228us-3 40001 Up

SEN01418-09
HYDRAULIC PC228US -3E0

EXCAVATOR
PC228USLC -3E0
PC228US- 40001
SERIAL NUMBERS and up
PC228USLC- 40001
SEN01420-09
HYDRAULIC EXCAVATOR 1SHOP MANUAL
PC228US-3E0
PC228USLC-3E0
Machine model Serial number

PC228US-3E0 40001 and up
PC228USLC-3E0 40001 and up
00 Index and foreword 1

Index
Composition of shop manual .......................................................................................................................... 2
Table of contents ............................................................................................................................................. 4
PC228US, USLC-3E0 1
SEN01420-09 00 Index and foreword
Composition of shop manual 1

The contents of this shop manual are shown together with Form No. in a list.
Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly.
The marks shown to the right of Form No. denote the following:
Q: New issue (to be filed additionally) q: Revision (to be replaced for each Form No.)
Note 2: This shop manual can be supplied for each Form No.
Note 3: To file this shop manual in the special binder for management, handle it as follows:
• Place a divider on the top of each section in the file after matching the Tub No. with No. indicated
next to each Section Name shown in the table below:
• File overview and other materials in sections in the order shown below and utilize them accord-
ingly.
Section Title Form Number
Shop Manual, contents binder, binder label and tabs SEN01418-09
00 Index and foreword SEN01419-09

Index SEN01420-09 q
Foreword and general information SEN01421-02
01 Specification SEN01422-01
Specification and technical data SEN01423-01
10 Structure, function and maintenance standard SEN01424-03

Engine and cooling system SEN01425-00
Power train SEN01426-00
Undercarriage and frame SEN01427-00
Hydraulic system, Part 1 SEN01428-00
Hydraulic system, Part 2 SEN01429-01 q
Work equipment SEN01431-00
Cab and its attachments SEN01432-00
Electrical system SEN01433-03 q
20 Standard value table SEN01434-02

Standard service value table SEN01441-02
30 Testing and adjusting SEN01435-05

Testing and adjusting, Part 1 SEN01879-04 q
Testing and adjusting, Part 2 SEN01880-04
40 Troubleshooting SEN01436-04
Failure code table and fuse locations SEN01882-04
General information on troubleshooting SEN01883-03
Troubleshooting by failure code (Display of code), Part 1 SEN01884-02
Troubleshooting of electrical system (E-mode) SEN01888-02
2 PC228US, USLC-3E0
Troubleshooting of hydraulic and mechanical system (H-mode) SEN01889-02

Troubleshooting of engine (S-mode) SEN01890-03
50 Disassembly and assembly SEN01437-05

General information on disassembly and assembly SEN01923-03
Engine and cooling system SEN01924-04 q
Hydraulic system SEN01927-02 q
Electrical system SEN01930-01
90 Diagrams and drawings SEN01438-02

Hydraulic diagrams and drawings SEN01439-01
Electrical diagrams and drawings SEN01440-02
PC228US, USLC-3E0 3
Table of contents 1
00 Index and foreword
Index SEN01420-09
Composition of shop manual ................................................................................................... 2
Table of contents...................................................................................................................... 4
Foreword and general information SEN01421-02
Safety notice ............................................................................................................................ 2
How to read the shop manual.................................................................................................. 7
Explanation of terms for maintenance standard ...................................................................... 9
Handling of electric equipment and hydraulic component ....................................................... 11
Handling of connectors newly used for engines ...................................................................... 20
How to read electric wire code................................................................................................. 23
Precautions when carrying out operation ................................................................................ 26
Method of disassembling and connecting push-pull type coupler ........................................... 29
Standard tightening torque table .............................................................................................. 32
Conversion table...................................................................................................................... 36
01 Specification
Specification and technical data SEN01423-01
Specification dimension drawings............................................................................................ 2
Working range diagram ........................................................................................................... 3
Specifications........................................................................................................................... 4
Weight table ............................................................................................................................. 6
Table of fuel, coolant and lubricants ........................................................................................ 8
10 Structure, function and maintenance standard

Engine related parts................................................................................................................. 2
Radiator, oil cooler, aftercooler and fuel cooler........................................................................ 3
Power train............................................................................................................................... 2
Final drive ................................................................................................................................ 4
Swing machinery ..................................................................................................................... 6
Swing circle.............................................................................................................................. 8
Track frame.............................................................................................................................. 2
Idler.......................................................................................................................................... 4
Carrier roller............................................................................................................................. 6
Track roller ............................................................................................................................... 7
Track shoe ............................................................................................................................... 8
Hydraulic equipment layout drawing........................................................................................ 2
Hydraulic tank .......................................................................................................................... 4
Hydraulic pump........................................................................................................................ 6
Control valve............................................................................................................................ 2
CLSS ....................................................................................................................................... 14
Functions and operation by valve ............................................................................................ 18
Merge-divider valve ................................................................................................................. 33
Attachment circuit selector valve ............................................................................................. 56
Hydraulic drift prevention valve................................................................................................ 58
Valve control ............................................................................................................................ 2
PPC valve ................................................................................................................................ 4
PPC Accumulator .................................................................................................................... 22
4 PC228US, USLC-3E0
Return oil filter ......................................................................................................................... 23

Center swivel joint ................................................................................................................... 24
Travel motor............................................................................................................................. 25
Swing motor............................................................................................................................. 35
Hydraulic cylinder .................................................................................................................... 44
Dimensions of components ..................................................................................................... 4
Air conditioner piping ............................................................................................................... 2
Engine control.......................................................................................................................... 2
Electrical control system.......................................................................................................... 12
Monitor system ........................................................................................................................ 38
Sensor ..................................................................................................................................... 56
KOMTRAX system .................................................................................................................. 59
20 Standard value table

Standard service value table SEN01441-02
Standard value table for engine related parts.............................................................................. 2
Standard value table for chassis ................................................................................................. 3
30 Testing and adjusting

Tools for testing, adjusting, and troubleshooting ..................................................................... 3
Sketches of special tools ......................................................................................................... 8
Testing engine speed............................................................................................................... 9
Testing intake air pressure (boost pressure) ........................................................................... 10
Checking exhaust gas color .................................................................................................... 11
Adjusting valve clearance........................................................................................................ 12
Testing compression pressure................................................................................................. 14
Testing blow-by pressure......................................................................................................... 17
Testing engine oil pressure...................................................................................................... 18
Handling fuel system parts ...................................................................................................... 19
Releasing residual pressure from fuel system......................................................................... 19
Testing fuel pressure ............................................................................................................... 20
Reduced cylinder mode operation........................................................................................... 23
No-injection cranking ............................................................................................................... 23
Testing fuel delivery, return rate and leakage .......................................................................... 24
Bleeding air from fuel circuit .................................................................................................... 27
Checking fuel circuit for leakage.............................................................................................. 28
Checking and adjusting air conditioner compressor belt tension ............................................ 29
Replacement of fan belt........................................................................................................... 30
Testing clearance in swing circle bearings .............................................................................. 2
Checking and adjusting track shoe tension ............................................................................. 3
Testing and adjusting hydraulic oil pressure in hydraulic circuit for work equipment,
swing and travel....................................................................................................................... 4
Testing control circuit oil pressure ........................................................................................... 8
Testing and adjusting pump PC control circuit oil pressure ..................................................... 9
Testing and adjusting pump LS control circuit oil pressure...................................................... 12
Testing solenoid valve output pressure ................................................................................... 17
Testing PPC valve output pressure ......................................................................................... 20
Adjusting play of work equipment and swing PPC valves ....................................................... 21
Inspection of locations of hydraulic drift of work equipment .................................................... 22
Release of residual pressure from hydraulic circuit................................................................. 24
Testing oil leakage ................................................................................................................... 25
PC228US, USLC-3E0 5
Bleeding air from each part...................................................................................................... 28

Procedure for replacing boom angle potentiometer................................................................. 30
Inspection procedures for diode .............................................................................................. 31
Adjusting mirrors...................................................................................................................... 32
Special functions of machine monitor ...................................................................................... 2
Handling voltage circuit of engine controller ............................................................................ 30
Starting KOMTRAX terminal operations .................................................................................. 31
Indicator lamps of KOMTRAX terminal.................................................................................... 35
Preparation work for troubleshooting of electrical system ....................................................... 38
Pm-clinic service...................................................................................................................... 40
40 Troubleshooting
Failure code table and fuse locations SEN01882-04
Failure code table .................................................................................................................... 2
Fuse locations.......................................................................................................................... 5
General information on troubleshooting SEN01883-03
Points to remember when troubleshooting .............................................................................. 2
Sequence of events in troubleshooting.................................................................................... 3
Checks before troubleshooting ................................................................................................ 4
Classification and troubleshooting steps ................................................................................. 5
Information in troubleshooting table......................................................................................... 6
Possible problems and troubleshooting No. ............................................................................ 8
Connection table for connector pin numbers ........................................................................... 11
T- branch box and T- branch adapter table.............................................................................. 47
Failure code [AA10NX] Air cleaner Clogging........................................................................... 3
Failure code [AB00KE] Charge Voltage Low ........................................................................... 4
Failure code [B@BAZG] Eng Oil Press Low............................................................................ 6
Failure code [B@BAZK] Eng Oil Level Low............................................................................. 7
Failure code [B@BCNS] Eng Water Overheat ........................................................................ 8
Failure code [B@BCZK] Eng Water Level Low ....................................................................... 9
Failure code [B@HANS] Hyd Oil Overheat ............................................................................. 10
Failure code [CA111] EMC Critical Internal Failure.................................................................. 10
Failure code [CA115] Eng Ne and Bkup Speed Sens Error..................................................... 11
Failure code [CA122] Chg Air Press Sensor High Error .......................................................... 12
Failure code [CA123] Chg Air Press Sensor Low Error........................................................... 14
Failure code [CA131] Throttle Sensor High Error .................................................................... 16
Failure code [CA132] Throttle Sensor Low Error..................................................................... 18
Failure code [CA144] Coolant Temp Sens High Error ............................................................. 20
Failure code [CA145] Coolant Temp Sens Low Error .............................................................. 22
Failure code [CA153] Chg Air Temp Sensor High Error .......................................................... 24
Failure code [CA154] Chg Air Temp Sensor Low Error ........................................................... 26
Failure code [CA155] Chg Air Temp High Speed Derate......................................................... 28
Failure code [CA187] Sens Supply 2 Volt Low Error ............................................................... 30
Failure code [CA221] Ambient Press Sens High Error ............................................................ 32
Failure code [CA222] Ambient Press Sens Low Error............................................................. 34
Failure code [CA227] Sens Supply 2 Volt High Error .............................................................. 36
Failure code [CA234] Eng. Overspeed .................................................................................... 37
Failure code [CA238] Ne Speed Sens Supply Volt Error ......................................................... 38
Failure code [CA271] IMV/PCV1 Short Error........................................................................... 39
Failure code [CA272] IMV/PCV1 Open Error .......................................................................... 40
Failure code [CA322] Inj #1 (L#1) Open/Short Error ............................................................... 42
6 PC228US, USLC-3E0

Failure code [CA342] Calibration Code Incompatibility ........................................................... 3
Failure code [CA351] Injectors Drive Circuit Error................................................................... 4
Failure code [CA352] Sens Supply 1 Volt Low Error ............................................................... 6
Failure code [CA386] Sens Supply 1 Volt High Error .............................................................. 8
Failure code [CA428] Water in Fuel Sensor High Error........................................................... 10
Failure code [CA429] Water in Fuel Sensor Low Error............................................................ 12
Failure code [CA435] Eng Oil Press Sw Error......................................................................... 14
Failure code [CA441] Battery Voltage Low Error ..................................................................... 15
Failure code [CA442] Battery Voltage High Error .................................................................... 18
Failure code [CA449] Rail Press Very High Error.................................................................... 20
Failure code [CA451] Rail Press Sensor High Error................................................................ 22
Failure code [CA452] Rail Press Sensor Low Error ................................................................ 24
Failure code [CA488] Chg Air Temp High Torque Derate........................................................ 26
Failure code [CA553] Rail Press High Error ............................................................................ 26
Failure code [CA559] Rail Press Low Error ............................................................................. 27
Failure code [CA689] Eng Ne Speed Sensor Error ................................................................. 29
Failure code [CA731] Eng Bkup Speed Sens Phase Error...................................................... 31
Failure code [CA757] All Continuous Data Lost Error ............................................................. 32
Failure code [CA778] Eng Bkup Speed Sensor Error.............................................................. 34
Failure code [CA1633] KOMNET Datalink Timeout Error........................................................ 36
Failure code [CA2185] Throt Sens Sup Volt High Error .......................................................... 38
Failure code [CA2186] Throt Sens Sup Volt Low Error ........................................................... 39
Failure code [CA2249] Rail Press Very Low Error................................................................... 40
Failure code [CA2311] IMV Solenoid Error.............................................................................. 42
Failure code [CA2555] Grid Htr Relay Volt High Error............................................................. 44
Failure code [CA2556] Grid Htr Relay Volt Low Error ............................................................. 46
Failure code [D110KB] Battery Relay Drive Short Circuit ........................................................ 2
Failure code [D196KA] Service Return Relay Disc. ................................................................ 4
Failure code [D196KB] Service Return Relay S/C .................................................................. 6
Failure code [DA22KK] Pump Solenoid Power Low Error....................................................... 8
Failure code [DA25KP] 5V Sensor 1 Power Abnormality ........................................................ 10
Failure code [DA2RMC] CAN Discon (Pump Con Detected) .................................................. 12
Failure code [DA2SKQ] Model Selection Abnormality............................................................. 14
Failure code [DAFRMC] CAN Discon (Monitor Detected) ....................................................... 16
Failure code [DGH2KB] Hyd Oil Sensor Short ........................................................................ 18
Failure code [DHPAMA] F Pump Press Sensor Abnormality................................................... 20
Failure code [DHPBMA] R Pump Press Sensor Abnormality .................................................. 22
Failure code [DHSAMA] Sw RH PPC Press Sen. Abnormality ............................................... 24
Failure code [DHSBMA] Sw LH PPC Press Sen. Abnormality ................................................ 26
Failure code [DW43KA] Travel Speed Sol Open Circuit.......................................................... 4
Failure code [DW43KB] Travel Speed Sol Short Circuit .......................................................... 6
Failure code [DW45KA] Swing Brake Sol Open Circuit........................................................... 8
Failure code [DW45KB] Swing Brake Sol Short Circuit........................................................... 12
Failure code [DW91KA] Travel Junction Sol Open Circuit....................................................... 14
Failure code [DW91KB] Travel Junction Sol Short Circuit....................................................... 16
Failure code [DW4GKA] Boom Slow Down Sol. Disc.............................................................. 18
Failure code [DW4GKB] Boom Slow Down Sol. S/C............................................................... 20
Failure code [DWJ0KA] Merge-divider Sol Open Circuit ......................................................... 22
Failure code [DWJ0KB] Merge-divider Sol Short Circuit ......................................................... 24
Failure code [DWK0KA] 2-stage Relief Sol Open Circuit ........................................................ 26
Failure code [DWK0KB] 2-stage Relief Sol Short Circuit ........................................................ 28
Failure code [DXA0KA] PC-EPC Sol Open Circuit.................................................................. 30
Failure code [DXA0KB] PC-EPC Sol Short Circuit .................................................................. 32
Failure code [DXE0KA] LS-EPC Sol Open Circuit .................................................................. 34
PC228US, USLC-3E0 7
Failure code [DXE0KB] LS-EPC Sol Short Circuit................................................................... 36

Failure code [DXE4KA] Service Current EPC Open Circuit .................................................... 38
Failure code [DXE4KB] Service Current EPC Short Circuit..................................................... 39
Failure code [DY20KA] Wiper Working Abnormality................................................................ 40
Failure code [DY20MA] Wiper Parking Abnormality ................................................................ 42
Failure code [DY2CKB] Washer Drive Short Circuit ................................................................ 44
Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit......................................................... 46
Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit ......................................................... 48
Troubleshooting of electrical system (E-mode) SEN01888-02
Before carrying out troubleshooting of electrical system ......................................................... 3
Information contained in troubleshooting table ........................................................................ 5
E-1 Engine does not start ........................................................................................................ 6
E-2 Auto-decelerator does not operate.................................................................................... 9
E-3 Automatic warming-up system does not operate .............................................................. 11
E-4 Preheater does not operate .............................................................................................. 12
E-5 All work equipment, swing, and travel mechanism do not move....................................... 14
E-6 Power maximizing function does not operate ................................................................... 16
E-7 Machine monitor does not display at all ............................................................................ 18
E-8 Machine monitor does not display some items ................................................................. 20
E-9 Contents of display by machine monitor are different from applicable machine ............... 20
E-10 Fuel level monitor was lighted in red while engine running............................................. 21
E-11 Engine coolant temperature gauge does not indicate normally ...................................... 22
E-12 Hydraulic oil temperature gauge does not indicate normally .......................................... 24
E-13 Fuel level gauge does not indicate normally ................................................................... 25
E-14 Swing lock monitor does not indicate normally ............................................................... 26
E-15 When monitor switch is operated, monitor displays nothing ........................................... 28
E-16 Windshield wiper and window washer do not operate .................................................... 30
E-17 Monitoring function fails to display “boom raise” normally .............................................. 34
E-18 Monitoring function fails to display “boom lower” normally.............................................. 35
E-19 Monitoring function fails to display “arm IN” normally ..................................................... 36
E-20 Monitoring function fails to display “arm OUT” normally ................................................. 37
E-21 Monitoring function fails to display “bucket CURL” normally........................................... 38
E-22 Monitoring function fails to display “bucket DUMP” normally .......................................... 39
E-23 Monitoring function fails to display “swing left” normally ................................................. 40
E-24 Monitoring function fails to display “swing right” normally ............................................... 42
E-25 Monitoring function fails to display “travel” normally ....................................................... 44
E-26 Monitoring function fails to display “travel differential pressure” normally ....................... 46
E-27 Monitoring function fails to display “service” normally..................................................... 48
E-28 The KOMTRAX system does not work properly ............................................................. 50
E-29 Air conditioner does not operate ..................................................................................... 52
E-30 Travel alarm does not sound or does not stop sounding ................................................ 54
E-31 Horn does not sound....................................................................................................... 56
E-32 Attachment circuit does not change ................................................................................ 58
Troubleshooting of hydraulic and mechanical system (H-mode) SEN01889-02
System chart for hydraulic and mechanical systems............................................................... 4
Information contained in troubleshooting table ........................................................................ 6
H-1 All work equipment lack power, or travel and swing speeds are slow .............................. 7
H-2 Engine speed sharply drops or engine stalls .................................................................... 9
H-3 No work equipment, travel or swing move ........................................................................ 10
H-4 Abnormal noise is heard from around hydraulic pump ..................................................... 10
H-5 Auto-decelerator does not work ........................................................................................ 11
H-6 Fine control mode does not function................................................................................. 11
H-7 Boom moves slowly or lacks power .................................................................................. 12
H-8 Arm moves slowly or lacks power..................................................................................... 13
H-9 Bucket moves slowly or lacks power ................................................................................ 14
H-10 Work equipment does not move in its single operation................................................... 14
H-11 Work equipment has a bit too large hydraulic drift .......................................................... 15
H-12 Work equipment has big time lag.................................................................................... 16
8 PC228US, USLC-3E0
H-13 Other work equipment moves when relieving single circuit ............................................ 16
H-14 One-touch power max. switch does not operate ............................................................ 16
H-15 In compound operation, work equipment with larger load moves slowly ........................ 17
H-16 In swing + boom RAISE operation, boom moves slowly ................................................ 17
H-17 In swing + travel, travel speed drops sharply.................................................................. 17
H-18 Machine swerves in travel .............................................................................................. 18
H-19 Machine travels slowly.................................................................................................... 19
H-20 Machine cannot be easily steered or lacks power .......................................................... 20
H-21 Travel speed does not shift, or it is slower or faster than preset speed.......................... 21
H-22 Track shoe does not turn (on one side only)................................................................... 21
H-23 Machine does not swing ................................................................................................. 22
H-24 Swing acceleration is poor, or swing speed is slow ........................................................ 24
H-25 Excessive overrun when stopping swing ........................................................................ 26
H-26 There is big shock when stopping swing ........................................................................ 27
H-27 There is big abnormal noise caused when stopping swing ............................................ 27
H-28 Swing natural drift is too big............................................................................................ 28
H-29 Attachment circuit does not change................................................................................ 29
H-30 Flow rate in attachment circuit cannot be adjusted......................................................... 29
Troubleshooting of engine (S-mode) SEN01890-03
Method of using troubleshooting chart .................................................................................... 3
S-1 Starting performance is poor ............................................................................................. 6
S-2 Engine does not start ........................................................................................................ 7
S-3 Engine does not pick up smoothly .................................................................................... 10
S-4 Engine stops during operations ........................................................................................ 11
S-5 Engine does not rotate smoothly ...................................................................................... 12
S-6 Engine lack output (or lacks power).................................................................................. 13
S-7 Exhaust smoke is black (incomplete combustion) ............................................................ 14
S-8 Oil consumption is excessive (or exhaust smoke is blue)................................................. 15
S-9 Oil becomes contaminated quickly ................................................................................... 16
S-10 Fuel consumption is excessive ....................................................................................... 17
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down).............................. 18
S-12 Oil pressure drops........................................................................................................... 19
S-13 Oil level rises (Entry of coolant/fuel) ............................................................................... 20
S-14 Coolant temperature becomes too high (overheating).................................................... 21
S-15 Abnormal noise is made ................................................................................................. 22
S-16 Vibration is excessive ..................................................................................................... 23
50 Disassembly and assembly

General information on disassembly and assembly SEN01923-03
How to read this manual.......................................................................................................... 2
Coating materials list ............................................................................................................... 4
Special tools list ....................................................................................................................... 7
Sketches of special tools ......................................................................................................... 10
Removal and installation of fuel supply pump assembly ......................................................... 2
Removal and installation of fuel injector assembly .................................................................. 5
Removal and installation of engine front seal .......................................................................... 11
Removal and installation of engine rear seal........................................................................... 13
Removal and installation of cylinder head assembly ............................................................... 16
Removal and installation of radiator assembly ........................................................................ 29
Removal and installation of hydraulic oil cooler assembly ...................................................... 32
Removal and installation of aftercooler assembly ................................................................... 34
Removal and installation of fuel cooler assembly.................................................................... 36
Removal and installation of engine assembly ......................................................................... 38
Removal and installation of fuel tank assembly....................................................................... 40
Removal and installation of travel motor and final drive assembly .......................................... 2
PC228US, USLC-3E0 9
Disassembly and assembly of final drive assembly................................................................. 3

Removal and installation of swing machinery assembly.......................................................... 11
Disassembly and assembly of swing machinery assembly ..................................................... 13
Removal and installation of swing circle assembly .................................................................. 21
Disassembly and assembly of track roller assembly ............................................................... 2
Disassembly and assembly of idler assembly ......................................................................... 3
Disassembly and assembly of recoil spring............................................................................. 6
Expansion and installation of track shoe assembly ................................................................. 8
Removal and installation of revolving frame ............................................................................ 10
Removal and installation of counterweight assembly .............................................................. 12
Removal and installation of maintenance counterweight (at rear of engine) ........................... 13
Removal and installation of maintenance counterweight assembly (above pump) ................. 14
Hydraulic system SEN01927-02
Removal and installation of center swivel joint assembly ........................................................ 2
Disassembly and assembly of center swivel joint.................................................................... 4
Removal and installation of hydraulic tank assembly .............................................................. 5
Removal and installation of work equipment pump ................................................................. 7
Removal and installation of control valve assembly ................................................................ 11
Disassembly and assembly of control valve assembly............................................................ 13
Disassembly and assembly of work equipment PPC valve assembly..................................... 15
Disassembly and assembly of travel PPC valve assembly ..................................................... 17
Disassembly and assembly of hydraulic cylinder assembly .................................................... 20
Removal and installation of work equipment assembly ........................................................... 2
Removal and installation of operator’s cab assembly.............................................................. 2
Removal and installation of operator’s cab glass (Stuck glass)............................................... 4
Removal and installation of front window assembly ................................................................ 13
Removal and installation of floor frame assembly ................................................................... 14
Removal and installation of air conditioner compressor assembly .......................................... 2
Removal and installation of air conditioner condenser assembly ............................................ 4
Removal and installation of air conditioner unit assembly ....................................................... 5
Removal and installation of machine monitor assembly .......................................................... 7
Removal and installation of pump controller assembly............................................................ 8
Removal and installation of engine controller assembly .......................................................... 9
Removal and installation of KOMTRAX communication modem assembly ............................ 11
90 Diagrams and drawings

Hydraulic diagrams and drawings SEN01439-01
Hydraulic circuit diagram ......................................................................................................... 3
Electrical diagrams and drawings SEN01440-02
Electrical circuit diagram.......................................................................................................... 3
Connector list and stereogram................................................................................................. 17
10 PC228US, USLC-3E0
PC228US, USLC-3E0 11
SEN01420-09
PC228US, 228USLC-3E0 Hydraulic excavator

Form No. SEN01420-09
© 2010 KOMATSU
All Rights Reserved
Printed in Japan 09-10
12
SEN01421-02
PC228US-3E0
PC228USLC-3E0

00 Index and foreword 1

Foreword and general information
Safety notice ................................................................................................................................................... 2
How to read the shop manual ......................................................................................................................... 7
Explanation of terms for maintenance standard ............................................................................................. 9
Handling of electric equipment and hydraulic component .............................................................................11
Handling of connectors newly used for engines ........................................................................................... 20
How to read electric wire code...................................................................................................................... 23
Precautions when carrying out operation...................................................................................................... 26
Method of disassembling and connecting push-pull type coupler................................................................. 29
Standard tightening torque table ................................................................................................................... 32
Conversion table ........................................................................................................................................... 36
PC228US, USLC-3E0 1
Safety notice 1
(Rev. 2008/08)
Important safety notice
Proper service and repair are 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 dangerous situa-
tion arises or may possibly arise, first consider safety, and take the necessary actions to deal with
the situation.
1. General precautions 7) If welding repairs are needed, always

k Mistakes in operation are extremely have a trained and experienced welder
dangerous. Read the Operation and carry out the work. When carrying out
Maintenance Manual carefully before w eld in g wo rk , alw ay s wear wel din g
operating the machine. In addition, gloves, apron, shielding goggles, cap and
read this manual and understand its other clothes suited for welding work.
contents before starting the work. 8) Before starting work, warm up your body
1) Before carrying out any greasing or thoroughly to start work under good condi-
repairs, read all the safety labels stuck to tion.
the machine. For the locations of the 9) Avoid continuing work for long hours and
safety labels and detailed explanation of take rests at proper intervals to keep your
precautions, see the Operation and Main- body in good condition. Take rests in
tenance Manual. specified safe places.
2) Decide a place in the repair workshop to
keep tools and removed parts. Always Safety points
keep the tools and parts in their correct
places. Always keep the work area clean 1 Good arrangement
and make sure that there is no dirt, water, 2 Correct work clothes
or oil on the floor. Smoke only in the areas 3 Following work standard
provided for smoking. Never smoke while
working. 4 Making and checking signs
3) When carrying out any operation, always Prohibition of operation and handling by
5
wear safety shoes and helmet. Do not unlicensed workers
wear loose work clothes, or clothes with 6 Safety check before starting work
buttons missing.
Wearing protective goggles
q Always wear safety glasses when hit- 7
(for cleaning or grinding work)
ting parts with a hammer.
q Always wear safety glasses when Wearing shielding goggles and protectors
8
grinding parts with a grinder, etc. (for welding work)
4) When carrying out any operation with 2 or 9 Good physical condition and preparation
more workers, always agree on the oper- Precautions against work which you are
ating procedure before starting. Always 10
not used to or you are used to too much
inform your fellow workers before starting
any step of the operation. Before starting
work, hang UNDER REPAIR warning
signs in the operator's compartment.
5) Only qualified workers must carry out work
and operation which require license or
qualification.
6) Keep all tools in good condition, learn the
correct way to use them, and use the
proper ones of them. Before starting work,
thoroughly check the tools, machine, fork-
lift, service car, etc.
2 PC228US, USLC-3E0
2. Preparations for work 6) When removing a cover which is under

1) Before adding oil or making any repairs, internal pressure or under pressure from a
park the machine on a hard and level spring, always leave 2 bolts in diagonal
ground, and apply the parking brake and positions. Loosen those bolts gradually
block the wheels or tracks to prevent the and alternately to release the pressure,
machine from moving. and then remove the cover.
2) Before starting work, lower the work 7) When removing components, be careful
equipment (blade, ripper, bucket, etc.) to not to break or damage the electrical wir-
the ground. If this is not possible, insert ing. Damaged wiring may cause electrical
the lock pin or use blocks to prevent the fires.
work equipment from falling. In addition, 8) When removing piping, stop the fuel or oil
be sure to lock all the control levers and from spilling out. If any fuel or oil drips
hang warning signs on them. onto the floor, wipe it up immediately. Fuel
3) When disassembling or assembling, sup- or oil on the floor can cause you to slip
port the machine with blocks, jacks, or and can even start fires.
stands before starting work. 9) As a general rule, do not use gasoline to
4) Remove all mud and oil from the steps or wash parts. Do not use it to clean electri-
other places used to get on and off the cal parts, in particular.
machine. Always use the handrails, lad- 10) Be sure to assemble all parts again in their
ders or steps when getting on or off the original places. Replace any damaged
m a c h i n e . N e v e r j u m p o n o r o ff t h e parts and parts which must not be reused
machine. If it is impossible to use the with new parts. When installing hoses and
handrails, ladders or steps, use a stand to wires, be sure that they will not be dam-
provide safe footing. aged by contact with other parts when the
machine is operated.
3. Precautions during work 11) When installing high pressure hoses,
1) Before disconnecting or removing compo- make sure that they are not twisted. Dam-
nents of the oil, water, or air circuits, first aged tubes are dangerous, so be
release the pressure completely from the extremely careful when installing tubes for
circuit. When removing the oil filler cap, a high pressure circuits. In addition, check
drain plug, or an oil pressure pickup plug, t h a t c o n n e c t i n g pa r ts a r e c o r r e c t l y
loosen it slowly to prevent the oil from installed.
spurting out. 12) When assembling or installing parts,
2) The coolant and oil in the circuits are hot always tighten them to the specified
when the engine is stopped, so be careful torques. When installing protective parts
not to get scalded. Wait for the oil and such as guards, or parts which vibrate vio-
coolant to cool before carrying out any lently or rotate at high speed, be particu-
work on the oil or water circuits. l a r l y c a r e fu l t o c he c k t h a t t h ey ar e
3) Before starting work, stop the engine. installed correctly.
When working on or around a rotating 13) When aligning 2 holes, never insert your
part, in particular, stop the engine. When fingers or hand. Be careful not to get your
checking the machine without stopping fingers caught in a hole.
the engine (measuring oil pressure, 14) When measuring hydraulic pressure,
revolving speed, temperature, etc.), take check that the measuring tools are cor-
extreme care not to get rolled or caught in rectly assembled.
rotating parts or moving parts. 15) Take care when removing or installing the
4) Before starting work, remove the leads tracks of track-type machines. When
from the battery. Always remove the lead removing the track, the track separates
from the negative (–) terminal first. suddenly, so never let anyone stand at
5) When raising a heavy component (heavier either end of the track.
than 25 kg), use a hoist or crane. Before 16) If the engine is operated for a long time in
starting work, check that the slings (wire a place which is not ventilated well, you
ropes, chains, and hooks) are free from may suffer from gas poisoning. Accord-
damage. Always use slings which have ingly, open the windows and doors to ven-
ample capacity and install them to proper tilate well.
places. Operate the hoist or crane slowly
to prevent the component from hitting any
other part. Do not work with any part still
raised by the hoist or crane.
PC228US, USLC-3E0 3
4. Precautions for sling work and making

signs
1) Only one appointed worker must make
signs and co-workers must communicate
with each other frequently. The appointed
sign maker must make specified signs
clearly at a place where he is well seen
from the operator's seat and where he can
see the working condition easily. The sign
maker must always stand in front of the
load and guide the operator safely.
q Do not stand under the load.
q Do not step on the load.
2) Check the slings before starting sling
work.
8) When installing wire ropes to an angular
3) Keep putting on gloves during sling work.
load, apply pads to protect the wire ropes.
(Put on leather gloves, if available.)
If the load is slippery, apply proper mate-
4) Measure the weight of the load by the eye
rial to prevent the wire rope from slipping.
and check its center of gravity.
9) Use the specified eyebolts and fix wire
5) Use proper sling according to the weight
ropes, chains, etc. to them with shackles,
of the load and method of slinging. If too
etc.
thick wire ropes are used to sling a light
10) Apply wire ropes to the middle portion of
load, the load may slip and fall.
the hook.
6) Do not sling a load with 1 wire rope alone.
q Slinging near the tip of the hook may
If it is slung so, it may rotate and may slip
cause the rope to slip off the hook
out of the rope. Install 2 or more wire
during hoisting. The hook has the
ropes symmetrically.
k Slinging with 1 rope may cause
maximum strength at the middle por-
tion.
turning of the load during hoisting,
untwisting of the rope, or slipping
of the rope from its original wind-
ing position on the load, which can
result in a dangerous accident.
7) Limit the hanging angle to 60°, as a rule.
Do not sling a heavy load with ropes form-
ing a wide hanging angle from the hook.
When hoisting a load with 2 or more
ropes, the force subjected to each rope
will increase with the hanging angle. The
table below shows the variation of allow-
able load in kN {kg} when hoisting is made
with 2 ropes, each of which is allowed to
sling up to 9.8 kN {1,000 kg} vertically, at
various hanging angles. When the 2 ropes 11) Do not use twisted or kinked wire ropes.
sling a load vertically, up to 19.6 kN {2,000 12) When lifting up a load, observe the follow-
kg} of total weight can be suspended. ing.
This weight is reduced to 9.8 kN {1,000 q Wind in the crane slowly until wire
kg} when the 2 ropes make a hanging ropes are stretched. When settling
angle of 120°. If the 2 ropes sling a 19.6 the wire ropes with the hand, do not
kN {2,000 kg} load at a lifting angle of grasp them but press them from
150°, each of them is subjected to a force above. If you grasp them, your fingers
as large as 39.2 kN {4,000 kg}. may be caught.
q After the wire ropes are stretched,
stop the crane and check the condi-
tion of the slung load, wire ropes, and
pads.
4 PC228US, USLC-3E0
q If the load is unstable or the wire rope 13) If the hoist stops because of a power fail-
or chains are twisted, lower the load ure, turn the power switch OFF. When
and lift it up again. turning on a switch which was turned OFF
q Do not lift up the load slantingly. by the electric shock prevention earth
13) When lifting down a load, observe the fol- leakage breaker, check that the devices
lowing. related to that switch are not in operation
q When lifting down a load, stop it tem- state.
porarily at 30 cm above the floor, and 14) If you find an obstacle around the hoist,
then lower it slowly. stop the operation.
q Check that the load is stable, and 15) After finishing the work, stop the hoist at
then remove the sling. the specified position and raise the hook
q Remove kinks and dirt from the wire to at least 2 m above the floor. Do not
ropes and chains used for the sling leave the sling installed to the hook.
work, and put them in the specified
place. 7. Selecting wire ropes
1) Select adequate ropes depending on the
5. Precautions for using mobile crane weight of parts to be hoisted, referring to
a Read the Operation and Maintenance the table below.
Manual of the crane carefully in advance
and operate the crane safely. Wire ropes
(Standard “Z” twist ropes without galvanizing)
6. Precautions for using overhead hoist crane (JIS G3525, No. 6, Type 6X37-A)
k When raising a heavy part (heavier Nominal
Allowable load
than 25 kg), use a hoist, etc. In Disas- diameter of rope
sembly and assembly, the weight of a mm kN ton
part heavier than 25 kg is indicated 10 8.8 0.9
after the mark of 4. 12 12.7 1.3
1) Before starting work, inspect the wire 14 17.3 1.7
ropes, brake, clutch, controller, rails, over 16 22.6 2.3
wind stop device, electric shock preven- 18 28.6 2.9
tion earth leakage breaker, crane collision 20 35.3 3.6
prevention device, and power application
25 55.3 5.6
warning lamp, and check safety.
30 79.6 8.1
2) Observe the signs for sling work.
40 141.6 14.4
3) Operate the hoist at a safe place.
4) Check the direction indicator plates (east, 50 221.6 22.6
west, south, and north) and the directions 60 318.3 32.4
of the control buttons without fail.
5) Do not sling a load slantingly. Do not move a The allowable load is one-sixth of the
the crane while the slung load is swinging. breaking strength of the rope used
6) Do not raise or lower a load while the (Safety coefficient: 6).
crane is moving longitudinally or laterally.
7) Do not drag a sling.
8) When lifting up a load, stop it just after it
leaves the ground and check safety, and
then lift it up.
9) Consider the travel route in advance and
lift up a load to a safe height.
10) Place the control switch on a position
where it will not be an obstacle to work
and passage.
11) After operating the hoist, do not swing the
control switch.
12) Remember the position of the main switch
so that you can turn off the power immedi-
ately in an emergency.
PC228US, USLC-3E0 5
8. Precautions for disconnecting and con- a Example of O-ring (Fitted to every joint of
necting hoses and tubes in air conditioner hoses and tubes)
circuit
1) Disconnection
k For the environment, the air condi-
tioner of this machine uses the
refrigerant (air conditioner gas:
R134a) which has fewer factors of
the depletion of the ozone layer.
However, it does not mean that you
may discharge the refrigerant into
the atmosphere as it is. Be sure to
recover the refrigerant when dis-
connecting the refrigerant gas cir-
cuit and then reuse it.
a Ask professional traders for collecting a For tightening torque, see the precautions for
and filling operation of refrigerant installation in each section of "Disassembly
(R134a). and assembly".
a Never release the refrigerant (R134a)
to the atmosphere.
k If the refrigerant gas gets in your
eyes or contacts your skin, you
may lose your sight and your skin
may be frozen. Accordingly, put
on safety glasses, safety gloves
and safety clothes when recover-
ing or adding the refrigerant.
Refrigerant gas must be recovered
and added by a qualified person.
2) Connection
1] When installing the air conditioner cir-
cuit hoses and tubes, take care that
dirt, dust, water, etc. will not enter
them.
2] When connecting the air conditioner
hoses and tubes, check that O-rings
(1) are fitted to their joints.
3] Check that each O-ring is not dam-
aged or deteriorated.
4] When connecting the refrigerant pip-
ing, apply compressor oil for refriger-
ant (R134a) (DENSO: ND-OIL8,
VA L E O T H E R M A L S Y S T E M S :
ZXL100PG (equivalent to PAG46))
to its O-rings.
6 PC228US, USLC-3E0
How to read the shop manual 1
q Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one
of them is required, consult KOMATSU distributors.
q Materials and specifications are subject to change without notice.
q Shop manuals are divided into the “Chassis volume” and “Engine volume”. For the engine unit, see the
engine volume of the engine model mounted on the machine.
1. Composition of shop manual

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

This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification
This section explains the specifications of the machine.
10. Structure, function and maintenance standard

This section explains the structure, function, and maintenance standard values of each component.
The structure and function sub-section explains the structure and function of each component. It
serves not only to give an understanding of the structure, but also serves as reference material for
troubleshooting. The maintenance standard sub-section explains the criteria and remedies for dis-
assembly and service.
20. Standard value table

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

This section explains measuring instruments and measuring methods for testing and adjusting, and
method of adjusting each part. The standard values and judgement criteria for testing and adjusting
are explained in Testing and adjusting.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is
divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also
explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly

This section explains the special tools and procedures for removing, installing, disassembling, and
assembling each component, as well as precautions for them. In addition, tightening torque and
quantity and weight of coating material, oil, grease, and coolant necessary for the work are also
explained.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
q Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q Engine volume
This section explains the method of reproducing, repairing, and replacing parts.
2. Revision and distribution

Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most
up-to-date information before you start any work.
PC228US, USLC-3E0 7
3. Filing method
File by the brochures in the correct order of the form number printed in the shop manual composition
table.
q Revised edition mark

When a manual is revised, the ones and tens digits of the form number of each brochure is
increased by 1. (Example: 00, 01, 02 …)
q Revisions
Revised brochures are shown in the shop manual composition table.
4. Symbols
Important safety and quality portions are marked with the following symbols so that the shop manual will
be used practically.
Symbol Item Remarks
k Safety Special safety precautions are necessary when performing work.
Special technical precautions or other precautions for preserving stan-

a Caution
dards are necessary when performing work.
4
Weight of parts of component or parts. Caution necessary when
Weight
selecting hoisting wire, or when working posture is important, etc.
3
Tightening Places that require special attention for tightening torque during
torque assembly.
2 Coat Places to be coated with adhesives, etc. during assembly.
5
Oil, coolant Places where oil, etc. must be added, and capacity.
6
Drain Places where oil, etc. must be drained, and quantity to be drained.
5. Units
In this shop manual, the units are indicated with International System of units (SI). For reference, con-
ventionally used Gravitational System of units is indicated in parentheses { }.
8 PC228US, USLC-3E0
Explanation of terms for maintenance standard 1

The maintenance standard chapter explains the criteria for replacing or reusing products and parts in the
machine maintenance work. The following terms are used to explain the criteria.
1. Standard size and tolerance

q To be accurate, the finishing size of parts
is a little different from one to another.
q To specify a finishing size of a part, a tem-
porary standard size is set and an allow-
able difference from that size is indicated.
q The above size set temporarily is called
the “standard size” and the range of differ-
ence from the standard size is called the
“tolerance”.
q The tolerance with the symbols of + or – is
indicated on the right side of the standard
size.
Example:
Standard size Tolerance
–0.022
120
–0.126
a The tolerance may be indicated in the text

and a table as [standard size (upper limit
of tolerance/lower limit of tolerance)].
Example) 120 (–0.022/–0.126)
q Usually, the size of a hole and the size of

the shaft to be fitted to that hole are indi-
cated by the same standard size and dif-
ferent tolerances of the hole and shaft.
The tightness of fit is decided by the toler-
ance.
q Indication of size of rotating shaft and hole
and relationship drawing of them
Example:
Tolerance
Standard size
Shaft Hole
–0.030 +0.046
60
–0.076 +0
PC228US, USLC-3E0 9
2. Standard clearance and standard value 5. Clearance limit

q The clearance made when new parts are q Parts can be used until the clearance
assembled is called the “standard clear- between them is increased to a certain
ance“, which is indicated by the range limit. The limit at which those parts cannot
from the minimum clearance to the maxi- be used is called the “clearance limit”.
mum clearance. q If the clearance between the parts
q When some parts are repaired, the clear- exceeds the clearance limit, they must be
ance is generally adjusted to the standard replaced or repaired.
clearance.
q A value of performance and function of 6. Interference limit
new products or equivalent is called the q The allowable maximum interference
“standard value“, which is indicated by a between the hole of a part and the shaft of
range or a target value. another part to be assembled is called the
q When some parts are repaired, the value “interference limit”.
of performance/function is set to the stan- q The interference limit shows the repair
dard value. limit of the part of smaller tolerance.
q If the interference between the parts
3. Standard interference exceeds the interference limit, they must
q When the diameter of a hole of a part be replaced or repaired.
shown in the given standard size and tol-
erance table is smaller than that of the
mating shaft, the difference between those
diameters is called the “interference”.
q The range (A – B) from the difference (A)
between the minimum size of the shaft
and the maximum size of the hole to the
difference (B) between the maximum size
of the shaft and the minimum size of the
hole is the “standard interference”.
q After repairing or replacing some parts,
measure the size of their hole and shaft
and check that the interference is in the
standard range.
4. Repair limit and allowable value or allow-

able dimension
q The size of a part changes because of
wear and deformation while it is used. The
limit of changed size is called the “repair
limit”.
q If a part is worn to the repair limit, it must
be replaced or repaired.
q The performance and function of a prod-
uct lowers while it is used. A value which
the product can be used without causing a
problem is called the “allowable value” or
“allowable dimension”.
q If a product is worn to the allowable value,
it must be checked or repaired. Since the
permissible value is estimated from vari-
ous tests or experiences in most cases,
however, it must be judged after consider-
ing the operating condition and customer's
requirement.
Handling of electric equipment and hydraulic component 1

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 gear oil and hydraulic oil).
Points to remember when handling electric

equipment
1. Handling wiring harnesses and connectors
Wiring harnesses consist of wiring connecting
one component to another component, con-
nectors used for connecting and disconnecting
one wire from another wire, and protectors or
tubes used for protecting the wiring.
Compared with other electrical components fit-
ted in boxes or cases, wiring harnesses are
more likely to be affected by the direct effects
of rain, water, heat, or vibration. Furthermore,
during inspection and repair operations, they
are frequently removed and installed again, so
they are likely to suffer deformation or damage.
For this reason, it is necessary to be extremely
careful when handling wiring harnesses.
2. Main failures occurring in wiring harness

1) Defective contact of connectors (defec-
tive contact between male and female)
Problems with defective contact are likely
to occur because the male connector is
not properly inserted into the female con-
nector, or because one or both of the con-
nectors is deformed or the position is not
correctly aligned, or because there is cor-
rosion or oxidization of the contact sur-
faces. The corroded or oxidized contact
surfaces may become shiny again (and
contact may become normal) by connect-
ing and disconnecting the connector about
10 times.
2) Defective crimping or soldering of connec-

tors
The pins of the male and female connec-
tors are in contact at the crimped terminal
or soldered portion, but if there is exces-
sive force brought to bear on the wiring,
the plating at the joint will peel and cause
improper connection or breakage.
3) 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 connector may separate, or the sol-
dering may be damaged, or the wiring
may be broken.
4) High-pressure water entering connector

The connector is designed to make it diffi-
cult for water to enter (drip-proof struc-
ture), but if high-pressure water is sprayed
directly on the connector, water may enter
the connector, depending on the direction
of the water jet. Accordingly, take care not
to splash water over the connector. The
connector is designed to prevent water
from entering, but at the same time, if
water does enter, it is difficult for it to be
drained. Therefore, if water should get into
the connector, the pins will be short-cir-
cuited by the water, so if any water gets in,
immediately dry the connector or take
other appropriate action before passing
electricity through it.
5) Oil or dirt stuck to connector

If oil or grease are stuck to the connector
and an oil film is formed on the mating sur-
face 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 stuck to the connector, wipe it
off with a dry cloth or blow it dry with com-
pressed air and spray it with a contact
restorer.
a When wiping the mating portion of the
connector, be careful not to use
excessive force or deform the pins.
a If there is oil or water in the com-
pressed air, the contacts will become
even dirtier, so remove the oil and
water from the compressed air com-
pletely before cleaning with com-
pressed air.
3. Removing, installing, and drying connec-

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

q Both of the connector and clip have
stoppers, which are engaged with
each other when the connector is
installed.
q When removing a connector from a

clip, pull the connector in a parallel
direction to the clip for removing stop-
pers.
a If the connector is twisted up and
down or to the left or right, the
housing may break.
3] Action to take after removing connec-

tors
After removing any connector, cover it
with a vinyl bag to prevent any dust,
dirt, oil, or water from getting in the
connector portion.
a If the machine is left disassem-
bled for a long time, it is particu-
larly easy for improper contact to
occur, so always cover the con-
nector.
2) Connecting connectors
1] Check the connector visually.
Check that there is no oil, dirt, or
water stuck to the connector pins
(mating portion).
Check that there is no deformation,
defective contact, corrosion, or dam-
age to the connector pins.
Check that there is no damage or
breakage to the outside of the con-
nector.
a If there is any oil, water, or dirt
stuck to the connector, wipe it off
with a dry cloth. If any water has
got inside the connector, warm
the inside of the wiring with a
dryer, but be careful not to make
it too hot as this will cause short
circuits.
a If there is any damage or break-
age, replace the connector.
2] Fix the connector securely.
Align the position of the connector
correctly, and then insert it securely.
For connectors with the lock stopper,
push in the connector until the stop-
per clicks into position.
3] Correct any protrusion of the boot and
any misalignment of the wiring har-
ness.
For connectors fitted with boots, cor-
rect any protrusion of the boot. In
addition, if the wiring harness is mis-
aligned, or the clamp is out of posi-
tion, adjust it to its correct position.
a If the connector cannot be cor-
rected easily, remove the clamp
and adjust the position.
q If the connector clamp has been
removed, be sure to return it to
its original position. Check also
that there are no loose clamps.
3) Heavy duty wire connector (DT 8-pole, 12- q Disconnection q Connection (Example of
pole) incomplete setting of (a))
Disconnection (Left of figure)
While pressing both sides of locks (a)
and (b), pull out female connector (2).
Connection (Right of figure)
1] Push in female connector (2) horizon-
tally until the lock clicks.
Arrow: 1)
2] Since locks (a) and (b) may not be set
completely, push in female connector
(2) while moving it up and down until
the locks are set normally.
Arrow: 1), 2), 3)
a Right of figure: Lock (a) is pulled
down (not set completely) and
lock (b) is set completely.
(1): Male connector
(2): Female connector
(a), (b): Locks
4) Drying wiring harness

If there is any oil or dirt on the wiring har-
ness, 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.
1] Disconnect the connector and wipe
off the water with a dry cloth.
a If the connector is blown dry with
compressed air, there is the risk
that oil in the air may cause
defective contact, so remove all
oi l a nd wa ter fr om th e c om -
pressed air before blowing with
air.
2] Dry the inside of the connector with a
dryer.
If water gets inside the connector, use
a dryer to dry the connector.
a Hot air from the dryer can be
used, but regulate the time that
the hot air is used in order not to
make the connector or related
parts too hot, as this will cause
deformation or damage to the
connector.
3] Carry out a continuity test on the con-
nector.
After drying, leave the wiring harness
disconnected and carry out a continu-
ity test to check for any short circuits
between pins caused by water.
a After completely drying the con-
n e c t o r, b l o w i t w i t h c o n ta c t
restorer and reassemble.
4. Handling controller
1) The controller 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 controller.
2) Do not place objects on top of the control-
ler.
3) Cover the control connectors with tape or
a vinyl bag. Never touch the connector
contacts with your hand.
4) During rainy weather, do not leave the
controller in a place where it is exposed to
rain.
5) Do not place the controller on oil, water, or
soil, or in any hot place, even for a short
time. (Place it on a suitable dry stand).
6) Precautions when carrying out arc welding
When carrying out arc welding on the
body, disconnect all wiring harness con-
nectors connected to the controller. Fit an
arc welding ground close to the welding
point.
5. Points to remember when troubleshooting

electric circuits
1) Always turn the power OFF before discon-
necting or connecting connectors.
2) Before carrying out troubleshooting, check
that all the related connectors are properly
inserted.
a Disconnect and connect the related
connectors several times to check.
3) Always connect any disconnected con-
nectors before going on to the next step.
a If the power is turned ON with the
connectors still disconnected, unnec-
essary abnormality displays will be
generated.
4) When carrying out troubleshooting of cir-
cuits (measuring the voltage, resistance,
continuity, or current), move the related
wiring and connectors several times and
check that there is no change in the read-
ing of the tester.
a If there is any change, there is proba-
bly defective contact in that circuit.
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 circuit. When adding hydraulic oil, or when disassembling 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 check 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 dustproof workshop, and the perfor-
mance should be checked with special test
equipment.
3. Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from
entering. If the opening is left open or is
blocked with a rag, there is danger of dirt
entering or of the surrounding area being
made dirty by leaking oil so never do this. Do
not simply drain oil out onto the ground, but
collect it and ask the customer to dispose of it,
or take it back with you for disposal.
4. 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 more effective method.
5. Change hydraulic oil when the temperature

is high
When hydraulic oil or other oil is warm, it flows
easily. In addition, the sludge can also be
drained out easily from the circuit together with
the oil, so it is best to change the oil when it is
still warm. When changing the oil, as much as
possible of the old hydraulic oil must be
drained out. (Drain the oil from the hydraulic
tank; also drain the oil from the filter and from
the drain plug 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 secondary 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 cir-
cuit. The oil cleaning equipment is used to
remove the ultra fine (about 3 m) particles that
the filter built in the hydraulic equipment can-
not remove, so it is an extremely effective
device.
Handling of connectors newly used for engines 1

a Mainly, following engines are object for follow- 2. Pull lock type (PACKARD-2)
ing connectors. q 95 – 170, 12V140 engines
q 95E-5 q Various temperature sensors
q 107E-1 Example)
q 114E-3 Intake air temperature sensor in
q 125E-5 intake manifold: TIM
q 140E-5 Fuel temperature sensor: TFUEL
q 170E-5 Oil temperature sensor: TOIL
q 12V140E-3 Coolant temperature sensor: TWTR,
etc.
1. Slide lock type Disconnect the connector by pulling lock
(FRAMATOME-3, FRAMATOME-2) (B) (on the wiring harness side) of connec-
q 95 – 170, 12V140 engines tor (2) outward.
q Various pressure sensors and NE
speed sensor
Examples)
Intake air pressure sensor in intake
manifold: PIM
(125, 170, 12V140 engines)
Oil pressure sensor: POIL
(125, 170, 12V140 engines)
Oil pressure switch
(95, 107, 114 engines)
Ne speed sensor of flywheel housing:
NE (95 – 170, 12V140 engines)
Ambient pressure sensor: PAMB
(125, 170, 12V140 engines)
Disconnect connector (1) according to the fol-

lowing procedure.
1) Slide lock (L1) to the right.
2) While pressing lock (L2), pull out connec-
tor (1) toward you.
a Even if lock (L2) is pressed, connec-
tor (1) cannot be pulled out toward
you, if part A does not float. In this
case, float part A with a small screw-
driver while press lock (L2), and then
pull out connector (1) toward you.
3. Push lock type

q 95, 107, 114 engines
Example)
Fuel pressure sensor in common rail
(BOSCH-03)
Disconnect connector (3) according to the fol-

lowing procedure.
1) While pressing lock (C), pull out connector
(3) in the direction of the arrow.
q 114 engine
q 107, 114 engines

Example)
Intake air pressure/temperature sensor in
intake manifold
(SUMITOMO-04)
3) While pressing lock (D), pull out connector

(4) in the direction of the arrow.
q 107 engine
a If the lock is on the underside, use

flat-head screwdriver [1] since you
cannot insert your fingers.
2) While pressing up lock (C) of the connec-
tor with flat-head screwdriver [1], pull out
connector (3) in the direction of the arrow.
q 95, 125 – 170, 12V140 engines 4. Turn-housing type (Round green connector)
4) While pressing lock (E) of the connector, q 140 engine
pull out connector (5) in the direction of Example)
the arrow. Intake air pressure sensor in intake mani-
fold (CANNON-04): PIM etc.
Example)
Fuel pressure sensor in common rail: 1) Disconnect connector (6) according to the
PFUEL etc. (AMP-3) following procedure.
1] Turn housing (H1) in the direction of
the arrow.
a When connector is unlocked,
housing (H1) becomes heavy to
turn.
2] Pull out housing (H1) in the direction
of the arrow.
a Housing (H1) is left on the wiring har-
ness side.
Example)
Injection pressure control valve of fuel
supply pump: PCV (SUMITOMO-2)
2) Connect the connector according to the

following procedure.
1] Insert the connector to the end, while
setting its groove.
2] Turn housing (H1) in the direction of
the arrow until it “clicks”.
Example)
Speed sensor of fuel supply pump:
G (SUMITOMO-3)
a Pull the connector straight up.
How to read electric wire code 1

a The information about the wires unique to each machine model is described in Troubleshooting section,
Relational information of troubleshooting.
In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by sym-
bols. The electric wire code is helpful in understanding the electric circuit diagram.
Example: AEX 0.85 L - - - Indicates blue, heat-resistant, low-voltage wire for automobile, having nomi-
nal No. of 0.85
Indicates color of wire by color code.
Color codes are shown in Table 3.
Indicates size of wire by nominal No.

Size (Nominal No.) is shown in Table 2.
Indicates type of wire by symbol.

Type, symbol, and material of wire are shown in Table 1.
(Since AV and AVS are classified by size (nominal No.), they are not indi-
cated.)
1. Type, symbol, and material

AV and AVS are different in only thickness and outside diameter of the cover. AEX is similar to AV in
thickness and outside diameter of AEX and different from AV and AVS in material of the cover.
(Table 1)
Using
Sym-
Type Material temperature Example of use
bol
range (°C)
Low-voltage Conduc- Annealed copper for elec-
General wiring
wire for AV tor tric appliance
(Nominal No. 5 and above)
automobile Insulator Soft polyvinyl chloride
Thin-cover Conduc- Annealed copper for elec- –30 to +60
low-voltage tor tric appliance General wiring
AVS
wire for (Nominal No. 3 and below)
automobile Insulator Soft polyvinyl chloride
Heat-resis- Conduc- Annealed copper for elec-
General wiring in extremely
tant low-volt- tor tric appliance
AEX –50 to +110 cold district, wiring at high-tem-
age wire for Heat-resistant crosslinked
Insulator perature place
automobile polyethylene
2. Dimensions
(Table 2)
Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5
Number of
strands/Diam- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32
eter of strand
Conductor
Sectional
0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23
area (mm2)
d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0
AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6 –
Cov-
AV Standard – – – – – – – 4.6
er D
AEX Standard 2.0 2.2 2.7 3.0 3.1 – 3.8 4.6
Nominal No. 8 15 20 30 40 50 60 85 100

Number of
strands/Diam- 50/0.45 84/0.45 41/0.80 70/0.80 85/0.80 108/0.80 127/0.80 169/0.80 217/0.80
eter of strand
Conductor
Sectional
7.95 13.36 20.61 35.19 42.73 54.29 63.84 84.96 109.1
area (mm2)
d (approx.) 3.7 4.8 6.0 8.0 8.6 9.8 10.4 12.0 13.6
AVS Standard – – – – – – – – –
Cov-
AV Standard 5.5 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
er D
AEX Standard 5.3 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
“f” of nominal No. denotes flexible”.
3. Color codes table
(Table 3)
Color Code Color of wire Color Code Color of wire
B Black LgW Light green & White
Br Brown LgY Light green & Yellow
BrB Brown & Black LR Blue & Red
BrR Brown & Red LW Blue & White
BrW Brown & White LY Blue & Yellow
BrY Brown & Yellow O Orange
Ch Charcoal P Pink
Dg Dark green R Red
G Green RB Red & Black
GB Green & Black RG Red & Green
GL Green & Blue RL Red & Blue
Gr Gray RW Red & White
GR Green & Red RY Red & Yellow
GW Green & White Sb Sky Blue
GY Green & Yellow Y Yellow
L Blue YB Yellow & Black
LB Blue & Black YG Yellow &Green
Lg Light green YL Yellow & Blue
LgB Light green & Black YR Yellow & Red
LgR Light green & Red YW Yellow & White
Remarks: In a color code consisting of 2 colors, the first color is the color of the background and
the second color is the color of the marking.
Example: “GW” means that the background is Green and marking is White.
4. Types of circuits and color codes
(Table 4)
Type of wire AVS or AV AEX
Charge R WG – – – – R –
Ground B – – – – – B –
Start R – – – – – R –
Light RW RB RY RG RL – D –
Instrument Y YR YB YG YL YW Y Gr
Signal G GW GR GY GB GL G Br
L LW LR LY LB – L –
Type of
Br BrW BrR BrY BrB – – –
circuit
Lg LgR LgY LgB LgW – – –
O – – – – – – –
Others Gr – – – – – – –
P – – – – – – –
Sb – – – – – – –
Dg – – – – – – –
Ch – – – – – – –
Precautions when carrying out operation 1

[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general
precautions given below when carrying out the operation.]
1. Precautions when carrying out removal work

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

Nominal
Flange (hose end) Sleeve head (tube end) Split flange
number
04 07379-00400 07378-10400 07371-30400
05 07379-00500 07378-10500 07371-30500
3) If the part is not under hydraulic pressure, the following corks can be used.
Nominal Dimensions
Part 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
2. Precautions when carrying out installation work

q Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
q Install the hoses without twisting or interference and fix them with intermediate clamps, if there are any.
q Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
q Bend the cotter pins and lock plates securely.
q When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded por-
tion with 2 – 3 drops of adhesive.
q 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.
q Clean all parts, and correct any damage, dents, burrs, or rust.
q Coat rotating parts and sliding parts with engine oil.
q When press fitting parts, coat the surface with anti-friction compound (LM-P).
q After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
q When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect
securely.
q When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align
the direction of the hook.
q When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
a When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other
hydraulic equipment removed for repair, always bleed the air as follows:
1) Start the engine and run at low idle.
2) Operate the work equipment control lever to operate the hydraulic cylinder 4 – 5 times, stopping the
cylinder 100 mm from the end of its stroke.
3) Next, operate the hydraulic cylinder 3 – 4 times to the end of its stroke.
4) After doing this, run the engine at normal speed.
a When using the machine for the first time after repair or long storage, follow the same procedure.
3. Precautions when completing the operation

1) Refilling with coolant, oil and grease
q If the coolant has been drained, tighten the drain valve, and add coolant to the specified level.
Run the engine to circulate the coolant through the system. Then check the coolant level
again.
q If the hydraulic equipment has been removed and installed again, add engine oil to the speci-
fied level. Run the engine to circulate the oil through the system. Then check the oil level
again.
q If the piping or hydraulic equipment have been removed, always bleed the air from the system
after reassembling the parts.
a For details, see Testing and adjusting, “Bleeding air”.
q Add the specified amount of grease (molybdenum disulphide grease) to the work equipment
parts.
2) Checking cylinder head and manifolds for looseness
Check the cylinder head and intake and exhaust manifold for looseness.
If any part is loosened, retighten it.
q For the tightening torque, see “Disassembly and assembly”.
3) Checking engine piping for damage and looseness
Intake and exhaust system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for air
suction and exhaust gas leakage.
If any part is loosened or damaged, retighten or repair it.
Cooling system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for
coolant leakage.
Fuel system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for fuel
leakage.
4) Checking muffler and exhaust pipe for damage and looseness

1] Visually check the muffler, exhaust pipe and their mounting parts for a crack and damage.
If any part is damaged, replace it.
2] Check the mounting bolts and nuts of the muffler, exhaust pipe and their mounting parts for
looseness.
If any bolt or nut is loosened, retighten it.
5) Checking muffler function
Check the muffler for abnormal sound and sound different from that of a new muffler.
If any abnormal sound is heard, repair the muffler, referring to “Troubleshooting” and “Disassembly
and assembly”.
Method of disassembling and connecting push-pull type coupler 1

k Before carrying out the following work, loosen the oil filler cap of the hydraulic tank gradually to
release the residual pressure from the 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.
Type 1
1. Disconnection
1) Hold adapter (1) and push hose joint (2)
into mating adapter (3). (Fig. 1)
a The adapter can be pushed in about
3.5 mm.
a Do not hold rubber cap portion (4).
2) After hose joint (2) is pushed into adapter
(3), press rubber cap portion (4) against
adapter (3) until it clicks. (Fig. 2)
3) Hold hose adapter (1) or hose (5) and pull
it out. (Fig. 3)
a Since some hydraulic oil flows out,
prepare an oil receiving container.
2. Connection
1) Hold hose adapter (1) or hose (5) and
insert it in mating adapter (3), aligning
them with each other. (Fig. 4)
a Do not hold rubber cap portion (4).
2) After inserting the hose in the mating
adapter perfectly, pull it back to check its
connecting condition. (Fig. 5)
a When the hose is pulled back, the
rubber cap portion moves toward the
hose about 3.5 mm. This does not
indicate abnormality, however.
Type 2
1. Disconnection
1) Hold the tightening portion and push body
(7) straight until sliding prevention ring (6)
contacts contact surface (a) of the hexag-
onal portion at the male end. (Fig. 6)
2) While holding the condition of Step 1), turn
lever (8) to the right (clockwise). (Fig. 7)
3) While holding the condition of Steps 1)
and 2), pull out whole body (7) to discon-
nect it. (Fig. 8)
2. Connection
q Hold the tightening portion and push body
contacts contact surface (a) of the hexag-
Type 3
1. Disconnection
1) Hold the tightening portion and push body
contacts contact surface (b) of the hexag-
2) While holding the condition of Step 1),
push cover (10) straight until it contacts
contact surface (b) of the hexagonal por-
tion at the male end. (Fig. 11)
3) While holding the condition of Steps 1)
and 2), pull out whole body (9) to discon-
nect it. (Fig. 12)
2. Connection
q Hold the tightening portion and push body
(9) straight until the sliding prevention ring
contacts contact surface (b) of the hexag-
Standard tightening torque table 1

1. Table of tightening torques for bolts and nuts
a Unless there are special instructions, tighten metric nuts and bolts to the torque below.
a The following table applies to the bolts in Fig. A.
Thread diameter of bolt Width across flats Tightening torque

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 6.0 – 7.5
12 19 98 – 123 10.0 – 12.5
14 22 157 – 196 16 – 20
16 24 245 – 309 25 – 31.5
18 27 343 – 427 35 – 43.5
20 30 490 – 608 50 – 62
22 32 662 – 829 67.5 – 84.5
24 36 824 – 1,030 84 – 105
27 41 1,180 – 1,470 120 – 150
30 46 1,520 – 1,910 155 – 195
33 50 1,960 – 2,450 200 – 250
36 55 2,450 – 3,040 250 – 310
39 60 2,890 – 3,630 295 – 370
a The following table applies to the bolts in Fig. B.

mm mm Nm kgm
6 10 5.9 – 9.8 0.6 – 1.0
8 12 13.7 – 23.5 1.4 – 2.4
10 14 34.3 – 46.1 3.5 – 4.7
12 17 74.5 – 90.2 7.6 – 9.2
a Fig. A a Fig. B
Remarks: The widths across flats against the thread diameters of flanged bolts (marks with "*") in Fig. A are
the ones indicated in the table for bolts shown in Fig. B.
(Values of tightening torques shown in the table for Fig. A are applied.)
2. Table of tightening torques for split flange bolts

a Unless there are special instructions, tighten split flange bolts to the torque below.

mm mm Nm kgm
10 14 59 – 74 6.0 – 7.5
12 17 98 – 123 10.0 – 12.5
16 22 235 – 285 23.5 – 29.5
3. Table of tightening torques for O-ring boss piping joints

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

Nominal 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 connec- 128 – 186 {13.0 – 19.0} 157 {16.0}
10,12 33 tor. 363 – 480 {37.0 – 49.0} 422 {43.0}
14 42 746 – 1,010 {76.0 – 103} 883 {90.0}
4. Table of tightening torques for O-ring boss plugs

a Unless there are special instructions, tighten O-ring boss plugs to the torque below.
Nominal Thread diameter Width across flats Tightening torque Nm {kgm}

No. mm mm Range Target
08 8 14 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75}
10 10 17 9.81 – 12.74 {1.0 – 1.3} 11.27 {1.15}
12 12 19 14.7 – 19.6 {1.5 – 2.0} 17.64 {1.8}
14 14 22 19.6 – 24.5 {2.0 – 2.5} 22.54 {2.3}
16 16 24 24.5 – 34.3 {2.5 – 3.5} 29.4 {3.0}
18 18 27 34.3 – 44.1 {3.5 – 4.5} 39.2 {4.0}
20 20 30 44.1 – 53.9 {4.5 – 5.5} 49.0 {5.0}
24 24 32 58.8 – 78.4 {6.0 – 8.0} 68.6 {7.0}
30 30 32 93.1 – 122.5 { 9.5 – 12.5} 107.8 {11.0}
33 33 – 107.8 – 147.0 {11.0 – 15.0} 127.4 {13.0}
36 36 36 127.4 – 176.4 {13.0 – 18.0} 151.9 {15.5}
42 42 – 181.3 – 240.1 {18.5 – 24.5} 210.7 {21.5}
52 52 – 274.4 – 367.5 {28.0 – 37.5} 323.4 {33.0}
5. Table of tightening torques for hoses (taper seal type and face seal type)
a Unless there are special instructions, tighten the hoses (taper seal type and face seal type) to the
torque below.
a Apply the following torque when the threads are coated (wet) with engine oil.
Tightening torque Nm {kgm} Taper seal Face seal

Nominal Width Nominal No. –
No. of across Thread
Thread size Number of
hose flats Range Target diameter (mm)
(mm) threads, type of
(Reference)
thread
34 – 54 { 3.5 – 5.5} – 9/16-18UN 14.3
02 19 44 { 4.5}
34 – 63 { 3.5 – 6.5} 14 – –
22 54 – 93 { 5.5 – 9.5} 74 { 7.5} – 11/16-16UN 17.5
03
24 59 – 98 { 6.0 – 10.0} 78 { 8.0} 18 – –
04 27 84 – 132 { 8.5 – 13.5} 103 {10.5} 22 13/16-16UN 20.6
05 32 128 – 186 {13.0 – 19.0} 157 {16.0} 24 1-14UNS 25.4
06 36 177 – 245 {18.0 – 25.0} 216 {22.0} 30 1-3/16-12UN 30.2
(10) 41 177 – 245 {18.0 – 25.0} 216 {22.0} 33 – –
(12) 46 197 – 294 {20.0 – 30.0} 245 {25.0} 36 – –
(14) 55 246 – 343 {25.0 – 35.0} 294 {30.0} 42 – –
6. Table of tightening torques for face seal joints

a Tighten the face seal joints (sleeve nut type) made of plated steel pipes for low pressure service to
be used for engines etc. to the torque shown in the following table.
a Apply the following torque to the face seal joint while their threaded parts are coated with engine oil
(wetted).
Outer Width Tightening torque Nm {kgm} Face seal

diameter across Nominal No. – Thread diameter
of pipe flats Range Target Number of threads, (mm)
(mm) (mm) type of thread (Reference)
8 19 14 – 16 {1.4 – 1.6} 15 {1.5} 9/16-18UN 14.3
10 22 24 – 27 {2.4 – 2.7} 25.5 {2.6} 11/16-16UN 17.5
12 24 (27) 43 – 47 {4.4 – 4.8} 45 {4.6} 13/16-16UN 20.6
15 (16) 30 (32) 60 – 68 {6.1 – 6.8} 64 {6.5} 1-14UN 25.4
22 (20) 36 90 – 95 {9.2 – 9.7} 92.5 {9.4} 1-3/16-12UN 30.2
Reference: The face seal joints of the dimensions in ( ) are also used, depending on the specification.
7. Table of tightening torques for 102, 107 and 114 engine series (Bolts and nuts)
a Unless there are special instructions, tighten the metric bolts and nuts of the 102, 107 and 114
engine series to the torque below.
Tightening torque
Thread size
Bolts and nuts
mm Nm kgm
6 10 ± 2 1.02 ± 0.20
8 24 ± 4 2.45 ± 0.41
10 43 ± 6 4.38 ± 0.61
12 77 ± 12 7.85 ± 1.22
14 — —
8. Table of tightening torques for 102, 107 and 114 engine series (Eye joints)
a Unless there are special instructions, tighten the metric eye joints of the 102, 107 and 114 engine
series to the torque below.
Thread size Tightening torque

mm Nm kgm
6 8±2 0.81 ± 0.20
8 10 ± 2 1.02 ± 0.20
10 12 ± 2 1.22 ± 0.20
12 24 ± 4 2.45 ± 0.41
14 36 ± 5 3.67 ± 0.51
9. Table of tightening torques for 102, 107 and 114 engine series (Taper screws)
a Unless there are special instructions, tighten the taper screws (unit: inch) of the 102, 107 and 114
engine series to the torque below.
Tightening torque
Material In cast iron or steel In aluminum
Thread size (inch) Nm kgm Nm kgm
1/16 15 ± 2 1.53 ± 0.20 5±1 0.51 ± 0.10
1/8 20 ± 2 2.04 ± 0.20 15 ± 2 1.53 ± 0.20
1/4 25 ± 3 2.55 ± 0.31 20 ± 2 2.04 ± 0.20
3/8 35 ± 4 3.57 ± 0.41 25 ± 3 2.55 ± 0.31
1/2 55 ± 6 5.61 ± 0.61 35 ± 4 3.57 ± 0.41
3/4 75 ± 8 7.65 ± 0.82 45 ± 5 4.59 ± 0.51
Conversion table 1
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), and then draw a hori-
zontal line from (A).
2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line
down from (B).
3) Take the point where the 2 lines cross as (C). This point (C) gives the value when converting from
millimeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.

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

1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
(C)
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
(A)
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 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
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
Liters to U.S. Gallons

1 l = 0.2642 U.S.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
Liters to U.K. Gallons

1 l = 0.21997 U.K.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.699 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
kgm to ft.lb
1 kgm = 7.233 ft.lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
kg/cm2 to lb/in2
1 kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1,010 1,024 1,038 1,053 1,067 1,081 1,095 1,109 1,124
80 1,138 1,152 1,166 1,181 1,195 1,209 1,223 1,237 1,252 1,266
90 1,280 1,294 1,309 1,323 1,337 1,351 1,365 1,380 1,394 1,408
100 1,422 1,437 1,451 1,465 1,479 1,493 1,508 1,522 1,536 1,550
110 1,565 1,579 1,593 1,607 1,621 1,636 1,650 1,664 1,678 1,693
120 1,707 1,721 1,735 1,749 1,764 1,778 1,792 1,806 1,821 1,835
130 1,849 1,863 1,877 1,892 1,906 1,920 1,934 1,949 1,963 1,977
140 1,991 2,005 2,020 2,034 2,048 2,062 2,077 2,091 2,105 2,119
150 2,134 2,148 2,162 2,176 2,190 2,205 2,219 2,233 2,247 2,262
160 2,276 2,290 2,304 2,318 2,333 2,347 2,361 2,375 2,389 2,404
170 2,418 2,432 2,446 2,460 2,475 2,489 2,503 2,518 2,532 2,546
180 2,560 2,574 2,589 2,603 2,617 2,631 2,646 2,660 2,674 2,688
190 2,702 2,717 2,731 2,745 2,759 2,773 2,788 2,802 2,816 2,830
200 2,845 2,859 2,873 2,887 2,901 2,916 2,930 2,944 2,958 2,973
210 2,987 3,001 3,015 3,030 3,044 3,058 3,072 3,086 3,101 3,115
220 3,129 3,143 3,158 3,172 3,186 3,200 3,214 3,229 3,243 3,257
230 3,271 3,286 3,300 3,314 3,328 3,343 3,357 3,371 3,385 3,399
240 3,414 3,428 3,442 3,456 3,470 3,485 3,499 3,513 3,527 3,542
Temperature
Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centi-
grade temperature reading or vice versa is to enter the accompanying table in the center (boldface column)
of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
When convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of Fahren-
heit temperatures and read the corresponding Centigrade temperature in the column at the left.
When convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of Centi-
grade values, and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8°F
°C °F °C °F °C °F °C °F
–40.4 –40 –40.0 –11.7 11 51.8 7.8 46 114.8 27.2 81 177.8
–37.2 –35 –31.0 –11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
–34.4 –30 –22.0 –10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
–31.7 –25 –13.0 –10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
–28.9 –20 –4.0 –9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
–28.3 –19 –2.2 –8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

–27.8 –18 –0.4 –8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
–27.2 –17 1.4 –7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
–26.7 –16 3.2 –7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
–26.1 –15 5.0 –6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
–25.6 –14 6.8 –6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

–25.0 –13 8.6 –5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
–24.4 –12 10.4 –5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
–23.9 –11 12.2 –4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
–23.3 –10 14.0 –3.9 25 77.0 15.6 60 140.0 35.0 95 203.0
–22.8 –9 15.8 –3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

–22.2 –8 17.6 –2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
–21.7 –7 19.4 –2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
–21.1 –6 21.2 –1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
–20.6 –5 23.0 –1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
–20.0 –4 24.8 –0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

–19.4 –3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
–18.9 –2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
–18.3 –1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
–17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
–17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0

–16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
–16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
–15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
–15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
–14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

–13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
–13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
–12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
–12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
SEN01421-02

© 2009 KOMATSU
All Rights Reserved
Printed in Japan 01-09 (01)
42
SEN01423-01
PC228US-3E0
PC228USLC-3E0

01 Specification 1
Specification and technical data
Specification dimension drawings ................................................................................................................... 2
Working range diagram................................................................................................................................... 3
Specifications .................................................................................................................................................. 4
Weight table .................................................................................................................................................... 6
Table of fuel, coolant and lubricants................................................................................................................ 8
PC228US, USLC-3E0 1
SEN01423-01 01 Specification
Specification dimension drawings 1
Check item Unit PC228US-3E0 PC228USLC-3E0

A Overall length mm 8,700 8,890
B Overall height mm 3,035 3,035
C Overall width mm 2,800 3,080
D Shoe width mm 600 700
E Cab height mm 3,035 3,035
F Tail swing radius mm 1,680 1,680
G Overall track length mm 4,070 4,450
Length of track on
H mm 3,275 3,655
ground
J Min. ground length mm 440 440
2 PC228US, USLC-3E0
Working range diagram 1
Check item Unit PC228US-3E0 PC228USLC-3E0

A Max. digging reach mm 9,875 9,875
B Max. digging depth mm 6,620 6,620
C Max. digging height mm 10,700 10,700
Max. vertical wall dig-
D mm 5,980 5,980
ging depth
E Max. dumping height mm 7,825 7,825
F Min. dumping height mm 2,940 2,940
Max. reach at ground
G mm 9,700 9,700
level
PC228US, USLC-3E0 3
Specifications 1
Machine model PC228US-3E0 PC228USLC-3E0

Serial number 40001 and up
3
Bucket capacity m 0.8 0.8
Operating weight kg 21,500 22,800
Max. digging depth mm 6,620 6,620
Working range
Max. vertical wall digging depth mm 5,980 5,980

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

Max. digging force (when power max. 138.0 {14,100} 138.0 {14,100}
kN {kg}
function is turned on) (149.0 {15,200}) (149.0 {15,200})
Swing speed rpm 11.0 11.0
Swing operation max. slope angle degree 20 20
Travel speed km/h Lo: 3.0 Mi: 4.1 Hi: 5.5 Lo: 3.0 Mi: 4.1 Hi: 5.5
Gradability degree 35 35
2
Ground pressure (Standard shoe) kPa {kg/cm } 49.0 {0.50} 40.0 {0.41}
Overall length mm 8,700 8,890
Overall width mm 2,980 3,080
Overall crawler width mm 2,800 3,080
Overall height (During transportation) (*) mm 3,035 3,035
Machine body overall height (*) mm 3,035 3,035
Ground clearance of upper structure
mm 1,058 1,058
bottom
Dimensions
Min. ground clearance mm 440 440

Tail swing radius mm 1,680 1,680
Work equipment min. swing radius mm 2,310 2,310
Top height at min. swing radius of
mm 8,250 8,250
work equipment
Length of track on ground mm 3,275 3,655
Track gauge mm 2,200 2,380
Cab height mm 2,287 2,287
Width of standard shoe mm 600 700
Grouser height (26 mm) included.
4 PC228US, USLC-3E0

Model SAA6D107E-1
4-cycle, water-cooled in-line, direct injection with
Type
turbocharger and air-cooled aftercooler
Number of cylinders – bore x stroke mm 6 – 107 x 124
Piston displacement l {cc} 6.69 {6,690}
kW/rpm
Rated pressure 110/2,000 {148/2,000}
{HP/rpm}
Performance
Engine
Nm/rpm
Max. torque 609/1,500 {62.1/1,500}
{kgm/rpm}
High idle under no load rpm 2,060 ± 50
Low idle under no load rpm 1,050 ± 50
Min. fuel consumption ratio g/kWh{g/HPh} 215 {158}
Starting motor 24 V, 4.5 kW
Alternator 24 V, 35 A
Battery 12 V, 110 Ah x 2
Radiator type Aluminum wave 4 rows
Undercarriage
Carrier roller 2 on one side

Track roller 7 on one side 9 on one side
Assembly-type triple grosser Assembly-type triple grosser
Track shoe
45 on one side 49 on one side
Hydraulic motor Control valve Hydraulic pump
Type and numbers HPV95+95, Variable displacement piston type: 2

Delivery l/min Piston: 262 x 2
Set pressure MPa {kg/cm2} Piston: 37.2 {380}
Type and number 6-spool type + 1-spool type × 1 with 2 service valves
Operating method Hydraulic
HMV110ADT-2, piston type: 2

Travel motor
(with brake valve and parking brake)
Hydraulic system
KMF125ABE-6, piston type: 1

Swing motor
(with safety valve and parking brake)
Boom Arm (*) Bucket

Double acting Double acting Double acting
Hydraulic cylinder
Type
piston piston piston
Cylinder inner diameter mm 120 135 115
Piston rod diameter mm 85 95 80
Stroke mm 1,385 1,490 1,120
Max. pin-to-pin distance mm 3,255 3,565 2,800
Min. pin-to-pin distance mm 1,870 2,075 1,680
Hydraulic tank Closed type
Hydraulic oil filter Tank return side
Hydraulic oil cooler CF40-1 (Air-cooling type)
*: Cushions are provided on the head and bottom side
PC228US, USLC-3E0 5
Weight table 1
k This weight table is prepared for your reference when handling or transporting the components.
Unit: kg
Engine assembly 735 735
• Engine 575 575
• Damper 6 6
• Hydraulic pump 154 154
Radiator and oil cooler assembly 126 126
Hydraulic tank and filter assembly (Not including hydraulic oil) 146 146
Fuel tank assembly (Not including fuel) 131 131
Revolving frame 1,854 1,854
Cab 251 251
Operator’s seat 27 27
Counterweight 6,060 6,060
Swing machinery 224 224
Control valve 280 280
Swing motor 51.5 51.5
Travel motor 98 x 2 98 x 2
Center swivel joint 30.3 30.3
Track frame assembly (Not including piping) 4,269 4,797
• Track frame 2,260 2,644
• Swing circle 267 267
• Idler 101 x 2 101 x 2
• Idler cushion 118 x 2 118 x 2
• Carrier roller 14 x 4 14 x 4
• Track roller 36 x 14 36 x 18
• Final drive (including travel motor) 372 x 2 372 x 2
Track shoe assembly
• Standard triple shoe (600 mm) 1,215 x 2 1,395 x 2
• Flat shoe (600 mm) 1,635 x 2 1,780 x 2
• Swamp shoe (860 mm) 1,630 x 2 1,775 x 2
• Road liner (Rubber pad type) (600 mm) 1,470 x 2 1,600 x 2
6 PC228US, USLC-3E0
Unit: kg
Boom assembly 1,381 1,381
Arm assembly 633 633
Bucket assembly 632 632
Boom cylinder assembly 167 x 2 167 x 2
Arm cylinder assembly 223 223
Bucket cylinder assembly 133 133
Link (large) assembly 83 83
Link (small) assembly 22 × 2 22 × 2
Boom pin 42 + 8 × 2 + 28 + 10 + 26 42 + 8 × 2 + 28 + 10 + 26
Arm pin 12 + 8 12 + 8
Bucket pin 20 × 2 20 × 2
Link pin 13 × 2 13 × 2
PC228US, USLC-3E0 7
Table of fuel, coolant and lubricants 1

a For details of the notes (Note 1, Note 2...) in the table, see Operation and Maintenance Manual.
8 PC228US, USLC-3E0
Unit: l
PC228US-3E0, PC228USLC-3E0
Refilling points
Specified capacity Refill capacity
Engine oil pan 25.4 23.1
Swing machinery case 7.1 7.1
Final drive case (both sides) 5.4 5.2
Damper case 0.65 0.65
Hydraulic oil system 185 126
Fuel tank 320 —
Cooling system 21 —
PC228US, USLC-3E0 9
SEN01423-01

© 2007 KOMATSU
All Rights Reserved
10
SEN01425-00
PC228US-3E0
PC228USLC-3E0

10 Structure, function and

maintenance standard 1
Engine and cooling system
Engine and cooling system ............................................................................................................................. 2
Engine related parts ............................................................................................................................. 2
Radiator, oil cooler, aftercooler and fuel cooler .................................................................................... 3
PC228US, USLC-3E0 1
SEN01425-00 10 Structure, function and maintenance standard
Engine and cooling system 1

Engine related parts 1
1. Drive plate Outline

2. Torsion spring A damper assembly is wet type.
3. Stopper pin Oil capacity: 0.65 l
4. Friction plate
5. Muffler
6. Rear engine mount
7. Front engine mount
8. Damper assembly
2 PC228US, USLC-3E0
Radiator, oil cooler, aftercooler and fuel cooler 1
1. Aftercooler
2. Oil cooler
3. Radiator
4. Condenser
5. Fuel cooler
6. Cooler check valve
7. Cooler check valve block
PC228US, USLC-3E0 3
SEN01425-00

© 2006 KOMATSU
All Rights Reserved
4
SEN01426-00
PC228US-3E0
PC228USLC-3E0


Power train
Power train...................................................................................................................................................... 2
Power train ........................................................................................................................................... 2
Final drive............................................................................................................................................. 4
Swing machinery.................................................................................................................................. 6
Swing circle .......................................................................................................................................... 8
PC228US, USLC-3E0 1
Power train 1
Power train 1
1. PPC lock solenoid valve 7. Final drive

2. Travel speed switch solenoid valve 8. Travel motor (HMV110ADT-2)
3. Swing brake solenoid valve 9. Hydraulic pump (HPV95+95)
4. Idler 10. Engine (SAA6D107E-1)
5. Center swivel joint 11. Swing motor (KMF125ABE-6)
6. Control valve 12. Swing machinery
13. Swing circle
2 PC228US, USLC-3E0
Final drive 1
4 PC228US, USLC-3E0
1. Level plug
2. No. 1 planetary gear (No. of teeth: 48)
3. Drain plug
4. No. 1 sun gear (No. of teeth: 11)
5. No. 2 sun gear (No. of teeth: 20)
6. No. 1 planetary carrier
7. Cover
8. Ring gear (No. of teeth: 109, 96)
10. Retainer
11. Hub
12. Sprocket
13. Floating seal
14. Travel motor
15. No. 2 planetary gear (No. of teeth: 37)
Specifications
11+ 109 20 + 96
Reduction ratio: – 11
x 20 + 1 = – 62.273
Unit: mm
No. Check item Criteria Remedy
Backlash between No. 2 planetary carrier and Standard clearance Clearance limit
16
travel motor 0.16 – 0.53 —
Backlash between No. 2 planetary gear and
17 0.16 – 0.57 1.00
ring gear
Backlash between No. 2 sun gear and No. 2
18 0.15 – 0.49 1.00
planetary gear
Replace
19 0.16 – 0.53 1.00
ring gear
20 0.14 – 0.44 1.00
planetary gear
Backlash between No. 1 planetary carrier and
21 0.36 – 0.65 1.00
No. 2 sun gear
22 Amount of wear on sprocket tooth Repair limit: 6
Rebuild or
Standard size Repair limit
23 Width of sprocket tooth replace
71 68
PC228US, USLC-3E0 5
Swing machinery 1
6 PC228US, USLC-3E0
1. Drain plug
2. Swing pinion (No. of teeth: 13)
4. No. 2 planetary gear
5. No. 2 sun gear
7. No. 1 planetary gear
8. Swing motor
9. Oil level gauge
10. No. 1 sun gear
11. Ring gear
12. Case
Specifications
17 + 58 18 + 58
Reduction ratio: x = 18.627
17 18
Unit: mm
Backlash between swing motor shaft and No. Standard clearance Clearance limit
13
1 sun gear 0.18 – 0.28 —
14 0.16 – 0.50 1.00
planetary gear
15 0.18 – 0.59 1.10
ring gear
16 0.39 – 0.71 1.20
No. 2 sun gear
17 0.16 – 0.50 0.90
planetary gear Replace
18 0.18 – 0.59 1.00
ring gear
19 0.07 – 0.23 —
swing pinion
Backlash between swing pinion and swing cir-
20 0.22 – 1.32 2.00
cle
Clearance between plate and No. 2 planetary
21 0.66 – 1.14 —
carrier
22 Clearance between No. 2 sun gear and plate 1.66 – 2.94 —
Standard size Repair limit Apply hard
Wear of swing pinion surface contacting with chrome plating
23 0
oil seal 125 –0.100 — recondition, or
replace
PC228US, USLC-3E0 7
Swing circle 1
1. Swing circle inner race (No. of teeth: 96) Specifications

2. Ball 96
3. Swing circle outer race Reduction ratio: – = –7.385
13
Amount of grease: 14.6 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
8 PC228US, USLC-3E0
SEN01426-00

© 2006 KOMATSU
All Rights Reserved
10
SEN01427-00
PC228US-3E0
PC228USLC-3E0


Undercarriage and frame
Undercarriage and frame ................................................................................................................................ 2
Track frame .......................................................................................................................................... 2
Idler ...................................................................................................................................................... 4
Carrier roller ......................................................................................................................................... 6
Track roller ........................................................................................................................................... 7
Track shoe............................................................................................................................................ 8
PC228US, USLC-3E0 1
Undercarriage and frame 1

Track frame 1
a The following drawing indicates PC228US-3E0.
1. Idler q The dimensions and the number of track roll-

2. Track frame ers depend on the model, but the basic struc-
3. Carrier roller ture is not different.
4. Final drive q Number of track rollers
5. Track roller
Model Q'ty (One side)
6. Track shoe
7. Center guard PC228US-3E0 7
8. Front guard PC228USLC-3E0 9
2 PC228US, USLC-3E0
Standard shoe
Models
PC228US-3E0 PC228USLC-3E0
Item
Shoe width (mm) 600 700
Link pitch (mm) 190 190
Q'ty (One side) 45 49
Unit: mm
Standard size Tolerance Repair limit
Vertical width of
9 Track frame 107 — —
idler guide Build-up welding
Idler support 105 — —
or replace
Horizontal width Track frame 250 — —
10
of idler guide Idler support 247.4 — —
Free length
Installation Installation Installation
x Outside Free length
length load load
diameter
11 Recoil spring Replace
109.2 kN 87.4 kN
PC228US-3E0 558 x 238 417 531
{11,150 kg} {8,920 kg}
PC228 126.3 kN 101 kN
561.4 x 237 433 561
USLC-3E0 {12,890 kg} {10,300 kg}
PC228US, USLC-3E0 3
Idler 1
4 PC228US, USLC-3E0
Unit: mm
1 Outside diameter of protrusion
538 —
2 Outside diameter of tread 500 488
Build-up welding
3 Thickness of tread 26 20
or replace
4 Difference of tread 19 25
5 Total width 159 —
6 Width of tread 37.5 —
Standard Tolerance Standard Clearance
Clearance between shaft and size Shaft Hole clearance limit
7
bushing –0.250 +0.164 0.176 –
65 —
–0.350 –0.074 0.514
Tolerance Standard
Standard Interfer-
interfer- Replace bushing
Interference between idler and size Shaft Hole ence limit
8 ence
bushing
+0.108 –0.032 0.040 –
72 —
+0.008 –0.062 0.170
Clearance between bushing Standard clearance Clearance limit
9 and support (Sum of clearance
at both sides) 0.5 – 1.0 —
PC228US, USLC-3E0 5
Carrier roller 1
Unit: mm
1 Outside diameter of flange
145 —
2 Outside diameter of tread 120 106
3 Width of tread 43 —
4 Thickness of tread 23 16
5 Width of flange 14 —
Clearance between shaft and size Shaft Hole clearance limit
6 Replace
bushing –0.170 +0.301 0.338 –
40 —
–0.190 +0.168 0.491
Tolerance Standard
Standard Interfer-
interfer-
Interference between roller and size Shaft Hole ence limit
7 ence
bushing
+0.061 –0.000 0.016 –
47 —
+0.016 –0.040 0.101
Standard clearance Clearance limit
8 Axial clearance of roller
0.44 – 0.76 —
6 PC228US, USLC-3E0
Track roller 1
Unit: mm
Outside diameter Standard size Repair limit
1
of flange 188 —
Outside diameter
2 156 144
of tread
Rebuild
3 Thickness of tread 44.5 38.5 or
4 Overall width 225 — replace
5 Inside width 85 —
6 Width of tread 44.5
7 Width of flange 25.5
Clearance size clearance limit
Shaft Hole
8 between shaft and
bushing –0.215 +0.195 0.215 –
60 1.5
–0.315 0 0.510 Replace
Standard Tolerance Standard Interference bushing
Interference size interference limit
Shaft Hole
9 between roller and
bushing +0.153 +0.030 0.023 –
67 —
+0.053 0 0.153
PC228US, USLC-3E0 7
Track shoe 1
a P portion shows the link of bushing press fitting end.
1. Triple grouser shoe

2. Road liner
3. Swamp shoe
4. Flat shoe
8 PC228US, USLC-3E0
Unit: mm
1 Link pitch
190.3 193.3
Reverse or
Standard size Reverse
2 Outside diameter of bushing replace
59.3 54.3
3 Thickness of bushing metal 10.4 5.4
4 Link height
105 97
Repair or replace
Thickness of link metal
5 28.5 20.5
(bushing press-fitting portion)
6 160.4
7 Shoe bolt pitch 124.4
8 62
Inside
9 84.8
width
Link Overall
10 45.4
width
11 Tread width 39.6
Regular 2.5 Adjust or replace
12 Protrusion of pin
Master 2.5
Protrusion of bush- Regular 4.85
13
ing Master 0.0
Overall length of Regular 212
14
pin Master 212
Overall length of Regular 138.5
15
bushing Master 128.7
16 Thickness of spacer —
17 Bushing 88.2 – 245 kN{9 – 25 ton}
18 Regular pin 127.4 – 274.4 kN{13 – 28 ton}
Press-fitting force —
19
Master pin 78.4 – 147 kN{8 – 15 ton}
(*)
* Dry type track link
PC228US, USLC-3E0 9
Unit: mm
Tightening torque (Nm {kgm}) Retightening angle (deg.)
Triple grouser 490 ± 49
a. Regular 120 ± 10
shoe {50 ± 5}
link
Road liner (Rub- 549 ± 59
20 Shoe bolt — Retighten
ber pad type) {56 ± 6}
Tightening torque Retightening angle Lower limit torque
b. Master (Nm {kgm}) (deg.) (Nm {kgm})
link
— — —
Tolerance Standard interfer-
Standard size
Interference between bushing Shaft Hole ence
21
and link +0.434 +0.074
59 0.320 – 0.434
+0.394 –0.000
Interference between regular +0.222 –0.138
22 38 0.300 – 0.422
pin and link +0.162 –0.200
Tolerance Standard clear-
Standard size
Clearance between regular pin Shaft Hole ance
23
and bushing +0.222 +0.902
38 0.180 – 0.740 Adjust or replace
+0.162 +0.402
Tolerance Standard interfer-
Standard size
24 Interference between master Shaft Hole ence
(*) pin and link +0.280 +0.062
37.8 0.188 – 0.280
+0.250 –0.000
Tolerance Standard clear-
Standard size
25 Clearance between master pin Shaft Hole ance
(*) and bushing –0.150 +0.902
38 0.552 – 1.252
–0.350 +0.402
* Dry type track link
Triple grouser shoe
Swamp shoe
Road liner
Flat shoe
Unit: mm
1 Height
26 16
10
2 Thickness
(*) 8.5
3 Length of base 26
4 Length of base 19
5 Length at tip 20 Build-up welding
6 Length at tip 14 or replace
7 Length at tip 19
8 Thickness 36 26
(*) 34.5 24.5
9 Height 102.5 90.5
10 Thickness 17 5
11 Height 70
12 Height 54 Replace
13 Height 13
*: PC228US-3E0: 600 mm triple grouser shoe.
SEN01427-00

© 2006 KOMATSU
All Rights Reserved
14
SEN01428-00
PC228US-3E0
PC228USLC-3E0


Hydraulic system, Part 1
Hydraulic system, Part 1 ................................................................................................................................. 2
Hydraulic equipment layout drawing .................................................................................................... 2
Hydraulic tank ...................................................................................................................................... 4
Hydraulic pump .................................................................................................................................... 6
PC228US, USLC-3E0 1
Hydraulic system, Part 1 1

Hydraulic equipment layout
drawing 1
1. Bucket cylinder
2. Arm cylinder
3. Boom cylinder
4. Hydraulic oil filter
5. Hydraulic tank
6. Hydraulic pump
7. L.H. travel motor
8. Oil cooler
9. Swing motor
10. Left PPC valve
11. Lock lever
12. Center swivel joint
13. Travel PPC valve
14. Right PPC valve
15. Control valve
16. Accumulator
17. Solenoid valve assembly
17A. PPC lock solenoid valve
17B. 2-stage relief solenoid valve
17C. Travel speed solenoid valve
17D. Swing brake solenoid valve
17E. Travel junction solenoid valve
17F. Merge-divider solenoid valve
2 PC228US, USLC-3E0
PC228US, USLC-3E0 3
Hydraulic tank 1
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 ± 6.9 kPa
7. Suction strainer {0.17 ± 0.07 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}
4 PC228US, USLC-3E0
Hydraulic pump 1
Type: HPV95+95
6 PC228US, USLC-3E0
Outline
q This pump consists of 2 variable capacity
swash plate piston pumps, PC valve, LS valve,
and EPC valve.
IM : PC mode selector current

ISIG : LS set pressure selector current
OCP : Oil inspection port
OFP : Oil filler port
PAF : Front pump delivery port
PAR : Rear pump delivery port
PBF : Pump pressure input port
PD1F : Case drain port
PD1R : Air bleeder
PD2F : Drain plug
PD2R : Drain plug
PENF : Front control pressure detection port
PENR : Rear control pressure detection port
PEPC : EPC basic pressure port
PFC : Front pump discharge pressure detection
port
PLSF : Front load pressure input port
PLSFC : Front load pressure detection port
PLSR : Rear load pressure input port
PLSRC : Rear load pressure detection port
PM : PC mode selector pressure detection
port
PRC : Rear pump discharge pressure detection
port
PS : Pump suction port
PSIG : LS set selector pressure detection port
1. Front pump
2. Rear pump
3. LS valve
4. PC valve
5. LS-EPC valve
6. PC-EPC valve
PC228US, USLC-3E0 7
1. Front shaft
2. Cradle
3. Front case
4. Rocker cam
5. Shoe
6. Piston
7. Cylinder block
8. Valve plate
9. End cap
10. Rear shaft
11. Rear case
12. Servo piston
13. PC valve
8 PC228US, USLC-3E0
Function q Piston (6) carries out relative movement in the

q The pump converts the engine rotation trans- axial direction inside each cylinder chamber of
mitted to its shaft to oil pressure and delivers cylinder block (7).
pressurized oil corresponding to the load. q Cylinder block (7) seals the pressurized oil to
q It is possible to change the discharge amount valve plate (8) and carries out relative rotation.
by changing the swash plate angle. q This surface is designed so that the oil pres-
sure balance is maintained at a suitable level.
Structure q The oil inside the respective cylinder chambers
q Cylinder block (7) is supported to shaft (1) by of cylinder block (7) is suctioned and dis-
spline (14). charged through valve plate (8).
q Shaft (1) is supported by front and rear bear-
ings (15).
q Tip of piston (6) is shaped as a concave ball
and shoe (5) is caulked to it to form one unit.
q Piston (6) and shoe (5) constitute the spherical
bearing.
q Rocker cam (4) has flat surface (A), and shoe
(5) is always pressed against this surface while
sliding in a circular movement.
q Rocker cam (4) conducts high pressure oil to
the cylinder surface (B) with cradle (2), which
is secured to the case, and forms a static pres-
sure bearing when it slides.
PC228US, USLC-3E0 9
Operation of pump
q Cylinder block (7) rotates together with shaft q As center line (X) of rocker cam (4) matches
(1), and shoe (5) slides on flat surface (A). the axial direction of cylinder block (7) (swash
q When this happens, rocker cam (4) moves plate angle (a) = 0), the difference between
along cylindrical surface (B), so angle (a) volumes (E) and (F) inside cylinder block (7)
between center line (X) of rocker cam (4) and becomes 0.
the ax ial di rec tio n of cy li nder b loc k (7) q Suction and discharge of pressurized oil is not
changes. carried out in this state. Namely pumping
q (a) is named the swash plate angle. action is not performed. (Actually, however, the
swash plate angle is not set to 0)
q With center line (X) of rocker cam (4) at a

swash plate angle (a) in relation to the axial
direction of cylinder block (7), flat surface (A)
acts as a cam in relation to shoe (5).
q In this way, piston (6) slides on the inside of
cylinder block (7), so a difference between vol-
umes (E) and (F) is created inside cylinder
block (7).
q A single piston (6) suctions and discharges the
oil by the amount (F) – (E).
q As cylinder block (7) rotates and the volume of
chamber (E) becomes smaller, the pressurized
oil is discharged.
q On the other hand, the volume of chamber (F)
grows larger and, in this process, the oil is suc-
tioned.
Control of delivery
q If the swash plate angle (a) becomes larger,
the difference between volumes (E) and (F)
b ec o me s l ar g er a nd pu m p d el i v e r y ( Q )
increases.
q Servo piston (12) is used for changing swash
plate angle (a).
q Servo piston (12) carries out linear reciprocal
movement according to the signal pressure
from the PC and LS valves.
q This linear movement is transmitted to rocker
cam (4) via slider (13).
q Being supported by cradle (2) on the cylindrical
surface, rocker cam (4) slides on the surface
while continuing revolving movement.
q Space of the pressure receiving area of servo
piston (12) are not identical on the left side and
right side. Main pump discharge pressure (self
pressure) (PP) is always brought to the pres-
sure chamber of the small diameter piston
side.
q Output pressure (PEN) of the LS valve is
brought to the chamber receiving the pressure
at the large diameter piston end.
q The relationship in the size of pressure (PP) at
the small diameter piston end and pressure
(PEN) at the large diameter piston end, and
the ratio between the area receiving the pres-
sure of the small diameter piston and the large
diameter piston controls the movement of
servo piston (12).
1. LS valve
PA : Pump port 1. Sleeve

PDP : Drain port 2. Piston
PLP : LS control pressure output port 3. Spool
PLS : LS pressure input port 4. Spring
PP : Pump port 5. Sheet
PPL : Control pressure input port 6. Sleeve
PSIG : LS mode selector pilot port 7. Plug
8. Locknut
Function
q The LS (load sensing) valve detects the load
and controls the delivery.
q This valve controls main pump delivery (Q)
according to differential pressure (dPLS)[= PP
– PLS], called the LS differential pressure (the
difference between main pump pressure (PP)
and control valve outlet port pressure (PLS)).
q Main pump pressure (PP), pressure (PLS)
(called the LS pressure) coming from the con-
trol valve output, and pressure (PSIG) (called
the LS selector pressure) from the proportional
solenoid valve enter this valve.
q The relationship between the LS differential
pressure between the main pump pressure
(PP) and LS pressure (PLS) (dPLS) [= (PP) –
(PLS)] and the pump delivery (Q) changes as
shown in the diagram according to LS selector
current (ISIG) of the LS-EPC valve.
q If (ISIG) changes from 0 to 1A, setting force of
the spring changes, too. As the result, the
specified median of the pump delivery volume
switching point changes as shown in the dia-
gram. It will change in the range of 0.69 to 2.2
MPa {in the range of 7.0 to 22.0 kg/cm2}.
Operation
1) When the control valve is situated at neutral
q The LS valve is a 3-way selector valve, with q Spool (6) is pushed to the right, and port (C)
pressure (PLS) (LS pressure) from the outlet and port (D) will be connected.
port of the control valve brought to spring q Pump discharge pressure (PP) is conducted to
chamber (B), and main pump discharge pres- the larger diameter end from port (K).
sure (PP) brought to port (H) of sleeve (8). q The same pump pressure (PP) is conducted to
q Magnitude of the force resulting from this LS the smaller diameter end from port (J).
pressure (PLS), force of spring (4) and the q According to the difference in the areas on
pump discharge pressure (self pressure) (PP) servo piston (12), the pressure moves in such
determine the position of spool (6). that the swash plate angle may be minimized.
q However, magnitude of the output pressure
(PSIG) (called the LS selector pressure) of the
EPC valve for the LS valve entering port (G)
also changes the position of spool (6). (Setting
force of the spring is changed)
q Before the engine is started, servo piston (12)
is pushed to the left. (See the figure)
q If the control lever is at the neutral position
when the engine is started, LS pressure (PLS)
will be set to 0 MPa {0 kg/cm2}. (It is intercon-
nected to the drain circuit via the control valve
spool)
2) Action for the direction of maximizing the pump delivery
q When the difference between the main pump q If the output pressure of the EPC valve for the
pressure (PP) and LS pressure (PLS), in other LS valve enters port (G), rightward force is
wo r ds , L S d iff er e nti a l p re s s ur e ( dP L S) generated on piston (7).
becomes smaller (for example, when the area q If piston (7) is pushed to the right, setting force
of opening of the control valve becomes larger of spring (4) is weakened, changing the LS dif-
and pump pressure PP drops), spool (6) is ferential pressure (dPLS) [Difference between
pushed to the left by the combined force of LS oil pressures (PLS) and (PP)] when ports (D)
pressure (PLS) and the force of spring (4). and (E) of spool (6) are connected.
q When spool (6) moves, port (D) and port (E)
are interconnected and connected to the PC
valve.
q The PC valve is connected to the drain port, so
the pressure across circuits (D) and (K)
becomes drain pressure (PT). (The operation
of the PC valve is explained later.)
q The pressure at the large diameter end of
servo piston (12) becomes drain pressure
(PT), and pump pressure (PP) enters port (J)
at the small diameter end, so servo piston (12)
is pushed to the left side. Therefore, the swash
plate is moved in the direction to make the
delivery amount larger.
3) Action for the direction of minimizing the pump delivery
q When LS differential pressure (dPLS)

becomes larger (for example, when the area of
opening of the control valve becomes smaller
and pump pressure (PP) rises) because of the
rightward move (it reduces discharge amount)
of servo piston (12), pump pressure (PP)
pushes spool (6) to the right.
q When spool (6) moves, main pump pressure
(PP) flows from port (C) to port (D) and from
port (K), it enters the large diameter end of the
piston.
q Main pump pressure (PP) also enters port (J)
of the small diameter end of the piston, but
because of the difference in area between the
large diameter end and the small diameter end
on servo piston (12), it is pushed to the right.
As the result, the servo piston (12) moves into
the direction of reducing the swash plate
angle.
q As LS selector pressure (PSIG) is input to port
(G), setting force of spring (4) is reduced.
4) When servo piston is balanced
q Let us take the area receiving the pressure at q Force of spring (4) is adjusted in such that the
the large diameter end of the piston as (A1), position of the balanced stop of this spool (6)
the area receiving the pressure at the small may be determined when (PP) – (PLS) = 2.2
diameter end as (A0), and the pressure flowing MPa {22.0 kg/cm2} at the median of the speci-
into the large diameter end of the piston as fied value.
(PEN). q If (PSIG) [Output pressure of LS-EPC valve, 0
q If the main pump pressure (PP) of the LS valve to 2.9 MPa {0 to 30 kg/cm2}] is input to port (G),
and the combined force of spring (4) and LS the position of the balanced stop is changed in
pressure (PLS) are balanced, and the relation- the range of (PP) – (PLS) = 2.2 to 0.69 MPa
ship is (A0) x (PP) = (A1) x (PEN), servo piston {22.0 to 7.0 kg/cm 2 } in proportion to (PSIG)
(12) will stop in that position. pressure.
q The swash plate of the pump will be held at the
intermediate position. [Spool (6) will be
stopped at a position where the distance of the
opening from port (D) to port (E) and the dis-
tance from port (C) to port (D) is almost the
same.]
q At this point, the relationship between the pres-
sure receiving areas across servo piston (12)
is (A0) : (A1) = 3 : 5, so the pressure applied
across the piston when it is balanced becomes
(PP) : (PEN) C 5 : 3.
2. PC valve
PA : Pump port 1. Plug

PA2 : Pump pressure pilot port 2. Servo piston assembly
PDP : Drain port 3. Pin
PM : Mode selector pressure pilot port 4. Spool
PPL : Control pressure output port (to LS valve) 5. Retainer
6. Sheet
7. Cover
8. Wiring
Function
q When the pump discharge pressure (PP1) q If the engine speed goes below the specified
(self-pressure) and (PP2) (other pump pres- value because of increased load, the controller
sure) are high, the PC valve controls the pump sends a command current to PC-EPC valve
so that the volume of oil beyond the discharge solenoid in order to reduce the slope angle in
pressure-based specific flowrate may not be proportion to reduction in the engine speed.
conducted however you may increase the con-
trol valve stroke. Namely it is intended at con-
trolling the horsepower for the pumps so that it
may not exceed the engine horsepower.
q If the pump discharge pressure increases due
to increased load during operation, this valve
decreases the pump delivery.
q And if the pump discharge pressure goes low,
it increases the pump delivery.
q In this case, relation between the mean dis-
charge pressure of the front and rear pumps
[(PP1) + (PP2)]/2 and the pump delivery (Q)
will become as shown in the diagram if the
relation is represented as the parameter of the
current value (X) to be given to PC-EPC valve
solenoid.
q The controller continues counting the actual
engine speed.
q If the engine speed is slowed down due to
increased load, the controller reduces the
pump delivery to recover the speed.
Operation
1) When pump controller is normal
(1) When the load on the actuator is small and pump discharge pressures (PP1) and (PP2) are low
Action of PC-EPC valve solenoid (1)

q Command current (X) is being sent to PC-EPC a Other pump's pressure denotes the pressure
valve solenoid (1) from the pump controller. of the pump situated on the opposite side.
q This command current acts on PC-EPC valve For the front pump pressure, the other pump's
to output the signal pressure in order to modify pressure is that of the rear pump.
the force pushing piston (2). And for the rear pump pressure, the other
q Spool (3) stops at a position where the com- pump's pressure is that of the front pump.
bined spool-pushing force is balanced by the
setting force of springs (4) and (6) as well as
the pump pressures (PP1) (self-pressure) and
(PP2) (another pump's pressure).
q The pressure [port (C) pressure] output from
PC valve is changed depending on the above
position.
q The size of command current (X) is determined
by the nature of the operation (lever opera-
tion), the selected working mode, and the set
value and actual value of the engine speed.
Action of spring
q Load of springs (4) and (6) on the PC valve is q Self pressure (PP1) enters port (B) and the
determined by the swash plate position. small diameter end of servo piston (9), and
q As servo piston (9) moves to right, spring (6) is other pump pressure (PP2) enters port (A).
retracted. q When pump pressures (PP1) and (PP2) are
q If the servo piston moves further, it will be con- small, spool (3) will be positioned in the left
tacted again seat (5) and spring (6) will be side.
fixed. q Port (C) and (D) are connected, and the pres-
q After that, spring (4) alone will operate. sure entering the LS valve becomes drain
q The spring load is changed by servo piston (9) pressure (PT).
as it extends or compresses springs (4) and q If port (E) and port (G) of the LS valve are con-
(6). nected, the pressure entering the large diame-
The spring load changes as the servo piston ter end of the piston from port (J) becomes
(9) extends and contracts the springs (4) and drain pressure (PT), and servo piston (9)
(6). moves to the left side.
q If the command current (X) to PC-EPC valve q The pump delivery will be set to the increasing
solenoid (1) changes, so does the force push- trend.
ing piston (2). q Accompanied with move of servo piston (9),
q Spring load of springs (4) and (6) is also springs (4) and (6) will be expanded and the
affected by the command current (X) to PC- spring force becomes weaker.
EPC valve solenoid.
q Port (C) of the PC valve is connected to port
(E) of the LS valve.
q As the spring force is weakened, spool (3)

moves to the right, the connecting between
port (C) and port (D) is shut off and the pump
discharge pressure ports (B) and (C) are con-
nected.
q As a result, the pressure on port (C) rises and
the pressure on the large diameter end of the
piston also rises. Thus, the leftward move of
servo piston (9) is stopped.
q Servo piston (9) stop position (= Pump deliv-
ery) is decided by the position where the push-
ing force generated from the pressures (PP1)
and (PP2) applied to spool (3), the pushing
force of the solenoid in PC-EPC valve gener-
ates and the pushing force of springs (4) and
(6) are balanced.
(2) When load on actuator is large and pump discharge pressure is high
Outline q When servo piston (9) moves to the right,

q When the load is large and pump discharge springs (4) and (6) are compressed and push
pressures (PP1) and (PP2) are high, the force back spool (3).
pushing spool (3) to the right becomes larger q When spool (3) moves to the left, the opening
and spool (3) will be moved to the position of port (C) and port (D) becomes larger.
shown in above figure. q As a result, the pressure on port (C) (= J) is
q Part of the pressure to be conducted from port decreased and the rightward move servo pis-
(C) to LS valve flows from port (B) to port (C) ton (9) is stopped.
and (D) via LS valve. At the end this flow, level q The position in which servo piston (9) stops at
of this pressure becomes approximately half of this time is further to the right than the position
the main pump pressure (PP2). when pump pressures (PP1) and (PP2) are
low.
Operation
q When port (E) and port (G) of the LS valve are
connected, this pressure from port (J) enters
the large diameter end of servo piston (9),
stopping servo piston (9).
q If main pump pressure (PP2) increases further
and spool (3) moves further to the right, main
pump pressure (PP1) flows to port (C) and acts
to make the pump delivery the minimum.
q The relationship between the average pump

pressure (PP1 + PP2)/2 and servo piston (9) in
terms of their positions can be represented by
the broken line in the figure springs (4) and (6)
form the double springs.
q The relationship between the average pump
pressure (PP1 + PP2)/2 and average pump
delivery (Q) becomes as shown below.
q If command voltage (X) sent to PC-EPC valve

solenoid (1) increases further, the relationship
between average pump pressure (PP1 + PP2)/
2, and pump delivery (Q) is proportional to the
force of the PC-EPC valve solenoid and moves
in parallel.
q Namely, the force of PC-EPC valve solenoid
(1) is added to the pushing force to the right
because of the pump pressure applied to the
spool (3), so the relationship between the aver-
age pump pressure (PP1 + PP2)/2 and the
pump delivery (Q) moves from (A) to (B) as the
command current (X) is increased.
2) As the emergency pump drive switch is turned on due to failure on the pump
controller
(1) When the main pump is under light load
q If there is a failure in the pump controller, the q Since the pressure on the small diameter end
emergency pump drive switch is turned on to of the piston large, servo piston (9) moves in
hand the control to the resistor side. the direction to make the discharge amount
q In this case, the power is directly supplied from larger.
the battery. The current, however, is too large
as is, so the resistor is set in between to con-
trol the current flowing to PC-EPC valve sole-
noid (1).
q The current becomes constant, so the force
pushing piston (2) is also constant.
q If the main pump pressures (PP1) and (PP2)
are low, the combined force of the pump pres-
sure and the PC-EPC valve solenoid (1) is
weaker than the spring set force, so spool (3)
is balanced at a position to the left.
q The port (C) is connected to the drain pressure
of the port (D), and the large diameter end of
the servo piston (9) also becomes the drain
pressure (PT) through the LS valve.
(2) When the main pump is under heavy load
q If the emergency pump drive switch is turned q The curve resulting when the emergency pump
on in the same way as in above, the command drive switch is ON is situated further to the left
current (X) sent to PC-EPC valve solenoid (1) (B) than when the pump controller is normal
becomes constant. (A).
q For this reason, the force of piston (2) pushing
spool (3) is constant.
q If main pump pressures (PP1) and (PP2)
increase, spool (3) moves further to the right
than when the main pump load is light, and is
balanced at the position in the figure above.
q In this case, the pressure from port (B) flows to
port (C), so servo piston (9) moves to the right
(smaller pump delivery) and stops at a position
to the further to the right then when the load on
the pump is light.
q When the emergency pump drive switch is
turned on, too, the pump pressure (PP) and
pump delivery (Q) have a relationship as
shown with the curve in the figure correspond-
ing to the current sent to the PC-EPC valve
solenoid through the resistor.
3. LS (PC)-EPC valve
C : To LS (PC) valve
P : From self pressure reducing valve
T : To tank
1. Connector
2. Coil
3. Body
4. Spring
5. Spool
6. Rod
7. Plunger
Function Operation
q The EPC valve consists of the proportional
solenoid portion and the hydraulic valve por- 1) When signal current is 0 (coil is de-
tion. energized)
q When it receives signal current (i) from the q When there is no signal current flowing from
controller, it generates the EPC output pres- the controller to coil (2), coil (2) is de-ener-
sure in proportion to the size of the signal, and gized.
outputs it to the LS (PC) valve. q Spool (5) is pushed to the left by spring (4).
q Port (P) closes and the pressurized oil from the
self pressure reducing valve does not flow to
the LS (PC) valve.
q The pressurized oil from the LS (PC) valve is
drained to the tank via port (C) and port (T).
2) When signal current is very small 3) When signal current is maximum

(coil is energized) (coil is energized)
q When a very small signal current flows to coil q As the signal current flows to coil (2), coil (2) is
(2), coil (2) is energized, and a propulsion force energized.
is generated on the right side of plunger (7). q When this happens, the signal current is at its
q Rod (6) pushes spool (5) to the right, and pres- maximum, so the propulsion force of plunger
surized oil flows from port (P) to port (C). (7) is also at its maximum.
q Pressures on port (C) increases and the force q Spool (5) is pushed toward right side by rod
to act on spool (5) surface and the spring load (6).
on spring (4) become larger than the propul- q The maximum volume of pressurized oil is
sion force of plunger (7). conducted from port (P) to port (C), increasing
q Spool (5) is pushed to the left, and port (P) is the circuit pressure across EPC valve and LS
shut off from port (C). (PC) valve to the maximum level.
q Port (C) and port (T) are connected. q Since port (T) is closed, pressurized oil does
q Spool (5) moves up and down so that the pro- not flow to the tank.
pulsion force of plunger (7) may be balanced
with pressure of port (C) + spring load of spring
(4).
q The circuit pressure between the EPC valve
and the LS (PC) valve is controlled in propor-
tion to the size of the signal current.
SEN01428-00

© 2006 KOMATSU
All Rights Reserved
28
SEN01429-01
PC228US-3E0
PC228USLC-3E0


Control valve ........................................................................................................................................ 2
CLSS.................................................................................................................................................. 14
Functions and operation by valve ...................................................................................................... 18
Merge-divider valve............................................................................................................................ 33
Attachment circuit selector valve........................................................................................................ 56
Hydraulic drift prevention valve .......................................................................................................... 58
PC228US, USLC-3E0 1

Control valve 1
Outline
q The control valve consists of a 6-spool valve
(unit type) and a set of service valves. A
merge-divider valve, a back pressure valve, a
boom drift prevention valve are installed to it.
q Since all the valves are assembled together
with connecting bolts and their passes are con-
nected to each other inside the assembly, the
assembly is compact and easy to maintain.
q With one spool provided for one work equip-
ment, this control valve is simple in construc-
tion.
A1: To bucket cylinder head PLS1: To rear pump control

A2: To R.H. travel motor PLS2: To front pump control
A3: To boom cylinder head PP1: From rear pump
A4: To swing motor PP2: From front pump
A5: To L.H. travel motor PP1S: Pump discharge pressure sensor port
A6: To arm cylinder head PP2S: Pump discharge pressure sensor port
A-1: To Attachment 1 PPS2: To front pump control
A-2: To Attachment 2 PR: To solenoid valve, PPC valve, and EPC valve
B1: To bucket cylinder bottom PS: From merge-divider solenoid valve
B2: To R.H. travel motor PST: From travel junction valve solenoid valve
B3: To boom cylinder bottom PX1: From 2-stage relief solenoid valve
B4: To swing motor PX2: From 2-stage relief solenoid valve
B5: To L.H. travel motor T: To tank
B6: To arm cylinder bottom TS: To tank
B-1: To Attachment 1 TSW: To swing motor
B-2: To Attachment 2
BP1: From LS select valve 1. 6-spool valve
BP3: From attachment select solenoid valve 2. Cover A
BP4: From attachment select solenoid valve 3. Cover B
BP5: From attachment select solenoid valve 4. Service valve 1
BP6: From attachment select valve 5. Service valve 2
P1: From bucket PPC and EPC valves 6. Merge-divider valve
P2: From bucket PPC and EPC valves 7. Boom drift prevention valve
P3: From R.H. Travel PPC valve
P4: From R.H. Travel PPC valve
P5: From boom PPC and EPC valves
P6: From boom PPC and EPC valves
P7: From swing PPC and EPC valves
P8: From swing PPC and EPC valves
P9: From L.H. Travel PPC valve
P10: From L.H. Travel PPC valve
P11: From arm PPC and EPC valves
P12: From arm PPC and EPC valves
P-1: From Service 1 and PPC valves
2 PC228US, USLC-3E0
General view
PC228US, USLC-3E0 3
Sectional view
(1/5)
4 PC228US, USLC-3E0
1. Pressure compensation valve (Arm OUT)

2. Pressure compensation valve (R.H. travel
REVERSE)
3. Pressure compensation valve (R.H. swing)
4. Pressure compensation valve (Boom RAISE)
5. Pressure compensation valve (L.H. travel
REVERSE)
6. Pressure compensation valve (Bucket DUMP)
7. Variable pressure compensation valve (Ser-
vice 1)
8. Variable pressure compensation valve (Ser-
vice 2)
9. Pressure compensation valve (Bucket CURL)
10. Pressure compensation valve (L.H. travel
FORWARD)
11. Pressure compensation valve (Boom LOWER)
12. Pressure compensation valve (L.H. swing)
13. Pressure compensation valve (R.H. travel
FORWARD)
14. Pressure compensation valve (Arm IN)
15. Main relief valve
16. Unload valve
17. Unload valve
19. Spool (Service 2)
20. Spool (Service 1)
21. Spool (Bucket)
22. Spool (L.H. travel)
23. Spool (Boom)
24. Spool (Swing)
25. Spool (R.H. travel)
26. Spool (Arm)
Unit: mm
Free length x Installed Installed Installed
Free length
27 Spool return spring Outside diameter length load load
393 N 315 N If damaged or
54.2 x 34.8 51.2
{40.1 kg}
— {32.1 kg} deformed, replace
417 N 333 N spring.
28 Spool return spring 54.2 x 34.8 51.2
{42.5 kg}
— {34.0 kg}
421 N 336 N
{42.9 kg}
— {34.3 kg}
PC228US, USLC-3E0 5
(2/5)
6 PC228US, USLC-3E0
1. Safety-suction valve (Arm OUT)

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

Free length
24 Suction valve spring Outside diameter length load load If damaged or
5.49 N 4.41 N deformed, replace
46.8 x 7.5 40.6
{0.56 kg}
— {0.45 kg} spring.
1.47 N 1.18 N
25 Check valve spring 11.5 x 4.6 8.5
{0.15 kg}
— {0.12 kg}
PC228US, USLC-3E0 7
(3/5)
8 PC228US, USLC-3E0
1. Unload valve
2. Safety valve (Boom RAISE)
4. Lift check valve
Arm valve
5. LS shuttle valve
6. Pressure compensation valve (IN)
7. Spool
8. Safety-suction valve (IN)
9. Regeneration circuit check valve
10. Safety-suction valve (OUT)
11. Pressure compensation valve (OUT)
R.H. travel valve

12. LS shuttle valve
13. Pressure compensation valve (FORWARD)
14. Spool
15. Suction valve (FORWARD)
16. Suction valve (REVERSE)
17. Pressure compensation valve (REVERSE)
Swing valve
18. LS select valve
19. Pressure compensation valve (R.H.)
20. Spool
21. Pressure compensation valve (L.H.)
Unit: mm

Free length
22 Spool return spring Outside diameter length load load If damaged or
50.0 x 14.4 42.0
{2.0 kg}
— {1.6 kg} spring.
5.88 N 4.71 N
{0.6 kg}
— {0.48 kg}
PC228US, USLC-3E0 9
(4/5)
1. Merge-divider valve (for LS)

2. Valve (Sequence valve)
3. Merge-divider valve (Main)
Boom valve
4. Drift prevention valve
5. LS shuttle valve
6. Pressure compensation valve (LOWER)
7. Spool
8. 2-stage safety-suction valve (LOWER)
9. Regeneration circuit check valve
10. Suction valve (RAISE)
11. Pressure compensation valve (RAISE)
L.H. travel valve

12. Merge-divider valve (Travel junction valve)
14. Pressure compensation valve (FORWARD)
15. Spool
16. Suction valve (FORWARD)
17. Suction valve (REVERSE)
18. Pressure compensation valve (REVERSE)
Bucket valve
20. Pressure compensation valve (CURL)
21. Spool
22. Safety-suction valve (CURL)
23. Safety-suction valve (DUMP)
24. Pressure compensation valve (DUMP)
Unit: mm

Free length
25 Spool return spring Outside diameter length load load
157 N 126 N
46.6 x 21.8 33.0
{16.0 kg}
— {12.8 kg}
250 N 200 N
{25.5 kg}
— {20.4 kg}
178 N 142 N If damaged or
{18.1 kg}
— {14.5 kg} deformed, replace
35.3 N 28.2 N spring.
{3.6 kg}
— {2.88 kg}
13.7 N 11.0 N
{1.4 kg}
— {1.12 kg}
5.88 N 4.71 N
{0.6 kg}
— {0.48 kg}
50.0 N 40.0 N
31 Piston return spring 30.7 x 20.5 23.0
{5.1 kg}
— {4.08 kg}
(5/5)
Service valve 1
1. LS shuttle valve
2. Variable pressure compensation valve
3. Spool
4. 2-stage safety-suction valve
5. Safety-suction valve
Service valve 2
6. LS shuttle valve
7. Variable pressure compensation valve
8. Spool
10. Unload valve

12. LS bypass plug
CLSS 1
Outline of CLSS
Features Configuration
CLSS stands for Closed center Load Sensing Sys- q CLSS is configured with variable capacity pis-
tem, which has the following characteristics: ton pumps, control valves, and respective
actuators.
q Fine control not influenced by load q The hydraulic pump is configured with pump
q Controllability enabling digging even with fine body, PC valve and LS valve.
control
q Ease of compound operation ensured by flow
divider function using area of opening of spool
during compound operations
q Energy saving using variable pump control
Basic principle
1. Pump swash plate angle control
q The pump swash plate angle (pump delivery) q The pump swash plate angle shifts toward the
is controlled so that LS differential pressure maximum position if LS differential pressure
(dPLS) (the difference between pump pressure (dPLS) is lower than the set pressure of the LS
PP and control valve outlet port LS pressure valve (when the actuator load pressure is
PLS) (load pressure of actuator) is constant. high).
q [LS differential pressure (dPLS) = Pump dis- q If it becomes higher than the set pressure
charge pressure (PP) – LS pressure (PLS)] (when the actuator load pressure is low), the
pump swash plate angle shifts toward the mini-
mum position.
LS differential pressure (dPLS) and pump

swash plate angle
a For details of functions, see the “Hydraulic

pump” paragraph.
2. Pressure compensation control
q A pressure compensation valve is installed to

the outlet port side of the control valve to bal-
ance the load.
q When actuators are operated together, the
pressure difference (dP) between the
upstream (inlet port) and downstream (outlet
port) of the spool of each valve becomes the
same regardless the size of the load (pres-
sure).
q The flow of oil from the pump is divided (com-
pensated) in proportion to the area of opening
(S1) and (S2) of each valve.
3. System diagram
a The illustration shows actuator (7) in the merge 1. Front pump

mode with stroke end at the time of relief. 2. Rear pump
4. Unload valve
5. Merge-divider valve
6. Control valve
7. Actuator
8. Pump circuit
9. LS circuit
10. Tank circuit
11. Valve
12. Spring
13. LS bypass valve
14. LS valve
15. PC valve
Functions and operation by valve 1

Hydraulic circuit diagram and the name of valves
1. Arm valve 30. Main relief valve (Arm side)

2. R.H. travel valve Set pressure:
3. Swing valve 34.8 ± 0.5 MPa {355.5 ± 5 kg/cm2}
4. Boom valve
5. L.H. travel valve When digging force increased:
6. Bucket valve 37.4 ± 0.5 MPa {382 ± 5 kg/cm2}
7. Service valve 1
8. Service valve 2 31. Unload valve (Bucket side)
9. Arm spool Cracking pressure:
10. R.H. travel spool 2.9 ± 0.5 MPa {30 ± 5 kg/cm2}
11. Swing spool
12. Boom spool 32. Unload valve (Arm side)
13. L.H. travel spool Cracking pressure:
14. Bucket spool 2.9 ± 0.5 MPa {30 ± 5 kg/cm2}
15. Service spool 1
16. Service spool 2 33. Safety-suction valve
17. Pressure compensation valve Set pressure:
18. Variable pressure compensation valve 24.5 ± 0.5 MPa {250 ± 5 kg/cm2}
19. Suction valve
20. Check valve (for boom regeneration circuit) 34. Safety-suction valve
21. Check valve (for arm regeneration circuit) Set pressure:
22. LS shuttle valve 38.2 ± 0.5 MPa {390 ± 5 kg/cm2}
23. LS select valve
24. Merge-divider valve 35. 2-stage safety-suction valve
25. Self pressure reducing valve Set pressure:
26. Travel junction valve 1 stage: 24.5 ± 0.5 MPa {250 ± 5 kg/cm2}
27. Back pressure valve 2 stage: 20.6 ± 0.5 MPa {210 ± 5 kg/cm2}
28. Boom drift prevention valve
29. Main relief valve (Bucket side) 36. Safety valve
Set pressure: Set pressure:
34.8 ± 0.5 MPa {355.5 ± 5 kg/cm2} 38.2 ± 0.5 MPa {390 ± 5 kg/cm2}
When digging force increased:

37.4 ± 0.5 MPa {382 ± 5 kg/cm2}
Unload valve
1. When the unload valve is actuating
1. LS circuit 4. Tank circuit

2. Valve 5. Spring
3. Pump circuit
Function
q Drains an oil discharge for the portion of the
minimum pump swash plate angle while all
control valves are in the holding.
q The pump pressure will correspond to a set
load of spring (5) inside the valve (this pres-
sure will be P1).
q Since LS pressure is drained from the LS
bypass valve, LS pressure C tank pressure C 0
MPa {0 kg/cm2}.
Operation 2. Operation of relief valve

q Pressure of pump circuit (3) is received by the q When the cylinder reaches the stroke end, the
end of valve (2). main relief valve opens.
q Since the control valve is in neutral position, q The pump delivery (Q) is relieved to the
pressure of LS circuit (1) is 0 MPa {0 kg/cm2}. tank.(See the system diagram)
q Pressurized oil of pump circuit (3) stops at q The pump discharge pressure (PP) and LS
valve (2), and the pressure rises as no relief is pressure (PLS) become approximately the
available. same as each has not flow at the upstream
q When this pressure becomes larger than the and downstream of the spool, and LS differen-
force of spring (5), valve (2) moves to the left. tial pressure (dPLS) becomes 0 MPa {0 kg/
q Ports (b) and (c) are interconnected and the cm2}.
pump pressure flows to tank circuit (4). q As LS differential pressure (dPLS) is lower
q The pressurized oil of LS circuit (1) passes than the LS set pressure of LS valve, LS valve
from orifice (a) via port (c) and is drained to the is actuated to maximize the pump swash plate
tank circuit (4). angle.
q When actuated, LS pressure C tank pressure. q Mechanically, operation of PC valve has the
q Since the pump discharge pressure – LS cir- prevalence to that of LS valve.
cuit pressure during unloading is larger than q The pump is held at a minimum swash plate
the pump LS control pressure, the signal is angle by the cut-off function of PC valve.
output to minimize the pump swash plate
angle.
q During operation (a work within a scope of dis-
charge by a minimum swash plate angle), the
discharge pressure for the portion of minimum
pump swash plate angle is set to LS pressure
+ P1 pressure.
q LS control differential pressure (dPLS) of dis-
charge for the portion of minimum swash plate
angle will be equal to P1 pressure.
Introduction of LS pressure
1. Hydraulic pump
2. Main spool
3. Pressure compensation valve
4. Valve
5. Check valve
6. LS circuit
7. LS shuttle valve
Function
q Introduces the upstream pressure (down-
stream pressure of the spool meter-in) of pres-
sure compensation valve (3) and leads to LS
shuttle valve (7) as the LS pressure.
q Connected to actuator port (B) via valve (4),
and makes LS pressure C actuator load pres-
sure.
q Inlet pore (a) inside main spool (2) has a small
diameter concurrently serving as a throttle.
Operation
q When main spool (2) is operated, the pump
pressure enters port (c) via inlet pore (a) and is
led to the LS circuit.
q When the pump pressures rises to reach the
load pressure of port (B), check valve (5)
opens.
LS bypass plug
1. Hydraulic pump
2. Main spool
4. LS shuttle valve
5. LS bypass plug
6. LS circuit
Function
q Releases the residual pressure in LS pressure
circuit (6) from orifices (a) and (b).
q Slows down the rising rate of LS pressure to
prevent a sudden change of hydraulic pres-
sure.
q Bypass flow from LS bypass plug (5) causes a
pressure loss to be generated due to the circuit
resistance between throttle (c) of main spool
(2) and LS shuttle valve (4).
q Effective LS differential pressure drops to
improve a dynamic stability of the actuator.
Pressure compensation valve

1. During independent operation and under maximum load pressure
(If the load pressure is higher than other work equipment during a combined operation)
1. Hydraulic pump 4. Piston

2. Valve 5. Spring
3. Shuttle valve 6. LS shuttle valve
Function q As principle, port (C) and spring chamber (E)

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

q High stress may occur when valve (2) collides
with valve chamber seat portion (C) if a high
peak pressure is generated in the actuator cir-
cuit or repetitive peak pressure occurs continu-
ously (example: when using the breaker).
q To prevent this, a pressure compensation
valve with integrated valve (2) and piston (4) is
used.
q With the present machine, this device is
adopted for the bucket valve (cylinder bottom)
and the service valve.
2. When compensated
(If the load pressure is lower than other work equipment during a combined operation)
Function
q The pressure compensation valve closes
under LS pressure of port (D), and the spool
meter-in downstream pressure of port (B)
becomes equivalent to the maximum pressure
of other work equipment.
q Since the spool meter-in upstream pressure of
port (A) is the pump pressure, the spool meter-
in differential pressure [upstream pressure port
(A) pressure] – downstream pressure [port (B)
pressure] becomes equivalent to all the spools
in operation.
q Pump flow is divided according to the ratio of
the meter-in opening area.
Operation
q Spring chamber (E) is interconnected to port
(D).
q Piston (4) and valve (2) operate in the closing
direction (to the right) under the LS circuit pres-
sure from other work equipment of port (F).
q Valve upstream pressure (= spool meter-in
downstream pressure) of port (B) is controlled
with LS pressure.
3. Pressure compensation valve area ratio
Function
q The state of division changes according to the
area ratio of pressure compensation portion
(A1) and (A2). Area ratio = (A2)/(A1)
q If area ratio = 1 : the spool meter-in down-
stream pressure will be equal to the maximum
load pressure, and the pressure will be divided
according to the opening area ratio.
q If area ratio = 1 or over : the spool meter-in
downstream pressure will be greater than the
maximum load pressure, and the pressure will
be divided smaller than the opening area ratio.
q If area ratio = 1 or under : the spool meter-in
downstream pressure will be smaller than the
maximum load pressure, and the pressure will
be divided greater than the opening area ratio.
Pressure compensation valve inner shuttle valve

1. If holding pressure at port (A) is larger than LS pressure in the springing chamber (B)
1. Hydraulic pump
2. Valve
3. Pressure compensation valve inner shuttle
valve
4. Piston
Function
q Shuttle valve (3) is pushed to the right by port
(A) pressure and cuts off interconnection
between ports (A) and (C).
q Holding pressure at port (A) is led to the spring
chamber (B) to push piston (4) to the left so
that piston (4) and valve (2) will not be sepa-
rated.
2. In the case of travel
Outline
q Since no holding pressure is generated at port
(A) of the travel circuit, a pressure compensa-
tion valve without shuttle valve (3) is adopted.
Boom regeneration circuit

1. If the cylinder head pressure is lower than the bottom pressure (free fall, etc.)
1. Hydraulic pump
2. Boom spool
5. Suction valve
6. Check valve
7. LS shuttle valve
Function Operation
q Provides the regeneration circuit from the cyl- q If the cylinder head pressure is lower than the
inder bottom to the cylinder head when the bottom pressure, pressurized oil (A) from the
boom is lowered and increases flow to the cyl- cylinder bottom flows to drain circuit (B) from
inder bottom. the notch of boom spool (2).
q On the other hand, remaining oil flows to
regeneration circuit (C), opens check valve (6)
and flows to the cylinder head via circuit (D).
q Flow from regeneration circuit (C) and pump
(1) merges in circuit (E).
2. If the cylinder head pressure is higher than the bottom pressure (digging work, etc.)
Function
q Check valve (6) provided to regeneration cir-
cuit (C) closes to shut off the flow from the cyl-
inder bottom to the head.
Arm regeneration circuit

1. If the cylinder head pressure is higher than the bottom pressure
1. Hydraulic pump
2. Arm spool
5. Suction valve
6. Check valve
7. LS shuttle valve
Function Operation
q During arm digging, regeneration circuit pro- q If the cylinder head pressure is lower than the
vided from the cylinder head to the bottom bottom pressure, pressurized oil (A) from the
increases the cylinder speed as the cylinder cylinder bottom flows to drain circuit (B) from
flow involves the pump delivery plus regener- the notch of arm spool (2).
ated flow. q On the other hand, remaining oil flows to
regeneration circuit (C), opens check valve (6)
and flows to the cylinder head via circuit (D).
q Flow from regeneration circuit (C) and pump
(1) merges in circuit (E).
2. If the cylinder head pressure is lower than the bottom pressure
Function
q Check valve (6) provided to regeneration cir-
cuit (C) closes to shut off the flow from the cyl-
inder bottom to the head.
Merge-divider valve 1
1. When flows from the pumps merge [if pilot pressure (PS) is OFF]
1. Main spool 5. LS circuit (bucket side)

2. Spring 6. LS circuit (bucket side)
3. LS spool 7. LS circuit (arm side)
4. Spring 8. LS circuit (arm side)
Function Operation
q Merges pressurized oil (P1) and (P2) dis- q Since pilot pressure (PS) is OFF, output pres-
charged from the two pumps or divides (to sure from PPC valve is 0 MPa {0 kg/cm2}.
respective control valve group). q Main spool (1) is pressed to the right by spring
q Merges and divides LS circuit pressure. (2) and ports (E) and (F) are interconnected.
q Merges pressurized oil (P1) and (P2) dis-
charged from the two pumps at ports (E) and
(F) and sends to necessary control valve.
q Since pilot pressure (PS) is OFF for LS spool
(3), it is pressed to the right by spring (4), and
ports (A) – (D) and ports (B) – (C) are intercon-
nected.
q Forwards LS pressure led from respective con-
trol valve spools to LS circuits (5), (6), (7) and
(8) to all the pressure compensation valves.
2. When flows from the pumps are divided [if pilot pressure (PS) is ON]
Operation
q Pilot pressure (PS) turns ON, and output pres-
sure from the PPC valve shifts main spool (1)
to the left, and ports (E) and (F) are divided.
q Pressurized oil discharged from the two pumps
are sent to respective control valves.
P1 pressure: To bucket, L.H. travel, and boom

P2 pressure: To swing, R.H. travel, and arm
q LS spool (3) too shifts to the left under the out-

put pressure from the PPC valve, intercon-
nects ports (A) and (C) and divides other ports.
q Forwards LS pressure led from each control
valve spool to LS circuits (5), (6), (7) and (8) to
respective control valves.
LS select valve
Function Operation
q Prevents high LS pressure from the swinging 1. If pilot pressure (BP) is OFF
from entering the LS circuit of work valves q Since pilot pressure (BP) is OFF, piston (3) is
while the swinging and work equipment are in pressed to the left by spring (2).
combined operation. q When swing-operated, swing LS pressure (P1)
q Prevents high pressure generated during enters port (A) after passing swing spool (5).
swing drive and improves operability of work q Valve (1) is pressed to the left and ports (A)
equipment. and (B) are interconnected.
q Swing LS pressure (P1) flows to LS shuttle
valve (8).
2. If pilot pressure (BP) is ON

q If pilot pressure (BP) is ON, BP pressure con-
tracts spring (2), and piston (3) shifts to the
right.
q Valve (1) is pressed to the right and intercon-
nection between ports (A) and (B) is closed.
q Swing LS pressure (P1) stops flowing to LS
shuttle valve (8).
q If swing LS pressure (P1) rises, other LS cir-
cuits are not affected.
a The illustration shows the state of simulta-

neous operation of swinging and R.H. travel.
[(BP) pressure ON]
1. Valve
2. Spring
3. Piston
4. Piston
5. Swing spool
6. L.H. travel spool
7. Arm spool
8. LS shuttle valve
9. LS circuit
Self pressure reducing valve
Function
q Reduces the discharge pressure of the main
pump and supplies it as control pressure for
the solenoid valves, EPC valves, etc.
Operation
1. While engine is stopped
q Poppet (11) is pressed by spring (12) against
the seat and port (PR) is not connected to
(TS).
q Valve (14) is pressed by spring (13) against the
left side and port (P2) is connected to (TS).
q Valve (7) is pressed by spring (8) against the
left side and port (P2) is closed to (A2).
2. During neutral and when load pressure (P2) 3. When load pressure (P2) is high
is low q Load pressure (A2) increases with the opera-
a When load pressure (A2) is lower than self tion of digging, etc., and the pump discharge
pressure reducing valve output pressure (PR) increases accordingly.
q Pressure (P2) increases to [(φd area × P2
q Valve (7) is pressed to the closing direction of pressure) = force of spring (8) + (φd area × PR
circuit between ports (P2) and (A2) by spring pressure)]., and valve (7) moves to the right to
(8) and under pressure (PR) (which is 0 MPa the stroke end.
{0 kg/cm2}). q As a result, opening between ports (P2) and
q When pressurized oil flows in from port (P2), a (A2) increases, and the pass resistance
balance is reached due to [(φd area × P2 pres- reduces, reducing the engine horsepower loss.
sure) = force of spring (8) + (φd area × PR q When pressure (PR) rises above the set pres-
pressure)]. sure, poppet (11) opens.
q Adjusts valve (7) opening to keep pressure q Pressurized oil flows from port (PR) to orifice
(P2) at a constant level over pressure (PR). (a) in spool (14), then flows to seal drain port
q When pressure (PR) rises above the set pres- (TS) from poppet (11) opening.
sure, poppet (11) opens. q Differential pressure is generated before and
q Pressurized oil flows from port (PR) to orifice after orifice (a) in spool (14) and then spool
(a) in spool (14), then flows to seal drain port (14) moves to close the pass between ports
(TS) from poppet (11) opening. (P2) and (PR).
q Differential pressure is generated before and q Pressure (P2) is reduced by the opening at this
after orifice (a) in spool (14) and then spool time and adjusted to a constant pressure (the
(14) moves to close the pass between ports set pressure) and supplied as pressure (PR).
(P2) and (PR).
q Pressure (P2) is reduced by the opening at this
time and adjusted to a constant pressure (the
set pressure) and supplied as pressure (PR).
4. When abnormally high pressure is generated

q If pressure (PR) of self pressure reducing
valve becomes abnormally high, ball (16) con-
tracts spring (15) and becomes separated from
the seat.
q Allows the pressurized oil to (TS) from port
(PR) and lowers pressure (PR).
q Protects PPC valve, solenoid valve and other
devices from abnormal pressure.
Travel junction valve

1. When pilot pressure is turned ON
Function Operation
q This valve connects the L.H. and R.H. travel q Pilot pressure from the travel junction solenoid
circuits via travel junction valve so that the valve contracts spring (1), and travel junction
hydraulic oil will be supplied evenly to both spool (2) moves to the left to the stroke end.
travel motors to improve machine's straight q Junction circuit between port (PTL) (L.H. travel
travel performance. circuit) and port (PTR) (R.H. travel circuit) is
q When the machine is steered, outside pilot closed.
pressure (PST) closes the travel junction valve
to improve steering performance.
2. When pilot pressure is turned OFF
Operation
q If pilot pressure (PST) from the solenoid valve q If the oil flow rates to the L.H. and R.H. travel
is 0, travel junction spool (2) is pressed by the motors become different from each other, the
force of spring (1) against the right side and oil flows through the route between port (PTL),
the pass between ports (PTL) and (PTR) is travel junction spool (2), and port (PTR) so that
open. the oil flow rates to both motors will be equal-
ized again.
Travel PPC shuttle valve

1. When travel lever is in neutral
Function Operation
q Regulates flow to each cylinder by controlling q The oil in stroke regulation signal chamber (a)
the stroke of each spool of the boom, arm, and is drained through orifices (5) and (6) of pis-
bucket using the pilot pressure of travel PPC tons (3) and (4) in the travel spring case and
valve while climbing a steep grade, raising the the travel PPC valve.
boom, digging with arm, dumping, bucket-dig- q When operated for boom raising (or arm dig-
ging or operating dump. ging, dumping, bucket digging, dumping),
q When controlling the stroke of the boom, arm spool (1) moves to the left until it makes con-
and/or bucket, pilot pressure of travel PPC tact with the end face of spring casing (2) (st0).
valve passes through the circuit inside the con-
trol valves to actuate the system.
2. When traveling
Operation
q If the right travel lever is set in the reverse (or q Maximum stroke of the spool is limited to (st1)
forward) direction, pilot pressure from the PPC for the amount of movement (st2) of piston (8)
valve presses spool (7) to the left (or right). to the right.
q Spool (7) pushes piston (3) to close orifice (5)
and shuts off stroke regulation signal chamber
(a) and the drain circuit of the travel PPC
valve.
q At this time, the right travel reverse (or forward)
lever is set, PPC pressure is applied through
orifice (6) of piston (4) to the left end of piston
(8) to push piston (8) to the right.
q When operated for boom raising (or arm IN,
OUT, bucket CURL, DUMP), spool (1) moves
to the left.
Boom drift prevention valve

1. When raising boom
Function
q This valve prevents the oil in the boom cylinder
bottom from leaking through spool (1) and the
boom from lowering under its weight while the
boom lever is not operated.
Operation
q When the boom is raised, pressurized oil from
the control valve works on the ring-shaped
area (S) [= φ (d1) area – φ (d2) area] caused by
the difference between outside diameter (d1)
of poppet (5) and seat diameter (d2) to move it
to the left.
q Contracts spring (4) and poppet (5) moves to
the left.
q As a result, pressurized oil from the control
valve passes through the opening of poppet
(5) and flows to the bottom end of the boom
cylinder.
2. When the boom is in neutral
Operation
q Moves the lever to neutral with the boom
raised.
q Pressurized oil flown inside poppet (5) from
orifice (a) of poppet (5) is closed by pilot piston
(2).
q The holding pressure of boom cylinder bottom
works on the ring-shaped area (S) caused by
the difference between outside diameter (d1)
of poppet (5) and seat diameter (d2) to move it
to the right.
q The sum of this force and the force of spring
(4) closes poppet (5).
q Pressurized oil from the control valve and the
holding pressure of the boom cylinder bottom
are shut off.
3. When lowering boom
Operation
q When the boom is lowered, pilot pressure from
the PPC valve presses pilot spool (2).
q Pressurized oil in chamber (b) inside the pop-
pet is drained via orifice (c).
q Pressurized oil of the boom bottom flows to ori-
fice (a) o chamber (b) o orifice (c) o drain (T),
and the pressurized oil in chamber (b) lowers.
q As the pressure of chamber (b) lowers under
the pressure of port (B), poppet (5) opens.
q Pressurized oil from port (B) is led to port (A)
and then flows to the control valve.
Arm drift prevention valve

(if equipped)
1. When arm OUT
Function
q This valve prevents the oil in the arm head
from leaking through spool (1) and the boom
from lowering under its weight while the arm
lever is not operated.
Operation
q When the arm OUT is operated, pressurized
oil from the control valve works on the ring-
shaped area (S) [= φ (d1) area – φ (d2) area]
caused by the difference between the outside
diameter (d1) of poppet (5) and the seat diam-
eter (d2) to move it to the left.
q Contracts spring (4) and poppet (5) moves to
the left.
q As a result, pressurized oil from the control
valve passes through the opening of poppet
(5) and flows to the arm cylinder head.
2. When the arm is in neutral
Operation
q Moves the lever to neutral with the arm
dumped.
q Pressurized oil flown inside poppet (5) from
orifice (a) of poppet (5) is closed by pilot piston
(2).
q The holding pressure of arm cylinder head
works on ring-shaped area (S) caused by the
difference between outside diameter (d1) of
poppet (5) and seat diameter (d2) to move it to
the right.
q The sum of this force and the force of spring
(4) closes poppet (5).
q Pressurized oil from the control valve and the
holding pressure of the arm cylinder head are
shut off.
3. When arm IN
Operation
q When the arm IN is operated, pilot spool (2) is
pushed under the pilot pressure from the PPC
valve.
q Pressurized oil in chamber (b) inside the pop-
pet is drained via orifice (c).
q Pressurized oil of the arm head flows to orifice
(a) o chamber (b) o orifice (c) o drain (T),
and the pressurized oil in chamber (b) lowers.
q As the pressure of chamber (b) lowers under
the pressure of port (B), poppet (5) opens.
q Pressurized oil from port (B) is led to port (A)
and then flows to the control valve.
4. When abnormally high pressure is generated
q If abnormally high pressure is generated in the q If arm drift prevention valve (optional) is
boom cylinder bottom circuit, the pressurized installed to the arm cylinder head circuit, the
oil in port (B) pushes check valve (6) open, boom cylinder bottom circuit pressure force or
then safety valve (3) operates. arm cylinder head circuit pressure force,
whichever having higher pressurized oil,
pushes check valve (6) or (6A) open to actuate
safety valve (3).
Lift check valve

Function 2. While engine is running
q This valve applies back pressure to the drain q Output pressure (PR) of the self pressure
circuit to prevent generation of negative pres- reducing valve is applied via the control valve
sure on each actuator (motors, cylinders, etc.). to spring chamber (c) of back pressure valve
(3).
Operation q Output pressure (PR) applied to spring cham-
1. While engine is stopped ber (c) is applied to the left end of valve (1)
q Pressurized oil is not fed to the self pressure (area of φd) to push valve (1) to the right.
reducing valve from the pump, and valve (1) is q At this time, pressure (PA) of drain circuit (a) of
pressed to the right by the force of spring (2). the control valve is applied to the right end of
q Drain circuit (a) of the control valve is con- valve (1) (area of φd1) to push valve (1) to the
nected with port (T) through orifice (b) of valve left.
(1). q Valve (1) strikes balance to make the back
pressure equal to (PA) in the equation below.
(Area of φd) × PR + force of spring (2)

PA =
Area of φd1
Main relief valve
1. Spring
2. Poppet
Function
q Set pressure of the relief valve is in two stages.
q When power is needed, pilot pressure (P) is
turned ON and the set pressure becomes
higher.
Operation
q The set pressure of relief valve is determined
by spring (1) installed load. (1st stage)
q Respective setting is not required for both the
1st and 2nd stages. Setting the 1st stage com-
pletes the setting of the 2nd stage.
1. If pilot pressure (P) is OFF: Low-pressure

setting
Set pressure is determined by spring (1)
installed load.
2. If pilot pressure (P) is ON: High-pressure

setting
Spring (1) installed load is added with pilot
pressure (P) applied to the area of poppet
diameter (d1), raising the set pressure to
higher level.
2-stage safety-suction valve

[Installed to port (B) of the service valve]
1. Spring
2. Piston
3. Spring
4. Holder
Function Operation
q Enables to provide the safety valve set pres- q The safety set pressure is determined by
sure in two stages, and make the low-pressure spring (1) installed load.
setting smaller.
q Enables to relieve a load without lever opera- 1. If pilot pressure is OFF (high-pressure set-
tion if high load is applied to the cylinder. ting)
q Improves work efficiency and reduces machine q Since pilot pressure (P) is OFF, piston (2) is
body vibration. pressed to the left by spring (3). [Spring (1)
installed load < spring (3) installed load]
q Spring (1) installed load becomes maximum
and the set pressure rises.
q Passage (B) is interconnected to the drain cir-
cuit via passage (C) and chamber (D).
2. If pilot pressure is ON (low-pressure set-

ting)
q If the pilot pressure (P) is ON, the pilot pres-
sure is led to section (A) via passage (B).
q Piston (2) works on the pressure-receiving
bore portion [(d2) – (d1)] of section (A).
q This pilot pressure contracts spring (3), and
piston (2) moves to the right until making con-
tact with holder (4).
q Spring (1) stretches, installed load is reduced,
and the set pressure lowers.
q Pressurized oil proportionate to the piston
stroke is drained via passage (C) and chamber
(D).
Variable pressure compensation valve

(Installed to the service valve)
A. Pump discharge pressure (P) (From service

valve spool)
B. Cylinder port
C. Load pressure of other work equipment
1. Valve
2. Spring
3. Sleeve
4. Poppet
5. Spring
6. Screw
7. Locknut
8. Cap
Function
q Regulates flow distribution to the service valve
when the service valve (attachment) and the
work equipment valve (boom raising, etc.) are
operated together. (Equivalent surface area
ratio variable)
q Pressurized oil from the service valve spool is
applied to the left side of valve (1) and is led to
chamber (g) via orifice (a).
q LS pressure is led to chamber (e) via orifice
(d).
q Pressurized oil of cylinder port is led to cham-
ber (h) via passage (c) and orifice (f).
q The force of spring (2) acts on valve (1), and
the force of spring (5) acts on poppet (4).
q The force of spring (5) can be adjusted with
screw (6).
Operation when jointly operated with a high-load q If the difference between the pump discharge
work equipment (such as the boom raising) pressure (P) and cylinder port pressure (B) is
q Both of the pump discharge pressure (P) and larger than the force of spring (5), poppet (4) is
LS pressures are determined by other equip- pressed to the right.
ment's pressure, while cylinder port pressure q Pump discharge pressure (P) flows to orifice
causes the attachment to operate. (a) and chamber (g) and is interconnected to
q If the difference between the pump discharge cylinder port via passages (b) and (c).
pressure (P) and cylinder pressure is smaller q Differential pressure is generated between the
than the force of spring (5), the balance of upstream and downstream of orifice (a), which
forces applying to valve (1) may be expressed reduces the pressure force in chamber (g).
with the following equation: q Force that presses valve (1) to the left is
reduced.
P × A1 = P × A2 + LS (A2 – 1) + F q A state is reached where the area ratio has
become smaller.
A1: Area of φD1 q Valve (1) moves to the right, and the flow
A2: Area of φD2 increases from the pump to the cylinder.
F: Force of spring
P: Pump discharge oil pressure
Attachment circuit selector valve 1
ACC: To accumulator 1. Spool

ATT: To attachment 2. Spring
P1: From attachment selector solenoid valve
T: To hydraulic oil tank
TS: To hydraulic oil tank
V: To control valve
Unit: mm

Free length × Installed Installed Installed If damaged or
Free length
3 Spool return spring Outside diameter length load load deformed, replace
834 N 667 N spring.
132 × 29 114.5 —
{85.0 kg} {68.0 kg}
Function
q When a breaker is installed, the return oil from
the breaker does not pass through the main
valve, but returns directly to the hydraulic tank.
q When other attachments (crusher, etc.) are
installed, the attachment and the main valve
are interconnected.
Operation
1. When attachment other than breaker is 2. When breaker is installed
installed q Pilot pressure from the attachment circuit
q Spool (1) is pressed to the left by the force of selector solenoid valve contracts spring (2),
spring (2). and spool (1) moves to the right to the stroke
q Ports (ATT) and (V) are interconnected and end.
ports (ATT) and (T) are shut off. Attachment is q Ports (ATT) and (V) are shut off and ports
thus interconnected to the control valve. (ATT) and (T) are interconnected.
q Pressurized oil returning from the breaker
returns directly to the hydraulic tank via port (T)
without passing through the control valve.
Hydraulic drift prevention valve 1

(For the boom and arm)
CY: To work equipment cylinder

PCY: For pressure pickup port and equalizer circuit
PI: From PPC valve
T: To tank
V: From control valve
1. Pilot spool
2. Spring (1st stage spool)
3. Spring (2nd stage spool)
4. Safety valve
5. Check valve
6. Spring
Unit: mm
Free length × Installed Installed Installed
Free length
7 Check valve spring Outside diameter length load load
12.7 N 10.2 N
20.8 × 12.2 13.5 —
{1.3 kg} {1.04 kg} If damaged or
8 Spool return spring 41.1 × 9.6 35.0
{6.0 kg}
—
{4.8 kg} spring.
78.5 N 62.8 N
{8.0 kg}
—
{6.4 kg}
181 N 145 N
{18.5 kg}
—
{14.8 kg}
Function
q Prevents the pressurized oil from reversing
from the work equipment cylinder and the latter
from a sudden drop if the piping bursts
between the control valve and the work equip-
ment cylinder.
Operation
1. When the work equipment lever is in neutral
When the piping is free of burst If the piping is bursted

q Check valve (5) is closed under the holding q If piping (A) bursts between the control valve
pressure of the cylinder led from port (CY) to and the work equipment cylinder, chambers (a)
chamber (b). and (b) are shut off same as when the piping
q Pilot pressure led to port (PI) from the PPC has no burst.
valve when in neutral is 0 MPa {0 kg/cm2}. q Pressure for the work equipment cylinder is
q Spool (1) is pressed to the left by the force of held to prevent a sudden drop of the work
springs (2) and (3) equipment.
q Chambers (a) and (b) are shut off.
q No pressurized oil flows between the control
valve and the work equipment cylinder.
q Accordingly, the work equipment is held in
position.
q If the work equipment cylinder has abnormally
high pressure, safety valve (4) is actuated by
the holding pressure of the work equipment
cylinder.
q Chambers (b) of L.H. and R.H. hydraulic drift
prevention valve for the boom are intercon-
nected by port (PCY).
q Chambers (b) will have the same pressure if
the L.H. and R.H. hydraulic drift prevention
valves have a difference in leakage.
2. When pressurized oil flows from the main valve to the cylinder
When the piping is free of burst

q Pressurized oil led to chamber (a) from the
control valve becomes higher than the com-
bined force of pressure from work equipment
cylinder circuit chamber (b) and spring (6).
q Check valve (5) opens and chambers (a) and
(b) are interconnected.
q Pressurized oil flows from the control valve to
the work equipment cylinder.
If the piping is bursted

q If piping (A) bursts between the control valve
and the work equipment cylinder, pressurized
oil in chamber (a) flows outside from the
bursted portion.
q Pressure force in chamber (a) drops.
q Pressure force in chamber (a) drops lower than
the combined pressure force of chamber (b)
and spring (6).
q Check valve (5) closes and chambers (a) and
(b) are cut off.
q Pressure for the work equipment cylinder is
held to prevent a sudden drop of the work
equipment.
3. When returning pressurized oil to the main valve from the work equipment cylinder
When the piping is free of burst If the piping is bursted

q Holding pressure of the work equipment cylin- q If piping (A) bursts between the control valve
der is led to chamber (b) and check valve (5) and the work equipment cylinder.
closes. q Pressurized oil in chamber (a) flows out to the
q Pilot pressure from the PPC valve is led to port bursted portion but resupplied from chamber
(PI) and reaches [Pilot Pressure > Force of (b).
Spring (3)] (area of d). q Since pressurized oil flows via opening (c) of
q Spool (1) moves to the right to the standby spool (1), a sudden drop of the cylinder is pre-
position. (1st stage stroke) vented.
q At this point, chambers (a) and (b) are not
interconnected.
q Pilot pressure further rises, and reaches [Pilot
pressure > Force of spring (2)] (area of d).
q Spool (1) moves further to the right, and cham-
bers (a) and (b) are interconnected. (2nd stage
stroke)
q Pressurized oil returns to the control valve
from the work equipment cylinder.
SEN01429-01

© 2010 KOMATSU
All Rights Reserved
64
SEN01430-00
PC228US-3E0
PC228USLC-3E0


Valve control......................................................................................................................................... 2
PPC valve ............................................................................................................................................ 4
PPC Accumulator............................................................................................................................... 22
Return oil filter .................................................................................................................................... 23
Center swivel joint .............................................................................................................................. 24
Travel motor ....................................................................................................................................... 25
Swing motor ....................................................................................................................................... 35
Hydraulic cylinder............................................................................................................................... 44
PC228US, USLC-3E0 1

Valve control 1
1. Travel PPC valve Lever positions

2. Service PPC valve A. Hold
3. Service pedal B. Boom (RAISE)
4. L.H. travel lever C. Boom (LOWER)
5. R.H travel lever D. Bucket (DUMP)
6. R.H. PPC valve E. Bucket (CURL)
7. R.H. work equipment control lever F. Hold
8. Solenoid block G. Arm (IN)
9. Control valve H. Arm (OUT)
10. Accumulator J. Swing (RIGHT)
11. Hydraulic pump K. Swing (LEFT)
12. L.H. work equipment control lever L. Neutral
13. L.H. PPC valve M. Travel (REVERSE)
14. Lock lever N. Travel (FORWARD)
P. Free
Q. Lock
2 PC228US, USLC-3E0
PPC valve 1
Work equipment and swing PPC valve
P: From self pressure reducing valve

P1: L.H. PPC: Arm out/R.H. PPC: Boom lower
P2: L.H. PPC: Arm in/R.H. PPC: Boom raise
P3: L.H. PPC: Swing left/R.H. PPC: Bucket curl
P4: L.H. PPC: Swing right/R.H. PPC: Bucket dump
T: To tank
4 PC228US, USLC-3E0
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 lever connection)
Unit: mm

Centering spring Free length
12 (for ports P3 and P4)
Outside diameter length load load
17.7 N 13.7 N If damaged or
42.5 × 15.5 34.0 —
{1.80 kg} {1.40 kg} deformed, replace
Centering spring 29.4 N 23.5 N spring.
13 (for ports P1 and P2)
44.5 × 15.5 34.0
{3.0 kg}
—
{2.40 kg}
16.7 N 13.7 N
14 Metering spring 26.5 × 8.15 24.9
{1.70 kg}
—
{1.40 kg}
PC228US, USLC-3E0 5
Operation
1. When in neutral q The relationship of the position of spool (1) and
q Ports (A) and (B) of the control valve and ports body (10) [fine control hole (f) is in the middle
(P1) and (P2) of the PPC valve are connected between drain chamber (D) and pump pres-
to drain chamber (D) via fine control hole (f) in sure chamber (PP)] does not change until
spool (1). retainer (9) contacts spool (1).
q Metering spring (2) contracts in proportion to
the stroke of the control lever.
q Pressure at port (P1) also rises in proportion to
q In this way, 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.
2. During fine control

(Neutral o fine control)
q When piston (4) is pushed by disc (5), retainer
(9) is pushed, spool (1) is also pushed by
metering spring (2), and moves down.
q When fine control hole (f) is shut off from drain
chamber (D), it is almost simultaneously inter-
connected to pump pressure chamber (PP).
q Pilot pressurized oil of the control pump is led
to port (A) from port (P1) via fine control hole
(f).
q When the pressure at port (P1) becomes higher,
spool (1) is pushed back and fine control hole (f)
is shut off from pump pressure chamber (PP). At
almost the same time, it is connected to drain
chamber (D) to release the pressure at port (P1).
q As a result, spool (1) moves up and down until
the force of metering spool (2) is balanced with
the pressure at port (P1).
6 PC228US, USLC-3E0
3. During fine control 4. At full stroke

(When control lever is returned) q Disc (5) pushes down piston (4), and retainer
q When disc (5) starts to be returned, spool (1) is (9) pushes down spool (1).
pushed up by the force of centering spring (3) q Fine control hole (f) is shut off from drain
and the pressure at port (P1). chamber (D), and is interconnected to pump
q Because of this, fine control hole (f) is con- pressure chamber (PP).
nected to drain chamber (D), and the pressur- q Therefore, the pilot pressure oil from the self
ized oil at port (P1) is released. pressure reducing valve passes through fine
q If the pressure of port (P1) is lowered exces- control hole (f) and flows to chamber (A) from
sively, spool (1) is pushed down by metering port (P1) to push the control valve spool.
spring (2). q The oil returning from chamber (B) passes
q Fine control hole (f) is shut off from drain from port (P2) through fine control hole (f') and
chamber (D), and it is almost simultaneously flows to drain chamber (D).
interconnected to pump pressure chamber
(PP).
q Pump pressure is supplied until the pressure at
port (P1) recovers to the level equivalent to the
lever position.
q When the spool of the control valve returns,
the 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 replenish the cham-
ber with pressurized oil.
PC228US, USLC-3E0 7
Travel PPC valve
P: From self pressure reducing valve

P1: L.H. reverse
P2: L.H. forward
P3: R.H. reverse
P4: R.H. forward
P5: Travel signal
P6: Steering signal
T: To tank
8 PC228US, USLC-3E0
1. Plate
2. Body
3. Piston
4. Collar
5. Centering spring
6. Metering spring
7. Valve
8. Dumper
9. Steering signal spool
10. Steering signal spool spring
Unit: mm

Free length
11 Centering spring Outside diameter length load load
108 N 86.3 N If damaged or
47.6 × 15.5 32.5 —
{11.0 kg} {8.8 kg} deformed, replace
16.7 N 13.7 N spring.
{1.7 kg}
—
{1.4 kg}
8.8 N 7.1 N
13 Steering signal spring 12.8 × 7.3 8.5
{0.9 kg}
—
{0.72 kg}
1. Pressure reducing valve
Operation q The relationship of the position of spool (1) and

1) When in neutral body (10) [fine control hole (f) is in the middle
q Ports (A) and (B) of the control valve and ports between drain chamber (D) and pump pres-
(P1) and (P2) of the PPC valve are connected sure chamber (PP)] does not change until
to drain chamber (D) via fine control hole (f) in retainer (9) contacts spool (1).
spool (1). q Metering spring (2) contracts in proportion to
q Pressure at port (P1) also rises in proportion to
q In this way, 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.
2) During fine control

(Neutral o fine control)
q When piston (4) is pushed by disc (5), retainer
(9) is pushed, spool (1) is also pushed by
metering spring (2), and moves down.
q When fine control hole (f) is shut off from drain
chamber (D), it is almost simultaneously inter-
connected to pump pressure chamber (PP).
q Pilot pressurized oil of the control pump is led
to port (A) from port (P1) via fine control hole
(f).
q When the pressure at port (P1) becomes
higher, spool (1) is pushed back and fine con-
trol hole (f) is shut off from pump pressure
chamber (PP). At almost the same time, it is
connected to drain chamber (D) to release the
pressure at port (P1).
q As a result, spool (1) moves up and down until
the force of metering spool (2) is balanced with
the pressure at port (P1).
3) During fine control q Therefore, the pilot pressure oil from the self
(When control lever is returned) pressure reducing valve passes through fine
q When lever (5) starts to be returned, spool (1) control hole (f) and flows to chamber (A) from
is pushed up by the force of centering spring port (P1) to push the control valve spool.
(3) and pressure at port (P1). q The oil returning from chamber (B) passes
q Because of this, fine control hole (f) is con- from port (P2) through fine control hole (f') and
nected to drain chamber (D), and the pressur- flows to drain chamber (D).
ized oil at port (P1) is released.
q If the pressure of port (P1) is lowered exces-
sively, spool (1) is pushed down by metering
spring (2).
q Fine control hole (f) is shut off from drain
chamber (D), and it is almost simultaneously
interconnected to pump pressure chamber
(PP).
q Pump pressure is supplied until the pressure at
port (P1) recovers to the level equivalent to the
lever position.
q When the spool of the control valve returns,
the 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 replenish the cham-
ber with pressurized oil.
2. Travel signal/Steering function

Travel signal
q Travel signal if either of the L.H. or R.H. travel
levers is operated, the higher PPC output pres-
sure of both sides is output as the travel signal.
q Accordingly, whether the machine is travelling
is judged by the signal of port (P5).
Steering signal
q If the operation quantities of both levers are dif-
ferent from each other as in the steering opera-
ti o n , t h e hi g h e r o ne o f t h e P P C o u tp u t
pressures of both sides is output as the steer-
ing signal.
q Any signal is not output from port (P6) while
the machine is travelling straight (forward or
reverse) or in neutral.
4) At full stroke
q Accordingly, whether the machine is being
q Lever (5) pushes down piston (4), and retainer
steered is judged by the signal of port (P6).
(9) pushes down spool (1).
q Fine control hole (f) is shut off from drain
chamber (D), and is interconnected to pump
pressure chamber (PP).
Operation
1) When in neutral
q No output is made from respective output ports

[from port (P1) to (P4)], travel signal [port (P5)]
and steering signal [port (P6)].
2) During straight travel
a The Illustration shows the circuit for travelling straight forward.
q When operating L.H. motor forward [port (P2)

output] and R.H. motor forward [port (P4) out-
put], pressure of both L.H. spring chamber (k)
and R.H. spring chamber (l) rises high.
q Steering signal spool (j) remains at neutral
position and does not output a steering signal
to port (P6).
3) When steered or pivot-turned
a The Illustration shows the circuit for left forward (slow) and right forward (fast) operation.
q If the operation quantities of both levers are dif- q Port (P4) pressure of the L.H. or R.H. PPC
ferent from each other as in the steering opera- valves, whichever having a higher output pres-
tion (if the difference of the pilot pressure sure, is output to port (P6) as the steering signal.
between both sides is higher than a certain
level), the pilot pressure is output as the steer-
ing signal.
q The pressure in left spring chamber (k) of steer-
ing signal spool (j) is (P2).
q The pressure in right spring chamber (l) is
(P4).
q When the pressure state reaches [(P4 – P2) ×
(Spool section) > Spring set load], the spool is
switched to the direction of the arrow.
4) When counter-rotated
a The illustration shows the circuit for travelling left reverse and right forward.
q When operating L.H. motor reverse [port (P1)

output] and R.H. motor forward [port (P4) out-
put], pressure of the R.H. spring chamber (l)
only rises high.
q Steering signal spool (j) strokes to the left to
output the steering signal to port (P6).
Service PPC valve
a For the details of operation, see the paragraph of “Work equipment swing PPC valve”.
P: From self pressure reducing valve 1. Spool

P1: To service valve 2. Piston
P2: To service valve 3. Lever
T: To tank 4. Plate
5. Retainer
6. Body
Unit: mm
Free length
7 Centering spring Outside diameter length load load If damaged or
125 N 100 N deformed, replace
33.9 × 15.3 28.4 — spring.
{12.7 kg} {10.2 kg}
16.7 N 13.3 N
{1.70 kg}
—
{1.36 kg}
Solenoid valve
PPC lock, 2-stage relief, swing brake, travel speed, travel junction, and merge-divider solenoid valves
1. PPC lock solenoid valve 8. Moving core

2. 2-stage relief solenoid valve 9. Coil
3. Travel speed solenoid valve 10. Spool
4. Swing brake solenoid valve 11. Block
5. Travel junction solenoid valve 12. Spring
6. Merge-divider solenoid valve
7. Connector
T: To tank When solenoid is energized

A1: To PPC valve
q As the signal current flows from the controller
A2: To main valve (2-stage relief valve)
to solenoid (9), solenoid (9) is energized.
A3: To L.H. and R.H. travel motors
Accordingly, spool (10) is pushed to the right.
A4: To swing motor
This operation flows the pressurized oil from
A5: To main valve (Travel junction valve) the main pump, through port (P), via inside
A6: To main valve (Merge-divider) spool (10), to port (A), and eventually to the
P1: From main pump actuator.
ACC: To accumulator At the same time, port (T) closes, the oil does
not flow to the tank.
Operation
When solenoid is de-energized
q Since the signal current does not flow from the
controller, solenoid (9) is de-energized.
For this reason, spool (10) is pushed to the left
by spring (12).
Since port (P) is closed to port (A), pressurized
oil from the main pump does not flow to the
actuator.
At this time, the oil from the actuator is drained
through ports (A) and (T) into the tank.
PPC Accumulator 1
1. Gas plug
2. Shell
3. Poppet
4. Holder
5. Bladder
6. Oil port
Specifications
Gas capacity: 300 cc (for PPC)
500 cc (for swing(s))
Return oil filter 1

For breaker
1. Drain plug Specifications

2. Filter Rated pressure: 6.9 MPa {70 kg/cm2}
3. Case Flow rate: 200 l/min
4. Head cover Relief valve cracking pressure:
5. Relief valve 0.34 ± 0.05 MPa {3.5 ± 0.5 kg/cm2}
Filter mesh size: 6 mm
Filtering area: 4,570 cm2
Center swivel joint 1
1. Cover A1: To L.H. travel motor port PB

2. Body A2: From control valve port A5
3. Slipper seal B1: To L.H. travel motor port PA
4. O-ring B2: From control valve port B5
5. Shaft C1: To R.H. travel motor port PA
C2: From control valve port A2
D1: To R.H. travel motor port PB
D2: From control valve port B2
E: To L.H. and R.H. travel motors port P
T1: From L.H. and R.H. travel motors port T
T2: To tank
Unit: mm
Clearance between rotor and Standard size Standard clearance Clearance limit
6 shaft
Replace
80 — —
Travel motor 1
Type: HMV110-2
B: Brake release pressure port Specifications

MA: MA pressure detection port Type : HMV110-2
MB: MB pressure detection port Theoretical displacement
P: From travel speed solenoid valve (Min.) : 74 cm3/rev
PA: From control valve (Max.) : 110.7 cm3/rev
PB: From control valve Rated pressure : 37.3 MPa {380 kg/cm2}
T: To tank Rated speed
(Capacity min.) : 2,980 rpm
(Capacity max.) : 1,485 rpm
Brake release pressure : 1.18 MPa {12 kg/cm2}
Travel speed selector pressure
(differential pressure) : 0.78 MPa {8 kg/cm2}
1. Regulator piston
2. Regulator valve
3. Motor case
4. Suction safety valve
5. Check valve
6. Output shaft
7. Rocker cam
8. Retainer guide
9. Pin
10. Piston
11. Retainer
12. Cylinder block
13. Valve plate
14. Counterbalance valve
15. Ring
16. Brake piston
17. Plate
18. Disc
19. Ball
Unit: mm

Free length x Installation Installation Installation
Free length
20 Regulator piston spring Outside diameter length load load
147 N 118 N
52.6 x 20.3 36.0 —
{15.0 kg} {12.0 kg}
54.9 N 43.9 N If damaged or
21 Regulator valve spring 21.5 x 11.1 17.1
{5.6 kg}
—
{4.48 kg} deformed, replace
1.96 N spring.
1.57 N
{0.2 kg}
—
{0.16 kg}
7.16 N 5.69 N
{0.73 kg}
—
{0.58 kg}
427 N 341 N
{43.5 kg}
—
{34.8 kg}
Operation of motor
1) At slow speed (motor swash plate angle at maximum)
q As the solenoid valve is de-energized, the pilot q Rocker cam (4) is inclined in the maximum
pressurized oil from the self pressure reducing swash plate angle direction. The motor capac-
valve does not flow to port (P). ity becomes maximum, turning on the low
q Regulator valve (9) is pushed to the right by speed travel.
spring (10).
q Pressurized oil being conducted from the con-
trol valve to end cover (8) by pressing check
valve (22) is shut off by regulator valve (9).
q Fulcrum (a) of rocker cam (4) is eccentric to
the working point (b) of the combined force of
the propulsion force of cylinder (6).
q The combined force of the piston propulsion
forces works as the moment of inclining rocker
cam (4) toward the maximum swash plate
angle.
q The pressurized oil at regulator piston (15)
passes through orifice (c) of regulator valve (9)
and is drained to the motor case.
2) At high speed (motor swash plate angle at minimum)
q As the solenoid valve is energized, the pilot

pressurized oil from the self pressure reducing
valve flows to port (P).
q Regulator valve (9) is pushed to the left.
q The pressurized oil from the control valve
passes through passage (d) in regulator valve
(9) and enters regulator piston (15).
q Regulator piston (15) is pushed to the right.
q Rocker cam (4) is inclined in the minimum
swash plate angle direction. The motor capac-
ity becomes minimum, turning on the high
speed travel.
Operation of parking brake
1) When starting travel
q As the travel lever is operated, pressurized oil

from the pump activates counterbalance valve
spool (19), opening the parking brake circuit.
q The pressurized oil is conducted to chamber
(e) of brake piston (12) and compresses spring
(11), pushing piston (12) toward left.
q Since the pushing force to plate (13) and disc
(14) disappears, plate (13) is separated from
disc (14) and the brake is released.
2) When travel is stopped
q As the travel lever is placed in neutral, counter-

balance valve spool (19) returns to the neutral
position and closing the parking brake circuit.
q The pressurized oil in chamber (e) of brake
piston (12) passes through orifice (f) of brake
piston (12) and is drained to the motor case.
q Brake piston (12) is pushed to the right by
spring (11).
q Plate (13) and disc (14) are pushed together,
and the brake is applied.
q As brake piston (12) returns, flow of pressur-
ized oil is reduced with slow return valve (22).
q The time delay will be set to activate the brake
only after the machine has stopped.
Brake valve Operation when pressurized oil is supplied

q The brake valve consists of suction safety q Operating the travel lever conducts the pres-
valve (18A) and counterbalance valve (18). surized oil from the control valve to port (PA).
q Functions and operations of respective compo- q The pressurized oil push-opens suction safety
nents shall conform to the following. valve (18A) and then flows to motor outlet port
(MB) via motor inlet port (MA).
1) Counterbalance valve and check valve q The motor outlet side is closed by suction
safety valve (18B) and spool (19), so the pres-
Function sure at the supply side rises.
q When traveling downhill, the machine travel
speed tends to get faster than the motor
(engine) speed because of the downward force
generated from its own weight.
q If the machine travels with the engine at low
speed, the motor may rotate without load,
causing the machine to run away; resulting in a
very dangerous situation.
q These valves are used to prevent above by
controlling the machine to travel according to
the engine speed (pump delivery).
q The pressurized oil on the supply side flows to Operation of brake during travelling downhill
chamber (S1) via orifice (E1) and orifice (E2) of q If indication of the machine runaway is sensed
the spool (19). while travelling downhill, the motor will be
q As the pressure in chamber (S1) goes above caused to rotate without load to decrease the
the spool selector pressure, spool (19) is inlet side oil pressure.
pushed toward right. q Pressure in chamber (S1) is released via ori-
q Port (MB) and port (PB) are connected, open- fices (E1) and (E2).
ing the motor outlet port side and starting the q As the pressure in chamber (S1) goes below
motor rotating. the spool selector pressure, spool (19) is
returned to the left by spring (20) and outlet
port (MB) is throttled.
q The pressure at the outlet port side rises, gen-
erating rotation resistance on the motor to pre-
vent the machine from running away.
q The spool moves to a position where the pres-
sure on outlet port (MB) can be balanced
against the machine's own weight and the inlet
port pressure.
q Oil flow from the outlet circuit is reduced to
ensure the travel speed corresponded to the
pump delivery.
2) Safety valve q When the pressure rises above the set pressure
of the suction safety valve, poppet (1) opens.
Function q The pressurized oil passes through notch (A1)
of spool (19) into chamber (MA) of the circuit at
q As long as the machine travel is stopped (or it the opposite side.
is travelling downhill), the counterbalance q At the time of counterclockwise rotation, it
valve closes the inlet and outlet circuits of the makes reverse operation of clockwise rotation.
motor.
q Since the motor is rotated by inertial force,
pressure in the motor outlet port side is abnor-
mally increased, potentially resulting in dam-
ages on the motor and piping.
q The safety valve releases this abnormal pres-
sure to the inlet port side of the motor in order
to prevent damages to the equipment.
Operation
(1) When travel is stopped
(or when travelling downhill) (Right rotation)
q Reduction of the pressure at motor inlet (PA)
decreases the pressure in chamber (S1). 3) When starting travel
q When it drops beyond the spool switching
(or when traveling at a constant speed)
pressure, spool (19) is returned to the left by
q As the travel lever is operated, the pressurized
spring (20), reducing the pressure at outlet
oil from the pump moves spool (19) toward right.
passage (B1).
q The passage to the suction safety valve func-
q The motor tries to continue rotation resorting to
tions as a circuit which passes through notch
inertial force, thus pressure on the outlet port
(B2) of spool (19), producing large differential
(MB) is increased.
pressure.
q The pump pressure rises, providing a large
tractional force to the valve.
Swing motor 1
Type: KMF125ABE-5
B: From swing holding brake solenoid Specifications

MA: From control valve Type : KMF125ABE-5
MB: From control valve Theoretical displacement : 125 cm3/rev
S: From control valve Safety valve set pressure : 28.9 MPa {295 kg/cm2}
T: To tank Rated engine speed : 1,503 rpm
Brake release pressure : 1.9 MPa {19 kg/cm2}
1. Reverse prevention valve
2. Safety valve
1. Brake spring
2. Drive shaft
3. Spacer
4. Case
5. Disc
6. Plate
7. Brake piston
8. Housing
9. Piston
10. Cylinder block
11. Valve plate
12. Center shaft
13. Center spring
14. Check valve
15. Shuttle valve
Unit: mm
Free length
16 Check valve spring Outside diameter length load load If damaged or
62.5 × 20.0 39.0 — spring.
{0.31 kg} {0.25 kg}
13.7 N 11.0 N
17 Shuttle valve spring 16.4 × 8.9 11.5
{1.4 kg}
—
{1.12 kg}
Swing holding brake

1. When solenoid valve is de-energized 2. When solenoid valve is energized
Operation Operation
q As the swing holding brake is de-energized, the q As the swing brake solenoid valve is ener-
pressurized oil from the self pressure reducing gized, the valve is switched.
valve is shut off. q The pressurized oil from the self pressure
q Port (B) is connected to tank circuit (T). reducing valve is conducted brake chamber (a)
q Brake piston (7) is pushed down by brake via port (B).
spring (1). q After entering chamber (a), the pressurized oil
q Disc (5) and plate (6) are pushed together, and compresses brake spring (1) and pushes
the brake is applied. brake piston (7) up.
q Disc (5) is separated from plate (6), releasing
the brake.
Relief valve portion 2. When swing is stopped

q When the swing control lever is returned to
Outline neutral, the supply of pressurized oil from the
q The relief valve portion consists of check pump to port (MA) is stopped.
valves (2) and (3), shuttle valves (4) and (5), q The pressurized oil from the motor outlet can't
and relief valve (1). return to the tank since the returning circuit to
the tank is closed from control valve (6). Thus,
Function pressure on port (MB) increases.
q Rotation resistance is generated on the motor
q When the machine is in the swing holding
and hence the brake starts working.
mode, control valve (6) closes the motor outlet
q Shuttle valve (4) is pressed as pressure on
circuit, but the motor rotation is continued by
port (MB) goes above port (MA).
inertial force.
q The pressure on chamber (C) is increased to
q The motor output, therefore, is abnormally
the se t pr es sure of relief va lv e (1) an d
increased, resulting in damaging the motor.
becomes the same as that of port (MB).
q In order to prevent the motor damages, the
q A high braking torque works on the motor,
relief valve relieves the abnormally high pres-
thereby stopping the motor.
sure to port (S) from the motor outlet side
q When relief valve (1) is being actuated, the
(high-pressure side) of the motor.
relieved pressurized oil and the pressurized oil
from port (S) are fed to port (MA) via check
Operation
valve (3).
1. When starting swing q Above prevents cavitation on port (MA).
q When the swing control lever is operated to the
right- swing, the pressurized oil from the pump
is supplied to port (MA) via control valve (6).
q The pressure on port (MA) rises, the starting
torque is generated in the motor, and the motor
starts to rotate.
q The pressurized oil from the outlet port of the
motor passes from port (MB) through the con-
trol valve (6) and returns to the tank.
Reverse prevention valve
MA: From control valve

MB: From control valve
T1: To tank
T2: To tank
1. Valve body
2. Spool (MA side)
3. Spring (MA side)
4. Plug (MA side)
5. Spool (MB side)
6. Spring (MB side)
7. Plug (MB side)
Explanatory drawing of effects
Function 2. When motor is stopped temporarily

q This valve reduces the swing back generation q The motor rotation is reversed by the closing
in the swing body by the inertia of the swing pressure generated at port (MB). (1st time:
body, the backlash and rigidity of the machin- reverse rotation)
ery system, and the compression of the q Reversing pressure is generated on port (MA).
hydraulic oil when the swing is stopped. Pressure (MA) is conducted to chamber (a).
q The valve contributes in preventing collapsing q The pressure compresses spring (3) by use of
of load when the swing is stopped and also the difference in areas of circles (φD3 > φD4) of
contributes in reducing cycle time (enhances spool (2) and moves spool (2) to the right side.
the positioning performance, enabling you to q Port (MA) o chamber (b) will be intercon-
proceed to the next work quicker than ever). nected.
q Then ports (b) and (f) will be interconnected
Operation through the drilled hole (h) on spool (5). This
1. When port (MB) brake pressure is gener- interconnection bypasses the reversing pres-
ated sure on port (MA) to port (T), thereby prevent-
q Pressure (MB) is conducted to chamber (d) via ing the reverse rotation of the 2nd time.
notch (g).
q The pressure compresses spring (6) by use of
the difference in areas of circles (φD1 > φD2) of
spool (5) and moves spool (5) to the left side.
q Port (MB) o chamber (e) will be intercon-
nected.
q Since pressure (MA) is lower than the set pres-
sure of spring (3), spool (2) does not move and
the pressurized oil is kept in. Thus the braking
force is ensured.
Hydraulic cylinder 1
Boom cylinder
Arm cylinder
Bucket cylinder
Unit: mm

Cylinder
size Shaft Hole clearance limit
–0.036 +0.222 0.083 –

Boom 85 0.412
Clearance between pis- –0.090 +0.047 0.312
1 Replace bushing
ton rod and bushing
–0.036 +0.222 0.083 –
Arm 95 0.412
–0.090 +0.047 0.312
–0.030 +0.222 0.077 –
Bucket 80 0.398
–0.076 +0.047 0.298
–0.030 +0.190 0.100 –
Boom 80 1.0
–0.060 +0.070 0.250
Clearance between pis-
–0.030 +0.190 0.100 –
2 ton rod support shaft Arm 80 1.0
–0.076 +0.070 0.266
and bushing
–0.030 +0.170 0.100 –
Bucket 70 1.0
–0.076 +0.070 0.246 Replace pin or
–0.030 +0.165 0.075 – bushing
Boom 70 1.0
–0.060 +0.045 0.225
Clearance between cyl-
–0.030 +0.190 0.100 –
3 inder bottom support Arm 80 1.0
–0.076 +0.070 0.266
shaft and bushing
–0.030 +0.165 0.075 –
Bucket 70 1.0
–0.060 +0.045 0.225
SEN01430-00

© 2006 KOMATSU
All Rights Reserved
46
SEN01431-00
PC228US-3E0
PC228USLC-3E0


Work equipment
Work equipment .............................................................................................................................................. 2
Work equipment ................................................................................................................................... 2
Dimensions of components .................................................................................................................. 4
PC228US, USLC-3E0 1
Work equipment 1
Work equipment 1
2 PC228US, USLC-3E0
Unit: mm
Clearance between connecting size clearance limit
Shaft Hole
1 pin and bushing of revolving
frame and boom –0.036 +0.135 0.110 –
90 1.0
–0.071 +0.074 0.206
Clearance between connecting
–0.036 +0.137 0.113 –
2 pin and bushing of boom and 90 1.0
–0.071 +0.077 0.208
arm
Clearance between connecting –0.030 +0.158 0.108 –
3 70 1.0 Replace
pin and bushing of arm and link –0.076 +0.078 0.234
–0.030 +0.137 0.104 –
4 pin and bushing of arm and 80 1.0
–0.076 +0.074 0.213
bucket
–0.030 +0.166 0.116 –
5 pin and bushing of link and 80 1.0
–0.076 +0.086 0.242
bucket
Clearance between connecting –0.030 +0.154 0.104 –
6 70 1.0
pin and bushing of link and link –0.076 +0.074 0.230
PC228US, USLC-3E0 3
Dimensions of components 1
1. Dimension of arm
4 PC228US, USLC-3E0
Unit: mm
PC228US-3E0, PC228USLC-3E0
No.
+0.1
1 φ80
+0.1
+1.5
2 109.3
+0.1
–0.5
3 305.3
–0.5
+0.054
4 φ90
+0.054
5 402.1 ±1
6 187.2 ±0.5
7 829.1 ±1
8 2,919 —
9 2,630.5 ±1
10 410 ±1
11 640 ±0.2
12 600 ±0.5
13 458.1 —
14 1,486 —
+0.1
15 φ80
+0.1
16 325 ±0.5
+0.1
17 φ80
+0.1
–0.5
Arm as individual part 311
18 –0.5
When press-fitting bushing 325 —
Min. 1,680 —
19
Max. 2,800 —
PC228US, USLC-3E0 5
2. Dimension of bucket
6 PC228US, USLC-3E0
Unit: mm
PC228US-3, PC228USLC-3
No.
1 457.6 ±0.5
2 22 ±0.5
3 92° 45’ —
4 458.1 —
5 1,477.3 —
6 158.6 —
7 — —
8 15° 54’ —
+0.1
9 φ80
+0.1
10 326.5 ±1
11 56 —
12 106 —
13 470 —
14 φ23.5 —
15 φ140 —
16 φ190 —
17 133.2 —
18 131.6 —
19 107 —
20 85 —
+2
21 348.5
+0
22 38 —
PC228US, USLC-3E0 7
SEN01431-00

© 2006 KOMATSU
All Rights Reserved
8
SEN01432-00
PC228US-3E0
PC228USLC-3E0


Cab and its attachments
Cab and its attachments ................................................................................................................................. 2
Air conditioner piping............................................................................................................................ 2
PC228US, USLC-3E0 1
Cab and its attachments 1

Air conditioner piping 1
1. Duct A: Fresh air

2. Air conditioner unit B: Recirculated air
3. Hot water return piping C: Hot/cool air
4. Hot water pickup piping
5. Refrigerant piping
6. Air conditioner compressor
7. Condenser
2 PC228US, USLC-3E0
SEN01432-00

© 2006 KOMATSU
All Rights Reserved
4
SEN01433-03
PC228US-3E0
PC228USLC-3E0


Electrical system
Engine control ................................................................................................................................................. 2
Electrical control system ............................................................................................................................... 12
Monitor system.............................................................................................................................................. 38
Sensor........................................................................................................................................................... 56
KOMTRAX system........................................................................................................................................ 59
PC228US, USLC-3E0 1
Engine control 1
1. Starting switch Outline

2. Fuel control dial q The engine can be started and stopped with
3. Starting motor only starting switch (1).
4. Engine throttle controller
5. Battery
6. Pump controller
7. Battery relay
2 PC228US, USLC-3E0
Operation of system 1 Stopping engine

Starting engine q When detecting that the starting switch is set to
q When the starting switch is turned to the the “STOP” position, the engine controller cuts
START position, the starting signal flows to the the signal of the supply pump drive solenoid to
starting motor. Then, the starting motor turns to stop the engine.
start the engine.
When it happens, the engine controller checks

the signal voltage from the fuel control dial and
sets the engine speed to the speed set by the
fuel control dial.
Engine speed control

q The fuel control dial sends a signal voltage cor-
responding to the rotation angle to the engine
controller.
The engine controller sends a driving signal to

the supply pump depending on the signal volt-
age to control the fuel injection pump, and
eventually controls the engine speed.
PC228US, USLC-3E0 3
Component
Fuel control dial
1. Knob 4. Ball
2. Dial 5. Potentiometer
3. Spring 6. Connector
4 PC228US, USLC-3E0
Function
q The fuel control dial is installed under the
machine monitor.
q Turning knob (1) rotates the shaft of potentiom-
eter (5).
q The rotation of the shaft changes the resis-
tance of the variable resistor in potentiometer
(5), sending any throttle signal to the engine
controller.
q The hatched area in the graph below is the
abnormality detection area. When the throttle
voltage is within this area, the engine is run-
ning at low idle.
PC228US, USLC-3E0 5
Engine controller
q Meanings of signal classes in the terminal CN-CE01

table shown below are as follows. Input/
A: Power Supply Pin No. Signal name
output
B: Input 11 NC(*) –
C: Ground/Shield/Return 12 NC(*) –
D: Output 13 NC(*) B
E: Communication 14 WATER-IN-FUEL sensor B
CN-CE01 15 Coolant temperature sensor B
Input/ 16 5V electric power supply for sensor A
Pin No. Signal name
output 17 Oil pressure switch B
1 NC(*) – 18 NC(*) –
2 Electric power supply for IMA D 19 NC(*) –
3 Atmosphere sensor B 20 NC(*) –
4 NC(*) – 21 NC(*) –
5 NC(*) – 22 NC(*) D
6 CAN(–) E 23 Boost temperature sensor B
7 NC(*) – 24 NC(*) –
8 CAN(+) E 25 Common rail pressure sensor B
9 NC(*) – 26 Buckup sensor B
10 NC(*) – 27 NE sensor (+) B
*: Never connect to NC or malfunctions or failures will *: Never connect to NC or malfunctions or failures will
occur. occur.
6 PC228US, USLC-3E0
CN-CE01 CN-CE02
Input/ Input/
Pin No. Signal name Pin No. Signal name
output output
28 NC(*) – 13 NC(*) B
29 NC(*) – 14 NC(*) B
30 NC(*) – 15 NC(*) B
31 NC(*) D 16 NC(*) B
32 IMA return C 17 NC(*) B
33 5 V electric power supply for sensor A 18 NC(*) B
34 NC(*) – 19 NC(*) B
35 NC(*) A 20 NC(*) E
36 NC(*) – 21 NC(*) A
37 5 V electric power supply for sensor A 22 Fuel control dial (+5V) A
38 GND C 23 Fuel control dial (–) C
39 NC(*) – 24 NC(*) B
40 NC(*) – 25 NC(*) B
41 NC(*) – 26 NC(*) B
42 NC(*) C 27 NC(*) B
43 NC(*) – 28 NC(*) B
44 Boost pressure sensor B 29 NC(*) C
45 Injector #1 (+) D 30 NC(*) B
46 Injector #5 (+) D 31 NC(*) B
47 Buckup sensor C 32 NC(*) C
48 Ne sensor (–) C 33 GND C
49 NC(*) – 34 NC(*) C
50 NC(*) – 35 NC(*) B
51 Injector #2 (–) C 36 NC(*) B
52 Injector #3 (–) C 37 NC(*) C
53 Injector #1 (–) C 38 NC(*) D
54 Injector #2 (+) D 39 Key switch (ACC) A
55 Injector #3 (+) D 40 Electrical intake air heater relay drive D
56 Injector #4 (+) D 41 NC(*) D
57 Injector #6 (+) D 42 Electrical intake air heater relay return C
58 Injector #4 (–) C 43 NC(*) D
59 Injector #6 (–) C 44 NC(*) D
60 Injector #5 (–) C 45 NC(*) –
*: Never connect to NC or malfunctions or failures will 46 CAN(+) E
occur. 47 CAN(–) E
48 NC(*) D
CN-CE02 49 PWM OUTPUT D
Input/ 50 NC(*) D
Pin No. Signal name
output *: Never connect to NC or malfunctions or failures will
1 NC(*) B occur.
2 NC(*) B
3 NC(*) B CN-CE03
4 NC(*) B Input/
Pin No. Signal name
5 NC(*) B output
6 NC(*) B 1 GND C
7 NC(*) B 2 NC(*) C
8 NC(*) B Electric power supply (+24V con-
3 A
9 Fuel control dial (+) B stantly)
10 NC(*) B 4 NC(*) A
11 NC(*) B *: Never connect to NC or malfunctions or failures will
12 NC(*) B occur.
*: Never connect to NC or malfunctions or failures will
occur.
PC228US, USLC-3E0 7
Coolant temperature sensor
1. Connector
2. Sensor
3. O-ring
Oil pressure switch
1. Connector
2. Sensor
3. O-ring
8 PC228US, USLC-3E0
Rotation sensor
1. Connector
2. Sensor
3. O-ring
Boost pressure and temperature sensor
1. Connector
2. Sensor
3. O-ring
PC228US, USLC-3E0 9
WIF (water-in-fuel detection) sensor
1. Connector
2. Tube
3. Sensor
4. O-ring
Engine oil level sensor
1. Connector
2. Bracket
3. Float
4. Switch
Electrical control system 1

Machine control system diagram
1. Engine and pump composite control function
Function 1) Control method in each mode

q This function allows the operator to select P mode and E mode
engine torque (T) and pump absorption torque q Matching point
d e p e n d i n g o n t h e w o r k c o n t e n ts o f t h e
machine. Mode Matching point
Four modes of P, E, L and B are specified as 105.8 kW/1,900 rpm
working modes. P
{142 HP/1,900 rpm}
To select a working mode, use the working 88.9 kW/1,800 rpm
mode selector switch of the machine monitor. E
{119 HP/1,800 rpm}
q The pump controller controls the pump so that
it can absorb all the torque at the output points
q In P and E mode, engine speed is always
of the engine depending on the pump absorp-
controlled so that it is kept around the
tion torque specified for each mode, rotation
matching point specified for each mode.
set by the fuel control dial, and actual engine
q If the pump load increases and the pres-
speed.
sure rises, engine speed (N) lowers. If it
happens, the engine speed is increased to
around the matching point, allowing the
pump controller to decrease pump deliv-
ery (Q). On the contrary, the pump load
decreases and the pressure lowers, the
pump controller continues to increase
pump delivery until the engine speed
reaches around the matching point.
B mode and L mode
Mode B L
Partial output point 76% 70%
Mode Matching point

80.9 kW/1,650 rpm
B
{108 HP/1,650 rpm}
73.6 kW/1,800 rpm
L
{99 HP/1,800 rpm}
q In B or L mode, engine output is controlled

to a constant level. 2) Function to control pump during travel
q The controller controls the pump absorp- q Traveling the machine in P mode increases
tion torque to decrease the engine speed engine speed (N).
while keeping the engine torque at a con- q Traveling the machine in E or B mode
stant level along the equal engine horse- leaves the working mode unchanged, but
power curve. raises the pump absorption torque and
q The controller controls pump delivery (Q) engine speed (N) to values same as those
so that the engine torque can be kept at a in P mode.
constant level along the equal engine q If the machine travels in L mode, the work-
horsepower curve. ing mode and engine speed (N) do not
change, but the pump absorption torque is
increased.
3) Function to control when emergency pump

drive switch is turned on
q Even if any abnormality occurs in the controller
or sensor, setting emergency pump drive
switch (10) to the “ON” position activates the
machine with an absorption torque approxi-
mately equivalent to that in E mode.
In this case, a constant current flows from the
battery to the EPC valve for PC and therefore,
the oil pressure is sensed by only the EPC
valve for PC.
2. Pump and valve control function
Function
q The machine is matched to various types of
work properly with the 2-stage relief function to
increase the digging force, etc.
1) LS control function 3) 2-stage relief function

q Depending on the operation condition of q The relief pressure in the normal work is
the actuator, this function changes the 34.8 MPa {355 kg/cm 2 }. If the 2-stage
pressure output from the LS-EPC valve to relief function is turned on, however, the
LS valve to change the change point (LS relief pressure rises to about 37.2 MPa
set differential pressure (DLS)) of the {380 kg/cm 2 }. By this operation, the
pump discharge in the LS valve. hydraulic force is increased further.
q By this operation, the start-up time of the
pump discharge is optimized and the com- Operating condition for turning on
Relief pressure
posite operation and fine control perfor- 2-stage relief function
mance is improved. • During travel
• When swing lock switch is turned to 34.8 MPa
the ON position {355 kg/cm2}
• When boom is lowered O
• When power maximizing function is 37.2 MPa
turned on {380 kg/cm2}
• When L mode is operated
2) Cut-off function
q This function increases PC-EPC current
(J) to reduce the flow rate in the relief
state, improving fuel consumption.
Operating condition for turning on cut-off function

When the average value of the front and rear pressure
sensors is above 27.9 MPa {285 kg/cm2} with the power
maximizing function off.
The cut-off function does not work, however, while the
machine is travelling in P mode, swing lock switch is in
the “ON” position.
3. Power maximizing function
Function
q The power maximizing function allows the
operator to increase power for a certain time
by operating the left knob switch.
1) Power maximizing function

q This function is used to increase digging
force for a certain period of time (e.g.,
when digging up a large rock).
q If the left knob switch is pressed in P or E
mode, the hydraulic force is increased
about 7% to increase the digging force.
Each function is set automatically as
shown below.
Setting
Function
P mode E mode
Matching point
Engine and pump 142 HP/1,900rpm Matching at
control O rated output point
146 HP/1,900rpm
34.8 MPa
{355 kg/cm2}
2-stage relief
function O
37.2 MPa
{380 kg/cm2}
Software cut-off
Cancel
function
q These settings are automatically reset

after 8.5 seconds when the switch is
pressed.
4. Auto-deceleration function
Function
q The auto-deceleration function automatically
reduces the engine speed to its medium speed
range when the all control levers are set in
NEUTRAL while waiting for a dump truck or
work to reduce the fuel consumption and
noise.
q If any lever is operated, the engine speed
instantly returns to the speed set with the fuel
control dial.
Operation
When control levers are set in neutral
q If all the control levers are kept to NEUTRAL
for 4 sec. during operation at a engine speed
above a decelerator operation level (approxi-
mately 1,400 rpm), this function lowers the
engine speed to the deceleration operation
level (approximately 1,400 rpm) and keeps it
until you operate any lever.
When any control lever is operated
q If you operate any control lever while the
engine speed is kept at the deceleration opera-
tion level, the engine speed instantly rises to
the level set with the fuel control dial.
5. Auto-warm-up and overheat prevention function
Function
q The engine automatic warm-up function
increases the engine speed to warm up the
engine if coolant temperature is too low after
the engine starts.
q The overheat prevention function reduces the
pump load when coolant or hydraulic oil tem-
perature is too high during operation to protect
the engine from overheating.
1) Auto-warm-up function
q After the engine is started, if the engine coolant temperature is low, the engine speed is raised auto-
matically to warm up the engine.
Operating condition (All) Operated

Coolant temperature: Below 30°C.
Engine speed: Max. 1,200 rpm ⇒ Engine speed: Max. 1,200 rpm
⇓
Resetting condition (Any one) Reset
⇒
Coolant 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
Manual
sec. or longer
2) Overheat prevention function

q If the engine coolant temperature rises too high during work, the pump load and engine speed are
reduced to protect the engine from overheating.
q This function is turned on when the coolant temperature rises above 95°C.
Operating condition Operation/Remedy Resetting condition

Hydraulic oil temperature: Below
⇒ ⇒
Work mode: Travel 95°C
Hydraulic oil tempera-
Engine speed: Keep as is. • Under above condition, controller
ture: Above 95°C
Lower travel speed. is set to condition before opera-
tion of function. (Automatic reset)

Hydraulic oil or coolant tempera-
⇒ ⇒
Hydraulic oil or cool- Work mode: P mode ture: Below 100°C
ant temperature: Engine speed: Keep as is. • Under above condition, controller
Above 100°C Lower pump discharge. is set to condition before opera-

Work mode: P, E or B mode
⇒ ⇒
Hydraulic oil or cool- ture: Below 102°C
Engine speed: Keep as is.
ant temperature: • Under above condition, controller
Monitor alarm lamp: Lights up.
Above 102°C is set to condition before opera-
Lower pump discharge.

ture: Below 105°C
Work mode: Any mode
⇒ ⇒
Hydraulic oil or cool- Fuel control dial: Return to low idle
Engine speed: Low idle
ant temperature: position once.
Monitor alarm lamp: Lights up
Above 105°C • Under above condition, controller
Alarm buzzer: Sounds
is set to condition before opera-
tion of function. (Manual reset)
6. Swing control function
Function
The swing lock and swing holding brake function
are provided as a swing control function.
1) Swing lock and swing holding brake func- 2) Quick hydraulic oil warm-up function when
tion swing lock switch is turned on
q The swing lock function (manual) is used q If swing lock switch (4) is turned on, the
to lock machine from swinging at any posi- pump cut-off function is cancelled and the
tion. The swing holding brake function relief pressure rises from 34.8 MPa {355
(automatic) is used to prevent hydraulic kg/cm2} to 37.2 MPa {380 kg/cm2}. If the
drift after the machine stops swinging. work equipment is relieved under this con-
q Operation of swing lock switch and swing dition, the hydraulic oil temperature rises
lock/holding brake quickly and the warm-up time can be
shortened.
Lock Lock Func-
Operation
switch lamp tion
If swing lever is set in
neutral, swing brake
Swing operates in about 5 sec.
OFF OFF holding If swing lever is oper-
brake ated, brake is released
and machine can swing
freely.
Swing lock operates and
machine is locked from
swinging.
Swing
ON ON Even if swing lever is
lock
operated, swing lock is
not reset and machine
does not swing.
Swing holding brake release switch

q If the controller, etc. has a problem, the
swing holding brake does not work nor-
mally, and the machine cannot swing, the
swing lock can be reset with the swing
holding brake release switch.
q 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.
q If the swing lock is reset, only the hydrau-
lic brake is applied by the safety valve.
Note that if swinging is stopped on a
slope, the upper structure may swing by
its gravity.
Swing
holding ON OFF
brake (when controller has (when controller is nor-
release trouble) maly)
switch
Swing lock
ON OFF ON OFF
switch
Swing
Swing lock Swing lock Swing lock
Swing holding
is turned is can- is turned
brake brake is
on. celed. on.
turned on.
7. Travel control function
Function
q The machine is provided with a function that
ensures travel performance best fit to the type
of work and jobsite by controlling pumps during
travel or allowing operator to change travel
speed automatically or manually.
1) Pump control function during travel 2) Travel speed change function

q If the machine travels in a work mode 1] Manual change with travel speed switch
other than P mode, the work mode and If one of Lo, Mi and Hi is selected with the
the engine speed are kept as they are and travel speed switch, the pump controller
the pump absorption torque is increased. controls the pump capacity and motor
q For details, see "Engine and pump com- capacity at each gear speed as shown
posite control function." below to change the travel speed.
Lo (Low Mi (Midium Hi (High

Travel speed switch
speed) speed) speed)
Pump capacity (%) 73 67 100
Motor capacity Max. Max. Min.
Travel speed (km/h) 3.0 4.1 5.5
2] Automatic change by engine speed

If the fuel control dial is used to set the
engine speed to less than 1,500 rpm, the
travel speed changes to Lo when the
machine is travelling in Mi or Hi, and the
travel speed will not change to Mi or Hi.
3] Automatic change by pump discharge

pressure
When traveling with the travel speed
switch set to Hi or Mi, if the load
increases, such as when travelling uphill,
and the travel pressure goes above 37.3
MPa {380 kg/cm2} for more than 0.5 sec,
the travel motor capacity will automatically
change to low speed (equivalent to Lo).
(The travel speed switch will stay at Hi or
Mi.)
If the load decreases, such as when trav-
elling on level ground or travelling down-
hill, and the travel pressure goes below
17.6 MPa {180 kg/cm2} for more than 0.5
sec, the travel motor capacity will auto-
matically change and will return to Hi or
Mi.
8. Boom stroke and electronic cushion function
Function
q 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 cylinders
are reduced.
1) Electronic cushion function
q There is a cushion range before the boom rais-
ing stroke end (about 35°).
q 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.
.
q By this operation, the shock at the stroke end
is reduced.
2) Reset function
Resetting of input signal (Installed angle of
potentiometer)
q 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.
q With the resetting function, this error can be
corrected easily without measuring the output
voltage or adjusting the potentiometer finely.
q 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 (installation error) is saved
as the "correction value".
q 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 adjusting.)
3) Emergency work equipment operation

switch
q 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.
9. Attachment flow control and circuit selector function (if equipped)
Function
q This function is available only with the attach-
ment specification.
q The function acts as follows according to the
flow command and working mode from the
monitor.
1) It throttles the attachment PPC pressure
and controls the flow when the pedal is
depressed fully.
2) In B mode and the other modes, it
switches to attachment single acting (B) or
double acting (other modes).
10. System component parts

1) 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 ± 0.05 MPa {3.0 ± 0.5 kg/cm2}
Function
q The junction block has 6 PPC oil pressure
switches.
q This sensor detects the operating condition of
each actuator by the PPC pressure and trans-
mit it to the pump controller.
2) Oil pressure sensor
1. Sensor
2. Connector
Function q The relationship between the pressure applied

q The pump pressure sensor is installed to the to sensors (P) and output voltage (E) is shown
input circuit of the control valve. in the figure below.
q It converts the pump discharge pressure into a
voltage and transmits it to the pump controller.
Operation
q The oil pressure is applied to the diaphragm of
the oil pressure sensor from the pressure
intake part, the diaphragm is deformed.
q The deformation in the diaphragm causes the
resistance of the gauge to change. This
causes a change in the output voltage, which
is transmitted to the amplifier (voltage ampli-
fier).
q The amplifier magnifies output voltage (E) and

transmits it to the pump controller.
3) Pump pressure sensor (high pressure)
1. Sensor
2. Connector
Operation
q The relationship between the pressure applied
to sensors (P) and output voltage (E) is shown
in the figure below.
4) Pump controller
CN-CP01 CN-CP02
Input/ Input/
output output
1 NC(*) Input 1 NC(*) output
2 R pump pressure sensor Input 2 Emergency swing parking switch Input
3 NC(*) Input 3 NC(*) Input
4 NC(*) – 4 232C_RXD Input
7 Overload sensor (Analog) Input 7 Machine select 4 (ATT) Input
8 F pump pressure sensor Input 8 Service circuit SOL signal output
10 GND (SIG) – 10 NC(*) Input
11 Knob switch Input 11 NC(*) output
12 NC(*) Input 12 CAN_SH –
13 Bucket digging pressure sensor Input 13 Machine select 5 (ATT) Input
14 NC(*) Input 14 232C_TXD output
16 NC(*) output 16 Travel steering signal Input
17 Key switch (C-terminal) Input 17 Machine select 3 Input
19 Arm digging pressure sensor Input 19 NC(*) output
21 NC(*) – Input/
21 NC(*)
22 POT-PWR output output
23 Key switch (ACC-terminal) Input Input/
22 CANO_L
24 NC(*) Input output
*: Never connect to NC or malfunctions or failures will Input/
23 NC(*)
occur. output
24 FWE_switch Input
25 NC(*) Input
26 NC(*) Input
27 Machine select 2 Input
28 NC(*) Input
29 NC(*) –
30 NC(*) Input
31 NC(*) –
Input/
32 CANO_H
output
Input/
33 NC(*)
output
34 GND (232C GND) –
35 Service pressure switch Input
36 NC(*) Input
37 Machine select 1 Input
38 Swing prolix switch Input
39 NC(*) –
40 NC(*) Input
occur.
CN-CP03
Input/
Pin No. Signal name
output
1 VB (Controller PWR) Input
2 VIS (Solenoid PWR) Input
3 SOL_COM (SOL. COM. GND) –
4 Battery relay drive signal output
5 NC(*) output
6 LS-EPC output
7 Travel junction solenoid output
8 NC(*) output
9 (Bucket digging pressure switch) Input
10 Boom rise pressure switch Input
11 VB (Controller PWR) Input
12 VIS (Solenoid PWR) Input
14 KEY_SIG Input
15 NC(*) output
16 PC-EPC output
17 Merge divider solenoid output
18 NC(*) output
19 Bucket dump pressure switch Input
20 Boom down pressure switch Input
21 GND (Controller GND) –
22 NC(*) Input
24 KEY_SIG Input
25 NC(*) output
26 ATT currented output
27 Travel speed solenoid output
28 2-stage relief solenoid output
29 Swing pressure switch Input
30 (Arm digging pressure switch) Input
34 NC(*) –
35 NC(*) output
36 NC(*) output
37 Swing parking brake SOL output
38 NC(*) output
39 Travel pressure switch Input
40 Arm dump pressure switch Input
occur.
Monitor system 1
q The monitor system notifies the operator of

machine status. It monitors the condition of the
machine with sensors installed on various
parts of the machine, processes and immedi-
ately displays the obtained information on the
panel. The information that appears on the
panel is roughly divided as follows.
1. Alarms that are issued when the machine
has troubles
2. Machine status, including coolant temper-
ature, hydraulic oil temperature and fuel
level
q The machine monitor also has various mode
selector switches and functions to operate the
machine control system.
Machine monitor
Outline
q The machine monitor has the functions to dis-
play various items and the functions to select
modes and electric parts.
q The machine monitor has a CPU (Central Pro-
cessing Unit) in it to process, display, and out-
put the information.
q The monitor display employs an LCD (Liquid
Crystal Display). The switches are flat sheet
switches.
Input and output signals
CN-1 CN-3
Input/ Input/
output output
1 Key ON Input 1 NC (*) Input
2 Key ON Input 2 NC (*) Input
3 Window washer motor output output 3 NC (*) Input
4 Starting signal Input 4 NC (*) Input
5 Limit switch (W) Input 5 NC (*) Input
6 GND – 6 NC (*) Input
7 GND – 7 RS230C CTS Input
8 VB+ Input 8 RS230C RXD Input
9 Wiper motor (+) output Input/
9 RS230C RXD
10 Wiper motor (–) output output
11 Buzzer ON signal Input Input/
10 RS230C RXD
12 Limit switch (P) Input output
11 BOOTSW Input
12 NC (*) Input
CN-2
13 GND –
Input/
Pin No. Signal name 14 CAN (SHIELD) Input
output
15 CAN (+) Input
1 Engine coolant temperature Input
16 CAN (–) Input
2 Fuel level Input
3 Radiator coolant level Input
occur.
4 (Hydraulic oil level) Input
5 Air cleaner clogging Input
6 NC (*) Input
7 Engine oil pressure Input
8 Engine oil level Input
Input/
9 Network signal
output
Input/
10 Network signal
output
11 Charge amount Input
12 Hydraulic oil temperature (analog) Input
13 GND (for analog signal) –
14 Buzzer drive Input
15 Limit switch (window) Input
16 Buzzer cancel Input
17 Swing lock Input
18 Preheating Input
19 Light switch Input
20 Network GND –
occur.
Monitor control and display portion

Monitor portion
1. Wiper monitor
2. Preheating monitor
3. Swing lock monitor
4. Engine coolant temperature monitor
5. Hydraulic oil temperature gauge
6. Engine coolant temperature gauge
7. Working mode monitor
8. Service monitor
9. Travel speed monitor
10. Fuel gauge
11. Fuel level monitor
12. Hydraulic oil temperature monitor
13. Power maximizing monitor
14. Auto-deceleration monitor
15. Engine oil pressure monitor
16. Charge level monitor
17. Radiator coolant level monitor
18. Engine oil level monitor
19. Air cleaner clogging monitor
20. Maintenance time warning monitor
Monitor items and display
Symbol Display item Display method
Swing holding brake

Swing lock switch Swing lock monitor
release switch
OFF OFF OFF
Swing lock
ON OFF ON
OFF ON Flashes
ON ON ON
Continuous set time Preheating monitor status

Up to 30 sec. ON
Preheating
From 30 sec. to 40 sec. Flashes
More than 40 sec. OFF
Power max. switch status Power max. monitor status

Lights up but goes out after approx.
Power max. Being pressed
9 sec. when kept pressed
Not being pressed Flashes
Engine coolant
temperature
Hydraulic oil
See gauge display on the next page
temperature
Fuel level
Temperature or
Gauge Range Indicator Buzzer sound
volume
A1 105 Red Q
A2 102 Red
Engine coolant tem- A3 100 Green
perature (°C) A4 80 Green
A5 60 Green
A6 30 White
B1 105 Red
B2 102 Red
Hydraulic oil temper- B3 100 Green
ature (°C) B4 80 Green
B5 40 Green
B6 20 White
C1 230 Green
C2 195 Green
Fuel level C3 160 Green
(l) C4 80 Green
C5 60 Green
C6 40 Red
Checks before starting (all symbols light up), when maintenance interval is exceeded.
If the checks before starting or maintenance interval is exceeded items light up, the display of the hydraulic
oil temperature gauge and the hydraulic oil temperature monitor disappear and the following symbols are
displayed.
Check before When engine is When engine is

Symbol Display item
starting item stopped running
When abnormal,
Engine oil pressure l — lights up and buzzer
sounds
Lights up when
Battery charge l —
abnormal
When abnormal,
Radiator coolant Lights up when
l lights up and buzzer
level abnormal
sounds
Lights up when
Engine oil level l —
abnormal
Lights up when
Air cleaner clogging l —
abnormal
Lights up when there is a warning. Lights up

Maintenance for only 30 sec. after key is turned ON, then
goes out.
Symbols appear in the order in which they occur

from the upper left. When symbols are displayed, if
the hydraulic oil temperature is high or low, only its
symbol is displayed.
Condition of hydraulic oil Color of symbol

Low temperature Black on
(Max. B6 or equivalent) white background
Normal (B6 – B2) No display
High temperature White on
(Min. B2) red background
Display category Symbol Display item Display range Display method
INT ON OFF Displays set con-

Wiper
dition
Displays set
Working mode
mode
Monitor
Displays set
Travel speed
speed
Auto-decelera- Displays actua-

ON ⇔ OFF
tion tion status
Lights up when
Service meter
Service meter When service meter is working service meter is
indicator
working
Switches
1. Working mode selector switch

2. Selector switch
3. Buzzer cancel switch
4. Display brightness, contrast adjustment switch
5. Control switch
6. Window washer switch
7. Wiper switch
8. Maintenance switch
9. Travel speed selector switch
10. Auto-deceleration switch
Working mode selector switch Wiper switch

Press one of the P, E, B and L switches to set the Each time the wiper switch is pressed, the wiper
desired working mode. It is possible to check which setting changes as shown below.
mode is active with the working mode monitor. The OFF o INT o ON o OFF o…..
relationship between each working mode and the The wiper settings can be viewed on the wiper
monitor display is shown in the table below. monitor. The relationship between the wiper setting
and the monitor display is shown in the table below.
Switch that Dis- Working mode status
is pressed play after setting Display Setting Wiper actuation status
[P] P P mode (default) Stowing stopped or
None OFF
[E] E E mode now stowing
[L] L L mode Wiper symbol
INT Intermittent actuation
+ INT
[B] B B mode
Wiper symbol
ON Continuous actuation
+ ON
Selector switch
This is used when making detailed settings in each
Window washer switch
working mode. For details, see "Attachment flow
control function". While the switch is being pressed, window washer
liquid is sprayed out. There is a time delay before
Buzzer cancel switch the wiper starts.
Pressing this switch when the alarm buzzer is mak-
Control switch
ing sound stops the alarm buzzer.
If a new abnormality is detected, the alarm buzzer This is used for control when using the mainte-
sounds. nance function or select function. For details, see
Depending on the alarm buzzer type, it does not each function.
stop even if you press the buzzer cancel switch.
Display brightness, contrast adjustment switch
Maintenance switch This function is used to adjust the brightness and
Check the condition of the maintenance items. For contrast of the display. For details, see each func-
details, see "Maintenance function". tion.
Auto-deceleration switch
The auto-deceleration switch toggles the auto-
deceleration function on and off. When the working
mode is switched, it is automatically set to ON.
When it is set to ON, the auto-deceleration monitor
appears.
Travel speed selector switch

Each time the travel speed selector switch is
pressed, the travel speed changes as shown
below.
Lo o Mi o Hi o Lo o…..
The travel speed settings can be viewed on the
monitor. The relationship between the speed set-
ting and the monitor display is shown in the table
below.
Display Setting
Crawler symbol + Lo Low speed (default)
Crawler symbol + Mi Midium speed
Crawler symbol + Hi High speed
Select mode function

1. Setting of oil flow
q This is used when setting the flow in each
working mode.
q It is available when genuine attachment piping
is installed and "Attachment installed" is
selected with the initial value setting function
on the service menu.
q It is possible to check on the working mode
monitor if this function can be used.
Working mode Monitor display
P mode [P] + crusher symbol
E mode [E] + crusher symbol
3) Press control switch (2) and select the
B mode [B] + flow symbol flow level.
Control switch Actuation
Flow level bar graph
extends to the right
retracts to the left
Method of use
a Carry out the setting on the normal screen
P mode, E mode
1) Press select switch (1).
4) After completing the level selection, press
input confirmation switch (3). The selec-
tion flow level is confirmed and the screen
moves to the normal screen. When input
confirmation switch (3) is pressed, the
attachment flow is updated. The relation-
ship between the flow level and the flow is
shown in the table below.
Flow level Flow (l/min) Remarks
8 430 Default
7 350
6 250
5 170
4 140
2) When the screen changed as below,
select "01" by operating switch (2), and 3 115
press input confirmation switch (3). 2 90
1 30
a Flow level is not changed until the
input confirmation switch is pressed.
It is, therefore, possible not to change
the flow level by pressing return
switch (4) to return to the normal
screen.
B mode 9) After the flow level is confirmed, the

5) Press select switch (1). screen changes to the screen shown in
6) When the screen changed as below, the diagram below. With this screen, it is
select "01" by operation switch (2), and possible to make fine adjustment to the
press input confirmation switch (3). flow.
7) Select one of the three flow levels by mov- Control switch Actuation
ing the cursor with operation switch (2) or Flow level bar graph
entering the relevant number (01, 02 or extends to the right
03) with the 10-key pad. Flow level bar graph
10) Pressing input confirmation switch (3)

after selecting the flow level finalizes the
selection.
q The relationship between the flow
level and the flow is shown in the
table below.
When flow When flow When flow
Flow
is 100 l/ is 140 l/ is 180 l/ Remarks
level
min. min. min.
7 130 170 210
6 120 160 200
q The relationship between the flow
level and the flow is shown in the 5 110 150 190
table below. 4 100 140 180 Default
No. Flow (l/min) Remarks 3 90 130 170
01 180 Default 2 80 120 160
02 140 1 70 110 150
03 100
a Flow level is not finalized until input
confirmation switch (3) is pressed.
8) Pressing input confirmation switch (3) Returning to the normal screen by
after selecting the flow level finalizes the pressing return switch (4) will leave
selection. the flow level setting unchanged.
a Flow level is not finalized until the
input confirmation switch is pressed.
Returning to the normal screen by
pressing return switch (4) will leave
the flow level setting unchanged.
11) Check the set value with the working

mode monitor. The relationship between
the display level and the set value is
shown in the table below.
Display level Set value (l/min.)
8 200 or 210
7 180 or 190
6 160 or 170
5 140 or 150
4 120 or 130
3 100 or 110
2 80 or 90
1 70
Maintenance function 1. Method of checking maintenance items

q This function alerts the operator when routine a Carry out the setting on the normal screen
maintenance (replacement, inspection or filling 1) Press maintenance switch (1) and switch
for the 11 maintenance items) is due. to the maintenance list display screen.
q When maintenance switch (1) is pressed, any The maintenance items are displayed as
maintenance item that is due is displayed yel- symbols on the screen.
low or red for 30 seconds. 2) Select one of the maintenance items by
moving the cursor with control switch (2)
or entering the relevant number (01 to 10)
with the 10-key pad.
a If the remaining time is less than 30
hours, the item is displayed in yellow,
and if it is less than 0 hours, it is dis-
played in red.
q The table below shows the maintenance items

and replacement intervals. The time remaining
to maintenance is reduced as the machine is
operated.
Replacement interval
No. Item
(Hours)
01 Engine oil 500 2. Maintenance operation
02 Engine oil filter 500 1) After completing the selection, press input
03 Fuel main filter 1000 confirmation switch (3). The screen will
41 Fuel prefilter 500 change to the maintenance reset screen.
04 Hydraulic filter 1000 2) The maintenance reset screen shows the
time remaining before maintenance is
05 Hydraulic tank breather 500
due. To reset the remaining time, press
06 Corrosion resistor 1000(*) input confirmation switch (3). When input
07 Damper case oil 1000 confirmation switch (3) is pressed, the
08 Final case oil 2000 screen changes to the check screen. To
09 Machinery case oil 1000 return to the maintenance list screen,
10 Hydraulic oil 5000 press return switch (4).
*: If equipped (To be determined)
q The content of the caution display differs

according to the remaining time. The relation-
ship is as shown in the table below.
Display Condition
Remaining time for mainte-
None nance for all items is more
than 30 hours
There is one or more items
Notice display (black sym-
with less than 30 hours
bol displayed on yellow
remaining time for mainte-
background)
nance
There is one or more items
Warning display (white
with less than 0 hours
symbol displayed on red
remaining time for mainte-
background)
nance
3) The check screen shows the symbol for

the selected maintenance item and the set
time in large letters.
4) To reset the remaining time, press input
confirmation switch (3). The remaining
time is reset and the screen returns to the
maintenance list display screen. To return
to the maintenance list screen without
resetting the remaining time, press return
switch (4).
5) On the maintenance list display screen,
the background color of the symbol for the
item where the maintenance item was
reset is the same as the background of the
screen.
Brightness, contrast adjustment function 1

This function is used to adjust the brightness and 2) Press operation switch (2), or use the 10-
contrast of the display. key pad to input the number (01 – 02) to
a Carry out the setting on the normal screen select either contrast or brightness.
3) After completing the selection, press input
1. Adjustment method confirmation switch (3) to return to the
1) Press display brightness/contrast adjust- adjustment screen. Pressing return switch
ment switch (1) and switch to the adjust- (4) without pressing input confirmation
ment screen. switch (3) or entering 00 with the 10-key
pad and then pressing input confirmation
switch (3) causes the screen to return to
the normal screen.
4) Press operation switch (2) and adjust the

brightness or contrast as desired.
Control switch Actuation
extends to the right

q Relationship between menu symbol

and content.
No. Symbol Content
00 Return mark Return
01 Contrast
02 Brightness
Service meter check function 1 Display LCD check function

q With the starting switch in the OFF position, q On the normal screen, if monitor return switch
pressing return switch (1) while holding down (1) and working mode switch "P" (2) are kept
operation switch (2) of the monitor for 3 to 5 pressed at the same time, the whole screen
seconds displays the service meter. will become white. If any part of the display is
q When the 2 switches are released, the display black, the LCD is broken.
goes out.
User code display function q If there are more than one service or failure
q If there is any problem in operating the codes, they are displayed in turn every 2 sec-
machine, the user code is displayed on the onds.
monitor to advise the operator of the steps to q Any service codes/failure codes that are not
take. This code appears on the normal screen. related to the displayed user code is displayed
q On the normal screen, the user code is dis- with this function.
played on the portion for the hydraulic oil tem-
perature gauge in the center of the screen.
q If the telephone number has been set using the

service menu, the screen shows the service
q If there are more than one user codes, they are code/failure code as well as telephone symbol
displayed in turn every 2 seconds. and telephone number. For details of inputting
the telephone number, see "Special functions
of monitor panel" in the "Testing and adjusting"
section.
q While the user code is being displayed, if the

input confirmation switch is pressed, the ser-
vice code and failure code can be displayed.
Both service code and failure code identify the
cause of problem corresponding to the dis-
played user code.
Sensor 1
q The signals from the sensors are input to the
monitor panel directly.
q Either side of a sensor of contact type is
always connected to the chassis ground.
Type of When When
Sensor name
sensor normal abnormal
ON OFF
Hydraulic oil level Contact
(Closed) (Open)
Hydraulic oil Resis-
– –
temperature tance
Resis-
Coolant temperature – –
tance
Resis-
Fuel level – –
tance
OFF ON
Air cleaner clogging Contact
(Closed) (Open)
Hydraulic oil level sensor
1. Connector
2. Bracket
3. Float
4. Switch
Hydraulic oil temperature sensor, coolant temperature sensor 1
1. Thermistor 4. Tube
2. Body 5. Wire
3. Tube 6. Connector
Fuel level sensor 1
1. Float 3. Cover
2. Connector 4. Variable resistor
Air cleaner clogging sensor 1
KOMTRAX system 1
q The KOMTRAX system consists of the

KOMTRAX terminal, communication antenna,
machine monitor and GPS antenna.
q This system sends various information of the
machine via wireless communication. It allows
operators of the KOMTRAX to obtain the
machine information from the office and to pro-
vide various services with the customers.
q The information available from the KOMTRAX
system are as follows:
1. Operation map
2. Service meter
3. Machine location
4. Error record
a To provide the services, you need to make an
arrangement for starting the KOMTRAX ser-
vice separately.
KOMTRAX terminal 1
Model: TC301
q The KOMTRAX system uses satellite communication technology.
1. Communication antenna connector

2. GPS antenna connector
3. Machine harness connector (DEUTSCH-40P)
Input and output signals

DEUTSCH-40P [CN-G01]
Input/Output Input/Output
signal signal
1 NC (*) — 21 Input for check 0 Input
2 NC (*) — 22 Input for check 1 Input
3 NC (*) — 23 NC (*) —
4 NC (*) — 24 NC (*) —
5 NC (*) — 25 NC (*) —
6 CAN shield GND — 26 NC (*) —
7 CAN signal (L) Input/Output 27 C-terminal input Input
8 CAN signal (H) Input/Output 28 R-terminal input Input
9 S-NET shield GND — 29 NC (*) —
10 S-NET signal Input/Output 30 NC (*) —
11 NC (*) — 31 NC (*) —
12 NC (*) — 32 NC (*) —
13 NC (*) — 33 NC (*) —
14 NC (*) — 34 NC (*) —
15 NC (*) — 35 NC (*) —
16 NC (*) — 36 ACC input(analog) Input
17 NC (*) — 37 Power supply —
18 NC (*) — 38 Power supply —
19 NC (*) — 39 Unswitched power supply Input
20 Relay output Output 40 Unswitched power supply Input
*: Never connect to NC, or malfunctions or failure will
occur.
Outline
q This terminal sends various machine informa-
tion based on the network signals and input
signals in the machine, as well as GPS posi-
tion data, via wireless communication.
This terminal can send information via commu-
nication antenna.
q This terminal cannot be used in the countries
or territories where it is not authorized by the
low.
q This terminal has LED lamps and 7-segment
lamp indicator used for testing and trouble-
shooting on its display section.
a When starting to use the KOMTRAX system or
changing the country where it is used, you are
required to notify the country where it will be
used in advance.
a When using the KOMTRAX system in Japan,
the terminal special to Japan must be
mounted.
SEN01433-03

© 2010 KOMATSU
All Rights Reserved
62
SEN01441-02
PC228US-3E0
PC228USLC-3E0

20 Standard value table 1

Standard service value table
Standard value table for engine related parts ................................................................................................. 2
Standard value table for chassis ..................................................................................................................... 3
PC228US, USLC-3E0 1
SEN01441-02 20 Standard value table
Standard value table for engine related parts 1
PC228US-3E0
Applicable model
PC228USLC-3E0
Engine SAA6D107E-1
Cate- Standard value for new

gory
Item Measurement condition Unit Judgement criteria
machine
High idle rpm 2,060 ± 50 2,060 ± 50

• Coolant
Engine speed temperature: Low idle rpm 1,050 ± 25 1,050 ± 25
operating range
Rated speed rpm 2,000 2,000
• Coolant temperature: operating

Intake pressure kPa Min. 133 103
range
(boost pressure) {mmHg} {Min. 1,000} {775}
• Arm IN relief + Power Max.
At sudden
• Coolant % Max. 25 35
acceleration
Exhaust gas color temperature:
operating range At rated
% Max. 12 22
output
Intake valve mm 0.25 0.152 – 0.381

Valve clearance • Normal temperature
Exhaust valve mm 0.51 0.381 – 0.762
Compression MPa Min. 2.41 1.69

Compression • Oil temperature: pressure {kg/cm2} {Min. 24.6} {17.2}
pressure 40 – 60°C
Engine
Engine speed rpm 250 – 280 250 – 280
• Coolant temperature: operating

kPa Max. 0.98 1.96
Blow-by pressure range
{mmH2O} {Max. 100} {200}
• Arm IN relief + power max.
• SAE0W30E0S,
SAE5W40E0S, MPa Min. 0.29 0.25
High idle
SAE10W30DH, {kg/cm2} {Min. 3.0} {2.5}
SAE15W40DH,
Oil pressure
SAE30DH engine oil
• Coolant MPa Min. 0.10 0.07
temperature: Low idle
{kg/cm2} {Min. 1.0} {0.7}
operating range
Oil temperature • Whole speed range (inside oil pan) °C 80 – 110 120
• Between fan pulley and alternator

pulley
Fan belt tension mm 8 6 – 10
• Deflection when pressed with finger
force of approx. 98 N{10 kg}
• Between fan pulley and compressor
Air conditioner
pulley
compressor belt mm 6.3 – 8.7 6.3 – 8.7
• Deflection when pressed with finger
tension
force of approx. 60 N{6.1 kg}
2 PC228US, USLC-3E0
Standard value table for chassis 1

(All values in the table are for P mode)
PC228US-3E0
Applicable model
PC228USLC-3E0
Cate-
gory
Item Measurement conditions Unit Standard value Permissible value
• Hydraulic oil temperature:

45 – 55°C
2 pumps at relief • Coolant temperature: 2,010 ± 100 2,010 ± 100
Within operating range
Engine speed
• 2-pump relief: Arm relief

• Arm relief rpm
At 2-pump relief +
• One touch power up 2,000 ± 100 2,000 ± 100
one touch power up
• Engine at high idle
Speed when auto-
• Fuel control dial at MAX.
deceleration is 1,400 ± 100 1,400 ± 100
• Control lever at neutral
operated
Boom control valve a b a b
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
• Center of lever knob

Boom control lever mm 85 ± 10 Min. 75, Max. 95
• Read max. value to end of travel
• Engine stopped
Arm control lever • Excluding neutral play 85 ± 10 Min. 75, Max. 95
Travel of control levers
Bucket control lever 85 ± 10 Min. 75, Max. 95
Swing control lever 85 ± 10 Min. 75, Max. 95
Blade control lever 52 ± 5 Min. 47, Max. 57
Travel control lever 115 ± 12 Min. 103, Max. 127
Work equipment Max. 15 Max. 20

Play of control lever
Travel Max. 20 Max. 25
• Engine at high idling
Boom control lever 15.7 ± 3.9 {1.6 ± 0.4} Max. 24.5 {2.5}
• Oil temperature: 45 – 55°C
Operating force of control levers
• 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 travel
Bucket control lever 12.7 ± 2.9 {1.3 ± 0.3} Max. 21.6 {2.2}
N
Swing control lever 12.7 ± 2.9 {1.3 ± 0.3} Max. 21.6 {2.2}
{kg}
Blade control lever 26.7 ± 5.5 {2.7 ± 0.6} Max. 32.2 {3.3}
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, USLC-3E0 3
PC228US-3E0
Applicable model
PC228USLC-3E0
Cate-
gory
Item Measurement condition Unit Standard Value Permissible value
• P mode
• Oil temperature: 45 – 55°C
3.9 ± 1.0 3.9 ± 1.0
Unload pressure • Engine at high idle
{40 ± 10} {40 ± 10}
• All levers at neutral
• Pump output pressure
• Hydraulic oil temperature: 45 – 55°C
Boom (a1) • Relief pressure with engine at high
idle (Relieve only circuit to be 34.8 ± 1.0 33.3 – 36.8
measured) {355 ± 10} {340 – 375}
Arm • P mode
• Figures in ( ) are when power max.
function is used (reference)
• Pump output pressure
( 37.3 ± 1.0
{380 ± 10} ) ( 36.3 – 39.2
{370 – 400} )
Bucket
a 1: Boom pressure is raise relief
Hydraulic pressure
oil pressure at emergency

work equipment actuation 33.3 ± 1.0 33.3 ± 1.0
Blade MPa
switch at EMERGENCY {340 ± 10} {340 ± 10}
{kg/cm²}
(RAISE).
Swing (a2) a 2: For swing, measure with swing 30.9 ± 1.5 28.9 – 32.9
lock switch ON. {315 ± 15} {295 – 335}
a 3: For travel, measure oil pres-
sure for relief on one side (rear 38.2 ± 1.0 37.3 – 40.2
Travel (a3)
pump pressure when relieving {390 ± 10} {380 – 410}
left side; front pump pressure
Self-reducing when relieving right side). 3.23 ± 0.2 2.84 – 3.43
pressure valve {33 ± 2} {29 – 35}
• Hydraulic oil 3.9 ± 1.0 3.9 ± 1.0

Levers at neutral
temperature: {40 ± 10} {40 ± 10}
LS differential 45 – 55°C Travel speed : Hi
pressure • Engine at high Rotating under no 2.2 ± 0.1 2.2 ± 0.1
idle load {22 ± 1.0} {22 ± 1.0}
• In P mode Travel lever half
4 PC228US, USLC-3E0
PC228US-3E0
Applicable model
PC228USLC-3E0
Cate-
gory
Item Measurement condition Unit Standard Value Permissible value
Swing brake angle deg. Max. 100 Max. 130
• P mode
• Stop after swinging one turn and measure
distance that swing circle moves
90° 3.1 ± 0.3 Max. 3.7
Time taken to start

sec.
swing
• P mode
180° 4.4 ± 0.4 Max. 5.5
• Time taken to swing 90° and 180°
from starting position
Swing
+3.6
Time taken to swing sec. 27.3 –1.7 Max. 33
• P mode
• Swing one turn, and measure time taken to
swing next 5 turns
Hydraulic drift of
mm 0 0
swing • Engine stopped
• 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.
• P mode
Leakage from
• Hydraulic oil temperature: 45 – 55°C l/min. Max. 5 Max. 10
swing motor
• Swing lock switch ON
• Relieve swing circuit
PC228US, USLC-3E0 5
PC228US-3E0
Applicable model
PC228USLC-3E0
Cate-
gory
Travel
speed
STD: 51.3 ± 5.1 STD: 46.2 – 60.5
LC: 55.9 ± 5.6 LC: 50.3 – 66.0
Lo
Travel speed
(Rotating under no sec.
load) • P mode STD: 37.5 ± 3.8 STD: 33.8 – 45.0
Mi
• Engine at high idle LC: 40.8 ± 4.1 LC: 36.7 – 49.0
• Raise track on one side at a time,
rotate one turn, then measure time STD: 26.5 ± 1.3 STD: 25.2 – 29.9
Hi
taken for next 5 turns with no load. LC: 28.9 ± 1.4 LC: 26.0 – 32.7
Lo 24.0 ± 2.4 21.6 – 26.4
Travel speed (travel) Mi sec. 17.6 ± 1.8 15.8 – 19.3

• P mode
Travel
• Run up for at least 10 m, and

measure time taken to travel next 20 Hi 13.1 ± 0.7 12.4 – 13.7
m on flat ground.
• P mode
Travel deviation • Run up for at least 10 m, and measure deviation mm Max. 150 Max. 250
when traveling next 20 m on flat ground.
a Use a hard horizontal surface.
a Measure dimension .
6 PC228US, USLC-3E0
PC228US-3E0
Applicable model
PC228USLC-3E0
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
l/min. 13.6 27.2
motor

• Lock shoes and relieve travel circuit.
Total work
equipment
Max. 600 Max. 900
(hydraulic drift at
tip of bucket teeth)
Boom cylinder
(amount of
Max. 18 Max. 27
Hydraulic drift of work equipment
retraction of
cylinder) • Place in above posture and measure
extension or retraction of each cylinder and
Work equipment
downward movement at tip of bucket teeth.

Arm cylinder
• Bucket: Rated load (1,440 kg)
(amount of
• Horizontal, flat ground mm Max. 160 Max. 240
extension of
• Levers at neutral
cylinder)
• Engine stopped
Bucket cylinder • Start measuring immediately after setting.
(amount of • Measure hydraulic drift every 5 minutes, and
judge from results for 15 minutes. Max. 40 Max. 58
retraction of
cylinder)
• Measure amount of sinking of blade tip from

Blade (amount of max. raise position for 15 minutes.
sinking of blade Max. 60 Max. 90
tip)
PC228US, USLC-3E0 7
PC228US-3E0
Applicable model
PC228USLC-3E0
Cate-
gory
RAISE
3.7 ± 0.4 Max. 4.8
(4.0 ± 0.4) (Max. 5.2)
Boom
Bucket teeth in • P mode

contact with • Engine at high idle
ground • Hydraulic oil temperature: 45 – 55°C
• Emergency work equipment actuation
Cylinder fully switch: Abnormal (RAISE)
extended
k The cushion at the end of the boom
LOWER
2.8 ± 0.3 Max. 4.4
(3.2 ± 0.3) (Max. 5.0)
RAISE stroke is set so that it is not
actuated. For this reason, there is a large
shock, so carry out the measurement on
firm level ground. IN
Arm 3.5 ± 0.3 Max. 4.5

Work equipment speed
Work equipment
Cylinder fully
retracted
sec.
OUT
Fully extended • P mode 2.7 ± 0.3 Max. 3.5

CURL
Bucket 2.6 ± 0.3 Max. 3.3
Cylinder fully
retracted
DUMP
Fully extended • P mode

1.9 ± 0.2 Max. 2.7
• P mode
RAISE
Blade • Hydraulic oil temperature: 45 – 55°C 1.6 ± 0.2 Max. 2.0
Blade in contact
with ground
LOWER
Cylinder fully
retracted 1.9 ± 0.2 Max. 2.3
( ): for North America
8 PC228US, USLC-3E0
PC228US-3E0
Applicable model
PC228USLC-3E0
Cate-
gory
Boom Max. 1.0 Max. 1.2

• P mode
• Lower boom and measure time taken from point
where bucket contacts ground to point where
chassis rises from ground
• Engine at low idle
Time lag
sec.
Work equipment
Arm Max. 2.0 Max. 2.8

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

• P mode
• Stop bucket suddenly and measure time taken
for bucket to stop at bottom and then start again

Internal leakage
Cylinders • Engine at high idle 4.5 20

• Relieve circuit to be measured
cc/min
Center swivel
10 50
joint
PC228US, USLC-3E0 9
PC228US-3E0
Applicable model
PC228USLC-3E0
Cate-
gory

Performance in compound operation
a Use a hard horizontal surface
Travel deviation
when work
mm Max. 200 Max. 220
equipment + travel
are operated
a Measure dimension .
Performance of hydraulic pump
Hydraulic pump delivery
Piston pump See next page l/min. See next page
Cate- Discharge amount of main piston pump

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

Test pump Discharge Average Standard value for Judgement
discharge pressure of pressure discharge standard lower
Check point
pressure other pump amount Q limit Q
(MPa {kg/cm²}) (MPa {kg/cm²}) (MPa {kg/cm²}) (l/min) (l/min)
As desired P1 P2 (P1 + P2) See graph See graph

2
a As far as possible, bring pump discharge pressure P1 and P2 as close as possible to the average pressure when measuring.
The error is large near the point where the graph curves, so avoid measuring at this point.
a 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.
Flow control characteristics of PC valve (STD)

a The values in this table are used as reference values when carrying out troubleshooting
Cate- PC228US-3E0
gory
Item Measurement conditions Unit
PC228USLC-3E0
Performance in compound operations
Time taken for swing for

Max. 4.4
boom RAISE + starting sec.
(Reference value)
swing
• P mode
• Load the bucket with the rated load and measure
the time taken from the position of starting the
swing to the point of passing the 90° position.
SEN01441-02

© 2009 KOMATSU
All Rights Reserved
14
SEN01879-04
PC228US-3E0
PC228USLC-3E0

30 Testing and adjusting 1

Testing and adjusting, Part 1
Tools for testing, adjusting, and troubleshooting............................................................................................. 3
Sketches of special tools ................................................................................................................................ 8
Testing engine speed ...................................................................................................................................... 9
Testing intake air pressure (boost pressure) ................................................................................................. 10
Checking exhaust gas color...........................................................................................................................11
Adjusting valve clearance ............................................................................................................................. 12
Testing compression pressure ...................................................................................................................... 14
Testing blow-by pressure .............................................................................................................................. 17
Testing engine oil pressure ........................................................................................................................... 18
Handling fuel system parts............................................................................................................................ 19
Releasing residual pressure from fuel system .............................................................................................. 19
Testing fuel pressure..................................................................................................................................... 20
Reduced cylinder mode operation ................................................................................................................ 23
No-injection cranking .................................................................................................................................... 23
Testing fuel delivery, return rate and leakage ............................................................................................... 24
Bleeding air from fuel circuit.......................................................................................................................... 27
Checking fuel circuit for leakage ................................................................................................................... 28
PC228US, 228USLC-3E0 1
SEN01879-04 30 Testing and adjusting
Checking and adjusting air conditioner compressor belt tension .................................................................. 29

Replacement of fan belt ................................................................................................................................ 30
2 PC228US, 228USLC-3E0
Tools for testing, adjusting, and troubleshooting 1
Sketch
Sym-
Q'ty
Testing/Adjusting item Part No. Part name Remarks
bol
Measuring intake air – 101 – 200 kPa

R 799-201-2202 Boost gauge kit 1
pressure (boost pressure) {– 760 – 1,500 mmHg}
1 799-201-9001 Handy smoke checker 1
Checking exhaust gas
A Commercially Bosch index: 0 – 9
color 2 Smoke meter 1
available
1 795-799-1131 Gear 1
Adjusting valve clearance B Commercially
2 Clearance gauge 1 Intake: 0.25 mm, Exhaust: 0.51 mm
available
1 795-502-1590 Compression gauge 1 0 – 7.0 MPa {0 – 70 kg/cm2}
Measuring compression 2 795-799-6700 Puller 1 For 107E-1 engine
C
pressure 3 795-790-4410 Adapter 1 For 107E-1 engine
4 6754-11-3130 Gasket 1 For 107E-1 engine
Measuring blow-by 1 799-201-1504 Blow-by checker 1 0 – 5 kPa {0 – 500 mmH2O}
D
pressure 2 795-790-3300 Blow-by tool 1 For 107E-1 engine
Pressure gauge:
799-101-5002 Hydraulic tester 1 2.5, 6, 40, 60 MPa
Measuring engine oil 1 {25, 60, 400, 600 kg/cm2}
E
pressure
790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
2 799-401-2320 Hydraulic tester 1 Pressure gauge: 1.0 MPa {10 kg/cm2}
Pressure gauge:
1 {25, 60, 400, 600 kg/cm2}
Measuring fuel pressure F 2 6732-81-3170 Adapter 1
10 × 1.0 mm o R1/8
6215-81-9710 O-ring 1
3 799-401-2320 Gauge 1 Pressure gauge: 1.0 MPa {10 kg/cm2}
4 795-790-5110 Screw 1
5 799-201-2202 Boost gauge kit 1
1 795-790-4700 Tester kit 1
2 795-790-6700 Adapter 1
6754-71-5340 Connector 1
3
6754-71-5350 Washer 1
Commercially
Measuring fuel return rate 4 Measuring cylinder 1
G available
and leakage
Commercially
5 Stopwatch 1
available
Commercially
6 Hose 1 (Inside diameter: 14 mm)
available
Commercially
7 Hose 1 (Inside diameter: 8 mm)
available
Measuring swing circle Commercially
H Dial gauge 1
bearing clearance available
Pressure gauge:
Measuring and adjusting 1 {25, 60, 400, 600 kg/cm2}
oil pressure in work
J 790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
equipment, swing, and
travel circuits 799-101-5220 Nipple 2
2 Size: 10 × 1.25 mm
07002-11023 O-ring 2
Sketch
Sym-
Q'ty
bol
Pressure gauge:
1 {25, 60, 400, 600 kg/cm2}
Measuring basic pressure
K 790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
of control circuit
799-101-5220 Nipple 1
2 Size: 10 × 1.25 mm
07002-11023 O-ring 1
Pressure gauge:
Measuring and adjusting 1 {25, 60, 400, 600 kg/cm2}
oil pressure in pump PC L 790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
control circuit
799-101-5220 Nipple 4
2 Size: 10 × 1.25 mm
07002-11023 O-ring 4
Pressure gauge:
1 {25, 60, 400, 600 kg/cm2}
Measuring and adjusting 790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
oil pressure in pump LS M
799-101-5220 Nipple 4
control circuit 2 Size: 10 × 1.25 mm
07002-11023 O-ring 4
Differential pressure
3 799-401-2701 1 50 MPa {500 kg/cm2}
gauge
Pressure gauge:
Measuring solenoid valve 1 {25, 60, 400, 600 kg/cm2}
N
output pressure
2 799-401-3100 Adapter 1 Size: 02
Pressure gauge:
1 {25, 60, 400, 600 kg/cm2}
Measuring PPC valve
P 790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
output pressure
799-401-3100 Adapter 1 Size: 02
2
799-401-3200 Adapter 1 Size: 03
Commercially
Measuring oil leakage Q Measuring cylinder 1
available
Measuring coolant
temperature and oil — 799-101-1502 Digital thermometer 1 – 99.9 – 1,299°C
temperature
Measuring operating effort 79A-264-0021 Push-pull scale 1 0 – 294 N {0 – 30 kg}
—
and depressing force 79A-264-0091 Push-pull scale 1 0 – 490 N {0 – 50 kg}
Measuring stroke and Commercially
— Ruler 1
hydraulic drift available
Measuring work Commercially
— Stopwatch 1
equipment speed available
Measuring voltage and Commercially
— Circuit tester 1
resistance available
Removal and installation
Commercially 3.26 mm TORX wrench
of boost pressure and — TORX wrench 1
available (KTC Q4T15 or equivalent)
temperature sensors
Removal and installation
of engine oil pressure — (Not set yet) Deep socket 1 27 mm deep socket
sensor
Sketch
Sym-
Q'ty
bol
21 mm deep socket
Commercially (MITOLOY 4ML-21 or equivalent)
— Socket 1
available Applicable engine serial number:
Removal and installation 26500006 – 28530192
of engine coolant
temperature sensor 19 mm deep socket
(MITOLOY 4ML-19 or equivalent)
— 795T-981-1010 Socket 1 Q
Applicable engine serial number:
28530193 and up
799-601-4101
— or T-adapter assembly 1
799-601-4201
For DRC60, ECONO*2 (Max 60P)
— 799-601-4350 • T-box 1 (Does not include in assembly
No.799-601-4201)
For engine (CRI-T3) coolant temper-
ature sensor (PACKARD 2P)
For engine (CRI-T3) fuel temperature
— 795-799-5530 • Socket 1
sensor (PACKARD 2P)
For engine (CRI-T3) oil temperature
sensor (PACKARD 2P)
For engine (CRI-T3) ambient pres-
— 799-601-4140 • Socket 1
sure sensor (AMP 3P)
For engine (CRI-T3) boost pressure
— 799-601-4230 • Socket 1
sensor (SUMITOMO 3P)
For engine (CRI-T3) G (Bkup) sensor
— 799-601-4330 • Socket 1
(SUMITOMO 3P)
For engine (CRI-T3) supply pump
Engine related controller, — 799-601-4340 • Socket 1 PCV1, supply pump PCV sensor
sensor and actuator (SUMITOMO 3P)
diagnosis
For engine (CRI-T3) NE sensor
— 799-601-4130 • T-adapter 1
(FRAMTOME 3P)
For engine (CRI-T3) common rail
— 799-601-4190 • T-adapter 1
pressure sensor (AMP 3P)
For engine controller (DRC26-50P)
— 799-601-4211 • T-adapter 1 (Does not include in assembly
No.799-601-4201)
For engine controller (DRC26-60P)
— 799-601-4220 • T-adapter 1 (Does not include in assembly
No.799-601-4201)
For engine controller (DTP-4P)
— 799-601-4260 • T-adapter 1 (Include in assembly No.799-601-
9000 and 799-601-9100, too)
For DT 4P (Include in assembly
— 799-601-9040 • T-adapter 1 No.799-601-9000 and 799-601-9200,
too)
— 799-601-9020 • T-adapter 1 No.799-601-9000 and 799-601-9200,
too)
Sketch
Sym-
Q'ty
bol
799-601-9000
or
— 799-601-9100 T-adapter assembly 1
or
799-601-9300
— 799-601-9320 • T-box 1 For ECONO*1 (Max 24P)
— 799-601-4350 • T-box 1 For DRC60, ECONO*2 (Max 60P)
799-601-7000
or
799-601-7100
799-601-7400
or
799-601-8000
For ECONO*3 (Max 21P)
— 799-601-2600 • T-box 1 (Does not include in assembly
No.799-601-7000)
— 799-601-7210 • T-adapter 1 For AMP040 16P
— 799-601-7090 • T-adapter 1 For M 2P
— 799-601-7120 • T-adapter 1 For M 4P
— 799-601-7130 • T-adapter 1 For M 6P
— 799-601-7340 • T-adapter 1 For M 8P (No assembly No.)
— 799-601-7140 • T-adapter 1 For S 8P
— 799-601-7350 • T-adapter 1 For S 12P (White) (No assembly No.)
Machine related controller — 799-601-7170 • T-adapter 1 For S 16P (Blue)
and sensors/wiring — 799-601-7330 • T-adapter 1 For S 16P (White) (No assembly No.)
harnesses diagnosis
For SWP 8P (Does not include in
— 799-601-7060 • T-adapter 1
assembly No.799-601-8000)
— 799-601-7310 • T-adapter 1
— 799-601-7070 • T-adapter 1
— 799-601-7320 • T-adapter 1 For SWP 16P (No assembly No.)
— 799-601-7010 • T-adapter 1 For X 1P
— 799-601-7020 • T-adapter 1 For X 2P
— 799-601-7040 • T-adapter 1 For X 4P
799-601-9000
799-601-9200
— 799-601-9040 • T-adapter 1 No.799-601-4101 and 799-601-4201,
too)
— 799-601-9020 • T-adapter 1 For DT 2P
— 799-601-9030 • T-adapter 1 For DT 3P
— 799-601-9050 • T-adapter 1 For DT 6P
— 799-601-9110 • T-adapter 1 For DT 12P (Gray)
— 799-601-9120 • T-adapter 1 For DT 12P (Black)
— 799-601-9130 • T-adapter 1 For DT 12P (Green)
— 799-601-9140 • T-adapter 1 For DT 12P (Brown)
Sketch
Sym-
Q'ty
bol
For HD36 24-21P (Does not include

in assembly No.799-601-9200)
— 799-601-9270 • T-adapter 1
(Include in assembly No.799-601-
9100, too)
Machine related controller — 799-601-9360 • T-adapter 1 For pump controller (DRC26-24P)
and sensors/wiring
— 799-601-9350 • T-adapter 1 For pump controller (DRC26-40P)
harnesses diagnosis
— 799-601-7360 • T-adapter 1 For relay 5P (No assembly No.)
— 799-601-7370 • T-adapter 1 For relay 6P (No assembly No.)
For AMP 3P (Pressure sensor)
— 799-601-9420 • T-adapter 1 (Include in assembly No.799-601-
4101, 799-601-4201)
Sketches of special tools 1

Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
Socket
Testing engine speed 1 3. Measuring high idle speed

1) Start the engine and set the fuel control
a Measure the engine speed with the monitoring dial in the high idle (MAX) position.
function of the machine monitor. 2) Set the working mode in the power mode
a Measure the engine speed under the following (P) and turn the auto-decelerator OFF.
condition. 3) Set all the levers and pedals for work
q Engine coolant temperature: Within oper- equipment control, swing control, and
ating range travel in neutral and measure the engine
q Hydraulic oil temperature: Within operat- speed.
ing range
4. Measuring 2-pump relief speed
1. Preparation work 1) Start the engine and operate the arm cyl-
Operate the machine monitor so that the inder to the IN stroke end.
engine speed can be monitored. 2) Set the fuel control dial in the high idle
a For the operating method of the machine (MAX) position and set the working mode
monitor, see Special functions of machine in the power mode (P).
monitor. 3) Operate the left work equipment control
a Monitoring code: 01002 Engine speed lever to relieve the arm circuit at the IN
stroke end and measure the engine
speed.
5. Measuring 2-pump relief and power maxi-

mizing speed (near rated speed)
1) Start the engine and operate the arm cyl-
inder to the IN stroke end.
2) Set the fuel control dial in the high idle
(MAX) position and set the working mode
in the power mode (P).
3) While operating the left work equipment
control lever to relieve the arm circuit at
the IN stroke end and depressing the
power maximizing switch, measure the
engine speed.
2. Measuring low idle speed a The power maximizing function is reset
1) Start the engine and set the fuel control automatically in about 8.5 seconds even if
dial in the low idle (MIN) position. the switch is kept depressed. Accordingly,
2) Set all the levers and pedals for work measure the engine speed in that period.
equipment control, swing control, and a You may check with the swing lock switch
travel in neutral and measure the engine ON (In this case, you do not need to oper-
speed. ate the power maximizing switch.)
6. Measuring auto-deceleration speed

1) Start the engine, set the fuel control dial in
the high idle position (MAX), and turn the
auto-decelerator ON.
2) Set all the levers and pedals for work
equipment control, swing control, and
travel in neutral and measure the engine
speed when the auto-decelerator oper-
ates.
a The engine speed lowers to a certain level
about 5 seconds after all the levers and
pedals are set in neutral. This level is the
auto-deceleration speed.
Testing intake air pressure 3. Run the engine at middle or higher speed and
(boost pressure) 1 bleed oil from the hose.
a Insert the connecting parts of the gauge
a Testing tools for intake air pressure (boost and hose about a half and open the self-
pressure) seal on the hose side repeatedly, and the
Symbol Part No. Part name oil will be drained.
a If Pm kit (A) is available, you use the air-
R 799-201-2202 Boost gauge kit
bleeding coupling (790-261-1130) in that
kit.
k Stop the machine on a level ground and
a If oil is left in the hose, the gauge does not
lower the work equipment to the ground.
work. Accordingly, be sure to drain the oil.
a Measure the intake air pressure under the fol-
lowing condition.
4. Set the working mode in the power mode (P)
q Engine coolant temperature: Within oper-
and turn the swing lock switch ON.
ating range
a If the swing lock switch is turned ON, the
q Hydraulic oil temperature: Within operat-
main relief valve is set for high-pressure
ing range
relief.
1. Open the engine hood and remove intake air
5. While running the engine at high idle, relieve
pressure pickup plug (1) from the intake air
the arm circuit at the IN and measure the
connector.
intake air pressure.
2. Install nipple [1] of boost gauge kit R and con-

6. After finishing measurement, remove the mea-
nect it to gauge [2].
suring tools and return the removed parts.
10 PC228US, 228USLC-3E0
Checking exhaust gas color 1

a Checking tools for exhaust gas color
Symbol Part No. Part name
1 799-201-9001 Handy smoke checker
A Commercially
2 Smoke meter
available

k Be careful not to touch any hot part when
removing or installing the checking tools.
a Check the exhaust gas color under the follow-
ing condition.
q Engine coolant temperature: Within oper- 2) Connect the probe hose, receptacle of the
ating range accelerator switch, and air hose to smoke
a If an air source and an electric power source meter A2.
are not available in the field, use handy smoke a Limit the supplied air pressure to 1.5
checker A1. When recording official data, use MPa {15 kg/cm2}.
smoke meter A2. 3) Connect the power cable to an AC 100 V
receptacle.
1. Measuring with handy smoke checker A1 a Before connecting the cable, check
1) Stick a sheet of filter paper to smoke that the power switch of the smoke
checker A1. meter is turned OFF.
2) Insert the exhaust gas intake pipe in 4) Loosen the cap nut of the suction pump
exhaust pipe (1). and fit the filter paper.
3) Start the engine and accelerate it sud- a Fit the filter paper securely so that the
denly or run it at high idle and operate the exhaust gas will not leak.
handle of smoke checker A1 so that the 5) Turn on the power switch of smoke meter
filter paper will absorb the exhaust gas. A2.
a Absorbing time: 1.4 ± 0.2 sec
6) Start the engine and accelerate it sud-

denly or run it at high idle and depress the
4) Remove the filter paper and compare it accelerator pedal of smoke meter A2 and
with the attached scale. collect the exhaust gas into the filter
5) After finishing checking, remove the mea- paper.
suring tools and return the removed parts. 7) Place the contaminated filter paper on the
clean filter paper (at least 10 sheets) in the
2. Checking with smoke meter A2 filter paper holder and read the indicated
1) Insert probe [1] of smoke meter A2 in the value.
outlet of the exhaust pipe and fix it to the 8) After finishing checking, remove the
exhaust pipe with a clip. checking tools and return the removed
parts.
PC228US, 228USLC-3E0 11
Adjusting valve clearance 1 4. Rotate the crankshaft forward with gear B1

and set wide slit (b) of the rotation sensor ring
a Testing tools for valve clearance to projection top (a) of front cover.
Symbol Part No. Part name a Projection top (a) must be within the range
of wide slit (b) when it is seen from the air
1 795-799-1131 Gear
conditioner compressor side.
B Commercially
2 Clearance gauge a If you can see the yellow marks of projec-
available
tion top (a) and wide slit (b), you may set
them to each other.
k
k When the crankshaft is set as above,
Stop the machine on a level ground and
the piston in the No. 1 or No. 6 cylinder
a Measure the valve clearance under the follow-
is not set to the compression top dead
ing condition.
center (TDC). Take care.
q Engine coolant temperature: Normal tem-
perature
1. Open the engine hood and remove the belt

guard from the top of the air conditioner com-
pressor.
2. Remove cylinder head cover (1).

a Since the breather connector on the rear
side of the cylinder head cover is con-
nected to the flywheel housing through the
O-ring, pull it together with the cylinder
head cover.
5. Check the movement of the rocker arm of the

No. 1 cylinder to judge the valve to be
adjusted.
a If you can move the rocker arms of air

intake valves (IN) with the hand by the
valve clearance, adjust the valves marked
with Q in the valve arrangement drawing.
a If you can move the rocker arms of
exhaust valves (EX) with the hand by the
valve clearance, adjust the valves marked
with q in the valve arrangement drawing.
a Valve arrangement drawing
3. Remove plug (2) from the top of the starting
motor and insert gear B1.
12 PC228US, 228USLC-3E0
6. Adjust the valve clearance according to the fol-

lowing procedure.
1) While fixing adjustment screw (3), loosen
locknut (4).
2) Insert thickness gauge B2 in the clearance
between rocker arm (5) and crosshead (6)
and adjust the valve clearance with
adjustment screw (3).
a With the clearance gauge inserted,
turn the adjustment screw to a degree
that you can move the clearance
gauge lightly.
3) While fixing adjustment screw (3), tighten
locknut (4).
3 Locknut:
24 ± 4 Nm {2.45 ± 0.41 kgm}
a After tightening the locknut, check the
valve clearance again.
7. Rotate the crankshaft forward by 1 turn and set

wide slit (b) to projection top (a) according to
step 4.
8. Adjust the other valve clearances according to

steps (5) and (6).
a If the valves marked with q in the valve
arrangement drawing were adjusted in
steps (5) and (6), adjust the valves
marked with Q.
a If the valves marked with Q in the valve
arrangement drawing were adjusted in
steps (5) and (6), adjust the valves
marked with q.
9. After finishing adjustment, remove the adjust-

ing tools and return the removed parts.
k Remove gear B1 without fail.
3 Cylinder head cover mounting nut:
24 ± 4 Nm {2.45 ± 0.41 kgm}
PC228US, 228USLC-3E0 13
Testing compression pressure 1 2. Disconnect injector wiring harness (2) and

move the wiring harness.
a Testing instruments for compression pressure
1 795-502-1590 Compression gauge
2 795-799-6700 Puller
C
3 795-790-4410 Adapter
4 6754-11-3130 Gasket
k Stop the machine on a flat place and lower

the work equipment to the ground.
a Measure the compression pressure under the
following condition.
q Engine oil temperature: 40 – 60°C
k When measuring the compression pres- 3. Disconnect fuel high pressure tube (3).
sure, take care not to burn yourself on the a The inlet connector is connecting the fuel
exhaust manifold, muffler, etc. or get tube to the injector.
caught in a rotating part.
1. Open the engine hood and remove cylinder

head cover (1).
a Since the breather connector on the rear
side of the cylinder head cover is con-
nected to the flywheel housing through the
O-ring, pull it together with the cylinder
head cover.
4. Loosen injector terminal nut (4) and remove

the terminal from the injector.
5. Bring the piston of the cylinder to be checked

to the compression top dead center.
a See “Adjusting valve clearance”.
6. Remove rocker arm assembly (5).
14 PC228US, 228USLC-3E0
7. Remove retainer (6) and fuel inlet connector 14. Adjust the valve clearance.
(7). a See “Adjustment valve clearance”.
8. Remove holder (8).
9. Remove injector (9).

a Using tool C2, remove the injector with
impacts of the sledge hammer.
a Do not pry off the top of the injector.
15. Disconnect all the injector wiring harness con-

nectors.
k If the connectors are not disconnected,
the engine will start during measure-
ment and that will be dangerous.
Accordingly, be sure to disconnect
them.
k If the engine is cranked without turning
the controller ON, the common rail will
be damaged. Accordingly, be sure to
check that the controller is turned ON.
k Cover the disconnected connectors
with vinyl sheets etc. to prevent a leak,
a ground fault, etc.
16. Crank the engine with the starting motor and

measure the compression pressure.
a Read the gauge when its pointer is stabi-
lized.
10. Install gasket C4 to the end of adapter C3 and

insert them in the mounting area of the injector.
11. Fix adapter C3 with the injector holder.

a Tighten the holder mounting bolts alter-
nately.
3 Holder mounting bolt:
8 ± 0.8 Nm {0.8 ± 0.08 kgm}
12. Connect gauge assembly C2 to adapter C3.

a If a little engine oil is applied to the con-
necting parts of the adapter and gauge, air
does not leak easily.
13. Install rocker arm assembly (5).

3 Rocker arm assembly mounting bolt:
36 ± 5 Nm {3.67 ± 0.51 kgm}
PC228US, 228USLC-3E0 15
17. After finishing measurement, remove the mea- 7) Tighten the sleeve nuts of fuel high-pres-
suring instruments and return the removed sure tube (3) at the head end and com-
parts. mon rail end in order.
a Install the injector and fuel high-pressure 3 Sleeve nut:
tube according to the following procedure. 35 ± 3.5 Nm {3.6 ± 0.4 kgm}
1) While setting projection “a” of the injector
to notch “b” of the holder, set the injector
to the cylinder head.
a When setting, direct the above setting
position toward the fuel inlet connec-
tor insertion.
18. Install the rocker arm assembly and adjust the

valve clearance, referring to “Adjusting valve
clearance”.
3 Rocker arm assembly mounting bolt:
36 ± 5 Nm {3.67 ± 0.51 kgm}
2) Tighten injector holder mounting bolts (10) 19. Tighten the injector terminal nut to the follow-
by 3 – 4 turns. ing torque.
3) Set fuel inlet connector (7). 3 Terminal nut:
a Push in the connector until the O-ring 1.5 ± 0.25 Nm {0.15 ± 0.025 kgm}
fits and you feel a click. a Check that the injector wiring harness
4) Temporarily fit inlet connector (7) with does not interfere with the rocker arm.
retainer (6).
3 Retainer: 20. Tighten the head cover mounting nut to the fol-
15 ± 5.0 Nm {1.5 ± 0.5 kgm} lowing torque.
5) Tighten injector holder mounting bolt (10) 3 Head cover mounting nut:
alternately. 24 ± 4 Nm {2.45 ± 0.41 kgm}
3 Holder mounting bolt:
8 ± 0.8 Nm {0.8 ± 0.08 kgm}
6) Tighten fuel inlet connector retainer (6).
3 Retainer:
50 ± 5 Nm {5.1 ± 0.5 kgm}
16 PC228US, 228USLC-3E0
Testing blow-by pressure 1

a Testing tools for blow-by pressure
1 799-201-1504 Blow-by checker
D
2 795-790-3300 Blow-by tool

a Measure the blow-by pressure under the fol-
lowing condition.
ating range
q Hydraulic oil temperature: Within operat-
5. After finishing measurement, remove the mea-
ing range
1. Remove the undercover of the hydraulic pump.
2. Install tool and adapter [1] of blow-by checker

D1 or blow-by tool D2 to breather hose (1) and
connect gauge [2].
3. Start the engine, set the working mode in the

power mode (P), and turn the swing lock
switch ON.
a If the swing lock switch is turned ON, the
main relief valve is set for high-pressure
relief.
4. While running the engine at high idle, relieve

the arm circuit at the IN and measure the blow-
by pressure.
a Read the gauge when the pointer is stabi-
lized.
PC228US, 228USLC-3E0 17
Testing engine oil pressure 1

a Testing tools for engine oil pressure
799-101-5002 Hydraulic tester
1
E 790-261-1204 Digital hydraulic tester
2 799-401-2320 Hydraulic tester

a Measure the engine oil pressure under the fol-
lowing condition.
ating range 5. After finishing measurement, remove the mea-
1. Open the side cover of the pump room and
remove oil pressure pickup plug (1) from the
engine oil filter.
2. Install nipple [1] of hydraulic tester E1 and con-

nect hydraulic tester E2.
3. Start the engine and turn the auto-decelerator

OFF.
4. Run the engine and measure the engine oil

pressure at high idle and low idle.
18 PC228US, 228USLC-3E0
Handling fuel system parts 1 Releasing residual pressure from

a Precautions for checking and maintaining fuel fuel system 1
system a Pressure is generated in the low-pressure cir-
The common rail fuel injection system (CRI) cuit and high-pressure circuit of the fuel sys-
consists of more precise parts than the con- tem while the engine is running.
ventional fuel injection pump and nozzle. If for- Low-pressure circuit:
eign matter enters this system, it can cause a Feed pump – Fuel main filter – Supply pump
trouble. High-pressure circuit:
When checking and maintaining the fuel sys- Supply pump – Common rail – Injector
tem, take care more than the past. If dust, etc. a The pressure in both low-pressure circuit and
sticks to any part, wash that part thoroughly high-pressure circuit lowers to a safety level
with clean fuel. automatically 30 seconds after the engine is
a Precautions for replacing fuel filter cartridge stopped.
Be sure to use the Komatsu genuine fuel filter a Before the fuel circuit is checked and its parts
cartridge. are removed, the residual pressure in the fuel
Since the common rail fuel injection system circuit must be released completely. Accord-
(CRI) consists of more precise parts than the ingly, observe the following.
conventional fuel injection pump and nozzle, it k Before checking the fuel system or remov-
employs a high-efficiency special filter to pre- ing its parts, wait at least 30 seconds after
vent foreign matter from entering it. If a filter stopping the engine until the residual pres-
other than the genuine one is used, the fuel sure in the fuel circuit is released. (Do not
system may have a trouble. Accordingly, never start the work just after stopping the engine
use such a filter. since there is residual pressure.)
PC228US, 228USLC-3E0 19
Testing fuel pressure 1

a Testing tools for fuel pressure
1
790-261-1204 Digital hydraulic tester
Adapter
6732-81-3170
2 (10 × 1.0 mm o R1/8)
F
6215-81-9710 O-ring
3 799-401-2320 Gauge
4 795-790-5110 Screw
5 799-201-2202 Boost gauge kit
3) Run the engine at low idle and measure
k Stop the machine on a level ground and the pressure in the fuel low-pressure cir-
lower the work equipment to the ground. cuit.
a Measure only the fuel pressure in the low-pres- a If the pressure in the fuel low-pres-
sure circuit from the feed pump through the sure circuit is in the following range, it
fuel main filter to the supply pump and the is normal.
return circuit from the supply pump/common
rail/injector to fuel tank. 0.5 – 1.3 MPa
k
At low idle
Since the pressure in the high-pressure cir- {5.1 – 13.3 kg/cm2}
cuit from the supply pump through the 0.3 – 1.1 MPa
During cranking
common rail to the injector is very high, it {3.1 – 11.3 kg/cm2}
cannot be measured.
k If the engine cannot be started, you
1. Measuring pressure in fuel low-pressure may measure the fuel pressure
circuit while rotating the engine with the
1) Open the engine hood and remove fuel starting motor. Do not rotate for
pressure pickup plug (1) from the fuel more than 20 seconds continu-
main filter. ously, however, for protection of
the starting motor.
2) Install adapter F2 and nipple [1] of hydrau-

lic tester F1 and connect them to oil pres- 4) After finishing measurement, remove the
sure gauge F3. measuring tools and return the removed
a Use the oil pressure gauge of 2.5 MPa parts.
{25 kg/cm2}. 3 Fuel pressure pickup plug:
10 ± 2 Nm {1 ± 0.2 kgm}
20 PC228US, 228USLC-3E0
2. Measuring pressure in fuel return circuit 3) Run the engine at low idle and measure
1) Open the engine hood and remove fuel the pressure in the fuel return circuit.
pressure pickup plug (2) from the fuel a If the pressure in the fuel return circuit
return block. is in the following range, it is normal.
At low idle Max. 0.02 MPa
During cranking {Max. 0.19 kg/cm2}

may measure the fuel pressure
while rotating the engine with the
starting motor. Do not rotate for
more than 20 seconds continu-
ously, however, for protection of
the starting motor.
2) Install adapter F2, then install nipple [3] of

hydraulic tester F1 and nipple [1] and con-
nect them to gauge F3.
a Nipple [3]:
790-301-1530, 07002-11223
4) After finishing measurement, remove the

measuring tools and return the removed
parts.
3 Fuel pressure pickup plug:
24 ± 4 Nm {2.4 ± 0.4 kgm}
PC228US, 228USLC-3E0 21
3. Measurement of pressure in fuel negative

pressure circuit
1) Open the engine hood and remove joint
bolt (2) of fuel hose (1) between the prefil-
ter and supply pump (3) from the supply
pump.
2) Connect fuel hose (1) to supply pump (3)

by using tool F4 instead of joint bolt (2).
a When installing tool F4, fit the gaskets
to both sides of the fuel hose eye
joint.
3 Tool F4:
19.6 – 29.4 Nm {2.0 – 3.0 kgm}
3) Connect tool F5 to tool F4.
4) While running the engine at high idle,

measure the circuit negative pressure.
Standard circuit negative pressure:
Max. –50.7 kPa {–380 mmHg}
5) If the negative pressure exceeds the stan-
dard pressure, the fuel prefilter may be
clogged. Replace the fuel prefilter and
measure the negative pressure again.
measuring instruments and return the
removed parts.
3 Joint bolt (2):
19.6 – 29.4 Nm {2.0 – 3.0 kgm}
22 PC228US, 228USLC-3E0
Reduced cylinder mode operation No-injection cranking 1

a Reduced cylinder mode operation means to a No-injection cranking means to crank the
run the engine with the fuel injectors of 1 or engine with the starting motor while all the
more cylinders disabled electrically to reduce injections are stopped electrically. The pur-
the number of effective cylinders. The purpose and effect of this operation are as follows.
poses and effects of this operation are as fol- Before the engine is started after it or the
lows. machine has been stored for a long period, the
1. This operation is used to find out a cylinder no-injection cranking is performed to lubricate
which does not output power normally (or, the engine parts and protect them from sei-
combustion in it is abnormal). zure.
2. When a cylinder is selected for the reduced
cylinder mode operation, if the engine speed
and output do not change from the normal
operation (all-cylinder operation), that cylinder
has 1 or more defects.
The possible defects are as follows.
q Leakage through cylinder head gasket
q Defective injection
q Defective piston or piston ring
q Defective valve mechanism
(Moving valve system)
q Defect in electrical system
3. Since the common rail fuel injection system
controls the injector of each cylinder electroni-
cally, the operator can perform the reduced cyl-
inder mode operation easily with switches to
find out a defective cylinder.
PC228US, 228USLC-3E0 23
Testing fuel delivery, return rate 1. Measuring supply pump delivery

and leakage 1 1) Loosen clamp (2) of discharge tube (1) of
the supply pump and disconnect tube (1).
a Testing tools for fuel delivery, return rate and
leakage
1 795-790-4700 Tester kit
2 795-790-6700 Adapter
6754-71-5340 Connector
3
6754-71-5350 Washer
Commercially
4 Measuring cylinder
G available
Commercially
5 Stopwatch
available
Commercially Hose (Inside diameter: 14
6
available mm)
Commercially Hose (Inside diameter: 8 2) Install test hose G6 to the nipple on the
7
available mm) discharge side of the supply pump.
a Fix the hose with a wire etc.
a Since some fuel flows out during check, pre- a Adjust the route of the test hose so
pare an oil (receiving) pan of about 20 l. that it will not slacken and put its end
k Stop the machine on a level ground and in an oil receiving pan.
3) Crank the engine for 30 seconds and

measure the delivery with measuring cyl-
inder G4.
a Adjust the route of the test hose so
that it will not slacken and put its end
in an oil receiving pan.
a Do not crank the engine for more than
30 seconds to protect the starting
motor in any case other than this
measurement.
a If the supply pump delivery is in the
following standard range, it is normal.
At cranking speed
Min. 75 cc
(125 rpm)
At cranking speed
Min. 90 cc
(150 rpm)
24 PC228US, 228USLC-3E0

4) After finishing measurement, remove the the return rate in 25 seconds with measur-
measuring instruments and return the ing cylinder G4.
removed parts. a If the return rate from the supply
3 Tube sleeve nut: pump is in the following range, it is
35 ± 4 Nm {3.6 ± 0.4 kgm} normal.
3 Clamp mounting bolt:
10 ± 2 Nm {1.0 ± 0.2 kgm} At low idle Max. 400 cc
2. Measuring return rate from supply pump

1) Open the engine hood and disconnect
return hose (1) of the supply pump.
a The return hose is connected by a
quick coupler.

parts.
a When measuring the leakage from
the pressure limiter or finishing the
measurement: Return the removed
2) Install connector G3 and cap nut [1] of parts to their original positions.
tester kit G1 to the return hose to stop the a When measuring the leakage from
fuel from flowing out. the injector: Leave the removed parts
3) Connect test hose [2] of tester kit G1 to as they are and keep the hose end in
the supply pump. the oil pan.
a Lay the test hose so that it will not
slacken and put its end in the oil
(receiving) pan.
PC228US, 228USLC-3E0 25
3. Measuring leakage from pressure limiter

1) Open the engine hood and disconnect
return hose (2) of the pressure limiter.
a Install the seal washer to the connec-
tor bolt.
5) After finishing measurement, remove the mea-

3 Joint bolt:
24 ± 4 Nm {2.4 ± 0.4 kgm}
4. Measuring return rate from injector

2) Install removed connector bolt (3) and cap
a The leakage from the injector is measured
nut [1] of tester kit G1 to the return hose to
while the return hose of the pressure lim-
stop the fuel from flowing out.
iter is connected. Accordingly, before
3) Install connector G3 to the common rail
measuring the leakage from the injector,
and connect test hose [2] of tester kit G1.
check that the leakage from the pressure
a Lay the test hose so that it will not
limiter is normal.
slacken and put its end in the oil
1) Referring to “Measuring return rate from
(receiving) pan.
supply pump”, set the supply pump for
testing.
a Since it is difficult to disconnect the
injector return hose of the cylinder
head, work on the block side.
k The fuel returning from the supply
pump flows out during measure-
ment of the return rate from the
injector. Accordingly, keep the test
hose end in the oil pan.
2) Disconnect connector bolt (4) of the return
block.
a Install the seal washer to the return
hose.

the return rate in 1 minute with measuring
cylinder G4.
a If the leakage from the pressure limiter
is in the following range, it is normal.
At low idle 0 cc (No leakage)
26 PC228US, 228USLC-3E0
3) Install connector bolt [3] of adapter G2 Bleeding air from fuel circuit 1
instead of the removed connector bolt,
and connect test hose [6]. a If fuel is used up or if a fuel circuit part is
a Lay the test hose so that it will not removed and installed, bleed air from the fuel
slacken and put its end in the oil circuit according to the following procedure.
(receiving) pan.
1. Fill the fuel tank with fuel.

a Add fuel until the float of the sight gauge
reaches the maximum position.
2. Open the side cover of the pump room.
3. Loosen knob (1) of the feed pump and pull it

out, and then operate it forward and backward.
a Move the knob until it becomes heavy.
a The plug at the top of the fuel main filter
does not need to be removed.

the return rate in 1 minute with measuring
cylinder G4.
a If the return rate from the injector is in
the following range, it is normal.
At low idle Max. 180 cc
During cranking Max. 90 cc

may measure the fuel return rate
while rotating the engine with the
starting motor. Do not rotate for
more than 20 seconds continu- 4. After bleeding air, push in and tighten knob (1).
ously, however, for protection of
the starting motor.

parts.
3 Joint bolt:
24 ± 4 Nm {2.4 ± 0.4 kgm}
PC228US, 228USLC-3E0 27
Checking fuel circuit for leakage 1 9. Check the fuel piping and devices for fuel leak-
age.
k Very high pressure is generated in the high- a Check mainly around the high-pressure
pressure circuit of the fuel system. If fuel circuit parts coated with the color checker
leaks while the engine is running, it is dan- for fuel leakage.
gerous since it can catch fire. a If any fuel leakage is detected, repair it
After checking the fuel system or removing and check again from step 2.
its parts, check it for fuel leakage according a If no fuel leakage is detected, check is
to the following procedure. completed.
a Clean and degrease the engine and the parts
around it in advance so that you can check it
easily for fuel leakage.
1. Spray color checker (developer) over the fuel

supply pump, common rail, fuel injector, and
joints of the high-pressure piping.
2. Run the engine at speed below 1,000 rpm and

stop it after its speed is stabilized.
3. Check the fuel piping and devices for fuel leak-

age.
a Check mainly around the high-pressure
circuit parts coated with the color checker
for fuel leakage.
a If any fuel leakage is detected, repair it
and check again from step 2.
4. Run the engine at low idle.

age.
a Check mainly around the high-pressure
circuit parts coated with the color checker
for fuel leakage.
6. Run the engine at high idle.

age.
a Check around the high-pressure circuit
parts coated with the color checker for fuel
leakage.
8. Run the engine at high idle and load it.

a Relieve the arm circuit at the IN stroke
end.
28 PC228US, 228USLC-3E0
Checking and adjusting air Adjusting

conditioner compressor belt a If the belt deflection is abnormal, adjust it
tension 1 according to the following procedure.
k Stop the machine on a level ground and 1. Loosen bolts (1) and (2).
2. Move compressor (3) and bracket (4) together
Checking to adjust the belt tension.
1. Open the engine hood and remove the belt
guard from the top of the air conditioner com- 3. After positioning compressor (3), tighten bolts
pressor. (1) and (2).
a Check each pulley for breakage, wear of
2. Press the intermediate point of the belt the V-groove, and contact of the V-belt
between fan pulley and compressor pulley with and V-groove.
a finger and measure deflection (a) of the belt. a If the V-belt is so lengthened that the
q Belt pressing force: 60 N {6.1 kg} adjustment allowance is eliminated or it
q Belt deflection: 6.3 – 8.7 mm has a cut or a crack, replace it.
a If the belt is replaced, adjust their tension
again after operating the machine for 1
hour.
a After tightening the bolts, check the belt
tension again according the above check-
ing procedure.
4. After finishing measurement, return the removed

parts.
PC228US, 228USLC-3E0 29
Replacement of fan belt 1

a Since the auto-tensioner is installed, the fan
belt tension usually does not need to be
checked or adjusted.
a When replacing the fan belt, remove the air
conditioner compressor belt in advance.
1. Put the wrench (a) in part (A) (width across

flats: 12.7 mm) of tensioner assembly (2) and
turn it in the unwinding direction to decrease
the tension of fan belt (3).
k Set the wrench securely to part (A) of
tensioner assembly (2) before turning
it. (The spring of tensioner assembly
(2) is strong. If the wrench is set incom-
pletely and turned, it comes off and
that is very dangerous.)
k After removing fan belt (3), return ten-
sioner assembly (2) slowly and care-
fully.
k Take care not to catch your finger
between the pulley and fan belt (3) dur-
ing work.
2. Replace fan belt (3).

q Check each pulley for breakage and
cracking.
30 PC228US, 228USLC-3E0
PC228US, 228USLC-3E0 31
SEN01879-04

© 2010 KOMATSU
All Rights Reserved
32
SEN01880-04
PC228US-3E0
PC228USLC-3E0


Testing clearance in swing circle bearings...................................................................................................... 2
Checking and adjusting track shoe tension .................................................................................................... 3
Testing and adjusting hydraulic oil pressure in hydraulic circuit for work equipment, swing and travel .......... 4
Testing control circuit oil pressure................................................................................................................... 8
Testing and adjusting pump PC control circuit oil pressure ............................................................................ 9
Testing and adjusting pump LS control circuit oil pressure ........................................................................... 12
Testing solenoid valve output pressure......................................................................................................... 17
Testing PPC valve output pressure............................................................................................................... 20
Adjusting play of work equipment and swing PPC valves ............................................................................ 21
Inspection of locations of hydraulic drift of work equipment.......................................................................... 22
Release of residual pressure from hydraulic circuit ...................................................................................... 24
Testing oil leakage ........................................................................................................................................ 25
Bleeding air from each part ........................................................................................................................... 28
Procedure for replacing boom angle potentiometer...................................................................................... 30
Inspection procedures for diode.................................................................................................................... 31
Adjusting mirrors ........................................................................................................................................... 32
Testing clearance in swing circle 4. Hold the arm nearly perpendicular to the
bearings 1 ground, and lower the boom until the track
shoes will be lifted at the machine front.
a Swing circle bearing clearance testing tools a The upper structure is raised at the front
Symbol Part No. Part name and lowered at the rear at that time.
H Commercial product Dial gauge
5. Read off the value in dial gauge H in this condi-
tion.
a Follow the steps explained below, when mea-
a The value indicated in dial gauge H
suring clearance in the swing circle bearing in
expresses clearance in the bearings.
the actual machine.
k Be careful not to put a hand or foot under the
undercarriage, while taking measurement.
1. Fasten dial gauge H to swing circle outer race

(1) or inner race (2), and contact the probe with
the end surface of inner race (2) or outer race
(1) on the opposite side.
a Set dial gauge H at the machine front or
rear.
6. Return the machine to the posture in Item 2

above, and confirm reading of dial gauge H is
zero.
a If zero value is not indicated, repeat the
steps in Items 3 through 5.
2. Keep the work equipment in the max. reach

posture and keep the height of the bucket teeth
tip level with the lower height of the revolving
frame.
a The upper structure is lowered at the front
and raised at the rear at that time.
3. Set dial gauge H at zero point.
Checking and adjusting track a You may add grease until dimension (b)
shoe tension 1 between the idler guide and track frame
end becomes 0 mm. If the tension is still
Checking low, the pins and bushings are worn
1. Travel the machine forward by the length of much. In this case, reverse or replace the
track on ground with the engine at low idle and pins and bushings.
then stop the machine slowly.
2. Place straight bar [1] on the track shoe
between the idler and the 1st carrier roller.
a L beam is recommended for bar [1]
because of its deflection-free nature.
3. Measure maximum clearance (a) between bar
[1] and the track shoe.
q Standard clearance (a): 10 – 30 mm
2. Decreasing tension
1) Loosen valve (2) to discharge grease, and
then tighten it.
k Do not loosen the valve more than
1 turn. If it is loosened more, it may
jump out because of the high-pres-
sure grease in it.
2) To check that the tension is normal, run
Adjusting the engine at low idle and move the
a If the track shoe tension is abnormal, adjust it machine forward slowly by the length of
according to the following procedure. track on ground, then stop.
3) After adjusting, check the track shoe ten-
1. Increasing tension sion according to the above procedure.
1) Add grease through grease fitting (1) with
a grease gun.
2) To check that the tension is normal, run
the engine at low idle and move the
machine forward slowly by the length of
track on ground, then stop.
3) After adjusting, check the track shoe ten-
sion according to the above procedure.
Testing and adjusting hydraulic

oil pressure in hydraulic circuit
for work equipment, swing and
travel 1
a Testing and adjusting tools for hydraulic oil
pressure in hydraulic circuit for work equip-
ment, swing and travel
1
J
799-101-5220 Nipple (10 x 1.25 mm)
2
07002-11023 O-ring
2) Fit nipple J2 and connect it to oil pressure
gauge [1] of hydraulic tester J1.
a Hydraulic oil pressure in the hydraulic circuit for
a Use an oil pressure gauge with the
work equipment, swing and travel (hydraulic
capacity of 60 MPa {600 kg/cm2}.
pump output pressure) may be also confirmed
with a monitoring function in the machine moni-
tor (special function of machine monitor).
3) Start the engine and keep it running until

the hydraulic oil temperature rises to the
operating range.
Measurement
1. Pre-measurement work
k Lower the work equipment to the
ground, then release the remaining
pressure in the piping by operating the
control lever several times after stop-
ping the engine, and release the pres-
sure inside the hydraulic tank by
gradually loosening the oil filler cap.
1) Remove hydraulic oil pressure measuring

plugs (1) and (2).
q Plug (1): For measurement of front
pump discharge pressure
q Plug (2): For measurement of rear
pump discharge pressure
2. Combination of pump, actuator and valve a Keep the swing lock switch in the
a When oil flow from the pumps is divided, OFF position during the inspection. If
the front and rear pumps work indepen- it is moved to the ON position,
dently of each other for each actuator, as hydraulic oil pressure is turned to high
well as that different relief valves are acti- relief pressure, as the constant 2-
vated then. See the table below. stage relief valve is moved to the ON
a Oil flow from the pumps is merged in the position.
single pressure relief when the work
equipment swings, while it is divided in the 5. Measurement of swing relief pressure
single pressure relief when the machine 1) Start the engine and move the swing lock
travels. switch to the ON position.
a The actuators in the table below are 2) Measure hydraulic oil pressure when the
arranged in the order that the control engine is running at high idle and the
valves are viewed from the machine front. swing circuit is relieved.
(Service: 1 attachment is installed) a Hydraulic oil pressure when the swing
motor safety valve is relieved is dis-
Pump Actuator Relieve valve activated
played.
(R unload valve) (R main relief valve) a The swing motor relief pressure is
Service Safety valve lower than the main relief pressure.
Rear
Bucket R main relief valve
pump 6. Measurement of travel circuit relief pres-
Travel, left R main relief valve
sure
Boom R main relief valve 1) Start the engine and lock travel.
(Pump merge-divider valve) (Travel junction valve) k Put pin [2] in between the sprocket
Swing Swing motor safety valve and the track frame to make sure
locking travel.
Front Travel, right F main relief valve
pump Arm F main relief valve
(F unload valve) (F main relief valve)
(Centralized safety valve) (Back-pressure valve)
3. Measurement of unload pressure

1) Start the engine.
2) Measure hydraulic oil pressure, when the
engine is running at high idle and all the
control levers are moved to the NEUTRAL
position.
a Hydraulic oil pressure when the
unload valve unloads is displayed.
2) Measure hydraulic oil pressure when the
4. Measurement of work equipment relief engine is running at high idle and the
pressure travel circuit is relieved.
1) Start the engine and move the cylinder to a Hydraulic oil pressure with the main
be measured to its stroke end. relief valve in relief condition is dis-
2) Measure hydraulic oil pressure, when the played. In the travel circuit relief, the
engine is running at high idle and the cyl- pressure is high pressure relief all the
inder is in relief condition. time.
a Hydraulic oil pressure when the main
relief valve is in relief condition is dis-
played.
a If one-touch power max. switch is
depressed, the oil pressure is turned
to high relief pressure, and if
released, it is turned to low relief
pressure.
Adjustment 4) Tighten locknut (7) while fixing holder (6).

a The unload valve cannot be adjusted. 3 Locknut: 49 – 58.8 Nm {5 – 6 kgm}
1. Adjustment of main relief pressure

(high pressure setting side)
a If relief pressure of the high pressure in
the work equipment and travel circuits is
not normal, adjust the high pressure set-
ting side of main relief valves (3) and (4) in
the following manner.
q Main relief valve (3): Front main relief
valve
q Main relief valve (4): Rear main relief
valve
a When adjusting the main relief valve on
the front pump side, remove the cover
under the control valve.
a When adjusting the main relief valve on 5) Connect pilot hose.
the rear pump side, remove the fuel tank 6) Check the pressure again after the adjust-
cover. ment, following the aforementioned steps
a The relief pressure at high pressure indi- for measurement.
cates that when the 2-stage relief valve is a If high pressure setting side is adjusted,
ON and pilot pressure is applied to the low pressure setting side is also affected,
switching port. so adjust it, too.
2. Adjustment of main relief pressure (low

pressure setting side)
a When low pressure relief pressure of the
work equipment is not normal, or when
adjustment is made of the high pressure
setting side, adjust the low pressure side
of the main relief valve, too.
a The relief pressure at high pressure indi-
cates that when the 2-stage relief valve is
OFF and pilot pressure is not applied to
the switching port.
1) Disconnect pilot hose.
2) Loosen locknut (9) while fixing holder (8).
1) Disconnect pilot hose. 3) Adjust the pressure by turning holder (8).
2) Loosen locknut (7) while fixing holder (6). a If the holder is turned to the right, the
3) Adjust the pressure by turning holder (6). pressure rises.
a If the holder is turned to the right, the If the holder is turned to the left, the
pressure rises. pressure falls.
If the holder is turned to the left, the a Adjustment amount per turn of holder:
pressure falls. Approx. 12.5 MPa {approx. 128 kg/cm2}
a Adjustment amount per turn of holder:
Approx. 12.5 MPa {approx. 128 kg/cm2}
4) Tighten locknut (9) while fixing holder (8). 3) Tighten locknut (12) while fixing adjusting
3 Lock nut: screw (11).
34.3 – 44.1 Nm {3.5 – 4.5 kgm} 3 Locknut:
78 – 103 Nm {8.0 – 10.5 kgm}
5) Connect pilot hose.

6) Check the pressure again after the adjust- 4) Check the pressure again after the adjust-
ment, following the aforementioned steps ment, following the aforementioned steps
for measurement. for measurement.
3. Adjustment of swing relief pressure

a If the swing relief pressure is not normal,
adjust it with swing motor safety valve (10)
in the following manner.
a When adjusting the swing motor safety
valve, open the swing motor upper cover
(rubber) toward the front of the machine.
1) Loosen locknut (12) while fixing adjusting

screw (11).
2) Adjust the pressure by turning adjusting
screw (11).
a If the adjusting screw is turned to the
right, the pressure rises.
If the adjusting screw is turned to the
left, the pressure falls.
a Adjustment amount per turn of adjust-
ing screw:
Approx. 6.71 MPa {approx. 68.4 kg/cm2}
Testing control circuit oil 4. Measure oil pressure with the engine running
pressure 1 at high idle and all the control levers in the
NEUTRAL position.
a Testing tools for control circuit oil pressure
1
K
799-101-5220 Nipple (10 x 1.25 mm)
2
07002-11023 O-ring
Measurement
k Lower the work equipment to the ground
and, after stopping the engine, release
residual pressure in the piping by operating
the control lever several times. Then loosen
the oil filler cap gradually to release pres- 5. Detach all the measurement tools after the
sure inside the tank. measurement, and make sure that the
machine is back to normal condition.
1. Remove oil pressure measurement plug (1). a The control circuit basic pressure relief
valve cannot be adjusted.
2. Fit nipple K2 and connect it to oil pressure

gauge [1] of hydraulic tester K1.
a Use an oil pressure gauge with the capac-
ity of 6 MPa {60 kg/cm2}.
3. Start the engine and keep it running until the

hydraulic oil temperature rises to the operating
range.
Testing and adjusting pump PC q (3): Front PC valve output pressure

control circuit oil pressure 1 pickup plug
q (4): Rear PC valve output pressure
a Testing and adjusting tools for pump PC con- pickup plug
trol circuit oil pressure
1
L
799-101-5220 Nipple (10 x 1.25 mm)
2
07002-11023 O-ring
Measurement
a Before measuring the pump PC control circuit
oil pressure, check that the oil pressure in the
work equipment, swing, and travel circuits and
the control circuit basic pressure are normal.
k Lower the work equipment to the ground 2) Install nipple L2 and connect it to oil pres-
and stop the engine. Operate the control sure gauge [1] of hydraulic tester L1.
lever several times to release the residual a Use the oil pressure gauge of 60 MPa
pressure in the piping, and then loosen the {600 kg/cm2}.
hydraulic oil filler cap slowly to release the q The figure shows the pump discharge
internal pressure of the hydraulic tank. pressure side.
1. Measurement of PC valve output pressure

(servo piston inlet pressure)
a Measure the PC valve output pressure
(servo piston inlet pressure) and the pump
discharge pressure simultaneously, and
then compare them.
1) Remove oil pressure pickup plugs (1), (2),
(3), and (4).
q (1): Front pump discharge pressure
pickup plug
q (2): Rear pump discharge pressure
pickup plug
q The figure shows the PC valve output

pressure side.
3) Run the engine and heighten the hydraulic 2. Measurement of PC-EPC valve output pres-
oil temperature to the operating range. sure
1) Remove oil pressure pickup plug (5).
4) Run the engine at high idle under the fol-

lowing condition and measure the pump 2) Install nipple L2 and connect it to oil pres-
discharge pressure and PC valve output sure gauge [1] of hydraulic tester L1.
pressure (servo piston inlet pressure) a Use the oil pressure gauge of 6 MPa
simultaneously. {60 kg/cm2}.
q Working mode: P
q Swing lock switch: ON (When 2nd
relief is ON, high-pressure relief is
ON)
q Work equipment, swing, and travel
levers: Relieve by arm IN operation.
a Judging method
If the ratio of the pump discharge
pressure to the PC valve output pres-
sure (servo piston output pressure) is
as follows, those pressures are nor-
mal.
Measured oil pressure Ratio of oil pressure

Pump discharge
1 3) Run the engine and heighten the hydraulic
pressure
oil temperature to the operating range.
PC valve output Approx. 0.6
pressure (Approx. 3/5)
a If the PC valve or the servo piston is

defective, the PC valve output pres-
sure (servo piston output pressure) is
“the same as the pump discharge
pressure” or “almost 0”.
10 PC228US, 228USLC-3E0
4) Set all the control levers in neutral and 2. Turn adjusting screw (9) to the right or left.
measure the oil pressure at low idle and a Turn the adjusting screw in the following
high idle. directions.
a If the PC-EPC valve output pressure q If the work equipment speed is low,
changes as shown below, it is normal. turn the adjusting screw to the right
(to increase the pump absorption
Engine Control levers Oil pressure torque).
2.9 MPa q If the engine speed is low, turn the
Low idle
{30 kg/cm2} adjusting screw to the left (to
Neutral
0 MPa decrease the pump absorption
High idle
{0 kg/cm2} torque).
Adjustment 3. Tighten locknut (8).

a If either of the following phenomena occurs 3 Locknut:
and the PC valves seem to be defective, adjust 27.5 – 34.3 Nm {2.8 – 3.5 kgm}
PC valves (6) and (7) according to the proce-
dure shown below.
q As the working load increases, the engine
speed lowers remarkably.
q The engine speed is normal but the work
equipment speed is low.
q (6): Front pump PC valve
q (7): Rear pump PC valve
a The width across flats of the PC valve locknut
is 13 mm and that of the adjusting screw
(inside width) is 4 mm.
Do not turn any other locknut or adjusting
screw since they affect the hydraulic pump per-
formance.
4. After finishing adjustment, check that the PC
valve output pressure (servo piston inlet pres-
sure) is normal according to the procedure for
measurement described above.
1. Loosen locknut (8).

a Before loosening the locknut, make a
match mark at the end of the adjusting
screw so that you can see the position of
the adjusting screw before adjustment (so
that you can return the adjusting screw to
the original position after you turn it in the
opposite direction).
PC228US, 228USLC-3E0 11
Testing and adjusting q (3): Front LS valve output pressure

pump LS control pickup plug
q (4): Rear LS valve output pressure
circuit oil pressure 1 pickup plug
a Testing and adjusting tools for pump LS control

circuit oil pressure
1
M 799-101-5220 Nipple (10 x 1.25 mm)
2
07002-11023 O-ring
3 799-401-2701 Differential pressure gauge
Measurement
a Before measuring the pump LS control circuit
oil pressure, check that the oil pressure in the 2) Install nipple M2 and connect it to oil pres-
work equipment, swing, and travel circuits and sure gauge [1] of hydraulic tester M1.
the control circuit basic pressure are normal. a Use the oil pressure gauge of 60 MPa
k Lower the work equipment to the ground
{600 kg/cm2}.
and stop the engine. Operate the control q The figure shows the pump discharge
lever several times to release the residual pressure side.
pressure in the piping, and then loosen the
hydraulic oil filler cap slowly to release the
internal pressure of the hydraulic tank.
1. Measurement of LS valve output pressure

(servo piston inlet pressure)
a Measure the LS valve output pressure
(servo piston inlet pressure) and the pump
discharge pressure simultaneously, and
then compare them.
1) Remove oil pressure pickup plugs (1), (2),
(3), and (4).
q (1): Front pump discharge pressure
pickup plug
q (2): Rear pump discharge pressure
q The figure shows the LS valve output
pickup plug
pressure side.
12 PC228US, 228USLC-3E0
3) Run the engine and heighten the hydraulic 2. Measurement of LS differential pressure
oil temperature to the operating range and a Measure the pump discharge pressure
raise the right or left track shoe with the and LS pressure (actuator load pressure)
work equipment, depending on the circuit simultaneously and calculate the differ-
to be measured. ence between them.
q When measuring front circuit: Raise 1) Remove oil pressure pickup plugs (1), (2),
right track shoe. (5), and (6).
q When measuring rear circuit: Raise q (1): Front pump discharge pressure
left track shoe. pickup plug
k Since the raised track shoe will be q (2): Rear pump discharge pressure
rotated to measure the pressure, pickup plug
secure a sufficient working area.
q (5): Front pump LS pressure pickup

4) Measure the pump discharge pressure plug
and LS valve output pressure (pressure at q (6): Rear pump LS pressure pickup
servo piston inlet) at the same time after plug
setting following conditions with the
engine running at high idle.
q Working mode: P
q Work equipment, swing, and travel:
When all levers are at neutral and
when travel lever is at half stroke (one
side of travel is at idle).
a Let the raised track shoe idly rotate,
paying enough attention to the sur-
roundings for safety.
a Tseting condition and judgment
method: When the hydraulic pres-
sures are within ratio in the table, LS
valve is normal.
Position of levers and pedals 2) Install nipple M2 and connect it to differen-
Travel lever tial pressure gauge M3 or the oil pressure
All levers and
moved
pedals are at
halfway
gauge of hydraulic tester M1.
neutral
(Travel at idle) a When using the differential pressure
1 gauge:
Pump discharge
(Actual value Connect the pump discharge pres-
Hydraulic pressure
is set as 1)
pressure to Almost same sure to the high pressure side (back
be measured LS valve output Approx. 3/5 of
pressure side) and connect the LS pressure to
pressure the low pressure side (lower side).
above
Since the differential pressure gauge
5) Remove the measurement tool after the needs a 12-V power source, connect
measurement, and make sure that the it to a battery.
machine is back to normal condition.
PC228US, 228USLC-3E0 13
a When using oil pressure gauge:

Use the oil pressure gauge of 60 MPa
{600 kg/cm 2 }, unit of 1 MPa {10 kg/
cm2}.
Since the differential pressure is
about 2.9 MPa {30 kg/cm2} at maxi-
mum, measure it by installing the
same gauge to the pickup plugs alter-
nately.
q The figure shows the pump discharge
pressure side.
4) Run the engine at high idle under the fol-

lowing condition and measure the pump
discharge pressure and LS pressure
(actuator load pressure) simultaneously.
q Working mode: P
q Travel speed: Hi
q Work equipment, swing, and travel
levers: Measure when all of these
levers are in neutral and when the
travel lever is moved halfway (to rotate
the raised track shoe).
q The figure shows the LS pressure a Rotate the raised track shoe, taking
side. care of the safety around the machine
sufficiently.
a Calculation of LS differential pressure
(When oil pressure gauge is used):
LS differential pressure =
Pump dischange pressure – LS pres-
sure
a If the LS differential pressure is as fol-
lows, it is normal.
LS differential
Operation of lever
pressure
Unload pressure
When all levers are in
(See standard
neutral
values table)
When travel lever is Standard LS differen-
3) Run the engine and heighten the hydraulic moved halfway tial pressure
oil temperature to the operating range and (When raised track (See standard
raise the right or left track shoe with the shoe is rotated) values table)
work equipment, depending on the circuit
to be measured.
measuring instruments and return the
q When measuring front circuit: Raise
removed parts.
right track shoe.
q When measuring rear circuit: Raise
left track shoe.
k Since the raised track shoe will be
rotated to measure the pressure,
secure a sufficient working area.
14 PC228US, 228USLC-3E0
3. Measurement of LS-EPC valve output pres- 4) Running the engine at high idle, operate
sure the travel speed switch and travel lever
1) Remove oil pressure pickup plug (7). and measure the oil pressure.
a If the LS-EPC valve output pressure
is as follows, it is normal.
Travel
Travel Lever Oil Pressure
Speed
Approx. 2.9 MPa
Lo Neutral
{Approx. 30 kg/cm2}
Fine opera-
Hi 0 MPa {0 kg/cm2}
tion (Note)
Note: Move the travel lever to a degree

that the PPC oil pressure switch is
turned ON (before the track starts
moving).
2) Install nipple M2 and connect it to oil pres- 5) After finishing measurement, remove the
sure gauge [1] of hydraulic tester M1. measuring instruments and return the
a Use the oil pressure gauge of 6 MPa removed parts.
{60 kg/cm2}.
3) Run the engine and heighten the hydraulic

oil temperature to the operating range.
PC228US, 228USLC-3E0 15
Adjustment
a If the LS differential pressure is abnormal,
adjust LS valves (8) and (9) according to the
q (8): Front pump LS valve
q (9): Rear pump LS valve
1. Fixing adjusting screw (10), loosen locknut

(11).
2. Turn adjusting screw (10) to adjust the LS dif-
ferential pressure.
a If the adjusting screw is
q turned to the right, the differential
pressure rises.
q turned to the left, the differential pres-
sure lowers.
a Quantity of adjustment (LS differential
pressure) per turn of adjusting screw:
Approx. 1.3 MPa {Approx. 13.3 kg/cm2}
3. Fixing adjusting screw (10), tighten locknut
(11).
3 Lock nut: 49 – 64 Nm {5 – 7 kgm}
4. After finishing adjustment, check again that the

LS valve output pressure (servo piston inlet
pressure) is normal according to the procedure
for measurement described above.
16 PC228US, 228USLC-3E0
Testing solenoid valve output

pressure 1
a Testing tools for solenoid valve output pressure

1
N 790-261-1204 Digital hydraulic tester
2 799-401-3100 Adapter (Size: 02)
a Before measuring the solenoid valve output

pressure, check that the control circuit basic
pressure is normal.
k Lower the work equipment to the ground 4. Run the engine and heighten the hydraulic oil
and stop the engine. Operate the control temperature to the operating range.
lever several times to release the residual
pressure in the piping, and then loosen the
hydraulic oil filler cap slowly to release the
internal pressure of the hydraulic tank.
1. Disconnect outlet hoses (1) – (6) of the sole-

noid valve to be measured.
No. Solenoid valve to be measured
1 PPC lock solenoid valve
2 2-stage relief solenoid valve
3 Travel speed shifting solenoid valve
4 Swing holding brake solenoid valve
5 Travel junction solenoid valve
5. Run the engine at full throttle and operate the
6 Pump merge-divider solenoid valve control levers and switches and measure the
pressure when each solenoid valve is turned
ON or OFF.
a For the conditions for turning each sole-
noid valve ON and OFF, see the "Table for
Functioning Conditions of the solenoid
valves".
a The functioning conditions of the solenoid
valves can be checked with the monitoring
function of the machine monitor (a special
function of the machine monitor).
a If the output pressure of a solenoid valve
is as follows, that solenoid valve is normal.
Solenoid valve Output pressure
OFF (De-energized) 0 MPa {0 kg/cm2}
2. Install adapter N2 and connect the discon- Almost same as control
nected hoses again. ON (Energized) basic pressure (See
3. Install nipple [2] and connect it to oil pressure standard values table)
gauge [3].
a Use the oil pressure gauge of 6 MPa {60 6. After finishing measurement, remove the mea-
kg/cm2}. suring instruments and return the removed
a The measuring instruments installed to the parts.
outlet hose of the PPC lock solenoid valve
are shown in the figure.
PC228US, 228USLC-3E0 17
Table for Functioning Conditions – PPC lock solenoid valve

Functioning condition Functioning
Locked OFF
Lock lever
Released ON
Table for Functioning Conditions – 2-stage relief solenoid valve

When overheat setting of 1st stage is ON
When overheat setting of 2nd stage is ON OFF
When all signals for work equipment, swing, and travel are OFF
When swing lock switch is ON
When travel signal is ON
When working mode is L
ON
When boom LOWER signal is ON
When signals other than swing operation only signal
When working mode is When one-touch power is ON
P or E maximizing switch is ON
When swing operation only signal is ON
OFF
In conditions other than above
Table for Functioning Conditions – Travel speed shifting solenoid valve

When overheat setting of 2nd stage is ON
When fuel dial indicates less than 1,500 rpm
When travel speed switch is at Lo
OFF
When travel signal is OFF
When front or rear pump pressure is above 33.3 MPa
When travel speed
{340 kg/cm2}
switch is Mi or Hi When travel signal is ON
When front or rear pump pressure is below 17.6 MPa
{180 kg/cm2} ON
In conditions other than above
Table for Functioning Conditions – Swing holding brake solenoid valve

When all of them are OFF OFF
Work equipment, swing, and travel signals
When any of them is ON ON
Table for Functioning Conditions – Travel junction solenoid valve

When travel steering signal is ON ON
When travel only signal When front or rear pump pressure is above 24.5 MPa
When travel steering ON
is ON {250 kg/cm2}
signal is OFF
In conditions other than above OFF
18 PC228US, 228USLC-3E0
Table for Functioning Conditions – Pump merge-divider solenoid valve

When signals other than boom LOWER only signal is
When working mode is When service signal is ON
ON
B ON
When boom LOWER only signal is ON
OFF
When working mode is L When boom RAISE and swing signals are ON
When travel only signal is ON
When compound travel When travel steering When front or rear pump pressure is above 19.6 MPa ON
operation signal is ON signal is ON {200 kg/cm2}
When swing lock switch is ON
When working mode is P OFF
When travel signal is ON When swing signal is ON

When front or rear pump
When swing signal is When service & arm
pressure is above 19.6 ON
OFF dump signal is ON
MPa {200 kg/cm2}
In conditions other than above OFF
PC228US, 228USLC-3E0 19
Testing PPC valve output 1. Disconnect hydraulic hose (2) of PPC circuit,
pressure 1 install adapter P2, and connect the hydraulic
hose (2) again.
a Testing tools for PPC valve output pressure 2. Fit nipple [1] of hydraulic tester P1 to adapter
Symbol Part No. Part name P2 and connect oil pressure gauge [2].
a Use an oil pressure gauge with the capac-
1 ity of 6 MPa {60 kg/cm2}.
790-261-1204 Digital hydraulic tester a The photo below shows the situation that
P
799-401-3100 Adapter (Size : 02) the measuring tools are installed to the
2
799-401-3200 Adapter (Size : 03) bucket CURL PPC oil pressure switch
installation position.
a Measure PPC valve output pressure after con-
firming that control circuit original pressure is
normal.
Circuit to be Circuit to be
No. No.
measured measured
1 Boom, RAISE (S06) 6 Bucket, DUMP (S05)
2 Boom, LOWER (S02) 7 Swing, left (S03)
3 Arm, IN (S04) 8 Swing, right (S07)
4 Arm, OUT (S08) 9 Travel (black) (S30)
5 Bucket, CURL (S01) 10 Steering (red) (S31)
a Oil pressure switches (1) through (8) are

installed in the PPC relay block, and (9) and 3. Start the engine and keep it running until the
(10) are installed at the rear of operator's cab. hydraulic oil temperature rises to the operating
range.
20 PC228US, 228USLC-3E0
4. Measure the pressure when the engine is run- Adjusting play of work equipment
ning at high idle and the control lever of the cir- and swing PPC valves 1
cuit to be measured is kept in the NEUTRAL
position and at the full stroke. a If the right and left work equipment levers have
a If PPC valve output pressure is at the level large play, adjust them according to the follow-
shown below, it is judged normal. ing procedure.
Lever Control Hydraulic pressure 1. Remove the work equipment and swing PPC
In NEUTRAL 0 MPa {0 kg/cm2} valve assembly.
Nearly equal to control
At full stroke original pressure 2. Remove boot (1).
(see standard value table)
3. Loosen locknut (2) and screw in disc (3) until it
contacts the heads of 4 pistons (4).
5. Detach all the measurement tools, and make a Do not move the piston while doing this
sure that the machine is back to normal condi- work.
tion.
4. Keep disc (3) in place and tighten locknut (2) to
the specified tightening torque.
3 Locknut: 69 – 88 Nm {7 – 9 kgm}
5. Install boot (1).
6. Install the work equipment and swing PPC

valve assembly.
PC228US, 228USLC-3E0 21
Inspection of locations of 2. Inspection of arm cylinder

hydraulic drift of work equipment1 1) Operate the arm cylinder to move the arm
to the position 100 mm before the IN
stroke end, and stop the engine.
a If there is any hydraulic drift in the work equip-
ment (cylinders), check in the following manner
to determine if the cause is in the cylinder
packing or in the control valve.
1. Inspection of boom and bucket cylinders

1) Set the work equipment in the same pos-
ture as when measuring hydraulic drift,
and stop the engine.
a Fill the bucket with earth or apply the
rated load to the bucket.
2) Operate the arm control lever to move the

arm to the IN side.
q If the lowering speed increases, the
cylinder packing is defective.
q If there is no change, the control
valve is defective.
a Operate the control lever with the
engine starting switch in the ON posi-
tion.
a If pressure in the accumulator has
dropped, run the engine for approx.
2) Operate the control lever to the RAISE 10 seconds to charge the accumula-
position or the bucket control lever to the tor again.
CURL position. [Reference]If the cause of the hydraulic drift is in
q If the lowering speed increases, the the defective packing, and the above
cylinder packing is defective. operation is carried out, downward
q If there is no change, the control movement is accelerated for the follow-
valve is defective. ing reasons.
a Operate the control lever with the 1) If the work equipment is set to the above pos-
engine starting switch in the ON posi- ture (holding pressure applied to the bottom
tion. end), the oil at the bottom end leaks to the
a If pressure in the accumulator has head end. However, the volume at the head
dropped, run the engine for approx. end is smaller than the volume at the bottom
10 seconds to charge the accumula- end by the volume of the rod end, so the inter-
tor again. nal pressure at the hea d end increases
because of the oil flowing in from the bottom
end.
2) When the internal pressure at the head end
increases, the pressure at the bottom end also
rises in proportion to this. The balance is main-
tained at a certain pressure (this differs accord-
ing to the amount of leakage) by repeating this
procedure.
22 PC228US, 228USLC-3E0
3) When the pressure is balanced, the downward

movement becomes slower. If the lever is then
operated according to the procedure given
above, the circuit at the head end is opened to
the drain circuit (the bottom end is closed by
the check valve), so the oil at the head end
flows to the drain circuit and the downward
movement becomes faster.
3. Inspection of boom lock valve

1) Set the work equipment at the maximum
reach and the boom top horizontal. Then
stop the engine.
k Lock the work equipment lock levers
and release the pressure inside the
hydraulic tank.
k Do not allow anyone to come under the
work equipment during the work.
2) Disconnect drain hose (1) of the control
valve, and install an oil stopper plug in the
hose.
q Part No. for the oil stopper plug:
07376-70210
a Leave the control valve end open.
a If any oil leaks out from the port that is
left open, following hydraulic drift of
the work equipment, the boom lock
valve is defective (loose contact).
4. Inspection of PPC valve

Measure the amount of hydraulic drift of the
work equipment when the accumulator is
charged with pressure and the work equipment
lock lever is put to the LOCK and FREE posi-
tions.
a Operate the control lever with the engine
starting switch in the ON position.
a If pressure in the accumulator has
dropped, run the engine for approx. 10
seconds to charge the accumulator again.
a If there is any difference in the hydraulic
drift between LOCK and FREE positions,
the PPC valve is defective (some internal
failure).
PC228US, 228USLC-3E0 23
Release of residual pressure from 4) Repeat above steps 2) and 3) 2 – 3 times,

hydraulic circuit 1 and all residual pressure is released from
the piping.
1. Release of residual pressure from hydrau- 3. Release of residual pressure from swing
lic tank motor circuit
k The hydraulic tank is enclosed and a Release the residual pressure from the
pressurized. When removing a hose or swing motor circuit by performing the pro-
a plug connected to the hydraulic tank, cedure for “2. Release of residual pres-
release the residual pressure from the sure from hydraulic cylinder circuit
hydraulic tank according to the follow- (Operate the work equipment control
ing procedure. levers in swing direction only)”.
1) Lower the work equipment to the ground
in a stable posture and stop the engine. 4. Release of residual pressure from travel
2) Slowly loosen oil filler cap (1) of the motor circuit
hydraulic tank to release the air from the a Since the control valve spool of the travel
tank. motor is open, release the residual pres-
sure from the travel motor circuit by per-
forming the procedure for “1. Release of
residual pressure from hydraulic tank”.
2. Release of residual pressure from hydrau-

lic cylinder circuit
k When disconnecting the piping
between a hydraulic cylinder and the
control valve, release the residual pres-
sure from the piping according to the
1) Referring to “1. Release of residual pres-
sure from hydraulic tank”, release the
residual pressure from the hydraulic tank.
a Leave the oil filler cap of the hydraulic
tank removed.
2) Turn the starting switch to the ON position
and set the work equipment lock lever in
the FREE position, and then operate the
work equipment control levers on both
sides forward, backward, to the right, and
to the left.
a The control valve is driven with the
pressure in the accumulator. If it is
operated 2 – 3 times, the pressure
lowers.
3) Start the engine and run it at low idle for 5
seconds to heighten the pressure in the
accumulator.
24 PC228US, 228USLC-3E0
Testing oil leakage 1 2. Measuring oil leakage from arm cylinder

1) Move the arm cylinder to the IN stroke end
a Testing tools for oil leakage and stop the engine.
Symbol Part No. Part name k Release the residual pressure from
the piping on the arm cylinder
Commercially
Q Measuring cylinder head si de. For detai ls, see
available
“Release of residual pressure from
a Measure the oil leakage under the following hydraulic circuit” (Operate the
condition. lever in the arm IN direction only,
q Hydraulic oil temperature: Within operating however).
range 2) Disconnect hose (2) on the cylinder head
side and block the hose side with a flange.
k Take care not to disconnect the
1. Measuring oil leakage from boom cylinder
1) Move the boom cylinder to the RAISE hose on the cylinder bottom side.
stroke end and stop the engine. a Use the following part to block the
k Release the residual pressure from
hose side.
the piping on the boom cylinder 07379-00640 (Flange #06)
h e a d s i d e . F o r d e ta i l s , s e e
“Release of residual pressure from
hydraulic circuit” (Operate the
lever in the boom RAISE direction
only, however).
2) Disconnect hose (1) on the cylinder head
hose on the cylinder bottom side.
a Use the following part to block the
hose side.
07379-00640 (Flange #06)
3) Run the engine at high idle and relieve the

arm circuit by moving the arm IN.
k Take care not to “move the arm
OUT”.
4) Start measuring the oil leakage in 30 sec-
onds after relieving is started and mea-
sure for 1 minute.
5) After finishing measurement, return the
removed parts.

boom circuit by raising the boom.
k Take care not to “lower the boom”.
sure for 1 minute.
removed parts.
PC228US, 228USLC-3E0 25
3. Measuring oil leakage from bucket cylinder 4. Measuring oil leakage from swing motor
1) Move the bucket cylinder to the CURL 1) Remove the steel top of the swing motor.
stroke end and stop the engine. 2) Disconnect 2 drain hoses (4) and block
k Release the residual pressure from the hose side with plugs.
the piping on the bucket cylinder a Use the following parts to block the
h e a d s i d e . F o r d e ta i l s , s e e hose side.
“Release of residual pressure from 07376-70522 (Plug #05)
hydraulic circuit” (Operate the
lever in the bucket CURL direction
only, however).
2) Disconnect hose (3) on the cylinder head
hose on the cylinder bottom side.
hose side.
07379-00640 (Flange #06)
3) Turn the swing lock switch ON.

swing circuit by swinging.
a Start measuring the oil leakage in 30
seconds after relieving is started and
measure for 1 minute.
a After measuring 1 time, swing 180°,
and then measure again.
removed parts.
bucket circuit by curling the bucket.
k Take care not to “dump the bucket”.
sure for 1 minute.
removed parts.
26 PC228US, 228USLC-3E0
5. Measuring oil leakage from travel motor

1) Remove the travel motor cover.
2) Run the engine, lock the travel mecha-
nism, and stop the engine.
k Put pin [1] between the sprocket
and track frame to lock the travel
mechanism securely.
3) Disconnect drain hose (5) of the travel

motor and block the hose side with a plug.
hose side.
07376-70422 (Plug #04)
4) Run the engine at high idle, relieve the

travel circuit, and measure the oil leakage.
k Before operating the travel lever,
check the position and locking
direction of the locked sprocket
again.
k Wrong operation of the lever can
cause an accident. Accordingly,
make signs and checks securely.
a Start measuring the oil leakage in 30
seconds after relieving is started and
measure for 1 minute.
a Measure several times, moving the
motor a little (changing the position of
the valve plate and cylinder and that
of the cylinder and piston) each time.
removed parts.
PC228US, 228USLC-3E0 27
Bleeding air from each part 1
Air bleeding item Air bleeding procedure

1 2 3 4 5 6
Bleeding Bleeding Bleeding Checking
Bleeding
air from Starting air from air from oil level
air from
hydraulic engine swing travel and start-
cylinder
Contents of work pump motor motor ing work
• Replacement of hydraulic oil q q
q q q q
• Cleaning of strainer (See Note) (See Note)
• Replacement of return filter element q q
• Replacement or repair of hydraulic

pump q q q q
• Removal of suction piping
• Replacement or repair of control valve
q q q
• Removal of control valve piping
• Replacement or repair of cylinder
q q q
• Removal of cylinder piping
• Replacement or repair of swing motor
q q q
• Removal of swing motor piping
• Replacement or repair of travel motor
q q q
• Removal of travel motor piping
Note: Bleed air from the swing motor and travel motor only when the oil was drained from the motor cases.
1. Bleeding air from hydraulic pump 2. Starting engine

a Keep the oil filler cap of the hydraulic tank When running the engine after performing step
loosened while the air is bled from the 1, keep its speed at low idle for 10 minutes.
hydraulic pump. a If the engine coolant temperature is low
1) Loosen air bleeder (1) and check that oil and the automatic warm-up operation is
oozes out from it. started, stop the engine temporarily and
2) After oil containing no bubbles flows out, reset the automatic warm-up operation
tighten air bleeder (1). with the fuel control dial (Set the starting
3 Air bleeder: switch in the ON position and hold the fuel
7.8 – 9.8 Nm{0.8 – 1.0 kgm} control dial in the MAX position for 3 sec-
onds, and the automatic warm-up opera-
tion is reset).
3. Bleeding air from cylinder

a If a cylinder was replaced, bleed air from it
before connecting the work equipment. In
particular, the boom cylinder does not
move to the lowering stroke end, if it is
installed to the work equipment.
1) Run the engine at low idle for about 5 min-
utes.
2) Running the engine at low idle, raise and
lower the boom 4 – 5 times.
a Stop the piston rod about 100 mm
be f or e e a c h s t r ok e e nd . D o n o t
relieve the oil.
28 PC228US, 228USLC-3E0
3) Running the engine at high idle, perform 2) Check the oil level by sight gauge (3) of
step 2). the hydraulic tank.
4) Running the engine at low idle, move the a If the oil leakage is between lines H
piston rod to the stroke end and relieve and L, it is normal.
the oil. a If the oil level is below line L, add new
5) Bleed air from the arm cylinder and bucket oil.
cylinder according to steps 2) – 4).
4. Bleeding air from swing motor

1) Run the engine at low idle.
2) Swing to the right and left slowly to bleed
air.
5. Bleeding air from travel motor

1) Run the engine at low idle.
2) Loosen air bleeder (2) and check that oil
oozes out from it.
3) After oil containing no bubbles flows out,
tighten air bleeder (2).
3 Air bleeder:
27.5 – 35.3 Nm {2.8 – 3.6 kgm}
6. Checking oil level and starting work

1) Run the engine, retract the arm cylinder
and bucket cylinder to the stroke ends,
lower the work equipment to the ground,
and stop the engine.
PC228US, 228USLC-3E0 29
Procedure for replacing boom Installation

angle potentiometer 1 1. Carry out installation in the reverse order to
removal.
a Replace the boom angle potentiometer accord- 2. Set the machine monitor in the service mode
ing to the following procedure. and perform initial setting for the boom angle
a If the boom angle potentiometer is replaced, potentiometer.
the initial set values recorded in the pump con- a For the procedure for adjustment, “see
troller are changed. Accordingly, be sure to Sp e c i al f u n c t i o ns of monitor panel”
perform the initial setting operation after install- (Adjustment in service mode [07]).
ing the new boom angle potentiometer.
Removal
1. Remove the potentiometer cover.
2. Disconnect A53 connector (1).
3. Disconnect lever (2) from the boom and fix it to

plate (3).
a Fix the lever to the plate so that it will not
move unexpectedly.
4. Remove plate (3) and potentiometer together.
5. Remove lever (2), then remove potentiometer

assembly (4) from plate (3).
a Do not swing the potentiometer assembly
around the lever or turn the lever unnec-
essarily.
30 PC228US, 228USLC-3E0
Inspection procedures for diode 1
a Check an assembled-type diode (8 pins) and

single diode (2 pins) in the following manner.
a The continuity direction of an assembled-type
diode is as shown in the diagram below.
a The continuity direction of a single diode is
shown on the diode surface.
2. When using analog type circuit tester

1) Switch the testing mode to resistance
range.
2) Check the needle swing in case of the fol-
lowing connections.
1] Put the red probe (+) of the test lead
to the anode (P) and the black probe
(–) to the cathode (N) of diode.
2] Put the red probe (+) of the test lead
to the cathode (N) and the black
probe (–) to the anode (P) of diode.
3) Determine if a specific diode is good or no
good by the way the needle swings.
q If the needle swings in Case 1], but
does not swing in Case 2]: Normal
(but the breadth of swing (i.e. resis-
tance value) will differ depending on a
circuit tester type or a selected mea-
surement range)
q If the needle swings in either case of
1] and 2]: Defective (short-circuited
internally)
q If the needle does not swing in any
1. When using digital type circuit tester case of 1] and 2]: Defective (short-cir-
1) Switch the testing mode to diode range cuited internally)
and confirm the indicated value.
a Voltage of the battery inside is dis-
played with conventional circuit
testers.
2) Put the red probe (+) of the test lead to the
anode (P) and the black probe (–) to the
cathode (N) of diode, and confirm the dis-
played value.
3) Determine if a specific diode is good or no
good with the indicated value.
q No change in the indicated value: No
continuity (defective).
q Change in the indicated value: Conti-
nuity established (normal) (Note)
Note: A silicon diode shows a value
between 400 and 600.
PC228US, 228USLC-3E0 31
Adjusting mirrors 1
1. Mirrors installed positions
3. Adjusting mirror (b)

Adjust mirror (b) so that the operator can see a
person who is at the rear end of the machine.
a For installation of the mirror, see the
dimensions in the figure and the projection
drawing in the mirror.
a If the mirror is hard to adjust, loosen bolt
(3).
q Dimension (M): 30 mm
2. Adjusting mirror (a)

Adjust mirror (a) so that the operator can see a
person who is at the left rear end of the
machine.
a For installation of the mirror, see the
dimensions in the figure and the projection
drawing in the mirror.
(1).
a Fix the mirror stay (2) with the mirror pro-
jected out most.
q Dimension (L): 30 mm
32 PC228US, 228USLC-3E0
4. Adjusting mirror (c/d)

Adjust mirror (c/d) so that the operator can see
a person who is on the ground 1m around the
machine (hatched part) from the operator's
seat.
(4).
q Dimension (W): 1,000 mm
PC228US, 228USLC-3E0 33
SEN01880-04

© 2010 KOMATSU
All Rights Reserved
34
SEN01881-03
PC228US-3E0
PC228USLC-3E0


Special functions of machine monitor ............................................................................................................. 2
Handling voltage circuit of engine controller ................................................................................................. 30
Starting KOMTRAX terminal operations ....................................................................................................... 31
Indicator lamps of KOMTRAX terminal ......................................................................................................... 35
Preparation work for troubleshooting of electrical system ............................................................................ 38
Pm-clinic service ........................................................................................................................................... 40
Special functions of machine monitor 1
[1]: Figure input switch 1 [/]: Return switch

[2]: Figure input switch 2 [E]: Upward move switch
[3]: Figure input switch 3 [R]: Downward move switch
[4]: Figure input switch 4 [3]: Input confirmation switch
[5]: Figure input switch 5
Ordinary functions and special functions of machine monitor
The machine monitor has the ordinary function and special functions and displays information of various
types on the multi-display.
Some items are displayed automatically and others are displayed through the switch operations according to
the internal setting of the machine monitor.
q Ordinary functions: Operator menu
The functions in this mode are displayed ordinarily. Display and setting of these functions are available
from the operator's switch operations.
q Special functions: Service menu
The functions in this mode are not ordinarily displayed. Display and setting of these functions are avail-
able from the serviceman's operations of the special switches.
This mode is used for special setting, testing, adjusting or troubleshooting.
Operator menu Service menu
1 Password input and setting function 16 Function of monitoring [01]
2 KOMATSU logo display screen Function of abnor- Electrical systems
17
3 Check before starting function mality record [02] Mechanical systems
4 Maintenance display function 18 Function of maintenance record [03]
5 Caution items display function 19 Function of maintenance mode change [04]
Check of working mode and travel speed func-
6 20 Function of phone number entry [05]
tion
7 Ordinary screen display function Mode with key ON
Display's brightness and contrast adjustment
8 Language
function Function of default
21
E-mode adjustment and pump flow rate adjust- [06] Unit
9 ment function when breaker or attachment is
used With/Without attachment
10 Check of maintenance information function Pump absorption torque

Function of adjust-
22 Adjustment of flow to attach-
11 Service meter display function ment [07]
ment in compound operation
12 Check of display LCD function 23 Function of cylinder cut-out operation [08]
13 Caution generation display function 24 Function of no injection cranking [09]
14 Action code display function
15 Failure code display function
Operation of operator menu and display (outline)
a This section introduces only the outline of the 3. Check before starting function
operator menu. For details on the contents and Check before starting screen is displayed for 2
operation steps of each menu, refer to the seconds succeeding to display of KOMATSU
“Operation and maintenance manual” or the logo.
chapter of “Structure, function and mainte-
nance standard” in this shop manual.
1. Password input and setting function

Displays the password input screen as the
starting switch is turned ON.
a Above display is available only when the
password function is selected.
4. Maintenance display function

Succeeding to display of the check before
starting screen, a maintenance mark appears
for 30 seconds pointing the oil or filter whose
specified maintenance time has already
expired or is going to expire soon.
a Below display is available only when the
maintenance function is selected.
2. KOMATSU logo display screen
KOMATSU logo is displayed for 2 seconds as
a password is entered (as a password is speci-
fied) or the starting switch is turned ON.
5. Caution items display function

Succeeding display of the check before start-
ing scre en, an ap plica ble caution m ark
appears pointing a check before starting item
on which a problem was found.
8. Display's brightness and contrast adjusting

function
The screen adjustment switches allow adjust-
ing the display brightness and contrast.
6. Check of working mode and travel speed

function
Succeeding to display of the check before
starting screen, symbol marks of the working
mode and travel speed appear sizably on the
screen to alert the operator attention to the set-
ting.
9. E-mode adjustment, flow rate adjustment

function when breaker or attachment is
used (for a machine equipped with breaker
and attachment)
The select switch allows adjusting E-mode and
also adjusting the pump flow rate when the
breaker or attachment is used.
a There are some differences between the
7. Ordinary screen display function symbol mark of the breaker and attach-
The ordinary display is turned on succeeding ment displayed on the screen as well as in
to display of the check of working mode and the messages displayed.
travel speed screen.
a If the currently set working mode or travel

speed is changed or if setting of the auto-
deceleration or wiper is enabled from the
ordinary screen, an applicable symbol
mark is displayed large for 2 seconds.
a The engine pre-heating monitor is dis-
played only when the pre-heating opera-
tion is turned on.
10. Check of maintenance information function 12. Check of display LCD function
The maintenance switch allows checking Display of the display LCD can be checked by
detailed information of the maintenance items operating the following switches from the pass-
(specified maintenance time and elapsed word input screen or ordinary screen.
time). It also allows resetting after the mainte- q Switch operation: [/] + [P]
nance. (Simultaneous operation)
a Setting and resetting of the maintenance a The entire LCD should come on, turning
function as well as setting of the mainte- the screen to white. The display is, there-
nance time is done from the service menu. fore, acceptable if it is free from any black
spot.
a Operating any switch from the checkup
display restores the immediately preced-
ing screen.
11. Service meter display function

Display of the service meter alone becomes
available by operating the following switches
after the starting switch is turned OFF.
q Switch operation: [/] + [E] 13. Caution generation display function
(Simultaneous operation) If a caution is warned for a caution item, appli-
cable symbol mark is displayed large for 2 sec-
onds and then it remains on the screen in a
smaller size until the trouble is eliminated.
14. Action code display function

If a trouble occurs on the machine, an applica-
ble action code is automatically displayed
depending on the seriousness of the trouble in
order to alert the operator to take an appropri-
ate action.
a Operating any switch while an action code
is on the screen, switches the failure code
display screen (see Item 15).
a Action codes and actions requested to operator

Action code Failure mode Action
When emergency pump drive switch is at the up (emergency)
E02 Pump control system error position, normal operations become possible, but have
inspection carried out immediately.
E03 Swing brake system error Have inspection carried out immediately.
Engine controller power source error
Engine controller drive system circuit
E10 Have inspection carried out immediately.
error
(engine stopped)
Engine controller system error Operate machine to a safe posture and have inspection car-
E11
(Output reduced to protect engine) ried out immediately.
Operate machine to a safe posture and have inspection car-
E14 Throttle system error
ried out immediately.
Engine sensor (coolant temperature, fuel
Operations are possible, but have inspection carried out
E15 temperature and oil pressure) system
immediately.
error
Operate machine to a safe posture and have inspection car-
E0E Network error
ried out immediately.
15. Failure code display function a The telephone mark and telephone num-
Operating any switch while an action code is ber are displayed only when the telephone
on the screen, sequentially displays the phone number is registered to the machine moni-
mark (if registered), phone number (if regis- tor.
tered) and failure code. Registration, correction or deletion of a
q Switching operation: (3) (keep the switch telephone number is done from the ser-
depressed) vice menu.
a The screen display sequentially changes a For detailed information of failure codes,
as shown below as long as the switch is see the "Failure codes table".
being depressed.
(1) Telephone symbol mark
(2) Telephone number
(3) Failure code
Failure codes table

Action Device in Category
Failure code Trouble (Displayed on screen)
code charge of record
Mechani-
— AA10NX Air cleaner Clogging MON cal sys-
tem
Mechani-
— AB00KE Charge Voltage Low MON cal sys-
tem
Mechani-
— B@BAZG Eng Oil Press Low ENG cal sys-
tem
Mechani-
— B@BAZK Eng Oil Level Low MON cal sys-
tem
Mechani-
— B@BCNS Eng Water Overheat ENG cal sys-
tem
Mechani-
— B@BCZK Eng Water Level Low MON cal sys-
tem
Mechani-
— B@HANS Hyd Oil Overheat MON cal sys-
tem
Electrical
E10 CA111 EMC Critical Internal Failure ENG
system
Electrical
E10 CA115 Eng Ne and Bkup Speed Sens Error ENG
system
Electrical
E11 CA122 Chg Air Press Sensor High Error ENG
system
Electrical
E11 CA123 Chg Air Press Sensor Low Error ENG
system
Electrical
E14 CA131 Throttle Sensor High Error ENG
system
Electrical
E14 CA132 Throttle Sensor Low Error ENG
system
Electrical
E15 CA144 Coolant Temp Sens High Error ENG
system
Electrical
E15 CA145 Coolant Temp Sens Low Error ENG
system
Electrical
E15 CA153 Chg Air Temp Sensor High Error ENG
system
Electrical
E15 CA154 Chg Air Temp Sensor Low Error ENG
system
Electrical
E11 CA155 Chg Air Temp High Speed Derate ENG
system
Electrical
E15 CA187 Sens Supply 2 Volt Low Error ENG
system
Electrical
E11 CA221 Ambient Press Sens High Error ENG
system
Electrical
E11 CA222 Ambient Press Sens Low Error ENG
system
Electrical
E15 CA227 Sens Supply 2 Volt High Error ENG
system

Mechani-
— CA234 Eng Overspeed ENG cal sys-
tem
Electrical
E15 CA238 Ne Speed Sens Supply Volt Error ENG
system
Electrical
E10 CA271 IMV/PCV1 Short Error ENG
system
Electrical
E10 CA272 IMV/PCV1 Open Error ENG
system
Electrical
E11 CA322 Inj #1 (L#1) Open/Short Error ENG
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
E10 CA342 Calibration Code Incompatibility ENG
system
Electrical
E10 CA351 Injectors Drive Circuit Error ENG
system
Electrical
E15 CA352 Sens Supply 1 Volt Low Error ENG
system
Electrical
E15 CA386 Sens Supply 1 Volt High Error ENG
system
Electrical
E15 CA428 Water in Fuel Sensor High Error ENG
system
Electrical
E15 CA429 Water in Fuel Sensor Low Error ENG
system
Electrical
E15 CA435 Eng Oil Press Sw Error ENG
system
Electrical
E10 CA441 Battery Voltage Low Error ENG
system
Electrical
E10 CA442 Battery Voltage High Error ENG
system
Electrical
E11 CA449 Rail Press Very High Error ENG
system
Electrical
E11 CA451 Rail Press Sensor High Error ENG
system
Electrical
E11 CA452 Rail Press Sensor Low Error ENG
system
Electrical
E11 CA488 Chg Air Temp High Torque Derate ENG
system
Electrical
E15 CA553 Rail Press High Error ENG
system
Electrical
E15 CA559 Rail Press Low Error ENG
system
10 PC228US, 228USLC-3E0

Electrical
E15 CA689 Eng Ne Speed Sensor Error ENG
system
Electrical
E15 CA731 Eng Bkup Speed Sens Phase Error ENG
system
Electrical
E10 CA757 All Continuous Data Lost Error ENG
system
Electrical
E11 CA778 Eng Bkup Speed Sensor Error ENG
system
Electrical
E0E CA1633 KOMNET Datalink Timeout Error ENG
system
Electrical
E14 CA2185 Throt Sens Sup Volt High Error ENG
system
Electrical
E14 CA2186 Throt Sens Sup Volt Low Error ENG
system
Electrical
E11 CA2249 Rail Press Very Low Error ENG
system
Electrical
E11 CA2311 IMV Solenoid Error ENG
system
Electrical
E15 CA2555 Grid Htr Relay Volt High Error ENG
system
Electrical
E15 CA2556 Grid Htr Relay Volt Low Error ENG
system
Electrical
— D110KB Battery Relay Drive Short Circuit PUMP
system
Electrical
— D196KA Service Return Relay Disc. PUMP
system
Electrical
— D196KB Service Return Relay S/C PUMP
system
Electrical
E0E DA22KK Pump Solenoid Power Low Error PUMP
system
Electrical
— DA25KP 5V Sensor 1 Power Abnormality PUMP
system
Electrical
E0E DA2RMC CAN Discon (Pump Con Detected) PUMP
system
Electrical
— DA2SKQ Model Selection Abnormality PUMP
system
Electrical
E0E DAFRMC CAN Discon (Monitor Detected) MON
system
Electrical
— DGH2KB Hyd Oil Sensor Short PUMP
system
Electrical
— DHPAMA F Pump Press Sensor Abnormality PUMP
system
Electrical
— DHPBMA R Pump Press Sensor Abnormality PUMP
system
Electrical
— DHSAMA Swing RH PPC Press Sensor Abnormality PUMP
system
Electrical
— DHSBMA Swing LH PPC Press Sensor Abnormality PUMP
system
Electrical
— DW43KA Travel Speed Sol Open Circuit PUMP
system
Electrical
— DW43KB Travel Speed Sol Short Circuit PUMP
system
PC228US, 228USLC-3E0 11

Electrical
E03 DW45KA Swing Brake Sol Open Circuit PUMP
system
Electrical
E03 DW45KB Swing Brake Sol Short Circuit PUMP
system
Electrical
— DW91KA Travel Junction Sol Open Circuit PUMP
system
Electrical
— DW91KB Travel Junction Sol Short Circuit PUMP
system
Electrical
E06 DW4GKA Boom Slow Down Sol. Disc. PUMP
system
Electrical
E06 DW4GKB Boom Slow Down Sol. S/C PUMP
system
Electrical
— DWJ0KA Merge-divider Sol Open Circuit PUMP
system
Electrical
— DWJ0KB Merge-divider Sol Short Circuit PUMP
system
Electrical
— DWK0KA 2-stage Relief Sol Open Circuit PUMP
system
Electrical
— DWK0KB 2-stage Relief Sol Short Circuit PUMP
system
Electrical
E02 DXA0KA PC-EPC Sol Open Circuit PUMP
system
Electrical
E02 DXA0KB PC-EPC Sol Short Circuit PUMP
system
Electrical
— DXE0KA LS-EPC Sol Open Circuit PUMP
system
Electrical
— DXE0KB LS-EPC Sol Short Circuit PUMP
system
Electrical
— DXE4KA Service Current EPC Open Circuit PUMP
system
Electrical
— DXE4KB Service Current EPC Short Circuit PUMP
system
Electrical
— DY20KA Wiper Working Abnormality MON
system
Electrical
— DY20MA Wiper Parking Abnormality MON
system
Electrical
— DY2CKB Washer Drive Short Circuit MON
system
Electrical
— DY2DKB Wiper Drive (Fwd) Short Circuit MON
system
Electrical
— DY2EKB Wiper Drive (Rev) Short Circuit MON
system
a This table lists the failed sections in the order of the failure code.
a Those failure codes to which the corresponding number is not indicated in the action code space are not displayed
on the ordinary screen if a failure is found. They are just recorded in the failure record (electrical system and mechan-
ical system) of the service menu.
a The category of record is used for indicating to which of the electrical and mechanical system of the service menu’s
abnormality record a given failure is classified.
a E at beginning of the action code indicates the following state.
q With E: The failure still remains without being resolved.
q Without E: The failure is already resolved.
12 PC228US, 228USLC-3E0
Service menu operation and display

3) Displaying menu screen
Switching to Service Menu The display is changed to the initial display of
a When using the service menu, switch the Service Menu program. Select an appropriate
screen through the following special operation. item from among the menu.
1) Confirmation of display
Make sure that the conventional display is
turned on.
a Changing to Service Menu is usually avail-
able only from this conventional display.
No. Service menu

00 Return (Ends the service menu)
01 Monitoring
02 Abnormality record
03 Maintenance record
2) Switch operation 04 Maintenance mode change
Do the following switch operation.
05 Phone number entry
q Switch operation:
[E] + [1] o [2] o [3] 06 AAAA/ Default
(Enter the numbers while holding E down) 07 Adjustment
08 Cylinder cut out
09 No injection cranking
10 (Unused)
4) Ending the menu and function

When ending the operation from the service
menu screen or respective menu screens,
select either of the following operations.
q Press [/] switch (enables every screen).
q When “RETURN” switch is displayed,
press the applicable switch.
q When “Return” menu is displayed, select
the menu and press [3] switch.
PC228US, 228USLC-3E0 13
16. Monitoring [01] function a In case of monitoring 1 to 3 items,

The machine monitor monitors signals from the move to the monitoring information
switch sensor actuators on various machine screen through any of the following
parts. It allows displaying and checking the switch operations after the registra-
monitored information through following operation work has been completed.
tions. q [Hold down [3] switch (for about
3 seconds).
1) Menu selection q Select menu “99999” and press
Select “01 Monitoring” in the initial display [3] switch.
of Service Menu and depress [3] switch. a When you have registered all the
items that can be registered, the
screen will be automatically switched
to the monitoring information screen.
a Monitored information are transmitted
via communication circuits. Thus the
number of selected items can impact
the communication speed. If truly real
time monitoring is required, reduce
the selected items to the minimum.
a For details on the monitoring items,
display unit, etc., refer to the “List of
Monitoring Items”.
3) Operation for monitoring

2) Setting a monitoring item As the monitoring information screen is
1] Select and register an item to be displayed, confirm the monitored informa-
monitored through the following tion operating the machine.
switch operation.
q [E] switch: Selection
q [R] switch: Selection
q [3] switch: Registration
2] Selection with numeral input switches:
If a 5-digit code is input, the item cor-
responding to it is selected directly,
and you can confirm it by depressing
[3].
a A monitoring item can be set from 1 to

4 at maximum (Depending upon the
selected item, the max. number can
be less than four).
14 PC228US, 228USLC-3E0
4) Monitored information holding function

You can hold every monitored information
by pressing [E] while monitoring is contin-
ued.
If you press [R] switch again in this condi-
tion, the currently held information will be
released.
5) Machine setup mode switching function

If it becomes necessary to change set-
tings of working mode, select mode, travel
speed and auto-decel while monitoring,
depress the corresponding switch, then
the mode confirmation display is shown.
a Above figure shows the screen dis-

play in P-and E-mode (in B-mode,
part of the symbol mark shape is dif-
ferent from above).
a After confirming the setting, press [3]
switch to return to the monitoring
screen.
a If the setting was changed during
monitoring, the new setting is held
even after the operator menu is
restored from the service menu after
the monitoring is finished.
PC228US, 228USLC-3E0 15
List of Monitoring Items

Code Unit (Default: ISO)
Monitoring item Remarks
No. ISO meter inch
00000 Return (Not display) End menu
Display execution
99999 Display execution (Not display)
menu
00200 Controller Model Select Numbers
00201 Machine ID Numbers
01002 Engine Speed r/min rpm rpm
01601 2nd Eng. Speed Command
01100 F Pump Pressure MPa kg/cm2 psi
2
01101 R Pump Pressure MPa kg/cm psi
2
09001 Swing left PPC Pressure MPa kg/cm psi
09002 Swing right PPC Pressure MPa kg/cm2 psi
04107 Coolant Temperature °C °C °F
04401 Hydr. Oil Temperature °C °C °F
01300 PC-EPC Sol. Curr. mA mA mA
01500 LS-EPC Sol. Curr. mA mA mA
01700 Service Sol. Curr. mA mA mA
01800 Boom RAISE throttle EPC current mA mA mA
03200 Battery Voltage V V V
03203 Battery Power Supply V V V
04300 Battery Charge Vol. V V V
01006 Engine Seed r/min rpm rpm
2
36400 Rail Pressure MPa kg/cm psi
37400 Ambient Pressure kPa kg/cm2 psi
18500 Charge Temperature °C °C °F
2
36500 Boost Pressure kPa kg/cm psi
36700 Engine Torque Ratio % % %
18700 Engine Output Torque Nm kgm lbft
03000 Fuel Dial Pos Sens Volt V V V
04200 Fuel Level Sensor Vol. V V V
04105 Eng. Water Temp. Vol. Lo V V V
04402 Hydr. Temp. Sensor Vol. V V V
37401 Ambient Press Sens Volt V V V
18501 Charge Temp Sens Volt V V V
36501 Charge Press Sens Volt V V V
36401 Rail Pressure Sens Volt V V V
17500 Engine Power Mode — — —
31701 Throttle Position % % %
31706 Final Throttle Position % % %
18600 Inject Fueling Command mm3/st mm3/st mm3/st
36200 Rail Press Command MPa kg/cm2 psi
36300 Injection Timing Command CA CA CA
37300 Fuel Rate L/h L/h L/h
01602 2nd Eng. Speed Command % % %
13113 Main Pump Absorb Torque Nm kgm lbft
16 PC228US, 228USLC-3E0

No. ISO meter inch
Swing ON/OFF
Travel ON/OFF
Boom Lower ON/OFF
01900 Pressure Switch 1
Boom Raise ON/OFF
Arm In ON/OFF
Arm Out ON/OFF
Bucket Curl ON/OFF
Bucket Dump ON/OFF
01901 Pressure Switch 2
Service ON/OFF
Travel Steering ON/OFF
Travel Junction ON/OFF
Swing Brake ON/OFF
02300 Solenoid Valve 1 Merge-divider ON/OFF
2-Stage Relief ON/OFF
Travel Speed ON/OFF
02301 Solenoid Valve 2 Service Return ON/OFF
Lever Sw. ON/OFF
02200 Switch Input 1 Swing Release Sw. ON/OFF
Swing Brake SW. ON/OFF
Model Select 1 ON/OFF
02201 Switch Input 2
Low Viscosity Fuel Mode ON/OFF
02202 Switch Input 3 Key Switch (ACC) ON/OFF
03700 Controller Output 1 Battery Relay Output ON/OFF
Key Switch ON/OFF
Start ON/OFF
04500 Monitor Input 1 Preheat ON/OFF
Light ON/OFF
Rad. Level ON/OFF
Air cleaner ON/OFF
Eng. Oil Level ON/OFF
04501 Monitor Input 2
Spare Open (Full-tank sensor) ON/OFF
Battery Charge ON/OFF
Swing Brake Sw. ON/OFF
Bzzr Cancel Sw. ON/OFF
04502 Monitor Input 3 Window Limit Sw. ON/OFF
W Limit Sw. ON/OFF
P Limit Sw. ON/OFF
18800 Water In Fuel — — —
20216 ECM Build Version — — —
20217 ECM CAL Data Ver — — —
PC228US, 228USLC-3E0 17

No. ISO meter inch
18900 ECM Internal Temp °C °C °F
20400 ECM Serial No — — —
20227 Monitor Ass’y P/N — — —
20402 Monitor Serial No — — —
20200 Monitor Prog. Version — — —
20229 Pump Con. Ass’y P/N — — —
20403 Pump Con. Serial No — — —
20230 Pump Con. Prog. P/N — — —
20212 Pump Con. Prog. Version — — —
18 PC228US, 228USLC-3E0
17. Function of abnormality record [02] 3) Contents of display of electrical system

abnormality record information screen
The monitor panel records and classifies the (1): Occurrence order of abnormalities
past failure information as into the electrical f r o m l a t e s t o n e / To ta l n u m b e r o f
and mechanical failures. It allows displaying records
and checking the information through the fol- (2): Failure code (Equipment: 4 digits,
lowing operations. Phenomena: 2 digits)
1) Menu selection (3): Elapsed time on service meter from
Select “02 Abnormality Record” in the ini- the first occurrence
tial display of Service Menu and depress (4): Contents of trouble
[3] switch. a See the operator menu “Failure
codes table”.
2) Sub menu selection

Select the sub menu from the abnormality 4) Contents of display of mechanical system
record menu screen and then press [3] abnormality record information screen
switch. (1): Record number
(2): Contents of trouble
(3): Failure code (Equipment: 4 digits,
Phenomena: 2 digits)
(4): Total number of occurrences
(5): Service meter reading at first occur-
rence
a See the operator menu “Failure
codes table”.
Num
Sub menu of abnormality record
ber
00 Return (End of abnormality record)
01 Electrical systems
02 Mechanical systems
PC228US, 228USLC-3E0 19
5) Resetting electrical systems abnormality

record
a Resetting abnormality record (dele-
tion) is possible only with the electri-
cal system. The abnormality record in
the mechanical system cannot be
reset.
a When resetting individual or all infor-
mation in the abnormality record of
the electrical systems, implement the
18. Function of maintenance record [03]

The machine monitor records the maintenance
information of the filters, oils, etc., which the
operator can display and check by the follow-
ing operations.
1) Menu selection
Select “03 Maintenance Record” from the
initial display of Service Menu and then
depress [3] switch.
1] Following switch operation from the

electrical system abnormality record
screen opens the reset screen.
q Switch operation:
[E] + [1] o [2] o [3]
a Above is the same as that done when
switching to the service menu.
2) Information to be displayed
q Oil and filter names
q Replacement time elapsed up to
present
q Time elapsed on service meter up to
the last replacement
2] From the reset screen, do the switch

operation according to the screen
instructions.
a When a specific individual infor-
mation alone is to be reset, be
sure to display the subject infor-
mation on the screen using [E]
switch or [R] switch.
a When resetting all information,
the information to be displayed
on the screen can be any.
20 PC228US, 228USLC-3E0
19. Function of maintenance mode change [04]

Num
Following procedure allows changing the cur- Items of the maintenance mode change
ber
rently set operating conditions of the mainte-
nance display function. Return (End of change in the maintenance
00
mode)
q Set function effective or ineffective
q Change set replacement interval 01 Maintenance mode on/off
02 Engine oil change int.
1) Menu selection 03 Engine oil filter change int.
Select “04 Maintenance Mode Change”
04 Fuel main filter change int.
from the “Service Menu” and then depress
[3] switch. 41 Fuel pre filter change int.
06 Hyd oil filter change int.
07 Hyd tank breather change int.
08 Corrosion resistor change int.
09 Damper case service int.
10 Final drive case oil change int.
11 Machinery case oil change int.
12 Hydraulic oil change int.
13 Initialize all items
a 01 and 13 menus are provided for

setting the whole maintenance mode,
while those from 02 through 12 are
2) Selection of item to be changed for setting individual items.
Select the item to be changed from the
“Maintenance Mode Change Selection 3) Contents of “Maintenance Mode On/Off”
Menu” screen. q Use (On): The maintenance display
function of all oil and filter-related
items are turned effectual. (Irrespec-
tive of whether “On” or “Off” set for
individual items, this setting prevails)
q Not use (Off): The maintenance dis-
play function of all oils and filter-
related items is disabled (prece-
dence is given to this setting over the
“On” or “Off” selected for an individual
items).
PC228US, 228USLC-3E0 21
4) Description of individual setting items

(1): Default value: The maintenance time
set in the monitor (recommended by
the m anufa cturer a nd cann ot be
changed).
(2): Set value: Denotes the maintenance
time that can be freely set. The main-
tenance mode operates based on this
time (the time can be increased or
decreased in multiple of 50 hours by
use of [E] and [R] switches).
(3): Use (On): Maintenance display func-
tion for this item is enabled.
(4): Not use (Off): Maintenance display
function for this item is disabled. 2) Changing the display
a The lower limit of this setting is 50 Select “Entry” next to change the display
hours. to the “Phone Number Entry” display.
a Even if a Phone number is already
inputted, it is deleted if you switch the
“Phone Number Entry” screen.
5) Description of “Initialize all items”

Select this menu and then press [3]
switch to restore the default value for the
individually set information. 3) Entry and setting phone number
Following the method explained below,
20. Function of phone number entry [05] entry a phone number in the “Phone Num-
When the action code is displayed, following ber Entry” display. (Entry automatically
procedure allows entering or correcting the begins with a cursor at the left end)
phone numbers to be displayed alternately
with the failure code.
a If a telephone number is not input, the
phone number screen is not displayed.
1) Menu selection
Select “05 Phone Number Entry” menu
from the Service Menu initial screen and
then depress [3] switch.
22 PC228US, 228USLC-3E0
1] Using the numerical keypad, enter

the number starting with the cursor
position situated at the left end.
a Numbers can be entered up to
the max. 12 digits, bu t om it
unnecessary digits.
a When entered a wrong number,
depress [B] switch to return the
cursor by one digit.
2] Depress [3] switch when all the num-
bers have been entered.
a Upon completing entry, the
screen changes to the telephone
No. entry screen. If the telephone
n um ber is displaye d on th is
screen the entry is normal. Num
Sub menu of default value
ber
21. Function of default [06] 00 Return (End of default)
Following machine monitor- or machine- 01 Key-on mode
related settings are modifiable. Do necessary
02 Language
modifications as needed.
q Working mode as starting switch is turned 03 Unit
ON 04 With/without service cir.
q Language used in the service menu
q Unit to be displayed in relation to the mon- 3) Mode to be selected as key is turned ON
itoring function Following operation allows specifying the
q With/Without attachment working mode to be displayed on the
machine monitor as the starting key is
1) Menu selection turned ON.
Select “06 Default” menu from the Service
Menu initial screen and then press [3]
switch.
q P-mode, E-mode, L-mode and B-

mode: If any of above modes is spec-
ified, that mode will be constantly
2) Selecting sub menu turned ON as the starting switch is
Select the target sub menu of setting pressed.
change and then press [3] switch. q The mode that had been selected as
the starting key was turned off in the
last operation: This setting turns ON
the last used mode as the starting
switch is pressed.
q Default: This setting turns ON the
delivered default mode (P-mode) as
the starting switch is pressed.
PC228US, 228USLC-3E0 23
a If the engine is stopped from B-mode 6) Function for selecting distinction of “With/
on a machine equipped with the Without Service Cir”.
attachment, this mode will be invari- It is possible in this function to set a dis-
ably selected as the starting switch is tinction between with or without attach-
turned ON the next time independent ment.
of above setting. q With Service Circuit: When an attach-
ment is installed.
4) Language setting function q Without Service Circuit: When no
Service Menu allows switching the lan- attachment is installed.
guage between Japanese and English.
a When the attachment is installed, you

a The default language of the machine must select “With Service Circuit”
monitor is English. from this screen. Otherwise, the
a When using the machine monitor, selection function (the function for
which is a spare part, in the Japa- sharing the attachment) won't be
nese-speaking sphere, switch this available from the operator mode.
function from English to Japanese.
5) Unit selection function

You can select one from the three units to
be used in the monitoring function display
of Service Menu.
a SI unit system is the default setting of
the machine monitor.
24 PC228US, 228USLC-3E0
22. Function of adjustment [07] 3) Function for Pump Absorption Torque

Adjustment
The operator can adjust various items related The pump absorption torque can be
to the machine with the machine monitor. adjusted within the range shown in the
1) Menu selection table below.
Select “07 Adjustment” menu from the
Service Menu initial screen and then
depress [3] switch.
Adjustment value Torque adjustment value

220 +4.0 kgm
221 +3.0 kgm
2) Sub menu selection
222 +2.0 kgm
Select the sub menu on which setting
223 +1.0 kgm
change is to be done and then press [3]
switch. 224 0.0 kgm
225 –1.0 kgm
226 –2.0 kgm
227 –3.0 kgm
228 –4.0 kgm
4) Function for Adjustment of Flow for Attach-

ment in Compound Operation
The distribution of oil flow for attachments
in compound operation can be adjusted
within the range shown in the table below.
Num
Adjustment of sub menu
ber
00 Return (Ends the adjustment)
01 Pump absorption torque
02 Service current adjustment
03 Boom angle compensation
Distribution of oil flow

Adjustment value
to attachment
370 0.5 Time
371 0.7 Time
372 1.0 Time
373 0.4 Time
PC228US, 228USLC-3E0 25
5) Boom potentiometer initialization function 3] Depress switch [1] to save the boom
a When the boom potentiometer or angle potentiometer adjustment
boom is removed and installed or value.
when the boom stroke end electronic a The angle displayed on the
cushion function does not operate machine monitor is updated to
normally, initialize the boom potenti- the adjustment value.
ometer according to the following pro- a If setting is completed, the
cedure. buzzer sounds for 0.5 seconds.
1] Display the boom potentiometer ini- a When setting again, depress
tialization screen. switch [2] to clear the adjustment
a "---" blinks at the center of the value and then repeat from step 1].
screen (at intervals of 1 second). a If the installed angle of the poten-
tiometer is 10° or more off the
standard value in the controller,
the buzzer sounds for 2 seconds
and the adjustment value is not
saved. In this case, adjust the
installation of the potentiometer
and then repeat from step 1].
4] Hold down the [SET] switch for 3 sec-
onds and check the screen.
a Lighting of "000": Initialization
was completed normally and the
current state is held for about 5
seconds.
a Blinking of "---": Initialization was
2] Start the engine, raise the boom to not completed normally and the
the stroke end, and check the screen. current state is held for about 5
seconds.
5] After 5 seconds, the screen changes.
Then, carry out the following opera-
tion.
a Blinking of "0--": This is displayed
after 5 seconds, regardless of
the initialization result.
a If normal finish of initialization was
indicated in 3], finish initialization
(The initial set value was saved in
the memory of the controller).
a If abnormal finish of initialization
was indicated in 3], repeat the
procedure from the first (The
data in the memory of the con-
troller was cleared to zero).
26 PC228US, 228USLC-3E0
23. Function of cylinder cut out operation [08]

The operator can perform the engine on cylin-
der cut out operation with the machine monitor.
“Cylinder cut out” operation means to run the
engine with 1 or more fuel injectors disabled
electrically to reduce the number of effective
cylinders. This operation is used to find out a
cylinder which does not output power normally
(combustion in it is abnormal).
1) Selecting menu
Select “08 Cylinder cut out” menu from the
service menu initial screen and press [3]
switch.
3) Resetting cut out cylinder
Press the switch corresponding to the dis-
abled cylinder number from switches [1] to
[6] of the machine monitor to be reset.
a If pressing the switch changes the
cylinder number on the screen to a
black letter enclosed in the black
frame, the cylinder is reset.
2) Selecting cylinder to be disabled

Press a switch corresponding to the cylin-
der No. to be disabled from switches [1] to
[6] of the machine monitor.
a If pressing the switch changes the
cylinder number on the screen to a
white letter enclosed in the white
frame, the cylinder is disabled (when
a wrong number is selected, press
the correct switch again).
a Number of cylinders to be reduced is any.
PC228US, 228USLC-3E0 27
4) Engine speed holding function [Reference]: Using the holding function effectively
Pressing [E] switch while the engine The engine speed being displayed on the screen
operation on cylinder cut out screen is through the holding function remains on it until the
turned on holds the engine speed and its holding is cancelled. In other words, enabling or
speed is newly displayed in the lower disabling of the cylinder cut out mode does not
space. affect the display.
Pressing [ R ] switch during holding can- Thus, when identifying a failed cylinder quicker, fol-
cels the holding function and deletes the lowing operation is effective.
display in the lower space.
a If the holding function is used, the (1) Run the engine from the normal operation
held speed is displayed in the lower mode (no cylinder cut out) and then hold the
space along with ( ) and the upper speed of that time.
space continuously displays the cur- (2) Specify the cylinder to be diagnosed as the cut
rent speed. out.
a The holding function is usable inde- (3) Run the engine under the same condition as
pendent of the currently set mode – that for (1). Then compare the engine speed at
the cylinder cut out or not. that time and the held speed being displayed
to diagnose the cylinder.
(4) Reset a cut out cylinder independent of the
fluctuations in the engine speed.
(5) Repeat above steps (2) to (4) and then com-
pare the results against that obtained from
other cylinders.
a If the diagnosis identified a cylinder on which
there was no decrease in the engine speed or
the decrease was small, it can be safely
judged that there must be some abnormalities
in its fuel.
28 PC228US, 228USLC-3E0
24. Function of no injection cranking [09] 3) As the checkup is over, following screen
No injection cranking of the engine is available appears.
from the machine monitor.
No injection cranking refers to preventing the
injector from injecting fuel until lubricant
reaches respective parts by cranking engine
with the starting motor when restarting the
engine after storage for an extended period of
time.
a This setting must be done after stopping
the engine.
1) Selecting menu
Select “09 No Injection Cranking” from the
service menu initial screen and press [3]
switch.
4) Select “No Injection” and press [3] switch.
“Under Preparation” will be displayed on
the screen.
a The letters “Under Preparation” are
displayed in red.
2) The initial screen for the no injection

cranking will appear.
a “Check Communication” will be dis-
played in red.
5) As the preparation for no injection crank-
ing is completed, display of “Under Prepa-
ration” is replaced with “After No
Injection”.
a The letters “After No Injection” are
displayed in green.
6) From this state, crank the engine using
the starting motor.
k Limit the cranking time to 20 seconds to

protect the starting motor.
PC228US, 228USLC-3E0 29
7) After the no injection cranking is over, Handling voltage circuit of engine

press [3] switch from the previous screen controller 1
and the letters “End” will be displayed for 3
seconds. 1. The starting switch must be turned OFF before
a The letters “End” are displayed in disconnecting or connecting the connector
green. across the engine controller and engine.
8) Press “Return” when ending the no injec-
tion cranking. 2. It is prohibited to start the engine for diagnosis
purpose when a T-adapter is inserted in or
connected to the connector across the engine
controller and engine.
a You may turn the starting switch to the
OFF or ON position but must not turn it to
the START position.
a If the no injection cranking function is

inadvertently selected while the
engine is running, “Engine Running”
will appear as No Injection in step 4)
is selected. This “Engine Running”
display remains on the screen even
after the engine is stopped. Restoring
the service menu screen alone
deletes the display.
30 PC228US, 228USLC-3E0
Starting KOMTRAX terminal 3) When about 3 to 5 seconds elapsed after

operations 1 the starting switch was set to ACC, make
sure that the 7-segment indicator lamp
In the case where the KOMTRAX terminal has changes to hyphen “–” on the KOMTRAX
already been installed at the plant before ship- terminal.
ment:
a Implement the following procedure in the case
where the KOMTRAX terminal has already
been installed at the plant before shipment (as
standard equipment).
1. Notification of model, part number and

serial number
Notify the KOMTRAX operations administrator
of model, part number and serial number.
2. Registration of machine
The KOMTRAX operations administrator shall
use a KOMTRAX client PC to register the
machine.
a Refer to “Manual for KOMTRAX opera-
tions administrator” for the procedure.
a Now the terminal is ready for use.
In the case where the KOMTRAX terminal is ret-

rofitted:
a When retrofitting the KOMTRAX terminal after
shipment (retro-fitted machine), follow the
steps below.
1. Station opening check in machine side

a Complete steps 3) to 5) within 60 sec-
onds. If 60 seconds or above elapsed,
begin with step 1) again.
4) Disconnect check connector 1, and wait
1) Turn OFF the starting switch and then,
for about 3 to 5 seconds as it is.
after making sure 5 seconds have
a Ensure that the connector is discon-
elapsed, proceed to the next step.
nected.
2) Visually check that two check connectors
5) Reconnect check connector 1, and wait
are connected.
for about 3 to 5 seconds as it is.
q Check connector 1:
a If the KOMTRAX terminal detects that
G02 (female) and G03 (male)
the connector was disconnected and
q Check connector 2:
connected, the dot on the 7-segment
G04 (female) and G05 (male)
indicator lamp blinks a few times.
PC228US, 228USLC-3E0 31
6) Make sure that the 7-segment indicator a As [Normal] is indicated, proceed to

lamp is indicated normally on the the next step.
KOMTRAX terminal. a If “–” remains displayed, execute
a If so, the 7-segment indicator lamp will steps 1) to 5) again.
indicate characters “d”, “0”, and “–”
repeatedly for 30 seconds after step 5)
was ended.
a Those characters, even if displayed
normally, will change to a character
other than hyphen “–”after 30 sec-
onds or above elapsed.
The display may change to a charac-
ter other than “0” even within 30 sec-
onds.
7) Turn the starting switch to START position

for about 3 to 5 seconds, and make sure
that the engine does not start.
a If the engine starts, re-execute the
procedure above from step 1).
a Do not return the starting switch to
OFF position.
8) Turn the starting switch from ACC position
to START position again, and make sure
that the engine starts.
9) Make sure that the KOMTRAX terminal's
indicator lamps are normally turned on.
a Move on to the next step if you can
check that the display is [Normal]. (It
takes from 90 seconds to 15 minutes
before the display turns normal.)
a If [GPS position data detection trou-
ble] is indicated, check if there is any
abnormality on the GPS antenna or
cable. If there is any abnormality,
repair it and start from procedure 1)
again.
a If [Reception trouble] is indicated,
check if there is any abnormality on
the appearance of the communication
antenna or cable. If there is any
abnormality, repair it then repeat from
procedure 1) again.
a If [GPS position data detection trouble
and reception trouble] is indicated,
check if there is any abnormality on
the GPS antenna/cable or communi-
cation antenna/cable. If there is any
abnormality, repair it and start from
procedure 1) again.
32 PC228US, 228USLC-3E0
a If [Network trouble] is indicated, 10) Turn the starting switch OFF.

check the display of [LED-C4] refer- 11) Make sure that the 7-segment indicator
ring to “Lamp display of KOMTRAX lamp is displayed normally after 5 seconds
terminal”. If the CAN is not recog- elapsed.
nized, check the CAN harness of the a When [Normal] appears, station
KOMTRAX terminal, and then if there opening check is completed.
is any abnormality, repair it and start a If [Abnormal] appears, station open-
from procedure 1) again. ing check does not end normally, so
[A]: Normal you should perform the procedure
[B]: GPS position data detection trou- above from step 1) again.
ble a If station opening check ends nor-
[C]: Reception trouble mally, it should not be rechecked.
[D]: GPS position data detection trou-
ble and reception trouble
[E]: Network trouble
12) When station opening check ended nor-

m a l l y, a c o m m u n i c a t i o n w i t h t h e
KOMTRAX server starts automatically,
and settings are stored in KOMTRAX.
(This requires about 25 minutes to 4
hours.)
a During this time, you may turn the
starting switch off and start the
engine.
a During the communication and check
above, you should park the machine
outside to enable a frequent commu-
nication with the ORBCOMM satellite.
The station opening check may not
be completed in doors that cause
radio waves from the satellite to be
intercepted.
PC228US, 228USLC-3E0 33
2. Application for the start of use

a Application for the start of use should be
made only after the sign-up test is fin-
ished.
1) Notify the KOMTRAX operations adminis-
trator of the following information about
the machine that completed the station
opening check in the machine side.
1] Information (model, part number, and
serial number) about the machine
that completed the station opening
check in the machine side
2] Part number and serial number of
KOMTRAX terminal
3] Value of service meter when the
KOMTRAX terminal was installed (in
0.1 hours)
2) The KOMTRAX operations administrator

shall use a KOMTRAX client PC to regis-
ter the machine.
a Refer to “Manual for KOMTRAX oper-
ations administrator” for the proce-
dure.
a Now the terminal is ready for use.
34 PC228US, 228USLC-3E0
Indicator lamps of KOMTRAX terminal 1
LED lamps for CPU 7-segment and dot displays for CPU
1. LED-C1 (State of R or ACC signal) 7. 7 segments (Number of unsent mails)
2. LED-C2 (Starting output state) 8. Dot (GPS positioning state)
3. LED-C3 (State of S-NET or C signal)
4. LED-C4 (CAN state)
5. LED-C5 (Download write state)
6. LED-C6 (Download write state)
PC228US, 228USLC-3E0 35
In the KOMTRAX system, various information and processing details are displayed on the LED on the upper
surface of the KOMTRAX terminal. Therefore, if a detect is suspected in the system, perform the following
checks.
q Check of antennas
q Check of terminal LED displays
Before using the KOMTRAX system, make sure that the application for starting its use is completed as well
as the station opening check in the machine side.
Check of antennas
a Before checking the LED displays, check that there is no abnormality around the communication
antenna and GPS antenna.
q The communication antenna should not be off or damaged.
q The communication antenna cable should not be broken and normally be connected to the KOMTRAX
terminal.
q The GPS antenna should not be off or damaged.
q The GPS antenna cable should not be broken and normally be connected to the KOMTRAX terminal.
Check of terminal LED displays

1. Meaning of CPU LED displays
a The LED displays should be checked with the starting switch ON, starting switch START, or with the
engine started.
Display
No. LED Name/function Description
(*1)
ON Starting switch ACC signal: ON, Alternator R signal: ON
States of starting switch Fast blink Starting switch ACC signal: OFF, Alternator R signal: ON
1 LED-C1 ACC signal and alternator R
signal Slow blink Starting switch ACC signal: ON, Alternator R signal: OFF
OFF Starting switch ACC signal: OFF, Alternator R signal: OFF
ON Engine control signal: ON
2 LED-C2 State of engine control signal
OFF Engine control signal: OFF
ON S-NET: Connected, Starting switch C signal: OFF
States of S-NET connection Fast blink Starting switch C signal: ON
3 LED-C3
and starting switch C signal Slow blink (Not used)
OFF S-NET: Not connected, Starting switch C signal: OFF
ON CAN: Connected (without fuel sensor)
Fast blink CAN: Connected (with fuel sensor)
4 LED-C4 State of CAN connection
Slow blink CAN: Not connected (with fuel sensor)
OFF CAN: Not connected (without fuel sensor)
5 LED-C5 1-LED ON Download write mode (system administrator only function)

Download write state
2-LED
6 LED-C6 Normal operation mode
OFF
*1: Blink types and blink times

Fast blink: Blinks in about 1-second cycle
Slow blink: Blinks in about 4-second cycle
36 PC228US, 228USLC-3E0
2. Contents of 7-segment and dot displays for CPU

a The LED display should be checked with the starting switch turned ON.
Display
No. LED Name/function Description
(*2)
The number indicates the number of unsent mails. (10 or more
0 to 9
unsent mails are indicated by “9”.) Light-on indicates that the
Number of unsent displayed
machine is in process of capturing the satellite.
7 7 segments mails, satellite
capture state The number indicates the number of unsent mails. (10 or more
0 to 9
unsent mails are indicated by “9”.) Fast blink indicates that the
fast blink
satellite is not captured.
GPS positioning was completed. (The position can be con-
ON
GPS positioning firmed. *3)
8 Dot
status GPS positioning was not completed. (The position cannot be
OFF
confirmed. *3)
*2: Blink types and blink times

Fast blink: Blinks in about 0.5-second cycle
Slow blink: Blinks in about 2.0-second cycle
*3: Supplementary explanation of GPS positioning status
One or more minute may be taken until GPS positioning is completed after the starting switch was
turned ON even in an outdoor service area.
GPS positioning will fail in a weak signal or non-service area.
PC228US, 228USLC-3E0 37
Preparation work for 2. Engine controller

troubleshooting of electrical a The engine controller is installed in the left
side of the engine.
system 1 1) Open the engine hood and remove the
a When troubleshooting the electric circuit compressor assembly from the air condi-
related to the machine monitor, pump control- tioner.
ler, engine controller or KOMTRAX terminal, 2) Open the engine hood.
expose the related connectors according to the 3) Insert or connect troubleshooting T-adapter in
following procedure. or to connectors ENGINE MODULE/CE01,
CE02 and CE03 of engine controller (3).
1. Machine monitor a Connectors are fixed with screw.
1) Take off cover (1). Loosen the screws before discon-
a The cover is fixed with two upper and necting them.
lower clips. Pull it up for the removal. a When returning the connectors back
a If the sunlight sensor is equipped for to their position, tighten them to the
an air conditioner, disconnect P15 specified torque.
connector at the cover rear side. 3 Screw: 2.82 Nm {0.288 kgm}
2) Remove the 3 mounting screws to discon- 3. Pump controller

nect machine monitor (2) from the mount. a The pump controller is installed in the
a Take care so that the screws may not cover situated in the rear side of the oper-
fall into the console. ator seat.
3) Insert or connect troubleshooting T- 1) Remove the cover from the rear of the
adapter in or to connectors P01, P02, and operator seat, referring to the section for
P70 of machine monitor. KOMTRAX terminal.
2) Remove cover (5).
38 PC228US, 228USLC-3E0
3) Insert or connect troubleshooting T-

adapter in or to connectors CP01, CP02
and CP03 of pump controller (6).
a Connectors are fixed with screws.
Loosen the screws before discon-
necting them.
a When returning the connectors back
to their position, tighten them to the
specified torque.
3 Screw: 2.82 Nm {0.288 kgm}
5. Removing and installing the atmospheric

pressure and temperature sensor, the
engine oil pressure switch, and position
sensor (cam and crank)
q Removal
Shift the lever in the arrowhead direction
(a) and pull it out while pushing lock (b).
q Installation
Insert the connector and then shift the
lever in the arrowhead direction (f).
4. KOMTRAX terminal
a KOMTRAX terminal is installed in the
cover situated in the rear side of the oper-
ator seat.
2) Insert or connect troubleshooting T-

adapter in or to connector G01 of
KOMTRAX terminal (8).
a The connectors are fixed with screws.
Loosen the screws before discon-
necting them.
a When returning the connectors to
their original positions, fix them by
tightening the screws with the speci-
fied torque.
3 Screw: 2.82 Nm {0.288 kgm}
a Cable (9) is used for the communica-
tion antenna (2 systems).
a Cable (10) is used for the GPS
antenna.
PC228US, 228USLC-3E0 39
Pm-clinic service 1
PC228US-3E0
PC228USLC-3E0
40 PC228US, 228USLC-3E0
Engine
PC228US, 228USLC-3E0 41
Hydraulic system
42 PC228US, 228USLC-3E0
Check sheet (PC228US-3E0/PC228USLC-3E0)

Model Serial No. Service meter User's name Date of execution Inspector
/ /
1. Engine
Checking condition
Standard Mea-
Good
Service limit
Bad
No. Check item Fuel Work- Auto- Operation of Unit value for new sured
Left knob value
control ing decel- work machine value
switch
dial mode eration equipment
1 Engine speed rpm 2,010 – 2,110 2,010 – 2,110
All levers in
Engine oil MAX MPa Min. 0.29 0.25
2 neutral
pressure {kg/cm2} {Min. 3.0} {2.5}
OFF
3 Engine speed rpm 1,025 – 1,075 1,025 – 1,075
All levers in
Engine oil MIN OFF MPa Min. 0.10 0.07
4 neutral
pressure P {kg/cm2} {Min. 1.0} {0.7}
5 Engine speed rpm 1,900 – 2,100 1,900 – 2,100
Blow-by ON Arm IN relief kPa Max. 0.98 1.96
6
pressure MAX {mmH2O} {Max. 100} {200}
Engine oil All levers in
7 ON OFF rpm 1,300 – 1,500 1,300 – 1,500
pressure neutral
2. Work equipment speed

Checking condition
Standard Mea-
Good
Fuel Work- Service limit
Bad
No. Check item Unit value for new sured
control ing Checking posture, etc. value
machine value
dial mode
1 Boom RAISE Work equipment extended fully sec 3.3 – 4.1 Max. 5.2
P
sec 3.2 – 3.8 Max. 4.5
2 Arm IN E sec 3.1 – 4.4 Max. 5.0
Boom top horizontal
L sec 6.0 – 7.4 Max. 7.7
3 Arm OUT sec 2.4 – 3.0 Max. 3.5
Boom top horizontal
4 Bucket CURL sec 2.3 – 2.9 Max. 3.3
Arm cylinder retracted fully
MAX Work equipment extended fully
5 Swing (5 turns) sec 21.7 – 26.7 Max. 30
Swing right and left
P STD 46.2 – 56.4 46.2 – 61.7
LO sec
LC 50 – 61.5 50 – 67.1
One side of track
Travel STD 33.8 – 41.4 33.8 – 45.1
6 pushed up and turned MI sec
(5 idle turns) LC 36.8 – 45.0 36.8 – 49.1
forward and backward
STD 26.6 – 29.4 26.6 – 30.8
HI sec
LC 29.0 – 32.0 27.0 – 33.6
PC228US, 228USLC-3E0 43
44 PC228US, 228USLC-3E0
PC228US, 228USLC-3E0 45
SEN01881-03

© 2010 KOMATSU
All Rights Reserved
46
SEN01882-04
PC228US-3E0
PC228USLC-3E0

40 Troubleshooting 1
Failure code table and fuse locations
Failure code table ........................................................................................................................................... 2
Fuse locations................................................................................................................................................. 5
SEN01882-04 40 Troubleshooting
Failure code table 1
Action Device in Reference

Failure code Trouble (Displayed on screen) Category of record
code charge documents No.
— AA10NX Air cleaner Clogging MON Mechanical system
— AB00KE Charge Voltage Low MON Mechanical system
— B@BAZG Eng Oil Press Low ENG Mechanical system
— B@BAZK Eng Oil Level Low MON Mechanical system
— B@BCNS Eng Water Overheat ENG Mechanical system
— B@BCZK Eng Water Level Low MON Mechanical system
— B@HANS Hyd Oil Overheat MON Mechanical system
E10 CA111 EMC Critical Internal Failure ENG Electrical system
E10 CA115 Eng Ne and Bkup Speed Sens Error ENG Electrical system
E11 CA122 Chg Air Press Sensor High Error ENG Electrical system
E11 CA123 Chg Air Press Sensor Low Error ENG Electrical system
E14 CA131 Throttle Sensor High Error ENG Electrical system
E14 CA132 Throttle Sensor Low Error ENG Electrical system
E15 CA144 Coolant Temp Sens High Error ENG Electrical system
E15 CA145 Coolant Temp Sens Low Error ENG Electrical system
Troubleshooting
E15 CA153 Chg Air Temp Sensor High Error ENG Electrical system by failure code,
E15 CA154 Chg Air Temp Sensor Low Error ENG Electrical system Part 1
SEN01884-02
E11 CA155 Chg Air Temp High Speed Derate ENG Electrical system
E15 CA187 Sens Supply 2 Volt Low Error ENG Electrical system
E11 CA221 Ambient Press Sens High Error ENG Electrical system
E11 CA222 Ambient Press Sens Low Error ENG Electrical system
E15 CA227 Sens Supply 2 Volt High Error ENG Electrical system
— CA234 Eng Overspeed ENG Mechanical system
E15 CA238 Eng Ne Speed Sens Supply Volt Error ENG Electrical system
E10 CA271 IMV/PCV1 Short Error ENG Electrical system
E10 CA272 IMV/PCV1 Open Error ENG Electrical system
E11 CA322 Inj #1 (L#1) Open/Short Error ENG Electrical system
E10 CA342 Calibration Code Incompatibility ENG Electrical system
E10 CA351 Injectors Drive Circuit Error ENG Electrical system
E15 CA352 Sens Supply 1 Volt Low Error ENG Electrical system
Troubleshooting
E15 CA386 Sens Supply 1 Volt High Error ENG Electrical system by failure code,
E15 CA428 Water in Fuel Sensor High Error ENG Electrical system Part 2
SEN01885-04
E15 CA429 Water in Fuel Sensor Low Error ENG Electrical system
E15 CA435 Eng Oil Press Sw Error ENG Electrical system
E10 CA441 Battery Voltage Low Error ENG Electrical system

E10 CA442 Battery Voltage High Error ENG Mechanical system
E11 CA449 Rail Press Very High Error ENG Electrical system
E11 CA451 Rail Press Sensor High Error ENG Electrical system
E11 CA452 Rail Press Sensor Low Error ENG Electrical system
E11 CA488 Chg Air Temp High Torque Derate ENG Electrical system
E15 CA553 Rail Press High Error ENG Electrical system
E15 CA559 Rail Press Low Error ENG Electrical system
E15 CA689 Eng Ne Speed Sensor Error ENG Electrical system
Troubleshooting
E15 CA731 Eng Bkup Speed Sens Phase Error ENG Electrical system by failure code,
E10 CA757 All Persistent Data Lost Error ENG Electrical system Part 2
SEN01885-04
E15 CA778 Eng Bkup Speed Sensor Error ENG Electrical system
E0E CA1633 KOMNET Datalink Timeout Error ENG Electrical system
E14 CA2185 Throt Sens Sup Volt High Error ENG Electrical system
E14 CA2186 Throt Sens Sup Volt Low Error ENG Electrical system
E11 CA2249 Rail Press Very Low Error ENG Electrical system
E11 CA2311 IMV Solenoid Error ENG Electrical system
E15 CA2555 Grid Htr Relay Volt High Error ENG Electrical system
E15 CA2556 Grid Htr Relay Volt Low Error ENG Electrical system
— D110KB Battery Relay Drive Short Circuit PUMP Electrical system
— D196KA Service Return Relay Disc. PUMP Electrical system
— D196KB Service Return Relay S/C PUMP Electrical system
E0E DA22KK Pump Solenoid Power Low Error PUMP Electrical system
— DA25KP 5V Sensor 1 Power Abnormality PUMP Electrical system
E0E DA2RMC CAN Discon (Pump Con Detected) PUMP Electrical system Troubleshooting
by failure code,
— DA2SKQ Model Selection Abnormality PUMP Electrical system
Part 3
E0E DAFRMC CAN Discon (Monitor Detected) MON Electrical system SEN01886-02
— DGH2KB Hyd Oil Sensor Short PUMP Electrical system
— DHPAMA F Pump Press Sensor Abnormality PUMP Electrical system
— DHPBMA R Pump Press Sensor Abnormality PUMP Electrical system
— DHSAMA Swing RH PPC Press Sensor Abnormality PUMP Electrical system
— DHSBMA Swing LH PPC Press Sensor Abnormality PUMP Electrical system
— DW43KA Travel Speed Sol Open Circuit PUMP Electrical system
— DW43KB Travel Speed Sol Short Circuit PUMP Electrical system
E03 DW45KA Swing Brake Sol Open Circuit PUMP Electrical system
E03 DW45KB Swing Brake Sol Short Circuit PUMP Electrical system
— DW91KA Travel Junction Sol Open Circuit PUMP Electrical system
Troubleshooting
— DW91KB Travel Junction Sol Short Circuit PUMP Electrical system by failure code,
E06 DW4GKA Boom Slow Down Sol. Disc PUMP Electrical system Part 4
SEN01887-02
E06 DW4GKB Boom Slow Down Sol. S/C PUMP Electrical system
— DWJ0KA Merge-divider Sol Open Circuit PUMP Electrical system
— DWJ0KB Merge-divider Sol Short Circuit PUMP Electrical system
— DWK0KA 2-stage Relief Sol Open Circuit PUMP Electrical system
— DWK0KB 2-stage Relief Sol Short Circuit PUMP Electrical system

E02 DXA0KA PC-EPC Sol Open Circuit PUMP Electrical system
E02 DXA0KB PC-EPC Sol Short Circuit PUMP Electrical system
— DXE0KA LS-EPC Sol Open Circuit PUMP Electrical system
— DXE0KB LS-EPC Sol Short Circuit PUMP Electrical system
— DXE4KA Service Current EPC Open Circuit PUMP Electrical system Troubleshooting
by failure code,
— DXE4KB Service Current EPC Short Circuit PUMP Electrical system
Part 4
— DY20KA Wiper Working Abnormality MON Electrical system SEN01887-02
— DY20MA Wiper Parking Abnormality MON Electrical system
— DY2CKB Washer Drive Short Circuit MON Electrical system
— DY2DKB Wiper Drive (Fwd) Short Circuit MON Electrical system
— DY2EKB Wiper Drive (Rev) Short Circuit MON Electrical system
a This table lists the failed sections in the order of the failure code.
a Those failure codes to which the corresponding number is not indicated in the action code space are not displayed
on the ordinary screen if a failure is found. They are just recorded in the failure record (electrical system and mechan-
ical system) of the service menu.
a The category of record is used for indicating to which of the electrical and mechanical system of the service menu’s
abnormality record a given failure is classified.
a E at beginning of the action code indicates the following state.
q With E: The failure still remains without being resolved.
q Without E: The failure is already resolved.
Fuse locations 1
Connection table of fuse box
a This connection table shows the devices to which each power supply of the fuse box supplies power (A
switch power supply is a device which supplies power while the starting switch is in the ON position and
a constant power supply is a device which supplies power while the starting switch is in the OFF and ON
positions).
a When carrying out troubleshooting related to the electrical system, you should check the fuses and fus-
ible links to see if the power is supplied normally.
Fuse
Type of power supply Fusible link Fuse No. Destination of power
capacity
Lamp relay, rear lamp relay, cab lamp relay
PC-EPC (F) solenoid valve, PC-EPC (R) solenoid valve
1 10A [When pump drive switch is operated in emergency]
Swing holding brake solenoid valve
[When swing holding brake release switch is operated]
2 20A Pump controller (Solenoid power supply)
F04
Switch power supply PPC oil pressure lock solenoid valve
(60A)
3 20A Starting motor cut-out relay (PPC lock)
Starting motor cut-out relay (Personal code)
Cigarette lighter
4 10A
Windshield washer motor
5 10A Horn relay, horn
6 10A Intake air heater
7 10A Rotary lamp
Right headlamp, working lamp (boom), working lamp
F04 8 20A
Switch power supply (rear)
(60A)
Radio
9 10A
Left knob switch (pump controller input)
10 10A (Spare)
Air conditioner unit
11 20A
Air conditioner compressor electromagnetic clutch
12 10A (Spare)
F04
Switch power supply 13 20A Headlamp
(60A)
14 10A Optional power supply (1)
Travel alarm
15 10A
Optional power supply (2)
Radio (backup power supply)
16 10A
A/C servo
Starting switch
F05
Constant power supply 17 20A Machine monitor
(30A)
Pump controller
18 10A (Spare)
19 30A Engine controller
Starting switch
Switch power supply 20 5A Engine controller (ACC signal)
ACC
SEN01882-04

© 2009 KOMATSU
All Rights Reserved
8
SEN01883-03
PC228US-3E0
PC228USLC-3E0

General information on troubleshooting
Points to remember when troubleshooting ..................................................................................................... 2
Sequence of events in troubleshooting........................................................................................................... 3
Checks before troubleshooting ....................................................................................................................... 4
Classification and troubleshooting steps......................................................................................................... 5
Information in troubleshooting table................................................................................................................ 6
Possible problems and troubleshooting No. ................................................................................................... 8
Connection table for connector pin numbers .................................................................................................11
T- branch box and T- branch adapter table ................................................................................................... 47
Points to remember when troubleshooting 1

k Stop the machine in a level place, and check that the lock pin, blocks, and parking brake are
securely fitted.
k When carrying out the operation with 2 or more workers, keep strictly to the agreed signals, and
do not allow any unauthorized person to come near.
k If the radiator cap is removed when the engine is hot, hot water may spurt out and cause burns,
so wait for the engine to cool down before starting troubleshooting.
k Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
k When disconnecting wiring, always disconnect the negative (–) terminal of the battery first.
k When removing the plug or cap from a location which is under pressure from oil, water, or air,
always release the internal pressure first. When installing measuring equipment, be sure to con-
nect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to pre-
vent reoccurrence of the failure. When carrying out troubleshooting, an important point is of course to under-
stand the structure and function. However, a shortcut to effective troubleshooting is to ask the operator
various questions to form some idea of possible causes of the failure that would produce the reported symp-
toms.
1. When carrying out troubleshooting, do not 4) Other maintenance items can be checked
hurry to disassemble the components. externally, so check any item that is con-
If components are disassembled immediately sidered to be necessary.
after any failure occurs:
q Parts that have no connection with the fail- 4. Confirming failure
ure or other unnecessary parts will be dis- Confirm the extent of the failure yourself, and
assembled. judge whether to handle it as a real failure or
q It will become impossible to find the cause as a problem with the method of operation, etc.
of the failure. a When operating the machine to reenact
It will also cause a waste of manhours, parts, the troubleshooting symptoms, do not
or oil or grease, and at the same time, will also carry out any investigation or measure-
lose the confidence of the user or operator. For ment that may make the problem worse.
this reason, when carrying out troubleshooting,
it is necessary to carry out thorough prior 5. Troubleshooting
investigation and to carry out troubleshooting Use the results of the investigation and inspec-
in accordance with the fixed procedure. tion in Items 2 – 4 to narrow down the causes
of failure, then use the troubleshooting table or
2. Points to ask user or operator troubleshooting flowchart to locate the position
1) Have any other problems occurred apart of the failure exactly.
from the problem that has been reported? a The basic procedure for troubleshooting is
2) Was there anything strange about the as follows.
machine before the failure occurred? 1] Start from the simple points.
3) Did the failure occur suddenly, or were 2] Start from the most likely points.
there problems with the machine condition 3] Investigate other related parts or
before this? information.
4) Under what conditions did the failure
occur? 6. Measures to remove root cause of failure
5) Had any repairs been carried out before Even if the failure is repaired, if the root cause
the failure? When were these repairs car- of the failure is not repaired, the same failure
ried out? will occur again.To prevent this, always investi-
6) Has the same kind of failure occurred gate why the problem occurred. Then, remove
before? the root cause.
3. Check before troubleshooting

1) Is there any sign of irregularities of the
machine?
2) Make checks before starting day's work.
3) Make checks of other items.
Sequence of events in troubleshooting 1
Checks before troubleshooting 1
Item Criterion Remedy

1. Check of level and type of fuel — Add fuel
2. Check of fuel for foreign matter — Clean and drain
3. Check of fuel filter — Replace
4. Check of hydraulic oil level — Add oil
Lubricating 5. Check of hydraulic oil strainer — Clean and drain
oil/Coolant 6. Check of swing machinery oil level — Add oil
7. Check of level and type of engine oil (in oil pan) — Add oil
8. Check of coolant level — Add coolant
9. Check of dust indicator for clogging — Clean or replace
10. Check of hydraulic oil filter — Replace
1. Check of battery terminals and wiring for loose-
— Retighten or replace
ness and corrosion
Electrical 2. Check of alternator terminals and wiring for
equipment looseness and corrosion
3. Check of starting motor terminals and wiring for
looseness and corrosion
Hydraulic/ 1. Check for abnormal noise and smell — Repair

Mechanical 2. Check for oil leakage — Repair
equipment 3. Bleeding air — Bleed air
1. Check of battery voltage (with engine stopped) 20 – 30 V Replace
2. Check of electrolyte level — Add or replace
3. Check of wires for discoloration, burn, and
— Replace
removal of cover
4. Check for released wire clamp and drooping wire — Repair
Electric,
electrical 5. Check of wires for wetness (Check connectors Disconnect the
—
equipment and terminals for wetness, in particular) connectors and dry
6. Check of fuse for disconnection and corrosion — Replace
7. Check of alternator voltage (while engine speed After operating for several
Replace
is at middle or higher) minutes: 27.5 – 29.5 V
8. Check of battery relay for operating sound (when
— Replace
starting switch is turned ON or OFF)
Classification and troubleshooting steps 1

Classification of troubleshooting
Mode Contents
Display of code Troubleshooting by failure code
E-mode Troubleshooting of electrical system
H-mode Troubleshooting of hydraulic and mechanical system
S-mode Troubleshooting of engine
Troubleshooting steps
If a problem that appears to be a failure occurs on the machine, identify the relevant troubleshooting No. by
performing the following steps and proceed to the main body of troubleshooting.
1. Procedure for troubleshooting to be taken when action code is displayed on machine monitor:
When action code is displayed on machine monitor, press [3] switch at panel switch section to display
failure code.
Carry out the troubleshooting for the corresponding [Display of code] according to the displayed failure
code.
2. Procedure for troubleshooting to be taken when failure code is recorded in abnormality record:
If an action code is not displayed on the machine monitor, check a failure code with the abnormality
record function of the machine monitor.
If a code is recorded, carry out troubleshooting for the corresponding [Display of code] according to the
recorded code.
a If an electrical system failure code is recorded, delete all the codes and reproduce them, and then
see if the trouble is still detected.
a An error code of the mechanical system cannot be deleted.
3. Procedure for troubleshooting to be taken when action code is not displayed and no failure code
is recorded in abnormality record:
If an action code is not displayed on the machine monitor and no failure code is recorded in the abnor-
mality record, a trouble that the machine cannot find out by itself may have occurred in the electrical
system or hydraulic and mechanical system.
In this case, check the phenomenon looking like a trouble again and select the same phenomenon from
the table of “Possible troubles and troubleshooting No.”, and then carry out troubleshooting correspond-
ing to that phenomenon in the “E-mode”, “H-mode”, or “S-mode”.
Information in troubleshooting table 1

a The following information is summarized in the troubleshooting table and the related electrical circuit
diagram. Before carrying out troubleshooting, understand that information fully.
Action code Failure code

Display on Trouble name displayed in abnormality record machine moni-
Display on machine Trouble
machine monitor
monitor
tor
Contents of
Contents of trouble detected by machine monitor or controller
trouble
Action of
Action taken by machine monitor or controller to protect system or devices when engine con-
machine moni-
troller detects trouble
tor or controller
Problem that
Problem that appears on machine as result of action taken by machine monitor or controller
appears on
(shown above)
machine
Related infor-
Information related to detected trouble or troubleshooting
mation
Cause Standard value in normal state/Remarks on troubleshooting
<Contents of description>
• Standard value in normal state to judge possible causes
• Remarks on judgment
1 <Troubles in wiring harness>
• Disconnection
Connector is connected imperfectly or wiring harness is bro-
ken.
• Ground fault
Wiring harness which is not connected to chassis ground
circuit is in contact with chassis ground circuit.
• Hot short
Wiring harness which is not connected to power source (24
V) circuit is in contact with power source (24 V) circuit.
2
• Short circuit
Independent wiring harnesses are in contact with each other
Possible causes abnormally.
and standard Possible causes of trouble
value in normal (Given numbers are refer-
state ence numbers, which do not <Precautions for troubleshooting>
indicate priority) (1) Method of indicating connector No. and handling of T-
adapter
Insert or connect T-adapter as explained below for trouble-
3 shooting, unless otherwise specified.
• If connector No. has no marks of “male” and “female”,
disconnect connector and insert T-adapters in both male
side and female side.
• If connector No. has marks of “male” and “female”, dis-
connect connector and connect T-adapter to only male
side or female side.
(2) Entry order of pin Nos. and handling of tester leads
Connect positive (+) lead and negative (–) lead of tester as
explained below for troubleshooting, unless otherwise
4 specified.
• Connect positive (+) lead to pin No. or wiring harness
entered on front side.
• Connect negative (–) lead to pin No. or harness entered
on rear side.
Related circuit diagram
This drawing is a part of the electric circuit diagram related to trouble-

shooting.
q Connector No.: Indicates (Model – Number of pins) and
(Color).
q “Connector No. and pin No.” from each branching/merging
point: Shows the ends of branch or source of merging within
the parts of the same wiring harness.
q Arrow (⇔): Roughly shows the location on the machine.
Possible problems and troubleshooting No. 1

Troubleshooting
No. Phenomena looking like troubles Display of
E-mode H-mode S-mode
code
Phenomena related to action code/failure code
1 An action code is displayed on machine monitor.
According
When abnormality record is checked, failure code is displayed in
2 to
electrical system abnormality record
displayed
When abnormality record is checked, failure code is displayed in code
3
mechanical system abnormality record
Phenomena related to engine
4 Starting performance is poor (it always starts up slowly) S-1
5 Engine does not rotate E-1 S-2 a)
Engine does
6 Engine rotates, but exhaust gas does not come out S-2 b)
not start
7 Engine emits exhaust gas, but it does not start S-2 c)
8 Engine does not pick up smoothly (follow-up performance is poor) S-3
9 Engine stops during operations S-4
10 Engine rotation is unstable (it hunts). S-5
11 Engine lacks output or power S-6
12 Exhaust smoke is black (incomplete combustion) S-7
13 Oil consumption is excessive or exhaust smoke is blue S-8
14 Oil becomes contaminated quickly S-9
15 Fuel consumption is excessive S-10
16 Oil is in coolant, coolant spurts back or coolant level goes down S-11
17 Oil pressure drops S-12
18 Oil level rises (Entry of coolant or fuel) S-13
19 Coolant temperature becomes too high (overheating) S-14
20 Abnormal noise is made S-15
21 Vibration is excessive S-16
22 Auto-decelerator does not operate E-2 H-5
23 Automatic warm-up system does not operate E-3
24 Preheater does not operate E-4
Phenomena related to work equipment, swing, and travel
25 Speed or power of whole work equipment, swing and travel is low H-1 S-6
26 Engine speed lowers extremely or engine stalls H-2 S-4
27 Work equipment, swing, travel mechanism do not move E-5 H-3
28 Abnormal sound comes out from around hydraulic pump H-4
29 Fine control performance or response is low H-6
Phenomena related to work equipment
30 Speed or power of boom is low E-17,18 H-7
31 Speed or power of arm is low E-19,20 H-8
32 Speed or power of bucket is low E-21,22 H-9
33 Work equipment does not move singly H-10
34 Hydraulic drift of work equipment is large H-11
35 Time lag of work equipment is large H-12
When part of work equipment is relieved singly, other parts of work
36 H-13
equipment move
Troubleshooting
code
37 Power maximizing function does not work. E-6, 17 – 22 H-14
Phenomena related to compound operation
In compound operation of work equipment, speed of part loaded
38 H-15
more is low
When machine swings and raises boom simultaneously, boom rising
39 H-16
speed is low
When machine swings and travels simultaneously, travel speed
40 H-17
lowers largely
Phenomena related to travel
41 Machine deviates during travel H-18
42 Travel speed is low E-25 H-19
43 Machine is not steered well or steering power is low E-25,26 H-20
44 Travel speed does not change or travel speed is low or high E-25 H-21
45 Travel system does not move (only one side) H-22
Phenomena related to swing
46 Upper structure does not swing E-23, 24 H-23
47 Swing acceleration or swing speed is low H-24
48 Upper structure overruns remarkably when it stops swinging H-25
49 Large shock is made when upper structure stops swinging H-26
50 Large sound is made when upper structure stops swinging H-27
51 Hydraulic drift of swing is large H-28
Phenomena related to machine monitor (Operator menu: ordinary screen)
52 Machine monitor does not display any items E-8
53 Machine monitor does not display some items E-9
Contents of display by machine monitor are different from applicable
54 E-9
machine
Radiator coolant level monitor lights up in red during check before
55 B@BCZK
starting
56 Engine oil level monitor lights up in red during check before starting B@BAZK
Maintenance interval monitor lights up in red during check before See the Operation and Maintenance
57
starting Manual.
58 Charge level monitor lights up in red while engine is running AB00KE
59 Fuel level monitor lights up in red while engine is running E-13
60 Air cleaner clogging monitor lights up in red while engine is running AA10NX
Engine coolant temperature monitor lights up in red while engine is
61 B@BCNS S-14
running
Hydraulic oil temperature monitor lights up in red while engine is
62 B@HANS
running
63 Engine coolant temperature gauge does not indicate normally E-11
64 Hydraulic oil temperature gauge does not indicate normally E-12
65 Fuel level gauge does not indicate normally E-13
66 Swing lock monitor does not indicate normally E-14
Machine monitor display anything even when operated on monitor
67 E-15
switch section
68 Windshield wiper and window washer do not operate E-16
Troubleshooting
code
Phenomena related to machine monitor (Service menu: special functions screen)
69 Monitoring function does not display “Boom RAISE” normally E-17
70 Monitoring function does not display “Boom LOWER” normally E-18
71 Monitoring function does not display “Arm IN” normally E-19
72 Monitoring function does not display “Arm OUT” normally E-20
73 Monitoring function does not display “Bucket CURL” normally E-21
74 Monitoring function does not display “Bucket DUMP” normally E-22
75 Monitoring function does not display “Swing” normally E-23
76 Monitoring function does not display “Swing RIGHT” normally E-24
77 Monitoring function does not display “Travel LEFT” normally E-25
78 Monitoring function does not display “Travel Steering” normally E-26
79 Monitoring function does not display “Service” normally E-27
Phenomena related to KOMTRAX
80 KOMTRAX system does not operate normally E-28
Other phenomena
81 Air conditioner does not operate E-29
82 Travel alarm does not sound or does not stop sounding E-30
83 Horn does not sound E-31
10 PC228US, 228USLC-3E0
Connection table for connector pin numbers (Rev. 2009.04)
a The terms of male and female refer to the pins, while the terms of male housing and female housing
refer to the mating portion of the housing.
PC228US, 228USLC-3E0 11
12 PC228US, 228USLC-3E0
PC228US, 228USLC-3E0 13
14 PC228US, 228USLC-3E0
PC228US, 228USLC-3E0 15
16 PC228US, 228USLC-3E0
PC228US, 228USLC-3E0 17
18 PC228US, 228USLC-3E0
PC228US, 228USLC-3E0 19
20 PC228US, 228USLC-3E0
PC228US, 228USLC-3E0 21
22 PC228US, 228USLC-3E0
PC228US, 228USLC-3E0 23
24 PC228US, 228USLC-3E0
PC228US, 228USLC-3E0 25
26 PC228US, 228USLC-3E0
PC228US, 228USLC-3E0 27
28 PC228US, 228USLC-3E0
PC228US, 228USLC-3E0 29
30 PC228US, 228USLC-3E0
PC228US, 228USLC-3E0 31
32 PC228US, 228USLC-3E0
PC228US, 228USLC-3E0 33
34 PC228US, 228USLC-3E0
PC228US, 228USLC-3E0 35
36 PC228US, 228USLC-3E0
PC228US, 228USLC-3E0 37
38 PC228US, 228USLC-3E0
PC228US, 228USLC-3E0 39
40 PC228US, 228USLC-3E0
PC228US, 228USLC-3E0 41
42 PC228US, 228USLC-3E0
PC228US, 228USLC-3E0 43
44 PC228US, 228USLC-3E0
PC228US, 228USLC-3E0 45
46 PC228US, 228USLC-3E0
T- branch box and T- branch adapter table 1

(Rev. 2009.03)
a The vertical column indicates a part number of T-branch box or T-branch adapter while the horizontal
column indicates a part number of harness checker assembly.
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol
799-601-2600 T-box (for ECONO) 21 q q q q q

799-601-3100 T-box (for MS) 37 q
799-601-3200 T-box (for MS) 37 q
799-601-3380 Plate for MS (14-pin) q
799-601-3410 Adapter for BENDIX (MS) 24 MS-24P q
799-601-3470 Case q
799-601-2710 Adapter for MIC 5 MIC-5P q q q
799-601-2720 Adapter for MIC 13 MIC-13P q q q
799-601-2730 Adapter for MIC 17 MIC-17P q q q q q q
799-601-2740 Adapter for MIC 21 MIC-21P q q q q q q
799-601-2950 Adapter for MIC 9 MIC-9P q q q q
799-601-2750 Adapter for ECONO 2 ECONO2P q q
799-601-2810 Adapter for DLI 8 DLI-8P q q
799-601-2840 Extension cable (ECONO type) 12 ECONO12P q q q
799-601-2850 Case q
799-601-4350 T-box (for DRC 60, ECONO) 60 q
799-601-4360 Case q
799-601-7010 Adapter for X (T-adapter) 1 q q
799-601-7020 Adapter for X 2 X2P q q q q
799-601-7050 Adapter for SWP 6 SW6P q q q
799-601-7060 Adapter for SWP 8 SW8P q q q
799-601-7310 Adapter for SWP 12 SW12P q
799-601-7070 Adapter for SWP 14 SW14P q q
799-601-7320 Adapter for SWP 16 SW16P q
799-601-7080 Adapter for M (T-adapter) 1 q q
799-601-7090 Adapter for M 2 M2P q q q q
PC228US, 228USLC-3E0 47
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol

799-601-7340 Adapter for M 8 M8P q
799-601-7140 Adapter for S 8 S8P q q q q
799-601-7150 Adapter for S (White) 10 S10P q q q q
799-601-7160 Adapter for S (Blue) 12 S12P q q q
799-601-7170 Adapter for S (Blue) 16 S16P q q q q
799-601-7330 Adapter for S (White) 16 S16PW q
799-601-7350 Adapter for S (White) 12 S12PW q
799-601-7180 Adapter for AMP040 8 A8P q
799-601-7190 Adapter for AMP040 12 A12P q q
799-601-7210 Adapter for AMP040 16 A16P q q q q
799-601-7220 Adapter for AMP040 20 A20P q q q q
799-601-7230 Short connector for X 2 — q q q q
799-601-7240 Case q q
799-601-7270 Case q
799-601-7510 Adapter for 070 10 07-10 q
799-601-7520 Adapter for 070 12 07-12 q
799-601-7530 Adapter for 070 14 07-14 q
799-601-7540 Adapter for 070 18 07-18 q
799-601-7550 Adapter for 070 20 07-20 q
799-601-7360 Adapter for relay 5 REL-5P q
799-601-7370 Adapter for relay 6 REL-6P q
799-601-7380 Adapter for JFC 2 — q
799-601-9010 Adapter for DTM 2 DTM2 q q
799-601-9020 Adapter for DT 2 DT2 q q q q
799-601-9030 Adapter for DT 3 DT3 q q
799-601-9040 Adapter for DT 4 DT4 q q q q
799-601-9050 Adapter for DT 6 DT6 q q
799-601-9060 Adapter for DT (Gray) 8 DT8GR q q
799-601-9070 Adapter for DT (Black) 8 DT8B q q
799-601-9080 Adapter for DT (Green) 8 DT8G q q
799-601-9090 Adapter for DT (Brown) 8 DT8BR q q
799-601-9110 Adapter for DT (Gray) 12 DT12GR q q
799-601-9120 Adapter for DT (Black) 12 DT12B q q
799-601-9130 Adapter for DT (Green) 12 DT12G q q
799-601-9140 Adapter for DT (Brown) 12 DT12BR q q
799-601-9210 Adapter for HD30-18 8 D18-8 q q
799-601-9310 Plate for HD30 (24-pin) q q q
799-601-9320 T-box (for ECONO) 24 q q q
48 PC228US, 228USLC-3E0
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol
799-601-9330 Case q
799-601-9340 Case q
799-601-9350 Adapter for DRC 40 DRC-40 q
799-601-9360 Adapter for DRC 24 DRC-24 q
799-601-9410* Socket for engine (CRI-T2) 2 G q
Adapter for engine (CRI-T2)
799-601-9420 Adapter for engine (CRI-T3) PFUEL 3 A3 q q
Oil pressure sensor
Socket for engine (CRI-T2)
799-601-9430* 2 P q q
Socket for engine (CRI-T3) PCV
799-601-9440* Socket for engine (CRI-T2) 3 1,2,3 q
795-799-5520* Socket for engine (HPI-T2) 2 S q
Socket for engine (HPI-T2)
795-799-5530* Socket for engine (CRI-T3) 2 C q q
Temperature sensor
Socket for engine (HPI-T2)
795-799-5540* 2 A q q
Socket for engine (CRI-T3) TIM
795-799-5460 Cable for engine (HPI-T2) 3 — q
799-601-4110 Adapter for engine (140-T3) PIM 4 ITT3N q q
799-601-4130 Adapter for engine (CRI-T3) NE, CAM 3 FCIN q q
799-601-4140 3 FCIG q q
Atomosphere pressure
799-601-4150 Adapter for engine (CRI-T3) POIL 3 FCIB q q
799-601-4160 2 4160 q q
Oil pressure switch
799-601-4180 Adapter for engine (CRI-T3) PEVA 3 4180 q q
799-601-4190* 3 1,2,3L q q
Commonrail pressure
799-601-4230* 4 1,2,3,4C q q
Air intake pressure/temperature
799-601-4240* Socket for engine (CRI-T3) PAMB 3 1,2,3A q q
799-601-4250* Socket for engine (CRI-T3) PIM 3 1,2,3B q q
799-601-4330* Socket for engine (CRI-T3) G 3 1,2,3,G q q
799-601-4340* 2 2,PA q q
Pump actuator
Socket for engine (CRI-T3)(95)
799-601-4380* 4 1,2,3,4T q
Air intake pressure/temperature
799-601-4260 Adapter for controller (ENG) 4 DTP4 q q
799-601-4211 Adapter for controller (ENG) 50 DRC50 q
799-601-4220 Adapter for controller (ENG) 60 DRC60 q
799-601-4390* Socket for controller (95 ENG) 60 — q
799-601-4280* Box for controller (PUMP) 121 — q
799-601-9720 Adapter for controller (HST) 16 HST16A q
799-601-9710 Adapter for controller (HST) 16 HST16B q
799-601-9730 Adapter for controller (HST) 26 HST26A q
2,
Multi-adapter for
799-601-9890 3, — q
DT2 – 4 and DTM2
4,
“*” Shows not T-adapter but socket.
PC228US, 228USLC-3E0 49
SEN01883-03

© 2009 KOMATSU
All Rights Reserved
50
SEN01884-02
PC228US-3E0
PC228USLC-3E0

Troubleshooting by failure code
(Display of code), Part 1
Failure code [AA10NX] Air cleaner Clogging .................................................................................................. 3
Failure code [AB00KE] Charge Voltage Low .................................................................................................. 4
Failure code [B@BAZG] Eng Oil Press Low................................................................................................... 6
Failure code [B@BAZK] Eng Oil Level Low.................................................................................................... 7
Failure code [B@BCNS] Eng Water Overheat................................................................................................ 8
Failure code [B@BCZK] Eng Water Level Low............................................................................................... 9
Failure code [B@HANS] Hyd Oil Overheat................................................................................................... 10
Failure code [CA111] EMC Critical Internal Failure....................................................................................... 10
Failure code [CA115] Eng Ne and Bkup Speed Sens Error ...........................................................................11
Failure code [CA122] Chg Air Press Sensor High Error ............................................................................... 12
Failure code [CA123] Chg Air Press Sensor Low Error ................................................................................ 14
Failure code [CA131] Throttle Sensor High Error ......................................................................................... 16
Failure code [CA132] Throttle Sensor Low Error .......................................................................................... 18
Failure code [CA144] Coolant Temp Sens High Error .................................................................................. 20
Failure code [CA145] Coolant Temp Sens Low Error ................................................................................... 22

Failure code [CA153] Chg Air Temp Sensor High Error................................................................................ 24
Failure code [CA154] Chg Air Temp Sensor Low Error................................................................................. 26
Failure code [CA155] Chg Air Temp High Speed Derate .............................................................................. 28
Failure code [CA187] Sens Supply 2 Volt Low Error..................................................................................... 30
Failure code [CA221] Ambient Press Sens High Error ................................................................................. 32
Failure code [CA222] Ambient Press Sens Low Error .................................................................................. 34
Failure code [CA227] Sens Supply 2 Volt High Error.................................................................................... 36
Failure code [CA234] Eng. Overspeed ......................................................................................................... 37
Failure code [CA238] Ne Speed Sens Supply Volt Error .............................................................................. 38
Failure code [CA271] IMV/PCV1 Short Error ................................................................................................ 39
Failure code [CA272] IMV/PCV1 Open Error................................................................................................ 40
Failure code [CA322] Inj #1 (L#1) Open/Short Error..................................................................................... 42
Failure code [AA10NX] Air cleaner Clogging 1
Action code Failure code Air cleaner clogging

Trouble
— AA10NX (Machine monitor system)
Contents of • While engine was running, signal circuit of air cleaner clogging switch was opened (disconnected
trouble with GND).
Action of
machine moni- • None in particular.
tor
Problem that
appears on • If machine is operated as it is, engine may be damaged.
machine
• If an air cleaner clogging caution symbol appears on the machine monitor while the engine is run-
Related infor- ning, this failure code will be recorded.
mation • Input from the air cleaner clogging switch (ON/OFF) can be checked with monitoring function.
(Code 04501: Monitor Input 2)

Clogging of air cleaner a Check the air cleaner for clogging and then clean or replace it if
1
(when system is normal) clogged.
a Prepare with starting switch OFF, then start engine and carry
out troubleshooting.
Defective air cleaner clog-
2 ging switch P23 (male) Air cleaner Resistance
(internal disconnection) Value in normal state Max. 1 z
Between (1) – (2)
Value when clogged Min. 1Mz
Possible causes
a Prepare with starting switch OFF, then carry out troubleshoot-
and standard
Disconnection in wiring har- ing without turning starting switch ON.
value in normal ness
state Wiring harness between P02 (female) (5) – Resis-
3 (Disconnection in wiring or Max. 1 z
H10 – A06 – P23 (female) (1) tance
defective contact in connec-
tor) Wiring harness between P23 (female) (2) – Resis-
Max. 1 z
chassis ground tance
4 Defective machine monitor P02 Air cleaner Voltage
Between (5) – chas- Value in normal state Max. 1 V
sis ground Value when clogged 20 – 30 V
Circuit diagram related to air cleaner clogging switch of machine monitor
Failure code [AB00KE] Charge Voltage Low 1
Action code Failure code Charge voltage low

Trouble
— AB00KE (Machine monitor system)
Contents of
• While engine is running, power generation signal from the alternator is not input.
trouble
Action of
tor
Problem that
appears on • If machine is operated as it is, battery may not be charged.
machine
• If a charge level caution symbol appears on the machine monitor while the engine is running, this
Related infor-
failure code will be recorded.
mation
• Input from alternator (voltage) can be checked with monitoring function. (Code: 04300 Charge voltage)

Defective alternator
1 Alternator Engine speed Voltage
(Low power generation)
L terminal – chassis
Min. medium speed 27.5 – 29.5 V
ground
Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshoot-
ness ing without turning starting switch ON.
2 (Disconnection in wiring or Wiring harness between P02 (female) (11) –
Resis-
defective contact in connec- H11 – J02 – A07 – E08 – E12 – Alternator L Max. 1 z
tor) tance
Possible causes terminal
and standard a Prepare with starting switch OFF, then carry out troubleshoot-
value in normal
ing without turning starting switch ON.
state
Ground fault in wiring har- Wiring harness between P02 (female) (11) –
ness H11 – J02 – A07 – E08 – E12 – Alternator L
3
(Short circuit with GND cir- terminal, between P02 (female) (11) – H11 – Resis-
cuit) Min. 1Mz
J02 – D01 (female) (6) and between P02 tance
(female) (11) – H11 – J02 – R17 (female) (2)
with chassis ground
4 Defective machine monitor P02 Engine speed Voltage
Between (11) – chas-
Min. medium speed 27.5 – 29.5 V
sis ground
Circuit diagram related to starting and charge of machine monitor
Failure code [B@BAZG] Eng Oil Press Low 1
Action code Failure code Engine oil pressure low

Trouble
— B@BAZG (Engine controller system)
Contents of
• Engine oil pressure drops while engine is running.
trouble
Action of
• Limits output and continues operation.
controller
Problem that
• Engine output lowers.
appears on
• If machine is operated as it is, engine may be damaged.
machine
Related
•
information

Possible causes
Lowering of engine oil Engine oil pressure may be low. Check it directly and remove cause if it
and standard 1
pressure is low.
value in normal
state Defective engine oil pres- If cause 1 is not detected, engine oil switch system may be detective.
2
sure sensor system Carry out troubleshooting for the failure code [CA435].
Failure code [B@BAZK] Eng Oil Level Low 1
Action code Failure code Engine oil level low

Trouble
— B@BAZK (Machine monitor system)
Contents of • When starting switch is turned ON (but engine is not started), signal circuit of engine oil level switch
trouble detected low engine oil level (sensor contact opened).
Action of
• Displays engine oil level monitor on machine monitor.
machine moni-
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
tor
Problem that
appears on • If machine is operated as it is, engine may be damaged.
machine
• Engine oil level switch signal can be checked with monitoring function.
Related infor-
mation
• Method of reproducing failure code: Turn starting switch ON.

Lowering of engine oil level a Check the engine oil level and add new oil.
1
(when system is normal) (If this phenomenon frequently occurs, investigate the cause.)
Defective engine oil level P44 (male) Engine oil level Resistance
2 switch
(Internal disconnection) Value in normal state Max. 1 z
sis ground Value when oil level is
Min. 1Mz
Possible causes low
and standard Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshoot-
value in normal ness ing without turning starting switch ON.
state
3 (Disconnection in wiring or
defective contact in connec- Wiring harness between P02 (female) (8) – Resis-
Max. 1 z
tor) H10 – A03 – P44 (female) (1) tance
a Prepare with starting switch OFF, then turn starting switch ON

and carry out troubleshooting.
P02 Engine oil level Voltage
4 Defective machine monitor
Value in normal state Max. 1 V
sis ground Value when oil level is
20 – 30 V
low
Circuit diagram related to engine oil level switch of machine monitor
Failure code [B@BCNS] Eng Water Overheat 1
Action code Failure code Engine coolant overheat

Trouble
— B@BCNS (Engine controller system)
Contents of
Engine coolant overheats while engine is running.
trouble
Action of
controller
Problem that
appears on
• If machine is operated as it is, engine may be damaged.
machine
Related
information

Possible causes Engine coolant may be overheating. Check it directly and remove cause
1 Engine coolant overheat
and standard if it is overheating.
value in normal If cause 1 is not detected, coolant temperature sensor system may be
state Defective coolant tempera-
2 detective. Carry out troubleshooting for the failure codes [CA144] and
ture sensor system
[CA145].
Failure code [B@BCZK] Eng Water Level Low 1
Action code Failure code Engine coolant level low

Trouble
— B@BCZK (Machine monitor)
Contents of • While engine was running, signal circuit of radiator coolant level switch was opened (disconnected
trouble with GND).
Action of
tor
Problem that
appears on • If machine is operated as it is, engine may overheat.
machine
• If radiator coolant level caution symbol appears on the machine monitor while the engine is running,
Related infor- this failure code will be recorded.
mation • Input from the radiator coolant level switch (ON/OFF) can be checked with monitoring function.

Lowering of radiator coolant
a Check the coolant level and add coolant.
1 level
(If this phenomenon frequently occurs, investigate the cause.)
(when system is normal)
Defective radiator coolant P24 (male) Radiator coolant level Resistance
2 level switch (internal discon-
nection) Value in normal state Max. 1 z
Between (1) – (2) Value when coolant
Min. 1Mz
level is low
Possible causes
value in normal Disconnection in wiring har- ing without turning starting switch ON.
state ness
Wiring harness between P02 (female) (3) – Resis-
P24 (female) (1) tance
Max. 1 z
P02 Radiator coolant level Voltage
Value in normal state Max. 1 V
sis ground Value when coolant
20 – 30 V
level is low
Circuit diagram related to radiator coolant level switch of machine monitor
Failure code [B@HANS] Hyd Oil Overheat 1

Action code Failure code Hydraulic oil overheat
Trouble
— B@HANS (Machine monitor system)
Contents of • While engine was running, signal circuit of hydraulic oil temperature sensor detected overheating of
trouble hydraulic oil (above about 102°C).
Action of • Displays hydraulic oil temperature monitor with red on machine monitor.
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • If machine is operated as it is, engine may be seized.
machine
• Hydraulic oil temperature sensor signal is input to engine controller and then transmitted to machine
monitor.
Related infor-
• Hydraulic oil temperature can be checked with monitoring function
mation
(Code: 04401 Hydraulic oil temperature)
• Method of reproducing failure code: Start engine.

Possible causes Overheating of hydraulic oil Hydraulic oil may be overheating. Check it and remove cause if it is
1
and standard (when system is normal) overheating.
value in normal If cause 1 is not detected, hydraulic oil temperature gauge system
state Defective hydraulic oil tem-
2 may be defective. Carry out troubleshooting for “E-12 Hydraulic oil
perature gauge system
temperature gauge does not work normally” in E-mode.
Failure code [CA111] EMC Critical Internal Failure 1

Action code Failure code Critical internal failure
Trouble
E10 CA111 (Engine controller system)
Contents of
• Memory or power supply circuit in engine controller is defective.
trouble
Action of
• None in particular.
controller
Problem that
appears on • Engine does not start.
machine
Related infor-
mation
Possible causes Cause Standard value in normal state/Remarks on troubleshooting

and standard
value in normal 1 Carry out troubleshooting for failure code [CA757].
state
10 PC228US, 228USLC-3E0
Failure code [CA115] Eng Ne and Bkup Speed Sens Error 1

Action code Failure code Engine Ne and Bkup speed sensor error
Trouble
Contents of
• Both signals of engine Ne speed sensor and engine Bkup speed sensor are abnormal.
trouble
Action of
controller
Problem that
• Engine stops.
appears on
• Engine does not start.
machine
Related infor-
mation

Defective Ne speed sensor Ne speed sensor may be connected defective. Carry out trouble-
1
system shooting for code [CA689].
Defective Bkup speed sen- Bkup speed sensor may be connected defective. Carry out trouble-
2
sor system shooting for code [CA778].
Possible causes
Defective mount of Ne speed Check mount of Ne speed sensor directly for defect (defective
and standard 3
sensor installation of sensor, internal trouble of flywheel, etc)
value in normal
state Defective mount of Bkup Check mount of Bkup speed sensor directly for defect (defective
4
speed sensor installation of sensor, internal trouble of supply pump, etc)
Defective connection (Wrong Check Ne speed sensor and Bkup speed sensor directly for defec-
5
connection) of sensor tive connection (wrong connection).
If causes 1 – 5 are not detected, engine controller may be defective.
6 Defective engine controller
(Since trouble is in system, troubleshooting cannot be carried out.)
PC228US, 228USLC-3E0 11
Failure code [CA122] Chg Air Press Sensor High Error 1

Action code Failure code Charge air pressure sensor high error
Trouble
Contents of
• Pressure signal circuit of boost pressure/temperature sensor detected high voltage.
trouble
Action of
• Fixes charge pressure value and continues operation.
controller
Problem that
appears on • Engine output lowers.
machine
• Signal voltage on boost pressure side of boost pressure/temperature sensor can be checked with
Related infor-
monitoring function. (Code: 36501 Boost pressure sensor voltage)
mation

Defective sensor power sup- If failure code [CA227] is also indicated, carry out troubleshooting
1
ply 2 system for it first.
Defective boost pressure/ BOOST PRESS & IMT Voltage
2 temperature sensor [pres- Between (3) – (1) Power supply 4.75 – 5.25 V
sure signal system]
Voltage is measured with wiring harness connected. Accordingly, if
voltage is abnormal, check wiring harness and controller, too, for
another cause of trouble, and then judge.
Hot short (Short circuit with 5 and carry out troubleshooting.
3 V/24 V circuit) in wiring har-
ness Wiring harness between CE01 (female) (44)
Possible causes Voltage Max. 1 V
– BOOST PRESS & IMT (female) (4)
and standard
a Prepare with starting switch OFF, then carry out troubleshooting
value in normal
without turning starting switch ON.
state Short circuit in wiring har-
4 ness (with another wiring Wiring harness between CE01 (female) (44)
harness) – BOOST PRESS & IMT (female) (4) and Resis- Min. 100
between CE01 (female) (37) – JC01 – tance kz
BOOST PRESS & IMT (female) (3)
Connecting parts between boost pressure/temperature sensor –
engine wiring harness – engine controller may be defective. Check
Defective wiring harness them directly.
5
connector • Looseness of connector, breakage of lock, or breakage of seal
• Corrosion, bend, breakage, push-in, or expansion of pin
• Moisture or dirt in connector or defective insulation
CE01 Voltage
Between (37) – (47) Power supply 4.75 – 5.25 V
12 PC228US, 228USLC-3E0
Circuit diagram related to charge air pressure, temperature sensor (combination sensor)
PC228US, 228USLC-3E0 13
Failure code [CA123] Chg Air Press Sensor Low Error 1
Action code Failure code Charge air pressure sensor low error
Trouble
Contents of
• Pressure signal circuit of charge air pressure, temperature sensor detected low voltage.
trouble
Action of con-
• Fixes charge pressure value and continues operation.
troller
Problem that
machine
Related infor-
mation

1
Defective charge air pres- BOOST PRESS & IMT Voltage
2 sure, temperature sensor Between (1) – (4) Power supply 4.75 – 5.25 V
[pressure signal system]
Ground fault in wiring har- ing without turning starting switch ON.
ness
3 Wiring harness between CE01 (female) (44)
(Short circuit with GND cir- Resis- Min.
Possible causes cuit) – BOOST PRESS & IMT (female) (4) and
tance 100 kz
and standard chassis ground
value in normal a Prepare with starting switch OFF, then carry out troubleshoot-
state ing without turning starting switch ON.
Short circuit in wiring har-
4 ness Wiring harness between CE01 (female) (44)
(with another wiring harness) – BOOST PRESS & IMT (female) (4) and Resis- Min.
between CE01 (female) (47) – BOOST tance 100 kz
PRESS & IMT (female) (1)
Connecting parts between charge air pressure, temperature sensor
– engine wiring harness – engine controller may be defective.
Defective wiring harness Check them directly.
5
CE01 Voltage
14 PC228US, 228USLC-3E0
Circuit diagram related to charge air pressure, temperature sensor (combination sensor)
PC228US, 228USLC-3E0 15
Failure code [CA131] Throttle Sensor High Error 1

Action code Failure code Throttle sensor high error
Trouble
Contents of
• Signal circuit of fuel control dial detected high voltage.
trouble
• If trouble occurs while starting switch is in ON position, controller fixes voltage value to level just
Action of before detection of trouble and continues operation.
controller • If starting switch is turned ON while voltage is abnormally high, controller continues operation with
voltage at 100% value.
Problem that
appears on • Engine speed cannot be controlled with fuel control dial.
machine
• Signal voltage of fuel control dial can be checked with monitoring function. (Code: 03000 Fuel control
Related infor-
dial voltage)
mation

Defective throttle sensor If failure code [CA2185] is also indicated, carry out troubleshooting
1
power supply system for it first.
P20 Voltage
2 Defective fuel control dial Between (1) – (3) Power supply 4.75 – 5.25 V
Hot short (Short circuit with 5 and carry out troubleshooting.
3 V/24 V circuit) in wiring har-
Possible causes Wiring harness between CE02 (female) (9) –
ness Voltage Max. 1 V
and standard P20 (female) (2)
value in normal
state
Short circuit in wiring har- without turning starting switch ON.
4 ness (with another wiring Wiring harness between CE02 (female) (9) –
harness) Resis- Min. 100
P20 (female) (2) and between CE02 (female)
tance kz
(22) – P20 (female) (1)
Connecting parts between fuel control dial – machine wiring har-
ness – engine controller may be defective. Check them directly.
Defective wiring harness
5 • Looseness of connector, breakage of lock, or breakage of seal
connector
CE02 Voltage
16 PC228US, 228USLC-3E0
Circuit diagram related to fuel control dial
PC228US, 228USLC-3E0 17
Failure code [CA132] Throttle Sensor Low Error 1

Action code Failure code Throttle sensor low error
Trouble
Contents of
• Signal circuit of fuel control dial detected low voltage.
trouble
Problem that
machine
• Signal voltage of fuel control dial can be checked with monitoring function. (Code: 03000 Fuel control
Related infor-
dial voltage)
mation

Defective throttle sensor If failure code [CA2186] is also indicated, carry out troubleshooting
1
P20 Voltage
2 Defective fuel control dial Between (1) – (3) Power supply 4.75 – 5.25 V
Ground fault in wiring har- without turning starting switch ON.
3 ness (Short circuit with GND
Possible causes Wiring harness between CE02 (female) (9) – Resis- Min. 100
circuit)
and standard P20 (female) (2) tance kz
value in normal
state
P20 (female) (2) and between CE02 (female)
tance kz
(23) – P20 (female) (3)
connector
CE02 Voltage
18 PC228US, 228USLC-3E0
PC228US, 228USLC-3E0 19
Failure code [CA144] Coolant Temp Sens High Error 1

Action code Failure code Coolant temperature sensor high error
Trouble
Contents of
• Signal circuit of coolant temperature sensor detected high voltage.
trouble
Action of
• Fixes coolant temperature value and continues operation.
controller
Problem that • Engine does not start easily at low temperature.
appears on • Exhaust gas becomes white.
machine • Overheat prevention function does not work.
• Signal voltage of coolant temperature sensor can be checked with monitoring function. (Code: 04105
Related infor-
Coolant temperature sensor voltage)
mation

COOLANT TEMP
Coolant temperature Resistance
(male)
Defective coolant tempera- 0°C 30 – 37 kz
1
ture sensor
25°C 9.3 – 10.7 kz
Between (A) – (B) 50°C 3.2 – 3.8 kz
80°C 1.0 – 1.3 kz
95°C 700 – 800 z
Disconnection in wiring har- without turning starting switch ON.
ness (Disconnection in wiring Wiring harness between CE01 (female) (15) Resis-
2 Max. 10 z
or defective contact in con- – COOLANT TEMP (female) (B) tance
nector) Wiring harness between CE01 (female) (38) Resis-
Max. 10 z
– JC03 – COOLANT TEMP (female) (A) tance
Possible causes
and standard a Prepare with starting switch OFF, then carry out troubleshooting
value in normal Short circuit in wiring har- without turning starting switch ON.
state 3 ness (with another wiring Wiring harness between CE01 (female) (15)
– each of CE01 (female) pins (With all wiring
tance kz
harness connectors disconnected)
Connecting parts between coolant temperature sensor – engine wir-
ing harness – engine controller may be defective. Check them
Defective wiring harness directly.
4
CE01 (female) Coolant temperature Resistance
0°C 30 – 37 kz
25°C 9.3 – 10.7 kz
Between (15) – (38) 50°C 3.2 – 3.8 kz
80°C 1.0 – 1.3 kz
95°C 700 – 800 z
20 PC228US, 228USLC-3E0
Circuit diagram related to engine coolant temperature sensor
PC228US, 228USLC-3E0 21
Failure code [CA145] Coolant Temp Sens Low Error 1
Action code Failure code Coolant temperature sensor low error

Trouble
Contents of
• Signal circuit of coolant temperature sensor detected low voltage.
trouble
Action of con-
• Fixes coolant temperature value and continues operation.
troller
Problem that • Engine does not start easily at low temperature.
appears on • Exhaust gas becomes white.
machine • Overheat prevention function does not work.
Related infor-
mation

COOLANT TEMP
Coolant temperature Resistance
(male)
Defective coolant tempera- 0°C 29 – 36 kz

1
ture sensor 25°C 9 – 11 kz
Between (A) – (B)
40°C 4.9 – 5.8 kz
100°C 600 – 700 z
Between (B) –
All range Min. 100 kz
chassis ground
ness
cuit) – COOLANT TEMP (female) (B) and chassis
tance 100 kz
ground
Possible causes a Prepare with starting switch OFF, then carry out troubleshoot-
and standard ing without turning starting switch ON.
value in normal 3 ness
state Between CE01 (female) (15) – each of CE01
(with another wiring harness) (female) pins (With all wiring harness con- Resis- Min.
tance 100 kz
nectors disconnected)
4
CE01 (female) Coolant temperature Resistance
0°C 29 – 36 kz
5 Defective engine controller 25°C 9 – 11 kz
Between (15) – (38)
40°C 4.9 – 5.8 kz
100°C 600 – 700 z
Between (15) –
chassis ground
22 PC228US, 228USLC-3E0
PC228US, 228USLC-3E0 23
Failure code [CA153] Chg Air Temp Sensor High Error 1

Action code Failure code Charge air temperature sensor high error
Trouble
Contents of
• Temperature signal circuit of boost pressure/temperature sensor detected high voltage.
trouble
Action of
• Fixes charge temperature value and continues operation.
controller
Problem that
• Exhaust gas becomes white.
appears on
• Engine protection function based on boost temperature does not work
machine
• Signal voltage on boost temperature side of boost pressure/temperature sensor can be checked with
Related infor-
monitoring function. (Code: 18501 Boost temperature sensor voltage)
mation

BOOST PRESS
Charge temperature Resistance
Defective boost pressure/ & IMT (male)
1 temperature sensor [temper- 0°C 29 – 36 kz
ature signal system]
25°C 9 – 11 kz
Between (2) – (1)
40°C 4.9 – 5.8 kz
100°C 600 – 700 z
2 Max. 10 z
or defective contact in con- – BOOST PRESS & IMT (female) (2) tance
Max. 10 z
– JC02 – BOOST PRESS & IMT (female) (1) tance
Possible causes
tance kz
Connecting parts between boost pressure/temperature sensor –
engine wiring harness – engine controller may be defective. Check
Defective wiring harness them directly.
4
CE01 (female) Charge temperature Resistance
25°C 9 – 11 kz
Between (23) – (47)
40°C 4.9 – 5.8 kz
100°C 600 – 700 z
24 PC228US, 228USLC-3E0
Circuit diagram related to boost pressure, temperature sensor (combination sensor)
PC228US, 228USLC-3E0 25
Failure code [CA154] Chg Air Temp Sensor Low Error 1
Action code Failure code Charge air temperature sensor low error
Trouble
Contents of
• Temperature signal circuit of boost pressure, temperature sensor detected low voltage.
trouble
Action of con-
troller
Problem that
• Exhaust gas becomes white.
appears on
• Engine protection function based on boost temperature does not work
machine
Related infor-
mation

BOOST PRESS
Charge temperature Resistance
& IMT (male)
Defective boost pressure, 0°C 29 – 35 kz
1 temperature sensor [temper-
25°C 9 – 11 kz
ature signal system] Between (2) – (1)
40°C 4.9 – 5.8 kz
100°C 600 – 700 z
Between (2) –
chassis ground
ness
– BOOST PRESS & IMT (female) (3) and
cuit) tance 100 z
chassis ground
and standard ing without turning starting switch ON.
value in normal 3 ness
state Between CE01 (female) (23) – each of CE01
(with another wiring harness) (female) pins (With all wiring harness con- Resis- Min.
tance 100 kz
Connecting parts between charge air pressure, temperature sensor
– engine wiring harness – engine controller may be defective.
Defective wiring harness Check them directly.
4
CE01 (female) Charge temperature Resistance
0°C 29 – 35 kz
Between (23) – (47)
40°C 4.9 – 5.8 kz
100°C 600 – 700 z
Between (23) –
chassis ground
26 PC228US, 228USLC-3E0
Circuit diagram related to boost pressure/temperature sensor (Combination sensor)
PC228US, 228USLC-3E0 27
Failure code [CA155] Chg Air Temp High Speed Derate 1

Action code Failure code Charge air temperature high speed derate
Trouble
Contents of
• Temperature signal of boost pressure/temperature sensor exceeded control upper temperature limit.
trouble
Action of
controller
Problem that
appears on
• Engine stops.
machine
Related infor- • Boost temperature can be checked with monitoring function. (Code: 18500 Boost temperature)
mation • Method of reproducing failure code: Start engine

Cooling performance of aftercooler may be low. Check following
points directly.
Lowering of cooling perfor-
Possible causes 1 • Looseness and breakage of fan belt.
mance of aftercooler
and standard • Insufficiency of cooling air
value in normal • Clogging of aftercooler fins
state Abnormal rise of turbo- Outlet temperature of turbocharger may be abnormally high. Check
2
charger outlet temperature related parts directly.
28 PC228US, 228USLC-3E0
PC228US, 228USLC-3E0 29
Failure code [CA187] Sens Supply 2 Volt Low Error 1

Action code Failure code Sensor power supply 2 voltage low error
Trouble
Contents of
• Low voltage was detected in sensor power supply 2 circuit.
trouble
• Fixes boost pressure value and continues operation.
Action of
controller
Problem that
machine
Related infor-
mation

a Disconnect connector with starting switch OFF, then turn starting
switch ON and carry out troubleshooting.
Disconnect sensors Boost pressure/tem- BOOST PRESS &
and wiring harness at perature sensor IMT
right in order and
Defective sensor or wiring carry out operation to Common rail pres-
1 FUEL RAIL PRESS
harness reproduce trouble. If sure sensor
“E” of failure code
Possible causes
goes off when a sen-
and standard Bkup sensor CAM SENSOR
sor or wiring harness
value in normal
is disconnected, that
state Engine wiring har-
sensor or wiring har- CE01
ness is defective. ness
Connecting parts between each sensor – engine wiring harness –
engine controller may be defective. Check them directly.
connector
30 PC228US, 228USLC-3E0
Circuit diagram related to sensor power supply 2
PC228US, 228USLC-3E0 31
Failure code [CA221] Ambient Press Sens High Error 1

Action code Failure code Ambient pressure sensor high error
Trouble
Contents of
• High voltage was detected in signal circuit of ambient pressure sensor.
trouble
Action of
• Fixes ambient pressure value and continues operation.
controller
Problem that
• Engine does not start easily.
appears on
machine
• Signal voltage of ambient pressure sensor can be checked with monitoring function. (Code: 37401
Related infor-
Ambient pressure sensor voltage
mation

1
AMBAIR PRESSURE Voltage
Defective ambient pressure
2 Between (1) – (2) Power supply 4.75 – 5.25V
sensor
Hot short (Short circuit with and carry out troubleshooting.
3 5V/24V circuit) in wiring har-
Possible causes ness Wiring harness between CE01 (female) (3) –
Voltage Max. 1 V
and standard AMBAIR PRESSURE (female) (3)
value in normal a Prepare with starting switch OFF, then carry out troubleshooting
state without turning starting switch ON.
harness) AMBAIR PRESSURE (female) (3) and Resis- Min. 100
between CE01 (female) (33) – AMBAIR tance kz
PRESSURE (female) (1)
Connecting parts between ambient pressure sensor – engine wiring
harness – engine controller may be defective. Check them directly.
connector
CE01 Voltage
Between (33) – (38) Voltage 4.75 – 5.25 V
32 PC228US, 228USLC-3E0
Circuit diagram related to atmospheric pressure sensor
PC228US, 228USLC-3E0 33
Failure code [CA222] Ambient Press Sens Low Error 1

Action code Failure code Ambient pressure sensor low error
Trouble
Contents of
• Low voltage was detected in signal circuit of ambient pressure sensor.
trouble
Action of
controller
Problem that
appears on
machine
• Signal voltage of ambient pressure sensor can be checked with monitoring function. (Code: 37401
Related infor-
Ambient pressure sensor voltage
mation

1
AMBAIR PRESSURE Voltage
Defective ambient pressure
2 Between (1) – (2) Power supply 4.75 – 5.25V
sensor
Possible causes circuit) Wiring harness between CE01 (female) (3) – Resis- Min. 100
and standard AMBAIR PRESSURE (female) (3) tance kz
state without turning starting switch ON.
harness) AMBAIR PRESSURE (female) (3) and Resis- Min. 100
between CE01 (female) (38) – JC03 – tance kz
AMBAIR PRESSURE (female) (2)
connector
CE01 Voltage
Between (33) – (38) Voltage 4.75 – 5.25 V
34 PC228US, 228USLC-3E0
Circuit diagram related to atmospheric pressure sensor
PC228US, 228USLC-3E0 35
Failure code [CA227] Sens Supply 2 Volt High Error 1

Action code Failure code Sensor power supply 2 voltage high error
Trouble
Contents of
• High voltage was detected in sensor power supply 2 circuit.
trouble
• Fixes boost pressure value and continues operation.
Action of
controller
Problem that
machine
Related infor-
mation

Possible causes engine controller may be defective. Check them directly.
and standard 1 • Looseness of connector, breakage of lock, or breakage of seal
connector
value in normal • Corrosion, bend, breakage, push-in, or expansion of pin
state • Moisture or dirt in connector or defective insulation
If cause 1 is not detected, engine controller may be defective.
36 PC228US, 228USLC-3E0
Failure code [CA234] Eng. Overspeed 1
Action code Failure code Engine overspeed

Trouble
— CA234 (Engine controller system)
Contents of
• Engine speed exceeded control upper speed limit.
trouble
Action of con-
• Stops injection until engine speed lowers to normal level.
troller
Problem that
appears on • Engine speed fluctuates.
machine
Related infor-
• Method of reproducing failure code: Run engine at high idle.
mation

1 Use of improper fuel Fuel used may be improper. Check it directly.
Possible causes
and standard Machine may be used improperly. Teach operator proper using
2 Improper use
value in normal method.
state If causes 1 and 2 are not detected, engine controller may be defec-
3 Defective engine controller tive. (Since trouble is in system, troubleshooting cannot be carried
out.)
PC228US, 228USLC-3E0 37
Failure code [CA238] Ne Speed Sens Supply Volt Error 1

Action code Failure code Ne speed sensor power supply voltage error
Trouble
Contents of
• Low voltage was detected in power supply circuit of engine Ne speed sensor.
trouble
Action of
• Continues control with signal from engine Bkup speed sensor.
controller
Problem that
appears on
• Engine hunts.
machine
Related infor-
mation

Disconnect sensor
and wiring harness at
right in order and Ne speed sensor CRANK SENSOR
Defective sensor or wiring carry out operation to
1 reproduce trouble. If
Possible causes harness
and standard “E” of failure code
value in normal goes off when sensor
state or wiring harness is Engine wiring har-
disconnected, that CE01
ness
sensor or wiring har-
ness is defective.
connector
Circuit diagram related to engine Ne speed sensor
38 PC228US, 228USLC-3E0
Failure code [CA271] IMV/PCV1 Short Error 1
Action code Failure code IMV/PCV1 short error

Trouble
Contents of
• Short circuit was detected in drive circuit of supply pump actuator.
trouble
Action of con-
troller
Problem that • Engine speed does not rise from low idle.
machine • Common rail fuel pressure rises above command value.
Related infor-
mation

Defective supply pump actu- ing without turning starting switch ON.
1
ator CP3 PUMP REGULATOR (male) Resistance
Between (1) – chassis ground Min. 100 kz
ness
2 Wiring harness between CE01 (female) (2) –
cuit) CP3 PUMP REGULATOR (female) (1) and
tance 100 kz
chassis ground
and standard Short circuit in wiring har- ing without turning starting switch ON.
value in normal
3 ness Between CE01 (female) (2) – each of CE01
state Resis- Min.
(with another wiring harness) (female) pins (With all wiring harness con-
tance 100 kz
Connecting parts between supply pump actuator – engine wiring
connector
CE01 (female) Resistance
Circuit diagram related to supply pump actuator (metering unit)
PC228US, 228USLC-3E0 39
Failure code [CA272] IMV/PCV1 Open Error 1

Action code Failure code IMV/PCV1 open error
Trouble
Contents of
• Opening was detected in drive circuit of supply pump actuator.
trouble
Action of
controller
Problem that
• Engine runs but its operation is unstable.
appears on
• Common rail fuel pressure rises above command value.
machine
Related infor-
mation

Defective supply pump actu- without turning starting switch ON.
1
ator CP3 PUMP REGULATOR (male) Resistance
Between (1) – (2) Max. 5 z
ness (Disconnection in wiring Wiring harness between CE01 (female) (2) – Resis-
2 Max. 10 z
or defective contact in con- CP3 PUMP REGULATOR (female) (1) tance
Max. 10 z
– CP3 PUMP REGULATOR (female) (2) tance
Possible causes 3
24V circuit) in wiring harness Wiring harness between CE01 (female) (2) –
and standard Voltage Max. 3 V
CP3 PUMP REGULATOR (female) (1)
value in normal
state a Prepare with starting switch OFF, then carry out troubleshooting
Short circuit in wiring harness
4 Wiring harness between CE01 (female) (2) –
(with another wiring harness) Resis- Min. 100
each of CE01 (female) pins (With all wiring
tance kz
connector
40 PC228US, 228USLC-3E0
PC228US, 228USLC-3E0 41
Failure code [CA322] Inj #1 (L#1) Open/Short Error 1

Action code Failure code Injector #1 (L#1) open/short circuit error
Trouble
Contents of
• Opening or short circuit was detected in drive circuit of No. 1 injector.
trouble
Action of
controller
Problem that
• Combustion becomes irregular or engine hunts.
appears on
machine
Related infor-
mation

1 Defective No. 1 injector INJ CYL 1 (Injector unit) Resistance
2 Max. 2 z
or defective contact in con- – INJ CYL 1 (1) tance
Max. 2 z
– INJ CYL 1 (2) tance
Wiring harness between CE01 (female) (45) Resis-
circuit) Max. 2 z
Possible causes a Prepare with starting switch OFF, then carry out troubleshooting
and standard without turning starting switch ON.
value in normal
state Wiring harness between CE01 (female) (45)
Resis- Min. 100
Short circuit in wiring harness – each of CE01 (female) pins (With all wiring
4 tance kz
(with another wiring harness) harness connectors disconnected)
Wiring harness between CE01 (female) (53)
Resis- Min. 100
tance kz
Connecting parts between No. 1 injector – engine wiring harness –
connector
Defective other cylinder If the failure codes of other injectors are displayed, carry out trouble-
6
injectors or wiring harness shooting of them, too.
7 Defective engine controller CE01 (female) Resistance
Between (45) – (53) Max. 2 z
42 PC228US, 228USLC-3E0
Related electrical circuit diagram
PC228US, 228USLC-3E0 43

Trouble
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related infor-
mation

2 Max. 2 z
Max. 2 z
circuit) Max. 2 z
value in normal
Resis- Min. 100
4 tance kz
Resis- Min. 100
tance kz
connector
6
Between (46) – (60) Max. 2 z
44 PC228US, 228USLC-3E0
PC228US, 228USLC-3E0 45

Trouble
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related infor-
mation

2 Max. 2 z
Max. 2 z
circuit) Max. 2 z
value in normal
Resis- Min. 100
4 tance kz
Resis- Min. 100
tance kz
connector
6
Between (55) – (52) Max. 2 z
46 PC228US, 228USLC-3E0
PC228US, 228USLC-3E0 47

Trouble
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related infor-
mation

2 Max. 2 z
Max. 2 z
circuit) Max. 2 z
value in normal
Resis- Min. 100
4 tance kz
Resis- Min. 100
tance kz
connector
6
Between (57) – (59) Max. 2 z
48 PC228US, 228USLC-3E0
PC228US, 228USLC-3E0 49

Trouble
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related infor-
mation

2 Max. 2 z
Max. 2 z
circuit) Max. 2 z
value in normal
Resis- Min. 100
4 tance kz
Resis- Min. 100
tance kz
connector
6
Between (54) – (51) Max. 2 z
50 PC228US, 228USLC-3E0
PC228US, 228USLC-3E0 51

Trouble
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related infor-
mation

2 Max. 2 z
Max. 2 z
circuit) Max. 2 z
value in normal
Resis- Min. 100
4 tance kz
Resis- Min. 100
tance kz
connector
6
Between (56) – (58) Max. 2 z
52 PC228US, 228USLC-3E0
PC228US, 228USLC-3E0 53
SEN01884-02

© 2009 KOMATSU
All Rights Reserved
54
SEN01885-04
PC228US-3E0
PC228USLC-3E0

Failure code [CA342] Calibration Code Incompatibility................................................................................... 3
Failure code [CA351] Injectors Drive Circuit Error .......................................................................................... 4
Failure code [CA352] Sens Supply 1 Volt Low Error ...................................................................................... 6
Failure code [CA386] Sens Supply 1 Volt High Error...................................................................................... 8
Failure code [CA428] Water in Fuel Sensor High Error ................................................................................ 10
Failure code [CA429] Water in Fuel Sensor Low Error ................................................................................. 12
Failure code [CA435] Eng Oil Press Sw Error .............................................................................................. 14
Failure code [CA441] Battery Voltage Low Error .......................................................................................... 15
Failure code [CA442] Battery Voltage High Error ......................................................................................... 18
Failure code [CA449] Rail Press Very High Error ......................................................................................... 20
Failure code [CA451] Rail Press Sensor High Error ..................................................................................... 22
Failure code [CA452] Rail Press Sensor Low Error...................................................................................... 24
Failure code [CA488] Chg Air Temp High Torque Derate ............................................................................. 26
Failure code [CA553] Rail Press High Error ................................................................................................. 26
Failure code [CA559] Rail Press Low Error .................................................................................................. 27

Failure code [CA689] Eng Ne Speed Sensor Error....................................................................................... 29
Failure code [CA731] Eng Bkup Speed Sens Phase Error ........................................................................... 31
Failure code [CA757] All Continuous Data Lost Error................................................................................... 32
Failure code [CA778] Eng Bkup Speed Sensor Error ................................................................................... 34
Failure code [CA1633] KOMNET Datalink Timeout Error ............................................................................. 36
Failure code [CA2185] Throt Sens Sup Volt High Error ................................................................................ 38
Failure code [CA2186] Throt Sens Sup Volt Low Error................................................................................. 39
Failure code [CA2249] Rail Press Very Low Error ........................................................................................ 40
Failure code [CA2311] IMV Solenoid Error ................................................................................................... 42
Failure code [CA2555] Grid Htr Relay Volt High Error .................................................................................. 44
Failure code [CA2556] Grid Htr Relay Volt Low Error ................................................................................... 46
Failure code [CA342] Calibration Code Incompatibility 1

Action code Failure code Calibration code incompatibility
Trouble
Contents of
• Incompatibility of data occurred in engine controller.
trouble
Action of
controller
Problem that
• Continues normal operation.
appears on
• Engine stops or does not start.
machine
Related infor-
mation

and standard
state
Failure code [CA351] Injectors Drive Circuit Error 1

Action code Failure code Injectors Drive Circuit Error
Trouble
Contents of
• There is error in drive power circuit of injector.
trouble
Action of
controller
• Exhaust gas becomes black.
Problem that
• Combustion becomes irregular.
appears on
machine
• Engine cannot be started.
Related infor-
mation

1 Defect in related system If another failure code is displayed, carry out troubleshooting for it.
2 Defective fuse No. 19 If fuse is broken, circuit probably has ground fault.
Defective relay for engine
3 Replace relay (R23, R24) for engine controller with another relay
controller power supply
and perform reproducing operation. If “E” of failure code goes off at
Possible causes this time, replaced relay is defective.
value in normal without turning starting switch ON.
state
Disconnection in wiring har- Wiring harness between F01-19 – R23, R24 Resis- Max.
ness (Disconnection in wiring (female) (3) tance 0.5 z
4
or defective contact in con- Wiring harness between R23, R24 (female) Resis- Max.
nector) (5) – CE03 (female) (3) tance 0.5 z
Wiring harness between CE03 (female) (1) – Resis-
Max. 10 z
chassis ground (T12) tance
Circuit diagram related to engine controller power supply
Failure code [CA352] Sens Supply 1 Volt Low Error 1

Action code Failure code Sensor power supply 1 voltage low error
Trouble
Contents of
• Low voltage was detected in sensor power supply 1 circuit.
trouble
Action of
controller
Problem that
appears on
machine
Related infor-
mation

Disconnect sensor
and wiring harness at
right in order and Ambient pressure
AMBAIR PRESURE
carry out operation to sensor
Defective sensor or wiring
1 reproduce trouble. If
harness
“E” of failure code
Possible causes
goes off when sensor
and standard
or wiring harness is Engine wiring har-
value in normal CE01
disconnected, that ness
state
sensor or wiring har-
ness is defective.
connector
Failure code [CA386] Sens Supply 1 Volt High Error 1

Action code Failure code Sensor power supply 1 voltage high error
Trouble
Contents of
• High voltage was detected in sensor power supply 1 circuit.
trouble
Action of
controller
Problem that
appears on
machine
Related infor-
mation

Possible causes harness – engine controller may be defective. Check them directly.
and standard 1 • Looseness of connector, breakage of lock, or breakage of seal
connector
value in normal • Corrosion, bend, breakage, push-in, or expansion of pin
state • Moisture or dirt in connector or defective insulation
If cause 1 is not detected, engine controller may be defective.
Failure code [CA428] Water in Fuel Sensor High Error 1

Action code Failure code Water-in-fuel sensor high error
Trouble
Contents of
• High voltage was detected in signal circuit of water-in-fuel sensor.
trouble
Action of
controller
Problem that
appears on • Water separator monitor does not display normally.
machine
• Condition water-in-fuel sensor signal can be checked with monitoring function. (Code: 18800 Condi-
Related infor-
tion of WIF sensor)
mation

Defective water-in-fuel sen- without turning starting switch ON.
1
sor P47 (female) Resistance
Between (1) – (2) Max. 100 kz
2 Max. 10 z
or defective contact in con- – P47 (female) (1) tance
Max. 10 z
– P47 (female) (2) tance
Possible causes
harness) Resis- Min.
tance 100 kz
Connecting parts between water-in-fuel sensor – engine wiring har-
connector
Between (14) – (47) Max. 100 kz
10 PC228US, 228USLC-3E0
Circuit diagram related to water-in-fuel sensor
PC228US, 228USLC-3E0 11
Failure code [CA429] Water in Fuel Sensor Low Error 1
Action code Failure code Water-in-fuel sensor low error

Trouble
Contents of
• Low voltage was detected in signal circuit of water-in-fuel sensor.
trouble
Action of con-
troller
Problem that
appears on • Water separator monitor does not display normally.
machine
Related infor-
mation

Defective water-in-fuel sen- P47 (female) Resistance
1
sor
Between (1) – (2) Max. 100 kz
Ground fault in wiring har- a Prepare with starting switch OFF, then carry out troubleshoot-
2
(Short circuit with GND cir- Wiring harness between CE01 (female) (14) Resis- Min.
cuit) – P47 (female) (1) and chassis ground tance 100 kz
and standard Short circuit in wiring har- ing without turning starting switch ON.
value in normal 3 ness Between CE01 (female) (14) – each of CE01
state (with another wiring harness) (female) pins (With all wiring harness con- Resis- Min.
tance 100 kz
Connecting parts between water-in-fuel sensor – engine wiring har-
connector
Between (14) – (47) Max. 100 kz
12 PC228US, 228USLC-3E0
Circuit diagram related to water-in-fuel sensor
PC228US, 228USLC-3E0 13
Failure code [CA435] Eng Oil Press Sw Error 1

Action code Failure code Engine oil pressure switch error
Trouble
Contents of
• There is error in signal circuit of engine oil pressure switch.
trouble
Action of
controller
Problem that
• Engine protection function based on engine oil pressure does not work.
appears on
• Engine oil pressure monitor does not display normally
machine
Related infor-
• Method of reproducing failure code: Turn starting switch ON or start engine.
mation

Defective engine oil pressure without turning starting switch ON.
1
switch OIL PRESSURE SWITCH (male) Resistance
Between (1) – chassis ground Max. 10 z
Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting
ness (Disconnection in wiring without turning starting switch ON.
2
or defective contact in con- Wiring harness between CE01 (female) (17) Resis-
nector) Max. 10 z
– OIL PRESSURE SWITCH (male) (1) tance
Possible causes Short circuit in wiring har- without turning starting switch ON.
and standard 3 ness (with another wiring Wiring harness between CE01 (female) (17)
value in normal harness) Resis- Min.
state tance 100 kz
Connecting parts between engine oil pressure switch – engine wir-
4
Between (17) – chassis ground Max. 10 z
Circuit diagram related to engine oil pressure switch
14 PC228US, 228USLC-3E0
Failure code [CA441] Battery Voltage Low Error 1

Action code Failure code Battery voltage low error
Trouble
Contents of
• There is low voltage in controller power supply circuit.
trouble
Action of con-
troller
Problem that
• Engine stops.
appears on
machine
Related infor-
mation

Looseness or corrosion of
1 Battery terminal may be loosened or corroded. Check it directly.
battery terminal
a Prepare with starting switch OFF, then keep starting switch
OFF and turn it to START and carry out troubleshooting in each
case.
2 Defective battery voltage
Battery (1 piece) Starting switch Voltage
Between (+) – (–) ter- OFF Min. 12 V
minals START Min. 6.2 V
3 Defective fuse No. 19 If fuse is broken, circuit probably has ground fault. (See Cause 6)
this time, replaced relay is defective.
Disconnection in wiring har-
Wiring harness between F01-19 – R23, R24 Resis-
Possible causes ness Max. 10 z
and standard (female) (3) tance
value in normal Wiring harness between R23, R24 (female) Resis-
defective contact in connec- Max. 10 z
state tor) (5) – CE03 (female) (3) tance
Max. 10 z
ness Wiring harness between F01-19 – R23, R24 Resis- Min.
6
(Short circuit with GND cir- (female) (3) and chassis ground tance 100 kz
cuit) Wiring harness between R23, R24 (female) Resis- Min.
(5) – CE03 (female) (3) and chassis ground tance 100 kz
Between CE03 (female) (3) – CE03 (female) Resis- Min.
(1) pins (With battery terminal disconnected) tance 100 kz
Short circuit in wiring harness Between CE03 (female) (3) – each of CE02
7 Resis- Min.
(with another wiring harness) (female) pins (With battery terminal discon-
tance 100 kz
nected)
Between CE03 (female) (1) – each of CE02
Resis- Min.
(female) pins (With battery terminal discon-
tance 100 kz
nected)
PC228US, 228USLC-3E0 15

Connecting parts between fuse No. 19 – machine wiring harness –
Defective wiring harness con-
nector
Possible causes • Corrosion, bend, breakage, push-in, or expansion of pin
and standard • Moisture or dirt in connector or defective insulation
value in normal a Prepare with starting switch OFF, then turn starting switch ON
state and start engine and carry out troubleshooting in each case.
9 Defective engine controller CE03 (female) Starting switch Voltage
ON Min. 24 V
Between (3) – (1)
START Min. 12 V
16 PC228US, 228USLC-3E0
PC228US, 228USLC-3E0 17
Failure code [CA442] Battery Voltage High Error 1

Action code Failure code Battery voltage high error
Trouble
Contents of
• There is high voltage (36 V or higher) in controller power supply circuit.
trouble
Action of con-
troller
Problem that
appears on • Engine may stop.
machine
Related infor-
mation

1 Defective battery voltage
Battery Voltage
Between (+) – (–) terminals Max. 32 V
Possible causes a Prepare with starting switch OFF, then start engine and carry
and standard out troubleshooting.
value in normal 2 Defective alternator Alternator Engine speed Voltage
state
L terminal – chassis
Medium or higher 27.5 – 29.5 V
ground
CE03 (female) Voltage
Between (3) – (1) Max. 32 V
18 PC228US, 228USLC-3E0
PC228US, 228USLC-3E0 19
Failure code [CA449] Rail Press Very High Error 1

Action code Failure code Common rail pressure very high error
Trouble
Contents of
• There is high pressure error in common rail circuit.
trouble
Action of
controller
Problem that
• Engine sound becomes large when no or light load is applied.
appears on
machine
• Common rail pressure can be checked with monitoring function.
Related infor-
(Code: 36400 Common rail pressure)
mation

There may be air in low pressure circuit. Check it directly according
to the following procedure.
2 Air in low pressure circuit 1) Remove pressure pickup plug (outlet side) of fuel main filter.
2) Operate feed pump of fuel pre-filter.
3) Check pressure pickup plug for leakage of fuel and air.
a For check of fuel return circuit pressure, see Testing and adjust-
Defect in fuel return circuit ing, Checking fuel pressure.
3
parts Fuel return circuit Low idle running or Max. 0.02 MPa
Possible causes pressure cranking {Max. 0.19 kg/cm2}
and standard
a Prepare with starting switch ON, then keep starting switch ON
value in normal
and carry out troubleshooting in each case.
state
Monitoring code
Defective common rail pres- Monitoring information
4 (Machine monitor)
sure sensor
36400
While engine is 0 ± 0.39 MPa
Common rail
stopped {0 ± 4 kg/cm2}
pressure
a For check of leakage through pressure limiter, see Testing and
adjusting, Checking fuel return rate and leakage.
5 Defective pressure limiter
Leakage through
During low idle 0 cc (No leakage)
pressure limiter
6 Defective supply pump If causes 1 – 5 are not detected, supply pump may be defective.
20 PC228US, 228USLC-3E0
PC228US, 228USLC-3E0 21
Failure code [CA451] Rail Press Sensor High Error 1

Action code Failure code Common rail pressure sensor high error
Trouble
Contents of
• There is high voltage in signal circuit of common rail pressure sensor.
trouble
Action of
controller
Problem that
appears on
• Engine speed or output lowers.
machine
• Signal voltage of common rail pressure sensor can be checked with monitoring function.
Related infor-
(Code: 36401 Common rail pressure sensor voltage)
mation

Defective sensor power sup- If failure code [CA227] is also displayed, carry out troubleshooting
1
FUEL RAIL PRESS Voltage
Defective common rail pres-
2 Between (3) – (1) Power supply 4.75 – 5.25 V
sure sensor
Possible causes Voltage Max. 1 V
– FUEL RAIL PRESS (female) (2)
and standard
value in normal
harness) – FUEL RAIL PRESS (female) (2) and Resis- Min.
between CE01 (female) (37) – JC01 – FUEL tance 100 kz
RAIL PRESS (female) (3)
Connecting parts between common rail pressure sensor – engine
wiring harness – engine controller may be defective. Check them
5
CE01 Voltage
22 PC228US, 228USLC-3E0
Circuit diagram related to common rail pressure sensor and engine controller ground line
PC228US, 228USLC-3E0 23
Failure code [CA452] Rail Press Sensor Low Error 1

Action code Failure code Common rail pressure sensor low error
Trouble
Contents of
• There is low voltage in signal circuit of common rail pressure sensor.
trouble
Action of
controller
Problem that
appears on
• Engine speed or output lowers.
machine
• Signal voltage of common rail pressure sensor can be checked with monitoring function.
Related infor-
(Code: 36401 Common rail pressure sensor voltage)
mation

1
FUEL RAIL PRESS Voltage
Defective common rail pres-
sure sensor
Ground fault in wiring har- and carry out troubleshooting.
circuit) Wiring harness between CE01 (female) (25) Resis- Min.
Possible causes – FUEL RAIL PRESS (female) (2) tance 100 kz
and standard
value in normal
harness) – FUEL RAIL PRESS (female) (2) and Resis- Min.
between CE01 (female) (47) – JC02 – FUEL tance 100 kz
RAIL PRESS (female) (1)
Connecting parts between common rail pressure sensor – engine
wiring harness – engine controller may be defective. Check them
5
CE01 Voltage
24 PC228US, 228USLC-3E0
Circuit diagram related to common rail pressure sensor
PC228US, 228USLC-3E0 25
Failure code [CA488] Chg Air Temp High Torque Derate 1

Action code Failure code Charge air temperature high torque derate
Trouble
Contents of
• Temperature signal of boost pressure/temperature sensor exceeded control upper temperature limit.
trouble
Action of
controller
Problem that
machine
Related infor- • Boost temperature can be checked with monitoring function. (Code: 18500 Boost temperature)
mation • Method of reproducing failure code: Start engine.

Cooling performance of aftercooler may be low. Check following
points directly.
Lowering of cooling perfor-
Possible causes 1 • Looseness and breakage of fan belt.
mance of aftercooler
and standard • Insufficiency of cooling air
value in normal • Clogging of aftercooler fins
state Abnormal rise of turbo- Outlet temperature of turbocharger may be abnormally high. Check
2
charger outlet temperature related parts directly.
Failure code [CA553] Rail Press High Error 1

Action code Failure code Common rail pressure high error
Trouble
Contents of
• There is high pressure error in common rail circuit.
trouble
Action of
machine monitor
Problem that
• Engine sound becomes large when no or light load is applied.
appears on
machine
Related infor-
mation

Ground terminal may be connected defectively. Check following ter-
Possible causes minals directly.
and standard Defective connection of • Ground terminal of machine ((–) terminal of battery)
value in normal 2
ground terminal • Ground terminal of engine
state • Ground terminal of engine controller
• Ground terminal of starting motor
Breakage of O-ring of supply
3 O-ring of supply pump actuator may be broken. Check it directly.
pump actuator
26 PC228US, 228USLC-3E0
Failure code [CA559] Rail Press Low Error 1

Action code Failure code Common rail pressure low error
Trouble
Contents of
• There is low pressure error in common rail circuit.
trouble
Action of
controller
Problem that • Engine does not start at all or does not start easily.
appears on • Exhaust gas becomes black.
machine • Engine output lowers.
• Common rail pressure can be checked with monitoring function. (Code: 36400 Common rail pres-
Related infor-
sure)
mation

1 Improper fuel Improper fuel may be used. Check it directly.
Fuel may be leaking to outside. Check it directly (Check visually
2 Fuel leakage to outside
while running engine at low idle).
a For troubleshooting, see “Note 1”. For testing pressure in fuel
low-pressure circuit, see Testing and adjusting, “Testing fuel
pressure”.
Fuel supply pump
inlet negative pres- At high idle (When Max. –50.7 MPa
Defective low-pressure cir- sure (Outlet side of engine can start) {Max. –380 mmHg}
3 fuel prefilter)
cuit device
During cranking
0.3 – 1.1 MPa
Possible causes (When engine can-
Fuel main filter inlet {3.1 – 11.3 kg/cm2}
and standard not start)
pressure
value in normal At low idle (when 0.5 – 1.3 MPa
state engine can start) {5.1 – 13.3 kg/cm2}
a For check of leakage through pressure limiter, see Testing and
adjusting, “Checking fuel return rate and leakage”.
4 Defective pressure limiter
Leakage through
During low idle 0 cc (No leakage)
pressure limiter
a For check of return rate from injector, see Testing and adjusting,
“Checking fuel return rate and leakage”.
During cranking
Defective injector (including (if engine cannot be Max. 90 cc/min.
5
high pressure piping in head) Return rate from started)
injector During low idle
(if engine can be Max. 180 cc/min.
started)
PC228US, 228USLC-3E0 27

a For check of return rate from supply pump, see Testing and
adjusting, “Checking fuel return rate and leakage”.
Possible causes
and standard During cranking
value in normal (if engine cannot be Max. 140 cc/min.
6 Defective supply pump
state Return rate from sup- started)
ply pump During low idle
(if engine can be Max. 1,000 cc/min.
started)
Note 1. If a low-pressure fuel circuit device seems to be defective, check the following.
1) Fuel level
2) Clogging of fuel tank breather
3) Leakage and clogging of fuel low-pressure piping
4) Clogging of fuel prefilter
5) Clogging of fuel main filter
6) Replace fuel filter if cause of failure is not detected with checking clogging.
28 PC228US, 228USLC-3E0
Failure code [CA689] Eng Ne Speed Sensor Error 1

Action code Failure code Engine Ne speed sensor error
Trouble
Contents of
• There is error in signal from engine Ne speed sensor.
trouble
Action of
• Continues control with signal from engine Bkup speed sensor.
controller
Problem that • Engine hunts.
appears on • Engine does not start easily.
Related infor-
mation

Defective Ne speed sensor If failure code [CA238] is also displayed, carry out troubleshooting
1
CRANK SENSOR Voltage
Defective engine Ne speed
sensor
Breakage or improper clear-
Engine Ne speed sensor may be broken or may have improper
3 ance of engine Ne speed
clearance. Check it directly.
sensor
Breakage of rotation sensor
4 Rotation sensor wheel may be broken. Check it directly.
wheel
Possible causes 5
and standard or defective contact in con- Wiring harness between CE01 (female) (27) Resis-
nector) Max. 10 z
value in normal – CRANK SENSOR (female) (3) tance
– CRANK SENSOR (female) (3) tance 100 kz
Voltage Max. 1 V
– CRANK SENSOR (female) (3)
– CRANK SENSOR (female) (3) or between Resis- Min.
CE01 (female) (16) – CRANK SENSOR tance 100 kz
8 ness (with another wiring
(female) (1)
harness)
– CRANK SENSOR (female) (3) or between Resis- Min.
CE01 (female) (48) – CRANK SENSOR tance 100 kz
(female) (2)
PC228US, 228USLC-3E0 29

Connecting parts between engine Ne speed sensor – engine wiring
Possible causes 9 • Looseness of connector, breakage of lock, or breakage of seal
connector
and standard • Corrosion, bend, breakage, push-in, or expansion of pin
value in normal • Moisture or dirt in connector or defective insulation
state a Prepare with starting switch OFF, then turn starting switch ON
CE01 Voltage
Circuit diagram related to engine Ne speed sensor
30 PC228US, 228USLC-3E0
Failure code [CA731] Eng Bkup Speed Sens Phase Error 1

Action code Failure code Engine Bkup speed sensor phase error
Trouble
Contents of
• Phase error was detected in signals from engine Ne speed sensor and engine Bkup speed sensor
trouble
Action of
• Continues control with signal from engine Ne speed sensor.
controller
Problem that • Engine does not start at all or does not start easily.
appears on • Idle speed is unstable.
machine • Exhaust gas becomes black.
Related infor-
mation

Breakage of engine Ne
1 Engine Ne speed sensor may be broken. Check it directly.
speed sensor
Breakage of engine Bkup
2 Engine Bkup speed sensor may be broken. Check it directly.
speed sensor
Rotation sensor wheel on crankshaft side may be installed defec-
tively or broken. Check it according to the following procedure.
Defective installation or
1) Set No. 1 cylinder at compression top dead center (Match
3 breakage of rotation sensor
stamped mark).
wheel on crankshaft side
2) If center of oblong hole of rotation sensor wheel is at tip of Ne
speed sensor, rotation sensor wheel is installed normally.
Possible causes Rotation sensor ring on camshaft side may be installed defectively
and standard or broken. Check it according to the following procedure.
value in normal Defective installation or 1) Set No. 1 cylinder at compression top dead center (Match
state 4 breakage of rotation sensor stamped mark).
ring on camshaft side 2) Remove Bkup speed sensor.
3) If 2 grooves (1 crest) of rotation sensor ring are seen through
sensor mounting hole, rotation sensor ring is installed normally.
Defective timing of crank- Timing of crankshaft and camshaft may be defective. Check it
5
shaft and camshaft directly.
Ground terminal may be connected defectively. Check following ter-
minals directly.
Defective connection of • Ground terminal of machine ((–) terminal of battery)
6
ground terminal • Ground terminal of engine
• Ground terminal of engine controller
• Ground terminal of starting motor
PC228US, 228USLC-3E0 31
Failure code [CA757] All Continuous Data Lost Error 1

Action code Failure code All continuous data lost error
Trouble
Contents of
• All data in engine controller are lost.
trouble
Action of
controller
Problem that
• Engine may stop and may not be started again.
appears on
• Monitoring function of machine monitor (engine controller system) may not work normally.
machine
Related infor-
mation

Looseness or corrosion of
2 Battery terminal may be loosened or corroded. Check it directly.
battery terminal
a Prepare with starting switch OFF, then keep starting switch OFF
and start engine and carry out troubleshooting in each case.
3 Low battery voltage Battery (1 piece) Starting switch Voltage
Between (+) – (–) OFF Min. 12 V
terminals START Min. 6.2 V
4 Defective fuse No. 19 If fuse is broken, circuit probably has ground fault.
this time, replaced relay is defective.
Possible causes
value in normal without turning starting switch ON.
state Disconnection in wiring har- Wiring harness between F01-19 – R23, R24 Resis-
Max. 10 z
ness (Disconnection in wiring (female) (3) tance
6
or defective contact in con- Wiring harness between R23, R24 (female) Resis-
nector) Max. 10 z
(5) – CE03 (female) (3) tance
Max. 10 z
Connecting parts between fuse No. 19 – machine wiring harness –
connector
and start engine and carry out troubleshooting in each case.
8 Defective engine controller CE03 (female) Starting switch Voltage
ON Min. 24 V
Between (3) – (1)
START Min. 12 V
32 PC228US, 228USLC-3E0
PC228US, 228USLC-3E0 33
Failure code [CA778] Eng Bkup Speed Sensor Error 1

Action code Failure code Engine Bkup speed sensor error
Trouble
Contents of
• There is error in signal from engine Bkup speed sensor.
trouble
Action of
• Continues control with signal from engine Ne speed sensor.
controller
Problem that
appears on
machine
Related infor-
mation

1
CAM SENSOR Voltage
Defective engine Bkup
speed sensor
Breakage or improper clear-
Engine Bkup speed sensor may be broken or may have improper
3 ance of engine Bkup speed
clearance. Check it directly.
sensor
Breakage of rotation sensor
4 Rotation sensor ring may be broken. Check it directly.
ring
Possible causes 5
and standard or defective contact in con- Wiring harness between CE01 (female) (26) Resis-
nector) Max. 10 z
value in normal – JC03 – CAM SENSOR (female) (3) tance
– JC03 – CAM SENSOR (female) (3) tance 100 kz
Voltage Max. 1 V
– JC03 – CAM SENSOR (female) (3)
– JC03 – CAM SENSOR (female) (3) or Resis- Min.
between CE01 (female) (37) – JC01 – CAM tance 100 kz
8 ness (with another wiring
SENSOR (female) (1)
harness)
– JC03 – CAM SENSOR (female) (3) or Resis- Min.
between CE01 (female) (47) – JC02 – CAM tance 100 kz
SENSOR (female) (2)
34 PC228US, 228USLC-3E0

Connecting parts between engine Bkup speed sensor – engine wir-
Possible causes 9
and standard • Corrosion, bend, breakage, push-in, or expansion of pin
value in normal • Moisture or dirt in connector or defective insulation
state
CE01 Voltage
Circuit diagram related to engine Bkup speed sensor
PC228US, 228USLC-3E0 35
Failure code [CA1633] KOMNET Datalink Timeout Error 1

Action code Failure code KOMNET Datalink timeout error
Trouble
E0E CA1633 (Engine controller system)
Contents of • Engine controller detected communication error in KOMNET communication circuit between pump
trouble controller and machine monitor.
Action of • Continues operation in default mode.
Problem that
• Information may not transmitted normally by KOMNET communication and machine may not operate
appears on
normally. (Trouble phenomenon depends on failed section.)
machine
Related infor-
mation

Wiring harness between P70 (female) (15) –
Disconnection in wiring har- CP02 (female) (32), – CE02 (female) (46), Resis-
Max. 1 z
ness (Disconnection in wiring G01 (female) (8) – N08 (male) (3), – K02 tance
1
or defective contact in con- (female) (A) – K31 (female) (A)
nector) Wiring harness between P70 (female) (16) –
CP02 (female) (22), – CE02 (female) (47), Resis-
Max. 1 z
G01 (female) (7) – N08 (male) (10), – K02 tance
(female) (B) – K31 (female) (B)
CP02 (female) (32), – CE02 (female) (46),
Resis-
G01 (female) (8) – N08 (male) (3), – K02 Min. 1 Mz
Ground fault in wiring har- tance
(female) (A) – K31 (female) (A) and chassis
ground
circuit)
Possible causes CP02 (female) (22), – CE02 (female) (47),
and standard Resis-
value in normal tance
(female) (B) – K31 (female) (B) and chassis
state ground
Max.
G01 (female) (8) – N08 (male) (3), – K02 Voltage
5.5 V
Hot short (Short circuit with (female) (A) – K31 (female) (A) and chassis
3
24V circuit) in wiring harness ground
Max.
G01 (female) (7) – N08 (male) (10), – K02 Voltage
5.5 V
(female) (B) – K31 (female) (B) and chassis
ground
Defective CAN terminal without turning starting switch ON.
4 resistance (Internal short cir-
K02 (male) Resistance
cuit or disconnection)
Between (A) – (B) 120 ± 12 z
36 PC228US, 228USLC-3E0
PC228US, 228USLC-3E0 37
Failure code [CA2185] Throt Sens Sup Volt High Error 1

Action code Failure code Throttle sensor supply voltage high error
Trouble
Contents of
• High voltage (5.25 V or higher) was detected in throttle sensor power supply circuit.
trouble
Problem that
machine
Related infor-
mation

Short circuit in wiring har- Wiring harness between CE02 (female) (22)
Resis- Min.
1 ness (with another wiring – each of CE02 (female) pins (With P20 dis-
tance 100 kz
harness) connected)
Possible causes
and standard Wiring harness between CE02 (female) (22) Resis- Min.
value in normal – CE03 (female) (3) (With P20 disconnected) tance 100 kz
state Connecting parts between fuel control dial – machine wiring har-
connector
38 PC228US, 228USLC-3E0
Failure code [CA2186] Throt Sens Sup Volt Low Error 1

Action code Failure code Throttle sensor supply voltage low error
Trouble
Contents of
• Low voltage was detected in throttle sensor power supply circuit.
trouble
Problem that
machine
Related infor-
mation

– P20 (female) (1) tance 100 kz
Possible causes
and standard 2 ness (with another wiring Wiring harness between CE02 (female) (9) –
value in normal each of CE02 (female) pins (With P20 dis-
tance 100 kz
state connected)
connector
PC228US, 228USLC-3E0 39
Failure code [CA2249] Rail Press Very Low Error 1

Action code Failure code Common rail pressure very low error
Trouble
Contents of
• There is low pressure error in common rail circuit.
trouble
Action of
controller
Problem that • Engine does not start easily.
appears on • Exhaust gas becomes black.
Related infor-
mation

and standard
state
40 PC228US, 228USLC-3E0
PC228US, 228USLC-3E0 41
Failure code [CA2311] IMV Solenoid Error 1

Action code Failure code IMV solenoid error
Trouble
Contents of
• Resistance of supply pump actuator circuit is abnormally high or low.
trouble
Action of
controller
Problem that
machine
Related infor-
mation

Defective supply pump actu- CP3 PUMP REGULATOR (male) Resistance
2
ator
ness (Disconnection in wiring Wiring harness between CE01 (female) (2) – Resis-
3 Max. 5 z
or defective contact in con- CP3 PUMP REGULATOR (female) (1) tance
Possible causes Max. 5 z
and standard – CP3 PUMP REGULATOR (female) (2) tance
state Ground fault in wiring har- without turning starting switch ON.
circuit) Wiring harness between CE01 (female) (2) – Resis- Min.
CP3 PUMP REGULATOR (female) (1) tance 100 kz
connector
42 PC228US, 228USLC-3E0
PC228US, 228USLC-3E0 43
Failure code [CA2555] Grid Htr Relay Volt High Error 1

Action code Failure code Grid heater relay volt high error
Trouble
Contents of
• Disconnection was detected in drive circuit of intake air heater relay.
trouble
Action of
controller
Problem that
• Intake air heater does not work (Engine does not start easily and exhaust gas becomes white at low
appears on
temperature).
machine
Related infor- • Method of reproducing failure code: Turn starting switch ON when engine coolant temperature is
mation below –4°C.

without turning starting switch ON. (Troubleshooting for relay
unit)
R18 (male) Resistance
Defective automatic pre-
Between (1) – (2) 300 – 600 z
1 heater relay (Internal discon-
nection) a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting. (Troubleshooting by replacement)
Replace automatic preheater relay (R18)) with another relay and
perform reproducing operation. If “E” of failure code goes off at this
time, replaced relay is defective.
2 Max. 10 z
Possible causes or defective contact in con- – R18 (female) (1) tance
and standard nector) Wiring harness between CE02 (female) (42) Resis-
value in normal Max. 10 z
– R18 (female) (2) tance
state
– each of CE02 (female) pins (With R18 dis-
tance 100 kz
connected)
Connecting parts between automatic preheater relay – machine wir-
4
Between (40) – (42) 300 – 600 z
44 PC228US, 228USLC-3E0
Circuit diagram related to preheating, starting and charging engine
PC228US, 228USLC-3E0 45
Failure code [CA2556] Grid Htr Relay Volt Low Error 1

Action code Failure code Grid heater relay volt low error
Trouble
Contents of
• Short circuit was detected in drive circuit of intake air heater relay.
trouble
Action of
controller
Problem that
• Intake air heater does not work (Engine does not start easily and exhaust gas becomes white at low
appears on
temperature).
machine
Related infor- • Method of reproducing failure code: Turn starting switch ON when engine coolant temperature is
mation below –4°C.

without turning starting switch ON. (Troubleshooting for relay
unit)
R18 (male) Resistance
Defective automatic pre-
Between (1) – (2) 300 – 600 z
1 heater relay (Internal discon-
nection) a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting. (Troubleshooting by replacement)
Replace automatic preheater relay (R18)) with another relay and
perform reproducing operation. If “E” of failure code goes off at this
time, replaced relay is defective.
Possible causes Wiring harness between CE02 (female) (40) Resis- Min.
circuit)
and standard – R18 (female) (1) tance 100 kz
value in normal
state
– each of CE02 (female) pins (With R18 dis-
tance 100 kz
connected)
Connecting parts between automatic preheater relay – machine wir-
4
Between (40) – (42) 300 – 600 z
46 PC228US, 228USLC-3E0
Circuit diagram related to engine preheating, starting and charging engine
PC228US, 228USLC-3E0 47
SEN01885-04

© 2009 KOMATSU
All Rights Reserved
48
SEN01886-02
PC228US-3E0
PC228USLC-3E0

Failure code [D110KB] Battery Relay Drive Short Circuit ............................................................................... 2
Failure code [D196KA] Service Return Relay Disc......................................................................................... 4
Failure code [D196KB] Service Return Relay S/C.......................................................................................... 6
Failure code [DA22KK] Pump Solenoid Power Low Error .............................................................................. 8
Failure code [DA25KP] 5V Sensor 1 Power Abnormality ............................................................................. 10
Failure code [DA2RMC] CAN Discon (Pump Con Detected)........................................................................ 12
Failure code [DA2SKQ] Model Selection Abnormality .................................................................................. 14
Failure code [DAFRMC] CAN Discon (Monitor Detected) ............................................................................ 16
Failure code [DGH2KB] Hyd Oil Sensor Short.............................................................................................. 18
Failure code [DHPAMA] F Pump Press Sensor Abnormality ........................................................................ 20
Failure code [DHPBMA] R Pump Press Sensor Abnormality ....................................................................... 22
Failure code [DHSAMA] Sw RH PPC Press Sen. Abnormality..................................................................... 24
Failure code [DHSBMA] Sw LH PPC Press Sen. Abnormality ..................................................................... 26
Failure code [D110KB] Battery Relay Drive Short Circuit 1
Action code Failure code Battery relay drive short circuit

Trouble
— D110KB (Pump controller system)
Contents of
• Abnormal current flowed at output to battery relay drive circuit.
trouble
Action of con- • Turns output to battery relay drive circuit OFF.
troller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • Engine does not stop.
machine
Related infor- • Operating condition of battery relay (ON/OFF) can be checked with monitoring function.
mation Code 03700: Controller Output)

Battery relay Resistance
Defective battery relay
1 Between R02 (terminal BR) –
(Internal defect) There is continuity
R01 (terminal E)
Between R02 (terminal BR) –
Min. 1 Mz
chassis ground
Possible causes
state 2 Wiring harness between CP03 (female) (4) –
(Short circuit with GND cir- Resis-
cuit) D01 – J01 – R02 (terminal BR) and chassis Min. 1 Mz
tance
ground
Turn starting switch
3 Defective pump controller CP03 (female) Voltage
OFF.
Between (4) – chas- 20 – 30 V
ON o OFF
sis ground (4 – 7 sec.)
q S/C: Short circuit
Circuit diagram related to battery relay drive
Failure code [D196KA] Service Return Relay Disc. 1
Action code Failure code Service return relay disconnection

Trouble
— D196KA (Pump controller system)
Contents of • When service return relay circuit was disconnected with GND (when output was turned OFF), 24V
trouble was not generated.
Action of con- • None in particular.
troller • If cause of failure disappears, system resets itself.
Problem that
appears on • Hydraulic circuit for attachment does not change to single operation circuit.
machine
• Carry out troubleshooting only for setting with ATT. (Confirm settings on machine monitor.)
a This code detects only a trouble in the primary side (coil side) of service return relay.
Related infor- When service return solenoid may be in defective operation, check the power supply, wiring har-
mation ness, and solenoid in the secondary side (Limit SW side) of the relay.
• Operating condition of service return relay (ON/OFF) can be checked with monitoring function.
(Code 02301: Solenoid 2)

1 Defective fuse No.2 If fuse is broken, circuit probably has ground fault. (See cause 4.)
Defective service return relay ing without turning starting switch ON.
2
(Internal disconnection) R20 (male) Resistance
Between (1) – (2) 100 – 500 z
ness
Wiring harness between CP02 (female) (8) – Resis-
R20 (female) (2) tance
Possible causes defective contact in connec-
tor) Wiring harness between R20 (female) (1) – Resis-
and standard Max. 1 z
value in normal J03 – F01-2 outlet tance
state a Prepare with starting switch OFF, then turn starting switch ON
Hot short in wiring harness and carry out troubleshooting.
4
(Short circuit with 24V circuit) Wiring harness between CP02 (female) (8) –
Voltage Max. 1V
R20 (female) (2) and chassis ground
CP02 Working mode Voltage
5 Defective pump controller When B-mode is not
20 – 30 V
Between (8) – chas- selected
sis ground When B-mode is
Max. 1 V
selected
Circuit diagram related to service return relay and solenoid of pump controller
Failure code [D196KB] Service Return Relay S/C 1
Action code Failure code Service return relay short

Trouble
— D196KB (Pump controller system)
Contents of • When service return relay circuit was connected to GND (when output was turned ON), abnormal
trouble current flowed.
Action of con- • Turns output to service return relay circuit OFF.
Problem that
appears on • Hydraulic circuit for attachment does not change to single operation circuit.
machine
• Carry out troubleshooting only for setting with ATT. (Confirm settings on machine monitor.)
a This code detects only a trouble in the primary side (coil side) of service return relay.
Related infor- When service return solenoid may be in defective operation, check the power source, wiring har-
mation ness, and solenoid in the secondary side (Limit SW side) of the relay.
• Operating condition of service return relay (ON/OFF) can be checked with monitoring function.

Defective service return relay ing without turning starting switch ON.
1
(Internal short circuit) R20 (male) Resistance
Between (1) – (2) 100 – 500 z
Ground fault in wiring har-
Possible causes Wiring harness between CP02 (female) (8) – Resis-
2 ness (Short circuit with GND Min. 1 Mz
and standard R20 (female) (2) and chassis ground tance
circuit)
value in normal
Wiring harness between R20 (female) (1) – Resis-
state Min. 1 Mz
J03 – F01-2 outlet and chassis ground tance
3 Defective pump controller When B-mode is not
20 – 30 V
sis ground When B-mode is
Max. 1 V
selected
Circuit diagram related to service return relay and solenoid of pump controller
Failure code [DA22KK] Pump Solenoid Power Low Error 1
Action code Failure code Pump Solenoid Power Low Error

Trouble
E0E DA22KK (Pump controller system)
Contents of
• Pump controller solenoid source voltage is below 18 V.
trouble
Action of con-
• Solenoid stops operation.
troller
Problem that
appears on • Work equipment, swing, and travel systems do not work.
machine
Related infor-
• If [D110KB] is displayed, carry out troubleshooting for it first.
mation

Defective fuse No. 2 or If fuse or fusible link is broken, circuit probably has ground fault.
1
fusible link F04 (See cause 3.)
Wiring harness between CP03 (female) (2), Resis-
Max. 1 z
(12) – fuse F01-2 outlet tance
Wiring harness between fuse F01-2 inlet – Resis-
Disconnection in wiring Max. 1 z
A01 – F04 (female) (2) tance
harness (Disconnection in
2
wiring or defective contact in Wiring harness between F04 (female) (1) – Resis-
Max. 1 z
connector) battery relay terminal M tance
Wiring harness between starting switch ter-
Possible causes Resis-
minal BR – H15 – J01 – A02 – battery relay Max. 1 z
and standard tance
terminal BR
value in normal
state Max. 1 z
(32), (33) – chassis ground tance
Min. 1 Mz
Ground fault in wiring (12) – fuse F01-2 outlet tance
3
harness Wiring harness between fuse F01-2 inlet – Resis-
Min. 1 Mz
A01 – F04 (female) (2) tance
Wiring harness between F04 (female) (1) – Resis-
Min. 1 Mz
battery relay terminal M tance
4 Defective pump controller and carry out troubleshooting.
Between CP03 (2), (12) – (21), (32), (33) Voltage 20 – 30 V
Circuit diagram related to pump controller solenoid
Failure code [DA25KP] 5V Sensor 1 Power Abnormality 1
Action code Failure code 5V Sensor 1 power abnormality

Trouble
E02 DA25KP (Pump controller system)
Contents of
• Abnormal current flowed in pressure sensor power supply (5V) circuit.
trouble
• Turns output to power supply (5V) circuit OFF.
Action of con-
• Even if phenomenon of failure disappears, system does not reset itself until starting switch is turned
troller
OFF.
Problem that
• Signal of pressure sensor is not input normally.
appears on
• Pressure sensor failure code is displayed at the same time.
machine
Related infor-
mation

a Disconnect connector with starting switch OFF, then turn start-
ing switch ON and carry out troubleshooting.
F pump pressure
A51 connector
sensor
Disconnect sensor
Defective pressure sensor and wiring harness at R pump pressure
1 A52 connector
(Internal short circuit) right in order. If no sensor
failure code is dis- Swing left pressure
played, that sensor is P03 connector
sensor
defective.
Swing right pressure
P07 connector
sensor
Possible causes
and standard Wiring harness between CP01 (female) (22)
Resis-
value in normal – J07 – A03 – A51 (female) (3) and chassis Min. 1 Mz
tance
state ground [F pump pressure sensor system]
Ground fault in wiring har- Wiring harness between CP01 (female) (22)
Resis-
ness – J07 – A03 – A52 (female) (3) and chassis Min. 1 Mz
2 tance
(Short circuit with GND cir- ground [R pump pressure sensor system]
cuit)
Wiring harness between CP01 (female) (22)
Resis-
– J07 – A03 – P03 (female) (3) and chassis Min. 1 Mz
tance
ground [Swing left pressure sensor system]
Resis-
– J07 – A03 – P07 (female) (3) and chassis Min. 1 Mz
tance
ground [Swing right pressure sensor system]
3 Defective pump controller
CP01 Voltage
Between (22) – (10) 4.5 – 5.5 V
10 PC228US, 228USLC-3E0
Circuit diagram related to pressure sensor power supply of pump controller
PC228US, 228USLC-3E0 11
Failure code [DA2RMC] CAN Discon (Pump Con Detected) 1
Action code Failure code CAN disconnection (Pump controller detected)

Trouble
E0E DA2RMC (Pump controller system)
Contents of • Pump controller detected communication error in CAN communication circuit between machine mon-
trouble itor and engine controller.
Action of con- • Fixes engine output to E-mode, and limits pump absorption torque to about 80%.
Problem that
• Output lowers. (Pump absorption torque decreases.)
appears on
• As the working load increases, engine may stall.
machine
Related infor-
mation

CE02 (female) (47), – CP02 (female) (22) – Resis-
ness Max. 1 z
tor) Wiring harness between P70 (female) (15) –
Max. 1 z
(female) (A) – K31 (female) (A)
CE02 (female) (47), – CP02 (female) (22), –
Resis-
Ground fault in wiring har- G01 (female) (7) – N08 (male) (10), – K02 Min. 1 Mz
tance
ness (female) (B) – K31 (female) (B) – other
2
(Short circuit with GND cir- related circuit and chassis ground
Possible causes cuit)
and standard
value in normal Resis-
state tance
(female) (A) – K31 (female) (A) – other
related circuit and chassis ground
G01 (female) (7) – N08 (male) (10), – K02 Voltage Max. 1 V
Hot short (Short circuit with (female) (B) – K31 (female) (B) – other
3
24V circuit) in wiring harness related circuit and chassis ground
Defective CAN terminal ing without turning starting switch ON.
4
resistance K02 (male), K31 (male) Resistance
Between (A) – (B) 120 ± 12 z
12 PC228US, 228USLC-3E0

and standard Defective machine monitor, If causes 1 – 4 are not detected, machine monitor, engine controller,
value in normal 5 engine controller, or pump or pump controller may be defective. (Since trouble is in system,
state controller troubleshooting cannot be carried out.)
PC228US, 228USLC-3E0 13
Failure code [DA2SKQ] Model Selection Abnormality 1
Action code Failure code Model selection abnormality

Trouble
— DA2SKQ (Pump controller system)
Contents of
• Model code signal for model which is not registered in controller is input.
trouble
Action of con- • Changes input model code to code of default model (PC228) and continues control.
Problem that
appears on • None in particular.
machine
• Controller-recognized model name (digits) can be checked with monitoring function. (Code: 00200)
Related infor-
• Input of model selection signal (ON/OFF) can be checked with monitoring function. (Code 02200:
mation
Switch Input 2)

Defective model selection ing without turning starting switch ON.
connector S30 (female) Resistance
1
(Internal disconnection or
short circuit) Between (2), (3) – (8) Max. 1 z
Between (1), (4), (5), (6), (7) – (8) Min. 1 Mz
Max. 1 z
S30 (male) (4) and chassis ground tance
Wiring harness between CP02 (female) (17) Resis-
Disconnection in wiring har- Max. 1 z
– S30 (male) (3) tance
ness
Possible causes tor) Wiring harness between CP02 (female) (13) Resis-
value in normal
state Max. 1 z
Wiring harness between S30 (male) (8) – Resis-
Max. 1 z
J05 – A01 – chassis ground tance
Min. 1 Mz
S30 (male) (4) and chassis ground tance
Ground fault in wiring har- Wiring harness between CP02 (female) (13) Resis-
Min. 1 Mz
ness – S30 (male) (7) and chassis ground tance
3
(Short circuit with GND cir- Wiring harness between CP02 (female) (17) Resis-
cuit) Min. 1 Mz
– S30 (male) (3) and chassis ground tance
Min. 1 Mz
– S30 (male) (1) and chassis ground tance
Min. 1 Mz
14 PC228US, 228USLC-3E0

Possible causes and carry out troubleshooting.
and standard CP02 Voltage
value in normal 4 Defective pump controller Between (7), (13), (37) – chassis
state 20 – 30 V
ground
Between (17) (27) – chassis
Max. 1 V
ground
Circuit diagram related to model selection connector of pump controller
PC228US, 228USLC-3E0 15
Failure code [DAFRMC] CAN Discon (Monitor Detected) 1
Action code Failure code CAN disconnection (Monitor detected)

Trouble
E0E DAFRMC (Machine monitor system)
Contents of • Machine monitor detected communication error in CAN communication circuit between pump con-
trouble troller and engine controller.
Action of con- • Fixes engine output to E-mode, and limits pump absorption torque to about 80%.
Problem that
• Output lowers. (Pump absorption torque decreases.)
appears on
• As the working load increases, engine may stall.
machine
Related infor-
mation

ness Max. 1 z
tor) Wiring harness between P70 (female) (15) –
Max. 1 z
(female) (A) – K31 (female) (A)
Resis-
Ground fault in wiring har- G01 (female) (7) – N08 (male) (10), – K02 Min. 1 Mz
tance
ness (female) (B) – K31 (female) (B) – other
2
(Short circuit with GND cir- related circuit and chassis ground
Possible causes cuit)
and standard
value in normal Resis-
state tance
Hot short (Short circuit with (female) (B) – K31 (female) (B) – other
3
24V circuit) in wiring harness related circuit and chassis ground
Defective CAN terminal ing without turning starting switch ON.
4
resistance K02 (male), K31 (male) Resistance
Between (A) – (B) 120 ± 12 z
16 PC228US, 228USLC-3E0

and standard Defective machine monitor, If causes 1 – 4 are not detected, machine monitor, engine controller,
value in normal 5 engine controller, or pump or pump controller may be defective. (Since trouble is in system,
state controller troubleshooting cannot be carried out.)
Circuit diagram related to CAN communication of machine monitor
PC228US, 228USLC-3E0 17
Failure code [DGH2KB] Hyd Oil Sensor Short 1

Action code Failure code Hydraulic oil temperature sensor short
Trouble
— DGH2KB (Machine monitor system)
Contents of
• Ground fault was detected in hydraulic oil temperature sensor circuit.
trouble
Action of • Fixes hydraulic oil temperature value at 40°C and continues operation.
Problem that
• While hydraulic oil temperature rises normally, hydraulic oil temperature gauge does not move from
appears on
top of white range (bottom of green range).
machine
• Signal voltage of hydraulic oil temperature sensor can be checked with monitoring function.
Related infor-
(Code: 04402 Hydraulic oil temperature sensor voltage)
mation

Defective hydraulic oil tem-
1 perature sensor (Internal dis- P22 (male) Resistance
connection or short circuit) Between (1) – (2) 3.5 – 90 kz
Between (2) – chassis ground Min. 1 Mz
Possible causes
and standard Ground fault in wiring har- without turning starting switch ON.
value in normal 2 ness (Short circuit with GND
state circuit) Wiring harness between P02 (female) (12) – Resis-
Min. 1 Mz
3 Defective machine monitor P02 (female) Resistance
Between (12) – (13) 3.5 – 90 kz
Circuit diagram related to hydraulic oil temperature sensor
18 PC228US, 228USLC-3E0
PC228US, 228USLC-3E0 19
Failure code [DHPAMA] F Pump Press Sensor Abnormality 1
Action code Failure code F pump press sensor abnormality

Trouble
— DHPAMA (Pump controller system)
Contents of
• Signal voltage from F pump pressure sensor is below 0.3 V or above 4.42 V.
trouble
Action of con- • Fixes F pump pressure at 0 MPa {0 kg/cm2} and continues control.
Problem that
appears on • No automatic gear shifting
machine
a If 5V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor
Related infor- will be broken. Accordingly, take extreme care when checking.
mation • Input from F pump pressure sensor (pressure) can be checked with monitoring function.
(Code 01112: F pump pressure

Defective sensor power sup- If failure code [DA25KP] is also displayed, carry out troubleshooting
1
ply system for it first.
Defective F pump pressure
2 sensor A51 Voltage
(Internal defect) Between (3) – (1) 4.5 – 5.5 V
Between (2) – (1) 0.5 – 4.5 V
Disconnection in wiring har- Wiring harness between CP01 (female) (22) Resis-
ness Max. 1 z
– J07 – A03 – A51 (female) (3) tance
tor) – A06 – A51 (female) (1) tance
Max. 1 z
and standard A06 – A51 (female) (2) tance
state
4
(Short circuit with GND cir- Wiring harness between CP01 (female) (8) – Resis-
cuit) Min. 1 Mz
A06 – A51 (female) (2) and chassis ground tance
Hot short (Short circuit with
5 – J07 – A03 – A51 (female) (3) and chassis Voltage 4.5 – 5.5 V
24V circuit) in wiring harness
ground
Wiring harness between CP01 (female) (8) –
Voltage Max. 1 V
A06 – A51 (female) (2) and chassis ground
6 Defective pump controller CP01 Voltage
Between (22) – (10) 4.5 – 5.5 V
Between (8) – (10) 0.5 – 4.5 V
20 PC228US, 228USLC-3E0
Circuit diagram related to F pump pressure sensor of pump controller
PC228US, 228USLC-3E0 21
Failure code [DHPBMA] R Pump Press Sensor Abnormality 1
Action code Failure code R pump pressure sensor abnormality

Trouble
— DHPBMA (Pump controller system)
Contents of
• Signal voltage from R pump pressure sensor is below 0.3 V or above 4.42 V.
trouble
Action of con- • Fixes R pump pressure at 0 MPa {0 kg/cm2} and continues control.
Problem that
machine
mation • Input from R pump pressure sensor (pressure) can be checked with monitoring function.
(Code 01113: R pump pressure

1
Defective R pump pressure
2 sensor A52 Voltage
(Internal defect) Between (3) – (1) 4.5 – 5.5 V
Between (2) – (1) 0.5 – 4.5 V
ness Max. 1 z
– J07 – A03 – A52 (female) (3) tance
tor) – A06 – A52 (female) (1) tance
Max. 1 z
and standard A06 – A52 (female) (2) tance
state
4
cuit) Min. 1 Mz
A06 – A52 (female) (2) and chassis ground tance
5 – J07 – A03 – A52 (female) (3) and chassis Voltage 4.5 – 5.5 V
ground
Wiring harness between CP01 (female) (2) –
Voltage 0.5 – 4.5 V
A06 – A52 (female) (2) and chassis ground
Between (22) – (10) 4.5 – 5.5 V
Between (2) – (10) 0.5 – 4.5 V
22 PC228US, 228USLC-3E0
Circuit diagram related to R pump pressure sensor of pump controller
PC228US, 228USLC-3E0 23
Failure code [DHSAMA] Sw RH PPC Press Sen. Abnormality 1
Action code Failure code Sw RH PPC press sen. abnormality

Trouble
— DHSAMA (Pump controller system)
Contents of
• Signal voltage from swing right PPC pressure sensor is below 0.3 V or above 4.72 V.
trouble
Action of con- • Fixes swing right PPC pressure at 0 MPa {0 kg/cm2} and continues control.
Problem that
machine
mation • Input from swing right PPC pressure sensor (pressure) can be checked with monitoring function.
(Code 09002: Swing right PPC pressure

1
Defective swing right PPC
2 pressure sensor (Internal P07 Voltage
defect) Between (3) – (1) 4.5 – 5.5 V
Between (2) – (1) 0.5 – 4.5 V
ness Max. 1 z
– J07 – A03 – P07 (female) (3) tance
tor) – A06 – P07 (female) (1) tance
Possible causes Wiring harness between CP01 (female) (19) Resis-
Max. 1 z
and standard – A05 – P07 (female) (2) tance
state
4
cuit) Min. 1 Mz
– A05 – P07 (female) (2) and chassis ground tance
5 – J07 – A03 – P07 (female) (3) and chassis Voltage 4.5 – 5.5 V
ground
– A05 – P07 (female) (2) and chassis ground
Between (22) – (10) 4.5 – 5.5 V
Between (19) – (10) 0.5 – 4.5 V
24 PC228US, 228USLC-3E0
Circuit diagram related to swing right PPC pressure sensor of pump controller
PC228US, 228USLC-3E0 25
Failure code [DHSBMA] Sw LH PPC Press Sen. Abnormality 1
Action code Failure code Sw LH PPC press sen. abnormality

Trouble
— DHSBMA (Pump controller system)
Contents of
• Signal voltage from swing left PPC pressure sensor is below 0.3 V or above 4.42 V.
trouble
Action of con- • Fixes swing left PPC pressure at 0 MPa {0 kg/cm2} and continues control.
Problem that
machine
mation • Input from swing left PPC pressure sensor (pressure) can be checked with monitoring function.
(Code 09001: Swing left PPC pressure)

1
Defective swing left PPC
2 pressure sensor (Internal P03 Voltage
defect) Between (3) – (1) 4.5 – 5.5 V
Between (2) – (1) 0.5 – 4.5 V
ness Max. 1 z
– J03 – A03 – P03 (female) (3) tance
Max. 1 z
and standard – A05 – P03 (female) (2) tance
state
4
cuit) Min. 1 Mz
5 – J07 – A03 – P03 (female) (3) and chassis Voltage 4.5 – 5.5 V
ground
Between (22) – (10) 4.5 – 5.5 V
Between (13) – (10) 0.5 – 4.5 V
26 PC228US, 228USLC-3E0
Circuit diagram related to swing left PPC pressure sensor of pump controller
PC228US, 228USLC-3E0 27
SEN01886-02

© 2009 KOMATSU
All Rights Reserved
28
SEN01887-02
PC228US-3E0
PC228USLC-3E0

Failure code [DW43KA] Travel Speed Sol Open Circuit ................................................................................. 4
Failure code [DW43KB] Travel Speed Sol Short Circuit ................................................................................. 6
Failure code [DW45KA] Swing Brake Sol Open Circuit .................................................................................. 8
Failure code [DW45KB] Swing Brake Sol Short Circuit ................................................................................ 12
Failure code [DW91KA] Travel Junction Sol Open Circuit ............................................................................ 14
Failure code [DW91KB] Travel Junction Sol Short Circuit ............................................................................ 16
Failure code [DW4GKA] Boom Slow Down Sol. Disc. .................................................................................. 18
Failure code [DW4GKB] Boom Slow Down Sol. S/C .................................................................................... 20
Failure code [DWJ0KA] Merge-divider Sol Open Circuit .............................................................................. 22
Failure code [DWJ0KB] Merge-divider Sol Short Circuit............................................................................... 24
Failure code [DWK0KA] 2-stage Relief Sol Open Circuit.............................................................................. 26
Failure code [DWK0KB] 2-stage Relief Sol Short Circuit .............................................................................. 28
Failure code [DXA0KA] PC-EPC Sol Open Circuit ....................................................................................... 30
Failure code [DXA0KB] PC-EPC Sol Short Circuit ....................................................................................... 32
Failure code [DXE0KA] LS-EPC Sol Open Circuit ........................................................................................ 34

Failure code [DXE0KB] LS-EPC Sol Short Circuit ........................................................................................ 36
Failure code [DXE4KA] Service Current EPC Open Circuit.......................................................................... 38
Failure code [DXE4KB] Service Current EPC Short Circuit .......................................................................... 39
Failure code [DY20KA] Wiper Working Abnormality ..................................................................................... 40
Failure code [DY20MA] Wiper Parking Abnormality ..................................................................................... 42
Failure code [DY2CKB] Washer Drive Short Circuit...................................................................................... 44
Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit .............................................................................. 46
Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit............................................................................... 48
Failure code [DW43KA] Travel Speed Sol Open Circuit 1
Action code Failure code Travel speed solenoid disconnection

Trouble
— DW43KA (Pump controller system)
Contents of
• No current flows at output to travel speed solenoid circuit.
trouble
Action of con- • None in particular. (Since no current flows, solenoid does not operate.)
Problem that
appears on • Travel speed does not change to Hi. (Machine monitor changes to the normal state.)
machine
• Operating condition of travel speed solenoid (ON/OFF) can be checked with monitoring function.
Related infor-
• Solenoid detects disconnection when output is turned on. To confirm the reproduction after repair, be
mation
sure to turn output on. (For more information on how to turn output on/off, see troubleshooting for
failure code [DW43KB].)

Defective travel speed sole- ing without turning starting switch ON.
1
noid (Internal disconnection) V03 (male) Resistance
Between (1) – (2) 20 – 60 z
ness
Possible causes 2 (Disconnection in wiring or Max. 1 z
– A05 – V03 (female) (1) tance
and standard defective contact in connec-
tor) Wiring harness between V03 (female) (2) – Resis-
state A04 – CP03 (female) (3), (13), (23) tance
3
24V circuit) in wiring harness Wiring harness between CP03 (female) (27)
Voltage Max. 1 V
– A05 – V03 (female) (1) and chassis ground
CP03 (female) Resistance
Between (27) – chassis ground 20 – 60 z
Circuit diagram related to travel speed solenoid of pump controller
Failure code [DW43KB] Travel Speed Sol Short Circuit 1
Action code Failure code Travel speed solenoid short circuit

Trouble
— DW43KB (Pump controller system)
Contents of
• Abnormal current flowed at output to travel speed solenoid circuit.
trouble
Action of con- • Turns output to travel speed solenoid circuit OFF.
Problem that
appears on • Travel speed does not change to Hi. (Machine monitor changes to the normal state.)
machine
Related infor- • Operating condition of travel speed solenoid (ON/OFF) can be checked with monitoring function.
mation (Code 02300: Solenoid 1)

Defective travel speed sole-
1 noid (Internal short circuit or V03 (male) Resistance
ground fault) Between (1) – (2) 20 – 60 z
Possible causes
and standard
value in normal 2
state (Short circuit with GND cir- Wiring harness between CP03 (female) (27) Resis-
cuit) Min. 1 Mz
– A05 – V03 (female) (1) and chassis ground tance
3 Defective pump controller CP03 Travel speed Voltage
Between (27) – chas- Lo Max. 1 V
sis ground Hi + Travel operation 20 – 30 V
Circuit diagram related to travel speed solenoid of pump controller
Failure code [DW45KA] Swing Brake Sol Open Circuit 1
Action code Failure code Swing holding brake solenoid disconnection

Trouble
E03 DW45KA (Pump controller system)
Contents of
• No current flows at output to swing holding brake solenoid circuit.
trouble
Problem that
appears on • Machine cannot swing.
machine
• Operating condition of swing holding brake solenoid (ON/OFF) can be checked with monitoring func-
tion. (Code 02300: Solenoid 1)
• If solenoid and wiring harness are normal, operator can swing machine by setting emergency swing
brake release switch in release position (Swing holding brake does not work, however, when
Related infor-
machine stops).
mation
• Turn both of swing lock and emergency swing release switches OFF during troubleshooting.

Defective swing holding ing without turning starting switch ON.
1 brake solenoid (Internal dis-
V04 (male) Resistance
connection)
Between (1) – (2) 20 – 60 z
Defective swing lock switch S04 (female) Switch Resistance
2
(Internal disconnection)
OFF Max. 1 z
Between (3) – (4)
LOCK Min. 1 Mz
Possible causes
value in normal Defective assembled-type ing without turning starting switch ON.
state 3 diode D01
D01 (male) Digital circuit tester Continuity
Between (7) – (3) Diode mode There is continuity
– D01 (female) (7) tance
ness
Wiring harness between D01 (female) (3) – Resis-
J02 – H15 – S04 (male) (3) tance
tor) Wiring harness between S04 (male) (4) – Resis-
Max. 1 z
H15 – J06 – A05 – V04 (female) (1) tance
Wiring harness between V04 (female) (2) – Resis-
Max. 1 z
CP03 (female) (3), (13), (23) tance

Hot short (Short circuit with – D01 – J02 – H15 – S04 (male) (3) and Voltage Max. 1 V
5
24V circuit) in wiring harness chassis ground
Possible causes
and standard Wiring harness between V04 (female) (1) –
value in normal A05 – J06 – H15 – S04 (male) (4) and chas- Voltage Max. 1 V
state sis ground
6 Defective pump controller CP03 (female) Disconnect D01 and Resistance

connect pins (3) and
Between (37) – chas- (7) on male side
20 – 60 z
sis ground directly.
Circuit diagram related to swing holding brake solenoid of pump controller
10 PC228US, 228USLC-3E0
PC228US, 228USLC-3E0 11
Failure code [DW45KB] Swing Brake Sol Short Circuit 1
Action code Failure code Swing holding brake solenoid short circuit
Trouble
E03 DW45KB (Pump controller system)
Contents of
• Abnormal current flowed at output to swing holding brake solenoid circuit.
trouble
Action of con- • Turns output to swing holding brake solenoid circuit OFF.
Problem that
appears on • Machine cannot swing.
machine
• Operating condition of swing holding brake solenoid (ON/OFF) can be checked with monitoring func-
tion. (Code 02300: Solenoid 1)
Related infor-
• If solenoid and wiring harness are normal, operator can swing machine by setting emergency swing
mation
brake release switch in release position (Swing holding brake does not work, however, when
machine stops).

Defective swing holding
1 brake solenoid (Internal short V04 (male) Resistance
circuit or ground fault) Between (1) – (2) 20 – 60 z
Defective assembled-type ing without turning starting switch ON.
2 diode D01
D01 (male) Resistance
(Internal short circuit)
Between (3) – (7) Min. 1 Mz
Possible causes
value in normal ing without turning starting switch ON.
state Ground fault in wiring har- Wiring harness between CP03 (female) (37)
Resis-
ness – D01 – J02 – H15 – S04 (male) (3) and Min. 1 Mz
3 tance
(Short circuit with GND cir- chassis ground
cuit)
Wiring harness between V04 (female) (1) –
Resis-
A05 – J06 – H15 – S04 (male) (4) and chas- Min. 1 Mz
tance
sis ground
4 Defective pump controller CP03 Swing lever Voltage
Between (37) – chas- At neutral Max. 1 V
sis ground At swing 20 – 30 V
12 PC228US, 228USLC-3E0
Circuit diagram related to swing holding brake solenoid of pump controller
PC228US, 228USLC-3E0 13
Failure code [DW91KA] Travel Junction Sol Open Circuit 1
Action code Failure code Travel junction solenoid disconnection

Trouble
— DW91KA (Pump controller system)
Contents of
• No current flows at output to travel junction solenoid circuit.
trouble
Problem that
appears on • Hard to turn when operating travel steering.
machine
• Operating condition of travel junction solenoid (ON/OFF) can be checked with monitoring function.
Related infor-
mation

Defective travel junction ing without turning starting switch ON.
1 solenoid
Between (1) – (2) 20 – 60 z
ness Wiring harness between CP03 (female) (7) – Resis-
Max. 1 z
Possible causes 2 (Disconnection in wiring or A05 – V05 (female) (1) tance
tor) Resis-
value in normal A04 – CP03 (female) (3), (13), (23) and Max. 1 z
state tance
chassis ground
3
24V circuit) in wiring harness Wiring harness between CP03 (female) (7) –
Voltage Max. 1 V
A05 – V05 (female) (1) and chassis ground
Between (7) – (3), (13), (23) 20 – 60 z
14 PC228US, 228USLC-3E0
Circuit diagram related to travel junction solenoid of pump controller
PC228US, 228USLC-3E0 15
Failure code [DW91KB] Travel Junction Sol Short Circuit 1
Action code Failure code Travel junction solenoid short circuit

Trouble
— DW91KB (Pump controller system)
Contents of
• Abnormal current flowed at output to travel junction solenoid circuit.
trouble
Action of con- • Turns output to travel junction solenoid OFF.
Problem that
appears on • Hard to turn when operating travel steering.
machine
Related infor- • Operating condition of travel junction solenoid (ON/OFF) can be checked with monitoring function.
mation Code 02300: Solenoid 1)

Defective travel junction ing without turning starting switch ON.
solenoid V05 (male) Resistance
1
(Internal short circuit or
Possible causes
and standard
value in normal 2
state (Short circuit with GND cir- Wiring harness between CP03 (female) (7) – Resis-
cuit) Min. 1 Mz
A05 – V05 (female) (1) and chassis ground tance
3 Defective pump controller CP03 Travel lever Voltage
Between (7) – (3), At straight-travel Max. 1 V
(13), (23) At steering 20 – 30 V
16 PC228US, 228USLC-3E0
Circuit diagram related to travel junction solenoid of pump controller
PC228US, 228USLC-3E0 17
Failure code [DW4GKA] Boom Slow Down Sol. Disc. 1
Action code Failure code Disconnection in boom RAISE throttle EPC solenoid
Trouble
E06 DW4GKA (Pump controller system)
Contents of
• Any current does not flow in the boom throttle EPC solenoid circuit.
trouble
Action of con- • None in particular. (Since any current does not flow, the solenoid does not operate.)
troller • If the cause of the failure disappears, the system resets itself.
Problem that
appears on • The boom cannot be raised (The boom RAISE PPC circuit is kept closed).
machine
• The output to the boom RAISE throttle EPC solenoid (current) can be checked in the monitoring
Related infor- function. (Code: 01800 Boom RAISE throttle EPC solenoid current)
mation • If the solenoid and wiring harness are normal, the boom can be raised by keeping the emergency
work equipment drive switch in the emergency position.

Defective boom RAISE throt- a Turn the engine starting switch OFF for the preparations, and
tle EPC solenoid (Internal hold it in the OFF position during the troubleshooting.
1
short circuit or grounding V09 (male) Resistance value
fault) Between (1) and (2) 5 - 25 z
a Turn the engine starting switch OFF for the preparations, and
hold it in the OFF position during the troubleshooting.
Defective emergency work Emergency work
S25 (male) Resistance value
equipment drive switch equipment drive switch
2
(Internal short circuit or Between (13) Normal Max. 1 z
grounding fault) and (12) Emergency Min. 1 Mz
Between (15) Normal Max. 1 z
and (16) Emergency Min. 1 Mz
Resis-
tance Max. 1 z
and S25 (female) (13)
Possible causes value
and standard Disconnection in wiring har- Resis-
Wiring harness between S25 (female) (12)
value in normal ness (Disconnection in wiring tance Max. 1 z
3 and V09 (female) (1)
state or defective contact in con- value
nector) Resis-
Wiring harness between CP03 (female) (3),
tance Max. 1 z
(13), (23) and S25 (female) (16)
value
Resis-
Wiring harness between S25 (female) (15)
tance Max. 1 z
and V09 (female) (2)
value
hold it in the ON position during the troubleshooting.
Between wiring harness between CP03
Short circuit with power
(female) (36) to S25 (female) (13) and Voltage Max. 1 V
4 source in wiring harness
grounding
(Contact with 24-V circuit)
Between wiring harness between S25
(female) (12) to V09 (female) (1) and ground- Voltage Max. 1 V
ing
5 Pump controller defective
CP03 (female) Resistance value
Between (36) and (3) (13) (23) 5 – 25 z
18 PC228US, 228USLC-3E0
Circuit diagram related to boom RAISE throttle EPC solenoid
PC228US, 228USLC-3E0 19
Failure code [DW4GKB] Boom Slow Down Sol. S/C 1
Action code Failure code Short circuit in boom RAISE throttle EPC solenoid
Trouble
E06 DW4GKB (Pump controller system)
Contents of
• An abnormal current flowed in the boom RAISE throttle EPC solenoid circuit.
trouble
• Turns off the output to the boom RAISE throttle EPC solenoid circuit.
Action of con-
• Even if the cause of the failure disappears, the system does not reset itself until the starting switch is
troller
turned OFF.
Problem that
appears on • The boom cannot be raised (The boom RAISE PPC circuit is kept closed).
machine
• The output to the boom RAISE throttle EPC solenoid (current) can be checked in the monitoring
function. (Code: 01800 Boom RAISE throttle EPC solenoid current)
Related infor-
• If the solenoid and wiring harness are normal, the boom can be raised by keeping the emergency
mation
work equipment drive switch in the emergency position. (Failure code [DW4GKA] is displayed at this
time, but that is not abnormal.)

Defective boom RAISE throt- hold it in the OFF position during the troubleshooting.
tle EPC solenoid (Internal V09 (male) Resistance value
1
short circuit or grounding
fault) Between (1) and (2) 5 – 25 z
Between (1) and ground Min. 1 Mz
Emergency work
Defective emergency work S25 (male) equipment drive Resistance value
equipment drive switch switch
2
grounding fault) Between (13) and
Min. 1 Mz
Possible causes (14)
Normal
and standard Between (13) and
value in normal Min. 1 Mz
grounding
state
Short circuit of wiring harness between CP03 Resis-
Short circuit with chassis
(female) (36) and S25 (female) (13) with tance Min. 1 Mz
3 ground in wiring harness
ground value
(Contact with ground circuit)
Short circuit of wiring harness between S25 Resis-
(female) (12) and V09 (female) (1) with tance Min. 1 Mz
ground value
4 Pump controller defective CP03 (female) Resistance value
Between (36) and (3) (13) (23) 5 – 25 z
Between (36) and grounding Min. 1 Mz
20 PC228US, 228USLC-3E0
Circuit diagram related to boom RAISE throttle EPC solenoid
PC228US, 228USLC-3E0 21
Failure code [DWJ0KA] Merge-divider Sol Open Circuit 1
Action code Failure code Merge-divider solenoid disconnection

Trouble
— DWJ0KA (Pump controller system)
Contents of
• No current flows at output to merge-divider solenoid circuit.
trouble
Problem that
appears on • Single operation speed of work equipment and swing is high in lifting mode (L).
machine
• Operating condition of merge-divider solenoid (ON/OFF) can be checked with monitoring function.
Related infor-
mation
failure code [DWJ0KB].)

Defective merge-divider ing without turning starting switch ON.
1 solenoid
Between (1) – (2) 20 – 60 z
ness Wiring harness between CP03 (female) (17) Resis-
Max. 1 z
Possible causes 2 (Disconnection in wiring or – A05 – V06 (female) (1) tance
tor) Resis-
value in normal A04 – CP03 (female) (3), (13), (23) and Max. 1 z
state tance
chassis ground
3
Voltage Max. 1 V
Between (17) – (3), (13), (23) 20 – 60 z
22 PC228US, 228USLC-3E0
Circuit diagram related to merge-divider solenoid of pump controller
PC228US, 228USLC-3E0 23
Failure code [DWJ0KB] Merge-divider Sol Short Circuit 1
Action code Failure code Merge-divider solenoid short circuit

Trouble
— DWJ0KB (Pump controller system)
Contents of
• Abnormal current flowed at output to merge-divider solenoid circuit.
trouble
Action of con- • Turns output to merge-divider solenoid circuit OFF.
Problem that
appears on • Single operation speed of work equipment and swing is high in lifting mode (L).
machine
Related infor- • Operating condition of merge-divider solenoid (ON/OFF) can be checked with monitoring function.

Defective merge-divider ing without turning starting switch ON.
solenoid V06 (male) Resistance
1
Possible causes Ground fault in wiring har- a Prepare with starting switch OFF, then carry out troubleshoot-
and standard ness ing without turning starting switch ON.
value in normal 2
state cuit) Min. 1 Mz
CP03 Travel lever Voltage
At neutral Max. 1 V
Between (17) – (3),
(13), (23) When either side is
20 – 30 V
operated
24 PC228US, 228USLC-3E0
Circuit diagram related to merge-divider solenoid of pump controller
PC228US, 228USLC-3E0 25
Failure code [DWK0KA] 2-stage Relief Sol Open Circuit 1
Action code Failure code 2-stage relief solenoid disconnection

Trouble
— DWK0KA (Pump controller system)
Contents of
• No current flows at output to 2-stage relief solenoid circuit.
trouble
Problem that
appears on • Power maximizing function does not work.
machine
• Operating condition of 2-stage relief solenoid (ON/OFF) can be checked with monitoring function.
Related infor-
mation
failure code [DWK0KB].)

Defective 2-stage relief sole- ing without turning starting switch ON.
1 noid
Between (1) – (2) 20 – 60 z
ness
tor) Wiring harness between V02 (female) (2) – Resis-
state A04 – CP03 (female) (3), (13), (23) tance
3
Voltage Max. 1 V
Between (28) – chassis ground 20 – 60 z
26 PC228US, 228USLC-3E0
Circuit diagram related to 2-stage relief solenoid of pump controller
PC228US, 228USLC-3E0 27
Failure code [DWK0KB] 2-stage Relief Sol Short Circuit 1
Action code Failure code 2-stage relief solenoid short circuit

Trouble
— DWK0KB (Pump controller system)
Contents of
• Abnormal current flowed at output to 2-stage relief solenoid circuit.
trouble
Action of con- • Turns output to 2-stage relief solenoid circuit OFF.
Problem that
appears on • Power maximizing function does not work.
machine
Related infor- • Operating condition of 2-stage relief solenoid (ON/OFF) can be checked with monitoring function.

Defective 2-stage relief sole- ing without turning starting switch ON.
noid V02 (male) Resistance
1
Possible causes
and standard 2
value in normal (Short circuit with GND cir- Wiring harness between CP03 (female) (28) Resis-
cuit) Min. 1 Mz
state – A05 – V02 (female) (1) and chassis ground tance
3 Defective pump controller When L-mode is not
Max. 1 V
sis ground When L-mode is
20 – 30 V
selected
28 PC228US, 228USLC-3E0
Circuit diagram related to 2-stage relief solenoid of pump controller
PC228US, 228USLC-3E0 29
Failure code [DXA0KA] PC-EPC Sol Open Circuit 1
Action code Failure code PC-EPC solenoid disconnection

Trouble
E02 DXA0KA (Pump controller system)
Contents of
• No current flows to PC-EPC solenoid circuit.
trouble
Problem that
appears on • If pump load increases, engine speed lowers largely and engine may stall.
machine
• Output to PC-EPC solenoid (current value) can be checked with monitoring function.
(Code 01300: PC-EPC solenoid current)
Related infor-
• If solenoid and wiring harness are not defective, turn emergency drive switch on; the operator can
mation
operate the machine with output equivalent to E-mode. (Failure code [DXA0KA] is then displayed,
but it is not defective.)

Defective PC-EPC solenoid ing without turning starting switch ON.
1
(Internal disconnection) V11 (male) Resistance
Between (1) – (2) 7 – 14 z
S25 Switch Resistance
Defective emergency pump
2 drive switch (Internal discon- OFF Max. 1 z
Between (2) – (3)
nection) ON Min. 1 Mz
OFF Max. 1 z
Between (5) – (6)
ON Min. 1 Mz
Max. 1 z
and standard Disconnection in wiring har- – S25 (3) tance
value in normal ness Wiring harness between S25 (2) – A04 – V11 Resis-
state Max. 1 z
3 (Disconnection in wiring or (female) (1) tance
Wiring harness between CP03 (female) (3),
tor) Resis-
(13), (23) – A04 – V19 (female) (2) – chassis Max. 1 z
tance
ground
Wiring harness between S25 (5) – A04 – V11 Resis-
Max. 1 z
(female) (2) tance
Hot short (Short circuit with Wiring harness between CP03 (female) (16)
4 Voltage Max. 1 V
24V circuit) in wiring harness – S25 (3) and chassis ground
Wiring harness between S25 (2) – A04 – V11
Voltage Max. 1 V
(female) (1) and chassis ground
Between (16) – (3), (13), (23) 7 – 14 z
30 PC228US, 228USLC-3E0
Circuit diagram related to LS-EPC and PC-EPC solenoids of pump controller
PC228US, 228USLC-3E0 31
Failure code [DXA0KB] PC-EPC Sol Short Circuit 1
Action code Failure code PC-EPC solenoid short circuit

Trouble
E02 DXA0KB (Pump controller system)
Contents of
• Abnormal current flowed to PC-EPC solenoid circuit.
trouble
Action of con- • Sets output to PC-EPC solenoid circuit to 0.
Problem that
appears on • If pump load increases, engine speed lowers largely and engine may stall.
machine
• Output to PC-EPC solenoid (current value) can be checked with monitoring function.
(Code 01300: PC-EPC solenoid current)
Related infor- • If solenoid and wiring harness are not defective, turn emergency drive switch on; the operator can
mation operate the machine with output equivalent to E-mode. (Failure code [DXA0KA] is then displayed,
but it is not defective.)
a Turn emergency pump drive switch OFF during troubleshooting.

Defective PC-EPC solenoid
1 (Internal short circuit or V11 (male) Resistance
Possible causes
and standard
value in normal 2
cuit) Min. 1 Mz
– S25 – V11 (female) (1) and chassis ground tance
3 Defective pump controller CP03 (female) Resistance
Between (16) – (3), (13), (23) 7 – 14 z
32 PC228US, 228USLC-3E0
PC228US, 228USLC-3E0 33
Failure code [DXE0KA] LS-EPC Sol Open Circuit 1
Action code Failure code LS-EPC solenoid disconnection

Trouble
— DXE0KA (Pump controller system)
Contents of
• No current flows to LS-EPC solenoid circuit.
trouble
Problem that
• Travel speed Mi or Lo is high.
appears on
• Speed of work equipment and swing is high in lifting mode (L).
machine
Related infor- • Output to LS-EPC solenoid (current value) can be checked with monitoring function.
mation (Code 01500: LS-EPC solenoid current)

Defective LS-EPC solenoid ing without turning starting switch ON.
1
(Internal disconnection) V19 (male) Resistance
Between (1) – (2) 7 – 14 z
ness
A04 – V19 (female) (1) tance
tor) Wiring harness between CP03 (female) (3), Resis-
state (13), (23) – A04 – V19 (female) (2) tance
3
Voltage Max. 1 V
A04 – V19 (female) (1) and chassis ground
Between (6) – (3), (13), (23) 7 – 14 z
34 PC228US, 228USLC-3E0
PC228US, 228USLC-3E0 35
Failure code [DXE0KB] LS-EPC Sol Short Circuit 1
Action code Failure code LS-EPC solenoid short circuit

Trouble
— DXE0KB (Pump controller system)
Contents of
• Abnormal current flowed to LS-EPC solenoid circuit.
trouble
Action of con- • Sets output to LS-EPC solenoid circuit to 0.
Problem that
• Travel speed Mi or Lo is high.
appears on
• Work equipment speed and swing speed are high in lifting mode (L).
machine
Related infor- • Output to LS-EPC solenoid (current value) can be checked with monitoring function.
mation (Code 01500: LS-EPC solenoid current)

Defective LS-EPC solenoid
1 (Internal short circuit or V19 (male) Resistance
Possible causes
and standard
value in normal 2
state (Short circuit with GND cir- Wiring harness between CP03 (female) (6) – Resis-
cuit) Min. 1 Mz
A04 – V19 (female) (1) and chassis ground tance
Between (6) – (3), (13), (23) 7 – 14 z
36 PC228US, 228USLC-3E0
PC228US, 228USLC-3E0 37
Failure code [DXE4KA] Service Current EPC Open Circuit 1
Action code Failure code Service current EPC solenoid disconnection

Trouble
— DXE4KA (Pump controller system)
Contents of
• No current flows to service current EPC solenoid circuit.
trouble
Problem that
appears on • Attachment does not move.
machine
• Carry out troubleshooting only for setting with ATT. (Confirm settings on the machine monitor.)
Related infor-
• Output to service current EPC solenoid (current value) can be checked with monitoring function.
mation
(Code 01700: Service solenoid current)

Defective service current ing without turning starting switch ON.
1 EPC solenoid (Internal dis-
connection)
Between (1) – (2) 7 – 14 z
ness
tor) Wiring harness between CP03 (female) (3), Resis-
state (13), (23) – A04 – V07 (female) (2) tance
3
Voltage Max. 1 V
Between (26) – (3), (13), (23) 7 – 14 z
Circuit diagram related to service current EPC solenoid of pump controller
38 PC228US, 228USLC-3E0
Failure code [DXE4KB] Service Current EPC Short Circuit 1
Action code Failure code Service current EPC solenoid short circuit
Trouble
— DXE4KB (Pump controller system)
Contents of
• Abnormal current flowed to service current EPC solenoid circuit.
trouble
Action of con- • Sets output to service current EPC solenoid circuit to 0.
Problem that
appears on • Attachment does not move.
machine
• Carry out troubleshooting only for setting with ATT. (Confirm settings on the machine monitor.)
Related infor-
• Output to service current EPC solenoid (current value) can be checked with monitoring function.
mation
(Code 01700: Service solenoid current)

Defective service current
1 EPC solenoid (Internal short V07 (male) Resistance
circuit or ground fault) Between (1) – (2) 7 – 14 z
Possible causes
and standard
value in normal 2
cuit) Min. 1 Mz
Between (26) – (3), (13), (23) 7 – 14 z
Circuit diagram related to service current EPC solenoid of pump controller
PC228US, 228USLC-3E0 39
Failure code [DY20KA] Wiper Working Abnormality 1
Action code Failure code Wiper working abnormality

Trouble
— DY20KA (Machine monitor system)
Contents of
• When windshield wiper works, W signal of working ends is not input.
trouble
Action of
machine moni- • Turns working output to wiper motor OFF.
tor
Problem that
appears on • Windshield wiper does not operate.
machine
Related infor- • Input of W signal in wiper working area (ON/OFF) can be checked with monitoring function.
mation (Code 04502: Monitor Input 3)

Defective wiper motor W04 (female) Wiper blade Resistance
1
(Internal disconnection) Operating range top Max. 1 z
Between (6) – (5) Other than operating
Min. 1 Mz
range top
Possible causes Disconnection in wiring har- ing without turning starting switch ON.
and standard ness
value in normal 2 (Disconnection in wiring or Max. 1 z
state W04 (male) (6) tance
tor) Wiring harness between W04 (male) (5) – Resis-
Max. 1 z
P01 Wiper blade Voltage
Operating range top Max. 1 V
sis ground Other than operating
20 – 30 V
range top
40 PC228US, 228USLC-3E0
Circuit diagram related to wiper motor of machine monitor
PC228US, 228USLC-3E0 41
Failure code [DY20MA] Wiper Parking Abnormality 1
Action code Failure code Wiper resting abnormality

Trouble
— DY20MA (Machine monitor system)
Contents of
• When windshield wiper rests, P signal of storage area is not input.
trouble
Action of
machine moni- • Turns resting output to wiper motor OFF.
tor
Problem that
appears on • Windshield wiper does not rest.
machine
Related infor- • Input of P signal in wiper resting area (ON/OFF) can be checked with monitoring function.

Defective wiper motor W04 (female) Wiper blade Resistance
1
Storage area Max. 1 z
Between (4) – (5)
Working area Min. 1 Mz
Possible causes Disconnection in wiring har- ing without turning starting switch ON.
and standard ness
value in normal 2 (Disconnection in wiring or Max. 1 z
state W04 (male) (4) tance
tor) Wiring harness between W04 (female) (5) – Resis-
Max. 1 z
3 Defective machine monitor P01 Wiper blade Voltage
Between (12) – chas- Storage area Max. 1 V
sis ground Working area 20 – 30 V
42 PC228US, 228USLC-3E0
PC228US, 228USLC-3E0 43
Failure code [DY2CKB] Washer Drive Short Circuit 1
Action code Failure code Window washer drive system short circuit
Trouble
— DY2CKB (Machine monitor system)
Contents of • When washer drive circuit was connected to GND (when output was turned ON), abnormal current
trouble flowed.
Action of
machine moni- • Turns output to washer motor circuit OFF.
tor
Problem that
appears on • Window washer operation stops.
machine
Related infor-
mation

Defective washer motor ing without turning starting switch ON.
1
(Internal short circuit) M06 (male) Resistance
Between (1) – (2) 5 – 20 z
Possible causes and carry out troubleshooting.
and standard Hot short (Short circuit with
2
value in normal 24V circuit) in wiring harness Wiring harnesses between P01 (female) (3)
state – H10 – J04 – A05 – M06 (female) (2), – D02 Voltage Max. 1 V
3 Defective machine monitor P01 Washer switch Voltage
Between (3) – chas- OFF 20 – 30 V
sis ground ON Max. 1 V
44 PC228US, 228USLC-3E0
Circuit diagram related to window washer motor of machine monitor
PC228US, 228USLC-3E0 45
Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit 1
Action code Failure code Wiper motor drive forward system short circuit
Trouble
— DY2DKB (Machine monitor system)
Contents of
• Abnormal current flowed at output to wiper motor drive forward circuit.
trouble
Action of
machine moni- • Turns output to wiper motor drive forward circuit OFF.
tor
Problem that
machine
Related infor-
mation

Defective wiper motor
1 (Internal short circuit or W04 (female) Continuity/Resistance
ground fault) Between (3) – (1) There is continuity
value in normal 2
(Short circuit with GND cir- Wiring harness between P01 (female) (9) – Resis-
W04 (male) (3) and chassis ground tance
P01 Wiper switch Voltage
OFF Max. 3 V
sis ground Max. 3 V ⇔ 20 – 30 V
ON
(Constant cycle)
46 PC228US, 228USLC-3E0
PC228US, 228USLC-3E0 47
Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit 1
Action code Failure code Wiper motor drive reverse system short circuit
Trouble
— DY2EKB (Machine monitor system)
Contents of
• Abnormal current flowed at output to wiper motor drive reverse circuit.
trouble
Action of
machine moni- • Turns output to wiper motor drive reverse circuit OFF.
tor
Problem that
machine
Related infor-
mation

Defective wiper motor
1 (Internal short circuit or W04 (female) Continuity/Resistance
ground fault) Between (1) – (3) There is continuity
value in normal 2
W04 (male) (1) and chassis ground tance
OFF Max. 3 V
sis ground Max. 3 V ⇔ 20 – 30 V
ON
(Constant cycle)
48 PC228US, 228USLC-3E0
PC228US, 228USLC-3E0 49
SEN01887-02

© 2009 KOMATSU
All Rights Reserved
50
SEN01888-02
PC228US-3E0
PC228USLC-3E0

Troubleshooting of electrical system
(E-mode)
Before carrying out troubleshooting of electrical system ................................................................................ 3
Information contained in troubleshooting table ............................................................................................... 5
E-1 Engine does not start ............................................................................................................................... 6
E-2 Auto-decelerator does not operate........................................................................................................... 9
E-3 Automatic warming-up system does not operate ....................................................................................11
E-4 Preheater does not operate.................................................................................................................... 12
E-5 All work equipment, swing, and travel mechanism do not move............................................................ 14
E-6 Power maximizing function does not operate......................................................................................... 16
E-7 Machine monitor does not display at all ................................................................................................. 18
E-8 Machine monitor does not display some items ...................................................................................... 20
E-9 Contents of display by machine monitor are different from applicable machine .................................... 20
E-10 Fuel level monitor was lighted in red while engine running .................................................................. 21
E-11 Engine coolant temperature gauge does not indicate normally............................................................ 22
E-12 Hydraulic oil temperature gauge does not indicate normally................................................................ 24
E-13 Fuel level gauge does not indicate normally ........................................................................................ 25

E-14 Swing lock monitor does not indicate normally..................................................................................... 26
E-15 When monitor switch is operated, monitor displays nothing................................................................. 28
E-16 Windshield wiper and window washer do not operate.......................................................................... 30
E-17 Monitoring function fails to display “boom raise” normally.................................................................... 34
E-18 Monitoring function fails to display “boom lower” normally ................................................................... 35
E-19 Monitoring function fails to display “arm IN” normally........................................................................... 36
E-20 Monitoring function fails to display “arm OUT” normally....................................................................... 37
E-21 Monitoring function fails to display “bucket CURL” normally ................................................................ 38
E-22 Monitoring function fails to display “bucket DUMP” normally ............................................................... 39
E-23 Monitoring function fails to display “swing left” normally....................................................................... 40
E-24 Monitoring function fails to display “swing right” normally .................................................................... 42
E-25 Monitoring function fails to display “travel” normally............................................................................. 44
E-26 Monitoring function fails to display “travel differential pressure” normally ............................................ 46
E-27 Monitoring function fails to display “service” normally .......................................................................... 48
E-28 The KOMTRAX system does not work properly................................................................................... 50
E-29 Air conditioner does not operate........................................................................................................... 52
E-30 Travel alarm does not sound or does not stop sounding...................................................................... 54
E-31 Horn does not sound ............................................................................................................................ 56
E-32 Attachment circuit does not change ..................................................................................................... 58
Before carrying out troubleshooting of electrical system 1

Connection table of fuse box
a This connection table shows the devices to which each power supply of the fuse box supplies power (A
switch power supply is a device which supplies power while the starting switch is in the ON position and
a constant power supply is a device which supplies power while the starting switch is in the OFF and ON
positions).
a When carrying out troubleshooting related to the electrical system, you should check the fuses and fus-
ible links to see if the power is supplied normally.
Fuse
Type of power supply Fusible link Fuse No. Destination of power
capacity
Lamp relay, rear lamp relay, cab lamp relay
PC-EPC (F) solenoid valve, PC-EPC (R) solenoid valve
1 10A [When pump drive switch is operated in emergency]
Swing holding brake solenoid valve
[When swing holding brake release switch is operated]
2 20A Pump controller (Solenoid power supply)
F04
Switch power supply PPC oil pressure lock solenoid valve
(60A)
3 20A Starting motor cut-out relay (PPC lock)
Starting motor cut-out relay (Personal code)
Cigarette lighter
4 10A
Windshield washer motor
5 10A Horn relay, horn
6 10A Intake air heater relay
7 10A Rotary lamp
Right headlamp, working lamp (boom), working lamp
F04 8 20A
Switch power supply (rear)
(60A)
Radio
9 10A
Left knob switch (pump controller input)
10 10A (Spare)
Air conditioner unit
11 20A
Air conditioner compressor electromagnetic clutch
12 10A (Spare)
F04
Switch power supply 13 20A Headlamp
(60A)
14 10A Optional power supply (1)
Travel alarm
15 10A
Optional power supply (2)
Radio (backup power supply)
16 10A
A/C servo
Starting switch
F05
Constant power supply 17 20A Machine monitor
(30A)
Pump controller
18 10A (Spare)
19 30A Engine controller
Starting switch
Switch power supply 20 5A Engine controller (ACC signal)
ACC
Information contained in troubleshooting table 1

a Troubleshooting Table and Related Circuit Diagram collectively carry the following information. Carry out
troubleshooting work after fully grasping their contents.
Failure phe-
Phenomenon occurring on machine
nomenon
Relative infor-
Information on the failure occurred as well as the troubleshooting
mation
<Contents of description>
• Standard value in normal state to judge possible causes
• Remarks on judgment
1 <Troubles in wiring harness>
• Disconnection
Connector is connected imperfectly or wiring harness is bro-
ken.
• Ground fault
Wiring harness which is not connected to chassis ground
circuit is in contact with chassis ground circuit.
• Hot short
Wiring harness which is not connected to power source (24
V) circuit is in contact with power source (24 V) circuit.
2
• Short circuit
Independent wiring harnesses are in contact with each other
Possible causes abnormally.
and standard Possible causes of trouble
value in normal (Given numbers are refer-
state ence numbers, which do not <Precautions for troubleshooting>
indicate priority) (1) Method of indicating connector No. and handling of T-
adapter
Insert or connect T-adapter as explained below for trouble-
3 shooting, unless otherwise specified.
• If connector No. has no marks of “male” and “female”,
disconnect connector and insert T-adapters in both male
side and female side.
• If connector No. has marks of “male” and “female”, dis-
connect connector and connect T-adapter to only male
side or female side.
(2) Entry order of pin Nos. and handling of tester leads
Connect positive (+) lead and negative (–) lead of tester as
explained below for troubleshooting, unless otherwise
4 specified.
• Connect positive (+) lead to pin No. or wiring harness
entered on front side.
• Connect negative (–) lead to pin No. or harness entered
on rear side.
Relative Electrical Circuit Diagram
This is part of the electrical circuit diagram

which shows the portion where the failure
occurred.
• Connector No.: Indicates (Type – numbers of a
pin) (color)
• Arrow : Roughly indicates the location in the
machine where it is installed.
E-1 Engine does not start 1
Trouble • Engine does not start (Engine does not turn).

• Engine starting circuit has following 2 start lock mechanisms:
Related infor- 1) Start lock by the machine monitor password
mation 2) Start lock by the lock lever
• In the case no failure code for the engine controller mechanism is indicated

Battery voltage Specific gravity of battery
1 Low charge level of battery
Min. 24 V Min. 1.26
If fuse or fusible link is burnt out, the circuit probably has ground
Defective fuse No. 3, No. 17 fault.
2
or fusible link F04 and F05 In the case the machine monitor does not light up, check the power
circuit between the battery and the fuse.
Defective starting switch H15 (male) Position Resistance
3
OFF Min. 1 Mz
Between (1) – (4)
START Max. 1 z
Defective lock switch S14 (female) Lock lever Resistance
4
(internal short circuit)
Free Min. 1 Mz
Between (1) – (3)
Lock Max. 1 z
Possible causes
and standard
value in normal ing without turning starting switch ON.
Defective starting motor cut-
state out relay R06 or R07 (Inter- R06 (female), R07 (female) Resistance
5
nal short circuit or ground Between (1) – (2) 100 – 500 z
fault) Between (3) – (5) Min. 1 Mz
(If power supply and starting input and output are normal but
starting motor does not turn, starting motor is defective.)
Defective starting motor
Starting
6 (Internal disconnection or Starting motor Voltage
switch
breakage)
Power supply: Between terminal
20 – 30 V
B and chassis ground When
Starting input: Terminal C – chas- started
20 – 30 V
sis ground
Defective alternator or start engine and carry out troubleshooting.
7
(Internal short circuit) Alternator Voltage
Terminal L – chassis ground Max. 1 V

Wiring harness between F01-17 outlet – H15 Resis-
Max. 1 z
(female) (1) tance
Wiring harness between H15 (female) (4) – Resis-
Max. 1 z
J01 – R06 (female) (5) tance
Disconnection in wiring har- Wiring harness between R07 (female) (3) – Resis-
ness Max. 1 z
A07 – R17 (female) (1) tance
Wiring harness between F01-3 outlet – J06 – Resis-
tor) S14 (male) (1) tance
Max. 1 z
Max. 1 z
Max. 1 z
Possible causes Wiring harness between battery relay termi-
Resis-
and standard nal B (R04) – F05 – A01 – F01-17 inlet and Min. 1 Mz
tance
value in normal chassis ground
state Wiring harness between F01-17 outlet – H15 Resis-
Min. 1 Mz
(female) (1) and chassis ground tance
Ground fault in wiring har- Wiring harness between H15 (female) (4) – Resis-
Min. 1 Mz
ness J01 – R06 (female) (5) and chassis ground tance
9
(Short circuit with GND cir- Wiring harness between R07 (female) (3) – Resis-
cuit) Min. 1 Mz
A07 – R17 (female) (1) and chassis ground tance
Min. 1 Mz
S14 (female) (1) and chassis ground tance
Wiring harness between S14 (female) (3) – Resis-
Min. 1 Mz
R06 (female) (1) and chassis ground tance
Wiring harness between R07 (female) (2) –
Resis-
J05 – H11 – P02 (female) (14) and chassis Min. 1 Mz
tance
ground
Hot short (Short circuit with Wiring harness between P02 (female) (11) –
10
24V circuit) in wiring harness H11 – J02 – A07 – R17 (female) (2), – D01
Voltage Max. 1 V
(female) (6), – alternator terminal L and
chassis ground
Defective engine controller As the engine controller power supply can be detective, carry out
11
power supply troubleshooting for “Failure code CA441, CA442”.
Circuit diagram related to engine start and battery charging
E-2 Auto-decelerator does not operate 1
Trouble • Auto-decelerator does not operate.

• Set speed of auto-decelerator is 1,300 rpm. Accordingly, set the fuel control dial to a higher rpm than
Related infor-
this speed. If set speed is under 1,300 rpm, the auto-decelerator will not operate.
mation
• Check all the monitoring indications after starting the engine.

In the case monitoring is not normally indicated, proceed to trouble-
shooting No. E-17.
Defective boom RAISE sig- Monitoring code Item Normal display
1
nal Operation of lever:
01900 Boom RAISE ON
Lever in neutral: OFF
shooting No. E-18.
Defective boom LOWER sig- Monitoring code Item Normal display
2
01900 Boom LOWER ON
shooting No. E-19.
Monitoring code Item Normal display
3 Defective arm IN signal
Operation of lever:
01900 Arm IN ON
Possible causes shooting No. E-20.
and standard
value in normal Monitoring code Item Normal display
4 Defective arm OUT signal
state Operation of lever:
01900 Arm OUT ON
shooting No. E-21.
Defective bucket CURL sig- Monitoring code Item Normal display
5
01901 Bucket CURL ON
shooting No. E-22.
Defective bucket DUMP sig- Monitoring code Item Normal display
6
01901 Bucket DUMP ON
shooting No. E-23, E-24.
7 Defective swing signal
Operation of lever:
01900 Swing ON

shooting No. E-25.
8 Defective travel signal
Operation of lever:
01900 Travel ON
Possible causes Lever in neutral: OFF
and standard In the case monitoring is not normally indicated, proceed to trouble-
value in normal shooting No. E-27.
state
9 Defective attachment signal
Operation of lever:
01901 Service ON
Since trouble is in system, troubleshooting cannot be carried out.
10 Defective pump controller (If causes 1 – 9 above are not detected, pump controller may be
defective.)
10 PC228US, 228USLC-3E0
E-3 Automatic warming-up system does not operate 1
Trouble • Automatic warming-up system does not operate

• When engine coolant temperature is below 30°C, automatic warm-up system raises engine speed to
Related infor- 1,250 rpm.
mation • If fuel control dial is opened more than 70% for 3 seconds or longer when starting switch is turned
ON or after engine is started, automatic warm-up system is turned OFF.

shooting No. E-11.
Possible causes Defective engine coolant Monitoring code Item Normal display
1
and standard temperature signal Compare with actual
value in normal Engine coolant tem-
04105 engine coolant tem-
state perature
perature
Since trouble is in system, troubleshooting cannot be carried out. (If
2 Defective pump controller causes stated above are not detected, pump controller may be
defective.)
PC228US, 228USLC-3E0 11
E-4 Preheater does not operate 1
Trouble (1) When starting switch is turned to HEAT position, preheating monitor does not light up.
Related infor- Input of preheating signal (ON/OFF) can be checked with monitoring function.

Defective starting switch sys- If preheating fails to operate (the heater does not warm up), perform
1
tem troubleshooting for Trouble (2).
Disconnection in wiring har- a Prepare with starting switch OFF, then turn starting switch ON
ness and carry out troubleshooting.
Possible causes 2 (Disconnection in wiring or
and standard defective contact in connec- Wiring harness between P02 (female) (18) – Resis-
Max. 1 z
value in normal tor) H11 – J02 (male) (7) tance
state
3 Defective machine monitor P02 Starting switch Voltage
Between (18) – chas- OFF Max. 1 V
sis ground HEAT 20 – 30 V
Trouble (2) • When starting switch is turned to HEAT position, preheater does not warm up.
Related infor- • During low temperature (coolant temperature below –4°C), engine controller actuates to automati-
mation cally preheat.

Defective starting switch H15 (male) Starting switch Resistance
1
OFF Min. 1 Mz
Between (1) – (3)
HEAT Max. 1 z
Defective heater relay Heater relay Resistance
2
Possible causes (Internal disconnection) Coil terminal (R15) –
and standard 300 – 600 z
chassis ground
value in normal
Between contact terminals Min. 1 Mz
state
Defective intake air heater ing without turning starting switch ON.
3
(Internal disconnection).
Between heater terminals Normal if conductive
ness Wiring harness between H15 (female) (3) – Resis-
Max. 1 z
4 (Disconnection in wiring or J02 – A07 – Heater relay terminal R15 tance
defective contact in connec- Wiring harness between battery relay termi-
tor) Resis-
nal M (R03) – Heater relay terminal power Max. 1 z
tance
supply inlet
12 PC228US, 228USLC-3E0
Circuit diagram related to engine preheater
PC228US, 228USLC-3E0 13
E-5 All work equipment, swing, and travel mechanism do not move 1
Trouble • All travel, swing, and work equipment mechanism do not move.
Related infor-
—
mation

If fuse is burnt out, the circuit probably has ground fault. (See Cause
1 Defective fuse No. 3
4.)
Defective lock switch (inter- S14 (female) Lock lever Resistance
2
nal disconnection)
Lock Min. 1 Mz
Between (1) – (2)
Free Max. 1 z
Defective PPC lock solenoid
3 (Internal disconnection or V01 (male) Resistance
short circuit) Between (1) – (2) 20 – 60 z
Possible causes Defective assembled-type ing without turning starting switch ON.
and standard 4 diode D01
D01 (male) Resistance
value in normal (Internal short circuit)
state Between (4) – (8) Min. 1 Mz
Disconnection in wiring har- Wiring harness between F01-3 outlet – J06 – Resis-
ness Max. 1 z
S14 (male) (1) tance
tor) J02 – A05 – V01 (male) (1) tance
Max. 1 z
ness Min. 1 Mz
6 S14 (male) (1) and chassis ground tance
(Short circuit with GND cir-
cuit) Wiring harness between S14 (male) (2) –
Resis-
J02 – A05 – V01(female) (1), – D01(female) Min. 1 Mz
tance
(4) and chassis ground
14 PC228US, 228USLC-3E0
Circuit diagram related to PPC lock solenoid
PC228US, 228USLC-3E0 15
E-6 Power maximizing function does not operate 1
Trouble • Power maximizing function does not work.

• Symbol mark is indicated on the machine monitor when the power maximizing switch is depressed
Related infor- during work equipment operation while the engine is running in P- or E-mode.
mation • Input state of power maximizing switch (left knob switch) can be checked with monitoring function
(Code 02200: Switch Input 1)

If fuse is burnt out, the circuit probably has ground fault. (See Cause
4.)
Defective power maximizing
2 switch (Internal disconnec- M23 (male) Switch Resistance
tion) Released Min. 1 Mz
Between (1) – (2)
Pressed Max. 1 z
ness
Wiring harness between F01-9 outlet – M23 Resis-
(female) (1) tance
tor) Wiring harness between M23 (female) (2) – Resis-
state CP01 (female) (11) tance
ness Wiring harness between F01-9 outlet – M23 Resis-
4 Min. 1 Mz
(Short circuit with GND cir- (female) (1) and chassis ground tance
cuit)
Wiring harness between M23 (female) (2) – Resis-
Min. 1 Mz
CP01 (female) (11) and chassis ground tance
5 Defective pump controller CP01 Switch Voltage
Between (11) – chas- Released Max. 1 V
sis ground Pressed 20 – 30 V
Circuit diagram related to power max. switch
16 PC228US, 228USLC-3E0
PC228US, 228USLC-3E0 17
E-7 Machine monitor does not display at all 1
Trouble • Machine monitor does not display at all when starting switch is turned ON
Related infor-
—
mation

If fuse is burnt out, the circuit probably has ground fault.
(See cause 3.)
ness
Wiring harness between P01(female) (1) (2) Resis-
– H10 – J06 – F01-3 outlet tance
tor) Wiring harness between P01 (female) (6), Resis-
Max. 1 z
(7) – chassis ground tance
Possible causes
and standard Ground fault in wiring har- ing without turning starting switch ON.
state 3 Wiring harness between P01(female) (1), (2)
cuit) – H10 – J06 – F01-3 outlet and chassis Min. 1 Mz
tance
ground
P01 (female) Voltage/Resistance
4 Defective machine monitor Between (1), (2) –
Voltage: 20 – 30 V
chassis ground
Between (6), (7) –
Resistance: Max. 1 z
chassis ground
18 PC228US, 228USLC-3E0
Circuit diagram related to power source in machine monitor
PC228US, 228USLC-3E0 19
E-8 Machine monitor does not display some items 1
Trouble • Machine monitor does not display some items when starting switch is turned ON
Related infor-
—
mation

When following switches are operated, if all LCD panel is lighted up
Possible causes Defective machine monitor
1 (all surface becomes white), LCD panel is normal.
and standard LCD
• Switch operation: [/] + [A] (Simultaneous operation)
value in normal
state Since trouble is in system, troubleshooting cannot be carried out. (If
2 Defective machine monitor causes stated above are not detected, machine monitor may be
defective.)
E-9 Contents of display by machine monitor are different from

applicable machine 1
Trouble • Contents of display by machine monitor are different from applicable machine.
Related infor-
—
mation

In the case monitoring display is not normal, proceed to failure code
[DA2SKQ].
Possible causes Defective model code signal Monitoring code Item Normal display
1
and standard (Internal defect) 00200 Controller model
value in normal code 228
state 00201 Select model
Since trouble is in system, troubleshooting cannot be carried out. (If
2 Defective machine monitor causes stated above are not detected, machine monitor may be
defective.)
20 PC228US, 228USLC-3E0
E-10 Fuel level monitor was lighted in red while engine running 1
Trouble • Fuel level monitor was lighted in red while the engine running
• If fuel level gauge on the machine monitor indicates red range, fuel level monitor turns red.
Related infor-
• Input signal (voltage) from the fuel level sensor can be checked with monitoring function.
mation
(Code 04200: Fuel level sensor voltage)

Low fuel level
1 a Add fuel
(When system is normal)
Defective fuel level sensor P21 (male) Fuel level Resistance
2
Between (1) and FULL (Upper limit) Approx. 12 z
Possible causes chassis ground EMPTY (Lower limit) 85 – 110 z
and standard Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshoot-
value in normal ness ing without turning starting switch ON.
state 3 (Disconnection in wiring or
Max. 1 z

4 Defective machine monitor P02 (female) Fuel level Resistance
Between (2) and FULL (Upper limit) Approx. 12 z
chassis ground EMPTY (Lower limit) 85 – 110 z
Circuit diagram related to fuel level sensor
PC228US, 228USLC-3E0 21
E-11 Engine coolant temperature gauge does not indicate normally 1
• While engine coolant temperature is rising normally, temperature gauge does not rise from white
Trouble range (C).
• While engine coolant temperature is stabilized normally, temperature gauge rises to red range (H).
• Input from the engine coolant temperature sensor (temperature) can be checked with monitoring
function. (Code: 04105: Engine coolant temperature)
Related infor- • Check if failure code for abnormal communication (machine monitor) system [DAFRMC] is indicated
mation (if yes, diagnose that failure first.)
• Signal of engine coolant temperature sensor is input to engine controller and then its information is
transmitted to machine monitor through communication system.

Defective coolant tempera- without turning starting switch ON.
1
ture sensor COOLANT TEMP (male) Resistance
Between (A) – (B) 0.18 – 160 kz
2 Max. 10 z
or defective contact in con- – COOLANT TEMP (female) (B) tance
Max. 10 z
– JC03 – COOLANT TEMP (female) (A) tance
value in normal
state Resis- Min. 100
harness) – each of CE01 (female) pins (With all wiring
tance kz
4
Between (15) – (38) 0.18 – 160 kz
22 PC228US, 228USLC-3E0
PC228US, 228USLC-3E0 23
E-12 Hydraulic oil temperature gauge does not indicate normally 1
• While hydraulic oil temperature is rising normally, temperature gauge does not rise from white range
Trouble (C).
• While hydraulic oil temperature is stabilized normally, temperature gauge rises to red range (H).
Related infor- • Input from the hydraulic oil temperature sensor (temperature) can be checked with monitoring func-
mation tion. (Code 04402: Hydraulic oil temperature)

Defective hydraulic oil tem- Hydraulic oil
perature sensor P22 (male) Resistance
1 temperature
short circuit) Between (2) – (1) 90 – 3.5 kz
Between (2) – chas- 10 – 100°C
Min. 1 Mz
sis ground
ness
and standard
value in normal Ground fault in wiring har- a Prepare with starting switch OFF, then carry out troubleshoot-
state ness ing without turning starting switch ON.
3
cuit) Min. 1 Mz
P22 (female) (2) and chassis ground tance
4
24V circuit) in wiring harness Wiring harness between P02 (female) (12) –
Voltage Max. 1 V
P22 (female) (2) and chassis ground
Hydraulic oil
P02 Resistance
5 Defective machine monitor temperature
Between (12) – (13) 90 – 3.5 kz
Between (12) – chas- 10 – 100°C
Min. 1 Mz
sis ground
Circuit diagram related to hydraulic oil temperature sensor
24 PC228US, 228USLC-3E0
E-13 Fuel level gauge does not indicate normally 1
• While fuel is added, fuel level gauge does not rise from red range (E).
Trouble
• While fuel level is low, fuel level gauge does not lower from green range (F)
Related infor- • Input signal (voltage) from the fuel level sensor can be checked with monitoring function. (Code
mation 04200: Fuel level sensor voltage)

Defective fuel level sensor
1 (Internal disconnection or P21 (male) Fuel level Resistance
short circuit)
Between (1) – chas- FULL (Upper limit) Approx. 12 z
sis ground EMPTY (Lower limit) 85 – 110 z
Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshoot-
Max. 1 z
and standard
ness
value in normal 3 Wiring harness between P02 (female) (2) –
state H10 – A06 – P21 (female) (1) and chassis Min. 1 Mz
cuit) tance
ground
4
H10 – A06 – P21 (female) (1) and chassis Voltage Max. 1 V
ground
5 Defective machine monitor P02 Fuel level Resistance
Between (2) – chas- FULL (Upper limit) Approx. 12 z
sis ground EMPTY (Lower limit) 85 – 110 z
Circuit diagram related to fuel level sensor
PC228US, 228USLC-3E0 25
E-14 Swing lock monitor does not indicate normally 1
• When swing lock switch is turned ON, swing lock monitor does not light up.
Trouble
• When swing lock switch is turned OFF, swing lock monitor lights up.
Related infor- • Input from swing lock switch (ON/OFF) can be checked with monitoring function.

Defective swing lock switch
1 (Internal disconnection or S04 (female) Swing lock switch Resistance
short circuit) OFF Min. 1 Mz
Between (1) – (2)
ON Max. 1 z
ness
H11 – J02 – H15 – S04 (male) (1) tance
tor) Wiring harness between S04 (male) (2) – Resis-
Max. 1 z
Possible causes
state 3 Wiring harness between P02 (female) (17) –
cuit) H11 – J02 – H15 – S04 (male) (1) and chas- Min. 1 Mz
tance
sis ground
4
H11 – J02 – H15 – S04 (male) (1) and chas- Voltage Max. 1 V
sis ground
5 Defective machine monitor P02 Swing lock switch Voltage
Between (17) – OFF 20 – 30 V
chassis ground ON Max. 1 V
26 PC228US, 228USLC-3E0
Circuit diagram related to swing lock switch
PC228US, 228USLC-3E0 27
E-15 When monitor switch is operated, monitor displays nothing 1
Trouble (1) • Operating the working mode select switch fails to display working mode monitor.
Related infor-
—
mation

and standard
value in normal 1 Defective machine monitor Since trouble is in system, troubleshooting cannot be carried out.
state
Trouble (2) • When auto-decelerator switch is operated, auto-decelerator monitor is not displayed.
Related infor-
a If auto-decelerator fails to operate, proceed with troubleshooting No. E-2.
mation

and standard
state
Trouble (3) • Operating the travel speed select switch fails to display travel speed monitor.
Related infor-
a If travel speed selection fails, proceed with troubleshooting No. H-21.
mation

and standard
state
Trouble (4) • When wiper switch is operated, wiper monitor is not displayed.
Related infor-
a If wiper fails to operate, proceed with troubleshooting No. E-16.
mation

and standard
state
• When select switch is operated, adjust screen is not displayed.

Trouble (5) • When LCD monitor adjust switch is operated, adjust screen is not displayed.
• When maintenance switch is operated, maintenance item screen is not displayed.
Related infor-
—
mation

and standard
state
28 PC228US, 228USLC-3E0
PC228US, 228USLC-3E0 29
E-16 Windshield wiper and window washer do not operate 1
Trouble • Windshield wiper and window washer do not operate (1) Windshield wiper does not operate.
Related infor- • Input from window limit switch (ON/OFF) can be checked with monitoring function.

Defective window limit switch W03 (male) Front window Resistance
1 (Internal disconnection or When installed to
short circuit) Min. 1 Mz
front
Between (1) – (2)
When retracted to
Max. 1 z
rear
Defective wiper motor W04 (male) Resistance
2 (Internal disconnection or
short circuit) Between (3) – (1)
Between (3), (1) – chassis
Min. 1 Mz
ground
ness
W04 (female) (3) tance
Possible causes defective contact in connec-
and standard tor) Wiring harness between P01 (female) (10) – Resis-
Max. 1 z
value in normal W04 (female) (1) tance
state a Prepare with starting switch OFF, then carry out troubleshoot-
ness
4 Wiring harness between P02 (female) (15) –
cuit) H11 – H08 – W03 (female) (1) and chassis Min. 1 Mz
tance
ground
Defective machine monitor P02 Front window Voltage
(window limiter switch sys- When installed to
tem) 20 – 30 V
Between (15) – chas- front
sis ground When retracted to
Max. 1 V
rear
5
Defective machine monitor
(Wiper motor system) Between (9) – OFF Max. 3 V
chassis ground
Between (10) – Max. 3 V ⇔ 20 – 30 V
ON
chassis ground (Constant cycle)
30 PC228US, 228USLC-3E0
Circuit diagram related to windshield wiper motor
PC228US, 228USLC-3E0 31
Trouble • Windshield wiper and window washer do not operate (2) Window washer does not operate.
Related infor-
mation

1 Defective fuse No. 4 If fuse is broken, circuit probably has ground fault (See cause 4).
Defective washer motor
2 (Internal disconnection or M06 (male) Resistance
short circuit) Between (1) – (2) 5 – 20 z
ness
Wiring harness between F01-4 – J03 – J06 – Resis-
A05 – M06 (female) (1) tance
tor) Wiring harness between M06 (female) (2) – Resis-
A05 – J04 – H10 – P01 (female) (3) tance
and standard
value in normal
state ing without turning starting switch ON.
Wiring harness between F01-4 – J03 – J06 –
A05 – M06 (female) (1), – D02 (female) (3), Resis-
ness Min. 1 Mz
4 – other harnesses between related circuits tance
(Short circuit with GND cir-
and chassis ground
cuit)
Wiring harness between M06 (female) (2) –
Resis-
A05 – J04 – H10 – P01 (female) (3), – D02 Min. 1 Mz
tance
Defective machine monitor Windshield washer
5 (window limiter switch sys- P01 Voltage
switch
tem)
Between (3) – OFF 20 – 30 V
chassis ground ON Max. 1 V
32 PC228US, 228USLC-3E0
Circuit diagram related to window washer motor of machine monitor
PC228US, 228USLC-3E0 33
E-17 Monitoring function fails to display “boom raise” normally 1
Trouble • Boom RAISE operation is not displayed normally by machine monitoring function (Special functions)
Related infor-
• Monitoring code: 01900 (Pressure Switch 1)
mation

Defective boom RAISE PPC out troubleshooting.
oil pressure switch (Internal P06 (male) Boom lever Resistance
1
disconnection or short cir-
cuit) Neutral Min. 1 Mz
Between (1) – (2)
Boom RAISE Max. 1 z
ness
and standard
3
cuit) Min. 1 Mz
– P06 (female) (1) and chassis ground tance
4
Voltage Max. 1 V
– P06 (female) (1) and chassis ground
5 Defective pump controller CP03 Boom lever Voltage
Between (10) – Neutral 20 – 30 V
chassis ground Boom RAISE Max. 1 V
Circuit diagram related to boom RAISE PPC oil pressure switch
34 PC228US, 228USLC-3E0
E-18 Monitoring function fails to display “boom lower” normally 1
• Boom LOWER operation is not displayed normally by machine monitoring function (Special func-
Trouble
tions)
Related infor-
• Monitoring code: 01900 (Output Switch 1)
mation

Defective boom LOWER out troubleshooting.
PPC oil pressure switch P12 (male) Boom lever Resistance
1
short circuit) Neutral Min. 1 Mz
Between (1) – (2)
Boom LOWER Max. 1 z
ness
A06 – P12 (female) (1) tance
and standard
3
cuit) Min. 1 Mz
A06 – P12 (female) (1) and chassis ground tance
4
Voltage Max. 1 V
A06 – P12 (female) (1) and chassis ground
5 Defective pump controller CP03 Boom lever Voltage
chassis ground Boom LOWER Max. 1 V
Circuit diagram related to boom LOWER PPC oil pressure switch
PC228US, 228USLC-3E0 35
E-19 Monitoring function fails to display “arm IN” normally 1
Trouble • Arm IN operation is not displayed normally by machine monitoring function (Special functions)
Related infor-
mation

Defective arm IN pressure out troubleshooting.
sensor P04 (male) Arm lever Resistance
1
Between (1) – (2)
IN Max. 1 z
ness
– A06 – P04 (female) (1) tance
and standard
3
cuit) Min. 1 Mz
4
Voltage Max. 1 V
5 Defective pump controller CP03 Arm lever Voltage
chassis ground IN Max. 1 V
Circuit diagram related to arm IN PPC oil pressure switch
36 PC228US, 228USLC-3E0
E-20 Monitoring function fails to display “arm OUT” normally 1
Trouble • Arm OUT operation is not displayed normally by machine monitoring function (Special functions)
Related infor-
mation

Defective arm OUT PPC oil
1 pressure switch (Internal dis- P08 (male) Arm lever Resistance
connection or short circuit) Neutral Min. 1 Mz
Between (1) – (2)
Arm OUT Max. 1 z
ness
and standard
3
cuit) Min. 1 Mz
4
Voltage Max. 1 V
5 Defective pump controller CP03 Arm lever Voltage
chassis ground Arm OUT Max. 1 V
Circuit diagram related to arm OUT PPC oil pressure switch
PC228US, 228USLC-3E0 37
E-21 Monitoring function fails to display “bucket CURL” normally 1
Trouble • Bucket CURL is not displayed normally by machine monitoring function (Special functions)
Related infor-
• Monitoring code:01901 (Output Switch 2)
mation

Defective bucket CURL pres-
1 sure sensor (internal discon- P11 (male) Bucket lever Resistance
nection or short circuit) Neutral Min. 1 Mz
Between (1) – (2)
CURL Max. 1 z
ness
A06 – P11 (female) (1) tance
and standard
3
cuit) Min. 1 Mz
A06 – P11 (female) (1) and chassis ground tance
4
Voltage Max. 1 V
A06 – P11 (female) (1) and chassis ground
5 Defective pump controller CP03 Bucket lever Voltage
chassis ground CURL Max. 1 V
Circuit diagram related to Bucket CURL PPC oil pressure switch
38 PC228US, 228USLC-3E0
E-22 Monitoring function fails to display “bucket DUMP” normally 1
Trouble • Bucket DUMP operation is not displayed normally by machine monitoring function (Special functions)
Related infor-
mation

Defective bucket DUMP PPC out troubleshooting.
oil pressure switch (Internal P05 (male) Bucket lever Resistance
1
disconnection or short cir-
cuit) Neutral Min. 1 Mz
Between (1) – (2)
Bucket DUMP Max. 1 z
ness
and standard
3
cuit) Min. 1 Mz
4
Voltage Max. 1 V
5 Defective pump controller CP03 Bucket lever Voltage
chassis ground Bucket DUMP Max. 1 V
Circuit diagram related to bucket DUMP PPC oil pressure switch
PC228US, 228USLC-3E0 39
E-23 Monitoring function fails to display “swing left” normally 1
Trouble • Swing left is not displayed normally by machine monitoring function (Special function)
Related infor- • If failure code DHSBMA is displayed, carry out troubleshooting for it first.
mation • Monitoring code: 09001 (Swing left PPC pressure)

Defective swing left PPC oil
1 pressure switch (Internal dis- P03 Voltage
connection or short circuit) Between (3) – (1) 4.5 – 5.5 V
Between (2) – (1) 0.5 – 4.5 V
Disconnection in wiring har- Wiring harnesses between CP01 (female) Resis-
ness Max. 1 z
(13) – A05 – P03 (male) (2) tance
Max. 1 z
Possible causes
and standard
value in normal
state ness Wiring harnesses between CP01 (female) Resis-
3 Min. 1 Mz
(Short circuit with GND cir- (13) – A05 – P03 (female) (2) tance
cuit) Wiring harness between CP01 (female) (22) Resis-
Min. 1 Mz
Hot short (Short circuit with Wiring harnesses between CP01 (female)
4 Voltage Max. 1 V
24V circuit) in wiring harness (13) – A05 – P03 (female) (2)
Voltage Max. 1 V
5 Defective pump controller CP01 Swing lever Voltage
Between (22) – (10) Neutral 4.5 – 5.5 V
Between (13) – (10) Left or Right 0.5 – 4.5 V
40 PC228US, 228USLC-3E0
Circuit diagram related to right and left swing PPC oil pressure switches
PC228US, 228USLC-3E0 41
E-24 Monitoring function fails to display “swing right” normally 1
Trouble • Monitoring function (special function) of machine monitor fails to display “swing right” normally.
Related infor- • If failure code DHSAMA is displayed, carry out troubleshooting for it first.
mation • Monitoring code: 09002 (Swing right PPC pressure)

Defective swing right PPC out troubleshooting.
pressure sensor P07 Voltage
1
short circuit) Between (3) – (1) 4.5 – 5.5 V
Between (2) – (1) 0.5 – 4.5 V
Max. 1 z
ness (Disconnection in wiring – A05 – P07 (female) (2) tance
2
or defective contact in con- Wiring harness between CP01 (female) (22) Resis-
nector) Max. 1 z
Max. 1 z
Possible causes
and standard
value in normal Ground fault in wiring
state Wiring harness between CP01 (female) (19) Resis-
3 harness (Short circuit with Min. 1 Mz
GND circuit)
Min. 1 Mz
Hot short (Short circuit with Wiring harness between CP01 (female) (19)
4 Voltage Max. 1 V
24V circuit) in wiring harness – A05 – P07 (female) (2)
Voltage Max. 1 V
– A03 – P07 (female) (3)
Between (22) – (10) 4.5 – 5.5 V
Between (19) –- (10) 0.5 – 4.5 V
42 PC228US, 228USLC-3E0
Circuit diagram related to swing right PPC pressure sensor
PC228US, 228USLC-3E0 43
E-25 Monitoring function fails to display “travel” normally 1
Trouble • Travel is not displayed normally by machine monitoring function (Special functions)
Related infor-
mation

Defective travel PPC oil out troubleshooting.
pressure switch P09 (male) Travel lever Resistance
1
Between (1) – (2)
Forward or reverse Max. 1 z
ness
– J01 – P09 (female) (1) tance
Max. 1 z
Possible causes
state 3 Wiring harness of CP03 (female) (39) – J01
cuit) – P09 (female) (1), – A43 (female) (2) and Min. 1 Mz
tance
chassis ground
4
24V circuit) in wiring harness Wiring harness of CP03 (female) (39) – J01
– P09 (female) (1), – A43 (female) (2) and Voltage Max. 1 V
chassis ground
chassis ground Forward or reverse Max. 1 V
44 PC228US, 228USLC-3E0
Circuit diagram related to travel PPC oil pressure switch and travel alarm
PC228US, 228USLC-3E0 45
E-26 Monitoring function fails to display “travel differential pressure”

normally 1
• Travel differential pressure is not displayed normally by machine monitoring function (Special func-
Trouble
tions)
• Travel differential pressure is turned on as a pressure difference occurred between the right and left
Related infor-
travel PPC circuits (during steering).
mation

Defective travel steering out troubleshooting.
PPC oil pressure switch P10 (male) Travel lever Resistance
1
Between (1) – (2)
Left or right only Max. 1 z
ness
and standard
3
cuit) Min. 1 Mz
– P10 (female) (1) and chassis ground tance
4
Voltage Max. 1 V
– P10 (female) (1) and chassis ground
chassis ground Left or right only Max. 1 V
46 PC228US, 228USLC-3E0
Circuit diagram related to travel steering PPC oil pressure switch
PC228US, 228USLC-3E0 47
E-27 Monitoring function fails to display “service” normally 1
Trouble • Service is not displayed normally by machine monitoring function (Special functions)
Related infor-
mation

Defective service (front) PPC out troubleshooting.
oil pressure switch S10 (male) Service pedal Resistance
1
Between (1) – (2)
Front Max. 1 z
Defective service (rear) PPC out troubleshooting.
oil pressure switch S11(male) Service pedal Resistance
2
Between (1) – (2)
Rear Max. 1 z
Disconnection in wiring har- Wiring harness between CP02 (female) (35)
Resis-
ness – A05 – S09 – S10 (female) (1), – S11 Max. 1 z
tance
3 (Disconnection in wiring or (female) (1)
Possible causes
and standard defective contact in connec- Wiring harness between S10 (female) (2) – Resis-
tor) Max. 1 z
value in normal chassis ground tance
state Wiring harness between S11 (female) (2) – Resis-
Max. 1 z
ness
4 Wiring harness between CP02 (female) (35)
cuit) – A05 – S09 – S10 (female) (1), – S11 Min. 1 Mz
tance
5
– A05 – S09 – S10 (female) (1), – S11 Voltage Max. 1 V
6 Defective pump controller CP02 Service pedal Voltage
chassis ground Front or rear Max. 1 V
48 PC228US, 228USLC-3E0
Circuit diagram related to service PPC oil pressure switch
PC228US, 228USLC-3E0 49
E-28 The KOMTRAX system does not work properly 1
Trouble • The KOMTRAX system does not work properly.

• If the KOMTRAX system administrator asks to you to check whether any defect occurs in the
Related infor-
machine system, carry out the following troubleshooting.
mation
• A defect in the KOMTRAX system, if any, does not appear especially as a defective phenomenon.

1 Defective power supply G01 Signal Voltage
Between (39), (40) – Constant power
20 – 30 V
(37), (38) supply
a Turn the starting switch ON, then start engine and carry out
troubleshooting.
LED (1) Normal state
LED-C1 ON
Defective starting switch a Turn the starting switch ON, then start engine and carry out
2 ACC signal and alternator R troubleshooting.
signal
G01 Signal Voltage
Between (36) and
Starting switch ACC 20 – 30 V
(37), (38)
Between (28) –
Alternator R 20 – 30 V
(37), (38)
G01 Signal Voltage
Possible causes Between (27) and
Starting switch C Max. 1 V
and standard Defective starting switch C (37), (38)
value in normal 3
signal a Prepare with starting switch OFF, then turn starting switch
state
START and carry out troubleshooting.
G01 Signal Voltage
Between (27) and
Starting switch C 20 – 30 V
(37), (38)
a Turn starting switch ON, and carry out troubleshooting.
LED-C4 ON
Defective CAN connection
4
state a Prepare with starting switch OFF, and carry out troubleshooting
G01 (female) Signal Resistance
Between (7) and (8) CAN 40– 80 z
5 Number of unset mails LED (7) Normal state
7 segment 0–9
Defective GPS positioning Dot ON
6
state
One or more minute may be taken until GPS positioning is com-
pleted after the starting switch was turned ON even in an outdoor
service area.
50 PC228US, 228USLC-3E0
LED display section of KOMTRAX terminal G01 connector
CPU LED
1. LED-C1 (R signal and ACC signal status)
2. LED-C2 (engine control signal status)
3. LED-C3 (S-NET, C signal status)
4. LED-C4 (CAN status)
5. LED-C5 (download writing condition)
6. LED-C6 (download writing condition)
7 segments and dot for CPU

7. 7 segments (number of mails not yet sent)
8. Dot (GPS positioning in progress)
PC228US, 228USLC-3E0 51
E-29 Air conditioner does not operate 1
Trouble • Air conditioner does not operate.

Related infor- • For electrical circuit inside the air conditioner unit, refer to the structure, function and maintenance
mation standard, “Air conditioner system.”

1 Defective fuse No. 11 If fuse is burnt, circuit probably has ground fault.
Wiring harness between F01-11 outlet – M26 Resis-
(male) (2), (10) tance
ness
Wiring harness between M26 (male) (4), (12) Resis-
– A02 (female) (1) – chassis ground tance
tor) Wiring harness between F01-16 outlet – M26 Resis-
Max. 1 z
(male) (1) tance
Possible causes
A07 – AC02 (female) (1) tance
value in normal
state a Prepare with starting switch OFF, then carry out troubleshoot-
ness Wiring harness between F01-11 outlet – M26 Resis-
3 Min. 1 Mz
(Short circuit with GND cir- (male) (4) and chassis ground tance
cuit) Wiring harness between M26 (male) (12) Resis-
Min. 1 Mz
and chassis ground tance
4 Defective air conditioner unit (The table indicates internal defect of an air conditioner)
M26 Voltage
Between (1), (2), (10) – (4), (12) 20 – 30 V
52 PC228US, 228USLC-3E0
Circuit diagram related to air conditioner
PC228US, 228USLC-3E0 53
E-30 Travel alarm does not sound or does not stop sounding 1
• Alarm does not sound during travel.

Trouble
• Alarm sounds in stopped state.
Related infor- • Carry out troubleshooting when monitoring function displays “travel” normally. (If display is abnormal,
mation carry out troubleshooting for “E-25” first.

1 Defective fuse No. 15 If fuse is burnt out, the circuit probably has ground fault.
shooting No. E-25.
2 Defective travel signal Operation of lever:

01900
Travel ON
(Output switch 1)
When the monitoring display is not correct, proceed to diagnosis for
“'Travel is not normally indicated' in the monitoring function”
out troubleshooting (insert T-adapter).
Possible causes A43 Travel lever Voltage
Defective travel alarm
and standard
value in normal 3 (Internal disconnection or Neutral Max. 1 V
short circuit) Between (1) – (2)
state Operated 20 – 30 V
If above voltage is normal and travel alarm does not sound, travel
alarm is defective.
ness
Wiring harness between F01-15 outlet – J03 Resis-
– A07 – A43 (female) (1) tance
tor) Wiring harness between A43 (female) (2) – Resis-
Max. 1 z
A07 –J01 (19) tance
5
(Short circuit with GND cir- Wiring harness between F01-15 outlet – J03 Resis-
cuit) Min. 1 Mz
– A07 – A43 (female) (1) and chassis ground tance
54 PC228US, 228USLC-3E0
Circuit diagram related to travel PPC oil pressure switch and travel alarm
PC228US, 228USLC-3E0 55
E-31 Horn does not sound 1
Trouble Horn does not sound

Related infor-
mation

1 Defective fuse F01-(5) If fuse is broken, circuit probably has ground fault. (See Cause 6)
2 Defective horn relay If the horn sounds after replacing the relay, the relay was defective
Between M07 (2) – chassis ground (with
Voltage 20 – 30 V
horn switch turned ON)
3 Defective high tone horn a Prepare with starting switch OFF, then carry out troubleshoot-
Resis-
Between M07 (female) (1) – chassis ground Max. 1 z
tance
If above is normal, the horn is defective
Between M08 (2) – chassis ground (with
Voltage 20 – 30 V
horn switch turned ON)
4 Defective low tone horn a Prepare with starting switch OFF, then carry out troubleshoot-
Possible causes Resis-
Between M08 (female) (1) – chassis ground Max. 1 z
and standard tance
value in normal If above is normal, the horn is defective
state
Wiring harness between F01 (5) – M22 Resis-
(female) (1) – R08 (female) (3) tance
ness
R08 (female) (1) – A07 – M07 (female) (2) tance
tor) Wiring harness between R08 (female) (5) – Resis-
Max. 1 z
A07 – M08 (female) (2) tance
Max. 1 z
J05 (male) (5) – J04 – A07 – chassis ground tance
Wiring harness between F01 (5) – M22
Resis-
Ground fault in wiring har- (female) (1) – R08 (female) (3) and chassis Min. 1 Mz
tance
ness ground
6
(Short circuit with GND cir- Wiring harness between M22 (female) (2) –
cuit) Resis-
R08 (female) (1) – A07 – M07 (female) (2) Min. 1 Mz
tance
and chassis ground
Min. 1 Mz
A07 – M08 (female) (2) and chassis ground tance
56 PC228US, 228USLC-3E0
Circuit diagram related to horn
PC228US, 228USLC-3E0 57
E-32 Attachment circuit does not change 1
(1) When working mode P or E is selected, attachment circuit is not

• Attachment circuit does not switched to crusher circuit (reciprocation circuit).
Trouble
change. (2) When working mode B is selected, attachment circuit is not
switched to breaker circuit (one-way circuit).
• If the primary side (coil side) of the attachment return selector relay has a fault (short-circuit or dis-
Related infor-
connection), an error code is displayed. A fault on the secondary side (contact side) cannot be
mation
detected, however.

Attachment return selector hold it in the OFF position during the troubleshooting.
solenoid defective V12 (male) Resistance
1
short-circuit) Between (1) and (2) 20 – 60 z
Between (1) and grounding Min. 1 Mz
Attachment return selector hold it in the OFF position during the troubleshooting.
relay defective R20 (male) Resistance value
2
short-circuit) Between (3) and (4) Max. 1 z
Possible causes
and standard Between (3) and (5) Min. 1 Mz
value in normal a Turn the engine starting switch OFF for the preparations, and
state hold it in the OFF position during the troubleshooting.
Disconnection of wiring har- Wiring harness between CP02 (female) (8) Resis-
Max. 1 z
ness and R20 (female) (2) tance
3
(Disconnection or defective Wiring harness between R20 (female) (5) Resis-
contact with connector) Max. 1 z
and V12 (female) (1) tance
Max. 1 z
C03 (female) (3)(13)(23) and grounding tance
Short-circuit of wiring har- hold it in the ON position during the troubleshooting.
4 ness
(Contact with 24 V circuit) Between wiring harness and R20 (female)
Voltage Max. 1 V
(5) and V12 (female) (1) and grounding
58 PC228US, 228USLC-3E0
Circuit diagram related to attachment return selector relay and solenoid
PC228US, 228USLC-3E0 59
SEN01888-02

© 2009 KOMATSU
All Rights Reserved
60
SEN01889-02
PC228US-3E0
PC228USLC-3E0

Troubleshooting of hydraulic and
mechanical system (H-mode)
System chart for hydraulic and mechanical systems ...................................................................................... 4
Information contained in troubleshooting table ............................................................................................... 6
H-1 All work equipment lack power, or travel and swing speeds are slow...................................................... 7
H-2 Engine speed sharply drops or engine stalls............................................................................................ 9
H-3 No work equipment, travel or swing move ............................................................................................. 10
H-4 Abnormal noise is heard from around hydraulic pump........................................................................... 10
H-5 Auto-decelerator does not work ..............................................................................................................11
H-6 Fine control mode does not function .......................................................................................................11
H-7 Boom moves slowly or lacks power ....................................................................................................... 12
H-8 Arm moves slowly or lacks power .......................................................................................................... 13
H-9 Bucket moves slowly or lacks power...................................................................................................... 14
H-10 Work equipment does not move in its single operation........................................................................ 14
H-11 Work equipment has a bit too large hydraulic drift ............................................................................... 15
H-12 Work equipment has big time lag ......................................................................................................... 16
H-13 Other work equipment moves when relieving single circuit.................................................................. 16

H-14 One-touch power max. switch does not operate .................................................................................. 16
H-15 In compound operation, work equipment with larger load moves slowly ............................................. 17
H-16 In swing + boom RAISE operation, boom moves slowly ...................................................................... 17
H-17 In swing + travel, travel speed drops sharply ....................................................................................... 17
H-18 Machine swerves in travel .................................................................................................................... 18
H-19 Machine travels slowly ......................................................................................................................... 19
H-20 Machine cannot be easily steered or lacks power................................................................................ 20
H-21 Travel speed does not shift, or it is slower or faster than preset speed ............................................... 21
H-22 Track shoe does not turn (on one side only) ........................................................................................ 21
H-23 Machine does not swing....................................................................................................................... 22
H-24 Swing acceleration is poor, or swing speed is slow.............................................................................. 24
H-25 Excessive overrun when stopping swing.............................................................................................. 26
H-26 There is big shock when stopping swing.............................................................................................. 27
H-27 There is big abnormal noise caused when stopping swing .................................................................. 27
H-28 Swing natural drift is too big ................................................................................................................. 28
H-29 Attachment circuit does not change ..................................................................................................... 29
H-30 Flow rate in attachment circuit cannot be adjusted .............................................................................. 29
System chart for hydraulic and mechanical systems 1
a This is a system chart that has been drawn up by simplifying the whole hydraulic circuit chart. Use it as
a reference material when troubleshooting the hydraulic and mechanical systems.
Information contained in troubleshooting table 1

a Troubleshooting table and related circuit diagram collectively carry the following information. Carry out
troubleshooting work after fully grasping their contents.
Failure phe-
Phenomenon occurring on machine
nomenon
Relative infor-
Information on the failure occurred as well as the troubleshooting
mation
Cause Standard value in normalcy and references for troubleshooting
2
Presumed Cause for presumed failure
cause and stan- [Contents]
(The attached No. is for fil-
dard value in • The standard values in normalcy by which to judge “Good”
3 ing and reference purpose
normalcy or “No Good” about presumed causes.
only. It does not stand for
• References for making judgement of “good” or “No Good”
any priority.)
4
H-1 All work equipment lack power, or travel and swing speeds are slow1
Trouble • All the work equipment lack power, or their travel and swing speeds are slow.
Related infor-
• Set the working mode at P mode for troubleshooting.
mation

a Stop engine for preparations. Start troubleshooting at engine
high idle.
Malfunctioning of unload
1 Control lever Unload pressure
valve
3.9 ± 1.0 MPa
All control levers in NEUTRAL
{40 ± 10kg/cm2}
high idle.
Control lever Main relief pressure
Improper adjustment or
2 malfunctioning of main relief 33.3 – 36.8 MPa
Arm, DIGGING
valve {340 – 375kg/cm2}
If the pressure does not return to normalcy even after the adjust-
ment, malfunctioning of main relief valve or its internal failure is sus-
pected. In that case, check the valve itself.
Malfunctioning of self high idle.
3 pressure decompression Control lever Control circuit source pressure
Possible causes valve
and standard 2.84 – 3.43 MPa
All control levers in NEUTRAL
value in normal {29 – 35kg/cm2}
state a Stop engine for preparations. Start troubleshooting at engine
high idle.
Oil pressure to be Measurement
Oil pressure ratio
measured condition
Pump delivery
Improper adjustment or 1
4 pressure Swing lock: ON
malfunctioning of PC valve
PC valve output Arm: Digging relief Approx. 0.6
If the oil pressure does not return to normalcy even after the adjust-
ment, malfunctioning of PC valve or its internal failure is suspected.
In that case, check the valve itself.
high idle.
LS-EPC output
Malfunctioning of LS-EPC Travel speed Travel control lever
5 pressure
valve
Approx. 2.9 MPa
Lo NEUTRAL
{Approx. 30 kg/cm2}
Hi OPERATED 0 MPa {0 kg/cm2}

high idle.
Oil pressure ratio
Oil pressure to be Travel without load
measured All control levers in
(control lever held at
NEUTRAL
half stroke)
6 Pump delivery
Possible causes malfunctioning of LS valve 1
pressure Nearly equal
and standard
value in normal LS valve output pressure Approx. 0.6
state pressure (Approx. 3/5)
ment, malfunctioning of LS valve or its internal failure is suspected.
In that case, check the valve itself.
Malfunctioning of servo
7 Malfunctioning of servo piston is suspected. Check the piston itself.
piston
If none of the above listed causes is detected, the piston pump is
8 Piston pump defective suspected of deteriorated performance, malfunctioning or internal
failure.
H-2 Engine speed sharply drops or engine stalls 1

Trouble • The engine speed sharply drops or the engine stalls.
Related infor-
• Set working mode at P mode for troubleshooting
mation

high idle.
Control lever Main relief pressure
1 malfunctioning of main relief 33.3 – 36.8 MPa
Arm, DIGGING
valve {340 – 375kg/cm2}
ment, malfunctioning of the main relief valve or its internal failure is
suspected. In that case, check the valve itself.
high idle.
Oil pressure to be Measurement
Oil pressure ratio
measured condition
Pump delivery
Improper adjustment or 1
2 pressure Swing lock: ON
malfunctioning of PC valve
PC valve output Arm: Digging relief Approx. 0.6
Possible causes
and standard If the oil pressure does not return to normalcy even after the adjust-
value in normal ment, malfunctioning of the PC valve or its internal failure is sus-
state pected. In that case, check the valve itself.
high idle.
Oil pressure ratio
measured All control levers in
NEUTRAL
half stroke)
3 Pump delivery
malfunctioning of LS valve 1
LS valve output pressure Approx. 0.6
ment, malfunctioning of the LS valve or its internal failure is sus-
Orifice or filter in servo The orifice or filter in the pump servo equipment is suspected of
4
equipment clogged clogging. Check the equipment itself.
The servo piston is suspected of malfunction. Check the piston
5 Malfunction of servo piston
itself.
H-3 No work equipment, travel or swing move 1

Trouble • No work equipment nor travel and swing functions can be set in motion.
Related infor-
• Set the working mode at P mode for the troubleshooting.
mation

high idle.
Malfunctioning of PPC lock Lock lever Solenoid output pressure
1
solenoid valve Locked 0 MPa {0 kg/cm2}
2.84 – 3.43 MPa
Released
{29 – 35kg/cm2}
Possible causes a Stop engine for preparations. Start troubleshooting at engine
and standard high idle.
Malfunctioning of self
value in normal
2 pressure decompression Control lever Control circuit source pressure
state
valve All control levers in 2.84 – 3.43 MPa
NEUTRAL position {29 – 35kg/cm2}
The piston pump is suspected of malfunctioning or an internal fail-
ure. Diagnose it in the following manner.
3 Piston pump defective
• Remove the main oil pressure measurement plug and crank the
engine. If oil flows out, it is in normal condition.
It is presumed that the pump shaft does not rotate due to some
4 Damper defective
internal failure of the damper. Check the damper itself.
H-4 Abnormal noise is heard from around hydraulic pump 1

Trouble • An abnormal noise is heard from around the hydraulic pump.
Related infor-
—
mation

1 Hydraulic oil level lowered Make a visual check.
2 Quality of hydraulic oil bad Air may have got mixed with the oil. Make a visual check.
Possible causes It is presumed that the breather in the cap of hydraulic tanks is
Hydraulic tank cap breather
and standard 3 clogged, thereby causing negative pressure inside the tank. Make a
clogged
value in normal visual check.
state It is presumed that the strainer in the hydraulic tank is clogged,
Hydraulic tank strainer
4 thereby causing negative pressure in the suction circuit. Make a
clogged
visual check.
The piston pump is suspected of an internal failure. Check the pump
5 Piston pump defective
itself.
10 PC228US, 228USLC-3E0
H-5 Auto-decelerator does not work 1

Trouble • The auto-decelerator does not work.
• This troubleshooting mode is applied when the auto-decelerator does not work, while operating the
Related infor- travel control lever. (A shuttle valve is provided between PPC valve and the hydraulic switch only in
mation the travel circuit -actually located inside PPC valve)

Possible causes high idle.
and standard
Malfunctioning of travel PPC Travel control lever PPC valve output pressure
value in normal 1
state valve (shuttle valve) NEUTRAL 0 MPa {0 kg/cm2}
Above 2.7 MPa
Operation
{Above 28 kg/cm2}
H-6 Fine control mode does not function 1

Trouble • The fine control mode poorly functions or its response is slow.
Related infor-
mation

high idle.
LS-EPC valve output
1 pressure
valve
Approx. 2.9 MPa
Lo NEUTRAL
{Approx. 30 kg/cm2}
Hi OPERATED 0 MPa {0 kg/cm2}
The orifice in the LS circuit is presumed to be clogged. Check the
2 Orifice in LS circuit clogged
orifice itself.
Possible causes
and standard high idle.
value in normal Oil pressure ratio
state Oil pressure to be Travel without load
measured All control levers
in NEUTRAL
half stroke)
3 Pump delivery
malfunctioning of LS valve 1
pressure Nearly equal oil
PC valve output pressure Approx. 0.6
ment, malfunctioning of the LS valve or its internal failure is sus-
Malfunctioning of servo Malfunctioning of the servo piston is suspected. Check the piston
4
piston itself.
PC228US, 228USLC-3E0 11
H-7 Boom moves slowly or lacks power 1

Trouble • The boom moves slowly or lacks power
Related infor-
mation

high idle.
R.H. work equipment
Malfunctioning of right PPC PPC valve output pressure
1 control lever
valve (in boom circuit)
NEUTRAL 0 MPa {0 kg/cm2}
Boom RAISE Above 2.7 MPa
Boom LOWER {Above 28 kg/cm2}
high idle.
Malfunction of merge/divide Working mode Solenoid output pressure
2
solenoid valve P mode 0 MPa {0 kg/cm2}
2.84 – 3.43 MPa
Other than P mode
{29 – 35 kg/cm2}
Malfunctioning of merge/
The merge/divide valve of control valve (main and LS valves) is pre-
3 divide valve (main and LS
sumed to malfunction. Check the valve itself.
valves)
Malfunctioning of boom
The boom throttle EPC solenoid valve is presumed to malfunction.
4 throttle EPC solenoid valve
Check the valve itself.
(raise side only)
Malfunctioning of boom The spool in the boom control valve is presumed to malfunction.
Possible causes 5
control valve (spool) Check the valve itself.
and standard
value in normal The pressure compensation valve in the boom control valve is pre-
6 control valve (pressure com-
state sumed to malfunction. Check the valve itself.
pensation valve)
The regeneration valve in the boom control valve or the seal is pre-
7 control valve
(regeneration valve)
Malfunctioning of boom The lock valve in the boom control valve is presumed to malfunc-
8
control valve (lock valve) tion. Check the valve itself.
Malfunctioning of safety
The safety valve for the lock valve is presumed to malfunction, or
9 valve for lock valve or seal
the seal is suspected to be defective. Check the valve itself.
defective
The suction valve (bottom side) in the boom control valve is pre-
10 control valve (suction valve)
sumed to malfunction, or the seal is suspected to be defective.
or seal defective
Malfunctioning of boom The safety and suction valves (head side) in the boom control valve
11 control valve (safety and suc- are presumed to malfunction, or the seal is suspected to be defec-
tion valves) or seal defective tive. Check those valves themselves.
Malfunctioning of LS shuttle LS shuttle valves in the left travel control valve, bucket control valve
12 valve (left travel, bucket and and service control valve are presumed to malfunction. Check those
service valves) valves themselves.
high idle.
13 Boom cylinder defective
Boom cylinder Amount oil leakage from cylinder
Raise relief 20 cc/min
12 PC228US, 228USLC-3E0
H-8 Arm moves slowly or lacks power 1

Trouble • The arm moves slowly, or lacks power.
Related infor-
mation

high idle.
L.H. work equipment
Malfunctioning of left PPC PPC valve output pressure
1 control lever
valve (arm circuit)
Arm DIGGING Above 2.7 MPa
Arm DUMPING {Above 28 kg/cm2}
high idle.
Malfunctioning of merge/ Working mode Solenoid output pressure
2
divide solenoid valve P mode 0 MPa {0 kg/cm2}
2.84 – 3.43 MPa
Other than P mode
{29 – 35 kg/cm2}
Malfunctioning of merge/
The merge/divide valve of control valve (main and LS valves) is pre-
3 divide valve
Possible causes sumed to malfunction. Check the valve itself.
(main and LS valves)
and standard
Malfunctioning of arm control The spool in the arm control valve is presumed to malfunction.
value in normal 4
valve (spool) Check the valve itself.
state
Malfunctioning of arm control
The pressure compensation valve in the arm control valve is pre-
5 valve (pressure compensa-
tion valve)
The generation valve in the arm control valve is presumed to mal-
Malfunctioning of arm control
6 function, or the seal is suspected to be defective. Check the valve
valve (regeneration valve)
itself.
Malfunctioning of arm control The safety and suction valves in the arm control valve are presumed
7 valve (safety and suction to malfunction, or the seal is suspected of defect. Check those
valves) or seal defective valves themselves.
Malfunctioning of LS shuttle
LS shuttle valves in the right travel control valve, boom control
valve (right travel, boom, left
8 valve, left travel control valve, bucket control valve and service
travel, bucket and service
valve are presumed to malfunction. Check those valves themselves.
valves)
high idle.
9 Arm cylinder defective
Arm cylinder Amount oil leakage from cylinder
Digging relief 20 cc/min
PC228US, 228USLC-3E0 13
H-9 Bucket moves slowly or lacks power 1

Trouble • The bucket moves slowly, or lacks power.
Related infor-
mation

high idle.
R.H. work equipment
Malfunctioning of right PPC PPC valve output pressure
1 control lever
valve (bucket circuit)
Bucket DIGGING Above 2.7 MPa
Bucket DUMPING {Above 28 kg/cm2}
Malfunctioning of bucket The spool in the bucket control valve is presumed to malfunction.
2
Possible causes control valve (spool) Check the valve itself.
and standard Malfunctioning of bucket
value in normal The pressure compensation valve in the bucket control valve is pre-
state sumed to malfunction. Check the valve itself.
pensation valve)
Malfunctioning of bucket The safety and suction valves in the bucket control valve are pre-
4 control valve (safety and suc- sumed to malfunction, or the seal is suspected to be defective.
tion valves) or seal defective Check those valves themselves.
Malfunction of LS shuttle The LS shuttle valve in the service control valve is presumed to mal-
5
valve (service valve) function. Check the valve itself.
high idle.
6 Bucket cylinder defective
Bucket cylinder Amount oil leakage from cylinder
H-10 Work equipment does not move in its single operation 1

• Work equipment does not move in its single operation
(1) The boom does not move when operated independently.
Trouble
(2) The arm does not move when operated independently.
(3) The bucket does not move when operated independently.
Related infor-
mation

high idle.
Possible causes Work equipment control lever PPC valve output pressure
1 Malfunctioning of PPC valve
and standard NEUTRAL 0 MPa {0 kg/cm2}
value in normal
Above 2.7 MPa
state Operated
{Above 28 kg/cm2}
Malfunctioning of work
The spool in the work equipment control valve is presumed to mal-
2 equipment control valve
function. Check the valve itself.
(spool)
14 PC228US, 228USLC-3E0
H-11 Work equipment has a bit too large hydraulic drift 1

• Work equipment has a bit too large hydraulic drift
Trouble
(1) Hydraulic drift of the boom is a bit too large.
Related infor-
mation

high idle.
Possible causes 1 Boom cylinder defective
Boom cylinder Amount oil leakage from cylinder
and standard
value in normal Raise relief 20 cc/min
state Boom control lever (lock The seal at lock valve in the boom control lever is suspected to be
2
valve) seal defective defective. Check the valve itself.
Seal at safety valve for lock The seal at the safety valve in the lock valve is suspected to be
3
valve defective defective. Check the valve itself.

Trouble
(2) Hydraulic drift of the arm is a bit too large.
Related infor- • Set the working mode at P mode for the troubleshooting.
mation •

high idle.
1 Arm cylinder defective
Arm cylinder Amount oil leakage from cylinder
Possible causes The seal for safety and suction valves (bottom side) in the arm con-
and standard Arm control valve (safety and
trol valve is suspected to be defective. Check the valve itself.
value in normal 2 suction valves) seal
(Whether the seal is defective or not may well be determined by
state defective
changing for other safety and suction valves.)
Arm control valve (spool) he seal for spool in the arm control valve is suspected to be defec-
3
seal defective tive. Check the seal itself.
Arm control valve (pressure
The seal for pressure compensation valve (bottom side) in the arm
4 compensation valve) seal
control valve is suspected to be defective. Check the seal itself.
defective

Trouble
(3) Hydraulic drift of the bucket is a bit too large.
Related infor-
mation

high idle.
1 Bucket cylinder defective
Bucket cylinder Amount oil leakage from cylinder
Possible causes The seal for the safety and suction valves (bottom side) in the
and standard Bucket control valve (safety bucket control lever is suspected to be defective. Check the seal
value in normal 2 and suction valves) seal itself.
state defective (Whether the seal is defective or not may well be determined by
changing for other safety and suction valves.)
Bucket control valve (spool) The seal for spool in the bucket control valve is suspected to be
3
seal defective defective. Check the seal itself.
Bucket control valve (pres- The seal for pressure compensation valve (bottom side) in the
4 sure compensation valve) bucket control valve is suspected to be defective. Check the seal
seal defective itself.
PC228US, 228USLC-3E0 15
H-12 Work equipment has big time lag 1

Trouble • The work equipment has a big time lag.
Related infor-
mation

high idle.
LS-EPC valve
1 output pressure
valve
Approx. 2.9 MPa
Lo NEUTRAL
{approx. 30 kg/cm2}
Possible causes Hi Operation 0 MPa {0 kg/cm2}
and standard Malfunctioning of control
The regeneration valve in the control valve is presumed to malfunc-
value in normal 2 valve (regeneration valve) -
tion. Check the valve itself.
state with boom and arm only
The safety and suction valves (boom : head side, arm and bucket :
Malfunctioning of control bottom side) of the control valve are presumed to malfunction.
3 valves (safety & suction Check those valves themselves directly.
valve) (Whether they are defective or not may well be determined by
changing them for other safety and suction valves.)
Malfunctioning of control
The pressure compensation valve of the control valve is presumed
4 valve (pressure compensa-
to malfunction. Check the valve itself directly.
tion valve)
H-13 Other work equipment moves when relieving single circuit 1

Trouble • Other work equipment moves when relieving the single circuit of specific work equipment.
Related infor-
mation

and standard Control valve (pressure
value in normal The seal for pressure compression valve in the control valve is sus-
1 compensation valve) seal
state pected to be defective. Check the seal itself.
defective
H-14 One-touch power max. switch does not operate 1

Trouble • The one-touch power max. switch does not operate.
Related infor-
mation

high idle.
Possible causes
Malfunctioning of 2-stage Swing lock switch Solenoid valve output pressure
and standard 1
solenoid valve
value in normal OFF 0 MPa {0 kg/cm2}
state
ON 2.84 – 3.43 MPa {29 – 35kg/cm2}
Malfunctioning of main relief The main relief valve of control valve is presumed to malfunction.
2
valve Check the valve itself.
16 PC228US, 228USLC-3E0
H-15 In compound operation, work equipment with larger load moves

slowly 1
Trouble • In a compound operation, work equipment with larger load tends to move slowly.
Related infor-
—
mation

The pressure compensation valve for the work equipment with
larger load is presumed to malfunction. Check the valve itself.
Combination of com- Work equipment with Work equipment with
pound operation larger load smaller load
Boom RAISE +
Possible causes Boom Arm
arm DIGGING
and standard Malfunctioning of pressure
value in normal Boom RAISE +
1 compensation valve for work Arm Boom
state arm DUMPING
equipment with larger load
Boom RAISE +
Boom Bucket
bucket DIGGING
Arm DUMPING +
Arm Bucket
bucket DIGGING
Boom LOWER +
Arm Boom
arm DUMPING
H-16 In swing + boom RAISE operation, boom moves slowly 1

Trouble • In a compound operation of swing + boom RAISE, the boom tends to move slowly.
Related infor-
• If the boom moves slowly in the single operation of boom RAISE, carry out the H-7 check first.
mation

and standard The LS select valve of control valve is presumed to malfunction, or
value in normal Malfunctioning of LS select
1 the seal is suspected to be defective. Check the valve and seal
state valve or seal defective
themselves.
H-17 In swing + travel, travel speed drops sharply 1

Trouble • In a compound operation of swing + travel, the travel speed drops sharply.
Related infor-
• If the travel speed is slow in the single operation of travel, carry out the H-19 check first.
mation

and standard
value in normal Malfunctioning of LS shuttle The LS shuttle valve in the left travel control valve or the swing con-
1
state valve (left travel and swing) trol valve is presumed to malfunction. Check both of them directly.
PC228US, 228USLC-3E0 17
H-18 Machine swerves in travel 1

Trouble • The machine tends to swerve while traveling.
Related infor-
mation

high idle.
Travel control lever PPC valve output pressure
Malfunctioning of travel PPC
1 Operated to Forward Above 2.7 MPa
valve
Operated to Reverse {Above 28 kg/cm2}
Differential output between
0.4 MPa {4 kg/cm2}
right and left sides
Malfunctioning of self-pres- high idle.
2
sure decompression valve Control lever Control circuit source pressure
All control levers in NEUTRAL 2.83 – 3.43 MPa {29 – 35 kg/cm2}
high idle.
Oil Pressure ratio
measured All control levers
Improper adjustment or mal- (control lever held at
3 in NEUTRAL
functioning of LS valve half stroke)
Pump delivery
Possible causes 1
and standard
value in normal LS valve output pressure Approx. 0.6
state pressure (Approx. 3/5)
high idle.
Malfunctioning of travel inter- Travel control lever PPC valve output pressure
4
locking solenoid valve
Operating one side only 2.84 – 3.43 MPa {29 – 35 kg/cm2}
Malfunctioning of travel inter- The travel interlocking valve of control valve is presumed to mal-
5
locking valve function. Check the valve itself.
Malfunctioning of travel con- The spool in the travel interlocking valve is presumed to malfunc-
6
trol valve (spool) tion. Check the spool itself.
high idle.
7 Malfunction of travel motor Amount of oil leakage from
travel motor
Travel relief 27.2 l/min
The final drive is suspected of an internal failure. Check the inside of
the final drive directly.
8 Final drive defective (An internal failure in the final drive may well be determined by an
abnormal noise from within, abnormal heat or metal chip or dust
contained in the drained oil.)
18 PC228US, 228USLC-3E0
H-19 Machine travels slowly 1

Trouble • The machine's travel speed is slow.
Related infor-
mation

high idle.
Travel control lever PPC valve output pressure
Malfunctioning of travel PPC
1 Operated to Forward Above 2.7 MPa
valve
Operated to Reverse {Above 28 kg/cm2}
Output differential between right Below 0.4 MPa
and left or front and rear {Below 4 kg/cm2}
Malfunctioning of self-pres- high idle.
2
sure decompression valve Control lever Control circuit source pressure
All control levers in NEUTRAL 2.83 – 3.43 MPa {29 – 35kg/cm2}
high idle.
LS-EPC valve
3 output pressure
valve
Approx. 2.9 MPa
Possible causes Lo NEUTRAL
{approx. 30 kg/cm2}
and standard
value in normal Hi Operated 0 MPa {0 kg/cm2}
state Malfunction of travel control The spool in the travel control valve is presumed to malfunction.
4
valve (spool) Check the spool itself.
Malfunctioning of travel con-
The pressure compensation valve in the travel control valve is pre-
5 trol valve (pressure compen-
sation valve)
Malfunctioning of travel The suction valve in the travel control valve is presumed to malfunc-
6
control valve (suction valve) tion. Check the valve itself.
Malfunctioning of LS shuttle The LS shuttle valve in the bucket control valve is presumed to mal-
7
valve (bucket) function. Check the valve itself.
high idle.
8 Malfunction of travel motor Amount of oil leakage from
travel motor
9 Final drive defective (An internal failure in the final drive may well be determined by an
abnormal noise from within, abnormal heat or metal chip or dust
contained in the drained oil.)
PC228US, 228USLC-3E0 19
H-20 Machine cannot be easily steered or lacks power 1

Trouble • The machine cannot be easily steered.
Related infor-
mation

high idle.
PPC valve output pressure
Malfunctioning of travel PPC Travel control lever
1 (steering)
valve (steering spool)
NEUTRAL on both sides 0 MPa {0 kg/cm2}
Above 2.7 MPa
Operating one side only
{Above 28 kg/cm2}
high idle.
Malfunctioning of travel Travel control lever Solenoid valve output pressure
2
interlocking solenoid valve
Operating one side only 2.84 – 3.43 MPa {29 – 35 kg/cm2}
Malfunctioning of travel The travel interlocking valve of control valve is presumed to mal-
3
interlocking valve function. Check the valve itself.
high idle.
Malfunctioning of merge/ Travel control lever Solenoid valve output pressure
4
divide solenoid valve
Possible causes NEUTRAL 0 MPa {0 kg/cm2}
and standard
OPERATED 2.84 – 3.43 MPa {29 – 35 kg/cm2}
value in normal
state Malfunctioning of merge/ The merge/divide valve of control valve is presumed to malfunction.
5
divide valve Check the valve itself.
Malfunction of travel control The spool in the travel control valve is presumed to malfunction.
6
valve (spool) Check the spool itself.
Malfunctioning of travel
The pressure compensation valve in the travel control valve is pre-
pensation valve)
Malfunctioning of travel The suction valve in the travel control valve is presumed to malfunc-
8
control valve (suction valve) tion. Check the valve itself.
Malfunctioning of LS shuttle The LS shuttle valve in the bucket control valve is presumed to mal-
9
valve (bucket) function. Check the valve itself.
Check valve seal defective at The seal in the check valve of LS oil pressure pickup port is sus-
10
LS oil pressure pickup port pected to be defective. Check the seal itself.
The seal in the check valve of the travel motor is suspected to be
Malfunctioning of travel defective. Check the seal itself. (Whether the seal is defective or not
11
motor (safety valve) may well be determined by swapping the motors between forward
and reverse, or right and left.)
The seal in the check valve of the travel motor is suspected of
Malfunctioning of travel defect. Check the seal itself. (Whether the seal is defective or not
12
motor (check valve) may well be determined by swapping the motors between forward
and reverse, or right and left.)
20 PC228US, 228USLC-3E0
H-21 Travel speed does not shift, or it is slower or faster than preset
speed 1
Trouble • Travel speed does not shift, or it is slower or faster than preset speed.
Related infor-
mation

high idle.
Travel speed Travel control lever Monitoring [15]
Lo Fine control 810 mA
Mi (to the extent that the 470 mA
decelerator is
Hi released) 0 mA
Malfunctioning of LS-EPC
1
valve a Stop engine for preparations. Start troubleshooting at engine
high idle.
Possible causes LS-EPC valve
Travel speed Travel control lever
and standard output pressure
value in normal Approx. 2.9 MPa
Lo NEUTRAL
state {approx. 30 kg/cm2}
Hi Operation 0 MPa {0 kg/cm2}
high idle.
Solenoid output
Malfunctioning of travel Travel speed Travel control lever
2 pressure
speed solenoid valve
Lo NEUTRAL 0 MPa {0 kg/cm2}
2.84 – 3.43 MPa
Hi Operation
{29 – 35 kg/cm2}
Malfunctioning of travel The travel motor is presumed to malfunction when shifting speed.
3
motor (speed shifting) Check the speed shifting portion directly.
H-22 Track shoe does not turn (on one side only) 1
Trouble • A track shoe does not turn (only on one side).
Related infor-
mation

Travel control valve (suction The suction valve seat in the travel control valve is suspected of
1
valve) seat defective defect. Check the seat itself.
Travel motor (safety valve) The safety valve seat in the travel motor is suspected of defect.
2
seat defective Check the seat itself.
Travel motor (check valve) The check valve seat in the travel motor is suspected of defect.
3
seat defective Check the seat itself.
Possible causes
and standard
value in normal high idle.
state 4 Travel Motor speed Amount of oil leakage from travel
motor
5 Final drive defective (A failure inside the final drive may well be determined by an abnor-
mal noise from within, abnormal heat generated or metal dust or
chips contained in the drained oil.)
PC228US, 228USLC-3E0 21
H-23 Machine does not swing 1

• Machine does not swing
Trouble
(1) The machine swings neither to the right nor to the left.
Related infor-
mation

high idle.
Malfunctioning of swing L.H. work equipment
1 Solenoid valve output pressure
holding brake solenoid valve control lever
Swing operated 2.84 – 3.43 MPa {29 – 35 kg/cm2}
Malfunctioning of swing The parking brake portion of the swing motor is presumed to mal-
2
motor (holding brake) function. Check it directly.
high idle.
L.H. work equipment
Possible causes Swing lock switch Swing relief pressure
Improper adjustment or control lever
and standard 3 malfunctioning of swing 28.9 – 32.9 MPa
value in normal motor (safety valve) ON Swing relief
{295 – 335 kg/cm2}
state
ment, the safety valve is presumed to malfunction, or suspected of
an internal failure. Check the valve itself.
high idle.
4 Swing motor defective L.H. work equipment Amount of oil leakage from
control lever swing motor
Swing relief Below 10 l/min
The swing machinery is suspected of an internal failure. Check the
inside of the swing machinery directly.
5 Swing machinery defective (A failure inside the swing machinery may well be determined by an
abnormal noise from within, abnormal heat generated or metal dust
or chips contained in the drained oil.)
22 PC228US, 228USLC-3E0
• Machine does not swing

Trouble
(2) The machine does not swing in one direction.
Related infor-
mation

high idle.
L.H. work equipment
Malfunctioning of swing PPC PPC valve output pressure
1 control lever
valve
Above 2.7 MPa
Swing operated
Possible causes {Above 28 kg/cm2}
and standard Malfunctioning of swing The spool in the swing control valve is presumed to malfunction.
2
value in normal control valve (spool) Check the spool itself.
state The seal in the suction valve of the swing motor is suspected of
defect. Check the seal itself.
Swing motor (suction valve)
3 (Whether the seal is defective or not may well be determined by
seal defective
swapping the right and left suction valves and watching if there is
any change.)
The seal in the check valve of the swing motor is suspected of
Swing motor (check valve) defect. Check the seal itself.
4
seal defective (Whether the seal is defective or not may well be determined by
swapping the right and left check valves and watching the result.)
PC228US, 228USLC-3E0 23
H-24 Swing acceleration is poor, or swing speed is slow 1

• Swing acceleration is poor, or swing speed is slow
Trouble
(1) Swing acceleration is poor, or swing speed is slow.
Related infor-
mation

Malfunctioning of LS shuttle The LS shuttle valves for all the control valves are presumed to mal-
1
valve (all LS shuttles) function. Check them directly.
Malfunctioning of swing The swing holding brake portion of the swing motor is presumed to
2
motor (holding brake) malfunction. Check it directly.
high idle.
L.H. work equipment
Swing lock switch Swing relief pressure
3 malfunctioning of swing 28.9 – 32.9 MPa
motor (safety valve) ON Swing relief
Possible causes {295 – 335 kg/cm2}
and standard If the oil pressure does not return to normalcy even after the adjust-
value in normal ment, the safety valve is presumed to malfunction, or suspected of
state an internal failure. Check the valve itself.
high idle.
Inside of the swing machinery is presumed to malfunction. Check
itself.
5 Swing machinery defective (Whether it is defective or not may well be determined by abnormal
noise, abnormal generation of heat and the mixture of the metal par-
ticles in drain oil.)
24 PC228US, 228USLC-3E0
• Swing acceleration is poor, or swing speed is slow

Trouble
(2) Swing acceleration is poor only on one side, or swing speed is slow.
Related infor-
mation

high idle.
L.H. work equipment
1 control lever
valve
Above 2.7 MPa
Swing operated
{Above 28 kg/cm2}
Possible causes Malfunctioning of swing The spool in the swing control valve is presumed to malfunction.
2
and standard control valve (spool) Check the valve itself.
value in normal Malfunctioning of swing
state The pressure compensation valve in the swing motor is presumed
to malfunction. Check the valve itself.
pensation valve)
The seal in the suction valve of the swing motor is suspected of
Swing motor (suction valve) defect. Check the seal itself.
4
swapping the right and left suction valves and watching the result.)
5
PC228US, 228USLC-3E0 25
H-25 Excessive overrun when stopping swing 1

• Excessive overrun when stopping swing
Trouble
(1) The work equipment overruns excessively when stopping swing.
Related infor-
mation

high idle.
L.H. work equipment
Swing lock switch Swing relief pressure
1 malfunctioning of swing 28.9 – 32.9 MPa
Possible causes motor (safety valve) ON Swing relief
{295 – 335 kg/cm2}
and standard
value in normal If the oil pressure does not return to normalcy even after the adjust-
state ment, the safety valve is presumed to malfunction, or suspected of
an internal failure. Check the valve itself.
high idling.
• Excessive overrun when stopping swing

Trouble
(2) Swing acceleration is poor only on one side, or swing speed is slow.
Related infor-
mation

high idle.
L.H. work equipment control
1 lever
valve
Above 2.7 MPa
Swing operated
{Above 28 kg/cm2}
The PPC slow return valve is suspected of clogging. Check the
Possible causes Swing PPC slow return valve valve itself.
and standard 2
clogged (Whether the valve is clogged or not may well be determined by
value in normal swapping the right and left valves and watching the result.)
state
Malfunctioning of swing The spool in the swing control valve is resumed to malfunction.
3
control valve (spool) Check the valve itself.
The seal in the suction valve of the swing motor is suspected of
Swing motor (suction valve) defect. Check the seal itself.
4
swapping the right and left suction valves and watching the result.)
5
26 PC228US, 228USLC-3E0
H-26 There is big shock when stopping swing 1

Trouble • There is a big shock caused when stopping a swing motion.
Related infor-
mation

high idle.
L.H. work equipment
1 control lever
valve
Possible causes NEUTRAL 0 MPa {0 kg/cm2}
and standard Above 2.7 MPa
value in normal Swing operated
{Above 28 kg/cm2}
state
The swing PPC slow return valve is presumed to malfunction.
Malfunctioning of swing PPC Check the valve itself.
2
slow return valve (Whether the valve malfunctions or not may well be determined by
swapping the right and left valves and watching the result.)
Malfunctioning of swing The swing motor shockless valve is presumed to malfunction.
3
motor (shockless valve) Check the valve itself.
H-27 There is big abnormal noise caused when stopping swing 1

Trouble • There is a big abnormal noise caused when stopping a swing motion.
Related infor-
mation

Malfunctioning of backpres- The backpressure valve is presumed to malfunction. Check the
1
sure valve valve itself.
Malfunction of swing motor The safety valve in the swing motor is presumed to malfunction.
2
(safety valve) Check the valve itself.
Possible causes The seal in suction valve of the swing motor is suspected of defect.
and standard Malfunction of swing motor Check the seal itself.
value in normal 3
(suction valve) (Whether the seal is defective or not may well be determined by
state swapping the right and left valves and watching the result.)
The swing machinery is suspected of an internal failure. Check the
inside of the machinery itself.
4 Swing machinery defective (A failure inside the swing machinery may well be determined by
monitoring abnormal noise, abnormal heat generated or metal dust
or chips contained in the drained oil.)
PC228US, 228USLC-3E0 27
H-28 Swing natural drift is too big 1

• Swing natural drift is too big.
Trouble
(1) When the swing holding brake is activated.
• When the swing lock switch is ON position, or the swing holding brake release switch is in the normal
Related infor-
position, the swing brake is activated and the swing is fixed with a disc brake.
mation
• Set the working mode in P mode for troubleshooting.

high idle.
Possible causes L.H. work equipment
Swing and holding brake Solenoid valve output pressure
and standard 1 control lever
solenoid valve malfunctioned
value in normal
state NEUTRAL 0 MPa {0 kg/cm2}
Swing operated 2.84 – 3.43 MPa {29 – 35 kg/cm2}
Swing motor (parking brake The parking portion of the swing motor is suspected of malfunction-
2
portion) malfunctioned ing and interior failure. Check that portion directly.
• Swing natural drift is too big.

Trouble
(2) When the swing holding brake is released.
• When the swing holding brake release switch is in the emergency condition, the swing brake is
Related infor-
released and the swing is retained only hydraulically.
mation
• Set the working mode in P mode for troubleshooting.

Swing control valve (spool) The seal in the spool of the swing control valve is suspected of
1
malfunctioned defect. Check the spool itself directly.
Swing control valve (pres-
The pressure compensation valve seal in the swing control valve is
2 sure compensation valve)
suspected of defect. Check the valve itself directly.
malfunctioned
Possible causes
Swing motor (safety valve) The safety valve seal in the swing motor is suspected of defect.
and standard 3
defective Check the valve itself directly.
value in normal
state Swing motor (suction valve) The suction valve seal in the swing motor is suspected of defect.
4
Swing motor (check valve) The check valve seal in the swing motor is suspected of defect.
5
Swing motor (shockless The shockless valve in the swing motor is suspected of malfunction
6 valve) malfunctioned or seal or the seal is suspected of defect. Check the valve or seal itself
defective directly.
28 PC228US, 228USLC-3E0
H-29 Attachment circuit does not change 1

When attachment is installed
Trouble • The return circuit of the attachment circuit does not change.
• If an attachment is installed, the service circuit changes according to the selected working mode as
shown below.
Related infor- 1) In mode P or E: The double acting circuit is selected and the safety valve is set to the low pres-
mation sure.
2) In mode B: The single acting circuit is selected and the safety valve is set to the high pressure.
* Setting of the safety valve on only port B side is changed. Port A is always set to the low pressure.

a Keep the engine stopped for the preparations, and keep it run-
ning at high idle during the troubleshooting.
Malfunction of attachment
Possible causes 1 return selector solenoid Working mode Solenoid valve output pressure
and standard valve Mode E or P 0 MPa {0 kg/cm2}
value in normal Mode B 2.84 – 3.43 MPa {29 – 35 kg/cm2}
state
Malfunction of attachment The attachment return selector valve may have a malfunction.
2
return selector valve Check it directly.
Malfunction of service control The safety valve of the service control valve (on port B side) may
3
valve (safety valve) have a malfunction. Check it directly.
H-30 Flow rate in attachment circuit cannot be adjusted 1

When attachment is installed
Trouble • Flow rate in attachment circuit cannot be adjusted.
• If an attachment is installed, the flow rate in the service circuit changes according to the selected
Related infor- working mode.
mation • How to adjust the flow rate in modes P and E is different from that in mode B. For details, see “Oper-
ation and Maintenance Manual”.

Malfunction of attachment
The attachment flow rate adjustment EPC valve may have a mal-
1 flow rate adjustment EPC
function. Check it directly.
valve
Possible causes a Keep the engine stopped for the preparations, and keep it run-
and standard ning at high idle during the troubleshooting.
value in normal Wiring harness PPC valve output
state Service pedal
Malfunction of service PPC connector pressure
2
valve Disconnect connec- In NEUTRAL 0 MPa {0 kg/cm2}
tor V07 of attachment
flow rate adjustment Above 2.7 MPa
Operated
EPC valve. {Above 28 kg/cm2}
PC228US, 228USLC-3E0 29
SEN01889-02

© 2009 KOMATSU
All Rights Reserved
30
SEN01890-03
PC228US-3E0
PC228USLC-3E0

Troubleshooting of engine (S-mode)
Method of using troubleshooting chart............................................................................................................ 3
S-1 Starting performance is poor .................................................................................................................... 6
S-2 Engine does not start ............................................................................................................................... 7
S-3 Engine does not pick up smoothly.......................................................................................................... 10
S-4 Engine stops during operations ...............................................................................................................11
S-5 Engine does not rotate smoothly ............................................................................................................ 12
S-6 Engine lack output (or lacks power) ....................................................................................................... 13
S-7 Exhaust smoke is black (incomplete combustion).................................................................................. 14
S-8 Oil consumption is excessive (or exhaust smoke is blue) ...................................................................... 15
S-9 Oil becomes contaminated quickly ......................................................................................................... 16
S-10 Fuel consumption is excessive............................................................................................................. 17
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) ................................................... 18
S-12 Oil pressure drops ................................................................................................................................ 19
S-13 Oil level rises (Entry of coolant/fuel)..................................................................................................... 20
S-14 Coolant temperature becomes too high (overheating) ......................................................................... 21
S-15 Abnormal noise is made....................................................................................................................... 22
S-16 Vibration is excessive ........................................................................................................................... 23
Method of using troubleshooting

chart 1
The troubleshooting chart consists of the “ques-
tions”, “check items”, “causes”, and “troubleshoot-
ing” blocks.
The questions and check items are used to pinpoint
high probability causes by simple inspection or
from phenomena without using troubleshooting
tools.
Next, troubleshooting tools or direct inspection are
applied to check the narrowed causes in order from
the most probable one to make final confirmation
according to the troubleshooting procedure.
Questions
Items to be drawn from the user or operator.
They correspond to A and B in the chart on the
right. The items in A are basic ones. The items
in B can be drawn from the user or operator,
depending on their level.
Check items
Simple check items used by the serviceman to
narrow the causes. They correspond to C in
the chart on the right.
Causes
Items to be narrowed from the questions and
check items. The serviceman narrows down
the probable causes from A, B, and C.
Troubleshooting
Items used to find out the true cause by verify-
ing the narrowed causes finally in order from
the most probable one by applying trouble-
shooting tools or direct inspection.
Items listed in the [Questions] and [Check items]

and related to the [Causes] are marked with E, Q,
and w.
E : Causes to be referred to for questions and
check items
Q : Causes related to questions and check items
w : Causes highly probable among ones marked
with Q
a When narrowing the “causes”, apply the items
marked with w before those marked with Q.
When narrowing the causes, do not apply the
items marked with E. (If no items have other
marks and the causes cannot be narrowed,
however, you may apply them.)
<Example of troubleshooting> Exhaust gas is black

Let us assume that a trouble of “Exhaust gas is black” occurred and we checked the [Questions] and [Check
items] and found the following 3 items to be the causal symptoms; [Exhaust gas slowly became black],
[Power slowly became weaker], and [Dust indicator is lighting red].
There is a causal relationship between 3 items in the [Questions] and [Check items] sections and 5 items in
the [Causes] section.
The method of pinpointing the “cause” from the causal relationship and approaching the “troubleshooting” is
explained according to Step 1 – Step 3 shown below.
S-1 Starting performance is poor 1

General causes why starting performance is poor Causes
q Defective electrical system
Leaking or clogged fuel piping, entry of air

Clogged air breather hole of fuel tank cap
Defective alternator (generator section)

q Insufficient supply of fuel
Defective alternator (regulator section)

Defective contact of valve, vale seat
q Insufficient intake of air
Stuck, seized supply pump plunger
Defective intake air heater system

q Improper selection of fuel
Defective, deteriorated battery

a The common rail fuel injection system (CRI) recognizes the
Clogged air cleaner element
Clogged fuel filter, element

Worn piston ring, cylinder
fuel injection timing electrically. Accordingly, even if the
starting operation is carried out, the engine may not start
until the crankshaft revolves 2 turns at maximum. This phe-
Defective injector
nomenon does not indicate a trouble, however.
Confirm recent repair history

Degree of use of machine Operated for long period E E E
Became worse gradually Q w w Q
Starting performance
Engine starts easily when warm w w
Questions
Non-specified fuel is being used Q Q Q

Replacement of filters has not been carried out according to Operation and Mainte- w w Q Q
nance Manual
Engine oil must be added more frequently w
When engine is preheated or when temperature is low, preheating monitor does not w
indicate normally
During operation, charge level monitor indicates abnormal charge w w
Dust indicator is red w
Air breather hole of fuel tank cap is clogged w
Fuel is leaking from fuel piping w Q
When priming pump is operated, it makes no reaction or it is heavy w Q
Starting motor cranks engine slowly w
If air bleeding plug of fuel filter is removed, fuel does not w
While engine is cranked flow out
with starting motor
If spill hose from injector is disconnected, little fuel spills w
Check items
When exhaust manifold is touched immediately after starting engine, temperature of w

some cylinders is low
Engine does not pick up smoothly and combustion is irregular Q Q w
There is hunting from engine (rotation is irregular) Q w Q
Blow-by gas is excessive w
Inspect air cleaner directly q

When compression pressure is measured, it is found to be low q q
When air is bled from fuel system, air comes out q
Inspect fuel filter, strainer directly q
Troubleshooting
Carry out troubleshooting according to “Rail Press (Very) Low Error (*1)” indicated by
q
code
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not
q
change
When starting switch is turned to HEAT, intake air heater mount does not become warm q
Is voltage 20 – 30 V between alternator terminal L and terminal E with Yes q
engine at low idle? No q
When specific gravity of electrolyte and voltage of battery are measured, they are low q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
correct
Adjust
Clean
Clean
Clean
Remedy
*1: Displayed failure codes [CA559] and [CA2249]
S-2 Engine does not start 1

a) Engine does not turn Causes
Defective connection of battery terminal
Defective starting motor (motor section)

General causes why engine does not turn
q Internal parts of engine seized
o See “S-4 Engine stops during operations
Defective or deteriorated battery
Defective starting circuit wiring

q Defective electrical system
q Defective electrical system (Starting circuit)
Broken flywheel ring gear
Defective starting switch

Defective battery relay
Defective safety relay

Questions
Degree of use of machine Operated for long period E E

Condition of horn when Horn does not sound Q Q w
starting switch is turned ON Horn volume is low w
Battery electrolyte is low w
Battery terminal is loose w
When starting switch is turned ON, there is no operating sound from battery relay Q w
When starting switch is turned to START, starting pinion does not move out Q Q w
Check items
Speed of rotation is low w

When starting switch is Makes grating noise w w
turned to START, starting
pinion moves out, but Soon disengages again w
Makes rattling noise and does not turn Q Q Q
Inspect flywheel ring gear directly q

Carry out troubleshooting

There is not voltage (20 – 30 V) between battery relay terminal B and
q
Troubleshooting
terminal E
in E-mode
When terminal B and terminal C of starting switch are connected,
q
engine starts
Turn starting switch OFF, When terminal B and terminal C at safety relay outlet are connected,
connect cord, and carry out q
troubleshooting at ON engine starts
Even if terminal B and terminal C at safety relay outlet are con-
q
nected, engine does not start
When safety switch terminal and terminal B of starting motor are con-
q
nected, engine starts
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Remedy
b) Engine turns but no exhaust smoke comes out Causes
Defective operation of overflow valve (Does not close)

General causes why engine turns but no exhaust smoke comes
out
q Fuel is not being supplied
q Supply of fuel is extremely small

q Improper selection of fuel (particularly in winter)
Defective common rail pressure limiter

Seized, abnormally worn feed pump

Defective supply pump MPROP
Clogged fuel filter element
Broken supply pump shaft

Insufficient fuel in tank
Use of improper fuel
Questions

Exhaust smoke suddenly stopped coming out (when starting again) w Q w w
Replacement of filters has not been carried out according to Operation and Mainte- w E
nance Manual
When fuel tank is inspected, it is found to be empty w
Air breather hole of fuel tank cap is clogged Q w
Rust and water are found when fuel tank is drained Q E E E
When fuel filter is removed, there is not fuel in it w w
w
Check items
Fuel is leaking from fuel piping

If air bleeding plug of fuel filter is removed, fuel does not Q Q w Q
While engine is cranked flow out
with starting motor
If spill hose from injector is disconnected, little fuel spills Q w w w

Inspect fuel filter directly q
Troubleshooting
Inspect feed pump directly q

Carry out troubleshooting according to “Rail Press (Very) Low Error (*1)” indicated by q q
code
Carry out troubleshooting according to “IMV/PCV1 Short (Open) Error (*2)” indicated by
q
code
Inspect overflow valve directly q
If pressure limiter return pipe is disconnected, fuel flows out q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Remedy
Add

c) Exhaust smoke comes but engine does not start (fuel is Causes
Worn dynamic valve system (Valve, rocker lever, etc.)
Defective coolant temperature sensor, wiring harness

being injected)
General causes why exhaust smoke comes out but engine does
not start
Leaking or clogged fuel system, entry of air

q Lack of rotating force due to defective electrical system

Defective intake air heater system

Clogged injector, defective spray
Defective, deteriorated battery


Use of improper fuel
Clogged fuel filter

Suddenly failed to start w w Q
Questions
Non-specified fuel is being used Q Q

Replacement of filters has not been carried out according to Operation and Mainte- w w
nance Manual
When engine is preheated or when temperature is low, preheating monitor does not w
indicate normally
Air breather hole of fuel tank cap is clogged Q
Rust and water are found when fuel tank is drained w
When fuel filter is removed, there is not fuel in it w
Fuel is leaking from fuel piping w
Starting motor cranks engine slowly w
When engine is cranked, abnormal sound is generated around cylinder head w
Check items
If air bleeding plug of fuel filter is removed, fuel does not

While engine is cranked Q w
flow out
with starting motor,
If spill hose from injector is disconnected, little fuel spills w
When exhaust manifold is touched immediately after starting engine, temperature of
some cylinders is low w

Inspect dynamic valve system directly q
When compression pressure is measured, it is found to be low q
q
Troubleshooting
When air is bled from fuel system, air comes out

Inspect fuel filter directly q
Carry out troubleshooting according to “Rail Press (Very) Low Error (*1)” indicated by
q
code
Engine can be started in reduced cylinder mode. q
Coolant temperature gauge does not indicate normally q
When starting switch is turned to HEAT, intake air heater mount does not become warm q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Remedy
S-3 Engine does not pick up smoothly 1

General causes why engine does not pick up smoothly Causes
Seized turbocharger, interference of turbocharger

q Defective condition of fuel spray

Defective contact of valve and valve seat
q Controller is controlling in derate mode (limiting injection rate

Clogged injector, defective spray
(output) because of an error in electrical system)

Improper valve clearance
Clogged fuel filter

Degree of use of machine Operated for long period E E E E
Questions
Engine pick-up suddenly became worse w Q Q Q

Non-specified fuel is being used w w w
Replacement of filters has not been carried out according to Operation and Maintenance
Manual w w
Oil must be added more frequently w

Rust and water are found when fuel tank is drained w
When exhaust manifold is touched immediately after starting engine, temperature of some
cylinders is low Q w
Blue under light load w

Color of exhaust gas
Check items
Black w Q w w
When engine is cranked, interference sound is generated around turbocharger w
High idle speed under no load is normal, but speed suddenly drops when load is applied Q w
There is hunting from engine (rotation is irregular) Q Q Q

Troubleshooting
Inspect valve clearance directly q

When turbocharger is rotated by hand, it is found to be heavy q
Carry out troubleshooting according to “Rail Press (Very) Low Error (*1)” indicated by code q
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change q
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Clean
Clean
Clean
Remedy
10 PC228US, 228USLC-3E0
S-4 Engine stops during operations 1

General causes why engine stops during operations Causes
Broken dynamic valve system (valve, rocker arm, etc.)

q Seized parts inside engine
Defective power supply wiring for engine controller

q There is overheating
Broken auxiliary equipment (pump, etc.)

q Defective hydraulic pump
Broken, seized piston, connecting rod

Broken, seized crankshaft bearing
Clogged feed pump gauze filter
Defective starting switch wiring

Broken supply pump shaft, key
Leaking, clogged fuel piping
Problem in hydraulic pump

Clogged fuel filter, strainer
Broken, seized feed pump

Broken, seized gear train
Abnormal noise was heard and engine stopped sud-
denly w w w w Q w Q w w
w Q Q
Questions
Condition when engine Engine overheated and stopped

stopped
Engine stopped slowly w Q Q Q Q
There was hunting and engine stopped w Q Q Q Q Q Q
Non-specified fuel is being used Q Q Q Q
Replacement of filters has not been carried out according to Operation and Mainte- w w
nance Manual
Fuel level monitor indicates low level w
Rust and water are found when fuel tank is drained w w
Metal particles are found when oil is drained w w Q Q
Check items
Does not turn at all w w
When engine is cranked by Turns in opposite direction w

hand Moves by amount of gear backlash w w
Supply pump shaft does not turn w
Engine turns, but stops when load is applied to machine w
q
Carry out troubleshooting in H mode
Inspect piston, connecting rod directly
Inspect crankshaft bearing directly q
Inspect gear train directly q

Troubleshooting
Inspect feed pump gauze filter directly q
Inspect feed pump directly q
Carry out troubleshooting according to “No-pressure feed by supply pump (*1)” q q
Engine rotates when pump auxiliary equipment (pump, etc.) is removed q
Check power supply wiring for engine controller q
Check starting switch wiring q

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Remedy
Add
*1: Failure code [CA559] and failure code [CA2249]
PC228US, 228USLC-3E0 11
S-5 Engine does not rotate smoothly 1

General causes why engine does not rotate smoothly Causes
q Air in fuel system
Clogged injector, defective spray (dirt in injector)
Defective Bkup speed sensor, wiring harness

q Defective speed sensor (Error at degree that it is not indicated)
Defective Ne speed sensor, wiring harness

Clogged fuel filter

Degree of use of machine Operated for long period E
Q Q
Questions
Occurs at a certain speed range

Occurs at low idle Q Q Q Q Q
Condition of hunting
Occurs even when speed is raised Q Q Q
Occurs on slopes w
Replacement of filters has not been carried out according to Operation and Maintenance Manual w
Check items
Rust and water are found when fuel tank is drained Q


Troubleshooting

Carry out troubleshooting according to “Eng Ne Speed Sensor Error (*1)” indicated by code q
Carry out troubleshooting according to “Eng Bkup Speed Sensor Error (*2)” indicated by code q
Replace
Replace
Replace
Replace
Replace
Clean
Remedy
Add
*1: Displayed failure codes [CA689]

*2: Displayed failure code [CA778]
12 PC228US, 228USLC-3E0
S-6 Engine lack output (or lacks power) 1

General causes why engine lacks output Causes

Defective boost pressure sensor, wiring harness

Clogged injector, defective spray (dirt in injector)
Defective installation of boost pressure sensor

Defective drive of injector (signal, solenoid)

q Defective spray condition of fuel


Air leakage from air intake piping

o See “S-14 Coolant temperature becomes too
Leaking, clogged fuel piping

high (Overheating)”.

q Controller is controlling in derate mode (limiting
injection rate (output) because of an error in
Clogged spill piping

Clogged fuel filter
electrical system)
(air leakage)
Suddenly Q w Q Q Q Q
Questions
Power was lost

Gradually Q Q Q Q Q Q
Non-specified fuel is being used Q Q Q
Replacement of filters has not been carried out according to Operation w w
and Maintenance Manual
Engine oil must be added more frequently Q Q
Dust indicator is red w Q
Output becomes insufficient after short stop of operation Q
Black Q w w
When exhaust manifold is touched immediately after starting engine, w w
temperature of some cylinders is low
When engine is cranked, interference sound is generated around w
Check items
turbocharger
High idle speed is too high Q
High idle speed under no load is normal, but speed suddenly drops when Q w Q Q
load is applied
Engine does not pick up smoothly and combustion is irregular w w Q Q w
There is hunting from engine (rotation is irregular) Q Q Q Q Q
Blow-by gas is excessive w w

Inspect air intake piping directly q
When boost pressure is measured, it is found to be low q q q
Inspect valve clearance directly q
Troubleshooting
Inspect fuel piping q

Inspect spill port check valve directly q
Carry out troubleshooting according to “Rail Press (Very) Low Error (*1)”
indicated by code q
When a cylinder is cut out for reduced cylinder mode operation, engine q q
speed does not change
Inspect boost pressure sensor mount directly q
Carry out troubleshooting according to “Chg Air Press Sensor High (Low)
Error (*2)” indicated by code q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Adjust
Clean
Clean
Remedy

PC228US, 228USLC-3E0 13
S-7 Exhaust smoke is black (incomplete combustion) 1

General causes why exhaust smoke is black Causes
Leakage of air between turbocharger and cylinder head


q Defective condition of fuel injection

o See “S-14 Coolant temperature becomes too high

(Overheating)”.
q Controller is controlling in derate mode (limiting injection
Improper fuel injection pressure

rate (output) because of an error in electrical system)
Improper fuel injection timing


Crushed, clogged muffler
Abnormally worn injector

Clogged, seized injector
Suddenly became black w w Q Q Q
Questions
Color of exhaust gas Gradually became black w Q Q

Suddenly w Q Q Q
Power was lost
Gradually Q Q Q Q
Muffler is crushed w
Air leaks between turbocharger and cylinder head, clamp is loosened w
Engine is operated in low-temperature mode at normal temperature Q Q Q
When exhaust manifold is touched immediately after starting engine, temperature of
some cylinders is low Q w
Check items

Pump relief speed is high (Fuel is injected excessively) Q
Exhaust noise is abnormal Q w Q
Engine does not pick up smoothly and combustion is irregular Q Q Q Q Q w
If spill hose from injector is disconnected, abnormally much fuel spills w

When turbocharger is rotated by hand, it is found to be heavy q
q
Troubleshooting
Inspect valve clearance directly

When muffler is removed, exhaust colour improves q
Carry out troubleshooting according to “Rail Press (Very) Low Error (*1)” indicated
q q
by code
When a cylinder is cut out for reduced cylinder mode operation, engine speed does q
not change
Carry out troubleshooting according to “Coolant Temp Sens High (Low) Error (*2)”
q
indicated by code
Check with monitoring function q q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Adjust
Clean
Remedy

14 PC228US, 228USLC-3E0
S-8 Oil consumption is excessive (or exhaust smoke is blue) 1

General causes why oil consumption is excessive Causes
q Abnormal consumption of oil
Turbocharger
Oil leakage from oil pan, cylinder head, etc.

q Long-time operation of engine at low idle or high idle
Worn, damaged valve (stem, guide, seal)

(Do not run engine at idle for more than 20 minutes
continuously)
Dust sucked in from intake system
Clogged breather, breather hose

q External leakage of oil
Worn seal at turbocharger end
Oil leakage from oil drain plug

Worn, damaged rear oil seal
q Wear of parts in lubrication system
Oil leakage from oil cooler
Oil leakage from oil piping

Worn seal at blower end
Oil leakage from oil filter

Broken piston ring
Broken oil cooler

E E E E
Questions
Degree of use of machine Operated for long period

Oil consumption suddenly increased w Q
Oil must be added more frequently w Q
Oil becomes contaminated quickly Q Q w
Outside of engine is dirty with oil w w w w w
There are loose piping clamps in intake system w
Inside of turbocharger intake outlet pipe is dirty with oil w
Inside of turbocharger exhaust outlet pipe is dirty with oil Q w
Check items
There is oil in coolant w

Oil level in damper chamber of applicable machine is high w
Exhaust smoke is blue under light load w w
Excessive Q Q w w
Amount of blow-by gas
None w
When intake manifold is removed, dust is found inside q

When intake manifold is removed, inside is found to be dirty abnormally q
Troubleshooting
Excessive play of turbocharger shaft q q

Check breather and breather hose directly q
Inspect rear oil seal directly q
Pressure-tightness test of oil cooler shows there is leakage q q
There is external leakage of oil from engine q q q q
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Correct
Correct
Clean
Remedy
PC228US, 228USLC-3E0 15
S-9 Oil becomes contaminated quickly 1

General causes why oil becomes contaminated quickly Causes
q Entry of exhaust gas into oil due to internal wear
Clogged turbocharger lubrication drain tube

Defective seal at turbocharger turbine end
q Clogging of lubrication passage
q Use of improper fuel
q Use of improper oil
Clogged breather, breather hose

q Operation under excessive load
Defective oil filter safety valve

Worn valve, valve guide
Exhaust smoke is bad

Clogged oil cooler
Clogged oil filter
Questions

Metal particles are found when oil is drained Q Q w
Inside of exhaust pipe is dirty with oil w
Engine oil temperature rises quickly w
Check items
Color of exhaust gas color

Black w
Excessive Q Q w Q
Amount of blow-by gas
None w
Excessive play of turbocharger shaft q

Troubleshooting
Check breather and breather hose directly q
See S-7
Inspect oil cooler directly q
Inspect oil filter directly q
Spring of oil filter safety valve is hitched or broken q
Inspect turbocharger lubrication drain tube directly q
Replace
Replace
Replace
Replace
Replace
Clean
Clean
Clean
—
Remedy
16 PC228US, 228USLC-3E0
S-10 Fuel consumption is excessive 1

General causes why fuel consumption is excessive Causes
q Leakage of fuel

q Defective condition of fuel injection (fuel pressure, injection timing)
q Excessive injection of fuel
Fuel leakage from fuel filter, piping, etc.
Defective common rail pressure

Fuel leakage inside head cover
Defective supply pump plunger
Defective operation of injector

Improper fuel injection timing
Defective feed pump oil seal
Defective spray by injector

E E E
Questions

More than for other machines of same model Q Q Q Q
Condition of fuel Gradually increased Q Q
consumption
Suddenly increased Q Q
There is external leakage of fuel from engine w
Combustion is irregular w
Engine oil level rises and oil smells of diesel fuel w w
When exhaust manifold is touched immediately after starting engine, temperature of some w
cylinders is low
Check items
Low idle speed is high Q

Pump relief speed is high Q
Black Q Q Q Q
Exhaust smoke color
White Q
Remove and inspect head cover directly q

Inspect feed pump oil seal directly q
Troubleshooting
Carry out troubleshooting according to “Rail Press (Very) Low Error (*1)” indicated by code q
If spill hose from injector is disconnected, much fuel spills q
Carry out troubleshooting according to “Coolant Temp Sens High (Low) Error (*2)” indicated by
q
code
Check with monitoring function q q
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy

PC228US, 228USLC-3E0 17
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)
General causes why oil is in coolant Causes
q Internal leakage in lubrication system
Broken cylinder head, head gasket

q Internal leakage in cooling system
Internal cracks in cylinder block
Broken oil cooler core, O-ring

Holes caused by pitting
E E
Questions

Oil level
Gradually increased Q Q
Hard water is being used as coolant Q Q
Oil level has risen, oil is milky Q Q w
Check
items
There are excessive air bubbles in radiator, coolant spurts back w
Pressure-tightness test of cylinder head shows there is leakage q

shooting
Trouble-
Inspect cylinder block directly q q

Pressure-tightness test of oil cooler shows there is leakage q
Replace
Replace
Replace
Replace
Remedy
18 PC228US, 228USLC-3E0
S-12 Oil pressure drops 1

General causes why oil pressure drops Causes
q Leakage, clogging, wear of lubrication system
Leaking, crushed, clogged hydraulic piping

Defective oil level sensor, wiring harness
q Defective oil pressure control
q Selection of oil by the temperature etc. specified in the Operation
and Maintenance Manual is not observed.
Clogged, broken pipe in oil pan

q Deterioration of oil due to overheating
Clogged strainer in oil pan
Defective regulator valve

Worn journal of bearing
Lack of oil in oil pan
Defective oil pump

Coolant, fuel in oil
Clogged oil filter

Questions
Oil pressure monitor indicates low oil pressure Q w

Non-specified oil is being used Q Q
Replacement of filters has not been carried out according to Operation and Maintenance
w
Manual
Indicates pressure drop at low idle w
Oil pressure monitor Indicates pressure drop at low, high idle Q w w w Q
(if installed) Indicates pressure drop on slopes w
Sometimes indicates pressure drop w Q
Oil level monitor indicates oil level drop w w
Oil level in oil pan is low w
External hydraulic piping is leaking, crushed w
Check items
Oil is milky or smells of diesel oil w

Metal particles are found when oil pan is drained w
Metal particles are found when oil filter is drained w Q
Metal particles are found in oil filter q

Troubleshooting
Inspect oil pan strainer, pipe directly q q

See S-13
Oil pump rotation is heavy, there is play in oil pump q

Valve spring of regulator valve is fatigued, damaged q
Inspect oil filter directly q
If oil level sensor is replaced, oil pressure monitor indicates normally q
Replace
Replace
Correct
Adjust
Clean
Clean
Clean
Clean
—
Remedy
Add
PC228US, 228USLC-3E0 19
S-13 Oil level rises (Entry of coolant/fuel) 1

General causes why oil level rises Causes
Coolant in oil (milky)
Defective seal of auxiliary equipment (pump, compressor)

q
q Fuel in oil (smells diluted diesel fuel)
a If oil is in coolant, carry out troubleshooting for “S-11 Oil is in coolant”.
Broken oil cooler core, O-ring

Worn, damaged rear oil seal
Cracks inside cylinder block
Defects in supply pump

Broken injector O-ring
Questions

Fuel must be added more frequently w w
Coolant must be added more frequently Q Q
There is oil in coolant Q Q Q Q w
Oil smells of diesel fuel w w
Oil is milky Q Q
When engine is started, drops of water come from muffler Q
When radiator cap is removed and engine is run at low idle, an abnormal number of bubbles appear, w Q
Check items
or coolant spurts back

Exhaust smoke is white Q
Oil level in damper chamber is low w
Oil level in hydraulic tank is low w

Remove injector and inspect O-ring q
Troubleshooting
Inspect cylinder block directly q q

Inspect rear oil seal directly q
Pressure-tightness test of oil cooler shows there is leakage q
Remove and inspect supply pump directly q
Inspect seal of auxiliary equipment directly q
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Remedy
20 PC228US, 228USLC-3E0
S-14 Coolant temperature becomes too high (overheating) 1

General causes why coolant temperature becomes too high Causes
q Lack of cooling air (deformation, damage of fan)
Defective radiator cap (pressure valve)
Defective coolant temperature gauge

q Drop in heat dissipation efficiency
Defective operation of thermostat
Slipping fan belt, worn fan pulley
Rise of hydraulic oil temperature

q Problem in coolant circulation system
Clogged, crushed radiator fins

Clogged, broken oil cooler
Clogged radiator core

Broken water pump
Lack of coolant
Questions
Sudden overheated Q w Q
Condition of overheating
Always tends to overheat Q w w Q
Coolant temperature Rises quickly Q w
gauge (if installed) Does not go down from red range w
Radiator coolant level monitor indicates drop of coolant level (if monitor is installed) w
Engine oil level has risen and oil is milky w Q
Fan belt tension is low w
When fan belt is turned, it has play w
Milky oil is floating on coolant w
There are excessive air bubbles in radiator, coolant spurts back w
Check items
When light bulb is held behind radiator core, no light passes through w
Radiator shroud, inside of underguard are clogged with dirt or mud w w
Coolant is leaking because of cracks in hose or loose clamps w
Coolant flows out from radiator overflow hose w
Fan belt whines under sudden acceleration w
Hydraulic oil temperature enters red range faster than engine coolant temperature w

Inspect cylinder directly q
on applicable machine side

Carry out troubleshooting
Inspect oil cooler directly q
q
Troubleshooting
Temperature difference between upper and lower tanks of radiator is large

When operation of thermostat is carried out, it does not open at cracking
temperature q
Temperature difference between upper and lower tanks of radiator is slight q

Inspect radiator core directly q
When operation of radiator cap is carried out, its cracking pressure is low q
Inspect fan belt, pulley directly q
When coolant temperature is measured, it is fount to be normal q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
Add
PC228US, 228USLC-3E0 21
S-15 Abnormal noise is made 1

General causes why abnormal noise is made Causes
Abnormality due to defective parts
Deformed cooling fan, loose fan belt, interference of fan belt

q
Defective inside of muffler (dividing board out of position)

q Abnormal combustion
Leakage of air between turbocharger and cylinder head

q Air sucked in from intake system
Improper fuel injection timing (abnormality in coolant

low temperature sensor, boost temperature sensor)
a Judge if the noise is an internal noise or an external
Broken dynamic valve system (valve, rocker lever)

Interference of turbocharger, seized turbocharger
noise before starting troubleshooting.
a The engine is operated in the low-temperature mode
while it is not warmed up sufficiently. Accordingly, the
Excessive wear of piston ring, cylinder

engine sound becomes a little larger. This does not indi-
cate abnormality, however.
a When the engine is accelerated, it is operated in the
Improper gear train backlash

acceleration mode and its sound becomes a little larger
Removed, seized bushing

Clogged, seized injector

for up to about 3 seconds. This does not indicate abnor-
Dirt caught in injector

mality, however.

Degree of use of machine Operated for long period E
Questions
Condition of abnormal Gradually occurred Q Q

noise Sudden occurred Q Q Q
Non-specified fuel is being used Q
Metal particles are found when oil filter is drained w w
Air leaks between turbocharger and cylinder head w
When engine is cranked, abnormal sound is generated around cylinder head w w
When engine is cranked, beat noise is generated around muffler w
Check items
When exhaust manifold is touched immediately after starting engine, temperature of w Q

some cylinders is low
Black Q w Q
Engine does not pick up smoothly and combustion is irregular w
Abnormal noise is loud when engine is accelerated Q Q Q Q
When turbocharger is rotated by hand, it is fount to be heavy q

When muffler is removed, abnormal noise disappears q
q
Troubleshooting
Inspect valve clearance directly

Inspect gear train directly q q
Inspect fan and fan belt directly q
When a cylinder is cut out for reduced cylinder mode operation, engine speed does
q q
not change
Abnormal noise is heard only when engine is started q
Confirm with monitoring function q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Remedy
22 PC228US, 228USLC-3E0
S-16 Vibration is excessive 1

General causes why vibration is excessive Causes
Defective parts (abnormal wear, breakage)
Improper injection timing (Abnormality in coolant temperature sensor, boost temperature sensor)
q
q Misalignment between engine and chassis
q Abnormal combustion
a If abnormal noise is made and vibration is excessive, carry out trouble-
shooting for “S-15 Abnormal noise is made”, too.
Stuck dynamic valve system (valve, rocker lever)
Loose engine mounting bolts, broken cushions

Worn main bearing, connecting rod bearing
Broken output shaft, parts in damper

Improper gear train backlash
Worn camshaft bushing
E E E
Questions

Condition of vibration
Gradually increased Q Q Q
Non-specified oil is being used Q Q
Metal particles are found when oil filter is drained w w
Metal particles are found when oil pan is drained w w
Oil pressure is low at low idle Q Q
Check items
Vibration occurs at mid-range speed Q Q

Vibration follows engine speed Q Q Q
Exhaust smoke is black w Q

Inspect main bearing and connecting rod bearing directly q
Troubleshooting
Inspect gear train directly q

Inspect camshaft bushing directly q
Check with monitoring function q
Inspect engine mounting bolts and cushions directly q
Inspect inside of damper directly q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Remedy
PC228US, 228USLC-3E0 23
SEN01890-03

© 2009 KOMATSU
All Rights Reserved
24
SEN01923-03
PC228US-3E0
PC228USLC-3E0


General information on disassembly and
assembly
How to read this manual ................................................................................................................................. 2
Coating materials list....................................................................................................................................... 4
Special tools list .............................................................................................................................................. 7
Sketches of special tools .............................................................................................................................. 10
SEN01923-03 50 Disassembly and assembly
How to read this manual 1

(Rev. 2009.1)
1. Removal and installation of assemblies
Special tools Removal

q Special tools which are necessary for q In “Removal” section, the work procedures,
r e m o v a l o r i n s ta l l a t i o n o f pa r ts a r e precautions and know-how to do the work, and
described as A1, ••• X1 etc. and their part the amount of oil and coolant to be drained are
numbers, part names and quantities are described.
described in the special tool list. q Common tools that are necessary for removal
q Also the following information is de- are described as [1], [2]••• etc. and their part
scribed in the special tool list. numbers, part names and quantities are not
1) Necessity described.
t : Special tools that cannot be substi- q Various symbols used in “Removal” section are
tuted and should always be used explained and listed below.
q : Special tools that will be useful if avail-
able and are substitutable with tools k : Precautions related to work safety
available on the market a : Guidance or precautions for the work
2) Distinction of new and existing special [*1] : This mark shows that instructions or precau-
tools tions for parts installation work are given in
N: Tools newly developed for this “Installation” section.
model. They have a new part num- 6 : Amount of oil or coolant to be drained
4:
ber respectively.
Weight of part or component
R: Tools made available by redesign-
ing the existing tools which were
Installation
developed for other models. Each
of them has a new part number q Unless otherwise instructed, installation of
assigned by setting forward the parts is to be done in the reverse order to
part number of the existing tool. removal.
Blank : Tools already available for other q Instructions and precautions for parts installa-
models. They can be used without tion is shown with the mark ([*1], [*2]...) which
any modification. corresponds to the mark in “Removal” section.
3) Circle mark Q in sketch column: q Common tools that are necessary for installa-
q The sketch of the special tool is pre- tion are described as [1], [2]••• etc. and their
sented in the section of “Sketches of part numbers, part names and quantities are
special tools”. not described.
q Part No. of special tools starting with q Marks shown in the “Installation” section stand
79 T- - : for the following.
* *** ****
means that they are not available
from Komatsu Ltd. (i.e. tools to be k : Precautions related to work safety
made locally). a : Guidance or precautions for the work
2 : Type of coating material
3 : Tightening torque
5 : Amount of oil or coolant to be replenished
Sketches of special tools

q Various special tools are illustrated for the local
manufacture.
2. Disassembly and assembly of assemblies
Special tools Disassembly

q Special tools which are necessary for dis- q In “Disassembly” section, the work procedures,
assembly and assembly of parts are precautions and know-how to do the work, and
described as A1, ••• X1 etc. and their part the amount of oil and coolant to be drained are
numbers, part names and quantities are described.
described in the special tool list. q Common tools that are necessary for disas-
q Also the following information is described sembly are described as [1], [2]••• etc. and
in the special tool list. their part numbers, part names and quantities
1) Necessity are not described.
t : Special tools that cannot be substi- q The meanings of the symbols used in “Disas-
tuted and should always be used. sembly” section are as follows.
q : Special tools that will be useful if avail-
able and are substitutable with tools k : Precautions related to work safety
available on the market. a : Guidance or precautions for the work
2) Distinction of new and existing special 6 : Amount of oil or coolant drained
tools
N: Tools newly developed for this
model. They have a new part num- Assembly
ber respectively. q In “Assembly” section, the work procedures,
R: Tools made available by redesign- precautions and know-how to do the work, and
ing the existing tools which were the amount of oil and coolant to be replenished
developed for other models. Each are described.
of them has a new part number q Common tools that are necessary for assem-
assigned by setting forward the bly are described as [1], [2]••• etc. and their
part number of the existing tool. part numbers, part names and quantities are
Blank : Tools already available for other not described.
models. They can be used without q The meanings of the symbols used in “Assem-
any modification. bly” section are as follows.
3) Circle mark Q in sketch column:
k
q The sketch of the special tool is pre- : Precautions related to work safety
sented in the section of “Sketches of a : Guidance or precautions for the work
2 : Type of coating material
special tools”.
3 : Tightening torque
q Part No. of special tools starting with
5
79 T- - :
* *** ****
means that they are not available
: Amount of oil or coolant to be replenished
from Komatsu Ltd. (i.e. tools to be
made locally).
Sketches of special tools
q Various special tools are illustrated for the local
manufacture.
Coating materials list 1

(Rev. 2009.08)
a The recommended coating materials such as adhesives, liquid gaskets, and greases used for disas-
sembly and assembly are listed below.
a For coating materials not listed below, use the equivalent of products shown in this manual.
Cate- Komatsu
Part No. Capacity Container Main features and applications
gory code
q Use to prevent rubber gaskets, rubber cushions,

LT-1A 790-129-9030 150 g Tube
and cork plugs from coming out.
q Use for plastic (except polyethylene, polypropy-
20 g Polyethylene lene, tetrafluoroethylene and vinyl chloride), rub-
LT-1B 790-129-9050
(2 pcs.) container ber, metal, and non-metal parts which require
immediate and strong adhesion.
Polyethylene q Features: Resistance to heat and chemicals.
LT-2 790-129-9040 50 g
container q Use to fix and seal bolts and plugs.
790-129-9060 Adhesive:
(Set of adhe- 1 kg
LT-3 Can q Use to bond and seal metal, glass and plastics.
sive and hard- Hardener:
ener) 500 g
Adhesive
Polyethylene
LT-4 790-129-9040 250 g q Use to seal plugs for blank holes
container
Holtz
790-129-9120 75 g Tube q Heat-resistant seal used to repair engines.
MH 705
q Instantaneous adhesive.
ThreeBond Polyethylene q Curing time: From 5 sec. to 3 min.
790-129-9140 50 g
1735 container q Use mainly to bond metals, rubbers, plastics, and
woods.
q Instantaneous adhesive.
Aron-alpha Polyethylene q Quick-curing type (max. strength is obtained after
790-129-9130 2g
201 container 30 minutes)
q Use mainly to bond rubbers, plastics, and metals.
q Features: Resistance to heat and chemicals.
Loctite Polyethylene
79A-129-9110 50 cc q Use for fitted portions subjected to high tempera-
648-50 container
ture.
q Use to seal various threaded portions, pipe joints,
Polyethylene and flanges.
LG-5 790-129-9080 1 kg
container q Use to seal taper plugs, elbows, and nipples for
hydraulic piping.
q Features: Silicon-based heat and cold-resistant
sealant.
LG-6 790-129-9160 200 g Tube
q Use to seal flange surfaces and threaded portions.
Liquid gasket
q Use to seal oil pan, final drive case, etc.

q Features: Silicon-based quick-curing sealant.
LG-7 790-129-9170 1 kg Tube q Use to seal flywheel housing, intake manifold, oil
pan, thermostat housing, etc.
LG-8 q Features: Silicon-based, heat and cold-resistant,
ThreeBond 419-15-18131 100 g Tube vibration-resistant, impact-resistant sealant.
1207B q Use to seal transfer case, etc.
q Use for rough surfaces such as the circle gear top
LG-9
seal which is not clamped by bolts, gaps in the
ThreeBond 790-129-9310 200 g Tube
weld which must be caulked, etc.
1206D
q Can be coated with paint.
Cate- Komatsu
gory code
LG-10 q Use as lubricant/sealant when installing the radia-
ThreeBond 790-129-9320 200 g Tube tor hoses to the water tubes.
Liquid gasket
1206E q Can be coated with paint.

LG-11 q Feature: Can be used together with solid gaskets.
ThreeBond 790-129-9330 200 g Tube q Use for covers of the transmission case and steer-
1121 ing case etc.
ThreeBond
790-129-9090 100 g Tube q Liquid gasket used to repair engine.
1211
q Use to prevent galling and seizure of press-fitted
Molybdenum disulfide
portions, shrinkage-fitted portions, and threaded

LM-P 09940-00040 200 g Tube
portions.
lubricant
q Use to lubricate linkages, bearings, etc.

q Spray type
q Thin molybdenum disulphide films are made on
— 09995-00250 190 g Can metal surfaces to prevent the metals from galling.
q Use for the drive shaft splines, needle bearings,
various link pins, bolts, etc.
prevention compound
q Feature: Seizure and galling prevention com-

Seizure
LC-G pound with metallic super-fine-grain, etc.

NEVER- — — Can q Use for the mounting bolt in the high temperature
SEEZ area of the exhaust manifold and the turbocharger,
etc.
SYG2-400LI
SYG2-350LI
SYG2-400LI-A
G2-LI
SYG2-160LI
G0-LI (*) q Feature: Lithium grease with extreme pressure lu-
SYGA-160CNLI Various Various
*: For cold brication performance, general purpose type.
SYG0-400LI-A
district
(*)
SYG0-160CNLI
(*)
q Use for parts under heavy load.
Molybde- Caution:
num disul- SYG2-400M 400 g × 10 Bellows-type q Do not use this grease for rolling bearings like
fide grease SYG2-400M-A 400 g × 20 container swing circle bearings, etc. and spline.
LM-G SYGA-16CNM 16 kg Can q Use this grease for work equipment pins only
(G2-M) when installing them, but do not use it after-
ward.
SYG2-400T-A
Grease
Hyper White
SYG0-400T-A q Seizure resistance, heat resistance and water re-
G2-T, Bellows-type
(*) 400 g sistance higher than molybdenum disulfide
G0-T (*) container
SYG2-16CNT grease.
*: For cold 16 kg Can
SYG0-16CNT q Not conspicuous on machine since color is white.
district
(*)
Biogrease
G2-B SYG2-400B
G2-BT (*) SYG2-400BT
Bellows-type q Since this grease is biodegradable in short period,
*: For use at (*) 400 g
container it has less impact on microorganisms, animals,
high temper- SYGA-16CNB
16 kg Can and plants.
ature and SYGA-16CNBT
under high (*)
load
q Feature: Silicone grease with wide usable temper-
G2-S ature range, high resistance to thermal-oxidative
ThreeBond — 200 g Tube degradation and performance to prevent deterio-
1855 ration of rubber and plastic parts.
q Use for oil seals of the transmission, etc.
Cate- Komatsu
gory code
q Feature: Urea (organic system) grease with heat
Grease
resistance and long life, can be packed into the

G2-U-S
427-12-11871 2 kg Can confined space and left intact until next overhaul.
ENS grease
q Use for rubber, bearing and oil seal in damper.
Caution: Do not mix with lithium grease.
SUNSTAR q Use as primer for painted cab sheet metal
PAINT Glass con- surface.
20 ml
PRIMER tainer (Effective period: four months after date of
580 SUPER manufacture)
417-926-3910
SUNSTAR
q Use as primer for glass.
GLASS Glass con-
20 ml (Effective period: four months after date of
For adhered window glass

PRIMER tainer
manufacture)
580 SUPER
SUNSTAR q Use as primer for painted cab sheet metal
PAINT Glass con- surface.
Primer
22M-54-27230 20 ml
435-95 manufacture)
q Use as primer for black ceramic-coated
SUNSTAR
glass surface and for hard polycarbonate-
GLASS
22M-54-27240 150 ml Can coated surface.
PRIMER
(Effective period: four months after date of
435-41
manufacture)
SUNSTAR q Use as primer for sash (anodized aluminum
SASH Glass con- surface).
22M-54-27250 20 ml
GP-402 manufacture)
SUNSTAR q Use "S" in high-temperature season and "W"
PENGUINE in low-temperature season as adhesive for
Polyethylene
SEAL580 417-926-3910 320 ml glass.
container
SUPER "S" (Effective period: four months after date of
Adhesive
or "W" manufacture)
Sika Japan, q Use as adhesive for glass.
Polyethylene
Sikaflex 20Y-54-39850 310 ml (Effective period: six months after date of
container
For adhered window glass
256HV manufacture)
SUNSTAR q Use as adhesive for glass.
Ecocart (Spe-
PENGUINE 22M-54-27210 320 ml (Effective period: six months after date of
cial container)
SUPER 560 manufacture)
SUNSTAR
q Use to seal glass-to-glass joints.
PENGUINE Polyethylene
417-926-3920 320 ml (Effective period: four months after date of
SEAL No. container
manufacture)
Caulking material
2505
SEKISUI q Use to seal front window.
Polyethylene
SILICONE 20Y-54-55130 333 ml (Effective period: six months after date of
container
SEALANT manufacture)
GE
q Use to seal glass-to-glass joint. Translucent
TOSHIBA
white seal.
SILICONES 22M-54-27220 333 ml Cartridge
(Effective period: 12 months after date of
TOSSEAL
manufacture)
381
Special tools list 1

a Tools with part number 79 T- - means that they are not available from Komatsu Ltd. (i.e.
tools to be made locally).
* *** ****
a Necessity: t ............ Special tools that cannot be substituted and should always be used
q ............ Special tools that will be useful if available and are substitutable with tools
available on the market
a New/Redesign: N ............ Tools newly developed for this model. They have a new part number respec-
tively.
R ............ Tools made available by redesigning the existing tools which were developed
for other models. Each of them has a new part number assigned by setting for-
ward the part number of the existing tool.
Blank ..... Tools already available for other models. They can be used without any mod-
ification.
a Tools marked with Q in the sketch column are presented in the sketches of the special tools (See
"Sketches of special tools").
New/remodel
Necessity
Symbol
Sketch
Q'ty
Component Part No. Part name Nature of work, remarks
1 795-799-6400 Seal puller t 1 Removal of front seal

2 795-799-6500 Seal puller t 1 Removal of rear seal
3 795-799-6700 Puller t 1 Removal of injector
Positioning of No.3 and No.4
4 795-799-1131 Gear t 1
top
Removal, installation
of engine assembly
A 5 795-799-8150 Remover q 1 Removal of inlet connector
6 790-331-1120 Wrench (Angle) q 1 Tightening of bolt
Measurement of cylinder
7 795-790-4550 Gauge q 1
head bolt length
Installation of fuel supply
8 795-799-6130 Support t 1
pump assembly
Removal, installation
C 795-931-1100 Seal puller q 1 Removal of seal
of engine rear seal
790-101-2501 Push puller q 1
790-101-2510 • Block 1
790-101-2520 • Screw 1
Disassembly, 791-112-1180 • Nut 1
assembly of 1 790-101-2540 • Washer 1 Removal of rotor and ring
center swivel joint 790-101-2630 • Leg 2
E 790-101-2570 • Plate 4
790-101-2560 • Nut 2
709-101-3650 • Adapter 2
Disassembly, 2 796T-416-1010 Push tool t 1 Q
assembly of Press fitting of bushing
3 796T-416-1030 Push tool t 1 Q
travel PCC valve
assembly 4 796T-416-1020 Push tool t 1 Q Press fitting of pin
Removal, installation of
1 796-427-1200 Wrench t 1
round nut
2
791-545-1510 Installer t 1 Installation of floating seal
796T-427-1220 Push tool t 1 Q
Disassembly, 790-101-2510 Block t 1
assembly of 792-104-3940 Bolt t 2
F
travel motor and final
drive assembly 3 05180-11610 Nut t 2 Installation of hub assembly
01613-31645 Washer t 2
790-105-2100 Jack t 1
790-101-1102 Hydraulic pump t 1
4 790-331-1110 Wrench t 1 Installation of cover
New/remodel
Necessity
Symbol
Sketch
Q'ty
1 796T-426-1410 Push tool t 1 Q Press fitting of main bearing

Disassembly, 2 796T-426-1120 Push tool t 1 Press fitting of sub bearing
assembly of swing G 796T-426-1130 Plate t 1 Q
machinery assembly 3 790-101-5241 Grip t 1 Press fitting of oil seal
01010-61240 Bolt t 1
791-600-2001 Compressor (A)
or or t 1
791-685-8000 compressor (B)
t Compression and expansion
1 791-635-3160 Extension 1
of recoil spring
Cylinder
Disassembly, 791-101-1600 t 1
assembly of recoil J (686 kN {70 ton})
spring assembly 790-101-1102 Hydraulic pump t 1
790-201-1500 Push tool kit q 1
790-201-1620 Plate 1
2 Press fitting of dust seal
790-101-5021 Grip 1
01010-51816 Bolt 1
Disassembly, 1 790-434-1630 Installer t 1 Installation of floating seal
assembly of K
idler assembly 2 791-601-1000 Oil pump t 1 Refilling with oil
Disassembly, 1 790-434-1640 Installer t 1 Installation of floating seal
assembly of L
track roller assembly 2 791-601-1000 Oil pump t 1 Refilling with oil
791-630-3000 Remover t 1
Expansion and
Cylinder Removal, installation of
installation of M 790-101-1300 t 1
(980 kN {100 ton}) master pin
track shoe assembly
Removal, installation 1 796-460-1210 Oil stopper q 1 Stopping oil from hydraulic
of work equipment N
pump assembly 2 796T-460-1230 Adapter q 1 Q tank
1 796-946-1410 Guide (for a) t 1 Installation of pressure com-
pensation valve slipper seal
2 796-946-1420 Guide (for a) t 1
(Groove: 1 on periphery and
3 795-946-1430 Sleeve (for a) t 1 1 on hexagonal part)
1 796-946-1310 Guide (for b) t 1 Installation of pressure com-
2 796-946-1320 Guide (for b) t 1
3 796-946-1330 Sleeve (for b) t 1 4 on hexagonal part)
1 796-946-1610 Guide (for c) t 1 Installation of pressure com-
2 796-946-1620 Guide (for c) t 1
3 796-946-1630 Sleeve (for c) t 1 2 on hexagonal part)
Disassembly, 1 796-946-2210 Guide (for d) t 1 Installation of pressure com-
assembly of control P pensation valve slipper seal
2 796-946-2220 Guide (for d) t 1
valve assembly (Groove: 2 on periphery and
3 796-946-2230 Sleeve (for d) t 1 3 on hexagonal part)
1 796-946-1910 Guide (for e, h) t 1 Installation of pressure com-
2 796-946-1920 Guide (for e, h) t 1
1 on hexagonal part)
3 796-946-1930 Sleeve (for e, h) t 1 1 on hexagonal part)
1 796-946-1810 Guide (for f, g) t 1 Installation of pressure com-
2 796-946-1820 Guide (for f, g) t 1 (Groove: 2 on periphery and
no grooves on hexagonal
3 796-946-1830 Sleeve (for f, g) t 1 part)
New/remodel
Necessity
Symbol
Sketch
Q'ty
790-502-1003 Cylinder repair stand q 1 Disassembly, assembly of

1
790-101-1102 Pump q 1 piston rod assembly
790-102-4300 Wrench assembly t 1 Removal, installation of pis-
2
790-102-4310 Pin t 1 ton
3 790-720-1000 Expander t 1 Expansion of piston ring
796-720-1660 Ring t 1 Installation of piston ring
(For piston 115 mm in diame-
07281-01159 Clamp t 1 ter)
4
796-720-1670 Ring t 1 Installation of piston ring
(For piston 120 mm, 130 mm,
07281-01279 Clamp t 1 and 135 mm in diameter)
Disassembly, 790-201-1702 Push tool kit t 1
Press fitting of cylinder head
assembly of 790-101-5021 • Grip 1
Q bushing
hydraulic cylinder 01010-50816 • Bolt 1
assembly
5 790-201-1831 • Push tool 1 (For rod 80 mm in diameter)
790-201-1940 • Push tool 1 (For rod 85 mm in diameter)
790-201-1500 Push tool kit t 1
Press fitting of cylinder head
790-201-5021 • Grip 1
dust seal
01010-50816 • Bolt 1
6 790-201-1620 • Push tool 1 (For rod 80 mm in diameter)
Removal, installation 796-900-1200 Remover t 1
of work equipment V 790-101-4000 Puller (490 kN {50 ton}) t 1 Removal of boom foot pin
assembly 790-101-1102 Hydraulic pump t 1
Removal, installation 1 793-498-1210 Lifter (Suction cup) t 2 Holding of glass
of operator's cab X
glass (Stuck glass) 2 20Y-54-13180 Adapter t 2 Fixing of glass
Commercially
Removal, installation Impact wrench q 1
available Removal and installation of
of counterweight Z
Commercially counterweight mounting bolt
assembly Socket wrench q 1
available
Sketches of special tools 1
NOTE: Komatsu cannot accept any responsibility for special tools manufactured according to these
sketches.
E2 Push tool
E3 Push tool
10 PC228US, 228USLC-3E0
sketches.
E4 Push tool
F3 Push tool
PC228US, 228USLC-3E0 11
sketches.
G1 Push tool
G3 Plate
12 PC228US, 228USLC-3E0
sketches.
N2 Adapter
PC228US, 228USLC-3E0 13
SEN01923-03

© 2010 KOMATSU
All Rights Reserved
14
SEN01924-04
PC228US-3E0
PC228USLC-3E0


Engine and cooling system
Removal and installation of fuel supply pump assembly ................................................................................ 2
Removal and installation of fuel injector assembly ......................................................................................... 5
Removal and installation of engine front seal ................................................................................................11
Removal and installation of engine rear seal ................................................................................................ 13
Removal and installation of cylinder head assembly .................................................................................... 16
Removal and installation of radiator assembly ............................................................................................. 29
Removal and installation of hydraulic oil cooler assembly ............................................................................ 32
Removal and installation of aftercooler assembly......................................................................................... 34
Removal and installation of fuel cooler assembly ......................................................................................... 36
Removal and installation of engine assembly ............................................................................................... 38
Removal and installation of fuel tank assembly ............................................................................................ 40
Removal and installation of fuel 4. Disconnect fuel supply hose (5).

supply pump assembly 1
5. Disconnect fuel filter hoses (7) and (8) from
Special tools fuel supply pump (6). [*1]
a Remove mud from the joints in advance
Necessity
(since the lock (L) may become hard
Symbol
Sketch
Q’ty
N/R
Part number Part name because of mud).
a While pressing the lock (L) from both
A 8 795-799-6130 Support t 1
sides, pull out the hose.
a When the hose is disconnected, fuel flows
out. Put a plug to the hose adapter to pre-
Removal vent the fuel from leaking.
k Swing the upper structure 90°, stop the a Do not use a wooden plug since its chips
engine and disconnect the cable from the may enter the fuel line.
negative (–) terminal of the battery.
6. Disconnect wiring connector CP3 (9).
1. Close fuel stop valve (2) from the inspection
window of cover (1).
7. Disconnect fuel return tube (10). [*2]
2. Remove the center weight. For details, see 8. Disconnect fuel return hose (11).
“Removal and installation of center weight”.
9. Disconnect high-pressure pipe (3) from pump
3. Disconnect 2 clamps (4) of high-pressure pipe (6). [*3]
(3).
10. Remove mounting nuts (A) and fuel supply 2) Install a puller [1] between the flange and
pump assembly (6). [*4] gear (14).
a Fuel supply pump assembly (6) comes off 3) Install a puller [2] onto the puller [1] and
together with the gear. the shaft.
The gear teeth are not worked (removal of 4) Rotate the center bolt (15) until the gear is
a tooth) to set the 1.6TOP point. separated from the shaft.
5) Remove the pullers [1], [2].
11. When disassembling the fuel pump drive gear

from the fuel supply pump, follow the proce- 6) Remove the nut (13), lock washer (17),
dure described below. [*5] and gear (18) from the shaft (16).
1) Use a support A8 and a 1/2 inch breaker
bar (12) to retain the gear, then loosen the
nut (13).
a Do not remove the nut (13) from the
shaft.
Installation [*4]
q Carry out installation in the reverse order to 3 Fuel supply pump mounting nut:
removal. 24 ± 4 Nm {2.45 ± 0.41 kgm}
a Refer to the removal drawing.
[*5]
[*1] q How to install the gear (18)
When installing a connector of quick coupler a The shaft (16) and gear (18) mating face must
type, observe the following points. be clean (without dirt or foreign material) and
a The internal parts of the adapter may be dry prior to assembly.
damaged when the hose is removed. 1. Install the gear (18) onto the shaft (16).
Accordingly, do not reuse the adapter but
use new one when installing the hose 2. Install the lock washer (17) and nut (13) and
again, as a rule. finger tighten.
a Check that mud or dirt is not sticking to the
hose adapter in advance.
a Press and insert the connector straight (in
direction (b)) without bending it to the right
or left.
(If it is difficult to insert the connector, do
not push it in forcibly but pull it out. Then,
check the convex and concave parts for
abnormality and mud.)
3. Use the support A8 and 1/2 inch breaker bar

(12) to hold the gear in place while tightening
the nut (13).
3 Mounting nut of fuel supply pump gear:
105 ± 5 Nm {10.7 ± 0.51 kgm}
[*2]
3 Fuel return tube (10) mounting bolt:
24 ± 4 Nm {2.45 ± 0.41 kgm}
[*3]
q How to install high-pressure pipe (3)
1. Tighten the sleeve nut.
3 Sleeve nut:
35 ± 3.5 Nm {3.57 ± 0.36 kgm}
2. Install 2 tube clamps (4).

3 Clamp mounting bolt: Bleeding air
24 ± 4 Nm {2.45 ± 0.41 kgm} q Bleed air from the fuel system. For details, see
Testing and adjusting, “Bleeding air from fuel
3. Install the fuel spray prevention caps. circuit”.
a Install each fuel spray prevention cap with
the slits out and down.
a The fuel spray prevention caps are
installed so that fuel will not spout over the
hot parts of the engine and catch fire when
it leaks for some reason.
Removal and installation of fuel 3. Open engine hood (4) and fix it with the fixing
injector assembly 1 bar.
Special tools 4. Remove cover (5).
Necessity
Symbol
Sketch
Part number Part name
Q’ty
N/R
3 795-799-6700 Puller t 1
A 4 795-799-1131 Gear t 1
5 795-799-8150 Remover q 1
Removal
k Disconnect the cable from the negative (–)
terminal of the battery.
1. Close fuel stop valve (2) from the inspection

window of cover (1). 5. Remove covers (6) and (7).
6. Remove rubber partition (8).
7. Remove muffler cover (9).
2. Open the inspection cover at the right rear side

and remove partition (3).
8. Remove 2 head cover mounting bolts of blow-

by duct (10). [*1]
9. Remove 6 head cover bolts (11). [*2]
10. Remove head cover (12).
11. Remove wiring harness nuts (13) from the 16. Remove retaining nut (20) and inlet connector
injector. (21).
a Clean around the inlet connector so that
12. Remove 2 mounting bolts (14) and rocker arm mud sticking to it will not enter its hole.
assembly (15). a Use tool A5 to remove inlet connector
a Loosen locknuts (16), and then loosen (21).
adjustment screws (17) by 2 – 3 turns so
that an excessive force will not be applied 17. Remove 2 wiring harness mounting nuts (41)
to the push rod when the rocker arm from fuel injector assembly (22).
assembly is installed.
Wiring harness color Cylinder No.
13. Remove crosshead (15a). White 1, 3, 5
a Record the position and direction (shapes Black 2, 4, 6
of holes (a) and (b)) of each crosshead.
a Do not remove the connector (42) of injec-
(When reinstalling the crosshead, set it in
tor harness from rocker housing unless it
the same direction.)
is necessary.
14. Remove fuel spray prevention caps (18) at the
cylinder head side and common rail side.
15. Remove high-pressure pipe (19). [*3]

a Clean around the pipe so that mud stick-
ing to it will not enter the hole of the con-
nector.
18. Remove mounting bolts (23) of fuel injector

assembly (22).
19. Using tool A3, remove fuel injector assembly Installation

(22). 1. Fuel injector assembly
a Take care that dirt and foreign matter will a When replacing the injector with new one,
not enter the mounting section of the fuel replace the inlet connector, too.
injector assembly. a Check that fuel injector sleeve (26) is free
from flaw and dirt.
1) Fit O-ring (28) and gasket (29) to fuel

injector (27).
a Replace the O-ring and gasket with
new ones.
2) Apply engine oil to O-ring (28) of fuel
injector (27) and the fuel injector sleeve.
2 O-ring (28) and fuel injector sleeve:
Engine oil (For details, see "Table
of fuel, coolant and lubricants")
3) While setting the concave and convex (A),
install holder (30) to fuel injector (27).
4) Install the fuel injector assembly, with the

fuel inlet hole (inlet connector mounting
hole) toward the air intake manifold.
5) Install fuel injector assembly (22) to the
fuel injector sleeve and tighten mounting
bolts (23) by 3 – 4 turns.
6) Apply engine oil to O-ring (31) of inlet con-

nector (21) and the inlet connector mount-
ing hole (on the cylinder head side).
a Precautions for installing inlet con-
nector
Check the inlet connector visually,
and if it has any of the following faults,
replace the inlet connector and the
fuel injector assembly with new one at
the same time.
q There is a burr or a worn part at
front end (a) or rear end (b) of the
inlet connector.
q There is a foreign matter in the
edge filter at rear end (c) of the
inlet connector.
q The O-ring at upper part (d) of
the inlet connector is cracked or
deteriorated.
q There is a worn part or an
uneven seat contact mark on
sealing face (e) at the front end
8) Install inlet connector (21) and tighten
of the inlet connector.
retaining nut (20) lightly.
a If high-pressure fuel leaks
3 Retaining nut:
through the inlet connector, the
15 ± 5 Nm {1.5 ± 0.5 kgm}
seal face has fine streaks or
9) Tighten right and left mounting bolts (23)
cracks.
of fuel injector assembly (22) alternately.
3 Fuel injector mounting bolts (23):
7) While setting parts (B) of inlet connector
(21) to the groove (upper side) on the
8 ± 0.8 Nm {0.8 ± 0.08 kgm}
head, insert the inlet connector perfectly.
2 O-ring (21) and inlet connector
10) Tighten retaining nut (20) to the specified
torque.
3 Retaining nut (20):
mounting hole: Engine oil
(For details, see "Table of fuel,
50 ± 5 Nm {5.1 ± 0.51 kgm}
coolant and lubricants".)
4) After adjusting the valve clearance, check

that locknut (16) is tightened to the speci-
fied torque.
3 Locknut (16):
24 ± 4 Nm {2.4 ± 0.4 kgm}
5) Install wirings (11) and tighten the wiring
nuts (41).
a Check that the wiring does not inter-
fere with the rocker arm.
a Installed positions of wires
Wire color Cylinder No.
White 1, 3, 5
Black 2, 4, 6
2. Install the rocker arm according to the follow- 3 Wiring mounting nut:
ing procedure. 1.5 ± 0.25 Nm {0.15 ± 0.03 kgm}
1) Install crossheads (15a).
a Install the crossheads in the position
and direction (shapes of holes (a) and
(b)) recorded when removed.
a When the connector of injector harness is

removed:
When assembling the injector harness
connector (42) to the housing, apply gas-
ket sealant (LG-7) to the O-ring portion
(43) and the flange face of connector (44).
When applying gasket sealant (LG-7) to
the O-ring portion, be sure to apply a
string of LG-7 f3 mm in diameter until O-
ring groove is completely filled.
If O-ring is damaged, replace as a har-
ness assembly.
3 Connector flange mounting bolt
(45): 10 ± 2 Nm {1.0 ± 0.2 kgm}
2) Install rocker arm (15) and tighten mount-

ing bolt (14).
a Check that adjustment screw (17) is
loosened thoroughly.
3 Rocker arm mounting bolt (14):
36 ± 5 Nm {3.7 ± 0.5 kgm}
3) Adjusting the valve clearance. For details,
see Testing and adjusting, "Adjusting
valve clearance".
a Use tool A4 to rotate the engine.
q Carry out the following installation in the a Installation procedure for high-pressure piping
reverse order to removal. 1) Tighten sleeve nuts by hand at the cylin-
der head side and the common rail side.
[*1] 2) Temporarily tighten them by 0.2 – 0.8 Nm
a When installing the blow-by duct, check that {0.02 – 0.08 kgm}: first at the cylinder
the O-ring is fitted. head side and next common rail side.
3 Blow-by duct mounting bolt: 3) Tighten them up by the specified torque.
7 ± 2 Nm {0.71 ± 0.2 kgm} 3 Sleeve nut:
35 ± 3.5 Nm {3.57 ± 0.36 kgm}
[*2]
3 Cylinder head cover mounting bolt: k Direct the fuel spray prevention cap slits
24 ± 4 Nm {2.4 ± 0.4 kgm} out and down.
a If the stud bolts were removed, tighten The fuel spray prevention caps are installed
them to the following torque. so that fuel will not spout over the hot parts
3 Stud bolt: 24 ± 4 Nm {2.4 ± 0.4 kgm} of the engine and catch fire when it leaks
for some reason.
[*3]
a Precautions for installing fuel injection pipe and a Refer to [*7] [*8] in "Disassembly and assem-
fuel high-pressure pipe bly of cylinder head assembly", for assembling
k Do not bend the fuel injection pipe and fuel whole fuel injector assembly.
high-pressure pipe to collect before install-
ing.
k Be sure to use the genuine fuel injection
q Bleeding air
pipe clamps and observe the tightening Bleed air from the fuel system. For details, see
Testing and adjusting, "Bleeding air from fuel
torque.
k After installing the fuel injection pipe and
system".
fuel high-pressure pipe, be sure to install
the fuel spray prevention caps to the sleeve
nuts.
k Direct the fuel spray prevention cap slits
out and down.
a Before installing the fuel injection pipe and fuel
high-pressure pipe, check them for the follow-
ing defects.
q If there is any defect, it can cause fuel
leakage. Accordingly, replace the fuel
injection pipe and fuel high-pressure pipe.
q Check the taper seal of the connecting
part (Part (j): Part of 2 mm from the end)
for visible lengthwise slit (k) and dent (l).
q Check part (m) (End of the taper seal: Part
at 2 mm from the end) for stepped-type
wear (fatigue) which your nail can feel.
10 PC228US, 228USLC-3E0
Removal and installation of Installation

engine front seal 1 1. Install front seal (3) using tool A1.
a Before installing the seal, check that the
Special tools end corners and lip sliding surfaces of the
crankshaft are free from flaw, burr, and
Necessity
rust of the housing.
Symbol
Sketch
Part number Part name a When installing the seal, do not coat the
Q’ty
N/R
shaft and seal lip with oil, grease etc. Also,
1 795-799-6400 Seal puller t 1
wipe off grease from the shaft completely.
A
6 790-331-1120 Wrench (Angle) q 1
Removal
1. Remove the engine assembly referring to the

section of “Removal and installation of engine
assembly”.
2. Remove 6 mounting bolts (1) and remove

vibration damper (2).
a From cover (C) of seal (3)

q Extrusion (x): less than 0.38 mm
q Facial runout (TIR: total indicator
reading) (y): less than 0.25 mm
3. Remove seal (3).
PC228US, 228USLC-3E0 11
2. Vibration damper q Carry out the rest of installation in the reverse

1) Install vibration damper (2), aligning its order to removal.
dowel hole with dowel pin (a) of the crank-
shaft.
2) Tightening procedure of bolts (1)
1] Tighten to a torque of 55 ± 5 Nm {5.6
± 0.5 kgm} in diagonal order.
2] Loosen the bolts 180°.
3] Tighten to a torque of 55 ± 5 Nm {5.6
± 0.5 kgm} in diagonal order.
4] Tighten to 90 ± 5°.
a Tool A6: wrench is adopted for
angle tightening. (Refer to the
Special tools.)
q When an angle tightening tool is not used:

Put marks on the vibration damper and bolts
with a felt-tip pen, and then tighten the bolts an
additional 90° ± 5°.
12 PC228US, 228USLC-3E0
Removal and installation of 6. Lift off flywheel assembly (4) to remove it.
engine rear seal 1 4 Flywheel assembly: 35 kg
Special tools
Necessity
Symbol
Sketch
Q’ty
N/R
A 2 795-799-6500 Seal puller t 1
Removal
1. Remove the hydraulic pump assembly refer-
ring to the section of “Removal and installation
of hydraulic pump assembly”.
2. Remove mounting bolt (1) and set guide bolt 7. Remove rear seal according to the following
[1]. procedure.
1) Install tool A2 to the crankshaft.
3. Remove damper assembly (2). 2) Screw tap screw [1] of tool A2 into the
seal carrier of rear seal (5).
3) Turn the handle clockwise and remove
rear seal (5).
4. Remove mounting bolt (3) and insert guide

bolts [2]. [*1]
a Width across flats: 18 mm
a Take care in the removal so that the crank-
5. Lift temporarily flywheel assembly (4) and pull shaft may not be damaged.
out flywheel assembly (4).
a Be careful not to let the guide bolts drop
out.
PC228US, 228USLC-3E0 13
Installation 4. Install rear seal (5) on flywheel housing (7) to

1. Install the rear seal according to the following the proper depth by using tool A2.
procedure. a Push in rear seal (5) taking care that there
a Do not remove pilot [5] which is attached are no bend etc. on it.
to rear seal (5) until rear seal (5) is a Extrusion of rear seal (5) from flywheel
inserted to the crankshaft. housing (7)
a Before installing the rear seal, degrease, (X): less than 0.38 mm
clean and dry the crankshaft sealing face
and the seal lip face to prevent oil leak-
age.
2. Insert pilot [5] to crankshaft (6) and push rear

seal (5) into flywheel housing (7).
3. Push in rear seal (5) further and pull out pilot

[5].
q Carry out the rest of installation in the reverse

order to removal.
[*1]
a Tighten the 8 flywheel assembly mounting
bolts in the order of [1] through [8] as shown in
the figure below.
3 Flywheel assembly mounting bolt:
137 ± 7 Nm {13.97 ± 0.71 kgm}
14 PC228US, 228USLC-3E0
a Tighten the bolts using plate [3] for preventing

rotation of the flywheel assembly.
q Measurement of radial runout

a Radial runout: less than 0.13 mm
1) Set dial gauge [4] to the stand, and set it
to flywheel housing (7).
2) Bring the dial gauge probe into contact
with faucet joint portion (a) or the outer
perimeter surface of the flywheel at a right
angle.
3) Rotate the flywheel 360° and measure the
difference of the maximum swing of the
dial gauge indicator.
a Check that the dial gauge indicator is
back in the original position after the
flywheel is rotated 360°.
q Measurement of facial runout

a Facial runout: less than 0.20 mm
4) As in the case of measurement of radial
runout, bring the dial gauge probe into
contact with end surface (b) near the outer
perimeter of the flywheel at a right angle.
a Conduct measurement pulling the
crankshaft to either the front or rear
side to prevent errors caused by
shakiness.
5) Rotate the flywheel 360° and measure the
difference of the maximum swing of the
dial gauge indicator.
PC228US, 228USLC-3E0 15
Removal and installation of 4. Referring to “Removal and installation of cen-

cylinder head assembly 1 ter weight”, remove center weight, engine hood
(4), covers (5) and (6), and fuel filter and
Special tools bracket assembly (7).
5. Remove covers (8) and (9).
Necessity
Symbol
Sketch
Q’ty
N/R
6. Remove frame (10).
3 795-799-6700 Puller t 1
4 795-799-1131 Gear t 1
A 5 795-799-8150 Remover q 1
6 790-331-1120 Wrench (Angle) q 1
7 795-790-4550 Gauge q 1
Removal
1. Remove cover (1).
2. Open drain valve (2) to drain the coolant. 7. Remove covers (11) and (12).
6 Coolant: 21 l
9. Remove muffler cover (14).
3. Open the inspection cover at right rear side

and remove partition (3).
16 PC228US, 228USLC-3E0
11. Remove clamp (16). 16. Remove air conditioner compressor drive belt
a When removing the clamp bolt, fix to the (22). [*2]
nut on the opposite side with a spanner so
that a load will not be applied to the 17. Remove 3 mounting bolts (23).
bracket. a Do not remove 4 air compressor mounting
bolts (24a). [*3]
18. Remove air conditioner compressor assembly

(24).
a Remove air conditioner compressor
assembly in one piece with the bracket
and put them aside.
12. Remove 4 muffler mount bracket mounting

bolts (18).
19. Loosen 2 clamps (25) and disconnect hose

(26).
20. Disconnect connector (27).
21. Disconnect bracket (28). [*4]
22. Remove tube (29).

13. Lift off muffler assembly (19). [*1]
a The clearance to pass the sling is narrow. 23. Remove electrical intake air heater (30).
4 Muffler assembly: 35 kg
24. Disconnect heater hose (31).
25. Disconnect radiator hose (32). [*5]
26. Remove alternator according to the following

procedure.
1) Disconnect wirings (62a) and (62b).
2) Insert a wrench [1] to the portion (A) (width
across flats T 12.7 mm) of the tensioner
assembly (63), and rotate it to the wind-
ing-up direction (R) to slacken fan belt
(33).
3) Remove fan belt (33) from alternator (65).
k Make sure that the wrench [1] is
14. Disconnect connector (20). secured at the portion (A) before rotat-
ing it. (The spring of the tensioner
15. Loosen air conditioner compressor drive belt assembly (63) is strong. If the wrench
mounting adjustment bolt (21). [1] is loosely inserted, the wrench may
accidentally come off while being
rotated and it is extremely dangerous.)
PC228US, 228USLC-3E0 17
k After removing the fan belt (33), loosen 28. Disconnect fuel filter hoses (36) and (37) from
wrench [1] slowly with care. fuel supply pump (35).
k Be careful not to get your fingers a Remove mud from the joints in advance
caught between the pulley and fan belt (since the lock (L) may become hard
(33) during work. because of mud).
4) Remove alternator mounting bolts to a While pressing the lock (L) from both
remove alternator assembly (65). sides, pull out the hose.
27. Remove fan (34). [*6]

a Place the fan onto the bottom.
29. Remove clamps (38) and (39) from the cylinder

block.
30. Remove fuel spray prevention cap (41) of the

supply pump side.
31. Disconnect high-pressure pipe (40) from the

supply pump side.
32. Disconnect 3 connectors (42).

a Since you cannot hold each connector,
disconnect it with 2 flat-head screwdrivers
according to the following procedure.
1) Keep pressing the lock of connector (42)
with flat-head screwdriver [1].
2) Insert flat-head screwdriver [2] in the
clearance between the connectors on the
right and left sides of the lock and move it
to the right and left to pull out the connec-
tor gradually.
18 PC228US, 228USLC-3E0

a While pushing up the lock of connector
(43) with flat-head screwdriver [1], pull the
connector in the direction of the arrow.
34. Remove 6 fuel spray prevention caps (41).

a Remove only the fuel spray prevention
cap on the cylinder head side.
35. Disconnect 6 high-pressure pipes (44) from the

cylinder head. [*7]
36. Remove common rail and high-pressure pipe

assembly (45). [*8]
43. Remove blow-by duct (51).
37. Disconnect high-pressure pipe (40) from the
common rail mounting part. 44. Disconnect fuel drain hose (52).
38. Disconnect fuel return hose (46). [*9]
39. Disconnect fuel return hose (47).
40. Remove bracket (48). [*10]
41. Remove fuel block (49). [*11]
42. Connector: Disconnect boost pressure/intake

air temperature sensor connector (50).
a Move the disconnected connector aside.
[*12]
45. Loosen air hose clamp (53) and disconnect
hose (54). [*13]
46. Loosen air tube clamp (55) and disconnect

tube (56). [*14]
47. Disconnect lubrication inlet hose (57) and lubri-

cation outlet hose (58). [*15]
a Fix the turbocharger side connector (53)
with wrench so that the inlet hose does not
move together.
PC228US, 228USLC-3E0 19
48. Remove all the mounting bolts (60) for exhaust

manifold (59) except a few pieces. [*16]
49. Lift temporarily exhaust manifold and turbo-

charger assembly (61), and remove the
remaining mounting bolts.
50. Lift off exhaust manifold and turbocharger

assembly (61) to remove it.
4 Exhaust manifold and turbocharger
assembly: 25 kg
53. Remove head cover (69).
51. Disconnect clamp (66).
52. Disconnect connector with water temperature

sensor (67) and atmospheric pressure sensor
(68).
a Connector with water temperature sensor 54. Remove nuts (70) for the harnesses from the
(67): injector.
Pull the lock (female side) to the outside. Harness color Cylinder No.
a Atmospheric pressure sensor (68): White 1, 3, 5
1) Push lock (L1) and slide it.
2) Pull out the connector while pushing Black 2, 4, 6
lock (L2).
55. Remove 12 mounting bolts and remove 6
rocker arm assemblies (71).
a Loosen locknuts (72) and then loosen
adjustment screws (73) a few turns so that
excessive force is not put on the push rod
when the rocker arm is installed.
20 PC228US, 228USLC-3E0
a Keep records of installation position and

direction of the crosshead (hole shape of
(a) and (b) parts) (Install it in the same
direction when reinstalling.)
56. Remove crosshead (71a).
57. Remove retaining nuts (74) and then remove 6

inlet connectors (75).
a Remove and flush dirt etc. off the sur-
rounding area in advance to prevent them
from entering the connector holes.
a Tool A5: remover is adopted for removing
inlet connectors (75). (Refer to the Special
tools.) 60. Remove push rods (78).
61. Remove rocker arm support (79).
62. Remove rocker housing assembly (80).
63. Remove 26 mounting bolts (81) and lift off cyl-

inder head assembly (82) to remove it.
4 Cylinder head assembly: 75 kg
64. Remove cylinder head gasket (83).
58. Remove 2 mounting bolts (77) for injector

assembly (76).
59. Remove injector assembly (76) using tool A3.

a Be careful not to let any dust or foreign
materials enter the fuel injector assembly
mounting portion.
PC228US, 228USLC-3E0 21
Installation
1. Cylinder head assembly
1) Measure stem length (a) of all the cylinder
head mounting bolts to check that they are
within the length limit.
q Bolt length limit: less than 132.1 mm
a If a bolt is longer than the using limit,
do not reuse it but replace it.
2) Set cylinder head gasket (83) to the cylin-

der block.
a Check that there is no dirt and foreign
matter on the cylinder head mounting
surface and in the cylinders.
a Check that the holes of the cylinder q When not using angle tightening tool
head gasket are matched to the holes Make a mark on the cylinder head and each
of the cylinder head. bolt with a marker and then tighten the bolt by
3) Sling cylinder head assembly (82), set it 90 ± 5°.
on the cylinder block, and tighten mount-
ing bolts (81) at least 2 – 3 turns with the
fingers.
4) Tighten the cylinder head mounting bolts
in the order of [1] to [26] according to the
2 Apply engine oil (EO15W-40) to the
threads and seats of the mounting
bolts.
1] Tighten to 70 ± 6 Nm {7 ± 0.6 kgm}.
2] Return all the bolts by 360 ± 5°.
3] Tighten to
105 ± 3 Nm {10.7 ± 0.3 kgm}.
4] Tighten by 90 ± 5°.
a Use the angle tightening tool for 2] 2. Install rocker housing assembly according to
and 4]. the following procedure.
1) Install rocker housing assembly (80) and
tighten 5 mounting bolts (80a).
a Replace gasket with new one.
3 Mounting bolt:
24 ± 4 Nm {2.4 ± 0.4 kgm}
2) Install push rods (78).
3) Install rocker arm support (79).
22 PC228US, 228USLC-3E0
3. Install fuel injector assembly and inlet connec- a Check the inlet connector visually, and if it
tor according to the following procedure. has any of the following faults, replace the
a When replacing the injector with new one, inlet connector and the fuel injector
replace the inlet connector with new one, assembly with new one at the same time.
too. q There is a burr or a worn part at front
a Check that the fuel injector sleeve (84a) is end (a) or rear end (b) of the inlet
free from flaw and dirt. connector.
q There is foreign matter in the edge fil-
ter at rear end (c) of the inlet connec-
tor.
q The O-ring at upper part (d) of the
inlet connector is cracked or deterio-
rated.
q There is a worn part or an uneven
seat contact mark on sealing face (e)
at the front end of the inlet connector.
a If high-pressure fuel leaks
through the inlet connector, the
seal face has fine streaks or
cracks.
a Replace O-ring and gasket with new one.
1) Install O-ring (85) and gasket (86) to fuel

injector (84).
2) Coat O-ring (85) and the head side of fuel
injector (84) with engine oil (EO15W-40).
2 O-ring (85) and the head side of
fuel injector (84):
Engine oil (EO15W-40)
3) Install holder (87) to fuel injector (84) with
concavity and convexity (A) fitted together.
4) Assemble fuel injector assembly (76) to

the cylinder head with its fuel inlet hole
facing the intake manifold side.
5) Tighten bolts (77) 3 or 4 turns.
6) Coat the head side (B part) of inlet con-
nector (75) with engine oil (EO15W-40).
7) Coat O-ring (C) of inlet connector (75) with
engine oil (EO15W-40). Then insert inlet
connector (75) completely, aligning (D
part) with the side groove of the head.
PC228US, 228USLC-3E0 23
3) Adjust the valve clearances.

a Refer to the “Adjusting valve clear-
ance” section in the Testing and
adjusting chapter of this manual.
3 Locknut (72):
24 ± 4 Nm {2.4 ± 0.4 kgm}
8) Tighten inlet connector (75) with retaining

nut (74) by hand. (Push it into the injector
hole.)
3 Retaining nut:
15 ± 3 Nm {1.5 ± 0.5 kgm}
9) Tighten mounting bolts (77) for fuel injec-
tor assembly (76) alternately.
3 Fuel injector mounting bolt
1st time:
3.5 ± 0.35 Nm {0.35 ± 0.035 kgm}
2nd time: 75 ± 5°
(Tighten with angle tightening tool)
10) Tighten retaining nut (74).
3 Retaining nut:
50 ± 5 Nm {5.1 ± 0.5 kgm}
5. Install the harness with harness mounting nuts

(70).
a Harness installation position
Harness color Cylinder No.
White 1, 3, 5
Black 2, 4, 6
3 Mounting nut:
4. Install rocker arm and crosshead assembly 1.5 ± 0.25 Nm {0.15 ± 0.03 kgm}
1) Install crosshead (71a).
2) Install rocker arm and crosshead assem-
bly (71).
a When reusing the crosshead, install
the same intake and exhaust valves
in the same direction because the
shapes of its holes (a) and (b) are dif-
ferent.
a Tighten the mounting bolt after check-
ing that the ball portion of adjustment
screw (73) is well seated in the push
rod socket.
3 Mounting bolt:
36 ± 5 Nm {3.7 ± 0.5 kgm}
24 PC228US, 228USLC-3E0
6. Fit the O-ring and install head cover (69). [*3]

3 Mounting nut: When 4 air compressor mounting bolts (24a) were
24 ± 4 Nm {2.4 ± 0.4 kgm} loosened, tighten them by the following torque.
a If the air compressor mounting bolts are tight-
7. Install blow-by duct (51). ened above the specified torque, inside of the
3 Blow-by duct mounting bolt: air conditioner compressor may have damage.
10 ± 2 Nm {1.0 ± 0.2 kgm} 3 Air conditioner compressor mounting torque:
27 – 34 Nm {2.8 – 3.5 kgm}
8. Install fuel drain hose (52).
3 Joint bolt: 24 ± 4 Nm {2.4 ± 0.4 kgm} [*4]
3 Bracket mounting bolt:
43 ± 6 Nm {4.4 ± 0.6 kgm}
[*5]
3 Radiator hose clamp:
10.8 – 11.8 Nm {1.1 – 1.2 kgm}
[*6]
q Install fan belt (33) according to the following
procedure.
1. Set the fan belt (33) to each pulley.
2. Loosen tensioner assembly (63) and install fan

q Carry out the following installation in the belt (33) to afternator pulley.
reverse order to removal. a Insert a wrench to the portion (A) (width
across flats T 12.7 mm) of the tensioner
[*1] assembly (63), and rotate it to the wind-
If muffler (19) had been removed at portion [E], ing-up direction (R).
install muffler (19) after applying thermosetting
sealant to whole connecting portion to hose. 3. Install fan belt (33) and return tensioner
2 Entire perimeter of (E) section: Thermoset- assembly (63).
ting sealant (equivalent of Holts Firegum) k Make sure that the wrench is secured
at the portion (A) of the tensioner
assembly (63) before rotating it. (The
spring of the tensioner assembly (63) is
strong. If the wrench is loosely
inserted, the wrench may accidentally
come off while being rotated and it is
extremely dangerous.)
k After installing the fan belt (33), return
the tensioner assembly slowly with
care.
k Be careful not to get your fingers
caught between the pulley and fan belt
during work.
[*2]
a Refer to the “Checking and adjusting air condi-
tioner compressor belt tension” section in the
Testing and adjusting chapter of this manual.
PC228US, 228USLC-3E0 25
[*7], [*8] 4) Tighten high-pressure pipe (40) in the

q Installing procedure of high-pressure pipes order of firstly pump (35) side, then com-
and common rail mon rail side.
k Do not bend the high-pressure pipe to col- 3 Sleeve nut:
lect before installing. 35 ± 3.5 Nm {3.6 ± 0.4 kgm}
k Be sure to use the genuine high-pressure 5) Tighten clamps (38), (39) of high-pressure
pipe clamps and observe the tightening pipe (40).
torque. 3 Mounting bolt:
k After installing the high-pressure pipe, be 24 ± 4 Nm {2.4 ± 0.4 kgm}
sure to install the fuel spray prevention 6) Tighten common rail with 4 bolts.
caps to the sleeve nuts. a Coat the 2 bolt threads on the inner
k Direct the fuel spray prevention cap slits side of the engine with sealant (LG-
out and down. 7).
a Before installing the high-pressure pipe, check 3 Mounting bolt:
them for the following defects. 24 ± 4 Nm {2.4 ± 0.4 kgm}
q If there is any defect, it can cause fuel 7) Install fuel spray prevention caps (41) to
leakage. Accordingly, replace the fuel each high-pressure pipe. (14 pieces)
injection pipe and fuel high-pressure pipe a Set the slits of each fuel spray pre-
with new one. vention cap out and down.
q Check the taper seal of the connecting a The fuel spray prevention caps are
part (Part (j): Part of 2 mm from the end) installed so that fuel will not spout
for visible lengthwise slit (k) and dent (I). over the hot parts of the engine and
q Check part (m) (End of the taper seal: Part catch fire when it leaks for some rea-
at 2 mm from the end) for stepped-type son.
wear (fatigue) which your nail can feel.
1) Assemble common rail and high-pressure

pipe assembly (45) temporarily.
3 Sleeve nut and mounting bolt:
0.2 – 0.8 Nm {0.02 – 0.08 kgm}
2) Tighten high-pressure pipes (91) – (96)
3 Sleeve nut:
35 ± 3.5 Nm {3.6 ± 0.4 kgm}
1] Head side of high-pressure pipes (91)
and (96)
2] Common rail side of high-pressure
pipes (96) and (91)
3] Head side of high-pressure pipes
(92), (93), (94) and (95)
4] Common rail side of high-pressure
pipes (92), (93), (94) and (95)
3) Tighten the sleeve nut of high-pressure
pipe (40) temporarily.
26 PC228US, 228USLC-3E0
q Handling of fuel pressure sensor and relief

valve
1) Replace fuel pressure sensor (2), if neces-
sary, according to the following procedure.
a Do not remove fuel pressure sensor
(2) from common rail (1) for a pur-
pose other than replacement.
a Once the fuel pressure sensor is
removed from the common rail, be
sure to replace it.
1] Before removing the fuel pressure
sensor, remove mud etc. from around
it thoroughly and clean it.
2] Remove the fuel pressure sensor.
3] Check the fuel pressure sensor con-
nector for crack, breakage, damage
of the seal, foreign matter on the pin
and corrosion, bend and breakage of
the pin.
4] Install a new fuel pressure sensor.
2 Threaded part of fuel pressure
sensor: Gear oil (#90)
3 Fuel pressure sensor:
70 ± 5 Nm {7.1 ± 0.5 kgm}
5] Connect the engine wiring harness.
At this time, take care not to connect
the wiring harness in reverse.
6] Start the engine and check that fuel [*9]
does not leak. 3 Joint bolt: 24 ± 4 Nm {2.4 ± 0.4 kgm}
For the testing procedure, see Testing
and adjusting, "Testing fuel system for [*10]
leakage". 3 Mounting bolt: 24 ± 4 Nm {2.4 ± 0.4 kgm}
2) Replace relief valve (3), if necessary,
according to the following procedure. [*11]
1] Before removing the relief valve, 3 Fuel block mounting bolt:
remove mud etc. from around it thor- 32 ± 4 Nm {3.3 ± 0.4 kgm}
oughly and clean it.
2] Remove the relief valve. [*12]
3] If the leakage from the relief valve k When installing, keep the distance of more
exceeds the specified value, do not than 10 mm between the high-pressure
reuse it. pipe and the harness.
4] Check that high-pressure seal sur-
faces (A) of the relief valve and rail [*13]
are free from damage. 3 Air hose clamp:
5] Install the relief valve. 10.0 – 11.0 Nm {1.02 – 1.12 kgm}
2 Threaded part of relief valve:
Gear oil (#90)
3 Relief valve:
100 ± 4 Nm {10.2 ± 0.4 kgm}
Excessive tightening can cause
leakage. Take care not to tighten
too strongly.
6] Start the engine and check that fuel
does not leak.
For the testing procedure, see Testing
and adjusting, "Testing fuel system for
leakage".
PC228US, 228USLC-3E0 27
[*14] [*15]
q Install the disconnected air tube (56) according 3 Mounting nut of turbocharger lubricating oil
to the following procedure. supply hose: 35 ± 3.5 Nm {3.57 ± 0.36 kgm}
a Use a new MIKALOR clamp. a When tightening the hose mounting nut,
1) Align the hose to the original position (marking fix the connector on the turbocharger side
position). securely by using a wrench because its
(Reference) tightening torque is low.
Depth of insertion: 40 mm (turbocharger) a If the connector is loosened, tighten it to
60 mm (aftercooler side) the following torque.
2) Set bridge (BR) under the clamp bolt so that it 3 Connector on turbocharger:
will be lapped over the band by following 9.8 – 12.7 Nm {1.0 – 1.3 kgm}
dimension (b). 3 Turbocharger mounting nut:
Dimension (b): Min. 5 mm 24 ± 4 Nm {2.4 ± 0.4 kgm}
3) Tightening of the clamp. a If the stud bolt is removed, install it and
2 Clamp bolt (BC): Lubricating oil (THREE- tighten to the following torque.
BOND PANDO 18B) 3 Stud bolt:
a Do not use an impact wrench. 10 ± 2 Nm {1.0 ± 0.2 kgm}
q When reusing the hose 3 Mounting bolt of turbocharger lubricating oil
Install the clamp to the clamp mark made return tube: 10 ± 2 Nm {1.0 ± 0.2 kgm}
on the hose. (Hexagonal head bolt M6×1.0)
3 Tighten to torque of at least 6 Nm
{0.6 kgm}. [*16]
q When using a new hose a Tighten the bolts in the order shown below.
Tighten until dimension (BDG) is 7 – 3 Exhaust manifold mounting bolt:
10 mm. First time: in the order of [1] – [12]
Tighten to a torque of
24 ± 4 Nm {2.4 ± 0.4 kgm}.
Second time: in the order of [1] – [12]
53 ± 6 Nm {5.4 ± 0.6 kgm}.
Third time: in the order of [1] – [4]
53 ± 6 Nm {5.4 ± 0.6 kgm}.
q Refilling engine coolant

Refill coolant through the coolant filler port up
to the specified level. Start the engine and cir-
culate the coolant, and then check the coolant
level.
5 Coolant: 21 l
28 PC228US, 228USLC-3E0
Removal and installation of 5. Disconnect radiator hose (6). [*1]

radiator assembly 1
6. Remove mounting bolts (7) for cover (3).
Removal
k Swing the upper structure 90°, lower the
work equipment to the ground safely and
stop the engine. Then, loosen the hydraulic
tank cap gradually to release the internal
pressure of the hydraulic tank.
2. Drain the coolant through drain valve (2).

6 Coolant: 21 l
7. Remove aftercooler hose (8).
3. Remove mounting bolts (4) for cover (3).
PC228US, 228USLC-3E0 29
8. Disconnect clamp (9). 13. Disconnect reservoir tank hose (13).
9. Remove mounting bolts (10) for cover (3). 14. Disconnect radiator hose (14). [*2]
a Make marks at the disconnected hose end
10. Move cover (3) upwards. and the mating part of the radiator to indi-
cate the insertion position of the hose.
(See the following figure.)
15. Remove radiator mounting bolts (15).
11. Remove engine hood (11). For details, see

“Removal and installation of maintenance
counterweight assembly (At rear part of
engine)”.
(Example of marking)
16. Sling radiator assembly (16). [*3]

4 Radiator assembly: 16 kg
30 PC228US, 228USLC-3E0
Installation
q Carry out installation in the reverse order to
removal.
[*1][*2]
a Reference
Hose insertion depth: 45 mm (Both top and
bottom)
10.8 – 11.8 Nm {1.1 – 1.2 kgm}
[*3]
a Check that the heat insulation sealant
(sponge) on the outside of the radiator is
not damaged.
a If the heat insulation sealant (sponge) is
damaged, replace it.
a When lowering the radiator assembly to
install it, take care not to damage the heat
insulation sealant (sponge) on its outside.
a Check from the undercover side that pro-
jections (A) at the radiator bottom are
matched to hollows (B) on the machine.
q Refilling with coolant

Add coolant through the coolant filler to the
specified level. Run the engine to circulate the
coolant through the system. Then, check the
coolant level again.
5 Coolant: 21 l
PC228US, 228USLC-3E0 31
Removal and installation of a If tools N1 and N2 are available, remove

hydraulic oil cooler assembly 1 the hydraulic tank strainer and stop the oil
with tools N1 and N2.
Special tools
Necessity
Symbol
Sketch
Q’ty
N/R
1 790-460-1210 Oil stopper q 1
N
2 796T-460-1230 Adapter q 1
Removal
work equipment safely to the ground and
stop the engine. Then, loosen the hydraulic
tank cap gradually to release the internal
pressure of the hydraulic tank.
k Disconnect the cable from the negative (–) 3. Remove cover (3).
4. Remove plug (4) to drain the rest of oil from the

hydraulic oil cooler.
2. Remove drain plug (2) and drain the hydraulic

oil.
6 Hydraulic oil: 126 l
32 PC228US, 228USLC-3E0
5. Disconnect tube (5). 11. Lift off hydraulic oil cooler assembly (7). [*1]
4 Hydraulic oil cooler assembly: 35 kg
6. Disconnect hydraulic oil cooler check valve (6)
from hydraulic oil cooler (7).
Installation
7. Remove engine hood (8) and cover (9). q Installation is done in the reverse order of
For details, see “Removal and installation of removal.
maintenance counterweight assembly (At rear
part of engine)”. [*1]
a Confirm that the heat insulating seal material
(sponge) of the hydraulic oil cooler peripheral
part is not damaged. If the heat insulating seal
material (sponge) is damaged, replace it to the
new one.
Confirm from the undercover side that convex-
ity (A) of the hydraulic oil cooler is correctly set
to concavity (B) of the chassis.
8. Disconnect tube (10).
9. Remove 2 hydraulic oil cooler mounting bolts

(11).
10. Remove screws (12) from the hinge and dis-

connect nets (13) from the hydraulic oil cooler.
q Refilling with oil (hydraulic oil tank)

a Check that oil cooler drain plug is closed
before refilling oil.
a Refill with hydraulic oil through the oil filler
port to the specified level. Let the oil circu-
late in the hydraulic system by starting the
engine. Then check the oil level again.
PC228US, 228USLC-3E0 33
Removal and installation of 5. Remove hose clamps (8) and move hoses (9)
aftercooler assembly 1 to the radiator.
Removal
work equipment safely to the ground and
stop the engine.
1. Conduct the following items, referring to

“Removal and installation of radiator assem-
bly”:
1) Drain of coolant.
2) Removal of cover (1).
6. Disconnect radiator hose (10).
7. Remove 2 aftercooler mounting bolts (11).
2. Referring to “Removal and installation of radia-

tor assembly”, remove engine hood (2) and
cover (3).
8. Lift off the aftercooler assembly (12). [*1]
3. Remove covers (4), (5) and (6).
4 Aftercooler assembly: 15 kg
34 PC228US, 228USLC-3E0
Installation
q Installation is done in the reverse order of
removal.
[*1]
a Confirm from the under cover side that
convexity (A) of the aftercooler is correctly
set to concavity (B) of the chassis.
PC228US, 228USLC-3E0 35
Removal and installation of fuel 4. Disconnect 2 hoses (4). [*1]

cooler assembly 1 a When disconnecting each hose, be sure
to fix the elbow (L) on the fuel cooler side
Removal with another spanner so that a force will
k Disconnect the cable from the negative (–) not be applied to the cooler.
terminal of the battery. a If spanner [1] is not used, a force will be
a If the fuel level is high, the fuel does not stop applied to the cooler and welded part (M)
flowing out through the fuel tank return hose. In will be removed. Take care.
this case, drain the fuel.
5. Remove 4 fuel cooler mounting bolts (5).
1. Remove 4 air conditioner condenser mounting
bolts (1). 6. Remove fuel cooler (6).
2. Move air conditioner condenser (2) aside.
3. Remove rubber cover (3).
36 PC228US, 228USLC-3E0
Installation
removal.
[*1]
a When tightening each hose, be sure to fix the
elbow (L) on the fuel cooler side with another
spanner so that a force will not be applied to
the cooler.
a If spanner [1] is not used, a force will be
applied to the cooler and welded part (M) will
be removed. Take care.
PC228US, 228USLC-3E0 37
Removal and installation of 10. Disconnect fuel return hose (10).

engine assembly 1
Removal
k Lower the work equipment safely to the
ground and stop the engine. Then, loosen
the hydraulic tank cap gradually to release
the internal pressure of the hydraulic tank.
k Close the fuel stop valve.
1. Conduct the step1. – 28. in the “Removal and

installation of cylinder head assembly”.
11. Disconnect connectors (12) and (13) from
2. Remove the work equipment pump assembly,
engine controller (11).
referring to the “Removal and installation of
work equipment pump assembly”.
3. Disconnect wiring harnesses (1), (2) and (3).
13. Disconnect ground wire (15).
4. Disconnect heater hose (4).
14. Remove 4 mounting bolts (16). [*2]
5. Disconnect hose (5).
6. Disconnect hose (6).
7. Disconnect radiator hose (7). [*1]
15. Lift off engine assembly (17).

a Before slinging the engine assembly,
check that all the wires and pipes are dis-
connected.
a Sling the engine by 3 points so that its
angle can be adjusted and raise it slowly
8. Disconnect fuel supply hose (8).
while adjusting its position.
4 Engine assembly: 570 kg
9. Disconnect 2 fuel filter hoses (9).
a Disconnect these hoses by pressing locks
(L) on both sides of each connector.
38 PC228US, 228USLC-3E0
Installation
removal.
[*1]
a Align the hose to the original position (marking
position).
a Align the clamp to the original position.
a Reference
Inserted hose length: 49 mm
10.8 – 11.8 Nm {1.1 – 1.2 kgm}
[*2]
a The bolt length of the engine front side is
shorter than that of rear side.
a The engine mounting rubber size of the engine
front side is smaller than that of rear side.
3 Engine mounting bolt:

245 – 308.9 Nm {25 – 31.5 kgm}
q Refilling engine coolant

Refill coolant through the coolant filler port up
to the specified level. Start the engine and cir-
culate the coolant, and then check the coolant
level.
5 Coolant: 21 l
q Refilling with oil (hydraulic tank)

Refill with hydraulic oil through the oil filler port
to the specified level. Let the oil circulate in the
hydraulic system by starting the engine. Then
check the oil level again.
5 Hydraulic tank: 126 l
3 Hydraulic tank drain plug:
58.8 – 78.5 Nm {6.0 – 8.0 kgm}
PC228US, 228USLC-3E0 39
Removal and installation of fuel 6. Disconnect lower hoses (10) – (12) of the fuel
tank assembly 1 tank. [*1]
Removal
k When removing and installing the fuel tank
assembly, lower the work equipment com-
pletely to the ground.
1. Remove the undercover of the fuel tank and

drain the fuel from the fuel tank.
6 Fuel tank: 320 l (When full)
2. Remove handrails (1) and (2).

7. Remove the 6 mounting bolts and lift off fuel
3. Remove covers (3) – (6). tank assembly (13). [*2]
4 Fuel tank assembly: 130 kg
4. Disconnect fuel level sensor connector CN-

A60 (7).
5. Remove pre-filter (8), engine oil filter (9), and Installation

bracket as an assembly. q Carry out installation in the reverse order to
a Move the engine oil filter and the pre-filter removal.
toward the hydraulic pump so that they will
not interfere with the fuel tank. [*1]
3 Clamp:
3.3 ± 0.49 Nm {0.34 ± 0.05 kgm}
[*2]
3 Fuel tank mounting bolt:
245 – 309 Nm {25.0 – 31.5 kgm}
40 PC228US, 228USLC-3E0
PC228US, 228USLC-3E0 41
SEN01924-04

© 2010 KOMATSU
All Rights Reserved
42
SEN01925-01
PC228US-3E0
PC228USLC-3E0

50 Disassembly and assembly1

Power train
Removal and installation of travel motor and final drive assembly ................................................................. 2
Disassembly and assembly of final drive assembly........................................................................................ 3
Removal and installation of swing machinery assembly ................................................................................11
Disassembly and assembly of swing machinery assembly .......................................................................... 13
Removal and installation of swing circle assembly ....................................................................................... 21
Removal and installation of travel 5. Sling and remove the travel motor and final
motor and final drive assembly 1 drive assembly (3).
4 Travel motor and final drive assembly:
380 kg
Removal
k Lower the work equipment completely to
the ground. Referring to “Releasing resid-
ual pressure in hydraulic circuit”, release
the residual pressure in the hydraulic cir-
cuit.
1. Remove the track shoe. For details, see

"Expansion and installation of track shoe
assembly".
Installation
removal.
3 Mounting bolt of travel motor and final

drive assembly:
265 – 309 Nm {27 – 31.5 kgm}
(Average torque:
Min. 275 Nm {Min. 28 kgm})
3. Disconnect 4 travel motor hoses (2).
q Bleeding air
4. Slinging travel motor and final drive assembly
Bleed air from the travel motor circuit. For
(3) temporarily, remove 18 mounting bolts (4).
details, see Testing and adjusting, “Bleeding
air from each part”.
q 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.
Disassembly and assembly of 4. Washer

final drive assembly 1 Remove washer (2).
Special tools
Necessity
Symbol
Sketch
Q’ty
N/R
1 796-427-1200 Wrench t 1
2 791-545-1510 Installer t 1
796T-427-1220 Push tool t 1 Q
790-101-2510 Block t 1
792-104-3940 Bolt t 2
F
3 05180-11610 Nut t 2 5. No. 1 carrier assembly
01613-31645 Washer t 2 1) Remove No. 1 carrier assembly (3).
790-105-2100 Jack t 1
4 790-331-1110 Wrench t 1
Disassembly
1. Sprocket
Remove the 20 mounting bolts and sprocket.
2. Draining oil
Remove the drain plug to drain the oil from the
final drive case.
2) Disassemble the No. 1 carrier assembly
6 Final drive: 5.4 l according to the following procedure.
1] Drive pin (4) into pin (5) to remove pin
3. Cover (5) from carrier (6).
Remove the 20 mounting bolts. Using hanging a After removing pin (5), remove
bolts [1], lift off cover (1). pin (4) from pin (5).
a If ring gear (12) is also lifted up, hit it lightly 2] Remove thrust washer (7), No. 1
with a plastic hammer to separate it. planetary gear (8), needle roller bear-
ing (9), and thrust washer (10).
6. No. 1 sun gear shaft 2) Disassemble the No. 2 carrier assembly

Remove No. 1 sun gear shaft (11). according to the following procedure.
1] Drive pin (17) into pin (18) to remove
pin (18) from carrier (19).
a After removing pin (18), remove
pin (17) from pin (18).
2] Remove thrust washer (20), No. 2
planetary gear (21), needle roller
bearing (22), and thrust washer (23).
7. No. 1 and No. 2 ring gears

Remove No. 1 and No. 2 ring gears (12).
8. Thrust washer
Remove thrust washer (13).
9. No. 2 sun gear

Remove No. 2 sun gear (14). 12. Lock
1) Remove lock (24).
2) Using tool F1, remove lock (25).
10. Washer
Remove washer (15).
13. Hub assembly
11. No. 2 carrier assembly 1) Using hanging bolts [2], remove hub
1) Remove No. 2 carrier assembly (16). assembly (26).
2) Disassemble the hub assembly according Assembly

to the following procedure. a Clean all the parts and check them for dirt or
1] Remove floating seal (27). damage. Coat their sliding surfaces with oil
2] Remove ball bearings (28) and (29) (SAE30) before installing.
from hub (30).
1. Travel motor assembly
1) Set floating seal (31) to tool F2.
a Thoroughly degrease and dry the O-
ring and O-ring fitting surface of the
floating seal before installing.
14. Travel motor assembly

Remove floating seal (31) from travel motor
(32).
2) Install floating seal (31) to travel motor

(32).
a After installing the floating seal, check
that its slant is less than 1 mm.
a After installing the floating seal, check
that the sliding surfaces are free from
dirt and thinly apply oil (SAE30) to
those surfaces.
2. Hub assembly 2) Using the hanging bolts [2], set hub

1) Assemble the hub assembly according to assembly (26) to the travel motor.
the following procedure. a If the hub assembly is difficult to
1] Using the push tool, press fit ball install, hit the inner race of the bear-
bearings (29) and (28) to hub (30). ing lightly, using the push tool.
2] Set floating seal (27) to tool F2. 3. Lock

a Thoroughly degrease and dry the 1) Using tool F3, press the inner race of the
O-ring and O-ring fitting surface ball bearing.
of the floating seal before install- q Standard pressing force: 8.8 – 12.7 N
ing. {0.9 – 1.3 tons}
3] Install floating seal (27) to hub (30). 2) Pressing the bearing, rotate hub assembly
a After installing the floating seal, (26) by 2 – 3 turns.
check that its slant is less than 1 3) Under this condition, measure distance (a)
mm. from the top of the travel motor to the top
a After installing the floating seal, of the inner race of the bearing.
check that the sliding surfaces a After measuring, remove tool F3.
are free from dirt and thinly apply
oil (SAE30) to those surfaces.
4) Measure thickness (b) of lock (25). 8) Install lock (24).

5) Calculate screwing depth (c) of lock (25) 2 Mounting bolt: Adhesive (LT-2)
from measured distance (a) and thickness a Do not apply adhesive to the screw
(b). hole of the lock.
q (c) = (a) – (b) – (0 to 0.1) a When installing the lock, fit it to the
6) Using tool F1, screw in lock (25) to calcu- spline of the travel motor.
lated depth (c).
a Screwing depth (c) is the distance
from the top of the travel motor to the
top of the lock.
4. No. 2 carrier assembly

1) Assemble the No. 2 carrier assembly
1] Install thrust washer (23), needle
7) Using push puller scale [3], measure the roller bearing (22), No. 2 planetary
tangential force (starting force) of hub gear (21), and thrust washer (20) to
assembly (26). carrier (19).
a Measure the tangential force (starting a When using the disassembled
force) at the sprocket mounting bolt carrier as it is, repair the caulked
hole. parts around pin hole (d) of the
q Tangential force (Starting force): Max. carrier in advance.
294 N {Max. 30 kg} a Replace the thrust washer with
a If the tangential force (starting force) new one.
is abnormal, disassemble again and
check for the cause.
2] Install pin (18). 5. Washer

a Before inserting the pin fully, Install washer (15).
align its hole with the hole of the
carrier. 6. No. 2 sun gear
a When installing the shaft, rotate Install No. 2 sun gear (14).
the planetary gear and take care
not to damage the thrust washer. 7. Thrust washer
3] Install pin (17). Install thrust washer (13).
a Replace the pin with new one.
a Before inserting the pin, set its 8. No. 1 sun gear
direction so that 3 claws (e) on its Install No. 1 sun gear (11).
periphery will not be applied to
the thin parts of the carrier.
a After inserting the pin, caulk 2
places around the pin hole to
prevent the pin from coming out.
a After assembling the No. 2 car-
rier assembly, check that all the
gears rotate smoothly.
9. No. 1 and No. 2 ring gears

1) Fit the O-ring to the hub side.
2) Using hanging bolts [4], install the No. 1
and No. 2 ring gears (12) to the hub.
a Degrease the mating faces of the ring
gears and hub. Do not apply the gas-
ket sealant to those faces.
a Match the bolt holes of the ring gears
2) Install No. 2 carrier assembly (16). to those of the hub.
a Match the bottoms of the 4 pins of the
No. 2 carrier assembly to the 4 dents
of the motor case.
10. No. 1 carrier assembly 2) Install No. 1 carrier assembly (3).

1) Assemble the No. 1 carrier assembly a Check that all the gears are meshed
according to the following procedure. normally. If not, vibrate the hub in the
1] Install thrust washer (10), needle rotating direction several times to
roller bearing (9), No. 2 planetary mesh the gears normally.
gear (8), and thrust washer (7) to car-
rier (6). 11. Spacer
a When using the disassembled Install spacer (2).
carrier as it is, repair the caulked
parts around pin hole (g) of the
carrier in advance.
a Replace the thrust washer with
new one.
a After installing spacer (2), measure dis-

tance (j) from the top of planetary gear (8)
to the top of hub assembly (12) and check
the assembly condition.
q Dimension (j): 1.0 ± 0.51 mm
2] Install pin (5).
a If dimension (j) is out of above range, they
a Before inserting the pin fully,
are not assembled correctly. In this case,
check again.
carrier.
a When installing the shaft, rotate
the planetary gear and take care
not to damage the thrust washer.
3] Install pin (4).
a Replace the pin with new one.
a Before inserting the pin, set its
direction so that 3 claws (h) on its
periphery will not be applied to
the thin parts of the carrier.
places (i) around the pin hole to
12. Cover
1) Using hanging bolts [1], install cover (1).
2 Mating faces of cover and ring
gear: Gasket sealant (LG-6)
2) Using tool F4, tighten the 20 mounting

bolts.
3 Mounting bolt:
1st time: 147 Nm {15 kgm}
2nd time: 85 – 95° (Turning angle)
13. Refilling with oil

Tighten the drain plug and add engine oil
through the oil filler.
5 Final drive: 5.4 l
a After installing the travel motor and final
drive assembly to the machine, check the
oil level finally.
14. Sprocket
Install the sprocket and tighten the 20 mount-
ing bolts.
2 Mounting bolt: Adhesive (LT-2)
3 Mounting bolt:
441 – 490 Nm {45 – 50 kgm}
10 PC228US, 228USLC-3E0
Removal and installation of swing

machinery assembly 1 5. Disconnect swing motor hoses (10) – (15).
a The port of each hose is as follows.
q (10), (11): Main circuit (Ports MA and
MB)
Removal q (12): Suction circuit (Port S)
k Lower the work equipment completely to q (13): Parking brake circuit (Port B)
the ground. Referring to "Releasing resid- q (14), (15): Drain circuit (Port T)
ual pressure in hydraulic circuit", release a After disconnecting the hoses of the suc-
the residual pressure in the hydraulic cir- tion circuit and drain circuit, plug them.
cuit.
1. Remove covers (1), (2) and (3).
6. Remove the 12 mounting bolts and lift off

swing motor and swing machinery assembly
(16). [*2]
2. Remove covers (4) and (5), and frames (6) and
4
(7).
Swing motor and swing machinery
assembly: 240 kg
4. Remove turbocharger inlet pipe (9). [*1]
PC228US, 228USLC-3E0 11
Installation
Carry out installation in the reverse order to
removal.
[*1]
a Inserting length of hose: 60 mm
3 Pipe clamp:
7 ± 1.1 Nm {0.7 ± 0.1 kgm}
3 Hose clamp:
10.8 ± 1 Nm {1.1 ± 0.1 kgm}
[*2]
3 Mounting bolt of travel motor and swing
machinery assembly:
490 – 608 Nm {50 – 62 kgm}
q Bleeding air
Bleed air from the swing motor circuit. For

again.
12 PC228US, 228USLC-3E0
Disassembly and assembly of 3. No. 1 sun gear

swing machinery assembly 1 Remove No. 1 sun gear (2).
Special tool
Necessity
Symbol
Sketch
Q’ty
N/R
1 796T-426-1410 Push tool t 1 Q
2 796-426-1120 Push tool t 1
G 796T-426-1130 Plate t 1 Q
3 790-101-5241 Grip t 1
01010-61240 Bolt t 1
Disassembly 1) Remove No. 1 carrier assembly (3).
1. Draining oil
Remove the drain plug to drain the oil from the
swing machinery case.
6 Swing machinery: 7.1 l
2. Swing motor assembly

1) Set the swing motor and swing machinery
assembly on block [1].
2) Remove the 6 mounting bolts and swing
motor assembly (1).
4 Swing motor assembly: 70 kg
PC228US, 228USLC-3E0 13
2) Disassemble the No. 1 carrier assembly 7. No. 2 carrier assembly

according to the following procedure. 1) Remove mounting bolt (12) of the No. 2
1] Remove snap ring (4), and then carrier assembly.
remove thrust washer (5), No. 1 plan- 2) Remove No. 2 carrier assembly (13).
etary gear (6), needle roller bearing
(7), and thrust washer (8) from carrier
(30).
2] Remove washer (9).
3] Remove snap ring (31). Then, using a
press, remove pin (32).
q Pin pressing force for assembly
(Reference):
11.2 – 25.8 kN {1,140 – 2,630 kg}
3) Disassemble No. 2 carrier assembly

1] Drive pin (14) into pin (15) to remove
pin (15) from carrier (16).
a After removing pin (15), remove
pin (14) from pin (15).
2] Remove thrust washer (17), No. 2
planetary gear (18), needle roller
bearing (19), and thrust washer (20).
5. No. 1 and No. 2 ring gears 3] Remove plate (21).
Remove the 18 mounting bolts and No. 1 and
No. 2 ring gears (10).
6. No. 2 sun gear

Remove No. 2 sun gear (11).
14 PC228US, 228USLC-3E0
8. Shaft and case assembly 9. Bearing

1) Remove mounting bolts (23). Using the push tool, remove bearing (35) from
2) Set the shaft and case assembly on the case (36).
press. Using push tool [2], remove shaft
assembly (24) from case assembly (25).
3) Disassemble the shaft assembly accord-

ing to the following procedure.
1] Using push tool [3], remove cover
assembly (26) and bearing (27) from
shaft (28).
2] Remove oil seal (29) from cover (34).
PC228US, 228USLC-3E0 15
Assembly
a Clean the all parts and check them for dirt or
damage. Coat their sliding surfaces with
engine oil before installing.
a Do not reuse the used bearings and oil seals.
1. Bearing
Using push tool [5], press fit bearing (27) to
case (36).
a Use new bearing (27).
3) Install cover assembly (26) to case (36)

and tighten mounting bolts (23).
a Match the drain ports.
2 Cover fitting face:
Gasket sealant (LG-6)
a When applying the gasket sealant, take
care not to project it into the drain port.
3 Mounting bolt:
66.2 ± 7.4 Nm {6.75 ± 0.75 kgm}
2 Oil seal lip: Grease (G2-LI)
2. Cover assembly
1) Set oil seal (29) on cover (34) horizontally.
2) Using push tool G3, press fit oil seal (29)
to cover (34).
a Use new oil seal (29).
2 Periphery of oil seal:
a Take care that the gasket sealant
(LG-6) will not stick to the oil seal lip.
a When not using push tool G3, use
another push tool to push part (A)
around the oil seal evenly.
a Take care that oil seal (29) will not
slant.
16 PC228US, 228USLC-3E0
3. Shaft and case assembly

1) Set case assembly (25) to shaft (28).
a Take care not to damage the oil seal.
4. Sub bearing
Using tool G2, press fit bearing (35).
a Use new bearing (35).
2) Using push tools G1 and [8], hit the shaft a Press the bearing inner race and outer
so that it will not fall down. race simultaneously.
a Loosen sling [9]. q Press fitting force for bearing (Reference):
Inner race side:
9.4 – 26.6 kN {960 – 2,710 kg}
Outer race side: 0 – 8.9 kN {0 – 910 kg}
a After press fitting the bearing, check that
the case rotates smoothly.
3) Set the assembly on the press.

4) Using push tools G1, [8] and [10], press fit
the bearing inner race.
a Press fitting force: Several ton
a Set push tool [10] so that case assembly
(25) will not slant largely.
a Hit the flange of case assembly (25) lightly
and frequently to correct its slant.
a Set case assembly (25) horizontally so
that oil seal lip contact face (B) of shaft
(28) will be at the center of oil seal (29).
PC228US, 228USLC-3E0 17
5. No. 2 carrier assembly 2) Install No. 2 carrier assembly (13).

1) Assemble the No. 2 carrier assembly 3) Tighten mounting bolts (12) of the No. 2
according to the following procedure. carrier assembly.
1] Install plate (21) to carrier (16). 2 Mounting bolt: Adhesive (LT-2)
a When using the removed carrier 3 Mounting bolt:
as it is, repair the caulked parts 157 – 196 Nm {16 – 20 kgm}
around pin hole (b) of the carrier
in advance.
2] Install thrust washer (20), needle
roller bearing (19), No. 2 planetary
gear (18), and thrust washer (17).
a Install the shaft while rotating the
planetary gear and taking care
6. No. 2 sun gear

1) Install No. 2 sun gear (11).
2) Install the O-ring to the case.
3] Install pin (15).

a Before inserting the pin fully,
carrier.
a Install the shaft while rotating the
planetary gear and taking care
4] Install pin (14).
places (c) around the pin hole to
18 PC228US, 228USLC-3E0
7. No. 1 and No. 2 ring gears 2] Install snap ring (31).

Using the eyebolts, install No. 1 and No. 2 ring 3] Press pin (32) in the opposite direc-
gears (10). tion to step 1].
a Degrease the mating faces of the ring a Press back the pin until the snap
gears and case. ring is fitted to the end of the car-
a Do not stick gasket sealant to the mating rier. Take care not to press back
faces of the ring gears and case. too much.
a Match hollow (d) on the top of ring gear
(10) to projection (e) on the periphery of
the case.
a Install the washer.
3 Mounting bolt:
157 – 196 Nm {16 – 20 kgm}
4] Install washer (9) to carrier (30).

5] Install thrust washer (8), needle roller
bearing (7), planetary gear (6), and
thrust washer (5) and secure them
with snap ring (4).
2) Install No. 1 carrier assembly (3).

1) Assemble the No. 1 carrier assembly
1] Using a press, press fit pin (32) to
carrier (30).
a Press fit the pin until the snap
ring groove on th e o ne side
comes out of the opposite side of
the carrier.
q Press fitting force of pin (Refer-
ence):
11.2 – 25.8 kN {1,140 – 2,630 kg}
PC228US, 228USLC-3E0 19
9. No. 1 sun gear 11. Oil level check tube and oil supply tube
Install No. 1 sun gear (2). a When installing the oil level check tube
a Install the No. 1 sun gear with the longer and oil supply tube, observe the following
shoulder portion (g) side up. points.
1) When installing the oil level check tube
and oil supply tube, adjust their tips as
shown in the following figure.
2) After the tubes are installed to the
machine, if they interfere with other parts,
loosen the clip nuts and tube sleeve nuts
and adjust their positions.
3 Clip nut: 59 – 74 Nm {6.0 – 7.5 kgm}
3 Tube sleeve nut:
42.1 – 70.6 Nm {4.3 – 7.2 kgm}
10. Swing motor assembly

Install the O-ring toward the ring gear (10),
then install swing motor assembly (1).
a Degrease the mating faces of the swing
motor and ring gear.
a Install the swing motor assembly, match-
ing port MA/MB face (f) to projection (e) on
the periphery of the case.
3 Mounting bolt:
59 – 74 Nm {6.0 – 7.5 kgm}
Tighten the drain plug and add power train oil
through the oil filler.
5 Swing machinery: 7.1 l
20 PC228US, 228USLC-3E0
Removal and installation of swing Installation

circle assembly 1 q Carry out installation in the reverse order to
removal.
[*1]
2
Removal Mounting bolt of swing circle assembly:
1. Remove the revolving frame assembly. For Adhesive (LT-2)
3
details, see “Removal and installation of Mounting bolt of revolving frame assem-
revolving frame assembly”. bly:
1st time:
2. Remove mounting bolts (1) and sling swing cir- 191.2 ± 19.6 Nm {19.5 ± 2 kgm}
cle assembly (2) temporarily. [*1] 2nd time: 48 ± 5° (Turning angle)
a Leaving 1 mounting bolt each at the front
and rear parts, sling the swing circle [*2]
assembly by 3 points. a When installing the swing circle assembly,
match the dowel pin for the outer race and
3. Remove the left mounting bolts and swing cir- track frame.
cle assembly (2). [*2] a After installing the swing circle assembly,
match the soft zone of the inner race (the
4 Swing circle assembly: 270 kg stamped (S) on the top) to the soft zone of
the outer race (part (a) at the ball insertion
place).
PC228US, 228USLC-3E0 21
SEN01925-01

© 2009 KOMATSU
All Rights Reserved
22
SEN01926-02
PC228US-3E0
PC228USLC-3E0


Undercarriage and frame
Disassembly and assembly of track roller assembly ...................................................................................... 2
Disassembly and assembly of idler assembly ................................................................................................ 3
Disassembly and assembly of recoil spring .................................................................................................... 6
Expansion and installation of track shoe assembly......................................................................................... 8
Removal and installation of revolving frame ................................................................................................. 10
Removal and installation of counterweight assembly ................................................................................... 12
Removal and installation of maintenance counterweight (at rear of engine) ................................................ 13
Removal and installation of maintenance counterweight assembly (above pump) ...................................... 14
Disassembly and assembly of 2. Filling with oil

track roller assembly 1 Using tool L2, fill the shaft with oil.
5 Quantity of oil: 190 – 200 cc (SAE30)

3
a In this section, only precautions for assembling Oil filler plug: 10 – 20 Nm {1 – 2 kgm}
the track roller assembly are explained.
Special tools
Necessity
Symbol
Sketch
Q’ty
N/R
1 790-434-1640 Installer t 1
L
2 791-601-1000 Oil pump t 1
Assembly
1. Installation of floating seal
Using tool L1, install 4 sets of floating seal (1).
a Thoroughly degrease and dry the O-ring

and O-ring fitting surface of the floating
seal (hatched parts) before installing. Take
care that the contact surfaces of the float-
ing seal will be free from dirt.
a After installing the floating seal, check that
its slant is less than 1 mm and its projec-
tion (a) is 5 – 7 mm.
Disassembly and assembly of 3. Remove idler (4) from shaft and support
idler assembly 1 assembly (5 and 7).
a The space between the shaft and idler is
Special tools filled with about 80 cc of oil. Receive it in a
container or spread cloths to absorb it.
Necessity
Symbol
Sketch
Part number Part name 4. Remove floating seal (6) on the opposite side
Q’ty
N/R
from idler (4) and shaft and support assembly
(5 and 7).
1 790-434-1630 Installer t 1
K
2 791-601-1000 Oil pump t 1
Disassembly
5. Remove dowel pin (8), and then remove sup-

port (7) from shaft (5).
6. Remove bushings (9) and (10) from idler (4).
1. Remove dowel pin (1) and support (2).
2. Remove floating seal (3) from support (2) and

idler (4).
Assembly 2. Fit the O-ring, install shaft (5) to support (7),

and secure them with dowel pin (8).
3. Using tool K1, install floating seal (6) to shaft

and support assembly (5 and 7) and idler (4).
1. Using a press, press fit bushings (10) and (9)

to idler (4).
q Press fitting force of bushing (Reference):
43.1 – 107.8 N {4.4 – 11.0 tons}

4. Install shaft and support assembly (5 and 7) to 6. Fit the O-ring, install support (2) to shaft (5),
idler (4). and secure them with dowel pin (1).
7. Using tool K2, fill the shaft with oil.

5 Quantity of oil: 70 – 80 cc (SAE30)
3 Oil filler plug:
157 – 255 Nm {16 – 26 kgm}
5. Using tool K1, install floating seal (3) to idler

(4) and support (2).

Disassembly and assembly of 1. Disconnection of spring assembly and

recoil spring 1 shaft assembly
Disconnect shaft assembly (2) from spring
Special tools assembly (1).
Necessity
Symbol
2. Disassembly of recoil spring assembly
Sketch
Part number Part name 1) Set recoil spring assembly (1) to tool J1.
k Since the installed load of the
Q’ty
N/R
791-600-2001 Compressor (A) spring is heavy and dangerous, set
or or t 1 the spring to tool J1 securely.
791-685-8000 compressor (B) q Installed load of spring:
1 791-635-3160 Extension t 1 126,300 N {12,900 kg}
Cylinder
791-101-1600 t 1
(686 kN {70 ton})
J
790-201-1500 Push tool kit q 1
790-201-1620 • Plate 1
2
790-101-5021 • Grip 1
01010-51816 • Bolt 1
Disassembly
2) Increase the hydraulic pressure of tool J1

gradually to compress spring (5), and then
remove lock plate (3) and nut (4).
k Compress the spring securely until
the nut is loosened.
k After removing the nut, release the
hydraulic pressure of tool J1 grad-
ually to lower the spring tension
perfectly.
q Free length of spring: 603.5 mm
3) Remove yoke (6) and spring (5) from cyl-
inder (7).
4) Remove snap ring (8), and then remove
dust seal (9) and bushing (10) from cylin-
der (7).
3. Disassembly of piston assembly

1) Remove lock plate (11), and then remove
valve (12) from shaft (13).
2) Remove snap ring (14), U-packing (15),
and ring (16).
Assembly 4) Install spring (5) and yoke (6) to cylinder

(7) and set them to tool J1.
2 Sliding parts of cylinder and yoke:
Grease (G2-LI)
k Since a heavy load will be applied
to the spring, set the spring to tool
J1 securely.
5) Increasing the hydraulic pressure of tool

J1 gradually to compress spring (5),
tighten nut (4) and adjust installed length
(a).
q Installed length of spring (a): 466 mm
1. Assembly of shaft assembly

1) Install ring (16) and U-packing (15) to
shaft (13) and secure them with snap ring
(14).
2) Tighten valve (12) lightly and secure it with
lock plate (11).
2. Assembly of spring assembly

1) Install bushing (10) to the cylinder.
2) Using tool J2, install dust seal (9) to cylin-
der (7).
3) Install snap ring (8) to the cylinder. 6) Secure nut (4) with lock (3).
k After installing the lock, release the
hydraulic pressure of tool J1 grad-
ually to lower the spring tension
perfectly, and then remove spring
assembly (1) from tool J1.
3. Connection of spring assembly and shaft

assembly
Install shaft assembly (2) to spring assembly
(1).
a Before assembling, pour 300 cc of grease
(G2-LI) in the cylinder. After assembling,
bleed air through the valve.
2 Sliding parts of piston and shaft:
Grease (G2-LI)
a Install the shaft assembly so that the valve
will be on its side.
Expansion and installation of 3. Using tool M, pull out master pin (2). [*2]
track shoe assembly 1 a After pulling out the master pin, remove
tool M, leaving the temporary pin.
Special tools
Necessity
Symbol
Sketch
Q’ty
N/R
791-630-3000 Remover t 1
Cylinder
M 790-101-1300 t 1
(980 kN {100 ton})
Expansion
1. Set 1 master pin between the idler and front
track roller so that the track shoe can be 4. Start the engine and move the machine for-
expanded in the forward and backward direc- ward so that temporary pin [1] will be in front of
tions, and then stop the engine. the idler, and then set block [2] under the track
a There are 2 master pins on each side and shoe.
a hole is made at the end of each of them.
5. Pull out temporary pin [1] and remove the dust
2. Loosen valve (1) to slacken the track shoe. [*1] seal. [*3]
k Since the internal pressure of the
adjustment cylinder is very high, do 6. Move the machine slowly in reverse to expand
not loosen the valve more than 1 turn. track shoe assembly (3).
If the grease does not come out suffi-
ciently, start the engine and move the
machine forward and in reverse.
Installation
expansion.
[*1]
a Adjust the track shoe tension. For detail,
see Testing and adjusting, “Testing and
adjusting track shoe tension”.
[*2]
a Using tool M, press fit the master pin so
that its projection (a) will be as follows.
q Projection (a): 2.5 ± 1 mm (Each side)
[*3]
a When fitting the dust seal, apply grease
(G2-LI) to its contact face against the
bushing. (Do not apply grease to the
mounting face of the bushing on the link
side.)
a Precaution for installation of track shoe of
road liner type
If the rubber of the track shoe of road liner
type (rubber pad type) is worn and broken
to damage the mounting bolt heads,
replace the shoe with new one immedi-
ately. If the bolt heads are crushed, the
bolts cannot be replaced.
Removal and installation of 5. Remove boom cylinder assembly (3).

revolving frame 1 4 Boom cylinder assembly (1 piece):
170 kg
Removal
1. Remove the counterweight assembly. For
details, see "Removal and installation of coun-
terweight assembly".
2. Remove the work equipment assembly. For

details, see "Removal and installation of work
equipment assembly".
3. Disconnect 4 boom cylinder hoses (1).
6. Disconnect upper hoses (4) – (9) of the swivel

joint.
a Before disconnecting the hoses, put tags
to them and write the mounting positions.
7. Pull out the pin of stopper plate (10) and dis-

connect the plate from the swivel joint.
4. Remove bottom pin (2).
10 PC228US, 228USLC-3E0
8. Sling revolving frame assembly (11) tempo- Installation

rarily. q Carry out installation in the reverse order to
a Sling the revolving frame assembly by the removal.
4 points of the 2 counterweight mounting
bolt holes and 2 boom foot pin holes. [*1]
2 Mounting bolt of revolving frame assem-
9. Remove the 36 mounting bolts and revolving bly: Adhesive (LT-2)
frame assembly (11). [*1] 3 Mounting bolt of revolving frame assem-
a All the mounting bolts are installed from bly:
underside of the outer race of the swing 1st time:
circle. 294.2 ± 29.4 Nm {30 ± 3 kgm}
a Leaving 2 – 3 mounting bolts at the front 2nd time: 60 ± 6° (Turning angle)
and rear parts, adjust the balance of the
revolving frame with lever blocks, etc. q Bleeding air
Then, remove those mounting bolts. Bleed air from the travel motor circuit. For
k When removing the revolving frame details, see Testing and adjusting, “Bleeding
assembly, take care that it will not inter- air from each part”.
fere with the center swivel joint.
4 Revolving frame assembly: q Refilling with oil
4,700 kg Add oil through the oil filler to the specified
again.
PC228US, 228USLC-3E0 11
Removal and installation of Installation

counterweight assembly 1 q Carry out installation in the reverse order to
removal.
Special tools
[*1]
2
Necessity
Symbol
Mounting bolt: Adhesive (LT-2)
Sketch
3
Q’ty
N/R
Part number Part name Mounting bolt:
3,430 – 4,217 Nm {350 – 430 kgm}
Commercially
Impact wrench q 1
available
Z Socket wrench
Commercially
(Width across flats: q 1
available
65 mm)
a Select an impact wrench and a socket wrench

for the tightening torque of the counterweight
mounting bolt.
a The word of counterweight described in this
section includes the maintenance counter-
weight assemblies (at the rear of the engine
and above the hydraulic pump).
Removal
k When removing and installing the counter-
weight assembly, lower the work equipment
completely to the ground.
1. Remove or disconnect engine hood, covers,

and wirings. For details, see "Removal and
installation of maintenance counterweight (at
rear of engine)"
2. Sling the counterweight assembly (1) tempo-

rarily.
3. Remove the mounting bolts and counterweight

assembly (1). [*1]
a When removing the counterweight, take
care not to hit it against the machine.
4 Counterweight assembly: 6,100 kg
12 PC228US, 228USLC-3E0
Removal and installation of 9. Disconnect wiring connector (10).

maintenance counterweight (at
rear of engine) 1
Removal
1. Remove light wiring connector (1).
2. Remove plate (2).
10. Sling upper center weight (11) temporarily and

remove mounting bolts (10).
11. Lift off upper center weight (11).

4 Upper center weight assembly: 190 kg
3. Open and sling engine hood (3) and discon-

nect supporting rod (4).
5. Remove the mounting bolts of engine hood (3)

and lift off the engine hood.
4 Engine hood: 35 kg
12. Similarly, lift off lower center weight (12).

4 Lower center weight: 500 kg
7. Remove air conditioner compressor hose

clamp (7).
8. Remove fuel filter and bracket assembly (8)

from upper center weight (9).
Installation
removal.
PC228US, 228USLC-3E0 13
Removal and installation of 5. Remove maintenance counterweight assembly

maintenance counterweight (6).
4 Maintenance counterweight assembly:
assembly (above pump) 1
290 kg
Removal
k When removing and installing the mainte-
nance counterweight assembly, lower the
work equipment completely to the ground.
1. Open engine hood (1) and fix it with fixing bar

(2).
Installation
removal.
4. Remove rubber cover (5).
14 PC228US, 228USLC-3E0
PC228US, 228USLC-3E0 15
SEN01926-02

© 2009 KOMATSU
All Rights Reserved
16
SEN01927-02
PC228US-3E0
PC228USLC-3E0


Hydraulic system
Removal and installation of center swivel joint assembly ............................................................................... 2
Disassembly and assembly of center swivel joint ........................................................................................... 4
Removal and installation of hydraulic tank assembly...................................................................................... 5
Removal and installation of work equipment pump ........................................................................................ 7
Removal and installation of control valve assembly ......................................................................................11
Disassembly and assembly of control valve assembly ................................................................................. 13
Disassembly and assembly of work equipment PPC valve assembly .......................................................... 15
Disassembly and assembly of travel PPC valve assembly........................................................................... 17
Disassembly and assembly of hydraulic cylinder assembly ......................................................................... 20
Removal and installation of center 4. Disconnect upper hoses (8) – (13) of the swivel
swivel joint assembly 1 joint. [*2]
Removal 5. Pull out the pin of stopper plate (14) and dis-
k Lower the work equipment completely to connect the plate from the swivel joint.
the ground. Referring to “Release of resid-
u al pre ssure fro m hydraulic circu it”,
release the residual pressure in the hydrau-
lic circuit.
a Before disconnecting hoses, put tags to them
and write the mounting positions.
1. Remove the 2 top covers and 1 frame of the

swing motor.
2. Disconnect swing motor hoses (1) – (6).

a The port of each hose is as follows.
q (1), (2): Main circuit (Ports MA and MB) 6. Disconnect lower hoses (15) – (22) of the
q (3): Suction circuit (Port S) swivel joint.
q (4): Parking brake circuit (Port B)
q (5), (6): Drain circuit (Port T)
a After disconnecting the hoses of the suction
circuit and drain circuit, plug them.
7. Remove the 4 mounting bolts and center

swivel joint assembly (23). [*3]
4 Center swivel joint assembly: 40 kg
3. Remove the 6 mounting bolts and lift off swing

motor assembly (7). [*1]
4 Swing motor assembly: 60 kg
Installation
removal.
[*1]
3 Swing motor assembly mounting bolt:
59 – 74 Nm {6.0 – 7.5 kgm}
[*2]
a Before installing the swivel joint to the
machine, connect the swivel joint end of
the drain hose between the swivel joint
and swing motor.
[*3]
3 Center swivel joint assembly mounting
bolt: 98.1 – 122.6 Nm {10 – 12.5 kgm}
q Bleeding air
Bleed air from the travel motor circuit. For

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.
Disassembly and assembly of Disassembly

center swivel joint 1 1. Remove the 4 mounting bolts and cover (1).
2. Remove snap ring (2) and ring (3).

a If the ring is difficult to remove, pull it out
together with the swivel rotor in step 3.
3. Using tool E, pull rotor (4) out of shaft (5).
4. Remove 6 slipper seals (6) and O-ring (7) from

rotor (4).
5. Remove seal (8) from shaft (5).
6. Remove plug (9) from shaft (5).
Assembly
Special tools 1. Install plug (9) to shaft (5).
a Before installing the plug, clean, degrease,
Necessity
Symbol
and dry it.

Sketch

a After installing the plug, check that it is
Q’ty
N/R
lower than the shaft end.

790-101-2501 Push puller q 1 3 Plug: 33.3 ± 3.9 Nm {3.4 ± 0.4 kgm}
790-101-2510 • Block 1
2. Install seal (8) to shaft (5).
790-101-2520 • Screw 1
791-112-1180 • Nut 1 3. Install 6 slipper seals (6) and O-ring (7) to rotor
E 1 790-101-2540 • Washer 1 (4).
790-101-2630 • Leg 2
4. Install rotor (4) to shaft (5).
2 Contact surfaces of rotor and shaft:
790-101-2570 • Plate 4
790-101-2560 • Nut 2 Grease (G2-LI)
709-101-3650 • Adapter 2 a Set the rotor to top of the shaft and lightly
hit it with a plastic hammer to insert it into
the shaft.
a When installing the rotor, take care extremely
not to damage the slipper seals and O-ring.
5. Install ring (3) and secure it with snap ring (2).
6. Fit the O-ring and install cover (1).

3 Plug: 31.4 ± 2.9 Nm {3.2 ± 0.3 kgm}
Removal and installation of 2. Remove the maintenance counterweight assem-

hydraulic tank assembly 1 bly (above the pump) (3). For details, see
“Removal and installation of maintenance coun-
Removal terweight assembly (above pump)”.
the ground. Referring to “Release of resid-
ual pre ssure from hydra ulic circuit”,
lic circuit.
1. Drain the oil from the hydraulic tank.

2) Remove drain plug (2) to drain the oil.

4. Disconnect return hoses (6) – (9) of the

hydraulic tank.
5. Disconnect return hose (10). 10. Remove the 6 mounting bolts and lift off
hydraulic tank assembly (16).
6. Remove partition bracket (11). 4 Hydraulic tank assembly: 150 kg
7. Disconnect return hoses (12) and (13) of the

hydraulic tank. Installation
8. Disconnect clamp bracket (14). removal.
q Bleeding air
Bleed air from the hydraulic pump circuit. For

9. Disconnect suction tube (15) of the hydraulic

tank.
Removal and installation of work 2. Remove drain plug (2) and drain the hydraulic
equipment pump 1 tank oil.
Special tools
Necessity
Symbol
Sketch
Q’ty
N/R
1 790-460-1210 Oil stopper q 1
N
2 796T-460-1230 Adapter q 1
Removal
k Set the machine at 45°, lower the work

equipment completely to the ground, stop
the engine, loosen the hydraulic tank cap a If tool N1 and N2 are available, remove
gradually to release the pressure in the the hydraulic tank strainer and stop the oil
hydraulic tank, and set the lock lever in the with tools N1 and N2.
lock position.

a Put tags to the disconnected hoses and pipes

to prevent a mistake in re-connecting them.
1. Remove undercover (1).
3. Drain the damper oil through drain plug (3).

6 Damper case: 0.65 l
4. Remove the counterweight and following parts. 9. Remove muffler mount bolts (12).
For details, see “Removal of maintenance
counterweight (rear of engine)”.
1) Engine hood (4)
2) Cover (5)
3) Fuel filter and bracket assembly (6)
10. Remove the muffler cover.
11. Lift off muffler assembly (13).

6. Remove partition (rubber) (9).
12. Remove side weight (14). For details, see

“Removal and installation of maintenance
counterweight (rear of engine)”.
8. Open the rear right inspection cover and remove

cover (11).
13. Disconnect connectors (15) and (16). 19. Disconnect pre-filter (22) and its bracket
q (15) : V19 (Red) on front pump side together.
q (16) : V11 (White) on rear pump side
20. Disconnect engine oil filter (23) and its bracket
14. Disconnect damper case oil feed hose (17). together.
15. Disconnect high-pressure pipe clamps (18).
16. Remove bracket (19).
17. Disconnect 2 high-pressure pipes (20).
21. Remove partition (rubber) (24) and its bracket

together from the hydraulic tank.
22. Remove bracket (25).
18. Disconnect fuel tank fuel level sensor connec-

tor (21).
a Disconnect the wiring clamp, too.
23. Disconnect hose (26) and remove elbow (27). Installation

24. Remove hose (28) and joint (29). removal.
25. Disconnect hoses (30), (31), (32) and (33). [*1]

2 Hydraulic pump involute spline:
26. Disconnect hose clamp bracket (34) from the Lubricant (LM-G)
hydraulic tank. 2 Hydraulic pump mating face:
27. Remove work equipment pump mounting a Since the flywheel housing is made of alu-
bolts. minum, take care not to apply excessive
a Sling the work equipment pump assembly torque to the bolts.
temporarily. a Do not use an impact wrench.
q Refilling with oil (Damper case)

level.
5 Damper case: EO30-DH, Approx. 0.65 l
q Refilling with oil (Hydraulic tank)

3 Hydraulic tank drain plug:
58.8 – 78.5 Nm {6.0 – 8.0 kgm}
q Bleeding air
See Testing and adjusting, “Bleeding air from
each part”.
28. Lift off work equipment pump assembly (36). [*1]

4 Work equipment pump assembly: 160 kg
10 PC228US, 228USLC-3E0
Removal and installation of 5. Disconnect 8 connectors (9) of the PPC oil

control valve assembly 1 pressure switch.
Removal
ual pre ssure from hydra ulic circuit”,
lic circuit.
a Before disconnecting the connectors, write
their locations (connector Nos.)
1. Open inspection cover (1) in right rear, remove 6. Disconnect hoses (10) – (14) of the solenoid
the cover and disconnect tube (2) of the wind- valves.
shield washer tank and connector CN-A50 (3). q (10) : Basic pressure hose (2 pieces)
a Disconnect the clamp on the frame side, too. q (11) : Drain hose
q (12) : Outlet hose of PPC lock solenoid
q (13) : Outlet hose of travel speed solenoid
q (14) : Outlet hose of swing holding brake
solenoid
a Do not disconnect the hoses other than
the above, since they will be removed
together with the control valve assembly.
7. Disconnect 6 connectors (15) of the solenoid

valves.
2. Remove guards (4) and (5).
3. Remove steps (6) and (7).
4. Remove cover (8) and frame as an assembly.
PC228US, 228USLC-3E0 11
8. Disconnect 4 PPC hoses (16) of the travel cir- 12. Disconnect F-LS pressure hose (23) and R-LS
cuit. pressure hose (24).
a Before disconnecting the hoses, put tags
to them and write the mounting positions 13. Disconnect 12 control valve outlet hoses/tubes
(band colors). (25).
a The figure shows the 1-attachment speci-
fication.
9. Disconnect F pump hose (17) and R pump

hose (18).
14. Remove control valve assembly (26), mount-
10. Disconnect F pump pressure hose (19) and ing bracket, and solenoid valve assembly as
PPC and solenoid basic pressure hose (20). an assembly.
4 Control valve assembly: 270 kg
11. Disconnect F pump pressure sensor connector
CN-A51 (21) and R pump pressure sensor
connector CN-A52 (22).
Installation
removal.

again.
q Bleeding air
Bleed air from the hydraulic cylinder circuit,
swing motor circuit, and travel motor circuit.
For details, see Testing and adjusting, “Bleed-
ing air from each part”.
12 PC228US, 228USLC-3E0
Disassembly and assembly of Installation of pressure compensation

control valve assembly 1 valve seal
a If the seal of the pressure compensation valve
is removed, install it according to the following
a In this section, only precautions for assembling
procedure.
the control valve assembly are explained.
1. Fit the O-ring of the seal to piston (1).
Special tools
a Before assembling the pressure compen-
sation valve, clean it thoroughly.
Necessity
Symbol
Sketch
2. Set tool P1 to piston (1) and insert seal (2) to
Q’ty
N/R
the seal groove on the deeper side, expanding
1 796-946-1410 Guide (for a) t 1 it evenly.
2 796-946-1420 Guide (for a) t 1 a You may push in the seal to the flat part of
3 795-946-1430 Sleeve (for a) t 1 tool P1 first, and then set tool P1 to the
piston and push in the seal.
1 796-946-1310 Guide (for b) t 1
2 796-946-1320 Guide (for b) t 1
3 796-946-1330 Sleeve (for b) t 1
1 796-946-1610 Guide (for c) t 1
2 796-946-1620 Guide (for c) t 1
3 796-946-1630 Sleeve (for c) t 1
P
1 796-946-2210 Guide (for d) t 1
2 796-946-2220 Guide (for d) t 1
3 796-946-2230 Sleeve (for d) t 1
1 796-946-1910 Guide (for e, h) t 1
2 796-946-1920 Guide (for e, h) t 1
3 796-946-1930 Sleeve (for e, h) t 1
1 796-946-1810 Guide (for f, g) t 1 3. Fit the O-ring of the seal to piston (1).
2 796-946-1820 Guide (for f, g) t 1
4. Set tool P2 to piston (1) and insert seal (3) to
3 796-946-1830 Sleeve (for f, g) t 1
the seal groove on this side, expanding it
evenly.
a Combination of tools and pressure compensa- a You may push in the seal to the flat part of
tion valves tool P2 first, and then set tool P2 to the
piston and push in the seal.
PC228US, 228USLC-3E0 13
5. Insert piston (1) in tool P3 to fit seals (2) and Assembly of control valve assembly
(3). a For the tightening torque of each part, see
a Leave the piston inserted for about 1 minute Structure, function and maintenance standard,
to fit the seals thoroughly. “Control valve”.
a After removing the piston from tool P3, a Apply engine oil (SAE30) to the sliding sur-
check that the seals are not projected or faces of the parts before installing.
broken. 2 Mating face: Liquid seal
(SEALEND 242 or equivalent)
a Do not apply the liquid seal to the mating faces
of the lock valve and back pressure valve,
however.
a Tighten the mounting bolts of the merge-divider
valve, lock valve, back pressure valve, and cover
block in the order shown below.
6. Insert piston (3) in the sleeve of the pressure

compensation valve.
a If the piston is not inserted smoothly, do
not push in forcibly, but fit the seals more
with tool P3, and then insert the piston
again.
a After inserting the piston, push it with your
hand and check that it is returned by the
internal spring.
14 PC228US, 228USLC-3E0
Disassembly and assembly of work equipment PPC valve assembly 1
a Only precautions for assembling the work Assembly

equipment PPC valve assembly are explained a The head of plug (2) must not be projected
below. from the body (1) surface.
3 Plug (2): 6 – 11 Nm {0.6 – 1.1 kgm}
Disassembly a When installing plug (3) to body (1), check the
a Spring (6) and spring (7) consist of each one of insertion depth so that the tip of plug does not
two types of springs with different installed enter the inside Ø20 hole of the body.
loads in four places, so check the mounting 3 Plug (3): 4 – 9 Nm {0.4 – 0.9 kgm}
position (oil pressure port) and mark with tags a Install spring (5) with its small diameter side on
to prevent mistakes when installing. the shim (4) side.
q Diameter of spring (Inside diameter)
Small diameter side: Ø4.9 mm
Large diameter side: Ø5.55 mm
a When installing springs (6) and (7), note that
they are different and they must be installed to
different hydraulic ports.
q Installed height: 31.8 mm (Common to
both springs)
q Installed load:
Spring (6) (P1, P2): 35.3 N {3.6 kg}
Spring (7) (P3, P4): 21.6 N {2.2 kg}
a When installing piston (8), apply grease (G2-
LI) to its outside and the inside of the body (1)
hole.
3 Bolt (11):
11.8 – 14.7 Nm {1.2 – 1.5 kgm}
PC228US, 228USLC-3E0 15
a When installing joint (12) to body (1), apply

LOCTITE as shown below.
1) When installing the joint, apply 1 drop
(approx. 0.02 g) of LOCTITE (No. 648)
each to 2 places of the female screw (A)
of the body. Before installing the joint,
thoroughly degrease and dry its male
screw and the female screw of the body
with DRYSOL.
2) Drop LOCTITE to the following positions.
2 Female screw (A) of body:
LOCTITE No. 262
3 Joint (12): 39 – 49 Nm {4 – 5 kgm}
a Apply grease (G2-LI) to the sliding parts of joint

(12) and contact surfaces of disc (13) and pis-
ton (8).
2 Quantity of grease (G2-LI)
1) Sliding parts of joint: 2 – 4 cc/periphery
2) Contact surfaces of disc and piston:
0.3 – 0.8 cc/place
a When assembling disc (13), adjust it so that
the end play of the lever will be 0.5 – 3 mm at
200 mm from the center of revolution.
a See Testing and adjusting, "Adjusting play
of work equipment and swing PPC valve".
a Tighten nut (14) to the following tightening
torque.
3 Nut (14): 69 – 88 Nm {7 – 9 kgm}
16 PC228US, 228USLC-3E0
Disassembly and assembly of

travel PPC valve assembly 1
Special tool 5. Remove mounting bolt (10) to remove plate

(22).
New/Remodel
a Check the thickness and the mounting

Symbol
Necessity
Part No. Part name position of washer (18).

Sketch
a Remove pin (23) from body (1).

Q'ty
2 796T-416-1010 Push tool t 1 N Q 6. Remove seal (9) and collar (8).

E 3 796T-416-1030 Push tool t 1 N Q
7. Remove piston (7) to remove retainer (6),
4 796T-416-1020 Push tool t 1 N Q springs (5) and (4) and shim (3).
a Store shim (3) after checking the thickness
Disassembly and the number of shims at each mount-
1. Remove screw (20) and damper assembly ing position.
(16).
8. Remove valve (2) from body (1).
2. Remove mounting bolt (21) to remove case
(12), shaft (14) and lever (15) assembly.
3. Remove pin (3).
4. Remove lever (15), bushing (10), (11) and

shaft (14) from the case.
PC228US, 228USLC-3E0 17
Assembly 2) Using tool E3, insert busing (11) in case.

Only the precautions for assembling the travel PPC a Insert the bushing (11) from the 10°
valve assembly are described. chamfered side.
a Insert bushing (11) so that dimension
a When assembling, clean and inspect the parts (b) will be as follows.
closely and take care fully so that dirt, rust, q Dimension (b): 0 mm
flaw, etc. will not cause a trouble. a Do not drive the pin with direct impact
loads of a hammer etc.
a When installing piston (7), apply grease (G2-
LI) to its outside and the inside of the body
hole.
a Install spring (4) with its small diameter side on

the shim (3) side.
q Diameter of spring (Inside diameter)
Small diameter side: 4.9 mm, Large diam-
eter side: 5.55 mm
a Assemble shaft (14) in the following procedure.

1) Using tool E2, insert bushing (10) in case.
a Insert the bushing (10) from the 10°
chamfered side.
a Insert bushing so that dimension (a) 3) Insert lever (15).
will be as follows. 4) Insert shaft (14).
q Dimension (a): 20.4 ± 0.3 mm 5) Using tool E4, insert pin (13).
a Do not drive the bushing with direct a Insert pin (13) so that dimension (c)
impact loads of a hammer etc. will be as follows.
q Dimension (c): 0 – 0.5 mm
a Do not drive the pin with direct impact
loads of a hammer etc.
18 PC228US, 228USLC-3E0
aApply grease (G2-LI) to the rocking part of

shaft (14) and the contact surfaces of lever
(15) and piston (7) and the contact surfaces of
damper (16) and pin (17).
2 Quantity of grease (G2-LI)
Rocking part of shaft: 4 – 8 cc/periphery
Contact surfaces of lever (15) and piston (7):
0.3 – 0.8 cc/place
Contact surfaces of damper (16) and pin
(17): 0.3 – 0.8 cc/place
a Install washer (18) 1.6 mm thick first. If the dif-

ference between both sides at the stroke end
of the lever exceeds 0.7°, change the washer
thickness to reduce the difference to below
0.7°. (If the washer thickness is reduced by
0.3 mm, the stroke end angle is increased by
0.39°.)
q Thickness of washer (t):
1.0, 1.3, 1.6, 1.9, 2.2 mm
a Tighten each part to the following torque.

q Bolt (19): 27 – 34 Nm {2.8 – 3.5 kgm}
q Screw (20):
0.441 – 0.558 Nm {0.045 – 0.06 kgm}
q Bolt (21): 25 – 31 Nm {2.5 – 3.2 kgm}
q Bolt (24): 19.6 – 27.4 Nm {2.0 – 2.8 kgm}
q Plug (25): 24.5 – 34.3 Nm {2.5 – 3.5 kgm}
q Plug (26): 24.5 – 34.3 Nm {2.5 – 3.5 kgm}
q Plug (27): 9.8 – 14.7 Nm {1.0 – 1.5 kgm}
q Plug (28): 4 – 9 Nm {0.4 – 0.9 kgm}
q Plug (29): 6 – 11 Nm {0.6 – 1.1 kgm}
q Plug (30): 1.27 – 1.67 Nm {0.13 – 0.17
kgm}
PC228US, 228USLC-3E0 19
Disassembly and assembly of Disassembly

hydraulic cylinder assembly 1 Disconnection of cylinder assembly and piston rod
assembly
Special tools 1. Remove the piping from the cylinder assem-
bly.
Necessity
1) Remove the 12 mounting bolts and discon-
Symbol
Sketch
Part number Part name nect head assembly (1) from the cylinder.
Q’ty
N/R
2) Pull out piston rod assembly (2).
Cylinder repair
3) Put a container under the cylinder to receive
790-502-1003 q 1 oil.
1 stand
790-101-1102 Pump q 1
Wrench assem-
790-102-4300 t 1
2 bly
790-102-4310 Pin t 1
3 790-720-1000 Expander t 1
796-720-1660 Ring t 1
07281-01159 Clamp t 1
4
796-720-1670 Ring t 1
07281-01279 Clamp t 1
790-101-5021 Grip 1
Q
01010-50816 Bolt 1
2. Disassembly of cylinder assembly and pis-
5 790-201-1831 Push tool 1 ton rod assembly
790-201-1940 Push tool 1 1) Set piston rod assembly (2) to tool Q1.
790-201-1841 Push tool 1
790-201-1930 Push tool 1
790-201-5021 Grip 1
01010-50816 Bolt 1
6 790-201-1620 Push tool 1
790-101-1630 Push tool 1
790-201-1640 Push tool 1
790-201-1650 Push tool 1
20 PC228US, 228USLC-3E0
2) Remove lock screw (3) at the end of the 6) Remove cap (8), 12 balls (9), and plunger
piston assembly with a hexagonal wrench. (10).
q Screw size: 12 × 1.75 mm q Perform this work for only the arm cyl-
(length: 16 mm) inder.
a If screw (3) is so caulked that you
cannot remove it, tighten it tempo-
rarily and tap the threads on it, and
then remove it.
3. Disassembly of piston assembly

1) Remove 2 rings (11).
2) Remove 2 wear rings (12).
3) Remove piston ring (13).
3) Using tool Q2, remove piston assembly (4). 4) Remove the O-ring and 2 backup rings (14).
4) Remove plunger (5) and collar (6). 4. Disassembly of cylinder head assembly
q Perform this work for only the arm cyl- 1) Remove the O-ring and backup ring (15).
inder. 2) Remove snap ring (16) and dust seal (17).
5) Remove cylinder head assembly (7). 3) Remove rod packing (18) and buffer ring
(19).
4) Remove bushing (20).
PC228US, 228USLC-3E0 21
5. Disassembly of cylinder assembly (For only 2. Assembly of cylinder head assembly

arm cylinder) 1) Using tool Q5, press fit bushing (20).
1) Remove plug (21). 2) Install buffer ring (19) and rod packing (18).
2) Remove spring (22) and valve (23). 3) Using tool Q6, install dust seal (17) and
secure it with snap ring (16).
4) Install backup ring (15) and O-ring.
Assembly
a Take care not to damage the packings, dust
seals, O-rings, etc.
a Clean the all parts. After installing them, cover
the piping ports and pin holes to prevent dirt
from entering.
a Do not insert each backup ring forcibly, but
warm it in water at 50 – 60°C and then insert it.
1. Assembly of cylinder head assembly (For

only arm cylinder)
1) Install valve (23) and spring (22).
2) Fit the O-ring and install plug (21).
a Clean and dry the threads of the plug,
and then apply gasket sealant (LG-5) to 3. Assembly of piston assembly
all the periphery of the threaded part. 1) Set piston ring (13) to tool Q3 and turn the
3 Plug: 83.4 – 147 Nm {8.5 – 15.0 kgm} handle 8 – 10 times to expand the piston
ring.
2) Remove piston ring (13) from tool Q3 and
install it to the piston.
3) Set tool Q4 and contract piston ring (13).
22 PC228US, 228USLC-3E0
4) Install 2 backup rings (14) and O-ring.

a Install the backup rings and O-ring as
shown in the figure.
5) Install wear rings (12).
6) Install rings (11).
a Do not increase the closed gap of the
ring too much.
5) Set plunger (10) to the piston rod assem-

bly. Install 12 balls (9) and secure them
with cap (8).
a After installing the plunger, check that
it has a little play at its end.
q Perform this work for only the arm cyl-
inder.
4. Assembly of piston rod assembly
1) Set piston rod assembly (2) to tool Q1.
6) When reusing both of the piston rod

assembly (2) and piston assembly (4),
2) Install cylinder head assembly (7). assemble them according to the following
3) Fit the O-ring and backup rings to collar procedure. (When replacing either or both
(6), and then install them to the piston rod. of them with new ones, see 7).)
a Install the 2 backup rings to before i) Using tool Q2, install piston assembly
and after the O-ring. (4) to the piston rod assembly (2).
q Perform this work for only the arm cyl- a If there is any burr on the threaded
inder. part, remove it with a file in advance.
4) Install plunger (5).
q Perform this work for only the arm cyl-
inder.
PC228US, 228USLC-3E0 23
a Tighten the piston assembly (4) a If the cylinder has the head cush-
fully until it touches rod end (b), ion, check that plunger (5) has a
and then match the holes (H) of little play after installing the pis-
the piston and rod end screw ton assembly (4).
near that point.
a If the cylinder has the head cush-
ion, check that plunger (5) has a
little play after installing the pis-
ton assembly (4).
ii) Make a screw hole on piston assem-

bly (4) and the piston rod assembly
(2) at the threaded part.
a Apply a drill to the V-groove of
the piston assembly (4) and the
ii) Install screw (3) to secure the piston threaded part of the piston rod
assembly (4) and piston rod assembly assembly (2) and make a hole
(2). horizontally.
2 Screw: a For the cylinder with bottom cush-
Adhesive (LOCTITE #262) ion (arm cylinder), avoid the cap
3 Screw: machining holes position when
58.9 – 73.6 Nm {6 – 7.5 kgm} machining.
a After tightening the screw (3), q Dimensions of a screw hole
caulk 4 places (a) around it.
Tap drill diameter 10.3 mm
Tap drill hole depth 24 mm
Screw hole size 12 × 1.75 mm
Screw hole depth 20 mm
a After threading the hole, remove

all the chip and dirt from it.
7) When replacing either or both of them with

new ones, assemble the new ones
i) Using tool Q2, tighten piston assembly
(4) until it touches rod end (b).
a If the cylinder has the bottom
cushion, make a mark of the
tightening position of the ball cap
at the rod end.
3 Piston assembly:
294 ± 29.4 Nm {30 ± 3.0 kgm}
24 PC228US, 228USLC-3E0
iii) Install screw (3) to secure the piston 2) Tighten the mounting bolts of cylinder head
assembly (4) and piston rod assembly assembly (1).
(2). 3 Mounting bolt:
2 Screw: Boom cylinder:
Adhesive (LOCTITE #262) 270 ± 39 Nm {27.5 ± 4.0 kgm}
3 Screw: Arm cylinder:
58.9 – 73.6 Nm {6 – 7.5 kgm} 375 ± 54 Nm {38.0 ± 5.5 kgm}
a After tightening the screw (3), Bucket cylinder:
caulk 4 places (a) around it. 270 ± 39 Nm {27.5 ± 4.0 kgm}
5. Connection of cylinder assembly and pis- 3) Install the piping.

ton rod assembly a Tighten the mounting bolt of the pipe
1) Install piston rod assembly (2) to the cylin- band to the following torque.
der assembly. 3 Band bolt:
a Set abutment joint (c) of the ring at a 27 ± 7 Nm {2.8 ± 0.7 kgm}
side and insert the piston rod, aligning
it with the cylinder tube.
a After inserting the piston rod, check
that the ring is not broken or
removed, and then insert to the end.
PC228US, 228USLC-3E0 25
SEN01927-02

© 2010 KOMATSU
All Rights Reserved
26
SEN01928-01
PC228US-3E0
PC228USLC-3E0


Work equipment
Removal and installation of work equipment assembly .................................................................................. 2
Removal and installation of work 4. Remove head pin (5). [*2]

equipment assembly 1 a Check the quantity and positions of the
inserted shims.
Special tools
Necessity
Symbol
Sketch
Q’ty
N/R
796-900-1200 Remover t 1
Puller
(490 kN {50 tons}) t 1
V 790-101-4000
Removal
k Extend the arm and bucket fully, lower the
work equipment completely to the ground, 5. Start the engine and retract the piston rod of
and set the lock lever to the LOCK position. the boom cylinder to lower the boom cylinder
k Disconnect the cable from the negative (–) onto a stand.
terminal of the battery. a Bind the rod with wires, etc. so that it will
not be extracted.
1. Disconnect grease hose (1). a Disconnect the boom cylinder on the
opposite side similarly according to steps
2. Sling boom cylinder assembly (2) temporarily 1 – 5.
and remove lock bolt and nut (3). [*1] k Release the residual pressure in the boom
cylinder circuit. For details, see “Releasing
3. Remove plate (4). residual pressure in hydraulic circuit”.
6. Disconnect the hoses (6) for the arm cylinder Installation

and bucket cylinder (4 pieces in total) and put q Carry out installation in the reverse order to
oil stopper plugs. removal.
7. Disconnect working lamp connector (CN-A42). [*1]

a Tighten the locknut so that clearance (a)
8. Remove covers (7) and (8) and boom angle between the plate and nut will be 0.5 – 1.5
potentiometer (9). [*3] mm.
a See Testing and adjusting, “Replacement
procedure for boom angle potentiometer”.
[*2]
2 Inside wall of bushing before assem-
bling pin:
Anti-friction composition (LM-P)
2 Greasing after assembling pin:
Grease (LM-G)
k When aligning the pin holes, never insert
your fingers in them.
a Adjust the shim thickness so that clear-
ance (b) between cylinder rod (12) and
plate (13) will be 1 mm or less.
a Standard shims: 0.8, 1.5 mm
9. Sling work equipment assembly (9). Using tool V,

remove foot pin (10). Remove the work equip-
ment assembly. [*4]
4 Work equipment assembly: 3,400 kg
[*3]
a Initialize the boom positioner. For details,
see Testing and adjusting, “Special func-
tions of machine monitor”.
[*4]
2 Inside wall of bushing before assem-
bling pin:
Anti-friction composition (LM-P)
2 Greasing after assembling pin:
Grease (LM-G)
k When aligning the pin holes, never
insert your fingers in them.
a Adjust the shim thickness so that clear-
ance (c) between boom (13) and bracket
(14) will be 1 mm or less.
a Standard shims: 0.8, 1.0, 1.5 mm
q Bleeding air
Bleed air. For details, see Testing and adjust-
ing, “Bleeding air from each part”.

SEN01928-01

© 2009 KOMATSU
All Rights Reserved
6
SEN01929-01
PC228US-3E0
PC228USLC-3E0


Cab and its attachments
Removal and installation of operator’s cab assembly..................................................................................... 2
Removal and installation of operator’s cab glass (Stuck glass) ...................................................................... 4
Removal and installation of front window assembly ..................................................................................... 13
Removal and installation of floor frame assembly ........................................................................................ 14
Removal and installation of 6. Remove covers (9) – (12).

operator’s cab assembly 1
Removal
2. Remove covers (2) – (5) in order.

a When removing cover (3), disconnect cig-
arette lighter connector CN-M19.
7. Remove covers (13) – (15).
3. Remove duct (6) and the duct on the right of

the operator's seat.
4. Disconnect air conditioner mode duct connec-

tor CN-M88 (7). 8. Disconnect connectors CN-M45 (16), CN-H08
(17), CN-H09 (18), CN-M31 (19), and CN-M03
5. Disconnect windshield washer hose (8). (20).
9. Remove duct (21).
10. Disconnect connectors CN-K19 (22) and CN- Installation

K20 (23). q Carry out installation in the reverse order to
removal.
11. Remove the mounting bolts of engine throttle
and pump controller (24) and move it and its [*1]
wiring harness toward the operator's seat. a Before tightening the bolts and nuts, check
that there is not clearance on the mounting
face.
12. Disconnect connectors CN-H10 (25), CN-H11

(26), CN-H12 (27), and CN-M87 (28).
13. Remove ducts (29) and (30).
14. Remove the 6 mounting bolts and 4 mounting

nuts and lift off operator's cab assembly (31).
[*1]
a Check that all the wires are disconnected.
4 Operator's cab assembly: 250 kg
Removal and installation of operator’s cab glass (Stuck glass) 1
a Among the panes of window glass on the 4 (1) : Right side window glass
sides of the operator's cab, 5 panes (1) – (5) (2) : Left side rear window glass
are stuck. (3) : Door upper window glass
In this section, the procedure for replacing the (4) : Door lower window glass
stuck glass is explained. (5) : Front window glass
When replacing front window glass (5), remove (6) : Front window assembly
front window assembly (6). (It is impossible to (Front window glass + Front frame)
replace only the front window glass while the (7) : Both-sided adhesive tape
front window assembly is installed to the oper- (16) : Center trim seal
ator's cab.)
For the procedure for replacing the front win-
dow assembly, see “Removal and installation
of front window assembly”.
Special tools Installation

1. Using a knife and scraper [5], remove the
Necessity
Symbol
remaining adhesive and both-sided adhesive
Sketch
Part number Part name tape from the metal sheets (glass sticking sur-
Q’ty
N/R
faces) of the operator's cab.
Lifter a Remove the adhesive and both-sided
1 793-498-1210 t 2
X (Suction cup) adhesive tape to a degree that they will
2 20Y-54-13180 Adapter t 2 not affect adhesion of the new adhesive.
Take care not to scratch the painted sur-
faces.
(If the painted surfaces are scratched,
Removal adhesion will be lowered.)
a Remove the window glass to be replaced
1. Using seal cutter [1], cut the adhesive between

broken window glass (9) and operator's cab
(metal sheet) (8).
2. Remove oil, dust, dirt, etc. from the sticking

surfaces of cab (8) and window glass (9) with
white gasoline.
a If the sticking surfaces are not cleaned
well, the glass may not be stuck perfectly.
a Clean the all black part on the back side of
a If a seal cutter is not available, widening the window glass.
the cut with a screwdriver, cut the adhe- a After cleaning the sticking surfaces, leave
sive and both-sided adhesive tape with them for at least 5 minutes to dry.
knife [4].
k If the window glass is broken finely, be
careful not to harm yourself.
2. Remove the window glass.
3) Evenly apply paint primer to the surfaces

to stick both-sided adhesive tapes and the
surfaces out of those surfaces on opera-
tor's cab (8) which will be coated with the
adhesive.
2 Paint primer: SUNSTAR PAINT
PRIMER 580 SUPER or equivalent
a Do not apply the primer more than 2
times. (If it is applied more than 2 times,
its performance will be lowered.)
3. Apply primer (10).

a The using limit of primer (10) is 4 months
after the date of manufacture. Do not use
primer (10) after this limit.
a Use the primer within 2 hours after unpack-
ing it.
a Even if the primer is packed again just
after it is unpacked, use it within 24 hours
after it is unpacked for the first time.
(Discard the primer 24 hours after it is
a Parts to be coated with primer: Apply
packed.)
the primer all over dimension (a).
1) Stir the primers for paint and glass suffi-
q Dimension to apply primer (a):
ciently before using them.
25 mm
a If the primer has been stored in a
refrigerator, leave it at the room tem-
perature for at least half a day before
stirring it.
(If the primer is unpacked just after
taken out of the refrigerator, water will
be condensed. Accordingly, leave the
primer at the room temperature for a
sufficient time.)
2) When reusing primer brush (11), wash it in
white gasoline.
a After washing the brush, check it
again for dirt and foreign matter.
a Prepare respective brushes for the
paint primer glass primer.
a As for right side window glass (1), a Never apply wrong primer. If the glass
apply the primer to only the surfaces primer is applied by mistake, wipe it
to stick both-sided adhesive tapes off with white gasoline.
and the surfaces out of those sur-
faces.
q Part (b)
a After applying the primer, leave it for at
least 5 minutes (within 8 hours) to dry.
4. Stick both-sided adhesive tape (7) along the

inside edge of the glass sticking section.
a Do not remove the release tape of the
both-sided adhesive tape on the glass
sticking side before sticking the glass.
a Never apply wrong primer. If the glass a When sticking the both-sided adhesive
primer is applied by mistake, wipe it tape, do not touch the cleaned surface as
off with white gasoline. long as possible.
4) Evenly apply glass primer to the sticking a Take care that the both-sided adhesive
surfaces of window glass (9). tape will not float at each corner of the
2 Glass primer: SUNSTAR GLASS window frame.
PRIMER 580 SUPER or equivalent
a Do not apply the primer more than 2
times. (If it is applied more than 2 times,
its performance will be lowered.)
a Parts to be coated with primer: Apply

the primer to the sticking surfaces of
window glass (9) and all over dimen-
sion (d) which will be on both-sided
adhesive tape (7) and operator's cab
(8).
a Do not apply the primer to the boarder
about 5 mm wide between the black
part and transparent part of the glass.
a After applying the primer, leave it for at
least 5 minutes (within 8 hours) to dry.
a When sticking both-sided adhesive tape 2) Stick both-sided adhesive tape (7) for left
(7) around a frame, do not lap its finishing side rear window glass (2) as shown in the
end over the starting end but make clear- figure.
ance (e) of about 5 mm between them.
1) Stick both-sided adhesive tape (7) for right
side window glass (1) as shown in the fig-
ure.
3) Stick both-sided adhesive tape (7) for door

upper window glass (3) and door lower
window glass (4) as shown in the figure.
(The figure shows the door upper window
a Stick both-sided adhesive tape (7a) glass.)
additionally for right side window
glass (1).
q Positions to stick additional both-
sided adhesive tape for right side win-
dow glass:
(f): 140 mm
(g): 500 mm
(The figure shows the door lower window

glass.)
4) Stick both-sided adhesive tape (7) for front

window glass (5) as shown in the figure.
a Both-sided adhesive tape: 1,004 mm ×
2 pieces
a When positioning front window glass

(5), set its horizontal and vertical posi-
tions as shown below.
Part (m) (Right side):
q Details of the sticking positions are as Project by “3.8 mm” from the
follows. frame end.
(h): Stick to inside end of right and left Part (o) (Upper side):
front frames (17). Retract by “3.0 mm” from the
(j): Retract by “3.0 mm” from the end frame end.
of front frame (17).
5. Position the new window glass.

1) Check the clearance between the window
glass and the operator's cab on the right,
left, upper, and lower sides, and then
adjust it evenly.
2) Stick tapes [6] between window glass (9)
and operator's cab (8) and draw position-
ing line (n).
a Stick tapes [6] to the right, left, and
lower parts of the right side window
glass, left side rear window glass, and
door lower window glass (upper and
lower) for accurate positioning.
3) Cut the tape between window glass (9)
and operator's cab (8) with a knife, and
then remove the window glass.
a Do not remove the tapes left on the
window glass and operator's cab
before installing the window glass.
6. Apply adhesive.
a Use either of the 2 types of the adhesive.
2 Adhesive (April – October): SUNSTAR
PENGUINE SEAL 580 SUPER “S”
2 Adhesive (October – April): SUNSTAR
PENGUINE SEAL 580 SUPER “W”
a The using limit of the adhesive is 4 months
after the date of manufacture. Do not use
the adhesive after this limit.
a Keep the adhesive in a dark place where
the temperature is below 25°C.
a Never heat the adhesive higher than 30°C.
a When reusing the adhesive, remove the
all hardened part from the nozzle tip.
1) Break aluminum seal (13) of the outlet of 4) Remove the release tape of the both-
adhesive cartridge (12) and install the sided adhesive tape on the glass side.
nozzle. 5) Apply adhesive (15) to the outside of both-
sided adhesive tape (7) of the operator's
cab.
2) Cut the tip of the adhesive nozzle (14) so

that dimensions (q) and (r) will be as follows.
q Dimension (q): 10 mm a Apply adhesive (15) to dimensions (s)
q Dimension (r): 15 mm and (t) of both-sided adhesive tape
(7) of operator's cab (8).
q Dimension (s): 10 mm
q Dimension (t): 15 mm
a Apply adhesive (15) higher than both-
sided adhesive tape (7).
a Apply the adhesive evenly.
3) Set adhesive cartridge (12) to caulking gun

[7].
a An electric caulking gun is more efficient.
10 PC228US, 228USLC-3E0
a As for the right side window glass,

apply the adhesive to the outside of
the both-sided adhesive tape on the
periphery of the glass.
a After installing front window glass (5),

install the center trim seal to its bot-
tom. Then, apply caulking material all
around the glass to fill part U between
7. Install the window glass. the glass and center trim seal.
1) Install window glass (9), matching it to the a When caulking, neatly arrange the
lines of the positioning tapes drawn in step 5. form of the adhesive at the right and
a Since the window glass cannot be left ends with a rubber spatula.
removed and stuck again, stick it very 2 Adhesive: Sikaflex 256HV manu-
carefully. factured by Sika Japan
a Stick the glass within 5 minutes after
applying the adhesive.
2) After sticking window glass (9), press all
around it until it is stuck to the both-sided
adhesive tape.
a Press the corners of the window glass
firmly.
a You can perform this work efficiently

by pulling window glass (9) from
inside of the operator's cab with suc-
tion cup X1.
(The figure shows the operator's cab
of PC200-7.)
PC228US, 228USLC-3E0 11
8. Fix the window glass. 9. After installing the window glass, remove the
1) After installing right window glass (1) to primer and adhesive from the operator's cab
the operator's cab, insert stopper rubbers and window glass.
X2 to 2 places (v) at the bottom of the a Using white gasoline, wipe off the adhe-
glass to fix the glass. sive before it is dried up.
(The figure shows the operator's cab of a When cleaning the glass, do not give an
PC200-7.) impact to it.
10. Protect the stuck window glass.

1) Keep the stopper rubbers, styrene foam
blocks, and rubber bands installed for 10
hours (at temperature of 20°C and humid-
ity of 60%).
2) After removing the stopper rubbers, sty-
rene foam blocks, and rubber bands, wait
at least 14 hours, at least 24 hours in total,
before operating the machine actually.
(The figure shows the operator's cab of

PC200-7.)
2) Using styrene foam blocks [9] and rubber

bands [10], fix the window glass and both-
sided adhesive tape to fit them completely.
(The figure shows the operator's cab of
PC200-7.)
12 PC228US, 228USLC-3E0
Removal and installation of front

window assembly 1

the ground and stop the engine.
a To replace the front window glass, the front
window assembly must be removed from the
operator's cab. The procedure for removing
and installing the front window assembly (front
frame and front window glass) is explained
below.
Removal
1. Raise the front window assembly to the ceiling
and fix it with the rear locks (on the right and
left sides).
2. Remove left lower corner block (1) and right

lower block (2).
5. Twist front window assembly (3) to the right

and left to remove right and left upper rollers
(6) and (7) from the rails, and then remove
front window assembly (3).
a For (6) and (7), see the figure above.
3. Reset the lock at the rear of the cab.
4. Lower front window assembly (3) carefully a lit-

tle. Put out rollers (4) and (5) under the right
and left sides of the front window through the
portion from which the right and left lower
blocks were removed in step 2 (the bottom of
the rails).
Installation
removal.
PC228US, 228USLC-3E0 13
Removal and installation of floor

frame assembly 1
Removal
ual pressure in hydraulic circuit”, release
the residual pressure in the hydraulic cir-
cuit.
k In the case that you do not drain the cool-
ant, if you disconnect the heater hose when
the coolant temperature in the radiator is
high, you may be scalded. In this case, wait 5. Disconnect PPC hoses (2) (port P) and (3)
until the coolant temperature lowers and (port T) and travel PPC valve hoses (4) (4
then disconnect the heater hose. pieces).
k Collect the air conditioner refrigerant You may disconnect travel PPC valve hoses
(R134a) from air conditioner circuit in (4) (4 pieces) from the control valve.
advance.
a Ask professional traders for collecting and fill-
ing operation of refrigerant (R134a).
a Never release the refrigerant (R134a) to the
atmosphere.
k If refrigerant gas (R134a) gets in your eyes,

you may lose your sight. Accordingly, put
on protective goggles while you are collect-
ing the refrigerant (R134a) or filling the air
conditioner circuit with the refrigerant
(R134a). Collecting and filling work must be
conducted by a qualified person.
q Quantity of refrigerant: 700 ± 50 g

1. Turn the upper structure by 90°.
2. Remove the operator's cab assembly.

For details, see “Removal and installation of
operator's cab assembly”.
3. Remove the cover under the operator's cab.
4. Disconnect heater hoses (1) (2 pieces).

a Cover the battery relay, starting motor
safety relay, electrical intake air heater
relay, and other electric parts to protect
from the coolant.
14 PC228US, 228USLC-3E0
6. Remove control valve top cover (5) and front a Remove clamp (8) at the right front of the
cover (6) under the boom foot (to remove the revolving frame and clamp (9) in the boom
clamp). foot cover at the center. When disconnect-
ing the travel PPC hose from the control
valve, remove clamp (9) on the deeper
side (rear side), too.
7. Disconnect hoses (7) (8 pieces) for the work

equipment and swing PPC valve. [*2]
a The following color bands are put to the
PPC hoses in order from above. 8. Disconnect air conditioner hoses (10) and (11)
q For bucket CURL : White from the air conditioner unit. [*3]
q For boom LOWER : Brown
q For swing LEFT : No band
q For arm IN : Blue
q For bucket DUMP : Black
q For boom RAISE : Green
q For swing RIGHT : Red
q For arm OUT : Yellow
9. Lift off floor frame assembly (12).

4 Floor frame assembly: 270 kg
PC228US, 228USLC-3E0 15
Installation
removal.
[*1]
a Using tool A8, charge the air conditioner
circuit with refrigerant (air conditioner gas
R134a).
[*2]
a Connect the PPC hoses, checking their
band colors.
q For bucket CURL : White
q For boom LOWER : Brown
q For swing LEFT : No band
q For arm IN : Blue
q For bucket DUMP : Black
q For boom RAISE : Green
q For swing RIGHT : Red
q For arm OUT : Yellow
[*3]
a Install hoses in the air conditioner circuit
with care so that dirt, dust, water, etc. may
not enter them.
a Install air conditioner hoses only after
checking that an O-ring is in place at the
connecting part.
a Check that there is no damage on O-rings,
or that they have not deteriorated.
a When connecting the refrigerant piping,
coat the O-ring with compressor oil for
R134a (DENSO: ND-OIL 8, ZEXEL: ZXL
100 PG (PAG 46 or equivalent)) and
tighten the nuts with 2 spanners.
3 Hose clamp (M6 bolt):
8 – 12 Nm {0.8 – 1.2 kgm}
3 Hose screw M16 × 1.5:
12 – 15 Nm {1.2 – 1.5 kgm}
20 – 25 Nm {2.0 – 2.5 kgm}
30 – 35 Nm {3.0 – 3.5 kgm}

q Refilling with coolant

Add coolant through the coolant filler to the
specified level. Run the engine to circulate the
coolant through the system. Then, check the
coolant level again.
16 PC228US, 228USLC-3E0
PC228US, 228USLC-3E0 17
SEN01929-01

© 2009 KOMATSU
All Rights Reserved
18
SEN01930-01
PC228US-3E0
PC228USLC-3E0


Electrical system
Removal and installation of air conditioner compressor assembly ................................................................. 2
Removal and installation of air conditioner condenser assembly ................................................................... 4
Removal and installation of air conditioner unit assembly .............................................................................. 5
Removal and installation of machine monitor assembly ................................................................................. 7
Removal and installation of pump controller assembly ................................................................................... 8
Removal and installation of engine controller assembly ................................................................................. 9
Removal and installation of KOMTRAX communication modem assembly...................................................11
Removal and installation of air 6. Loosen 2 mounting bolts (4) and then remove
conditioner compressor air conditioner compressor belt (5) from the
pulleys.
assembly 1
7. Remove 2 mounting bolts (4) and air condi-
Removal
k
tioner compressor and bracket assembly (6).
Disconnect the cable from the negative (–)
[*3]
8. Remove 4 air conditioner compressor mount-
ing bolts (7).
high, you may be scalded. In this case, wait
9. Disconnect air conditioner compressor from
until the coolant temperature lowers and
the bracket. [*4]
then disconnect the heater hose.
k Collect the air conditioner refrigerant
(R134a) from air conditioner circuit in
advance.
atmosphere.

2. Open the engine hood and remove step (1).
3. Disconnect wiring connector (2) (CN-E06).
4. Collect the air conditioner refrigerant. [*1]
5. Disconnect 2 hoses (3). [*2]

a Plug the hoses to prevent dirt and water
from entering them.
a Take care not to damage or lose the O-rings.
Installation
removal.
[*1]
R134a).
[*2]
a When installing the air conditioner circuit
hoses, take care that dirt and water will
not enter them.
a When installing each air conditioner hose,
check that the O-ring is fitted to the joint.
a Check each O-ring for a flaw and deterio-
ration.
a When connecting the refrigerant piping,
coat the O-ring with compressor oil for
100 PG (PAG 46 or equivalent)) and
3 Hose flange mounting bolt (M6 bolt):
8 – 12 Nm {0.8 – 1.2 kgm}
[*3]
a Adjust the air conditioner compressor belt
tension. For details, see Testing and adjust-
ing, “Testing and adjusting air conditioner
compressor belt tension”.
[*4]
When 4 air compressor mounting bolts (24a) were
loosened, tighten them by the following torque.
a If the air compressor mounting bolts are tight-
ened above the specified torque, inside of the
air conditioner compressor may have damage.
3 Air conditioner compressor mounting torque:
27 – 34 Nm {2.8 – 3.5 kgm}
Removal and installation of air 3. Remove 4 mounting bolts (3) for the air condi-
conditioner condenser assembly1 tioner condenser and then remove air condi-
tioner condenser (3).
Removal a Take care not to damage the core of the
k Disconnect the cable from the negative (–) air conditioner condenser.
advance.
atmosphere.
Installation
k If refrigerant gas (R134a) gets in your eyes, q Carry out installation in the reverse order to
you may lose your sight. Accordingly, put removal.
ing the refrigerant (R134a) or filling the air [*1]
conditioner circuit with the refrigerant Using tool A8, charge the air conditioner circuit
(R134a). Collecting and filling work must be with refrigerant (air conditioner gas R134a).
2. Disconnect hoses (1) and (2) from the air con-

ditioner condenser.
Removal and installation of air 4. Remove ducts (6) and (7) and the duct on the
conditioner unit assembly 1 right of the operator's seat.
Removal 5. Disconnect the air conditioner hose (8) from air

k Disconnect the cable from the negative (–) conditioner unit. [*2]
advance.
atmosphere.

3. Remove covers (2) – (5) in order.
a When removing cover (3), disconnect cig-
arette lighter connector CN-M19.
8. Disconnect connector CN-M87 (16). Installation

9. Remove ducts (17) and (18). removal.
[*1]
R134a).
[*2]
a When installing the air conditioner circuit
hoses, take care that dirt and water will
not enter them.
a When installing each air conditioner hose,
check that the O-ring is fitted to the joint.
a Check each O-ring for a flaw and deterio-
ration.
10. Disconnect connectors CN-M26 (19), CN-M85 a When connecting the refrigerant piping,
(20), and CN-M84 (21). coat the O-ring with compressor oil for
11. Disconnect heater hoses (22) and (23). 100 PG (PAG 46 or equivalent)) and
3 Hose clamp (M6 bolt):
8 – 12 Nm {0.8 – 1.2 kgm}
12 – 15 Nm {1.2 – 1.5 kgm}
20 – 25 Nm {2.0 – 2.5 kgm}
30 – 35 Nm {3.0 – 3.5 kgm}
12. Remove the seat stand mounting bolts (5

pieces). Tighten bolts [1] (M12, L = 100 mm)
into the seat stand lifting nuts (2 on the left and
1 on the right) to lift up the seat stand.
13. Remove the air conditioner unit mounting bolts

(6 pieces) and pull out air conditioner unit
assembly (25) from under the operator's seat
to remove it.
Removal and installation of 4. Disconnect connectors P07 (3), P02 (4), and
machine monitor assembly 1 P01 (5).
a Connector No.
Removal q (3) : P07
k Disconnect the negative terminal (–) of the q (4) : P02
battery before starting the work. q (5) : P01
Installation
2. Remove mounting bolt (2). q Carry out installation in the reverse order to
removal.
3. Pull machine monitor assembly.
a Pull it carefully to avoid cutting wires.
Removal and installation of pump Installation

controller assembly 1 q Carry out installation in the reverse order to
removal.
Removal
k Disconnect the negative (–) terminal of the
battery before starting the work.
3. Disconnect connectors (6), (7) and (8).
4. Remove 4 mounting bolts (9) for pump control-

ler assembly.
5. Remove pump controller assembly (10).
Removal and installation of 3. Remove 3 controller mounting nuts (5). [*1]

engine controller assembly 1 a Bolts (5) are used to fix the wiring harness
clamps, too.
Removal
k Disconnect the cable from the negative (–) 4. Remove 2 controller mounting bolts (6) and
terminal of the battery. (7). [*2]
a Bolt (6) is used to fix ground wire (E), too.
1. Remove counterweight (1). For details, see
“Removal and installation of maintenance coun- 5. Remove engine controller (8).
terweight assembly (at rear part of engine)”.
2. Disconnect connectors (2), (3) and (4).

a Connectors (2) and (3) are locked with
hexagon socket head bolts [L1] (4 mm).
a When disconnecting connector (4), press
its lock.
Installation [*1]
q Carry out installation in the reverse order to When installing mounting bolts (5), fix the wir-
removal. ing harness clamp, too.
a Reference [*2]
q Method of replacing O-ring of power sup- When installing mounting bolt (6), fix ground
ply connector (9) wire (E), too.
O-ring seal: 1010-074-0406
(NIHON-DEUTSH LIMITED)
1) Using tweezers [1], hold the claw and take
out cover (10).
2) Using tweezers [1], take out O-ring (11).
10 PC228US, 228USLC-3E0
Removal and installation of

KOMTRAX communication
modem assembly 1
Removal
k Disconnect the negative (–) terminal of the
battery before starting the work.
3. Remove mounting bolts (3).
4. Remove KOMTRAX communication modem

assembly (4).
Installation
removal.
PC228US, 228USLC-3E0 11
SEN01930-01

© 2009 KOMATSU
All Rights Reserved
12
SEN01439-01
PC228US-3E0
PC228USLC-3E0

90 Diagrams and drawings 1

Hydraulic diagrams and drawings
Hydraulic circuit diagram................................................................................................................................. 3
PC228US, USLC-3E0 1
SEN01439-01 90 Diagrams and drawings
2 PC228US, USLC-3E0
Hydraulic circuit diagram (1/2)
Hydraulic circuit diagram (1/2) PC228US, USLC-3E0
SEN01439-01
PC228US, USLC-3E0 3
Hydraulic circuit diagram (2/2)
PC228US, USLC-3E0 5
SEN01439-01

© 2009 KOMATSU
All Rights Reserved
6
SEN01440-02
PC228US-3E0
PC228USLC-3E0

90 Diagrams and drawings 1

Electrical diagrams and drawings
Electrical circuit diagram ................................................................................................................................. 3
Connector list and stereogram...................................................................................................................... 17
PC228US, USLC-3E0 1
SEN01440-02 90 Diagrams and drawings
2 PC228US, USLC-3E0
Electrical circuit diagram (1/7)
Electrical circuit diagram (1/7) PC228US, USLC-3E0
SEN01440-02
PC228US, USLC-3E0 3
SEN01440-02
PC228US, USLC-3E0 5
SEN01440-02
PC228US, USLC-3E0 7
SEN01440-02
PC228US, USLC-3E0 9
SEN01440-02
SEN01440-02
Connector list and stereogram
PC228US, USLC-3E0
Connector list and stereogram PC228US-3E0, PC228USLC-3E0
Number Address of Number Address of

Connector No. Model Component name Connector No. Model Component name
of pins stereogram of pins stereogram
A01 X 4 Intermediate connector (Power supply system) L-2 M31 M 2 Optional power supply 2 Y-2
A02 X 4 Intermediate connector (Power supply system) M-2 M32 M 2 Optional power supply 1 W-1
A03 SWP 12 Intermediate connector L-1 M33 M 2 12V optional power supply Z-2
A04 SWP 12 Intermediate connector L-1 M40 YAZAKI 2 Cab headlamp (Left) AD-7
A05 SWP 16 Intermediate connector L-2 M41 YAZAKI 2 Cab headlamp (Right) AC-7
A06 SWP 14 Intermediate connector L-1 M45 DT 12 Network bus AA-5
A07 SWP 16 Intermediate connector M-1 M71 M 2 Room lamp AH-8
A08 SWP 12 Intermediate connector M-1 M72 M 4 DC/DC converter (12V power supply) (If equipped) Z-3
A10 Terminal 1 Revolving frame ground M-2 M73 M 2 Speaker (Left) AH-8
A11 Terminal 1 Revolving frame ground M-3 M79 YAZAKI 2 12V outlet (If equipped) AA-6
A12 Terminal 1 Revolving frame ground M-3 M87 S 12 Air conditioner unit V-1
A13 Terminal 1 Revolving frame ground M-3 M88 YAZAKI 9 Air conditioner floor air outlet servo R-2
A15 Terminal 1 Revolving frame ground N-1 N08 DT 12 Service connector Y-9
A16 Terminal 1 Revolving frame ground N-2 OIL PRESURE Terminal 1 Engine oil pressure switch AM-1
SWIITCH
A30 Terminal 2 Air conditioner external air sensor M-4
P01 '070 12 Machine monitor P-5
A42 DT 2 Intermediate connector (Boom working lamp) I-1
A43 DT 3 Travel alarm AJ-6
P03 AMP 3 Swing left pressure sensor A-6
A51 AMP 3 Front pump pressure sensor F-1
P04 X 2 Arm in pressure switch A-6
A52 AMP 3 Rear pump pressure sensor E-8
P05 X 2 Bucket dump pressure switch A-6
A53 DT 3 Boom angle potentiometer (if equipped) H-9
P06 X 2 Boom raise pressure switch A-6
AB Terminal 1 Alternator B terminal AL-9
P07 AMP 3 Swing right pressure sensor A-6
AC02 X 1 Air conditioner compressor electromagnetic clutch AJ-4
P08 X 2 Arm dump pressure switch A-5
AMBAIR
PRESURE FRAMTOME 3 Ambient air pressure sensor AI-2 P09 X 2 Travel pressure switch S-1
BOOST SUMITOMO 4 Boost pressure/temperature sensor AK-5 P10 X 2 Travel steering pressure switch T-1
PRESS&IMT
P11 X 2 Bucket curl pressure switch A-7
CAM SENSOR FRAMTOME 3 Engine Bkup speed sensor AI-1
P12 X 2 Boom lower pressure switch A-6
CE01 DRC 60 Engine controller AK-1
P15 '050 2 Daylight sensor P-6
CE02 DRC 50 Engine controller AJ-1
P20 M 3 Fuel control dial S-7
CE03 DTP 4 Engine controller AK-1
P21 X 2 Fuel level sensor AI-8
COOLANT TEMP PACKARD 2 Coolant temperature sensor AI-3
P22 DT 2 Hydraulic oil temperature sensor AJ-6
CP01 DRC 24 Pump controller AA-7
P23 DT 2 Air cleaner clogging sensor M-5
P24 DT 2 Radiator coolant level sensor M-4
P44 DT 2 Engine oil level sensor AM-8
CRANK SENSOR FRAMTOME 3 Engine NE speed sensor AJ-1
P47 '040 2 Fuel water sensor AI-6
D01 SWP 8 Diode array V-1
D02 SWP 8 Diode array V-1
R01 Terminal 1 Battery relay E terminal N-8
D10 M 2 Diode X-1
R02 Terminal 1 Battery relay BR terminal N-8
D11 M 2 Diode U-9
R03 Terminal 1 Battery relay M terminal N-8
E01 Terminal 1 Intake air heater AK-5
R04 Terminal 1 Battery relay B terminal N-8
E06 DT 2 Intermediate connector (Fuel water sensor) AL-1
R05 SHINAGAWA 5 Working lamp relay S-7
E08 X 1 Intermediate connector (Alternator L terminal) AL-9
R06 SHINAGAWA 5 Starting motor cut relay (PPC oil pressure lock) S-7
E10 DT 1 Starting motor C terminal AK-6
R07 SHINAGAWA 5 Starting motor cut relay (Personal code) S-8
E12 SUMITOMO 3 Alternator AM-9
R08 SHINAGAWA 5 Horn relay AG-2
F01 — 20 Fuse box AA-4
R12 SHINAGAWA 5 Cab light relay AH-2
F02 SWP 2 Intermediate connector (Rotary lamp) (If equipped) AG-9
R15 Terminal 1 Intake air heater coil drive terminal L-7
F03 DT 2 Rotary lamp (If equipped) AF-9
R16 Terminal 1 Intake air heater contact output terminal L-9
F04 L 2 Fusible link (65A) M-5
Intermediate connector (Starting motor safety relay C
F05 M 2 Fusible link (30A) M-5 R17 X 2 terminal) M-9
FUEL RAIL R18 SHINAGAWA 5 Auto preheat relay AG-2

PRESS BOSCH 3 Common rail pressure sensor AM-5
R20 SHINAGAWA 5 ATT circuit selector relay AH-3
FUEL BOSCH 2 Supply pump solenoid (IMV) AN-2
REGULATOR R21 SHINAGAWA 5 Arm crane relay (Arm crane specification) W-9
G01 DRC 40 KOMTRAX Z-9 R23 SHINAGAWA 5 Engine controller unswitched power supply relay AH-2
G02 X 1 Test connector (Female) X-9 R24 SHINAGAWA 5 Engine controller unswitched power supply relay AH-2
G03 X 1 Test connector (Male) X-9 R28 Terminal 1 Starting motor safety relay C terminal M-7
G04 X 1 Test connector (Female) Y-9 S01 Terminal 6 Starting switch S-6
G05 X 1 Test connector (Male) Y-9 S02 M 2 Light switch T-8
H08 M 8 Intermediate connector (Cab wiring harness) AA-5, AH-4 S04 M 4 Swing lock switch T-8
H09 S 8 Intermediate connector (Cab light) AA-5, AH-4 S07 M 2 Rotary lamp switch AA-3
H10 S 16 Intermediate connector (Machine monitor) W-1 S09 X 2 Intermediate connector (Service valve pressure switch) A-7
H11 S 16 Intermediate connector (Machine monitor) W-1 S10 X 2 Service valve pressure switch (Front) (1 ATT) B-7
H12 S 12 Intermediate connector (Machine monitor) V-1 S11 X 2 Service valve pressure switch (Rear) (1 ATT) C-8
H15 S090 20 Intermediate connector (Right upper console) S-6 S12 X 2 Service valve pressure switch (A) (2 ATT)) B-7
INJ CYL 1 Terminal 2 Injector #1 AI-4 S13 X 2 Service valve pressure switch (B) (2 ATT) C-8
INJ CYL 2 Terminal 2 Injector #2 AJ-4 S14 X 2 Service valve pressure switch (B) (3 ATT) A-7
INJ CYL 3 Terminal 2 Injector #3 AJ-5 S15 X 2 Service valve pressure switch (B) (3 ATT) C-8
INJ CYL 4 Terminal 2 Injector #4 AK-5 S21 Terminal 6 Emergency pump drive switch V-9
INJ CYL 5 Terminal 2 Injector #5 AL-5 S22 Terminal 6 Swing holding brake release switch U-9
INJ CYL 6 Terminal 2 Injector #6 AL-5 S23 Terminal 6 Emergency work equipment operation switch U-9
INJ CYL 1 & 2 DT 4 Intermediate connector (for injectors #1, #2) AI-3 Intermediate connector (Right console emergency
S25 '090 16 switch) T-9
INJ CYL 3 & 4 DT 4 Intermediate connector (for injectors #3, #4) AK-5
S30 S 8 Model selection AH-3
INJ CYL 5 & 6 DT 4 Intermediate connector (for injectors #5, #6) AM-6
SB Terminal 1 Starting motor B terminal AJ-7
J01 J (Black) 20 Junction connector W-9
SC Terminal 1 Starting motor C terminal AJ-7
J02 J (Black) 20 Junction connector X-2
T05 Terminal 1 Floor frame ground Y-2
J03 J (Green) 20 Junction connector AA-5
T06 Terminal 1 Radio body ground AA-4
J04 J (Green) 20 Junction connector X-1
T06A Terminal 1 Intermediate connector (Radio body ground) Y-2
J05 J (Pink) 20 Junction connector W-9
T08 Terminal 1 Revolving frame ground N-2
J06 J (Orange) 20 Junction connector X-1
T11 Terminal 1 Cab ground AH-4
J07 J (Orange) 20 Junction connector AA-6
T12 Terminal 1 Engine cylinder block ground AL-1
K02 DT 3 CAN terminal resistor AL-1
TOOL PORT DT 3 Communication connector AI-2
K19 M 2 Resistor (for driving pump) AA-6
V01 DT 2 PPC oil pressure lock solenoid A-2
K20 M 2 Resistor (for raising boom) AA-7
V02 DT 2 2-stage relief solenoid A-2
K31 DT 3 CAN terminal resistor P-4
V03 DT 2 Travel speed shifting solenoid A-2
L01A DT 2 Working lamp (Boom right) F-8
V04 DT 2 Swing holding brake solenoid A-2
L01B DT 2 Working lamp (Boom left) F-8
V05 DT 2 Travel junction solenoid A-1
M06 KES0 2 Window washer motor A-6
V06 DT 2 Pump merge-divider solenoid A-1
M07 '090 2 Horn (High tone) I-1
V07 DT 2 ATT EPC solenoid L-2
M08 '090 2 Horn (Low tone) H-1
V09 DT 2 Boom raise throttle EPC solenoid G-1
M13 M 2 Speaker (Right) AG-8
V11 DT 2 PC-EPC solenoid J-9, AN-4
M19 YAZAKI 2 Cigarette lighter P-3
V12 DT 2 ATT return selector solenoid G-1
M21 PA 9 Radio AA-3
V19 DT 2 LS-EPC solenoid I-9, AN-5
M22 Y090 2 Horn switch S-6
W03 X 2 Rear limit switch AH-8
M23 '090 2 Left knob switch Y-2
W04 M 6 Wiper motor P-4, AC-4
M26 SWP 12 Air conditioner unit V-9
SEN01440-02
PC228US, USLC-3E0
17
SEN01440-02

© 2009 KOMATSU
All Rights Reserved
20

228us-3 40001 Up

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SEN01418-09

HYDRAULIC PC228US -3E0

HYDRAULIC EXCAVATOR 1SHOP MANUAL

Machine model Serial number

00 Index and foreword 1

Composition of shop manual 1

Section Title Form Number

Shop Manual, contents binder, binder label and tabs SEN01418-09

00 Index and foreword SEN01419-09

10 Structure, function and maintenance standard SEN01424-03

20 Standard value table SEN01434-02

30 Testing and adjusting SEN01435-05

Troubleshooting of hydraulic and mechanical system (H-mode) SEN01889-02

50 Disassembly and assembly SEN01437-05

90 Diagrams and drawings SEN01438-02

10 Structure, function and maintenance standard

Return oil filter ......................................................................................................................... 23

20 Standard value table

30 Testing and adjusting

Bleeding air from each part...................................................................................................... 28

Failure code [CA332] Inj #4 (L#4) Open/Short Error ............................................................... 52

Failure code [DXE0KB] LS-EPC Sol Short Circuit................................................................... 36

50 Disassembly and assembly

Disassembly and assembly of final drive assembly................................................................. 3

90 Diagrams and drawings

PC228US, 228USLC-3E0 Hydraulic excavator

HYDRAULIC EXCAVATOR 1SHOP MANUAL

Machine model Serial number

00 Index and foreword 1

1. General precautions 7) If welding repairs are needed, always

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

4. Precautions for sling work and making

How to read the shop manual 1

1. Composition of shop manual

00. Index and foreword

10. Structure, function and maintenance standard

20. Standard value table

30. Testing and adjusting

50. Disassembly and assembly

2. Revision and distribution

q Revised edition mark

Symbol Item Remarks

k Safety Special safety precautions are necessary when performing work.

Special technical precautions or other precautions for preserving stan-

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

Explanation of terms for maintenance standard 1

1. Standard size and tolerance

a The tolerance may be indicated in the text

q Usually, the size of a hole and the size of

2. Standard clearance and standard value 5. Clearance limit

4. Repair limit and allowable value or allow-

Handling of electric equipment and hydraulic component 1

Points to remember when handling electric

2. Main failures occurring in wiring harness

2) Defective crimping or soldering of connec-

4) High-pressure water entering connector

5) Oil or dirt stuck to connector

3. Removing, installing, and drying connec-

2] When removing from clips

q When removing a connector from a

3] Action to take after removing connec-

4) Drying wiring harness

5. Points to remember when troubleshooting