code [DWK0KA] 2-stage Relief Sol Open Circuit 40-296

User code Failure code 2-stage relief solenoid open circuit
Failure
(Pump controller system)
– DWK0KA
q When stop outputting current to 2-stage relief solenoid circuit, controller solenoid output voltage is
Detail of failure
above standard value and open circuit is detected.
Action of con- q None in particular (Since no current flows, solenoid does not operate).
troller q If cause of failure disappears, machine becomes normal by itself.
Problem on q Travel power is low (The main relief valve is not set in the HIGH PRESSURE position)
machine q One-touch power maximizing function does not work.
q Controller's command (ON/OFF) to 2-stage relief solenoid can be checked with monitoring func-
tion. (If controller sends solenoid ON command, monitoring display is ON even if solenoid is not
switched ON due to open circuit.)
Related infor- (Code: 02300 Solenoid 1)
mation q As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be mea-
sured at pump controller connector.
q Controller detects open circuit when no current is output to solenoid.
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Defective 2-stage relief solenoid 2. Disconnect connector V05, and connect T-adapter to male side.
1
(Internal open circuit)
Between V05 (male) (1) and (2) Resistance 20 – 60 z
1. Turn starting switch to OFF position.
2. Disconnect connector C02 and connect T-adapter to female side.
Open or short circuit in wiring har- a If resistance is above 1 Mz, wiring harness has open circuit. If resistance is
2 below 1 z, wiring harness has short circuit.
ness
Between C02 (female) (109) and (115) or
Resistance 20 – 60 z
(117) or (120)
a If cause 2 is not the cause for the trouble, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors C02 and V05, and connect T-adapters to each
Open circuit in wiring harness female side of them.
3 (Wire breakage or defective con- Between C02 (female) (109) and V05
tact of connector) Resistance Max. 1 z
(female) (1)
Between V05 (female) (2) and C02 (female)
Resistance Max. 1 z
(115) or (117) or (120)

If no abnormality is found by the above checks, pump controller may be defec-

4 Defective pump controller
tive. (Since this is an internal failure, troubleshooting cannot be performed.)

40-296 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [DWK0KA] 2-stage Relief Sol Open Circuit

Circuit diagram related to 2-stage relief solenoid 40-297

PC228US-8,PC228USLC-8 40-297
(01)
Troubleshooting by failurecode
Failure code [DWK0KB] 2-stage Relief Sol Short Circuit

Failure code [DWK0KB] 2-stage Relief Sol Short Circuit 40-298

User code Failure code 2-stage relief solenoid short circuit
Failure
(Pump controller system)
– DWK0KB
q When outputting current to drive 2-stage relief solenoid circuit, abnormal current flows in circuit and
Detail of failure
short circuit is detected.
q Stop outputting current to 2-stage relief solenoid circuit.
Action of con-
q Even if cause of failure disappears, machine does not become normal until starting switch is turned
troller
to OFF position.
Problem on q Travel power is low (The main relief valve is not set in the HIGH PRESSURE position)
machine q One-touch power maximizing function does not work.
q Controller's command (ON/OFF) to 2-stage relief solenoid can be checked with monitoring func-
tion. (If controller sends solenoid ON command, monitoring display is ON even if solenoid is not
switched ON due to short circuit.)
Related infor- (Code: 02300 Solenoid 1)
mation q As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be mea-
sured at pump controller connector.
q Controller detects open circuit when no current is output to solenoid.
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Defective 2-stage relief solenoid 2. Disconnect connector V05, and connect T-adapter to male side.
1 (Internal short circuit or ground
Between V05 (male) (1) and (2) Resistance 20 – 60 z
fault)
Between V05 (female) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connectors C02 and V05, and connect T-adapter to female side
Ground fault in wiring harness of V05.
2
(Contact with ground circuit)
Between C02 (female) (109) or V05 (female) (1)
Resistance Min. 1 Mz
and ground
1. Turn starting switch to OFF position.
2. Disconnect connectors C02 and V05, and connect T-adapter to female side
3 Short circuit in wiring harness of V05.
Between V05 (female) (1) and (2) Resistance Min. 1 Mz

If no abnormality is found by the above checks, pump controller may be defec-

4 Defective pump controller
tive. (Since this is an internal failure, troubleshooting cannot be performed.)

40-298 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [DWK0KB] 2-stage Relief Sol Short Circuit

Circuit diagram related to 2-stage relief solenoid 40-29

PC228US-8,PC228USLC-8 40-299
(01)
Troubleshooting by failurecode
Failure code [DXA8KA] PC-EPC (F) Sol Open Circuit

Failure code [DXA8KA] PC-EPC (F) Sol Open Circuit 40-30

User code Failure code F-PC-EPC solenoid system open circuit
Failure
(Pump controller system)
E02 DXA8KA
Detail of failure q When F-PC-EPC solenoid is driven, no current flows and open circuit is detected.
Action of con- q None in particular (Since no current flows, solenoid does not operate).
troller q If cause of failure disappears, machine becomes normal by itself.
Problem on
q If the pump load increases, the engine speed lowers sharply and may cause engine stall.
machine
q When solenoid and wiring harness are normal, engine can be prevented from stalling by turning
emergency pump drive switch to ON.
Related infor-
q Drive current of F-PC-EPC solenoid can be checked with monitoring function.
mation
(Code: 01300 PC-EPC solenoid current (F))
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Defective F-PC-EPC solenoid 2. Disconnect connector V11, and connect T-adapter to male side.
1
(Internal open circuit)
Between V11 (male) (1) and (2) Resistance 3 – 14 z
1. Turn starting switch to OFF position.
2. Disconnect connector S25, and connect T-adapter to male side.
Switch position: Normal Resistance Max. 1 z
Emergency pump drive switch Between S25 (male) (3)
and (2) Switch position: Emer-
2 defective Resistance Min. 1 Mz
gency
(Internal open circuit in wiring)
Switch position: Normal Resistance Max. 1 z
Between S25 (male) (6)
and (5) Switch position: Emer-
Resistance Min. 1 Mz
gency
1. Turn starting switch to OFF position.
2. Disconnect connector C02 and connect T-adapter to female side.
Open or short circuit in wiring har- a Check that emergency pump drive switch is at normal position (lower side).
3
ness
Between C02 (female) (96) and (115) or (117) or
Resistance 3 – 14 z
(120)
a If no abnormality is found in checks on cause 3, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors C02, S25 and V11, and connect T-adapters to each
female side of them.
Open circuit in wiring harness Between C02 (female) (96) and S25 (female) (3) Resistance Max. 1 z
4 (Wire breakage or defective con-
tact of connector) Between S25 (female) (2) and V11 (female) (1) Resistance Max. 1 z
Between S25 (female) (6) and C02 (female) (115)
Resistance Max. 1 z
or (117) or (120)
Between S25 (female) (5) and V11 (female) (2) Resistance Max. 1 z
If no abnormality is found by above checks, pump controller is defective.
5 Defective pump controller
(Since this is an internal failure, troubleshooting cannot be performed.)

40-300 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [DXA8KA] PC-EPC (F) Sol Open Circuit

Circuit diagram related to PC-EPC solenoid 40-301

PC228US-8,PC228USLC-8 40-301
(01)
Troubleshooting by failurecode
Failure code [DXA8KB] PC-EPC (F) Sol Short Circuit

Failure code [DXA8KB] PC-EPC (F) Sol Short Circuit 40-302

User code Failure code F-PC-EPC solenoid system short circuit
Failure
(Pump controller system)
E02 DXA8KB
Detail of failure q When F-PC-EPC solenoid is driven, abnormal current flows in circuit and short circuit is detected.
q Stops outputting current to F-PC-EPC solenoid.
Action of con-
q Even if cause of failure disappears, machine does not become normal until starting switch is turned
troller
to OFF position.
Problem on
q If the pump load increases, the engine speed lowers sharply and may cause engine stall.
machine
q When solenoid and wiring harness are normal, engine can be prevented from stalling by turning
emergency pump drive switch to ON.
Related infor-
q Drive current of F-PC-EPC solenoid can be checked with monitoring function.
mation
(Code: 01300 PC-EPC solenoid current (F))
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Defective F-PC-EPC solenoid 2. Disconnect connector V11, and connect T-adapter to male side.
1 (Internal short circuit or ground
Between V11 (male) (1) and (2) Resistance 3 – 14 z
fault)
Between V11 (male) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector S25, and connect T-adapter to male side.
Defective emergency pump drive
2 switch (Internal short circuit or Between S25 (male) (2) or (3) and (5) Resistance Min. 1 Mz
ground fault) Switch posi-
Between S25 (male) (2) or (3) and tion: Normal Resistance Min. 1 Mz
ground
1. Turn starting switch to OFF position.
2. Disconnect connector C02 and connect T-adapter to female side.
a Check that emergency pump drive switch is at normal position (lower side).
Short circuit or ground fault in wir-
3 Between C02 (female) (96) and (115) or (117) or
ing harness Resistance 3 – 14 z
(120)
Between C02 (female) (96) and ground Resistance Min. 1 Mz
a If no abnormality is found in checks on cause 3, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors C02, S25 and V11, and connect T-adapter to
female side of either connector.
Ground fault in wiring harness
4 Between C02 (female) (96) or S25 (female) (3) and
(Contact with ground circuit) Resistance Min. 1 Mz
ground
Between S25 (female) (5) or V11 (female) (2) and
Resistance Min. 1 Mz
ground
If no abnormality is found by above checks, pump controller is defective.
5 Defective pump controller
(Since this is an internal failure, troubleshooting cannot be performed.)

40-302 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [DXA8KB] PC-EPC (F) Sol Short Circuit

Circuit diagram related to PC-EPC solenoid 40-303

PC228US-8,PC228USLC-8 40-303
(01)
Troubleshooting by failurecode
Failure code [DXA9KA] PC-EPC (R) Sol Open Circuit

Failure code [DXA9KA] PC-EPC (R) Sol Open Circuit 40-304

User code Failure code R-PC-EPC solenoid system open circuit
Failure
(Pump controller system)
E02 DXA9KA
Detail of failure q When R-PC-EPC solenoid is driven, no current flows and open circuit is detedted.
Action of con- q None in particular (Since no current flows, solenoid does not operate).
troller q If cause of failure disappears, machine becomes normal by itself.
Problem on
q If the pump load increases, the engine speed lowers sharply and may cause engine stall.
machine
q When solenoid and wiring harness are normal, engine can be prevented from stalling by turning
emergency pump drive switch to ON.
Related infor-
q Drive current of R-PC-EPC solenoid can be checked with monitoring function.
mation
(Code: 01300 PC-EPC solenoid current (R))
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Defective R-PC-EPC solenoid 2. Disconnect connector V12, and connect T-adapter to male side.
1
(Internal open circuit)
Between V12 (male) (1) and (2) Resistance 3 – 14 z
1. Turn starting switch to OFF position.
2. Disconnect connector S25, and connect T-adapter to male side.
Switch position: Normal Resistance Max. 1 z
Emergency pump drive switch Between S25 (male) (3)
and (2) Switch position: Emer-
2 defective Resistance Min. 1 Mz
gency
(Internal open circuit)
Switch position: Normal Resistance Max. 1 z
Between S25 (male) (6)
and (5) Switch position: Emer-
Resistance Min. 1 Mz
gency
1. Turn starting switch to OFF position.
2. Disconnect connector C02 and connect T-adapter to female side.
Open or short circuit in wiring har- a Check that emergency pump drive switch is at normal position (lower side).
3
ness
Between C02 (female) (96) and (115) or (117) or
Resistance 3 – 14 z
(120)
a If no abnormality is found in checks on cause 3, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors C02, S25 and V12, and connect T-adapters to each
female side of them.
Open circuit in wiring harness Between C02 (female) (96) and S25 (female) (3) Resistance Max. 1 z
4 (Wire breakage or defective con-
tact of connector) Between S25 (female) (2) and V12 (female) (1) Resistance Max. 1 z
Between S25 (female) (6) and C02 (female) (115)
Resistance Max. 1 z
or (117) or (120)
Between S25 (female) (5) and V12 (female) (2) Resistance Max. 1 z
If no abnormality is found by above checks, pump controller is defective.
5 Defective pump controller
(Since this is an internal failure, troubleshooting cannot be performed.)

40-304 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [DXA9KA] PC-EPC (R) Sol Open Circuit

Circuit diagram related to PC-EPC solenoid 40-305

PC228US-8,PC228USLC-8 40-305
(01)
Troubleshooting by failurecode
Failure code [DXA9KB] PC-EPC (R) Sol Short Circuit

Failure code [DXA9KB] PC-EPC (R) Sol Short Circuit 40-306

User code Failure code R-PC-EPC solenoid system short circuit
Failure
(Pump controller system)
E02 DXA9KB
Detail of failure q When R-PC-EPC solenoid is driven, abnormal current flows and short circuit is detected.
q Stops outputting current to R-PC-EPC solenoid.
Action of con-
q Even if cause of failure disappears, machine does not become normal until starting switch is turned
troller
to OFF position.
Problem on
q If the pump load increases, the engine speed lowers sharply and may cause engine stall.
machine
q When solenoid and wiring harness are normal, engine can be prevented from stalling by turning
emergency pump drive switch to ON.
Related infor-
q Drive current of R-PC-EPC solenoid can be checked with monitoring function.
mation
(Code: 01300 PC-EPC solenoid current (R))
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Defective R-PC-EPC solenoid 2. Disconnect connector V12, and connect T-adapter to male side.
1 (Internal short circuit or ground
Between V12 (male) (1) and (2) Resistance 3 – 14 z
fault)
Between V12 (male) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector S25, and connect T-adapter to male side.
Defective emergency pump drive
2 switch (Internal short circuit or Between S25 (male) (2) or (3) and (5) Resistance Min. 1 Mz
ground fault) Switch posi-
Between S25 (male) (2) or (3) and tion: Normal Resistance Min. 1 Mz
ground
1. Turn starting switch to OFF position.
2. Disconnect connector C02 and connect T-adapter to female side.
a Check that emergency pump drive switch is at normal position (lower side).
Short circuit or ground fault in wir-
3 Between C02 (female) (96) and (115) or (117) or
ing harness Resistance 3 – 14 z
(120)
Between C02 (female) (96) and ground Resistance Min. 1 Mz
a If no abnormality is found in checks on cause 3, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors C02, S25 and V12, and connect T-adapter to
female side of either connector.
Ground fault in wiring harness
4 Between C02 (female) (96) or S25 (female) (3) and
(Contact with ground circuit) Resistance Min. 1 Mz
ground
Between S25 (female) (5) or V12 (female) (2) and
Resistance Min. 1 Mz
ground
If no abnormality is found by above checks, pump controller is defective.
5 Defective pump controller
(Since this is an internal failure, troubleshooting cannot be performed.)

40-306 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [DXA9KB] PC-EPC (R) Sol Short Circuit

Circuit diagram related to PC-EPC solenoid 40-307

PC228US-8,PC228USLC-8 40-307
(01)
Troubleshooting by failurecode
Failure code [DXE0KA] LS-EPC Sol Open Circuit

Failure code [DXE0KA] LS-EPC Sol Open Circuit 40-308

User code Failure code LS-EPC solenoid system open circuit
Failure
(Pump controller system)
– DXE0KA
Detail of failure q When LS-EPC solenoid is driven, no current flows and open circuit is detected .
Action of con- q None in particular (Since no current flows, solenoid does not operate).
troller q If cause of failure disappears, machine becomes normal by itself.
Problem on q Travel speed is high at Lo and Mi.
machine q Work equipment speed and swing speed are high in fine control mode (L).
q Drive current of LS-EPC solenoid can be checked with monitoring function.
Related infor-
(Code: 01500 LS-EPC solenoid current)
mation
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Defective LS-EPC solenoid 2. Disconnect connector V19, and connect T-adapter to male side.
1
(Internal open circuit)
Between V19 (male) (1) and (2) Resistance 3 – 14 z
1. Turn starting switch to OFF position.
Open or short circuit in wiring har- 2. Disconnect connector C02 and connect T-adapter to female side.
2
ness Between C02 (female) (88) and (115) or (117) or
Resistance 3 – 14 z
(120)
a If cause 2 is not the cause of failure, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors C02 and V19, and connect T-adapters to each
Open circuit in wiring harness
female side of them.
3 (Wire breakage or defective con-
tact of connector) Between C02 (female) (88) and V19 (female) (1) Resistance Max. 1 z
Between V19 (female) (2) and C02 (female) (115)
Resistance Max. 1 z
or (117) or (120)
If no abnormality is found by above checks, pump controller is defective.
4 Defective pump controller
(Since this is an internal failure, troubleshooting cannot be performed.)

40-308 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [DXE0KA] LS-EPC Sol Open Circuit

Circuit diagram related to LS-EPC solenoid 40-309

PC228US-8,PC228USLC-8 40-309
(01)
Troubleshooting by failurecode
Failure code [DXE0KB] LS-EPC Sol Short Circuit

Failure code [DXE0KB] LS-EPC Sol Short Circuit 40-310

User code Failure code LS-EPC solenoid system short circuit
Failure
(Pump controller system)
– DXE0KB
Detail of failure q When LS-EPC solenoid is driven, abnormal current flows and short circuit is detected .
q Stops outputting current to LS-EPC solenoid.
Action of con-
q Even if cause of failure disappears, machine does not become normal until starting switch is turned
troller
to OFF position.
Problem on q Travel speed is high at Lo and Mi.
machine q Work equipment speed and swing speed are high in fine control mode (L).
q Drive current of LS-EPC solenoid can be checked with monitoring function.
Related infor-
(Code: 01500 LS-EPC solenoid current)
mation
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Defective LS-EPC solenoid 2. Disconnect connector V19 and connect T-adapter to male side.
1 (Internal short circuit or ground
Between V19 (male) (1) and (2) Resistance 3 – 14 z
fault)
Between V19 (male) (2) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector C02 and connect T-adapter to female side.
Short circuit or ground fault in wir-
2 Between C02 (female) (88) and (115) or (117) or
ing harness Resistance 3 – 14 z
(120)
Between C02 (female) (88) and ground Resistance Min. 1 Mz
a If cause 2 is not the cause of failure, this check is not required.
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors C02 and V19, and connect T-adapter to female side
3 of either of them.
(Contact with ground circuit)
Between C02 (female) (88) or V19 (female) (1) and
Resistance Min. 1 Mz
ground
If no abnormality is found by above checks, pump controller is defective.
4 Defective pump controller
(Since this is an internal failure, troubleshooting cannot be performed.)

40-310 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [DXE0KB] LS-EPC Sol Short Circuit

Circuit diagram related to LS-EPC solenoid 40-31

PC228US-8,PC228USLC-8 40-311
(01)
Troubleshooting by failurecode
Failure code [DXE4KA] Service Current EPC Disc.

Failure code [DXE4KA] Service Current EPC Disc. 40-312

User code Failure code Service flow throttle EPC open circuit
Failure
(Pump controller system)
– DXE4KA
Detail of failure q When service flow throttle EPC solenoid is driven, no current flows and ope circuit is detected.
Action of con- q None in particular (Since no current flows, solenoid does not operate).
troller q If cause of failure disappears, machine becomes normal by itself.
Problem on
q Attachment does not move.
machine
q Drive current of service current EPC solenoid can be checked with monitoring function.
Related infor-
(Code: 01700 Service solenoid current)
mation
q Method of reproducing failure code: Turn starting switch ON and set machine in breaker mode (B).

Cause Procedure, measuring location, criteria and remarks

Defective service current EPC 1. Turn starting switch to OFF position.

1 solenoid for attachment (Internal 2. Disconnect connector V30, and connect T-adapter to male side.
open circuit) Between V30 (male) (1) and (2) Resistance 3 – 14 z
1. Turn starting switch to OFF position.
Open or short circuit in wiring har- 2. Disconnect connector C02 and connect T-adapter to female side.
2
ness Between C02 (female) (97) and (115) or (117) or
Resistance 3 – 14 z
(120)
a If cause 2 is not the cause of failure, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors C02 and V30, and connect T-adapters to each
Open circuit in wiring harness
female side of them.
3 (Wire breakage or defective con-
tact of connector) Between C02 (female) (97) and V30 (female) (1) Resistance Max. 1 z
Between V30 (female) (2) and C02 (female) (115)
Resistance Max. 1 z
or (117) or (120)
If no abnormality is found by above checks, pump controller is defective.
4 Defective pump controller
(Since this is an internal failure, troubleshooting cannot be performed.)

40-312 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [DXE4KA] Service Current EPC Disc.

Circuit diagram related to service flow throttle EPC 40-313

PC228US-8,PC228USLC-8 40-313
(01)
Troubleshooting by failurecode
Failure code [DXE4KB] Service Current EPC S/C

Failure code [DXE4KB] Service Current EPC S/C 40-314

User code Failure code Service flow throttle EPC short circuit
Failure
(Pump controller system)
– DXE4KB
q When service flow throttle EPC solenoid is driven, abnormal current flows and short circuit is de-
Detail of failure
tected .
q Stops outputting current to service EPC solenoid.
Action of con-
q Even if cause of failure disappears, machine does not become normal until starting switch is turned
troller
to OFF position.
Problem on
q Attachment does not move.
machine
q Drive current of service flow adjust EPC solenoid can be checked with monitoring function.
Related infor-
(Code: 01700 Service solenoid current)
mation
q Method of reproducing failure code: Turn starting switch ON and set machine in breaker mode (B).

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Defective service EPC solenoid 2. Disconnect connector V30, and connect T-adapter to male side.
1 (Internal short circuit or ground
Between V30 (male) (1) and (2) Resistance 3 – 14 z
fault)
Between V30 (male) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector C02 and connect T-adapter to female side.
Short circuit or ground fault in wir-
2 Between C02 (female) (97) and (115) or (117) or
ing harness Resistance 3 – 14 z
(120)
Between C02 (female) (97) and ground Resistance Min. 1 Mz
a If cause 2 is not the cause of failure, this check is not required.
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors C02 and V30, and connect T-adapter to female side
3 of either connector.
(Contact with ground circuit)
Between C02 (female) (97) or V30 (female) (1) and
Resistance Min. 1 Mz
ground
If no abnormality is found by above checks, pump controller is defective.
4 Defective pump controller
(Since this is an internal failure, troubleshooting cannot be performed.)

40-314 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [DXE4KB] Service Current EPC S/C

Circuit diagram related to service flow throttle EPC 40-315

PC228US-8,PC228USLC-8 40-315
(01)
Troubleshooting by failurecode
Failure code [DXE5KA] Merge-divider Main Sol Open Circuit

Failure code [DXE5KA] Merge-divider Main Sol Open Circuit 40-316

User code Failure code Merge-divider main solenoid open circuit
Failure
(Pump controller system)
– DXE5KA
q When pump merge-divider (main) EPC solenoid is driven, no current flows and open circuit is de-
Detail of failure
tected .
q None in particular (Since no current flows, merge-divider main solenoid does not operate. Since no
Action of con- current flows, merge-divider LS solenoid does not operate, either.)
troller q Even if cause of failure disappears, machine does not become normal until starting switch is turned
to OFF position.
Problem on q Single operation speed of work equipment and swing is high in fine control mode (L).
machine q Machine cannot be steered easily during travel.
q Drive current of merge-divider main EPC solenoid can be checked with monitoring function.
Related infor-
(Code: 08000 Merge-divider (main) solenoid current)
mation
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Defective merge-divider main EPC 2. Disconnect connector V23, and connect T-adapter to male side.
1
solenoid (internal open circuit)
Between V23 (male) (1) and (2) Resistance 3 – 14 z
1. Turn starting switch to OFF position.
Open or short circuit in wiring har- 2. Disconnect connector C02 and connect T-adapter to female side.
2
ness Between C02 (female) (112) and (115) or (117) or
Resistance 3 – 14 z
(120)
a If cause 2 is not the cause of failure, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors C02 and V23, and connect T-adapters to each
Open circuit in wiring harness
female side of them.
3 (Wire breakage or defective con-
tact of connector) Between C02 (female) (112) and V23 (female) (1) Resistance Max. 1 z
Between V23 (female) (2) and C02 (female) (115)
Resistance Max. 1 z
or (117) or (120)
If no abnormality is found by above checks, pump controller is defective.
4 Defective pump controller
(Since this is an internal failure, troubleshooting cannot be performed.)

40-316 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [DXE5KA] Merge-divider Main Sol Open Circuit

Circuit diagram related to pump merge-divider main solenoid 40-317

PC228US-8,PC228USLC-8 40-317
(01)
Troubleshooting by failurecode
Failure code [DXE5KB] Merge-divider Main Sol Short Circuit

Failure code [DXE5KB] Merge-divider Main Sol Short Circuit 40-318

User code Failure code Merge-divider main solenoid short circuit
Failure
(Pump controller system)
– DXE5KB
q When pump merge-divider (main) EPC solenoid is driven, abnormal current flows and short circuit
Detail of failure
is detected.
q Stops outputting current to merge-divider (main) EPC solenoid. (Since no current flows, merge-di-
Action of con- vider LS solenoid does not operate, either.)
troller q Even if cause of failure disappears, machine does not become normal until starting switch is turned
to OFF position.
Problem on q Single operation speed of work equipment and swing is high in fine control mode (L).
machine q Machine cannot be steered easily during travel.
q Drive current of merge-divider main EPC solenoid can be checked with monitoring function.
Related infor-
(Code: 08000 Merge-divider (main) solenoid current)
mation
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Defective merge-divider main EPC 2. Disconnect connector V23, and connect T-adapter to male side.
1 solenoid (internal short circuit or
Between V23 (male) (1) and (2) Resistance 3 – 14 z
ground fault)
Between V23 (male) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector C02 and connect T-adapter to female side.
Short circuit or ground fault in wir-
2 Between C02 (female) (112) and (115) or (117) or
ing harness Resistance 3 – 14 z
(120)
Between C02 (female) (112) and ground Resistance Min. 1 Mz
a If cause 2 is not the cause of failure, this check is not required.
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors C02 and V23, and connect T-adapter to female side
3 of either of them.
(Contact with ground circuit)
Between C02 (female) (112) or V23 (female) (1)
Resistance Min. 1 Mz
and ground
If no abnormality is found by above checks, pump controller is defective.
4 Defective pump controller
(Since this is an internal failure, troubleshooting cannot be performed.)

40-318 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [DXE5KB] Merge-divider Main Sol Short Circuit

Circuit diagram related to pump merge-divider main solenoid 40-319

PC228US-8,PC228USLC-8 40-319
(01)
Troubleshooting by failurecode
Failure code [DXE6KA] Merge-divider LS Sol Open Circuit

Failure code [DXE6KA] Merge-divider LS Sol Open Circuit 40-320

User code Failure code Merge-divider LS solenoid open circuit
Failure
(Pump controller system)
– DXE6KA
q When pump merge-divider (LS) EPC solenoid is driven, no current flows and open circuit is detect-
Detail of failure
ed.
q None in particular (Since no current flows, merge-divider LS solenoid does not operate. Since no
Action of con- current flows, merge-divider main solenoid does not operate, either.)
troller q Even if cause of failure disappears, machine does not become normal until starting switch is turned
to OFF position.
Problem on q Single operation speed of work equipment and swing is high in fine control mode (L).
machine q Machine cannot be steered easily during travel.
q Drive current of merge-divider LS EPC solenoid can be checked with monitoring function.
Related infor-
(Code: 08001 Merge-divider (LS) solenoid current)
mation
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Defective merge-divider LS EPC 2. Disconnect connector V24, and connect T-adapter to male side.
1
solenoid (internal open circuit)
Between V24 (male) (1) and (2) Resistance 3 – 14 z
1. Turn starting switch to OFF position.
Open or short circuit in wiring har- 2. Disconnect connector C02 and connect T-adapter to female side.
2
ness Between C02 (female) (89) and (115) or (117) or
Resistance 3 – 14 z
(120)
a If cause 2 is not the cause of failure, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors C02 and V24, and connect T-adapters to each
Open circuit in wiring harness
female side of them.
3 (Wire breakage or defective con-
tact of connector) Between C02 (female) (89) and V24 (female) (1) Resistance Max. 1 z
Between V24 (female) (2) and C02 (female) (115)
Resistance Max. 1 z
or (117) or (120)
If no abnormality is found by above checks, pump controller is defective.
4 Defective pump controller
(Since this is an internal failure, troubleshooting cannot be performed.)

40-320 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [DXE6KA] Merge-divider LS Sol Open Circuit

Circuit diagram related to pump merge-divider LS solenoid 40-321

PC228US-8,PC228USLC-8 40-321
(01)
Troubleshooting by failurecode
Failure code [DXE6KB] Merge-divider LS Sol Short Circuit

Failure code [DXE6KB] Merge-divider LS Sol Short Circuit 40-32

User code Failure code Merge-divider LS solenoid short circuit
Failure
(Pump controller system)
– DXE6KB
q When pump merge-divider (LS) EPC solenoid is driven, abnormal current flows and short circuit is
Detail of failure
detected.
q Stops outputting current to merge-divider (LS) EPC solenoid. (Since no current flows, merge-divid-
Action of con- er main solenoid does not operate, either.)
troller q Even if cause of failure disappears, machine does not become normal until starting switch is turned
to OFF position.
Problem on q Single operation speed of work equipment and swing is high in fine control mode (L).
machine q Machine cannot be steered easily during travel.
q Drive current of merge-divider LS EPC solenoid can be checked with monitoring function.
Related infor-
(Code: 08000 Merge-divider (LS) solenoid current)
mation
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Defective merge-divider LS EPC 2. Disconnect connector V24, and connect T-adapter to male side.
1 solenoid (internal short circuit or
Between V24 (male) (1) and (2) Resistance 3 – 14 z
ground fault)
Between V24 (male) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector C02 and connect T-adapter to female side.
Short circuit or ground fault in wir-
2 Between C02 (female) (89) and (115) or (117) or
ing harness Resistance 3 – 14 z
(120)
Between C02 (female) (89) and ground Resistance Min. 1 Mz
a If cause 2 is not the cause of failure, this check is not required.
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors C02 and V24, and connect T-adapter to female side
3 of either of them.
(Contact with ground circuit)
Between C02 (female) (89) or V24 (female) (1) and
Resistance Min. 1 Mz
ground
If no abnormality is found by above checks, pump controller is defective.
4 Defective pump controller
(Since this is an internal failure, troubleshooting cannot be performed.)

40-322 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [DXE6KB] Merge-divider LS Sol Short Circuit

Circuit diagram related to pump merge-divider LS solenoid 40-323

PC228US-8,PC228USLC-8 40-323
(01)
Troubleshooting by failurecode
Failure code [DY20KA] Wiper Working Abnormality

Failure code [DY20KA] Wiper Working Abnormality 40-324

User code Failure code Wiper working abnormality
Failure
(Pump controller system)
– DY20KA
Detail of failure q When windshield wiper works, W signal of working ends is not input.
Action of con- q Stops outputting current to wiper motor.
troller q If cause of failure disappears, machine becomes normal by itself.
Problem on
q Wiper motor does not work.
machine
q
Signal input (ON/OFF) of W contact signal that indicates wiper working area end can be checked
with monitoring function.
(Code: 02204 Switch input 5)
Related infor- q As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be mea-
mation sured at pump controller connector.
a Single wiper does not have lower wiper of double wiper (Upper wiper is called wiper).
q Method of reproducing failure code: Turn starting switch to ON position and set wiper switch to INT
or ON.

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connector M05 and connect T-adapter to female side.
Wiper position: working
Resistance Max. 1 z
Defective wiper motor Between M05 (female) area end
1
(Internal open circuit) (6) and (5) Wiper position: other than
Resistance Min. 1 Mz
working area end
Between M05 (female) Wiper position: whole
Resistance Max. 20 z
(1) and (3) range
1. Turn starting switch to OFF position.
2. Disconnect connectors C01 and C02 and connect T-adapters to female
side of them.
Wiper position: working
Open or short circuit in wiring har- Resistance Max. 1 z
2 Between C01 (female) area end
ness
(56) and ground Wiper position: other than
Resistance Min. 1 Mz
working area end
Between C02 (female) Wiper position: whole
Resistance Max. 20 z
(114) and (119) range
a If cause 2 is not the cause of failure, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors CP01, CP02, and M05.
3. Connect T-adapters to female sides of connector CP01 and CP02 and male
Open circuit in wiring harness side of M05.
3 (Wire breakage or defective con- Between C01 (female) (56) and M05 (male) (6) Resistance Max. 1 z
tact of connector)
Between M05 (male) (5) and ground (T05) Resistance Max. 1 z
Between C02 (female) (114) and M05 (male) (1) Resistance Max. 1 z
Between C02 (female) (119) and M05 (male) (3) Resistance Max. 1 z
If no abnormality is found by above checks, pump controller is defective.
4 Defective pump controller
(Since this is an internal failure, troubleshooting cannot be performed.)

40-324 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [DY20KA] Wiper Working Abnormality

Circuit diagram related to wiper 40-325

PC228US-8,PC228USLC-8 40-325
(01)
Troubleshooting by failurecode
Failure code [DY20MA] Wiper Parking Abnormality

Failure code [DY20MA] Wiper Parking Abnormality 40-326

User code Failure code Wiper resting abnormality
Failure
(Pump controller system)
– DY20MA
Detail of failure q When windshield wiper rests, P signal for rest area is not input.
Action of con- q Stops outputting current to rest wiper motor.
troller q If cause of failure disappears, machine becomes normal by itself.
Problem on
q Wiper motor does not rest.
machine
q Condition of P contact signal of wiper resting area can be checked with monitoring function.
(Code: 02204 Switch input 5)
Related infor- q As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be mea-
mation sured at pump controller connector.
q Method of reproducing failure code: Turn starting switch to ON position and set wiper switch from
INT/ON to OFF.

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connector M05 and connect T-adapter to female side.

Defective wiper motor Wiper position: rest area Resistance Max. 1 z

1 Between M05 (female)
(Internal open circuit) (4) and (5) Wiper position: working
Resistance Min. 1 Mz
area
Between M05 (female) Wiper position: whole
Resistance Max. 20 z
(1) and (3) range
1. Turn starting switch to OFF position.
2. Disconnect diode arrays C01 and C02 and connect T-adapters to each
female side of them.
Open or short circuit in wiring har- Wiper position: rest area Resistance Max. 1 z
2 Between C01 (female)
ness Wiper position: working
(75) and ground Resistance Min. 1 Mz
area
Between C02 (female) Wiper position: whole
Resistance Max. 20 z
(114) and (119) range
a If cause 2 is not the cause of failure, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors C01, C02, and M05.
3. Connect T-adapters to female sides of connector C01 and C02 and male
Open circuit in wiring harness side of M05.
3 (Wire breakage or defective con- Between C01 (female) (75) and M05 (male) (4) Resistance Max. 1 z
tact of connector)
Between M05 (male) (5) and ground (T05) Resistance Max. 1 z
Between C02 (female) (114) and M05 (male) (1) Resistance Max. 1 z
Between C02 (female) (119) and M05 (male) (3) Resistance Max. 1 z
If no abnormality is found by above checks, pump controller is defective.
4 Defective pump controller
(Since this is an internal failure, troubleshooting cannot be performed.)

40-326 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [DY20MA] Wiper Parking Abnormality

Circuit diagram related to wiper 40-327

PC228US-8,PC228USLC-8 40-327
(01)
Troubleshooting by failurecode
Failure code [DY2CKA] Washer drive discon

Failure code [DY2CKA] Washer drive discon 40-328

User code Failure code Window washer drive system open circuit
Failure
(Pump controller system)
– DY2CKA
q When stop outputting current to window washer drive, no voltage is applied to output pin (pin No.
Detail of failure
3) of controller and open circuit is detected.
Action of con- q None in particular (Washer motor does not work because no current flows to it).
troller q If cause of failure disappears, machine becomes normal by itself.
Problem on
q Window washer does not operate.
machine
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation

Cause Procedure, measuring location, criteria and remarks

If the fuse is broken, the circuit probably has a grounding fault, etc. (See
1 Defective fuse No.4
Cause 6.)
1. Turn starting switch to OFF position.
Defective washer motor 2. Disconnect diode array M06 and connect T-adapter to male side.
2 (internal open circuit or ground
Between M06 (male) (1) and (2) Resistance 5 – 20 z
fault)
Between ground and M06 (male) (1) or (2) Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector D02 and connect T-adapter to male side.
Defective diode array D02
3
(Internal short circuit) Between D02 (male) (7) (+) and (3) (-) Continuity
Between D02 (male) (3) (+) and (7) (-) No continuity
1. Turn starting switch to OFF position.
2. Disconnect connector C01 and connect T-adapter to female side.
Open circuit or ground fault in wir- 3. Turn starting switch to ON position.
4
ing harness a Ignore failure code displayed on machine monitor.
Between C01 (female) (3) and ground Voltage 20 – 30 V
a If no abnormality is found by check on cause 4, this check is not required.
1. Turn starting switch to OFF position.
2. Remove fuse F01 (4).
Open circuit in wiring harness
3. Disconnect connectors M06 and C01 and connect T-adapter to each female
5 (Wire breakage or defective con-
side of them.
tact of connector)
Between F01 (4) and M06 (female) (1) Resistance Max. 1 z
Between C01 (female) (3) and M06 (female) (2) Resistance Max. 1 z
a If no abnormality is found by check on cause 4, this check is not required.
1. Turn starting switch to OFF position.
2. Remove fuse F01 (4).
3. Disconnect connectors M06, C01, and D02, and connect T-adapter to
Ground fault in wiring harness female side of either connector.
6
(Contact with ground circuit) Between F01 (4) or M06 (female) (1) or D02
Resistance Min. 1 Mz
(female) (3) and ground
Between C01 (female) (3) or M06 (female) (2) or
Resistance Min. 1 Mz
D02 (female) (7) and ground
If no abnormality is found by above checks, pump controller is defective.
7 Defective pump controller
(Since this is an internal failure, troubleshooting cannot be performed.)

40-328 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [DY2CKA] Washer drive discon

Circuit diagram related to window washer motor 40-329

PC228US-8,PC228USLC-8 40-329
(01)
Troubleshooting by failurecode
Failure code [DY2CKB] Washer drive short

Failure code [DY2CKB] Washer drive short 40-3 0

User code Failure code Window washer drive system short circuit
Failure
(Pump controller system)
– DY2CKB
q When outputting current to window washer motor, abnormal current flows and short circuit is de-
Detail of failure
tected.
q Stops outputting current to washer motor.
Action of con-
q Even if cause of failure disappears, machine does not become normal until starting switch is turned
troller
to OFF position.
Problem on
q Window washer does not operate.
machine
Related infor- q Method of reproducing failure code: Turn starting switch to ON position and turn washer switch to
mation ON position.

Cause Procedure, measuring location, criteria and remarks

If the fuse is broken, the circuit probably has a grounding fault, etc. (See fail-
1 Defective fuse No.4
ure code [DY2CKA].)
1. Turn starting switch to OFF position.
Defective washer motor 2. Disconnect diode array M06 and connect T-adapter to male side.
2 (internal open circuit or ground
Between M06 (male) (1) and (2) Resistance 5 – 20 z
fault)
Between ground and M06 (male) (1) or (2) Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector D02 and connect T-adapter to male side.
Defective diode array D02 a Check the continuity in diode range.
3
(Internal short circuit) Between D02 (male) (7) (+) and (3) (-) Continuity
Between D02 (male) (3) (+) and (7) (-) No continuity
1. Turn starting switch to OFF position.
2. Disconnect connectors C01 and M06 and connect T-adapter to female side
of C01.
Hot short circuit in wiring harness 3. Remove fuse No. 4.
4
(Contact with 24 V circuit) 4. Turn starting switch to ON position.
a Ignore failure code displayed on machine monitor.
Between C01 (female) (3) and ground Voltage Max. 1 V
If no abnormality is found by above checks, pump controller is defective.
5 Defective pump controller
(Since this is an internal failure, troubleshooting cannot be performed.)

40-330 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [DY2CKB] Washer drive short

Circuit diagram related to window washer motor 40-3 1

PC228US-8,PC228USLC-8 40-331
(01)
Troubleshooting by failurecode
Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit

Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit 40-3 2

User code Failure code Wiper motor drive normal rotation system short circult
Failure
(Pump controller system)
– DY2DKB
q When outputting current to normal rotation side of wiper motor drive, abnormal current flows in cir-
Detail of failure
cuit and short circuit is detected.
q Stops outputting current to wiper motor drive forward side.
Action of con-
q Even if cause of failure disappears, machine does not become normal until starting switch is turned
troller
to OFF position.
Problem on
q Windshield wiper does not operate.
machine
q As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be mea-
Related infor- sured at pump controller connector.
mation q Method of reproducing failure code: Turn starting switch to ON position and set wiper switch to INT
or ON.

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Defective wiper motor 2. Disconnect connector M05 and connect T-adapter to female side.
1 (Internal short circuit or ground
Between M05 (female) (3) and (1) Continuity
fault)
Between M05 (female) (3) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connectors CP02 and M05 and connect T-adapter to wiring
2 Short circuit in wiring harness harness side of either of them.
Between C02 (female) (119) and (114), or between
Resistance Min. 1 Mz
M05 (male) (1) and (3)
1. Turn starting switch to OFF position.
2. Disconnect connectors C02 and M05 and connect T-adapter to wiring
Ground fault in wiring harness harness side of either of them.
3
(Contact with ground circuit)
Between C02 (female) (119) or M05 (male) (3) and
Resistance Min. 1 Mz
ground
If no abnormality is found by above checks, pump controller is defective. (Since
this is an internal failure, troubleshooting cannot be performed.)
q Reference
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector M05.
4 Defective pump controller 3. Turn starting switch to ON position.
4. Turn wiper switch ON and OFF, and troubleshoot.
Wiper switch:
Voltage Max. 3 V
Between M05 (3) and OFF
(5) Pulse below 3 V io
Wiper switch: ON Voltage
above 20 V

40-332 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit

Circuit diagram related to wiper 40-3 3

PC228US-8,PC228USLC-8 40-333
(01)
Troubleshooting by failurecode
Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit

Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit 40-3 4

User code Failure code Wiper motor drive reverse rotation system short circuit
Failure
(Pump controller system)
– DY2EKB
q When outputting current to reverse rotation side of wiper motor drive is turned ON, abnormal cur-
Detail of failure
rent flows in circuit and short circuit is detected.
q Stops outputting current to wiper motor drive reverse rotation side.
Action of con-
q Even if cause of failure disappears, machine does not become normal until starting switch is turned
troller
to OFF position.
Problem on
q Windshield wiper does not operate.
machine
q As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be mea-
Related infor- sured at pump controller connector.
mation q Method of reproducing failure code: Turn starting switch to ON position and set wiper switch to INT
or ON.

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Defective wiper motor 2. Disconnect connector M05 and connect T-adapter to female side.
1 (Internal short circuit or ground
Between M05 (female) (1) and (3) Continuity
fault)
Between M05 (female) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connectors C02 and M05 and connect T-adapter to wiring
2 Short circuit in wiring harness harness side of either of them.
Between C02 (female) (119) and (114), or between
Resistance Min. 1 Mz
M05 (male) (1) and (3)
1. Turn starting switch to OFF position.
2. Disconnect connectors C02 and M05 and connect T-adapter to wiring
Ground fault in wiring harness harness side of either of them.
3
(Contact with ground circuit)
Between C02 (female) (114) or M05 (male) (1) and
Resistance Min. 1 Mz
ground
If no abnormality is found by above checks, pump controller is defective. (Since
this is an internal failure, troubleshooting cannot be performed.)
q Reference
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector M05.
4 Defective pump controller 3. Turn starting switch to ON position.
4. Turn wiper switch ON and OFF, and troubleshoot.
Wiper switch:
Voltage Max. 3 V
Between M05 (1) and OFF
(5) Pulse below 3 V io
Wiper switch: ON Voltage
above 20 V

40-334 PC228US-8,PC228USLC-8
(01)
 Troubleshooting by failurecode
Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit

Circuit diagram related to wiper 40-3 5

PC228US-8,PC228USLC-8 40-335
(01)
Troubleshooting by failurecode
Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit

40-336 PC228US-8,PC228USLC-8
(01)
 Troubleshooting of electrical system (E-mode)
E-1 Engine does not start (Engine does not crank)

Troubleshooting of electrical system (E-mode) 40-3 7

E-1 Engine does not start (Engine does not crank) 40-3 7
Failure q Engine does not start (Engine does not crank).
q Engine starting circuit has following two start lock mechanisms.
1) Start lock by using password of machine monitor
Related infor-
2) Start lock by using lock lever
mation
q In the case that "Battery relay does not make operating sound" when starting switch is turned to
ON position, perform troubleshooting for E-1 also.

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
1 Defective fusible links F04 or F05 2. Remove fusible links F04 and F05
Between terminals F04 and F05 Resistance Max. 1 z
Defective fuses Nos. 3 and 17 in
2 If fuse is broken, circuit probably has ground fault. (See Cause 16.)
fuse box F01
1. Turn starting switch to OFF position.
Loose terminal connection or open
3 Check terminals of starting motor, alternator, battery relay, grounds T04 and
circuit at terminal
T08, etc.
1. Turn starting switch to OFF position.
Between battery relay terminal R01 and ground
Defective contact (ground) a Check grounding at machine frame.
4
between battery relay and frame a Loosened or rusted terminal T08 Resistance Max. 1 z
a Rusted contact faces of battery bracket and
frame
a Be ready with starting switch OFF, then perform troubleshooting without
turning starting switch ON.
5 Insufficient battery capacity Battery voltage (two pieces) Min. 24 V
Electrolyte specific gravity (one piece) Min. 1.26
Engine controller power supply and ACC signal are diagnosed with proce-
6 Defective engine controller system dures for failure codes [DA2RMC] and [DAFRMC]. If these codes are dis-
played, perform troubleshooting for them first.
1. Turn starting switch to OFF position.
2. Disconnect connector H15 and connect T-adapter to male side.
3. After troubleshooting, turn starting switch to ON/START position and
perform troubleshooting again.
Turn starting switch to
Resistance Min. 1 Mz
Between H15 (male) (1) OFF position.
and (2) Turn starting switch to
Resistance Max. 1 z
Defective starting switch ON position.
7
(Open circuit in internal wiring) Turn starting switch to
Resistance Min. 1 Mz
Between H15 (male) (1) OFF position.
and (5) Turn starting switch to
Resistance Max. 1 z
ON position.
Turn starting switch to
Resistance Min. 1 Mz
Between H15 (male) (1) OFF position.
and (4) Turn starting switch to
Resistance Max. 1 z
START position
1. Turn starting switch to OFF position.
2. Disconnect connector S14 and connect T-adapter to female side.
Defective lock lever switch
8
(Open circuit in internal wiring) Between S14 (female) (1) Lock lever FREE position Resistance Min. 1 Mz
and (3) Lock lever LOCK position Resistance Max. 1 z

PC228US-8,PC228USLC-8 40-337
(01)
Troubleshooting of electrical system (E-mode)
E-1 Engine does not start (Engine does not crank)

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connectors R06 and R07 and connect T-adapter to male side.
200 to
Between R06 (male) (1) and (2) Resistance
600 z
Defective starting motor cutout
Between R06 (male) (3) and (4) Resistance Max. 1 z
relay R06 or personal code relay
9
R07 Between R06 (male) (3) and (5) Resistance Min. 1 Mz
(Open circuit in internal wiring) 200 to
Between R07 (male) (1) and (2) Resistance
600 z
Between R07 (male) (3) and (4) Resistance Max. 1 z
Between R07 (male) (3) and (5) Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect cable only from C terminal on starting motor safety relay.
3. Insert T-adapter between male and female sides of connector R17.
4. Turn starting switch to START position and perform troubleshooting.
Power sup-
Between safety relay terminal B and E Voltage 20 to 30 V
ply
Command
power input
Between safety relay terminal R
Defective starting motor safety from alter- Voltage Max. 1 V
(R17-2) and safety relay terminal E
10 relay nator gener-
(Internal defect) ation
Starting
Between safety relay terminal S
command Voltage 20 to 30 V
(R17-1) and safety relay terminal E
input
Starting
Between safety relay terminal C (R28)
power out- Voltage 20 to 30 V
and safety relay terminal E
put
If power supply, command power input, and starting command input are nor-
mal but starting command output is not normal, starting motor safety relay is
defective.
1. Turn starting switch to OFF position.
2. Turn starting switch to START position and perform troubleshooting.
Between starting motor terminal B Power sup-
Voltage 20 to 30 V
Defective starting motor (SB) and ground ply
11 Starting
(Internal defect) Between starting motor terminal C
command Voltage 20 to 30 V
(SC) and ground
input
If power supply and starting command input are normal but starting motor
does not rotate, starting motor is defective.
a Be ready with starting switch OFF, then perform troubleshooting with start-
ing switch in ON position and perform troubleshooting.
Command
Defective alternator
12 power out-
(Internal short circuit) Between alternator terminal L and
put from Voltage Max. 1 V
ground
alternator
generation
1. Turn starting switch to OFF position.
2. Disconnect connector D01 and connect T-adapter to diode.
a Measure by using multimeter in diode range.
Defective diode D01 Between D01 (male) (1) (+) and (5) (-) No continuity
13 (open or short circuit in internal
wiring) Between D01 (male) (5) (+) and (1) (-) Continuity
Between D01 (male) (2) (+) and (6) (-) No continuity
Between D01 (male) (6) (+) and (2) (-) Continuity

40-338 PC228US-8,PC228USLC-8
(01)
 Troubleshooting of electrical system (E-mode)
E-1 Engine does not start (Engine does not crank)

Cause Procedure, measuring location, criteria and remarks

q Battery relay
1. Turn starting switch to OFF position.
Between terminal B02 and H15 (female) (2) Resistance Max. 1 z
q Battery relay
1. Turn starting switch to OFF position.
2. Turn starting switch to ON position.
a Check to where 24 V is supplied to isolate open section.
Between terminals R04 and R01 Voltage 20 to 30 V
Between terminals R02 and R01 Voltage 20 to 30 V
Between terminals R03 and R01 Voltage 20 to 30 V
Between terminal R01 and ground Voltage Max. 1 V
q Alternator and starting motor
1. Turn starting switch to OFF position.
2. Disconnect battery ground cable.
3. Insert T-adapters into connectors H15, S14, R07, R17, E10, and E12.
4. Connect ground strap.
5. Turn starting switch to START position and troubleshoot.
a Check to where 24 V power is supplied to isolate open section.
Between H15 (4) and ground Voltage 20 to 30 V
Between S14 (1) and ground Voltage 20 to 30 V
Between S14 (3) and ground Voltage 20 to 30 V
Between R07 (4) and ground Voltage 20 to 30 V
Between R17 (1) and ground Voltage 20 to 30 V

Open circuit in wiring harness Between R17 (2) and ground Voltage 20 to 30 V
14 (Wire breakage or defective con- Between E10 (1) and ground Voltage 20 to 30 V
tact of connector)
Between E12 (1) and ground Voltage 20 to 30 V
Between alternator B terminal and ground Voltage 20 to 30 V
Between starting motor terminal B and ground Voltage 20 to 30 V
a If fuse or fusible link is broken, replace it.
1. Turn starting switch to OFF position.
2. Disconnect H15, S14, R06 and R07.
3. Connect T-adapter to female sides of H15, R06 and R07, and to male side
of S14.
4. Remove fuse F01-3.
Between H15 (female) (4) and R06 (female) (5) Resistance Max. 1 z
Between R06 (female) (3) and R07 (female) (4) Resistance Max. 1 z
Between R07 (female) (1) and S14 (male) (1) Resistance Max. 1 z
Between R07 (female) (2) and CM01 (female) (6) Resistance Max. 1 z
Between R07 (female) (3) and starting motor termi-
Resistance Max. 1 z
nal S
Between alternator B and starting motor B Resistance Max. 1 z
Between starting motor B and battery relay R03 Resistance Max. 1 z
Between alternator R and starting motor L Resistance Max. 1 z
Between alternator R and D01 (female) (6) Resistance Max. 1 z
Between F01-3 and S14 (male) (1) Resistance Max. 1 z
Between S14 (male) (3) and R06 (male) (1) Resistance Max. 1 z
Between R06 (male) (2) and ground (T04) Resistance Max. 1 z

PC228US-8,PC228USLC-8 40-339
(01)
Troubleshooting of electrical system (E-mode)
E-1 Engine does not start (Engine does not crank)

Cause Procedure, measuring location, criteria and remarks

Defective battery relay If only terminal R03 voltage is abnormal during battery relay check for cause
15
(Does not activate) 14, battery relay is defective.
1. Turn starting switch to OFF position.
2. Disconnect H15, S14, R06 and R07.
3. Connect T-adapter to female sides of H15, R06 and R07, and to male side
of S14.
4. Remove fuse F01-3.
Between H15 (female) (4) and ground, or between
Resistance Min. 1 Mz
R06 (female) (5) and ground
Between R06 (female) (3) and ground, or between
Resistance Min. 1 Mz
R07 (female) (4) and ground
Ground fault in wiring harness Between R07 (female) (3) and ground, or between
16 Resistance Min. 1 Mz
(Contact with ground circuit) R17 (female) (1) and ground
Between starting motor safety relay B or battery
Resistance Min. 1 Mz
relay R03 and ground
Between starting motor safety relay C or starting
Resistance Min. 1 Mz
motor C (SC) and ground
Between F01-3 or S14 (male) (1) and ground Resistance Min. 1 Mz
Between S14 (male) (3) and ground, or between
Resistance Min. 1 Mz
R06 (female) (1) and ground
1. Turn starting switch to OFF position.
Hot short circuit in wiring harness 2. Insert T-adapter between male and female sides of connector R17 or E08.
17 3. Turn starting switch to ON position.
(Contact with 24 V circuit)
Between R17 (female) (2) or E08 (1) and ground Voltage Max. 1 V

40-340 PC228US-8,PC228USLC-8
(01)
 Troubleshooting of electrical system (E-mode)
E-1 Engine does not start (Engine does not crank)

Circuit diagram related to engine start circuit 40-341

PC228US-8,PC228USLC-8 40-341
(01)
Troubleshooting of electrical system (E-mode)
E-2 Preheater does not operate

E-2 Preheater does not operate 40-342

Failure 1)Manual preheater does not operate.
a This troubleshooting describes the procedures to be followed when manual preheating does
not function to heat the electrical intake air heater mounting section.
q There are "Automatic preheater" and "Manual preheater" installed. When either function is
operated, preheating monitor lights up. (When only preheating does not light up, troubleshoot
"3) While preheater is operating, preheating monitor does not light up")
Related information
q If "the machine monitor does not light up" or " battery relay does not make operating sound"
when turning starting switch ON, main electric power supply system is supposed to be defec-
tive. So, troubleshoot E-3 and E-1.
q Before performing out troubleshooting, check that no related failure code is displayed.
(If failure codes [D110KB] is displayed, troubleshoot it first.)

Cause Procedure, measuring location, criteria and remarks

Defective fuse No. 17 in fuse box If fuse No. 17 in fuse box F01 is broken, circuit probably has ground fault. In
1
F01 this case, perform troubleshooting for cause 8 first.

Loose terminal or disconnection at 1. Turn starting switch to OFF position.

2
terminal Check terminals of heater relay, battery relay, electrical intake air heater, etc.
1. Turn starting switch to OFF position.
2. Disconnect connector D02 and connect T-adapter to diode.
Defective diode D02
a Measure by using multimeter in diode range.
3 (open or short circuit in internal
wiring) Between D02 (male) (1) (+) and (5) (-) No continuity
Between D02 (male) (5) (+) and (1) (-) Continuity

Defective electrical intake air 1. Turn starting switch to OFF position.

4 heater 2. Disconnect terminal E01.
(open circuit in internal wiring) Between E01 terminal and ground Continuity
1. Turn starting switch to OFF position.
2. Disconnect battery ground cable.
3. Disconnect connector H15 and connect T-adapter to male side.
5 Defective starting switch 4. Turn starting switch to OFF/HEAT position and troubleshoot.
OFF Resistance Min. 1 Mz
Between H15 (male) (1) and (3)
HEAT Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect connectors CM01 and H15, and connect T-adapter to female
side of H15.
Between H15 (female) (3) and ground Continuity
1. Turn starting switch to OFF position.
2. Turn starting switch to ON position.
Open or short circuit in wiring har- Between input terminal on contact side of heater
6 Voltage 20 to 30 V
ness relay and ground
1. Turn starting switch to OFF position.
2. Disconnect heater relay terminal R16.
a Disconnect so that current does not flow in heater when starting switch
is turned to HEAT position.
3. Turn starting switch to HEAT position (Connect R1).
Between heater relay terminal R15 and ground Voltage 20 to 30 V
Defective heater relay If no failure is found by check on cause 6 and heater relay operation sound is
7
(Does not work) (Terminal R16) not heard, heater relay is defective.

40-342 PC228US-8,PC228USLC-8
(01)
 Troubleshooting of electrical system (E-mode)
E-2 Preheater does not operate

Cause Procedure, measuring location, criteria and remarks

a If cause 6 is not cause for trouble, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors H15 and CM01, terminals R15 and E01, and
starting motor terminal B.
Ground fault in wiring harness Between heater relay terminal R15 (wiring harness
8 Resistance Min. 1 Mz
(contact with ground circuit) side) and ground
Between input terminal on contact side of heater
Resistance Min. 1 Mz
relay and ground
Between heater relay terminal E01 (wiring harness
Resistance Min. 1 Mz
side) and ground

Failure 2) Automatic preheater does not operate.

q Automatic preheater operates when boosted air temperature is below -4 °C.
(Monitoring code Boost temperature: 18500)
q If automatic preheater does not operate, check if manual preheater operates.
Related informa-
q Engine controller troubleshoots primary (coil) side of preheater relay (connector R18) for failure
tion
codes [CA2555] and [CA2556].
q Engine controller troubleshoots charged (boosted) air temperature sensor for failure codes
[CA153] and [CA154].

Cause Procedure, measuring location, criteria and remarks

Defective fuse No. 6 in fuse If fuse No. 6 in fuse box 01 is broken, circuit probably has ground fault. In this case,
1
box 01 troubleshoot cause 5 first.
1. Turn starting switch to OFF position.
Defective preheater relay 2. Replace preheater relay (connector R18) with horn relay (connector R08), for
R18 example.
2
(open or short circuit in inter- 3. Turn starting switch to ON position.
nal wiring) If automatic preheater operates when charged (boosted) air temperature is below
-4 °C, original preheater relay is defective.
1. Turn starting switch to OFF position.
2. Disconnect connectors CM01 and R18, and then connect T-adapter to female
side of R18.
Open circuit or ground fault a If resistance is above 1 Mz, wiring harness has open circuit. If resistance is be-
3
of wiring harness low 1 z, wiring harness has short circuit.
a Heater relay coil resistance
Between R18 (female) (5) and ground Resistance Approx. 20 z
1. Turn starting switch to OFF position.
2. Disconnect connectors R18 and CM01, and then connect T-adapter to female
Open circuit in wiring har- side of R18.
ness 3. Remove fuse No. 6 in fuse box F01.
4
(Wire breakage or defective
Between R18 (female) (3) and F01-6 Resistance Max. 1 z
contact)
Between R18 (female) (5) and heater relay terminal
Resistance Max. 1 z
R15
If fuse is not blown, this check is not required.
Ground fault in wiring har- 1. Turn starting switch to OFF position.
5 ness 2. Disconnect connectors CM01, R18, and starting motor terminal B, and then
(contact with ground circuit) connect T-adapter to female side of R18.
Between R18 (female) (3) and ground Resistance Min. 1 Mz

PC228US-8,PC228USLC-8 40-343
(01)
Troubleshooting of electrical system (E-mode)
E-2 Preheater does not operate

Failure 3) While preheater is operating, preheating monitor does not light up.
q There are "Automatic preheater" and "Manual preheater" installed. When either function is oper-
Related informa-
ated, preheating lamp lights up.
tion
q Check that manual preheater operates first.

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Open circuit in wiring har- 2. Disconnect connectors H15, CM01, and R18, and connect T-adapters to their
ness female sides.
1
(Wire breakage or defective Between H15 (female) (3) and CM01 (female) (16) Resistance Max. 1 z
contact)
Between R18 (female) (5) and CM01 (female) (16) Resistance Max. 1 z
If cause is not found by above checks, machine monitor is defective.
q Reference
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector CM01.
2 Defective machine monitor 3. Disconnect heater relay terminal R16.
a Disconnect so that current does not flow in heater when starting switch is turned
to HEAT position.
4. Turn the starting switch to HEAT position.
Between CM01 (16) and (3) Resistance 20 to 30 V

40-344 PC228US-8,PC228USLC-8
(01)
 Troubleshooting of electrical system (E-mode)
E-2 Preheater does not operate

Circuit diagram related to preheating of engine 40-345

PC228US-8,PC228USLC-8 40-345
(01)
Troubleshooting of electrical system (E-mode)
E-2 Preheater does not operate

40-346 PC228US-8,PC228USLC-8
(01)
 Troubleshooting of electrical system (E-mode)
E-3 When starting switch is turned to ON position, machine monitor displays nothing

E-3 When starting switch is turned to ON position, machine monitor

displays nothing 40-347
Failure q When starting switch is turned to ON position, machine monitor displays nothing.
q When starting switch is turned to ON position, machine monitor displays KOMATSU logo, screen
to input password (if set), screen to check breaker mode (if set), screen of check before starting,
Related infor- screen to check working mode and travel speed, and standard screen in order.
mation q When engine is started, battery voltage may lower suddenly, depending on the ambient tempera-
ture and condition of battery.
In this case, machine monitor goes off for a moment. This phenomenon is not a failure, however.

Cause Procedure, measuring location, criteria and remarks

a Be ready with starting switch in OFF position, then perform troubleshooting with-
out turning starting switch ON.
1 Insufficient battery capacity Battery voltage (two pieces) Min. 24 V
Electrolyte specific gravity (one piece) Min. 1.26

Defective fusible link F05

2 If fusible link or fuse is blown, circuit probably has ground fault. (See Cause 7.)
Defective fuse F01-17

a If machine monitor is not replaced, this check is not required.

Wrong connection of con- Machine monitor connector may be connected wrongly. Check it directly.
3
nector a Connector CM02 and CM03 can be installed even if they are exchanged. Since
both male and female parts of CM03 are green, check their colors.
1. Turn starting switch to OFF position and disconnect ground cable.
2. Insert T-adapter into connector CM01.
3. Connect battery ground cable, and turn starting switch to ON position (connect
Defective wiring harness, ACC).
4 starting switch, or machine
Between CM01 (1) and (3) Voltage 20 to 30 V
monitor
Between CM01 (2) and (4) Voltage 20 to 30 V
Between CM01 (14) and (4) Voltage 20 to 30 V
1. Turn starting switch to OFF position.
2. Disconnect connector H15 and connect T-adapter to male side.
Defective starting switch 3. Turn starting switch to ON position and troubleshoot again.
5 (open circuit in internal wir- Turn starting switch to OFF
ing) Resistance Min. 1 Mz
Between H15 (male) (1) position.
and (5) Turn starting switch to ON
Resistance Max. 1 z
position.
If check result on cause 4 is normal, this check is not required.
1. Turn starting switch to OFF position and disconnect ground cable.
2. Disconnect fusible link F05, No. 17 of fuse F01, and connectors H15 and CM01.
3. Connect T-adapters to male side of connector F05 and female side of H15 and
CM01.
Between battery (-) and ground Resistance Max. 1 z
Open circuit in wiring har-
ness Between battery (+) and F03 (male) (1) Resistance Max. 1 z
6
(Wire breakage or defective
Between F03 (male) (2) and F01-16D Resistance Max. 1 z
contact of connector)
Between F01-17 and CM01 (female) (1), (2) Resistance Max. 1 z
Between CM01 (female) (3), (4) and ground (T09) Resistance Max. 1 z
Between F01-17 and H15 (female) (1) Resistance Max. 1 z
Between H15 (female) (5) and CM01 (female) (14) Resistance Max. 1 z

PC228US-8,PC228USLC-8 40-347
(01)
Troubleshooting of electrical system (E-mode)
E-3 When starting switch is turned to ON position, machine monitor displays nothing

Cause Procedure, measuring location, criteria and remarks

If check result on cause 4 is normal, this check is not required.
1. Turn starting switch to OFF position and disconnect ground cable.
2. Disconnect fusible link F05, No. 17 of fuse F01, terminal 20E, and connectors
H15, CM01, and C01.
3. Connect T-adapters to male side of connector F05 and female side of H15 and
CM01.
Ground fault in wiring har- Between battery (+) and ground, or between F03
Resistance Min. 1 Mz
7 ness (male) (1) and ground
(contact with ground circuit) Between F05 (male) (2) and ground, or between
Resistance Min. 1 Mz
F01-16D and ground
Between F01-17 and ground, or between CM01
(female) (1), (2) and ground, or between H15 (female) Resistance Min. 1 Mz
(1) and ground
Between H15 (female) (5) and ground, or between
Resistance Min. 1 Mz
CM01 (female) (14) and ground
If no failure is found by above checks, machine monitor is defective. (Since failure is
8 Defective machine monitor
in monitor, troubleshooting cannot be performed.)

40-348 PC228US-8,PC228USLC-8
(01)
 Troubleshooting of electrical system (E-mode)
E-3 When starting switch is turned to ON position, machine monitor displays nothing

Circuit diagram related to machine monitor power supply 40-349

PC228US-8,PC228USLC-8 40-349
(01)
Troubleshooting
Troubleshootingofof electrical
electrical system
system(E-mode)
(E-mode)
E-4 When
E-4 When starting
starting switch
switch is
is turned
turned to
to ON
ON position
position (before
(before starting
starting engine),
engine), basic
basic check
check monitor
monitor lights
lights up.
up.

E-4 When starting switch is turned to ON position (before starting

engine), basic check monitor lights up. 40-350
1) When starting switch is turned to ON position (with engine stopped), engine oil level monitor
Failure
lights up in red.
Related information

Cause Procedure, measuring location, criteria and remarks

Defective engine oil level switch
1 Perform troubleshooting for failure code [B@BAZK].
system (machine monitor system)
If cause 1 is not detected, machine monitor may be defective.
2 Defective machine monitor
(Since trouble is in system, troubleshooting cannot be performed.)

Failure 2) Radiator coolant level monitor lights up in red.

Related information

Cause Procedure, measuring location, criteria and remarks

Low radiator coolant level
1 Coolant level may be low. Check coolant level and add coolant if necessary.
(When system works properly)
Radiator sub tank coolant level
2 Perform troubleshooting for failure code [B@BCZK].
switch system

40-350 PC228US-8,PC228USLC-8
(01)
 Troubleshooting of electrical system (E-mode)
E-5 Precaution monitor lights up while engine is running

E-5 Precaution monitor lights up while engine is running 40-351

Failure 1) Engine coolant temperature monitor lights up in white.
q Signal of engine coolant temperature sensor is input to engine controller and then data is
transmitted to machine monitor through CAN communication system.
Related information
q Engine coolant temperature can be checked with monitoring function
(Code: 04107 Engine coolant temperature)

Cause Procedure, measuring location, criteria and remarks

If monitor lights up in white, engine coolant temperature may be low (below
Insufficient warm-up of machine approximately 30 °C). Warm up engine.
1
(When system works properly) q Lighting up in white: Engine coolant temperature is low.
q Lighting up in blue: Engine coolant temperature is proper.
If cause 1 is not cause for trouble, engine coolant temperature gauge system
Defective engine coolant tempera-
2 may be defective. Perform troubleshooting for "E-8 Engine coolant tempera-
ture gauge system
ture gauge does not display properly".

Failure 2) Hydraulic oil temperature monitor lights up in white.

q Signal of hydraulic oil temperature sensor is input to pump controller and then data is trans-
mitted to machine monitor through CAN communication system.
Related information
q Hydraulic oil temperature can be checked with monitoring function
(Code: 04401 Hydraulic oil temperature)

Cause Procedure, measuring location, criteria and remarks

If monitor lights up in white, hydraulic oil temperature may be low (below
Insufficient warm-up of machine approximately 20 °C). Warm up engine.
1
(When system works properly) q Lighting up in white: Hydraulic oil temperature is low.
q Lighting up in blue: Hydraulic oil temperature is proper.
If cause 1 is not the cause for trouble, hydraulic oil temperature gauge system
Defective hydraulic oil temperature
2 may be defective. Perform troubleshooting for "E-9 hydraulic oil temperature
gauge system
gauge does not display properly".

Failure 3) Charge level monitor lights up while engine is running.

q Condition of generation signal of alternator can be checked with monitoring function.
Related information
(Code: 04300 Charge voltage)

Cause Procedure, measuring location, criteria and remarks

1 Defective alternator system Perform troubleshooting for failure code [AB00KE].

Failure 4) Fuel level monitor lights up in red.

q Signal voltage of fuel sensor can be checked with monitoring function.
Related information
(Code: 04200 Fuel sensor voltage)

Cause Procedure, measuring location, criteria and remarks

Low fuel level
1 Fuel level may be low. Check it and add fuel if necessary.
(When system works properly)
If cause 1 is not cause for trouble, fuel level gauge system may be defective.
2 Defective fuel level gauge system
Perform troubleshooting for "E-7 Fuel level gauge does not display properly".

PC228US-8,PC228USLC-8 40-351
(01)
Troubleshooting of electrical system (E-mode)
E-5 Precaution monitor lights up while engine is running

Failure 5) Air cleaner clogging monitor lights up in red.

q Condition of air cleaner clogging switch signal can be checked with monitoring function.
Related information
(Code: 04501 Monitor input 2)

Cause Procedure, measuring location, criteria and remarks

Clogging of air cleaner
1 Air cleaner may be clogged. Check it, then clean or replace if necessary.
(When system works properly)
Defective air cleaner clogging
2 Perform troubleshooting for failure code [AA10NX].
switch system

Failure 6) Water separator monitor (Water level in water separator is high)

q Detection of water by fuel filter sensor can be checked with monitoring function.
Related information
(Code: 18800 Condition of WIF sensor)

Cause Procedure, measuring location, criteria and remarks

High water level in water separator
1 Water is detected in water separator. Check and drain water separator.
(When system works properly)
Defective fuel filter sensor system If cause 1 is not cause for trouble, fuel filter system may be defective. Perform
2
(engine controller circuit) troubleshooting for failure codes [CA428] and [CA429].
If causes 1 and 2 are not cause for trouble, machine monitor may be defective
3 Defective machine monitor
(Since failure is in monitor, troubleshooting cannot be performed.)

40-352 PC228US-8,PC228USLC-8
(01)
 Troubleshooting of electrical system (E-mode)
E-6 Emergency stop monitor lights up while engine is running

E-6 Emergency stop monitor lights up while engine is running 40-353

Failure 1) Engine coolant temperature monitor lights up in red.
q Signal of engine coolant temperature sensor is input to engine controller and then data is trans-
Related infor- mitted to machine monitor through CAN communication system.
mation q Engine coolant temperature can be checked with monitoring function
(Code: 04107 Engine coolant temperature)

Cause Procedure, measuring location, criteria and remarks

If monitor lights up in red, engine coolant temperature may be high (above approxi-
mately 102 °C). Cool down engine coolant (Run engine at low idle).
Overheating of engine cool-
q Lighting up in red: Engine coolant temperature is high (overheating).
1 ant (when system works
q Lighting up in blue: Engine coolant temperature is proper.
properly)
Perform troubleshooting for "S-14 Coolant temperature becomes too high (over-
heating)".
If cause 1 is not cause for trouble, engine coolant temperature gauge system may
Defective engine coolant
2 be defective. Perform troubleshooting for "E-8 Engine coolant temperature gauge
temperature gauge system
does not display properly".

Failure 2) Hydraulic oil temperature monitor lights up in red.

q Signal of hydraulic oil temperature sensor is input to pump controller and then the data is transmit-
Related infor- ted to machine monitor through CAN communication system.
mation q Hydraulic oil temperature can be checked with monitoring function
(Code: 04401 Hydraulic oil temperature)

Cause Procedure, measuring location, criteria and remarks

If monitor lights up in red, hydraulic oil temperature may be high (above approxi-
Overheating of hydraulic oil
mately 102 °C). Cool down hydraulic oil (Run engine at low idle).
1 (When system works prop-
q Lighting up in red: Hydraulic oil temperature is high (overheating).
erly)
q Lighting up in blue: Hydraulic oil temperature is proper.
If cause 1 is not cause for trouble, hydraulic oil temperature gauge system may be
Defective hydraulic oil tem-
2 defective. Perform troubleshooting for "E-9 hydraulic oil temperature gauge does
perature gauge system
not display properly".

Failure 3) Engine oil pressure monitor lights up in red.

q Signal of engine oil pressure switch is input to engine controller. If engine oil pressure switch is
Related infor-
turned ON while engine is running, failure code [B@BAZG] is transmitted from engine controller
mation
to machine monitor through CAN communication.

Cause Procedure, measuring location, criteria and remarks

Low engine oil pressure
Since engine oil pressure may be low, check it. If it is low, perform troubleshooting
1 (When system works prop-
for "S-12 Oil pressure decreases".
erly)
Defective engine oil pres- If cause 1 is not cause for trouble, engine oil pressure switch system may be defec-
2
sure switch system tive. Perform troubleshooting for failure code [CA435].

PC228US-8,PC228USLC-8 40-353
(01)
Troubleshooting of electrical system (E-mode)
E-7 Fuel level gauge does not indicate correctly

E-7 Fuel level gauge does not indicate correctly 40-354

1) While fuel is added, fuel level gauge indicator does not rise from red range (E).
Failure
2) While fuel level is low, fuel level gauge indicator does not lower from green range top (F)
Related infor- q Signal voltage of fuel sensor can be checked with monitoring function.
mation (Code: 04200 Fuel sensor voltage)

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Defective fuel level sensor 2. Disconnect connector P21 and connect T-adapter to male side.
1 (Open or short circuit in
Between P21 (male) (1) Fuel level: FULL Resistance Approx. 12 z
internal wiring)
and ground Fuel level: EMPTY Resistance 85 to 110 z
1. Turn starting switch to OFF position.
2. Disconnect connector CM01 and connect T-adapter to female side.
Open or short circuit in wir-
2
ing harness Between CM01 (female) Fuel level: FULL Resistance Approx. 12 z
(9) and ground Fuel level: EMPTY Resistance 85 to 110 z
a If check result on cause 2 is normal, this check is not required.
Open circuit in wiring har- 1. Turn starting switch to OFF position.
ness 2. Disconnect connectors CM01 and P21, and connect T-adapter on each female
3
(Wire breakage or defective side.
contact of connector)
Between CM01 (female) (9) and P21 (female) (1) Resistance Max. 1 z
1. Turn starting switch to OFF position.
Ground fault in wiring har- 2. Disconnect connectors CM01 and P21, and connect T-adapter to female side of
4 ness either one.
(contact with ground circuit) Between CM01 (female) (9) and ground, or between
Resistance Min. 1 Mz
P21 (female) (1) and ground
1. Turn starting switch to OFF position.
2. Disconnect connector P21.
Hot short circuit in wiring 3. Insert T-adapter between male and female sides of connector CM01 or connect
5 harness T-adapter to female side of connector P21.
(contact with 24 V circuit) 4. Turn starting switch to ON position.
Between CM01 (9) and ground, or between P21 Approx. 3.3
Voltage
(female) (1) and ground V
If no failure is found by above checks, machine monitor is defective. (Since failure is
6 Defective machine monitor
in monitor, troubleshooting cannot be performed.)

Circuit diagram related to fuel level sensor 40-354

40-354 PC228US-8,PC228USLC-8
(01)
 Troubleshooting of electrical system (E-mode)
E-7 Fuel level gauge does not indicate correctly

3) Indiacation of fuel level gauge is different from actual fuel level.

Failure
4) Indiacation of fuel level gauge is different from display of fuel level monitor.
Related infor- q Signal voltage of fuel sensor can be checked with monitoring function.
mation (Code: 04200 Fuel sensor voltage)

Cause Procedure, measuring location, criteria and remarks

a Turn starting switch to ON position or start engine and perform troubleshooting.
Fuel level Reading of fuel level gauge Color of monitor light (a)
230 l 6
195 l 5
1 Defective machine monitor
160 l 4 Blue
80 l 3
60 l 2
40 l 1 Red

Fuel level gauge and fuel level monitor 40-35

PC228US-8,PC228USLC-8 40-355
(01)
Troubleshooting of electrical system (E-mode)
E-8 Engine coolant temperature gauge does not indicate correctly

E-8 Engine coolant temperature gauge does not indicate correctly 40-356
1) While engine coolant temperature is rising properly, temperature gauge does not rise from white
Failure range (C).
2) While engine coolant temperature is stabilized normally, temperature gauge rises to red range (H).
q Signal of engine coolant temperature sensor is input to engine controller and then data is trans-
Related infor- mitted to machine monitor through CAN communication system.
mation q Engine coolant temperature can be checked with monitoring function
(Code: 04107 Engine coolant temperature)

Cause Procedure, measuring location, criteria and remarks

Defective engine coolant Engine coolant temperature sensor system may be defective. Perform troubleshoot-
1
temperature sensor system ing for failure codes [CA144] and [CA145].
If cause 1 is not detected, machine monitor may be defective.
2 Defective machine monitor
(Since trouble is in system, troubleshooting cannot be performed.)

3) Indication of the coolant temperature gauge is different from actual engine coolant temperature.
Failure 4) Indication of engine coolant temperature gauge is different from display of engine coolant temper-
ature monitor.
q Signal voltage of engine coolant temperature sensor is input to engine controller and then data is
Related infor- transmitted to machine monitor through CAN communication system.
mation q Engine coolant temperature can be checked with monitoring function.
(Code: 04107 Engine coolant temperature)

Cause Procedure, measuring location, criteria and remarks

a Turn starting switch to ON position or start engine and perform troubleshooting.
Engine coolant tempera-
Coolant temperature level Color of monitor light (a)
ture
105 °C 6
Red
102 °C 5
1 Defective machine monitor
100 °C 4
85 °C 3 Blue
60 °C 2
30°C 1 White

Engine coolant temperature gauge and coolant

temperature monitor 40-356

40-356 PC228US-8,PC228USLC-8
(01)
 Troubleshooting of electrical system (E-mode)
E-8 Engine coolant temperature gauge does not indicate correctly

PC228US-8,PC228USLC-8 40-357
(01)
Troubleshooting of electrical system (E-mode)
E-9 Hydraulic oil temperature gauge does not indicate correctly

E-9 Hydraulic oil temperature gauge does not indicate correctly 40-358
(1) While hydraulic oil temperature is rising properly, temperature gauge does not rise from white
range (C).
Failure
(2) Although hydraulic oil temperature is stabilized normally, temperature gauge rises to red range
(H).
q Signal of hydraulic oil temperature sensor is input to pump controller and then data is transmitted
Related to machine monitor through CAN communication system.
information q Hydraulic oil temperature can be checked with monitoring function.
(Code: 04401 Hydraulic oil temperature)

Cause Procedure, measuring location, criteria and remarks

1 Defective machine monitor See the next page.
1. Turn starting switch to OFF position.
2. Disconnect connector P22 and connect T-adapter to male side.
Approx.
10°C Resistance
90 kz
Defective hydraulic oil tem-
Approx.
perature sensor Between P22 (male) (1) and (2) 30°C Resistance
2 35 kz
(open or short circuit in inter- a Temperature characteristics of oil
Approx.
nal wiring) temperature sensor 80°C Resistance
6.5 kz
Approx.
100°C Resistance
3.5 kz
Between P22 (male) (2) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector C01 and connect T-adapter to female side.
Open circuit or ground fault Between C01 (female) (29) and (46)
3
in wiring harness a Resistance accords with value on temperature char- Resistance 3.5 to 90 kz
acteristics table in cause 2.
Between C01 (female) (29) and ground Resistance Min. 1 Mz
a If no failure is found in checks on cause 3, this check is not required.
Open circuit in wiring har- 1. Turn starting switch to OFF position.
ness 2. Disconnect connectors C01 and P22, and connect T-adapters to each female
4 side.
(Wire breakage or defective
contact of connector) Between C01 (female) (29) and P22 (female) (2) Resistance Max. 1 z
Between C01 (female) (46) and P22 (female) (1) Resistance Max. 1 z
a If no failure is found in checks on cause 3, this check is not required.
Ground fault in wiring har- 1. Turn starting switch to OFF position.
5 ness 2. Disconnect connectors C01 and P22, and connect T-adapter to female side of
(contact with ground circuit) Between either one.
C01 (female) (29) and ground, or between
Resistance Min. 1 Mz
P22 (female) (2) and ground
1. Turn starting switch to OFF position.
2. Disconnect connector P22.
Hot short circuit in wiring har- 3. Insert T-adapter between male and female sides of connector C01 or connect
6 ness T-adapter to female side of connector P22.
(contact with 24 V circuit) 4. Turn starting switch to ON position.
Between C01 (29) and ground, or between P22
Voltage Approx. 5 V
(female) (2) and ground
If no failure is found by above checks, pump controller is defective. (Since failure is
7 Defective pump controller
in controller, troubleshooting cannot be performed.)

40-358 PC228US-8,PC228USLC-8
(01)
 Troubleshooting of electrical system (E-mode)
E-9 Hydraulic oil temperature gauge does not indicate correctly

Circuit diagram related to hydraulic oil temperature sensor 40-359

PC228US-8,PC228USLC-8 40-359
(01)
Troubleshooting of electrical system (E-mode)
E-9 Hydraulic oil temperature gauge does not indicate correctly

(3) Indication of hydraulic oil temperature gauge is different from actual hydraulic oil temperature.
Failure (4) Indication of hydraulic oil temperature gauge is different from display of hydraulic oil temperature
monitor.
q Signal of hydraulic oil temperature sensor is input to pump controller and then data is transmitted
Related infor- to machine monitor through CAN communication system.
mation q Hydraulic oil temperature can be checked with monitoring function
(Code: 04401 Hydraulic oil temperature)

Cause Procedure, measuring location, criteria and remarks

a Turn starting switch to ON position or start engine and perform troubleshooting.
Hydraulic oil temperature
Hydraulic oil temperature Color of monitor light (a)
level
105°C 6
Red
102°C 5
1 Defective machine monitor
100°C 4
85°C 3 Blue
40°C 2
20°C 1 White

Hydraulic oil temperature gauge and hydraulic

oil temperature monitor 40-360

40-360 PC228US-8,PC228USLC-8
(01)
 Troubleshooting of electrical system (E-mode)
E-10 Displays on machine monitor are different from those for actual machine

E-10 Displays on machine monitor are different from those for actual
machine 40-361
Failure q Display on machine monitor are different from those for applicable model.
Related information

Cause Procedure, measuring location, criteria and remarks

a Turn starting switch to ON position and perform troubleshooting (with mon-
itoring function).
Monitoring code Correct display
1 Defective model code signal
00200 Controller model code PC228US-8
If display on monitor is incorrect, perform troubleshooting for failure code
[DA29KQ].
If no failure is found in check on cause 1, machine monitor is defective. (Since
2 Defective machine monitor
failure is in monitor, troubleshooting cannot be performed.)

E-11 Some areas of machine monitor screen are not displayed 40-361
Failure q Machine monitor does not display some items
q The LCD panel may have black pixels (that do not light up) or bright pixels (that stay on). If
Related information the number of the bright pixels and black pixels does not exceed ten, it does not indicate a
failure or a defect.

Cause Procedure, measuring location, criteria and remarks

a Turn starting switch ON and performed troubleshooting.
Defective machine monitor When following switches are operated, if all LCD panel is lighted up (all sur-
1
(LCD panel) face becomes white), LCD panel is normal.
q Operation of switches: [4] + [F2] (Press simultaneously)

Defective machine monitor If cause 1 is not detected, machine monitor may be defective.
2
(body) (Since trouble is in system, troubleshooting cannot be performed.)

E-12 Function switch does not operate 40-361

Failure q The function switch does not work.
q The condition of signal of function switch can be checked with the monitoring function.
Related information
(Code: 04503 Monitor function switch)

Cause Procedure, measuring location, criteria and remarks

Machine monitor may be defective. (Since trouble is in system, troubleshoot-
1 Defective machine monitor
ing cannot be performed.)

PC228US-8,PC228USLC-8 40-361
(01)
Troubleshooting of electrical system (E-mode)
E-13 Automatic warm-up system does not operate (in cold season)

E-13 Automatic warm-up system does not operate (in cold season) 40-362
Failure q Automatic warm-up system does not operate (in cold weather).
q Automatic warm-up function increases engine speed to 1,200 rpm when engine coolant tem-
perature is below 30 °C.
q With starting switch at ON position or after engine is started, if fuel control dial is kept at 70%
of full open range or more for 3 seconds, automatic warm-up operation is canceled.
q If machine is equipped with air conditioner, when blower is operated, ambient temperature is
Related information
below 5 °C and engine coolant temperature is below 55 °C, automatic warm-up function in-
creases engine speed to 1,300 rpm. If engine coolant temperature reaches 60 °C, automatic
warm-up function is canceled.
q If engine coolant temperature is below 10 °C, turbocharger protection function operates to
keep engine speed below 1,000 rpm for up to 5 seconds after engine is started.

Cause Procedure, measuring location, criteria and remarks

a Turn starting switch to ON position or start engine and perform trouble-
shooting.
Engine coolant tempera- Coolant temperature
Monitoring code
ture gange level
105 °C 6 (a: Red)
102 °C 5 (a: Red)
Defective engine coolant tempera- 04107 100 °C 4 (a: Blue)
1
ture signal system Engine coolant tempera-
ture 85 °C 3 (a: Blue)
60 °C 2 (a: Blue)
30 °C 1 (a: White)
If engine coolant temperature does not match with coolant temperature gauge
level, perform troubleshooting for "E-8 Engine coolant temperature gauge
does not indiate correctly".
If no failure is found in cause 1, the engine controller is defective. (Since fail-
2 Defective engine controller
ure is in controller, troubleshooting cannot be performed.)

Engine coolant temperature gauge and engine

coolant temperature monitor 40-362

40-362 PC228US-8,PC228USLC-8
(01)
 Troubleshooting of electrical system (E-mode)
E-14 Auto-decelerator does not operate properly

E-14 Auto-decelerator does not operate properly 40-363

1) When auto-decelerator switch is operated, auto-decelerator monitor does not light up or does
Failure
not go off.
q Condition of signal of auto-decelerator switch can be checked with monitoring function.
Related information
(Code: 04504 Monitor 1st, 2nd line switches)

Cause Procedure, measuring location, criteria and remarks

Machine monitor may be defective. (Since trouble is in system, troubleshoot-
1 Defective machine monitor
ing cannot be performed.)

Failure 2) Auto-decelerator is not operated or canceled with lever.

q Since set speed of auto-decelerator is 1,050 rpm, it is not operated or canceled if fuel control
Related information dial is set below this speed.
q Auto-deceleration does not function in arm crane mode (L) for machines with arm crane.

Cause Procedure, measuring location, criteria and remarks

a Start engine and perform troubleshooting (with monitoring function).
Monitoring code Item Correct display
Swing
Travel
When lever is operated:
01900 Boom LOWER ON
Pressure switch 1 Boom RAISE When lever is in neutral:
OFF
1 Defective PPC oil pressure signal Arm IN
Arm OUT
Bucket CURL When lever is operated:
01901 ON
Bucket DUMP
Pressure Switch 2 When lever is in neutral:
Service OFF
If display of monitor is incorrect, perform troubleshooting for "E-26 - 34 Moni-
toring function does not display *** properly".
If no failure is found in check on cause 1, machine monitor may be defective.
2 Defective machine monitor
(Since failure is in monitor, troubleshooting cannot be performed.)
If no failure is found in checks on causes 1 and 2, pump controller may be
3 Defective pump controller
defective (Since failure is in controller, troubleshooting cannot be performed.)
If no failure is found in checks on causes 1 and 3, engine controller may be
4 Defective engine controller
defective. (Since failure is in controller, troubleshooting cannot be performed.)

PC228US-8,PC228USLC-8 40-363
(01)
Troubleshooting of electrical system (E-mode)
E-15 Working mode does not change

E-15 Working mode does not change 40-364

Failure 1) When working mode switch is operated, working mode selection screen is not displayed.
q Condition of signal of working mode switch can be checked with monitoring function.
Related information
(Code: 04504 Monitor 1st, 2nd line switches)

Cause Procedure, measuring location, criteria and remarks

Machine monitor may be defective. (Since trouble is in system, troubleshoot-
1 Defective machine monitor
ing cannot be performed.)

Failure 2) When working mode is changed, setting of engine and hydraulic pump is not changed.
Related information

Cause Procedure, measuring location, criteria and remarks

Machine monitor may be defective. (Since trouble is in system, troubleshoot-
1 Defective machine monitor
ing cannot be performed.)
Pump controller may be defective. (Since failure is in controller, troubleshoot-
2 Defective pump controller
ing cannot be performed.)

40-364 PC228US-8,PC228USLC-8
(01)
 Troubleshooting of electrical system (E-mode)
E-16 Travel speed does not change

E-16 Travel speed does not change 40-365

Failure 1) When travel speed switch is operated, travel speed monitor does not change.
q Condition of signal of travel speed switch can be checked with monitoring function.
Related information
(Code: 04504 Monitor 1st, 2nd line switches)

Cause Procedure, measuring location, criteria and remarks

Machine monitor may be defective. (Since trouble is in system, troubleshoot-
1 Defective machine monitor
ing cannot be performed.)

Failure 2) When travel speed selection is changed, actual travel speed does not change.
q If cause 1 occurs, actual travel speed does not lower when travel speed selection is changed
to Lo.
Related information
q As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be
measured at pump controller connector.

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Hot short circuit in wiring harness 2. Disconnect connector V04 and connect T-adapter to female side.
1 3. Turn starting switch to ON position.
(contact with 24 V circuit)
Between V04 (female) (2) and ground Voltage Max. 1 V
If no failure is found in checks on cause 1, machine monitor may be defective.
2 Defective machine monitor
(Since failure is in monitor, troubleshooting cannot be performed.)
If no failure is found in checks on cause 1 and 2, pnmp controller may be
3 Defective pump controller
defective (Since failure is in controller, troubleshooting cannot be performed.)

Circuit diagram related to travel speed solenoid 40-365

PC228US-8,PC228USLC-8 40-365
(01)
Troubleshooting of electrical system (E-mode)
E-17 Alarm buzzer cannot be canceled

E-17 Alarm buzzer cannot be canceled 40-36

Failure q Alarm buzzer cannot be canceled
q Condition of signal of alarm buzzer cancel switch can be checked with monitoring function.
Related information (Code: 04504 Monitor 1st, 2nd line switches)
a Alarm buzzer related to failure of arm crane cannot be cancelled.

Cause Procedure, measuring location, criteria and remarks

Machine monitor may be defective. (Since failure is in monitor, troubleshooting
1 Defective machine monitor
cannot be performed.)

E-18 When starting switch is turned OFF, service meter is not displayed40-36
Failure q When starting switch is turned OFF, service meter is not displayed.
q While starting switch is at OFF position, if following switches are operated, service meter is
Related information displayed at top center of screen.
Operation of switches: [4] + [1] (Press simultaneously)

Cause Procedure, measuring location, criteria and remarks

When starting switch is turned ON, if machine monitor displays nothing,
Defective backup power supply backup power supply system may be defective. In this case, perform trouble-
1
system shooting for "E-3 When starting switch is turned ON, machine monitor displays
nothing".
If cause 1 is not detected, machine monitor may be defective.
2 Defective machine monitor
(Since trouble is in system, troubleshooting cannot be performed.)

40-366 PC228US-8,PC228USLC-8
(01)
 Troubleshooting of electrical system (E-mode)
E-19 Service mode cannot be selected

E-19 Service mode cannot be selected 40-367

Failure q Machine monitor cannot be set in service mode
q Following switch operation sets the machine monitor in service mode.
Related information
Switch operation: [4] + [1] o [2] o [3] (While pressing [4], press [1], [2], and [3] in order)

Cause Procedure, measuring location, criteria and remarks

Machine monitor may be defective. (Since trouble is in system, troubleshoot-
1 Defective machine monitor
ing cannot be performed.)

PC228US-8,PC228USLC-8 40-367
(01)
Troubleshooting of electrical system (E-mode)
E-20 Any of work equipment, swing and travel do not operate or cannot be locked

E-20 Any of work equipment, swing and travel do not operate or cannot
be locked 40-368
Failure 1) All of work equipment, swing, and travel mechanism do not move.
Related infor-
mation

Cause Procedure, measuring location, criteria and remarks

1 Defective fuse F01-3 If the fuse is blown, the circuit probably has a ground fault. (See cause 6.)

1. Turn starting switch to OFF position.

Defective lock lever 2. Disconnect connector S14 and connect T-adapter to female side.
2 switch (open circuit in
Between S14 (male) (1) and Lock lever: LOCK Resistance Min. 1 Mz
internal wiring)
(2) Lock lever: FREE Resistance Max. 1 z
1. Turn starting switch to OFF position.
Defective PPC lock sole- 2. Disconnect connector V01 and connect T-adapter to male side.
3 noid (open or short circuit
Between V01 (male) (1) and (2) Resistance 20 – 60 z
in internal wiring)
Between V01 (male) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Remove diode array D01 and connect T-adapter to male side.
Defective diode array D01 a Check the continuity in diode range.
4
(internal short circuit) Between D01 (male) (8) (+) and (4) (-) Continuity
Between D01 (male) (4) (+) and (8) (-) No continuity
1. Turn starting switch to OFF position.
2. Set lock lever to FREE position.
3. Remove fuse F01-3.
Between F01-3 and ground (coil resistance of PPC lock
Resistance 20 – 60 z
solenoid)
Open circuit in wiring har- a If above check result is normal, this check is not required.
ness 1. Turn starting switch to OFF position.
5
(Wire breakage or defec- 2. Remove fuse F01-3.
tive contact of connector) 3. Disconnect connectors S14 and V01 and then connect T-adapters to male side of
S14 and female side of V01.
Between F01-3 and S14 (male) (1) Resistance Max. 1 z
Between S14 (male) (2) and V01 (female) (1) Resistance Max. 1 z
Between V01 (female) (2) and ground (T09) Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Remove fuse F01-3.
Ground fault in wiring har- 3. Disconnect connectors S14, V01, and D01, and then connect T-adapter to male
ness side of S14 or female side of V01 or D01.
6
(Contact with ground cir- Between F01-3 or S14 (male) (1) and ground Resistance Min. 1 Mz
cuit)
Between ground and S14 (male) (2), V01 (female) (1) or
Resistance Min. 1 Mz
D01 (female) (4)

40-368 PC228US-8,PC228USLC-8
(01)
 Troubleshooting of electrical system (E-mode)
E-20 Any of work equipment, swing and travel do not operate or cannot be locked

Failure 2) All of work equipment, swing, and travel mechanism do not lock.
Related informa-
tion

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Defective lock lever switch 2. Disconnect connector S14, and connect T-adapter to male side.
1 (short circuit in internal wir-
Between S14 (male) (1) Lock lever: LOCK Resistance Min. 1 Mz
ing)
and (2) Lock lever: FREE Resistance Max. 1 z
1. Turn starting switch to OFF position.
Hot short circuit in wiring 2. Connect T-adapter to connector V01.
2 harness 3. Turn starting switch to ON position.
(contact with 24 V circuit)
Between V01 (male) (1) and (2) Voltage Max. 1 V

Related circuit diagram 40-369

PC228US-8,PC228USLC-8 40-369
(01)
Troubleshooting of electrical system (E-mode)
E-20 Any of work equipment, swing and travel do not operate or cannot be locked

40-370 PC228US-8,PC228USLC-8
(01)
 Troubleshooting of electrical system (E-mode)
E-21 Swing brake does not operate properly

E-21 Swing brake does not operate properly 40-371

Failure 1) When swing brake cancel switch is set to CANCEL position, machine cannot swing.
Related infor- q Condition of swing lock switch signal can be checked with monitoring function.
mation (Pump controller system code: 02200 Switch input 1)

Cause Procedure, measuring location, criteria and remarks

If fuse F01-1 is broken, circuit probably has ground fault. In this case, troubleshoot
1 Defective fuse F01-1
cause 6 first.
1. Turn starting switch to OFF position.
2. Disconnect connector S25, and connect T-adapter to male side.
Defective swing brake can-
Swing brake cancel switch:
2 cel switch (internal short cir- Resistance Min. 1 Mz
cuit) Between S25 (male) (13) LOCK
and (14) Swing brake cancel switch:
Resistance Max. 1 z
CANCEL
1. Turn starting switch to OFF position.
2. Remove diode arrays D01 and D03, and connect T-adapters to male side.
a Check the continuity in diode range.
Defective diode array D01 or Between D01 (male) (7) (+) and (3) (-) Continuity
3
D03 (internal short circuit) Between D01 (male) (3) (+) and (7) (-) No continuity
Between D03 (male) (7) (+) and (3) (-) Continuity
Between D03 (male) (3) (+) and (7) (-) No continuity
1. Turn starting switch to OFF position.
2. Disconnect connector V03 and connect T-adapter to female side.
3. Turn starting switch to ON position.
4 Defective wiring harness Swing brake cancel switch:
Voltage 20 to 30 V
Between V03 (female) (1) CANCEL
and (2) Swing brake cancel switch:
Voltage Max. 1 V
LOCK
a If no failure is found in checks on cause 4, this check is not required.
1. Turn starting switch to OFF position.
Open circuit in wiring har-
2. Disconnect connectors V03 and S25, and connect T-adapters to female sides of
ness
5 them.
(Wire breakage or defective
contact of connector) Between V03 (female) (1) and S25 (female) (14) Resistance Max. 1 z
Between V03 (female) (2) and C02 (female) (115) Resistance Max. 1 z
a If no failure is found in checks on cause 3, this check is not required.
Ground fault in wiring har- 1. Turn starting switch to OFF position.
6 ness 2. Disconnect connectors S25, V03, D01 and D03, and connect T-adapter to
(contact with ground circuit) female side of V03.
Between V03 (female) (1) and ground Resistance Min. 1 Mz

Failure 2) When swing brake cancel switch is set to LOCK position, swing brake does not operate.
Related infor-
mation

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connector S25, and connect T-adapter to male side.
Defective swing brake can-
Swing brake cancel switch:
1 cel switch (internal short cir- Resistance Min. 1 Mz
cuit) Between S25 (male) (13) LOCK
and (14) Swing brake cancel switch:
Resistance Max. 1 z
CANCEL

PC228US-8,PC228USLC-8 40-371
(01)
Troubleshooting of electrical system (E-mode)
E-21 Swing brake does not operate properly

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Hot short circuit in wiring 2. Disconnect connector V03 and connect T-adapter to female side.
2 harness 3. Turn starting switch to ON position.
(contact with 24 V circuit) 4. Swing lock switch: ON
Between V03 (female) (1) and ground Voltage Max. 1 V

40-372 PC228US-8,PC228USLC-8
(01)
 Troubleshooting of electrical system (E-mode)
E-21 Swing brake does not operate properly

Circuit diagram related to swing brake solenoid 40-373

PC228US-8,PC228USLC-8 40-373
(01)
Troubleshooting of electrical system (E-mode)
E-22 One-touch power maximizing function does not operate properly

E-22 One-touch power maximizing function does not operate properly 40-374
1) When L.H. knob switch is pressed, one-touch power maximizing monitor is not displayed.
Failure
2) When L.H. knob switch is pressed, work equipment power is not increased.
q One-touch power maximizing function does not operate when working mode is not power mode
Related infor- (P) or economy mode (E).
mation q Condition of L.H. knob switch signal can be checked with monitoring function.
(Code: 02200 Switch Input 1)

Cause Procedure, measuring location, criteria and remarks

When L.H. knob switch is pressed, if work equipment power is increased but fact is not
Defective machine moni-
1 displayed on monitor, machine monitor may be defective (Since trouble is in monitor,
tor
troubleshooting cannot be performed.)

2 Defective fuse No. 9 If fuse is blown, circuit probably has a ground fault. (See cause 6.)

1. Turn starting switch to OFF position.

2. Disconnect connector S11, and connect T-adapter to male side.
Defective left knob switch
3
(internal open circuit) Between S11 (female) (1) L.H. knob switch: Released Resistance Min. 1 Mz
and (2) L.H. knob switch: Pressed Resistance Max. 1 z
1. Turn starting switch to OFF position.
Defective PPC lock sole- 2. Disconnect connector V01 and connect T-adapter to male side.
4 noid (open or short circuit
Between V01 (male) (1) and (2) Resistance 20 – 60 z
in internal wiring)
Between V01 (male) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector C01 and connect T-adapter to female side.
3. Turn starting switch to ON position.
Open circuit in or ground
5 a Ignore displayed failure code.
fault of wiring harness
Between C01 (female) (41) L.H. knob switch: Released Voltage Max. 1 V
and ground L.H. knob switch: Pressed Voltage 20 – 30 z
a If no failure is found in checks on cause 4, this check is not required.
1. Turn starting switch to OFF position.
Open circuit in wiring har-
2. Remove fuse F01-9.
ness
6 3. Disconnect connectors C01 and S11 and connect T-adapters to their female sides.
(Wire breakage or defec-
tive contact of connector) Between F01-9 and S11 (female) (1) Resistance Max. 1 z
Between S11 (female) (2) and C01 (female) (41) Resistance Max. 1 z
a If no failure is found in checks on cause 4, this check is not required.
1. Turn starting switch to OFF position.
Ground fault in wiring har- 2. Remove fuse F01-9.
ness 3. Disconnect connectors C01 and S11 and connect T-adapter to female side of S11.
7
(contact with ground cir-
cuit) Between F01-9 or S11 (female) (1) and ground Resistance Min. 1 Mz
Between S11 (female) (2) or C01 (female) (41) and
Resistance Min. 1 Mz
ground
If no failure is found by above checks, pump controller is defective. (Since failure is in
8 Defective pump controller
controller, troubleshooting cannot be performed.)

40-374 PC228US-8,PC228USLC-8
(01)
 Troubleshooting of electrical system (E-mode)
E-22 One-touch power maximizing function does not operate properly

Circuit diagram related to one-touch power maximizing switch 40-375

PC228US-8,PC228USLC-8 40-375
(01)
Troubleshooting of electrical system (E-mode)
E-22 One-touch power maximizing function does not operate properly

Failure 3) When L.H. knob switch is released, work equipment power is not returned to normal.
Related informa- q Condition of L.H. knob switch signal can be checked with monitoring function.
tion (Code: 02200 Switch Input 1)

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Hot short circuit in wiring 2. Disconnect connector V02 and connect T-adapter to female side.
1 harness 3. Turn starting switch to ON position.
(contact with 24 V circuit)
Between V02 (female) (1) and (2) Voltage Max. 1 V
If no failure is found in check on cause 1, pump controller is defective. (Since failure
2 Defective pump controller
is in controller, troubleshooting cannot be performed.)

Circuit diagram related to 2-stage relief solenoid 40-376

40-376 PC228US-8,PC228USLC-8
(01)
 Troubleshooting of electrical system (E-mode)
E-23 Travel alarm does not sound or does not stop sounding

E-23 Travel alarm does not sound or does not stop sounding 40-37
Failure 1) Alarm does not sound during travel.
Related infor- q Output to travel alarm can be checked with monitoring function.
mation (Code: 03701 Controller output 2)

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Defective travel alarm 2. Disconnect connector M14 and connect T-adapter to male side.
1
(internal defect)
Between M14 (male) (1) and (2) Continuity
1. Turn starting switch to OFF position.
Open circuit in wiring har- 2. Disconnect connectors M14 and C02 and connect T-adapters to their female
ness sides.
2
(Wire breakage or defective Between C02 (female) (107) and M14 (female) (1) Resistance Max. 1 z
contact of connector)
Between C02 (female) (115) and M14 (female) (2) Resistance Max. 1 z
1. Turn starting switch to OFF position.
Ground fault in wiring har- 2. Disconnect connectors C02 and M14, and connect T-adapter to female side of
3 ness either connector.
(contact with ground circuit) Between C02 (female) (107) or M14 (female) (1) and
Resistance Min. 1 Mz
ground

Failure 2) Alarm does not stop sounding while machine is stopped.

Related infor-
mation

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Hot short circuit in wiring 2. Disconnect connector M14 and connect T-adapter to female side.
1 harness 3. Turn starting switch to ON position.
(contact with 24 V circuit)
Between M14 (female) (1) and ground Voltage Max. 1 V

Circuit diagram related to travel alarm 40-37

PC228US-8,PC228USLC-8 40-377
(01)
Troubleshooting of electrical system (E-mode)
E-24 Horn does not sound or does not stop

E-24 Horn does not sound or does not stop 40-378

Failure 1) Horn does not sound.
Related infor-
mation

Cause Procedure, measuring location, criteria and remarks

If fuse F01-5 is broken, circuit probably has ground fault. In this case, trouble-
1 Defective fuse F01-5
shoot cause 7 first.
1. Turn starting switch to OFF position.
Defective horn relay 2. Replace horn relay (connector: R08) with another relay.
2 (open or short circuit in internal 3. Turn starting switch to ON position.
wiring) 4. Press L.H. knob switch.
If horn sounds, original horn relay is defective.
1. Turn starting switch to OFF position.
2. Disconnect connector S10 and connect T-adapter to male side.
Defective horn switch
3
(internal open or short circuit) Between S10 (male) (1) Switch: OFF Resistance Min. 1 Mz
and (2) Switch: ON Resistance Max. 1 z
1. Turn starting switch to OFF position.
Defective high-tone horn (M07) 2. Disconnect connectors M07 and M08 and connect T-adapters to their male
or low-tone horn (M08) (open sides.
4
circuit or short circuit in internal Between M07 (male) (1) and (2) Continuity
wiring)
Between M08 (male) (1) and (2) Continuity
1. Turn starting switch to OFF position.
2. Disconnect connector R08 and connect T-adapter to female side.
3. Turn starting switch to ON position.
5 Defective wiring harness 4. Press L.H. knob switch.
Between R08 (female) (1) and (2) Voltage 20 to 30 V
Between R08 (female) (3) and (2) Voltage 20 to 30 V
1. Turn starting switch to OFF position.
2. Disconnect connector R08 and connect T-adapter to female side.
Between R08 (female) (5) and ground Continuity
Between R08 (female) (1) and ground Continuity
a If no failure is found in above checks, this check is not required.
Open circuit in wiring harness 1. Turn starting switch to OFF position.
6 (Wire breakage or defective con- 2. Remove fuse F01-5.
tact) 3. Disconnect connectors R08 and S10, and connect T-adapters to female sides
of them.
Between F01-5 and S10 (female) (1) Resistance Max. 1 z
Between S10 (female) (2) and R08 (female) (1) Resistance Max. 1 z
Between R08 (female) (2) and ground Resistance Max. 1 z
Between R08 (female) (3) and F01-5 Resistance Max. 1 z
a If fuse is not blown, this check is not required.
1. Turn starting switch to OFF position.
2. Remove fuse F01-5.
3. Disconnect connectors R08, M07, and M08, and connect T-adapter to female
Ground fault in wiring harness side of R08.
7
(contact with ground circuit)
Between R08 (female) (1) and ground Resistance Min. 1 Mz
Between R08 (female) (3) and ground Resistance Min. 1 Mz
Between R08 (female) (5) and ground Resistance Min. 1 Mz

40-378 PC228US-8,PC228USLC-8
(01)
 Troubleshooting of electrical system (E-mode)
E-24 Horn does not sound or does not stop

Cause Procedure, measuring location, criteria and remarks

Defective horn
8 If cause cannot be found by above checks, horn may be defective.
(internal defect)

Failure 2) Horn does not stop sounding.

Related infor-
mation

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Defective horn relay (R08) 2. Remove horn relay (connector R08).
1 (open or short circuit in internal 3. Turn starting switch to ON position.
wiring)
If horn stops sounding, original horn relay is defective.
1. Turn starting switch to OFF position.
2. Disconnect connectors M07 and M08 and connect T-adapters to their
female sides.
Hot short circuit in wiring harness
2 3. Turn starting switch to ON position.
(contact with 24 V circuit)
Between M07 (female) (2) and (1) Voltage Max. 1 V
Between M08 (female) (2) and (1) Voltage Max. 1 V

Circuit diagram related to horn 40-379

PC228US-8,PC228USLC-8 40-379
(01)
Troubleshooting of electrical system (E-mode)
E-25 Windshield wiper and window washer do not operate

E-25 Windshield wiper and window washer do not operate 40-380

Failure 1) When wiper switch is operated, wiper monitor does not light up or go off.
Related informa- q Condition of wiper switch signal can be checked with monitoring function.
tion (Code: 04504 Monitor 1st, 2nd line switches)

Cause Procedure, measuring location, criteria and remarks

Machine monitor may be defective. (Since failure is in monitor, troubleshooting can-
1 Defective machine monitor
not be performed.)

Failure 2) When wiper switch is operated, wiper does not operate.

q Condition of window rear limit switch signal can be checked with monitoring function.
Related informa-
(Code: 02204 Switch input 5)
tion
q Wiper motor is troubleshot for failure codes [DY20KA], [DY20MA], [DY2DKB], and [DY2EKB].

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connector W03.
Defective rear limit switch for
1 window (internal short cir- Front window: when closed Resistance Min. 1 Mz
cuit) Between W03 (male) (1)
and (2) Front window: when pulled
Resistance Max. 1 z
up

Defective wiper motor 1. Turn starting switch to OFF position.

2 (internal open circuit in wir- 2. Disconnect connector M05 and connect T-adapter to female side.
ing) Between M05 (female) (1) and (3) Continuity
a Wiper motor system
Open circuit in wiring har- See troubleshooting for [DY20KA], [DY20MA], [DY2DKB], and [DY2EKB].
ness a Rear limit switch system
3 (Wire breakage in wiring or 1. Turn starting switch to OFF position.
defective contact of connec- 2. Disconnect connector C01 and connect T-adapter to female side.
tor) 3. Pull up front window.
Between C01 (female) (57) and ground Resistance Max. 1 z
1. Turn starting switch to OFF position.
Ground fault in wiring har- 2. Disconnect connector C01 and connect T-adapter to female side.
4 ness 3. Close front window.
(contact with ground circuit)
Between C01 (female) (57) and ground Resistance Min. 1 Mz
If no failure is found by above checks, pump controller is defective. (Since failure is
5 Defective pump controller
in controller, troubleshooting cannot be performed.)

Failure 3) When window washer switch is operated, window washer does not operate.
q Condition of window washer switch signal can be checked with monitoring function.
Related informa-
(Code: 04504 Monitor 1st, 2nd line switches)
tion
q Window washer is troubleshot for failure codes [DY2CKA] and [DY2CKB].

Cause Procedure, measuring location, criteria and remarks

Machine monitor may be defective. (Since failure is in monitor, troubleshooting can-
1 Defective machine monitor
not be performed.)

40-380 PC228US-8,PC228USLC-8
(01)
 Troubleshooting of electrical system (E-mode)
E-25 Windshield wiper and window washer do not operate

Circuit diagram related to wiper 40-381

PC228US-8,PC228USLC-8 40-381
(01)
Troubleshooting of electrical system (E-mode)
E-26 BOOM LOWER indicator is not displayed properly with monitoring function

E-26 BOOM LOWER indicator is not displayed properly with monitoring

function 40-382
Failure Boom LOWER operation is not displayed properly with monitoring function.
q Monitoring code: 01900 Pressure switch 1
q Use "short connector": 799-601-7230 for 2-pin X connector in test for Cause 6.
Related information
q As pump controller connector uses "socket-type box" T-adapter, operating voltage cannot be
measured at pump controller connector.

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connector P02 and connect T-adapter to male side.
3. Start engine
Defective boom lower PPC pres- 4. Operate R.H. work equipment control lever and perform troubleshooting.
1 sure switch (open or short circuit in R.H. work equipment
internal wiring) Resistance Min. 1 Mz
control lever: NEUTRAL
Between P02 (male) (1)
and (2) R.H. work equipment
control lever: Boom Resistance Max. 1 z
LOWER
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector P02.
3. Start engine
4. Operate R.H. work equipment control lever and perform troubleshooting.
Defective harness or pump con-
2 R.H. work equipment
troller Voltage Approx. 7 V
control lever: NEUTRAL
Between P02 (2) and (1) R.H. work equipment
control lever: Boom Voltage Max. 1 V
LOWER
a If no failure is found in checks on cause 2, this check is not required.
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Disconnect connectors C01 and P02 and connect T-adapters to each
3 (Wire breakage or defective con- female side.
tact of connector) Between C01 (female) (14) and P02 (female) (1) Resistance Max. 1 z
Between P02 (female) (2) and ground (T10) Resistance Max. 1 z
a If no failure is found in checks on cause 2, this check is not required.
1. Turn starting switch to OFF position.
Ground fault of harness 2. Disconnect connectors C01 and P02 and connect T-adapter to female side
4
(contact with ground circuit) of either of them.
Between ground and C01 (female) (14) or P02
Resistance Min. 1 Mz
(female) (1)
a If no failure is found in checks on cause 2, this check is not required.
1. Turn starting switch to OFF position.
Hot short circuit in wiring harness 2. Disconnect connector P02 and connect T-adapter to female side.
5
(contact with 24 V circuit) 3. Turn starting switch to ON position.
Between P02 (female) (1) and ground Voltage Approx. 7 V
1. Turn starting switch to OFF position.
2. Disconnect connector P02 and connect T-adapter to female side.
3. Connect "short connector" to male side of T-adapter.
6 Defective pump controller 4. Turn starting switch to ON position.
If voltage between P02 (1) and (2) is below 1 V but "Boom LOWER" is dis-
played "OFF", pump controller is defective.
a After finishing test, restore connector.

40-382 PC228US-8,PC228USLC-8
(01)
 Troubleshooting of electrical system (E-mode)
E-26 BOOM LOWER indicator is not displayed properly with monitoring function

Circuit diagram related to boom LOWER oil pressure switch 40-383

PC228US-8,PC228USLC-8 40-383
(01)
Troubleshooting of electrical system (E-mode)
E-27 ARM OUT indicator is not displayed properly with monitoring function

E-27 ARM OUT indicator is not displayed properly with monitoring func-
tion 40-384
Failure Arm OUT operation is not displayed properly with monitoring function.
q Monitoring code: 01900 Pressure switch 1
q Use "short connector": 799-601-7230 for 2-pin X connector in test for Cause 6.
Related information
q As pump controller connector uses "socket-type box" T-adapter, operating voltage cannot be
measured at pump controller connector.

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connector P08 and connect T-adapter to male side.
3. Start engine
Defective Arm OUT PPC oil pres- 4. Operate L.H. work equipment control lever and perform troubleshooting.
1 sure switch (internal open or short L.H. work equipment
circuit) Resistance Min. 1 Mz
Between P08 (male) (1) control lever: NEUTRAL
and (2) L.H. work equipment
Resistance Max. 1 z
control lever: Arm OUT
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector P08.
3. Start engine.
4. Operate L.H. work equipment control lever and perform troubleshooting.
Defective harness or pump con-
2 L.H. work equipment
troller Voltage Approx. 7 V
control lever: NEUTRAL
Between P08 (2) and (1)
L.H. work equipment
Voltage Max. 1 V
control lever: Arm OUT
a If no failure is found in checks on cause 2, this check is not required.
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Disconnect connectors C01 and P08 and connect T-adapters to each
3 (Wire breakage or defective con- female side.
tact of connector) Between C01 (female) (15) and P08 (female) (1) Resistance Max. 1 z
Between P08 (female) (1) and ground (T10) Resistance Max. 1 z
a If no failure is found in checks on cause 2, this check is not required.
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors C01 and P08 and connect T-adapter to female side
4
(contact with ground circuit) of either one.
Between ground and C01 (female) (15) or P08
Resistance Min. 1 Mz
(female) (1)
a If no failure is found in checks on cause 2, this check is not required.
1. Turn starting switch to OFF position.
Hot short circuit in wiring harness 2. Disconnect connector P08, and connect T-adapter to female side.
5
(contact with 24 V circuit) 3. Turn starting switch to ON position.
Between P08 (female) (1) and ground Voltage Approx. 7 V
1. Turn starting switch to OFF position.
2. Disconnect connector P08, and connect T-adapter to female side.
3. Connect "short connector" to male side of T-adapter.
6 Defective pump controller 4. Turn starting switch to ON position.
If voltage between P08 (1) and (2) is below 1 V but"OFF" is displayed for "Arm
OUT", pump controller is defective.

40-384 PC228US-8,PC228USLC-8
(01)
 Troubleshooting of electrical system (E-mode)
E-27 ARM OUT indicator is not displayed properly with monitoring function

Circuit diagram related to arm OUT oil pressure switch 40-385

PC228US-8,PC228USLC-8 40-385
(01)
Troubleshooting of electrical system (E-mode)
E-28 ARM IN indicator is not displayed properly with monitoring function

E-28 ARM IN indicator is not displayed properly with monitoring func-

tion 40-386
Failure Arm IN operation is not displayed properly with monitoring function.
Related information q Monitoring code: 01900 Pressure switch 1

Cause Procedure, measuring location, criteria and remarks

Defective arm IN PPC oil pressure
1 sensor system (internal open cir- Perform troubleshooting for failure code [DHS3MA].
cuit or short circuit)

E-29 BOOM RAISE indicator is not displayed properly with monitoring

function 40-386
Failure Boom RAISE operation is not displayed properly with monitoring function.
Related informa-
q Monitoring code: 01900 Pressure switch 1
tion

Cause Procedure, measuring location, criteria and remarks

Defective boom RAISE PPC
oil pressure sensor system
1 Perform troubleshooting for failure code [DHS8MA].
(internal open circuit or short
circuit)

E-30 BUCKET CURL indicator is not displayed properly with monitoring

function 40-386
Failure Bucket CURL operation is not displayed properly with monitoring function.
Related information q Monitoring code: 01901 Pressure switch 2

Cause Procedure, measuring location, criteria and remarks

Defective bucket CURL PPC oil
1 Perform troubleshooting for failure code [DHS4MA].
pressure sensor system

40-386 PC228US-8,PC228USLC-8
(01)
 Troubleshooting of electrical system (E-mode)
E-31 BUCKET DUMP indicator is not displayed properly with monitoring function

E-31 BUCKET DUMP indicator is not displayed properly with monitoring

function 40-387
Failure Bucket DUMP operation is not displayed properly with monitoring function.
Related information q Monitoring code: 01901 Pressure switch 2

Cause Procedure, measuring location, criteria and remarks

Defective bucket DUMP PPC oil
1 Perform troubleshooting for failure code [DHSDMA].
pressure sensor system

E-32 SWING indicator is not displayed properly with monitoring func-

tion 40-387
Failure Swing operation is not displayed properly with monitoring function.
Related information q Monitoring code: 01901 Pressure switch 2

Cause Procedure, measuring location, criteria and remarks

Defective swing PPC oil pressure
sensor system
1 Perform troubleshooting for failure codes [DHSAMA] and [DHSBMA].
(internal open circuit or short cir-
cuit)

E-33 TRAVEL indicator is not displayed properly with monitoring func-

tion 40-387
Failure Travel operation is not displayed properly with monitoring function.
Related information q Monitoring code: 01901 Pressure switch 2

Cause Procedure, measuring location, criteria and remarks

Defective travel PPC oil pressure
sensor system Perform troubleshooting for failure codes [DHSFMA], [DHSGMA], [DHSHMA]
1
(internal open circuit or short cir- and [DHSJMA].
cuit)

PC228US-8,PC228USLC-8 40-387
(01)
Troubleshooting of electrical system (E-mode)
E-34 ATTACHMENT indicator is not displayed properly with monitoring function

E-34 ATTACHMENT indicator is not displayed properly with monitoring

function 40-38
Failure Attachment is not displayed properly with monitoring function.
q Monitoring code: 01901 Pressure switch 2
q For safety, use "short connector" 799-601-7230 for 2-pin X connector in tests for Causes 1
Related information and 2.
k Do not check oil pressure switch connector while engine is running.

Cause Procedure, measuring location, criteria and remarks

A. If monitoring function does not indicate that attachment control pedal is
operated when engine is started and attachment control pedal is depressed at
front end
1. Turn starting switch to OFF position.
2. Disconnect connector P14 and connect "short connector" to male side.
3. Turn starting switch to ON position.
a After finishing test, restore connectors.
If monitoring function indicates that "attachment control pedal" is "operated",
Defective PPC oil pressure switch PPC oil pressure switch (P14) for front end of attachment control pedal is
1 (P14) for front end of attachment defective (Note 1).
control pedal
B. If monitoring function indicates that attachment control pedal is operated
when starting switch is turned to ON position
1. Turn starting switch to OFF position.
2. Disconnect connector P14.
3. Turn starting switch to ON position.
If monitoring function indicates that "attachment control pedal" is "released",
PPC oil pressure switch (P14) for front end of attachment control pedal is
defective (Note 2).
A. If monitoring function does not indicate that attachment control pedal is
operated when engine is started and attachment control pedal is depressed at
rear end
1. Turn starting switch to OFF position.
2. Disconnect connector P15 and connect "short connector" to male side.
3. Turn starting switch to ON position.
a After finishing test, restore connectors.
If monitoring function indicates that "attachment control pedal" is "operated",
Defective PPC oil pressure switch PPC oil pressure switch (P15) for rear end of attachment control pedal is
2 (P15) for rear end of attachment defective (Note 1).
control pedal
B. If monitoring function indicates that attachment control pedal is operated
when starting switch is turned to ON position
1. Turn starting switch to OFF position.
2. Disconnect connector P15.
3. Turn starting switch to ON position.
If monitoring function indicates that "attachment control pedal" is "released",
PPC oil pressure switch (P15) for rear end of attachment control pedal is
defective (Note 2).
1. Turn starting switch to OFF position.
2. Insert T-adapter into P13.
3. Start engine.
Defective wiring harness or pump 4. Operate attachment control pedal, and perform troubleshooting.
3 attachment control pedal:
controller Between P13 (1) and (2) Voltage Approx. 7 V
Neutral
attachment control pedal:
Between P13 (1) and (2) Voltage Max. 1 V
front end or rear end

40-388 PC228US-8,PC228USLC-8
(01)
 Troubleshooting of electrical system (E-mode)
E-34 ATTACHMENT indicator is not displayed properly with monitoring function

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connectors C01, P14, and P15, and connect T-adapters to their
female sides.
Open circuit in wiring harness Between C01 (female) (52) and P14 (female) (1) Resistance Max. 1 z
4 (Wire breakage or defective con-
tact of connector) Between C01 (female) (52) and P15 (female) (1) Resistance Max. 1 z
Between P14 (female) (2) and ground (T06) Resistance Max. 1 z
Between P15 (female) (2) and ground (T06) Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect connectors C01, P14, and P15, and connect T-adapter to
Ground fault in wiring harness female side of either one.
5
(contact with ground circuit)
Between ground and C01 (female) (52), P14
Resistance Min. 1 Mz
(female) (1) or P15 (female) (1)
1. Turn starting switch to OFF position.
2. Disconnect connectors P14 and P15, and connect T-adapter to female side
of either one.
6 Short circuit in wiring harness
3. Turn starting switch to ON position.
Between P14 (female) (1) and ground, or between
Voltage Approx. 7 V
P15 (female) (1) and ground
If no failure is found by above checks, pump controller is defective. (Since fail-
7 Defective pump controller
ure is in controller, troubleshooting cannot be performed.)

Note 1: If monitoring function indicates that "attachment control pedal" is "released" while voltage between
C01 (52) and ground is below 1 V, pump controller is defective.
Note 2: If monitoring function indicates that "attachment control pedal" is "operated" while voltage between
C01 (52) and ground is approximately 7 V, pump controller is defective.

Circuit diagram related to attachment control pedal PPC oil pressure switch (service pressure switch)40-389

PC228US-8,PC228USLC-8 40-389
(01)
Troubleshooting of electrical system (E-mode)
E-35 Attachment hydraulic circuit cannot be changed

E-35 Attachment hydraulic circuit cannot be changed 40-390

q Attachment circuit is not changed
Failure 1) When working mode P or E is selected, crusher circuit (two-way circuit) is not selected.
2) When working mode B is selected, breaker circuit (one-way circuit) is not selected.
Related infor- q Failures (open circuit/short circuit) of attachment oil return selector solenoid are troubleshot for fail-
mation ure codes [DWA2KA] and [DWA2KB].

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Defective attachment oil return 2. Disconnect connector SSTC and connect T-adapter to male side.
1 selector solenoid (internal short
Between V06 (male) (1) and (2) Resistance 20 – 60 z
circuit)
Between V06 (male) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
Hot short circuit in wiring harness 2. Disconnect connector V06 and connect T-adapter to female side.
2 3. Turn starting switch to ON position.
(contact with 24 V circuit)
Between V06 (female) (1) and ground Voltage Max. 1 V

Circuit diagram related to attachment oil return selector solenoid 40-390

40-390 PC228US-8,PC228USLC-8
(01)
 Troubleshooting of electrical system (E-mode)
E-36 KOMTRAX system does not operate properly

E-36 KOMTRAX system does not operate properly 40-391

Failure q KOMTRAX system does not operate properly.
q Perform following troubleshooting if administrator of KOMTRAX system requests to check
whether failure is occurring in system on machine.
Related information
q Even when KOMTRAX system is defective, no problem appears on machine.
q Check all of results of troubleshooting on service menu display of machine monitor.
Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to ON position.
2. Display “Terminal status” screen.
1 Defective communication 1
Check item:
To be completed
Station set-up check
1. Turn starting switch to ON position.
2. Display “GPS & Communication Status” screen.
N ###.##.## (Latitude)
Check item:
E ###.##.## (Longitude)
2 Defective positioning by GPS Positioning
In positioning
If latitude and longitude are not displayed within 5 minutes with machine
stayed outdoor which opens clearly for sky, contact KOMTRAX service hot
line.
1. Turn starting switch to ON position.
2. Display “GPS & Communication Status” screen.
Check item: Satellite in View or No Satellite in
Defective communication environ- Communication View
3
ment
If Communication Status does never display “Satellite in View” within 15 min-
utes with machine stayed outdoor which opens clearly for sky, check if con-
nector of TH300 or antenna on top of cab are properly connected.
1. Turn starting switch to ON position.
2. Display “GPS & Communication Status” screen.
4 Defective communication 2
Check item:
0 to 60 (normally 0)
Number of message not yet sent
a Select “Terminal Status” from “12 Display of a Select “GPS & Communication Status” from “12
KOMTRAX setting” in service menu of machine Display of KOMTRAX setting” in service menu of
monitor. machine monitor.

PC228US-8,PC228USLC-8 40-391
(01)
Troubleshooting of electrical system (E-mode)
E-36 KOMTRAX system does not operate properly

40-392 PC228US-8,PC228USLC-8
(01)
 Troubleshooting of hydraulic and mechanical system (H-mode)
Information in troubleshooting table

Troubleshooting of hydraulic and mechanical system (H-mode) 40-393

Information in troubleshooting table 40-393

(Rev. 2010/03)
a The following information is summarized in the troubleshooting table. Before carrying out troubleshooting,
understand that information fully.
Failure Description of failure code
Related infor-
Information related to the detected failure or troubleshooting
mation

Cause Criteria and troubleshooting procedure

2
Probable Probable causes for trou- <Contents of description>
causes and cri- ble (Each number is serial q Standard value in normal condition to judge probable
teria 3
number, not priority causes
sequence.) q Remarks on judgment
4

PC228US-8,PC228USLC-8 40-393
(01)
Troubleshooting of hydraulic and mechanical system (H-mode)
System chart for hydraulic and mechanical systems

System chart for hydraulic and mechanical systems 40-394

40-394 PC228US-8,PC228USLC-8
(01)
 Troubleshooting of hydraulic and mechanical system (H-mode)
System chart for hydraulic and mechanical systems

a This is a system chart that is drawn up by simplifying the whole hydraulic circuit chart. Use it as a reference
material when troubleshooting the hydraulic and mechanical systems.

PC228US-8,PC228USLC-8 40-395
(01)
Troubleshooting of hydraulic and mechanical system (H-mode)
Failure mode and cause table

Failure mode and cause table 40-396

Failed parts Tank Hydraulic pump Control valve

Pump merge-divider main EPC valve

Pump merge-divider LS-EPC valve
Pump merge-divider main valve
Pump merge-divider LS valve
Pressure compensation valve
Self-pressure reducing valve

Boom throttle EPC solenoid

Pump swash plate sensor

Boom regeneration valve

Boom lock valve
Main relief valve
Engine system

LS line throttle
PC-EPC valve

LS-EPC valve

Unload valve
Piston pump
Servo piston
Hydraulic oil

PC valve

LS valve
Damper

Strainer

Spool
Cap
Failure mode
All of work equipment, swing and travel work slow or lack
QQQQQQQQ Q QQ Q
Any of work equipment,

power
swing and travel

Engine speed lowers extremely or engine stalls Q QQQQQQQ

Any of work equipment, swing and travel systems does
not work.
Q QQ Q
Unusual sound is heard from around hydraulic pump QQQQ
Fine control performance or response is poor Q QQ Q
Speed or power of boom is low Q Q QQQQQQQ
Speed or power of arm is low Q Q QQQQ
Speed or power of bucket is low Q Q
Work equipment does not move in single operation Q
Work equipment

Boom Q Q
Hydraulic drift of work
equipment is large
Arm Q Q
Bucket Q Q
Time lag of work equipment operation is large Q Q Q
Other wok equipment moves when one of work equip-
ment is relieved
Q
One-touch power maximizing function does not work. Q
In combined operation of work equipment, equipment
having heavier load moves slower
Q
and travel and boom
Swing

In combined operations of swing and boom RAISE, boom

rising speed is low
Swing

Travel speed drops largely in combined operation of

swing and travel

Machine does not travel straight QQ Q Q Q

Travel speed is low. Q Q QQ
Travel

Machine is hard to steer or travel power is low Q Q QQQQ

Travel speed does not change or travel speed is too low
or high
Q
One of tracks does not run
Upper structure swings nei-
Upper structure does not ther to the right nor left
Q
swing Upper structure does not
swing in only one direction
Q
Poor or low for both of the
Swing acceleration is poor right and left
Q
or swing speed is low Poor or low for only in one
direction
Q Q
Largely for both of the right
Swing

Upper structure overruns

and left
considerably when it stops
swinging
Largely for only in one direc-
tion
Q
Shock is larger when upper structure stops swinging
Large sound is made when upper structure stops swing-
ing
Swing drift on a slope is When swing brake works
large When swing brake works Q Q
Attachment circuit is not changed
Attach-
ment

Oil flow in attachment circuit cannot be changed

40-396 PC228US-8,PC228USLC-8
(01)
 Safety valve

Q
Q
Q
Q

(01)
Suction valve

Q
LS shuttle valve

Q
Q Q
Q Q
Q
QQ Q
QQ Q
Arm regeneration valve

Q
Arm quick return valve
Arm lock valve

QQ Q Q Q Q

Q
Control valve

Swing LS select valve

Q
Travel jinterconnection valve

Q
Q
Back pressure valve

Q
Service valve (safety valve)

PC228US-8,PC228USLC-8
PPC valve (right lever)

Q
Q
PPC valve (left lever)

Q
Q
Q
Q
QQ
PPC valve (travel lever)

Q
Q
Q
PPC valve (service)

Q
Swing PPC slow return valve

Q
Q
Oil flow adjuster EPC valve for attachment

Q
Q Work equipment lock solenoid
2-stage relief solenoid

Q
Travel interconnection solenoid

Q
Q
Travel speed selector solenoid

Q
Swing parking brake solenoid

Q
Q
Solenoid valve

ATT return selector solenoid

Q
Piston motor
Safety valve

Q
Q Q
Q Q
Q Q
Check valve

Q Q
Suction valve

Q
Q Q
Q Q
Shockless valve

Q Q QQ
Q
Swing electric motor

Parking brake

Q
Swing machinery

Q
Q Q
Q Q
Center swivel joint
Piston motor

Q Q

Q
Q
Q
Counterbalance valve
Check valve

Q QQ Q
Safety valve

Q Q
Travel motor

Parking brake
Final drive

Q Q Q Q
Q
Hydraulic cylinder
Q

Q
Q
Q
Q
Q

Diagnosis codes
H-9
H-8
H-7
H-6
H-5
H-4
H-3
H-2
H-1

H-11

H-29
H-28
H-27
H-26
H-25
H-24
H-23
H-22
H-21
H-20
H-19
H-18
H-17
H-16
H-15
H-14
H-13
H-12
H-10
Failure mode and cause table

40-397
Troubleshooting of hydraulic and mechanical system (H-mode)
Troubleshooting of hydraulic and mechanical system (H-mode)
H- 1 All of work equipment, swing and travel work slow or lack power

H- 1 All of work equipment, swing and travel work slow or lack power 40-398

Failure q Speed or power of all work equipment, swing, and travel is low.
q Perform all troubleshooting with working mode in POWER (P) mode.
q For items other than swing, check whether speed becomes normal when swing lock switch is
Related infor-
turned to ON position.
mation
If speed becomes normal, check swash plate sensor of No. 1 pump for malfunction.
If speed does not become normal, perform troubleshooting No. 2 and after.

Cause Criteria and troubleshooting procedure

a Prepare with engine stopped, then troubleshoot with engine at
full speed.
Measurement conditions Sensor output voltage
Malfunction of swash plate
1
sensor of pump All levers in NEUTRAL 1.57 ± 0.63 V
Run one track idle off ground
3.75 ± 0.63 V
Swing lock switch: ON
a Prepare with engine stopped, then troubleshoot with engine at
full speed.
2 Malfunction of unload valve Control lever Unload pressure
3.5 ± 1.0 MPa
All levers in NEUTRAL
{6 ± 10 kg/cm2}
a Prepare with engine stopped, then troubleshoot with engine at
full speed.
Left work equipment control lever Main relief pressure
Defective adjustment or mal-
3 33.3 – 36.8 MPa
function of main relief valve Arm IN to hydraulic relief
{340 – 375 kg/cm2}
If normal oil pressure is not obtained by adjustment, main relief
valve may malfunction or have internal defect. Check it directly.
Probable a Prepare with engine stopped, then troubleshoot with engine at
causes and cri- full speed.
teria Malfunction of self-pressure Control lever Control circuit source pressure
4
reducing valve
2.84 – 3.4 MPa
All levers in NEUTRAL
{29 – 35 kg/cm2}
a Prepare with engine stopped, and then run engine at full speed
and low speed to perform troubleshooting at each speed.
PC-EPC valve
Engine Control lever
Malfunction of PC-EPC output pressure
5
valve 2.9 MPa
At low idle
All levers in NEU- {30 kg/cm2}
TRAL 0.52 – 0.91 MPa
At high idle
{5.3 – 9.3 kg/cm2}
a Prepare with engine stopped, then troubleshoot with engine at
full speed.
Measured oil pres- Measurement condi-
Ratio of oil pressures
sure tions
Defective adjustment or mal- Pump delivery pres- Swing lock 1
6 sure switch: ON
function of PC valve
PC valve output pres- Arm IN to hydraulic Approx. 0.6 (Approx.
sure relief 3/5)
If normal oil pressure is not obtained after adjustment, PC valve
may malfunction or internal defect. Check PC valve.

40-398 PC228US-8,PC228USLC-8
(01)
 Troubleshooting of hydraulic and mechanical system (H-mode)
H- 1 All of work equipment, swing and travel work slow or lack power

Cause Criteria and troubleshooting procedure

a Prepare with engine stopped, then troubleshoot with engine at
full speed.
LS-EPC valve
Travel speed setting Travel lever
output pressure
7 Malfunction of LS-EPC valve Approx. 2.9 MPa
Low NEUTRAL
{30 kg/cm2}
FORWARD or 0 MPa
High
REVERSE {0 kg/cm2}
a Prepare with engine stopped, then troubleshoot with engine at
full speed.
Probable
Operation of levers and oil pressure ratio
causes and cri-
Measured oil pres- Run track idle off
teria All levers in NEU-
sure ground
TRAL
Defective adjustment or (lever at half stroke)
8
malfunction of LS valve Pump delivery pres-
1
sure Almost same pres-
LS valve out put sure Approx. 0.6 (Approx.
pressure 3/5)
If normal oil pressure is not obtained by adjustment, the LS valve
may malfunction or have internal defect. Check LS valve.
Servo piston may malfunction. Check change in voltage from
9 Malfunction of servo piston
swash plate sensor by using monitoring function.
Piston pump may have performance deterioration, malfunction or
10 Defective piston pump
internal failure.

PC228US-8,PC228USLC-8 40-399
(01)
Troubleshooting of hydraulic and mechanical system (H-mode)
H- 2 Engine speed lowers significantly or engine stalls

H- 2 Engine speed lowers significantly or engine stalls 40-40

Failure q Engine speed lowers significantly or engine stalls.

q Perfom all troubleshooting with working mode in POWER (P) mode.
Related infor- q Check whether speed becomes normal when swing lock switch is turned to ON position.
mation If speed becomes normal, check swash plate sensor of No. 1 pump for malfunction.
If speed does not become normal, perform troubleshooting No. 2 and after.

Cause Criteria and troubleshooting procedure

a Prepare with engine stopped, then troubleshoot with engine at full
speed.
Malfunction of swash plate Measurement conditions Sensor output voltage
1
sensor of pump All levers in NEUTRAL 1.57 ± 0.63 V
Run one track idle off ground
3.75 ± 0.63 V
Swing lock switch: ON
a Prepare with engine stopped, then troubleshoot with engine at full
speed.
Left work equipment control lever Main relief pressure
Defective adjustment or mal-
2 33.3 – 36.8 MPa
function of main relief valve Arm IN to bydraulic relief
{340 – 375 kg/cm2}
If normal oil pressure is not obtained by adjustment, main relief valve
may malfunction or have internal defect. Check main relief valve.
a Prepare with engine stopped, and then run engine at full speed
and low speed to perform troubleshooting at each speed.
PC-EPC valve
Engine Control lever
Malfunction of PC-EPC Output pressure
3
valve 2.9MPa
At low idle
All levers in NEU- {30 kg/cm2}
TRAL 0.52 – 0.91MPa
At high idle
{5.3 – 9.3 kg/cm2}
Probable a Prepare with engine stopped, then troubleshoot with engine at full
causes and cri- speed.
teria Measured oil pres- Measurement condi-
Ratio of oil pressures
sure tion
Defective adjustment or mal- Pump delivery pres- Swing lock 1
4 sure switch: ON
function of PC valve
PC valve output pres- Arm IN to hydraulic Approx. 0.6 (Approx.
sure relief 3/5)
If normal oil pressure is not obtained after adjustment, PC valve may
malfunction or have internal defect. Check PC valve.
a Prepare with engine stopped, then troubleshoot with engine at full
speed.
Operation of levers and oil pressure ratio
Measured oil pres- Run track idle off
sure All levers in NEU-
ground
TRAL
Defective adjustment or mal- (lever at half stroke)
5
function of LS valve Pump delivery pres-
1
sure Almost same pres-
LS valve out put pres- sure Approx. 0.6 (Approx.
sure 3/5)
If normal oil pressure is not obtained by adjustment, the LS valve
may malfunction or have internal defect. Check LS valve.
Clogged orifice or filter in Orifice or filter in pump servomechanism may be clogged. Check
6
servomechanism them directly.
Servo piston may malfunction. Check change in voltage from swash
7 Malfunction of servo piston
plate sensor by using monitoring function.

40-400 PC228US-8,PC228USLC-8
(01)
 Troubleshooting of hydraulic and mechanical system (H-mode)
H- 3 Any of work equipment,swing and travel does not work

H- 3 Any of work equipment,swing and travel does not work 40-401

Failure q Any of work equipment, swing and travel systems does not work.
Related infor-
q Perform all troubleshooting with working mode in POWER (P) mode.
mation

Cause Criteria and troubleshooting procedure

a Prepare with engine stopped, then troubleshoot with engine at
full speed.
Work equipment lock lever Solenoid output pressure
Malfunction of PPC lock
1
solenoid valve LOCK 0 MPa {0 kg/cm2}
2.9 MPa
FREE
{30 kg/cm2}
Probable a Prepare with engine stopped, then troubleshoot with engine at
causes and cri- full speed.
teria Malfunction of self-pressure Control lever Control circuit source pressure
2
reducing valve
2.84 – 3.43 MPa
All levers in NEUTRAL
{29 – 35 kg/cm2}
Piston pump may malfunction or have internal defect. Check it by
following method.
3 Defective piston pump
q Crank the engine with main oil pressure pickup port plug re-
moved. If any oil flows out, piston pump is normal.
Pump shaft may not rotate due to some internal failure of damper.
4 Defective damper
Check the damper.

H- 4 Unusual sound is heard from around hydraulic pump 40-401

Failure q Unusual sound is heard from around hydraulic pump.

Related infor-
–
mation

Cause Criteria and troubleshooting procedure

1 Lowered hydraulic oil level Make a visual check.
2 Defective hydraulic oil Air may mix in hydraulic oil. Check it directly.
Probable
causes and cri- Clogging of hydraulic tank Breather in cap of the hydraulic tank may be clogged, causing neg-
3
teria cap ative pressure inside tank. Check cap directly.
Clogging of hydraulic tank Strainer in hydraulic tank may be clogged, causing negative pres-
4
strainer sure in suction circuit. Check strainer directly.
5 Defective piston pump Piston pump may have internal defect. Check it.

PC228US-8,PC228USLC-8 40-401
(01)
Troubleshooting of hydraulic and mechanical system (H-mode)
H- 5 Fine control performance or response is poor

H- 5 Fine control performance or response is poor 40-402

Failure q Fine control performance or response is poor.

Related infor-
q Perform all troubleshooting with working mode in POWER (P) mode.
mation

Cause Criteria and troubleshooting procedure

a Prepare with engine stopped, then troubleshoot with engine at
full speed.
LS-EPC valve output
Travel speed setting Travel lever
pressure
1 Malfunction of LS-EPC valve Approx. 2.9 MPa
Low NEUTRAL
{Approx. 30 kg/cm2}
FORWARD or
High
REVERSE 0 MPa {0 kg/cm2}

2 Clogging of LS circuit orifice Orifice in LS circuit may be clogged. Check orifice .

Probable a Prepare with engine stopped, then troubleshoot with engine at

causes and cri- full speed.
teria Ratio of oil pressures
Measured oil pres- Run track idle off
sure All levers in NEU-
ground
TRAL
Defective adjustment or (lever at half stroke)
3
malfunction of LS valve Pump delivery pres-
1
sure Almost same pres-
LS valve out put sure Approx. 0.6 (Approx.
pressure 3/5)
If normal oil pressure is not obtained by adjustment, the LS valve
may malfunction or have internal defect. Check LS valve.
Servo piston may malfunction. Check change in voltage from
4 Malfunction of servo piston
swash plate sensor by using monitoring function.

40-402 PC228US-8,PC228USLC-8
(01)
 Troubleshooting of hydraulic and mechanical system (H-mode)
H- 6 Boom operation lacks speed or power

H- 6 Boom operation lacks speed or power 40-403

Failure q Speed or power of boom is low.

Related infor-
q Perform all troubleshooting with working mode in POWER (P) mode .
mation

Cause Criteria and troubleshooting procedure

a Prepare with engine stopped, then troubleshoot with engine at
full speed.
Right work equipment control
PPC valve output pressure
Malfunction of right PPC lever
1
valve (boom circuit) NEUTRAL 0 MPa {0 kg/cm2}
Boom RAISE 2.84 – 3.43 MPa
Boom LOWER {29 – 35 kg/cm2}
Malfunction of merge-divider
2 Merge-divider main EPC valve may malfunction. Check it directly.
main EPC valve
Malfunction of merge-divider
3 Merge-divider LS-EPC valve may malfunction. Check it directly.
LS-EPC valve
Malfunction of merge-divider
4 Merge-divider main valve may malfunction. Check it directly.
main valve
Malfunction of merge-divider
5 Merge-divider LS valve may malfunction. Check it directly.
LS valve
Defective operation of boom
6 throttle EPC solenoid valve Boom throttle EPC solenoid may malfunction. Check it directly.
(raise side only)
Malfunction of boom control
7 Spool of boom control valve may malfunction. Checkit directly.
valve (spool)
Probable
causes and cri- Malfunction of boom control
Pressure compensation valve of boom control valve may malfunc-
teria 8 valve (pressure compensa-
tion. Check it directly.
tion valve)
Malfunction of boom control Regeneration valve of boom control valve may malfunction or seal-
9
valve (regeneration valve) ing may be defective. Check it directly.
Malfunction of boom control Lock valve of boom control valve may malfunction. Check it
10
valve (lock valve) directly.
Malfunction or defective
Safety valve for lock valve may malfunction or sealing may be
11 sealing of safety valve for
defective. Check it directly.
lock valve
Malfunction or defective
Suction valve (bottom side) of boom control valve may malfunction
12 sealing of boom control
or sealing may be defective. Check it directly.
valve (suction valve)
Malfunction or defective
Suction-safety valve (head side) of boom control valve may mal-
13 sealing of boom control
function or sealing may be defective. Check it directly.
valve (suction-safety valve)
Malfunction of LS shuttle
LS shuttle valve of left travel , bucket or service valve may malfunc-
14 valve (left travel, bucket and
tion.Check it directly.
service valves)
a Prepare with engine stopped, then troubleshoot with engine at
full speed.
15 Defective boom cylinder Boom cylinder Leakage from cylinder
Boom RAISE to hydraulic relief 20 cc/min

PC228US-8,PC228USLC-8 40-403
(01)
Troubleshooting of hydraulic and mechanical system (H-mode)
H- 7 Arm operation lacks speed or power

H- 7 Arm operation lacks speed or power 40-404

Failure q Speed or power of arm is low.

Related infor-
q Perform all troubleshooting with working mode in POWER (P) mode .
mation

Cause Criteria and troubleshooting procedure

a Prepare with engine stopped, then troubleshoot with engine at
full speed.
Left work equipment control
PPC valve output pressure
lever
Malfunction of left PPC valve
1 0 MPa
(arm circuit) NEUTRAL
{0 kg/cm2}
Arm IN 2.84 – 3.43 MPa
Arm OUT {29 – 35 kg/cm2}
Malfunction of merge-divider
2 Merge-divider main EPC valve may malfunction. Check it directly.
main EPC valve
Malfunction of merge-divider
3 Merge-divider LS-EPC valve may malfunction. Check it directly.
LS-EPC valve
Malfunction of merge-divider
4 Merge-divider main valve may malfunction. Check it directly.
main valve
Malfunction of merge-divider
5 Merge-divider LS valve may malfunction. Check it directly.
LS valve
Malfunction of arm control
6 Spool of arm control valve may malfunction. Check it directly.
valve (spool)
Malfunction of arm control
Probable Pressure compensation valve of boom control valve may malfunc-
7 valve (pressure compensa-
causes and cri- tion. Check it directly.
tion valve)
teria Regeneration valve of arm control valve may have malfunction.
Malfunction of arm control
8 Check it directly.
valve (regeneration valve)

Malfunction of arm control Quick return valve of arm control valve may malfunction. Check it
9
valve (quick return valve) directly.
Malfunction or defective
Safety valve for lock valve may malfunction or sealing may be
10 sealing of safety valve for
defective. Check it directly.
lock valve
Malfunction or defective
Suction valve of arm control valve may malfunction. Check it
11 sealing of arm control valve
directly.
(suction valve)
Malfunction or defective
Suction-safety valve of arm control valve may malfunction or seal-
12 sealing of arm control valve
ing may be defectivel. Check it directly.
(suction-safety valve)
Malfunction of each control
LS shuttle valve of right travel , boom , left travel , bucket , or ser-
13 valve (LS shuttle valve)
vice valve may malfunction. Check them directly.

a Prepare with engine stopped, then troubleshoot with engine at

full speed .
14 Defective arm cylinder Left work equipment control
Leakage from arm cylinder
lever
Arm IN to hydaulic relief 20 cc/min

40-404 PC228US-8,PC228USLC-8
(01)
 Troubleshooting of hydraulic and mechanical system (H-mode)
H- 8 Bucket operation lacks speed or power

H- 8 Bucket operation lacks speed or power 40-405

Failure q Speed or power of bucket is low.

Related infor-
q Perform all troubleshooting with working mode in POWER (P) mode.
mation

Cause Criteria and troubleshooting procedure

a Prepare with engine stopped, then troubleshoot with engine at
full speed.
Right work equipment control
PPC valve output pressure
lever
Malfunction of right PPC
1 0 MPa
valve (bucket circuit) NEUTRAL
{0 kg/cm2}
Bucket CURL 2.84 – 3.43 MPa
Bucket DUMP {29 – 35 kg/cm2}
Malfunction of bucket control
2 Spool of bucket control valve may malfunction. Check it directly.
valve (spool)
Probable
causes and cri- Malfunction of bucket control
Pressure compensation valve of bucket control valve may malfunc-
teria 3 valve (pressure compensa-
tion. Check it directly.
tion valve)
Malfunction or defective
Suction-safety valve of bucket control valve may malfunction or
4 sealing of bucket control
sealing may be defective . Check it directly.
valve (suction-safety valve)
Malfunction of LS shuttle LS shuttle valve of service control valve may have malfunction.
5
valve (service valve) Check it directly.(If service valve is installed)
a Prepare with engine stopped, then troubleshoot with engine at
full speed.
6 Defective bucket cylinder Right work equipment control
Leakage from bucket cylinder
lever
Bucket CURL to hydraulic relief 20 cc/min

H- 9 Work equipment does not move in single operation 40-405

(1) Boom does not move when it is operated independently.

Failure (2) Arm does not move when it is operated independently.
(3) Bucket does not move when it is operated independently.
Related infor-
q Perform all troubleshooting with working mode in POWER (P) mode .
mation

Cause Criteria and troubleshooting procedure

a Prepare with engine stopped, then troubleshoot with engine at
full speed.
Work equipment control lever PPC valve output pressure
Probable
1 Malfunction of PPC valve
causes and cri- NEUTRAL 0 MPa {0 kg/cm2}
teria
2.84 – 3.43 MPa
Operation
{29 – 35 kg/cm2}
Malfunction of control valve
2 Spool of control valve may malfunction. Check it directly.
(spool)

PC228US-8,PC228USLC-8 40-405
(01)
Troubleshooting of hydraulic and mechanical system (H-mode)
H-10 Hydraulic drift of work equipment is large

H-10 Hydraulic drift of work equipment is large 40-406

Failure (1) Hydraulic drift of boom is large.

Related infor-
q Perform all troubleshooting with working mode in POWER (P) mode .
mation

Cause Criteria and troubleshooting procedure

a Prepare with engine stopped, then troubleshoot with engine at
full speed.
1 Defective boom cylinder Right work equipment control
Leakage from boom cylinder
Probable lever
causes and cri- Boom RAISE to hydraulic relief 20 cc/min
teria
Defective sealing for boom Sealing for lock valve in boom control valve may be defective.
2
control valve (lock valve) Check it directly.
Defective sealing for safety Sealing for safety valve for lock valve may be defective. Check it
3
valve for lock valve directly.

Failure (2) Hydraulic drift of arm is large.

Related infor-
q Perform all troubleshooting with working mode in POWER (P) mode .
mation

Cause Criteria and troubleshooting procedure

a Prepare with engine stopped, then troubleshoot with engine at
full speed.
1 Defective arm cylinder Left work equipment control
Leakage from arm cylinder
lever
Arm IN to hydraulic relief 20 cc/min
Probable Sealing for suction-safety valve (bottom side) in arm control valve
causes and cri- Defective sealing for arm
may be defective. Check it directly.
teria 2 control valve (suction-safety
* This defect can be judged by replacing it with another
valve)
suction-safety valve and watching how condition changes.
Defective sealing for arm Sealing for spool of arm control valve may be defective .Check it
3
control valve (spool) directly.
Defective sealing for arm
Sealing for pressure compensation valve (bottom side) in arm con-
4 control valve (pressure com-
trol valve may be defective. Check it directly.
pensation valve)

40-406 PC228US-8,PC228USLC-8
(01)
 Troubleshooting of hydraulic and mechanical system (H-mode)
H-10 Hydraulic drift of work equipment is large

Failure (3) Hydraulic drift of bucket is large.

Related infor-
q Perform all troubleshooting with working mode in POWER (P) mode .
mation

Cause Criteria and troubleshooting procedure

a Prepare with engine stopped, then troubleshoot with engine at
full speed.
1 Defective bucket cylinder Right work equipment control Leakage amount from bucket
lever cylinder
Bucket CURL to hydraulic relief 20 cc/min
Probable Sealing for suction-safety ( bottom side) in bucket control valve
causes and cri- Defective sealing for bucket
may be defective. Check it directly.
teria 2 control valve (suction-safety
* This defect can be judged by replacing it with another
valve)
suction-safety valve and watching how condition changes.
Defective sealing for bucket Sealing for spool of bucket control valve may be defective. Check it
3
control valve (spool) directly.
Defective sealing for bucket
Sealing for pressure compensation valve (bottom side) in bucket
4 control valve (pressure com-
control valve may be defective. Check it directly.
pensation valve)

PC228US-8,PC228USLC-8 40-407
(01)
Troubleshooting of hydraulic and mechanical system (H-mode)
H-11 Time lag of work equipment is large

H-11 Time lag of work equipment is large 40-408

Failure q Time lag of work equipment is large.

Related infor-
q Perform all troubleshooting with working mode in POWER (P) mode.
mation

Cause Criteria and troubleshooting procedure

a Prepare with engine stopped, then troubleshoot with engine at
full speed.
LS-EPC valve output
Travel speed setting Travel lever
pressure
1 Malfunction of LS-EPC valve
Approx. 2.9 MPa
Low NEUTRAL
{Approx. 30 kg/cm2}
Probable High Operation 0 MPa {0 kg/cm2}
causes and cri- Malfunctioning of control
teria Regeneration valve in control valve may malfunction. Check it
2 valve (regeneration valve)
directly.
[only boom and arm]
Suction-safety valve in control valve (boom: head side, arm and
Malfunction of control valve bucket: bottom side) may malfunction. Check it directly.
3
(suction-safety valve) * This defect can be judged by replacing it with another
suction-safety valve and watching how condition changes.
Malfunction of control valve
Pressure compensation valve of control valve may malfunction.
4 (pressure compensation
Check it directly.
valve)

H-12 Other work equipment moves when one of work equipment is

relieved 40-408

Failure q When performing hydraulic relief of a work equipment, other work equipment move.
Related infor-
mation

Cause Criteria and troubleshooting procedure

Probable
causes and cri- Defective sealing for control
Sealing for pressure compression valve in control valve may be
teria 1 valve (pressure compensa-
defective. Check it directly.
tion valve)

40-408 PC228US-8,PC228USLC-8
(01)
 Troubleshooting of hydraulic and mechanical system (H-mode)
H-13 One-touch power maximizing function does not work

H-13 One-touch power maximizing function does not work 40-409

Failure q Power maximizing function does not work.

Related infor-
q Perform all troubleshooting with working mode in POWER (P) mode .
mation

Cause Criteria and troubleshooting procedure

a Prepare with engine stopped, then troubleshoot with engine at
full speed.
Swing lock switch Solenoid output pressure
Probable Malfunction of 2-stage relief
1
causes and cri- solenoid valve OFF 0 MPa {0 kg/cm2}
teria
2.9 MPa
ON
{30 kg/cm2}
Malfunction of main relief Main relief valve of control valve may malfunction. Check it
2
valve directly.

H-14 In combined operation of work equipment , equipment having

heavier load moves slower. 40-409

Failure q Work equipment on large load side moves slower during combined operation
Related infor-
mation

Cause Criteria and troubleshooting procedure

Pressure compensation valve for work equipment on low load side
may malfunction. Check the valve directly.
Combined
Large load side Low load side
operation
Boom RAISE
+ Boom RAISE Arm IN
Arm IN
Probable Boom RAISE
causes and cri- Malfunction of control valve + Arm OUT Boom RAISE
teria 1 (pressure compensation Arm OUT
valve) on low load side
Boom RAISE
+ Boom RAISE Bucket CURL
Bucket CURL
Arm OUT
+ Arm OUT Bucket CURL
Bucket CURL
Boom LOWER
+ Arm OUT Boom LOWER
Arm OUT

PC228US-8,PC228USLC-8 40-409
(01)
Troubleshooting of hydraulic and mechanical system (H-mode)
H-15 In combined operation of swing and boom RAISE, boom rising speed is low

H-15 In combined operation of swing and boom RAISE, boom rising

speed is low 40-410

Failure q When performing combined operation of swing and boom RAISE , boom RAISE speed is slow.
Related infor- q If boom RAISE speed is also low when it is operated singly, perform troubleshooting for "H- 6 Boom
mation operation lacks speed or power".

Cause Criteria and troubleshooting procedure

Probable
causes and cri- Malfunction or defective
LS select valve of swing control valve may malfunction or sealing
teria 1 sealing of swing control
may be defective. Check it directly.
valve (LS select valve)

H-16 Travel speed drops largely in combined operation of swing and

travel 40-410

Failure q When performing combined operation of swing and travel , travel speed lowers significantly.
Related infor- q If travel speed is also low when machie is operated only to travel, perfom troubleshooting for "H-18
mation Travel speed is low" first.

Probable Cause Criteria and troubleshooting procedure

causes and cri- Malfunction of each control LS shuttle valve of left travel control valve or swing control valve
teria 1
valve (LS shuttle valve) may malfunction. Check it directly.

40-410 PC228US-8,PC228USLC-8
(01)
 Troubleshooting of hydraulic and mechanical system (H-mode)
H-17 Machine does not travel straight

H-17 Machine does not travel straight 40-41

Failure q Machine deviates during travel

Related infor-
q Perform all troubleshooting with working mode in POWER (P) mode .
mation

Cause Criteria and troubleshooting procedure

a Prepare with engine stopped, then troubleshoot with engine at
full speed.
Malfunction of travel PPC Travel lever PPC valve output pressure
1
valve
FORWARD 2.84 – 3.43 MPa
REVERSE {29 – 35 kg/cm2}
a Prepare with engine stopped, then troubleshoot with engine at
full speed .
Malfunction of self-pressure Control lever Control circuit source pressure
2
reducing valve
2.84 – 3.43 MPa
All levers in NEUTRAL
{29 – 35 kg/cm2}
a Prepare with engine stopped, then troubleshoot with engine at
full speed.
Ratio of oil pressures
Measured oil pres- Run track idle off
sure All levers in NEU-
ground
TRAL
Defective adjustment or (lever at half stroke)
3
malfunction of LS valve Pump delivery pres-
1
sure Almost same pres-
LS valve out put sure Approx. 0.6 (Approx.
Probable pressure 3/5)
causes and cri- If normal oil pressure is not obtained by adjustment, LS valve may
teria malfunction or may have internal defect. Check it directly
a Prepare with engine stopped, then troubleshoot with engine at
full speed.
Travel lever Solenoid output pressure
Malfunction of travel junc-
4
tion solenoid valve NEUTRAL 0 MPa {0 kg/cm2}
2.9 MPa
When either lever is operated
{30 kg/cm2}
Malfunction of travel junc-
5 Travel junction valve may malfunction. Check it directly.
tion valve
Malfunction of travel control
6 Spool of travel control valve may malfunction. Check it directly.
valve (spool)
Interchange connection ports of right and left hoes connecting
7 Defective center swivel joint swivel joint and travel motors and check if deviation direction
changes.
a Prepare with engine stopped, then troubleshoot with engine at
full speed.
8 Defective travel motor Travel lever Leakage from travel motor
F or R to hydraulic relief 27.2 l/min
Final drive may have internal failure. Check it directly.
9 Defective fainal drive * (This defect can be judged by unusual sound, unusual heat,
metal chips in drained oil, etc.)

PC228US-8,PC228USLC-8 40-411
(01)
Troubleshooting of hydraulic and mechanical system (H-mode)
H-18 Travel speed is low

H-18 Travel speed is low 40-412

Failure q Travel speed is low.

Related infor-
q Perform all troubleshooting with working mode in POWER (P) mode .
mation

Cause Criteria and troubleshooting procedure

a Prepare with engine stopped, then troubleshoot with engine at
full speed.
Travel lever PPC valve output pressure
Malfunction of travel PPC
1 0 MPa
valve NEUTRAL
{0 kg/cm2}
FORWARD 2.84 – 3.43 MPa
REVERSE {29 – 35 kg/cm2}
a Prepare with engine stopped, then troubleshoot with engine at
full speed.
Malfunction of self-reducing Control lever Control circuit source pressure
2
pressure valve
2.84 – 3.43 MPa
All levers in NEUTRAL
{29 – 35 kg/cm2}
a Prepare with engine stopped, then troubleshoot with engine at
full speed.
LS-EPC valve
Travel speed setting Travel lever
output pressure
Probable 3 Malfunction of LS-EPC valve
Approx. 2.9 MPa
causes and cri- Low NEUTRAL
{Approx. 30 kg/cm2}
teriat
FORWARD or
High
REVERSE 0 MPa {0 kg/cm2}
Malfunction of travel control
4 Spool of travel control valve may malfunction. Check it directly.
valve (spool)
Malfunction of travel control
Pressure compensation valve of travel control valve may malfunc-
5 valve (pressure compensa-
tion. Check it directly.
tion valve)
Malfunction of travel control Suction valve of travel control valve may malfunction. Check it
6
valve (suction valve) directly.
Malfunctio of LS shuttle LS shuttle valve of bucket control valve may malfunction. Check it
7
valve (bucket) directly.
a Prepare with engine stopped, then troubleshoot with engine at
full speed.
8 Defective travel motor Travel lever Leakage from travel motor
F or R to hydraulic relief 27.2 l/min
Final drive may have internal failure. Check it directly.
9 Defective fainal drive * (This defect can be judged by unusual sound, unusual heat,
metal chips in drained oil, etc.)

40-412 PC228US-8,PC228USLC-8
(01)
 Troubleshooting of hydraulic and mechanical system (H-mode)
H-19 Machine is hard to steer or travel power is low

H-19 Machine is hard to steer or travel power is low 40-413

Failure q Machine is not steered well or steering power is low

Related infor-
q Perform all troubleshooting with working mode in POWER (P) mode.
mation

Cause Criteria and troubleshooting procedure

a Prepare with engine stopped, then troubleshoot with engine at
full speed.
Travel lever PPC valve output pressure
Malfunction of travel PPC
1
valve Both levers in NEUTRAL 0 MPa {0 kg/cm2}
2.84 – 3.43 MPa
When either lever is operated
{29 – 35 kg/cm2}
a Prepare with engine stopped, then troubleshoot with engine at
full speed.
Travel lever Solenoid valve output pressure
Malfunction of travel junc-
2
tion solenoid valve NEUTRAL 0 MPa {0 kg/cm2}
2.9 MPa
When either lever is operated
{30 kg/cm2}
Malfunction of travel junc- Travel junction valve of control valve may malfunction. Check it
3
tion valve directly.
Malfunction of merge-divider
4 Merge-divider main EPC valve may malfunction. Check it directly.
main EPC valve
Malfunction of merge-divider
5 Merge-divider LS-EPC valve may malfunction. Check it directly.
LS-EPC valve
Malfunction of merge-divider
6 Merge-divider main valve may malfunction. Check it directly.
main valve
Probable Malfunction of merge-divider
causes and cri- 7 Merge-divider LS valve may malfunction. Check it directly.
LS valve
teria
Malfunction of travel control
8 Spool of travel control valve may malfunction. Check it directly.
valve (spool)
Malfunction of travel control
Pressure compensation valve of travel control valve may malfunc-
9 valve (pressure compensa-
tion. Check it directly.
tion valve)
Malfunction of travel control Suction valve of travel control valve may malfunction. Check it
10
valve (suction valve) directly.
Malfunctio of LS shuttle LS shuttle valve of bucket control valve may malfunction. Check it
11
valve (bucket) directly.
Defective sealing for check
Sealing for check valve at LS oil pressure pickup port may be
12 valve at LS oil pressure
defective. Check it directly.
pickup port
Interchange connection ports of right and left hoses connecting
13 Defective center swivel joint swivel joint and travel motors and check if turning direction
changes.
Sealing for safety valve of travel motor may be defective. Check it
directly.
Malfunctioning of travel
14 * This failure can be checked by interchanging valves from for-
motor (safety valve)
ward and reverse circuits of motor or those from right and left
motors and watching how condition changes.
Sealing for check valve of travel motor may be defective. Check it
directly.
Malfunctioning of travel
15 * This failure can be checked by interchanging valves ftom for-
motor (check valve)
ward and reverse circuits of motor or those from right and left
motors and watching how condition changes.

PC228US-8,PC228USLC-8 40-413
(01)
Troubleshooting of hydraulic and mechanical system (H-mode)
H-20 Travel speed does not change, or travel speed is too low or high

H-20 Travel speed does not change, or travel speed is too low or high 40-414

Failure q Travel speed does not switch or travel speed is too low or high.
Related infor-
q Perform all troubleshooting with working mode in POWER (P) mode .
mation

Cause Criteria and troubleshooting procedure

a Prepare with engine stopped, then troubleshoot with engine at
full speed .
Travel
speed Travel lever Monitoring code: 01500
setting
Low 617 mA (See *)
FORWARD or
Medium 679 mA
REVERSE
High 0 mA
1 Malfunction of LS-EPC valve
a Prepare with engine stopped, then troubleshoot with engine at
full speed.
Travel
Probable speed Travel lever LS-EPC valve output pressure
causes and cri- setting
teria Approx. 2.9 MPa
Low NEUTRAL
{Approx. 30 kg/cm2}
FORWARD or
High
REVERSE 0 MPa {0 kg/cm2}
a Prepare with engine stopped, then troubleshoot with engine at
full speed.
Travel
speed Travel lever Solenoid valve output pressure
Malfunction of travel speed
2 setting
solenoid valve
Low NEUTRAL 0 MPa {0 kg/cm2}
FORWARD or Approx. 2.9 MPa
High
REVERSE {Approx. 30 kg/cm2}
Malfunction of travel motor Speed-select unit of travel motor may malfunction. Check it
3
(speed-select unit) directly.
* : Travel speed: Speed of Low can be adjusted with adjustment function of machine monitor. Therefore, if it has been
changed from initial set value, indicated value changes more or less.

40-414 PC228US-8,PC228USLC-8
(01)
 Troubleshooting of hydraulic and mechanical system (H-mode)
H-21 One of tracks does not run

H-21 One of tracks does not run 40-415

Failure q Track does not move (only track on one side)

Related infor-
q Perform all troubleshooting with working mode in POWER (P) mode .
mation

Cause Criteria and troubleshooting procedure

Defective sealing for travel Sealing for suction valve of travel motor may be defective. Check it
1
control valve (suction valve) directly.
Sealing for safety valve of travel motor may be defective. Check it
directly.
Defective sealing for travel
2 * This failure can be checked by interchanging safety valves from
motor (safety valve)
forward and reverse circuits of motor or those from right and left
motors and watching how condition changes.
Sealing for check valve of travel motor may be defective. Check it
directly.
Defective sealing for travel
Probable 3 * This failure can be checked by interchanging check valves from
motor (check valve)
causes and cri- forward and reverse circuits of motor or those from right and left
teria motors and watching how condition changes.
Malfunction of travel motor
4 Parking brake of travel motor may malfunction. Check it directly.
(parking brake)
a Prepare with engine stopped, then troubleshoot with engine at
full speed.
5 Defective travel motor Travel lever Leakage from travel motor
F or R to hydraulic relief 27.2 l/min
Final drive may have internal failure. Check it directly.
6 Defective fainal drive * (This defect can be judged by unusual sound, unusual heat,
metal chips in drained oil, etc.)

PC228US-8,PC228USLC-8 40-415
(01)
Troubleshooting of hydraulic and mechanical system (H-mode)
H-22 Upper structure does not swing

H-22 Upper structure does not swing 40-416

Failure (1) Upper structure swings neither to right nor left

Related infor-
q Perform all troubleshooting with working mode in POWER (P) mode .
mation

Cause Criteria and troubleshooting procedure

a Prepare with engine stopped, then troubleshoot with engine at
full speed.
Left work equipment control Output pressure of swing brake
lever solenoid valve
Malfunction of swing brake
1 0 MPa
solenoid valve
NEUTRAL
{0 kg/cm2}
Left swing 2.9 MPa
Right swing {30 kg/cm2}
Malfunction of swing control
2 Spool of swing control valve may malfunction. Check it directly.
valve (spool)
Malfunction of swing motor
3 Swing brake of swing motor may malfunction. check it directly.
(swing brake)
a Prepare with engine stopped, then troubleshoot with engine at
Probable
full speed.
causes and cri-
teriat Swing lock Left work equipment
Swing
Improper adjustment or mal- switch control lever
4 function of swing motor Swing to hydraulic 28.9 – 3 2.9 MPa
(safety valve) ON
relief {295 – 335 kg/cm2}
If normal oil pressure is not obtained by adjustment, swing motor
safety valve may malfunction or may internal defect. Check it
directly.
a Prepare with engine stopped, then troubleshoot with engine at
full speed.
Swing lock Left work equipment Leakage from swing
5 Defective swing motor
switch control lever motor
Swing to hydraulic
ON Below 10 l/min
relief
Swing machinery may internal failure. Check it directly.
6 Defective swing machinery * (This defect can be judged by unusual sound, unusual heat,
metal chips in drained oil, etc.)

40-416 PC228US-8,PC228USLC-8
(01)
 Troubleshooting of hydraulic and mechanical system (H-mode)
H-22 Upper structure does not swing

Failure (2) Upper structure does not swing in only one direction.
Related infor-
q Perform all troubleshooting with working mode in POWER (P) mode .
mation

Cause Criteria and troubleshooting procedure

a Prepare with engine stopped, then troubleshoot with engine at
full speed.
Left work equipment control
PPC valve output pressure
lever
Malfunction of swing PPC
1 0 MPa
valve NEUTRAL
{0 kg/cm2}
Left swing 2.84 – 3.43 MPa
Probable Right swing {29 – 35 kg/cm2}
causes and cri-
Malfunction of swing control
teria 2 Spool of swing control valve may malfunction. Check it directly.
valve (spool)
Suction valve of swing motor may malfunction. Check it directly.
Malfunction of swing motor * This failure can be checked by interchaning right and left suc-
3
(suction valve) tion valves of swing motor and watching how condition
changes.

Check valve of swing motor may malfunction. Check it directly.

Malfunction of swing motor
4 * This failure can be checked by interchaning right and left check
(check valve)
valves of swing motor and watching how condition changes.

PC228US-8,PC228USLC-8 40-417
(01)
Troubleshooting of hydraulic and mechanical system (H-mode)
H-23 Swing acceleration is poor or swing speed is low

H-23 Swing acceleration is poor or swing speed is low 40-418

Failure (1) Swing acceleration is poor or swing speed is slow in both right and left directions.
Related infor-
q Perform all troubleshooting with working mode in POWER (P) mode .
mation

Cause Criteria and troubleshooting procedure

Malfunction of swing control
1 Spool of swing control valve may malfunction. Check it directly.
valve (spool)
Malfunction of all control LS shuttle valves for all control valves may malfunction. Check
2
valves (LS shuttle valves) them directly.
Malfunction of swing motor
3 Swing brake of swing motor may malfunction, check it directly.
(swing brake)
a Prepare with engine stopped, then troubleshoot with engine at
full speed.
Swing lock Left work equipment
Swing relief pressure
Improper adjustment or mal- switch control lever
Probable
4 function of swing motor Swing to hydraulic 28.9 – 32.9 MPa
causes and cri- ON
(safety valve) relief {295 – 335 kg/cm2}
teria
If normal oil pressure is not obtained by adjustment, swing motor
safety valve may malfunction or may internal defect. Check it
directly.
a Prepare with engine stopped, then troubleshoot with engine at
full speed.
Swing lock Left work equipment Leakage from swing
5 Defective swing motor
switch control lever motor
Swing to hydraulic
ON Below 10 l/min
relief
Swing machinery may be defective. check it directly.
6 Defective swing machinery * (This failure can be checked by unusual sound, unusual heat,
metal chips in drained oil, etc.)

40-418 PC228US-8,PC228USLC-8
(01)
 Troubleshooting of hydraulic and mechanical system (H-mode)
H-23 Swing acceleration is poor or swing speed is low

Failure (2) Swing acceleration performance is poor or swing speed is slow in only one direction.
Related infor-
q Perform all troubleshooting with working mode in POWER (P) mode.
mation

Cause Standard value in normal condition/Remarks on troubleshooting

a Prepare with engine stopped, then troubleshoot with engine at
full speed.
Left work equipment control
PPC valve output pressure
lever
Malfunction of swing PPC
1 0 MPa
valve NEUTRAL
{0 kg/cm2}
Left swing 2.84 – 3.43 MPa
Right swing {29 – 35 kg/cm2}
Possible
Malfunction of swing control
causes and 2 Spool of swing control valve may malfunction. Check it directly.
valve (spool)
standard value
for judgment Malfunction of swing control
Pressure compensation valve of swing control valve may malfunc-
3 valve (pressure compensa-
tion. Check it directly.
tion valve)
Suction valve of swing motor may malfunction. Check it directly.
Malfunction of swing motor * This failure can be checked by interchaning right and left suc-
4
(suction valve) tion valves of swing motor and watching how condition
changes.
Check valve of swing motor may malfunction. Check it directly.
Malfunction of swing motor
* This failure can be checked by interchaning right and left suc-
5 (check valve)
tion valves of swing motor and watching how condition
changes.

PC228US-8,PC228USLC-8 40-419
(01)
Troubleshooting of hydraulic and mechanical system (H-mode)
H-24 Upper structure overruns excessively when it stops swinging

H-24 Upper structure overruns excessively when it stops swinging 40-420

Failure (1) Upper structure overruns excessively when it stops swinging in both right and left directions.
Related infor-
q Perform all troubleshooting with working mode in POWER (P) mode.
mation

Cause Criteria and troubleshooting procedure

a Prepare with engine stopped, then troubleshoot with engine at
full speed.
Swing lock Left work equipment
Swing
Improper adjustment or mal- switch control lever
1 functioning of swing motor Swing to hydraulic 28.9 – 32.9 MPa
(safety valve) ON
Probable relief {295 – 335 kg/cm2}
causes and cri- If normal oil pressure is not obtained by adjustment, swing motor
teria safety valve may malfunction or may have internal defect. Check it
directly.
a Prepare with engine stopped, then troubleshoot with engine at
full speed.
Swing lock Left work equipment Leakage from swing
2 Defective swing motor
switch control lever motor
Swing to hydraulic
ON Below 10 l/min
relief

Failure (2) Upper structure overruns excessively when it stops swinging in only one direction.
Related infor-
q Perform all troubleshooting with working mode in POWER (P) mode.
mation

Cause Criteria and troubleshooting procedure

a Prepare with engine stopped, then troubleshoot with engine at
full speed.
Left work equipment control
PPC valve output pressure
lever
Malfunction of swing PPC
1 0 MPa
valve NEUTRAL
{0 kg/cm2}
Left swing 2.84 – 3.43 MPa
Right swing {29 – 35 kg/cm2}

Probable Swing PPC slow return valve may malfunction. Check it directly.
Clogged swing PPC slow
causes and cri- 2 * This failure can be checked by interchaning right and left swing
return valve
teria PPC slow return valves and watching how condition changes.

Malfunction of swing control

3 Spool of swing control valve may malfunction. Check it directly.
valve (spool)
Suction valve of swing motor may malfunction. Check it directly.
Malfunction of swing motor * This failure can be checked by interchaning right and left suc-
4
(suction valve) tion valves of swing motor and watching how condition
changes.

Check valve of swing motor malfunction. Check it directly.

Malfunction of swing motor
5 * This failure can be checked by interchaning right and left check
(check valve)
valves of swing motor and watching how condition changes.

40-420 PC228US-8,PC228USLC-8
(01)
 Troubleshooting of hydraulic and mechanical system (H-mode)
H-25 Shock is large when upper structure stops swinging

H-25 Shock is large when upper structure stops swinging 40-421

Failure q Large shock is made when upper structure stops swinging.

Related infor-
q Perform all troubleshooting with working mode in POWER (P) mode .
mation

Cause Criteria and troubleshooting procedure

a Prepare with engine stopped, then troubleshoot with engine at
full speed.
Left work equipment control
PPC valve output pressure
Malfunction of swing PPC lever
1
valve NEUTRAL 0 MPa {0 kg/cm2}
Probable
Right swing 2.84 – 3.43 MPa
causes and cri-
teria Left swing {29 – 35 kg/cm2}

Swing PPC slow return valve may malfunction. Check it directly.

Clogged swing PPC slow
2 * This failure can be checked by interchaning right and left swing
return valve
PPC slow return valves and watching how condition changes.

Malfunction of swing motor

3 Shockless valve of swing motor may malfunction. Check it directly.
(shockless valve)

H-26 Large unusual noise is heard when upper structure stops swinging40-421

Failure q Large sound is made when upper structure stops swinging

Related infor-
q Perform all troubleshooting with working mode in POWER (P) mode .
mation

Cause Criteria and troubleshooting procedure

Malfunctioning of back pres- Back pressure valve of control valve may malfunction. Check it
1
sure valve directly.
Malfunction of swing motor
2 Safety valve of swing motor may malfunction. Check it directly.
Probable (safety valve)
causes and cri- Suction valve of swing motor may malfunction. Check it directly.
teria Malfunction of swing motor
3 * This failure can be checked by interchaning right and left swing
(suction valve)
motor suction valves and watching how condition changes.
Swing machinery may be defective .Check it directly.
4 Defective swing machinery * (This failure can be checked by unusual sound, unusual heat,
metal chips in drained oil, etc.)

PC228US-8,PC228USLC-8 40-421
(01)
Troubleshooting of hydraulic and mechanical system (H-mode)
H-27 Swing drift on a slope is large

H-27 Swing drift on a slope is large 40-42

q Swing drift on a slope is excessive.

Failure
(While swing brake is applied)
q When swing lock switch is in ON position, or swing brake release switch is in normal position, swing
Related infor-
brake is applied and disc brake holds upper structure.
mation
q Perform all troubleshooting with working mode in POWER (P) mode .

Cause Criteria and troubleshooting procedure

a Prepare with engine stopped, then troubleshoot with engine at
full speed.
Left work equipment control
Solenoid valve output pressure
Probable Malfunction of swing brake lever
1
causes and cri- solenoid valve NEUTRAL 0 MPa {0 kg/cm2}
teria
Right swing 2.9 MPa
Left swing {30 kg/cm2}
Malfunction of swing motor Swing brake of swing motor may malfunction or may have internal
2
(swing brake part) defect. Check it directly.

q Swing drift on a slope is excessive.

Failure
(While swing brake is released)
q When swing brake release switch is in emergency position, swing brake is released and upper
Related infor-
structure is held with only hydraulic pressure.
mation
q Perform all troubleshooting with working mode in POWER (P) mode .

Cause Criteria and troubleshooting procedure

Malfunction of swing control Sealing for spool of swing control valve may be defective . Check it
1
valve (spool) directly.
Malfunction of swing control
Sealing for pressure compensation valve of swing control valve
2 valve (pressure compensa-
may be defective . Check it directly.
tion valve)
Probable Defective swing motor Sealing for safety valve of swing motor may be defective .Check
3
causes and cri- (safety valve) the valve directly.
teria Defective swing motor (suc- Sealing for suction valve of swing motor may be defective. Check
4
tion valve) it directly.
Defective swing motor Sealing for check valve of swing motor may be defective . Check it
5
(check valve) directly.

Defective seaing for swing Sealing for shockless valve of swing motor may be defective.
6
motor (shockless valve) Check it directly.

40-422 PC228US-8,PC228USLC-8
(01)
 Troubleshooting of hydraulic and mechanical system (H-mode)
H-28 Attachment circuit cannot be changed

H-28 Attachment circuit cannot be changed 40-423

For machines with provision for attachment 40-423

Failure q Attachment circuit is not switched to desired one.
q For machines with provision for attachment, service circuit changes as shown below according to
selected working mode.
1) ATT mode: Double-acting circuit (2-WAY) is selected and safety valve is set to low-pressure
Related infor-
setting.
mation
2)B mode : Single acting (1-WAY) circuit is selected and safety valve is set to high-pressure setting.
q Setting of safety valve is changed on only port B side. Setting on port A side is kept to low-pres-
sure setting.

Cause Criteria and troubleshooting procedure

a Prepare with engine stopped, then troubleshoot with engine at
full speed.
ATT return selector solenoid
Working mode
Malfunction of ATT return valve output pressure
1
Probable selector solenoid valve
ATT mode 0 MPa {0 kg/cm2}
causes and cri-
teria 2.9 MPa
B mode
{30 kg/cm2}
Malfunction of ATT return
2 ATT return selector valve may malfunction. Check it directly.
selector valve
Malfunction of service valve Safety valve (port B side) of service valve may malfunction. Check
3
(safety valve) it directly.

H-29 Oil flow in attachment circuit cannot be controlled 40-423

For machines with provision for attachment 40-423

Failure q Flow rate of attachment circuit cannot be adjusted
q For machines with provision for attachment, flow rate of service circuit changes according to setting
Related infor- selected in user mode.
mation q How to adjust flow rate in ATT mode is different from that in B mode. For details, see Operation
and Maintenance Manual.

Cause Criteria and troubleshooting procedure

Malfunction of attachment
Probable Attachment flow rate adjustment EPC valve may malfunction.
1 flow rate adjustment EPC
causes and cri- Check it directly.
valve
teria
Malfunction of service PPC
2 Service PPC valve may malfunction. Check it directly.
valve

PC228US-8,PC228USLC-8 40-423
(01)
Troubleshooting of engine (S-mode)
Method of using troubleshooting chart

Troubleshooting of engine (S-mode) 40-424

Method of using troubleshooting chart 40-424

The troubleshooting chart consists of the "Ques-

tions", "Check items", "Causes", and "Troubleshoot-
ing" blocks.
The Questions and Check items are used to narrow
down high probability causes by simple inspection
or from symptoms without using troubleshooting
tools.
Next, use troubleshooting tools or perform direct in-
spection to check the selected Causes in the order
of probability to determine the real cause.
Questions:
Questions placed in the sections A and B in the
table on the next page are those to be answered
by the customer or operator.
Questions in section A are for basic information
about the failure. Depth and accuracy of their an-
swers to the questions in section B may depend
on their concerns on the machine condition.
Check items:
Check items placed in the section C in the table
on the right are to be simply checked by the tech-
nician to select highly probable causes.
[Causes]:
Various causes are listed is this block.
The technician will be able to narrows down the
probable causes by taking the actions listed in
the blocks A, B, and C.
[Troubleshooting]:
This section includes various items of trouble-
shooting that are performed in order to verify the
results of the diagnosis made by asking the
questions and inspecting the machine. The trou-
bleshooting is performed in order from the most
probable one by applying troubleshooting tools
or direct inspection.

40-424 PC228US-8,PC228USLC-8
(01)
 Troubleshooting of engine (S-mode)
Method of using troubleshooting chart

This troubleshooting chart marks the content of the questions and check items with E, Q or w according to
their closer relationship with the causes.
E: Reference information for estimation of the cause
Q: Information and inspection result that indicate the cause of the failure
w: A cause particularly probable among those marked with Q above.
a Count the priority level of each marking as w > Q when determining the cause.
Don't count E when determining the cause. The item with this marking may be counted, however, if no
difference is present than this and the cause cannot be determined.

PC228US-8,PC228USLC-8 40-425
(01)
Troubleshooting of engine (S-mode)
Method of using troubleshooting chart

<Example of troubleshooting> Exhaust smoke is black (Incomplete combustion) 40-426

a The following legend contains items which are not applicable to this machine.
Let us assume that a trouble of “Exhaust smoke is black” occurred and we checked the [Questions] and
[Check items] and found the following 3 items to be the causal symptoms; [Color of exhaust smoke gradually
became black], [Power was lost gradually], and [Dust indicator indicates a red zone].

40-426 PC228US-8,PC228USLC-8
(01)
 Troubleshooting of engine (S-mode)
Method of using troubleshooting chart

There is a causal relationship between 3 items in the [Questions] and [Check items] sections and 6 items in
the [Causes] sections.
The method of pinpointing the [cause] from the causal relationship and approaching the [troubleshooting] is
explained according to Step 1 – Step 3 shown below.

PC228US-8,PC228USLC-8 40-427
(01)
Troubleshooting of engine (S-mode)
S-1 Startability is poor

S-1 Startability is poor 40-428

General causes why startability is poor Cause

Leakage or clogging of fuel piping or air in the fuel piping

q Defective electrical system
q Insufficient supply of fuel
q Insufficient intake of air
q Improper selection of fuel
a The common rail fuel injection system (CRI) controls the fuel injection timing

Clogged air breather hole in fuel tank cap

Defective contact of valve with valve seat
electrically. Accordingly, even if the engine is cranked properly, the engine

Defective alternator (generator section)

Defective alternator (regulator section)
may not start until the crankshaft rotates two turns under the most disadvan-

Stuck or seized supply pnmp pluger

tageous condition. This phenomenon does not mean a problem, however.

Defective intake air heater system

Defective or deteriorated battery

Clogged air cleaner element

Worn piston ring or cylinder

Clogging of fuel filter

Defective injector
Check recent repair history.
Machine opera-
Operated for long period E E E
tion hours
Starting perfor- Became worse gradually Q w w Q
w w
Questions

mance Engine starts easily when warm.

Fuel other than specified one is used. Q Q Q
The filter was not replaced as specified by the operation and Maintenance
w w Q Q
Manual.
Engine oil must be added more frequently. w
When engine is preheated or when temperature is low, preheating monitor
w
does not indicate proper functioning of preheating system.
During operation, charge level monitor indicates abnormal charge. w w
Dust indicator indicate a red zone. w
Air breather hole in fuel tank cap is clogged. w
Fuel leaks from fuel piping. w Q
If priming pump is operated, no resistance is felt or it is heavy. w Q
Starting motor cranks engine slowly. w
When engine is Even if air bleeding plug in fuel filter head is removed, fuel
w
cranked with does not flow out.
Check items

starting motor, If spill hose from injector is disconnected, little fuel spills. w
When exhaust manifold is touched immediately after starting engine, temper-
w
ature of some cylinders is low.
Engine does not pick up smoothly and combustion is irregular. Q Q w
Engine hunts. Q w Q
Blowby gas is excessive. w
Check air cleaner. q
When compression pressure is measured, it is found to be low. q q
When air is bled from fuel system, air comes out. q
q
Troubleshooting

Check fuel filter.

Perform troubleshooting for "Supply pump pressure low error” according to
q
failure code (*1).
Even if a cylinder is cut out, engine speed does not change. q
Even if starting switch is turned to HEAT, intake air heater mount does not
q
become warm.
Is voltage 20 – 30 V between alternator terminal B and terminal E Yes q
when engine is running at low idle speed? None q
Specific gravity of electrolyte and voltage of battery are low. q
Replace
Replace

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Clean

Clean

Remedy

*1: Failure codes [CA559] and [CA2249]

40-428 PC228US-8,PC228USLC-8
(01)
 Troubleshooting of engine (S-mode)
S-2 Engine does not start

S-2 Engine does not start 40-429

a) Engine does not crank Cause

General causes why engine does not crank

Defective connection of battery cable terminal

q Internal parts of engine seized.
oSee "S-4 Engine stops during operations"

Defective starting motor (motor section)

q Defective electrical system
q Defect in hydraulic pump

Defective or deteriorated battery

Defective starting circuit wiring

Broken flywheel ring gear

Defective hydraulic pump

Defective starting switch
Defective battery relay

Defective safety relay

Check recent repair history.
Machine operation
Questions

Operated for long period EE

hours
Condition of horn Horn does not sound. Q Q w
when starting switch
Horn volume is low. w
is turned ON
Battery electrolyte level is low. w
Battery cable terminal is loose w
When starting switch is turned ON, no operating sound is heard from battery relay. Q w
When starting switch is turned to START, starter pinion does not plunge. Q Q w
Check items

When starting switch Rotation speed is low. w

is turned to START, Unusual noise is heard around ring gear. w w
starter pinion Pinion returns halfway. w
plunges, but: Unusual noise is heard around relay and engine does not rotate. Q QQ Q
Check flywheel ring gear. q

Perform H-mode troubleshooting

Perform E-mode troubleshooting
Specific gravity of electrolyte and voltage of battery are low. q
Voltage (20 – 30 V) between battery relay terminal B and terminal
q
Troubleshooting

E is not found.
Turn starting switch to When terminal B and terminal C of starting switch are connected, q
OFF position and engine cranks.
connect cable, and When terminal B at safety relay outlet and terminal C are con-
q
perform troubleshoot- nected, engine cranks.
Even if terminal B at safety relay outlet and terminal C are con-
ing with starting q
switch at ON. nected, engine will not crank.
When terminal at safety switch and terminal B at starting motor
q
are connected, engine cranks.
Replace
Replace

Replace
Replace
Replace
Replace
Repair

Remedy
–
–

PC228US-8,PC228USLC-8 40-429
(01)
Troubleshooting of engine (S-mode)
S-2 Engine does not start

b) Engine cranks but no exhaust smoke comes out Cause

Leakage or clogging of fuel piping or air in the fuel piping

General causes why engine cranks but no exhaust smoke comes out

q Fuel is not being supplied.

Malfunction of overflow valve (Does not close)

q Supply of fuel is extremely small.
q Improper selection of fuel (particularly in winter)

Clogged air breather hole in fuel tank cap

Seized or prematurely worn feed pump

Defective common rail pressure limiter

Stuck or seized supply pump plunger
Defective IMV for supply pump
Broken supply pump shaft
Insufficient fuel in tank

Defective fuel injector

Clogging of fuel filter
Use of improper fuel
Check recent repair history.
Machine opera-
Questions

Operated for long period EE

tion hours
Exhaust smoke suddenly stopped coming out (at restarting after short time
w Q w w
stoppage).
Fuel other than specified fuel one is used. w
The filter was not replaced as specified by the Operation and Maintenance
w E
Manual.
Fuel tank is found to be empty. w
Air breather hole in fuel tank cap is clogged. w
Rust and water are found when fuel tank is drained. QE EE
There is no fuel in the removal fuel filter. w w
Fuel is leaking from fuel piping. w
When priming pump is operated, no resistance is felt or it is heavy. w Q
Check items

Even if air bleeding plug in fuel filter head is removed, fuel

When engine is Q Q w Q
does not flow out.
cranked with
Even if spill hose from injector is disconnected, little fuel
starting motor, Q w w w Q
spills.
When air is bled from fuel system, air comes out. q
Check fuel filter. q
Troubleshooting

Check feed pump. q

Perform troubleshooting for "Supply pump pressure low error” according to
q q
failure code (*1).
Perform troubleshooting for the error "IMV/IMA short or open circuit" accord-
q
ing to failure code (*2).
Check pressure relief valve. q
Fuel flows out when pressure limiter return piping is disconnected. q
Replace

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Clean
Add

Remedy

*1: Failure codes [CA559] and [CA2249]

*2: Failure codes [CA271] and [CA272]

40-430 PC228US-8,PC228USLC-8
(01)
 Troubleshooting of engine (S-mode)
S-2 Engine does not start

c) Exhaust smoke comes out but engine will not start (fuel is injected) Cause

Leakage or clogging of fuel piping or air in the fuel system

Defective coolant temperature sensor or wiring harness

General causes why exhaust smoke comes out but engine does not start

q Lack of cranking force due to defective electrical system

q Insufficient supply of fuel

Worn valve system (valve, rocker lever, etc.)

Clogged injection nozzle, or defective spray

q Insufficient intake of air

Clogged air breather hole in fuel tank cap

q Improper selection of fuel

Stuck or seized supply pump plunger

Defective intake air heater system

Defective or deteriorated battery
Clogged air cleaner element

Worn piston ring or cylinder

Clogging of fuel filter

Use of improper fuel
Check recent repair history.
Machine operation
Operated for long period E E E
hours
Suddenly become unstartable. w w Q
Questions

Fuel other than specified one is used. Q Q

The filter was not replaced as specified by the Operation and Maintenance
w w
Manual.
Oil must be added more frequently w
When engine is preheated or when temperature is low, preheating monitor
w
does not indicate proper function of preheating system.
Dust indicator indicates a red zone. w
Air breather hole of fuel tank cap is clogged. Q
Rust and water are found when fuel tank is drained. w
There is no fuel in the removal fuel filter. w
Fuel is leaking from fuel piping. w
When priming pump is operated, no resistance is felt or it is heavy. wQ
Starting motor cranks engine slowly. w
When engine is running, unusual noise is heard around cylinder head. w
Even if air bleeding plug in fuel filter head is removed, fuel
Check items

When engine is Q w
does not flow out.
cranked with start-
Even if spill hose from injector is disconnected, little fuel
ing motor, w
spills.
When exhaust manifold is touched immediately after starting engine, tempera-
w
ture of some cylinders is low.
Check air cleaner. q
Check valve system. q
When compression pressure is measured, it is found to be low. q
Troubleshooting

When air is bled from fuel system, air comes out. q

Check fuel filter. q
Perform troubleshooting for "Supply pump pressure low error” according to
q
failure code (*1).
Specific gravity of electrolyte and voltage of battery are low. q
Coolant temperature gauge indication is not correct. q
Even if starting switch is turned to HEAT, intake air heater mount does not
q
become warm.
Replace
Replace
Replace

Replace
Replace
Replace
Replace
Replace
Replace
Repair
Clean

Clean

Remedy

*1: Failure codes [CA559] and [CA2249]

PC228US-8,PC228USLC-8 40-431
(01)
Troubleshooting of engine (S-mode)
S-3 Engine does not pick up smoothly

S-3 Engine does not pick up smoothly 40-432

General causes why engine will not pick up smoothly Cause

Leaking or clogging of fuel piping or air in the fuel

q Insufficient intake of air
q Insufficient supply of fuel

Clogged injection nozzle, or defective spray

q Improper of fuel injection

Clogged air breather hole in fuel tank cap

Defective contact of valve with valve seat
q Improper selection of fuel

Seizure or interference at turbocharger

Stuck or seized supply pump plunger

q Controller is controlling in derate mode
(limiting injection rate (power) because of an error in electrical system)

Clogged air cleaner element

Worn piston ring or cylinder

Improper valve clearance

Clogging of fuel filter

Check recent repair history.
Machine opera-
Operated for long period EE E E
Questions

tion hours
Engine pickup suddenly became worse. w QQ Q
Fuel other than specified one is used. www
The filter was not replaced as specified by the Operation and Maintenance Manual. w w
Engine oil must be added more frequently. w
Dust indicator indicates a red zone. w
Air breather hole in fuel tank cap is clogged. w
Rust and water are found when fuel tank is drained. w
Fuel is leaking from fuel piping. w
When priming pump is operated, no resistance is felt or it is heavy. wQ
When exhaust manifold is touched immediately after starting engine, temperature of
Qw
some cylinders is low.
Color of exhaust Blue under light load. w
Check items

smoke Black. wQ w w
While engine is running, unusual noise is heard around cylinder head. w
While engine is running, interference sound is heard around turbocharger. w
High idle speed is normal, but speed suddenly drops when load is applied. Q w
Engine hunts. Q Q Q
Blowby gas is excessive. w
Check air cleaner. q
When compression pressure is measured, it is found to be low. q q
Troubleshooting

Check valve clearance. q

When turbocharger is rotated by hand, it is found to be heavy. q
When air is bled from fuel system, air comes out. q
Check fuel filter. q
Perform troubleshooting for "Supply pump pressure low error” according to failure
q
code (*1).
Even if a cylinder is cut out, engine speed does not change. q
Replace
Replace

Replace
Replace
Replace
Repair

Repair
Adjust
Clean

Clean

Remedy

*1: Failure codes [CA559] and [CA2249]

40-432 PC228US-8,PC228USLC-8
(01)
 Troubleshooting of engine (S-mode)
S-4 Engine stops during operation

S-4 Engine stops during operation 40-43

General causes why engine stops during operation Cause

Broken auxiliary equipment (pump or air compressor, etc.)

q Internal parts of engine seized
q Insufficient supply of fuel

Damage of valve system (valve, rocker lever, etc.)

q Engine overheating

Defective engine controller power supply wiring

q Defect in hydraulic pump

Clogged air breather hole in fuel tank cap

Broken or seized piston connecting rod
Broken or seized crankshaft bearing

Stuck or seized supply pnmp pluger

Clogging of feed pnmp gauze filter

Defective starting switch wiring

Clogged or leaking fuel piping

Broken or seized feed pump

Broken or seized gear train

Broken supply pump shaft

Defective hydraulic pump

Insufficient fuel in tank

Clogging of fuel filter

Check recent repair history.
Machine operation
Operated for long period. EE
hours
Unusual noise was heard and engine
wwww QwQw w
Questions

Condition when stopped suddenly.

engine stopped
Engine overheated and stopped. wQ Q
Engine stopped slowly. w Q Q QQ
Engine hunted and stopped. wQ Q QQ QQ
Fuel other than specified one is used. Q QQ Q
The filter was not replaced as specified by the Operation and
w w
Maintenance Manual.
Fuel level monitor indicates low level. w
Fuel tank is found to be empty. w
Air breather hole in fuel tank cap is clogged. w
Fuel is leaking from fuel piping. w
When priming pump is operated, no resistance is felt or it is wQQ
Rust and water are found when fuel tank is drained. ww
Metal particles are found in oil drained from oil pan. ww QQ
Check items

It does not rotate at all. ww

When engine is It rotates only in opposite direction. w
Crankshaft moves by amount of gear
rotated by hand: w w
backlash.
Supply pump shaft does not turn. w
Engine operates, but stops when load is applied from machine. w
Check valve system. q
Perform H-mode trouble-

Check piston and connecting rod. q

Check crankshaft bearing. q
Check gear train. q
Troubleshooting

shooting

Check fuel filter. q

Check feed pump gauze filter. q
Check the feed pump. q
Perform troubleshooting for "Supply pump pressure low error”
qq
according to failure code (*1).
Engine operates if auxiliary equipment (pump, air compressor,
q
etc.) is removed.
Check engine controller power supply wiring. q
Check starting switch wiring. q
Replace
Replace
Replace
Replace

Replace

Replace
Replace
Replace
Replace
Repair

Repair
Repair
Clean

Clean
Add

Remedy
–

*1: Failure codes [CA559] and [CA2249]

PC228US-8,PC228USLC-8 40-433
(01)
Troubleshooting of engine (S-mode)
S-5 Engine runs rough or is unstable

S-5 Engine runs rough or is unstable 40-434

General causes why engine runs rough or is unstable Cause

Leakage or clogging of fuel piping or air in the fuel piping

q Air in fuel system
q Defective engine speed sensor (error at degree that does not generate failure code)

Clogged injector or defective spray (dirt in injector)

Defective Ne speed sensor, or wiring harness
Defective Ne speed sensor, or wiring harness
Clogged air breather hole in fuel tank cap
Insufficient fuel in tank

Clogging of fuel filter

Check recent repair history.
Machine operation
Operated for long period E
hours
Questions

Occurs at a certain speed range. Q Q

Occurs at low idle. Q Q Q Q Q
Hunting:
Occurs even when speed is raised. Q Q Q
Occurs on slope. w
The filter was not replaced as specified by the Operation and Maintenance Manual. w
Fuel tank is found to be empty. w
Air breather hole in fuel tank cap is clogged. w
Troubleshooting Check items

Rust and water are found when fuel tank is drained. Q

Fuel is leaking from fuel piping. w
When priming pump is operated, no resistance is felt or it is heavy. w Q
When air is bled from fuel system, air comes out. q
Check fuel filter. q
Even if a cylinder is cut out, engine speed does not change. q
Perform troubleshooting for "Eng Ne Speed Sensor Error" according to failure code (*1). q
Perform troubleshooting for "Eng Backup Speed Sensor Error" according to failure code (*2). q
Replace
Replace
Replace
Replace
Replace
Clean
Add

Remedy

*1: Failure code [CA689]

*2: Failure code [CA778]

40-434 PC228US-8,PC228USLC-8
(01)
 Troubleshooting of engine (S-mode)
S-6 Engine lacks power

S-6 Engine lacks power 40-435

General causes why engine lacks power Causes

Defective installation of boost pressure sen-

Air leakage from air intake piping and after-

Clogged injector nozzle, or defective spray

Defective injector drive (signal or solenoid)

Defective boost pressure sensor or wiring

Clogged air breather hole in fuel tank cap
Defective contact of valve with valve seat
q Insufficient intake of air

Seizure or interference at turbocharger

q Insufficient supply of fuel

Stuck or seized supply pnmp pluger

q Improper fuel injection
q Improper selection of fuel
q

Clogged or leaking fuel piping

Engine overheating

Clogged air cleaner element

oSee “S-14 Coolant temperature becomes too high (over-

Worn piston ring or cylinder

Improper valve clearance
heating)“.

Clogged fuel spill piping

q Controller is controlling in derate mode.

Clogging of fuel filter

(limiting injection rate (power) because of an error in electrical
system)

(dirt in injector)

sor (air leak)

harness
cooler
Check recent repair history.
Machine opera-
Operated for long period E E E E
tion hours
Questions

Power was lost

suddenly Q w Q Q Q Q
gradually Q Q Q Q Q Q
Fuel other than specified one is used. QQ Q
The filter was not replaced as specified by the Operation and
w w
Maintenance Manual.
Oil must be added more frequently. Q Q
Dust indicator indicates a red zone. w w
Air breather hole in fuel tank cap is clogged. w
Fuel is leaking from fuel piping. w
Power becomes insufficient after short stop of operation. w
Color of exhaust black w w
smoke blue under light load w
When exhaust manifold is touched immediately after starting
w w
engine, temperature of some cylinders is low.
While engine is running, interference sound is heard around tur-
w
Check items

bocharger.
While engine is running, unusual noise is heard around cylinder
w
head.
High idle speed is too high. Q
High idle speed is normal, but speed suddenly drops when load is
Q wQ Q
applied.
Engine does not pick up smoothly and combustion is irregular. w w QQ w
Engine hunts. QQQ Q Q
Blowby gas is excessive. w w
Check air cleaner. q
Check air intake piping. q
When boost pressure is measured, it is found to be low. q q q
When compression pressure is measured, it is found to be low. q q
q
Troubleshooting

Check valve clearance.

Check fuel piping. q
Check fuel filter. q
Check spill port check valve. q
Perform troubleshooting for "Supply pump pressure low error”
q
according to failure code (*1).
Even if a cylinder is cut out, engine speed does not change. q q
Check boost air pressure sensor mount. q
Perform troubleshooting for "Charge pressure sensor error"
q
according to failure code (*2).
Replace

Replace

Replace
Replace
Replace
Replace

Replace
Replace
Repair

Repair

Repair

Repair
Adjust
Clean

Clean

Remedy

*1: Failure codes [CA559] and [CA2249]

*2: Failure codes [CA122] and [CA123]

PC228US-8,PC228USLC-8 40-435
(01)
Troubleshooting of engine (S-mode)
S-7 Exhaust smoke is black (incomplete combustion)

S-7 Exhaust smoke is black (incomplete combustion) 40-436

General causes why exhaust smoke is black Cause

Air leak at tubing between turbocharger and cylinder head

Defective coolant temperature sensor or wiring harness

q Insufficient intake of air
q Improper fuel injection
q Improper selection of fuel
q Engine overheating
oSee “S-14 Coolant temperature becomes too high (overheating)“.

Defective contact of valve with valve seat

q Controller is controlling in derate mode.

Seizure or interference at turbocharger

(limiting injection rate (power) because of an error in electrical system)

Stuck or seized supply pnmp pluger

Improper fuel injection pressure

Improper fuel injection timing
Clogged air cleaner element

Worn piston ring or cylinder

Crushed or clogged muffler

Prematurely worn injector

Cloggedor seized injector
Improper valve clearance
Check recent repair history.
Machine opera-
Operated for long period E E E E
tion hours
w w QQQ
Questions

Color of exhaust Suddenly became black.

smoke
Gradually became black. w Q Q
Is blue under light load. w
Fuel other than specified one is used. QQ
Engine oil must be added more frequently. w
Power was lost
Suddenly w Q QQ
Gradually Q Q Q Q
Dust indicator indicates a red zone. w
Muffler is crushed. w
Air leaks at tubing between turbocharger and cylinder head, and loose
w
clamp.
Engine is operated in low-temperature mode at normal temperature. QQQ
When exhaust manifold is touched immediately after starting engine, tem-
Qw
perature of some cylinders is low.
w
Check items

While engine is running, interference sound is heard around turbocharger.

While engine is running, unusual noise is heard around cylinder head. w
Torque converter stall speed or pump relief speed is high (Fuel is injected
Q
excessively).
Exhaust noise is unusual. Q w Q
Engine does not pick up smoothly and combustion is irregular. Q QQQ Qw
Blowby gas is excessive. w
When spill hose from injector is disconnected, fuel spills excessibly. w
Check air cleaner. q
When turbocharger is rotated by hand, it is fount to be heavy. q
When compression pressure is measured, it is found to be low. q q
Troubleshooting

Check valve clearance. q

If muffler is removed, exhaust sound improves. q
Perform troubleshooting for "Supply pump pressure low error” according to
q q
failure code (*1).
Even if a cylinder is cut out, engine speed does not change. q
Perform troubleshooting for "Coolant sensor error" according to failure code
q
(*2).
Check the condition by using monitoring function of the machine monitor. qq
Replace

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Repair

Repair
Adjust
Clean

Remedy

*1: Failure codes [CA559] and [CA2249]

*2: Failure codes [CA144] and [CA145]

40-436 PC228US-8,PC228USLC-8
(01)
 Troubleshooting of engine (S-mode)
S-8 Oil consumption is excessive (or exhaust smoke is blue)

S-8 Oil consumption is excessive (or exhaust smoke is blue) 40-437

General causes why oil consumption is excessive Cause

Turbocharger

Oil leakage from oil pan, cylinder head, etc.

q Excessive oil carry-over

Worn/damaged valve (stem, guide, seal)

q Long-time operation of engine at low idle or high idle
(Do not idle the engine for more than 20 minutes continuously)

Dust sucked in at air intake system

q External leakage of oil

Clogged breather or breather hose

q Wear of parts in lubrication system

Worn or damaged rear oil seal

Oil leakage from oil drain plug

Worn piston ring or cylinder

Oil leakage from oil cooler

Oil leakage from oil piping

Worn seal at turbine end
Worn seal at blower end

Oil leakage from oil filter

Broken piston ring

Broken oil cooler

Check recent repair history.
Machine operation
Questions

Operated for long period EEE E

hours
Oil consumption suddenly increased. w Q
Engine oil must be added more frequently. w Q
Oil becomes contaminated quickly. Q Q w
Outside of engine is dirty with oil. w w w w w
Loose hose clamps are found in air intake system. w
Inside of air outlet pipe at turbo compressor side is dirty with oil. w
Inside of turbo exhaust outlet pipe is dirty with oil. Q w
Check items

Oil in coolant w
Oil level in damper chamber is increasing. w
Exhaust smoke is blue under light load. w w
Excessive Q Q w w
Amount of blowby gas
None w
When intake manifold is removed, dust is found inside. q
When intake manifold is removed, inside is abnormally dirty. q
Troubleshooting

Excessive play of turbocharger shaft q q

Check breather or breather hose. q
When compression pressure is measured, it is found to be low. q q
Check rear oil seal. q
Pressure tightness test result of oil cooler shows oil leakage. q q
External leakage of oil from engine q q q q
Replace
Replace

Replace
Replace
Replace
Replace
Replace
Repair
Repair

Repair
Repair
Repair
Repair
Clean

Remedy

PC228US-8,PC228USLC-8 40-437
(01)
Troubleshooting of engine (S-mode)
S-9 Oil becomes contaminated early

S-9 Oil becomes contaminated early 40-438

General causes why oil becomes contaminated early Cause

Clogged turbocharger lubrication oil drain tube

Defective sealing at turbocharger turbine end
q Entry of exhaust gas into oil due to internal wear
q Clogging of lubrication passage
q Use of improper fuel
q Use of improper oil

Clogged breather or breather hose

q Operation under excessive load

Defective oil filter safety valve

Worn piston ring or cylinder
Worn valve or valve guide

Exhaust smoke is bad

Clogged oil cooler
Clogged oil filter
Check recent repair history.
Questions

Machine operation hours Operated for long period EEE

Fuel other than specified one is used. Q Q
Oil must be added more frequently. w
Metal particles are found in the removed oil filter. Q Q w
Inside of exhaust pipe is dirty with oil. w
Engine oil temperature rises quickly. w
Blue under light load w
Check items

Color of exhaust smoke

Black w
Excessive Q Q w Q
Amount of blowby gas
None w
Excessive play of turbocharger shaft q
Troubleshooting

When compression pressure is measured, it is found to be low. q q

q

See S-7
Check breather or breather hose.
Check oil cooler. q
Check oil filter. q
Spring of oil filter safety valve is stuck or broken. q
Check turbocharger lubrication oil drain tube. q
Replace
Replace
Replace

Replace
Replace
Clean
Clean

Clean

Remedy
–

40-438 PC228US-8,PC228USLC-8
(01)
 Troubleshooting of engine (S-mode)
S-10 Fuel consumption is excessive

S-10 Fuel consumption is excessive 40-439

General causes why fuel consumption is excessive Cause

Defective coolant temperature sensor or wiring harness

q Leakage of fuel
q Improper fuel injection (fuel pressure or injection timing)
q Excessive injection of fuel

Fuel leakage from fuel filter, piping, etc.

Defective atomization by injector

Improper common rail pressure
Defective supply pump plunger

Defective operation of injector

Fuel leakage at cylinder head

Defective feed pump oil seal

Improper injection timing

Check recent repair history.
Machine opera-
Questions

Operated for long period EE E

tion hours
is more than that on other machines of same model. Q QQQ
Fuel consump-
Gradually increased. Q Q
tion:
Suddenly increased. QQ
External leakage of fuel from engine w
Combustion is irregular. w
Engine oil level rises and oil smells of diesel fuel. w w
When exhaust manifold is touched immediately after starting engine, temperature of
w
Check items

some cylinders is low.

Low idle speed is high. Q
Pump relief speed is high. Q
Color of exhaust Black QQ QQ
smoke White Q
Remove head cover and check for fuel leak. q
Check oil seal of feed pump. q
Troubleshooting

Perform troubleshooting for "Supply pump pressure low error” according to failure code
q
(*1).
Even if a cylinder is cut out, engine speed does not change. q
Too much fuel is returned from injector. q
Perform troubleshooting for "Coolant sensor error" according to failure code (*2). q
Check the condition by using monitoring function of machine monitor. q q
Replace
Replace

Replace
Replace
Replace
Replace
Repair
Repair

Repair

Remedy

*1: Failure codes [CA559] and [CA2249]

*2: Failure codes [CA144] and [CA145]

PC228US-8,PC228USLC-8 40-439
(01)
Troubleshootingof
Troubleshootingofengine(S-mode)
engine(S -m ode)
S-11 Oil
S-11 Oil is
is in
in coolant
coolant (or
(or coolant
coolant spurts
spurts or
or coolant
coolant level
level goes
goes down)
down)

S-11 Oil is in coolant (or coolant spurts or coolant level goes down) 40-4 0

General causes why oil is present in coolant Cause

Broken cylinder head or cylinder head gasket

q Internal leakage in lubrication system
q Internal leakage in cooling system

Internal cracks in cylinder block

Broken oil cooler core or O-ring

Holes caused by pitting
Check recent repair history.
Machine operation
EE
Questions

Operated for long period

hours
suddenly Q Q
Oil level rose:
gradually Q Q
Hard water is being used as coolant. Q Q
Oil level has risen and oil is milky. Q Q w
Check items

Unusual air bubbles are found in radiator, or coolant spurts. w

Troubleshooting

Pressure tightness test result of cylinder head shows oil leakage. q

Check cylinder block. q q

Pressure tightness test result of oil cooler shows oil leakage. q

Replace
Replace
Replace
Replace

Remedy

40-440 PC228US-8,PC228USLC-8
(01)
 Troubleshooting of engine (S-mode)
S-12 Oil pressure drops

S-12 Oil pressure drops 40-4 1

General causes why oil pressure drops Cause

Defective coolant temperature sensor or wiring harness

q Leakage, clogging, or wear on lubrication system
q Defective oil pressure control
q Selection of oil by the temperature etc. specified in the Operation and Maintenance
Manual is not observed.
q Deterioration of oil due to overheating

Leaking, crushed, clogged oil piping

Clogged or broken pipe in oil pan
Clogged strainer in oil pan

Defective regulator valve

Coolant or fuel in oil
Lack of oil in oil pan
Worn main hearing

Defective oil pump

Clogged oil filter

Check recent repair history.
Machine opera-
Questions

Operated for long period E E E

tion hours
Oil pressure monitor indicates low oil pressure. Qw
Non-specified oil is being used. Q Q
The filter was not replaced as specified by the Operation and Maintenance Manual. w
Indicates pressure drop at low idle. w
Oil pressure
Indicates pressure drop at low and high idle. Q wwwQ
monitor:
Indicates pressure drop on slope. w
(if installed)
Sometimes indicates pressure drop. w Q
Oil pressure monitor indicates low oil pressure. w w
Oil level in oil pan is low. w
External lubrication piping is leaking or crushed. w
Troubleshooting Check items

Oil is milky or smells of diesel fuel. w

Metal particles are found in oil drained from oil pan. w
Metal particles are found in the removed oil filter. w Q
Metal particles are found in oil filter. q
Inspect oil pan strainer and pipe. qq
See S-13

Oil pump rotation is heavy or there is play in oil pump. q

Valve and spring of regulator valve are fatigued or damaged. q
Check oil filter. q
If oil level sensor is replaced, oil level monitor indicates correct oil level. q
Replace

Replace

Replace
Repair
Adjust
Adjust
Clean
Clean
Add

Remedy
–

PC228US-8,PC228USLC-8 40-441
(01)
Troubleshooting of engine (S-mode)
S-13 Oil level rises (coolant or fuel in oil)

S-13 Oil level rises (coolant or fuel in oil) 40-4 2

General causes why oil level rises Causes

Defective seal of auxiliaries (water pump or air compressor)

q Coolant in oil (milky)
q Fuel in oil (oil smell of diluted diesel fuel)
a If oil is in coolant, perform troubleshooting for “S-11 Oil is in coolant”.

Broken cylinder head or cylinder head gasket

Internal cracks in cylinder block

Broken oil cooler core or O-ring

Worn or damaged rear oil seal

Defects in supply pump

Holes caused by pitting
Broken injector O-ring
Check recent repair history.
Questions

Machine opera-
Operated for long period E EE E
tion hours
Fuel must be added more frequently. w w
Coolant must be added more frequently. Q Q
Oil in coolant QQQQ w
Oil smells of diesel fuel w w
Oil is milky. Q Q
While engine is running, drops of water come from muffler. Q
If radiator cap is removed and engine is run at low idle, an unusual number of bubbles
Check items

w Q
appears, or coolant spurts.
Exhaust smoke is white. Q
Oil level in damper chamber decreases. w
When compression pressure is measured, it is found to be low. q
Troubleshooting

Remove injector and check O-ring. q

Check cylinder block. qq
Check rear oil seal. q
Pressure tightness test result of oil cooler shows oil leakage. q
Remove and check supply pump. q
Check seal of auxiliaries. q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

Remedy

40-442 PC228US-8,PC228USLC-8
(01)
 Troubleshooting of engine (S-mode)
S-14 Coolant temperature rises too high (overheating)

S-14 Coolant temperature rises too high (overheating) 40-4 3

General causes why coolant temperature rises too high Causes

q Lack of cooling air (deformation or damage of fan)
q Drop in heat dissipation efficiency
q Problem in coolant circulation system

Broken cylinder head or cylinder head gasket

Defective radiator cap (pressure valve)

Defective coolant temperature gauge

Slipping fan belt or worn fan pulley

Rise in hydraulic oil temperature

Clogged or crushed radiater fins
Clogged or broken oil cooler

Malffunction of water pump

Holes caused by pitting

Clogged radiator core

Defective thermostat
Lack of coolant
Check recent repair history.
Machine opera-
Operated for long period EE EE
Questions

tion hours
Suddenly occurred. Q w Q
Overheating
Tends to occur always. Q w w Q
Coolant temper- Indiacates quick temperature rise. Q w
ature gauge: Does not go down from red range. w
Radiator coolant level monitor indicates drop of coolant level. w
Engine oil level has risen and oil is milky. w Q
Fan belt tension is low. w
When fan pulley is turned, it has play. w
Milky oil is floating on coolant. w
Unusual air bubbles are found in radiator or coolant spurts. w
Check items

When light bulb is held behind radiator core, no light passes through. w
Radiator shroud and inside of underguard are clogged with dirt or mud. w w
Coolant is leaking because of cracks in hose or loose clamps. w
Coolant flows out from radiator overflow hose. w
Fan belt whines under sudden acceleration. w
Hydraulic oil temperature gauge enters red range faster than engine coolant
w
temperature gauge.

When compression pressure is measured, it is found to be low. q

q
Perform H-mode troubleshooting.

Check cylinder.
Check oil cooler. q
q
Troubleshooting

Temperature difference between upper and lower tanks of radiator is large.

When operation of thermostat is tested, it does not open at specified opening
q
temperature.
Temperature difference between upper and lower tanks of radiator is slight. q
Check radiator core. q
When operation of radiator cap is tested, its opening pressure is low. q
Check fan belt and pulley. q
When coolant temperature is measured, it is found to be normal. q
Replace
Replace
Replace

Replace
Replace

Replace

Replace
Repair
Repair

Repair
Add

Remedy
–

PC228US-8,PC228USLC-8 40-443
(01)
Troubleshooting of engine (S-mode)
S-15 Unusual noise is made

S-15 Unusual noise is made 40-4 4

General causes why unusual noise is heard Cause

Improper fuel injection timing (defect in low coolant temperature

q Abnormality due to defective parts

Deformed cooling fan, loose fan belt, interference of fan belt

q Abnormal combustion

Defective inside of muffler (partition board out of position)

Air leak at tubing between turbocharge and cylinder head
q Air sucked in from air intake system
a Judge if the noise is an internal noise or an external noise before starting trou-
bleshooting.
a The engine is operated in the low-temperature mode while it is not warmed

Damage of valve system (valve or rocker lever)

up sufficiently. Accordingly, the engine sound becomes a little larger. This
does not indicate abnormality, however.

Excessively worn piston ring or cylinder

a When the engine is accelerated, it is operated in the acceleration mode and

Seizure or interference at turbocharger

sensor or boost temperature sensor)

its sound becomes a little larger for up to about three seconds. This does not
indicate abnormality, however.

Dislocated or seized bushing

Improper gear train backlash

Clogged or seized injector

Improper valve clearance

Dirt caught in injector

Check recent repair history.
Machine opera-
Operated for long period E
Questions

tion hours
Gradually occurred. Q Q
Abnormal noise
Sudden occurred. QQ Q
Fuel other than specified one is used. Q
Engine oil must be added more frequently. w
Metal particles are found in the removed oil filter. w w
Air leaks at tubing between turbocharger and cylinder head. w
While engine is running, interference sound is heard from turbocharger. w
While engine is running, unusual noise is heard around cylinder head. w w
While engine is running, beat noise is heard around muffler. w
Check items

When exhaust manifold is touched immediately after starting engine, tem-

wQ
perature of some cylinders is low.
Color of exhaust Blue under light load w
smoke: Black Qw Q
Engine does not pick up smoothly and combustion is irregular. w
Unusual noise is loud when engine is accelerated Q Q QQ
Blowby gas is excessive. w
When turbocharger is rotated by hand, it is found to be heavy. q
Check valve system. q
If muffler is removed, unusual noise disappears. q
Troubleshooting

Check valve clearance. q

When compression pressure measured, it is found to be low. q
Check gear train. qq
Check fan and fan belt. q
Even if a cylinder is cut out, engine speed does not change. qq
Unusual noise is heard only when engine is cranked. q
Check the condition by using monitoring function of machine monitor. q
Replace
Replace
Replace
Replace

Replace
Replace
Replace

Replace
Replace
Replace
Repair
Adjust

Remedy

40-444 PC228US-8,PC228USLC-8
(01)
 Troubleshooting of engine (S-mode)
S-16 Vibration is excessive

S-16 Vibration is excessive 40-4 5

General causes why vibration is excessive Cause

Improper injection timing (Problem with coolant or boost temperature sensor)

q Defective parts (premature wear or breakage)
q Misalignment between engine snd hydraulic pump
q Abnormal combustion
a If unusual noise is made and vibration is excessive, perform troubleshooting also
for “S-15 Unusual noise is made”.

Worn main bearing and connecting rod bearing

Loose engine mount bolts or broken cushions

Stuck valve system (valve, rocker arm, etc.)

Misalignment of engine and hydraulic pump

Broken parts in damper chamber
Improper gear train backlash
Worn camshaft bushing
Check recent repair history.
Machine opera-
Questions

Operated for long period E E E

tion hours
Suddenly increased. Q Q
Vibration
Gradually increased. Q Q Q
Non-specified oil is being used. Q Q
Metal particles are found in the removed oil filter. w w
Metal particles are found in oil drained from oil pan. w w
Oil pressure is low at low idle. Q Q
Check items

Vibration occurs at mid-range speed. Q Q

Vibration follows engine speed. Q Q Q Q
Exhaust smoke is black. w Q
Check valve system. q
Check main bearing and connecting rod bearing. q
Troubleshooting

Check gear train. q

Check camshaft bushing. q
Check the condition by using monitoring function of machine monitor. q
Check engine mounting bolts and cushions. q
When radial runout and facial runout are checked, misalignment is found. q
Check inside of damper chamber. q
Replace
Replace
Replace
Replace
Replace
Replace

Replace
Adjust

Remedy

PC228US-8,PC228USLC-8 40-445
(01)
Troubleshooting of engine (S-mode)
S-16 Vibration is excessive

40-446 PC228US-8,PC228USLC-8
(01)
SEN0533427-00 50-1

PC228US-8, PC228USLC-8

HYDRAULIC EXCAVATOR
Shop Manual 50-1

PC228US-8
PC228USLC-8

Machine model Serial number

PC228US-8 50001 and up
PC228USLC-8 50001 and up

50 Disassembly and assembly 50-1

PC228US-8, PC228USLC-8 50-1

(02)
Table of contents

Table of contents 50-2

50 Disassembly and assembly
General information on disassembly and assembly ............................................................... 50- 4
How to read Disassembly and Assembly............................................................................. 50- 4
Coating materials list............................................................................................................ 50- 6
Special tools list ................................................................................................................... 50- 9
Sketches of special tools ..................................................................................................... 50- 13
Engine and cooling system ..................................................................................................... 50- 18
Removal and installation of fuel supply pump assembly ..................................................... 50- 18
Removal and installation of fuel injector assembly .............................................................. 50- 22
Removal and installation of cylinder head assembly ........................................................... 50- 29
Removal and installation of radiator assembly .................................................................... 50- 44
Removal and installation of hydraulic oil cooler assembly................................................... 50- 47
Removal and installation of aftercooler assembly................................................................ 50- 49
Removal and installation of engine assembly...................................................................... 50- 52
Removal and installation of engine front seal ...................................................................... 50- 56
Removal and installation of engine rear seal ....................................................................... 50- 58
Removal and installation of fuel cooler assembly ................................................................ 50- 61
Removal and installation of fuel tank assembly ................................................................... 50- 63
Power train.............................................................................................................................. 50- 66
Removal and installation of travel motor and final drive assembly ...................................... 50- 66
Disassembly and assembly of final drive assembly............................................................. 50- 67
Removal and installation of swing motor and swing machinery assembly .......................... 50- 75
Disassembly and assembly of swing machinery assembly ................................................. 50- 77
Removal and installation of swing circle assembly .............................................................. 50- 85
Undercarriage and frame ........................................................................................................ 50- 86
Separation and connection of track shoe assembly ............................................................ 50- 86
Removal and installation of idler and idler cushion assembly.............................................. 50- 88
Disassembly and assembly of idler assembly ..................................................................... 50- 89
Disassembly and assembly of idler cushion assembly ........................................................ 50- 92
Disassembly and assembly of track roller assembly ........................................................... 50- 94
Disassembly and assembly of carrier roller assembly ......................................................... 50- 96
Removal and installation of revolving frame assembly ........................................................ 50- 99
Removal and installation of counterweight assembly .......................................................... 50- 101
Removal and installation of maintenance counterweight assembly..................................... 50- 103
Hydraulic system..................................................................................................................... 50- 106
Removal and installation of center swivel joint assembly .................................................... 50- 106
Disassembly and assembly of center swivel joint assembly................................................ 50- 109
Removal and installation of hydraulic tank assembly .......................................................... 50- 111
Removal and installation of main pump assembly............................................................... 50- 113
Removal and installation of main pump input shaft oil seal ................................................. 50- 117
Removal and installation of control valve assembly ............................................................ 50- 118
Disassembly and assembly of control valve assembly ........................................................ 50- 123
Disassembly and assembly of work equipment PPC valve assembly ................................. 50- 127
Disassembly and assembly of travel PPC valve assembly.................................................. 50- 129
Work equipment...................................................................................................................... 50- 132
Removal and installation of work equipment assembly ....................................................... 50- 132
Removal and installation of anti-drop valve assembly for boom.......................................... 50- 134-1
Removal and installation of anti-drop valve assembly for arm............................................. 50- 134-4
Disassembly and assembly of anti-drop valve assembly..................................................... 50- 134-6
Disassembly and assembly of work equipment cylinder assembly ..................................... 50- 135

50-2 PC228US-8, PC228USLC-8

(04)
 Table of contents

Cab and its attachments ......................................................................................................... 50- 142

Removal and installation of operator's cab assembly.......................................................... 50- 142
Removal and installation of operator's cab glass (adhered window glass).......................... 50- 146
Removal and installation of front window assembly ............................................................ 50- 156
Removal and installation of floor frame assembly ............................................................... 50- 157
Removal and installation of air conditioner unit assembly ................................................... 50- 164
Electrical system ..................................................................................................................... 50- 170
Removal and installation of air conditioner compressor assembly ...................................... 50- 170
Removal and installation of air conditioner condenser assembly ........................................ 50- 172
Removal and installation of engine controller assembly...................................................... 50- 173
Removal and installation of pump controller assembly........................................................ 50- 175
Removal and installation of machine monitor assembly...................................................... 50- 178
Removal and installation of pump swash plate sensor........................................................ 50- 180
Removal and installation of KOMTRAX terminal assembly ................................................. 50- 181

PC228US-8, PC228USLC-8 50-3

(04)
General information on disassembly and assembly
How to read Disassembly and Assembly

General information on disassembly and assembly 50-4

How to read Disassembly and Assembly 50-4
(Rev. 2009. 01)
1. Removal and installation of assemblies 50-4

Special tools 50-4 Removal 50-4

q Special tools which are necessary for removal or q In “Removal” section, the work procedures, pre-
installation of parts are described as A1 ••• X1 cautions and know-how to do the work, and the
etc. and their part numbers, part names and amount of oil and coolant to be drained are de-
quantities are described in the special tool list. scribed.
q In the special tools table, the follwing information q Common tools that are necessary for removal
is described, as well as the above items. are described as [1], [2]••• etc. and their part
1) Necessity numbers, part names and quantities are not de-
t: Special tools that cannot be substituted scribed.
and should always be used. q Various symbols used in “Removal” section are
q: Special tools that will be useful if available explained and listed below.
and are substitutable with tools available k : Precautions related to work safety
on the market. a : Know-how or precautions for work
2) New/redesign [*1] : This mark shows that instructions or
N : Tools newly developed for this model. precautions for parts installation work are
They have a new part number respec- given in “Installation” section.
tively. 6 : This mark shows the amount of oil or
R : Tools made available by redesigning coolant to be drained
the existing tools which were devel- 4 : Weight of part or component
oped for other models. Each of them
has a new part number assigned by Installation 50-4
setting forward the part number of the q Unless otherwise instructed, installation of parts
existing tool. is to be done in the reverse order to removal.
Blank :Tools already available for other q Instructions and precautions for parts installation
models. They can be used without any is shown with the mark ([*1], [*2]...) which corre-
modification. sponds to the mark in “Removal” section.
3) Circle mark Q in sketch column: q Common tools that are necessary for installation
q The sketch of the special tool is present- are described as [1], [2]••• etc. and their part
ed in the section of “Sketches of special numbers, part names and quantities are not de-
tools”. scribed.
q Part No. of special tools starting with q Marks shown in the "Installation" section stand
79*T-***-****: means that they are not for the following.
available from Komatsu Ltd. (i.e. tools to k : Precautions related to work safety
be made locally). a : Know-how or precautions for work
2 : Type of coating material
3 : Tightening torque
5 : Amount of oil or coolant to be replen-
ished

Sketches of special tools 50-4

q Various special tools are illustrated for the local
manufacture.

50-4 PC228US-8, PC228USLC-8

(02)
 General information on disassembly and assembly
How to read Disassembly and Assembly

2. Disassembly and assembly of assemblies 50-5

Special tools 50-5 Assembly 50-5
q Special tools which are necessary for disassem- q In “Assembly” section, the work procedures, pre-
bly and assembly of parts are described as cautions and know-how to do the work, and the
A1•••X1 etc. and their part numbers, part names amount of oil and coolant to be replenished are
and quantities are described in the special tool described.
list. q Common tools that are necessary for assembly
q In the special tools table, the follwing information are described as [1], [2]••• etc. and their part
is described, as well as the above items. numbers, part names and quantities are not de-
1) Necessity scribed.
t: Special tools that cannot be substituted q The meanings of the symbols used in "Assem-
and should always be used. bly" section are as follows.
q: Special tools that will be useful if available k : Precautions related to work safety
and are substitutable with tools available a : Know-how or precautions for work
on the market. 2 : Type of coating material
2) New/redesign 3 : Tightening torque
N : Tools newly developed for this model. 5 : Amount of oil or coolant to be replen-
They have a new part number respec- ished
tively.
R : Tools made available by redesigning Sketches of special tools 50-5
the existing tools which were devel- q Various special tools are illustrated for the local
oped for other models. Each of them manufacture.
has a new part number assigned by
setting forward the part number of the
existing tool.
Blank :Tools already available for other
models. They can be used without any
modification.
3) Circle mark Q in sketch column:
q The sketch of the special tool is present-
ed in the section of “Sketches of special
tools”.
q Part No. of special tools starting with
79*T-***-****: means that they are not
available from Komatsu Ltd. (i.e. tools to
be made locally).

Disassembly 50-5
q In “Disassembly” section, the work procedures,
precautions and know-how to do the work, and
the amount of oil and coolant to be drained are
described.
q Common tools that are necessary for disassem-
bly are described as [1], [2]••• etc. and their part
numbers, part names and quantities are not de-
scribed.
q The meanings of the symbols used in "Disas-
sembly" section are as follows.
k : Precautions related to work safety
a : Know-how or precautions for work
6 : Amount of oil or coolant drained.

PC228US-8, PC228USLC-8 50-5

(02)
General information on disassembly and assembly
Coating materials list

Coating materials list 50-6

(Rev. 2009. 08)
a The recommended coating materials such as adhesives, liquid gaskets, and greases used for disassem-
bly and assembly are listed below.
a For coating materials not listed below, use the equivalent of products shown in this manual.
Cate-
Komatsu code Part number capacity Container Main features and applications
gory
q Use to prevent rubber gaskets, rubber cushions,
LT-1A 790-129-9030 150 g Tube
and cork plugs from coming out.
q Use for plastic (except polyethylene, polypropyl-
20 g Polyethyl-
ene, tetrafluoroethylene and vinyl chloride), rubber,
LT-1B 790-129-9050 (2 pcs. ene con-
metal, and non-metal parts which require immedi-
contained ) tainer
ate and strong adhesion.
Polyethyl-
q Features: Resistance to heat and chemicals
LT-2 09940-00030 50 g ene con-
q Use to fix and seal bolts and plugs.
tainer
790-129-9060 Adhesive:
(Set of adhe- 1 kg
LT-3 Can q Use to bond and seal metal, glass and plastics.
sive and hard- Hardener:
ener) 500 g
Adhesive

Polyethyl-
LT-4 790-129-9040 250 g ene con- q Use to seal plugs for blank holes
tainer
Holtz
790-129-9120 75 g Tube q Heat-resistant seal used to repair engines.
MH 705
q Instanetaneous adhesive.
Polyethyl-
ThreeBond q Curing time: From 5 sec. to 3 min.
790-129-9140 50 g ene con-
1735 q Use mainly to bond metals, rubbers, plastics, and
tainer
woods.
q Instanetaneous adhesive.
Polyethyl-
Aron-alpha q Quick-curing type (max. strength is obtained after
790-129-9130 2g ene con-
201 30 minutes)
tainer
q Use mainly to bond rubbers, plastics, and metals.
Polyethyl-
q Features: Resistance to heat and chemicals
Loctite 648-50 79A-129-9110 50 cc ene con-
q Used for fitted portions used at high temperatures.
tainer
q Use to seal various threaded portions, pipejoints,
Polyethyl-
and flanges.
LG-5 790-129-9080 1 kg ene con-
q Use to seal taper plugs, elbows, and nipples for hy-
tainer
draulic piping.
q Features: Silicon-based heat and cold-resistant
sealant
LG-6 790-129-9160 200 g Tube q To be used to seal threaded portions on flange sur-
Liquid gasket

face
q Use to seal oil pan, final drive case, etc.
q Features: Silicon-based quick-curing sealant
LG-7 790-129-9170 1 kg Tube q Use to seal flywheel housing, intake manifold, ther-
mostat old, oil pan, thermostat housing, etc.
LG-8 q Features: Silicon-based, heat-resistant, vibra-
ThreeBond 419-15-18131 100 g Tube tion-resistant, impact-resistant sealant
1207B q Use to seal transfer case, etc.
q Use for rough surfaces such as the circle gear top
LG-9
seal which is not clamped by bolts, gaps in the weld
ThreeBond 790-129-9310 200 g Tube
which must be caulked, etc.
1206D
q Can be coated with paint.

50-6 PC228US-8, PC228USLC-8

(02)
 General information on disassembly and assembly
Coating materials list

Cate-
Komatsu code Part number capacity Container Main features and applications
gory
LG-10 q Use as lubricant/sealant when installing the radiator
ThreeBond 790-129-9320 200 g Tube hoses to the water tubes.
Liquid gasket

1206E q Can be coated with paint.

LG-11 q Feature: Can be used together with solid gaskets.
ThreeBond 790-129-9330 200 g Tube q Use for covers of the transmission case and steer-
1121 ing case etc.
ThreeBond
790-129-9090 100 g Tube q Liquid gasket used to repair engine.
1211
q Use to prevent galling and seizure of press-fitted
Molybdenum disulphide

portions, shrinkage-fitted portions, and threaded

LM-P 09940-00040 200 g Tube
portions.
lubricant

q Use to lubricate linkages, bearings, etc.

q Spray type
q Thin molybdenum disulphide films are made on
– 09995-00250 190 g Can metal surfaces to prevent the metals from galling.
q Use for the drive shaft splines, needle bearings,
various link pins, bolts, etc.
prevention compound

q Feature: Seizure and galling prevention compound

Seizure

with metallic super-fine-grain, etc.

LC-G
– – Can q Use for the mounting bolt in the high temperature
NEVER-SEEZ
area of the exhaust manifold and the turbocharger,
etc.

SYG2-400LI
SYG2-350LI
SYG2-400LI-A
G2-LI
SYG2-160LI
G0-LI (*) q Feature: Lithium grease with extreme pressure lu-
SYGA-160CNLI Various Various
*: For cold dis- brication performance, general purpose type.
SYG0-400LI-A
trict
(*)
SYG0-16CNLI
(*)
q Used for parts under heavy load.
Bel- Caution:
Molybdenum
SYG2-400M 400 g × 10 lows-type q Do not use this grease for rolling bearings like
disulphide
SYG2-400M-A 400 g × 20 container swing circle bearings, etc. and spline.
grease
SYGA-16CNM 16 kg q Use this grease for work equipment pins only
LM-G (G2-M)
Can when installing them, but do not use it after-
ward.
Grease

SYG2-400T-A
Hyper White
SYG2-16CNT Bel- q Seizure resistance, heat resistance and water re-
G2-T
SYG0-400T-A 400 g lows-type sistance higher than molybdenum disulphide
G0-T (*)
(*) 16 kg container grease.
*: For cold dis-
SYG0-16CNT Can q Not conspicuous on machine since color is white.
trict
(*)
Biogrease
SYG2-400B
G2-B
SYGA-16CNB Bel-
G2-BT (*) q Since this grease is biodegradable in short period,
SYG2-400BT 400 g lows-type
*: For use at it has less impact on microorganisms, animals, and
(*) 16 kg container
high tempera- plants.
SYGA-16CNBT Can
ture and under
(*)
high load
q Feature: Silicone grease with wide usable temper-
G2-S ature range, high resistance to thermal-oxidative
ThreeBond – 200 g Tube degradation and performance to prevent deteriora-
1855 tion of rubber and plastic parts
q Use for oil seals of the transmission, etc.

PC228US-8, PC228USLC-8 50-7

(02)
General information on disassembly and assembly
Coating materials list

Cate-
Komatsu code Part number capacity Container Main features and applications
gory
q Feature: Urea (organic system) grease with heat
resistance and long life, can be packed into the
Grease

G2-U-S
427-12-11871 2 kg Can confined space and left intact until next overhaul.
ENS grease
q Use for rubber, bearing and oil seal in damper.
Caution: Do not mix with lithium grease.
SUNSTAR q Use as primer for painted cab sheet metal
PAINT Glass con- surface.
20 ml
PRIMER580 tainer (Effective period: 4 months after date of
SUPER manufacture)
417-926-3910
SUNSTAR
q Use as primer for glass.
GLASS Glass con-
20 ml (Effective period: 4 months after date of

For adhered window glass

PRIMER 580 tainer
manufacture)
SUPER
SUNSTAR q Use as primer for painted cab sheet metal
PAINT Glass con- surface.
Primer

22M-54-27230 20 ml
PRIMER tainer (Effective period: 4 months after date of
435-95 manufacture)
q Use as primer for black ceramic-coated glass
SUNSTAR
surface and for hard polycarbonate-coated
GLASS
22M-54-27240 150 ml Can surface.
PRIMER
(Effective period: 4 months after date of
435-41
manufacture)
SUNSTAR q Use as primer for sash (anodized aluminum
SASH Glass con- surface).
22M-54-27250 20 ml
PRIMER tainer (Effective period: 4 months after date of
GP-402 manufacture)
SUNSTAR q Use “S" in high-temperature season and “W"
PENGUINE Polyethyl- in low-temperature season as adhesive for
SEAL580 417-926-3910 320 ml ene con- glass.
SUPER “ S" or tainer (Effective period: 4 months after date of
Adhesive

“ W" manufacture)
Sika Japan, Polyethyl- q Use as adhesive for glass.
Sikaflex 20Y-54-39850 310 ml ene con- (Effective period: 6 months after date of
For adhered window glass

256HV tainer manufacture)

SUNSTAR Ecocart q Use as adhesive for glass.
PENGUINE 22M-54-27210 320 ml (Special (Effective period: 6 months after date of
SUPER 560 container) manufacture)
SUNSTAR
Polyethyl- q Use to seal glass-to-glass joints.
PENGUINE
417-926-3920 320 ml ene con- (Effective period: 4 months after date of
SEAL No.
Caulking material

tainer manufacture)
2505
SEKISUI SILI- Polyethyl- q Use to seal front window.
CONE SEAL- 20Y-54-55130 333 ml ene con- (Effective period: 6 months after date of
ANT tainer manufacture)
q Use to seal glass-to-glass joint. Translucent
GE TOSHIBA
white seal.
SILICONES 22M-54-27220 333 ml Cartridge
(Effective period: 12 months after date of
TOSSEAL381
manufacture)

50-8 PC228US-8, PC228USLC-8

(02)
 General information on disassembly and assembly
Special tools list

Special tools list 50-9

a A tool number in the format 79*T-***-**** indicates a non-supplied (locally made) item.
a Necessity:
t … … Special tools that cannot be substituted and should always be used.
q …… Special tools that will be useful if available and are substitutable with tools available on the market.
a New/Remodel :
N:Tools newly developed for this model. They have a new part number respectively.
R……Tools made available by redesighning the existing tools which were developed for other models.
Blank: Tools already available for other models, can be used without any modification.
a Tools marked Q in the Sketch column are tools introduced in the sketches of the special tools (See Sketch-
es of special tools)

New/redesign
Necessity

Sketch
Sym

Q'ty
Work Part number Part name Contents of work and remarks
-bol

Removal and installa-

Holding of fuel supply pump
tion of fuel supply pump 1 795-799-6130 Support t 1
gear
assembly
Removal and installa- Removal of fuel injector assem-
2 795-799-6700 Puller t 1
tion of fuel injector bly
assembly and cylinder 3 795-799-1131 Gear t 1 Adjustment of valve clearance
head assembly 4 795-799-8150 Remover q 1 Removal of inlet connector
Removal and installa- A 5 790-331-1120 Wrench (angle) q 1 Angle tightening of bolt
tion of cylinder head
Judgment of cylinder head bolt
assembly and engine 6 795-799-8150 Remover q 1
front seal length
Removal and installa-
7 795-799-6400 Seal puller t 1 Installation of engine front seal
tion of engine front seal
Removal and installa-
8 795-799-6500 Seal puller t 1 Installation of engine rear seal
tion of engine rear seal
Removal and installation of
1 796-427-1200 Wrench t 1
round nut
2 791-545-1510 Installer t 1 Installation of floating seal
796T-427-1220 Push tool t 1 Q
Disassembly and 790-101-2510 Block t 1
assembly of final drive F 792-104-3940 Bolt t 2
assembly 3 05180-11613 Nut t 2 Installation of hub assembly
01613-31645 Washer t 2
790-105-2100 Jack t 1
790-101-1102 Hydraulic pump t 1
4 790-331-1110 Wrench t 1 Installation of cover
1 796T-426-1410 Push tool t 1 Q Press fit of main bearing
Disassembly and 2 796-426-1120 Push tool t 1 Press fitting of sub bearing
assembly of swing G 796T-426-1130 Plate t 1 Q
machinery assembly 3 790-101-5241 Grip t 1 Press fit of oil seal
01010-81240 Bolt t 1
Disassembly and
assembly of idler assem- J 791-530-1510 Installer t 1 Installation of floating seal
bly
Disassembly and
assembly of track roller K 796-670-1020 Installer t 1 Installation of floating seal
assembly
Disassembly and
assembly of carrier roller L 790-434-1660 Installer t 1 Installation of floating seal
assembly

PC228US-8, PC228USLC-8 50-9

(02)
General information on disassembly and assembly
Special tools list

New/redesign
Necessity

Sketch
Sym

Q'ty
Work Part number Part name Contents of work and remarks
-bol

791-600-2001 Compressor (A) t 1

or
791-685-8006 Compressor (B) t 1
790-201-2780 Spacer
Disassembly and assembly of
1 791-635-3160 Extension t 1
idler cushion assembly
Cylinder
790-101-1600 t 1
(686 kN {70 ton})
Disassembly and 790-101-1102 Pump t 1
assembly of idler cush- M 790-640-2180 Guide bolt t 1
ion assembly 790-101-5201 Push tool kit (B) q 1
790-101-5241 q Plate 1
2 Press fit of bushing
790-101-5221 q Grip 1
01010-51225 q Bolt 2
790-201-1500 Push tool kit q 1
790-201-1620 q Plate 1
3 Press fit of dust seal
790-101-5021 q Grip 1
01010-50816 q Bolt 2
791-630-3000 Remover t 1
Separation and connec-
Cylinder (980 kN {100 Removal and installation of
tion of track shoe N 790-101-1300 t 1
ton}) master pin
assembly
790-101-1102 Hydraulic pump t 1
Disassembly and 1 796T-416-1010 Push tool t 1 Q Press fit of bushing
assembly of travel PPC Q 2 796T-416-1030 Push tool t 1 Q Press fit of bushing
valve 3 796T-416-1020 Push tool t 1 Q Press fit of pin
Removal and installa- 1 796-460-1210 Oil stopper q 1 To stop flow of oil from hydraulic
tion of main pump R
assembly 2 796T-460-1230 Adapter q 1 Q tank
Removal and installa-
tion of main pump input S 796T-467-2410 Push tool t 1 Q Press fit of input shaft oil seal
shaft oil seal
790-101-2501 Push-puller q 1
790-101-2510 q Block 1
790-101-2520 q Screw 1
Disassembly and 791-112-1180 q Nut 1
assembly of center T 1 790-101-2540 q Washer 1 Removal of rotor and ring
swivel joint assembly 790-101-2630 q Leg 2
790-101-2570 q Plate 4
790-101-2560 q Nut 2
790-101-2650 q Adapter 2

50-10 PC228US-8, PC228USLC-8

(02)
 General information on disassembly and assembly
Special tools list

New/redesign
Necessity

Sketch
Sym

Q'ty
Work Part number Part name Contents of work and remarks
-bol

796-946-1310 Guidef 21.8

t 1
(For 723-46-40100)
796-946-1610 Guidef 21.4
t 1
(For 723-46-41100)
796-946-1810 Guidef 21.2
2 t 1
(For 723-46-43100 and 723-46-43400)
796-946-1910 Guidef 21.0
t 1
(For 723-46-46101 and 723-46-46300)
796-946-2210 Guidef 20.6
t 1
(For 723-46-45100 and 723-46-45700)
796-946-1320 Guidef 21.8
t 1
(For 723-46-40100)
796-946-1620 Guidef 21.4
t 1
(For 723-46-41100)
796-946-1820 Guidef 21.2
t 1
(For 723-46-43100 and 723-46-43400)
Disassembly and 3
796-946-1920 Guidef 21.0 Replacement of pressure com-
assembly of control T t 1
(For 723-46-46101 and 723-46-46300) pensation valve seal
valve assembly
796-946-2220 Guidef 20.6
t 1
(For 723-46-45100)
796-946-1420 Guidef 21.6
t 1
(For 723-46-42700)
796-946-1330 Sleeve
t 1
(For 723-46-40100)
796-946-1630 Sleeve
t 1
(For 723-46-41100)
796-946-1830 Sleeve
t 1
(For 723-46-43100 and 723-46-43400)
4
796-946-1930 Sleeve
t 1
(For 723-46-46101 and 723-46-46300)
796-946-2230 Sleeve
t 1
(For 723-46-45100)
796-946-1430 Sleeve
t 1
(For 723-46-42700)
790-502-1003 Cylinder repair stand q 1 Disassembly and assembly of
1
790-101-1102 Pump q 1 piston rod assembly
790-102-4300 Wrench assembly t 1 Removal and installation of pis-
2
790-102-4310 Pin t 1 ton
3 790-720-1000 Expander t 1 Expansion of piston ring
796-720-1660 Ring t 1 Installation of piston ring (for
07281-01159 Clamp t 1 piston dia. f 115 mm)
4 796-720-1670 Ring t 1 Installation of piston ring (for
piston dia. f120 mm, 130 mm,
07281-01279 Clamp t 1 f135 mm)
Disassembly and 790-201-1702 Push tool kit t 1 Press fit of cylinder head bush-
assembly of work equip- U 790-101-5021 Grip 1
ment cylinder assembly ing
01010-50816 Bolt 1
5 790-201-1831 Push tool 1 (For rod dia. 80 mm)
790-201-1940 Push tool 1 (For rod dia. 85 mm)
790-201-1841 Push tool 1 (For rod dia. 90 mm)
790-201-1930 Push tool 1 (For rod dia. 95 mm)
790-201-1500 Push tool kit t 1 Press fit of cylinder head dust
790-201-5021 Grip 1
seal
01010-50816 Bolt 1
6 790-201-1620 Push tool 1 (For rod dia. 80 mm)
790-101-1630 Push tool 1 (For rod dia. 85 mm)
790-201-1640 Push tool 1 (For rod dia. 90 mm)
790-201-1650 Push tool 1 (For rod dia. 95 mm)

PC228US-8, PC228USLC-8 50-11

(02)
General information on disassembly and assembly
Special tools list

New/redesign
Necessity

Sketch
Sym

Q'ty
Work Part number Part name Contents of work and remarks
-bol

Removal and installa- 796-900-1200 Remover t 1

tion of work equipment V 790-101-4000 Puller (50 ton) t 1 Removal of boom foot pin
assembly 790-101-1102 Hydraulic pump t 1
Removal and installa- 1 793-498-1210 Lifter (Suction cup) t 2 Holding of glass
tion of operator's cab X
glass 2 20Y-54-13180 Stopper rubber t 2 Fixing of glass
Commercially
Removal and installa- Impact wrench q 1 Removal and installation of
available
tion of counterweight Z counterweight assembly mount-
Commercially Socket wrench
assembly q 1 ing bolt
available (width across flats: 65 mm)

50-12 PC228US-8, PC228USLC-8

(02)
 General information on disassembly and assembly
Sketches of special tools

Sketches of special tools 50-13

Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.
F3: Push tool 50-13

G1: Push tool 50-13

PC228US-8, PC228USLC-8 50-13

(02)
General information on disassembly and assembly
Sketches of special tools

Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.
G3: Plate 50-14

Q1: Push tool 50-14

50-14 PC228US-8, PC228USLC-8

(02)
 General information on disassembly and assembly
Sketches of special tools

Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.
Q2: Push tool 50-15

Q3: Push tool 50-15

PC228US-8, PC228USLC-8 50-15

(02)
General information on disassembly and assembly
Sketches of special tools

Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
R2: Adapter 50-16

S: Push tool 50-16

50-16 PC228US-8, PC228USLC-8

(02)
 General information on disassembly and assembly
Sketches of special tools

PC228US-8, PC228USLC-8 50-17

(02)
Engine and cooling system
Removal and installation of fuel supply pump assembly

Engine and cooling system 50-18

Removal and installation of fuel supply pump assembly 50-18

Special tools 50-18 3. Loosen two clamps (4) for high-pressure pipe
(3).

New/redesign
Necessity

Sketch
Symbo

Q'ty
Part number Part name
l

A 1 795-799-6130 Support t 1

Removal 50-18
k Swing the upper structure 90 °, stop the en-
gine, and disconnect the cable from the neg-
ative (-) terminal of the battery.

1. Through the inspection window in cover (1),

close fuel stop valve (2).

4. Disconnect fuel supply hose (5).

5. Disconnect fuel filter hoses (7) and (8) from fuel

supply pump (6). [*1]
a Remove any dirt from the fitting. (Dirt on the
fitting may cause lock (L) to be stuck.)
a Pull out the hose while pressing lock L from
both sides.
a When disconnecting the hoses, fuel will flow
out. Plug the fittings, to prevent fuel from
flowing out.
a Do not use a wooden plug because wooden
chips may enter the fuel line.

6. Disconnect connector (9).

2. Remove the maintenance counterweight

assembly. For details, see "Removal and instal-
lation of maintenance counterweight assembly".

50-18 PC228US-8, PC228USLC-8

(02)
 Engine and cooling system
Removal and installation of fuel supply pump assembly

7. Disconnect fuel return tube (10). [*2] 11. Remove the gear from the fuel supply pump
according to the following procedure. [*5]
8. Disconnect fuel return hose (11). 1) While locking the gear using support A1 and
1/2-inch spin handle (12), loosen nut (13).
9. Disconnect high-pressure pipe (3) from pump a At this stage, loosen nut (13) partially so
(6). [*3] that it stays on the shaft.

10. Remove mounting nuts (A) and remove fuel 2) Install puller [1] between the flange and gear
supply pump assembly (6). [*4] (14).

a Fuel supply pump assembly (6) comes off

with the gear.
The gear is not worked on its teeth (no
missing tooth) to show the mark for 1.6 TDC
adjustment.

PC228US-8, PC228USLC-8 50-19

(02)
Engine and cooling system
Removal and installation of fuel supply pump assembly

3) Install puller [2] on puller [1] and the shaft. Installation 50-20
4) Turn center bolt (15) until the gear comes off q Perform installation in the reverse order to re-
the shaft. moval.
5) Remove pullers [1] and [2]. a Drawing: See Removal

[*1]
q When installing a connector of quick coupler
type, observe the following points.
a The internal parts of the fitting may be dam-
aged when the hose or tube is removed. Ac-
cordingly, do not reuse the hose or tube.
When installing, replace it with a new one.
a Ensure that mud or dirt is not sticking to the
hose joint portions in advance.
a Push the connector straight (in the direction
of (b)). Do not pry it in or wobble it.
If it is difficult to insert the connector, do not
push it in forcibly but pull it out. Then, check
the male and female couplings for damage
6) Remove nut (13), lock washer (17), and gear
and sticking mud.
(18) from shaft (16).

[*2]
3 Joint bolt for fuel return tube:
24 ± 4 Nm {2.45 ± 0.41 kgm}

50-20 PC228US-8, PC228USLC-8

(02)
 Engine and cooling system
Removal and installation of fuel supply pump assembly

[*3]
q Install high-pressure pipe (3) according to the
following procedure.
1. Tighten the sleeve nuts on the pump side and
then on the common rail side.
3 Sleeve nut:
35 ± 3.5 Nm {3.57 ± 0.36 kgm}
2. Install two tube clamps (4).
3 Clamp mounting bolt:
24 ± 4 Nm {2.45 ± 0.41 kgm}
3. Install the fuel spray prevention cap.
a Install each cap with its slit outward and
down.
a The caps are installed so that fuel will not
spout over the hot parts of the engine and
q Bleeding air
catch fire if it leaks for some reason.
Bleed air from the fuel system.
a Refer to the Testing and adjusting.
[*4]
3 Fuel supply pump mounting nut:
10 ± 2 Nm {1.0 ± 0.2 kgm}

[*5]
q Install gear (18) according to the following proce-
dure.

a Clean and dry the mating surfaces on shaft (16)

and gear (18) so that the surfaces are free of dirt
and foreign material.

1. Install gear (18) to shaft (16).

2. Install lock washer (17) and nut (13) and

finger-tighten the nut.

3. While locking the gear by using support A1 and

1/2-inch spin handle (12), tighten nut (13) to the
specified torque.
3 Fuel supply pump gear mounting nut:
105 ± 5 Nm {10.7 ± 0.51 kgm}

PC228US-8, PC228USLC-8 50-21

(02)
Engine and cooling system
Removal and installation of fuel injector assembly

Removal and installation of fuel injector assembly 50-2

Special tools 50-2 6. Loosen two harness mounting nuts (9) on fuel
injector assembly (8).

New/redesign
Necessity
Harness color Cylinder No.

Sketch
Q'ty
Symbol Part number Part name White 1, 3, 5
Black 2, 4, 6
a Do not remove injector harness connector
2 795-799-6700 Puller t 1 (10) from the rocker housing unless needed.
A 3 795-799-1131 Gear t 1
4 795-799-8150 Remover q 1

Removal 50-2
k Disconnect the cable from the negative (-)
terminal of the battery.

1. Open engine hood (3) and keep it open with a

lock bar.

2. Remove cover (4).

7. Remove two mounting bolts (11) and remove

rocker arm assembly (12).
a Loosen lock nut (13) and loosen adjustment
screw (14) two or three turns so that the push
rod is not subjected to excessive force when
the rocker arm is installed.

8. Remove crosshead (15).

a Note the installed positions and orientation
(the shapes of the holes at parts a and b) of
the crossheads. (Install it in the same direc-
3. Remove two mounting bolts for blowby duct (5) tion when assembling.)
on the head cover side [*1]
9. Disconnect three connectors (40).
4. Remove six head cover bolts (6). [*2] a As you cannot hold the connector, remove it
as follows, using two flat-head screwdrivers.
5. Remove head cover (7). 1) Keep the lock of each connector (40) pushed
with flat head screwdriver [1].
2) Inserting another flat-head screwdriver [2] in
one and the other gaps on both sides of the
connector's lock alternately, pry the
connector in both directions to disconnect the
connector little by little.

50-22 PC228US-8, PC228USLC-8

(02)
 Engine and cooling system
Removal and installation of fuel injector assembly

10. Disconnect connector (41). 12. Remove fuel injection pipe (17). [*3]
a While pushing up the lock of connector (41) a Clean the surrounding area and remove dirt
with flat-head screwdriver [1], pull the con- etc. in advance to prevent them from entering
nector in the direction of the arrow to discon- the connector hole.
nect it.

13. Remove retaining nut (18) and remove inlet

connector (19).
a Remove dirt from the inlet connector in ad-
vance so that it does not enter the connector
hole.
a Use tool A4 to remove inlet connector (19).

14. Remove mounting bolts (20) of fuel injector

assembly (8).

11. Remove fuel spray prevention caps (16) on the

cylinder head and common rail sides.

PC228US-8, PC228USLC-8 50-23

(02)
Engine and cooling system
Removal and installation of fuel injector assembly

15. Using tool A2, remove fuel injector assembly (8). Installtion 50-24
a Take care so that dirt and foreign material do 1. Fuel injector assembly
not enter the fuel injector assembly mounting a When replacing the fuel injector assembly
area. with a new one, be sure to replace the inlet
connector as well.
a Ensure that fuel injector mounting bore (21)
is free of damage or dirt.

1) Install O-ring (23) and gasket (24) to fuel

injector (22).
a Replace the O-ring and gasket with new
ones.
2) Apply engine oil to O-ring (23) of fuel injector
(22) and the fuel injector mounting bore.
2 O-ring (23) and fuel injector mount-
ing bore: Engine oil (EO15W-40)
3) Engage the male and female parts at (A) to
install holder (25) to fuel injector (22).

4) When installing, direct the fuel inlet hole (inlet

connector mounting hole) toward the air
intake manifold.

50-24 PC228US-8, PC228USLC-8

(02)
 Engine and cooling system
Removal and installation of fuel injector assembly

5) Install fuel injector assembly (8) to fuel

injector sleeve. Finger-tighten mounting bolts
(20) at least three or four turns.

6) Apply engine oil to O-ring (26) of inlet

connector (19) and to the inlet connector
mounting bore (in the cylinder head).
a Check the inlet connector visually for the
following defects. If it has any of those de-
fects, replace it and fuel injector assembly
with new ones.
q Front end (a) or rear end (b) of the inlet
connector is burred or worn.
q Foreign material is trapped by the edge
filter at rear end (c) of the inlet connector.
8) Install inlet connector (19) and tighten
q Cracks or deterioration is recognizable in
retaining nut (18) lightly.
3 Retaining nut (lightly):
O-ring of the inlet connector upper (d)
portion.
15 ± 5 Nm {1.5 ± 0.5 kgm}
q Sealing surface (e) on the edge of the in-
9) Alternately tighten mounting bolts (20) of fuel
let connector is worn or has uneven con-
injector assembly (8).
3 Fuel injector mounting bolt (20):
tact pattern.
a If high-pressure fuel leaks through the
8 ± 0.8 Nm {0.8 ± 0.08 kgm}
inlet connector, the sealing surface
10)Tighten retaining nut (18) to the specified
has fine streaks or cracks.
torque.
3 Retaining nut (18):
7) Fully insert inlet connector (19) aligning parts
(B) of inlet connector (19) with the groove in
50 ± 5 Nm {5.1 ± 0.51 kgm}
the cylinder head (upper part of the bore).
2 O-ring (26) and inlet connector
mounting bore: Engine oil
(EO15W-40)

PC228US-8, PC228USLC-8 50-25

(02)
Engine and cooling system
Removal and installation of fuel injector assembly

2. Install the rocker arm assembly according to the 5) Install harness mounting nuts (9) of fuel
following procedure. injector assembly (8).
1) Install crossheads (15). a Check that the harness does not interfere
a Installated position and orientation of with the rocker arm.
crossheads a Installed positions of harnesses
Install them to the same positions and the Harness color Cylinder No.
same or entation (hole shapes of (a) and
(b)) as those when they were removed. White 1, 3, 5
Black 2, 4, 6

3 Mounting nut:
1.5 ± 0.25 Nm {0.15 ± 0.03 kgm}

a If injector harness connector (10) is re-

moved, apply liquid gasket LG-7 to O-ring
(27) and flange (28) of the connector.
Apply a bead of LG-7 3 mm in diameter to
the O-ring so that the ring groove is
completely sealed.
If the O-ring is damaged, replace it and
the harness assembly as a unit.
3 Connector flange mounting bolt
2) Install rocker arm assembly (12) and tighten (29):
mounting bolts (11). 10 ± 2 Nm {1 ± 0.2 kgm}
a Ensure that adjustment screw (14) is suf-
ficiently loose.
a Ensure that the ball of adjustment screw
(14) is fitted in the socket of the push rod
before tightening mounting bolt (11).
3 Rocker arm mounting bolt (11):
36 ± 5 Nm {3.7 ± 0.51 kgm}
3) Adjust the valve clearance. For details, see
Testing and adjusting, “Testing and adjusting
valve clearance”.
a Use tool A3 to turn the crankshaft.
4) After valve clearance adjustment, ensure
that lock nut (13) is tightened to the specified
torque.
3 Lock nut (13):
24 ± 4 Nm {2.4 ± 0.4 kgm}

50-26 PC228US-8, PC228USLC-8

(02)
 Engine and cooling system
Removal and installation of fuel injector assembly

q Perform the subsequent installation in the re- a Install the high-pressure pipe according to the
verse order to removal. following procedure.
1) Connect the high-pressure pipe to both the
[*1] cylinder head and common rail.
a When installing the blowby duct, check that the 3 Sleeve nut:
O-ring is fitted. 0.2 – 0.8 Nm {0.02 – 0.08 kgm}
3 Blowby duct mounting bolt: 2) Tighten the sleeve nut on the cylinder head
7 ± 2 Nm {0.71 ± 0.2 kgm} end, and then one on the common rail end to
the specified torque.
[*2] 3 Sleeve nut:
3 Cylinder head cover mounting nut: 35 ± 3.5 Nm {3.6 ± 0.4 kgm}
24 ± 4 Nm {2.4 ± 0.4 kgm} 1] Cylinder head ends of high-pressure
a If the stud bolt is removed, install it and tighten to pipes (42) and (47).
the following torque. 2] Common rail ends of high-pressure
3 Stud bolt: pipes (47) and (42).
24 ± 4 Nm {2.4 ± 0.4 kgm} 3] Cylinder head ends of high-pressure
[*3] pipes (43), (44), (45) and (46).
a Precautions for installing fuel injection pipe 4] Common rail ends of high-pressure
k Do not reuse the fuel injection pipe by pipes (43), (44), (45) and (46).
bending it. 3) Install a fuel spray prevention cap (48) on
k Be sure to use genuine fuel injection pipe both the cylinder head and common rail
clamps and tighten them to the specified ends.
torque.
k After installing the fuel injection pipe, be
sure to install the fuel spray prevention
cap to cover the sleeve nut.
k Ensure that the fuel spray prevention cap
faces out and down.
a Before installing the fuel injection pipe, check the
following.
q If the fuel injection pipe has a fault, it may
leak the fuel. Accordingly, replace it with a
new one.
q Taper seal section (j) at the connecting end:
Check that there is no visible streaky slits (k)
or spotty dimples (l) in the 2 mm distance
k
area from the end. Install the fuel spary prevention cap with the
q Check that portion (m) (the end of the taper
slit out and down.
seal section: 2 mm from the end) Check that The caps are installed so that fuel will not
there is no steps (deformation) that your nail spout over the hot parts of the engine and
can feel. catch fire if it leaks for some reason.

PC228US-8, PC228USLC-8 50-27

(02)
Engine and cooling system
Removal and installation of fuel injector assembly

a If all of the fuel injector assemblies have been re-

moved, see [*7] and [*8], "Removal and installa-
tion of cylinder head assembly" for assembly
procedure.

q Bleeding air
Bleed air from the fuel system. For details, see
the Testing and adjusting "Air bleeding of fuel
circuit".

50-28 PC228US-8, PC228USLC-8

(02)
 Engine and cooling system
Removal and installation of cylinder head assembly

Removal and installation of cylinder head assembly 50-29

Special tools 50-29 3. Remove the rear right inspection cover and
remove partition plate (3).

New/redesign
Necessity

Sketch
Q'ty
Symbol Part number Part name

2 795-799-6700 Puller t 1
3 795-799-1131 Gear t 1
A 4 795-799-8150 Remover q 1
5 790-331-1120 Wrench (angle) q 1
6 795-790-4510 Gauge q 1

Removal 50-29
k Disconnect the cable from the negative (-)
terminal of the battery. 4. Remove the following components. For details,
see "Removal and installation of maintenance
1. Remove cover (1). counterweight assembly".
1) Engine hood (4)
2) Covers (5), (6) and (7)
3) Frame (8)
4) Fuel filter and bracket assembly (9)
5) Maintenance counterweight assembly (10)

2. Open drain valve (2) to drain coolant.

6 Coolant:
21 l

5. Remove partition plate (11).

PC228US-8, PC228USLC-8 50-29

(02)
Engine and cooling system
Removal and installation of cylinder head assembly

6. Remove clamp (12). [*1] 9. Remove drive belt (15) of the air conditioner
a When removing the clamp bolt, fix the nut on compressor.
the opposite side by using a spanner so that [*2]
the force is not applied to the bracket.
10. Disconnect radiator hose (16) and aeration hose
(17). [*3]

11. Loosen two clamps (18) and disconnect after-

cooler hose (19).

12. Disconnect connector E01 (20) of the electric

intake air heater.

13. Detach bracket (21). [*4]

14. Disconnect tube (22).

15. Remove electric intake air heater (23).

7. Remove mounting bolts (13) of the muffler
mounting bracket. 16. Disconnect heater hose (24).

17. Remove three mounting bolts (25).

a Do not loosen four mounting bolts (26) of the
air conditioner compressor. [*5]

18. Remove air conditioner compressor assembly

(27).
a Remove the air conditioner compressor as-
sembly and the bracket as a unit and put
them aside.

8. Sling and remove muffler (14).

a Space for winding the lifting tool is small.
4 Muffler:
35 kg

50-30 PC228US-8, PC228USLC-8

(02)
 Engine and cooling system
Removal and installation of cylinder head assembly

19. Remove the alternator according to the following

procedure.
1) Disconnect wiring (28) and (29).
2) Slacken fan belt (31) by inserting wrench [1]
in hole (A) (width across flats:12.7 mm) in
tensioner assembly (30) and turning the
wrench counterclockwise (R) as viewed from
the front of the engine.
3) Remove fan belt (31) from alternator
assembly (32).
k Turn the tensioner assembly only after
making sure that wrench [1] is fitted
completely in hole (A) in tensioner as-
sembly (30). (The tensioner assembly 21. Disconnect fuel supply hose (34).
is loaded with strong spring tension. If
the wrench [1] is incompletely fitted in 22. Disconnect fuel filter hoses (36) and (37) from
the hole, the wrench could disengage fuel supply pump assembly (35).
from the hole while the tensioner is be- a Before disconnecting each hose, be sure to
ing turned, possibly leading to a very remove dirt from its fitting. (Dirt on the fitting
dangerous consequence.)
k After removing fan belt (31), be sure to
may cause lock (L) to be stuck.)
a Disconnect each hose while pressing lock (L)
release wrench [1] slowly and careful- from both sides.
ly.
k During the fan belt removal operation,
be fully careful so as not to pinch your
fingers between the pulley and fan belt
(31).
4) Remove the mounting bolts of the alternator
to remove alternator assembly (32).

20. Remove fan (33). [*6]

a Put the fan down.

23. Remove clamps (38) and (39) from the cylinder

block.

24. Remove fuel spray prevention cap (40) on the

supply pump side.

PC228US-8, PC228USLC-8 50-31

(02)
Engine and cooling system
Removal and installation of cylinder head assembly

25. Disconnect high-pressure pipe (41) from the 36. Disconnect boost pressure and temperature
supply pump. sensor connector (50).
a Place the harness aside. [*12]

26. Disconnect three connectors (42).

a As you cannot hold the connector, remove it
as follows, using two flat-head screwdrivers.
1) Keep the lock of each connector (42) pushed
with flat head screwdriver [2].
2) Inserting another flat-head screwdriver [3] in
one and the other gaps on both sides of the
connector's lock alternately, pry the
connector in both directions to disconnect the
connector little by little.

27. Disconnect connector (43).

a While pushing up the lock of connector (43)
with flat-head screwdriver [2], pull the con-
nector in the direction of the arrow to discon-
nect it.

28. Remove six fuel spray prevention caps (40).

a Cylinder head side only

29. Disconnect six high-pressure pipes (44) from the

cylinder head.
[*7]

30. Remove common rail and high-pressure pipe

assembly (45).
[*8]

31. Disconnect high-pressure pipe (41) from the

common rail.

32. Disconnect fuel return hose (46). [*9]

33. Disconnect fuel return hose (47).

34. Remove bracket (48). [*10]

35. Remove fuel block (49). [*11]

50-32 PC228US-8, PC228USLC-8

(02)
 Engine and cooling system
Removal and installation of cylinder head assembly

37. Remove blowby duct (51). 42. Remove mounting bolts (61) of exhaust manifold
(60), leaving some of the bolts unremoved. [*16]
38. Disconnect fuel drain hose (52).

43. Sling exhaust manifold and turbocharger

39. Loosen air hose clamp (53) and disconnect hose assembly (62), then remove the remaining
(54). [*13] mounting bolts.

40. Loosen air tube clamp (55) and disconnect tube 44. Sling and remove exhaust manifold and turbo-
(56). [*14] charger assembly (62).
4 Exhaust manifold and turbocharger
41. Disconnect lubrication inlet hose (57) and lubri- assembly:
cation outlet hose (58). 25 kg
[*15]
a When disconnecting the lubrication inlet
hose, hold connector (59) on the turbocharg-
er side with a wrench to prevent the connec-
tor from turning.

PC228US-8, PC228USLC-8 50-33

(02)
Engine and cooling system
Removal and installation of cylinder head assembly

45. Disconnect clamp (63). 48. Remove nuts (67) of the harness from the
injector.
46. Disconnect the connectors of coolant tempera- Harness color Cylinder No.
ture sensor (64) and ambient pressure sensor
(65). White 1, 3, 5
a Coolant temperature sensor (64): Black 2, 4, 6
Pull the lock (female half) outward.
a Ambient pressure sensor (65):
1] Slide lock (L1) by pushing it. 49. Remove the 12 mounting bolts to remove six
2] While pressing lock (L2), pull out the rocker arm assemblies (68).
connector. a Loosen lock nuts (69) and then adequately
loosen adjustment screws (70) to avoid ex-
cessive forces that would otherwise work on
the push rods when the rocker arms are rein-
stalled.
a Note of the installed positions and orientation
(the shapes of the holes at parts a and b) of
the crossheads (to assure that the cross-
heads can be reinstalled in the original posi-
tion).

50. Remove crossheads (71).

51. Remove retaining nuts (72), then remove six

inlet connectors (73).
a Clean the surrounding area and remove dirt
etc. in advance to prevent them from entering
the connector hole.
a Use Tool A4: Remover for removing inlet
connectors (73). (See Tool Table.)

47. Remove cylinder head cover (66).

50-34 PC228US-8, PC228USLC-8

(02)
 Engine and cooling system
Removal and installation of cylinder head assembly

52. Remove two mounting bolts (75) of injector 57. Remove 26 mounting bolts (79) and sling and
assembly (74). remove cylinder head assembly (80).
4 Cylinder head assembly:
53. Using tool A2, remove fuel injector assembly 75 kg
(74).
a Take care so that dirt and foreign material do 58. Remove cylinder head gasket (81).
not enter the fuel injector assembly mounting
area.

54. Remove push rods (76).

55. Remove rocker arm support (77).

56. Remove rocker housing assembly (78).

PC228US-8, PC228USLC-8 50-35

(02)
Engine and cooling system
Removal and installation of cylinder head assembly

Installation 50-36
1. Cylinder head assembly
1) Using Tool A6, measure stem length (a) of
every cylinder head mounting bolt to make
sure that the length is within the service limit.
(See Special Tool Table.)
q Service limit length of bolt: Less than
132.1 mm
a If the stem length of a bolt is longer than
the service limit, do not reuse that bolt but
replace it with a new one.

2) Set cylinder head gasket (81) in position on

the cylinder block.
a Check that the cylinder head mounting
q Method without using angle tightening
face and inside of the cylinders are free
wrench A5.
from dirt and foreign matter.
Put a mark across the cylinder head and
a Check that the holes in cylinder head gas-
bolt with a marker pen, then retighten the
ket (81) are aligned with the holes in the
bolt by 90 ± 5 °.
cylinder head.
3) Sling cylinder head assembly (80), set the
assembly in position on the cylinder block,
and finger-tighten mounting bolts (79) more
than two to three turns.
4) Tighten the cylinder head mounting bolts
according to the following procedure in
sequence, beginning with [1] and ending with
[26].
2 Apply engine oil (EO15W-40) to the
threaded portion and seat surface
of each cylinder head mounting
bolt.
3 Mounting bolt:
a Tighten the bolts 3 times in the order
shown in the figure.
1] 90 ± 3 Nm {9.2 ± 0.3 kgm}
2] 90 ± 3 Nm {9.2 ± 0.3 kgm}
3] 90°± 5° (When tightened with angle
tightening tool A5)

50-36 PC228US-8, PC228USLC-8

(02)
 Engine and cooling system
Removal and installation of cylinder head assembly

2. Install the rocker housing assembly according to 4) Install fuel injector assembly (84) into the
the following procedure. cylinder head with the fuel inlet hole toward
1) Install rocker housing assembly (78) and the air intake manifold.
tighten seven rocker housing mounting bolts 5) Screw in mounting bolts (75) by three to four
(82). threads.
a Replace the gasket with new one. 6) Apply engine oil (EO15W-40) to the cylinder
3 Mounting bolt: head side threads (section B) of inlet
24 ± 4 Nm {2.4 ± 0.4 kgm} connector (73).
2) Install push rods (76). 7) Apply engine oil (EO15W-40) to O-ring (C) of
3) Install rocker arm support (77). inlet connector (73). Align part D with the
groove in the cylinder head and inlet
3. Install each fuel injector and the inlet connector connector (73) with the fuel inlet hole of the
according to the following procedure. fuel injector assembly. Insert inlet connector
a When replacing the fuel injector assembly (73) fully into the cylinder head.
with a new one, be sure to replace the inlet a Visually check the inlet connector. If any
connector as well. of the following defects is found, replace
a Check that fuel injector mounting bore (83) is the fuel injector and inlet connector with
free from dirt or other particles. new ones as a unit.
q Burrs or wear is recognizable in the in-
let connector front-end (a) and
back-end (b) portions.
q Foreign material is collected in the
edge filter at rear end (c) of the inlet
connector.
q Cracks or deterioration is recogniz-
able in O-ring of the inlet connector
upper (d) portion.
q Sealing surface (e) at the front end of
the inlet connector is worn or seated
unevenly.
a If high-pressure fuel leaks through the
inlet connector, the sealing surface
a Be sure to replace all O-rings and gaskets has fine streaks or cracks.
with new ones.
1) Install O-ring (85) and gasket (86) to fuel
injector (84).
2) Apply engine oil (EO15W-40) to O-ring (85)
and cylinder head side surface of fuel injector
(84).
2 O-ring (85) and cylinder head side
surface of fuel injector (84): Engine
oil (EO15W-40)
3) Engage the male and female parts at (A) to
install holder (87) to fuel injector (84).

PC228US-8, PC228USLC-8 50-37

(02)
Engine and cooling system
Removal and installation of cylinder head assembly

4. Install the rocker arm assembly and crosshead

according to the following procedure.
1) Install crosshead (71).
2) Install rocker arm assembly (68).
a The shape of the hole at part a of the
crosshead is different from that at part b.
When reusing a crosshead, be sure to
use it for the same intake and exhaust
valves for which the crosshead was used
before removal, and also, its ends should
be pointed in the original directions.
a Check that the spherical portion of adjust-
ment screw (70) is fitted properly in the
socket of the push rod and then tighten
the mounting bolt.
3 Mounting bolt:
36 ± 5 Nm {3.7 ± 0.5 kgm}
3) Adjust the valve clearances.
a For details, see Testing and adjusting,
"Testing and adjusting valve clearance".
3 Lock nut (69)
24 ± 4 Nm {2.4 ± 0.4 kgm}

8) Install inlet connector (73) and tighten

retaining nut (72) lightly (to force the inlet
connector into the injector hole).
3 Retaining nut (lightly):
15 ± 5 Nm {1.5 ± 0.5 kgm}
9) Alternately tighten mounting bolts (75) of fuel
injector assembly (74).
3 Fuel injector mounting bolt:
8 ± 0.8 Nm {0.8 ± 0.08 kgm}
10)Tighten retaining nut (72) to the specified
torque.
3 Retaining nut:
50 ± 5 Nm {5.1 ± 0.51 kgm}

50-38 PC228US-8, PC228USLC-8

(02)
 Engine and cooling system
Removal and installation of cylinder head assembly

5. Install the harness using harness mounting nuts q Perform the subsequent installation in the re-
(67). verse order to removal.
a Harness installation position
Harness color Cylinder No. [*1]
a Install muffler (14) to the exhaust pipe after ap-
White 1, 3, 5 plying thermosetting sealant to the entire exter-
Black 2, 4, 6 nal surfaces of both the end of the exhaust pipe
and the exhaust pipe fitting end (E) of the muf-
fler.
3 Mounting nut: 2 Muffler's surface E: Thermosetting
1.5 ± 0.25 Nm {0.15 ± 0.03 kgm} sealant (Musashi Holts FIREGUM or
equivalent)

6. Install the gasket and then cylinder head cover

(66). a Replace clamp (12) with a new one.
3 Mounting nut: 3 Clamp bolt
24 ± 4 Nm {2.4 ± 0.4 kgm} First time: 39.2 – 49 Nm {4.0 – 5.0 kgm}
2nd time: 68.6 – 122.5 Nm {7.0 – 12.49
7. Install blowby duct (51). kgm}
3 Blowby duct mounting bolt:
7 ± 2 Nm {0.71 ± 0.2 kgm}

8. Install fuel drain hose (52).

3 Joint bolt:
24 ± 4 Nm {2.4 ± 0.4 kgm}

[*2]
a For details, see Testing and adjusting, "Testing
and adjusting tension of air conditioner compres-
sor belt".
[*3]
3 Radiator hose clamp:
10.8 – 11.8 Nm {1.1 – 1.2 kgm}
[*4]
3 Bracket mounting bolt:
43 ± 6 Nm {4.4 ± 0.6 kgm}

PC228US-8, PC228USLC-8 50-39

(02)
Engine and cooling system
Removal and installation of cylinder head assembly

[*5] [*7] [*8]

q If four mounting bolts (26) of the air conditioner q Installation of high-pressure pipes and common
compressor are loosened, tighten them to the rail
torque indicated below. k Do not reuse the fuel injection pipe by bend-
a If the bolts are tightened to a torque greater than ing it.
the specified, problems may occur with the inter- k Be sure to use genuine fuel injection pipe
nal components of the air conditioner compres- clamps and tighten them to the specified
sor. torque.
k After installing the fuel injection pipe, be sure
3 Air compressor mounting bolt : to install the fuel spray prevention cap to
27 – 34 Nm {2.8 – 3.5 kgm} cover the sleeve nut.
[*6] k Ensure that the fuel spray prevention cap
q Install fan belt (31) according to the following faces outward and downward.
procedure. a Before installing the fuel injection pipe, check the
1. Install fan belt (31) on each of the pulleys. following.
2. Loosen tensioner assembly (30), then install fan q If the fuel injection pipe has a fault, it may
belt (31) on the pulley of alternator assembly leak the fuel. Accordingly, replace it with a
(32). new one.
a Insert a wrench in hole (A) (width across flats: q Taper seal section (j): Check that there is no
12.7 mm) in tensioner assembly (30) and turn visible streaky slits (k) and spotty dimples (l)
the wrench counterclockwise (R) as viewed in the 2 mm distance area from the end.
from the front of the engine. q Portion (m): Check that there is no steps (de-
3. Install fan belt (31) and return tensioner formation) that your nail can feel in the 2 mm
assembly (30) to the working position. distance area from the end of the taper seal
section.
k Turn the tensioner assembly only after mak-
ing sure that the wrench is fitted completely
in hole (A) in tensioner assembly (30). (The
tensioner assembly is loaded with strong
spring tension. If the wrench is turned when
it is incompletely fitted in the hole, the
wrench could disengage from the hole, pos-
sibly leading to a very dangerous conse-
quence.)
k When returning tensioner assembly (30) to
the working position after installing fan belt
(31), be sure to return the tensioner assembly
slowly and carefully.
k During the fan belt installation operation, be
fully careful so as not to pinch your fingers
1) Install common rail and high-pressure pipe
between the pulley and fan belt.
assembly (45) partially.
3 Sleeve nut and mounting bolt:
0.2 – 0.8 Nm {0.02 – 0.08 kgm}
2) Tighten high-pressure pipes (88) to (93)
according to the following procedure.
3 Sleeve nut:
35 ± 3.5 Nm {3.6 ± 0.4 kgm}
1] Cylinder head ends of high-pressure
pipes (88) and (93)
2] Common rail ends of high-pressure pipes
(93) and (88)
3] Cylinder head ends of high-pressure
pipes (89), (90), (91) and (92)
4] Common rail ends of high-pressure pipes
(89), (90), (91) and (92)

50-40 PC228US-8, PC228USLC-8

(02)
 Engine and cooling system
Removal and installation of cylinder head assembly

3) Tighten the sleeve nut of high-pressure pipe a Be sure to replace the sensor removed from
(41) lightly. the common rail with a new sensor.
4) Tighten the pump (35) end of high-pressure 1) Before removing the sensor, clean the area
pipe first and then tighten its common rail around it to remove dirt, etc. throughly
end. 2) Remove the sensor.
3 Sleeve nut: 3) Check the sensor connector for crack,
35 ± 3.5 Nm {3.6 ± 0.4 kgm} damage, damaged seal, foreign matter at
5) Tighten clamps (38) and (39) of high-pres- pin, corroded, bent or damaged pin, etc.
sure pipe (41). 4) Install a new sensor.
3 Mounting bolt: 2 Threaded part of fuel pressure sen-
10 ± 2 Nm {1.0 ± 0.2 kgm} sor:
Gear oil (#90)
6) Install the common rail by tightening four 3 Tightening torque:
mounting bolts. 70 ± 5 Nm {7.1 ± 0.5 kgm}
a Coat the two bolt threads on the inner 5) Connect the engine wiring harness. At this
side of the engine with sealant (LG-7). time, take care not to connect the wiring
3 Mounting bolt: harness in reverse.
24 ± 4 Nm {2.4 ± 0.4 kgm} 6) Start the engine and check that there are no
7) Install fuel spray prevention cap (40) on each leaks. For details, see Testing and adjusting
high-pressure pipe. (14 caps) in the Engine Shop Manual.
a Set the slit of each cap out and down.
a The caps are installed so that fuel will not 2. If necessary, replace relief valve (3) according to
spout over the hot parts of the engine and the following procedure.
catch fire if it leaks for some reason. 1) Before removing the relief valve, remove dirt
the area surrounding the valve.
2) Remove the relief valve.
3) If the leakage through the relief valve
exceeds the specified value, do not reuse
that relief valve.
4) Check that there is no damage on high-pres-
sure fuel sealing surfaces (A) on the relief
valve and common rail.
5) Install the new relief valve.
2 Relief valve:
Gear oil (#90)
3 Tightening torque:
100 ± 4 Nm {10.2 ± 0.4 kgm}
Tightening too strongly can cause
leakage.
6) Start the engine and check that there are no
leaks. For details, see Testing and adjusting
in the Shop Manual.

q Handling of fuel pressure sensor and relief valve

1. If necessary, replace fuel pressure sensor (2)
according to the following procedure.
a Do not remove fuel pressure sensor (2) from
common rail (1) unless replacement of the
sensor is necessary.

PC228US-8, PC228USLC-8 50-41

(02)
Engine and cooling system
Removal and installation of cylinder head assembly

q When using a new hose

Tighten the clamp so that BDG dimension is as
follows.
BDG: 7 – 10 mm

[*9]
3 Joint bolt:
24 ± 4 Nm {2.4 ± 0.4 kgm}
[*10]
3 Mounting bolt:
24 ± 4 Nm {2.4 ± 0.4 kgm} [*15]
[*11] 3 Mounting nut of lubricating oil inlet hose
3 Fuel block mounting bolt: for turbocharger
32 ± 4 Nm {3.3 ± 0.4 kgm} 35 ± 5 Nm {3.57 ± 0.5 kgm}
[*12] a When tightening the hose mounting nut, fix
k Install each high-pressure pipe and harness the connector on the turbocharger side se-
at least 10 mm apart from each other. curely by using a wrench since its tightening
[*13] is low.
3 Air hose clamp: a If the connector had been loosened with the
10.0 – 11.0 Nm {1.02 – 1.12 kgm} nut, tighten the connector the following
[*14] torque.
q Reconnect the disconnected air tubes according 3 Connector:
to the following procedure. 36 ± 5 Nm {3.7 ± 0.5 kgm} (turbocharg-
a Use a new MIKALOR clamp. er side)
1) Set the hose to the original position (marked 24 ± 4 Nm {2.4 ± 0.4 kgm} (oil cooler
position). side)
(Reference) a If the stud bolt is removed, install it and tight-
Air hose fitting depth: en to the following torque.
40 mm (turbocharger end) 3 Stud bolt:
65 mm (aftercooler end) 24 ± 4 Nm {2.4 ± 0.4 kgm}
2) With bridge (BR) set under the clamp bolt, 3 Mounting bolt of lubricating oil return
tighten the bolt so that bridge (BR) overlaps tube for turbocharger:
with the band by dimension (b) indicated 24 ± 4 Nm {2.4 ± 0.4 kgm}
below.
Dimension (b): 5 mm or more
2 Threaded portion of clamp bolt
(BC):
Lubricating oil (THREEBOND PAN-
DO 18B)
a Do not use an impact wrench.

q When reusing the hose

Install the clamp to the clamp mark made on the
hose.
2 Clamp bolt:
6 Nm {0.6 kgm}

50-42 PC228US-8, PC228USLC-8

(02)
 Engine and cooling system
Removal and installation of cylinder head assembly

[*16]
a Tighten the bolts in the order shown below.
3 Exhaust manifold mounting bolt:
First time:
Tighten the bolts in the order of [1] to [12]
to 24 ± 4 Nm {2.4 ± 0.4 kgm}.
2nd time:
Tighten the bolts in the order of [1] to [12]
to 53 ± 6 Nm {5.4 ± 0.6 kgm}.
3rd time: Tighten only bolts [1] to [4] in
this order to 53 ± 6 Nm {5.4 ± 0.6 kgm}.

a Refilling with coolant

Supply coolant through the coolant filler to the
specified level. Run the engine to circulate the
coolant through the system. Then, check the
coolant level again.
5 Coolant:
21 l

PC228US-8, PC228USLC-8 50-43

(02)
Engine and cooling system
Removal and installation of radiator assembly

Removal and installation of radiator assembly 50-4

Removal 50-4 3. Disconnect radiator hose (3). [*1]

k Swing the upper structrue 90 °, lower the
work equipment to the ground and stop the
engine. Gradually loosen the hydraulic oil
tank cap to release the pressure inside the
hydraulic oil tank.
k Disconnect the cable from the negative (-)
terminal of the battery.

1. Remove cover (1).

4. Remove mounting bolt (5) of cover (4).

2. Drain the coolant through drain valve (2).

6 Coolant:
21 l

5. Remove aftercooler hose (6).

50-44 PC228US-8, PC228USLC-8

(02)
 Engine and cooling system
Removal and installation of radiator assembly

6. Disconnect clamp (7). 13. Remove radiator mounting bolts (15).

7. Remove mounting bolt (8) of cover (4).

8. Change the positon of cover (4) upward.

(example of marking)

9. Open engine hood (9) and cover (10).

10. Remove cover (11).

14. Sling and remove radiator assembly (16). [*3]

a Carefully lift the radiator assembly so that its
lower part is not caught.
4 Radiator assembly:
15 kg

11. Disconnect reservoir tank hose (12).

12. Disconnect radiator hose (13) and aeration hose

(14). [*2]
a In order to show the original position of the
hose, put a mark of the hose-end on the radi-
ator.
(See figure bottom)

PC228US-8, PC228USLC-8 50-45

(02)
Engine and cooling system
Removal and installation of radiator assembly

Installation 50-46
q Perform installation in the reverse order to re-
moval.

[*1][*2]
a Reference
Hose installation depth: 45 mm (both upper and
lower hoses)
3 Radiator hose clamp:
10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}

[*3]
a Make sure that the insulation seal (sponge) at
the radiator periphery is not damaged.
a If the heat insulation seal (sponge) is damaged,
replace it.
a When installing the radiator assembly, carefully
lower it to avoid the insulation seal (sponge) at
the periphery from being damaged.
a Check that the convexed parts (A) at the bottom
of the radiator properly fits with the concaved
parts (B) of the machine from the undercover
side.

q Refilling with coolant

Supply coolant through the coolant filler to the
specified level. Run the engine to circulate the
coolant through the system. Then, check the
coolant level again.
5 Coolant:
21 l

50-46 PC228US-8, PC228USLC-8

(02)
 Engine and cooling system
Removal and installation of hydraulic oil cooler assembly

Removal and installation of hydraulic oil cooler assembly 50-47

Removal 50-47
k Swing the upper structure 90 °, lower the 4. Remove plug (6) to drain the remaining oil in the
work equipment to the ground and stop the hydraulic oil cooler.
engine. Gradually loosen the hydraulic oil
tank cap to release the pressure inside the
hydraulic oil tank.
k Disconnect the cable from the negative (-)
terminal of the battery.

1. Open the inspection cover at the left rear and

remove battery cover (2).

5. Disconnect hydraulic oil cooler tube block (7)

from hydraulic oil cooler (8).

2. Remove batteries (3).

6. Open engine hood (9) and cover (10).

7. Remove cover (11).

3. Remove cover (5).

8. Disconnect tube block (12).

PC228US-8, PC228USLC-8 50-47

(02)
Engine and cooling system
Removal and installation of hydraulic oil cooler assembly

9. Remove two hydraulic oil cooler mounting bolts Installation 50-48

(13). q Perform installation in the reverse order to re-
moval.
10. Remove butterfly nut (14), then disconnect net
(15) from the hydraulic oil cooler. [*1]
a Make sure that the insulation seal (sponge) at
the hydraulic oil cooler periphery is not dam-
aged.
a If the heat insulation seal (sponge) is damaged,
replace it.
a When installing the hydraulic oil cooler assem-
bly, carefully lower it to avoid the insulation seal
(sponge) at the periphery from being damaged.
a Check that the convexed parts (A) at the bottom
of the hydraulic oil cooler properly fits with the
concaved parts (B) of the machine from the un-
dercover side.

11. Sling and remove hydraulic oil cooler assembly

(16). [*1]
4 Hydraulic oil cooler assembly:
22 kg

q Refilling with oil (Hydraulic tank)

a Before supplying oil, make sure that the oil cool-
er drain plug is securely tightened.
a Supply hydraulic oil through the oil filler port to
the specified level. Run the engine to circulate
the oil through the piping. Then, check the oil lev-
el again.

50-48 PC228US-8, PC228USLC-8

(02)
 Engine and cooling system
Removal and installation of aftercooler assembly

Removal and installation of aftercooler assembly 50-49

Removal 50-49
k Swing the upper structure 90 °, lower the 5. Change the positon of cover (5) upward.
work equipment to the ground, then stop the
engine.
k Disconnect the cable from the negative (-)
terminal of the battery.

1. Remove cover (1).

6. Open engine hood (7).

7. Remove covers (8) and (9).

8. Remove cover (10).

2. Remove aftercooler hose (3). [*1]

9. Remove frame (11), and covers (12) and (13).

3. Disconnect clamp (4).

4. Remove mounting bolt (6) of cover (5).

PC228US-8, PC228USLC-8 50-49

(02)
Engine and cooling system
Removal and installation of aftercooler assembly

10. Open cover (14). 15. Reposition hoses (23) to the radiator side.

11. Remove cover (15), and remove rubber (16). 16. Remove air hose (24).

12. Remove covers (17) and (18), and remove the 17. Remove two aftercooler mounting bolts (25).
hose clamp.

18. Sling and remove aftercooler assembly (26).

13. Remove clamps (19) and (20). [ *2]
4 Aftercooler assembly:
12 kg

14. Remove hose clamps (21) and (22).

50-50 PC228US-8, PC228USLC-8

(02)
 Engine and cooling system
Removal and installation of aftercooler assembly

Installation 50-51
q Perform installation in the reverse order to re- [*2]
moval. a Make sure that the insulation seal (sponge) at
the aftercooler periphery is not damaged.
[*1] a If the heat insulation seal (sponge) is damaged,
a Install aftercooler hose (3) to the aftercooler as- replace it.
sembly first, then install clamps (19) and (20). a When installing the aftercooler assembly, care-
fully lower it to avoid the insulation seal (sponge)
at the periphery from being damaged.
a Check that the convexed parts (A) at the bottom
of the aftercooler properly fits with the concaved
parts (B) of the machine from the undercover
side.

PC228US-8, PC228USLC-8 50-51

(02)
Engine and cooling system
Removal and installation of engine assembly

Removal and installation of engine assembly 50-52

Removal 50-52
k Lower the work equipment completely to the
ground. After stopping the engine, gradually
loosen the hydraulic oil tank cap to release
the pressure inside the hydraulic oil tank.
k Disconnect the cable from the negative (-)
terminal of the battery.
k Close the fuel stop valve.

1. Remove the main pump assembly. For details,

see "Removal and installation of main pump
assembly".
2. Remove cover (1), and remove rubber (2).

3. Remove drive belt (3) of the air conditioner 11. Remove the alternator according to the following
compressor. procedure.
[*1] 1) Disconnect wiring (14) and (15).
4. Disconnect radiator hose (4) and aeration hose 2) Slacken fan belt (17) by inserting wrench [1]
(5). [*2] in hole (A) (width across flats: 12.7 mm) in
5. Loosen two clamps (6) and disconnect after- tensioner assembly (16) and turning the
cooler hose (2). wrench counterclockwise (R) as viewed from
6. Disconnect heater hose (8). the front of the engine.
7. Disconnect wiring connector AC02(9) from the 3) Remove fan belt (17) from alternator
air conditioner compressor. assembly (18).
k Turn the tensioner assembly only after
8. Disconnect wiring clamp (10).
9. Remove three mounting bolts (11). [*3] making sure that wrench [1] is fitted
a Do not loosen four air conditioner compres- completely in hole (A) in tensioner as-
sor mounting bolts (12). [*4] sembly (16). (The tensioner assembly
10. Remove air conditioner compressor assembly is loaded with strong spring tension. If
(13). the wrench [1] is incompletely fitted in
a Remove the air conditioner compressor as- the hole, the wrench could disengage
sembly and the bracket as a unit and put from the hole while the tensioner is be-
them aside. ing turned, possibly leading to a very
dangerous consequence.))
k After removing fan belt (17), be sure to
release wrench [1] slowly and careful-
ly.
k During the fan belt removal operation,
be fully careful so as not to pinch your
fingers between the pulley and fan belt
(17).

50-52 PC228US-8, PC228USLC-8

(02)
 Engine and cooling system
Removal and installation of engine assembly

4) Remove the mounting bolts of the alternator

to remove alternator assembly (18).

12. Remove fan (19). [*5]

a Put the fan down.

19. Disconnect fuel supply hose (32).

20. Disconnect two fuel filter hoses (33) and (34).
a Press locks (L) on both sides of the connec-
tor to disconnect the hose.

21. Disconnect fuel return hose (35).

13. Loosen air hose clamp (20) and disconnect hose

(21). [*6]
14. Loosen air tube clamp (22) and disconnect tube 22. Disconnect wiring connector CE02 (37) from
(23). [*7] engine controller (36).
15. Loosen air hose clamp (24) and disconnect radi- a Connector (37) is locked with a hexagonal
ator hose (25). [*8] socket head bolt L1(4 mm).
23. Press the locks to disconnect wiring connector
CE03 (38).
24. Remove four grounding cables (39).

16. Disconnect hoses (26) and (27).

17. Disconnect engine ground cable (28).
18. Disconnect wiring connectors E08 (29), E10 (30)
and (31).

PC228US-8, PC228USLC-8 50-53

(02)
Engine and cooling system
Removal and installation of engine assembly

25. Disconnect hoses (40) and (41). [*9] Installation 50-54

26. Separate elbows (42) and (43). q Perform installation in the reverse order to re-
27. Remove four mounting bolts (44). [*10] moval.

[*1]
a For details, see Testing and adjusting, "Testing
and adjusting tension of air conditioner compres-
sor belt".
[*2]
3 Radiator hose clamp:
10.8 – 11.8 Nm {1.1 – 1.2 kgm}
[*3]
3 Bracket mounting bolt:
43 ± 6 Nm {4.4 ± 0.6 kgm}
[*4]
q If four mounting bolts (12) of the air conditioner
compressor are loosened, tighten them to the
28. Sling and remove engine assembly (45). torque indicated below.
a After checking that all wiring and piping con- a If the bolts are tightened to a torque greater than
nections are disconnected, lift the engine. the specified, problems may occur with the inter-
a Using 3-point lifting method that allows for nal components of the air conditioner compres-
angle adjustment, slowly lift the engine while sor.

3
adjusting its position.
4 Engine assembly:
Air compressor mounting bolt :
580 kg 27 – 34 Nm {2.8 – 3.5 kgm}
[*5]
q Install fan belt (17) according to the following
procedure.
1. Install fan belt (17) on each of the pulleys.
2. Loosen tensioner assembly (16), then install fan
belt (17) on the pulley of alternator assembly
(18).
a Insert a wrench in hole (A) (width across
flats: 12.7 mm) in the tensioner assembly
(16), and turn it counterclockwise (R) viewed
from the front of the engine.
3. Install fan belt (17) and return tensioner
assembly (16) to the working position.
k Turn the tensioner assembly only after mak-
ing sure that the wrench is fitted completely
in hole (A) in tensioner assembly (16). (Ten-
sioner assembly (16) is loaded with large
spring tension. If the wrench is turned when
it is incompletely fitted in the hole, the
wrench could disengage from the hole, pos-
sibly leading to a very dangerous conse-
quence.)
k When returning tensioner assembly (16) to
the working position after installing fan belt
(17), be sure to return the tensioner assembly
slowly and carefully.
k During the fan belt installation operation, be
fully careful so as not to pinch your fingers
between the pulley and fan belt.

50-54 PC228US-8, PC228USLC-8

(02)
 Engine and cooling system
Removal and installation of engine assembly

[*6] [*9]
3 Air hose clamp: 3 Hydraulic oil hose clamp:
10.0 – 11.0 Nm {1.02 – 1.12 kgm} 128 – 186 Nm {13.0 – 19.0 kgm}
[*7][*8]
q Reconnect the disconnected air tubes according [*10]
to the following procedure. a The bolt length of the engine front side is shorter
a Use a new MIKALOR clamp. than that of the rear side.
1) Set the hose to the original position (marked a The engine mounting rubber size on the front
position). side is smaller than that on the rear side.
(Reference)
Air hose fitting depth:
40 mm (turbocharger end)
65 mm (aftercooler end)
2) With bridge (BR) set under the clamp bolt,
tighten the bolt so that bridge (BR) overlaps
with the band by dimension (b) indicated
below.
Dimension (b): 5 mm or more
2 Threaded portion of clamp bolt
(BC):
Lubricant (THREEBOND PANDO
18B)
a Do not use an impact wrench.
3 Engine mount mounting bolt:
q When reusing the hose
245 – 308.9 Nm {25 – 31.5 kgm}
Install the clamp to the clamp mark made on the
hose.
3 Clamp bolt:
q Refilling with coolant
Supply coolant through the coolant filler port to
6 Nm {0.6 kgm}
the specified level. Run the engine to circulate
the coolant through the system. Then, check the
q When using a new hose
coolant level again.
5 Coolant:
Tighten the clamp so that BDG dimension is as
follows.
21 l
BDG: 7 - 10 mm
q Refilling with oil (Hydraulic tank)
Supply oil through the oil filter port to the speci-
fied level. Run the engine to circulate the oil
through the piping. Then, check the oil level
again.
5 Hydraulic tank:
126 l
3 Hydraulic tank drain plug:
58.8 – 78.5 Nm {6.0 – 8.0 kgm}

PC228US-8, PC228USLC-8 50-55

(02)
Engine and cooling system
Removal and installation of engine front seal

Removal and installation of engine front seal 50-56

Special tools 50-56 Installation 50-56

New/redesign
Necessity
1. By using tool A7, install front seal (3).

Sketch
a Before installing the seal, check that the end

Q'ty
Symbol Part number Part name
corners and lip sliding surfaces of the crank-
shaft are free from flaw, burr, and rust.
5 790-331-1120 Wrench (angle) q 1 a When installing the seal, do not apply oil or
A grease to the crankshaft and seal lip. Wipe
7 795-799-6400 Seal puller t 1
off the oil from the crankshaft.

Removal 50-56
1. Remove the engine assembly. For details, see
"Removal and installation of engine assembly".

2. Remove vibration damper mounting bolts (1),

and remove vibration damper(2).

a Protrusion and facial runout of seal (3) from

cover (C):
q Protrusion x: 0.38 mm or less
q Facial runout (TIR: Total Indicator Read-
ing) y: 0.25 mm or less

3. Remove seal (3).

50-56 PC228US-8, PC228USLC-8

(02)
 Engine and cooling system
Removal and installation of engine front seal

2. Vibration damper q When an angle tightening tool is not used:

1) Align the hole in vibration damper (2) with Place marks on the vibration damper and the
dowel pin [a] on the crankshaft when bolts using a marker pen, etc. Then retighten the
installing the damper. bolts 90 ° ± 5 °.
2) Bolts (1) tightening sequence:
1] Tighten diagonally to a torque of 55 ± 5
Nm {5.6 ± 0.5 kgm}.
2] Loosen bolts 180 °.
3] Tighten diagonally to a torque of 55 ± 5
Nm {5.6 ± 0.5 kgm}.
4] Retighten the bolts 90 ± 5 °
For angle tightening, tool A5: wrench is
available. (See the special tool list)

q Perform the subsequent installation in the re-

verse order to removal.

PC228US-8, PC228USLC-8 50-57

(02)
Engine and cooling system
Removal and installation of engine rear seal

Removal and installation of engine rear seal 50-58

Special tools 50-58 6. Sling and remove flywheel assembly (4). [*2]
4 Flywheel assembly:

New/redesign
Necessity
35 kg

Sketch
Q'ty
Symbol Part number Part name

A 8 795-799-6500 Seal puller t 1

Removal 50-58
1. Remove the main pump assembly. For details,
see "Removal and installation of main pump
assembly".

2. Remove mounting bolt (1) and set guide bolt [1].

3. Remove damper assembly (2).

7. Remove the rear oil seal according to the
following procedure.
1) Mount tool A8 on the crankshaft.
2) Screw-in tapping screw [1] of tool A8 into the
seal carrier part of rear oil seal (5).
3) Turn the handle clockwise to remove rear oil
seal (5).

4. Remove mounting bolts (3) and insert guide

bolts [2]. [*1]
a Width across flats: 18 mm

5. Sling flywheel assembly (4) and pull out it.

a Be careful not to let the guide bolts drop out.

a Take care in the removal so that the

crankshaft is not damaged.

50-58 PC228US-8, PC228USLC-8

(02)
 Engine and cooling system
Removal and installation of engine rear seal

Installation 50-59

1. Install the oil seal according to the following 4. Using tool A8 to install rear oil seal (5) to an
procedure. appropriate depth of flywheel housing (7).
a Do not remove pilot [5] attached to rear oil a Push in oil seal (5) while checking it for any
seal (5) until the seal is installed to the crank- bend.
shaft. a Protrusion of rear oil seal from flywheel hous-
a Before installing the rear seal, degrease, ing (7)
clean and dry the seal contact surface on the X: 0.38 mm or less
crankshaft and the seal lip face to prevent oil
leakage.

2. Install pilot [5] to crankshaft (6), and push rear oil

seal (5) into flywheel housing (7).

3. Push rear oil seal (5) further in and remove pilot

[5].

q Perform the subsequent installation in the re-

verse order to removal.

PC228US-8, PC228USLC-8 50-59

(02)
Engine and cooling system
Removal and installation of engine rear seal

[*1] [*2]
a Tighten the eight flywheel assembly mounting q Measurement of radial runout
bolts in the order of (1) through (8) as shown in a Radial runout: Max. 0.13 mm
the figure below. 1) Install dial gauge [4] on the stand, and set the
3 Flywheel assembly mounting bolt: stand on flywheel housing (7).
137 ± 7 Nm {13.97 ± 0.71 kgm} 2) Make the probe of dial gauge contact with
spigot joint portion (a) or outer circumference
of the flywheel at a right angle.
3) Rotate the flywheel 360° and measure the
maximum swing width of the dial gauge indi-
cator.
a Check that the dial gauge indicator is
back in the original position after the fly-
wheel is rotated 360 °.
q Measuring facial runout
a Facial runout: 0.20 mm or less
1) Similarly to measurement of radial runout,
make the probe of dial gauge contact at a
right angle with the end face (b) near the
outer circumference of the flywheel.
a Conduct measurement pulling the crank-
a Use plate [3] to prevent the flywheel assembly
shaft to either the front or rear side of the
from rotating when tightening the bolts.
engine to prevent errors caused by back-
lash.
2) Rotate the flywheel 360° and measure the
maximum swing width of the dial gauge indi-
cator.

50-60 PC228US-8, PC228USLC-8

(02)
 Engine and cooling system
Removal and installation of fuel cooler assembly

Removal and installation of fuel cooler assembly 50-61

Removal 50-61 6. Remove fuel cooler (6).

k Disconnect the cable from the negative (-)
terminal of the battery.
a If the fuel is too much, drain the fuel in order to
stop the fuel flow from the fuel tank return hose.

1. Remove four mounting bolts (1) for the air condi-

tioner condenser.

2. Put aside air conditioner condenser (2).

3. Remove rubber cover (3).

4. Disconnect two hoses (4). [*1]

a Make sure to hold elbow [L] on the fuel cooler
by using another spanner while disconnect-
ing the hoses to avoid stressing the cooler.
a If a spanner [1] is not used, stress will be ap-
plied to the cooler and the welded portions
(M) may come apart.

5. Remove four fuel cooler mounting bolts (5).

PC228US-8, PC228USLC-8 50-61

(02)
Engine and cooling system
Removal and installation of fuel cooler assembly

Installation 50-62
q Perform installation in the reverse order to re-
moval.

[*1]
a Make sure to hold elbow [L] on the fuel cooler by
using another spanner while connecting the hos-
es to avoid stressing the cooler.
a If a spanner [1] is not used, stress will be applied
to the cooler and the welded portions (M) may
come apart.

50-62 PC228US-8, PC228USLC-8

(02)
 Engine and cooling system
Removal and installation of fuel tank assembly

Removal and installation of fuel tank assembly 50-63

Removal 50-63 7. Disconnect fuel tank lower hoses (9), (10) and
k When removing and installing the fuel tank (11).
assembly, lower the work equipment com- [*1]
pletely to the ground.
k Disconnect the cable from the negative (-)
terminal of the battery.

1. Remove the undercover of the fuel tank and

drain the fuel from the fuel tank.
6 Fuel tank:
320 l (when tank is full)

2. Remove handrails (1) and (2).

3. Remove mirror (3).
4. Remove covers (4) and (5).

8. Remove additional pilot filter (12) for breaker.

5. Disconnect fuel level sensor connector P21 (6).

6. Remove fuel pre-filter (7) and bracket (8).
a Reposition the fuel pre-filter and bracket to-
ward the main pump so that they will not in- 9. Remove hose clamps (13) and (14).
terfere with the fuel tank when removing the
tank.

PC228US-8, PC228USLC-8 50-63

(02)
Engine and cooling system
Removal and installation of fuel tank assembly

10. Remove the six mounting bolts. Sling and

remove fuel tank assembly (15). [*2]
4 Fuel tank assembly:
130 kg

Inatallation 50-64
q Perform installation in the reverse order to re-
moval.

[*1]
2 Fuel tank hose (9) threads:
Liquid gasket (LG-5)
3 Fuel tank hose (9):
3.9 – 7.8 Nm {0.4 – 0.8 kgm}
3 Fuel tank hose (11):
54 – 93 Nm {5.5 – 9.5 kgm}

[*2]
3 Fuel tank mounting bolt:
245 – 309 Nm {25.0 – 31.5 kgm}

50-64 PC228US-8, PC228USLC-8

(02)
 Engine and cooling system
Removal and installation of fuel tank assembly

PC228US-8, PC228USLC-8 50-65

(02)
Power train
Removal and installation of travel motor and final drive assembly

Power train 50-6

Removal and installation of travel motor and final drive assembly 50-6

Removal 50-6 5. Sling and remove travel motor and final drive
k Lower the work equipment completely to the assembly (3).
ground. Referring to “Releasing residual 4 Travel motor and final drive assembly:
pressure in hydraulic circuit” , release the re- 380 kg
sidual pressure in the hydraulic circuit.

1. Remove the track shoe assembly. For details,

see "Separation and connection of track shoe
assembly".

2. Remove cover (1).

Installation 50-6
q Perform installation in the reverse order to re-
moval.
3 Travel motor and final drive assembly
mounting bolt:
265 – 309 Nm {27 – 31.5 kgm}
(Average torque: Min. 275 Nm {28 kgm})
3. Disconnect four travel motor hoses (2).
q Bleeding air
4. Sling travel motor and final drive assembly and Bleed air from the travel motor circuit. For
remove eighteen mounting bolts (4) to remove details, see Testing and adjusting, “Bleeding air
the assembly. from each part” .

q Refilling with oil

Supply oil through the oil filler port to the speci-
fied level. Run the engine to circulate the oil
through the system. Then, check the oil level
again.

50-66 PC228US-8, PC228USLC-8

(02)
 Power train
Disassembly and assembly of final drive assembly

Disassembly and assembly of final drive assembly 50-67

Special tools 50-67 4. Washer

Remove washer (2).

New/redesign
Necessity

Sketch
Q'ty
Symbol Part number Part name

1 796-427-1200 Push tool t 1

2 791-545-1510 Installer t 1
796T-427-1220 Push tool t 1 Q
790-101-2510 Block t 1
792-104-3940 Bolt t 1
F 05180-11613 Nut t 1
3
01613-31645 Washer t 1
790-105-2100 Jack t 1
5. No. 1 carrier assembly
790-101-1102 Hydraulic pump t 1 1) Remove No. 1 carrier assembly (3).

4 790-331-1110 Wrench t 1

Disassembly 50-67
1. Sprocket
Remove 20 mounting bolts of the travel motor
and final drive assembly to remove the sprocket.
4 Sprocket:
40 kg
2. Draining oil
Remove the drain plug to drain the oil from the
final drive case.
6 Final drive:
5.4 l 2) Disassemble the No. 1 carrier assembly
3. Cover according to the following procedure.
Remove 20 mounting bolts. Using eyebolts [1], 1] Drive pin (4) into pin (5) to remove pin (5)
sling and remove cover (1). from carrier (6).
a If ring gear (12) lifts off together with the cov- a After removing pin (5), remove pin (4)
er, gently tap the ring gear off the cover by from pin (5).
using a plastic hammer. 2] Remove thrust washer (7), No. 1 plane-
tary gear (8), needle bearing (9), and
thrust washer (10).

PC228US-8, PC228USLC-8 50-67

(02)
Power train
Disassembly and assembly of final drive assembly

6. No. 1 sun gear shaft 11. No. 2 carrier assembly

Remove No. 1 sun gear shaft (11). 1) Remove No. 2 carrier assembly (16).

7. No.1 & No. 2 ring gear 2) Disassemble the No. 2 carrier assembly
Remove No. 1 & No. 2 ring gear (12). according to the following procedure.
1] Drive pin (17) into pin (18) to remove pin
8. Thrust washer (18) from carrier (19).
Remove thrust washer (13). a After removing pin (18), remove pin
(17) from pin (18).
9. No. 2 sun gear 2] Remove thrust washer (20), No. 2 plane-
Remove No. 2 sun gear (14). tary gear (21), needle bearing (22), and
thrust washer (23).

10. Washer
Remove washer (15). 12. Lock
1) Remove lock (24).
2) Use tool F1 to remove lock (25).

50-68 PC228US-8, PC228USLC-8

(02)
 Power train
Disassembly and assembly of final drive assembly

13. Hub assembly Assembly 50-69

1) Using eyebolts [2], remove hub assembly a Before assembly, clean the parts and ensure
(26). that they are free of dirt and damage and apply
oil (T030) on their sliding surfaces.

1. Travel motor assembly

1) Install floating seal (31) to tool F2.
a Install the floating seal after degreasing
and drying the O-ring and O-ring contact
surface completely.

2) Disassemble the hub assembly according to

the following procedure.
1] Remove floating seal (27).
2] Remove ball bearings (28) and (29) from
hub (30).

2) Install floating seal (31) to travel motor (32).

a After installing the floating seal, check
that its leaning is less than 1 mm.
a After installing the floating seal, check
that the sliding surface is free of dirt, and
apply a thin film of oil (T030) to the sur-
face.

14. Travel motor assembly

Remove floating seal (31) from travel motor (32).

PC228US-8, PC228USLC-8 50-69

(02)
Power train
Disassembly and assembly of final drive assembly

2. Hub assembly 2) Using eyebolts [2], place hub assembly (26)

1) Assemble the hub assembly according to the on the travel motor.
following procedure. a If the hub assembly is difficult to install,
1] Using the push tool, press fit ball bearings use the push tool and lightly tap the bear-
(29) and (28) into hub (30). ing inner race to install.

2] Install floating seal (27) to tool F2. 3. Lock

a Install the floating seal after degreas- 1) Using tool F3, push the inner race of the ball
ing and drying the O-ring and O-ring bearing.
contact surface completely. q Specified pressing force:

3] Install floating seal (27) on hub (30). 8.8 – 12.7 N {0.9 – 1.3 tons}
a After installing the floating seal, check 2) While pressing the bearing, turn hub
that its leaning is less than 1 mm. assembly (26) 2 to 3 turns.
a After installing the floating seal, check 3) In this state, measure distance a from the top
that the sliding surface is free of dirt, face of the travel motor to the top face of the
and apply a thin film of oil (T030) to the bearing inner race.
surface. a After measurement, remove tool F3.

50-70 PC228US-8, PC228USLC-8

(02)
 Power train
Disassembly and assembly of final drive assembly

4) Measure thickness (b) of lock (25). 8) Install lock (24).

5) Based on measured values (a) and (b), 2 Mounting bolt:
calculate screw-in depth (c) for lock (25). Adhesive (LT-2)
q c = a - b - (0 to 0.1) a Do not apply liquid adhesive to the screw
6) Using tool F1, screw in lock (25) to calculated holes for the lock.
depth (c). a Install the lock so that its splines are en-
a Screw-in depth (c) corresponds to the gaged with the splines of the travel motor.
distance from the upper face of the travel
motor to the upper face of the lock.

4. No. 2 carrier assembly

1) Assemble the No. 2 carrier assembly
7) Using push-pull scale [3], measure the according to the following procedure.
tangential (starting) force of hub assembly 1] Install thrust washer (23), needle bearing
(26). (22), No. 2 planetary gear (21), and thrust
a Use a hole for a sprocket mounting bolt to washer (20) to carrier (19).
measure the tangential (starting) force. a If a disassembled carrier is reused,
q Tangential (starting) force: 294 N {30 kg} the crimping damage left in pin hole
or less (d) in the carrier must be repaired be-
a If the measured tangential (starting) force fore reassembly.
is not to specification, disassemble the a Replace the thrust washer with a new
assembly and locate the cause. part.

2] Install pin (18).

a Before inserting the pin fully, align its
hole with the hole of the carrier.
a Install the shaft while turning the plan-
etary gear and taking care not to dam-
age the thrust washer.

PC228US-8, PC228USLC-8 50-71

(02)
Power train
Disassembly and assembly of final drive assembly

3] Install pin (17). 5. Washer

a Replace the pin with a new one. Install washer (15).
a Before inserting the pin, ensure that
the pin is oriented such that three tabs 6. No. 2 sun gear
(e) on the periphery of the pin do not Install No. 2 sun gear (14).
catch the thin wall part of the carrier.
a After inserting the pin, crimp the pe- 7. Thrust washer
riphery of the pin hole at two places to Install thrust washer (13).
prevent the pin from coming out.
a After assembling the No. 2 carrier as- 8. No. 1 sun gear shaft
sembly, ensure that all gears can be Install No. 1 sun gear shaft (11).
turned smoothly.

9. No.1 & No. 2 ring gear

2) Install No. 2 carrier assembly (16). 1) Install the O-ring to the hub.
a Position the No. 2 carrier assembly so 2) Using eyebolts [4], place No. 1 & No. 2 ring
that the four protrusions on the bottom of gear (12) on the hub.
the pin engage with the four recesses in a Degrease the mating faces of the ring
the motor case. gear and hub. Do not apply liquid gasket
on the mating faces.
a Align the bolt holes of the ring gear with
those of the hub.

50-72 PC228US-8, PC228USLC-8

(02)
 Power train
Disassembly and assembly of final drive assembly

10. No. 1 carrier assembly

1) Assemble the No. 1 carrier assembly
according to the following procedure.
1] Install thrust washer (10), needle bearing
(9), No. 2 planetary gear (8), and thrust
washer (7) to carrier (6).
a If a disassembled carrier is reused,
the crimping damage left in pin hole
(g) in the carrier must be repaired be-
fore reassembly.
a Replace the thrust washer with a new
one.

2) Install No. 1 carrier assembly (3).

a Ensure that all gears are engaged cor-
rectly. If not, engage the gears correctly
by wobbling the hub in the direction of ro-
tation and back several times.

11. Washer
Install washer (2).
a Measure distance (j) from the top face of
planetary gear (8) to the top face of ring gear
(12).
a If measurement (j) is not between 1.0 ± 0.51
2] Install pin (5). mm, the assembly is assembled incorrectly.
a Before inserting the pin fully, align its
hole with the hole of the carrier.
a Install the shaft while turning the plan-
etary gear and taking care not to dam-
age the thrust washer.
3] Install pin (4).
a Replace the pin with a new one.
a Before inserting the pin, ensure that
the pin is oriented such that three tabs
(h) on the periphery of the pin do not
catch the thin wall part of the carrier.
a After inserting the pin, crimp the pe-
riphery of the pin hole at two places (i)
to prevent the pin from coming out.
a After assembling the No. 1 carrier as-
sembly, ensure that all gears can be
turned smoothly.

PC228US-8, PC228USLC-8 50-73

(02)
Power train
Disassembly and assembly of final drive assembly

12. Cover 13. Refilling with oil

1) Using eyebolts [1], install cover (1). Tighten the drain plug and supply power train oil
2 Mating faces of cover and ring (TO30) through the oil filler port.
gear: 5 Final drive:
Liquid gasket (LG-6) 5.4 l
a After installing the travel motor and final drive
assembly to the machine, check the oil level
finally.

14. Sprocket
Install the sprocket and tighten the 20 mounting
bolts.
2 Mounting bolt:
Adhesive (LT-2)
3 Mounting bolt:
441 – 490 Nm {45 – 50 kgm}

2) Using tool F4, install the 20 mounting bolts.

3 Mounting bolt:
1st time: 147 Nm {15 kgm}
2nd time: 85 – 95° (retighten-
ing angle)

50-74 PC228US-8, PC228USLC-8

(02)
 Power train
Removal and installation of swing motor and swing machinery assembly

Removal and installation of swing motor and swing machinery

assembly 50-75

Removal 50-75 4. Remove rubber partition plate (7) and frame (8).
k Lower the work equipment completely to the
ground. Referring to “Releasing residual
pressure in hydraulic circuit” , release the re-
sidual pressure in the hydraulic circuit.
k Disconnect the cable from the negative (-)
terminal of the battery.
k Note the connector numbers and installed
positions before disconnecting wiring and
hoses.

1. Open engine hood (1).

2. Remove covers (2), (3) and frame (4).

5. Disconnect swing motor hoses (9) to (14).

a Hoses are connected to the following ports:
q (9) and (10): Main circuit (Ports MA and
MB)
q (11): Suction circuit (port S)
q (12): Parking brake circuit (port B)
q (13) and (14): Drain circuit (port T)
a After suction and drain circuit hoses are dis-
connected, plug the hoses.

3. Remove covers (5) and (6).

PC228US-8, PC228USLC-8 50-75

(02)
Power train
Removal and installation of swing motor and swing machinery assembly

6. Loosen the 12 mounting bolts. Sling and remove Installation 50-76

swing motor and swing machinery assembly q Perform installation in the reverse order to re-
(15). moval.
[*1]
4 Swing motor and swing machinery as- [*1]
sembly: 3 Swing motor and swing machinery
240 kg assembly mounting bolt:
490 – 608 Nm {50 – 62 kgm}

q Bleeding air
Bleed air from the swing motor circuit. For
details, see Testing and adjusting, “Bleeding air
from each part” .

q Refilling with oil

Supply oil through the oil filler to the specified
level. Run the engine to circulate the oil through
the system. Then, check the oil level again.

50-76 PC228US-8, PC228USLC-8

(02)
 Power train
Disassembly and assembly of swing machinery assembly

Disassembly and assembly of swing machinery assembly 50-7

Special tools 50-7 3. No. 1 sun gear

Remove No. 1 sun gear (2).

New/redesign
Necessity

Sketch
Sym-

Q'ty
Part number Part name
bol

1 796T-426-1410 Push tool t 1 Q

2 796-426-1120 Push tool t 1
G 796T-426-1130 Plate t 1 Q
3 790-101-5241 Grip t 1
01010-81240 Bolt t 1

Disassembly 50-7
1. Draining oil
Remove the drain plug to drain the oil in the
swing machinery case.
6 Swing machinery: 4. No. 1 carrier assembly
7.1 l 1) Remove No. 1 carrier assembly (3).

2. Swing motor assembly

1) Place the swing motor and swing machinery
assembly on block [1].
2) Remove the six mounting bolts to remove
swing motor assembly (1).
4 Swing motor assembly:
70 kg

2) Disassemble the No. 1 carrier assembly

according to the following procedure.
1] Remove snap ring (4). Remove thrust
washer (5), No. 1 planetary gear (6),
needle bearing (7), and thrust washer (8)
from carrier (30).
2] Remove washer (9).
3] Remove snap ring (31). Using a press,
remove pin (32).
q Pin pressing force for assembly (refer-
ence):
11.2 – 25.8 kN {1,140 – 2,630 kg}

PC228US-8, PC228USLC-8 50-77

(02)
Power train
Disassembly and assembly of swing machinery assembly

7. No. 2 carrier assembly

1) Loosen mounting bolt (12) for the No. 2
carrier assembly.
2) Remove No. 2 carrier assembly (13).

5. No.1 & No. 2 ring gear

Loosen the 18 mounting bolts and remove No. 1
& No. 2 ring gear (10).

3) Disassemble the No. 2 carrier assembly

according to the following procedure.
1] Drive pin (14) into pin (15) to remove pin
(15) from carrier (16).
a After removing pin (15), remove pin
(14) from pin (15).
2] Remove thrust washer (17), No. 2 plane-
tary gear (18), needle bearing (19), and
thrust washer (20).
3] Remove plate (21).

6. No. 2 sun gear

Remove No. 2 sun gear (11).

50-78 PC228US-8, PC228USLC-8

(02)
 Power train
Disassembly and assembly of swing machinery assembly

8. Shaft and case assembly 9. Bearing

1) Remove mounting bolts (23). Using the push tool, remove bearing (35) from
2) Install the shaft and case assembly on the case (36).
press. Using push tool [2], remove shaft
assembly (24) from case assembly (25).

Assembly 50-79
a Before assembly, clean the parts and ensure
3) Disassemble the shaft assembly according that they are free of dirt and damage and apply
to the following procedure. engine oil on their sliding surfaces.
1] Using push tool [3], remove cover a Do not reuse the disassembled bearings and oil
assembly (26) and bearing (27) from seals.
shaft (28).
2] Remove oil seal (29) from cover (34). 1. Bearing
Using push tool [5], press fit bearing (27) to case
(36).
a Use new bearing (27).

PC228US-8, PC228USLC-8 50-79

(02)
Power train
Disassembly and assembly of swing machinery assembly

2. Cover assembly 3) Install cover assembly (26) to case (36) and

1) Set oil seal (29) horizontally on cover (34). tighten mounting bolts (23).
2) Using push toolG3, press fit oil seal (29) to a Match the drain ports.
cover (34). 2 Cover mounting face:
a Use new oil seal (29). Liquid gasket (LG-6)
2 Outer periphery of oil seal: a When applying the liquid gasket, take
Liquid gasket (LG-6) care not to project it into the drain port.
a Take care not to stick the liquid gasket 3 Mounting bolt:
(LG-6) to the oil seal lip at the time of 66.2 ± 7.4 Nm {6.75 ± 0.75 kgm}
press fitting. 2 Oil seal lip:
a If push tool G3 is not available, use a Grease (G2-LI)
push tool that can evenly push periph-
ery A of the oil seal.
a Check that oil seal (29) is not leaned.

3. Shaft and case assembly

1) Set case assembly (25) on shaft (28).
a Take care not to damage the oil seal.

50-80 PC228US-8, PC228USLC-8

(02)
 Power train
Disassembly and assembly of swing machinery assembly

2) Using push Tool G1 and tool [8], tap while

taking care not to drop the shaft.
a Keep sling [9] loose.

4. Sub-bearing
Using tool G2, press fit bearing (35).
a Use new bearing (35).
3) Set the assembly to the press. a Press the bearing inner race and outer race
4) Using push tool G1 and tools [8] and [10], simultaneously.
press fit the bearing inner race. q Bearing press fit force (reference):
a Press-fit force: Several tons Inner race: 9.4 - 26.6 kN {960 - 2,710 kg}
a Keep push tool [10] so that it can be used Outer race: 0 - 8.9 kN {0 - 910 kg}
in the event that case assembly (25) tilts a After press-fitting the bearing, check that the
severely. case rotates smoothly.
a Keep case assembly (25) in a horizontal
position by lightly tapping the case flange
as required.
a Bring case assembly (25) to a horizontal
position so that oil seal lip contact surface
B of shaft (28) is located in the center of
oil seal (29).

PC228US-8, PC228USLC-8 50-81

(02)
Power train
Disassembly and assembly of swing machinery assembly

5. No. 2 carrier assembly 2) Install No. 2 carrier assembly (13).

1) Assemble No. 2 carrier assembly according 3) Tighten mounting bolt (12) for No. 2 carrier
to the following procedure. assembly (13).
1] Install plate (21) to carrier (16). 2 Mounting bolt:
a If a disassembled carrier is reused, Adhesive (LT-2)
the crimping damage left in pin hole 3 Mounting bolt:
(b) in the carrier must be repaired be- 157 - 196 Nm {16 – 20 kgm}
fore reassembly.
2] Install thrust washer (20), needle bearing
(19), No. 2 planetary gear (18), and thrust
washer (17).
a Install the shaft while turning the plan-
etary gear and taking care not to dam-
age the thrust washer.

6. No. 2 sun gear

1) Install No. 2 sun gear (11).
2) Install the O-ring to the case.

3] Install pin (15).

a Before inserting the pin fully, align its
hole with the hole of the carrier.
a Install the shaft while turning the plan-
etary gear and taking care not to dam-
age the thrust washer.
4] Install pin (14).
a After inserting the pin, crimp the pe-
riphery of the pin hole at two places (c)
to prevent the pin from coming out.

50-82 PC228US-8, PC228USLC-8

(02)
 Power train
Disassembly and assembly of swing machinery assembly

7. No.1 & No. 2 ring gear 3] Press pin (32) in the direction opposite to
Using eyebolts, install No. 1 & No. 2 ring gear that in Step 1].
(10). a Push back the pin until the snap ring is
a Degrease the mating faces of the ring gear tight on the end face of the carrier.
and case. Use care not to push back the pin too
a Do not stick liquid gasket to the mating faces much.
of the ring gear and case.
a Ensure that concave (d) on the top face of
ring gear (10) is engaged with cast convex
(e) on the case periphery.
a Install the washer.
3 Mounting bolt:
157 – 196 Nm {16 – 20 kgm}

4] Install washer (9) to carrier (30).

5] Install thrust washer (8), needle bearing
(7), planetary gear (6), and thrust washer
(5). Install snap ring (4) to fix them in posi-
tion.

2) Install No. 1 carrier assembly (3).

8. No. 1 carrier assembly
1) Assemble the No. 1 carrier assembly
according to the following procedures.
1] Using the press, press fit pin (32) into
carrier (30).
a Press fit the pin until the snap ring
groove on the one side comes out of
the opposite side of the carrier.
q Press fit force of pin (reference):
11.2 - 25.8 kN {1,140 - 2,630 kg}
2] Install snap ring (31).

PC228US-8, PC228USLC-8 50-83

(02)
Power train
Disassembly and assembly of swing machinery assembly

9. No. 1 sun gear 11. Oil level gauge

Install No. 1 sun gear (2). a Observe the following points when installing
a Install the No. 1 sun gear with longer stepped the oil level gauge.
portion (g) up. 1) Make adjustments so that the end of the
gauge is located as shown in the figure
below.
2) If the oil level gauge interferes with other
parts after installation on the machine,
loosen the clip and tube sleeve nuts and
reposition the gauge to avoid interference.
3 Clip nut:
59 – 74 Nm {6.0 – 7.5 kgm}
3 Tube sleeve nut:
42.1 – 70.6 Nm {4.3 – 7.2 kgm}

10. Swing motor assembly

Install the O-ring to ring gear (10), then install
swing motor assembly (1).
a Degrease the mating faces of the swing mo-
tor and ring gear.
a Install the swing motor assembly with face (f)
having ports MA and MB facing cast convex
(e) on the case periphery.
3 Mounting bolt:
59 – 74 Nm {6.0 – 7.5 kgm}
q Refilling with oil
Tighten the drain plug and supply power train oil
through the oil filler.
5 Swing machinery:
7.1 l

50-84 PC228US-8, PC228USLC-8

(02)
 Power train
Removal and installation of swing circle assembly

Removal and installation of swing circle assembly 50-85

Removal 50-85 Installation 50-85

1. Remove the revolving frame assembly. For q Perform installation in the reverse order to re-
details, see "Removal and installation of moval.
revolving frame assembly".
[*1]
2. Remove swing circle assembly mounting bolts 2 Mounting bolt of swing circle assembly:
(1) and sling swing circle assembly (2). Adhesive (LT-2)
[*1] 3 Revolving frame assembly mounting bolt:
a Leaving one mounting bolt each at the front 1st time: 191.2 ± 19.6 Nm {19.5 ± 2
and rear parts, sling the swing circle assem- kgm}
bly by 3-point lifting method. 2nd time: 48 ± 5° (retightening an-
gle)
3. Remove the remaining mounting bolts to remove
swing circle assembly (2). [*2]
[*2] a When installing the swing circle assembly, posi-
4 Swing circle assembly: tion the outer race to the track frame by aligning
270 kg the dowel pin and hole.
a After installing the swing circle assembly, align
the inner race soft zone position (stamped "S" on
top surface) with the outer race soft zone posi-
tion (at a where the ball is inserted).

PC228US-8, PC228USLC-8 50-85

(02)
Undercarriage and frame
Separation and connection of track shoe assembly

Undercarriage and frame 50-86

Separation and connection of track shoe assembly 50-86

Special tools 50-86 3. By using tool N, remove master pin (2).

[*2]

New/redesign
a After removing the pin, leave the temporary

Necessity

Sketch
Sym-

Q'ty
Part number Part name pin, and remove tool N.
bol

1 791-630-3000 Remover t 1
Cylinder
N 2 790-101-1300 (980 kN {100 t 1
tons})
3 790-101-1102 Hydraulic pump t 1

Separation 50-86
1. Position the track with the master pin at a posi-
tion between the idler and front track roller so
that the separated track can be spread toward
the front and rear. Swing the upper structure 90°
and stop the engine.
a Each track has two master pins and each
4. Run the engine and move the machine forward
master pin has a hole in its end face.
until the temporary pin [1] is positioned in front of
the idler. Place blocks [2] under the track.
2. Loosen valve (1) to loosen the track tension.
[*1]
k
5. Remove temporary pin [1] and remove the dust
Since the internal pressure of the adjust-
seal.
ment cylinder is very high, do not loosen
[*3]
the valve more than one turn. If the grease
does not come out sufficiently, start the
6. Move the machine slowly in reverse to spread
engine and move the machine forward
track assembly (3).
and in reverse.

50-86 PC228US-8, PC228USLC-8

(02)
 Undercarriage and frame
Separation and connection of track shoe assembly

Connection 50-87
q Perform connection in the reverse order to sep-
aration.

[*1]
a For details, see Testing and adjusting, “Testing
and adjusting track tension”.

[*2]
a By using tool N, press fit the master pin until the
pin protrusion (a) reaches the specified dimen-
sion.
q Pin protrusion (a): 2.5 ± 1 mm (each side)

[*3]
a When installing the dust seal, apply grease
(G2-LI) to the contact surfaces on the dust seal
and bushing (do not apply grease to the mount-
ing face on the bushing to the link).
a Precaution for road liner type track shoe:
If the rubber of road liner type track shoe (rubber
pad type) is worn and broken to damage the
mounting bolt heads, replace the shoe with new
one immediately. If the bolt heads are crushed,
the bolts cannot be replaced.

PC228US-8, PC228USLC-8 50-87

(02)
Undercarriage and frame
Removal and installation of idler and idler cushion assembly

Removal and installation of idler and idler cushion assembly 50-8

Removal 50-8 4. Disconnect idler cushion assembly (4) from idler

1. Remove the track shoe assembly. For details, assembly (3).
see "Separation and connection of track shoe 4 Idler assembly:
assembly". 110 kg
4 Idler cushion assembly:
2. By using a prybar [1], move the idler and idler 130 kg
cushion assembly (1) forward to a position
where it can be lifted.

Installation 50-8
q Perform installation in the reverse order to re-
3. Sling the idler and idler cushion assembly (1), moval.
pull it forward to remove from track frame (2).
4 Idler and idler cushion assembly:
Approx. 240 kg

50-88 PC228US-8, PC228USLC-8

(02)
 Undercarriage and frame
Disassembly and assembly of idler assembly

Disassembly and assembly of idler assembly 50-89

Special tools 50-89 3. Remove idler (4) from the assembly of shaft (5)
and support (7).

New/redesign
a Since 250 ml of oil is charged in the idler,

Necessity

Sketch
Sym-

Q'ty
Part number Part name drain the oil at this time point or lay rags to
bol
prevent contamination.

J 791-530-1510 Installer t 1 4. Remove floating seals (6) on the opposite side

from idler (4) and the assembly of shaft (5) and
Disassembly 50-89 support (7).
q Structural illustration

5. Remove dowel pin (8) to remove support (7)

from shaft (5).

6. Remove bushings (9) and (10) from idler (4).

1. Remove dowel pin (1) to dismount support (2).

2. Remove floating seals (3) from support (2) and

idler (4).

PC228US-8, PC228USLC-8 50-89

(02)
Undercarriage and frame
Disassembly and assembly of idler assembly

Assembly 50-90 2. Install support (7) with the O-ring to shaft (5) by
q Structural illustration using dowel pin (8).

3. By using tool J, install floating seals (6) to idler

(4) and the assembly of shaft (5) and support (7).
a Completely clean, degrease and dry the con-
tact surfaces (hatched area in the drawing) of
the floating seal and the O-ring.
a Apply oil to the sliding surface of the floating
seal, and take care not to have any dirt stuck
on it.
a After inserting the floating seal, check that
the leaning of the seal is less than 1 mm and
that the protrusion (a) is within the range of 7
– 11 mm.

1. Press fit bushings (9) and (10) to idler (4).

50-90 PC228US-8, PC228USLC-8

(02)
 Undercarriage and frame
Disassembly and assembly of idler assembly

4. Install the assembly of shaft (5) and support (7) 6. Install support (2) with the O-ring to the shaft by
to idler (4). using dowel pin (1).
a See structural illustration.

7. Supply oil and tighten the plug.

5 Quantity of oil:
245 – 255 cc (EO30-DH)
3 Plug:
205.8 ± 49 Nm {21 ± 5 kgm}

5. By using tool J (above-mentioned), install

floating seals (3) to idler (4) and support (2).
a Completely clean, degrease and dry the con-
tact surfaces (hatched area shown in the
drawing) of the floating seal and the O-ring.
a Apply oil to the sliding surface of the floating
seal, and take care not to have any dirt stuck
on it.
a After inserting the floating seals, check that
the leaning of the seal is less than 1 mm and
protrusion (a) is within the range of 7 - 11
mm.

PC228US-8, PC228USLC-8 50-91

(02)
Undercarriage and frame
Disassembly and assembly of idler cushion assembly

Disassembly and assembly of idler cushion assembly 50-92

Special tools 50-92 1. Remove piston assembly (2) from idler cushion
assembly (1).

New/redesign
Necessity

Sketch
Sym-

Q'ty
Part number Part name 2. Disassembling idler cushion assembly
bol
1) Install tool M1 to idler cushion assembly (1).
k The tool must be installed correctly as
791-600-2001 Compressor (A) t 1 the load at installed length of the
or spring is large and dangerous.
791-685-8006 Compressor (B) t 1 a Load at installed length: 126 kN {12,900
790-201-2780 Spacer kg}
1 791-635-3160 Extension t 1
Cylinder
790-101-1600 t 1
(686 kN {70 ton})
790-101-1102 Pump t 1
M 790-640-2180 Guide bolt t 1
790-101-5201 Push tool kit (B) q 1
790-101-5241 q Plate 1
2
790-101-5221 q Grip 1
01010–51225 q Bolt 2
790-201-1500 Push tool kit q 1
790-201-1620 q Plate 1
3
790-101-5021 q Grip 1
01010-50816 q Bolt 2

Disassembly 50-92
q Structural illustration
2) Apply hydraulic pressure gradually to
compress the spring and remove lock plate
(3) and nut (4).
a Compress the spring up to the point
where the nut gets loose.
a Release the hydraulic pressure slowly to
release the tension of the spring.
a Free length of spring: 561 mm
3) Remove yoke (6) and cylinder (7) from spring
(5).
4) Remove snap ring (8), dust seal (9) and
bushing (10), in turn from cylinder (7).

3. Disassembling piston assembly (2)

1) Remove lock plate (12) from piston (11), and
then valve (13).
2) Remove snap ring (14), then remove
U-packing (15) and ring (16).

50-92 PC228US-8, PC228USLC-8

(02)
 Undercarriage and frame
Disassembly and assembly of idler cushion assembly

Assembly 50-93 4) Install cylinder (7) and yoke (6) to spring (5).
q Structural illustration Install the assembly to tool M1.
2 Sliding surface of cylinder:
Grease (G2-LI)

1. Assembling piston assembly (2)

1) Install ring (16) and U-packing (15) to piston
(11), and secure them with snap ring (14). 5) Slowly apply hydraulic pressure to compress
2) Tighten valve (13) lightly, and secure it with the spring. Tighten nut (4) until the installed
lock plate (12). length of the spring reaches dimension (a).
Install lock plate (3).
2. Assembling idler cushion assembly a Installed length (a) of spring: 433 mm
1) Using tool M2, press fit bushing (10) into
cylinder (7).
2) Using tool M3, install dust seal (9) to cylinder
(7).
3) Secure them by using snap ring (8).

6) Remove idler cushion assembly (1) from tool

M1.

3. Install piston assembly (2) to the idler cushion

assembly (1).
2 Sliding surface of cylinder: :
Grease (G2-LI)
2 Wear ring:
Grease (G2-LI)
a Install the piston assembly with the valve in-
stalled position outward.
a Pump 300 cc of grease (G2-LI) into the cylin-
der and bleed air. Check that grease comes
out of the grease hole.

PC228US-8, PC228USLC-8 50-93

(02)
Undercarriage and frame
Disassembly and assembly of track roller assembly

Disassembly and assembly of track roller assembly 50-94

Special tools 50-94 Assembly 50-94

1. Using push tool [1], press fit bushings (9) and

New/redesign
Necessity
(10) to roller (4).

Sketch
Sym-

Q'ty
Part number Part name
bol
2. Install collar (8) with the O-ring to shaft (5), and
install pin (7).
K 796-670-1020 Installer t 1

Disassembly 50-94
1. Remove pin (1), then remove collar (2).

2. Remove floating seals (3) from collar (2) and

roller (4).

3. Remove roller (4) from the assembly of shaft (5)

and collar (8).
a Since 195 ml of oil is charged in the roller,
drain the oil at this time point or lay rags to
prevent contamination.

4. Remove floating seals (6) on the opposite side

from roller (4), and the assmbly of shaft (5) and
collar (8).

5. Remove pin (7) and then collar (8) from shaft (5).

6. Remove bushings (9) and (10) from roller (4).

50-94 PC228US-8, PC228USLC-8

(02)
 Undercarriage and frame
Disassembly and assembly of track roller assembly

3. By using tool K, install floating seal (6a) to collar 5. Install shaft (5) to roller (4).
(8).
a Completely clean, degrease and dry the con- 6. Turn over the assembly of roller (4) and shaft (5).
tact surfaces (hatched area in the drawing).
And take care not to have any dirt stuck on
the contact surfaces.
a After inserting the floating seals, check that
the leaning is less than 1 mm and the protru-
sion (a) is within the range of 7 - 11 mm.

4. By using tool K, install floating seals (6b) and

(3b) to roller (4).
a As to precautions for installation of floating
seals (6b) and (3b), refer to a marked com-
ments in step 3.

7. By using tool K, install floating seal (3a) to collar

(2).
a As to precautions for installation of floating
seal (3a), refer to a marked comments in
step 3.
a Apply oil to the sliding surface of the floating
seal, and take care not to have any dirt stuck
on it.

8. Install collar (2) with the O-ring to the shaft with

pin (1).

9. Supply oil and tighten the plug.

5 Quantity of oil:
190 – 200 cc (E030-DH)
3 Plug:
15 ± 1.5 Nm {1.5 ± 0.5 kgm}

PC228US-8, PC228USLC-8 50-95

(02)
Undercarriage and frame
Disassembly and assembly of carrier roller assembly

Disassembly and assembly of carrier roller assembly 50-96

Special tools 50-96 a Shaft (2) and cover (3) under the shaft are re-
moved as a unit.

New/redesign
Necessity

Sketch
Sym-

Q'ty
Part number Part name
bol

L 790-434-1660 Installer t 1

q Sectional view
a A number in the drawing is the number shown in
the text.

3. Remove ring (5) from roller (4).

4. Remove floating seal (6) from ring (5).
a Take care not to damage the sealing surface.

Disassembly 50-96
1. Remove plug (9) and drain the oil from carrier
roller (1).
6 Carrier roller :
75 – 85 ml

5. Remove floating seal (7) from roller (4).

a Take care not to damage the sealing surface.

2. Using push tool [1], push the end surface of the

shaft to remove shaft (2) from carrier roller (1) to
separate followings.
q The assembly of roller (4) and ring (5), shaft
(2) and cover (3).
q Press fit force (reference): 59 kN {6,000 kg}
or more.
a The press fit between shaft (2) and ring (5),
and also between roller (4) and cover (3) are
disengaged.

50-96 PC228US-8, PC228USLC-8

(02)
 Undercarriage and frame
Disassembly and assembly of carrier roller assembly

6. Using push tools [2] and [3], remove bushing (8)

from roller (4).

Assembly 50-97
1. Using push tools [3] and [4], press fit bushing (8)
to roller (4).
a Press fit it from the side of cover (3)

2. Floating seal
1) By using tool L, install floating seal (7) to
roller (4).
2) By using tool L, install floating seal (6) to ring
(5).
a Completely clean, degrease and dry the
contact surfaces (hatched area in the
drawing) of the floating seal and the
O-ring. And take care not to have any dirt
stuck on the contact surfaces.
a When installing floating seals, use tool L
and make sure to press the O-ring.
a After inserting the floating seal, check that
the leaning is less than 1 mm and that the
protrusion (a) is within the range of 7 – 11
mm.

PC228US-8, PC228USLC-8 50-97

(02)
Undercarriage and frame
Disassembly and assembly of carrier roller assembly

3. Install roller (4) and ring (5) to shaft (2). 5. Using push tool [8], press fit cover (3) to roller
a Apply oil to the sliding surface of the floating (4).
seal, and take care not to have any dirt stuck a Degrease, wash and dry the surfaces where
on it. roller (4) and cover (3) fit tight.
q Press-fit force (reference) 59 kN {6,000 kg}
or more.

4. Place washers [7] between push tool [6] and

roller (4). Press fit ring (5) to shaft (2) until the
height difference of roller (4) and ring (6) 6. Fill carrier roller assembly (1) with oil and tighten
becomes 1.8 ± 0.2 mm. plug (9).
a Thickness of washer [7] = 1.8 ± 0.2 mm 5 Carrier roller :
a Use push tool [5] to support shaft (2) on it. 75 – 85 cc (E030-DH)
3 Plug:
15 ± 5 Nm {1.5 ± 0.5 kgm}

50-98 PC228US-8, PC228USLC-8

(02)
 Undercarriage and frame
Removal and installation of revolving frame assembly

Removal and installation of revolving frame assembly 50-9

Removal 50-9 5. Remove boom cylinder assembly (3).

1. Remove the counterweight assembly. For 4 Boom cylinder assembly (x1):
details, see "Removal and installation of coun- 70 kg (Standard specification)
terweight assembly". 190 kg (Demolition specification)

2. Remove the work equipment assembly. For

details, see Removal and installation of work
equipment assembly.

3. Disconnect four boom cylinder hoses (1).

6. Disconnect upper hoses (4) - (9) from the swivel

joint. [*1]
a Before disconnecting the hoses, put tags to
them and write the mounting positions.

7. Remove the pin from stopper plate (10) and

4. Remove bottom pin (2). disconnect the stopper plate from the swivel
joint.

PC228US-8, PC228USLC-8 50-99

(02)
Undercarriage and frame
Removal and installation of revolving frame assembly

8. Sling revolving frame assembly (11). Installation 50-10

a Use two counterweight mounting bolt holes q Perform installation in the reverse order to re-
and two boom foot pin holes as lifting points moval.
to sling the revolving frame assembly by
4-point lifting method. [*1]
a Before installing the swivel joint on the machine,
9. Remove the 36 mounting bolts to remove connect the drain hose between swivel joint and
revolving frame assembly (11). [*2] swing motor to the swivel joint side.
a All the mounting bolts are installed from un-
derside of the outer race of the swing circle. [*2]
a Leaving two or three mounting bolts at the 2 Revolving frame assembly mounting bolt:
front and rear parts, adjust the balance of the Adhesive (LT-2)
revolving frame by using lever blocks, etc. 3 Revolving frame assembly mounting bolt:
Then, remove those mounting bolts. 1st time: 294.2 ± 29.4Nm {30 ± 3kgm}
k When removing the revolving frame as- 2nd time: 60 ± 6°(retightening angle)
sembly, take care so that it does not inter-
fere with the center swivel joint. q Bleeding air
4 Revolving frame assembly: Bleed air from the travel motor circuit. For
4,700 kg (Standard specification) details, see Testing and adjusting , "Air bleeding
4,900 kg(Demolition specification) from each part".

q Refilling with oil

Supply oil through the oil filler to the specified
level. Run the engine to circulate the oil through
the system. Then, check the oil level again.

50-100 PC228US-8, PC228USLC-8

(02)
 Undercarriage and frame
Removal and installation of counterweight assembly

Removal and installation of counterweight assembly 50-101

Special tools 50-101 5. Disconnect rear camera wiring connector A40

(8).

New/redesign
Necessity

Sketch
Sym

Q'ty
Part number Part name 6. Remove wiring clamp (9).
bol
7. Remove radiator hose clamps (10).
Commercially
Impact wrench q 1
available 8. Remove air conditioner compressor hose clamp
Z Socket wrench (11).
Commercially
(Width across flats: q 1
available
65 mm)
9. Remove fuel filter and bracket assembly (12),
a Use the impact wrench and socket wrench with and reposition it forward so that it does not inter-
a torque enough for tightening the counterweight fere with the maintenance counterweight
mounting bolts. assembly.

Removal 50-101
k Perform removal work with the machine
parked on a flat surface and the work equip-
ment completely lowered on the ground.

1. Open engine hood (1).

2. Remove cover (2).

3. Remove cover (3).

4. Remove frame (4).

10. Disconnect rear lamp wiring connector A15 (13).

PC228US-8, PC228USLC-8 50-101

(02)
Undercarriage and frame
Removal and installation of counterweight assembly

11. Open the right rear inspection cover and remove Installation 50-102
hose connector (14). q Perform installation in the reverse order to re-
moval.

[*1]
2 Mounting bolt:
Adhesive (LT-2)
3 Mounting bolt:
3,430 – 4,217 Nm {350 – 430 kgm}

12. Sling counterweight assembly (15).

13. Using tool Z, remove the mounting bolts.

Remove counterweight assembly (15).
[*1]
a Remove the counterweight assembly care-
fully so that it does not hit the machine.
4 Counterweight (15):
6,040 kg (Standard specification)
7,360 kg (Demolition specification)

50-102 PC228US-8, PC228USLC-8

(02)
 Undercarriage and frame
Removal and installation of maintenance counterweight assembly

Removal and installation of maintenance counterweight assembly 50-103

Removal 50-103 8. Remove fuel filter and bracket assembly (12),

k Perform removal work with the machine and reposition it forward so that it does not inter-
parked on a flat surface and the work equip- fere with the maintenance counterweight.
ment completely lowered on the ground.

1. Open engine hood (1).

2. Remove cover (2).

3. Remove cover (3).

9. Disconnect rear lamp wiring connector A15 (13).

10. Sling engine hood (14) and remove mounting

bolts (15).

11. Sling and remove engine hood (14).

4 Engine hood:
35 kg
4. Disconnect rear camera wiring connector A40
(8).

5. Remove wiring clamps (9).

6. Remove radiator hose clamp (10).

7. Remove air conditioner compressor hose clamp

(11).

PC228US-8, PC228USLC-8 50-103

(02)
Undercarriage and frame
Removal and installation of maintenance counterweight assembly

12. Disconnect air conditioner compressor wiring Installation 50-104

connector AC02 (16). q perform installation in the reverse order to re-
moval.
13. Loosen mounting bolts (19) and reposition air
conditioner compressor assembly (17) forward
so that it does not interfere with maintenance
counterweight assembly (18).

14. Remove cushion (20).

15. Remove maintenance counterweight assembly

mounting bolts (21).

16. Sling and remove maintenance counterweight

assembly (18).
4 Maintenance counterweight assem-
bly:
500 kg

50-104 PC228US-8, PC228USLC-8

(02)
 Undercarriage and frame
Removal and installation of maintenance counterweight assembly

PC228US-8, PC228USLC-8 50-105

(02)
Hydraulic system
Removal and installation of center swivel joint assembly

Hydraulic system 50-106

Removal and installation of center swivel joint assembly 50-106

Removal 50-106 4. Remove rubber partition plate (7) and frame (8).
k Lower the work equipment completely to the
ground. Referring to “Releasing residual
pressure in hydraulic circuit” , release the re-
sidual pressure in the hydraulic circuit.
k Disconnect the cable from the negative (-)
terminal of the battery.
k Note connector numbers and installed posi-
tions before disconnecting wiring and hoses.

1. Open engine hood (1).

2. Remove covers (2) and (3), and frame (4).

5. Disconnect swing motor hoses (9) to (14).

a Hoses are connected to the following ports:
q (9) and (10): Main circuit (ports MA and
MB)
q (11): Suction circuit (port S)
q (12): Parking brake circuit (port B)
(13) and (14): Drain circuit (port T)
a After suction and drain circuit hoses are dis-
connected, plug the hose.

3. Remove covers (5) and (6).

50-106 PC228US-8, PC228USLC-8

(02)
 Hydraulic system
Removal and installation of center swivel joint assembly

6. Remove six mounting bolts. Sling and remove 9. Disconnect lower hoses (23) to (30) from the
swing motor assembly (7). [*1] swivel joint.
4 Swing motor assembly:
60 kg

10. Remove four mounting bolts and remove center

swivel joint assembly (31). [*3]
7. Disconnect upper hoses (16) to (21) from the 4 Center swivel joint assembly:
swivel joint. [*2] 40 kg
a Before disconnecting the hoses, put tags to
them and write the installed positions.
8. Remove the pin from stopper plate (22) and
disconnect the stopper plate from the swivel
joint.

PC228US-8, PC228USLC-8 50-107

(02)
Hydraulic system
Removal and installation of center swivel joint assembly

Installation 50-108
q Perform installation in the reverse order to re-
moval.
[*1]
3 Swing motor assembly mounting bolt:
59 – 74 Nm {6.0 – 7.5 kgm}

[*2]
a Before installing the swivel joint to the machine,
connect the drain hose between the swivel joint
and swing motor to the swivel joint side.

[*3]
3 Center swivel joint assembly mounting
bolt:
98.1 – 122.6 Nm {10 – 12.5 kgm}

q Bleeding air
Bleed air from the travel motor circuit. For
details, see Testing and adjusting, “Bleeding air
from each part” .

q Refilling with oil

Supply oil through the oil filler to the specified
level. Run the engine to circulate the oil through
the system. Then, check the oil level again.

50-108 PC228US-8, PC228USLC-8

(02)
 Hydraulic system
Disassembly and assembly of center swivel joint assembly

Disassembly and assembly of center swivel joint assembly 50-109

Special tools 50-109

New/redesign
Necessity

Sketch
Sym-

Q'ty
Part number Part name
bol

790-101-2501 Push-puller q 1
790-101-2510 q Block 1
790-101-2520 q Screw 1
791-112-1180 q Nut 1
T 1 790-101-2540 q Washer 1
790-101-2630 q Leg 2
790-101-2570 q Plate 4
790-101-2560 q Nut 2
791-101-2650 q Adapter 2

Disassembly 50-109
1. Remove four mounting bolts to remove cover
(1).

2. Remove snap ring (2) and ring (3).

a If the ring is difficult to remove, remove it to-
gether with the swivel rotor in step 3.

3. By using tool T1, pull out rotor (4) from shaft (5).

4. Remove six slipper seals (6) and O-ring (7) from

rotor (4).

5. Remove seal (8) from shaft (5).

6. Remove plug (9) from shaft (5).

PC228US-8, PC228USLC-8 50-109

(02)
Hydraulic system
Disassembly and assembly of center swivel joint assembly

Assembly 50-1 0
1. Install plug (9) to shaft (5).
a Before installing the plug, clean, degrease,
and dry it.
a After installing the plug, check that it is sunk
lower than the shaft end face.
3 Plug:
33.3 ± 3.9 Nm {3.4 ± 0.4 kgm}

2. Install seal (8) to shaft (5).

3. Install six slipper seals (6) and O-ring (7) to rotor

(4).

4. Install rotor (4) to shaft (5).

2 Contact surfaces on rotor and shaft:
Grease (G2-LI)
a Set the rotor to the top of the shaft and lightly
hit it with a plastic hammer to install it to the
shaft.
a When installing the rotor, take extreme care
not to damage the slipper seals and O-ring.

5. Install ring (3) and secure with snap ring (2).

6. Install cover (1) with the O-ring.

3 Plug:
31.4 ± 2.9 Nm {3.2 ± 0.3 kgm}

50-110 PC228US-8, PC228USLC-8

(02)
 Hydraulic system
Removal and installation of hydraulic tank assembly

Removal and installation of hydraulic tank assembly 50-1 1

Removal 50-1 1 2. Remove cover (3).

k Lower the work equipment completely to the
ground. Referring to “Releasing residual
pressure in hydraulic circuit” , release the re-
sidual pressure in the hydraulic circuit.
k Disconnect the cable from the negative (-)
terminal of the battery.
k Note the connector numbers and installed
positions before disconnecting wiring and
hoses.

1. Drain oil from the hydraulic tank.

1) Remove cover (1).

3. Remove covers (4) and (5).

2) Remove drain plug (2) to drain the hydraulic

oil.
6 Hydraulic tank:
126 l 4. Remove filter bracket (6).

5. Disconnect three drain hoses (7) to (9).

q (7) and (8) : From control valve
q (9) : From upper side of oil cooler

PC228US-8, PC228USLC-8 50-111

(02)
Hydraulic system
Removal and installation of hydraulic tank assembly

6. Disconnect hydraulic tank return hoses (10) and 9. Remove four bolts (18) and disconnect suction
(11). hose (19).

7. Remove clamp bracket (12). 10. Remove six mounting bolts (20).

8. Disconnect five drain hoses (13) to (17). 11. Sling and remove hydraulic tank assembly (21).
q (13): Main valve drain 4 Hydraulic tank assembly:
q (14): PPC valve drain 120 kg
q (15): 6-spool solenoid valve drain
q (16): Boom RAISE EPC valve drain
q (17): ATT selector valve drain

a Use multi eyebolts [1] to remove hydraulic tank

assembly (21).
q Multi eyebolt: M12 x 1.75

Installation 50-1 2
q Perform installation in the reverse order to re-
moval.

q Bleeding air
Bleed air from the hydraulic pump circuit. For
details, see Testing and adjusting, “ Bleeding air
from each part” .

q Refilling with oil

Supply oil through the oil filler to the specified
level. Run the engine to circulate the oil through
the system. Then, check the oil level again.

50-112 PC228US-8, PC228USLC-8

(02)
 Hydraulic system
Removal and installation of main pump assembly

Removal and installation of main pump assembly 50-1 3

Special tools 50-1 3 a If using tool R1 and R2, remove the hydraulic
tank strainer and stop oil with tool R1 and R2.

New/redesign
Necessity

Sketch
Sym

Q'ty
Part number Part name
bol

1 796-460-1210 Oil stopper q 1

R
2 796T-460-1230 Adapter q 1 Q

Removal 50-1 3
k Swing the upper structure 45 ° and lower the
work equipment completely to the ground.
Stop the engine. Slowly open the hydraulic
tank cap to release pressure in the tank. Set
the lock lever to LOCK position.
k Disconnect the cable from the negative (-) 3. Drain damper oil through drain plug (3).
terminal of the battery. 6 Damper case:
k Note the connector numbers and installed Approx. 0.65 l
positions before disconnecting wiring and
hoses.
a Attach tags to the hoses to show their installed
positions to prevent any mistake when installing.

1. Remove under cover (1).

2. Remove drain plug (2) to drain hydraulic oil from

the hydraulic oil tank.
6 Hydraulic tank:
126 l

PC228US-8, PC228USLC-8 50-113

(02)
Hydraulic system
Removal and installation of main pump assembly

4. Open engine hood (4) and remove covers (5), 7. Remove mounting bolts (13) of the muffler
(6), and frame (7). mounting bracket.

5. Remove partition plate (11). 8. Sling and remove muffler (14).

a Space for winding the lifting tool is small.
4 Muffler assembly
35 kg

6. Remove clamp (12). [* 1 ]

a When removing the clamp mounting bolt, fix
the nut on the opposite side by using a span-
ner so that the force is not applied to the 9. Remove pre-filter bracket (15).
bracket.

50-114 PC228US-8, PC228USLC-8

(02)
 Hydraulic system
Removal and installation of main pump assembly

10. Remove filter bracket (16). 13. Disconnect two hoses (27).

11. Disconnect hoses (17) to (21). 14. Disconnect connector (28).

q (17): Rear pump discharge port
q (18): Front pump discharge port
q (19): Rear load pressure pickup port
q (20): Front load pressure pickup port
q (21): Pump suction port

15. Loosen 12 mounting bolts (29) for the work

equipment pump.

a Sling work equipment pump assembly (30).

12. Disconnect hoses (22) to (25).

q (22): Case drain port
q (23): Rear load pressure input port
q (24): EPC source pressure port
q (25): Pump pressure input port
q (26): Front load pressure input port

16. Sling and remove main pump assembly (30).

4 Main pump assembly:

170 kg

PC228US-8, PC228USLC-8 50-115

(02)
Hydraulic system
Removal and installation of main pump assembly

Installation 50-1 6 q Oil filling (damper case)

q Perform installation in the reverse order to re- Supply oil through the oil filler to the specified
moval. level.
5 Damper case: 0.65 l(EO30-DH)
[*1]
q Oil filling (hydraulic tank)
a Install muffler (14) to the exhaust pipe after ap- Supply oil through the oil filler to the specified
plying thermosetting sealant to the entire exter- level. Run the engine to circulate the oil through
nal surfaces of both the end of the exhaust pipe the system. Then, check the oil level again.
and the exhaust pipe fitting end (E) of the muf- 5 Hydraulic tank: 126 l
fler. 3 Hydraulic tank drain plug:
2 Entire periphery of E: Thermosetting 58.8 – 78.5 Nm {6.0 – 8.0 kgm}
sealant (Musashi Holts FIREGUM or
equivalent) q Bleeding air
See Testing and adjusting, “Bleeding air from
each part”.

a Replace clamp (12) with a new one.

3 Clamp bolt
First time: 39.2 – 49 Nm {4.0 – 5.0 kgm}
2nd time: 68.6 – 122.5 Nm {7.0 – 12.49
kgm}

50-116 PC228US-8, PC228USLC-8

(02)
 Hydraulic system
Removal and installation of main pump input shaft oil seal

Removal and installation of main pump input shaft oil seal 50-1 7

Special tools 50-1 7 Installation 50-1 7

q Perform installation in the reverse order to re-

New/redesign
Necessity
moval.

Sketch
Sym-

Q'ty
Part number Part name
bol
[*1]
2 Oil seal lip:
S 796T-467-2410 Push tool t 1 Q Grease (G2-LI)
2 Oil seal outer periphery:
Removal 50-1 7 Grease (G2-LI)
1. Remove the main pump assembly. For details, a Apply a thin film of the grease on the oil seal out-
see "Removal and installation of main pump er circumference.
assembly". a By using tool S and tools [1] and [2], press fit oil
seal (3).
2. Remove snap ring (1) and then remove spacer
(2).

3. By using a screwdriver, pry off oil seal (3).

[*1]
a Take care not to damage the shaft when re-
moving the oil seal.

PC228US-8, PC228USLC-8 50-117

(02)
Hydraulic system
Removal and installation of control valve assembly

Removal and installation of control valve assembly 50-1 8

Removal 50-1 8 3. Open right rear inspection cover (56) and

k Lower the work equipment completely to the disconnect tube (57) of the window washer tank
ground. Referring to “Releasing residual and connector CN-M06 (3).
pressure in hydraulic circuit” , release the re- a Disconnect the clamp on the frame as well.
sidual pressure in the hydraulic circuit.
k Disconnect the cable from the negative (-)
terminal of the battery.
k Note the connector numbers and installed
positions before disconnecting wiring and
hoses.

1. Remove under cover (1).

4. Remove handrails (4) and (5) and mirror (6).

5. Remove covers (7) and (8).

6. Remove cover (9) and the frame as a unit.

2. Remove drain plug (2) to drain hydraulic oil from

the hydraulic oil tank.
6 Hydraulic tank:
126 l

50-118 PC228US-8, PC228USLC-8

(02)
 Hydraulic system
Removal and installation of control valve assembly

7. Disconnect hoses (10) to (12). 11. Disconnect solenoid valve hoses (18) to (23).

q (18): Relief solenoid valve

q (19): Travel solenoid valve
q (20): Swing brake solenoid valve
q (21): Merge-divider solenoid valve
q (22): Swing brake solenoid outlet hose
q (23): Travel interconnection solenoid outlet
hose

12. Disconnect rear pump hose (24) and front pump

hose (25).

13. Disconnect solenoid valve, PPC and EPC hose

(26), and front pump control hose (27).
8. Disconnect hoses (13) to (15).
9. Remove bolt (16).

14. Disconnect attachment hose (28) and hydraulic

tank hose (29).
10. Sling and remove attachment selector valve
assembly (17).

4 Attachment selector valve assembly:

50 kg

PC228US-8, PC228USLC-8 50-119

(02)
Hydraulic system
Removal and installation of control valve assembly

15. Disconnect 17 connectors (30). 18. Disconnect hoses (36) to (43).

a Before disconnecting the connectors, note
their installed positions (connector numbers). q (36): Rear pump control valve
q (37): Front pump control valve
q (38): Bucket cylinder head
q (39): Left travel motor
q (40): Boom cylinder bottom
q (41): Swing motor
q (42): Right travel motor
q (43): Arm cylinder head

16. Disconnect hose (31) of the attachment selector

solenoid valve.

19. Disconnect hoses (44) to (49).

q (44): Bucket cylinder bottom

q (45): Left travel motor
q (46): Boom cylinder bottom
q (47): Swing motor
q (48): Right travel motor
q (49): LS select solenoid valve

17. Disconnect hoses (32) to (35).

q (32): PPC valve

q (33): Left travel PPC valve
q (34): Right travel PPC valve
q (35): Swing motor S port

50-120 PC228US-8, PC228USLC-8

(02)
 Hydraulic system
Removal and installation of control valve assembly

20. Disconnect arm cylinder bottom hose (51) and 23. Remove four mounting bolts (54) for the control
hydraulic tank hose (50). valve assembly.

21. Disconnect hose (52).

24. Remove control valve assembly (55) and the

solenoid valve assembly as a unit.
22. Disconnect main valve drain hose (53). 4 Control valve assembly:
330 kg

PC228US-8, PC228USLC-8 50-121

(02)
Hydraulic system
Removal and installation of control valve assembly

Installation 50-12
q Perform out installation in the reverse order
to removal.

q Refilling with oil (Hydraulic tank)

Supply oil through the oil filler to the specified
level. Run the engine to circulate the oil
through the system. Then, check the oil level
again.

q Bleeding air
Bleed air from the hydraulic cylinder, swing
motor, and travel motor circuits. For details,
see Testing and adjusting, "Air bleeding"
from each part.

50-122 PC228US-8, PC228USLC-8

(02)
 Hydraulic system
Disassembly and assembly of control valve assembly

Disassembly and assembly of control valve assembly 50-123

a This section explains only the precautions for as- Replacement of pressure compensation valve
sembling the contol valve assembly. seal 50-123
Special tools 50-123 a Since there are many types of pressure compen-
sation valve, put a mark and note the installed

New/redesign
Necessity
position when removing it.

Sketch
Sym-

Q'ty
Part number Part name 1. Remove piston (2), plug (3) and spring (4) from
bol
pressure compensation valve (1).

796-946-1310 Guide f21.8 2. Remove seals (5) and (6) from piston (2).
t 1
(For 723-46-40100)
796-946-1610 Guide f21.4
t 1
(For 723-46-41100)
796-946-1810 Guide f21.2
(For 723-46-43100 and t 1
2 723-46-43400)
796-946-1910 Guide f21.0
(For 723-46-46101 and t 1
723-46-46300)
796-946-2210 Guide f20.6
(For 723-46-45100 and t 1
723-46-45700)
796-946-1320 Guide f21.8
t 1
(For 723-46-40100)
796-946-1620 Guide f21.4
t 1
(For 723-46-41100)
796-946-1820 Guide f21.2
a There are many types of pistons.
(For 723-46-43100 and t 1
723-46-43400)
3 3. Install tool T2 on piston (2), put the seal on the
T 796-946-1920 Guide f21.0
(For 723-46-46101 and t 1 tool and slowly push seal (5) down by hand so
723-46-46300) that it evenly expands.
796-946-2220 Guide f20.6
t 1
(For 723-46-45100) a You may put the seal on the tool and push it
796-946-1420 Guide f21.6
t 1 down to the flat part of the tool, and them in-
(For 723-46-42700)
796-946-1330 Sleeve stall the tool to the pistion to install the seal in
t 1 position.
(For 723-46-40100)
796-946-1630 Sleeve
t 1
(For 723-46-41100)
796-946-1830 Sleeve
(For 723-46-43100 and t 1
723-46-43400)
4
796-946-1930 Sleeve
(For 723-46-46101 and t 1
723-46-46300)
796-946-2230 Sleeve
t 1
(For 723-46-45100)
796-946-1430 Sleeve
t 1
(For 723-46-42700)

PC228US-8, PC228USLC-8 50-123

(02)
Hydraulic system
Disassembly and assembly of control valve assembly

4. Repeat the same process to install another seal

(6). Install tool T3 on the same end of piston (2).
Slowly push seal (6) down so that it evenly
expands.
a You may put the seal on the tool and push it
down to the flat part of the tool, and them in-
stall the tool to the pistion to install the seal in
position.

5. Install settling tool T4 on piston (2) for approx.

one minute to make seals (5) and (6) settle.
a Check that there is no protrusion or cut on the
seal.

6. Fit plug (3) and spring (4) to piston (2), then

install pressure compensation valve (1).
a After the installation, push the piston by hand
and check that the piston returns only with
spring force.

50-124 PC228US-8, PC228USLC-8

(02)
 Hydraulic system
Disassembly and assembly of control valve assembly

Assembly of control valve 50-125

q Apply engine oil to the sliding surfaces before

assembling.
q Install spools (7) and (8) into the valve chamber,
with drill holes (H1) and (H2) facing the direc-
tions as shown in the drawing respectively.
a The same applies to cross sections H-H, K-K,
L-L, and M-M.

q Install filters (13) in PLS1 and PLS2 PORTs as

shown in the drawing. (Check the positions of
the crimped parts*.)
TRUE: Correct
ERROR: Incorrect

PC228US-8, PC228USLC-8 50-125

(02)
Hydraulic system
Disassembly and assembly of control valve assembly

q Upper and lower control valve cover blocks

2 Mating face of upper and lower control
valve cover blocks (SE):
Loctite 242 or equivalent
q Tighten the mounting bolts for the upper and
lower control valve covers in order of figure.
(AoDoCoB)
3 Mounting bolt for upper and lower control
covers:
156.9 – 176.5 Nm {16 – 18 kgm}

q Merge-divider valve
2 Merge valve mating face (SE2):
Loctite 242 or equivalent
q Tighten the mounting bolts for the merge-divider
valve in the same sequence as that for the con-
trol valve cover mounting bolts.
3 Merge-divider valve mounting bolt:
156.9 – 176.5 Nm {16 – 18 kgm}
q Tighten the mounting bolts of the back pressure
valve, boom lock valve, arm quick return valve,
and arm check valve in the same order as that
for the control valve cover.
3 Mounting bolts of back pressure valve,
boom lock valve, and arm quick return
valve, and arm check valve:
58.8 – 73.6 Nm {6 – 7 kgm}
q After assembling, put stoppers (CAP) to prevent
oil and detergent liquid from entering through
f12 holes.
q Pressure compensation valve
a Install each pressure compensation valve,
checking the mark that was put when remov-
ing it. Especially, do not install BKC1 and
BKC2 adversely.
q Main relief valve assembly
After installing the main relief valve assembly in
the control valve, see Testing and adjusting,
"Testing and adjusting of work equipment,
swing, and travel circuit pressure" to perform the
check and adjustment.

50-126 PC228US-8, PC228USLC-8

(02)
 Hydraulic system
Disassembly and assembly of work equipment PPC valve assembly

Disassembly and assembly of work equipment PPC valve assembly 50-127

a Only precautions for assembling the work equip- a Install spring (5) with its small diameter end to-
ment PPC valve assembly are explained below. ward the shim (4).
q Diameter of spring (inside diameter)
Disassembly 50-127 Small end: f 4.9 mm Large end: f 5.55 mm
a Each of springs (6) and (7), consists of two
springs having different load at installed length. a When installing springs (6) and (7), note that
Note their installed positions (hydraulic ports) they are different by hydraulic port to install.
and identify them with tags to ensure correct in- q Installed height 31.9 mm (all)
stallation. q Load at installed length
Spring (6)(P1, P2): 35.3 N {3.6 kg}
Assembly 50-127 Spring (7)(P3, P4): 21.6 N {2.2 kg}
a Before assembly, thoroughly clean the parts and
check them for any dirt, rust or damage to pre- a Before installing piston (8), apply grease (G2-LI)
vent failures. to the periphery of the piston and the bore in the
a The head of plug (2) must not be projected from valve body.
the surface of valve body (1). 3 Bolt (11):
3 Plug (2): 11.8 – 14.7 Nm {1.2 – 1.5 kgm}
6 – 11 Nm {0.6 – 1.1 kgm}

a When installing plug (3) to valve body (1), check

the insertion depth so that the tip of plug does
not protrudes from the f 20 hole bottom surface
of the valve body.
3 Plug (3):
4 – 9 Nm {0.4 – 0.9 kgm}

PC228US-8, PC228USLC-8 50-127

(02)
Hydraulic system
Disassembly and assembly of work equipment PPC valve assembly

a When installing joint (12) to valve body (1), apply

LOCTITE according to the following procedure.
1) Before installing the joint, apply one drop
(approx. 0.02 g) of Loctite (No. 262) to two
locations of the threaded portion (A) of the
valve body. Before installation, thoroughly
degrease and dry the threaded portions of
the joint and valve body with Drysol.
2) Drop LOCTITE to the following positions.
2 Female threads of valve body (A):
Loctite No. 262
3 Joint (12):
39 – 49 Nm {4 – 5 kgm}

a Apply grease (G2-LI) to the sliding surface of

joint (12) and to the contact surfaces of disc (13)
and piston (8).
2 Quantity of grease (G2-LI)
1) Sliding surface of joint: 2 – 4 cc/circumfer-
ence
2) Contact parts of disc and piston:
0.3 – 0.8 cc/part

a Install disc (13) according to the following proce-

dure.
Adjust the disc so that the play at the lever end
is within the following range.
Lever play:
0.5 – 3 mm (at 200 mm from lever pivot point)
a For details, see Testing and adjusting "Ad-
justment of play in work equipment & swing
PPC valve".
a Tighten nut (14) to the following torque.
3 Nut (14):
69 – 88 Nm {7 – 9 kgm}

50-128 PC228US-8, PC228USLC-8

(02)
 Hydraulic system
Disassembly and assembly of travel PPC valve assembly

Disassembly and assembly of travel PPC valve assembly 50-129

Special tools 50-129 a Remove pin (24) from valve body (1).
6. Remove seal (9) and collar (8).
New/redesign
Necessity

Sketch

Sym-
Q'ty

Part number Part name 7. Remove pistons (7) to remove retainers (6),
bol
springs (5) and (4) and shims (3).
a Note the installed position, quantity and
1 796T-416-1010 Push tool t 1 Q thickness of each pack of shims (3) and keep
Q 2 796T-416-1030 Push tool t 1 Q them.
3 796T-416-1020 Push tool t 1 Q
8. Remove valves (2) from valve body (1).
Disassembly 50-129
1. Remove screws (22) and remove damper
assemblies (21).

2. Remove mounting bolt (19) and remove case

(18), shafts (16) and levers (13) as a unit.

3. Remove pins (17).

4. Remove levers (13), bushings (14) and (14a),

and shafts (16) from the case.

5. Remove mounting bouts (11) to remove plate

(10).
a Note the thickness and installed position of
each washer (12).

PC228US-8, PC228USLC-8 50-129

(02)
Hydraulic system
Disassembly and assembly of travel PPC valve assembly

Assembly 50-130
Only precautions for assembly are discribed.

a Before assembly, throughly clean the part and

check them for dirt, rust, or damage to prevent
failure.
a When installing piston (7), apply grease (G2-LI)
to its periphery and the inside of the valve body
hole.

a Install spring (4) with its small diameter end to-

ward shim (3).
q Diameter of spring (inside diameter)
Small end: f 4.9 Large end: f 5.55
3) Install lever (13).
a Install shaft (16) according to the following pro-
4) Install shaft (16).
cedure.
5) Using tool Q3, install pin (17).
1) Using tool Q1, install bushing (14) to the
a Install the pin so that distance C is as fol-
case.
lows.
a Install bushing with 10 ° chamfered end
q Distance C: 0 – 0.5 mm
ahead.
a Do not hit it with a hammer directly.
a Install the bushing so that distance A is as
follows.
q Distance A: 20.4 ± 0.3 mm
a Do not hit it with a hammer directly.

a Apply grease (G2-LI) to the sliding surfaces of

shaft (16), contact parts of lever (13) and piston
(7), and contact parts of damper (21) and pin
(20).
2 Quantity of grease (G2-LI)
2) Using tool Q2, install bushing (14a) to the
case.
Sliding surfaces of shaft: 4 – 8 cc/circum-
a Install bushing with 10 ° chamfered end
ference
ahead.
Contact parts of lever and piston: 0.3 – 0.8
a Install the bushing so that distance B is as
cc/part
follows (bushing end face flush is with
Contact parts of damper and pin: 0.3 – 0.8
case end face).
cc/part
q Distance B: 0 mm
a Do not hit it with a hammer directly.
a Install washer (12) of t=1.6. If the difference in le-
ver angle between left and right travel control le-
vers at full lever stroke is more than 0.7 °, adjust
the washer thickness to keep the difference with-
in 0.7 °. (Decreasing the thickness of washer by
0.3 mm increases the lever angle at full stroke by
0.39°.)
q Available washer: t= 1.0, 1.3, 1.6, 1.9, 2.2

50-130 PC228US-8, PC228USLC-8

(02)
 Hydraulic system
Disassembly and assembly of travel PPC valve assembly

1. Tighten each part to the following torque.

q Plug (26): 6 – 11 Nm {0.6 – 1.1 kgm}
q Plug (25): 4 – 9 Nm {0.4 – 0.9 kgm}
q Screw (22): 7.8 – 9.8 Nm {0.8 – 1.0 kgm}
q Bolt (19): 25 – 30 Nm {2.5 – 3.2 kgm}
q Bolt (11): 27 – 34 Nm {2.8 – 3.5 kgm}

PC228US-8, PC228USLC-8 50-131

(02)
Work equipment
Removal and installation of work equipment assembly

Work equipment 50-132

Removal and installation of work equipment assembly 50-132

Special tools 50-132 4. Remove head side pin (5).

[*2]

New/redesign
a Shims are installed, so note the quantity and

Necessity

Sketch
Sym-

Q'ty
Part number Part name thickness.
bol

796-900-1200 Remover t 1
V 790-101-4000 Puller (50 ton) t 1
790-101-1102 Hydraulic pump t 1

Removal 50-132
k Fully extend the arm and bucket and com-
pletely lower the work equipment to the
ground. Set the lock lever to LOCK position.
k Disconnect the cable from the negative (-)
terminal of the battery.

1. Disconnect grease hose (1).

5. Start the engine, retract the piston rod of the
2. Sling boom cylinder assembly (2) and remove boom cylinder, and place the boom cylinder on
lock bolt (3). the stand.
[*1] a Wire the rod to prevent it from extending.
a Perform the same steps 1 to 5 for the boom
3. Remove plate (4). cylinder of the other side.
k Relieve the remaining pressure in the
boom cylinder circuit. See Testing and
adjusting, "Relieving remaining pressure
in hydraulic circuits".

6. Disconnect hoses (6) (four in total) of the arm

and bucket cylinders and plug them.

7. Disconnect work lamp connector A13.

8. Remove covers (7) and (8) and remove boom

angle potentiometer (9).
[*3]
a See Testing and adjusting, "Replacement
procedure for boom angle potentiometer".

50-132 PC228US-8, PC228USLC-8

(02)
 Work equipment
Removal and installation of work equipment assembly

Installation 50-13
q Perform installation in the reverse order to re-
moval.

[*1]
a Tighten the lock nut so that the clearance (a) be-
tween the plate and the nut is 0.5 to 1.5 mm.

9. Sling work equipment assembly (10), remove

foot pin (11) by using tool V, and remove work
equipment assembly (10).
[*4]
4 Work equipment assembly (10)
3,400 kg (Standard
specification)
3,900 kg (Demolition [*2]
specification) 2 Inside surface of bushing when installing
pin:
Molybdenum disulfide lubricant (LM-P)
2 Greasing after installing pin:
Grease (LM-G)
k When aligning the pin holes, never insert
your fingers in them.
a st1: Resin shim (1.0 mm in thickness)
a Set the clearance (b) between cylinder rod (12)
and plate (4) to 1.5 mm or less by shimming.
Available shims: 1.0, 2.0 mm
a Install one shim or more on each end face.

PC228US-8, PC228USLC-8 50-133

(02)
Work equipment
Removal and installation of work equipment assembly

q Demolition specification [*3]

a Insert resin shim (1.0 mm in thickness) in the a Perform the initial setting of the boom potentiom-
same manner as that for standard specification eter. See Testing and adjusting, "Special func-
machine. tions of machine monitor (EMMS)".
1) Operation
[*4]
2 Inside surface of bushing when installing
pin:
Molybdenum disulphide lubricant (LM-P)
2 Greasing after installing pin:
Grease (LM-P)
k When aligning the pin holes, never insert
your fingers in them.
a Set the clearance (c) between the foot end face
of boom (13) and bracket (14) to 1 mm or less by
shimming.
Available shims: 2.0, 2.5, 3.0, 3.5 mm
a Install one shim or more on each end face.

2) When lifting the machine (e.g. when loading

the machine on a vessel)

q Bleeding air
Bleed air. See Testing and adjusting "Air
bleeding from each part".

q Refilling with oil (Hydraulic tank)

Supply oil through oil filler port to the specified
level. Run the engine to circulate the oil through
the system. Then check the oil level again.

50-134 PC228US-8, PC228USLC-8

(02)
 Work equipment
Removal and installation of anti-drop valve assembly for boom

Removal and installation of anti- 3. Turn the starting switch to ON position.

drop valve assembly for boom 1 4. Set the work equipment lock lever in FREE
position.
k Place the machine on a level ground. 5. Check that the work equipment is lowered to
k Remove the anti-drop valve assembly from the ground by operating the work equipment
the machine body, and then perform disas- control lever to the boom LOWER direction
sembling of the anti-drop valve assembly. fully to the stroke end.
k High remaining pressure may remain in the
anti-drop valve assembly even after per-
forming normal releasing procedure. Be
sure to perform this procedure, and then
perform the releasing procedure.
k When the arm cylinder moves only in one
direction inside the anti-drop valve for arm,
operate the cylinder to the stroke end in a
movable direction. Lower the bucket to the
ground, and then perform releasing the
remaining pressure.
If the bucket is not lowered and the anti-
drop valve is removed from the cylinder,
the high pressurized oil may spurt out. It is
k
very dangerous. Perform the step 3. to 5 in 15 seconds
a Wash around the anti-drop valve assembly in after the engine stopped, since the bat-
order to prevent any dust or dirt from entering tery charge in the PPC accumulator
it, and then perform the work. lowers gradually.
k
a Install a plug or flange in the place where a If the work equipment is not lowered or
hydraulic hose is disconnected to prevent oil stops on the way, the battery charge of
from flowing out. the PPC accumulator may be lowered.
a Check the connector numbers and installed In such case, the remaining pressure
positions before disconnecting wirings and cannot be released with this proce-
hoses, and record them. dure.
a If the work equipment is lowered by its
own weight to the ground, the battery
Removal charge of the PPC accumulator is normal.
Check for the function of PPC circuit accumulator. a PPC accumulator is a periodic inspection
1. Set the arm cylinder and bucket cylinder to the item and an important periodic replace-
most retracted position (maximum arm OUT/ ment part.
bucket DUMP position), and hold the work
equipment at the height (a) off from the Releasing the remaining pressure in hydraulic
ground. cylinder circuit
(a): 1.5 m 6. Start the engine.
7. Set the arm cylinder and bucket cylinder to the
most extended position (maximum arm IN/
bucket CURL position) or the most retracted
position (maximum arm OUT/bucket DUMP
position), and lower the work equipment to the
ground.
a Anti-drop valve is installed to the bottom
side of the boom cylinder. When the work
equipment is lowered with this posture,
the oil in the bottom side of the boom cyl-
inder is drained, and the remaining pres-
sure is low.

2. Keep the arm cylinder and bucket cylinder at

the most retracted position. Turn the starting
switch to OFF position to stop the engine.

PC228US-8,PC228USLC-8 50-134-1
(04)
Work equipment
Removal and installation of anti-drop valve assembly for boom

Anti-drop valve assembly

15. Place an oil container under the anti-drop
valve assembly (7) to receive oil.
k Place an oil mat as well in case the oil
leaks.
k Slowly loosen the fitting of the hose (4)
so that the remaining pressure in the
circuit between the anti-drop valve and
the cylinder is released.
The remaining pressure may damage
the O-ring, and the oil may be
splashed. Use a waste cloth to protect
the fitting and around it.
16. Disconnect the hoses (3), (4), and (5).
17. Slowly loosen the bolt (6) (4 pieces), and
check that the oil pressure is released.
a Slowly loosen the bolt (6) in case the
inside pressure may be remained.
18. Remove the bolts (1) (4 pieces), and discon-
nect the tube (2).
19. Remove the bolts (6) (4 pieces), and remove
the anti-drop valve assembly (7).

8. Turn the starting switch to OFF position.

9. Loosen the oil filler cap of the hydraulic tank
slowly, and bleed the air in the hydraulic tank.
a Leave the oil filler cap of the hydraulic tank
removed.
10. Turn the starting switch to ON position.
11. Set the work equipment lock lever in FREE
position, and operate the R.H. and L.H. work
equipment control levers forward and back-
ward, and to the right and left.
a The work equipment can be operated with
the battery charged in the PPC accumula-
tor, but the battery charged in it will be dis-
charged after the work equipment control
lever is operated a couple of times.
12. Set the work equipment lock lever in LOCK
position.
13. Start the engine, run it with the fuel control dial
in MIN (low idle) position for more than 10 sec-
onds so that the PPC accumulator is accumu-
lated.
14. Repeat the steps 10. to 13. to release the
remaining pressure in the hydraulic cylinder
circuit.

50-134-2 PC228US-8,PC228USLC-8
(04)
 Work equipment
Removal and installation of anti-drop valve assembly for boom

Installation
Anti-drop valve assembly
1. Install the anti-drop valve assembly (7) with the
bolts (6) (4 pieces).
2. Connect the tube (2) with the bolts (1) (4
pieces).
3. Connect the hoses (3), (4), and (5).

Refilling with oil

q Refill with oil to the specified level through the
oil filler port of the hydraulic tank. Start the
engine to circulate the oil through the piping.
Then check the oil level again.

Air bleeding
q Bleed air from the hydraulic circuit. See Testing
and adjusting, “Bleeding air from hydraulic
circuit”.

PC228US-8,PC228USLC-8 50-134-3
(04)
Work equipment
Removal and installation of anti-drop valve assembly for arm

Removal and installation of anti- 2. Keep the arm cylinder and bucket cylinder at
the most retracted position. Turn the starting
drop valve assembly for arm 1 switch to OFF position to stop the engine.
k Place the machine on a level ground. 3. Turn the starting switch to ON position.
k Remove the anti-drop valve assembly from 4. Set the work equipment lock lever in FREE
the machine body, and then perform disas- position.
sembling of the anti-drop valve assembly.
k
5. Check that the work equipment is lowered to
High remaining pressure may remain in the
the ground by operating the work equipment
anti-drop valve assembly even after per-
control lever to the boom LOWER direction
forming normal releasing procedure. Be
fully to the stroke end.
sure to perform this procedure, and then
perform the releasing procedure.
k Anti-drop valve assembly is installed to the
high place. Set the scaffolding and wear the
safety belt always when performing this
work.
k When the arm cylinder moves only in one
direction inside the anti-drop valve for arm,
operate the cylinder to the stroke end in a
movable direction. Lower the bucket to the
ground, and then perform releasing the
remaining pressure.
If the arm cylinder is not at the stroke end
and it is removed from the cylinder of the
k
anti-drop valve, it is very dangerous.
Perform the step 3. to 5 in 15 seconds
a Wash around the anti-drop valve assembly in
after the engine stopped, since the bat-
order to prevent any dust or dirt from entering
tery charge in the PPC accumulator
it, and then perform the work.
lowers gradually.
k
a Install a plug or flange in the place where a
If the work equipment is not lowered or
hydraulic hose is disconnected to prevent oil
stops on the way, the battery charge of
from flowing out.
the PPC accumulator may be lowered.
a Check the connector numbers and installed
In such case, the remaining pressure
positions before disconnecting wirings and
cannot be released with this proce-
hoses, and record them.
dure.
a If the work equipment is lowered by its
own weight to the ground, the battery
Removal
charge of the PPC accumulator is normal.
Check for the function of PPC circuit accumula-
a PPC accumulator is a periodic inspection
tor.
item and an important periodic replace-
1. Set the arm cylinder and bucket cylinder to the ment part.
most retracted position (maximum arm OUT/
bucket DUMP position), and hold the work Releasing the remaining pressure in hydraulic
equipment at the height (a) off from the cylinder circuit
ground.
6. Start the engine.
(a): 1.5 m
7. Set the arm cylinder to the most extended
position (maximum arm IN position), and lower
the work equipment to the ground.
a Anti-drop valve is installed to the arm cyl-
inder, its head side. When the work equip-
ment is lowered with this posture, the oil in
the head side of the arm cylinder is
drained, and the remaining pressure is
low.
a Remaining oil amount on the head side is
low.

50-134-4 PC228US-8,PC228USLC-8
(04)
 Work equipment
Removal and installation of anti-drop valve assembly for arm

k Slowly loosen the bolt (5) in case the

inside pressure may be remained.
18. Remove the bolts (1) (4 pieces), and discon-
nect the tube (2).
19. Remove the bolts (5) (4 pieces), and remove
the anti-drop valve assembly (6).

8. Turn the starting switch to OFF position.

9. Loosen the oil filler cap of the hydraulic tank
slowly, and bleed the air in the hydraulic tank.
a Leave the oil filler cap of the hydraulic tank
removed.
10. Turn the starting switch to ON position.
11. Set the work equipment lock lever in FREE Installation
position, and operate the R.H. and L.H. work Anti-drop valve assembly
equipment control levers forward and back- 1. Install the anti-drop valve assembly (6) with the
ward, and to the right and left. bolts (5) (4 pieces).
a The work equipment can be operated with 2. Connect the tube (2) with the bolts (1) (4
the battery charged in the PPC accumula- pieces).
tor, but the battery charged in it will be dis- 3. Connect the hoses (3) and (4).
charged after the work equipment control
lever is operated a couple of times.
12. Set the work equipment lock lever in LOCK
position.
13. Start the engine, run it with the fuel control dial
in MIN (low idle) position for more than 10 sec-
onds so that the PPC accumulator is accumu-
lated.
14. Repeat the steps 10. to 13. to release the
remaining pressure in the hydraulic cylinder
circuit.

Anti-drop valve assembly

15. Place an oil container under the anti-drop Refilling with oil
valve assembly (6) to receive oil. q Refill with oil to the specified level through the
k Place an oil mat as well in case the oil oil filler port of the hydraulic tank. Start the
leaks. engine to circulate the oil through the piping.
k Slowly loosen the plug of the anti-drop Then check the oil level again.
valve assembly (6) so that the remain-
ing pressure in the circuit between the Air bleeding
anti-drop valve and the cylinder is q Bleed air from the hydraulic circuit. See Testing
released. and adjusting, “Bleed air from hydraulic
The remaining pressure may damage circuit”.
the O-ring of the plug of the anti-drop
valve assembly (6), and the oil may be
splashed. Use a waste cloth to protect
the plug and around it.
16. Disconnect the hoses (3) and (4).
17. Slowly loosen the bolt (5) (4 pieces), and
check that the oil pressure is released.

PC228US-8,PC228USLC-8 50-134-5
(04)
Work equipment
Disassembly and assembly of anti-drop valve assembly

Disassembly and assembly of Assembly

anti-drop valve assembly 1 Wash the parts thoroughly with clean hydraulic oil.
Replace the O-ring with the new one.
k Remove the anti-drop valve assembly from
the machine body always before disassem-
bling it. Never disassemble the anti-drop
valve when it is installed to the machine.
Otherwise, oil or parts will spurt out due to
the high remaining pressure.
k Slowly loosen the cover on the spool por-
tion or check valve when they are to be
removed.
k There is a spring inside them. Be careful
that the inside part may jump out.
k Do not stand in a direction where the inside
part may jump out when performing disas-
sembly, otherwise the inside part that will
jump out may hit your body.
k Insert a wooden piece or a thick cloth to fix
the anti-drop valve to the vise when per-
forming the disassembly.
k Wash the parts thoroughly with clean
hydraulic oil when performing assembly.
Replace the O-ring with the new one.

Disassembly
Do not stand in a direction where the inside part
may jump out with the reaction force of the spring
when removing the bolts (1), (2), and the check
valve (3). Otherwise the inside part that will jump
out may hit your body.

50-134-6 PC228US-8,PC228USLC-8
(04)
 Work equipment
Disassembly and assembly of work equipment cylinder assembly

Disassembly and assembly of work equipment cylinder assembly 50-135

Special tools 50-135 Disassembly 50-135

1. Disconnecting the cylinder assembly from

New/redesign
Necessity
the piston rod assembly

Sketch
Sym-

Q'ty
Part number Part name 1) Remove piping from the cylinder assembly.
bol
2) Loosen the 12 mounting bolts and discon-
nect head assembly (1) from the cylinder.
Cylinder repair 3) Pull out piston rod assembly (2).
790-502-1003 q 1
1 stand a Place an oil pan or other appropriate con-
790-102-1102 Pump q 1 tainer under the cylinder to collect oil from
790-102-4300 Wrench assembly t 1 the cylinder.
2
790-102-4310 Pin t 1
3 790-720-1000 Expander t 1
796-720-1660 Ring t 1
07281-01159 Clamp t 1
4
796-720-1670 Ring t 1
07281-01279 Clamp t 1
790-201-1702 Push tool kit t 1
790-101-5021 Grip 1
U 01010-50816 Bolt 1
5 790-201-1831 Push tool 1
790-201-1940 Push tool 1 2. Disassembling the cylinder and piston rod
assemblies
790-201-1841 Push tool 1 1) Install piston rod assembly (2) on tool U1.
790-201-1930 Push tool 1
790-201-1500 Push tool kit t 1
790-201-5021 Grip 1
01010-50816 Bolt 1
6
790-201-1620 Push tool 1
790-101-1630 Push tool 1
790-201-1640 Push tool 1
790-201-1650 Push tool 1

PC228US-8, PC228USLC-8 50-135

(02)
Work equipment
Disassembly and assembly of work equipment cylinder assembly

2) Using a hexagonal wrench, loosen locking 6) Remove cap (8) and twelve balls (9) before
screw (3) on the end of the piston assembly. removing plunger (10).
q Screw size: 12x1.75 mm (16 mm in q Arm cylinder only
length)
a If screw (3) has been crimped too firmly to
be loosened, tighten the screw further in
and tap on the screw before removing the
crimp.

3. Disassembling the piston assembly

1) Remove two rings (11).
2) Remove two wear rings (12).
3) Remove piston ring (13).
4) Remove the O-ring and two backup rings
3) Using tool U2, remove piston assembly (4). (14).

4) Remove plunger (5) and collar (6).

q Arm cylinder only
5) Remove cylinder head assembly (7).

50-136 PC228US-8, PC228USLC-8

(02)
 Work equipment
Disassembly and assembly of work equipment cylinder assembly

4. Disassembling the cylinder head assembly assembly 50-137

1) Remove the O-ring and backup ring (15). a Be careful not to damage the packings, dust
2) Remove snap ring (16), then remove dust seals, O-rings, etc.
seal (17). a Clean each part. After installing them, cover the
3) Remove rod packing (18) and buffer ring piping ports and pin holes to prevent entering of
(19). dirt.
4) Remove snap ring (30). a Before installing the buffer ring, warm it in hot
5) Remove bushing (20). water of approx. 50-60 °C. Do not attempt to in-
sert it forcibly.

1. Assembly of cylinder assembly (for only arm

cylinder)
1) Assemble valve (23) and spring (22).
2) Install the O-ring and plug (21).
a Clean and dry the threads of the plug, and
then apply liquid gasket (LG-5) to all the
periphery of the threaded part.
3 Plug:
83.4–102.9 Nm {8.5–10.5 kgm}

5. Disassembling the cylinder assembly (arm

cylinder only)
1) Remove plug (21).
2) Remove spring (22) and valve (23).

PC228US-8, PC228USLC-8 50-137

(02)
Work equipment
Disassembly and assembly of work equipment cylinder assembly

2. Assembling the cylinder head assembly 3. Assembling the piston assembly

1) Using tool U5, press fit bushing (20). 1) Install piston ring (13) on tool U3. Expand
2) Install snap ring (30). piston ring (13) by turning the crankhandle
3) Assemble buffer ring (19) and rod packing 8-10 turns.
(18). 2) Remove piston ring (13) from tool U3.
4) Install dust seal (17) using tool U6, and install Assemble the ring on the piston.
snap ring (16). 3) Using tool U4, compress piston ring (13).
5) Install backup ring (15) and the O-ring.

4) Install two backup rings (14) and the O-ring.

a Install the backup rings and O-ring as
shown in the figure.
5) Assemble wear ring (12).
6) Install ring (11).
a Be careful not to open the end gap of the
ring too wide.

50-138 PC228US-8, PC228USLC-8

(02)
 Work equipment
Disassembly and assembly of work equipment cylinder assembly

4. Assembling the piston rod assembly 5) Place plunger (10) on piston rod assembly
1) Set piston rod assembly (2) to tool U1. (2). Install 12 balls (9) and then cap (8).
a After installing the plunger, check that it
has a little play at its end.
q Arm cylinder only

2) Assemble cylinder head assembly (7).

3) Install the O-ring and the backup ring on
collar (6) and install the subassembly on the
piston rod. 6) If both piston rod assembly (2) and piston
a Install the two backup rings, one each in assembly (4) are reused, assemble them in
the front and rear of the O-ring. the following sequence. (If one or both of
q Arm cylinder only them is (are) replaced with a new one (new
4) Assemble plunger (5). ones), go to Step 7.)
q Arm cylinder only 1] Using tool U2, install piston assembly (4)
on piston rod assembly (2).
a Any burrs or sharp edges on threaded
portions must be removed using files
before installation.

a Fully screw in piston assembly (4) un-

til it comes into contact with the rod
end face b. Then, screw out the as-
sembly until the screw holes H in the
piston and the rod end face become
aligned with each other.

PC228US-8, PC228USLC-8 50-139

(02)
Work equipment
Disassembly and assembly of work equipment cylinder assembly

a On a cylinder with head cushion, en- a On a cylinder with head cushion, en-
sure that plunger (5) has play with pis- sure that plunger (5) has play with pis-
ton assembly (4) installed. ton assembly (4) installed.

2] Install screw (3) to lock piston assembly 2] Drill a screw hole in the threaded portions
(4) and piston rod assembly (2). of piston rod assembly (2) and piston
2 Screw: assembly (4).
Adhesive (LOCTITE #262) a With a drill aligned with V groove in
3 Screw: piston assembly (4) and piston rod as-
58.9–73.6 Nm {6–7.5 kgm} sembly (2), drill the groove into a
a With screw (3) installed, crimp the square one.
screw at four peripheral places (a). a The cylinder with bottom cushion must
not be machined in the cap machining
hole position.
q Dimensions of a screw hole (mm):
Tap drill diameter 10.3
Bottom hole depth 27
Screw hole size 12x1.75
Screw hole depth 20

a After tapping the screw hole, remove

chips and other dirt and thoroughly
clean the area.

7) When replacing either or both of piston rod

assembly (2) and piston assembly with new
ones, assemble the new ones according to
the following procedure.
1] Using tool U2, screw in piston assembly
(4) until it comes into contact with end
face (b) of the rod.
a If the cylinder has the bottom cushion,
put a mark to indicate the tightening
position of the ball cap at the rod end.
3 Piston assembly (4):
294 ± 29.4 Nm {30 ± 3.0 kgm}

50-140 PC228US-8, PC228USLC-8

(02)
 Work equipment
Disassembly and assembly of work equipment cylinder assembly

3] Install screw (3) to lock piston assembly 2) Tighten the mounting bolt for cylinder head
(4) and piston rod assembly (2). assembly (1).
2 Screw: 3 Mounting bolt:
Liquid adhesive compound Boom cylinder:
(Loctite #262) 270 ± 39 Nm {27.5 ± 4.0 kgm}
3 Screw: Arm cylinder:
58.9–73.6 Nm {6–7.5 kgm} 373 ± 54 Nm {38.0 ± 5.5 kgm}
a With screw (3) installed, crimp the Bucket cylinder:
screw at four peripheral places (a). 270 ± 39 Nm {27.5 ± 4.0 kgm}

5. Assembling the cylinder assembly onto the 3) Install piping.

piston rod assembly a Tighten the mounting bolt of the piping
1) Assemble piston rod assembly (2) onto the band to the following torque.
cylinder assembly. 3 Band mounting bolt:
a Align ring gaps (c) in a horizontal line. 27 ± 7 Nm {2.8 ± 0.7 kgm}
Align the axis of the cylinder tube with that
of the piston rod assembly before insert-
ing the assembly into the tube.
a Insert the piston fully while ensuring that
the rings are not damaged or dislocated.

PC228US-8, PC228USLC-8 50-141

(02)
Cab and its attachments
Removal and installation of operator's cab assembly

Cab and its attachments 50-142

Removal and installation of operator's cab assembly 50-142

Removal 50-142 7. Remove duct (12).

k Park the machine on level ground, lower the 8. Disconnect connector M05 (13) of the wiper
work equipment to the ground completely, wiring harness.
stop the engine, and set the lock lever to
LOCK position.
k Disconnect the cable from the negative (-)
terminal of the battery.
a Note the installed positions of disconnected
wires and connectors.

1. Remove front window assembly (1). For details,

see "Removal and installation of front window
assembly".
2. Remove floor mat (2) and cover (3).
3. Remove machine monitor (4). For details, see
"Removal and installation of machine monitor
assembly".
4. Remove right covers (5) and (6). 9. Remove wiring harness clamp (14).
10. Disconnect wiper washer hose (15).

5. Remove machine monitor cover (7) and duct (8).

6. Remove two clips (9) and pull ducts (10) and 11. Remove rear joint duct (16).
(11) downward in the direction of the arrow to 12. Remove rear right clip (17) to unclamp harness.
remove the ducts. [*1]

50-142 PC228US-8, PC228USLC-8

(02)
 Cab and its attachments
Removal and installation of operator's cab assembly

13. Remove cable clip (19) on right side duct (18) to 18. Open cover (25) on the left side of the machine
disconnect cable (20) from duct lever (21). and remove fresh air filter (26) of the air condi-
a Remove cable clip (19) by lowering it with a tioner.
flat-head screwdriver that is inserted in the
gap between the cable and clip.
14. Remove two mounting bolts (22) at the front and
rear of right side duct (18).

19. Remove fresh air duct (27) of the air conditioner.

20. Remove rear left clip (28) and clamp (29).
21. Remove four mounting bolts (31) of bracket (30),
and place the bracket beside the operator's seat
15. Remove right side duct (18) by pulling it in the together with the harness.
direction of the arrow.

22. Disconnect wiring harness connector H15 (32).

16. Remove cover (23) after tilting the operator's 23. Disconnect wiring harness connector H16 (33).
seat forward and down.
17. Remove cover (24).

PC228US-8, PC228USLC-8 50-143

(02)
Cab and its attachments
Removal and installation of operator's cab assembly

24. Remove clamp (34), clip (35) and band (36). 29. Remove lock plate mounting bolt (44) to remove
25. Disconnect wiring harness connectors H08 (37), lock plate (45) from the underside of the cab.
H09 (38) and H20 (39). [*2]
26. Disconnect wiring harness connector H16 (40). 30. Remove mounting bolt of cab tipping stopper
(46).
[*3]

27. Remove mounting bolts (41) (seven bolts

marked A) and mounting nuts (42) (four nuts
marked B) inside the operator cab. 31. Sling and remove operator's cab assembly (47).
a Note the lengths of the removed bolts. a Before removing the operator is cap assem-
a Nuts (42) are also used for fastening the floor bly, make sure that all wiring and piping are
frame. disconnected.
[*4]
a Before lifting off the operator's cab assembly,
keep harnesses from moving away from the
cab with cable ties or other suitable means to
prevent the harnesses from being damaged.
4 Operator's cab assembly:
440 kg

28. Remove cover (43) from the underside of the

cab.

50-144 PC228US-8, PC228USLC-8

(02)
 Cab and its attachments
Removal and installation of operator's cab assembly

Installation 50-145
q Perform installation in the reverse order to re-
moval.

[*1]
q Install ducts (10) and (11) according to the fol-
lowing procedure.
1) Install machine monitor cover (7).
2) Install ducts (10) and (11) to the base of right
side duct (18) in advance.
3) Pull ducts (10) and (11) upward in the direc-
tion of the arrow to install them.

[*2]
3 Lock plate mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
[*3]
3 Cab tipping stopper mounting bolt:
245 – 309 Nm {25 – 31. 5kgm}
[*4]
a When installing the operator's cab assembly, be
careful to prevent the harnesses from getting
caught between the cab and other parts.

PC228US-8, PC228USLC-8 50-145

(02)
Cab and its attachments
Removal and installation of operator's cab glass (adhered window glass)

Removal and installation of operator's cab glass (adhered window glass)50-146

a Among the panes of window glass on the four (1): Right side window glass
sides of the operator’s cab, five panes (1) – (5) (2): Left side rear window glass
are adhered. (3): Door upper window glass
This section describes the replacement proce- (4): Door lower window glass
dure of adhered glass. Replace front glass (5) (5): Front window glass
with front window assembly (6) removed. (6): Front window assembly
(It is impossible to replace only the front window (front window glass + front frame)
glass while the front window assembly is (7): Dam rubber
installed to the operator’s cab.) (16):Center trim seal
For the procedure for replacing the front window
assembly, see "Removal and installation of front
window assembly".

50-146 PC228US-8, PC228USLC-8

(02)
 Cab and its attachments
Removal and installation of operator's cab glass (adhered window glass)

Removal 50-147 a If the window glass is broken finely, it may be

removed with knife [4] and a flat-head screw-
Special tools 50-147 driver.
a While widening the cut-opening with a

New/redesign
Necessity
flat-head screwdriver, separate the dam rub-

Sketch
Sym-

Q'ty
Part number Part name ber and adhesive layer using a utility knife [4].
bol
(The figure shows the operator’s cab of a
wheel loader.)
1 793–498–1210 Lifter (Suction cup) t 2
X
2 20Y-54-13180 Stopper rubber t 2

a Remove the window glass to be replaced ac-

cording to the following procedure.

1. Using seal cutter [1], cut the adhesive between

broken window glass (9) and operator’s cab
(metal sheet) (8).

2. Remove the window glass.

a When a seal cutter is not available, an alter-

native method can be used: Drill a hole in the
adhesive and dam rubber layer and let an ex-
tra-fine wire (piano wire), etc. [2] go through
the hole. Hold or reel each end of this ex-
tra-fine wire with two pliers [3] etc. Saw
through the adhesive and dam rubber using
this wire.
(The figure shows the operator’s cab of a
wheel loader.)

PC228US-8, PC228USLC-8 50-147

(02)
Cab and its attachments
Removal and installation of operator's cab glass (adhered window glass)

Installation 50-148
1. Use a utility knife and scraper [5] to remove the
remaining adhesive and dam rubber on the
sheet metal (adhesion surface) of the operator’s
cab.
a A small amount of adhesive or dam rubber
can remain on the sheet metal surface as far
as they do not affect the adhesion perfor-
mance of new adhesive. Avoid excessive
scraping to prevent damage on the painted
surface. (damaging the painted surface may
cause the adhesive strength to be weak-
ened.)
(The figure shows the operator’s cab of a
wheel loader.) 3. Apply primer (10).
a The using limit of primer is 4 months after the
date of manufacture. Do not use the primer
after this limit.
a Use the primer within two hours after opening
the container.
a Even if the primer is packed again just after it
is unpacked, use it within 24 hours after it is
unpacked for the first time. (Discard the
primer 24 hours after it is packed.)
1) Stir the primer for painted surface and glass
sufficiently before using it.
a If the primer is stored in a refrigerator,
leave it at the room temperature for at
least half a day before stirring it.
2. Remove oil, dust, dirt, etc. from the adhesion (If the primer is unpacked just after taken
surfaces on cab (8) and window glass (9) with out of the refrigerator, water will be
white gasoline. condensed. Accordingly, leave the primer
a If the adhesion surfaces are not cleaned well, at the room temperature for a sufficient
the glass may not be stuck perfectly. time.)
a Clean the all black part on the back side of 2) Before reusing brush (11) for applying
the window glass. primer, wash it clean in white gasoline.
a After cleaning the adhesion surfaces, leave a After washing the brush, check it again for
them for at lease 5 minutes to dry. dirt and contaminant.
a Prepare respective brushes for the paint-
ed sufrace primer and glass primer.

50-148 PC228US-8, PC228USLC-8

(02)
 Cab and its attachments
Removal and installation of operator's cab glass (adhered window glass)

3) Evenly apply the painted surface primer over

the dam rubber mounting position of oper-
ator’s cab (8) and its outside areas to be
coated with the adhesive.
2 Primer for painted surface:
SUNSTAR PAINT PRIMER 580 SU-
PER
a The maximum times of primer application
must be limited to two.
(If it is applied more than two times, its
performance will be lowered.)
a Places to apply: Apply over the entire cir-
cumferential area of dimension (a).
q Primer applying dimension (a): 30 mm

4) Evenly apply the glass primer on the adhe-

sion surfaces of window glass (9).
2 Primer for glass:
SUNSTAR GLASS PRIMER 435-41
a The maximum times of primer application
must be limited to two.
(If it is applied more than two times, its
performance will be lowered.)

a Places to apply: Apply the primer on the

entire circumferential area of window
glass (9) mounting position (d) that is rel-
ative to dam rubber (7) in stalled on oper-
ator’s cab (8).
a For right side window glass (1), it is a Do not apply over the strip area (width:
enough to apply the primer only on the approx. 5 mm) bordering to the transpar-
outer dam rubber mounting position and ent portion of the dark part of glass.
its outside area to be coated with the ad- a After applying the primer, leave it in air for
hesive. at least five minutes (maximum eight
q (b) area hours ) to dry.
a After applying the primer, leave it in air for a Never apply wrong primer. If the painted
at least five minutes (maximum eight surface primer, etc. is applied by mistake,
hours ) to dry. wipe it off with white gasoline.
a Never apply wrong primer. If the glass
primer, etc. is applied by mistake, wipe it
off with white gasoline.

PC228US-8, PC228USLC-8 50-149

(02)
Cab and its attachments
Removal and installation of operator's cab glass (adhered window glass)

a Install additional dam rubber (7a) for right

4. Install dam rubber (7) along the inside edge of side window glass (1).
the glass sticking section. q Additional dam rubber for the right side
a Do not remove the release tape of dam rub- window glass
ber on the glass sticking side before sticking Installed position:
the glass. (f): 140 mm
a When installing the dam rubber, do not touch (g): 500 mm
the cleaned surface.
a Take extra care so that the dam rubber does
not float at each corner of the window frame.

2) Install dam rubber (7) for left side rear

window glass (2) to the position as shown in
a When installing dam rubber (7) around the the figure.
window frame, the ends must not overlap at
the joint. Instead, leave a clearance of ap-
proximately 5 mm at the joint (e).
1) Install dam rubber (7) for right side window
glass (1) to the position as shown in the
figure.

50-150 PC228US-8, PC228USLC-8

(02)
 Cab and its attachments
Removal and installation of operator's cab glass (adhered window glass)

3) Install dam rubber (7) for door upper window q Details of the sticking positions are as fol-
glass (3) and door lower window glass (4) to lows.
the position as shown in the figure. (h): Install the dam rubber along each
(The figure shows the door upper window inner edge of right and left front frames
glass.) (17).
(j): Install the dam rubber "3.0 mm" short
from the edge of front frame (17).

(The figure shows the door lower window

glass.)

5. Position the new window glass.

1) Check the clearances between the window
glass and the operator cab on the right, left,
upper, and lower sides, and then position the
window glass with the clearance evenly.
2) Stick tapes [6] between window glass (9) and
operator cab (8) and draw positioning line
(n).
a Stick tapes [6] to three points, that is, the
right, left, and lower portions of the right
side window glass, left side rear window
glass, and door window glasses (upper
and lower) for accurate positioning.
4) Install dam rubber (7) for front window glass 3) Use a utility knife, etc. to cut the tape
(5) at the position shown in the figure. between window glass (9) and operator cab
a Dam rubber: 1,004 mm x 2 (8), and remove the window glass.
a Do not remove the tapes left on the win-
dow glass and the operator's cab before
installing the window glass.

PC228US-8, PC228USLC-8 50-151

(02)
Cab and its attachments
Removal and installation of operator's cab glass (adhered window glass)

a The right-and-left and top-and-bottom in- 1) Break aluminum dehumidification membrane

stalled positions for positioning front win- (13) at the mouth of adhesive cartridge (12)
dow glass (5) are as follows: and attach there the dedicated nozzle.
(m) portion (right side): Project "3.8 mm"
from the frame end face.
(o) portion (top side): Make "3.0 mm"
short from the frame end face.

2) Cut the tip of the adhesive cartridge nozzle

(14) to dimensions (q) and (r) shown in the
figure.
q Dimension (q): 10 mm
q Dimension (r): 15 mm

6. Apply adhesive.
a Use either of two types of adhesives accord- 3) Set adhesive cartridge (12) to caulking gun
ing to the season. [7].
2 Adhesive (summer season):
SUNSTAR penguine seal 580 super
"S"
2 Adhesive (winter season):
SUNSTAR penguine seal 580 super
"W"
a The effeclive period of the adhesive is 4
months after the date of manufacture. Do not
use the adhesive after this limit.
a Keep the adhesive in a dark place where the
temperature is below 25 °C.
a Never heat the adhesive higher than 30 °C.
a When reusing the adhesive, remove the all
hardened part form the nozzle tip.

50-152 PC228US-8, PC228USLC-8

(02)
 Cab and its attachments
Removal and installation of operator's cab glass (adhered window glass)

4) Remove the release tape of the dam rubber 7. Install the window glass.
on the glass side. 1) Install window glass (9) while aligning it with
5) Apply adhesive (15) on the outside of dam the positioning tape mentioned in Step 5
rubber (7) on the operator’s cab. above.
a Since the window glass is not allowed to
be removed and adhered again, adhere it
very carefully.
a Adhere the glass within five minutes after
applying the adhesive.

a Apply adhesive (15) to dimensions (s)

and (t) relative to dam rubber (7) on oper-
ator’s cab (8) shown in the figure.
q Dimension (s): 10 mm
q Dimension (t): 15 mm
a The bead of adhesive (15) must be higher 2) After sticking window glass (9), press all
than dam rubber (7). around it until it sticks to the dam rubber.
a Apply the adhesive evenly with same a Press the corners of the window glass
height level. firmly.
a As for the right side window, apply the ad- a The work efficiency can be improved by
hesive to the outside area of the outside pulling window glass (9) using suckers X1
dam rubber. from the inside of the operator’s cab.
(The figure shows the operator’s cab of
PC200-7.)

PC228US-8, PC228USLC-8 50-153

(02)
Cab and its attachments
Removal and installation of operator's cab glass (adhered window glass)

a For front window glass (5), install the cen- 8. Fix the window glass.
ter trim seal to the lower part of the glass 1) For right window glass (1) after installing it in
after mounting it. the operator’s cab, install stopper rubber X2
In addition, apply caulking for the entire for fixation in two (v) portions at the bottom of
circumference to avoid producing a gap the glass.
at the portion U between the glass and (The figure shows the operator’s cab of
center trim seal. PC200-7.)
a When caulking, neatly arrange the form of
the adhesive at the right and left ends with
a rubber spatula.
2 Adhesive: Sika Ltd., Japan
Sikaflex 256HV

(The figure shows the operator’s cab of

PC200-7.)

2) In order to make the window glass and dam

rubber closely adhered to each other, use
styrene foam [9] and rubber bands [10] to fix
them for curing.
(The figure shows the operator’s cab of
PC200-7.)

50-154 PC228US-8, PC228USLC-8

(02)
 Cab and its attachments
Removal and installation of operator's cab glass (adhered window glass)

9. Clean the remaining primer and adhesive on the

window glass and operator’s cab after
completing the installation of the window glass.
a Use white gasoline to wipe the remaining ad-
hesive before it dries up.
a After cleaning, take care not to impact the
window glass.

10. Protect the adhered window glass.

1) Keep the window glass fixed for ten hours
without removing the stopper rubber, styrene
foam and rubber bands.
(ambient temperature 20 °C / humidity 60%)
2) Keep curing the adhered glass for 14 hours
after removing the stopper rubber, styrene
foam and rubber bands, and 24 hours after
applying the adhesive before operating the
machine.

PC228US-8, PC228USLC-8 50-155

(02)
Cab and its attachments
Removal and installation of front window assembly

Removal and installation of front window assembly 50-156

Removal 50-156
k Lower the work equipment to the ground and
stop the engine.
a To replace the front window glass, the front win-
dow assembly must be removed from the opera-
tor's cab. The procedure for removing and
installing the front window assembly (front frame
and front window glass) is explained below.

1. Raise the front window assembly to the ceiling

and fix it with the rear locks (on both sides).

2. Remove left lower block (1) and right lower block

(2).

3. Release the rear locks of the cab.

4. Lower front window assembly (3) carefully a

little. Put out rollers (4) and (5) under the right
and left sides of the front window through the
portion from which the right and left lower blocks
were removed in step 2 (the bottom of the rails).

5. Remove front window assembly (3) by twisting it

to the left and right to release left and right upper
rollers (6) and (7) from the rail.
a See figure in the right for (6) and (7).

Installation 50-156
q Perform installation in the reverse order to re-
moval.

50-156 PC228US-8, PC228USLC-8

(02)
 Cab and its attachments
Removal and installation of floor frame assembly

Removal and installation of floor frame assembly 50-157

50-157
Removal 50-157
k Park the machine on level ground, lower the
work equipment to the ground completely,
stop the engine, and set the lock lever to
LOCK position.
k Disconnect the cable from the negative (-)
terminal of the battery.
k To prevent burn injury, disconnect the heater
hose after the radiator coolant temperature
lowers.
k Loosen the cap of the hydraulic tank gradu-
ally to release the internal pressure of the hy-
draulic tank.
5. Removal of exterior parts
1. Collect the refrigerant (gas for air conditioner: 1) Remove handrails (3) and (4).
R134a) from the air conditioner circuit. [*1] 2) Remove mirror (5).
a Ask a qualified person for collecting, adding 3) Remove covers (6), (7), and (8).
and filling operation of refrigerant (R134a).
a Never release the refrigerant (R134a) to the
atmosphere.
k If refrigerant gets in your eyes, you may
lose your sight. And if it touches your
skins, you may suffer from frostbite. Ac-
cordingly, put on protective eyeglasses,
gloves and working suits with long
sleeves while you are collecting the re-
frigerant or filling the air conditioner cir-
cuit with the refrigerant. Collecting and f
illing work must be conducted by a quali-
fied person.
q Amount of refrigerant to be collected: 790
± 50 g
4) Remove covers (9) and (10).
2. Remove cover (1).

3. Swing the upper structure 90 ° .

4. Open drain valve (2) to drain the coolant.

6 Coolant:
21 l

PC228US-8, PC228USLC-8 50-157

(02)
Cab and its attachments
Removal and installation of floor frame assembly

5) Remove cover (11) under the operator’s cab. (27): P08 (arm OUT)
(28): P25 (front pump)
(29): P26 (rear pump)
a In the figure hoses are disconnected for
easy understanding.

6. Remove the operator’s cab assembly. For

details, see "Removal and installation of oper-
ator’s cab assembly."

7. Removal of wiring and hoses around the control

valve assembly 3) Disconnect boom RAISE throttle EPC valve
a Remove the clamps, clips and bands that are connector V09 (30).
fixing the wiring and hoses at the same time.
1) Disconnect connectors (12) to (19) around
the solenoid valves.
(12): V01 (PPC source pressure lock sole-
noid valve)
(13): V02 (travel interconnection valve sole-
noid valve)
(14): V03 (swing brake)
(15): V04 (travel HI-LO solenoid valve)
(16): V05 (2-stage relief solenoid valve)
(17): V06 (ATT return selector solenoid
valve)
(18): V23 (merge-divider EPC valve (main))
(19): V24 (merge-divider EPC valve (LS))
4) Open the rear right inspection cover and
disconnect washer motor connector M06
(31) and washer hose (32).

2) Disconnect connectors (20) to (29) around

the control valve assembly.
(20): P01 (bucket CURL)
(21): P02 (boom LOWER)
(22): P03 (swing LEFT)
(23): P04 (arm IN)
(24): P05 (bucket DUMP)
(25): P06 (boom RAISE)
(26): P07 (swing RIGHT)

50-158 PC228US-8, PC228USLC-8

(02)
 Cab and its attachments
Removal and installation of floor frame assembly

5) Disconnect hoses (33) to (40) from the PPC

valves for the work equipment and swing.
a Each PPC hose is attached with the fol-
lowing ID band in the order from top to
bottom.
(33): white (bucket CURL)
(34): brown (boom LOWER)
(35): none (swing LEFT)
(36): blue (arm IN)
(37): black (bucket DUMP)
(38): green (boom RAISE)
(39): red (swing RIGHT)
(40): yellow (arm OUT)

10)Disconnect PPC drain hose (47).

6) Disconnect hose (41) to the attachment.

(Machine with the attachment)
(ID band color: yellow) 8. Disconnection of wiring around the boom
7) Disconnect hoses (42) and (43). mounting section.
(42): red (L.H. travel FORWARD) a Remove the clamps, clips and bands that are
(43): green (R.H. travel FORWARD) fixing the wiring at the same time.
1) Disconnect horn connectors M07 (48) and
M08 (49).
2) Disconnect work equipment harness
connector A13 (50).

8) Disconnect hose (44) to the attachment.

(Machine with the attachment)
(ID band color: none)
9) Disconnect hoses (45) and (46).
(45): none (L.H. travel REVERSE)
(46): blue (R.H. travel REVERSE)

PC228US-8, PC228USLC-8 50-159

(02)
Cab and its attachments
Removal and installation of floor frame assembly

3) Disconnect boom angle potentiometer

connector A53 (51).

2) Disconnect rear camera wiring connector

A40 (64).
4) Disconnect air cleaner clogging sensor
connector P23 (52).
5) Disconnect air conditioner outer sensor
connector P32 (53).
6) Disconnect radiator coolant level sensor
connector P24 (54).
7) Disconnect fusible link connectors F04 (55)
and F05 (56).

3) Disconnect rear lamp wiring connector A15

(65).

9. Removal of wiring for the engine assembly

a Remove the clamps, clips and bands that are
fixing the wiring at the same time.
1) Disconnect connectors (57) to (65) at the left
side of the engine assembly.
(57): AC02 (air conditioner compressor)
(58): E01 (electrical intake air heater)
(59): K02 (terminating resistor)
(60): CE02 (engine controller (CM850))
(61): CE03 (engine controller (CM850))
(62): T12 (engine controller ground (GND))
(63): E06 (engine harness)

50-160 PC228US-8, PC228USLC-8

(02)
 Cab and its attachments
Removal and installation of floor frame assembly

4) Disconnect connectors (66) to (68) at the

right side of the engine assembly.
(66): E08 (engine harness)
(67): P44 (engine oil level sensor)
(68): E10 (starting motor)

11. Disconnection of wiring and hoses under the

floor
1) Disconnect harnesses T04 (78), T05 (79),
T06 (80), T07 (81), T08 (82), T09 (83) and
T10 (84).
10. Removal of wiring for the main pump assembly 2) Disconnect battery relays R3 (85) and R4
a Remove the clamps, clips and bands that are (86).
fixing the wiring at the same time. 3) Remove clips (87) and (88), and clamps (89),
1) Disconnect connectors (69) to (71) around (90), (91) and (92).
the main pump assembly.
(69): P21 (fuel level sensor)
(70): P47 (water-in-fuel sensor)
(71): M14 (travel alarm)

4) Disconnect floor harnesses T01 (93) and T14

(94).
5) Remove clamps (95) and (96).

2) Disconnect connectors (72) to (77) for the

main pump assembly.
(72): P22 (hydraulic oil temperature sensor)
(73): V12 (R-PC_EPC)
(74): V11 (F-PC_EPC)
(75): V19 (LS_EPC)
(76): A54 (front pump swash plate sensor)
(77): A55 (rear pump swash plate sensor)

PC228US-8, PC228USLC-8 50-161

(02)
Cab and its attachments
Removal and installation of floor frame assembly

6) Disconnect electrical intake air heater relays 15)Disconnect wiring connector P17(119) for the
R15 (97) and R16 (98). air conditioner high/low pressure switch.
7) Disconnect starting motor safety relays R17
(99) and R28 (100). 16)Disconnect air conditioner hoses (120) and
8) Disconnect battery relays R1 (101) and R2 (121). [*1]
(102).
9) Disconnect L.H. travel forward connector 17)Disconnect heater hose (122).
P10 (103) and L.H. travel reverse connector
P28 (104).
10)Disconnect R.H. travel forward connector P9
(105) and R.H. travel reverse connector P27
(106).
11)Remove clips (107), (108) and (109), and
clamp (110).

12. Disconnect ground cable (123).

12)Disconnect attachment pressure switch

connector P13 (111) and ATT_EPC
connector V30 (112).
13)Disconnect hoses (113) to (116) from the
travel PPC valve.
(113): red (L.H. travel FORWARD)
(114): none (L.H. travel REVERSE)
(115): green (R.H. travel FORWARD)
(116): blue (R.H. travel REVERSE) 13. Remove wiring fixing pad (124) and draw out
14)Disconnect hoses (117) and (118). wiring (125).

50-162 PC228US-8, PC228USLC-8

(02)
 Cab and its attachments
Removal and installation of floor frame assembly

14. Sling and remove floor frame assembly (126). Installation 50-163
a Before lifting the floor frame assembly, check q Perform installation in the reverse order to re-
that every wiring connector and clamp is dis- moval.
connected.
a While gradually lifting up floor frame assem- [*1]
bly (126), pull out the wiring on the control a When installing the air conditioner hose, take
valve side. care so that dust, dirt or water does not enter the
a When pulling out wiring on the control valve hose.
side, it may catch obstacles on the way to re- a Install the air conditioner hose after checking
sist smooth removal. Do not pull the wire that O-ring (127) is installed in the coupler.
forcibly. Manage to evade obstacles patient- a Check O-ring (127) for any damage or deteriora-
ly. tion.
4 Floor frame assembly: a When connecting refrigerant piping, apply com-
Approx. 220 kg pressor oil for R134a system (DENSO: ND-OIL8
equivalent) to O-ring (127), and tighten the cou-
pler using a double-wrench method.
3 Hose clamp (M6 bolt):
9.8 ± 1.96 Nm {1. 0± 0.2 kgm}
3 Air conditioner hose mounting bolt:
8 – 12 Nm {0.8 – 1.2 kgm}

Refilling with oil

q Run the engine to circulate the oil through the
system. Then, supply the oil to the specified lev-
el.

Refilling with refrigerant

q Refill the air conditioner circuit with refrigerant
(R134a).
a Refrigerant refilling volume: 790 ± 50 g

Refilling with coolant

q Supply coolant through the coolant filler port to
the specified level. Run the engine to circulate
the coolant, and then check the coolant level.
5 Coolant:
21 l

PC228US-8, PC228USLC-8 50-163

(02)
Cab and its attachments
Removal and installation of air conditioner unit assembly

Removal and installation of air conditioner unit assembly 50-164

Removal 50-164 4. Open drain valve (2) to drain the coolant.

k Park the machine on level ground, lower the 6 Coolant:
work equipment to the ground completely, 21 l
stop the engine, and set the lock lever to
LOCK position.
k Disconnect the cable from the negative (-)
terminal of the battery.
k To prevent burn injury, disconnect the heater
hose after the radiator coolant temperature
lowers.
a Note the installed positions of disconnected
wires and connectors.

1. Collect the refrigerant (R134a) from the air

conditioner circuit.
a Ask a qualified person for collecting, adding
and filling operation of refrigerant (R134a).
a Never release the refrigerant (R134a) to the 5. Remove cover (3) under the operator’s cab.
atmosphere.
k If refrigerant gets in your eyes, you may
lose your sight. And if it touches your
skins, you may suffer from frostbite. Ac-
cordingly, put on protective eyeglasses,
gloves and working suits with long
sleeves while you are collecting the re-
frigerant or filling the air conditioner cir-
cuit with the refrigerant. Collecting and
filling work must be conducted by a qual-
ified person.
q Amount of refrigerant to be collected: 790
± 50 g

2. Remove cover (1).

6. Disconnect wiring connector P17 (4) for the air
conditioner high/low pressure switch.
7. Disconnect air conditioner hoses (5) and (6).[*1]
8. Disconnect heater hose (7).

3. Swing the upper structure 90 ° .

50-164 PC228US-8, PC228USLC-8

(02)
 Cab and its attachments
Removal and installation of air conditioner unit assembly

9. Remove front window assembly (8). For details, 17. Open cover (20) on the left side of the machine
see "Removal and installation of front window and remove fresh air filter (21) of the air condi-
assembly". tioner.
10. Remove floor mat (9) and cover (10).
11. Remove machine monitor (11). For details, see
"Removal and installation of machine monitor
assembly."
12. Remove front cover (12) of the air conditioner
unit assembly.
13. Remove right side covers (13) and (14).

18. Remove fresh air duct (22) of the air conditioner.

19. Remove rear left clip (23) and clamp (24).
20. Remove four mounting bolts (26) of bracket (25),
and reposition the bracket and the harness as a
unit beside the operator's seat.

14. Remove two clips (15) and draw ducts (23) and
(24) down in the direction of arrow. [*2]

21. Remove rear joint duct (27).

22. Remove clip (28) and the clamp at the rear right
of the unit.

15. Remove cover (18) after tilting the operator's

seat forward and down.
16. Remove cover (19).

PC228US-8, PC228USLC-8 50-165

(02)
Cab and its attachments
Removal and installation of air conditioner unit assembly

23. Remove band (29). 29. Using mounting bolt (42) as a fulcrum, turn
24. Disconnect harness connectors AC01 (30) and machine monitor cover (40) in the direction of the
N10 (31). arrow.
25. Disconnect harness connectors (33) and (34) a Secure it at a position where it does not inter-
from engine controller (32). fere right side duct (35).

26. Remove cable clip (36) on right side duct (35) to 30. Remove right side duct (35) by pulling it in the
disconnect cable (37) from duct lever (38). direction of the arrow.
a Remove cable clip (36) by lowering it with a
flat-head screwdriver that is inserted in the
gap between the cable and clip.
27. Remove two mounting bolts (39) at the front and
rear of right side duct (35).

31. Remove left cover (44) from seat mounting

bracket (43).

28. Remove three mounting bolts (41) of machine

monitor cover (40) and loosen mounting bolt (42)
a little.

50-166 PC228US-8, PC228USLC-8

(02)
 Cab and its attachments
Removal and installation of air conditioner unit assembly

32. Remove wiring harness clamp (45). 36. Screw in the forcing screws [1] evenly on the
33. Remove three mounting bolts (46) for each right right and left sides to raise seat mounting
and left left of seat mounting bracket (43). bracket (43) for producing clearance (a) from the
floor.
Clearance (a): Approx. 100 mm
a Secure clearance (a) for preventing any in-
terference when drawing out the air condi-
tioner unit assembly.

34. Remove air conditioner unit assembly mounting

bolts (4), three front mounting bolts, and two rear
mounting bolts.

37. Pull out air conditioner unit assembly (48) in the

direction of the arrow to remove it.
a Check that all the wiring and piping are dis-
connected before removing the air condition-
er unit.

35. Install forcing screws (M12, L=130 mm) [1]; two

at the left side and one at the right side, respec-
tively.

PC228US-8, PC228USLC-8 50-167

(02)
Cab and its attachments
Removal and installation of air conditioner unit assembly

Installation 50-168 [*2]

q Perform installation in the reverse order to re- q Install ducts (16) and (17) according to the fol-
moval. lowing procedure.
1) Insert ducts (16) and (17) beforehand to the
[*1] base of right side duct (35).
a When installing the air conditioner hose, take 2) Using mounting bolt (42) as a fulcrum, turn
care so that dust, dirt or water does not enter the machine monitor cover (40) in the direction of
hose. the arrow to restore it to the original position.
a Install the air conditioner hose, after checking 3) Pull ducts (16) and (17) upward in the direc-
that O-ring (70) is installed in the coupler. tion of the arrow to install them.
a Check O-ring (70) for any damage or deteriora-
tion.
a When connecting refrigerant piping, apply com-
pressor oil for R134a system (DENSO:
ND-OIL8) to O-ring (70), and tighten the coupler
using a double-wrench method.
3 Hose clamp (M6 bolt):
9.8 ± 1.96 Nm {1.0 ± 0.2 kgm}
3 Air conditioner hose mounting bolt:
8 – 12 Nm {0.8 – 1.2 kgm}

q Refilling with refrigerant (R134a)

Refill the air conditioner circuit with refrigerant
(R134a).
a Refrigerant refilling volume: 790 ± 50 g

q Addition of air compressor oil

See Air conditioner, "Handling of compressor
oil".

q Refilling with coolant

Supply coolant through the coolant filler port to
the specified level. Run the engine to circulate
the coolant, and then check the coolant level
again.

5 Coolant:
21 l

50-168 PC228US-8, PC228USLC-8

(02)
 Cab and its attachments
Removal and installation of air conditioner unit assembly

PC228US-8, PC228USLC-8 50-169

(02)
Electrical system
Removal and installation of air conditioner compressor assembly

Electrical system 50-170

Removal and installation of air conditioner compressor assembly 50-170

Removal 50-170 3. Disconnect rear camera wiring connector A40

k Disconnect the cable from the negative (-) (8).
terminal of the battery. 4. Remove wiring clamp (9).
5. Remove radiator hose clamp (10).
1. Collect the refrigerant (R134a) from the air 6. Remove air conditioner compressor hose clamp
conditioner circuit. (11).
a Ask a qualified person for collecting, add- 7. Remove fuel filter and bracket assembly (12),
ing and filling operation of refrigerant and reposition them forward so that it does not
(R134a). interfere with the maintenance counterweight
a Never release the refrigerant (R134a) to assembly.
the atmosphere.
k If refrigerant gets in your eyes, you may
lose your sight. And if it touches your
skins, you may suffer from frostbite. Ac-
cordingly, put on protective eyeglasses,
gloves and working suits with long
sleeves while you are collecting the re-
frigerant or filling the air conditioner cir-
cuit with the refrigerant. Collecting and
filling work must be conducted by a qual-
ified person.
q Amount of refrigerant to be collected: 790 ±
50 g

2. Open engine hood (1) and remove cover (2). 8. Disconnect rear lamp wiring connector A15 (13).
9. Sling engine hood (14) and remove mounting
bolts (15).
10. Sling and remove engine hood (14).
4 Engine hood:
35 kg

50-170 PC228US-8, PC228USLC-8

(02)
 Electrical system
Removal and installation of air conditioner compressor assembly

11. Disconnect wiring connector AC02 (16) for the Installation 50-171
air conditioner compressor. q Perform installation in the reverse order to re-
12. Disconnect two air conditioner compressor moval.
hoses (17) and (18). [*1]
a Plug the hose to prevent any dirt, dust and [*1]
water from entering. a When installing the air conditioner hose, take
a Take care not to damage or lose the O-rings. care so that dust, dirt or water does not enter the
hose.
13. Loosen mounting bolts (19) and (20), and a Install the air conditioner hose after checking
remove air conditioner compressor belt (21) that O-ring (70) is installed in the coupler.
from pulleys. [*2] a Check O-ring (70) for any damage or deteriora-
tion.
14. Remove wiring clamp (22). a When connecting refrigerant piping, apply com-
15. Remove four air conditioner compressor pressor oil for R134a system (DENSO: ND-OIL8
mounting bolts (23). [*3] equivalent) to O-ring (70) before tightening.
3 Hose fitting mounting bolt (M6 bolt):
16. Disconnect air conditioner compressor 8 – 12 Nm {0.8 – 1.2 kgm}
assembly (24) from the bracket.

[*2]
a Adjust air conditioner compressor belt tension.
For details, see Testing and adjusting, "Testing
and adjusting tension of air conditioner compres-
sor belt".

[*3]
3 Air conditioner compressor mounting
bolt (23):
24.5 – 29 Nm {2.5 – 3.0 kgm}

Refilling with refrigerant

q Refill the air conditioner circuit with refrigerant
(R134a).
a Refrigerant refilling volume: 790 ± 50 g

PC228US-8, PC228USLC-8 50-171

(02)
Electrical system
Removal and installation of air conditioner condenser assembly

Removal and installation of air conditioner condenser assembly 50-172

Removal 50-172
k Disconnect the cable from the negative (-)
terminal of the battery.

1. Collect the refrigerant (R134a) from the air

conditioner circuit.
a Ask a qualified person for collecting, add-
ing and filling operation of refrigerant
(R134a).
a Never release the refrigerant (R134a) to
the atmosphere.
k If refrigerant gets in your eyes, you may
lose your sight. And if it touches your
skins, you may suffer from frostbite. Ac-
cordingly, put on protective eyeglasses, Installation 50-172
gloves and working suits with long q Perform installation in the reverse order to re-
sleeves while you are collecting the re- moval.
frigerant or filling the air conditioner cir- [*1]
cuit with the refrigerant. Collecting and a When installing the air conditioner circuit hose,
filling work must be conducted by a qual- take care so that dust, dirt or water does not en-
ified person. ter the hose.
q Amount of refrigerant to be collected: 790 ±
a When installing the air conditioner hose, check
50 g that O-ring (70) is installed in the coupler.
a Check O-ring (70) for any damage and deterio-
2. Disconnect hoses (1) and (2) from the air condi- ration.
tioner condenser. a When connecting refrigerant piping, apply com-
[*1] pressor oil for R134a system (DENSO:
ND-OIL8) to O-ring (70) and then tighten the
connector using a double-wrench method.
3 Hose mounting bolt (M6):
9.8 ± 1.96 Nm {1.0 ± 0.2 kgm}

3. Remove four air conditioner condenser

mounting bolts (3) and remove air conditioner
condenser assembly (4). [*2]
a In this removal operation, take care so as not
to damage the core part.
[*2]
a Mount the air conditioner condenser assembly
by inserting cushions in place.
3 Air conditioner condenser assembly
mounting bolt:
12.5 ± 2.5 Nm {1.27 ± 0.25 kgm}
Refilling with refrigerant
q Refill the air conditioner circuit with refrigerant
(R134a) .
a Refrigerant refilling volume: 790 ± 50 g

50-172 PC228US-8, PC228USLC-8

(02)
 Electrical system
Removal and installation of engine controller assembly

Removal and installation of engine controller assembly 50-173

Removal 50-173
k Disconnect the cable from the negative (-)
terminal of the battery.

1. Remove the maintenance counterweight

assembly. For details, see "Removal and instal-
lation of maintenance counterweight assembly".

2. Disconnect wiring connectors CE02 (2) and (3)

from engine controller (1).
a Connectors (2) and (3) are locked with a hex-
agonal socket head bolt L1(4 mm).
3. Press the locks to disconnect wiring connector
E03 (4) from engine controller (1).

4. Remove three engine controller mounting bolts

(5).
[*1]
a The harness clamp is tightened with blot (5).

5. Remove engine controller mounting bolts (6)

and (7). [*2]
a Ground cable (8) is tightened with bolt (6).

6. Remove engine controller (1).

PC228US-8, PC228USLC-8 50-173

(02)
Electrical system
Removal and installation of engine controller assembly

Installation 50-174 [*1]

q Perform installation in the reverse order to re- When installing mounting bolts (5), tighten the har-
moval. ness clamps together.

a Reference [*2]
q Method of replacing the O-ring of power supply When installing mounting bolt (6), tighten the
connector (9). ground cable (8) together.
O-ring seal:
1010-074-0406 (Deutsch Japan Ltd.)
1) Remove the cover (10) by holding down the
tabs with tweezers [1].

2) Use tweezers [1] to pick out O-ring (11).

50-174 PC228US-8, PC228USLC-8

(02)
 Electrical system
Removal and installation of pump controller assembly

Removal and installation of pump controller assembly 50-175

Removal 50-175 6. Disconnect harness connectors C01 (8) and

k Disconnect the cable from the negative (-) C02 (9) at the back of bracket (6).
terminal of the battery. a For disconnecting harness connectors C01
(8) and C02 (9) of the pump controller as-
1. Remove cover (1) after tilting the operator's seat sembly, press the connector locks (a) and
forward and down. pull each lever (13) to the inside.
2. Remove cover (2). 7. Remove bracket (10).
8. Remove four mounting bolts (11) and remove
pump controller assembly (12).

3. Remove fresh air duct (3) of the air conditioner.

4. Remove rear left clip (4) and clamp (5).
5. Remove four mounting bolts (7) of bracket (6),
and place the bracket and the harness, as a unit
beside the operator's seat.

PC228US-8, PC228USLC-8 50-175

(02)
Electrical system
Removal and installation of pump controller assembly

Installation 50-176 a Connector cover (1) removed

q Perform installation in the reverse order to re-
moval.

a Reference
1. How to remove connector cover (1)
1) Cut and remove cable tie (2).
2) Move lever (3) upward.

2. How to install connector covers

1) Push right and left sliders (4) in all the way.

3) Lightly press part (A) of connector cover (1)

to release tabs (B).
4) To escape tab (C), remove connector cover
(1) while swinging it just like drawing an arc.

a Right and left sliders (4) pushed in all the

way (left figure)
2) Move lever (3) on connector cover (1) from
the top position to the left position in the
figure (locked position).
a (B) , (C) : Tabs
a If the sliders and lever are not set as
shown in the following figure, the connec-
tor is not disconnected or locked securely
with the lever. Accordingly, check their
positions again

50-176 PC228US-8, PC228USLC-8

(02)
 Electrical system
Removal and installation of pump controller assembly

3) Set tab (C) on the connector and place

connector cover (1) in position.
a Take care so as not to let harness (5) be
caught in.

4) Install connector cover (1) with the tabs (B)

set in position.

5) Replace the cut cable tie with a new one and

fasten connector cover (1) and harness with
the new cable tie. (See 1.1.)

PC228US-8, PC228USLC-8 50-177

(02)
Electrical system
Removal and installation of machine monitor assembly

Removal and installation of machine monitor assembly 50-178

Removal 50-178 3. Disconnect harness connectors CM01 (3),

k Disconnect the cable from the negative (-) CM02 (4) and CM03 (5).
terminal of the battery. 4. Remove four mounting bolts (6) and draw out
k Park the machine on level ground, lower the machine monitor assembly (7) a little. [*1]
work equipment to the ground completely,
stop the engine, and set the lock lever to
LOCK position.

1. Remove the three mounting bolts and two clips,

then remove cover (1).
a One of the mounting bolts is installed in the
cap on the right of the sunlight sensor.
a When removing cover (1), disconnect also
wiring connector P31 for the sunlight sensor
at the same time.

5. Remove mounting bolt (8) and remove cover (9).

2. Remove duct (2).

6. Turn cover (9), and disconnect cigarette lighter

harness connector M04 (10).

50-178 PC228US-8, PC228USLC-8

(02)
 Electrical system
Removal and installation of machine monitor assembly

7. With machine monitor assembly (7) drawn out a Installation 50-179

little, disconnect rear camera harness connector q Perform installation in the reverse order to re-
A43 (11) and GPS antenna harness connector moval.
(12). q For the setup procedure after replacing the ma-
8. Remove machine monitor assembly (7). chine monitor assembly, see Service News
(AT07196.)

[*1]
a Since cover (9) may not be properly set if the in-
stallation is performed in the reverse order to re-
moval, follow the steps below:
1. Temporarily fasten machine monitor assembly
(7) with four mounting bolts (6).
2. Install cigarette lighter harness connector M04
(10) to cover (9).
3. Install cover (9) to the machine monitor
assembly.
4. With cover (9) in place, fully tighten the machine
monitor assembly mounting bolt (6).

PC228US-8, PC228USLC-8 50-179

(02)
Electrical system
Removal and installation of pump swash plate sensor

Removal and installation of pump swash plate sensor 50-180

Removal 50-180
k Disconnect the cable from the negative (-)
terminal of the battery.

1. Open the rear right inspection cover and remove

partition plate (1).

2. Disconnect front pump swash plate sensor

harness connector A54 (2) and rear pump
swash plate sensor harness connector A55 (3).
a Front pump swash plate sensor harness con-
nector A54 (2) is installed on the left side of
the main pump.
3. Disconnect front pump swash plate sensor
harness clamp (4) and rear pump swash plate Installation 50-180
sensor harness clamp (5). q Perform installation in the reverse order to re-
4. Remove mounting bolts (6), then remove front moval.
pump swash plate sensor (7) and rear pump
swash plate sensor (8). [*1]
[*1] a Adjust the pump swash plate sensor. For details,
see Testing and adjusting "Testing and adjust-
ment of pump swash plate sensors".
3 Pump swash plate sensor mounting bolt:
11.8 – 14.7 Nm {1.2 – 1.5 kgm}

50-180 PC228US-8, PC228USLC-8

(02)
 Electrical system
Removal and installation of KOMTRAX terminal assembly

Removal and installation of KOMTRAX terminal assembly 50-181

Removal 50-181 6. Disconnect wiring connectors CK01 (8), CK02

k Disconnect the cable from the negative (-) (9) and antenna cable (10).
terminal of the battery.
7. Remove four mounting bolts (11) and remove
1. Fold the operator's seat forward and remove KOMTRAX terminal assembly (12).
cover (1).
2. Remove cover (2).

Installation 50-181
q Perform installation in the reverse order to re-
3. Remove air conditioner fresh air duct (3). moval.
4. Remove clip (4) and clamp (5) from the rear left
side.
5. Remove four mounting bolts (7) for bracket (6).
Move the bracket and harness toward the oper-
ator's seat.

PC228US-8, PC228USLC-8 50-181

(02)
Electrical system
Removal and installation of KOMTRAX terminal assembly

50-182 PC228US-8, PC228USLC-8

(02)
SEN0533429-00 60-1

PC228US-8,PC228USLC-8

HYDRAULIC EXCAVATOR
Shop Manual 60-1

PC228US-8
PC228USLC-8

Machine model Serial number

PC228US-8 50001 and up
PC228USLC-8 50001 and up

60 Maintenance standard 60-1

PC228US-8,PC228USLC-8 60-1
Contents

Contents 60-2
60 Maintenance standard
Engine and cooling system ..................................................................................................... 60- 4
Engine mount....................................................................................................................... 60- 4
Cooling system .................................................................................................................... 60- 5
Power train.............................................................................................................................. 60- 6
Swing circle.......................................................................................................................... 60- 6
Swing machinery.................................................................................................................. 60- 8
Final drive ............................................................................................................................ 60- 10
Sprocket............................................................................................................................... 60- 12
Undercarriage and frame ........................................................................................................ 60- 14
Track frame and idler cushion.............................................................................................. 60- 14
Idler ...................................................................................................................................... 60- 16
Track roller ........................................................................................................................... 60- 18
Carrier roller ......................................................................................................................... 60- 19
Track shoe ........................................................................................................................... 60- 20
Hydraulic system..................................................................................................................... 60- 25
Hydraulic tank ...................................................................................................................... 60- 25
Main pump ........................................................................................................................... 60- 26
Control valve ........................................................................................................................ 60- 29
Swing motor ......................................................................................................................... 60- 39
Travel motor......................................................................................................................... 60- 41
PPC valve ............................................................................................................................ 60- 45
Solenoid valve...................................................................................................................... 60- 53
Attachment circuit selector valve ......................................................................................... 60- 55
Anti-drop valve ..................................................................................................................... 60- 58
Center swivel joint................................................................................................................ 60- 60
Work equipment...................................................................................................................... 60- 62
Work equipment................................................................................................................... 60- 62
Dimensions of components.................................................................................................. 60- 64
Work equipment cylinder ..................................................................................................... 60- 68

60-2 PC228US-8,PC228USLC-8
 Contents

PC228US-8,PC228USLC-8 60-3
Engine and cooling system
Engine mount

Engine and cooling system 60-4

Engine mount 60-4

60-4 PC228US-8,PC228USLC-8
 Engine and cooling system
Cooling system

Cooling system 60-5

PC228US-8,PC228USLC-8 60-5
Power train
Swing circle

Power train 60-6

Swing circle 60-6
Standard specification 60-6

Unit: mm

No. Item Criteria Remedy

Standard clearance Allowable clearance
Axial clearance of bearing
1 Replace
(when installed on machine) 0.5 – 1.6 3.2

60-6 PC228US-8,PC228USLC-8
 Power train
Swing circle

North America specification 60-7

Unit: mm

No. Item Criteria Remedy

Standard clearance Allowable clearance
Axial clearance of bearing
1 Replace
(when installed on machine) 0.5 – 1.6 3.2

PC228US-8,PC228USLC-8 60-7
Power train
Swing machinery

Swing machinery 60-8

60-8 PC228US-8,PC228USLC-8
 Power train
Swing machinery

Unit: mm

No. Item Criteria Remedy

Standard clearance Allowable clearance
Backlash between swing motor
1
shaft and No. 1 sun gear 0.18 – 0.28 –
Backlash between No. 1 sun gear
2 0.16 – 0.50 1.0
and No. 1 planetary gear
Backlash between No. 1 planetary
3 0.18 – 0.59 1.1
gear and ring gear
Backlash between No. 1 planetary
4 0.39 – 0.71 1.2
carrier and No. 2 sun gear
Backlash between No. 2 sun gear
5 0.16 – 0.50 0.9
Replace
and No. 2 planetary gear
Backlash between No. 2 planetary
6 0.18 – 0.59 1.0
gear and ring gear
Backlash between No. 2 planetary
7 0.07 – 0.23 –
carrier and swing pinion
Backlash between swing pinion and
8 0.22 – 1.32 2.0
swing circle
Clearance between plate and No. 2
9 0.9 ± 0.24 –
planetary carrier
Clearance between plate and No. 2
10 2.3 ± 0.64 –
sun gear
Standard dimension Tolerance Repair limit Repair by hard
Outside diameter of oil seal contact
11 0 chrome-plating or
surface on swing pinion collar 125 –
-0.100 replace

PC228US-8,PC228USLC-8 60-9
Power train
Final drive

Final drive 60-10

60-10 PC228US-8,PC228USLC-8
 Power train
Final drive

Unit: mm

No. Item Criteria Remedy

Standard clearance Allowable clearance
Backlash between No. 2 planetary
1
carrier and travel motor 0.16 – 0.53 –
Backlash between No. 2 planetary
2 0.16 – 0.57 1.00
gear and ring gear
Backlash between No. 2 planetary
3 0.15 – 0.49 1.00
Replace
gear and No. 2 sun gear
Backlash between No.1 planetary
4 0.16 – 0.53 1.00
gear and ring gear
Backlash between No. 1 planetary
5 0.14 – 0.44 1.00
gear and No. 1 sun gear
Backlash between No.1 planetary
6 0.36 – 0.65 1.00
carrier and No.2 sun gear
7 Amount of wear on sprocket tooth Repair limit: 6
Build-up welding for
Standard dimension Repair limit rebuilding or
8 Width of sprocket tooth replace
71 68

PC228US-8,PC228USLC-8 60-11
Power train
Sprocket

Sprocket 60-12

Unit: mm

No. Item Criteria Remedy

Standard dimension Repair limit
1 Wear of tooth tip
294.5 282.5
Build-up welding for
2 Thickness of tooth root 17 11
rebuilding or
replace
3 Width of tooth 71 68
Repair limit: 6 (use a full-size drawing of sprocket tooth shape to
4 Wear of tooth shape
judge)

60-12 PC228US-8,PC228USLC-8
 Power train
Sprocket

Full-size drawing of sprocket tooth shape 60-13

a Duplicate the drawing onto an OHP viewgraph at a magnification that restores the scale to the full-size.

PC228US-8,PC228USLC-8 60-13
Undercarriage and frame
Track frame and idler cushion

Undercarriage and frame 60-14

Track frame and idler cushion 60-14
a The following figure shows PC228US-8.

60-14 PC228US-8,PC228USLC-8
 Undercarriage and frame
Track frame and idler cushion

Unit: mm

No. Item Criteria Remedy

Standard dimension Tolerance Repair limit
Vertical Track
107 – –
1 frame
width of idler guide
Idler sup- Build-up welding
105 – –
port for rebuilding or
Track replace
frame
250 – –
Horizontal
2
width of idler guide Idler sup-
port
247.4 – –

Standard dimension Repair limit

Load at
Free length x Installed Free
Installed load installed
Outside diameter length length
length
Standard 126.3 kN 101 kN
3 Recoil spring specifica- 561 x 237 433 534 Replace
tion {12,890 kg} {10,300 kg}
North
America
specifica- 137.3 kN 109.8 kN
tion and
556 x 241 433 532
{14,010 kg} {11,200 kg}
KUK speci-
fication

PC228US-8,PC228USLC-8 60-15
Undercarriage and frame
Idler

Idler 60-16

60-16 PC228US-8,PC228USLC-8
 Undercarriage and frame
Idler

Unit: mm
No. Item Criteria Remedy
Standard dimension Repair limit
1 Outside diameter of protrusion
538 –

2 Outside diameter of tread 500 488

Build-up welding for
3 Thickness of tread 26 20
rebuilding or
replace
4 Difference of tread 19 25

5 Overall width 159 –

6 Width of tread 37.5 –

Standard Tolerance Standard Allowable

Clearance between shaft and bush- dimension Shaft Hole clearance clearance
7
ing - 0.250 + 0.164 0.176 –
65 –
- 0.350 - 0.074 0.514
Standard Tolerance Standard Allowable
Interference between idler and dimension Shaft Hole interference interference Replace bushing
8
bushing + 0.108 - 0.032 0.040 –
72 –
+ 0.008 - 0.062 0.170
Clearance between bushing and Standard size Repair limit
9 support
0.5 – 1.0 –
(Total of both sides)

PC228US-8,PC228USLC-8 60-17
(02)
Undercarriage and frame
Track roller

Track roller 60-18

Unit: mm
No. Item Criteria Remedy
Standard dimension Repair limit
1 Outside diameter of flange
188 –

2 Outside diameter of tread 156 144

Build-up welding for
3 Thickness of tread 44.5 38.5
rebuilding or
replace
4 Overall width 225 –

5 Width of tread 44.5 –

6 Width of flange 25.5 –

Standard Tolerance Standard Allowable

Clearance between shaft and bush- dimension Shaft Hole clearance clearance
7
ing - 0.215 + 0.195 0.215 –
60 –
- 0.315 0 0.510
Replace bushing
Standard Tolerance Standard Allowable
Interference between roller and dimension Shaft Hole interference Interference
8
bushing + 0.153 + 0.030 0.023 –
67 –
+ 0.053 0 0.153
Clearance between bushing and Standard size Repair limit
9 collar Replace
0.5 – 1.0 –
(Total of both sides)

60-18 PC228US-8,PC228USLC-8
 Undercarriage and
Undercarriage and frame
frame
Carrier roller
Carrier roller

Carrier roller 60-19

Unit: mm
No. Item Criteria Remedy
Standard dimension Repair limit
1 Outside diameter of flange
145 –

2 Outside diameter of tread 120 106

3 Width of tread 43 –

4 Thickness of tread 23 16

5 Width of flange 14 –

Standard Tolerance Standard Allowable Replace

Clearance between shaft and bush- dimension Shaft Hole clearance clearance
6
ing - 0.170 + 0.301 0.338 –
40 –
- 0.190 + 0.168 0.491
Standard Tolerance Standard Allowable
Interference between roller and dimension Shaft Hole interference interference
7
bushing + 0.061 0 0.016 –
47 –
+ 0.016 - 0.040 0.101
Standard clearance Allowable clearance
8 End play in axial direction
0.44 – 0.76 –

PC228US-8,PC228USLC-8 60-19
Undercarriage and frame
Track shoe

Track shoe 60-20

a P portion shows the link of bushing press-fitting end.

*1. Triple grouser shoe

*2. Road liner shoe [PC228USLC-8 (North America
specification only)]

60-20 PC228US-8,PC228USLC-8
 Undercarriage and frame
Track shoe

Unit: mm
No. Item Criteria Remedy
Standard dimension Repair limit
1 Link pitch
190.3 193.3
Standard dimension Reverse
Reverse or replace
2 Outside diameter of bushing
59.3 54.3

3 Thickness of bushing 10.4 5.4

Standard dimension Repair limit
4 Link height
105 97
Repair or replace
Thickness of link (bushing press-fit
5 28.5 20.5
part)
6 160.4

7 Shoe bolt pitch 124.4

8 62

9 Inside width 84.8

Overall
10 Link width
45.4

11 Tread width 39.6

Regular 2.5
12 Protrusion of pin
Master 2.5 Adjust or replace

Regular 4.85
13 Protrusion of bushing
Master 0.0

Regular 212
14 Overall length of pin
Master 212

Regular 138.5
Overall length of bush-
15
ing
Master 128.7

16 Thickness of spacer –

17 Bushing 88.2 – 245 kN {9 – 25 ton}

18 Press-fitting force Regular pin 127.4 – 274.4 kN {13 – 28 ton} –

19
Master pin 78.4 – 147 kN {8 – 15 ton}
(*)
* Dry type track link

PC228US-8,PC228USLC-8 60-21
Undercarriage and frame
Track shoe

Unit: mm
No. Item Criteria Remedy
Tightening torque Retightening angle
(Nm {kgm}) (deg.)
a. Regular 490 ± 49
link Triple grouser shoe 120 ± 10
{50 ± 5}
Road liner 549 ± 59
20 Shoe bolt – Retighten
(Rubber pad type) {56 ± 6}
Tightening torque Retightening angle Lower limit torque
b. Master (Nm {kgm}) (deg.) (Nm {kgm})
link
– – –

Tolerance Standard interfer-

Standard dimension
Interference between bushing and Shaft Hole ence
21
link + 0.434 + 0.074
59 0.320 – 0.434
+ 0.394 0
Interference between regular pin + 0.222 - 0.138
22 38 0.300 – 0.422
and link + 0.162 - 0.200
Tolerance
Standard dimension Standard clearance
Clearance between regular pin and Shaft Hole
23
bushing + 0.222 + 0.902
38 0.180 – 0.740 Adjust or replace
+ 0.162 + 0.402
Tolerance Standard interfer-
Standard dimension
24 Interference between master pin Shaft Hole ence
(*) and link + 0.280 + 0.062
37.8 0.188 – 0.280
+ 0.250 0
Tolerance
25 Clearance between master pin and Standard dimension Shaft Hole
Standard clearance
(*) bushing - 0.150 + 0.902
38 0.552 – 1.252
- 0.350 + 0.402
* Dry type track link

60-22 PC228US-8,PC228USLC-8
 Undercarriage and frame
Track shoe

Triple grouser shoe 60-23

Unit: mm

No. Item Criteria Remedy

Standard dimension Repair limit
1 Grouser overall height
26 16

36 26
2 Shoe overall height
(*) 34.5 24.5

10
3 Plate thickness Build-up welding for
(*) 8.5
rebuilding or
replace
4 26
Grouser bottom length
5 19

6 20

7 Grouser tip length 14

8 19

*: The 600 mm wide triple shoe for the PC228US-8 (standard specification) is shown.

PC228US-8,PC228USLC-8 60-23
Undercarriage and frame
Track shoe

Road liner 60-24

Unit: mm

No. Item Criteria Remedy

1 Shoe height 70 Replace

60-24 PC228US-8,PC228USLC-8
 Hydraulic system
Hydraulic tank

Hydraulic system 60-25

Hydraulic tank 60-25

PC228US-8,PC228USLC-8 60-25
Hydraulic system
Main pump

Main pump 60-26

Type: HPV95+95

60-26 PC228US-8,PC228USLC-8
(02)
 Hydraulic system
Main pump

PC228US-8,PC228USLC-8 60-27
(02)
Hydraulic system
Main pump

60-28 PC228US-8,PC228USLC-8
 Hydraulic system
Control valve

Control valve 60-29

General view 60-29

PC228US-8,PC228USLC-8 60-29
Hydraulic system
Control valve

Sectional view 60-30

(1/5)

60-30 PC228US-8,PC228USLC-8
 Hydraulic system
Hydraulic system
Control valve
Control valve

Unit: mm

No. Item Criteria Remedy

Standard dimension Repair limit
Free length x Load at Load at
Installed Free
Outside installed installed
1 Spool return spring length length
diameter length length
407 N 326 N
55.2 x 34.4 51.2 – If damaged or
{41.5 kg} {33.2 kg}
deformed, replace
393 N 315 N
2 Spool return spring 54.5 x 34.8 51.2 – spring.
{40.1 kg} {32.1 kg}
375 N 300 N
3 Spool return spring 54.4 x 34.8 51.2 –
{38.2 kg} {30.6 kg}
421 N 336 N
4 Spool return spring 54.6 x 34.8 51.2 –
{42.9 kg} {34.3 kg}

PC228US-8,PC228USLC-8 60-31
Hydraulic system
Control valve

(2/5)

60-32 PC228US-8,PC228USLC-8
(02)
 Hydraulic system
Control valve

Unit: mm

No. Item Criteria Remedy

Standard dimension Repair limit
Free length x Load at Load at
Installed Free
Outside installed installed
1 Suction valve spring length length If damaged or
diameter length length
deformed, replace
5.5 N 4.4 N
46.8 x 7.5 40.6 – spring.
{0.56 kg} {0.45 kg}
1.5 N 1.2 N
2 Check valve spring 11.5 x 4.6 8.5 –
{0.15 kg} {0.12 kg}

PC228US-8,PC228USLC-8 60-33
Hydraulic system
Control valve

(3/5)

60-34 PC228US-8,PC228USLC-8
 Hydraulic system
Control valve

Unit: mm

No. Item Criteria Remedy

Standard dimension Repair limit
Free length x Load at Load at
Installed Free
Outside installed installed
1 Check valve return spring length length
diameter length length
14.7 N 11.8 N
59.3 x 14.4 43 –
{1.5 kg} {1.2 kg}
13.7 N 11 N
2 Check valve spring 33.8 x 6 29 – If damaged or
{1.4 kg} {1.12 kg}
deformed, replace
170 N 135 N
3 Piston return spring 60.2 x 20 36 – spring.
{17.3 kg} {13.8 kg}
5.9 N 4.71 N
4 Check valve spring 31.5 x 10.3 19.5 –
{0.6 kg} {0.48 kg}
157 N 126 N
5 Piston return spring 88.2 x 28.4 65 –
{16 kg} {12.8 kg}
52.7 N 42.2 N
6 Piston return spring 22.35 x 9.3 13.4 –
{5.37 kg} {4.30 kg}

PC228US-8,PC228USLC-8 60-35
Hydraulic system
Control valve

(4/5)

60-36 PC228US-8,PC228USLC-8
 Hydraulic system
Control valve

Unit: mm

No. Item Criteria Remedy

Standard dimension Repair limit
Free length x Load at Load at
Installed Free
Outside installed installed
1 Spool return spring length length
diameter length length
121 N 96.5 N
36.4 x 21.8 33.0 –
{12.3 kg} {9.84 kg}
250 N 200 N
2 Check valve spring 70.9 x 18.0 56.0 –
{25.5 kg} {20.4 kg}
If damaged or
178 N 142 N
3 Spool return spring 64.5 x 32.3 63.0 – deformed, replace
{18.1 kg} {14.5 kg}
spring.
35.3 N 28.2 N
4 Check valve spring 33.0 x 12.0 26.0 –
{3.6 kg} {2.88 kg}
13.7 N 11.0 N
5 Check valve spring 33.8 x 6.0 29.0 –
{1.4 kg} {1.12 kg}
5.9 N 4.71 N
6 Check valve return spring 31.5 x 10.3 19.5 –
{0.6 kg} {0.48 kg}
50.0 N 40.0 N
7 Piston return spring 30.7 x 20.5 23 –
{5.1 kg} {4.08 kg}

PC228US-8,PC228USLC-8 60-37
Hydraulic system
Control valve

(5/5)

60-38 PC228US-8,PC228USLC-8
 Hydraulic system
Swing motor

Swing motor 60-39

Type: KMF125AB-5

PC228US-8,PC228USLC-8 60-39
Hydraulic system
Swing motor

Unit: mm
No. Item Criteria Remedy
Standard dimension Repair limit
Free length x Load at Load at
Installed Free
Outside diam- installed installed
1 Check valve spring length length If damaged or
eter length length
deformed, replace
3.53 N 2.84 N
57.2 x 20.0 30.0 – spring.
{0.36 kg} {0.29 kg}
13.7 N 11.0 N
2 Shuttle valve spring 16.4 x 8.9 11.5 –
{1.4 kg} {1.12 kg}

60-40 PC228US-8,PC228USLC-8
 Hydraulic system
Travel motor

Travel motor 60-41

Type: HMV110-2

PC228US-8,PC228USLC-8 60-41
Hydraulic system
Travel motor

60-42 PC228US-8,PC228USLC-8
 Hydraulic system
Travel motor

Unit: mm
No. Item Criteria Remedy
Standard dimension Repair limit
Free length x Load at Load at
Installed Free
Outside diam- installed installed
1 Regulator piston spring length length
eter length length
147 N 118 N
52.6 x 20.3 36.0 –
{15.0 kg} {12.0 kg}
If damaged or
54.9 N 43.9 N
2 Regulator piston spring 21.5 x 11.1 17.1 – deformed, replace
{5.6 kg} {4.48 kg}
spring.
1.96 N 1.57 N
3 Check valve spring 13.0 x 6.5 9.5 –
{0.2 kg} {0.16 kg}
7.16 N 5.69 N
4 Check valve spring 32.5 x 6.5 24.2 –
{0.73 kg} {0.58 kg}
427 N 341 N
5 Check valve spring 58.4 x 30.0 42.0 –
{43.5 kg} {34.8 kg}

PC228US-8,PC228USLC-8 60-43
(02)
Hydraulic system
Travel motor

60-44 PC228US-8,PC228USLC-8
 Hydraulic system
PPC valve

PPC valve 60-45

a PPC: Abbreviation for Proportional Pressure Control

Work equipment and swing PPC valve 60-45

PC228US-8,PC228USLC-8 60-45
(02)
Hydraulic system
PPC valve

60-46 PC228US-8,PC228USLC-8
(02)
 Hydraulic system
PPC valve

Unit: mm
No. Item Criteria Remedy
Standard dimension Repair limit
Free length x Load at Load at
Installed Free
Centering spring Outside diam- installed installed
1 length length
(for ports P3 and P4) eter length length
If damaged or
17.7 N 14.1 N
42.5 x 15.5 34.0 – deformed, replace
{1.80 kg} {1.44 kg}
spring
Centering spring 29.4 N 23.5 N
2 44.5 x 15.5 34.0 –
(for ports P1 and P2) {3.0 kg} {2.40 kg}
16.7 N 13.3 N
3 Metering spring 26.5 x 8.15 24.9 –
{1.70 kg} {1.36 kg}

PC228US-8,PC228USLC-8 60-47
Hydraulic system
PPC valve

Travel PPC valve 60-48

60-48 PC228US-8,PC228USLC-8
 Hydraulic system
PPC valve

Unit: mm
No. Item Criteria Remedy
Standard dimension Repair limit
Free length x Load at Load at
Installed Free
Outside diam- installed installed
1 Centering spring length length If damaged or
eter length length
deformed, replace
108 N 86.3 N
48.57 x 15.5 32.5 – spring
{11 kg} {8.8 kg}
16.7 N 13.3 N
2 Metering spring 26.53 x 8.15 24.9 –
{1.7 kg} {1.36 kg}

PC228US-8,PC228USLC-8 60-49
Hydraulic system
PPC valve

R.H. attachment PPC valve 60-50

(with EPC valve) 60-50

Unit: mm
No. Item Criteria Remedy
Standard dimension Repair limit
Free length x Load at Load at
Installed Free
Outside diam- installed installed
1 Centering spring length length If damaged or
eter length length
deformed, replace
125 N 100 N
33.9 x 15.3 28.4 – spring
{12.7 kg} {10.2 kg}
16.7 N 13.3 N
2 Metering spring 22.7 x 8.10 22.0 –
{1.70 kg} {1.36 kg}

60-50 PC228US-8,PC228USLC-8
 Hydraulic system
PPC valve

EPC valve 60-51

Unit: mm
No. Item Criteria Remedy
Standard dimension Repair limit
Free length x Load at Load at If damaged or
Installed Free
Outside diam- installed installed deformed, replace
1 Metering spring length length
eter length length the EPC valve
3.24 N assembly
9.5 8.4 – –
{0.33 kg}

PC228US-8,PC228USLC-8 60-51
Hydraulic system
PPC valve

L.H. attachment PPC valve 60-52

(if equipped) 60-52

Unit: mm
No. Item Criteria Remedy
Standard dimension Repair limit
Free length x Load at Load at
Installed Free
Outside diam- installed installed
1 Centering spring length length If damaged or
eter length length
deformed, replace
125 N 100 N
33.9 x 15.3 28.4 – spring
{12.7 kg} {10.2 kg}
16.7 N 13.3 N
2 Metering spring 22.7 x 8.10 22.0 –
{1.70 kg} {1.36 kg}

60-52 PC228US-8,PC228USLC-8
 Hydraulic system
Solenoid valve

Solenoid valve 60-53

a The figure shows the type for a machine ready for attachments.

PC228US-8,PC228USLC-8 60-53
Hydraulic system
Solenoid valve

Boom RAISE cushion EPC valve 60-54

Unit: mm
No. Item Criteria Remedy
Standard dimension Repair limit
If damaged or
Free Installed Load at Free Load at
deformed, replace
1 Return spring length length installed length length installed length
the EPC valve
3.24 N
9.5 8.4 – – assembly
{0.33 kg}

60-54 PC228US-8,PC228USLC-8
 Hydraulic system
Attachment circuit selector valve

Attachment circuit selector valve 60-5

High-pressure side

Unit: mm
No. Item Criteria Remedy
Standard dimension Repair limit
Free length x Load at Load at
Installed Free If damaged or
Outside diam- installed installed
1 Spool return spring length length deformed, replace
eter length length
spring.
834 N 667 N
132 x 29 114.5 –
{85.0 kg} {68.0 kg}

PC228US-8,PC228USLC-8 60-55
Hydraulic system
Attachment circuit selector valve

Low-pressure side

Unit: mm
No. Item Criteria Remedy
Standard dimension Repair limit
Free length x Load at Load at
Installed Free If damaged or
Outside diam- installed installed
1 Spool return spring length length deformed, replace
eter length length
spring.
28.7 N 22.9 N
33.4 x 11.2 27.3 –
{2.93 kg} {2.34 kg}

60-56 PC228US-8,PC228USLC-8
 Hydraulic system
Attachment circuit selector valve

PC228US-8,PC228USLC-8 60-57
Hydraulic system
Anti-drop valve

Anti-drop valve 60-58

For boom and arm cylinder 60-58
(if equipped)

60-58 PC228US-8,PC228USLC-8
 Hydraulic system
Hydraulic system
Anti-drop valve
Anti-drop valve

Unit: mm

No. Item Criteria Remedy

Standard dimension Repair limit
Free length x Load at Load at
Installed Free
Outside installed installed
1 Check valve spring length length
diameter length length
12.7 N 10.2 N
20.8 x 12.2 13.5 – If damaged or
{1.3 kg} {1.04 kg}
deformed, replace
58.8 N 47.1 N
2 Spool return spring 41.1 x 9.6 35.0 – spring.
{6.0 kg} {4.8 kg}
78.5 N 62.8 N
3 Spool return spring 41.9 x 25.8 41.0 –
{8.0 kg} {6.4 kg}
181 N 145 N
4 Spool return spring 44.6 x 25.6 41.0 –
{18.5 kg} {14.8 kg}

PC228US-8,PC228USLC-8 60-59
Hydraulic system
Center swivel joint

Center swivel joint 60-60

Unit: mm
No. Item Criteria Remedy
Standard dimension Standard clearance Allowable clearance
1 Clearance between rotor and shaft Replace
80 0.056 - 0.105 0.111

60-60 PC228US-8,PC228USLC-8
 Hydraulic
Hydraulic system
system
Center swivel
Center swivel joint
joint

PC228US-8,PC228USLC-8 60-61
Work equipment
Work equipment

Work equipment 60-62

Work equipment 60-62

Unit: mm

No. Item Criteria Remedy

Standard Tolerance Standard Allowable
Clearance between connecting pin
dimension Shaft Hole clearance clearance
1 and bushing of revolving frame and
boom -0.036 +0.135
90 0.110 – 0.206 1.0
-0.071 +0.074
Clearance between connecting pin -0.036 +0.137
2 90 0.113 – 0.208 1.0
and bushing of boom and arm -0.071 +0.077
Clearance between connecting pin -0.030 +0.335 Replace pin or
3 70 0.305 – 0.411 1.0 bushing
and bushing of arm and link –0.076 +0.275
Clearance between connecting pin -0.030 +0.324
4 80 0.300 – 0.400 1.0
and bushing of arm and bucket –0.076 +0.270
Clearance between connecting pin -0.030 +0.337
5 80 0.303 – 0.413 1.0
and bushing of link and bucket –0.076 +0.273
Clearance between connecting pin -0.030 +0.335
6 70 0.305 – 0.411 1.0
and bushing of link and link –0.076 +0.275

60-62 PC228US-8,PC228USLC-8
 Work equipment
Work equipment

PC228US-8,PC228USLC-8 60-63
Work equipment
Dimensions of components

Dimensions of components 60-64

Arm

60-64 PC228US-8,PC228USLC-8
 Work equipment
Dimensions of components

Unit: mm

PC228US-8, PC228USLC-8
No. Tolerance
Measurement point Standard dimension
Shaft Hole
- 0.030 + 0.100
1 – 80
- 0.076 0
+ 1.5
Arm side 109.3
0
2
Cylinder head side 106 ±1.2
+ 0.5
Boom side 310
0
3
0
Arm side 305.5
- 0.5
- 0.036 + 0.054
4 – 90
- 0.071 0
5 – 402.1 ±1.0

6 – 187.2 ±0.5

7 – 829.1 ±1.0

8 – 2,919 –

9 – 2,630.5 ±1.0

10 – 410 ±1.0

11 – 640 ±0.2

12 – 600 ±0.5

13 – 458.1 –

14 – 1,486 –
- 0.030 + 0.100
15 – 80
- 0.076 0
Link side 325 ±0.5
16
Bucket side 326.5 ±1.0
- 0.030 + 0.100
17 – 80
- 0.076 0
0
Arm boss (without bushing) 311
- 0.5
18
When press-fitting bushing
325 ±2.5
(with bushing)
Min. 1,680 –
19
Max. 2,800 –

PC228US-8,PC228USLC-8 60-65
Work equipment
Dimensions of components

Bucket

60-66 PC228US-8,PC228USLC-8
 Work equipment
Dimensions of components

Unit: mm

PC228US-8, PC228USLC-8
No.
Measurement point Standard dimension Tolerance

1 – 457.6 ± 0.5

2 – 22 ± 0.5

3 – 92 °45 ´ –

4 – 458.1 –

5 – 1,477.3 –

6 – 158.6 –

7 – 45 ° –

8 – 15 °54 ´ –
+ 0.1
9 – 80
0
10 – 90 –
+ 0.1
11 – 110
0
12 – 326.5 ±1.0

13 – 56 –

14 – 106 –

15 – 470 –

16 – 23.5 –

17 – 140 –

18 – 150 –

19 – 190 –

20 – 146 –

21 – 150 –
+ 2.0
22 – 348.5
0
23 – 56 –

24 – 38 –

25 – 131.6 –

26 – 137.4 –

27 – 107 –

28 – 85 –

PC228US-8,PC228USLC-8 60-67
Work equipment
Work equipment cylinder

Work equipment cylinder 60-68

Boom cylinder

Arm cylinder

Bucket cylinder

60-68 PC228US-8,PC228USLC-8
 Work equipment
Work equipment cylinder

Unit: mm
No. Item Criteria Remedy
Cylinder Standard Tolerance Standard Allowable
name dimension Shaft Hole clearance clearance
Boom - 0.036 + 0.222
(Standard)
85 0.083 – 0.312 0.412
- 0.090 + 0.047
Clearance between pis- Boom - 0.036 + 0.257
1 (large 90 0.084 – 0.347 0.447 Replace bushing
ton rod and bushing - 0.090 + 0.048
diameter)
- 0.036 + 0.222
Arm 95 0.083 – 0.312 0.412
- 0.090 + 0.047
- 0.030 + 0.258
Bucket 80 0.078 – 0.334 0.434
- 0.076 + 0.048
Boom - 0.030 + 0.190
(Standard)
80 0.100 – 0.250 1.0
- 0.060 + 0.070
Boom - 0.030 + 0.190
Clearance between pis- (large 80 0.100 – 0.250 1.0
diameter) - 0.060 + 0.070
2 ton rod supporting shaft
and bushing - 0.030 + 0.190
Arm 80 0.100 – 0.266 1.0
- 0.076 + 0.070
- 0.030 + 0.424
Bucket 70 0.380 – 0.500 1.0
- 0.076 + 0.350 Replace pin or
Boom - 0.030 + 0.165 bushing
(Standard)
70 0.075 – 0.225 1.0
- 0.060 + 0.045
Boom - 0.030 + 0.165
Clearance between cyl- (large 70 0.075 – 0.225 1.0
diameter) - 0.060 + 0.045
3 inder bottom support
shaft and bushing - 0.030 + 0.190
Arm 80 0.100 – 0.266 1.0
- 0.076 + 0.070
- 0.030 + 0.165
Bucket 70 0.075 – 0.225 1.0
- 0.060 + 0.045
Boom
(Standard)
270 ± 39.2 Nm {27.5 ± 4.0 kgm}
Boom
(large 270 ± 39.2 Nm {27.5 ± 4.0 kgm}
Tightening torque for diameter)
4
cylinder head
Arm 373 ± 53.9 Nm {38.0 ± 5.5 kgm}

Bucket 270 ± 39.2 Nm {27.5 ± 4.0 kgm}

Boom
(Standard)
294 ± 29.4 Nm {30.0 ± 3.0 kgm}
Boom
(large 294 ± 29.4 Nm {30.0 ± 3.0 kgm}
Tightening torque for diameter)
5 Retighten
cylinder piston
Arm 294 ± 29.4 Nm {30.0 ± 3.0 kgm}

Bucket 294 ± 29.4 Nm {30.0 ± 3.0 kgm}

Boom
(Standard)
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
Boom
Tightening torque for (large 58.8 – 73.5 Nm {6.0 – 7.5 kgm}
6 cylinder piston lock diameter)
screw Arm 58.8 – 73.5 Nm {6.0 – 7.5 kgm}

Bucket 58.8 – 73.5 Nm {6.0 – 7.5 kgm}

PC228US-8,PC228USLC-8 60-69
Work equipment
Work equipment cylinder

60-70 PC228US-8,PC228USLC-8
SEN0533431-00 80-1

PC228US-8,PC228USLC-8

HYDRAULIC EXCAVATOR
Shop Manual 80-1

PC228US-8
PC228USLC-8

Machine model Serial number

PC228US-8 50001 and up
PC228USLC-8 50001 and up

80 Appendix 80-1

PC228US-8,PC228USLC-8 80-1
(01)
Contents

Contents 80-2
80 Appendix
Air conditioner ......................................................................................................................... 80- 3
Precautions for refrigerant ................................................................................................... 80- 3
Air conditioner component ................................................................................................... 80- 4
Configuration and function of refrigeration cycle.................................................................. 80- 6
Outline of refrigeration cycle ................................................................................................ 80- 8
Air conditioner unit ............................................................................................................... 80- 10
Air conditioner controller ...................................................................................................... 80- 15
Compressor ......................................................................................................................... 80- 16
Condenser and Modulator ................................................................................................... 80- 17
Sensor.................................................................................................................................. 80- 18
Procedure for testing and troubleshooting ........................................................................... 80- 20
Circuit diagram and arrangement of connector pins ............................................................ 80- 22
System diagram ................................................................................................................... 80- 24
Detail of air conditioner unit ................................................................................................. 80- 26
Parts and connectors layout ................................................................................................ 80- 28
Testing air leakage (duct) .................................................................................................... 80- 32
Testing with self-diagnosis function ..................................................................................... 80- 33
Testing vent (mode) changeover ......................................................................................... 80- 36
Testing FRESH/RECIRC air changeover ............................................................................ 80- 37
Testing inner sensor ............................................................................................................ 80- 38
Testing outer sensor ............................................................................................................ 80- 39
Testing sunlight sensor ........................................................................................................ 80- 40
Testing (dual) pressure switch for refrigerant ...................................................................... 80- 41
Testing relays....................................................................................................................... 80- 42
Troubleshooting chart 1 ....................................................................................................... 80- 44
Troubleshooting chart 2 ....................................................................................................... 80- 46
Information in troubleshooting table..................................................................................... 80- 48
Troubleshooting for power supply and CAN communication system (Air conditioner does not operate)
............................................................................................................................................. 80- 50
Troubleshooting for compressor and refrigerant system (Air is not cooled) ........................ 80- 54
Troubleshooting for blower motor system (No air comes out or air flow is abnormal) ......... 80- 57
Troubleshooting for temperature control.............................................................................. 80- 60
Troubleshooting for vent (mode) changeover ...................................................................... 80- 62
Troubleshooting for FRESH/RECIRC air changeover ......................................................... 80- 64
Troubleshooting for temperature sensor system ................................................................. 80- 66
Troubleshooting with gauge pressure.................................................................................. 80- 68
Connection of service tool.................................................................................................... 80- 70
Precautions for disconnecting and connecting air conditioner piping .................................. 80- 72
Handling of compressor oil .................................................................................................. 80- 74
Desiccant replacement procedure ....................................................................................... 80- 76

80-2 PC228US-8,PC228USLC-8
(01)
 Air conditioner
Precautions for refrigerant

Air conditioner 80-3

Precautions for refrigerant 80-3

k Collect the refrigerant (Air conditioner gas:

R134a) from air conditioner circuit before
disconnecting air conditioner hose to re-
place air conditioner unit, air conditioner
compressor or air conditioner condenser
and so on.
a Ask a qualified person for collecting, adding and
filling operations of the refrigerant (R134a).
a Never release the refrigerant (R134a) to the atmo-
sphere.
k If refrigerant gas (R134a) gets in your eyes,
you may lose your sight. And if it touches
your skins, you may suffer from frostbite. Ac-
cordingly, put on the safety glasses, gloves
and working suits with long sleeves while
you are collecting the refrigerant (R134a) or
filling the air conditioner circuit with the re-
frigerant (R134a). Collecting and filling work
must be conducted by a qualified person.

PC228US-8,PC228USLC-8 80-3
(01)
Air conditioner
Air conditioner component

Air conditioner component 80-4

80-4 PC228US-8,PC228USLC-8
(01)
 Air conditioner
Air conditioner component

1. Compressor A: Front warm/cool air vent

2. Condenser B: Rear warm/cool air vent
3. Modulator* C: Foot warm/cool air vent
4. Hot water piping D: Defroster warm
5. Hot water return piping E: RECIRC inlet
6. Refrigerant piping F: FRESH inlet
7. Dual pressure switch
8. Sight glass
9. Outside air temperature sensor Specification 80-5
10. Air conditioner unit Refrigerant R134a
11. Recirculation air filter Refrigerant refilling level (g) 790 ± 50
12. Fresh air filter
13. Machine monitor
14. Sunlight sensor
15. Air conditioner controller

*: Receiver drier and condenser are integrated on this product. The existing receiver drier unit is called "mod-
ulator" here.

PC228US-8,PC228USLC-8 80-5
(01)
Air conditioner
Configuration and function of refrigeration cycle

Configuration and function of refrigeration cycle 80-6

Cycle Compression Condensation Expansion Evaporation
(Component) (Compressor) (Condenser) (Expansion valve) (Evaporator)
In operator cab In operator cab
Location Engine compartment Front of radiator
(In air conditioner unit) (In air conditioner unit)
Circulates refrigerant
gas and increases its Lowers temperature and Evaporates refrigerant to
Condenses refrigerant
temperature and pres- pressure of refrigerant liq- absorb heat from air
to discharge heat
sure so that it can be uid and gas for easy evap- around evaporator, and
Function absorbed in evaporator.
liquefied easily in con- oration with throttle. cool the air.
(condensation of refrig-
denser. Controls flow rate, too. (Evaporation of refriger-
erant)
(Compression of (Throttle of refrigerant) ant)
refrigerant)
GasoGas GasoLiquid
LiquidoLiquid and gas Liquid and gas oGas
State of refriger-
ant Adiabatic compres- Cnstant pressure
Adiabatic expansion Cnstant pressure change
sion change

80-6 PC228US-8,PC228USLC-8
(01)
 Air conditioner
Configuration and function of refrigeration cycle

PC228US-8,PC228USLC-8 80-7
(01)
Air conditioner
Outline of refrigeration cycle

Outline of refrigeration cycle 80-8

The refrigeration cycle is comprised of 4 cycles. The refrigerant is circulated while repeatedly vaporizing and
liquefying.

1. Compression (Compressor) The expansion valve controls the refrigerant

The compressor sucks in the refrigerant that has feed rate so that the optimum quantity of liquid
been vaporized in the evaporator and refrigerant is supplied to the evaporator.
compresses it into a state where it can be easily
liquefied at the ambient temperature. (*1) Throttle action
The gaseous refrigerant sucked into the If there is a narrow section in the passage
compressor cylinder is compressed to a temper- through which liquid is flowing at a constant rate,
ature and pressure at which it can be easily a resistance to the flow will be generated.
liquefied when cooled to the ambient tempera- The liquid expands when it passes through the
ture. narrow section and rushes into the passage
where the sectional area is larger, and conse-
2. Condensation (Condenser) quently, its pressure and temperature are
The condenser cools and liquefies the high pres- reduced.
sure and high-temperature gaseous refrigerant No heat is transferred from or to the outside
sent from the compressor. during the throttle action.
The heat released to the outside from the
condenser is called condensation heat. 4. Evaporation (Evaporator)
The amount of condensation heat is the sum The evaporator evaporates the liquid refrigerant
total of the heat absorbed by the evaporator from (superheated vapor).
the air in the cab and the quantity of the work The refrigerant evaporates, while absorbing an
applied (the value converted into a heat quantity) amount of heat necessary for evaporation (evap-
by compression of the compressor. oration heat) from the air around the cooling fins
The refrigerant liquefied in the condenser is sent (air in the cab).
to the receiver drier, where moisture is removed. After the heat has been removed, the cooled air
In the compression cycle, the gaseous refrig- is sent into the cab by the blower fan, reducing
erant and liquid refrigerant coexist. the temperature inside the cab.
The temperature (condensation temperature) The mist refrigerant that has been sent from the
and the pressure (condensation pressure) at expansion valve coexists with the evaporated
which the gaseous refrigerant is liquefied are refrigerant in the evaporator
proportional to each other. The temperature (evaporation temperature) and
the pressure (evaporation pressure) at which the
Reference: The pressure varies depending on liquid refrigerant is evaporated are proportional
the condensation temperature of the refrigerant. to each other.
The compressor sucks in the evaporated refrig-
3. Expansion (Expansion valve) erant in order to keep the pressure level in the
The expansion valve reduces the liquid refrig- evaporator as low as possible so that the liquid
erant pressure to a level where liquid refrigerant refrigerant can be evaporated at a much lower
can be easily evaporated by the throttle action temperature.
(*1).
The action of reducing the liquid refrigerant pres- Relationship between refrigerant and defective
sure to a level where it can be easily evaporated air conditioning 80-8
before it is sent to the evaporator is called q The refrigerant circulates in the refrigeration cir-
expansion. cuit while repeating the refrigeration cycle to ex-
The expansion valve, which reduces the refrig- pel the heat from inside the cab.
erant pressure, also adjusts the refrigerant flow q If there is an insufficient quantity of refrigerant,
rate simultaneously. all of it will be evaporated while it is passing
The quantity of the liquid refrigerant that can be through the evaporator. This causes evaporator
evaporated in the evaporator depends on the efficiency to deteriorate, which will result in de-
amount of heat (refrigeration load) to be fective air conditioning.
removed under the specific evaporation temper-
ature (evaporation pressure).

80-8 PC228US-8,PC228USLC-8
(01)
 Air conditioner
Outline of refrigeration cycle

q If there is excessive refrigerant, not all of it will be

evaporated and part of it will be sucked into the
compressor in liquid form, which will cause the
compressor to compress the liquid and may
damage the components.
q If water gets into the refrigeration circuit, it will
freeze at a small hole in the expansion valve,
lower the refrigerant flow, and may result in de-
fective air conditioning.

PC228US-8,PC228USLC-8 80-9
(01)
Air conditioner
Air conditioner unit

Air conditioner unit 80-10

80-10 PC228US-8,PC228USLC-8
(01)
 Air conditioner
Air conditioner unit

A: Refrigerant inlet (from condenser) Vent (mode) changeover 80-1

B: Refrigerant outlet (to compressor) q Whenever a vent switch is operated on the ma-
C: Hot water inlet chine monitor, mode data is sent to the air con-
D: Hot water outlet ditioner controller. The air conditioner controller
controls the mode changeover servomotor (7) to
1. Evaporator adjust the opening angle of the door (8) and thus
2. Heater core perform vent changeover.
3. Expansion valve a The defroster/face changeover door is located
4. Blower fan, blower motor inside the duct. (See "Testing vent (mode)
5. Air mix servomotor changeover.")
6. Air mix door
7. Mode changeover servomotor FRESH/RECIRC air changeover 80-1
8. Mode changeover door q Whenever a FRESH/RECIRC air changeover
9. FRESH/RECIRC air changeover servo motor switch is operated on the machine monitor,
10. FRESH/RECIRC air changeover door FRESH/RECIRC air changeover setting data is
11. Power transistor sent to the air conditioner controller. The air con-
12. Evaporator temperature sensor ditioner controller controls FRESH/RECIRC air
13. Inside air temperature sensor changeover servomotor (9) to open and close
14. Recirculation air filter FRESH/RECIRC air changeover door (10).

Outline 80-1 Automatic air conditioning 80-1

q The air conditioner unit consists of the evapora- q The inside air temperature sensor (13) detects
tor (1) and heater core (2), and is used to cool the room temperature based on changes in re-
down or warm up the air in the cab. sistance. The air conditioner controller detects
the room temperature by converting the changes
Temperature control 80-1 in the resistance of the inside air temperature
q Whenever a temperature control switch is oper- sensor (13) into voltage changes.
ated on the machine monitor, temperature set- The air conditioner controller checks the voltage
ting data is sent to the air conditioner controller, of the inside air temperature sensor (13) and
which is located behind the operator seat. The controls the room temperature so that it matches
air conditioner controller controls the air mix ser- the setting made on the machine monitor.
vomotor (5) and changes the angle of the air mix Data from the outside air temperature sensor
door (6) in order to adjust the temperature. and the sunlight sensor is also taken into consid-
eration when adjusting the inside temperature.
Overcooling (freezing) prevention 80-1
q The resistance of the evaporator temperature a Two fuses (5 A) for the air conditioner unit are at-
sensor (12) changes in response to tempera- tached to the harness.
ture. a The door is the same as the damper.
q The air conditioner controller detects the temper-
ature of the evaporator (1) by converting the
changes in the resistance of the evaporator tem-
perature sensor (12) into voltage changes.
q The air conditioner controller performs control to
prevent freezing of the evaporator (1) by operat-
ing the compressor clutch relay (*) to stop the
compressor.
*: See "Parts and connectors layout" for details re-
garding the compressor clutch relay.

Air flow control 80-1

q Whenever an air flow control switch is operated
on the machine monitor, air flow setting data is
sent to the air conditioner controller. The air con-
ditioner controller controls the blower motor us-
ing the power transistor (11) in order to adjust
the air flow.

PC228US-8,PC228USLC-8 80-11
(01)
Air conditioner
Air conditioner unit

Functions of main component parts 80-12 q When the potential difference fails to reach a
Evaporator 80-12 predefined voltage for control of the servomotor,
q Evaporator (1) is cooled by the low-pressure, the air conditioner controller notifies the machine
low-temperature refrigerant gas being sent from monitor of an abnormality. A red "Air conditioner
expansion valve (3). Air from the blower fan is Error" is displayed on the air conditioner control
cooled and dehumidified when passing through screen of the machine monitor.
the evaporator fins. a FRESH/RECIRC air changeover servo motor
does not feature a variable resistance, and
Heater core 80-12 therefore, does not have a self-diagnosis
q Heater core (2) is warmed by the hot water (en- function.
gine coolant) being sent from the engine. Air a If attempting to operate a servomotor during in-
from the blower fan is warmed when passing specting, do not supply power directly between
through the heater core fins. servomotor terminals (6) and (7).

Evaporator temperature sensor 80-12

q In order to prevent freezing of the evaporator,
the air conditioner controller detects the temper-
ature of the evaporator based on changes in the
resistance of the evaporator temperature sen-
sor.

Servomotors 80-12

a Servomotors are used to adjust the temperature

(air mix) and to perform vent (mode) change-
over.

q Whenever a switch on the machine monitor is

operated, the air conditioner controller delivers
power to the servomotor by raising the voltage
between terminals (6) and (7) to 24 V. (The rota-
tion direction changes based on the supply po-
larity.)

q The servomotor contains a variable resistance,

and its resistance value changes as the motor
turns.
q The air conditioner controller delivers voltage at
5 V to the variable resistance and detects motor
rotation based on the potential difference.
q When the door (damper) reaches the position
specified by each switch, the air conditioner con-
troller stops the supply of current to the servomo-
tor, then the corresponding door stops.

80-12 PC228US-8,PC228USLC-8
(01)
 Air conditioner
Air conditioner unit

Expansion valve 80-13

A: When evaporator outlet temperature is high Structure 80-13

B: When evaporator outlet temperature is low q The box-type expansion valve (1) consists of
C: From receiver drier (high-pressure refrigerant) needle valve (1a), spring (1b), etc.
D: To compressor (low-pressure refrigerant) q Refrigerant gas (2) is sealed in the diaphragm
chamber (hatched area) outside diaphragm
1. Expansion valve (1a-1) of needle valve (1a).
la. Needle valve q The opening angle of needle valve (1a) is deter-
la-1. Diaphragm mined based on the balance between the reac-
1a-2. Thermoprobe tion force exerted by spring (1b) in a rightward
1b. Spring direction, and force (Fg) of refrigerant gas (2)
2. Refrigerant gas pushing needle valve (1a) through diaphragm
3. Evaporator (1a-1) in a leftward direction.
q The refrigerant flow rate flowing from the receiv-
Outline 80-13 er drier to evaporator (3) is determined based on
q The expansion valve converts high-pressure the opening angle of needle valve (1a).
and high-temperature liquid refrigerant from the
receiver drier to low-pressure, low-temperature
misty refrigerant through the throttle action.
q It controls the flow rate of refrigerant by changing
the level of throttling depending on the tempera-
ture in the cab.
q The temperature of the air blown out of the air
vent is adjusted depending on the volume of re-
frigerant circulating in the evaporator (3).

PC228US-8,PC228USLC-8 80-13
(01)
Air conditioner
Air conditioner unit

Operation 80-14 Dual pressure switch 80-14

q Thermoprobe (1a-2) senses the refrigerant tem- a The dual pressure switch is mounted on the air
perature after it passes through the evaporator conditioner hose under the floor.
(3). q The dual pressure switch turns "OFF" when the
q After the refrigerant passes through evaporator refrigerant circuit pressure becomes abnormally
(3), its temperature is transferred to the refriger- low or abnormally high.
ant gas (2) in the diaphragm chamber (hatched q When the dual pressure switch turns "OFF", the
area) through the thermoprobe (1a-2). air conditioner controller turns the compressor
q The pressure of the refrigerant gas (2) sealed in clutch relay "OFF". As a result, the compressor's
the diaphragm chamber (hatched area) changes magnet clutch is released and air conditioner
in response to the temperature change of the components are protected.
thermoprobe (1a-2), which therefore changes
the force (Fg) pushing the needle valve (1a).
q The opening angle of the needle valve (1a) is de-
termined based on the balance between the re-
action force exerted by the spring (1b) in a
rightward direction, and the force (Fg) of the re-
frigerant gas (2) pushing the needle valve (1a)
through the diaphragm (1a-1) in a leftward direc-
tion.

When evaporator (3) outlet temperature is high: 80-14

[Air in the cab is not cooled: condition (A) in the
figure] 80-14
q The pressure of the refrigerant gas (2) in the di-
aphragm chamber is high and the volume is in- a LA or low: Abnormally low pressure
creased. a HA or high: Abnormally high pressure
q The force (Fg) of the refrigerant gas (2) pushing
the needle valve (1a) is increased, and the nee- LA: 0.20 MPa {2 kg/cm2}
dle valve (1a) moves leftward. LB: 0.02 MPa {0.2 kg/cm2}
q As a result, the opening angle of the needle HA: 3.14 MPa {32 kg/cm2}
valve (1a) is increased and the refrigerant flow HB: 0.59 MPa {6 kg/cm2}
rate to the evaporator (3) is increased to improve
cooling capacity.

When evaporator (3) outlet temperature is low: 80-14

[Air in the cab is already cooled: condition (B) in
the figure] 80-14
q The pressure of the refrigerant gas (2) in the di-
aphragm chamber is low and the volume is de-
creased.
q The force (Fg) of the refrigerant gas (2) pushing
the needle valve (1a) is reduced, and the needle
valve (1a) is moved rightward by the spring force
(1b).
q The opening angle of the needle valve (1a) is re-
duced and the refrigerant flow rate to the evapo-
rator (3) is reduced to lower the cooling capacity.

80-14 PC228US-8,PC228USLC-8
(01)
 Air conditioner
Air conditioner controller

Air conditioner controller 80-15

a See "System Diagrams" for details regarding in-

put/output signals.

PC228US-8,PC228USLC-8 80-15
(01)
Air conditioner
Compressor

Compressor 80-16

A: Refrigerant inlet (from air conditioner unit) Function 80-16

B: Refrigerant outlet (to condenser) q Other than circulating the refrigerant, compres-
C: Pulley sor compresses the refrigerant gas from the
D: Relief valve evaporator to a high-pressure, high-temperature
misty refrigerant so that it may be easily regen-
erated (liquefied) at normal temperature.
q The magnetic clutch is built in and the clutch is
engaged by the evaporator temperature and re-
frigerant pressure. By the engagement of the
cluch, the shaft in the compressor rotates to op-
erate the compressor.
Specification 80-16
Piston capacity
157.3
(cc/rev)
Allowable maximum speed
6,000
(rpm)
Denso: ND-OIL8 (For
Refrigerant oil used
R134a)
Refrigerant oil refilling volume
180
(cc)

80-16 PC228US-8,PC228USLC-8
(01)
 Air conditioner
Condenser and Modulator

Condenser and Modulator 80-17

A: Refrigerant inlet (from compressor)

B: Refrigerant outlet (to air conditioner unit)

Function 80-17 Function 80-17

q Condenser (1) q Modulator (2)
It cools and liquefies the high-pressure, a This has desiccant in it. See "Desiccant replace-
high-temperature misty refrigerant from the ment procedure".
compressor. It is used to store liquefied high-pressure,
a If the fin is crushed or is clogged with dust, heat high-temperature misty refrigerant from the
exchange efficiency is reduced and complete liq- condenser. It is capable of completely liquefying
uefaction of refrigerant becomes impossible. As the refrigerant even when bubbles are contained
a result, pressure in refrigerant circulation circuit in the refrigerant due to the condenser condition
is increased, applying extra load to the engine or in heat dissipation.
reducing cooling effect. Take extreme care not It eliminates foreign substances in the circulation
to crush or damage the fins when handling them line and moisuture in the refrigerant by use of the
or checking them in daily inspection. built-in filter and desiccant.

Specification 80-17 Specification 80-17

Fin pitch (mm) 4.0 Weight of desiccating 290
Height x Width x Thickness agent (g)
421 x 540 x 16
(mm)
Weight (kg) 3.2

PC228US-8,PC228USLC-8 80-17
(01)
Air conditioner
Sensor

Sensor 80-18

Sunlight sensor 80-18 Outside air temperature sensor 80-18

1. Connector 1. Connector
2. Sensor 2. Sensor

Outline 80-18 Outline 80-18

q The sunlight sensor is mounted on top of the ma- q The outside air temperature sensor is installed in
chine monitor. the battery room at the rear left of the machine.
q It detects the strength of incident sunlight and q The outside air temperature sensor has feature
sends signals to the air conditioner controller. of change in resistance by temperature change,
q When performing automatic air conditioning, the therefore, can detect the ambient temperature.
air conditioner controller controls the blower mo- q The air conditioner controller detects the ambi-
tor and the air mix servomotor in order to adjust ent temperature by converting the changes in
the temperature and air flow. the resistance of the outside air temperature
sensor into voltage changes.
Output characteristics 80-18 q When performing automatic air conditioning, the
air conditioner controller controls the blower mo-
tor and the air mix servomotor in order to adjust
the temperature and air flow.

80-18 PC228US-8,PC228USLC-8
(01)
 Air conditioner
Sensor

PC228US-8,PC228USLC-8 80-19
(01)
Air conditioner
Procedure for testing and troubleshooting

Procedure for testing and troubleshooting 80-20

The air conditioner is provided with self-diagnosis functionality in order to provide for inspection of its main
components. Specifically, the operation of sensors and servomotors can be examined.
If a troubled section is detected, every part of that section must be inspected.

1. After basic check, find the troubled section according to the detected trouble of the air conditioner.
2. Narrow down the sections with the self-diagnosis function (See “Check with self-diagnosis”).
If, however, the entire air conditioner unit fails to operate, inspect for problems with the supply of power to
the air conditioner controller and with CAN communication between the machine monitor and the air condi-
tioner controller.
If any part of the air conditioner unit can operate, it will indicate that the air conditioner controller is
receiving power normally and that CAN communication between the machine monitor and the air condi-
tioner controller is normal.
3. After finding out the troubled section, inspect the component parts in that section and repair the troubled
part.

Basic check and troubleshooting sequence

80-20 PC228US-8,PC228USLC-8
(01)
 Air conditioner
Procedure for testing and troubleshooting

*1: By error display or abnormal display on “Abnormality Record” screen on machine monitor.
*2: Simple checking of refrigerant volume by sight glass.
Start up the engine, set the air conditioner switch to ON, and then wait for five minutes before proceeding
with the inspection.
A) If the continuous stream of bubbles can be seen, the system contains insufficient refrigerant.
B) If the bubbles can be seen intermittently, the refrigerant volume is sufficient.
C) If no bubbles can be seen (i.e., the liquid is perfectly clear), the system contains too much refrigerant
or no refrigerant at all.
The above should be treated as general guidelines as certain exceptions do exist.
See "Troubleshooting with gauge pressure" and use gauge pressure to determine whether or not the
condition is normal.

S: Sight glass condition

R: Receiver drier internal condition
LR: Liquid refrigerant

*3: If any leakage of refrigerant is occurring, the compressor oil circulating within the air conditioner circuit will
definitely be leaking from the same point.
In such a case, retighten in accordance with the table of retightening torques from "Precautions for discon-
necting and connecting air conditioner piping."

*4: Start the engine and perform the check with the air conditioner switch set to ON.

PC228US-8,PC228USLC-8 80-21
(01)
Air conditioner
Circuit diagram and arrangement of connector pins

Circuit diagram and arrangement of connector pins 80-2

80-22 PC228US-8,PC228USLC-8
(01)
 Air conditioner
Circuit diagram and arrangement of connector pins

PC228US-8,PC228USLC-8 80-23
(01)
Air conditioner
System diagram

System diagram 80-24

a This air conditioner has automatic temperature control.

80-24 PC228US-8,PC228USLC-8
(01)
 Air conditioner
System diagram

Input and output signals of the air conditioner q Operation of air conditioner controller
controller 1. Performing CAN communication with the
Controller side connector: AMP 040-36PM machine monitor, the air conditioner controller
Harness side connectors: [1], [2] controls the air conditioner unit by inputting
[1]AMP 040-16PF switches associated with air conditioning.
Pin Input/o 2. The air conditioner controller controls three
Symbol Signal name servomotors located inside the air conditioner
No. utput
1 – – – unit in order to adjust the temperature (airmix),
A/M servo potentiometer volt- perform vent (mode) changeover, and perform
2 A/M P Input
age FRESH/RECIRC air changeover.
Servo potentiometer 5 V 3. The air conditioner controller controls the
3 POT 5 V Output
power supply ON/OFF condition of the blower main relay (i.e.,
(Dual) pressure switch
4 PRESS Input a switch for blowing air) and of the compressor
(Refrigerant pressure)
5 – – – clutch relay (i.e., a switch for activating the
6 +24 V bk Backup power supply Input compressor).
7 BLOW F/B Blower feedback signal Input 4. The air conditioner controller controls the air flow
Power transistor control sig- volume using the power transistor.
8 PTR B Output
nal a The power transistor has an overcurrent pre-
Blow out (mode) servo poten- vention fuse in it.
9 MODE P Input
tiometer voltage 5. The air conditioner controller detects the evapo-
10 – – –
11 THI Inside air temperature sensor Input
rator temperature using the evaporator tempera-
Evaporator temperature sen- ture sensor.
12 THEVA Input 6. In order to prevent freezing of the evaporator,
sor
Outside air temperature sen- the air conditioner controller controls the
13 THO Input
sor compressor by turning the compressor clutch
14 – – – relay ON and OFF.
15 SS Sunlight sensor Input a When the dual pressure switch detects a
16 GND GND Input
pressure abnormality (i.e., turns OFF), the air
[2]AMP 040-20PF conditioner controller turns the compressor
Pin Input/o clutch relay OFF, and therefore, the com-
Symbol Signal name pressor stops operating.
No. utput
Input/ 7. When performing automatic air conditioning, the
17 CAN_H CAN communication (H)
output air conditioner controller controls the inside air
Input/ temperature to the set temperature based on
18 CAN_L CAN communication (L)
output data from the sunlight sensor, the outside air
Recirculated air and fresh air temperature sensor, and the inside air tempera-
19 R/F A Output
servo terminal A
ture sensor.
Recirculated air and fresh air
20 R/F B Output 8. The air conditioner controller has the self-diag-
servo terminal B
21 A/M A A/M servo terminal A Output nosis function. If any abnormality is detected, the
22 A/M B A/M servo terminal B Output control amplifier notifies it to the machine
Blow out (mode) servo termi- monitor by the CAN communication. Then, the
23 MODE A Output
nal A letters of "A/C Controller Error" are displayed red
Blow out (mode) servo termi- on the air conditioner operation screen of the
24 MODE B Output
nal B machine monitor.
25 +24 V Power supply Input
26 – – –
27 GND S Sensor GND Input
28 – – –
29 – – –
30 – – –
31 – – –
32 – – –
33 – – –
34 – – –
35 CCRL Compressor clutch relay Output
36 BLOW RL Blower main relay Output
q A/M: Air mix
q F/B: Feed back
q R/F: Recirculation/Fresh

PC228US-8,PC228USLC-8 80-25
(01)
Air conditioner
Detail of air conditioner unit

Detail of air conditioner unit 80-26

80-26 PC228US-8,PC228USLC-8
(01)
 Air conditioner
Detail of air conditioner unit

1. Foot door
2. FRESH/RECIRC air changeover door
3. Inside air temperature sensor
4. Expansion valve
5. Fuse (5 A)
6. FRESH/RECIRC air changeover servomotor
A: Recirculation air port
B: Fresh air port

[1], [2]: Control amplifier connectors

[3]: Blower (fan) motor connector
[4]*: Power transistor (PTR) connector
[5]*: Vent (mode) servomotor connector
[6]*: Temperature adjustment (air mix) servomotor
connector
[7]: FRESH/RECIRC air changeover servomotor
connector
[8]: Inner sensor connector
[9]: Evaporator temperature sensor connector
*: Although shown in the circuit diagram, these con-
nectors cannot be seen from outside.
a Connectors [3], [7], and [9] also cannot be seen
with the air conditioner unit assembled.

PC228US-8,PC228USLC-8 80-27
(01)
Air conditioner
Parts and connectors layout

Parts and connectors layout 80-28

a There are five fuses in total. Three are located a Condition with cover removed
inside the fuse box behind the left side of the op- q R20: Blower main relay
erator's seat. The remaining two are mounted on q R21: Compressor clutch relay
the harness between the air conditioner unit and q (4): Air conditioner controller
the controller. q (5): Fuse 5 A
a The air conditioner unit is located below the op- For supply of power to air conditioner unit
erator's seat. and air conditioner controller (including
a Rotate the unit 90 degrees. primary power for the blower main relay
1. Open the cover of the fuse box located behind and the air conditioner compressor relay,
the left side of the operator's seat. and power for FRESH/RECIRC air
(See fuse mounting positions in "Trouble- changeover servo motor )
shooting.") q Part No. of fuse
q No. 11 (20 A) from fuse box: ND93940-05002
For supply of power to blower (fan) and air q [1] and [2]: Connector of air conditioner
conditioner compressor controller
q No. 18 (5 A) from fuse box: q N10: Air conditioner unit connector for 24
For supply of power to air conditioner V power supply and CAN communication
controller (i.e., backup power source) with the machine monitor (communication
q No. 10 (5 A) from fuse box: lines shared with engine controller and
For supply of primary power to air conditioner pump controller)
unit, air conditioner controller, and relays q AC01: Air conditioner unit connector for
R20 and R21 GND, compressor, pressure switch, re-
q Part No. of fuse lays, sunlight sensor, and outside (air)
20 A: 080-041-02000 temperature sensor
5 A: 080-041-00500

2. Remove holder cup (1).

3. Remove bracket (2).
4. Remove cover (3).

80-28 PC228US-8,PC228USLC-8
(01)
 Air conditioner
Parts and connectors layout

5. Remove floor mat (6). 9. Remove cover (15).

6. Remove covers (7) to (9).

q P17: Pressure switch connector

7. Remove pin (P1) and remove ducts 10) to (13).
a Pin (P1) is also provided under duct (11).

10. Open the engine hood.

q ACC: Air conditioner compressor
8. Using bolt (B), raise seat bracket (14). q AC02: Air conditioner compressor connector
q A/C U: Air conditioner unit q E: Ground
[8]: Inside air temperature sensor connector

PC228US-8,PC228USLC-8 80-29
(01)
Air conditioner
Parts and connectors layout

11. Remove air cleaner (16).

1] Insert a flat-head screwdriver into the slit

a Condition with air cleaner removed (SL) and lift up.
q P32: Outside (air) temperature sensor con- 2] Release lock (L) and remove cover (5).
nector 3] At the rear of cover (5), disconnect the
connector (M04) for the cigarette lighter.

12. Testing sunlight sensor connector P31 and

machine monitor connector CM02 (CAN
communication connector)
a If the connector CM02 for the machine moni-
tor is disconnected, CAN communication
with the engine controller and the pump con-
troller is not be possible, and therefore, the
error code [DAFRMC] is displayed. Further-
more, a red "Air conditioner Error" is dis-
played on the air conditioner control screen.
Inspection is only required when this error is
displayed.
Note: An "Air conditioner Error" is also
displayed on the air conditioner control
screen when vent changeover is not
possible, when a temperature adjustment
abnormality occurs, or when the refrigerant's
pressure switch is set to OFF.
1) Remove cap (1).
2) Remove cover (2), and disconnect connector
P31 for the air conditioner sunlight sensor
(S).
3) Remove duct (4).
4) Remove cover (5) as shown in the following.
[*1]

80-30 PC228US-8,PC228USLC-8
(01)
 Air conditioner
Parts and connectors layout

5) Remove 4 mounting bolts and lift up machine

monitor (6). [*2]
6) Check connectors CM02.
a CM02 and CM03 can be assembled in re-
verse, take care not to assemble them in
reverse. CM03 is the green connector.
a The connector CN-5 is connected on
models with rear view camera specifica-
tion.

Caution about installation

[*1], [*2]
1. Tighten lightly the four mounting bolts for the
machine monitor (6), and assemble cover (5).
2. With cover (5) in place, fully tighten the machine
monitor's mounting bolts.
q Carry out the rest of installation in the reverse
order to removal.

PC228US-8,PC228USLC-8 80-31
(01)
Air conditioner
Testing air leakage (duct)

Testing air leakage (duct) 80-32

1. Remove front window (1). 9. Check the following ducts.
2. Remove floor mat (2). 1) Rear duct
3. Remove cover [3] from the machine monitor in Check duct (10) for disconnection.
accordance with item 12 of "Part and connector 2) Defroster duct (11), face duct (12)
locations." 1] Check pin (P1) and ducts (11), (12) for
4. Remove covers (4) and (5). disconnection.
a Pin (P1) is also provided under duct
(11).

5. Remove cup holder (6).

6. Remove bracket (7).
7. Remove rear cover (8). 2] Check defroster duct (13) for disconnec-
8. Remove duct cover (9). tion.

3) Fresh air duct

Check pin (P) and duct (14) for disconnec-
tion.

80-32 PC228US-8,PC228USLC-8
(01)
 Air conditioner
Testing with self-diagnosis function

Testing with self-diagnosis function 80-3

Outline 80-3 How to enter air conditioner “Abnormality Re-

On the air conditioner operation screen of the ma- cord” screen in service mode of machine
chine monitor, the system performs self-diagnosis monitor. 80-3
for the communication with the air conditioner unit,
temperature control, vent (mode) changeover and q Overview of machine monitor operating pro-
refrigerant pressure with the pressure switch, and if cedure
a problem is detected, the failure is displayed in red Normal screen
as "A/C Controller Error" O While pressing [4], press [1], [2], and [3] in this
order.
Service menu (Mode)
O Press [F3] once. Press [F6].
02Abnormality Record
O Press [F3] twice. Press [F6].
03Air-conditioning System "Abnormality Record"
screen

q Detailed description of machine monitor op-

erating procedure
1. On the normal operation screen, while pressing
number key [4], press [1], [2], and [3] in this
order.
a Even if the cause of a detected problem is re-
stored to normal, the self-diagnosis failure condi-
tion will not automatically be reset. To reset the
failure condition, the starter switch must be set to
OFF.
a On the air-conditioning system abnormality re-
cord screen that appears in service mode of the
machine monitor, the system performs self-diag-
nosis for various sensors in addition to the above
items, and if a problem is detected, screen dis-
plays it in red as "Abnormal."
a FRESH/RECIRC air changeover servomotor is
not checked with self-diagnosis function.

2. On the service menu screen, press [F3] (R)

once, and then select "02 Abnormality Record."

3. Press [F6] ( ) to confirm.

PC228US-8,PC228USLC-8 80-33
(01)
Air conditioner
Testing with self-diagnosis function

4. On the Abnormality Record screen, press [F3] Caution

(R) twice, and then select "03 Air conditioning Inner Sensor means "inside temp. sensor" on
System." "system diagram " or "circuit diagram".
"Ventilating Sensor is abnormal" means that
5. Press [F6] ( ) to confirm. evaporator temperature sensor is short circuit or
disconnected.
Sunlight Sensor is abnormal" meas that Sunlight
Sensor is short circuit only.
"Ventilation is abnormal" means servomotor for
vent changeover (mode) damper does not rotate
judging from the servomotor potentiometer
voltage.
a Damper is the same as door.
"Air Mix is abnormal" means servomotor for Air
Mix (temperature adjustment) damper does not
rotate judging from the servomotor potentiom-
eter voltage. "Refrigerant" means refrigerant
pressure from dual pressure switch. Namely,
"refrigerant is abnormal" means that dual pres-
q Air Conditioning System Abnormality Re- sure switch of refrigerant is OFF.
cord screen: Information displayed in "03 Air
Conditioning System" 1. CAN status: Abnormal
(a): System or Component name Normal communication is not possible between
(b): Number of abnormality occurrence time the machine monitor and air conditioner
(c): Condition (Normal or abnormal) controller.
(d): If the CAN communication condition is a Display of failure code [DAFRMC] CAN com-
displayed as being abnormal, it will indicate that munication failure (with engine controller) in-
the air conditioner unit is disconnected and CAN dicates that the entire communication line
communication is not possible. Accordingly, the has failed. In this case, see failure code [DA-
display for the other (d) items will be cleared. FRMC] in Chapter 40. If failure code [DA-
(e): If [E] is displayed to the left of the condition, FRMC] is not displayed, communication
it indicates that the abnormality is ongoing or that failure is limited to between the controller and
restoration to normal has not yet been detected. the machine monitor alone.
[F2]: Clear "Abnormality Record" In such a case, confirm whether connectors
[F5]: Return to Abnormality Record screen AC01, CN-N10, [1], and [2] have been
disconnected. See item 2 from "Parts and
connectors layout." Alternatively, see "Trou-
bleshooting for power supply and CAN
communication system."

2. Setting : Abnormal
The air conditioner controller software and the
monitor software are not compatible. Confirm
the part number of each.

3. Inner sensor: Abnormal

a Inner Sensor is the same as inside temp.
sensor on "System diagram" or "circuit dia-
gram".
An open circuit or short circuit has been detected
q Clearing "Abnormality Record" on machine between the air conditioner controller and the
monitor inner sensor.
While the "Abnormality Record " screen is a Air conditioner controller remedy:
displayed, press [F2], and the number of occur- As it is not possible to use data from inner
rence time of abnormality is reset. If it is sensor, control the air conditioner using only
confirmed at this time that the abnormality has the temperature setting in automatic air
been reset, the trouble was resolved. conditioning mode.

80-34 PC228US-8,PC228USLC-8
(01)
 Air conditioner
Testing with self-diagnosis function

a Trouble: Automatic air conditioner functions a Damper is the same as door.

do not work, but manual operations do. a Trouble: Vent is not changed over.
a If an abnormality is detected in inner sensor, a Air conditioner controller remedy:
see "Testing inner sensor." Output to the vent (mode) selection servo-
motor is stopped.
4. Outer sensor: Abnormal a Even if the link is disconnected and the
a Outer sensor is the same as outside temp. damper does not rotate, the self-diagnosis
sensor on "System diagram" or "Circuit dia- system judges the damper normal since the
gram". servomotor potentiometer voltage changes
An open circuit or short circuit has been detected normally.
between the air conditioner controller and the a In the case of "Ventilation: Abnormal", see
outer sensor. "Testing vent (mode) changeover."
a Air conditioner controller remedy:
As it is not possible to use data from outer 8. Air Mix: Abnormal
sensor, control the air conditioner using only It has been determined based on the servo-
the inside air temperature sensor and the motor's potentiometer voltage that the servo-
sunlight sensor in automatic air conditioning motor for the air mix (temperature adjustment)
mode. damper is not operating.
a Trouble: Automatic air conditioner functions a Damper is the same as door.
operate without referencing the outside air a Trouble: The temperature control system
temperature. Manual operations function does not work.
normally. a Air conditioner controller remedy:
a If an abnormality is detected in outer sensor, Output to the air mix servomotor is stopped.
see "Testing outer sensor." a Even if the link is disconnected and the
damper does not rotate, the self-diagnosis
5. Ventilating sensor: Abnormal system judges the damper normal since the
a Ventilating sensor means the evaporator servomotor potentiometer voltage changes
temperature sensor. normally.
An open circuit or short circuit has been a If an abnormality is detected in the Air Mix
detected between the air conditioner (A/M)damper, repeat the temperature setting
controller and the evaporator temperature 18.0 °C(Max. cooling)io32.0 °C(Max.
sensor. heating) several times. If the A/M damper ab-
a Air conditioner controller remedy: normality count does not increase, A/M
Output to the compressor is stopped. damper is normal. (This abnormality poten-
a Trouble: The air conditioner does not tially happens at low temperature) When the
work. A/M damper abnormality count increases,
a If an abnormality is detected in the venti- see "Troubleshooting for temperature con-
lating sensor, see "Troubleshooting for trol."
temperature sensor system."
9. Refrigerant: Abnormal
6. Sunlight sensor: Abnormal (Dual) pressure switch signal for refrigerant is
A short circuit has been detected between the air abnormal. Namely pressure switch for refrig-
conditioner controller and the sunlight sensor. erant is OFF.
a Air conditioner controller remedy: a Trouble: The air conditioner does not work.
Control is carried out without referencing a Air conditioner controller remedy:
sunlight sensor. Output to the compressor is stopped.
a Trouble: The automatic air conditioner does k When replacing a pressure switch, refrig-
not work when the machine is exposed to the erant must be collected in advance. See
direct sunlight in the automatic air conditioner "Caution about refrigerant"
mode. a If an abnormality is detected in the refriger-
a If an abnormality is detected in the sunlight ant, see "Testing (dual) pressure switch for
sensor, see "Testing sunlight sensor." refrigerant."

7. Ventilation: Abnormal
It has been determined based on the servo-
motor's potentiometer voltage that the servo-
motor for the vent (mode) changeover damper is
not operating.

PC228US-8,PC228USLC-8 80-35
(01)
Air conditioner
Testing vent (mode) changeover

Testing vent (mode) changeover 80-36

Outline 80-36 7. Press the face and defroster selector switch on

The vent (mode) is selected by changing the angles the air conditioner screen of the machine
of the two doors (dampers) in the air conditioner unit monitor and visually check that lever (L) moves
and the door (damper) in the duct. The angles of the smoothly between the face mode (F) and
doors (dampers) are changed with the mode defroster mode (D) shown in the figure.
changeover servomotor and all the doors (dampers)
are not seen from the outside. Even if the air condi- 8. Press the foot and defroster selector switch on
tioner unit is removed, the mode changeover servo- the air conditioner screen of the machine
motor is not seen from the outside. Visually check monitor and visually check that foot door (8)
opening and closing of the foot door (damper) and opens and closes.
the angle of the lever of the defroster-face selector 9. Stop the engine.
door (damper) inside the duct to see these doors
from the outside.

a To reset the self-diagnosis system (to clear the

"A/C Controller Error" displayed on the air condi-
tioner screen of the machine monitor), the start-
ing switch must be turned OFF (While "A/C
Controller Error" is displayed with self-diagnosis
system, no signals are output to the servomo-
tor).

1. Remove front window (1).

2. Remove floor mat (2).
3. Remove covers (3) - (5).

4. Check the connection of cable (6) and lever (L).

(Check whether the connector has been partially
removed.)
5. Check clip (7) for coming off.
6. Start the engine and turn the air conditioner
power ON.

80-36 PC228US-8,PC228USLC-8
(01)
 Air conditioner
Testing FRESH/RECIRC air changeover

Testing FRESH/RECIRC air changeover 80-37

Outline 80-37
FRESH/RECIRC air changeover servo motor per-
forms switching between fresh and recirculated air
by changing the angle of the FRESH/RECIRC air
changeover door (damper) located inside the air
conditioner unit. Check visually opening and closing
of this door .
a The system does not have self-diagnosis func-
tion for FRESH/RECIRC air changeover servo
motor.
1. Open cover (1) and remove outside air filter (2).

2. Start the engine and turn the air conditioner

power ON.
3. Press the FRESH/RECIRC selector switch on
the machine monitor's air conditioner control
screen, and then check the opening and closing
operation of FRESH/RECIRC air changeover
door (4) using mirror (3).
a As the connector for FRESH/RECIRC air
changeover servo motor is located on the floor of
the air conditioner unit, its connection condition
cannot be checked.

PC228US-8,PC228USLC-8 80-37
(01)
Air conditioner
Testing inner sensor

Testing inner sensor 80-38

a Inner sensor means inside (air) temperature 9. Turn the starting switch to ON position and if
sensor. "Inner sensor Abnormal" is still displayed with
q If "Inner sensor Abnormal" is displayed with self-diagnosis (on "03 Air conditioning System"
self-diagnosis (on "03 Air conditioning System" screen of "Abormality Record" in the machine
screen of "Abormality Record" in the machine monitor), replace the air conditioner controller.
monitor), test the following.
q To reset the self-diagnosis system (detection of
abnormalities), the starting switch must be
turned OFF.

1. Referring to "Parts and connectors layout", raise

seat bracket (9) by using bolt (B).
a Prepare bolt (B) in advance.
2. Check the contact of inner sensor connector [8].
(Check whether the connector has been partially
disconnected.)
3. Standard resistance between terminals on
sensor side of connector [8]:
1.6 kz (at 0 °C)
5 kz (at 25 °C)
a If the resistance is not the above value, re-
place the inner sensor.

4. Referring to item 2. in "Parts and connectors

layout", disconnect connectors [1] and [2].
5. Ensure that the female terminals (on the wiring
harness side) of connector [8] are not being
shorted by each other.
a If the terminals are shorted, the wiring har-
ness is defective.
6. Between connector [8] (female: wiring harness
side) (2) (PB) and connector [1] (wiring harness
side) (11) (PB):
Ensure Max. 1 z.
a If the resistance is not the above value, the
wiring harness is defective.
7. Between connector [8] (female: wiring harness
side) (1) (BrR) and connector [2] (wiring harness
side) (27) (BrR):
Max. 1 z
a If the resistance is not the above value, the
wiring harness is defective.
8. Connect all the connectors.

80-38 PC228US-8,PC228USLC-8
(01)
 Air conditioner
Testing outer sensor

Testing outer sensor 80-39

a Outer sensor means outside (air) temperature 8. Turn the starting switch to ON position, and if
sensor. "Outer Sensor Abnormal" is still displayed with
q If an "Outer Sensor Abnormal" is displayed with self-diagnosis (On the air-conditioning system
self-diagnosis (on "03 Air-conditioning System" abnormality record screen in the machine
screen of "Abormality Record" in the machine monitor), replace the air conditioner controller.
monitor), test the following.
q To reset the self-diagnosis system (detection of
abnormalities), the starting switch must be
turned OFF.

1. Check contact of the outer sensor connector

(P32) in accordance with item 11 of "Parts and
connectors layout."
(Check whether the connector has been partially
disconnected.)
2. Standard resistance between terminals on the
sensor side of connector (P32):
1.7 kz (at 25 °C)
a If the resistance is not the above value, re-
place the outer sensor.

3. Referring to items 2. to 4 in "Parts and connec-

tors layout", disconnect connectors [1] and [2].
4. Ensure that the female terminals on the harness
side of the connector (P32) are not being
shorted.
a If the terminals are shorted, the wiring har-
ness is defective.
5. Condition between female (2) (RW) from the
harness side of the connector (P32) and (13)
(RW) from the harness side of connector [1]:
Ensure Max. 1 z.
a If the resistance is not the above value, the
wiring harness is defective.
6. Condition between female (1) (BrR) from the
harness side of the connector (P32) and (27)
(BrW) from the harness side of connector [2]:
Max. 1 z
a If the resistance is not the above value, the
wiring harness is defective.
7. Connect all the connectors.

PC228US-8,PC228USLC-8 80-39
(01)
Air conditioner
Testing sunlight sensor

Testing sunlight sensor 80-40

q If "Sunlight Sensor Abnormal" is displayed by the 4. Disconnect connector [1] from the air conditioner
self-diagnosis (on "03 Air conditioning System" controller in line with item 2 from "Parts and
screen of "Abormality Record" in the machine connectors layout".
monitor), test sunlight sensor connector P31. 5. Ensure that the female terminals of the
q To reset the self-diagnosis system (detection of connector P31 (harness side) are not being
abnormality), the starting switch must be turned shorted. (If the terminals are shorted, the
OFF. harness is defective.)
a If sunlight sensor (S) is mesured with resistance 6. Confirm whether the condition between the
range of tester, sunlight sensor may be de- female terminal of the connector P31 (harness
stroyed, so do not measure with resistance side) (2) (YW) and the terminal of connector [1]
range of tester. (harness side) (15) (YW) is 1 z or less.
1. Remove cap (1). (If not, the wiring harness is defective.)
2. Remove cover (2) and inspect the connector a If the result of item 6 or item 7 is abnormal,
P31 (3) for the sunlight sensor (S), which is check the contact of connector CN-AC01.
located on back side of the cover. (Check (See "Parts and connectors layout".)
whether the connector has been partially discon- 7. Confirm whether the condition between the
nected.) female terminal of connector P31 (harness side)
3. Disconnect connector P31, and using a tester (1) (RB) and the terminal of connector [1]
set to the voltage range, measure the voltage (harness side) (3) (RB) is 1 z or less. (If this is
between the male side terminals on the sunlight not the case, the harness is defective.)
sensor (S). 8. Connect all the connectors.
q Approximate voltage of sunlight sensor unit 9. Turn the starting switch to ON position, and if
0.55 V: Direct sunlight "Sunlight Sensor Abnormal" is still displayed
0.45 V: Cloudy with self-diagnosis (on "03 Air conditioning
0.4 V: Indoors System" screen of "Abnormal Record" in the
machine monitor), replace the air conditioner
controller.

80-40 PC228US-8,PC228USLC-8
(01)
 Air conditioner
Testing (dual) pressure switch for refrigerant

Testing (dual) pressure switch for refrigerant 80-41

q If "Refrigerant Abnormal" is displayed by the q Dual pressure switch
self-diagnosis (on "03 Air-conditioning System"
screen of "Abormality Record" in the machine
monitor), test the dual pressure switch connector
P17.
q To reset the self-diagnosis system (detection of
abnormality), the starting switch must be turned
OFF.
q The dual pressure switch is ON when the refrig-
erant pressure is normal and OFF when it is ab-
normal.
a As the refrigerant pressure will drop when the
ambient temperature is below 0 °C, there is a
possibility that the dual pressure switch is
OFF. In such a case, the dual pressure
switch is actually normal (i.e., not defective). LA: 0.20 MPa {2 kg/cm2}
1. Remove undercover in operator cab by referring LB: 0.02 MPa {0.2 kg/cm2}
to item 9 of "Parts and connectors layout." HA: 3.14 MPa {32 kg/cm2}
2. Disconnect the dual pressure switch connector HB: 0.59 MPa {6 kg/cm2}
k If the pressure switch is to be replaced, re-
P17.
frigerant must be collected in advance.
q If resistance between the switch-side terminals
from connector P17 is shorted (ON): (See "Trou-
bleshooting for the compressor and refrigerant
system" for the circuit diagram.)
1. Disconnect connector [1] from the controller in
line with item 2 from "Parts and connectors
layout".
2. Confirm whether the condition between the
female terminal of the connector P17 (harness
side) (2) (B) and the machine ground is 1 z or
less. (If this is not the case, the harness is defec-
tive.)
3. Ensure that the resistance between the 3. Confirm whether the condition between the
switch-side terminals from connector P17 is female terminal of the connector P17 (harness
shorted (ON). (If not shorted (OFF), the dual side) (1) (GB) and the terminal of connector [1]
pressure switch will detect a refrigerant pressure (harness side) (4) (GB) is 1 z or less.(If this is
abnormality.) not the case, the harness is defective.)
a When the pressure switch is OFF, connect a a If the result of item 3 is abnormal, check con-
pressure gauge to the high pressure side of tact of connector CN-AC01. (See "Parts and
the air conditioner compressor and check the connectors layout".)
refrigerant pressure. See "Connection of ser- 4. Connect all the connectors.
vice tool" and "Troubleshooting with gauge 5. Turn the starting switch ON and if "Refrigerant
pressure." Abnormal" is still displayed with self-diagnosis
a If refrigerant pressure is normal, the pressure (On the air-conditioning system abnormality
switch is defective. record screen in the machine monitor), replace
the air conditioner controller.

PC228US-8,PC228USLC-8 80-41
(01)
Air conditioner
Testing relays

Testing relays 80-42

a If the air conditioner compressor is normal (cool- q Checking relay unit
ing) and air is being discharged, the test can be Blower main relay (R20)
omitted. Compressor clutch relay (R21)
a Listen closely to the relay to determine whether 1) The coil resistance between terminals (1)
or not it is defective. and (3) is 140 – 340 z.
There are two relays. 2) The condition between terminals (2) and (4)
q Blower main relay R20: is OFF when no voltage (20-30 V DC) is
Turning the fan motor ON/OFF being applied between terminals (1) (+) and
q Compressor clutch relay R21: (3).
Used to turn the compressor (clutch) ON/OFF. 3) The condition between terminals (2) and (4)
1. Remove rear cover in operator cab by referring is ON when voltage (20-30 V DC) is being
to items 2 to 4 of "Parts and connectors layout." applied between terminals (1) (+) and (3).
2. Check the connections of connectors R20 and
R21. (Check whether the connectors have been
partially disconnected.)
3. Turn the starting switch ON (do not start the
engine) and turn the main power of the air condi-
tioner ON. If the blower off relay is normal, it is
turned ON. Check its click.
4. If the air conditioner switch is turned ON at this
time, the compressor relay is turned ON if it is
normal. Check its click.
a The air conditioner controller will not turn on
the compressor relay in the following cases.
1) When the evaporator temperature is below
3 °C (depending on the input voltage from
the evaporator temperature sensor).
2) When the pressure switch detects abnor-
mality (it is turned OFF).
a If the sound produced by the compressor relay
cannot be heard due to the sound of the fan, turn
the starter switch off temporarily and disconnect
the connector R20.

80-42 PC228US-8,PC228USLC-8
(01)
 Air conditioner
Testing relays

PC228US-8,PC228USLC-8 80-43
(01)
Air conditioner
Troubleshooting chart 1

Troubleshooting chart 1 80-4

The numbers in the boxes are the item numbers in the troubleshooting table.

1. Cooling trouble 80-4

80-44 PC228US-8,PC228USLC-8
(01)
 Air conditioner
Troubleshooting chart 1

2. Heating trouble 80-45

PC228US-8,PC228USLC-8 80-45
(01)
Air conditioner
Troubleshooting chart 2

Troubleshooting chart 2 80-46

1. During cooling, the blower fan motor does not operate or the rotation speed does not match the air flow
setting.
a See "Troubleshooting of blower motor system (Air does not come out or air flow is abnormal)".
Probable cause Check method Remedy
Defective blower main relay See "Testing relays" Replace
Check connector of blower fan motor for disconnection. Repair broken parts
Wire breakage or defective con-
See "Detail of air conditioner unit" and "Parts and connectors and connect cor-
nection
layout." rectly
See "Troubleshooting of blower motor system" and "Parts and
Defective blower fan motor Replace
connectors layout".
Operate the fan switches in order and check the fan speed.
Defective power transistor (PTR) Replace
See "Troubleshooting the blower motor system."

2. During cooling, the blower fan motor is normal but the flow of air is very light.
Probable cause Check method Remedy
Large duct resistance Check the filter for clogging and the duct for crushing. Repair
Check duct joints.
Air leakage through duct joints Repair
Check for defective duct seal and disconnection of duct
Remove obstruc-
Obstruction at evaporator inlet Check evaporator for stain and obstruction
tion and clean
Evaporator is frozen.
Defective evaporator tempera- Sensor fixing clip inspection, sensor contaminated
ture sensor Inspect the air conditioner hose around the pressure switch for Repair or replace
Defective expansion valve* frost.
(when freezing has advanced even further)
*: The evaporator temperature sensor and expansion valve are located inside the air conditioner unit.

3. Pressure abnormality (high-pressure / low-pressure) during cooling.

Probable cause Check method Remedy
Repair leaking part,
then charge with
Insufficient refrigerant
proper quantity of
Check the refrigerant volume through sight glass.
refrigerant again
Specifically, perform checking with the gauge manifold con-
Collect refrigerant,
nected.
then fill up with
Overcharge with refrigerant
proper quantity of
refrigerant again
Normal pressure range
Low pressure: Approx. 0.13 - 0.2 MPa {1.3 - 2.0 kg/cm2} See Troubleshoot-
Judgment by pressure at
High pressure: Approx. 1.5 - 1.7 MPa {15 - 17 kg/cm2} ing with gauge pres-
inlet/outlet of compressor
Temperature in operator's cab: 30 – 35 °C, Engine speed: sure
Approx. 1,500 rpm

80-46 PC228US-8,PC228USLC-8
(01)
 Air conditioner
Troubleshooting chart 2

4. During cooling, the compressor cannot operate easily or at all.

a See "Troubleshooting of compressor system (Air is not cooled)".
Troubled part Probable cause Check method Remedy
Compressor
Slack of belt Deflection of belt is large. Adjust tension
belt
Trouble in compressor Slip of belt Repair or replace
Compressor Insufficient compressor oil See "Handling com-
Heating of compressor
Seizing on compressor pressor oil".
Drop of battery voltage Slip of clutch Charge battery
Open or short circuit in coil Inspect with circuit tester (10 - 20 z) Replace
Magnet clutch Check ground wire and connections
Wire breakage or defective con-
See "Troubleshooting for compressor and Repair
nection of ground wire
refrigerant system".
Relay Defective compressor clutch relay See "Testing relays" Replace
Refrigerant Low/high pressure (Operation of See "Troubleshooting
See "Troubleshooting with gauge pressure".
pressure pressure switch) with gauge pressure".
Pressure See "Troubleshooting for compressor and
Defective pressure switch Replace
switch refrigerant system".

5. During cooling, the blower fan motor is normal and the flow of air is very light.
Probable cause Check method Remedy
Large duct resistance Check the filter for clogging and the duct for crushing. Repair
Check duct joints for defective duct seal and disconnection of
Air leakage through duct joints Repair
duct
Clogging of heater core fins Check heater core fins for clogging Clean

6. Engine coolant temperature or volume abnormalities during heating or cooling

Probable cause Check method Remedy
Low engine coolant tempera-
Warm up engine, and then check engine coolant temperature Find out cause
ture
Low engine coolant level Check coolant level in radiator Add coolant
Insufficient circulation of engine Check engine coolant piping for clogging
Bleed air and correct
coolant (Hose, pipe, and core)
The connection of IN and OUT
Check the destination of heater hoses Correct
heater hoses is in reverse.

7. Fan speed abnormalities during cooling

Probable cause Check method Remedy
See "Testing and adjusting of Air conditioner compressor belt
Fan speed is low tension" in the "Testing and adjusting" of Chapter 30 of the Correct
shop manual.

8. Other abnormalities
Probable cause Check method Remarks
Temperature cannot be con-
(See "Troubleshooting the temperature adjustment system.")
trolled
Vent (mode) changeover is not "Testing vent (mode) changeover" Common to cooling and
possible. See "Troubleshooting vent (mode) changeover." heating
FRESH/RECIRC air cannot be See "Testing FRESH/RECIRC air changeover" and "Trouble-
changed over shooting for FRESH/RECIRC air changeover"
Excessive compressor oil See "Handling compressor oil".
Cooling only
Water leakage into the cab Clogging of drain hole

PC228US-8,PC228USLC-8 80-47
(01)
Air conditioner
Information in troubleshooting table

Information in troubleshooting table 80-48

Information in troubleshooting table 80-48
a The following information is summarized in the troubleshooting table and the related electrical circuit dia-
gram. Before performing troubleshooting, understand that information fully.
Failure Problem on machine
Related information Information related to detected failure or troubleshooting
Cause Procedure, measuring location, criteria and remarks
<Information described>
q Procedure
q Measuring location
1 a "Between A – B" means “Measure voltage or resistance and so on between A and B".
Probable causes of q Standard value in normal condition to judge probable causes
trouble q Remarks required for judgement
(Perform trouble-
shooting according <Notes on troubleshooting>
to these.) (1) Pin number description sequence and tester lead handling
2 For troubleshooting, connect the plus (+) and minus (–) tester leads as shown below unless
otherwise specified.
q Connect the plus (+) lead to a pin or harness indicated in the front.
q Connect the minus(–) lead to a pin or harness indicated in the rear.
(2) Example of troubleshooting by inspection of multiple items
a Normal in 1 but abnormal in 2
At this time“ - defective” shown at left is applied
3 - defective

a If a wiring harness is burnt, replace it.

<Defective wiring harness>
q Open circuit
Connector is connected imperfectly or wiring harness is disconnected.
q Ground fault
A harness not to be connected to the ground (earth) circuit comes into contact with the ground (earth)
circuit or chassis accidentally.
q Hot short circuit
A harness not to be connected to the power (24 V) circuit comes into contact with the power (24 V) circuit
accidentally.
q Short circuit
An independent wire in the harness abnormally comes into contact with one of another wire. (Defective
insulation in connector or others)

Related circuit diagram 80-48

This is the excerpted circuit diagram related to troubleshooting
q Indicates connector No., and pin No.
q See "Circuit diagram and arrangement of connector pins" and "Parts and connector locations" for connector location
q The circuit diagram shows the size and colors of wires.
W: White, B: Black, R: Red, G: Green, Y: Yellow, L: Blue, V: Purple, P: Pink, O: Orange, Br: Brown, Gr: Gray, Sb:
Sky blue, Lg: Light green, Dg: Dark green, Ch: Dark brown
a When there are two colors
Example: WY: Yellow line on white background
a The number before the wire color indicates the wire size.
q N.C.: Normally closed (Normally ON)
q [1], [2],··· are numbers of unlabeled connectors.
q Arrow (↔): Roughly indicates their mounting place on the machine.

80-48 PC228US-8,PC228USLC-8
(01)
 Air conditioner
Information in troubleshooting table

PC228US-8,PC228USLC-8 80-49
(01)
Air conditioner
Troubleshooting for power supply and CAN communication system (Air conditioner does not operate)

Troubleshooting for power supply and CAN communication system (Air

conditioner does not operate) 80-50
Air conditioner does not operate due to failure on power supply system or CAN communication sys-
Failure
tem.
Problem on q "A/C Controller Error" is displayed in red on air conditioner screen of machine monitor.
machine q No air blows out (Blower motor does not rotate).
q If a failure code or [DAFRMC] error is displayed on the machine monitor, see first of all Chapter 40
and troubleshoot it.
a The machine monitor, engine controller, pump controller, and air conditioner controller are connect-
ed via CAN communication.
q In the following cases, "A/C Controller Error" will be displayed in red on the machine monitor's air
conditioner control screen. Of these, 1), 2), and 3) will be covered below.
1) The air conditioner controller is receiving no power.
2) The air conditioner controller is malfunctioning.
3) No communication is possible between the air conditioner controller and the machine monitor.
4) Vent (mode) door (damper) servomotor does not rotate.
5) Temperature control (Air Mix) door (damper) servomotor does not rotate.
6) Refrigerant pressure is abnormal.
Related infor- q Referring to "Testing with self-diagnosis function", display the air conditioning system abnormality
mation record screen on the machine monitor and check condition of CAN communication. Abnormality in
CAN communication denotes that CAN communication is disabled between the air conditioner con-
troller behind the air conditioner unit and the machine monitor.
CAN Status is indicated as abnormal in any case of 1), 2) and 3) above.
q Referring to "Parts and connectors locations", ensure that the No. 10 fuse (5 A) from fuse box F01
and the Fu5A fuse from the air conditioner harness have not blown.
q Ground cable of air conditioner is connected in machine wiring harness together with electrical
equipment of machine.
q For each connector, see "Parts and connectors layout".
q In cases where fuses are blown when the A/C switch is pressed, see "Troubleshooting for compres-
sor and refrigerant system."
q T-adapter for connector [1]: 799-601-7210, T-adapter for connector [2]: 799-601-7220
a T-adapter is not prepared for other connectors.

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect the cable from the negative (–) terminal of the battery.
3. Disconnect connector [1] from the air conditioner controller, and connect
1 Defective wiring harness (ground)
the T-adapter to the harness side.
Between (16) (black) on the harness side of connector
Resistance Max. 1 z
[1] and the machine ground
1. Turn starting switch to OFF position.
2 Blown fuse 2. Referring to "Parts and connectors layout", inspect the No. 10 fuse (5 A)
from fuse box F01 and the Fu5A fuse on the air conditioner harness.

80-50 PC228US-8,PC228USLC-8
(01)
 Air conditioner
Troubleshooting for power supply and CAN communication system (Air conditioner does not operate)

Cause Procedure, measuring location, criteria and remarks

a If fuse described in related information is broken, replace it.
1) Turn starting switch to OFF position.
2) Disconnect the cable from the negative (–) terminal of the battery.
3) Disconnect connectors [1] and [2] from the air conditioner controller,
and connect the T-adapter to the harness side.
4) Turn starting switch to ON position.
Between connector [2] (25) (red) and con-
nector [1] (16) (B), both on the harness Voltage 20 – 30 V A
side.
a If fuse is broken again in test A above, perform following procedure.
(Replace blown fuse )
3 Defective wiring harness 1. Turn starting switch to OFF position.
2. Disconnect the cable from the negative (–) terminal of the battery.
3. Disconnect connectors [1] and [2] from the air conditioner controller, and
connect the T-adapter to the harness side.
a If the fuse is blown again in the above test A and both B and C below are
normal, it is likely that the cause of the problem lies within the blower motor
circuit. In such a case, see "Troubleshooting the blower motor system."
Between connector [2] (25) (red) and con-
nector [1] (16) (black), both on the har- Resistance Min. 1 Mz B
ness side.
Between (25) (red) on the harness side of
Resistance Min. 1 Mz C
connector [2] and the machine ground
a If fuse is broken again in test A for cause 3 and result of B or C is abnormal,
identify wiring harness having ground fault.
1. Turn starting switch to OFF position.
2. Disconnect the cable from the negative (–) terminal of the battery.
3. Disconnect connectors AC01, N10, and [1].
4. Connect the T-adapter to the harness side of connector [1], and connect the
T-adapter to the harness side.
a Abnormality in D or E below: Short circuit in air conditioner harness
Ground fault in wiring harness a Abnormality in F or G below: Short circuit in machine harness
4 Between connector [2] (25) (red) and con-
(Contact with ground circuit)
nector [1] (16) (black), both on the har- Resistance Min. 1 Mz D
ness side.
Between (25) (red) on the harness side of
Resistance Min. 1 Mz E
connector [2] and the machine ground
Between connector N10 (female) (4) and
Resistance Min. 1 Mz F
AC01 (female) (6) (black)
Between connector AC01 (female) (9)
Resistance Min. 1 Mz G
(red) and (6) (black)
a If none of the fuses described in the related information have blown and an
5 Open circuit in wiring harness abnormality is recorded for Cause 3 A, inspect the circuit with respect to cir-
cuit diagrams.

PC228US-8,PC228USLC-8 80-51
(01)
Air conditioner
Troubleshooting for power supply and CAN communication system (Air conditioner does not operate)

Cause Procedure, measuring location, criteria and remarks

a Short circuit in CAN communication lines, or if a ground fault has occurred,
a [DAFRMC] error is displayed.
a Terminating resistors of approximately 120 z are in machine monitor and
on engine. Since they are connected in parallel, combined resistance is ap-
proximately 60 z.
1. Turn starting switch to OFF position.
2. Disconnect the cable from the negative (–) terminal of the battery.
3. Disconnect connectors [1] and [2] from the air conditioner controller, and
connect the T-adapter on the harness side.
Between (17) and (18) on the harness Approx.
Resistance H
Disconnection in CAN communi- side connector [2] 60 z
cation circuit a If result H above is abnormal, perform following procedure.
6 (communication is not possible a If an abnormality is recorded for H above and J below, the cab harness has
between the machine monitor and failed.
the air conditioner controller) a If an abnormality is recorded for H above but J below is normal, the air con-
ditioner harness has failed.
a Terminating resistors of approximately 120 z are in machine monitor and
on engine. Since they are connected in parallel, combined resistance is ap-
proximately 60 z.
1. Turn starting switch to OFF position.
2. Disconnect the cable from the negative (–) terminal of the battery.
3. Disconnect connectors [1] and [2] from the air conditioner controller, and
connect the T-adapter to the harness side.
Between (male) (1) and (2) of connector Approx.
Resistance J
N10 60 z
If results of Cause 1 and Cause 2, 3 A, and 6 H are normal, the air conditioner
7 Defective air conditioner controller
controller must be replaced.
8 Defective machine monitor When test results for causes 1 – 7 are normal, machine monitor is defective.

80-52 PC228US-8,PC228USLC-8
(01)
 Air conditioner
Troubleshooting for power supply and CAN communication system (Air conditioner does not operate)

Circuit diagram related to power supply and CAN communication 80-53

PC228US-8,PC228USLC-8 80-53
(01)
Air conditioner
Troubleshooting for compressor and refrigerant system (Air is not cooled)

Troubleshooting for compressor and refrigerant system (Air is not

cooled) 80-54
Failure Air is not cooled due to compressor or refrigerant system failure.
q When engine is started and A/C switch is pressed on air conditioner screen of machine monitor, air
is not cooled as displayed on screen.
q Air conditioner compressor does not operate.
Problem on
q A/C Controller Error may be displayed in red on air conditioner screen of machine monitor.
machine
There are 6 cases, items 1) to 6), of the information relevant to "Troubleshooting for power supply
and CAN communication system". As for 1) through 3), see "Troubleshooting for the power supply
and CAN communication system."
The following description deals with item 6), refrigerant pressure abnormality.
q Referring to "Testing with self-diagnosis function", display air conditioner fault history screen on
machine monitor and check to see if refrigerant pressure is abnormal. If refrigerant pressure is ab-
normal, compressor is not turned ON and air is not cooled consequently.
Related infor- a Abnormal refrigerant pressure indicates that "Signal (connector [1] (4)) from pressure switch is not
mation grounded".
q In certain cases, the air conditioner will not turn on at 3 °C or lower (normal).
q For each connector and fuse, see "Parts and connectors layout".
q T-adapter for connector [1]: 799-601-7210, T-adapter for connector [2]: 799-601-7220
a T-adapter is provided only for connectors [1], [2], and AC02.

Cause Procedure, measuring location, criteria and remarks

a If "A/C Controller Error" is displayed in red on air conditioner operation
screen of machine monitor, perform following procedure.
1. Turn starting switch to OFF position.
2. Disconnect the cable from the negative (–) terminal of the battery.
3. Disconnect the pressure switch connector P17.
a In certain cases, the pressure switch may be operating normally and set to
1 Defective pressure switch
OFF; therefore, if a failure is recorded for the following (i.e., switch OFF),
attach a pressure gauge to the air conditioner compressor and check the
refrigerant pressure. (See "Troubleshooting with gauge pressure.")
Between (1) and (2) of connector P17 (male) Resistance Max. 1 z
k Before replacing pressure switch, collect refrigerant.
1. Turn starting switch to OFF position.
2. Disconnect the connector AC02 from the air conditioner compressor and
connect a T-adapter to the male side.
Defective air conditioner compres- a Ensure connection of air conditioner compressor ground cable (E).
2
sor (See "Parts and connectors layout".)
Between connector AC02 (male) (1) and the
Approx.
machine ground (i.e., air conditioner compressor Resistance
15 z
coil resistance)
1. Turn starting switch to OFF position.
2. Disconnect connectors [1] and R21, and troubleshoot in that condition.
a Ensure that the result of checking for Cause 1 (pressure switch ON) and
Cause 2 (air conditioner compressor normal) are both normal.
3 Open circuit in wiring harness Between connector [1] (4) and the machine ground
Resistance Max. 1 z
(Pressure switch is turned ON)
Between connector R21 (female) (2) and the
Approx.
machine ground Resistance
15 z
(Air conditioner compressor coil resistance)

80-54 PC228US-8,PC228USLC-8
(01)
 Air conditioner
Troubleshooting for compressor and refrigerant system (Air is not cooled)

Cause Procedure, measuring location, criteria and remarks

q Referring to "Testing relays", check sound made
when compressor clutch relay is turned ON.
a If the sound produced when the compressor Click
A
clutch relay turns ON cannot be heard due to the is heard.
sound of the blower, turn the starter switch off
temporarily and disconnect the connector R20.
a If A above and B below are abnormal and C is normal (relay is normal), go
to causes 7 and 8.
1. Turn starting switch to OFF position.
Defective compressor clutch relay 2. Disconnect connector R21.
4 3. Use a wire to short-circuit (2) (white) and (4)
(Does not turn ON) Air is
(blue on red) of connector R21 (harness side) . B
cooled.
(This forces the compressor to operate without
using the relay.)
4. Turn starting switch to ON position.
1. Turn starting switch to OFF position.
2. Disconnect connector R21 and troubleshoot in that condition.
Approx. 140
Between (1) and (3) of connector R21
Resistance - C
(male) (i.e., coil resistance)
340 z
a If the fuse is not blown, skip troubleshooting.
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors R21 and AC02, and connect a T-adapter to the
5
(Contact with ground circuit) female side of AC02.
Between (1) of connector AC02 (female) and the
Resistance Min. 1 Mz
machine ground
1. Turn starting switch to OFF position.
2. Disconnect connectors R21 and [2], and then connect the T-adapter to [2]
on the harness side.
6 Short circuit in wiring harness
a Ensure that test result for cause 2 is normal.
Between (25) and (35) on the harness side of con-
Resistance Min. 1 Mz
nector [2]
7 Open circuit in wiring harness a See circuit diagram and inspect.
1. Turn starting switch to OFF position.
2. Disconnect connectors [1] and [2] and insert the T-adapter to the harness
side.
8 Defective air conditioner controller 3. Turn starting switch to ON position.
4. Display the air conditioner control screen on the machine monitor and press
the A/C switch.
Between connector [2] (35) and connector [1] (16) Voltage Max. 1 V
1. Turn starting switch to ON position.
Defective machine monitor 2. Display the air conditioner control screen on the machine monitor.
9
(Defective switch)
Press A/C switch. "A/C ON" is displayed

PC228US-8,PC228USLC-8 80-55
(01)
Air conditioner
Troubleshooting for compressor and refrigerant system (Air is not cooled)

Circuit diagram related to compressor and refrigerant system 80-56

80-56 PC228US-8,PC228USLC-8
(01)
 Air conditioner
Troubleshooting for blower motor system (No air comes out or air flow is abnormal)

Troubleshooting for blower motor system (No air comes out or air flow
is abnormal) 80-57
Failure q No air comes out or air flow is abnormal due to blower motor system failure.
q The machine monitor shows air flow as normal on the air conditioner control screen, but no air is
Problem on
blown out.
machine
q Air flow does not match fan switch setting on air conditioner operation screen.
q This failure is not checked with self-diagnosis function.
q In cases where the blown-air volume begins to behave in an unpredictable manner after a certain
while during cooling, freezing of the evaporator is a likely cause.
This may be due to the followings.
1) Defective compressor clutch relay (i.e., stuck in ON position) (see item 4 A from "Trouble-
shooting for compressor and refrigerant system")
2) Detachment of the evaporator temperature sensor's mounting holder
Related infor- 3) Incorrect adjustment of the expansion valve
mation a In the case of 2) and 3) above, the air conditioner unit must be replaced.
q If air comes out, fuse and relay are normal and wiring harness is seldom abnormal.
q In cases where air is discharged but with unpredictable volumes even during heating, the power
transistor has failed, and therefore, the air conditioner unit must be replaced.
a The power transistor and the blower motor cannot be replaced.
q For details regarding connectors and relays, see "Parts and connectors layout."
q T-adapter for connector [1]: 799-601-7210, T-adapter for connector [2]: 799-601-7220
a T-adapter is not prepared for other connectors.

Cause Procedure, measuring location, criteria and remarks

q Referring to “Testing relays”, check turn-on sound Click is
A
of blower main relay. heard.
a If A above is B below are abnormal and C is normal (relay is normal), go to
cause 2.
1. Turn starting switch to OFF position.
2. Disconnect connector R20.
3. Use a wire to short-circuit (2) (red/yellow) and (4) (red/blue) from connector
R20 (harness side). (This forces ON without using the relay.)
Defective blower main relay 4. Turn starting switch to ON position.
1
(Does not turn ON) Air comes
Operate fan on air conditioner operation screen. B
out.
a If air does not come out even when blower motor is turned ON forcibly with-
out using relay, cause is part other than relay.
1. Turn starting switch to OFF position.
2. Disconnect connector R20 and troubleshoot in that condition.
Approx.
Between (1) and (3) from R20 (relay side) Resis-
140 – C
(coil resistance) tance
340 z
1. Turn starting switch to OFF position.
2. Disconnect connector [2] and connect the T-adapter to the wiring harness
side.
2 Open circuit in wiring harness 3. Remove fuse No. 10 of fuse box F01.
Approx.
Between F01 (10) and [2] on wiring harness side (36)
Resistance 140 –
(R20 coil resistance)
340 z
1. Turn starting switch to OFF position.
2. Disconnect connectors [1], [2], and AC01, and then connect the T-adapter
Open circuit in harness, power to [1] and [2] on the harness side.
transistor is defective, or blower
Between (8) and (16) on the harness side of connec-
3 (fan) motor is defective. Approx. 11 kz or below
tor [1] (power transistor's internal resistance)
(Replacement of air conditioner
unit) Between (7) on the harness side of connector [1] and
AC01 (male) (10) (power transistor’s internal resis- Approx. 2.2 kz or below
tance)

PC228US-8,PC228USLC-8 80-57
(01)
Air conditioner
Troubleshooting for blower motor system (No air comes out or air flow is abnormal)

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connectors R20, [1] and [2], and then connect the T-adapter to
[1] and [2] on the wiring harness side.
4 Short circuit in wiring harness Between (16) and (7) on the harness side Resis-
Min. 1 Mz
of connector [1] tance
Between (25) and (36) on the harness Resis-
Min. 1 Mz
side of connector [2] tance
1. Turn starting switch to OFF position.
2. Disconnect connectors [1] and [2] and insert the T-adapter.
3. Turn starting switch to ON position.
4. Press fan switch on air conditioner operation screen. (Air flow may be set
5 Defective air conditioner controller to any position.)
Between (36) of connector [2] and (16) of
Voltage Max. 1 V
connector [1]
Between (8) and (16) of connector [1] Voltage Max. 2 V
1. Turn starting switch to ON position.
2. Display the air conditioner control screen on the machine monitor.
Defective machine monitor
6 The air volume display
(Defective switch)
Press the fan switches from MIN to MAX moves between MIN
and MAX.

80-58 PC228US-8,PC228USLC-8
(01)
 Air conditioner
Troubleshooting for blower motor system (No air comes out or air flow is abnormal)

Circuit diagram related to blower motor system 80-59

PC228US-8,PC228USLC-8 80-59
(01)
Air conditioner
Troubleshooting for temperature control

Troubleshooting for temperature control 80-60

Failure q Temperature cannot be controlled
q"A/C Controller Error" may be displayed in red on air conditioner control screen of the machine
Problem on monitor. (See "Troubleshooting for power supply and CAN communication system.")
machine q While air conditioner operation screen of machine monitor is displayed, temperature does not
change even if temperature control switch is operated.
a Temperature control is achieved by mixing cold and warm air.
q Referring to "Testing with self-diagnosis function", display "03 Air conditioning system" screen of
"Abnormality Record" of the machine monitor and check whether an "Air mix", "Outer sensor", or
"Inner sensor" abnormality has occurred.
q In the case of "Air Mix (damper) abnormal", repeat the temperature setting 18.0 °C (Max.
cooling)io32.0 °C (Max. heating) several times. If the Air Mix (damper) abnormal count does not
Related infor- increase, Air Mix damper is normal. (This abnormality potentially happens only at low temperature.)
mation q In the case of "Inner sensor Abnormal", see "Testing inner sensor".
q Air mix servomotor and vent (mode) servomotor use the same servomotor. However, since con-
nectors [5] and [6] are not visible from outside, you cannot judge whether servomotor is defective.
q T-adapter for connector [1]: 799-601-7210, T-adapter for connector [2]: 799-601-7220
q For each connector, see "Parts and connectors layout".
a Connectors [5] and [6] cannot be seen from the outside, therefore, signals must be monitored at air
conditioner controller during operation.

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connectors [1] and [2] and insert the T-adapter.
3. Turn starting switch to ON position.
Between connector [1] (3) and connector [2] (27) Voltage 5V
1. Turn starting switch to OFF position.
2. Disconnect connectors [1] and [2] and insert the T-adapter.
3. Turn starting switch to ON position.
4. Operate the temperature adjustment switch on the air conditioner controller
screen and prepare by setting to COOL MAX.
5. Operate the temperature adjustment switch on the air conditioner controller
Defective air conditioner unit or air screen and set to HOT MAX.
1 a Voltage appears across (21) and (22) of connector [2] for approximately 3
conditioner controller
seconds (only while door moves).
a The voltage will be vary between connectors [1](2) and [2](27) for approxi-
mately 3 seconds (only while door moves). (When the door stops, the volt-
age will stabilize.)
Between (21) (+) and (22) (–) of con-
nector [2]
Approx. 24
a If temperature is changed from Voltage A
V
HOT MAX to COOL MAX, voltage
polarities are reversed.
Between connector [1] (2) (+) and con- Variable
Voltage B
nector [2] (27) (-) max. 5 V
a If the results of checking for Cause 1 A are normal and for Cause 1 B are
2 Defective air conditioner unit
abnormal, the air conditioner unit is defective.
a If the results of checking for Cause 1 A are abnormal, the air conditioner
3 Defective air conditioner controller
controller is defective.
1. Turn starting switch to ON position.
Defective machine monitor 2. Display the air conditioner control screen on the machine monitor.
4
(Defective switch) display changes
Press temperature control switch.
between 18 and 32 °C

80-60 PC228US-8,PC228USLC-8
(01)
 Air conditioner
Troubleshooting for temperature control

Circuit diagram related to temperature adjustment 80-61

a Servomotors are common.

PC228US-8,PC228USLC-8 80-61
(01)
Air conditioner
Troubleshooting for vent (mode) changeover

Troubleshooting for vent (mode) changeover 80-62

Failure q Vent (mode) changeover is not possible.
q"A/C Controller Error" is displayed in red on air conditioner control screen of the machine monitor.
Problem on (See "Troubleshooting for power supply and CAN communication system.")
machine q When vent selector switch on air conditioner operation screen of machine monitor is operated, vent
does not change.
q As described in "Testing with self-diagnosis function", display "03 Air-conditioning system" screen
of "abnormality record" in the machine monitor and check whether a "Ventilation Abnormal" has oc-
curred.
q Even in cases where cables, etc. have been disconnected (see "Testing the vent (mode) change-
over"), self-diagnosis will determine the condition to be normal if the vent (mode) servomotor's po-
tentiometer reaches the correct voltage when current is sent to the vent (mode) servomotor as a
Related infor- result of switch operation.
mation q Although the air mix servomotor and the vent (mode) servomotor are identical, connectors [5] and
[6] cannot be seen from the outside, and therefore, it is not possible to determine whether this ser-
vomotor is defective.
q T-adapter for connector [1]: 799-601-7210, T-adapter for connector [2]: 799-601-7220
q For each connector, see "Parts and connectors layout".
a Connectors [5] and [6] cannot be seen from the outside, therefore, signals must be monitored at air
conditioner controller during operation.

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connectors [1] and [2] and insert the T-adapter.
3. Turn starting switch to ON position.
Between connector [1] (3) and connector [2] (27) Voltage 5V
1. Turn starting switch to OFF position.
2. Disconnect connectors [1] and [2] and insert the T-adapter.
3. Turn starting switch to ON position.
4. Operate the vent switch on the air conditioner controller screen and prepare
by setting to face mode.
5. Operate the vent switch on the air conditioner controller screen and set to
Defective air conditioner unit defrost mode.
1 a Voltage will be output between connectors [2] (24) and [2] (23) for approx-
or air conditioner controller
imately 3 seconds (only while door moves).
a The voltage will be vary between connectors [1] (9) and [2] (27) for approx-
imately 3 seconds (only while door moves). (When the door stops, the volt-
age will stabilize.)
Between (24) (+) and (23) (–) of con-
nector [2]
Approx. 24
a If vent is changed from DEFROST Voltage A
V
to FACE, voltage polarities are re-
versed.
Between connector [1] (9) (+) and con- Variable
Voltage B
nector [2] (27) (-) max. 5 V
a If the results of checking for Cause 1 A are normal and for Cause 1 B are
2 Defective air conditioner unit
abnormal, the air conditioner unit is defective.
a If the results of checking for Cause 1 A are abnormal, the air conditioner
3 Defective air conditioner controller
controller is defective.
1. Turn starting switch to ON position.
2. Display the air conditioner control screen on the machine monitor.
Defective machine monitor
4 Operate the vent switch to display face, face and The display will switch
(Defective switch)
rear, foot and face and rear, foot, foot and defroster, between the various
and defroster. modes.

80-62 PC228US-8,PC228USLC-8
(01)
 Air conditioner
Troubleshooting for vent (mode) changeover

Circuit diagram related to vent (mode) changeover 80-63

a Servomotors are common.

PC228US-8,PC228USLC-8 80-63
(01)
Air conditioner
Troubleshooting for FRESH/RECIRC air changeover

Troubleshooting for FRESH/RECIRC air changeover 80-64

Failure q FRESH/RECIRC air cannot be changed over
qWhen FRESH/RECIRC selector switch of machine monitor is operated, recirculated or fresh air
Problem on
does not changeover.
machine
(FRESH/RECIRC air changeover door (damper) does not rotate)
q FRESH/RECIRC air changeover is not checked with self-diagnosis function.
q Referring to "Testing FRESH/RECIRC air changeover", operate the FRESH/RECIRC air selector
switch and confirm whether or not the FRESH/RECIRC air changeover door (damper) opens and
closes.
Related infor-
q FRESH/RECIRC air changeover servo motor cannot be seen from the outside.
mation
q T-adapter for connector [1]: 799-601-7210, T-adapter for connector [2]: 799-601-7220
q For each connector, see "Parts and connectors layout".
a T-adapters for connectors AC02 and [7] are not prepared, and therefore, signals must be monitored
at air conditioner controller during operation.

Cause Standard value in normal condition/Remarks on troubleshooting

1. Turn starting switch to OFF position.
2. Disconnect connector [2] and insert the T-adapter.
3. Turn starting switch to ON position.
4. Operate the FRESH/RECIRC selector switch on the air conditioner control
screen, and set to recirculated air.
5. Operate the FRESH/RECIRC selector switch on the air conditioner control
screen, and set to fresh air.
a Voltage will be output between connectors [2] (25) and [2] (20) for approx-
imately 3 seconds (only while door moves to the fresh air position).
Defective air conditioner controller Between connector [2] (25) (+) and connector [2] Approx. 24
1 Voltage
or air conditioner unit (20) (-) V
See1. – 3. above.
4. Set FRESH/RECIRC selector switch on air conditioner operation screen to
FRESH.
5. Set FRESH/RECIRC selector switch on air conditioner operation screen to
RECIRC.
a Voltage will be output between connectors [2] (25) and [2] (19) for approx-
imately 3 seconds (only while door moves to the recirculated air position).
Between connector [2] (25) (+) and connector [2] Approx. 24
Voltage
(19) (-) V
a If the results of checking for Cause 1 are normal and the FRESH/RECIRC
2 Defective air conditioner unit
air changeover door does not operate, the air conditioner unit is defective.
a If the results of checking for Cause 1 are abnormal, the air conditioner con-
3 Defective controller
troller is defective.
1. Turn starting switch to ON position.
Defective machine monitor 2. Display the air conditioner control screen on the machine monitor.
4
(Defective switch) Display of Recirc/Fresh
Press FRESH/RECIRC air selector switch.
changes.

80-64 PC228US-8,PC228USLC-8
(01)
 Air conditioner
Troubleshooting for FRESH/RECIRC air changeover

Circuit diagram related to FRESH/RECIRC air changeover 80-65

PC228US-8,PC228USLC-8 80-65
(01)
Air conditioner
Troubleshooting for temperature sensor system

Troubleshooting for temperature sensor system 80-6

Air is not cooled or automatic air conditioner mode does not operate due to the failure of temperature
Failure
sensor system.
Problem on q Air conditioner does not operate even when its activation switch is pressed, or automatic air condi-
machine tioner mode does not operate even when the AUTO switch is pressed.
q The system has three temperature sensors: evaporator temperature sensor, inside (air) temperature
sensor, and outside (air) temperature sensor.
q See "Testing with self-diagnostic function" and troubleshoot the system if any of the following abnor-
malities is found. Ventilating sensor (evaporator temperature sensor) Abnormal, Inner sensor (inside
Related infor-
(air) temperature sensor) Abnormal, or Outer sensor (outside (air) temperature sensor) Abnormal
mation
q The connector of evaporator temperature sensor cannot be inspected when it is mounted on the ma-
chine.
q T-adapter for connector [1]: 799-601-7210, T-adapter for connector [2]: 799-601-7220
q For each connector and other parts, see "Parts and connectors layout".

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connectors [1] and [2] from air conditioner controller, and connect
Defective evaporator tempera-
T-adapter to each connector on the wiring harness side.
ture sensor
1 Between connector [1] (12) and connec- Approx.
(Replacement of air conditioner 0°C Resistance
tor [2] (27) 4.8 kz
unit)
(Resistance of evaporator temperature Approx.
15°C Resistance
sensor) 2.3 kz
1. Turn starting switch to OFF position.
2. Disconnect connectors [1] and [2] from air conditioner controller, and connect
Defective inside air temperature
T-adapter to each connector on the wiring harness side.
sensor
2 Between connector [1] (11) and connec- Approx.
(Replacement of air conditioner 0°C Resistance
tor [2] (27) 1.6 kz
unit)
(Resistance of inside air temperature Approx.
25°C Resistance
sensor) 5 kz
1. Turn starting switch to OFF position.
Defective outside air tempera- 2. Disconnect connector P32.
3
ture sensor Approx.
Between P32 (male) (1) and (2) 25°C Resistance
1.7 kz
1. Turn starting switch to OFF position.
2. Disconnect connectors [1] and [2] from air conditioner controller, and connect
T-adapter to each connector on the wiring harness side.
4 Open circuit in wiring harness Between connector [1] (13) and connec-
tor [2] (27) Approx.
25°C Resistance
(Resistance of outside air temperature 1.7 kz
sensor)
5 Defective air conditioner con-
If cause is not found by above checks, air conditioner controller is defective.
troller

80-66 PC228US-8,PC228USLC-8
(01)
 Air conditioner
Troubleshooting for temperature sensor system

Circuit diagram related to temperature sensors 80-67

PC228US-8,PC228USLC-8 80-67
(01)
Air conditioner
Troubleshooting with gauge pressure

Troubleshooting with gauge pressure 80-68

Perform troubleshooting according to the high and <Measurement condition for pressure>
low gauge pressures of the cooling cycle. For de- Item Condition value
tails, see "Connection of service tool". Ambient temperature 25 – 50 °C
a The gauge pressure varies largely with the Engine speed 1,500 rpm
weather condition and operating condition of the Air conditioner switch ON
Fan switch HI
machine. Check the gauge pressure under the
Set temperature Full cool
pressure measurement conditions.
q High-pressure line pressure is too high: Above q Dual pressure switch
approx. 2.5 MPa {25 kg/cm2} a The swiths is normally "ON", and becomes
q High-pressure line pressure is too low: Below
"OFF" for compressor operation when it detects
abnormal pressure.
approx. 1 MPa {10 kg/cm2}
q Low-pressure line pressure is too high: Above

approx. 0.3 MPa {3 kg/cm2}

q Low-pressure line pressure is too low: Below ap-

prox. 0.05 MPa {0.5 kg/cm2}

a Dual pressure switch turns "OFF" to protect the
air conditioner circuit if the pressure of the
high-pressure or low-perssure line is abnormal.

LA: 0.20 MPa {2 kg/cm2}

LB: 0.02 MPa {0.2 kg/cm2}
HA: 3.14 MPa {32 kg/cm2}
HB: 0.59 MPa {6 kg/cm2}

80-68 PC228US-8,PC228USLC-8
(01)
 Air conditioner
Troubleshooting with gauge pressure

Indicated gauge
Cause Check method Remedy
pressure
Air conditioner cycle is operating normally.
If there is any trouble (cooling trouble), there is another cause.
Pressure is normal –
High- pressure: Approx 1.5 - 1.7 MPa {15 – 17 kg/cm2}
2
Low-pressure: Approx 0.13 - 0.2 MPa {1.3 - 2.0 kg/cm }
Collect refrigerant, then fill up
Bubble can be seen through sight glass. *1, with proper quantity of refriger-
Insufficient refrigerant
*3 ant again
*2
There is a temperature difference between
Replace
Clogging of receiver drier inlet and outlet pipes of receiver drier.
*2
Tank is frosty
Clean or replace
Both high-pressure Clogging of expansion valve Expansion valve is frosted
*2
and low-pressure
Gas leakage at heat sensing tube of Replace
are too low> Low-pressure gauge reads vacuum
expansion valve *2
Repair or replace
Low-pressure gauge Evaporator is frozen
Replace receiver drier
reads vacuum Defective evaporator temperature Flow rate of refrigerant is reduced due to
Collect refrigerant, then fill up
sensor or defective contact of sen- freezing.
with proper quantity of refriger-
sor (coming off of mounting clip) (At cool max. and HI speed of fan, later it
ant again
becomes not to cold.)
*2
Piping between receiver drier and com-
pressor is clogged or crushed. Clean or replace
Clogged or crushed piping
If clogged completely, low-pressure gauge *2
reads vacuum
Collect refrigerant, then fill up
with proper quantity of refriger-
Filling too much with refrigerant Connect gauge manifold
ant again
*2
Clean, repair fins, or repair or
Dirty condenser, clogging or crushing of
<Both high-pres- Defective cooling of condenser replace condenser
fins, or defective revolution of cooling fan
sure and low-pres- *2
sure are too high> Improper adjustment of expansion Replace
Bubble can be seen through sight glass. *3
valve (Valve is opened too wide) *2
Evacuate and then fill up with
proper quantity of refrigerant
Air in cycle parts Bubble can be seen through sight glass. *3
again
*2
<High-pressure is Clean inside of cycle or
Clogged or crushed piping between There is a remarkable temperature differ-
too high and low- replace
compressor and condenser ence across clogged part
pressure is too low> *2
<High-pressure is Both high-pressure and low-pressure are
too low and Defective compressor (Compres- balanced while compressor is in operation. Replace
low-pressure is too sion trouble of compressor) Compressor has seized and is extremely *2
high> hot.
*1 If refrigerant leaks, compressor oil in the air conditioner circuit always leaks, too. So perform the check
mainly on pipe joints and dirty parts with oil.
*2
k When replacing a cooling cycle part, see “Caution about refrigerant” and collect refrigerant. After
replacing it, fill up the air conditioner system with refrigerant again.
*3 Sight glass (1) is placed near condenser.

PC228US-8,PC228USLC-8 80-69
(01)
Air conditioner
Connection of service tool

Connection of service tool 80-70

Sym- Part number Part name Connect the gauge manifold, hoses and other ser-
bol vice tools according to the following procedure.
X 799 - 703 - 1200 Service tool kit 1. Close high-pressure valve (6) and low-pressure
a Use the service tool kit for R134a. valve (7) of gauge manifold (1).
Service tool kit X 2. Connect the red charging hose (2) to the HI side
(1): Gauge manifold of the gauge manifold and the blue charging
(2): High-pressure charging hose (red) hose (3) to the LO side.
(3): Low pressure charging hose (blue) 3. Connect quick joints (4) and (5) to each hose.
(4): Quick joint for HI side (large diameter) 4. Connect quick joints (4) and (5) to service valves
(5): Quick joint for LO side (small diameter) (8) and (9) of high- and low-pressure pipes
respectively.
(a): As the thread is coarse, care should be taken
with regard to loosening.

80-70 PC228US-8,PC228USLC-8
(01)
 Air conditioner
Connection of service tool

A: From Cab
B: To Condenser

PC228US-8,PC228USLC-8 80-71
(01)
Air conditioner
Precautions for disconnecting and connecting air conditioner piping

Precautions for disconnecting and connecting air conditioner piping 80-72

Precautions for disconnecting 80-72 Precautions for connecting 80-72

k Collect the refrigerant (Air conditioner gas: q When connecting piping, apply compressor oil
R134a) from air conditioner circuit before (ND-OIL8) for R134a to its O-rings. (See item 4
disconnecting air conditioner hose to re- of "Handling compressor oil")
place air conditioner unit, air conditioner Do not apply oil to the threads of a bolt, nut or
compressor or receiver drier and so on. union, however.
a Ask a gualified person for collecting, adding and q Once an O-ring is used, it is deformed and dete-
filling operations of the refrigerant (R134a). riorated. Accordingly, do not reuse it. When re-
a Never release the refrigerant (R134a) to the at- moving it, use a soft tool (such as a toothpick) so
mosphere. that the piping will not be damaged.
k If refrigerant gas (R134a) gets in your eyes, q Push in each pipe to the stopper and tighten the
you may lose your sight. And if it touches bolt or nut fully with your fingers.
your skins, you may suffer from frostbite. Ac- q Be sure to use two wrenches to tighten each nut.
cordingly, put on the safety glasses, gloves Use one wrench to fix and tighten the nut with
and working suits with long sleeves while the other wrench to the specified torque (Use a
you are collecting the refrigerant (R134a) or torque wrench for tightening).
filling the air conditioner circuit with the re-
frigerant (R134a). Collecting and filling work
must be conducted by a qualified person.

q When loosening the air conditioner hose nuts af-

ter collecting the refrigerant, be sure to use 2
wrenches; use one wrench to fix and use the oth-
er one to loosen the nuts.

80-72 PC228US-8,PC228USLC-8
(01)
 Air conditioner
Precautions for disconnecting and connecting air conditioner piping

Table of tightening torque for refrigerant pipe joint.

Thread size Tightening torque Nm {kgm}
M6 x 1.0 8 to 12 {0.8 to 1.2}

1. Engine
2. Compressor
3. Condenser
4. Modulator
5. Air conditioner unit

PC228US-8,PC228USLC-8 80-73
(01)
Air conditioner
Handling of compressor oil

Handling of compressor oil 80-74

1. Compressor oil management (DENSO: 2. Filling compressor oil 80-74
ND-OIL8 for R134a) 80-74
k Refrigerant is potentially hazardous to health
Although compressor oil differs from engine oil in and to the environment. Before disconnect-
that it does not need regular checking or filling, the ing air conditioner hoses, therefore, this liq-
following types of problem can occur if the amount uid should be collected in accordance with
in the system is too high or too low. "Precautions for connecting air conditioner
Condition Content piping."
Insufficiency of Lubrication trouble and seizure of com- a If oil for CFC-12 (R-12) is used, lubrication trou-
oil pressor ble will occur and the compressor may be broken
Cooling trouble or seized.
Excess of oil (Excessive oil stick to parts and lower Be sure to use an oil suitable for R134a (
heat exchange performance)
DENSO: ND-OIL8).
a Oil for use with R134a is extremely hygroscopic,
Accordingly, compressor oil must be filled to the and therefore, the cap must be immediately
specified level, similarly to refrigerant. closed after use to limit contact with air.
Store the oil can in a dry and ventilated place.
a Precautions for using oil
Do not allow oil for use with R134a to come into
contact with acrylic plastic or polystyrene
surfaces (without a baked finish) as it may
dissolve these plastics.
Check compressor oil in the following cases, and
then add new oil if necessary.
q When much refrigerant is discharged because of
leakage.
q When the compressor is troubled and replaced.
(See 3 below)
q When a cycle parts such as the air conditioner
unit, condenser, receiver drier, evaporator unit,
etc. is replaced.

q Quantity of oil to be added when cycle part is re-

placed
Quantity to be
Air conditioner part
added (cc)
Air conditioner unit, evaporator Approx. 40
Condenser Approx. 40
Receiver drier Approx. 20
Hose (Compressor – Cab) Approx. 35
Hose (Compressor – Condenser) Approx. 20
Hose (Cab - Condenser) Approx. 5

80-74 PC228US-8,PC228USLC-8
(01)
 Air conditioner
Handling of compressor oil

3. Replacement of compressor 80-75 4. Applying compressor oil to O-rings 80-75

q In case of compressor seizure or breakage. Whenever connecting piping or hoses, the com-
Metal chips will circulate through the air condi- pressor oil (ND-OIL8) must be applied to O-rings in
tioner circuit and contaminate the compressor oil order to prevent the leakage of refrigerant.
extremely.
In this case, flush the air conditioner circuit and
replace the compressor and receiver drier.
The compressor oil is removed from the air
conditioner circuit by flushing. Accordingly,
install a new compressor with the oil of the spec-
ified quantity (180 cc) filled in it.

q Other cases
a New compressor contains compressor oil of 180
cc in it.
1) Prepare an oil container and drain oil from
the old compressor.
2) Measure the quantity of the drained oil with a
measuring cylinder, and note the quantity or
mark the level.

3) Drain below-mentioned quantity of oil from

the new compressor.
Quantity to be drained= 180 cc - "Noted
quantity"
Example: If 30 cc was drained from the
removed compressor, the quantity to be
drained from the new compressor would be
150 cc (i.e., 180 - 30 cc).

PC228US-8,PC228USLC-8 80-75
(01)
Air conditioner
Desiccant replacement procedure

Desiccant replacement procedure 80-76

a Prepare desiccant replacement kit Taking out desiccant (D) 80-76
(20Y-810-1250). 1. Remove snap ring (SR) from receiver drier (2).
2. Remove cap (C) from receiver drier (2).
Hold boss (B) of cap (C) with pliers etc. to
remove.
a Cap (C) may be hard to remove. When re-
moving it, take care not to damage or deform
the seal or receiver drier (2).
3. Remove filter (F) from receiver drier (2)
4. Take desiccant (D) out of receiver drier (2).
a Removed snap ring (SR), cap (C), filter (F),
desiccant (D) will be replaced with the parts
of the drier (desiccant replacement kit) and
will not be necessary any more.

k When replacing the desiccant, be sure to col-

lect the refrigerant from the air conditioning
cycle. If the desiccant is replaced without
collecting the refrigerant, the refrigerant may
blind you or cap (C) may fly out and injure
you because of the refrigerant pressure in
the cycle.
1. Condenser
2. Receiver drier
a The desiccant is in receiver drier (2).

80-76 PC228US-8,PC228USLC-8
(01)
 Air conditioner
Desiccant replacement procedure

Installing new desiccant (D) 80-7

1. Apply ND-OIL 8 to the periphery of O-ring (OR)
of cap (C).
2. Install filter (F) to cap (C).

3. Insert desiccant (D) in receiver drier (2).

4. Install cap (C) with filter (F) to receiver drier (2).
5. Install snap ring (SR) to receiver drier (2).
a Install snap ring (SR) to the groove in receiv-
er drier (2) securely. If it is not installed se-
curely, cap (C) may come off.

PC228US-8,PC228USLC-8 80-77
(01)
Air conditioner
Desiccant replacement procedure

80-78 PC228US-8,PC228USLC-8
(01)
 0 -1

PC228US-8,PC228USLC-8

HYDRAULIC EXCAVATOR
Shop Manual 0-1

PC228US-8
PC228USLC-8

Machine model Serial number

PC228US-8 50001 and up
PC228USLC-8 50001 and up

90 Diagrams and drawings 0 -1

PC228US-8,PC228USLC-8 90-1
Table of contents

Table of contents 50-2

90 Diagrams and drawings
Hydraulic circuit diagram......................................................................................................... 90- 3
Symbols used in hydraulic circuit diagrams ......................................................................... 90- 3
Hydraulic circuit diagram (1/4) ............................................................................................. 90- 7
Hydraulic circuit diagram (2/4) ............................................................................................. 90- 7-2
Hydraulic circuit diagram (3/4) ............................................................................................. 90- 7-4
Hydraulic circuit diagram (4/4) ............................................................................................. 90- 7-6
Electrical circuit diagram ........................................................................................................ 90- 9
Symbols used in electric circuit diagrams ........................................................................... 90- 9
Electrical circuit diagram ..................................................................................................... 90- 13
Air conditioner electrical circuit diagram ............................................................................. 90- 47

90-2 PC228US-8,PC228USLC-8
(05)
 Hydraulic circuit diagram
Symbols used in hydraulic circuit diagrams

Hydraulic circuit diagram 90-3

Symbols used in hydraulic circuit diagrams 90-3
(Rev. 2010/03)

PC228US-8,PC228USLC-8 90-3
Hydraulic circuit diagram
Symbols used in hydraulic circuit diagrams

90-4 PC228US-8,PC228USLC-8
 Hydraulic circuit diagram
Symbols used in hydraulic circuit diagrams

PC228US-8,PC228USLC-8 90-5
Hydraulic circuit diagram
Symbols used in hydraulic circuit diagrams

90-6 PC228US-8,PC228USLC-8
Hydraulic circuit diagram (1/4) Hydraulic circuit diagram (1/4)
PC228US-8,PC228USLC-8
PC228US-8,PC228USLC-8
a This figure covers the equipment and devices that are unavailable as optional items in some areas.

PC228US-8,PC228USLC-8 90-7
(05)
Hydraulic circuit diagram (2/4) Hydraulic circuit diagram (2/4)
PC228US-8,PC228USLC-8
PC228US-8,PC228USLC-8
a This figure covers the equipment and devices that are unavailable as optional items in some areas.

PC228US-8,PC228USLC-8 90-9
90-7-2
(05)
Hydraulic circuit diagram (3/4) Hydraulic circuit diagram (3/4)
PC228US-8,PC228USLC-8
PC228US-8,PC228USLC-8
a This figure covers the equipment and devices that are unavailable as optional items in some areas.

PC228US-8,PC228USLC-8 90-11
90-7-4
(05)
Hydraulic circuit diagram (4/4) Hydraulic circuit diagram (4/4)
PC228US-8,PC228USLC-8
PC228US-8,PC228USLC-8
a This figure covers the equipment and devices that are unavailable as optional items in some areas.

PC228US-8,PC228USLC-8 90-13
90-7-6
(05)
 Electrical circuit diagram
Symbols used in electric circuit diagrams

Electrical circuit diagram 90-9

Symbols used in electric circuit diagrams 90-9
(Rev. 2010/03)

PC228US-8,PC228USLC-8 90-9
Electrical circuit diagram
Symbols used in electric circuit diagrams

90-10 PC228US-8,PC228USLC-8
 Electrical circuit diagram
Symbols used in electric circuit diagrams

PC228US-8,PC228USLC-8 90-11
Electrical circuit diagram
Symbols used in electric circuit diagrams

90-12 PC228US-8,PC228USLC-8
Electrical circuit diagram (1/6) Electrical circuit diagram (1/6)
(Standard spec.)
(Standard specification) PC228US-8,PC228USLC-8
PC228US-8,PC228USLC-8
a This figure covers the equipment and devices that are unavailable as optional items in some areas.

PC228US-8,PC228USLC-8 90-13
Electrical circuit diagram (2/6) Electrical circuit diagram (2/6)
(Standard spec.)
(Standard specification) PC228US-8,PC228USLC-8
PC228US-8,PC228USLC-8
a This figure covers the equipment and devices that are unavailable as optional items in some areas.

PC228US-8,PC228USLC-8 90-15
90-14
Electrical circuit diagram (3/6) Electrical circuit diagram (3/6)
(Standard spec.)
(Standard specification) PC228US-8,PC228USLC-8
PC228US-8,PC228USLC-8
a This figure covers the equipment and devices that are unavailable as optional items in some areas.

PC228US-8,PC228USLC-8 90-17
90-15
Electrical circuit diagram (4/6) Electrical circuit diagram (4/6)
(Standard spec.)
(Standard specification) PC228US-8,PC228USLC-8
PC228US-8,PC228USLC-8
a This figure covers the equipment and devices that are unavailable as optional items in some areas.

PC228US-8,PC228USLC-8 90-19
90-16
Electrical circuit diagram (5/6) Electrical circuit diagram (5/6)
(Standard spec.)
(Standard specification) PC228US-8,PC228USLC-8
PC228US-8,PC228USLC-8
a This figure covers the equipment and devices that are unavailable as optional items in some areas.

PC228US-8,PC228USLC-8 90-21
90-17
Electrical circuit diagram (6/6) Electrical circuit diagram (6/6)
(Standard spec.)
(Standard specification) PC228US-8,PC228USLC-8
PC228US-8,PC228USLC-8
a This figure covers the equipment and devices that are unavailable as optional items in some areas.

PC228US-8,PC228USLC-8 90-23
90-18
Electrical circuit diagram (1/6) Electrical circuit diagram (1/6)
(KUK spec.)
(KUK specification) PC228US-8,PC228USLC-8
PC228US-8,PC228USLC-8
a This figure covers the equipment and devices that are unavailable as optional items in some areas.

PC228US-8,PC228USLC-8 90-25
Electrical circuit diagram (2/6) Electrical circuit diagram (2/6)
(KUK spec.)
(KUK specification) PC228US-8,PC228USLC-8
PC228US-8,PC228USLC-8
a This figure covers the equipment and devices that are unavailable as optional items in some areas.

PC228US-8,PC228USLC-8 90-27
90-26
Electrical circuit diagram (3/6) Electrical circuit diagram (3/6)
(KUK spec.)
(KUK specification) PC228US-8,PC228USLC-8
PC228US-8,PC228USLC-8
a This figure covers the equipment and devices that are unavailable as optional items in some areas.

PC228US-8,PC228USLC-8 90-29
90-27
Electrical circuit diagram (4/6) Electrical circuit diagram (4/6)
(KUK spec.)
(KUK specification) PC228US-8,PC228USLC-8
PC228US-8,PC228USLC-8
a This figure covers the equipment and devices that are unavailable as optional items in some areas.

PC228US-8,PC228USLC-8 90-31
90-28
Electrical circuit diagram (5/6) Electrical circuit diagram (5/6)
(KUK spec.)
(KUK specification) PC228US-8,PC228USLC-8
PC228US-8,PC228USLC-8
a This figure covers the equipment and devices that are unavailable as optional items in some areas.

PC228US-8,PC228USLC-8 90-33
90-29
Electrical circuit diagram (6/6) Electrical circuit diagram (6/6)
(KUK spec.)
(KUK specification) PC228US-8,PC228USLC-8
PC228US-8,PC228USLC-8
a This figure covers the equipment and devices that are unavailable as optional items in some areas.

PC228US-8,PC228USLC-8 90-35
90-30
Electrical circuit diagram (1/5) Electrical circuit diagram (1/5)
(KAL spec.)
(KAL specification) PC228US-8,PC228USLC-8
PC228US-8,PC228USLC-8
a This figure covers the equipment and devices that are unavailable as optional items in some areas.

PC228US-8,PC228USLC-8 90-37
Electrical circuit diagram (2/5) Electrical circuit diagram (2/5)
(KAL spec.)
(KAL specification) PC228US-8,PC228USLC-8
PC228US-8,PC228USLC-8
a This figure covers the equipment and devices that are unavailable as optional items in some areas.

PC228US-8,PC228USLC-8 90-39
90-38
Electrical circuit diagram (3/5) Electrical circuit diagram (3/5)
(KAL spec.)
(KAL specification) PC228US-8,PC228USLC-8
PC228US-8,PC228USLC-8
a This figure covers the equipment and devices that are unavailable as optional items in some areas.

PC228US-8,PC228USLC-8 90-41
90-39
Electrical circuit diagram (4/5) Electrical circuit diagram (4/5)
(KAL spec.)
(KAL specification) PC228US-8,PC228USLC-8
PC228US-8,PC228USLC-8
a This figure covers the equipment and devices that are unavailable as optional items in some areas.

PC228US-8,PC228USLC-8 90-43
90-40
Electrical circuit diagram (5/5) Electrical circuit diagram (5/5)
(KAL spec.)
(KAL specification) PC228US-8,PC228USLC-8
PC228US-8,PC228USLC-8
a This figure covers the equipment and devices that are unavailable as optional items in some areas.

PC228US-8,PC228USLC-8 90-45
90-41
Air conditioner electrical circuit diagram Air conditioner electrical circuit diagram
PC228US-8,PC228USLC-8
PC228US-8,PC228USLC-8
a This figure covers the equipment and devices that are unavailable as optional items in some areas.

PC228US-8, PC228USLC-8 90-47

 Index

Index
A Disassembly and assembly of work equipment cylinder
Adjusting mirrors 30-63 assembly 50-135
Adjusting play of work equipment and swing PPC vavles Disassembly and assembly of work equipment PPC valve
30-52 assembly 50-127
Air conditioner component 80-4
Air conditioner controller 80-15 E
Air conditioner electrical circuit diagram 90-47 E-1 Engine does not start (Engine does not crank)
Air conditioner unit 80-10 40-337
Angle adjustment of rear view camera 30-65 E-2 Preheater does not operate 40-342
Anti-drop valve 10-142,60-58 E-3 When starting switch is turned to ON position,
Attachment circuit selector valve 10-138,60-55 machine monitor displays nothing 40-347
E-4 When starting switch is turned to ON position (before
B starting engine), basic check monitor lights up. 40-350
Bleeding air from each part 30-59 E-5 Precaution monitor lights up while engine is running
Bleeding air from fuel circuit 30-27 40-351
E-6 Emergency stop monitor lights up while engine is
running 40-353
C
E-7 Fuel level gauge does not indicate correctly 40-354
Carrier roller 60-19
E-8 Engine coolant temperature gauge does not indicate
Center swivel joint 10-148,60-60
correctly 40-356
Checking and adjusting track tension 30-32
E-9 Hydraulic oil temperature gauge does not indicate
Checking cab tipping stopper 30-62
correctly 40-358
Checking fuel delivery, return rate and leakage 30-24
E-10 Displays on machine monitor are different from
Checks before troubleshooting 40-10
those for actual machine 40-361
Circuit diagram and arrangement of connector pins 80-22
E-11 Some areas of machine monitor screen are not
Classification and procedures for troubleshooting 40-34
displayed 40-361
CLSS 10-21
E-12 Function switch does not operate 40-361
Coating materials list 50-6
E-13 Automatic warm-up system does not operate (in cold
Compressor 80-16
season) 40-362
Condenser and Modulator 80-17
E-14 Auto-decelerator does not operate properly 40-363
Configuration and function of refrigeration cycle 80-6
E-15 Working mode does not change 40-364
Connection of service tool 80-70
E-16 Travel speed does not change 40-365
Connection table for connector pin numbers 40-60
E-17 Alarm buzzer cannot be canceled 40-366
Connector list and layout 40-48
E-18 When starting switch is turned OFF, service meter is
Control valve 10-48,60-29
not displayed 40-366
Conversion table 00-42
E-19 Service mode cannot be selected 40-367
Cooling system 10-4,60-5
E-20 Any of work equipment, swing and travel do not
Cylinder cut-out test mode 30-22
operate or cannot be locked 40-368
E-21 Swing brake does not operate properly 40-371
D E-22 One-touch power maximizing function does not
Desiccant replacement procedure 80-76 operate properly 40-374
Detail of air conditioner unit 80-26 E-23 Travel alarm does not sound or does not stop
Dimensions of components 60-64 sounding 40-377
Disassembly and assembly of anti-drop valve assembly E-24 Horn does not sound or does not stop 40-378
50-134-6 E-25 Windshield wiper and window washer do not operate
Disassembly and assembly of carrier roller assembly 40-380
50-96 E-26 BOOM LOWER indicator is not displayed properly
Disassembly and assembly of center swivel joint with monitoring function 40-382
assembly 50-109 E-27 ARM OUT indicator is not displayed properly with
Disassembly and assembly of control valve assembly monitoring function 40-384
50-123 E-28 ARM IN indicator is not displayed properly with
Disassembly and assembly of final drive assembly 50-67 monitoring function 40-386
Disassembly and assembly of idler assembly 50-89 E-29 BOOM RAISE indicator is not displayed properly
Disassembly and assembly of idler cushion assembly with monitoring function 40-386
50-92 E-30 BUCKET CURL indicator is not displayed properly
Disassembly and assembly of swing machinery assembly with monitoring function 40-386
50-77 E-31 BUCKET DUMP indicator is not displayed properly
Disassembly and assembly of track roller assembly50-94 with monitoring function 40-387
Disassembly and assembly of travel PPC valve assembly E-32 SWING indicator is not displayed properly with
50-129 monitoring function 40-387

PC228US-8,PC228USLC-8 1
(04)
Index

E-33 TRAVEL indicator is not displayed properly with Failure code [CA227] Sens Supply 2 Volt High Error
monitoring function 40-387 40-140
E-34 ATTACHMENT indicator is not displayed properly Failure code [CA2311] IMV Solenoid Error 40-195
with monitoring function 40-388 Failure code [CA234] Eng Overspeed 40-141
E-35 Attachment hydraulic circuit cannot be changed Failure code [CA238] Ne Speed Sens Supply Volt Error
40-390 40-142
E-36 KOMTRAX system does not operate properly Failure code [CA2555] Grid Htr Relay Open Circuit Error
40-391 40-196
Electrical circuit diagram 90-13 Failure code [CA2556] Grid Htr Relay Short Circuit Error
Electronic control system 10-154 40-198
Engine mount 60-4 Failure code [CA271] IMV/PCV1 Short Error 40-144
Engine related parts 10-3 Failure code [CA272] IMV/PCV1 Open Error 40-146
Explanation of terms for maintenance standard 00-11 Failure code [CA322] Inj #1(L#1) Open/Short Error
40-148
Failure code [CA323] Inj #5 (L#5) Open/Short Error
F 40-150
Failure code [989L00] Engine Controller Lock Caution 1 Failure code [CA324] Inj #3(L#3) Open/Short Error
40-102 40-152
Failure code [989M00] Engine Controller Lock Caution 2 Failure code [CA325] Inj #6 (L#6) Open/Short Error
40-102 40-154
Failure code [989N00] Engine Controller Lock Caution 3 Failure code [CA331] Inj #2(L#2) Open/Short Error
40-103 40-156
Failure code [AA10NX] Air Cleaner Clogging 40-104 Failure code [CA332] Inj #4(L#4) Open/Short Error
Failure code [AB00KE] Charge Voltage Low 40-106 40-158
Failure code [B@BAZG] Eng Oil Press Low 40-108 Failure code [CA342] Calibration Code Incompatibility
Failure code [B@BAZK] Eng Oil Level Low 40-109 40-160
Failure code [B@BCNS] Eng Water Overheat 40-110 Failure code [CA351] Injectors Drive Circuit Error 40-161
Failure code [B@BCZK] Eng Water Level Low 40-112 Failure code [CA352] Sens Supply 1 Volt Low Error
Failure code [B@HANS] Hyd Oil Overheat 40-114 40-162
Failure code [CA111] ECM Critical Internal Failure Failure code [CA386] Sens Supply 1 Volt High Error
40-115 40-164
Failure code [CA115] Eng Ne and Bkup Speed Sens Error Failure code [CA428] Water in Fuel Sensor High Error
40-115 40-166
Failure code [CA122] Chg Air Press Sensor High Error Failure code [CA429] Water in Fuel Sensor Low Error
40-116 40-168
Failure code [CA123] Chg Air Press Sensor Low Error Failure code [CA435] Eng Oil Press Sw Error 40-170
40-118 Failure code [CA441] Battery Voltage Low Error 40-172
Failure code [CA131] Throttle Sensor High Error 40-120 Failure code [CA442] Battery Voltage High Error 40-174
Failure code [CA132] Throttle Sensor Low Error 40-122 Failure code [CA449] Rail Press Very High Error 40-175
Failure code [CA144] Coolant Temp Sens High Error Failure code [CA451] Rail Press Sensor High Error
40-124 40-176
Failure code [CA145] Coolant Temp Sens Low Error Failure code [CA452] Rail Press Sensor Low Error
40-126 40-178
Failure code [CA153] Chg Air Temp Sensor High Error Failure code [CA488] Chg Air Temp High Torque Derate
40-128 40-180
Failure code [CA154] Chg Air Temp Sensor Low Error Failure code [CA553] Rail Press High Error 40-181
40-130 Failure code [CA559] Rail Press Low Error 40-182
Failure code [CA155] Chg Air Temp High Speed Derate Failure code [CA689] Eng Ne Speed Sensor Error
40-132 40-184
Failure code [CA1633] KOMNET Datalink Timeout Error Failure code [CA731] Eng Bkup Speed Sens Phase Error
40-191 40-186
Failure code [CA187] Sens Supply 2 Volt Low Error Failure code [CA757] All Continuous Data Lost Error
40-134 40-187
Failure code [CA2185] Throt Sens Sup Volt High Error Failure code [CA778] Eng Bkup Speed Sensor Error
40-192 40-188
Failure code [CA2186] Throt Sens Sup Volt Low Error Failure code [D110KB] Battery Relay Drive Short Circuit
40-193 40-200
Failure code [CA221] Ambient Press Sens High Error Failure code [D19JKZ] Personal Code Relay Abnormality
40-136 40-202
Failure code [CA222] Ambient Press Sens Low Error Failure code [D862KA] GPS Antenna Open Circuit
40-138 40-204
Failure code [CA2249] Rail Press Very Low Error 40-194 Failure code [DA22KK] Pump Solenoid Power Low Error
40-206

2 PC228US-8,PC228USLC-8
(04)
 Index

Failure code [DA25KP] 5V Sensor1 Power Abnormality Failure code [DW4WKA] Cancel Bucket Dump Open
40-208 Circuit 40-284
Failure code [DA26KP] 5V Sensor2 Power Abnormality Failure code [DW4WKB] Cancel Bucket Dump Short
40-210 Circuit 40-286
Failure code [DA29KQ] Model Selection Abnormality Failure code [DW91KA] Travel Junction Sol. Disc.40-288
40-214 Failure code [DW91KB] Travel Junction Sol. S/C 40-290
Failure code [DA2RMC] CAN Discon (Pump Con Failure code [DWA2KA] Attachment Sol Open Circuit
Detected) 40-217 40-292
Failure code [DAF8KB] Camera Power Supply Short Failure code [DWA2KB] Attachment Sol Short Circuit
Circuit 40-222 40-294
Failure code [DAFGMC] GPS Module Error 40-224 Failure code [DWK0KA] 2-stage Relief Sol Open Circuit
Failure code [DAFRMC] CAN Discon (Monitor Detected) 40-296
40-226 Failure code [DWK0KB] 2-stage Relief Sol Short Circuit
Failure code [DGH2KB] Hyd Oil Sensor Short 40-230 40-298
Failure code [DHPAMA] Pump Press Sensor Abnormality Failure code [DXA8KA] PC-EPC (F) Sol Open Circuit
40-232 40-300
Failure code [DHPBMA] R Pump Press Sensor Failure code [DXA8KB] PC-EPC (F) Sol Short Circuit
Abnormality 40-234 40-302
Failure code [DHS3MA] Arm IN PPC Sen. Abnormality Failure code [DXA9KA] PC-EPC (R) Sol Open Circuit
40-236 40-304
Failure code [DHS4MA] Bucket CURL PPC Press Sensor Failure code [DXA9KB] PC-EPC (R) Sol Short Circuit
Abnormality 40-238 40-306
Failure code [DHS8MA] Boom RAISE PPC Press Sensor Failure code [DXE0KA] LS-EPC Sol Open Circuit 40-308
Abnormality 40-240 Failure code [DXE0KB] LS-EPC Sol Short Circuit 40-310
Failure code [DHSAMA] Swing RH PPC Press Sensor Failure code [DXE4KA] Service Current EPC Disc.
Abnomality 40-242 40-312
Failure code [DHSBMA] Swing LH PPC Press Sensor Failure code [DXE4KB] Service Current EPC S/C 40-314
Abnomality 40-244 Failure code [DXE5KA] Merge-divider Main Sol Open
Failure code [DHSDMA] Bucket Dump PPC Press Sensor Circuit 40-316
Abnormality 40-246 Failure code [DXE5KB] Merge-divider Main Sol Short
Failure code [DHSFMA] Travel FW L PPC Press Sensor Circuit 40-318
Abnormality 40-248 Failure code [DXE6KA] Merge-divider LS Sol Open
Failure code [DHSGMA] Travel FW R PPC Press Sensor Circuit 40-320
Abnormality 40-250 Failure code [DXE6KB] Merge-divider LS Sol Short Circuit
Failure code [DHSHMA] Travel BW L PPC Press Sensor 40-322
Abnormality 40-252 Failure code [DY20KA] Wiper Working Abnormality
Failure code [DHSJMA] Travel BW R PPC Press Sensor 40-324
Abnormality 40-254 Failure code [DY20MA] Wiper Parking Abnormality
Failure code [DHX1MA] Overload Sensor Abnormality 40-326
40-257 Failure code [DY2CKA] Washer drive discon 40-328
Failure code [DKA0KA] Boom Angle Sensor Open Circuit Failure code [DY2CKB] Washer drive short 40-330
40-260 Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit
Failure code [DKA0KB] Boom Angle Sensor Power Short 40-332
Circuit 40-262 Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit
Failure code [DKA0PH] Boom Angle Sensor Install 40-334
Abnormality 40-264 Failure codes table 40-37
Failure code [DKR0MA] F pump S/P sensor Abnormality Failure mode and cause table 40-396
40-266 Final drive 10-12,60-10
Failure code [DKR1MA] R pump S/P sensor Abnormality Function and operation by valve 10-60
40-268 Fuse location table 40-100
Failure code [DV20KB] Travel Alarm Short Circuit 40-270
Failure code [DW43KA] Travel Speed Sol Open Circuit H
40-272 H- 1 All of work equipment, swing and travel work slow or
Failure code [DW43KB] Travel Speed Sol Short Circuit lack power 40-398
40-274 H- 2 Engine speed lowers significantly or engine stalls
Failure code [DW45KA] Swing Brake Sol Open Circuit 40-400
40-276 H- 3 Any of work equipment,swing and travel does not
Failure code [DW45KB] Swing Brake Sol Short Circuit work 40-401
40-278 H- 4 Unusual sound is heard from around hydraulic pump
Failure code [DW4GKA] Boom Slow Down Sol. Disc. 40-401
40-280 H- 5 Fine control performance or response is poor
Failure code [DW4GKB] Boom Slow Down Sol. Short 40-402
Circuit 40-282 H- 6 Boom operation lacks speed or power 40-403

PC228US-8,PC228USLC-8 3
(04)
Index

H- 7 Arm operation lacks speed or power 40-404 M

H- 8 Bucket operation lacks speed or power 40-405 Machine monitor system 10-192
H- 9 Work equipment does not move in single operation Main pump 10-26,60-26
40-405 Method of disconnecting and connecting push-pull type
H-10 Hydraulic drift of work equipment is large 40-406 coupler 00-15
H-11 Time lag of work equipment is large 40-408 Method of using troubleshooting chart 40-424
H-12 Other work equipment moves when one of work Multi-control valve 10-147
equipment is relieved 40-408
H-13 One-touch power maximizing function does not work
N
40-409
No-injection cranking 30-23
H-14 In combined operation of work equipment ,
equipment having heavier load moves slower. 40-409
H-15 In combined operation of swing and boom RAISE, O
boom rising speed is low 40-410 Outline of refrigeration cycle 80-8
H-16 Travel speed drops largely in combined operation of
swing and travel 40-410 P
H-17 Machine does not travel straight 40-411 Parts and connectors layout 80-28
H-18 Travel speed is low 40-412 Pm clinic service 30-131
H-19 Machine is hard to steer or travel power is low Points to remember when troubleshooting 40-8
40-413 Power train 10-7
H-20 Travel speed does not change, or travel speed is too PPC accumulator 10-149
low or high 40-414 PPC valve 10-115,60-45
H-21 One of tracks does not run 40-415 Precautions for disconnecting and connecting air
H-22 Upper structure does not swing 40-416 conditioner piping 80-72
H-23 Swing acceleration is poor or swing speed is low Precautions for refrigerant 80-3
40-418 Precautions when performing work 00-31
H-24 Upper structure overruns excessively when it stops Preparatory work for troubleshooting of electrical system
swinging 40-420 30-124
H-25 Shock is large when upper structure stops swinging Procedure for testing and troubleshooting 80-20
40-421 Procedure for testing diodes 30-129
H-26 Large unusual noise is heard when upper structure
stops swinging 40-421
H-27 Swing drift on a slope is large 40-422
R
H-28 Attachment circuit cannot be changed 40-423 Releasing remaining pressure from fuel system 30-18
H-29 Oil flow in attachment circuit cannot be controlled Releasing remaining pressure from hydraulic circuit
40-423 30-56
Handling fuel system parts 30-17 Removal and installation of aftercooler assembly 50-49
Handling of compressor oil 80-74 Removal and installation of air conditioner compressor
Handling of electric equipment 00-18 assembly 50-170
Handling of hydraulic components 00-13 Removal and installation of air conditioner condenser
Handling voltage circuit of engine controller 30-123 assembly 50-172
How to read Disassembly and Assembly 50-4 Removal and installation of air conditioner unit assembly
How to read electric wire code 00-28 50-164
How to read the shop manual 00-9 Removal and installation of anti-drop valve assembly for
Hydraulic circuit diagram 90-7 arm 50-134-4
Hydraulic equipment layout drawing 10-16 Removal and installation of anti-drop valve assembly for
Hydraulic tank 10-19,60-25 boom 50-134-1
Removal and installation of center swivel joint assembly
50-106
I Removal and installation of control valve assembly
Idler 60-16 50-118
Information in troubleshooting table 40-393 Removal and installation of counterweight assembly
Information in troubleshooting table 40-44 50-101
Information in troubleshooting table 80-48 Removal and installation of cylinder head assembly
Isolating the parts causing hydraulic drift of work 50-29
equipment 30-54 Removal and installation of engine assembly 50-52
Removal and installation of engine controller assembly
K 50-173
KOMTRAX system 10-208 Removal and installation of engine front seal 50-56
Removal and installation of engine rear seal 50-58
L Removal and installation of floor frame assembly 50-157
Removal and installation of front window assembly
List of Abbreviation 00-38
50-156
Removal and installation of fuel cooler assembly 50-61

4 PC228US-8,PC228USLC-8
(04)
 Index

Removal and installation of fuel injector assembly 50-22 Sensor 80-18

Removal and installation of fuel supply pump assembly Sensors 10-210
50-18 Separation and connection of track shoe assembly 50-86
Removal and installation of fuel tank assembly 50-63 Sequence of events in troubleshooting 40-9
Removal and installation of hydraulic oil cooler assembly Sketches of special tools 50-13
50-47 Solenoid valve 10-132,60-53
Removal and installation of hydraulic tank assembly Special tools list 50-9
50-111 Specifications 01-6
Removal and installation of idler and idler cushion Specifications drawing 01-4
assembly 50-88 Speial function of machine monitor (EMMS) 30-67
Removal and installation of KOMTRAX terminal assembly Sprocket 60-12
50-181 Standard tightening torque table 00-34
Removal and installation of machine monitor assembly Standard value table for engine 20-3
50-178 Standard value table for machine 20-4
Removal and installation of main pump assembly 50-113 Swing circle 10-8,60-6
Removal and installation of main pump input shaft oil seal Swing machinery 10-10,60-8
50-117 Swing motor 10-97,60-39
Removal and installation of maintenance counterweight Symbols used in electric circuit diagrams 90-9
assembly 50-103 Symbols used in hydraulic circuit diagrams 90-3
Removal and installation of operator's cab assembly Symptom and troubleshooting numbers 40-42
50-142 System chart for hydraulic and mechanical systems
Removal and installation of operator's cab glass (adhered 40-394
window glass) 50-146 System diagram 80-24
Removal and installation of pump controller assembly
50-175 T
Removal and installation of pump swash plate sensor T- branch box and T- branch adapter table 40-96
50-180 Table of fuel, coolant and lubricants 01-20
Removal and installation of radiator assembly 50-44 Table of weight 01-16
Removal and installation of revolving frame assembly Testing (dual) pressure switch for refrigerant 80-41
50-99 Testing air leakage (duct) 80-32
Removal and installation of swing circle assembly 50-85 Testing and adjusting air conditioner compressor belt
Removal and installation of swing motor and swing tension 30-29
machinery assembly 50-75 Testing and adjusting oil pressure in pump LS control
Removal and installation of travel motor and final drive circuit 30-42
assembly 50-66 Testing and adjusting oil pressure in pump PC control
Removal and installation of work equipment assembly circuit 30-38
50-132 Testing and adjusting oil pressure in work equipment,
Replacement procedure of boom angle potentiometer swing and travel circuits 30-33
30-61 Testing and adjusting valve clearance 30-10
Replacing fan belt 30-30 Testing blowby pressure 30-15
Testing compression pressure 30-12
S Testing control circuit source pressure 30-37
S-1 Startability is poor 40-428 Testing engine oil pressure 30-16
S-2 Engine does not start 40-429 Testing engine speed 30-7
S-3 Engine does not pick up smoothly 40-432 Testing exhaust gas color 30-9
S-4 Engine stops during operation 40-433 Testing FRESH/RECIRC air changeover 80-37
S-5 Engine runs rough or is unstable 40-434 Testing fuel circuit for leakage 30-28
S-6 Engine lacks power 40-435 Testing fuel pressure 30-19
S-7 Exhaust smoke is black (incomplete combustion) Testing inner sensor 80-38
40-436 Testing intake air pressure (boost pressure) 30-8
S-8 Oil consumption is excessive (or exhaust smoke is Testing oil leakage amount 30-57
blue) 40-437 Testing outer sensor 80-39
S-9 Oil becomes contaminated early 40-438 Testing PPC valve output pressure 30-50
S-10 Fuel consumption is excessive 40-439 Testing pump swash plate sensor 30-53
S-11 Oil is in coolant (or coolant spurts or coolant level Testing relays 80-42
goes down) 40-440 Testing solenoid valve output pressure 30-47
S-12 Oil pressure drops 40-441 Testing sunlight sensor 80-40
S-13 Oil level rises (coolant or fuel in oil) 40-442 Testing swing circle bearing clearance 30-31
S-14 Coolant temperature rises too high (overheating) Testing vent (mode) changeover 80-36
40-443 Testing with self-diagnosis function 80-33
S-15 Unusual noise is made 40-444 Tools for testing, adjusting, and troubleshooting 30-3
S-16 Vibration is excessive 40-445 Track frame and idler cushion 10-14,60-14
Safety notice 00-4 Track roller 60-18

PC228US-8,PC228USLC-8 5
(04)
Index

Track shoe 60-20

Travel motor 10-105,60-41
Troubleshooting chart 1 80-44
Troubleshooting chart 2 80-46
Troubleshooting for blower motor system (No air comes
out or air flow is abnormal) 80-57
Troubleshooting for compressor and refrigerant system
(Air is not cooled) 80-54
Troubleshooting for FRESH/RECIRC air changeover
80-64
Troubleshooting for power supply and CAN
communication system (Air conditioner does not operate)
80-50
Troubleshooting for temperature control 80-60
Troubleshooting for temperature sensor system 80-66
Troubleshooting for vent (mode) changeover 80-62
Troubleshooting method for open circuit in wiring harness
of pressure sensor system 40-46
Troubleshooting with gauge pressure 80-68

V
Valve control 10-18

W
Work equipment 10-152,60-61
Work equipment cylinder 60-68
Working range diagram 01-5

6 PC228US-8,PC228USLC-8
(04)
Shop Manual
PC228US-8,PC228USLC-8 HYDRAULIC EXCAVATOR

Form Number: SEN05331-05

©2017 KOMATSU
All Rights Reserved
Printed in Japan 02-17 (01)