Pc228us LC-3

SEBM023104
MACHINE MODEL SERIAL NUMBER

PC228US-3 00 20001 and up 00
PC228USLC-3 00 20001 and up 00
00 00
00 00
• This shop manual may contain attachments and optional equipment that are not avail-
able in your area. Please consult your local Komatsu distributor for those items you may
require.
Materials and specifications are subject to change without notice
• PC228US-3, PC228USLC-3 mounts the SAA6D102E engine.
For details of the engine, see the 102 Series Engine Shop Manual.
© 2004
All Rights Reserved 00-1
Printed in Japan 10-04 (01) (4)
00
CONTENTS
00
No. of page
01 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .01-1
10 STRUCTURE, FUNCTION AND MAINTENANCE

STANDARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
20 TESTING AND ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . 20-1
30 DISASSEMBLY AND ASSEMBLY. . . . . . . . . . . . . . . . . . . 30-1
90 OTHERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-1
PC228US-3
00-2 PC228US-3
2
The affected pages are indicated by the use of the
following marks. It is requested that necessary Mark Indication Action required
actions be taken to these pages according to the
table below.
Page to be newly added Add
Page to be replaced Replace
( ) Page to be deleted Discard
Pages having no marks are those previously

revised or made additions.
LIST OF REVISED PAGES 00
Revision Revision Revision Revision Revision

Mark Pages Mark Pages Mark Pages Mark Pages Mark Pages
number number number number number
q 00-1 (4) 01-1 10-15 10-42 10-69

00-2 (2) 01-2 10-16 10-43 10-70
q 00-2-1 (4) 01-3 10-17 10-44 10-71
q 00-2-2 (4) 01-4 10-18 10-45 10-72
q 00-2-3 (4) 01-5 10-19 10-46 10-73
q 00-2-4 (4) 01-6 10-20 10-47 10-74
q 00-3 01-7 10-21 10-48 10-75
q 00-4 01-8 10-22 10-49 10-76
q 00-5 01-9 10-23 10-50 10-77
q 00-6 01-10 10-24 10-51 10-78
q 00-7 01-11 10-25 10-52 10-79
q 00-8 01-12 10-26 10-53 10-80
q 00-9 10-27 10-54 10-81
q 00-10 10-1 10-28 10-55 10-82
q 00-11 10-2 10-29 10-56 10-83
q 00-12 10-3 10-30 10-57 10-84
q 00-13 10-4 10-31 10-58 10-85
q 00-14 10-5 10-32 10-59 10-86
q 00-15 10-6 10-33 10-60 10-87
q 00-16 10-7 10-34 10-61 10-88
q 00-17 10-8 10-35 10-62 10-89
q 00-18 10-9 10-36 10-63 10-90
q 00-19 10-10 10-37 10-64 10-91
q 00-20 10-11 10-38 10-65 10-92
q 00-21 10-12 10-39 10-66 10-93
q 00-22 10-13 10-40 10-67 10-94
10-14 10-41 10-68 10-95
PC228US-3 00-2-1
(4)
10-96 10-135 20-1 20-120 (1) 20-224 (1)

10-97 10-136 20-2 20-121 (1) 20-225 (1)
10-98 10-137 20-3 20-122 (1) 20-226 (1)
10-99 10-138 20-4 20-123 (1) 20-227 (1)
10-100 10-139 20-5 20-124 (1) 20-228 (1)
10-101 10-140 20-6 20-125 (1) 20-229 (1)
10-102 10-141 20-7 20-126 (1) 20-230 (1)
10-103 10-142 20-8 20-127 (1) 20-231 (1)
10-104 q 10-143 (4) 20-9 20-128 (1) 20-232 (1)
10-105 10-144 20-10 20-129 (1) 20-233 (1)
10-106 10-145 20-11 20-130 (1) 20-234 (1)
10-107 10-146 20-12 20-131 (3) 20-235 (1)
10-108 10-147 20-13 20-132 (1) 20-236 (1)
10-109 10-148 20-14 20-133 (1) 20-237 (1)
10-110 10-149 20-15 20-134 (1) 20-238 (1)
10-111 10-150 20-16 20-135 (1) 20-239 (1)
10-112 10-151 20-17 20-201 (1) 20-240 (1)
10-113 10-152 20-18 20-202 (1) 20-241 (1)
10-114 10-153 20-19 20-203 (1) 20-242 (1)
10-115 10-154 20-20 20-204 (1) 20-243 (1)
10-116 10-155 20-101 (1) 20-205 (1) 20-244 (1)
10-117 10-156 q 20-102 (4) 20-206 (1) 20-245 (1)
10-118 10-157 20-103 (1) 20-207 (1) 20-246 (1)
10-119 10-158 q 20-104 (4) 20-208 (1) 20-247 (1)
10-120 10-159 20-105 (1) 20-209 (1) q 20-248 (4)
10-121 10-160 20-106 (1) 20-210 (1) q 20-249 (4)
10-122 10-161 20-107 (1) 20-211 (1) q 20-250 (4)
10-123 10-162 20-108 (1) 20-212 (1) (20-251)
10-124 10-163 20-109 (1) 20-213 (1) 20-252 (1)
10-125 10-164 20-110 (1) 20-214 (1) 20-253 (1)
10-126 10-165 20-111 (1) 20-215 (1) q 20-254 (4)
10-127 10-166 q 20-112 (4) 20-216 (1) 20-255 (1)
10-128 10-167 20-113 (1) 20-217 (1) 20-256 (1)
10-129 10-168 20-114 (1) 20-218 (1) 20-257 (1)
10-130 10-169 20-115 (1) 20-219 (1) 20-258 (1)
10-131 10-170 q 20-116 (4) 20-220 (1) 20-259 (1)
10-132 10-171 20-117 (1) 20-221 (1) 20-260 (1)
10-133 10-172 20-118 (1) 20-222 (1) 20-301 (1)
10-134 20-119 (1) 20-223 (1) 20-302 (1)
00-2-2 PC228US-3
(4)
20-401 (1) 20-510 (1) 20-605 (1) 20-728 (1) 30-5 (2)
20-402 (1) 20-511 (1) 20-606 (1) 20-729 (1) 30-6 (2)
20-403 (1) 20-512 (1) 20-607 (1) 20-730 (1) 30-7 (2)
20-404 (1) 20-513 (1) 20-608 (1) 20-731 (1) q 30-8 (4)
20-405 (1) 20-514 (1) 20-609 (1) 20-801 (1) q 30-9 (4)
20-406 (1) 20-515 (1) 20-610 (1) 20-802 (1) 30-10 (2)
20-407 (1) 20-516 (1) 20-611 (1) 20-803 (1) Q 30-10-1 (4)
20-408 (1) 20-517 (1) 20-612 (1) 20-804 (1) Q 30-10-2 (4)
20-409 (1) 20-518 (1) 20-613 (1) 20-805 (1) 30-12 (2)
20-410 (1) 20-519 (1) 20-614 (1) 20-806 (1) 30-13 (2)
20-411 (1) 20-520 (1) 20-615 (1) 20-807 (1) 30-14 (2)
20-412 (1) 20-521 (1) 20-616 (1) 20-808 (1) 30-15 (2)
20-413 (1) 20-522 (1) 20-617 (1) 20-809 (1) 30-16 (2)
20-414 (1) 20-523 (1) 20-701 (1) 20-810 (1) 30-17 (2)
20-415 (1) 20-524 (1) 20-702 (1) 20-811 (1) 30-18 (2)
20-416 (1) 20-525 (1) 20-703 (1) 20-812 (1) 30-19 (2)
20-417 (1) 20-526 (1) 20-704 (1) 20-813 (1) 30-20 (2)
20-418 (1) 20-527 (1) 20-705 (1) 20-814 (1) 30-21 (2)
20-420 (1) 20-528 (1) 20-706 (1) 20-815 (1) 30-22 (2)
20-421 (1) 20-529 (1) 20-707 (1) 20-816 (1) 30-23 (2)
20-422 (1) 20-530 (1) 20-708 (1) 20-817 (1) 30-24 (2)
20-424 (1) 20-531 (1) 20-709 (1) 20-818 (1) 30-25 (2)
20-425 (1) 20-532 (1) 20-710 (1) 20-819 (1) 30-26 (2)
20-426 (1) 20-533 (1) 20-711 (1) 20-820 (1) 30-27 (2)
20-427 (1) 20-534 (1) 20-712 (1) 20-821 (1) 30-28 (2)
20-428 (1) 20-535 (1) 20-714 (1) 20-822 (1) 30-29 (2)
20-429 (1) 20-536 (1) 20-715 (1) 20-823 (1) 30-30 (2)
20-430 (1) 20-537 (1) 20-716 (1) 20-824 (1) 30-31 (2)
20-431 (1) 20-538 (1) 20-717 (1) 20-825 (1) 30-32 (2)
20-432 (1) 20-539 (1) 20-718 (1) 20-826 (1) 30-33 (2)
20-433 (1) 20-540 (1) 20-719 (1) 20-827 (1) 30-34 (2)
20-501 (1) 20-541 (1) 20-720 (1) 20-828 (1) 30-35 (2)
20-502 (1) 20-542 (1) 20-721 (1) 20-829 (1) 30-36 (2)
20-504 (1) 20-543 (1) 20-722 (1) 20-830 (1) 30-37 (2)
20-505 (1) 20-544 (1) 20-723 (1) 30-38 (2)
20-506 (1) 20-601 (1) 20-724 (1) 30-1 (2) 30-39 (2)
20-507 (1) 20-602 (1) 20-725 (1) 30-2 (2) 30-40 (2)
20-508 (1) 20-603 (1) 20-726 (1) 30-3 (2) 30-41 (2)
20-509 (1) 20-604 (1) 20-727 (1) 30-4 (2) 30-42 (2)
PC228US-3 00-2-3
(4)
30-43 (2) 30-82 (2)

30-44 (2) 30-83 (2)
30-45 (2) 30-84 (2)
30-46 (2) 30-85 (2)
30-47 (2) 30-86 (2)
30-48 (2) 30-87 (2)
30-49 (2) 30-88 (2)
30-50 (2) 30-89 (2)
30-51 (2) 30-90 (2)
30-52 (2) 30-91 (2)
30-53 (2) 30-92 (2)
30-54 (2)
30-55 (2) 90-1
30-56 (2) 90-3
30-57 (2) 90-5
30-58 (2) 90-7
30-59 (2) 90-9
30-60 (2) 90-11
30-61 (2) 90-13
30-62 (2) 90-15
30-63 (2) 90-17
30-64 (2)
30-65 (2)
30-66 (2)
30-67 (2)
30-68 (2)
30-69 (2)
30-70 (2)
30-71 (2)
30-72 (2)
30-73 (2)
30-74 (2)
30-75 (2)
30-76 (2)
30-77 (2)
30-78 (2)
30-79 (2)
30-80 (2)
30-81 (2)
00-2-4 PC228US-3
(4)
SAFETY SAFETY NOTICE
SAFETY
SAFETY NOTICE
IMPORTANT SAFETY NOTICE
Proper service and repair is extremely important for safe machine operation. The service and
repair techniques recommended by Komatsu and described in this manual are both effective
and safe. Some of these techniques require the use of tools specially designed by Komatsu for
the specific purpose.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual.
The cautions accompanying these symbols should always be followed carefully. If any danger-
ous situation arises or may possibly arise, first consider safety, and take the necessary actions
to deal with the situation.
GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to keep

tools and removed parts. Always keep the tools
Mistakes in operation are extremely dangerous. and parts in their correct places. Always keep
Read the Operation and Maintenance Manual care- the work area clean and make sure that there is
fully BEFORE operating the machine. no dirt or oil on the floor. Smoke only in the areas
1. Before carrying out any greasing or repairs, read provided for smoking. Never smoke while work-
all the precautions given on the decals which are ing.
fixed to the machine.
2. When carrying out any operation, always PREPARATIONS FOR WORK
wear safety shoes and helmet. Do not wear
loose work clothes, or clothes with buttons 7. Before adding oil or making any repairs, park the
missing. machine on hard, level ground, and block the
• Always wear safety glasses when hitting wheels or tracks to prevent the machine from
parts with a hammer. moving.
• Always wear safety glasses when grinding 8. Before starting work, lower blade, ripper, bucket
parts with a grinder, etc. or any other work equipment to the ground. If
3. If welding repairs are needed, always have a this is not possible, insert the safety pin or use
trained, experienced welder carry out the work. blocks to prevent the work equipment from fall-
When carrying out welding work, always wear ing. In addition, be sure to lock all the control
welding gloves, apron, hand shield, cap and levers and hang warning signs on them.
other clothes suited for welding work. 9. When disassembling or assembling, support the
4. When carrying out any operation with two or machine with blocks, jacks or stands before
more workers, always agree on the operating starting work.
procedure before starting. Always inform your 10.Remove all mud and oil from the steps or other
fellow workers before starting any step of the places used to get on and off the machine.
operation. Before starting work, hang UNDER Always use the handrails, ladders or steps when
REPAIR signs on the controls in the operator's getting on or off the machine. Never jump on or
compartment. off the machine. If it is impossible to use the
5. Keep all tools in good condition and learn the handrails, ladders or steps, use a stand to pro-
correct way to use them. vide safe footing.
00-3
SAFETY SAFETY NOTICE
PRECAUTIONS DURING WORK 19.Be sure to assemble all parts again in their origi-
nal places.
11.When removing the oil filler cap, drain plug or Replace any damaged parts with new parts.
hydraulic pressure measuring plugs, loosen • When installing hoses and wires, be sure
them slowly to prevent the oil from spurting out. that they will not be damaged by contact
Before disconnecting or removing components with other parts when the machine is being
of the oil, water or air circuits, first remove the operated.
pressure completely from the circuit. 20.When installing high pressure hoses, make sure
12.The water and oil in the circuits are hot when the that they are not twisted. Damaged tubes are
engine is stopped, so be careful not to get dangerous, so be extremely careful when install-
burned. ing tubes for high pressure circuits. Also, check
Wait for the oil and water to cool before carry- that connecting parts are correctly installed.
ing out any work on the oil or water circuits. 21.When assembling or installing parts, always use
13.Before starting work, remove the leads from the the specified tightening torques. When installing
battery. Always remove the lead from the nega- protective parts such as guards, or parts which
tive (–) terminal first. vibrate violently or rotate at high speed, be par-
14.When raising heavy components, use a hoist or ticularly careful to check that they are installed
crane. correctly.
Check that the wire rope, chains and hooks are 22.When aligning two holes, never insert your fin-
free from damage. gers or hand. Be careful not to get your fingers
Always use lifting equipment which has ample caught in a hole.
capacity. 23.When measuring hydraulic pressure, check that
Install the lifting equipment at the correct places. the measuring tool is correctly assembled before
Use a hoist or crane and operate slowly to pre- taking any measurements.
vent the component from hitting any other part.
24.Take care when removing or installing the tracks
Do not work with any part still raised by the hoist
of track-type machines.
or crane.
When removing the track, the track separates
15.When removing covers which are under internal suddenly, so never let anyone stand at either
pressure or under pressure from a spring, end of the track.
always leave two bolts in position on opposite
sides. Slowly release the pressure, then slowly
loosen the bolts to remove.
16.When removing components, be careful not to
break or damage the wiring. Damaged wiring
may cause electrical fires.
17.When removing piping, stop the fuel or oil from
spilling out. If any fuel or oil drips onto the floor,
wipe it up immediately. Fuel or oil on the floor
can cause you to slip, or can even start fires.
18.As a general rule, do not use gasoline to wash
parts. In particular, use only the minimum of
gasoline when washing electrical parts.
00-4
FOREWORD GENERAL
FOREWORD
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an
accurate understanding of the product and by showing him the correct way to perform repairs and make judge-
ments. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service
workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are fur-
ther divided into the each main group of components.
STRUCTURE AND FUNCTION

This section explains the structure and function of each component. It serves not only to give an under-
standing of the structure, but also serves as reference material for troubleshooting.
In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and mainte-
nance standards.
TESTING AND ADJUSTING

This section explains checks to be made before and after performing repairs, as well as adjustments to
be made at completion of the checks and repairs.
Troubleshooting charts correlating "Problems" with "Causes" are also included in this section.
DISASSEMBLY AND ASSEMBLY

This section explains the procedures for removing, installing, disassembling and assembling each com-
ponent, as well as precautions for them.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts.
The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.
In addition, this section may give the specifications of attachments and options together.
NOTICE
The specifications contained in this shop manual are subject to change at any time and without any
advance notice. Use the specifications given in the book with the latest date.
00-5
FOREWORD HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL REVISED EDITION MARK
VOLUMES When a manual is revised, an edition mark

Shop manuals are issued as a guide to carrying out ((1)(2)(3)....) is recorded on the bottom of the pages.
repairs. They are divided as follows:
Chassis volume: Issued for every machine model REVISIONS

Engine volume: Issued for each engine series
Each issued as one Revised pages are shown in the LIST OF REVISED
Electrical volume:
}
Attachments volume: · volume to cover all
models
PAGES next to the CONTENTS page.
SYMBOLS
These various volumes are designed to avoid dupli-
cating the same information. Therefore, to deal with So that the shop manual can be of ample practical
all repairs for any model , it is necessary that chas- use, important safety and quality portions are
sis, engine, electrical and attachment volumes be marked with the following symbols.
available.
DISTRIBUTION AND UPDATING

Any additions, amendments or other changes will be
sent to KOMATSU distributors. Get the most up-to- Symbol Item Remarks
date information before you start any work.
k
Special safety precautions
Safety are necessary when per-
forming the work.
FILING METHOD
1. See the page number on the bottom of the page. Special technical precau-
File the pages in correct order. tions or other precautions
2. Following examples show how to read the page a Caution for preserving standards
number. are necessary when per-
forming the work.
Example 1 (Chassis volume):
Weight of parts of sys-
10 - 3
4
tems. Caution necessary
Weight when selecting hoisting
Item number (10. Structure and wire, or when working pos-
Function) ture is important, etc.
Consecutive page number for each
3
Places that require special
item. Tightening
attention for the tightening
torque
torque during assembly.
Example 2 (Engine volume):
2
Places to be coated with
12 - 5 Coat adhesives and lubricants,
etc.
Unit number (1. Engine) Places where oil, water or
5
Item number (2. Testing and Adjust- Oil, water fuel must be added, and
ing) the capacity.
Consecutive page number for each
Places where oil or water
6
item.
Drain must be drained, and
quantity to be drained.
3. Additional pages: Additional pages are indicated
by a hyphen (-) and number after the page
number. File as in the example.
Example:
10-4 12-203
10-4-1 12-203-1
Added pages
10-4-2 12-203-2
10-5 12-204
00-6
FOREWORD HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
HOISTING
Slinging near the edge of the hook may cause

k Heavy parts (25 kg or more) must be lifted the rope to slip off the hook during hoisting, and
with a hoist, etc. In the DISASSEMBLY a serious accident can result. Hooks have max-
AND ASSEMBLY section, every part imum strength at the middle portion.
weighing 25 kg or more is indicated clearly
with the symbol 4
• If a part cannot be smoothly removed from the

machine by hoisting, the following checks
should be made:
1) Check for removal of all bolts fastening the 100% 88% 79% 71% 41%
part to the relative parts. SAD00479
2) Check for existence of another part causing
3) Do not sling a heavy load with one rope alone,
interference with the part to be removed.
but sling with two or more ropes symmetrically
wound onto the load.
k Slinging with one rope may cause turning
WIRE ROPES
1) Use adequate ropes depending on the
weight of parts to be hoisted, referring to of the load during hoisting, untwisting of
the table below: the rope, or slipping of the rope from its
original winding position on the load, which
Wire ropes can result in a dangerous accident.
(Standard "Z" or "S" twist ropes
without galvanizing) 4) Do not sling a heavy load with ropes forming a
wide hanging angle from the hook.
Rope diameter Allowable load
When hoisting a load with two or more ropes,
the force subjected to each rope will increase
mm kN tons with the hanging angles. The table below
shows the variation of allowable load kN {kg}
10 9.8 1.0 when hoisting is made with two ropes, each of
11.5 13.7 1.4 which is allowed to sling up to 9.8 kN {1000 kg}
12.5 15.7 1.6
vertically, at various hanging angles.
14 21.6 2.2
16 27.5 2.8
When two ropes sling a load vertically, up to
18 35.3 3.6 19.6 kN {2000 kg} of total weight can be sus-
20 43.1 4.4 pended. This weight becomes 9.8 kN {1000 kg}
22.4 54.9 5.6 when two ropes make a 120° hanging angle.
30 98.1 10.0 On the other hand, two ropes are subjected to
40 176.5 18.0 an excessive force as large as 39.2 kN {4000
50 274.6 28.0 kg} if they sling a 19.6 kN {2000 kg} load at a
60 392.2 40.0 lifting angle of 150°.
★ The allowable load value is estimated to be one-

sixth or one-seventh of the breaking strength of
the rope used.
2) Sling wire ropes from the middle portion of the

hook.
00-7
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
k Before carrying out the following work, release Type 1

the residual pressure from the hydraulic tank.
For details, see TESTING AND ADJUSTING,
Releasing residual pressure from hydraulic
tank.
k Even if the residual pressure is released from

the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly,
prepare an oil receiving container.
Disconnection
1) Release the residual pressure from the hydrau-
lic tank. For details, see TESTING AND
ADJUSTING, Releasing residual pressure from
hydraulic tank.
2) Hold adapter (1) and push hose joint (2) into

mating adapter (3). (See Fig. 1)
★ The adapter can be pushed in about 3.5
mm.
★ Do not hold rubber cap portion (4).
3) After hose joint (2) is pushed into adapter (3),

press rubber cap portion (4) against (3) until it
clicks. (See Fig. 2)
4) Hold hose adapter (1) or hose (5) and pull it out.

(See Fig. 3)
★ Since some hydraulic oil flows out, prepare
an oil receiving container.
Connection
1) Hold hose adapter (1) or hose (5) and insert it in
mating adapter (3), aligning them with each
other. (See Fig. 4)
★ Do not hold rubber cap portion (4).
2) After inserting the hose in the mating adapter

perfectly, pull it back to check its connecting
condition. (See Fig. 5)
★ When the hose is pulled back, the rubber
cap portion moves toward the hose about
3.5 mm. This does not indicate abnormality,
however.
00-8
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
Type 2 Type 3
1) Hold the mouthpiece of the tightening portion 1) Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of
the hexagonal portion at the male end. the hexagonal portion at the male end.
2) Hold in the condition in Step 1), and turn 2) Hold in the condition in Step 1), and push
lever (4) to the right (clockwise). until cover (3) contacts contact surface a of
the hexagonal portion at the male end.
Disassembly
3) Hold in the condition in Steps 1) and 2), and 3) Hold in the condition in Steps 1) and 2), and
pull out whole body (2) to disconnect it. pull out whole body (2) to disconnect it.
• Hold the mouthpiece of the tightening portion • Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of
the hexagonal portion at the male end to con- the hexagonal portion at the male end to con-
nect it. nect it.
Connection
00-9
FOREWORD COATING MATERIALS
COATING MATERIALS
★ The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly
and assembly are listed below.
★ For coating materials not listed below, use the equivalent of products shown in this list.
Category Komatsu code Part No. Q'ty Container Main applications, features
• Used to prevent rubber gaskets, rub-

LT-1A 790-129-9030 150 g Tube ber cushions, and cock plug from
coming out.
• Used in places requiring an immedi-
ately effective, strong adhesive.
20 g Polyethylene Used for plastics (except polyethyl-
LT-1B 790-129-9050 (2 pcs.) container ene, polyprophylene, tetrafluoroeth-
lene and vinyl chloride), rubber,
metal and non-metal.
• Features: Resistance to heat and
Polyethylene chemicals
LT-2 09940-00030 50 g container • Used for anti-loosening and sealant
purpose for bolts and plugs.
Adhesive: • Used as adhesive or sealant for met-
790-129-9060 al, glass and plastic.
1 kg
(Set of adhesive
LT-3 Hardening Can
and hardening agent:
agent) 500 g
Adhesives
Polyethylene • Used as sealant for machined holes.
LT-4 790-129-9040 250 g container
Holtz • Used as heat-resisting sealant for re-

790-126-9120 75 g Tube pairing engine.
MH 705
• Quick hardening type adhesive
Three bond Polyethylene • Cure time: within 5 sec. to 3 min.
790-129-9140 50 g
1735 container • Used mainly for adhesion of metals,
rubbers, plastics and woods.
• Quick hardening type adhesive
• Quick cure type (max. strength after
Aron-alpha Polyethylene
790-129-9130 2g 30 minutes)
201 container • Used mainly for adhesion of rubbers,
plastics and metals.
• Resistance to heat, chemicals
Loctite Polyethylene
79A-129-9110 50 cc • Used at joint portions subject to high
648-50 container temperatures.
• Used as adhesive or sealant for gas-
LG-1 790-129-9010 200 g Tube kets and packing of power train case,
etc.
• Used as sealant for various threads,
pipe joints, flanges.
LG-5 790-129-9080 1 kg Can • Used as sealant for tapered plugs,
elbows, nipples of hydraulic piping.
• Features: Silicon based, resistance
to heat, cold
• Used as sealant for flange surface,
LG-6 790-129-9020 200 g Tube tread.
• Used as sealant for oil pan, final
Gasket drive case, etc.
sealant
• Features: Silicon based, quick hard-
ening type
LG-7 790-129-9070 1 kg Tube • Used as sealant for flywheel hous-
ing, intake manifold, oil pan, thermo-
stat housing, etc.
Three bond • Used as heat-resisting sealant for re-
790-129-9090 100 g Tube pairing engine.
1211
• Features: Silicone type, heat resist-
ant, vibration resistant, and impact
Three bond 419-15-18131 100 g Tube resistant sealing material
1207B • Used as sealing material for transfer
case
00-10
FOREWORD COATING MATERIALS
Category Komatsu code Part No. Q'ty Container Main applications, features
• Used as lubricant for sliding portion

LM-G 09940-00051 60 g Can (to prevent from squeaking).
Molybdenum • Used to prevent seizure or scuffling
disulphide of the thread when press fitting or
lubricant LM-P 09940-00040 200 g Tube shrink fitting.
• Used as lubricant for linkage, bear-
ings, etc.
SYG2-400LI • General purpose type
SYG2-350LI
G2-LI SYG2-400LI-A Various Various
SYG2-160LI
SYGA-160CNLI
SYG2-400CA • Used for normal temperature, light

SYG2-350CA load bearing at places in contact
G2-CA SYG2-400CA-A Various Various with water or steam.
SYG2-160CA
SYGA-160CNCA
Molybdenum • Used for heavy load portion

SYG2-400M 400 g × 10 Bellows type
disulphide
Grease SYG2-400M-A 400 g × 20 Bellows type
grease SYGA-16CNM 16 kg Can
LM-G (G2-M)
• Seizure resistance and heat resist-
Hyper White
Grease G2-T SYG2-400T-A ance higher than molybdenum di-
SYG2-16CNT 400 g Bellows type sulfide grease
G0-T (*) SYG0-400T-A (*) 16 kg Can • Since this grease is white, it does
*: For use in cold SYG0-16CNT (*) not stand out against machine
district
body.
Biogrease G2B • Since this grease is decomposed
SYG2-400B by bacteria in short period, it has
G2-BT (*) SYGA-16CNB 400 g Bellows type less effects on microorganisms,
*: For high SYG2-400BT (*) 16 kg Can animals, and plants.
temperature SYGA-16CNBT (*)
and large load
SUNSTAR • Used as primer for cab side

Glass (Using limit: 4 months)
PAINT PRIMER 20 ml container
580 SUPER
Primer
SUNSTAR • Used as primer for glass side
Glass (Using limit: 4 months)
GLASS PRIMER 20 ml container
580 SUPER 417-926-3910
Adhesive for cab glass
• "S" is used for high-tempera-

SUNSTAR ture season (April - October)
PENGUINE Polyethylene and "W" for low-temperature
SEAL 580 320 ml container season (November - April) as
SUPER "S" or
Adhesive adhesive for glass.
"W" (Using limit: 4 months)
Sika Japan, Polyethylene • Used as adhesive for glass.
20Y-54-39850 310 ml (Using limit: 6 months)
Sikaflex 256HV container
SUNSTAR • Used to seal joints of glass

Polyethylene parts.
PENGUINE 417-926-3920 320 ml container (Using limit: 4 months)
SEAL No. 2505
Caulking
material • Used to seal front window.
SEKISUI Polyethylene (Using limit: 6 months)
SILICONE 20Y-54-55130 333 ml container
SEALANT
00-11
FOREWORD STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH)
★ In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque given in
the table below.
Tightening torque
Thread diameter Width across
of bolt flats
mm mm Nm kgm
6 10 11.8 – 14.7 1.2 – 1.5

8 13 27 – 34 2.8 – 3.5
10 17 59 – 74 6 – 7.5
12 19 98 – 123 10 – 12.5
14 22 153 – 190 15.5 – 19.5
16 24 235 – 285 23.5 – 29.5

18 27 320 – 400 33 – 41
20 30 455 – 565 46.5 – 58
22 32 610 – 765 62.5 – 78
24 36 785 – 980 80 – 100
27 41 1150 – 1440 118 – 147

30 46 1520 – 1910 155 – 195
33 50 1960 – 2450 200 – 250
36 55 2450 – 3040 250 – 310
39 60 2890 – 3630 295 – 370
Tightening torque
Thread diameter Width across
of bolt flats
mm mm Nm kgm
6 10 5.9 – 9.8 0.6 – 1.0

8 13 13.7 – 23.5 1.4 – 2.4
10 14 34.3 – 46.1 3.5 – 4.7
12 27 74.5 – 90.2 7.6 – 9.2
Sealing surface
TABLE OF TIGHTENING TORQUES FOR FLARED NUTS

★ In the case of flared nuts for which there is no
special instruction, tighten to the torque given in
the table below. SAD00483
Thread diameter Width across flat Tightening torque
mm mm Nm kgm
14 19 24.5 ± 4.9 2.5 ± 0.5

18 24 49 ± 19.6 5±2
22 27 78.5 ± 19.6 8±2
24 32 137.3 ± 29.4 14 ± 3
30 36 176.5 ± 29.4 18 ± 3
33 41 196.1 ± 49 20 ± 5
36 46 245.2 ± 49 25 ± 5
42 55 294.2 ± 49 30 ± 5
00-12
TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS

★ In the case of split flange bolts for which there is no special instruction, tighten to the torque given in the
table below.
Thread diameter Width across flat Tightening torque
mm mm Nm kgm
10 14 59 – 74 6 – 7.5
12 17 98 – 123 10 – 12.5
16 22 235 – 285 23.5 – 29.5
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS

★ Unless there are special instructions, tighten the O-ring boss piping joints to the torque below.
Thread diameter Width across flat Tightening torque (Nm {kgm})

Norminal No.
mm mm Range Target
02 14 35 – 63 {3.5 – 6.5} 44 {4.5}

03, 04 20 Varies depending 84 – 132 {8.5 – 13.5} 103 {10.5}
05, 06 24 on type of 128 – 186 {13.0 – 19.0} 157 {16.0}
10, 12 33 connector. 363 – 480 {37.0 – 49.0} 422 {43.0}
14 42 746 – 1010 {76.0 – 103} 883 {90.0}
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS

★ Unless there are special instructions, tighten the O-ring boss plugs to the torque below.
Thread diameter Width across flat Tightening torque (Nm {kgm})

Norminal No.
mm mm Range Target
08 08 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} 124.4 {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}
00-13
TIGHTENING TORQUE FOR 102 ENGINE SERIES

1) BOLT AND NUTS
Use these torques for bolts and nuts (unit: mm) of Cummins Engine.
Thread diameter Tightening torque
mm Nm kgm
6 10 0 2 1.02 0 0.20
8 24 0 4 2.45 0 0.41
10 43 0 6 4.38 0 0.61
12 77 0 12 7.85 0 1.22
2) EYE JOINTS
Use these torques for eye joints (unit: mm) of Cummins Engine.
mm Nm kgm
6 802 0.81 0 0.20
8 10 0 2 1.02 0 0.20
10 12 0 2 1.22 0 0.20
12 24 0 4 2.45 0 0.41
14 36 0 5 3.67 0 0.51
3) TAPERED SCREWS
Use these torques for tapered screws (unit: inch) of Cummins Engine.
inch Nm kgm
1 / 16 301 0.31 0 0.10
1/8 802 0.81 0 0.20
1/4 12 0 2 1.22 0 0.20
3/8 15 0 2 1.53 0 0.41
1/2 24 0 4 2.45 0 0.41
3/4 36 0 5 3.67 0 0.51
1 60 0 9 6.12 0 0.92
TIGHTENING TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE)
★ Tighten the hoses (taper seal type and face seal type) to the following torque, unless otherwise specified.
★ Apply the following torque when the threads are coated (wet) with engine oil.
Taper seal
Tightening torque (Nm {kgm}) Face seal type
type
Nominal size Width across
of hose flats Nominal thread
Thread size size Root diameter
Range Target - Threads per
(mm) inch, Thread series (mm) (Reference)
9
02 19 34 - 63 {3.5 - 6.5} 44 {4.5} 14 – - 18UNF 14.3
16
11
22 54 - 93 {5.5 - 9.5} 74 {4.5} – – - 16UN 17.5
03 16
24 59 - 98 {6.0 - 10.0} 78 {8.0} 18 – –
13
04 27 84 - 132 {8.5 - 13.5} 103 {10.5} 22 – - 16UN 20.7
16
05 32 128 - 186 {13.0 - 19.0} 157 {16.0} 24 1 - 14UNS 25.4
3
06 36 177 - 245 {18.0 - 25.0} 216 {22.0} 30 1 – - 12UNF 30.3
16
(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 – –
00-14
FOREWORD ELECTRIC WIRE CODE
ELECTRIC WIRE CODE

In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires.
This wire code table will help you understand WIRING DIAGRAMS.
Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe.
CLASSIFICATION BY THICKNESS
Copper wire
Norminal Cable O.D. Current
number Dia. of Cross (mm) rating Applicable circuit
Number of strands section (A)
strands (mm2) (mm2)
0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal

etc.
2 26 0.32 2.09 3.1 20 Lighting, signal etc.
5 65 0.32 5.23 4.6 37 Charging and signal
15 84 0.45 13.36 7.0 59 Starting (Glow plug)
40 85 0.80 42.73 11.4 135 Starting
60 127 0.80 63.84 13.6 178 Starting
100 217 0.80 109.1 17.6 230 Starting
CLASSIFICATION BY COLOR AND CODE
Circuits
Priori- Charging Ground Starting Lighting Instrument Signal Other
ty Classi-
fication
Code W B B R Y G L
Pri-
1 mary
Color White Black Black Red Yellow Green Blue
Code WR — BW RW YR GW LW
2
Color White & Red — White & Black Red & White Rellow & Red Green & White Blue & White
Code WB — BY RB YB GR LR
3
Color White & Black — Black & Yellow Red & Black Yellow & Black Green & Red Blue & Yellow
Code WL — BR RY YG GY LY
Auxi-
4 liary Yellow & Green &
Color White & Blue — Black & Red Red & Yellow Blue & Yellow
Green Yellow
Code WG — — RG YL GB LB
5
Color White & Green — — Red & Green Yellow & Blue Green & Black Blue & Black
Code — — — RL YW GL n
6
Color — — — Red & Blue Yellow & White Green & Blue n
00-15
FOREWORD CONVERSION TABLE
CONVERSION TABLE
METHOD OF USING THE CONVERSION TABLE

The Conversion Table in this section is provided to enable simple conversion of figures. For details of the
method 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, 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 two lines cross as C. This point C gives the value when converting from mil-
limeters 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 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
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
C
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
A 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 2.874 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
00-16
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 2.874 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 51.91 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
00-17
Liter to U.S. Gallon

1l = 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
Liter to U.K. Gallon

1l = 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 7.969 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
00-18
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
00-19
kg/cm2 to lb/in2
1kg/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 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 1934 1949 1963 1977
140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119
150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830
200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542
00-20
Temperature
Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Cen-
tigrade temperature reading or vice versa is to enter the accompanying table in the center or boldface col-
umn of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of
Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as 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 81 117.8

–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 0 140.0 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
00-21
FOREWORD UNITS
UNITS
In this manual, the measuring units are indicated with Internatinal System of units (SI).
As for reference, conventionally used Gravitational System of units are indicated in parentheses { }.
Example:
N {kg}
Nm {kgm}
MPa {kg/cm2}
kPa {mmH2O}
kPa {mmHg}
kW/rpm {HP/rpm}
g/kWh {g/HPh}
00-22 11-04
01 GENERAL
SPECIFICATION DIMENSION DRAWINGS . 01-2

SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . 01-4
WEIGHT TABLE . . . . . . . . . . . . . . . . . . . . . . . 01-8
FUEL, COOLANT, AND LUBRICANTS . . . . 01-12
PC228US-3 01-1
GENERAL SPECIFICATION DIMENSION DRAWINGS
12
SPECIFICATION DIMENSION DRAWINGS
PC228US-3
PC228USLC-3
Unit: mm
Model PC228US-3 PC228USLC-3
Dimension
A 8,700 8,890
B 3,035 3,035
C 2,980 2,980
D 600 700
E 3,035 3,035
F 1,680 1,680
G 4,080 4,450
H 3,270 3,640
01-2 PC228US-3
GENERAL SPECIFICATION DIMENSION DRAWINGS
12
Unit: mm
Model PC228US-3 PC228USLC-3
Dimension
A 9,875 9,875
B 6,620 6,620
C 10,700 10,700
D 5,980 5,980
E 7,825 7,825
F 2,940 2,940
G 9,700 9,700
PC228US-3 01-3
GENERAL SPECIFICATIONS
SPECIFICATIONS
Machine model PC228US-3
Serial Number 20001 and up
Bucket capacity m³ 0.8
Operating weight kg 21,800
Max. digging depth mm 6,620

Working ranges
Max. vertical wall depth mm 5,980

Max. digging reach mm 9,875
Max. reach at ground level mm 9,670
Max. digging height mm 10,700
Max. dumping height mm 7,825
Performance
Max. digging force

(using power max. function) kN {kg} 137 {14,000} (147 {15,000})
Swing speed rpm 11.0
Swing max. slope angle deg. 20
Travel speed km/h Lo: 3.0 Hi: 5.5
Gradeability deg. 35
Ground pressure
(triple grouser shoe width: 600 mm kPa {kg/cm²} 50 {0.51}
Overall length (for transport) mm 8,700

Overall width mm 2,980
Overall width of track mm 2,800
Overall height (for transport) mm 3,010
Overall height to chassis mm 3,035
Dimensions
Ground clearance to bottom of upper structure mm 1,058

Min. ground clearance mm 440
Tail swing radius mm 1,680
Min. swing radius of work equipment mm 2,310
Height of work equipment at min. swing radius mm 8,250
Length of track on ground mm 3,270
Track gauge mm 2,200
Height of machine cab mm 2,287
01-4 PC228US-3
12
Model SAA6D102E
Type 4-cycle, water-cooled, in-line, vertical, direct injec-
tion, with turbo charger and air-cooled aftercooler
No. of cylinders - bore x stroke mm 6 - 102 x 120
Piston displacement l {cc} 5.883 {5,883}
Flywheel horsepower kW/rpm {HP/rpm} 107/1,950 {145/1,950}

Performance
Engine
Max. torque Nm/rpm {kgm/rpm} 610.0/1,500 {62.2/1,500}

Max. speed at no load rpm 2,150 ± 70
Min. speed at no load rpm 1,030 ± 50
Min. fuel consumption g/kWh {g/HPh} 215 {158}
Starting motor 24V, 4.5 kW

Alternator 24V, 35 A
Battery 12V, 110 Ah x 2
Radiator core type Corrugated CWX-4
Carrier roller 2 on each side

carriage
Under-
Track roller 7 on each side

Track shoe Triple grouser, 45 on each side
Hydraulic
Type x no. HPV95+95, variable displacement piston type x 2

pump
Delivery l/min Piston type: 262 x 2

Set pressure MPa (kg/cm²) Piston type: 37.2 {380}
Control
Type x No. (6 spool +1 spool +1 service valve) x 1

valve
Control method Hydraulic
Travel motor HMV110-2, Piston type

Hydraulic
motor
(with brake valve, parking brake): x 2

Hydraulic system
Swing motor KMF125ABE-5, Piston type

(with safety valve, holding brake): x 1
Type Boom Arm Bucket
Double acting Double acting Double acting

Hydraulic culinder
piston piston piston

mm 120 135 115
Inside diameter of cylinder
Diameter of piston rod mm 85 95 80
Stroke mm 1,385 1,490 1,120
Max. distance between pins mm 3,255 3,565 2,800
Min. distance between pins mm 1,870 2,075 1,680
Hrdraulic tank Box-shaped, sealed

Hydraulic filter Tank return side
Hydraulic cooler CF40-1
PC228US-3 01-5
12
Machine model PC228USLC-3
Bucket capacity m³ 0.8
Operating weight kg 23,100
Max. digging depth mm 6,620

Working ranges
Max. vertical wall depth mm 5,980
Max. digging reach mm 9,875
Max. reach at ground level mm 9,670
Max. digging height mm 10,700
Max. dumping height mm 7,825

Performance
Max. digging force
(using power max. function) kN {kg} 137 {14,000} (147 {15,000})
Swing speed rpm 11.0
Swing max. slope angle deg. 20
Travel speed km/h Lo: 3.0 Hi: 5.5
Gradeability deg. 35
Ground pressure
(triple grouser shoe width: 600 mm kPa {kg/cm²} 41 {0.42}
Overall length (for transport) mm 8,890
Overall width mm 2,980
Overall width of track mm 3,080
Overall height (for transport) mm 3,010
Overall height to chassis mm 3,035

Dimensions
Ground clearance to bottom of upper structure mm 1,058
Min. ground clearance mm 440
Tail swing radius mm 1,680
Min. swing radius of work equipment mm 2,310
Height of work equipment at min. swing radius mm 8,250
Length of track on ground mm 3,640
Track gauge mm 2,380
Height of machine cab mm 2,287
01-6 PC228US-3
12
Model SAA6D102E
Type 4-cycle, water-cooled, in-line, vertical, direct injec-
tion, with turbo charger and air-cooled aftercooler
No. of cylinders - bore x stroke mm 6 - 102 x 120
Piston displacement l {cc} 5.883 {5,883}
Flywheel horsepower kW/rpm {HP/rpm} 107/1,950 {145/1,950}

Performance
Max. torque Nm/rpm {kgm/rpm} 610.0/1,500 {62.2/1,500}

Engine
Max. speed at no load rpm 2,150 ± 70

Min. speed at no load rpm 1,030 ± 50
Min. fuel consumption g/kWh {g/HPh} 215 {158}
Starting motor 24V, 4.5 kW

Alternator 24V, 35 A
Battery 12V, 110 Ah x 2
Radiator core
Corrugated CWX-4
Carrier roller
2 on each side
carriage
Track roller
Under-
9 on each side
Track shoe
Triple grouser, 49 on each side
Hydraulic
Type x No. HPV95+95, variable displacement piston type x 2

pump
Delivery l/min Piston type: 206 x 2

Set pressure MPa (kg/cm²) Piston type: 37.2 {380}
Control
valve
Type x No. 6 spool type x 1

Control method Hydraulic
Travel motor HMV110-2, Piston type

Hydraulic
motor
(with brake valve, parking brake): x 2

Hydraulic system
Swing motor KMF125ABE-5, Piston type

(with safety valve, holding brake): x 1
Type Boom Arm Bucket

Hydraulic culinder
Double acting Double acting Double acting

piston piston piston
Inside diameter of cylinder mm 120 135 115
Diameter of piston rod mm 85 95 80
Stroke mm 1,385 1,490 1,120
Max. distance between pins mm 3,255 3,565 2,800
Min. distance between pins mm 1,870 2,075 1,680
Hrdraulic tank Box-shaped, sealed

Hydraulic filter Tank return side
Hydraulic cooler CF40-1
PC228US-3 01-7
GENERAL
12
WEIGHT TABLE
This weight table is for use when handling or transporting the components.
Unit: kg
Engine assembly 753

• Engine 550
• Damper 6
• Hydraulic pump 154

Radiator oil cooler assembly 110
Hydraulic tank, filter assembly (excluding hydraulic oil) 146
Fuel tank (excluding fuel) 127
Revolving frame 1,827
Operator’s cab 245
Operator’s seat 22
Counterweight 6,335
Swing machinery 160
Control valve 206
Swing motor 59.5
Travel motor 98 x 2
Center swivel joint 29.9
Track frame assembly 4,394
• Track frame 2,231
• Swing circle 267
• Idler 140 x 2
• Idler cushion 130 x 2
• Carrier roller 21 x 4
• Track roller 38 x 14
• Final drive (including travel motor) 370 x 2
01-8 PC228US-3
GENERAL WEIGHT TABLE
12
Unit: kg
Track shoe assembly
• Standard triple grouser shoe (600 mm) 1,225 x 2
• Wide triple grouser shoe (800 mm) 1,565 x 2
• Road liner (rubber pad type) (600 mm) 1,470 x 2
Boom assembly 1,378
Arm assembly 639
Bucket assembly 629
Boom cylinder assembly 175 x 2
Arm cylinder assembly 233
Bucket cylinder assembly 140
Link assembly (large) 78
Link assembly (small) 22 x 2
Boom pin 52 + 10 x 2 + 31 + 19 + 24
Arm pin 13.2 + 9.2
Bucket pin 20 x 2
Link pin 13 x 2
PC228US-3 01-9
12
Unit: kg
Engine assembly 753

• Engine 550
• Damper 6
• Hydraulic pump 154
Radiator oil cooler assembly 110
Hydraulic tank, filter assembly (excluding hydraulic oil) 146
Fuel tank (excluding fuel) 127
Revolving frame 1,827
Operator’s cab 245
Operator’s seat 22
Counterweight 6,335
Swing machinery 160
Control valve 206
Swing motor 59.5
Travel motor 98 x 2
Center swivel joint 29.9
Track frame assembly 5,008

• Track frame 2,693
• Swing circle 267
• Idler 140 x 2
• Idler cushion 130 x 2
• Carrier roller 21 x 4
• Track roller 38 x 18
• Final drive (including travel motor) 370 x 2
01-10 PC228US-3
12
Unit: kg
Track shoe assembly
• Wide triple grouser shoe (800 mm) 1,700 x 2
• Road liner (rubber pad type) (600 mm) 1,600 x 2
Boom assembly 1,378
• 1st boom —
• 2nd boom —
• Bracket —
Arm assembly 639
Bucket assembly 626
Boom cylinder assembly 175 x 2
Arm cylinder assembly 233
Bucket cylinder assembly 140
Offset cylinder assembly —
Offset sub link —
Link assembly (large) 78
Link assembly (small) 22 x 2
Boom pin 52 + 10 x 2 + 31 + 19 + 24
Arm pin 13.2 + 9.2
Bucket pin 20 x 2
Link pin 13 x 2
PC228US-3 01-11
GENERAL
12
FUEL, COOLANT, AND LUBRICANTS
KIND AMBIENT TEMPERATURE CAPACITY (l)

RESERVOIR OF -22 -4 14 32 50 68 86 104°F
FLUID Specified Refill
-30 -20 -10 0 10 20 30 40°C
SAE 30
SAE 10W
Engine oil pan 26.3 24
SAE 10W-30
SAE 15W-40
Damper case 0.75 —

Swing machinery case 6.6 6.6
Engine
Final drive case (each side) SAE 30 5.4 5.2
oil
Idler (1 each) 0.07-0.08 0.07-0.08
Track roller (1 each) 0.19-0.20 0.19-0.20
Carrier roller (1 each) 0.075-0.085 0.075-0.085
SAE 10W
SAE 10W-30
Hydraulic system 185 126
SAE 15W-40
Hydraulic
HO46-HM
oil
ASTM D975 No. 2

Diesel
Fuel tank 320 —
fuel
ASTM D975A
No.1
Cooling system Coolant Add antifreeze 21.5 —
01-12 PC228US-3
10 STRUCTURE AND FUNCTION
12
ENGINE RELATED PARTS . . . . . . . . . . . . . . . . . . . . 10-2

RADIATOR • OIL COOLER • AFTERCOOLER . . . . . . 10-3
POWER TRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
FINAL DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6
SWING CIRCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8
SWING MACHINERY . . . . . . . . . . . . . . . . . . . . . . . 10-10
TRACK FRAME • RECOIL SPRING . . . . . . . . . . . . . 10-12
TRACK SHOE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-18
HYDRAULIC TANK . . . . . . . . . . . . . . . . . . . . . . . . . 10-22
HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . 10-24
CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . 10-46
CLSS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-58
SELF PRESSURE REDUCING VALVE . . . . . . . . . . 10-61
TRAVEL JUNCTION VALVE . . . . . . . . . . . . . . . . . . 10-64
BOOM HYDRAULIC DRIFT PREVENTION VALVE . 10-66
TRAVEL PPC SHUTTLE VALVE . . . . . . . . . . . . . . . 10-69
LIFT CHECK VALVE . . . . . . . . . . . . . . . . . . . . . . . . . 10-71
HOLDING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . 10-72
SWING MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-78
REVERSE PREVENTION VALVE . . . . . . . . . . . . . . . 10-83
CENTER SWIVEL JOINT . . . . . . . . . . . . . . . . . . . . . 10-85
TRAVEL MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-86
VALVE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . 10-95
WORK EQUIPMENT • SWING PPC VALVE . . . . . . 10-96
TRAVEL PPC VALVE . . . . . . . . . . . . . . . . . . . . . . . 10-100
SERVICE PPC VALVE . . . . . . . . . . . . . . . . . . . . . . 10-110
PPC ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . 10-113
SOLENOID VALVE . . . . . . . . . . . . . . . . . . . . . . . . 10-114
HYDRAULIC CYLINDER . . . . . . . . . . . . . . . . . . . . 10-116
WORK EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . 10-118
ENGINE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . 10-124
ELECTRONIC CONTROL SYSTEM . . . . . . . . . . . . 10-133
MONITORING SYSTEM . . . . . . . . . . . . . . . . . . . . 10-162
SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-169
PC228US-3 10-1
STRUCTURE AND FUNCTION ENGINE RELATED PARTS
12
ENGINE RELATED PARTS
1. Drive plate 5. Damper assembly OUTLINE

2. Torsion spring 6. Muffler
3. Stopper pin 7. Rear engine mount • The damper assembly is a wet type.
4. Friction plate 8. Front engine mount Oil capacity: 0.75 l
10-2 PC228US-3
STRUCTURE AND FUNCTION RADIATOR • OIL COOLER • AFTERCOOLER
12
RADIATOR • OIL COOLER • AFTERCOOLER
1. Radiator cap SPECIFICATIONS

2. Bell-mouth shroud
3. Shroud Radiator : CWX-4
4. Radiator Oil cooler : CF40-1
5. Aftercooler
6. Oil cooler
PC228US-3 10-3
STRUCTURE AND FUNCTION POWER TRAIN
12
POWER TRAIN
1. PPC lock solenoid valve 7. Final drive

2. Travel speed switch solenoid valve 8. Travel motor
3. Swing brake solenoid valve 9. Hydraulic pump
4. Idler 10. Engine
5. Center swivel joint 11. Swing motor
6. Control valve 12. Swing machinery
13. Swing circle
10-4 PC228US-3
STRUCTURE AND FUNCTION FINAL DRIVE
12
FINAL DRIVE
10-6 PC228US-3
STRUCTURE AND FUNCTION FINAL DRIVE
12
1. Level plug
2. Drain plug
3. No. 2 sun gear (No. of teeth: 11)
4. No. 1 sun gear (No. of teeth: 20)
5. No. 2 planetary carrier
6. Cover
8. Retainer
9. Sprocket
10. Floating seal
11. Travel motor
12. Hub
13. No. 1 planetary gear (No. of teeth: 37)
14. Ring gear (No. of teeth: 109)
15. No. 2 planetary gear (No. of teeth: 48)
SPECIFICATIONS
11 + 109 20 + 96
Reduction ratio: –  --------------------- ×  ------------------ + 1 = – 62.273
 11   20 
Unit: mm
No. Check item Criteria Remedy
Backlash between No. 1 sun gear and Standard clearance Clearance limit
16
No. 1 planetary gear 0.15 - 0.49 1.00
Backlash between No. 1 planetary gear
17 0.16 - 0.57 1.00
and ring gear
Backlash between No. 1 planetary car-
18 0.16 - 0.53 —
rier and retainer
Replace
Backlash between No. 2 sun gear and
19 0.14 - 0.44 1.00
No. 2 planetary gear
Backlash between No. 2 planetary gear
20 0.16 - 0.53 1.10
and ring gear
Backlash between No. 2 planetary car-
21 0.36 - 0.65 1.00
rier and No. 1 sun gear
9 Amount of wear on sprocket tooth Repair limit: 6
Rebuild or
Standard size Repair limit
22 Width of sprocket tooth replace
71 68
PC228US-3 10-7
STRUCTURE AND FUNCTION SWING CIRCLE
12
SWING CIRCLE
1. Swing circle inner race (No. of teeth: 110) SPECIFICATIONS

2. Ball
3. Swing circle outer race Reduction ratio: 110
--------- = 7.333
4. Ball 15
Amount of grease: 14.5 l (G2-LI)
a. Inner race soft zone S position
b. Outer race soft zone S position
Unit: mm
Axial clearance of bearing Standard clearance Clearance limit

4 Replace
(when mounted on chassis) 0.5 - 1.6 3.2
10-8 PC228US-3
STRUCTURE AND FUNCTION SWING MACHINERY
12
SWING MACHINERY
10-10 PC228US-3
STRUCTURE AND FUNCTION SWING MACHINERY
12
1. Swing pinion (No. of teeth: 15)

2. Spacer
3. Case
5. No. 2 sun gear
6. Ring gear
7. No. 1 sun gear
8. Swing motor
9. Oil level gauge
10. No. 1 planetary gear
12. No. 2 planetary gear
13. Drain plug
SPECIFICATIONS
17 + 58 18 + 58
Reduction ratio: ------------------- × ------------------- = 18.627
17 18
Unit: mm
Backlash between swing motor shaft and Standard clearance Clearance limit
14
No. 1 sun gear 0.18 - 0.24 —
Backlash between No. 1 sun gear and No. 1
15 0.16 - 0.50 1.00
planetary gear
Backlash between No. 1 planetary gear and
16 0.18 - 0.59 1.10
ring gear
Backlash between No. 1 planetary carrier
17 0.39 - 0.71 1.20
and No. 2 sun gear
Backlash between No. 2 sun gear and No. 2 Replace
18 0.16 - 0.50 0.90
planetary gear
Backlash between No. 2 planetary gear and
19 0.18 - 0.59 1.00
ring gear
Backlash between No. 2 planetary carrier
20 0.07 - 0.23 —
and swing pinion
Backlash between swing pinion and swing
21 0.22 - 1.32 2.00
circle
Clearance between plate and planetary car-
22 0.66 - 1.14 —
rier
Standard size Repair limit Apply hard
Wear of swing pinion surface contacting chrome plating
23 0
with oil seal 115 — recondition, or
-0.100 replace
PC228US-3 10-11
STRUCTURE AND FUNCTION TRACK FRAME • RECOIL SPRING
12
TRACK FRAME • RECOIL SPRING
1 Idler • The dimensions and the number of track rollers depend

2 Track frame on the model, but the basic structure is not different.
3 Carrier roller • Number of track rollers
4 Final drive
5 Track roller Model Q’ty
6 Track shoe
7 Center guard PC228US-3 7
8 Recoil spring
9 Front guard PC228USLC-3 9
10-12 PC228US-3
12
Standard shoe
Model
PC228US-3 PC228USLC-3
Item
Shoe width 600 mm 700 mm
Link pitch 190 mm —
No. on track (one side) 45 (pieces) 49 (pieces)
Unit: mm
Standard
Tolerance Repair limit
size
10 Vertical width of idler guide
Track frame 107 Rebuild
or
Idler support 105
replace
Horizontal width of idler Track frame 250
11
guide Idler support 247.4
Free length Installation Installation Free Installation

8 Recoil spring x O.D. length load length load Replace
108.8 kN 87.3 kN
558 X 238 437 534
(11,100 kg) (8,900 kg)
PC228US-3 10-13
12
IDLER
10-14 PC228US-3
12
Unit: mm

1 Outside diameter of protruding
560 —
2 Outside diameter of tread 520 508 Rebuild

or
3 Thickness of tread — — replace
4 Total width 164 —
5 Width of tread 39.5 45.5
Standard Tolerance Standard Clearance

Clearance between shaft and size Shaft Hole clearance limit
6
bushing
-0.250 +0.074
65 0.214 - 0.424 1.5
-0.350 -0.036 Replace
Tolerance bushing
Standard Standard Interference
Interference between idler and size Shaft Hole interference limit
7
bushing
+0.089 -0.006
72 0.065 - 0.161 —
+0.059 -0.072
PC228US-3 10-15
12
CARRIER ROLLER
Unit: mm

1 Outside diameter of flange
145 —
2 Outside diameter of tread 120 —
3 Width of tread 43 —
4 Thickness of tread 36.5 —
5 Width of flange 14 —
Standard Tolerance Standard Interference Replace

Interference between shaft size Shaft Hole interference limit
6
and bushing
-0.179 +0.284
40 0.339 - 0.474 —
-0.190 +0.169
Interference between idler -0.061 0
7 47 0.036 - 0.101 —
and bushing -0.036 -0.040
Standard clearance Clearance limit

8 Axial clearance of roller
— —
10-16 PC228US-3
12
TRACK ROLLER
Unit: mm

1 Outside diameter of flange
188 —
2 Outside diameter of tread 156 144
3 Thickness of tread 44.5 — Rebuild

or
4 Overall width 225 — replace
5 Inside width 85 —
6 Width of tread 44.5 —
7 Width of flange 25.5 —

Clearance between shaft and size Shaft Hole clearance limit
8
bushing
-0.215 +0.195
60 0.215 - 0.510 1.5
-0.315 0 Replace
Tolerance bushing
Standard Standard Interference
Interference between roller size Shaft Hole interference limit
9
and bushing
-0.153 +0.030
67 0.023 - 0.153 —
-0.053 0
PC228US-3 10-17
STRUCTURE AND FUNCTION TRACK SHOE
12
TRACK SHOE
TRIPLE GROUSER SHOE, ROAD LINER, SWAMP SHOE, FLAT SHOE
★ P portion shows the link of bushing press fitting end.
1.Triple-grouser shoe 3.Swamp shoe

2.Road liner 4.Flat shoe
10-18 PC228US-3
12
Unit: mm

1 Link pitch
190.25 194.25
Reverse or
When turned
Standard size replace
2 Bushing outside diameter Normal load Impact load
59.3 — 54.3
Standard size Repair limit Repair or

3 Link height
105 97 replace
Thickness of link metal

4 28.5
(bushing press-fitting portion)
5 160.4 Replace
6 Shoe bolt pitch 62
7 18
8 Inside width 84.8

9 Overall width 45.5 Repair or
Link
replace
10 Tread width
40.3
11 Protrusion of pin 4
12 Protrusion of regular bushing 4.85
13 Overall length of pin 212 Adjust or

14 Overall length of bushing 128.7 replace
15 Thickness of bushing metal 10.4
16 Thickness of spacer —
17 Bushing 88.2 - 245 kN {9 - 25 ton}
18 Press-fitting Regular pin 127.4 - 274.4 kN {13 - 28 ton}

—
force
Master pin 78.4 - 147 kN {8 - 15 ton}
19
: Dry type track link
PC228US-3 10-19
12
Unit: mm
Tightening torque Additional tightening

(Nm {kgm}) angle (deg.)
Triple shoe
Swamp shoe 490 ± 49
a. Regular link 120 ± 10
Flat shoe {50 ± 5}
Rubber pad shoe Reverse or
20 Shoe bolt replace
549 ± 59
Road liner —
{56 ± 6}
Tightening torque Additional tightening Lower limit torque
b. Master link (Nm {kgm}) angle (deg.) (Nm {kgm})
— — —
No. of shoes (each side) PC228US - 3:45, PC228USLC - 3:49 —
Standard Tolerance
Standard
size
Interference between Shaft Hole interference
21
bushing and link
+0.304 +0.074
59 0.320 - 0.436
+0.264 0
Interference between +0.222 -0.138 0.300 - 0.422

22 38
regular pin and link +0.072 -0.200
Standard Tolerance Standard

Clearance between regular pin size Shaft Hole clearance
23
and bushing
+0.222 +0.902 Adjust or
38 0.180 - 0.740 replace
+0.072 +0.402

Interference between master size Shaft Hole interference
24 pin and bushing
+0.280 +0.062
37.8 0.188 - 0.280
+0.250 0

Clearance between master pin size clearance
Shaft Hole
and bushing
25
-0.150 +0.902
38 0.552 - 1.252
-0.350 +0.402
Standard size Repair limit Lug welding,

Triple-grouser rebuild or
Height of 26 16 replace
#
grouser
Road liner
70 25 Replace
: Dry type track link
10-20 PC228US-3
12
TRIPLE GROUSER SHOE
Unit: mm
No. Item Criteria Remedy
Basic dimension Repair limit

1 Height
26 16
2 Thickness 8.5
3 27 Repair by overlaying,
Length of base
4 22 welding, or replace
5 21
6 Length of top 14
7 19
PC228US-3 10-21
STRUCTURE AND FUNCTION HYDRAULIC TANK
12
HYDRAULIC TANK
1. Sight gauge SPECIFICATIONS

2. Hydraulic tank Tank capacity: 165 l
3. Oil filler cap Amount of oil inside tank: 126 l
4. Filter element Pressure valve
5. Strainer Relief cracking pressure:
6. Bypass valve 16.7 ± 3.9 kPa
7. Suction strainer {0.17 ± 0.04 kg/cm²}
Suction cracking pressure:
0 - 0.49 kPa
{0 - 0.005 kg/cm²}
Bypass Valve set pressure:
150 ± 30 kPa
{1.5 ± 0.3 kg/cm²}
10-22 PC228US-3
STRUCTURE AND FUNCTION HYDRAULIC PUMP
12
HYDRAULIC PUMP
HPV95 + 95
1. Front main pump IM : PC mode selector current PENR : Control pressure pickup port
2. Rear main pump ISIG : LS set selection current PLSF : Load pressure input port
3. LS valve PAF : Front pump discharge port PLSFC: Load pressure pickup port
4. PC valve PAR : Rear pump discharge port PLSR : Load pressure input port
5. LS-EPC valve PBF : Pump pressure input port PS : Pump suction port
6. PC-EPC valve PD1F: Case drain port PSIG : LS set selection pressure pickup port
PENF: Control pressure pickup port
Outline
• This pump consists of 2 variable capacity swash plate
piston pumps, PC valve, LS valve, and EPC valve.
10-24 PC228US-3
12
1. Shaft (Front) 7. Cylinder block

2. Cradle 8. Valve plate
3. Case (Front) 9. End cap
4. Rocker cam 10. Shaft (Rear)
5. Shoe 11. Case (Rear)
6. Piston 12. Servo piston
PC228US-3 10-25
12
Function
• The rotation and torque transmitted to the • Rocker cam (4) has flat surface A, and shoe
pump shaft are converted into hydraulic (5) is always pressed against this surface
energy, and pressurized oil is discharged while sliding in a circular movement.
according to the load. Rocker cam (4) brings high pressure oil at cyl-
• It is possible to change the discharge amount inder surface B with cradle (2), which is
by changing the swash plate angle. secured to the case, and forms a static pres-
Structure sure bearing when it slides.
• Cylinder block (7) is supported to shaft (1) by • Piston (6) carries out relative movement in
a spline, and shaft (1) is supported by the the axial direction inside each cylinder cham-
front and rear bearings. ber of cylinder block (7).
• The tip of piston (6) is a concave ball, and • The cylinder block seals the pressure oil to
shoe (5) is caulked to it to form one unit. Pis- valve plate (8) and carries out relative rota-
ton (6) and shoe (5) form a spherical bearing. tion. This surface is designed so that the oil
pressure balance is maintained at a suitable
level. The oil inside each cylinder chamber of
cylinder block (7) is sucked in and discharged
through valve plate (8).
10-26 PC228US-3
12
Operation
1) Operation of pump
i Cylinder block (7) rotates together with
shaft (1), and shoe (5) slides on flat surface
A.
When this happens, rocker cam (4) moves
along cylindrical surface B, so angle α
between center line X of rocker cam (4) and
the axial direction of cylinder block (7)
changes. (Angle α is called the swash plate
angle.)
ii Center line X of rocker cam (4) maintains
swash plate angle α in relation to the axial
direction of cylinder block (7), and flat sur-
face A moves as a cam in relation to shoe
(5).
In this way, piston (6) slides on the inside of
cylinder block (7), so a difference between
volumes E and F is created inside cylinder
block (7). The suction and discharge is car-
ried out by this difference F - E.
In other words, when cylinder block (7)
rotates and the volume of chamber E
becomes smaller, the oil is discharged dur-
ing that stroke. On the other hand, the vol-
ume of chamber F becomes larger, and as
the volume becomes bigger, the oil is
sucked in.
iii If center line X of rocker cam (4) is in line
with the axial direction of cylinder block (7)
(swash plate angle = 0), the difference
between volumes E and F inside cylinder
block (7) becomes 0, so the pump does not
carry out any suction or discharge of oil.
(In actual fact, the swash plate angle never
becomes 0.)
PC228US-3 10-27
12
2) Control of discharge amount
• If the swash plate angle α becomes larger,
the difference between volumes E and F
becomes larger and discharge amount Q
increases.
• Swash plate angle α is changed by servo
piston (12).
• Servo piston (12) moves in a reciprocal
movement (↔) according to the signal
pressure from the PC and LS valves. This
straight line movement is transmitted
through rod (13) to rocker cam (4), and
rocker cam (4), which is supported by the
cylindrical surface to cradle (2), slides in a
rotating movement in direction of arrow.
• With servo piston (12), the area receiving
the pressure is different on the left and
the right, so main pump discharge pres-
sure (self pressure) PP is always brought
to the chamber receiving the pressure at
the small diameter piston end.
• Output pressure Pen of the LS valve is
brought to the chamber receiving the
pressure at the large diameter and. The
relationship in the size of pressure PP at
the small diameter piston end and pres-
sure Pen at the large diameter end, and
the ratio between the area receiving the
pressure of the small diameter piston and
the large diameter piston controls the
movement of servo piston (12).
10-28 PC228US-3
12
LS VALVE
PA : Pump port 1. Plug

PDP : Drain port 2. Locknut
PLP : LS control pressure output port 3. Sleeve
PLS : LS pressure input port 4. Spring
PP : Pump port 5. Seat
PPL : Control pressure input port 6. Spool
PSIG : LS mode selection pilot port 7. Piston
8. Sleeve
PC VALVE
1. Servo piston assembly PA : Pump port

2. Plug PA2 : Pump pressure pilot port
3. Pin PDP : Drain port
4. Spool PM : Mode selector pressure pilot port
5. Retainer PPL : Control pressure output port
6. Seat
7. Cover
8. Wiring
PC228US-3 10-29
12
Function
(1) LS valve
The LS valve detects the load and controls the
discharge amount.
This valve controls main pump discharge
amount Q according to differential pressure
∆PLS (=PP - PLS) [called the LS differential
pressure] (the difference between main pump
pressure PP and control valve outlet port
pressure PLS).
Main pump pressure PP, pressure PLS {called
the LS pressure} coming from the control
valve output, and pressure Psig {called the
LS selector pressure} from the proportional
solenoid valve enter this valve. The relation-
ship between discharge amount Q and differ-
ential pressure ∆PLS, (the difference between
main pump pressure PP and LS pressure
PLS) (= PP - PLS) changes as shown in the
diagram at the right according to LS pressure
selector current isig of the LS-EPC valve.
When isig changes between 0 and 1A, the set
pressure of the spring changes according to
this, and the selector point for the pump dis-
charge amount changes at the rated central
valve between 0.69 ↔ 2.2 MPa {6.9 ↔ 22 kg/
cm²}.
(2) PC valve
When the pump discharge pressure PP1
(self-pressure) and PP2 (other pump pres-
sure) are high, the PC valve controls the
pump so that no more oil than the constant
flow (in accordance with the discharge pres-
sure) flows even if the stroke of the control
valve becomes larger. In this way, it carries
out equal horsepower control so that the
horsepower absorbed by the pump does not
exceed the engine horsepower.
In other words, If the load during the opera-
tion becomes larger and the pump discharge
pressure rises, it reduces the discharge
amount from the pump; and if the pump dis-
charge pressure drops, it increases the dis-
charge amount from the pump. The
relationship between the average of the front
and rear pump discharge pressures (average
discharge amount of F, R pumps (PP1 +
PP2)/2) and pump discharge amount Q is
shown on the right, with the current given to
the PC-EPC valve solenoid shown as a param-
eter. The controller senses the actual speed of
the engine, and if the speed drops because of
an increase in the load, it reduces the pump
discharge amount to allow the speed to the set value, the command current to the PC-
recover. In other words, when the load EPC valve solenoid from the controller
increases and the engine speed drops below increases according to the drop in the engine
speed to reduce the pump swash plate angle.
10-30 PC228US-3
12
OPERATION
(1) LS valve
1) When control valve is at neutral position
• The LS valve is a three-way selector valve, At this point, spool (6) is pushed to the left,
with pressure PLS (LS pressure) from the and port C and port D are connected. Pump
inlet port of the control valve brought to pressure PP enters the large diameter end of
spring chamber B, and main pump discharge the piston from port K and the same pump
pressure PP brought to port H of sleeve (8). pressure PP also enters port J at the small
The size of this LS pressure PLS + force Z of diameter end of the piston, so the swash plate
spring (4) and the main pump pressure (self is moved to the minimum angle by the differ-
pressure) PP determines the position of ence in the area of the piston (11).
spool (6). However, the size of the output
pressure PSIG (the LS selection pressure) of
the EPC valve for the LS valve entering port G
also changes the position of spool (6). (The
set pressure of the spring changes).
• Before the engine is started, servo piston (11)
is pushed to the right. (See the diagram on
the right)
• When the engine is started and the control
lever is at the neutral position, LS pressure
PLS is 0 MPa {0 kg/cm²}. (It is interconnected
with the drain circuit through the control
valve spool.)
PC228US-3 10-31
12
2) Operation in increase direction for pump

discharge amount
• When the difference between the main pump • For this reason, the pressure at the large
pressure PP and LS pressure PLS, in other diameter end of servo piston (12) becomes
words, LS differential pressure ∆PLS, drain pressure PT, and pump pressure PP
becomes smaller (for example, when the area enters port J at the small diameter end, so
of opening of the control valve becomes servo piston (12) is pushed to the right. There-
larger and pump PP drops), spool (6) is fore, the swash plate moves in the direction
pushed to the right by the combined force of to make the discharge amount larger. If the
LS pressure PLS and the force of spring (4). output pressure of the EPC valve for the LS
• When spool (6) moves, port D and port E are valve enters port G, this pressure creates a
joined and connected to the PC valve. When force to move piston (7) to the left. If piston
this happens, the PC valve is connected to the (7) is pushed to the left, it acts to make the set
drain port, so circuit D - K becomes drain pressure of spring (4) weaker, and the differ-
pressure PT. (The operation of the PC valve is ence between PLS and PP changes when
explained later). ports D and E of spool (6) are connected.
10-32 PC228US-3
12
3) Operation in decrease direction for

pump discharge amount
• The following explains the situation if the • Main pump pressure PP also enters port J at
servo piston (12) moves to the left (the dis- the small diameter end of the piston, but
charge amount becomes smaller). When LS because of the difference in area between the
differential pressure ∆PLS becomes larger large diameter end and the small diameter
(for example, when the area of opening of the end of servo piston (12), servo piston (12) is
control valve becomes smaller and pump pushed to the left.
pressure PP rises), pump pressure PP • As a result, the swash plate moves in the
pushes spool (6) to the left. direction to make angle smaller.
• When spool (6) moves, main port pressure • If LS selection pressure PSIG enters port G, it
PP flows from port C and port D and from acts to make the set pressure of spring (4)
port K, it enters the large diameter end of the weaker.
piston.
PC228US-3 10-33
12
4) When servo piston is balanced

• Let us take the area receiving the pressure at • At this point, the relationship between the
the large diameter end of the piston as A1, area receiving the pressure at both ends of
the area receiving the pressure at the small piston (12) is A0 : A1 = 1:2, so the pressure
diameter end as A0, and the pressure flowing applied to both ends of the piston when it is
into the large diameter end of the piston as balanced becomes PP : Pen = 2:1.
Pen. If the main pump pressure PP of the LS • The position where spool (6) is balanced and
valve and the combined force of force Z of stopped is the standard center, and the force
spring (4) and LS pressure PLS are balanced, of spring (4) is adjusted so that it is deter-
and the relationship is A0 x PP = A1 x Pen, mined when PP - PLS = 2.2 MPa {22 kg/cm²}.
servo piston (11) will stop in that position, and However, if PSIG (the output pressure of 0 ↔
the swash plate will be kept at an intermedi- 2.9 MPa {0 ↔ 30 kg/cm²} of the EPC valve of
ate position. (It will stop at a position where the LS valve) is applied to port G, the balance
the opening of the throttle from port D to port stop position will change in proportion to
E and from port C to port D of spool (6) is pressure PSIG between PP - PLS = 2.2 ↔
approximately the same.) 0.69 MPa {22 ↔ 6.9 kg/cm²}.
10-34 PC228US-3
12
(2) PC Valve
1) When pump controller is normal
a. When the load on the actuator is small
and pump pressures PP1 and PP2 are
• the pressure (pressure of port C) output
low
from the PC valve changes according to
➀ Movement of PC-EPC solenoid (1)
this position.
• The command current from the pump
• The size of command current X is deter-
controller flows to PC-EPC solenoid
mined by the nature of the operation
(1).This command current acts on the PC-
(lever operation), the selection of the
EPC valve and outputs the signal pres-
working mode, and the set value and
sure. When this signal pressure is
actual value for the engine speed.
received, the force pushing piston (2) is
changed. ★ Other pump pressure
• On the opposite side to the force pushing This is the pressure of the pump at the
this piston (2) is the spring set pressure of opposite end.
springs (4) and (6) and pump pressure For the F pump, it is the R pump pressure
PP1 (self pressure) and PP2 (other pump For the R pump, it is the F pump pressure
pressure) pushing spool (3). Piston (2)
stops at a position where the combined
force pushing spool (3) is balanced, and
PC228US-3 10-35
12
➁ Action of spring
• The spring load of springs (4) and (6) in the • If the command circuit input to PC-EPC valve
PC valve is determined by the swash plate solenoid (1) changes further, the force push-
position. ing piston (2) changes, and the spring load of
• If piston (9) moves to the left, spring (6) is springs (4) and (6) also changes according to
compressed, and if it moves further to the left, the valve of the PC-EPC valve solenoid com-
spring (6) contacts seat (5) and is fixed in mand current.
position. In other words, the spring load is
changed by piston (9) extending or compress-
ing springs (4) and (6).
10-36 PC228US-3
12
• Port C of the PC valve is connected to port E

of the LS valve (see (1) LS valve). Self pres-
sure PP1 enters port B and the small diame-
ter end of servo piston (9), and other pump
pressure PP2 enters port A.
• When pump pressures PP1 and PP2 are
small, spool (3) is on the left. At this point,
port C and D are connected, and the pressure
entering the LS valve becomes drain pressure
PT. If port E and port G of the LS valve are
connected (see (1) LS valve), the pressure
entering the large diameter end of the piston
from port J becomes drain pressure PT, and
servo piston (9) moves to the right. In this
way, the pump discharge amount moves in
the direction of increase.
• As servo piston (9) moves further, springs (4)
and (6) expand and the spring force becomes
weaker. When the spring force becomes
weaker, spool (3) moves to the right, so the
connection between port C and port D is cut,
and the pump discharge pressure ports B and
C are connected. As a result, the pressure at
port C rises, and the pressure at the large
diameter end of the piston also rises, so the
movement of piston (9) to the right is
stopped.
• In other words, the stop position for piston (9)
(= pump discharge amount) is decided at the
point where the force of springs (4) and (6)
and the pushing force from the PC-EPC valve
solenoid and the pushing force created by the
pressures PP1 and PP2 acting on the spool
(3) are in balance.
PC228US-3 10-37
12
b. When load on actuator is large and

pump discharge pressure is high
• When the load is large and pump dis- • If main pump pressure PP increases fur-
charge pressures PP1 and PP2 are high, ther and spool (3) moves further to the
the force pushing spool (3) to the left left, main pump pressure PP1 flows to
becomes larger and spool (3) moves to port C and acts to make the discharge
the position in the diagram above. When amount the minimum. When piston (9)
this happens, as shown in the diagram moves to the left, springs (4) and (6) are
above, part of the pressurized oil from compressed and push back spool (3).
port B flows out through port C where the When spool (3) moves to the left, the
LS valve is actuated to port D, and the opening of port C and port D becomes
pressurized oil flowing from port C to the larger. As a result, the pressure at port C
LS valve becomes approximately half of (= J) drops, and piston (9) stops moving
main pump pressure PP. to the left.
• When port E and port G of the LS valve • The position in which piston (9) stops
are connected (see (1) LS valve), the pres- when this happens is further to the left
sure from port J enters the large diameter than the position when pump pressures
end of servo piston (9), and servo piston PP1 and PP2 are low.
(9) stops.
10-38 PC228US-3
12
• The relation of average pump pressure

(PP1 + PP2)/2 and the position of servo
piston (9) forms a bent line because of
the double-spring effect of springs (4)
and (6). The relationship between aver-
age pump pressure (PP1 + PP2)/2 and
pump discharge amount Q is shown in
the figure at the right.
• If command voltage X sent to PC-EPC

valve solenoid (1) increases further, the
relationship between average pump
pressure (PP1 + PP2)/2, and pump dis-
charge amount Q is proportional to the
pushing force of the PC-EPC valve sole-
noid and moves in parallel. In other
words, the pushing force of PC-EPC
solenoid (1) is added to the force push-
ing to the left because of the pump pres-
sure applied to the spool (3), so the
relationship between the average pump
pressure (PP1 + PP2)/2 and Q moves
from ➀ to ➁ in accordance with the
increase in X.
PC228US-3 10-39
12
2) When pump controller is abnormal and

PC prolix switch is ON
a. When load on main pump is light
• If there is a failure in the pump controller, • At this point, port C is connected to the
turn emergency pump drive switch ON to drain pressure of port D, and the large
switch to the resistor side. In this case, the diameter end of the piston of servo piston
power source is taken directly from the (9) also becomes the drain pressure PT
battery. But if the current is used as it is, it through the LS valve. When this happens,
is too large, so use the resistor to control the pressure at the small diameter end of
the current flowing to PC-EPC valve sole- the piston is large, so servo piston (9)
noid (1). moves in the direction to make the dis-
• When this is done, the current becomes charge amount larger.
constant, so the force pushing piston (2)
is also constant.
• If the main pump pressure PP1 and PP2
are low, the combined force of the pump
pressure and the force of PC-EPC valve
solenoid (1) is weaker than the spring set
force, so spool (3) is balanced at a posi-
tion to the left.
10-40 PC228US-3
12
b. When main pump load is heavy

• In the same way as in the previous item, and discharge amount Q is determined as
when the emergency pump drive switch shown in the diagram for the valve of the
is ON, the command current sent to PC- current sent to the PC-EPC valve solenoid
EPC valve solenoid (1) becomes constant. through the resistor.
For this reason, the force of piston (2) The curve when the PC prolix switch is
pushing spool (3) is constant. ON is curve ➁, which is to the left of curve
• If main pump pressures PP1 and PP2 ➀ for when the pump controller is normal.
increase, spool (3) moves further to the
left than when the main pump load is
light, and is balanced at the position in
the diagram above.
• In this case, the pressure from port A
flows to port C, so servo piston (9) moves
to the left (to make the discharge amount
smaller) by the same mechanism as
explained in item 2)-b, and stops at a
position to the left of the position when
the load on the pump is light. In other
words, even when the emergency pump
drive switch is ON, the curve for the
pump pressure PP
PC228US-3 10-41
12
LS-EPC VALVE
1. Body 5. Coil C : To LS valve

2. Spool 6. Plunger T : To tank
3. Spring 7. Connector P : From main pump
4. Rod
10-42 PC228US-3
12O
Function
• The EPC valve consists of the proportional

solenoid portion and the hydraulic valve
portion.
• When it receives signal current i from the
pump controller, it generates the EPC out-
put pressure in proportion to the size of the
signal, and outputs it to the LS valve.
Operation
1. When signal current is 0 (coil deener-

gized)
• When there is no signal current flowing
from the controller to coil (5), coil (5) is
generalized.
• For this reason, spool (2) is pushed to the
right in the direction of the arrow by spring
(3).
• As a result, port P closes and the pressur-
ized oil from the main pump does not flow
to the LS valve.
At the same time, the pressurized oil from
the LS valve passes from port C through
port T and is drained to the tank.
PC228US-3 10-43
2. When signal current is very small (coil

energized)
• When a very small signal current flows to
coil (5), coil (5) is energized, and a propul-
sion force is generated which pushes
plunger (6) to the left.
• Push pin (4) pushes spool (2) to the left,
and pressurized oil flows from port P to
port C.
• When the pressure at port C rises and the
load of spring (3) + the force acting on sur-
face a of spool (2) becomes greater than
the propulsion force of plunger (6), spool
(2) is pushed to the right. The circuit
between port P and port C is shut off, and
at the same time, port C and port T are
connected.
• As a result, spool (2) is moved up or down
until the propulsion force of plunger (6) is
balanced with the load of spring (3) + pres-
sure of port C.
• Therefore, the circuit pressure between the
EPC valve and the LS valve is controlled in
proportion to the size of the signal current.
3. When signal current is maximum (coil

energized)
• When the signal current flows to coil (5),
coil (5) is energized.
• When this happens, the signal current is at
its maximum, so the propulsion force of
plunger (6) is also at its maximum.
• For this reason, spool (2) is pushed fully to
the left by push pin (4).
• As a result, the maximum flow of pressur-
ized oil from port P flows to port C, and the
circuit pressure between the EPC valve and
LS valve becomes the maximum.
At the same time, port T closes and stops
the oil from flowing to the tank.
10-44 PC228US-3
STRUCTURE AND FUNCTION CONTROL VALVE
12
CONTROL VALVE
1. 6-spool valve Outline
2. Cover 1
3. Cover 2 • This control valve consists of a 6-spool
4. Pump merge-divider valve valve (unit type), 3 service valves, a pump
5. Back pressure valve merge-divider valve, a back pressure valve,
6. Boom lock valve and a boom hydraulic drift prevention
7. Service Valve valve.
8. Service Valve • The 7-spool valve (6-spool valve + Service
9. Service Valve valve) is made by removing the upper 2
sets (section AA-AA) of the valve stack.
• Since all the valves are assembled together
with connecting bolts and their passes are
connected to each other inside the assem-
bly, the assembly is small in size and easy
to maintain.
• Since one spool of this control valve is
used for one work equipment unit, its struc-
ture is simple.
A1 : To bucket cylinder head P10 : From right travel PPC valve

A2 : To left travel motor P11 : From arm PPC valve
A3 : To boom cylinder bottom P12 : From arm PPC valve, EPC valve
A4 : To swing motor P-1 : From service PPC valve
A5 : To right travel motor P-2 : From service PPC valve
A6 : To arm cylinder head P-3 : From service PPC valve
A-1 : To attachment P-4 : From service PPC valve
B1 : To bucket cylinder bottom BP1 : Boom RAISE PPC output pressure
B2 : To left travel motor BP2 : From BP4
B3 : To bottom cylinder head BP3 : From BP4
B4 : To swing motor BP4 : To BP2, BP3
B5 : To right travel motor PLS1: To rear pump control
B6 : To arm cylinder bottom PLS2: To front pump control
B-1 : To attachment PP1 : From rear main pump
B-2 : To attachment PP2 : From front main pump
B-3 : To attachment PR : To solenoid valve, PPC valve, EPC valve
P1 : From bucket PPC valve PS : From pump merge-divider solenoid valve
P2 : From bucket PPC valve PST : From travel junction valve
P3 : From left travel PPC valve PX1 : From 2-stage solenoid valve
P4 : From left travel PPC valve PX2 : From 2-stage solenoid valve
P5 : From boom PPC valve, EPC valve SA : Pressure sensor fitting port
P6 : From boom PPC valve, EPC valve SB : Pressure sensor fitting port
P7 : From swing PPC valve T : To tank
P8 : From swing PPC valve TS : To tank
P9 : From right travel PPC valve TSW: To swing motor
10-46 PC228US-3
12
9-spool valve
(6-spool valve + 3 service valves)
(1/9)
PC228US-3 10-47
12
(2/9)
10-48 PC228US-3
12
(3/9)
1. Unload valve 11. Pressure compensation valve (Service)

2. Pressure compensation valve (Arm OUT) 12. Pressure compensation valve (Service)
3. Pressure compensation valve (Right travel 13. Pressure compensation valve (Service)
Reverse) 14. Pressure compensation valve (Bucket CURL)
4. Pressure compensation valve (Right swing) 15. Pressure compensation valve (Left travel for-
5. Pressure compensation valve (Boom RAISE) ward)
6. Pressure compensation valve (Left travel 16. Pressure compensation valve (Boom LOWER)
reverse) 17. Pressure compensation valve (Left swing)
7. Pressure compensation valve (Bucket DUMP) 18. Pressure compensation valve (Right travel
8. Pressure compensation valve (Service) forward)
9. Pressure compensation valve (Service) 19. Pressure compensation valve (Arm IN)
10. Pressure compensation valve (Service 20. Main relief valve
PC228US-3 10-49
12
(4/9)
1. Spool (Arm) 7. Spool (Service)

2. Spool (Right travel) 8. Spool (Service)
3. Spool (Swing) 9. Spool (Service)
4. Spool (Boom) 10. Unload valve
5. Spool (Left travel) 11. Main relief valve
6. Spool (Bucket) 12. Spool return spring
10-50 PC228US-3
12
(5/9)
1. Safety-suction valve (Arm OUT) 15. Suction valve (Right travel forward)
2. Suction valve (Right travel reverse) 16. Safety-suction valve (Arm IN)
3. Suction valve (Boom RAISE) 17. LS shuttle valve (Arm)
4. Suction valve (Left travel reverse) 18. LS shuttle valve (Right travel)
5. Safety-suction valve (Bucket DUMP) 19. LS select valve
6. Safety-suction valve (Service) 20. LS shuttle valve (Boom)
7. Safety-suction valve (Service) 21. LS shuttle valve (Left travel)
8. Safety-suction valve (Service) 22. LS shuttle valve (Bucket)
9. Safety-suction valve (Service) 23. LS shuttle valve (Service)
12. Safety-suction valve (Bucket CURL) 26. LS check valve
13. Suction valve (Left travel forward) 27. Pressure relief valve
14. Safety-suction valve (Boom LOWER)
PC228US-3 10-51
12
(6/9)
Arm Control Valve R. H. travel control valve
1. Unload valve 5. Safety-suction valve 12. Suction valve

2. Main relief valve 6. Spool 13. Spool
3. Safety valve (Boom RAISE) 7. Pressure compensation valve (OUT) 14. Pressure compensation valve
4. Lift check valve 8. LS shuttle valve (Reverse)
9. Pressure compensation valve (IN) 15. LS shuttle valve
10. Safety-suction valve 16. Pressure compensation valve
11. Check valve for regeneration circuit (Forward)
17. Suction valve
10-52 PC228US-3
12
(7/9)
Bucket control valve Service valve Swing control valve
1. Safety-suction valve 7. Safety-suction valve 13. Safety-suction valve

2. Spool 8. Spool 14. Spool
3. Pressure compensation 9. Pressure compensation 15. Pressure compensation
valve (DUMP) valve valve
4. LS shuttle valve 10. LS shuttle valve 16. LS shuttle valve
5. Pressure compensation 11. Pressure compensation 17. Pressure compensation
valve (CURL) valve valve
6. Safety-suction valve 12. Safety-suction valve 18. Safety-suction valve
PC228US-3 10-53
12
(8/9)
Swing control valve Boom control valve L. H. travel control valve
1. Spool 5. Suction valve 13. Pump merge-divider valve

2. Pressure compensation 6. Spool (Travel junction valve)
valve (Right) 7. Pressure compensation 14. Return spring
3. LS select valve valve (RAISE) 15. Suction valve
4. Pressure compensation 8. Hydraulic drift prevention 16. Spool
valve (Left) valve 17. Pressure compensation
9. LS shuttle valve valve (Reverse)
10. Pressure compensation 18. LS shuttle valve
valve (Lower) 19. Pressure compensation
11. Safety-suction valve valve (Forward)
12. Check valve for regeneration 20. Suction valve
circuit
10-54 PC228US-3
12
(9/9)
1. Unload valve 9. LS bypass plug

2. Main relief valve 10. Screw
3. Pump merge-divider valve (Main) 11. Puppet
4. Return spring 12. Spring (Pressure reducing valve pilot)
5. Pump merge-divider valve (For LS) 13. Spring (Pressure reducing valve main)
6. Return spring 14. Valve (Pressure reducing valve)
7. Valve (Sequence valve) 15. Spring (Safety valve)
8. Spring (Sequence valve) 16. Ball
PC228US-3 10-55
12
VARIABLE PRESSURE COMPENSATION VALVE
10-56 PC228US-3
12
Unit: mm
Basic dimensions Allowable limits

Free length x Installed Installed Free Installed
A Spool return spring Outside diameter length load length load
416.5 N 333.2 N
54.2 x 34.8 51.2 —
{42.5 kg} {34 kg}
430.2 N 344.2 N
B Spool return spring 54.6 x 34.8 51.2 —
{43.9 kg} {35.1 kg}
393 N 314.6 N
C Spool return spring 54.5 x 34.8 51.2 —
{40.1 kg} {32.1 kg}
406.7 N 325.6 N
D Relief spring 30.7 x 9.6 25.9 —
{41.5 kg} {33.2 kg}
69.6 N 55.7 N
E Valve spring 24.3 x 8 19.5 —
{7.1 kg} {5.7 kg}
83.4 N 66.7 N
F Unload spring 31.5 x 10.2 26 —
{8.5 kg} {6.8 kg}
Regeneration valve 6.2 N 4.9 N
G 31.5 x 10.3 19.5 —
spring {0.6 kg} {0.5 kg}
17.5 N 14.0 N
H Piston return spring 48.1 x 10.8 28 —
{1.8 kg} {1.4 kg}
79.4 N 63.5 N
J Piston return spring 56.4 x 11.9 45 —
{8.1 kg} {6.5 kg}
29.4 N 23.5 N
K Piston return spring 36.9 x 11.1 28 —
{3 kg} {2.4 kg} If damaged or
428.3 N 343 N deformed,
L Load spring 30.4 x 16.7 27 — replace spring
{43.7 kg} {35.0 kg}
3.0 N 2.4 N
M Check valve spring 13.6 x 5.5 10 —
{0.3 kg} {0.25 kg}
35.3 N 28.2 N
N Check valve spring 33.0 x 12.0 26 —
{3.6 kg} {2.9 kg}
13.7 N 11.0 N
P Check valve spring 16.4 x 8.9 11.5 —
{1.4 kg} {1.1 kg}
50.0 N 40.0 N
Q Spool return spring 30.7 x 20.5 23 —
{5.1 kg} {4.1 kg}
9.8 N 7.8 N
R Piston return spring 32.76 x 8.5 20.5 —
{1.0 kg} {0.8 kg}
74.5 N 59.8 N
S Relief valve spring 17.1 x 9 15.5 —
{7.6 kg} {6.1 kg}
1.5 N 1.2 N
T Check valve spring 11.5 x 4.6 8.5 —
{0.15 kg} {0.12 kg}
156.8 N 125.5 N
U Spool return spring 46.6 x 21.8 3.3 —
{16.0 kg} {12.8 kg}
177.5 N 142.0 N
V Spool return spring 64.5 x 32.3 63 —
{18.1 kg} {14.5 kg}
Sequence valve 199.8 N 160.0 N
W 70.9 x 18 59 —
spring {20.4 kg} {16.3 kg}
10.4 N 8.3 N
X Spool return spring 13 x 8.8 7.7 —
{1.1 kg} {0.8 kg}
PC228US-3 10-57
STRUCTURE AND FUNCTION CLSS
12
CLSS
OUTLINE OF CLSS
Features Structure
• CLSS stands for Closed center Load Sensing • The CLSS consists of a main pump (2
System, and has the following features. pumps), control valve, and actuators for the
work equipment.
1) Fine control not influenced by load • The main pump body consists of the pump
2) Control enabling digging even with fine con- itself, the PC valve and LS valve.
trol
3) Ease of compound operation ensured by flow
divider function using area of opening of
spool during compound operations
4) Energy saving using variable pump control
10-58 PC228US-3
12
Basic principle
1) Control of pump swash plate
• The pump swash plate angle (pump dis-
charge amount) is controlled so that LS dif-
ferential pressure ∆PLS (the difference
between pump pressure PP and control
valve outlet port LS pressure PLS) (load
pressure of actuator) is constant.
(LS pressure ∆PLS = Pump discharge pres-
sure PP – LS pressure PLS)
• If LS differential pressure ∆PLS becomes

lower than the set pressure of the LS valve
(when the actuator load pressure is high),
the pump swash plate moves towards the
maximum position; if it becomes higher
than the set pressure of the LS valve (when
the actuator load pressure is low), the
pump swash plate moves towards the min-
imum position.
PC228US-3 10-59
12
2) Pressure compensation
• A pressure compensation valve is installed to In this way, the flow of oil from the pump is
the outlet port side of the control valve to bal- divided (compensated) in proportion to the
ance the load. area of opening S1 and S2 of each valve.
• When two actuators are operated together,
this valve acts to make pressure difference ∆P
between the upstream (inlet port) and down-
stream ( outlet port) of the spool of each valve
the same regardless of the size of the load
(pressure).
10-60 PC228US-3
STRUCTURE AND FUNCTION SELF PRESSURE REDUCING VALVE
12
SELF PRESSURE REDUCING VALVE
Function
• This value reduces the discharge pressure

of the main pump and supplies it as control
pressure for the solenoid valves, PPC
valves, etc..
Operation
1. When engine is stopped

• Puppet (11) is pressed by spring (12)
against the seat and port PR is not con-
nected to TS.
• Valve (14) is pressed by spring (13) against
the left side and port P2 is connected to PR.
• Valve (7) is pressed by spring (8) against
the left side and port P2 is not connected to
A2.
(See Fig. 1.)
Fig. 1
PC228US-3 10-61
2. When in neutral or load pressure P2 is

low (When boom is lowered and arm is in IN
position and they are moving down under
own weight)
Note: When load pressure A2 is lower than self-pres-
sure reducing valve output pressure PR.
• Valve (7) receives the force of spring (8) and
PR pressure (which is 0 MPa {0 kg/cm²} when
the engine is stopped) in the direction to close
the circuit between ports P2 and A2. If the
hydraulic oil flows in port P2, the P2 pressure
becomes equal to the total of the force of
spring (8) and the value of area of ∅d x PR
pressure, then the area of the pass between
ports P2 and A2 is so adjusted that the P2
pressure will be kept constant above the PR
pressure.
• If the PR pressure rises above the set level,
puppet (11) opens and the hydraulic oil flows
from the PR port through orifice "a" in spool
(14) and open part of puppet (11) to seal drain
port TS.
Accordingly, differential pressure is generated
between before and after orifice "a" in spool
(14) and then spool (14) moves to close the
pass between port P2 and PR. The P2 pres-
Fig. 2
sure is controlled constant (at the set pres-
sure) by the area of the oil pass at this time
and supplied as the PR pressure. (See Fig. 2.)
3. When load pressure P2 is high
• If load pressure A2 rises and the pump dis-
charge increases because of operation of the
work equipment, the P2 pressure rises higher
than the total of the force of spring (8) and the
value of ∅d x PR pressure, and then valve (7)
moves to the right stroke end.
• As a result, the area of the pass between ports
P2 and A2 increases and the pass resistance
lowers and the loss of the engine power is
reduced.
• If the PR pressure rises above the set pres-
sure, puppet (11) opens and the hydraulic oil
flows from the PR port through orifice "a" in
spool (14) and open part of puppet (11) to seal
drain port TS.
Accordingly, differential pressure is generated
between before and after orifice "a" in spool
(14) and then spool (14) moves to close the
pass between port P2 and PR. The P2 pres-
sure is controlled constant (at the set pres-
sure) by the area of the oil pass at this time
and supplied as the PR pressure. (See Fig. 3.)
Fig. 3
10-62 PC228US-3
12
4. When abnormally high pressure is

generated
• If the PR pressure on the self-pressure
reducing valve rises high abnormally, ball
(16) separates from the seat against the
force of spring (15) and the hydraulic oil
flows from output port PR to TS. Accord-
ingly, the PR pressure lowers. By this oper-
ation, the hydraulic devices (PPC valves,
solenoid valves, etc.) are protected from
abnormal pressure. (See Fig. 4.)
Fig. 4
PC228US-3 10-63
STRUCTURE AND FUNCTION TRAVEL JUNCTION VALVE
12
TRAVEL JUNCTION VALVE
Function Operation
• This valve connects both travel circuits to each When pilot pressure is turned ON
other so that the hydraulic oil will be supplied • If the pilot pressure from the travel junction sole-
evenly to both travel motors and the machine will noid valve becomes higher than the force of
travel straight. spring (14), travel junction spool (13) moves to the
• When the machine is steered, outside pilot pres- left stroke end and the junction circuit between
sure PST closes the travel junction valve to secure port PTL (Left travel circuit) and PTR (Right travel
high steering performance. circuit) is closed.
10-64 PC228US-3
STRUCTURE AND FUNCTION TRAVEL JUNCTION VALVE
When pilot pressure is turned OFF

• If pilot pressure PST from the sole- • If the oil flow rates in both travel motors
noid valve is 0, travel junction spool become different from each other, the oil
(13) is pressed by the force of spring flows through the route between port PTL,
(14) against the left side and the pass travel junction spool (13), and port PTR so
between ports PTL and PTR is open. that the oil flow rates will be equalized again.
PC228US-3 10-65
STRUCTURE AND FUNCTION BOOM HYDRAULIC DRIFT PREVENTION VALVE
12
BOOM HYDRAULIC DRIFT PREVENTION VALVE
When boom control valve is at RAISE
When boom control valve is at NEUTRAL
10-66 PC228US-3
12
Function
The main hydraulic oil is shut off from the
• This valve prevents the oil in the boom cylin- holding pressure on the boom cylinder bot-
der bottom from leaking through spool (1) tom side.
and the boom from lowering under its weight • At this time, the holding pressure on the
while the boom lever is not operated. boom cylinder bottom side is applied toward
the right to area "A" of the ring formed by the
Operation
difference between outside diameter d1 of
1. When boom lever is in "RAISE" position puppet (5) and seat diameter d2 (= Area of
∅d1 - Area of ∅d2). The total of this pressure
If the boom lever is set in the "RAISE" posi-
tion, the pressure of the main hydraulic oil is and the force of spring (4) closes puppet (5) to
applied toward the left to area "A" of the ring shut off the main hydraulic oil from the hold-
formed by the difference between outside ing pressure on the boom cylinder bottom.
diameter d1 of puppet (5) and seat diameter Accordingly, the boom is held.
d2 (= Area of ∅d1 - Area of ∅d2). At this time, 3. When boom lever is in "LOWER" position
if this pressure is higher than the force of If the boom lever is set in the "LOWER" posi-
spring (4), puppet (5) moves to the left. By this tion, pilot spool (2) is pushed by the pilot
operation, the main hydraulic oil from the pressure from the PPC valve and the hydrau-
control valve flows through the open part of lic oil in chamber "b" in the puppet is drained
puppet (5) to the boom cylinder bottom. through orifice "c".
2. When boom lever is in neutral The oil on the boom bottom side flows from
• If the control lever is returned to the neutral orifice "a" through chamber "b" and orifice "c"
position while the boom is raised, the oil in to the drain hole, and the oil pressure in
puppet (5) which has flowed through orifice chamber "b" lowers.
"a" is sealed by pilot piston (2). If the pressure in chamber "b" lowers below
the pressure at port A, puppet (4) opens and
the hydraulic oil from port B flows through
port A to the control valve.
PC228US-3 10-67
12
4. When abnormally high pressure is gen- • If the hydraulic drift prevention valve for the
erated arm cylinder head circuit is installed
• If abnormally high pressure is generated in (optional), the hydraulic oil in the boom cylin-
the boom cylinder bottom circuit, the hydrau- der bottom circuit or that in the arm cylinder
lic oil in port B pushes check valve (6) open, head circuit, having higher pressure, pushes
then safety valve (3) operates. check valve (6 or 6A) open, then safety valve
(3) operates.
10-68 PC228US-3
STRUCTURE AND FUNCTION TRAVEL PPC SHUTTLE VALVE
TRAVEL PPC SHUTTLE VALVE

Function the stroke of the bucket is regulated, the
• If the boom lever is set to the "RAISE" posi- travel PPC pressure is applied through the
tion or the arm lever is set in the "IN" or outside circuit.
"OUT" position or the bucket lever is set in the Operation
"CURL" or "DUMP" position while the 1 When travel lever is in neutral
machine is travelling up a sharp slope, the • The oil in stroke regulation signal chamber
travel PPC shuttle valve regulates the spool "a" is drained through orifices (5) and (6) of
strokes of the boom, arm, and bucket control pistons (3) and (4) in the travel spring case
valves with the travel PPC pressure to limit and the travel PPC valve.If the boom lever is
the flow of the oil into the boom, arm, and set to the "RAISE" position (or the arm lever is
bucket cylinders. set in the "IN" or "OUT" position or the bucket
• When the strokes of the boom and arm are lever is set in the "CURL" or "DUMP" posi-
regulated, the travel PPC pressure is applied tion), spool (1) moves to the left until it
through the circuit in the control valve. When reaches the end of spring case (2) (st0).
PC228US-3 10-69
STRUCTURE AND FUNCTION TRAVEL PPC SHUTTLE VALVE
12
2. When travel lever is operated
• If the right travel lever is set in the reverse (or • At this time, the right travel reverse (or for-
forward) direction, the right travel reverse (or ward) PPC pressure is applied through orifice
forward) PPC pressure pushes spool (7) to the (6) of piston (4) to the left end of piston (8) to
left (or right). push piston (8) to the right.
• Spool (7) pushes piston (3) to close orifice (5) • If the boom lever is set to the "RAISE" posi-
and shut off stroke regulation signal chamber tion (or the arm lever is set to the "IN" or
"a" from the drain circuit of the travel PPC "OUT" position), spool (1) moves to the left.
valve. At this time, the maximum stroke of the spool
is reduced by the distance by which piston (8)
moved (st2) and becomes st1.
10-70 PC228US-3
STRUCTURE AND FUNCTION LIFT CHECK VALVE
12
LIFT CHECK VALVE
Function
This valve applies back pressure to the drain

circuit to prevent generation of negative pres-
sure on the hydraulic devices for the work
equipment (motors, cylinders, etc.)
Operation
1. While engine is stopped

Any oil is not supplied from the pump to
the self-pressure reducing valve and valve
(1) is pressed by only the force of spring (2)
toward the right and drain circuit "a" of the
control valve is connected through orifice
"b" of valve (1) to port T.
2. While engine is running

• Output pressure PR of the self-pressure
reducing valve is applied through the con-
trol valve to spring chamber "c" of the back
pressure valve.
• Output pressure PR applied to spring
chamber "c" is applied to the left end of
valve (1) (area of ∅d) to push valve (1) to
the right.
• At this time, pressure PA of drain circuit "a"
of the control valve is applied to the right
end of valve (1) (area of ∅d1) to push valve
(1) to the left.
• Valve (1) is balanced so that the back pres-
sure PA will be as follows.
PA = {(Area of ∅d) x PR + Force of spring
(2)} / (Area of ∅d1)
PC228US-3 10-71
STRUCTURE AND FUNCTION HOLDING VALVE
HOLDING VALVE
Downward movement prevention valve
(For boom and arm)
V : From control valve

T : To hydraulic tank
CY : To hydraulic cylinder
PI : From PPC valve
PCY : For pressure pickup and equalizer circuits
10-72 PC228US-3
12
1. Pilot spool
2. Spring (1st stage of spool)
3. Spring (2nd stage of spool)
4. Safety valve
5. Check valve
6. Spring
Unit: mm

A Check valve spring Outside diameter length load length load
4.9 N 3.9 N
25.4 x 11.6 18 —
{0.5 kg} {0.4 kg} If damaged or
29.4 N 23.5 N deformed,
B Spool return spring 31.8 x 8.5 25 — replace spring
{3.0 kg} {2.4 kg}
51 N 41.2 N
C Spool return spring 30.4 x 20.6 29 —
{5.2 kg} {4.2 kg}
75.5 N 60.8 N
D Spool return spring 32 x 20.4 29 —
{7.7 kg} {6.2 kg}
PC228US-3 10-73
12
Function
If the piping between the main valve and a

work equipment cylinder bursts, this valve pre-
vents the oil from flowing back from the work
equipment cylinder to prevent sudden fall of
the work equipment.
Operation
1 When the work equipment is in neu-

tral
[When piping is normal]
• Check valve (5) is closed by the work
equipment cylinder holding pressure
applied through port CY to chamber
"b".
• When the work equipment is in neutral,
no pilot pressure is applied from the
PPC valve to port Pi. Accordingly, pilot
spool (1) is moved to the left end by the
force of springs (2) and (3), then cham-
bers "a" and "b" are shut off from each
other.
• By this operation, oil does not flow
between the main valve and the work
equipment cylinder, thus the work
equipment cylinder is held.
• If the pressure in the work equipment
cylinder rises high abnormally, work
equipment cylinder holding pressure
Pb operates safety valve (4).
• In the downward movement preven-
tion valves for the boom, chambers "b"
of both of them are connected through
ports PCY. Accordingly, even if the
leakages are different between both
downward movement prevention
valves, the pressures in both chambers
"b" become the same.
[When piping bursts]
Even if piping A between the main
valve and work equipment cylinder
bursts, chamber "a" is shut off from
chamber "b" as in the case where the
piping is normal. Accordingly, the
work equipment cylinder is held.
10-74 PC228US-3
12
2. When oil is sent from main valve to

cylinder
• If pressure Pa of the oil sent from the
main valve to chamber "a" is higher
than the total of pressure Pb in cham-
ber "b" connected to the work equip-
ment cylinder and the force of spring
(6), check valve (5) opens and chambers
"a" and "b" are connected to each other
and the oil flows from the main valve
to the work equipment cylinder.
• If piping A between the main valve and
the work equipment cylinder bursts,
the oil in chamber "a" flows out
through the burst part and pressure Pa
in chamber "a" lowers.
• If Pa lowers below the total of pressure
Pb in chamber "b" and the force of
spring (6), check valve (5) closes and
chambers "a" and "b" are shut off from
each other. Accordingly, pressure Pb in
the cylinder is held and the work equip-
ment does not fall suddenly.
PC228US-3 10-75
12
3. When oil is returned from work equip-

ment cylinder to main valve
• The work equipment cylinder holding
pressure is applied to chamber "b" and
check valve (5) closes.
• The pilot pressure from the PPC valve is
applied to port Pi. If it is higher than the
force of spring (2) (area of ∅d), spool (1)
moves to the right standby position (1st-
stage stroke).
• At this time, chambers "a" and "b" are not
connected to each other.
• If the pilot pressure rises higher than the
force of spring (3) (area of ∅d), spool (1)
moves further to the right and chambers
"a" and "b" are connected to each other
(2nd-stage stroke).
• Accordingly, the oil is returned from the
work equipment cylinder to the main
valve.
• If piping A between the main valve and
work equipment cylinder bursts, the oil in
chamber "a" flows out through the burst
part. Since the oil supplied from chamber
"b" to chamber "a" flows through opening
"c" of spool (1), however, the cylinder
does not fall suddenly.
10-76 PC228US-3
STRUCTURE AND FUNCTION SWING MOTOR
12
SWING MOTOR
KMF125ABE-5
B : From swing lock solenoid valve Specifications

S : From control valve
T : To tank Model : KMF125ABE-5
MA : From control valve Theoretical displacement : 125.0 cm³/rev
MB : From control valve Safety valve set pressure : 27.9 MPa {285 kg/cm²}
Rated revolving speed : 1,503 rpm
Brake release pressure : 1.9 MPa {19 kg/cm²}
10-78 PC228US-3
12
1. Brake spring 8. Housing 15. Safety valve

2. Drive shaft 9. Piston 16. Check valve
3. Spacer 10. Cylinder 17. Check valve spring
4. Case 11. Valve plate 18. Shuttle valve
5. Disc 12. Reverse prevention valve 19. Shuttle valve spring
6. Plate 13. Center shaft
7. Brake piston 14. Center spring
PC228US-3 10-79
12
Unit: mm

A Check valve spring Outside diameter length load length load If damaged or
62.5 x 20.0 35 — replace spring
{0.36 kg} {0.29 kg}
13.7 N 10.8 N
B Shuttle valve spring 16.4 x 8.9 11.5 —
{1.4 kg} {1.1 kg}
10-80 PC228US-3
12
Operation of swing lock

1. When swing lock solenoid valve is deacti-
vated
When the swing lock solenoid valve is deacti-
vated, the pressurized oil from the main pump is
shut off and port B is connected to the tank cir-
cuit.
As a result, brake piston (7) is pushed down by
brake spring (1), discs (5) and plates (6) are
pushed together, and the brake is applied.
2. When swing lock solenoid valve is excited

When the swing lock solenoid valve is excited,
the valve is switched and the pressure oil from
the main pump enters port B and flows to brake
chamber a.
The pressure oil entering chamber a overcomes
brake spring (1) and pushes brake piston (7) up.
As a result, discs (5) and plates (6) are separated
and the brake is released.
PC228US-3 10-81
12
RELIEF VALVE PORTION
1) Outline
The relief portion consists of check valves
(2) and (3), shuttle valves (4) and (5), and
relief valve (1).
2. Function
When the swing is stopped, the outlet port
circuit of the motor from the control valve
is closed, but the motor continues to rotate
under inertia, so the pressure at the output
side of the motor becomes abnormally
high, and this may damage the motor.
To prevent this, the abnormally high pres-
sure oil is relieved to port S from the outlet
port of the motor (high-pressure side) to
prevent any damage.
3. Operation
1) When starting swing
• When the swing control lever is operated
to swing right, the pressure oil from the
pump passes through the control valve and
is supplied to port MA. As a result, the
pressure at port MA rises, the starting
torque is generated in the motor, and the
motor starts to rotate. The oil from the out-
let port of the motor passes from port MA
through the control valve and returns to
the tank. (Fig. 1)
2) When stopping swing
• When the swing control lever is returned to
neutral, the supply of pressure oil from the
pump to port MA is stopped. With the oil
from the outlet port of the motor, the return
circuit to the tank is closed by the control
valve , so the pressure at port MB rises. As
a result, rotation resistance is generated in
the motor, so the braking effect starts.
• If the pressure at port MB becomes higher
than the pressure at port MA, it pushes
shuttle valve A (4) and chamber C
becomes the same pressure as port MB.
The oil pressure rises further until it
reaches the set pressure of relief valve (1).
As a result, a high braking torque acts on
the motor and stops the motor. (Fig.2)
• When relief valve (1) is being actuated, the
relief oil and oil from port S passes
through check valve B (3) and is supplied to
port MA. This prevents cavitation at port
MA.
10-82 PC228US-3
STRUCTURE AND FUNCTION REVERSE PREVENTION VALVE
12
REVERSE PREVENTION VALVE
Operation diagram
1. Valve body
2. Spool (MA side)
3. Spring (MA side)
4. Plug
5. Spool (MB side)
6. Spring (MB side)
7. Plug
Explanation of effect
PC228US-3 10-83
STRUCTURE AND FUNCTION REVERSE PREVENTION VALVE
12
Outline
This valve reduces the swing back genera-
tion in the swing body by the inertia of the
swing body, the backlash and rigidity of the
machinery system, and the compression of
the hydraulic oil when the swing is
stopped. This is effective in preventing
spillage of the load and reducing the cycle
time when stopping the swing (the posi-
tioning ability is good and it is possible to
move swiftly to the next job.
Operation
1) When brake pressure is being gener-
ated at port MB
• Pressure MB passes through the notch and
goes to chamber d, spool (5) pushes spring
(6) according to the difference in area D1 >
D2, moves to the left, and MB is connected
to e.
When this happens, pressure MA is below
the set pressure of spring (3), so spool (2)
does not move. For this reason, the pres-
sure oil is closed by spool (2), and the brak-
ing force is ensured.
2) After motor stops

• The motor is reversed by the closing pres-
sure generated at port MB. (1st reversal)
When this happens, reversal pressure is
generated at port MA. Pressure MA goes
to chamber a, so spool (2) pushes spring (3)
and moves to the right, and MA is con-
nected to B. At the same time, b is con-
nected to f through the drill hole in spool
(5), so the reversal pressure at port MA is
bypassed to port T to prevent the 2nd
reversal.
10-84 PC228US-3
STRUCTURE AND FUNCTION CENTER SWIVEL JOINT
12
CENTER SWIVEL JOINT
1. Cover A1. From port B2 of control valve D1. From port B5 of control valve
2. Body A2. To port PA of left travel motor D2. To port PB of right travel motor
3. Slipper seal B1. From port A2 of control valve E. To port P of both travel motors
4. O-ring B2. To port PB of left travel motor T1. To tank
5. Shaft C1. From port A5 of control valve T2. From port T of both travel motors
C2. To port PA of right travel motor
Unit: mm
No. Check Item Criteria Remedy
Clearance between Standard Dimension Standard clearance Repair limit

6 Replace
rotor and shaft 80 — —
PC228US-3 10-85
STRUCTURE AND FUNCTION TRAVEL MOTOR
TRAVEL MOTOR
HMV110-2
P : From travel speed solenoid valve SPECIFICATIONS

T : To tank
Model
PA : From control valve PC228US-3
Item
PB : From control valve
Type HMV110-2
Theoretical Min. 74 cm³/rev

Delivery Max. 110.7 cm³/rev
Set pressure 32.7 MPa {333 kg/cm²}
Min.
2,980 rpm
Capacity
Rated speed
Max.
1,485 rpm
capacity
Brake releasing pressure 1.2 MPa {12 kg/cm²}
Travel speed
Differential
switching pres- 0.8 MPa {8 kg/cm²}
pressure
sure
10-86 PC228US-3
12
1. Regulator piston 9. Check valve spring 17. Valve plate

2. Spring 10. Output shaft 18. Counterbalance valve
3. Regulator valve 11. Rocker cam 19. Ring
4. Spring 12. Retainer guide 20. Spool return spring
5. Motor case 13. Pin 21. Brake piston
6. Suction safety valve spring 14. Piston 22. Plate
7. Suction safety valve 15. Retainer 23. Disc
8. Check valve 16. Cylinder 24. Ball
PC228US-3 10-87
12
Unit: mm
Standard dimensions Repair limits

A Check valve spring Outside diameter length load length load
2.55 N 1.96 N
31.6 x 6.5 24.2 —
{0.26 kg} {0.2 kg} If damaged or
B Check valve spring 13.0 x 6.5 9.5 — replace spring
{0.2 kg} {0.16 kg}
411 N 329 N
C Return spring 58.43 x 30 42.6 —
{41.9 kg} {33.5 kg}
55 N 44 N
D Regulator valve spring 21.5 x 11.1 17.1 —
{5.6 kg} {4.5 kg}
10-88 PC228US-3
OPERATION OF MOTOR
1) Motor swash plate angle at maximum
• At the same time, the pressurized oil at regu-

• The solenoid valve is deactivated, so the pilot lator piston (15) passes through orifice c in
pressure oil from the main pump does not regulator valve (9) and is drained to the motor
flow to port P. case.
For this reason, regulator valve (9) is pushed • As a result, swash plate (4) moves in the max-
to the right in the direction of the arrow by imum swash plate angle direction, the motor
spring (10). capacity becomes maximum.
• Because of this, it pushes check valve (22),
and the main pressure oil from the control
valve going to end cover (8) is shut off by reg-
ulator valve (9).
• Fulcrum a of swash plate (4) is eccentric to
point of force b of the combined force of the
propulsion force of cylinder (6), so the com-
bined force of the piston propulsion force acts
as a moment to angle swash plate (4) in the
direction of the maximum swash plate angle.
PC228US-3 10-89
12
2) Motor swash plate angle at minimum
• When the solenoid valve is excited, the pilot

pressure oil from the main pump flows to
port P, and pushes regulator valve (9) to the
left direction of the arrow.
• Because of this, the main pressure oil from
the control valve passes through passage d in
regulator valve (9), enters regulator piston
(15) at the bottom, and pushes regulator pis-
ton (15) to the right in the direction of the
arrow.
• As a result, swash plate (4) moves in the mini-
mum swash plate angle direction, the motor
capacity becomes minimum.
10-90 PC228US-3
12
OPERATION OF PARKING BRAKE

1) When starting to travel
When the travel lever is operated, the pres-
surized oil from the pump actuates coun-
terbalance valve spool (19), opens the
circuit to the parking brake, and flows into
chamber A of the brake piston (12).
It overcomes the force of spring (11), and
pushes piston (12) to the left in the direc-
tion of the arrow.
When this happens, the force pushing plate
(13) and disc (14) together is lost, so plate
(13) and disc (14) separate and the brake is
released.
2. When stopping travel

When the travel lever is placed in neutral,
counterbalance valve spool (19) returns to
the neutral position and the circuit to the
parking brake is closed.
The pressurized oil in chamber A of brake
piston (12) is drained to the case from the
orifice in the brake piston, and brake piston
(12) is pushed to the right in the direction
of the arrow by spring (11).
As a result, plate (13) and disc (14) are
pushed together, and the brake is applied.
A time delay is provided by having the
pressurized oil pass through a throttle in
slow return valve (22) when the brake pis-
ton returns, and this ensures that the brake
is still effective after the machine stops.
PC228US-3 10-91
12
OPERATION OF BRAKE VALVE

• The brake valve consists of a suction safety
valve (18A), counterbalance valve (18) in a
circuit as shown in the diagram on the
right. (Fig. 1)
• The function and operation of each compo-
nent is as given below.
1) Counterbalance valve, check valve

Function
• When traveling downhill, the weight of the
machine makes it try to travel faster than
the speed of the motor.
As a result, if the machine travels with the
engine at low speed, the motor will rotate
without load and the machine will run
away, which is extremely dangerous.
To prevent this these valves act to make the
machine travel according to the engine
speed (pump discharge amount).
Operation when pressure oil is supplied

• When the travel lever is operated, the pres-
surized oil from the control valve is sup-
plied to port PA. It pushes open suction
safety valve (18A) and flows from motor
inlet port MA to motor outlet port MB.
However, the motor outlet port is closed by
suction safety valve (18B) and spool (19),
so the pressure at the supply side rises.
(Fig. 2)
• The pressurized oil at the supply side flows

from orifice E1 and E2 in spool (19) to
chamber S1. When the pressure in cham-
ber S1 goes above the spool switching
pressure, spool (19) is pushed to the right
in the direction of the arrow.
As a result, port MB and port PB are con-
nected, the outlet port side of the motor is
opened, and the motor starts to rotate. (Fig.
3)
10-92 PC228US-3
Operation of brake when traveling downhill

• If the machine tries to run away when travel-
ing downhill, the motor will turn under no
load, so the pressure at the motor inlet port
will drop, and the pressure in chamber S1
through orifices E1 and E2 will also drop.
When the pressure in chamber S1 drops
below the spool switching pressure, spool
(19) is returned to the left, in the direction of
the arrow by spring (20), and outlet port MB
is throttled.
As a result, the pressure at the outlet port
side rises, resistance is generated to the rota-
tion of the motor, and this prevents the
machine from running away.
In other words, the spool moves to a position
where the pressure at the outlet port MB bal-
ances the pressure at the inlet port and the
force generated by the weight of the
machine. It throttles the outlet port circuit
and controls the travel speed according to
the amount of oil discharged from the pump.
(Fig. 4)
2) Safety valve
Function
• When travel is stopped (or when traveling
downhill), the circuits at the inlet and outlet
ports of the motor are closed by the counter-
balance valve, but the motor is rotated by
inertia, so the pressure at the outlet port of
the motor will become abnormally high and
damage the motor or piping. The safety
valve acts to release this abnormal pressure
and send it to the inlet port side of the motor
to prevent damage to the equipment.
Operation
1. When travel is stopped (or when travel-
ing downhill, rotating to right)
• When the motor inlet port pressure (pressure
PA) goes down, the pressure in chamber S1
also goes down. When it goes below the
switching pressure of the spool, spool is
returned to the left by spring (20), and outlet
port passage B1 is throttled. When this hap-
pens, the motor continues to rotate under
inertia, so the outlet pressure (pressure MB)
rises. (Fig. 5)
• If the pressure goes above the set pressure
of suction-safety valve (18A), the poppet
opens. The oil then passes through large
notch A1 in counterbalance valve spool (19)
and flows to chamber MA in the circuit on
the opposite side. (Fig. 6)
2. When rotating to left
The operation is the reverse of when rotating
to the right.
PC228US-3 10-93
3) When starting travel (or during normal

travel)
• When the travel lever is operated, the pres-
sure oil from the pump moves counterbal-
ance valve spool (19) to the right. When
this happens, the passage to the suction-
safety valve becomes the circuit flowing
through the small notch in the counterbal-
ance valve spool. As a result, a big differ-
ence in pressure is created, and the pump
pressure rises to provide a powerful draw-
bar pull. (Fig. 7)
10-94 PC228US-3
STRUCTURE AND FUNCTION VALVE CONTROL
12
VALVE CONTROL
Lever positions
(1) Hold (9) Swing "RIGHT" 1. Travel PPC valve 8. Solenoid block
(2) Boom "RAISE" (10) Swing "LEFT" 2. Service PPC valve 9. Control valve
(3) Boom "LOWER" (11) Neutral 3. Service pedal 10. Accumulator
(4) Bucket "DUMP" (12) Travel "REVERSE" 4. Left travel lever 11. Hydraulic pump
(5) Bucket "CURL" (13) Travel "FORWARD" 5. Right travel lever 12. Left work equipment
(6) Hold (14) Lock 6. Right PPC valve control lever
(7) Arm "IN" (15) Free 7. Right work equipment 13. Left PPC valve
(8) Arm "OUT" control lever 14. Safety lock lever
PC228US-3 10-95
STRUCTURE AND FUNCTION WORK EQUIPMENT • SWING PPC VALVE
12
WORK EQUIPMENT • SWING PPC VALVE
A C
C A
E E
D D
a B b
c d
f e
SBP00273
a. Port P (From main pump) d. Port P4 (Left: Swing LEFT/Right: Bucket DUMP)
b. Port T (To tank) e. Port P1 (Left: Arm OUT/Right: Boom LOWER)
c. Port P2 (Left: Arm IN/Right: Boom RAISE) f. Port P3 (Left: Swing RIGHT/Right: Bucket CURL)
10-96 PC228US-3
12
1 Spool 7. Joint
2. Metering spring 8. Plate
3. Centering spring 9. Retainer
4. Piston 10. Body
5. Disc 11. Filter
6. Nut (For connection of lever)
Unit: mm
Basic dimensions Allowable dimension

Centering spring
A Outside diameter length load length load
(For P3 and P4)
17.6 N 13.7 N If damaged or
42.5 x 15.5 34 —
{1.8 kg} {1.4 kg} deformed,
replace spring
Centering spring 29.4 N 23.5 N
B 44.5 x 15.5 34 —
(For P3 and P4) {3.0 kg} {2.4 kg}
16.7 N 13.7 N
C Metering spring 26.5 x 8.2 24.9 —
{1.7 kg} {1.4 kg}
PC228US-3 10-97
OPERATION
1) At neutral
Ports A and B of the control valve and
ports P1 and P2 of the PPC valve are con-
nected to drain chamber D through fine
control hole f in spool (1). (Fig. 1)
2) During fine control (neutral → fine

control)
When piston (4) starts to be pushed by disc
(5), retainer (9) is pushed; spool (1) is also
pushed by metering spring (2), and moves
down.
When this happens, fine control hole f is
shut off from drain chamber D, and at
almost the same time, it is connected to
pump pressure chamber PP, so pilot pres-
sure oil from the main pump passes
through fine control hole f and goes from
port P1 to port A.
When the pressure at port P1 becomes
higher, spool (1) is pushed back and fine
control hole f is shut off from pump pres-
sure chamber PP. At almost the same time,
it is connected to drain chamber D to
release the pressure at port P1. When this
happens, spool (1) moves up or down so
that the force of metering spring (2) is bal-
anced with the pressure at port P1. The
relationship in the position of spool (1) and
body (10) (fine control hole f is at a point
midway between drain hole D and pump
pressure chamber PP) does not change
until retainer (9) contacts spool (1).
Therefore, metering spring (2) is com-
pressed proportionally to the amount of
movement of the control lever, so the pres-
sure at port P1 also rises in proportion to
the travel of the control lever. In this way,
the control valve spool moves to a position
where the pressure in chamber A (the
same as the pressure at port P1) and the
force of the control valve spool return
spring are balanced. (Fig. 2)
10-98 PC228US-3
12
3) During fine control (when control

lever is returned)
• When disc (5) starts to be returned, spool
(1) is pushed up by the force of centering
spring (3) and the pressure at port P1.
connected to drain chamber D and the
pressure oil at port P1 is released.
If the pressure at port P1 drops too far,
spool (1) is pushed down by metering
spring (2), and fine control hole f is shut off
from drain chamber D. At almost the same
time, it is connected to pump pressure
chamber PP, and the pump pressure is sup-
plied until the pressure at port P1 recovers
to a pressure that corresponds to the lever
position.
When the spool of the control valve
returns, oil in drain chamber D flows in
from fine control hole f in the valve on the
side that is not working. The oil passes
through port P2 and enters chamber B to
fill the chamber with oil. (Fig. 3)
4) At full stroke
When disc (5) pushes down piston (4), and
retainer (9) pushes down spool (1), fine
control hole f is shut off from drain cham-
ber D, and is connected with pump pres-
sure chamber PP. Therefore, the pilot
pressure oil from the main pump passes
through fine control hole f and flows to
chamber A from port P1, and pushes the
control valve spool.
The oil returning from chamber B passes
from port P2 through fine control hole f
and flows to drain chamber D. (Fig. 4)
PC228US-3 10-99
STRUCTURE AND FUNCTION TRAVEL PPC VALVE
12
TRAVEL PPC VALVE
P : From main pump P3 : Right reverse

T : To tank P4 : Right forward
P1 : Left reverse P5 : Travel signal
P2 : Left forward P6 : Steering signal
10-100 PC228US-3
12
1. Plate 6. Centering spring

2. Body 7. Valve
3. Piston 8. Damper
4. Collar 9. Steering signal
5. Metering spring 10. Steering signal valve spring
PC228US-3 10-101
12
Unit: mm
Basic dimensions Allowable dimension

A Metering spring Outside diameter length load length load
16.7 N 13.7 N If damaged or
26.5 x 8.15 24.7 —
{1.7 kg} {1.4 kg} deformed,
replace spring
108 N 86.3 N
B Centering spring 48.1 x 15.5 32.5 —
{11 kg} {8.8 kg}
8.8 N 7.1 N
C Steering signal spring 12.8 x 7.3 8.5 —
{0.9 kg} {0.72 kg}
10-102 PC228US-3
12
OPERATION
1) At neutral
Ports A and B of the control valve and
ports P1 and P2 of the PPC valve are con-
nected to drain chamber D through fine
control hole f in spool (1). (Fig. 1)
2) Fine control (neutral → fine control)

When piston (4) starts to be pushed by disc
(5), retainer (9) is pushed. Spool (1) is also
pushed by metering spring (2), and moves
down.
shut off from drain chamber D. At almost
the same time, it is connected to pump
pressure chamber PP, and the pilot pres-
sure of the main pump is sent from port A
through fine control hole f to port P1.
When the pressure at port P1 rises, spool
(1) is pushed back. Fine control hole f is
shut off from pump pressure chamber PP.
At almost the same time, it is connected to
drain chamber D, so the pressure at port
P1 escapes.
As a result, spool (1) moves up and down
until the force of metering spool (2) is bal-
anced with the pressure at port P1.
The relationship of the position of spool (1)
and body (10) (fine control hole f is in the
middle between drain hole D and pump
pressure chamber PP) does not change
until retainer (9) contacts spool (1).
Therefore, metering spring (2) is com-
pressed in proportion to the travel of the
control lever, so the pressure at port P1
also rises in proportion to the travel of the
control lever. In this way, the spool of the
control valve spool moves to a position
where the pressure of chamber A (same as
pressure at port P1) and the force of the
return spring of the control valve spool are
balanced. (Fig. 2)
PC228US-3 10-103
12
3) Fine control (control lever returned)

When lever (5) starts to be returned, spool
(1) is pushed up by the force of centering
spring (3) and the pressure at port P1.
Because of this, fine control hole f is con-
nected to drain chamber D, and the pressur-
ized oil at port P1 is released.
If the pressure at port P1 drops too much,
spool (1) is pushed up by metering spring
(2), so fine control hole f is shut off from
drain chamber D. At almost the same time,
it is connected to pump pressure chamber
PP, so the pressure at port P1 supplies the
pump pressure until the pressure recovers
to a pressure equivalent to the position of
the lever.
When the control valve returns, oil in drain
chamber D flows in from fine control hole f
of the valve on the side that is not moving.
It passes through port P2 and goes to cham-
ber B to charge the oil. (Fig. 3)
4) At full stroke
Lever (5) pushes down piston (4), and
retainer (9) pushes down on spool (1). Fine
control hole f is shut off from drain chamber
D, and is connected to pump pressure
chamber PP. Therefore, the pilot pressure
oil from the main pump passes through fine
control hole f and flows to chamber A from
port P1 to push the control valve spool. The
return oil from chamber B passes from port
P2 through fine control hole f and flows to
drain chamber D. (Fig. 4)
10-104 PC228US-3
2. Travel signal/Steering function

• Travel signal
If either of the travel levers is operated, the maximum PPC output pressure on both sides is output as
the travel signal. Accordingly, if the machine is traveling is judged by the signal of port P5.
• Steering signal
If the operation quantities of both levers are different from each other as in the steering operation, the
higher one of the PPC output pressures on both sides is output as the steering signal.
Any signal is not output from port P6 while the machine is travelling straight (forward or reverse) or in
neutral.
Accordingly, if the machine is being steered is judged by the signal of port P6.
Operation
1) While in NEUTRAL
The signals of the output ports (P1 - P4), travel signal (Port P5), and steering signal (Port P6) are not out-
put.
PC228US-3 10-105
2) While travelling straight

(The following drawing shows the circuit for traveling straight forward.)
While the left motor is operating for forward travel (the signal of port P2 is output) and the right motor
is also operating for forward travel (the signal of port P4 is output), the pressures in left spring chamber
(k) and right spring chamber (l) of steering signal valve (j) are set high. Accordingly, the steering signal
valve is kept in neutral and the steering signal (Port P6) is not output.
10-106 PC228US-3
12
3) When steered or pivot-turned
(The following drawing shows the circuit for left forward (slow) and right forward (fast) operation.)
If the operation quantities of both levers are different from each other as in the steering operation (If the
difference of the pilot pressure between both sides is higher than a certain level), the pilot pressure is
output as the steering signal.
In the case of the following drawing, the pressure in left spring chamber (k) of steering signal valve (j) is
P2. The pressure in right spring chamber (l) is P4.
If (P4 - P2) x (Sectional area of spool) > Set spring load, the spool is changed to the direction of the
arrow and the higher one of both PPC output pressures (the pressure of port P4 in this drawing) is out-
put as the steering signal to port P6.
PC228US-3 10-107
12
4) When pivot-turned
(The following drawing shows the circuit for left reverse and right forward operation.)
While the left motor is operating for reverse travel (the signal of port P1 is output) and the right motor is
operating for forward travel (the signal of port P4 is output), only the pressure in right spring chamber
(l) of steering signal valve (j) is set high. Accordingly, the steering signal valve moves to the left and
outputs the steering signal (port P6).
10-108 PC228US-3
STRUCTURE AND FUNCTION SERVICE PPC VALVE
12
SERVICE PPC VALVE
1. Spool
2. Metering spring
3. Centering spring
4. Piston
5. Lever
6. Plate
7. Retainer
8. Body
T : To tank
P : From main pump
P1 : Port
P2 : Port
Unit: mm

A Centering spring Outside diameter length load length load If damaged or
124.5 N 100 N deformed,
33.9 x 15.3 28.4 — replace spring
{12.7 kg} {10.2 kg}
16.7 N 13.7 N
B Metering spring 22.7 x 8.1 22 —
{1.7 kg} {1.4 kg}
10-110 PC228US-3
12
OPERATION
At neutral
• The pressurized oil from the main pump
enters from port P and is blocked by spool
(1).
• Ports A and B of the control valve and
ports a and b of the PPC valve are con-
nected to drain port T through fine control
hole X of spool (1).
When operated
• When lever (5) is moved, metering spring

(2) is pushed by piston (4) and retainer (7),
and spool (1) is pushed down by this.
• As a result, fine control portion Y is con-
nected with port a, and the pressurized oil
from port P flows from port a to port A of
the control valve.
PC228US-3 10-111
12
• When the pressure at port a becomes

higher, spool (1) is pushed back by the
force acting on the end of the spool, and
fine control portion Y closes.
• As a result, spool (1) moves up and down
to balance the force at port a and the force
at metering spring (2).
• Therefore, metering spring (2) is com-
pressed in proportion to the amount the
control lever is moved. The spring force
becomes larger, so the pressure at port a
also increases in proportion to the amount
the control lever is operated.
In this way, the control valve spool moves
to a position where the pressure of port A
(the same as the pressure at port a) is bal-
anced with the force of the return spring of
the control valve spool.
10-112 PC228US-3
STRUCTURE AND FUNCTION PPC ACCUMULATOR
12
PPC ACCUMULATOR
1
1. Gas plug
2. Shell
3. Poppet
2 4. Holder
5. Bladder
6. Oil port
3
SPECIFICATIONS
Gas capacity: 300 cc (for PPC)
500 cc (for port S)
4
SBP00290
PC228US-3 10-113
STRUCTURE AND FUNCTION SOLENOID VALVE
12
SOLENOID VALVE
PPC lock, 2-stage relief, travel speed, swing brake, pump merge-divider, travel junction solenoid valves
1. PPC lock solenoid valve T : To tank A5 : To main valve (Travel junc-

2. 2-stage relief solenoid valve A1 : To PPC valve tion valve)
3. Travel speed solenoid valve A2 : To main valve (2-stage relief A6 . To main valve (Pump
4. Swing brake solenoid valve valve) merge-divider valve)
5. Travel junction solenoid A3 : To both travel motors P1 : From main pump
valve A4 : To swing motor ACC : To accumulator
6. Pump merge-divider sole-
noid valve
10-114 PC228US-3
STRUCTURE AND FUNCTION SOLENOID VALVE
12
1. Connector
2. Moving core
3. Coil
4. Spool
5. Block
6. Spring
Operation
When solenoid is turned off
• Since the signal current does not flow from

the controller, solenoid (3) is turned off.
Accordingly, spool (4) is pressed by spring
(6) against the left side.
By this operation, the pass from P to A is
closed and the hydraulic oil from the main
pump does not flow into the actuator.
At this time, the oil from the actuator is
drained through ports A and T into the
tank.
When solenoid is turned on
The signal current flows from the controller

to solenoid (3), and the latter is turned on.
Accordingly, spool (4) is pressed against to
the right side.
By this operation, the hydraulic oil from the
main pump flows through port P and spool
(4) to port A, then flows into the actuator.
At this time, port T is closed and the oil
does not flow into the tank.
PC228US-3 10-115
STRUCTURE AND FUNCTION HYDRAULIC CYLINDER
12
HYDRAULIC CYLINDER
BOOM CYLINDER
ARM CYLINDER
BUCKET CYLINDER
10-116 PC228US-3
STRUCTURE AND FUNCTION HYDRAULIC CYLINDER
12
Unit: mm

Cylinder
size Shaft Hole clearance limit
-0.036 +0.222
Clearance Boom 85 0.083 ~ 0.312 0.412
-0.090 +0.047 Replace
1 between piston
bushing
rod and bushing -0.036 +0.222
Arm 95 0.083 ~ 0.312 0.412
-0.090 +0.047
-0.030 +0.257
Bucket 80 0.078 ~ 0.334 0.447
-0.076 +0.048
-0.030 +0.143
Boom 80 0.104 ~ 0.203
-0.060 +0.074
Clearance
between piston -0.030 +0.143
2 Arm 80 0.104 ~ 0.203
rod support pin -0.076 +0.074
and bushing
-0.030 +0.143
Bucket 70 0.104 ~ 0.236
-0.076 +0.074 Replace pin
-0.030 +0.142 or bushing
Boom 70 0.104 ~ 0.202
-0.060 +0.074
Clearance
between cylinder -0.030 +0.143
3 Arm 80 0.104 ~ 0.203
bottom support -0.060 +0.074
pin and bushing
-0.030 +0.143
Bushing 70 0.104 ~ 0.218
-0.076 +0.074
PC228US-3 10-117
STRUCTURE AND FUNCTION WORK EQUIPMENT
12
WORK EQUIPMENT
10-118 PC228US-3
12
Unit: mm

Clearance between connecting size clearance limit
Shaft Hole
1 pin and bushing of revolving
frame and boom -0.036 +0.140
90 0.110 ~ 0.211 1.0
-0.071 +0.074
Clearance between connecting
-0.036 +0.139
2 pin and bushing of boom and 90 0.110 ~ 0.210 1.0
-0.071 +0.074
arm
Clearance between connecting -0.030 +0.160

3 70 0.104 ~ 0.236 1.0 Replace
pin and bushing of arm and link -0.076 +0.074

-0.030 +0.337
4 pin and bushing of arm and 80 0.303 ~ 0.413 1.0
-0.076 +0.273
bucket

-0.030 +0.169
5 pin and bushing of link and 80 0.114 ~ 0.245 1.0
-0.076 +0.084
bucket
Clearance between connecting -0.030 +0.160

6 80 0.104 ~ 0.236 1.0
pin and bushing of link and link -0.076 +0.074
PC228US-3 10-119
12
1. DIMENSION OF ARM
10-120 PC228US-3
12
Unit: mm
Model
PC228US-3, PC228USLC-3
No.
1 ∅ 80 +0.1
0
2 107.3 +1.5
0
3 310 +0.5
0
4 ∅ 90 -0.036
-0.071
5 361.7 ±1
6 187.2 ±0.5
7 829.1 ±1
8 2,919
9 2,631.3 ±1
10 410 ±1
11 640 ±0.2
12 600 ±0.5
13 458.1
14 1,486
15 80
16 326.5 ±1
17 ∅ 80
Arm as individual part 0
311-0.5
18
When pressfitting bushing 325
Min. 1,680
19
Max. 2,800
PC228US-3 10-121
12
2.DIMENSION OF BUCKET
10-122 PC228US-3
12
Unit: mm
Model
PC228US-3, PC228USLC-3
No.
1 457.6 ±0.5
2 22 ±0.5
3 92° 45’
4 458.1
5 1,477.4
6 159.8
7 —
8 0
9 ∅ 80 +0.2
0
10 326.5 ±1
11 56
12 106
13 470
14 ∅ 22
15 ∅ 140
16 ∅ 190
17 132
18 129
19 107
20 82
21 348.5 +20
22 38
PC228US-3 10-123
STRUCTURE AND FUNCTION ENGINE CONTROL
12
ENGINE CONTROL
10-124 PC228US-3
12
1. Starting switch
2. Fuel control dial
3. Starting motor
4. Linkage
5. Battery
6. Engine throttle and pump controller
7. Battery relay
8. Fuel injection pump
9. Governor motor
Outline
• The engine can be started and stopped with

only starting switch (1).
• The engine throttle and pump controller(6)
reveives the signal of fuel control dial (2) and
transmits the drive signal to governor motor
(9) to control the governor lever angle of fuel
injection pump (8) and control the engine
speed.
PC228US-3 10-125
12
1. OPERATION OF SYSTEM
Starting engine
• When the starting switch is turned to the
START position, the starting signal flows to
the starting motor, and the starting motor
turns to start the engine.
When this happens, the engine throttle and
pump controller checks the signal from the
fuel control dial and sets the engine speed
to the speed set by the fuel control dial.
Engine speed control

• The fuel control dial sends a signal to the
engine throttle and pump controller
according to the position of the dial. The
engine throttle and pump controller calcu-
lates the angle of the governor motor
according to this signal, and sends a signal
to drive the governor motor so that it is at
that angle.
When this happens, the operating angle of
the governor motor is detected by the
potentiometer, and feedback is sent to the
engine throttle and pump controller, so
that it can observe the operation of the
governor motor.
Stopping engine
• When the starting switch is turned to the
STOP position, the engine throttle and
pump controller drives the governor motor
so that the governor lever is set to the NO
INJECTION position.
• When this happens, to maintain the electric
power in the system until the engine stops
completely, the engine throttle and pump
controller itself drives the battery relay.
10-126 PC228US-3
12
2. COMPONENT
Fuel control dial
1. Knob
2. Dial
3. Spring
4. Ball
5. Potentiometer
6. Connector
Function
• The fuel control dial is installed under the
monitor panel, and a potentiometer is
installed under the knob. The potentiome-
ter shaft is turned by turning the knob.
• As the potentiometer shaft is turned, the
resistance of the variable resistor in the
potentiometer changes and a throttle sig-
nal is sent to the engine throttle and pump
controller.
The hatched area in the graph shown at
right is the abnormality detection area.
PC228US-3 10-127
12
Governor motor
10-128 PC228US-3
12
1. Potentiometer
2. Cover
3. Shaft
4. Dust seal
5. Bearing
6. Motor
7. Gear
8. Connector
Function
• The motor is turned according to the drive
signal from the engine throttle and pump
controller to control the governor lever of the
fuel injection pump.
This motor used as the motive power source
is a stepping motor.
• A potentiometer for feedback is installed to
monitor the operation of the motor.
• Revolution of the motor is transmitted
through the gear to the potentiometer.
Operation
While motor is stopped
• Electric power is applied to both phases A

and B of the motor.
While motor is running
• The engine throttle and pump controller sup-

plies a pulse current to phases A and B, and
the motor revolves, synchronizing to the
pulse.
PC228US-3 10-129
12
Engine throttle and pump controller
10-130 PC228US-3
12
Input and output signals
CN-1 CN-3 CN-4

Pin Signal name Input/ Pin Signal name Input/ Pin Signal name Input/
No. output No. output No. output
1 Battery relay drive output Output 1 Boom angle potentiometer Input 1 NC
2 Pump merge-divider solenoid Output 2 NC 2 NC
3 Wing holding brake solenoid Output 3 Pump pressure input Input 3 RS232C TXD
4 NC 4 Throttle potentiometer input Input 4 RS232C RXD
5 NC 5 NC 5 NC
6 GND Input 6 Pressure sensor power source (+24 V) Output 6 NC
7 Power source (+24 V) Input 7 Potentiometer power source (+5 V) Output 7 NC
8 Travel junction solenoid Output 8 Key switch (ACC) Input 8 Flash writing switch
9 Travel Hi/Lo selector solenoid Output 9 Knob switch Input 9 NC
10 2-stage relief solenoid Output 10 Arm crane input Input 10 GND (RS232C)
11 Ribbon heater output Output 11 NC Input 11 NC
12 GND Input 12 NC Input 12 NC
13 Power source (+24 V) Input 13 Pump R pressure input Input CN-5
CN-2 14 Feedback potentiometer input Input Pin Signal name Input/
No. output
Pin Signal name Input/ 15 NC 1 Engine speed sensor GND Input
No. output
1 Solenoid power source (+24 V) Input 16 GND for pressure sensor Input 2 Engine speed sensor Input
2 Governor motor phase A (+) Output 17 GND for potentiometer Input 3 GND Input
3 Governor motor phase A (-) Output 18 Key switch (Terminal C) Input 4 GND Input
4 Governor motor phase B (+) Output 19 Auto grease controller trouble Input 5 Swing pressure switch Input
5 Governor motor phase B (-) Output 20 NC 6 Service pressure switch Input
6 NC 21 NC 7 NC
7 LS-EPC solenoid (+) Output 22 Boom RAISE pressure switch Input 8 NC
8 PC-EPC solenoid (+) Output 23 Arm IN pressure switch Input 9 Travel & steering signal pressure Input
switch
9 Boom RAISE throttle solenoid 2 (+) Output 24 S-NET (+) Input, 10 Engine revolution sensor GND Input
output
10 ATT EPC (+) Output 25 Model selection 1 Input 11 Bucket CURL pressure switch Input
11 PGND Input 26 Model selection 3 Input 12 Bucket DUMP pressure switch Input
12 Solenoid power source (+24 V) Input 27 Model selection 5 Input 13 Travel pressure switch Input
13 NC 28 Emergency swing lock release switch Input 14 NC
14 NC 29 NC 15 Overload sensor Input
15 NC 30 Boom LOWER pressure switch Input 16 NC
16 NC 31 Arm OUT pressure switch Input 17 NC
17 LS-EPC solenoid (-) Output 32 S-NET (+) Input,
output
18 PC-EPC solenoid 1 (-) Output 33 Model selection 2 Input
19 Boom RAISE throttle solenoid 2 (-) Output 34 Model selection 4 Input
20 ATT EPC (-) Output 35 Kerosene mode selection Input
21 PGND Input 36 Swing lock switch Input
PC228US-3 10-131
STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM
12
ELECTRONIC CONTROL SYSTEM
Control function 1
Engine/Pump composite control function
2
Pump/Valve control function
3
One-touch power maximizing function
4
Auto-deceleration function
5
Auto-warm-up/Overheat prevention function
Electronic control system
6
Swing control function
7
Travel control function
8
Boom stroke end electronic cushion function
9
ATT PPC throttle function (Optional)
Self-diagnosis function
★ For the self-diagnosis function, see "TROUBLE SHOOTING".
PC228US-3 10-133
12
10-134 PC228US-3
12
PC228US-3 10-135
12
1. Engine and Pump control function
10-136 PC228US-3
12
Function
• The operator can set the work mode switch

on the monitor panel to mode A, E, or B
and select proper engine torque and pump
absorption torque according to the type of
work.
• The arm crane operation width is con-
trolled with the arm crane pump in any of
the work mode on the monitor panel.
• The engine throttle and pump controller
detects the speed of the engine governor
set with the fuel control dial and the actual
engine speed and controls them so that the
pump will absorb all the torque at each out-
put point of the engine, according to the
pump absorption torque set in each mode.
PC228US-3 10-137
12
1) Control method in each mode

Mode A
• Matching point in mode A:
Model PC228US-3
Mode A 106.6 kW/1,950 rpm {145 PS/1,950 rpm}
• If the pump load increases and the pressure

rises, the engine speed lowers.
At this time, the controller lowers the pump
discharge so that the engine speed will be
near the full output point. If the pressure low-
ers, the controller increases the pump dis-
charge so that the engine speed will be near
the full output point.
By repeating these operations, the controller
constantly uses the engine near the full out-
put point.
10-138 PC228US-3
12
Mode E / Mode B
• Matching point in mode E, mode B:

85% partial output point
Mode Digging Breaker Finishing
Partial output point 90% 85% 80%
Model PC228US-3
Mode E 88.2 kW/1,650 rpm {120 PS/1,650 rpm}
Mode B 80.9 kW/1,650 rpm {110 PS/1,650 rpm}
• At this time, the controller keeps the pump

absorption torque along the constant horse-
power curve and lower the engine speed by
the composite control of the engine and
pump.
By this method, the engine is used in the low
fuel consumption area.
PC228US-3 10-139
12
Operation width of arm crane
• Matching point of operation width of arm

crane:
70% partial output point
Model
PC228US-3
Mode
Operation
width of arm 56.6 kW/1,450 rpm {77 PS/1,450 rpm}
crane
• If the pump load increases and the pressure

rises, the engine speed lowers.
At this time, the controller lowers the pump
discharge so that the engine speed will be
near the full output point. If the pressure low-
ers, the controller increases the pump dis-
charge so that the engine speed will be near
the full output point.
By repeating these operations, the controller
constantly uses the engine near the full out-
put point.
10-140 PC228US-3
12
2) Function to control pump during

travel
• If the machine travels in mode A, either of
engine speed and pump absorption torque
does not change.
• If the machine travels in mode E, mode B,
the working mode and engine speed are
not changed, but the pump absorption
torque is increased.145
•
3) Function to control when emergency

pump drive switch is turned ON
• Even if the controller or a sensor has a
trouble, the functions of the machine can
be secured with pump absorption torque
almost equivalent to mode E by turning on
emergency pump drive switch (10).
In this case, a constant current flows from
the battery to the EPC valve for PC and the
oil pressure is sensed by only the EPC
valve for PC.
PC228US-3 10-141
12
2. Pump/Valve control function
Function
• The machine is matched to various types of
work properly with the 2-stage relief function
to increase the digging force, etc.
10-142 PC228US-3
12
1) LS control function
• The change point (LS set differential pressure)
of the pump discharge in the LS valve is
changed by changing the output pressure
from the LS-EPC valve to the LS valve accord-
ing to the operating condition of the actuator.
• By this operation, the start-up time of the
pump discharge is optimized and the com-
posite operation and fine control perfor-
mance is improved.
2) Cut-off function
• When the cut-off function is turned on, the
PC-EPC current is increased to near the maxi-
mum value.
By this operation, the flow rate in the relief
state is lowered to reduce fuel consumption.
• Operating condition for turning on cut-off
function
Condition
• The average value of the front and rear

pressure sensors is above 27.9 MPa {285
kg/cm²} and the one-touch power maximiz-
ing function is not turned on
The cut-off function does not work, however,

while the machine is travelling in mode A or the
arm crane operation width swing lock switch is
turned on.
3. 2-stage relief function
• The relief pressure in the normal work is 34.8
MPa {355 kg/cm²}. If the 2-stage relief func-
tion is turned on, however, the relief pressure
rises to about 37.2 MPa {380 kg/cm²}.
By this operation, the hydraulic force is
increased further.
• Operating condition for turning on 2-stage
relief function
Condition Relief pressure
• During travel
• When swing lock switch is 34.8 MPa
turned on {355 kg/cm²}
• When boom is lowered ⇓
• When one-touch power maxi- 37.2 MPa
mizing function is turned on {380 kg/cm²}
• When arm crane is operated
PC228US-3 10-143
(4)
12
3. One-touch power maximizing function
Function
• Power can be increased for a certain time by

operating the left knob switch.
10-144 PC228US-3
12
1) One-touch power maximizing function

• When the operator needs more digging force
to dig up a large rock, etc., if the left knob
switch is pressed, the hydraulic force is
increased about 7% to increase the digging
force.
• If the left knob switch is turned on in working
mode "A" or "E", each function is set automat-
ically as shown below.
⇓ Software cut-off function
Working Engine/Pump
2-stage relief function Operation time
mode control
34.8 MPa {335 kg/cm²}
Matching at rated Automatically
A, E ⇓ Cancel
output point reset at 8.5 sec
37.2 MPa {380 kg/cm²}
PC228US-3 10-145
12
4. Auto-deceleration function
Function
• If the all control levers are set in NEUTRAL

while waiting for a dump truck or work, the
engine speed is lowered to the medium level
automatically to reduce the fuel consumption
and noise.
• If any lever is operated, the engine speed
rises to the set level instantly.
10-146 PC228US-3
12
Operation
When control levers are set in neutral
• If all the control levers are set in NEUTRAL

while the engine speed is above the decelera-
tor operation level (about 1,400 rpm), the
engine speed lowers instantly to the first
deceleration level about 100 rpm lower than
the set speed.
• If 4 more seconds pass, the engine speed
lowers to the second deceleration level
(about 1,400 rpm) and keeps at that level until
any lever is operated again.
When any control lever is operated
• If any control lever is operated while the

engine speed is kept at the second decelera-
tion level, the engine speed rises instantly to
the level set with the fuel control dial.
PC228US-3 10-147
12
5. Auto-warm-up/Overheat prevention
function
Function
• After the engine is started, if the engine cool-

ing water temperature is low, the engine
speed is raised automatically to warm up the
engine. If the engine cooling water tempera-
ture rises too high during work, the pump
load is reduced to prevent overheating.
10-148 PC228US-3
12
1) Auto-warm-up function
• After the engine is started, if the engine cool-
ing water temperature is low, the engine
speed is raised automatically to warm up the
engine.
Operating condition (All) Operated
Water temperature: Below 30°C.

Engine speed: Max. 1,200 rpm ⇒ Engine speed: Max. 1,200 rpm
⇓
Resetting condition (Any one) Reset
⇒
Water temperature: Above 30°C
Auto
Auto-warm-up operation time: Min. 10 minutes
Engine speed: Any level
Fuel control dial: Kept at 70% of full level for 3 sec.
Manual
or longer
2) Overheat prevention function • This function is turned on when the water

• If the engine cooling water temperature rises temperature rises above 105°C.
too high during work, the pump load and
engine speed are reduced to prevent over-
heating.
Operating condition Operation/Remedy Resetting condition

Water temperature: Below 105°C
Fuel control dial: Return to low idle
⇒ ⇒
Work mode: Any mode
Water temperature: Engine speed: Low idle position once.
Above 105°C Monitor alarm lamp: Lights up • Under above condition, controller
Alarm buzzer: Sounds is set to condition before operation
of function. (Manual reset)

⇒ ⇒
Work mode: Mode A or E
Water temperature: • Under above condition, controller
Engine speed: Keep as is.
Above 102°C is set to condition before operation
Monitor alarm lamp: Lights up.
of function. (Automatic reset)

⇒ ⇒
Work mode: Mode A
Lower pump discharge.

⇒ ⇒
Work mode: Travel
Lower travel speed.
PC228US-3 10-149
12
6. Swing control function
Function
The swing lock and swing holding brake func-

tions are installed.
10-150 PC228US-3
12
1) Swing lock and swing holding brake 2) Quick hydraulic oil warm-up function
functions when swing lock switch is turned on
• The swing lock function (manual) is used to • If swing lock switch (11) is turned on, the
lock machine from swinging at any position. pump-cut function is cancelled and the relief
The swing holding brake function (automatic) pressure rises from 34.8 MPa {355 kg/cm²} to
is used to prevent hydraulic drift after the 37.2 MPa {380 kg/cm²}. If the work equipment
machine stops swinging. is relieved under this condition, the hydraulic
• Swing lock switch and swing lock/holding oil temperature rises quickly and the warm-up
brake time can be shortened.
Lock Lock
Function Operation
switch lamp
If swing lever is set in neutral,

Swing swing brake operates in
OFF OFF holding about 5 sec. If swing lever is
brake operated, brake is released
and machine can swing freely.
Swing lock operates and

machine is locked from
Swing swinging. Even if swing lever
ON ON
lock is operated, swing lock is not
reset and machine does not
swing.
Operation of swing holding brake release

switch
• If the controller, etc. has a problem, the swing
holding brake does not work normally, and
the machine cannot swing, the swing lock can
be reset with the swing holding brake release
switch.
Swing hold- ON OFF

ing brake (When control has (When controller is nor-
release switch trouble) mal)
Swing lock
ON OFF ON OFF
switch
Swing Swing Swing lock Swing hold-
Swing brake lock is lock is is turned ing brake is
turned on. canceled. on. turned on.
★ Even if the swing holding brake release

switch is turned on, if the swing lock switch is
turned on, the swing brake is not released.
★ If the swing lock is reset, swinging is stopped
by only the hydraulic brake of the safety
valve. Accordingly, if swinging is stopped on
a slope, the upper structure may drift hydrau-
lically.
PC228US-3 10-151
12
7. Travel control function
Function
• The pumps are controlled and the travel

speed is changed manually or automatically,
to secure proper travel performance matched
to the type of work and jobsite during travel.
10-152 PC228US-3
12
1) Pump control function during travel

• If the machine travels in a work mode other
than mode A, the work mode and the engine
speed are kept as they are and the pump
absorption torque is increased.
★ For details, see ENGINE/PUMP COMPOSITE
CONTROL FUNCTION.
2. Travel speed change function

i) Manual change with travel speed switch
If the travel speed switch is changed
between Lo and Hi, the governor/pump
controller controls the pump capacity and
motor capacity at each gear speed as
shown at right to change the travel speed.
Travel speed switch Lo (Low speed) Hi (High speed)
Pump capacity (%) 80 100
Motor capacity Max. Min.
Travel speed (km/h) 3.0 5.5
ii) Automatic change by engine speed

If the engine speed is lowered to 1,500
rpm or less with the fuel control dial dur-
ing travel;
• the travel speed does not change even if
the travel speed switch is changed from
Lo to Hi,
• the travel speed changes to Lo automati-
cally if the travel speed has been Hi.
iii) Automatic change by pump discharge
pressure
While the machine is traveling with the
travel speed switch at Hi, if the load is
increased because of an upslope ground,
etc. and the travel pressure keeps above
33.3 MPa {340 kg/cm²} for 0.5 seconds, the
pump discharge is changed automatically
and the travel speed is lowered (to the Lo
level) (The travel speed switch is kept at
Hi, however).
While the machine is travelling at Lo, if
the load is reduced on a flat or downslope
ground, etc. and the travel pressure keeps
below 17.6 MPa {180 kg/cm²} for 0.5 sec-
onds, the pump discharge is changed
automatically and the travel speed is set
to Hi again.
PC228US-3 10-153
12
8. Boom stroke end electronic cushion

function
10-154 PC228US-3
12
Function
• When the boom is raised, its speed is lowered

before its stroke end to reduce the shock at
the stroke end. As a result, less material spills
and the loads on the machine body and cylin-
ders are reduced.
1) Electronic cushion function
• There is a cushion range before the boom
raising stroke end (about 35°).
• If the boom enters this range, the EPC valve
reduces the output pressure of the boom PPC
valve applied to the boom control valve
.
(RAISE side) to lower the boom raising speed.
• By this operation, the shock at the stroke end
is reduced.
2) Reset function
Resetting of input signal (Installed angle of
potentiometer)
• If the potentiometer is replaced or the work
equipment is replaced, an input signal error is
made because of the error of the installation
of the potentiometer.
• With the resetting function, this error can be
corrected easily without measuring the out-
put voltage or adjusting the potentiometer
finely.
• If the boom is raised to the stroke and the
input reset signal is input, the difference
between the angle calculated from the actual
output voltage of the potentiometer and the
standard angle set to the controller (installa-
tion error) is saved as the "correction value".
Since the controller keeps the "correction
value", the potentiometer must be corrected
when the controller is replaced. (For the cor-
rection method, see TESTING AND ADJUST-
ING.)
3) Emergency work equipment operation

switch
• Even if the work equipment cannot be oper-
ated because of controller trouble, it can be
operated again with the emergency work
equipment operation switch.
The stroke end cushion does not work in this
case, however
PC228US-3 10-155
12
9. ATT PPC throttle function (Optional)
Function
When the breaker is used and the boom is low-

ered in mode B, the PPC pressure of the attach-
ment is reduced to limit the oil flow to brace the
machine body.
This function is effective only on the breaker
specification model.
10-156 PC228US-3
12
10. System component parts

1) Engine revolution sensor
1. Wire
2. Magnet
3. Terminal
4. Housing
5. Connector
Function
• The engine revolution sensor is installed to

the ring gear of the engine flywheel. It electri-
cally calculates the number of the gear teeth
which pass in front of it and transmits the
result to the governor/pump controller.
• A magnet is used to sense the gear teeth.
Each time a gear tooth passes in front of the
magnet, a current is generated.
PC228US-3 10-157
12
2) PPC oil pressure switch
1. Plug
2. Switch
3. Connector
Specifications
Type of contacts: Normally open contacts

Operating (ON) pressure: 0.5 ± 0.1 MPa
{5.0 ± 1.0 kg/cm²}
Resetting (OFF) Pressure: 0.3 ± 0.5 MPa
{3.0 ± 0.5 kg/cm²}
Function
• The junction block has 9 pressure switches,

which check the operating condition of each
actuator by the PPC pressure and transmit it
to the governor/pump controller.
10-158 PC228US-3
12
3) Pump pressure sensor
1. Sensor
2. Connector
Function
• The pump pressure sensor is installed to the

inlet circuit of the control valve. It converts
the pump discharge pressure into a voltage
and transmits it to the governor/pump con-
troller.
Operation
• The oil pressure applied from the pressure

intake part presses the diaphragm of the oil
pressure sensor, the diaphragm is deformed.
• The gauge layer facing the diaphragm mea-
sures the deformation of the diaphragm by
the change of its resistance, then converts the
change of the resistance into a voltage and
transmits it to the amplifier (voltage ampli-
fier).
• The amplifier amplifies the received voltage
and transmits it to the governor/pump con-
troller.
• Relationship between pressure P (MPa {kg/
cm²}) and output voltage (V) is as follows.
V = 0.008 x P + 1.0
PC228US-3 10-159
12
4) Potentiometer
1. Sensor 4. Sensor
2. Rotor 5. Cover
3. Bearing 6. Connector
Function
• The potentiometer is installed to the boom

foot to sense the boom angle.
• The potentiometer converts the boom angle
into a signal voltage with a 5 V source voltage
and a variable resistor, and transmits it to the
controller.
★ On the arm crane specification model, the
potentiometer is also installed to the arm foot
to sense the arm angle.
10-160 PC228US-3
12
5) Resistor
• For PC-EPC valve
• For boom RAISE throttle EPC valve
1. Resistor
2. Connector
Function Specifications
• This resistor is used to supply a constant cur- Resistance:

rent to the PC-EPC valve and boom RAISE 30Ω (For PC-EPC valve)
throttle EPC valve according to the present 20Ω (For boom RAISE throttle EPC valve)
condition.
PC228US-3 10-161
STRUCTURE AND FUNCTION MONITORING SYSTEM
12
MONITORING SYSTEM
• The monitor system monitors the condition • The monitor panel also has various mode
of the machine with sensors installed on vari- selector switches and functions to operate the
ous parts of the machine. It processes and machine control system.
immediately displays the obtained informa-
tion on the panel notifying the operator of the
condition of the machine.
The panel is roughly divided as follows.
1. Monitor section to output alarms when
the machine has troubles
2. Gauge section to display the condition
constantly (Coolant temperature, fuel
level, etc.)
10-162 PC228US-3
12
1. Monitor panel
Outline Input and output signals
• The monitor panel has the functions to dis- CN-PO1 CN-PO2

play various items and the functions to Pin Signal name Pin Signal name
select modes and electric parts. No. No.
1 Key switch (Battery) 1 Engine water temperature
The monitor panel has a CPU (Central Pro- 2 Key switch (Battery) 2 Fuel
cessing Unit) in it to process, display, and 3 Washer motor output 3 Radiator water level
output the information. 4 Key switch (Terminal C) 4 NC
The monitor display unit consists of LCD 5 Wiper contact W 5 Air cleaner clogging sensor
(Liquid Crystal Display) and LED (Light 6 GND 6 NC
Emitting Diode). The switches are flat sheet 7 GND 7 Engine oil pressure sensor
switches. 8 VB + (24 V) 8 Engine oil level sensor
9 Wiper motor (+) 9 Network signal
10 Wiper motor (-) 10 Network signal
11 (Buzzer ON signal input) 11 Charge level
12 Wiper contact P 12 NC
13 GND (For analog signal)
14 NC
15 Wind limit switch
16 Buzzer cancel
17 Swing lock
18 Preheating
19 Limit switch
20 Network (GND)
PC228US-3 10-163
12
Display section of monitor
1. Service meter display

2. Coolant temperature gauge
3. Coolant temperature caution
4. Digital meter display (Service code and user
code are displayed when trouble occurs)
5. Fuel level caution
6. Fuel level gauge
7. Engine oil level caution lamp
8. Preheating pilot lamp
9. Swing holding brake pilot lamp
10. Oil maintenance pilot lamp
11. Battery charge caution lamp
12. Air cleaner clogging caution lamp
13. Engine oil pressure caution lamp
10-164 PC228US-3
12
Monitored items and display

When engine is
Symbol Displayed item Display range While engine is running
stopped
Max. 1,500 rpm Lights when normal.
Max. 0.05 MPa (Goes off when
{0.5 kg/cm²} engine is started.) Flashes and buzzer
Engine oil pressure
Min. 1,500 rpm sounds when abnormal.
Max. 0.15 MPa
{1.5 kg/cm²}
Air cleaner clogging When clogged Goes off. Flashes when abnormal.
SAP00521
Lights when normal.

When charge is (Goes off when
Charge level engine is started.) Flashes when abnormal.
abnormal
Flashes when abnor-

Engine oil level Below low level Goes off.
SAP00523
mal.
When swing is Lights up when swing is locked. Flashes when

Packing (Swing lock)
locked swing holding brake release switch is turned on.
SAT00098
Oil maintenance See "OIL MAINTENANCE FUNCTION" on next page.
Lights up for 30 sec. when starting switch is set

Preheating When preheated to HEAT. Then, flashes for 10 sec. to indicated
SAP00526 completion of preheating.
Flashes at 102°C or higher. Flashes and

Coolant temperature
buzzer sounds at 105°C or higher.
SAP00527
Fuel level Flashes when below low level.
PC228US-3 10-165
12
Oil maintenance function
1. Function and operation

At a set time after the engine oil is replaced, the
oil maintenance function is turned on to notify
the operator by the LED lamp on the monitor
panel that it is time to replace the oil. The func-
tion to indicate the phone number of the place to
make contact for service on the LCD unit is
installed, too.
1) Check of elapsed time

Nothing is displayed normally until point
B shown in the figure at right after this
function is reset. If the key is turned on
with the buzzer cancel switch processed
(for 2.5 seconds), however, the elapsed
time is displayed on the service meter
section.
2) Display of replacement of oil
If time passes point B after this function is
reset, the elapsed time is displayed on the
service meter section and the LED flashes
when the key is turned on.
2. Setting of time interval

1) The time interval is set in the interval set-
ting mode. It can be set to "125h", "250h",
"500h", "Not set", or "Demo-mode". The
default is "Not set".
2) To enter the interval setting mode, press
and hold the clock switch for 2.5 seconds.
3) If the buzzer cancel switch is pressed in
the interval setting mode, the clock dis-
play section changes to "—" → "125" →
"250" → "500" → " d" in order. ("—" corre-
sponds to "Not set" and " d" corresponds
to "Demo-mode".)
4) To save the time interval, set a desired
time (mode) on the monitor panel and
press and hold the clock switch for 2.5
seconds.
10-166 PC228US-3
12
3. Timing and contents of display

1) When replacement of oil is displayed
The elapsed time is displayed for 10 sec-
onds after all segments are turned on.
Phone number is displayed for the next 10
seconds.
If the phone number has not been input,
however, the elapsed time is displayed for
20 seconds after all segments are turned
on.
2) When elapsed time is checked
The elapsed time is displayed for 10 sec-
onds after all segments are turned on.
4. Resetting elapsed time

1) When the replacement of oil and elapsed
time are displayed, press the buzzer can-
cel switch 10 seconds after all segments
are turned on (while the elapsed time is
displayed) and hold for 3 seconds. The
elapsed time is reset. After this operation,
"0h" is displayed for 1 second.
2) When the set time is changed, the elapsed
time is reset to "0h".
5. Demo-mode
1) In the demo-mode, the time is set to 250h,
the elapsed time is set to 240h, and
replacement of oil is displayed when the
key is turned on. The elapsed time does
not increase, however. The time can be
reset in this mode. Turn on the key 3
times in this mode, and the time interval
is automatically set to "Not set" at the 4th
time and after. The elapsed time is set to
"0h" and counting of elapsed time is
started.
PC228US-3 10-167
12
Mode selector switches
1. Travel speed switch

2. Auto-deceleration switch
3. Wiper switch
4. Work mode selector switch
• There are 4 sets of the mode selector Operations table of switch section
switches on the switch section. Each time one
switch is pressed, the machine condition ★ The bold letters are the positions of the
changes. The current condition is indicated switches reset when the starting switch is
by the lighting of the LED above the switch. turned on.
• The initial setting of only the work mode after Item Operation
the starting switch is turned on can be
changed. Work mode A↔E↔B
★ For how to change the setting, see "Work Auto-deceleration ON↔OFF
mode default setting mode" in TROUBLE-
SHOOTING-Display and special functions of Wiper OFF↔Intermittent↔ON
monitor panel.
Travel speed Hi↔Lo
10-168 PC228US-3
STRUCTURE AND FUNCTION SENSOR
12
SENSOR
• The signals from the sensors are input to the
panel directly. Either side of a sensor of con-
tact type is always connected to the chassis
ground.
Sensor When When

Type of sensor
name normal abnormal
Engine oil ON OFF

Contact
level (Closed) (Open)
Engine oil OFF ON

Contact
pressure (Open) (Closed)
Coolant
Resistance — —
temperature
Fuel level Resistance — —
Air cleaner OFF ON

Resistance
clogging (Closed) (Open)
PC228US-3 10-169
12
A. Engine oil level sensor
1. Connector
2. Bracket
3. Float
4. Switch
B. Engine oil pressure sensor (For low pressure)
1. Plug
2. Contact ring
3. Contact
4. Diaphragm
5. Spring
6. Terminal
C. Coolant temperature sensor
1. Connector
2. Plug
3. Thermistor
10-170 PC228US-3
12
A. Fuel level sensor
1. Float
2. Connector
3. Cover
4. Variable resistor
B. Air cleaner clogging sensor
PC228US-3 10-171
20 TESTING AND ADJUSTING
12
STANDARD VALUE TABLE FOR ENGINE. . . . . 20-2
★ Note the following when making judgements using the standard value tables for testing, adjust-
ing, or troubleshooting
1. The standard value for a new machine given in the table is the value used when shipping the
machine from the factory and is given for reference. It is used as a guideline for judging the
progress of wear after the machine has been operated, and as a reference value when carrying
out repairs.
2. The service limit value given in the tables is the estimated value for the shipped machine based
on the results of various tests. It is used for reference together with the state of repair and the
history of operation to judge if there is a failure.
3. These standard values are not the standards used in dealing with claims.
When carrying out testing, adjusting, or troubleshooting, park the machine on level ground, inset
the safety pins, and use blocks to prevent the machine from moving.
When carrying out work together with other workers, always use signals and do not let unautho-
rized people near the machine.
When checking the water level, always wait for the water to cool down. If the radiator cap is
removed when the water is still hot, the water will spurt out and cause burns.
Be careful not to get caught in the fan, fan belt or other rotating parts.
PC228US-3 20-1
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE
12
STANDARD VALUE TABLE FOR ENGINE
Applicable model PC228US-3
Engine SAA6D102E
Standard value
Item Measurement conditions Unit Service limit value
for new machine
High idling Working 2,150 ± 70 —
Low idling 1,030 ± 50 —

Engine speed rpm
Rated
Working 1,950 —
speed
At sudden acceleration Max. 1.0 2.0

Bosch
Exhaust gas color
index
At high idling Max. 0.5 1.5
Intake valve 0.25 —

Valve clearance
mm
(normal temperature)
Exhaust valve 0.51 —
Oil temperature: MPa 2.4 Difference between cylinders

Compression pressure
40 - 60° C {kg/cm²} {24.6} Min. 1.0 {10.3}
(SAE15W-40 oil)
(Engine speed) (rpm) Min. (250) (250)
(Water temperature: kPa

Blowby pressure
Operating range) (mmH O) Max. 1.2 {123} 5.1 {520}
(SAE oil) 2
At rated output
(Water temperature:
Operating range)
At high idling MPa 0.39 - 0.64 0.25 {2.6}
Oil pressure
(SAE15W-40) {kg/cm²} {4.0 - 6.5}
At low idling Min. 0.15 {1.5} 0.09 {0.9
(SAE15W-40)
Whole speed range

Oil temperature °C 80 - 110 120
(inside oil pan)
°
Fuel injection timing Before top dead center 11 ± 1 11 ± 1
(degree)
Deflection Fan pulley -

8 Min. 6, Max. 10
when tension pulley
pressed
Belt tension with finger Fan pulley - mm
force of air conditioner
5-8 5-8
approx. compressor
58.8N {6 kg} pulley
20-2 PC228US-3
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
12
STANDARD VALUE TABLE FOR CHASSIS
Cate-
Item Measurement conditions Unit Standard value Permissible value
gory
• Hydraulic oil temperature:
45 - 55°C
2 pumps at relief • Coolant temperature: 2,000 ± 100 —
Within operating range
Engine speed
• 2-pump relief: Arm relief

• Arm relief rpm
At 2-pump relief + one
• One touch power up 1,900 ± 100 1,900 ± 100
touch power up
• Engine at high idling
Speed when auto-
• Fuel control dial at MAX.
deceleration is oper- 1,400 ± 100 1,400 ± 100
• Control lever at neutral
ated
Bottom control valve A B C D
Arm control valve

Spool stroke
Bucket control valve

9.5 ± 0.5 9.5 ± 0.5 9.5 ± 0.5 9.5 ± 0.5
Swing control valve
Travel control valve
Boom control lever • Center of lever knob mm 85 ± 10 Min. 75, Max. 95

• Read max. value to end of
Travel of control levers
Arm control lever travel 85 ± 10 Min. 75, Max. 95

• Engine stopped
Bucket control lever • Excluding neutral play 85 ± 10 Min. 75, Max. 95
Swing control lever 85 ± 10 Min. 75, Max. 95
Travel control lever 115 ± 12 Min. 103, Max. 127
Play control lever Max. 10 Max. 15
Boom control lever • Engine at high idling 15.7 ± 3.9 {1.6 ± 0.4} Max. 24.5 {2.5}
Operating force of control levers
• Oil temperature: 45 - 55°C

• Fit push-pull scale to center of
Arm control lever control lever knob to measure 15.7 ± 3.9 {1.6 ± 0.4} Max. 24.5 {2.5}
• Measure max. value to end of
Bucket control lever travel 12.7 ± 2.9 {1.3 ± 0.3} Max. 21.6 {2.2}
N
{kg}
Swing control lever 12.7 ± 2.9 {1.3 ± 0.3} Max. 21.6 {2.2}
Lever 24.5 ± 5.9 {2.5 ± 0.6} Max. 39.2 {4.0}

Travel control lever
Pedal 74.5 ± 18.6 {7.6 ± 1.9} Max. 107.6 {11}
PC228US-3 20-3
12
Cate-
Item Measurement conditions Unit Standard Value Permissible value
gory
• A mode
• Oil temperature: 45 - 55°C
3.9 ± 1.0 3.9 ± 1.0
Unload pressure • Engine at high idling
{40 ± 10} {40 ± 10}
• All levers at neutral
• Pump output pressure
• Hydraulic oil temperature: 45 - 55°C

Boom • Relief pressure with engine at high idling
(Relieve only circuit to be measured)
• A mode 34.8 ± 1.0 Max. 36.8 {375}
• Figures in [ ] are when power max. func- {355 ± 10} Min. 33.3 {340}
Arm tion is used (reference)
• Pump output pressure 37.3 ± 1.0 Max. 39.2 {400}
{380 ± 10} Min. 36.3 {370}
★ 1: For travel, measure oil pressure for
Hydraulic pressure
Bucket relief on one side (rear pump pres-

sure when relieving left side; front
pump pressure when relieving
MPa
right side).
{kg/cm²} 30.9 ± 1.5 Max. 32.9 {335}
Swing ★ 2: For swing, measure with swing
lock switch ON. {315 ± 15} Min. 28.9 {295}
★ 3: Boom pressure is oil pressure at
RAISE and emergency work equip- 38.2 ± 1.0 Max. 40.2 {410}
Travel ment actuation switch at EMER- {390 ± 10} Min. 37.3 {380}
GENCY (RAISE).
Self-reducing 3.2 ± 0.2 Max. 3.43 {35}

pressure valve {33 ± 2} Min. 2.84 {30}
• Hydraulic oil tem- 2.9 ± 1.0 2.9 ± 1.0

Levers at neutral
perature: 45 - 55°C {30 ± 10} {30 ± 10}
LS differential • Engine at high
idling • Travel speed Hi,
pressure rotating under no 2.37 ± 0.1 2.37 ± 0.1
• In heavy-duty oper-
load {24.2 ± 1.0} {24.2 ± 1.0}
ation mode
• Travel lever half
20-4 PC228US-3
12
Cate-
gory
deg.
Swing brake angle Max. 100 Max. 130
<mm>
• A mode
• Stop after swinging one turn and mea-
sure distance that swing circle moves
90° 3.1 ± 0.3 Max. 3.7
Time taken to start

sec.
swing • Engine at high idling
• Hydraulic oil temperature: 45 -
55°C 180° 4.4 ± 0.4 Max. 5.5
• In H/O mode
• Time taken to swing 90° and 180°
from starting position
Swing
Time taken to swing sec. 27.3 +3.6

-1.7 Max. 33
• In H/O mode
• Swing one turn, and measure time taken
to swing next 5 turns
Hydraulic drift of
• Engine stopped mm 0 0
swing
• Set machine on 15° slope, and set upper
structure at 90° to the side.
• Make match marks on swing circle outer
race and track frame.
• Measure distance that match marks
move apart after 5 minutes.
Leakage from swing • Hydraulic oil temperature: 45 - 55°C
l/min. Max. 5 Max. 10
motor • Swing lock switch ON
• Relieve swing circuit
PC228US-3 20-5
12
Cate-
gory
Travel
speed
+5.7
STD: 51.3 -4.7 STD: 46.6 - 61.0
LC: 55.9
+6.2 LC: 50.8 - 66.1
Lo -5.1
Travel speed (1) sec.

• A mode
• Hydraulic oil temperature: 45 - 55°C +1.6
STD: 28.0 -1.5 STD: 26.5 - 31.6
• Raise track on one side at a time, Hi
LC: 30.5
+2.4 LC: 29.4 - 34.9
rotate one turn, then measure time -1.1
taken for next 5 turns with no load.
Lo 24 ± 2.5 21.5 - 27.5
Travel speed (2) sec.

• In H/O mode Hi 13 ± 1 12 - 15
Swing
• Run up for at least 10 m, and mea-

sure time taken to travel next 20 m
on flat ground.

• Run up for at least 10 m, and measure
deviation when traveling next 20 m on flat
Travel deviation ground. mm Max. 150 Max. 250
★ Use a hard horizontal surface.
★ Measure dimension χ.
20-6 PC228US-3
12
Cate-
gory
Hydraulic drift of travel mm 0 0

• Engine stopped
• Stop machine on 12° slope with
sprocket facing straight up the slope.
Travel
• Measure the distance the machine

moves in 5 minutes.
Leakage of travel motor l/min. 13.6 27.2

• Lock shoes and relieve travel circuit.
Total work equip-

ment (hydraulic drift Max. 600 Max. 900
at tip of bucket teeth)
Hydraulic drift of work equipment
Boom cylinder
(amount of retrac- • Place in above posture and measure Max. 18 Max. 27
Work equipment
tion of cylinder) extension or retraction of each cylin-

der and downward movement at tip
of bucket teeth. mm
Arm cylinder • Bucket: Rated load
(amount of exten- • Horizontal, flat ground Max. 160 Max. 240
sion of cylinder) • Levers at neutral
• Engine stopped
• Start measuring immediately after
Bucket cylinder setting.
(amount of retrac- • Measure hydraulic drift every 5 min- Max. 46 Max. 58
tion of cylinder) utes, and judge from results for 15
minutes.
PC228US-3 20-7
12
Cate-
gory
RAISE
+0.5
3.7 -0.3
Max. 5.2
Boom
• A mode
Bucket teeth in
contact with • Engine at high idling
ground • Hydraulic oil temperature: 45 - 55°C
• Emergency work equipment actua-
↕ tion switch: RAISE (EMERGENCY) !
LOWER
Cylinder fully
extended The cushion at the end of the 2.8 ± 0.3 Max. 4.4
Hydraulic drift of work equipment
boom RAISE stroke is set so

that it is not actuated. For this
reason, there is a large shock,
so carry out the measurement
Work equipment
on firm level ground.
sec.
Arm 3.5 ± 0.3 Max. 4.5
IN
Cylinder fully
retracted
↕ • A mode
OUT
+0.4
Fully extended 2.7 -0.2 Max. 3.5
CURL
Bucket 2.6 ± 0.3 Max. 3.3
Cylinder fully
retracted
↕
DUMP
• A mode +0.4
Fully extended • Engine at high idling 1.9 -0.2 Max. 2.7
20-8 PC228US-3
12
Cate-
gory
Boom Max. 1.0 Max. 1.2

• Lower boom and measure time
taken from point where bucket con-
tacts ground to point where chassis
rises from ground
• Engine at low idling
Time lag
sec.
Work equipment
Arm Max. 1.0 Max. 2.8

• Stop arm suddenly and measure
time taken for arm to stop
Bucket Max. 1.0 Max. 3.6

• Stop bucket suddenly and measure
time taken for bucket to stop at bot-
tom and then start again
Internal leakage
Cylinders 4.5 20
• Engine at high idling cc/min
Center swivel • Relieve circuit to be measured 10 50
joint
PC228US-3 20-9
12
Cate-
gory
Performance in compound operation

★ Use a hard horizontal surface

Travel deviation when
work equipment + travel mm Max. 200 Max. 220
are operated
★ Measure dimension χ.
Performance of hydraulic pump
Hydraulic pump e delivery
Piston pump See next page See next page
20-10 PC228US-3
12
Cate- Discharge amount of main piston pump

gory
Performance of hydraulic pump
• Pump speed: At 1,950 rpm, PC current 310 mA

Test pump Discharge Average Standard value Judgement
discharge pressure of pressure for discharge standard
Check point
pressure other pump amount Q lower limit Q
(MPa {kg/cm²}) (MPa {kg/cm²}) (MPa {kg/cm²}) (l/min) (l/min)
P1 + P2
As desired P1 P2 -------------------- See graph See graph
2
★ As far as possible, bring pump discharge pressure P1 and P2 as close as possible to the average pres-
sure when measuring.
The error is large near the point where the graph curves, so avoid measuring at this point.
★ When measuring with the pump mounted on the machine, if it is impossible to set the engine speed to
the specified speed with the fuel control dial, take the pump discharge amount and the engine speed at
the point of measurement, and use them as a base for calculating the pump discharge amount at the
specified speed.
PC228US-3 20-11
12
Flow control characteristics of PC valve (STD)
★ The values in this table are used as reference values when carrying out troubleshooting
Category Item Measurement conditions Unit PC228US-3

Performance in compound operations
Time taken for swing for

boom RAISE + starting sec. 4.2 ± 0.4
swing • Engine at high idling
• A mode
• Load the bucket with the rated load and
measure the time taken from the position
of starting the swing to the point of pass-
ing the 90° position.
20-12 PC228US-3
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL RELATED PARTS
12
STANDARD VALUE TABLE FOR ELECTRICAL RELATED
PARTS
Sys- Name of Connector Inspection Measurement

Judgement table
tem component No. method conditions
If the condition is as shown in the table below, it is normal 1) Turn starting
Power switch OFF.
C01 Measure Between CO1 (7), (13) and CO1 (6), (12) 20 - 30 V 2) Insert T-adapter.
source volt-
C02 voltage 3) Turn starting
age Between CO2 (11), (21) and CO1 (6), (12) 20 - 30 V switch ON.

switch OFF.
PPC basic Safety lock lever at FREE 2) Insert T-adapter.
pressure Measure 20 - 30 V
V01 (solenoid ON) Between 3) Turn starting
lock sole- voltage switch ON.
Safety lock lever at LOCK (1) - (2)
noid Max. 1 V
(solenoid OFF)
If the condition is as shown in the table below, it is normal 1) Start engine.

Monitor- 2) Set monitoring
Kerosene Measure In standard mode Bit 5 OFF code to 27
ing code
mode voltage
27 In kerosene mode Bit 5 ON

switch OFF.
Between (8) - (18) 177 ± 100 mA (177 ± 100 mV) 2) Insert T-adapter.
3) Turn starting
★ Measuring the voltage at the (-) connector is the same switch ON.
Measure as measuring the value of the current (= value of the 4) Set fuel control
PC-EPC
C02 current
Controller
solenoid voltage) {value inside ( )}. dial to FULL.

(voltage) 5) Emergency
pump drive
switch: Normal
6) Place all levers
at neutral.
switch OFF.
At travel Hi Between 0 ± 100 mA (0 ± 100 mV) 2) Insert T-adapter.
Measure (7) - (17) 3) Turn starting
LS-EPC At travel Lo 683 ± 100 mA (683 ± 100 mV)
C02 current switch ON.
solenoid
(voltage) ★ Measuring the voltage at the (-) connector is the same
as measuring the value of the current (= value of the
voltage) {value inside ( )}.
switch OFF.
Pump Travel lever operated 20 - 30 V
Between (2) - (6) 2) Insert T-adapter.
merge/ Measure 3) Turn starting
C01 Travel lever at neutral Max. 1 V
divider voltage switch ON.
solenoid ★ Operate the lever slightly (do not make the machine
move).
switch OFF.
Boom Measure Between (9) - (19) 950 ± 30 mA (950 ± 3 0 mV) 2) Insert T-adapter.
RAISE EPC C02 current ★ Measuring the voltage at the (-) connector is the same 3) Turn starting
solenoid (voltage) switch ON.
4) Oil detection
voltage) {value inside ( )}. posture.
PC228US-3 20-13
12

Judgement table
Attachment pedal + boom 590 ± 30 mA switch OFF.
LOWER lever operated (590 ± 30 mV) 2) Insert T-
Between
(10) and (20)
adapter.
900 ± 30 mA 3) Start engine.
Measure All levers at HOLD
ATT EPC (900 ± 30 mV)
C02 current
solenoid ★ Operate the lever slightly (do not make the machine
voltage
move).
★ Measuring the voltage at the (-) connector is the same
voltage) {value inside ( )}.
switch OFF.
Potentiome- Between (7) - (17) 4.9 - 5.1 V
Measure 2) Insert T-
ter power C03
voltage adapter.
source
3) Turn starting
switch ON.
2) Insert T-
Travel speed Hi or Mi (solenoid
adapter.
ON: Travel motor swash plate 20 - 30 V
3) Fuel control
at MIN) Between dial at MAX.
Travel speed Lo (solenoid OFF: (9) - (6),(12) 4) Operate
Travel motor swash plate at 0-3V travel lever
Travel
Measure MAX) slightly.
speed sole- C01
voltage Solenoid OFF
noid
Controller
can also be
checked by
measuring
with fuel con-
trol dial at
MIN (below
1200 rpm)
switch OFF.
Fuel control Measure Low idling Between (4) - (17) 4.0 - 4.75 V 2) Insert T-
C03
dial voltage High idling Between (19) - (9) 0.25 - 1.0 V adapter.
3) Turn starting
switch ON.
switch OFF.
Between (A) - (B) 0.25 - 5 kΩ
Potenti- Measure 2) Disconnect
E10 (male)
ometer resistance Between (B) - (C) 0.25 - 5 kΩ connector.
Between (A) - (C 4 - 6 kΩ
Governor motor

switch OFF.
Between (1) - (2) 2.5 - 7.5 Ω 2) Disconnect
Between (3) - (4) 2.5 - 7.5 Ω connector.
Measure
Motor E11 (male) Between (1) - (3) No continuity
resistance
Between (1) - chassis No continuity
Between (3) - chassi No continuity
PC228US-3 20-14
12

Judgement table
Attach- If the condition is as shown in the table below, it is normal 1) Turn starting
ment switch OFF.
(breaker) Measure When attachment (breaker) is 2) Insert T-
Max. 1 V
pressure
C06
voltage operated (pressure switch ON) Between adapter.
(6) - (3),(4)
switch sig- At HOLD 20 - 30 V 3) Turn starting
nal switch ON.
2) Turn swing
When one of swing or work lock switch
equipment control levers is OFF.
20 - 30 V
operated (solenoid ON: Swing 3) Swing hold-
holding brake canceled) ing brake
Between
Swing 5 seconds after all of swing or (3) - (6),(12) cancel switch:
holding Measure work equipment control levers Normal
C01 4) Insert T-
brake sole- voltage are returned to HOLD (sole- 0-3V
noid noid OFF: Swing holding adapter.
brake applied) It is possible
to operate the
lever slightly
(do not make
the machine
move).
Controller

switch ON.
2-stage Swing lock switch ON (Sole-
Measure 20 - 30 V 2) Insert T-
relief sole- C01 noid ON: High pressure) Between adapter.
voltage
noid Swing lock switch OFF (Sole- (10) - (6),(12)
0-3V
noid OFF: Low pressure)
If the condition is as shown in the table below, it is norma 1) Turn starting

switch ON.
Between (14) - (17) (low idling) 2.3 - 3.3 V
Governor 2) Insert T-
Measure
potentiom- C03 Between (14) - (17) (high idling) 0.5 - 0.9 V adapter.
voltage
eter
Between (7) - (17) (power source) 4.75 - 5.25 V

Governor Measure Between (2) - (3) 1.8 - 4.6 V switch ON.
C02 2) Insert T-
motor voltage
Between (4) - (5) 1.8 - 4.6 V adapter.

switch ON.
Battery Measure Between (1) - (6) 20 - 30 V 2) Insert T-
C01
relay voltage adapter.
★ Only for 2.5 sec. after starting switch is operated
(ON→OFF); all other times: 0 V.
PC228US-3 20-15
12

Judgement table
Knob switch OFF Max. 1 V switch OFF.
Measure Between 2) Insert T-
Power max. C03 (9) - chassis
voltage Knob switch ON 20 - 30 V adapter.
3) Turn starting
switch ON.
Measure Between (4), (12) - chassis 4-8V switch ON.
S - NET C04
voltage 2) Insert T-
adapter.
Monitor- switch ON.
Model Measure Displays "228"
ing code 2) Set monitor-
selection voltage
0002 ing code to
0002.
switch OFF.
Between (1) - (17) 0.86 - 1.13 V 2) Insert T-
Measure adapter.
C03
voltage 3) Turn starting
switch ON.
Boom 4) End of boom
potentiom- RAISE stroke.
eter
switch OFF.
Between (1) - (17) 0.25 - 4.5 kΩ
Controller
Measure 2) Disconnect
C03
resistance connector.
3) Connect T-
adapter.
2) Set monitor-
High idling (rpm)
ing code to
A mode Approx. 2150 0010 or 0016
Monitor-
Measure (command
No. 2 throt- ing code B mode Approx. 1800
engine value).
tle signal 0010
speed C mode Approx. 1800 3) Operate
0016
working
mode switch.
4) Cancel auto-
deceleration.
Boom switch OFF.
RAISE EPC V09 (male)
Measure Between (1) - (2) 7 - 14 Ω
resistance 2) Disconnect
solenoid Between (1), (2) - chassis Min. 1 MΩ connector.

switch OFF.
ATT EPC
V07 (male)
solenoid resistance 2) Disconnect
Between (1), (2) - chassis Min. 1 MΩ connector.

Air cleaner 2) Disconnect
clogging A31 (male) Continuity Air cleaner normal Between Continuity
connector.
sensor Air cleaner clogged (1) - (2) No continuity
PC228US-3 20-16
12

Judgement table
PC-EPC switch OFF.
(TVC) sole- V21 (male)
noid valve Between (1), (2) - chassis Min. 1 MΩ connector.

LS-EPC switch OFF.
solenoid V22 (male)
valve Between (1), (2) - chassis Min. 1 MΩ connector.
Swing If the condition is as shown in the table below, it is normal 1) Turn starting
holding Measure Between (1) - (2) 20 - 60 Ω switch OFF.
V04 (male) 2) Disconnect
brake sole- resistance

Controller
2-stage switch OFF.

relief sole- V02 (male)
Pump If the condition is as shown in the table below, it is normal 1) Turn starting
merge/ Between (1) - (2) 20 - 60 Ω switch OFF.
Measure
divider V06 (male) 2) Disconnect
resistance
solenoid Between (1), (2) - chassis Min. 1 MΩ connector.
valve
PPC basic If the condition is as shown in the table below, it is normal 1) Turn starting
pressure Measure Between (1) - (2) 20 - 60 Ω switch OFF.
V01 (male) 2) Disconnect
lock sole- resistance

Travel switch OFF.
speed sole- V03 (male)
PC228US-3 20-17
12
Name of Inspec-
Sys- Measurement
compo- Connector No. tion Judgement table
tem conditions
nent method
If the condition is as shown in the table below, it is normal 1) Turn start-
ing switch
Between (1) - (2) 0.25 - 5 kΩ OFF.
Fuel con- Measure
E06 (male) 2) Disconnect
trol dial resistance Between (2) - (3) 0.25 - 5 kΩ
connector.
Between (1) - (3) 4 - 6 kΩ

ing switch
Between (male) (1) - (2) 500 - 1000 Ω
OFF.
Measure
resistance
Between (male) (1), (2) - chassis Min. 1 MΩ 2) Disconnect
connector.
3) Connect T-
adapter.
Engine Measure with AC range 1) Turn start-
speed E04 ing switch
Between (1) - (2) 0.5 - 3.0 V
sensor OFF.
Measure
2) Insert T-
voltage
adapter.
3) Start
engine.
1) Screw in rotation sensor until it contacts ring gear, then
Adjust turn back 1 ± 1/6 turns.
2) It must work normally when adjusted as above.
Controller
Travel S30 If the condition is as shown in the table below, it is normal 1) Start
Travel steering S31 engine. (or
Boom RAISE S06
Between (male) All levers at neutral Min. 1 MΩ with accu-
Arm OUT S08 mulator
(1) - (2) Lever operated Max. 1 Ω
Boom LOWER S02 charged if
PPC Arm IN S04 Measure engine is
pressure Bucket CURL S01 stopped)
switch
resistance Between (male) (1), (2) - chassis Min. 1 MΩ
Bucket DUMP S05 2) Disconnect
Swing right S07 connector.
Swing left S03
1ATT ( ) S10
1ATT ( ) S11
If the condition is as shown in the table below, it is normal 1) Start
engine.
Between (2) - (1) 18 - 28 V 2) Set fuel con-
Pump
A52 (male) (rear) Measure trol dial to
pressure
A51 (male) (front) voltage All levers at HOLD 0.5 - 1.5 V MAX.
sensor
Between (3) - (1) 3) Insert T-
Arm IN circuit relieved 3.1 - 4.5 V adapter.

Swing ing switch
lock X05 (female)
Measure Between (1) - (2) Switch at OFF Min. 1 MΩ OFF.
switch Between (3) - (4) Switch at ON Max. 1 Ω connector.
: OPT
PC228US-3 20-18
Sys- Name of Measurement

Connector No. Inspection method Judgment table
tem component conditions
If the condition is as shown in Table 1 and Table 2, the monitor panel is 1) Connect T-adapter
normal.
Table 1 (CHECK, CAUTION section)
Monitor item Measurement Sensor
Display
(input connector) conditions signal input
ON Max. 1 V
Engine oil pressure Engine started
OFF 20 - 30 V
ON Max. 5 V
Battery charge Engine started
CHECK, OFF 20 - 30 V
CAUTION ON 20 - 20 V
section Engine oil level Engine stopped
OFF Max. 1 V
ON 20 - 30 V
Preheating Engine stopped
OFF Max. 1 V
Air cleaner normal ON 20 - 30 V
Air cleaner clogging
Air cleaner clogged OFF Max. 1 V
Swing lock switch ON ON 20 - 30 V
Swing lock
Machine monitor system
Swing lock switch OFF OFF Max. 1 V
Table 2 (Gauges) 1) Turn starting

switch OFF, insert
Display level dummy resis-
Content of guage resistance (kΩ) tance, or measure
display (Monitor panel input resistance of
resistance) sensor.
2) Turn starting
Starting switch ON Starting switch OFF switch ON and
check display.
Min. - Max.
Top 9 ~ 3.42
8 3.70 ~ 3.72
Gauges Measure ↑ 7 3.91 ~ 4.01

resistance
6 4.24 ~ 4.36
between cool-
ant tempera- Display 5 4.74 ~ 5.15
ture gauge PO2 position
(1) - (13) 4 5.61 ~ 6.87
↓ 3 7.52 ~ 10.90
2 12.01 ~ 36.73
Bottom 1 42.86 ~
★ Levels 8 and 9 flash.
PC228US-3 20-19
Sys Name of Connector Inspection Measurement

Judgment table
1) Turn start-
Display level ing switch
Content of guage resistance (kΩ) OFF, insert
display (Monitor panel input dummy
resistance) resistance,
or mea-
Starting switch ON Starting switch OFF
sure resis-
Min. - Max. tance of
sensor.
9 ~ 10 2) Turn start-
Top
ing switch
8 10 ~ 21.8 ON and
check dis-
Measure ↑ 7 21.8 ~ 31.1 play.
Gauges resistance
between 6 31.1 ~ 36.6
coolant Display
temperature 5 36.6 ~ 42.1
position
gauge PO2 4 42.1 ~ 47.8
(2) - chassis
↓ 3 47.8 ~ 62.8
2 62.8 ~ 85
Bottom 1 85 ~
Machine monitor system
★ Level flashes.
If the condition is as shown in the table below, it is normal 1) Install oil
pressure
Above 68.6 kPa
Engine oil Max. 1 Ω gauge.
Measure Between sensor {0.7 kg/cm²}
pressure E02 2) Disconnect
resistance terminal - chassis Below 29.4 kPa
sensor terminal.
Min. 1 MΩ
{0.3 kg/cm²} 3) Start
engine.
If the condition is as shown in the table below, it is normal 1) Disconnect
Engine oil connector.
Measure Oil level normal Max. 1 Ω
level sen- E02 (male) Between E03 2) Turn start-
resistance
sor (male) - chassis Oil level abnormal Min. 1 MΩ ing switch
OFF.
Coolant connector.
Normal temperature
tempera- E05 (male)
Measure Between Approx. 37 - 50 kΩ 2) Turn start-
resistance (25° C)
ture sensor (1) - (2) ing switch
110° C Approx. 3.5 - 4.0 kΩ OFF.

connector.
Fuel level Measure Full Max. approx. 12 Ω
A60 (male) Between A60 2) Turn start-
sensor resistance
(male) - chassis Empty Approx. 85 - 110 Ω ing switch
OFF.
Between When engine is running (1/2 throttle or above): 1) Start
alternator → 27.5 - 29.5 V engine
Measure
Alternator L (R) If the battery is old, or after starting in cold areas,
voltage
terminal - the voltage may not rise for some time.
chassis
PC228US-3 20-20
12

Tools for testing, adjusting, and troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-102
Measuring engine speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-104
Measuring exhaust gas color . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-105
Adjusting valve clearance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-106
Measuring compression pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-107
Measuring blow-by pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-107
Testing and adjusting fuel injection timing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-108
Measuring engine oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-109
Testing and adjusting belt tension for air conditioner compressor . . . . . . . . . . . . . . . . . . . . . . 20-110
Measuring speed sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110
Testing and adjusting governor motor lever stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-111
Testing and adjusting hydraulic pressure in work equipment, swing, travel circuit . . . . . . . . .20-112
Testing and adjusting PC valve output pressure (servo piston input pressure) . . . . . . . . . . . .20-115
Testing and adjusting LS valve output pressure (servo piston input pressure) and
LS differential pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-117
Testing and adjusting control circuit oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120
Measuring solenoid valve output pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-121
Measuring PPC valve output pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-124
Adjusting work equipment, swing PPC valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-125
Testing travel deviation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-126
Testing locations causing hydraulic drift of work equipment . . . . . . . . . . . . . . . . . . . . . . . . . . 20-127
Measuring swing, travel motor oil leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-128
Releasing remaining pressure in hydraulic circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-128
Testing clearance of swing circle bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-129
Testing wear of sprocket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-130
Testing and adjusting track shoe tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-131
Bleeding air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-132
Procedure for replacing boom angle potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-134
Procedure for checking diode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-135
PC228US-3 20-101
1
TESTING AND ADJUSTING TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
12
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
Check or measurement item Symbol Part No. Part Name Remarks
1 799-205-1100 Tachometer kit 6.0 - 99999.9 r/min (rpm)

Engine speed A
2 795-750-2500 Take-off drive
Water and oil temperatures B 799-101-1502 Digital temperature gauge —99 to 1,299° C
Pressure gauge: 2.5, 5.9,
799-101-5002 Hydraulic tester 39.2, 58.8 MPa
1 {25, 60, 400, 600 kg/cm²}
Pressure gauge: 69 MPa
790-261-1203 Digital hydraulic tester
{700 kg/cm²}
1.0 MPa {10 kg/cm²}
2 799-401-2320 Hydraulic gauge
(for engine oil pressure)
Male, female both 14 x 1.5
•790-261-1311
(female PT 1/8)
•790-261-1321
(female PT 1/8)
Oil pressure C 3 Adapter
•790-261-1331
(female PT 1/8)
•790-261-1340
(female PT 1/8)
4 799-401-2701 Differential pressure gauge (12 V)
790-261-1360 Adapter
(female PT 1/8)
5 790-261-1370 Nut For 14 x 1.5 blind
07003-31419 Gasket For blind
07040-11409 Plug For 14 x 1.5 blind
1 795-502-1205 Compression gauge
Compression pressure D 0 - 6.9 MPa {0 - 70 kg/cm²}
2 795-502-1700 Adapter
0 - 4.9 MPa
799-201-1504 Blow-by checker
Blow-by pressure E {0 - 500 mmH2O}
795-790-1950 Tool For 102 Engine
Commercially
Valve clearance F Feeler gauge
available
1 799-201-9001 Handy Smoke Checker

Exhaust color G Bosch index: 0 - 9
Commercially
2 Smoke meter
available
Air supply pressure
H 799-201-2201 Pressure gauge —760 to 1,500 mmHg
(boost pressure)
79A-264-0021 0 - 294 N {0 - 30 kg}
Operating effort J Push-pull scale
79A-264-0091 0 - 490 N {0 - 50 kg}
Commercially
Stroke, hydraulic drift K Scale
available
Commercially
Work equipment speed L Stop watch
available
Measuring voltage and
M 79A-264-0211 Tester
resistance values
20-102 PC228US-3
(4)
TESTING AND ADJUSTING TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
Check or measurement item Symbol Part No. Part Name Remarks
1 799-601-8000 T-adapter assembly

2 799-601-7360 Adapter For 5-pin relay
3 799-601-7400 T-adapter assembly
799-601-7500 AMP070 connector adapter assembly For AMP07010
•799-601-7510 For AMP07012
•799-601-7520 For AMP07014
4
•799-601-7530 Adapter For AMP07018
•799-601-7540 For AMP07020
•799-601-7550
Troubleshooting of wiring
N 799-601-9320 T-adapter assembly
harnesses and sensors 5
799-601-9310 Plate for T-adapter assembly
799-601-9200 DT Series connector adapter assembly For DT2
•799-601-9020 For DT3
•799-601-9030 For DT4
•799-601-9040 For DT6
6
•799-601-9050 Adapter For DTM2
•799-601-9010 For DT8B
•799-601-9070 For DT12B
•799-601-9120
Measuring wear of sprocket P 796-427-1190 Wear gauge For cranking
Fuel injection timing,
Q 795-799-1131 Adapter
valve clearance
PC228US-3 20-103
1
TESTING AND ADJUSTING MEASURING ENGINE SPEED
12
MEASURING ENGINE SPEED

When removing or installing the measuring
equipment, be careful not to touch any high
temperature parts.
★ Measure the engine speed under the following

conditions.
• Coolant temperature: Within operating
range
• Hydraulic oil temperature: 45 - 55° C.
1. Open the cover at the top of the engine.
2. Remove cover (1) at the timing gear case end.
3. Install take-off drive A2 to the speed pick-up

port, then connect tachometer kit A1.
When measuring the speed, be careful not to

touch any rotating part or high temperature
part.
4. Start the engine, and measure the engine speed

when it is set to the conditions for measuring.
1) Measuring at low idling and high idling:
Measure the engine speed with the fuel
control dial set to low idling and high idling.
2) Measuring speed at pump relief:
Run the engine at full throttle and measure
the engine speed when the pump is
relieved.
3) Measure the speed at near the rated speed.
Run the engine at full throttle, operate the
arm lever, and measure the speed when the
arm circuit is relieved.
20-104 PC228US-3
(4)
TESTING AND ADJUSTING MEASURING EXHAUST GAS COLOR
12
MEASURING EXHAUST GAS

COLOR
• When measuring in the field when there is no
air or power supply, use smoker checker G1,
when recording official data, use smoke meter
G2.
★ Raise the coolant temperature to the operating
range before measuring.
When removing or installing the measuring
equipment, be careful not to touch any high
temperature parts.
1. Measuring with handy smoke checker G1

1) Fit filter paper in tool G1.
2) Insert the exhaust gas intake port into the
exhaust pipe, accelerate the engine sud-
denly, and at the same time operate the
handle of tool G1 to catch the exhaust gas
on the filter paper.
3) Remove the filter paper and compare it with
the scale provided to judge the condition.
2. Measuring with smoke meter G2
1) Insert probe into the outlet port of exhaust
pipe, then tighten the clip to secure it to the
exhaust pipe.
2) Connect the probe hose, accelerator switch
plug, and air hose to tool G2.
★ The pressure of the air supply should be
less than 1.47 MPa {15 kg/cm²}.
3) Connect the power cord to the AC outlet.
★ When connecting the port, check first
that the power switch of tool G2 is OFF.
4) Loosen the cap nut of the suction pump,
then fit the filter paper.
★ Fit the filter paper securely so that the
exhaust gas does not leak.
5) Turn the power switch of tool G2 ON.
6) Accelerate the engine suddenly, and at the
same time, depress the accelerator pedal of
tool G2 and catch the exhaust gas color on
the filter paper.
7) Lay the filter paper used to catch the
exhaust gas color on top of unused filter
papers (10 sheets or more) inside the filter
paper holder, and read the indicated value.
PC228US-3 20-105
1
TESTING AND ADJUSTING ADJUSTING VALVE CLEARANCE
12
ADJUSTING VALVE CLEAR-

ANCE
1. Remove the engine hood, then remove the
counterweight for maintenance at the engine
end (rear of chassis).
(For details, see TESTING AND ADJUSTING,
Removal and installation of counterweight.)
2. Remove the cylinder head cover.
3. Using the cranking tool Q, rotate the crankshaft
in the normal direction until timing pin (1)
enters the hole in the gear.
★ If timing pin (1) cannot be pushed into the
gear hole at this position, rotate one more
turn. Timing pin (1) can now be pushed
into the hole in the gear.
★ This position is the No. 1 cylinder compres-
sion top dead center.
4. When No. 1 cylinder is at compression top dead
center, adjust the valves marked •. Next, rotate
the crankshaft one turn (360°) in the normal
direction and adjust the valve clearance of the
remaining valves marked O.
★ Make match marks on the crankshaft pulley
or damper, then rotate 360°.
5. To adjust the valve clearance, loosen locknut
(6), then insert feeler gauge F between rocker
lever (3) and valve stem (4), and turn adjust-
ment screw (5) until the clearance is a sliding
fit. Then tighten locknut (6) to hold the adjust-
ment screw in position.
Locknut: 44.1 ± 4.9 Nm {4.5 ± 0.5 kgm}
★ After adjusting No. 1 cylinder at compression

top dead center, it is also possible to turn the
crankshaft 180° each time and adjust the valve
clearance of each cylinder according to the fir-
ing order.
• Firing order: 1 - 5 - 3 - 6 - 2 - 4
★ After tightening the locknut, check the valve
clearance again.
★ There is no timing mark on the front pulley,
so set to compression top dead center as
follows.
i) If the firing order is followed, the next
cylinder after No. 1 cylinder is No. 5 cyl-
inder, so watch the movement of the
No. 2 cylinder valves and rotate in the
normal direction.
ii) When the clearance of both the intake
and exhaust valves of the No. 2 cylinder
is 0, the No. 5 cylinder is at compression
top dead center. (For the No. 3 cylinder,
watch the movement of the No. 4 Cylin-
der valves.
20-106 PC228US-3
1
TESTING AND ADJUSTING MEASURING COMPRESSION AND BLOW-BY PRESSURE
12
MEASURING COMPRESSION AND BLOW-BY

PRESSURE
When measuring the compression pressure.
Be careful not to touch the exhaust manifold
or muffler, or to get your clothes caught in
the fan, fan belt or other rotating parts.
1. Adjust the valve clearance.
For details, see ADJUSTING VALVE CLEAR-
ANCE.
2. Warm up the engine to make the oil tempera-
ture 40 - 60° C.
3. Remove the nozzle holder assembly (1) from
the cylinder to be measured.
4. Install adapter D2 in the mount of the nozzle
holder, then connect pressure gauge D1.
5. Set tachometer A in position.
6. Disconnect the fuel control rod, place the gov-
ernor lever of the injection pump in the NO
INJECTION position, then crank the engine with
the starting motor and measure the compres-
sion pressure.
★ Measure the compression pressure at the point
where the pressure gauge indicator remains
steady.
★ When measuring the compression pressure,
measure the engine speed to confirm that it is
within the specified range.
★ After measuring the compression pressure,
install the nozzle holder assembly (1).
MEASURING BLOW-BY
PRESSURE
★ Measure the blow-by pressure under the fol-
lowing conditions.
range
• Hydraulic oil temperature: 50 - 80° C.
1. Install the nozzle of blow-by checker E to blow-
by hose.
2. Connect the nozzle and gauge with the hose.
3. Set the working mode to the A mode, fit a block
between the sprocket and frame, then run the
engine at high idling and relieve the travel cir-
cuit.
4. Measure the blow-by at the point where the
gauge indicator remains steady.
PC228US-3 20-107
1
TESTING AND ADJUSTING FUEL INJECTION TIMING
12

FUEL INJECTION TIMING
1. Testing
1) Remove the engine hood, then remove the
counterweight for maintenance at the rear
of chassis (engine end).
(For details, see TESTING AND ADJUST-
ING, Removal and installation of counter-
weight.)
2) Using cranking tool Q, rotate the crankshaft

in the normal direction until timing pin (1)
enters the hole in the gear.
3) Remove plug (2), reverse timing pin (3), and
check that pin (3) is meshed with timing pin
pointer (4) at the injection pump side.
2. Adjusting
• If the timing pin does not mesh
i) Remove the fuel injector pump.
For details, see REMOVAL OF FUEL INJEC-
TION PUMP ASSEMBLY.
ii) Rotate the camshaft of the injection pump
and mesh timing pin (3) with timing pin
pointer (4).
iii) Install the fuel injection pump assembly.
For details, see INSTALLATION OF FUEL
INJECTION PUMP ASSEMBLY.
20-108 PC228US-3
1
TESTING AND ADJUSTING MEASURING ENGINE OIL PRESSURE
12
MEASURING ENGINE OIL

PRESSURE
★ Measure the engine oil pressure under the fol-
lowing conditions.
range.
1. Remove oil pressure pick-up plug (2) from the

top of engine oil filter (1), then install the
adapter of oil pressure gauge kit C1 and oil
pressure gauge C2 (1.0 MPa {10 kg/cm²}) (see
TOOLS FOR TROUBLESHOOTING.)
2. Start the engine, and measure the oil pressure

with the engine at low idling and at high idling.
PC228US-3 20-109
1
TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR
12

BELT TENSION FOR AIR
CONDITIONER COMPRESSOR
★ If the deflection of the belt when it is pressed at
a point midway between the drive pulley and
the compressor pulley is not within the stan-
dard value, or when carrying out maintenance
after replacing the belt, adjust the belt tension
as follows.
1. Remove the cover at the top of the compressor,
and loosen bolts (1) and (2).
2. Loosen locknut (3), then adjust the belt tension
with adjustment screw (4).
★ Belt tension a (standard value): 5 - 8 mm
3. When the position of the compressor is
decided, tighten bolts (2) and (1), then tighten
locknut (3) to hold in position.
4. After adjusting the belt tension, repeat the
above procedure to check that the belt tension
is within the standard value.
MEASURING SPEED SENSOR

1. Screw in until the tip of the sensor (1) contacts
gear (2).
2. When gear (2) contacts sensor (1), turn back 1 ±
1/6 turn.
3. Tighten locknut (3).
★ Be particularly careful when securing the sen-
sor wiring to ensure that no excessive force is
brought to bear on the wiring.
★ Be careful not to let the tip of the sensor be
scratched or to let any iron particles stick to the
sensor tip.
20-110 PC228US-3
1
TESTING AND ADJUSTING GOVERNOR MOTOR LEVER STROKE
12

GOVERNOR MOTOR LEVER
STROKE
1. Testing
★ Use the governor motor adjustment mode.
1) Preparatory work
i) Keep [Buzzer cancel switch (12)] +
[Auto-deceleration switch (11)] pressed
for 2.5 seconds.
ii) Press [Buzzer cancel switch (12)] +
[Working mode selector (UP) or
(DOWN) switch] and set so that the
value display on the service meter is
[03].
iii) Press setting switch (10).
iv) Check that "GOV" is displayed on digital
meter display (8) and "G SET" (read as g
set) is displayed on service meter dis-
play (9).
★ Any working mode can be used.
2) In this condition, check that governor lever
(4) is in contact with FULL stopper (5) of the
injection pump.
2. Adjusting
1) Turn the starting switch OFF, then remove
the nut and disconnect joint (1) from gover-
nor lever (4).
2) Repeat the procedure in Step 1-1) above to
set the governor motor adjustment mode.
3) Set the fuel control dial to the MAX posi-
tion.
4) Set the governor lever (4) to a position
where it contacts FULL stopper (5) of the
injection pump, then adjust the length of
spring assembly (2) and rod (3), and con-
nect joint (1) with the nut.
5) From the above position, turn rod (3) back
1.5 turns (retract the rod approx. 3.7 mm),
and secure in position with locknuts (6) and
(7).
Caution
When the spring assembly is removed and the
starting switch is at the OFF position, if the gov-
ernor motor lever is moved suddenly, the gov-
ernor motor will generate electricity, and this
may cause a failure in the governor controller.
★ If there are problems with the adjustment of the
governor motor, it is possible to operate the
engine at full throttle by loosening locknut (8)
and holding the lever in position with bolt (9).
PC228US-3 20-111
1
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT
12
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN

WORK EQUIPMENT, SWING TRAVEL CIRCUIT
1. Measuring
★ Oil temperature when measuring: 45 - 55° C.
Lower the work equipment to the ground and
stop the engine. Loosen the oil filter cap
slowly to release the pressure inside the
hydraulic tank. Then put the safety lock lever
in the LOCK position.
• Remove pressure pick-up plug (1) or (2) (Thread
dia. = 10 mm, Pitch = 1.25 mm) from the circuit
to be measured, then install oil pressure gauge
C1 (58.8 MPa {600 kg/cm²}).
★ Pressure pick-up plugs (1) and (2) are as fol-
lows.
• (1): For front pump
• (2): For rear pump
1) Measuring unload pressure
• Unload pressure when front and rear pump
flows are merged
Measure the oil pressure in A mode with
the engine at full throttle and the control
levers at neutral.
Table 1 Combination of pumps and actuators con-

trolled when flow from front and rear
pumps is divided
Pump Controlled actuator
• Arm cylinder
Front pump * • Swing motor
• R. H. travel motor
• Boom cylinder
Rear pump • Bucket cylinder
• L. H. travel motor
* Be careful that the set pressure of the safety

valve is lower than the set pressure of the main
relief valve.
20-112 PC228US-3
(4)
12
2) Measuring pump relief pressure

i) Low setting
(oil pressure: 34.8 MPa {355 kg/cm²}).
➀ Measure the pressure when each actuator
except the travel actuator is relieved in A
mode with the engine at full throttle.
★ Note that the set pressure of the safety
valve for the swing motor and head end
of the boom is lower than the main
relief low pressure, so the value mea-
sured will be the relief pressure of the
safety valve.
If the swing lock switch is turned ON,
the pressure will rise, so always keep
the lock switch OFF when measuring.
★ When measuring the swing relief pres-
sure, measure with the swing lock
switch turned ON.
ii) High setting
(oil pressure: 38.2 MPa {390 kg/cm²}).
➀ When travel is operated
Measure the oil pressure when the travel is
relieved on each side separately in A mode
with the engine at full throttle.
★ To relieve the travel circuit, put block ➀
under the track shoe grouser, or put
block ➁ between the sprocket and frame
to lock the track.
➁ At power max (oil pressure: 37.3 MPa {380
kg/cm²})
When measuring in A mode with the engine
at full throttle at power max., relieve any of
the boom, arm, or bucket circuits.
PC228US-3 20-113
1
12
2. Adjusting
• (1): For front pump.
• (2): For rear pump.
1) Adjusting high pressure setting
loosen locknut (3), then turn holder (4) to
adjust.
★ Turn the holder to adjust as follows.
To INCREASE pressure, turn COCK-
WISE.
To DECREASE pressure, turn COUNTER-
CLOCKWISE.
★ Amount of adjustment for one turn of
holder: Approx. 12.5 MPa {128 kg/cm²}
Locknut:
53.5 ± 4.9 Nm {5.5 ± 0.5 kgm}
★ When the high pressure setting is
adjusted, the low pressure setting will
also change, so adjust the low pressure
setting also.
2) Adjusting low pressure setting
Loosen Locknut (5), then turn holder (6) to
adjust.
★ Turn the holder to adjust as follows.
WISE.
CLOCKWISE.
★ Amount of adjustment for one turn of
holder: Approx. 12.5 MPa {128 kg/cm²}
Locknut:
53.5 ± 4.9 Nm {5.5 ± 0.5 kgm}
★ Normally, the pressure applied to port
PX1 is 0 MPa {0 kg/cm²}; at the high
pressure setting, it is 2.9 MPa {30 kg/
cm²}.
3) Swing motor safety valve
• Loosen swing motor safety valve (7)
and locknut (8), then turn adjustment
screw (9) to adjust.
★ Turn the adjustment screw to adjust as
follows.
WISE.
CLOCKWISE.
20-114 PC228US-3
1
TESTING AND ADJUSTING PC VALVE OUTPUT PRESSURE
12

PC VALVE OUTPUT PRES-
SURE SERVO PISTON INPUT
PRESSURE)
Measuring
★ Oil temperature when measuring: 45 - 55° C
• Measure the oil pressure when the circuit is
relieved in the pressure rise mode.
1) Remove oil pressure measurement plugs
(1) (front pump discharge pressure), (2)
(rear pump discharge pressure), (3) (front
pump servo piston control pressure), and
(4) (rear pump servo piston control pres-
sure) (10 mm, P=1.25), then install oil pres-
sure gauge C1 (39.2 MPa {400 kg/cm²}).
2) Turn the swing lock switch ON.
★ When the swing lock switch is turned
ON, it sets to the pressure rise mode.
3) Set the working mode to A mode.
4) Run the engine at full throttle, turn the knob
switch ON, and measure the oil pressure
when the arm (IN) circuit is relieved.
★ Check that the servo piston input pres-
sure is 3/5 of the pump discharge pres-
sure.
[Reference]
If there is any abnormality in the LS valve or
servo piston, the servo piston input pressure
will be 0 or almost the dame as the pump dis-
charge pressure.
PC228US-3 20-115
1
TESTING AND ADJUSTING PC VALVE OUTPUT PRESSURE
12
Adjusting
★ If either of the following phenomena occurs
and the PC valves seem to be defective, adjust
PC valves (5) and (6) according to the procedure
shown below.
• As the working load increases, the engine
speed lowers remarkably.
• The engine speed is normal but the work
equipment speed is low.
★ The width across flats of the PC valve locknut is
13 mm and that of the adjustment screw (inside
width) is 4 mm.
Do not turn any other locknut or adjustment
screw since they affect the hydraulic pump per-
formance.
1. Loosen locknut (7).

★ Before loosening the locknut, make a match
mark at the end of the adjustment screw so
that you can see the position of the adjust-
ment screw before adjustment (so that you
can return the adjustment screw to the orig-
inal position after you turn it in the opposite
direction).
2. Turn adjustment screw (8) to the right or left.

★ Turn the adjustment screw in the following
directions.
• If the work equipment speed is low, turn
the adjustment screw to the right (to
increase the pump absorption torque).
• If the engine speed is low, turn the adjust-
ment screw to the left (to decrease the
pump absorption torque).
3. Tighten locknut (7).

3 Locknut: 27.5 - 34.3 Nm {2.8 - 3.5 kgm}
4. After finishing adjustment, check that the PC

valve output pressure (servo piston inlet pres-
sure) is normal according to the measurement
procedure described above.
20-116 PC228US-3
(4)
TESTING AND ADJUSTING LS VALVE OUTPUT AND LS DIFFERENTIAL PRESSURE
12

LS VALVE OUTPUT PRES-
SURE (SERVO PISTON
INPUT PRESSURE) AND LS
DIFFERENTIAL PRESSURE
1. Measuring LS valve output pressure (servo
piston input pressure)
1) Remove oil pressure measurement plugs
(1) (front pump discharge pressure), (2)
(rear pump discharge pressure), (3) (front
pump servo piston control pressure), and
(4) (rear pump servo piston control pres-
sure) (10 mm, P=1.25), then install oil pres-
• Oil pressure when travel is rotating under no
load on one side.
i) Set the working mode to A mode, and turn
the travel speed selector switch to Hi.
ii) Use the work equipment to raise the track
assembly on one side.
iii) Run the engine at half throttle and operate
the travel lever to the end of its stroke and
measure the oil pressure with the track
rotating with no load.
Run the engine at half throttle, operate the
travel lever to the end of its stroke, and
measure the oil pressure when the working
mode and travel speed are switched as
shown in Table 1.
Table 1
Pump Servo inlet
Working Travel
pressure port pressure Remarks
mode lever
MPa {kg/cm²} MPa {kg/cm²}
About
A 3.7 ± 0.7 3.7 ± 0.7
Neutral same
mode {38 ± 7} {38 ± 7}
pressure
About
A 6.9 ± 1.0 3.4 ± 1.0
Half 3/5 of
mode {70 ± 10} {35 ± 10}
pressure
PC228US-3 20-117
1
12
2. Measuring LS differential pressure

1) Measuring with a differential pressure
gauge.
i) Remove oil pressure measurement
plugs (1) (front pump discharge pres-
sure), (2) (rear pump discharge pres-
sure) (10 mm, P=1.25), (5) (front pump
LS pressure), (4) (rear pump LS pres-
sure), then install differential gauge C4.
★ Connect the high-pressure end to
the pump discharge pressure end
and the low-pressure end to the LS
pressure end.
Table 2
Fuel Differential
Working
control Operation Pressure
mode
dial MPa {kg/cm²}
A 2.9 ± 1.0
Full Levers at neutral
mode {30 ± 10}
Travel speed: Hi
A Travel circuit under no 2.2 ± 0.1
Full
mode load {22 ± 1}
(lever operated half way)
2) Measuring with oil pressure gauge
★ The maximum differential pressure is
2.9 ± 1.0 MPa {30 ± 10 kg/cm²}, so mea-
sure with the same gauge.
i) Remove oil pressure measurement
plugs (1) and (2) (thread dia. =10 mm,
pitch = 1.25 mm), and install the plugs
inside hydraulic tester C1.
ii) Install oil pressure gauge C1 (58.8 MPa
{600 kg/cm²}) to the measurement plug
for the pump discharge pressure.
★ Use a gauge with a scale in units of
1.0 MPa {10 kg/cm²}.
(If no 58.8 MPa {600 kg/cm²} pres-
sure gauge is available, a 39.2 MPa
{400 kg/cm²} pressure gauge can be
used).
iii) Set to the conditions in Table 2 and
measure the pump discharge pressure.
★ Stand directly in front of the indica-
tor and be sure to read it correctly.
20-118 PC228US-3
1
12
iv) Remove hoses (5) and (6), then install

oil pressure gauge C1.
v) Set to the conditions in Table 2 and
measure the LS pressure.
★ Stand directly in front of the indica-
tor and be sure to read it correctly.
(Pump discharge pressure) -
(LS pressure) = Differential pressure
3. Adjusting LS pressure
When the differential pressure is measured
under the conditions above, and the results
show that the differential pressure is not within
the standard value, adjust as follows.
1) Loosen locknut (7) and turn screw (8) to
adjust the differential pressure.
• Turn the screw to adjust the differential
pressure as follows.
To INCREASE pressure, turn CLOCKWISE.
CLOCKWISE.
★ Amount of adjustment (LS differential
pressure) for one turn of screw: 1.3
MPa {13.3 kg/cm²}
2) After adjusting, tighten locknut (7)
Locknut: 49 - 64 Nm {5 - 7 kgm}
Note: Always measure the differential pres-
sure while adjusting.
PC228US-3 20-119
1
TESTING AND ADJUSTING CONTROL CIRCUIT OIL PRESSURE
12

CONTROL CIRCUIT OIL
PRESSURE
Measuring
★ Oil temperature when measuring 45 - 55° C
stop the engine. Loosen the oil filler cap
slowly to release the pressure inside the
hydraulic tank. Then set the safety lock lever
in the LOCK position.
1) Remove circuit pressure measurement plug

(1) and install oil pressure gauge C1 (5.8
MPa {60 kg/cm²}).
2) Start the engine and measure with the

engine at full throttle.
20-120 PC228US-3
1
TESTING AND ADJUSTING MEASURING SOLENOID VALVE OUTPUT PRESSURE
12
MEASURING SOLENOID
VALVE OUTPUT PRESSURE
Measuring
★ Oil temperature when measuring: 45 - 55° C.
1) Measuring output pressure of PC-EPC sole-
noid valve (PC mode switching pressure).
i) Disconnect plug (1) of the PC-EPC sole-
noid valve output (for PC mode switch-
ing pressure detection) at the top of the
pump.
ii) Use adapter C3 to install oil pressure
gauge C1 (5.9 MPa {60 kg/cm²}).
iii) Measure the output pressure under the
conditions in Table 1.
Table 1
Output pressure
Conditions
(MPa {kg/cm²})
Engine at low
All control 2.94 {30}
idling
levers
at NEUTRAL Engine at
0 (0)
high idling
2) Measuring output pressure of LS-EPC sole-

noid valve (LS set switching pressure)
i) Disconnect plug (2) of the LS-EPC sole-
noid valve output (LS set switching
pressure detection), then use adapter
C3 in the oil pressure gauge kit to install
oil pressure gauge C1 (5.9 MPa {60 kg/
cm²}).
ii) Run the engine at full throttle and mea-
sure the output pressure in travel mode
as shown in Table 2.
Table 2
Output pressure
Travel mode
(MPa {kg/cm²})
Lo 2.9 {30}
Hi 0
PC228US-3 20-121
1
12
3) Measuring output pressure of ON-OFF sole- Output pressure of pump merge/divider solenoid valve
noid valve
i) Open the cover at the front right of the
chassis.
ii) Disconnect outlet hose (3) of the sole-
noid valve, then use adapter C3 in the
oil pressure gauge kit to install oil pres-
iii) Measure the solenoid valve output
pressure under the conditions in Table
3.
20-122 PC228US-3
1
12
Table 3
Operating Condition of Oil pressure
Solenoid Measurement conditions Remarks
condition solenoid (MPa {kg/cm²})
Swing or work equipment digging Min. 2.7
Brake canceled ON
Swing lever operated {Min. 28}
1 holding Swing control lever at neutral (5 sec.
brake after returning to neutral) or work Brake actuated OFF 0
equipment control lever at HOLD
• Fuel control dial at 1500 rpm or
Motor
above
Min. 2.7 swash plate
• Travel speed selector switch at Hi, Travel speed Hi ON
{Min. 28} angle at
travel switch ON, and travel at high
minimum
Travel speed
2 speed Travel speed selector switch at Lo
selector • Travel speed selector switch at Hi Motor
and travel switch OFF swash plate
Travel speed Lo OFF 0
• At arm crane angle at
• Fuel control dial at less than 1500 maximum
rpm
• Independent operation of travel
• Compound operation with travel,
higher pump discharge pressure of
Front and rear Min. 2.7
Pump F or R at <19.6 MPa {200 kg/cm²} ON LS merge/
pump flow divided {Min. 28}
merge/ and steering signal OFF divider valve
3
divider • At arm crane actuated at
valve • B mode and service switch ON same time
Front and rear
Except above pump flow OFF 0
merged
Swing switch ON, A mode, power
max. switch ON (pressed)(8 sec after
Min. 2.7
2-stage being turned ON), travel control lever Pressure rise ON
4 {Min. 28}
relief operated (move slightly), or boom
LOWER operated (move slightly)
All levers at neutral OFF
• Travel steering signal ON
• Travel operated independently,
Travel Cut ON 0
higher pump discharge pressure of
5 junction
F or R at >24.52 MPa {250 kg/cm²}
valve
Min. 2.7
Except above Interconnected OFF
{Min.28}
Min. 2.7
PPC basic Safety lock lever: FREE ON
{Min. 28}
6 pressure
lock PPC basic
Safety lock lever: LOCK OFF 0
pressure locked
Note 1: Operation of solenoid valve

ON: Energized (oil pressure generated)
OFF: De-energized (oil pressure: 0)
Note 2: The measurement conditions in the table are typical conditions for measuring the output pressure.
The solenoid valve may also be actuated (ON/OFF) under conditions other than the measurement
conditions given in the table.
When operating the levers, operate only
slightly. Do not make the machine move.
PC228US-3 20-123
1
TESTING AND ADJUSTING MEASURING PPC VALVE OUTPUT PRESSURE
12
MEASURING PPC VALVE

OUTPUT PRESSURE
(STD)
1. Measuring PPC valve output pressure

1) Disconnect hose (1) of the circuit to be mea-
sured.
2) Install adapter C3 between hose (1) and
elbow (2).
3) Install oil pressure gauge C1 (5.9 MPa {60
kg/cm²}) to adapter C3.
4) Run the engine at full throttle, operate the
control lever of the circuit to be measured,
and measure the oil pressure.
If the output at the control valve end is low,
measure the input pressure of the PPC
valve.
If it is normal, there is defective actuation of
the PPC valve.
★ Measurement positions
a. Bucket CURL
b. Bucket DUMP
c. L.H. travel FORWARD
d. L.H. travel REVERSE
e. Boom LOWER
f. Boom RAISE
g. Left swing
h. Right swing
i. R.H. travel FORWARD
j. R.H. travel REVERSE
k. Arm IN
l. Arm OUT
20-124 PC228US-3
1
TESTING AND ADJUSTING ADJUSTING WORK EQUIPMENT • SWING PPC VALVE
12
ADJUSTING WORK EQUIP-

MENT • SWING PPC VALVE
★ If there is excessive play in the work equipment
or swing lever, adjust as follows.
stop the engine. Loosen the oil filler cap slowly
to release the pressure inside the hydraulic
tank. Then set the safety lock lever to the LOCK
position.
1. Remove the PPC valve

2. Remove boot (1).
3. Loosen locknut (2), then screw disc (3) until it
contacts the 4 heads of piston (4).
★ When doing this, do not move the piston.
4. Screw disc (3) in position, then tighten locknut
(2) to the specified torque.
Locknut: 98 - 127 Nm {10 - 13 kgm}
5. Install boot (1).
★ With the above adjustment, the clearance
between disc (3) and piston (4) becomes 0.
PC228US-3 20-125
1
TESTING AND ADJUSTING TESTING TRAVEL DEVIATION
12
TESTING TRAVEL DEVIATION

★ When traveling on level ground.
1. Set the machine in the travel posture.
★ For the travel posture, extend the bucket
and arm cylinder rods fully, and hold the
boom angle at 45°.
2. Travel for 10 m, then measure the deviation A
when traveling for the next 20 m.
★ Set to A mode and measure with the engine
at high idling.
★ Install the hydraulic pressure gauge and
measure the pump discharge pressure at
the same time.
20-126 PC228US-3
1
TESTING AND ADJUSTING TESTING LOCATIONS CAUSING HYDRAULIC DRIFT
12
TESTING LOCATIONS CAUS-

ING HYDRAULIC DRIFT
OF WORK EQUIPMENT
1. Work equipment cylinders
★ If the hydraulic drift of the work equipment is
not within the standard value, measure the
leakage inside the cylinders as follows to deter-
mine if the cause of the hydraulic drift is in the
cylinder or in the control valve.
• If the leakage is within the standard value,
the cause is the control valve.
• If the leakage is not within the standard
value, the cause is the cylinder.
1) Fully extend the rod of the cylinder to be
measured, then stop the engine.
2) Disconnect piping (1) - (3) at the head end,
then block the piping at the chassis end with
blind plugs.
• (1): For boom cylinder
• (2): For arm cylinder
• (3): For bucket cylinder
Be careful not to disconnect the piping at
the bottom end.
3) Start the engine, run at full throttle, and
apply relief pressure to the bottom end of
the cylinder.
4) Continue this condition for 30 seconds, then
measure the oil leakage for the next one
minute.
1. Checking PPC valve

If there is any difference in the hydraulic drift with
the safety lock at FREE and LOCK (with the engine
running), the PPC valve is defective.
PC228US-3 20-127
1
TESTING AND ADJUSTING MEASURING SWING, TRAVEL MOTOR OIL LEAKAGE
12
MEASURING SWING, TRAVEL

MOTOR OIL LEAKAGE
1. Swing motor
1) Disconnect drain hose (1) from the swing
motor and fit a blind plug at the hydraulic
tank end.
★ Disconnect travel motor drain hose (2)
also and fit a blind plug.
2) Set the swing lock switch to LOCK.
3) Start the engine and operate the swing
relief with the engine at high idling.
minute.
★ After measuring, swing 180° and mea-
sure again.
2. Travel motor
1) Disconnect drain hose (2) from the travel
motor, then fit a blind plug at the hose end.
2) Fit block ➀ under the track shoe grouser, or
fit block ➁ between the sprocket and frame
to lock the track.
3) Start the engine and operate the travel relief
with the engine at high idling.
When measuring the oil leakage from the
travel motor, mistaken operation of the
control lever may lead to a serious acci-
dent, so always use signals and check
when carrying out this operation.
minute.
★ When measuring, move the motor slightly
(to change the position between the valve
plate and cylinder, and piston and cylinder),
and measure several times.
RELEASING REMAINING
PRESSURE IN HYDRAULIC
CIRCUIT ★ When the levers are operated 2 - 3 times,
the pressure stored in the accumulator is
removed.
★ If the piping between the hydraulic cylinder and
the control valve is disconnected, release the 3. Start the engine, run at low idling for approx. 5
remaining pressure from the circuit as follows. minutes, then stop the engine and operate the
The travel circuit is an open circuit, so there is control levers.
no remaining pressure. It is enough to remove ★ Repeat the operation 2 - 3 times to release
the oil filler cap. all the remaining pressure.
1. Loosen the oil filler cap slowly to release the
pressure inside the tank.
2. Operate the control levers.
20-128 PC228US-3
1
TESTING AND ADJUSTING TESTING CLEARANCE OF SWING CIRCLE BEARING
12
TESTING CLEARANCE OF
SWING CIRCLE BEARING
Method of testing clearance os swing circle
bearing when mounted on machine
1. Fix a magnet-type dial gauge to the outer circle
(or inner circle) of the swing circle, and put the
tip of the probe in contact with the inner circle
(or outer circle).
Set the dial gauge at the front or rear.
2. Extend the work equipment to the maximum

reach, and set the tip of the bucket to the same
height as the bottom of the revolving frame.
When this is done, the upper structure will tilt
forward, so the front will go down and the rear
will rise.
3. Set the dial gauge to the zero point.
4. Set the arm more or less at right angles to the

ground surface, then lower the boom until the
front of the machine comes off the ground.
When this is done, the upper structure will tilt
back, so the front will rise and the rear will go
down.
5. Read the value on the dial gauge at this point.
The value on the dial gauge is the clearance of
the swing circle bearing.
When carrying out the measurement, do not

put your hands of feet under the undercarriage.
6. Return to the condition in Step 2, and check that

the dial gauge has returned to the zero point. If
it has not returned to the zero point, repeat Step
2 to 5.
PC228US-3 20-129
1
TESTING AND ADJUSTING TESTING WEAR OF SPROCKET
12
TESTING WEAR OF
SPROCKET
1. Remove the track shoe assembly.

★ For details, see TESTING AND ADJUST-
ING, REMOVAL OF STEEL SHOE ASSEM-
BLY or REMOVAL OF ROAD LINER
(RUBBER PAD) ASSEMBLY.
2. Align wear gauge P with the sprocket.
★ Align the benchmark line, then align the
sprocket wave pattern and wear gauge
wave pattern.
3. Judge the wear of the sprocket.
★ If the sprocket wave pattern is above the
wear limit line, it is possible to use the
sprocket as it is.
★ If the sprocket wave pattern has reached
the wear limit line, replace the sprocket
with a new part.
20-130 PC228US-3
1
TESTING AND ADJUSTING TRACK SHOE TENSION
12

TRACK SHOE TENSION
TESTING
1. Travel the machine forward by the length of
track on ground, keeping the engine at low
idling, and stop the machine slowly.
2. Place straight bar [1] on the track shoe between
the idler and the 1st carrier roller.
+ L beam is recommended for bar [1], because
of its deflection-free nature.
3. Measure max. clearance a between bar [1] and the
track shoe.
• Max. standard clearance a: 10-30mm
ADJUSTING
+ If the track shoe tension is not proper, adjust it
in the following manner.
1. When the tension is too strong.

Discharge grease by loosening valve (1).
Do not loosen valve (1) by more than one
turn, because grease will spurt out due to
its internal high pressure.
2. When the tension is too weak.

Add grease through grease fitting (2).
+ If the normal track shoe tension is not
restored even after greasing, move the
machine slowly back and forth.
PC228US-3 20-131
3
TESTING AND ADJUSTING BLEEDING AIR
12
BLEEDING AIR
Order for operation and procedure for bleeding air
Air bleeding item Air bleeding procedure
1 2 3 4 5 6 7
Between
Bleeding Bleeding
Bleeding Bleeding EPC
Start air from air from Start
air from air from solenoid -
engine swing travel operations
Nature of work pump cylinder control
motor motor
valve
• Replace hydraulic oil
• Clean strainer
O O O O
(Note 1)
O
(Note 1)
O
• Replace return filter element O O
• Replace, repair pump
• Remove suction piping
O O O O
• Replace, repair control valve O O O
• Replace cylinder
• Remove cylinder piping
O O O
• Replace swing motor
• Remove swing motor piping
O O O
• Replace travel motor, swivel
• Remove travel motor, swivel piping
O O O
Note 1: Bleed the air from the swing and travel motors
only when the oil inside the motor case has been
drained.
1. Bleeding air from pump

1) Loosen air bleed plug (1), and check that oil
oozes out from the plug.
2) When the oil oozes out, tighten plug (1).
Plug: 7.8 ~ 9.8 Nm
{0.8 ~ 1.0 kgm}
★ Precautions when starting the engine
After completing the above procedure and
starting the engine, run the engine at low
idling for 10 minutes.
★ If the coolant temperature is low and auto-
matic warming-up is carried out, cancel it
by using the fuel control dial after starting
the engine.
20-132 PC228US-3
1
TESTING AND ADJUSTING BLEEDING AIR
12
2. Bleeding air from hydraulic cylinders

1 Start the engine and run at idling for
approx. 5 minutes.
2 Run the engine at low idling, then raise and
lower boom 4 - 5 times in succession.
★ Operate the piston rod approx. 100 mm
before the end of its stroke. Do not
relieve the circuit under any circum-
stances.
3) Run the engine at full throttle and repeat
Step 2). After that, run the engine at low
idling, and operate the piston rod to the end
of its stroke to relieve the circuit.
4) Repeat Steps 2) and 3) to bleed the air from
the arm and bucket cylinders.
★ When the cylinder has been replaced,
bleed the air before connecting the pis-
ton rod.
Be particularly careful not to operate the
cylinder to the end of its stroke when
the piston rod has been connected to
the LOWER end of the boom cylinder.
3. Bleeding air from swing motor

1) Run the engine at low idling, loosen air
bleed plug, and check that oil oozes out.
4. Bleeding air from travel motor

Run the engine at low idling, loosen air bleed
plug, and when oil flows out, tighten the plug
again.
PC228US-3 20-133
1
TESTING AND ADJUSTING REPLACEMENT OF BOOM ANGLE POTENTIOMETER
12
PROCEDURE FOR REPLACE-

MENT OF BOOM ANGLE
POTENTIOMETER
★ If the boom potentiometer has been replaced or
removed, always carry out compensation for
the boom angle potentiometer. (The engine
throttle, pump controller saves the installation
compensation value in memory.)
★ The potentiometer cannot be replaced as an
individual part. Always replace the whole case
assembly.
However, if it is to be used again, secure lever
(2) to body (3) before removing.
1. Disconnect the connector (CN-A53) and the pin

connecting lever (2) to the work equipment,
then remove potentiometer assembly (1).
★ When the potentiometer assembly has
been removed, do not swing or rotate the
lever unnecessarily.
2. Install potentiometer assembly (1) to the work
equipment.
3. Always carry out compensation for the boom
angle potentiometer.
★ For details, see TROUBLESHOOTING (Fore-
word), Monitor panel display and special
functions.
20-134 PC228US-3
1
TESTING AND ADJUSTING PROCEDURE FOR CHECKING DIODE
12
PROCEDURE FOR CHECK-

ING DIODE
In case of diode only
• Use the following procedure to check the diode
as individual part and the wiring harness
including the diode.
★ There is a mark showing the direction of the
current on the surface of the diode.
1. When using digital tester

1) Switch to the diode range and check the dis-
play value.
★ With a normal tester, the internal bat-
tery voltage is displayed.
2) Put the red (+) end of the test pin in contact
with the anode (P) of the diode, and the
black (-) end in contact with the cathode (N).
★ The value when the tester is in contact In case of diode in wiring harness
indicates the following.
• No change: No continuity
• Changes: There is continuity (normal)
(Note)
• Value is 0 or near 0: Short circuit inside
diode
Note: In the case of silicon diodes, a
value between 450 and 600 is dis-
played.
2. When using analog tester
1) Set to the resistance range, then check the
deflection of the indicator in the following
Steps i) and ii).
i) Put the red (+) end of the test pin in con-
tact with the anode (P) of the diode, and
the black (-) end in contact with the cath-
ode (N).
II) Put the black (-) end of the test pin in
contact with the anode (P) of the diode,
and the red (+) end in contact with the
cathode (N).
★ Make judgement as follows.
• If the indicator does not deflect in Step
i), but it deflects in Step ii) → Normal
(note that the amount of the deflection
(resistance value) differs according to
the type of tester and the selection of
the measurement range.)
• If the indicator deflects in both Step i)
and Step ii)
→ defective (short circuit)
• If the indicator does not deflect in
either Step i) or Step ii)
→ defective (disconnection)
PC228US-3 20-135
1
12
TROUBLESHOOTING
Points to remember when troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-202
Sequence of events in troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-203
Points to remember when carrying out maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-204
Checks before troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-212
Connector types and mounting locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-213
Connection table for connector pin numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-220
Explanation of control mechanism of electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-235
Display method and special functions of monitor panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-236
Method of using judgement table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-252
Method of using troubleshooting charts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-254
Details of troubleshooting and troubleshooting procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-256
Troubleshooting of communications abnormality (N mode) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-301
Troubleshooting of engine throttle and pump controller (governor control system) (E mode). 20-401
Troubleshooting of engine throttle and pump controller (pump control system) (C mode) . . . 20-501
Troubleshooting of engine throttle and pump controller (input signal system) (F mode) . . . . . 20-601
Troubleshooting of hydraulic and mechanical system (H mode) . . . . . . . . . . . . . . . . . . . . . . . . . 20-701
Troubleshooting of machine monitor system (M mode) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-801
PC228US-3 20-201
1
TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING
12
POINTS TO REMEMBER WHEN TROUBLESHOOTING

Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are securely fitted.
When carrying out the operation with two or more workers, keep strictly to the agreed signals, and do not allow
any unauthorized person to come near.
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.
Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
When disconnecting wiring, always disconnect the negative (-) terminal of the battery first.
When removing the plug or cap from a location which is under pressure from oil, water, or air, always release
the internal pressure first. When installing measuring equipment, be sure to connect 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 understand 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 symptoms.
1. When carrying out troubleshooting, do not 2) Check for any external leakage of oil from
hurry to disassemble the components. the piping or hydraulic equipment.
If components are disassembled immedi- 3) Check the travel of the control levers.
ately any failure occurs: 4) Check the stroke of the control valve
• Parts that have no connection with the spool.
failure or other unnecessary parts will 5) Other maintenance items can be checked
be disassembled. externally, so check any item that is con-
• It will become impossible to find the sidered to be necessary.
cause of the failure. 4. Confirming failure
• It will also cause a waste of man-hours, Confirm the extent of the failure yourself, and
parts, or oil or grease, and at the same judge whether to handle it as a real failure or
time, will also lose the confidence of as a problem with the method of operation,
the user or operator. etc.
For this reason, when carrying out ★ When operating the machine to reenact
troubleshooting, it is necessary carry the troubleshooting symptoms, do not
out thorough prior investigation and to carry out any investigation or measure-
carry out troubleshooting in accor- ment that may make the problem worse.
dance with the fixed procedure.
5. Troubleshooting
2. Points to ask user or operator Use the results of the investigation and
1) Have any other problems occurred inspection in items 2 - 4 to narrow down the
apart from the problem that had been causes of failure, then use the troubleshoot-
reported? ing flowchart to locate the position of the fail-
2) Was there anything strange about the ure exactly.
machine before the failure occurred? ★ The basic procedure for troubleshooting
3) Did the failure occur suddenly, or were is as follows.
there problems with the machine con- 1) Start from the simple points.
dition before this? 2) Start from the most likely points.
4) Under what conditions did the failure 3) Investigate other related parts or
occur? information.
5) Had any repairs been carried out 6. Measures to remove root cause of failure
before the failure? Even if the failure is repaired, if the root
When were these repairs carried out? cause of the failure is not repaired, the same
6) Has the same kind of failure occurred failure will occur again.
before? To prevent this, always investigate why the
3. Check before troubleshooting problem occurred. Then , remove the root
1) Check the oil level causer.
20-202 PC228US-3
1
TROUBLESHOOTING SEQUENCE OF EVENTS IN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
PC228US-3 20-203
1
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
12
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

To maintain the performance of the machine over a long period, and to prevent failures or other troubles
before they occur, correct operation, maintenance and inspection, troubleshooting, and repairs must be
carried out. This section deals particularly with correct repair procedures for mechatronics and is aimed at
improving the quality of repairs. For this purpose, it gives sections on "Handling electric equipment" and
"Handling hydraulic equipment" (particularly hydraulic oil).
1. PRECAUTIONS WHEN HANDLING
ELECTRIC EQUIPMENT
1) Handling wiring harnesses and con-
nectors
Wiring harnesses consist of wiring con-
necting one component to another compo-
nent, connectors used for connecting and
disconnecting one wire from another wire,
and protector or tubes used for protecting
the wiring.
Compared with other electrical compo-
nents fitted in boxes or cases, wiring har-
nesses are more likely to be affected by the
direct effects of rain, water, heat, or vibra-
tion. 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.
Main failures occurring in wiring har-

ness
➀ Defective contact of connectors (defec-
tive contact between male and female)
Problems with defective contact are
likely to occur because the male con-
nector is not properly inserted 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 oxidation
of the contact surfaces.
➁ Defective crimping or soldering of con-

nectors
The pins of the male and female con-
nectors are in contact at the crimped
terminal or soldered portion, but there
is excessive force brought to bear on
the wiring, the plating at the joint will
peel and cause improper connection or
breakage.
20-204 PC228US-3
1
12
➂ Disconnections in wiring
If the wiring is held and the connectors are
pulled apart, or components are lifted with a
crane with the wiring still connected, or a heavy
object hits the wiring, the crimping of the con-
nector may separate, or the soldering may be
damaged, or the wiring may be broken.
➃ High pressure water entering a 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.
As already said, 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.
➄ 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
between 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 or stuck to the connector,
wipe it off with a dry cloth or blow dry with air
and spray it with a contact restorer.
★ When wiping the mating portion of the con-
nector, be careful not to use excessive force
or deform the pins.
★ 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-3 20-205
1
12
1) Removing, installing, and drying connec-

tors and wiring harnesses
• Disconnecting connectors
➀ Hold the connectors when disconnecting.
When disconnecting the connectors, hold
the connectors and not the wires. For con-
nectors held by a screw, loosen the screw
fully, then hold the male and female con-
nectors 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.
★ Never pull with one hand
➁ When removing from clips

When removing a connector from a clip,
pull the connector in a parallel direction to
the clip.
★ If the connector is twisted up and down
or to the left and right, the housing may
break.
➂ Action to take after removing connectors

After removing any connector, cover it with
a vinyl bag to prevent any dust, dirt, oil, or
water from getting in the connector portion.
★ If the machine is left disassembled for a
long time, it is particularly easy for
improper contact to occur, so always
cover the connector.
20-206 PC228US-3
1
12
• Connecting connectors
➀ Check the connector visually.
1) Check that there is no oil, dirt, or water
stuck to the connector pins (mating por-
tion).
2) Check that there is no deformation,
defective contact, corrosion, or damage
to the connector pins.
3) Check that there is no damage or break-
age to the outside of the connector.
★ If there is any oil, water, or dirt stuck to
the connector, wipe it off with a dry
cloth. If any water has gotten inside the
connector, warm the inside of the wir-
ing with a dryer, but be careful not to
make it too hot as this will cause short
circuits.
★ If there is any damage or breakage,
replace the connector.
➁ Fix the connector securely.

Align the position of the connector cor-
rectly, then insert it securely.
For connectors with a lock stopper, push in
the connector until the stopper clicks into
position.
➂ Correct any protrusion of the boot and any
misalignment of the wiring harness.
For connectors fitted with boots, correct any
protrusion or the boot. In addition, if the
wiring harness is misaligned, or the clamp
is out of position, adjust it to its correct
position.
★ If the connector cannot be corrected
easily, remove the clamp and adjust the
position.
➃ If the connector clamp has been removed,
be sure to return it to its original position.
Check also that there are no loose clamps.
PC228US-3 20-207
1
12
• Drying wring 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 pressure
water or steam directly on the wiring harness.
If water gets directly on the connector, do as fol-

lows.
➀ Disconnect the connector and wipe off the
water with a dry cloth.
★ If the connector is blown dry with com-
pressed air, there is the risk that oil in
the air may cause defective contact, so
remove all oil and water from the com-
pressed air before blowing with air.
➁ Dry the inside of the connector with a dryer.

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

After drying, leave the wiring harness dis-
connected and carry out a continuity test to
check for any short circuits between pins
caused by water.
★ After completely drying the connector,
blow it with contact restorer and reas-
semble.
20-208 PC228US-3
1
12
3) Handling control box

➀ The control box contains a microcomputer
and electronic control circuits. These con-
trol all of the electronic circuits on the
machine, so be extremely careful when
handling the control box.
➁ Do not open the cover of the control box
unless necessary.
➂ Do not place objects on top of the control

box.
➃ Cover the control connectors with tape or a
vinyl bag.
Never touch the connector contacts with
your hand.
➄ During rainy weather, do not leave the con-
trol box in a place where it is exposed to
rain.
➅ Do not place the control box on oil, water,

or soil, or in any hot place, even for a short
time.
(Place it on a suitable dry stand).
➆ Precautions when carrying out arc welding
When carrying out arc welding on the body,
disconnect all wiring harness connectors
connected to the control box. Fit an arc
welding ground close to the welding point.
2. Points to remember when troubleshooting electric circuits

1) Always turn power OFF before disconnecting or connecting connectors.
2) Before carrying out troubleshooting, check that all the related connectors are properly inserted.
★ Disconnect and connect the related connectors several times to check.
3) Always connect any disconnected connectors before going on to the next step.
★ If the power is turned ON with the connectors still disconnected, unnecessary abnormality dis-
plays will be generated.
4) When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity, or cur-
rent), move the related wiring and connectors several times and check that there is no change in the
reading of the tester.
★ If there is any change, there is probably defective contact in that circuit.
PC228US-3 20-209
1
12
3. POINTS TO REMEMBER WHEN HANDLING

HYDRAULIC EQUIPMENT
With the increase in pressure and precision of

hydraulic equipment, the most common cause of
failure is dirt (foreign material) in the hydraulic cir-
cuit. When adding hydraulic oil, or when disassem-
bling or assembling hydraulic equipment, it is
necessary to be particularly careful.
1) Be careful of the operating environment.

Avoid adding hydraulic oil, replacing filters, or
repairing the machine in rain or high winds, or
places where there is a lot of dust.
2) Disassembly and maintenance work in the

field
If disassembly or maintenance work is carried
out on hydraulic equipment in the field, there is
danger of dust entering the equipment. It is also
difficult to confirm the performance after
repairs, so it is desirable to use unit exchange.
Disassembly and maintenance of hydraulic
equipment should be carried out in a specially
prepared dust proof workshop, and the perfor-
mance should be confirmed 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 enter-
ing or of the surrounding area being made dirty
by leaking oil so never do this.
Do not simply drain oil out onto the ground,
collect it and ask the customer to dispose of it,
or take it back with you for disposal.
4) Do not let any dirt or dust get in 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 clean-
ing device is used, it is possible to filter out the
dirt that has collected during storage, so this is
an even effective method.
20-210 PC228US-3
1
12
5) Change hydraulic oil when the tempera-

ture is high.
When the 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. (Do not drain the oil from the
hydraulic tank. Drain the oil from the filter and
from the drain plug 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 carried out twice: primary
flushing is carried out with flushing oil, and sec-
ondary flushing is carried out with the specified
hydraulic oil.
7) Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the
machine, carry out oil cleaning to remove the
sludge or contaminants in the hydraulic oil cit-
cuit.
The oil cleaning equipment is used to remove
the ultra-fine (about 3 µ) particles that the filter
built into hydraulic equipment cannot remove,
so it is an extremely effective device.
PC228US-3 20-211
1
TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING
12
CHECKS BEFORE TROUBLESHOOTING
Item Judgement Action

value
1. Check fuel level, type of fuel — Add fuel
2. Check for impurities in fuel — Clean, drain

Lubricating oil, cooling water
3. Check hydraulic oil level — Add oil
4. Check hydraulic strainer — Clean, drain
5. Check swing machinery oil level — Add oil
6. Check engine oil level — Add oil
7. Check coolant level — Add water
8. Check dust indicator for clogging — Clean or replace
9. Check hydraulic filter — Replace
10. Check final drive oil level — Add oil
11. Check for looseness, corrosion of battery terminal, wiring — Tighten or replace
equipment
Electrical
12. Check for looseness, corrosion of alternator terminal, wiring — Tighten or replace
13. Check for looseness, corrosion of starter motor terminal, wiring — Repair or replace
14. Check operation of instruments — Repair or replace
15. Check for abnormal noise, smell — Repair

mechanical
equipment
Hydraulic,
16. Check for oil leakage — Repair

17. Carry out air bleeding — Bleed air
18. Check battery voltage (engine stopped) 24 - 26 V Replace

Electrics, electrical equipment
19. Check battery electrolyte level — Add or replace
20. Check for discolored, burnt, or exposed wiring — Replace
21. Check for missing wiring clamps or hanging wiring — Repair
22. Check for water leaking on wiring (be particularly careful and — Disconnect
attentive to water leaking on connectors or terminals. connector and dry
23. Check for brown, corroded fuses — Replace

After running for
24. Check alternator voltage (engine running at 1/2 throttle or above) several minutes: Replace
27.5 - 29.5 V
25. Check the sound of the battery relay actuator (when starting — —
switch is turned ON, OFF)
20-212 PC228US-3
1
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS
12
CONNECTOR TYPES AND MOUNTING LOCATIONS

★ The Address column in the table shows the address in the connector arrangement drawing (3-dimen-
sional drawing).
Con- No. Con- No.
nector Type of Mounting location Address nector Type of Mounting location Address
No. pins No. pins
A01 X 4 Intermediate connector C2 A43 M 1 Working lamp (boom) E9
(to chassis wiring harness)
A02 X 4 Intermediate connector B2 A50 KES0 2 Washer motor E5
A03 SWP 16 Intermediate connector B2 A51 DT1 3 F pump pressure sensor E2
A04 SWP 12 Intermediate connector C1 A52 DT1 3 R pump pressure sensor F9
A05 SWP 14 Intermediate connector B1 A53 X 3 Boom angle potentiometer G9
A06 SWP 14 Intermediate connector B2 A60 X 1 Fuel level sensor G9
A07 SWP 16 Intermediate connector B1 A90 Yazaki 2 Diode for window washer E4
A08 SWP 12 Intermediate connector C1 C01 MIC 13 Engine throttle. pump controller X6
A10 Terminal 1 Revolving frame ground C2 C02 MIC 21 Engine throttle. pump controller X7
A11 Terminal 1 Revolving frame ground C2 C03 AMP040 20 Engine throttle. pump controller X6
A12 Terminal 1 Revolving frame ground C2 CO4 AMP040 16 Engine throttle. pump controller X6
A13 Terminal 1 Revolving frame ground C2 C05 AMP040 12 Engine throttle. pump controller X6
A14 Terminal 1 Revolving frame ground D2 C06 MIC 17 Engine throttle. pump controller X7
A15 Terminal 1 Revolving frame ground D1 D01 Yazaki 2 Diode (for electrical intake air W2
heater relay 1)
A16 Terminal 1 Revolving frame ground D2 Diode (for
D03 Yazaki 4 2-stage relief solenoid, X1
A20 Terminal 1 Battery relay terminal E C9 swing holding brake solenoid,
travel speed selector solenoid)
A21 Terminal 1 Battery relay terminal BR C8 Diode (for pump
D04 Yazaki 4 merge/divider flow solenoid, X2
A22 Terminal 1 Battery relay terminal M C8 PPC safety lock solenoid,
travel junction solenoid)
A23 Terminal 1 Battery relay terminal B C8 D05 KES1 2 Diode (for emergency swing V1
holding brake)
A24 Terminal 1 Electrical intake air heater A9 D07 Yazaki 3 Diode (for battery relay) V1
A25 Terminal 1 Electrical intake air heater B9 D08 Yazaki 2 Diode (for electrical intake air W1
heater relay 2)
A26 Terminal 1 Electrical intake air heater A8 E01 Terminal 1 Electrical intake air heater L7
A27 X 2 Starting motor safety relay B9 E02 Terminal 1 Engine oil pressure switch L6
A28 Terminal 1 Starting motor safety relay A7 E03 X 1 Engine oil level sensor L5
terminal B
A29 Terminal 1 Starting motor safety relay B7 E04 DT1 2 Engine speed sensor L7
terminal C
A30 Yazaki 2 Air conditioner FRESH sensor K1 E05 X 2 Engine water temperature K8
(opt) sensor
A31 DT1 2 Air cleaner clogging sensor K2 E06 X 1 Air conditioner compressor K8
electromagnetic switch
A34 L 2 Fusible link L5 E06 M 3 Fuel control dial P7
A35 L 2 Fusible link L5 E07 Terminal 1 Starting motor J9
A40 — 1 Horn (low tone) G1 E08 X 1 Intermediate connector L5
A41 — 1 Horn (high tone) G1 E10 DT1 3 Governor potentiometer L6
A42 M 1 Intermediate connector H1 E11 DT1 3 Governor motor L6

[for working lamp (boom)]
A43 X 2 Travel alarm (opt) I1 E12 X 2 Alternator L6
PC228US-3 20-213
1
Con- No. Con- No.

No. pins No. pins
F02 Yazaki 2 Rotating lamp (opt) J9 M41 Yazaki 2 Lamp (opt) I1
FB1 — — Fuse box X4 M45 DT1 12 Network bus V2
H8 M 8 Intermediate connector X3 M71 Yazaki 2 Room light L8

(to cab wiring harness)
H9 S 8 Intermediate connector W2 M73 KES0 2 Speaker (left) L7
H10 S 16 Intermediate connector T1 M80 — 20 Air conditioner panel X4
H11 S 16 Intermediate connector T1 M81 — 16 Air conditioner panel X4
H12 S 12 Intermediate connector T1 M83 Sumitomo 3 Intake duct (air conditioner) X4
H13 M 4 Intermediate connector (to arm X8 M84 SWP 14 Intermediate connector U9
crane wiring harness inside cab) (air conditioner unit)
H14 SWP 6 Arm crane monitor (opt) M7 M85 SWP 16 Intermediate connector T9
(air conditioner unit)
H15 AMP090 20 Intermediate connector (to P6 M87 S 12 Intermediate connector S1
right console upper) (air conditioner unit)
H16 M 2 Arm crane buzzer (opt) M4 M88 Yazaki 9 Air conditioner foot vent servo O2
Intermediate connector
H17 SWP 12(emergency work equipment X3 P01 AMP070 12 Monitor panel M6
actuation switch)
J01 Sumitomo 20 Joint connector (orange) P1 P02 AMP040 20 Monitor panel M5
J02 Sumitomo 20 Joint connector (yellow) V1 P03 M 2 Buzzer cancel switch R9
J03 Sumitomo 20 Joint connector (purple) U1 P05 M 2 Rotating lamp switch (opt) X5
J04 Sumitomo 20 Joint connector (green) U1 P15 AMP040 2 Solar radiation sensor (opt) M6
J05 Sumitomo 20 Joint connector (brown) Q1 R10 Shinagawa 5 Light relay (opt) P7
J06 Sumitomo 20 Joint connector (orange) O1 R11 Shinagawa 5 Starting motor cut (PPC lock) P8
relay
J07 Sumitomo 20 Joint connector (orange) Q1 S01 X 2 Bucket CURL PPC pressure E5
switch
K19 M 2 Pump resistor V9 S02 X 2 Boom LOWER PPC pressure E5
switch
K20 M 2 Boom RAISE resistor V9 S03 X 2 Left swing PPC pressure switch E5
M07 M 2 Light switch R8 S04 X 2 Arm IN PPC pressure switch E5
M13 KES0 2 Speaker (right) J9 S05 X 2 Bucket DUMP PPC E5

pressure switch
M16 — 1 Large capacity horn G1 S06 X 2 Boom RAISE PPC E5
(low tone) (opt) pressure switch
M17 — 1 Large capacity horn G1 S07 X 2 Right swing PPC E4
(high tone) (opt) pressure switch
M19 Yazaki 2 Cigarette lighter M3 S08 X 2 Arm OUT PPC E4
pressure switch
M21 PA 9 Radio X5 S09 X 2 Intermediate connector B7
(for S10, S11)
M22 AMP090 2 Horn switch P6 S10 X 2 Front PPC pressure switch (opt) B7
M23 Yazaki 2 Power max. switch U1 S11 X 2 Rear PPC pressure switch (opt) C7
M26 S 12 Air conditioner unit T9 S14 M 3 PPC oil pressure lock switch V2
M31 M 2 Option power source W2 S21 Terminal 6 Emergency pump drive switch T9
M32 M 2 Option power source W2 S22 Terminal 6 Swing holding brake cancel S9
switch
M40 Yazaki 2 Lamp (std) H9 S23 Terminal 6 Emergency work equipment S9
actuation switch
20-214 PC228US-3
1
12
Con- No. Con- No.

No. pins No. pins
S25 AMP090 16 Intermediate connector (to right S9 Y25 X 2 Boom LOWER throttle H1
console emergency switch) EPC valve
S30 X 2 Travel pressure switch P1
S31 X 2 Travel steering pressure switch O1
T05 Terminal 1 Ground (floor frame) X3
T06A M 1 Intermediate connector V2

(to floor ground)
V01 X 2 PPC oil pressure lock solenoid E8
V02 X 2 2-stage relief solenoid D8
V03 X 2 Travel Hi/Lo selector solenoid D8
V04 X 2 Swing holding brake solenoid D8
V05 X 2 Travel junction solenoid C7
V06 X 2 Pump merge/divider flow solenoid C7
V07 X 2 Attachment EPC valve (opt) E1
V09 X 2 Boom RAISE EPC valve F1
V21 X 2 PC-EPC valve I9
V22 X 2 LS-EPC valve H9
W03 X 1(X2) Rear limit switch L8
W04 M 6 Wiper motor M4
X05 M 4 Swing lock switch R9
Y01 MIC 21 Arm crane controller (opt) W9
Y02 AMP040 20 Arm crane controller (opt) W9
Y03 AMP040 16 Arm crane controller (opt) X8
Y07 SWP 8 Intermediate connector I9
Y08 X 2 Bucket DUMP solenoid G1

for arm crane
Y09 X 3 Boom cylinder bottom H9
pressure sensor for arm crane
Y10 X 4 Intermediate connector (to arm I9
angle potentiometer for arm crane)
Y11 X 3 Arm angle potentiometer for arm B3
crane
Y12 X 3 Intermediate connector G9
(to main body wiring harness)
Y15 Shinagawa 6 Crane mode selector relay X8
Y17 Yazaki 1 Diode for arm crane X7
Y18 Yazaki 2 Fuse for arm crane W9
Y19 M 2 Model selection permission signal W9

(opt)
Y20 M 4 Specification selection switch (opt) U9
Y24 X 2 Intermediate connector I1
PC228US-3 20-215
1
12
20-216 PC228US-3
1
12
PC228US-3 20-217
1
12
20-218 PC228US-3
1
12
PC228US-3 20-219
1
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
12
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

★ The terms male and female refer to the pins, while the terms male housing and female housing refer to
the mating portion of the housing.
No. X type connector

of
Pins Male (female housing) Female (male housing)
20-220 PC228US-3
1
12
No. SWP type connector

of
12
14
16
PC228US-3 20-221
1
12
No. M type connector

of
20-222 PC228US-3
1
12
No. S type connector

of
10
(White)
12
(White)
16
(White)
PC228US-3 20-223
1
12
No. S type connector

of
10
(Blue)
12
(Blue)
16
(Blue)
20-224 PC228US-3
1
12
No. L type connector

of
PC228US-3 20-225
1
12
No. AMP070 type connector

of
14
18
20-226 PC228US-3
1
12
No. Automobile connector

of
PC228US-3 20-227
1
12
No. Relay connector

of
20-228 PC228US-3
1
12
No. MIC type connector

of
13
17
21
PC228US-3 20-229
1
12

of
12
16
20
20-230 PC228US-3
1
12

of
10
12
14
18
20
PC228US-3 20-231
1
12
No. M type connector

of
20-232 PC228US-3
1
12
No. DT Series connector

of
Pins Body (plug) Body (receptacle)
PC228US-3 20-233
1
12
No. DT Series connector

of
Pins Body (plug) Body (receptacle)
10
20-234 PC228US-3
1
TROUBLESHOOTING EXPLANATION OF CONTROL MECHANISM FOR ELECTRICAL SYSTEM
12
EXPLANATION OF CONTROL MECHANISM FOR ELECTRICAL

SYSTEM
The control mechanism fro the electrical system consists of the monitor panel, and engine throttle • pump
controller. The monitor panel and the engine throttle • pump controller all input the signals that are neces-
sary, and together with the signals selected by the monitor panel, the engine throttle • pump controller
outputs or inputs the necessary signals and control the pump absorption torque and engine output.
Network data
1) Working mode (A, E, B) data (Monitor panel → engine throttle, pump controller)
2) Auto-deceleration (ON/OFF) signal (Monitor panel → engine throttle, pump controller)
3) Travel Hi/Lo signal (Monitor panel → engine throttle, pump controller)
4) Coolant temperature (water temperature) data (Monitor panel → engine throttle, pump controller)
5) Service code (troubleshooting code) data (Engine throttle, pump controller → monitor panel)
PC228US-3 20-235
1
TROUBLESHOOTING DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL
12
DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR

PANEL
1. Troubleshooting function of lamps, gauges, buzzer
When the starting switch is turned on, all the lamps and gauges light up for approx. 3 seconds, and the
buzzer sounds for approx. 1 second. During this time, the monitor itself carries out self-diagnosis, and
after it has finished, it gives the normal display (if any lamp does not light up during the visual check,
the lamp bulb is blown).
2. User code display function
All the abnormality data for the engine controller and pump controller are transmitted to the monitor
panel.
Of the abnormality data, items with a high emergency level are displayed as a user code automatically
on digital meter display (1) of the monitor panel to advise the operator of the action to take.
★ On digital meter display (1) and service meter display (2), only the places marked [x] in the illustra-
tion below light up. All the other places are OFF.
1) User code display

(1) Digital meter display
(2) Service meter display
(3) Working mode selector (UP) switch
(4) Working mode selector (DOWN) switch
(5) Setting switch
(6) Travel speed switch
(7) Auto-deceleration switch
(8) Buzzer cancel switch
Example: When user code [E02] is displayed
2) Table of user codes
User code Abnormal system
E02 PC-EPC system
E03 Swing holding brake system
E05 Governor motor system
E06 Boom RAISE stroke end throttle EPC system
20-236 PC228US-3
1
12
3. User code display function

All the abnormality data for the engine controller and pump controller are transmitted to the monitor
panel.
These abnormality data, regardless of whether they are necessary to display as a user code or not, are
all stored inside the monitor panel as service codes.
When the following operations are carried out, the service codes are displayed on the monitor panel
digital display; the existing problems are marked with ""E"" and are displayed together with the elapsed
time data (time on the service meter) on the service meter display panel.
1) Method of displaying and deleting service codes
i) To switch to the service code display mode, do
as follows:
➀ Keep [Buzzer cancel switch (8)] + [Auto-decel-
eration switch (7)] pressed for at least 2.5
seconds.
➁ Press [Buzzer cancel switch (8)] + [Working
mode selector (UP) switch (3)] (or [Working
mode selector (DOWN) switch (4)]) and set
so that [01] is displayed in the 2nd and 3rd
digits from the left on service meter display
(2).
➂ Press [setting switch (5)]. (1) Digital meter display (5) Setting switch
(2) Service meter display (6) Travel speed switch
(3) Working mode selec- (7) Auto-deceleration
tor (UP) switch switch
(4) Working mode selec- (8) Buzzer cancel switch
tor (DOWN) switch
Example 1: When [01] is displayed on service

meter display (2)
Example 2: When [E213] occurred 6 hours before

★ If the problem still exists, ""E"" is displayed
at the 2nd digit from the left on service
meter display (2); if the situation has
returned to normal, ""E"" is not displayed.
★ The 3 digits on the right from service
meter display (2) show the elapsed time.
PC228US-3 20-237
1
12
Example 3: When no service code is recorded, all digits on digital meter display (1) and service
meter display (2) show [-].
ii) To go on to the next service code display,
press [Buzzer cancel switch (8)] + [Working
mode selector (UP) switch (3)].
iii) To go back to the previous service code dis-
play, press [Buzzer cancel switch (8)] + [Work-
ing mode selector (DOWN) switch (4)].
iv) To finish using the service code display mode,
press [Buzzer cancel switch (8)] + [Auto-decel-
eration switch (7)].
v) To delete the service codes from memory,
keep [Buzzer cancel switch (8)] pressed and
turn the starting switch OFF. Then turn the
starting switch ON again and keep [Buzzer can-
cel switch (8)] pressed for 5 seconds.
★ If the number of service codes in memory
exceeds 20, the oldest service codes are
deleted in turn.
2) Table of service codes
Service code Abnormal system User code
E101 Abnormality in data —
E104 Abnormality in air cleaner clogging sensor detected —
E108 Engine water temperature over 105° C detected —
E112 Short circuit in wiper drive normal rotation system —
E113 Short circuit in wiper drive reverse rotation system —
E114 Short circuit in window washer drive system —
E115 Wipe failure continues for 10 seconds —
E206 Stow failure continues for 10 seconds —

E201 Short circuit in travel junction solenoid system —
E203 Short circuit in swing holding brake solenoid system E03
E204 Short circuit in pump merge/divider solenoid system —
E205 Short circuit in 2-stage relief solenoid system —
E206 Short circuit in travel speed Hi/Lo selector solenoid system —
E211 Disconnection in travel junction solenoid system —
20-238 PC228US-3
1
12
Service code Abnormal system User code
E213 Disconnection in swing holding brake solenoid system E03
E214 Disconnection in pump merge/divider solenoid system —
E215 Disconnection in 2-stage relief solenoid system —
E216 Disconnection in travel speed Hi/Lo selector solenoid system —
E217 Error in machine model selection input —
E218 Abnormality in S-NET communication —
E222 Short circuit in LS-EPC solenoid system E02
E223 Disconnection in LS-EPC solenoid system E02
E224 Abnormality in F pump pressure sensor system —
E225 Abnormality in R pump pressure sensor system —
E226 Abnormality in pressure sensor system power source —
E227 Abnormality in engine speed sensor system —
E232 Short circuit in PC-EPC solenoid system E02
E233 Disconnection in PC-EPC solenoid system E02
E234 Short circuit in boom RAISE stroke end throttle EPC system E06
E235 Disconnection in boom RAISE stroke end throttle EPC system E06
Abnormality in boom angle potentiometer system

E241 —
(outside input value range)
Abnormality in boom angle potentiometer compensation value

E255 —
(outside compensation range)
E256 Check sum abnormality —
E306 Abnormality in feedback potentiometer system —
E308 Abnormality in fuel control dial input value E05
E313 Error in automatic greasing controller system —
E315 Short circuit in battery relay output —
E316 Step-out in governor motor —
E317 Disconnection in governor motor system E05
E318 Short circuit in governor motor system E05
PC228US-3 20-239
1
12
4. Monitoring code display function

The input signals from the sensors to each component and the output signals to drive the solenoid can
be checked in real time with the monitoring code.
When the following operations are carried out, the monitoring code Nos. are displayed on the 3rd to
5th digits from the left on service meter display (2) and the monitoring data are displayed on digital
meter display (1).
1) Method of displaying monitoring codes

i) To switch to the monitoring code, do as fol-
lows.
➀ Keep [Buzzer cancel switch (8)] + [Auto-
deceleration switch (7)] pressed for at least
2.5 seconds.
➁ Press [Buzzer cancel switch (8)] + [Working
mode selector (UP) switch (3)] (or [Working
mode selector (DOWN) switch (4)]) and set
so that [02] is displayed in the 2nd and 3rd
digits from the left on service meter dis-
play (2).
➂ Press [Setting switch (5)]. (1) Digital meter display (5) Setting switch
(4) Working mode selec- (8) Buzzer cancel switch
tor (DOWN) switch
Example 1: When a numeric display monitoring

code (engine speed: 2050 rpm) is dis-
played
Example 2: When bit pattern display monitoring

code No. 20 (switch input condition
(1)) is displayed
20-240 PC228US-3
1
12
ii) To go on to the next monitoring code

display, press [Buzzer cancel switch (8)]
+ [Working mode selector (UP) switch
(3)].
iii) To go back to the previous service code
display, press [Buzzer cancel switch (8)]
+ [Working mode selector (DOWN)
switch (4)].
iv) To finish using the monitoring code dis-
play mode, keep [Buzzer cancel switch
(8)] + [Auto-deceleration switch (7)]
pressed for at least 2.5 seconds.
2) Table of monitoring codes

★ For details of the code displayed as (6 bit) in the Unit column, see the bit pattern chart.
Code No. Item Unit Name of component
002 Engine throttle, pump controller model code — Engine throttle, pump controller
010 Engine speed 10 rpm Engine throttle, pump controller
011 Pump discharge pressure (F) input kg/cm² Engine throttle, pump controller
012 Pump discharge pressure (R) input kg/cm² Engine throttle, pump controller
013 PC-EPC output current 10 mA Engine throttle, pump controller
015 LS-EPC current output 10 mA Engine throttle, pump controller
016 No. 2 throttle command value 10 rpm Engine throttle, pump controller
018 Boom RAISE stroke end throttle EPC current 10 mA Engine throttle, pump controller
019 ATT PPC throttle EPC current 10 mA Engine throttle, pump controller
020 Engine throttle, pump controller switch input condition (1) (6 bit) Engine throttle, pump controller
021 Engine throttle, pump controller switch input condition (2) (6 bit) Engine throttle, pump controller
022 Engine throttle, pump controller switch input condition signal (3) (6 bit) Engine throttle, pump controller
023 Engine throttle, pump controller solenoid drive condition (6 bit) Engine throttle, pump controller
024 Engine throttle, pump controller solenoid drive condition (1) (6 bit) Engine throttle, pump controller
027 Engine throttle, pump controller switch input condition signal (4) (6 bit) Engine throttle, pump controller
030 Fuel control dial input value 10 mV Engine throttle, pump controller
031 Governor potentiometer feedback voltage 10 mV Engine throttle, pump controller
032 Battery voltage (VBB voltage) 100 mV Engine throttle, pump controller
033 Governor motor phase A current 10 mA Engine throttle, pump controller
034 Governor motor phase B current 10 mA Engine throttle, pump controller
035 Battery relay output voltage 100 mA Engine throttle, pump controller
PC228US-3 20-241
1
12
Code No. Item Unit Name of component
036 Engine throttle, pump input condition (6 bit) Engine throttle, pump controller
037 Engine throttle, pump output condition (6 bit) Engine throttle, pump controller
041 Coolant temperature sensor input voltage 10 mV Engine throttle, pump controller
042 Fuel level sensor input voltage 10 mV Engine throttle, pump controller
043 Alternator (charge) input voltage 100 mV Engine throttle, pump controller
044 Hydraulic oil temperature sensor voltage 10 mV Engine throttle, pump controller
045 Sensor input condition (1) (6 bit) Engine throttle, pump controller
046 Sensor input condition (2) (6 bit) Engine throttle, pump controller
049 (Spare) (6 bit) Engine throttle, pump controller
060 Boom angle 10 mV Engine throttle, pump controller
200 Program version (monitor)
201 Program version (controller)
3) Bit pattern display (bit for applicable No.

lights up)
★ (1) to (6) of digital display (1) indicate
the bit Nos.
★ The 2nd to 4th digits from the left on
service meter display (2) indicate the
monitoring code Nos.
Code Content Bit Details (condition when bit is lighted up)
➀ Swing PPC pressure switch (ON)
➁ Travel PPC pressure switch (ON)
Input condition of governor, pump controller ➂ Boom LOWER PPC pressure switch (ON)
020
PPC pressure switches ➃ Boom RAISE PPC pressure switch (ON)
➄ Arm IN PPC pressure switch (ON)
➅ Arm OUT PPC pressure switch (ON)
➀ Bucket CURL PPC pressure switch (ON)
➁ Bucket DUMP PPC pressure switch (ON)
Input condition of governor, pump controller ➂

021
PPC pressure switches and other switches ➃ Service PPC pressure switch (ON)
➄ Travel steering pressure switch (ON)
20-242 PC228US-3
1
12
➀
➁
Input condition of engine throttle and ➂ Knob switch (24 V connected)
022
pump controller for switches ➃ Swing holding brake cancel switch (GND connected)
➄ Swing lock switch (GND connected)
➅
➀
➁ Travel junction solenoid (ON)
Solenoid drive condition of engine ➂ Swing holding brake solenoid (ON)

023
throttle and pump controller ➃ Pump merge/divider solenoid (ON)
➄ 2-stage relief solenoid (ON)
➅ Travel speed Hi/Lo selector solenoid (ON)
➀
➁
Solenoid drive condition on engine ➂
024
throttle and pump controller (1) ➃
➄
➅
➀ Model selection 1 (GND connected)
➁ Model selection 2 (GND connected)
Input condition of engine throttle and ➂ Model selection 3 (GND connected)

027
pump controller for switches (2) ➃ Model selection 4 (GND connected)
➄ Model selection 5 (GND connected)
➅ Kerosene mode input (GND connected)
➀
➁
Input/output condition of engine throttle ➂
036
and pump controller ➃
➄ Starting switch (ON)
➅
➀ Battery relay (when actuated)
➁
Input condition of engine throttle and ➂
037
pump controller ➃
➄
➅
PC228US-3 20-243
1
12
➀ Starting switch [ON] (ON)

➁ Starting switch [START] [START] (ON)
➂ Preheating switch (ON)
045 Sensor input condition
➃ Light switch (ON)
➄
➅
➀ (Always OFF)
➁ (Always OFF)
➂ (Always OFF)
046 Sensor input condition
➃ (Always OFF)
➄ (Always OFF)
➅ (Always ON)
➀ Alarm buzzer (Actuated)
➁
➂
047 (Spare)
➃
➄
➅
➀
➁ Washer on (ON)
048 ➂ Wiper drive 1 (ON)

( ) ➃ Wiper drive 2 (ON)
➄ Wiper drive 3 (ON)
➅ Wiper drive 4 (ON)
➀ Swing lock switch (ON)
➁ Buzzer cancel switch (ON)
➂ Window washer switch (ON)
049
➃ W contact (ON)
➄ P contact (ON)
➅
Code No. [048]: When wiper is stopped, bit Nos. (4) and (6) light up
When wiper is actuated, bit Nos. (3) and (6) or (4) and (5) light up
20-244 PC228US-3
1
12
5. Function for setting working mode default

The working mode on the monitor panel is set so that the A mode normally lights up when the starting
switch is turned ON.
If the function for setting the default is used as follows, it is possible to change the setting so that the
system starts with the working mode desired by the operator.
1) Method of setting default
i) To switch to the default setting mode, do as
follows.
➀ Keep [Buzzer cancel switch (8)] + [Auto-
deceleration switch (7)] pressed for at
least 2.5 seconds.
➁ Press [Buzzer cancel switch (8)] +
[Working mode selector (UP) switch
(3)] (or [Working mode selector
(DOWN) switch (4)]) and set so that [05]
is displayed in the 2nd and 3rd digits
from the left on service meter display
(2).
➂ Press [Setting switch (5)]. (1) Digital meter display (5) Setting switch
★ ""d[]SET"" is displayed in service (2) Service meter display (6) Travel speed switch
meter display (2) and indicator (10) (3) Working mode selec- (7) Auto-deceleration
for the mode set as default flashes. tor (UP) switch switch
ii) To change the default set mode, do as fol- (4) Working mode selec- (8) Buzzer cancel switch
tor (DOWN) switch
lows.
➀ Press [Working mode selector (UP)
switch (3)] or [Working mode selector
(DOWN) switch (4)].
➁ Press [Setting switch (5)].
iii) To finish using the default setting mode
(default setting mode complete), keep
[Buzzer cancel switch (8)] + [Auto-decelera-
tion switch (7)] pressed for at least 2.5 sec-
onds.
★ If the starting switch is turned OFF
when the normal mode LED is flashing
(default setting mode), the content of
the working mode default is not
changed.
PC228US-3 20-245
1
12
iv) Method of checking after setting work-

ing mode default
➀ Check that the LED has changed to
continuous lighting up.
➁ Turn the starting switch OFF, then
turn the starting switch ON again.
➂ Check that the default for the work-
ing mode has changed to the new
setting.
6. Governor motor adjustment mode
This is used when adjusting the linkage
between the governor motor and the injection
pump.
★ For details of the procedure, see TESTING
AND ADJUSTING, Testing and adjusting
governor motor lever stroke.
1) Method of displaying governor motor
adjustment mode
i) To switch to the governor motor adjust-
ment mode, do as follows.
➀ Keep [Buzzer cancel switch (8)] +
[Auto-deceleration switch (7)]
(1) Digital meter display (5) Setting switch
➁ Press [Buzzer cancel switch (8)] + (3) Working mode selec- (7) Auto-deceleration
[Working mode selector (UP) switch tor (UP) switch switch
(3)] (or [Working mode selector (4) Working mode selec- (8) Buzzer cancel switch
(DOWN) switch (4)]) and set so that tor (DOWN) switch
[03] is displayed in the 2nd and 3rd
digits from the left on service meter
display (2).
➂ Press [Setting switch (5)].
★ ""GOV"" is displayed on digital
meter display (1) and ""GSET""
is displayed on service meter
display (2).
ii) To finish using the governor motor
adjustment mode, keep [Buzzer cancel
switch (8)] + [Auto-deceleration switch
(7)] pressed for at least 2.5 seconds.
20-246 PC228US-3
1
12
7. Boom angle potentiometer compensation

mode
This is used when adjusting the boom angle
potentiometer
1) Method of displaying boom angle potenti-
ometer compensation mode
i) To switch to the boom angle potentiom-
eter compensation mode, do as follows.
➁ Press [Buzzer cancel switch (8)] +
[Working mode selector (UP) switch
(3)] (or [Working mode selector (1) Digital meter display (5) Setting switch
(DOWN) switch (4)]) and set so that (2) Service meter display (6) Travel speed switch
[06] is displayed in the 2nd and 3rd
digits from the left on service meter (4) Working mode selec- (8) Buzzer cancel switch
display (2). tor (DOWN) switch
➂ Press [Setting switch (5)].
★ Check that ""1[]SET"" is dis-
played on service meter display
(2) (the center 3 segments on
digital display (1) flash).
ii) To adjust the boom angle potentiome-
ter compensation mode, do as follows.
➀ After changing to the mode in Step
i), start the engine and operate the
boom to the end of the RAISE
stroke.
★ ""o--"" (compensation possible
range) or ""---"" (compensation
impossible) will flash on the dig-
ital display.
★ If compensation is impossible,
the mounting of the boom angle
potentiometer is probably
defective, so check it.
➁ Press [Setting switch (5)].
★ The same flashing display as in
Step (1) will appear on digital
meter display (1).
PC228US-3 20-247
1
12
➂ If the compensation is carried out

correctly (if the boom angle is
within the theoretical value, ""ooo""
will be displayed for 5 seconds on
digital meter display (1)), and the
system will return to Step (1) (boom
angle potentiometer compensation
mode).
★ If compensation could not be
carried out, ""---"" will flash on
digital display (2), the buzzer
will sound 5 times, and the sys-
tem will return to Step (1).
★ If compensation is impossible,
the mounting of the boom angle
potentiometer is probably
defective, so check it.
8. Displaying and setting oil maintenance function

On machines equipped with the oil mainte-
nance function, the LED of [Oil maintenance
lamp (9)] on the monitor lights up from a point
10 hours before the time set for the oil change
and stays lighted up until the system is reset.
The elapsed time is displayed on service meter
display (2). (It is displayed for 20 seconds after
the starting switch is turned ON; after that, the
display returns to the service meter time dis-
play.)
★ No display is given (does not light up) on
digital meter display (1).
With the oil maintenance function, it is pos-
sible to set, change, or cancel the display.
1) Oil maintenance function display

i) As explained above, the oil mainte-
nance display mode automatically gives
a display when the remaining time is
less than 10 hours from the set time.
ii) To finish the oil maintenance function
(within 20 seconds after the starting
switch is turned ON), press [Setting
switch (5)] quickly and return to the nor-
mal display mode.
Example: When the display shows the fol-

lowing:
Oil change interval setting: 250
h
Time elapsed since last oil
change: 245 h
20-248 PC228US-3
(4)
12
2) Setting interval and resetting elapsed time

i) Setting interval
➁ Press [Setting switch (5)] (the dis-
play switches each time the switch
is pressed) and select the interval.
Example: When selecting interval:
250 h (no display is given on digital
meter display (1))
★ Interval display (displayed
(1) Digital meter display (5) Setting switch
repeatedly in turn)
0: Default mode (oil mainte- (3) Working mode selec- (7) Auto-deceleration
nance function not set) tor (UP) switch switch
125h: Interval is set for every 125 (4) Working mode selec- (8) Buzzer cancel switch
hours tor (DOWN) switch
250h: Interval is set for every 250
hours
500h: Interval is set for every 500
hours
d: Demo mode is set
(See Step iv) for details.)
★ Set the interval according to the
Operation and Maintenance
Manual.
➂ Keep [Buzzer cancel switch (8)] +
pressed for at least 2.5 seconds to
complete the setting of the interval.
PC228US-3 20-249
(4)
12
ii) Checking elapsed time

★ Nothing is displayed until the
elapsed time enters the period of 10
hours before the change interval.
(If you want to see the elapsed time
when there is no display, keep [Set-
ting switch (5)] pressed and turn the
starting switch ON. Continue to
press [Setting switch (5)].)
iii) Resetting elapsed time after changing
oil
Press [Setting switch (5)] and keep it
depressed for 3 seconds while the
elapsed time and telephone number are
being displayed (within 20 seconds) on
the monitor panel. The elapsed time
will be reset and the display will show
""Elapsed time: 0h"" for one second.
iv) Demo mode
If the demo mode is used, a demonstra-
tion of the oil maintenance function can
be carried out when the machine is
delivered.
★ The same display is given as for the oil
maintenance function. For the purpose
of demonstration, the elapsed time is
fixed at 240h
★ After setting to the demo mode, turn
the starting switch ON again to start the
demonstration.
Note: If the starting switch is turned OFF
↔ ON four times, the demo mode is
canceled (the demo mode can be used 3
times) and the system automatically
switches to the default mode. (If you
want to continue the demonstration, it
is necessary to set to the demo mode
again.)
20-250 PC228US-3
(4)
TROUBLESHOOTING METHOD OF USING JUDGEMENT TABLE
12
METHOD OF USING JUDGEMENT TABLE

This judgement table is a tool to determine if the problem with the machine is caused by an abnormality in
the electrical system or by an abnormality in the hydraulic or mechanical system. The symptoms are then
used to decide which troubleshooting table (E-OO, S-OO, N-OO, C-OO, F-OO, H-OO, M-OO) matches the
symptoms.
The judgement table is designed so that it is easy to determine from the user code and service code which
troubleshooting table to go to.
★ The abnormality display (warning) given by the monitor panel leads directly to troubleshooting of the
machine monitor (M-OO). (See troubleshooting of the machine monitor system).
1. When using judgement table for governor, pump controller (governor control system) and
engine related parts.
• If a service code is displayed on the monitor panel, go to the troubleshooting code at the bottom of
the judgement table (E-OO).
(A ● mark is put at the places where the failure mode and service code match).
• If a problem has appeared but no service code is displayed on the monitor panel, go to the point
where the failure mode matches the troubleshooting code on the right of the judgement table (E-
OO or S-OO).
<Example> Failure mode "Engine does not start".
Procedure: Check if the service code is being displayed on the monitor panel.
Abnormality in engine throttle and pump controller power source system
Engine throttle and pump Machine
Troubleshooting code if no service code display is given

controller, engine related parts Checking monitoring, check items monitor
(E3: system) check item
Is red range displayed?

Self-diagnostic display
Fuel control dial command value
Governor motor A phase current
Governor motor B phase current

Governor motor potentiometer
No. 2 throttle command value
Coolant temperature voltage

Abnormality (disconnection) in motor drive system
Abnormality (short circuit) in battery relay output

Abnormality (short circuit) in motor drive system
Does starting motor turn?

Battery relay drive signal
Abnormality in feedback potentiometer system
Abnormality in fuel control dial input value
102° C or above
105° C or above
Abnormality (step-out) in motor
Monitoring code
35 16 30 31 33 34 41 108
S-1
O S-2
O S-3
User code E05
Failure mode S-4
Service code 308 317 318 306 315 316
1 Engine does not start easily E-9A), S-5
2 Engine does not start E-9A), S-5
3 Engine speed stays at low idling, and does not follow accelerator; or engine pickup is poor ● ● ● ● ●
O E-10, S-6
4 Engine stops during operation
When idling speed is irregular E-3 and E-4
5 Engine rotation is irregular
When there is hunting ● ● ● ● ● O E-11
6 Lack of output ( engine high idling speed is too low) ● ●
O O E-3 and E-4
7 Auto-deceleration does not work
See ENGINE SHOP MANUAL
8 Engine does not stop ● ● ● ● ●
9 Warming-up operation is defective
10 Exhaust gas is black
11 Oil consumption is excessive, or exhaust gas is blue
12 Oil becomes dirty prematurely See ENGINE SHOP MANUAL
13 Fuel consumption is excessive, or exhaust gas is blue See ENGINE SHOP MANUAL
14 Oil is mixed in coolant See ENGINE SHOP MANUAL
15 Engine oil pressure caution lamp lights up O O See ENGINE SHOP MANUAL
16 Oil level rises See ENGINE SHOP MANUAL
17 Coolant temperature rises too high (overheating)
18 Abnormal noise is generated
E-3 and E-4
19 There is excessive vibration
20 Engine speed does not change even when working mode is switched
— — — — — — — — — —
Troubleshooting code when service code is displayed E-1 E-2 E-3 E-4 E-5 E-6 E-7 E-12 — — — — — M-13 M-13 E-8
Troubleshooting code when there is abnormality in monitoring or machine monitor check — — — — — — — O: This shows item to check with monitoring or machine monitor
[Judgement]
1) If a service code is being displayed on the monitor panel........go to troubleshooting [E3:OO] for the gov-
ernor, pump controller (governor control system).
2) If no service code is displayed on the monitor panel, and the engine does not start:
Go to troubleshooting S-2 of
Starting motor rotates......................
mechanical system
• Check that starting
motor rotates
Go to troubleshooting E-8 of
Starting motor does not rotate........
electrical system
20-252 PC228US-3
1
TROUBLESHOOTING METHOD OF USING JUDGEMENT TABLE
12
3. When using judgement table for governor, pump controller (governor control system) and
hydraulic related parts.
• If a service code is displayed on the monitor panel, go to the troubleshooting code at the bottom of
the judgement table (C-OO).
(A ● mark is put at the places where the failure mode and service code match).
• If a problem has appeared but no service code is displayed on the monitor panel, go to the point
where the failure mode matches the input signal, and check the display for the input signal (the dis-
play at the place with a O mark)
• If it is displayed normally, go to the troubleshooting code on the right of the judgement table (H-
OO).
• If the input signal is not displayed on the monitor panel, go to the troubleshooting code at the
bottom of the judgement table (F-OO).
<Example> Failure mode "Upper structure does not swing".

Procedure: Check if the service code is being displayed on the monitor panel.
Solenoid valve Swing motor Travel motor Oil pressure switch

Parts causing failure
Travel speed selector servo piston

Pressure
Leakage, breakage inside body

Boom Arm Bucket Swing Sensor
Troubleshooting code
Counterbalance valve
Hydraulic cylinder
Boom RAISE EPC valve
Swing machinery
Travel speed selection
Final drain valve

PPC oil pressure lock
Travel junction valve

Pump merge-divider
Engine system
Safety valve
Check valve
Front pump
Rear pump
Holding brake
Suction valve
LOWER
2-stage relief
Swing brake
Safety valve
DUMP
Travel
RAISE
CURL
Right
OUT
Left
IN
PC-EPC
Failure mode
H-1
{ H-2
Speeds of all work equipment, swing, travel are slow or lack power {
All work equipment
H-3
There is excessive drop in engine speed, or engine stalls
travel, swing
No work equipment, travel, swing move { H-4
Abnormal noise generated (around pump) { { { { { { { { { H-5
Auto-deceleration does not work H-6
Fine control ability is poor or response is poor { { { { H-7
Boom is slow or lacks power { { { { { H-8

Arm is slow or lacks power { { { { H-9
Bucket is slow or lacks power
Work equipment
Boom does not move { H-10

Arm does not move
Bucket does not move { H-11
Excessive hydraulic drift H-12
Excessive time lag (engine at low idling) { H-13
Other equipment moves when single circuit is relieved
{ { { { { { H-14
Lack of power when pressure rises {
H-15
In compound operations, work equipment with larger load is slow
Compound
operations
H-16
In swing + boom (RAISE), boom is slow
H-17
In swing + travel, travel speed drops excessively
{
Deviation is excessive during normal travel H-18
Travel deviation {
Deviation is excessive when starting
Travel system
{ { H-19
Travel speed is slow {
{ { H-20
Steering does not turn or lacks power { { {
{ { { { H-21
Travel speed does not switch or is faster then specified { {
{ { { { { H-22
Does not move (one side only)
{ { {
Both left and right { { { H-23
Does not swing
One direction only {
Swing acceleration is poor or swing speed is Both left and right { H-24
slow { {
Swing system
One direction only

Both left and right {
Excessive overrun when stopping swing H-25
One direction only {
Excessive shock when stopping swing (one direction only) H-26
Excessive abnormal noise when stopping { { { H-27
Excessive hydraulic drift of When holding brake is released { { {

H-28
swing When holding brake is applied { {
[Judgement]
1) If a service code is being displayed on the monitor panel........go to troubleshooting [E2:OO] for the gov-
ernor, pump controller (governor control system).
2) If no service code is displayed on the monitor panel, and the upper structure does not swing:
There is a signal............ Go to troubleshooting H-25 of mechani-

cal system
Check governor, pump
• controller input signal
(Check in monitoring mode)
There is no signal.......... Go to troubleshooting F-OO of governor,

pump controller input signal system
(F mode for applicable system)
PC228US-3 20-253
1
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
12
METHOD OF USING TROUBLESHOOTING CHARTS

1. Category of troubleshooting code
Troubleshooting Code No. Component Service code
N-OO Troubleshooting of communication abnormality E218
Troubleshooting of electrical system for engine throttle and pump

E-OO E3-OO group
controller (governor control system)
Troubleshooting of electrical system for engine throttle and pump

C-OO E2-OO group
controller (pump control system)
Troubleshooting of engine throttle and pump controller (input signal

F-OO —
system)
H-OO Troubleshooting of hydraulic, mechanical system —
M-OO Troubleshooting of machine monitor E1-OO group
2. Method of using troubleshooting table for each troubleshooting mode

1) Troubleshooting code number and problem
The title of the troubleshooting chart gives the troubleshooting code, service code, and failure
mode (problem with the machine). (See Example (1))
2) Distinguishing conditions
Even with the same failure mode (problem), the method of troubleshooting may differ according to
the model, component, or problem. In such cases, the failure mode (problem) is further divided into
sections marked with small letters (for example, a), so go to the appropriate section to carry out
troubleshooting. (See Example (2)) If the troubleshooting table is not divided into sections, start
troubleshooting from the first check item in the failure mode.
3) Method of following troubleshooting chart
• Check or measure the item inside , and according to the answer follow either the YES
line or the NO line to go to the next . (Note: The number written at the top right corner of
the is an index number; it does not indicate the order to follow.)
• Following the YES or NO lines according to the results of the check or measurement will lead finally to
the Cause column. Check the cause and take the action given in the Remedy column on the right.
(See Example (3))
• Below the there are the methods for inspection or measurement, and the judgement values.
If the judgement values below the are correct of the answer to the question inside the
is YES, follow the YES line; if the judgement value is not correct, or the answer to the question
is NO, follow the NO line.
• Below the is given the preparatory work needed for inspection and measurement, and the
judgement values. If this preparatory work is neglected, or the method of operation or handling
is mistaken, there is danger that it may cause mistaken judgement, or the equipment may be
damaged. Therefore, before starting inspection or measurement, always read the instructions
carefully, and start the work in order from Item 1.
4) General precautions
When carrying out troubleshooting for the failure mode (problem), precautions that apply to all
items are given at the top of the page and marked with ✭ (See Example (4)).
The precautions marked ✭ are not given in the , but must always be followed when carrying
out the check inside the .
5) Troubleshooting tools
When carrying out troubleshooting, prepare the necessary troubleshooting tools. For details, see
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING.
20-254 PC228US-3
(4)
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
12
6. Location of connectors
For details of the connector type and inspection and measurement locations of the wiring connector
Nos. appearing in each flowchart in the troubleshooting mode, see Connector types and mounting
locations and the Connector pin No. Table.
Example:
➀ M-13 When starting switch is ON and engine is started, basic check items flash
➃ ✭ Before carrying out troubleshooting, check that all the related connectors are properly
inserted. (Given in the Contents Column)
★ Always connect any disconnected connectors before going on to the next step. (Given in
the Contents Column)
★ Check both the alternator system and the engine oil pressure system.
}
➁ a) Alternator system
a) When divided into a) and b)
b) Engine oil pressure system
➂ Cause Remedy
2 YES
Defective monitor panel Replace
Is voltage between P02
YES (female) (11) and chas-
1 sis ground normal? Defective contact or dis-
Repair
connection in wiring har-
Is voltage between alter- or
• Run engine at mid- NO ness between alternator
nator terminal R and replace
range speed or above. R and P02 (female) (11)
chassis ground normal?
• 20 - 30 V
• Run engine at mid-
range speed or above. Defective alternator Replace
NO
• 20 - 30 V
PC228US-3 20-255
1
TROUBLESHOOTING DETAILS AND TROUBLESHOOTING PROCEDURE
12
DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING

PROCEDURE
If any abnormality should occur, it is necessary to go to the correct troubleshooting chart in accordance
with the judgement table for that type of failure (governor, pump controller (governor control system) and
governor, pump controller (pump control system)). For details of the troubleshooting and troubleshooting
procedure, refer to this flowchart.
When carrying out troubleshooting, ask the operator as much as possible about the condition of the
machine, and check the following items before starting. ➀ Condition of controller connections (check with
monitoring codes 02 - 04) ➁ Blown fuses ➂ Battery voltage (monitoring mode 32) ➃ Generation of electric-
ity (charge input) voltage (monitoring code 43).
The procedure for carrying out check items No. 3 and 4 in the flowchart below is given on the following
pages.
YES E02 (PC-EPC system)

E03 (Swing holding brake system) Go to Item 2
E05 (Governor motor system)
YES E2:00 group: Troubleshooting for engine throttle, pump controller Carry out trouble-
1 (pump control system) (C mode) shooting in
E3:00 group: Troubleshooting for engine throttle, pump controller applicable mode
Is user code
(governor control system) (E mode)
displayed on
monitor panel?
Engine 5 YES Carry out troubleshoot-

system Is engine electrical ing for engine (S mode)
system for which
Carry out troubleshooting
4 there is no failure for engine electrical
2 code display normal? system (E mode).
Is problem in engine
Is service code YES system or hydraulic • Go to flowchart for NO (Use flowchart for items
displayed on (mechanical) section where where there is no display)
NO (E8 - E12)
monitor panel? 3 system? there is no abnor-
mality display on
• Operate and Are engine throttle, • After adjusting oil judgement table.
check pump controller pressure, judge
service code. input and output from engine speed.
YES • Is all work equip-
signals normal?
ment slow and
• Check with does engine speed
monitoring drop under heavy Hydraulic (mechanical) Carry out troubleshooting
code. load? system for H mode.
Carry out troubleshooting for input

signal system (F mode).
NO
★ When making judgement, see governor, pump controller (governor control system)
(pump control system) in the JUDGEMENT TABLE.
20-256 PC228US-3
1
12
If there is no abnormality display in the communications system transmitted in S-NET, it can be taken that
the output signal from the monitor panel has been transmitted. However, even if there is no abnormality
display, if the operation is defective, use the following procedure when checking directly.
If any abnormality occurs in the S-NET system, the system is automatically switched to the default mode
given below, so be careful when carrying out troubleshooting.
Default modes when communications cannot be carried out for the monitor panel and governor, pump
controller
Set mode Pump control Governor control
1 Working mode E mode E mode
2 Throttle signal Equivalent of E mode Equivalent of E mode
3 Auto-deceleration ON (deceleration mode) ON (deceleration mode)
4 Coolant temperature signal Taken as below 30° C Taken as below 30° C
5 Travel speed Lo —
6 Automatic warming up — ON (automatic warming-up mode)
1. Procedure for checking monitor panel output signal

★ For details of operating the monitoring mode, see MONITOR PANEL DISPLAY AND SPECIAL FUNC-
TIONS.
1. Connection condition of components
1) Set to the monitoring mode and display monitoring code [08].
2) The time display (bits) will light up to display the components that are connected.
★ Engine throttle, pump controller (pump control system) (1) and governor, pump controller
(governor control system) (2) will light up.
2. Checking working mode signal {check No. 2 throttle signal (monitoring code [16]) at the same time}
2) Switch the working mode as shown in Table 1 and check that the engine speed changes.
Table 1
(high idling speed)
Working mode Operation Engine speed [The figures in ( ) are the rated speed] (rpm)
Work equipment Approx. 2,150 (1,950)

A
Travel Approx. 2,150 (1,950)
E
Travel Approx. 1,800 (—)
B
Arm crane
PC228US-3 20-257
1
12
3) Checking travel speed selection signal

2) Change the speed selector switch to Hi and run the engine at 1500 rpm or above. Check that bit
➅ lights up (or goes out) when traveling at Hi or Mi (front or rear pump oil pressure: See ).
: Comes ON (bit ➅ lights up) when oil pressure goes up to 33.34 MPa (340 kg/cm²) or more;
goes OFF (bit ➅ goes out) when oil pressure goes down to 17.65 MPa {180 kg/cm²} or less.
2. Checking input signal of engine throttle and pump controller
★ Check the controller input signals as follows.
• Pump control system
1. Checking input signal
1) Check hydraulic switch
i) Set to the monitoring mode, and display monitoring codes [20] and [21].
ii) Operate each work equipment lever, and check how the bit pattern lights up.
★ For details of the bit pattern chart, see MONITOR PANEL DISPLAY AND SPECIAL FUNC-
TIONS.
2) Check speed sensor (check engine speed)
i) Set to the monitoring mode, and display monitoring code [10].
ii) Use the fuel control dial to change the speed, and measure the speed when this is done.
3) Check pump discharge pressure sensor
★ Code [11] is for the front pump and code [12] is for the rear pump.
ii) Refer to Table 2 and measure the hydraulic pressure at the front or rear pump.
Table 2 Pump merge/flow logic and pumps actuated by control levers

Independent operation Travel operated independently or com-
(basic flow merged) pound operation together with travel .
Front pump Rear pump Front pump Rear pump
R.H. travel O O
Swing O O O
Arm O O O
Boom O O O
Bucket O O O
L.H. travel O O
Conditions for compound operation with travel.

1) When measuring the oil pressure for any circuit other than travel, operate the travel lever
slightly or connect a short connector (X-2P) to the travel oil pressure switch connector (CN-
S30).
2) The front pump and rear pump pressure divides at 19.61 MPa (200 kg/cm²) when the pres-
sure rises, and divides at 14.71 MPa {150 kg/cm²} when the pressure goes down.
3) The travel steering signal must not be input.
(Operate both the left and right travel levers slightly.)
20-258 PC228US-3
1
12
4) Check kerosene mode input signal

ii) Connect connector C05 (15) of the engine throttle, pump controller to the ground and check that
bit (6) lights up.
5) Check knob switch input signal
ii) Turn the knob switch ON and check that bit (3) lights up.
2. Check output signals
1) Check LS-EPC solenoid output current
ii) Run the engine at high idling with all the levers at neutral and in A mode, and measure the cur-
rent.
★ All levers at neutral: 900 ± 100 mA
Engine at full throttle, lever operated (other than travel): 0 A
2) No. 2 throttle signal
ii) Use the procedure in Step 2 for checking the monitor panel output signal and measure the
engine speed.
3) Check ON ↔ OFF solenoid condition
ii) Refer to Table 3 and check that the applicable bit lights up.
Table 3 Types of solenoid and conditions for actuation
Name of solenoid Actuation condition Bit that lights up
Swing holding brake Swing or work equipment lever operated Monitoring code [23](3)
Travel speed Hi/Lo Fuel control dial at 1500 rpm or more and Monitoring code [23](6)
travel speed switch at Hi and travel switch
ON and at Hi rotation
Pump merge/divider Travel operated independently Monitoring code [23](4)

2-stage relief Swing lock switch ON Monitoring code [23](5)
Travel junction Travel steering signal ON (connect short Monitoring code [23](2)
connector to CN- S31)
Note 1: Operate the lever slightly (not enough to move the machine).
4) Check PC-EPC solenoid output current

ii) With the starting switch kept at the ON position (heavy-duty operation mode), measure the cur-
rent when the fuel control dial is turned to the MAX position with the auto-deceleration turned
OFF.
• Current (in diesel mode) with starting switch ON (A mode) and fuel control dial at MAX (auto-
deceleration OFF): 177 ± 100 (mA)
PC228US-3 20-259
1
12
• Governor control system

1. Check input signal
1) Check fuel control dial input voltage
ii) Measure the voltage when the fuel control dial is turned from low idling to high idling.
★ Voltage: 0.25 - 4.75 V
2 Check fuel control dial input voltage
ii) Measure the potentiometer voltage when the fuel control dial is turned from low idling to
high idling.
★ Voltage: 0.5 - 4.2 V (Note: When auto-deceleration is OFF)
2. Check output signal

1) Check governor motor drive current
★ Code [33] is the A phase and code [34] is the B phase.
ii) Measure the governor motor drive current when the fuel control dial is turned in the engine
speed acceleration direction and deceleration direction.
★ Current: 700 ± 70 (mA)
2) Measure battery relay drive (output) voltage
ii) Measure the battery relay drive (output) voltage when the starting switch is turned from ON
to OFF.
or
iii) Set to the monitoring mode, and display monitoring code [37].
iv) Check that bit (1) lights up when the starting switch is turned from ON to OFF.
20-260 PC228US-3
1
12
TROUBLESHOOTING OF COMMUNICATIONS ABNORMALITY
(N MODE)
N-1 Communications abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-302
★ This troubleshooting is carried out when there is still an abnormality, so when disconnecting the con-
nector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its
original position, if an "E" service code is not displayed, the problem has been removed.
★ If the starting switch is turned OFF after an abnormality occurs, turn the starting switch ON and check if
an "E" is displayed with the service code. (If it is not displayed, the problem has been removed.)
★ Before carrying out troubleshooting, check that all the related connectors are properly inserted.
★ Always connect any disconnected connectors before going on to the next step.
PC228US-3 20-301
1
N-1 TROUBLESHOOTING OF COMMUNICATIONS ABNORMALITY
12
N-1 [E218] Communications abnormality
Cause Remedy
YES
System is reset
Is [228] displayed
on monitoring YES Defective engine
code 03? throttle, pump Replace
Is voltage between controller
• Disconnect C17. C04 (4) (12) and
• Turn starting NO chassis normal?
YES Defective monitor
switch ON. Replace
• Turn starting Is resistance panel
switch ON. between P02 (9),
• Min. 7.5 V NO (10) and C04 (4), Disconnection in
(12) normal? wiring harness Replace
• Disconnect C04
and measure • Disconnect NO between P02 (9), (10)
voltage at wiring P02 and C04. and C04 (4), (12)
harness end. • Max. 1 Ω
• When the controllers are not connected to the network, "- --" is displayed. If the correct letter or number
is not displayed (another model is displayed), there is an abnormality in the controller model selection
N-1 Related electrical circuit diagram
20-302 PC228US-3
1
12
TROUBLESHOOTING OF ENGINE THROTTLE AND

PUMP CONTROLLER
(GOVERNOR CONTROL SYSTEM)
(E MODE)
Points to remember when carrying out troubleshooting of engine throttle and

pump controller system (governor control system) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-402
Action taken by controller when abnormality occurs and problems on machine. . . . . . . . . . . . 20-404
Judgement table for engine throttle and pump controller (governor control system)
and engine related parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-408
Electrical circuit diagram for E mode system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-410
E- 1 Abnormality in engine throttle and pump controller power source
(controller LED is OFF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-412
E- 2 [E308] Abnormality in fuel control dial input value is displayed . . . . . . . . . . . . . . . . 20-413
E- 3 [E317] Abnormality (disconnection) in governor motor drive system
is displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-414
E- 4 [E318] Abnormality (short circuit) in governor motor drive system is displayed . . . 20-415
E- 5 [E306] Abnormality in feed back potentiometer system is displayed . . . . . . . . . . . . 20-416
E- 6 [E315] Abnormality (short circuit) in battery relay output system is displayed . . . . 20-417
E- 7 [E316] Abnormality (step-out) in governor motor is displayed . . . . . . . . . . . . . . . . . 20-418
E- 8 Engine does not start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-420
E- 9 Engine is irregular . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-424
a)Idling speed is irregular . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-424
b)There is hunting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-426
E-10 Lack of power (engine high idling speed is too low) . . . . . . . . . . . . . . . . . . . . . . . . . . 20-428
E-11 Engine does not stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-430
E-12 Defective operation of battery relay system (engine does not stop) . . . . . . . . . . . . . 20-432
★ If any abnormality occurs, turn the starting switch OFF, then turn it ON again and check that "E"
is displayed with the service code. (If it is not displayed, the problem has been removed.)
PC228US-3 20-401
1
TROUBLESHOOTING POINTS TO REMEMBER
12
POINTS TO REMEMBER WHEN CARRYING OUT TROUBLE-

SHOOTING OF ENGINE THROTTLE AND PUMP CONTROLLER
SYSTEM
1. This engine is equipped with the control system below to prevent seizure of the turbocharger when
starting at low temperatures (engine water temperature below 30° C).
Engine speed forcibly fixed during warming-up As desired

(throttle command ignored) (follows throttle signal)
Governor motor
potentiometer
(control)
2 sec.
Starting Starting
switch at switch at
ON START
In other words, when the engine water temperature is low (below 30° C), the engine does not start. When
inspection is carried out to check if the governor motor related parts move or not, even if the governor
motor is normal, it is not actuated. (The same happens when [E218] Abnormality in communication
occurs. The governor motor is not actuated, so troubleshooting is carried out, and if it is normal, it is actu-
ated.)
★ To cancel the control when starting in low temperatures, connect a short connector to the engine
water temperature sensor (CN-E05), which is connected to CN-P02 (1) of the monitor panel, and
short circuit it to the ground {or short circuit CN-E05 (female) (1) to the ground}. Or check the
actuation in the governor adjustment mode.
2. Points to remember when there is abnormality which is not displayed by user code
The engine is controlled by the engine throttle and pump controller.
The problems that may occur with the system include the following.
1. Idling speed is too high (too low)
2. High idling speed is too low
3. Auto-deceleration speed is too high (too low)
4. Engine speed for automatic warming-up operation is too high (too low)
5. There is hunting
6. Engine does not stop
If any abnormality occurs, and the abnormality is displayed on the time display portion of the monitor
panel, use the troubleshooting table to determine the appropriate troubleshooting flow chart from E- 1
to E-10. However, if there is any abnormality in the machine and no abnormality display is given, it is
necessary to determine whether the problem is in the mechanical system or in the electrical system. If
the linkage between the governor motor and the injection pump is not properly adjusted, problems 1 to
6 listed above may occur. Therefore, if there is no abnormality display, but one of the problems 1 to 6
occurred, carry out troubleshooting as follows.
20-402 PC228US-3
1
12
YES 2
If linkage between YES Defective adjustment of governor motor
governor motor linkage See TESTING AND ADJUSTING
1 and injection pump
If linkage between is disconnected,
governor motor and does operation of
injection pump is governor motor Go to troubleshooting E- 9 — E-12
disconnected and become normal? NO of electrical system
pump level is oper-
• With starting switch at ON, operate fuel
ated by hand or is
control dial and working mode switch.
fixed with wire, does Go to troubleshooting S-1 — S-16
condition return to NO of engine system
normal.
• If engine does not stop, push
governor lever to STOP position
and check if engine stops.
Disconnect the linkage as explained above, or check the adjustment and go to the troubleshooting flow
chart for the mechanical system or electrical system.
For details of the procedure for adjusting the linkage, see TESTING AND ADJUSTING.
3. Points to remember if abnormality returns to normal by itself

In the following two cases, there is a high probability that the same problem will occur again, so it is
desirable to follow up this problem carefully.
1) If any abnormality returns to normal by itself, or
2) If the connector is disconnected and the T-adapter is inserted, or if the T-adaptor is removed and the
connector is returned to its original position when carrying out troubleshooting of the failure, and
the service code is not longer displayed, or if the monitor display returns to normal.
3) After completing troubleshooting, always erase the service code from memory.
4. User code memory retention function
When displaying the abnormality code in memory and carrying out troubleshooting, note down the
content of the display, then erase the display. After trying t re-enact the problem, carry out trouble-
shooting according to the failure code that is displayed.
(There are cases where mistaken operation or abnormalities that occur when the connector is discon-
nected are recorded by the memory function. Erasing the data in this way saves any wasted work.
PC228US-3 20-403
1
TROUBLESHOOTING ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS
12
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY

OCCURS AND PROBLEMS ON MACHINE
User Service
Abnormal system Nature of abnormality
code code
1. Short circuit in wiring harness between C03 (7) - (14), (7) - (17), (14) - (17)
2. Short circuit in wiring harness between E10 (A) - (B), (A) - (C), (B) - (C)
3. Short circuit in wiring harness between E06 (1) - (2), (1) - (3), (2) - (3
4. Short circuit in wiring harness between A53 (1) - (2), (1) - (3), (2) - (3)
Abnormality in fuel 5. Short circuit in wiring harness between C03 (7) - (4), (4) - (17)
E308
control dial input value 6. Disconnection in wiring harness between C03 (7) - E06 (1)
7. Disconnection in wiring harness between C03 (4) - E06 (2)
9. Defective fuel control dial
10. Defective contact of connector C03, H15, E06
1. Disconnection inside governor motor

Abnormality 3. Disconnection in wiring harness between C02 (4) - E11 (3)
E05 E317 (disconnection) in
motor drive system 4. Disconnection in wiring harness between C02 (3) - E11 (2)
6. Defective contact of connector E11
1. Short circuit inside governor motor

2. Short circuit in wiring harness between C02 (2) - E11 (1), and between
Abnormality C02 (4) - E11 (3) with wiring harness between C02 (3) - E11 (2)
E318 (short circuit) motor
drive system 3. Short circuit in wiring harness between C02 (4) - E11 (3), and between
C02 (2) - E11 (1) with wiring harness between C02 (5) - E11 (4)
4. Short circuit with chassis ground in wiring harness in Items 2, 3.
20-404 PC228US-3
1
12
Condition when normal Action by controller when Problem that appears on machine
(voltage, current, resistance) abnormality is detected when there is abnormality
1. Does not become partial speed
when set at MAX position
2. Does not reach high idling when
C03 E06 Resistance set at partial speed
(female) (male) value 3. There are causes of hunting
(7) - (4) (1) - (2) 0.25 - 5 kΩ Maintains engine speed at 4. Lacks output (max. speed of
position of fuel control dial engine is too low)
(4) - (17) (2) - (3) 0.25 - 5 kΩ
immediately before abnor-
— (1) - (3) 4 - 6 kΩ mality occurred
Between
each pin — Min. 1 MΩ
and chassis
1. When there is a disconnection in

both the A phase and B phase at
E11 C02 Resistance
(male) (female) value the same time, the problem is the
same as for a short circuit in the
(1) - (2) (2) - (3) 0.25 - 7.5 Ω
governor motor system
(3) - (4) (4) - (5) 0.25 - 7.5 Ω 2. When there is a disconnection in
(1) - (3) (2) - (4) Min. 1 MΩ only one of A phase or B phase
(1) - (4) (2) - (5) Min. 1 MΩ
Takes no particular action
1) Engine does not stop
Between Between 2) Stops moving at position
pin (1), (2), pin (1), (2), immediately before failure, so
Min. 1 MΩ
(3), (4) and (3), (4) and engine speed cannot be con-
chassis chassis
trolled
Motor drive current: Hold: 0.7 A 3) There are cases of hunting
Start: 0.84 A
1. If during operation
E11 C02 Resistance 1) Set to low idling
(male) (female) value 2) Engine does not stop
(1) - (2) (2) - (3) 0.25 - 7.5 Ω 3) There are cases of hunting
(3) - (4) (4) - (5) 0.25 - 7.5 Ω 2. When stopped
(1) - (3) (2) - (4) Min. 1 MΩ 1) Engine starts, but stays at low
Sets motor drive current to 0 idling
(1) - (4) (2) - (5) Min. 1 MΩ
Between Between 2) Engine does not stop after
pin (1), (2), pin (1), (2), starting
Min. 1 MΩ
(3), (4) and (3), (4) and 3) There are cases of hunting
chassis chassis
Motor drive current: Hold: 0.7 A
Start: 0.84 A
PC228US-3 20-405
1
12
User Service
code code
3. Short circuit in wiring harness between E06 (1) - (2), (1) - (3), (2) - (3)
Abnormality in feed- 5. Short circuit in wiring harness between C03 (7) - (4), (4) - (17)
— E306 back potentiometer
system 6. Disconnection in wiring harness between C03 (7) - E10 (1)
9. Defective governor motor potentiometer
10. Defective contact of connector C03, E10
Abnormality (short cir- If excess current flows between C03 (1) and battery relay
— E315 cuit) in battery relay ★ This occurs only when turning starting switch to OFF and stopping
output system engine
1. Defective adjustment of rod or scuffing of loose spring

Abnormality
— E316
(step-out) in motor 2. Abnormality in governor motor
3. Abnormality in engine throttle and pump controller
20-406 PC228US-3
1
12
Condition when normal Action by controller when abnor- Problem that appears on machine
(voltage, current, resistance) mality is detected when there is abnormality
1. Precision of engine speed control
may be reduced.
For example:
1) Engine does not rise to high
idling speed (a little too low)
2) Engine does not go down to
C03 E04 Resistance low idling speed (a little too
(female) (male) value high)
(7) - (14) (1) - (2) 0.25 - 5 kΩ Calculates position of motor and 3) Defective engine speed for
carries out control from value of auto-deceleration or automatic
(7) - (17) (2) - (3) 0.25 - 5 kΩ
voltage immediately before abnor- warming-up
— (1) - (3) 4 - 6 kΩ mality occurred
4) Engine may not stop
Between
★ The governor motor
moves in the direction to
and chassis
stop the engine, but the
motor may not move
completely to the position
to stop the engine.
5) There are cases of hunting
Between C03 (1) and chassis: 20 - 30 V

★ Holds with the motor in the stop
position for 2 - 2.5 sec., returns to Sets battery relay drive current to 0 6) Engine does not stop
the low idling position, then turns
the battery relay OFF.
1. Linkage adjustment correct 1. Displays when returning from

high idling to low idling
★ Starts again (repeats step- Engine speed cannot be controlled
2. Must move lightly when connec-
out) (particularly at high idling), so there is
tor is removed
2. In some cases it may not dis- hunting
3. Normal play when returning from par-
tial speed to low idling
PC228US-3 20-407
1
TROUBLESHOOTING JUDGEMENT TABLE
JUDGEMENT
12 TABLE
JUDGEMENT TABLE FOR ENGINE THROTTLE AND PUMP
CONTROLLER (GOVERNOR CONTROL SYSTEM) AND ENGINE
RELATED PARTS
Abnormality in engine throttle and pump controller power source system

Engine throttle and pump
controller, engine related parts
(E3: system)
Abnormality (disconnection) in motor drive system
Abnormality (short circuit) in battery relay output

Abnormality (short circuit) in motor drive system
Abnormality in feedback potentiometer system

Abnormality in fuel control dial input value
Abnormality (step-out) in motor

User code E05
Failure mode
Service code 308 317 318 306 315 316
1 Engine does not start easily
2 Engine does not start
3 Engine speed stays at low idling, and does not follow accelerator; or engine pickup is poor ● ● ● ● ●
4 Engine stops during operation

When idling speed is irregular
5 Engine rotation is irregular
When there is hunting ● ● ● ● ●
6 Lack of output ( engine high idling speed is too low) ● ●
7 Auto-deceleration does not work

8 Engine does not stop " ● ● ● ●
9 Warming-up operation is defective

10 Exhaust gas is black
11 Oil consumption is excessive, or exhaust gas is blue
12 Oil becomes dirty prematurely
13 Fuel consumption is excessive, or exhaust gas is blue
14 Oil is mixed in coolant
15 Engine oil pressure caution lamp lights up
16 Oil level rises
17 Coolant temperature rises too high (overheating)
18 Abnormal noise is generated
19 There is excessive vibration
20 Engine speed does not change even when working mode is switched
Troubleshooting code when service code is displayed E-1 E-2 E-3 E-4 E-5 E-6 E-7
Troubleshooting code when there is abnormality in monitoring or machine monitor check — — — — — — —
": This shows applicable item service
20-408 PC228US-3
1
Machine
Checking monitoring, check items monitor
check item
Troubleshooting code if no service code display is given

Is red range displayed?
Fuel control dial command value
Governor motor A phase current
Governor motor B phase current

Governor motor potentiometer
No. 2 throttle command value
Coolant temperature voltage
Does starting motor turn?

Battery relay drive signal
102° C or above
105° C or above
Monitoring code
35 16 30 31 33 34 41 108
S-1
O S-2
O S-3
S-4
E-9A), S-5
E-9A), S-5
O E-10, S-6
E-3 and E-4
O E-11
O O E-3 and E-4
O O See ENGINE SHOP MANUAL
E-3 and E-4
— — — — — — — — — —
E-12 — — — — — M-13 M-13 E-8
O : This shows item to check with monitoring or machine monitor
: This shows item that needs only checking with monitoring
PC228US-3 20-409
1
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM FOR E MODE
12
ELECTRICAL CIRCUIT DIAGRAM FOR E MODE
20-410 PC228US-3
1
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM FOR E MODE
12
PC228US-3 20-411
1
TROUBLESHOOTING E-1
12
E-1 Abnormality in engine throttle and pump controller

power source (controller LED is OFF)
★ Check that fuse 11 is normal.
★ When the starting motor turns normally (if the starting motor does not turn, go to E-8)
Cause Remedy
YES
Defective engine throttle,
pump controller Replace
1
Is voltage between
C01 (7)(13) and 2 YES Defective contact or disconnec-
tion in wiring harness between Repair or
(6)(12) normal?
Is voltage between fuse 11 and C01 (female) (7)(13) replace
• Turn starting fuse 11 and chas-
switch ON. NO sis normal? Defective contact or disconnec-
• 20 - 30 V Repair or
• Turn starting tion in wiring harness between
NO replace
switch ON. fuse 11 and battery relay M
• 20 - 30 V
E-1 Related electrical circuit diagram
20-412 PC228US-3
1
TROUBLESHOOTING E-2
12
E-2 [E308] Abnormality in fuel control dial input value is

displayed
Cause Remedy
NO
Defective engine throttle, Replace
1 pump controller system
Is resistance
between E06 (male)
2 YES Defective wiring harness of
(1) - (2), (2) - (3) as Replace
shown in Table 1? Is resistance where resistance is defective
• Turn starting between pins of
YES C03 (female) (4) (7)
switch OFF.
(17) or each pin Defective fuel control dial Replace
• Disconnect NO
E06. and chassis as
shown in Table 1?
• Turn starting
switch OFF.
• Disconnect
C03.
★ If E306 and E241 occur at the same time, check the following wiring harnesses.
• Short circuit with ground in wiring harness between C03 (female) (7) - E10 (female) (A), C03 (female)
(7) - A53 (female) (1), or contact with other wiring harness
★ If the other wiring harnesses are normal, the wiring harness related to C03 (female) (7) - (17) is the
cause.
Table 1
C03 (female E06 (male) Resistance value
(7) - (4) (1) - (2) 0.25 - 5 kΩ
(4) - (2) - (3) 0.25 - 5 kΩ
— (1) - (3) 4 - 6 kΩ
Between each pin

— Min. 1 MΩ
and chassis
PC228US-3 20-413
1
TROUBLESHOOTING E-3
12
E-3 [E317] Abnormality (disconnection) in governor drive

system displayed
★ During operation, if there is
1) a simultaneous disconnection in A phase and B phase:
1) the engine will run at low idling
2) the engine will not stop
2) a disconnection in either A phase or B phase, the engine speed will remain the same as before the
abnormality occurred
★ If the problem occurs when the engine is stopped
1) the engine can be started, but it stays in low idling, or 2) it will not stop after it is started.
Check with the engine stopped (push the fuel control lever of the fuel injection pump to the
NO INJECTION position).
Cause Remedy
YES Defective engine throttle

Replace
Is resistance • pump controller
between each pin
YES
of C02 (female), or
1 between each pin
Is resistance and chassis as
Defective wiring harness in
between each pin of shown in Table 1? Replace
system with defective
E11 (male), or • Turn starting NO resistance
between each pin switch OFF.
and chassis as • Disconnect C02.
shown in Table 1?
• Turn starting Defective governor motor Replace
switch OFF. NO
• Disconnect E11.
Table 1
E11 C02 Resistance

(male) (female) value
(1) - (2) (2) - (3) 2.5 - 7.5 Ω
(3) - (4) (4) - (5) 2.5 - 7.5 Ω
E-3 Related electric circuit diagram
20-414 PC228US-3
1
TROUBLESHOOTING E-4
12
E-4 [E318] Abnormality (short circuit) in motor drive system

is displayed
★ If the abnormality occurs during operation, because of the force of the spring,
1) the engine will run at low idling
2) the engine will not stop
★ If the problem occurs when the engine is stopped
1) the engine can be started, but it stays in low idling, or 2) it will not stop after it is started.
Cause Remedy
YES Defective engine throttle

Replace
Is resistance • pump controller
between each pin
YES
of C02 (female), or
1 between each pin
between each pin of shown in Table 1? Replace
E11 (male), or • Turn starting NO resistance
between each pin switch OFF.
and chassis as • Disconnect C02.
shown in Table 1?
switch OFF. NO
• Disconnect E11.
E11 C02 Resistance

(male) (female) value
(1) - (2) (2) - (3) 2.5 - 7.5 Ω
(3) - (4) (4) - (5) 2.5 - 7.5 Ω
(1) - (3) (2) - (4) Min. 1 MΩ
(1) - (4) (2) - (5) Min. 1 MΩ
Between chassis Between chassis
and pins and pins Min. 1 MΩ
(1) (2) (3) (4) (1) (2) (3) (4)
PC228US-3 20-415
1
TROUBLESHOOTING E-5
12
E-5 [E306] Abnormality in feedback potentiometer system is displayed
Cause Remedy
Is resistance YES Defective engine throttle,

between each pin
of C03 (female) (4)
YES
(7) (14), or between
1 each pin and
Is resistance chassis as shown
between E10 (male) in Table 1? Replace
(1)-(2), (2)-(3) as • Turn starting NO resistance
shown in Table 1? switch OFF.
• Disconnect C03.

switch OFF. NO
• Disconnect E10.
★ If E308, E241 also occurs at the same time, check the wiring harness below.
• Wiring harness between C03 (female) (7) - E06 (female) (1), C03 (female) (7) - A53 (female) (1) short
circuiting with ground, or contact with other wiring harness
★ Wiring harness related to C03 (female) (7) - (17) has a possibility to be a cause of failure when other
wiring harness is normal.
Table 1
C03 (female E10 (male) Resistance value
(7) - (14) (1) - (2) 0.25 - 5 kΩ
(14) - (17) (2) - (3) 0.25 - 5 kΩ
— (1) - (3) 4 - 6 kΩ
Between each pin

— Min. 1 MΩ
and chassis
20-416 PC228US-3
1
TROUBLESHOOTING E-6
12
E-6 [E315] Abnormality (short circuit) in battery relay output

system is displayed
★ This only occurs when the engine is stopped and the starting switch is turned OFF.
Cause Remedy
1 YES Defective engine throttle, Replace

pump controller system
Is resistance
between C01 2 YES
Defective battery relay Replace
(female) (1) and Is resistance
chassis normal? between each pin
• Between C01 of C02 (female) (1)
(female) (1) and and battery relay
chassis: Approx. terminal BR, and
NO
100 Ω between wiring 1) Contact between other
• Turn starting harness and chas- wiring harness and wiring
switch OFF. sis normal? harness between C01 Replace
• Disconnect C01. • Between C01 NO (female) (1) battery relay
(female) (1) and BR.
battery relay BR: 2) When light is connected
Max. 1 Ω
• Between wiring
harness and
chassis: Min. 1 Ω
• Turn starting
switch OFF.
• Disconnect C01
and battery relay
BR.
PC228US-3 20-417
1
TROUBLESHOOTING E-7
12
E-7 [E316] Abnormality (step-out) in governor motor is

displayed
★ If any other service code [E306] - [E318] has occurred at the same time, start troubleshooting from the
code except code [E316].
★ Check that the fuse is normal.
★ Read the precautions given in TESTING AND ADJUSTING, "Adjusting travel of governor motor lever"
before carrying out the troubleshooting.
Cause Remedy
YES Go to applicable failure —
mode
1
Are E306, E317, 3 YES Defective engine throttle
Replace
and E318 Operate fuel con- • pump controller
displayed? YES
trol dial 0 ↔ MAX
2 and turn starting 4 YES 1) Defective linkage.
• Turn starting 2) Defective injection
switch ON. Is adjustment of switch OFF. Is Is there any
operation normal? pump
linkage normal? scuffing when
NO spring rod is
• Turn starting NO
moved to injec-
• Turn starting switch ON. tion pump end? Adjust or
Defective governor
switch ON. • Turn auto
• Disconnect NO motor replace
• Turn auto- deceleration
E05.
deceleration OFF. OFF.
• Disconnect
• Set to governor
linkage at
motor
governor
adjustment. Adjust (For
motor end. details, see
• See TESTING
Defective governor TESTING AND
AND ADJUST-
NO linkage TROUBLE-
ING.
SHOOTING)
20-418 PC228US-3
1
TROUBLESHOOTING E-8
12
E-8 Engine does not start
★ Check that the signal from battery relay terminal M of the monitor screen is normal.
★ When starting motor does not rotate.
★ Check that fuse 14 is not blown before starting troubleshooting.
★ Set the PPC oil pressure lock switch to LOCK.
(Raise the work equipment lever stand.
4 YES
Is voltage between
starting motor
YES
terminal B and
chassis normal?
switch ON.
• 20 - 29 V.
YES
3 7
YES YES Is voltage

Is there sound of between starting
starting motor motor terminal C
pinion engaging? and chassis
normal?
6 Same conditions
as Item 5.
YES NO
Is voltage between
safety relay
2
terminal C and
chassis normal?
YES When starting 5
switch is turned
OFF, is around Same conditions
heard from battery as Item 5.
relay? Is voltage between
starting switch
terminal C and
• See Table 1. NO chassis normal?
• Turn starting
switch ON → NO
1 OFF. • Turn starting

switch to START.
• 20 - 29 V.
Is voltage and
specific gravity of NO
battery normal?
• Min. 24 V. 13 YES
• Specific gravity:
Min. 1.26 12 YES Is there continuity
between chassis
11 YES Is there continuity ground and
between starting battery relay
YES switch terminal BR terminal E?
Is there continuity and battery relay?
between starting • Turn starting
switch terminal B NO
switch OFF.
and BR? • Use tester in
10
diode range, and
• Turn starting contact (+) pole
Is voltage of switch ON. with starting
NO starting switch • Remove terminal switch and (-) NO
terminal B normal? B.
pole with battery relay.
• Disconnect both starting switch and
• Connect negative • battery relay ends.
(-) pole of tester to
(-) terminal of NO
battery.
• 20 - 29 V.
NO
NO
20-420 PC228US-3
1
TROUBLESHOOTING E-8
12
Cause Remedy
Defective starting motor Repair or

(starting motor protect) replace
Defective contact of wir-

ing harness between
battery (+) - battery relay Repair or
B - battery relay M - replace
starting motor terminal B
(including battery relay)
Defective starting motor Repair or

(magnetic clutch) replace
Defective contact or
YES disconnection in wiring Repair or
harness between safety replace
relay terminal C - T13 (1)-
8 starting motor terminal
C.
Is voltage between
safety relay terminal
9 YES
C and chassis
Defective safety relay Replace
normal?
Is voltage between
safety relay terminal R
Same conditions NO and chassis normal?
as Item 5.
• Turn starting
switch ON. Repair or
Defective alternator
• Max. 13 V replace
NO
Defective contact or
disconnection in wiring
Repair or
harness between X07 replace
(female)(10) - M02 (1) -
safety relay terminal S
Defective starting switch

(between terminals B Replace
and C)
Defective battery relay Replace
Defective contact of
wiring harness between
Replace or
battery relay terminal E
replace
and revolving frame
ground terminal
Defective contact, or
harness between
starting switch terminal Replace
BR - D13- battery relay
terminal BR
(including diode)
Defective starting switch Replace

(between B and BR)
harness between battery
terminal (+) - M11 - H14 Replace
(1), (5) - X07 (1) - starting
switch terminal B
(including fusible link)
Change or
Lack of battery capacity
replace
PC228US-3 20-421
1
TROUBLESHOOTING E-8
20-422 PC228US-3
1
TROUBLESHOOTING E-9
12
E-9 Engine speed is irregular

a) Idling speed is irregular
YES
When linkage YES

2 YES between governor
motor and pump
YES is adjusted, does
Is E218 condition become
displayed?
normal?
NO
• Turn starting 3 • See TESTING
switch ON. AND
When linkage is Starting motor signal 7 YES
ADJUSTING.
disconnected
and motor lever YES Is voltage
between C03 (8)
1 NO is placed at Potentiometer 6 and chassis
position engine normal and
low idling? YES Is voltage stable?
Is controller
model code Fuel control dial 5 between C03 • During NO
• Turn starting (14) and (17) nor-
"228" ? switch ON. operation:
Is voltage mal and stable?
between C03 (4) 20 - 30 V
• Turn starting NO and (17) normal • At MIN:
switch ON. and stable? 2.9 - 3.3 V NO
• Set to
monitoring • At MIN:
code 02. 4.0 - 4.75 V
NO
NO
20-424 PC228US-3
1
TROUBLESHOOTING E-9
Cause Remedy
See N mode
Defective adjustment Adjust

of linkage
Defective injection See S

pump mode
Defective governor
motor Replace
wiring harness
between starting Repair or
switch ACC - C03 replace
(female) (10), or
defective starting
switch.
See E-5 —
—
See E-2
See C-22 —
PC228US-3 20-425
1
TROUBLESHOOTING E-9
12
b) There is hunting
YES
When linkage YES

2 YES between governor
motor and pump is
YES adjusted, does
Is E218 condition become
displayed?
normal?
3 NO
• Turn starting When linkage is
switch ON. disconnected Starting motor signal 7 YES
and motor lever
is matched with YES Is voltage
fuel control dial, between C03 (8)
1 NO does engine Potentiometer 6 and chassis
stop? normal and
YES Is voltage stable?
Is controller between C03
model code • Turn starting Fuel control dial 5 NO
(14) and (17) nor- • During
"228" ? switch ON.
Is voltage mal and stable? operation:
• Turn fuel between C03 (4) 20 - 30 V
• Turn starting control dial NO and (17) normal
from MIN to and stable? • At low idling:
switch ON. NO
MAX and stop 2.3 - 3.3 V
• Set to
also at mid- • At full throttle:
monitoring • At low idling:
way position. 0.5 - 0.9 V
code 02. 4.0 - 4.75 V
• At full throttle: NO
0.25 - 1.0 V
NO
20-426 PC228US-3
1
TROUBLESHOOTING E-9
12
Cause Remedy
See N mode
Defective adjustment
of linkage Adjust

pump mode
Defective governor
motor Replace
wiring harness
(female) (8), or
defective starting
switch.
See E-5 —
—
See E-2
See C-22 —
PC228US-3 20-427
1
TROUBLESHOOTING E-10
12
E-10 Lack of power (engine high idling speed is too low)
YES
YES
2
YES
Is E218
displayed?
• Turn starting 3 YES

switch ON. Potentiometer 6
Does injection
pump lever YES Is voltage
contact FULL between C03
1 NO stopper? Fuel control dial 5 (14) and (17)
normal and
YES Is voltage stable?
Is controller
model code between C03 (4) • At low idling: NO
• Start engine. and (17) normal
"228" ? and stable? 2.3 - 3.3 V
• Set fuel control • At full throttle:
• Turn starting dial to MAX. 4 • At low idling: 0.5 - 0.9 V
switch ON. • A mode. 4.0 - 4.75 V
Is adjustment of NO
• Set to linkage between • At full throttle:
monitoring NO governor motor 0.25 - 1.0 V
code 02. and pump
normal? 8 YES
When linkage
between governor
motor and pump
NO is adjusted, does
condition become
normal? NO
• See TESTING
AND
ADJUSTING.
NO
20-428 PC228US-3
1
12
Cause Remedy
See N mode —

pump mode
Starting motor
signal 7 YES Defective governor
motor Replace
Is voltage between
C03 (8) and chassis Defective contact of
normal and stable? wiring harness
• During operation: NO (female) (8), or
20 - 30 V. defective starting
switch.
See E-5 —
See E-2 —
Defective adjustment Adjust

of governor motor
linkage.
See S mode —
See C-22
E10 Related electric circuit diagram
PC228US-3 20-429
1
12
E-11 Engine does not stop
★ Read the precautions given in TESTING AND ADJUSTING, "Adjusting travel of governor motor lever"
before carrying out the troubleshooting.
YES
2
YES Does governor
lever contact the
engine stop side YES
stopper, and
does engine
stop? 3
• When linkage Potentiometer 6 YES
Turn starting
switch ON!OFF. is adjusted,
YES When starting
does condi- switch is OFF, is
1 NO tion become Relay drive signal 5 voltage between
normal? C03 (14) and (17)
YES When starting normal and
Is controller • Does loose switch is OFF,
model code stable? NO
spring move does voltage
"228" ? between C01 (1) • When engine is
freely?
Starting motor and (6)(12)
signal 4 stopped
• Turn starting • See TESTING change as
shown in • 2.9 - 3.3 V
switch ON. AND
When starting Table 1? NO
• Set to ADJUSTING. switch is OFF, is
monitoring NO voltage between • 20 - 30 V.
code 03 or 02. C03 (8) and
chassis normal?
• Max. 1 V. NO
NO
Table 1
Note 1: When the starting switch is ON, the controller end is OFF, but a voltage of approx. 20 - 30 V is
always flowing from starting switch BR, so if the voltage is measured at C01 (1), there is a voltage
of 20 - 30 V.
20-430 PC228US-3
1
12
Cause Remedy
Defective injection pump See S mode
Defective adjustment of
linkage Adjust
Defective governor motor Replace
See E-5 —
Defective engine throttle

and pump controller Replace
Contact with 24 V wiring

harness of wiring
harness between starting Replace
switch ACC - C03 (female)
(8), or defective starting
switch.
See C-22 —
PC228US-3 20-431
1
12
E-12 Defective operation of battery relay system (engine

does not stop)
★ This only occurs when the engine is stopped and the starting switch is turned OFF.
Cause Remedy
YES
See E-6 —
1
Is E315
displayed? YES Defective engine
throttle and pump Replace
• Turn starting Relay drive signal 2 controller
switch ON. Is display moni-
toring code 35 as
NO shown in Table 1? 3 YES Defective battery
relay Replace
Is resistance
• Turn starting between C01
switch OFF. (female) (1) and
• 20 - 30 V battery relay 1) Disconnection in
NO terminal BR, and wiring harness Repair or
between wiring between C01 replace
NO (female) (1) -
harness and
chassis normal? battery relay BR.
1) When light is
• Between C01 (female) (1) and connected
battery relay BR: Max. 1 Ω
• Between wiring harness and
chassis: Max. 1 MΩ
• Turn starting switch OFF.
• Disconnect C01 and battery relay BR.
Table 1
Voltage from When ON (Approx. 24V)

starting switch (C03 (8))
To battery relay (BR)

OFF
See Note 1 Voltage output from controller when starting switch is OFF
When ON
(Approx. 24V)
Condition of actuation To battery relay (BR)
of controller circuit OFF
C01 (1) Min. 4.0 sec.
Drive time Max. 7sec. (when it is impossible to set to
NO IINJECTION because of failure in motor)
BKP00206
Note: When the starting switch is ON, the controller end is OFF, but a voltage of approx. 20 - 30 V is
always flowing from starting switch BR, so if the voltage is measured at C01 (1), there is a voltage
of 20 - 30 V.
20-432 PC228US-3
1
12
PC228US-3 20-433
1
12
TROUBLESHOOTING OF ENGINE THROTTLE AND

PUMP CONTROLLER
(PUMP CONTROL SYSTEM)
(C MODE)
Points to remember when carrying out troubleshooting pump controller system. . . . . . . . . . . 20-502
Action taken by controller when abnormality occurs and problems on machine. . . . . . . . . . . . 20-504
Judgement table for engine throttle and pump controller (pump control system)
and hydraulic related parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-514
Electrical circuit diagram for C mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-516
C- 1 Abnormality in controller power source (controller LED is OFF) . . . . . . . . . . . . . . . . 20-518
C- 2 [E232] Short circuit in PC-EPC solenoid system is displayed . . . . . . . . . . . . . . . . . . . 20-519
C- 3 [E233] Disconnection in PC-EPC solenoid system is displayed . . . . . . . . . . . . . . . . . 20-520
C- 4 [E203] Short circuit in swing brake solenoid system is displayed . . . . . . . . . . . . . . . 20-521
C- 5 [E213] Disconnection in swing brake solenoid system is displayed . . . . . . . . . . . . . 20-523
C- 6 [E234] Short circuit in boom RAISE throttle EPC solenoid system is displayed . . . . 20-525
C- 7 [E235] Disconnection in boom RAISE throttle EPC solenoid system is displayed . . 20-526
C- 8 [E204] Short circuit in pump merge/divider solenoid system is displayed . . . . . . . . 20-527
C- 9 [E214] Disconnection in pump/divider solenoid system is displayed . . . . . . . . . . . . 20-528
C-10 [E206] Short circuit in travel speed solenoid system is displayed . . . . . . . . . . . . . . . 20-529
C-11 [E216] Disconnection in travel speed solenoid system is displayed . . . . . . . . . . . . . 20-530
C-12 [E205] Short circuit in 2-stage relief solenoid system is displayed . . . . . . . . . . . . . . 20-531
C-13 [E215] Disconnection in 2-Stage relief solenoid system is displayed . . . . . . . . . . . . 20-532
C-14 [E217] Machine Model selection input error is displayed . . . . . . . . . . . . . . . . . . . . . . 20-533
C-15 [E222] Short circuit in LS-EPC solenoid system is displayed . . . . . . . . . . . . . . . . . . . 20-534
C-16 [E223] Disconnection in LS-EPC solenoid system is displayed . . . . . . . . . . . . . . . . . 20-535
C-17 [E224] Abnormality in front pump pressure sensor system is displayed . . . . . . . . . 20-536
C-18 [E225] Abnormality in rear pump pressure sensor system is displayed . . . . . . . . . . 20-537
C-19 [E226] Abnormality in pressure sensor power system is displayed . . . . . . . . . . . . . 20-538
C-20 [E201] Short circuit in travel junction solenoid system is displayed . . . . . . . . . . . . . 20-539
C-21 [E211] Disconnection in travel junction solenoid system is displayed. . . . . . . . . . . . 20-540
C-22 [E227] Abnormality in engine speed sensor is displayed . . . . . . . . . . . . . . . . . . . . . . 20-541
C-23 [E241] Abnormality in boom angle potentiometer system input value is displayed 20-542
C-24 [E255] Abnormality in boom angle potentiometer compensation value
(outside compensation range) is displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-543
C-25 [E256] Check sum abnormality is displayed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-543
C-26 [E313] Abnormality in automatic greasing is displayed . . . . . . . . . . . . . . . . . . . . . . . 20-543
C-27 Abnormality in ATT-EPC solenoid system is displayed . . . . . . . . . . . . . . . . . . . . . . . . 20-544
★ This troubleshooting is carried out when there is still an abnormality, so when dis-
connecting the connector and inserting the T-adapter, or when removing the T-
adapter and returning the connector to its original position, if an E service code is
not displayed, the problem has been removed.
PC228US-3 20-501
1
POINTS TO REMEMBER WHEN TROUBLESHOOTING PUMP

CONTROLLER SYSTEM
1. Points to remember if abnormality returns to normal by itself

In the following two cases, there is a high probability that the same problem will occur again, so it is
desirable to follow up this problem carefully.
1) If any abnormality returns to normal by itself, or
2) If the connector is disconnected and the T-adapter is inserted, or if the T-adapter is removed and the
connector is returned to its original position when carrying out troubleshooting of the failure, and
the service code is no longer displayed. or if the monitor display returns to normal.
3) After completing troubleshooting, always erase the user code from memory.
2. User code memory retention function
When displaying the abnormality code in memory and carrying out troubleshooting, note down the
content of the display, then erase the display. After trying to re-enact the problem, carry out trouble-
shooting according to the failure code that is displayed.
(There are cases where mistaken operation or abnormalities that occur when the connector is discon-
nected are recorded by the memory function. Erasing the data in this way saves any wasted work.)
20-502 PC228US-3
1
TROUBLESHOOTING ACTION TAKEN BY THE CONTROLLER WHEN ABNORMALITY OCCURS
12
ACTION TAKEN BY THE CONTROLLER WHEN ABNORMAL-

ITY OCCURS AND PROBLEMS ON MACHINE
User Service
code code
1. Short circuit with ground, short circuit inside pump EPC solenoid
Short circuit in 2. Short circuit with power source, short circuit with ground in wiring harness
E232 pump EPC between controller C02 (8) and solenoid C13 (1) ((+) side)
solenoid system 3. Short circuit with power source in wiring harness between controller C02 (18)
and solenoid C13 (2) ((-) side)
4. Defective engine throttle pump and controller
1. Disconnection , defective contact inside pump EPC solenoid
E02 2. Disconnection, defective contact in wiring harness between controller C02 (8)
and solenoid C13 (1) ((+) side)
3. Disconnection, defective contact, short circuit with ground in wiring harness
Disconnection in
between controller C02 (18) and solenoid C13 (2) ((-) side)
E233 pump EPC
4. Defective engine throttle and pump controller
solenoid system
Short circuit in 1. Short circuit with ground, short circuit inside swing holding brake solenoid
swing holding 2. Short circuit with ground in wiring harness between controller C01 (3) and
E203 brake solenoid 3. solenoid V04 (2) ((+) side)
system 4. Defective engine throttle and pump controller
E03 Disconnection in 1. Disconnection, defective contact inside holding brake solenoid

swing holding 2. Disconnection, defective contact, short circuit with power source in wiring
brake solenoid harness between controller C01 (3) and solenoid V04 (2) ((+) side)
E213 system
1. Short circuit, short circuit with chassis ground inside boom RAISE throttle EPC
solenoid
Short circuit in 2. Short circuit with chassis ground, short circuit with power source in wiring
boom throttle harness ((+) end) between engine throttle, pump controller C02 (9) and solenoid
E234
EPC solenoid V09 (1)
system 3. Short circuit with power source in wiring harness ((-) end) between engine
throttle, pump controller C02 (19) and solenoid V09 (2)
E06 4. Defective engine throttle, pump controller
1. Defective contact or disconnection inside boom RAISE throttle EPC solenoid
2. Defective contact or disconnection in wiring harness ((+) end) between engine
Disconnection in
throttle, pump controller C02 (9) and solenoid V09 (1)
boom throttle
E235 3. Disconnection, defective contact, short circuit with chassis ground in wiring
EPC solenoid
harness ((-) end) between engine throttle, pump controller C02 (19) and solenoid
system
V09 (2)
4. Defective engine throttle, pump controller
20-504 PC228US-3
1
12
Condition when normal Problem that appears on machine

Action by controller when abnormality is detected
(voltage, current, resistance) when there is abnormality
1. Makes output to EPC solenoid 0. 1. No current flows to the PC-EPC
2. Displays user code E02 on monitor panel. solenoid.
• Resistance of solenoid: ★ If the abnormality is restored by the vibration of Therefore, when the load is
7 - 14 Ω the machine, it resets the power source to large, there is a big drop in the
restore to the proper condition. (However, the engine speed which may result
service code display does not go out.) in the machine stalling.
1. The current stops flowing to the solenoid, so no 1. In the case of 1, it is the same
particular action is taken. as E232.
• Resistance of solenoid: 2. If there is a short circuit with the ground at the 2. In the case of 2, the current
7 - 14 Ω (-) end, the current (min. 1A) continues to flow (min. 1 A) continues to flow to
• Current: 1000 mA to the solenoid. the PC-EPC solenoid, so the
(H/O mode, auto-decelera- 3. It displays user code E02 on the monitor panel. output of the PC-EPC valve
tion ON, levers at neutral, ★ If the abnormality is restored by the vibration of increases and the overall speed
fuel control dial at MAX.) the machine, it resets the power source to becomes slower.
restore to the proper condition. (However, the
service code display does not go out.)
1. Makes output to solenoid 0.

2. Displays user code E03 on monitor panel. When the swing is operated, the
• Resistance of solenoid: ★ If the abnormality is restored by the vibration of motor brake is not released, so the
20 - 60 Ω the machine, it resets the power source to upper structure does not swing.
1. The current stops flowing to the solenoid, so no
particular action is taken.
2. Displays user code E03 on monitor panel.
• Resistance of solenoid:
★ If the abnormality is restored by the vibration of Same as display for E203
20 - 60 Ω
the machine, it resets the power source to
• Resistance of solenoid: 1. Stops output to EPC solenoid. 1. Boom RAISE does not work.
5 - 25 Ω 2. Reports user code [E06].
3. If there is short circuit with ground at (-) end,
current (1 A or more) continues to flow to sole-
noid.
• Resistance of solenoid: 1. Reports user code [E06]. 1. Boom RAISE does not work.
5 - 25 Ω 2. Buzzer sounds.
• Current value: 950 ± 30
mA (oil detection posture)
PC228US-3 20-505
1
12
User Service
code code
1. Short circuit with ground, short circuit inside pump merge/divider sole-
Short circuit in noid
— E204 pump merge/ 2. Short circuit with ground in wiring harness between controller C0 (2)
divider solenoid and solenoid V06 (2) ((+) side)
1. Short circuit with ground, short circuit inside 2-stage relief solenoid
Short circuit in 2- 2. Short circuit with ground in wiring harness between controller C01 (10)
— E205 stage relief sys- and solenoid V02 (2) ((+) side)
tem 3. Defective engine throttle and pump controller
1. Short circuit with ground, short circuit inside travel speed solenoid
Short circuit in 2. Short circuit with ground in wiring harness between controller C01 (10)
— E206 travel speed sole- and solenoid V03 (2) ((+) side)
noid system 3. Defective engine throttle and pump controller
1. Short circuit with ground, short circuit inside active mode solenoid
Short circuit in 2. Short circuit with ground in wiring harness between controller C01 (8)
— E207 active solenoid and solenoid V05 (2) ((+) side)
system 3. Defective engine throttle and pump controller
1. Defective contact or disconnection inside active mode solenoid

Disconnection in 2. Defective contact or disconnection, contact with power source in wiring
— E208 active mode sole- harness between controller C01 (8) and solenoid V05 (2) ((+) side)
noid system 3. Defective contact, disconnection in wiring harness between solenoid
V05 (1) and chassis ground ((-) side)
1. Disconnection , defective contact inside pump merge/divider solenoid
Disconnection in 2. Disconnection, defective contact, short circuit with power source in wir-
pump merge/ ing harness between controller C01 (2) and solenoid V06 (2) ((+) side)
— E214
divider solenoid 3. Disconnection, defective contact, in wiring harness between solenoid
system V06 (2) ((-) side)
1. Disconnection , defective contact inside 2-stage solenoid
Disconnection in 2. Disconnection, defective contact, short circuit with power source in wir-
— E215 2-stage relief sole- ing harness between controller C01 (10) and solenoid V02 (2) ((+) side)
noid system 3. Disconnection, defective contact, in wiring harness between solenoid
V02 (1) ((-) side)
20-506 PC228US-3
1
12
Condition when normal Action by controller when abnormality is Problem that appears on machine
(voltage, current, resistance) detected when there is abnormality
1. Makes output to solenoid 0. The pump merge/divider valve con-
★ If the abnormality is restored by the vibration tinues to merge the oil flow.
• Resistance of solenoid: of the machine, it resets the power source to 1. In the L/O modes, the work
20 - 60 Ω restore to the proper condition. (However, equipment and swing speeds
the service code display does not go out.) become faster.
2. The steering is difficult to turn.
1. Makes output to solenoid 0. 1. There is no power when traveling
• Resistance of solenoid: ★ If the abnormality is restored by the vibration or when power max. function is
of the machine, it resets the power source to used (relief pressure is not
20 - 60 Ω
restore to the proper condition. (However, increased).
the service code display does not go out.)
1. Makes output to solenoid 0.
Even when the travel speed is
• Resistance of solenoid: ★ If the abnormality is restored by the vibration switched, the travel speed does not
20 - 60 Ω of the machine, it resets the power source to change (Travel motor swash plate
restore to the proper condition. (However, angle MAX).
1. Makes output to solenoid 0. 1. In the standard mode (active
• Resistance of solenoid: ★ If the abnormality is restored by the vibration mode OFF), the boom LOWER
of the machine, it resets the power source to speed becomes faster.
20 - 60 Ω
restore to the proper condition. (However,
1. The current stops flowing to the solenoid, so
no particular action is taken.
• Resistance of solenoid: ★ If the abnormality is restored by the vibration Same content as display for E208
20 - 60 Ω of the machine, it resets the power source to
PC228US-3 20-507
1
12
User Service
code code
1. Disconnection, defective contact inside travel speed solenoid
2. Disconnection, defective contact, short circuit with power source in wiring
Disconnection in harness between controller C01 (9) and solenoid V06 (2) ((+) side)
— E216
travel speed solenoid 3. Disconnection, defective contact in wiring harness between solenoid V06 (1)
and chassis ground ((-) side)
Model selection 1. Disconnection , defective contact, short circuit with ground in model selec-
input error tion wiring harness C04 (5) (6) (7) (13) (14)
— E217
Network response 1. Disconnection, short circuit, short circuit with ground in network wiring har-
overtime error ness.
2. Abnormality in governor, pump controller
— E218 3. Abnormality in monitor
1. Short circuit with ground, short circuit inside LS-EPC solenoid

Short circuit in 2. Short circuit with power source, short circuit with ground in wiring harness
— E222 LS-EPC solenoid between controller C02 (7) and solenoid V22 (1) ((+) side)
system 3. Short circuit with power source in wiring harness between controller C02
(17) and solenoid V22 (2) ((-) side)
Disconnection in 1. Disconnection, defective contact inside LS-EPC solenoid
LS-EPC solenoid 2. Disconnection, defective contact in wiring harness between controller C02
system (7) and solenoid V22 (1) ((+) side)
3. Disconnection, defective contact C02 (17) and solenoid V22 (2) ((-) side)
— E223 4. Defective engine throttle, pump controller
1. Disconnection, defective contact, short circuit, short circuit with ground

inside front pump pressure sensor
2. Disconnection, defective contact, short circuit in wiring harness between
controller C03 (6) and pressure sensor A51 (B) ((+) side)
Abnormality in front
3. Disconnection, defective contact, short circuit with power source, short cir-
— E224 pump pressure
cuit with ground in wiring harness between controller C03 (3) and pressure
sensor system
sensor A51 (C) (SIG side) engine throttle, pump controller C02 (19) and sole-
noid V09 (2)
20-508 PC228US-3
1
12
Detects abnormality in input 1. Engine stalls, or
• Between C04 (5) (6) (7)
1) Retains data when starting switch is ON 2. Work equipment, swing, travel
(13) (14) - chassis:
2) Functions as PC228US-3 when non-set condi- speeds are slow, and there is no
Min. 1 MΩ
tions are input. power
1. When communications are impossible with 1. ➀ Even when travel is operated,

the monitor, control is carried out with the the power max. function does
following settings. not work
➀ Working mode: E ➁ The auto-deceleration cannot
➁ Travel speed: Lo be cancelled
➂ Auto-deceleration: ON ➂ The travel speed does not
④ Power max.: ON (others are as usual) increase
1. Makes output to LS-EPC solenoid 0. 1. The low travel speed is too fast.
★ If the abnormality is restored by the vibration
Resistance of solenoid: of the machine, it resets the power source to
7 - 14 Ω restore to the proper condition. (However,
1. The current stops flowing to the LS-EPC sole- 1. In the case of 1, it is the same as
noid, so no particular action is taken. E2: 22
2. If there is a short circuit with the ground at 2. In the case of 2, electric current
• Current: Approx. 900 mA the (-) end, the current (min. 1 A) continues to (min. 1 A) continues to flow to the
(Levers at neutral, low flow to the LS-EPC solenoid. LS-EPC solenoid, so the work
idling) ★ If the abnormality is restored by the vibration equipment, travel, and swing
of the machine, it resets the power source to speeds are slow
• Between C03 (3) and (16): 1. Takes front pump pressure as 0 MPa 1. The travel speed does not auto-
0.5 - 4.5 V {0 kg/cm²} when actuating. matically shift (it does not change
• Between C03 (6) and (16): ★ If the abnormality is restored by the vibration from Hi to Lo).
18 - 28 V of the machine, it resets the power source to ★ If the button is operated man-
• Between C03 (female) (3) restore to the proper condition. (However, ually, the panel display is
and (16), (3) and Chassis the service code display does not go out.) switched.
• Resistance: Min. 1 MΩ 2. During high load travel, the work
(Disconnect connectors equipment speed drops.
C03 and A51) 3. The steering becomes difficult to
turn immediately after it is turned.
PC228US-3 20-509
1
12
User Service
code code
1. Disconnection, defective contact inside, short circuit, short circuit with

ground inside rear pump pressure sensor
2. Disconnection, defective contact, short circuit in wiring harness between
Abnormality in
controller C03 (6) and pressure sensor A52 (B) ((+) side) and between
rear pump
— E225 C03 (16) and A52 (A) ((-) side)
pressure
3. Disconnection , defective contact, short circuit with power source, short
sensor system
circuit with ground in wiring harness between controller C03 (13) and
pressure sensor A52 (C) (SIG side)
1. Short circuit, short circuit with ground inside front pressure sensor or
Abnormality in rear pump pressure sensor
pressure sensor 2. Short circuit, short circuit with ground in wiring harness between con-
— E226
power source troller C03 (6) and front pressure sensor A51 (B) or rear pressure sensor
system A52 (B) ((+) side)
1. Disconnection, defective contact, short circuit, short circuit inside engine

Abnormality in speed sensor
— E227 engine speed 2. Disconnection, defective contact, short circuit with ground in wiring
sensor system harness between controller C06 (1) and speed sensor E04 (2) ((-) side)
and between C06 (2) and E04 (1) (SIG side)
4. Short circuit in wiring harness between E06 (1) - (2), (1) - (3), (2) - (3)
Short circuit in
5. Short circuit in wiring harness between C03 (7) - (1), (1) - (17)
— E241 LS-EPC solenoid
6. Disconnection in wiring harness between C03 (7) - A53 (1)
system
9. Defective boom angle potentiometer
10. Defective contact of connector C03, A07, E53
Disconnection in
— E255 LS-EPC solenoid 1. Defective controller
system
Abnormality in
front pump
— E256 1. Defective controller
pressure sensor
system
Abnormality in
— E313 automatic 1. Defective automatic greasing controller (option)
greasing
20-510 PC228US-3
1
12
• Between C03 (13) and (16): 1. Takes rear pump pressure as 0 MPa 1. The travel speed does not
0.5 - 4.5 V {0 kg/cm²} when actuating. automatically shift (it does
• Between C03 (6) and (16): ★ If the abnormality is restored by the not change from Hi to Lo).
18 - 28 V vibration of the machine, it resets the ★ If the button is operated
• Between C03 (female) (13) power source to restore to the proper manually, the panel
and (16), (13) and chassis condition. (However, the service code display is switched.
• Resistance: Min. 1 MΩ display does not go out.) 2. During high load travel, the
(Disconnect connectors C03 work equipment speed drops.
and A52 3. The steering becomes diffi-
cult to turn immediately after
it is turned.
1. The travel speed does not
automatically shift (it does
not change from Hi to Lo).
★ If the button is operated
1. Takes front pump and rear pump manually, the panel
• Voltage between C03 (6) and
pressure as 0 MPa {0 kg/cm²} when display is switched.
(16): 18 - 28 V
actuating. 2. During high load travel, the
work equipment speed drops.
3. The steering becomes
difficult to turn immediately
after it is turned.
• Resistance: 500 - 1000 Ω It operates about the same as

1. It functions in the equivalent of the
Voltage (AC range): 0.5 - 3.0 V digging mode (prolix) (the power
digging mode (the speed rises).
(engine started) is slightly lower)
1. Boom RAISE does not work.

C03 A53 Resistance
(female) (male) value
(7) - (4) (1) - (2) 0.25 - 5 kΩ
(4) - (17) (2) - (3) 0.25 - 5 kΩ Takes boom angle as end of boom RAISE
— (1) - (3) 4 - 6 kΩ stroke.
Between
and chassis
1. Sets compensation value for end of Effect of cushion at end of boom

boom RAISE stroke to 0 (theoretical RAISE stroke becomes poor or
— value). weak (end of boom RAISE stroke
recognized by engine throttle,
pump controller is different from
actual end of stroke).
Same problem as with [E255] may

— Takes no particular action.
appear.
— Takes no particular action. (Buzzer sounds.) Auto-greasing is not carried out.
PC228US-3 20-511
1
12
User Service
code code
1. Short circuit, short circuit with chassis ground inside service
ATT-PPC throttle EPC solenoid
Short circuit in 2. Short circuit with chassis ground, short circuit with power
— service ATT-PPC source in wiring harness ((+) end) between engine throttle,
— pump controller C02 (10) and EPC solenoid V07 (1)
(None) throttle EPC
solenoid system 3. Short circuit with power source in wiring harness ((-) end)
between engine throttle, pump controller C02 (20) and EPC
solenoid V07 (2)
1. Disconnection, defective contact in wiring harness inside ser-
vice ATT-PPC throttle EPC solenoid
2. Defective contact or disconnection in wiring harness ((+) end)
Disconnection in
— service ATT-PPC between engine throttle, pump controller C02 (10) and EPC
— solenoid V07 (1)
(None) throttle EPC
solenoid system 3. Disconnection, defective contact, short circuit with chassis
ground in wiring harness ((+) end) between engine throttle,
pump controller C02 (20) and EPC solenoid V07 (2)
20-512 PC228US-3
1
12
1. Stops the output to the EPC solenoid. 1. Current does not flow to the
★ If the abnormality is restored by the service ATT-PPC throttle EPC
• Solenoid resistance value: vibration of the machine, it resets the solenoid.
7 - 14 Ω power source to restore to the proper Therefore, no oil flows to the
condition. (However, the service code attachment and the attach-
display does not go out.) ment does not move.
• Solenoid resistance value: 1. The current stops flowing to the EPC 1. Same content as 1 above.
7 - 14 Ω solenoid, so no particular action is 2. In case 2, the flow of oil to the
taken. attachment at B mode boom
• Current value: 950 + 50 mA
2. If there is a short circuit with the ground LOWER is not throttled
at (-) end, current (1A or more) contin- (machine does not thrust).
ues to flow to the solenoid.
PC228US-3 20-513
1
12
JUDGEMENT TABLE FOR ENGINE THROTTLE • PUMP
CONTROLLER (PUMP CONTROL SYSTEM) AND HYDRAULIC
RELATED PARTS
Engine throttle and pump controller (E2:XX system)
Abnormality in controller power source

Self diagnostic display
Disconnection in LS-EPC solenoid
Abnormality in R pump pressure

Abnormality in F pump pressure
Short circuit in PC-EPC solenoid
Short circuit in LS-EPC solenoid
Disconnection in travel junction

Disconnection in swing holding
Abnormality in pressure sensor

Disconnection in pump PC-EPC
Disconnection in pump merge/
Disconnection in 2-stage relief

Disconnection in boom RAISE
throttle EPC solenoid system
throttle EPC solenoid system
Short circuit in travel junction

Disconnection in travel speed
Short circuit in swing holding
Short circuit in pump merge/
Short circuit in 2-stage relief

Short circuit in boom RAISE
Short circuit in travel speed
Model selection input error

divider solenoid system
divider solenoid system
power source system

solenoid system
solenoid system
solenoid system
selector system
selector system
sensor system
sensor system
brake system
brake system
solenoid
system
valve
valve
Failure mode User code LED E02 E03 E06 — — —
Service code 232 233 203 213 234 235 204 214 206 216 205 215 217 222 223 224 225 226 201 202
Speeds of all work equipment, swing, travel are slow or
! ! ! !
lack power
All work equipment
There is excessive drop in engine speed, or engine stalls ! ! !

travel, swing
No work equipment, travel, swing move
Abnormal noise generated (around pump)
Auto-deceleration does not work ! !

Fine control ability is poor or response is poor ! ! ! !
Boom is slow or lacks power ! !
Arm is slow or lacks power ! !
Work equipment
Boom does not move ! !

Arm does not move
Bucket does not move
Excessive hydraulic drift
Excessive time lag (engine at low idling) ! ! !

Compound operation
Lack of power when pressure rises ! !

Effect of cushion at end of boom RAISE stroke becomes
poor or weak
In compound operations, work equipment with larger load
is slow
In swing + travel, travel speed drops excessively ! !

Deviation is excessive during normal
travel
!
Travel deviation
Travel system
Travel speed is slow ! !

Steering does not turn or lacks power ! ! ! ! !
Travel speed does not switch or is faster then specified ! ! ! ! ! ! ! ! !
Does not move (one side only) ! !
Both left and right ! !
Does not swing
One direction only
Swing acceleration is poor or swing Both left and right

speed is slow One direction only
Swing system
Excessive overrun when stopping Both left and right

swing One direction only
Excessive shock when stopping swing (one direction only)
Excessive abnormal noise when stopping
Excessive hydraulic drift When holding brake is released

of swing When holding brake is applied ! !
Troubleshooting code when service code is displayed C-1 C-2 C-3 C-4 C-5 C-6 C-7 C-8 C-9 C-10 C-11 C-12 C-13 C-14 C-15 C-16 C-17 C-18 C-19 C-20 C-21
Troubleshooting code when there is abnormality in monitoring check — — — — — — — — — — — — — — — — — — — — —
": This shows item that needs only checking with monitoring.
20-514 PC228US-3
1
Abnormality in engine speed sensor
—
!
!
!
!
system
Abnormality in boom angle
—
!
potentiometer input value
Abnormality in boom angle
—
potentiometer compensation value
PC228US-3
Abnormality in check sum
—
! !
Engine throttle, pump
Abnormality in check sum
—
227 241 255 256 313
controller (E2:XX system)
(1) Swing
C-22 C-23 C-24 C-25 C-26 —

"
"
!
F-1
(2) Travel
—
!
!
!
F-2
TROUBLESHOOTING
(3) Boom LOWER
—
!
F-3
20
(4) Boom RAISE
—
! !
F-4
(5) Arm IN
—
!
F-5
(6) Arm OUT
—
! !
F-6
(1) Bucket CURL
—
!
Oil pressure switch
F-7
(2) Bucket BUMP
—
! ! ! ! ! !
! !
F-8
21
Bit pattern
Service (4)
—
" " " " " " "
" " " " " " "
! ! ! ! ! ! ! ! !
Travel steering (5)
—
Swing holding brake cancel (4)
—
(5) Swing lock switch
—
" "
" "
22
! !
(3) Knob switch
—
!
(6) Kerosene mode
—
27
F-9 F-10 F-12 F-13 F-11 F-14

Travel junction (2)
—
—
"
Swing holding brake (3)
—
—
"
"
Check items in monitoring mode
Pump merge/divider flow (4)
—
—
23
2-stage relief (5)
—
—
" "
"
Travel Hi/Lo selector (6)
—
—
"
Solenoid drive condition
Model code
—
—
02
Engine speed input
—
—
" "
10
Front pump discharge pressure input
—
—
" "
11
Rear pump discharge pressure input
—
—
12
" "
" "
" "
PC-EPC current output
—
—
"
13
Monitoring code
LS-EPC current output
—
—
" " " " " "
15
Boom RAISE throttle EPC current
—
—
18
"
output
ATT PPC throttle EPC current output
—
—
19
★ If service code E218 (abnormality in network system) is displayed, go to troubleshooting for N mode
Troubleshooting code if no service code is

—
H-9
H-8
H-7
H-6
H-5
H-4
H-3
H-2
H-1
displayed
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-11
H-10
JUDGEMENT TABLE
1
20-515
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM FOR C MODE
ELECTRICAL CIRCUIT DIAGRAM FOR C MODE
20-516 PC228US-3
1
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM FOR C MODE
12
PC228US-3 20-517
1
TROUBLESHOOTING C1
12
C1 Abnormality in controller power source system (con-

troller LED is off)
★ Check that fuse 11 is not blown.
★ When the starting motor rotates normally. (If the starting motor also does not rotate, go to E-8.)
Cause Remedy
YES
Defective engine throttle,
1
Is voltage between
C01 (7)(13) and C01 2 YES Defective contact or disconnec-
tion in wiring harness between Repair or
(6)(12) normal?
Is voltage between fuse 11 and C01 (female) (7)(13) replace
• Turn starting fuse 11 and chas-
switch ON. NO sis normal? Defective contact or disconnec-
• 20 - 30 V Repair or
• Turn starting tion in wiring harness between
NO replace
switch ON. fuse 11 and battery relay M
• 20 - 30 V
C-1 Related electrical circuit diagram
20-518 PC228US-3
1
TROUBLESHOOTING C2
12
C2 ([E232 Short circuit in PC-EPC solenoid system) is

displayed
★ Always turn the emergency pump drive switch OFF (lower side)
Cause Remedy
YES Defective engine throttle, Replace
pump controller
Short circuit with chassis
2 ground or short circuit with
power source in wiring har-
YES 4 YES ness between C02 (female) Repair or
Is resistance
between C02 (8) and S25 (female) (3), or replace
(female) (8) - (18), Is resistance short circuit with power
(8) - chassis as YES between S25 source in wiring harness
shown in Table 1? (male) (2) - (3), between C02 (female) (18)
3 (5) - (6), S25 and S25 (female) (6)
1 (male) (2),(3), (5),
• Turn starting Is resistance (6) - and chassis Defective pump prolix
Is resistance switch OFF. between S25 as shown in Table switch (internal short
between V21 • Disconnect (female) (2) - (5), 2? circuit with chassis ground Replace
(male) (1) - (2), C02. NO (2) - and chassis or short circuit with power
(1) - chassis as as shown in Table source)
shown in Table 1? NO
• Turn starting Short circuit with ground or
1? switch OFF.
• Turn starting short circuit with power
• Disconnect source in wiring harness Repair or
switch OFF. S25. between S25 (female) (2) replace
• Turn starting • Disconnect S25. • Emergency
switch OFF. and V21 (female), or short
work equip- circuit with power source in
• Disconnect V21. ment actuation wiring harness between
switch: Down S25 (female) (8) and V21
(normal) (female) (2)
NO Defective pump PC-EPC
solenoid (internal short cir- Replace
cuit or short circuit with
chassis ground)
NO
Table 1 Table 2
Troubleshooting No. 2 Troubleshooting No. 3 Troubleshooting No. 4 Resistance Troubleshooting No. 5 Resistance
value value
Between V21 (male) Between C02 (female) Between S25 (female) Between S25 (male) (2) -
(1) and (2) (8) and (18) (2) and (5) 5 - 25 Ω (3), (5) - (6) Max. 1 Ω
Between V21 (male) Between C02 (female) Between S25 (female) Min. 1 MΩ Between S25 (male) (2), Min. 1 MΩ
(1) and chassis (8) and chassis (2) and chassis (3), (5), (6) - chassis
PC228US-3 20-519
1
TROUBLESHOOTING C3
12
C3 ([E233 Disconnection in PC-EPC solenoid system) is

displayed
★ If there is a disconnection in the solenoid or wiring harness, no current flows to the solenoid.
If the No. 2 pin of the solenoid is short circuiting with the ground, the current (approx. 1 A) continues to
flow to the solenoid.
★ Always turn the emergency pump drive switch OFF (lower side)
Cause Remedy
pump controller
2 ground or short circuit with
power source in wiring har-
YES 4 YES ness between C02 (female) Repair or
Is resistance
between C02 (8) and S25 (female) (3), or replace
(female) (8) - (18), Is resistance short circuit with power
(18) - chassis as YES between S25 source in wiring harness
shown in Table 1? (male) (2) - (3), between C02 (female) (18)
3 (5) - (6), S25 and S25 (female) (6)
1 • Turn starting (male) (2),(3), (5),
Is resistance (6) - and chassis Defective pump prolix
switch OFF. between S25 switch (internal short
Is resistance • Disconnect C02. as shown in Table
between V21 (female) (2) - (5), 2? circuit with chassis ground Replace
(male) (1) - (2), NO (2) - and chassis or short circuit with power
(2) - chassis as as shown in Table source)
1? • Turn starting Short circuit with ground or
switch OFF. short circuit with power
• Turn starting source in wiring harness Repair or
switch OFF. • Disconnect
• Turn starting S25. between S25 (female) (2) - replace
• Disconnect S25. • Turn emer- S25 (female) (5), or short
switch OFF.
• Disconnect V21. gency pump circuit with power source in
prolix switch: wiring harness between
OFF S25 (female) (4) and V21
(female) (2)
NO Defective pump PC-EPC
chassis ground)
NO
Table 1 Table 2
Troubleshooting No. 2 Troubleshooting No. 3 Troubleshooting No. 4 Resistance Troubleshooting No. 5 Resistance
value value
Between V21 (male) Between C02 (female) Between S25 (female) 7 - 14 Ω Between S25 (male) (2) - Max. 1 Ω
(1) and (2) (8) and (18) (2) and (5) (3), (5) - (6)
Between V21 (male) Between C02 (female) Between S25 (female) Between S25 (male) (2),
(2) and chassis (8) and chassis (2) and chassis Min. 1 MΩ (3), (5), (6) - chassis Min. 1 MΩ
20-520 PC228US-3
1
TROUBLESHOOTING C-4
12
C-4([E203] Short circuit in swing holding brake solenoid

system) is displayed
an E service code is displayed. (If it is not displayed, the problem has been removed.)
★ Always turn the swing holding brake cancel switch OFF (normal) and the swing lock switch OFF (nor-
mal) before checking.
Cause Remedy
3 YES Defective engine
throttle • pump Replace
2 YES Is resistance controller
between C01
Is resistance (female) (3) and
between V04 chassis normal?
YES (male) (1) and (2),
(2) and chassis Go to A
1 normal? NO
• Turn starting
Interchange switch OFF.
• Turn starting • Disconnect
connector with switch OFF.
other solenoid. C01.
• Disconnect • Turn starting
Is [E203] V04.
displayed? switch OFF.
• 20 - 60 Ω
• Turn starting
switch OFF.
• Interchange
V04 with NO Defective swing hold-
other ing brake
connector. solenoid (internal Replace
• Start engine. short circuit or short
• Operate NO
circuit with ground)
swing lever
(Operate
lever slightly)
Short circuit with

chassis ground in wir-
YES ing harness between Repair or
C01 (female) (3) - D26 replace
4 Yes (1)(2) - J02 (11)(1) -
Is resistance
between X05 X05 (male) (3)
Is resistance (male) (4) and
between X05 chassis
A (female) (3) (4) normal?
Short circuit with
and chassis chassis ground in Repair or
normal? • Turn starting wiring harness replace
switch OFF. NO between X05 (male)
• Disconnect (4) J06 (18)(19) - V04
X05. (female) (2)
• Turn starting • 20 - 60 Ω
switch OFF.
• Disconnect
X05. Defective swing lock
• Turn starting switch (internal short Replace
switch OFF. NO circuit with ground)
• Min. 1 MΩ
Table 1
Between V04 (male) (1) — (2) 20 — 60 Ω
Between V04 (male) (2) — chassis Min. 1 MΩ
PC228US-3 20-521
1
TROUBLESHOOTING C-4
12
20-522 PC228US-3
1
TROUBLESHOOTING C-5
12
C-5 ([E213] Disconnection in swing holding brake solenoid

★ Always turn the swing holding brake cancel switch OFF (normal) and the swing lock switch OFF
(normal) before checking.
Note: When the swing holding brake cancel switch is turned OFF (swing FREE), error [E213] is detected, but
this is not a failure.
Note: If error [E213] is generated when the swing lock switch is turned ON (swing lock), carry out trouble-
shooting F-9 for failure in the swing lock signal input system.
Cause Remedy
3 YES Defective engine
throttle, pump Replace
2 YES Is resistance controller
between C01 (3)
between V04 shown in
YES (male) (1) and (2) Table 1?
normal? Go to A
1 NO
• Disconnect D05.
Interchange • Turn starting • Turn starting
connector with switch OFF. switch ON.
other sole- • Disconnect
noid. Is [E213] Defective swing hold-
V04. ing brake solenoid
displayed? • 20 - 60 Ω NO
(internal disconnec- Replace
• Turn starting NO tion or short circuit
with power source)
switch OFF.
• Interchange Defective contact or
V04 with other disconnection in wir-
6 YES ing harness between
connector. Repair or
5 YES Is resistance D05 (female) (1) - J02 replace
• Turn starting (11),(1) - X05 (male) (3)
between C01
switch ON 4 YES Is resistance (female) (3) and
between X05 D05 (female) (3) Defective contact or
Is resistance normal? disconnection in wir-
A between X05 (male) (4) and
chassis normal? ing harness between
(female) (3) and • Turn starting NO C01 (female) (3) and Repair or
(4) normal? switch OFF. D05 (female) (2) replace
• Turn starting • Disconnect C01
• Turn starting Short circuit with
switch OFF. and D05. power source or
switch OFF. • Disconnect X05. • Max. 1 Ω defective contact or
• Disconnect • 20 - 60 Ω disconnection in Repair or
X05. NO wiring harness replace
between X05 (male)
• Max. 1 Ω (4) - J06 (18),(19) - V04
(female) (2)
Defective swing lock Replace
switch (internal
NO disconnection or short
circuit with power
source)
Table 1
Troubleshooting No. 3 Voltage Measurement conditions
0 - 10 V 4 - 5 sec. after all levers placed at neutral

Between D05 (1) - chassis Swing or work equipment lever operated slightly (not
20 - 30 V
enough to move swing or work equipment)
PC228US-3 20-523
1
TROUBLESHOOTING C-5
12
20-524 PC228US-3
1
TROUBLESHOOTING C-6
12
C-6 ([E234] Short circuit in boom RAISE throttle EPC

solenoid system) is displayed
★ Always push the emergency work equipment actuation switch down (normal).
Cause Remedy
pump controller
2 Short circuit with chassis

ground or short circuit with
YES Is resistance 4 YES power source in wiring har-
between C02 ness between C02 (female) Repair or
(female) (9) - (19), Is resistance (9) and S25 (female) (13), or replace
(19) - chassis as YES between S25 short circuit with power
shown in Table 1? (male) (12) - (13), source in wiring harness
3 (15) - (16), S25 between C02 (female) (19)
1 • Turn starting Is resistance (male) (12),(13), and S25 (female) (16)
switch OFF. between S25 (15), (16) -
Is resistance • Disconnect C02. (female) (12) - chassis as shown Defective emergency work
between V09 (15), (12) - in Table 2? equipment actuation switch
(male) (1) - (2), NO
chassis as shown (internal short circuit with Replace
(1) - chassis as in Table 1? • Turn starting NO chassis ground or short
shown in Table switch OFF. circuit with power source)
1? • Turn starting • Disconnect
switch OFF. S25. Short circuit with chassis
• Turn starting • Emergency ground or short circuit with
• Disconnect S25.
switch OFF. work equip- power source in wiring har- Repair or
• Disconnect V09. ment actuation ness between S25 (female) replace
switch: Down (12) and V09 (female), or
(normal) short circuit with power
source in wiring harness
NO between S25 (female) (15)
and V09 (female) (2)
Defective boom RAISE EPC

NO chassis ground)
Table 1 Table 2
Resistance Resistance
Troubleshooting No. 2 Troubleshooting No. 3 Troubleshooting No. 4 value Troubleshooting No. 5 value
Between V09 (male) Between C02 (female) Between S25 (female) 7 - 14 Ω Between S25 (male) (12) Max. 1 Ω
(1) and (2) (9) and (19) (12) and (15) - (13), (15) - (16)
PC228US-3 20-525
1
TROUBLESHOOTING C-7
12
C-7 ([E235] Disconnection in boom RAISE throttle EPC
solenoid system) is displayed
★ If there is a disconnection in the solenoid or wiring harness, no current flows to the solenoid.
If the No. 2 pin of the solenoid is short circuited with the ground, current (approx. 1A) continues to flow
to the solenoid.
★ Always push the emergency work equipment actuation switch down (normal).
Cause Remedy
pump controller
2 Defective contact or discon-

nection in wiring harness
YES Is resistance 4 YES between C02 (female) (9)
between C02 and S25 (female) (13), or Repair or
(female) (9) - (19), Is resistance defective contact, discon- replace
(19) - chassis as YES between S25 nection, or short circuit with
shown in Table 1? (male) (12) - (13), chassis ground in wiring
3 (15) - (16), harness between C02
1 • Turn starting S25 (male) (female) (19) and S25
switch OFF. Is resistance (12),(13),(15),(16) - (female) (16)
Is resistance between S25 chassis as shown
• Disconnect C02.
between V09 (female) (12)-(15), in Table 2? Defective emergency work
(male) (1) - (2), NO (12) - chassis as equipment actuation switch Replace
(2) - chassis as shown in Table 1? (internal disconnection,
shown in Table defective contact, or short
switch OFF.
1? circuit with chassis ground)
• Turn starting • Disconnect
switch OFF. S25.
• Turn starting • Emergency Defective contact or discon-
• Disconnect S25. nection in wiring harness Repair or
switch OFF. work equip-
• Disconnect V09. ment actuation between S25 (female) (12) replace
switch: Down and V09 (female), or defec-
(normal) tive contact, disconnection,
or short circuit with chassis
NO ground in wiring harness
between S25 (female) (15)
Defective boom RAISE EPC Replace

solenoid (internal discon-
NO nection or defective
contact)
Table 1 Table 2
Resistance Resistance
Troubleshooting No. 2 Troubleshooting No. 3 Troubleshooting No. 4 value Troubleshooting No. 5 value
Between V09 (male) Between C02 (female) Between S25 (female) 7 - 14 Ω Between S25 (male) (12) Max. 1 Ω
(1) and (2) (9) and (19) (12) and (15) - (13), (15) - (16)
20-526 PC228US-3
1
TROUBLESHOOTING C-8
12
C-8 ([E204] Short circuit in pump merge/divider solenoid

Cause Remedy
pump controller
2 YES Is resistance
Is resistance between C01
1 YES
between V06 (female) (2) and Short circuit with chassis
Interchange (male) (1) - (2), (2) chassis normal? ground in wiring harness Repair or
connector with - chassis as between C01 (female) (2) - replace
other solenoid. • Turn starting NO J07 (5),(6) - V06 (female) (2)
shown in Table 1?
Is [E204] switch OFF.
displayed? • Turn starting • Disconnect C01.
switch OFF. • 20 - 60 Ω
• Turn starting
switch OFF. • Disconnect V06.
• Interchange V06
with other con- NO
nector.
Defective pump merge/
• Start engine.
divider solenoid (internal Replace
• Operate travel NO short circuit or short circuit
independently
with chassis ground)
(operate lever
slightly).
Table 1
Between V06 (male) (1) — (2) 20 — 60 Ω
PC228US-3 20-527
1
TROUBLESHOOTING C-9
12
C-9 ([E214] Disconnection in pump merge/divider solenoid

Cause Remedy
pump controller
2 YES Is resistance
between C01
1 YES Is resistance
(female) (2) and Short circuit with chassis
Interchange between V06 chassis normal?
(male) (1) and (2) ground in wiring harness Repair or
connector with between C01 (female) (2) - replace
other solenoid. normal? • Turn starting NO
J07 (5),(6) - V06 (female) (2),
Is [E214] switch OFF. or between V06 (female) (1)
• Turn starting • Disconnect C01.
displayed? and chassis
switch OFF.
• 20 - 60 Ω
• Turn starting • Disconnect V06.
• Interchange V06
with other con- NO
nector.
• Turn starting Defective pump merge/
switch ON. divider solenoid (internal Replace
NO short circuit or short circuit
with power source)
20-528 PC228US-3
1
TROUBLESHOOTING C-10
12
C-10 ([E206] Short circuit in travel speed selector system) is

displayed
Cause Remedy
pump controller
2 YES Is resistance
between C01
1 YES
Is resistance (female) (9) and Short circuit with chassis
Interchange between V03 chassis normal? ground in wiring harness Repair or
connector with (male) (1) and (2), between C01 (female) (9) - replace
other solenoid. • Turn starting NO
(2) and chassis as J07 (2),(3) - V03 (female) (2)
Is [E206] shown in Table 1. switch OFF.
displayed? • Disconnect C01.
• Turn starting • Turn starting • 20 - 60 Ω
switch OFF. switch OFF.
• Interchange V03 • Disconnect V03.
with other con- Defective travel speed selec-
NO
nector. tor solenoid (internal short
• Start engine. circuit or short circuit with
• Travel speed power source) Replace
NO
switch at Mi or
Hi
• Operate the lever slightly not enough
to move the machine.
Table 1
Between V03 (male) (1) — (2) 20 — 60 Ω
PC228US-3 20-529
1
12
C-11 ([E216] Disconnection in travel speed solenoid system)

is displayed
Cause Remedy
pump controller
2 YES Is resistance
between C01
1 YES
(female) (9) and Short circuit with chassis
Interchange Is resistance chassis normal? ground in wiring harness Repair or
connector with between V03
between C01 (female) (9) - replace
other solenoid. (male) (1) and (2) • Turn starting NO
J07 (2),(3) - V03 (female) (2),
Is [E216] normal? switch OFF. or between V03 (female) (1)
displayed? • Disconnect C01. and chassis
• Turn starting • 20 - 60 Ω
• Turn starting
switch OFF.
switch OFF.
• Disconnect V03.
• Interchange V03
with other con- • 20 - 60 Ω NO
nector. Defective travel speed selec-
• Start engine. tor solenoid (internal short Replace
• Turn starting NO circuit or short circuit with
switch ON. power source)
20-530 PC228US-3
1
12
C-12 ([E205] Short circuit in 2-stage relief solenoid system)

is displayed
Cause Remedy
pump controller
2 YES Is resistance
between C01
1 YES
Is resistance (female) (10) and Short circuit with chassis
Interchange between V02 chassis normal? ground in wiring harness Repair or
connector with (male) (1) and (2), between C01 (female) (10) replace
other solenoid. • Turn starting NO
(2) and chassis as and V02 (female) (2)
Is [E205] shown in Table 1. switch OFF.
displayed? • Disconnect C01.
• 20 - 60 Ω
• Turn starting • Turn starting
switch OFF. switch OFF.
• Interchange V02 • Disconnect V02.
NO
with other con-
nector. Defective 2-stage relief sole-
• Start engine. noid (internal short circuit or Replace
NO short circuit with power
• Turn swing lock
switch ON or set source)
to L/O mode.
Table 1
Between V05 (male) (1) — (2) 20 — 60 Ω
PC228US-3 20-531
1
12
C-13 ([E205] Disconnection in 2-stage relief solenoid system)

is displayed
Cause Remedy
pump controller
2 YES Is resistance
between C01
1 YES Is resistance
(female) (10) and Short circuit with power
Interchange between V02 chassis normal?
(male) (1) and (2) ground, defective contact or Repair or
connector with disconnection in wiring har- replace
other solenoid. normal? • Turn starting NO
ness between C01 (female)
Is [E215] switch ON. (10) and V02 (female) (2), or
displayed? between V02 (female) (1)
switch OFF.
• 20 - 60 Ω and chassis
• Turn starting • Disconnect V02.
• Interchange V02
with other con- NO
nector.
• Turn starting
switch ON. Defective 2-stage relief sole- Replace
NO noid (internal disconnection
or short circuit with power
source)
20-532 PC228US-3
1
12
C-14 ([E217] Machine Model selection input error) is displayed
Cause Remedy
YES
1 pump controller
Is [228] 2 YES
displayed on Is voltage
monitoring between C17
code [02]? NO (5)(6)(7)(13)(14)
• Turn starting and chassis as
switch ON. shown in Table 1? Short circuit with ground in Repair or
• Set to monitor- • Turn starting NO terminal with defective replace
ing code [02]. switch ON. voltage
Table 1 Voltage of wiring harness

C04 Between (5) and chassis
Voltage 20 - 30 V
PC228US-3 20-533
1
12
C-15 ([E222] Short circuit in LS-EPC solenoid system) is

displayed
Cause Remedy
pump controller
YES Is resistance
between C02 Short circuit with ground or
1 (female) (7) and short circuit with power
Is resistance (17), and (7) and source in wiring harness
between V22 chassis as shown between C02 (female) (7) - Repair or
(male) (1) and (2), in Table 1? V22 (female) (1), or short replace
(1) and chassis as circuit with power source in
• Turn starting wiring harness between
switch OFF. C02 (female) (17) - V22
• Turn starting • Disconnect C02. (female ) (2).
switch OFF.
• Disconnect V22.
Defective LS-EPC solenoid
(internal short circuit with Replace
ground or short circuit with
NO power source.
Table 1
Resistance
Troubleshooting No. 1 Troubleshooting No. 2
value
Between V22 (male) Between C02 (female)
5 - 25 Ω
(1) and (2) (7) and (17)
Min. 1 MΩ
(1) and chassis (7) and chassis
20-534 PC228US-3
1
12
C-16 ([E223] Disconnection in LS-EPC solenoid system) is

displayed
Cause Remedy
pump controller
YES Is resistance
between C02 Defective contact or short
1 (female) (7) and circuit with chassis ground
Is resistance (17), and (17) and in wiring harness between
between V22 chassis as shown C02 (female) (7) - V22 Repair or
(male) (1) and (2), in Table 1? (female) (1), or defective replace
(2) and chassis as contact, short circuit with
• Turn starting ground, or disconnection in
switch OFF. wiring harness between
• Turn starting • Disconnect C02. C02 (female) (17) - V22
switch OFF. (female ) (2).
• Disconnect V22.
Defective LS-EPC solenoid Replace

(internal disconnection,
NO defective contact, or short
circuit with ground.
Table 1
Resistance
value
5 - 15 Ω
(1) and (2) (7) and (17)
Min. 1 MΩ
PC228US-3 20-535
1
12
C-17 ([E223] Abnormality in front pump pressure sensor

Cause Remedy
3 YES Defective engine throt- Replace
tle, pump controller
YES
Is voltage
between C03 (3) Short circuit with
and (16) normal? power source, defec-
2 tive contact, or discon- Repair or
• Engine at high idling NO nection in wiring replace
YES
Is voltage harness between C03
between A51 (B) • Operate repeatedly arm IN (female) (3) - A51
and (C) normal? relief ↔ lever NEUTRAL. (female) (C).
• 0.5 - 4.5 V
Short circuit with
• Turn starting ground, defective con-
1 switch ON. 4 YES tact, or disconnection Repair or
• 18 - 28 V in wiring harness replace
Interchange Is voltage
connector with rear between A51 (B) between C03 (female)
pump pressure and chassis (16) and A51 (female)
sensor. Is [E224] (A).
NO normal?
displayed?
• Disconnect A51. NO Short circuit with
• Turn starting switch ground, defective con-
• Turn starting ON. tact, or disconnection Repair or
switch OFF. in wiring harness replace
• 18 - 28 V
between C03 (female)
• Interchange A51
(6) and A51 (female)
with A52. (B).
• Engine at high
idling
Defective front pump
pressure sensor (inter-
nal disconnection, Replace
NO
defective contact,
short circuit, or short
20-536 PC228US-3
1
12
C-18 ([E225] Abnormality in rear pump pressure sensor

Cause Remedy
3 YES Defective engine throt- Replace
tle, pump controller
YES
Is voltage
between C03 (3) Short circuit with
and (16) normal? power source, defec-
2 tive contact, or discon- Repair or
• Engine at high idling NO nection in wiring replace
YES
Is voltage harness between C03
between A52 (2) • Operate repeatedly arm IN (female) (13) - A52
and (1) normal? relief ↔ lever NEUTRAL. (female) (C).
• 0.5 - 4.5 V
Short circuit with
• Turn starting ground, defective con-
1 switch ON. 4 YES tact, or disconnection Repair or
• 18 - 28 V in wiring harness replace
Is voltage
Interchange between C03 (female)
between A52 (B)
connector with front (16) and A52 (female)
and chassis
pump pressure (A).
sensor. Is [E225] NO normal?
displayed? • Disconnect A52. NO Short circuit with
• Turn starting switch ground, defective con-
• Turn starting ON. tact, or disconnection Repair or
switch OFF. in wiring harness replace
• 18 - 28 V
between C03 (female)
• Interchange A51
(6) and A52 (female)
with A52. (B).
• Engine at high
idling
Defective rear pump
nal disconnection, Replace
NO
defective contact,
short circuit, or short
PC228US-3 20-537
1
12
C-19 ([E226] Abnormality in pressure sensor power system)

is displayed
Cause Remedy
YES Defective front pump Replace
2 nal short circuit or
short circuit with
ground)
YES Is voltage
between C03 (6) Defective rear pump
and (16) normal? 3 YES
pressure sensor (inter- Replace
1 nal short circuit or
short circuit with
• Turn starting Is voltage
Is resistance ground)
switch ON. between C03 (6)
between C03 NO and (16) normal?
(female) (6) and • Disconnect A51.
(16), (6) (16) and • 18 - 28 V Defective engine throt- Replace
chassis normal? • Turn starting tle, pump controller
NO
switch ON.
• Turn starting • Disconnect A52.
switch OFF. • 18 - 28 V
• Disconnect C03, Short circuit or short
circuit with ground in Repair or
A51, and A52.
wiring harness of sys- replace
• Min. 1 MΩ NO tem where resistance
value is defective
20-538 PC228US-3
1
12
C-20 ([E201] Short circuit in travel junction solenoid system)

is displayed
Cause Remedy
pump controller
Is resistance
YES between C01
2 (female) (8) and
chassis normal? Short circuit with chassis Repair or
YES Is resistance
ground in wiring harness replace
1 between V05 • Turn starting NO between C01 (female) (8)
(male) (1) - (2), (1) switch OFF. and V05 (female) (1)
Interchange - chassis as • Disconnect C01.
connector with shown in Table 1? • 20 - 60 Ω
other solenoid. Is
[E201] displayed?
• Turn starting
switch OFF. • Disconnect V05.
NO
• Interchange V05
with other
connector. Defective travel junction
• Turn starting solenoid (internal short Replace
switch ON. NO circuit or short circuit with
• Connect short chassis ground).
connector to
connector S31 of
travel steering
pressure switch.
Table 1
Between V05 (male) (1) — (2) 20 — 60 Ω
PC228US-3 20-539
1
12
C-21([E211] Disconnection in travel junction solenoid system)

is displayed
Cause Remedy
4 YES Defective contact or Repair or
disconnection in replace
Is voltage wiring harness
between V05 (female)
3 YES between V05 (2) and chassis ground
(female) (1) and
Is voltage chassis as shown Defective contact, dis-
2 YES between C01 in Table 1? connection, or short
(male) (8) and circuit with power
chassis as shown • Disconnect NO source in wiring har- Repair or
V05. ness between C01 replace
Is resistance in Table 1?
1 YES between V05 (female) (5) and V05
• Turn starting
(male) (1) and (2) • Turn starting (female) (1)
switch ON.
Interchange normal? switch ON.
connector with • Disconnect C01.
other solenoid. Defective engine
Is [E211] • Turn starting NO throttle, pump Replace
displayed? switch OFF. controller
NO
• Disconnect V05.
• Turn starting • 20 - 60 Ω Defective travel Replace
switch OFF.
junction solenoid
• Interchange V05 NO
with other
connector.
• Turn starting
switch ON.
Table 1
Troubleshooting No. 3 Troubleshooting No. 4 Voltage Measurement condition
0 - 30 V All levers at neutral

Between C01 (male) (5) Between V05 (female) (1)
and chassis and chassis Work equipment lever operated
20 - 30 V
+ power max. switch ON
20-540 PC228US-3
1
12
C-22([E227] Abnormality in engine speed sensor) is displayed
Cause Remedy
pump controller
YES
Is resistance
1 between C06 Short circuit with ground,
Is resistance (female) (1) and defective contact, or dis-
between E04 (2) normal? connection in wiring har- Replace
(male) (1) and (2) ness between C06 (female)
normal? • Turn starting NO (2) - E04 (female) (1), or C16
switch OFF. (female) (1) - E04 (female)
• Turn starting • Disconnect C04. (2)
switch OFF. • 500 - 1000 Ω
• Disconnect E04.
• 500 - 1000 Ω
Defective engine speed
sensor (internal disconnec- Replace
NO tion, defective contact, or
short circuit with ground)
PC228US-3 20-541
1
12
C-23([E241] Abnormality in boom angle potentiometer sys-

tem input value) is displayed
Cause Remedy
pump controller
YES Is resistance
between pins of
1 C03 (female)
Is resistance (1)(7)(14) or
between A53 between each pin
(male) (1) - (2), (2) and chassis as
- (3) as shown in shown in Table 1? Defective wiring harness in
Table 1? NO system with defective Replace
• Turn starting resistance
switch OFF.
switch OFF.
• Disconnect A53.
Defective boom angle Replace

NO potentiometer
★ If E306 and E308 occur at the same time, carry out troubleshooting of the following wiring harnesses.
• Short circuit with ground in wiring harness between C03 (female) (7) - E10 (female) (1), C03 (female) (7)
- E06 (female) (1), or contact with other wiring harness
★ If the other wiring harnesses are normal, the wiring harness related to C03 (female) (7) - (17) is the
cause.
Table 1
Resistance
C03 (female) A53 (male)
value
(7) - (1) (1) - (2) 0.5 - 4.5 kΩ
(1) - (17) (2) - (3) 0.5 - 4.5 kΩ
— (1) - (3) 4 - 6 kΩ
Between each
— Min. 1 MΩ
pin and chassis
PC228US-3 20-542
1
TROUBLESHOOTING C-24, C-25, C-26
12
C-24 ([E255]
C-24, Abnormality in boom angle potentiometer
C-25, C-26
compensation value (outside compensation range)
is displayed
Cause Remedy

pump controller
C-25 ([E256] Abnormality in check sum is displayed

Cause Remedy

pump controller
C-26 ([E313] Abnormality in automatic greasing is displayed

Cause Remedy
Defective automatic Replace

grease supply controller
(check C03 (9) signal)
PC228US-3 20-543
1
12
C-27 [E313] Abnormality in ATT-EPC solenoid system
Cause Remedy
pump controller
YES Is resistance
1 between C02 Defective contact, discon-
(male) (10) - (20), nection, short circuit with
Is resistance (10) - chassis as chassis ground, or short cir-
between V07 shown in Table 1? cuit with power source in
(male) (1) - (2), (1) wiring harness between Repair or
- chassis as shown C02 (female) (10) and V07 replace
in Table 1? NO
• Turn starting (female) (1), or defective
switch OFF. contact, disconnection, or
• Turn starting • Disconnect C02. short circuit with power
switch OFF. source in wiring harness
• Disconnect V07. between C02 (female) (20)
Defective ATT-EPC sole- Replace

NO noid (internal short circuit
with chassis ground)
Table 1
Resistance
value
7 - 14 Ω
(1) and (2) (10) and (20)
Min. 1 MΩ
PC228US-3 20-544
1
12
TROUBLESHOOTING OF ENGINE THROTTLE AND PUMP

CONTROLLER (INPUT SIGNAL SYSTEM)
(F MODE)
Electrical circuit diagram for F mode system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-602

F - 1 Bit pattern 20-(1) Swing oil pressure switch ON display does not light up . . . . . . . . . . . 20-604
F - 2 Bit pattern 20-(2) Travel oil pressure switch ON display does not light up . . . . . . . . . . . 20-605
F - 3 Bit pattern 20-(3) Boom LOWER oil pressure switch ON display does not light up . . . . 20-606
F - 4 Bit pattern 20-(4) Boom RAISE oil pressure switch ON display does not light up . . . . . 20-607
F - 5 Bit pattern 20-(5) Arm IN oil pressure switch ON display does not light up . . . . . . . . . . 20-608
F - 6 Bit pattern 20-(6) Arm OUT oil pressure switch ON display does not light up . . . . . . . . 20-609
F - 7 Bit pattern 21-(1) Bucket CURL oil pressure switch ON display does not light up . . . . . 20-610
F - 8 Bit pattern 21-(2) Bucket DUMP oil pressure switch ON display does not light up. . . . . 20-611
F - 9 Bit pattern 21-(4) Service pressure switch ON display does not light up. . . . . . . . . . . . . 20-612
F -10 Bit pattern 21-(5) Travel steering pressure switch ON display does not light up . . . . . . 20-613
F -11 Bit pattern 22-(3) L.H. knob switch ON display does not light up . . . . . . . . . . . . . . . . . . . 20-614
F -12 Bit pattern 22-(4) Emergency swing holding brake release switch ON display
does not light up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-615
F -13 Bit pattern 22-(5) Swing lock switch ON display does not light up. . . . . . . . . . . . . . . . . . 20-616
F -14 Bit pattern 27-(6)Kerosene mode connection display does not light up . . . . . . . . . . . . . 20-617
★ This troubleshooting is carried out when there is still an abnormality, so when disconnecting
the connector and inserting the T-adapter, or when removing the T-adapter and returning the
connector to its original position, if the service code E is not displayed, the problem has been
removed.
PC228US-3 20-601
1
TROUBLESHOOTING F - MODE ELECTRICAL CIRCUIT DIAGRAM
12
F - MODE ELECTRICAL CIRCUIT DIAGRAM
20-602 PC228US-3
1
TROUBLESHOOTING F - MODE ELECTRICAL CIRCUIT DIAGRAM
12
PC228US-3 20-603
1
TROUBLESHOOTING F-1
12
F-1 Bit pattern 20-(1) Swing oil pressure switch ON

display does not light up
Turn the swing lock switch ON before operating the swing lever. (It is enough to operate only slightly.)
★ When measuring with the engine stopped, charge the accumulator first.
Cause Remedy
4 YES Defective engine Replace
throttle, pump
controller
Is voltage
3 YES between C06 (5)
and chassis Defective contact or
Is resistance
normal? disconnection in wir- Repair or
2 YES between C16 ing harness between replace
(female) (5) - S03,
Is resistance • Start engine. S03 (female) (1), S07
S07 (female) (2) NO
between S03 • Swing lever at (female) (1) and chas-
normal, and is
1 YES (male) (1) and (2) neutral: sis ground
circuit insulated
normal, and is from chassis? 20 - 30 V
Is resistance
circuit insulated • Swing lever
between S03 • Turn starting Short circuit with chas-
from chassis? operated:
(male) (1) and switch OFF. sis ground, defective
(2) normal, and • Disconnect S07. • Disconnect C16,
Max. 1 V contact, or disconnec- Replace
is circuit • Start engine. tion in wiring harness
insulated from S03, S07. NO
• Swing lever at between C06 (female)
chassis? • Between (5) and S03 (female)
neutral: C16 - S03, S07:
• Disconnect S03. (2), S07 (female) (2)
Min. 1 MΩ Max. 1 Ω
• Start engine. • Swing lever • Between wiring
• Swing lever at operated to right harness and
neutral: Min. 1 swing: Max. 1 Ω chassis:
MΩ • See Note. Min. 1 MΩ
• Swing lever Defective right swing
operated to left NO oil pressure switch Replace
swing: Max. 1 Ω
• See Note. Defective left swing oil
pressure switch Replace
NO
Note: It is also possible to fit a short connector and judge the condition. In this case, check the voltage
between C06 (5) and the chassis.
• If it is 20 - 30 V: Go to YES
• If it is less than 1 V: Go to NO
F-1 Related electrical circuit diagram
20-604 PC228US-3
1
TROUBLESHOOTING F-2
12
F-2 Bit pattern 20-(2) Travel pressure switch ON display

does not light up
Before operating the travel lever, check that the surrounding area is safe.
(It is enough to operate only slightly.)
★ If there is no display when the travel lever is operated in any direction, the PPC shuttle valve is defective
(go to H-5).
★ When measuring with the engine stopped, charge the accumulator first.
★ Check that joint connectors J01 and J05 are normal.
Cause Remedy
pump controller
Is voltage
YES between C06 (13)
2 and chassis
normal? Defective contact or Repair or
YES
disconnection in wiring replace
Is resistance
1 NO harness between S30
between C06 • Start engine. (female) (1) and chassis
(female) (13) and
Is resistance • Travel lever at ground
S30 (female) (2)
between S30 normal, and is cir- neutral:
(male) (1) and (2) cuit insulated 20 - 30V
normal, and is from chassis? • Travel lever
circuit insulated operated:
from chassis? Repair or
Max. 1 V
• Turn starting Defective contact, short cir- replace
switch OFF. cuit with ground, or discon-
• Disconnect S30. NO nection in wiring harness
• Disconnect C06
• Start engine. between C06 (female) (13)
and S30.
• Travel lever at and S30 (female) (2)
neutral: • Between C06 and S30: Max. 1 Ω
Min. 1 MΩ • Between wiring harness and chassis:
• Travel lever Min. 1 MΩ
operated:
Replace
Max. 1 Ω NO Defective travel pressure
• See Note.
switch
Note: It is also possible to fit a short connector and judge the condition. In this case, check the voltage
PC228US-3 20-605
1
TROUBLESHOOTING F-3
12
F-3 Bit pattern 20-(3) Boom LOWER oil pressure switch

ON display does not light up
Cause Remedy
YES
1 pump controller
Is voltage between 3 YES disconnection in wiring Repair or
C40 (10) and chassis harness between S02 replace
normal? Is resistance (female) (1) and chassis
YES between C04 ground
(female) (10) and
2 S02 (female) (2) Defective contact, short
• Start engine. normal, and is circuit with ground, or Repair or
Is resistance
• Boom lever at circuit insulated disconnection in wiring replace
between S02
neutral: 20 - 30 V from chassis? NO harness between C04
(male) (1) and (2)
• Boom lever normal, and is (female) (10) - S02
NO • Turn starting switch OFF.
operated to circuit insulated (female) (2)
• Disconnect C04 and S02
LOWER: Max. 1 V from chassis?
• Between C04 and S02: Max. 1 Ω
• Disconnect S02.
• Between wiring harness and chassis: Defective boom LOWER Replace
• Start engine. Min. 1 MΩ oil pressure switch
• Boom lever at
neutral: NO
Min. 1 MΩ
• Boom lever operated to LOWER: Max. 1 Ω
• See Note 1.
Note 1: It is also possible to fit a short connector and judge the condition. In this case, check the voltage
20-606 PC228US-3
1
TROUBLESHOOTING F-4
12
F-4 Bit pattern 20-(4) Boom RAISE oil pressure switch

Cause Remedy
YES
1 pump controller
(female) (2) and S06
2 (female) (2) Defective contact, short
• Start engine. normal, and is circuit with ground, or Repair or
Is resistance
• Boom lever at circuit insulated disconnection in wiring replace
between S06
neutral: 20 - 30 V from chassis? NO harness between C04
(male) (1) and (2)
• Boom lever normal, and is (female) (2) - S06 (female)
operated to circuit insulated (2)
• Disconnect C04 and S06.
RAISE: Max. 1 V from chassis?
• Disconnect S06.
• Between wiring harness and chassis: Defective boom RAISE oil Replace
• Start engine.
Min. 1 MΩ pressure switch
• Boom lever at
neutral:
NO
Min. 1 MΩ
• Boom lever operated to RAISE: Max. 1 Ω
• See Note 1.
PC228US-3 20-607
1
TROUBLESHOOTING F-5
12
F-5 Bit pattern 20-(5) Arm IN oil pressure switch

Cause Remedy
YES
1 pump controller
• Start engine. 2 (female) (2) Defective contact, short
• Arm lever at normal, and is
Is resistance circuit with ground, or Repair or
neutral: 20 - 30 V circuit insulated disconnection in wiring replace
between S04
• Arm lever from chassis? NO harness between C04
(male) (1) and (2)
operated to IN: normal, and is (female) (3) - S04 (female)
Max. 1 V circuit insulated (2)
from chassis?
• Disconnect S04.
• Between wiring harness and chassis: Defective boom IN oil Replace
• Start engine.
Min. 1 Ω pressure switch
• Arm lever at
neutral:
NO
Min. 1 MΩ
• Arm lever operated to IN: Max. 1 Ω
• See Note 1.
20-608 PC228US-3
1
TROUBLESHOOTING F-6
12
F-6 Bit pattern 20-(6) Arm OUT oil pressure switch

Cause Remedy
YES
1 pump controller
(female) (11) and
• Start engine. 2 S08 (female) (2) Defective contact, short
• Arm lever at normal, and is
between S08
• Arm lever from chassis? NO harness between C04
(male) (1) and (2)
operated to OUT: normal, and is (female) (11) - S08
Max. 1 V circuit insulated (female) (2)
from chassis?
• Disconnect S08.
• Between wiring harness and chassis: Defective boom OUT oil Replace
• Start engine.
• Arm lever at
neutral:
NO
Min. 1 MΩ
• Arm lever operated to OUT: Max. 1 Ω
• See Note 1.
PC228US-3 20-609
1
TROUBLESHOOTING F-7
12
F-7 Bit pattern 21-(1) Bucket CURL oil pressure switch

Cause Remedy
YES
1 pump controller
(female) (11) and
• Bucket lever at normal, and is
between S01
• Bucket lever from chassis? NO harness between C06
(male) (1) and (2)
operated to CURL: normal, and is (female) (11) - S01
Max. 1 V circuit insulated (female) (2)
from chassis?
• Disconnect S01.
• Between wiring harness and chassis: Defective bucket CURL oil Replace
• Start engine.
• Bucket lever at
neutral:
NO
Min. 1 MΩ
• Bucket lever operated to CURL: Max. 1 Ω
• See Note 1.
20-610 PC228US-3
1
TROUBLESHOOTING F-8
12
F-8 Bit pattern 21-(2) Bucket DUMP oil pressure switch

Before operating the bucket lever, check that the surrounding area is safe.
(It is enough to operate only slightly.)
Cause Remedy
YES
1 pump controller
(female) (12) and
• Bucket lever at normal, and is
between S05
• Bucket lever from chassis? NO harness between C06
(male) (1) and (2)
operated to normal, and is (female) (12) - S05
DUMP: Max. 1 V circuit insulated (female) (2)
from chassis?
• Disconnect S05.
• Between wiring harness and chassis: Defective bucket DUMP Replace
• Start engine.
Min. 1 MΩ oil pressure switch
• Bucket lever at
neutral:
NO
Min. 1 MΩ
• Bucket lever operated to DUMP: Max. 1 Ω
• See Note 1.
PC228US-3 20-611
1
TROUBLESHOOTING F-9
12
F-9 Bit pattern 21-(4) Service pressure switch ON display

does not light up
When measuring with the engine running, operate the lever slightly and make sure that the
attachment does not move. (When measuring with the engine stopped, charge the accumulator first.)
Cause Remedy
pump controller
YES Defective contact or

disconnection in wiring Repair or
1 4 harness between S10 replace
Is resistance (female) (1), S11 (female)
Is voltage between C16 (1) - chassis ground
between C06 (6) YES (female) (5) and
and chassis 3 S10, S11 (female)
normal? (2) normal, and is
Is resistance circuit insulated
between S10 from chassis?
• Start engine. YES (male) (1) and (2) Defective contact, short
• Swing lever at normal, and is circuit with ground, or Repair or
2 • Turn starting
neutral: circuit insulated disconnection in wiring replace
switch OFF. NO harness between C06
20 - 30 V Is resistance from chassis?
• Swing lever • Disconnect (female) (6) - S10
between S10 • Disconnect S10.
operated: C16, S10, and (female) (2), S11 (female)
(male) (1) and (2) • Start engine.
NO S11. (2)
Max. 1 V normal, and is • Attachment pedal
circuit insulated lever at neutral: • Between C16 and
from chassis? Min. 1 MΩ S10, S11: Max. 1 Ω
• Attachment pedal • Between wiring
• Disconnect S10. service (rear) harness and chassis:
• Start engine. pressure switch Min. 1 MΩ
• Attachment pedal operated: Defective service (rear) Replace
at neutral: Max. 1 Ω NO pressure switch
Min. 1 MΩ • See Note.
• Attachment pedal
service (front) Defective service (front) Replace
pressure switch NO pressure switch
operated:
Max. 1 Ω
• See Note.
20-612 PC228US-3
1
TROUBLESHOOTING F-10
12
F-10 Bit pattern 21-(5) Travel steering pressure ON display

switch does not light up
When starting the engine and operating the travel lever, check carefully that there is no one in the
surrounding area and that the area is safe.
Cause Remedy
YES
1 pump controller
2 (female) (2) normal, Short circuit with chassis
• Start engine. and is circuit
• Travel lever at After connecting ground, defective con- Repair or
insulated from tact, or disconnection in replace
neutral: 20 - 30 V short connector
chassis? NO wiring harness between
• Travel lever on to S31, is voltage
between C06 (9) C06 (female) (9) - S31
one side operated NO • Turn starting switch OFF. (female) (2)
and chassis
to operate • Disconnect C06 and S31.
normal?
steering: Max. 1 V • Between C06 and S31: Max. 1 Ω
• Connect short
• Between wiring harness and chassis:
connector to S31.
Min. 1 MΩ
• Turn starting Defective travel steering Replace
switch ON. pressure switch
NO
• Max. 1 V.
PC228US-3 20-613
1
12
F-11 Bit pattern 22-(3) L. H. knob switch ON display does

not light up
★ Check that fuse 9 is not blown.
Cause Remedy
YES
1 pump controller
Is voltage between 3 YES disconnection in wiring Repair
C03 (9) and chassis harness between knob wiring
normal? switch M23 (2) - C03 harness
YES Is resistance (female) (9)
between terminals
• Turn starting 2 of knob switch M23
switch ON. (male) (1) - (2)
• Knob switch Is voltage normal? Defective L.H. knob Repair
ON: 20 - 30 V between knob NO switch
switch inlet
OFF: Max. 1 V NO terminal and • Turn starting switch OFF.
chassis normal? • Disconnect switch terminal M23.
• Knob switch ON: Max. 1 Ω
• Turn starting OFF: 1 MΩ
switch ON. Defective contact, or Repair
• 20 - 30 V. disconnection in wiring wiring
NO harness between fuse harness
No. 9 - M23 (1) knob
switch inlet
20-614 PC228US-3
1
12
F-12 Bit pattern 22-(4) Emergency swing holding brake

release switch ON display does not light up
★ When the panel display is normal. (If the swing lock lamp does not light up, go to M-22.)
Cause Remedy
YES
1 pump controller

Is voltage between 3 YES ground, defective Repair or
C04 (8) and chassis contact, or disconnection replace
normal? in wiring harness
Is resistance
YES between C04 (male) between S25 (female) (2)
(8) and S25 (female) and chassis ground
• Turn starting 2
(10) normal, and is
switch ON. Is resistance circuit insulated Short circuit with chassis
• Emergency swing between S25 from chassis? ground, defective con- Repair or
holding brake (male) (9) and (10) NO tact, or disconnection in replace
cancel switch normal, and is wiring harness between
circuit insulated C04 (female) (8) and S25
ON (swing free): • Disconnect C04 and S25.
from chassis? (female) (10)
20 - 30 V • Between C04 and S25: Max. 1 Ω
OFF (normal): • Turn starting
switch OFF.
Max. 1 V chassis: Min. 1 MΩ Defective emergency Replace
• Disconnect S25. swing holding brake
• Emergency swing NO release switch
holding brake
release switch
ON (swing free):
Min. 1 MΩ
OFF (normal):
Max. 1 Ω
PC228US-3 20-615
1
12
F-13 Bit pattern 22-(5) Swing lock switch ON display

does not light up
★ When the panel display is normal. (If the swing lock lamp does not light up, go to M-22.)
Cause Remedy
pump controller
1
ground, defective Repair or
Is voltage between 3 YES contact, or disconnection replace
C04 (16) and chassis in wiring harness
normal? Is resistance between X05 (female) (2)
YES between C04 and chassis ground
(female) (15) and
• Turn starting 2 X05 (female) (1) Short circuit with chassis
switch ON. normal, and is ground, defective
Is resistance
• Swing lock switch circuit insulated contact, or disconnection Repair or
between X05
ON: Max. 1 V from chassis? NO in wiring harness replace
(female) (1) and
OFF: 10 - 30 V (") between C04 (female)
NO (2) normal, and is • Turn starting switch OFF.
circuit insulated (16) and X05 (male) (1)
from chassis? • Disconnect C04 and X05.
• Between C04 and X05: Max. 1 Ω
• Turn starting
switch OFF.
chassis: Min. 1 MΩ
• Disconnect X05. Defective swing lock Replace
• Swing lock switch NO switch
ON: Max. 1 Ω
OFF: Min. 1 MΩ
" The internal power supply of the engine throttle, pump controller (24 V system) and the monitor panel
(24 V system) is different, so the voltage differs according to the connection (J02 (15) - P02 (17)) with the
monitor panel.
20-616 PC228US-3
1
12
F-14 Bit pattern 27-(6) Kerosene mode connection display

does not light up
★ When the kerosene mode wiring harness is connected.
Cause Remedy
1 YES
pump
controller
Is voltage between
C04 (15) and chassis
normal? Defective contact or
harness between wiring Repair or
harness for replace
NO kerosene mode
• Turn starting {C04 (female) (15)} and
switch ON. chassis
• Wiring harness for
kerosene mode
• Connected:
Max. 1 V
Open: 20 - 30 V
PC228US-3 20-617
1
126 TROUBLESHOOTING OF HYDRAULIC AND
MECHANICAL SYSTEM
(H MODE)
TABLE OF FAILURE MODES AND CAUSES FOR HYDRAULIC AND MECHANICAL SYSTEM (1/2) 20-702
PUMP MERGE/DIVIDER LOGIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-706
ON/OFF SOLENOID ACTUATION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-707
H-1 SPEEDS OF ALL WORK EQUIPMENT, SWING, TRAVEL ARE SLOW OR LACK POWER . . . . . 20-708
H-2 THERE IS EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS . . . . . . . . . . . . . . . . . . 20-710
H-3 NO WORK EQUIPMENT, TRAVEL, SWING MOVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-711
H-4 ABNORMAL NOISE GENERATED (AROUND PUMP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-711
H-5 AUTO-DECELERATION DOES NOT WORK (PPC SHUTTLE VALVE IS EQUIPPED ONLY IN
TRAVEL PPC VALVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-712
H-6 FINE CONTROL ABILITY IS POOR OR RESPONSE IS POOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-712
H-7 BOOM IS SLOW OR LACKS POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-714
H-8 ARM IS SLOW OR LACKS POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-716
H-9 BUCKET IS SLOW OR LACKS POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-718
H-10 WORK EQUIPMENT (BOOM, ARM, BUCKET) DOES NOT MOVE (BUT TRAVEL AND
SWING AREA NORMAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-719
H-11 EXCESSIVE HYDRAULIC DRIFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-719
H-12 EXCESSIVE TIME LAG (ENGINE AT LOW IDLING) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-720
H-13 OTHER EQUIPMENT MOVES WHEN SINGLE CIRCUIT IS RELIEVED . . . . . . . . . . . . . . . . . . . 20-720
H-14 LACK OF POWER WHEN PRESSURE RISES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-720
H-15 IN COMPOUND OPERATIONS, WORK EQUIPMENT WITH LARGER LOAD IS SLOW . . . . . . 20-721
H-16 IN SWING + BOOM RAISE, BOOM RAISE IS SLOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-721
H-17 IN SWING + TRAVEL, TRAVEL SPEED DROPS EXCESSIVELY . . . . . . . . . . . . . . . . . . . . . . . . . 20-721
H-18 TRAVEL DEVIATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-722
H-19 TRAVEL SPEED IS SLOW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-723
H-20 STEERING IS DIFFICULT TO TURN OR LACKS POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-724
H-21 TRAVEL SPEED DOES NOT SWITCH OR IS FASTER THAN SPECIFIED SPEED . . . . . . . . . . . 20-726
H-22 TRAVEL DOES NOT MOVE (ONE SIDE ONLY). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-726
H-23 DOES NOT SWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-727
H-24 SWING ACCELERATION IS POOR OR SWING SPEED IS SLOW . . . . . . . . . . . . . . . . . . . . . . . 20-728
H-25 EXCESSIVE OVERRUN WHEN STOPPING SWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-729
H-26 EXCESSIVE SHOCK WHEN STOPPING SWING (ONE DIRECTION ONLY . . . . . . . . . . . . . . . . 20-729
H-27 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING . . . . . . . . . . . . . . . . . . . . . . . . . . 20-730
H-28 EXCESSIVE HYDRAULIC DRIFT OF SWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-731
PC228US-3 20-701
1
TESTING AND ADJUSTING TABLE OF FAILURE MODES AND CAUSES FOR HYDRAULIC AND
12
TABLEOF FAILURE MODES AND CAUSES FOR HYDRAULIC AND
MECHANICAL SYSTEM (1/2)
Piston pump
Parts causing failure Front Rear
Pump proper
Pump proper
Servo piston
Servo piston
PC valve
PC valve
LS valve
LS valve
Strainer
Damper
Failure mode
Speeds of all work equipment, swing, travel are slow or lack power ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲
All work equipment
There is excessive drop in engine speed, or engine stalls ! ! ! ! ! !

travel, swing
No work equipment, travel, swing move ! ! !

Abnormal noise generated (around pump) ! ! !
Auto-deceleration does not work
Fine control ability is poor or response is poor ! ! ! !
Boom is slow or lacks power
Arm is slow or lacks power
Work equipment
Boom does not move

Arm does not move
Excessive time lag (engine at low idling)
Lack of power when pressure rises
Compound
operations

Deviation is excessive during normal travel ! !
Travel deviation
Travel system
Travel speed is slow

Steering does not turn or lacks power
Travel speed does not switch or is faster than set speed
Does not move (one side only) ! !
Both left and right
Does not swing
One direction only
Swing acceleration is poor or swing speed is Both left and right

slow
Swing system
One direction only

Both left and right
Excessive overrun when stopping swing
One direction only
Excessive abnormal noise when stopping swing
Excessive hydraulic drift of When holding brake is OFF

swing When holding brake is ON
★ In the failure modes, modes for compound operations are used when independent operations are nor-
mal.
20-702 PC228US-3
1
Spool
!
!
!
!
!
!
!
!
!
!
!
!
!
▲
Main relief valve
!
!
For
front
pump
Unload valve
PC228US-3
Main relief valve
!
!
▲
For
rear
Unload valve pump
▲
Pressure compensation valve
!
!
!
!
!
!
!
!
!
!
!
For main
!
!
!
For LS
!
!
!
!
divider valve
Pump merge-
Main circuit check valve
!
LS circuit check valve
!
LS shuttle valve
Control valve
!
!
!
!
!
!
LS circuit throttle
!
Boom
!
!
circuit
Arm
!
!
Regeneration
Safety-suction valve
!
!
!
!
!
Suction valve
!
!
!
!
!
!
Self pressure reducing valve
Back pressure valve
!
!
! Boom lock valve

!
PPC valve
!
!
!
!
!
!
!
!
!
!
!
!
Shuttle with built-in travel PPC valve
!
!
For steering signal (spool) with built-in travel PPC
!
!
valve
Swing PPC (EPC) slow return valve
!
!
Swivel joint
Engine system
!
H-9
H-8
H-7
H-6
H-5
H-4
H-3
H-2
H-1
TABLE OF FAILURE MODES AND CAUSES FOR HYDRAULIC AND
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-11
H-10
20-703
1
(2/2)
Solenoid valve Swing motor
Parts causing failure

Boom RAISE EPC valve
Travel speed selection
PPC oil pressure lock

Pump merge-divider
Holding brake
Suction valve
2-stage relief
Swing brake
Safety valve
PC-EPC
Failure mode
Speeds of all work equipment, swing, travel are slow or lack power !
All work equipment
There is excessive drop in engine speed, or engine stalls

travel, swing
No work equipment, travel, swing move !

Abnormal noise generated (around pump)
Auto-deceleration does not work
Fine control ability is poor or response is poor !
Boom is slow or lacks power ! !
Arm is slow or lacks power !
Work equipment
Boom does not move !

Arm does not move
Excessive time lag (engine at low idling) !
Lack of power when pressure rises !
Compound
operations

Deviation is excessive during normal travel
Travel deviation
Travel system
Travel speed is slow !

Steering does not turn or lacks power ! ! !
Travel speed does not switch or is faster then specified ! !
Does not move (one side only)
Both left and right ! ! !
Does not swing
One direction only !
Swing acceleration is poor or swing speed is Both left and right !

slow ! !
Swing system
One direction only

Both left and right !
Excessive overrun when stopping swing
One direction only !
Excessive abnormal noise when stopping ! !
Excessive hydraulic drift of When holding brake is released ! ! !

swing When holding brake is applied ! !
20-704 PC228US-3
1
Travel motor Oil pressure switch
Pressure
Boom Arm Bucket Swing Sensor
Travel speed selector servo piston
Counterbalance valve
Hydraulic cylinder
Swing machinery
Final drain valve
Engine system
Safety valve
Check valve
Front pump
Rear pump
LOWER
DUMP
Travel
RAISE
CURL
Right
OUT
Left
IN
H-1
! H-2
H-3
H-4
! ! ! ! ! ! ! ! ! H-5
H-6
! ! ! H-7
! ! ! H-8
! ! ! H-9
H-10
! H-11
H-12
H-13
! ! ! ! ! ! H-14
H-15
H-16
H-17
!
H-18
!
! ! H-19
! ! H-20
! ! ! ! H-21
! ! ! ! ! H-22
! ! !
H-23
H-24
H-25
H-26
! H-27
H-28
PC228US-3 20-705
1
TESTING AND ADJUSTING PUMP MERGE/DIVIDER LOGIC
PUMP MERGE/DIVIDER LOGIC
Divide Merge
Solenoid ON Solenoid OFF
• At crane arm
• In B mode and service pressure switch signal ON

• In B mode and service pressure switch signal ON
and boom lower signal ON
• Except above All operations except those above and on left

• Travel operated independently
• Compound operation with travel ("1) and steer-
ing signal ON
• With travel OFF
• Swing lock switch ON
• Swing lock switch OFF
• A mode ON
• Except A mode, with swing signal ON
• Except A mode
• Arm OUT + service ON + pressure
sensor signal pressure as in ("1)
"1: Higher of F or R pump oil pressure >19.6 MPa {200 kg/cm2}
20-706 PC228US-3
1
TESTING AND ADJUSTING ON/OFF SOLENOID ACTUATION TABLE
ON/OFF SOLENOID ACTUATION TABLE
Name of solenoid ON (energized) OFF (de-energized)

PPC oil pressure lock Cancel Lock
2-stage relief Pressure rising Pressure not rising
Hi/Lo selection Travel motor swash plate MIN Travel motor swash plate MAX
Swing holding brake Brake released Brake applied
Travel junction Junction cut Junction
Pump merge/divider valve Divide Merge
PC228US-3 20-707
1
TESTING AND ADJUSTING H-1
H-1 Speeds of all work equipment, swing, travel are slow or lack power
★ Carry out troubleshooting in the A mode.

★ Check that no abnormal noise is being generated from the main pump before carrying out trouble-
shooting. (If there is abnormal noise, carry out troubleshooting for H-4.)
YES
YES 5
Does condition
become normal
6 YES
when PC valve is
adjusted?
Does condition
become normal
4 NO when PC valve
assembly is
YES replaced?
Is input pressure of
servo piston
approx. 3/5 of main NO
circuit pressure?
3
YES • Engine at high YES

idling 7
Is output pressure
of LS-EPC valve • A mode Does condition
normal? • L.H. knob switch become normal
ON when LS valve
• Arm IN relief assembly is
• 0.2±0.2 MPa replaced?
{2±2 kg/cm²} • See Note 1
• Engine at high YES • Distribution of NO
idling LS valve and pis-
2 • operate work ton pump (servo
equipment lever piston)
YES a little
Is main pump relief NO
pressure normal?
• 33.3-36.8 MPa YES

{340-375 kg/cm²}
• Engine at high
idling
1 • Arm IN relief 8
Does condition 9 YES

become normal
Is control circuit NO when main relief
pressure normal? Does condition
valves are become normal
adjusted? when unload
valves are
• 33.3-36.8 MPa replaced?
• Check and mea- {340-375kg/cm²}
sure circuit oil • Engine at high NO • 30.4-33.8 MPa NO
idling {310-345 kg/cm²
pressure. For
• Arm IN relief • Engine at high
details, see
idling
TESTING AND
• Arm IN relief
ADJUSTING.
NO
" The PPC control circuit oil pressure is reduced in Item No. 4
Note 1: Measuring servo piston inlet port pressure in Item No. 4
Basically, the pressure at the large diameter end is approx. 3/5 of the small diameter end.
(For details, see TESTING AND ADJUSTING.)
20-708 PC228US-3
1
Cause Remedy
Defective adjustment of
Adjust
PC valve
Defective PC valve servo Repair or

assembly replace
Repair or
Defective piston pump
replace
Repair or
Defective LS valve
assembly replace
Defective piston pump Repair or

(servo piston) replace
Defective operation of Replace

LS-EPC solenoid valve
Defective operation of
main relief assembly Adjust
(valve which becomes
normal when adjusted)
Replace
unload valve (valve
which becomes normal
when replaced
main relief valve Replace
Defective self-reducing Replace

pressure valve
PC228US-3 20-709
1
H-2 There is excessive drop in engine speed, or engine stalls

★ Check that the main relief pressure is normal.
Cause Remedy
Clogged throttle inside Clean

YES servo or clogged filter
inside servo
YES Adjust or
Defective PC valve or replace
3 defective operation of LS servo
valve valve
1 YES Does condition assembly
become normal
when PC valve
Is throttle inside assembly is Adjust or
servo or filter replaced? 4 YES replace LS
Defective LS valve valve
inside servo 2
clogged? Does condition assembly
become normal
when LS valve
• Is engine speed at NO assembly is
arm IN relief nor- replaced? Replace
NO mal? (piston
Defective servo piston pump
NO assembly)
• See Note 1. See troubleshooting for —
engine (S mode)
NO
Note 1: Replace the servo valve assembly on the defective side with a new part, and if the engine speed is
lower than the reference value below, carry out troubleshooting for S mode (engine). If it is higher,
it can be judged that the servo valve is defective, so replace it.
★ Engine speed (reference) at arm IN relief when engine and pump are normal
Model Engine speed at arm IN relief Conditions
PC228US-3 Min. 1800 rpm • Engine at high idling

• A mode
• L.H. knob switch ON
20-710 PC228US-3
1
TESTING AND ADJUSTING H-3, H-4
H-3, H-4
H-3 No work equipment, travel, swing move
Cause Remedy
Defective self-reducing
YES 2 YES pressure valve, defective Replace
1 When main pump control circuit, or defective
pressure pickup main piston pump
plug is removed,
does oil come
Is safety lock valve Defective damper Replace
out?
working properly?
• Crank with
NO
starting motor
safety lock valve or safety Adjust
NO linkage
H-4 Abnormal noise generated (around pump)
Cause Remedy
3 YES
Go to 4
Do bubbles disap-
2 pear when engine
is stopped?
YES
Are there bub- Improper hydraulic oil Change
bles inside NO hydraulic oil
hydraulic tank?
1 4 YES Clogged by external
object (cloth, etc.) Remove
(strainer)
Is hydraulic Is suction strainer
tank oil level clogged by exter- 5 YES Repair or
normal? nal object? Defect inside pump replace
Is suction strainer
clogged with
• External object:
metal particles or
cloth, etc.
are metal parti-
cles stuck to drain Inspect again
NO Operate for a short time (depending on
plug? and watch for any changes in
NO change in symptoms symptoms)
Lack of hydraulic oil Add hydraulic

NO oil
PC228US-3 20-711
1
H-5, H-6
H-5 Auto-deceleration does not work (PPC Shuttle valve is equipped only in
travel PPC valve)
★ The control pressure for the travel passes through the PPC shuttle valve and is supplied to the pressure
switch.
Cause Remedy
1
YES
Does condition Defective pressure Replace
become normal switch
when pressure
switch is
replaced? Defective operation of Repair or
NO PPC shuttle valve with replace
travel PPC valve
H-6 Fine control ability is poor or response is poor
Cause Remedy
2 YES Clogged throttle in LS Clean

circuit
YES Is throttle in LS
1
circuit clogged
Is output pres- Defective LS valve, or
sure of LS-EPC NO defective servo piston Replace
normal?
Defective LS-EPC valve Repair or
• 0 MPa replace
NO
{0 kg/cm²}
20-712 PC228US-3
1
12
H-7 Boom is slow or lacks power
★ When travel and swing speeds are normal.

★ Carry out troubleshooting in A mode.
YES
Is relief pressure
YES of front and rear
pumps normal
when boom
RAISE circuit is
relieved?
5
Is boom pressure
compensation
YES valve normal, or NO
does pressure
compensation
piston move
4 smoothly?
• It is also possible
to interchange
YES Does boom con- with another
trol valve spool compensation
3 move smoothly? valve.
• See Note 2.
YES Is boom RAISE

EPC solenoid
2 normal? NO
YES Is output pres- • Current: 950±30

sure of PPC mA.
1 valve normal? • Check with mon- NO
itoring code [18].
Is boom • 2.7 MPa

RAISE, LOWER {28 kg/cm²}
pressure • Engine at high NO
switch normal? idling.
• Operate boom.
• See judge-
ment table.
(Bit pattern NO
203, 4)
• See Note 1.
NO
Note 1: If auto-deceleration is canceled when boom RAISE or boom LOWER is operated, the condition is
normal.
Note 2: After inspection, do not forget to return the interchanged valves to their original position.
20-714 PC228US-3
1
Cause Remedy
8 YES Defective operation of Correct or

High boom lock valve replace
Is actuating pres-
YES sure normal
when boom
7 RAISE is being
operated?
Defective boom cylinder Correct or
• 14.7 ± 1.5 MPa
Low piston packing replace
Does LS shuttle NO
valve move {150 ± 15 kg/cm²}
smoothly? • Engine at high
idling.
• At max. reach, no
• Check R.H. travel load
Defective operation of LS
and LS shuttle for Correct or
shuttle valve (R.H. travel
bucket. NO replace
or LS shuttle for bucket)
9 YES Defective operation of

pump merge/divider Correct or
valve or LS pump merge/ replace
Is output pressure divider valve
Front pump is of pump merge/
low divider solenoid
valve normal?
pump merge/divider sole- Correct or
• Boom raised: NO replace
noid valve
0 MPa {0 kg/cm²}
10 YES Defective boom lock valve
High or boom suction valve of
Correct or
control valve
Is actuating pres- replace
Both front and sure normal
rear pumps are when boom
low LOWER is being
operated?
• 4.9 ± 2.9 MPa
Low boom regeneration valve Replace
NO
{50 ± 30 kg/cm²}
• Engine at high
idling. Defective boom pressure
compensation valve or
defective operation of Correct or
pressure compensation replace
piston (for boom RAISE
end, check boom Hi also)
control valve spool (for Correct or
boom RAISE end, check replace
boom Hi spool also)
Defective boom RAISE Correct or

EPC valve replace
Defective PPC valve Replace
Defective boom RAISE or

LOWER pressure switch Replace
PC228US-3 20-715
1
H-8 Arm is slow or lacks power

YES
6
YES Does LS shuttle

valve move
smoothly?
• Check LS shut-
tle for L.H.
5 travel, boom, NO
R.H. travel and
Is relief pressure bucket
YES of front and rear
pumps normal
when arm cir- Rear is low
4 cuit is relieved?
Is pressure com- • 33.3-36.8 MPa
pensation valve for {340-375 kg/cm²}
YES arm normal, or • Engine at high
does pressure com- idling
pensation piston
3 move smoothly?
Both front and
• It is also possible rear are low
Does control to interchange
YES valve spool for with other com-
arm move pensation
smoothly? valves.
2 • See Note 2. NO
YES Is output pres-

sure of PPC
valve normal?
1 NO
• 2.7 MPa
Is boom {28 kg/cm²}
RAISE, LOWER • Engine at high
pressure idling. NO
switch normal? • Operate arm.
• See judge-
ment Table.
(Bit pattern NO
205, 6)
• See Table 1.
Note 1: If auto-deceleration is canceled when arm IN or arm OUT is operated, the system is normal.
20-716 PC228US-3
1
Cause Remedy
7 YES Defective operation of Correct or

arm regeneration valve replace
Is leakage from
arm cylinder nor-
mal?
Defective arm cylinder Correct or
• Max. 20 cc/min NO piston packing replace
shuttle valve (LS shuttle Correct or
for L.H. travel, boom, R.H. replace
travel or bucket)
pump merge/divider Correct or
Is pump merge/ valve or LS pump merge/ replace
divider valve
divider solenoid
valve output pres-
sure normal?
Defective operation of Correct or
pump merge/divider sole- replace
• 0 MPa {0 kg/cm²} NO noid valve
• Arm lever operated
arm safety-suction valve Replace
arm pressure compensa- Correct or
tion valve or pressure replace
compensation piston (for
arm Lo and arm Hi)

control valve spool replace
Defective arm IN or arm

OUT pressure switch Replace
PC228US-3 20-717
1
H-9 Bucket is slow or lacks power
Cause Remedy
3 YES
Go to A
Does control
YES valve spool for
2 bucket move
smoothly?
YES Is output pressure NO control valve spool for
of PPC valve nor- bucket replace
1 mal?
Is pressure
switch for • Min. 2.7 MPa
bucket CURL, {28 kg/cm²} Defective PPC valve Replace
DUMP nor- • Engine at high NO
mal? idling
• Operate bucket.
• See judge-
ment Table. Defective bucket CURL
(Bit pattern NO or bucket DUMP pres- Replace
211, 2) sure switch
• See Note 1.
5 YES
Defective operation of Repair or
safety-suction valve for replace
YES Is leakage from
bucket
bucket cylinder
4 normal?
Is pressure compen- Defective bucket cylin- Repair or
sation valve for
bucket normal, or
• Max. 20 cc/min NO der piston packing replace
does pressure com- • Engine at high
pensation piston idling
move smoothly?
• It is also possible pressure compensation Repair or
to interchange valve for bucket or pres-
with other com- NO sure compensation pis- replace
pensation valves. ton
• See Note 2.
Note 1: If the auto-deceleration is canceled when bucket CURL or bucket DUMP is operated, the system is
normal.
Note 2: After inspection, do not forget to return the interchanged valves to the original position.
20-718 PC228US-3
1
H-10, H-11
H-10 Work equipment (boom, arm, bucket) does not move (but travel and
swing are normal)
★ When boom, arm, and bucket are each operated independently

Cause Remedy
2 YES Defective control valve Correct or

spool replace
1 YES Is boom RAISE
EPC solenoid nor-
mal?
Is output pres-
sure of PPC Defective RAISE EPC valve Replace
valve normal? • Current: 950±30 NO
mA
• Check with moni-
• Min. 2.7 MPa toring code [18].
{28 kg/cm²} Defective PPC valve Replace
• Engine at high NO
idling
H-11 Excessive hydraulic drift

1. Excessive hydraulic drift of boom
Cause Remedy
1 YES Defective hydraulic cylinder Correct or

piston packing replace
Does hydraulic
drift become
faster when
lever is oper- 2 YES Defective operation of
ated? safety-suction valve
Does condition Replace
• See TESTING AND become normal
ADJUSTING.} when safety-suc-
• It is also possible NO tion valve is inter-
to measure leak- changed?
age from cylinder. Defective operation of
• Max. 20 cc/min. boom lock valve Replace
NO
• At relief.
• Engine at high
idling.
2. Excessive hydraulic drift of arm or bucket

Cause Remedy
1 YES Defective hydraulic cylinder Correct or

piston packing replace
Does hydraulic
drift become YES Defective operation of
faster when safety-suction valve
lever is oper- 2
ated?
Does condition Replace
• See TESTING AND become normal 3 YES Defective control valve
ADJUSTING.} when safety-suc- Is slipper seal of
• It is also possible NO tion valve is inter- spool
pressure compensa-
to measure leak- changed? tion valve free of
age from cylinder.
• Max. 20 cc/min.
damage? And does Replace
NO pressure compensa- Damaged slipper seal of
• At relief.
tion piston move pressure compensation
• Engine at high
smoothly? valve, or defective opera-
idling.
• It is also possible NO tion of pressure compensa-
to interchange
with another tion piston
compensation
valve.
• See Note 1.
PC228US-3 20-719
1
TESTING AND ADJUSTING H-12, H-13, H-14
H-12, H-13, H-14
H-12 Excessive time lag (engine at low idling)

Cause Remedy
Boom, arm Defective safety-suction Correct or

valve, or defective regener- replace
YES ation valve
2
Is pressure com- Defective safety-suction
pensation valve Bucket valve Replace
YES normal, or does
1 pressure com-
pensation piston
move smoothly?
Is output pres- Defective operation of pres- Replace
sure of LS-EPC • It is also possible sure compensation valve or
solenoid valve to interchange pressure compensation pis-
with other com- NO
normal? ton
pensation valves.
• See Note 2.
• 0 MPa
{0 kg/cm²}
• Engine at high Defective operation of LS-
idling. NO EPC solenoid valve
H-13 Other equipment moves when single circuit is relieved

Cause Remedy
pressure compensation
valve slipper seal (Then Replace
slipper seal in the pres-
sure compensation
valve of the circuit that
moved is defective.
H-14 Lack of power when pressure rises

• If condition is normal except when pressure rises
Cause Remedy
2 YES
Defective main relief valve Replace
Is output pressure
1 YES of 2-stage relief
solenoid valve
normal?
Is pressure Defective operation of 2- Correct or
switch normal? • Min. 2.7 MPa {28 NO stage relief solenoid valve replace
kg/cm²}
• Swing lock switch
• Operate each ON
control lever, • L.H. knob switch Replace
When ON
Defective pressure switch
auto-deceleration is canceled, condition is
normal (note: if shuttle valve with PPC valve
is normal)
20-720 PC228US-3
1
TESTING AND ADJUSTING H-15, H-16, H-17
12
H-15, H-16, H-17
H-15 In compound operations, work equipment with larger load is slow
Cause Remedy
Defective operation of pressure Replace (replace pressure compensation

compensation valve valve on the side where load is lower
Combination of compound operation Side where load is larger
1 Boom RAISE + arm IN Boom RAISE
2 Boom RAISE + arm OUT Arm OUT

3 Boom RAISE + bucket CURL Boom RAISE
4 Arm OUT + bucket CURL Arm OUT
5 Boom LOWER + arm OUT Arm OUT
H-16 In swing + boom RAISE, boom RAISE is slow

★ If swing and boom RAISE work normally when operated independently.
Cause Remedy
swing stroke limit sole- Correct or
noid replace

LS select valve replace
H-17 In swing + travel, travel speed drops excessively

★ If swing and boom RAISE work normally when operated independently.
Cause Remedy
LS shuttle valve (LS Correct or
shuttle for L.H. travel or replace
swing)
PC228US-3 20-721
1
H-18 Travel deviation

★ When swing and work equipment speeds are normal.
A. When there is deviation in normal travel
Cause Remedy
4 YES
Go to A
Does travel junc-
YES tion spool of con-
3 trol valve move
smoothly?
YES Is output pressure NO travel junction spool replace
of travel junction
solenoid normal?
2
• Output pressure:
0 MPa {0 kg/cm²}
Defective travel junction Replace
YES Is speed of travel NO solenoid
under no load
normal?
1
Is PPC valve "See STANDARD Adjust or
output pres- VALUE TABLE. Defective LS valve replace
sure and differ- NO
ence between
left and right
normal?
• Min. 2.7 MPa 5 YES
{28 kg/cm²}
Defective travel motor Correct or
• Difference in
assembly replace
pressure Does control
between left valve spool move
and right: NO smoothly?
Within 0.4 MPa
{4 kg/cm²}
• Engine at high NO control valve spool replace
idling
6 YES
Is output pressure
From A of self pressure
reducing valve
normal?
Defective self pressure Replace
• 2.84 - 3.43 MPa NO reducing valve
{29 - 35 kg/cm²}
• Engine at high
idling
20-722 PC228US-3
1
12
H-19 Travel speed is slow

★ Check that the spool of the travel PPC valve is moving the full stroke before carrying out troubleshoot-
ing.
★ When the swing and work equipment speeds are normal.
Cause Remedy
3 YES Defective operation of LS Correct or

shuttle valve (for bucket) replace
Is output pressure
YES of LS-EPC sole-
2 noid valve nor-
mal?
Slow in both Is pressure switch • 0 MPa {0 kg/cm²} NO LS-EPC solenoid valve replace
FORWARD and • Engine at high
REVERSE normal?
idling
Defective travel pres- Replace

NO sure switch
1
Is speed slow in
both FORWARD 5 YES
and REVERSE, or To A
is it slow in one
direction only? YES Does travel spool
of control valve
move smoothly?
4 Defective operation of Correct or
Is differential pres- NO control valve travel spool replace
sure of left and right
Slow in one direc- PPC output pres-
tion only sure normal, and
output pressure nor-
mal? 6 YES
• Difference in out-
put pressure Is output pressure
between FOR- of self-reducing
WARD and NO pressure valve
REVERSE: Within normal?
0.4 MPa {4kg/cm²} Defective self-reducing Replace
• Output pressure: • It is also possible NO pressure valve
Min. 2.7 MPa to interchange
{28kg/cm²} with other com-
• Engine at high pensation valves
idling • See Note 2
• Travel relief
8 YES
Does condition travel suction valve of
control valve replace
YES become normal
when travel suction
7 valve of control
Is pressure compen- valve is replaced?
Defective travel motor Correct or
sation valve nor- • 2.84-3.43 MPa assembly replace
mal, or does NO
From A pressure compensa- {29-35 kg/cm²}
tion piston move • Engine at high
smoothly? idling Defective pressure com-
• See Note 1 pensation valve, or
defective operation of Correct or
NO replace
pressure compensation
piston
Note 1: Measure the travel speed when operated under no load or the specified time for 20 m. (See Stan-
dard Value Table for Engine related parts.)
• Measurement of travel motor speed when rotated under no load ➪ Remove the connector of the
LS-EPC solenoid, then measure the travel speed in Hi and Lo.
Note 2: After inspection, do not forget to return the interchanged valves to the original position.
PC228US-3 20-723
1
12
H-20 Steering is difficult to turn or lacks power

YES
5
Is it difficult to
turn to both left
YES and right, or is it
difficult to turn in
one direction
only?
Does travel junc-

YES tion spool of NO
control valve
move smoothly?
Is output pres-
YES sure of travel
junction sole-
noid normal?
2
• When travel
steering pres-
YES Is travel steering sure switch is NO
pressure switch
normal? ON.
1 • 2.7 MPa {28 kg/
cm²}
• Check with mon- • Engine at high NO
Is travel oil itoring code [20- idling
pressure 2].
switch normal?
NO
NO
20-724 PC228US-3
1
12
Cause Remedy
Mistaken connection
Pressure on side that is of LS pilot hoses (F Connect
not relieved is high and R sides connected correctly
in reverse)
Mistaken connection
6 7 YES of LS pilot hoses (F Correct or
When circuit is and R sides connected replace
Is output pressure in reverse)
relieved on one of pump merge/
Difficult to turn to
side, how is relief F and R both high
both left and right
pressure of F and divider solenoid
valve normal? Defective operation of
R pump? Correct or
pump merge/divider replace
NO solenoid valve
Only side that is relieved Defective operation of Correct or

is high (oil pressure nor- travel pressure com- replace
mal) pensation valve
F and R both high

Defective operation LS Correct or
circuit check valve replace
8
When circuit is Defective operation of
relieved on one control main circuit Correct or
Difficult to turn in Neither F nor R rise to
side, how is relief
one direction only
pressure of F and
relief pressure check valve (stays replace
open)
R pump?
9 YES
Go to A
During power
When steering is oper- max., is work
ated, drive side is low
(opposite side is normal) equipment relief
pressure normal?
• Min. 36.3 - 39.2 MPa
Go to B
NO
{370 - 400 kg/cm²}
Defective travel junc- Correct or
tion spool replace
Defective travel junc- Replace

tion solenoid
Defective travel steer-

ing pressure switch Replace
Defective travel pres- Replace

sure switch
YES Defective control valve

suction valve Replace
10
Does condition
become normal
when suction 11 YES Defective travel motor Correct or
From A check valve
valve of control Does condition replace
valve is inter- become normal
changed? when suction
• Interchange left NO valve of motor is
and right spools.
interchanged? Defective travel motor Replace
NO safety valve
See troubleshooting
When steering does
not turn to left or right for "Lacks power when —
YES pressure rises" (H-14)
From B
Does bucket LS
When steering does
not turn to left only shuttle valve
move smoothly?
NO LS shuttle valve for Correct or
replace
bucket
PC228US-3 20-725
1
H-21, H-22
H-21 Travel speed does not switch or is faster than specified speed
Cause Remedy

travel speed selector Replace
Is output pressure servo piston
YES of travel speed
3 solenoid valve
normal? Defective operation of
travel speed solenoid Repair or
YES Is output pressure • Min. 2.7 MPa NO valve replace
of LS control EPC {28 kg/cm²}
valve normal? • Travel speed
2 switch: Mi, Hi
• Travel lever oper-
• See Table 1. ated Defective operation of LS Repair or
• Check monitoring
YES Is pump pressure NO control EPC valve replace
code [15]
sensor normal?
1
Defective pump pressure
Is travel oil sensor Replace
NO
pressure switch
normal?
• See JUDGE-
Defective travel oil pres-
MENT TABLE
sure Replace
(Bit pattern 20 NO
2).
• Note:
If auto-decel-
eration is can-
celed when
travel is oper-
ated, system is
normal?
Table 1 Output current of LS-EPC solenoid

Lo Hi
683 ± 100mA 0mA

• Travel lever fine control position (auto-deceleration canceled)
• Check current value with monitoring code [15]
H-22 Travel does not move (one side only)

Cause Remedy
YES Repair or
Defective final drive replace
1
Is any dirt found 3 YES Defective operation of suc- Replace

in final drive
drain? YES Does condition tion valve of control valve
become normal
2 when left and right
suction valves of
control valve are Defective counterbalance
Is drain amount interchanged?
of travel motor valve, or defective opera- Replace
NO normal? NO tion of travel motor safety
valve
• Max: 30l/min
• Engine ar high idling
• Operate swing lever Defective travel motor Replace
(or operate work NO
equipment lever).
20-726 PC228US-3
1
H-23 Does not swing

A. Does not swing to either left or right
Cause Remedy
3 YES Repair or
Defective swing machinery replace
Is any foreign
YES material found in
2 oil drained from
swing machinery?
Is output pressure Defective swing holding Repair or
YES of swing holding NO brake or swing motor replace
brake release
1 solenoid valve
normal?
Is swing pres- • Min. 2.7 MPa Defective operation of hold- Correct or
sure switch nor- {28 kg/cm²}
mal? NO ing brake solenoid valve replace
• Operate swing
lever (or operate
work equipment
• See JUDGE-
MENT TABLE (Bit lever).
pattern 20 1). Defective swing pressure
• If auto-decelera- Replace
NO switch
tion is canceled
when travel is
operated, system
is normal?
B. Does not swing in one direction only
Cause Remedy
2 YES
Defective swing motor Replace
safety valve or suction
Does control valve
1 YES valve spool for
swing move
smoothly?
Is PPC valve Defective operation of con- Correct or
output pres- trol valve spool for swing replace
sure normal? NO
• Min. 2.7 MPa

• Operate swing NO
lever (or oper-
ate work equip-
ment lever).
PC228US-3 20-727
1
12
H-24 Swing acceleration is poor or swing speed is slow

★ When individual operation of the work equipment is normal.
A. Swing acceleration is poor
Cause Remedy
2 YES Defective swing motor

assembly Replace
Both left and Does LS shuttle

right valve move
smoothly?
shuttle valve (all LS shut- Correct
replace
or
NO tles)
1
Is swing accel-
eration poor in 4 YES
both direc- To A
tions or in one
direction only? YES Does control
valve swing spool
3 move smoothly? Defective operation of Correct or
control valve swing
spool replace
One direction Is PPC valve out- NO
only put pressure nor-
mal?
• Min. 2.7 MPa

• Engine at high NO
idling
• Operate swing
5 YES Defective swing motor Correct or

safety valve or suction
Is pressure compen- valve replace
sation valve nor-
From A mal, or does
pressure compensa-
tion piston move Defective pressure com-
smoothly? pensation valve, or Correct or
• It is also possible NO defective operation of replace
to interchange compensation piston
with other com-
pensation valves
• See Note 1
Note 1: After checking, always return the interchanged valves to their original positions.
20-728 PC228US-3
1
12
H-25 Excessive overrun when stopping swing

A. One direction only
Cause Remedy
3 YES Defective swing PPC Correct or

Is problem slow return valve replace
reversed when
YES left and right
2 swing PPC slow
return valves are
Is problem interchanged?
reversed when Defective PPC valve Replace
YES left and right NO
1 hoses of PPC
valve are inter-
changed?
Does control
valve spool for Defective swing motor Replace
swing move NO safety valve
smoothly?
control valve spool for Correct or
NO swing replace
B. Both directions
Cause Remedy
Defective swing motor Repair or replace
H-26, H-27
H-26 Excessive shock when stopping swing (one direction only)

Cause Remedy
1 YES Defective swing PPC valve Correct or

slow return valve (check replace
Does condition valve)
become nor-
mal when left
and right swing
PPC slow return
valves are inter-
changed?
NO
PC228US-3 20-729
1
H-27 Excessive abnormal noise when stopping swing
Cause Remedy
YES Defective operation of

swing motor safety or suc- Clean
1 tion valve
Does condition
become normal
when swing YES Defective swing motor
motor safety or safety or suction valve Replace
2
suction valve is
cleaned? Does condition
become normal
when swing
NO motor safety or 3 YES Repair or
suction valve is Defective swing machinery replace
replaced?
Is foreign mate-
rial found in swing
NO machinery?
Defective back pressure Correct or

NO valve replace
20-730 PC228US-3
1
12
H-28 Excessive hydraulic drift of swing

A. When swing holding brake is released
Cause Remedy
2 YES Defective swing motor Correct or

Is pressure compen- safety or suction valve replace
sation valve on defec-
tive side normal, or
One direction only does pressure com-
1 Defective pressure com-
pensation piston
move smoothly? pensation valve for swing, Correct or
Is hydraulic drift or defective operation of
excessive in both NO pressure compensation pis- replace
directions or one ton
direction only?
YES Defective control valve
spool for swing Replace
Both left and right Is drain amount

from motor normal?
Repair or
Defective swing motor replace
NO
B. When swing holding brake is applied
Cause Remedy
1 YES
Defective operation of Repair or
swing holding brake replace
Is output pres-
sure of swing
holding brake
solenoid valve
normal?
swing holding brake sole- Correct
replace
or
• 0.2 ± 0.2 MPa NO noid valve
{2 ± 2 kg/cm²}
• When 4-5 sec-
onds have
passed after all
swing and work
equipment con-
trol levers have
been returned
to neutral.
PC228US-3 20-731
1
12 TROUBLESHOOTING OF
MONITOR PANEL SYSTEM
(M MODE)
★ This troubleshooting is carried out when there is still an abnormality, so when disconnecting the con-
nector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its
original position, if the monitor code display does not indecate E, the problem has been removed.
an E service code is displayed. If it is not displayed, the system has been reset.
★ Before carrying our troubleshooting, check that all the related connectors are properly inserted.
ACTION TAKEN BY MONITOR PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-801
M-MODE ELECTRICAL CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-803
M-1 [E101] ABNORMALITY IN ERROR DATA IS DISPLAYED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-805
M-2 [E104] AIR CLEANER CLOGGING DETECTED IS DISPLAYED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-806
M-3 [E108] ENGINE WATER TEMPERATURE 105° DETECTED IS DISPLAYED . . . . . . . . . . . . . . . . . . . . 20-806
M-4 [E114] SHORT CIRCUIT IN WIPER NORMAL ROTATION OUTPUT IS DISPLAYED . . . . . . . . . . . . . 20-806
M-5 [E115] SHORT CIRCUIT IN WIPER REVERSE ROTATION OUTPUT IS DISPLAYED. . . . . . . . . . . . . 20-806
M-6 [E116] CONTACT OF WASHER OUTPUT 24V IS DISPLAYED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-806
M-7 [E117] WIPE FAILURE CONTINUES FOR 10 SECONDS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-806
M-8 [E118] STOW FAILURE CONTINUES FOR 10 SECONDS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-807
M-9 WHEN STARTING SWITCH IS TURNED ON, NONE OF THE LAMPS ON THE MONITOR PANEL
LIGHT UP FOR 3 SECONDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-807
M-10 WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL LAMPS ALL STAY UP AND DO
NOT GO OUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-809
M-11 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), BASIC CHECK ITEM
FLASHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-809
M-12 PREHEATING IS NOT BEING USED BUT (PREHEATING MONITOR) LIGHTS UP . . . . . . . . . . . . . 20-810
M-13 WHEN STARTING SWITCH IS ON AND ENGINE IS STARTED, BASIC CHECK ITEMS FLASH . . 20-811
M-14 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), EMERGENCY ITEMS FLASH
(BATTERY, ENGINE OIL PRESSURE LAMPS DO NOT LIGHT UP) . . . . . . . . . . . . . . . . . . . . . . . . . . 20-813
M-15 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, CAUTION ITEMS,
EMERGENCY ITEMS FLASH (WHEN THERE IS NO ABNORMALITY IN ENGINE OR ITEMS
TO CHECK BEFORE TROUBLESHOOTING) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-815
M-16 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), BUZZER DOES NOT SOUND
FOR 1 SECOND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-818
M-17 NIGHT LIGHTING ON MONITOR PANEL DOES NOT LIGHT UP (LIQUID CRYSTAL DISPLAY IS
NORMAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-819
M-18 COOLANT TEMPERATURE GAUGE DOES NOT RISE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-820
M-19 COOLANT TEMPERATURE GAUGE DOES NOT GIVE ANY DISPLAY (NONE OF GAUGE
LAMPS LIGHT UP DURING OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-820
M-20 FUEL LEVEL GAUGE ALWAYS DISPLAYS FULL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-821
M-21 FUEL LEVEL GAUGE DOES NOT GIVE DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-821
M-22 SWING LOCK SWITCH IS TURNED ON (LOCK) BUT (SWING LOCK MONITOR) DOES NOT
LIGHT UP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-822
M-23 SERVICE METER DOES NOT ADVANCE WHEN ENGINE IS RUNNING . . . . . . . . . . . . . . . . . . . . . 20-822
M-24 DEFECTIVE FUEL LEVEL SENSOR SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-823
M-25 DEFECTIVE COOLANT TEMPERATURE SENSOR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-824
M-26 DEFECTIVE ENGINE OIL LEVEL SENSOR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-825
M-27 WIPER DOES NOT WORK OR SWITCH IS NOT BEING USED BUT WIPER IS ACTUATED. . . . . . 20-826
M-28 WASHER MOTOR DOES NOT WORK, OR WASHER SWITCH IS NOT BEING USED BUT
WASHER MOTOR IS ACTUATED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-829
PC228US-3 20-801
1
TESTING AND ADJUSTING ACTION TAKEN BY MONITOR PANEL
12
ACTION TAKEN BY MONITOR PANEL WHEN ABNORMALITY

OCCURS AND PROBLEMS ON MACHINE
User Service
Abnormal System Nature of Abnormality
Code code
1. Abnormality in internal memory
2. Excess voltage (more than 36V) has occurred
— E101 Abnormality in error data
3. Low voltage (less than 12V) has occurred
4. Connector has separated
Air cleaner clogging

— E104 1. Air cleaner clogging sensor has detected clogging
detected is displayed
Engine water temperature

1. Coolant temperature gauge has detected water
— E108 105°C detected is
temperature of 105°C
displayed
1. Short circuit or short circuit with ground inside wiper

motor
Short circuit in wiper 2. Short circuit or short circuit with ground in wiring harness
— E112 motor drive normal between monitor panel P01 (female) " and relay box W08
rotation system 3, or between monitor panel P01 (female) " and wiper
motor W04 (female) 1
3. Defective monitor panel
1. Short circuit or short circuit with ground inside wiper
motor
Short circuit in wiper 2. Short circuit or short circuit with ground in wiring harness
— E113 motor drive reverse between monitor panel P01 (female) " and relay box
system W083, or between monitor panel P01 (female) " and
wiper motor W04 (female)1
1. Short circuit inside washer motor

Short circuit in window 2. Short circuit with power supply between monitor panel
— E114
washer drive system P01 (female)3 and A50 (female)2
1. Defective wiper motor

2. Defective contact, disconnection, short circuit, short circuit
with chassis ground in wiring harness between monitor
— E115 Wiper failure continues for panel P01 (female) 5 and W04 6
10 seconds 3. Defective contact, disconnection, short circuit with chassis
ground in wiring harness between monitor panel P01
(female) and W04 4Defective monitor panel
1. Defective wiper motor

2. Defective contact, disconnection, short circuit, with chassis
ground in wiring harness between monitor panel P01
Stow failure continues for (female) 5 and W04 6
— E116
10 seconds 3. Defective contact, disconnection, short circuit, short circuit
with chassis ground in wiring harness between monitor
panel P01 (female) and W04 4
20-802 PC228US-3
1
TESTING AND ADJUSTING ACTION TAKEN BY MONITOR PANEL
Condition when normal Action by controller when Problem that appears on machine
(voltage, current, resistance) abnormality is detected when there is abnormality
— 1. Service code cannot be cleared.
1. If abnormality detection contin-

• Resistance between A31 (male) 1 and 2:
— ues, air cleaner clogging caution
Max. 1 Ω (engine running) lamp flashes and buzzer sounds.
1. If abnormality detection contin-

ues, coolant temperature caution
• Resistance between E51 (male) 1 and 2: lamp flashes and buzzer sounds.
—
Max. 3.7 Ω (engine running) 2. If abnormality continues to be
detected, engine speed changes
to low idling.
• Voltage between W04 3 and 5:

1. Stops output to wiper
Max. 3V ↔ 20 - 30 V 1. Stops actuation of wiper motor.
motor.
• Repeats in a constant cycle.
• Voltage between W04 3and 5:

Max. 3V ↔ 20 - 30 V Same as [E112] Same as [E112]
• Repeats in a constant cycle.
• Voltage between P013 and chassis

1. Stops output to washer 1. Stops actuation of window
• When washer switch is OFF: 20 - 30 V
motor. washer motor.
• When washer switch is ON: Max. 1 V
• Timing chart for wiper switch [ON] and

Same as [E112] Same as [E112]
[INT] is as in Tables 1 and 2 of M-27.
• Timing chart for wiper switch [ON] and

Same as [E112] Same as [E112]
[INT] is as in Tables 1 and 2 of M-27.
PC228US-3 20-803
1
TESTING AND ADJUSTING M-MODE ELECTRICAL CIRCUIT DIAGRAM
M-MODE ELECTRICAL CIRCUIT DIAGRAM
20-804 PC228US-3
1
TESTING AND ADJUSTING M-MODE ELECTRICAL CIRCUIT DIAGRAM
PC228US-3 20-805
1
TESTING AND ADJUSTING M-1
M-1 [E101] (Abnormality in error data history) is displayed

★ This is not an abnormality. It occurs during troubleshooting when disconnecting and connecting con-
nector P01 (for the monitor panel power supply system), connector H10, fuse 17, connector A02, con-
nector A01, connector A35, battery relay terminal B, or the battery terminal.
(When the starting switch is turned OFF, the monitor panel power supply circuit is shut off.)
★ If a service code appears again after action is taken to restore the system, carry out troubleshooting as
follows.
Cause Remedy
2 YES
YES
Is voltage between
1 P01 8 and chassis
Disconnection, defec-
Does service code normal? tive contact, short cir- Repair or
display appear again NO
cuit with ground in replace
• Turn starting switch wiring harness between
after system has OFF. battery- battery relay B-
been reset? • 20 - 30 V
A3512-P01 (female) 8
• After resetting sys- Normal —
tem, carry out nor- NO
mal operations for a
short time and watch
the condition. (See
Note 1.
Note 1: Resetting operation:

Turn the starting switch OFF. Then keep the buzzer cancel switch depressed, switch the starting
switch ON again, and keep for 5 seconds to return the system to normal.
(When this operation, all the service codes in the internal memory are erased.)
M-1 Related electrical circuit diagram
20-806 PC228US-3
1
TESTING AND ADJUSTING M-2, M-3, M-4, M-5, M-6, M-7, M-8
M-2, M-3, M-4, M-5, M-6, M-7, M-8
M-2 [E104] (Air cleaner clogging detected) is displayed
Cause Remedy
1 YES
See M-15-(e) —
Is air cleaner
clogging caution 2 YES
lamp on monitor Is "E" displayed Defective monitor panel Replace
flashing? on the top of the
NO service code? Failure in engine sys- —
NO tem (See Note 1)
• Turn starting
switch ON.
M-3 [E108] (Engine water temperature 105° detected) is not displayed
Cause Remedy
1 YES —
See M-15-(c)
Does coolant tem-
perature gauge on
monitor panel dis-
play red range and is 2 YES
caution lamp flash- Defective monitor panel Replace
ing Is "E" displayed
on the top of the
NO service code? Failure in engine sys- —
• Turn starting switch NO tem (See Note 1)
ON.
M-4 [E114] (Short circuit in wiper motor normal rotation output) is displayed
★ See M-28.
M-5 [E115] (Short circuit in wiper motor reverse rotation output) is displayed
★ See M-28.
M-6 [E116] (Short circuit with power supply in washer output) is displayed
★ See M-29.
M-7 [E117] (Wiping failure continues for 10 seconds) is displayed

★ See M-28.
M-8 [E118] (Storing wiper blade failure continues for 10 seconds) is displayed
★ See M-28.
PC228US-3 20-807
1
M-9 When starting switch is turned ON, none of the lamps on the monitor
panel light up for 3 seconds
★ Check that fuses No. 12 and 17 are not blown.
A. None of the lamps on the monitor panel light up
Cause Remedy
YES
2
Is voltage
YES between P0167 Disconnection, defective
YES contact, short circuit with Repair or
and chassis nor- 3 ground in wiring harness replace
mal? Is voltage between P01 (female) 7
between fuse and fuse No. 12
• Turn starting
1 NO No. 12 and chas-
switch ON.
Is voltage • 20 - 30 V sis normal? Disconnection, defective
between P018 • Turn starting contact, short circuit with
Repair or
NO ground in wiring harness
and 67 nor- switch ON.
between fuse No. 12 and replace
mal? • 20 - 30 V battery relay M
• Turn starting
switch ON. Disconnection, defective
• 20 - 30 V YES Repair or
4 contact, short circuit with
ground in wiring harness replace
Is voltage
between fuse No. between P02 (female) 7
and fuse No. 13
NO 17 and chassis
normal?
Disconnection, defective
• Turn starting contact, short circuit with
NO Repair or
switch ON. ground in wiring harness replace
• 20 - 30 V between fuse No. 17 and
battery relay B
B. Some of the lamps on the monitor panel do not light up
Cause Remedy
20-808 PC228US-3
1
M-9 a) Related electrical circuit diagram
M-10 When starting switch is turned ON, monitor panel lamps all stay
lighted up and do not go out
Cause Remedy
M-11 When starting switch is turned ON (engine stopped), basic check

item flashes
(engine oil level) flashes
★ Check that the engine oil level is at the specified level before carrying out troubleshooting.
PC228US-3 20-809
1
★ Check bit 4 of monitoring code [46]. If it is lighted up, the monitor panel is defective.
Cause Remedy
YES
1 Defective engine oil
Does display go out level sensor system —
when E03 (female) 2 (see M-27)
1is connected to Is continuity between
chassis ground? P02 (female) 8 and YES Defective monitor Replace
chassis as shown in the panel
• Disconnect E03. table?
• Turn starting NO Defective contact or
switch ON.
• Turn starting switch disconnection in
OFF. NO wiring harness
• Disconnect P02 and Repair or
E03. between P02 replace
• Connect ↔disconnect (female)8and E03
E03 (female) 1 to chas-
sis ground. (female)1
Connection with Continuity

chassis ground
Connected Yes
Disconnected No
20-810 PC228US-3
1
M-12 Preheating is not being used but (preheating monitor) lights up
Cause Remedy
2 YES
YES
Is voltage
1
between P02
and chassis normal? Short circuit with power
Is voltage between source in wiring harness Repair or
starting switch ter- • Turn starting switch NO between starting switch replace
minal R1 and chas- OFF. R1 and P02 (female) 8
sis normal? • 20 - 30 V or J02 8 and A07 (male)
5
• Disconnect terminal
R1.
• Turn starting switch Defective starting switch Replace
ON. NO
• Max. 1 V
PC228US-3 20-811
1
M-13 When starting switch is ON and engine is started, basic check item
flashes
A. Alternator system
★ Check monitoring code [43]. If 100 or more is displayed with the engine at a mid-range speed or
above, the monitor panel is defective.
Cause Remedy
2 YES Defective monitor Replace

panel
Is voltage between
YES P02 (female) and
chassis ground nor- Defective contact or Repair or
1
disconnection in wiring replace
mal?
Is voltage between harness between alter-
• Run engine at mid-range NO
alternator terminal R nator R and P02
speed or above. (female)
and chassis ground • 20 - 30 V
normal?
Defective alternator Replace
• Run engine at mid-
NO
range speed or above.
• 20 - 30 V
20-812 PC228US-3
1
B. Engine oil pressure system

★ Check that the engine oil pressure is normal before carrying out troubleshooting.
Cause Remedy
1 YES
Defective oil pressure Replace
When engine is run- sensor (low-pressure)
ning at low idling and
oil pressure sensor ter- 2 YES Short circuit with Repair or
minal E02 is removed, ground in wiring har- replace
Is there continuity ness between P02
does display go out? between P02 (female) (female) 7 and sensor
• Engine at low idling 7and chassis?
NO Replace
Defective monitor panel
• Turn starting switch NO
OFF.
• Disconnect sensor wir-
ing harness and P02.
M-13 b) Related electrical circuit diagram
PC228US-3 20-813
1
M-14 When starting switch is turned ON (engine stopped), caution items,

emergency items flash, engine oil pressure lamps do not light up
A. Alternator system
★ Check monitoring code [43]. If 100 or more is displayed with the engine at a mid-range speed or
above, the monitor panel is defective.
Cause Remedy
2 YES
Defective monitor Replace
YES
Is voltage between P02 panel
(female) and chas-
1
Short circuit with
sis ground normal? power source in wiring Repair or
Is voltage between harness between P02 replace
• Disconnect P02. NO (female) and alter-
alternator terminal R • Turn starting switch ON.
and chassis normal? nator terminal R
• Max. 1V
• Disconnect terminal R.
• Turn starting switch Defective alternator Replace
ON. NO
• Max. 1 V
20-814 PC228US-3
1
B. Engine oil pressure sensor system

Cause Remedy
2 YES
Defective monitor Replace
Is there continuity panel
YES
between P02 (female)
1 and sensor termi- Defective contact or
disconnection in wiring Repair or
nal E02? harness between P02 replace
Is there continuity
NO (female) 7 and sensor
between sensor termi- • Turn starting switch OFF.
• Disconnect P02 and sen- terminal E02
nal E02 and chassis? sor terminal E02.
• Turn starting switch Defective oil pressure Replace
OFF. sensor
• Disconnect sensor NO
terminal E02.
M-14 b) Related electrical circuit diagram
PC228US-3 20-815
1
M-15 When starting switch is turned ON and engine is started, caution

items, emergency items flash (when there is no abnormality in
engine or items to check before troubleshooting)
A. (engine oil pressure) flashes
Cause Remedy
See M-13 b) —
B. (coolant level) flashes
★ Check that the coolant level is normal before carrying out troubleshooting.
Cause Remedy
See M-9 a) —
C. (battery charge) flashes
Cause Remedy
See M-13 a) —
20-816 PC228US-3
1
D. (coolant temperature) flashes
★ Check that the coolant temperature is normal before carrying out troubleshooting.
Cause Remedy
2 YES Defective coolant tempera- —
When E05 is discon- ture sensor system (see M-
YES 25)
nected, does only
level 1 (lower end) of
gauge display light 3 Defective contact of dis-
YES Repair or
up? Is resistance connection in wiring har- replace
1 between P02 ness between P02(female)
• Start engine (female) 1-E05
Is coolant tem- NO
(female) and E05(female)1
perature in red
range? • Turn starting Defective contact or dis-
switch OFF. NO connection in wiring har- Repair or
• Start engine and • Disconnect P02 ness between P02 replace
run at mid-range and E05. (female)1 and E05
or above
• Max. 1 MΩ (female) 2

NO
M-15 d) Related electrical circuit diagram
E. (fuel level) flashes

SAP00528
★ Check that there is fuel before carrying out troubleshooting.
Cause Remedy
2 YES Defective fuel level sensor —
When A60(female) system (See M-24)
YES 1is connected to
chassis ground, do all 3 YES
lamps to level 9 (right Defective monitor panel Replace
end) of gauge display Is voltage between
1 light up? P022 and chas-
NO
sis normal? Defective contact or dis-
Is fuel gage in • Start engine Repair or
red range? • Wait for approx. 2 NO connection in wiring har-
• Connect A60 ness between P02 (female) replace
minutes. (The fuel (female) 1to chas-
level may vary, so
2 and A60 (female) 1
• Start engine. sis ground.
the display is given • Turn starting switch
a time delay.) to ON.
• Max. 0.3 V
NO
M-15 e) Related electrical circuit diagram
PC228US-3 20-817
1
F. (air cleaner clogging) flashes
★ Check that the air cleaner is not clogged before starting troubleshooting.
Cause Remedy
YES Defective air cleaner clog- Replace
ging sensor
1 3
YES
YES Is continuity between Defective monitor panel Replace
Does display go out
when wiring har- P02 (female) 5 and
chassis as shown in Defective contact or dis- Repair or
ness between A31 connection in wiring har-
(female) 1 and 2 is Table 1? NO replace
2 ness between P02 (female)
connected (short cir- • Turn starting switch OFF. 5 and A31 (female) 1
cuited)? Is there continuity • Disconnect P02 and A31.
• Start engine. between A31 (female) • Connect ↔disconnect
NO 2 and chassis? A31 (female) 1 and 2.
Defective contact or dis- Repair or
• Turn starting switch connection in wiring har- replace
OFF. NO ness between A31 (female)
• Disconnect A31. 2 and chassis ground
M-15 f) Related electrical circuit diagram
Table 1
Between P02 A31 (female)1 and 2

A31 disconnected
(female) 5 connected (short circuited)
and chassis Continuity No continuity
20-818 PC228US-3
1
M-16 When starting switch is turned ON (engine stopped), buzzer does

not sound for 1 second
Caution item lamp flashes but buzzer does not sound
★ Of the caution items, the buzzer will not sound even if there is an abnormality in the battery charge or
fuel level.
★ The buzzer is controlled inside the monitor panel. The buzzer sounds if it is necessary, or if the voltage
at P01 is 20 - 30 V.
Cause Remedy
2 YES Defective monitor Replace

Is voltage between P02 panel
YES
and chassis nor-
1 Defective contact, dis-
mal? connection, or short cir- Repair or
Is resistance between cuit with chassis replace
P03 (female) 1and 2 • Disconnect P03. NO
ground in wiring har-
normal? • Turn starting switch ON. ness between P02
• 20 - 30 V (female) and P03
• Turn starting switch
(female) 1
OFF.
• Disconnect P03.
• Buzzer cancel switch Defective buzzer cancel Replace
NO switch sensor
ON: Max. 1Ω
Buzzer cancel switch
OFF: Min. 1Ω
PC228US-3 20-819
1
M-17 Night lighting on monitor panel does not light up (liquid crystal dis-
play is normal)
★ When the front lamp and working lamp light up normally.
Cause Remedy
1 YES
➤
Does bit 4 of 2 YES
monitoring code
[45] go out? Is voltage between
P02 and chassis
NO normal? Defective contact, or
• Turn starting disconnection in wiring Repair or
switch ON. harness between P02 replace
NO
• Set to monitoring • Turn starting switch ON.
code [45]. • Turn light switch ON. (female) and H15
• 20 - 30 V (male) 7
20-820 PC228US-3
1
TESTING AND ADJUSTING M-18, M-19
M-18, M-19
M-18 Coolant temperature gauge always displays low
★ If the coolant temperature actually does not rise, check the engine system.
Cause Remedy
YES Defective coolant tempera- —
1 ture sensor system (see M-
When short connec- 25)
tor is connected to 3 YES
E05 (female), does Defective monitor panel Replace
Is there continuity
gauge level go up 1 YES between P02
stage at a time, and
finally do all gauge (female) , Defective contact or dis-
2 Repair or
level lamps go out? and E05 (female) connection in wiring har-
Is there continuity 1? ness between P02 (female) replace
between P02 (female) NO
• Disconnect E05. , - P05 (female) 1
• Turn starting NO 1 and E05 (female) • Turn starting switch
switch ON. 2? OFF.
• Disconnect P02 and
• Turn starting switch Defective contact or dis-
E05. connection in wiring har- Repair or
OFF. replace
NO ness between P02 (female)
E05.
1 and E05 (female) 2
M-19 Coolant temperature gauge does not give any display (none of gauge
elements light up during operation)
Cause Remedy
1 YES Defective coolant temperature —

When E05 is dis- sensor system (see M-25)
connected, does YES
coolant tempera- 2 Short circuit with chassis
ture gauge display Is there continuity ground in wiring harness Repair or
appear? between P02 between P02 (female) 1 and replace
(female) 1 and E05 (female) 2
• Disconnect E05. NO chassis?
• Turn starting switch Defective monitor panel Replace
ON. • Turn starting switch NO
OFF.
E05.
M-18, M-19 Related electrical circuit diagram
PC228US-3 20-821
1
M-20, M-21
M-20 Fuel level gauge always displays full
★ Check if the tank is actually full before carrying out troubleshooting.
Cause Remedy
1
YES Defective fuel level sen- —
When A60 is discon- sor system (see M-24)
nected, does gauge
level go down 1 Short circuit with chas-
stage at a time, and 2 YES
sis ground in wiring Repair or
finally do all gauge harness between P02 Replace
level lamps go out? Is there continuity
between P02 (female)2 and A60
• Turn starting switch NO (female) 2 and (female) 1
ON. chassis?
• Wait for approx. 2 min- Defective monitor panel Replace
utes. (The fuel level OFF.
may suddenly change, • Disconnect P02 and
so the display is given A60.
a time delay.)
M-21 Fuel level gauge does not give display

★ Check that there is actually no fuel before carrying out troubleshooting.
Cause Remedy
YES
1 Defective fuel level sen- —
sor system (see M-24)
Does display
2
appear when YES
A60 (female) 1is When A60 (female) 1 Defective monitor panel Replace
connected to and chassis ground are
chassis ground? connected, is there con-
NO tinuity between P02 Defective contact, or Repair or
• Disconnect A60.
• Turn starting switch (female) 2 and chassis? disconnection in wiring replace
ON. NO harness between P02
• Turn starting switch OFF. (female) 2 and A60
• Disconnect P02 and A60. (female) 1
M-20, M-21 Related electrical circuit diagram
20-822 PC228US-3
1
M-22, M-23
M-22 Swing lock switch is turned ON (lock) but (swing lock moni-
tor) does not light up SAT00098
★ Carry out this troubleshooting only if the swing lock is actually being actuated.
Cause Remedy
1 YES
Is voltage between
P02 and chassis
as shown in table? Defective contact or dis-
connection in wiring Repair or
• Turn starting switch NO harness between P02 replace
ON. (female) and X05
(male) 1
Table
Swing lock switch ON Max. 1 V
Swing lock switch OFF 20 - 30 V
M-23 Service meter does not advance when engine is running
Cause Remedy
1 YES
Is the charging See M-15 c) —
caution lamp flash-
ing on and off?
NO
• Start the engine
and run at idle
speed.
PC228US-3 20-823
1
M-24 Defective fuel level sensor system

★ Remove the fuel level sensor when carrying out the troubleshooting.
Cause Remedy
3 YES
Interference with sen- Replace (See
YES Is there any large sor inside tank Note 2)
2
crack, chip, or
damage to float?
YES Does arm move Defective contact of Clean
smoothly? NO connector connector or
1 replace
When float is Defective sensor (See Replace
moved up and NO Note 2)
down, is resistance
between connector
1 and flange as YES
Disconnection in wiring
shown in table? 4 harness (See Note 3), Replace sensor
defective clamp, exter-
Check wiring nal force applied
harness visually,
NO Is it broken?
Defective sensor Replace
NO
Table
Top (FULL) Stopper position Approx. 12 Ω or below
Bottom (EMPTY) stopper posi-

Approx. 85 - 110 Ω
tion
Note 1: Difference between fuel level and gauge display

For gauge display position 14 (FULL), the amount of fuel is 78-100%; and for display position 1
(EMPTY) it is below 14.5%. If the chassis is at an angle, the displayed amount of fuel will be different
from the actual amount. Therefore, when checking, stop the machine at a horizontal place and wait
for at least 2 minutes before checking the gauge. (The display is given a time delay so that the
gauge can deal with sudden changes in the fuel level.)
Note 2: There is the possibility of defective installation or interference with the sensor inside the tank, so be
careful when installing.
Note 3: Check for vibration at the connector mount. If there is excessive vibration, take the appropriate
action.
20-824 PC228US-3
1
M-25 Defective coolant temperature sensor system
Cause Remedy
YES Defective contact of con- Clean

1
nector (See Note 1) connector or
Is resistance between replace sensor
temperature sensor
connector (male) 1 YES Disconnection in wiring
harness (See Note 2) Replace sensor
and 2 as shown in (defective clamp)
table? Check wiring (external force applied)
harness visually,
NO Is it broken?
NO
Table
Normal temperature (25°C) Approx. 37 - 50 kΩ
100°C Approx. 3.5 - 4.0 kΩ
Note 1: If the problem occurs again, the connector (female) at the chassis end is probably defective, so
check the connector and wiring harness at the chassis end.
action.
PC228US-3 20-825
1
M-26 Defective engine oil level sensor system

★ Remove the engine oil level sensor when carrying out troubleshooting
Cause Remedy
YES
Defective movement of Clean
float due to dirt
2
Is any foreign 3 YES
YES material (dirt) Resonance of mount Replace sensor
stuck to moving (See Note 2) (See Note 4)
Is there any large
1 part of float? crack, chip, or
When float is damage to float? Defective contact con- Clean
moved up and nector (See Note 2) connector or
down, is resistance NO NO replace
between connector
1 and flange as YES
Disconnection in wiring
shown in table? 4 harness (See Note 3) Replace sensor
(defective clamp) (exter-
Check wiring nal force applied)
harness visually,
NO Is it broken?
NO
Table
Float UP Max. 1 Ω
Float DOWN Min. 1 Ω
UP
DOWN
BLP00292
Note 1: Variation in oil level

The oil level may change according to the angle of the machine, the engine speed, or the tempera-
ture of the oil, so if there is any display, check the oil level again with the machine at a horizontal
place.
Note 2: If the problem occurs again, the connector (female) at the chassis end is probably defective, so
check the connector and wiring harness at the chassis end.
action.
Note 4: Defective installation is a possible cause, so be careful when installing. If the problem occurs again,
check for any vibration of the mount, and if there is excessive vibration, take the appropriate action.
20-826 PC228US-3
1
M-27 Wiper does not work, or switch is not being used but wiper is
actuated
A. Wiper does not work

★ Carry out this troubleshooting if service codes [E112], [E113], [E115], or [E116] are displayed.
Cause Remedy
YES
3 Defective wiper motor Replace
Is voltage
YES between each
2 pin of W04 as 4 YES
shown in Table Defective monitor panel Replace
When wiper switch 1? Is resistance
YES is turned to [ON] or between each pin
[INT], do bits 4, 5 • Turn starting of P01 (female) Defective contact, dis-
of monitoring code switch ON. NO and W04 (male) as connection, short cir- Repair or
[49] go out? shown in Table 2? cuit, or short circuit with replace
NO chassis ground in wir-
• Turn starting switch • Turn starting switch
ON. OFF. ing harness with defec-
1 tive resistance
• Wiper switch: ON • Disconnect P02 and
Does bit (3) of or INT W04.
monitoring code • Set to monitoring
[49] light up? Defective monitor panel Replace
code [49]. NO
6
YES
• Front window: Is resistance between Defective monitor panel Replace
Closed position YES rear limit switch ter-
• Front window: 5 minal W03 1 B - P02
Closed position Defective contact or dis- Repair or
• Set to monitoring Is resistance (female) , W03 2 -
chassis normal? connection in wiring replace
code [49]. between rear limit NO harness with defective
switch terminal • Max. 1 Ω resistance
NO W03 (1) and (2)
normal? • Disconnect P02 and W03.
Defective rear limit Repair or
• Max. 1Ω
switch or front window replace
is open
OFF.
• Disconnect W03.
B. Wiper switch is not being used but wiper is actuated
Cause Remedy
2
When wiper switch YES Short circuit with power
YES is turned to [ON] or source in wiring harness Repair or
[INT], do bits 4, 5 between P01 (female) 9 - replace
1 of monitoring code W04 (female0 3 or P01
[49] go out? NO (female) " - W04 (female)
Does bit 3 of
monitoring code • Turn starting switch ON. 1
• Wiper switch: ON or INT.
[49] light up?
• Set to monitoring code
[49].
➤
• Front window:
Closed position Defective monitor panel Replace
NO
• Turn starting
switch ON.
• Set to monitoring
code [49].
PC228US-3 20-827
1
Table 1
Timing chart when wiper switch is at ON
Item Symbol Set time
Length of pause until

Tla 0.13sec
next actuation
Safety circuit during

operation of wiper Tsa 10sec
[safety function (1)]
Length of pause
when stowing wiper Tlp 1.5sec
blade

stowing of wiper Tsp 10sec
Timing chart when wiper switch is at INT

Item Symbol Set time
Length of pause until

Tla 4sec
next actuation

operation of wiper Tsa 10sec
Length of pause
when stowing wiper Tlp 1.5sec
blade

stowing of wiper Tsp 10sec
Table 2
Troubleshooting No. 4 Resistance
Between P01 (female) " and W04 (female)1

Between P01 (female) 9 and W04 (female)3
Between P01 (female) and W04 (female)4 Max. 1Ω
Between P01 (female) 6,7 and W04 (female)5

Between P01 (female) 5 and W04 (female)6
Between W04 (female) 1,3,4,5,6 and GND Min. 1MΩ
20-828 PC228US-3
1
PC228US-3 20-829
1
M-28 Washer motor does not work, or washer switch is not being used
but washer motor is actuated
A. Washer motor does not work

a)-1 When [E114] is displayed
Cause Remedy
1 YES
Is voltage between
P01 (female) 3, A50
(female) 2 and Short circuit with power
chassis normal? source in wiring harness Repair or
• Max. 1 V NO between P01 (female) 3 replace
• Turn starting switch and A50 (female) 2
ON.
A50.
a)-2 When [E114] is not displayed
Cause Remedy
3
YES
YES Is voltage between
2 P01 (female)3 and
chassis normal? Defective washer motor Replace
Is resistance between NO
YES P01 (female) 3 and
• Max. 1 V
1 A50 (female) 2 nor- • Turn starting switch ON.
mal? • Turn washer switch ON. Defective contact or dis-
Is voltage between connection in wiring har- Repair or
fuse 14 and A50 • Turn starting switch ness between P01 (female) replace
NO
(female) 1 nor- OFF.
3 and A50 (female) 2
mal?
• 20 - 30 V Defective contact or dis-

• Turn starting switch connection in wiring har- Repair or
ON. ness between fuse 14 and replace
NO
• Disconnect A50. A50 (female) 1
B. Switch is not being used but washer motor is actuated
Cause Remedy
1 YES
Is resistance
between A50
(female) 2 and Short circuit with chassis
chassis normal? ground in wiring harness Repair or
NO between P01 (female) 3 replace
• Min. 1Ω
and A50 (female) 2
• Turn starting switch
OFF.
A50.
20-830 PC228US-3
1
30 DISASSEMBLY AND ASSEMBLY
12
Method of Using Manual . . . . . . . . . . . . . . . .30- 3 Installation of Track Shoe Assembly
Precautions When Carrying Out Operation .30- 5 (Road liner). . . . . . . . . . . . . . . . . . . . . . . . . . . 30-57
Special Tool List . . . . . . . . . . . . . . . . . . . . . . .30- 8 Removal of Hydraulic Tank Assembly . . . . . 30-58
Removal of Engine Assembly . . . . . . . . . . . .30-12 Installation of Hydraulic Tank Assembly . . . 30-58
Installation of Engine Assembly . . . . . . . . . .30-14 Removal of Hydraulic Pump Assembly . . . . 30-59
Removal of Engine Front Seal . . . . . . . . . . . .30-15 Installation of Hydraulic Pump Assembly . . 30-60
Installation of Engine Front Seal . . . . . . . . . .30-15 Removal of Control Valve Assembly . . . . . . 30-61
Removal of Engine Rear Seal . . . . . . . . . . . .30-17 Installation of Control Valve Assembly . . . . 30-63
Installation of Engine Rear Seal. . . . . . . . . . .30-18 Disassembly of Control Valve Assembly. . . 30-64
Removal of Radiator Assembly . . . . . . . . . . .30-19 Assembly of Control Valve Assembly . . . . . 30-70
Installation of Radiator Assembly . . . . . . . . .30-20 Disassembly of Pump Merge-divider Valve/
Removal of Hydraulic Oil Cooler Assembly .30-21 Self-pressure Reducing Valve/Travel Junction
Installation of Hydraulic Oil Cooler Valve Assembly (Combination Valve
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-22 Assembly). . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-76
Removal of Aftercooler Assembly. . . . . . . . .30-23 Assembly of Pump Merge-divider Valve/
Installation of Aftercooler Assembly. . . . . . .30-23 Self-pressure Reducing Valve/Travel Junction
Removal of Fuel Tank Assembly . . . . . . . . . .30-24 Valve Assembly (Combination Valve
Installation of Fuel Tank Assembly . . . . . . . .30-24 Assembly). . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-77
Removal of Center Swivel Joint . . . . . . . . . .30-25 Disassembly of Main Relief Valve Assembly30-78
Installation of Center Swivel Joint . . . . . . . .30-26 Assembly of Main Relief Valve Assembly . . 30-78
Disassembly of Center Swivel Joint Disassembly of Work Equipment PPC
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-27 Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . 30-79
Assembly of Center Swivel Joint Disassembly of Travel PPC Valve Assembly 30-80
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-27 Assembly of Travel PPC Valve Assembly . . 30-80
Removal of Final Drive, Travel Motor Removal of Work Equipment Assembly . . . 30-81
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-28 Installation of Work Equipment Assembly . 30-82
Installation of Final Drive, Travel Motor Removal of Operator’s Cab Assembly. . . . . 30-83
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-28 Installation of Operator’s Cab Assembly . . . 30-84
Disassembly of Final Drive Assembly . . . . . .30-29 Removal of Floor Frame Assembly . . . . . . . 30-85
Assembly of Final Drive Assembly . . . . . . . .30-32 Installation of Floor Frame Assembly . . . . . 30-86
Removal of Swing Motor And Swing Removal of Air Conditioner Compressor
Machinery Assembly . . . . . . . . . . . . . . . . . . .30-38 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-87
Installation of Swing Motor And Swing Installation of Air Conditioner Compressor
Machinery Assembly . . . . . . . . . . . . . . . . . . .30-38 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-87
Disassembly of Swing Machinery Assembly30-39 Removal of Air Conditioner Condensor
Assembly of Swing Machinery Assembly . .30-41 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-88
Removal of Revolving Frame Assembly. . . .30-47 Installation of Air Conditioner Condensor
Installation of Revolving Frame Assembly . .30-48 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-88
Removal of Swing Circle Assembly . . . . . . .30-48 Removal of Air Conditioner Unit Assembly 30-88
Installation of Swing Circle Assembly . . . . .30-49 Installation of Air conditioner Unit
Disassembly of Recoil Spring Assembly . . .30-50 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-89
Assembly of Recoil Spring Assembly . . . . . .30-51 Removal, Installation of Counterweight
Assembly of Idler Assembly . . . . . . . . . . . . .30-52 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-90
Assembly of Track Roller Assembly . . . . . . .30-54 Removal of Monitor Panel Assembly . . . . . 30-92
Expansion of Track Shoe Assembly . . . . . . .30-56 Installation of Monitor Panel Assembly. . . . 30-92
Installation of Track Shoe Assembly
(Steel shoe) . . . . . . . . . . . . . . . . . . . . . . . . . . .30-56
PC228UC-3 30-1
2
DISASSEMBLY AND ASSEMBLY METHOD OF USING MANUAL
12
METHOD OF USING MANUAL

1. When removing or installing unit assemblies
(1) When removing or installing a unit assembly, the order of work and techniques used are given for
the removal operation; the order of work for the installation operation is not given.
(2) Any special techniques applying only to the installation procedure are marked , and the same
mark is placed after the relevant step in the removal procedure to indicate which step in the installa-
tion procedure it applies to.
(Example)
REMOVAL OF !!! ASSEMBLY ............................... Title of operation
................................................................................. Precautions related to safety when carrying
out the operation
1. XXXX(1) .................................................................... Step in operation
★ ............................................................................... Technique or important point to remember
when removing XXXX (1).
2. ∆ ∆ ∆ (2): ................................................................... Indicates that a technique is listed for
use during installation
3. ❒ ❒ ❒ ❒ assembly (3)
....................................................................... See Lubricant and Coolant Table
INSTALLATION OF !!! ASSEMBLY........................ Title of operation

• Carry out installation in the reverse
order of removal
................................................................. Technique used during installation
★ ...................................................................... Technique or important point to remember
when installing ∆ ∆ ∆ (2).
• Adding water, oil ................................................. Step in operation
★ ..................................................................... Point to remember when adding water or oil
............................................................... Quantity when filling with oil and water
2. General precautions when carrying out installation or removal (disassembly or assembly) of units are
given together as PRECAUTION WHEN CARRYING OUT OPERATION, so be sure to follow these precau-
tions when carrying out the operation.
3. Listing of special tools

(1) For details of the description, part number, and quantity of any tools (A1, etc.) that appear in the
operation procedure, see the SPECIAL TOOL LIST given in this manual.
PC228UC-3 30-3
➁
DISASSEMBLY AND ASSEMBLY METHOD OF USING MANUAL
12
4. General tightening torque table (when using torque wrench)

★ In case of metric nuts and bolts for which there is no instruction, tighten to the torque given in the table
below.
Thread diameter Width across flats
mm mm N·m kgm
6 10 13.2 ± 1.4 1.35 ± 0.15
8 13 31.4 ± 2.9 3.2 ± 0.3
10 17 65.7 ± 6.8 6.7 ± 0.7
12 19 112 ± 9.8 11.5 ± 1.0
14 22 177 ± 19 18.0 ± 2.0
16 24 279 ± 29 28.5 ± 3
18 27 383 ± 39 39 ± 4
20 30 549 ± 58 56 ± 6
22 32 745 ± 78 76 ± 8
24 36 927 ± 98 94.5 ± 10
27 41 1320 ± 140 135 ± 15
30 46 1720 ± 190 175 ± 20
33 50 2210 ± 240 225 ± 25
36 55 2750 ± 290 280 ± 30
39 60 3280 ± 340 335 ± 35
5. Table of tightening torques for flared nuts

★ In the case of flared nuts for which there is no instruction, tighten to the torque given in the table below.
Thread diameter Width across flats Tightening torque
mm mm N·m kgm
14 19 24.5 ± 4.9 2.5 ± 0.5
18 24 49 ± 9.8 5±1
22 27 78.5 ± 9.8 8±1
24 32 137.3 ± 29.4 14 ± 3
30 36 176.5 ± 29.4 18 ± 3
33 41 196.1 ± 49 20 ± 5
36 46 245.2 ± 49 25 ± 5
42 55 294.2 ± 49 30 ± 5
6. Table of tightening torques for split flanged bolts

★ In the case of split flange bolts for which there is no special instruction, tighten to the torque given in
the table below.
Thread diameter Width across flats Tightening torque
mm mm N·m kgm
10 14 65.7 ± 6.8 6.7 ± 0.7
12 17 112 ± 98 11.5 ± 1
16 22 279 ± 29 28.5 ± 3
30-4 PC228UC-3
➁
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION
12
PRECAUTIONS WHEN CARRYING OUT OPERATION

[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the gen-
eral precautions given below when carrying out the operation.]
1. Precautions when carrying out removal work
• If the coolant contains antifreeze, dispose of it correctly.

• After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from entering.
• When draining oil, prepare a container of adequate size to catch the oil.
• Confirm the match marks showing the installation position, and make match marks in the necessary
places before removal to prevent any mistake when assembling.
• To prevent any excessive force from being applied to the wiring, always hold the connectors when dis-
connecting the connectors.
• Fit wires and hoses with tags to show their installation position to prevent any mistake when installing.
• Check the number and thickness of the shims, and keep in a safe place.
• When raising components, be sure to use lifting equipment of ample strength.
• When using forcing screws to remove any components, tighten the forcing screws alternately.
• Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from
entering after removal.
★ Precautions when handling piping during disassembling

Fit the following blind plugs into the piping after disconnecting it during disassembly operations.
1) Hoses and tubes using sleeve nuts
Nominal Plug (nut end) Sleeve nut (elbow end)
number Use the two items below as a set
02 07376-50210 07221-20210 (Nut), 07222-00210 (Plug)
03 07376-50315 07221-20315 (Nut), 07222-00312 (Plug)
04 07376-50422 07221-20422 (Nut), 07222-00414 (Plug)
05 07376-50522 07221-20522 (Nut), 07222-00515 (Plug)
06 07376-50628 07221-20628 (Nut), 07222-00616 (Plug)
10 07376-51034 07221-21034 (Nut), 07222-01018 (Plug)
12 07376-51234 07221-21234 (Nut), 07222-01219 (Plug)
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 Number
number D d L
06 07049-00608 6 5 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 30
27 07049-02734 27 22.5 34
PC228UC-3 30-5
➁
12
2. Precautions when carrying out installation work

• Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
• Install the hoses without twisting or interference.
• Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
• Bend the cotter pin or lock plate securely.
• When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded por-
tion with 2 - 3 drops of adhesive.
• When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is
no dirt or damage, then coat uniformly with gasket sealant.
• Clean all parts, and correct any damage, dents, burrs, or rust.
• Coat rotating parts and sliding parts with engine oil.
• When press fitting parts, coat the surface with antifriction compound (LM-P).
• After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
• When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect
securely.
• When using eye bolts, check that there is no deformation or deterioration, screw them fully, and align
the direction of the hook.
• When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
3. Precautions when completing the operations

• If the coolant has been drained, tighten the drain valve, and add water to the specified level. Run the
engine to circulate the water through the system. Then check the coolant water level again.
• If the hydraulic equipment has been removed and installed again, add engine oil to the specified level.
Run the engine to circulate the oil through the system. Then check the oil level again.
• If the piping or hydraulic equipment, such as hydraulic cylinders, pumps, or motors, have been
removed for repair, always bleed the air from the system after reassembling the parts.
★ For details, see TESTING AND ADJUSTING, Bleeding air.
• Add the specified amount of grease (molybdenum disulphide grease) to the work equipment related
parts.
4. Other precautions
• To maintain the performance of the machine and to prevent failures, it is particularly important to pay
attention to the degree of cleanliness of the oil in the hydraulic circuits. When adding oil or changing
the oil, or when replacing the filters, check that the oil container and area around the filler of the hydrau-
lic tank are clean.
• To keep the hydraulic circuits clean and to protect the hydraulic equipment, be careful of the following
points when disassembling or assembling.
• Before disassembling, wash the machine. Be particularly careful to completely clean the area that is
to be disassembled.
• Do not let dirt or dust get into the hydraulic circuits when disassembling or assembling.
• Carry out thorough flushing of the parts, and be particularly careful to do this thoroughly for the cir-
cuits of parts that have failed.
• When disassembling or after flushing, always mask the openings of the piping or hydraulic equip-
ment completely.
• Do not use the seal tape for the thread of the plug mounts or connectors.
• If any internal part of the hydraulic equipment breaks, disassemble and clean all the hydraulic equip-
ment and circuits to remove any dirt or pieces from the circuit. If any parts of the hydraulic circuits are
disassembled and assembled, also carry out thorough flushing of the hydraulic circuits.
• When changing the oil in the hydraulic tank, or when removing the piston pump or piston pump piping,
always bleed the air before the engine to prevent seizure of the pump.
For details, see TESTING AND ADJUSTING, Bleeding air from piston pump.
30-6 PC228UC-3
➁
12
★ After replacing or flushing the hydraulic tank oil, filter element, or strainer, or when removing and
installing any hydraulic cylinder, hydraulic pump or any other hydraulic equipment or work equipment
piping, always bleed the air as follows after completion of installation.
1. Run the engine at low idling, and extend and retract the steering, bucket, and lift arm cylinders 4 - 5
times without going to the end of this strike. (Stop approx. 100 mm before the end of the stroke.)
2. Operate the steering, bucket, and lift arm cylinders 3 - 4 times to the end of the stroke, then stop the
engine and bleed the air from the plugs at the top of the hydraulic tank filter.
3. Raise the engine speed and repeat Step 2. to bleed the air. Repeat this procedure until no more air
comes out from the plugs.
4. After completing bleeding the air, tighten the plugs
Plug: 11.3 ± 1.5 N·m {1.15 ± 0.15 kgm}
★ If the engine is run at high speed from the start, or the cylinders are operated to the end of this
stroke, the air inside the cylinder will cause damage to the piston packing.
★ After repair or long storage, follow the same procedure.
PC228UC-3 30-7
➁
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
12
SPECIAL TOOL LIST

★ Tools with part number 79OT-OOO-OOOO cannot be supplied (they are items to be locally manufac-
tured).
★ Necessity: ■: . . . . . . . . . . . Cannot be substituted, should always be installed (used).
●: . . . . . . . . . . . Very convenient if available, can be substituted with commercially
available part.
★ New/remodel: N: . . . . . . . . Tools with new part numbers, newly developed for this model.
R: . . . . . . . . Tools with upgraded part numbers, remodeled from items already
available for other models.
Blank: . . . . . . . . . Tools already available for other models, used without any modification.
★ Tools marked { in the Sketch column are tools introduced in special sketches (See SKETCHES OF
SPECIAL TOOLS).
Neces- Qty. New/ Sketch

Component Symbol Part No. Part Name Nature of work, remarks
sity remodel
790-331-1110 Wrench ■ 1 Removal, installation of
1 cylinder head
795-799-1130 Gear ■ 1
Disassembly, 795-799-1390 Puller ■ 1 Removal, installation of

2 injection pump assembly
assembly of A 795-799-1130 Nut ■ 1
engine
■ Removal, installation of
3 795-799-1170 Puller 1 nozzle holder
4 795-799-1380 Installer ● 1 Installation of front seat
1 796-726-1120 Push tool ■ 1 Press fitting of bearing
Disassembly,
assembly of 796T-426-1130 Plate ● 1 Q
F
swing 2 790-101-5421 Grip ● 1 Press fitting of oil seal
machinery
01010-61240 Bolt ● 1
■ Removal installation of
1 796-427-1200 Wrench 1 round nut
Removal installation of
2 790-331-1110 Wrench ■ 1 final drive cover
796T-427-1220 Push tool ■ 1 Q
Disassembly, 790-101-2510 Block ■ 1
assembly of J 792-104-3930 Bolt ■ 2
final drive Press fit of main bearing
3 05180-1163 Nut ■ 2
inner races
01613-31645 Washer ■ 2
790-105-2100 Jack ■ 1
790-101-1102 Hydraulic pump ■ 1
4 791-545-1510 Installer ■ 1 Installation of floating seal
■ Installation of idler,
1 790-434-1630 Installer 1 floating seal
■ Installation of track roller

Disassembly, 2 790-434-1640 Installer 1 floating seal
assembly of
idler, L ■ Angle tightening of track
3 795-331-1110 Wrench 1 roller
track roller,
Disassembly, assembly of
carrier roller 4 797-101-1121 Wrench ■ 1 carrier roller
Installation of carrier roller,
5 790-434-1650 Installer ■
floating seal
30-8 PC228US-3
(4)
12
Neces- Qty. New/ Sketch

Component Symbol Part No. Part Name Nature of work, remarks
sity remodel
Disassembly, Press fitting of carrier
6 796-430-1110 Push tool ■ 1
assembly of roller, ring
idler, L
791-601-1000 Oil
track roller, pump Filling carrier roller, track
7 ● 1
carrier roller assembly roller, idler with oil
791-600-2001 Compressor (A) ■ 1
791-685-8005 Compressor (B) ■ 1
Disassembly, Removal, installation of
assembly of M 1 791-635-3160 Extension ■ 1 recoil spring
recoil spring
790-101-1600 Cylinder (70 ton) ■ 1
791-630-3000 Remover ■ 1
assembly of R 1 790-101-1300 Cylinder (100 ton) ■ 1 link pin
track
796-460-1210 Oil stopper ● 1 Removal, installation of
1
796-460-1230 Adapter ● 1 Q hydraulic pump
Hydraulic S
pump related 791-463-1141 Push tool ■ 1 Replacement of pump
2
790-201-2740 Spacer ■ 1 shaft oil seal
790-101-2501 Push-puller ● 1
790-101-2510 Block 1
790-101-2520 Screw 1
790-112-1180 Nut 1
Disassembly Disassembly of center
of center T 1 790-101-2540 Washer 1
swivel joint
swivel joint
790-101-2630 Leg 2
790-101-2570 Plate 4
790-101-2560 Nut 2
790-101-2650 Adapter 2
790-502-1003 Repair stand ■ 1 Disassembly, assembly of
1
790-101-1102 Hydraulic pump ■ 1 cylinder
790-102-4300 Wrench assembly ■ 1 Removal, installation of

2
790-102-4310 Pin ■ 1 piston boom, arm, bucket
assembly of 3 790-102-1480 Socket ■ 2
U nylon nut
hydraulic
cylinder Removal, installation of
790-720-1000 Expander ■ 1 piston cylinder
4 796-720-1660 Ring ■ 1
Bucket cylinder
07281-01159 Clamp ■ 1
796-720-1670 Ring ■ 1 Boom, arm cylinder
PC228US-3 30-9
(4)
12
Component Symbol Part No. Part Name Neces- Qty. New/ Sketch Nature of work,
sity remodel remarks
796-720-1680 Ring ■ 1
4 Offset cylinder
07281-01589 Clamp ■ 1
5 790-102-3802 Wrench assembly ■ 1 Removal, installation of

cylinder head
790-201-1702 Push tool kit ■ 1 Press fitting of coil

bushing
790-101-5021 Grip 1 All cylinders
6 01010-50816 Bolt 1 All cylinders
Disassembly,
assembly of 790-201-1831 Push tool 1 Bucket, offset cylinder
hydraulic U
cylinder 790-201-1930 Push tool 1 Arm cylinder
790-201-1841 Push tool 1 Boom cylinder
790-201-1500 Push tool kit ● 1 Inserting dust seal
790-201-5021 Grip 1 All cylinders
01010-50818 Bolt 1 All cylinders
7
790-201-1640 Plate 1 Bucket, offset cylinder
790-201-1650 Plate 1 Boom cylinder
790-201-1990 Plate ● 1 Arm cylinder
796-900-1200 Remover ■ 1
Removal of work Removal of boom foot
equipment pin
V 1 790-101-4000 Puller (50 ton) ■ 1 pin
Recovering, 1 799-703-1200 Service tool kit ■ 1

Charging air
reusing new X 2 799-703-1100 Vacuum pump ■ 1 conditioner with gas
freon gas
3 799-703-1400 Gas leak tester ■ 1
30-10 PC228UC-3
➁
12
SKETCHES OF SPECIAL TOOLS

NOTE: Komatsu cannot accept any responsibility for special tools manufactured according to these
drawings
F2 Plate
J3 Push tool
PC228US-3 30-10-1
(4)
12
S1 Adapter
30-10-2 PC228US-3
(4)
DISASSEMBLY AND ASSEMBLY ENGINE
12
REMOVAL OF ENGINE
ASSEMBLY
Lower the work equipment to the ground and 7. Remove bellmouth shroud (4) (only the upper
release the residual pressure from the hydrau- one) and fan (5).
lic circuit. Refer to TESTING AND ADJUST- 8. Disconnect radiator inlet hose (6) and outlet
ING, Releasing residual pressure from hose (7) on the engine side.
hydraulic circuit. ★ Since outlet hose (7) is secured with a
Disconnect the cable from the negative (-) clamp to the lower part (on the radiator
terminal of the battery. side), disconnect the clamp from the frame.
9. Disconnect heater hoses (8) and (9).
1. Release the air conditioner refrigerant. ★ When disconnecting the heat hoses, take
2. Remove the hydraulic pump assembly. For sufficient care not to bend the radiator
details, see REMOVAL OF HYDRAULIC PUMP tubes.
ASSEMBLY.
★ Before lifting off the engine assembly, bind
the engine oil filter and hose together to the
engine assembly, so that they will not be
damaged.
3. Drain the cooling water.
Quantity of cooling water: 21.5 L
4. Remove the engine hood and hood frame (1).
5. Remove the maintenance counterweight

assembly (central one at the rear of the engine).
For details, see REMOVAL OF COUNTER-
WEIGHT ASSEMBLY.
6. Remove hydraulic tank return hoses (2) and (3).
★ Remove the nipples and elbows on the
hydraulic tank side.
30-12 PC228UC-3
➁
12
10. Disconnect alternator intermediate connector 12. Disconnect fuel return hose (20), engine oil
(10) (CN-E08), starting motor terminals B (11) temperature sensor connector (CN-E05) (21),
and C (12), and engine oil level sensor connec- engine speed sensor connector (CN-E04) (22),
tor (CN-E03) (13) (On the right side of the governor motor connectors (E10) (23) and (CN-
engine). E11) (24), and ribbon heater connector (CN-E01)
(25) (On the left side of the engine).
11. Disconnect fuel feed hose (14), return hose (15),

air compressor connector (CN-E06) (16), air
conditioner hoses (17) and (18), and engine oil
pressure sensor connector (CN-E02) (19). (On
the left side front of the engine)
13. Disconnect hydraulic tank return hoses (26) and

(27). (On the right rear side of the engine)
PC228UC-3 30-13
➁
12
INSTALLATION OF ENGINE
ASSEMBLY
14. Disconnect engine ground cable (28). • Carry out installation in the reverse order of
removal.
• Charge the air conditioner with refrigerant

(R134a).
★ Adjust bellmouth mounting oblong holes "b" so

that clearance "a" between the periphery of the
fan and the bellmouth shroud will be even all
around the fan.
• Standard clearance "a" (All around):
Approx. 15 mm
15. Remove the engine mounting bolts (4 pieces)

and lift off the engine assembly (29).
★ Before lifting off the engine assembly, bind
the engine oil filter and hose together to the
engine assembly so that they will not be
damaged.
Engine assembly mounting bolt:

245 - 308.9 N·m {25 -31.5 kgm}
• Refilling with water
Add water through the water filler to the speci-
fied level. Run the engine to circulate the water
through the system. Then, check the water
level again.
• Refilling with oil
Add 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.
Hydraulic tank: Approx. 126 L (SAE10W-
CD)
Bleeding air
• Operate the priming pump to bleed air from the
fuel system.
30-14 PC228UC-3
➁
DISASSEMBLY AND ASSEMBLY ENGINE FRONT SEAL
12
REMOVAL OF ENGINE
FRONT SEAL FRONT SEAL
Disconnect the cable from the negative (-) 5. Support cover (6) and push out oil seal (7) for-
terminal of the battery. ward with a screwdriver, etc. from the rear side
of the cover.
1. Remove the radiator assembly. For details, see
REMOVAL OF RADIATOR ASSEMBLY.
2. Using lever (1), remove fan belt (1) and pulley

(2).
3. Remove 4 mounting bolts (3) and crankshaft

pulley/vibration damper (4).
4. Remove 20 mounting bolts (5) and cover (6).
FRONT SEAL
• Carry out installation in the reverse order of
removal.
Crankshaft pulley/Vibration damper

mounting bolt:
125 ± 5 N·m {12.75 ± 0.51 kgm}
★ Install the crankshaft pulley/vibration damper
temporarily and install the fan belt, then tighten
the mounting bolts to the specified torque.
PC228UC-3 30-15
➁
DISASSEMBLY AND ASSEMBLY ENGINE FRONT SEAL
12
★ When installing the vibration damper, check Lead the sealing part of the front cover to the crank-
index lines "A" of damper hub B and inertia shaft with pilot (2) installed and tighten the cover
piece "C". If those lines are deviated from each mounting bolts to the specified torque, then
other more than 1.59 mm or rubber part "D" is remove pilot (2).
broken, replace the damper. Front cover mounting face:
Gasket sealant (LG-6)
Cover (6) mounting bolt:

24 ± 4 N·m {2.45 ± 0.41 kgm}
★ Install the oil seal according to the following

procedure.
1) Install pilot (2) to oil seal (8).
2) Set the oil seal to tool A4 with the dust lip
face up.
★ Apply liquid adhesive to the outside of
the seal.
Outside of seal: Liquid adhesive (LT-2)
3) Push in the oil seal from the inside of front

cover (6) toward outside.
Push in until tool A4 reaches the bottom of
front cover (6).
★ Degrease and dry the seal contact face
of the crankshaft and seal lip face to
prevent oil leakage.
30-16 PC228UC-3
➁
DISASSEMBLY AND ASSEMBLY ENGINE REAR SEAL
12
ENGINE REAR SEAL
REMOVAL OF ENGINE REAR
SEAL
Disconnect the cable from the negative (-) ★ Make a hole about 3 mm in diameter on the
terminal of the battery. seal carrier.
1. Remove the hydraulic pump assembly. For
details, see REMOVAL OF HYDRAULIC PUMP
ASSEMBLY.
2. Remove damper assembly (1).

3. Remove the mounting bolts and set guide bolts
(1), then lift off flywheel assembly (2).
★ Install a dent puller to a slide hammer and

insert them in the above hole to pull out seal
(3).
4 Remove seal (3).

★ Make a hole about 3 mm in diameter on the
seal carrier. Install a dent puller to a slide ham-
mer and insert them in the hole to pull out the
seal.
★ The seal can be removed by breaking the seal
carrier with a screwdriver, etc. In this case, take
care not to damage the seal fitting part of the
flywheel, wear ring of the crankshaft, etc.
PC228UC-3 30-17
➁
DISASSEMBLY AND ASSEMBLY ENGINE REAR SEAL
12
REAR SEAL
• Carry out installation in the reverse order of 2) Insert the assembly of oil seal (4) and pilot
removal. (2) in the crankshaft and push the seal into
the flywheel.
3) Pull out pilot (2). Push in the oil seal from
Flywheel mounting bolt: the inside of the front cover toward outside.
137.0 N·m {14.0 kgm} 4) Using the aligning tool, install the seal to a
proper depth of the housing.
★ Tighten the mounting bolts in the order
shown below. ★ Tap the top, bottom, right, and left parts
of the aligning tool with a hammer to
push in the seal, checking that the seal
carrier is free from bent, etc.
★ Install the oil seal according to the following

procedure.
1) Install pilot (2) to new oil seal (4).
★ Before installing the oil seal, degrease and
dry the seal contact face of the crankshaft
and seal lip face to prevent oil leakage.
30-18 PC228UC-3
➁
DISASSEMBLY AND ASSEMBLY RADIATOR
12
RADIATOR
REMOVAL OF RADIATOR
ASSEMBLY
release the residual pressure from the hydrau-
lic circuit. Refer to TESTING AND ADJUST-
ING, Releasing residual pressure from
hydraulic circuit.
Disconnect the cable from the negative (-)
terminal of the battery.
1. Remove the hydraulic oil cooler assembly. For
details, see REMOVAL OF HYDRAULIC OIL
COOLER ASSEMBLY.
2. Drain the cooling water. 7. Remove radiator upper frame (8) and stay bolt
3. Remove the maintenance central counter- (9).
weight (1). 8. Loosen lower mounting bolts (2 pieces each) of
frames (10) and (11) and tilt them in the oppo-
site direction to the radiator (toward the side).
Counterweight: 470 kg
★ The lower mounting bolts are tightened
from the underside of the machine body
(Do not remove them but loosen them).
4. Remove the bellmouth shroud (2) (only the

upper one) and fan (3). 9. Remove the mounting bolts (4 pieces each) of
5. Disconnect radiator inlet hose (4) and outlet the air conditioner condenser and air after-
hose (5) on the engine side. cooler.
★ Since outlet hose (5) is secured with a ★ Do not disconnect the piping.
clamp to the lower part (on the radiator 10. Lift off radiator assembly (12).
side), disconnect the clamp from the frame.
6. Disconnect heater hoses (6) and (7). Radiator: 40 kg
PC228UC-3 30-19
➁
DISASSEMBLY AND ASSEMBLY RADIATOR
12
INSTALLATION OF RADIA-
TOR ASSEMBLY
removal.
★ Be sure to return the sponge seats for balancing

the heater to their original positions.
★ Adjust bellmouth mounting oblong holes "b" so
that clearance "a" between the periphery of the
fan and the bellmouth shroud will be even all
around the fan.
• Standard clearance "a" (All around):
Approx. 15 mm

through the system. Then, check the oil
level again.
Hydraulic tank: Approx. 185 L
30-20 PC228UC-3
➁
DISASSEMBLY AND ASSEMBLY HYDRAULIC COOLER
12
REMOVAL OF HYDRAULIC COOLER
OIL COOLER ASSEMBLY
release the residual pressure from the hydrau-
lic circuit. Refer to TESTING AND ADJUST-
ING, Releasing residual pressure from
hydraulic circuit.
1. Remove the hydraulic tank strainer. Using tool 3. Remove battery (2) and toolbox (3).
B, stop the oil.
• When you do not use tool B, remove the
drain plug and drain the oil from the
hydraulic tank and piping.
Hydraulic tank: 185 L
4. Remove the small maintenance cover from the

rear part of the operator's cab.
2. Drain the oil from the hydraulic tank through

drain valve (1).
6. Remove nets (5), (6), and (7).
PC228UC-3 30-21
➁
DISASSEMBLY AND ASSEMBLY HYDRAULIC COOLER
12
7. Disconnect radiator reservoir tank hose (8). 10. Lift off hydraulic oil cooler assembly (13).
8. Remove the clamp of air conditioner hose (9)

and move the hose to the operator’s cab.
9. Remove frames (10) and (11). Disconnect

hydraulic oil cooler pipe (12) from the hydraulic
oil cooler and move it to the operator's cab. INSTALLATION OF HYDRAU-
LIC OIL COOLER ASSEMBLY
removal.
again.
• Refilling with water

Add water through the water filler to the speci-
level again.
30-22 PC228UC-3
➁
DISASSEMBLY AND ASSEMBLY AFTERCOOLER
12
AFTERCOOLER
REMOVAL OF AFTER- INSTALLATION OF AFTER-
COOLER ASSEMBLY COOLER ASSEMBLY
Lower the work equipment to the ground and • Carry out installation in the reverse order of
release the residual pressure from the removal.
hydraulic circuit. Refer to TESTING AND
ADJUSTING, Releasing residual pressure ★ Inserting length of upper hose and lower hose:
from hydraulic circuit.
Approx. 40 mm
terminal of the battery. Upper hose and lower hose clamp:
8.3 - 9.3 N·m {0.85 - 0.95 kgm}
1. Remove the small maintenance cover from the
rear part of the operator's cab.
2. Disconnect upper air hose (2) [together with

pipe (3)] and lower air hose (4) and remove
engine air aftercooler assembly (5).
PC228UC-3 30-23
➁
DISASSEMBLY AND ASSEMBLY FUEL TANK
12
FUEL TANK
REMOVAL OF FUEL TANK 4. Lift off fuel tank assembly (13).
ASSEMBLY
Lower the work equipment to the ground.

1. Remove handrail (1) and covers (2) - (5).
2. Disconnect fuel level gauge connector (CN-A60) INSTALLATION OF FUEL

(6), engine oil filter (7), and mount bracket and
hose clamp of water separator (8) from the fuel
TANK ASSEMBLY
tank.
removal.
Fuel tank (Empty): 130 kg
3. Disconnect fuel tank lower hoses (9) - (12).
30-24 PC228UC-3
➁
12
CENTER SWIVEL JOINT
REMOVAL OF ASSEMBLY
CENTER SWIVEL JOINT
3. Disconnect center swivel joint upper hoses
Lower the work equipment to the ground and (8) - (12) (5 pieces in total).
stop the engine. Then, loosen the hydraulic ★ When disconnecting each hose, put a tag to
oil filler cap slowly to release the internal it for identification.
pressure of the hydraulic tank. ★ Since drain hose (13) was disconnected
from the swing motor when the swing
motor was removed, it does not need to be
1. Remove swing motor upper cover (2 pieces) disconnected to remove the center swivel
and frame (1 piece) and disconnect swing joint. If this hose is disconnected from the
motor hoses (1) - (6) from the swing motor. center swivel joint, it cannot be connected
★ The hoses are connected to the following when the center swivel joint is installed.
ports.
• (1), (2): For swing (Ports MA and MB) 4. Pull out the pin on the center swivel joint and
• (3): Drain hose (Port S) disconnect lock plate (14) from the center
• (4): Pilot hose for releasing swing brake swivel joint.
(Port B)
• (5), (6): Drain hose (Port T)
★ When disconnecting drain hoses (3 pieces),
plug the hydraulic tank to prevent the
hydraulic oil from flowing out.
5. Disconnect swivel joint lower hoses (15) - (22)

(8 pieces in total).
★ When disconnecting each hose, put a tag to
it for identification.
2. Remove swing motor assembly (7).
PC228UC-3 30-25
➁
12
INSTALLATION OF CENTER
SWIVEL JOINT
6. Remove the mounting bolts and lift off center • Carry out installation in the reverse order of
swivel joint assembly (23). removal.
Center swivel joint: 40 kg

Center swivel joint mounting bolt:
98.1 - 122.6 N·m {10 - 12.5 kgm}
• Bleeding air
★ Bleed air from the circuit. For details, see
TESTING AND ADJUSTING, Bleeding air
from each part.
30-26 PC228UC-3
➁
12
DISASSEMBLY OF CENTER ASSEMBLY OF CENTER

SWIVEL JOINT ASSEMBLY SWIVEL JOINT ASSEMBLY
1. Remove cover (1). 1. Assembly slipper seal (7) and O-ring (6) to
2. Remove snap ring (2). swivel rotor.
3. Using tool T1, pull out swivel rotor (4) and ring 2. Set swivel shaft (5) to block, then using push
(3) from swivel shaft (5). tool, tap swivel rotor (4) with plastic hammer
4. Remove O-ring (6) and slipper seal (7) from and install.
swivel rotor.
Contact surface of rotor, shaft:
Grease (G2-LI)
★ When installing rotor, be extremely careful
not to damage the slipper seal and the O-
ring.
3. Install ring (3) and secure with snap ring (2).
4. Fit O-ring and install cover (1).
Mounting bolt:
31.7 ± 3 N·m {3.2 ± 0.3 kgm}
PC228UC-3 30-27
➁
DISASSEMBLY AND ASSEMBLY FINAL DRIVE, TRAVEL MOTOR
12
FINAL DRIVE, TRAVEL MOTOR
REMOVAL OF FINAL DRIVE, INSTALLATION OF FINAL
TRAVEL MOTOR ASSEMBLY DRIVE, TRAVEL MOTOR
ASSEMBLY
Lower the work equipment completely to the
ground and stop the engine. Then, loosen the
oil filler cap slowly to release the pressure • Carry out installation in the reverse order of
inside the hydraulic tank. removal.
5. Remove track shoe assembly.

For details, see REMOVAL OF TRACK SHOE Final drive, travel motor assembly
ASSEMBLY. mounting bolt:
6. Remove cover (1). 280.2 ± 32.7 N·m {28.3 ± 3.3 kgm}
• Refilling with hydraulic oil
Run the engine to circulate the oil through the
system. Then add oil through the oil filler to the
specified level.
Hydraulic tank:
Approx. 126 L (SAE10W-CD)
• Bleeding air
Bleed the air from the travel motor.
For details, see TESTING AND ADJUSTING,
Bleeding Air.
7. Disconnect travel motor hoses (2).
8. Sling final drive and travel motor assembly (3),

then remove mounting bolts (4) and lift off.
Final drive, travel motor assembly:

360 kg
30-28 PC228UC-3
➁
DISASSEMBLY AND ASSEMBLY FINAL DRIVE
12
FINAL DRIVE
DISASSEMBLY OF FINAL
DRIVE ASSEMBLY
1. Draining oil 4. No. 1 carrier assembly
Remove drain plug and drain oil from final 1) Remove No. 1 carrier assembly (3).
drive case.
Final drive case: Approx. 5.4 L
2. Cover
Remove mounting bolts, then use eyebolts ➀
to remove cover (1).
★ Ring gear (12) and cover (1) form one unit,
so when lifting, tap the ring gear with a
wooden hammer to remove the ring gear.
2) Disassemble No. 1 carrier assembly as fol-

lows.
i) Push in pin (4), then knock out shaft (5)
from carrier (6)
★ After removing the shaft, remove
pin (4).
ii) Remove thrust washer (7), gear (8),
bearing (9), and thrust washer (10).
3. Spacer
Remove spacer (2).
PC228UC-3 30-29
➁
12
5. No. 1 sun gear shaft 9. Thrust washer

Remove No. 1 sun gear shaft (11). Remove thrust washer (15).
10. No. 2 carrier assembly

1) Remove No. 2 carrier assembly (16).
6. Ring gear
Remove ring gear (12)
2) Disassemble No. 2 carrier assembly as fol-
7. Thrust washer lows.
Remove thrust washer (13).
i) Push in pin (17), then knock out shaft
(18) from carrier (19).
8. No. 2 sun gear
Remove No. 2 sun gear (14). ★ After removing the shaft, remove
pin (17).
30-30 PC228UC-3
➁
12
11. Nut 2) Disassemble hub assembly as follows.

1) Remove lock plate (24). i) Remove floating seal (27).
2) Using tool J1, remove nut (25). ii) Remove bearings (28) and (29) from
hub (30).
★ When removing bearing (28), do not
hit the plastic holder of the bearing.
12. Hub assembly

1) Using eyebolts ➂, remove hub assembly
(26) from travel motor.
3) Remove floating seal (31) from travel motor
(32).
PC228UC-3 30-31
➁
12
ASSEMBLY OF FINAL DRIVE

ASSEMBLY
★ Clean all parts, and check for dirt or damage. 3) Using tool J4, install floating seal (31) to
Coat the sliding surfaces of all parts with engine travel motor (32).
oil before installing. ★ For details of the installation procedure,
see Item 2) above.
1. Hub assembly
1) Using push tool, press fit bearings (28) and
(29) to hub (30).
4) Using eyebolts ➂, set hub assembly (26) to

travel motor, then using push tool, tap to
press fit bearing portion.
2) Using tool J4, install floating seal (27).
★ Remove all oil and grease from the O-
ring and O-ring contact surface, and dry
the parts before installing the floating
seal.
★ After installing the floating seal, check
that the angle of the floating seal is
within 1 mm.
★ After installing the floating seal, coat
the sliding surface thinly with engine
oil.
30-32 PC228UC-3
➁
12
2. Nut vi) Using push-pull scale ➄, measure tan-

1) Install nut as follows gential force in direction of rotation of
i) Using tool J3, push inner race portion hub in relation to motor case.
of bearing. ★ Tangential force:
★ Do not heat the bearing with a Max. 297.0 N {Max. 30.0 kg}
burner, or hit or push the plastic ★ The tangential force is the maxi-
holder directly. mum force when starting rotation.
★ Pushing force: 0.9 - 1.3 tons
★ Rotate the hub 2 - 3 times before
applying the pushing force to the
bearing inner race.
ii) Measure dimension a in the condition
in Step i) above.
vii) Install lock plate (24).

★ Install the lock plate as shown in the
diagram below.
iii) Measure thickness b of nut as an indi-

vidual part.
Thread of mounting bolt:

Thread tightener (LT-2)
iv) Calculate a - b = c.
v) Using tool J1, tighten nut (25) until
dimension d is c - 00.1 mm.
PC228UC-3 30-33
➁
12
3. No. 2 Carrier assembly ★ After inserting the pin, caulk the pin
1) Assemble No. 2 carrier assembly as follows. portion of the carrier.
★ Replace thrust washers (20) and (23) ★ After assembling the carrier assembly,
and pin (17) with new parts. check that gear (21) rotates smoothly.
★ There are the remains of the caulking 2) Install No. 2 carrier assembly (16).
when the pin is inserted at the end face ★ Align the position so that the three tips
of hole h at the side of the carrier, so of the gear shafts of carrier assembly
remove the caulked metal from the (16) enter the three hollows in the end
inside diameter of the hole before start- face of the motor case, then install.
ing to assemble.
i) Assemble bearing (22) to gear (21), fit

top and bottom thrust washers (20) and
(23), then set gear assembly in carrier
(19).
ii) Align with position of pin holes of shaft
and carrier, then tap with a plastic ham-
mer to install shaft (18).
★ When installing the shaft, rotate the
planetary gear, and be careful not to
damage the thrust washer.
iii) Insert pin (17).
★ When inserting the pin, take care
that the 3 claws (parts h) on the
periphery of the pin will not be
placed on the thin parts of the car-
rier (parts i). Since the thin parts
may be on the opposite side, con-
firm them on each carrier. If there is
a groove, avoid placing the claws on
the groove.
30-34 PC228UC-3
➁
12
4. Thrust washer 9. No. 1 carrier assembly

Install thrust washer (15). 1) Assemble No. 1 carrier assembly as follows.
★ Replace thrust washers (7) and (10) and
5. No. 2 sun gear pin (4) with new parts.
Install No. 2 sun gear (14).
★ There are the remains of the caulking
when the pin is inserted at the end face
6. Thrust washer
of hole h at the side of the carrier, so
Install thrust washer (13).
remove the caulked metal from the
inside diameter of the hole before start-
7. No. 1 sun gear shaft
ing to assemble.
Install No. 1 sun gear shaft (11).
i) Assemble bearing (9) to gear (8), fit top
and bottom thrust washers (7) and (10),
then set gear assembly to carrier (6).
ii) Align position of pin holes of shaft and
carrier, then tap with a plastic hammer
to install shaft (5).
★ When installing the shaft, rotate the
planetary gear, and be careful not to
damage the thrust washer.
8. Ring gear
Fit the O-ring to the hub. Sling and install ring
gear (12) to the hub by using hanging bolts (2),
matching their bolt holes to each other.
★ Degrease the mating faces of the ring gear
and hub.
★ Never put gasket sealant to the mating
faces of the ring gear and hub.
PC228UC-3 30-35
➁
12
iii) Insert pin (4). 2) Install No. 1 carrier assembly (3).

★ When inserting the pin, take care ★ Mesh the gears in the following order;
that the 3 claws (parts h) on the No. 1 sun gear shaft (11) and gear (8),
periphery of the pin will not be ring gear (12) and gear (8), No. 2 sun
placed on the thin parts of the car- gear (14) and carrier (6). If No. 2 sun
rier (parts i). Since the thin parts gear (14) and carrier (6) do not mesh
may be on the opposite side, con- with each other, shake hub (30) in the
firm them on each carrier. If there is turning (circumferential) direction sev-
a groove, avoid placing the claws on eral times, and they will mesh.
that groove.
10. Spacer
Install spacer (2).
★ After installing the spacer, measure dimen-
sion "x". If "x" is larger than 19 mm, the
assembly has not been assembled cor-
rectly. In this case, check the assembly.
★ After inserting the pin, caulk the pin

portion of the carrier.
★ After assembling the carrier assembly,
check that gear (8) revolves smoothly.
30-36 PC228UC-3
➁
12
11. Cover 12. Refilling with oil

Using eyebolts ➀, install cover (1), then using Tighten drain plug and add engine oil through
angle tightening wrench J2, tighten mounting oil filler.
bolts.
Final drive case: Approx. 5.4 L
Mounting surface of cover:
Gasket sealant (LG-6) ★ Carry out final check of the oil level at the
specified position after installing the final
Mounting bolt:
drive assembly to the chassis.
Initial torque: 147 N·m {15.0 kgm}
Additional tightening angle: 80 - 90°
PC228UC-3 30-37
➁
DISASSEMBLY AND ASSEMBLY SWING MOTOR, SWING MACHINERY
12
SWING MOTOR, SWING MACHINERY
REMOVAL OF SWING
MOTOR AND SWING ★ When disconnecting drain hoses (3 pieces),
MACHINERY ASSEMBLY plug the hydraulic tank to prevent the
hydraulic oil from flowing out.
stop the engine. Then, loosen the hydraulic
oil filler cap slowly to release the internal
pressure of the hydraulic tank.
5. Lift off swing motor and swing machinery

assembly (9).
Swing motor and swing machinery

assembly: 240 kg
★ Sling the assembly carefully, particularly
until the socket and spigot are removed
2. Disconnect air cleaner hose (2) from the engine from each other.
(turbocharger).
INSTALLATION OF SWING
3. Remove the swing motor upper covers MOTOR AND SWING MACHIN-
(2 pieces) and frame (1 piece).
ERY ASSEMBLY
4. After removing the swing motor upper covers
(2 pieces) and frame (1 piece), disconnect swing ★ Carry out installation in the reverse order of
motor hoses (3) - (8) from the swing motor. removal.
★ The hoses are connected to the following
ports.
Swing machinery mounting bolt:
• (3), (4): For swing (Ports MA and MB)
590 - 608 N·m {57 - 62 kgm}
• (5): Drain hose (Port S)
• (6): Pilot hose for releasing swing brake • Bleeding air
(Port B) ★ Bleed air from the circuit. For details, see
• (7), (8): Drain hose (Port T) TESTING AND ADJUSTING, Bleeding air
from each part.
30-38 PC228UC-3
➁
DISASSEMBLY AND ASSEMBLY SWING MACHINERY
12
SWING MACHINERY
DISASSEMBLY OF SWING
MACHINERY ASSEMBLY
1. Draining oil 4. No. 1 carrier assembly
Loosen drain plug and drain oil from swing 1) Remove No. 1 carrier assembly (3).
machinery case.
Swing machinery case:

Approx. 5.5 L
2. Swing motor assembly

1) Set swing motor and swing machinery
assembly on block ➀.
2) Remove mounting bolts, then remove
swing motor assembly (1).
2) Disassemble the No. 1 carrier assembly

according to the following procedure.
Remove snap ring (4) first, then remove
shaft (5), gear (6), bearing (7), thrust washer
(8), and plate (9).
3. No. 1 sun gear

Remove No. 1 sun gear (2).
5. Ring gear
Remove the mounting bolts and ring gear (10).
PC228UC-3 30-39
➁
12
6. No. 2 sun gear 2) Disassemble the No. 2 carrier assembly

Remove No. 2 sun gear (11). according to the following procedure.
i) Push in pin (14) and drive shaft (15) out
of carrier (16).
★ After removing the shaft, remove
pin (14).
iii) Remove plate (21).
7. Bolt
Remove holder mounting bolt (12).
8. No. 2 carrier assembly

1) Remove No. 1 carrier assembly (13).
9. Shaft assembly
1) Set the shaft and case assembly to the
press. Using push tool (2), remove shaft
assembly (22) from case assembly (23).
30-40 PC228UC-3
➁
12
ASSEMBLY OF SWING
MACHINERY ASSEMBLY
2) Disassemble the shaft assembly according ★ Clean all the parts and check them for dirt or
to the following procedure. damage. Coat their sliding surfaces with
Using push tool (3), remove bearing (24) engine oil before installing.
and plate (25) from shaft (26).
1. Bearing
1) Fill the hatched part (part a) with grease
(G2-LI).
Grease: Approx. 150 g
2) Using push tool F1, press fit bearing (24) to

case (29).
10. Bearing
Using the push tool, remove bearing (27) and
oil seal (28) from case (29).
2. Case assembly
1) Set plate (25) to shaft (26).
2) Set case assembly (23) to shaft (26). Using
push tool (4), press fit the inner race of the
bearing.
PC228UC-3 30-41
➁
12
3. Oil seal 5. No. 2 carrier assembly

Using tool (5), press fit oil seal (28). 1) Assemble the No. 2 carrier assembly
Periphery of oil seal: according to the following procedure.
Gasket sealant (LG-6) ★ There is a caulking mark around side
hole "h" of the carrier, made when the
★ When press fitting the oil seal, take care
pin was inserted. Remove the swollen
that gasket sealant (LG-6) will not stick to
part inside the hole in advance.
the lip of the oil seal.
i) Install plate (21) to carrier (16).
Lubricate seal lip: ii) Install bearing (19) to gear (18). Fit
Grease (G2-LI) upper and lower thrust washers (17)
and (20) and set gear assembly to car-
rier (16).
iii) Matching the pin holes of shaft (15) and
carrier to each other, tap the shaft with a
plastic hammer, etc. to install it.
★ When installing the shaft, revolve
the planetary gear and take care not
to damage the thrust washers.
iv) Insert pin (14).
4. Bearing
Using tool (6), press fit bearing (27).
★ Press fit both the inner race and outer race
of the bearing simultaneously. Do not press
fit only the inner race.
★ After press fitting the bearing, check that the
case revolves smoothly.
30-42 PC228UC-3
➁
12
★ When inserting the pin, take care 7. No. 2 sun gear

that the 3 claws (parts a) on the Install No. 2 sun gear (11).
periphery of the pin will not be
placed on the thin parts of the car-
rier (parts b). Since the thin parts
may be on the opposite side, con-
firm them on each carrier. If there is
a groove, avoid placing the claws on
that groove.
8. Ring gear
Fit the O-ring to case (29) and install ring gear
(10) by using hanging bolt (M10 x 1.5).
★ After inserting the pin, caulk the pin

portion of the carrier.
2) Install No. 2 carrier assembly (13).
6. Bolt
Tighten bolt (12).
Thread of mounting bolt:
Adhesive (LT-2)
Mounting bolt:
176.5 ± 19.6 N·m {18 ± 2.0 kgm}
PC228UC-3 30-43
➁
12
★ When installing the ring gear, match its 9. No. 1 carrier assembly
match mark (part c) to the projection (part d) 1) Assemble No. 1 carrier assembly according
of the case flange. to the following procedure.
i) Press fit shaft (5) to the carrier in the
direction of the arrow until the snap ring
groove is seen.
ii) Fit snap ring (4) and push back the shaft
from the opposite side until the snap
ring is fitted to face P of the carrier.
Take care not to push back too much.
iii) Fit plate (9), then install thrust washer

(8), bearing (7), gear (6), and snap ring
(4).
★ Degrease the mating faces of ring gear (10)

and case (29).
faces of ring gear (10) and case (29).
Mounting bolt:
157 - 196 N·m {16 - 20 kgm}
★ Do not fit any washer.
30-44 PC228UC-3
➁
12
iv) Install No. 1 carrier assembly (3). 11. Swing motor assembly
Fit the O-ring to ring gear (10) and install swing
motor assembly (1).
10. No. 1 sun gear

Install the No. 1 sun gear (2). ★ When installing the swing motor assembly,
set the motor port (part f) and the projection
(part g) of the case in the same direction.
★ Take care not to install the No. 1 sun gear

upside down.
• Install the No. 1 sun gear with the tooth ★ Degrease the mating faces of swing motor
(part e) down. assembly (1) and ring gear (10).
faces of swing motor assembly (1) and ring
gear (10).
Mounting bolt:
58.8 - 73.5 N·m {6 - 7.5 kgm}
PC228UC-3 30-45
➁
12
12. Oil feed pipe
1) When installing oil feed pipe (30), adjust the

center of cap (31) as shown in the following
figure.
2) After mounting the swing motor and swing

machinery assembly, when installing the
outer parts, if the assembly interferes with
the grommet of the outer parts, loosen U-
bolt (32), nut (33), and sleeve nut (34), then
adjust again.
Nut (33):
10.8 - 26.7 N·m {1.1 - 2.7 kgm}
Sleeve nut (34):

147 - 206 N·m {15 - 21 kgm}
13. Refilling with oil.

Tighten the drain plug and add engine oil
through the oil filler to the specified level.
30-46 PC228UC-3
➁
DISASSEMBLY AND ASSEMBLY REVOLVING FRAME
12
REVOLVING FRAME
REMOVAL OF REVOLVING
FRAME ASSEMBLY
1. Remove the engine hood and the covers 10. Install 4 sling wires to the 2 counterweight
around it. mounting holes and the 2 mounting parts of the
2. Remove the counterweight assembly. For work equipment assembly and lift up revolving
details, see REMOVAL OF COUNTERWEIGHT frame assembly (11) temporarily.
ASSEMBLY. 11. Remove the mounting bolts and lift off revolv-
3. Remove the work equipment assembly. For ing frame assembly (11).
details, see REMOVAL OF WORK EQUIPMENT ★ Leave 2 mounting bolts each installed on
ASSEMBLY. the front and rear sides. Balance the revolv-
4. Disconnect hose (1). ing frame assembly with lever blocks, etc.
5. Remove the plate, bottom pin (2), and boom Then, remove all the mounting bolts and lift
cylinder assembly (3). off the assembly.
★ Check the quantity and positions of the
When removing the revolving frame
inserted shims.
assembly, take care not to let it interfere
with the center swivel joint assembly.
Boom cylinder assembly: 180 kg
Revolving frame assembly: 4,700 kg
6. Disconnect travel speed selector hose (4).

7. Disconnect travel hoses (5), (6), (7), and (8).
8. Disconnect drain hose (9).
★ Disconnect the hose from the swing motor.
9. Pull out the pin and disconnect lock link (10)
from the center swivel joint.
PC228UC-3 30-47
➁
DISASSEMBLY AND ASSEMBLY REVOLVING FRAME, SWING CIRCLE
12
REVOLVING FRAME,
SWING CIRCLE
INSTALLATION OF REVOLV- REMOVAL OF SWING CIR-
ING FRAME ASSEMBLY CLE ASSEMBLY
• Carry out installation in the reverse order of 1. Remove the revolving frame assembly. For
removal. details, see REMOVAL OF REVOLVING FRAME
ASSEMBLY.
Mating face of swivel circle: 2. Remove swing circle mounting bolts (1), leav-
Gasket sealant (LG-1) ing 1 piece each installed on the front and rear
sides.
Swivel joint mounting bolt:
★ Swing circle mounting bolt: 36 pieces
98.1 - 122.6 N·m {10 - 12.5 kgm}
• Refilling with oil (Hydraulic tank) 3. Install 3 sling wires to swing circle assembly (2)
Add oil through the oil filler to the specified and lift it up temporarily, then remove the left
level. Run the engine to circulate the oil mounting bolts.
again. 4. Lift off the swing circle assembly (2).
Hydraulic tank: 185 Ls (SAE10W-CD) Swing circle assembly: 280 kg

• Bleeding air
Bleed air from the travel motor. For details, see
TESTING AND ADJUSTING, Bleeding air.
30-48 PC228UC-3
➁
DISASSEMBLY AND ASSEMBLY SWING CIRCLE
12
SWING CIRCLE
INSTALLATION OF SWING
CIRCLE ASSEMBLY
removal. ★ Set the soft zone S mark on the inside ring
of the inner race facing the right side of the
machine as shown in the diagram, then
Swing circle mounting bolt: install to the track frame.
1st pass: 191.3 ± 19.6 N·m {19.5 ± 2.0 kgm}
Amount of circle grease:
2nd pass: 1) When using tool L3 Grease (G2-LI) 21 L
Set tool L3 to bolt (1), install
clips to the other bolts, then
tighten the bolt 48° ± 5°.
2) When not using tool L3

i) Using the angle of the
bolt head as the bench-
mark, make a start mark
on the swing circle and
socket.
ii) Make an end mark at a
point on the swing circle
48° ± 5° from the start
mark.
iii)Tighten so that the start
mark on the socket is
aligned with the 48° ± 5°
end mark on the swing
circle.
PC228UC-3 30-49
➁
DISASSEMBLY AND ASSEMBLY RECOIL SPRING
12
RECOIL SPRING
DISASSEMBLY OF RECOIL
SPRING ASSEMBLY
1. Remove piston assembly (2) from recoil spring 3. Disassembly of piston assembly
assembly (1). 1) Remove lock plate (10) from piston (9), then
remove valve (11).
2. Disassembly of recoil spring assembly 2) Remove snap ring (12), then remove U-
1) Set tool M1 to recoil spring assembly (1). packing (13) and ring (14).
The recoil spring is under large installed
load, so be sure to set the tool properly.
Failure to do this is dangerous.
★ Installed load of spring:
126,549 N {12,900 kg}
2) Apply hydraulic pressure slowly to com-

press spring, then remove lock plate (3) and
nut (4).
★ Compress the spring to a point where
the nut becomes loose.
★ Release the hydraulic pressure slowly to
relieve the spring tension.
★ Free length of spring: 603 mm.
3) Remove yoke (6), cylinder (7), and dust seal

(8) from spring (5).
30-50 PC228UC-3
➁
DISASSEMBLY AND ASSEMBLY RECOIL SPRING
12
ASSEMBLY OF RECOIL
SPRING ASSEMBLY
1. Assembly of piston assembly 3. Assemble piston assembly (2) to recoil spring
1) Assemble ring (14) and U-packing (13) to assembly (1).
piston (9), then secure with snap ring (12). Piston sliding portion, wear ring:
2) Tighten valve (11) temporarily, and secure Grease (G2-LI)
with lock plate (10).
2. Assembly of recoil spring assembly ★ Assemble the cylinder assembly so that the
mounting position of the valve is 90° to the
1) Using tool U-7, assemble dust seal (8) to cyl-
side.
inder (7).
★ Fill the inside of the cylinder with approx.
300 cc of grease (G2-LI), then bleed the air
and check that grease comes out of the
grease hole.
2) Assemble cylinder (7) and yoke (6) to spring

(5), and set in tool M1.
Sliding portion of cylinder:
Grease (G2-LI)
3) Apply hydraulic pressure slowly to com-

press spring, and tighten nut (4) so that
installed length of spring is dimension "a",
then secure with lock plate (3).
★ Installed length "a" of spring: 466 mm.

4) Remove recoil spring assembly (1) from
tool M1.
PC228UC-3 30-51
➁
DISASSEMBLY AND ASSEMBLY IDLER
12
ASSEMBLY OF IDLER
ASSEMBLY
3. Using tool L1, install floating seal (6) to idler (4)
1. Press fit bushings (9) and (10) to idler (4). and shaft (5) and support (7) assembly.
★ Coat the sliding surface of the floating seal

2. Fit O-ring and install support (7) to shaft (5) with with oil, and be careful not to let any dirt or
dowel pin (8). dust get stuck to it.
★ Remove all grease and oil from the contact
surface of the O-ring and the floating seal.
4. Assemble shaft (5) and support (7) assembly to

idler (4).
30-52 PC228UC-3
➁
DISASSEMBLY AND ASSEMBLY IDLER
12
5. Using tool L1, install floating seal (3) to idler (4) 6. Install O-ring, then install support (2) with
and support (2). dowel pin (1).
★ Coat the sliding surface of the floating seal 7. Add oil using tool L7, then tighten plug.
with oil, and be careful not to let any dirt or
Oil: Approx. 80 cc (EO 30-CD)
dust get stuck to it.
★ Remove all grease and oil from the contact
surface of the O-ring and the floating seal. Plug: 207.9 ± 49.5 N·m {21.0 ± 5.0 kgm}
PC228UC-3 30-53
➁
DISASSEMBLY AND ASSEMBLY TRACK ROLLER
TRACK
12 ROLLER
ASSEMBLY OF TRACK
ROLLER ASSEMBLY
1. Using tool ➀, press fit bushings (9) and (10) to 4. Using tool L2, install floating seals (6) and (3) to
roller (4). roller (4).
★ For details of the precautions when install-
ing floating seals (6b) and (6d), and (3b) and
(3d), see the precautions marked ★ for Step
3.
2. Assemble collar (8) to shaft (5), and install pin

(7).
3. Using tool L2, install floating seal (6) to shaft 5. Assemble shaft (5) to roller (4).
(5).
★ When assembling the floating seal, clean 6. Turn over roller (4) and shaft (5) assembly
the contact surface of O-ring (6c) and float-
ing seal (6a), remove all grease and oil, and 7. Using tool L2, install floating seal (3) to collar
dry it. Make sure that no dirt or dust sticks (2).
to the contact surface of the floating seal. ★ For details of the precautions when install-
ing floating seals (a) and (3c), see the pre-
cautions marked ★ for Step 3.
30-54 PC228UC-3
➁
DISASSEMBLY AND ASSEMBLY TRACK ROLLER
12
8. Assemble collar (2) to shaft (5), and install pin 10. Using tool L7, fill track roller assembly with oil,
(1). then tighten plug (11).
9. Using tool L7, apply basic pressure to roller oil

filler port, and check for leakage of air from seal. Plug: 14.9 ± 5.0 N·m {1.5 ± 0.5 kgm}
★ Basic pressure: 0.1 MPa {1 kg/cm²}
★ Method of checking Track roller oil: 190 - 215 cc (EO 30-CD)
The basic pressure shall be maintained for
10 seconds and the indicator of the gauge
shall not go down.
PC228UC-3 30-55
➁
DISASSEMBLY AND ASSEMBLY TRACK SHOE
12
TRACK SHOE
EXPANSION OF TRACK
SHOE ASSEMBLY
Steel shoe
1. Stop the machine so that the master pin will be

between the idler and carrier roller and the track
shoe can be expanded in the forward and back-
ward directions.
2. Lower the work equipment to the ground and

loosen lubricator (1) to slacken the track shoe.
Since the internal pressure of the adjustment

cylinder is very high, do not loosen the lubri-
cator more than 1 turn. If the grease does
not come out sufficiently, move the machine INSTALLATION OF TRACK
forward and in reverse.
SHOE ASSEMBLY
Steel shoe
★ Adjust the tension of the track shoe. For

detail, see TESTING AND ADJUSTING, Test-
ing and adjusting track shoe tension.
★ Using tool I, press fit the master pin so that

it will be projected by "a".
Projection "a" of master pin: 4 ± 2 mm
3. Using tool I, pull out master pin (2).
★ When fitting the dust seal, apply grease

(G2-LI) to its contact face against the bush-
4. Remove tool I and move the machine forward ing.
so that temporary pin (2) will be in front of the
★ If the rubber parts of the Road Liner (Rubber
idler, then set block (1).
pad type) are worn or broken and the mounting
bolt heads are damaged, replace the shoe
5. Pull out temporary pin (2) and remove the dust
immediately. If the head of a bolt is crushed,
seal. Move the machine in reverse to expand
that bolt cannot be removed.
track shoe (3).
30-56 PC228UC-3
➁
DISASSEMBLY AND ASSEMBLY TRACK SHOE
12
Road Liner
1. Stop the machine so that the master pin will be

just above the idler and the track shoe can be
expanded in the forward and backward direc-
tions.
2. Lower the work equipment to the ground and

loosen lubricator (1) to slacken the track shoe.
Since the internal pressure of the adjustment

cylinder is very high, do not loosen the lubri-
cator more than 1 turn. If the grease does
not come out sufficiently, move the machine
forward and in reverse.
3. Remove Road Liner (1). INSTALLATION OF TRACK

SHOE ASSEMBLY
Road Liner

removal.
★ Adjust the tension of the track shoe. For

detail, see TESTING AND ADJUSTING, Test-
ing and adjusting track shoe tension.
Road Liner mounting bolt:

4. Set block ➀. 490 - 608 N·m {50.0 - 62.0 kgm}
5. Using tool R1 and temporary pin (2), pull out

master pin (2). ★ Using tool R1, press fit the master pin so
that it will be projected by "a".
Projection "a" of master pin: 2.5 ± 1 mm
6. Remove tool R1 and move the machine forward
and pull out temporary pin (2).
7. Remove the dust seal and move the machine in

reverse to expand track shoe (3).
★ Apply grease (G2-LI) to the contact faces of

the dust seal and bushing.
PC228UC-3 30-57
➁
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK
12
HYDRAULIC TANK
REMOVAL OF HYDRAULIC
TANK ASSEMBLY
release the residual pressure from the
ADJUSTING, Releasing residual pressure
1. Drain the oil from the hydraulic tank.
2. Lift off maintenance counterweight (1) from

above the pump.
5. Disconnect suction pipe (11).
3. Remove covers (2) and (3).
INSTALLATION OF HYDRAU-
LIC TANK ASSEMBLY
removal.
4. Disconnect hydraulic tank return hoses (4) - (9) again.
and pipe (10).
• Bleeding air
Bleed air from the circuit. For details, see TEST-
ING AND ADJUSTING, Bleeding air from each
part.
30-58 PC228UC-3
➁
DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP
12
HYDRAULIC PUMP
REMOVAL OF HYDRAULIC
PUMP ASSEMBLY
Lower the work equipment to the ground and 5. Lift off the maintenance counterweight (2) from
release the residual pressure from the above the pump.
Disconnect the cable from the negative (-) ter-
minal of the battery.
1. Remove the hydraulic tank strainer. Using tool

B, stop the oil.
• When you do not use tool B, remove the
drain plug and drain the oil from the
hydraulic tank and piping.
Hydraulic tank: 185 LL

6. Remove muffler (3).
7. Remove muffler mounting bracket (4).

2. Drain the oil from the damper case.
3. Open the engine hood and remove the muffler

upper cover.
4. Remove engine cover board (1).
PC228UC-3 30-59
➁
DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP
12
8. Remove the mounting bolts of water separator 11. Lift off hydraulic pump assembly (18).
(5) and engine oil filter (6) and place them
under the pump.
Hydraulic pump assembly: 160 kg
9. Disconnect PC-EPC solenoid connector (7) (CN-
V21) and LS-EPC solenoid connector (8) (CN-
V22).
10. Disconnect F and R pump discharge hoses (9)

and (10) [Remove pipes (11) and (12), too], case
drain hose (13), pump pressure input port hose
(14), EPC main pressure port hose (15), and LS
pressure hoses (16) and (17).
INSTALLATION OF HYDRAU-
LIC PUMP ASSEMBLY
removal.
Pump mounting bolt:

58.8 - 73.5 N·m {6 - 7.5 kgm}
Mating face of hydraulic pump case:

Gasket sealant (LG-6)
• Refilling with oil (Damper case)

level.
Damper: 0.75 L
• Refilling with oil (Hydraulic tank)

again.
• Bleeding air
from each part.
30-60 PC228UC-3
➁
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
CONTROL
12 VALVE
REMOVAL OF CONTROL
VALVE ASSEMBLY
Lower the work equipment to the ground and 4. Disconnect 8 pressure switch connectors (8)
stop the engine. Then, loosen the hydraulic and connector (9) (CN-S09).
oil filler cap slowly to release the internal • The pressure switch connectors are num-
pressure of the hydraulic tank and set the bered from above as shown below.
safety lock lever in the lock position. CN-S01, CN-S02, CN-S03, CN-S04, CN-S05,
★ Put tags to the disconnected pipes to pre- CN-S06, CN-S07, CN-S08
vent a mistake in re-connecting them.
5. Disconnect 8 PPC hoses (10).
1. Remove step (1) and guard (2). • The following color bands are installed to
the PPC hoses from above.
2. Open cover (3) and disconnect tube (5), connec- White (CURL BUCKET), Brown (LOWER
tor (6), and clamp (7) of windshield washer tank BOOM), No band (SWING LEFT), Blue (ARM
(4). IN), Black (DUMP BUCKET), Green (RAISE
BOOM), Red (SWING RIGHT), Yellow (ARM
3. Remove cover (3) together with the frame. OUT)
★ Remove the hose clamp from the frame.
6. Disconnect boom cushion valve hoses (11) and

(12).
• Disconnect hose (12) from the control valve.
PC228UC-3 30-61
➁
12
7. Disconnect 6 connectors (14) of solenoid valve 9. Disconnect hoses (20) and (21).
assembly (13). • Color bands of hoses
• The solenoid connectors are numbered (19): Green (Drain), (20): No band (Pump),
from the left as shown below. (21): Yellow (Pump)
CN-V01, CN-V02, CN-V03, CN-V04, CN-V05,
CN-V06 10. Disconnect 2 connectors (22) of the pump pres-
sure sensor.
8. Disconnect hoses (15), (16), (17), and (18). • The pressure sensors are numbered as
• Color bands of hoses shown below.
(15): Red (PPC lock), (16): Brown (2-stage CN-A51: Front pump pressure
relief), (17): Blue/Yellow (Travel Hi/Lo), (18): CN-A52: Rear pump pressure
Red/Yellow (Brake)
11. Disconnect front pump hose (23), rear pump

hose (24), and drain tube (25).
• Loosen the mounting bolt of PPC pressure
switch block (26) and move the block to this
side and disconnect tube (25).
30-62 PC228UC-3
➁
12
INSTALLATION OF CONTROL
VALVE ASSEMBLY
12. Disconnect travel PPC hoses (27), (28), (29), and • Carry out installation in the reverse order of
(30). removal.
• Color bands of hoses • Refilling with oil (Hydraulic tank)
(27): No band (Left reverse), (28): Blue Add oil through the oil filler to the specified
(Right reverse), (29): Red (Left forward), level. Run the engine to circulate the oil
(30): Green (Right forward) through the system. Then, check the oil level
again.
• Bleeding air
★ Bleed air from the circuit between the
valves and hydraulic cylinders. For details,
see TESTING AND ADJUSTING, Bleeding
air from each part.
13. Disconnect 13 main hoses and 3 pilot hoses.
14. Remove the control valve and solenoid assem-

bly (31).
Control valve and solenoid assembly:

270 kg
PC228UC-3 30-63
➁
12
DISASSEMBLY OF CONTROL VALVE ASSEMBLY
30-64 PC228UC-3
➁
12
PC228UC-3 30-65
➁
12
30-66 PC228UC-3
➁
12
PC228UC-3 30-67
➁
12
★ Do not disassemble the safety valve since its 6. Remove covers (24) and (25).
pressure cannot be set while it is installed in the
machine. 7. Arm control valve
• The 6-spool valve is explained in this section. 1) Remove case (25), spring (26), and retainer
(27).
1. Main relief valve 2) Remove case (28), spring (29), and retainer
1) Remove main relief valves (1) (2 pieces). (30).
3) Remove spool assembly (31).
2. Unload valves, centralized safety valve, safety ★ Do not disassemble spool assembly
suction valves, and suction valves. (31).
• Remove unload valves (2) (2 pieces), cen-
tralized safety valve (57), safety suction 8. Right travel control valve
valves (3) (5 pieces), and suction valves (4) 1) Remove case (25), spring (32), and retainer
(5 pieces) (33).
2) Remove case (28), spring (29), and retainer
3. Pressure compensation valves (30).
★ Before removing each pressure compensa- 3) Remove spool assembly (34).
tion valve, mark its position.
★ Do not disassemble spool assembly
• Remove bucket dump pressure compensa- (34).
tion valve (5), bucket digging pressure com-
pensation valve (6), right reverse pressure 9. Swing control valve
compensation valve (7), right forward pres-
sure compensation valve (8), boom raising
(37).
pressure compensation valve (9), boom
lowering pressure compensation valve (10), 2) Remove case (38), spring (29), and retainer
right swing pressure compensation valve (30).
(11), left swing pressure compensation 3) Remove spool assembly (39).
valve (12), left reverse pressure compensa- ★ Do not disassemble spool assembly
tion valve (13), left forward pressure com- (39).
pensation valve (14), arm dump pressure
compensation valve (15), and arm digging 10. Boom control valve
pressure compensation valve (16). 1) Remove case (35), spring (40), and retainer
★ After removing the pressure compensation (41).
valves, remove check valve (17) from the fit- 2) Remove case (38), spring (42), and retainer
ting position of each pressure compensa- (43).
tion valve. 3) Remove spool assembly (44).
4. LS selector valve
(44).
Remove LS selector valve (18).
5. LS shuttle valves, pump merge-divider valve/

self-pressure reducing valve/travel junction
valve assembly, back pressure valve, and boom
lock valve
1) Remove LS shuttle valves (19) and (20).
2) Remove the pump merge-divider valve/self-
pressure reducing valve/travel junction
valve assembly, back pressure valve (22),
and boom lock valve (23).
30-68 PC228UC-3
➁
12
11. Left travel control valve

(47).
(50).
(51).
12. Bucket control valve

(54).
(30).
(56).
13. Boom regeneration valve

1) After removing the pump merge-divider
valve and self-pressure reducing valve (22),
remove boom regeneration spring (58) and
boom regeneration valve (59).
2) Remove plate (60), arm regeneration spring
(61), and arm regeneration valve (62).
PC228UC-3 30-69
➁
12
ASSEMBLY OF CONTROL VALVE ASSEMBLY
30-70 PC228UC-3
➁
12
PC228UC-3 30-71
➁
12
30-72 PC228UC-3
➁
12
PC228UC-3 30-73
➁
12
• Before installing the parts, apply engine oil to 3) Install retainer (37) and spring (36). Fit the
their sliding surfaces. O-ring to case (35) and install them.
1. Bucket control valve Case mounting bolt:

1) Install spool assembly (56) to the valve 27.5 - 34.3 N·m {2.8 - 3.5 kgm}
body.
2) Install retainer (30) and spring (29). Fit the 5. Right travel control valve
O-ring to case (55) and install them. 1) Install spool assembly (34) to the valve
body.
Case mounting bolt: 2) Install retainer (30) and spring (29). Fit the
27.5 - 34.3 N·m {2.8 - 3.5 kgm} O-ring to case (48) and install them.
3) Install retainer (54) and spring (53). Fit the
Case mounting bolt:
O-ring to case (52) and install them. 27.5 - 34.3 N·m {2.8 - 3.5 kgm}
Case mounting bolt:
27.5 - 34.3 N·m {2.8 - 3.5 kgm} 6. Arm control valve
1) Install spool assembly (31) to the valve
2. Left travel control valve body.
1) Install spool assembly (51) to the valve 2) Install retainer (30) and spring (29). Fit the
body. O-ring to case (28) and install them.
Case mounting bolt:
Case mounting bolt: 3) Install retainer (69) and spring (74). Fit the
27.5 - 34.3 N·m {2.8 - 3.5 kgm} O-ring to case (70) and install them.
Case mounting bolt:
Case mounting bolt:
27.5 - 34.3 N·m {2.8 - 3.5 kgm} 7. Covers
• Fit the O-rings to covers (25) and (24) and
3. Boom control valve install them.
1) Install spool assembly (44) to the valve Mating faces of covers (16) and (9):
body. Seal End 242 or equivalent
O-ring to case (38) and install them. ★ Tighten the mounting bolts in the order
shown below.
Case mounting bolt:
27.5 - 34.3 N·m {2.8 - 3.5 kgm} Mounting bolt:
156.9 - 176.5 N·m {16 - 18 kgm}
O-ring to case (35) and install them.
Case mounting bolt:

27.5 - 34.3 N·m {2.8 - 3.5 kgm}
4. Swing control valve

1) Install spool assembly (39) to the valve
body.
O-ring to case (38) and install them.
Case mounting bolt:

27.5 - 34.3 N·m {2.8 - 3.5 kgm}
30-74 PC228UC-3
➁
12
8. LS shuttle valves, pump merge-divider valve/ 2) Fit the O-rings and install bucket dump
self-pressure reducing valve/travel junction pressure compensation valve (5), bucket
valve assembly, back pressure valve, boom lock digging pressure compensation valve (6),
valve, and boom regeneration valve right reverse pressure compensation valve
1) Install boom regeneration valve (59) and (7), right forward pressure compensation
spring (58) to the valve body, then install valve (8), boom raising pressure compensa-
the pump merge-divider valve/self-pressure tion valve (9), boom lowering pressure
reducing valve/travel junction valve assem- compensation valve (10), right swing pres-
bly (22). sure compensation valve (11), left swing
★ Tighten the mounting bolts in order pressure compensation valve (12), left
reverse pressure compensation valve (13),
shown in Step 7 above.
left forward pressure compensation valve
Mounting bolt: (14), arm dump pressure compensation
156.9 - 176.5 N·m {16 - 18 kgm} valve (15), and arm digging pressure com-
pensation valve (16).
2) Install back pressure valve (22).
★ Tighten the mounting bolts in order Each pressure compensation valve:
shown in Step 7 above. 372.7 - 411.9 N·m {38 - 42 kgm}
Mounting bolt: 11. Arm regeneration valve

58.8 - 73.6 N·m {6 - 7.5 kgm} • Install arm regeneration valve (62) and
3) Install boom lock valve (23). spring (61), then install plate (60).
★ Tighten the mounting bolts in order
Plate mounting bolt:
shown in Step 7 above. 58.8 - 73.6 N·m {6 - 7.5 kgm}
Mounting bolt:
58.8 - 73.6 N·m {6 - 7.5 kgm} 12. Unload valves, centralized safety valve, safety
suction valves, and suction valves
4) Install LS shuttle valves (20) and (19). 1) Fit the O-rings and install suction valve
assemblies (4) (5 pieces).
Mounting bolt:
58.8 - 73.6 N·m {6 - 7.5 kgm} Suction valve:
137.3 - 156.9 N·m {14 - 16 kgm}
9. LS selector valve
Install LS selector valve (18). 2) Fit the O-rings and install safety suction
valves (3) (5 pieces).
LS selector valve:
107.9 - 147.1 N·m {11 - 15 kgm} Suction valve:
137.3 - 156.9 N·m {14 - 16 kgm}
10. Pressure compensation valves 3) Fit the O-rings and install unload valve
• When installing each pressure compensa- assemblies (2) (2 pieces).
tion valve, check its position marked when it
was removed. Unload valve assembly:
1) Before installing the following pressure 147.1 - 186.3 N·m {15 - 19 kgm}
compensation valves, install check valve
(17). 13. Main relief valve
• Fit the O-rings and install main relief valve
assemblies (1) (2 pieces).
Main relief valve assembly:

49.0 - 58.8 N·m {5 - 6 kgm}
PC228UC-3 30-75
➁
DISASSEMBLY AND ASSEMBLY COMBINATION VALVE ASSEMBLY
12
COMBINATION VALVE ASSEMBLY
DISASSEMBLY OF PUMP MERGE-DIVIDER VALVE/SELF-PRESSURE
REDUCING VALVE/TRAVEL JUNCTION VALVE ASSEMBLY
30-76 PC228UC-3
➁
DISASSEMBLY AND ASSEMBLY COMBINATION VALVE ASSEMBLY
ASSEMBLY OF PUMP MERGE-

DIVIDER VALVE/SELF-PRES-
SURE REDUCING VALVE/TRAVEL
JUNCTION VALVE ASSEMBLY
1. Remove case (2) from valve body (1), then • Before installing the parts, apply engine oil to
remove retainer (3), spring (4), retainer (5), and their sliding surfaces.
spool (6).
1. Fit the O-ring and install ball (20), spring (19),
2. Remove plug (7), then remove spring (8) and and seat (18) to block (13).
spool (9).
Seat: 9.8 - 12.7 N·m {1.1 - 3 kgm}
3. Remove plug (10), then remove spring (11) and
spool (12). 2. Fit the O-ring and install valve assembly (17) to
block (13).
4. Remove plug (14) from block (13), then remove
★ Check that the filter is installed.
spring (15) and spool (16).
Valve assembly:
5. Remove valve assembly (17) from block (13). 24.5 - 34.3 N·m {2.3 - 3.5 kgm}
6. Remove seat (18), spring (19), and ball (20) from 3. Install spool (16) and spring (15), then install the
block (13).
O-ring and plug (14).
★ After disassembling, if any of body (1) and
spools (6), (9), and (15) is defective, replace the Plug: 19.6 - 24.5 N·m {2 - 2.5 kgm}
pump merge-divider valve assembly.
4. Fit the O-ring to plug (10) and install them to
valve body (1).
Plug (10):
147.1 - 186.3 N·m {15 - 19 kgm}
5. Install spool (9) and spring (8), then install the

O-ring and plug (7).
Plug (7):
147.1 - 186.3 N·m {15 - 19 kgm}
6. Install spool (6), retainer (5), and spring (4), then

install the O-ring and case (2).
Case (2) mounting bolt:

27 - 34 N·m {2.8 - 3.5 kgm}
PC228UC-3 30-77
➁
DISASSEMBLY AND ASSEMBLY MAIN RELIEF VALVE
12
MAIN RELIEF VALVE
DISASSEMBLY OF MAIN ASSEMBLY OF MAIN RELIEF
RELIEF VALVE ASSEMBLY VALVE ASSEMBLY
1. Loosen locknut (9), remove plug (8), then • Coat the sliding surfaces of all parts with engine
remove retainer (6). oil before installing.
2. Loosen locknut (10), then remove holder (7), 1. Assemble spring (4) and valve (3), and install
spring (11), poppet (5), and seat (12). ring (1).
3. Remove ring (1), then remove valve (3) and 2. Install seat (12), poppet (5), spring (11), and
spring (4). holder (7), and locknut (10).
★ After disassembling, it there is any abnor-
mality in any part, replace the whole main Locknut: 54.5 ± 5.0 N·m {5.5 ± 0.5 kgm}
relief valve assembly. Individual parts can-
not be supplied. 3. Fit retainer (6) and install plug (8), then lock
with locknut (9).
Locknut: 39.6 ± 5.0 N·m {4.0 ± 0.5 kgm}
★ After installing the control valve assembly,

adjust the pressure.
For details, see TESTING AND ADJUS-
TONG.
Testing and adjusting oil pressure in work
equipment, swing, travel circuits.
30-78 PC228UC-3
➁
DISASSEMBLY AND ASSEMBLY MAIN RELIEF VALVE
12
DISASSEMBLY OF WORK
EQUIPMENT PPC VALVE
ASSEMBLY
(PPC VALVE FOR BOOM, BUCKET,
ARM, SWING CONTROL)
1. Remove nut (1), then remove disc (2) and boot

(3).
2. Remove bolts, then remove plate (5).

★ Do not remove joint (4) unless it is to be
replaced.
3. Remove seal (6) and collar (7).
4. Pull out piston (8), then remove retainer (9),

springs (10) and (11), and shim (12).
★ Spring (10) consists of two each of two
types of springs with different installed
loads, so check the mounting position (oil
pressure port) and mark with tags to pre-
vent mistakes when installing.
5. Pull out valve (13) from body (14).
PC228UC-3 30-79
➁
DISASSEMBLY AND ASSEMBLY TRAVEL PPC VALVE
12
TRAVEL PPC VALVE
DISASSEMBLY OF TRAVEL
PPC VALVE ASSEMBLY
1. Remove cover and cam assembly (1), then
remove shims (2).
★ Check the number and thickness of shims
(2) for each mounting position, and keep in
a safe place.
2. Remove plate (3).
3. Remove seal (4) and collar (5).
4. Pull out piston (6), then remove retainer (7),

springs (8) and (9), and shims (10).
★ Check the number and thickness of shims
(10) for each mounting position, and keep in
a safe place.
5. Pull out valve (11) from body (12).
ASSEMBLY OF TRAVEL PPC

VALVE ASSEMBLY
1. Assemble valve (11) in body (12).
2. Assemble shims (10) and spring (9) to valve

(11).
★ Assemble the same number and thickness
of shims (10) as was removed during disas-
sembly.
Standard shim: 0.3 mm
★ Spring (9) is not symmetrical at the top and
bottom, so assemble with the small coil
diameter (inside diameter) at the shim end.
3. Assemble spring (8), retainer (7), and piston (6).

Outside circumference of piston, body
hole: Grease (G2-LI)
4. Fit O-ring to collar (5) and assemble in body

(11), then install seal (4).
5. Assemble plate (3).
6. Fit cover and cam assembly (1) and assemble

shims (2), then tighten with bolt.
Rocking portion of shaft, connection of
lever and piston: Grease (G2-LI)
30-80 PC228UC-3
➁
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT
WORK EQUIPMENT
12
REMOVAL OF WORK EQUIP-

MENT ASSEMBLY
Extend the boom and bucket fully and lower
the work equipment to the ground and set
the safety lock lever in the lock position.
1. Disconnect grease hose (1).

2. Sling boom cylinder assembly (2) temporarily
and remove lock bolt (3).
3. Remove the plate and head pin (4).
★ Check the quantity and positions of the
inserted shims.
4. Start the engine and retract the boom cylinder

rod and lower the boom cylinder on a block.
★ Bind the rod with wires, etc. so that it will 8. Sling work equipment assembly (9) and remove
not be extracted. foot pin (10) with tool V, then remove the work
equipment assembly.
★ Perform steps 1 - 4 above for the boom cyl-
inder on the opposite side, too.
Work equipment assembly: 3,300 kg
Release the residual pressure from the boom
cylinder circuit. Refer to TESTING AND
5. Disconnect the arm cylinder and bucket cylin-

der hoses (5) (4 pieces in total) and fit plugs to
them.
6. Disconnect working lamp connector (CN-A42).
7. Remove covers (6) and (7) and boom angle
potentiometer (8).
★ For details, see TESTING AND ADJUSTING,
Replacing boom angle potentiometer.
PC228UC-3 30-81
➁
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT
12
INSTALLATION OF WORK
EQUIPMENT ASSEMBLY
removal.
• Correct the boom angle potentiometer. For
details, see Correction mode of boom angle
★ Tighten the locknut so that clearance "a" potentiometer in the preface of TROUBLE-
between the plate and nut will be 0.5 - 1.5 SHOOTING.
mm.
Inside wall of bushing before assem-

bling pin:
Anti-friction composition (LM-P)
Greasing after assembling pin:

Grease (LM-G)
When aligning the pin holes, never insert

your fingers into them.
★ Adjust the shim thickness so that clearance
"c" between boom (13) and bracket (14) will
be 1 mm or less.
★ Standard shim: 0.8, 1.0, 1.5 mm
Inside wall of bushing before assem-
bling pin:
Anti-friction composition (LM-P)
Greasing after assembling pin:

Grease (LM-G)
When aligning the pin holes, never insert

your fingers into them.
★ Adjust the shim thickness so that clearance
"b" between cylinder rod (11) and plate (12)
will be 1 mm or less.
★ Standard shim: 0.8, 1.5 mm
• Bleeding air
from each part.
• Refilling with oil (Hydraulic tank)

★ Add oil through the oil filler to the specified
through the system. Then, check the oil
level again.
30-82 PC228UC-3
➁
DISASSEMBLY AND ASSEMBLY OPERATOR’S CAB
12
OPERATOR’S CAB
REMOVAL OF OPERATOR'S
CAB ASSEMBLY
Disconnect the cable from the negative (-) 4. Loosen the mounting bolts (4 pieces) of the
terminal of the battery. bracket of governor pump controller (13) and
shift the controller forward (to the operator's
seat).
1. Remove covers (1) - (4) from the monitor panel.
★ Remove the covers in the order of (1), (2),
(3), and (4). Note that they cannot be
removed in any other order.
★ When removing cover (2), disconnect ciga-
rette lighter connector (CN-M19).
5. Remove cover (14) and disconnect connector

(CN-H10) (15), (CN-H11) (16), (CN-H12) (17), and
(CN-M87) (18). (At the right rear part in the
operator's cab)
2. Remove cover (5) from under the front of the

operator's seat, then remove ducts (6) - (8).
3. Remove rear covers (9) - (12) in the operator's

cab.
PC228UC-3 30-83
➁
DISASSEMBLY AND ASSEMBLY OPERATOR’S CAB
12
6. Remove ducts (19) -(21). 10. Lift off operator's cab assembly (29).
Operator's cab assembly: 250 kg
7. Disconnect connectors (CN-H08) (22), (CN-H09)

(23), and (CN-H17) (24). (At the left rear part in
the operator's cab)
8. Disconnect intake duct selector connector (CN-

M83) (25) and remove duct (26).
★ Lift up duct (26) to remove it.
INSTALLATION OF OPERA-
TOR'S CAB ASSEMBLY
removal.
9. Remove mounting bolts (27) (4 pieces marked

#) and nuts (28) (6 pieces marked ").
★ Nuts (28) are tightened together with the
floor frame.
30-84 PC228UC-3
➁
DISASSEMBLY AND ASSEMBLY FLOOR FRAME
12
FLOOR FRAME
REMOVAL OF FLOOR FRAME
ASSEMBLY
Disconnect the cable from the negative (-) 6. Remove control valve upper cover (5) and front
terminal of the battery. cover (6) under the boom foot (to remove the
clamp).
1. Release the air conditioner refrigerant.
2. Remove the operator's cab assembly. For
details, see REMOVAL OF OPERATOR'S CAB
ASSEMBLY.
3. Remove the operator's cab lower cover.
4. Disconnect heater hoses (1) (2 pieces).
★ Cover the battery relay, starting motor
safety relay, ribbon heater relay, and other
electrical parts with vinyl sheets, etc. to pro-
tect them from the cooling water.
7. Disconnect PPC valve hoses (7) (8 pieces) for

work equipment and swing mechanism.
★ The PPC hoses are colored for identification
as shown below from above.
• For CURL BUCKET : White
• For LOWER BOOM : Brown
• For SWING LEFT : Not colored
• For ARM IN : Blue
• For DUMP BUCKET : Blue
• For RAISE BOOM : Green
5. Disconnect PPC hoses (2) (Port P) and (3) (Port
T) and travel PPC valve hoses (4) (4 pieces). • For SWING RIGHT : Red
★ Travel PPC valve hoses (4) (4 pieces) may be • For ARM OUT : Yellow
disconnected from the control valve.
PC228UC-3 30-85
➁
DISASSEMBLY AND ASSEMBLY FLOOR FRAME
12
INSTALLATION OF FLOOR
★ Remove clamp (8) from the right front of the FRAME ASSEMBLY
revolving frame and clamp (9) from inside
of the boom foot cover. • Carry out installation in the reverse order of
When disconnecting the travel PPC hose removal.
from the control valve, remove the clamp
Charging with air conditioner refrigerant
from the deeper (rear) side of clamp (9),
too. • Charge the air conditioner with refrigerant
(R134a).
Refilling with oil
• Run the engine to fill the piping with oil. Then,

add oil to the specified level.
Refilling with water
• Add water through the water filler to the speci-

level again.
8. Disconnect air conditioner hoses (10) and (11)

from the air conditioner unit.
9. Lift off floor frame assembly (12).
Floor frame assembly: 270 kg
30-86 PC228UC-3
➁
DISASSEMBLY AND ASSEMBLY AIR COMPRESSOR
12
AIR COMPRESSOR
REMOVAL OF AIR CONDI- INSTALLATION OF AIR CON-
TIONER COMPRESSOR DITIONER COMPRESSOR
ASSEMBLY ASSEMBLY
Disconnect the cable from the negative (-) • Carry out installation in the reverse order of
terminal of the battery. removal.
1. Open the engine hood and remove step (1).

★ When installing the air conditioner circuit
hoses, take care that dirt, dust, water, etc.
will not enter them.
★ Check that the O-ring is fitted to the joint of
each air conditioner hose.
★ Check that the O-rings are free from flaw,
deterioration, etc.
★ Adjust the tension of the air conditioner

compressor belt. For detail, see TESTING
AND ADJUSTING, Testing and adjusting
tension of air conditioner compressor belt.
2. Disconnect wiring connector (2) (CN-E06).
3. Disconnect 2 hoses (3).
• Charging with air conditioner refrigerant
★ Release all the air conditioner refrigerant
Using tool X1, charge the air conditioner circuit
(R134a) with tool X1 before disconnecting
with refrigerant (R134a).
the hoses.
★ Plug the hoses so that dust and water will
not enter them.
★ Take care not to damage or lose the O-rings.
4. Loosen locknut (4), adjustment bolt (5), and
mounting bolts (6) and (7), then remove air con-
ditioner compressor belt (8) from the pulley.
5. Remove mounting bolts (6) and (7) and air con-
ditioner compressor assembly (9).
PC228UC-3 30-87
➁
DISASSEMBLY AND ASSEMBLY CONDENSER AND AIR CONDITIONER UNIT
12
CONDENSER AND AIR CONDITIONER UNIT
REMOVAL OF AIR CONDI- REMOVAL OF AIR CONDI-
TIONER CONDENSER TIONER UNIT ASSEMBLY
ASSEMBLY
2. Open the inspection cover at the left rear part of
1. Drain the cooling water.
the machine body.
3. Disconnect hoses (1) and (2) and remove air
conditioner condenser assembly (3). Cooling water: 21.5 L

(3), and (4). Note that they cannot be
removed in any other order.
INSTALLATION OF AIR CON-

DITIONER CONDENSER
ASSEMBLY
removal.
4. Remove cover (5) from under the front of the
operator's seat, then remove ducts (6) - (8).
After assembling, charge the air conditioner
circuit with refrigerant (R134a).
30-88 PC228UC-3
➁
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER UNIT
12
AIR CONDITIONER UNIT
5. Remove rear covers (9) - (12) of the operator's 7. Remove ducts (15) - (17).
cab.
8. Disconnect connectors (CN-M26) (18), (CN-M85)

6. Remove cover (13) and disconnect connector (19), and (CN-M84) (20). (At the rear part of the
(14) (CN-M87). (At the right rear part in the operator's seat)
operator's cab)
9. Disconnect governor pump controller connec-
tors (CN-C01 - C06) (6 places) and remove gov-
ernor pump controller (21).
10. Disconnect heater hoses (22) and (23).

★ Remove the mounting bolts of the assem-
bled bracket and tube (24) and shift the
bracket and tube together.
PC228UC-3 30-89
➁
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER UNIT, COUNTER WEIGHT
12
AIR CONDITIONER UNIT,
COUNTER WEIGHT REMOVAL, INSTALLATION
11. Remove the seat stand mounting bolts (5 OF COUNTERWEIGHT
pieces). Tighten bolts (1) (M12, L = 100 mm)
into the seat stand lifting nuts (2 pieces on the
ASSEMBLY
left side and 1 piece on the right side) installed
by the seat stand to raise the seat stand. Extend the boom and bucket fully and lower
the work equipment to the ground and set
12. Remove the air conditioner unit mounting bolts the safety lock lever in the lock position.
(6 pieces) and pull air conditioner unit assembly
(25) out from under the operator's seat. Removal of maintenance counterweight (cen-
tral one at rear of engine)
1. Remove engine hood rear frame (1). Install a

sling (chains, etc.) to the hook and lift off main-
tenance counterweight (central one at the rear
of the engine) (1).
Counterweight assembly (1): 470 kg
INSTALLATION OF AIR CON-

DITIONER UNIT ASSEMBLY
removal.
★ When installing the air conditioner circuit
hoses, take care that dirt, dust, water, etc. will
not enter them.
★ Check that the O-ring is fitted to the joint of each Installation of maintenance counterweight
air conditioner hose. (central one at rear of engine)
★ Check that the O-rings are free from flaw, dete- • Carry out installation in the reverse order of
rioration, etc. removal.
• Charging with air conditioner refrigerant

Using tool X1, charge the air conditioner circuit
with refrigerant (R134a).
30-90 PC228UC-3
➁
DISASSEMBLY AND ASSEMBLY COUNTER WEIGHT
12
COUNTER WEIGHT
Removal of counterweight assembly
Removal of maintenance counter- (including central counterweight at
weight assembly (above pump) rear of engine and counterweight
above pump)
1. Remove the muffler upper cover. Install a sling
(chains, etc.) to the hook and lift off mainte- 1. Install a sling (chains, etc.) to the hook and lift
nance counterweight (above the pump) (2). off counterweight assembly (including the cen-
tral counterweight at the rear of the engine and
Counterweight assembly (2): 180 kg counterweight above the pump) (3).
Counterweight assembly (3): 6,400 kg
Installation of maintenance counterweight

assembly (above pump)
Installation of counterweight assembly
(including central counterweight at rear of
removal.
engine and counterweight above pump)

removal.
Counterweight mounting bolt:

Liquid adhesive (LT-2)
Counterweight mounting bolt:

3,430 - 4,217 Nm {350 - 430 kgm}
PC228UC-3 30-91
➁
DISASSEMBLY AND ASSEMBLY MONITOR PANEL
MONITOR
12 PANEL
REMOVAL OF MONITOR INSTALLATION OF MONITOR
PANEL ASSEMBLY PANEL ASSEMBLY
Disconnect the cable from the negative (-) ★ Carry out installation in the reverse order of
terminal of the battery. removal.

and (3). Note that they cannot be removed
in any other order.
2. Disconnect monitor panel connector (CN-P01)

(4) and (CN-P02) (5) and remove monitor panel
(6).
30-92 PC228UC-3
➁
90 OTHERS
HYDRAULIC CIRCUIT DIAGRAM

STD MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . 90- 3
ARM CRANE TYPE MACHINE . . . . . . . . . . . . . . . 90- 5
ELECTRICAL CIRCUIT DIAGRAM
(1/5) STD MACHINE . . . . . . . . . . . . . . . . . . . . . . . 90- 7
(2/5) STD MACHINE . . . . . . . . . . . . . . . . . . . . . . . 90- 9
(3/5) STD MACHINE . . . . . . . . . . . . . . . . . . . . . . . 90-11
(4/5) STD MACHINE . . . . . . . . . . . . . . . . . . . . . . . 90-13
(5/5) ARM CRANE TYPE MACHINE. . . . . . . . . . . 90-15
ELECTRICAL CIRCUIT DIAGRAM
FOR AIR CONDITIONER. . . . . . . . . . . . . . . . . . . . 90-17
PC228US-3 90-1
STD machine
PC228US-3 90-3
PC228US-3
12
Arm crane type machine
PC228US-3 90-5
12
ELECTRICAL CIRCUIT DIAGRAM (1/5)
STD machine
PC228US-3 90-7
12
STD machine
PC228US-3 90-9
12
STD machine
PC228US-3 90-11
12
STD machine
PC228US-3 90-13
12
Arm crane type machine
PC228US-3 90-15
STRUCTURE AND FUNCTION electrical circuit diagram for air conditioner
ELECTRICAL CIRCUIT DIAGRAM FOR AIR CONDITIONER
PC228US-3 90-17

Pc228us LC-3

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SEBM023104

MACHINE MODEL SERIAL NUMBER

PC228USLC-3 00 20001 and up 00

10 STRUCTURE, FUNCTION AND MAINTENANCE

20 TESTING AND ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . 20-1

30 DISASSEMBLY AND ASSEMBLY. . . . . . . . . . . . . . . . . . . 30-1

Page to be replaced Replace

( ) Page to be deleted Discard

Pages having no marks are those previously

LIST OF REVISED PAGES 00

Revision Revision Revision Revision Revision

q 00-1 (4) 01-1 10-15 10-42 10-69

10-96 10-135 20-1 20-120 (1) 20-224 (1)

30-43 (2) 30-82 (2)

IMPORTANT SAFETY NOTICE

GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to keep

STRUCTURE AND FUNCTION

TESTING AND ADJUSTING

DISASSEMBLY AND ASSEMBLY

HOW TO READ THE SHOP MANUAL REVISED EDITION MARK

VOLUMES When a manual is revised, an edition mark

Chassis volume: Issued for every machine model REVISIONS

DISTRIBUTION AND UPDATING

Slinging near the edge of the hook may cause

• If a part cannot be smoothly removed from the

★ The allowable load value is estimated to be one-

2) Sling wire ropes from the middle portion of the

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

k Before carrying out the following work, release Type 1

k Even if the residual pressure is released from

2) Hold adapter (1) and push hose joint (2) into

3) After hose joint (2) is pushed into adapter (3),

4) Hold hose adapter (1) or hose (5) and pull it out.

2) After inserting the hose in the mating adapter

• Used to prevent rubber gaskets, rub-

Holtz • Used as heat-resisting sealant for re-

• Used as lubricant for sliding portion

SYG2-400CA • Used for normal temperature, light

Molybdenum • Used for heavy load portion

SUNSTAR • Used as primer for cab side

• "S" is used for high-tempera-

SUNSTAR • Used to seal joints of glass

STANDARD TIGHTENING TORQUE

6 10 11.8 – 14.7 1.2 – 1.5

16 24 235 – 285 23.5 – 29.5

27 41 1150 – 1440 118 – 147

6 10 5.9 – 9.8 0.6 – 1.0

TABLE OF TIGHTENING TORQUES FOR FLARED NUTS

Thread diameter Width across flat Tightening torque

14 19 24.5 ± 4.9 2.5 ± 0.5

TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS

Thread diameter Width across flat Tightening torque

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS

Thread diameter Width across flat Tightening torque (Nm {kgm})

02 14 35 – 63 {3.5 – 6.5} 44 {4.5}

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS

Thread diameter Width across flat Tightening torque (Nm {kgm})

08 08 14 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75}

TIGHTENING TORQUE FOR 102 ENGINE SERIES

ELECTRIC WIRE CODE

0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal

2 26 0.32 2.09 3.1 20 Lighting, signal etc.

5 65 0.32 5.23 4.6 37 Charging and signal