UEN05331-03
HYDRAULIC EXCAVATOR
PC228US-8 PC228USLC-8 SERIAL NUMBERS
PC228US-8 50001 and up PC228USLC-8 50001
Notice of revision
Notice of revision 2011/02
3rd. revision The affected pages are indicated by the use of the following marks. It is requested that necessary actions must be taken to these pages according to the list below.
Mark
Indication
Action required
Q
Page to be newly added
Add
q
Page to be replaced
Replace
()
Page to be deleted
Discard
List of revised pages Mark
Page
q q q q q q q
1 2 3 4 5 6 7 8 00-1 00-2 00-3 00-4 00-5 00-6 00-7 00-8 00-9 00-10 00-11 00-12 00-13 00-14 00-15 00-16 00-17 00-18 00-19 00-20 00-21 00-22 00-23 00-24 00-25 00-26 00-27 00-28 00-29 00-30 00-31 00-32 00-33
q
Revision number 03 03 03 03 03 03 03
03
PC228US-8,PC228USLC-8
Mark
Page 00-34 00-35 00-36 00-37 00-38 00-39 00-40 00-41 00-42 00-43 00-44 00-45 00-46 00-47 00-48 00-49 00-50 00-51 00-52 00-53 00-54 01-1 01-2 01-3 01-4 01-5 01-6 01-7 01-8 01-9 01-10 01-11 01-12 01-13 01-14 01-15 01-16 01-17 01-18 01-19 01-20
Revision number
Mark
q q
q q q
Page 01-21 01-22 10-1 10-2 10-3 10-4 10-5 10-6 10-7 10-8 10-9 10-10 10-11 10-12 10-13 10-14 10-15 10-16 10-17 10-18 10-19 10-20 10-21 10-22 10-23 10-24 10-25 10-26 10-27 10-28 10-29 10-30 10-31 10-32 10-33 10-34 10-35 10-36 10-37 10-38 10-39
Revision number
Mark
q 03 03
03 03 03 q
Page 10-40 10-41 10-42 10-43 10-44 10-45 10-46 10-47 10-48 10-49 10-50 10-51 10-52 10-53 10-54 10-55 10-56 10-57 10-58 10-59 10-60 10-61 10-62 10-63 10-64 10-65 10-66 10-67 10-68 10-69 10-70 10-71 10-72 10-73 10-74 10-75 10-76 10-77 10-78 10-79 10-80
Revision number
03
03
1 (03)
Notice of revision
Mark
q q
q
2 (03)
Page 10-81 10-82 10-83 10-84 10-85 10-86 10-87 10-88 10-89 10-90 10-91 10-92 10-93 10-94 10-95 10-96 10-97 10-98 10-99 10-100 10-101 10-102 10-103 10-104 10-105 10-106 10-107 10-108 10-109 10-110 10-111 10-112 10-113 10-114 10-115 10-116 10-117 10-118 10-119 10-120 10-121 10-122 10-123 10-124 10-125 10-126 10-127 10-128 10-129 10-130 10-131 10-132
Revision number
03 03
03
Mark
Page 10-133 10-134 10-135 10-136 10-137 10-138 10-139 10-140 10-141 10-142 10-143 10-144 10-145 10-146 10-147 10-148 10-149 10-150 10-151 10-152 10-153 10-154 10-155 10-156 10-157 10-158 10-159 10-160 10-161 10-162 10-163 10-164 10-165 10-166 10-167 10-168 10-169 10-170 10-171 10-172 10-173 10-174 10-175 10-176 10-177 10-178 10-179 10-180 10-181 10-182 10-183 10-184
Revision number
Mark
Page 10-185 10-186 10-187 10-188 10-189 10-190 10-191 10-192 10-193 10-194 10-195 10-196 10-197 10-198 10-199 10-200 10-201 10-202 10-203 10-204 10-205 10-206 10-207 10-208 10-209 10-210 10-211 10-212 10-213 10-214 10-215 10-216 10-217 10-218 10-219 10-220 10-221 10-222 10-223 10-224 10-225 10-226 10-227 10-228 20-1 20-2 20-3 20-4 20-5 20-6 20-7 20-8
Revision number
Mark
Page
Revision number
20-9 20-10 20-11 20-12 20-13 20-14 30-1 30-2 30-3 30-4 30-5 30-6 30-7 30-8 30-9 30-10 30-11 30-12 30-13 30-14 30-15 30-16 30-17 30-18 30-19 30-20 30-21 30-22 30-23 30-24 30-25 30-26 30-27 30-28 30-29 30-30 30-31 30-32 30-33 30-34 30-35 30-36 30-37 30-38 30-39 30-40 30-41 30-42 30-43 30-44 30-45 30-46
PC228US-8,PC228USLC-8
Notice of revision
Mark
Page
Revision number
30-47 30-48 30-49 30-50 30-51 30-52 30-53 30-54 30-55 30-56 30-57 30-58 30-59 30-60 30-61 30-62 30-63 30-64 30-65 30-66 30-67 30-68 30-69 30-70 30-71 30-72 30-73 30-74 30-75 30-76 30-77 30-78 30-79 30-80 30-81 30-82 30-83 30-84 30-85 30-86 30-87 30-88 30-89 30-90 30-91 30-92 30-93 30-94 30-95 30-96 30-97 30-98
PC228US-8,PC228USLC-8
Mark
Page 30-99 30-100 30-101 30-102 30-103 30-104 30-105 30-106 30-107 30-108 30-109 30-110 30-111 30-112 30-113 30-114 30-115 30-116 30-117 30-118 30-119 30-120 30-121 30-122 30-123 30-124 30-125 30-126 30-127 30-128 30-129 30-130 30-131 30-132 30-133 30-134 30-135 30-136 30-137 30-138 30-139 30-140 40-1 40-2 40-3 40-4 40-5 40-6 40-7 40-8 40-9 40-10
Revision number
Mark
Page 40-11 40-12 40-13 40-14 40-15 40-16 40-17 40-18 40-19 40-20 40-21 40-22 40-23 40-24 40-25 40-26 40-27 40-28 40-29 40-30 40-31 40-32 40-33 40-34 40-35 40-36 40-37 40-38 40-39 40-40 40-41 40-42 40-43 40-44 40-45 40-46 40-47 40-48 40-49 40-50 40-51 40-52 40-53 40-54 40-55 40-56 40-57 40-58 40-59 40-60 40-61 40-62
Revision number
Mark
Page
Revision number
40-63 40-64 40-65 40-66 40-67 40-68 40-69 40-70 40-71 40-72 40-73 40-74 40-75 40-76 40-77 40-78 40-79 40-80 40-81 40-82 40-83 40-84 40-85 40-86 40-87 40-88 40-89 40-90 40-91 40-92 40-93 40-94 40-95 40-96 40-97 40-98 40-99 40-100 40-101 40-102 40-103 40-104 40-105 40-106 40-107 40-108 40-109 40-110 40-111 40-112 40-113 40-114
3 (03)
Notice of revision
Mark
Page 40-115 40-116 40-117 40-118 40-119 40-120 40-121 40-122 40-123 40-124 40-125 40-126 40-127 40-128 40-129 40-130 40-131 40-132 40-133 40-134 40-135 40-136 40-137 40-138 40-139 40-140 40-141 40-142 40-143 40-144 40-145 40-146 40-147 40-148 40-149 40-150 40-151 40-152 40-153 40-154 40-155 40-156 40-157 40-158 40-159 40-160 40-161 40-162 40-163 40-164 40-165 40-166
4 (03)
Revision number
Mark
Page 40-167 40-168 40-169 40-170 40-171 40-172 40-173 40-174 40-175 40-176 40-177 40-178 40-179 40-180 40-181 40-182 40-183 40-184 40-185 40-186 40-187 40-188 40-189 40-190 40-191 40-192 40-193 40-194 40-195 40-196 40-197 40-198 40-199 40-200 40-201 40-202 40-203 40-204 40-205 40-206 40-207 40-208 40-209 40-210 40-211 40-212 40-213 40-214 40-215 40-216 40-217 40-218
Revision number
Mark
Page 40-219 40-220 40-221 40-222 40-223 40-224 40-225 40-226 40-227 40-228 40-229 40-230 40-231 40-232 40-233 40-234 40-235 40-236 40-237 40-238 40-239 40-240 40-241 40-242 40-243 40-244 40-245 40-246 40-247 40-248 40-249 40-250 40-251 40-252 40-253 40-254 40-255 40-256 40-257 40-258 40-259 40-260 40-261 40-262 40-263 40-264 40-265 40-266 40-267 40-268 40-269 40-270
Revision number
Mark
Page
Revision number
40-271 40-272 40-273 40-274 40-275 40-276 40-277 40-278 40-279 40-280 40-281 40-282 40-283 40-284 40-285 40-286 40-287 40-288 40-289 40-290 40-291 40-292 40-293 40-294 40-295 40-296 40-297 40-298 40-299 40-300 40-301 40-302 40-303 40-304 40-305 40-306 40-307 40-308 40-309 40-310 40-311 40-312 40-313 40-314 40-315 40-316 40-317 40-318 40-319 40-320 40-321 40-322
PC228US-8,PC228USLC-8
Notice of revision
Mark
Page
Revision number
40-323 40-324 40-325 40-326 40-327 40-328 40-329 40-330 40-331 40-332 40-333 40-334 40-335 40-336 40-337 40-338 40-339 40-340 40-341 40-342 40-343 40-344 40-345 40-346 40-347 40-348 40-349 40-350 40-351 40-352 40-353 40-354 40-355 40-356 40-357 40-358 40-359 40-360 40-361 40-362 40-363 40-364 40-365 40-366 40-367 40-368 40-369 40-370 40-371 40-372 40-373 40-374
PC228US-8,PC228USLC-8
Mark
Page 40-375 40-376 40-377 40-378 40-379 40-380 40-381 40-382 40-383 40-384 40-385 40-386 40-387 40-388 40-389 40-390 40-391 40-392 40-393 40-394 40-395 40-396 40-397 40-398 40-399 40-400 40-401 40-402 40-403 40-404 40-405 40-406 40-407 40-408 40-409 40-410 40-411 40-412 40-413 40-414 40-415 40-416 40-417 40-418 40-419 40-420 40-421 40-422 40-423 40-424 40-425 40-426
Revision number
Mark
Page 40-427 40-428 40-429 40-430 40-431 40-432 40-433 40-434 40-435 40-436 40-437 40-438 40-439 40-440 40-441 40-442 40-443 40-444 40-445 40-446 40-447 40-448 40-449 40-450 40-451 40-452 40-453 40-454 40-455 40-456 40-457 40-458 40-459 40-460 40-461 40-462 40-463 40-464 40-465 40-466 40-467 40-468 40-469 40-470 50-1 50-2 50-3 50-4 50-5 50-6 50-7 50-8
Revision number
Mark
q
Page 50-9 50-10 50-11 50-12 50-13 50-14 50-15 50-16 50-17 50-18 50-19 50-20 50-21 50-22 50-23 50-24 50-25 50-26 50-27 50-28 50-29 50-30 50-31 50-32 50-33 50-34 50-35 50-36 50-37 50-38 50-39 50-40 50-41 50-42 50-43 50-44 50-45 50-46 50-47 50-48 50-49 50-50 50-51 50-52 50-53 50-54 50-55 50-56 50-57 50-58 50-59 50-60
Revision number
03
5 (03)
Notice of revision
Mark
Page 50-61 50-62 50-63 50-64 50-65 50-66 50-67 50-68 50-69 50-70 50-71 50-72 50-73 50-74 50-75 50-76 50-77 50-78 50-79 50-80 50-81 50-82 50-83 50-84 50-85 50-86 50-87 50-88 50-89 50-90 50-91 50-92 50-93 50-94 50-95 50-96 50-97 50-98 50-99 50-100 50-101 50-102 50-103 50-104 50-105 50-106 50-107 50-108 50-109 50-110 50-111 50-112
6 (03)
Revision number
Mark
q
q q
q
Page 50-113 50-114 50-115 50-116 50-117 50-118 50-119 50-120 50-121 50-122 50-123 50-124 50-125 50-126 50-127 50-128 50-129 50-130 50-131 50-132 50-133 50-134 50-135 50-136 50-137 50-138 50-139 50-140 50-141 50-142 50-143 50-144 50-145 50-146 50-147 50-148 50-149 50-150 50-151 50-152 50-153 50-154 50-155 50-156 50-157 50-158 50-159 50-160 50-161 50-162 50-163 50-164
Revision number
03
03 03
03
Mark
Page 50-165 50-166 50-167 50-168 50-169 50-170 50-171 50-172 50-173 50-174 50-175 50-176 50-177 50-178 50-179 50-180 50-181 50-182 60-1 60-2 60-3 60-4 60-5 60-6 60-7 60-8 60-9 60-10 60-11 60-12 60-13 60-14 60-15 60-16 60-17 60-18 60-19 60-20 60-21 60-22 60-23 60-24 60-25 60-26 60-27 60-28 60-29 60-30 60-31 60-32 60-33 60-34
Revision number
Mark
Page
Revision number
60-35 60-36 60-37 60-38 60-39 60-40 60-41 60-42 60-43 60-44 60-45 60-46 60-47 60-48 60-49 60-50 60-51 60-52 60-53 60-54 60-55 60-56 60-57 60-58 60-59 60-60 60-61 60-62 60-63 60-64 60-65 60-66 60-67 60-68 60-69 60-70 80-1 80-2 80-3 80-4 80-5 80-6 80-7 80-8 80-9 80-10 80-11 80-12 80-13 80-14 80-15 80-16
PC228US-8,PC228USLC-8
Notice of revision
Mark
Page
Revision number
80-17 80-18 80-19 80-20 80-21 80-22 80-23 80-24 80-25 80-26 80-27 80-28 80-29 80-30 80-31 80-32 80-33 80-34 80-35 80-36 80-37 80-38 80-39 80-40 80-41 80-42 80-43 80-44 80-45 80-46 80-47 80-48 80-49 80-50 80-51 80-52 80-53 80-54 80-55 80-56 80-57 80-58 80-59 80-60 80-61 80-62 80-63 80-64 80-65 80-66 80-67 80-68
PC228US-8,PC228USLC-8
Mark
Page
q q q q q q q q q q Q Q q q q q q q q q q q q q q q q q q
80-69 80-70 80-71 80-72 80-73 80-74 80-75 80-76 80-77 80-78 90-1 90-2 90-3 90-4 90-5 90-6 90-7 90-8 90-9 90-10 90-11 90-12 90-13 90-14 90-15 90-16 90-17 90-18 90-19 90-20 90-21 90-22 90-23 90-24 90-25 90-26 90-27 90-28 90-29
Revision number
Mark
Page
Revision number
Mark
Page
Revision number
03 03 03 03 03 03 03 03 03 03 03 03 03 03 03 03 03 03 03 03 03 03 03 03 03 03 03 03 03
7 (03)
Notice of revision
8 (03)
PC228US-8,PC228USLC-8
0-1
PC228US-8,PC228USLC-8
HYDRAULIC EXCAVATOR PC228US-8 PC228USLC-8 Shop Manual
Machine model
Serial number
PC228US-8 PC228USLC-8
50001 and up 50001 and up
0-1
00 Index and foreword
PC228US-8,PC228USLC-8
00-1
Table of Contents
Table of Contents Notice of revision ........................................................................................................................... 1 00 Index and Foreword Table of Contents........................................................................................................................... 00-2 Foreword and general information ................................................................................................. 00-12 Safety notice ............................................................................................................................... 00-12 How to read the shop manual ..................................................................................................... 00-17 Explanation of terms for maintenance standard ......................................................................... 00-19 Handling of hydraulic components.............................................................................................. 00-21 Method of disconnecting and connecting push-pull type coupler ............................................... 00-23 Handling of electric equipment.................................................................................................... 00-26 How to read electric wire code.................................................................................................... 00-36 Precautions when performing work............................................................................................. 00-39 Standard tightening torque table................................................................................................. 00-42 List of Abbreviation ..................................................................................................................... 00-46 Conversion table ......................................................................................................................... 00-50 01 Specification Specifications................................................................................................................................. 01-4 Specifications drawing ................................................................................................................ 01-4 Working range diagram............................................................................................................... 01-5 Specifications.............................................................................................................................. 01-6 Table of weight............................................................................................................................ 01-16 Table of fuel, coolant and lubricants ........................................................................................... 01-20 10 Structure and function Engine and cooling system ............................................................................................................ 10-3 Engine related parts.................................................................................................................... 10-3 Cooling system ........................................................................................................................... 10-4 Power train system ........................................................................................................................ 10-7 Power train.................................................................................................................................. 10-7 Swing circle................................................................................................................................. 10-8 Swing machinery......................................................................................................................... 10-10 Final drive ................................................................................................................................... 10-12 Undercarriage and frame ............................................................................................................... 10-14 Track frame and idler cushion..................................................................................................... 10-14 Hydraulic system............................................................................................................................ 10-16 Hydraulic equipment layout drawing ........................................................................................... 10-16 Valve control ............................................................................................................................... 10-18 ATT EPC Valve Assembly .......................................................................................................... 10-19 Hydraulic tank ............................................................................................................................. 10-21 CLSS........................................................................................................................................... 10-23 Main pump .................................................................................................................................. 10-28 Control valve ............................................................................................................................... 10-50 Function and operation by valve ................................................................................................. 10-62 Swing motor ................................................................................................................................ 10-99 Travel motor................................................................................................................................ 10-107 PPC valve ................................................................................................................................... 10-117 Solenoid valve............................................................................................................................. 10-134 Attachment circuit selector valve ................................................................................................ 10-140 Quick coupler control valve......................................................................................................... 10-144 Anti-drop valve ............................................................................................................................ 10-146 00-2
PC228US-8,PC228USLC-8
Table of Contents
Multi-control valve....................................................................................................................... 10-151 Centre swivel joint....................................................................................................................... 10-152 Accumulator................................................................................................................................ 10-153 Work equipment............................................................................................................................. 10-156 Work equipment.......................................................................................................................... 10-156 Electrical system ............................................................................................................................ 10-158 Electronic control system............................................................................................................ 10-158 Machine monitor system............................................................................................................. 10-197 PPC Levers................................................................................................................................. 10-214 KOMTRAX system...................................................................................................................... 10-216 Sensors....................................................................................................................................... 10-218 20 Standard value table Standard value table ...................................................................................................................... 20-3 Standard value table for engine.................................................................................................. 20-3 Standard value table for machine ............................................................................................... 20-4 30 Testing and adjusting Tool for testing, adjusting and troubleshooting .............................................................................. 30-3 Tools for testing, adjusting, and troubleshooting ........................................................................ 30-3 Engine and cooling system ............................................................................................................ 30-9 Testing engine speed ................................................................................................................. 30-9 Testing intake air pressure (boost pressure) .............................................................................. 30-10 Testing exhaust gas colour......................................................................................................... 30-11 Testing and adjusting valve clearance........................................................................................ 30-12 Testing compression pressure.................................................................................................... 30-14 Testing blow-by pressure............................................................................................................ 30-17 Testing engine oil pressure......................................................................................................... 30-18 Handling fuel system parts ......................................................................................................... 30-19 Releasing remaining pressure from fuel system......................................................................... 30-20 Testing fuel pressure .................................................................................................................. 30-21 Cylinder cut-out test mode.......................................................................................................... 30-24 No-injection cranking .................................................................................................................. 30-25 Checking fuel delivery, return rate and leakage ......................................................................... 30-26 Bleeding air from fuel circuit ....................................................................................................... 30-29 Testing fuel circuit for leakage .................................................................................................... 30-30 Testing and adjusting air conditioner compressor belt tension................................................... 30-31 Replacing fan belt ....................................................................................................................... 30-32 Undercarriage and frame ............................................................................................................... 30-33 Testing swing circle bearing clearance....................................................................................... 30-33 Checking and adjusting track tension ......................................................................................... 30-34 Hydraulic system ........................................................................................................................... 30-35 Testing and adjusting oil pressure in work equipment, swing and travel circuits........................ 30-35 Testing control circuit source pressure ....................................................................................... 30-39 Testing and adjusting oil pressure in pump PC control circuit .................................................... 30-40 Testing and adjusting oil pressure in pump LS control circuit..................................................... 30-44 Testing solenoid valve output pressure ...................................................................................... 30-49 Testing PPC valve output pressure ............................................................................................ 30-52 Adjusting play of work equipment and swing PPC valves .......................................................... 30-54 Measuring and adjusting quick coupler control valve output pressure ....................................... 30-55 Testing pump swash plate sensor .............................................................................................. 30-56 Isolating the parts causing hydraulic drift of work equipment ..................................................... 30-57 Releasing remaining pressure from hydraulic circuit .................................................................. 30-59 Testing oil leakage amount......................................................................................................... 30-60 PC228US-8,PC228USLC-8
00-3
Table of Contents
Bleeding air from each part......................................................................................................... 30-62 Work equipment............................................................................................................................. 30-64 Replacement procedure of boom angle potentiometer............................................................... 30-64 Cab and its attachments ................................................................................................................ 30-65 Checking cab tipping stopper...................................................................................................... 30-65 Adjusting mirrors ......................................................................................................................... 30-66 Angle adjustment of rear view camera........................................................................................ 30-68 Electrical system ............................................................................................................................ 30-70 Special function of machine monitor (EMMS)............................................................................. 30-70 Handling voltage circuit of engine controller ............................................................................... 30-126 Preparatory work for troubleshooting of electrical system .......................................................... 30-127 Procedure for testing diodes ....................................................................................................... 30-132 Pm clinic......................................................................................................................................... 30-133 Pm clinic service ......................................................................................................................... 30-133 40 Troubleshooting General information on troubleshooting ......................................................................................... 40-8 Points to remember when troubleshooting ................................................................................. 40-8 Sequence of events in troubleshooting....................................................................................... 40-9 Checks before troubleshooting ................................................................................................... 40-10 Classification and procedures for troubleshooting ...................................................................... 40-34 Failure codes table...................................................................................................................... 40-37 Symptom and troubleshooting numbers ..................................................................................... 40-42 Information in troubleshooting table............................................................................................ 40-44 Troubleshooting method for open circuit in wiring harness of pressure sensor system ............. 40-46 Connector list and layout ............................................................................................................ 40-48 Connection table for connector pin numbers .............................................................................. 40-60 T- branch box and T- branch adapter table ................................................................................ 40-96 Fuse location table...................................................................................................................... 40-100 Troubleshooting by failure code..................................................................................................... 40-102 Failure code [989L00] Engine Controller Lock Caution 1 ........................................................... 40-102 Failure code [989M00] Engine Controller Lock Caution 2 .......................................................... 40-102 Failure code [989N00] Engine Controller Lock Caution 3........................................................... 40-103 Failure code [AA10NX] Air Cleaner Clogging ............................................................................. 40-104 Failure code [AB00KE] Charge Voltage Low .............................................................................. 40-106 Failure code [B@BAZG] Eng Oil Press Low............................................................................... 40-108 Failure code [B@BAZK] Eng Oil Level Low................................................................................ 40-109 Failure code [B@BCNS] Eng Water Overheat ........................................................................... 40-110 Failure code [B@BCZK] Eng Water Level Low .......................................................................... 40-112 Failure code [B@HANS] Hyd Oil Overheat................................................................................. 40-114 Failure code [CA111] ECM Critical Internal Failure .................................................................... 40-115 Failure code [CA115] Eng Ne and Bkup Speed Sens Error ....................................................... 40-115 Failure code [CA122] Chg Air Press Sensor High Error ............................................................. 40-116 Failure code [CA123] Chg Air Press Sensor Low Error .............................................................. 40-118 Failure code [CA131] Throttle Sensor High Error ....................................................................... 40-120 Failure code [CA132] Throttle Sensor Low Error ........................................................................ 40-122 Failure code [CA144] Coolant Temp Sens High Error ................................................................ 40-124 Failure code [CA145] Coolant Temp Sens Low Error................................................................. 40-126 Failure code [CA153] Chg Air Temp Sensor High Error ............................................................. 40-128 Failure code [CA154] Chg Air Temp Sensor Low Error .............................................................. 40-130 Failure code [CA155] Chg Air Temp High Speed Derate ........................................................... 40-132 Failure code [CA187] Sens Supply 2 Volt Low Error .................................................................. 40-134 Failure code [CA221] Ambient Press Sens High Error ............................................................... 40-136 Failure code [CA222] Ambient Press Sens Low Error ................................................................ 40-138 00-4
PC228US-8,PC228USLC-8
Table of Contents
Failure code [CA227] Sens Supply 2 Volt High Error ................................................................. 40-140 Failure code [CA234] Eng Overspeed ........................................................................................ 40-141 Failure code [CA238] Ne Speed Sens Supply Volt Error............................................................ 40-142 Failure code [CA271] IMV/PCV1 Short Error.............................................................................. 40-144 Failure code [CA272] IMV/PCV1 Open Error ............................................................................. 40-146 Failure code [CA322] Inj #1(L#1) Open/Short Error ................................................................... 40-148 Failure code [CA323] Inj #5 (L#5) Open/Short Error .................................................................. 40-150 Failure code [CA324] Inj #3(L#3) Open/Short Error ................................................................... 40-152 Failure code [CA325] Inj #6 (L#6) Open/Short Error .................................................................. 40-154 Failure code [CA331] Inj #2(L#2) Open/Short Error ................................................................... 40-156 Failure code [CA332] Inj #4(L#4) Open/Short Error ................................................................... 40-158 Failure code [CA342] Calibration Code Incompatibility .............................................................. 40-160 Failure code [CA351] Injectors Drive Circuit Error...................................................................... 40-161 Failure code [CA352] Sens Supply 1 Volt Low Error .................................................................. 40-162 Failure code [CA386] Sens Supply 1 Volt High Error ................................................................. 40-164 Failure code [CA428] Water in Fuel Sensor High Error .............................................................. 40-166 Failure code [CA429] Water in Fuel Sensor Low Error............................................................... 40-168 Failure code [CA435] Eng Oil Press Sw Error ............................................................................ 40-170 Failure code [CA441] Battery Voltage Low Error........................................................................ 40-172 Failure code [CA442] Battery Voltage High Error ....................................................................... 40-174 Failure code [CA449] Rail Press Very High Error....................................................................... 40-175 Failure code [CA451] Rail Press Sensor High Error................................................................... 40-176 Failure code [CA452] Rail Press Sensor Low Error.................................................................... 40-178 Failure code [CA488] Chg Air Temp High Torque Derate .......................................................... 40-180 Failure code [CA553] Rail Press High Error ............................................................................... 40-181 Failure code [CA559] Rail Press Low Error ................................................................................ 40-182 Failure code [CA689] Eng Ne Speed Sensor Error .................................................................... 40-184 Failure code [CA731] Eng Bkup Speed Sens Phase Error......................................................... 40-186 Failure code [CA757] All Continuous Data Lost Error ................................................................ 40-187 Failure code [CA778] Eng Bkup Speed Sensor Error................................................................. 40-188 Failure code [CA1633] KOMNET Datalink Timeout Error........................................................... 40-191 Failure code [CA2185] Throt Sens Sup Volt High Error ............................................................. 40-192 Failure code [CA2186] Throt Sens Sup Volt Low Error .............................................................. 40-193 Failure code [CA2249] Rail Press Very Low Error...................................................................... 40-194 Failure code [CA2311] IMV Solenoid Error................................................................................. 40-195 Failure code [CA2555] Grid Htr Relay Open Circuit Error .......................................................... 40-196 Failure code [CA2556] Grid Htr Relay Short Circuit Error .......................................................... 40-198 Failure code [D110KB] Battery Relay Drive Short Circuit ........................................................... 40-200 Failure code [D19JKZ] Personal Code Relay Abnormality ......................................................... 40-202 Failure code [D862KA] GPS Antenna Open Circuit.................................................................... 40-204 Failure code [DA22KK] Pump Solenoid Power Low Error .......................................................... 40-206 Failure code [DA25KP] 5V Sensor1 Power Abnormality ............................................................ 40-208 Failure code [DA26KP] 5V Sensor2 Power Abnormality ............................................................ 40-210 Failure code [DA29KQ] Model Selection Abnormality ................................................................ 40-214 Failure code [DA2RMC] CAN Discon (Pump Con Detected) ..................................................... 40-217 Failure code [DAF8KB] Camera Power Supply Short Circuit ..................................................... 40-222 Failure code [DAFGMC] GPS Module Error ............................................................................... 40-224 Failure code [DAFRMC] CAN Discon (Monitor Detected) .......................................................... 40-226 Failure code [DGH2KB] Hyd Oil Sensor Short ........................................................................... 40-230 Failure code [DHPAMA] Pump Press Sensor Abnormality......................................................... 40-232 Failure code [DHPBMA] R Pump Press Sensor Abnormality ..................................................... 40-234 Failure code [DHS3MA] Arm IN PPC Sen. Abnormality ............................................................. 40-236 Failure code [DHS4MA] Bucket CURL PPC Press Sensor Abnormality .................................... 40-238 Failure code [DHS8MA] Boom RAISE PPC Press Sensor Abnormality..................................... 40-240 PC228US-8,PC228USLC-8
00-5
Table of Contents
Failure code [DHSAMA] Swing RH PPC Press Sensor Abnormality.......................................... 40-242 Failure code [DHSBMA] Swing LH PPC Press Sensor Abnormality .......................................... 40-244 Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality .................................... 40-246 Failure code [DHSFMA] Travel FW L PPC Press Sensor Abnormality ...................................... 40-248 Failure code [DHSGMA] Travel FW R PPC Press Sensor Abnormality ..................................... 40-250 Failure code [DHSHMA] Travel BW L PPC Press Sensor Abnormality...................................... 40-252 Failure code [DHSJMA] Travel BW R PPC Press Sensor Abnormality ...................................... 40-254 Failure code [DHX1MA] Overload Sensor Abnormality .............................................................. 40-257 Failure code [DKA0KA] Boom Angle Sensor Open Circuit ......................................................... 40-260 Failure code [DKA0KB] Boom Angle Sensor Power Short Circuit .............................................. 40-262 Failure code [DKA0PH] Boom Angle Sensor Install Abnormality ............................................... 40-264 Failure code [DKR0MA] F pump S/P sensor Abnormality .......................................................... 40-266 Failure code [DKR1MA] R pump S/P sensor Abnormality .......................................................... 40-268 Failure code [DV20KB] Travel Alarm Short Circuit ..................................................................... 40-270 Failure code [DW43KA] Travel Speed Sol Open Circuit............................................................. 40-272 Failure code [DW43KB] Travel Speed Sol Short Circuit ............................................................. 40-274 Failure code [DW45KA] Swing Brake Sol Open Circuit .............................................................. 40-276 Failure code [DW45KB] Swing Brake Sol Short Circuit .............................................................. 40-278 Failure code [DW4GKA] Boom Slow Down Sol. Disc. ................................................................ 40-280 Failure code [DW4GKB] Boom Slow Down Sol. Short Circuit .................................................... 40-282 Failure code [DW4WKA] Cancel Bucket Dump Open Circuit ..................................................... 40-284 Failure code [DW4WKB] Cancel Bucket Dump Short Circuit ..................................................... 40-286 Failure code [DW91KA] Travel Junction Sol. Disc...................................................................... 40-288 Failure code [DW91KB] Travel Junction Sol. S/C....................................................................... 40-290 Failure code [DWA2KA] Attachment Sol Open Circuit................................................................ 40-292 Failure code [DWA2KB] Attachment Sol Short Circuit................................................................ 40-294 Failure code [DWK0KA] 2-stage Relief Sol Open Circuit............................................................ 40-296 Failure code [DWK0KB] 2-stage Relief Sol Short Circuit............................................................ 40-298 Failure code [DXA8KA] PC-EPC (F) Sol Open Circuit................................................................ 40-300 Failure code [DXA8KB] PC-EPC (F) Sol Short Circuit................................................................ 40-302 Failure code [DXA9KA] PC-EPC (R) Sol Open Circuit ............................................................... 40-304 Failure code [DXA9KB] PC-EPC (R) Sol Short Circuit ............................................................... 40-306 Failure code [DXE0KA] LS-EPC Sol Open Circuit...................................................................... 40-308 Failure code [DXE0KB] LS-EPC Sol Short Circuit ...................................................................... 40-310 Failure code [DXE4KA] Service Current EPC Disc..................................................................... 40-312 Failure code [DXE4KB] Service Current EPC S/C...................................................................... 40-314 Failure code [DXE5KA] Merge-divider Main Sol Open Circuit .................................................... 40-316 Failure code [DXE5KB] Merge-divider Main Sol Short Circuit .................................................... 40-318 Failure code [DXE6KA] Merge-divider LS Sol Open Circuit ....................................................... 40-320 Failure code [DXE6KB] Merge-divider LS Sol Short Circuit........................................................ 40-322 Failure code [DY20KA] Wiper Working Abnormality................................................................... 40-324 Failure code [DY20MA] Wiper Parking Abnormality ................................................................... 40-326 Failure code [DY2CKA] Washer drive discon ............................................................................. 40-328 Failure code [DY2CKB] Washer drive short................................................................................ 40-330 Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit ............................................................ 40-332 Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit............................................................. 40-334 Failure code [DXEAKA] Service Current EPC1 Discon .............................................................. 40-336 Failure code [DXEAKB] Service Current EPC1 Short................................................................. 40-337 Failure code [DXE7KA] Service Current EPC2 Discon............................................................... 40-338 Failure code [DXE7KB] Service Current EPC2 Short ................................................................. 40-339 Failure code [DXE8KA] Service Current EPC3 Discon............................................................... 40-340 Failure code [DXE8KB] Service Current EPC3 Short ................................................................. 40-341 Failure code [DXE9KA] Service Current EPC4 Discon............................................................... 40-342 Failure code [DXE9KB] Service Current EPC4 Short ................................................................. 40-344 00-6
PC228US-8,PC228USLC-8
Table of Contents
Failure code [DFB1KZ] Service Lever Potentio 1 Abnormality ................................................... 40-346 Failure code [DFB2KZ] Service Lever Potentio 2 Abnormality ................................................... 40-348 Failure code [DFB5KZ] Service Lever Sub Potentio 1 Abnormality............................................ 40-350 Failure code [DFB6KZ] Service Lever Sub Potentio 2 Abnormality............................................ 40-352 Failure code [DFB3L8] Service Lever 1 Potentio Error............................................................... 40-354 Failure code [DFB4L8] Service Lever 2 Potentio Error............................................................... 40-355 Troubleshooting of electrical system (E-mode).............................................................................. 40-357 E-1 Engine does not start (Engine does not crank) .................................................................... 40-357 E-2 Preheater does not operate ................................................................................................. 40-362 E-3 When starting switch is turned to ON position, machine monitor displays nothing .............. 40-367 E-4 When starting switch is turned to ON position (before starting engine), basic check monitor lights up................................................................................................................................................ 40-370 E-5 Precaution monitor lights up while engine is running ........................................................... 40-371 E-6 Emergency stop monitor lights up while engine is running .................................................. 40-373 E-7 Fuel level gauge does not indicate correctly ........................................................................ 40-374 E-8 Engine coolant temperature gauge does not indicate correctly ........................................... 40-376 E-9 Hydraulic oil temperature gauge does not indicate correctly ............................................... 40-378 E-10 Displays on machine monitor are different from those for actual machine ........................ 40-381 E-11 Some areas of machine monitor screen are not displayed ................................................ 40-381 E-12 Function switch does not operate ...................................................................................... 40-381 E-13 Automatic warm-up system does not operate (in cold season) ......................................... 40-382 E-14 Auto-decelerator does not operate properly....................................................................... 40-383 E-15 Working mode does not change ........................................................................................ 40-384 E-16 Travel speed does not change........................................................................................... 40-385 E-17 Alarm buzzer cannot be cancelled ..................................................................................... 40-386 E-18 When starting switch is turned OFF, service meter is not displayed.................................. 40-386 E-19 Service mode cannot be selected ...................................................................................... 40-387 E-20 Any of work equipment, swing and travel do not operate or cannot be locked .................. 40-388 E-21 Swing brake does not operate properly ............................................................................. 40-391 E-22 One-touch power maximizing function does not operate properly ..................................... 40-394 E-23 Travel alarm does not sound or does not stop sounding ................................................... 40-397 E-24 Horn does not sound or does not stop ............................................................................... 40-398 E-25 Windshield wiper and window washer do not operate ....................................................... 40-400 E-26 BOOM LOWER indicator is not displayed properly with monitoring function ..................... 40-402 E-27 ARM OUT indicator is not displayed properly with monitoring function ............................. 40-404 E-28 ARM IN indicator is not displayed properly with monitoring function ................................. 40-406 E-29 BOOM RAISE indicator is not displayed properly with monitoring function ....................... 40-406 E-30 BUCKET CURL indicator is not displayed properly with monitoring function..................... 40-406 E-31 BUCKET DUMP indicator is not displayed properly with monitoring function .................... 40-407 E-32 SWING indicator is not displayed properly with monitoring function .................................. 40-407 E-33 TRAVEL indicator is not displayed properly with monitoring function ................................ 40-407 E-34 ATTACHMENT indicator is not displayed properly with monitoring function ..................... 40-408 E-35 Attachment hydraulic circuit cannot be changed................................................................ 40-410 E-36 KOMTRAX system does not operate properly ................................................................... 40-411 Troubleshooting of hydraulic and mechanical system (H-mode) ................................................... 40-413 Information in troubleshooting table............................................................................................ 40-413 System chart for hydraulic and mechanical systems.................................................................. 40-414 Failure mode and cause table .................................................................................................... 40-416 H- 1 All of work equipment, swing and travel work slow or lack power ...................................... 40-418 H- 2 Engine speed lowers significantly or engine stalls.............................................................. 40-420 H- 3 Any of work equipment, swing and travel does not work .................................................... 40-421 H- 4 Unusual sound is heard from around hydraulic pump ........................................................ 40-421 H- 5 Fine control performance or response is poor .................................................................... 40-422 H- 6 Boom operation lacks speed or power................................................................................ 40-423 PC228US-8,PC228USLC-8
00-7
Table of Contents
H- 7 Arm operation lacks speed or power................................................................................... 40-424 H- 8 Bucket operation lacks speed or power .............................................................................. 40-425 H- 9 Work equipment does not move in single operation ........................................................... 40-425 H-10 Hydraulic drift of work equipment is large .......................................................................... 40-426 H-11 Time lag of work equipment is large .................................................................................. 40-428 H-12 Other work equipment moves when one of work equipment is relieved ............................ 40-428 H-13 One-touch power maximizing function does not work........................................................ 40-429 H-14 In combined operation of work equipment , equipment having heavier load moves slower.40-429 H-15 In combined operation of swing and boom RAISE, boom rising speed is low ................... 40-430 H-16 Travel speed drops largely in combined operation of swing and travel ............................. 40-430 H-17 Machine does not travel straight ........................................................................................ 40-431 H-18 Travel speed is low ............................................................................................................ 40-432 H-19 Machine is hard to steer or travel power is low .................................................................. 40-433 H-20 Travel speed does not change, or travel speed is too low or high ..................................... 40-434 H-21 One of tracks does not run................................................................................................. 40-435 H-22 Upper structure does not swing ......................................................................................... 40-436 H-23 Swing acceleration is poor or swing speed is low .............................................................. 40-438 H-24 Upper structure overruns excessively when it stops swinging ........................................... 40-440 H-25 Shock is large when upper structure stops swinging ......................................................... 40-441 H-26 Large unusual noise is heard when upper structure stops swinging.................................. 40-441 H-27 Swing drift on a slope is large ............................................................................................ 40-442 H-28 Attachment circuit cannot be changed ............................................................................... 40-443 H-29 Oil flow in attachment circuit cannot be controlled ............................................................. 40-443 Troubleshooting of engine (S-mode) ............................................................................................. 40-444 Method of using troubleshooting chart........................................................................................ 40-444 S-1 Startability is poor................................................................................................................. 40-448 S-2 Engine does not start ........................................................................................................... 40-449 S-3 Engine does not pick up smoothly........................................................................................ 40-452 S-4 Engine stops during operation.............................................................................................. 40-453 S-5 Engine runs rough or is unstable.......................................................................................... 40-454 S-6 Engine lacks power .............................................................................................................. 40-455 S-7 Exhaust smoke is black (incomplete combustion)................................................................ 40-456 S-8 Oil consumption is excessive (or exhaust smoke is blue) .................................................... 40-457 S-9 Oil becomes contaminated early .......................................................................................... 40-458 S-10 Fuel consumption is excessive........................................................................................... 40-459 S-11 Oil is in coolant (or coolant spurts or coolant level goes down) ......................................... 40-460 S-12 Oil pressure drops .............................................................................................................. 40-461 S-13 Oil level rises (coolant or fuel in oil).................................................................................... 40-462 S-14 Coolant temperature rises too high (overheating) .............................................................. 40-463 S-15 Unusual noise is made ....................................................................................................... 40-464 S-16 Vibration is excessive......................................................................................................... 40-465 Quick coupler troubleshooting ....................................................................................................... 40-466 Quick coupler .............................................................................................................................. 40-466 50 Disassembly and assembly General information on disassembly and assembly ...................................................................... 50-4 How to read Disassembly and Assembly.................................................................................... 50-4 Coating materials list................................................................................................................... 50-6 Special tools list .......................................................................................................................... 50-9 Sketches of special tools ............................................................................................................ 50-13 Engine and cooling system ............................................................................................................ 50-18 Removal and installation of fuel supply pump assembly ............................................................ 50-18 Removal and installation of fuel injector assembly ..................................................................... 50-22 Removal and installation of cylinder head assembly .................................................................. 50-29 00-8
PC228US-8,PC228USLC-8
Table of Contents
Removal and installation of radiator assembly ........................................................................... 50-44 Removal and installation of hydraulic oil cooler assembly.......................................................... 50-47 Removal and installation of aftercooler assembly ...................................................................... 50-49 Removal and installation of engine assembly............................................................................. 50-52 Removal and installation of engine front seal ............................................................................. 50-56 Removal and installation of engine rear seal.............................................................................. 50-58 Removal and installation of fuel cooler assembly....................................................................... 50-61 Removal and installation of fuel tank assembly.......................................................................... 50-63 Power train..................................................................................................................................... 50-66 Removal and installation of travel motor and final drive assembly ............................................. 50-66 Disassembly and assembly of final drive assembly.................................................................... 50-67 Removal and installation of swing motor and swing machinery assembly ................................. 50-75 Disassembly and assembly of swing machinery assembly ........................................................ 50-77 Removal and installation of swing circle assembly ..................................................................... 50-85 Undercarriage and frame ............................................................................................................... 50-86 Separation and connection of track shoe assembly ................................................................... 50-86 Removal and installation of idler and idler cushion assembly .................................................... 50-88 Disassembly and assembly of idler assembly ............................................................................ 50-89 Disassembly and assembly of idler cushion assembly............................................................... 50-92 Disassembly and assembly of track roller assembly .................................................................. 50-94 Disassembly and assembly of carrier roller assembly................................................................ 50-96 Removal and installation of revolving frame assembly............................................................... 50-99 Removal and installation of counterweight assembly ................................................................. 50-101 Removal and installation of maintenance counterweight assembly ........................................... 50-103 Hydraulic system ........................................................................................................................... 50-106 Removal and installation of centre swivel joint assembly ........................................................... 50-106 Disassembly and assembly of centre swivel joint assembly....................................................... 50-109 Removal and installation of hydraulic tank assembly ................................................................. 50-111 Removal and installation of main pump assembly...................................................................... 50-113 Removal and installation of main pump input shaft oil seal ........................................................ 50-117 Removal and installation of control valve assembly ................................................................... 50-118 Disassembly and assembly of control valve assembly............................................................... 50-123 Disassembly and assembly of work equipment PPC valve assembly........................................ 50-127 Disassembly and assembly of travel PPC valve assembly ........................................................ 50-129 Work equipment............................................................................................................................. 50-132 Removal and installation of work equipment assembly .............................................................. 50-132 Disassembly and assembly of work equipment cylinder assembly ............................................ 50-135 Cab and its attachments ................................................................................................................ 50-142 Removal and installation of operator's cab assembly................................................................. 50-142 Removal and installation of operator's cab glass (adhered window glass)................................. 50-146 Removal and installation of front window assembly ................................................................... 50-156 Removal and installation of floor frame assembly ...................................................................... 50-157 Removal and installation of air conditioner unit assembly .......................................................... 50-164 Electrical system ............................................................................................................................ 50-170 Removal and installation of air conditioner compressor assembly ............................................. 50-170 Removal and installation of air conditioner condenser assembly ............................................... 50-172 Removal and installation of engine controller assembly............................................................. 50-173 Removal and installation of pump controller assembly............................................................... 50-175 Removal and installation of machine monitor assembly............................................................. 50-178 Removal and installation of pump swash plate sensor............................................................... 50-180 Removal and installation of KOMTRAX terminal assembly ........................................................ 50-181 Disassembly and Assembly of Quick Coupler Valve .................................................................. 50-182 60 Maintenance standard PC228US-8,PC228USLC-8
00-9
Table of Contents
Engine and cooling system ............................................................................................................ 60-4 Engine mount.............................................................................................................................. 60-4 Cooling system ........................................................................................................................... 60-5 Power train..................................................................................................................................... 60-6 Swing circle................................................................................................................................. 60-6 Swing machinery......................................................................................................................... 60-8 Final drive ................................................................................................................................... 60-10 Sprocket...................................................................................................................................... 60-12 Undercarriage and frame ............................................................................................................... 60-14 Track frame and idler cushion..................................................................................................... 60-14 Idler ............................................................................................................................................. 60-16 Track roller .................................................................................................................................. 60-18 Carrier roller ................................................................................................................................ 60-19 Track shoe .................................................................................................................................. 60-20 Hydraulic system............................................................................................................................ 60-26 Hydraulic tank ............................................................................................................................. 60-26 Main pump .................................................................................................................................. 60-27 Control valve ............................................................................................................................... 60-29 Swing motor ................................................................................................................................ 60-39 Travel motor................................................................................................................................ 60-41 PPC valve ................................................................................................................................... 60-45 Solenoid valve............................................................................................................................. 60-53 Attachment circuit selector valve ................................................................................................ 60-55 Anti-drop valve ............................................................................................................................ 60-58 Centre swivel joint....................................................................................................................... 60-60 Work equipment............................................................................................................................. 60-62 Work equipment.......................................................................................................................... 60-62 Dimensions of components......................................................................................................... 60-64 Work equipment cylinder ............................................................................................................ 60-68 80 Appendix Air conditioner ................................................................................................................................ 80-3 Precautions for refrigerant .......................................................................................................... 80-3 Air conditioner component .......................................................................................................... 80-4 Configuration and function of refrigeration cycle......................................................................... 80-5 Outline of refrigeration cycle ....................................................................................................... 80-8 Air conditioner unit ...................................................................................................................... 80-10 Air conditioner controller ............................................................................................................. 80-15 Compressor ................................................................................................................................ 80-16 Condenser and Modulator .......................................................................................................... 80-17 Sensor......................................................................................................................................... 80-17 Procedure for testing and troubleshooting .................................................................................. 80-20 Circuit diagram and arrangement of connector pins ................................................................... 80-22 System diagram .......................................................................................................................... 80-23 Detail of air conditioner unit ........................................................................................................ 80-27 Parts and connectors layout ....................................................................................................... 80-28 Testing air leakage (duct) ........................................................................................................... 80-32 Testing with self-diagnosis function ............................................................................................ 80-33 Testing vent (mode) changeover ................................................................................................ 80-37 Testing FRESH/RECIRC air changeover ................................................................................... 80-37 Testing inner sensor ................................................................................................................... 80-38 Testing outer sensor ................................................................................................................... 80-38 Testing sunlight sensor ............................................................................................................... 80-39 Testing (dual) pressure switch for refrigerant ............................................................................. 80-40 00-10
PC228US-8,PC228USLC-8
Table of Contents
Testing relays ............................................................................................................................. 80-41 Troubleshooting chart 1 .............................................................................................................. 80-44 Troubleshooting chart 2 .............................................................................................................. 80-45 Information in troubleshooting table............................................................................................ 80-47 Troubleshooting for power supply and CAN communication system (Air conditioner does not operate) 80-50 Troubleshooting for compressor and refrigerant system (Air is not cooled) ............................... 80-53 Troubleshooting for blower motor system (No air comes out or air flow is abnormal) ................ 80-56 Troubleshooting for temperature control..................................................................................... 80-59 Troubleshooting for vent (mode) changeover............................................................................. 80-61 Troubleshooting for FRESH/RECIRC air changeover ................................................................ 80-63 Troubleshooting for temperature sensor system ........................................................................ 80-65 Troubleshooting with gauge pressure......................................................................................... 80-67 Connection of service tool .......................................................................................................... 80-69 Precautions for disconnecting and connecting air conditioner piping ......................................... 80-70 Handling of compressor oil ......................................................................................................... 80-72 Desiccant replacement procedure .............................................................................................. 80-74 90 Diagrams and drawings Hydraulic circuit diagram ............................................................................................................... 90-3 Symbols used in hydraulic circuit diagrams................................................................................ 90-3 Hydraulic circuit diagram (1/3) .................................................................................................... 90-7 Hydraulic circuit diagram (2/3) .................................................................................................... 90-9 Hydraulic circuit diagram (3/3) .................................................................................................... 90-11 Electrical circuit diagram ................................................................................................................ 90-13 Symbols used in electric circuit diagrams ...................................................................................... 90-13 Electrical circuit diagram (1/6) .................................................................................................... 90-17 Electrical circuit diagram (2/6) .................................................................................................... 90-19 Electrical circuit diagram (3/6) .................................................................................................... 90-21 Electrical circuit diagram (4/6) .................................................................................................... 90-23 Electrical circuit diagram (5/6) .................................................................................................... 90-25 Electrical circuit diagram (6/6) .................................................................................................... 90-27 Air conditioner electrical circuit diagram ..................................................................................... 90-29
PC228US-8,PC228USLC-8
00-11 (03)
Foreword and general information Safety notice
Foreword and general information Safety notice (Rev. 2010/03)
Important safety notice Appropriate servicing and repair are extremely important to ensure safe operation of the machine. The shop manuals describe the effective and safe servicing and repair methods recommended by Komatsu. Some of the servicing and repair methods require use of special tools designed by Komatsu for special purposes. The symbol mark "k" is indicated for such matters that require special precautions. The work indicated with the warning mark should be performed according to the instructions with special attention to the precautions. Should a hazardous situation occur or be anticipated during such work, be sure to keep safe first and take every necessary measure. 6) Keep all tools in good condition, learn the correct way to use them, and use the proper 1. General precautions ones. Before starting work, thoroughly check k Inappropriate handling creates an exthe tools, machine, forklift truck, service car, treme danger. Read and understand what etc. is described in the Operation and Mainte7) If welding repairs are needed, always have a nance Manual before operating the matrained and experienced welder perform the chine. Read and understand what is work. When performing welding work, always described in this manual before starting wear welding gloves, apron, shielding work. goggles, cap and other clothes suited for 1) Before performing any greasing or repairs, welding work. read all the safety labels stuck to the 8) Before starting work, warm up your body machine. For the locations of the safety thoroughly to start work under good condilabels and detailed explanation of precaution. tions, see the Operation and Maintenance 9) Avoid continuing work for long hours and Manual. take rests at proper intervals to keep your 2) Locate a place in the repair workshop to keep body in good condition and at the provided tools and removed parts. Always keep the place. tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt, water, or oil on the floor. Safety points Smoke only in the areas provided for 1 Good arrangement 2 Correct work clothes smoking. Never smoke while working. 3 Following work standard 3) When performing any operation, always 4 Making and checking signals wear safety shoes and helmet. Do not wear Prohibition of operation and handling by unliloose work clothes, or clothes with buttons 5 censed workers missing. 6 Safety check before starting work q Always wear the safety glasses when hitWearing protective goggles (for cleaning or grind7 ting parts with a hammer. ing work) q Always wear the safety glasses when Wearing shielding goggles and protectors (for 8 welding work) grinding parts with a grinder, etc. 9 Good physical condition and preparation 4) When performing any operation with two or Precautions against work which you are not used more workers, always agree on the operating 10 to or you are used to too much procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR warning tag in the operator's compartment. 5) Only qualified workers must perform the work and operation which require license or qualification.
00-12
PC228US-8,PC228USLC-8
Foreword and general information Safety notice
2. Preparation work 1) Before adding oil or making any repairs, park the machine on a hard and level ground, and apply the parking brake and chock the wheels or tracks to prevent the machine from moving. 2) Before starting work, lower the work equipment (blade, ripper, bucket, etc.) to the ground. If this is not possible, insert the lock pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning tag on them. 3) When disassembling or assembling, support the machine with blocks, jacks, or stands before starting the work. 4) Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing. 3. Precautions during work 1) Before disconnecting or removing components for the oil, water, or air circuits, first release the pressure completely from the circuit. When removing the oil filler cap, a drain plug, or an oil pressure pickup plug, loosen it slowly to prevent the oil from spurting out. 2) The coolant and oil in the circuits are hot when the engine is shut down, so be careful not to get scalded. Wait for the oil and coolant to cool before performing any work on the oil or water circuits. 3) Before starting work, shut down the engine. When working on or around a rotating part, in particular, shut down the engine. When checking the machine without shutting down the engine (measuring oil pressure, revolving speed, temperature, etc.), take extreme care not to get caught in rotating parts or moving parts. 4) Before starting work, remove the cables from the battery. Always remove the cable from the negative (–) terminal first. 5) When raising a heavy component (heavier than 25 kg), use a hoist or crane. Before starting work, check that the slings (wire ropes, chains, and hooks) are free from damage. Always use slings which have ample capacity and install them to proper places. Operate the hoist or crane slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane. PC228US-8,PC228USLC-8
6) When removing a cover which is under internal pressure or under pressure by a spring, always leave two bolts in diagonal positions. Loosen those bolts gradually and alternately to release the pressure, and then remove the cover. 7) When removing components, be careful not to break or damage the electrical wiring. Damaged wiring may cause electrical fires. 8) When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips onto the floor, wipe it off immediately. Fuel or oil on the floor can cause you to slip and can even cause fires. 9) As a general rule, do not use gasoline to wash parts. Do not use it to clean electrical parts, in particular. 10)Be sure to assemble all parts again in their original places. Replace any damaged parts and parts which must not be reused with new parts. When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is operated. 11)When installing high pressure hoses and tubes, make sure that they are not twisted. Damaged hoses and tubes are dangerous, so be extremely careful when installing hoses and tubes for high pressure circuits. In addition, check that connections of them are correct. 12)When assembling or installing parts, always tighten them to the specified torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speeds, be particularly careful to check that they are installed correctly. 13)When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. 14)When measuring hydraulic pressure, check that the measuring tools are correctly installed. 15)Take care when removing or installing the tracks of track-type machines. When removing the track, the track separates suddenly, so never let anyone stand at either end of the track. 16)If the engine is operated for a long time in a place which is not ventilated well, you may suffer from gas poisoning. Accordingly, open the windows and doors to ventilate well.
00-13
Foreword and general information Safety notice
4. Precautions for slinging work and making signals 1) Only one appointed worker must make signals and co-workers must communicate with each other frequently. The appointed signaller must make specified signals clearly at a place where he is well seen from the operator's seat and where he can see the working condition easily. The signaller must always stand in front of the load and guide the operator safely. q Do not stand under the load. q Do not step on the load. 2) Check the slings before starting sling work. 3) Keep putting on gloves during sling work. (Put on leather gloves, if available.) 4) Measure the weight of the load by the eye and check its centre of gravity. 5) Use proper sling according to the weight of the load and method of slinging. If too thick wire ropes are used to sling a light load, the load may slip and fall. 6) Do not sling a load with one wire rope alone. If it is slung so, It may rotate and may slip out of the rope. Install two or more wire ropes symmetrically. k Slinging with one rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding position on the load, which can result in a dangerous accident. 7) Limit the hanging angle to 60 degree, as a rule. Do not sling a heavy load with ropes forming a wide hanging angle from the hook. When hoisting a load with two or more ropes, the force subjected to each rope will increase with the hanging angle. The table below shows the variation of allowable load in kN {kg} when hoisting is made with two ropes, each of which is allowed to sling up to 9.8 kN {1,000 kg} vertically, at various hanging angles. When the two ropes sling a load vertically, up to 19.6 kN {2,000 kg} of total weight can be suspended. This weight is reduced to 9.8 kN {1,000 kg} when the two ropes make a hanging angle of 120 degree. If the two ropes sling a 19.6 kN {2,000 kg} load at a lifting angle of 150 degree, each of them is subjected to a force as large as 39.2 kN {4,000 kg}.
00-14
8) When installing wire ropes to an angular load, apply pads to protect the wire ropes. If the load is slippery, apply proper material to prevent the wire rope from slipping. 9) Use the specified eyebolts and fix wire ropes, chains, etc. to them with shackles, etc. 10)Apply wire ropes to the middle portion of the hook. q Slinging near the tip of the hook may cause the rope to slip off the hook during hoisting. The hook has the maximum strength at the middle portion.
11)Do not use twisted or kinked wire ropes. 12)When lifting up a load, observe the following. q Wind in the crane slowly until wire ropes are stretched. When settling the wire ropes with the hand, do not grasp them but press them from above. If you grasp them, your fingers may be caught. q After the wire ropes are stretched, stop the crane and check the condition of the slung load, wire ropes, and pads.
PC228US-8,PC228USLC-8
Foreword and general information Safety notice
If the load is unstable or the wire rope or chains are twisted, lower the load and lift it up again. q Do not lift up the load at an angle. 13)When lowering a load, observe the following. q When lifting down a load, stop it temporarily at 30 cm above the floor, and then lower it slowly. q Check that the load is stable, and then remove the sling. q Remove kinks and dirt from the wire ropes and chains used for the sling work, and put them in the specified place. q
5. Precautions for using mobile crane a Read the Operation and Maintenance Manual of the crane carefully in advance and operate the crane safely. 6. Precautions for using overhead traveling crane k A hoist crane or similar device must be used for lifting a heavy load (25 kg or more). The weight of a part that is 25 kg or more is indicated with the symbol "4" in "Disassembly and assembly". 1) Before starting work, inspect the wire ropes, brake, clutch, controller, rails, over wind stop device, ground fault circuit interrupter, crane collision prevention device, and power application warning lamp, and check safety. 2) Observe the signals for sling work. 3) Operate the hoist at a safe place. 4) Check the direction indicator plates (east, west, south, and north) and the directions of the control buttons without fail. 5) Do not sling a load at an angle. Do not move the crane while the slung load is swinging. 6) Do not raise or lower a load while the crane is moving longitudinally or laterally. 7) Do not drag a sling. 8) When lifting up a load, stop it just after it leaves the ground and check safety, and then lift it up. 9) Consider the travel route in advance and lift up a load to a safe height. 10)Place the control switch in a position where it will not be an obstacle to work and passage. 11)After operating the hoist, do not swing the control switch. 12)Remember the position of the main switch so that you can turn off the power immediately in an emergency.
PC228US-8,PC228USLC-8
13)If the hoist stops because of a power failure, turn the power switch OFF. When turning on a switch which was turned OFF by the ground fault circuit interrupter, check that the devices related to that switch are not in operating condition. 14)If you find an obstacle around the hoist, stop the operation. 15)After finishing the work, stop the hoist at the specified position and raise the hook to at least 2 m above the floor. Do not leave the sling installed to the hook. 7. Selecting wire ropes 1) Select adequate ropes depending on the weight of parts to be hoisted, referring to the table below. Wire ropes (Standard "Z" twist ropes without galvanizing) (JIS G3525, No. 6, Type 6X37-A) Allowable load Nominal diameter of rope mm kN ton 10 8.8 0.9 12 12.7 1.3 14 17.3 1.7 16 22.6 2.3 18 28.6 2.9 20 35.3 3.6 25 55.3 5.6 30 79.6 8.1 40 141.6 14.4 50 221.6 22.6 60 318.3 32.4
a The allowable load is one-sixth of the breaking strength of the rope to be used (Safety coefficient: 6).
00-15
Foreword and general information Safety notice
8. Precautions for disconnecting and connecting hoses and tubes in an air conditioner circuit 1) Disconnection k Although the refrigerant (refrigerant gas: R134a) used on the machine's air conditioner is less destructive to the ozone layer for environmentally friendliness, it is not allowed to be released into the atmosphere as is. Whenever disconnecting the air conditioner gas circuit, be sure to recover the refrigerant gas to reuse it. a Ask a qualified person for collection and charge of the refrigerant (R134a). a Never release the refrigerant (R134a) to the atmosphere. k If the refrigerant gas gets in your eyes or contacts your skin, you may lose your sight or your skin may be frozen. Whenever recovering or adding refrigerant gas, you must put on safety glasses, safety gloves and long sleeved clothes. The refrigerant gas must be recovered and added by a qualified person.
a For tightening torque, see the precautions for installation in each section of "Disassembly and assembly".
2) Connection 1] When installing the air conditioner circuit hoses and tubes, take care that dirt, dust, water, etc. will not enter them. 2] When connecting the air conditioner hoses and tubes, check that O-rings (1) are fitted to their joints. 3] Check that O-ring (1) is free from flaw and deterioration. 4] When connecting the refrigerant piping, apply compressor oil for refrigerant (R134a) (DENSO: ND-OIL8, VALEO THERMAL SYSTEMS: ZXL100PG (equivalent to PAG46)) to its O-rings. a Example of O-ring (Fitted to every joint of hoses and tubes)
00-16
PC228US-8,PC228USLC-8
Foreword and general information How to read the shop manual
How to read the shop manual (Rev. 2010/03) q q 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. Materials and specifications are subject to change without notice. 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 contains the index, foreword, safety and basic information. If any revision is made, the LIST OF REVISED PAGES will be added. 01. Specification This section explains the specifications of the machine. 10. Structure and function This section explains the structure and function of each component. It serves not only to give an understanding for the structure of each component, but also serves as reference material for troubleshooting. 20. Standard value table This section explains the standard values for new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting. 30. Testing and adjusting This section explains measuring tools and measuring methods for testing and adjusting, as well as the adjusting method of each part. The standard values and judgment criteria for "Testing and adjusting" are explained in "Standard value table". 40. Troubleshooting This section explains how to find out failed parts and how to repair them. The troubleshooting is divided by failure modes. The "S mode" of the troubleshooting related to the engine may be also explained in the Chassis volume and Engine volume. In this case, see the Chassis volume. 50. Disassembly and assembly This section explains the special tools and procedures for removing, installing, disassembling, and 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. 60. Maintenance standard This section gives maintenance standard values of each component. The maintenance standard sub-section explains the criteria and remedies for disassembly and service. 80. Appendix This section explains the structure, function, testing, adjusting, and troubleshooting for the equipment not classifiable in other sections. 90. Diagrams and drawings (chassis volume) /Repair and replacement of parts (engine volume) q Chassis volume This section gives hydraulic circuit diagrams and electrical circuit diagrams. q Engine volume This section explains the method of re manufacturing and repairing engine and replacing parts. PC228US-8,PC228USLC-8
00-17
Foreword and general information How to read the shop manual
2. Revision and distribution Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most up-to-date information before you start any work. 3. Filing method File the revised or added pages in the correct order of the page numbers printed in the LIST OF REVISED PAGES. q
Revision number When a manual is revised, revision number of each page is increased by 1. (Example: (01), (02), (03)...)
q
Revisions The revised pages are shown in the LIST OF REVISED PAGES.
4. Symbol Important safety and quality portions are marked with the following symbols so that the shop manual will be used practically. Symbol
Item
Description
k
Safety
Special safety precautions which are necessary when performing work are described.
a
Caution
Special technical precautions or other precautions for preserving standards which are necessary when performing work are described.
4
Weight
Weight of parts of component or parts are indicated. Caution necessary when selecting hoisting wire, or when working posture is important, etc. are described.
3
Tightening torque
Places that require special attention for tightening torque during assembly are indicated.
2
Coat
5
Oil, coolant
6
Drain
Places to be coated with adhesives, etc. during assembly are indicated.
Places where oil, etc. must be added, and capacity are indicated.
Places where oil, etc. must be drained, and quantity to be drained are indicated.
5. Unit In this shop manual, the units are indicated with International System of units (SI). For reference, conventionally used Gravitational System of units is indicated in parentheses { }.
00-18
PC228US-8,PC228USLC-8
Foreword and general information Explanation of terms for maintenance standard
Explanation of terms for maintenance standard (Rev. 2010/03) 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 dimension and tolerance q To be accurate, the finished dimension of parts is slightly different from one to another. q To specify the finished dimension of a part, a certain dimension is set for the part and an allowable difference from that dimension is indicated. q The above dimension set is called the "standard dimension" and the range of difference from the standard dimension is called the "tolerance". q The tolerance with the symbols of + or – is indicated on the right side of the standard dimension. Example: Standard dimension
q
When some parts are repaired, the value of performance/function is set to the standard value.
Tolerance -0.022 -0.126
120
a The tolerance may be indicated in the text and a table as [standard dimension (upper limit of tolerance/lower limit of tolerance)]. Example) 120 (–0.022/–0.126) q
q
Usually, the dimension of a hole and the dimension of the shaft to be inserted into that hole are indicated by the same standard dimension and different tolerances of the hole and shaft. The tightness of fit is decided by the tolerance. Indication of dimension of rotating shaft and hole and their related drawing.
Example: Standard dimension 60
Tolerance Shaft -0.030 -0.076
Hole +0.046 0
2. Standard clearance and standard value q The clearance made when new parts are assembled is called the "standard clearance", which is indicated by the range from the minimum clearance to the maximum clearance. q When some parts are repaired, the clearance is generally adjusted to the standard clearance. q The values indicating performance and function of new products or equivalent are called the "standard value", which is indicated by a range or a target value.
PC228US-8,PC228USLC-8
3. Standard interference q When the diameter of a hole of a part shown in the given standard dimension and tolerance table is smaller than that of the shaft to be inserted, the difference between those diameters is called the "interference". q The range (between A and B) from the difference (A) between the minimum dimension of the shaft and the maximum dimension of the hole to the difference (B) between the maximum dimension of the shaft and the minimum dimension of the hole is the “standard interference”. q After repairing or replacing some parts, measure the dimension of their hole and shaft and check that the interference is in the standard range.
00-19
Foreword and general information Explanation of terms for maintenance standard
4. Repair limit and allowable value or allowable dimension q The dimension of a part changes because of wear and deformation while it is used. The limit of changed dimension is called the "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 product lowers while it is used. A value with which the product can be used without causing a problem is called the "allowable value" or "allowable dimension". q If a product deviates from the allowable value, it must be checked or repaired. However, since most of the allowable values are estimated from various tests or experiences in most cases, it must be judged after considering the operating condition and customer's requirement. 5. Allowable clearance q Parts can be used until the clearance between them is increased to a certain limit. The limit at which those parts cannot be used is called the "allowable clearance". q If the clearance between the parts exceeds the allowable clearance, they must be replaced or repaired. 6. Allowable interference q The allowable maximum interference between the hole of a part and the shaft of another part to be assembled is called the "allowable interference". q The allowable interference shows the repair limit of the part of smaller tolerance. q If the interference between the parts exceeds the allowable interference, they must be replaced or repaired.
00-20
PC228US-8,PC228USLC-8
Foreword and general information Handling of hydraulic components
Handling of hydraulic components (Rev. 2010/03) With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt (foreign material) in the hydraulic circuit. Therefore, special precaution is required when adding hydraulic oil, or when disassembling or assembling hydraulic components. 1. Be careful of the operating environment Avoid adding hydraulic oil, replacing filters, or repairing the machine in rain or high winds, or at places where there is a lot of dust. 2. Disassembly and maintenance work in the field If disassembly or maintenance work is performed on hydraulic components in the field, there is danger of dust entering the components. It is also difficult to check the performance after repairs, so it is desirable to use unit exchange. Disassembly and maintenance of hydraulic components should be performed in a specially prepared dustproof workshop, and the performance should be checked with special test equipment.
3. Sealing openings After any piping or equipment is removed, the openings should be sealed with caps, tapes, or vinyl bags to prevent any dirt or dust from entering. If the opening is left open or is blocked with a rag, there is danger of dirt entering or of the surrounding area being made dirty by leaking oil so never do this. Do not simply drain oil out onto the ground, but collect it and ask the customer to dispose of it, or take it back with you for disposal.
4. Preventing intrusion of foreign materials during refilling operations. Be careful not to let any dirt or dust get in when refilling with hydraulic oil. Always keep the oil filler and the area around it clean, and also use clean pumps and oil containers. If an oil cleaning device is used, it is possible to filter out the dirt that has been collected during storage, so this is an even more effective method.
PC228US-8,PC228USLC-8
00-21
Foreword and general information Handling of hydraulic components
5. Replacing hydraulic oil while its temperature is high When hydraulic oil or other oil is warm, it flows easily. In addition, the sludge can also be drained out easily from the circuit together with the oil, so it is best to change the oil when it is still warm. When changing the oil, as much as possible of the old hydraulic oil must be drained out. (Drain the oil from the hydraulic tank; also drain the oil from the filter and from the drain plug hole in the circuit.) If any old oil is left, the contaminants and sludge in it will mix with the new oil and will shorten the life of the hydraulic oil. 6. Flushing operations After disassembling and assembling the equipment, or changing the oil, use flushing oil to remove the contaminants, sludge, and old oil from the hydraulic circuit. Normally, flushing is performed twice. Primary flushing is performed by use of flushing oil and secondary flushing is performed by use of the specified hydraulic oil.
7. Cleaning operations After repairing the hydraulic equipment (pump, control valve, etc.) or when running the machine, perform oil cleaning to remove the sludge or contaminants in the hydraulic oil circuit. The oil cleaning equipment can remove the ultra fine (about 3 m) particles that the filter built in the hydraulic equipment cannot remove, so it is an extremely effective device.
00-22
PC228US-8,PC228USLC-8
Foreword and general information Method of disconnecting and connecting push-pull type coupler
Method of disconnecting and connecting push-pull type coupler (Rev. 2010/03)
k Before performing the following work, loosen the oil filler cap of the hydraulic tank gradually to
release the remaining pressure in the hydraulic tank.
k Even if the remaining pressure is released from the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly, prepare an oil container. Type 1
0 -15
1. Disconnection 1) Hold adapter (1) and push hose joint (2) into mating adapter (3). (Fig. 1) a The adapter can be pushed in about 3.5 mm. a Do not hold rubber cap portion (4). 2) With hose joint (2) pushed into adapter (3), press rubber cap portion (4) against adapter (3) until it clicks. (Fig. 2) 3) Hold hose adapter (1) or hose (5) and pull it out. (Fig. 3) a Since some hydraulic oil flows out, prepare an oil container.
2. Connection 1) Hold hose adapter (1) or hose (5) and insert it in mating adapter (3), aligning them with each other. (Fig. 4) a Do not hold rubber cap portion (4). 2) After inserting the hose fitting in the adapter on the other side perfectly, pull it back to check the connecting condition (Fig. 5) a When the hose is pulled back, the rubber cap portion moves toward the hose about 3.5 mm. This does not indicate abnormality, however.
PC228US-8,PC228USLC-8
00-23
Foreword and general information Method of disconnecting and connecting push-pull type coupler
Type 2
0 -16
1. Disconnection 1) Hold the tightening portion and push body (7) straight until sliding prevention ring (6) contacts contact surface (a) of the hexagonal portion at the male end. (Fig. 6) 2) While holding the condition of Step 1), turn lever (8) to the right (clockwise). (Fig. 7) 3) While holding the condition of Steps 1) and 2), pull out whole body (7) to disconnect it. (Fig. 8)
2. Connection q Hold the tightening portion and push body (7) straight until sliding prevention ring (6) contacts contact surface (a) of the hexagonal portion at the male end. (Fig. 9)
00-24
PC228US-8,PC228USLC-8
Foreword and general information Method of disconnecting and connecting push-pull type coupler
Type 3
0 -17
1. Disconnection 1) Hold the tightening portion and push body (9) straight until sliding prevention ring (8) contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 10) 2) While holding the condition of Step 1), push cover (10) straight until it contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 11) 3) While holding the condition of Steps 1) and 2), pull out whole body (9) to disconnect it. (Fig. 12)
2. Connection q Hold the tightening portion and push body (9) straight until sliding prevention ring (8) contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 13)
PC228US-8,PC228USLC-8
00-25
Foreword and general information Handling of electric equipment
Handling of electric equipment (Rev. 2010/03) 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 performed. 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". Points to remember when handling electric equipment 1. Handling wiring harnesses and connectors Wiring harnesses consist of wires connecting one component to another component, connectors used for connecting and disconnecting one wire from another wire, and protectors or tubes used for protecting the wires. Compared with other electrical components fitted in boxes or cases, wiring harnesses are more likely to be affected by the direct effects of rain water, heat, or vibration. Furthermore, during inspection and repair operations, they are frequently removed and installed again, so they are likely to suffer deformation or damage. For this reason, it is necessary to be extremely careful when handling wiring harnesses.
0 -18
2. Main failures occurring in wiring harnesses 1) Defective contact of connectors (defective contact between male and female connectors) Problems with defective contact are likely to occur because the male connector is not properly fitted into the female connector, or because one or both of the connectors is deformed or the position is not correctly aligned, or because there is corrosion or oxidization of the contact surfaces. The corroded or oxidized contact surfaces may become shiny again (and contact may become normal) by connecting and disconnecting the connector about ten times. 2) Defective crimping or soldering of connectors The pins of the male and female connectors are attached to wires by crimping or soldering. If excessive force is applied to the wire, the joint is separated and causes a defective contact or the wire is broken.
00-26
PC228US-8,PC228USLC-8
Foreword and general information Handling of electric equipment
3) Disconnections in wiring If the harness is pulled to disconnect the connector, or components are lifted with a crane with the harness still connected, or a heavy object hits the harness, the crimping of the connector may separate, or the soldering may be damaged, or the harness may be broken.
4) High-pressure water entering connector The connector is designed to make it difficult for water to enter (drip-proof structure), but if high-pressure water is sprayed directly on the connector, water may enter the connector, depending on the direction of the water jet. Accordingly, take care not to spray water over the connector. The connector is designed to prevent water from entering, but at the same time, if water does enter, it is difficult for it to be drained. Therefore, if water should get into the connector, the pins will be short-circuited by the water, so if any water gets in, immediately dry the connector or take other appropriate action before passing electricity through it. 5) Oil or dirt stuck to connector If oil or grease are stuck to the connector and an oil film is formed on the mating surface of the male and female pins, the oil will not let the electricity pass, so there will be defective contact. If there is oil or grease stuck to the connector, wipe it off with a dry cloth or blow it to dry with compressed air and spray it with electric contact cleaner. a When wiping the joint portion of the connector, be careful not to apply excessive force or deform the pins. a If there is oil or water in the compressed air, the contacts will become even dirtier, so remove the oil and water from the compressed air completely before cleaning with compressed air.
PC228US-8,PC228USLC-8
00-27
Foreword and general information Handling of electric equipment
3. Removing, installing, and drying connectors and wiring harnesses 1) Disconnecting connectors 1] Hold the connectors when disconnecting. When disconnecting the connectors, hold the connectors. For connectors held by a screw, loosen the screw fully, then hold the male and female connectors in each hand and pull apart. For connectors which have a lock stopper, press down the stopper with your thumb and pull the connectors apart. a Never pull with one hand. 2] When removing from clips q Both of the connector and clip have stoppers, which are engaged with each other when the connector is installed.
When removing a connector from a clip, pull the connector in a parallel direction to the clip for removing stoppers. a If the connector is pried up and down or to the left or right, the housing may break.
q
3] Action to take after removing connectors After removing a connector, cover it with a vinyl bag to prevent the entry of dust, dirt, oil, or water to the contact portion. a If the machine is left disassembled for a long time, it is particularly easy for improper contact to occur, so always cover the connector.
00-28
PC228US-8,PC228USLC-8
Foreword and general information Handling of electric equipment
2) Connecting connectors 1] Check the connector visually. Check that no oil, dirt, or water is stuck to connector pins (joint portion). Check that connector pins are free from deformation, defective contact, corrosion, or damage. Check that external surfaces of the connectors are free from damage or breakage. a If there is any oil, water, or dirt stuck to the connector, wipe it off with a dry cloth. If any water has got inside the connector, warm the inside of the connector and harness with a dryer, but be careful not to make them too hot as this will cause short circuits. a If there is any damage or breakage, replace the connector. 2] Fix the connector securely. Position the connectors correctly, and then fit them securely. For connectors with the lock stopper, push in the connector until the stopper clicks into position. 3] Correcting protrusion of the boot and misalignment of the wiring harness For connectors fitted with the boot, correct any extrusion of the boot. In addition, if the wiring harness is moved in laying, or the clamp is out of position, correct it to its right position. a If the connector cannot be corrected easily, remove the clamp and adjust the position. q If the connector clamp is removed, be sure to return it to its original position. Check also that there are no loose clamps.
PC228US-8,PC228USLC-8
00-29
Foreword and general information Handling of electric equipment
3) Deutsch connector (DT 8-pin, 12-pin) Disconnection (Left of figure) While pressing locks (a) and (b), pull out the female connector (2). Connection (Right of figure) 1] Push in female connector (2) horizontally until the lock clicks. Arrow: 1) 2] Since locks (a) and (b) may not be set completely, push in female connector (2) while moving it up and down until the locks are set normally. Arrow: 1), 2), 3) a Right of figure: Lock (a) is pulled down (not set completely) and lock (b) is set completely. (1): Male connector (2): Female connector (a), (b): Locks
00-30
q
Disconnection
q
Connection (Example of incomplete setting of (a))
PC228US-8,PC228USLC-8
Foreword and general information Handling of electric equipment
4) Drying wiring harness If there is any oil or dirt on the wiring harness, wipe it off with a dry cloth. Avoid washing it in water or using steam. If the connector must be washed in water, do not use high-pressure water or steam directly on the wiring harness. If water gets directly on the connector, do as follows. 1] Disconnect the connector and wipe off the water with a dry cloth. a If the connector is to be blown with dry compressed air, there is the risk that oil in the air may cause defective contact, remove oil and water in the air before starting air blow. 2] Dry the inside of the connector with a dryer. If water gets inside the connector, use a dryer to dry the connector. a Hot air from the dryer can be used, but regulate the time that the hot air is used in order not to make the connector or related parts too hot, as this will cause deformation or damage to the connector.
3] Perform a continuity test on the connector. After drying, leave the wiring harness disconnected and perform a continuity test to check for any short circuits between pins caused by water. a After completely drying the connector, blow it with electric contact cleaner and reassemble.
PC228US-8,PC228USLC-8
00-31
Foreword and general information Handling of electric equipment
4. Handling of connectors used on engine a Mainly, following engines are object for following connectors. q 95E-5 q 107E-1 q 114E-3 q 125E-5 q 140E-5 q 170E-5 q 12V140E-3 1) Slide, lock type (FRAMATOME-3, FRAMATOME-2) q 95/107/114/125/140/170/12V140 Series q Various pressure sensors and NE speed sensor Examples) Intake air pressure sensor in intake manifold: PIM (125/170/12V140 series) Oil pressure sensor: POIL (125/170/12V140 series) Oil pressure switch (95/107/114 series) Ne speed sensor on flywheel housing: NE (95/107/114/125/140/170/12V140 series) Ambient pressure sensor: PAMB (125/170/12V140 series) Disconnection 1] Slide lock L1 to the right. 2] While pressing lock L2, pull out connector (1) toward you. a Even if lock L2 is pressed, connector (1) cannot be pulled out toward you, if part (A) does not float. In this case, float part (A) with a small screwdriver while pressing lock L2, and then pull out connector (1) toward you.
Examples) Intake air temperature sensor in intake manifold: TIM Fuel temperature sensor: TFUEL Oil temperature sensor: TOIL Coolant temperature sensor: TWTR, etc. Disconnection Disconnect the connector by pulling lock (B) (on the wiring harness side) of connector (2) outward.
Connection Insert the connector straight until it "clicks".
Connection Insert the connector straight until it "clicks". 2) Pull lock type (PACKARD-2) q 95/107/114/125/140/170/12V140 Series q Various temperature sensors 00-32
PC228US-8,PC228USLC-8
Foreword and general information Handling of electric equipment
3) Push lock type (1) q 95/107/114 series Example) Fuel pressure common rail (BOSCH-03)
sensor
in
While pressing up lock (C) of the connector with flat-head screwdriver [1], pull out connector (3) in the direction of the arrow.
Disconnection While pressing lock (C), pull out connector (3) in the direction of the arrow. q
114 series
Connection Insert the connector straight until it "clicks". 4) Push lock type (2) q 107/114 series Example) Intake air pressure/temperature sensor in intake manifold (SUMIq
107 series
TOMO-04)
Disconnection While pressing lock (D), pull out connector (4) in the direction of the arrow.
a If the lock is located on the underside, use flat-head screwdriver [1] since you cannot insert your fingers. Connection Insert the connector straight until it "clicks".
PC228US-8,PC228USLC-8
00-33
Foreword and general information Handling of electric equipment
5) Push lock type (3) q 95/125/140/170/12V140 series Disconnection While pressing lock (E) of the connector, pull out connector (5) in the direction of the arrow. Example) Fuel pressure sensor in common rail: PFUEL etc. (AMP-3)
Example) Intake air pressure sensor in intake manifold. (CANNON-04): PIM, etc.
Disconnection 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 harness side.
Example) Injection pressure control valve of fuel supply pump: PCV (SUMITOMO-2)
Connection 1] Insert the connector to the end, while setting its groove. 2] Turn housing (H1) in the direction of the arrow until it "clicks".
Examples) Speed sensor of fuel supply pump: G (SUMITOMO-3) a Pull the connector straight up.
Connection Insert the connector straight until it "clicks". 6) Turn-housing type (Round green connector) q 140 series 00-34
PC228US-8,PC228USLC-8
Foreword and general information Handling of electric equipment
5. Handling controller 1) The controller contains a microcomputer and electronic control circuits. These control all of the electronic circuits on the machine, so be extremely careful when handling the controller. 2) Do not place objects on top of the controller. 3) Cover the control connectors with tape or a vinyl bag. Never touch the connector contacts with your hand. 4) During rainy weather, do not leave the controller in a place where it is exposed to rain. 5) Do not place the controller on oil, water, or soil, or in a place that can be heated to a high temperature even for a short time. (Place it on a suitable dry stand.) 6) Precautions when performing arc welding When performing arc welding on the machine body, disconnect all of the wiring harness connectors connected to the controller. Fit an arc welding ground to the place close to the welding point. 6. Points to remember when troubleshooting electric circuits 1) Be sure to turn the power OFF before disconnecting or connecting connectors. 2) Before performing troubleshooting, check all the related connectors for loose connection. a Disconnect and connect the related connectors several times to check. 3) Be sure to connect any disconnected connectors before going on to the next step. a If the power is turned ON with the connectors still disconnected, unnecessary warning will be displayed. 4) When performing troubleshooting of circuits (measuring the voltage, resistance, continuity, or current), wag the related wiring harnesses and connectors several times and check that there is no change in the reading of the tester. a If there is any change, there may be defective contact in the circuit.
PC228US-8,PC228USLC-8
00-35
Foreword and general information How to read electric wire code
How to read electric wire code (Rev. 2010/03) In the electric circuit diagram, the material, thickness, and colour of each electric wire are indicated by symbols. The electric wire code is helpful in understanding the electric circuit diagram. Example: AEX
0.85
L
---
Indicates blue, heat-resistant, low-voltage wire for automobile, having nominal No. of 0.85 Indicates colour of wire by colour code. Colour codes are shown in Table 3. Indicates size of wire by nominal No. Size (Nominal No.) is shown in Table 2. Indicates type of wire by symbol. Type, symbol, and material of wire are shown in Table 1. (Since the use of AV and AVS wires depends on size (nominal No.), their symbols are not indicated on the diagram.)
1. Type, symbol, and material AV and AVS are different only in thickness and outside diameter of the cover. CAVS has a circular compressed conductor. It differs from AV and AVS in the outside diameter and thickness of the cover. And AEX is similar to AV in thickness and outside diameter of the cover but different from AV and AVS in material of the cover. (Table 1) Type Low-voltage wire for automobiles Thin low-voltage wire for automobile (type 1) Thin low-voltage wire for automobile (type 2) Heat resistant low-voltage wire for automobiles
00-36
Symbol
Material Conductor
Annealed copper for electric appliance
Insulator
Soft polyvinyl chloride
Conductor
Annealed copper for electric appliance
AV
AVS Insulator
Soft polyvinyl chloride
Conductor
Annealed copper for electric appliance
Insulator
Soft polyvinyl chloride
CAVS
Example of use
General wiring (nominal No. 5 and above)
-30 – +60
Annealed copper for electric appliance -50 – +110 Heat-resistant crosslinked polInsulator yethylene
Conductor AEX
Temperature range for use ( °C)
General wiring (nominal No. 3 and below)
For mid- to small-size excavators (nominal No. 1.25 and below) General wiring in extremely cold weather district, wiring at high ambient temperature place
PC228US-8,PC228USLC-8
Foreword and general information How to read electric wire code
2. Dimensions (Table 2) Nominal No.
Cover D
Conductor
Number of strands/Diameter of strand Sectional area (mm2)
0.75f
(0.85)
1.25f
(1.25)
2f
2
3f
3
5
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 0.51
0.56
0.76
0.88
1.27
1.29
1.96
2.09
3.08
3.30
5.23
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
–
AV
Standard
–
–
–
–
–
–
–
4.6
AEX
Standard
2.0
2.2
2.7
3.0
3.1
–
3.8
4.6
8
15
20
30
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
7.95
13.36
20.61
35.19
42.73
54.29
63.84
84.96
109.1
d (approx.)
3.7
4.8
6.0
8.0
8.6
9.8
10.4
12.0
13.6
AVS
Standard
–
–
–
–
–
–
–
–
–
AV
Standard
5.5
7.0
8.2
10.8
11.4
13.0
13.6
16.0
17.6
AEX
Standard
5.3
7.0
8.2
10.8
11.4
13.0
13.6
16.0
17.6
Conductor
Cover D
(0.5)
d (approx.)
Nominal No. Number of strands/Diameter of strand Sectional area (mm2)
Nominal No.
Conductor
Cover D
0.5f
CAVS
40
50
60
85
100
0.5f
0.5
0.75f
0.85
1.25f
1.25
–
7/Circular compressed
–
11/Circular compressed
–
16/Circular compressed
–
0.56
–
0.88
–
1.29
d (approx.)
–
0.9
–
1.1
–
1.4
Standard
–
1.6
–
1.8
–
2.1
Number of strands/Diameter of strand Sectional area (mm2)
"f" of nominal No. denotes "flexible".
PC228US-8,PC228USLC-8
00-37
Foreword and general information How to read electric wire code
3. Color codes table (Table 3) Colour Code B Br BrB BrR BrW BrY Ch Dg G GB GL Gr GR GW GY L LB Lg LgB LgR
Colour of wire Black Brown Brown & Black Brown & Red Brown & White Brown & Yellow Charcoal Dark green Green Green & Black Green & Blue Gray Green & Red Green & White Green & Yellow Blue Blue & Black Light green Light green & Black Light green & Red
Colour Code LgW LgY LR LW LY O P R RB RG RL RW RY Sb Y YB YG YL YR YW
Colour of wire Light green & White Light green & Yellow Blue & Red Blue & White Blue & Yellow Orange Pink Red Red & Black Red & Green Red & Blue Red & White Red & Yellow Sky Blue Yellow Yellow & Black Yellow & Green Yellow & Blue Yellow & Red Yellow & White
Remarks: In a colour code consisting of 2 colours, the first colour is the colour of the background and the second colour is the colour 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
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
–
Br
BrW
BrR
BrY
BrB
–
–
–
Lg
LgR
LgY
LgB
LgW
–
–
–
O
–
–
–
–
–
–
–
Gr
–
–
–
–
–
–
–
P
–
–
–
–
–
–
–
Sb
–
–
–
–
–
–
–
Dg
–
–
–
–
–
–
–
Ch
–
–
–
–
–
–
–
Type of circuit
Others
00-38
AVS, AV, CAVS
PC228US-8,PC228USLC-8
Foreword and general information Precautions when performing work
Precautions when performing work (Rev. 2010/03) When removing, installing, disassembling or assembling a unit, be sure to follow the general precautions given below. 1. Precautions for removal work q If the coolant contains antifreeze, dispose of it correctly as chemicals. q After disconnecting hoses or tubes, cover them or fit plugs to prevent dirt or dust from entering. q When draining oil, prepare a container of adequate size to catch the oil. q Check the match marks showing the installation position, and put match marks in the necessary places before removal to prevent any mistake when assembling. q To prevent any excessive force from being applied to the wiring, always hold the connectors when disconnecting the connectors. Do not pull the wires. q Attach the tags to wires and hoses to show their installation position to prevent any mistake when installing. q Check the number and thickness of the shims, and keep them in a safe place. q When slinging component, be sure to use lifting equipment of ample strength. q When using forcing screws to remove any component, tighten the forcing screws uniformly and alternately. q Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from entering after removal. a Precautions when handling piping during disassembly
Put the following plugs into the piping after disconnecting it during disassembly operations. 1) Face seal type hoses and tubes Nominal number 02 03 04 05 06 10 12
Plug (nut end)
Sleeve nut (elbow end)
07376 - 70210 07376 - 70315 07376 - 70422 07376 - 70522 07376 - 70628 07376 - 71034 07376 - 71234
02789 - 20210 02789 - 20315 02789 - 20422 02789 - 20522 02789 - 20628 07221 - 21034 07221 - 21234
2) Split flange type hoses and tubes Nominal number 04 05
Flange (hose end)
Sleeve head (tube end)
Split flange
07379 - 00400 07379 - 00500
07378 - 10400 07378 - 10500
07371 - 30400 07371 - 30500
3) If the part is not under hydraulic pressure, the following corks can be used. Nominal number 06 08 10 12 14 16 18 20 22 24 27
Part No. 07049 - 00608 07049 - 00811 07049 - 01012 07049 - 01215 07049 - 01418 07049 - 01620 07049 - 01822 07049 - 02025 07049 - 02228 07049 - 02430 07049 - 02734
PC228US-8,PC228USLC-8
D 5 8 10 12 14 16 18 20 22 24 27
Dimensions d L 6 8 6.5 11 8.5 12 10 15 11.5 18 13.5 20 15 22 17 25 18.5 28 20 29 22.5 34
00-39
Foreword and general information Precautions when performing work
2. Precautions for installation work q Tighten all of the bolts and nuts (sleeve nuts) to the specified torque (KES). q Install the hoses without twisting or interference and fix them with intermediate clamps, if available. q Replace all of the gaskets, O-rings, cotter pins, and lock plates with new parts. q Bend the cotter pins and lock plates securely. q When coating with adhesive, clean and degrease the part, and coat the threaded portion with two to three drops of adhesive. q When coating with liquid gasket, clean and degrease the surface, and apply it uniformly after making sure that the surface is free from dirt or damage. q Clean all of the parts, and correct any damage, dents, burrs, or rust found on them. q Coat the rotating parts and sliding parts with engine oil. q When press-fitting parts, coat the surface with molybdenum disulphide lubricant (LM-P). q After installing the snap rings, check that the snap ring is settled in the ring groove completely. q When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect them securely. q When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align the direction of the hook. q When installing split flanges, fasten them uniformly and alternately to prevent excessive tightening on one side. a When operating the hydraulic cylinders for the first time after reassembling the cylinders, hydraulic pumps and other hydraulic component removed for repair, be sure to bleed the air as follows: 1] Start and run the engine at low idle. 2] Operate the work equipment control lever to operate the hydraulic cylinder four to five times, stopping the piston at 100 mm off the end of its stroke. 3] Next, operate the hydraulic cylinder three to four times to the end of its stroke. a When using the machine for the first time after repair or long storage, follow the same procedure. 3. Precautions for completing work 1) Refilling of coolant, oil and grease q If the coolant is drained, close the drain valve, and add coolant to the specified level. Run the engine to circulate the coolant through the system. Then add the coolant again if necessary. q If the hydraulic component is removed and installed again, add engine oil to the specified level. Run the engine to circulate the oil through the system. Then add the oil again if necessary. q If the hydraulic piping or hydraulic equipment are removed, be sure to bleed air from the system after reassembling the parts, by referring to "Testing and adjusting". q Supply the specified amount of grease (molybdenum disulphide grease) to the work equipment parts. 2) Checking cylinder head and manifolds mountings for looseness Check the cylinder head and intake and exhaust manifold mountings for looseness. If any part is loosened, retighten it. q For the tightening torques, see the "Disassembly and assembly". 3) Checking engine piping for damage and looseness Intake and exhaust system Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for air suction and exhaust gas leakage. If any part is loosened or damaged, retighten or repair it. Cooling system Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for coolant leakage. If any part is loosened or damaged, retighten or repair it. Fuel system Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for fuel leakage. If any part is loosened or damaged, retighten or repair it.
00-40
PC228US-8,PC228USLC-8
Foreword and general information Precautions when performing work
4) Checking muffler, exhaust pipe and their mounts for damage and looseness 1] Visually check the muffler, exhaust pipe and their mounts for a crack and damage. If any part is damaged, replace it. 2] Check the mounting bolts and nuts of the muffler, exhaust pipe and their mounts for looseness. If any part is loosened, retighten it. 5) Checking muffler function Check the muffler for unusual sound and sound different from that of a new muffler. If any unusual sound is heard, repair the muffler, referring to "Troubleshooting" and "Disassembly and assembly".
PC228US-8,PC228USLC-8
00-41
Foreword and general information Standard tightening torque table
Standard tightening torque table (Rev. 2010/03) 1. Table of tightening torques for bolts and nuts a Unless otherwise specified, tighten metric nuts and bolts to the torque shown in the following table. 1) The following table applies to the bolts in Fig. A. Thread diam- Width across eter of bolt flats mm mm 6 10(10) 8 13(12) 10 17(14) 12 19(17) 14 22 16 24 18 27 20 30 22 32 24 36 27 41 30 46 33 50 36 55 39 60
Tightening torque Nm 11.8 –14.7 27 – 34 59 – 74 98 – 123 157 – 196 245 – 309 343 – 427 490 – 608 662 – 829 824 – 1,030 1,180 – 1,470 1,520 – 1,910 1,960 – 2,450 2,450 – 3,040 2,890 – 3,630
kgm 1.2 – 1.5 2.8 – 3.5 6.0 – 7.5 10.0 – 12.5 16 – 20 25 – 31.5 35 – 43.5 50 – 62 67.5 – 84.5 84 – 105 120 – 150 155 – 195 200 – 250 250 – 310 295 – 370
a Values with ( ) in the "Width across flats" column are for (*) marked bolt (flange bolt) shown in Fig. A. 2) The following table applies to the bolts in Fig. B. Thread diam- Width across eter of bolt flats mm mm 6 10 8 12 10 14 12 17
Fig. A
Tightening torque Nm 5.9 – 9.8 13.7 – 23.5 34.3 – 46.1 74.5 – 90.2
kgm 0.6 – 1.0 1.4 – 2.4 3.5 – 4.7 7.6 – 9.2
Fig. B
a Values with ( ) are applied to (*) marked bolt (flange bolt) as the width across flats.
00-42
PC228US-8,PC228USLC-8
Foreword and general information Standard tightening torque table
2. Table of tightening torque for split flanged bolts a Unless otherwise specified, tighten split flanged bolts to the torque shown in the following table. Thread diam- Width across eter of bolt flats mm mm 10 14 12 17 16 22
Tightening torque Nm 59 – 74 98 – 123 235 – 285
kgm 6.0 – 7.5 10.0 – 12.5 23.5 – 29.5
3. Table of tightening torque for O-ring boss piping joints a Unless otherwise specified, tighten O-ring boss piping joints to the torque shown in the following table. Nominal No. 02 03, 04 05, 06 10, 12 14
Thread diam- Width across eter flats mm mm 14 Varies 20 depending on 24 type of con33 nector. 42
Tightening torque (Nm {kgm}) Range 35 – 63 {3.5 – 6.5} 84 – 132 {8.5 – 13.5} 128 – 186 {13.0 – 19.0} 363 – 480 {37.0 – 49.0} 746 – 1,010 {76.0 – 103}
Target 44 {4.5} 103 {10.5} 157 {16.0} 422 {43.0} 883 {90.0}
4. Table of tightening torque for O-ring boss plugs a Unless otherwise specified, tighten O-ring boss plugs to the torque shown in the following table. Nominal No. 08 10 12 14 16 18 20 24 30 33 36 42 52
Thread diam- Width across eter flats mm mm 8 14 10 17 12 19 14 22 16 24 18 27 20 30 24 32 30 32 33 – 36 36 42 – 52 –
PC228US-8,PC228USLC-8
Tightening torque (Nm {kgm}) Range 5.88 – 8.82 {0.6 – 0.9} 9.8 – 12.74 {1.0 – 1.3} 14.7 – 19.6 {1.5 – 2.0} 19.6 – 24.5 {2.0 – 2.5} 24.5 – 34.3 {2.5 – 3.5} 34.3 – 44.1 {3.5 – 4.5} 44.1 – 53.9 {4.5 – 5.5} 58.8 – 78.4 {6.0 – 8.0} 93.1 – 122.5 { 9.5 – 12.5} 107.8 – 147.0 {11.0 – 15.0} 127.4 – 176.4 {13.0 – 18.0} 181.3 – 240.1 {18.5 – 24.5} 274.4 – 367.5 {28.0 – 37.5}
Target 7.35 {0.75} 11.27 {1.15} 17.64 {1.8} 22.54 {2.3} 29.4 {3.0} 39.2 {4.0} 49.0 {5.0} 68.6 {7.0} 107.8 {11.0} 127.4 {13.0} 151.9 {15.5} 210.7 {21.5} 323.4 {33.0}
00-43
Foreword and general information Standard tightening torque table
5. Table of tightening torque for hoses (taper seal type and face seal type) a Unless otherwise specified, tighten the hose fittings (taper seal type and face seal type) to the torque shown in the following table. a Apply the following torque when the threads are coated with engine oil (wetted). Tightening torque (Nm {kgm}) Nominal Width number of across hose flats (mm) 02 03 04 05 06 (10) (12) (14)
19 22 24 27 32 36 41 46 55
Taper seal
Range
Target
Thread size (mm)
34 – 54 {3.5 – 5.5} 34 – 63 {3.5 – 6.5} 54 – 93 {5.5 – 9.5} 59 – 98 {6.0 – 10.0} 84 – 132 {8.5 – 13.5} 128 – 186 {13.0 – 19.0} 177 – 245 {18.0 – 25.0} 177 – 245 {18.0 – 25.0} 197 – 294 {20.0 – 30.0} 246 – 343 {25.0 – 35.0}
44 {4.5} 44 {4.5} 74 {7.5} 78 {8.0} 103 {10.5} 157 {16.0} 216 {22.0} 216 {22.0} 245 {25.0} 294 {30.0}
– 14 – 18 22 24 30 33 36 42
Face seal Nominal No. Thread diame–Number of ter (mm) (Refthreads, type of erence) thread 9/16 – 18UN 14.3 – – 11/16 – 16UN 17.5 – – 13/16 – 16UN 20.6 1 – 14UNS 25.4 1-3/16 – 12UN 30.2 – – – – – –
6. Table of tightening torque for face seal joints a Tighten the face seal joints (sleeve nut type) made of plated steel pipes for low pressure service to be used for engines etc. to the torque shown in the following table. a Apply the following torque to the face seal joint while their threaded parts are coated with engine oil (wetted). Tightening torque (Nm {kgm}) Outer diam- Width across eter of pipe flats (mm) (mm) 8 10 12 15 (16) 22 (20)
19 22 24 (27) 30 (32) 36
Range
Target
14 – 16 {1.4 – 1.6} 24 – 27 {2.4 – 2.7} 43 – 47 {4.4 – 4.8} 60 – 68 {6.1 – 6.8} 90 – 95 {9.2 – 9.7}
15 {1.5} 25.5 {2.6} 45 {4.6} 64 {6.5} 92.5 {9.4}
Face seal Nominal No. Thread diameter –Number of (mm) threads, type of (Reference) thread 9/16 – 18UN 14.3 11/16 – 16UN 17.5 13/16 – 16UN 20.6 1 – 14UNS 25.4 1 – 3/16 – 12UN 30.2
Reference: The face seal joints of the dimensions in ( ) are also used, depending on the specification.
00-44
PC228US-8,PC228USLC-8
Foreword and general information Standard tightening torque table
7. Table of tightening torque for 102, 107 and 114 engine series (bolts and nuts) a Unless otherwise specified, tighten the metric bolts and nuts used for the 102, 107 and 114 engine series to the torque shown in the following table. Tightening torque Bolts and nuts
Thread size mm 6 8 10 12 14
Nm 10 ± 2 24 ± 4 43 ± 6 77 ± 12 –
kgm 1.02 ± 0.20 2.45 ± 0.41 4.38 ± 0.61 7.85 ± 1.22 –
8. Table of tightening torque for 102, 107 and 114 engine series (eye joints) a Unless otherwise specified, tighten the metric eye joints used for the 102, 107 and 114 engine series to the torque shown in the following table. Thread size mm 6 8 10 12 14
Tightening torque Nm 8±2 10 ± 2 12 ± 2 24 ± 4 36 ± 5
kgm 0.81 ± 0.20 1.02 ± 0.20 1.22 ± 0.20 2.45 ± 0.41 3.67 ± 0.51
9. Table of tightening torque for 102, 107 and 114 engine series (taper screws) a Unless otherwise specified, tighten NPT screws used for the 102, 107 and 114 engine series to the torque shown in the following table. Material Thread size (inch) 1/16 1/8 1/4 3/8 1/2 3/4
PC228US-8,PC228USLC-8
Tightening torque In cast iron or steel In aluminium Nm kgm Nm kgm 15 ± 2 1.53 ± 0.20 5±1 0.51 ± 0.10 20 ± 2 2.04 ± 0.20 15 ± 2 1.53 ± 0.20 25 ± 3 2.55 ± 0.31 20 ± 2 2.04 ± 0.20 35 ± 4 3.57 ± 0.41 25 ± 3 2.55 ± 0.31 55 ± 6 5.61 ± 0.61 35 ± 4 3.57 ± 0.41 75 ± 8 7.65 ± 0.82 45 ± 5 4.59 ± 0.51
00-45
Foreword and general information List of Abbreviation
List of Abbreviation (Rev. 2010/03) This list of abbreviations includes the abbreviations used in the text of the shop manual for parts, components, and functions whose meaning is not immediately clear. The spelling is given in full with an outline of the meaning. q Abbreviations that are used in general society may not be included. q Special abbreviations that appear infrequently are marked in the text with an *. q This list of abbreviations consists of two parts. The first part is a list of abbreviations used in the text of the manual, and the second part is a list of abbreviations used in circuit diagrams. List of abbreviations used in the shop manual q
Purpose of use (major applicable machine (*), or component/system)
Abbreviation
Full Spelling
A.B.S.
Anti-skid Brake System
Travel and brake (HD, HM)
With this function, when the tires skid (wheels stop rotating), the brakes are released, and when the wheels start to rotate, the brakes are applied again.
A.I.S.S.
Automatic Idling Setting System
Engine
This function automatically sets the idle speed.
A.J.S.S.
Advanced Joystick Steer- Steering ing System (WA)
A.R.A.C.
Automatic Retarder Accelerator Control
Travel and brake (HD, HM)
A.R.S.C.
Automatic Retarder Speed Control
Travel and brake (HD, HM)
A.S.R.
Automatic Spin Regulator
Travel and brake (HD, HM)
ATT.
Attachment
Work equipment
B.C.V.
Brake Cooling oil control Brake Valve (HD)
C.A.N.
Controller Area Network
Communication and electronic control
C.L.S.S.
Closed-centre Load Sensing System
Hydraulic
C.R.I.
Common Rail Injection
Engine
E.C.M.
Electronic Control Module
Electronic control system
E.C.M.V.
Electronic Control Modu- Transmission lation Valve (D, HD, WA, etc.)
E.C.S.S.
Electronically Controlled Travel Suspension System (WA)
E.C.U.
Electronic Control Unit
Electronic control system
E.G.R.
Exhaust Gas Recirculation
Engine
00-46
Explanation
Instead of a steering wheel, a lever is used to perform the steering operations as well as to shift gear and change direction (forward or reverse). When the machine is travelling downhill, if the accelerator pedal is released, this function automatically applies the retarder with a constant braking force. When the machine is travelling downhill, if the accelerator pedal is released, this function automatically applies the retarder to ensure that the machine speed does not accelerate above the speed set by the operator. When the rear wheels spin on soft ground surfaces, this function automatically uses the optimum braking force to drive both wheels. A device that can be fixed onto a machine in order to enable it to do different jobs. When the retarder is not being used, this valve bypasses part of the brake cooling oil to reduce the load on the hydraulic pump. Communications standard standardized as ISO11898. System that can simultaneously actuate multiple actuators regardless of the load (provides better ease of combined operation than O.L.S.S.). Uses engine controller to perform electronic control of supply pump, common rail, and injector. Functions to maintain optimum fuel injection amount and fuel injection timing. Electronic control device that uses the signals from the sensors on the machine to indicate to the actuators the optimum actuation. (same as ECU) Proportional electromagnetic valve that gradually increases oil pressure to engage clutch and reduces transmission shock. System that ensures smooth high-speed travel by using hydraulic spring effect of accumulator to absorb vibration of machine during travel Electronic control device that uses the signals from the sensors on the machine to indicate to the actuators the optimum actuation. (same as ECM) Functions to recirculate part of exhaust gas to combustion chamber in order to reduce combustion temperature, controls emission of Nox.
PC228US-8,PC228USLC-8
Foreword and general information List of Abbreviation
Abbreviation
Full Spelling
Purpose of use (major applicable machine (*), or component/system)
Equipment Management E.M.M.S. Machine monitor Monitoring System
E.P.C.
Electromagnetic ProporHydraulic tional Control
F-N-R
Forward-Neutral-Reverse Operation
G.P.S.
Global Positioning System
H.S.S.
Hydrostatic Steering Sys- Steering tem (D)
H.S.T.
Hydro Static Transmission
Transmission (D, WA)
I.M.A.
Inlet Metering Actuator
Engine
I.M.V.
Inlet Metering Valve
Engine
L.C.D.
Liquid Crystal Display
Machine monitor
L.E.D.
Light Emitting Diode
Electronic parts
L.S.
Load Sensing
Hydraulic
M.M.S.
Multimedia Messaging Service
Communication
N.C.
Normally Closed
Electric and hydraulic
N.O.
Normally Open
Electric and hydraulic
O.L.S.S. P.C.
Communication (KOMTRAX, VHMS)
Open-centre Load SensHydraulic ing System Pressure Control Hydraulic
P.C.C.S.
Palm Command Control Steering System (D)
P.C.V.
Pump Control Valve
Engine
P.P.C.
Proportional Pressure Control
Hydraulic
P.P.M.
Piston Pump and Motor
P.T.O.
Power Take Off Power Tilt and power Pitch dozer
P.T.P.
PC228US-8,PC228USLC-8
Hydraulic (D, PC, etc.) Power transmission Work equipment (D)
Explanation System that allows data (filter, oil replacement interval, malfunctions on machine, failure code, and failure history) from each sensor on the machine to be checked on monitor. Control system that moves an actuator in proportion to the amperage of an electric current passing through the solenoid. Position of the gear shift lever or switch. System that is used to determine the current location on the Earth of a ship, car, machine, etc. by receiving the radio wave signals transmitted from the navigation satellites. Steering function that uses a combination of hydraulic motor and bevel shaft to control difference in travel speed of right and left tracks to turn machine without using steering clutch. Hydraulic transmission system that uses a combination of hydraulic pump and hydraulic motor to shift gear steplessly without using gears. Valve installed at inlet port of pump to adjust fuel intake amount in order to control fuel discharge amount of supply pump. Same as IMV. Valve installed at inlet port of pump to adjust fuel intake amount in order to control fuel discharge amount of supply pump. Described as IMV (IMA). Image display device made up of a large number of pixels filled with liquid crystal. Semiconductor element that emits light when the voltage is applied in forward direction, positive voltage to anode and negative voltage to cathode. Function that senses differential pressure of pump and controls discharge amount according to load. Service that allows transmission and reception of short messages consisting of characters or voice or images between cell phones. Device actuated to open electric or hydraulic circuits that are normally closed if not actuated. Device actuated to close electric or hydraulic circuits that are normally open if not actuated. Hydraulic system that can operate multiple actuators at the same time, regardless of the load. Controlling the oil pressure. System in which a controller instantly analyses data from each lever, pedal, and dial, and performs optimum electronic control of the engine and transmission. Valve installed at inlet port of pump to adjust fuel intake amount in order to control fuel discharge amount of supply pump. Control system that moves an actuator in proportion to the oil pressure. Piston pump and motor. A device to take off power of the engine. Function that performs hydraulic control of the tilt and pitch of the bulldozer blade.
00-47
Foreword and general information List of Abbreviation
Abbreviation
Full Spelling
Purpose of use (major applicable machine (*), or component/system)
Explanation
International System of Units (abbreviated SI from the French Le Systeme Internationale d’Unites) is the modern form of the metric system, and is the Le Systeme International world’s most widely used system of measurement. S.I. Unit d’ Unites There are seven base units: meter (m), kilogram (kg), second (s), ampere (A), kelvin (K), candela (cd), and mole (mol). The derived units include Pascal (Pa), Newton (N), etc. Solenoid is a loop of wire. However, as a matter of fact in engineering, it refers to an actuator consists of a solenoid and an iron core that is moved by the SOL. Solenoid Electric magnetic force when the solenoid is energized. The word solenoid also often refers to a solenoid valve. T.W.V. Two Way Valve Hydraulic and electric Solenoid valve that switches over direction of flow. Communications system that transmits machine data, such as the present position of the machine, Monitoring and communica- daily or aggregate hours of operation, fuel conVehicle Health Monitoring V.H.M.S. tion sumption, radiator coolant temperature, oil or filter System (D, HD, PC, WA : Large size) replacement interval, to make it possible to collect and check this data from a distant place (Developed for use on large machines used in mines).
*: Code for machine family D: bulldozer HD: dump truck HM: articulate dump truck PC: hydraulic excavator WA: wheel loader
00-48
PC228US-8,PC228USLC-8
Foreword and general information List of Abbreviation
List of abbreviations used in the circuit diagrams Abbreviation A/C A/D A/M ACC ADD AUX BR CW CCW ECU ECM ENG EXGND F.G. GND IMA NC S/T STRG SIG SOL STD OPT OP SW T/C T/M
Full Spelling Air Conditioner Analogue-to-Digital Air Mix damper Accessory Additional Auxiliary Battery Relay Clockwise Counter Clockwise Electronic Control Unit Electronic Control Module Engine External Ground Frame Ground Ground Inlet Metering Actruator No Connection Steering Signal Solenoid Standard Option Switch Torque Converter Transmission
PC228US-8,PC228USLC-8
00-49
Foreword and general information Conversion table
Conversion table (Rev. 2010/03) Method of using the conversion table 0 -42 The conversion table in this section is provided to enable simple conversion of figures. For details of the 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 horizontal line from (A). 2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down from (B). 3) Take the point where the 2 lines cross as (C). This point (C) gives the value when converting from 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
(A)
00-50
(B)
0 10 20 30 40
0 0 0.394 0.787 1.181 1.575
1 0.039 0.433 0.827 1.220 1.614
2 0.079 0.472 0.866 1.260 1.654
3 0.118 0.512 0.906 1.299 1.693
4 0.157 0.551 0.945 1.339 1.732
50 60 70 80 90
1.969 2.362 2.756 3.150 3.543
2.008 2.402 2.795 3.189 3.583
2.047 2.441 2.835 3.228 3.622
2.087 2.480 2.847 3.268 3.661
2.126 2.520 2.913 3.307 3.701
5 0.197 0.591 0.984 1.378 1.772 (C) 2.165 2.559 2.953 3.346 3.740
6 0.236 0.630 1.024 1.417 1.811
7 0.276 0.669 1.063 1.457 1.850
2.205 2.598 2.992 3.386 3.780
2.244 2.638 3.032 3.425 3.819
1 mm = 0.03937 in 8 9 0.315 0.354 0.709 0.748 1.102 1.142 1.496 1.536 1.890 1.929 2.283 2.677 3.071 3.465 3.858
2.323 2.717 3.110 3.504 3.898
PC228US-8,PC228USLC-8
Foreword and general information Conversion table
Millimeters to inches
0 10 20 30 40
0 0 0.394 0.787 1.181 1.575
1 0.039 0.433 0.827 1.220 1.614
2 0.079 0.472 0.866 1.260 1.654
3 0.118 0.512 0.906 1.299 1.693
4 0.157 0.551 0.945 1.339 1.732
5 0.197 0.591 0.984 1.378 1.772
6 0.236 0.630 1.024 1.417 1.811
7 0.276 0.669 1.063 1.457 1.850
1 mm = 0.03937 in 8 9 0.315 0.354 0.709 0.748 1.102 1.142 1.496 1.536 1.890 1.929
50 60 70 80 90
1.969 2.362 2.756 3.150 3.543
2.008 2.402 2.795 3.189 3.583
2.047 2.441 2.835 3.228 3.622
2.087 2.480 2.847 3.268 3.661
2.126 2.520 2.913 3.307 3.701
2.165 2.559 2.953 3.346 3.740
2.205 2.598 2.992 3.386 3.780
2.244 2.638 3.032 3.425 3.819
2.283 2.677 3.071 3.465 3.858
0 10 20 30 40
0 0 22.05 44.09 66.14 88.18
1 2.20 24.25 46.30 68.34 90.39
2 4.41 26.46 48.50 70.55 92.59
3 6.61 28.66 50.71 72.75 94.80
4 8.82 30.86 52.91 74.96 97.00
5 11.02 33.07 55.12 77.16 99.21
6 13.23 35.27 57.32 79.37 101.41
7 15.43 37.48 59.53 81.57 103.62
1 kg = 2.2046 lb 8 9 17.64 19.84 39.68 41.89 61.73 63.93 83.78 85.98 105.82 108.03
50 60 70 80 90
110.23 132.28 154.32 176.37 198.42
112.44 134.48 156.53 178.57 200.62
114.64 136.69 158.73 180.78 202.83
116.85 138.89 160.94 182.98 205.03
119.05 141.10 163.14 185.19 207.24
121.25 143.30 165.35 187.39 209.44
123.46 145.51 167.55 189.60 211.64
125.66 147.71 169.76 191.80 213.85
127.87 149.91 171.96 194.01 216.05
0 10 20 30 40
0 0 2.642 5.283 7.925 10.567
1 0.264 2.906 5.548 8.189 10.831
2 0.528 3.170 5.812 8.454 11.095
3 0.793 3.434 6.076 8.718 11.359
4 1.057 3.698 6.340 8.982 11.624
5 1.321 3.963 6.604 9.246 11.888
6 1.585 4.227 6.869 9.510 12.152
7 1.849 4.491 7.133 9.774 12.416
50 60 70 80 90
13.209 15.850 18.492 21.134 23.775
13.473 16.115 18.756 21.398 24.040
13.737 16.379 19.020 21.662 24.304
14.001 16.643 19.285 21.926 24.568
14.265 16.907 19.549 22.190 24.832
14.529 17.171 19.813 22.455 25.096
14.795 17.435 20.077 22.719 25.361
15.058 17.700 20.341 22.983 25.625
2.323 2.717 3.110 3.504 3.898
Kilogram to pound
Liters to U.S. Gallons
PC228US-8,PC228USLC-8
130.07 152.12 174.17 196.21 218.26
1 l = 0.2642 U.S.Gal 8 9 2.113 2.378 4.755 5.019 7.397 7.661 10.039 10.303 12.680 12.944 15.322 17.964 20.605 23.247 25.889
15.586 18.228 20.870 23.511 26.153
00-51
Foreword and general information Conversion table
Liters to U.K. Gallons
1 l = 0.21997 U.K.Gal 8 9 1.760 1.980 3.950 4.179 6.159 6.379 8.359 8.579 10.559 10.778
0 10 20 30 40
0 0 2.200 4.399 6.599 8.799
1 0.220 2.420 4.619 6.819 9.019
2 0.440 2.640 4.839 7.039 9.239
3 0.660 2.860 5.059 7.259 9.459
4 0.880 3.080 5.279 7.479 9.679
5 1.100 3.300 5.499 7.699 9.899
6 1.320 3.520 5.719 7.919 10.119
7 1.540 3.740 5.939 8.139 10.339
50 60 70 80 90
10.998 13.198 15.398 17.598 19.797
11.281 13.418 15.618 17.818 20.017
11.438 13.638 15.838 18.037 20.237
11.658 13.858 16.058 18.257 20.457
11.878 14.078 16.278 18.477 20.677
12.098 14.298 16.498 18.697 20.897
12.318 14.518 16.718 18.917 21.117
12.528 14.738 16.938 19.137 21.337
12.758 14.958 17.158 19.357 21.557
0 10 20 30 40
0 0 72.3 144.7 217.0 289.3
1 7.2 79.6 151.9 224.2 296.6
2 14.5 86.8 159.1 231.5 303.8
3 21.7 94.0 166.4 238.7 311.0
4 28.9 101.3 173.6 245.9 318.3
5 36.2 108.5 180.8 253.2 325.5
6 43.4 115.7 188.1 260.4 332.7
7 50.6 123.0 195.3 267.6 340.0
1 kgm = 7.233 ft.lb 8 9 57.9 65.1 130.2 137.4 202.5 209.8 274.9 282.1 347.2 354.4
50 60 70 80 90
361.7 434.0 506.3 578.6 651.0
368.9 441.2 513.5 585.9 658.2
376.1 448.5 520.8 593.1 665.4
383.4 455.7 528.0 600.3 672.7
390.6 462.9 535.2 607.6 679.9
397.8 470.2 542.5 614.8 687.1
405.1 477.4 549.7 622.0 694.4
412.3 484.6 556.9 629.3 701.6
419.5 491.8 564.2 636.5 708.8
426.8 499.1 571.4 643.7 716.1
100 110 120 130 140
723.3 795.6 868.0 940.3 1012.6
730.5 802.9 875.2 947.5 1019.9
737.8 810.1 882.4 954.8 1027.1
745.0 817.3 889.7 962.0 1034.3
752.2 824.6 896.9 969.2 1041.5
759.5 831.8 904.1 976.5 1048.8
766.7 839.0 911.4 983.7 1056.0
773.9 846.3 918.6 990.9 1063.2
781.2 853.5 925.8 998.2 1070.5
788.4 860.7 933.1 1005.4 1077.7
150 160 170 180 190
1084.9 1157.3 1129.6 1301.9 1374.3
1092.2 1164.5 1236.8 1309.2 1381.5
1099.4 1171.7 1244.1 1316.4 1388.7
1106.6 1179.0 1251.3 1323.6 1396.0
1113.9 1186.2 1258.5 1330.9 1403.2
1121.1 1193.4 1265.8 1338.1 1410.4
1128.3 1200.7 1273.0 1345.3 1417.7
1135.6 1207.9 1280.1 1352.6 1424.9
1142.8 1215.1 1287.5 1359.8 1432.1
1150.0 1222.4 1294.7 1367.0 1439.4
12.978 15.178 17.378 19.577 21.777
kgm to ft.lb
00-52
PC228US-8,PC228USLC-8
Foreword and general information Conversion table
kg/cm2 to lb/in2
0 10 20 30 40
0 0 142.2 284.5 426.7 568.9
1 14.2 156.5 298.7 440.9 583.2
2 28.4 170.7 312.9 455.1 597.4
3 42.7 184.9 327.1 469.4 611.6
4 56.9 199.1 341.4 483.6 625.8
5 71.1 213.4 355.6 497.8 640.1
6 85.3 227.6 369.8 512.0 654.3
1 kg/cm2 = 14.2233 lb/in2 7 8 9 99.6 113.8 128.0 241.8 256.0 270.2 384.0 398.3 412.5 526.3 540.5 554.7 668.5 682.7 696.9
50 60 70 80 90
711.2 853.4 995.6 1,138 1,280
725.4 867.6 1,010 1,152 1,294
739.6 881.8 1,024 1,166 1,309
753.8 896.1 1,038 1,181 1,323
768.1 910.3 1,053 1,195 1,337
782.3 924.5 1,067 1,209 1,351
796.5 938.7 1,081 1,223 1,365
810.7 953.0 1,095 1,237 1,380
825.0 967.2 1,109 1,252 1,394
839.2 981.4 1,124 1,266 1,408
100 110 120 130 140
1,422 1,565 1,707 1,849 1,991
1,437 1,579 1,721 1,863 2,005
1,451 1,593 1,735 1,877 2,020
1,465 1,607 1,749 1,892 2,034
1,479 1,621 1,764 1,906 2,048
1,493 1,636 1,778 1,920 2,062
1,508 1,650 1,792 1,934 2,077
1,522 1,664 1,806 1,949 2,091
1,536 1,678 1,821 1,963 2,105
1,550 1,693 1,835 1,977 2,119
150 160 170 180 190
2,134 2,276 2,418 2,560 2,702
2,148 2,290 2,432 2,574 2,717
2,162 2,304 2,446 2,589 2,731
2,176 2,318 2,460 2,603 2,745
2,190 2,333 2,475 2,617 2,759
2,205 2,347 2,489 2,631 2,773
2,219 2,361 2,503 2,646 2,788
2,233 2,375 2,518 2,660 2,802
2,247 2,389 2,532 2,674 2,816
2,262 2,404 2,546 2,688 2,830
200 210 220 230 240
2,845 2,987 3,129 3,271 3,414
2,859 3,001 3,143 3,286 3,428
2,873 3,015 3,158 3,300 3,442
2,887 3,030 3,172 3,314 3,456
2,901 3,044 3,186 3,328 3,470
2,916 3,058 3,200 3,343 3,485
2,930 3,072 3,214 3,357 3,499
2,944 3,086 3,229 3,371 3,513
2,958 3,101 3,243 3,385 3,527
2,973 3,115 3,257 3,399 3,542
PC228US-8,PC228USLC-8
00-53
Foreword and general information Conversion table
Temperature
0 -46
Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading or vice versa is to enter the accompanying table in the centre (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 centre column to be a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left. When convert from Centigrade to Fahrenheit degrees, consider the centre column to be a table of Centigrade values, and read the corresponding Fahrenheit temperature on the right. °C -40.4 -37.2 -34.4 -31.7 -28.9
46 47 48 49 50
°F 114.8 116.6 118.4 120.2 122.0
°C 27.2 27.8 28.3 28.9 29.4
1 °C = 33.8°F °F 81 177.8 82 179.6 83 181.4 84 183.2 85 185.0
10.6 11.1 11.7 12.2 12.8
51 52 53 54 55
123.8 125.6 127.4 129.2 131.0
30.0 30.6 31.1 31.7 32.2
86 87 88 89 90
186.8 188.6 190.4 192.2 194.0
69.8 71.6 73.4 75.2 77.0
13.3 13.9 14.4 15.0 15.6
56 57 58 59 60
132.8 134.6 136.4 138.2 140.0
32.8 33.3 33.9 34.4 35.0
91 92 93 94 95
195.8 197.6 199.4 201.2 203.0
26 27 28 29 30
78.8 80.6 82.4 84.2 86.0
16.1 16.7 17.2 17.8 18.3
61 62 63 64 65
141.8 143.6 145.4 147.2 149.0
35.6 36.1 36.7 37.2 37.8
96 97 98 99 100
204.8 206.6 208.4 210.2 212.0
-0.6 0 0.6 1.1 1.7
31 32 33 34 35
87.8 89.6 91.4 93.2 95.0
18.9 19.4 20.0 20.6 21.1
66 67 68 69 70
150.8 152.6 154.4 156.2 158.0
40.6 43.3 46.1 48.9 51.7
105 110 115 120 125
221.0 230.0 239.0 248.0 257.0
33.8 35.6 37.4 39.2 41.0
2.2 2.8 3.3 3.9 4.4
36 37 38 39 40
96.8 98.6 100.4 102.2 104.0
21.7 22.2 22.8 23.3 23.9
71 72 73 74 75
159.8 161.6 163.4 165.2 167.0
54.4 57.2 60.0 62.7 65.6
130 135 140 145 150
266.0 275.0 284.0 293.0 302.0
42.8 44.6 46.4 48.2 50.0
5.0 5.6 6.1 6.7 7.2
41 42 43 44 45
105.8 107.6 109.4 111.2 113.0
24.4 25.0 25.6 26.1 26.7
76 77 78 79 80
168.8 170.6 172.4 174.2 176.0
68.3 71.1 73.9 76.7 79.4
155 160 165 170 175
311.0 320.0 329.0 338.0 347.0
-40 -35 -30 -25 -20
°F -40.0 -31.0 -22.0 -13.0 -4.0
°C -11.7 -11.1 -10.6 -10.0 -9.4
11 12 13 14 15
°F 51.8 53.6 55.4 57.2 59.0
°C 7.8 8.3 8.9 9.4 10.0
-28.3 -27.8 -27.2 -26.7 -26.1
-19 -18 -17 -16 -15
-2.2 -0.4 1.4 3.2 5.0
-8.9 -8.3 -7.8 -7.2 -6.7
16 17 18 19 20
60.8 62.6 64.4 66.2 68.0
-25.6 -25.0 -24.4 -23.9 -23.3
-14 -13 -12 -11 -10
6.8 8.6 10.4 12.2 14.0
-6.1 -5.6 -5.0 -4.4 -3.9
21 22 23 24 25
-22.8 -22.2 -21.7 -21.1 -20.6
-9 -8 -7 -6 -5
15.8 17.6 19.4 21.2 23.0
-3.3 -2.8 -2.2 -1.7 -1.1
-20.0 -19.4 -18.9 -18.3 -17.8
-4 -3 -2 -1 0
24.8 26.6 28.4 30.2 32.0
-17.2 -16.7 -16.1 -15.6 -15.0
1 2 3 4 5
-14.4 -13.9 -13.3 -12.8 -12.2
6 7 8 9 10
00-54
PC228US-8,PC228USLC-8
SEN0533404-00
01-
PC228US-8,PC228USLC-8
HYDRAULIC EXCAVATOR PC228US-8 PC228USLC-8 Shop Manual
Machine model
Serial number
PC228US-8 PC228USLC-8
50001 and up 50001 and up
01 Specifications
PC228US-8,PC228USLC-8
01-
01-1
Contents
Contents 01 Specifications Specifications................................................................................................................................. 01-4 Specifications drawing ................................................................................................................ 01-4 Working range diagram............................................................................................................... 01-5 Specifications.............................................................................................................................. 01-6 Table of weight............................................................................................................................ 01-16 Table of fuel, coolant and lubricants ........................................................................................... 01-20
01-2
PC228US-8,PC228USLC-8
Contents
PC228US-8,PC228USLC-8
01-3
Specifications Specifications drawing
Specifications Specifications drawing
PC228USLC-8 Item
Unit
PC228US-8
Standard specification
North America specification
Machine weight
kg
21,800
23,000
24,900
Bucket capacity
m3
0.8
0.8
0.8
Engine model
–
Komatsu SAA6D107E-1 diesel engine
Engine rated output q
Net (ISO 9249)
kW/rpm
110/2,000
q
Gross (ISO 14396)
kW/rpm
116/2,000
A Overall length
mm
8,700
8,890
8,890
B Overall height
mm
3,050
3,050
3,065
Overall width
mm
2,980
3,080
3,180
C Upper structure width
mm
2,980
2,980
2,980
D Overall track width
mm
2,800
3,080
3,180
E Shoe width
mm
600
700
800
F Tail swing radius
mm
1,680
1,680
1,810
G Overall crawler length
mm
4,070
4,450
4,450
Distance between tumbler centres
mm
3,275
3,655
3,655
Min. ground clearance
mm
440
440
440
Travelling speed (Low/Med/High)
km/h
3.0/4.1/5.5
3.0/4.1/5.5
3.0/4.1/5.5
Continuous swing speed
rpm
11.0
11.0
11.0
H
a The engine rated power is indicated in the net value and gross value. Gross value is the rated power measured of the bare engine. While, net value is the value measured of an engine under the same condition essentially as the condition that it is installed on the machine.
01-4
PC228US-8,PC228USLC-8
Specifications Working range diagram
Working range diagram
PC228USLC-8 Item
Unit
PC228US-8 Standard specification
North America specification
A Max. digging reach
mm
9,875
9,875
9,875
B Max. digging depth
mm
6,620
6,620
6,620
C Max. digging height
mm
10,700
10,700
10,700
Max. vertical wall digging D depth
mm
5,980
5,980
5,980
E Max. dumping height
mm
7,825
7,825
7,825
F Min. dumping height
mm
2,940
2,940
2,940
G Max. reach at ground level
mm
9,700
9,700
9,700
PC228US-8,PC228USLC-8
01-5
Specifications Specifications
Specifications PC228US-8
01-6 Machine model
PC228US-8
Serial number
50001 and up m3
0.8
Machine weight
kg
21,800
Max. digging depth
mm
6,620
Max. vertical wall digging depth
mm
5,980
Max. digging reach
mm
9,875
Max. reach at ground level
mm
9,700
Max. digging height
mm
10,700
Max. dumping height
Performance
Working ranges
Bucket capacity
mm
7,825
Max. digging force (when one-touch power max. function is turned on)
kN{kg}
138 {14,100} (149 {15,200})
Continuous swing speed
rpm
11.0
Swing operation max. slope angle
deg.
20
Travelling speed (Low/Med/High)
km/h
3.2/4.1/5.5
Gradeability
deg.
35
kPa {kg/cm2}
50 {0.51}
Overall length
mm
8,700
Overall width
mm
2,980
Overall height (During transportation) (*)
mm
3,050
Overall height (for work)
mm
3,025
Ground clearance of upper structure bottom
mm
1,060
Min. ground clearance
mm
440
Tail swing radius
mm
1,680
Min. swing radius of work equipment
mm
2,310
Maximum height at minimum swing radius of work equipment
mm
8,250
Overall track width
mm
2,800
Overall crawler length
mm
4,070
Track gauge
mm
2,200
Distance between tumbler centres
mm
3,275
Machine cab height
mm
2,285
Width of standard shoe
mm
600
Dimensions
Ground pressure (Standard shoe)
* : Including grouser height (26 mm)
01-6
PC228US-8,PC228USLC-8
Specifications Specifications
Machine model
PC228US-8
Serial number
50001 and up
Model
Number of cylinders – bore x stroke
mm
SAA6D107E-1 4-cycle, water-cooled, in-line and vertical type, direct injection type with turbocharger and air-cooled aftercooler 6 – 107 x 124
Total piston displacement
l {cc}
6.69 {6,690}
Type
Performance
Engine
Engine rated output q
Net [ISO 9249
kW/rpm
110/2,000
q
Gross [ISO 14396]
kW/rpm Nm/rpm {kgm/rpm}
116/2,000
Max. torque Max. high idle speed q
At mounted on machine
rpm
1,900 ± 70
q
At bear engine
rpm
2,060 ± 50
Min. low idle speed
rpm
1,050 ± 25
g/kWh {g/HPh}
215 {158}
Min. fuel consumption ratio
Undercarriage
609/1,500 {62.1/1,500}
Starting motor
24 V, 4.5 kW
Alternator
24 V, 35 A
Battery (*1)
12 V, 110 Ah x 2
Radiator type
Corrugated aluminium, 4 array
Carrier roller
2 on each side
Track roller
7 on each side
Track shoe
Assembly-type with triple grouser shoes, 45 on each side
*1. Battery capacity (Ah) is based on 5-hour rate. a The engine rated power is indicated in the net value and gross value. Gross value is the rated power measured of the bare engine. While, net value is the value measured of the engine under the same condition essentially as the condition that it is installed on the machine.
PC228US-8,PC228USLC-8
01-7
Hydraulic motor Control valve Hydraulic pump Hydraulic cylinder
Hydraulic system
Specifications Specifications
Machine model
PC228US-8
Serial number
50001 and up
Type x quantity Delivery Set pressure
Variable displacement piston type (HPV95+95) x 2 l/min
218.4 x 2
MPa {kg/cm2}
37.2 {380}
Type x quantity
6-spool type x 1
Operating method
Hydraulic
Travel motor
Variable displacement piston type (HMV110-2) x 2 (with brake valve and parking brake)
Swing motor
Fixed displacement piston type (KMF125AB-5) x 1 (with safety valve and parking brake)
Type
Boom Double acting piston 120
Arm (*2) Double acting piston 135
Bucket Double acting piston 115
Cylinder inner diameter
mm
Piston rod diameter
mm
85
95
Stroke
mm
1,385
1,490
80 1,120
Max. pin-to-pin distance
mm
3,255
3,565
2,800
Min. pin-to-pin distance
mm
1,870
2,075
1,680
Hydraulic tank
Box-shaped, closed type
Hydraulic oil filter
Tank return side
Hydraulic oil cooler
Air cooled (CF40-1)
*2. With head side cushion and bottom side cushion.
01-8
PC228US-8,PC228USLC-8
Specifications Specifications
PC228USLC-8 (standard specification)
01-9
Machine model
PC228USLC-8 (standard specification)
Serial number
50001 and up m3
0.8
Machine weight
kg
23,000
Max. digging depth
mm
6,620
Max. vertical wall digging depth
mm
5,980
Max. digging reach
mm
9,875
Max. reach at ground level
mm
9,700
Max. digging height
mm
10,700
Max. dumping height
Performance
Working ranges
Bucket capacity
mm
7,825
Max. digging force (when one-touch power max. function is turned on)
kN{kg}
138 {14,100} (149 {15,200})
Continuous swing speed
rpm
11.0
Swing operation max. slope angle
deg.
20
Travelling speed (Low/Med/High)
km/h
3.0/4.1/5.5
Gradeability
deg.
35
kPa {kg/cm2}
41 {0.42}
Overall length
mm
8,890
Overall width
mm
3,080
Overall height (During transportation) (*)
mm
3,050
Overall height (for work)
mm
3,025
Ground clearance of upper structure bottom
mm
1,060
Min. ground clearance
mm
440
Tail swing radius
mm
1,680
Min. swing radius of work equipment
mm
2,310
Maximum height at minimum swing radius of work equipment
mm
8,250
Overall track width
mm
3,080
Overall crawler length
mm
4,450
Track gauge
mm
2,380
Distance between tumbler centres
mm
3,655
Machine cab height
mm
2,285
Width of standard shoe
mm
700
Dimensions
Ground pressure (Standard shoe)
*: Grouser height (26 mm) included.
PC228US-8,PC228USLC-8
01-9
Specifications Specifications
Machine model
PC228USLC-8 (standard specification)
Serial number
50001 and up
Model
No. of cylinders - bore x stroke
mm
SAA6D107E-1 4-cycle, water-cooled, in-line and vertical type, direct injection type with turbocharger and air-cooled aftercooler 6 – 107 x 124
Total piston displacement
l {cc}
6.69 {6,690}
Type
Engine
Performance
Engine rated output q
Net [ISO 9249]
kW/rpm
110/2,000
q
Gross [ISO 14396]
kW/rpm Nm/rpm {kgm/rpm}
116/2,000
Max. torque Max. high idle speed q
At mounted on machine
rpm
1,900 ± 70
q
At bear engine
rpm
2,060 ± 50
Min. low idle speed
rpm
1,050 ±25
g/kWh {g/HPh}
215 {158}
Min. fuel consumption ratio
Undercarriage
609/1,500 {62.1/1,500}
Starting motor
24 V, 4.5 kW
Alternator
24 V, 35 A
Battery (*1)
12 V, 110 Ah x 2
Radiator type
Aluminium wave type, 4 rows
Carrier roller
2 on each side
Track roller
9 on each side
Track shoe
Assembly-type with triple grouser shoes, 49 on each side
*1. Battery capacity (Ah) is based on 5-hour rate. a The engine rated power is indicated in the net value and gross value. Gross value is the rated power measured of the bare engine. While, net value is the value measured of the engine under the same condition essentially as the condition that it is installed on the machine.
01-10
PC228US-8,PC228USLC-8
Hydraulic motor Control valve Hydraulic pump Hydraulic cylinder
Hydraulic system
Specifications Specifications
Machine model
PC228USLC-8 (standard specification)
Serial number
50001 and up
Type x quantity Delivery Set pressure
Variable displacement piston type (HPV95+95) x 2 l/min
218.4 x 2
MPa {kg/cm2}
37.2 {380}
Type x quantity
6-spool type x 1
Operating method
Hydraulic
Travel motor
Variable displacement piston type (HMV110-2) x 2 (with brake valve and parking brake)
Swing motor
Fixed displacement piston type (KMF125AB-5) x 1 (with safety valve and parking brake)
Type
Arm (*2) Double acting piston 135
Bucket Double acting piston 115
Cylinder inner diameter
mm
Boom Double acting piston 120
Piston rod diameter
mm
85
95
80
Stroke
mm
1,385
1,490
1,120
Max. pin-to-pin distance
mm
3,255
3,565
2,800
Min. pin-to-pin distance
mm
1,870
2,075
1,680
Hydraulic tank
Box-shaped closed type
Hydraulic oil filter
Tank return side
Hydraulic oil cooler
Air cooled (CF40-1)
*2. With head side cushion and bottom side cushion.
PC228US-8,PC228USLC-8
01-11
Specifications Specifications
PC228USLC-8 (North America specification)
01- 2
Machine model
PC228USLC-8 (North America specification)
Serial number
50001 and up m3
0.8
Machine weight
kg
24,900
Max. digging depth
mm
6,620
Max. vertical wall digging depth
mm
5,980
Max. digging reach
mm
9,875
Max. reach at ground level
mm
9,700
Max. digging height
mm
10,700
Max. dumping height
Performance
Working ranges
Bucket capacity
mm
7,825
Max. digging force (when one-touch power max. function is turned on)
kN{kg}
138 {14,100} (149 {15,200})
Continuous swing speed
rpm
11.0
Swing operation max. slope angle
deg.
20
Travelling speed (Low/Med/High)
km/h
3.0/4.1/5.5
Gradeability
deg.
35
kPa {kg/cm2}
39 {0.40}
Overall length
mm
8,890
Overall width
mm
3,080
Overall height (During transportation) (*)
mm
3,065
Overall height (for work)
mm
3,040
Ground clearance of upper structure bottom
mm
1,075
Min. ground clearance
mm
440
Tail swing radius
mm
1,810
Min. swing radius of work equipment
mm
2,310
Maximum height at minimum swing radius of work equipment
mm
8,250
Overall track width
mm
3,180
Overall crawler length
mm
4,450
Track gauge
mm
2,380
Distance between tumbler centres
mm
3,655
Machine cab height
mm
2,300
Width of standard shoe
mm
800
Dimensions
Ground pressure (Standard shoe)
*: Grouser height (26 mm) included.
01-12
PC228US-8,PC228USLC-8
Specifications Specifications
Machine model
PC228USLC-8 (North America specification)
Serial number
50001 and up
Model
No. of cylinders - bore x stroke
mm
SAA6D107E-1 4-cycle, water-cooled, in-line and vertical type, direct injection type with turbocharger and air-cooled aftercooler 6 – 107 x 124
Total piston displacement
l {cc}
6.69 {6,690}
Type
Performance
Engine
Engine rated output q
Net [ISO 9249]
kW/rpm
110/2,000
q
Gross [ISO 14396]
kW/rpm Nm/rpm {kgm/rpm}
116/2,000
Max. torque Max. high idle speed q
At mounted on machine
rpm
1,900 ± 70
q
At bear engine
rpm
2,060 ± 50
Min. low idle speed
rpm
1,050 ± 25
g/kWh {g/HPh}
215 {158}
Min. fuel consumption ratio
Undercarriage
609/1,500 {62.1/1,500}
Starting motor
24 V, 4.5 kW
Alternator
24 V, 35 A
Battery (*1)
12 V, 110 Ah x 2
Radiator type
Aluminium wave type, 4 rows
Carrier roller
2 on each side
Track roller
9 on each side
Track
Assembly-type with triple grouser shoes, 49 on each side
*1. Battery capacity (Ah) is based on 5-hour rate. a The engine rated power is indicated in the net value and gross value. Gross value is the rated power measured of the bare engine. While, net value is the value measured of the engine under the same condition essentially as the condition that it is installed on the machine.
PC228US-8,PC228USLC-8
01-13
Hydraulic cylinder
Hydraulic system
Hydraulic motor Control valve Hydraulic pump
Specifications Specifications
Machine model
PC228USLC-8 (North America specification)
Serial number
50001 and up
Type x quantity Delivery Set pressure
Variable displacement piston type (HPV95+95) x 2 l/min
218.4 x 2
MPa {kg/cm2}
37.2 {380}
Type x quantity
6-spool type x 1
Operating method
Hydraulic
Travel motor
Variable displacement piston type (HMV110-2) x 2 (with brake valve and parking brake)
Swing motor
Fixed displacement piston type (KMF125AB-5) x 1 (with safety valve and parking brake)
Type
Arm (*2) Double acting piston 135
Bucket Double acting piston 115
Cylinder inner diameter
mm
Boom Double acting piston 130
Piston rod diameter
mm
90
95
80
Stroke
mm
1,385
1,490
1,120
Max. pin-to-pin distance
mm
3,255
3,565
2,800
Min. pin-to-pin distance
mm
1,870
2,075
1,680
Hydraulic tank
Box-shaped closed type
Hydraulic oil filter
Tank return side
Hydraulic oil cooler
Air cooled (CF40-1)
*2. With head side cushion and bottom side cushion.
01-14
PC228US-8,PC228USLC-8
Specifications Specifications
PC228US-8,PC228USLC-8
01-15
Specifications Table of weight
Table of weight
k This weight table is prepared for your reference when handling or transporting the components.
PC228US-8
01- 6 Unit: kg Machine model
PC228US-8
Serial number
50001 and up
Engine assembly
735
q
Engine
575
q
Damper
6
q
Main pump
154
Radiator and oil cooler assembly
126
Hydraulic tank and filter assembly (Not including hydraulic oil)
146
Fuel tank assembly (Not including fuel)
131
Revolving frame
1,872
Operator's cab
445
Operator's seat
27
Counterweight
6,060
Swing machinery
224
Control valve
265
Swing motor
51.5
Travel motor
98 x 2
Centre swivel joint
30.3
Track frame assembly (Not including piping)
4,269
q
Track frame
2,260
q
Swing circle
267
q
Idler
101 x 2
q
Idler cushion
118 x 2
q
Carrier roller
14 x 4
q
Track roller
36 x 14
q
Final drive (including travel motor and sprocket)
372 x 2
Track shoe assembly q
Triple grouser shoe (600 mm)
1,215 x 2
q
Triple grouser shoe (700 mm)
1,405 x 2
q
Triple grouser shoe (800 mm)
1,530 x 2
Boom assembly
1,500
Arm assembly
633
Bucket assembly
632
Boom cylinder assembly
167 x 2
Arm cylinder assembly
223
Bucket cylinder assembly
133
Bucket link (large) assembly
52
01-16
PC228US-8,PC228USLC-8
Specifications Table of weight
Unit: kg Machine model
PC228US-8
Serial number
50001 and up
Bucket link (small) assembly
22 x 2
Boom pin
42 + 8 x 2 + 28 + 10 + 26
Arm pin
12 + 8
Bucket pin
20 x 2
Bucket link pin
13 x 2
PC228US-8,PC228USLC-8
01-17
Specifications Table of weight
PC228USLC-8
01- 8 Unit: kg PC228USLC-8 Machine model Standard specification Serial number
North America specification
50001 and up
Engine assembly
735
735
q
Engine
575
575
q
Damper
6
6
q
Main pump
154
154
Radiator and oil cooler assembly
126
126
Hydraulic tank and filter assembly (Not including hydraulic oil)
146
146
Fuel tank assembly (Not including fuel)
131
131
Revolving frame
1,872
1,980
Operator's cab
445
445
Operator's seat
27
27
Counterweight
6,060
7,400
Swing machinery
224
224
Control valve
265
265
Swing motor
51.5
51.5
Travel motor
98 x 2
98 x 2
Centre swivel joint
30.3
30.3
Track frame assembly (Not including piping)
4,797
4,797
q
Track frame
2,644
2,644
q
Swing circle
267
267
q
Idler
101 x 2
101 x 2
q
Idler cushion
118 x 2
118 x 2
q
Carrier roller
14 x 4
14 x 4
q
Track roller
36 x 18
36 x 18
q
Final drive (including travel motor and sprocket)
372 x 2
372 x 2
Track shoe assembly q
Triple grouser shoe (600 mm)
1,395 x 2
1,395 x 2
q
Triple grouser shoe (700 mm)
1,530 x 2
1,530 x 2
q
Triple grouser shoe (800 mm)
1,670 x 2
1,670 x 2
q
Road liner (rubber pad type)(600 mm)
–
1,600 x 2
Boom assembly
1,500
1,500
Arm assembly
633
633
Bucket assembly
632
632
Boom cylinder assembly
167 x 2
191 x 2
Arm cylinder assembly
223
223
Bucket cylinder assembly
133
133
Bucket link (large) assembly
52
52
01-18
PC228US-8,PC228USLC-8
Specifications Table of weight
Unit: kg PC228USLC-8 Machine model Standard specification Serial number Bucket link (small) assembly
North America specification
50001 and up 22 x 2
22 x 2
Boom pin
42 + 8 x 2 + 28 + 10 + 26
42 + 8 x 2 + 28 + 10 + 26
Arm pin
12 + 8
12 + 8
Bucket pin
20 x 2
20 x 2
Bucket link pin
13 x 2
13 x 2
PC228US-8,PC228USLC-8
01-19
Specifications Table of fuel, coolant and lubricants
Table of fuel, coolant and lubricants a For details of the notes (Notes 1, Note 2... ) in the table, see the Operation and Maintenance Manual.
01-20
PC228US-8,PC228USLC-8
Specifications Table of fuel, coolant and lubricants
Unit: l PC228US-8, PC228USLC-8 Reservoir Specified capacity
Refill capacity
Engine oil pan
25.4
23.1
Swing machinery case
7.1
7.1
Final drive case (right and left respectively)
5.4
5.2
Damper case
0.65
0.65
Hydraulic oil system
185
126
Cooling system
21
–
Fuel tank
320
–
PC228US-8,PC228USLC-8
01-21
Specifications Table of fuel, coolant and lubricants
01-22
PC228US-8,PC228USLC-8
SEN0533406-00
10-1
PC228US-8,PC228USLC-8
HYDRAULIC EXCAVATOR PC228US-8 PC228USLC-8 Shop Manual
Machine model
Serial number
PC228US-8 PC228USLC-8
50001 and up 50001 and up
10 Structure and function
PC228US-8,PC228USLC-8
10-1
10-1
Contents
Contents 10 Structure and function Engine and cooling system ............................................................................................................ 10-3 Engine related parts.................................................................................................................... 10-3 Cooling system ........................................................................................................................... 10-4 Power train system ........................................................................................................................ 10-7 Power train.................................................................................................................................. 10-7 Swing circle................................................................................................................................. 10-8 Swing machinery......................................................................................................................... 10-10 Final drive ................................................................................................................................... 10-12 Undercarriage and frame ............................................................................................................... 10-14 Track frame and idler cushion..................................................................................................... 10-14 Hydraulic system............................................................................................................................ 10-16 Hydraulic equipment layout drawing ........................................................................................... 10-16 Valve control ............................................................................................................................... 10-18 ATT EPC Valve Assembly .......................................................................................................... 10-19 Hydraulic tank ............................................................................................................................. 10-21 CLSS........................................................................................................................................... 10-23 Main pump .................................................................................................................................. 10-28 Control valve ............................................................................................................................... 10-50 Function and operation by valve ................................................................................................. 10-62 Swing motor ................................................................................................................................ 10-99 Travel motor................................................................................................................................ 10-107 PPC valve ................................................................................................................................... 10-117 Solenoid valve............................................................................................................................. 10-134 Attachment circuit selector valve ................................................................................................ 10-140 Quick coupler control valve......................................................................................................... 10-144 Anti-drop valve ............................................................................................................................ 10-146 Multi-control valve ....................................................................................................................... 10-151 Centre swivel joint....................................................................................................................... 10-152 Accumulator ................................................................................................................................ 10-153 Work equipment............................................................................................................................. 10-156 Work equipment.......................................................................................................................... 10-156 Electrical system ............................................................................................................................ 10-158 Electronic control system ............................................................................................................ 10-158 Machine monitor system ............................................................................................................. 10-197 PPC Levers................................................................................................................................. 10-214 KOMTRAX system...................................................................................................................... 10-216 Sensors....................................................................................................................................... 10-218
10-2
PC228US-8,PC228USLC-8
Engine and cooling system Engine related parts
Engine and cooling system Engine related parts
1.Muffler 2.Damper assembly 2a.Drive plate 2b.Torsion spring 2c.Stopper pin 2d.Friction plate 3.Rear engine mount 4.Front engine mount 5.Vibration damper
PC228US-8,PC228USLC-8
Outline A damper assembly is wet type.
10-3
Specification Oil type Oil capacity (l)
10-3 TO30 0.65
10-3
Engine and cooling system Cooling system
Cooling system
10-4
PC228US-8,PC228USLC-8
Engine and cooling system Cooling system
10. Reservoir tank 11. Accumulator (for oil cooler circuit) 12. Oil cooler outlet 13. Oil cooler inlet 14. Aftercooler outlet tube 15. Radiator outlet hose 16. Aftercooler inlet hose 17. Shroud 18. Fan guard
1. Aftercooler 2. Oil cooler 3. Radiator inlet hose 4. Radiator cap 5. Radiator 6. Condenser 7. Fuel cooler inlet 8. Fuel cooler 9. Fuel cooler outlet Specification
10-5 Radiator
Oil cooler
Aftercooler
Fuel cooler
Core type
Corrugated aluminium 4 array
CF40-1
Corrugated aluminium
Drawn cup
Fin pitch (mm)
3.5 / 2
3.5 / 2
3.5 / 2
4.0 / 2
Total heat dissipation area (m2)
32.60
7.87 x 2
14.05
0.59
68.6 ± 14.7 {0.7 ± 0.15}
–
–
–
-4.9 – 0 {-0.05 – 0}
–
–
–
Pressure valve cracking pressure (kPa {kg/cm2}) Vacuum valve cracking pressure (kPa {kg/cm2})
PC228US-8,PC228USLC-8
10-5
Engine and cooling system Cooling system
10-6
PC228US-8,PC228USLC-8
Power train system Power train
Power train system Power train
1. Idler 2. Control valve 2a. Self-pressure reducing valve 2b. Pump merge-divider valve 2c. Travel junction valve 3. PPC lock solenoid valve 4. Travel junction solenoid valve 5. Swing brake solenoid valve 6. Travel speed increase solenoid valve 7. 2-stage relief solenoid valve
PC228US-8,PC228USLC-8
8. Attachment selector solenoid valve (Machine ready for installing attachment) 9. Final drive 10. Travel motor 11. Main pump 12. Engine 13. Swing motor 14. Centre swivel joint 15. Swing machinery 16. Swing circle
10-7
Power train system Swing circle
Swing circle Standard specification
1. Swing circle pinion grease filler port 2. Swing circle bearing grease fitting 3. Outer race 4. Ball 5. Seal 6. Inner race (number of teeth: 96)
10-8
10-8
a. Outer race soft zone position b. Inner race soft zone position Specification
10-8
Reduction ratio Grease Amount of grease (l)
-96 / 13 = -7.385 G2-LI 14.5
PC228US-8,PC228USLC-8
Power train system Swing circle
North America specification
1. Swing circle pinion grease filler port 2. Swing circle bearing grease fitting 3. Outer race 4. Ball 5. Seal 6. Inner race (number of teeth: 96)
PC228US-8,PC228USLC-8
10-9
a. Outer race soft zone position b. Inner race soft zone position Specification Reduction ratio Grease Amount of grease (l)
10-9 -96 / 13 = -7.385 G2-LI 20.5
10-9
Power train system Swing machinery
Swing machinery
10-10
PC228US-8,PC228USLC-8
Power train system Swing machinery
1. Swing pinion (number of teeth: 13) 2. No. 2 planetary carrier 3. No. 2 sun gear (number of teeth: 18) 4. No. 2 planetary gear (number of teeth: 19) 5. No. 1 planetary carrier 6. No. 1 planetary gear (number of teeth: 20) 7. Swing motor 8. No. 1 sun gear (number of teeth: 17) 9. Ring gear (number of teeth: 58) 10. Swing machinery case 11. Drain plug 12. Oil level gauge 13. Oil filler port cap
PC228US-8,PC228USLC-8
Specification Reduction ratio Swing reduction ratio Swing speed (rpm)
10-1
((17 + 58) / 17) x ((18 + 58) / 18) =18.627 18.627 x 7.385 = 137.557
11.0
10-11
Power train system Final drive
Final drive
10-12
PC228US-8,PC228USLC-8
Power train system Final drive
1. Level plug 2. No. 1 planetary gear (number of teeth: 48) 3. Drain plug 4. No. 1 sun gear (number of teeth: 11) 5. No. 2 sun gear (number of teeth: 20) 6. No. 1 planetary carrier 7. Cover 8. Ring gear (number of teeth: 109, 96) 9. No. 2 planetary carrier 10. Retainer 11. Hub 12. Sprocket 13. Floating seal 14. Travel motor 15. No. 2 planetary gear (number of teeth: 37)
PC228US-8,PC228USLC-8
Specification Reduction ratio
10-13 -((11 + 109)/11) x ((20 + 96)/20) + 1 = -62.273
10-13
Undercarriage and frame Track frame and idler cushion
Undercarriage and frame Track frame and idler cushion a The following figure shows PC228US-8.
10-14
PC228US-8,PC228USLC-8
Undercarriage and frame Track frame and idler cushion
1. Idler 2. Track frame 3. Carrier roller 4. Final drive 5. Track roller 6. Track shoe 7. Centre guard 8. Idler cushion 9. Front guard Outline The dimensions and the number of track rollers depend on the model, but the basic structure is not different. q Number of track rollers
10-15
q
Model
Q'ty (each side)
PC228US-8
7
PC228USLC-8
9
Standard shoe Model
PC228US-8
PC228USLC-8
Shoe width (mm)
600
700
Link pitch (mm)
190
190
Number of shoes (each side)
45
49
PC228US-8,PC228USLC-8
10-15
Hydraulic system Hydraulic equipment layout drawing
Hydraulic system Hydraulic equipment layout drawing
10-16
PC228US-8,PC228USLC-8
Hydraulic system Hydraulic equipment layout drawing
1. Bucket cylinder 2. Arm cylinder 3. Attachment selector valve (for high pressure) (*2) 4. Accumulator (for high pressure) (*2) 5. Main pump 6. Swing motor 7. Oil cooler 8. Travel motor 9. Accumulator (for oil cooler circuit) 10. L.H. work equipment PPC valve 11. Centre swivel joint 12. Travel PPC valve 13. Attachment PPC valve 14. R.H. work equipment PPC valve 15. Boom anti-drop valve 16. Boom cylinder 17. Accumulator (for PPC circuit) 18. Solenoid valve 19. Control valve 20. Pilot oil filter 21. Return oil filter (*2) 22. Hydraulic tank 23. Attachment selector valve (for low pressure) (*2) 24. Boom cushion EPC valve 25. Multi-control valve (*1) 26. Accumulator (for low pressure) (*2) *1: If equipped *2: Machine ready for installing attachment
PC228US-8,PC228USLC-8
10-17
Hydraulic system Valve control
Valve control
1. Control valve 2. R.H. work equipment PPC valve 3. R.H. work equipment lever (for boom and bucket control) 4. L.H. work equipment lever (for arm and swing control) 5. L.H. work equipment PPC valve 6. Lock lever 7. Travel lever 8. Travel pedal
9. Travel PPC valve 10. Attachment PPC valve (*2) 11. Attachment pedal (*2) 12. Boom cushion EPC valve 13. Multi-control valve (*1) 14. Relay block 15. Accumulator (for PPC circuit) 16.Solenoid valve 17. Lock pin (*2)
*1: If equipped *2: Machine ready for installing attachment
10-18
PC228US-8,PC228USLC-8
Hydraulic system ATT EPC Valve Assembly
ATT EPC Valve Assembly
Pd
T
1D 1A
Pc Pa Pb
2 4-P3
P 4
5C
1C 3
3-P3
1B
4-P2 4-P1 3-P2
5D
5B
3-P1 5A
PC228US-8,PC228USLC-8
10-19
Hydraulic system ATT EPC Valve Assembly
1. Att EPC Valve Assembly 1A. 1 ATT EPC (LH) 1B. 1 ATT EPC (RH) 1C. 2 ATT EPC (LH) OPT. 1D. 2 ATT EPC (RH) OPT. 2. Block 3. Shuttle Valve A 4. Shuttle Valve B 5. Connector 5A. 1 ATT EPC (LH) to CN-V91. 5B. 1 ATT EPC (RH) to CN-V92. 5C. 2 ATT EPC (LH) OPT. to CN-V93. 5D. 2 ATT EPC (RH) OPT. to CN-V94. P: From self pressure reducing valve. T: To tank. Pa: To 3-P2 Pb: To 4-P2 Pc: To M/V 2 ATT RH PPC (N.B. LH delivery to work equipment.) Pd: To M/V 2 ATT LH PPC (N.B. RH delivery to work equipment.) 3-P1: From RH pedal PPC forward
4-P1: From RH pedal PPC backwards
3-P2: From Pa
4-P2 From Pb
3-P3:
To M/V1ATT RH PPC (N.B. LH delivery to W/E)
4-P3:
To M/V1ATT LH PPC (N.B. RH delivery to W/E)
ATT EPC Valve (1) For details of structure, function and operation See “ATT EPC Valve Assembly” on page 19.
Shuttle Valve (3 and 4) P1
P2
P3 Tightening torque 29.4~39.4 Nm (3.0~4.0Kgm)
The shuttle valve allows either the RH attachment pedal or RH lever to be used. Depending on the working mode selection, the lever function is different: q B Mode - Breaker switch on the RH lever can be operated (or pedal). q ATT Mode - Proportional control switch on the RH lever can be operated (or pedal).
10-20
PC228US-8,PC228USLC-8
Hydraulic system Hydraulic tank
Hydraulic tank
1. Filler cap 2. Breather 3. Hydraulic tank 4. Main pump 5. Drain plug 6. Sight gauge 7. Filter element 8. Bypass valve 9. Strainer 10. Suction strainer
PC228US-8,PC228USLC-8
Specification Hydraulic tank capacity (l) Amount of oil in hydraulic tank (l) Bypass valve set pressure (MPa {kg/cm2}
10-19 165 126 0.15 ± 0.03 {1.5 ± 0.3}
10-21
Hydraulic system Hydraulic tank
Oil filler cap
10-20
1. Filter element 2. Bottom plate 3. Gasket 4. Seam valve 5. Spring Prevention of negative pressure in tank 10-20 q The hydraulic tank is sealed and pressurized. When the oil level in the hydraulic tank drops, negative pressure is generated in the tank. To prevent this negative pressure generation, seam valve (4) is opened to draw the atmosphere to the tank. (Suction valve set pressure: 0 – 0.49 kPa {0 – 0.005 kg/cm2}) Prevention of pressure rise in tank 10-20 q When the hydraulic circuit is working, the pressure in the hydraulic tank increases as the hydraulic cylinders operate and the oil level and temperature increase in the tank. If the pressure in the tank rises above the set value, bottom plate (2) is pushed up to release the pressure in the tank. (Relief valve set pressure: 16.7 ± 6.86 kPa {0.17 ± 0.07 kg/cm2 })
10-22
Breather
10-20
1. Nut 2. Cover 3. Filter element 4. Case 5. Valve assembly 6. Body Prevention of negative pressure in tank 10-20 q The hydraulic tank is sealed and pressurized. When the oil level in the hydraulic tank drops, negative pressure is generated in the tank. To prevent this negative pressure generation, valve assembly (5) is opened to draw the atmosphere to the tank. (Suction valve set pressure: 1.96 ± 0.29 kPa {0.02 ± 0.003 kg/cm2}) Prevention of pressure rise in tank 10-20 q When the hydraulic circuit is working, the pressure in the hydraulic tank increases as the hydraulic cylinders operate and the oil level and temperature increase in the tank. If the pressure in the tank rises above the set value, valve assembly (5) is pushed up to release the pressure in the tank. (Relief valve set pressure: 16.7 ± 2.45 kPa {0.17 ± 0.025 kg/cm2})
PC228US-8,PC228USLC-8
Hydraulic system CLSS
CLSS a CLSS: Abbreviation for Closed centre Load Sensing System Outline of CLSS
Features 10-21 q Fine control not influenced by load q Fine control performance allowing for digging even with fine control operation q Ease of combined operation ensured by the flow divider function according to the open areas of spools during combined operations q Energy saving due to the control of variable pumps
PC228US-8,PC228USLC-8
10-21
Configuration 10-21 CLSS is configured with variable capacity piston pumps, control valves, and respective actuators. q The Main pump is configured with pump unit, PC valve and LS valve. q
10-23
Hydraulic system CLSS
Basic principle Pump swash plate angle control 10-2 q The pump swash plate angle (pump delivery) is controlled so that LS differential pressure (EPLS), the difference between pump (pressure (PP) and LS pressure (PLS)) (load pressure of actuator), at control valve outlet is constant. q [LS differential pressure (EPLS) = Pump delivery pressure (PP) – LS pressure (PLS)]
10-2 q
If it becomes higher than the set pressure (when the actuator load pressure is low), the pump swash plate angle shifts toward the minimum position.
LS differential pressure (EPLS) and pump swash plate angle
10-2
a For details of functions, see the “Main pump”.
q
The pump swash plate angle shifts toward the maximum position if LS differential pressure (EPLS) is lower than the set pressure of the LS valve (when the actuator load pressure is high).
10-24 (03)
PC228US-8,PC228USLC-8
Hydraulic system CLSS
Pressure compensation control
q
q
q
10-23
A pressure compensation valve is installed to the outlet port side of each control valve to balance the load pressures. When actuators are operated simultaneously, the pressure difference (EP) between the upstream (inlet port) and downstream (outlet port) of the spool of each valve becomes the same regardless the size of the load (pressure). The flow of oil from the pump is divided (compensated) in proportion to the areas of openings (S1) and (S2) of each valve.
PC228US-8,PC228USLC-8
10-25 (03)
Hydraulic system CLSS
System diagram
10-24
a The illustration shows the condition when actuator (7) is in relief condition at its stroke end in the merge mode. 1. Front pump 2. Rear pump 3. Main relief valve 4. Unload valve 5. Merge-divider valve 6. Control valve 7. Actuator 8. Pump circuit
10-26
9. LS circuit 10. Tank circuit 11. Valve 12. Spring 13. LS bypass valve 14. LS valve 15. PC valve
PC228US-8,PC228USLC-8
Hydraulic system CLSS
PC228US-8,PC228USLC-8
10-27
Hydraulic system Main pump
Main pump Type: HPV95+95
10-28
PC228US-8,PC228USLC-8
Hydraulic system Main pump
Outline 10-27 This pump consists of two variable capacity swash plate piston pumps, PC valve, LS valve, EPC valve, and swash plate sensor.
q
IMF: Front PC mode selector current IMR: Rear PC mode selector current ISIG: LS set pressure selector current PAF: Front pump delivery port PAR: Rear pump delivery port PBF: Pump pressure input port PD1F: Air bleeder PD1R: Case drain port PD2F: Drain plug PD2R: Drain plug PENF: Front control pressure pickup port PENR: Rear control pressure pickup port PEPC: EPC source pressure port PEPCC: EPC source pressure pickup port PFC: Front pump delivery pressure pickup port PLSF: Front load pressure input port PLSFC: Front load pressure pickup port PLSR: Rear load pressure input port PLSRC: Rear load pressure pickup port PMF: Front PC mode selector pressure pickup port PMR: Rear PC mode selector pressure pickup port PRC: Rear pump delivery pressure pickup port PS: Pump suction port PSIG: LS set selector pressure pickup port 1. Front pump 2. Rear pump 3. LS valve 4. PC valve 5. LS-EPC valve 6. PC-EPC valve
PC228US-8,PC228USLC-8
10-29
Hydraulic system Main pump
1. Front shaft 2. Cradle 3. Front case 4. Rocker cam 5. Shoe 6. Piston 7. Cylinder block 8. Valve plate 9. End cap 10. Rear shaft 11. Rear case 12. PC valve 13. Servo piston
10-30
PC228US-8,PC228USLC-8
Hydraulic system Main pump
Function 10-29 The pump converts the engine torque transmitted to its shaft (1) into oil pressure and delivers pressurized oil corresponding to the load. q It is possible to change the delivery by changing the swash plate angle.
q
q
q q q
Structure 10-29 q Cylinder block (7) is supported by shaft (1) on splined area (14). q Shaft (1) is supported by each bearing (15) at the front and rear. q The tip of piston (6) has a spherical hollow in which shoe (5) is being held by crimping. q Piston (6) and shoe (5) form a spherical bearing. q Rocker cam (4) has flat surface (A), and shoe (5) is always pressed against this surface while sliding in a circular pattern. q Rocker cam (4) conducts high pressure oil to cylinder surface (B) with cradle (2), which is secured to the case, and forms a static pressure bearing when it slides.
PC228US-8,PC228USLC-8
Piston (6) in each cylinder of cylinder block (7) reciprocates in the axial direction. Cylinder block (7) seals the pressurized oil to valve plate (8) and performs relative rotation. This surface is designed so that the oil pressure balance is maintained at a suitable level. The oil is sucked into and discharged from each cylinder in cylinder block (7) through valve plate (8).
10-31
Hydraulic system Main pump
Operation of pump q Cylinder block (7) rotates together with shaft (1) and shoe (5) slides on plane (A). q Rocker cam (4) moves along cylindrical face (B). As a result, angle (a) between centre line (X) of rocker cam (4) and the axis of cylinder block (7) changes. q Angle (a) is called the swash plate angle.
q
q
q q
q
q
q
10-30 As centre line (X) of rocker cam (4) matches the axis of cylinder block (7) (swash plate angle = 0), the difference between volumes (E) and (F) inside cylinder block (7) equals 0. The hydraulic oil is not sucked or discharged. (Actually, however, the swash plate angle does not become to 0)
If swash plate angle (a) is made between centre line (X) of rocker cam (4) and the axis of cylinder block (7), plane (A) functions as a cam against shoe (5). Piston (6) reciprocates inside cylinder block (7) and a difference is made between volumes (E) and (F) of cylinder chamber in cylinder block (7). Each piston (6) sucks and discharges oil by (F) – (E). If cylinder block (7) rotates and the volume of chamber (E) is decreased, the oil is discharged from chamber (E) during this process. The volume of chamber (F) is increased and the oil is sucked in chamber (F) during this process.
10-32
PC228US-8,PC228USLC-8
Hydraulic system Main pump
Control of delivery If swash plate angle (a) increases, the difference between volumes (E) and (F) increases, and pump delivery (Q) increases. q Swash plate angle (a) is changed by servo piston (12). q Servo piston (12) reciprocates straight according to the signal pressure from the PC and LS valves. q This linear reciprocating movement is transmitted to rocker cam (4) through slider (13). q Being supported by cradle (2) on the cylindrical surface, rocker cam (4) slides on the surface while continuing revolving movement. q Output pressure (PEN) of LS valve is supplied to the chamber receiving the pressure at the large diameter piston end. q The areas receiving the pressure on the right and left sides of servo piston (12) are different from each other, and delivery pressure (self pressure) (PP) of the main pump is constantly applied to the pressure chamber of the small diameter piston side. q The movement of servo piston (12) is controlled by the relationship of pressure between small diameter piston side (PP) and large diameter piston side (PEN) and by the ratio of the areas receiving the pressure of the small diameter piston and large diameter piston.
10-31
q
PC228US-8,PC228USLC-8
10-33
Hydraulic system Main pump
LS valve
PA: Pump port PDP: Drain port PLP: LS control pressure output port PLS: LS pressure input port PP: Pump port PPL: Control pressure input port PSIG: LS mode selector pilot port 1. Sleeve 2. Piston 3. Spool 4. Spring 5. Seat 6. Sleeve 7. Plug 8. Locknut
10-32
q
q
The relation between the pump delivery (Q) and the differential pressure (EPLS)[= (PP) – (PLS)] between the main pump pressure (PP) and LS pressure (PLS) is changed by the LS set pressure selector current (ISIG) as shown in the figure below. When the (ISIG) changes from 0 A to 1 A, the spring setting force will change accordingly, to let the centre of the standard value range of the pump delivery selector point vary within the range from 0.27 MPa {2.78 kg/cm2} to 1.7 MPa {17.75 kg/cm2}.
Function 10-32 q The LS (load sensing) valve detects the load of the actuator and controls the discharge amount. q This valve controls pump delivery (Q) with the differential pressure (EPLS) [= (PP) - (PLS)] (called the LS differential pressure) between pump delivery pressure (PP) and control valve outlet pressure (PLS). q This valve receives main pump delivery pressure (PP), pressure (PLS) (called the LS pressure) coming from the control valve output, and pressure (PSIG) (called the LS set selector pressure) from the proportional solenoid valve.
10-34 (03)
PC228US-8,PC228USLC-8
Hydraulic system Main pump
Operation
10-3
When control valve is in “NEUTRAL” position
10-3
q
q
q
q q
q
The LS valve is a 3-way selector valve, and LS pressure (PLS) (actuator load pressure) on the outlet of control valve is transmitted to spring chamber (B), and pump delivery pressure (PP) is transmitted to port (H) of sleeve (8). Magnitude of the force resulting from this LS pressure (PLS), force of spring (4) and the pump discharge pressure (self pressure) (PP) determine the position of spool (6). 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.) Before the engine is started, servo piston (12) is pushed to the left. (See the figure on the right) If the control lever is in the neutral position when the engine is started, LS pressure (PLS) is set to 0 MPa {0 kg/cm2}. (It is interconnected to the drain circuit via the control valve spool) Spool (6) is pushed to the right, and port (C) and port (D) will be connected.
PC228US-8,PC228USLC-8
q q
q
Pump pressure (PP) is conducted to the larger diameter end of the pump from the port (K). The same pump pressure (PP) is conducted to the smaller diameter end of the pump at the port (J). According to the area difference of servo piston (12), the servo piston is moved to the right, in the direction which makes the swash plate angle minimum (See the figure above).
10-35
Hydraulic system Main pump
When pump delivery is increased
q
q q
q
When the difference between pump delivery pressure (PP) and LS pressure (PLS), in other words, LS differential pressure (EPLS) decreases (for example, when the control valve open area increases and pump delivery pressure (PP) decreases), the combined force of LS pressure (PLS) and the force of spring (4) pushes spool (6) to the left. As spool (6) moves, ports (D) and (E) are interconnected and also connected to the PC valve. Since the PC valve and drain port are connected, the pressure between ports (D) and (K) becomes drain pressure (PT). (PC valve operation will be explained later.) The pressure on the large diameter piston side of servo piston (12) becomes drain pressure (PT), and pump pressure (PP) is constantly applied to port (J) on the small diameter side. Accordingly, servo piston (12) is pushed to the left and the swash plate is moved to increase the delivery.
10-36 (03)
10-34
q
q
At this time, when the output pressure from the EPC valve for the LS valve enters port (G), a force is applied on piston (7) to move the piston to the right. It piston (7) is pushed to the right, setting force of spring (4) is weakened, changing the LS differential pressure (EPLS) [Difference between oil pressures (PLS) and (PP)] when ports (D) and (E) of spool (6) are connected.
PC228US-8,PC228USLC-8
Hydraulic system Main pump
When pump delivery is decreased
q
q
q
q
10-35
When servo piston (12) moves to the right (the direction that reduces pump delivery) and LS differential pressure (EPLS) increases (for example, when the control valve open area decreases and pump delivery pressure (PP) increases), the force caused by pump delivery pressure (PP) pushes spool (6) to the right. The movement of spool (6) transmits pump delivery pressure (PP) to the large diameter end of the piston through port (C) , port (D) and port (K). Although pump delivery pressure (PP) is applied to port (J) on the small diameter piston side, servo piston (12) is pushed to the right by the area difference between the large diameter piston side and small diameter piston side of servo piston (12). As the result, the swash plate angle becomes smaller. When the LS set selector pressure (PSIG) enters port (G), the spring (4) setting force is weakened.
PC228US-8,PC228USLC-8
10-37 (03)
Hydraulic system Main pump
When servo piston is balanced
q
q
q
q
The symbols (A1), (A0) and (PEN) represent the area receiving the pressure at the large diameter end of the piston, the area receiving the pressure at the small diameter end and the pressure conducted to the large diameter end of the piston, respectively. When the force generated by main pump pressure (PP) of the LS valve is balanced with the combined force of LS pressure (PLS) and spring (4), and the relationship becomes (A0) x (PP) = (A1) x (PEN), servo piston (12) stops in that position. The swash plate of the pump is held at the intermediate position. [Spool (6) is stopped at a position where the opening area from port (D) to port (E) and the distance from port (C) to port (D) is almost the same.] The relationship between the area receiving the pressure at both ends of servo piston (12) is (A0):(A1) = 3:5, and the pressures applied to both ends of the piston when the piston is balanced is (PP):(PEN)C 5:3.
10-38
10-36
q
q
The force of spring (4) is adjusted so that spool (6) can be balanced at the specified centre when (PP) - (PLS) = 1.7 MPa {17.75 kg/cm2}. When (PSIG) [LS-EPC valve output pressure, 0 to 2.9 MPa {0 to 30 kg/cm2}]is applied to port (G), the balanced position will change in proportion to the (PSIG) pressure within a range of (PP) (PLS) = 1.7 MPa {17.75 kg/cm2} to 0.27 MPa {2.78 kg/cm2}.
PC228US-8,PC228USLC-8
Hydraulic system Main pump
PC valve
PA: Pump port PA2: Pump pressure pilot port PDP: Drain port PM: Mode selector pressure pilot port PPL: Control pressure output port (to LS valve) 1. Plug 2. Servo piston assembly 3. Pin 4. Spool 5. Retainer 6. Seat 7. Cover 8. Wiring
10-37
q
q
If the engine speed is slowed down due to increased load, the controller reduces the pump delivery to recover the speed. When the load increases and the engine speed decreases below a preset value, the controller increases the command current to the PC-EPC valve solenoid depending on the amount of engine speed decrease, to decrease the swash plate angle.
Function 10-37 q The PC valve limits the oil flow to a certain level (depends on the delivery pressure) even if the travel of the control valve is increased extremely. This is to ensure the horsepower absorbed by the pump not to exceed the engine horsepower, when pump delivery pressures (PP1) (self pressure) and (PP2) (other pump's pressure) are high. q If the pump delivery pressure increases due to increased load during work, this valve decreases the pump delivery. q And if the pump delivery pressure goes low, it increases the pump delivery. q The relation between the average delivery pressure of front and rear pumps [(PP1)+(PP2)]/2 and pump delivery (Q) is as shown in the figure, as a parameter for each current (X) values applied to the PC-EPC valve solenoid. q The controller continues counting the actual engine speed.
PC228US-8,PC228USLC-8
10-39
Hydraulic system Main pump
Operation
10-38
When the pump controller is normal
10-38
When load on the actuator is small and pump pressures (PP1) and (PP2) are low
10-38
Work of PC-EPC valve solenoid (1) 10-38 q Command current (X) from the pump controller flows to the PC-EPC valve solenoid (1). q This command current (X) acts on the PC-EPC valve to generate signal pressure to vary the force pushing piston (2). q Spool (3) stops at a position when the combined forces of springs (4) and (6), pump pressure (PP1) (self pressure), and pump pressure (PP2) (other pump's pressure) acting on spool (3) are balanced. q Depending on this position, the pressure output from the PC valve [port (C) pressure] varies. q The amperage of the command current (X) depends on the type of work (lever operation), work mode selection, engine speed setting, and the actual engine speed.
10-40
a Other pump’s pressure denotes the pressure of the pump situated on the opposite side. For the front pump pressure, the other pump's pressure is that of the rear pump. And for the rear pump pressure, the other pump's pressure is that of the front pump.
PC228US-8,PC228USLC-8
Hydraulic system Main pump
10-39 Action of spring The spring force of springs (4) and (6) in the PC valve depends on the position of the swash plate. q When servo piston (9) moves to the right, spring (6) is compressed. q When the piston moves further to the right, the piston comes in contact with seat (5) and spring (6) is fixed. q Then, only spring (4) operates. q When servo piston (9) compresses or decompresses springs (4) and (6), the spring load varies. q When the command current (X) input to PC-EPC valve solenoid (1) varies, the thrust pushing piston (2) varies. q The spring loads of springs (4) and (6) are also varied by the PC-EPC valve solenoid command current (X). q Port (C) on the PC valve is connected to port (E) on the LS valve. q Self pressure (PP1) enters the small diameter side of servo piston (9) port (B), and other pump's pressure (PP2) enters port (A).
q
q
PC228US-8,PC228USLC-8
q
q
q q
q
q
When pressures (PP1) and (PP2) are low, spool (3) is on the left. Port (C) and port (D) are connected, and the pressure entering the LS valve will be drain pressure (PT). When port (E) of the LS valve is connected to port (G), the pressure from port (J) entering the large diameter side of the piston becomes drain pressure (PT), and servo piston (9) moves to the left. The pump delivery goes to increase. The movement of servo piston (9) lets springs (4) and (6) to expand, and the spring force decreases. When the spring force decreases, spool (3) is moves to the right. Ports (C) and (D) are blocked, while pump delivery pressure port (B) is connected to port (C). Since the pressure in port (C) and the pressure at the large diameter side of the piston increase, servo piston (9) stops moving to the left.
10-41
Hydraulic system Main pump
q
Accordingly, the stop position (= pump delivery) of servo piston (9) is determined by the position where the thrust caused by pressures (PP1) and (PP2), the thrust generated by the PC-EPC valve solenoid, and the force of springs (4) and (6) acting on the spool (3) are balanced.
10-42
PC228US-8,PC228USLC-8
Hydraulic system Main pump
When load on the actuator is large and pump pressures (PP1) and (PP2) are high
Outline 10-41 q When the load is large and the pump delivery pressures (PP1) and (PP2) are high, the thrust moving spool (3) to the right increases, and spool (3) comes to a position as shown above. q The pressure from port (C) to the LS valve will be about half of pump pressure (PP2), because a part of the pressure from port (B) flows through the LS valve and port (C) to port (D), as shown above.
q q q
10-41
When spool (3) moves to the left, the openings of ports (C) and (D) widen. The pressure in port (C) (=J) decreases, and the movement of servo piston (9) to the right stops. Servo piston (9) will stop at a position further to the right than the position when pump pressures (PP1) and (PP2) are low.
Operation 10-41 When ports (E) and (G) of the LS valve are connected, the pressure enters from port (J) to the large diameter side of servo piston (9), and servo piston (9) stops moving. q When pump pressure (PP2) increases more and spool (3) moves further to the right, pump pressure (PP1) flows to port (C) to minimize the pump delivery. q When servo piston (9) moves to the right, springs (4) and (6) are compressed, and spool (3) is pushed back. q
PC228US-8,PC228USLC-8
10-43
Hydraulic system Main pump
q
q
q
q
The relation between the average pump pressure [(PP1)+(PP2)]/2 and servo piston (9) position are plotted as a bent line because two springs (4) and (6) are used. The relation between the average pump pressure (PP1+PP2)/2 and average pump delivery (Q) is shown below.
When the command current (X) input to PC-EPC valve solenoid (1) increases, the plotted line indicating the relation between the average pump pressure (PP1+PP2)/2 and average pump delivery (Q) makes parallel translation by a distance proportional to the PC-EPC valve solenoid thrust. Since PC-EPC valve solenoid (1) thrust is added to the thrust pressing spool (3) to the right, the curve indicating relation between the average pump pressure (PP1+PP2)/2 and average pump delivery (Q) shifts from (A) to (B) as the command current (X) is increased.
10-44
PC228US-8,PC228USLC-8
Hydraulic system Main pump
When the pump controller malfunctions and the emergency pump drive switch is at "ON" position 10-43 When load on the main pump is small
q
q
q q
q
q
10-43
If the pump controller fails, turn "ON" the emergency pump drive switch and select the resistor side. In this case, power must be taken directly from the battery, however, a resistor is needed to control the current supplied to PC-EPC valve solenoid (1). Since the current is constant, the thrust applied to piston (2) is constant. When main pump pressures (PP1) and (PP2) are low, the combined force of PC-EPC valve solenoid (1) thrust and the pump pressure is smaller than the force of springs. Spool (3) stays balanced at the left. Port (C) is connected to port (D) at drain pressure, and the pressure at the large diameter side of servo piston (9) comes to drain pressure (PT) through the LS valve. Since the pressure at the small diameter side of the piston is large, servo piston (9) moves in the direction to increase the delivery.
PC228US-8,PC228USLC-8
10-45
Hydraulic system Main pump
When load on the main pump is large
q
q q
q
q
q
10-4
As mentioned before, when the emergency pump drive switch is turned "ON", the command current (X) sent to PC-EPC valve solenoid (1) is constant. Therefore, the thrust applied by piston (2) to spool (3) comes to constant. When main pump pressures (PP1) and (PP2) increase, spool (3) moves to a position further to the right than when the main pump load is small, and stays balanced as shown above. Since the pressure from port (B) flows into port (C), servo piston (9) moves to the right (delivery decreases), and stops at a position further to the right than when the pump load is small. When the emergency pump drive switch is turned "ON", the curve indicating the relation between the pump pressure (PP) and delivery (Q) is plotted in accordance with the current supplied through the resistor to the PC-EPC valve solenoid. When the emergency pump drive switch is turned "ON", the curve is plotted as (B), which is shifted toward the left than curve (A) for a normal pump controller.
10-46
PC228US-8,PC228USLC-8
Hydraulic system Main pump
LS (PC)-EPC valve
10-45
C: To LS(PC) valve P: From self-pressure reducing valve T: To hydraulic tank 1. Connector 2. Coil 3. Body 4. Spring 5. Spool 6. Rod 7. Plunger
PC228US-8,PC228USLC-8
10-47
Hydraulic system Main pump
Function 10-46 q The EPC valve consists of the proportional solenoid and the hydraulic valve . q When a signal current (i) from the controller is received, an EPC output pressure proportional to the amperage of current is generated and output to the LS (PC) valve.
Operation
When signal current is zero (coil de-energized) 10-46
q q q
q
10-48
10-46
When the signal current from the controller is not flowing through coil (2), coil (2) is de-energized. Spool (5) is pushed to the left side by spring (4). Port (P) is closed, and the pressurized oil from the self pressure reducing valve does not flow to the LS (PC) valve. The pressurized oil from the LS (PC) valve flows through port (C) and then port (T), and is drained to the tank.
PC228US-8,PC228USLC-8
Hydraulic system Main pump
When signal current is small (coil energized)
q
q q
q q q
q
10-47
When a small signal current flows through coil (2), coil (2) is energized and a thrust pushing plunger (7) to the right is generated. Rod (6) pushes spool (5) to the right, and the pressurized oil flows from port (P) to port (C). The pressure at port (C) increases and the total of the force applied to the surface of spool (5) and load of spring (4) becomes larger than the thrust of plunger (7). Spool (5) is pushed to the left, and ports (C) and (D) are blocked. Port (C) connects to port (T). Spool (5) moves to a position where the thrust of plunger (7) becomes equal to the total of the pressure at port (C) and the load of spring (4). The circuit pressure between the EPC valve and LS (PC) valve is controlled in proportion to the amperage of signal current.
PC228US-8,PC228USLC-8
When signal current is maximum (coil energized)
q q q q
q
10-47
Coil (2) is energized when signal current is supplied to coil (2). As the amperage of signal current is maximum, the thrust of plunger (7) is also maximized. Spool (5) is pushed to the right by rod (6). The pressurized oil flows from port (P) to port (C) at the maximum rate, and the circuit pressure between the EPC valve and LS (PC) valve is maximized. Port (T) closes, and no pressurized oil flows to the tank.
10-49
Hydraulic system Control valve
Control valve Outline The control valves of the following types are set. q 6-spool valve (without service valve) q 7-spool valve (6-spool valve with service valve) q 8-spool valve (6-spool valve with two service valves) q q q q
10-48
This control valve consists of a 6-spool valve (unit type) and a set of service valve. A merge-divider valve, a back pressure valve and a boom hydraulic drift prevention valve are installed to it. Since all the valves are assembled together with connecting bolts and their passes are connected to each other inside the assembly, the assembly is compact and easy to maintain. With one spool provided for one work equipment, this control valve is simple in structure. As for outside views and sectional views, only the 8-spool valve (6-spool valve + 2 service valves) is shown.
A1: To bucket cylinder head A2: To L.H. travel motor A3: To boom cylinder bottom A4: To swing motor A5: To R.H. travel motor A6: To arm cylinder head A-1: To attachment 1 A-2: To attachment 2 ATT: From attachment B1: To bucket cylinder bottom B2: To L.H. travel motor B3: To boom cylinder head B4: To swing motor B5: To R.H. travel motor B6: To arm cylinder bottom B-1: To attachment 1 B-2: To attachment 2 BP1: From LS select solenoid valve BP5: From attachment selector solenoid valve C: To tank IS1: From controller IS2: From controller P1: From R.H. work equipment PPC valve (bucket DUMP) P2: From R.H. work equipment PPC valve (bucket CURL) P3: From travel PPC valve (L.H. travel reverse) P4: From travel PPC valve (L.H. travel forward) P5: From R.H. work equipment PPC valve (boom RAISE) P6: From R.H. work equipment PPC valve (boom LOWER)
P7: From L.H. work equipment PPC valve (swing RIGHT) P8: From L.H. work equipment PPC valve (swing LEFT) P9: From travel PPC valve (R.H. travel reverse) P10: From travel PPC valve (R.H. travel forward) P11: From L.H. work equipment PPC valve (arm OUT) P12: From L.H. work equipment PPC valve (arm IN) P-1: From R.H. attachment PPC valve P-2: From R.H. attachment PPC valve P-3: From L.H. attachment PPC valve P-4: From L.H. attachment PPC valve PLS1: To rear pump LS valve PLS2: To front pump LS valve PLSC: LS pressure pickup port PP1: From rear pump PP2: From front pump PP1S: Pressure sensor mounting port PPC: Pilot source pressure pickup port PP2S: Pressure sensor mounting port PPS2: To front pump LS valve PR: To solenoid valve, PPC valve, and EPC valve PST: From travel junction valve solenoid valve PX1: From 2-stage relief solenoid valve PX2: From 2-stage relief solenoid valve T: To tank T1: To tank TS: To tank TSW: From swing motor
1. 8-spool valve 2. Cover A 3. Cover B 4. Service valve 1 5. Service valve 2
6. Pump merge-divider valve 7. Boom hydraulic drift prevention valve 8. Arm check valve 9. Arm quick return valve
10-50
PC228US-8,PC228USLC-8
Hydraulic system Control valve
General view
PC228US-8,PC228USLC-8
10-49
10-51
Hydraulic system Control valve
Sectional view (1/5)
10-52
10-50
PC228US-8,PC228USLC-8
Hydraulic system Control valve
1. Pressure compensation valve (arm OUT) 2. Pressure compensation valve (R.H. travel REVERSE) 3. Pressure compensation valve (RIGHT swing) 4. Pressure compensation valve (Boom RAISE) 5. Pressure compensation valve (L.H. travel REVERSE) 6. Pressure compensation valve (Bucket DUMP) 7. Pressure compensation valve (Service 1) 8. Pressure compensation valve (Service 2) 9. Pressure compensation valve (Bucket CURL) 10. Pressure compensation valve (L.H. travel FORWARD) 11. Pressure compensation valve (Boom LOWER) 12. Pressure compensation valve (LEFT swing) 13. Pressure compensation valve (R.H. travel FORWARD) 14. Pressure compensation valve (arm IN) 15. Main relief valve 16. Unload valve 17. Main relief valve 18. Spool (Service 2) 19. Spool (Service 1) 20. Spool (Bucket) 21. Spool (L.H. travel) 22. Spool (Boom) 23. Spool (Swing) 24. Spool (R.H. travel) 25. Spool (Arm)
PC228US-8,PC228USLC-8
10-53
Hydraulic system Control valve
(2/5)
10-54
PC228US-8,PC228USLC-8
Hydraulic system Control valve
1. Suction valve (arm OUT) 2. Suction valve (R.H. travel REVERSE) 3. Suction valve (Boom RAISE) 4. Suction valve (L.H. travel REVERSE) 5. Suction safety valve (Bucket DUMP) 6. Suction safety valve (Service 1) 7. Suction safety valve (Service 2) 8. Suction 2-stage safety valve (Service) 9. Suction safety valve (Bucket CURL) 10. Suction valve (L.H. travel FORWARD) 11. Suction safety valve (Boom LOWER) 12. Suction valve (R.H. travel FORWARD) 13. Suction safety valve (arm IN) 14. LS shuttle valve (Arm) 15. LS shuttle valve (R.H. travel) 16. LS select valve 17. LS shuttle valve (Boom) 18. LS shuttle valve (Left travel) 19. LS shuttle valve (Bucket) 20. LS shuttle valve (Service 1) 21. LS shuttle valve (Service 2) 22. LS check valve
PC228US-8,PC228USLC-8
10-55
Hydraulic system Control valve
(3/5)
10-56
PC228US-8,PC228USLC-8
Hydraulic system Control valve
1. Unload valve 2. Safety valve (Boom RAISE) 3. Main relief valve 4. Back pressure valve Arm valve 5. Arm check valve 6. LS shuttle valve 7. Quick return valve 8. Pressure compensation valve (IN) 9. Spool 10. Suction safety valve (IN) 11. Cooler check valve 12. Regeneration circuit check valve 13. Suction valve (OUT) 14. Pressure compensation valve (OUT)
10-5
Right travel valve 15. LS shuttle valve 16. Pressure compensation valve (FORWARD) 17. Spool 18. Suction valve (FORWARD) 19. Suction valve (REVERSE) 20. Pressure compensation valve (REVERSE)
10-5
Swing valve 21. LS select valve 22. Pressure compensation valve (L.H.) 23. Spool 24. Pressure compensation valve (R.H.)
10-5
PC228US-8,PC228USLC-8
10-57
Hydraulic system Control valve
(4/5)
10-58
PC228US-8,PC228USLC-8
Hydraulic system Control valve
1. Return spring 2. Merge-divider valve (for LS) 3. Valve (Sequence valve) 4. Spring (Sequence valve) 5. Merge-divider valve (Main) 6. Return spring Boom valve 7. Drift prevention valve 8. LS shuttle valve 9. Pressure compensation valve (LOWER) 10. Spool 11. Suction safety valve (LOWER) 12. Regeneration circuit check valve 13. Suction valve (RAISE) 14. Pressure compensation valve (RAISE)
10-57
Left travel valve 15. Merge-divider valve (travel junction valve) 16. Return spring 17. LS shuttle valve 18. Pressure compensation valve (FORWARD) 19. Spool 20. Suction valve (FORWARD) 21. Suction valve (REVERSE) 22. Pressure compensation valve (REVERSE)
10-57
Bucket valve 23. LS shuttle valve 24. Pressure compensation valve (CURL) 25. Spool 26. Suction safety valve (Curl) 27. Suction safety valve (DUMP) 28. Pressure compensation valve (DUMP)
10-57
PC228US-8,PC228USLC-8
10-59
Hydraulic system Control valve
(5/5)
Service valve 1 1. LS shuttle valve 2. Pressure compensation valve 3. Spool 4. Suction 2-stage safety valve 5. Suction safety valve
10-60
10-58
Service valve 2 6. LS shuttle valve 7. Pressure compensation valve 8. Spool 9. Suction safety valve 10. Unload valve 11. Main relief valve 12. LS bypass plug
10-58
PC228US-8,PC228USLC-8
Hydraulic system Control valve
PC228US-8,PC228USLC-8
10-61
Hydraulic system Function and operation by valve
Function and operation by valve Hydraulic circuit diagram and valve names
10-62
10-60
PC228US-8,PC228USLC-8
Hydraulic system Function and operation by valve
1. Arm valve 2. Right travel valve 3. Swing valve 4. Boom valve 5. Left travel valve 6. Bucket valve 7. Service valve 1 8. Service valve 2 9. Arm spool 10. R.H. travel spool 11. Swing spool 12. Boom spool 13. L.H. travel spool 14. Bucket spool 15. Service spool 1 16. Service spool 2 17. Pressure compensation valve 18. Suction valve 19. Check valve (for boom regeneration circuit) 20. Check valve (for arm regeneration circuit) 21. EPC valve (for pump merge-divider valve main spool changeover) 22. EPC valve (for pump merge-divider valve LS spool changeover) 23. LS shuttle valve 24. LS bypass plug 25. LS select valve 26. Merge-divider valve
PC228US-8,PC228USLC-8
27. Arm quick return valve 28. Arm check valve (For centralized safety valve circuit) 29. Self-pressure reducing valve 30. Travel junction valve 31. Back pressure valve 32. Cooler check valve 33. Boom drift prevention valve 34. Main relief valve (for attachment, bucket, left travel and boom circuits) Set pressure: 34.9 ± 0.5 MPa {355.5 ± 5 kg/cm2} With power max. ON: 37.5 ± 0.5 MPa {382 ± 5 kg/cm2} 35. Main relief valve (for arm, right travel and swing circuits) Set pressure: 34.9 ± 0.5 MPa {355.5 ± 5 kg/cm2} With power max. ON: 37.5 ± 0.5 MPa {382 ± 5 kg/cm2} 36. Unload valve (bucket side) Cracking pressure: 2.5 ± 0.5 MPa {26 ± 5 kg/cm2} 37. Unload valve (arm side) Cracking pressure: 2.5 ± 0.5 MPa {26 ± 5 kg/cm2} 38. Suction-safety valve Set pressure: 24.5 ± 0.5 MPa {250 ± 5 kg/cm2} 39. Suction-safety valve Set pressure: 38.2 ± 0.5 MPa {390 ± 5 kg/cm2} 40. Suction 2-stage safety valve Set pressure: 1st stage: 24.5 ± 0.5 MPa {250 ± 5 kg/cm2} 2nd stage: 20.6 ± 0.5 MPa {210 ± 5 kg/cm2}
10-63
Hydraulic system Function and operation by valve
Unload valve
10-62
When unload valve is actuated
10-62
1. LS circuit 2. Valve 3. Pump circuit 4. Tank circuit 5. Spring Function 10-62 q When all control valves are at HOLD, this valve serves to drain as same amount of oil as the pump delivery with swash plate angle at the minimum. q The pump pressure becomes the pressure corresponding to the set load of spring (5) in the valve (referred to as P1). q As the LS pressure oil is drained from the LS bypass valve, the LS pressure comes to be that LS pressure C tank pressureC 0 MPa {0 kg/cm2}. Operation 10-62 q Pressure of pump circuit (3) is received by the end of valve (2). q As the control valve is in neutral, the pressure in LS circuit (1) is 0 MPa {0 kg/cm2}. q Pressurized oil of pump circuit (3) stops at valve (2), and the pressure rises as no relief is available. q When the force exerted by this pressure becomes larger than the force of spring (5), valve (2) moves to the left. q Ports (b) and (c) are connected, and the pump pressure oil flows to tank circuit (4) q The pressurized oil of LS circuit (1) passes from orifice (a) through port (c) and is drained to tank circuit (4). q When this valve is actuated, the LS pressure is nearly equal to the tank pressure. q When unloading, the pressure difference, pump delivery pressure minus LS circuit pressure, is greater than pump LS control pressure. This is the signal to control the pump swash plate angle to the minimum.
10-64 (03)
When operating actuators within the pump delivery with the swash plate angle at the minimum, the delivery pressure with swash plate angle at the minimum is controlled to the LS pressure plus P1 pressure. q The LS differential pressure (EPLS) with the swash plate angle at the minimum becomes P1 pressure. Operation of relief valve 10-62 q When the cylinder reaches its stroke end, the main relief valve opens. q The pump delivery (Q) is relieved to the tank. (See the system diagram) q As no flow is at upstream and downstream of the spool, the pump delivery pressure (PP) and LS pressure (PLS) are approximately the same, and the LS differential pressure (EPLS) is 0 MPa {0 kg/cm2}. q As LS differential pressure (EPLS) is lower than the LS set pressure of LS valve, LS valve operates to make the pump swash plate angle maximum. q Mechanically, operation of PC valve has priority over that of LS valve. q The pump is maintained at the minimum swash plate angle due to PC valve cut-off function. q
PC228US-8,PC228USLC-8
Hydraulic system Function and operation by valve
Introduction of LS pressure
10-63
1. Main pump 2. Main spool 3. Pressure compensation valve 4. Valve 5. Check valve 6. LS circuit 7. LS shuttle valve Function 10-63 q The upstream pressure (spool meter-in downstream pressure) of pressure compensation valve (3) is introduced and led to LS shuttle valve (7) as the LS pressure. q The pressure compensation valve connects to port (B) of actuator through valve (4), taking that the LS pressure is nearly equal to the actuator negative pressure. q In main spool (2), leading hole (a) with a small diameter also acts as an orifice. Operation 10-63 When main spool (2) is operated, the pump pressure enters port (c) through leading hole (a) and is led to the LS circuit. q When the pump pressures rises to reach the load pressure of port (B), check valve (5) opens and the pressurized oil flows. q
PC228US-8,PC228USLC-8
10-65
Hydraulic system Function and operation by valve
LS bypass plug
10-64
1. Main pump 2. Main spool 3. Pressure compensation valve 4. LS shuttle valve 5. LS bypass plug 6. LS circuit Function 10-64 q This plug relieves residual pressure in LS pressure circuit (6) from orifices (a) and (b). q This plug serves to slow down the rising rate of the LS pressure to prevent a sudden change of hydraulic pressure. q Depending on the bypass flow from LS bypass plug (5), a pressure loss is generated due to the circuit resistance from orifice (c) of main spool (2) to LS shuttle valve (4). q Effective LS differential pressure drops to improve a dynamic stability of the actuator.
10-66
PC228US-8,PC228USLC-8
Hydraulic system Function and operation by valve
Pressure compensation valve
10-65
When the work equipment is operated independently and the load pressure is the maximum (When the load pressure is higher than other work equipment during a combined operation)
10-65
1. Main pump 2. Valve 3. Shuttle valve 4. Piston 5. Spring 6. LS shuttle valve
q
q
q
Function 10-65 q Pressure compensation valve works as the load check valve. q If the pump pressure (LS pressure) is lower than the load pressure at port (c), shuttle valve (3) in pressure compensation valve piston (4) interconnects spring chamber (E) and port (C). q The force of spring (5) operates piston (4) and valve (2) to the closing direction.
As principle, port (C) and spring chamber (E) are not interconnected in an integrated pressure compensation valve. If high peak pressure is generated at port (C), valve (7) does not collide with the valve chamber. With a bucket valve, etc., port (C) and spring chamber (E) are designed to interconnect before valve (7) is seated.
Integrated pressure compensation valve 10-65 When a high peak pressure or continuous and repetitive peak pressure (as in breaker operation) is generated in the actuator circuit, valve (2) may collide with valve chamber seat (C), producing high stress in the parts. q To prevent this, a pressure compensation valve with integrated valve (2) and piston (4) is used. q With this machine, this valve is adopted for the bucket valve (cylinder bottom) and the service valve. q
PC228US-8,PC228USLC-8
10-67
Hydraulic system Function and operation by valve
When compensated (When the load pressure is lower than other work equipment during a combined operation)
10-6
Function 10-6 q The pressure compensation valve closes by the LS pressure of port (D), and the spool meter-in downstream pressure of port (B) becomes equivalent to the maximum pressure of other work equipment. q Since the spool meter-in upstream pressure of port (A) is the pump pressure, the spool meter-in differential pressure [upstream pressure (port (A) pressure)] – downstream pressure [(port (B) pressure)] becomes equivalent to all the spools in operation. q Pump flow is divided according to the ratio of the meter-in opening areas. Operation 10-6 Spring chamber (E) is interconnected to port (D). q Piston (4) and valve (2) is moved in the closing direction (to the right) by the LS circuit pressure of port (F) from other work equipment. q Valve upstream pressure (= spool meter-in downstream pressure) of port (B) is controlled with the LS pressure. q
10-68
PC228US-8,PC228USLC-8
Hydraulic system Function and operation by valve
Area ratio of pressure compensation valve
10-67
Function 10-67 q The condition of oil flow division changes according to the area ratio of pressure compensation valve portions (A1) and (A2). Area ratio = (A2)/(A1) q When area ratio = 1: As the spool meter-in downstream pressure is equal to the maximum load pressure, the oil flow is divided in the ratio as same as the opening area ratio. q When area ratio is more than 1: As the spool meter-in downstream pressure is higher than the maximum load pressure, the oil flow is divided in a ratio lower than the opening area ratio. q When area ratio is below 1: As the spool meter-in downstream pressure is lower than the maximum load pressure, the oil flow is divided in a ratio higher than the opening area ratio.
PC228US-8,PC228USLC-8
10-69
Hydraulic system Function and operation by valve
Shuttle valve in pressure compensation valve
10-68
When holding pressure at port (A) becomes higher than LS pressure in spring chamber (B)
10-68
1. Main pump 2. Valve 3. Shuttle valve 4. Piston 5. Pressure compensation valve Function 10-68 q Shuttle valve (3) is pressed to the right side by the pressure of port (A). As a result, port (A) is disconnected from port (C). q Holding pressure at port (A) is led to the spring chamber (B) to push piston (4) to the left so that piston (4) is not separated from valve (2).
10-70
PC228US-8,PC228USLC-8
Hydraulic system Function and operation by valve
When travelling
10-69
Outline 10-69 q Since no holding pressure is generated at port (A) of the travel circuit, a pressure compensation valve without shuttle valve (5) is adopted.
PC228US-8,PC228USLC-8
10-71
Hydraulic system Function and operation by valve
Boom regeneration circuit
10-70
When cylinder head pressure is lower than bottom pressure (hydraulic drift, etc.)
10-70
1. Main pump 2. Boom spool 3. Pressure compensation valve 4. Suction-safety valve 5. Suction valve 6. Check valve 7. LS shuttle valve Function 10-70 q The regeneration circuit from the cylinder bottom to the cylinder head is installed to increase flow to the cylinder head when the boom is lowered.
10-72
Operation 10-70 When the cylinder head pressure is lower than the bottom pressure, some of pressurized oil (A) from the cylinder bottom flows to drain circuit (B) from the notch of boom spool (2). q The remaining oil flows to regeneration circuit (C), opens check valve (6) and flows to the cylinder bottom through circuit (D). q Flow from regeneration circuit (C) and pump (1) merges in circuit (E). q
PC228US-8,PC228USLC-8
Hydraulic system Function and operation by valve
When cylinder head pressure is higher than bottom pressure (digging operation, etc.)
10-71
Function 10-71 q Check valve (6) provided to regeneration circuit (C) closes to shut off the flow from the cylinder bottom to the head.
PC228US-8,PC228USLC-8
10-73
Hydraulic system Function and operation by valve
Arm regeneration circuit
10-72
When cylinder head pressure is higher than bottom pressure
10-72
1. Main pump 2. Arm spool 3. Pressure compensation valve 4. Suction-safety valve 5. Suction valve 6. Check valve 7. LS shuttle valve Function 10-72 q The regeneration circuit from the cylinder head to cylinder bottom is installed to increase the flow to the cylinder (pump delivery flow + regeneration flow) during arm IN operation in order to accelerate the cylinder speed.
10-74
Operation 10-72 When the cylinder head pressure is higher than the bottom pressure, some of pressurized oil (A) from the cylinder head flows to drain circuit (B) from the notch of arm spool (2). q The remaining flow goes to the regeneration circuit (C), opens check valve (6), and flows to the cylinder bottom through circuit (D). q Flow from regeneration circuit (C) and pump (1) merges in circuit (E). q
PC228US-8,PC228USLC-8
Hydraulic system Function and operation by valve
When cylinder head pressure is lower than bottom pressure
10-73
Function 10-73 q Check valve (6) provided to regeneration circuit (C) closes to shut off the flow from the cylinder bottom to the head.
PC228US-8,PC228USLC-8
10-75
Hydraulic system Function and operation by valve
Merge-divider valve
10-74
When pump flow are merged [pump merge-divider valve changeover signals (IS1) and (IS2) are OFF]10-74
1. Main spool 2. Spring 3. LS spool 4. Spring 5. LS circuit (bucket side) 6. LS circuit (bucket side) 7. LS circuit (arm side) 8. LS circuit (arm side) 9. EPC valve (for main spool changeover) 10. EPC valve (for LS spool changeover) Function 10-74 q This valve merges or divides (distribute to each control valve group) the pressurized oils (P1) and (P2) from the two pumps. q This valve merges and divides LS circuit pressures.
10-76
Operation 10-74 As changeover signal (IS1) is OFF, the output pressure of EPC valve becomes 0 MPa {0 kg/cm2}. q Main spool (1) is pressed to the right by spring (2). As a result ports (E) and (F) are connected. q Pressurized oils (P1) and (P2) from the two pumps are merged by ports (E) and (F), and sent to the required control valves. q As changeover signal (IS2) is OFF, LS spool (3) is also pressed to the right by spring (4). As a result, ports (A) and (D) are connected, and ports (B) and (C) are connected. q LS pressures introduced from each control valve spool to LS circuit (5), (6), (7) and (8) are routed to all pressure compensation valves. q
PC228US-8,PC228USLC-8
Hydraulic system Function and operation by valve
When pump flow are divided [pump merge-divider valve changeover signals (IS1) and (IS2) are ON] 10-75
Operation 10-75 q As changeover signal (IS1) is ON, main spool (1) is moved to the left by the pressure from EPC valve. As a result, ports (E) and (F) are disconnected. q The pressurized oils from the two pumps are sent to respective control valve groups. P1 pressure: to bucket, left travel, boom P2 pressure: to swing, right travel, arm q When changeover signal (IS2) becomes ON, LS spool (3) is also moved to the left by the pressure from the EPC valve. As a result, ports (A) and (C) are connected, and other ports are disconnected. q The LS pressure introduced from each control valve spool to LS circuits (5), (6), (7) and (8) is routed to respective control valves.
PC228US-8,PC228USLC-8
10-77
Hydraulic system Function and operation by valve
LS selector valve Function 10-76 q This valve prevents high LS pressure from the swing valve from entering the LS circuits of work equipment valves when the swing and work equipment are in combined operation. q This valve prevents high pressure generated at swing drive to improve operability of work equipment.
10-76 Operation
10-76
When pilot pressure (BP) is not developed 10-76 q As pilot pressure (BP) is not developed, piston (3) is pressed to the left by spring (2). q When the swing is operated, swing LS pressure (P1) enters port (A) after passing swing spool (5). q Valve (1) is pressed to the left side, and ports (A) and (B) are connected. q Swing LS pressure (P1) is routed to LS shuttle valves (8).
When pilot pressure (BP) is developed 10-76 When pilot pressure (BP) is developed, spring (2) is compressed by the BP pressure and piston (3) is moved to the right. q Valve (1) is pressed to the right, and ports (A) and (B) are disconnected. q Swing LS pressure (P1) stops flowing to LS shuttle valves (8). q If swing LS pressure (P1) rises, other LS circuits are not affected. q
a The illustration shows the condition when swing and right travel are in combined operation. [(BP) pressure is developed] 1. Valve 2. Spring 3. Piston 4. Piston 5. Swing spool 6. R.H. travel spool 7. Arm spool 8. LS shuttle valve 9. LS circuit
10-78
PC228US-8,PC228USLC-8
Hydraulic system Function and operation by valve
Self-pressure reducing valve
10-7
Function 10-7 q This valve serves to reduce the delivery pressure of main pump and provide it as the control pressure for solenoid valves, EPC valves, etc. Operation
10-7
While engine is stopped 10-7 q Poppet (11) is pressed by spring (12) against the seat, so port (PR) is disconnected from port (TS). q As valve (14) is pressed to the left by spring (13), ports (P2) and (TS) are disconnected. q Valve (7) is pressed to the left by spring (8), so port (P2) is disconnected from port (A2).
PC228US-8,PC228USLC-8
10-79
Hydraulic system Function and operation by valve
When control valve is in NEUTRAL and when load pressure (P2) is low 10-78 a When load pressure (A2) is lower than output pressure (PR) of the self-pressure reducing valve q
q
q
q q
q
q
Force of spring (8) and the force exerted by the PR pressure (0 MPa {0 kg/cm2}, when engine is stopped), are applied to valve (7) in the direction to disconnect the circuit ports (P2) and (A2). When pressurized oil flows in from port (P2), valve (7) balance when [Force (φd area x P2 pressure) = force of spring (8) + force (φd area x PR pressure)] holds. The opening of valve (7) is adjusted so that pressure (P2) is at a constant level over pressure (PR). When pressure (PR) rises above the set pressure, poppet (11) opens. Pressurized oil flows from port (PR) to orifice (a) in spool (14), then flows to seal drain port (TS) from poppet (11) opening. Differential pressure is generated across orifice (a) in spool (14) and then spool (14) moves to close the passage between ports (P2) and (PR). Pressure (P2) is reduced by the opening at this time and adjusted to a constant pressure (the set pressure) and supplied as pressure (PR).
10-80 (03)
When load pressure (P2) is high 10-78 As load pressure (A2) increases with the operation of digging, etc., the pump delivery increases accordingly. q Pressure (P2) increases, and [Force (φd (area) x P2] becomes larger than [force of spring (8) + force (φd (area) x PR pressure)] holds. As a result, valve (7) moves to the right stroke end. q As a result, opening between ports (P2) and (A2) increases, and the passage resistance reduces, reducing the engine horsepower loss. q When pressure (PR) rises above the set pressure, poppet (11) opens. q Pressurized oil flows from port (PR) to orifice (a) in spool (14), then flows to seal drain port (TS) from poppet (11) opening. q Differential pressure is generated across orifice (a) in spool (14) and then spool (14) moves to close the opening between ports (P2) and (PR). q Pressure (P2) is reduced by the opening at this time and adjusted to a constant pressure (the set pressure) and supplied as pressure (PR). q
PC228US-8,PC228USLC-8
Hydraulic system Function and operation by valve
When abnormally high pressure is generated 10-79 If pressure (PR) of self-pressure reducing valve becomes abnormally high, ball (16) contracts spring (15) and separates from the seat. q The pressurized oil is allowed to flow to (TS) from port (PR) to lower pressure (PR). q As a result, components such as PPC valves and solenoid valves are protected from abnormal pressure. q
PC228US-8,PC228USLC-8
10-81
Hydraulic system Function and operation by valve
Travel junction valve When pilot pressure is developed
10-80
Function 10-80 q This valve connects the L.H. and R.H. travel circuits through travel junction valve so that the hydraulic oil will be supplied evenly to both travel motors to ensure machine's straight travel performance. q During steering operation, good steering performance is maintained by disconnecting the travel circuits by external pilot pressure (PST).
10-82
10-80
Operation 10-80 Pilot pressure (PST) from the travel junction solenoid valve compresses spring (1), and travel junction spool (2) moves to the left stroke end. q Junction circuit between port (PTL) (L.H. travel circuit) and port (PTR) (R.H. travel circuit) is closed. q
PC228US-8,PC228USLC-8
Hydraulic system Function and operation by valve
When pilot pressure is not developed
Operation q When pilot pressure (PST) from the solenoid valve is 0 MPa {0 kg/cm2}, the travel junction spool (2) is pressed to the right by the force of spring (1). As a result, port (PTL) connects to port (PTR).
PC228US-8,PC228USLC-8
10-81
q
10-81 If the oil flow rates to the L.H. and R.H. travel motors become different from each other, the oil flows through the route between port (PTL), the opening of travel junction spool (2), and port (PTR) so that the oil flow rates to both motors are equalized again.
10-83
Hydraulic system Function and operation by valve
Travel PPC shuttle valve
10-82
When travel lever is in NEUTRAL
Function 10-82 q In the case that boom RAISE, arm IN or OUT, bucket CURL or DUMP operation is performed when going a steep uphill, the oil flow to each cylinder is restricted by limiting the stroke of each spool of boom, arm and bucket valve, by using the pilot pressure of travel PPC valve. q The limit the stroke of the boom, arm or bucket spool, the pilot pressure of travel PPC valve acts on the spool through the internal circuit of respective control valves.
10-84
10-82
Operation 10-82 The oil in the stroke limiting signal chamber (a) is drained through orifices (5) and (6) of respective pistons (3) and (4) in the travel spring case and travel PPC valve. q When conducting boom (or arm IN or OUT, dump, bucket CURL or DUMP) operation, spool (1) moves to the left until it contacts with the end face of spring case (2) (st0). q
PC228US-8,PC228USLC-8
Hydraulic system Function and operation by valve
Travel operation
Operation 10-83 q When running the right track in reverse (or forward), the pilot pressure from the PPC valve pushes spool (7) to the left (or right). q Spool (7) pushes piston (3) to close orifice (5). As a result, the drain circuit from stroke limiting signal chamber (a) to the travel PPC valve is blocked off. q When running the right track in reverse (or forward), the pilot pressure from PPC valve is applied through orifice (6) of piston (4) to the left end face of piston (8) to push it to the right. q When conducting boom raise (or arm IN or OUT, bucket CURL or DUMP) operation, spool (1) moves to the left.
PC228US-8,PC228USLC-8
10-83
q
Maximum stroke of the spool is limited to (st1) for the amount of movement (st2) of piston (8) to the right.
10-85
Hydraulic system Function and operation by valve
Boom drift prevention valve
10-84
At boom RAISE operation
10-84
Function 10-84 q This valve prevents the boom from lowering under its weight due to the leak of oil in the boom cylinder bottom through spool (1) while the boom lever is not operated. Operation 10-84 When conducting boom RAISE operation, the pressurized oil from the control valve is applied to the ring-shaped area, which OD is the poppet (5) diameter (d1) and which ID is the seat diameter (d2), in the direction from right to left. q The force contracts spring (4) and poppet (5) moves to the left. q As a result, pressurized oil from the control valve passes through the opening of poppet (5) and flows to the bottom end of the boom cylinder. q
10-86
PC228US-8,PC228USLC-8
Hydraulic system Function and operation by valve
When boom lever is in NEUTRAL
10-85
Operation 10-85 q This explanation applies to the case that the boom lever is returned to NEUTRAL with the boom raised. q Pressurized oil flown inside poppet (5) from orifice (a) of poppet (5) is blocked by pilot piston (2). q The holding pressure of boom cylinder bottom acts on the ring-shaped area (S), whose OD is outside diameter (d1) of poppet (5) and whose ID is seat diameter (d2), to move it to the right. q The sum of this force and the force of spring (4) closes poppet (5). q Pressurized oil from the control valve and the holding pressure oil of the boom cylinder bottom are blocked.
PC228US-8,PC228USLC-8
10-87
Hydraulic system Function and operation by valve
At boom LOWER operation
10-86
Operation 10-86 q When boom LOWER operation is performed, the pilot pressure from the PPC valve presses pilot piston (2). q Pressurized oil in chamber (b) inside the poppet is drained through orifice (c). q The pressurized oil in the boom bottom flows in the sequence of orifice (a), o chamber (b), o orifice (c) o drain (T), and the pressurized oil in chamber (b) lowers. q When the pressure in chamber (b) lowers, the pressure at port (B) opens poppet (5). q Pressurized oil from port (B) is led to port (A) and then flows to the control valve.
10-88
PC228US-8,PC228USLC-8
Hydraulic system Function and operation by valve
Arm drift prevention valve
10-87
(if equipped) At arm OUT operation
10-87
Function 10-87 q This valve prevents the arm from drifting due to the leak of oil in the arm cylinder head through spool (1) while the arm lever is not operated. Operation 10-87 When conducting arm OUT operation, the pressurized oil from the control valve is applied to the ring-shaped area, whose OD is the poppet (5) diameter (d1) and whose ID is the seat diameter (d2), in the direction from right to left. q This force contracts spring (4) and poppet (5) moves to the left. q As a result, pressurized oil from the control valve passes through the opening of poppet (5) and flows to the arm cylinder head. q
PC228US-8,PC228USLC-8
10-89
Hydraulic system Function and operation by valve
When arm lever is in NEUTRAL
10-8
Operation 10-8 q This explanation applies to the case that the arm lever is returned to NEUTRAL with the arm at arm OUT position. q Pressurized oil flown into poppet (5) from orifice (a) of poppet (5) is blocked by pilot piston (2). q The holding pressure of arm cylinder head acts on ring-shaped area (S), whose OD is the outside diameter (d1) of poppet (5) and whose ID is seat diameter (d2) to move it to the right. q The sum of this force and the force of spring (4) closes poppet (5). q Pressurized oil from the control valve and the holding pressure oil of the arm cylinder head are blocked.
10-90
PC228US-8,PC228USLC-8
Hydraulic system Function and operation by valve
At arm IN operation
10-89
Operation 10-89 q When conducting arm IN operation, the pilot pressure from the PPC valve pushes pilot piston (2). q Pressurized oil in chamber (b) inside the poppet is drained through orifice (c). q The pressurized oil in arm head flows in the sequence of orifice (a), o chamber (b), o orifice (c) o drain (T), and the pressurized oil in chamber (b) lowers. q When the pressure in chamber (b) lowers, the pressure at port (B) opens poppet (5). q Pressurized oil from port (B) is led to port (A) and then flows to the control valve.
PC228US-8,PC228USLC-8
10-91
Hydraulic system Function and operation by valve
When abnormally high pressure is generated
Operation q If abnormally high pressure is generated in the boom cylinder bottom circuit, the pressurized oil in port (B) pushes check valve (6) open, then safety valve (3) works.
10-92
10-90
q
10-90 If arm drift prevention valve (if equipped) is installed to the arm cylinder head circuit, the oil of the boom cylinder bottom circuit pressure or arm cylinder head circuit pressure, whichever higher pressure, pushes check valve (6) or (6A) open to actuate safety valve (3).
PC228US-8,PC228USLC-8
Hydraulic system Function and operation by valve
Quick return valve
10-91
At arm OUT operation
Function 10-91 q Large amount of oil is returned from the cylinder bottom when conducting arm OUT operation. q The valve reduces this pressure loss.
10-91
q q q
Operation 10-91 q When conducting arm OUT operation, the pilot pressure from the PPC valve pushes pilot piston (1). q Pressurized oil in chamber (b) inside the valve is drained through orifice (c). q The pressurized oil in the arm bottom flows in the sequence of orifice (a) o chamber (b) o orifice (c) o drain (T), and the pressure in chamber (b) lowers. q If the pressure of chamber (b) drops lower than that of port (A), the force received by the pressure receiving portion [φd2 area (S2) (seat diameter area)] on the side of port (A) exceeds the sum of the force received by pressure receiving portion [φd1 area (S1)] on the chamber (b) side of valve (2) and the spring force. PC228US-8,PC228USLC-8
(Force received by area φd2 > Force received by area φd1 + Force of spring) Valve (2) is moved to the left and pressurized oil is routed from port (A) to port (B). From port (B), the pressurized oil is drained directly to the tank.
10-93 (03)
Hydraulic system Function and operation by valve
When arm lever is in NEUTRAL
10-92
Operation 10-92 q When arm lever is returned from arm OUT to NEUTRAL, the pilot pressure from PPC valve becomes 0 MPa {0 kg/cm2}. q The pressurized oil that is routed and drained through orifice (a) in valve (2) is blocked by pilot piston (1). q The holding pressure of the arm bottom is applied to the ring-shaped area with sectional area of (S2 -S1) of valve (2) in the direction from left to right. q Valve (2) is closed by the total of this force and the force of spring (3), so port (A) is disconnected from port (B).
10-94
PC228US-8,PC228USLC-8
Hydraulic system Function and operation by valve
Back pressure valve
10-93
Function 10-93 q This valve develops back pressure to the drain circuit to prevent generation of negative pressure on each actuator (motors, cylinders, etc.). Operation
10-93
While engine is stopped 10-93 q Pressurized oil is not fed to the self pressure reducing valve from the pump, and valve (1) is pressed to the right by the force of spring (2). q Drain circuit (a) of the control valve is connected to port (T) through orifice (b) of valve (1).
10-93 When engine is running The output pressure of self-pressure reducing valve is led through inside of control valve to spring chamber (c) of back pressure valve (3). q Output pressure (PR) introduced to spring chamber (c) acts on the left end face of valve (1) (area of φd) to push valve (1) to the right. q At this time, pressure (PA) of drain circuit (a) of the control valve acts on the right end face of valve (1) (area of φd1) to push valve (1) to the left. q Valve (1) balances so that the back pressure (PA) satisfies the equation below. q
PA=
PC228US-8,PC228USLC-8
(Area of φd) x PR + force of spring (2) Area of φd1
10-95 (03)
Hydraulic system Function and operation by valve
Main relief valve
10-94
1. Spring 2. Poppet Function 10-94 q The set pressure of relief valve can be set in two stages. q When power is needed, pilot pressure (P) is developed and the set pressure becomes high-pressure setting. Operation 10-94 The set pressure of the relief valve depends on the load at installed length of spring (1). (1st stage) q There is no need to conduct each setting for 1st and 2nd stages. When 1st stage is set, 2nd stage is set automatically. q
When pilot pressure (P) is not developed: Low pressure setting 10-94 Set pressure is determined by the load at installed length of spring (1). When pilot pressure (P) is developed: High pressure setting 10-94 The load at installed length of spring (1) is added with the force exerted by pilot pressure (P) applied to the area of poppet (2) of diameter (d1), raising the set pressure to higher level.
10-96
PC228US-8,PC228USLC-8
Hydraulic system Function and operation by valve
2-stage suction-safety valve
10-95
[Installed to port (B) of the service valve]
1. Spring 2. Piston 3. Spring 4. Holder Function 10-95 q This valve serves to provide the safety valve set pressure in two stages, and make the low-pressure setting smaller. q This valve relieves high load applied to the cylinder without lever operation. q This valve improves work efficiency and reduces machine body vibration. Operation 10-95 The safety valve set pressure is determined by the load at installed length of spring (1).
When pilot pressure is not developed (High pressure setting) 10-95 q As pilot pressure (P) is not developed, piston (2) is pressed to the left by spring (3). [Load at installed length of spring (1) < Load at installed length of spring (3)] q When the load at installed length of spring (1) is the maximum, the set pressure is at high-pressure setting. q Passage (B) is interconnected to the drain circuit via passage (C) and chamber (D).
q
PC228US-8,PC228USLC-8
10-97
Hydraulic system Function and operation by valve
When pilot pressure is developed (Low pressure setting) 10-96 q When pilot pressure (P) is developed, the pilot pressure is led to portion (A) through passage (B). q The pilot pressure acts on the pressure receiving diameter at portion (A) [(d2)– (d1)] of piston (2). q This pilot pressure contracts spring (3), and piston (2) moves to the right until it contacts with holder (4). q Spring (1) stretches, the force of spring is reduced, and the set pressure lowers. q The amount of pressurized oil for piston stroke is drained through passage (C) and chamber (D) .
10-98
PC228US-8,PC228USLC-8
Hydraulic system Swing motor
Swing motor Type: KMF125AB-5
MA: From left swing port of control valve MB: From right swing port of control valve B: From swing holding brake solenoid valve S: From control valve (back pressure valve) T: To hydraulic tank 1. Reversal prevention valve 2. Safety valve
PC228US-8,PC228USLC-8
Specification Theoretical delivery (cm3/rev) Safety valve set pressure (MPa {kg/cm2})
10-97 125 28.4 {290}
Rated speed: (rpm)
1,694
Brake release pressure (MPa {kg/cm2}
1.6 {16}
10-99
Hydraulic system Swing motor
10-100
PC228US-8,PC228USLC-8
Hydraulic system Swing motor
1. Brake spring 2. Drive shaft 3. Spacer 4. Case 5. Disc 6. Plate 7. Brake piston 8. Housing 9. Piston 10. Cylinder block 11. Valve plate 12. Centre shaft 13. Centre spring 14. Check valve 15. Shuttle valve
PC228US-8,PC228USLC-8
10-101
Hydraulic system Swing motor
Swing brake Operation When solenoid valve is "de-energized"
q
q q q
10-10 10-10 10-10
As the swing brake is de-energized, the pressurized oil from the self pressure reducing valve is blocked. Port (B) is connected to tank circuit (T). Brake piston (7) is pushed downward by brake spring (1). Disc (5) and plate (6) are pushed against each other to apply the brake.
When solenoid valve is "energized"
q q
q
q
10-102
10-10
As the swing brake solenoid valve is energized, the valve is switched The pressurized oil from self-pressure reducing valve enters port (B), and flows into brake chamber (a). After entering chamber (a), the pressurized oil compresses brake spring (1) and moves brake piston (7) upward. Disc (5) is separated from plate (6), releasing the brake.
PC228US-8,PC228USLC-8
Hydraulic system Swing motor
Relief valve portion 10-101 Outline 10-101 q The relief valve portion consists of check valves (2) and (3), shuttle valves (4) and (5), and relief valve (1).
When swing is stopped
10-101
Function 10-101 When the swing is stopped, control valve (6) blocks the motor outlet circuit, but the motor rotation is continued by inertial force. q The motor outlet pressure, therefore, is abnormally increased, resulting in damaging the motor. q In order to prevent the motor damages, the relief valve relieves the abnormally high pressure to port (S) from the motor outlet (high-pressure side) of the motor. q
Operation
10-101
When swinging is started
10-101
q
q
q q
q
q q
q
q
q
When the swing control lever is moved to the right swing, the pressurized oil from the pump is supplied to port (MA) through control valve (6). The pressure on port (MA) rises, the starting torque is generated in the motor, and the motor starts to rotate. The pressurized oil from the outlet of the motor passes from port (MB) through the control valve (6) and returns to the tank.
PC228US-8,PC228USLC-8
q
When the swing control lever is returned to NEUTRAL, the supply of pressurized oil from the pump to port (MA) is stopped. The pressurized oil from the motor outlet cannot return to the tank since the return circuit to the tank is blocked by control valve (6). Thus, pressure on port (MB) increases. Rotation resistance is generated on the motor and hence the brake starts working. When the pressure at port (MB) comes to be higher than that at port (MA), shuttle valve (4) is pressed. The pressure in chamber (C) becomes the same as that of port (MB), and is increased to the set pressure of relief valve (1). A high braking torque works on the motor, thereby stopping the motor. When relief valve (1) is actuated, the relieved pressurized oil and the pressurized oil from port (S) are fed to port (MA) through the check valve (3). Thus, cavitations is prevented from generating on port (MA).
10-103
Hydraulic system Swing motor
Reversal prevention valve
10-104
10-102
PC228US-8,PC228USLC-8
Hydraulic system Swing motor
MA: From left swing port of control valve MB: From right swing port of control valve T1: To hydraulic tank T2: To hydraulic tank 1. Valve body 2. Spool (MA side) 3. Spring (MA side) 4. Plug (MA side) 5. Spool (MB side) 6. Spring (MB side) 7. Plug (MB side) Explanatory drawing of effects
PC228US-8,PC228USLC-8
10-103
10-105
Hydraulic system Swing motor
Function 10-104 q At the stop of swing operation, the upper structure may swing back. This is due to inertia of the mass of the upper structure, the backlash and rigidity of the swing machinery system, and compressibility of the hydraulic oil. This valve prevents such movement. q The valve contributes in preventing spill of load when the swing is stopped and also contributes in reducing cycle time (enhances the positioning performance, enabling you to proceed to the next work quicker than ever). Operation
10-104
When brake pressure is generated port (MB)
10-104
When motor is stopped temporarily
q
q q
q q
q q
q q
10-104
The motor starts to turn in the opposite direction by trapped pressure generated in port (MB). (1st reverse turn) Reversing pressure is generated in port (MA). (MA) pressure is provided to chamber (a). As (φD3 > φD4) holds in regards to circle areas of spool (2), spring (3) is compressed and spool (2) is moved to the left. Port (MA) connects to chamber (b). Ports (b) (f) are interconnected through the drilled hole (h) in spool (5). This interconnection bypasses the reversing pressure on port (MA) to port (T), thereby preventing the reverse rotation of the 2nd time.
(MB) pressure is led to chamber (d) through notch (g). As (φD1 > φD2) holds in regards to circle areas of spool (5), spring (6) is compressed and spool (5) is moved to the left. Port (MB) connects to chamber (e). Since (MA) pressure is lower than the set pressure of spring (3), spool (2) does not move and the pressurized oil is blocked. Thus the braking force is ensured.
10-106 (03)
PC228US-8,PC228USLC-8
Hydraulic system Travel motor
Travel motor Type: HMV110-2
PA: Left travel motor: From left travel reverse port of control valve Right travel motor: From right travel forward port of control valve PB: Left travel motor: From left travel forward port of control valve Right travel motor: From right travel reverse port of control valve P: From travel speed acceleration valve T: To hydraulic tank B: Plug (Brake release pressure port) MA: Port PA oil pressure pickup port MB: Port PB oil pressure pickup port
PC228US-8,PC228USLC-8
Specification Min. Theoretical delivery Max. (cm3/rev) (Rated pressure: MPa {kg/cm2}) Min. Rated speed (rpm) Max. Brake release pressure (MPa {kg/cm2} Travel speed selector pressure (MPa {kg/cm2}
10-105 74 110.7 37.3 {380} 2,980 1,485 1.18 {12} 0.85 {8.7}
10-107
Hydraulic system Travel motor
10-108
PC228US-8,PC228USLC-8
Hydraulic system Travel motor
1. Regulator piston 2. Regulator valve 3. Motor case 4. Suction-safety valve 5. Check valve 6. Output shaft 7. Rocker cam 8. Retainer guide 9. Pin 10. Retainer 11. Piston 12. Cylinder block 13. Valve plate 14. Counterbalance valve spool 15. Ring 16. Brake piston 17. Plate 18. Disc 19. Ball retainer
PC228US-8,PC228USLC-8
10-109
Hydraulic system Travel motor
Operation of motor
10-108
At low-speed travel setting (motor swash plate angle is at maximum)
10-108
q
q q
q
q
When the solenoid valve is de-energized, the pilot pressure oil from the self-pressure reducing valve does not flow to port (P). Regulator valve (9) is pressed to the right by spring (10). The pressurized oil from the control valve pushes check valve (22) open and is led to end cover (8), but it is blocked by regulator valve (9). The fulcrum (a) of the rocker cam is located eccentric to the point of action (b) for the combined force of piston thrusts of cylinder (6). The combined force of piston thrusts act as a moment to tilt rocker cam (4) in the direction achieving the maximum swash plate angle.
10-110
q
q
The pressurized oil in regulator piston (15) flows through orifice (c) in regulator valve (9), and is drained into motor case. Rocker cam (4) tilts in the direction achieving the maximum swash plate angle, and the resultant maximized motor capacity realizes the low-speed travel setting.
PC228US-8,PC228USLC-8
Hydraulic system Travel motor
At high-speed travel setting (motor swash plate angle is at minimum)
q
q q
q q
10-109
When the solenoid valve is energized, the pilot pressure oil from the self-pressure reducing valve flows to port (P). Regulator valve (9) is pressed to the left. The pressurized oil from the control valve flows through passage (d) of regulator valve (9), and enters regulator piston (15). Regulator valve (15) is pressed to the right. Rocker cam (4) tilts in the direction achieving the minimum swash plate angle, and the resultant minimized motor capacity realizes the high speed travel setting.
PC228US-8,PC228USLC-8
10-111
Hydraulic system Travel motor
Operation of parking brake
10-1 0
When starting travelling
10-1 0
q
q
q
When the travel lever is operated, the pressurized oil from the pump activates counterbalance valve spool (19) to make the parking brake circuit. The oil enters chamber (e) of brake piston (12), compresses spring (11), and pushes piston (12) to the left. As pressing forces between plate (13) and disc (14) are eliminated, they are separated and the brake is released.
10-112
PC228US-8,PC228USLC-8
Hydraulic system Travel motor
When stopping travelling
q
q
q q q
q
10-1 1
When travel lever is in NEUTRAL, counterbalance valve spool (19) returns to the neutral position, and the parking brake circuit is blocked. The pressurized oil in chamber (e) of brake piston (12) is drained to the case through orifice (f) of brake piston (12). Brake piston (12) is pressed to the right by spring (11). Plate (13) and disc (14) are pressed each other, and the brake is applied. When brake piston (12) is returned, the flow of pressurized oil is restricted by slow return valve (22). The restriction of the return flow of pressurized oil delays the application of the parking brake. The parking brake is applied after the machine has stopped.
PC228US-8,PC228USLC-8
10-113
Hydraulic system Travel motor
Brake valve q Brake valve is comprised of suction safety valve (18A) and counterbalance valve (18). q Functions and operations of respective components are as follows. Counterbalance valve, check valve
10-1 2
Function
10-1 2
Operation when pressurized oil is supplied
q q
q q
q
q
When the machine travels down a slope, its travel speed tends to get faster than the motor (engine) speed because of the downward force generated from its own weight. If the machine travels with the engine at low speed, the motor may run idle, and the machine runs out of control ; it is in a very dangerous situation. These valves are used to prevent above by controlling the machine to travel according to the engine speed (pump delivery).
10-114
10-1 2 10-1 2
If the travel lever is operated, the pressurized oil is supplied from the control valve to port (PA). The oil opens suction-safety valve (18A), and flows from motor inlet port (MA) to motor outlet port (MB). As motor outlet is blocked by suction-safety valve (18B) and spool (19), the pressure of suction side increases.
PC228US-8,PC228USLC-8
Hydraulic system Travel motor
Brake operation at travelling downhill
q
q
q
The pressurized oil of suction side flows through orifices (E1) and (E2) of spool (19) to chamber(S1). When the pressure in chamber (S1) comes to be higher than the spool changeover pressure, spool (19) is pressed to the right. Port (MB) connects to port (PB), and the motor outlet opens and the motor rotates.
q
q q
q
q
q
PC228US-8,PC228USLC-8
10-1 3
If the machine start to run away is sensed while it travels down a slop, the motor runs idle and the inlet side pressure decreases. The pressure in chamber (S1) decreases, as the oil is drained through orifices (E1) and (E2). When the pressure in chamber (S1) becomes lower than the spool changeover pressure, spool (19) is returned to the left by spring (20), restricting the outlet port (MB). The pressure in the outlet port rises, generating rotation resistance on the motor to prevent the machine from a runaway. The spool moves to the position where the force exerted by the pressure at outlet port (MB) balances the sum of the force due to the machine weight and the force exerted by the inlet pressure. Restricting the oil flow from the outlet circuit allows the machine to travel a the travel speed corresponding to the pump delivery.
10-115
Hydraulic system Travel motor
Suction-safety valve
10-1 4
Function 10-1 4 q As long as the machine is stopped (or it is travels down a slope), the counterbalance valve blocks the inlet and outlet circuits of the motor. q Since the motor is rotated by inertial force, pressure in the motor outlet port is abnormally increased, potentially resulting in damages on the motor and piping. q The safety valve releases this abnormal pressure to the inlet port of the motor in order to prevent damages to the equipment. Operation
10-1 4
When stopping travelling (or downhill) (right turn)
10-1 4
q
q
q
When the pressure comes to be more than the set pressure of suction-safety valve, poppet (1) opens. The pressurized oil flows through slot (A1) of spool (19) to the chamber of opposite side circuit (MA). At the time of left turn, it makes reverse operation for right turn.
When starting travelling (or constant travel)
q q
q
As the pressure at motor inlet (PA) decreases, the pressure in chamber (S1) also decreases. When it becomes lower than the spool changeover pressure, spool (19) is returned to the left by spring (20), restricting the outlet passage (B1). As motor tends to keep rotating by inertial force, the pressure at outlet (MB) increases.
q q
q
10-116
10-1 4
If the travel lever is operated, the pressurized oil from the pump moves spool (19) to the right. As the passage to suction-safety valve is changed to that the oil flow through slot (B2) of spool (19), the differential pressure increases. The pump pressure rises and the large drawbar pull is obtained. PC228US-8,PC228USLC-8
Hydraulic system PPC valve
PPC valve a PPC: Abbreviation for Proportional Pressure Control Work equipment and swing PPC valve
P: From self-pressure reducing valve P1: Left side: To control valve (arm OUT port) Right side: To control valve (boom LOWER port) P2: Left side: To control valve (arm IN port) Right side: To control valve (boom RAISE port) P3: Left side: To control valve (left swing port) Right side: To control valve (bucket CURL port)
PC228US-8,PC228USLC-8
10-1 5
P4: Left side: To control valve (right swing port) Right side: To control valve (bucket DUMP port) T: To hydraulic tank
10-117
Hydraulic system PPC valve
10-118
PC228US-8,PC228USLC-8
Hydraulic system PPC valve
1. Spool 2. Piston 3. Disc 4. Nut (for lever connection) 5. Joint 6. Plate 7. Retainer 8. Body 9. Filter
PC228US-8,PC228USLC-8
10-119
Hydraulic system PPC valve
Operation
10-1 8
At neutral 10-1 8 q Ports (A) and (B) of the control valve and ports (P1) and (P2) of the PPC valve are connected to drain chamber (D) through fine control hole (f) in spool (1).
q
q q q
The positional relationship between spool (1) and valve body (10) [where fine control hole (f) is between drain chamber (D) and pump pressure chamber (PP)] does not change until retainer (9) comes in contact with spool (1). Metering spring (2) is compressed in proportion to the control lever travel. In addition, the pressure at port (P1) increases in proportion to the control lever travel. In this way, the control valve spool moves to a position where the pressure of port (A) (same as pressure at port (P1)) and the force of the return spring of the control valve spool are balanced.
When control lever is in fine control range 10-1 8 (fine control from neutral) 10-1 8 q When piston (4) is pushed by disc (5), retainer (9) is pushed and spool (1) is also pushed down through metering spring (2). q When fine control hole (f) is disconnected from drain chamber (D), it is connected to pump pressure chamber (PP) at almost the same time. q The pilot pressure oil of control pump is led from port (P1) through fine control hole (f) to port (A). q When the pressure at port (P1) becomes higher, spool (1) is pushed back and fine control hole (f) is shut off from pump pressure chamber (PP). At almost the same time, it is connected to drain chamber (D) to release the pressure at port (P1). q As a result, spool (1) moves up and down until the force of metering spring (2) is balanced with the force exerted by the pressure at port (P1).
10-120
PC228US-8,PC228USLC-8
Hydraulic system PPC valve
When control lever is in fine control range 10-1 9 (When returning control lever) 10-1 9 q When disc (5) begins to return, spool (1) is pushed up by the force of centring spring (3) and the force exerted by the pressure at port (P1). q Because of this, fine control hole (f) is connected to drain chamber (D), and the pressurized oil at port (P1) is released. q If the pressure at port (P1) is excessively reduced, spool (1) is depressed by metering spring (2). q Fine control hole (f) is disconnected from drain chamber (D), and at almost the same time, it is connected to pump pressure chamber (PP). q The pump pressure is provided until the pressure at port (P1) is recovered to the extent that the pressure is equal to a pressure for the lever position. q When the spool of the control valve returns, the oil in drain chamber (D) flows in through fine control hole (f') in the valve on the side that is not in operation. The oil passes through port (P2) and enters (B) chamber to replenish the port with pressurized oil.
PC228US-8,PC228USLC-8
At full stroke 10-1 9 Disc (5) depresses pistion (4), and retainer (9) depress spool (1). q Fine control hole (f) is disconnected from drain chamber (D), and it is connected to pump pressure chamber (PP). q The pilot oil flows from self pressure reducing valve through fine control hole (f) and port (P1) into port (A) and pushes the control valve spool. q The oil returning from port (B) flows through port (P2) and fine control hole (f') into drain chamber (D). q
10-121
Hydraulic system PPC valve
Travel PPC valve
10-120
P: From self-pressure reducing valve P1: To control valve (left reverse travel port) P2: To control valve (left forward travel port) P3: To control valve (right reverse travel port) P4: To control valve (right forward travel port) T: To hydraulic tank
10-122
PC228US-8,PC228USLC-8
Hydraulic system PPC valve
1. Plate 2. Body 3. Piston 4. Seal 5. Valve 6. Damper
PC228US-8,PC228USLC-8
10-123
Hydraulic system PPC valve
Operation
10-12
At neutral 10-12 q Ports (A) and (B) of the control valve and ports (P1) and (P2) of the PPC valve are connected to drain chamber (D) through fine control hole (f) in spool (1).
q
q q q
The positional relationship between spool (1) and valve body (10) [where fine control hole (f) is between drain chamber (D) and pump pressure chamber (PP)] does not change until retainer (9) comes in contact with spool (1). Metering spring (2) is compressed in proportion to the control lever travel. In addition, the pressure at port (P1) increases in proportion to the control lever travel. In this way, the control valve spool moves to a position where the pressure of port (A) (same as pressure at port (P1)) and the force of the return spring of the control valve spool are balanced.
When control lever is in fine control range 10-12 (fine control from neutral) 10-12 q When piston (4) is pushed by lever (5), retainer (9) is pushed and spool (1) is also pushed down through metering spring (2). q When fine control hole (f) is disconnected from drain chamber (D), it is connected to pump pressure chamber (PP) at almost the same time. q The pilot pressure oil of control pump is led from port (P1) through fine control hole (f) to port (A). q When the pressure at port (P1) becomes higher, spool (1) is pushed back and fine control hole (f) is shut off from pump pressure chamber (PP). At almost the same time, it is connected to drain chamber (D) to release the pressure at port (P1). q As a result, spool (1) moves up and down until the force of metering spring (2) is balanced with the force exerted by the pressure at port (P1).
10-124
PC228US-8,PC228USLC-8
Hydraulic system PPC valve
When control lever is in fine control range 10-123 (When returning control lever) 10-123 q When lever (5) begins to return, spool (1) is pushed up by the force of centring spring (3) and the force exerted by the pressure at port (P1). q Because of this, fine control hole (f) is connected to drain chamber (D), and the pressurized oil at port (P1) is released. q If the pressure at port (P1) is excessively reduced, spool (1) is depressed by metering spring (2). q Fine control hole (f) is disconnected from drain chamber (D), and at almost the same time, it is connected to pump pressure chamber (PP). q The pump pressure is provided until the pressure at port (P1) is recovered to the extent that the pressure is equal to a pressure for the lever position. q When the spool of the control valve returns, the oil in drain chamber (D) flows in through fine control hole (f') in the valve on the side that is not in operation. The oil passes through port (P2) and enters chamber (B) to replenish the port with pressurized oil.
PC228US-8,PC228USLC-8
At full stroke 10-123 Lever (5) depresses piston (4), and retainer (9) depresses spool (1). q Fine control hole (f) is disconnected from drain chamber (D), and it is connected to pump pressure chamber (PP). q The pilot oil flows from self pressure reducing valve through fine control hole (f) and port (P1) into port (A) and pushes the control valve spool. q The oil returning from port (B) flows through port (P2) and fine control hole (f') into drain chamber (D). q
10-125
Hydraulic system PPC valve
Right attachment PPC valve (with EPC valve)
10-124 10-124
a For the details of operation, see the section of " Work equipment and swing PPC valve" .
10-126
PC228US-8,PC228USLC-8
Hydraulic system PPC valve
P: From self-pressure reducing valve P1: To control valve (service valve 1 port) P2: To control valve (service valve 1 port) T: To hydraulic tank 1. Spool 2. Piston 3. Lever 4. Plate 5. Retainer 6. Block 7. Body 8. EPC valve
PC228US-8,PC228USLC-8
10-127
Hydraulic system PPC valve
EPC valve
P: From self-pressure reducing valve C: To right attachment PPC valve T: To hydraulic tank
10-128
10-126
1. Body 2. Plug 3. Spool 4. Push pin 5. Coil 6. Plunger 7. Connector
PC228US-8,PC228USLC-8
Hydraulic system PPC valve
Function 10-127 q The EPC valve consists of the proportional solenoid portion and the hydraulic valve portion. q When a signal current (i) from pump controller is received, an EPC output pressure proportional to the amperage of current is generated and output to control valve.
PC228US-8,PC228USLC-8
Operation
10-127
When signal current is zero (coil de-energized) 10-127 q When the signal current from controller does not flow through coil (14), the coil (14) is de-energized. q Spool (11) is pushed to the right by spring (12). q Port (P) is closed, and the pressurized oil from front pump does not flow to the control valve. q The pressurized oil from the control valve flows through port (C) and then port (T), and is drained to the tank.
10-129
Hydraulic system PPC valve
When signal current is small (coil energized) 10-128 q When small signal current flows through coil (5), coil (5) is energized and the thrust pushing plunger (6) leftward is generated. q Push pin (4) pushes spool (2) to the left, and the pressurized oil flows from port (P) to port (C). q The pressure at port (C) increases and the force applied to surface (a) of spool (2) plus force of spring (3) becomes larger than the thrust of plunger (6). q Spool (2) is pressed to the right side, and port (P) is disconnected from ports (C), while port (C) is is connected to ports (T). q Spool (2) changes its vertical position so that the thrust of plunger (6) is equal to the pressure at port (C) plus the force of spring (3). q The circuit pressure between the EPC valve and the control valve is controlled in proportion to the amperage of the signal current.
10-130
When signal current is maximum (coil energized) 10-128 q Coil (5) is energized when signal current is supplied to the coil). q As the signal current is the maximum, the thrust of plunger (6) is also maximized q Spool (2) is pushed to the left side by push pin (4). q The pressurized oil flows from port (P) to port (C) at the maximum rate, and the circuit pressure between EPC valve and control valve is maximized. q Port (T) closes, and there is no flow to the hydraulic oil tank.
PC228US-8,PC228USLC-8
Hydraulic system PPC valve
PC228US-8,PC228USLC-8
10-131
Hydraulic system PPC valve
Left attachment PPC valve (if equipped)
10-130 10-130
a For the details of operation, see the section of " Work equipment and swing PPC valve" .
10-132
PC228US-8,PC228USLC-8
Hydraulic system PPC valve
P: From self-pressure reducing valve P1: To control valve (service valve 2 port) P2: To control valve (service valve 2 port) T: To hydraulic tank 1. Spool 2. Piston 3. Lever 4. Plate 5. Retainer 6. Body
PC228US-8,PC228USLC-8
10-133
Hydraulic system Solenoid valve
Solenoid valve a The figure shows the type for a machine ready for installing attachments.
10-134
PC228US-8,PC228USLC-8
Hydraulic system Solenoid valve
P1: From self-pressure reducing valve A1: To PPC valve A2: To control valve, port PST A3: To swing motor, port B A4: To travel motor, port P A5: To control valve, port PX1 and PX2 A6: To attachment circuit selector valve T: To hydraulic tank ACC: To accumulator (for PPC circuit)
Operation
10-13
Check valve operation
10-13
1. PPC lock solenoid valve 2. Travel junction solenoid valve 3. Swing brake solenoid valve 4. Travel speed increase solenoid valve 5. 2-stage relief solenoid valve 6. Attachment selector solenoid valve (Machine ready for installing attachment) Solenoid valve 7. Coil (ON/OFF type) 8. Push pin 9. Valve spool 10. Sleeve 11. Block 12. Plug
10-13
Check valve 13. Plunger 14. Plug
10-13
PC228US-8,PC228USLC-8
q
q
This valve is installed between port (P) and PPC solenoid valve. When the engine is stopped, plunger (1) is pushed back to the left with spring (2) reaction force, and the path between ports (ACC) and (P) is closed to maintain the pressure in the accumulator. When the engine is running, plunger (1) is pushed to the right with the pilot pressure that is sent to port (P), and ports (P) and (ACC) are interconnected.
10-135
Hydraulic system Solenoid valve
Solenoid valve operation When solenoid valve is "de-energized" (circuit is closed) 10-134
q q q
Coil (1) is de-energized when no signal current is supplied to coil (1). Spool (2) is pushed back to the left by reaction force of spring (3). As the path between ports (P) and (A) is closed, the pilot pressure is not fed to the actuator through port (A). At the same time, the path to port (T) is open, draining the oil from the actuator to the hydraulic tank.
10-136
10-134 When solenoid valve is "energized" (circuit is open) 10-134
q q q
Coil (1) is energized when signal current is supplied to coil (1). Spool (2) is pushed to the right by push pin (4). The path between ports (P) and (A) opens, and the pilot pressure is fed to the actuator through port (A). At the same time, the path to port (T) is closed, shutting off the oil from the actuator to the hydraulic tank.
PC228US-8,PC228USLC-8
Hydraulic system Solenoid valve
Boom RAISE cushion EPC valve
10-135
P: From R.H. work equipment PPC valve (boom RAISE) C: To control valve, boom RAISE port T: To hydraulic tank 1. Body 2. Spool 3. Push pin 4. Coil 5. Plunger 6. Connector
PC228US-8,PC228USLC-8
10-137
Hydraulic system Solenoid valve
Function 10-136 q The EPC valve consists of the proportional solenoid portion and the hydraulic valve. q When a signal current (i) from the pump controller is received, the EPC output pressure proportional to the amperage of current is generated and output to the control valve.
Operation
When signal current is zero (coil de-energized) 10-136
q q q
q
10-138
10-136
When the signal current from the controller does not flow through coil (1), coil (1) is de-energized. Spool (2) is pushed to the right by spring (3). Port (P) is closed, and the pressurized oil from the work equipment PPC valve does not flow to the control valve. The pressurized oil from the control valve flows through port (C) and then port (T), and is drained to the hydraulic tank.
PC228US-8,PC228USLC-8
Hydraulic system Solenoid valve
When signal current is small (coil energized)
q
q q
q
q
q
10-137
When a small signal current flows through coil (5), coil (5) is energized and a thrust pushing plunger (6) leftward is generated. Push pin (4) pushes spool (2) to the left side, and pressurized oil flows from port (P) to port (C). The pressure at port (C) increases and the total of the force applied to surface (a) of spool (2) and the force of spring (3) becomes larger than the thrust of plunger (6). Spool (2) is pressed to the right side, and ports (P) and (C) are disconnected, while ports (C) and (T) are connected. Spool (2) changes its axial position so that the thrust of plunger (6) is equal to the total pressure of the pressure at port (C) and the force of spring (3). The circuit pressure between the EPC valve and the control valve is controlled in proportion to the size of the signal current.
PC228US-8,PC228USLC-8
When signal current is maximum (coil energized)
q q q q
q
10-137
Coil (5) is energized when signal current is supplied to the coil. As the amperage of signal current is maximum, the thrust of plunger (6) is also maximized. Spool (2) is pushed to the left side by push pin (4). Pressurized oil flows from port (P) to port (C) at the maximum rate, and the circuit pressure between EPC valve and control valve is maximized. Port (T) closes, and there is no flow to the hydraulic oil tank.
10-139
Hydraulic system Attachment circuit selector valve
Attachment circuit selector valve High-pressure side
PI: From attachment selector solenoid valve ACC: To accumulator ATT: To attachment TS: To hydraulic tank 1. Spool
10-140
PC228US-8,PC228USLC-8
Hydraulic system Attachment circuit selector valve
Function 10-139 q When a breaker is installed, the oil from the breaker returns to the hydraulic tank directly without passing through the main valve. q When other attachments (crusher, etc.) are installed, the attachment and the main valve are interconnected. Operation
When a breaker is installed
10-139
10-139
When attachments other than a breaker is installed 10-139
q
q q
q q
Pilot pressure (PI) from the attachment circuit selector solenoid valve will compress spring (2), and spool (1) will move to the right to its stroke end. Port (ATT) is disconnected from port (V), and ports (ATT) and (T) are interconnected. Pressurized oil returning from the breaker returns directly to the hydraulic tank via port (T) without passing through the control valve.
Spool (1) is pressed to the left by the force of spring (2). Ports (ATT) and (V) are interconnected and port (ATT) is disconnected from port (T). Attachment is thus interconnected to the control valve.
PC228US-8,PC228USLC-8
10-141
Hydraulic system Attachment circuit selector valve
Low-pressure side
PI: From attachment selector solenoid valve V: To control valve attachment 1 port ACC: To accumulator ATT: To attachment T: To hydraulic tank TS: To hydraulic tank 1. Spool
10-142
PC228US-8,PC228USLC-8
Hydraulic system Attachment circuit selector valve
Function 10-141 q When a breaker is installed, the main circuit from the control valve to the breaker will be connected to the accumulator. q When an attachment other than a breaker (crusher, etc.) is installed, the main circuit is blocked from the accumulator. Operation
When a breaker is installed
10-141
10-141
When attachments other than a breaker is installed 10-141
q
q
q q
Pilot pressure (PI) from the attachment circuit selector solenoid valve will compress spring (2), and spool (1) will move to the right to its stroke end. Port (ATT) and port (ACC) will be connected and oil will flow to the accumulator, where the oil pulsation is absorbed.
Spool (1) is pressed to the left by the force of spring (2). Port (ATT) and port (ACC) will be blocked and oil will not flow to the accumulator.
PC228US-8,PC228USLC-8
10-143
Hydraulic system Quick coupler control valve
Quick coupler control valve 2 1a 1b 2a
1 4
3
5 5a 5b 1 1a 1b 2 2a 3 4 5 5a 55b
Pressure regulating valve (Unlock) Lock nut Adjustment screw Solenoid Nut Directional control valve Block Pressure regulating valve (Lock) Lock nut Adjustment screw
Specification Min set pressure: 1MPa (10.2 kg/cm²). Max set pressure 30+/-5 Mpa (306+/-51kg/cm²) Flow: 120l/min. Operation 1.
When solenoid is switched OFF q Since the signal from the operation switches is off, solenoid (2) is de-energised. For this reason, directional control valve (3) is in the default position and oil will flow from port P to port B. q Oil returning from the quick coupler will flow from port A to port T. 1a. The setting of the pressure regulating valve (5) will determine the maximum
10-144
q
q
2.
pressure at port B. Note: If the settings of valve (1) is lower than valve (5) The maximum pressure at Port B will then be determined by valve (1). When the stroke end of the quick coupler cylinder is reached the pressure at the cylinder will be the set pressure of the regulating valve(1). The pressure regulating valve can be adjusted according to the specification of the coupler. The minimum setting is 1MPa and the maximum setting is 30+-5MPa.
When solenoid is switched ON When the quick coupler console switch and quick coupler LH lever switch are pressed at the same time current will flow to the solenoid (2) energising it. Accordingly, the directional control valve (3) will move upwards and oil will flow from port P to port A. q Oil returning from the quick coupler will flow from port B to port T. q The setting of the pressure regulating valve (1) will determine the maximum pressure at port A. When the stroke end of the quick coupler is reached the pressure at the cylinder will be the set pressure of the regulating valve (1). q
PC228US-8,PC228USLC-8
Hydraulic system Quick coupler control valve
Schematic
10-145
2. P
Supply pressure from main valve
T
To tank
B
Supply to quick coupler - lock and hold direction
B1 Low pressure warning switch port B2 Pressure checking port for B line A
Supply to quick coupler - unlock direction
Function This circuit enables the quick coupler to be locked and unlocked. 1. Normal condition (lock). Pressure from the main pump flows from port P to B (W/E RH side) and locks the quick coupler.
PC228US-8,PC228USLC-8
Unlock Press the quick coupler console switch, the lamp on the switch will illuminate and a warning buzzer will sound on the monitor panel. Press the quick coupler LH lever switch at the same time to activate the solenoid. Pressure from the main pump flows through port P to A (W/E LH side) and unlocks the quick coupler. 3. Low pressure warning system When the circuit pressure is below the setting of the pressure switch (25± 5Kg/cm2) and main pump pressure is greater than 35Kg/cm2, the buzzer sounds to warn the circuit pressure is low. This buzzer can not be cancelled with the buzzer cancel button on the monitor panel.
10-145
Hydraulic system Anti-drop valve
Anti-drop valve For boom and arm cylinder (if equipped)
10-146
10-142
PC228US-8,PC228USLC-8
Hydraulic system Anti-drop valve
CY: To work equipment cylinder PCY: For pressure pickup port and equalizer circuit PI: From PPC valve T: To hydraulic tank V: From control valve 1. Pilot spool 2. Spring (1st stage of spool) 3. Spring (2nd stage of spool) 4. Safety valve 5. Check valve 6. Spring
PC228US-8,PC228USLC-8
10-147
Hydraulic system Anti-drop valve
Function 10-14 q This valve prevents the pressurized oil from reversing from the work equipment cylinder in order to prevent sudden drift of the work equipment at breaking of the piping between the control valve and the work equipment cylinder. Operation
10-14
When the work equipment is in neutral
10-14
When there are no damages in the piping 10-14 q Check valve (5) is closed under the holding pressure of the cylinder led from port (CY) to chamber (b). q The pilot pressure from the PPC valve to port (PI) is 0 MPa {0 kg/cm2}. q Spool (1) is pressed to the left by the forces of springs (2) and (3). q Chambers (a) and (b) are shut off. q No pressurized oil flows between the control valve and the work equipment cylinder. q Accordingly, the work equipment is held in 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. anti-drop valves for the boom are interconnected by port (PCY). q Chambers (b) have the same pressure even if the L.H. and R.H. anti-drop valves have a difference in leakage. When the piping is damaged 10-14 If piping (A) is broken between the control valve and the work equipment cylinder, chambers (a) and (b) are shut off similarly to the case when the piping is not damaged. q Pressure for the work equipment cylinder is held to prevent a sudden drop of the work equipment. q
10-148
PC228US-8,PC228USLC-8
Hydraulic system Anti-drop valve
When pressurized oil flows from the main valve to the cylinder 10-145 When there are no damages in the piping 10-145 q Pressure of the oil led to chamber (a) from the control valve becomes higher than the combined force of pressure from work equipment cylinder circuit chamber (b) and spring (6). q Check valve (5) opens and chambers (a) and (b) are interconnected. q Pressurized oil flows from the control valve to the work equipment cylinder. When the piping is damaged 10-145 If piping (A) between the control valve and the work equipment cylinder is broken, the pressurized oil in chamber (a) flows outside from the damaged portion. q Pressure force in chamber (a) drops. q Pressure force in chamber (a) drops lower than the combined pressure force of chamber (b) and spring (6). q Check valve (5) closes and chambers (a) and (b) are shut off. q Pressure for the work equipment cylinder is held to prevent a sudden drop of the work equipment. q
PC228US-8,PC228USLC-8
10-149
Hydraulic system Anti-drop valve
When oil returns from the work equipment cylinder to the main valve 10-146 When there are no damages in the piping 10-146 q Holding pressure of the work equipment cylinder is led to chamber (b) and check valve (5) closes. q Pilot pressure from the PPC valve is led to port (PI) and pilot pressure gets larger than force of spring (3) (area of d). q Spool (1) moves to the right to the stand-by position. (1st stage of stroke) q At this point, chambers (a) and (b) are not interconnected. q Pilot pressure further rises, and pilot pressure gets larger than force of spring (2) (area of d). q Spool (1) moves to the right further, and chambers (a) and (b) are interconnected. (2nd stage of stroke) q Pressurized oil returns to the control valve from the work equipment cylinder. When the piping is damaged 10-146 If piping (A) bursts between the control valve and the work equipment cylinder. q Pressurized oil in chamber (a) flows out of the burst portion but resupplied from chamber (b). q Since pressurized oil flows via opening (c) of spool (1), a sudden drop of the cylinder is prevented. q
10-150
PC228US-8,PC228USLC-8
Hydraulic system Multi-control valve
Multi-control valve 2-way type (if equipped)
10-147
(1) ISO pattern (2) Backhoe pattern Control pattern switching diagram (Port names correspond to the marks on the above figures.)
PC228US-8,PC228USLC-8
10-151
Hydraulic system Centre swivel joint
Centre swivel joint
A1: To L.H. travel motor port PB A2: From control valve L.H. forward travel port B1: To L.H. travel motor port PA B2: From control valve L.H. reverse travel port C1: To R.H. travel motor port PA C2: From control valve R.H. forward travel port D1: To R.H. travel motor port PB D2: From control valve R.H. reverse travel port E1: To L.H. and R.H. travel motor port P E2: From travel speed increase solenoid valve DR1: From L.H. and R.H. travel motor port T DR2: To hydraulic tank
10-152
1. Cover 2. Slipper seal 3. Rotor 4. Dust seal 5. O-ring 6. Cover 7. Shaft
PC228US-8,PC228USLC-8
Hydraulic system Accumulator
Accumulator For PPC circuit
10-149 1. Gas plug 2. Shell 3. Poppet 4. Holder 5. Bladder 6. Oil port Outline 10-149 q The accumulator is installed on the solenoid valve. If the engine is stopped with the work equipment is kept at an elevated position, the pilot pressure is supplied to the control valve by the pressure of the compressed nitrogen gas in the accumulator. Therefor, the spool can be operated to lower the work equipment by its own weight. Specification Gas to be used Gas capacity (cc) Sealed gas pressure (MPa {kg/cm2} Maximum operating pressure (MPa {kg/cm2}
PC228US-8,PC228USLC-8
10-149 Nitrogen gas 300 1.18 {12} (at 80 °C) 6.86 {70}
10-153
Hydraulic system Accumulator
For oil cooler circuit
10-150 1. Gas plug 2. Poppet 3. Holder 4. Bladder 5. Film 6. Shell 7. Oil port Outline 10-150 q The accumulator installed between the work equipment control valve and the oil cooler absorbs the oil pulsation generated by work equipment operation, to protect the oil cooler. Specification Gas to be used Gas capacity (cc) Sealed gas pressure (MPa {kg/cm2} Maximum operating pressure (MPa {kg/cm2}
10-154
10-150 Nitrogen gas 500 0.10 {1} (at 80 °C) 1.47 {15}
PC228US-8,PC228USLC-8
Hydraulic system Accumulator
For breaker (for machine with provision for attachment)
10-151 10-151 1. Cap 2. Core 3. Gas port 4. Bladder 5. Shell 6. Valve 7. Oil port Outline 10-151 q The accumulator is installed in the attachment oil circuit. When the breaker operates, the oil pulsation is absorbed by the pressure of compressed nitrogen gas in the accumulator. This protects the hydraulic components and piping. Specification Gas to be used Gas capacity (cc) For Sealed gas pres- low-pressure sure For (MPa {kg/cm2} high-pressure Maximum operating pressure (MPa {kg/cm2}
PC228US-8,PC228USLC-8
10-151 Nitrogen gas 1,000 0.10 {1} (at 20 °C) 8.83 {90} (at 20 °C) 29.4 {300}
10-155
Work equipment Work equipment
Work equipment Work equipment
1. Bucket 2. Bucket link 3. Bucket cylinder 4. Arm 5. Arm cylinder 6. Boom 7. Boom cylinder
10-156
PC228US-8,PC228USLC-8
Work equipment Work equipment
PC228US-8,PC228USLC-8
10-157
Electrical system Electronic control system
Electrical system Electronic control system General system drawing a Items marked with "*1" in drawing may or may not be installed.
10-158
10-154
PC228US-8,PC228USLC-8
Electrical system Electronic control system
PC228US-8,PC228USLC-8
10-159
Electrical system Electronic control system
Engine control function
1. Battery 2. Battery relay 3. Fusible link 4. Fuse box 5. Starting switch 6. Engine controller 7. Lock lever 8. PPC lock switch 9. Starting motor cutout relay (for PPC lock) 10. Starting motor cutout relay (for personal code) 11. Fuel control dial 12. Safety relay 13. Starting motor 14. Supply pump 15. Sensors 16. Engine controller power cutoff relay A 17. Engine controller power cutoff relay B 18. Machine monitor 19. KOMTRAX terminal (if equipped)
10-160
10-156
Function 10-156 1. The neutral safety circuit is employed to secure safety when the engine is started. q The engine does not start until the lock lever is set to the LOCK position. 2. The KOMTRAX engine cut circuit is employed to disable the engine from starting when the KOMTRAX terminal receives an engine cut command issued through external operation. (if equipped)
PC228US-8,PC228USLC-8
Electrical system Electronic control system
Start engine 10-157 q When starting switch (5) is turned to ON position, engine controller (6) sends a command current to supply pump (14). For this reason, a fail-safe mechanism is provided with the electrical system to stop the engine when an electrical failure occurs. q When starting switch (5) is turned to START with lock lever (7) set to LOCK position, a starting current is supplied to starting motor (13) causing the engine to start. However, as the neutral safety mechanism is provided, the engine will not start if lock lever (7) is set to FREE position at this time; starting motor cut-out relay (9) cuts off the starting current to starting motor (13). q Upon receipt of the engine cutoff command from the external source, KOMTRAX terminal (19) sends the signal to machine monitor (18). Machine monitor (18) causes starting motor cut-out relay (10) to cut off the starting current to starting motor (13), therefore the engine does not start. (if equipped) Engine speed control 10-157 Upon receipt of a fuel control dial (11) control signal, engine controller (6) sends a command current to supply pump (14) to adjust the fuel injection amount to control the engine speed.
q
Engine stopped 10-157 When starting switch (5) is turned to OFF position, the current from the ACC terminal of starting switch (5) to engine controller (6) is cut off, and consequently the command current to supply pump (14) is cut off. Supply pump (14) stops fuel feed, causing the engine speed to go down and the engine stops.
q
PC228US-8,PC228USLC-8
10-161
Electrical system Electronic control system
Engine and pump combined control function
1. Battery 2. Battery relay 3. Fusible link 4. Fuse box 5. Resistor 6. Pump controller 7. Engine controller 8. Machine monitor 9. Emergency pump drive switch 10. Fuel control dial 11. Supply pump 12. Sensors 13. One-touch power maximizing switch 14. Front pump oil pressure sensor 15. Rear pump oil pressure sensor 16. Oil pressure sensor 17. Oil pressure switch 18. Front pump 18a. Servo 18b. LS valve 18c. PC valve 19. Rear pump 19a. Servo 19b. LS valve 19c. PC valve
10-162
10-158
20. Control valve 20a. Self-pressure reducing valve 20b. Pump merge-divider valve 20c. Travel junction valve 21. Front pump PC-EPC valve 22. Rear pump PC-EPC valve 23. LS-EPC valve Input/Output signal a. Front pump PC-EPC valve drive signal b. Rear pump PC-EPC valve drive signal c. Solenoid valve GND d. CAN signal e. LS-EPC valve drive signal f. Oil pressure sensor signal g. One-touch power maximizing switch signal h. Oil pressure switch signal i. Throttle signal j. Supply pump control signal k. Sensor signals
10-158
PC228US-8,PC228USLC-8
Electrical system Electronic control system
Function 10-159 q This function is for selecting one of the five working modes of P, E, L, ATT and B with the working mode selector switch of the machine monitor. The most suitable combination of engine torque (T) and pump absorption torque can be selected for the contents of work. If "Without" is selected for the attachment on the initial setting (Default) screen of the service mode, one of the three modes of P, E and L is selectable. q According to the pump absorption torque set at each mode, based on the engine governor set speed by the fuel control dial and the actual engine speed, the controller controls so that the pump absorbs all torques at each engine horsepower point. q When the engine speed is lowered, the controller reduces the power consumed by the pump in order to prevent engine stall.
PC228US-8,PC228USLC-8
10-163
Electrical system Electronic control system
Control method in each mode
10-160
P mode, E mode, and ATT mode q Matching point
10-160
Working mode P, ATT
Working
E q
q
q
q
q
Max. matching point 106.6 kW/1,800 rpm {143 HP/1,800 rpm} 91.9 kW/1,800 rpm {123 HP/1,800 rpm}
In P, E, or ATT modes, the engine speed is always controlled so that it is kept around the matching point specified for each mode. If the load on the pump and oil pressure increase, the engine speed (N) will decrease. The controller will decrease the pump delivery (Q) to increase the engine speed to near the matching point. If the load on the pump and oil pressure decrease, the pump delivery will be increased to keep the engine speed near the matching point. The controller calculates the pump delivery based on servo piston stroke signals sent from the swash plate sensor installed on the pump. The controller lowers the engine matching speed (Nm) at low loads (low delivery and torque) in accordance with the pump absorption torque and delivery. Variable matching of engine speeds contributes to minimize fuel consumption.
10-164
PC228US-8,PC228USLC-8
Electrical system Electronic control system
B mode and L mode
q
q q
q
10-161
Working mode
Partial horsepower
B L
75 % 70 %
Matching point: Working mode
Max. matching point
B mode
80.9 kW/1,800 rpm {108 HP/1,800 rpm}
L mode
73.5 kW/1,800 rpm {99 HP/1,800 rpm}
In B or L mode, engine horsepower is controlled to a constant level. The controller controls the pump absorption torque to decrease the engine speed while keeping the engine torque at a constant level along the equal engine horsepower curve. The controller adjusts the pump delivery (Q) to keep the engine torque constant along the engine horsepower curve.
PC228US-8,PC228USLC-8
10-165
Electrical system Electronic control system
Control function during travel 10-162 q The engine speed (N) rises when travelling in P or ATT mode. q When travelling in E or B mode, the work mode remains unchanged, while the pump absorption torque and engine speed (N) rise to the values as same as for P mode travelling. q When travelling in L mode, the work mode and engine speed (N) remains unchanged, while the pump absorption torque rises.
10-166
Function to control when emergency pump drive switch is turned on 10-162 q If the controller gets out of order and no work is possible because the main pump does not work properly, operating emergency pump drive switch (1) temporarily enables to maintain functions of the machine with absorption torques quite similar to those in the E mode. In this case, a constant current flows from the battery to the PC-EPC valve, so the oil pressure sensing by the PC-EPC valve only is performed. a: Emergency (when abnormal) b: Normal a Emergency pump drive switch (1) is of the alternative type. If the machine is operated after the switch is set to "Emergency (a)" even though the machine is normal, the user code "E02" will be shown on the display.
PC228US-8,PC228USLC-8
Electrical system Electronic control system
Pump and valve control function
1. Battery 2. Battery relay 3. Fusible link 4. Fuse box 5. Resistor 6. Pump controller 7. Engine controller 8. Machine monitor 9. Emergency pump drive switch 10. Fuel control dial 11. Supply pump 12. Sensors 13. Front pump 13a. Servo 13b. LS valve 13c. PC valve 14. Rear pump 14a. Servo 14b. LS valve 14c. PC valve 15. Control valve 15a. Self-pressure reducing valve 15b. Pump merge-divider valve 15c. Travel junction valve 15d. Main relief valve
PC228US-8,PC228USLC-8
10-163
16. Front pump PC-EPC valve 17. Rear pump PC-EPC valve 18. LS-EPC valve 19. Pump merge-divider EPC valve (for main spool) 20. Pump merge-divider EPC valve (for LS spool) 21. Travel junction solenoid valve 22. 2-stage relief solenoid valve Input/Output signal 10-163 a. Front pump PC-EPC valve drive signal b. Rear pump PC-EPC valve drive signal c. Solenoid valve GND d. CAN signal e. LS-EPC valve drive signal f. Pump merge-divider EPC valve (for main spool) drive signal g. Pump merge-divider EPC valve (for LS spool) drive signal h. Travel junction solenoid valve drive signal i. 2-stage relief solenoid valve drive signal j. Throttle signal k. Supply pump control signal l. Sensor signals
10-167
Electrical system Electronic control system
Function 10-164 q The LS control function, cutoff function, and 2-stage relief function work together to maintain the optimum matching under various working conditions. LS control function 10-164 q According to the actuator operation, the output pressure from the LS-EPC valve to LS valve varies in order to change the selector point for pump delivery amount [LS differential pressure (DLS) setting] in the LS valve. q The build-up time of pump delivery amount will be optimized, and the ease of combined operation and fine control will be improved.
2-stage relief function 10-164 The normal relief pressure is 34.8 MPa {355 kg/cm2}, however, this increases to approx. 37.2 MPa {380 kg/cm2} when the 2-stage relief function operates.
q
Operating conditions for 2-stage relief Relief presfunction sure q During travel 34.8 MPa q When swing lock switch is turned to {355 kg/cm2} the ON position q When the boom is lowered O q When one-touch power maximizing 37.2 MPa function is turned on {380 kg/cm2} q When L mode is selected
A: 0 MPa {0 kg/cm2} B: EPC pressure (Psig) = 1.8 MPa {18 kg/cm2} Cutoff function 10-164 PC-EPC current (J) is increased and the flow at relief is decreased to minimize fuel consumption.
q
Operating condition for turning on cutoff function When the one-touch power maximizing function is not activated and the average of front pump and rear pump oil pressure sensor values is 27.9 MPa {285 kg/cm2} or higher. However, this will not operate when travelling in P mode, when in the arm crane mode, or when the swing lock switch is "ON".
A: PC-EPC current at cutoff 10-168
PC228US-8,PC228USLC-8
Electrical system Electronic control system
Power maximizing function
1. Battery 2. Battery relay 3. Fusible link 4. Fuse box 5. Resistor 6. Pump controller 7. Engine controller 8. Machine monitor 9. Emergency pump drive switch 10. Fuel control dial 11. Fuel supply pump 12. Sensors 13. One-touch power maximizing switch 14. Front pump oil pressure sensor 15. Rear pump oil pressure sensor 16. Front pump 16a. Servo 16b. LS valve 16c. PC valve 17. Rear pump 17a. Servo 17b. LS valve 17c. PC valve
PC228US-8,PC228USLC-8
10-165
18. Control valve 18a. Self-pressure reducing valve 18b. Pump merge-divider valve 18c. Travel junction valve 18d. Main relief valve 19. Front pump PC-EPC valve 20. Rear pump PC-EPC valve 21. 2-stage relief solenoid valve Input/Output signal a. Front pump PC-EPC valve drive signal b. Rear pump PC-EPC valve drive signal c. Solenoid valve GND d. CAN signal e. 2-stage relief solenoid valve drive signal f. Pump oil pressure sensor signal g. One-touch power maximizing switch signal h. Throttle signal i. Supply pump control signal j. Sensor signals
10-165
10-169
Electrical system Electronic control system
Function 10-16 q By operating the one-touch power maximizing switch on the L.H. work equipment control lever knob, the power is maximized for a limited time. q This can be used when extra digging force is needed for a while, for example, when digging out a rock during excavating work. q When the one-touch power maximizing switch is pressed in P mode, E mode, or ATT mode, the hydraulic force will be increased by approx. 7%, and the horsepower will be increased by approx. 3% to boost the digging force. The functions are automatically set as follows. Function Engine and pump combined control 2-stage relief function Cutoff function
Setting Matching at rated output point 34.8 MPa {355 kg/cm2}
O
37.2 MPa {380 kg/cm2} Cancel
a The power is increased while the one-touch power maximizing switch is pressed. The function is automatically deactivated when the switch is continuously pressed for more than 8.5 seconds.
10-170
PC228US-8,PC228USLC-8
Electrical system Electronic control system
Auto-deceleration function
1. Pump controller 2. Engine controller 3. Machine monitor 4. Fuel control dial 5. Supply pump 6. Sensors 7. Oil pressure switch 8. Oil pressure sensor 9. Main pump 10. Control valve 10a. Self-pressure reducing valve 10b. Pump merge-divider valve 10c. Travel junction valve 11. PPC lock solenoid valve
PC228US-8,PC228USLC-8
10-167
Input/Output signal a. CAN signal b. Oil pressure switch signal c. Oil pressure sensor signal d. Throttle signal e. Supply pump control signal f. Sensor signals
10-167
10-171
Electrical system Electronic control system
Function 10-168 q When all the control levers are set to NEUTRAL for waiting for a dump truck or work, the engine speed is automatically reduced to a controlled speed, and fuel consumption and noise are lowered. q When any control lever is operated, the engine speed returns immediately to the speed that is set by the fuel control dial. Operation 10-168 Control lever in NEUTRAL 10-168 q If all the control levers are kept in neutral for 4 seconds with the engine speed higher than approx. 1,050 rpm, the engine speed is decreased to the controlled speed (approx. 1,050 rpm) and held until any control lever is operated. When any control lever is operated 10-168 With the engine speed at the controlled speed (approx. 1,050 rpm), when any control lever is operated, the engine speed increases immediately to the speed that is set by the fuel control dial.
q
A: All work equipment control levers in NEUTRAL B: Work equipment control levers OPERATED C: Fuel control dial set speed D: Controlled engine speed (approx. 1,050 rpm) E: 4 sec. F: Max. 2 sec. G: Max. 1 sec.
10-172
PC228US-8,PC228USLC-8
Electrical system Electronic control system
Engine automatic warm-up function
1. Battery 2. Battery relay 3. Fusible link 4. Fuse box 5. Resistor 6. Pump controller 7. Engine controller 8. Machine monitor 9. Air conditioner unit 10. Emergency pump drive switch 11. Fuel control dial 12. Supply pump 13. Sensors 14. Hydraulic oil temperature sensor 15. Front pump 15a. Servo 15b. LS valve 15c. PC valve 16. Rear pump 16a. Servo 16b. LS valve 16c. PC valve
PC228US-8,PC228USLC-8
10-169
17. Control valve 17a. Self-pressure reducing valve 17b. Pump merge-divider valve 17c. Travel junction valve 18. Front pump PC-EPC valve 19. Rear pump PC-EPC valve Input/Output signal a. Front pump PC-EPC valve drive signal b. Rear pump PC-EPC valve drive signal c. Solenoid valve GND d. CAN signal e. Hydraulic oil temperature signal f. Throttle signal g. Supply pump control signal h. Sensor signals
10-169
10-173
Electrical system Electronic control system
Function 10-170 q Raises the engine speed automatically to warm up the engine if the coolant temperature is low after start-up of the engine. Operating conditions 1 Machine specification: with air conditioner Air conditioner: blower "ON" Coolant temperature: Max. 55 °C Ambient temperature: below 5 °C
O
O
If any of operating conditions 1 is not satisfied Heater warm-up is disabled (normal warm-up) Operational conditions 2 (all required) Coolant temperature: Max. 30 °C Fuel control dial: below 70% of full speed (MAX)
O
Operation Engine speed: 1,200 rpm
When all of operating conditions 1 are satisfied Heater warm-up is enabled
O Operation Engine speed: 1,300 rpm
O
O
Cancellation conditions (either one required) Coolant temperature: Min. 30 °C Auto Duration of automatic warming-up: Min. 10 minutes Man- Fuel control dial: held at over 70% of maximum speed for 3 secual onds or more
O
Conditions for cancellation Coolant temperature: Min. 60 °C or Ambient temperature: min. 10 °C
O
Cancellation Engine speed: as desired
10-174
PC228US-8,PC228USLC-8
Electrical system Electronic control system
Overheat prevention function a See "Engine automatic warm-up function" section for system circuit diagram. q
10-171
Prevents overheat to protect the engine and hydraulic components by reducing load on the pump and lowering the engine speed if the coolant or hydraulic oil temperature becomes too high. Operating condition
Working mode: travel Hydraulic oil temperature: Min. 95 °C
Operation and actions taken o Engine speed: Remains unchanged. Travel speed: Down
Operating condition
Conditions for cancellation Hydraulic oil temperature: Max. 95 °C o q The original conditions are restored if above requirements are met (automatic restoration).
Operation and actions taken
Conditions for cancellation
Working mode: P, ATT, E Coolant temperature: Min. 100 °C or Hydraulic oil temperature: Min. 100 °C
Coolant temperature: Max. 100 °C Engine speed: Remains unchanged. Hydraulic oil temperature: Max. 100 °C o q Sends torque control signal to lower the o q The original conditions are restored if pump absorption torque and reduce the above requirements are met (automatic load on the engine. restoration).
Operating condition
Operation and actions taken
Conditions for cancellation
Working mode: P, ATT, E, B, L Coolant temperature: Min. 102 °C or Hydraulic oil temperature: Min. 102 °C
Engine speed: Remains unchanged. Coolant temperature: Max. 102 °C Alarm monitor: Lights up Hydraulic oil temperature: Max. 102 °C o o q Sends torque control signal to lower the q The original conditions are restored if pump absorption torque and reduce the above requirements are met (automatic load on the engine. restoration).
Operating condition
Operation and actions taken
Working mode: all modes Coolant temperature: Min. 105 °C or Hydraulic oil temperature: Min. 105 °C
o
Operating condition Coolant temperature: 95 – below 99 °C or Hydraulic oil temperature: 95 – below 99 °C
Operation and actions taken o Pump absorption torque decreased
Conditions for cancellation o
0 – 19.6 Nm {0 – 2 kgm}
Operating condition Coolant temperature: 90 – below 95 °C or Hydraulic oil temperature: 90 – below 95 °C
Engine speed: Low idle Alarm monitor: Lights up Alarm buzzer: Sounds
Conditions for cancellation Coolant temperature: Max. 105 °C Hydraulic oil temperature: Max. 105 °C Fuel control dial: Returns to low idle (MIN) posio tion. q The original conditions are restored if above requirements are met (manual restoration).
Operation and actions taken o Pump absorption torque decreased
PC228US-8,PC228USLC-8
0 – 39.2 Nm {0 – 4 kgm}
Coolant temperature: Max. 95 °C or Hydraulic oil temperature: Max. 95 °C
Conditions for cancellation o
Coolant temperature: Max. 90 °C or Hydraulic oil temperature: Max. 90 °C
10-175
Electrical system Electronic control system
Turbocharger protection function a See "Engine automatic warm-up function" section for system circuit diagram. q q
10-172
When the engine is started at low temperatures and the engine speed is increased sharply, the turbocharger may be seized. Controlling the engine speed prevents this problem. Duration of engine speed control depends on the coolant temperature. Operating condition 2
Engine oil pressure: below 50 kPa {0.51 kg/cm }
o
Operation Turbocharger protection (See the following figure)
A: Start engine B: Duration of turbocharger protection (approximately 0 – 20 sec.) C: Modulating time (approx. 1 sec.) D: 600 rpm E: 1,050 rpm F: 1,950 rpm(*1) *1. Working mode: P mode Fuel control dial: Full speed (MAX) position Travel lever operated
10-176
PC228US-8,PC228USLC-8
Electrical system Electronic control system
Swing control function
1. Battery 2. Battery relay 3. Fusible link 4. Fuse box 5. Swing brake cancel switch 6. Swing lock switch 7. Pump controller 8. Machine monitor 9. Oil pressure switch 10. Oil pressure sensor 11. Main pump 12. Control valve 12a. Self-pressure reducing valve 12b. Pump merge-divider valve 12c. Travel junction valve 13. Swing motor 14. Swing brake solenoid valve
PC228US-8,PC228USLC-8
10-173
Input/Output signal a. Swing brake cancel signal b. Swing brake solenoid valve drive signal c. CAN signal d. Solenoid valve GND e. Oil pressure switch signal f. Oil pressure sensor signal
10-173
10-177
Electrical system Electronic control system
Function
10-174
Swing lock and swing brake function q On machines with swing lock (manual), swing can be locked at any position by turning swing lock switch (1) to "ON" position. q Interlocked with the swing operation, the swing brake (auto lock) prevents hydraulic drift from occurring after the swing stops. q Interlocked with the L.H. and R.H. work equipment control levers and attachment control pedals operations, the swing brake is cancelled to reduce the load on the swing equipment during excavation work.
10-174 Swing lock switch Swing lock monitor
When the travel steering signal is OFF
ON
Off
ON
Function
Swing Brake
Swing lock
q
Operation q
When the L.H. and q R.H. work equipment control levers and attachment control ped- q als are set to NEUTRAL, the swing brake works in approx. 5 sec. When the L.H. and R.H. work equipment control levers or attachment control pedals are operated, the swing brake is cancelled and the upper structure becomes free to swing.
Swing brake applies and lock the swing. Even if the L.H. work equipment control lever is operated for swing, the swing brake cannot be cancelled, and the upper structure does not swing.
A: When a work equipment control lever or attachment control pedal is operated (Swing brake "CANCEL" ) B: When work equipment control levers and attachment control pedals are in "NEUTRAL" C: Swing brake "OPERATED" D: Approx. 5 sec.
10-178
PC228US-8,PC228USLC-8
Electrical system Electronic control system
Swing brake release function 10-175 q If the controller gets out of order and no swing is possible because the swing brake does not work properly, operating swing brake cancel switch (2) releases the swing brake and allows swing operation. a: Release (Emergency) b: Normal Swing brake cancel switch Swing lock switch
Release (When controller has trouble) ON
OFF
Normal (When the controller is normal) ON
Swing brake is Swing lock Swing Swing lock works released brake works (*1) *1:Hydraulic brake by the safety valve.
OFF Swing brake works
a Even if swing brake cancel switch is set to CANCEL, swing brake is not be released while swing lock switch is set to "ON". a When the swing brake is cancelled, only the hydraulic brake with the safety valve is effective for holding the upper structure. So, note that, when the swing stops on a slope, a hydraulic drift may occur. a Swing brake cancel switch (2) is of the alternative type. When the switch is turned to CANCEL (a) position, the swing lock monitor in the machine monitor will blink.
PC228US-8,PC228USLC-8
10-179
Electrical system Electronic control system
Travel control function
1. Pump controller 2. Engine controller 3. Machine monitor 4. Fuel control dial 5. Supply pump 6. Sensors 7. Front pump oil pressure sensor 8. Rear pump oil pressure sensor 9. Oil pressure sensor 10. Travel alarm 11. Front pump 11a. Servo 11b. LS valve 11c. PC valve 12. Rear pump 12a. Servo 12b. LS valve 12c. PC valve 13. Control valve 13a. Self-pressure reducing valve 13b. Pump merge-divider valve 13c. Travel junction valve
10-180
10-176
14. Travel motor 15. Travel speed increase solenoid valve 16. Travel junction solenoid valve 17. LS-EPC valve Input/Output signal 10-176 a. Oil pressure sensor signal b. CAN signal c. LS-EPC valve drive signal d. Solenoid valve GND e. Travel junction solenoid valve drive signal f. Travel speed increase solenoid valve drive signal g. Oil pressure sensor signal h. Travel alarm buzzer operation signal i. Throttle signal j. Supply pump control signal k. Sensor signals
PC228US-8,PC228USLC-8
Electrical system Electronic control system
Function
10-17
Travel speed selection function 10-17 1. Travel speed "Manual" change q Setting the travel speed selector switch to "Hi", "Mi" or "Lo" changes the motor capacity, which changes the machine travel speed. Travel speed selector switch Motor capacity (%) Travel speed (km/h) Travel motor swash plate angle
75
Mi (medium speed) 65
3.0
4.1
5.5
Max.
Min.
Min.
Lo (low speed)
Hi (high speed) 100
2. Travel speed "Automatic" change 1) Automatic change corresponding to engine speed q When the engine speed is lowered to below 1,500 rpm by the fuel control dial, the travel speed will not change from "Mi" to "Hi" while the machine is travelling with the travel speed selector switch set to "Mi", and will change from "Hi" to "Mi" while it is travelling with the travel speed selector switch set to "Hi". 2) Automatic change by pump delivery pressure q If the travel circuit oil pressure increases on an uphill with the travel speed selector switch in "Hi", and the travel circuit oil pressure exceeding 33.3 MPa 2 {340 kg/cm } continues for 0.5 seconds or more, the travel motor capacity is switched to that for low speed travel (corresponds to "Lo") automatically (the travel speed switch position remains in "Hi"). q If the travel circuit oil pressure decreases on a flat or downhill during low speed travel (caused by the automatic speed change due to increase in the load on the travel oil circuit), and the travel circuit oil pressure below 17.7 MPa {180 kg/cm2} continues for 0.5 seconds or more, the travel motor capacity is switched back to that for high speed travel (Hi) automatically.
PC228US-8,PC228USLC-8
A: 17.7 MPa {180 kg/cm2} B: 33.3 MPa {340 kg/cm2} C: Min. 0.5 sec. D: Min. 0.5 sec. Function to control pump during travel 10-17 a See " Pump and engine combined control function" for details. Travel junction function 10-17 q The controller detects the pilot pressure generated by travel control lever operation, and judges the operator’s intention, the straight travel or steered travel. q When travelling straight, a signal is sent to the travel junction solenoid valve to supply almost the same oil flow to the L.H. and R.H. travel motors. q When the steering is operated, the signal to the travel junction solenoid valve is shut off. This separates the pump flow to the right and left travel motors from each other and enhances the traction while steering.
10-181
Electrical system Electronic control system
PPC lock function
1. Battery 2. Battery relay 3. Fusible link 4. Fuse box 5. Starting switch 6. Lock lever 7. PPC lock switch 8. Main pump 9. Control valve 9a. Self-pressure reducing valve 9b. Pump merge-divider valve 9c. Travel junction valve 10. PPC lock solenoid valve
10-182
10-178
Function 10-178 Interlocked with the lock lever, the PPC lock switch is turned off when the lock lever is set to LOCK position. q When the PPC lock switch is turned off, the current to the PPC lock solenoid valve is shut off, causing neither the work equipment nor machine moves even if levers or pedal is operated. q
PC228US-8,PC228USLC-8
Electrical system Electronic control system
Boom RAISE cushion function
10-179
Emergency work equipment drive function 10-179 If the controller gets out of order and the work equipment becomes inoperable, boom RAISE can be temporarily enabled by operating the emergency work equipment drive switch (1). a: Emergency (controller failure) b: Normal
1. Battery 2. Battery relay 3. Fusible link 4. Fuse box 5. Resistor 6. Emergency work equipment drive switch 7. Pump controller 8. Machine monitor 9. Boom angle potentiometer 10. Main pump 11. Control valve 11a. Self-pressure reducing valve 11b. Pump merge-divider valve 11c. Travel junction valve 12. Boom RAISE cushion EPC valve 13. Boom cylinder Input/Output signal a. CAN signal b. Boom RAISE cushion EPC valve drive signal c. Solenoid valve GND d. Boom angle signal
q
a Emergency work equipment drive switch (1) is of the alternative type. If the switch is set to "Emergency (a)" when the user code "E06" is shown on the display, the work equipment will become operable. a The electrical control system does not work, so do not operate the machine for normal work with emergency work equipment drive switch (1) in "Emergency (a)". 10-179
Cushion function 10-179 q The boom end cushion function reduces the boom speed before the boom reaches its stroke end in order to lessen the shock at this point, and prevents spillage of the load and reduces the impact applied to the machine and cylinder. q When the boom enters the cushion range, the pilot pressure, which is fed from the PPC valve to the control valve, is reduced and then cut off by the EPC valve, and the boom is stopped.
PC228US-8,PC228USLC-8
10-183
Electrical system Electronic control system
Oil flow adjuster function for attachment (for machine with provision for attachment)
10-184
10-180 10-180
PC228US-8,PC228USLC-8
Electrical system Electronic control system
1. Battery 2. Battery relay 3. Fusible link 4. Fuse box 5. Resistor 6. Pump controller 7. Engine controller 8. Machine monitor 9. Emergency pump drive switch 10. Oil pressure switch 11. Fuel control dial 12. Supply pump 13. Sensors 14. Front pump 14a. Servo 14b. LS valve 14c. PC valve 15. Rear pump 15a. Servo 15b. LS valve 15c. PC valve 16. Control valve 16a. Self-pressure reducing valve 16b. Pump merge-divider valve 16c. Travel junction valve 17. Attachment selector solenoid valve 18. PPC lock solenoid valve 19. Oil flow adjuster EPC valve for attachment 20. Front pump PC-EPC valve 21. Rear pump PC-EPC valve 22. Attachment circuit selector valve (high pressure side) 23. Attachment circuit selector valve (low pressure side) 24. Attachment 25. Accumulator
PC228US-8,PC228USLC-8
Input/Output signal 10-181 a. Front pump PC-EPC valve drive signal b. Rear pump PC-EPC valve drive signal c. Solenoid valve GND d. CAN signal e. Attachment selector solenoid valve drive signal f. Oil flow adjuster EPC valve drive signal for attachment g. Oil pressure switch signal h. Throttle signal i. Supply pump control signal j. Sensor signals Function 10-181 q Setting of the working mode and oil flow rate on the machine monitor controls the oil flow to the attachment when the attachment control pedal is fully depressed.
10-185
Electrical system Electronic control system
Component
10-182
Engine controller
10-182
Input/Output signal q The following is the list of the symbols used for signal classification in the input/output signal table. A: Power supply B: Input C: Ground/Shield/Return D: Output E: Communication
10-182
DTP-4P [ CN-CE03 ] Pin No. 1 2 3 4
Signal name GND NC (*) Unswitched power supply (24 V) NC (*)
Signal classification – A –
*: Never connect any cable to NC, or malfunctions or failures will occur.
10-186
PC228US-8,PC228USLC-8
Electrical system Electronic control system
DRC-60P [ CN-CE01 ] Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
Signal name NC (*) IMA power supply Ambient pressure sensor NC (*) NC (*) CAN (-) NC (*) CAN (+) NC (*) NC (*) NC (*) NC (*) NC (*) Water-in-fuel sensor Coolant temperature sensor Sensor power supply (5 V) Engine oil pressure switch NC (*) NC (*) NC (*) NC (*) NC (*) Intake air temperature sensor NC (*) Common rail pressure sensor Camshaft speed sensor (+) Crankshaft speed sensor (+) NC (*) NC (*) NC (*)
Signal classification – D B – – E – E – – – – – B B A B – – – – – B – B B B – – –
Pin No. 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60
Signal name NC (*) IMA return Sensor power supply (5 V) NC (*) NC (*) NC (*) Sensor power supply (5 V) GND NC (*) NC (*) NC (*) NC (*) NC (*) Boost pressure sensor Injector #1 (+) Injector #5 (+) Sensor GND Crankshaft speed sensor (-) NC (*) NC (*) Injector #2 (–) Injector #3 (–) Injector #1 (–) Injector #2 (+) Injector #3 (+) Injector #4 (+) Injector #6 (+) Injector #4 (–) Injector #6 (–) Injector #5 (–)
Signal classification – C A – – – A C – – – – – B D D C C – – C C C D D D D C C C
*: Never connect any cable to NC, or malfunctions or failures will occur.
PC228US-8,PC228USLC-8
10-187
Electrical system Electronic control system
DRC-50P[ CN-CE02 ] Pin No.
Signal name
Signal classification – – – – – – – – B – – – – –
Pin No.
Signal name
26 27 28 29 30 31 32 33 34 35 36 37 38 39
NC (*) NC (*) NC (*) NC (*) NC (*) NC (*) NC (*) DIS_SEL0 (GND) NC (*) NC (*) NC (*) NC (*) NC (*) Starting switch ACC signal Electrical intake air heater relay drive NC (*) Electrical intake air heater relay return NC (*) NC (*) NC (*) CAN (+) CAN (-) NC (*) Engine controller power cutoff relay NC (*)
1 2 3 4 5 6 7 8 9 10 11 12 13 14
NC (*) NC (*) NC (*) NC (*) NC (*) NC (*) NC (*) NC (*) Fuel control dial (+) NC (*) NC (*) NC (*) NC (*) NC (*)
15
NC (*)
–
40
16
NC (*)
–
41
17
NC (*)
–
42
18 19 20 21 22 23 24 25
NC (*) NC (*) NC (*) NC (*) Fuel control dial (5 V) Fuel control dial (–) NC (*) NC (*)
– – – – A C – –
43 44 45 46 47 48 49 50
Signal category – – – – – – – C – – – – – B D – C – – – E E – D –
*: Never connect any cable to NC, or malfunctions or failures will occur.
10-188
PC228US-8,PC228USLC-8
Electrical system Electronic control system
Pump controller
PC228US-8,PC228USLC-8
10-185
10-189
Electrical system Electronic control system
Input/Output signal
10-186
AMP-81P [CN-C01] Pin No.
Signal name
1 2 3
Unswitched power supply (24 V) Unswitched power return Window washer
Input/Ou tput signal Input Input Output
4
Unswitched power supply (24 V)
5 6 7 8 9 10 11
Unswitched power return NC (*) NC (*) Potentiometer power supply (5 V) Potentiometer power supply (5 V) NC (*) Arm potentiometer Boom cylinder head oil pressure sensor
12
42 43 44
NC (*) Starting switch ACC signal NC (*)
Input
45
CAN_H
Input – – Output Output – Input
46 47 48 49 50 51 52
GND (analog signal) NC (*) NC (*) Front pump oil pressure sensor Rear pump swash plate sensor NC (*) Attachment oil pressure switch
Input/Ou tput signal – Input – Input/out put Input – – Input Input – Input
Input
53
Boom RAISE oil pressure sensor
Input
–
54
Pin No.
Signal name
13
NC (*)
14
Boom LOWER oil pressure switch
Input
55
15 16 17 18 19 20 21 22
Arm OUT oil pressure switch Swing left oil pressure sensor Arm IN pressure sensor GND (analog signal) Swing lock switch NC (*) Model Selection 2 NC (*)
Input Input Input Input Input – Input –
56 57 58 59 60 61 62 63
Left forward travel oil pressure sensor Right forward travel oil pressure sensor Wiper motor reverse (W) Cab front window open limit switch Model Selection 4 NC (*) Starting switch C signal NC (*) External drive signal NC (*)
23
NC (*)
–
64
CAN_L
24 25 26 27 28 29 30
Starting switch ACC signal NC (*) NC (*) NC (*) NC (*) Hydraulic oil temperature sensor Front pump swash plate sensor Boom cylinder bottom oil pressure sensor NC (*) NC (*) Bucket DUMP oil pressure sensor Left travel reverse oil pressure sensor Right travel reverse oil pressure sensor NC (*) Swing brake cancel switch Model Select 5 Model Select 1 One-touch power maximizing switch
Input – – – – Input Input
65 66 67 68 69 70 71
NC (*) NC (*) Boom potentiometer Rear pump oil pressure sensor NC (*) GND (analog signal) NC (*)
Input Input Input – Input – Input – Input/out put – – Input Input – Input –
Input
72
Swing right oil pressure sensor
Input
– – Input
73 74 75
Bucket CURL oil pressure sensor NC (*) Wiper motor stop (P)
Input – Input
Input
76
NC (*)
Input
77
Model Selection 3
Input
– Input Input Input
78 79 80 81
Overload alarm effective signal Starting switch ACC signal Arm crane relay monitoring NC (*)
Input Input Input –
31 32 33 34 35 36 37 38 39 40 41
Input Input
–
Input
*: Never connect any cable to NC, or malfunctions or failures will occur.
10-190
PC228US-8,PC228USLC-8
Electrical system Electronic control system
AMP-40P [CN-C02] Pin No. 82 83 84 85 86 87 88
Signal name
90 91
NC (*) NC (*) NC (*) NC (*) Attachment selector solenoid Travel speed increase solenoid LS-EPC valve Pump merge-divider EPC valve (LS) NC (*) NC (*)
92
NC (*)
93
Arm crane relay drive signal Bucket DUMP operation lock solenoid NC (*) Front pump PC-EPC valve Oil flow adjuster EPC for attachment NC (*) NC (*) NC (*) Swing brake solenoid
89
94 95 96 97 98 99 100 101
Input/Ou tput signal – – – – Output Output Output
Input/Ou tput signal –
Pin No.
Signal name
102 103 104 105 106 107 108
NC (*) NC (*) Rear pump PC-EPC valve Boom RAISE cushion EPC valve NC (*) Travel alarm Battery relay drive
Output
109
2-stage relief solenoid
Output
– –
110 111
Output –
–
112
Output
113
Travel junction SOL NC (*) Pump merge-divider EPC valve (main) NC (*)
Output
114
Wiper motor (-)
Output
– Output
115 116
GND (solenoid) Solenoid power supply
Input Input
Output
117
GND (solenoid)
Input
– – – Output
118 119 120 121
Solenoid power supply Wiper motor (+) GND (solenoid) Solenoid power supply
Input Output Input Input
– Output Output – Output Output
Output –
*: Never connect any cable to NC, or malfunctions or failures will occur.
PC228US-8,PC228USLC-8
10-191
Electrical system Electronic control system
Fuel control dial
10-18
1. Knob 2. Dial 3. Spring 4. Ball 5. Potentiometer 6. Connector Function q This dial is installed in the right console box. Turning knob (1) causes potentiometer (5) shaft to rotate. q As the potentiometer shaft is turned, the resistance of the variable resistor in potentiometer (5) changes and a throttle signal is sent to the engine controller. q The hatched areas in the graph are error detection areas. If the throttle voltage is within the area, the engine speed drops down to low idle.
10-192
10-18
PC228US-8,PC228USLC-8
Electrical system Electronic control system
Resistor
10-189
1. Resistance 2. Connector Specifications For PC-EPC valve: 20 z For boom RAISE cushion EPC valve: 20 z
10-189
Function 10-189 q When the emergency pump drive switch or the emergency work equipment drive switch is turned to ON position, this resistor sends an electric current to each PC-EPC valve that is appropriate for each condition. a No electric current flows in the normal condition.
PC228US-8,PC228USLC-8
10-193
Electrical system Electronic control system
Engine oil pressure switch
10-190
1. Connector 2. Sensor 3. O-ring Specifications Contact type: Normally closed
10-190
Function 10-190 q This oil pressure switch is installed in the cylinder block. It detects engine oil pressure, and turns the switch on when the pressure goes below the specified value.
10-194
PC228US-8,PC228USLC-8
Electrical system Electronic control system
PPC oil pressure switch
1. Plug 2. Switch 3. Connector Specifications 10-191 Type of contacts: Normally open Operating pressure to make contact point ON: 490 ± 98.1 kPa {5.0 ± 1.0 kg/cm2} Operating pressure to break contact point OFF: 294 ± 49.0 kPa {3.0 ± 0.5 kg/cm2}
PC228US-8,PC228USLC-8
10-191
Function 10-191 Two of these sensors are installed to the relay block in the pilot circuit between the PPC valve and control valve. They detect the PPC oil pressure when each actuator is operated, and turn the switch on when the pressure exceeds the specified value.
q
10-195
Electrical system Electronic control system
Quick coupler low pressure warning switch
1. 2. 3. 4.
Switch Wire Cover Connector
Specification q Switching pressure 25±5 bar (rising) Function q The quick coupler circuit has one pressure switch. This sensor detects the circuit pressure, if the pressure falls below the switch set pressure a buzzer is sounded in the operator cab to warn the operator.
10-196
PC228US-8,PC228USLC-8
Electrical system Machine monitor system
Machine monitor system
1. Machine monitor 2. Battery 3. Pump controller 4. Engine controller 5. Air conditioner controller 6. KOMTRAX terminal 7. Sensors and switches 8. Wiper motor and window washer motor Input/output signal a. Power supply b. CAN signal c. Sensor and switch signals d. Drive signal
PC228US-8,PC228USLC-8
Outline 10-192 The monitor system keeps the operator informed of all machine functions, by monitoring the machine conditions by using the sensors and switches installed in various parts of the machine and processing them instantly to display on the machine monitor. The information displayed on the machine monitor falls into the following types: 1. Alarm when the machine has problem 2. Machine condition display (coolant temperature, hydraulic oil temperature, and fuel level) q The switches on the machine monitor controls the machine. q
10-192
10-197
Electrical system Machine monitor system
Machine monitor
Outline 10-193 q The machine monitor has monitor display function, mode selection function and switch function for electrical parts etc. Also it has an alarm buzzer. q The machine monitor has a CPU (Central Processing Unit) in it to process, display, and output the information. q The machine monitor consists of a display and switches: the display is of LCD type, and the switches are of flat sheet switch. q If an error occurs in the machine monitor itself, controller or wiring circuit between monitor and controller, the monitor does not display properly.
10-198
10-193
Precautions on the machine monitor display 10-193 The LCD panel may has black points (points which are not lighted) and bright points (points which do not go off) for the reason of its characteristics. If the number of the bright points and black points does not exceed 10, it does not indicate a failure or a defect. q When the engine is started, the battery voltage may drop suddenly depending on ambient temperatures and battery conditions. In this case, the machine monitor display may go off for a moment. However, this phenomenon is not a failure. q Continuous operation of the machine monitor may display blue bright spots on the screen having a black background; it is quite normal. Blue points can never be a problem as the screen has usually blue or white background. (White in the LCD is made up of red, green and blue.) q
PC228US-8,PC228USLC-8
Electrical system Machine monitor system
Input/output signal
10-194
070-18P(1) [CN-CM01]
1
Unswitched power supply (24 V)
Input/Output signal Input
2
Unswitched power supply (24 V)
Input
Pin No.
Signal name
Pin No.
Signal name
10
NC (*)
11
Battery charge
Input/Output signal – Input
3
GND (unswitched power supply )
–
12
GND (machine analog signal)
4
GND (unswitched power supply )
–
13
Lamp switch
Input
5
Input/output
14
Starting switch ACC signal
Input
Output
15
Starting switch C signal
Input
7
Wake-up Starting motor cut-out relay (for personal code) NC (*)
Input
8
NC (*)
9
Fuel level
6
–
–
16
Preheating
–
17
NC (*)
–
Input
18
NC (*)
–
*: Never connect any cable to NC, or malfunctions or failures will occur. 070-12P(1) [CN-CM02] Pin No.
Signal name
Input/Output signal –
Pin No.
Signal name
1
NC (*)
2
Engine oil level sensor
3
Coolant level sensor
Input
9
CAN_H
Input/output
4
Air cleaner clogging sensor
Input
10
CAN_L
Input/output
5
Swing lock switch
Input
11
NC (*)
–
6
NC (*)
–
12
NC (*)
–
Input
7
NC (*)
8
CAN terminal
Input/Output signal – –
*: Never connect any cable to NC, or malfunctions or failures will occur. 070-18P(2) [CN-CM03] Pin No. 1 2 3 4 5 6 7 8 9
Signal name RS232C CD for communication terminal RS232C RXD for communication terminal RS232C SG for communication terminal GND (communication terminal control signal) Communication terminal selection signal For communication terminal: RS232C RTS For communication terminal: RS232C TXD For communication terminal: RS232C DTR For communication terminal: RS232C DSR
PC228US-8,PC228USLC-8
Input/Output signal
Pin No.
Input
10
Input
11
–
12
–
13
Input
14
Output
15
Output
16
Output
17
Input
18
Signal name For communication terminal: RS232C CTS For communication terminal: RS232C RI GND (communication terminal power supply) Communication terminal status signal CH1 Communication terminal power supply control signal Communication terminal control signal CH1 Communication terminal control signal CH2 Communication terminal status signal CH2 Communication terminal power supply (12 V)
Input/Output signal Input Input – Input Output Output Output Input Output
10-199
Electrical system Machine monitor system
070-12P(2) [CN-CM04]
1
NC (*)
Input/Output signal –
2
NC (*)
–
3
NC (*)
–
4
NC (*)
–
5
NC (*)
–
6
NC (*)
–
Pin No.
Signal name
7
NC (*)
Input/Output signal –
8
NC (*)
–
9
NC (*)
–
10
NC (*)
–
11
NC (*)
–
12
NC (*)
–
Pin No.
Signal name
*: Never connect any cable to NC, or malfunctions or failures will occur. B60-8P [CN-CM05] Pin No.
Signal name
Input/Output signal Output
Pin No.
Signal name
Input/Output signal –
1
Camera power supply (8 V)
5
GND (Camera power supply)
2
Camera NTSC signal 1
Input
6
GND (Camera signal 1)
–
3
Camera NTSC signal 2
Input
7
GND (Camera signal 2)
–
4
Camera NTSC signal 3
Input
8
GND (Camera signal 3)
–
10-200
PC228US-8,PC228USLC-8
Electrical system Machine monitor system
PC228US-8,PC228USLC-8
10-201
Electrical system Machine monitor system
Display
10-196
A: Standard screen B: All indicators light-up screen q If problems indicated by monitors (15) to (20) occur after starting the engine, the corresponding monitors are displayed from the left top in the order of occurrence of the problems. q If a problem indicated by monitors (15) to (20) occurs while working, the relevant monitor is displayed in large size for two seconds and then displayed in small size. q If the hydraulic oil temperature goes High or Low while a monitor is being displayed at the central portion of the screen, at which the hydraulic oil temperature monitor is to be displayed, the screen displays only hydraulic oil temperature monitor (2b). C: Screen with maintenance time reminder
10-202
PC228US-8,PC228USLC-8
Electrical system Machine monitor system
NO.
Display category
Display item
Description
Remarks
Tempera- Background q ture (°C) colour W1 105 Red q W2 102 Red W3 100 Blue q W4 85 Blue W5 60 Blue W6 30 White See the column "Gauge". Tempera- Background q Range ture (°C) colour H1 105 Red q H2 102 Red H3 100 Blue q H4 85 Blue H5 40 Blue H6 20 White See the column "Gauge". Background q Range Quantity (l) colour F1 230 Blue F2 195 Blue F3 160 Blue F4 80 Blue F5 60 Blue F6 40 Red See the column "Gauge". Segment Load level q Light to Green 1– 8 medium
Range
1a
Gauge
1b
Caution
2a
Gauge
2b
Caution
3a
Gauge
3b
Cautions
4
(*1) Engine coolant temperature
(*1) Hydraulic oil temperature
(*1) Fuel level
ECO gauge
Indicates corresponding temperature range. Alarm buzzer sounds when the temperature exceeds 105 °C. If the monitor background appears white, warm-up the engine.
Indicates corresponding temperature range. Alarm buzzer sounds when the temperature exceeds 105 °C. If the monitor background appears white, warm-up the hydraulic components. Indicates corresponding fuel level.
Indicates average load per minute on a scale of 1 to 10.
(Indicates when " Default (ECO display is set to active)" of the service mode is " ON" .) q Indicates accumulated engine operating hours (the alternator is running). Service meter reading 00000h - 99999h (F4 switch changes it for clock dis5 play.) q Displays time. q 12-hour display (AM/PM) (F4 switch changes it for service meter Clock q 24-hour display display.) Background (If KOMTRAX is installed.) Condition q The condition of the message is discolour 6 Message Green There is unread message. played. Blue There is unsent message. (OFF when no message exists.) Light ON: ON q Indicates air conditioner and air blower 7 Air conditioner Light OFF: OFF operating status. q Indicates front glass wiper operating INT: Intermittent Pilot condition. 8 Wiper ON: Continuous Light OFF:Stop Swing lock Swing brake Monitor dis- q Indicates swing lock operating status. cancel switch switch play OFF OFF OFF 9 Swing lock ON OFF ON OFF ON Blink ON ON Blink *1: If the gauge signal is not available due to open circuit in CAN communication line, the gauge pointer goes off. Orange
PC228US-8,PC228USLC-8
9,10
Heavy
10-203
Electrical system Machine monitor system
NO.
Display category
Display item
Description
Remarks
q Indicates preheat operating status. Elapsed time after turning Monitor disthe starting switch to play "HEAT (preheat)". 10 Preheating 0 – 30 sec. ON 30 – 40 sec. Blink After 40 sec. or longer OFF q Indicates the operating status of One-touch one-touch power maximizing function. power max. Monitor display switch One-touch ON 11 power max. ON (Goes off if pressed for 8.5 seconds) Pilot OFF Off q Indicates auto-decelerator operating Auto-decelera- Light ON: ON 12 status. tor Light OFF: OFF q Displays working mode. P: Heavy-duty operation E: Low-fuel consumption operation L: Fine operation 13 Working mode B: Breaker operation ATT: Double-acting attachment operation Lo: Low speed q Displays travel speed setting. 14 Travel speed Med: Medium speed Hi: High speed (*2) Light ON: Abnormal range (below the q When an error is detected with the en15 gine stopped, the monitor lights up on Radiator coolant specified value) the screen. level Light OFF: Normal range q When an error is detected with the enLight ON: Defective battery charge (*2) gine running, the monitor lights up on 16 (Charge voltage < Battery voltage) Battery charge the screen. Light OFF: Normal range (*2) Light ON: Abnormal range (below the q The monitor lights up on the screen and alarm buzzer sounds, when an er17 Engine oil pres- specified value) ror is detected with the engine running. sure Light OFF: Normal range Light ON: Abnormal range (below the q When an error is detected with the en(*2) 18 gine stopped, the monitor lights up on specified value) Engine oil level the screen. Light OFF: Normal range Caution (*2) Light ON: Abnormal range (above the q When an error is detected with the engine running, the monitor lights up on 19 Air cleaner clog- specified value) the screen. ging Light OFF: Normal range Light ON: Abnormal range (water level q When an error is detected with the en(*2) gine running, the monitor lights up on 20 is above the specified) Water separator the screen. Light OFF: Normal range q The display changes depending on the Background Condition time to/after the replacement. colour There is a maintenance q After the starting switch is turned to ON Maintenance item which is 30 hours or position, the monitor turns on if the 21 Yellow time less left before next monitor light-up conditions are met, replacement. and then goes off in 30 seconds. There is a replacement Red overdue item. *2: Included in the start-up check. After the staring switch is turned to ON position, the monitor turns on for two seconds, and changes to the standard screen if no error is found.
10-204
PC228US-8,PC228USLC-8
Electrical system Machine monitor system
PC228US-8,PC228USLC-8
10-205
Electrical system Machine monitor system
Switches
NO. 1
10-20
Model
Function Turns the auto-decelerator function Auto-deceleration switch ON/OFF. [Numeric keypad: 1] Light ON: ON Light OFF: OFF
q
Operation When the working mode is in "L" , the auto-decelerator does not work. OFF io ON
P: Heavy-duty operation E: Low-fuel consumption operation Displays the working mode selector L: Fine operation screen. B: Breaker operation ATT: Double attachment operation Changes the travel speed. o Lo (Low speed) o Mi (Medium speed) o Lo light ON: Low speed Hi (High speed) o Mi light ON: Medium speed I O i i i i i i Hi light ON: High speed q Stops the alarm buzzer. Stops the alarm buzzer. (Some alarm buzzer does not stop even if q The alarm buzzer resumes sounding when another error is detected. the switch is pressed.)
2
(*1) Working mode selector switch [Numeric keypad: 2]
3
Travel speed selector switch [Numeric keypad: 3]
4
Buzzer cancel switch [Numeric keypad: 4]
5
(*2) Wiper switch [Numeric keypad: 5]
Operates the front window glass wiper. INT: Intermittent ON: Continuous Light OFF: Stop
(*2) Window washer switch [Numeric keypad: 6]
ON: Washer fluid is sprayed and wiper works continuously. [When wiper stops] OFF: Wiper works twice and stops after the Sprays washer fluid onto the front window switch is released. glass. [When wiper operates intermittently] OFF: Wiper works twice continuously and returns to intermittent operation after the switch is released.
6
10-206
o INT o ON o OFF o I
(Intermit- (Continutent) ous) i
i
(Stop)
O
i
PC228US-8,PC228USLC-8
Electrical system Machine monitor system
NO.
Model
7a
Fan switch (increase) [Numeric keypad: 7]
7b
Fan switch (decrease)
8a
8b
Temperature control switch (UP) [Numeric keypad: 8] Temperature control switch (DOWN) [Numeric keypad: 0]
9
(*3) Auto switch [Numeric keypad: 9]
10
(*4) Air conditioner switch
11
FRESH/RECIRC air selector switch
12
Vent selector switch
13
OFF switch
14a 14b
Guidance icon Function switch
Function
Operation The air flow increases immediately after Controls the flow rate of the air condithe air conditioner adjustment screen tioner in 6 levels. appears. q The air flow decreases immediately after (Low, Medium 1, Medium 2, Medium 3, the air conditioner adjustment screen Medium 4, High) appears. q The preset temperature increases immediately after the air conditioner adControls the temperature inside the cab. justment screen appears. (18.0 °C – 32.0 °C: adjustable at every q The preset temperature decreases im0.5 °C) mediately after the air conditioner adjustment screen appears. q Automatically controls the air flow, air vent, fresh/recirculated air change acAuto-runs the air conditioner and air cording to the temperature setting, imblower. mediately after the air conditioner AUTO light ON: Auto run adjustment screen appears. q Switches to the air conditioner adjustTurns the air conditioner ON/OFF. ment screen, and pressing it again AC ON lights-up: manual operation switches ON/OFF. Light OFF:Stop OFF io ON q Switches to the air conditioner adjustment screen, and pressing it again Changes the FRESH/RECIRC. switches FRESH/RECIRC. RECIRC io FRESH q Switches to the air conditioner adjustSelects the air vent mode from 6 modes. ment screen, and pressing it again 1. Front switches air vent mode. 2. Front and rear Modes 5 and 6 are not available with 3. Front and rear foot auto mode. 4. Foot o1o2o3o4o5o6o 5. Foot and defroster I O 6. Defroster i i i i i i Stop the fan and air conditioner. q The fan and air conditioner stop. Light OFF: OFF q
a See "Guidance icon and function switch." section.
*1: When the working mode is changed, the auto-decelerator function turns "ON". *2: When the front window is open, the windshield wiper and the washer do not operate even if the switch is pressed. *3: When the temperature is set to 18.0 °C or 32.0 °C, the fan speed is kept at "High". Even if the set temperature is reached, the flow rate remains fixed at "High". *4: When the fan is set to Stop, the air conditioner does not start even if the switch is pressed.
PC228US-8,PC228USLC-8
10-207
Electrical system Machine monitor system
Guidance icon and function switch 10-202 q Functions available with the function switch vary depending on the guidance icon displayed above the switch. q No function is available if no guidance icon appears above the function switch. q The following is the list of guidance icons and the functions displayed above the function switches.
10-208
PC228US-8,PC228USLC-8
Electrical system Machine monitor system
Function switch
F1
Guidance icon
Role
Function
1
Clear
Clears selected/displayed item.
2
Display No. 1 camera screen
Selects No. 1 camera screen.
3
Change selectable items
Moves selectable item page down one page. (To the top page from the bottom page.)
4
Set
Performs setting.
5
Start
6
Stop
1
Return to default setting
2
Display No. 2 camera screen
Selects No. 2 camera screen.
3
Change selectable items
Moves selectable item page up one page. (To the bottom page from the top page.)
4
Clear
Clears selected/displayed item.
1
Switching to camera screen
Switches to camera screen.
2
Display No. 3 camera screen
Selects No. 3 camera screen.
3
Select item
4
Select item
1
Switching clock/service meter
F2
F3
2 F4 3 4 1 F5
Starts function. (Used for starting measurement of spilt fuel consumption.) Stops operation. (Used for stopping measurement of spilt fuel consumption.) Sets selected item back to default. (Used for screen adjustment.)
Moves selectable item down one item. (To the top item from the bottom item.) Releases holding of the monitor. Moves selectable item to the left. (To the rightmost item from the leftmost item.) Switches clock/service meter display.
Display No. 1 and No. 2 camera Display both images of No.1 and No.2 cameras simulscreens taneously. Moves selectable item up one item. Select item (To the bottom item from the top item.) Holds the monitor. Moves selectable item to the right. Select item (To the leftmost item from the rightmost item.) Selection of maintenance Switches to the maintenance screen. screen
2
Return
Returns to the previous screen or status.
1
Select user mode screen
Switches to the user mode screen.
2
Enter
Enters selected/set item.
F6
PC228US-8,PC228USLC-8
10-209
Electrical system Machine monitor system
Operator mode function 10-204 q The operator can select the information to be displayed on the standard screen and the function to be used, by operating the switches. Note that some information displays and function selections require the special operations of the switches. q Items available in the operator mode are as follows: Category (*1)
Item
V 1 2 3 4 5
Display order (*2) W X Y 1 1 1 2 2 3 2 3 3 4 4 4 5 5
Z KOMATSU logo screen 1 Password input screen Breaker mode check screen Start-up check screen 2 A Warning after "start-up check" screen Overdue replacement item screen 3 Working mode and travel speed check screen 4 Display of standard screen 5 Display of end screen Selection of auto-deceleration Selection of working mode Selection of travel speed Operation to stop alarm buzzer Operation of windshield wiper Operation of windshield washer Operation of air conditioner Operation to display camera mode Switching between clock display and service meter display B Check of maintenance information Entering user mode q Breaker/Attachment Settings q User Messages (including KOMTRAX messages for user) q Screen Adjustment q Clock Adjustment q Language q Economy Mode Adjustment Display of energy-saving guidance C Display of caution monitor Displaying user code and failure code Function of checking display of LCD (Liquid Crystal Display) D Function of checking service meter Function of changing attachment/maintenance password *1: The items available in the operator mode fall into the following categories. A: Display from the time starting switch is turned to ON position until the standard screen appears. Display after the starting switch is turned to OFF position. B: Display when the switch on the machine monitor is operated. C: Display when a certain condition is satisfied D: Display to requires special operation of the switches. *2: For the category A, the order in which items are displayed varies depending on the settings and conditions of the machine as follows: V: When engine start lock is set effective W: When engine start lock is disabled X: When working mode at start is set to "Breaker Mode (B)" Y: When an error is detected during start-up check. Z: When a replacement time overdue is detected. a For how to operate the operator mode functions, see the Operation and Maintenance Manual or "Special functions of machine monitor" section in Testing and adjusting. a For how to set the engine start lock on/off, see " Password setting/cancel manual" .
10-210
PC228US-8,PC228USLC-8
Electrical system Machine monitor system
Oil flow setting for breaker
q q
10-205
Oil flow setting for attachment
Oil flow for the breaker can be changed in the "Breaker/attachment setting" of the user mode. Oil flow level can be set as follows:
q
Flow level 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
q
Flow rate (l/min) 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210
Remarks
Oil flow for the 2-way attachment can be changed in the " Breaker/attachment setting" of the user mode. Oil flow level can be set as follows: Flow level 1 2 3 4 5 6 7 8
Flow rate (l/min) 30 90 115 140 170 250 350 430
Language setting
Remarks
Default
10-205
Default
q
q
PC228US-8,PC228USLC-8
10-205
The language used in the machine monitor can be changed in the " Language setting" of the user mode. The available languages are as follows: English, Japanese, Chinese, French, Spanish, Portuguese, Italian, German, Russian, Turkish, Indonesian, and Thai.
10-211
Electrical system Machine monitor system
Economy mode adjustment
q
q
10-206
Fuel consumption can be improved by adjusting the engine output power at "Economy Mode Adjustment" in user mode. The level can be selected from 4 stages, E0/E1/E2/E3. The larger, the number of stage becomes, the more the fuel consumption improves, while the production reduces.
10-212
PC228US-8,PC228USLC-8
Electrical system Machine monitor system
Service mode function 10-207 q The functions in this mode are not displayed on the standard screen. The arrangements for the information display and various setting can be made only by the technician through the special operation of the switches. This mode is used for special setting, testing, adjusting, or troubleshooting. q Items available in the service mode are as follows: Monitoring Abnormality Record
Mechanical Systems Electrical Systems Air-conditioning System
Maintenance Record Maintenance Mode Change Phone Number Entry
Default
Adjustment
Key-on Mode Unit With/Without Attachment Attachment/Maintenance Password Camera ECO Display Pump Absorption Torque (F) Pump Absorption Torque (R) Low Speed Attachment Flow Adjustment Initialize boom potentiometer Calib F pump swash plate sensor Calib R pump swash plate sensor
Cylinder Cut-Out No Injection Fuel Consumption KOMTRAX Settings
Terminal Status GPS & Communication Status Modem S/N
Service Message
a For how to operate the service mode functions, see "Special functions of machine monitor" section in Testing and adjusting.
PC228US-8,PC228USLC-8
10-213
Electrical system PPC Levers
PPC Levers LH PPC Lever
1
1
2
3
4
1. 2. 3. 4.
Lever Gaiter Harness Connector
10-214
PC228US-8,PC228USLC-8
Electrical system PPC Levers
RH PPC Lever
10-215
1
2
3
4
1. 2. 3. 4.
Lever Gaiter Harness Connector
PC228US-8,PC228USLC-8
10-215
Electrical system KOMTRAX system
KOMTRAX system (if equipped)
The KOMTRAX system consists of the KOMTRAX terminal, communication antenna, machine monitor and GPS antenna. q This system sends various information on the machine via wireless communication. It allows operators of the KOMTRAX to obtain the machine information from the office and to provide various services with the customers. q The information available from the KOMTRAX system are as follows: 1. Operation map 2. Service meter reading 3. Location information 4. Failure history and others. a To provide the services, you need to make an arrangement for starting the KOMTRAX service separately. q
10-216
PC228US-8,PC228USLC-8
Electrical system KOMTRAX system
KOMTRAX terminal 10-217 Model: TH300 q The KOMTRAX system utilizes satellite communications technology.
1. Communication antenna connection 2. Machine harness connection (AMP-14P) 3. Machine harness connection (AMP-10P) Input/output signal AMP-14P [CN-CK01] Input/Output signal A1 Power supply (12 V) Input A2 NC (*) A3 NC (*) A4 Power supply voltage switching Output A5 NC (*) A6 NC (*) A7 GND A8 GND A9 NC (*) A10 NC (*) A11 NC (*) A12 NC (*) A13 NC (*) A14 NC (*) *: Never connect any cable to NC, or malfunctions or failures will occur. Pin No.
Signal name
Outline 10-209 The terminal is a radio communication equipment which transmits various machine information obtained by the machine monitor through network signals and input signals, as well as GPS positioning data. The terminal can transmit data via the communication antenna. q The status of the terminal can be monitored on the machine monitor when it is in the service mode "KOMTRAX setting display". q Use of KOMTRAX terminal must be limited for the countries in which such communication is allowed. q
a When commencing operation of the KOMTRAX system or changing the country in which the system is used, you must give notice to Komatsu Ltd. a When operating the system in Japan, install a terminal dedicated for use in Japan.
AMP-10P [CN-CK02] Input/Output signal B1 RS232C DCD Output B2 RS232C RXD Output B3 RS232C TXD Input B4 RS232C DTR Input B5 RS232C SGND B6 RS232C DSR Output B7 NC (*) B8 NC (*) B9 NC (*) B10 NC (*) *: Never connect any cable to NC, or malfunctions or failures will occur. Pin No.
Signal name
PC228US-8,PC228USLC-8
10-217
Electrical system Sensors
Sensors Ambient pressure sensor
1. Connector
10-210
2. Pressure intake port
Function 10-210 q This sensor, installed to the air intake cover at the engine top side, senses the atmospheric pressure to output the corresponding variable voltage. Boost pressure/temperature sensor
1. Connector 2. Sensor
10-210
3. O-ring
10-210 Function q This sensor is installed in the intake manifold. It detects the boost pressure and intake air temperature, and outputs signal as a variable voltage for pressure, and a resistance change for temperature.
10-218
PC228US-8,PC228USLC-8
Electrical system Sensors
Coolant temperature sensor
1. Connector 2. Sensor
10-219
3. O-ring
10-21 Function q This sensor, installed on the cylinder head, converts the temperature variation into the change in resistance, and outputs the corresponding signals. Crankshaft speed sensor Camshaft speed sensor
1. Connector 2. Sensor
10-21 10-21
3. O-ring
10-21 Function q Crankshaft speed sensor and camshaft speed sensor are installed to the adjacency of the gear and the ring on the cooling fan side of crankshaft and camshaft, respectively, and output pulse voltages due to gear rotations.
PC228US-8,PC228USLC-8
10-219
Electrical system Sensors
Common rail pressure sensor
1. Common rail 2. Sensor
10-2 0
3. Connector
10-212 Function q The sensor is installed in the common rail. It detects the fuel pressure and outputs variable voltage signal. Engine oil level sensor
1. Connector 2. Bracket
10-212
3. Float 4. Switch
Function 10-212 q This sensor is installed on the side face of the oil pan, and turns "OFF" by the lowered float, if the oil level becomes lower than specified.
10-220
PC228US-8,PC228USLC-8
Electrical system Sensors
Fuel level sensor
1. Connector 2. Float 3. Arm 4. Body
10-213
5. Spring 6. Contact 7. Spacer
Function 10-213 q This sensor is installed on the side face of the fuel tank. The float moves up and down according to the fuel level. The movement of the float rotate the shaft of the variable resistor through the arm. As a result, the source voltage is changed according to the resistance change due to the arm angle change and is output as a signal.
PC228US-8,PC228USLC-8
10-221
Electrical system Sensors
Coolant level sensor
1. Float 2. Sensor
10-214
3. Connector 4. Reservoir tank
Function 10-214 q This sensor is integrated with reservoir tank, and turns "OFF" by the lowered float, if the coolant level becomes lower than specified.
10-222
PC228US-8,PC228USLC-8
Electrical system Sensors
Hydraulic oil temperature sensor
1. Connector 2. Plug
10-215
3. Thermistor
10-215 Function q This sensor, installed on the suction pipe of main pump, senses the temperature variation as the change in thermistor resistance, and outputs the corresponding signals. Front pump oil pressure sensor Rear pump oil pressure sensor
1. O-ring 2. Sensor 3. Connector
10-215 10-215
Output characteristics
10-215
Function 10-215 q Front pump oil pressure sensor and rear pump oil pressure sensor are installed to the control valves, detect the delivery pressures of pumps, and output the corresponding variable voltages.
PC228US-8,PC228USLC-8
10-223
Electrical system Sensors
PPC oil pressure sensor
1. O-ring 2. Sensor 3. Connector
10-216
Output characteristics
10-216
Function 10-216 q PPC oil pressure sensors, 6 of which are installed to interconnect blocks in the pilot circuit between control valves and PPC valve, and 4 of which are installed to travel PPC valves, detect the pilot pressures, and output the corresponding variable voltage.
Air cleaner clogging sensor
1. Boss 2. Switch 3. Conduit
10-216
4. Wire 5. Connector
10-216 Function q The sensor is installed on the air cleaner outlet side. It turns "ON", if the air cleaner is clogged and the pressure level drops to the specified level (negative pressure).
10-224
PC228US-8,PC228USLC-8
Electrical system Sensors
Front pump swash plate sensor Rear pump swash plate sensor
1. Sensor case 2. Spool 3. Lead wire 4. Connector
10-217 10-217
Output characteristics 10-217 The relation between stroke and output voltage is as shown in the graph below.
q
L: Operation stroke (9 mm) Function 10-217 q These sensors are installed to the front pump side and the rear pump side of main pump, detect the stroke of servo pistons, and output the corresponding variable voltages. q The output voltages are sent to the pump controller which converts the voltages into the pump swash plate angles (oil flow) to process them. q
PC228US-8,PC228USLC-8
The relation between oil flow of pump and output voltage is as shown in the graph below.
10-225
Electrical system Sensors
Water-in-fuel sensor
1. Connector 2. Conduit
10-218
3. Sensor
10-218 Function q This sensor is installed to the cup of fuel prefilter, and outputs a signal when detecting water exists in the fuel.
10-226
PC228US-8,PC228USLC-8
Electrical system Sensors
Boom angle potentiometer
1. Shaft 2. Housing 3. Bearing 4. Brush 5. Variable resistor 6. Connector
10-219
Output characteristics
10-219
Function 10-219 q This potentiometer is installed to the boom foot, and detects the boom angle. q Based on the boom angle, the potentiometer converts the supply voltage into signal voltage depending on the resistance value of the variable resistor.
PC228US-8,PC228USLC-8
10-227
Electrical system Sensors
10-228
PC228US-8,PC228USLC-8
SEN0533408-00
20-1
PC228US-8,PC228USLC-8
HYDRAULIC EXCAVATOR PC228US-8 PC228USLC-8 Shop Manual
Machine model
Serial number
PC228US-8 PC228USLC-8
50001 and up 50001 and up
20 Standard value table
PC228US-8,PC228USLC-8
20-1
20-1
Contents
Contents 20 Standard value table Standard value table ...................................................................................................................... 20-3 Standard value table for engine .................................................................................................. 20-3 Standard value table for machine ............................................................................................... 20-4
20-2
PC228US-8,PC228USLC-8
Standard value table Standard value table for engine
Standard value table Standard value table for engine PC228US-8 PC228USLC-8
Machine model Engine Item
Engine speed
Boost pressure
Exhaust gas colour
SAA6D107E-1 Unit
Standard value
Repair limit
High idle
rpm
1,900 ± 70
1,900 ± 70
Low idle
rpm
1,050 ± 25
1,050 ± 25
Rated speed
rpm
2,000
2,000
kPa {mmHg}
Min. 133 {Min. 1,000}
103 {775}
Max. 25
35
Max. 12
22
Measurement conditions q
q q
q
Coolant temperature: Within operating range
Coolant temperature: Within operating range Arm IN relief + One-touch power max.
Coolant temperature: Within operating range
At sudden acceleration Rated power
Valve clearance
Compression pressure
Blow-by pressure
q
q
q q
q
Oil temperature Fan belt tension Air conditioner compressor belt tension
Intake Valve
mm
0.25
0.152 – 0.381
Exhaust Valve
mm
0.51
0.381 – 0.762
MPa Compression pressure {kg/cm2} Engine oil temperature: 40 60 °C Engine rpm speed
Min. 2.41 {Min. 24.6}
1.69 {17.2}
250 – 280
250 – 280
kPa {mmH2O}
Max. 0.98 {Max. 100}
1.96 {200}
kPa {kg/cm2} kPa {kg/cm2}
Min. 0.29 {Min. 3.0}
0.25 {2.5}
Min. 0.10 {Min. 1.0}
0.07 {0.7}
°C
80 – 110
120
mm
Auto-tensioner
Autotensioner
mm
6.3 – 8.7
6.3 – 8.7
Normal temperature
Coolant temperature: Within operating range Arm IN relief + One-touch power max. High idle
q
Engine oil temperature: Min. 80 °C SAE30 Oil
q
Whole speed range (inside oil pan)
q
Between fan pulley and alternator pulley Deflection when pressed with thumb at approx. 98 N {10 kg} Between compressor pulley and fan pulley Deflection when pressed with thumb at approx. 60 N {6.1 kg}
Engine oil pressure
q q q
Discoloration % Discoloration %
PC228US-8,PC228USLC-8
Low idle
20-3
Standard value table Standard value table for machine
Standard value table for machine PC228US-8 PC228USLC-8
Category
Machine model
Item
Measurement conditions
Unit
Standard value
Repair limit
rpm
1,920 ± 100
1,920 ± 100
rpm
1,950 ± 100
1,950 ± 100
rpm
1,050 ± 100
1,050 ± 100
RAISE
mm
11.5 ± 0.5
11.5 ± 0.5
LOWER
mm
9.5 ± 0.5
9.5 ± 0.5
IN
mm
11.5 ± 0.5
11.5 ± 0.5
OUT
mm
9.5 ± 0.5
9.5 ± 0.5
CURL DUMP
mm
9.5 ± 0.5
9.5 ± 0.5
Swing control valve
Left swing Right swing
mm
9.5 ± 0.5
9.5 ± 0.5
Travel control valve
Forward Reverse
mm
9.5 ± 0.5
9.5 ± 0.5
mm
85 ± 10
85 ± 10
mm
85 ± 10
85 ± 10
mm
85 ± 10
85 ± 10
mm
85 ± 10
85 ± 10
q q
Speed at 2-pump relief
q
Engine speed
q q q
Speed at 2-pump relief + One-touch power maximizing
q q q q
Travel of control valve spool
Speed when auto-deceleration is operated
q q q
Coolant temperature: Within operating range Hydraulic oil temperature: Within operating range Engine at high speed Power mode (P) Arm IN relief Coolant temperature: Within operating range Hydraulic oil temperature: Within operating range Engine at high speed Power mode (P) Arm IN relief + Left knob switch in ON position Engine at high speed Auto-deceleration switch in ON position All control levers in NEUTRAL position
Boom control valve
Arm control valve q
Bucket control valve
q
Engine stopped For measuring point, see "Control valve".
Travel of control lever
Boom control lever
20-4
Arm control lever
q
Bucket control lever
q
Swing control lever
q
Engine stopped At centre of control lever grip Read Max. value through travel end. (except lever play in NEUTRAL position)
Travel control lever Play of control levers
mm
115 ± 12
115 ± 12
Work equipment
mm
Max. 15
Max. 20
Travel
mm
Max. 20
Max. 25
PC228US-8,PC228USLC-8
Standard value table Standard value table for machine
PC228US-8 PC228USLC-8
Operating effort of control lever and pedal Category
Machine model
Item
Unit
Standard value
Repair limit
Boom control lever
N {kg}
15.7 ± 3.9 {1.6 ± 0.4}
Max. 24.5 {Max. 2.5}
Arm control lever
N {kg}
15.7 ± 3.9 {1.6 ± 0.4}
Max. 24.5 {Max. 2.5}
N {kg}
12.7 ± 2.9 {1.3 ± 0.3}
Max. 21.6 {Max. 2.2}
N {kg}
12.7 ± 2.9 {1.3 ± 0.3}
Max. 21.6 {Max. 2.2}
Travel control lever
N {kg}
24.5 ± 5.9 {2.5 ± 0.6}
Max. 39.2 {Max. 4.0}
Travel control pedal
N {kg}
74.5 ± 18.6 {7.6 ± 1.9}
Max. 107.6 {Max. 11}
Bucket control lever
Measurement conditions
q q
Swing control lever q q q
q
Unload pressure
q q q
Boom relief pressure q
Arm relief pressure
q q
Oil pressure
q
Bucket relief pressure Swing relief pressure
q
Travel relief pressure
q
q q q
Control circuit source pressure
q q q
LS differential pressure
q q q q q
Hydraulic oil temperature: Within operating range Engine at high speed Control lever: At centre of grip Pedal: At tip of pedal Read Max. value through travel end.
Hydraulic oil temperature: Within operating range MPa Engine at high speed 3.5 ± 1.0 Power mode (P) {36 ± 10} {kg/cm2} Hydraulic pump output pressure with all control levers in NEUTRAL position MPa At normal 34.8 ± 1.0 relief {355 ± 10} {kg/cm2} MPa 37.3 ± 1.0 At power Hydraulic oil {380 ± 10} maximizing {kg/cm2} temperature: Within operating MPa At normal 34.8 ± 1.0 range relief {355 ± 10} {kg/cm2} Engine at high speed Power mode (P) MPa At power 37.3 ± 1.0 Hydraulic pump output pressure maximizing {kg/cm2} {380 ± 10} with all measurement circuits reMPa At normal 34.8 ± 1.0 lieved relief {355 ± 10} {kg/cm2} MPa At power 37.3 ± 1.0 maximizing {kg/cm2} {380 ± 10} Hydraulic oil MPa 30.3 ± 1.5 temperature: Within operating range {310 ± 15} {kg/cm2} Engine at high speed Power mode (P) MPa 38.7 (+1.0/-2.0) Hydraulic pump output pressure with all {kg/cm2} {395 (+10/-20)} measurement circuits relieved Hydraulic oil temperature: Within operating range MPa 3.23 (+0.2/-0.3) Engine at high speed 2} {33 (+2/-3)} {kg/cm Self-pressure reducing valve output pressure with all control levers in NEUTRAL position Hydraulic oil When all temperature: Within operating control MPa 3.5 ± 1.0 range levers in 2} {36 ± 10} {kg/cm Engine at high speed NEUTRAL Power mode (P) position Travel speed: Hi When travel MPa 1.8 ± 0.1 Run either track idle. levers at 2} {18 ± 1} LS differential pressure = Pump {kg/cm half travel pressure – LS pressure
PC228US-8,PC228USLC-8
3.5 ± 1.0 {36 ± 10}
33.3 – 36.8 {340 – 375} 36.3 – 39.2 {370 – 400} 33.3 – 36.8 {340 – 375} 36.3 – 39.2 {370 – 400} 33.3 – 36.8 {340 – 375} 36.3 – 39.2 {370 – 400} 28.4 – 32.3 {290 – 330} 36.8 – 40.2 {375 – 410}
2.75 – 3.43 {28 – 35}
3.5 ± 1.0 {36 ± 10}
1.8 ± 0.1 {18 ± 1}
20-5
Standard value table Standard value table for machine
PC228US-8 PC228USLC-8
Category
Machine model
Item
Measurement conditions q q
Overrun of swing
q q q q
q
Time required to start swinging
q q
q
Swing
q
Time required to finish swinging
q q q q q q
Swing drift on a slope
q
q q q q
Leakage from swing motor
q q q
20-6
Hydraulic oil temperature: Within operating range Engine at high speed Power mode (P) Swing circle misalignment amount when stopping after one turn For measuring posture, see "Swing 1". Hydraulic oil temperature: Within operating 90° range Engine at high speed Power mode (P) Time required to swing from swing start position to 90 de180° grees and 180 degrees For measuring posture, see "Swing 1". Hydraulic oil temperature: Within operating range Engine at high speed Power mode (P) Time required for five more turns after making initial one turn For measuring posture, see "Swing 1". Hydraulic oil temperature: Within operating range Engine stopped On slope of 15 degrees, set upper structure crosswise and make match mark on inner race and outer race of swing circle. Match mark misalignment amount during 5 minutes For measuring posture, see "Swing 2". Power mode (P) Engine at high speed Hydraulic oil temperature: Within operating range Swing lock switch: ON Relieve swing circuit.
Unit
Standard value
Repair limit
deg. (mm)
Max. 100 (–)
Max. 130 (–)
sec.
3.1 ± 0.3
Max. 3.7
sec.
4.4 ± 0.4
Max. 5.5
sec.
27.3 (+3.6/-1.7)
Max. 33
mm
0
0
l/min
Max. 5
Max. 10
PC228US-8,PC228USLC-8
Standard value table Standard value table for machine
PC228US-8 PC228USLC-8
Category
Machine model
Item
Measurement conditions
Unit
q
Power mode (P) Engine at high speed Lo q Hydraulic oil temperature: 45 55 °C Travel speed (idle run- q Raise either track of the ground Mi ning) and measure time required to move five turns idle after finishing one turn. Hi q For measuring posture, see "Travel 1". q Power mode (P) Lo q Engine at high speed q Hydraulic oil temperature: 45 55 °C Travel speed (actual Mi q Measure time required to travel 20 running) m after run-up of at least 10 m on a level ground. Hi q For testing posture, see "Travel 2". q Power mode (P) q Engine at high speed q Hydraulic oil temperature: 45 - 55 °C q Measure deviation made during travel of 20 Travel deviation m after run-up of at least 10 m on a level ground. a Use a hard and level ground. a Measure dimension X. q For measuring posture, see "Travel 2 and 3" q Engine stopped q Hydraulic oil temperature: 45 - 55 °C q Park machine on slope of 12° with sprocket Hydraulic drift of travel faced to the uphill side. q Travel distance by travel drift in 5 minutes q For measuring posture, see "Travel 4".
Travel
q
q
Leakage from travel motor
q q
Hydraulic drift in work equipment
Work equipment
q
Whole work equipment (Drop at bucket tooth tip)
q
q
Boom cylinder (Retraction of cyl- q inder) q Arm cylinder (Extension of cylinder)
q q q q
Bucket cylinder (Retraction of cyl- q inder)
PC228US-8,PC228USLC-8
Engine at high speed Hydraulic oil temperature: 45 - 55 °C Lock shoes and relieve travel circuit. For measuring posture, see "Travel 5". Measure extraction or retraction distance of each cylinder and drop distance of bucket tooth tip in posture "Work equipment 1". Bucket: Full of earth and sand or rated load (14.1 kN {1,440 kg}) Measure on level and flat surface. Set lever to NEUTRAL. Engine stopped Hydraulic oil temperature: 45 - 55 °C Start measurement just after setting. Measure drop distance every 5 minutes and judge after 15 minutes. For measuring posture, see "Work equipment 1".
Standard value
Repair limit
STD
STD
LC
LC
51.3 ± 55.9 ± 46.2 – 50.3 – 5.1 5.6 60.5 66.0 sec.
37.5 ± 40.8 ± 33.8 – 36.7 – 3.8 4.1 45.0 49.0 26.5 ± 28.9 ± 25.2 – 26.0 – 1.3 1.4 29.9 32.7 24.0 ± 2.4
21.6 – 26.4
17.6 ± 1.8
15.8 – 19.3
13.1 ± 0.7
12.4 – 13.7
mm
Max. 150
Max. 250
mm
0
0
l/min
13.6
27.2
Max. 600
Max. 900
Max. 18
Max. 27
Max. 160
Max. 240
Max. 40
Max. 58
sec.
mm
20-7
Standard value table Standard value table for machine
PC228US-8 PC228USLC-8
Category
Machine model
Item
Measurement conditions
Unit
Standard value
q
Power mode (P) Engine at high speed Boom and q Hydraulic oil temperature: 45 - 55 °C bucket q Emergency work equipment actuation tooth switch: touched on Emergency (upper) ground k Since boom raise stroke end cushI ion function is not activated , large O impacts are made at stroke end. Boom cylinTherefore, perform the measureder fully ment on level and hard ground. extended q For testing posture, see "Work equipment 2". Arm cylinder q Power mode (P) fully q Engine at high speed retracted q Hydraulic oil temperature: 45 - 55 °C I q For measuring posture, see "Work O equipment 3". Fully extracted Bucket cylinder q Power mode (P) fully q Engine at high speed retracted q Hydraulic oil temperature: 45 - 55 °C I q For measuring posture, see "Work O equipment 4". Fully extracted q q
Boom
q q q
Time lag
q q
Arm
q q q q q
Bucket
q q
Internal leakage
q
20-8
RAISE LOWER IN OUT
sec.
Centre swivel joint
q q
3.7 ± 0.4
4.1 ± 0.4
Max. 5.2 Max. 5.2
2.8 ± 0.3
3.1± 0.3
Max. 4.4 Max. 4.4
3.5 ± 0.3
4.5 ± 0.4
Max. 4.5 Max. 5.2
STD
Demolition specification
Max. 3.5
CURL
2.7 ± 0.3
2.6 ± 0.3
2.8 ± 0.3
Max. 3.3 Max 3.4
1.9 ± 0.2
2.2 ± 0.2
Max. 2.7 Max. 2.9
Power mode (P) Time required to raise machine at the ground after bucket touches ground Engine at low speed Hydraulic oil temperature: 45 - 55 °C For measuring posture, see "Work equipment 5".
Max. 1.0
Max.1.2
Power mode (P) Period of time while arm stops momentarily Engine at low speed. sec. Hydraulic oil temperature: 45 - 55 °C For measuring posture, see "Work equipment 6".
Max.2.0
Max.2.8
Power mode (P) Period of time while the bucket stops momentarily Engine at low speed Hydraulic oil temperature: 45 - 55 °C For measuring posture, see "Work equipment 7".
Max. 1.0
Max. 3.6
4.5
20
10
50
Cylinders q
STD
Demolition specification
DUMP
Work equipment
Work equipment speed
q
Repair limit
Hydraulic oil temperature: 45 - 55 °C Engine at high speed Relieve the circuit to be measured.
cc/min .
PC228US-8,PC228USLC-8
Standard value table Standard value table for machine
PC228US-8 PC228USLC-8
Characteristics of PC flow control Pump swash plate sensor Ease of combined operation Category
Machine model
–
Item
Measurement conditions
Unit
Standard value
Repair limit
mm
Max. 200
Max. 220
All control levers in NEUTRAL condition
V
1.57 ± 0.20
1.57 ± 0.63
When running track idle (lever at travel end)
V
3.75 ± 0.20
3.75 ± 0.63
Hydraulic oil temperature: Within operating range Engine at high speed Power mode (P) Bucket rated load (0.8 m3: 14,110 N {1,440 kg}) On hard and level ground, set arm vertically and lower back of bucket to ground Time required for turning from 0 to 90° with boom raised For measuring posture, see "Combined 1".
sec.
q Engine at high speed Travel deviation q Hydraulic oil temperature: 45 - 55 °C during work equipa Use a hard and level ground. ment operation + a Measure dimension X. travel q For measuring posture, see "Travel 3".
q
Pump swash plate sensor output volt- q q age q q
q q
Time required for swinging from 0 to 90° with boom RAISE
q q q q q
Hydraulic oil temperature: Within operating range Engine at high speed Power mode (P) Travel speed: Hi Run either track idle
Hydraulic pump delivery
PC228US-8,PC228USLC-8
4.0 ± 0.4 (Reference value)
See "Performance of hydraulic pump" (next page).
20-9
Standard value table Standard value table for machine
PC228US-8 PC228USLC-8
Category
Machine model
Item
Measurement conditions
Hydraulic pump
q q q
Performance of hydraulic pump
q
q
Pump speed (rpm): 2,000 PC-EPC current value (mA): 440 Test pump delivery pressure (MPa {kg/cm2}): P1 Delivery pressure of another pump (MPa {kg/cm2}): P2 Average delivery pressure (MPa {kg/cm2}): Pp=(P1+P2)÷2
Unit
Standard value
Repair limit
l/min
Q (See graph)
Q (See graph)
a Bring pump delivery pressure P1 and P2 as close as possible to the average pressure when measuring. Avoid measuring the near turning point of the graph because the error increases there. a When measuring with the pump mounted on the machine, if it is impossible to set the engine speed to the specified speed by using the fuel control dial, take the pump delivery and the engine speed at the time of measurement, and use them as a base for calculating the pump delivery the specified speed.
20-10
PC228US-8,PC228USLC-8
Standard value table Standard value table for machine
Posture of machine for measuring performance and measurement procedure 20-1
Travel 1: Travel speed (idle running)
Spool travel
Travel 2: Travel speed (actual running) and travel deviation Swing 1: Overrun of swing, time required to start swing and time required to finish swing
Travel 3: Travel deviation
Swing 2: Swing drift on a slope
PC228US-8,PC228USLC-8
20-11
Standard value table Standard value table for machine
Travel 4: Hydraulic drift of travel
Work equipment 2: Work equipment speed (boom)
Travel 5: Leakage from travel motor
Work equipment 3: Work equipment speed (arm)
Work equipment 1:Hydraulic drift in work equipment
Work equipment 4: Work equipment speed (bucket)
20-12
PC228US-8,PC228USLC-8
Standard value table Standard value table for machine
Work equipment 5: Time lag (boom)
Combined 1: Ease of combined operation
Work equipment 6: Time lag (arm)
Work equipment 7: Time lag (bucket)
PC228US-8,PC228USLC-8
20-13
Standard value table Standard value table for machine
20-14
PC228US-8,PC228USLC-8
SEN0533410-00
30-1
PC228US-8,PC228USLC-8
HYDRAULIC EXCAVATOR PC228US-8 PC228USLC-8 Shop Manual
Machine model
Serial number
PC228US-8 PC228USLC-8
50001 and up 50001 and up
30 Testing and adjusting
PC228US-8,PC228USLC-8
30-1
Contents
Contents 30 Testing and adjusting Tool for testing, adjusting and troubleshooting .............................................................................. 30-3 Tools for testing, adjusting, and troubleshooting ........................................................................ 30-3 Engine and cooling system ............................................................................................................ 30-9 Testing engine speed.................................................................................................................. 30-9 Testing intake air pressure (boost pressure) .............................................................................. 30-10 Testing exhaust gas colour ......................................................................................................... 30-11 Testing and adjusting valve clearance........................................................................................ 30-12 Testing compression pressure.................................................................................................... 30-14 Testing blow-by pressure............................................................................................................ 30-17 Testing engine oil pressure......................................................................................................... 30-18 Handling fuel system parts.......................................................................................................... 30-19 Releasing remaining pressure from fuel system......................................................................... 30-20 Testing fuel pressure .................................................................................................................. 30-21 Cylinder cut-out test mode .......................................................................................................... 30-24 No-injection cranking .................................................................................................................. 30-25 Checking fuel delivery, return rate and leakage.......................................................................... 30-26 Bleeding air from fuel circuit........................................................................................................ 30-29 Testing fuel circuit for leakage .................................................................................................... 30-30 Testing and adjusting air conditioner compressor belt tension ................................................... 30-31 Replacing fan belt ....................................................................................................................... 30-32 Undercarriage and frame ............................................................................................................... 30-33 Testing swing circle bearing clearance ....................................................................................... 30-33 Checking and adjusting track tension ......................................................................................... 30-34 Hydraulic system............................................................................................................................ 30-35 Testing and adjusting oil pressure in work equipment, swing and travel circuits........................ 30-35 Testing control circuit source pressure ....................................................................................... 30-39 Testing and adjusting oil pressure in pump PC control circuit .................................................... 30-40 Testing and adjusting oil pressure in pump LS control circuit..................................................... 30-44 Testing solenoid valve output pressure ...................................................................................... 30-49 Testing PPC valve output pressure ............................................................................................ 30-52 Adjusting play of work equipment and swing PPC valves .......................................................... 30-54 Measuring and adjusting quick coupler control valve output pressure ....................................... 30-55 Testing pump swash plate sensor .............................................................................................. 30-56 Isolating the parts causing hydraulic drift of work equipment ..................................................... 30-57 Releasing remaining pressure from hydraulic circuit .................................................................. 30-59 Testing oil leakage amount ......................................................................................................... 30-60 Bleeding air from each part......................................................................................................... 30-62 Work equipment............................................................................................................................. 30-64 Replacement procedure of boom angle potentiometer............................................................... 30-64 Cab and its attachments ................................................................................................................ 30-65 Checking cab tipping stopper...................................................................................................... 30-65 Adjusting mirrors ......................................................................................................................... 30-66 Angle adjustment of rear view camera........................................................................................ 30-68 Electrical system ............................................................................................................................ 30-70 Special function of machine monitor (EMMS)............................................................................. 30-70 Handling voltage circuit of engine controller ............................................................................... 30-126 Preparatory work for troubleshooting of electrical system .......................................................... 30-127 Procedure for testing diodes ....................................................................................................... 30-132 Pm clinic......................................................................................................................................... 30-133 Pm clinic service ......................................................................................................................... 30-133
30-2
PC228US-8,PC228USLC-8
Tool for testing, adjusting and troubleshooting Tools for testing, adjusting, and troubleshooting
Tool for testing, adjusting and troubleshooting Testing and adjusting item Symbol
Part number
Testing intake air pressure (boost pressure)
799-201-2202 Boost gauge kit
1 -101 – 200 kPa {-760 – 1,500 mmHg}
799-201-9001 Handy smoke checker Commercially Smoke meter available 795-799-1131 Gear Commercially Feeler gauge available 795-502-1590 Compression gauge 795-799-6700 Puller 795-790-4410 Adapter 6754-11-3130 Gasket 799-201-1504 Blow by checker 795-790-3300 Blow-by testing tool
1
R 1
Testing exhaust gas colour A Adjustment of valve clearance
2 1
B
2 1 2 3 4 1 2
Testing compression presC sure Testing blow-by pressure
D
Part name
Q'ty
Tools for testing, adjusting, and troubleshooting
799-101-5002 Hydraulic tester 1
Testing engine oil pressure E
790-261-1204 Digital hydraulic tester 2
799-401-2320 Hydraulic tester 799-101-5002 Hydraulic tester
1 790-261-1204 Digital hydraulic tester Testing fuel pressure
F
2 3 4 5 6 1 2 3
Testing fuel discharge, return rate and leakage
4 G 5 6 7
Testing swing circle bearing clearance
H
Measuring and adjusting oil pressure in work equipJ ment, swing, and travel circuits
795-790-4430 Adapter 6215-81-9710 O-ring 799-401-2320 Gauge 795-790-5110 Screw 799-201-2202 Boost gauge kit 796T-501-1110 Adapter 795-790-4700 Tester kit 795-790-6700 Adapter 6754-71-5340 Connector 6754-71-5350 Washer Commercially Measuring cylinder available Commercially Stopwatch available Commercially Hose available Commercially Hose available Commercially Dial gauge available 799-101-5002 Hydraulic tester
1 790-261-1204 Digital hydraulic tester 2
799-101-5220 Nipple 07002-11023 O-ring 799-101-5002 Hydraulic tester
Testing basic pressure of control circuit
1 K
790-261-1204 Digital hydraulic tester 2
PC228US-8,PC228USLC-8
799-101-5220 Nipple 07002-11023 O-ring
1
Remarks
Bosch index: 0 to 9
1 1 Intake: 0.25 mm, Exhaust: 0.51 mm 1 0 – 7 MPa {0 – 70 kg/cm2} 1 For 107E-1 engine 1 For 107E-1 engine 1 For 107E-1 engine 1 0 – 5 kPa {0 – 500 mmH2O} 1 for 107E-1 engine Pressure gauge: 2.5, 6, 40, 60MPa 1 {25, 60, 400, 600 kg/cm2} Pressure gauge: 60 MPa 1 {600 kg/cm2} 1 Pressure gauge: 1.0 MPa {10 kg/cm2} Pressure gauge: 2.5, 6, 40, 60MPa 1 {25, 60, 400, 600 kg/cm2} Pressure gauge: 60 MPa 1 {600 kg/cm2} 1 10 x 1.0 mm o R1/8 1 1 Pressure gauge: 1.0 MPa {10 kg/cm2} 1 1 1 Size: 12 x 1.5 mm 1 1 1 1 1 1 1 Internal dimension 14 mm 1 Internal dimension 8 mm 1 Pressure gauge: 2.5, 6, 40, 60 MPa {25, 60, 400, 600 kg/cm2} Pressure gauge: 60 MPa 1 {600 kg/cm2} 2 Size: 10 x 1.25 mm 2 Pressure gauge: 2.5, 6, 40, 60 MPa 1 {25, 60, 400, 600 kg/cm2} Pressure gauge: 60 MPa 1 {600 kg/cm2} 1 Size: 10 x 1.25 mm 1 1
30-3
Testing and adjusting item Symbol
Part number
Part name
799-101-5002 Hydraulic tester Measuring and adjusting oil pressure in pump PC control circuit
1 L
790-261-1204 Digital hydraulic tester 2
799-101-5220 Nipple 07002-11023 O-ring 799-101-5002 Hydraulic tester
1 Pump LS control Testing and adjusting circuit oil pressure
790-261-1204 Digital hydraulic tester M 2 3
799-101-5220 Nipple 07002-11023 O-ring Differential pressure 799-401-2701 gauge 799-101-5002 Hydraulic tester
1
Testing solenoid valve outN put pressure
790-261-1204 Digital hydraulic tester 2
799-401-3100 Adapter 02896-11008 O-ring 799-101-5002 Hydraulic tester
1 Testing PPC valve output pressure
790-261-1204 Digital hydraulic tester
P
799-401-3100 Adapter 799-401-3200 Adapter 3 796T-562-1110 Adapter Commercially Q Measuring cylinder available 2
Testing oil leakage Measuring coolant temperature and oil temperature Testing operating effort and depressing effort Measuring stroke and hydraulic drift Testing work equipment speed Measuring voltage and resistance Removal and installation of boost pressure and temperature sensors Removal and installation of engine oil pressure sensor Removal and installation of engine coolant temperature sensor
30-4
– – – – –
Q'ty
Tool for testing, adjusting and troubleshooting Tools for testing, adjusting, and troubleshooting
Remarks
Pressure gauge: 2.5, 6, 40, 60 MPa {25, 60, 400, 600 kg/cm2} Pressure gauge: 60 MPa 1 {600 kg/cm2} 4 Size: 10 x 1.25 mm 4 Pressure gauge: 2.5, 6, 40, 60 MPa 1 {25, 60, 400, 600 kg/cm2} Pressure gauge: 60 MPa 1 {600 kg/cm2} 4 Size: 10 x 1.25 mm 4 1
1 50 MPa {500 kg/cm2} Pressure gauge: 2.5, 6, 40, 60 MPa {25, 60, 400, 600 kg/cm2} Pressure gauge: 60 MPa 1 {600 kg/cm2} 1 Size: 02 1 Pressure gauge: 2.5, 6, 40, 60 MPa 1 {25, 60, 400, 600 kg/cm2} Pressure gauge: 60 MPa 1 {600 kg/cm2} 1 Size: 02 1 Size: 03 1 Size: 12 x 1.5 mm 1
1
799-101-1502 Digital thermometer
1 -99.9 – 1,299 °C
79A-264-0021 Push-pull scale 79A-264-0091 Push-pull scale Commercially Ruler available Commercially Stopwatch available Commercially Multimeter available
1 0 – 294 N {0 – 30 kg} 1 0 – 490 N {0 – 50 kg} 1 1 1
–
Commercially Hexlobe (TORX) available wrench
1
3.26 mm TORX wrench (KTC Q4T15 or equivalent)
–
795-799-6210 Socket
1 27 mm deep socket
–
795T-981-1010 Socket
1
19 mm deep socket (MITOLOY 4ML-19 or equivalent)
PC228US-8,PC228USLC-8
Testing and adjusting item Symbol
Part number
Part name
799-601-4101 or T-adapter assembly 799-601-4201
Troubleshooting for engine, controller sensor, and actuator
Troubleshooting for machine wiring harness
PC228US-8,PC228USLC-8
–
–
Q'ty
Tool for testing, adjusting and troubleshooting Tools for testing, adjusting, and troubleshooting
Remarks
1
799-601-4350 q
T-box
795-799-5530 q
Socket
799-601-4140 q
Socket
799-601-4230 q
Socket
799-601-4330 q
Socket
799-601-4340 q
Socket
799-601-4130 q
T-adapter
799-601-4190 q
T-adapter
799-601-4211 q
T-adapter
799-601-4220 q
T-adapter
799-601-4260 q
Adapter for DTP
799-601-9040 q
T-adapter
For DRC60, ECONO (Not included in Kit No. 799-601-4201) Engine (CRI-T3) water temperature sensor For (PACKARD 2P) Engine (CRI-T3) fuel temperature sen1 sor For (PACKARD 2P) Engine (CRI-T3) oil temperature sensor For (PACKARD 2P) Engine (CRI-T3) ambient pressure 1 sensor For (AMP 3P) Engine (CRI-T3) boost pressure sen1 sor and boost temperature sensor For (SUMITOMO 4P) Engine (CRI-T3) G (Backup) 1 For sensor (SUMITOMO 3P) For engine (CRI-T3) supply pump 1 PCV 1 and PCV 2 sensors (SUMITOMO 3P) Engine (CRI-T3) NE sensor 1 For (FRAMATOME 3P) Engine (CRI-T3) common rail fuel 1 pressure For sensor (AMP 3P) For engine controller DRC26-50P 1 (Not included in Kit No. 799-601-4201) For engine controller DRC26-60P 1 (Not included in Kit No. 799-601-4201) For engine controller DTP-4P 1 (Included in Kit Nos. 799-601-9000 and 799-601-9100, too) For DT 4P (Included in Kit Nos. 1 799-601-9000 and 799-601-9200, too)
799-601-9020 q
T-adapter
For DT 2P (Included in Kit Nos. 1 799-601-9000 and 799-601-9200, too)
1
799-601-9000 or 799-601-9100 T-adapter assembly or 799-601-9300 1 For ECONO (Max. 24P) 799-601-9320 q T-box 799-601-4101 q T-adapter assembly 1 For DRC60, ECONO (Max. 60P) 799-601-4350 q T-box 799-601-7000 or 799-601-7100 or T-adapter assembly 799-601-7400 or 799-601-8000 For ECONO (Max. 21P) 1 799-601-2600 q T-box (Not included in Kit No. 799-601-7000) 1 For AMP040 16P 799-601-7210 q T-adapter 799-601-7220 q T-adapter 1 For AMP040 20P 1 For M 2P 799-601-7090 q T-adapter
30-5
Testing and adjusting item Symbol
Troubleshooting for machine wiring harness
–
Part number
Part name
799-601-7120 q 799-601-7130 q 799-601-7340 q 799-601-7140 q
T-adapter T-adapter T-adapter T-adapter
799-601-7350 q
T-adapter
799-601-7170 q
T-adapter
799-601-7330 q
T-adapter
799-601-7060 q
T-adapter
799-601-7310 q
T-adapter
799-601-7070 q
T-adapter
799-601-7320 q
T-adapter
799-601-7010 q T-adapter 799-601-7020 q T-adapter 799-601-7040 q T-adapter 799-601-7500 T-adapter assembly 799-601-7520 q T-adapter 799-601-9000 or T-adapter assembly 799-601-9200 799-601-9040 q
T-adapter
799-601-9020 q 799-601-9030 q 799-601-9050 q 799-601-9110 q 799-601-9120 q 799-601-9130 q 799-601-9140 q
T-adapter T-adapter T-adapter T-adapter T-adapter T-adapter T-adapter
799-601-9270 q
T-adapter
799-601-9300 T-adapter assembly 799-601-9360 q T-adapter 799-601-9350 q T-adapter 799-601-7360 T-adapter 799-601-7370 T-adapter 799-601-9420 T-adapter
30-6
Q'ty
Tool for testing, adjusting and troubleshooting Tools for testing, adjusting, and troubleshooting
Remarks
1 For M 4P 1 For M 6P 1 For M 8P (Kit No. is not registered) 1 For S 8P For S 12P (white) (Kit No. is not regis1 tered) 1 For S 16P (blue) For S 16P (white) (Kit No. is not regis1 tered) For SWP 8P 1 (Not included in Kit No. 799-601-8000) For SWP 12P 1 (Not included in Kit No. 799-601-8000) For SWP 14P 1 (Not included in Kit No. 799-601-8000) For SWP 16P (Kit No. is not regis1 tered) 1 For X 1P 1 For X 2P 1 For X 4P 1 For AMP070 12P
For DT 4P (Included in Kit Nos. 799-601-4101 and 799-601-4201, too) 1 For DT 2P 1 For DT 3P 1 For DT 6P 1 For DT 12P (gray) 1 For DT 12P (black) 1 For DT 12P (green) 1 For DT 12P (brown) For HD36 24-21P 1 (Not include in Kit No. 799-601-9200) (Include in Kit No. 799-601-9100, too) 1
1 For pump controller DRC26-24P 1 For pump controller DRC26-40P 1 For 5P-relay (Kit No. is not registered) 1 For 6P-relay (Kit No. is not registered) For AMP 3P (Pressure sensor) 1 (Included in Kit Nos. 799-601-4101 and 799-601-4201, too)
PC228US-8,PC228USLC-8
Tool for testing, adjusting and troubleshooting Tools for testing, adjusting, and troubleshooting
Note: Komatsu will not be held responsible for special tools manufactured according to these sketches. -: Socket
F6 Adapter
PC228US-8,PC228USLC-8
30-7
Tool for testing, adjusting and troubleshooting Tools for testing, adjusting, and troubleshooting
Note: Komatsu will not be held responsible for special tools manufactured according to these sketches. P3 Adapter
30-8
PC228US-8,PC228USLC-8
Engine and cooling system Testing engine speed
Engine and cooling system Testing engine speed a Test the engine speed with the monitoring function of the machine monitor. a Measure the engine speed under the following conditions. q Engine coolant temperature: within operating range q Hydraulic oil temperature: within operating range 1. Preparation work Operate the machine monitor so that the engine speed can be monitored. a For the operating method of the machine monitor, see “Special functions of machine monitor”. a Monitoring code: 01002 Engine speed
2. Testing low idle speed 1) Start the engine and set the fuel control dial to the low idle (MIN) position. 2) Set all the control levers and pedals for work equipment, swing, and travel to the neutral position and test the engine speed. 3. Testing high idle speed 1) Start the engine and set the fuel control dial to the full speed (MAX) position. 2) Set the working mode in the Power Mode (P) and set the auto-deceleration to OFF. 3) Set all control the levers and pedals for work equipment, swing, and travel to the neutral position and test the engine speed.
3) Operate the left work equipment control lever to relieve the arm circuit at the IN stroke end and test the engine speed. 5. Testing speed (around rated speed) at 2-pomp relief + one-touch power maximizing function 1) Start the engine and operate the arm cylinder to the IN stroke end. 2) Set the fuel control dial to the full speed (MAX) position and set the working mode to the Power Mode (P). 3) While operating the left work equipment control lever to relieve the arm circuit at the IN stroke end and pressing the one-touch power maximizing switch, test the engine speed. a The one-touch power maximizing function is reset automatically in approximately 8.5 seconds even if the switch is kept pressed. Accordingly, test the engine speed in that period. a You may check with the swing lock switch ON (In this case, you do not need to operate the power maximizing switch.) 6. Testing auto-deceleration speed 1) Start the engine, set the fuel control dial to the high idle position (MAX), and set the auto-decelerator to ON. 2) Set all the control levers and pedals for work equipment, swing, and travel to the neutral position and measure the engine speed when the auto-deceleration operates. a The engine speed lowers to a certain level approximately 5 seconds after all the levers and pedals are set to neutral. This level is the auto-deceleration speed.
4. Testing 2-pomp relief speed 1) Start the engine and operate the arm cylinder to the IN stroke end. 2) Set the fuel control dial to the full speed (MAX) position and set the working mode to the Power Mode (P).
PC228US-8,PC228USLC-8
30-9
Engine and cooling system Testing intake air pressure (boost pressure)
Testing intake air pressure (boost pressure) a Boost pressure can be checked with monitoring code (36500). a Testing tools for intake air pressure (boost pressure) Symbol R
Part number Part name 799-201-2202 Boost gauge kit
k Stop the machine on the level ground and
lower the work equipment to the ground. a Test the intake air pressure under the following conditions. q Engine coolant temperature: within operating range q Hydraulic oil temperature: within operating range 1. Open the engine hood and remove intake air pressure pickup plug (1) from the intake air connector.
2. Install nipple [1] of boost pressure gauge kit R and connect it to gauge [2].
30-10
3. Run the engine at middle or higher speed and bleed oil from the hose. a Insert the hose connector into the gauge halfway to open the self-seal on the hose side repeatedly, and the oil will be purged. a If Pm kit (A) is available, you may use the air-bleeding coupling (790-261-1130) in that kit. a If oil is left in the hose, the gauge does not work. Accordingly, be sure to purge the oil. 4. Set the working mode to the Power Mode (P) and set swing lock switch to ON position. a If the swing lock switch is turned to the ON position, the main relief valve is set for high-pressure relief. 5. While running the engine at full speed, relieve the arm circuit at the IN and measure the intake air pressure.
6. After finishing test remove the testing tools and return the removed parts.
PC228US-8,PC228USLC-8
Engine and cooling system Testing exhaust gas colour
Testing exhaust gas colour a Testing tools for exhaust gas colour Symbol 1 A 2
Part number Part name 799-201-9001 Handy smoke checker Commercially Smoke meter available
k Stop the machine on the level ground and
lower the work equipment to the ground.
k Be careful not to touch any hot part when re-
moving or installing the testing tools. a Test the exhaust gas colour under the following conditions. q Engine coolant temperature: within operating range a If an air source and an electric power source are not available in the field, use handy smoke checker A1. When recording official data, use smoke meter A2. 1. Testing by using handy smoke checker A1 1) Stick a sheet of filter paper to smoke checker A1. 2) Insert the exhaust gas intake pipe in exhaust pipe (1). 3) Start the engine and operate the handle of smoke checker A1 when the engine is accelerated suddenly and when it is running at high idle so that the filter paper absorbs the exhaust gas. a Absorbing time: 1.4 ± 0.2 sec.
4) Remove the filter paper and compare it with the attached scale for judgement. 5) After finishing test remove the testing tools and return the removed parts. 2. Checking by using smoke meter A2 1) Insert probe [1] of smoke meter A2 in the outlet of the exhaust pipe (1) and fix it to the exhaust pipe by using a clip.
PC228US-8,PC228USLC-8
2) Connect the probe hose, plug of the accelerator switch, and air hose to smoke meter A2. a Limit the supplied air pressure to 1.5 MPa {15 kg/cm2} or below. 3) Connect the power cable to an AC receptacle. a Check that the smoke meter power switch is in the OFF position, before connecting the power cable to the receptacle. 4) Loosen the cap nut of the suction pump and place the filter paper. a Place the filter paper securely so that the exhaust gas does not leak. 5) Turn on the power switch of smoke meter A2.
6) Start the engine and depress the accelerator pedal of smoke meter A2 when the engine is accelerated suddenly and when it is running at high idle in order to collect the exhaust gas into the filter paper. 7) Put the polluted filter paper on non-polluted filter paper (more than 10 sheets) in the filter paper holder, and read the indicated value. 8) After finishing test remove the testing tools and return the removed parts.
30-11
Engine and cooling system Testing and adjusting valve clearance
Testing and adjusting valve clearance a Valve clearance testing and adjustment tools Symbol 1 B 2
Part number Part name 795-799-1131 Gear Commercially Feeler gauge available
3. Remove cylinder head cover (4). a Remove aeration hose (5) also.
k Stop the machine on the level ground and
lower the work equipment to the ground. a Test and adjust the valve clearance under the following condition. q Engine coolant temperature: normal temperature 1. Open the engine hood and remove plate (1).
4. Remove plug (6) located above the starting motor and insert gear B1.
2. Remove breather connector (2) and muffler cover plate (3) at the rear of the cylinder head cover. a Connector (2) has an O-ring, so take care not to fall the O-ring.
30-12
PC228US-8,PC228USLC-8
Engine and cooling system Testing and adjusting valve clearance
5. Rotate the crankshaft in the normal direction by using gear B1 to match wide slit (b) in the speed sensing ring with top (a) of the projection of the front cover. a When seen from the air conditioner compressor side, top (a) of the projection must be within the range of wide slit (b). a If top (a) of the projection and yellow paint of wide slit (b) can be checked, you may match them. k If this positioning is applied, note that the No. 1 or No. 6 cylinder is not at the compression top dead centre (TDC).
6. Check the movement of the rocker arm of the No. 1 cylinder to determine the valve to be adjusted. a If you can move the rocker arm of air intake valves (IN) with the hand by the valve clearance, adjust the valves marked with Q in the valve arrangement drawing. a If you can move the rocker arm of exhaust valves (EX) by hand by the valve clearance amount, adjust the valves marked with q in the valve arrangement drawing. a Valve arrangement drawing
7. Adjust the valve clearance according to the following procedure. 1) While fixing adjustment screw (7), loosen locknut (8). 2) Insert feeler gauge B2 in the clearance between rocker arm (9) and crosshead (10) and adjust the valve clearance with adjustment screw (7). a With the feeler gauge inserted, turn the adjustment screw to a degree that you can move the feeler gauge with some resistance. 3) While fixing adjustment screw (7), tighten locknut (8). 3 Locknut: 24 ± 4 Nm {2.45 ± 0.41 kgm} a After tightening the locknut, check the valve clearance again.
8. Rotate the crankshaft in the normal direction by one turn according to step 5 and match wide slit (b) with top (a) of the projection. 9. Adjust the clearances of the other valves according to steps 6 - 7. a If the valves marked with Q in the valve arrangement drawing were adjusted in steps 6 and 7, adjust the valves marked with q. a If the valves marked with q in the valve arrangement drawing were adjusted in steps 6 - 7, adjust the other valves marked with Q. 10. After completing adjustment, remove the adjusting tools and return the removed parts. k Be sure to remove gear B1. 3 Cylinder head cover mounting nut: 24 ± 4 Nm {2.45 ± 0.41 kgm}
PC228US-8,PC228USLC-8
30-13
Engine and cooling system Testing compression pressure
Testing compression pressure a Testing tools for compression pressure Symbol 1 2 C 3 4
Part number 795-502-1590 795-799-6700 795-790-4410 6754-11-3130
3. Disconnect high pressure fuel tube (3).
Part name Compression gauge Puller Adapter Gasket
k Stop the machine on the level ground and
lower the work equipment to the ground. a Test the intake air pressure under the following condition. q Engine oil temperature: 40 - 60 °C k When testing the compression pressure, take care not to burn yourself on the exhaust manifold, muffler, ect. or get caught in a rotation part. 1. Open the engine hood and remove cylinder head cover (1). a For the removal procedure, see "Adjusting valve clearance". 2. Disconnect injector harness connector (2) and shift the harness.
4. Loosen injector terminal nuts (4) and remove the harness terminals from the injector. 5. Set the cylinder to be tested to the compression top dead centre. a See "Adjusting valve clearance" for the barring method. 6. Remove rocker arm assembly (5).
30-14
PC228US-8,PC228USLC-8
Engine and cooling system Testing compression pressure
7. Remove retainer (6) and remove fuel inlet connector (7).
14. Adjust the valve clearances. a See "Adjusting valve clearance".
8. Remove holder (8). 9. Remove injector (9). a Remove the injector by using tool C2 and utilizing impacts of the slide hammer. a Do not hold the upper part of the injector and pry the injector out.
15. Operate the machine monitor to set the engine to the cylinder cutout mode operation. a See the section of "Special functions of machine monitor". k If engine is not set to the cutout mode operation and set all the cylinders to inactive, the engine starts during testing, and that is dangerous. Be sure to set the engine to the all-cylinder cutout mode operation. 16. Rotate the crankshaft by the starting motor and test the compression pressure. a Read the pressure gauge pointer when it is stabilized.
10. Install gasket C4 to the end of adapter C3 and insert them into the injector mounting bore. 11. Fix adapter C3 by using the injector holder. a Tighten the holder mounting bolts alternately. 3 Injector holder mounting bolt : 8 ± 0.8 Nm {0.8 ± 0.08 kgm}
17. After finishing testing, remove the testing tools and return the removed parts. a Install the injector and high-pressure fuel tube according to the following procedure. 1) Set the injector to the cylinder head, while matching projection a with notch b. a Set the injector with the above mating position toward the fuel inlet connector pass-through.
12. Connect gauge assembly C1 to adapter C3. a If a small amount of oil is applied to the connecting portions of the adapter and gauge, air will not leak easily. 13. Install rocker arm assembly (5). 3 Rocker arm assembly mounting bolt : 36 ± 5 Nm {3.67 ± 0.51 kgm}
PC228US-8,PC228USLC-8
30-15
Engine and cooling system Testing compression pressure
2) Tighten injector holder mounting bolts (10) by 3 – 4 turns. 3) Set fuel inlet connector (7). a Press it in until you feel the O-ring clicks in. 4) Loosely install the inlet connector (7) by using retainer (6). 3 Inlet connector retainer : 15 ± 5.0 Nm {1.5 ± 0.5 kgm} 5) Tighten injector holder mounting bolts (10) alternately. 3 Injector holder mounting bolt : 8 ± 0.8 Nm {0.8 ± 0.08 kgm} 6) Tighten retainer (6) of the fuel inlet connector. 3 Inlet connector retainer : 50 ± 5.0 Nm {5.1 ± 0.5 kgm}
18. After installing the rocker arm assembly, adjust the valve clearance. For details, see "Adjusting valve clearance". 3 Rocker arm assembly mounting bolt : 36 ± 5 Nm {3.67 ± 0.51 kgm} 19. Tighten the injector terminal nuts with the following torque. 3 Terminal nut : 1.5 ± 0.25 Nm {0.15 ± 0.025 kgm} a Check that the injector wiring harness does not interfere with the rocker arm. 20. Tighten the head cover mounting nuts to the following torque. 3 Head cover mounting nut : 24 ± 4 Nm {2.45 ± 0.41 kgm}
7) Tighten the high pressure fuel tube (3) sleeve nuts from the head side first, and then the common rail side. 3 Sleeve nut: 35 ± 3.5 Nm {3.6 ± 0.4 kgm}
30-16
PC228US-8,PC228USLC-8
Engine and cooling system Testing blow-by pressure
Testing blow-by pressure a Testing tools for blow-by pressure Symbol 1 D 2
Part number Part name 799-201-1504 Blowby checker 795-790-3300 Blowby testing tool
k Stop the machine on the level ground and
lower the work equipment to the ground. a Test the blowby pressure under the following conditions. q Engine coolant temperature: within operating range q Hydraulic oil temperature: within operating range 1. Install tool and adapter [1] of blowby checker D1 or blowby tool D2 to breather hose (1) and connect gauge [2].
4. After finishing test remove the testing tools and return the removed parts.
2. Start the engine, set the working mode to the Power Mode (P), and turn the swing lock switch ON. a If the swing lock switch is turned ON, the main relief valve is set for high-pressure relief. 3. While running the engine at full speed, relieve the arm circuit by arm IN operation and test the blowby pressure. a Read the gauge for blowby pressure when the pointer is stabilized.
PC228US-8,PC228USLC-8
30-17
Engine and cooling system Testing engine oil pressure
Testing engine oil pressure a Testing tools for engine oil pressure Symbol E
1 2
Part number Part name 799-101-5002 Hydraulic tester 790-261-1204 Digital hydraulic tester 799-401-2320 Hydraulic tester
k Stop the machine on the level ground and
3. Start the engine and turn the auto-decelerator OFF. 4. Test the oil pressure during low idle and high idle.
lower the work equipment to the ground. a Measure the engine oil pressure under the following condition. q Engine coolant temperature: within operating range 1. Open the side cover of the pump room and remove oil pressure pickup port plug (1) from the engine oil filter head.
5. After finishing test remove the testing tools and return the removed parts.
2. Install nipple [1] of hydraulic tester E1 and connect hydraulic tester E2.
30-18
PC228US-8,PC228USLC-8
Engine and cooling system Handling fuel system parts
Handling fuel system parts a Precautions in Inspection and Maintenance of Fuel System The common rail fuel injection system (CRI) consists of more precise parts than the conventional fuel injection pump and nozzles. If foreign matter enters this system, it can cause a trouble. During inspection and maintenance of the fuel system, pay more attention to foreign matters than in case of usual fuel injection system and wash the system carefully with clean fuel if dusts enter the system. a Precautions for replacing fuel filter cartridge Be sure to use the Komatsu genuine fuel filter cartridge. The common rail fuel injection system (CRI) consists of more precise parts than the conventional fuel injection pump and nozzles. It employs a high-efficiency special filter to prevent foreign matter from entering it. If a filter other than the genuine one is used, the fuel system may have a trouble. Accordingly, never use such a filter.
PC228US-8,PC228USLC-8
30-19
Engine and cooling system Releasing remaining pressure from fuel system
Releasing remaining pressure from fuel system a Pressure is generated in the low-pressure circuit and high-pressure circuit of the fuel system while the engine is running. Low-pressure circuit: Feed pump – Fuel main filter – Supply pump High-pressure circuit: Supply pump – Common rail – Injector a The pressure in both low-pressure circuit and high-pressure circuit lowers to a safety level automatically 30 seconds after the engine is stopped. a Before the fuel circuit is checked and its parts are removed, the remaining pressure in the fuel circuit must be released completely. Accordingly, observe the following. k Before checking the fuel system or removing its parts, wait at least 30 seconds after stopping the engine until the pressure remaining in the fuel circuit is released. (Do not start the work just after stopping the engine because there is the remaining pressure.)
30-20
PC228US-8,PC228USLC-8
Engine and cooling system Testing fuel pressure
Testing fuel pressure a Testing tools for fuel pressure Symbol 1 2 F
3 4 5 6
Part number Part name 799-101-5002 Hydraulic tester 790-261-1204 Digital hydraulic tester Adapter 795-790-4430 (10 x 1.0 mm o R1/8) 6215-81-9710 O-ring 799-401-2320 Gauge 795-790-5110 Screw 799-201-2202 Boost gauge kit Adapter 796T-501-1110 (12 x 1.5 mm o R1/8)
k Stop the machine on the level ground and
lower the work equipment to the ground. a Test only the fuel pressure in the low-pressure circuit from the feed pump through the fuel main filter to the supply pump and the return circuit from the supply pump/common rail/injector to fuel tank. k The pressure in the high-pressure circuit from the supply pump through the common rail to the injectors is very high, so it cannot be tested. 1. Testing pressure in low-pressure fuel circuit 1) Open the engine hood and remove fuel pressure pickup port plug (1) from the fuel main filter head.
2) Install adapter F2 and nipple [1] of the hydraulic tester F1 and connect them to gauge of boost gauge kit F3. a Use the oil pressure gauge of 2.5 MPa {25 kg/cm2}.
PC228US-8,PC228USLC-8
3) Run the engine at low idle and measure the pressure in the low-pressure fuel circuit. a If the pressure in the low-pressure fuel circuit is in the following range, it is normal. At low idle During cranking k If
0.5 – 1.3MPa {5.1 – 13.3 kg/cm2} 0.3 – 1.1MPa {3.1 – 11.3 kg/cm2}
the engine cannot be started, you may perform the measurement while rotating the engine by the starting motor. However, do not crank the engine for more than 20 seconds continuously for protection of the starting motor.
4) After finishing test remove the testing tools and return the removed parts. 3 Fuel pressure pickup port plug: 10 ± 2 Nm {1.0–0.2 kgm}
30-21
Engine and cooling system Testing fuel pressure
2. Testing pressure in fuel return circuit
1) Open the engine hood and remove fuel pressure pickup port plug (2) from the fuel return block.
4) After finishing test remove the testing tools and return the removed parts. 3 Fuel pressure pickup port plug: 24 ± 4 Nm {2.4 ± 0.4 kgm} 2) Install adapter F6 and nipple [1] of the hydraulic tester F1 and connect them to gauge F3.
3. Testing pressure in negative pressure fuel circuit 1) Open the engine hood and remove joint bolt (2) of fuel hose (1) between the pre-filter and supply pump from supply pump (3).
3) Run the engine at low idle and measure the pressure in the fuel return circuit. a If the pressure in the fuel return circuit is in the following range, it is normal. At low idle During cranking
Max. 0.02 MPa {Max. 0.19 kg/cm2}
k If the engine cannot be started, you may
perform the measurement while rotating the engine by the starting motor. However, do not crank the engine continuously for more than 20 seconds for protection of the starting motor.
30-22
PC228US-8,PC228USLC-8
Engine and cooling system Testing fuel pressure
2) Using tool F4 instead of joint bolt (2), connect fuel hose (1) to supply pump (3). a When installing tool F4, install the seal rings to both sides of eye joint of the fuel hose. 3 Tool F4: 19.6 – 29.4 Nm {2.0 – 3.0 kgm} 3) Connect tool F5 to F4.
4) Run the engine and measure the circuit negative pressure at high idle. Standard negative pressure in circuit: Max. -50.7 kPa {-380 mmHg} 5) If the negative pressure is higher than the criteria, the fuel pre-filter may be clogged. In this case, replace the fuel pre-filter and measure the pressure again. 6) After finishing test, remove the testing instruments and return the removed parts. 3 Joint bolt (2): 19.6 – 29.4 Nm {2.0 – 3.0 kgm}
PC228US-8,PC228USLC-8
30-23
Engine and cooling system Cylinder cut-out test mode
Cylinder cut-out test mode a The cylinder cut-out test mode operation means to run the engine with the fuel injectors of one or more cylinders disabled electrically to reduce the number of active cylinders. The purposes and effects of this operation are as follows. 1. This mode is used to find out a cylinder which does not output power properly (or, combustion in it is abnormal). 2. When a cylinder is cut out, if the engine speed and output power do not change from the normal operation (all-cylinder operation), that cylinder has one or more defects. The following problems can be considered: Gas leakage through the cylinder head gasket Defective injection from injector Defective piston or piston ring Defective valve mechanism Defective electrical system 3. The injector of each cylinder is separately controlled electronically in the common rail fuel injection system, so the cylinder cut-out test can be performed easily by the simple operations of the switches compared with the mechanical fuel injection system. This allows to find out a defective cylinder easily.
30-24
PC228US-8,PC228USLC-8
Engine and cooling system No-injection cranking
No-injection cranking a No-injection cranking means to crank the engine by using the starting motor while all the injections are stopped electrically. The purpose and effect of this operation are as follows. Before the engine is started after it or the machine has been stored for a long period, the no-injection cranking is performed to lubricate the engine parts and protect them from seizure.
PC228US-8,PC228USLC-8
30-25
Engine and cooling system Checking fuel delivery, return rate and leakage
Checking fuel delivery, return rate and leakage a Tools for inspecting fuel delivery, return, and leakage rates Symbol 1 2 3 4 G 5 6 7
Part number 795-790-4700 795-790-6700 6754-71-5340 6754-71-5350 Commercially available Commercially available Commercially available Commercially available
Part name Tester kit Adapter Connector Washer Measuring cylinder Stopwatch Hose (inner diameter 14 mm) Hose (inner diameter 8 mm)
a Prepare a container of approximately 20 l to receive the fuel flowing out during the test. k Stop the machine on the level ground and
lower the work equipment to the ground. 1. Testing supply pump delivery 1) Loosen clamp (2) of discharge tube (1) of the supply pump and disconnect tube (1).
2) Install test hose G6 to the nipple on the discharge side of the supply pump. a Tie the hose with a wire etc. a Adjust the route of the test hose so that it does not slacken and put its end in an container.
3) Crank the engine for 30 seconds and measure the discharged fuel by using measuring cylinder G4. a Do not crank the engine for more than 30 seconds to protect the starting motor in any case other than this test. a If the supply pump delivery is in the following standard range, it is normal. At cranking speed (125 rpm) At cranking speed (150 rpm)
75 cc or more 90 cc or more
4) Remove the measuring tools after the measurement and return the removed parts to their original position. 3 Tube sleeve nut: 35 ± 4 Nm {3.6 ± 0.4 kgm} 3 Clamp mounting bolt: 10 ± 2 Nm {1.0 ± 0.2 kgm} 2. Testing supply pump return rate 1) Open the engine hood and disconnect return hose (1) of the supply pump. a The return hose is connected by a quick coupler.
30-26
PC228US-8,PC228USLC-8
Engine and cooling system Checking fuel delivery, return rate and leakage
5) After finishing test remove the testing tools and return the removed parts. a When measuring the leakage from the pressure limitter or finishing the measurement: Return the removed parts to their original positions. a If the return rate from the injector is measured next, keep the engine as it is and put the test hose end in the container.
2) Install connector G3 and cap nut [1] of tester kit G1 to the return hose to stop the fuel from flowing out. 3) Connect test hose [2] of tester kit G1 to the supply pump. a Adjust the route of the test hose so that it does not slacken and put its end in an container.
4) While running the engine at low idle, measure the return rate in 1 minute by using measuring cylinder G4. a If the return rate from the supply pump is in the following range, it is normal. At low idle During cranking
3. Testing leakage from pressure limiter 1) Open the engine hood and disconnect return hose (2) of the pressure limitter. a Keep the seal washer attached to the connector bolt.
2) Install removed connector bolt (3) and cap nut [1] of tester kit G1 to the return hose to stop the fuel from flowing out. 3) Install connector G3 to the common rail and connect test hose [2] of tester kit G1. a Adjust the route of the test hose so that it does not slacken and put its end in an container.
Max. 1,000 cc Max. 140 cc
4) While running the engine at low idle, measure the leakage in 1 minute by using measuring cylinder G4. a If the leakage from the pressure limitter is in the following range, it is normal.
PC228US-8,PC228USLC-8
30-27
Engine and cooling system Checking fuel delivery, return rate and leakage
At low idle
0 cc (No leakage)
5) After finishing test remove the testing tools and return the removed parts. 3 Joint bolt: 24 ± 4 Nm {2.4 ± 0.4 kgm} 4. Testing return rate from injector a The fuel return rate from the injector is tested while the return hose of the pressure limitter is connected. Accordingly, before testing the return rate from the injector, check that the leakage from the pressure limitter is normal. 1) Referring to “Measuring return rate from supply pump”, set the supply pump for test. a The injector return hose of the cylinder head is difficult to disconnect, so work on the return block side. k The fuel returning from the supply pump flows out during measurement of the return rate from the injector. Keep the test hose end in the container. 2) Remove connector bolt (4) of the return block. a Keep the seal washer installed to the return hose.
3) Install connector bolt [3] of adapter G2 instead of the removed connector bolt and connect test hose [4]. a Adjust the route of the test hose so that it does not slacken and put its end in an container.
4) While running the engine at low idle, measure the return rate in 1 minute by using measuring cylinder G4. a If the return rate from the injector is in the following range, it is normal. At low idle During cranking
k If
Max. 180 cc 90 cc or less
the engine cannot be started, you may perform the measurement while rotating the engine by the starting motor. However, do not crank the engine for more than 30 seconds continuously for protection of the starting motor.
5) After finishing test remove the testing tools and return the removed parts. 3 Joint bolt: 24 ± 4 Nm {2.4 ± 0.4 kgm}
30-28
PC228US-8,PC228USLC-8
Engine and cooling system Bleeding air from fuel circuit
Bleeding air from fuel circuit a If fuel is used up or if a fuel circuit part is removed and installed, bleed air from the fuel circuit according to the following procedure. k Stop the machine on the level ground and lower the work equipment to the ground. 1. Fill fuel in the fuel tank to full. a Add fuel until float in the sight gauge rises to the maximum position. 2. Open the side cover of the pump room. 3. Loosen knob (1) of the feed pump and pull it out, and then operate it forward and backward. a Operate the knob until it becomes heavy. a The plug at the top of the fuel main filter head does not need to be removed.
4. After bleeding air, push in and tighten knob (1).
PC228US-8,PC228USLC-8
30-29
Engine and cooling system Testing fuel circuit for leakage
Testing fuel circuit for leakage k Very
high pressure is generated in the high-pressure circuit of the fuel system. If fuel leaks while the engine is running, it presents a serious danger that could result in a fire. After checking the fuel system or removing its parts, check it for fuel leakage according to the following procedure. k Stop the machine on the level ground and lower the work equipment to the ground. a Clean and degrease the engine and the parts around it in advance so that you can check it easily for fuel leakage.
a Check mainly around the high-pressure circuit parts coated with the colour checker for fuel leakage. a If any fuel leakage is detected, repair it and check again from step 1. a If no fuel leakage is detected, check is completed.
1. Spray colour checker (fuel leak detector) over the fuel supply pump, common rail, fuel injectors, and joints of the high-pressure fuel piping. 2. Start the engine, keep its speed at 1,000 rpm or below, and stop it when its speed is stabilized. 3. Stop the engine and check the fuel piping and devices for fuel leakage. a Check mainly around the high-pressure circuit parts coated with the colour checker for fuel leakage. a If any fuel leakage is detected, repair it and check again from step 1. 4. Run the engine at low idle. 5. Stop the engine and check the fuel piping and devices for fuel leakage. a Check mainly around the high-pressure circuit parts coated with the colour checker for fuel leakage. a If any fuel leakage is detected, repair it and check again from step 1. 6. Run the engine at high idle. 7. Stop the engine and check the fuel piping and devices for fuel leakage. a Check mainly around the high-pressure circuit parts coated with the colour checker for fuel leakage. a If any fuel leakage is detected, repair it and check again from step 1. 8. Run the engine at high idle and load it. a Relieve the arm circuit at the IN stroke end. 9. Stop the engine and check the fuel piping and devices for fuel leakage.
30-30
PC228US-8,PC228USLC-8
Engine and cooling system Testing and adjusting air conditioner compressor belt tension
Testing and adjusting air conditioner compressor belt tension k Stop the machine on the level ground and
lower the work equipment to the ground. Testing 30-29 1. Open the engine hood and remove plate (1) and belt guard (2) at the top of the air conditioner compressor.
2. Press the middle point of the belt between the fan pulley and compressor pulley with a thumb and measure deflection (a). q Belt pressing force: 60 N {6.2 kg} q Deflection of belt: 6.6 - 8.9 mm
Adjust 30-29 a If the belt deflection amount is not proper, adjust it in the following manner. 1. Loosen bolts (3) and (4). 2. Move compressor (5) and bracket (6) together to adjust the belt tension. 3. After positioning compressor (5), tighten bolts (3) and (4). a Check each pulley for breakage, wear of the V-groove, and contact of the V-belt and V-groove. a If the V-belt is elongated exceeding the adjustment allowance or it has a cut or a crack, replace it. a If the belt is replaced, adjust and check the tension again after operating the machine for one hour. a After tightening the bolts, check the belt tension again according to the above procedure.
4. After finishing checking and adjusting, return the removed parts.
PC228US-8,PC228USLC-8
30-31
Engine and cooling system Replacing fan belt
Replacing fan belt a The auto-tensioner is provided for the fan belt. Thus, testing and adjustment of the belt is usually not necessary. a Disconnect the air conditioner compressor belt before replacing the fan belt. 1. Insert a wrench to the portion A (width across flats: 12.7 mm) of the tensioner (3), and rotate it to the opposite to the winding-up direction to decrease the fan belt (2) tension. k Make sure that the wrench is secured at the portion (A) of the tensioner assembly (3) before rotating it. (The spring of the tensioner assembly (3) is strong. If the wrench is applied improperly, the wrench may accidentally come off while being rotated and it is extremely dangerous.) k After removing the fan belt (2), return the tensioner assembly (3) slowly with care. k Be careful not to get your fingers caught between the pulley and fan belt (2) during work.
2. Replace the fan belt (2). q Check each pulley for breakage and crack.
30-32
PC228US-8,PC228USLC-8
Undercarriage and frame Testing swing circle bearing clearance
Undercarriage and frame Testing swing circle bearing clearance a Swing circle bearing clearance measurement tools Symbol
Part number
H
Commercially available
Part name Dial gauge
a Follow the steps explained below when measuring clearance in the swing circle bearing on the actual machine. k Be careful not to put a hand or foot under the undercarriage, while taking measurement.
4. Set the arm almost perpendicular to the ground and lower the boom until the front part of the tracks float by 150 - 200 mm. a At this time the front of the upper structure rises and the rear lowers. 5. Under this condition, read dial gauge H. a The value indicated by dial gauge H is the clearance of the bearing.
1. Fix dial gauge H to outer race (1) or inner race (2) of the swing circle and apply the probe to the end face of inner race (2) or outer race (1). a Set dial gauge H to the front or rear of the machine.
6. Return the machine to the condition of step 2 and check that dial gauge H indicates 0. a If zero value is not indicated, repeat the steps 3 through 5.
2. Set the work equipment to the maximum reach position and set the bucket tip to the height of the underside of the revolving frame. a At this time the front of the upper structure lowers and the rear rises. 3. Set dial gauge H to the 0 point.
PC228US-8,PC228USLC-8
30-33
Undercarriage and frame Checking and adjusting track tension
Checking and adjusting track tension Testing 30-32 1. Run the engine at low idle and move the machine forward by the length of track on ground, and then stop slowly. 2. Place square bar [1] on the track shoes between the idler and the 1st carrier roller. a As the square bar [1], use an angle steel, etc. which deflects less.
a You may add grease until dimension (b) between the idler guide and track frame end becomes 0 mm. If the tension is still low, the pins and bushings are worn excessively. In this case, reverse or replace the pins and bushings.
3. Measure maximum clearance (a) between square bar [1] and track shoe. q Standard max. clearance (a): 10 - 30 mm
Adjust 30-32 a If the track tension is improper, adjust it according to the following procedure. 1. Increasing tension 1) Add grease through grease fitting (1) by using a grease gun. 2) To check that the tension is proper, run the engine at low idle and move the machine forward by the length of track on ground, then stop slowly. 3) After adjusting, check the track tension again according to the above procedure.
30-34
2. Decreasing tension 1) Loosen valve (2) to discharge grease, and then tighten it. k Do not loosen the valve more than 1 turn. Otherwise, the valve may jump out because of the high-pressure grease inside. 2) To check that the tension is proper, run the engine at low idle and move the machine forward by the length of track on ground, then stop slowly. 3) After adjusting, check the track tension again according to the above procedure.
PC228US-8,PC228USLC-8
Hydraulic system Testing and adjusting oil pressure in work equipment, swing and travel circuits
Hydraulic system Testing and adjusting oil pressure in work equipment, swing and travel circuits a Instruments for inspecting and adjusting oil pressure in work equipment, swing, and travel circuits Symbol 1
Part number
Part name
799-101-5002 Hydraulic tester 790-261-1204 Digital hydraulic tester
J
799-101-5220 Nipple (10 x 1.25 mm) 2 07002-11023
O-ring
k Stop the machine on the level ground and
lower the work equipment to the ground. Then, release the remaining pressure from the hydraulic circuit. For details, see “Releasing remaining pressure from hydraulic circuit”. Testing 30-3 a The oil pressure in the work equipment, swing, and travel circuits (pump discharge pressure) can be checked also by using monitoring function of the machine monitor. (For details, see "Special functions of machine monitor"). q Monitoring code: 01100 F pump pressure q Monitoring code: 01101 R pump pressure a Measure the oil pressure in the work equipment, swing, and travel circuits under the following condition. q Hydraulic oil temperature: within operating range 1. Preparation work k Lower the work equipment to the ground and stop the engine. Operate the control lever several times to release the remaining pressure in the piping, and loosen the oil filler cap of the hydraulic tank gradually to release the internal pressure of the tank. 1) Open the side cover of the pump room, remove the undercover of the pump, and remove oil pressure pickup port plugs (1) and (2). q (1): Rear pump discharge pressure pickup port plug q (2): The front pump oil pressure pickup port plug is installed to the delivery block that is located at the section below the figure (not shown in the figure due to limitation of the camera angle).
PC228US-8,PC228USLC-8
2) Install nipples J2 and connect it to oil pressure gauges [1] of hydraulic tester J1. a Use an oil pressure gauge with the capacity of 60 MPa {600 kg/cm2}.
3) Start the engine and keep it running until the hydraulic oil temperature rises to the operating range.
30-35
Hydraulic system Testing and adjusting oil pressure in work equipment, swing and travel circuits
2. Combination of pump, actuator, and valve a When the oil flow from the pumps is divided, the front pump and rear pump actuate each actuator independently as shown on the table. Note that the relieved valve varies depending on the actuator. a When the work equipment circuit or swing circuit is relieved singly, the oil flows from the pumps are merged. When the travel circuit is relieved singly, the oil flows from the pumps are divided. a The actuators in the table are arranged in the order that the control valves are viewed from the front of the machine. (As for the service valve, the table shows an example in which an attachment is installed.) Pump Actuator
3. Measuring unload pressure 1) Start the engine, set the working mode to the Power Mode (P), and turn the auto-decelerator OFF. 2) Set all control levers and pedals to the neutral and measure the oil pressure while running the engine at full speed. a Hydraulic oil pressure when the unload valve unloads is displayed.
Valve relieved
(R unload valve) (R main relief valve) Service Safety valve Rear
Bucket
R main relief valve
Left travel R main relief valve Boom
R main relief valve
(Pump merge-divider valve) (Travel junction valve) (Self-pressure reducing valve) Front
Swing
Swing motor safety valve
Right travel
F main relief valve
Arm
F main relief valve
(F unload valve) (F main relief valve) (Centralized safety valve) (Back pressure valve)
30-36
4. Testing work equipment relief pressure 1) Start the engine and move the cylinder to be measured to the stroke end. 2) Set the working mode to the Power Mode (P). 3) Measure hydraulic oil pressure when the cylinder is relieved while the engine is running at full speed. a The pressure at the time when the main relief valve is relieved is displayed. a If the one-touch power maximizing switch is not pressed, the low relief pressure is obtained. If the former is pressed, the high relief pressure is obtained. a If the swing lock switch is set to the ON position, the 2-stage relief valve is kept ON and the high relief pressure is obtained. Therefore, keep the swing lock switch at the OFF position.
PC228US-8,PC228USLC-8
Hydraulic system Testing and adjusting oil pressure in work equipment, swing and travel circuits
5. Testing swing relief pressure 1) Start the engine, set the working mode to the Power Mode (P), and turn the swing lock switch ON. 2) Measure hydraulic oil pressure when the engine is running at full speed and the swing circuit is relieved. a Hydraulic oil pressure when the swing motor safety valve is relieved is displayed. a The swing motor relief pressure is lower than that of the main relief valve. 6. Testing travel relief pressure 1) Run the engine and lock the travel mechanism. k Put pin [2] between the sprocket and track frame to lock the travel mechanism securely.
2) Set the working mode to the Power Mode (P). 3) Measure the pressure when the engine is running at full speed and the travel circuit is relieved. k Before operating the travel lever (pedal), check the pin position and locked direction of the travel again. a The pressure at the time when the main relief valve is relieved is displayed. The travel circuit is always relieved at high pressure.
PC228US-8,PC228USLC-8
7. Work after finishing testing After finishing test remove the testing tools and return the removed parts. 3 Oil pressure pickup port plug: 20 – 27 Nm {2.0 – 2.8 kgm} Adjust 30-35 a The unload valve cannot be adjusted. 1. Adjusting work equipment and travel relief pressure a If the relief pressure of the work equipment circuit and travel circuit is abnormal, adjust main relief valves (3) and (4) of the main relief valve according to the following procedure. q (3): Front main relief valve q (4): Rear main relief valve a When adjusting the main relief valve on the front pump, remove the cover under the control valve. a When adjusting the main relief valve for the rear pump circuit, remove the fuel tank cover. a Adjust only the low relief pressure of the main relief valve. If the low relief pressure is adjusted, the high relief pressure is set automatically. a The low relief pressure is the pressure applied when the 2-stage relief solenoid valve is turned OFF and the pilot pressure is not applied to the selector port.
1) Disconnect the pilot hose. 2) While fixing holder (6), loosen locknut (7). 3) Turn holder (6) to adjust the pressure. a If the holder is q Turned to the right, the pressure rises. q Turned to the left, the pressure lowers. a Pressure of adjustment per turn of holder: Approx. 20.5 MPa {Approx. 209 kg/cm2} 4) While fixing holder (6), tighten locknut (7). 3 Lock nut: 49 – 58.8 Nm {5 – 6 kgm}
30-37
Hydraulic system Testing and adjusting oil pressure in work equipment, swing and travel circuits
5) Connect the pilot hose. 6) After finishing adjustment, check the hydraulic pressure again according to the above measurement procedure.
2) While fixing adjustment screw (13), loosen locknut (14). 3) Adjust the pressure by rotating adjustment screw (13). a Turn the adjustment screw q Turned to the right, the pressure rises. q Turned to the left, the pressure lowers. a Quantity of pressure adjustment per turn of adjustment screw: 6.71 MPa {68.4 kg/m2} 4) While fixing adjustment screw (13), tighten locknut (14). 3 Lock nut: 78–103 Nm {8.0–10.5 kgm}
2. Adjusting swing relief pressure a If the swing relief pressure is improper, adjust swing motor safety valve (12) according to the following procedure. 1) Preparation work Remove step plates (8) and (9) and plates (10) and (11).
5) After finishing adjustment, check the hydraulic pressure again according to the above measurement procedure.
30-38
PC228US-8,PC228USLC-8
Hydraulic system Testing control circuit source pressure
Testing control circuit source pressure a Testing tools for control circuit pressure Symbol
Part number
Part name
4. Measure hydraulic oil pressure, when the engine is running at full speed and all the control levers are set to the neutral.
799-101-5002 Hydraulic tester 1 790-261-1204 Digital hydraulic tester K 799-101-5220 Nipple (10 x 1.25 mm) 2 07002-11023
O-ring
k Lower the work equipment to the ground and
stop the engine. Operate the control lever several times to release the remaining pressure in the piping, and loosen the oil filler cap of the hydraulic tank gradually to release the internal pressure of the tank. 1. Remove oil pressure pickup port plug (1). 5. After finishing test remove the testing tools and return the removed parts. a The control circuit source pressure may be tested at oil pressure pickup port plug (2) on the hydraulic pump.
2. Install nipple K2 and connect it to oil pressure gauges [1] of hydraulic tester K1. a Use the oil pressure gauge of 6.0 MPa {60 kg/cm2}. a Do not adjust the relief valve for control circuit source pressure.
3. Start the engine and keep it running until the hydraulic oil temperature rises to the operating range.
PC228US-8,PC228USLC-8
30-39
Hydraulic system Testing and adjusting oil pressure in pump PC control circuit
Testing and adjusting oil pressure in pump PC control circuit a Testing and adjusting tools for pump PC control circuit oil pressure Symbol
Part number
Part name
799-101-5002 Hydraulic tester 1 790-261-1204 Digital hydraulic tester L
2) Install nipples L2 and connect it to oil pressure gauges [1] of hydraulic tester L1. a Use an oil pressure gauge with the capacity of 60 MPa {600 kg/cm2}. q The figure shows the pump discharge pressure side.
799-101-5220 Nipple (10 x 1.25 mm) 2 07002-11023
O-ring
Testing 30-38 a Before testing the oil pressure in the pump PC control circuit, check that the oil pressure in the work equipment, swing, and travel circuits and the source pressure of the control circuit are proper. k Lower the work equipment to the ground and stop the engine. Operate the control lever several times to release the remaining pressure in the piping, and loosen the oil filler cap of the hydraulic tank gradually to release the internal pressure of the tank.
q
The figure shows the PC valve output pressure side.
1. Testing PC valve output pressure (servo piston inlet pressure) a Measure the PC valve output pressure (servo piston inlet pressure) and pump discharge pressure simultaneously and compare them. 1) Remove pressure pickup port plugs (1), (2), (3) and (4). q (1): Front pump delivery pressure pickup port plug q (2): Rear pump delivery pressure pickup port plug q (3):Front PC valve output pressure pickup port plug q (4): Output pressure pickup port plug of rear PC valve The pressure pickup port plug of the deliver block under the pump may be used to measure the discharge pressure.
30-40
PC228US-8,PC228USLC-8
Hydraulic system Testing and adjusting oil pressure in pump PC control circuit
3) Start the engine and keep it running until the hydraulic oil temperature rises to the operating range.
4) Measure the pump discharge pressure and PC valve output pressure (pressure at servo piston inlet) at the same time after setting the machine to the following conditions with the engine running at full speed. q Working mode: P-mode q Swing lock switch: ON (Turning 2-stage relief ON switches to high-pressure relief) q Work equipment, swing and travel: Arm IN relief a Judgment method: If the ratio between the pump discharge pressure and the PC valve output pressure (servo piston output pressure) reaches the following value, the pressures are proper. Measured oil Ratio of oil prespressure sures Pump discharge 1 pressure PC valve output Approx. 0.6 (3/5) pressure
2) Install nipples L2 and connect it to oil pressure gauges [1] of hydraulic tester L1. a Use the oil pressure gauge of 6.0 MPa {60 kg/cm2}.
3) Start the engine and keep it running until the hydraulic oil temperature rises to the operating range.
a If the PC valve or the servo piston is defective, the PC valve output pressure (servo piston output pressure) comes to the same pressure as the pump discharge pressure, or almost 0. 2. Testing PC-EPC valve output pressure 1) Open the side cover of the pump room and remove oil pressure pickup port plugs (5) and (6). q (5): output pressure pickup port plug of front PC-EPC valve q (6): output pressure pickup port plug of rear PC-EPC valve
PC228US-8,PC228USLC-8
30-41
Hydraulic system Testing and adjusting oil pressure in pump PC control circuit
4) Measure the hydraulic oil pressure with all the control levers set to the neutral and the engine running at full speed and at low idle. a You can assume that the PC-EPC valve output pressure is normal when the following changes are observed. Engine Low idle Full speed
Control lever
Pressure
Neutral
2.9 MPa {30 kg/cm2} 0 MPa {0 kg/cm2}
5) After finishing test remove the testing tools and return the removed parts.
Adjust 30-40 a If either of the following problem occurs and the PC valve seems to be defective, adjust PC valves (7) and (8) according to the procedure shown below. q As the work load increases, the engine speed decreases remarkably. q The engine speed is normal but the work equipment speed is low. q (7): Front pump PC valve q (8): Rear pump PC valve a The width across flats of the PC valve locknut is 13 mm and that (inside width) of the adjusting screw is 4 mm. Do not turn any lock nuts and adjustment screws other than the above because doing so affects the hydraulic pump performance.
1. Loosen locknut (9). a Before loosening the locknut, make a match mark on the end face of the adjustment screw to indicate the original position of the adjustment screw (so that you can return the adjustment screw to the original position if you turn it in the opposite direction). 2. Adjust the pressure by rotating adjustment screw (10) to the right or left. a Turn the adjustment screw q If the work equipment speed is low, turn it to the right. (The pump absorption torque will increase.) q If the engine speed lowers when the work load increases, turn it to the right. (The pump absorption torque will decrease.)
30-42
PC228US-8,PC228USLC-8
Hydraulic system Testing and adjusting oil pressure in pump PC control circuit
3. Tighten lock nut (9). 3 Lock nut: 27.5 – 34.3 Nm {2.8 – 3.5 kgm}
4. After the adjustment, make sure that the PC valve output pressure (servo piston inlet pressure) is normal according to the measurement steps explained earlier.
PC228US-8,PC228USLC-8
30-43
Hydraulic system Testing and adjusting oil pressure in pump LS control circuit
Testing and adjusting oil pressure in pump LS control circuit a Testing and adjusting tools for pump LS control circuit oil pressure Symbol
Part number
Part name
799-101-5002 Hydraulic tester 1 790-261-1204 Digital hydraulic tester M
790-101-5220 Nipple (10 x 1.25 mm) 2 07002-11023 3
O-ring
799-401-2701 Differential pressure gauge
Testing 30-42 a Before testing the oil pressure in the pump LS control circuit, check that the oil pressure in the work equipment, swing, and travel circuits and the source pressure of the control circuit are proper. k Lower the work equipment to the ground and stop the engine. Operate the control lever several times to release the remaining pressure in the piping, and loosen the oil filler cap of the hydraulic tank gradually to release the internal pressure of the tank. 1. Testing LS valve output pressure (servo piston inlet pressure) a Measure the LS valve output pressure (servo piston inlet pressure) and the pump discharge pressure simultaneously and compare them. 1) Remove pressure pickup port plugs (1), (2), (3) and (4). q (1): Front pump delivery pressure pickup port plug q (2): Rear pump delivery pressure pickup port plug q (3):Front PC valve output pressure pickup port plug q (4): Rear PC valve pressure pickup port plug The pressure pickup port plug of the deliver block under the pump may be used to measure the discharge pressure.
30-44
2) Install nipple M2 and connect it to oil pressure gauge [1] of hydraulic tester M1. a Use an oil pressure gauge with the capacity of 60 MPa {600 kg/cm2}. q The figure shows the pump discharge pressure side.
q
The figure shows the LS valve output side.
PC228US-8,PC228USLC-8
Hydraulic system Testing and adjusting oil pressure in pump LS control circuit
3) Run the engine and raise the hydraulic oil temperature to the operating range and raise the track to be tested off the ground by using the work equipment. q When measuring front circuit: Right track q When measuring rear circuit: Left track k Provide a working area of sufficient space, as the raised track must be run idle.
4) Measure the pump discharge pressure and PC valve output pressure (pressure at servo piston inlet) at the same time after setting the machine to the following conditions with the engine running at full speed. q Working mode: P-mode q Work equipment, swing and travel: When all levers are at neutral and when a travel lever is at half stroke (to run a track idle). a Run the raised track idle, paying enough attention to the surroundings for safety. a Measurement conditions and judgment method: If the ratio between the pump discharge pressure and LS valve output pressure (servo piston input pressure) reaches the following value, the pressures are correct.
2. Testing LS differential pressure a To obtain the LS differential pressure, measure the pump discharge pressure and LS pressure (actuator load pressure) at the same time and calculate the difference. 1) Open the side cover of the pump room, remove the undercover of the pump, and remove pressure pickup port plugs (1), (2), (5), and (6). q (1): Front pump delivery pressure pickup port plug q (2): Rear pump delivery pressure pickup port plug
q q
(5): Front pump LS pressure pickup port plug (6): Rear pump LS pressure pickup port plug
Position of levers and pedals
Measured oil pressure
All levers and pedals are at neutral Pump discharge pressure LS valve out put pressure
Almost same pressure
Travel lever set at half stroke (Track runs idle) Measure value is regarded as 1. Approx. 3/5 of the above
5) After finishing test remove the testing tools and return the removed parts.
PC228US-8,PC228USLC-8
30-45
Hydraulic system Testing and adjusting oil pressure in pump LS control circuit
2) Install nipple M2 and connect it to the differential pressure gauge M3 or hydraulic tester M1. a When using differential pressure gauge: Connect the pump delivery pressure hose to the high pressure side (back side) and connect the LS pressure hose to the low pressure side (lower side). The differential pressure gauge needs 12 V DC power, so connect a battery to it. a When using the oil pressure gauge: Use the oil pressure gauge of 60 MPa {600 kg/cm2} with the graduation by 1 MPa {10 kg/cm2}. The differential pressure is approximately 4 MPa {40 kg/cm2} at the maximum, so perform the measurement by using a gauge alternately. q The figure shows the pump discharge pressure side.
4) While running the engine at full speed under the following condition, measure the pump discharge pressure and LS pressure (actuator load pressure) simultaneously. q Working mode: P-mode q Travel speed: Hi q Work equipment, swing and travel: When all levers are at neutral and when travel lever is at half stroke (to run a track idle) a Run the raised track idle, paying enough attention to the surroundings for safety. a Calculating LS differential pressure (when the pressure gauge is used): LS differential pressure = pump outlet port pressure – LS pressure a If the LS differential pressure is as follows, it is normal. LS differential pressure Unload pressure When all control levers in (See standard neutral value table) Standard LS difWhen a travel lever is moved ferential preshalfway (Raised track runs sure idle) (See standard value table) Operation of lever
q
The figure shows the LS pressure side.
5) After finishing test remove the testing tools and return the removed parts.
3) Run the engine and raise the hydraulic oil temperature to the operating range and raise up the track to be tested. q When measuring front circuit: right track q When measuring rear circuit: left track k Provide a working area of sufficient space, as the raised track must be run idle. 30-46
PC228US-8,PC228USLC-8
Hydraulic system Testing and adjusting oil pressure in pump LS control circuit
3. Testing LS-EPC valve output pressure 1) Remove pressure pickup port plug (7).
2) Install nipple M2 and connect it to oil pressure gauge [1] of hydraulic tester M1. a Use the oil pressure gauge of 6.0 MPa {60 kg/cm2}.
5) After finishing test remove the testing tools and return the removed parts. Adjust 30-45 a If the LS differential pressure is improper, adjust LS valves (8) and (9) according to the following procedure. q (8): Front pump LS valve q (9): Rear pump LS valve
3) Start the engine and keep it running until the hydraulic oil temperature rises to the operating range. 4) Measure the oil pressure when the engine is running at full speed and the travel speed switch and travel control lever are operated. a If the LS-EPC valve output pressure changes as follows, it is normal. Travel speed
Travel lever
Low
Neutral
High
Fine travel lever control (Note)
Hydraulic Approx. 2.9 MPa {Approx. 30 kg/cm2} 0 MPa {0 kg/cm2}
Note: Operate the travel lever to a degree that the PPC oil pressure switch is just turned on (position before the tracks start moving).
PC228US-8,PC228USLC-8
1. While fixing adjusting screw (10), loosen locknut (11). 2. Turn adjusting screw (10) to adjust the pressure. a Turn the adjustment screw q Turned to the right, the differential pressure rises. q Turned to the left, the differential pressure lowers. a Amount of adjustment (LS differential pressure) per turn of adjustment screw: Quantity of pressure adjustment (LS differential pressure): 1.1 MPa {10.8 kg/cm2} 3. While fixing adjustment screw (10), tighten locknut (11). 3 Lock nut: 49 – 64 Nm {5 – 7 kgm}
30-47
Hydraulic system Testing and adjusting oil pressure in pump LS control circuit
4. After finishing adjustment, check that the LS valve output pressure (servo piston inlet pressure) is correct according to the testing procedure described above.
30-48
PC228US-8,PC228USLC-8
Hydraulic system Testing solenoid valve output pressure
Testing solenoid valve output pressure a Tools for measuring solenoid valve outlet pressure Symbol
Part number
Part name
799-101-5002 Hydraulic tester
a Use the oil pressure gauge of 6.0 MPa {60 kg/cm2}. a The figure shows the testing tools installed to the outlet hose of PPC lock solenoid valve.
1 790-261-1204 Digital hydraulic tester N 799-401-3100 Adapter (Size: 02) 2 02896-11008
O-ring
k Lower the work equipment to the ground and
stop the engine. Operate the control lever several times to release the remaining pressure in the piping, and loosen the oil filler cap of the hydraulic tank gradually to release the internal pressure of the tank. a Check that the control circuit basic oil pressure is correct before testing the solenoid valve outlet pressure. a Measure the solenoid valve outlet pressure under the following conditions: q Hydraulic oil temperature: within operating range
4. Start the engine.
1. Disconnect outlet hoses (1) to (6) of the solenoid valves to be measured. NO.
Solenoid valve to be tested
1
PPC lock solenoid valve
2
Travel junction solenoid valve
3
Swing brake solenoid valve
4
Travel speed selector solenoid valve
5
2-stage relief solenoid valve
6
ATT return selector solenoid valve (for the machine with the attachment)
2. Install adapter N2 and connect the disconnected hose again. 3. Install nipple [2] and connect it to pressure gauge [3]. PC228US-8,PC228USLC-8
5. While running the engine at full speed, operate each control lever and each switch to energize and de-energize each solenoid valve, and measure the pressure. a For the conditions for energizing or de-energizing the solenoid, see the operation table of each solenoid valve. a The operating status of each solenoid valve can be checked by using the monitoring function of the machine monitor. (For details, see "Special functions of machine monitor") q Monitoring code: 02300 Solenoid 1 q Monitoring code: 02301 Solenoid 2 a If the output pressure is as shown in the table, the solenoid valve is normal. Solenoid valve OFF (de-energized) ON (energized)
Outlet pressure 0 MPa {0 kg/cm2} 2.9 MPa {30 kg/cm2}
6. After finishing test remove the testing tools and return the removed parts. 30-49
Hydraulic system Testing solenoid valve output pressure
Solenoid valve ON-OFF control Solenoid valve (1) PPC lock (2) Swing brake
30-48 ON (energized) Free Brake is released. Motor swash plate angle is set to Min.
(3) Travel speed selector (4) 2-stage relief
Pressure is increased.
(5) Travel junction
Cut Single action, low pressure
(6) ATT selector
OFF (de-energized) Lock operates Brake is applied. Motor swash plate angle is set to Max. Pressure is not increased. Connected Double action, high pressure
(1) Operation table of PPC lock solenoid valve
30-48
Operating condition
Operation Lock
OFF
Released
ON
PPC lock lever
(2) Operation table of swing brake solenoid valve
30-48
Operating condition
Operation All are OFF.
OFF
Any one is ON.
ON
Signals of work equipment and swing (Work equipment includes attachment.)
(3) Operation table of travel speed selector solenoid valve
30-48
Operating condition
Operation
Overheat 2nd setting is ON. Arm crane is installed. Fuel control dial is at 1,500 rpm or below. OFF
Travel speed switch is at Lo. Travel signal is OFF. Travel speed switch: Mi, Hi Travel signal is ON.
When F or R pump pressure is 33.3 MPa {340 kg/cm2} or above. When F or R pump pressure is 17.6 MPa {180 kg/cm2} or below.
ON
Other than the above conditions
30-50
PC228US-8,PC228USLC-8
Hydraulic system Testing solenoid valve output pressure
(4) Operation table of 2-stage relief solenoid valve
30-49
Operating condition
Operation
Overheat 1st setting is ON. Overheat 2nd setting is ON.
OFF
When all the signals for work equipment, swing and travel are OFF. Swing lock switch is ON. Travel signal is ON. When L mode is selected.
ON
When the boom LOWER signal is ON When the working mode is P or E.
When one-touch power max. switch is ON.
Signals other than the "swing only" are ON. "Swing only " is ON. OFF
Other than above conditions
(5) Operation table of travel junction solenoid valve Operating condition
30-49 Operation
Travel steering signal is ON. Travel steering signal is OFF.
When " travel only" signal When F or R pump pressure is 24.5 MPa is ON. {250 kg/cm2} or above.
ON
Other than the above conditions
OFF
(6) Operation table of ATT return selector solenoid valve (for the machine with attachment) Operating condition
30-49
Operation
Working mode: Other than B
OFF
Working mode: B
ON
PC228US-8,PC228USLC-8
30-51
Hydraulic system Testing PPC valve output pressure
Testing PPC valve output pressure a Testing tools for PPC valve outlet pressure Symbol
Part number
Part name
799-101-5002 Hydraulic tester 1 790-261-1204 Digital hydraulic tester P
799-401-3100 Adapter (Size: 02)
The circuits marked with * can be checked by using the monitoring function of the machine monitor. a The circuit to be tested (1) to (8) are installed to the PPC relay block and (9) to (12) are installed to the reverse side of the cab.
q
2 799-401-3200 Adapter (Size: 03) 3
796T-562-1110 Adapter (12 x 1.5 mm)
a Check that the control circuit source pressure is correct before testing the PPC valve outlet pressure. a Test the PPC valve outlet pressure under the following condition. Hydraulic oil temperature: within operating range a The outlet pressure of the following PPC valve can be checked by using the monitoring function of the machine monitor. (For details, see "Special functions of machine monitor") Monitoring code: 07400 Boom RAISE PPC pressure Monitoring code: 07200 Arm IN PPC pressure Monitoring code: 07300 Bucket CURL PPC pressure Monitoring code: 07301 Bucket DUMP PPC pressure Monitoring code: 09001 Swing LEFT PPC pressure Monitoring code: 09002 Swing RIGHT PPC pressure Monitoring code: 07102 Travel LEFT FORWARD PPC pressure Monitoring code: 07103 Travel RIGHT FORWARD PPC pressure Monitoring code: 07104 Travel LEFT REVERSE PPC pressure Monitoring code: 07105 Travel RIGHT REVERSE PPC pressure No. 1 2 3 4 5 6 q
Circuit to be tested
No.
1. Disconnect hydraulic hose (2) of the PPC circuit, install adapter P2, and connect hydraulic hose (2) again.
Circuit to be tested
* Bucket CURL (White) 7 * Right swing (Red) Boom LOWER 8 Arm DUMP (Yellow) (Brown) Travel left forward * Left swing (Not 9 installed) (Red) Travel right forward * Arm IN (Blue) 10 (Green) * Bucket DUMP Travel right reverse 11 (Black) (Blue) Travel left reverse * Boom RAISE (Green) 12 (Not installed)
The colours in ( ) are the colours of the bands installed for piping identification.
30-52
PC228US-8,PC228USLC-8
Hydraulic system Testing PPC valve output pressure
2. Install nipple [1] of hydraulic tester P1 to adapter P2 or P3 and connect oil pressure gauge [2]. a Use the oil pressure gauge of 6.0 MPa {60 kg/cm2}. a The figure shows the testing tools installed to the position for the boom LOWER PPC oil pressure switch installation.
4. Measure the pressure when the engine is running at full speed and the control lever of the circuit to be measured is kept at the neutral position and at the full stroke. a If PPC valve output pressure is at the level shown below, it is correct. Operation of lever At neutral At full stroke
Pressure 0 MPa {0 kg/cm2} Almost the same pressure as the control circuit source pressure (See “Standard values table”)
5. After finishing test remove the testing tools and return the removed parts.
a The figure shows the testing tools installed to the position for the RIGHT travel reverse PPC oil pressure switch installation.
3. Start the engine and set the working mode to the Power Mode (P).
PC228US-8,PC228USLC-8
30-53
Hydraulic system Adjusting play of work equipment and swing PPC valves
Adjusting play of work equipment and swing PPC valves a If the right and left work equipment levers have large play, adjust them according to the following procedure. a The play of the lever measured at a position of 200 mm from the pivot must be 0.5 - 3 mm. 1. Remove the work equipment and swing PPC valve assembly. 2. Remove boot (1). 3. Loosen locknut (2) and tighten disc (3) until it touches the heads of four pistons (4). a Do not move the piston while doing this work. 4. Fix the position of disc (3) and tighten locknut (2) to the specified torque. 3 Lock nut: 69 –88 Nm {7 –9 kgm} 5. Install boot (1). 6. Install the work equipment and swing PPC valve assembly.
30-54
PC228US-8,PC228USLC-8
Hydraulic system Measuring and adjusting quick coupler control valve output pressure
Measuring and adjusting quick coupler control valve output pressure a
Measuring and adjusting tools for oil pressure in quick coupler circuit.
Symbol 1 J 2
Part No.
Part name
799-101-5002
Hydraulic tester
790-261-1204
Digital hydraulic tester
799-101-5220
Nipple (10 × 1.25 mm)
07002-11023
O-ring
Adjustment If the regulated pressure is not suitable for the quick coupler to be installed adjust the pressure of the regulating valve as follows: 1.
Loosen the locknut (1a). (using a 17mm spanner).
k Stop
the machine on a level ground and lower the work equipment to the ground. Then, release the residual pressure from the hydraulic circuit. For details, see "Releasing residual pressure from hydraulic circuit".
1b
Measuring Measure quick coupler control valve output pressure after checking that work equipment, swing and travel circuit pressures are normal. q Fit nipple J2 to port B2 and connect it to oil pressure gauge of hydraulic tester. q
1a 1b 2.
J2
Turn the adjustment screw (1b) to adjust the pressure. (Using a 5mm hexagon key). q If the screw is turned to the right the pressure increases. q If the screw is turned to the left the pressure reduces. q Quantity of adjustment per turn of the screw: Approx 5.5MPa. 3. After required pressure is achieved, hold adjustment screw (1b) and tighten the lock nut (1a). (Torque of lock nut (1a) 12+/-2Nm) 4. Note: Both pressure reducer valves are adjusted by the above method.
Use an oil pressure gauge with the capacity of 59MPa (600kg/cm²) q Start the engine. In order to raise the pressure to the set pressure of the pressure regulating valve it will be necessary to operate one of the main control circuits. Set the swing lock to ON and operate the swing lever. NOTE: When delivered from the factory the regulated pressure is set to 4MPa (41kg/cm². q
PC228US-8,PC228USLC-8
30-55
Hydraulic system Testing pump swash plate sensor
Testing pump swash plate sensor Testing 30-53 a Before testing pump swash plate sensor, check that oil pressure in work equipment, swing, and travel circuits, control circuit source pressure, and no-load travel speed are correct. a Test pump swash plate sensor under the following conditions. q Hydraulic oil temperature: within operating range q Working mode: P-mode Testing output voltage of pump swash plate sensor 30-53 a Output voltage of pump swash plate sensor can be checked by the monitoring function of machine monitor. (For the operating method, see " Special functions of machine monitor" .) q Monitoring code: 01138 F pump swash plate sensor voltage 01140 R pump swash plate sensor voltage
a Testing condition and judgment: If the voltages are as shown in the table, pump swash plate sensor is correct. Operation of lever All control levers and pedals are at neutral. Travel lever is at stroke end. (Track runs idle.)
Pump swash plate sensor voltage 1.57 ± 0.63 V 3.75 ± 0.63 V
1) Start the engine and raise the track on the side to be tested, by using the work equipment, and prepare for running the track idle. q When testing front pump: right track q When testing rear pump: left track k Provide
a working area of sufficient space, as the raised track must be run idle.
2) Set the working mode to the Power Mode (P) and set the travel speed to the High. 3) Set the swing lock switch to ON position. 4) While running the engine at full speed, set all the levers and pedals for work equipment, swing, and travel to the neutral, and then set the travel lever to stroke end in order to run a track idle, and measure the voltage during each operation. k While taking care of safety around the ma-
chine, run the raised track idle.
30-56
PC228US-8,PC228USLC-8
Hydraulic system Isolating the parts causing hydraulic drift of work equipment
Isolating the parts causing hydraulic drift of work equipment a If the work equipment (cylinder) drifts hydraulically, perform check to see if the problem is in the cylinder seal or control valve according to the following procedure.
2. Testing arm cylinder 1) Move the arm cylinder to about 100 mm before the IN stroke end and stop the engine.
1. Testing boom cylinder and bucket cylinder 1) Set the work equipment in the same posture as when measuring hydraulic drift, and stop the engine. a Put a weight equivalent to the rated load or fill the bucket with the earth and sand.
2) Operate the arm control lever to the arm IN position. q If the lowering speed is increased at this time, the cylinder seal is defective. q If the lowering speed does not change at this time, the control valve is defective.
2) When testing the boom cylinder, set the boom control lever to the RAISE position. When testing the bucket cylinder, set the bucket control lever to the CURL position. q If the lowering speed is increased at this time, the cylinder seal is defective. q If the lowering speed does not change at this time, the control valve is defective. a Operate the control lever while the starting switch is in the ON position. a If there is no more pressure in the accumulator, run the engine for approx. 10 seconds to charge the accumulator.
PC228US-8,PC228USLC-8
a Operate the control lever while the starting switch is in the ON position. a If there is no more pressure in the accumulator, run the engine for approx. 10 seconds to charge the accumulator. [Reference] If the cause of the hydraulic drift is a defect in the seal, the speed of downward movement in the above operation will become faster for the following reasons. 1) If the work equipment is set to the above posture (where the work equipment holding pressure is applied to the bottom side), the oil leaks from the bottom side to the head side. The volume on the head side is less than that on the bottom side by the volume of the rod, so the pressure in the head side is increased by the oil flowing in from the bottom side. 2) As the pressure in the head side is increased, it is balanced with the pressure in the bottom side at a certain level (which depends on the leak quantity), and the lowering speed is lowered. 3) If the circuit on the head side is opened to the drain circuit by the above operation of the lever (the bottom side is closed by the check valve at this time), the oil in the head side flows in the drain circuit. As a result, the pressure is unbalanced and the lowering speed is increased. 30-57
Hydraulic system Isolating the parts causing hydraulic drift of work equipment
3. Testing boom lock valve 1) Set the work equipment at the maximum reach with the boom top in level and stop the engine. k Set the work equipment lock lever to LOCK position and release the pressure in the hydraulic tank. k Do not allow anyone to come under the work equipment during the work. 2) Disconnect drain hose (1) of the control valve, and install an oil stopper plug in the hose. q Oil stopper plug: 07376-70210 a Leave the port in control valve open. a If oil flows out of the open port when the work equipment lowers by its own weight, the boom lock valve is defective (sealing is defective).
4. Testing PPC valve Measure the hydraulic drift of the work equipment when the work equipment lock lever is in the LOCK and FREE positions with the accumulator charged fully. a Operate the control lever while the starting switch is in the ON position. a If there is no more pressure in the accumulator, run the engine for approx. 10 seconds to charge the accumulator. a If there is a difference in the lowering distance between the LOCK position and FREE position, the PPC valve is defective (it has an internal defect).
30-58
PC228US-8,PC228USLC-8
Hydraulic system Releasing remaining pressure from hydraulic circuit
Releasing remaining pressure from hydraulic circuit 1. Releasing remaining pressure from hydraulic tank k The hydraulic tank is airtight and pressurized, so release the remaining pressure from it when removing a hose or a plug connected to it. 1) Lower the work equipment to the ground in a stable posture and stop the engine. 2) Loosen oil filler cap (1) of the hydraulic tank gradually to release the air in the tank.
3. Releasing remaining pressure from swing motor circuit a Release the remaining pressure from the swing motor circuit by performing the procedure for 2 (Releasing remaining pressure from hydraulic cylinder circuit). 4. Releasing remaining pressure from travel motor circuit a The control valve spool of the travel motor circuit is open, so the pressure in this circuit can be released by performing the operation for "Release remaining pressure from hydraulic tank".
2. Releasing remaining pressure from hydraulic cylinder circuit k When disconnecting a pipe between a hydraulic cylinder and the control valve, release the remaining pressure from the piping according to the following procedure. 1) Release the remaining pressure from the hydraulic tank. For details, see "Releasing remaining pressure from hydraulic tank" . a Leave the oil filler cap of the hydraulic tank removed. 2) Set the starting switch to ON position and set the lock lever to the FREE position, and then operate the right and left work equipment control levers forward, backward, to the right, and to the left. a The control valve is operated by the pressure in the accumulator. The pressure in the accumulator is used up, however, after the work equipment control levers are operated 2 to 3 times. 3) Start the engine and run it at low idle for 5 seconds to raise the pressure in the accumulator. a The engine does not start unless the lock lever is set to the LOCK position. 4) Repeat steps 2) and 3) above 2 to 3 times, and the remaining pressure in the piping is released completely.
PC228US-8,PC228USLC-8
30-59
Hydraulic system Testing oil leakage amount
Testing oil leakage amount a Testing tools for oil leakage Symbol
Part number
Part name
Q
Commercially available
Measuring cylinder
a Test the oil leakage under the following condition. q Hydraulic oil temperature: within operating range 1. Testing oil leakage from boom cylinder 1) Extend the boom cylinder to the boom RAISE stroke end and stop the engine. k Release the remaining pressure from the piping on the boom cylinder head side. For details, see "Releasing remaining pressure from hydraulic circuit" (Operate the lever to the boom RAISE direction only, however). 2) Disconnect hoses (1) on the cylinder head side and block the hose end by a flange. k Take care not to disconnect the hoses on the cylinder bottom side. a Use the following part to block the hose end. 07379-00640 (Flange #06)
2. Testing oil leakage from arm cylinder 1) Move the arm cylinder to the arm IN stroke end and stop the engine. k Release the remaining pressure from the piping on the arm cylinder head side. For details, see "Releasing remaining pressure from hydraulic circuit" (Operate the lever to arm IN only, however). 2) Disconnect hose (2) on the cylinder head side and block the hose end by a flange. k Take care not to disconnect the hose on the cylinder bottom side. a Use the following part to block the hose end. 07379-00640 (Flange #06)
3) Run the engine at full speed and relieve the arm circuit by moving the arm IN. k Take care not to "move the arm OUT". 4) Start measuring the oil leakage 30 seconds after relieving is started, and measure the leak for 1 minute. 5) After finishing measuring, return the machine status as it was.
3) Run the engine at full speed and relieve the boom circuit by raising the boom. k Take care not to "lower the boom". 4) Start measuring the oil leakage 30 seconds after relieving is started, and measure the leak for 1 minute. 5) After finishing measuring, return the machine status as it was.
30-60
3. Testing oil leakage from bucket cylinder 1) Move the bucket cylinder to the bucket CURL stroke end and stop the engine. k Release the remaining pressure from the piping on the bucket cylinder head side. For details, see "Releasing remaining pressure from hydraulic circuit" (Operate the lever in the bucket CURL direction only, however). 2) Disconnect hose (3) on the cylinder head side and block the hose end by a flange. k Take care not to disconnect the hose on the cylinder bottom side. a Use the following part to block the hose end. 07379-00640 (Flange #06)
PC228US-8,PC228USLC-8
Hydraulic system Testing oil leakage amount
5. Testing oil leakage from travel motor 1) Remove the travel motor cover. 2) Run the engine, lock the travel mechanism, and stop the engine. k Insert pin [1] between the sprocket and the track frame to securely lock the track.
3) Run the engine at full speed and relieve the bucket circuit by curling the bucket. k Take care not to perform "bucket DUMP operation". 4) Start measuring the oil leakage 30 seconds after relieving is started, and measure the leak for 1 minute. 5) After finishing measuring, return the machine status as it was. 4. Testing oil leakage from swing motor 1) Remove the upper cover (steel) of the swing motor. 2) Disconnect two drain hoses (4) and block the hose side end by plugs. a Use the following part to block the hose end. 07376-70522 (Plug #05)
3) Turn the swing lock switch to ON position. 4) Run the engine at full speed and relieve the swing circuit by swinging. a Start measuring the oil leakage 30 seconds after relieving is started, and measure the leak for 1 minute. a After measuring one time, swing 180°, and then measure the leak again. 5) After finishing testing, return the machine status as it was.
PC228US-8,PC228USLC-8
3) Disconnect drain hose (5) of the travel motor and block the hose end by a plug. a Use the following part to block on the hose end. 07376-70422 (Plug #04)
4) Run the engine at full speed, relieve the travel circuit, and measure the oil leakage. k Before operating the travel lever, check the pin position and locked direction of the travel again. k Wrong operation of the lever can cause the personal injury. Make the signals and checks securely. a Start measuring the oil leakage 30 seconds after relieving is started, and measure the leak t for 1 minute. a Take measurement several times, moving the motor a little each time (i.e. change the position of the valve plate and cylinder, and that of the cylinder and piston each time). 5) After finishing testing, return the machine status as it was.
30-61
Hydraulic system Bleeding air from each part
Bleeding air from each part q: Execution of work o: Go to next procedure Air bleeding procedure and item 1
Nature of work, remarks
q
q
q
o
o
o
q
q
q
o
o
q
q
q
o
o
q
Replacing and repairing cylinder Removing cylinder piping
q
q
o
o
q
Replacing or repairing swing motor Removing swing motor piping
q
o
q
o
q
Replacing or repairing travel motor Removing travel motor piping
q
o
o
q
q
Replacing or repairing swivel joint Installing swivel joint piping
q
o
o
o
q
q
Replacing or repairing hydraulic pump Removing suction piping Replacing or repairing control valve Removing control valve piping
q q q q q q q
6
Checking Bleeding air Bleeding air Bleeding air oil level from cylin- from swing from travel and der motor motor starting work
q
Replacing return filter element
q
5
q
q
q
4
Run engine
Replacing hydraulic oil Cleaning strainer
q
3
Bleeding air from hydraulic pump q
q
2
q
q
q
(See note) (See note)
q
Note: Bleed air from the swing motor and travel motor only when the oil in the motor cases is drained. 1. Bleeding air from hydraulic pump a Keep the oil filler cap of the hydraulic tank loosened while the air is bled from the hydraulic pump. 1) Loosen air bleeder (1) and check that oil oozes out through the air bleeder. 2) After oil containing no bubbles flows out, tighten air bleeder (1). 3 Air bleeder: 7.8 – 9.8 Nm {0.8 – 1.0 kgm}
2. Starting engine When running the engine after performing step 1, let it low-idle for 10 minutes. a If the automatic warm-up operation starts because of low engine coolant temperature, stop the engine and cancel the warm-up operation by operating the fuel control dial. (With the starting switch at the ON position, hold the fuel control dial at the MAX position for 3 seconds, and the automatic warm-up operation is cancelled) 3. Bleeding air from cylinder a If a cylinder is replaced, bleed air from it before connection to the work equipment. In particular, the boom cylinder does not move to the lowering stroke end, if it is installed to the work equipment. 1) Run the engine at low idle for approximately 5 minutes. 2) While running the engine at low speed, raise and lower the boom 4 to 5 times. a Stop the piston rod approximately 100 mm before each stroke end. Do not cause the relief.
30-62
PC228US-8,PC228USLC-8
Hydraulic system Bleeding air from each part
3) While running the engine at full speed, perform step 2). 4) While running the engine at low idle speed, move the piston rod to the stroke end and relieve the oil. 5) Bleed air from the arm cylinder and bucket cylinder according to steps 2) to 4).
7. 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.
4. Bleeding air from swing motor 1) Start the engine and run it at low idle. 2) Swing to the right and left slowly to bleed air. 5. Bleeding air from travel motor 1) Start the engine and run it at low idle. 2) Loosen air bleeder (2) and check that oil oozes out from it. 3) After oil containing no bubbles flows out, tighten air bleeder (2). 3 Air bleeder: 27.5–35.3 Nm {2.8–3.6 kgm}
2) Check the oil level by sight gauge (3) on the rear side of the hydraulic tank. a The oil level is acceptable if it is situated between H and L lines. a If the oil level is below line L, it is insufficient. Add oil.
6. Bleeding air from swivel joint 1) Start the engine and run it at low idle. 2) Raise a track and run it idle slowly (forward and reverse directions) to bleed air. Apply the same procedure to the right and left tracks.
PC228US-8,PC228USLC-8
30-63
Work equipment Replacement procedure of boom angle potentiometer
Work equipment Replacement procedure of boom angle potentiometer a Perform the removal and installation of the boom angle potentiometer according to the following procedure. a If the boom angle potentiometer is replaced, the initial set value recorded in the pump controller agree with the new potentiometer. Be sure to perform the initial setting operation after installing the new boom angle potentiometer. Removal 30-61 1. Remove the potentiometer cover. 2. Disconnect connector A53 (1). 3. Remove lever (2) from the boom and fix it to plate (3). a Fix the lever to the plate so that the lever does not move unexpectedly. 4. Remove plate (3) and potentiometer as a unit. 5. Remove lever (2) and remove potentiometer assembly (4) from plate (3). a Do not swing the potentiometer assembly by gripping the lever or move the lever unnecessary.
Connection 30-61 1. Carry out installation in the reverse order to the removal. 2. Set the machine monitor to the service mode and perform initial setting for the boom angle potentiometer. a For adjustment procedure, see "Special functions of monitor panel" (Adjustment in service mode [07]).
30-64
PC228US-8,PC228USLC-8
Cab and its attachments Checking cab tipping stopper
Cab and its attachments Checking cab tipping stopper
a Check the cab tipping stopper according to the following procedure. 1. Remove additional lower cover (5) at the rear of the operator cab.
2. Check the tightening torque of the mounting bolt (2) of the lock plate (1). 3 Bolt (2): 98 – 123 Nm {10 – 12.5 kgm} [Reference] Note that the tightening torque for mounting bolt (4) of cab tipping stopper (3) is different from that of a common bolt 30 mm in diameter. 3 Bolt (4): 245 – 309 Nm {25 – 31.5 kgm}
q
PC228US-8,PC228USLC-8
30-65
Cab and its attachments Adjusting mirrors
Adjusting mirrors 1. Mirror Installation position
q
2. Adjusting mirror (a) Adjust mirror (a) so that the operator can see a person at the left rear end of the machine. a If the mirror is folded, set it to the normal position before adjusting. a Install the mirror as shown below. (G): 10°, (H): 30°, (J): 35 mm, (K): 15 mm a If the mirror is hard to adjust, loosen mirror bolts (2). a Fix mirror stay (1) while the mirror is opened to the maximum position. 3 Bolt: 6.0–7.0 Nm {0.61–0.71 kgm}
30-66
Adjust the mirror so that the side of the machine is reflected in it as shown below.
3. Adjusting mirror (b) Adjust mirror ((b)) so that the operator can see a person at the right rear end of the machine. a Install the mirror as shown below. (L): 45°, (M): 15 mm a If the mirror is hard to adjust, loosen mirror bolts (3). 3 Bolt: 6.0–7.0 Nm {0.61–0.71 kgm}
PC228US-8,PC228USLC-8
Cab and its attachments Adjusting mirrors
q
Adjust the mirror so that the side of the machine is reflected in it as shown below.
4. Adjusting mirror (c) Adjust the mirror so that the operator can see persons on the ground at 1 meter around the machine (hatched area). a If the mirror is hard to adjust, loosen mirror screw (4). 3 Bolt: 3.0 – 3.5 Nm {0.31 – 0.35 kgm} q Dimension W: 1,000 mm
q
When installing the mirror, secure clearance (N) so that the mirror does not interfere with the mirror stay. (N): Min. 10 mm
PC228US-8,PC228USLC-8
30-67
Cab and its attachments Angle adjustment of rear view camera
Angle adjustment of rear view camera a Adjust the camera so that persons in area (w) at 1 meter around the machine is displayed on the machine monitor in the operator cab.
If the image displayed on the monitor is out of position, remove cover (2) of camera (1) and adjust the installation angle (A) of the rear view camera.
1. Remove cover (2) by inserting flat-head screwdriver [1] in the hole in cover (3) and pressing the internal pawl.
a Claw of cover (2) is made of plastic, it is easily damaged while removing, therefore take special care at work.
2. Remove two bolts (4). 3. Remove cover (2).
30-68
PC228US-8,PC228USLC-8
Cab and its attachments Angle adjustment of rear view camera
4. Loosen mounting bolts (5) of camera (1) and adjust installation angle (A) of camera so that the side line of camera is matched with the corner (B) of the bracket. Angle (A): 48°(+2°/0)
a A part of the machine is displayed on the monitor screen. Adjust the camera so that the image of the counterweight will occupy about 10 to 15% of the monitor screen.
5. After adjusting, tighten bolts (5). 3 Camera mounting bolt : 11.8–14.7 Nm {1.2–1.5 kgm}
6. Install covers (2) and (3).
PC228US-8,PC228USLC-8
30-69
Electrical system Special function of machine monitor (EMMS)
Electrical system Special function of machine monitor (EMMS)
30-70
PC228US-8,PC228USLC-8
Electrical system Special function of machine monitor (EMMS)
Upper part of machine monitor (display portion)30-69 (a): Multi-display a When the engine is started, the battery voltage may lower suddenly, depending on the ambient temperature and the condition of the battery. In this case, the machine monitor goes off for a moment. This phenomenon is not a failure, however. Upper part of machine monitor (switches portion) 30-68 [F1]: F1 function switch [F2]: F2 function switch [F3]: F3 function switch [F4]: F4 function switch [F5]: F5 function switch [F6]: F6 function switch a The function of each function switch is indicated by graphic mark in the multi-display (a) above that function switch. a If the graphic mark of a function switch is not displayed, that function switch is not working. Lower part of machine monitor (switches portion) 30-68 [1]: Numeral 1 input switch/Auto-deceleration switch [2]:Numeral 2 input switch/Working mode selector switch [3]: Numeral 3 input switch/Travel speed selector switch [4]: Numeral 4 input switch/Alarm buzzer stop switch [5]:Numeral 5 input switch/Wiper switch [5]:Numeral 6 input switch/Wind washer switch [7]:Numeral 7 input switch/Air conditioner or heater switch [8]:Numeral 8 input switch/Air conditioner or heater switch [9]:Numeral 9 input switch/Air conditioner or heater switch [0]: Numeral 0 input switch/Air conditioner or heater switch Switch having no numerals: Air conditioner or heater switch a Each switch has the function indicated by graphic mark and the function of inputting a numeral. a The machine monitor automatically judges which function of each switch is currently effective, according to the display condition of multi-display. Reference For the setup procedure after replacing the machine monitor assembly, see Service News(AT07196).
PC228US-8,PC228USLC-8
30-71
Electrical system Special function of machine monitor (EMMS)
t Ordinary functions and special functions of machine monitor 30-70 The machine monitor has the ordinary functions and special functions and displays information of various types on the multi-display. Some items are displayed automatically according to the internal setting of the machine monitor and the others are displayed according to the operation of the switches. 1. Ordinary functions: Operator mode The information items in this mode are displayed ordinarily. The operator can display and set them by operating the switches (Display and setting of some items need special operations of the switches). 2. Special function: Service mode The information items in this mode are not displayed ordinarily. Each technician can display them by operating the switches specially. This mode is used for special setting, testing, adjusting, or troubleshooting. While normal operation screen is displayed.
A Display of KOMATSU logo
Page 30-71 30-71
A Display of inputting password
30-72
A Display of check of breaker mode A Display of check before starting A Display of warning after check before starting A Display of overdue maintenance Working mode and travel speed check A screen A Display of standard screen A Display of end screen B Selection of auto-deceleration B Selection of working mode
30-74
B Selection of travel speed B Operation to stop alarm buzzer B Operation of wiper B Operation of window washer B Operation of air conditioner B Operation to display camera mode
30-75 30-75 30-76 30-76 30-76 30-76
B
Switching between clock display and service meter display
30-72 30-72 30-72 30-73
30-91 30-93 30-94 30-95
30-73
Telephone number registration
30-97
30-73 30-74 30-74 Default
Key-on Mode Unit With/Without Attachment Attachment/Maintenance Password Camera
30-98 30-99 30-100
ECO Display
30-103
30-101 30-102
30-77 30-77
No Injection
30-116
30-78
Fuel Consumption Terminal Status KOMTRAX GPS & Communication Status Settings MODEM IP address
30-118 30-119 30-120
Display of service message
30-122
30-77
30-78
30-72
o
30-90
Pump Absorption Torque (F) 30-104 Pump Absorption Torque (R) 30-105 Low Speed 30-106 Attachment Flow Adjustment 30-107 Boom potentiometer compensa30-108 Adjustment tion F pump swash plate sensor cali30-110 bration R pump swash plate sensor cali30-113 bration Cylinder Cut-Out 30-115
C Display of caution monitor Displaying function of user code and failure code O (Special operation) Function of checking display of LCD (Liquid D Crystal Display) D Function of checking service meter Function of changing attachment/mainteD nance password
Monitoring
Page 30-83 30-84
Mechanical system failure hisAbnormality tory Record Electrical system failure history Air conditioner failure history Maintenance history Change of maintenance mode
B Check of maintenance information Entering user mode B (including KOMTRAX messages for user) C Display function of energy-saving guidance
C
Service mode
(Special operation)
Operator mode (outline)
30-79
30-121
30-81 30-81 30-81
PC228US-8,PC228USLC-8
Electrical system Special function of machine monitor (EMMS)
a Classification of operator mode A: Screen or function that is displayed or enabled from the time when the starting switch is turned to ON position to the time when screen changes to the standard screen, and screen after starting switch is turned to OFF position B:Display/Function when switch of machine monitor is operated C:Display/Function when certain condition is satisfied D:Screen or function that needs special operation of switches to be displayed or enabled
PC228US-8,PC228USLC-8
30-73
Electrical system Special function of machine monitor (EMMS)
t Operator mode (outline) 30-72 a Only outline of the operator mode is described in this section. For details of contents/operation of each function/display, see the “Structure, function and maintenance standard”, or Operation and Maintenance Manual. a The following are the displays or functions of the operator mode explained in this section (including some items which need special operations).
Display of KOMATSU logo 30-71 When starting switch is turned ON, KOMATSU logo is displayed for 2 seconds. a After the KOMATSU logo is displayed for two seconds, the screen changes to "Password input" screen, or "Check before starting" screen.
Display pattern A B C D E 1 1 1 1 1 2 – – – – – – 2 – – 3 2 3 2 2 – – – 3 –
Display of KOMATSU logo Display of inputting password Display of check of breaker mode Display of check before starting Display of warning after check before starting Display of overdue maintenance – – – – 3 Working mode and travel speed check 4 3 4 4 4 screen Display of standard screen 5 4 5 5 5 Display of end screen Selection of auto-deceleration Selection of working mode Selection of travel speed Operation to stop alarm buzzer Operation of windshield wiper Operation of windshield washer Operation of air conditioner Operation to display camera mode Switching between clock display and service meter display Check of maintenance information Entering user mode (including KOMTRAX messages for user) Display of energy-saving guidance Display of caution monitor Displaying user code and failure code O (Special operation) Function of checking display of LCD (Liquid Crystal Display) Function of checking service meter Function of changing attachment/maintenance password
a The following screen may be displayed instead of the above “Display of inputting password screen”. a If this screen is displayed, call the person responsible to operation of KOMTRAX in your Komatsu distributor and ask for remedy.
a Display pattern of operator mode The contents of display from the time when starting switch is turned ON to time when screen changes to ordinary screen depends on the setting and condition of the machine. A: When engine start lock is set effective B: When engine start lock is set ineffective C: When working mode at start is set to Breaker mode (B) D: When there is abnormal item in check-before-starting items E: When there is maintenance item which is not maintained after specified interval
30-74
PC228US-8,PC228USLC-8
Electrical system Special function of machine monitor (EMMS)
Display of inputting password 30-72 After the KOMATSU logo is displayed, the screen to input the engine start lock password is displayed. a This screen is displayed only when the engine start lock function is set effective. a If the password is input normally, the screen changes to "Display of check before starting". a The machine monitor has some password functions other than the engine start lock. Those functions are independent from one another.
Display of check of breaker mode 30-72 When the starting switch is turned ON, if the working mode is set to the breaker mode [B], a message to inform the operator of starting in the breaker mode is displayed on the screen. k If an attachment other than the breaker is used while the working mode is set to the breaker mode [B], the machine may move unexpectedly or may not operate normally or the hydraulic components may be damaged. a After the check operation of the breaker mode is finished, the screen changes to "display of check before starting". If [No] is selected: Working mode is set to economy mode [E] If [Yes] is selected: Working mode is set to breaker mode [B]
PC228US-8,PC228USLC-8
Display of check before starting 30-72 When the screen changes to the check-before-starting screen, the check before starting is carried out for 2 seconds. a If any abnormality is detected by the check before starting, the screen changes to "Display of warning after check before starting" or "Display of overdue maintenance". a If no abnormality is detected by the check before starting, the screen changes to "Working mode and travel speed check" screen. a The monitors (2 pieces) displayed on the screen are the items under the check before starting.
Display of warning after check before starting 30-72 If any abnormality is detected by the check before starting, the warning monitor is displayed on the screen. a The following figure shows that the engine oil pressure monitor (a) that warns of low engine oil pressure.
30-75
Electrical system Special function of machine monitor (EMMS)
Display of overdue maintenance 30-73 When the check before starting is carried out, if a maintenance item is near or after the end of the set interval, the maintenance monitor is displayed for 30 seconds to urge the operator to maintenance. a This screen is displayed only when the maintenance function is enabled. If the remaining time of any item is 30 H or less, the yellow icon is displayed. If the remaining time of any item is 0 H or less, the red icon is displayed. a The maintenance reminder function is enabled or disabled by using the machine monitor in the service mode. a After this screen display is finished, the screen changes to "Working mode and travel speed check" screen.
Display of standard screen 30-73 If the machine monitor starts normally, the standard screen is displayed. a Service meter (a) or a clock is displayed at the centre upper section of the screen (use [F4] to switch the display between the service meter and clock). a ECO gauge (b) is displayed at the right end of the screen (specify display or non-display of the ECO gauge in the service mode).
Working mode and travel speed check screen 30-73 If the check before starting is finished successfully, the screen to check the working mode and travel speed is displayed for 2 seconds. a After the “Working mode and travel speed check” screen is finished, the screen changes to the "Standard” screen.
30-76
PC228US-8,PC228USLC-8
Electrical system Special function of machine monitor (EMMS)
Display of end screen 30-74 When starting switch is turned OFF, the end screen is displayed for 5 seconds. a Another message may be displayed on the end screen, depending on the message display function of KOMTRAX.
Selection of working mode 30-74 Select a working mode according to the following procedure. 1. While the standard screen is displayed, press the working mode selector switch, and the working mode selection screen is displayed.
Selection of auto-deceleration 30-74 While the standard screen is displayed, if the auto-deceleration switch is pressed, large auto-deceleration monitor (a) is displayed for 2 seconds and the setting of the auto-deceleration is changed. a Each time the auto-deceleration switch is pressed, the auto-deceleration is turned ON and OFF alternately. a If the auto-deceleration is set to ON, large monitor (a) and auto-deceleration monitor (b) are displayed simultaneously. a If the auto-deceleration is set to OFF, auto-deceleration monitor (b) goes off.
2. Operate the function switches or working mode selector switch to select the desired working mode and enter the selection. Function switch q [F3]: Move to lower working mode q [F4]: Move to upper working mode q [F5]: Cancel selection and return to standard screen q [F6]: Confirm selection and return to standard screen Working mode selector switch q Press: Move to lower working mode q Hold down:Confirm selection and return to standard screen a If you do not touch any of the function switches and working mode selector switch for 5 seconds, the selection is determined and the screen changes to the ordinary screen.
PC228US-8,PC228USLC-8
30-77
Electrical system Special function of machine monitor (EMMS)
3. When the standard screen is displayed again, large working mode monitor (a) is displayed for 2 seconds, and then the setting of the working mode is changed to the selected mode. a When large monitor (a) is displayed, the display of working mode monitor (b) is changed, too.
<Precautions for selecting breaker mode [B]> q If breaker mode [B] is selected, both of the control of the hydraulic pump and the setting of the hydraulic circuit are changed. q If an attachment other than the breaker is used, the machine may move unexpectedly or may not operate normally or the hydraulic components may be damaged. q After the breaker mode is selected, the screen to confirm the selection of the breaker mode is displayed (The buzzer sounds intermittently while this screen is displayed). q If the setting is confirmed on this screen, the screen changes to the standard screen. If "No" is selected: Screen returns to working mode selecting screen If [Yes] is selected: Working mode is set to breaker mode [B]
30-78
Selection of travel speed 30-75 While the standard screen is displayed, if the travel speed shifting switch is pressed, large travel speed monitor (a) is displayed for 2 seconds and the setting of the travel speed is changed. a Each time the travel speed shifting switch is pressed, the travel speed changes in the order of [Lo], [Mi], [Hi] and [Lo]. a When large monitor (a) is displayed, the display of travel speed monitor (b) is changed, too.
Operation to stop alarm buzzer 30-75 While the alarm buzzer is sounding, if the alarm buzzer cancel switch is pressed, the alarm buzzer stops. a Even if the alarm buzzer cancel switch is pressed, the screen does not change.
PC228US-8,PC228USLC-8
Electrical system Special function of machine monitor (EMMS)
Operation of wiper 30-76 While the standard screen is displayed, if the wiper switch is pressed, large wiper monitor (a) is displayed for 2 seconds and the wiper starts or stops. a The window washer does not operate if the window limit switch is "ON". a Each time the wiper switch is pressed, the wiper setting is changed in the order of INT, ON, OFF, and INT. a When the wiper is set to INT or ON, large monitor (a) is displayed and the display of wiper monitor (b) is changed, too. a If the wiper is set to OFF, large monitor (a) is not displayed and the wiper monitor disappears.
Operation of air conditioner 30-76 While the standard screen is displayed, if the air conditioner switch is pressed, the air conditioner adjustment screen is displayed. a While the air conditioner adjustment screen is displayed, if you do not touch any switch for 5 seconds, the screen changes to the standard screen.
Operation to display camera mode 30-76 If [F3] is pressed, the multi-display changes to the camera image (Set the connection of the camera in the service mode).
Operation of window washer 30-76 While the standard screen is displayed, if the window washer switch is pressed, the washer fluid is splashed only while the switch is held down. a Even if the window washer switch is pressed, the screen does not change.
a Up to three cameras can be connected. If the camera mode is selected, however, only the image of camera 1 is always displayed.
PC228US-8,PC228USLC-8
30-79
Electrical system Special function of machine monitor (EMMS)
a If any caution occurs in the camera mode, the corresponding caution monitor is displayed at the left top of the screen (excluding the low hydraulic oil temperature caution).
Check of maintenance information 30-7 While the maintenance monitor or ordinary screen is displayed, if [F5] is pressed, the Maintenance List screen is displayed.
a If no control lever is operated for 10 seconds while a failure enough to display user code is occurring in the camera mode, the screen returns to the standard screen and displays information about that failure. a When two or more cameras are connected, the image of one of them or the images of two of them can be displayed. a As 2-camera image display [F4] is selected, the image of camera 1 is displayed on the left side of the screen and the image of camera 2 is displayed on the right side. The image of camera 3 is displayed only singly. a If 2-camera image display operation is made, the images are displayed frame by frame at intervals of approximately 1 second on the right and left side of the screen.
a To reset the remaining time after finishing maintenance, more operations are necessary.
Switching between clock display and service meter display 30-7 While the standard screen is displayed, if [F4] is pressed, the service meter and the clock are displayed alternately in section (a). a When selecting the clock display, perform the time adjustment, 12-hour or 24-hour display setting, and summer time setting by using the user mode functions.
30-80
Entering user mode 30-7 (including KOMTRAX messages for user) To enter the user mode, press [F6] to display the "User Menu" screen while the standard screen is displayed.
PC228US-8,PC228USLC-8
Electrical system Special function of machine monitor (EMMS)
a There are following items in the user menu. Breaker/attachment setting Message display Screen adjustment Clock adjustment Language setting Economy mode adjustment
a The breaker/attachment setting menu is displayed only when "With attachment" is set in the service mode.
[KOMTRAX message] There are two types of KOMTRAX message; one is for the user and the other is for the service. q For user: A message transmitted from the KOMTRAX base station for the user. If it is received, the message monitor is displayed on the standard screen. To see the contents of the message, operate "User Message" in the above user menu. q For service: This is a message sent from the KOMTRAX base station for the technician. Even if it is received, no sign is displayed on the standard screen. To read the message, select "Service message display" on the service menu in the service mode.
Display of energy-saving guidance 30-78 When the machine is set in a certain operating condition, the energy-saving guidance screen is displayed automatically to urge the operator to the energy-saving operation. a The energy-saving guidance is displayed when the following condition is satisfied while the display setting is set effective in the service mode. a Condition for display: "Engine is running" and "All levers have been in neutral for 5 minutes" and "Caution (Note) or user code is not indicated" Note: Excluding hydraulic oil low temperature caution. a If any lever or pedal is operated, or [F5] is pressed, the screen returns to the standard screen.
q
PC228US-8,PC228USLC-8
Display of caution monitor 30-78 While the standard screen or the camera image screen is displayed, if a problem enough to display a caution monitor occurs, the caution monitor is displayed large for a moment and then displayed at section (a) on the screen. a On the camera mode screen, the caution monitor flashes at the left upper of the screen when a caution item is detected.
30-81
Electrical system Special function of machine monitor (EMMS)
Display function of user code and failure code 30-79 While the standard screen or the camera mode screen is displayed, if an abnormality which displays a user code and a failure code occurs, all the information of the abnormality is displayed. (a): User code (three digits) (b): Failure code (five or six digits) (c): Telephone mark (d): Telephone No. a This screen is displayed only when an abnormality (failure code) for which a user code is set occurs. a The telephone mark and telephone number are displayed only when the telephone number is registered in the service mode. a If multiple abnormalities occur simultaneously, all the codes are displayed repeatedly in order. a Since the information of the displayed failure code is recorded in the abnormality record in the service mode, check the details in the service mode.
a When the caution monitor is also displayed, the telephone mark is not displayed.
30-82
PC228US-8,PC228USLC-8
Electrical system Special function of machine monitor (EMMS)
a Remedies that the displayed user codes prompt the operator to take (The following table is an excerpt from the Operation and Maintenance Manual) User code
Failure mode
E02
Pump control system error
E03
Swing brake system error
E06
Electric system error
E10
E11 E14 E15 E20
Action If the emergency pump drive switch is set to the rear (emergency) position, normal operations become possible, but have inspection carried out immediately. Have inspection carried out immediately. The work equipment can be raised by setting the work equipment emergency operation switch to the ON position. In that instance, however, call on your Komatsu distributor for inspection immediately.
Defective engine controller power source Engine controller drive system Have inspection carried out immediately. circuit error (Engine stops) Engine controller system error Operate machine to a safe posture and have inspection carried out Output reduced to protect engine immediately. Problem in throttle system Operate machine to a safe posture and have inspection carried out (Abnormality in fuel control dial) immediately. Engine sensor (coolant temperaNormal operation is possible. Have the machine inspected immediture, fuel pressure, oil pressure) ately, however. system error Operate machine to a safe posture and have inspection carried out Problem in travel system immediately.
E0E
Network error
E50
Arm crane system error
PC228US-8,PC228USLC-8
Operate machine to a safe posture and have inspection carried out immediately. Stop crane work immediately. If there is any abnormality, ask your KOMATSU distributor for testing and repair. If another working mode is selected, the machine can perform digging work.
30-83
Electrical system Special function of machine monitor (EMMS)
Function of checking display of LCD (Liquid Crystal Display) 30-81 While the standard screen is displayed, if the following numeral input switch and function switch are operated as follows, all the LCD (Liquid Crystal Display) lights up in white. q Operation of switches (simultaneous): "4" + "F2" a When finishing the operation of the switches, release "F2" first. a If there is a display error in the LCD, only that part is indicated in black. a The LCD panel sometimes has black points (points which are not lighted) and bright points (points which do not go off) for the reason of its characteristics. If the number of the bright points and black points does not exceed 10, those points are not a failure or a defect. a To return to the former screen, press any one of the function switches.
Function of checking service meter 30-81 To check the service meter while the starting switch is in OFF position, operate the numeral input switches as follows. At this time, only the service meter section appears. q Operation of switches (simultaneous): "4"+ "1" a There is some time lag in start of the LCD, so hold down the switches until the LCD displays normally. a In the case of a machine monitor that has been used a long period of time, the machine monitor may display blue bright spots (spots which do not go off) on this screen; it is quite normal.
30-84
Function of changing attachment/maintenance password 30-81 When changing the attachment/maintenance password that is necessary for using the attachment setting function and maintenance setting function, perform the following procedures. 1. While the standard screen is displayed, perform the following operation with the numeral input switches. q Operation of switches (While pressing [4], perform the operation in order): [4]+[5]o[5]o[5] a This operation of the switches is not accepted until 10 minutes pass after the starting switch is turned to ON position.
2. After the Attachment/Maintenance PASSWORD screen is displayed, input the current password with the numeral input switches and confirm it with the function switch. q [F5]: Delete input numeral/Return to ordinary screen q [F6]: Confirm input numeral a Default password: [000000] a If the input password is correct, the screen changes to the next screen. a If the input password is incorrect, the message to request inputting the password again is displayed.
PC228US-8,PC228USLC-8
Electrical system Special function of machine monitor (EMMS)
4. After the New password input screen is displayed again, input a new password again by using the numeral input switches and confirm it by using the function switch. q [F5]: Delete input numeral/Return to standard screen q [F6]: Confirm input numeral a If a password different from the password input before is input, the message to input again is displayed.
3. After the "New Password" screen is displayed, input a new password with the numeral input switches and confirm it with the function switch. a Set a new password of 4 to 6 digits (If it has only 3 or less digits or has 7 or more digits, it is not accepted). q [F5]: Delete input numeral/Return to standard screen q [F6]: Confirm input numeral 5. If the screen to notify completion of setting is displayed and then the standard screen is displayed, the password has been changed successfully
PC228US-8,PC228USLC-8
30-85
Electrical system Special function of machine monitor (EMMS)
t Service mode 30-83 To change the operator mode to the service mode, perform the following operation. This operation is always required when you use the service mode. 1. Check of display of screen and operation of switches While the standard screen is displayed, perform the following operation with the numeral input switches. q Operation of switches (While pressing [4], perform the operation in order): [4]+[1]o[2]o[3] a This operation of the switches is accepted only while the ordinary screen is displayed.
2. Selection of service menu When the "Service Menu" screen is displayed, the service mode is selected. Select a service menu you use by using the function switches or numeral input switches. q [F3]: Move to lower item q [F4]: Move to upper item q [F5]: Return to standard screen (operator mode) q [F6]: Confirm selection a You may enter a 2-digit code with the numeral input switches to select the menu of that code and confirm it with [F6].
30-86
a The items which can be selected in the service menu are as follows (including some items which need special operations). 01 Monitoring Mechanical system abnormality record 02 Abnormality Electrical system abnormality Record record Air conditioning system abnormality record 03 Maintenance Record 04 Maintenance Mode Change 05 Phone Number Entry Key-on Mode Unit With/Without Attachment Attachment/Maintenance Pass06 Default word Camera ECO Display Pump Absorption Torque (F) Pump Absorption Torque (R) Low Speed Attachment Flow Adjustment 07 Adjustment Boom potentiometer initialization F pump swash plate sensor calibration R pump swash plate sensor calibration 08 Cylinder Cut-Out 09 No Injection 10 Fuel Consumption Terminal Status 11 KOMTRAX GPS & Communication Status Settings Modem S/N 12 Service message display
PC228US-8,PC228USLC-8
Electrical system Special function of machine monitor (EMMS)
Monitoring 30-84 The machine monitor can monitor the condition of the machine in real time by receiving signals from various switches, sensors, and actuators installed to many parts of the machine and the information from the controllers which are controlling switches, etc. 1. Selection of menu Select "Monitoring" on the "Service Menu" screen.
2. Selecting monitoring items After the "Monitoring selection menu screen" is displayed, select items to be monitored by using the function switches or numeral input switches. q [F1]: Move to next page (screen) q [F2]: Move to previous page (screen) q [F3]: Move to lower item q [F4]: Move to upper item q [F5]: Delete input numeral/Return to service menu screen q [F6]: Confirm selection a Selection with function switches: Select an item with [F3] or [F4] and determine it with [F6]. a Selection with numeral input switches: Enter a 5-digit code, and the item of that code is selected directly. Confirm that item with [F6]. a If the colour of the selected box changes from yellow to red, selection of the item of that box is confirmed. a Up to six monitoring items can be selected at a time. You may not able to set up to six items, however, depending on the display form of the selected items.
PC228US-8,PC228USLC-8
3. Deciding monitoring items After selecting monitoring items, execute monitoring with the function switch or numeral input switch. a Execution with function switch: Double-click or keep pressing [F6] (for approximately 2 seconds). a Execution with numeral input switch: Input [99999] and press [F6]. a When monitoring only two items, for example, select them and confirm with [F6]. If [F6] is pressed once more at this time, monitoring is executed. a If monitoring items are selected up to the limit number, monitoring is executed automatically.
30-87
Electrical system Special function of machine monitor (EMMS)
4. Executing monitoring After the "Executing monitoring screen" is displayed, perform the necessary operation of the machine and check the monitoring information. a Monitoring information is indicated by value, ON/OFF, or special display. a The unit of display can be selected in SI unit, metric unit, or inch unit with the Default function in the service mode.
5. Holding monitoring information The monitoring information can be held and released with the function switches. q [F3]: Release holding q [F4]: Hold information (displayed data is fixed) q [F5]: Return to monitoring selection menu screen
30-88
6. Changing machine setting mode To change the setting of the working mode, travel speed, or auto-deceleration during monitoring, operate the corresponding switch under the current condition, and the mode setting screen is displayed. While this screen is displayed, if the corresponding switch is operated further, the corresponding mode is changed. a After finishing changing the setting, press [F6] to return to the monitoring information screen. a If the setting is changed during monitoring, the new setting is held even after the screen returns to the standard screen after monitoring is finished.
a If the working mode is changed to breaker mode [B], the screen to confirm the change of the setting is displayed as in changing the working mode on the standard screen.
PC228US-8,PC228USLC-8
Electrical system Special function of machine monitor (EMMS)
Monitoring items list Unit (Initial setting: ISO) Code No.
Monitoring item (Display on screen) ISO
meter
inch
Comp onent in charge
00200 Controller Model Select
–
PUMP
00201 Machine ID
–
ENG
01002 Engine speed
r/min
rpm
01601 2nd Eng. Speed Command
r/min
rpm
rpm
ENG
rpm
PUMP
2
01100 F Pump Pressure
MPa
kg/cm
psi
PUMP
01101 R Pump Pressure
MPa
kg/cm2
psi
PUMP
07400 Boom Raise PPC Pressure
MPa
kg/cm2
psi
PUMP
MPa
kg/cm2
psi
PUMP
07300 Bucket Curl PPC Pressure
MPa
kg/cm2
psi
PUMP
07301 Bucket Dump PPC Pressure
MPa
kg/cm2
psi
PUMP
09001 Swing left PPC Pressure
MPa
kg/cm2
psi
PUMP
09002 Swing right PPC Pressure
MPa
kg/cm2
psi
PUMP
07102 Travel FW L PPC Pressure
MPa
kg/cm2
psi
PUMP
07103 Travel FW R PPC Pressure
MPa
kg/cm2
psi
PUMP
07104 Travel BW L PPC Pressure
MPa
kg/cm2
psi
PUMP
07105 Travel BW R PPC Pressure
MPa
kg/cm2
psi
PUMP
04107 Coolant Temperature
°C
°C
°F
ENG
04401 Hydr. Oil Temperature
°C
°C
°F
PUMP
01300 PC-EPC Sol. Curr. (F)
mA
mA
mA
PUMP
01302 PC-EPC Sol. Curr. (R)
mA
mA
mA
PUMP
01500 LS-EPC Sol. Curr.
mA
mA
mA
PUMP
08000 Merge-divider Sol. Curr. (Main)
mA
mA
mA
PUMP
08001 Merge-divider Sol. Curr. (LS)
mA
mA
mA
PUMP
01700 Service Sol. Curr.
mA
mA
mA
PUMP
01800 Boom slow down EPC current
mA
mA
mA
PUMP
03200 Battery Voltage
V
V
V
PUMP
03203 Battery Power Supply
V
V
V
ENG
04300 Battery Charge Vol.
V
V
V
MON
36400 Rail Pressure
MPa
kg/cm2
psi
ENG
37400 Ambient Pressure
kPa
kg/cm2
psi
ENG
18500 Charge Temperature
°C
°C
°F
ENG
36500 Boost Pressure
kPa
kg/cm2
psi
ENG
36700 Engine Torque Ratio
%
%
%
ENG
18700 Engine Output Torque
Nm
kgm
lbft
ENG
03000 Fuel Dial Pos Sens Volt
V
V
V
ENG
04200 Fuel Level Sensor Vol.
V
V
V
MON
07200 Arm Curl PPC Pressure
PC228US-8,PC228USLC-8
Remarks
Absolute value indication (including atmospheric pressure)
30-89
Electrical system Special function of machine monitor (EMMS)
Unit (Initial setting: ISO) Code No.
Monitoring item (Display on screen)
Comp onent in charge
ISO
meter
inch
04105 Eng. Water Temp. Vol. Lo
V
V
V
ENG
04402 Hydr. Temp. Sonser Vol.
V
V
V
PUMP
37401 Ambient Press Sens Volt
V
V
V
ENG
18501 Charge Temp Sens Volt
V
V
V
ENG
36501 Charge Press Sens Volt
V
V
V
ENG
36401 Rail Pressure Sens Volt
V
V
V
ENG
17500 Engine Power Mode
–
ENG
31701 Throttle Position
%
%
%
ENG
31706 Final Throttle Position
%
%
%
ENG
18600 Inject Fueling Command
mg/st
mg/st
mg/st
ENG
36200 Rail Press Command
MPa
kg/cm2
psi
ENG
36300 Injection Timing Command
CA
CA
CA
ENG
37300 Fuel Rate
l/h
l/h
gal/h
ENG
01602 2nd Eng. Speed Command
%
%
%
PUMP
13113 Main Pump Absorb Torque
Nm
kgm
lbft
PUMP
01137 F pump delivery
cc/rev
cc/rev
cc/rev PUMP
V
V
cc/rev
cc/rev
V
V
V
PUMP
15900 Boom Bottom Pressure
MPa
kg/cm2
psi
PUMP
06004 Boom Angle Potentio Voltage
V
V
V
PUMP
01138 F pump sw plate sensor volt 01139 R pump delivery 01140 R pump sw plate sensor volt
01900
V
PUMP
cc/rev PUMP
Swing
ON, OFF
PUMP
Travel
ON, OFF
PUMP
ON, OFF
PUMP
ON, OFF
PUMP
Arm Curl
ON, OFF
PUMP
Arm Dump
ON, OFF
PUMP
Bucket Curl
ON, OFF
PUMP
Pressure Switch Boom Lower 1 Boom Raise
Pressure Switch Bucket Dump 2 Service
ON, OFF
PUMP
ON, OFF
PUMP
Travel Steering
ON, OFF
PUMP
Travel Junction
ON, OFF
PUMP
Swing Brake
ON, OFF
PUMP
02300 Solenoid Valve 1 Merge-divider
ON, OFF
PUMP
2-Stage Relief
ON, OFF
PUMP
Travel Speed
ON, OFF
PUMP
ON, OFF
PUMP
Lever Sw.
ON, OFF
PUMP
Swing Release Sw.
ON, OFF
PUMP
Swing Brake Sw.
ON, OFF
PUMP
01901
02301 Solenoid Valve 2 Service Return
02200 Switch Input 1
30-90
Remarks
PC228US-8,PC228USLC-8
Electrical system Special function of machine monitor (EMMS)
Unit (Initial setting: ISO) Code No.
Monitoring item (Display on screen) ISO
meter
inch
Comp onent in charge
Model Select 1
ON, OFF
PUMP
Model Select 2
ON, OFF
PUMP
Model Select 3
ON, OFF
PUMP
Model Select 4
ON, OFF
PUMP
Model Select 5
ON, OFF
PUMP
Overload Alarm
ON, OFF
PUMP
Key Switch (ACC)
ON, OFF
PUMP
Window Limit SW.
ON, OFF
PUMP
P Limit SW.
ON, OFF
PUMP
W Limit SW.
ON, OFF
PUMP
Key Switch
ON, OFF
MON
Start
ON, OFF
MON
Preheat
ON, OFF
MON
Light
ON, OFF
MON
Rad. Level
ON, OFF
MON
Air cleaner
ON, OFF
MON
Eng. Oil Level
ON, OFF
MON
Battery Charge
ON, OFF
MON
Swing Brake Sw.
ON, OFF
MON
F1
ON, OFF
MON
F2
ON, OFF
MON
F3
ON, OFF
MON
F4
ON, OFF
MON
F5
ON, OFF
MON
F6
ON, OFF
MON
SW1
ON, OFF
MON
SW2
ON, OFF
MON
SW3
ON, OFF
MON
SW4
ON, OFF
MON
SW5
ON, OFF
MON
SW6
ON, OFF
MON
SW7
ON, OFF
MON
SW8
ON, OFF
MON
SW9
ON, OFF
MON
SW10
ON, OFF
MON
SW11
ON, OFF
MON
SW12
ON, OFF
MON
Remarks
02201 Switch Input 2
02202 Switch Input 3
02204 Switch Input 5
04500 Monitor input 1
04501 Monitor Input 2
04502 Monitor Input 3
04503
Monitor Function Switches
Monitor 1st & 04504 2nd Row Switches
Monitor 3rd & 04505 4th Row Switches
PC228US-8,PC228USLC-8
30-91
Electrical system Special function of machine monitor (EMMS)
Unit (Initial setting: ISO) Code No.
Monitoring item (Display on screen) ISO
meter
inch
Comp onent in charge
Remarks
SW13 Monitor 5th Row 04506 SW14 Switches SW15
ON, OFF
MON
ON, OFF
MON
ON, OFF
MON
18800 Water In Fuel
ON, OFF
ENG WIF: Water In Fuel
20216 ECM Build Version
–
ENG
20217 ECM CAL Data Ver
–
ENG
18900 ECM Internal Temp
°C
°C
°F
ENG
20400 ECM Serial No
–
ENG
20227 Monitor Ass'y P/N
–
MON
20402 Monitor Serial No
–
MON
20228 Monitor Prog. P/N
–
MON
20229 Pump Con. Ass'y P/N
–
PUMP
20403 Pump Con. Serial No
–
PUMP
20230 Pump Con. Prog. P/N
–
PUMP
a Listing order of items in table The items are listed in the order of display on the monitoring item selection menu screen. a Unit The display unit can be set to ISO, meter, or inch freely (Set it with unit selecting in "Default" setting of the service menu). "CA" in the display unit is an abbreviation for crankshaft angle. "mg/st" in the display unit is an abbreviation for milligram/stroke. a Component in charge MON: The machine monitor is in charge of detection of monitoring information. ENG: The engine controller is in charge of detection of monitoring information. PUMP: The pump controller is in charge of detection of monitoring information. Note 1:The momentary fuel consumption (monitoring code: 37300) is the theoretical fuel consumption (because it is a theoretical value, it is a little different from the actual fuel consumption).
30-92
PC228US-8,PC228USLC-8
Electrical system Special function of machine monitor (EMMS)
Abnormality Record (Mechanical Systems) 30-90 The machine monitor classifies and logs the failures which occurred in the past or which are occurring at present into the electrical system abnormality, mechanical system abnormality, and Air-conditioning System abnormality. To check the mechanical system abnormality record, perform the following procedures. a For the failure code list, see "40 Failure code list for troubleshooting". 1. Selection of menu Select "Abnormality Record" on the "Service Menu" screen.
2. Selecting sub menu After the "Abnormality Record" screen is displayed, select "Mechanical Systems" with the function switches or numeral input switches. q [F3]: Move to lower item q [F4]: Move to upper item q [F5]: Return to Service Menu screen q [F6]: Confirm selection a You may enter a 2-digit code with the numeral input switches to select the item of that code and confirm it with [F6]. a The following figure shows the display for the machines with air conditioner. As for machines with heater and heater-less machines, the character string of "03 Air-conditioning System" is different or is not displayed respectively.
3. Information displayed on "Abnormality Record" screen On the "Mechanical Systems" screen, the following information is displayed. (a): Occurrence order of abnormalities from latest one/Total number of abnormalities in the log (b): Failure code (c): Failure (d): Number of occurrences (limit of display: 0 65,535 times) (e): SMR at first occurrence (f): SMR at last occurrence q [F1]: Move to next page (screen) (if displayed) q [F2]: Move to previous page (screen) (if displayed) q [F5]: Return to Abnormality Record screen a If no abnormality is recorded, "No abnormality record" is displayed. a If the number of occurrences is one (first occurrence), the service meter reading at the first occurrence and that at the last occurrence are the same. a If [E] is displayed on the left of a failure code, the abnormality is still occurring or restoration has not been confirmed. a For all the failure codes that the machine monitor can record, see the "Failure code table".
4. Clearing abnormality record A contents of the mechanical system abnormality record cannot be clearing.
PC228US-8,PC228USLC-8
30-93
Electrical system Special function of machine monitor (EMMS)
Abnormality Record (Electrical Systems) 30-91 The machine monitor classifies and logs the failures which occurred in the past or which are occurring at present into the electrical system abnormality, mechanical system abnormality, and Air-conditioning System abnormality. To check the electrical system abnormality record, perform the following procedures. a For the failure code list, see "40 Failure code list for troubleshooting". 1. Selection of menu Select "Abnormality Record" on the "Service Menu" screen.
2. Selecting sub menu After the "Abnormality Record" screen is displayed, select "Electrical Systems" with the function switches or numeral input switches. q [F3]: Move to lower item q [F4]: Move to upper item q [F5]: Return to Service Menu screen q [F6]: Confirm selection a You may enter a 2-digit code with the numeral input switches to select the item of that code and confirm it with [F6].
30-94
3. Information displayed on "Abnormality Record" screen On the "Electrical Systems" screen, the following information is displayed. (a): Occurrence order of abnormalities from latest one/Total number of abnormalities in the log (b): Failure code (c): Failure (d): Number of occurrences (limit of display: 0 65,535 times) (e): SMR at first occurrence (f): SMR at last occurrence q [F1]: Move to next page (screen) (if displayed) q [F2]: Move to previous page (screen) (if displayed) q [F3]: Move to lower item q [F4]: Move to upper item q [F5]: Return to Abnormality Record screen a If no abnormality is recorded, "No abnormality record" is displayed. a If the number of occurrences is one (first occurrence), the service meter reading at the first occurrence and that at the last occurrence are the same. a If [E] is displayed on the left of a failure code, the abnormality is still occurring or restoration of it has not been confirmed. a For all the failure codes that the machine monitor can record, see the "Failure code table".
PC228US-8,PC228USLC-8
Electrical system Special function of machine monitor (EMMS)
4. Clearing abnormality record 1) While the "Electrical Systems" screen is displayed, perform the following operation with the numeral input switches. q Operation of switches (While pressing [4], perform the operation in order): [4]+[1]o[2]o[3]
2) Check that the screen is set in the clear mode, and then clear the items one by one or together with the function switches. a If the screen is set in the clear mode, graphic mark [CLEAR] is indicated above [F2]. q [F2]: Clear all items q [F3]: Move to lower item q [F4]: Move to upper item q [F5]: Return to Abnormality Record screen q [F6]: Clear selected item a To clear items one by one: Select the item to be cleared with [F3] or [F4] and press [F6]. a To clear all items together: Press [F2], and all the items are cleared, regardless of selection of the items. a If [E] is displayed on the left of a failure code, the clearing operation is accepted but the information is not reset.
PC228US-8,PC228USLC-8
3) After the "Electrical Sys. Error Reset" screen is displayed, operate the function switches. q [F5]: Return to Electrical systems screen (clear mode) q [F6]: Execute clearing a The following figure shows the screen displayed when the items are cleared one by one (which is a little different from the screen displayed when all the items are cleared together).
4) If the screen to notify completion of clearing is displayed and then the "Electrical Systems" (clear mode) screen is displayed, the clearing of the abnormality record is completed. a After a while, the screen returns to the "Electrical Systems" screen.
30-95
Electrical system Special function of machine monitor (EMMS)
Abnormality Record (Air-conditioning System) 30-93 The machine monitor classifies and logs the failures which occurred in the past or which are occurring at present into the electrical system abnormality, mechanical system abnormality, and Air-conditioning System abnormality. To check the air-conditioning abnormality record or heater abnormality record, perform the following procedures. 1. Selection of menu Select "Abnormality Record" on the "Service Menu" screen.
2. Selecting sub menu After the "Abnormality Record" screen is displayed, select "Air-conditioning System" by using the function switches or numeral input switches. q [F3]: Move to lower item q [F4]: Move to upper item q [F5]: Return to Service Menu screen q [F6]: Confirm selection You may enter a 2-digit code with the numeral input switches to select the item of that code and confirm it with [F6].
30-96
3. Information displayed on "Abnormality Record" screen On the "Air-conditioning System" screen, the following information is displayed. (a): System or component name (b): Number of failure occurrences (c): Status display (Normal or abnormal) q [F2]: Delete "Abnormality record" q [F5]: Return to Abnormality record screen If [E] is displayed on the left of a status display, the abnormality is still occurring or restoration of it has not been confirmed. If "CAN disconnection" is displayed for CAN Status, communication cannot be carried out normally. Accordingly, the statuses of other items are not displayed.
4. Clearing abnormality record While the "Air-conditioning system" screen is displayed, press [F2], and the number of occurrences of abnormality is cleared. If it is confirmed at this time that the system is restored, the status display changes to Normal.
PC228US-8,PC228USLC-8
Electrical system Special function of machine monitor (EMMS)
Maintenance Record 30-94 The machine monitor records the maintenance information of the filters, oils, etc., which are displayed and checked by the following operations. When maintenance is performed, if the remaining time is reset in the operator mode, the number of maintenance times is recorded in this record. 1. Selection of menu Select "Maintenance Record" on the "Service Menu" screen.
a The following items can be selected in the maintenance record. 01 Engine oil change 02 Engine oil filter change 03 Fuel main filter change 41 Change of fuel pre-filter 04 Hydraulic oil filter change 05 Hydraulic tank breather change 06 Corrosion resistor change 07 Damper case service 08 Final drive case oil change 09 Machinery case oil change 10 Hydraulic oil change 42 Oil cooler accumulator change
3. Items displayed on maintenance record screen The following items are displayed. (a): Maintenance item (b): Number of replacements up to now (c): SMR at previous replacement
2. Selecting maintenance record item After the "Maintenance Record" screen is displayed, select an item to be checked by using the function switches or numeral input switches. q [F1]: Move to next page (screen) q [F2]: Move to previous page (screen) q [F3]: Move to lower item q [F4]: Move to upper item q [F5]: Return to Service Menu screen a You may enter a 2-digit code with the numeral input switches to select the item of that code.
PC228US-8,PC228USLC-8
30-97
Electrical system Special function of machine monitor (EMMS)
Change of maintenance mode 30-95 The actuating condition of the maintenance reminder function in the operation mode can be set and changed by using this menu. q To enable or disable the function q To change set replacement interval (by item) q To initialize all set replacement intervals 1. Selection of menu Select of "Maintenance Mode Change" on the "Service Menu" screen.
2. Selecting sub menu After the "Maintenance Mode Change" screen is displayed, select an item of which the setting is to be changed by using the function switches or numeral input switches. q [F1]: Move to next page (screen) q [F2]: Move to previous page (screen) q [F3]: Move to lower item q [F4]: Move to upper item q [F5]: Return to Service Menu screen q [F6]: Confirm selection a You may enter a 2-digit code with the numeral input switches to select the item of that code and confirm it with [F6].
30-98
a The following items can be selected on the change of maintenance mode screen. 00 Maintenance mode on/off 01 Engine oil change int. 02 Engine oil filter change int. 03 Fuel main filter change int. 41 Fuel pre-filter change int. 04 Hyd oil filter change int. 05 Hyd tank breather change int. 06 Corrosion resistor change int. 07 Damper case service int. 08 Final drive case oil change int. 09 Machinery case oil change int. 10 Hydraulic oil change int. 42 Oil cooler accumulator change int. 99 Initialize all items
3. Details of setting of maintenance mode ON/OFF After selecting "Maintenance Mode On/Off", if the screen is displayed, select ON or OFF with the function switches. q ON: Maintenance reminder functions of all maintenance items are enabled in operator mode q OFF: Maintenance reminder functions of all maintenance items are disabled in operator mode q [F3]: Move to lower item q [F4]: Move to upper item q [F5]: Cancel selection and return to Maintenance Mode Change screen q [F6]: Confirm selection and return to Maintenance Mode Change screen a Even if ON/OFF of each item has been set, if the above setting is changed, it overrides the individual setting.
PC228US-8,PC228USLC-8
Electrical system Special function of machine monitor (EMMS)
4. Setting of each maintenance item After selecting each maintenance item, if the screen is displayed, set the item with the function switches.
Initial value: Maintenance interval set in machine monitor (Recommended by manufacturer and not changeable). q Set value: Maintenance interval which can be set freely. Maintenance reminder function in operator mode works according to this set time (which is increased or decreased by 50 hours). q ON: Maintenance reminder function of this item is enabled in operator mode. q OFF: Maintenance reminder function of this item is disabled in operator mode. q [F3]: Reduce set value (in upper column) or select OFF (in lower column). q [F4]: Increase set value (in upper column) or select ON (in lower column). q [F5]: Cancel setting before confirmation and return to “Maintenance Mode Change” screen. q [F6]: Confirm setting of upper or lower column a After the settings of the upper and lower columns are confirmed with [F6] and the screen changes to the Maintenance Mode Change screen with [F5], the settings are effective. a If the set value of an item of which maintenance reminder function is set to "ON" is changed after one operating hours or more from the setup, the change is recognized as a reset of the remaining time. q
PC228US-8,PC228USLC-8
5. Function of initializing all items After selecting "Use Default Value" and the screen is displayed, set with the function switches.
If this function is executed, the set values of all the maintenance items are initialized. q [F5]: Return to “Maintenance Mode Change” screen q [F6]: Perform initialization a A while after [F6] is pressed, the initialization completion screen is displayed. Then, return to the "Maintenance Mode Change" screen to complete the initialization. q
30-99
Electrical system Special function of machine monitor (EMMS)
Telephone number registration 30-97 The telephone number to be displayed together with the user code and failure code in the operator mode can be registered or changed according to the following procedure. If a telephone No. is not input by using this function, no telephone No. is displayed in the operator mode. 1. Selection of menu Select "Phone Number Entry" on the "Service Menu" screen.
a Up to 14 digits can be input from the left. Input nothing in the surplus positions. a If an input numeral is wrong, move the cursor (orange background) to that digit and overwrite it with the correct numeral. a If [F6] is pressed without inputting a digit, there is not information of telephone No. Accordingly, no telephone No. is displayed in the operator mode.
2. Registering and changing phone number After the "Phone Number Entry" screen is displayed, register or change the phone number q [F2]: Delete all input digits. q [F3]: Move to left position (if not blank) q [F4]: Move to right position (if not blank) q [F5]: Reset input digit/Return to Service Menu screen q [F6]:Confirm input
30-100
PC228US-8,PC228USLC-8
Electrical system Special function of machine monitor (EMMS)
Default (Key-on Mode) 30-98 Use the menu of “Default” to check or change various settings of the machine monitor and machine. Use the sub menu of "key-on Mode" to set the working mode selected and displayed on the machine monitor when the starting switch is turned to ON position. 1. Selection of menu Select "Default" on the "Service Menu" screen.
2. Selecting sub menu After the "Default" screen is displayed, select "Key-on Mode" by using the function switches or numeral input switches. a Select this item similarly to an item on the "Service Menu" screen.
PC228US-8,PC228USLC-8
3. Selecting mode After the "Key-on Mode" screen is displayed, select the mode to be set by using the function switches. q Power Mode: [P] is displayed when the starting switch is turned to ON position. q Economy Mode: [E] is displayed when the starting switch is turned to ON position. q Lifting Mode: [L] is displayed when the starting switch is turned to ON position. q Breaker Mode: [B] is displayed when the starting switch is turned to ON position. q Attachment Mode: [ATT] is displayed when the starting switch is turned to ON position. q Mode at Previous Key-off: Final mode in previous operation is displayed when the starting switch is turned to ON position. q [F3]: Move to lower item q [F4]: Move to upper item q [F5]: Cancel selection and return to Default screen q [F6]: Confirm selection and return to Default screen a Factory default is, "Mode at Previous Key-off". a If "With Attachment" is not selected for the attachment setting, the Attachment Mode cannot be selected. a For the machine selecting Attachment Mode [ATT], if the attachment setting is changed to "Without Attachment", Power Mode [P] is selected and displayed when the starting switch is turned to ON position. a If the engine is stopped with the working mode set to breaker mode [B] in the operator mode, Breaker Mode [B] is always displayed when the starting switch is turned to ON position, regardless of the above setting.
30-101
Electrical system Special function of machine monitor (EMMS)
Default (Unit) 30-9 Use the menu of “Default” to check or change various settings of the machine monitor and machine. Use the sub menu of "Unit" to select the unit of the data displayed for monitoring, etc. 1. Selection of menu Select "Default" on the "Service Menu" screen.
3. Selecting unit After the "Unit" screen is displayed, select the unit to be set by using the function switches. q [F3]: Move to lower item q [F4]: Move to upper item q [F5]: Cancel selection and return to Default screen q [F6]: Confirm selection and return to Default screen a Factory default is the “SI Unit”.
2. Selecting sub menu After the "Default" screen is displayed, select "Unit" by using the function switches or numeral input switches. a Select this item similarly to an item on the "Service Menu" screen.
30-102
PC228US-8,PC228USLC-8
Electrical system Special function of machine monitor (EMMS)
Default (With/Without Attachment) 30-10 Use the menu of “Default” to check or change various settings of the machine monitor and machine. Use the sub menu of "With/Without Attachment" to configure attachment setting when the attachment is installed or removed. 1. Selection of menu Select "Default" on the "Service Menu" screen.
3. Selecting With/Without After the "With/Without Attachment" screen is displayed, select the setting by using the function switches. q Without Attachment: When attachment is not installed q With Attachment: When attachment is installed q [F3]: Move to lower item q [F4]: Move to upper item q [F5]: Cancel selection and return to Default screen q [F6]: Confirm selection and return to Default screen a When an attachment is installed, if this setting is not configured correctly, the attachment setting in the operator mode cannot be performed. As a result, the attachment may not work normally or the hydraulic components may be damaged.
2. Selecting sub menu After the "Default" screen is displayed, select "With/Without Attachment" by using the function switches or numeral input switches. a Select this item similarly to an item on the "Service Menu" screen.
PC228US-8,PC228USLC-8
30-103
Electrical system Special function of machine monitor (EMMS)
Default (Attachment/Maintenance Password) 30-101 Use the menu of “Default” to check or change various settings of the machine monitor and machine. Use the sub menu of "Attachment/Maintenance Password" to set the password screen to be displayed when the functions related to the attachment and maintenance are used in the operator mode. 1. Selection of menu Select "Default" on the "Service Menu" screen.
2. Selecting sub menu After the "Default" screen is displayed, select "Attachment/Maintenance Password" by using the function switches or numeral input switches. a Select this item similarly to an item on the "Service Menu" screen.
3. Selecting Disable/Enable After the Attachment/Maintenance Password screen is displayed, select the setting by using the function switches. q Disable: Password screen is not displayed q Enable: Password screen is displayed q [F3]: Move to lower item q [F4]: Move to upper item q [F5]: Cancel selection and return to Default screen q [F6]: Confirm selection and return to Default screen
4. Displaying “Attachment/Maintenance Password” screen When the following operation is performed, the password screen is displayed in the operator mode. q Maintenance mode: When the Maintenance list screen is changed to the maintenance interval reset screen. q User mode: On the User Menu screen, the menu of "Breaker/Attachment settings" is selected and the screen is changed to the "Attachment Settings" screen. 5. Changing attachment/maintenance password The password can be changed with the special switch operation in the operator mode. a See Attachment/Maintenance password changing function in the operator mode. a Default password: [000000] a If the password setting is changed from Enable to Disable, the password is reset to the default. When Enable is set again, be sure to set a new password. a The attachment/maintenance password is different from the engine start lock password.
30-104
PC228US-8,PC228USLC-8
Electrical system Special function of machine monitor (EMMS)
Default (Camera) 30-102 Use the menu of “Default” to check or change various settings of the machine monitor and machine. Use the sub menu of "Camera" to configure camera setting when the camera is installed or removed. 1. Selection of menu Select "Default" on the "Service Menu" screen.
[F5]: Cancel settings before confirmation and return to Default screen q [F6]: Confirm selection of each column a When "Camera" screen is displayed, camera 1 is always ready for setting. a After confirming the setting of each column with [F6], return to the "Default" screen with [F5], and the setting is effective. a If a camera is connected but not configured normally with this function, the graphic mark of camera is not displayed above [F3] in the operator mode. Accordingly, the image of the camera cannot be screen. a If the camera is installed, check that the right and left portions of the displayed image are correct. q
2. Selecting sub menu After the "Default" screen is displayed, select "Camera" by using the function switches or numeral input switches. a Select this item similarly to an item on the "Service Menu" screen.
3. Selecting camera setting After the "Camera" screen for setting is displayed, select the setting by using the function switches. q OFF: Camera is not configured. q Original Image: Image from connected camera is displayed normally (A mirror image, select this setting for rear view monitor back monitor). q Reverse Image: Image from connected camera is displayed in reverse (View is displayed as seen directly, select this setting for a front or side monitor.) q [F3]: Move to left item q [F4]: Move to right item PC228US-8,PC228USLC-8
30-105
Electrical system Special function of machine monitor (EMMS)
Default (ECO Display) 30-103 Use the menu of “Default” to check or change various settings of the machine monitor and machine. Use the sub menu of "ECO Display" to set the ECO mark and ECO guidance to be displayed.
a If ECO Mark is set to ON, ECO mark is displayed when the screen changes to the standard screen. Even if ECO Guidance is set to ON, however, ECO Guidance screen is not displayed if the condition for display is not satisfied on the standard screen.
1. Selection of menu Select "Default" on the "Service Menu" screen.
a ECO mark (a)
2. Selecting sub menu After the "Default" screen is displayed, select "ECO Display" by using the function switches or numeral input switches a Select this item similarly to an item on the "Service Menu" screen.
a ECO Guidance screen
3. Selecting display setting After the "ECO Display" screen is displayed, select the setting by using the function switches. q ON: Display ECO q OFF: Do not display ECO q [F3]: Move to left item q [F4]: Move to right item q [F5]: Cancel settings before confirmation and return to Default screen q [F6]: Confirm selection of each column a After confirming the setting of the upper and lower columns with [F6], return to the "Default" screen with [F5], and the setting is effective.
30-106
PC228US-8,PC228USLC-8
Electrical system Special function of machine monitor (EMMS)
Adjustment (Pump Absorption Torque (F)) 30-104 The machine monitor allows for adjustment of various items related to the machine. The sub menu of Pump Absorption Torque (F) is used to finely adjust the absorption torque of the front hydraulic pump. 1. Selection of menu Select "Adjustment" on the "Service Menu" screen.
a Relationship between set value and torque adjustment value Code
021
2. Selecting sub menu After the "Adjustment" screen is displayed, select "Pump Absorption Torque (F)" by using the function switches or numeral input switches. a Select this item similarly to an item on the "Service Menu" screen.
Set value
Torque adjustment value
000
+39.2 Nm {+4 kgm}
001
+29.4 Nm {+3 kgm}
002
+19.6 Nm {+2 kgm}
003
+9.8 Nm {+1 kgm}
004
0 Nm {0 kgm}
005
-9.8 Nm {-1 kgm}
006
-19.6 Nm {-2 kgm}
007
-29.4 Nm {-3 kgm}
008
-39.2 Nm {-4 kgm}
3. Selecting pump absorption torque setting After the "Pump Absorption Torque (F)" screen is displayed, select a set value in the right column by using the function switches. q Set value: For actual torque adjustment value, see table q [F3]: Increase set value. q [F4]: Decrease set value. q [F6]: Confirm setting and return to Adjustment screen a The 3-digit number in the left column do not change since it is the code of this function.
PC228US-8,PC228USLC-8
30-107
Electrical system Special function of machine monitor (EMMS)
Adjustment (Pump Absorption Torque (R)) 30-105 The machine monitor allows for adjustment of various items related to the machine. The sub menu of Pump Absorption Torque (R) is used to finely adjust the absorption torque of the rear hydraulic pump. 1. Selection of menu Select "Adjustment" on the "Service Menu" screen.
2. Selecting sub menu After the “Adjustment” screen is displayed, select “Pump Absorption Torque (R)” by using the function switches or numeral input switches. a Select this item similarly to an item on the "Service Menu" screen.
3. Selecting pump absorption torque setting After the "Pump Absorption Torque (R)" screen is displayed, select a set value in the right column by using the function switches. q Set value: For actual torque adjustment value, see table q [F3]: Increase set value. q [F4]: Decrease set value. q [F6]: Confirm setting and return to Adjustment screen a The 3-digit number in the left column do not change since it is the code of this function.
a Relationship between set value and torque adjustment value Code
022
30-108
Set value
Torque adjustment value
000
+39.2 Nm {+4 kgm}
001
+29.4 Nm {+3 kgm}
002
+19.6 Nm {+2 kgm}
003
+9.8 Nm {+1 kgm}
004
0 Nm {0 kgm}
005
-9.8 Nm {-1 kgm}
006
-19.6 Nm {-2 kgm}
007
-29.4 Nm {-3 kgm}
008
-39.2 Nm {-4 kgm}
PC228US-8,PC228USLC-8
Electrical system Special function of machine monitor (EMMS)
Adjustment (travel low speed setting) 30-106 The machine monitor allows for adjustment of various items related to the machine. The sub menu of Low Speed is used to finely adjust the travel speed at Low setting. 1. Selection of menu Select "Adjustment" on the "Service Menu" screen.
2. Selecting sub menu After the "Adjustment" screen is displayed, select "Low speed" by using the function switches or numeral input switches. a Select this item similarly to an item on the "Service Menu" screen.
3. Selecting low speed After the "Low Speed" screen for setting is displayed, select a set value in the right column by using the function switches. q Set value code: For the actual travel speed at Low setting, see the following table. q [F3]: Increase set value. q [F4]: Decrease set value. q [F6]: Confirm setting and return to Adjustment screen a The 3-digit number in the left column do not change since it is the code of this function.
a Relationship between set value and travel speed at Low setting Code
Set value
Travel speed at Low
000
3.0 km/h
001
2.8 km/h
002
3.2 km/h
003
3.4 km/h
020
PC228US-8,PC228USLC-8
30-109
Electrical system Special function of machine monitor (EMMS)
Adjustment (Attachment Flow Adjustment) 30-107 The machine monitor allows for adjustment of various items related to the machine. The sub menu of "Attachment Flow Adjustment" is used to finely adjust the oil flow rate to the attachment in combined operation. 1. Selection of menu Select "Adjustment" on the "Service Menu" screen.
2. Selecting sub menu After the "Adjustment" screen is displayed, select "Attachment Flow Adjustment" by using the function switches or numeral input switches. a Select this item similarly to an item on the "Service Menu" screen.
3. Selecting distribution of oil flow After the screen of "Attachment Flow Adjustment" is displayed, select a set value in the right column by using the function switches. q Set value: For actual distribution of oil flow, see table q [F3]: Increase set value. q [F4]: Decrease set value. q [F6]: Confirm setting and return to Adjustment screen a The 3-digit number in the left column do not change since it is the code of this function.
a Relationship between set value and distribution of oil flow to attachment Code
Set Distribution of flow to attachvalue ment 000
50%
001
70%
002
100%
003
40%
044
30-110
PC228US-8,PC228USLC-8
Electrical system Special function of machine monitor (EMMS)
Adjustment (Boom potentiometer initialization) 30-108 When the boom potentiometer or boom is removed and installed, or when the boom stroke end electronic cushion function does not work normally, initialize the boom potentiometer according to the following procedure. 1. Selection of menu Select "Adjustment" on the "Service Menu" screen.
2. Selecting sub menu After the "Adjustment" screen is displayed, select "Initialize boom potentiometer" by using the function switches or numeral input switches. a Select this item similarly to an item on the "Service Menu" screen.
PC228US-8,PC228USLC-8
3. When the "Initialize boom potentiometer" screen is displayed, initialize the boom potentiometer by using the work equipment control lever and function switches. q [F1]: SET q [F2]: Clear q [F6]: Confirm settings.
4. Operate the right work equipment control lever to raise the boom to the maximum height. a Take care not to allow the boom to lower. a The arm may be at any position. q Fig. 1: Posture for initialization of boom potentiometer
30-111
Electrical system Special function of machine monitor (EMMS)
5. Press [F1] to save the adjusted value of the boom angle potentiometer. a "OK" is displayed for State of adjustment and the angle indication on the screen to updated to the adjusted values.
a To do the initialization again, press [F2] to delete the adjusted value and then perform the procedure again from step 1). a If the installed angle of the potentiometer deviates 10 or more degrees from the standard value in the controller, the buzzer sounds for approximately one seconds and the adjusted value is not saved. ("NG" is displayed for State of adjustment.) In this case, check the installed condition of the potentiometer and perform the procedure again from step 1). 6. Press [F6] to confirm the setting. a If the setting is accepted, the screen returns to the Adjustment screen.
30-112
PC228US-8,PC228USLC-8
Electrical system Special function of machine monitor (EMMS)
Adjustment (Calibration of front pump swash plate sensor) 30-1 0 The machine monitor allows for adjustment of various items related to the machine. The sub menu of Calib F pump swash plate sensor is used to calibrate the sensor installed on the actual machine to eliminate deviation of the sensor signal made when the front pump swash plate sensor is removed and installed or replaced with new one.
In adjustment menu of service menu
a The pump swash plate sensor needs to be adjusted in the following cases. CalibraCalibration of tion of rear front pump pump swash swash plate sen- plate sensor sor Removal and installation or replacement of front pump Necessary – swash plate sensor Removal and installation or replacement of rear pump – Necessary swash plate sensor Replacement of main pump Necessary Necessary assembly Replacement of pump controller Necessary Necessary Adjustment and disassembly of Necessary – front pump PC valve Adjustment and disassembly of – Necessary pump PC valve
a Before calibrating the pump swash plate sensor, check the pump swash plate sensor to confirm that the pump swash plate sensor is normal. a A rough flow of calibration of the pump swash plate sensor is as follows.
1. Preparation for calibration Before starting calibration, set the machine under the following condition. q Hydraulic oil temperature: 50 °C q Working mode: P mode q Travel speed setting: Hi 2. Selection of menu Select "Adjustment" on the "Service Menu" screen.
PC228US-8,PC228USLC-8
30-113
Electrical system Special function of machine monitor (EMMS)
3. Selecting sub menu After the "Adjustment" screen is displayed, select "Calib F pump swash plate sensor" by using the function switches or numeral input switches. a Select this item similarly to an item on the "Service Menu" screen.
4. Calibration of front pump swash plate sensor for the maximum angle 1) After the "Calib F pump swash plate sensor max" is displayed, calibrate the front pump swash plate sensor for the maximum angle by running track idle off the ground and operating the function switches. [F1]: Start [F2]: Clear [F5]: Return to Adjustment screen [F6]: Confirm setting.
k Provide a enough work space to run
the track idle off the ground.
k Be careful about safety around the ma-
chine while running the track idle off the ground.
3) When the speed of the track running idle is stabilized, hold down [F1] of the machine monitor to start calibration. A bar is displayed during calibration. Keep running the track idle until calibration is finished.
4) Calibration is finished successfully, "OK" is displayed for the State of adjustment to show that calibration for the maximum angle is completed. Press [F6] to go to calibration for the maximum angle. 2) Raise the right track off ground by using the work equipment and move the right travel lever to the stroke end to run the right track idle off the ground. q Fuel control dial: Max. position q Right travel lever: Full stroke Travel direction may be set in either of forward and reverse. q Swing lock switch may be set in either of ON and OFF.
30-114
PC228US-8,PC228USLC-8
Electrical system Special function of machine monitor (EMMS)
If calibration is finished unsuccessfully, "NG" is displayed for the State of adjustment and the failure cause code is displayed. Referring to the failure cause codes in Table 1, find out and remove the cause and repeat calibration.
2) Wait under the following conditions: q All levers: Neutral Fuel control dial may be at any position. 3) Hold down [F1] of the machine monitor to start calibration. A bar is displayed during calibration. Keep all the levers in NEUTRAL until calibration is finished.
a The calibration value can be initialized by holding down CLEAR button [F2]. If the calibration value is initialized, "READY" is displayed for the State of adjustment on the screen. 5. Calibration of front pump swash plate sensor for the minimum angle 1) After the "Calib F pump swash plate sensor min" is displayed, set all the levers in NEUTRAL and perform calibration the front pump swash plate sensor for the minimum angle with the function switches. [F1]: Start [F2]: Clear [F5]: Return to Adjustment screen [F6]: Confirm setting
PC228US-8,PC228USLC-8
4) Calibration is finished successfully, "OK" is displayed for the State of adjustment to show that calibration for the minimum angle is completed. Press [F6] to return to the Adjustment screen.
30-115
Electrical system Special function of machine monitor (EMMS)
If calibration is finished unsuccessfully, "NG" is displayed for the State of adjustment and the failure cause code is displayed. Referring to the failure cause codes in Table 1, find out and remove the cause and press [F6] to repeat the calibration for the minimum angle.
Adjustment (Calibration of rear pump swash plate sensor) 30-1 3 1. Preparation for calibration Before starting calibration, set the machine under the following condition q Hydraulic oil temperature: 50 °C q Working mode: P mode q Travel speed setting: Hi 2. Selection of menu Select "Adjustment" on the "Service Menu" screen.
a The calibration value can be initialized by holding down CLEAR button [F2]. If the calibration value is initialized, "READY" is displayed for the State of adjustment on the screen.
3. Selecting sub menu After the "Adjustment" screen is displayed, select "Calib R pump swash plate sensor" by using the function switches or numeral input switches. a Select this sub menu as in the case of selecting a menu on the "Service Menu" screen.
4. Perform the subsequent calibration procedure according to "Calibration of front pump swash plate sensor".
30-116
PC228US-8,PC228USLC-8
Electrical system Special function of machine monitor (EMMS)
Table 1. Failure cause codes Calibration failure cause codes (Displayed in descending order of priority) Cause code Object Content
Remedy
A-1
Engine speed signal is 0 rpm
Check that engine is started
A-2
Hydraulic oil temperature is low
Check hydraulic oil temperature (Min. 45 °C)
A-3
Hydraulic oil temperature is high
Check hydraulic oil temperature (Min. 90 °C)
A-4 A-6 A-7 B-1 B-3 C-1 C-2 C-3 C-4 C-5
Check for overheat Perform troubleshooting for pump pressure Pump pressure sensor (F, R) is defective sensor Perform troubleshooting for pump swash Pump swash plate (F, R) sensor is defective plate sensor Calibration for Pump pressure of calibrated pump is above Test unload pressure the minimum standard value Lever is not in NEUTRAL Check that all levers are in NEUTRAL angle Pump pressure of calibrated pump is below Perform troubleshooting for H-18 Travel standard value speed is low Travel speed setting is not Hi Check that travel speed setting is Hi Common
Fuel control dial is not set to Max. position Calibration for Both tracks are running the maximum Oil flow from two pumps are not divided angle
C-6 C-7 FF
Engine overheats
Common
Set fuel control dial to Max. position
Check that one travel lever is operated Check that work equipment lever are in NEUTRAL Perform troubleshooting for travel PPC presTravel PPC pressure sensor is defective sure sensor Travel PPC pressure is below standard Perform troubleshooting for H-18 Travel value speed is low Output voltage of pump swash plate sensor Perform troubleshooting for pump swash is out of calibration range plate sensor
PC228US-8,PC228USLC-8
30-117
Electrical system Special function of machine monitor (EMMS)
Cylinder Cut-Out 30-1 5 The machine monitor allows for running the engine in "Cylinder Cut-Out" mode. "Cylinder Cut-Out" operation means to run the engine with 1 or more fuel injectors disabled electrically to reduce the number of effective cylinders. This operation is used to locate a cylinder which does not output power normally (combustion in it is abnormal). 1. Selection of menu Select "Cylinder Cut-out" on the "Service Menu" screen.
2. Selecting cylinder to be disabled After the "Cylinder Cut-Out" screen is displayed, select a cylinder to be cut out by using the function switches. q [F1]: Move selection mark (R) to left q [F2]: Move selection mark (R) to right q [F3]: Reset holding q [F4]: Hold q [F5]: Return to Service Menu screen q [F6]: Confirm selection a This operation may be performed while the engine is running. a When [F6] is pressed, if background (a) of the selected cylinder No. becomes white, the cylinder is cut out. a If the machine monitor cuts out a cylinder but the engine controller cannot cut out that cylinder, the background (a) of the cylinder No. becomes yellow. a One or more cylinders can be cut-out. a During the cylinder Cut-Out operation, the auto-deceleration function can be enabled. If the auto-deceleration is set to ON, auto-deceleration monitor (b) is displayed.
30-118
3. Resetting Cut-Out cylinder When changing a cylinder to be cut out or when Cylinder Cut-Out operation is finished, select a cut-out cylinder to be reset with the function switches. a This operation may be performed while the engine is running. a When [F6] is pressed, if background (a) of the selected cylinder No. becomes blue, the cylinder is reset. a If the machine monitor resets a cut-out cylinder but the engine controller cannot reset that cut-out cylinder, the background (a) of the cylinder No. becomes red. a The cut-out cylinder is not automatically reset even after returning to the operator mode. Accordingly, be sure to perform the resetting operation after the Cylinder Cut-Out operation is finished. 4. Function of holding displayed information Each time [F4] is pressed during the Cylinder Cut-Out operation, the displayed data is newly held (c) (the real-time data is kept displayed on the left side). If [F3] is pressed with the condition of hold, the holding function is cancelled. a The holding function is available for a cylinder, regardless of whether it is cut out or not.
PC228US-8,PC228USLC-8
Electrical system Special function of machine monitor (EMMS)
[Reference] q If a normal cylinder is cut-out, the following phenomena occur. 1) Lowering of engine speed 2) Increase of final injection rate command (quantity) q If the engine is running near the high idle, however, the engine speed may not lower for the reason of engine control. q In this case, lower the engine speed with the fuel control dial and judge by increase of the injection rate command.
No Injection 30-1 6 If the engine is operated after long storage of the machine, it may be worn or damaged because of insufficient lubrication with oil. To prevent this, the machine monitor allows for cranking the engine without injecting fuel to lubricate the engine before starting it. Set the no-injection cranking while the engine is stopped. 1. Selection of menu Select "No Injection" on the "Service Menu" screen.
2. Displaying check screen When the "No injection" screen is displayed, the the message to ask if no injection cranking should be performed appears. Answer with the function switch. q [F5]: Do not perform (return to Service Menu screen) q [F6]: Perform a Before the following screen is displayed, the message of "Communication between controllers is being checked" appears.
PC228US-8,PC228USLC-8
30-119
Electrical system Special function of machine monitor (EMMS)
3. Starting no injection cranking If no injection cranking (fuel injection in no cylinders) becomes effective, "No Injection." is displayed on the screen. Under this condition, crank the engine with the starting motor. a Before the following screen is displayed, the message of "Setting is being prepared" appears. a Limit the cranking time to 20 seconds to protect the starting motor.
5. Prohibiting no injection cranking If the operator tries to perform the no injection cranking while the engine is running, the message "Engine is running" is displayed and the no injection cranking is not enabled. a This function can be selected even while the engine is running. If the no injection cranking is performed, however, the message of "Engine is running" is displayed on the screen.
4. Finishing no injection cranking After completing the no injection cranking operation, press [F6], and the message "Finished" is displayed and the screen returns to the "Service Menu" screen automatically.
30-120
PC228US-8,PC228USLC-8
Electrical system Special function of machine monitor (EMMS)
Fuel Consumption 30-1 8 Use this function to calculates the hourly fuel consumption from the actual fuel consumption in a measuring period and indicate it. 1. Selection of menu Select "Fuel Consumption" on the "Service Menu" screen.
2. Starting measurement After the screen of "Fuel Consumption" is displayed, start measurement by using the function switches. q [F1]: Start q [F2]: Clear q [F5]: Return to Service Menu screen a When the screen of "Fuel Consumption" is displayed, if a data is indicated, it is the data of the previous measurement. This data is not an obstacle to new measurement and can be deleted by pressing [F2]. a If [F1] is pressed, the data is displayed in the Start Time column and measurement starts.
3. Display and function during measurement Clock mark (a) flashes during measurement. a While the fuel consumption is being tested, the operator can work with the operator mode and other functions. Test is not finished until [F1] is pressed again on this screen (even if the starting switch is turned to OFF position, this function is kept effective, although fuel consumption is tested only while the engine is running).
4. Finishing measurement Press [F1], and measurement is finished and the data are displayed in the Stop Time column. 5. Displaying fuel consumption If the test is finished, the hourly fuel consumption calculated from the fuel consumption calculated by the engine controller and the elapsed time are displayed.
a The display unit of the fuel consumption changes according to the unit set with the Default (Unit) function. SI and metric unit: l/h, imperial unit: gal/h
PC228US-8,PC228USLC-8
30-121
Electrical system Special function of machine monitor (EMMS)
KOMTRAX Settings (Terminal Status) 30-1 9 The setting and operating status of KOMTRAX can be checked by using the menu of "KOMTRAX Settings". "KOMTRAX Settings" is used to check the setting condition of the KOMTRAX terminal. 1. Selection of menu Select "KOMTRAX Settings" on the "Service Menu" screen.
3. Contents displayed on Terminal Status screen On the "Terminal Status" screen, the following items are displayed. q Terminal type: Model name of KOMTRAX communication MODEM q KOMTRAX communication: Executing condition of station opening inspection q GMT time: Greenwich Mean Time q [F5]: Return to KOMTRAX Settings screen
2. Selecting sub menu After the "KOMTRAX Settings" screen is displayed, select "Terminal Status" by using the function switches or numeral input switches. a Select this item similarly to an item on the "Service Menu" screen.
30-122
PC228US-8,PC228USLC-8
Electrical system Special function of machine monitor (EMMS)
KOMTRAX Settings (GPS & Communication Status) 30-120 The setting and operating status of KOMTRAX can be checked by using the menu of "KOMTRAX Settings". "GPS & Communication Status" is used to check the positioning and communication status of the KOMTRAX terminal. 1. Selection of menu Select "KOMTRAX Settings" on the "Service Menu" screen.
3. Contents of display of “GPS & Communication Status” On the "GPS & Communication Status" screen, the following items are displayed. q Positioning: Positioning condition of GPS q Communication: Communication environment of communication MODEM and connecting condition of communication MODEM q Number of message not yet sent: Number of mails which are saved in machine monitor and not transmitted yet q [F5]: Return to KOMTRAX settings screen
2. Selecting sub menu After the "KOMTRAX Settings" screen is displayed, select “GPS & Communication Status” with the function switches or numeral input switches. a Select this item similarly to an item on the "Service Menu" screen.
PC228US-8,PC228USLC-8
30-123
Electrical system Special function of machine monitor (EMMS)
KOMTRAX Setting (MODEM S/N) 30-121 The setting and operating status of KOMTRAX can be checked by using the menu of "KOMTRAX Settings". Modem S/N is used to check the serial No. of the KOMTRAX communication modem.
3. Contents displayed on Modem S/N screen The serial No. of TH300 Modem is displayed. q [F5]: Return to KOMTRAX Settings screen
1. Selecting menu Select "KOMTRAX Settings" on the "Service Menu" screen.
2. Selecting sub menu After the "KOMTRAX Settings" screen is displayed, select "Modem S/N" with the function switches or numeral input switches. a Select this item similarly to an item on the "Service Menu" screen.
30-124
PC228US-8,PC228USLC-8
Electrical system Special function of machine monitor (EMMS)
Service Message 30-12 Special messages for the technician sent from the KOMTRAX base station (a distributor, etc.) can be checked with this function. If a received message has return mail setting, a return mail can be sent by using the numeral input switches. 1. Selection of menu Select "Service Message" on the Service Menu screen.
3. Display of message (with return mail function) If a message provides the Numeric Input line under the text, input a proper number by using the numeral input switches and enter it by using the function switch, and the information is returned to the KOMTRAX base station. q [F5]: Return to KOMTRAX Settings screen q [F6]: To enter and return input value a This message is different from that is sent for the operator in the operator mode a Since this message is special for the technician, the message monitor is not displayed when it is received with the machine monitor in the operator mode.
2. Display of message (read-only) If there is a message, its contents are displayed. If there is no message, "No message" is displayed. q [F5]: Return to Service Menu screen a This message is different from that is sent for the operator in the operator mode a Since this message is special for the technician, the message monitor is not displayed when it is received with the machine monitor in the operator mode.
PC228US-8,PC228USLC-8
30-125
Electrical system Handling voltage circuit of engine controller
Handling voltage circuit of engine controller 1. Before disconnecting or connecting the engine harness connector from/to the engine controller, be sure to turn the starting switch to OFF position. 2. If a T-adapter is inserted in or connected to the connector between the engine controller and engine harness for troubleshooting, do not start the engine. a You may turn the starting switch to the OFF or ON position, but must not turn it to the START position.
30-126
PC228US-8,PC228USLC-8
Electrical system Preparatory work for troubleshooting of electrical system
Preparatory work for troubleshooting of electrical system a When carrying out troubleshooting of an electric circuit related to the machine monitor, engine controller, pump controller, or KOMTRAX communication MODEM, expose the related connectors according to the following procedure. a Disconnect and connect the connectors, which have a special locking device, according to the following procedure. 1. Machine monitor 1) Remove two mounting bolts and cover (1). a One of the mounting bolts is installed in the cover on the right of the sunlight sensor. a While removing the mounting bolts, disconnect connector P31 of the sunlight sensor. 2) Remove cover (2). a The cover is fixed with the clip, so pull it up to remove. a While removing the mounting bolts, disconnect connector M04 of the cigarette lighter.
3) Remove a mounting bolt and duct (3).
PC228US-8,PC228USLC-8
4) Insert or connect troubleshooting T-adapters to connectors CM01, CM02, and CM03 on machine monitor (4). a Connectors CM02 and CM03 are of the same type. When returning them, check the mark plates on the mounting brackets and take care not to make a wrong connection.
2. Engine controller 1) Open the engine hood and remove the compressor assembly from the air conditioner. a The engine controller is mounted on the engine (on the counterweight side). 2) Insert or connect troubleshooting T-adapters to connectors CE01, CE02, and CE03 on engine controller (5). a Connectors CE01 and CE02 are fixed by screws. When disconnecting them, loosen the screws. a When returning connectors CE01 and CE02, tighten the screws to the specified torque. 3 Screw: 3 ± 1 Nm {0.3 ± 0.1 kgm}
30-127
Electrical system Preparatory work for troubleshooting of electrical system
3. Pump controller 1) Slide the operator's seat and seat stand to the forward end. 2) Remove mounting bolts and cool &amp; hot box (6). 3) Remove plate (7). 4) Remove duct (8). 5) Remove pump controller cover (9).
a The connectors of the pump controller have a special locking mechanism. Disconnect them according to steps (a) to (c) and connect them according to steps (d) to (f) as shown below. Disconnection: (a) Unlock o (b) Slide lever o (c) Disconnect connector. Connection:(d) Position connector o (e) Slide lever o (f) Lock.
4. KOMTRAX communication module 1) Slide the operator's seat and seat stand to the forward end. 2) Remove mounting bolts and cool &amp; hot box (6). 3) Remove plate (7).
6) Connect troubleshooting adapters to connectors C01 and C02 of pump controller (10). a Connect the adapters to only the wiring harness.
30-128
PC228US-8,PC228USLC-8
Electrical system Preparatory work for troubleshooting of electrical system
4) Connect troubleshooting T-adapters to connectors CK01 and CK02 of KOMTRAX communication module (13). a Cable (14) is for the communication antenna.
a Disconnection and connection of connector The connectors of the engine Ne speed sensor, engine Bkup speed sensor, engine oil pressure switch have a special locking mechanism. Disconnect them according to steps (a) to (c) and connect them according to steps (d) to (f) as shown below. Disconnection: (a) Slide lever o (b) Unlock o (c) Disconnect connector. Connection: (d) Connect connector o (e) Lock o (f) Slide lever.
5. Engine Ne speed sensor (CRANK SENSOR) Engine Bkup speed sensor (CAM SENSOR) Engine oil pressure switch (OIL PRESSURE SWITCH) a Removal and installation of sensor A deep socket is necessary for removal and installation of the engine oil pressure switch. See "Tools for testing, adjusting and troubleshooting". 6. Boost pressure temperature and sensor (BOOST PRES & IMT) a Disconnection and connection of connector The connector of the boost pressure temperature and sensor has a special locking mechanism. Disconnect it according to steps (a) to (b), and connect it according to steps (c) to (d) as shown below. Disconnection: (a) Unlock o (b) Disconnect connector. Connection: (c) Connect connector o (d) Lock.
PC228US-8,PC228USLC-8
30-129
Electrical system Preparatory work for troubleshooting of electrical system
a Removal and installation of sensor A Torx wrench is necessary for removal and installation of the boost pressure temperature and sensor. See "Tools for testing, adjusting and troubleshooting". 7. Supply pump IMV solenoid (FUEL REGULATOR) a Disconnection and connection of connector The connector of the supply pump IMV solenoid has a special locking mechanism. Disconnect it according to steps (a) to (b), and connect it according to steps (c) to (d) as shown below. Disconnection: (a) Unlock o (b) Disconnect connector. Connection: (c) Connect connector o (d) Lock.
8. Common rail pressure sensor (FUEL RAIL PRESS) a Disconnection and connection of connector The connector of the common rail pressure sensor has a special locking mechanism. Disconnect it according to steps (a) to (b), and connect it according to steps (c) to (d) as shown below. Disconnection: (a) Unlock o (b) Disconnect connector. Connection: (c) Connect connector o (d) Lock.
30-130
a Precautions for disconnecting connector The direction of the lock on the connector varies depending on position at which the tightening of the sensor has been stopped and the lock may be in a direction in which it is difficult to unlock (lock faces the engine or downward). In this case, pinch the lock in direction (a) by bent-long nose pliers [1] (commercially available), and the lock is unlocked. The lock clicks when it is unlocked, so disconnect the connector after a click is heard.
a Precautions for connecting connector Take care not to connect the connector reversely. Engage lock (e) on the wiring harness side with triangular projection (f) on the sensor side (Do not engage lock (e) with square guide (g) on the opposite side of triangular projection (f)).
PC228US-8,PC228USLC-8
Electrical system Preparatory work for troubleshooting of electrical system
9. Engine coolant temperature sensor (COOLANT TEMP) a Disconnection and connection of connector The connector of the engine coolant temperature sensor has a special locking device. Disconnect it in the order of steps (a) to (b) and connect it in the order of steps (c) to (d) as shown below. Disconnection: (a) Unlock o (b) Disconnect connector. Connection: (c) Connect connector o (d) Lock.
a Removal and installation of sensor A deep socket is necessary for removal and installation of the engine coolant temperature sensor. See Testing and adjusting, “Troubleshooting tools table”.
PC228US-8,PC228USLC-8
30-131
Electrical system Procedure for testing diodes
Procedure for testing diodes a Test the diode assay (8-pin) and the single diode (2-pin) according to the following procedure. a The conducting directions of the diode array are as follows.
a The conducting direction of the single diode is indicated on the surface of the diode.
1. When using digital multimeter 1) Set the multimeter to the diode range and read the indicated value. a When an ordinary circuit tester is used, the voltage of the internal battery is indicated. 2) Apply the red (+) lead of the multimeter to the anode (P) of the diode and apply the black (–) lead to the cathode (N), and check the indicated value. 3) Evaluate the condition of the diode by the indicated value. q The indicated value does not change: The diode does not have continuity (Defective). q The indicated value changes: The diode has continuity (Normal). Note: In the case of a silicon diode, a value in the range from 460 to 600 is indicated.
30-132
2. When using analog multimeter 1) Set the multimeter in the resistance range. 2) Apply the leads of the multimeter as explained below and check the movement of the pointer. 1] Apply the red (+) lead of the multimeter to the anode (P) of the diode and apply the black (–) lead to the cathode (N). 2] Apply the red (+) lead of the multimeter to the cathode (N) of the diode and apply the black (–) lead to the anode (P). 3) Evaluate the condition of the diode by the movement of the pointer. q The pointer does not move in i] but moves in ii): The diode is normal (The moving range (resistance) depends on the type and selected range of the multimeter, however). q The pointer moves in both i] and ii]: The diode is defective (internal short circuit). q The pointer moves in neither of i] and ii]: The diode is defective (internal open circuit).
PC228US-8,PC228USLC-8
Pm clinic Pm clinic service
Pm clinic Pm clinic service Model T PC228US-8 T PC228USLC-8 Customer name
Serial No.
Service meter reading h
Main components Boom T Standard T ( ) Arm T Standard T ( ) Bucket T Standard T ( )
T Breaker T( T(
Date of check / / Specification Attachments
Inspector
Shoe width
T 600 mm T 700 mm T( )
) ) Check of oil/coolant level T Radiator coolant When necessary T Machinery case oil T Engine oil T Damper case oil T( ) T Hydraulic oil T Final drive case oil Ambient temperature Height above sea level °C
m Operator's comment
Visual check result
Mechanical system abnormality record 989EKX __times/ 1st at ___hrs. / last at ___hrs. AA10NX __times/ 1st at ___hrs. / last at ___hrs. AB00KE __times/ 1st at ___hrs. / last at ___hrs. B@BAZG __times/ 1st at ___hrs. / last at ___hrs. B@BAZK __times/ 1st at ___hrs. / last at ___hrs. B@BCNS __times/ 1st at ___hrs. / last at ___hrs. B@BCZK __times/ 1st at ___hrs. / last at ___hrs. B@HANS __times/ 1st at ___hrs. / last at ___hrs. CA234 __times/ 1st at ___hrs. / last at ___hrs.
Electrical Systems __times/ 1st at ___hrs. / last at ___hrs. __times/ 1st at ___hrs. / last at ___hrs. __times/ 1st at ___hrs. / last at ___hrs. __times/ 1st at ___hrs. / last at ___hrs. __times/ 1st at ___hrs. / last at ___hrs. __times/ 1st at ___hrs. / last at ___hrs. __times/ 1st at ___hrs. / last at ___hrs. __times/ 1st at ___hrs. / last at ___hrs. __times/ 1st at ___hrs. / last at ___hrs.
Highest reading on engine coolant temperature gauge 30-131
Highest reading on hydraulic oil temperature gauge
PC228US-8,PC228USLC-8
30-131
30-133
Pm clinic Pm clinic service
Check items related to engine
30-134
30-132
PC228US-8,PC228USLC-8
Pm clinic Pm clinic service
Check items related to hydraulic pressure
PC228US-8,PC228USLC-8
30-13
30-135
Pm clinic Pm clinic service
Check sheet (PC228US-8, PC228USLC-8) Model
Serial No.
Service meter reading
Customer name
Date of check
Inspector
/ /
Testing conditions Standard MeasFuel Work- AutoLeft Operation of value for Service limit No. Check item Unit ured control ing decel- knob work equipnew value value dial mode erator switch ment machine 1 Engine speed rpm 1830 - 1970 1830 - 1970 All levers in MPa Min. 0.29 0.25 Engine oil MAX the neutral 2 {2.5} pressure position {kg/cm2} {Min. 3.0} OFF 3 Engine speed rpm 1025 - 1075 1025 - 1075 All levers in MPa OFF Min. 0.10 0.07 Engine oil MIN the neutral 4 2} {Min. 1.0} {0.7} pressure position {kg/cm P rpm 1820 - 2020 1820 - 2020 5 Engine speed kPa Blowby presMax. 0.98 1.96 ON Arm IN relief 6 {mmH2O} {Max. 100} sure {200} MAX All levers in 7 Engine speed ON OFF the neutral rpm 950 - 1150 950 - 1150 position
Good NG
1. Engine
Testing conditions Fuel WorkNo. Check item control ing dial mode Boom 1 RAISE P
E 2 Arm IN
MAX
L
3 Arm OUT 4
Bucket CURL
5
Swing (5 turns)
Travel 6 (five turns idle running)
30-136
P
Work equipment posture, etc.
Standard value for new machine
Service limit value
3.3 - 4.1
Max. 5.2
3.6 - 4.4
Max. 5.2
3.1 - 3.9
Max. 4.5
4.1 - 4.9
Max. 5.2
3.3 - 4.1
Max. 4.5
4.3 - 5.3
Max. 6.0
sec.
5.7 - 6.9
Max. 7.7
sec.
2.4 - 3.0
Max. 3.5
2.3 - 3.9
Max. 3.3
2.5 - 3.1
Max. 3.4
25.6 - 30.9
Max. 33
46.2 - 56.4 50.3 - 61.5 33.7 - 41.3 36.7 - 44.9 25.2 - 27.8 27.5 - 30.3
46.2 - 60.5 50.3 - 66 33.8 - 45.0 36.7 - 49 25.2 - 29.9 26 - 32.7
Unit
PC228US Work equipment extended fully
Demolition specification PC228US Demolition specification PC228US Demolition speciHorizontal boom top fication PC228US face Demolition specification PC228US Demolition specification Horizontal boom top PC228US Demolisurface and fully retracted arm cylin- tion specification der Work equipment extended fully Swing right and left STD LO LC One track raised and STD run idle forward and MI LC reverse STD HI LC
Measured value
Good NG
2. Work equipment speed
sec.
sec.
sec.
sec.
sec. sec. sec. sec.
PC228US-8,PC228USLC-8
Pm clinic Pm clinic service
Testing conditions No.
Check item
1
Drop amount of bucket tip
WorkFuel coning trol dial mode
Work equipment posture, etc.
Engine stopped
Boom top horizontal, Arm cylinder retracted fully, Bucket loaded
Unit
Standard Service limit value for new value machine
mm/15 min
Max. 600
Max. 900
[3] 60 MPa
[4] 60 MPa
Measured value
Good NG
3. Hydraulic drift of work equipment
4. Hydraulic circuit [2] 60 MPa
[5] 6 MPa
{600 kg/cm2} {600 kg/cm2} {600 kg/cm2} {600 kg/cm2} {60 kg/cm2} No. Check item
Left Fuel Workknob control ing dial mode switch
Self-pres1 sure reducing valve
Operation of F pump main work equipment All levers in the neutral position
R pump main
F pump LS
R pump LS
–
–
–
–
Good NG
[1] 60 MPa
Testing conditions
Control
A
OFF
Main relief 2 valve (low pressure)
B
B
B
B
–
C
C
C
C
–
D1
D2
D2
–
Arm OUT relief Main relief 3 valve (low pressure) 4
ON
Unload valve
5 LS valve
MAX
P
Swing 6 motor safety valve OFF
Standard value
Main relief valve, travel motor 7 safety valve, travel junction valve
Measured oil pressure Unit A (Control circuit source pressure) B (Work equipment relief pressure, low) MPa C (Work equipment relief pressure, high) {kg/cm2} D (Unload pressure) E (LS differential pressure) F (Swing relief pressure) G (Travel relief pressure)
PC228US-8,PC228USLC-8
All levers in the D1 neutral position Right track run idle, Lever E1 moved halfway Left track run idle, Lever moved halfway Swing lock switch ON, Right F swing relief Swing lock switch ON, Left F swing relief Right track locked ,Right G track forward relief Right track locked , Right G track reverse relief Left track locked, Left track forward relief Left track locked, Left track reverse relief
–
–
E2
–
E2
–
E1
–
–
F
–
–
–
F
–
–
–
–
–
–
–
–
–
–
–
–
G
–
–
–
–
G
–
–
–
Standard value for new machine
Service limit value
2.93 - 3.43 {30 - 35}
2.75 - 3.43 {28 - 35}
33.8 - 35.8 {345 - 365}
33.3 - 36.8 {340- 375}
36.3 - 38.3 {370 - 390}
36.3 - 39.2 {370 - 400}
D1 - D2 = 2.5 - 4.5 {26 - 46} E1 - E2 = 1.7 - 1.9 {17 - 19} 28.8 - 31.8 {295 - 325} 36.7 - 39.7 {375 - 405}
D1 - D2 = 2.5 - 4.5 {26 - 46} E1 - E2 = 1.7 - 1.9 {17 - 19} 28.4 - 32.3 {290 - 330} 36.8 - 40.2 {375 - 410}
30-137
Pm clinic Pm clinic service
Testing conditions No.
Standard value
8
[1]
[2]
[3a]
[4a]
[5]
60 MPa
60 MPa
60 MPa
60 MPa
6 MPa
{600 kg/cm2} {600 kg/cm2} {600 kg/cm2} {600 kg/cm2} {60 kg/cm2}
Check item
Fuel Work- Left Operation of F pump R pump control ing knob work equipmain main dial mode switch ment Servo pisArm OUT H1 H1 MAX P OFF ton relief Measured oil pressure Unit Standard value for new machine
H (Servo control pressure)
F pump servo
R pump servo
H2
H2
Good NG
* Gauge connection changing work: Exchange hoses of gauges [3] and [4].
Control –
Service limit value
H1: H2 = 1 : 0.6 (Oil pressure ratio)
–
* Gauge connection changing work: Replace gauges [3] and [4] with 60K and exchange hoses of [3], [4], and [5]. Testing conditions
[1]
[2]
[3b]
[4b]
[5a]
60 MPa
60 MPa
60 MPa
60 MPa
6 MPa
No. Check item
PC-EPC(F) valve 9 PC-EPC (R) valve
Fuel Workcontrol ing dial mode MIN
P E L B
OFF
MAX
Standard value
10
LS-EPC valve
P
Measured oil pressure J1 (PC-EPC valve output pressure 1) J2 (PC-EPC valve output pressure 2) J3 (PC-EPC valve output pressure 3) J4 (PC-EPC valve output pressure 4) J5 (PC-EPC valve output pressure 5) K1 (LS-EPC valve output pressure 1) K2 (LS-EPC valve output pressure 2) K3 (LS-EPC valve output pressure 3)
30-138
Left knob switch
Unit
Operation of work equipment All levers in the neutral position Travel speed: Lo, Travel lever in neutral Travel speed: Mi, Travel lever operated Travel speed: Hi, Travel lever operated
F pump main
R pump main
– – – – –
– – – – –
Good NG
{600 kg/cm2} {600 kg/cm2} {600 kg/cm2} {600 kg/cm2} {60 kg/cm2}
F pump (F) R pump (R)
J1 J2 J3 J4 J5
LS-EPC
J1 J2 J3 J4 J5
– – – – – K1
–
–
–
–
K2 –
–
–
–
K3 –
–
–
Standard value for new machine
–
Service limit value
Approx. 2.9 {Approx. 30} Approx. 0.7 {Approx. 7} Approx. 0.78 {Approx. 8} MPa {kg/cm2}
Approx. 1.7 {Approx. 17.5} Approx. 1.57 {Approx. 16} Approx. 2.45 {Approx. 25} Approx. 0.74 {Approx. 7.5} 0 {0 kg/cm2}
PC228US-8,PC228USLC-8
Pm clinic Pm clinic service
PC228US-8,PC228USLC-8
30-139
Pm clinic Pm clinic service
30-140
PC228US-8,PC228USLC-8
SEN0533412-00
40-1
PC228US-8,PC228USLC-8
HYDRAULIC EXCAVATOR PC228US-8 PC228USLC-8 Shop Manual
Machine model
Serial number
PC228US-8 PC228USLC-8
50001 and up 50001 and up
40 Troubleshooting
PC228US-8,PC228USLC-8
40-1
40-1
Contents
Contents 40 Troubleshooting General information on troubleshooting ......................................................................................... 40-8 Points to remember when troubleshooting ................................................................................. 40-8 Sequence of events in troubleshooting....................................................................................... 40-9 Checks before troubleshooting ................................................................................................... 40-10 Classification and procedures for troubleshooting ...................................................................... 40-34 Failure codes table...................................................................................................................... 40-37 Symptom and troubleshooting numbers ..................................................................................... 40-42 Information in troubleshooting table............................................................................................ 40-44 Troubleshooting method for open circuit in wiring harness of pressure sensor system ............. 40-46 Connector list and layout ............................................................................................................ 40-48 Connection table for connector pin numbers .............................................................................. 40-60 T- branch box and T- branch adapter table ................................................................................ 40-96 Fuse location table...................................................................................................................... 40-100 Troubleshooting by failure code..................................................................................................... 40-102 Failure code [989L00] Engine Controller Lock Caution 1 ........................................................... 40-102 Failure code [989M00] Engine Controller Lock Caution 2 .......................................................... 40-102 Failure code [989N00] Engine Controller Lock Caution 3........................................................... 40-103 Failure code [AA10NX] Air Cleaner Clogging ............................................................................. 40-104 Failure code [AB00KE] Charge Voltage Low .............................................................................. 40-106 Failure code [B@BAZG] Eng Oil Press Low............................................................................... 40-108 Failure code [B@BAZK] Eng Oil Level Low................................................................................ 40-109 Failure code [B@BCNS] Eng Water Overheat ........................................................................... 40-110 Failure code [B@BCZK] Eng Water Level Low .......................................................................... 40-112 Failure code [B@HANS] Hyd Oil Overheat................................................................................. 40-114 Failure code [CA111] ECM Critical Internal Failure .................................................................... 40-115 Failure code [CA115] Eng Ne and Bkup Speed Sens Error ....................................................... 40-115 Failure code [CA122] Chg Air Press Sensor High Error ............................................................. 40-116 Failure code [CA123] Chg Air Press Sensor Low Error .............................................................. 40-118 Failure code [CA131] Throttle Sensor High Error ....................................................................... 40-120 Failure code [CA132] Throttle Sensor Low Error ........................................................................ 40-122 Failure code [CA144] Coolant Temp Sens High Error ................................................................ 40-124 Failure code [CA145] Coolant Temp Sens Low Error................................................................. 40-126 Failure code [CA153] Chg Air Temp Sensor High Error ............................................................. 40-128 Failure code [CA154] Chg Air Temp Sensor Low Error .............................................................. 40-130 Failure code [CA155] Chg Air Temp High Speed Derate ........................................................... 40-132 Failure code [CA187] Sens Supply 2 Volt Low Error .................................................................. 40-134 Failure code [CA221] Ambient Press Sens High Error ............................................................... 40-136 Failure code [CA222] Ambient Press Sens Low Error ................................................................ 40-138 Failure code [CA227] Sens Supply 2 Volt High Error ................................................................. 40-140 Failure code [CA234] Eng Overspeed ........................................................................................ 40-141 Failure code [CA238] Ne Speed Sens Supply Volt Error............................................................ 40-142 Failure code [CA271] IMV/PCV1 Short Error.............................................................................. 40-144 Failure code [CA272] IMV/PCV1 Open Error.............................................................................. 40-146 Failure code [CA322] Inj #1(L#1) Open/Short Error.................................................................... 40-148 Failure code [CA323] Inj #5 (L#5) Open/Short Error................................................................... 40-150 Failure code [CA324] Inj #3(L#3) Open/Short Error.................................................................... 40-152 Failure code [CA325] Inj #6 (L#6) Open/Short Error................................................................... 40-154 Failure code [CA331] Inj #2(L#2) Open/Short Error.................................................................... 40-156 Failure code [CA332] Inj #4(L#4) Open/Short Error.................................................................... 40-158 Failure code [CA342] Calibration Code Incompatibility............................................................... 40-160
40-2
PC228US-8,PC228USLC-8
Contents
Failure code [CA351] Injectors Drive Circuit Error...................................................................... 40-161 Failure code [CA352] Sens Supply 1 Volt Low Error .................................................................. 40-162 Failure code [CA386] Sens Supply 1 Volt High Error ................................................................. 40-164 Failure code [CA428] Water in Fuel Sensor High Error .............................................................. 40-166 Failure code [CA429] Water in Fuel Sensor Low Error............................................................... 40-168 Failure code [CA435] Eng Oil Press Sw Error ............................................................................ 40-170 Failure code [CA441] Battery Voltage Low Error........................................................................ 40-172 Failure code [CA442] Battery Voltage High Error ....................................................................... 40-174 Failure code [CA449] Rail Press Very High Error....................................................................... 40-175 Failure code [CA451] Rail Press Sensor High Error................................................................... 40-176 Failure code [CA452] Rail Press Sensor Low Error.................................................................... 40-178 Failure code [CA488] Chg Air Temp High Torque Derate .......................................................... 40-180 Failure code [CA553] Rail Press High Error ............................................................................... 40-181 Failure code [CA559] Rail Press Low Error ................................................................................ 40-182 Failure code [CA689] Eng Ne Speed Sensor Error .................................................................... 40-184 Failure code [CA731] Eng Bkup Speed Sens Phase Error......................................................... 40-186 Failure code [CA757] All Continuous Data Lost Error ................................................................ 40-187 Failure code [CA778] Eng Bkup Speed Sensor Error................................................................. 40-188 Failure code [CA1633] KOMNET Datalink Timeout Error........................................................... 40-191 Failure code [CA2185] Throt Sens Sup Volt High Error ............................................................. 40-192 Failure code [CA2186] Throt Sens Sup Volt Low Error .............................................................. 40-193 Failure code [CA2249] Rail Press Very Low Error...................................................................... 40-194 Failure code [CA2311] IMV Solenoid Error................................................................................. 40-195 Failure code [CA2555] Grid Htr Relay Open Circuit Error .......................................................... 40-196 Failure code [CA2556] Grid Htr Relay Short Circuit Error .......................................................... 40-198 Failure code [D110KB] Battery Relay Drive Short Circuit ........................................................... 40-200 Failure code [D19JKZ] Personal Code Relay Abnormality ......................................................... 40-202 Failure code [D862KA] GPS Antenna Open Circuit.................................................................... 40-204 Failure code [DA22KK] Pump Solenoid Power Low Error .......................................................... 40-206 Failure code [DA25KP] 5V Sensor1 Power Abnormality ............................................................ 40-208 Failure code [DA26KP] 5V Sensor2 Power Abnormality ............................................................ 40-210 Failure code [DA29KQ] Model Selection Abnormality ................................................................ 40-214 Failure code [DA2RMC] CAN Discon (Pump Con Detected) ..................................................... 40-217 Failure code [DAF8KB] Camera Power Supply Short Circuit ..................................................... 40-222 Failure code [DAFGMC] GPS Module Error ............................................................................... 40-224 Failure code [DAFRMC] CAN Discon (Monitor Detected) .......................................................... 40-226 Failure code [DGH2KB] Hyd Oil Sensor Short ........................................................................... 40-230 Failure code [DHPAMA] Pump Press Sensor Abnormality......................................................... 40-232 Failure code [DHPBMA] R Pump Press Sensor Abnormality ..................................................... 40-234 Failure code [DHS3MA] Arm IN PPC Sen. Abnormality ............................................................. 40-236 Failure code [DHS4MA] Bucket CURL PPC Press Sensor Abnormality .................................... 40-238 Failure code [DHS8MA] Boom RAISE PPC Press Sensor Abnormality..................................... 40-240 Failure code [DHSAMA] Swing RH PPC Press Sensor Abnormality.......................................... 40-242 Failure code [DHSBMA] Swing LH PPC Press Sensor Abnormality .......................................... 40-244 Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality .................................... 40-246 Failure code [DHSFMA] Travel FW L PPC Press Sensor Abnormality ...................................... 40-248 Failure code [DHSGMA] Travel FW R PPC Press Sensor Abnormality ..................................... 40-250 Failure code [DHSHMA] Travel BW L PPC Press Sensor Abnormality...................................... 40-252 Failure code [DHSJMA] Travel BW R PPC Press Sensor Abnormality ...................................... 40-254 Failure code [DHX1MA] Overload Sensor Abnormality .............................................................. 40-257 Failure code [DKA0KA] Boom Angle Sensor Open Circuit......................................................... 40-260 Failure code [DKA0KB] Boom Angle Sensor Power Short Circuit .............................................. 40-262 Failure code [DKA0PH] Boom Angle Sensor Install Abnormality ............................................... 40-264 Failure code [DKR0MA] F pump S/P sensor Abnormality .......................................................... 40-266 PC228US-8,PC228USLC-8
40-3
Contents
Failure code [DKR1MA] R pump S/P sensor Abnormality .......................................................... 40-268 Failure code [DV20KB] Travel Alarm Short Circuit ..................................................................... 40-270 Failure code [DW43KA] Travel Speed Sol Open Circuit............................................................. 40-272 Failure code [DW43KB] Travel Speed Sol Short Circuit ............................................................. 40-274 Failure code [DW45KA] Swing Brake Sol Open Circuit .............................................................. 40-276 Failure code [DW45KB] Swing Brake Sol Short Circuit .............................................................. 40-278 Failure code [DW4GKA] Boom Slow Down Sol. Disc. ................................................................ 40-280 Failure code [DW4GKB] Boom Slow Down Sol. Short Circuit .................................................... 40-282 Failure code [DW4WKA] Cancel Bucket Dump Open Circuit ..................................................... 40-284 Failure code [DW4WKB] Cancel Bucket Dump Short Circuit ..................................................... 40-286 Failure code [DW91KA] Travel Junction Sol. Disc...................................................................... 40-288 Failure code [DW91KB] Travel Junction Sol. S/C....................................................................... 40-290 Failure code [DWA2KA] Attachment Sol Open Circuit................................................................ 40-292 Failure code [DWA2KB] Attachment Sol Short Circuit................................................................ 40-294 Failure code [DWK0KA] 2-stage Relief Sol Open Circuit............................................................ 40-296 Failure code [DWK0KB] 2-stage Relief Sol Short Circuit............................................................ 40-298 Failure code [DXA8KA] PC-EPC (F) Sol Open Circuit................................................................ 40-300 Failure code [DXA8KB] PC-EPC (F) Sol Short Circuit................................................................ 40-302 Failure code [DXA9KA] PC-EPC (R) Sol Open Circuit ............................................................... 40-304 Failure code [DXA9KB] PC-EPC (R) Sol Short Circuit ............................................................... 40-306 Failure code [DXE0KA] LS-EPC Sol Open Circuit...................................................................... 40-308 Failure code [DXE0KB] LS-EPC Sol Short Circuit ...................................................................... 40-310 Failure code [DXE4KA] Service Current EPC Disc..................................................................... 40-312 Failure code [DXE4KB] Service Current EPC S/C...................................................................... 40-314 Failure code [DXE5KA] Merge-divider Main Sol Open Circuit .................................................... 40-316 Failure code [DXE5KB] Merge-divider Main Sol Short Circuit .................................................... 40-318 Failure code [DXE6KA] Merge-divider LS Sol Open Circuit ....................................................... 40-320 Failure code [DXE6KB] Merge-divider LS Sol Short Circuit........................................................ 40-322 Failure code [DY20KA] Wiper Working Abnormality................................................................... 40-324 Failure code [DY20MA] Wiper Parking Abnormality ................................................................... 40-326 Failure code [DY2CKA] Washer drive discon ............................................................................. 40-328 Failure code [DY2CKB] Washer drive short................................................................................ 40-330 Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit ............................................................ 40-332 Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit............................................................. 40-334 Failure code [DXEAKA] Service Current EPC1 Discon .............................................................. 40-336 Failure code [DXEAKB] Service Current EPC1 Short................................................................. 40-337 Failure code [DXE7KA] Service Current EPC2 Discon............................................................... 40-338 Failure code [DXE7KB] Service Current EPC2 Short ................................................................. 40-339 Failure code [DXE8KA] Service Current EPC3 Discon............................................................... 40-340 Failure code [DXE8KB] Service Current EPC3 Short ................................................................. 40-341 Failure code [DXE9KA] Service Current EPC4 Discon............................................................... 40-342 Failure code [DXE9KB] Service Current EPC4 Short ................................................................. 40-344 Failure code [DFB1KZ] Service Lever Potentio 1 Abnormality ................................................... 40-346 Failure code [DFB2KZ] Service Lever Potentio 2 Abnormality ................................................... 40-348 Failure code [DFB5KZ] Service Lever Sub Potentio 1 Abnormality............................................ 40-350 Failure code [DFB6KZ] Service Lever Sub Potentio 2 Abnormality............................................ 40-352 Failure code [DFB3L8] Service Lever 1 Potentio Error............................................................... 40-354 Failure code [DFB4L8] Service Lever 2 Potentio Error............................................................... 40-355 Troubleshooting of electrical system (E-mode).............................................................................. 40-357 E-1 Engine does not start (Engine does not crank) .................................................................... 40-357 E-2 Preheater does not operate.................................................................................................. 40-362 E-3 When starting switch is turned to ON position, machine monitor displays nothing .............. 40-367 E-4 When starting switch is turned to ON position (before starting engine), basic check monitor lights up. ............................................................................................................................................... 40-370 40-4
PC228US-8,PC228USLC-8
Contents
E-5 Precaution monitor lights up while engine is running ........................................................... 40-371 E-6 Emergency stop monitor lights up while engine is running .................................................. 40-373 E-7 Fuel level gauge does not indicate correctly ........................................................................ 40-374 E-8 Engine coolant temperature gauge does not indicate correctly ........................................... 40-376 E-9 Hydraulic oil temperature gauge does not indicate correctly ............................................... 40-378 E-10 Displays on machine monitor are different from those for actual machine ........................ 40-381 E-11 Some areas of machine monitor screen are not displayed ................................................ 40-381 E-12 Function switch does not operate ...................................................................................... 40-381 E-13 Automatic warm-up system does not operate (in cold season) ......................................... 40-382 E-14 Auto-decelerator does not operate properly....................................................................... 40-383 E-15 Working mode does not change ........................................................................................ 40-384 E-16 Travel speed does not change........................................................................................... 40-385 E-17 Alarm buzzer cannot be cancelled ..................................................................................... 40-386 E-18 When starting switch is turned OFF, service meter is not displayed.................................. 40-386 E-19 Service mode cannot be selected ...................................................................................... 40-387 E-20 Any of work equipment, swing and travel do not operate or cannot be locked .................. 40-388 E-21 Swing brake does not operate properly ............................................................................. 40-391 E-22 One-touch power maximizing function does not operate properly ..................................... 40-394 E-23 Travel alarm does not sound or does not stop sounding ................................................... 40-397 E-24 Horn does not sound or does not stop ............................................................................... 40-398 E-25 Windshield wiper and window washer do not operate ....................................................... 40-400 E-26 BOOM LOWER indicator is not displayed properly with monitoring function ..................... 40-402 E-27 ARM OUT indicator is not displayed properly with monitoring function ............................. 40-404 E-28 ARM IN indicator is not displayed properly with monitoring function ................................. 40-406 E-29 BOOM RAISE indicator is not displayed properly with monitoring function ....................... 40-406 E-30 BUCKET CURL indicator is not displayed properly with monitoring function..................... 40-406 E-31 BUCKET DUMP indicator is not displayed properly with monitoring function .................... 40-407 E-32 SWING indicator is not displayed properly with monitoring function .................................. 40-407 E-33 TRAVEL indicator is not displayed properly with monitoring function ................................ 40-407 E-34 ATTACHMENT indicator is not displayed properly with monitoring function ..................... 40-408 E-35 Attachment hydraulic circuit cannot be changed................................................................ 40-410 E-36 KOMTRAX system does not operate properly ................................................................... 40-411 Troubleshooting of hydraulic and mechanical system (H-mode) ................................................... 40-413 Information in troubleshooting table............................................................................................ 40-413 System chart for hydraulic and mechanical systems.................................................................. 40-414 Failure mode and cause table .................................................................................................... 40-416 H- 1 All of work equipment, swing and travel work slow or lack power ...................................... 40-418 H- 2 Engine speed lowers significantly or engine stalls.............................................................. 40-420 H- 3 Any of work equipment, swing and travel does not work .................................................... 40-421 H- 4 Unusual sound is heard from around hydraulic pump ........................................................ 40-421 H- 5 Fine control performance or response is poor .................................................................... 40-422 H- 6 Boom operation lacks speed or power................................................................................ 40-423 H- 7 Arm operation lacks speed or power .................................................................................. 40-424 H- 8 Bucket operation lacks speed or power .............................................................................. 40-425 H- 9 Work equipment does not move in single operation ........................................................... 40-425 H-10 Hydraulic drift of work equipment is large .......................................................................... 40-426 H-11 Time lag of work equipment is large .................................................................................. 40-428 H-12 Other work equipment moves when one of work equipment is relieved ............................ 40-428 H-13 One-touch power maximizing function does not work ....................................................... 40-429 H-14 In combined operation of work equipment , equipment having heavier load moves slower.40-429 H-15 In combined operation of swing and boom RAISE, boom rising speed is low ................... 40-430 H-16 Travel speed drops largely in combined operation of swing and travel ............................. 40-430 H-17 Machine does not travel straight ........................................................................................ 40-431 H-18 Travel speed is low ............................................................................................................ 40-432 PC228US-8,PC228USLC-8
40-5
Contents
H-19 Machine is hard to steer or travel power is low .................................................................. 40-433 H-20 Travel speed does not change, or travel speed is too low or high ..................................... 40-434 H-21 One of tracks does not run................................................................................................. 40-435 H-22 Upper structure does not swing ......................................................................................... 40-436 H-23 Swing acceleration is poor or swing speed is low .............................................................. 40-438 H-24 Upper structure overruns excessively when it stops swinging ........................................... 40-440 H-25 Shock is large when upper structure stops swinging ......................................................... 40-441 H-26 Large unusual noise is heard when upper structure stops swinging.................................. 40-441 H-27 Swing drift on a slope is large ............................................................................................ 40-442 H-28 Attachment circuit cannot be changed ............................................................................... 40-443 H-29 Oil flow in attachment circuit cannot be controlled ............................................................. 40-443 Troubleshooting of engine (S-mode) ............................................................................................. 40-444 Method of using troubleshooting chart........................................................................................ 40-444 S-1 Startability is poor................................................................................................................. 40-448 S-2 Engine does not start ........................................................................................................... 40-449 S-3 Engine does not pick up smoothly........................................................................................ 40-452 S-4 Engine stops during operation.............................................................................................. 40-453 S-5 Engine runs rough or is unstable.......................................................................................... 40-454 S-6 Engine lacks power .............................................................................................................. 40-455 S-7 Exhaust smoke is black (incomplete combustion)................................................................ 40-456 S-8 Oil consumption is excessive (or exhaust smoke is blue) .................................................... 40-457 S-9 Oil becomes contaminated early .......................................................................................... 40-458 S-10 Fuel consumption is excessive........................................................................................... 40-459 S-11 Oil is in coolant (or coolant spurts or coolant level goes down) ......................................... 40-460 S-12 Oil pressure drops .............................................................................................................. 40-461 S-13 Oil level rises (coolant or fuel in oil).................................................................................... 40-462 S-14 Coolant temperature rises too high (overheating) .............................................................. 40-463 S-15 Unusual noise is made ....................................................................................................... 40-464 S-16 Vibration is excessive......................................................................................................... 40-465 Quick coupler troubleshooting ....................................................................................................... 40-466 Quick coupler .............................................................................................................................. 40-466
40-6
PC228US-8,PC228USLC-8
Contents
PC228US-8,PC228USLC-8
40-7
General information on troubleshooting Points to remember when troubleshooting
General information on troubleshooting Points to remember when troubleshooting (Rev. 2010/03)
k Stop the machine in a level place, and check that the lock pin, blocks, and parking brake are se-
curely fitted.
k When carrying out the operation with two or more service technicians, keep strictly to the agreed
signals, and do not allow any unauthorized person to come near.
k If the radiator cap is removed when the engine is hot, hot water may spurt out and cause burns, so
wait for the engine to cool down before starting troubleshooting.
k Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
k When disconnecting wiring, always disconnect the negative (–) terminal of the battery first.
k When removing the plug or cap from a component which is under pressure from oil, water, or air,
always release the internal pressure first. When installing measuring equipment, be sure to connect it properly. The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to prevent reoccurrence of the failure. When carrying out troubleshooting, an important point is of course to understand the structure and function. However, a short cut to effective troubleshooting is to ask the operator various questions to form some idea of possible causes of the failure that would produce the reported symptoms. 1. When carrying out troubleshooting, do not hurry to disassemble the components. If components are disassembled immediately after any failure occurs: q Parts that have no connection with the failure or other unnecessary parts will be disassembled. q It will become impossible to find the cause of the failure. It will also cause a waste of man-hours, parts, or oil or grease, and at the same time, will also lose the confidence of the user or operator. For this reason, when carrying out troubleshooting, it is necessary to carry out thorough prior investigation and to carry out troubleshooting in accordance with the fixed procedure. 2. Points to ask the user or operator 1) Have any other problems occurred apart from the problem that has been reported? 2) Was there anything strange about the machine before the failure occurred? 3) Did the failure occur suddenly, or were there problems with the machine condition before the failure? 4) Under what conditions did the failure occur? 5) Had any repairs been carried out before the failure? When were these repairs carried out? 6) Has the same kind of failure occurred before?
3) Make checks of other items. 4) Check other maintenance matters which can be checked externally and are considered to be necessary. 4. Confirming failure Confirm the extent of the failure yourself, and judge whether to handle it as a real failure or as a problem with the method of operation, etc. a When operating the machine to re-enact the troubleshooting symptoms, do not perform any inspection or measurement that may make the problem worse. 5. Troubleshooting Use the results of the investigation and inspection in Items 2 to 4 to narrow down the causes of failure, then use the troubleshooting flowchart to locate the failure exactly. a The basic procedure for troubleshooting is as follows. 1] Start from the simple points. 2] Start from the most likely points. 3] Investigate other related parts or information. 6. Measures to remove root cause of failure Even if the immediate failure is removed, the same failure may occur again, unless the root cause of the failure is repaired. To prevent this, always investigate why the cause of the failure occurred. Then, remove the root cause.
3. Check before troubleshooting 1) Is there any sign of irregularities of the machine? 2) Make checks before starting day's work.
40-8
PC228US-8,PC228USLC-8
General information on troubleshooting Sequence of events in troubleshooting
Sequence of events in troubleshooting (Rev.2007.12)
PC228US-8,PC228USLC-8
40-9
General information on troubleshooting Checks before troubleshooting
Checks before troubleshooting
b: Hydraulic and mechanical equipment
a: Engine, lubricating oil and coolant
No.
40-10
Item
Criterion
Remedy
1 Check for unusual sounds and smells
–
Repair
2 Check for dirt around engine
–
Remove
3 Check for water leakage around engine
–
Repair
4 Check for oil leakage around engine
–
Repair
5 Check for leakage from fuel line
–
Repair
6 Check of radiator for clogging
–
Remove
7 Check of level and type of fuel
–
Refill with fuel
8 Check for foreign matter in fuel
–
Clean and drain
9 Check of fuel pre-filter
–
Replace
10 Check of fuel main filter
–
Replace
11 Check of level (in oil pan) and type of engine oil
Between H – L
Refill with oil
12 Check of coolant level (in sub tank)
Between H – L
Refill with coolant
13 Check of air cleaner for clogging
No air cleaner clogging monitor on screen
Clean or replace
1 Check for abnormal sounds and smells
–
Repair
2 Check for oil leakage
–
Repair
3 Check of hydraulic oil level
Between H – L
Refill with oil
4 Check of hydraulic oil strainer
–
Clean and drain
5 Check of hydraulic oil filter
–
Replace
6 Check of swing machinery case oil level
Between H – L
Refill with oil
7 Check of damper case oil level
Between H – L
Refill with oil
8 Check of final drive case oil level
–
Refill with oil
9 Performing air bleeding
–
Air bleeding
PC228US-8,PC228USLC-8
General information on troubleshooting Checks before troubleshooting
No.
Item
Criterion
Remedy
1 Check of battery terminal for looseness and corrosion
–
Retighten or replace
2 Check of alternator terminal for looseness and corrosion
–
Retighten or replace
3 Check of starting motor terminal for looseness and corrosion
–
Retighten or replace
20 – 30 V
Charge or replace
Between H – L
Add or replace
6 Check of wiring harness for discoloration, burn and cover peeling
–
Repair or replace
7 Check of wiring harness for release from clamp and sagging
–
Repair
8 Check of grounding
–
Repair
9 Check for loose connector and damaged lock
–
Repair or replace
10 Check of connector pin for corrosion, bending and deformation
–
Repair or replace
11 Check for water and foreign matter in connector
–
Dry, clean or replace
12 Check of wiring harness for open or short circuit
–
Repair or replace
13 Check of fuse for blowout and corrosion
–
Replace
After several minutes operation: 27.5 – 29.5 V
Replace
–
Replace
16 Check and cleaning of rear view camera
–
Clean or repair
1 Check of undercarriage
–
Repair
2 Check of handrails and steps
–
Repair
3 Check of rear view mirrors
–
Clean or repair
1 Check of gauges and monitors
–
Clean or replace
2 Check of seat belt
–
Repair
4 Check of battery voltage (with engine stopped)
e: Interior parts d: Exterior parts
c: Electrical equipment
5 Check of battery electrolyte level
14
Check of alternator voltage (When engine speed is medium or higher)
15
Check of battery relay operation sound (when the starting switch is turned and ON or OFF position)
PC228US-8,PC228USLC-8
40-11
General information on troubleshooting Checks before troubleshooting
Testing procedure before troubleshooting Walk-around check
40-12 40-12
Before starting the engine, look around and under the machine to check for any loose nuts or bolts, leakages of oil, fuel or coolant, and check the condition of the work equipment and hydraulic system. Check the connectors for looseness, the wiring harnesses for play, and the hot parts for accumulated dust. k Accumulated combustibles around hot engine parts such as the engine muffler and turbocharger,
etc. and fuel or oil leakages may cause a machine fire. Be sure to check thoroughly and repair any abnormalities. a a1 and a2, ---, b1, b2, --- refer to the symbols in the table on the previous page. a1. and b1. Check for unusual sounds and smells Check for unusual sounds and smells. Some causes of unusual sounds and smells can damage the machine if they are left as they are. Therefore, stop the machine immediately when you find any abnormality. a2. Check for dirt around engine Check for and remove any accumulated dirt around the engine and any combustibles (dead leaves, twigs, etc.) on hot engine parts such as the engine muffler, turbocharger, etc. a3. Check for water leakage around engine a4. Check for oil leakage around engine Check for any oil leaks from the engine and any water leaks from the cooling system. If any of them is defective, carry out a repair. a5. Check for leakage from fuel line Check for any fuel leaks and damaged hoses and tubes. If any of them is defective, carry out a repair. a6. Check of radiator for clogging Check for and remove any accumulated dirt and combustibles (dead leaves, twigs, etc.) around the radiator. For removal of dirt from the radiator, see the Operation and Maintenance Manual, "Cleaning and testing of radiator fins, oil cooler fins, aftercooler fins, fuel cooler fins and air conditioner condenser fins (machine with the air conditioner)". b2. Check of work equipment, cylinders, linkage and hoses for breakage, wear and clearance Check the work equipment, cylinders, linkage and hoses for cracks and excessive wear, check that the clearances in them are within the normal range, and then repair any failures.
40-12
b3. Check of hydraulic equipment, hydraulic tank, hoses and joints for oil leakage Check and repair any oil leaks. c1. Check for dirt around battery Check for and remove any accumulated dirt and combustibles (dead leaves, twigs, etc.) around the battery. c16. Check and cleaning of rear view camera Check the rear view camera for any defect, and repair any failures. d1. Check of undercarriage (track, sprocket, idler and guard) for defect, wear, loose bolts and oil leakage from roller Repair any failures. d2. Check of handrails and steps for defect and loose bolts Repair any failures and retighten any loose bolts. d3. Check and cleaning of rear view mirrors Check for and repair any defective and broken rear view mirrors. Clean the mirror surfaces and adjust their angles so that the operator can see the area behind him at the operator's seat. e1. Check of gauges and monitors for defect Check the gauges and monitors inside the operator cab. If any of them is defective, replace it. Clean up the surfaces. e2. Check of seat belt and mounting hardware Check the hooks, locks and hook fittings for damage. If any of them has a problem, repair it.
PC228US-8,PC228USLC-8
General information on troubleshooting Checks before troubleshooting
Test according to testing procedure a. Engine, lubricating oil and coolant
40-13 40-13
a7. Check of level and type of fuel k Fuel is flammable and dangerous. Do not bring any open flame near fuel. k When adding fuel, take care not to let it overflow. k Wipe off any spilt fuel. If fuel has spilt over dirt and sand, remove the dirt and sand, too. 1. Turn the starting switch to the ON position and check the fuel level with fuel level gauge (1) on the monitor panel. After checking, return the switch to the OFF position.
q
If breather hole (3) in the oil filler cap is clogged, the pressure in the tank decreases and fuel may not be supplied. To prevent this, clean the breather hole.
2. If the fuel level is low, open oil filler cap (F) of the fuel tank and add fuel through the oil filler port to the necessary level, referring to the position of float gauge (G). 3. After adding the fuel, push float gauge (G) straight down using oil filler cap (F) and tighten oil filler cap (F) securely while taking care not to pinch float gauge (G) with pawls (2) of the oil filler cap (F).
PC228US-8,PC228USLC-8
40-13
General information on troubleshooting Checks before troubleshooting
a8. Check for foreign matter in fuel 1. Open the side cover on the rear right side of the machine. 2. Put a container under drain valve (1) to receive the drained fuel. 3. Turn drain valve (1) to "OPEN" position (O) to discharge the sediment and water in the bottom together with the fuel. 4. When only the clean fuel flows out, turn drain valve (1) to "CLOSE" position (S). 5. Close the side cover.
a9. Check of fuel pre-filter k Immediately after the engine is stopped, its parts and oil will still be very hot and may burn your hands on contact. Therefore, wait until they have cooled down before starting the work. k High pressure is generated in the engine fuel piping system while the engine is running. Wait for at least 30 seconds after stopping the engine until the internal pressure decreases, and then replace the filter. k Do not bring any open flame near the filter. a Komatsu genuine fuel filter cartridges use a special filter with a high filtration efficiency. When replacing, be sure to use a Komatsu genuine cartridge. a The common rail fuel injection system of this machine consists of parts that are more precise compared with the conventional injection pump and nozzle. If a fuel filter cartridge other than Komatsu genuine one is used, foreign matter may enter, which can cause a trouble in the injection system. Never use a substitute. a When testing and servicing the fuel system, be extremely careful that no foreign matter enters. If any dirt sticks, remove it completely by using fuel. q Prepare a container to receive the fuel. q Prepare the filter wrench. Check of water separator, and drainage of water and sediments 1. Turn valve (1) at the bottom of the fuel tank to "CLOSE" (S) position.
2. Open the side cover on the rear right side of the machine. q The water separator is integrated with fuel pre-filter (1).
40-14
PC228US-8,PC228USLC-8
General information on troubleshooting Checks before troubleshooting
3. Transparent cap (2) lets you identify the water level and presence/absence of sediments. If water or sediments are found, place a container under drain hose (3) to receive the drained water and sediments. 4. Loosen drain valve (4) to drain the water. 5. If drain hose (3) starts to discharge fuel, close drain valve (4) immediately.
a If water in transparent cap (2) is frozen, the water separator monitor may not light up. And after the engine starts, if the frozen water is melted into water due to the increased temperature surrounding fuel pre-filter (1), water separator monitor may suddenly light up. Drain water frequently during the cold season even if water separator monitor (5) is not lit up. a If water in transparent cap (2) is frozen, drain water only after confirming that it has completely melted. a If you cannot visually identify the presence of water due to stains on transparent cap (2), clean transparent cap (2) when replacing fuel pre-filter cartridge (1). a When you have removed drain valve (4) for the above cleaning process, coat the O-ring with grease and tighten drain valve until it touches the bottom.
a The sensor is installed in this machine for detecting accumulation of water in transparent cap (2). a If water separator monitor (5) lights up in red on the machine monitor, it indicates that water is accumulated in transparent cap (2). Drain water from the cap.
PC228US-8,PC228USLC-8
40-15
General information on troubleshooting Checks before troubleshooting
Replacing fuel pre-filter cartridge 1. Turn valve (1) at the bottom of the fuel tank to the "CLOSE" (S) position.
2. Open the side cover on the rear right side of the machine. 3. Place a container under the fuel pre-filter cartridge to receive the fuel. 4. Loosen drain valve (2) and drain water and sediments from transparent cup (3), and also drain all the fuel from filter cartridge (4). 5. Disconnect connector (5). Wrap the removed connector with a vinyl bag and the like to protect it from being exposed to fuel, oil and water. 6. Using the filter wrench, rotate transparent cap (3) to remove. (This cap is reused.) 7. Using the filter wrench, rotate filter cartridge (4) to remove. 8. Install currently removed transparent cap (3) to the bottom of the new filter cartridge. a At this time, replace O-ring (6) with a new one.
9. When installing the transparent cap, apply a thin film of oil to the O-ring, set it against the sealing surface of filter cartridge (4), and then tighten the transparent cap by turning 1/4 to 1/2 turn. a If the transparent cap is over tightened, fuel will leak because the O-ring will have been damaged. If the transparent cap is not tightened sufficiently, fuel will also leak through the clearance of the O-ring. Therefore, observe the tightening angle. 10. Clean the filter holder, fill the new filter cartridge with clean fuel, apply a thin film of oil to the O-ring , and then install the new filter cartridge on the filter holder. a Be sure to add fuel through 8 small holes (A) on the dirty side without removing centre cap (B). a After filling with the fuel, remove cap (B) at the centre before installing the fuel pre-filter. a Add clean fuel and take care that dirt is not mixed in it. Be sure to add fuel without removing cap (B) to prevent dirt from entering the clean side of the central part.
11. When installing the fuel pre-filter cartridge, tighten it by 3/4 turn after the O-ring come in contact with the sealing surface of the filter holder. a If the filter cartridge is over tightened, fuel will leak because the O-ring is damaged. If the filter cartridge is not tightened sufficiently, fuel will also leak through the clearance of the O-ring. Therefore, observe the tightening angle. a When using a filter wrench for tightening, take care not to leave flaws or dents on the filter. 12. Make sure that drain valve (2) is securely closed.
40-16
PC228US-8,PC228USLC-8
General information on troubleshooting Checks before troubleshooting
13. Remove the vinyl bag wrapping connector (5) and connect connector (5). a If connector (5) is exposed to water, the sensor may malfunction, lighting up the water separator monitor. Whenever disconnecting connector (5), take care not to allow the connector to come in contact with water. a If connector (5) does come in contact with water, dry it completely prior to connecting it.
a10. Check of main filter k Immediately after the engine is stopped, its parts and oil will still be very hot and may burn your hands on contact. Therefore, wait until they have cooled down before starting the work. k High pressure is generated in the engine fuel piping system while the engine is running. Wait for at least 30 seconds after stopping the engine until the internal pressure decreases, and then replace the filter. k Do not bring any open flame near the filter. a Komatsu genuine fuel filter cartridges use a special filter with a high filtration efficiency. When replacing, be sure to use a Komatsu genuine cartridge. a The common rail fuel injection system of this machine consists of parts that are more precise compared with the conventional injection pump and nozzle. If a fuel filter cartridge other than Komatsu genuine one is used, foreign matter may enter, which can cause a trouble in the injection system. Never use a substitute. a When testing and servicing the fuel system, be extremely careful that no foreign matter enters. If any dirt sticks, remove it completely by using fuel. q Prepare a container to receive the fuel. q Prepare the filter wrench. 1. Turn valve (1) at the bottom of the fuel tank to the "CLOSE" (S) position.
2. Open the engine hood. 3. Place a container under the filter cartridge to receive the fuel.
PC228US-8,PC228USLC-8
40-17
General information on troubleshooting Checks before troubleshooting
4. Using the filter wrench, rotate filter cartridge (2) to remove.
5. Clean the filter holder. Apply a thin film of oil to the packing of the new filter cartridge and install the cartridge to the filter holder. a Replace inside seal (3) with a new one.
a Do not fill the new filter cartridge with fuel. a Remove cap (A) at the centre before installing the filter cartridge.
a If the filter cartridge is over tightened, fuel will leak because the O-ring is damaged. If the filter cartridge is not tightened sufficiently, fuel will also leak through the clearance of the O-ring. Therefore, observe the tightening angle. 7. Turn valve (1) at the fuel tank bottom to "OPEN" (O) position. 8. Bleed air according to the following procedure. 1) Fill the fuel tank up with the fuel (until the float is in the upper limit position). 2) Loosen feed pump knob (4) and draw it out once, then push and pull several times until its movement becomes stiff. q You do not need to remove the plugs at the head of the fuel pre-filter and fuel main filter. q If fuel is used up, bleed air by operating feed pump knob (4) in the same manner.
3) Push in and tighten feed pump knob (4). 9. After replacing the filter cartridge, run the engine at low idle for approximately 10 minutes. 10. Check the filter sealing surface for fuel leakage. If fuel is leaking, check whether the filter cartridge is appropriately tightened. If fuel leakage recurs after the check, remove the filter cartridge by following the steps 1 to 4 and check the O-ring for damage or foreign matter being caught. If any of the above problems are detected on the O-ring, replace the cartridge with a new one. Then, perform step 5 and after.
6. When installing the filter cartridge, tighten it by 3/4 turn after the O-ring comes in contact with the sealing surface of the filter holder.
40-18
PC228US-8,PC228USLC-8
General information on troubleshooting Checks before troubleshooting
a11. Check of level (in oil pan) and type of engine oil k Immediately after the engine is stopped, its parts and oil will still be very hot and may burn your hands on contact. Therefore, wait until they have cooled down before starting the work. a If the engine has been operated, wait for at least 15 minutes after stopping it, and check the oil level. a When checking, set the machine in a horizontal position. 1. Stop the engine. 2. Open the engine hood. 3. Remove oil level gauge (G) and wipe off oil on the gauge with a cloth. 4. Insert oil level gauge (G) fully and pull it out.
6. If the oil level is above line H, drain the extra engine oil through drain valve (P) at the bottom of the engine oil pan and check the oil level again. 7. If the oil is at the correct level, tighten the oil filler cap securely and close the engine hood.
5. If the oil level is between stamped lines H and L on oil level gauge (G), it is at the correct level. If the oil level is below line L, add oil through oil filler port (F).
PC228US-8,PC228USLC-8
40-19
General information on troubleshooting Checks before troubleshooting
a12. Check of coolant level (in sub tank) k You do not need to open the radiator cap in the ordinary check. Check the coolant on the sub tank side after the engine has cooled down. k Immediately after the engine is stopped, the coolant will be hot and pressure will have accumulated in the radiator. If the cap is opened under these conditions, you may be scalded. If you need to remove the radiator cap, wait until the temperature drops before you do. Then rotate the cap slowly to release the pressure and remove it with care. 1. Open the side cover at the rear left side of the machine and check whether the coolant level is between lines FULL and LOW on sub tank (1) (see following figure). If there is not enough coolant, add it through the coolant filler port of sub tank (1) until the level reaches line FULL. 2. After adding the coolant, tighten the cap securely. 3. If the sub tank is vacant, coolant may have leaked. After checking, repair any failures immediately. If no failure is found, check the coolant level in the radiator. If the level is low, add coolant to the radiator first and then to the sub tank. 4. When you cannot identify the coolant level due to stains inside sub tank (1), clean the sub tank.
40-20
a13. Check of air cleaner for clogging
k When using compressed air for cleaning, put
on personal protective items such as safety glasses, gloves, dust mask, etc. to protect yourself from dirt that will fly out. k Removing the outer element from the air cleaner body forcibly is dangerous . When working in high places or on unstable footing, you may fall off due to the reaction when you pull out the outer element. Checking Clean the air cleaner element if air cleaner clogging monitor (1) on the monitor panel lights up.
a Do not clean the element until the air cleaner clogging monitor lights up on the monitor panel. If the element is cleaned frequently before the air cleaner clogging monitor on the monitor panel lights up, the true performance of the air cleaner will not be realized and the filtration efficiency will decrease. a If the outer element is checked or cleaned while the engine is running, the dirt sticking to it will fall into the inner element side more frequently and enter and damage the engine. Be sure to stop the engine before cleaning.
PC228US-8,PC228USLC-8
General information on troubleshooting Checks before troubleshooting
Cleaning of outer element a Do not leave or store the element in direct sunlight before or after cleaning it. a Replace the outer element after cleaning it six times or after using it for 1 year. When replacing the outer element, replace the inner element, too. a If the air cleaner clogging monitor (1) lights up soon after cleaning when the outer element has not been cleaned up to six times, replace both the inner and outer elements. 1. Open the side cover at the rear left side of the engine and disengage four hooks (2) to remove cover (3). 5. If dirt has piled up on vacuator valve (4) installed on cover (3), remove it.
2. Hold and pull out outer element (5) while swinging it up, down and laterally and rotating element to the left and right. a Never remove inner element (6). If it is removed, dirt will enter and can lead to engine troubles. a Do not use a screwdriver or another tool. a After removing outer element (5), check that the inner element has not come off or tilted. If the inner element is tilted, push it in straight by hand. 3. After removing outer element (5), cover the inner element (6) with a clean cloth or tape to prevent dirt from sticking to it. 4. Remove any dirt adhered to the inside of air cleaner body (7) and cover (3) with a piece of clean cloth, etc. a When cleaning the element, do not tap it or bump it against other objects.
PC228US-8,PC228USLC-8
6. Blow dry compressed air (Max. 0.69 MPa {7 kg/cm2}) along the inside pleats of the outer element. 7. Next, blow air along the outside pleats, and blow again along the inside pleats.
40-21
General information on troubleshooting Checks before troubleshooting
a After cleaning, light up the inside of the element to check it. If the element has a small hole or a thin component, replace it.
8. Remove the cloth or tape covering inner element (6). 9. Check and remove any dirt, oil, etc. sticking to the sealing surface of the cleaned or new element. a If the element or O-ring used for more than one year is cleaned and reused, it can cause a trouble. Therefore, do not reuse it. a Do not use the element if its pleats, gasket or seal is damaged. 10. Push the outer element straight into the air cleaner body while swinging it up, down and laterally. a Install the air cleaner element with its bottom (end with no hole) (C) on cover (3) side. If the air cleaner element is installed in reverse, it may be broken and the engine may be damaged seriously.
11. Install cover (3) according to the following procedure. 1) Set cover (3) to the element. a Be sure to install cover (3) so that vacuator (4) is at the bottom (A).
2) Hitch the tips of hooks (2) to the projection of the air cleaner body to lock. a Hitch hooks (2) diagonally (top and bottom, or right and left) to lock. a After installing cover (3), check for clearance between the air cleaner body and cover (3). If there is any clearance, remove and install cover (3) correctly.
12. Peel off a seal after cleaning the element each time.
40-22
PC228US-8,PC228USLC-8
General information on troubleshooting Checks before troubleshooting
Replacement of element 1. Remove outer element (5). For details, see "Cleaning of outer element". 2. Remove inner element (6) and install new inner element (6) quickly to air cleaner body (7). a Do not clean or reuse the inner element. When replacing the outer element, also replace the inner element.
5. Install cover (3). For details, see "Cleaning of outer element". 6. Replace seal (9) of cover (3) with a new one.
a Install the air cleaner element with its bottom (end with no hole) (B) on cover (3) side. If the air cleaner element is installed in reverse, it may be broken and the engine may be damaged seriously. a If the outer element and cover are installed while the inner element is not installed securely, the outer element may be broken. Install the inner element securely.
3. Push the outer element straight into the air cleaner body while swinging it up, down and laterally. a Install the air cleaner element with its bottom (end with no hole) (B) on cover (3) side. If the air cleaner element is installed in reverse, it may be broken and the engine may be damaged seriously. 4. Replace O-ring (8) of cover (3) with a new one.
PC228US-8,PC228USLC-8
40-23
General information on troubleshooting Checks before troubleshooting
b. Hydraulic and mechanical equipment
40-24
b3. Check of hydraulic oil level k Immediately after the engine is stopped, its parts and oil will still be very hot and may burn your hands on contact. Therefore, wait until they have cooled down before starting the work. k If the oil filler cap is removed quickly, the oil may spurt out. Therefore, rotate the oil filler cap slowly to release the internal pressure and remove it with care. 1. Set the work equipment in the posture as shown below and, after stopping the engine, check the oil level and add new oil if necessary. a If the work equipment posture is not as shown below, fully retract the cylinder rod for the arm and bucket while running the engine at low speed. Then lower the boom and stop the engine when the bucket teeth touch the ground.
2. Turn the starting switch to the ON position within 15 seconds after stopping the engine and operate each control lever (work equipment and travel) to the stroke end in each direction to release the internal pressure. 3. Sit down on the operator's seat and check sight gauge (G) through the right window. If the oil level is between lines H and L, there is sufficient oil. a If the oil level is below line L, add oil through oil filter port (F). a Do not add oil to above line H. If too much is added, it may damage the hydraulic circuit and spurt out. a If the oil level is higher than line H, swing the upper structure so that drain plug (P) at the bottom of the tank comes between the left and right tracks, and stop the engine. After the hydraulic oil has cooled, remove cover (1) to drain excessive oil through drain plug (P).
40-24
Since the oil level fluctuates according to the oil temperature, note the following when checking it. q Before operation (oil temperature: 10 30 °C), the oil level should be at the centre between lines H and L. q During normal operation (oil temperature: 50 - 80 °C), the oil level should be near line H.
PC228US-8,PC228USLC-8
General information on troubleshooting Checks before troubleshooting
b4. Check of hydraulic oil strainer
b5. Check of hydraulic oil filter
k Immediately after the engine is stopped, its
k Immediately after the engine is stopped, its
parts and oil will still be very hot and may burn your hands on contact. Therefore, wait until they have cooled down before starting the work. k If the oil filler cap is removed quickly, the oil may spurt out. Therefore rotate the oil filler cap slowly to release the internal pressure and remove it with care. 1. Stop the engine and remove oil filler cap (F) of the hydraulic tank to release the internal pressure. 2. Remove the bolts to remove cover (1). When removing the bolts, keep pressing down cover (1) since it may be flung toward you by spring (2). 3. Pull out rod (3) from the top, and take out spring (2) and strainer (4). 4. Remove dirt from strainer (4) and clean it using cleaning oil. If strainer (4) is damaged, replace it with a new one. 5. Insert and set strainer (4) in projected portion (5) of the tank. 6. While pressing down spring (2) with the projection at the bottom of cover (1), install the bolts. 7. Tighten the mounting bolts.
parts and oil will still be very hot and may burn your hands on contact. Therefore, wait until they have cooled down before starting the work. k If the oil filler cap is removed quickly, the oil may spurt out. Therefore rotate the oil filler cap slowly to release the internal pressure and remove it with care. 1. On a level and firm ground, set the work equipment to the posture as shown below and stop the engine.
2. Remove oil filler cap (F) of the hydraulic tank to release the internal pressure.
3. Remove the bolts to remove cover (1). When removing the bolts, keep pressing down cover (1) since it may be flung toward you by spring (2). 4. Remove spring (2), valve (3), strainer (4) and then remove element (5). q Check the bottom of the filter case and remove dirt if there is. At this time, take extreme care that dirt does not enter the hydraulic tank.
PC228US-8,PC228USLC-8
40-25
General information on troubleshooting Checks before troubleshooting
5. Clean the removed parts using cleaning oil. 6. Install new element (5). 7. Set strainer (4), valve (3) and spring (2) on the element. 8. Set cover (1) and install it with the mounting bolts while pressing it with your hand. 9. Tighten the mounting bolts.
6. After checking the oil level and adding oil, install oil level gauge (G) and oil filler cap (F).
10. Install oil filler cap (F). 11. Run the engine at a low speed for 10 minutes to bleed air. 12. Stop the engine. b6. Check of swing machinery case oil level k Immediately after the engine is stopped, its parts and oil will still be very hot and may burn your hands on contact. Therefore, wait until they have cooled down before starting the work. 1. Remove oil level gauge (G) and wipe off oil on the gauge with a cloth. 2. Insert oil level gauge (G) fully into the guide. 3. Pull out oil level gauge (G) and check the oil level. If the oil level is between the lines (H) and (L) on the oil level gauge, there is sufficient oil. 4. If the oil level is below line (L) on oil level gauge (G), remove the cap of oil filter port (F) and add oil. When adding oil, remove oil level gauge (G). 5. If the oil level is above line (H) of oil level gauge (G), loosen drain valve (P) to drain the excessive oil. q When draining the oil, place an oil container under drain valve (P).
40-26
PC228US-8,PC228USLC-8
General information on troubleshooting Checks before troubleshooting
b7. Check of damper case oil level
k Before checking the oil level, you must stop
the machine in a level place and wait for at least 30 minutes after the engine is stopped. 1. Open the side cover on the rear right side of the machine. 2. Remove plug (G) and check the oil level. If the oil level is near the lower edge of the plug hole, there is sufficient oil. If the oil level is insufficient, remove plug (F) and add oil through the hole of plug (F) up to the lower edge of the hole for plug (G). a Since an excessive oil can cause overheat, it must be drained to the specified oil level. 3. Install plug (G) and plug (F). 4. Close the side cover.
b8. Check of final drive case oil level k Since the oil may spurt out due to internal pressure, rotate the plug gradually from its side to release the internal pressure and then remove it carefully. k Immediately after the engine is stopped, its parts and oil will still be very hot and may burn your hands on contact. Therefore, wait until they have cooled down before starting the work. q Refill capacity (right and left, respectively): 5.2 l q Prepare the handle. 1. Set the final drive with TOP mark at the top, and the straight line connecting the mark and plug (p) is vertical to the ground surface. 2. Place the fuel receiving container under plug (P). 3. Remove plug (P) and (F) using the handle to drain oil. a Check the O-ring attached to the plug for damage. Replace it, if any.
PC228US-8,PC228USLC-8
4. Tighten plug (P). 5. Supply oil through the hole for plug (F). 6. If oil flows out from the hole for plug (F), install plug (F). 3 Tightening torque of Plugs (P) and (F): 68.6 ± 9.8 Nm {7 ± 1 kgm} a Plug (F) is provided in two locations. To add oil, use the hole that is easier to use or the internal gear can not be seen through it.
b9. Performing air bleeding For the procedure for bleeding air from the fuel system, see Testing and adjusting, "Bleeding air from fuel circuit". q For the procedure for bleeding air from the hydraulic equipment, see Testing and adjusting, "Bleeding air from each part". q
40-27
General information on troubleshooting Checks before troubleshooting
c. Electrical equipment
40-28
c1. Check of battery terminal for looseness and corrosion 1. Open the side cover on the rear left side of the machine and remove battery cover (1). 2. Check the battery cable terminals for looseness and corrosion.
c2. Check of alternator terminal for looseness and corrosion q Remove covers (1) and (2). q Check alternator terminal B (3) for open circuit, looseness and corrosion. c3. Check of starting motor terminal for looseness and corrosion q Check starting motor terminal B (4) and terminal C (5) for open circuit, looseness and corrosion.
40-28
PC228US-8,PC228USLC-8
General information on troubleshooting Checks before troubleshooting
c4. Check of battery voltage (with engine stopped) Test the battery voltage by using the battery tester while the engine is stopped. c5. Check of battery electrolyte level Check before operating the machine. k Do not use the battery while its electrolyte level is below LOWER LEVEL. If it is used under that condition, its inside will deteriorate, its service life will be shortened and it may lead to an explosion. k Since the battery produces combustible gas that can explode, do not bring any open flame near it. k Battery electrolyte is dangerous. Take care that it does not come in contact with your eyes or skin. If it does, wash it away with water and contact your doctor. a Do not add battery electrolyte beyond the UPPER LEVEL mark. Excessive addition can cause electrolyte leakage that damages the painted surface and corrodes the parts. a As purified water (example: commercially available battery fluid) added to the battery may freeze, add it before starting work for the day so that it does not freeze. q When checking the electrolyte level through the side face of the battery 1. Clean around the electrolyte level lines using a cloth soaked in water, and check that the electrolyte level is between UPPER LEVEL (U.L.) and LOWER LEVEL (L.L.) a Do not clean the battery with a dry cloth since static electricity may cause an explosion.
3. After adding the purified water, tighten cap (2) securely.
a If you have added purified water above the U.L. line, take some of it out using a syringe or similar tool. Neutralize the liquid that has been taken out with sodium bicarbonate or other suitable liquid, and wash it out with a large amount of water. q When electrolyte level cannot be checked through the side face of the battery 1. Remove cap (2) on the top of the battery. (Described previously) 2. Look into electrolyte level opening (3) to check the electrolyte level. If the electrolyte level is below sleeve (4), be sure to add purified water (example: commercially available battery fluid) up to the sleeve bottom (U.L. line). q (A) Correct level: Since the electrolyte level reaches to the sleeve bottom, the shape of the electrode plates will appear distorted due to the surface tension. q (B) Low: Since the electrolyte level does not reach the sleeve bottom, the shape of the electrode plates will appear straight. 3. After adding the purified water, tighten cap (2).
2. If the electrolyte level is below the centre between the U.L. and L.L. lines, remove cap (2) and add purified water (example: commercially available battery fluid) to the U.L. line immediately.
PC228US-8,PC228USLC-8
40-29
General information on troubleshooting Checks before troubleshooting
a If you have added purified water above the U.L. line, take some of it out using a syringe or similar tool. Neutralize the liquid that has been taken out with sodium bicarbonate or other suitable liquid, and wash it out with a large amount of water. c6. Check of wiring harness for discoloration, burn and cover peeling q Check the wiring harness and cables for discoloration and burn. a Discoloration and burn indicate that short circuit or ground fault is in the circuit. q Check the wiring harnesses and cables for damage and peeling of the covers. q If any failures are discovered, repair or replace the wiring harness or cable.
c7. Check of wiring harness for release from clamp and sagging q Check the wiring harnesses for sagging and loosening caused by release from a clamp. a In particular, carefully check the wiring harness around the hot and movable parts. q If any part is off the clamp, resecure it to the clamp.
c8. Check of grounding a Check the ground terminal for looseness and rust in particular. q Remove cover (1).
q
40-30
Check the connection of ground terminals (2), (3), (T01) and (T14).
PC228US-8,PC228USLC-8
General information on troubleshooting Checks before troubleshooting
Cab ground strap T02 a Since (T02) is situated at the bottom on the rear left side of the cab and connected to (T01), it is not particularly necessary to check it.
q
q
Check ground terminals (T04) - ( T10) for connection.
c9. Check for loose connector and damaged lock q Pull the male and female connectors of the connector by the hand to check the connection. q If the connection is defective, connect them securely.
Open the engine hood. a To check the connection of ground strap of the engine, remove the counterweight. q Check the connection of ground strap (4) of engine controller (EC). q
q q
PC228US-8,PC228USLC-8
Check that the connector is not unlocked and check its lock and housing for cracks. Check lock screws (L) of engine controller (EC) for looseness. a Use a hexagonal wrench with 4 mm width across flats.
40-31
General information on troubleshooting Checks before troubleshooting
c10. Check of connector pin for corrosion, bending and deformation q Disconnect the connector and check the pins for corrosion, bending and recession. Check that the female pins have not expanded. q If any pin is found to be damaged, repair or replace it. a If the pins are not shiny, apply contact restorer to them and connect and disconnect several times to shine them. (If the pins do not become shiny, connect and disconnect the connector 10 times)
q
Remove foreign matter in the connector by using a cloth or other material, and blow compressed air against the inside of the connector.
c11. Check for water and foreign matter in connector q Disconnect the connector and check for water, dirt, sand, etc. in it. c12. Check of wiring harness for open or short circuit q Check the connection (crimped parts) between each connector pin and wiring harness. q If any open circuit is in wiring harness or connector as (A) in the figure, repair or replace them.
a If sand or foreign matter is in the connector, check the seal for damage. q If the seal is defective, repair or replace it. q Dry the moisture in the connector by using a drier.
q
Check that any pin does not contact any adjacent pin due to peeling of the wire cover, defective crimping of the pin, etc.
c13. Check of fuse for blowout and corrosion a When replacing a fuse, be sure to turn off the power (turn the starting switch to the OFF position). q A fusible link is a large-capacity fuse. q If a fuse is corroded and coated with white powder, or there is any play between the fuse and fuse holder, replace the fuse. q Replace each fuse with the one of the same capacity.
40-32
PC228US-8,PC228USLC-8
General information on troubleshooting Checks before troubleshooting
Remove the cover at the left rear of the operator seat, and the fuse holder is seen.
Open the battery inspection cover and pull up the vinyl cover. You will find fusible links (F04) and (F05) there.
c14. Check of alternator voltage (when engine speed is medium or higher) 1. Open the engine hood. 2. Connect the positive (+) lead of the multimeter to alternator terminal (B) and connect the negative (-) lead to the chassis ground. 3. Start and warm up the engine and measure the voltage while running the engine at a medium or a higher speed. q If the voltage is out of the normal range abnormal, repair or replace the alternator. c15. Check of battery relay operation sound 1. Open the battery cover. 2. Check whether the battery relay operation sound is heard when starting switch is turned to ON/OFF position. q If the operation sound is not heard, check the related circuits, referring to E-1 described in the E mode troubleshooting. q If the related circuits are normal, replace the battery relay.
PC228US-8,PC228USLC-8
40-33
General information on troubleshooting Classification and procedures for troubleshooting
Classification and procedures for troubleshooting Classification for troubleshooting Mode
40-34 Contents
Display of code Troubleshooting by failure code E-mode
Troubleshooting of electrical system
H-mode
Troubleshooting of hydraulic and mechanical systems
S-mode
Troubleshooting of engine
Procedure for troubleshooting 40-34 If a problem occurs on the machine, proceed to the appropriate troubleshooting section according to the following procedure. 1. Procedure for troubleshooting when user code and failure code are displayed on machine monitor: If a user code and a failure code are displayed on the machine monitor, perform the troubleshooting for the corresponding "Display of code". a If multiple failure codes are displayed simultaneously, all the codes are displayed repeatedly in order. Note down all the codes. 2. Procedure for troubleshooting when a user code and a failure code are not displayed on machine monitor: Check the mechanical system failure code and the electrical system failure code by using the abnormality record function of the machine monitor. (See [*1].) 1) If failure code (s) is (are) recorded, perform troubleshooting for the failure code described in Troubleshooting [Display of code]. a If electrical system failure code (s) is (are) recorded, delete all the codes and reproduce them in order to see if the problem remains unsolved. (See [*2].) a The failure code of the mechanical system cannot be deleted. a If an air conditioner system failure is recorded in the abnormality record , perform "Inspection by self-diagnosis function " in "Air conditioner ". (See [*3].) 2) If no failure code is found in the abnormality record, a problem that the machine monitor cannot find out by itself may have occurred in the electrical system or hydraulic and mechanical system. In this case, check the phenomenon which is assumed to show a trouble again and select the same phenomenon from the list on the next page, and then perform troubleshooting corresponding to that phenomenon in the "E-mode", "H-mode", or "S-mode". 3. Action to take after trouble is eliminated Referring to the next page, clear all the failure codes in the electrical system abnormality record.
40-34
PC228US-8,PC228USLC-8
General information on troubleshooting Classification and procedures for troubleshooting
[*1], [*2] 1. While pressing numerical key [4] of the panel switch section with the standard screen displayed, press [1], [2] and [3] in order.
2. On the Service Menu screen, press [F3] switch (R) on the panel switch section once to select "02 Abnormality Record". 3. Press [F6] switch ( ) on the panel switch to confirm and go to "Abnormality Record" screen.
5. Press the [F3] switch (R) on the panel switch section to see if the next failure code is displayed and note down all the failure codes. a A mechanical system failure code cannot be cleared. 6. Press [F5] switch (Return) on the panel switch section to return to the "Abnormality Record" screen. 7. Select the "Electrical Systems " screen similarly to steps 2 and 3. 8. Press the [F3] switch (R) on the panel switch section to see if the next failure code is displayed and note down all of the failure codes. a "E" on the left of a failure code indicates that the failure code is "active" (the failure remains or restoration to the normal condition has not been verified). A failure code having no "E" on its left is a "inactive" one. Since it disappears at the following clear step, be sure to note it down. 9. While pressing numerical key [4] on the panel switch section, press [1], [2] and [3] in this order to select the "Clear mode". (Same as step 1) 10. Press [F2] switch (CLEAR) on the panel switch section. 11. Press [F6] switch ( ) on the panel switch to clear all the failure codes temporarily. 12. Press [F5] switch (Return) on the panel switch section to return to the "Electrical Systems" abnormality record screen. See if any failure code is still displayed and note down displayed ones. 13. Press [F5] switch (Return) on the panel switch section to return to the "Abnormality Record" screen.
4. Press [F6] switch ( ) on the panel switch to confirm and go to "Mechanical system" screen.
PC228US-8,PC228USLC-8
40-35
General information on troubleshooting Classification and procedures for troubleshooting
[*3] a For the method of accessing the "Abnormality Record" screen, see steps 1 to 3 in [*1] and [*2]. 1. On the "Abnormality Record" screen, press [F3] switch (R) on the panel switch section twice to select "03 Air-conditioning System". 2. Press [F6] switch ( ) on the panel switch to confirm and enter the "Air conditioner abnormality record" screen.
3. Note down the information in all the columns. a "E" on the left of a failure code (same as in the "Electrical Systems" abnormality record) indicates that the failure code is "active" (the failure remains or its restoration to the normal condition has not been verified). 4. Press [F2] switch (CLEAR) on the panel switch section to clear all the codes. Check whether any failure code is still displayed and note down displayed ones. (Same as step 10 of [*1] and [*2]) 5. Press [F5] switch (Return) on the panel switch section to return to the "Abnormality Record" screen.
40-36
PC228US-8,PC228USLC-8
General information on troubleshooting Failure codes table
Failure codes table Failure code
Failure (Displayed on screen)
Component Category of User code in charge record
989L00
Engine Controller Lock Caution 1
MON
–
989M00
Engine Controller Lock Caution 2
MON
–
989N00
Engine Controller Lock Caution 3
MON
–
AA10NX
Air Cleaner Clogging
MON
–
AB00KE
Charge Voltage Low
MON
–
B@BAZG
Eng Oil Press Low
ENG
–
B@BAZK
Eng Oil Level Low
MON
–
B@BCNS
Eng Water Overheat
ENG
–
B@BCZK
Eng Water Level Low
MON
–
B@HANS
Hyd Oil Overheat
MON
–
CA111
EMC Critical Internal Failure
ENG
E10
CA115
Eng Ne and Bkup Speed Sens Error
ENG
E10
CA122
Chg Air Press Sensor High Error
ENG
E11
CA123
Chg Air Press Sensor Low Error
ENG
E11
CA131
Throttle Sensor High Error
ENG
E14
CA132
Throttle Sensor Low Error
ENG
E14
CA144
Coolant Temp Sens High Error
ENG
E15
CA145
Coolant Temp Sens Low Error
ENG
E15
CA153
Chg Air Temp Sensor High Error
ENG
E15
CA154
Chg Air Temp Sensor Low Error
ENG
E15
CA155
Chg Air Temp High Speed Derate
ENG
E11
CA187
Sens Supply 2 Volt Low Error
ENG
E15
CA221
Ambient Press Sens High Error
ENG
E11
CA222
Ambient Press Sens Low Error
ENG
E11
CA227
Sens Supply 2 Volt High Error
ENG
E15
CA234
Eng Overspeed
ENG
–
CA238
Ne Speed Sens Supply Volt Error
ENG
E15
CA271
IMV/PCV1 Short Error
ENG
E10
CA272
IMV/PCV1 Open Error
ENG
E10
CA322
Inj #1 (L#1) Open/Short Error
ENG
E11
PC228US-8,PC228USLC-8
Electrical system Electrical system Electrical system Mechanical system Mechanical system Mechanical system Mechanical system Mechanical system Mechanical system Mechanical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system
Reference document page 40-102 40-102 40-103 40-104 40-106 40-108 40-109 40-110 40-112 40-114 1-115 40-115 40-116 40-118 40-120 40-122 40-124 40-126 40-128 40-130 40-132 40-134 40-136 40-138 40-140 40-141 40-142 40-144 40-146 40-148
40-37
General information on troubleshooting Failure codes table
CA323
Inj #5 (L#5) Open/Short Error
ENG
E11
CA324
Inj #3 (L#3) Open/Short Error
ENG
E11
CA325
Inj #6 (L#6) Open/Short Error
ENG
E11
CA331
Inj #2 (L#2) Open/Short Error
ENG
E11
CA332
Inj #4 (L#4) Open/Short Error
ENG
E11
CA342
Calibration Code Incompatibility
ENG
E10
CA351
Injectors Drive Circuit Error
ENG
E10
CA352
Sens Supply 1 Volt Low Error
ENG
E15
CA386
Sens Supply 1 Volt High Error
ENG
E15
CA428
Water in Fuel Sensor High Error
ENG
E15
CA429
Water in Fuel Sensor Low Error
ENG
E15
CA435
Eng Oil Press Sw Error
ENG
E15
CA441
Battery Voltage Low Error
ENG
E10
CA442
Battery Voltage High Error
ENG
E10
CA449
Rail Press Very High Error
ENG
E11
CA451
Rail Press Sensor High Error
ENG
E11
CA452
Rail Press Sensor Low Error
ENG
E11
CA488
Chg Air Temp High Torque Derate
ENG
E11
CA553
Rail Press High Error
ENG
E15
CA559
Rail Press Low Error
ENG
E15
CA689
Eng Ne Speed Sensor Error
ENG
E15
CA731
Eng Bkup Speed Sens Phase Error
ENG
E15
CA757
All Continuous Data Lost Error
ENG
E10
CA778
Eng Bkup Speed Sensor Error
ENG
E15
CA1633
KOMNET Datalink Timeout Error
ENG
E0E
CA2185
Throt Sens Sup Volt High Error
ENG
E14
CA2186
Throt Sens Sup Volt Low Error
ENG
E14
CA2249
Rail Press Very Low Error
ENG
E11
CA2311
IMV Solenoid Error
ENG
E11
CA2555
Grid Htr Relay Open Circuit Error
ENG
E15
CA2556
Grid Htr Relay Short Circuit Error
ENG
E15
D110KB
Battery Relay Drive Short Circuit
PUMP
–
40-38
Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system
40-150 40-152 40-154 40-156 40-158 40-160 40-161 40-162 40-164 40-166 40-168 40-170 40-172 40-174 40-175 40-176 40-178 40-180 40-181 40-182 40-184 40-186 40-187 40-188 40-191 40-192 40-193 40-194 40-195 40-196 40-198 40-200
PC228US-8,PC228USLC-8
General information on troubleshooting Failure codes table
D19JKZ
Personal Code Relay Abnormality
KOMTRAX
E01
D862KA
GPS Antenna Open Circuit
KOMTRAX
–
DA22KK
Pump Solenoid Power Low Error
PUMP
E0E
DA25KP
5 V Sensor1 Power Abnormality
PUMP
–
DA26KP
5 V Sensor2 Power Abnormality
PUMP
–
DA29KQ
Model Selection Abnormality
PUMP
–
DA2RMC
CAN Discon (Pump Con Detected)
PUMP
E0E
DAF8KB
Camera Power Supply Short Circuit
MON
–
DAFGMC
GPS Module Error
KOMTRAX
–
DAFRMC
CAN Discon (Monitor Detected)
MON
E0E
DGH2KB
Hyd Oil Sensor Short
PUMP
–
DHPAMA
F Pump Press Sensor Abnormality
PUMP
–
DHPBMA
R Pump Press Sensor Abnormality
PUMP
–
DHS3MA
Arm Curl PPC Press Sensor Abnormality
PUMP
–
DHS4MA
Bucket Curl PPC Press Sensor Abnormality
PUMP
–
DHS8MA
Boom Raise PPC Press Sensor Abnormality
PUMP
–
DHSAMA
Swing RH PPC Press Sensor Abnormality
PUMP
–
DHSBMA
Swing LH PPC Press Sensor Abnormality
PUMP
–
DHSDMA
Bucket Dump PPC Press Sensor Abnormality
PUMP
–
DHSFMA
Travel FW L PPC Press Sensor Abnormality
PUMP
E20
DHSGMA
Travel FW R PPC Press Sensor Abnormality
PUMP
E20
DHSHMA
Travel BW L PPC Press Sensor Abnormality
PUMP
E20
DHSJMA
Travel BW R PPC Press Sensor Abnormality
PUMP
E20
DHX1MA
Overload Sensor Abnormality
PUMP
–
DKA0KA
Boom Angle Sensor Open Circuit
PUMP
E50
DKA0KB
Boom Angle Sensor Power Short Circuit
PUMP
E50
DKA0PH
Boom Angle Sensor Install Abnormality
PUMP
E50
DKR0MA
F pump S/P sensor Abnormality
PUMP
–
DKR1MA
R pump S/P sensor Abnormality
PUMP
–
DV20KB
Travel Alarm Short Circuit
PUMP
–
DW43KA
Travel Speed Sol Open Circuit
PUMP
–
DW43KB
Travel Speed Sol Short Circuit
PUMP
–
PC228US-8,PC228USLC-8
Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system
40-202 40-204 40-206 40-208 40-210 40-214 40-217 40-222 40-224 40-226 40-230 40-232 40-234 40-236 40-238 40-240 40-242 40-244 40-246 40-248 40-250 40-252 40-254 40-257 40-260 40-262 40-264 40-266 40-268 40-270 40-272 40-274
40-39
General information on troubleshooting Failure codes table
DW45KA
Swing Brake Sol Open Circuit
PUMP
E03
DW45KB
Swing Brake Sol Short Circuit
PUMP
E03
DW4GKA
Boom Slow Down Sol. Disc.
PUMP
E06
DW4GKB
Boom Slow Down Sol. S/C
PUMP
E06
DW4WKA
Cancel Bucket Dump Sol Open Circuit
PUMP
E50
DW4WKB
Cancel Bucket Dump Sol Short Circuit
PUMP
E50
DW91KA
Travel Junction Sol Open Circuit
PUMP
–
DW91KB
Travel Junction Sol Short Circuit
PUMP
–
DWA2KA
Attachment Sol Open Circuit
PUMP
–
DWA2KB
Attachment Sol Short Circuit
PUMP
–
DWK0KA
2-stage Relief Sol Open Circuit
PUMP
–
DWK0KB
2-stage Relief Sol Short Circuit
PUMP
–
DXA8KA
PC-EPC (F) Sol Open Circuit
PUMP
E02
DXA8KB
PC-EPC (F) Sol Short Circuit
PUMP
E02
DXA9KA
PC-EPC (R) Sol Open Circuit
PUMP
E02
DXA9KB
PC-EPC (R) Sol Short Circuit
PUMP
E02
DXE0KA
LS-EPC Sol Open Circuit
PUMP
–
DXE0KB
LS-EPC Sol Short Circuit
PUMP
–
DXE4KA
Service Current EPC Open Circuit
PUMP
–
DXE4KB
Service Current EPC Short Circuit
PUMP
–
DXE5KA
Merge-divider Main Sol Open Circuit
PUMP
–
DXE5KB
Merge-divider Main Sol Short Circuit
PUMP
–
DXE6KA
Merge-divider LS Sol Open Circuit
PUMP
–
DXE6KB
Merge-divider LS Sol Short Circuit
PUMP
–
DY20KA
Wiper Working Abnormality
PUMP
–
DY20MA
Wiper Parking Abnormality
PUMP
–
DY2CKA
Washer Drive Open Circuit
PUMP
–
DY2CKB
Washer Drive Short Circuit
PUMP
–
DY2DKB
Wiper Drive (Fwd) Short Circuit
PUMP
–
DY2EKB
Wiper Drive (Rev) Short Circuit
PUMP
–
40-40
Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system
40-276 40-278 40-280 40-282 40-284 40-286 40-288 40-290 40-292 40-294 40-296 40-298 40-300 40-302 40-304 40-306 40-308 40-310 40-312 40-314 40-316 40-318 40-320 40-322 40-324 40-326 40-328 40-330 40-332 40-334
PC228US-8,PC228USLC-8
General information on troubleshooting Failure codes table
a In this table, failure codes are arranged in the order of characters from numeric to alphabetic character. a A component in charge means a controller or the machine monitor that is in charge of the system check. MON: Machine monitor ENG: Engine controller PUMP: Pump controller KOMTRAX: KOMTRAX part of machine monitor a The failure codes that do not have user codes in the user code columns are not displayed on the standard screen even if a failure code is generated. They are just recorded in the abnormality record (electrical system and mechanical system) on the service menu. a The category of record column shows in which system each failure is classified, the electrical equipment system or mechanical equipment system, when it is recorded in the abnormality record. For details, see "Troubleshooting by failure code (Display of code)".
PC228US-8,PC228USLC-8
40-41
General information on troubleshooting Symptom and troubleshooting numbers
Symptom and troubleshooting numbers Symptom and troubleshooting number Troubleshooting No.
Symptom of failure
Index
Reference document page
User code, failure code 1 User code and failure code are displayed on machine monitor The failure code is displayed on the mechanical system abnormality 2 record screen The failure code is displayed on the electrical system abnormality 3 record screen The failure code is displayed on the air conditioner or heater abnor4 mality record screen
No.
Take actions by following the failure code.
"Inspection by self-diagnosis function" in Chapter 80
Symptom of failure
Troubleshooting Reference document Index page
Symptom related to engine 5 Startability is poor 6 Engine does not start 7 Engine does not pick up smoothly 8 Engine stops during operation
S-1
40-428
E-1, S-2
40-337,40-429
S-3
40-432
S-4, H-2
40-433,40-400
9 Engine runs rough or is unstable (hunts)
S-5
40-434
10 Engine lacks power
S-6
40-435
11 Exhaust smoke is black (incomplete combustion)
S-7
40-436
12 Oil consumption is too much (or exhaust smoke is blue)
S-8
40-437
13 Oil becomes contaminated early
S-9
40-438
14 Fuel consumption is excessive
S-10
40-439
15 Oil is in coolant (or coolant spurts back or coolant level goes down)
S-11
40-440
16 Oil pressure drops
S-12
40-441
17 Oil level rises (coolant or fuel in oil)
S-13
40-442
18 Coolant temperature rises too high (Overheating)
S-14
40-443
19 Unusual noise is heard
S-15
40-444
20 Vibration is excessive
S-16
40-445
21 Preheater does not operate
E-2
40-342
22 Automatic warm-up system does not operate (in cold season)
E-13
40-362
23 Auto-decelerator does not operate normally
E-14
40-363
Symptom related to work equipment, swing and travel 24 Any of work equipment, swing, and travel does not work 25 All of work equipment, swing and travel work slow or lack power
E-20, H-3
40-368,40-401
H-1
40-398
H-2, S-6
40-400,40-435
27 Working mode does not change
E-15
40-364
28 Unusual sound is heard from around hydraulic pump
H-4
40-401
29 Fine control performance or response is poor
H-5
40-402
30 Speed or power of boom is low
H-6
40-403
31 Speed or power of arm is low
H-7
40-404
32 Speed or power of bucket is low
H-8
40-405
33 Work equipment does not move in single operation
H-9
40-405
34 Hydraulic drift of work equipment is large
H-10
40-406
35 Time lag of work equipment operation is large
H-11
40-408
26 Engine speed lowers significantly or engine stalls
Symptom related to work equipment
40-42
PC228US-8,PC228USLC-8
General information on troubleshooting Symptom and troubleshooting numbers
Troubleshooting No.
Symptom of failure
Index
36 Other work equipment moves when one of work equipment is relieved
Reference document page
H-12
40-408
37 One-touch power maximizing function does not work.
H-13, E-22
40-409,40-374
38 Attachment circuit can not be changed
H-28, E-35
40-423,40-390
H-29
40-423
H-14
40-409
H-15
40-409
H-16
40-410
43 Machine does not travel straight
H-17
40-411
44 Travel speed is low.
H-18
40-412
45 Machine is hard to steer or travel power is low
H-19
40-413
39 Oil flow in attachment circuit cannot be changed Symptom related to combined operation In combined operation of work equipment, equipment having heavier 40 load moves slower In combined operations of swing and boom RAISE, boom rising speed 41 is low 42 Travel speed drops largely in combined operation of swing and travel Symptom related to travel
H-20, E-16
40-414,40-365
47 One of tracks does not run
46 Travel speed does not change or travel speed is too low or high
H-21
40-415
48 Travel alarm does not sound or does not stop sounding
E-23
40-377
49 Upper structure does not swing
H-22
40-416
50 Swing acceleration is poor or swing speed is low
H-23
40-418
51 Upper structure overruns excessively when it stops swinging
H-24
40-420
52 Shock is larger when upper structure stops swinging
H-25
40-421
Symptom related to swing
53 Large unusual noise is heard when upper structure stops swinging H-26 Swing brake does not operate properly 54 H-27, E-21 Swing drift on a slope is large Symptom is related to machine monitor When starting switch is turned to ON position, machine monitor disE-3 55 plays nothing When starting switch is turned ON (before starting engine), basic 56 E-4 check monitor lights up 57 Precaution monitor lights up while engine is running. E-5
40-421 40-422,40-371
40-347 40-350 40-351
58 Emergency stop monitor lights up while engine is running
E-6
40-353
59 Engine coolant temperature gauge does not indicate correctly
E-8
40-356
60 Hydraulic oil temperature gauge does not indicate correctly
E-9
40-358
61 Fuel level gauge does not indicate correctly Contents of display on machine monitor is different from that of actual 62 machine 63 Some areas of machine monitor are not displayed
E-7
40-354
E-10
40-361
E-11
40-361
64 Function switch does not work
E-12
40-361
65 Alarm buzzer cannot be stopped
E-17
40-366
66 While starting switch is in OFF position, service meter is not displayed
E-18
40-366
67 Service mode can not be selected
E-19
40-367
68 Horn does not sound or does not stop
E-24
40-378
69 Windshield wiper and window washer do not operate Air conditioner does not operate normally (including air conditioner 70 fault record) 71 Monitoring function does not display lever control signal normally
E-25 40-380 "Testing and troubleshooting procedure" in Chapter 80 E-26 – 34 40-382 – 40-388
Others 72 KOMTRAX system does not work properly
PC228US-8,PC228USLC-8
E-36
40-391
40-43
General information on troubleshooting Information in troubleshooting table
Information in troubleshooting table (Rev. 2010/03) a The following information is summarized in the troubleshooting table and the related electrical circuit diagram. Before performing troubleshooting, understand that information fully. User code Failure code Display on Failure name displayed on the Abnormality Record screen of the Display on machine Failure machine monimachine monitor monitor tor Detail of failure Description of the failure detected by the machine monitor or controller Action of Action to be taken to protect the system and equipment when the machine monitor or controller detects machine monia trouble tor or controller Problem on Problem that appears on machine as result of action (above) taken by machine monitor or controller machine Related inforInformation related to detected failure or troubleshooting mation Cause
1
2
3
4
5
6
7
Procedure, measuring location, criteria and remarks <Details of description> q Procedure q Measuring location Defective component a "Between A and B" means the measurement of voltage, resistance or others between terminals A and B. q Criteria to judge probable causes (normal value) q Remarks for judgment <How to use troubleshooting sheet> q Perform troubleshooting procedures in numerical order. Open or short circuit in wiring q If the check result does not meet the criteria, the probable cause described harness on the left column is the actual cause of the failure. q If the check result shows no abnormality, and unless otherwise specified, proceed to the next step (next cause item). q Check that the failure is fixed after a failure was found and repaired. Open circuit in wiring harness <Failures in wiring harness> (wire breakage or defective con- q Open circuit in wiring tact of connector) The connector connection is defective or the wire is broken. q Ground fault A harness not connected to ground circuit contacts the ground wiring or machine. q Hot short circuit Ground fault in wiring harness A harness not connected to the power circuit (24 V) contacts with the power (contact with ground circuit) circuit. q Short circuit An independent wire in the harness contacts with other wire. (Poor insulation at connector and others) <Precautions for troubleshooting> Hot short circuit (1) Connector number indication method and handling of T-adapter (contact with 24 V circuit) For troubleshooting, insert or connect T-adapter as follows unless otherwise specified. q When "male" or "female" is not indicated with a connector number, disconnect the connector, and insert T-adapter between the male and female connectors. q When "male" or "female" is indicated with a connector number, disconShort circuit in wiring harness nect the connector, and connect T-adapter only to either male or female connector. (2) Description sequence of pin number and handling of tester lead For troubleshooting, connect the positive (+) and negative (-) leads as shown below unless otherwise specified. q Connect the positive (+) lead to pin or wire indicated first. Defective controller q Connect the negative (-) lead to a pin or wire indicated second.
40-44
PC228US-8,PC228USLC-8
General information on troubleshooting Information in troubleshooting table
Related circuit diagram
40-45
This is the excerpted circuit diagram related to troubleshooting q The circuit diagram contains the connector Nos., pin Nos., and connector colours related to the failure. q The circuit diagram contains the destination or source of the branch line in a wiring harness. q Arrow (io): Roughly shows the location on the machine. q NO: Normally Open q NC: Normally Closed
PC228US-8,PC228USLC-8
40-45
General information on troubleshooting Troubleshooting method for open circuit in wiring harness of pressure sensor system
Troubleshooting method for open circuit in wiring harness of pressure sensor system a Since pressure sensors consisting not only of resistor but also electronic circuit components such as amplifiers have variation in measured value and its own polarities. So troubleshooting must be performed carefully. Failure codes applicable to this diagnosis q CA123: Charge air pressure sensor low error q CA451: Common rail pressure sensor high error Procedure 1. Measure and record resistance of pressure sensor unit. 1) Disconnect pressure sensor connector (1) and connect socket (2) to the sensor side connector. 2) Measure resistances R1 and R2 between pins. a If polarities of multimeter probes to apply are reversed, measured values may change. Therefore, when measuring resistances in steps 1 and 2, apply the multimeter probes to the pressure sensor connector so that their polarities match these of the sensor. a If measured value is infinite, take measurements by applying the probes of opposite polarities and record the finite value obtained as a measured value. a Since measured values may be dispersed, take several measurements. Cause of this dispersion appears to be a charge in a sensor. Repeat steps 1 and 2 several times. Consider this dispersion when judging whether the wiring harness is open in step 3.
2. Measure and record resistance with the wiring harness between the pressure sensor and engine controller connected. 1) Since 5 V power supply to the pressure sensor is supplied to other sensors, disconnect other sensor connectors first. (*) 2) With the pressure sensor to measure connected, disconnect connector (3) on engine controller side, and connect T-adapter (4) to the harness side connector. 3) Connect T-box (5) to T-adapter (4) and measure resistances R1' and R2' between respective pins. 3. Judging open circuit If there is an "apparent difference" between resistances R1 and R2 measured in step 1 and resistances R1' and R2' measured in step 2, "wiring harness is open". a "Apparent difference" means a difference of 10 or more times.
40-46
PC228US-8,PC228USLC-8
General information on troubleshooting Troubleshooting method for open circuit in wiring harness of pressure sensor system
List of pressure sensor measuring locations and reference values Sensor
Measuring location at sensor pin
Charge pressure sen- R2: between (2) and (4) R1: between (1) and (4) sor R2: Between (3) and (1) Common rail pressure R1: Between (1) (+) and sensor (2) (-)
Measured internal resistRemarks ance of sensor (reference) Approx. 100 z Sensor is common to engine models Approx. 200 z 107 and 114 Sensor is common to engine models Approx. 23 kz 107 and 114 If polarities are inverted, resistance is Approx. 10 Mz infinite
*: In addition to the above, when measuring R2', disconnect the following: (See circuit diagram related to each failure code) q When measuring R2' of charge pressure sensor (CA123): Connectors of common rail pressure sensor, CAM sensor and water-in-fuel sensor (water separator) q When measuring R2' of common rail pressure sensor (CA451): Connectors of charge pressure sensor, CAM sensor and water-in-fuel sensor (water separator) Measurement record (For measuring locations, see circuit diagram related to each failure code.) Sensor
Sensor unit (Measuring location on sen- Measured value sor pin side connector)
Charge pressure sen- R2: between (2) and (4) sor R1: between (1) and (4) R2: Between (3) and (1) Common rail pressure R1: Between (1) (+) and sensor (2) (-)
PC228US-8,PC228USLC-8
Sensor + Wiring harness (Measuring location on wirMeasured value ing harness side connector of engine controller) R2': Between (37) and (47) (*) R1': Between (44) and (47) R2': Between (37) and (47) (*) R1': between (47)(+) and (25)(-)
40-47
General information on troubleshooting Connector list and layout
Connector list and layout PC228US-8, PC228USLC-8 Connector No.
Type
Number of pins
A08
SWP
12
Intermediate connector
Q1
A13
DT
2
Intermediate connector (working lamp)
I2
A15
DT
2
Rear working lamp (if equipped)
I8
A40
DT
4
Intermediate connector (camera)
H8
A41
DT
4
Intermediate connector
N4
A42
DT
4
Intermediate connector
N5
A43
S
8
Intermediate connector
R9
A53
DT
3
Boom angle potentiometer
G8
Equipment name
Layout address
A54
DT
3
Front pump swash plate sensor
J9
A55
DT
3
Rear pump swash plate sensor
K9
AB
Terminal
1
Alternator (B terminal)
AH9
AC01
YAZAKI
10
Air conditioner unit
W6
AC02 AMB. AIR PRESSURE BOOST PRESS & IMT C01
X
1
Air conditioner compressor electromagnetic clutch
AF3
–
3
Ambient pressure sensor
AE2
–
3
Boost pressure and temperature sensor
AG5
AMP
81
Pump controller
V4
C02
AMP
40
Pump controller
V4
CAM SENSOR
–
3
Engine Bkup speed sensor
AF1
CE02
DRC
50
Engine controller
AF1
CE03
DTP
4
Engine controller
AG1
CK01
AMP
14
KOMTRAX terminal
V7
CK02
AMP
10
KOMTRAX terminal
V6
CM01
070
18
Machine monitor
M8
CM02
070
12
Machine monitor
M7
CM03
070
18
Machine monitor
N7
CM04
070
12
Machine monitor (unconnected)
–
CM05
MITSUMI
8
Machine monitor (for camera connection)
O8
COOLANT TEMP CP3 PUMP REGULATOR CRANK SENSOR
–
2
Engine coolant temperature sensor
AE3
–
2
Supply pump solenoid (IMV)
AJ2
–
3
Engine Ne speed sensor
AF1
D01
SWP
8
Diode array
W7
D02
SWP
8
Diode array
W7
D03
SWP
8
Diode array
W8
D10
M
2
Diode
X7
D11
M
2
Diode
X8
E01
Terminal
1
Electrical intake air heater
AF4
W.I.F [E06]
DT
2
Intermediate connector
AI1
E08
X
1
Intermediate connector
AH9
E10
D
1
Intermediate connector
AG6
E12
SUMITOMO
3
Alternator (terminal IG, L)
AI9
ECM [CE01]
DRC
30
Engine controller
AG1
40-48
PC228US-8,PC228USLC-8
General information on troubleshooting Connector list and layout
Connector No.
Type
Number of pins
F01
–
–
F04
L mode
2
Fusible link (65 A)
K6
F05 FUEL RAIL PRESS GT5
M
2
Fusible link (30A)
K5
–
3
Common rail pressure sensor
AJ5
070
1
Machine monitor (GPS antenna)
N6
H08
M
4
Intermediate connector
V3
Equipment name Fuse box
Layout address T9
H09
M
8
Intermediate connector
V4
H15
090
22
Intermediate connector
R9
H16
S090
12
Intermediate connector
V3
INJECTOR CYL 1 INJECTOR CYL 1&2 INJECTOR CYL 2
Terminal
2
Injector #1
AE4
DT
4
Injector #1, 2
AE3
Terminal
2
Injector #2
AF4
Terminal
2
Injector #3
AG4
DT
4
Injector #3, 4
AG5
Terminal
2
Injector #4
AG5
INJECTOR CYL 5 INJECTOR CYL 5&6 INJECTOR CYL 6
Terminal
2
Injector #5
AH5
DT
4
Injector #5, 6
AI6
Terminal
2
Injector #6
AH5
J01
–
20
Junction connector (black)
S9
J02
–
20
Junction connector (black)
S9
J03
–
20
Junction connector (green)
T9
J04
–
20
Junction connector (green)
S9
INJECTOR CYL 3 INJECTOR CYL 3&4 INJECTOR CYL 4
J05
–
20
Junction connector (pink)
T9
J06
–
20
Junction connector (orange)
T9
K01
M
2
Pump (PC) resistor
X8
K02
DT
3
CAN terminating resistor
AH1
K03
M
2
Boom RAISE resistor
X8
L03
–
2
AD9
L05
SWP
2
L15
DT
2
M01
PA
9
Room lamp Intermediate connector (machines with revolving warning lamp) Revolving warning lamp [machines with revolving warning lamp] Radio
M02
M
2
Speaker (R.H.)
AC9
M03
M
2
Speaker (L.H.)
AB9
M04
–
2
Cigarette lighter
O8
AC9 AA9 V1
M05
M
5
Wiper motor
N5
M06
KESO
2
Wind washer motor
C1
M07
090
2
Horn (high tone)
H2
M08
090
2
Horn (low tone)
H2
M09
M
2
Optional power supply connector (1)
R9
M10
M
2
Optional power supply connector (2)
U1, AC1
M11
M
4
DC/DC converter (option)
AC2
M12
M
2
Optional power supply connector (12 V)
AC1
M13
M
2
Power supply socket (12 V)
AD3
PC228US-8,PC228USLC-8
40-49
General information on troubleshooting Connector list and layout
Connector No.
Type
Number of pins
M14
DT
2
Travel alarm
K6
M40
X
2
Headlamp [machines with headlamps]
Z8
M41
X
2
Headlamp [machines with headlamps]
Y7
M9A
DT
2
Working lamp (L.H. side of boom)
F8
M9B
DT
2
Working lamp (R.H. side of boom)
E7
N08
DT
12
Service connector
U9
N10 OIL PRESSURE SWITCH P01
SUMITOMO
4
Air conditioner unit
W6
Terminal
2
Engine oil pressure switch (low pressure)
AI1
AMP
3
Bucket CURL PPC pressure sensor
B3
P02
X
2
Boom LOWER PPC pressure switch
B3
P03
AMP
3
Swing LEFT pressure sensor
B3
P04
AMP
3
Arm In pressure sensor
B2
P05
AMP
3
Bucket DUMP PPC pressure sensor
B2
40-50
Equipment name
Layout address
P06
AMP
3
Boom RAISE PPC pressure sensor
B2
P07
AMP
3
Swing RIGHT pressure sensor
B1
P08
X
2
Arm DUMP PPC pressure switch
B1
P09
AMP
3
R.H. travel PPC pressure sensor (forward)
O1
P10
AMP
3
L.H. travel PPC pressure sensor (forward)
P1
P13
X
2
N4
P14
X
2
P15
X
2
P16
X
2
P17
S090
2
Intermediate connector Attachment pedal front PPC oil pressure switch [machines with provision for attachment] Attachment pedal rear PPC oil pressure switch [machines with provision for attachment] Attachment pedal front PPC oil pressure switch [machines with provision for attachment] Air conditioner high/low pressure switch
P20
M
3
Fuel control dial
P9
P21
X
1
Fuel level sensor
AE8
P22
D
2
Hydraulic oil temperature sensor
K7
P23
DT
2
Air cleaner clogging switch
K5
P24
X
2
Radiator coolant level switch
K4
P25
AMP
3
Front pump pressure sensor
B6
N1 N3 – N5
P26
AMP
3
Rear pump pressure sensor
A7
P27
AMP
3
R.H. travel PPC pressure sensor (reverse)
O1
P28
AMP
3
P1
P30
X
2
P31
–
2
L.H. travel PPC pressure sensor (reverse) Attachment pedal rear PPC oil pressure switch [machines with provision for attachment] Sunlight sensor
M9
P32
YAZAKI
2
Air conditioner outside air temperature sensor
K4
P44
DT
2
Engine oil temperature sensor
AI8
P47
DT
2
Water-in-fuel sensor
AE6
R01
Terminal
1
Battery relay (terminal E)
S1
–
R02
Terminal
1
Battery relay (terminal BR)
S1
R03
Terminal
1
Battery relay (terminal M)
T1
R04
Terminal
1
Battery relay (terminal B)
T1
PC228US-8,PC228USLC-8
General information on troubleshooting Connector list and layout
Connector No.
Type
Number of pins
R05
Relay
6
Working lamp relay
U9
R06
Relay
6
Starting motor cut-out relay (PPC lock)
W7
R07
Relay
6
Starting motor cut-out relay (Personal code)
V4
R08
Relay
6
Horn relay
V5
R10
Relay
6
Rear lamp relay [machines with rear lamp]
U9
R12
Relay
6
Cab lamp relay [machines with cab lamp]
V5
R15
Terminal
1
Electrical intake air heater relay (coil circuit)
R1
R16
Terminal
1
Electrical intake air heater relay (switch circuit)
R1
R17
X
2
Starting motor safety relay (terminal S, R)
S1
R18
Relay
6
Auto preheater relay
V5
R20
Relay
4
Air conditioner blower relay
V5
Equipment name
Layout address
R21
Relay
4
Air conditioner compressor relay
V5
R23
Relay
6
Engine controller relay (1)
X7
R24
Relay
6
Engine controller relay (2)
X7
R28
Terminal
1
Starting motor safety relay (terminal C)
S1
S01
Terminal
5
Starting switch
P9
S02
SWP
5
Light switch
Q9
S04
SWP
5
Q9
S07
SWP
5
Q9
S10
Y090
2
Swing lock switch Revolving warning lamp switch [machines with revolving warning lamp] R.H. knob switch (horn)
S11
Y090
2
L.H. knob switch
U1
S14
M
3
PPC oil pressure lock switch
V2
S21
Terminal
12
Emergency pump drive switch
V8
S22
Terminal
5
Swing brake release switch
V8
S23
Terminal
5
V7
S25
090
16
S26
SWP
5
Emergency work equipment operation switch Intermediate connector (R.H. console emergency drive switch) Emergency work equipment operation switch
W9
S30
S
8
Model selection connector
W9
SB
Terminal
1
Starting motor (terminal B)
AF7
P9
X9
SC
Terminal
1
Starting motor (terminal C)
AF7
T01
Terminal
1
Ground (floor frame)
U1
T02
Terminal
1
Ground (cab)
AD2
T03
M
1
Intermediate connector
V1
T03A
Terminal
1
Radio body ground
V1
T04
Terminal
1
Ground (revolving frame)
J2
T05
Terminal
1
Ground (revolving frame)
J2
T06
Terminal
1
Ground (revolving frame)
J2
T07
Terminal
1
Ground (revolving frame)
K2
T08
Terminal
1
Ground (revolving frame)
K1
T09
Terminal
1
Ground (revolving frame)
K1
T10
Terminal
1
Ground (revolving frame)
L1
T12
Terminal
1
Ground (engine block)
AH1
T14
Terminal
1
Ground (floor frame)
T1
PC228US-8,PC228USLC-8
40-51
General information on troubleshooting Connector list and layout
Connector No.
Type
Number of pins
TOOL PORT
–
3
Communication connector
AE2
V01
DT
2
PPC lock solenoid valve
C9
40-52
Equipment name
Layout address
V02
DT
2
Travel junction solenoid valve
B9
V03
DT
2
Swing brake solenoid valve
B9
V04
DT
2
Travel speed selector solenoid valve
B9
V05
DT
2
A9
V06
DT
2
V09
D
2
2-stage relief solenoid valve Attachment return selector solenoid valve [machines with provision for attachment] Boom RAISE throttle EPC valve
V11
D
2
F-PC-EPC valve
J8
V12
D
2
R-PC-EPC valve
J7
V19
D
2
LS-EPC valve
J8
V23
D
2
Pump merge-divider EPC valve (main)
D8
V24
D
2
D9
V30
DT
2
W03
X
2
Pump merge-divider EPC valve (LS) Oil flow adjuster EPC valve for attachment [machines with provision for attachment] Window rear limit switch
A9 E2
N4 AC9
PC228US-8,PC228USLC-8
General information on troubleshooting Connector list and layout
PC228US-8,PC228USLC-8
40-53
General information on troubleshooting Connector list and layout
Layout of connector (1/6)
40-54
PC228US-8,PC228USLC-8
General information on troubleshooting Connector list and layout
(2/6)
PC228US-8,PC228USLC-8
40-55
General information on troubleshooting Connector list and layout
(3/6)
40-56
PC228US-8,PC228USLC-8
General information on troubleshooting Connector list and layout
(4/6)
PC228US-8,PC228USLC-8
40-57
General information on troubleshooting Connector list and layout
(5/6)
40-58
PC228US-8,PC228USLC-8
General information on troubleshooting Connector list and layout
(6/6)
PC228US-8,PC228USLC-8
40-59
General information on troubleshooting Connection table for connector pin numbers
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.
40-60
PC228US-8,PC228USLC-8
General information on troubleshooting Connection table for connector pin numbers
PC228US-8,PC228USLC-8
40-61
General information on troubleshooting Connection table for connector pin numbers
40-62
PC228US-8,PC228USLC-8
General information on troubleshooting Connection table for connector pin numbers
PC228US-8,PC228USLC-8
40-63
General information on troubleshooting Connection table for connector pin numbers
40-64
PC228US-8,PC228USLC-8
General information on troubleshooting Connection table for connector pin numbers
PC228US-8,PC228USLC-8
40-65
General information on troubleshooting Connection table for connector pin numbers
40-66
PC228US-8,PC228USLC-8
General information on troubleshooting Connection table for connector pin numbers
PC228US-8,PC228USLC-8
40-67
General information on troubleshooting Connection table for connector pin numbers
40-68
PC228US-8,PC228USLC-8
General information on troubleshooting Connection table for connector pin numbers
PC228US-8,PC228USLC-8
40-69
General information on troubleshooting Connection table for connector pin numbers
40-70
PC228US-8,PC228USLC-8
General information on troubleshooting Connection table for connector pin numbers
PC228US-8,PC228USLC-8
40-71
General information on troubleshooting Connection table for connector pin numbers
40-72
PC228US-8,PC228USLC-8
General information on troubleshooting Connection table for connector pin numbers
PC228US-8,PC228USLC-8
40-73
General information on troubleshooting Connection table for connector pin numbers
40-74
PC228US-8,PC228USLC-8
General information on troubleshooting Connection table for connector pin numbers
PC228US-8,PC228USLC-8
40-75
General information on troubleshooting Connection table for connector pin numbers
40-76
PC228US-8,PC228USLC-8
General information on troubleshooting Connection table for connector pin numbers
PC228US-8,PC228USLC-8
40-77
General information on troubleshooting Connection table for connector pin numbers
40-78
PC228US-8,PC228USLC-8
General information on troubleshooting Connection table for connector pin numbers
PC228US-8,PC228USLC-8
40-79
General information on troubleshooting Connection table for connector pin numbers
40-80
PC228US-8,PC228USLC-8
General information on troubleshooting Connection table for connector pin numbers
PC228US-8,PC228USLC-8
40-81
General information on troubleshooting Connection table for connector pin numbers
40-82
PC228US-8,PC228USLC-8
General information on troubleshooting Connection table for connector pin numbers
PC228US-8,PC228USLC-8
40-83
General information on troubleshooting Connection table for connector pin numbers
40-84
PC228US-8,PC228USLC-8
General information on troubleshooting Connection table for connector pin numbers
PC228US-8,PC228USLC-8
40-85
General information on troubleshooting Connection table for connector pin numbers
40-86
PC228US-8,PC228USLC-8
General information on troubleshooting Connection table for connector pin numbers
PC228US-8,PC228USLC-8
40-87
General information on troubleshooting Connection table for connector pin numbers
40-88
PC228US-8,PC228USLC-8
General information on troubleshooting Connection table for connector pin numbers
PC228US-8,PC228USLC-8
40-89
General information on troubleshooting Connection table for connector pin numbers
40-90
PC228US-8,PC228USLC-8
General information on troubleshooting Connection table for connector pin numbers
PC228US-8,PC228USLC-8
40-91
General information on troubleshooting Connection table for connector pin numbers
40-92
PC228US-8,PC228USLC-8
General information on troubleshooting Connection table for connector pin numbers
PC228US-8,PC228USLC-8
40-93
General information on troubleshooting Connection table for connector pin numbers
40-94
PC228US-8,PC228USLC-8
General information on troubleshooting Connection table for connector pin numbers
PC228US-8,PC228USLC-8
40-95
General information on troubleshooting T- branch box and T- branch adapter table
T- branch box and T- branch adapter table
799-601-2600 799-601-3100 799-601-3200 799-601-3380 799-601-3410 799-601-3420 799-601-3430 799-601-3440 799-601-3450 799-601-3460 799-601-3510 799-601-3520 799-601-3530 799-601-2910 799-601-3470 799-601-2710 799-601-2720 799-601-2730 799-601-2740 799-601-2950 799-601-2750 799-601-2760 799-601-2770 799-601-2780
T-box (for ECONO) T-box (for MS) T-box (for MS) Plate for MS (14-pin) Adapter for BENDIX (MS) Adapter for BENDIX (MS) Adapter for BENDIX (MS) Adapter for BENDIX (MS) Adapter for BENDIX (MS) Adapter for BENDIX (MS) Adapter for BENDIX (MS) Adapter for BENDIX (MS) Adapter for BENDIX (MS) Adapter for BENDIX (MS) Case Adapter for MIC Adapter for MIC Adapter for MIC Adapter for MIC Adapter for MIC Adapter for ECONO Adapter for ECONO Adapter for ECONO Adapter for ECONO
24 24 17 17 5 10 5 17 19 14
MS-24P MS-24P MS-17P MS-17P MS-5P MS-10P MS-5P MS-17P MS-19P MS-14P
5 13 17 21 9 2 3 4 8
MIC-5P q MIC-13P q MIC-17P q MIC-21P q MIC-9P ECONO2P q ECONO3P q ECONO4P q ECONO8P q ECONO12 q P DLI-8P q DLI-12P q DLI-16P q ECONO12 q P
12
799-601-2810 Adapter for DLI 799-601-2820 Adapter for DLI 799-601-2830 Adapter for DLI
8 12 16
799-601-2840 Extension cable (ECONO type)
12
40-96
Case T-box (for DRC 60, ECONO) Case Adapter for X (T-adapter) Adapter for X Adapter for X Adapter for X Adapter for SWP Adapter for SWP Adapter for SWP Adapter for SWP Adapter for SWP Adapter for M (T-adapter) Adapter for M Adapter for M Adapter for M Adapter for M Adapter for M
q q q q q q q q q q
q q q q q q q q q
Out of kit
799-601-4201
799-601-4101
799-601-9300
799-601-9200
q q q q q
q
q
X2P X3P X4P SW6P SW8P SW12P SW14P SW16P M2P M3P M4P M6P M8P
q q q q q q q q q q q q q q
q q q
60 1 2 3 4 6 8 12 14 16 1 2 3 4 6 8
799-601-9100
q
799-601-9000
799-601-8000
q q
799-601-7500
799-601-7400
799-601-7100
q
799-601-7000
799-601-2800
q
21 37 37
799-601-2790 Adapter for ECONO
799-601-2850 799-601-4350 799-601-4360 799-601-7010 799-601-7020 799-601-7030 799-601-7040 799-601-7050 799 -601-7060 799-601-7310 799-601-7070 799-601-7320 799-601-7080 799 -601-7090 799-601-7110 799-601-7120 799-601-7130 799-601-7340
Identificati on symbol
799-601-2700
Part name
T-adapter kit 799-601-2500
Part No.
Number of pins
(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.
q q q q q q q q q q q q q q q q
q q q q
q
q
q q q q q q q q q q q q q
q q q q q
q q
q q
q
PC228US-8,PC228USLC-8
General information on troubleshooting T- branch box and T- branch adapter table
799-601-7140 Adapter for M 799-601-7150 Adapter for S (White) 799-601-7160 Adapter for S (Blue) 799-601-7170 Adapter for S (Blue) 799-601-7330 Adapter for S (White) 799-601-7350 Adapter for S (White) 799-601-7180 Adapter for AMP040 799-601-7190 Adapter for AMP040 799-601-7210 Adapter for AMP040 799-601-7220 Adapter for AMP040 799-601-7230 Short connector for X 799-601-7240 Case 799-601-7270 Case 799-601-7510 Adapter for 070 799-601-7520 Adapter for 070 799-601-7530 Adapter for 070 799-601-7540 Adapter for 070 799-601-7550 Adapter for 070 799-601-7360 Adapter for relay 799-601-7370 Adapter for relay 799-601-7380 Adapter for JFC 799-601-9010 Adapter for DTM 799-601- 9020 Adapter for DT 799-601-9030 Adapter for DT 799-601-9040 Adapter for DT 799-601-9050 Adapter for DT 799-601-9060 Adapter for DT (Gray) 799-601-9070 Adapter for DT (Black) 799-601-9080 Adapter for DT (Green) 799-601-9090 Adapter for DT (Brown) 799-601-9110 Adapter for DT (Gray) 799-601-9120 Adapter for DT (Black) 799-601-9130 Adapter for DT (Green) 799-601-9140 Adapter for DT (Brown) 799-601-9210 Adapter for HD30-18 799-601-9220 Adapter for HD30-18 799-601-9230 Adapter for HD30-18 799-601-9240 Adapter for HD30-18 799-601-9250 Adapter for HD30-24 799-601-9260 Adapter for HD30-24 799-601-9270 Adapter for HD30-24 799-601-9280 Adapter for HD30-24 799-601-9290 Adapter for HD30-24 799-601-9310 Plate for HD30 (24-pin) 799-601-9320 T-box (for ECONO) 799-601-9330 Case 799-601-9340 Case 799-601-9350 Adapter for DRC 799-601-9360 Adapter for DRC 799-601-9410* Socket for engine (CRI-T2) Adapter for engine (CRI-T2) 799-601-9420 Adapter for engine (CRI-T3) PFUEL Oil pressure sensor Socket for engine (CRI-T2) 799-601-9430* Socket for engine (CRI-T3) PCV
PC228US-8,PC228USLC-8
24
q q q q q q q q q q q q q q
q q
Out of kit
799-601-4201
799-601-4101
799-601-9300
799-601-9200
799-601-9100
q q
799-601-9000
799-601-8000
q q q q q q q q q q q q
799-601-7500
799-601-7400
07-10 07-12 07-14 07-18 07-20 REL-5P REL-6P – DTM2 DT2 DT3 DT4 DT6 DT8GR DT8B DT8G DT8BR DT12GR DT12B DT12G DT12BR D18-8 D18-14 D18-20 D18-21 D24-9 D24-16 D24-21 D24-23 D24-31
799-601-7100
10 12 14 18 20 5 6 2 2 2 3 4 6 8 8 8 8 12 12 12 12 8 14 20 21 9 16 21 23 31
799-601-7000
S8P S10P S12P S16P S16PW S12PW A8P A12P A16P A20P –
799-601-2800
8 10 12 16 16 12 8 12 16 20 2
799-601-2700
Identificati on symbol
799-601-2500
Part name
Number of pins
Part No.
T-adapter kit
q
q q q q q q q q q
q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q
40 24 2
DRC-40 DRC-24 G
3
A3
q q
2
P
q q
q q q
q
40-97
General information on troubleshooting T- branch box and T- branch adapter table
799-601-9440* Socket for engine (CRI-T2) 795-799-5520* Socket for engine (HPI-T2) Socket for engine (HPI-T2) 795-799-5530* Socket for engine (CRI-T3) Temperature sensor Socket for engine (HPI-T2) 795-799-5540* Socket for engine (CRI-T3) TIM 795-799-5460 Cable for engine (HPI-T2) 795-799-5470 Cable for engine (HPI-T2) 795-799-5480 Cable for engine (HPI-T2) 799-601-4110 Adapter for engine (140-T3) PIM 799-601-4130 Adapter for engine (CRI-T3) NE, CAM Adapter for engine (CRI-T3) 799-601-4140 Atmosphere pressure 799-601-4150 Adapter for engine (CRI-T3) POIL Adapter for engine (CRI-T3) 799-601-4160 Oil pressure switch 799-601-4180 Adapter for engine (CRI-T3) PEVA Socket for engine (CRI-T3) 799-601-4190* Common rail pressure Socket for engine (CRI-T3) 799-601-4230* Air intake pressure/temperature 799-601-4240* Socket for engine (CRI-T3) PAMB 799-601-4250* Socket for engine (CRI-T3) PIM 799-601-4330* Socket for engine (CRI-T3) G Socket for engine (CRI-T3) 799-601-4340* Pump actuator Socket for engine (CRI-T3)(95) 799-601-4380* Air intake pressure/temperature 799 -601-4260 Adapter for controller (ENG) 799 -601-4211 Adapter for controller (ENG) 799-601-4220 Adapter for controller (ENG) 799-601-4390* Socket for controller (95 ENG) 799-601-4280* Box for controller (PUMP) 799-601-9720 Adapter for controller (HST) 799-601-9710 Adapter for controller (HST) 799-601-9730 Adapter for controller (HST) 799-601-9890 Multi-adapter for DT2 – 4 and DTM2
q q
3
FCIB
q q
2
4160
q q
3
4180
q q
3
1, 2, 3 L
q q
4 1, 2, 3, 4 C
q q
3 3 3
1, 2, 3 A 1, 2, 3 B 1, 2, 3, G
q q q q q q
2
2, PA
q q
4
1, 2, 3, 4T
4 DTP4 50 DRC50 60 DRC60 60 – 121 – 16 HST16A 16 HST16B 26 HST26A 2, 3, – 4
Out of kit
FCIG
799-601-4201
3
799-601-4101
q q q q
799-601-9300
– – – ITT3N FCIN
799-601-9200
3 3 3 4 3
799-601-9100
q q
799-601-9000
A
799-601-8000
2
799-601-7500
q q
799-601-7400
C
799-601-7100
2
799-601-7000
1, 2, 3 S
799-601-2800
3 2
799-601-2700
Identificati on symbol
799-601-2500
Part name
Number of pins
Part No.
T-adapter kit
q q
q q q
q q q q q
q q q q q q
“*” Shows not T-adapter but socket.
40-98
PC228US-8,PC228USLC-8
General information on troubleshooting T- branch box and T- branch adapter table
PC228US-8,PC228USLC-8
40-99
General information on troubleshooting Fuse location table
Fuse location table Connection table of fuse box 40-10 a This connection table shows the fuse box and the devices which receive the power from the fuse box ( switching power supply is the power which is supplied while the starting switch is in ON position and the unswitched power supply is the power which is supplied while the starting switch is in OFF and ON positions). a When performing troubleshooting related to the electrical system, check the fuses and fusible links to see if the power is supplied properly. Type of Power supply power supply to fuse
Switching power supply
Fusible link F04 (60 A)
Unswitched power supply
Fusible link F05 (30A)
Switching power supply
Starting switch ACC
40-100
Fuse No.
Fuse capacity
Destination of power
1
10 A
2
30 A
3
10 A
4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
10 A 10 A 10 A 10 A 20 A 10 A 5A 20 A 10 A 10 A 10 A 10 A 10 A 20 A 5A 30 A
Lamp relay, rear lamp relay, cab lamp relay PC-EPC (F) solenoid valve, PC-EPC (R) solenoid valve [When emergency pump drive switch is operated] Swing brake solenoid valve [When swing brake release switch is operated] Boom RAISE throttle EPC valve [when boom RAISE throttle release switch is operated in emergency] Pump controller (Solenoid power supply) PPC oil pressure lock solenoid valve Starting motor cut-out relay (PPC lock) Starting motor cut-out relay (Personal code) Window washer motor, cigarette lighter Horn, horn relay Heater relay, electrical intake air heater Revolving warning lamp (if equipped) Working lamp Radio, speaker, L.H. knob switch (pump controller input) Air conditioner A/C unit blower motor, A/C compressor (Spare) Headlamp Optional power supply (1) Travel alarm, optional power supply (2) Radio backup and room lamp Machine monitor, pump controller and starting switch Air conditioner Engine controller
20
5A
ACC for engine controller
PC228US-8,PC228USLC-8
General information on troubleshooting Fuse location table
Locations of fusible link
40-101
Location of fuse box and fuse number
40-101
* The two fusible links (F04) and (F05) are accessible when the plastic cover is lifted.
PC228US-8,PC228USLC-8
40-101
Troubleshooting by failure code Failure code [989L00] Engine Controller Lock Caution 1
Troubleshooting by failure code Failure code [989L00] Engine Controller Lock Caution 1 User code
Failure code Failure
—
989L00
Detail of failure q Action of q machine moniq tor Problem on q machine Related information
q q
Engine controller lock is detected (Factor 1). None in particular If cause of failure disappears, machine becomes normal by itself. Engine cannot be started. If this failure code is displayed after machine monitor is replaced, user password must be changed to one before replacement. Method of reproducing failure code: Turn starting switch to ON position.
Cause 1
Engine controller lock caution 1 (Machine monitor system)
Procedure, measuring location, criteria and remarks
Replacement of machine monitor
This problem may be caused by replacement of machine monitor.
Failure code [989M00] Engine Controller Lock Caution 2 User code
Failure code Failure
—
989M00
Detail of failure q Action of q machine moniq tor Problem on q machine Related information
q q
Engine controller lock is detected (Factor 2). None in particular If cause of failure disappears, machine becomes normal by itself. Engine cannot be started. If this failure code is displayed after machine monitor is replaced, user password must be changed to one before replacement. Method of reproducing failure code: Turn starting switch to ON position.
Cause Replacement of 1 machine monitor 2
Engine controller lock caution 2 (Machine monitor system)
Procedure, measuring location, criteria and remarks This problem may be caused by replacement of machine monitor.
If this failure code is displayed while machine monitor is not replaced, machine monitor Defective machine monmay be defective. (Since this is an internal failure, troubleshooting cannot be peritor formed.)
40-102
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [989N00] Engine Controller Lock Caution 3
Failure code [989N00] Engine Controller Lock Caution 3 User code
Failure code Failure
—
989N00
Detail of failure q Action of q machine moniq tor Problem on machine Related infor- q mation
Engine controller lock caution 3 (Machine monitor system)
Engine controller lock is detected (Factor 3). Tries automatic resetting. If cause of failure disappears, machine becomes normal by itself.
Method of reproducing failure code: Failure code cannot be reproduced since machine recovers by cause of failure disappears.
Cause 1 Defective engine controller
PC228US-8,PC228USLC-8
Procedure, measuring location, criteria and remarks If this failure code is displayed repeatedly, engine controller may be defective. (Since this is internal failure, troubleshooting cannot be performed.)
40-103
Troubleshooting by failure code Failure code [AA10NX] Air Cleaner Clogging
Failure code [AA10NX] Air Cleaner Clogging User code
Failure code Failure
–
AA10NX
Air cleaner clogging (Machine monitor system)
q
Air cleaner clogging switch signal voltage was not 1 V or less while engine was running, and machine monitor detected clogging of air cleaner (open of switch contacts).
Action of controller
q
Displays clogging of air cleaner monitor red on machine monitor.
Problem on machine
q
If machine is operated as it is, engine may be damaged.
q
Input signal status (ON/OFF) from air cleaner clogging switch can be checked by using monitoring function. (Code: 04501 Monitor input 2) Method of reproducing failure code: Start engine.
Detail of failure
Related information q
Cause 1
2
Procedure, measuring location, criteria and remarks
Air cleaner clogging (When system is normal)
Air cleaner may be clogged. Check it for clogging and then clean or replace if clogged.
Defective air cleaner clogging switch (internal open circuit)
1. Turn starting switch to OFF position. 2. Disconnect connector P23 and connect T-adapter to male side. 3. Start engine. Air cleaner Resistance Max. 1 z When normal *1 Between P23 (male) (1) Air cleaner and (2) Resistance Min. 1 Mz When clogged *2
Open circuit in wiring harness 3 (wire breakage or defective contact of connector)
4 Defective machine monitor
1. Turn starting switch to OFF position. 2. Disconnect connectors CM02 and P23, and connect T-adapter to each female side. Between CM02 (female) (4) and P23 (female) (1)
Resistance
Max. 1 z
Between P23 (female) (2) and ground
Resistance
Max. 1 z
1. Turn starting switch to OFF position. 2. Insert T-adapters into connectors CM01 and CM02. 3. Start engine. Air cleaner Voltage When normal Between CM02 (4) and Air cleaner CM01 (3) Voltage When clogged
Max. 1 V 7 – 11 V
Air cleaner suction resistance *1: Max. -3,430 Pa {-350 mmH2O} *2: -7,470±490 Pa {-762 ± 50 mmH2O}
q
40-104
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [AA10NX] Air Cleaner Clogging
Circuit diagram related to air cleaner clogging sensor
PC228US-8,PC228USLC-8
40-105
40-105
Troubleshooting by failure code Failure code [AB00KE] Charge Voltage Low
Failure code [AB00KE] Charge Voltage Low User code
Failure code Failure
—
AB00KE
Charge voltage low (Machine monitor system)
Detail of failure q
While engine is running, signal voltage of alternator detects low charge voltage (below 7.8 V).
Action of q machine moni- q tor Problem on q machine
Displays charge level monitor red on machine monitor. Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position.
Related information
q q
If machine is operated as it is, battery may not be charged. Signal voltage of alternator can be checked by using monitoring function. (Code: 04300 Charge voltage) Method of reproducing failure code: Start engine.
Cause
Turn starting switch to OFF position. Check terminal. Turn starting switch to OFF position. Insert T-adapter into connector E12. a Connector E08 may be used for diagnosis. Defective generation by alternator 2 3. Start engine. (When system is normal) Between E12 (1) and Engine speed: medium ground or higher 1
3
Loose alternator terminal or open circuit at terminal
Procedure, measuring location, criteria and remarks
Defective wiring harness or machine monitor
1. 2. 1. 2.
Ground fault in wiring harness (contact with ground circuit)
6 Defective machine monitor
40-106
Voltage
20 – 30 V
a If no failure is found by checks on cause 2, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors CM01 and E12, and connect T-adapter to each female side. Between CM01 (female) (11) and E12 (female) (1)
5
27.5 - 29.5 V
1. Turn starting switch to OFF position. 2. Insert T-adapter into connector CM01. 3. Start engine. Between CM01 (11) and ground
Open circuit in wiring harness 4 (wire breakage or defective contact of connector)
Voltage
Resistance
Max. 1 z
a If no failure is found by checks on cause 2, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors CM01 and E02, and connect T-adapter to female side of either of them. Between CM01 (female) (11) or E12 (female) (1) Resistance Min. 1 Mz and ground If no failure is found by above checks, machine monitor is defective. (Since this is internal failure, troubleshooting cannot be performed.)
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [AB00KE] Charge Voltage Low
Electrical diagram related to charging circuit
PC228US-8,PC228USLC-8
40-107
40-107
Troubleshooting by failure code Failure code [B@BAZG] Eng Oil Press Low
Failure code [B@BAZG] Eng Oil Press Low User code
Failure code Failure
—
B@BAZG
Detail of failure Action of controller Problem on machine
q
While engine is running, engine controller detects engine oil pressure drop (sensor contact is closed) from signal voltage of engine oil pressure switch.
q q
Displays engine oil pressure monitor red on machine monitor. If cause of failure disappears, machine becomes normal by itself.
q
If machine is operated as it is, engine may be damaged.
q
Signal from engine oil pressure switch is input to engine controller. If engine oil pressure switch is closed (turned ON) while engine is running, engine controller transmits this signal to machine monitor to display this failure code. Method of reproducing failure code: Start engine.
Related information q
Cause Dropped engine oil pres1 sure (when system is normal) 2
Defective engine oil pressure monitor system
40-108
Engine oil pressure low (Engine controller system)
Procedure, measuring location, criteria and remarks Engine oil pressure may be low. Check it and remove cause if it is low. If no failure is found by check on causes, engine oil pressure monitor system may be defective. Perform troubleshooting for "E-6 Emergency stop lamp lights up while engine is running".
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [B@BAZK] Eng Oil Level Low
Failure code [B@BAZK] Eng Oil Level Low User code
Failure code Failure
-
B@BAZK
Eng oil level low (Machine monitor system)
q
While engine is running, signal voltage from engine oil level switch does not remain below 1 V, so machine monitor determines that engine oil level is low (oil level switch is open).
Action of controller
q
Displays engine oil level monitor red on machine monitor.
Problem on machine
q
If machine is operated as it is, engine may seize up.
q
Input (ON/OFF) from engine oil level switch can be checked by using monitoring function. (Code: 04501 Monitor input 2) Method of reproducing failure code: Start engine
Detail of failure
Related information
q
Cause 1
Lowered engine oil level (when system is normal)
Defective engine oil level switch 2 (internal failure)
Procedure, measuring location, criteria and remarks Check engine oil level. If it is low, remove cause. 1. Turn starting switch to OFF position. 2. Disconnect connector P44. 3. Turn starting switch to ON position. Between P44 (male) (1) and ground
Open circuit in wiring harness 3 (wire breakage or defective contact of connector)
4 Defective machine monitor
Max. 1 z
1. Turn starting switch to OFF position. 2. Disconnect connectors CM02 and P44, and connect T-adapter to each female side. Between CM02 (female) (2) and P44 (female) (1)
Resistance
Max. 1 z
If no failure is found by above checks, machine monitor is defective. q Reference 1. Turn starting switch to OFF position. 2. Insert T-adapters into connectors CM01 and CM02. 3. Turn starting switch to ON position. Between CM02 (2) and CM01 (3)
Circuit diagram related to engine oil level switch
PC228US-8,PC228USLC-8
Resistance
Voltage
Max. 1 V
40-109
40-109
Troubleshooting by failure code Failure code [B@BCNS] Eng Water Overheat
Failure code [B@BCNS] Eng Water Overheat User code
Failure code Failure
—
B@BCNS
Detail of failure Action of controller Problem on machine
Related information
Engine coolant overheat (Engine controller system)
q
While engine is running, engine controller detects overheating of engine coolant (above approx. 102 °C), from signal of engine coolant temperature sensor.
q q
Displays engine coolant temperature monitor red on machine monitor. If cause of failure disappears, machine becomes normal by itself.
q
If machine is operated as it is, engine may seize up.
q
Signal of engine coolant temperature sensor is input to engine controller and then data is transmitted to machine monitor through CAN communication system. Engine coolant temperature can be checked by using monitoring function. (Code: 04107 Engine coolant temperature) Method of reproducing failure code: Start engine.
q q
Cause
Procedure, measuring location, criteria and remarks
Overheating of engine coolEngine coolant may overheat. Check it and remove cause if it overheats. ant (when system is normal) If no failure is found by check on cause 1, engine coolant temperature gauge sysDefective engine coolant 2 tem may be defective. Perform troubleshooting for "E-8 Engine coolant temperature temperature gauge system gauge does not indicate normally."
1
40-110
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [B@BCNS] Eng Water Overheat
PC228US-8,PC228USLC-8
40-111
Troubleshooting by failure code Failure code [B@BCZK] Eng Water Level Low
Failure code [B@BCZK] Eng Water Level Low User code
Failure code Failure
-
B@BCZK
Radiator coolant level low (Machine monitor system)
q
While starting switch is at ON position (with engine stopped) or engine is running, radiator coolant level switch signal voltage does not remain below 1 V, so machine monitor determines that radiator coolant level is low (sensor contact is open).
Action of controller
q
Displays radiator coolant level monitor red on machine monitor.
Problem on machine
q
If machine is operated as it is, engine may overheat.
q
Input (ON/OFF) from radiator coolant level switch can be checked by using monitoring function. (Code: 04500 Monitor input 1) Method of reproducing failure code: Turn starting switch to ON position.
Detail of failure
Related information
1
2
q
Cause
Procedure, measuring location, criteria and remarks
Lowered radiator coolant level (when system is normal)
Check radiator sub tank for lowering of coolant level. If coolant level is low, add coolant.
Defective coolant level switch (internal failure)
Open circuit in wiring harness 3 (wire breakage or defective contact)
1. Turn starting switch to OFF position. 2. Disconnect connector P24 and connect T-adapter to male side. Between FULL and Resistance Max. 1 z Between P24 (male) (1) and (2) LOW lines Below LOW Resistance Min. 1 Mz line 1. Turn starting switch to OFF position. 2. Disconnect connectors CM02 and P24, and connect T-adapter to each female side. a Add coolant. Between CM02 (female) (3) and P24 (female) (1)
4 Defective machine monitor
40-112
Resistance
Max. 1 z
If no failure is found by above checks, machine monitor is defective. q Reference 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector CM02. 3. Turn starting switch to ON position. Between FULL and Voltage Max. 1 V LOW lines Between CM02 (3) and CM01 (3) Below LOW Voltage 7 – 11 V line
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [B@BCZK] Eng Water Level Low
Circuit diagram related to radiator coolant level switch
PC228US-8,PC228USLC-8
40-1 3
40-113
Troubleshooting by failure code Failure code [B@HANS] Hyd Oil Overheat
Failure code [B@HANS] Hyd Oil Overheat User code
Failure code Failure
— Detail of failure Action of controller Problem on machine
Related information
B@HANS
Hydraulic oil overheat (Pump controller system)
q
While engine is running, pump controller detects overheating of hydraulic oil (above approx. 102 °C), from signal of hydraulic oil temperature sensor.
q q
Displays hydraulic oil temperature monitor in red on machine monitor. If cause of failure disappears, machine becomes normal by itself.
q
If machine is operated as it is, hydraulic components may be damaged.
q
Signal of hydraulic oil temperature sensor is input to pump controller and then the data is transmitted to machine monitor through CAN communication system. Hydraulic oil temperature can be checked by using monitoring function (Code: 04401 Hydraulic oil temperature) See "E-9 Hydraulic oil temperature gauge does not display normally" in E-mode. Method of reproducing failure code: Start engine.
q q q
Cause
Procedure, measuring location, criteria and remarks
1
Overheating of hydraulic oil (when system is normal)
Hydraulic oil may overheat. Check it and remove cause if it overheats
2
Defective hydraulic oil temperature gauge system
If no failure is found by check on cause 1, hydraulic oil temperature sensor system may be defective. Perform troubleshooting for failure code [DGH2KB].
40-114
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [CA111] ECM Critical Internal Failure
Failure code [CA111] ECM Critical Internal Failure User code
Failure code Failure
E10
CA111
Engine controller has internal failure (Engine controller system)
Detail of failure q
Memory or power supply circuit in engine controller is defective.
Action of controller
q
None in particular
Problem on machine
q
Engine may stop during operation or may not be able to start.
q
Power supply voltage of engine controller can be checked by using monitoring function. (Code: 03203 Battery voltage) Method of reproducing failure code: Start engine.
Related information
q
Cause
Procedure, measuring location, criteria and remarks
1 Defect in related system
If another failure code is displayed, perform troubleshooting for it.
2 Perform troubleshooting for failure code [CA441].
Failure code [CA115] Eng Ne and Bkup Speed Sens Error User code
Failure code Failure
E10
CA115
Engine Ne and Bkup speed sensor error (Engine controller system)
Detail of failure q
Signals from both engine Ne speed sensor and engine Bkup speed sensor are abnormal.
Action of controller
q
None in particular
q q
Engine stops. Engine does not start
q
Method of reproducing failure code: Start engine.
Problem on machine Related information
Cause
Procedure, measuring location, criteria and remarks
Connectors of Ne speed sensor and Bkup speed sensor may be connected defectively (or to wrong connection). Check them directly. Perform troubleshooting for troubleshooting Nos. 1 to 10 of failure code 2 Defective Ne speed sensor system [CA689]. Defective Bkup speed sensor sys3 Perform troubleshooting for failure code [CA778]. tem If no failure is found by above checks, engine controller is defective. (Since 4 Defective engine controller this is internal failure, troubleshooting cannot be performed.) 1
Defective connection of sensor connector
PC228US-8,PC228USLC-8
40-115
Troubleshooting by failure code Failure code [CA122] Chg Air Press Sensor High Error
Failure code [CA122] Chg Air Press Sensor High Error User code
Failure code Failure
E11
CA122
Boost pressure sensor high error (Engine controller system)
Detail of failure q
High voltage appears in signal circuit of boost pressure & temperature sensor.
Action of controller
q
Takes charge pressure to be at fixed value and allows engines to run.
Problem on machine
q
Engine output lowers.
q
Input voltage from boost pressure sensor can be checked by using monitoring function. (Code: 36501 (V)) Boost pressure from boost pressure sensor can be checked by using monitoring function. (Code: 36500 (kPa)) Method of reproducing failure code: Turn starting switch to ON position. If sensor connector is disconnected, code [CA123] for "Low Error" is displayed, even in normal condition.
Related information
q q q
Cause
Procedure, measuring location, criteria and remarks
1
Defective wiring harness connector
See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "General information on troubleshooting", and check them directly.
2
Defective sensor power supply 2 line
If failure code [CA227] is also displayed, perform troubleshooting for it first.
3
Defective boost pressure & temperature sensor
4 Short circuit in wiring harness
1. Turn starting switch to OFF position. 2. Disconnect connector BOOST PRESS & IMT. 3. Turn starting switch to ON position. If failure code changes from [CA122] to [CA123] ,boost pressure sensor is defective. a Failure code [CA153] for temperature sensor is displayed at the same time. Ignore this failure code since it appears because of disconnection of sensor. 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and BOOST PRESS & IMT, and connect T-adapter to female side of ECM. Between ECM (female) (37) and (44)
5
Hot short circuit in wiring harness (contact with 24 V circuit)
Between ECM (44) and (47) 6 Defective engine controller
40-116
Resistance Min. 100 kz
1. Turn starting switch to OFF position. 2. Disconnect connector BOOST PRESS & IMT, and connect T-adapter to connector ECM. 3. Turn starting switch to ON position (with connector BOOST PRESS & IMT disconnected). Voltage
Max. 1 V
If no failure is found by above checks, engine controller is defective. (Since this is internal failure, troubleshooting cannot be performed.)
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [CA122] Chg Air Press Sensor High Error
Circuit diagram related to boost pressure sensor
PC228US-8,PC228USLC-8
40-1 7
40-117
Troubleshooting by failure code Failure code [CA123] Chg Air Press Sensor Low Error
Failure code [CA123] Chg Air Press Sensor Low Error User code
Failure code Failure
E11
CA123
Boost pressure sensor low error (Engine controller system)
Detail of failure q
Low voltage appears in pressure signal circuit of boost pressure & temperature sensor.
Action of controller
q
Takes charge pressure to be at fixed value and allows engine to run.
Problem on machine
q
Engine output lowers.
q
Input voltage from boost pressure sensor can be checked by using monitoring function. (Code: 36501 (V)) Boost pressure from boost pressure sensor can be checked by using monitoring function. (Code: 36500 (kPa)) Method of reproducing failure code: Turn starting switch to ON position. Since troubleshooting "socket" for this sensor features female connector alone, it is not usable for checking open circuit in wiring harness and voltage at sensor connector (not designed as a T-adapter). If sensor connector is disconnected, this failure code is displayed.
q
Related information
q q
q
Cause
Procedure, measuring location, criteria and remarks
See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "General information on troubleshooting", and check them directly. Defective power supply system of If failure code [CA187] or [CA227] is displayed, perform troubleshooting for it 2 boost pressure sensor first. 1
Defective wiring harness connector
3 Short circuit in wiring harness
Ground fault in wiring harness 4 (contact with ground circuit)
1. Turn starting switch to OFF position. 2. Disconnect connectors CAM SENSOR, FUEL RAIL PRESS, BOOST PRESS & IMT and ECM. 3. Connect T-adapter to female side of ECM. Between ECM (female) (37) and (47)
Resistance Min. 100 kz
Between ECM (female) (44) and (47)
Resistance Min. 100 kz
1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and BOOST PRESS & IMT, and connect T-adapter to female side of ECM. Between ECM (female) (44) and ground
5 Open circuit in wiring harness
Defective boost pressure & temperature sensor 6 (improper input voltage to engine controller)
7 Defective engine controller
Resistance Min. 100 kz
If no failure is found by above checks, there may be open circuit in wiring harness. (*) a If no failure is found by checks on 1 - 5 and check result of cause 6 is abnormal, sensor is defective. 1. Turn starting switch to OFF position. 2. Insert T-adapter to connector ECM. 3. Turn starting switch to ON position. Sensor outBetween ECM (44) and (47) Voltage 0.3 - 4.7 V put If no failure is found by above checks, engine controller is defective. (Since this is internal failure, troubleshooting cannot be performed.)
*: See "Troubleshooting method for open circuit in wiring harness of pressure sensor system" of "Related information of troubleshooting".
40-118
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [CA123] Chg Air Press Sensor Low Error
Circuit diagram related to boost pressure sensor
PC228US-8,PC228USLC-8
40-1 9
40-119
Troubleshooting by failure code Failure code [CA131] Throttle Sensor High Error
Failure code [CA131] Throttle Sensor High Error User code
Failure code Failure
E14
CA131
Detail of failure q Action of controller Problem on machine Related information
q
Throttle sensor high error (Engine controller system)
High voltage appears in fuel control dial circuit.
q
Uses throttle value obtained before failure detection and allows engine to run when failure is detected with starting switch at ON position. Uses full throttle value to run engine if starting switch is set to ON position after detecting failure.
q
Engine speed cannot be controlled by using fuel control dial.
q
Signal voltage from fuel control dial can be checked by using monitoring function. (Code: 03000 Fuel control dial voltage) Method of reproducing failure code: Turn starting switch to ON position.
q
Cause
Procedure, measuring location, criteria and remarks
1
Defective wiring harness connector
See descriptions of wiring harness and connectors in "c: Electrical equipment" of "Checks before troubleshooting" in "General information on troubleshooting" , and check them directly.
2
Defective throttle sensor power supply system
If failure code [CA2185] is also displayed, perform troubleshooting for it first. 1. Turn starting switch to OFF position. 2. Disconnect connector P20 and connect T-adapter to male side.
3
Defective fuel control dial (throttle Between P20 (male) (1) and (3) sensor) Between P20 (male) (2) and (3)
Resistance 0.25 - 5.0 kz
Between P20 (male) (1) and (2)
Resistance 0.25 - 5.0 kz
Resistance
4.0 - 6.0 kz
1. Turn starting switch to OFF position. 2. Disconnect connector CE02, and connect T-adapter to female side.
4
Open or short circuit in wiring harBetween CE02 (female) (22) and (23) ness Between CE02 (female) (9) and (23)
5 Short circuit in wiring harness
6
Hot short in wiring harness (contact with 24 V circuit)
40-120
4.0 - 6.0 kz
Resistance 0.25 - 5.0 kz
a If no failure is found by checks on cause 4, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors CE02 and P20, and connect T-adapter to female side of either connector. Between CE02 (female) (9) and (22), or between Resistance Min. 1 Mz P20 (female) (1) and (2) 1. Turn starting switch to OFF position. 2. Disconnect connector P20, and connect T-adapter to female side. 3. Turn starting switch to ON position. Between P20 (female) (2) and ground
7 Defective engine controller
Resistance
Voltage
Max. 1 V
If no failure is found by above checks, engine controller is defective. (Since this is internal failure, troubleshooting cannot be performed.) q Reference 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector CE02. 3. Turn starting switch to ON position. 4. Operate fuel control dial and perform troubleshooting. Power supBetween CE02 (22) and (23) Voltage 4.75 – 5.25V ply Sensor outBetween CE02 (9) and (23) Voltage 0.5 – 4.5 V put
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [CA131] Throttle Sensor High Error
Circuit diagram related to throttle sensor
PC228US-8,PC228USLC-8
40-121
40-121
Troubleshooting by failure code Failure code [CA132] Throttle Sensor Low Error
Failure code [CA132] Throttle Sensor Low Error User code
Failure code Failure
E14
CA132
Detail of failure q Action of controller Problem on machine Related information
q
Throttle sensor low error (Engine controller system)
Low voltage appears in fuel control dial circuit.
q
Uses throttle value obtained before failure detection and allows engine to run when failure is detected with starting switch at ON position. Uses full throttle value to run engine if starting switch is set to ON position after detecting failure.
q
Engine speed cannot be controlled by using fuel control dial.
q
Signal voltage from fuel control dial can be checked by using monitoring function. (Code: 03000 Fuel control dial voltage) Method of reproducing failure code: Turn starting switch to ON position.
q
Cause
Procedure, measuring location, criteria and remarks
1
Defective wiring harness connector
See the descriptions of wiring harness and connectors in "c: Electrical equipment" of "Checks before troubleshooting" in "General information on troubleshooting" , and check them directly.
2
Defective throttle sensor power supply system
If failure code [CA2186] is also displayed, perform troubleshooting for it first. 1. Turn starting switch to OFF position. 2. Disconnect connector P20 and connect T-adapter to male side.
3
Defective fuel control dial (throttle Between P20 (male) (1) and (3) sensor) Between P20 (male) (2) and (3)
Resistance
4.0 - 6.0 kz
Resistance
0.25 - 5.0 kz
Between P20 (male) (1) and (2)
Resistance
0.25 - 5.0 kz
1. Turn starting switch to OFF position. 2. Disconnect connector CE02, and connect T-adapter to female side.
4
Open or short circuit in wiring harBetween CE02 (female) (22) and (23) ness
Resistance
4.0 - 6.0 kz
Between CE02 (female) (9) and (23)
Resistance
0.25 - 5.0 kz
Open circuit in wiring harness 5 (wire breakage or defective contact of connector)
6 Short circuit in wiring harness
7
Ground fault of wiring harness (contact with ground circuit)
40-122
a If no failure is found by checks on cause 4, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors CE02 and P20, and connect T-adapter to each female side. Between CE02 (female) (22) and P20 Resistance Max. 1 z (female) (1) Between CE02 (female) (9) and P20 (female) Resistance Max. 1 z (2) Between CE02 (female) (23) and P20 Resistance Max. 1 z (female) (3) a If no failure is found by checks on cause 4, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors CE02 and P20, and connect T-adapter to female side of either connector. Between CE02 (female) (9) and (23), or Resistance Min. 1 Mz between P20 (female) (2) and (3) 1. Turn starting switch to OFF position. 2. Disconnect connectors CE02 and P20, and connect T-adapter to female side of either connector. Between CE02 (female) (9) or P20 (female) Resistance Min. 1 Mz (2) and ground
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [CA132] Throttle Sensor Low Error
Cause
8 Defective engine controller
Procedure, measuring location, criteria and remarks If no failure is found by above checks, engine controller is defective. (Since this is internal failure, troubleshooting cannot be performed.) q Reference 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector CE02. 3. Turn starting switch to ON position. 4. Operate fuel control dial and perform troubleshooting. Between CE02 (22) and (23) Power supply
Voltage
4.75 – 5.25V
Between CE02 (9) and (23)
Voltage
0.5 – 4.5 V
Circuit diagram related to throttle sensor
PC228US-8,PC228USLC-8
Sensor output
40-123
40-123
Troubleshooting by failure code Failure code [CA144] Coolant Temp Sens High Error
Failure code [CA144] Coolant Temp Sens High Error User code
Failure code Failure
E0E
CA144
Coolant temperature sensor high error (Engine controller system)
Detail of failure q
High voltage appears in signal circuit of coolant temperature sensor .
Action of controller
q
Takes coolant temperature to be at fixed value and allows engine to run.
q
Engine does not start easily at low temperature. Overheat prevention function does not work. Input voltage from engine coolant temperature sensor can be checked by using monitoring function. (Code: 04105 (V)) Temperature sensed by engine coolant temperature sensor can be checked by using monitoring function. (Code: 04107 (°C)) Method of reproducing failure code: Turn starting switch to ON position. This failure code is displayed if temperature sensor connector is disconnected. Since troubleshooting "socket" for this sensor features the female connector alone, it is not connectable to wiring harness side female connector and thus not usable for checking open circuit (not designed as a T-adapter).
Problem on machine
q q
q
Related information
q q q
Cause 1
Defective wiring harness connector
2
Defective coolant temperature sensor
Procedure, measuring location, criteria and remarks See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "General information on troubleshooting", and check them directly. 1. Turn starting switch to OFF position. 2. Disconnect connector COOLANT TEMP, and connect socket to male side. a If coolant temperature sensor has resistance of 700 z - 37 kz with coolant temperature above 0 °C, regard coolant temperature sensor as normal. Between COOLANT TEMP (male) (A) and (B) a Coolant temperatureResistance characteristics
0 °C
Resistance
30 - 37 kz
25 °C
Resistance
9.3 - 10.7 kz
50 °C
Resistance
3.2 - 3.8 kz
80 °C
Resistance
1.0 - 1.3 kz
95 °C
Resistance
700 – 800 z
1. Turn starting switch to OFF position. 2. Disconnect connector ECM and connect T-adapter to female side. Open or short circuit in wiring har- Between ECM (female) (15) and (38) (Coolant tem3 perature: Min. 0°C) ness Resista Use "Coolant temperature-Resistance charac700 z – 37 kz ance teristics" table shown above as resistance criteria. If no failure is found by above checks, engine controller is defective. (Since 4 Defective engine controller this is internal failure, troubleshooting cannot be performed.)
40-124
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [CA144] Coolant Temp Sens High Error
Circuit diagram related to coolant temperature sensor
PC228US-8,PC228USLC-8
40-125
40-125
Troubleshooting by failure code Failure code [CA145] Coolant Temp Sens Low Error
Failure code [CA145] Coolant Temp Sens Low Error User code
Failure code Failure
E0E
CA145
Coolant temperature sensor low error (Engine controller system)
Detail of failure q
Low voltage appears in signal circuit of coolant temperature sensor .
Action of controller
q
Takes coolant temperature to be at fixed value and allows engine to run.
q
Engine does not start easily at low temperature. Overheat prevention function does not work. Input voltage from engine coolant temperature sensor can be checked by using monitoring function. (Code: 04105 (V)) Temperature sensed by engine coolant temperature sensor can be checked by using monitoring function. (Code: 04107(°C) ) Method of reproducing failure code: Turn starting switch to ON position. If temperature sensor connector is disconnected, this failure code is not displayed but failure code [CA144] for "High Error" is displayed.
Problem on machine
q q
Related information
q
q q
Cause 1
2
Defective wiring harness connector
Defective coolant temperature sensor
3 Short circuit in wiring harness
4
Ground fault in wiring harness (contact with ground circuit)
5 Defective engine controller
40-126
Procedure, measuring location, criteria and remarks See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "General information on troubleshooting", and check them directly. 1. Turn starting switch to OFF position. 2. Disconnect connector COOLANT TEMP, and connect socket to male side. a If coolant temperature sensor has resistance of 700 z - 37 kz with coolant temperature above 0 °C, regard coolant temperature sensor as normal. Between COOLANT TEMP (male) (A) and (B) a Coolant temperatureResistance characteristics
0 °C
Resistance
30 – 37 kz
25 °C
Resistance
9.3 – 10.7 kz
50 °C
Resistance
3.2 – 3.8 kz
80 °C
Resistance
1.0 – 1.3 kz
95 °C
Resistance
700 – 800 z
Whole coolBetween (B) and ground ant temper- Resistance Min. 100 kz ature range 1. Turn starting switch to OFF position. 2. Disconnect connector ECM and connect T-adapter to female side. Between ECM (female) (15) and (38) (Coolant temperature: Min. 0 °C) Resista Use "Coolant temperature-Resistance charac700 z – 37 kz ance teristics" table shown above as resistance criteria. 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and COOLANT TEMP, and connect T-adapter to female side of ECM. ResistBetween ECM (female) (15) and ground Min. 100 kz ance If no failure is found by above checks, engine controller is defective. (Since this is internal failure, troubleshooting cannot be performed.)
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [CA145] Coolant Temp Sens Low Error
Circuit diagram related to coolant temperature sensor
PC228US-8,PC228USLC-8
40-127
40-127
Troubleshooting Troubleshooting by by failure failure code code Failure code code [CA153] [CA153] Chug Chg Air Failure AirTemp TempSensor SensorHigh HighError Error
Failure code [CA153] Chg Air Temp Sensor High Error User code
Failure code Failure
E0E
CA153
Boost temperature sensor high error (Engine controller system)
Detail of failure q
High voltage appears in temperature signal circuit of boost pressure & temperature sensor.
Action of controller
q
Takes boost temperature to be at fixed value and allows engine to run.
Problem on machine
q
Engine protection function based on boost temperature does not work.
q
Input voltage from boost temperature sensor can be checked by using monitoring function. (Code: 18501 (V)) Temperature sensed by boost temperature sensor can be checked by using monitoring function. (Code: 18500(°C)) Method of reproducing failure code: Turn starting switch to ON position. Since troubleshooting "socket" for this sensor features female connector alone, it is not connectable to wiring harness side female connector and thus not usable for checking open circuit (not designed as a T-adapter). This failure code is displayed if temperature sensor connector is disconnected.
q
Related information
q q
q
Cause 1
Defective wiring harness connector
Procedure, measuring location, criteria and remarks See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "General information on troubleshooting", and check them directly. 1. Turn starting switch to OFF position. 2. Disconnect connector BOOST PRESS & IMT, and connect socket to male side.
Between BOOST Defective boost temperature senPRESS & IMT (male) (3) 2 sor and (4) a Boost temperature -Resistance characteristic
-40 °C
Resistance
41 – 48 kz
-20 °C
Resistance
14 – 16 kz
0 °C
Resistance
5.4 – 6.1 kz
30 °C
Resistance
1.6 – 1.8 kz
60 °C
Resistance
560 – 600 z
90 °C
Resistance
230 – 250 z
130 °C
Resistance
80 – 90 z
1. Turn starting switch to OFF position. 2. Disconnect connector ECM and connect T-adapter to female side.
3
Open or short circuit in wiring harBetween ECM (female) (23) and (47) ness a Use "boost temperature-Resistance characteris- Resistance tics" table shown above as resistance criteria.
4 Defective engine controller
40-128
80 z – 48 kz
If no failure is found by above checks, engine controller is defective. (Since this is internal failure, troubleshooting cannot be performed.)
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [CA153] Chg Air Temp Sensor High Error
Circuit diagram related to boost temperature sensor
PC228US-8,PC228USLC-8
40-129
40-129
Troubleshooting by failure code Failure code [CA154] Chg Air Temp Sensor Low Error
Failure code [CA154] Chg Air Temp Sensor Low Error User code
Failure code Failure
E0E
CA154
Boost temperature sensor low error (Engine controller system)
Detail of failure q
Low voltage appears in temperature signal circuit of boost pressure & temperature sensor.
Action of controller
q
Takes boost temperature to be at fixed value and allows engine to run.
Problem on machine
q
Engine protection function based on boost temperature does not work.
q
Input voltage from boost temperature sensor can be checked by using monitoring function. (Code: 18501 (V)) Temperature sensed by boost temperature sensor can be checked by using monitoring function. (Code: 18500 (°C)) If temperature sensor connector is disconnected, this failure code is not displayed but failure code [CA153] for "High Error" is displayed. Method of reproducing failure code: Turn starting switch to ON position.
Related information
q q q
1
Cause
Procedure, measuring location, criteria and remarks
Defective wiring harness connector
See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "General information on troubleshooting", and check them directly. 1. Turn starting switch to OFF position. 2. Disconnect connector BOOST PRESS & IMT, and connect socket to male side.
2
Defective boost temperature sen- Between BOOST sor PRESS & IMT (male) (3) and (4) a Boost temperature -Resistance characteristic
-40 °C
Resistance
41 – 48 kz
-20 °C
Resistance
14 – 16 kz
0 °C
Resistance
5.4 – 6.1 kz
30 °C
Resistance
1.6 – 1.8 kz
60 °C
Resistance
560 – 600 z
90 °C
Resistance
230 – 250 z
130 °C
Resistance
80 – 90 z
1. Turn starting switch to OFF position. 2. Disconnect connector ECM and connect T-adapter to female side. 3 Short circuit in wiring harness
4
Ground fault in wiring harness (contact with ground circuit)
Between ECM (female) (23) and (47) a Use "boost temperature-Resistance characteris- Resistance tics" table shown above as resistance criteria.
a If no failure is found by checks on cause 3, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and BOOST PRESS & IMT, and connect T-adapter to female side of ECM. Between ECM (female) (23) and ground
5 Defective engine controller
40-130
80 z – 48 kz
Resistance Min. 100 kz
If no failure is found by above checks, engine controller is defective. (Since this is internal failure, troubleshooting cannot be performed.)
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [CA154] Chg Air Temp Sensor Low Error
Circuit diagram related to boost temperature sensor
PC228US-8,PC228USLC-8
40-131
40-131
Troubleshooting by failure code Failure code [CA155] Chg Air Temp High Speed Derate
Failure code [CA155] Chg Air Temp High Speed Derate User code
Failure code Failure
E11 Detail of failure Action of controller Problem on machine Related information
CA155
Boost temperature high enough for speed derate (Engine controller system)
q
Boost temperature sensed by boost pressure & temperature sensor exceeds upper limit of control temperature.
q
Limits engine output and allows engine to run.
q
Engine output lowers. Engine stops.
q q q
Boost temperature can be checked by using monitoring function. (Code: 18500 Boost temperature) Method of reproducing failure code: Start engine.
Cause
Procedure, measuring location, criteria and remarks
Aftercooler cooling performance may degrade. Directly check the following points: Lowered cooling performance of q Looseness and damage of fan belt 1 aftercooler q Insufficient cooling air q Clogging of aftercooler fins Abnormal rise of turbocharger out- Outlet temperature of turbocharger may be abnormally high. Check related 2 let temperature parts directly. 3
Defective boost temperature sen- If no failure is found by above checks, boost temperature sensor system may sor be defective. Perform troubleshooting for failure codes [CA153] and [CA154].
40-132
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [CA155] Chg Air Temp High Speed Derate
PC228US-8,PC228USLC-8
40-133
Troubleshooting by failure code Failure code [CA187] Sens Supply 2 Volt Low Error
Failure code [CA187] Sens Supply 2 Volt Low Error User code
Failure code Failure
E0E
CA187
Detail of failure q Action of controller
q
Problem on machine Related information
q
q
Low voltage appears in sensor power supply 2 circuit. Takes boost pressure & temperature set to be at fixed values and allows engine to run. Run engine with engine output limited.
q
Engine output lowers. Engine starting performance becomes deteriorated.
q
Method of reproducing failure code: Turn starting switch to ON position.
Cause 1
Sensor power supply 2 voltage low error (Engine controller system)
Defective wiring harness connector
2 Defective sensor or wiring harness
3 Defective engine controller
Procedure, measuring location, criteria and remarks See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "General information on troubleshooting", and check them directly. 1. Turn starting switch to OFF position. 2. Disconnect following connectors sequentially one by one and turn starting switch to ON position each time. 3. After each troubleshooting, return to 1. If this failure code is not displayed when a connector is disconnected, that sensor or engine wiring harness is defective. a Other failure codes are displayed, too. This is because of disconnection of connector. Ignore failure codes other than [CA187]. Sensor or harness
Connector
Boost pressure & temperature sensor
BOOST PRESS & IMT
Common rail pressure sensor
FUEL RAIL PRESS
Bkup sensor
CAM SENSOR
Engine wiring harness
ECM
1. Turn starting switch to OFF position. 2. Disconnect connector ECM and connect T-adapter to male side. 3. Turn starting switch to ON position with connector ECM disconnected. Between ECM (male) (37) and (47)
40-134
Voltage
4.75 - 5.25 V
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [CA187] Sens Supply 2 Volt Low Error
Circuit diagram related to sensor power supply 2
PC228US-8,PC228USLC-8
40-135
40-135
Troubleshooting by failure code Failure code [CA221] Ambient Press Sens High Error
Failure code [CA221] Ambient Press Sens High Error User code
Failure code Failure
E11
CA221
Ambient pressure sensor high error (Engine controller system)
Detail of failure q
High voltage appears in signal circuit of ambient pressure sensor.
Action of controller
q
Takes ambient pressure to be at fixed value and allows engine to run.
q
Engine output lowers. Engine starting performance becomes deteriorated. Input voltage from ambient pressure sensor can be checked by using monitoring function. (Code: 37401 (V)) Ambient pressure sensed by ambient pressure sensor can be checked by using monitoring function. (Code: 37400 (kPa)) Method of reproducing failure code: Turn starting switch to ON position.
Problem on machine
q q
Related information
q
q
Cause 1
Defective wiring harness connector
2
Defective sensor power supply 1 system
Procedure, measuring location, criteria and remarks See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "General information on troubleshooting", and check them directly. If failure code [CA352] or [CA386] is displayed simultaneously, perform troubleshooting for it first.
1. Turn starting switch to OFF position. 2. Disconnect connector AMB. AIR PRESSURE. 3 Defective ambient pressure sensor 3. Turn starting switch to ON position. If failure code changes from [CA221] to [CA222], sensor is defective.
4 Short circuit in wiring harness
5
Hot short circuit in wiring harness (contact with 24 V circuit)
6 Defective engine controller
40-136
1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and AMB. AIR PRESSURE, and connect T-adapter to female side of either one. Between ECM (female) (33) and (3), or between Resistance Min. 100 kz AMB. AIR PRESSURE (female) (1) and (3) 1. Turn starting switch to OFF position. 2. Disconnect connector AMB. AIR PRESSURE. 3. Connect T-adapter to female side of connector AMB. AIR PRESSURE or insert T-adapter in connector ECM. 4. Turn starting switch to ON position (with connector AMB. AIR PRESSURE disconnected). Between ECM (3) and (38), or between AMB. AIR Voltage Max. 1 V PRESSURE (female) (3) and (2) If no failure is found by above checks, engine controller is defective. (Since this is internal failure, troubleshooting cannot be performed.)
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [CA221] Ambient Press Sens High Error
Circuit diagram related to ambient pressure sensor
PC228US-8,PC228USLC-8
40-137
40-137
Troubleshooting by failure code Failure code [CA222] Ambient Press Sens Low Error
Failure code [CA222] Ambient Press Sens Low Error User code
Failure code
E11
CA222
Failure
Ambient pressure sensor low error (Engine controller system)
Detail of failure q
Low voltage appears in signal circuit of ambient pressure sensor.
Action of controller
q
Takes ambient pressure to be at fixed value and allows engine to run.
q
Engine output lowers. Engine starting performance becomes deteriorated. Input voltage from ambient pressure sensor can be checked by using monitoring function. (Code: 37401 (V)) Ambient pressure sensed by ambient pressure sensor can be checked by using monitoring function. (Code: 37400 (kPa)) If sensor connector is disconnected, this failure code is displayed. Method of reproducing failure code: Turn starting switch to ON position.
Problem on machine
q q
Related information
q
q q
Cause 1
Defective wiring harness connector
2
Defective power supply line of ambient pressure sensor
Short circuit in wiring harness 3 (wire breakage or defective contact of connector)
4
Ground fault in wiring harness (contact with ground circuit)
5 Short circuit in wiring harness
Procedure, measuring location, criteria and remarks See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "General information on troubleshooting", and check them directly. If failure code [CA352] or [CA386] is also displayed, perform troubleshooting for it first. 1. Turn starting switch to OFF position. 2. Disconnect connector AMB. AIR PRESSURE and connect T-adapter to female side. 3. Turn starting switch to ON position. Between AMB. AIR PRESSURE 4.75 – Power input Voltage (female) (1) and (2) 5.25 V 1. Turn starting switch to OFF position. 2. Disconnect connectors AMB. AIR PRESSURE and ECM, and connect T-adapter to each female side. a If power supply input in checks on cause 2 is normal, this check is not required. Resistance Max. 10 z Between ECM (female) (33) and AMB. AIR PRESSURE (female) (1) a If power supply input in checks on cause 2 is normal, this check is not required. Resistance Max. 10 z Between ECM (female) (38) and AMB. AIR PRESSURE (female) (2) Between ECM (female) (3) and AMB. AIR PRESResistance Max. 10 z SURE (female) (3) (sensor output) 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and AMB. AIR PRESSURE, and connect T-adapter to female side of either one. Between ECM (female) (3) and ground, or between Resistance Min. 100 kz AMB. AIR PRESSURE (female) (3) and ground 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and AMB. AIR PRESSURE, and connect T-adapter to female side of either one. Between ECM (female) (3) and (38), or between AMB. AIR PRESSURE (female) (2) and (3)
40-138
Resistance Min. 100 kz
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [CA222] Ambient Press Sens Low Error
Cause
Procedure, measuring location, criteria and remarks
a If no failure is found by checks on causes 1 to 5 and check result for cause 6 is abnormal, sensor is defective. Defective ambient pressure sensor 1. Turn starting switch to OFF position. 6 (improper input voltage to engine 2. Insert T-adapter to connector ECM. controller) 3. Turn starting switch to ON position. Sensor outBetween ECM (3) and (38) Voltage 0.5 – 4.5 V put If no failure is found by above checks, engine controller is defective. (Since 7 Defective engine controller this is internal failure, troubleshooting cannot be performed.)
Circuit diagram related to ambient pressure sensor
PC228US-8,PC228USLC-8
40-139
40-139
Troubleshooting by failure code Failure code [CA227] Sens Supply 2 Volt High Error
Failure code [CA227] Sens Supply 2 Volt High Error User code
Failure code Failure
E0E
CA227
Detail of failure q Action of controller
q
Problem on machine Related information
q
q
Sensor power supply 2 voltage high error (Engine controller system)
High voltage appears in sensor power supply 2 circuit. Takes boost pressure and charge temperature to be at fixed values and allows engine to run. Runs engine with output and limited.
q
Engine output lowers. Engine starting performance becomes deteriorated.
q
Method of reproducing failure code: Turn starting switch to ON position.
Cause
Procedure, measuring location, criteria and remarks Perform troubleshooting for failure code [CA187].
40-140
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [CA234] Eng Overspeed
Failure code [CA234] Eng Overspeed User code
Failure code Failure
–
CA234
Engine overspeed (Engine controller system)
Detail of failure q
Engine speed exceeded upper limit of control speed .
Action of controller
q
Stops injection until engine speed lowers to normal level.
Problem on machine
q
Engine speed fluctuates.
q
Engine speed can be checked by using monitoring function. (Code: 01002 Engine speed) Method of reproducing failure code: Run engine at high idle.
Related information
q
Cause
Procedure, measuring location, criteria and remarks
1 Use of improper fuel
Fuel used may be improper. Check it directly
2 Improper use
Machine may be used improperly. Instruct operator on proper way to use.
3 Defective engine controller
If no failure is found by checks on causes 1 and 2, engine controller may be defective. (Since this is internal failure, troubleshooting cannot be performed.)
PC228US-8,PC228USLC-8
40-141
Troubleshooting by failure code Failure code [CA238] Ne Speed Sens Supply Volt Error
Failure code [CA238] Ne Speed Sens Supply Volt Error User code
Failure code Failure
E0E
CA238
Ne speed power supply voltage error (Engine controller system)
Detail of failure q
Low voltage appears in power supply circuit of engine Ne speed sensor.
Action of controller
q
Controls the engine with signal from engine Bkup speed sensor.
q
q
Running engine stops (when Bkup speed sensor is also defective). Stopped engine cannot be started (when Bkup speed sensor is also defective). Starting performance is poor Engine hunts.
q
Method of reproducing failure code: Turn starting switch to ON position.
Problem on machine Related information
q q
Cause
Procedure, measuring location, criteria and remarks
See descriptions of wiring harness and connectors in "c: Electrical equipment" Defective wiring harness connec1 in "Checks before troubleshooting" of "General information on troubleshoottor ing", and check them directly. 1. Turn starting switch to OFF position. 2. Disconnect following connectors one by one and turn starting switch to ON position each time. 3. After each troubleshooting, return to step 1. If this failure code is not displayed when sensor is disconnected, sensor or engine wiring harness is defective. 2 Defective sensor or wiring harness a Other failure codes are displayed, too. This is because of disconnection of connector. Ignore failure codes other than [CA238].
3 Defective engine controller
Sensor or harness
Connector
Ne speed sensor
CRANK SENSOR
Engine wiring harness
ECM
1. Turn starting switch to OFF position. 2. Disconnect connector ECM and connect T-adapter to male side. 3. Turn starting switch to ON position with connector ECM disconnected. Between ECM (male) (16) and (48)
Circuit diagram related to engine Ne speed sensor
40-142
Voltage
4.75 – 5.25 V
40-142
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [CA238] Ne Speed Sens Supply Volt Error
PC228US-8,PC228USLC-8
40-143
Troubleshooting by failure code Failure code [CA271] IMV/PCV1 Short Error
Failure code [CA271] IMV/PCV1 Short Error User code
Failure code Failure
E10
CA271
Short circuit in IMV/PCV1 (Engine controller system)
Detail of failure q
Short circuit is detected in drive circuit of supply pump actuator.
Action of controller
q
None in particular
q q
Engine speed does not increase from low idle. Engine output lowers. Common rail fuel pressure rises above command value.
q
Method of reproducing failure code: Turn starting switch to ON position.
Problem on machine Related information
q
Cause 1
Defective wiring harness connector
2 Defective supply pump actuator
Procedure, measuring location, criteria and remarks See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "General information on troubleshooting", and check them directly. 1. Turn starting switch to OFF position. 2. Disconnect connector CP3 PUMP REGULATOR. 3. Turn starting switch to ON position. If failure code changes from [CA271] to [CA272] , supply pump actuator is defective. 1. Turn starting switch to OFF position. 2. Disconnect connector ECM and connect T-adapter to female side.
3
Short circuit or ground fault in wirBetween ECM (female) (2) and (32) ing harness
Between ECM (female) (2) and ground
4 Short circuit in wiring harness
Ground fault in wiring harness (contact with ground circuit)
40-144
Resistance Min. 100 kz
Resistance Min. 100 kz
a If no failure is found by checks on cause 3, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and CP3 PUMP REGULATOR and connect T-adapter to female side of ECM. Between ECM (female) (2) and ground
6 Defective engine controller
1–5z
a If no failure is found by checks on cause 3, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and CP3 PUMP REGULATOR and connect T-adapter to female side of ECM. Between ECM (female) (2) and (32)
5
Resistance
Resistance Min. 100 kz
If no failure is found by above checks, engine controller is defective. (Since this is internal failure, troubleshooting cannot be performed.)
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [CA271] IMV/PCV1 Short Error
Circuit diagram related to IMV/PCV1
PC228US-8,PC228USLC-8
40-145
40-145
Troubleshooting by failure code Failure code [CA272] IMV/PCV1 Open Error
Failure code [CA272] IMV/PCV1 Open Error User code
Failure code Failure
E10
CA272
Open circuit in IMV/PCV1 (Engine controller system)
Detail of failure q
Open circuit is detected in drive circuit of supply pump actuator.
Action of controller
q
None in particular
q
Engine runs but its speed does not stabilize. Common rail fuel pressure rises above command value. Method of reproducing failure code: Turn starting switch to ON position. Since troubleshooting "socket" for this sensor features female connector alone, it is not connectable to harness side female connector and thus not usable for checking open circuit (not designed as a T-adapter).
Problem on machine
q q
Related information
q
Cause
Procedure, measuring location, criteria and remarks
See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "General information on troubleshooting", and check them directly. 1. Turn starting switch to OFF position. 2. Disconnect connector CP3 PUMP REGULATOR. 2 Defective supply pump actuator Between CP3 PUMP REGULATOR (male) (1) and Resistance Max. 5 z (2) 1. Turn starting switch to OFF position. Open or short circuit in wiring har- 2. Disconnect connector ECM and connect T-adapter to female side. 3 ness Between ECM (female) (2) and (32) Resistance Max. 5 z 1
4
Defective wiring harness connector
Hot short circuit in wiring harness (contact with 24 V circuit)
1. 2. 3. 4.
Turn starting switch to OFF position. Disconnect connector CP3 PUMP REGULATOR. Insert T-adapter to connector ECM. Turn starting switch to ON position and perform troubleshooting after one minute or longer (with connector CP3 PUMP REGULATOR disconnected). a Average voltage is displayed because of PWM. Between ECM (2) and (32)
5 Defective engine controller
40-146
Voltage
Max. 3 V
If no failure is found by above checks, engine controller is defective. (Since this is internal failure, troubleshooting cannot be performed.)
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [CA272] IMV/PCV1 Open Error
Circuit diagram related to IMV/PCV1
PC228US-8,PC228USLC-8
40-147
40-147
Troubleshooting by failure code Failure code [CA322] Inj #1(L#1) Open/Short Error
Failure code [CA322] Inj #1(L#1) Open/Short Error User code
Failure code Failure
E11
CA322
Open or short circuit in injector #1 (L/B#1) (Engine controller system)
Detail of failure q
Open or short circuit is detected in drive circuit of No. 1 injector.
Action of controller
q
None in particular
q
Combustion becomes irregular or engine hunts. Engine output lowers.
Problem on machine Related information
q q q
Method of reproducing failure code: Start engine. While engine is running normally, pulse voltage of approx. 65 V is applied to injector (+) side but cannot be measured by using multimeter because it cannot measure pulse voltages.
Cause 1
Defective wiring harness connector
2 Defective No. 1 injector
Procedure, measuring location, criteria and remarks See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "General information on troubleshooting", and check them directly. 1. Turn starting switch to OFF position. 2. Disconnect connector INJECTOR CYL 1&2 and connect T-adapter to male side. Between INJECTOR CYL 1&2 (male) (3) and (4)
Resistance
Max. 2 z
Between INJECTOR CYL 1&2 (male) (3) and Resistance Min. 100 kz ground 1. Turn starting switch to OFF position. 2. Disconnect connector ECM and connect T-adapter to female side.
3
Open circuit or ground fault in wirBetween ECM (female) (45) and (53) ing harness
Between ECM (female) (45) and ground
Open circuit in wiring harness 4 (wire breakage or defective contact of connector)
5
Ground fault in wiring harness (contact with ground circuit)
7
Defective other cylinder injectors or wiring harness
8 Defective engine controller
40-148
Max. 2 z
Resistance Min. 100 kz
a If no failure is found by checks on cause 3, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and INJECTOR CYL 1&2 and connect T-adapter to each female side. Between ECM (female) (45) and INJECTOR CYL Resistance Max. 2 z 1&2 (female) (3) Between ECM (female) (53) and INJECTOR CYL Resistance Max. 2 z 1&2 (female) (4) a If no failure is found by checks on cause 3, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and INJECTOR CYL 1&2 and connect T-adapter to female side of either one. Between ECM (female) (45) or INJECTOR CYL 1&2 (female) (3) and ground
6 Short circuit in wiring harness
Resistance
Resistance Min. 100 kz
1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and INJECTOR CYL 1&2 and connect T-adapter to female side of ECM. a Check by using multimeter in continuity mode. Between ECM (female) (45) and each pin other No continuity (no sound than (45) is heard.) Between ECM (female) (53) and each pin other No continuity (no sound than (53) is heard.) If failure codes for other injectors are displayed, perform troubleshooting for them, too. If no failure is found by checks on causes 1 to 7, engine controller is defective. (Since this is internal failure, troubleshooting cannot be performed.)
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [CA322] Inj #1(L#1) Open/Short Error
Circuit diagram related to injector #1
PC228US-8,PC228USLC-8
40-149
40-149
Troubleshooting by failure code Failure code [CA323] Inj #5 (L#5) Open/Short Error
Failure code [CA323] Inj #5 (L#5) Open/Short Error User code
Failure code Failure
E11
CA323
Open or short circuit in injector #5 (L/B #5) (Engine controller system)
Detail of failure q
Open or short circuit is detected in drive circuit of No. 5 injector.
Action of controller
q
None in particular
q
Combustion becomes irregular or engine hunts. Engine output lowers.
Problem on machine Related information
q q q
Method of reproducing failure code: Start engine. While engine is running normally, pulse voltage of approx. 65 V is applied to injector (+) side but cannot be measured by using multimeter because it cannot measure pulse voltages.
Cause 1
Defective wiring harness connector
2 Defective No. 5 injector
Procedure, measuring location, criteria and remarks See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "General information on troubleshooting", and check them directly. 1. Turn starting switch to OFF position. 2. Disconnect connector INJECTOR CYL 5&6 and connect T-adapter to male side. Between INJECTOR CYL 5&6 (male) (3) and (4)
Resistance
Max. 2 z
Between INJECTOR CYL 5&6 (male) (3) and Resistance Min. 100 kz ground 1. Turn starting switch to OFF position. 2. Disconnect connector ECM and connect T-adapter to female side.
3
Open circuit or ground fault in wirBetween ECM (female) (46) and (60) ing harness
Between ECM (female) (46) and ground
Open circuit in wiring harness 4 (wire breakage or defective contact of connector)
5
Ground fault in wiring harness (contact with ground circuit)
7
Defective other cylinder injectors or wiring harness
8 Defective engine controller
40-150
Max. 2 z
Resistance Min. 100 kz
a If no failure is found by checks on cause 3, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and INJECTOR CYL 5&6 and connect T-adapter to each female side. Between ECM (female) (46) and INJECTOR CYL Resistance Max. 2 z 5&6 (female) (3) Between ECM (female) (60) and INJECTOR CYL Resistance Max. 2 z 5&6 (female) (4) a If no failure is found by checks on cause 3, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and INJECTOR CYL 5&6 and connect T-adapter to female side of either one. Between ECM (female) (46) or INJECTOR CYL 5&6 (female) (3) and ground
6 Short circuit in wiring harness
Resistance
Resistance Min. 100 kz
1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and INJECTOR CYL 5&6 and connect T-adapter to female side of ECM. a Check by using multimeter in continuity mode. Between ECM (female) (46) and each pin other No continuity (no sound than (46) is heard.) Between ECM (female) (60) and each pin other No continuity (no sound than (60) is heard.) If failure codes for other injectors are displayed, perform troubleshooting for them, too. If no failure is found by above checks, engine controller is defective. (Since this is internal failure, troubleshooting cannot be performed.)
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [CA323] Inj #5 (L#5) Open/Short Error
Circuit diagram related to injector #5
PC228US-8,PC228USLC-8
40-151
40-151
Troubleshooting by failure code Failure code [CA324] Inj #3(L#3) Open/Short Error
Failure code [CA324] Inj #3(L#3) Open/Short Error User code
Failure code Failure
E11
CA324
Open or short circuit in injector #3 (L/B #3) (Engine controller system)
Detail of failure q
Open or short circuit is detected in drive circuit of No. 3 injector.
Action of controller
q
None in particular
q
Combustion becomes irregular or engine hunts. Engine output lowers.
Problem on machine Related information
q q q
Method of reproducing failure code: Start engine. While engine is running normally, pulse voltage of approx. 65 V is applied to injector (+) side but cannot be measured by using multimeter because it cannot measure pulse voltages.
Cause 1
Defective wiring harness connector
2 Defective No. 3 injector
Procedure, measuring location, criteria and remarks See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "General information on troubleshooting", and check them directly. 1. Turn starting switch to OFF position. 2. Disconnect connector INJECTOR CYL 3&4 and connect T-adapter to male side. Between INJECTOR CYL 3&4 (male) (3) and (4)
Resistance
Max. 2 z
Between INJECTOR CYL 3&4 (male) (3) and Resistance Min. 100 kz ground 1. Turn starting switch to OFF position. 2. Disconnect connector ECM and connect T-adapter to female side.
3
Open circuit or ground fault in wirBetween ECM (female) (55) and (52) ing harness
Between ECM (female) (55) and ground
Open circuit in wiring harness 4 (wire breakage or defective contact of connector)
5
Ground fault in wiring harness (contact with ground circuit)
7
Defective other cylinder injectors or wiring harness
8 Defective engine controller
40-152
Max. 2 z
Resistance Min. 100 kz
a If no failure is found by checks on cause 3, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and INJECTOR CYL 3&4 and connect T-adapter to each female side. Between ECM (female) (55) and INJECTOR CYL Resistance Max. 2 z 3&4 (female) (3) Between ECM (female) (52) and INJECTOR CYL Resistance Max. 2 z 3&4 (female) (4) a If no failure is found by checks on cause 3, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and INJECTOR CYL 3&4 and connect T-adapter to female side of either one. Between ECM (female) (55) or INJECTOR CYL 3&4 (female) (3) and ground
6 Short circuit in wiring harness
Resistance
Resistance Min. 100 kz
1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and INJECTOR CYL 3&4 and connect T-adapter to female side of ECM. a Check by using multimeter in continuity mode. Between ECM (female) (55) and each pin other No continuity (no sound than (55) is heard.) Between ECM (female) (52) and each pin other No continuity (no sound than (52) is heard.) If failure codes for other injectors are displayed, perform troubleshooting for them, too. If no failure is found by above checks, engine controller is defective. (Since this is internal failure, troubleshooting cannot be performed.)
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [CA324] Inj #3(L#3) Open/Short Error
Circuit diagram related to injector #3
PC228US-8,PC228USLC-8
40-153
40-153
Troubleshooting by failure code Failure code [CA325] Inj #6 (L#6) Open/Short Error
Failure code [CA325] Inj #6 (L#6) Open/Short Error User code
Failure code Failure
E11
CA325
Open or short circuit in injector #6 (L/B #6) (Engine controller system)
Detail of failure q
Open or short circuit is detected in drive circuit of No. 6 injector.
Action of controller
q
None in particular
q
Combustion becomes irregular or engine hunts. Engine output lowers.
Problem on machine Related information
q q q
Method of reproducing failure code: Start engine. While engine is running normally, pulse voltage of approx. 65 V is applied to injector (+) side but cannot be measured by using multimeter because it cannot measure pulse voltages.
Cause 1
Defective wiring harness connector
2 Defective injector No. 6
Procedure, measuring location, criteria and remarks See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "General information on troubleshooting", and check them directly. 1. Turn starting switch to OFF position. 2. Disconnect connector INJECTOR CYL 5&6 and connect T-adapter to male side. Between INJECTOR CYL 5&6 (male) (1) and (2)
Resistance
Max. 2 z
Between INJECTOR CYL 5&6 (male) (1) and Resistance Min. 100 kz ground 1. Turn starting switch to OFF position. 2. Disconnect connector ECM and connect T-adapter to female side.
3
Open circuit or ground fault in wirBetween ECM (female) (57) and (59) ing harness
Between ECM (female) (57) and ground
Open circuit in wiring harness 4 (wire breakage or defective contact of connector)
5
Ground fault in wiring harness (contact with ground circuit)
7
Defective other cylinder injectors or wiring harness
8 Defective engine controller
40-154
Max. 2 z
Resistance Min. 100 kz
a If no failure is found by checks on cause 3, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and INJECTOR CYL 5&amp;6, and connect T-adapters to each female side. Between ECM (female) (57) and INJECTOR CYL Resistance Max. 2 z 5&6 (female) (1) Between ECM (female) (59) and INJECTOR CYL Resistance Max. 2 z 5&6 (female) (2) a If no failure is found by checks on cause 3, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and INJECTOR CYL 5&6 and connect T-adapter to female side of either one. Between ECM (female) (57) or INJECTOR CYL 5&6 (female) (1) and ground
6 Short circuit in wiring harness
Resistance
Resistance Min. 100 kz
1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and INJECTOR CYL 5&6 and connect T-adapter to female side of ECM. a Check by using multimeter in continuity mode. Between ECM (female) (57) and each pin other No continuity (no sound than (57) is heard.) Between ECM (female) (59) and each pin other No continuity (no sound than (59) is heard.) If failure codes for other injectors are displayed, perform troubleshooting for them, too. If no failure is found by above checks, engine controller is defective. (Since this is internal failure, troubleshooting cannot be performed.)
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [CA325] Inj #6 (L#6) Open/Short Error
Circuit diagram related to injector #6
PC228US-8,PC228USLC-8
40-15
40-155
Troubleshooting by failure code Failure code [CA331] Inj #2(L#2) Open/Short Error
Failure code [CA331] Inj #2(L#2) Open/Short Error User code
Failure code Failure
E11
CA322
Open or short circuit in injector #2 (L/B#2) (Engine controller system)
Detail of failure q
Open or short circuit is detected in drive circuit of No. 2 injector.
Action of controller
q
None in particular
q
Combustion becomes irregular or engine hunts. Engine output lowers.
Problem on machine Related information
q q q
Method of reproducing failure code: Start engine. While engine is running normally, pulse voltage of approx. 65 V is applied to injector (+) side but cannot be measured by using multimeter because it cannot measure pulse voltages.
Cause 1
Defective wiring harness connector
2 Defective No. 2 injector
Procedure, measuring location, criteria and remarks See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "General information on troubleshooting", and check them directly. 1. Turn starting switch to OFF position. 2. Disconnect connector INJECTOR CYL 1&2 and connect T-adapter to male side. Between INJECTOR CYL 1&2 (male) (1) and (2)
Resistance
Max. 2 z
Between INJECTOR CYL 1&2 (male) (2) and Resistance Min. 100 kz ground 1. Turn starting switch to OFF position. 2. Disconnect connector ECM and connect T-adapter to female side.
3
Open circuit or ground fault in wirBetween ECM (female) (54) and (51) ing harness
Between ECM (female) (54) and ground
Open circuit in wiring harness 4 (wire breakage or defective contact of connector)
5
Ground fault in wiring harness (contact with ground circuit)
7
Defective other cylinder injectors or wiring harness
8 Defective engine controller
40-156
Max. 2 z
Resistance Min. 100 kz
a If no failure is found by checks on cause 3, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and INJECTOR CYL 1&2 and connect T-adapter to each female side. Between ECM (female) (54) and INJECTOR CYL Resistance Max. 2 z 1&2 (female) (2) Between ECM (female) (51) and INJECTOR CYL Resistance Max. 2 z 1&2 (female) (1) a If no failure is found by checks on cause 3, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and INJECTOR CYL 1&2 and connect T-adapter to female side of either one. Between ECM (female) (54) or INJECTOR CYL 1&2 (female) (2) and ground
6 Short circuit in wiring harness
Resistance
Resistance Min. 100 kz
1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and INJECTOR CYL 1&2 and connect T-adapter to female side of ECM. a Check by using multimeter in continuity mode. Between ECM (female) (54) and each pin other No continuity (no sound than (54) is heard.) Between ECM (female) (51) and each pin other No continuity (no sound than (51) is heard.) If failure codes for other injectors are displayed, perform troubleshooting for them, too. If no failure is found by above checks, engine controller is defective. (Since this is internal failure, troubleshooting cannot be performed.)
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [CA331] Inj #2(L#2) Open/Short Error
Circuit diagram related to injector #2
PC228US-8,PC228USLC-8
40-157
40-157
Troubleshooting by failure code Failure code [CA332] Inj #4(L#4) Open/Short Error
Failure code [CA332] Inj #4(L#4) Open/Short Error User code
Failure code Failure
E11
CA332
Open or short circuit in injector #4 (L/B #4 ) (Engine controller system)
Detail of failure q
Open or short circuit is detected in drive circuit of No. 4 injector.
Action of controller
q
None in particular
q
Combustion becomes irregular or engine hunts. Engine output lowers.
Problem on machine Related information
q q q
Method of reproducing failure code: Start engine. While engine is running normally, pulse voltage of approx. 65 V is applied to injector (+) side but cannot be measured by using multimeter because it cannot measure pulse voltages.
Cause 1
Defective wiring harness connector
2 Defective No. 4 injector
Procedure, measuring location, criteria and remarks See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "General information on troubleshooting", and check them directly. 1. Turn starting switch to OFF position. 2. Disconnect connector INJECTOR CYL 3&4 and connect T-adapter to male side. Between INJECTOR CYL 3&4 (male) (1) and (2)
Resistance
Max. 2 z
Between INJECTOR CYL 3&4 (male) (2) and Resistance Min. 100 kz ground 1. Turn starting switch to OFF position. 2. Disconnect connector ECM and connect T-adapter to female side.
3
Open circuit or ground fault in wirBetween ECM (female) (56) and (58) ing harness
Between ECM (female) (56) and ground
Open circuit in wiring harness 4 (wire breakage or defective contact of connector)
5
Ground fault in wiring harness (contact with ground circuit)
7
Defective other cylinder injectors or wiring harness
8 Defective engine controller
40-158
Max. 2 z
Resistance Min. 100 kz
a If no failure is found by checks on cause 3, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and INJECTOR CYL 3&4 and connect T-adapter to each female side. Between ECM (female) (56) and INJECTOR CYL Resistance Max. 2 z 3&4 (female) (2) Between ECM (female) (58) and INJECTOR CYL Resistance Max. 2 z 3&4 (female) (1) a If no failure is found by checks on cause 3, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and INJECTOR CYL 3&4 and connect T-adapter to female side of either one. Between ECM (female) (56) or INJECTOR CYL 3&4 (female) (2) and ground
6 Short circuit in wiring harness
Resistance
Resistance Min. 100 kz
1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and INJECTOR CYL 3&4 and connect T-adapter to female side of ECM. a Check by using multimeter in continuity mode. Between ECM (female) (56) and each pin other No continuity (no sound than (56) is heard.) Between ECM (female) (58) and each pin other No continuity (no sound than (58) is heard.) If failure codes for other injectors are displayed, perform troubleshooting for them, too. If no failure is found by above checks, engine controller is defective. (Since this is internal failure, troubleshooting cannot be performed.)
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [CA332] Inj #4(L#4) Open/Short Error
Circuit diagram related to injector #4
PC228US-8,PC228USLC-8
40-159
40-159
Troubleshooting by failure code Failure code [CA342] Calibration Code Incompatibility
Failure code [CA342] Calibration Code Incompatibility User code
Failure code Failure
E10
CA342
Calibration code incompatible (Engine controller system)
Detail of failure q
Matching error occurred in engine controller data.
Action of controller
q
None in particular
Problem on machine
q
Machine continues normal operation, or engine is stopped and cannot be restarted.
q
Method of reproducing failure code: Turn starting switch to ON position. Power supply voltage of engine controller can be checked by using monitoring function. (Code: 03203 (V))
Related information
q
Cause 1 Defect in related system 2
Defective power supply voltage system
40-160
Procedure, measuring location, criteria and remarks If another failure code is displayed, perform troubleshooting for it. Perform troubleshooting for failure code [CA441].
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [CA351] Injectors Drive Circuit Error
Failure code [CA351] Injectors Drive Circuit Error User code
Failure code Failure
E10
CA351
Injectors drive circuit error (Engine controller system)
Detail of failure q
There is error in drive power circuit of injector.
Action of controller
q
Runs engine with engine output limited.
q
Exhaust smoke becomes black. Combustion becomes irregular. Engine output lowers. Engine cannot be started. Method of reproducing failure code: Start engine. Power supply voltage of engine controller can be checked by using monitoring function. (Code: 03203 (V))
Problem on machine
q q q
Related information
q q
Cause 1 Defect in related system 2
Defective power supply voltage system
PC228US-8,PC228USLC-8
Procedure, measuring location, criteria and remarks If another failure code is displayed, perform troubleshooting for it. Perform troubleshooting for failure code [CA441].
40-161
Troubleshooting by failure code Failure code [CA352] Sens Supply 1 Volt Low Error
Failure code [CA352] Sens Supply 1 Volt Low Error User code
Failure code Failure
E0E
CA352
Sensor power supply 1 low error (Engine controller system)
Detail of failure q
Low voltage appears in sensor power supply 1 circuit.
Action of controller
q
Takes ambient pressure to be at fixed value and allows engine to run.
q q
Engine output lowers. Engine starting performance becomes deteriorated.
q
Method of reproducing failure code: Turn starting switch to ON position.
Problem on machine Related information
Cause
Procedure, measuring location, criteria and remarks
See descriptions of wiring harness and connectors in "c: Electrical equipment" Defective wiring harness connec1 in "Checks before troubleshooting" of "General information on troubleshoottor ing", and check them directly. 1. Turn starting switch to OFF position. 2. Disconnect following connectors one by one and turn starting switch to ON position each time. 3. After each troubleshooting, return to step 1. If this failure code is not displayed when sensor is disconnected, sensor or engine wiring harness is defective. 2 Defective sensor or wiring harness a Other failure codes are displayed as well. This is because connector is unplugged. Ignore all failure codes other than [CA352].
3 Defective engine controller
Sensor or harness
Connector
Ambient pressure sensor
AMB. AIR PRESSURE
Engine wiring harness
ECM
1. Turn starting switch to OFF position. 2. Disconnect connector ECM and connect T-adapter to male side. 3. Turn starting switch to ON position with connector ECM disconnected. Between ECM (male) (33) and (38)
40-162
Voltage
4.75 - 5.25V
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [CA352] Sens Supply 1 Volt Low Error
Circuit diagram related to sensor power supply 1
PC228US-8,PC228USLC-8
40-163
40-163
Troubleshooting by failure code Failure code [CA386] Sens Supply 1 Volt High Error
Failure code [CA386] Sens Supply 1 Volt High Error User code
Failure code Failure
E0E
CA386
Sensor power supply 1 high error (Engine controller system)
Detail of failure q
High voltage appears in sensor power supply 1 circuit.
Action of controller
q
Takes ambient pressure to be at fixed value and allows engine to run.
q q
Engine output lowers. Engine starting performance becomes deteriorated.
q
Method of reproducing failure code: Turn starting switch to ON position.
Problem on machine Related information
Cause
Procedure, measuring location, criteria and remarks Perform troubleshooting for failure code [CA352]
40-164
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [CA386] Sens Supply 1 Volt High Error
PC228US-8,PC228USLC-8
40-165
Troubleshooting by failure code Failure code [CA428] Water in Fuel Sensor High Error
Failure code [CA428] Water in Fuel Sensor High Error User code
Failure code Failure
E0E
CA428
Water-in-fuel sensor high error (Engine controller system)
Detail of failure q
High voltage appears in signal circuit of water-in-fuel sensor installed to fuel pre-filter.
Action of controller
q
None in particular
Problem on machine
q
Water separator monitor is not displayed correctly.
q
Signal (ON/OFF) from water-in-fuel sensor can be checked by using monitoring function. (Code: 18800) Method of reproducing failure code: Turn starting switch to ON position.
Related information
q
Cause 1
Defective wiring harness connector
2
Defective water-in-fuel sensor installed to fuel pre-filter
Procedure, measuring location, criteria and remarks See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "General information on troubleshooting", and check them directly. 1. Turn starting switch to OFF position. 2. Disconnect connector P47, and connect T-adapter to female side. a If water is in water separator, drain it. Between P47 (female) (1) and (2)
Resistance Min. 100 kz
1. Turn starting switch to OFF position. Open or short circuit in wiring har- 2. Disconnect connector ECM and connect T-adapter to female side. 3 ness Between ECM (female) (14) and (47) Resistance Min. 100 kz (Resistance of water-in-fuel sensor) a If no failure is found by checks on cause 3, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and P47, and connect T-adapter to each Open circuit in wiring harness female side. 4 (wire breakage or defective contact of connector) Between ECM (female) (14) and P47 (female) (1) Resistance Max. 10 z Between ECM (female) (47) and P47 (female) (2)
5 Short circuit in wiring harness
6 Defective engine controller
40-166
Resistance
Max. 10 z
1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and P47, and connect T-adapters to female side of ECM. a Check by using multimeter in continuity mode. Between ECM (female) (14) and each pin other No continuity (no sound than (14) is heard.) If no failure is found by above checks, engine controller is defective. (Since this is internal failure, troubleshooting cannot be performed.)
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [CA428] Water in Fuel Sensor High Error
Circuit diagram related to water-in-fuel sensor
PC228US-8,PC228USLC-8
40-167
40-167
Troubleshooting by failure code Failure code [CA429] Water in Fuel Sensor Low Error
Failure code [CA429] Water in Fuel Sensor Low Error User code
Failure code Failure
E0E
CA429
Water-in-fuel sensor low error (Engine controller system)
Detail of failure q
Low voltage appears in signal circuit of water-in-fuel sensor installed to fuel pre-filter.
Action of controller
q
None in particular
Problem on machine
q
Water separator monitor is not displayed correctly.
q
Signal (ON/OFF) from water-in-fuel sensor can be checked by using monitoring function. (Code: 18800) Method of reproducing failure code: Turn starting switch to ON position.
Related information
q
Cause 1
Defective wiring harness connector
2
Defective water-in-fuel sensor installed to fuel pre-filter
Procedure, measuring location, criteria and remarks See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "General information on troubleshooting", and check them directly. 1. Turn starting switch to OFF position. 2. Disconnect connector P47, and connect T-adapter to female side. a If water is in water separator, drain it. Between P47 (female) (1) and (2)
Resistance Min. 100 kz
Between P47 (female) (1) and ground
Resistance Min. 100 kz
1. Turn starting switch to OFF position. 2. Disconnect connector ECM and connect T-adapter to female side. 3
Short circuit or ground fault in wirBetween ECM (female) (14) and (47) ing harness (Resistance of water-in-fuel sensor) Between ECM (female) (14) and ground
4 Short circuit in wiring harness
5
Ground fault in wiring harness (contact with ground circuit)
6 Defective engine controller
40-168
Resistance Min. 100 kz Resistance Min. 100 kz
1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and P47, and connect T-adapters to female side of ECM. a Check by using multimeter in continuity mode. Between ECM (female) (14) and each pin other No continuity (no sound than (14) is heard.) a If no failure is found by checks on cause 3, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and P47, and connect T-adapter to female side of either one. Between ECM (female) (14) and ground or between Resistance Min. 100 kz P47 (female) (1) and ground If no failure is found by above checks, engine controller is defective. (Since this is internal failure, troubleshooting cannot be performed.)
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [CA429] Water in Fuel Sensor Low Error
Circuit diagram related to water-in fuel sensor
PC228US-8,PC228USLC-8
40-169
40-169
Troubleshooting by failure code Failure code [CA435] Eng Oil Press Sw Error
Failure code [CA435] Eng Oil Press Sw Error User code
Failure code Failure
E0E
CA435
Engine oil pressure switch error (Engine controller system)
Detail of failure q
Abnormality is detected in signal circuit of engine oil pressure switch.
Action of controller
q
None in particular
q
Engine protection function based on engine oil pressure does not work. Engine oil pressure monitor is not displayed correctly.
Problem on machine
q q q
Related information
q q
Method of reproducing failure code: Turn starting switch to ON position or start engine. Engine oil pressure switch is closed (ON) when oil pressure is low (when engine is stopped), but is open (OFF) when high (when engine is running). To generate this failure code, engine controller checks if engine oil pressure switch is closed (ON), that is, if signal voltage is at GND level or not only while engine is stopped. When engine is running, engine oil pressure switch error is shown by failure code [B@BAZG].
Cause
Procedure, measuring location, criteria and remarks
See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "General information on troubleshooting", and check them directly. 1. Turn starting switch to OFF position. 2. Disconnect connector OIL PRESSURE SWITCH and connect T-adapter to Defective engine oil pressure 2 male side. switch Between OIL PRESSURE SWITCH (male) (1) and Resistance Max. 10 z ground 1. Turn starting switch to OFF position. Open or short circuit in wiring har- 2. Disconnect connector ECM and connect T-adapter to female side. 3 ness Between ECM (female) (17) and ground Resistance Max. 10 z 1
Defective wiring harness connector
4 Defective engine controller
If no failure is found by above checks, engine controller is defective. (Since this is internal failure, troubleshooting cannot be performed.)
Circuit diagram related to engine oil pressure switch
40-170
40-170
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [CA435] Eng Oil Press Sw Error
PC228US-8,PC228USLC-8
40-171
Troubleshooting by failure code Failure code [CA441] Battery Voltage Low Error
Failure code [CA441] Battery Voltage Low Error User code
Failure code Failure
E10
CA441
Battery voltage low error (Engine controller system)
Detail of failure q
Low voltage appears in controller power supply circuit.
Action of controller
q
None in particular
q
Engine stops. Starting performance is poor
Problem on machine Related information
q q q
Method of reproducing failure code: Turn starting switch to ON position. Power supply voltage of engine controller can be checked by using monitoring function. (Code: 03203 (V))
Cause
Procedure, measuring location, criteria and remarks
1 Loose or corroded battery terminal Battery cable terminal may be loose or corroded. Check it directly. 2
Loose terminal or partial open cir- 1. Turn starting switch to OFF position. cuit at terminal Check terminals of alternator, battery relay, ground terminal (T12), etc.
3
Defective wiring harness connector
4 Improper battery voltage
See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "General information on troubleshooting", and check them directly. 1. Turn starting switch to OFF position. 2. Perform troubleshooting with starting switch at OFF position and at engine cranking. Between battery terminals (+) and (-).
5 Defective alternator
40-172
20 – 30 V
Voltage
27.5 – 29.5 V
1. Turn starting switch to OFF position. 2. Insert T-adapter into connector E12. 3. Start engine (Engine speed: Middle or faster). Between E12 (1) and ground
6 Defective engine controller
Voltage
If no failure is found by above checks, engine controller is defective. (Since this is internal failure, troubleshooting cannot be performed.) q Reference 1. Turn starting switch to OFF position and disconnect ground cable. 2. Insert T-adapter in connector CE03. 3. Connect ground cable. 4. Measure voltage with starting switch at ON position and when starting engine. Between CE03 (3) and Starting switch: ON Voltage 20 – 30 V (1) Between CE03 (3) and Starting switch: START Voltage Min. 12 V (1)
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [CA441] Battery Voltage Low Error
Circuit diagram related to engine controller power supply
PC228US-8,PC228USLC-8
40-173
40-173
Troubleshooting by failure code Failure code [CA442] Battery Voltage High Error
Failure code [CA442] Battery Voltage High Error User code
Failure code Failure
E10
CA442
Battery voltage high error (Engine controller system)
Detail of failure q
High voltage (36 V or higher) appears in controller power supply circuit.
Action of controller
q
None in particular
q
Engine continues to run normally, but it may stop during running or may not be able to start if it is stopped.
q
Method of reproducing failure code: Turn starting switch to ON position. Power supply voltage of engine controller can be checked by using monitoring function. (Code: 03203 (V))
Problem on machine Related information
q
Cause
Procedure, measuring location, criteria and remarks Perform troubleshooting for failure code [CA441].
40-174
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [CA449] Rail Press Very High Error
Failure code [CA449] Rail Press Very High Error User code
Failure code Failure
E11
CA449
Common rail pressure high error (Engine controller system)
Detail of failure q
High pressure error (2) occurs in common rail circuit.
Action of controller
q
Limits engine output and allows engine to run.
q
Engine sound becomes large when no or light load is applied. Engine output lowers.
Problem on machine Related information
q q q
Common rail pressure can be checked by using monitoring function. (Code: 36400 Common rail pressure) Method of reproducing failure code: Start engine.
Cause 1 Defect in related system
2 Air in low pressure circuit
3 Defect in fuel return circuit parts
4
Defective common rail pressure sensor system
5 Defective pressure limitter
6 Defective supply pump
PC228US-8,PC228USLC-8
Procedure, measuring location, criteria and remarks If another failure code is displayed, perform troubleshooting for it. Air may be in low-pressure circuit. Check it directly according to following procedure. 1. Remove fuel pressure pick-up port plug (outlet side) of fuel main filter. 2. Operate feed pump of fuel pre-filter. 3. Check fuel and air from pressure pick-up plug for leakage level. a For check of pressure in fuel return circuit, see Testing and adjusting, "Testing fuel pressure". Max. 0.02 MPa Fuel return circuit presEngine at low idle or sure cranking {Max. 0.19 kg/cm2} Perform troubleshooting for failure codes [CA451] and [CA452] a For check of leakage from pressure limitter, see Testing and adjusting, "Checking fuel return rate and leakage". Leakage from pressure limited
At low idle
0 cc (no leakage)
If no failure is found by above checks, supply pump may be defective.
40-175
Troubleshooting by failure code Failure code [CA451] Rail Press Sensor High Error
Failure code [CA451] Rail Press Sensor High Error User code
Failure code Failure
E11
CA451
Common rail pressure sensor high error (Engine controller system)
Detail of failure q
High voltage appears in signal circuit of common rail pressure sensor.
Action of controller
q
Limits engine output and allows engine to run.
q
Engine speed or output lowers. Engine does not start Signal voltage of common rail pressure sensor can be checked with monitoring function. (Code: 36401 Common rail pressure sensor volt) Method of reproducing failure code: Turn starting switch to ON position. This failure code is displayed if common rail pressure sensor connector is disconnected. Since troubleshooting "socket" for this sensor features female connector alone, it is not usable for checking open circuit in wiring harness and voltage at sensor connector (not designed as a T-adapter).
Problem on machine
q q
Related information
q q q
Cause 1
Defective wiring harness connector
2
Defective common rail pressure sensor power supply line
3 Short circuit in wiring harness
Procedure, measuring location, criteria and remarks See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "General information on troubleshooting", and check them directly. If failure code [CA227] or [CA187] is also displayed, perform troubleshooting for it first. 1. Turn starting switch to OFF position. 2. Disconnect connectors CAM SENSOR, FUEL RAIL PRESS, BOOST PRESS & IMT and ECM. 3. Connect T-adapter to female side of ECM. Between ECM (female) (25) and (37)
4
Hot short circuit in wiring harness (contact with 24 V circuit)
1. Turn starting switch to OFF position. 2. Disconnect connector FUEL RAIL PRESS, and connect T-adapter to connector ECM. 3. Turn starting switch to ON position (with connector FUEL RAIL PRESS disconnected). a Pin (25) of ECM is connected to 5V line via resistor inside engine controller. Between ECM (25) and (47)
5 Open circuit in wiring harness
Defective common rail pressure sensor 6 (improper input voltage to engine controller)
7 Defective engine controller
Resistance Min. 100 kz
Voltage
Approx. 5 V
If no failure is found by above checks, there may be open circuit in wiring harness. (*) a If no failure is found by checks on causes 1 to 5 and check result for cause 6 is abnormal, sensor is defective. 1. Turn starting switch to OFF position. 2. Insert T-adapter to connector ECM. 3. Turn starting switch to ON position. Sensor outVoltage 0.2 – 4.6 V Between ECM (25) and (47) put If no failure is found by above checks, engine controller is defective. (Since this is internal failure, troubleshooting cannot be performed.)
*: See "Troubleshooting method for open circuit in wiring harness of pressure sensor system" of "Related information of troubleshooting".
40-176
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [CA451] Rail Press Sensor High Error
Circuit diagram related to common rail pressure sensor
PC228US-8,PC228USLC-8
40-17
40-177
Troubleshooting by failure code Failure code [CA452] Rail Press Sensor Low Error
Failure code [CA452] Rail Press Sensor Low Error User code
Failure code Failure
E11
CA452
Common rail pressure sensor low error (Engine controller system)
Detail of failure q
Low voltage appears in signal circuit of common rail pressure sensor.
Action of controller
q
Limits engine output and allows engine to run.
q
Engine speed or output lowers. Engine does not start
Problem on machine
q q
Related information
q q
Signal voltage of common rail pressure sensor can be checked with monitoring function. (Code: 36401 Common rail pressure sensor volt) Method of reproducing failure code: Turn starting switch to ON position. If sensor connector is disconnected even in normal condition, failure code [CA451] for "High Error" is displayed.
Cause 1
Defective wiring harness connector
2
Defective common rail pressure sensor power supply line
3
Defective common rail pressure sensor
Procedure, measuring location, criteria and remarks See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "General information on troubleshooting", and check them directly. If failure code [CA187] (ground fault in sensor power supply line) or [CA227] is indicated, perform troubleshooting for it first. a Check that failure code [CA187] (Ground fault in sensor power supply line) is not displayed. 1. Turn starting switch to OFF position. 2. Disconnect connector FUEL RAIL PRESS. 3. Turn starting switch to ON position. If failure code [CA452] changes to [CA451] , sensor is defective.
4
Ground fault in wiring harness (contact with ground circuit)
1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and FUEL RAIL PRESS, and connect T-adapter to female side of ECM. Between ECM (female) (25) and ground
5 Short circuit in wiring harness
1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and FUEL RAIL PRESS, and connect T-adapter to female side of ECM. Between ECM (female) (25) and (47)
6 Defective engine controller
40-178
Resistance Min. 100 kz
Resistance Min. 100 kz
If no failure is found by above checks, engine controller is defective. (Since this is internal failure, troubleshooting cannot be performed.)
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [CA452] Rail Press Sensor Low Error
Circuit diagram related to common rail pressure sensor
PC228US-8,PC228USLC-8
40-179
40-179
Troubleshooting by failure code Failure code [CA488] Chg Air Temp High Torque Derate
Failure code [CA488] Chg Air Temp High Torque Derate User code
Failure code Failure
E11
CA488
Boost temperature high error (Engine controller system)
q
Temperature signal from boost pressure & temperature sensor exceeds upper limit of control temperature.
Action of controller
q
Limits engine output and allows engine to run.
Problem on machine
q
Engine output lowers.
q
Boost temperature can be checked by using monitoring function. (Code: 18500 Boost temperature) Method of reproducing failure code: Start engine.
Detail of failure
Related information
q
Cause
Procedure, measuring location, criteria and remarks
Cooling performance of aftercooler may degrade. Directly check following points: Lowered cooling performance of q Looseness and breakage of fan belt 1 aftercooler q Insufficient cooling air q Clogging of aftercooler fins Abnormal rise of turbocharger out- Outlet temperature of turbocharger may be abnormally high. Check related 2 let temperature parts directly. 3 Defective engine controller
40-180
Perform troubleshooting for failure codes [CA153] and [CA154].
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [CA553] Rail Press High Error
Failure code [CA553] Rail Press High Error User code
Failure code Failure
E0E
CA553
Common rail pressure high error (Engine controller system)
Detail of failure q
High pressure error appears (1) in common rail circuit.
Action of controller
q
None in particular
q
Engine sound becomes large without load or with light load. Engine output lowers.
Problem on machine Related information
q q q
Common rail pressure can be checked by using monitoring function. (Code: 36400 Common rail pressure) Method of reproducing failure code: Start engine.
Cause 1 Defect in related system
2
Defective connection of ground terminal
Defective O-ring of supply pump actuator Defective common rail pressure 4 sensor system 3
PC228US-8,PC228USLC-8
Procedure, measuring location, criteria and remarks If another failure code is displayed, perform troubleshooting for it. Connection of ground terminal may be defective. Check following terminals directly. q Ground terminal of machine ((–) terminal of battery) q Ground terminal of engine q Ground terminal of engine controller q Ground terminal of starting motor O-ring of supply pump actuator may be damaged. Check it directly. Perform troubleshooting for failure codes [CA451] and [CA452]
40-181
Troubleshooting by failure code Failure code [CA559] Rail Press Low Error
Failure code [CA559] Rail Press Low Error User code
Failure code
E0E
CA559
Failure
Common rail pressure low error (Engine controller system)
Detail of failure q
Low pressure appears in common rail circuit.
Action of controller
q
None in particular
q
Engine does not start at all or does not start easily. Exhaust smoke becomes black. Engine output lowers.
Problem on machine Related information
q q q q
Common rail pressure can be checked by using monitoring function. (Code: 36400 Common rail pressure) Method of reproducing failure code: Start engine.
Cause 1 Use of improper fuel
Procedure, measuring location, criteria and remarks Check fuel used directly (for high viscosity).
Fuel may leak to outside. Check it directly (Check visually while running engine at low idle). a For more information on troubleshooting, see Note 1. a For check of fuel pressure in low-pressure circuit, see Testing and adjusting, "Testing fuel pressure". Negative pressure at fuel At high idle Max. -50.7 MPa supply pump inlet (outlet (if engine can be started) {Max. -380 mmHg} side of fuel pre-filter) Defect in low pressure circuit parts During cranking 0.3 – 1.1 MPa (if engine cannot be Inlet pressure of fuel {3.1 – 11.3 kg/cm2} started) main filter 0.5 – 1.3 MPa At low idle (if engine can be started) {5.1 – 13.3 kg/cm2} a For check of leakage through pressure limitter, see Testing and adjusting, “Checking fuel return rate and leakage”. Defective pressure limitter Leakage from pressure At low idle 0 cc (no leakage) limitter a For check of return rate from injector, see Testing and adjusting, “Checking fuel return rate and leakage”. Defective injector During cranking (including high-pressure piping in (if engine cannot be Max. 90 cc/min cylinder head) started) Return rate from injector At low idle Max. 180 cc/min (if engine can be started) a For check of return rate from supply pump, see Testing and adjusting, “Checking fuel return rate and leakage”. During cranking Defective supply pump (if engine cannot be Max. 140 cc/min Return rate from supply started) pump At low idle Max. 1,000 cc/min (if engine can be started) Defective common rail pressure Perform troubleshooting for failure codes [CA451] and [CA452] sensor system
2 Fuel leakage to outside
3
4
5
6
7
Note 1: Check the low-pressure line parts for the following. 1) Fuel level 2) Clogging of fuel tank breather 3) Leakage or clogging of low-pressure fuel piping 4) Clogging of fuel pre-filter 5) Clogging of fuel main filter 6) Replace the fuel filter if the problem is not removed after clearing the clog. 40-182
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [CA559] Rail Press Low Error
PC228US-8,PC228USLC-8
40-183
Troubleshooting by failure code Failure code [CA689] Eng Ne Speed Sensor Error
Failure code [CA689] Eng Ne Speed Sensor Error User code
Failure code Failure
E0E
CA689
Engine Ne speed sensor error (Engine controller system)
Detail of failure q
Signal from engine Ne speed sensor is abnormal.
Action of controller
q
Continues to control engine by using signal from engine Bkup speed sensor.
q
Engine hunts. Starting performance is poor. Engine output lowers. Method of reproducing failure code: Start engine. Since inside of speed sensor is not composed of coil but Hall sensor and electronic circuit, speed sensor cannot be determined to be normal by measuring its resistance with multimeter. Since speed sensor output is 5 V pulse voltage during normal operation, it cannot be measured with multimeter. Speed sensor senses passing slotted hole in speed sensing wheel that is installed on inside of crankshaft vibration damper and rotated by crankshaft.
Problem on machine
q q q q
Related information
q q
1
Cause
Procedure, measuring location, criteria and remarks
Defective wiring harness connector
See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "General information on troubleshooting", and check them directly.
Defective Ne speed sensor power If failure code [CA238] is also displayed, perform troubleshooting for it first. supply line Breakage or improper installation Engine Ne speed sensor may be broken or may have improper installation 3 (looseness) of engine Ne speed (looseness). Check it directly. sensor 1. Turn starting switch to OFF position. 2. Disconnect connector CRANK SENSOR and connect T-adapter to female Defective Ne speed sensor power side. 4 supply input 3. Turn starting switch to ON position. Between CRANK SENSOR (female) Power input Voltage 4.75 - 5.25V (1) and (2) 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and CRANK SENSOR. a If no failure is found by checks on cause 4, this check is not required. ResistMax. 10 z Between ECM (female) (16) and CRANK ance Open circuit in wiring harness SENSOR (female) (1) 5 (wire breakage or defective cona If no failure is found by checks on cause 4, this tact of connector) check is not required. ResistMax. 10 z Between ECM (female) (48) and CRANK ance SENSOR (female) (2) Between ECM (female) (27) and CRANK SENSOR ResistMax. 10 z (female) (3) ance 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and CRANK SENSOR. 2
6 Short circuit in wiring harness
7
Ground fault in wiring harness (contact with ground circuit)
40-184
Between ECM (female) (16) and (27) or CRANK SENSOR (female) (1) and (3)
Resistance
Min. 100 kz
Between ECM (female) (27) and (48) or CRANK SENSOR (female) (2) and (3)
Resistance
Min. 100 kz
1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and CRANK SENSOR. Between ECM (female) (27) or CRANK SENSOR (female) (3) and ground
Resistance
Min. 100 kz
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [CA689] Eng Ne Speed Sensor Error
Cause
Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position. Hot short circuit in wiring harness 2. Disconnect connector CRANK SENSOR. 8 3. Turn starting switch to ON position. (contact with 24 V circuit) Between CRANK SENSOR (female) (3) and ground
Voltage
Max. 1 V
Damage or loose mounting of 9 wheel for speed sensing
Check speed sensing wheel directly.
10 Defective Ne speed sensor
If no failure is found by above checks, Ne speed sensor is defective. (Since this is internal failure, troubleshooting cannot be performed.)
11 Defective engine controller
If no failure is found by above checks, engine controller is defective. (Since this is internal failure, troubleshooting cannot be performed.)
Circuit diagram related to engine Ne speed sensor
PC228US-8,PC228USLC-8
40-185
40-185
Troubleshooting by failure code Failure code [CA731] Eng Bkup Speed Sens Phase Error
Failure code [CA731] Eng Bkup Speed Sens Phase Error User code
Failure code Failure
E0E Detail of failure Action of controller Problem on machine Related information
CA731 q
Phase error is detected between signals from engine Ne speed sensor and engine Bkup speed sensor
q
Continues to control engine by using signal from engine Ne speed sensor.
q q
Engine does not start at all or does not start easily. Idle speed is unstable. Exhaust smoke becomes black.
q
Method of reproducing failure code: Start engine.
q
Cause 1 2
3
4
5
6
Engine Bkup speed sensor phase error (Engine controller system)
Procedure, measuring location, criteria and remarks
Breakage of engine Ne speed senEngine Ne speed sensor may be broken. Check it directly. sor Breakage of engine Bkup speed Engine Bkup speed sensor may be broken. Check it directly. sensor Speed sensing wheel on crankshaft side may be installed defectively or broken. Check it according to following procedure. Defective installation or breakage 1. Align paint mark (M1) on damper with Ne speed sensor top (M2). of speed sensing wheel on cranka Do not align with mark of No. 1 cylinder compression top dead centre. shaft side (Approx. 80 ° before compression top dead centre) 2. If centre of oblong hole (WS) of speed sensing wheel aligns with Ne speed sensor top (M2), installation is correct. Speed sensing ring on camshaft side may be installed defectively or broken. Check it according to the following procedure. 1. Align paint mark (M1) on damper with Ne speed sensor top (M2). Defective installation or breakage a Do not align with mark of No. 1 cylinder compression top dead centre. of speed sensing ring on camshaft (Approx. 80 ° before compression top dead centre) side 2. Remove Bkup speed sensor. 3. If you can see double-slot part (with one crest) (B) on speed sensing ring through sensor mounting hole (H), speed sensing ring is installed correctly. Defective timing of crankshaft and Timing of crankshaft and camshaft may be defective. Check it directly. camshaft Connection at ground terminal may be defective. Check following terminals directly. q Ground terminal of machine ((-) terminal of battery) Defective connection at ground q Ground terminal of engine terminal q Ground terminal of engine controller q Ground terminal of starting motor
40-186
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [CA757] All Continuous Data Lost Error
Failure code [CA757] All Continuous Data Lost Error User code
Failure code Failure
E10
CA757
All continuous data lost error (Engine controller system)
Detail of failure q
All data in engine controller are lost.
Action of controller
q
None in particular
q q
Engine may stop and may not be started again. Monitoring function of machine monitor (engine controller system) may not work normally.
q
Method of reproducing failure code: Turn starting switch to ON position.
Problem on machine Related information
Cause 1 Defect in related system
Procedure, measuring location, criteria and remarks If another failure code is displayed, perform troubleshooting for it.
2 Perform troubleshooting for failure code [CA441].
PC228US-8,PC228USLC-8
40-187
Troubleshooting by failure code Failure code [CA778] Eng Bkup Speed Sensor Error
Failure code [CA778] Eng Bkup Speed Sensor Error User code
Failure code Failure
E0E
CA778
Engine Bkup speed sensor error (Engine controller system)
Detail of failure q
Signal from engine Bkup speed (cam) sensor is abnormal.
Action of controller
q
Continues to control engine by using signal from engine Ne speed sensor.
q
Starting performance is poor. Engine output lowers. Method of reproducing failure code: Start engine. Since inside of speed sensor is not coil but Hall sensor and electronic circuit, speed sensor cannot be determined to be normal by measuring its resistance with multimeter. Since speed sensor outputs 5 V pulse voltage during normal operation, it cannot be measured by using multimeter. Speed sensor scans rotating slot of speed sensing ring mounted on the camshaft.
Problem on machine
q q q
Related information
q q
Cause
Procedure, measuring location, criteria and remarks
1
Defective wiring harness connector
See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "General information on troubleshooting", and check them directly.
2
Defective sensor power supply 2 line
If failure code [CA187] or [CA227] is also displayed, troubleshoot it first.
Damage or incorrect (loose) instalEngine Bkup speed (cam) sensor directly as it may be damaged or incorrectly 3 lation of engine Bkup speed (cam) (loosely) installed. Check it directly. sensor 1. Turn starting switch to OFF position. 2. Disconnect connector CAM SENSOR , and connect T-adapter to female Defective power supply input to side. 4 engine Bkup speed sensor 3. Turn starting switch to ON position. Between CAM SENSOR (female) (1) Power supVoltage 4.75 - 5.25V and (2) ply 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and CAM SENSOR, and connect T-adapter to each female side. Open circuit in wiring harness Between ECM (female) (37) and CAM SENSOR ResistMax. 10 z 5 (wire breakage or defective con- (female) (1) ance Between ECM (female) (47) and CAM SENSOR Resisttact of connector) Max. 10 z (female) (2) ance Between ECM (female) (26) and CAM SENSOR ResistMax. 10 z (female) (3) ance 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and CAM SENSOR, and connect T-adapter to female side of either connector. Between ECM (female) (26) and (37) or CAM SEN- Resist6 Short circuit in wiring harness Min. 100 kz SOR (female) (1) and (3) ance
7
Ground fault in wiring harness (contact with ground circuit)
8
Hot short circuit in wiring harness (contact with 24 V circuit)
Between ECM (female) (26) and (47) or CAM SEN- ResistMin. 100 kz SOR (female) (2) and (3) ance 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and CAM SENSOR, and connect T-adapter to female side of either connector. Between ECM (female) (26) or CAM SENSOR ResistMin. 100 kz (female) (3) and ground ance 1. Turn starting switch to OFF position. 2. Disconnect connector CAM SENSOR, and connect T-adapter to female side. 3. Turn starting switch to ON position. Between CAM SENSOR (female) (3) and ground
40-188
Voltage
Max. 1 V
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [CA778] Eng Bkup Speed Sensor Error
Cause 9 Loose speed sensing ring
10
Defective engine Bkup speed (cam) sensor
11 Defective engine controller
Procedure, measuring location, criteria and remarks Remove engine Bkup speed (cam) sensor, and check ring directly through hole (H). a If speed sensing ring (B) is loosely installed, follow instructions given in the "Reference" column. If no failure is found by above checks, engine Bkup speed (cam) sensor is defective. (Since this is internal failure, troubleshooting cannot be performed.) If no failure is found by above checks, engine controller is defective. (Since this is internal failure, troubleshooting cannot be performed.)
Circuit diagram related to engine Bkup speed sensor
PC228US-8,PC228USLC-8
40-189
40-189
Troubleshooting by failure code Failure code [CA778] Eng Bkup Speed Sensor Error
Reference for troubleshooting for CA778 (107 series engine) Checking camshaft ring for loose installation Remove the front cover and check the camshaft ring for looseness. a See "Removal and installation of front seal" in Disassembly and assembly. a Keep the front seal, liquid gasket LG-7 and front seal tool (795-799-6400) on hand. Removal 40-190 1. Remove the fan and fan belt. For details, see "Removal and installation of front seal" in Disassembly and assembly. 2. Remove damper assembly (1). (DP): Dowel pin
3. Remove front cover (2). 4. Remove front seal (3). (RING): Ring
40-190
5. Check mounting bolt (4) of camshaft ring (5) for looseness. 3 Mounting bolt (4): 10 ± 2 Nm (DP): Dowel pin
Connection 40-190 a See the figures in "Removal" for installation. 1. Install front cover (2). 3 Front cover: Liquid gasket (LG-7) 2. Install the front seal according to the following procedure. For details, see "Removal and installation of front seal" in Disassembly and assembly. 1) Install front seal (3). 2) Install the damper with the dowel pin (DP) assembly. 3) Install fan belt, and install the fan. 4) Install the cooling system assembly.
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [CA1633] KOMNET Datalink Timeout Error
Failure code [CA1633] KOMNET Datalink Timeout Error User code
Failure code Failure
E0E
CA1633
Detail of failure Action of controller Problem on machine Related information
KOMNET datalink timeout error (Engine controller system)
q
Engine controller detects communication error in KOMNET communication circuit between engine controller and pump controller or machine monitor.
q
Allows engine to run in default mode or keeps control conditions at the time of failure detection. If cause of failure disappears, machine becomes normal by itself.
q q
Machine may not operate normally because informations which are exchanged through KOMNET communication are not transmitted properly. (Failure symptom depends on failed section.)
q
Method of reproducing failure code: Turn starting switch to ON position.
Cause
Procedure, measuring location, criteria and remarks Perform troubleshooting for failure code [DA2RMC].
PC228US-8,PC228USLC-8
40-191
Troubleshooting by failure code Failure code [CA2185] Throt Sens Sup Volt High Error
Failure code [CA2185] Throt Sens Sup Volt High Error User code
Failure code Failure
E14
CA2185
Throttle sensor voltage high error (Engine controller system)
Detail of failure q
High voltage (5.25 V or higher) appears in throttle sensor power supply circuit.
Action of controller
q
Gets throttle position by using signal other than throttle sensor signal and allows engine to run.
q
Engine speed cannot be controlled by fuel control dial.
q
Method of reproducing failure code: Turn starting switch to ON position.
Problem on machine Related information
Cause
Procedure, measuring location, criteria and remarks
See descriptions of wiring harness and connectors in "c: Electrical equipment" Defective wiring harness connec1 in "Checks before troubleshooting" of "General information on troubleshoottor ing", and check them directly. 1. Turn starting switch to OFF position. 2. Disconnect connector P20, and turn starting switch to ON position. Defective throttle sensor (fuel con2 If this failure code is not displayed, throttle sensor is defective. trol dial) a Other failure codes are displayed, too. This is because of disconnection of connector. Ignore failure codes other than [CA2185].
3 Short circuit in wiring harness
4
Hot short circuit in wiring harness (contact with 24 V circuit)
1. Turn starting switch to OFF position. 2. Disconnect connectors CE02, CE03 and P20, and connect T-adapters to each female side of connectors CE02 and CE03. Between CE02 (female) (22) and each pin other ResistMin. 1 Mz than (22) ance ResistBetween CE02 (female) (22) and CE03 (female) (3) Min. 1 Mz ance 1. Turn starting switch to OFF position. 2. Disconnect connector P20, and connect T-adapter to female side. 3. Turn starting switch to ON position. Between P20 (female) (1) and ground
5 Defective engine controller
Between CE02 (male) (22) and (23)
Circuit diagram related to throttle sensor
40-192
Voltage
4.75 - 5.25V
1. Turn starting switch to OFF position. 2. Disconnect connector CE02, and connect T-adapter to male side. 3. Turn starting switch to ON position with wiring harness disconnected. Voltage
4.75 - 5.25V
40-192
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [CA2186] Throt Sens Sup Volt Low Error
Failure code [CA2186] Throt Sens Sup Volt Low Error User code
Failure code Failure
E14
CA2186
Throttle sensor voltage low error (Engine controller system)
Detail of failure q
Low voltage appears in throttle sensor power supply circuit.
Action of controller
q
Gets throttle position by using signal other than throttle sensor signal and allows engine to run.
q
Engine speed cannot be controlled by fuel control dial.
q
Method of reproducing failure code: Turn starting switch to ON position.
Problem on machine Related information
Cause 1
Defective wiring harness connector
Procedure, measuring location, criteria and remarks See the descriptions of wiring harness and connectors in "c: Electrical equipment" of "Checks before troubleshooting" in "General information on troubleshooting" , and check them directly. 1. Turn starting switch to OFF position. 2. Disconnect connector P20, and turn starting switch to ON position.
Defective throttle sensor (fuel conIf this failure code is not displayed, throttle sensor is defective. trol dial) a Other failure code is displayed too. This is because of disconnection of connector. Ignore failure codes other than [CA2186]. 1. Turn starting switch to OFF position. 2. Disconnect connectors CE02 and P20, and connect T-adapter to female Ground fault of wiring harness 3 side of either connector. (contact with ground circuit) Between CE02 (female) (22) or P20 (female) (1) ResistMin. 1 Mz and ground ance 1. Turn starting switch to OFF position. 2. Disconnect connectors CE02 and P20, and connect T-adapter to female side of connector CE02. 4 Short circuit in wiring harness 3. Turn starting switch to ON position. Between CE02 (female) (22) and each pin other ResistMin. 1 Mz than (22) ance
2
5 Defective engine controller
1. Turn starting switch to OFF position. 2. Disconnect connector CE02, and connect T-adapter to male side. 3. Turn starting switch to ON position with wiring harness disconnected. Between CE02 (male) (22) and (23)
Circuit diagram related to throttle sensor
PC228US-8,PC228USLC-8
Voltage
4.75 - 5.25V
40-193
40-193
Troubleshooting by failure code Failure code [CA2249] Rail Press Very Low Error
Failure code [CA2249] Rail Press Very Low Error User code
Failure code Failure
E11
CA2311
Common rail pressure very low error (Engine controller system)
Detail of failure q
Low pressure appears in common rail circuit.
Action of controller
q
Limits engine output and allows engine to run.
q
Starting performance is poor. Exhaust gas becomes black. Engine output lowers.
Problem on machine Related information
q q q q
Common rail pressure can be checked by using monitoring function. (Code: 36400 Common rail pressure) Method of reproducing failure code: Start engine.
Cause
Procedure, measuring location, criteria and remarks Perform troubleshooting for failure code [CA559] .
40-194
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [CA2311] IMV Solenoid Error
Failure code [CA2311] IMV Solenoid Error User code
Failure code Failure
E11
CA2311
IMV solenoid error (Engine controller system)
Detail of failure q
Resistance of supply pump actuator circuit is abnormally high or low.
Action of controller
q
None in particular
q
Engine output lowers.
q
Method of reproducing failure code: Start engine.
Problem on machine Related information
Cause
Procedure, measuring location, criteria and remarks Perform troubleshooting for failure codes [CA271] and [CA272].
PC228US-8,PC228USLC-8
40-195
Troubleshooting by failure code Failure code [CA2555] Grid Htr Relay Open Circuit Error
Failure code [CA2555] Grid Htr Relay Open Circuit Error User code
Failure code Failure
E0E
CA2555
Intake air heater relay open circuit (Engine controller system)
Detail of failure q
Open circuit is detected in drive circuit (primary circuit) of preheater relay.
Action of controller
q
None in particular
q
Intake air heater does not work in auto preheating (degraded starting performance at low temperature and emission of white smokes) Temperature sensed by boost temperature sensor can be checked by using monitoring function. (Code: 18500) Method of reproducing failure code: Turn starting switch to ON position (when boost temperature is below -4 °C) Troubleshooting for this failure code covers circuit starting from engine controller to primary circuit (coil) of preheater relay R18. For troubleshooting related to heater relay and secondary circuit of preheater relay R18, see E-2 in Troubleshooting [E-mode].
Problem on machine
q q
Related information
q q
Cause 1
Defective wiring harness connector
Procedure, measuring location, criteria and remarks See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "General information on troubleshooting", and check them directly. 1. Turn starting switch to OFF position. 2. Disconnect relay R18, and connect T-adapter to male side. Between R18 (male) (1) and (2)
2 Defective preheater relay R18
Resistance 200 – 400 z
1. Turn starting switch to OFF position. 2. Replace relay R18 with another one. 3. Turn starting switch to ON position. If this failure code disappears, original preheater relay R18 is defective.
1. Turn starting switch to OFF position. 2. Disconnect connector CE02, and connect T-adapter to female side. Open or short circuit in wiring har3 Between CE02 (female) (40) and (42) ness a Resistance of preheater relay R18 coil resist- Resistance 200 – 400 z ance a If no failure is found by checks on cause 3, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connector CE02 and relay R18, and connect T-adapter to each female side. 4 Open circuit in wiring harness Between CE02 (female) (40) and R18 (female) (1) Resistance Max. 1 z Between R18 (female) (2) and CE02 (42)
Resistance
Max. 1 z
5 Short circuit in wiring harness
1. Turn starting switch to OFF position. 2. Disconnect connector CE02 and relay R18, and connect T-adapter to female side of CE02. a Check by using multimeter in continuity mode. Between CE02 (female) (40) and each pin other No continuity than (40) (No sound is heard)
6 Defective engine controller
If no failure is found by above checks, engine controller is defective. (Since this is internal failure, troubleshooting cannot be performed.)
40-196
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [CA2555] Grid Htr Relay Open Circuit Error
Circuit diagram related to intake air heater relay
PC228US-8,PC228USLC-8
40-197
40-197
Troubleshooting by failure code Failure code [CA2556] Grid Htr Relay Short Circuit Error
Failure code [CA2556] Grid Htr Relay Short Circuit Error User code
Failure code Failure
E0E
CA2556
Intake air heater relay short circuit (Engine controller system)
Detail of failure q
Short circuit is detected in drive circuit (primary circuit) of preheater relay.
Action of controller
q
None in particular
q
Intake air heater does not work in auto preheating (degraded starting performance at low temperature and emission of white smokes) Temperature sensed by boost temperature sensor can be checked by using monitoring function. (Code: 18500 ) Method of reproducing failure code: Turn starting switch to ON position (when boost temperature is below -4 °C) Troubleshooting for this failure code covers circuit starting from engine controller to primary circuit (coil) of preheater relay R18. For troubleshooting related to heater relay and secondary circuit of preheater relay R18, see E-2 in Troubleshooting [E-mode].
Problem on machine
q q
Related information
q q
Cause 1
Defective wiring harness connector
Procedure, measuring location, criteria and remarks See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "General information on troubleshooting", and check them directly. 1. Turn starting switch to OFF position. 2. Disconnect relay R18, and connect T-adapter to male side. Between R18 (male) (1) and (2)
2 Defective preheater relay R18
Resistance 200 – 400 z
1. Turn starting switch to OFF position. 2. Replace relay R18 with another one. 3. Turn starting switch to ON position. If this failure code disappears, original preheater relay R18 is defective.
3 Ground fault in wiring harness
4 Short circuit in wiring harness
5 Defective engine controller
40-198
1. Turn starting switch to OFF position. 2. Disconnect connector CE02 and relay R18, and connect T-adapter to female side of either connector. Between CE02 (female) (40) or R18 (female) (1) Resistance Min. 1 Mz and ground 1. Turn starting switch to OFF position. 2. Disconnect connector CE02 and relay R18, and connect T-adapter to female side of CE02. a Check by using multimeter in continuity mode. Between CE02 (female) (40) and each pin other No continuity than (40) (No sound is heard) If no failure is found by above checks, engine controller is defective. (Since this is internal failure, troubleshooting cannot be performed.)
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [CA2556] Grid Htr Relay Short Circuit Error
Circuit diagram related to intake air heater relay
PC228US-8,PC228USLC-8
40-19
40-199
Troubleshooting by failure code Failure code [D110KB] Battery Relay Drive Short Circuit
Failure code [D110KB] Battery Relay Drive Short Circuit User code
Failure code Failure
–
D110KB
Detail of failure q Action of controller Problem on machine
Related information
q
Abnormal current flows when outputting 24 V to battery relay primary circuit (coil side).
q
Stops 24 V output to battery relay primary circuit (coil side). Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position.
q
Machine may have a trouble in writing data into ROM (non-volatile memory) of each controller.
q
As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be measured at pump controller connector. Output (ON/OFF) to battery relay can be checked by using monitoring function. (Code: 03700 Controller output 1) Method of reproducing failure code: During 0.5 second after turning starting switch from ON to OFF position
q q
Cause 1
Battery relay output system short circuit (Pump controller system)
Defective battery relay (internal short circuit)
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. Between terminal RE and terminal BR
Continuity
1. Turn starting switch to OFF position. 2. Disconnect negative battery cable (in order not to make short circuit). 3. Disconnect connector R01, terminal R02, and connectors D01, H15 and C02. 2
Ground fault of wiring harness (contact with ground circuit)
3 Defective pump controller
Between terminal R02 (BR) and ground
Min. 1 Mz
Between any of terminal R02 (harness side), D01 Resistance Min. 1 Mz (female) (1) or (2) and ground Between C02 (female) (108) or D01 (female) (5) Resistance Min. 1 Mz and ground If no failure is found by above checks, pump controller is defective. q Reference 1. Turn starting switch to OFF position. 2. Insert T-adapter in connector D01. 3. Turn starting switch to ON position. 4. Measure voltage during 4 to 7seconds after turning starting switch from ON to OFF position Between D01 (5) and ground
40-200
Resistance
Voltage
20 – 30 V
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [D110KB] Battery Relay Drive Short Circuit
Circuit diagram related to battery relay
PC228US-8,PC228USLC-8
40-201
40-201
Troubleshooting by failure code Failure code [D19JKZ] Personal Code Relay Abnormality
Failure code [D19JKZ] Personal Code Relay Abnormality User code
Failure code Failure
E01
D19JKZ
Detail of failure q q q Action of machine moni- q q tor
Personal code relay malfunction (KOMTRAX system in machine monitor)
Open circuit error or short circuit error is detected in primary (coil) circuit of personal code relay. None in particular (for open circuit error) Stops output to personal code relay (for short circuit error). If cause of failure disappears, machine becomes normal by itself (for open circuit error). Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position (when short circuit is detected).
Problem on machine q
Related information
q q
This failure code may be generated only when engine lock function is enabled. Method of reproducing failure code: Turn starting switch to ON position (for open circuit error). Failure code cannot be reproduced (for short circuit error). Troubleshooting for this failure code covers circuit starting from No. 3 of fuse F01, through primary (coil) circuit of personal code relay R07, to machine monitor.
Cause 1 Blown No. 3 of fuse F01
Procedure, measuring location, criteria and remarks When fuse is blown, ground fault may have probably occurred in circuit. 1. Turn starting switch to OFF position. 2. Disconnect relay R07, and connect T-adapter to male side.
Between R07 (male) (1) and (2) Resistance 100 – 500 z 2 Defective personal code relay R07 1. Turn starting switch to OFF position. 2. Replace relay R07 with another one. 3. Turn starting switch to ON position. If this failure code disappears, original personal code relay R07 is defective. 1. Turn starting switch to OFF position. 2. Remove fuse No. 3 of fuse box F01. Open circuit short circuit or ground 3. Disconnect connector CM01 and connect T-adapter to female side. 3 fault in wiring harness Between F01-3 and CM01 (female) (6) Resistance 100 – 500 z
4 Open circuit in wiring harness
Between F01-3 or CM01 (female) (6) and ground Resistance Min. 1 Mz a If no failure is found by checks on cause 3, this check is not required. 1. Turn starting switch to OFF position. 2. Remove fuse No. 3 of fuse box F01. 3. Disconnect connector CM01 and relay R07, and connect T-adapters to each female side. Between F01-3 and R07 (female) (1) Resistance Max. 1 z
Between R07 (female) (2) and CM01 (female) (6) Resistance Max. 1 z a If no failure is found by checks on cause 3, this check is not required. 1. Turn starting switch to OFF position. 2. Remove fuse No. 3 of fuse box F01. 3. Disconnect connector CM01 and relay R07, and connect T-adapter to 5 Ground fault in wiring harness female side of either one. Between F01-3 or R07 (female) (1) and ground Resistance Min. 1 Mz Between R07 (female) (2) or CM01 (female) (6) Resistance Min. 1 Mz and ground 1. Turn starting switch to OFF position. 2. Remove fuse No. 3 of fuse box F01. 3. Disconnect connectors CM01 and relay R07, and connect T-adapter to female side of connector CM01. 6 Short circuit in wiring harness a Check by using multimeter in continuity mode. Between CM01 (female) (6) and each pin other No continuity than pin (6) (No sound is heard) If no failure is found by the above checks, machine monitor (KOMTRAX secDefective machine monitor (KOM7 tion) is defective. (Since this is internal failure, troubleshooting cannot be perTRAX section) formed.)
40-202
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [D19JKZ] Personal Code Relay Abnormality
Circuit diagram related to personal code relay
PC228US-8,PC228USLC-8
40-203
40-203
Troubleshooting by failure code Failure code [D862KA] GPS Antenna Open Circuit
Failure code [D862KA] GPS Antenna Open Circuit User code
Failure code Failure
—
D862KA
Detail of failure q Action of q machine moniq tor Problem on q machine Related inforq mation
1
GPS antenna open circuit (KOMTRAX system in machine monitor)
Open circuit is detected in GPS antenna circuit. None in particular If cause of failure disappears, machine becomes normal by itself. GPS positioning cannot work. Method of reproducing failure code: Turn starting switch to ON position.
Cause
Procedure, measuring location, criteria and remarks
Defective GPS antenna or antenna cable
Probable causes are defective GPS antenna, open circuit or short circuit in antenna cable, and defective connection of antenna cable connector (GPS).
Structural illustration
40-204
40-204
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [D862KA] GPS Antenna Open Circuit
PC228US-8,PC228USLC-8
40-205
Troubleshooting by failure code Failure code [DA22KK] Pump Solenoid Power Low Error
Failure code [DA22KK] Pump Solenoid Power Low Error User code
Failure code Failure
E0E
DA22KK
Detail of failure q Action of controller Problem on machine Related information
q
Solenoid power supply voltage of controller is below 20 V.
q
Stops generation of failure codes (open circuit and short circuit) for all solenoid systems while this failure code is active. If cause of failure disappears, machine becomes normal by itself.
q
No solenoid valve is driven properly, so machine does not work properly.
q
As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be measured at pump controller connector. If failure code D110KB] is displayed, troubleshoot it first. Method of reproducing failure code: Turn starting switch to ON position.
q q
1
Pump solenoid power supply voltage low error (input) (Pump controller system)
Cause
Procedure, measuring location, criteria and remarks
Defective fusible link F04 or fuse No. 2 of fuse box F01
If fusible link or fuse is blown, circuit probably has ground fault. (See Cause 5.)
2 Improper battery voltage
1. Turn starting switch to OFF position. 2. After measuring voltage, measure it again when starting engine. Between battery (+) and ground
3 Defective wiring harness
4 Open circuit in wiring harness
5
Ground fault in wiring harness (contact with ground circuit)
40-206
20 – 30 V
1. Turn starting switch to OFF position and disconnect battery ground cable. 2. Disconnect connector C02 and connect T-adapter to female side. 3. Connect battery ground cable and turn starting switch to ON position. Between each of (116), (118) and (121) of C02 and Voltage 20 – 30 V ground a If no failure is found by checks on cause 3, this check is not required. 1. Turn starting switch to OFF position and disconnect battery ground cable. 2. Remove fusible link F02 and fuse (2) in fuse box F01. 3. Disconnect connector C02 and connect T-adapter to female side. Between each of (116), (118) and (121) of C02 Resistance Max. 1 z (female) and F01-2 Between F01-1A and F04 (male) (2)
Resistance
Max. 1 z
Between F04 (male) (1) and terminal R03
Resistance
Max. 1 z
a If no failure is found by checks on cause 3, this check is not required. 1. Turn starting switch to OFF position and disconnect battery ground cable. 2. Remove fusible link F04 and fuse No. 2 of fuse box F01. 3. Disconnect connector C02 and connect T-adapter to female side. Between each of (116), (118) and (121) of C02 Resistance Min. 1 Mz (female) or F01-2 and ground Between F01-1A or F04 (male) (2) and ground
6 Defective pump controller
Voltage
Resistance
Min. 1 Mz
Between F04 (male) (1) or terminal R03 and ground Resistance
Min. 1 Mz
If no failure is found by above checks, pump controller is defective. (Since this is internal failure, troubleshooting cannot be performed.)
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [DA22KK] Pump Solenoid Power Low Error
Circuit diagram related to solenoid power supply
PC228US-8,PC228USLC-8
40-207
40-207
Troubleshooting by failure code Failure code [DA25KP] 5V Sensor1 Power Abnormality
Failure code [DA25KP] 5V Sensor1 Power Abnormality User code
Failure code Failure
–
DA25KP
Detail of failure q Action of controller Problem on machine Related information
q q q q q q
5 V sensor power supply output 1 circuit defective (Pump controller system)
Voltage of 5 V sensor power supply output 1 circuit is below 2.5 V or above 6.0 V. Stops output from 5 V sensor power supply output 1 circuit. Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position. Automatic travel speed selector function does not work (pump pressure sensor system). Auto-decelerator keeps working and is not cancelled or fine control performance of work equipment is lowered (PPC pressure sensor system). As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be measured at pump controller connector. Method of reproducing failure code: Turn starting switch to ON position.
Cause
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect following sensors one by one, and turn starting switch to ON position for each troubleshooting. a If this failure code disappears, disconnected sensor is defective. 3. After each troubleshooting, turn starting switch to OFF position.
1
2
Defective pressure sensor (internal short circuit)
Hot short circuit in wiring harness (contact with 24 V circuit)
Sensor
Connector
Bucket CURL PPC pressure sensor
P01
Bucket DUMP PPC pressure sensor
P05
Arm IN pressure sensor
P04
Boom RAISE PPC pressure sensor
P06
Swing RIGHT PPC pressure sensor
P07
Swing LEFT PPC pressure sensor
P03
F Pump pressure sensor
P25
R Pump pressure sensor
P26
R.H. travel FORWARD PPC pressure sensor
P09
R.H. travel REVERSE PPC pressure sensor
P27
L.H. travel FORWARD PPC pressure sensor
P10
L.H. travel REVERSE PPC pressure sensor
P28
a Measure voltage before controller stops output. 1. Turn starting switch to OFF position. 2. Disconnect connectors P01, P03 to P07, P09, P10 and P25 to P28. 3. Connect T-adapter to female side of either of disconnected connectors (e.g. P07). 4. Turn starting switch to ON position (with connectors P01, P03 to P07, P09, P10 and P25 to P28 disconnected). Between P07 (female) (3) and ground
Ground fault in wiring harness 3 (contact with ground circuit) 4 Defective pump controller
40-208
Voltage
4.5 – 5.5 V
1. Turn starting switch to OFF position. 2. Disconnect connectors C01, P01, P03 to P07, P09, P10 and P25 to P28. 3. Connect T-adapter to female side of connector C01. Between C01 (female) (9) and ground Resistance Min. 1 Mz If no failure is found by above checks, pump controller is defective. (Since this internal failure, troubleshooting cannot be performed.)
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [DA25KP] 5V Sensor1 Power Abnormality
Circuit diagram related to 5 V sensor power supply 1 circuit
PC228US-8,PC228USLC-8
40-209
40-209
Troubleshooting by failure code Failure code [DA26KP] 5V Sensor2 Power Abnormality
Failure code [DA26KP] 5V Sensor2 Power Abnormality User code
Failure code Failure
–
DA26KP
Detail of failure q Action of controller Problem on machine Related information
q
Voltage of 5 V sensor power supply output 2 circuit is below 2.5 V or above 6.0 V.
q
Stops output from 5 V sensor power supply output 2 circuit. Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position.
q
All overload alarm functions do not operate normally (for overload specification machine).
q
As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be measured at pump controller connector. Method of reproducing failure code: Turn starting switch to ON position.
q
Cause
1
2
5 V sensor power supply output 2 circuit defective (Pump controller system)
Defective pressure sensor (internal short circuit)
Hot short circuit in wiring harness (contact with 24 V circuit)
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect following sensors one by one, and turn starting switch to ON position for each troubleshooting. a If this failure code disappears, disconnected sensor is defective. 3. After each troubleshooting, turn starting switch to OFF position. Sensor
Connector
Boom angle potentiometer
A53
Boom cylinder bottom pressure sensor *
Y09*
a Measure voltage before controller stops output. 1. Turn starting switch to OFF position. 2. Disconnect connectors A53 and Y09*. 3. Connect T-adapter to female side of connector A53. 4. Turn starting switch to ON position (with connectors A53 and Y09* disconnected). Between A53 (female) (C) and ground
3
Ground fault in wiring harness (contact with ground circuit)
Voltage
4.5 – 5.5 V
1. Turn starting switch to OFF position. 2. Disconnect connectors C01, A53, and Y09*. 3. Connect T-adapter to female side of connector C01. Between C01 (female) (8) and ground
Resistance
Min. 1 Mz
If no failure is found by above checks, pump controller is defective. (Since this internal failure, troubleshooting cannot be performed.) *: Connector Y09 is installed to only machine with overload alarm specification. 4 Defective pump controller
40-210
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [DA26KP] 5V Sensor2 Power Abnormality
Circuit diagram related to 5 V sensor power supply 2 circuit (Standard specification)
PC228US-8,PC228USLC-8
40-21
40-211
Troubleshooting by failure code Failure code [DA26KP] 5V Sensor2 Power Abnormality
Circuit diagram related to 5 V sensor power supply 2 circuit (Overload alarm specification machine) 40-212
40-212
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [DA26KP] 5V Sensor2 Power Abnormality
PC228US-8,PC228USLC-8
40-213
Troubleshooting by failure code Failure code [DA29KQ] Model Selection Abnormality
Failure code [DA29KQ] Model Selection Abnormality User code
Failure code Failure
—
DA29KQ
Detail of failure q Action of controller Problem on machine Related information
q
Model selection error (Pump controller system)
Model code of input signal is not registered in controller.
q
Controls machine, taking it that machine is default model (PC228). Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position.
q
Because pump controller recognizes machine as "PC228", no particular problem occurs.
q
Model code input to pump controller can be checked by using monitoring function. (Code: 00200 Controller model code) Condition of model selection signal can be checked by using monitoring function. (Code: 02201 Switch Input 2) Method of reproducing failure code: Turn starting switch to ON position.
q q
Cause
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector S30 and connect T-adapter to female side.
Between S30 (female) (1) and (2) Defective model selection connecBetween S30 (female) (3) and (4) 1 tor (Internal open circuit or short circuit) Between S30 (female) (7) and (8)
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Between S30 (female) (2) and (8)
Resistance
Max. 1 z
Between S30 (female) (3) and (8)
Resistance
Max. 1 z
1. Turn starting switch to OFF position. 2. Disconnect connector C01 and connect T-adapter to female side. 2 Open circuit in wiring harness
Between C01 (female) (21) and ground
Resistance
Max. 1 z
Between C01 (female) (77) and ground
Resistance
Max. 1 z
1. Turn starting switch to OFF position. 2. Disconnect connector C01 and connect T-adapter to female side. 3 Short circuit in wiring harness
Between C01 (female) (39) and C01 (21)
Resistance
Min. 1 Mz
Between C01 (female) (40) and C01 (21)
Resistance
Min. 1 Mz
Between C01 (female) (58) and C01 (21)
Resistance
Min. 1 Mz
1. Turn starting switch to OFF position. 2. Disconnect connector C01 and connect T-adapter to female side. 4
Ground fault in wiring harness (contact with ground circuit)
5 Defective pump controller
40-214
Between C01 (female) (40) and ground
Resistance
Min. 1 Mz
Between C01 (female) (58) and ground
Resistance
Min. 1 Mz
Between C01 (female) (39) and ground
Resistance
Min. 1 Mz
If no failure is found by above checks, pump controller is defective. (Since this is internal failure, troubleshooting cannot be performed.)
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [DA29KQ] Model Selection Abnormality
Circuit diagram related to model selection signal
PC228US-8,PC228USLC-8
40-215
40-215
Troubleshooting by failure code Failure code [DA29KQ] Model Selection Abnormality
40-216
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [DA2RMC] CAN Discon (Pump Con Detected)
Failure code [DA2RMC] CAN Discon (Pump Con Detected) User code
Failure code
E0E
Failure
CAN communication disabled (detected by pump controller) (Pump controller system)
DA2RMC q Pump controller has failed CAN communication with machine monitor or engine controller. Detail of failure 1) CAN communication line or ACC line of starting switch is abnormal. q Fixes engine output to that of P mode to limit pump absorption torque to certain value. Action of con- q Continues to control machine by using information obtained through CAN communication just before detection of error. troller q If cause of failure disappears, machine becomes normal by itself. q Engine output lowers. (Pump absorption torque decreases.) q If actuator load increases, engine may stall. Problem on q Information may not be transmitted normally through CAN communication lines and machine may machine not operate normally. (Failure symptom depends on failed section.) q Method of reproducing failure code: Turn starting switch to ON position. q Start of CAN communication is recognized by each controller when ACC signal of starting switch is received. q Failure code is sent to machine monitor through CAN communication. Accordingly, if failure code [DA2RMC] is displayed on machine monitor, CAN communication between pump controller and machine monitor is normal. That is, there can not be short circuit, ground fault or hot short circuit in CAN communication line. Related infor- q Since air conditioner is also controlled via CAN communication, check whether you can control air conditioner (such as power on/off and air flow rate control) on "Air conditioner" screen.) (air condimation tioner can be controlled even if failure code [DA2RMC] is displayed.) q If failure code [DAFRMC] is also displayed, engine controller may be defective. q If failure code [DY20KA], [DY20MA] or [DW43KA] is displayed, pump controller may be defective. q Since each controller and machine monitor are connected to battery directly, they receive unswitched power even while starting switch is at OFF position. q Since signal of active CAN communication line is pulse voltage, it cannot be measured by using multimeter. Cause
1 Blown fuse F01-18 or 20
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Remove fuses F01-18 (30 A fuse) and F01-20 (5 A fuse). a If fuse is blown, controller may have internal short circuit.
2
Defective engine controller (internal short circuit)
a If fuse is not blown, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connector CE03, and connect T-adapter to male side. a If measured resistance is below 10 z, engine controller is defective (internal short circuit). Between CE03 (male) (3) and (1)
3
Improper power supply to engine controller
Resistance
Min. 10 z
a Check ground terminal T12 for looseness and rust. 1. Turn starting switch to OFF position. 2. Disconnect connector CE03, and connect T-adapter to female side. a If fuse F01-18 is blown, replace it. 3. Turn starting switch to ON position. Between CE03 (female) (3) and (1)
Voltage
20 – 30 V
a If abnormality is found, perform troubleshooting for Detail of failure 2) "Engine controller power supply circuit is defective." 1. Turn starting switch to OFF position. 2. Disconnect connectors K02 and CM02, and connect T-adapter to each Defective CAN terminating resistor male side. 4 (open or short circuit in internal Between K02 (male) (A) and (B) Resistance 120 ± 12 z wiring) Between CM02 (male) (8) and (10)
PC228US-8,PC228USLC-8
Resistance 120 ± 12 z
40-217
Troubleshooting by failure code Failure code [DA2RMC] CAN Discon (Pump Con Detected)
Cause
Procedure, measuring location, criteria and remarks CAN communication line a CAN terminating resistor of 120 z is also installed inside machine monitor. Since 120 z resistors are connected in parallel, if combined resistance measured at connector of controller other than machine monitor is 60 z, CAN communication line has no open circuit. 1. Turn starting switch to OFF position and disconnect ground cable. 2. Disconnect connectors CE02, C01, N10, K02 and CM02 one by one, and connect T-adapter to female side of connector disconnected. a If short circuit occurs (if resistance between terminals is 1 z or less), disconnect all of connectors CE02, C01, N10, K02 and CM02. Then, check Open or short circuit in wiring harwhether failure is short circuit between wiring harnesses or within control5 ness ler. Approx. Between CE02 (female) (46) and (47) Resistance 60 z Approx. Between C01 (female) (45) and (64) Resistance 60 z Approx. Between N10 (female) (1) and (2) Resistance 60 z Approx. Between K02 (female) (A) and (B) Resistance 120 z Approx. Between CM02 (female) (9) and (10) Resistance 120 z a If no failure is found by checks on cause 5 , this check is not required. 1. Turn starting switch to OFF position and disconnect ground cable. 2. Disconnect connectors CE02, C01, N10, K02 and CM02, and connect T-adapter to each female side. Between C01 (female) (45) and each of CM02 Resistance Max. 1 z (female) (9) and (8). q
Open circuit in wiring harness 6 (Wire breakage or defective contact of connector)
7 Defective engine controller
40-218
Between C01 (female) (64) and CM02 (female) (10) Resistance
Max. 1 z
Between C01 (female)( 45) and CE02 (female) (46) Resistance
Max. 1 z
Between C01 (female) (64) and CE02 (female) (47) Resistance
Max. 1 z
Between C01 (female) (45) and N10 (female) (1)
Resistance
Max. 1 z
Between C01 (female) (64) and N10 (female) (2)
Resistance
Max. 1 z
Between CE02 (female) (46) and K02 (female) (A)
Resistance
Max. 1 z
Between CE02 (female) (47) and K02 (female) (B)
Resistance
Max. 1 z
q ACC signal from starting switch 1. Turn starting switch to OFF position and disconnect ground cable. 2. Insert T-adapters into connectors CE02, C01 and CM01. 3. Connect battery ground cable and turn starting switch to ON position.
Between CE02 (39) and ground
Voltage
20 – 30 V
Between each of C01 (24), (43) and (79) and C01 (2)
Voltage
20 – 30 V
Between CM01 (14) and (3)
Voltage
20 – 30 V
a If no failure is found by above checks, this check is not required. 1. Turn starting switch to OFF position and disconnect ground cable. 2. Disconnect connectors CE02, COL and CM01 one by one, and connect T-adapter to connector disconnected. Between starting switch (ACC) and each of C01 Resistance Max. 1 z (female) (24), (43) and (79). Between starting switch (ACC) and CM01 (female) Resistance Max. 1 z (14) Between starting switch (ACC) and CE02 (female) Resistance Max. 1 z (45) If no failure is found by above checks and if failure code [DAFRMC] is also displayed on machine monitor, engine controller is defective. (Since this is an internal failure, troubleshooting cannot be performed.)
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [DA2RMC] CAN Discon (Pump Con Detected)
Cause 8 Defective pump controller
Procedure, measuring location, criteria and remarks If no failure is found by above checks, pump controller is defective. (Since this is an internal failure, troubleshooting cannot be performed.)
Circuit diagram related to CAN communication line
PC228US-8,PC228USLC-8
40-219
40-219
Troubleshooting by failure code Failure code [DA2RMC] CAN Discon (Pump Con Detected)
Detail of failure
2) Engine controller power supply circuit is defective.
Cause
Procedure, measuring location, criteria and remarks
1 Loose or corroded battery terminal Battery terminal may be loosened or corroded. Check it directly. 2 Defective fuse F01-19 3
Remove fuse F01-19 (30 A fuse). a If fuse is blown, controller may have internal short circuit.
Defective wiring harness connector
4 Improper battery voltage
1. Turn starting switch to OFF position. 2. Perform troubleshooting with starting switch at OFF position and at engine cranking. Between battery (2 pieces) terminal (+) and (-)
Voltage
20 – 30 V
1. Turn starting switch to OFF position. 2. Exchange relays (R23 and R24 one by one) for engine controller power Defective relays (R23 and R24) for supply with other relays. 5 engine controller power supply 3. Turn starting switch to ON position. If this failure code disappears, original relay is defective. 1. Turn starting switch to OFF position. 2. Remove diode arrays D10 and D11 and connect T-adapters to each male side. a Measure by using multimeter in diode range. 6 Defective diode D10 and D11
Open circuit in wiring harness 7 (wire breakage or defective contact of connector)
Between D10 (male) (2) (+) and (1) (-)
Continuity
Between D10 (male) (1) (+) and (2) (-)
No continuity
Between D11 (male) (2) (+) and (1) (-)
Continuity
Between D11 (male) (1) (+) and (2) (-)
No continuity
1. Turn starting switch to OFF position. 2. Remove fuse F01-19 (30 A fuse). 3. Disconnect connectors each of R23, R24, CE02, CE03, D10 and D11, and connect T-adapters to each female side. Between F01-19 and each of R23 (female) (1) and Resistance Max. 1 z R24 (female) (3) Between each of R23 (female) (5) and R24 (female) Resistance Max. 1 z (5) and CE03 (female) (3) Between CE03 (female) (1) and ground (T12) Resistance Max. 1 z a Corroded or loosened ground terminal (T12) Between CE02 (female) (33) and each of R23 Resistance Max. 1 z (female) ( 2) and R24 (female) (2) Between each of R23 (female) (1) and R24 (female) (1) and each of D10 (female) (1) and D11 (female) Resistance Max. 1 z (1) Between battery relay R04 and each of R23 Resistance Max. 1 z (female) (3) and R24 (female) (3) Between CE02 (female) (49) and D11 (female) (2)
8
Ground fault in wiring harness (contact with ground circuit)
40-220
Resistance
Max. 1 z
1. Turn starting switch to OFF position and disconnect ground cable from battery. 2. Remove fuse F01-19 (30 A fuse). 3. Disconnect connectors R23, R24, CE02 and CE03, and connect T-adapter to female side of either one of them. Between any of F01-19 ,R23 (female) (3) or R24 Resistance Min. 1 Mz (female) (3) and ground Between any of R23 (female) (5), R24 (female) (5) Resistance Min. 1 Mz or CE03 (female) (3) and ground
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [DA2RMC] CAN Discon (Pump Con Detected)
Cause
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position and disconnect ground cable from battery. 2. Disconnect connectors CE02 and CE03, and connect T-adapters to each female side.
9 Short circuit in wiring harness
Between CE03 (female) (3) and (1) Between CE03 (female) (3) and CE02 (female) (each pin) Between CE03 (female) (1) and CE02 (female) (each pin)
Circuit diagram related to engine controller power supply
PC228US-8,PC228USLC-8
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
40-2 1
40-221
Troubleshooting by failure code Failure code [DAF8KB] Camera Power Supply Short Circuit
Failure code [DAF8KB] Camera Power Supply Short Circuit User code
Failure code Failure
– Detail of failure Action of machine monitor
DAF8KB q q q
Camera power supply short circuit (Machine monitor system)
Output power supply voltage (Rating: 8 V) from machine monitor to camera is below 6.0 V or above 10 V. Stops output of power supply voltage (Rating: 8 V) to camera. Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position.
Problem on machine
q
Camera image is not displayed on monitor screen.
Related information
q
Method of reproducing failure code: Turn starting switch to ON position.
Cause Defective camera (internal short 1 circuit)
2 Defective machine monitor
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect camera connector(s), and turn starting switch to ON position. Disconnect camera connectors and perform failure code reproducing procedure. If failure code disappears, camera is defective. 1. Turn starting switch to OFF position. 2. Disconnect connector CM05. 3. Connect T-adapter to male side of connector CM05. 4. Turn starting switch to ON position. Between CM05 (male) (1) and ground
Ground fault in wiring harness 3 (contact with ground circuit)
Voltage
6 – 10 V
1. Turn starting switch to OFF position. 2. Disconnect connector CM05 and camera connector(s). 3. Connect T-adapter to female side of connector CM05. Between CM05 (female) (1) and ground
Resistance
Min. 1 Mz
1. Turn starting switch to OFF position. 2. Disconnect camera connector(s). 3. Insert T-adapter into connector CM05. Hot short circuit in wiring harness 4. Turn starting switch to ON position. 4 (contact with 24 V circuit) (Disconnect camera connector(s) and check that camera is not defective in advance.) Between CM05 (1) and (7)
40-222
Voltage
Max. 10 V
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [DAF8KB] Camera Power Supply Short Circuit
Circuit diagram related to camera power supply
PC228US-8,PC228USLC-8
40-2 3
40-223
Troubleshooting by failure code Failure code [DAFGMC] GPS Module Error
Failure code [DAFGMC] GPS Module Error User code
Failure code Failure
–
DAFGMC
Detail of failure
q
Action of q machine moniq tor Problem on machine Related infor- q mation
GPS module error (KOMTRAX system in machine monitor)
Position data is not sent from GPS module (in machine monitor) to KOMTRAX communication modem in 50 seconds after KOMTRAX started. None in particular If cause of failure disappears, machine becomes normal by itself.
Method of reproducing failure code: Turn starting switch to ON position (At least 50 seconds after starting switch is turned to ON position).
Cause
Procedure, measuring location, criteria and remarks
1 Defective machine monitor
GPS module of machine monitor may be defective. (Since this is an internal failure, troubleshooting cannot be performed.)
40-224
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [DAFGMC] GPS Module Error
PC228US-8,PC228USLC-8
40-225
Troubleshooting by failure code Failure code [DAFRMC] CAN Discon (Monitor Detected)
Failure code [DAFRMC] CAN Discon (Monitor Detected) User code
Failure code Failure
E0E
DAFRMC
CAN communication disabled (detected by machine monitor) (Machine monitor system)
Detail of failure q
Machine monitor has failed CAN communication with pump controller or engine controller.
Action of machine moni- q tor
If cause of failure disappears, machine becomes normal by itself.
q
Problem on machine
q q
q q q
Related information q q q q
Engine output lowers. (Pump absorption torque decreases.) If actuator load increases, engine may stall. Information may not be transmitted normally through CAN communication lines and machine may not operate normally. (Failure symptom depends on failed section.) Method of reproducing failure code: Turn starting switch to ON position. Start of CAN communication is recognized by each controller when ACC signal of starting switch is received. Since air conditioner is also controlled via CAN communication, check whether you can control air conditioner (such as power ON/OFF and air flow rate control) on "Air conditioner "screen. (Air conditioner can be controlled even if failure code is displayed on monitor screen.) If air conditioner can be controlled, there is no possibility of ground fault or short circuit or hot short circuit in wiring harness (CAN communication line) If failure code [DA2RMC] is also displayed, engine controller may be defective. If failure code [DY20KA], [DY20MA] or [DW43KA] is displayed, pump controller may be defective. Since each controller and machine monitor are connected to battery directly, they receive unswitched power even while starting switch is at OFF position. Since signal of active CAN communication line is pulse voltage, it cannot be measured by using multimeter.
Cause
1 Blown fuse F01-18 or 20
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Remove fuses F01-18 (30 A fuse) and F01-20 (5 A fuse). a If fuse is blown, controller may have internal short circuit.
2
Defective engine controller (internal short circuit)
a If fuse is not blown, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connector CE03, and connect T-adapter to male side. a If measured resistance is below 10 z, engine controller is defective (internal short circuit). Between CE03 (male) (3) and (1)
3
Improper power supply to engine controller
Resistance
Min. 10 z
a Check ground terminal T12 for looseness and rust. 1. Turn starting switch to OFF position. 2. Disconnect connector CE03, and connect T-adapter to female side. a If fuse F01-18 is blown, replace it. 3. Turn starting switch to ON position. Between CE03 (female) (3) and (1)
Voltage
20 – 30 V
a If failure is found, perform troubleshooting for failure code [DA2RMC] (Detail of failure 2) "Engine controller power supply circuit is defective"). 1. Turn starting switch to OFF position. 2. Disconnect connectors K02 and CM02, and connect T-adapter to each male Defective CAN terminating resistor side. 4 (open or short circuit in internal Between K02 (male) (A) and (B) Resistance 120 ± 12 z wiring) Between CM02 (male) (8) and (10)
40-226
Resistance
120 ± 12 z
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [DAFRMC] CAN Discon (Monitor Detected)
Cause
Procedure, measuring location, criteria and remarks q
CAN communication line a CAN terminating resistor of 120 z is also installed inside machine monitor. Since 120 z resistors are connected in parallel, if combined resistance measured at connector of controller other than machine monitor is 60 z, CAN communication line has no open circuit. 1. Turn starting switch to OFF position and disconnect ground cable. 2. Disconnect connectors CE02, C01, N10, K02 and CM02 one by one, and connect T-adapter to female side of connector disconnected. a If short circuit occurs (if resistance between terminals is 1 z or less), disconOpen or short circuit in wiring har5 nect all of connectors CE02, C01, N10 ,K02 and CM02. Then, check whethness er failure is short circuit between wiring harnesses or within controller. Between CE02 (female) (46) and (47) Resistance Approx. 60 z Between C01 (female) (45) and (64)
Resistance
Approx. 60 z
Approx. 60 z Approx. Between K02 (female) (A) and (B) Resistance 120 z Approx. Between CM02 (female) (9) and (10) Resistance 120 z a If no failure is found by checks on cause 5 , this check is not required. 1. Turn starting switch to OFF position and disconnect ground cable. 2. Disconnect connectors CE02, C01, N10, K02 and CM02 one by one, and connect T-adapter to each female side. Between C01 (female) (45) and each of CM02 Resistance Max. 1 z (female) (9) and (8). Between C01 (female) (64) and CM02 (female) Resistance Max. 1 z (10) Between C01 (female)( 45) and CE02 (female) Resistance Max. 1 z (46) Between C01 (female) (64) and CE02 (female) Resistance Max. 1 z (47) Between C01 (female) (45) and N10 (female) (1) Resistance Max. 1 z Between N10 (female) (1) and (2)
Open circuit in wiring harness 6 (wire breakage or defective contact of connector)
PC228US-8,PC228USLC-8
Resistance
Between C01 (female) (64) and N10 (female) (2) Resistance Max. 1 z Between CE02 (female) (46) and K02 (female) Resistance Max. 1 z (A) Between CE02 (female) (47) and K02 (female) Resistance Max. 1 z (B) q ACC signal from starting switch 1. Turn starting switch to OFF position and disconnect ground cable. 2. Insert T-adapters into connectors CE02, C01 and CM01. 3. Connect battery ground cable and turn starting switch to ON position. Between CE02 (39) and ground Voltage 20 – 30 V Between each of C01 (24), (43) and (79) and C01 Voltage 20 – 30 V (2) Between CM01 (14) and (3) Voltage 20 – 30 V a If no failure is found by above checks, this check is not required. 1. Turn starting switch to OFF position and disconnect ground cable. 2. Disconnect connectors CE02, C01, N10, K02 and CM02 one by one, and connect T-adapter to each female side. Between starting switch (ACC) and each of C01 Resistance Max. 1 z (female) (24), (43) and (79). Between starting switch (ACC) and CM01 Resistance Max. 1 z (female) (14) Between starting switch (ACC) and CE02 Resistance Max. 1 z (female) (45)
40-227
Troubleshooting by failure code Failure code [DAFRMC] CAN Discon (Monitor Detected)
Cause
7
Ground fault in wiring harness (contact with ground circuit)
Short circuit or hot short circuit in 8 wiring harness (contact with 24 V circuit)
Procedure, measuring location, criteria and remarks a If failure code [DA2RMC] is displayed on machine monitor, or you can control air conditioner on " Air conditioner " screen, this check is not required. a If no failure is found by checks on cause 5 (no open circuit), measure resistance at one connector. Disconnect one of connectors CE02, C01, and CM02 and connect T-adapter to female side of connector disconnected. Between C01 (female) (45), CM02 (female) (8), Resistance Min. 1 Mz (9) or CE02 (female) (46) and ground Between C01 (64), CM02 (10) or CE02 (47) and Resistance Min. 1 Mz ground a If failure code [DA2RMC] is displayed on machine monitor, or you can control air conditioner on " Air conditioner " screen, this check is not required. a If no failure is found by checks on cause 5 (no open circuit), measure voltage at one connector. 1. Turn starting switch to OFF position and disconnect ground cable. 2. Insert T-adapter into connector CE02, C01 or CM02. 3. Connect ground cable. 4. Turn starting switch to ON position. a CAN_H and CAN_L lines are considered to be normal if their voltage are between 1 to 4 V although their normal voltage is 2.5 ± 1 V. Between C01 (45), CM02 (8), (9) or CE02 (46) Voltage 1–4V and ground Between C01 (64), CM02 (10) or CE02 (47) and ground
9 Defective engine controller
1–4V
If no failure is found by above checks and if failure code [DA2RMC] is also displayed, engine controller is defective. (Since this is internal failure, troubleshooting cannot be performed.) If no failure is found by above checks, and if failure code [DA2RMC] is not displayed or if air conditioner cannot be controlled, locate defective controller as follows. A. Procedure for judging by operation of air conditioner q Step 1 1. Turn starting switch to OFF position and disconnect ground cable. 2. Disconnect engine controller (connector CE02) and pump controller (connector C01). 3. Connect battery ground cable and turn starting switch to ON position. 4. Operate air conditioner. a If air conditioner can be controlled, go to step 2. NO
Defective air conditioner unit
YES
Either of removed controllers is defective
Can air conditioner be controlled?
10
Voltage
Defective engine controller, pump q Step 2 controller or air conditioner unit 1. Turn starting switch to OFF position and disconnect ground cable. 2. Disconnect either engine controller (connector CE02) or pump controller (connector C01). 3. Connect ground cable, turn starting switch to ON position and perform troubleshooting. 4. Return to Step 1, to troubleshoot other controller. Removed controller is defecCan air conditioner be controlled? YES tive B. Procedure for judging by display of failure code [DA2RMC] (When air conditioner is not installed) 1. Turn starting switch to OFF position and disconnect ground cable. 2. Disconnect engine controller (connector CE03). 3. Connect battery ground cable and turn starting switch to ON position. NO
Defective pump controller
YES
Defective engine controller
Is failure code [DA2RMC] displayed?
40-228
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [DAFRMC] CAN Discon (Monitor Detected)
Cause 11 Defective machine monitor
Procedure, measuring location, criteria and remarks If no failure is found by above checks, machine monitor is defective. (Since this is an internal failure, troubleshooting cannot be performed.)
Circuit diagram related to CAN communication line
PC228US-8,PC228USLC-8
40-2 9
40-229
Troubleshooting by failure code Failure code [DGH2KB] Hyd Oil Sensor Short
Failure code [DGH2KB] Hyd Oil Sensor Short User code
Failure code Failure
–
DGH2KB
Hydraulic oil temperature sensor short circuit (Pump controller system)
Detail of failure q
Signal voltage of hydraulic oil temperature sensor circuit is below 1 V and ground fault is detected.
Action of controller
q
If cause of failure disappears, machine becomes normal by itself.
q
While hydraulic oil temperature rises normally, indicator of hydraulic oil temperature gauge does not move from top of white range (bottom of green range). Signal voltage of hydraulic oil temperature sensor can be checked by using monitoring function. (Code: 04402: Hydraulic oil temperature sensor voltage) Method of reproducing failure code: Start engine.
Problem on machine Related information
q q
Cause
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector P22 and connect T-adapter to male side.
Defective hydraulic oil Between P22 (male) (1) and (2) temperature sensor 1 (internal open or short a Temperature-resistance characteristics of oil temperature sensor circuit) Between P22 (male) (2) and ground
10°C
Resistance
Approx. 90 kz
30°C
Resistance
Approx. 35 kz
80°C
Resistance
Approx. 6.5 kz
100°C
Resistance
Approx. 3.5 kz
Resistance
Min. 1 Mz
1. Turn starting switch to OFF position. 2. Disconnect connector P22 and connect T-adapter to female side. Open circuit, short cir- 3. Turn starting switch to ON position. cuit, ground fault or hot a If voltage is 0 V, wiring harness has open circuit, ground fault, or short circuit, and if 2 voltage is 24 V, wiring harness has hot short circuit. short circuit in wiring a Voltage of about 5 V is applied to temperature sensor signal lines through resistor in harness pump controller. Between P22 (female) (1) and (2)
Voltage
Approx. 5 V
1. Turn starting switch to OFF position. 2. Disconnect connector C01 and connect T-adapter to female side. a Use temperature-resistance characteristics table for troubleshooting on cause 1. Short circuit or ground a If resistance is above 1 Mz, wiring harness has open circuit. If resistance is below 1 z, 3 wiring harness has short circuit. fault in wiring harness
Ground fault in wiring 4 harness (contact with ground circuit)
5
Defective pump controller
40-230
Between C01 (female) (29) and (46)
Resistance
3.5 – 90 kz
Between C01 (female) (29) and ground
Resistance
Min. 1 Mz
a If no failure is found by checks cause 2, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors C01 and P22, and connect T-adapter to female side of either one. Between C01 (female) (29) and ground, or between Resistance Min. 1 Mz P22 (female) (2) and ground If no failure is found by above checks, pump controller is defective. (Since this is internal failure, troubleshooting cannot be performed.)
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [DGH2KB] Hyd Oil Sensor Short
Circuit diagram related to hydraulic oil temperature sensor
PC228US-8,PC228USLC-8
40-231
40-231
Troubleshooting by failure code Failure code [DHPAMA] Pump Press Sensor Abnormality
Failure code [DHPAMA] Pump Press Sensor Abnormality User code
Failure code
–
DHPAMA
Failure
Front pump pressure sensor malfunction (Pump controller system)
Detail of failure q
Signal voltage of front pump pressure sensor circuit is below 0.3 V or above 4.5 V.
Action of controller
q
Controls machine taking front pump pressure to be 0 MPa {0 kg/cm2}. If cause of failure disappears, machine becomes normal by itself.
Problem on machine
q
q
Automatic travel speed selector function does not work. Straight travel performance or steering performance lowers. a If 5 V circuit (3) and ground circuit (1) of pressure sensor are connected to reverse polarities, pressure sensor is damaged. Accordingly, take extreme care when checking. q As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be Related informeasured at pump controller connector. mation q Front pump pressure can be checked by using monitoring function. (Code: 01100 F pump pressure). q Method of reproducing failure code: Turn starting switch to ON position or start engine. q
Cause
Procedure, measuring location, criteria and remarks If failure code [DA25KP] is also displayed, perform troubleshooting for it first.
1. Turn starting switch to OFF position. Defective 5V sensor power supply 2. Disconnect connector P25, and connect T-adapter to female side. 1 system 3. Turn starting switch to ON position. a If power supply voltage is unusual, proceed to cause 3. Power supBetween P25 (female) (3) and (1) Voltage 4.5 – 5.5 V ply 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector P25. 3. Turn starting switch to ON position. Sensor outBetween P25 (2) and (1) Voltage 0.5 – 4.5 V put a If power supply voltage is normal and sensor output voltage is unusual, it is difficult to judge whether cause is defective sensor, ground fault or hot short Defective front pump pressure circuit in harness. Check as follows. 2 sensor (internal failure) 1. Turn starting switch to OFF position. 2. Replace connector P25 with connector P26 of R pump PPC pressure sensor. 3. Turn starting switch to ON position and display "Abnormality Record" screen of electrical system on machine monitor. 4. If E mark is not displayed for this failure code, front pump pressure sensor is defective. a After finishing test, return connectors as they were. 1. Turn starting switch to OFF position. 2. Disconnect connectors C01 and P25, and connect T-adapters to each female side. a If power supply voltage in checks 1 is normal, Open circuit in wiring harness this check is not required. Resistance Max. 1 z 3 (Wire breakage or defective con- Between C01 (female) (18) and P25 (female) (1) tact of connector) Between C01 (female) (49) and P25 (female) (2) Resistance Max. 1 z 1
4
Ground fault in wiring harness (contact with ground circuit)
40-232
a If power supply voltage in checks 1 is normal, this check is not required. Resistance Max. 1 z Between C01 (female) (9) and P25 (female) (3) 1. Turn starting switch to OFF position. 2. Disconnect connectors C01 and P25, and connect T-adapter to female side of either connector. Between C01 (female) (49) or P25 (female) (2) and Resistance Min. 1 Mz ground
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [DHPAMA] Pump Press Sensor Abnormality
Cause
Procedure, measuring location, criteria and remarks
1. 2. Hot short circuit in wiring harness 3. 5 (short to 5 V or 24 V circuit) 4.
Turn starting switch to OFF position. Disconnect connector P25. Connect T-adapter to female side of connector P25. Turn starting switch to ON position.
Between P25 (female) (2) and ground 6 Defective pump controller
Max. 1 V
If no failure is found by above checks, pump controller is defective. (Since this is internal failure, troubleshooting cannot be performed.)
Circuit diagram related to front pump pressure sensor
PC228US-8,PC228USLC-8
Voltage
40-23
40-233
Troubleshooting by failure code Failure code [DHPBMA] R Pump Press Sensor Abnormality
Failure code [DHPBMA] R Pump Press Sensor Abnormality User code
Failure code Failure
–
DHPAMA
Rear pump pressure sensor malfunction (Pump controller system)
Detail of failure q
Signal voltage of rear pump pressure sensor circuit is below 0.3 V or above 4.5 V.
Action of controller
Controls machine taking rear pump pressure to be 0 MPa {0 kg/cm2}. If cause of failure disappears, machine becomes normal by itself.
q q q
Automatic travel speed selector function does not work. Straight travel performance or steering performance lowers. a If 5 V circuit (3) and ground circuit (1) of pressure sensor are connected to reverse polarities, pressure sensor is damaged. Accordingly, take extreme care when checking. q As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be Related informeasured at pump controller connector. mation q Rear pump pressure can be checked by using monitoring function. (Code: 01101 R pump pressure) q Method of reproducing failure code: Turn starting switch to ON position or start engine. Problem on machine
q
Cause
Procedure, measuring location, criteria and remarks If failure code [DA25KP] is also displayed, perform troubleshooting for it first.
1. Turn starting switch to OFF position. Defective 5V sensor power supply 2. Disconnect connector P25, and connect T-adapter to female side. 1 system 3. Turn starting switch to ON position. a If power supply voltage is unusual, proceed to cause 3. Power supBetween P26 (female) (3) and (1) Voltage 4.5 – 5.5 V ply 1. Turn starting switch to OFF position. 2. Connect T-adapter to connector P26. 3. Turn starting switch to ON position. Sensor outBetween P26 (2) and (1) Voltage 0.5 – 4.5 V put a If power supply voltage is normal and sensor output voltage is unusual, it is difficult to judge whether cause is defective sensor, ground fault or hot short Defective rear pump pressure sencircuit in harness. Check as follows. 2 sor (internal defect) 1. Turn starting switch to OFF position. 2. Replace connector P26 with connector P25 of front pump PPC pressure sensor. 3. Turn starting switch to ON position and display "Abnormality Record" screen of electrical system on machine monitor. 4. If E mark is not displayed for this failure code, rear pump pressure sensor is defective. a After finishing test, return connectors as they were. 1. Turn starting switch to OFF position. 2. Disconnect connectors C01 and P26, and connect T-adapters to female sides of them. a If power supply voltage in checks 1 is normal, Open circuit in wiring harness this check is not required. Resistance Max. 1 z 3 (Wire breakage or defective con- Between C01 (female) (18) and P26 (female) (1) tact of connector) Between C01 (female) (68) and P26 (female) (2) Resistance Max. 1 z 1
4
Ground fault in wiring harness (contact with ground circuit)
40-234
a If power supply voltage in checks 1 is normal, this check is not required. Resistance Max. 1 z Between C01 (female) (9) and P26 (female) (3) 1. Turn starting switch to OFF position. 2. Disconnect connectors C01 and P26, and connect T-adapter to female side of either connector. Between C01 (female) (68) or P26 (female) (2) and Resistance Min. 1 Mz ground
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [DHPBMA] R Pump Press Sensor Abnormality
Cause
Procedure, measuring location, criteria and remarks
1. 2. Hot short circuit in wiring harness 3. 5 (short to 5 V or 24 V circuit) 4.
Turn starting switch to OFF position. Disconnect connector P26. Connect T-adapter to female side of connector P26. Turn starting switch to ON position.
Between P26 (female) (2) and ground 6 Defective pump controller
Max. 1 V
If no failure is found by above checks, pump controller is defective. (Since this is internal failure, troubleshooting cannot be performed.)
Circuit diagram related to rear pump pressure sensor
PC228US-8,PC228USLC-8
Voltage
40-235
40-235
Troubleshooting by failure code Failure code [DHS3MA] Arm IN PPC Sen. Abnormality
Failure code [DHS3MA] Arm IN PPC Sen. Abnormality User code
Failure code Failure
—
DHS3MA
Arm IN PPC sensor system malfunction (Pump controller system)
Detail of failure q
Signal voltage of arm IN PPC pressure sensor circuit is below 0.3 V or above 4.5 V.
Action of controller
Controls machine taking arm IN PPC pressure to be 0 MPa {0 kg/cm2}. If cause of failure disappears, machine becomes normal by itself.
q q q
Automatic deceleration cannot be cancelled. Arm IN performance lowers. a If 5 V circuit (3) and ground circuit (1) of pressure sensor are connected to reverse polarities, pressure sensor is damaged. Accordingly, take extreme care when checking. q As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be Related informeasured at pump controller connector. mation q Arm IN PPC pressure can be checked by using monitoring function. (Code: 07200 Arm IN PPC pressure) q Method of reproducing failure code: Turn starting switch to ON position or start engine. Problem on machine
q
Cause
Procedure, measuring location, criteria and remarks If failure code [DA25KP] is also displayed, perform troubleshooting for it first.
1. Turn starting switch to OFF position. Defective 5V sensor power supply 2. Disconnect connector P04 and connect T-adapter to female side. 1 system 3. Turn starting switch to ON position. a If power supply voltage is unusual, proceed to cause 3. Power supBetween P04 (female) (3) and (1) Voltage 4.5 – 5.5 V ply 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector P04 3. Turn starting switch to ON position. Sensor outBetween P04 (2) and (1) Voltage 0.5 – 4.5 V put a If power supply voltage is normal and sensor output voltage is unusual, it is difficult to judge whether cause is defective sensor, ground fault or hot short Defective arm IN PPC pressure circuit in harness. Check as follows. 2 sensor (internal failure) 1. Turn starting switch to OFF position. 2. Replace connector P04 with connector of other PPC pressure sensor. 3. Turn starting switch to ON position and display "Abnormality Record" screen of electrical system on machine monitor. 4. If E mark is not displayed for this failure code, arm IN PPC pressure sensor is defective. a After finishing test, return connectors as they were. 1. Turn starting switch to OFF position. 2. Disconnect connectors C01 and P04, and connect T-adapters to each female side. a If power supply voltage in checks 1 is normal, Open circuit in wiring harness this check is not required. Resistance Max. 1 z 3 ( wire breakage or defective con- Between C01 (female) (18) and P04 (female) (1) tact of connector) Between C01 (female) (17) and P04 (female) (2) Resistance Max. 1 z 1
4
Ground fault in wiring harness (contact with ground circuit)
40-236
a If power supply voltage in checks 1 is normal, this check is not required. Resistance Max. 1 z Between C01 (female) (9) and P04 (female) (2) 1. Turn starting switch to OFF position. 2. Disconnect connectors C01 and P04, and connect T-adapter to female side of either connector. Between C01 (female) (17) or P04 (female) (2) and Resistance Min. 1 Mz ground
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [DHS3MA] Arm IN PPC Sen. Abnormality
Cause
Procedure, measuring location, criteria and remarks
1. 2. Hot short circuit in wiring harness 3. 5 (short to 24 V circuit) 4.
Turn starting switch to OFF position. Disconnect connector P04. Connect T-adapter to female side of connector P04. Turn starting switch to ON position.
Between P04 (female) (2) and ground 6 Defective pump controller
Max. 1 V
If no failure is found by above checks, pump controller is defective. (Since this is internal failure, troubleshooting cannot be performed.)
Circuit diagram related to arm IN PPC pressure sensor
PC228US-8,PC228USLC-8
Voltage
40-237
40-237
Troubleshooting by failure code Failure code [DHS4MA] Bucket CURL PPC Press Sensor Abnormality
Failure code [DHS4MA] Bucket CURL PPC Press Sensor Abnormality User code
Failure code Failure
—
DHS4MA
Bucket CURL PPC pressure sensor system malfunction (Pump controller system)
Detail of failure q
Signal voltage of bucket CURL PPC pressure sensor circuit is below 0.3 V or above 4.5 V.
Action of controller
Controls machine taking bucket CURL PPC pressure to be 0 MPa {0 kg/cm2}. If cause of failure disappears, machine becomes normal by itself.
q q q
Automatic deceleration cannot be cancelled. Bucket CURL performance lowers. a If 5 V circuit (3) and ground circuit (1) of pressure sensor are connected to reverse polarities, pressure sensor is damaged. Accordingly, take extreme care when checking. q As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be Related informeasured at pump controller connector. mation q Bucket CURL PPC pressure can be checked by using monitoring function. (Code: 07300 Bucket CURL PPC pressure) q Method of reproducing failure code: Turn starting switch to ON position or start engine. Problem on machine
q
Cause
Procedure, measuring location, criteria and remarks If failure code [DA25KP] is also displayed, perform troubleshooting for it first.
1. Turn starting switch to OFF position. Defective 5V sensor power supply 2. Disconnect connector P01 and connect T-adapter to female side. 1 system 3. Turn starting switch to ON position. a If power supply voltage is unusual, proceed to cause 3. Power supBetween P01 (female) (3) and (1) Voltage 4.5 – 5.5 V ply 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector P01. 3. Turn starting switch to ON position. Sensor outBetween P01 (2) and (1) Voltage 0.5 – 4.5 V put a If power supply voltage is normal and sensor output voltage is unusual, it is difficult to judge whether cause is defective sensor, ground fault or hot short Defective bucket CURI PPC pres2 circuit in harness. Check as follows. sure sensor (internal failure) 1. Turn starting switch to OFF position. 2. Replace connector P01 with connector of other PPC pressure sensor. 3. Turn starting switch to ON position and display "Abnormality Record" screen of electrical system on machine monitor. 4. If E mark is not displayed for this failure code, bucket CURL PPC pressure sensor is defective. a After finishing test, return connectors as they were. 1. Turn starting switch to OFF position. 2. Disconnect connectors C01 and P01, and connect T-adapters to each female side. a If power supply voltage in checks 1 is normal, Open circuit in wiring harness this check is not required. Resistance Max. 1 z 3 (wire breakage or defective con- Between C01 (female) (18) and P01 (female) (1) tact of connector) Between C01 (female) (73) and P01 (female) (2) Resistance Max. 1 z 1
4
Ground fault in wiring harness (contact with ground circuit)
40-238
a If power supply voltage in checks 1 is normal, this check is not required. Resistance Max. 1 z Between C01 (female) (9) and P01 (female) (3) 1. Turn starting switch to OFF position. 2. Disconnect connectors C01 and P01, and connect T-adapter to female side of either connector. Between C01(female) (73) and ground, or between Resistance Min. 1 Mz P01 (female) (2) and ground
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [DHS4MA] Bucket CURL PPC Press Sensor Abnormality
Cause
Procedure, measuring location, criteria and remarks
1. 2. Hot short circuit in wiring harness 3. 5 (short to 24 V circuit) 4.
Turn starting switch to OFF position. Disconnect connector P01. Connect T-adapter to female side of connector P01. Turn starting switch to ON position.
Between P01 (female) (2) and ground 6 Defective pump controller
Max. 1 V
If no failure is found by above checks, pump controller is defective. (Since this is internal failure, troubleshooting cannot be performed.)
Circuit diagram related to bucket CURL PPC pressure sensor
PC228US-8,PC228USLC-8
Voltage
40-239
40-239
Troubleshooting by failure code Failure code [DHS8MA] Boom RAISE PPC Press Sensor Abnormality
Failure code [DHS8MA] Boom RAISE PPC Press Sensor Abnormality User code
Failure code Failure
—
DHS8MA
Boom RAISE PPC pressure sensor system malfunction (Pump controller system)
Detail of failure q
Signal voltage of boom RAISE PPC pressure sensor circuit is below 0.3 V or above 4.5 V.
Action of controller
Controls machine taking boom RAISE PPC pressure to be 0 MPa {0 kg/cm2}. If cause of failure disappears, machine becomes normal by itself.
q q q
Automatic deceleration cannot be cancelled. Boom RAISE performance lowers. a If 5 V circuit (3) and ground circuit (1) of pressure sensor are connected to reverse polarities, pressure sensor is damaged. Accordingly, take extreme care when checking. q As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be Related informeasured at pump controller connector. mation q Boom RAISE PPC pressure can be checked by using monitoring function. (code: 07400 Boom RAISE PPC pressure) q Method of reproducing failure code: Turn starting switch to ON position or start engine. Problem on machine
q
Cause
Procedure, measuring location, criteria and remarks If failure code [DA25KP] is also displayed, perform troubleshooting for it first.
1. Turn starting switch to OFF position. Defective 5V sensor power 2. Disconnect connector P06 and connect T-adapter to female side. 1 3. Turn starting switch to ON position. supply 1 system a If power supply voltage is unusual, proceed to cause 3. Power supBetween P06 (female) (3) and (1) Voltage 4.5 – 5.5 V ply 1. Turn starting switch to OFF position. 2. Insert T-adapter in connector P06. 3. Turn starting switch to ON position. Sensor outBetween P06 (2) and (1) Voltage 0.5 – 4.5 V put a If power supply voltage is normal and sensor output voltage is unusual, it is difficult to judge whether cause is defective sensor, ground fault or hot short circuit in harDefective boom RAISE PPC ness. Check as follows. 2 pressure sensor (internal fail1. Turn starting switch to OFF position. ure) 2. Replace connector P06 with connector of other PPC pressure sensor. 3. Turn starting switch to ON position and display "Abnormality Record" screen of electrical system on machine monitor. 4. If E mark is not displayed for this failure code, boom RAISE PPC pressure sensor is defective. a After finishing test, return connectors as they were. 1. Turn starting switch to OFF position. 2. Disconnect connectors C01 and P06, and connect T-adapters to female sides of them. a If power supply voltage in checks 1 is normal, this Open circuit in wiring harcheck is not required. Resistance Max. 1 z ness (Wire breakage or 3 Between C01 (female) (18) and P06 (female) (1) defective contact of connector)
Ground fault in wiring har4 ness (contact with ground circuit)
40-240
Between C01 (female) (53) and P06 (female) (2)
Resistance
Max. 1 z
a If power supply voltage in checks 1 is normal, this check is not required. Resistance Max. 1 z Between C01 (female) (53) and P06 (female) (3) 1. Turn starting switch to OFF position. 2. Disconnect connectors C01 and P06, and connect T-adapter to female side of either connector. Between C01(female) (53) and ground, or between P06 Resistance Min. 1 Mz (female) (2) and ground
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [DHS8MA] Boom RAISE PPC Press Sensor Abnormality
Cause
5
Hot short in wiring harness (short to 24 V circuit)
Procedure, measuring location, criteria and remarks 1. 2. 3. 4.
Turn starting switch to OFF position. Disconnect connector P06. Connect T-adapter to female side of connector P06. Turn starting switch to ON position.
Between P06 (female) (2) and ground 6 Defective pump controller
Max. 1 V
If no failure is found by above checks, pump controller is defective. (Since this is internal failure, troubleshooting cannot be performed.)
Circuit diagram related to boom RAISE PPC pressure sensor
PC228US-8,PC228USLC-8
Voltage
40-241
40-241
Troubleshooting by failure code Failure code [DHSAMA] Swing RH PPC Press Sensor Abnormality
Failure code [DHSAMA] Swing RH PPC Press Sensor Abnormality User code
Failure code Failure
–
DHSAMA
Swing RIGHT PPC pressure sensor system malfunction (Pump controller system)
Detail of failure q
Signal voltage of swing RIGHT PPC pressure sensor is below 0.3 V or above 4.5 V.
Action of controller
Controls machine taking swing RIGHT PPC pressure to be 0 MPa {0 kg/cm2}. If cause of failure disappears, machine becomes normal by itself.
q q q
Automatic deceleration cannot be cancelled. Swing RIGHT performance lowers. a If 5 V circuit (3) and ground circuit (1) of pressure sensor are connected to reverse polarities, pressure sensor is damaged. Accordingly, take extreme care when checking. q As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be Related informeasured at pump controller connector. mation q Swing RIGHT PPC pressure can be checked by using monitoring function. (Code 09002: Swing RIGHT PPC pressure) q Method of reproducing failure code: Turn starting switch to ON position or start engine. Problem on machine
q
Cause
Procedure, measuring location, criteria and remarks If failure code [DA25KP] is also displayed, perform troubleshooting for it first.
1. Turn starting switch to OFF position. Defective 5V sensor power supply 2. Disconnect connector P07, and connect T-adapter to female side. 1 1 system 3. Turn starting switch to ON position. a If power supply voltage is unusual, proceed to cause 3. Power supBetween P07 (female) (3) and (1) Voltage 4.5 – 5.5 V ply 1. Turn starting switch to OFF position. 2. Connect T-adapter to connector P07. 3. Turn starting switch to ON position. Sensor outBetween P07 (2) and (1) Voltage 0.5 – 4.5 V put a If power supply voltage is normal and sensor output voltage is unusual, it is difficult to judge whether cause is defective sensor, ground fault or hot short Defective swing RIGHT PPC pres2 circuit in harness. Check as follows. sure sensor (internal failure) 1. Turn starting switch to OFF position. 2. Replace connector P07 with connector of other PPC pressure sensor. 3. Turn starting switch to ON position and display "Abnormality Record" screen of electrical system on machine monitor. 4. If E mark is not displayed for this failure code, swing RIGHT PPC pressure sensor is defective. a After finishing test, return connectors as they were. 1. Turn starting switch to OFF position. 2. Disconnect connectors C01 and P07, and connect T-adapters to each female side. a If power supply voltage in checks 1 is normal, Open circuit in wiring harness this check is not required. Resistance Max. 1 z 3 (wire breakage or defective con- Between C01 (female) (18) and P07 (female) (1) tact of connector) Between C01 (female) (72) and P07 (female) (2) Resistance Max. 1 z
4
Ground fault in wiring harness (contact with ground circuit)
40-242
a If power supply voltage in checks 1 is normal, this check is not required. Resistance Max. 1 z Between C01 (female) (9) and P07 (female) (3) 1. Turn starting switch to OFF position. 2. Disconnect connectors C01 and P07, and connect T-adapter to female side of either connector. Between C01 (female) (72) or P07 (female) (2) and Resistance Min. 1 Mz ground
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [DHSAMA] Swing RH PPC Press Sensor Abnormality
Cause
Procedure, measuring location, criteria and remarks
1. 2. Hot short circuit in wiring harness 3. 5 (short to 5 V/24 V circuit) 4.
Turn starting switch to OFF position. Disconnect connector P07. Connect T-adapter to female side of connector P07. Turn starting switch to ON position.
Between P07 (female) (2) and ground 6 Defective pump controller
Max. 1 V
If no failure is found by above checks, pump controller is defective. (Since this is internal failure, troubleshooting cannot be performed.)
Circuit diagram related to swing RIGHT PPC pressure sensor
PC228US-8,PC228USLC-8
Voltage
40-243
40-243
Troubleshooting by failure code Failure code [DHSBMA] Swing LH PPC Press Sensor Abnormality
Failure code [DHSBMA] Swing LH PPC Press Sensor Abnormality User code
Failure code Failure
–
DHSBMA
Defective swing LEFT PPC pressure sensor (Pump controller system)
Detail of failure q
Signal voltage of swing LEFT PPC pressure sensor is below 0.3 V or above 4.5 V.
Action of controller
Controls machine taking swing LEFT PPC pressure to be 0 MPa {0 kg/cm2}. If cause of failure disappears, machine becomes normal by itself.
q q q
Automatic deceleration cannot be cancelled. Swing LEFT performance lowers. a If 5 V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor will be broken. Accordingly, take extreme care when checking. q As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be Related informeasured at pump controller connector. mation q Swing LEFT PPC pressure can be checked with monitoring function. (Code 09001: Swing LEFT PPC pressure) q Method of reproducing failure code: Turn starting switch to ON position or start engine. Problem on machine
q
Cause
Procedure, measuring location, criteria and remarks If failure code [DA25KP] is also displayed, perform troubleshooting for it first.
1. Turn starting switch to OFF position. Defective 5V sensor power supply 2. Disconnect connector P03 and connect T-adapter to female side. 1 1 system 3. Turn starting switch to ON position. a If power supply voltage is abnormal, proceed to cause 3. Power supBetween P03 (female) (3) and (1) Voltage 4.5 – 5.5 V ply 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector P03. 3. Turn starting switch to ON position. Sensor outBetween P03 (2) and (1) Voltage 0.5 – 4.5 V put a If power supply voltage is normal and sensor output voltage is abnormal, it Defective swing LEFT PPC presis difficult to judge whether cause is defective sensor, ground fault or hot 2 sure sensor short circuit of harness. Check as follows. (Internal failure) 1. Turn starting switch to OFF position. 2. Replace connector P03 with connector of another PPC pressure sensor. 3. Turn starting switch to ON position and display "Abnormality Record" screen of electrical system on machine monitor. 4. If E mark is not displayed in this failure code column, swing LEFT PPC pressure sensor is defective. a After finishing test, return connectors as they were. 1. Turn starting switch to OFF position. 2. Disconnect connectors C01 and P03, and connect T-adapters to each female side of them. a If power supply voltage in checks 1 is normal, Open circuit in wiring harness this check is not required. Resistance Max. 1 z 3 (Wire breakage or defective con- Between C01 (female) (18) and P03 (female) (1) tact of connector) Between C01 (female) (16) and P03 (female) (2) Resistance Max. 1 z
4
Ground fault in wiring harness (Contact with ground circuit)
40-244
a If power supply voltage in checks 1 is normal, this check is not required. Resistance Max. 1 z Between C01 (female) (9) and P03 (female) (3) 1. Turn starting switch to OFF position. 2. Disconnect connectors C01 and P03, and connect T-adapter to female side of either connector. Between ground and C01 (female) (16) or P03 Resistance Min. 1 Mz (female) (2)
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [DHSBMA] Swing LH PPC Press Sensor Abnormality
Cause
Procedure, measuring location, criteria and remarks
1. 2. Hot short circuit in wiring harness 3. 5 (Contact with 5 V/24 V circuit) 4.
Turn starting switch to OFF position. Disconnect connector P03. Connect T-adapter to female side of connector P03. Turn starting switch to ON position.
Between P03 (female) (2) and ground 6 Defective pump controller
Max. 1 V
If no abnormality is found by above checks, pump controller is defective. (Since this is an internal failure, troubleshooting cannot be performed.)
Circuit diagram related to swing LEFT PPC pressure sensor
PC228US-8,PC228USLC-8
Voltage
40-245
40-245
Troubleshooting by failure code Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality
Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality User code
Failure code Failure
—
DHSDMA
Bucket DUMP PPC pressure sensor failure (Pump controller system)
Detail of failure q
Signal voltage of bucket DUMP PPC pressure sensor is below 0.3 V or above 4.5 V.
Action of controller
Controls machine taking bucket DUMP PPC pressure to be 0 MPa {0 kg/cm2}. If cause of failure disappears, machine becomes normal by itself.
q q q
Automatic deceleration cannot be cancelled. Bucket dump performance lowers. a If 5 V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor will be broken. Accordingly, take extreme care when checking. q As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be Related informeasured at pump controller connector. mation q Bucket DUMP PPC pressure can be checked with monitoring function. (Code: 07301 Bucket DUMP PPC pressure) q Method of reproducing failure code: Turn starting switch to ON position or start engine. Problem on machine
q
Cause
Procedure, measuring location, criteria and remarks If failure code [DA25KP] is also displayed, carry out troubleshooting for it first.
1. Turn starting switch to OFF position. Defective 5V sensor power supply 2. Disconnect connector P05 and connect T-adapter to female side. 1 system 3. Turn starting switch to ON position. a If power supply voltage is abnormal, proceed to cause 3. Power supBetween P05 (3) and (1) Voltage 4.5 – 5.5 V ply 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector P05. 3. Turn starting switch to ON position. Sensor outBetween P05 (2) and (1) Voltage 0.5 – 4.5 V put a If power supply voltage is normal and sensor output voltage is abnormal, it is difficult to judge whether cause is defective sensor, ground fault or hot Defective bucket DUMP PPC presshort circuit of harness. Check as follows. 2 sure sensor (Internal failure) 1. Turn starting switch to OFF position. 2. Replace connector P05 with connector of another PPC pressure sensor. 3. Turn starting switch to ON position and display "Abnormality Record" screen of electrical system on machine monitor. 4. If E mark is not displayed in this failure code column, bucket DUMP PPC pressure sensor is defective. a After finishing test, return connectors as they were. 1. Turn starting switch to OFF position. 2. Disconnect connectors C01 and P05, and connect T-adapters to each female side of them. a If power supply voltage in checks 1 is normal, Open circuit in wiring harness this check is not required. Resistance Max. 1 z 3 (Wire breakage or defective con- Between C01 (female) (18) and P05 (female) (1) tact of connector) Between C01 (female) (34) and P05 (female) (2) Resistance Max. 1 z 1
4
Ground fault in wiring harness (Contact with ground circuit)
40-246
a If power supply voltage in checks 1 is normal, this check is not required. Resistance Max. 1 z Between C01 (female) (9) and P05 (female) (3) 1. Turn starting switch to OFF position. 2. Disconnect connectors C01 and P05, and connect T-adapter to female side of either of them. Between ground and C01 (female) (34) or P05 Resistance Min. 1 Mz (female) (2)
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality
Cause
Procedure, measuring location, criteria and remarks
1. 2. Hot short circuit in wiring harness 3. 5 (Contact with 24 V circuit) 4.
Turn starting switch to OFF position. Disconnect connector P05. Connect T-adapter to female side of connector P05. Turn starting switch to ON position.
Between P05 (female) (2) and ground 6 Defective pump controller
Max. 1 V
If no abnormality is found by above checks, pump controller is defective. (Since this is an internal failure, troubleshooting cannot be performed.)
Circuit diagram related to bucket DUMP PPC pressure sensor
PC228US-8,PC228USLC-8
Voltage
40-247
40-247
Troubleshooting by failure code Failure code [DHSFMA] Travel FW L PPC Press Sensor Abnormality
Failure code [DHSFMA] Travel FW L PPC Press Sensor Abnormality User code
Failure code Failure
E20
DHSFMA
Left travel FORWARD PPC pressure sensor abnormality (Pump controller system)
Detail of failure q
Signal voltage of left travel FORWARD PPC pressure sensor is below 0.3 V or above 4.5 V.
Action of controller
Controls machine taking left travel FORWARD PPC pressure to be 0 MPa {0 kg/cm2}. If cause of failure disappears, machine becomes normal by itself.
q q q
Automatic deceleration cannot be cancelled. Travel performance is poor. a If 5 V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor will be broken. Accordingly, take extreme care when checking. q As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be Related informeasured at pump controller connector. mation q Left travel FORWARD PPC pressure can be checked with monitoring function. (Code: 07102 Left travel FORWARD PPC pressure) q Method of reproducing failure code: Turn starting switch to ON position or start engine. Problem on machine
q
Cause
Procedure, measuring location, criteria and remarks If failure code [DA25KP] is also displayed, perform troubleshooting for it first.
1. Turn starting switch to OFF position. Defective 5V sensor power supply 2. Disconnect connector P10 and connect T-adapter to female side. 1 system 3. Turn starting switch to ON position. a If power supply voltage is abnormal, proceed to cause 3. Power supBetween P10 (female) (3) and (1) Voltage 4.5 – 5.5 V ply 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector P10. 3. Turn starting switch to ON position. Sensor outBetween P10 (2) and (1) Voltage 0.5 – 4.5 V put a If power supply voltage is normal and sensor output voltage is abnormal, it Defective left travel FORWARD is difficult to judge whether cause is defective sensor, ground fault or hot 2 PPC pressure sensor (Internal failshort circuit of harness. Check as follows. ure) 1. Turn starting switch to OFF position. 2. Replace connector P10 with connector of another PPC pressure sensor. 3. Turn starting switch to ON position and display "Abnormality Record" screen of electrical system on machine monitor. 4. If E mark is not displayed in this failure code column, left travel FORWARD PPC pressure sensor is defective. a After finishing test, return connectors as they were. 1. Turn starting switch to OFF position. 2. Disconnect connectors C01 and P10, and connect T-adapters to each female side of them. a If power supply voltage in checks 1 is normal, Open circuit in wiring harness this check is not required. Resistance Max. 1 z 3 (Wire breakage or defective con- Between C01 (female) (18) and P10 (female) (1) tact of connector) Between C01 (female) (54) and P10 (female) (2) Resistance Max. 1 z 1
4
Ground fault in wiring harness (Contact with ground circuit)
40-248
a If power supply voltage in checks 1 is normal, this check is not required. Resistance Max. 1 z Between C01 (female) (9) and P10 (female) (3) 1. Turn starting switch to OFF position. 2. Disconnect connectors C01 and P10, and connect T-adapter to female side of either connector. Between ground and C01 (female) (54) or P10 Resistance Min. 1 Mz (female) (2)
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [DHSFMA] Travel FW L PPC Press Sensor Abnormality
Cause
Procedure, measuring location, criteria and remarks
1. 2. Hot short circuit in wiring harness 3. 5 (Contact with 5 V/24 V circuit) 4.
Turn starting switch to OFF position. Disconnect connector P10. Connect T-adapter to female side of connector P10. Turn starting switch to ON position.
Between P10 (female) (2) and ground 6 Defective pump controller
Max. 1 V
If no abnormality is found by above checks, pump controller is defective. (Since this is an internal failure, troubleshooting cannot be performed.)
Circuit diagram related to travel PPC pressure sensor
PC228US-8,PC228USLC-8
Voltage
40-249
40-249
Troubleshooting by failure code Failure code [DHSGMA] Travel FW R PPC Press Sensor Abnormality
Failure code [DHSGMA] Travel FW R PPC Press Sensor Abnormality User code
Failure code Failure
E20
DHSGMA
Right travel FORWARD PPC pressure sensor abnormality (Pump controller system)
Detail of failure q
Signal voltage of right travel FORWARD PPC pressure sensor is below 0.3 V or above 4.5 V.
Action of controller
Controls machine taking right travel FORWARD PPC pressure to be 0 MPa {0 kg/cm2}. If cause of failure disappears, machine becomes normal by itself.
q q q
Automatic deceleration cannot be cancelled. Poor operatability of travel operation a If 5 V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor will be broken. Accordingly, take extreme care when checking. q As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be Related informeasured at pump controller connector. mation q Right travel FORWARD PPC pressure can be checked with monitoring function. (Code: 07103 Right travel FORWARD PPC pressure) q Method of reproducing failure code: Turn starting switch to ON position or start engine. Problem on machine
q
Cause
Procedure, measuring location, criteria and remarks If failure code [DA25KP] is also displayed, perform troubleshooting for it first.
1. Turn starting switch to OFF position. Defective 5V sensor power supply 2. Disconnect connector P09, and connect T-adapter to female side. 1 system 3. Turn starting switch to ON position. a If power supply voltage is abnormal, proceed to cause 3. Power supBetween P09 (female) (3) and (1) Voltage 4.5 – 5.5 V ply 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector P09. 3. Turn starting switch to ON position. Sensor outBetween P09 (2) and (1) Voltage 0.5 – 4.5 V put a If power supply voltage is normal and sensor output voltage is abnormal, it Defective right travel FORWARD is difficult to judge whether cause is defective sensor, ground fault or hot 2 PPC pressure sensor short circuit of harness. Check as follows. (Internal failure) 1. Turn starting switch to OFF position. 2. Replace connector P09 with connector of another PPC pressure sensor. 3. Turn starting switch to ON position and display "Abnormality Record" screen of electrical system on machine monitor. 4. If E mark is not displayed in this failure code column, right travel FORWARD PPC pressure sensor is defective. a After finishing test, return connectors as they were. 1. Turn starting switch to OFF position. 2. Disconnect connectors C01 and P09, and connect T-adapters to each female side of them. a If power supply voltage in checks 1 is normal, Open circuit in wiring harness this check is not required. Resistance Max. 1 z 3 (Wire breakage or defective con- Between C01 (female) (18) and P09 (female) (1) tact of connector) Between C01 (female) (55) and P09 (female) (2) Resistance Max. 1 z 1
4
Ground fault in wiring harness (Contact with ground circuit)
40-250
a If power supply voltage in checks 1 is normal, this check is not required. Resistance Max. 1 z Between C01 (female) (9) and P09 (female) (3) 1. Turn starting switch to OFF position. 2. Disconnect connectors C01 and P09, and connect T-adapter to female side of either connector. Between C01 (female) (55) or P09 (female) (2) and Resistance Min. 1 Mz ground
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [DHSGMA] Travel FW R PPC Press Sensor Abnormality
Cause
Procedure, measuring location, criteria and remarks
1. 2. Hot short circuit in wiring harness 3. 5 (Contact with 5 V/24 V circuit) 4.
Turn starting switch to OFF position. Disconnect connector P09. Connect T-adapter to female side of connector P09. Turn starting switch to ON position.
Between P09 (female) (2) and ground 6 Defective pump controller
Max. 1 V
If no abnormality is found by above checks, pump controller is defective. (Since this is an internal failure, troubleshooting cannot be performed.)
Circuit diagram related to travel PPC pressure sensor
PC228US-8,PC228USLC-8
Voltage
40-251
40-251
Troubleshooting by failure code Failure code [DHSHMA] Travel BW L PPC Press Sensor Abnormality
Failure code [DHSHMA] Travel BW L PPC Press Sensor Abnormality User code
Failure code Failure
E20
DHSHMA
Left travel REVERSE PPC pressure sensor abnormality (Pump controller system)
Detail of failure q
Signal voltage of left travel REVERSE PPC pressure sensor is below 0.3 V or above 4.5 V.
Action of controller
Controls machine taking left travel REVERSE PPC pressure to be 0 MPa {0 kg/cm2}. If cause of failure disappears, machine becomes normal by itself.
q q q
Automatic deceleration cannot be cancelled. Poor operatability of travel operation a If 5 V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor will be broken. Accordingly, take extreme care when checking. q As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be Related informeasured at pump controller connector. mation q Left travel REVERSE PPC pressure can be checked with monitoring function. (Code: 07104 Left travel REVERSE PPC pressure) q Method of reproducing failure code: Turn starting switch to ON position or start engine. Problem on machine
q
Cause
Procedure, measuring location, criteria and remarks If failure code [DA25KP] is also displayed, perform troubleshooting for it first.
1. Turn starting switch to OFF position. Defective 5V sensor power supply 2. Disconnect connector P28 and connect T-adapter to female side. 1 system 3. Turn starting switch to ON position. a If power supply voltage is abnormal, proceed to cause 3. Power supBetween P28 (female) (3) and (1) Voltage 4.5 – 5.5 V ply 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector P28 3. Turn starting switch to ON position. Sensor outBetween P28 (2) and (1) Voltage 0.5 – 4.5 V put a If power supply voltage is normal and sensor output voltage is abnormal, it Defective left travel REVERSE is difficult to judge whether cause is defective sensor, ground fault or hot 2 PPC pressure sensor short circuit of harness. Check as follows. (Internal failure) 1. Turn starting switch to OFF position. 2. Replace connector P28 with connector of another PPC pressure sensor. 3. Turn starting switch to ON position and display "Abnormality Record" screen of electrical system on machine monitor. 4. If E mark is not displayed in this failure code column, left travel REVERSE PPC pressure sensor is defective. a After finishing test, return connectors as they were. 1. Turn starting switch to OFF position. 2. Disconnect connectors C01 and P28, and connect T-adapters to each female side of them. a If power supply voltage in checks 1 is normal, Open circuit in wiring harness this check is not required. Resistance Max. 1 z 3 (Wire breakage or defective con- Between C01 (female) (18) and P28 (female) (1) tact of connector) Between C01 (female) (35) and P28 (female) (2) Resistance Max. 1 z 1
4
Ground fault in wiring harness (Contact with ground circuit)
40-252
a If power supply voltage in checks 1 is normal, this check is not required. Resistance Max. 1 z Between C01 (female) (9) and P28 (female) (3) 1. Turn starting switch to OFF position. 2. Disconnect connectors C01 and P28, and connect T-adapter to female side of either connector. Between ground and C01 (female) (35) or P28 Resistance Min. 1 Mz (female) (2)
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [DHSHMA] Travel BW L PPC Press Sensor Abnormality
Cause
Procedure, measuring location, criteria and remarks
1. 2. Hot short circuit in wiring harness 3. 5 (Contact with 5 V/24 V circuit) 4.
Turn starting switch to OFF position. Disconnect connector P28. Connect T-adapter to female side of connector P28. Turn starting switch to ON position.
Between P28 (female) (2) and ground 6 Defective pump controller
Max. 1 V
If no abnormality is found by above checks, pump controller is defective. (Since this is an internal failure, troubleshooting cannot be performed.)
Circuit diagram related to travel PPC pressure sensor
PC228US-8,PC228USLC-8
Voltage
40-253
40-253
Troubleshooting by failure code Failure code [DHSJMA] Travel BW R PPC Press Sensor Abnormality
Failure code [DHSJMA] Travel BW R PPC Press Sensor Abnormality User code
Failure code Failure
E20
DHSJMA
Right travel REVERSE PPC pressure sensor abnormality (Pump controller system)
Detail of failure q
Signal voltage of right travel REVERSE PPC pressure sensor is below 0.3 V or above 4.5 V.
Action of controller
Controls machine taking right travel REVERSE PPC pressure to be 0 MPa {0 kg/cm2}. If cause of failure disappears, machine becomes normal by itself.
q q q
Automatic deceleration cannot be cancelled. Poor operatability of travel operation a If 5 V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor will be broken. Accordingly, take extreme care when checking. q As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be Related informeasured at pump controller connector. mation q Right travel REVERSE PPC pressure can be checked with monitoring function. (Code: 07105 Right travel REVERSE PPC pressure) q Method of reproducing failure code: Turn starting switch to ON position or start engine. Problem on machine
q
Cause
Procedure, measuring location, criteria and remarks If failure code [DA25KP] is also displayed, perform troubleshooting for it first.
1. Turn starting switch to OFF position. Defective 5V sensor power supply 2. Disconnect connector P27, and connect T-adapter to female side. 1 system 3. Turn starting switch to ON position. a If power supply voltage is abnormal, proceed to cause 3. Power supBetween P27 (female) (3) and (1) Voltage 4.5 – 5.5 V ply 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector P27. 3. Turn starting switch to ON position. Sensor outBetween P27 (2) and (1) Voltage 0.5 – 4.5 V put a If power supply voltage is normal and sensor output voltage is abnormal, it Defective right travel REVERSE is difficult to judge whether cause is defective sensor, ground fault or hot 2 PPC pressure sensor short circuit of harness. Check as follows. (Internal failure) 1. Turn starting switch to OFF position. 2. Replace connector P27 with connector of another PPC pressure sensor. 3. Turn starting switch to ON position and display "Abnormality Record" screen of electrical system on machine monitor. 4. If E mark is not displayed in this failure code column, right travel REVERSE PPC pressure sensor is defective. a After finishing test, return connectors as they were. 1. Turn starting switch to OFF position. 2. Disconnect connectors C01 and P27, and connect T-adapters to each female side of them. a If power supply voltage in checks 1 is normal, Open circuit in wiring harness this check is not required. Resistance Max. 1 z 3 (Wire breakage or defective con- Between C01 (female) (18) and P27 (female) (1) tact of connector) Between C01 (female) (36) and P27 (female) (2) Resistance Max. 1 z 1
4
Ground fault in wiring harness (Contact with ground circuit)
40-254
a If power supply voltage in checks 1 is normal, this check is not required. Resistance Max. 1 z Between C01 (female) (9) and P27 (female) (3) 1. Turn starting switch to OFF position. 2. Disconnect connectors C01 and P27, and connect T-adapter to female side of either connector. Between C01 (female) (36) or P27 (female) (2) and Resistance Min. 1 Mz ground
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [DHSJMA] Travel BW R PPC Press Sensor Abnormality
Cause
Procedure, measuring location, criteria and remarks
1. 2. Hot short circuit in wiring harness 3. 5 (Contact with 5 V/24 V circuit) 4.
Turn starting switch to OFF position. Disconnect connector P27. Connect T-adapter to female side of connector P27. Turn starting switch to ON position.
Between P27 (female) (2) and ground 6 Defective pump controller
Max. 1 V
If no abnormality is found by above checks, pump controller is defective. (Since this is an internal failure, troubleshooting cannot be performed.)
Circuit diagram related to travel PPC pressure sensor
PC228US-8,PC228USLC-8
Voltage
40-25
40-255
Troubleshooting by failure code Failure code [DHSJMA] Travel BW R PPC Press Sensor Abnormality
40-256
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [DHX1MA] Overload Sensor Abnormality
Failure code [DHX1MA] Overload Sensor Abnormality Standard specification User code
40-257
Failure code Failure
-
DHX1MA
Detail of failure q Action of controller
q q
Problem on machine Related informaq tion
Overload Sensor Abnormality (Analog) (Pump controller system)
Monitor (overload alarm monitor) which is not set to be displayed is displayed. None in particular If cause of failure disappears, machine becomes normal by itself.
Method of reproducing failure code: Turn starting switch to ON position.
Cause
Procedure, measuring location, criteria and remarks
Defective pump control- Pump controller may be defective. (Since this is an internal failure, troubleshooting can1 ler not be performed.)
Overload alarm specification Detail of failure q Action of controller Problem on machine
q
40-257
Signal voltage of boom bottom pressure sensor circuit is below 0.3 V or above 4.5 V.
q
Continues outputting overload alarm. Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position.
q
Overload alarm is kept indicated on machine monitor, regardless of actual load.
q This failure code is detected for only overload alarm specification (pin 78 of connector C01 is GND). a If 5 V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor Related inforwill be broken. Accordingly, take extreme care when checking. q Boom cylinder bottom pressure can be checked with monitoring function. mation (Code: 15900 Boom bottom pressure) q Method of reproducing failure code: Turn starting switch to ON position or start engine.
Cause
Procedure, measuring location, criteria and remarks If failure code [DA26KP] is also displayed, troubleshoot it first.
1. Turn starting switch to OFF position. Defective 5 V sensor power supply 2. Disconnect connector Y09 and connect T-adapter to female side. 1 2 line 3. Turn starting switch to ON position. a If power supply voltage is abnormal, proceed to cause 3. Power supBetween Y09 (female) (3) and (1) Voltage 4.5 – 5.5 V ply 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector Y09. 3. Turn starting switch to ON position. Sensor outDefective boom bottom pressure Between Y09 (2) and (1) Voltage 0.5 – 4.5 V put 2 sensor a If power supply voltage is normal and sensor output voltage is abnormal, it (Internal failure) is difficult to judge whether cause is defective sensor, ground fault or hot short circuit of harness. Check as follows. q Check for causes 4 and 5 first. If result is normal, boom bottom pressure sensor is defective.
PC228US-8,PC228USLC-8
40-257
Troubleshooting by failure code Failure code [DHX1MA] Overload Sensor Abnormality
Cause
Open circuit in wiring harness 3 (Wire breakage or defective contact of connector)
4
Ground fault in wiring harness (Contact with ground circuit)
5
Hot short circuit in wiring harness (Contact with 5 V/24 V circuit)
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connectors C01 and Y09, and connect T-adapters to female sides of them. a If power supply voltage in checks 1 is normal, this check is not required. Resistance Max. 1 z Between C01 (female) (70) and Y09 (female) (1) Between C01 (female) (31) and Y09 (female) (2)
Between Y09 (female) (2) and ground 6 Defective pump controller
40-258
Resistance
Max. 1 z
a If power supply voltage in checks 1 is normal, this check is not required. Resistance Max. 1 z Between C01 (female) (8) and Y09 (female) (3) 1. Turn starting switch to OFF position. 2. Disconnect connectors C01 and Y09, and connect T-adapter to female side of either connector. Between C01 (female) (31) or Y09 (female) (2) and Resistance Min. 1 Mz ground 1. Turn starting switch to OFF position. 2. Disconnect connector Y09. 3. Connect T-adapter to female side of connector Y09. 4. Turn starting switch to ON position. Voltage
Max. 1 V
If no abnormality is found by above checks, pump controller is defective. (Since this is an internal failure, troubleshooting cannot be performed.)
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [DHX1MA] Overload Sensor Abnormality
Circuit diagram related to boom bottom pressure sensor (overload alarm specification)
PC228US-8,PC228USLC-8
40-259
40-259
Troubleshooting by failure code Failure code [DKA0KA] Boom Angle Sensor Open Circuit
Failure code [DKA0KA] Boom Angle Sensor Open Circuit User code
Failure code Failure
E40
DKA0KA
Detail of failure q q
Action of controller Problem on machine
q q q
The signal voltage of boom angle sensor circuit is below 0.3 V. Turns OFF an output to boom LOWER EPC. Turns OFF an output to boom RAISE EPC. Turns OFF an output to arm IN EPC. Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position.
q
Machine monitor does not display working radius, actual load and lifting height.
q
If the Arm Crane mode (L) is selected on an arm crane model, user code [E50] is displayed. Turning the emergency operating switch of work equipment to ON, work equipment can be operated. As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be measured at pump controller connector. The signal voltage of boom angle sensor can be checked with monitoring function. (Code: 15100 Boom angle) Method of reproducing failure code: Turn starting switch to ON position.
q
Related information
Boom angle sensor abnormality (open circuit) (Pump controller system)
q q q
Cause
Procedure, measuring location, criteria and remarks
1
Defective 5 V sensor power supply 2 line
If failure code [DA26KP] is also displayed, troubleshoot it first.
2
Defective installation of boom angle sensor
If failure code [DKA0PH] is also displayed, troubleshoot it first. 1. Turn starting switch to OFF position. 2. Disconnect connector A53 and connect T-adapter to male side.
3
Defective boom angle sensor (Internal open circuit in wiring)
Between A53 (male) (A) and (C)
Resistance
4.0 - 6.0 kz
Between A53 (male) (B) and (C)
Resistance
0.25 - 5.0 kz
Between A53 (male) (B) and (A)
Resistance
0.25 - 5.0 kz
1. Turn starting switch to OFF position. 2. Disconnect connectors C01, Y09, Y13 and Y11, and connect T-adapters to female side of them. Open or short circuit in wiring har4 ness Between C01 (female) (8) and (18) Resistance 4.0 - 6.0 kz Between C01 (female) (67) and (18)
Open circuit in wiring harness 5 (Wire breakage or defective contact of connector)
Resistance
Between C01 (female) (8) and A53 (female) (C) Resistance
6 Short circuit in wiring harness
7
Ground fault in wiring harness (Contact with ground circuit)
40-260
0.25 - 5.0 kz
a If no abnormality is found in checks on cause 4, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors C01 and A53, and connect T-adapters to each female side of them. Between C01 (female) (18) and A53 (female) Resistance Max. 1 z (A) Between C01 (female) (67) and A53 (female) Resistance Max. 1 z (B) Max. 1 z
a If no abnormality is found in checks on cause 4, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors C01 and A53, and connect T-adapter to female side of either connector. Between C01 (female) (67) and each of (18) Resistance Min. 1 Mz and (70), or between A53 (female) (B) and (A) 1. Turn starting switch to OFF position. 2. Disconnect connectors C01 and A53, and connect T-adapter to female side of either connector. Between ground and C01 (female) (67) or A53 Resistance Min. 1 Mz (female) (B)
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [DKA0KA] Boom Angle Sensor Open Circuit
Cause 8 Defective pump controller
Procedure, measuring location, criteria and remarks If cause is not found by above checks, pump controller is defective. (Since this is an internal failure, troubleshooting cannot be performed.)
Circuit diagram related to boom angle sensor
PC228US-8,PC228USLC-8
40-261
40-261
Troubleshooting by failure code Failure code [DKA0KB] Boom Angle Sensor Power Short Circuit
Failure code [DKA0KB] Boom Angle Sensor Power Short Circuit User code
Failure code Failure
E40
DKA0KB
Detail of failure q q
Action of controller Problem on machine
q q q
The signal voltage of boom angle sensor circuit is above 4.7 V. Turns OFF an output to boom LOWER EPC. Turns OFF an output to boom RAISE EPC. Turns OFF an output to arm IN EPC. Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position.
q
Machine monitor does not display working radius, actual load and lifting height.
q
If the Arm Crane mode (L) is selected on an arm crane model, user code [E50] is displayed. Turning the emergency operating switch of work equipment to ON, work equipment can be operated. As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be measured at pump controller connector. The signal voltage of boom angle sensor can be checked with monitoring function. (Code: 15100 Boom angle) Method of reproducing failure code: Turn starting switch to ON position.
q
Related information
Boom angle sensor abnormality (power short circuit) (Pump controller system)
q q q
Cause
Procedure, measuring location, criteria and remarks
1
Defective 5 V sensor power supply 2 line
If failure code [DA26KP] is also displayed, troubleshoot it first.
2
Defective installation of boom angle sensor
If failure code [DKA0PH] is also displayed, troubleshoot it first. 1. Turn starting switch to OFF position. 2. Disconnect connector A53 and connect T-adapter to male side.
3
Defective boom angle sensor (Internal short circuit)
Between A53 (male) (A) and (C)
Resistance
4.0 - 6.0 kz
Between A53 (male) (B) and (C)
Resistance
0.25 - 5.0 kz
Between A53 (male) (B) and (A)
Resistance
0.25 - 5.0 kz
1. Turn starting switch to OFF position. 2. Disconnect connectors C01, Y09, Y11 and Y13, and connect T-adapters to female side of them. Open or short circuit in wiring har4 ness Between C01 (female) (8) and (18) Resistance 4.0 - 6.0 kz Between C01 (female) (67) and (18)
Resistance
0.25 - 5.0 kz
a If no abnormality is found in checks on cause 4, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors C01 and A53, and connect T-adapter to female side 5 Short circuit in wiring harness of either connector. Between C01 (female) (67) and (8), or Resistance Max. 1 Mz between A53 (female) (C) and (B) 1. Turn starting switch to OFF position. Hot short circuit in wiring harness 2. Disconnect connector A53 and connect T-adapter to female side. 6 3. Turn starting switch to ON position. (Contact with 24 V circuit) Between A53 (female) (B) and ground Voltage Max. 1 V 7 Defective pump controller
40-262
If no abnormality is found by the above checks, the pump controller is defective. (Since this is an internal failure, troubleshooting cannot be performed.)
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [DKA0KB] Boom Angle Sensor Power Short Circuit
Circuit diagram related to boom angle sensor
PC228US-8,PC228USLC-8
40-263
40-263
Troubleshooting by failure code Failure code [DKA0PH] Boom Angle Sensor Install Abnormality
Failure code [DKA0PH] Boom Angle Sensor Install Abnormality User code
Failure code Failure
E40
DKA0PH
Defective installation of boom angle sensor (Pump controller system)
q
The boom angle sensor signal is more than the maximum angle by 5 °or more, or less than the minimum angle by 5 °or more.
Action of controller
q
If cause of failure disappears, machine becomes normal by itself.
Problem on machine
q
Machine monitor does not display working radius, actual load and lifting height.
q
If the Arm Crane mode (L) is selected on an arm crane model, user code [E50] is displayed. Turning the emergency operating switch of work equipment to ON, work equipment can be operated. The signal voltage of boom angle sensor can be checked with monitoring function. (Code: 15100 Boom angle) Method of reproducing failure code: Turn starting switch to ON position.
Detail of failure
q
Related information
q q
Cause 1
Defective installation of boom angle sensor
2 Defective pump controller
40-264
Procedure, measuring location, criteria and remarks The boom angle sensor may be installed incorrectly. Check for a mounting error, and correct it if abnormal. If cause 1 is not found, the pump controller may be defected. (Since this is an internal failure, troubleshooting cannot be performed.)
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [DKA0PH] Boom Angle Sensor Install Abnormality
Circuit diagram related to boom angle sensor
PC228US-8,PC228USLC-8
40-265
40-265
Troubleshooting by failure code Failure code [DKR0MA] F pump S/P sensor Abnormality
Failure code [DKR0MA] F pump S/P sensor Abnormality User code
Failure code Failure
—
DKR0MA
F pump swash plate sensor abnormality (Pump controller system)
Detail of failure q
Signal voltage of F pump swash plate sensor circuit is below 0.4 V or above 4.6 V.
Action of controller
If cause of failure disappears, machine becomes normal by itself.
q q
Automatic deceleration cannot be cancelled. One-touch power maximizing function does not work. q Engine is not so controlled that low-load matching speed is lowered. a If 5 V circuit (A) and ground circuit (B) of swash plate sensor are connected inversely, sensor will be broken. Accordingly, take extreme care when checking. q As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be Related informeasured at pump controller connector. mation q Voltage from front pump swash plate sensor can be checked with monitoring function. (Code: 01138 F pump swash plate sensor voltage) q Method of reproducing failure code: Turn starting switch to ON position or start engine. Problem on machine
q
Cause
Procedure, measuring location, criteria and remarks If failure code [DA25KP] is also displayed, carry out troubleshooting for it first.
1. Turn starting switch to OFF position. Defective 5V sensor power supply 2. Disconnect connector A54 and connect T-adapter to female side. 1 1 system 3. Turn starting switch to ON position. a If power supply voltage is abnormal, proceed to cause 3. Power supBetween A54 (female) (A) and (B) Voltage 4.5 – 5.5 V ply 1. Turn starting switch to OFF position. 2. Disconnect connector A54 and connect T-adapter to male side. Approx. Between A54 (male) (A) and (B) Resistance 6 kz Approx. Between A54 (female) (B) and (C) Resistance 6 kz Approx. Between A54 (female) (A) and (C) Resistance 170 z Between A54 (male) (C) and ground Resistance Min. 1 Mz 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector A54. Defective F pump swash plate 3. Turn starting switch to ON position. 2 sensor Sensor outBetween A54 (female) (C) and (B) Voltage Approx. 3 V (Internal failure) put a If power supply voltage is normal and sensor output voltage is abnormal, it is difficult to judge whether cause is defective sensor, ground fault or hot short circuit of harness. Check as follows. 1. Turn starting switch to OFF position. 2. Replace connector A54 with connector A55. 3. Turn starting switch to ON position and display "Abnormality Record" screen of electrical system on machine monitor. 4. If E mark is not displayed in this failure code column, F pump swash plate sensor is defective. a After finishing test, return connectors as they were.
40-266
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [DKR0MA] F pump S/P sensor Abnormality
Cause
Open circuit in wiring harness 3 (Wire breakage or defective contact of connector)
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connectors C01 and A54, and connect T-adapters to each female side of them. a If power supply voltage in checks 1 is normal, this check is not required. Resistance Max. 1 z Between C01 (female) (9) and A54 (female) (A) a If power supply voltage in checks 1 is normal, this check is not required. Resistance Max. 1 z Between C01 (female) (18) and A54 (female) (B) Between C01 (female) (30) and A54 (female) (C)
Resistance
Max. 1 z
1. Turn starting switch to OFF position. 2. Disconnect connectors C01 and A54, and connect T-adapter to female side Ground fault in wiring harness 4 of either connector. (Contact with ground circuit) Between C01 (female) (30) or A54 (female) (C) and Resistance Min. 1 Mz ground 1. Turn starting switch to OFF position. 2. Disconnect connector A54. Hot short circuit in wiring harness 3. Connect T-adapter to female side of connector A54. 5 (Contact with 24 V circuit) 4. Turn starting switch to ON position. Between A54 (female) (C) and ground 6 Defective pump controller
Max. 1 V
If no abnormality is found by above checks, pump controller is defective. (Since this is an internal failure, troubleshooting cannot be performed.)
Circuit diagram related to F and R pump swash plate sensors
PC228US-8,PC228USLC-8
Voltage
40-267
40-267
Troubleshooting by failure code Failure code [DKR1MA] R pump S/P sensor Abnormality
Failure code [DKR1MA] R pump S/P sensor Abnormality User code
Failure code Failure
—
DKR1MA
R pump swash plate sensor abnormality (Pump controller system)
Detail of failure q
Signal voltage of R pump swash plate sensor circuit is below 0.4 V or above 4.6 V.
Action of controller
If cause of failure disappears, machine becomes normal by itself.
q q
Automatic deceleration cannot be cancelled. One-touch power maximizing function does not work. q Engine is not so controlled that low-load matching speed is lowered. a If 5 V circuit (A) and ground circuit (B) of swash plate sensor are connected inversely, sensor will be broken. Accordingly, take extreme care when checking. q As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be Related informeasured at pump controller connector. mation q Voltage from rear pump swash plate sensor can be checked with monitoring function. (Code: 01140 R pump swash plate sensor voltage) q Method of reproducing failure code: Turn starting switch to ON position or start engine. Problem on machine
q
Cause
Procedure, measuring location, criteria and remarks If failure code [DA25KP] is also displayed, carry out troubleshooting for it first.
1. Turn starting switch to OFF position. Defective 5V sensor power supply 2. Disconnect connector A55 and connect T-adapter to female side. 1 1 system 3. Turn starting switch to ON position. a If power supply voltage is abnormal, proceed to cause 3. Power supBetween A55 (female) (A) and (B) Voltage 4.5 – 5.5 V ply 1. Turn starting switch to OFF position. 2. Disconnect connector A55 and connect T-adapter to male side. Approx. Between A55 (male) (A) and (B) Resistance 6 kz Approx. Between A55 (female) (B) and (C) Resistance 6 kz Approx. Between A55 (female) (A) and (C) Resistance 170 z Between A55 (male) (C) and ground Resistance Min. 1 Mz 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector A55. Defective R pump swash plate 3. Turn starting switch to ON position. 2 sensor Sensor outBetween A55 (C) and (B) Voltage Approx. 3 V (Internal defect) put a If power supply voltage is normal and sensor output voltage is abnormal, it is difficult to judge whether cause is defective sensor, ground fault or hot short circuit of harness. Check as follows. 1. Turn starting switch to OFF position. 2. Replace connector A55 with connector A54. 3. Turn starting switch to ON position and display "Abnormality Record" screen of electrical system on machine monitor. 4. If E mark is not displayed in this failure code column, R pump swash plate sensor is defective. a After finishing test, return connectors as they were.
40-268
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [DKR1MA] R pump S/P sensor Abnormality
Cause
Open circuit in wiring harness 3 (Wire breakage or defective contact of connector)
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connectors C01 and A55, and connect T-adapters to each female side of them. a If power supply voltage in checks 1 is normal, this check is not required. Resistance Max. 1 z Between C01 (female) (9) and A55 (female) (A) a If power supply voltage in checks 1 is normal, this check is not required. Resistance Max. 1 z Between C01 (female) (18) and A55 (female) (B) Between C01 (female) (50) and A55 (female) (C)
Resistance
Max. 1 z
1. Turn starting switch to OFF position. 2. Disconnect connectors C01 and A55, and connect T-adapter to female side Ground fault in wiring harness 4 of either connector. (Contact with ground circuit) Between C01 (female) (50) or A55 (female) (C) and Resistance Min. 1 Mz ground 1. Turn starting switch to OFF position. 2. Disconnect connector A55. Hot short circuit in wiring harness 3. Connect T-adapter to female side of connector A55. 5 (Contact with 24 V circuit) 4. Turn starting switch to ON position. Between A55 (female) (C) and ground 6 Defective pump controller
Max. 1 V
If no abnormality is found by above checks, pump controller is defective. (Since this is an internal failure, troubleshooting cannot be performed.)
Circuit diagram related to F and R pump swash plate sensors
PC228US-8,PC228USLC-8
Voltage
40-269
40-269
Troubleshooting by failure code Failure code [DV20KB] Travel Alarm Short Circuit
Failure code [DV20KB] Travel Alarm Short Circuit User code
Failure code Failure
–
DV20KB
Detail of failure q Action of controller Problem on machine Related information
q
Travel Alarm Short Circuit (Pump controller system)
When outputting current to travel alarm circuit, abnormal current flows.
q
Stops outputting current to travel alarm circuit. Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position.
q
Travel alarm does not sound.
q
Operation (ON or OFF) of travel alarm can be checked with monitoring function. (Code: 03701 Controller output 2) As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be measured at pump controller connector.
q
Cause
Procedure, measuring location, criteria and remarks 1. 2. 3. 4.
1
Defective travel alarm (Internal failure)
2
Ground fault in wiring harness (Contact with ground circuit)
3 Defective pump controller
40-270
Turn starting switch to OFF position. Disconnect connector M14, and connect T-adapter to female side. Turn starting switch to ON position. Operate travel lever and perform troubleshooting. Travel lever: Voltage Max. 1 V NEUTRAL Between M14 (female) (1) Travel lever: and (2) FORVoltage 20 – 30 V WARD/REVER SE a If the above voltage is normal but travel alarm does not sound, travel alarm is defective. 1. Turn starting switch to OFF position. 2. Disconnect connectors C02 and M14, and connect T-adapter to female side of either connector. Between C02 (female) (107) or M14 (female) Resistance Min. 1 Mz (1) and ground 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector M14. 3. Turn starting switch to ON position. 4. Operate travel lever and perform troubleshooting. Travel lever: Voltage Max. 1 V NEUTRAL Travel lever: Between M14 (1) and (2) FORVoltage 20 – 30 V WARD/REVER SE
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [DV20KB] Travel Alarm Short Circuit
Circuit diagram related to travel alarm
PC228US-8,PC228USLC-8
40-271
40-271
Troubleshooting by failure code Failure code [DW43KA] Travel Speed Sol Open Circuit
Failure code [DW43KA] Travel Speed Sol Open Circuit User code
Failure code Failure
– Detail of failure
DW43KA q
Action of controller
q
Problem on machine
q
q
q
Related information q
Travel speed solenoid system open circuit (Pump controller system)
When outputting current to travel speed selector solenoid, no current flows and open circuit is detected. None in particular (Since no current flows, solenoid does not operate). If cause of failure disappears, machine becomes normal by itself. "Hi" travel speed is slow. (Although "Hi" is displayed on machine monitor, actual travel speed is still "Lo".) Controller's command (ON/OFF) to travel speed selector solenoid can be checked with monitoring function. (If controller sends solenoid ON command, monitoring display is ON even if solenoid is not switched ON due to open circuit.) (Code: 02300 Solenoid 1) Method of reproducing failure code: Start engine, set travel speed to High and operate travel lever.
Cause Defective travel speed selector 1 solenoid (Internal open circuit)
Open circuit in wiring harness 2 (Wire breakage or defective contact of connector)
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector V04, and connect T-adapter to male side. Between V04 (male) (1) and (2)
Resistance
1. Turn starting switch to OFF position. 2. Disconnect connector C02 and connect T-adapter to female side. Between C02 (female) (87) and (115) or (117) or Resistance 20 – 60 z (120) a If above check result is normal, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors C02 and V04, and connect T-adapters to each female side of them. Between C02 (female) (87) and V04 (female) (1)
3 Defective pump controller
40-272
20 – 60 z
Resistance
Max. 1 z
Between V02 (female) (2) and C02 (female) (115) Resistance Max. 1 z or (117) or (120) If no abnormality is found by above checks, pump controller is defective. (Since this is an internal failure, troubleshooting cannot be performed.)
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [DW43KA] Travel Speed Sol Open Circuit
Circuit diagram related to travel speed solenoid
PC228US-8,PC228USLC-8
40-273
40-273
Troubleshooting by failure code Failure code [DW43KB] Travel Speed Sol Short Circuit
Failure code [DW43KB] Travel Speed Sol Short Circuit User code
Failure code Failure
–
DW43KB
Detail of failure Action of controller Problem on machine
q q q q q
Related information q
Travel speed solenoid short circuit (Pump controller system)
When outputting current to travel speed selector solenoid, abnormal current flows and short circuit is detected. Stops outputting current to travel speed selector solenoid. Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position. "Hi" travel speed is slow. (Although "Hi" is displayed on machine monitor, actual travel speed is still "Lo".) Controller's command (ON/OFF) to travel speed selector solenoid can be checked with monitoring function. (If controller sends solenoid ON command, monitoring display is ON even if solenoid is not switched ON due to short circuit.) (Code: 02300 Solenoid 1) Method of reproducing failure code: Start engine, set travel speed to High and operate travel lever.
Cause Defective travel speed 1 selector solenoid (Internal short circuit, ground fault)
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector V04, and connect T-adapter to male side. Between V04 (male) (1) and (2)
Resistance
20 – 60 z
Between V04 (male) (1) and ground
Resistance
Min. 1 Mz
1. Turn starting switch to OFF position. 2. Disconnect connector C02 and connect T-adapter to female side.
2
Short circuit or ground fault Between C02 (female) (87) and (115) or (117) or (120) in wiring harness Between C02 (female) (87) and ground
Resistance
20 – 60 z
Resistance
Min. 1 Mz
a If no abnormality is found in check on cause 2, this check is not required. 1. Turn starting switch to OFF position. Ground fault in wiring har2. Disconnect connectors C02 and V04, and connect T-adapter to female side of 3 ness either connector. (Contact with ground circuit) Between C02 (female) (87) or V04 (female) (1) and Resistance Min. 1 Mz ground If no abnormality is found by above checks, pump controller is defective. (Since this 4 Defective pump controller is an internal failure, troubleshooting cannot be performed.)
40-274
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [DW43KB] Travel Speed Sol Short Circuit
Circuit diagram related to travel speed solenoid
PC228US-8,PC228USLC-8
40-275
40-275
Troubleshooting by failure code Failure code [DW45KA] Swing Brake Sol Open Circuit
Failure code [DW45KA] Swing Brake Sol Open Circuit User code
Failure code Failure
E03 Detail of failure Action of controller Problem on machine
DW45KA q
q
When stops outputting current to swing brake solenoid, controller solenoid output voltage is above standard value and open circuit is detected. None in particular. (Since no current flows, solenoid does not work. Swing brake is kept applied.) If cause of failure disappears, machine becomes normal by itself.
q
Machine cannot swing (Swing brake is not released)
q
If solenoid and wiring harness are normal, swing operation is possible by setting swing brake release switch to RELEASE position. (However, swing brake is not released while upper structure is stopped. Swing brake continues to be applied.) Set swing brake release switch to RELEASE position during troubleshooting. When starting switch is turned to ON position in this condition, normally current can flow in swing brake solenoid circuit and break can be released. Controller's command (ON/OFF) to swing brake solenoid can be checked with monitoring function. (If controller sends solenoid ON command, monitoring display is ON even if solenoid is not switched ON due to open circuit.) (Code: 02300 Solenoid 1) Method of reproducing failure code: Turn starting switch to ON position. Swing brake solenoid circuit is powered from pin (101) of pump controller connector C02 or pin (1) of fuse box F01.
q
q
Related information
q
q q
Cause 1
Swing brake solenoid open circuit (Pump controller system)
Procedure, measuring location, criteria and remarks
Blown No. 1 of fuse F01 (right top If fuse has blown out, see [DW45KB]. fuse)
2 Defective swing brake solenoid
1. Turn starting switch to OFF position. 2. Disconnect connector V03, and connect T-adapter to male side. Between V03 (male) (1) and (2)
Resistance
20 – 60 z
1. Turn starting switch to OFF position. 2. Remove diode arrays D01 and D03, and connect T-adapters to their male side. a Check the continuity in diode range. 3 Defective diode array D01 or D03 Between D01 (male) (3) (+) and (7) (-) Between D01 (male) (7) (+) and (3) (-)
No continuity
Between D03 (male) (3) (+) and (7) (-)
No continuity
Between D03 (male) (7) (+) and (3) (-)
Continuity
Continuity
1. Turn starting switch to OFF position. 2. Remove diode D01. 3. Disconnect connector C02 and connect T-adapter to each female side of them. a Swing lock switch OFF Open circuit in wiring harness 4 (Wire breakage or defective contact of connector)
Between C02 (female) (101) and D01 (female) (7)
Resistance
Max. 1 z
Between D01 (female) (3) and C02 (female) (115)
Resistance
20 – 60 z
a If no abnormality is found by above check, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors D01, C02, and V03, and connect T-adapter to each female side of them. Between D01 (female) (3) and V03 (female) (1)
5 Defective pump controller
40-276
Resistance
Max. 1 z
Between V03 (female) (2) and C02 (female) (115) Resistance Max. 1 z or (117) or (120) If no abnormality is found by above checks, pump controller is defective. (Since this is an internal failure, troubleshooting cannot be performed.)
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [DW45KA] Swing Brake Sol Open Circuit
Circuit diagram related to swing brake solenoid
PC228US-8,PC228USLC-8
40-27
40-277
Troubleshooting by failure code Failure code [DW45KB] Swing Brake Sol Short Circuit
Failure code [DW45KB] Swing Brake Sol Short Circuit User code
Failure code Failure
E03 Detail of failure Action of controller Problem on machine
DW45KB q q q
When outputting current to swing brake solenoid, abnormal current flows in circuit and short circuit is detected. Stops outputting current to swing brake solenoid. Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position.
q
Machine cannot swing (Swing brake is not released)
q
If solenoid and wiring harness are normal, swing operation is possible by setting swing brake release switch to RELEASE position. (However, swing brake is not released while upper structure is stopped. Swing brake continues to be applied.) Keep swing lock switch in OFF position and swing holding brake release switch in RELEASE position during troubleshooting. When starting switch is turned to ON position in this condition, normally current can flow in swing brake solenoid circuit and brake can be released. Controller's command (ON/OFF) to swing brake solenoid can be checked with monitoring function. (If controller sends solenoid ON command, monitoring display is ON even if solenoid is not switched ON due to short circuit.) (Code: 02300 Solenoid 1) Method of reproducing failure code: Turn starting switch to ON position. Swing brake solenoid circuit is powered from pin (101) of pump controller connector C02 or pin (1) of fuse box F01.
q
Related information
q
q q
Cause 1
Swing brake solenoid short circuit (Pump controller system)
Procedure, measuring location, criteria and remarks
Blown No. 1 of fuse F01 (right top Even if fuse is blown, perform troubleshooting according to following steps to fuse) identify cause. 1. Turn starting switch to OFF position. 2. Disconnect connector V03, and connect T-adapter to male side.
2 Defective swing brake solenoid
Between V03 (male) (1) and (2)
Resistance
20 – 60 z
Between V03 (male) (1) and ground
Resistance
Min. 1 Mz
1. Turn starting switch to OFF position. 2. Remove diode arrays D01 and D03, and connect T-adapters to their male side. a Check the continuity in diode range. 3 Defective diode array D01 or D03 Between D01 (male) (3) (+) and (7) (-) Between D01 (male) (7) (+) and (3) (-)
No continuity
Between D03 (male) (3) (+) and (7) (-)
No continuity
Between D03 (male) (7) (+) and (3) (-)
Continuity
4
Ground fault in wiring harness (Contact with ground circuit)
5 Short circuit in wiring harness
6 Defective pump controller
40-278
1. 2. 3. 4.
Continuity
Turn starting switch to OFF position. Remove No. 1 of fuse F01 (right top fuse, 10 A) and diode D01. Disconnect connectors C02, D01 and V03. Connect T-adapters to female sides of connectors C02 and D01.
Between C02 (female) (101) and ground
Resistance
Min. 1 Mz
Between D01 (female) (3) and ground
Resistance
Min. 1 Mz
1. Turn starting switch to OFF position. 2. Remove No. 1 of fuse F01 (right top fuse, 10 A) and diode D01. 3. Disconnect connector C02. 4. Connect T-adapters to female sides of connectors D01 and C02. Between D01 (female) (3) and C02 (female) (115) Resistance 20 – 60 z or (117) or (120) If no abnormality is found by above checks, pump controller is defective. (Since this is an internal failure, troubleshooting cannot be performed.)
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [DW45KB] Swing Brake Sol Short Circuit
Circuit diagram related to swing brake
PC228US-8,PC228USLC-8
40-279
40-279
Troubleshooting by failure code Failure code [DW4GKA] Boom Slow Down Sol. Disc.
Failure code [DW4GKA] Boom Slow Down Sol. Disc. User code
Failure code Failure
E41
DW4GKA
Boom RAISE throttle EPC solenoid open circuit (Pump controller system)
q
When outputting current to boom RAISE throttle EPC solenoid, no current flows and open circuit is detected.
Action of controller
q
If cause of failure disappears, machine becomes normal by itself.
Problem on machine
q
Boom RAISE does not function.
q
Turning the emergency operating switch of work equipment to ON, work equipment can be operated. Drive current of boom RAISE throttle EPC solenoid can be checked with monitoring function. (Code: 01800 Boom RAISE throttle EPC solenoid current) Method of reproducing failure code: Turn starting switch to ON position.
Detail of failure
Related information
q q
Cause Defective boom RAISE throttle 1 EPC solenoid (Internal short circuit or ground fault)
2
Defective work equipment emergency operation switch
Open circuit in wiring harness 3 (Wire breakage or defective contact)
4 Defective pump controller
40-280
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector V09, and connect T-adapter to male side. Between V09 (male) (1) and (2)
Resistance
5 – 25 z
1. Turn starting switch to OFF position. 2. Disconnect connector S26, and connect T-adapter to male side. a Measure work equipment emergency operation switch at normal position (lower side). Between S26 (male) (2) and (3)
Resistance
Max. 1 z
Between S26 (male) (5) and (6)
Resistance
Max. 1 z
1. Turn starting switch to OFF position. 2. Disconnect connector C02 and connect T-adapter to each female side of them. a Measure work equipment emergency operation switch at normal position (lower side). Between C02 (female) (105) and (115) (Resistance of boom RAISE throttle EPC solenoid Resistance 5 – 25 z coil) a If no failure is found by above checks, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors C02 and V09, and connect T-adapters to each female side of them. Between C02 (female) (105) and V09 (female) (2)
Resistance
Max. 1 z
Between C02 (female) (115) and V09 (female) (1)
Resistance
Max. 1 z
If cause is not found by above checks, pump controller is defective.
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [DW4GKA] Boom Slow Down Sol. Disc.
Circuit diagram related to boom RAISE throttle EPC solenoid
PC228US-8,PC228USLC-8
40-281
40-281
Troubleshooting by failure code Failure code [DW4GKB] Boom Slow Down Sol. Short Circuit
Failure code [DW4GKB] Boom Slow Down Sol. Short Circuit User code
Failure code Failure
E41 Detail of failure Action of controller Problem on machine Related information
DW4GKB q q q
When outputting current to boom RAISE throttle EPC solenoid, abnormal current flows and short circuit is detected. Stops outputting current to boom RAISE throttle EPC. Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position.
q
Boom RAISE does not function.
q
Turning the emergency operating switch of work equipment to ON, work equipment can be operated. Drive current of boom raise adjust EPC solenoid can be checked with monitoring function. (Code: 01800 Boom RAISE throttle EPC solenoid current) Method of reproducing failure code: Start engine and operate lever to boom RAISE.
q q
Cause Defective boom RAISE throttle 1 EPC solenoid (Internal short circuit or ground fault)
2
3
Defective work equipment emergency operation switch
Ground fault in wiring harness (Contact with ground circuit)
4 Short circuit in wiring harness
5 Defective pump controller
40-282
Boom throttle EPC solenoid short circuit (Pump controller system)
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector V09, and connect T-adapter to male side. Between V09 (male) (1) and (2)
Resistance
5 – 25 z
1. Turn starting switch to OFF position. 2. Disconnect connector S26, and connect T-adapter to male side. a Measure work equipment emergency operation switch at normal position (lower side). Between S26 (male) (2) and (3)
Resistance
Max. 1 z
Between S26 (male) (5) and (6)
Resistance
Max. 1 z
1. Turn starting switch to OFF position. 2. Disconnect connectors C02 and V09, and connect T-adapters to each female side of them. a Measure work equipment emergency operation switch at normal position (lower side). Between C02 (female) (105) or V09 (female) (1) Resistance Min. 1 Mz and ground 1. Turn starting switch to OFF position. 2. Disconnect connectors C02 and V09, and connect T-adapter to female side of either of them. a Measure work equipment emergency operation switch at normal position (lower side). Between C02 (female) (105) and (115), or between Resistance Min. 1 Mz V09 (female) (1) and (2) If cause is not found by above checks, pump controller is defective.
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [DW4GKB] Boom Slow Down Sol. Short Circuit
Circuit diagram related to boom RAISE throttle EPC solenoid
PC228US-8,PC228USLC-8
40-283
40-283
Troubleshooting by failure code Failure code [DW4WKA] Cancel Bucket Dump Open Circuit
Failure code [DW4WKA] Cancel Bucket Dump Open Circuit User code
Failure code Failure
E50 Detail of failure Action of controller Problem on machine Related information
DW4WKA q
Bucket DUMP prohibit EPC solenoid open circuit (Pump controller system)
q
When stop outputting current to bucket DUMP prohibit EPC solenoid, controller solenoid output voltage is above standard value and open circuit is detected. None in particular (Since no current flows, solenoid does not operate). If cause of failure disappears, machine becomes normal by itself.
q
Bucket DUMP does not work.
q
This failure code is subject to be displayed only when arm crane mode (L) is selected for arm crane specification machine. Method of reproducing failure code: Turn starting switch to ON position and select arm crane mode (L).
q
q
Cause Defective bucket DUMP prohibit 1 EPC solenoid (Internal open circuit)
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector Y08 and connect T-adapter to male side. Between Y08 (male) (1) and (2)
Resistance
20 – 60 z
1. Turn starting switch to OFF position. Open or short circuit in wiring har- 2. Disconnect connector C02 and connect T-adapter to female side. 2 ness Between C02 (male) (94) and (115) Resistance 20 – 60 z (Resistance of EPC solenoid coil) a If no failure is found by above checks, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors C02 and Y08 and connect T-adapter to each female Open circuit in wiring harness side of them. 3 (Wire breakage or defective contact) Between C02 (female) (94) and Y08 (female) (1) Resistance Max. 1 z Between C02 (female) (115) and Y08 (female) (2) 4 Defective pump controller
40-284
Resistance
Max. 1 z
If cause is not found by above checks, pump controller is defective.
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [DW4WKA] Cancel Bucket Dump Open Circuit
Circuit diagram related to bucket DUMP prohibit EPC solenoid
PC228US-8,PC228USLC-8
40-285
40-285
Troubleshooting by failure code Failure code [DW4WKB] Cancel Bucket Dump Short Circuit
Failure code [DW4WKB] Cancel Bucket Dump Short Circuit User code
Failure code Failure
– Detail of failure Action of controller Problem on machine Related information
DW4WKB q q q
Bucket DUMP prohibit EPC solenoid short circuit (Pump controller system)
When outputting current to bucket DUMP prohibit EPC solenoid, abnormal current flows in circuit and short circuit is detected. Stops outputting current to bucket DUMP prohibit EPC solenoid. Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position.
q
Bucket DUMP does not work.
q
This failure code is detected only when other than arm crane mode (L) is set for the machine with arm crane specification. Method of reproducing failure code: Turn starting switch to ON position and select arm crane mode (L).
q
Cause Defective bucket DUMP prohibit 1 EPC solenoid (Internal short circuit or ground fault)
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector Y08 and connect T-adapter to male side. Between Y08 (male) (1) and (2)
Resistance
20 – 60 z
Between Y08 (male) (2) and ground
Resistance
Min. 1 Mz
1. Turn starting switch to OFF position. Open or short circuit in wiring har- 2. Disconnect connector C02 and connect T-adapter to female side. 2 ness Between C02 (male) (94) and (115) Resistance 20 – 60 z (Resistance of EPC solenoid coil) 1. Turn starting switch to OFF position. 2. Disconnect connectors C02 and Y08, and connect T-adapter to female side Ground fault in wiring harness 3 of either of them. (Contact with ground circuit) Between C02 (female) (94) or Y08 (female) (1) and Resistance Min. 1 Mz ground 4 Defective pump controller
40-286
If cause is not found by above checks, pump controller is defective.
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [DW4WKB] Cancel Bucket Dump Short Circuit
Circuit diagram related to bucket DUMP prohibit EPC solenoid
PC228US-8,PC228USLC-8
40-287
40-287
Troubleshooting by failure code Failure code [DW91KA] Travel Junction Sol. Disc.
Failure code [DW91KA] Travel Junction Sol. Disc. User code
Failure code Failure
– Detail of failure Action of controller Problem on machine
DW91KA q
Travel interconnection solenoid open circuit (Pump controller system)
q
When stop outputting current to travel interconnection valve solenoid, controller solenoid output voltage is above standard value and open circuit is detected. None in particular (Since no current flows, solenoid does not operate). If cause of failure disappears, machine becomes normal by itself.
q
Machine is not steered easily during travel.
q
Controller's command (ON/OFF) to travel junction valve solenoid can be checked with monitoring function. (If controller sends solenoid ON command, monitoring display is ON even if solenoid is not switched ON due to open circuit.) (Code: 02300 Solenoid 1) Method of reproducing failure code: Start engine and steer machine with right and left travel levers.
q
Related information q
Cause Defective travel interconnection 1 solenoid (Internal open circuit)
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector V02, and connect T-adapter to male side. Between V02 (male) (1) and (2)
Resistance
20 – 60 z
1. Turn starting switch to OFF position. Open or short circuit in wiring har- 2. Disconnect connector C02 and connect T-adapter to female side. 2 ness Between C02 (female) (110) and (115) or (117) or Resistance 20 – 60 z (120) a If no abnormality is found in checks on cause 2, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors C02 and V02, and connect T-adapters to each Open circuit in wiring harness female side of them. 3 (Wire breakage or defective contact of connector)
4 Defective pump controller
40-288
Between C02 (female) (110) and V02 (female) (1)
Resistance
Max. 1 z
Between V02 (female) (2) and C02 (female) (115) Resistance Max. 1 z or (117) or (120) If no abnormality is found by above checks, pump controller is defective. (Since this is an internal failure, troubleshooting cannot be performed.)
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [DW91KA] Travel Junction Sol. Disc.
Circuit diagram related to travel interconnection valve solenoid
PC228US-8,PC228USLC-8
40-289
40-289
Troubleshooting by failure code Failure code [DW91KB] Travel Junction Sol. S/C
Failure code [DW91KB] Travel Junction Sol. S/C User code
Failure code Failure
–
DW91KB
Detail of failure Action of controller Problem on machine
q q q
Travel interconnection solenoid short circuit (Pump controller system)
When outputting current to travel interconnection valve solenoid, abnormal current flows in circuit and short circuit is detected. Stop outputting current to travel junction solenoid. Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position.
q
Machine is not steered easily during travel.
q
Controller's command (ON/OFF) to travel junction valve solenoid can be checked with monitoring function. (If controller sends solenoid ON command, monitoring display is ON even if solenoid is not switched ON due to short circuit.) (Code: 02300 Solenoid 1) Method of reproducing failure code: Start engine and steer machine with right and left travel levers.
Related information q
Cause
Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position. Defective travel interconnec2. Disconnect connector V02, and connect T-adapter to male side. tion solenoid 1 Between V02 (male) (1) and (2) Resistance (Internal short circuit or ground fault) Between V02 (male) (1) and ground Resistance
2
Short circuit or ground fault in wiring harness
20 – 60 z Min. 1 Mz
1. Turn starting switch to OFF position. 2. Disconnect connector C02 and connect T-adapter to female side. Between C02 (female) (110) and (115) or (117) or (120) Resistance
20 – 60 z
Between C02 (female) (110) and ground
Min. 1 Mz
Resistance
a If no abnormality is found in checks on cause 2, this check is not required. 1. Turn starting switch to OFF position. Ground fault in wiring har2. Disconnect connectors C02 and V02, and connect T-adapter to female side of 3 ness either of them. (Contact with ground circuit) Between C02 (female) (110) or V02 (female) (1) and Resistance Min. 1 Mz ground If no abnormality is found by above checks, pump controller is defective. (Since this 4 Defective pump controller is an internal failure, troubleshooting cannot be performed.)
40-290
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [DW91KB] Travel Junction Sol. S/C
Circuit diagram related to travel interconnection valve solenoid
PC228US-8,PC228USLC-8
40-291
40-291
Troubleshooting by failure code Failure code [DWA2KA] Attachment Sol Open Circuit
Failure code [DWA2KA] Attachment Sol Open Circuit User code
Failure code Failure
– Detail of failure Action of controller Problem on machine
DWA2KA
Attachment single/multiple selector solenoid open circuit (Pump controller system)
q
When outputting current to attachment return selector solenoid, no current flows and open circuit is detected.
q q
None in particular (Since no current flows, solenoid does not operate). If cause of failure disappears, machine becomes normal by itself.
q
Hydraulic circuit for attachment does not change to single-acting circuit.
q
Controller's command (ON/OFF) to attachment return selector solenoid can be checked with monitoring function. (If controller sends solenoid ON command, monitoring display is ON even if solenoid is not switched ON due to open circuit.) (Code: 02301 Solenoid 2) Method of reproducing failure code: Turn starting switch ON and set machine in mode other than breaker mode (B).
Related information q
Cause
Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position. Defective attachment return selec- 2. Disconnect connector V06, and connect T-adapter to male side. 1 tor solenoid (Internal open circuit) Between V06 (male) (1) and (2) Resistance 20 – 60 z 1. Turn starting switch to OFF position. Open circuit or ground fault in wir- 2. Disconnect connector C02 and connect T-adapter to female side. 2 ing harness Between C02 (female) (86) and C02 (female) (115) Resistance 20 – 60 z or (117) or (120) a If no abnormality is found in checks on cause 2, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors C02 and V06, and connect T-adapters to each Open circuit in wiring harness female side of them. 3 (Wire breakage or defective conBetween C02 (female) (86) and V06 (female) (1) Resistance Max. 1 z tact of connector) Between V06 (female) (2) and C02 (female) (115) or (117) or (120) 4 Defective pump controller
40-292
Resistance
Max. 1 z
If no abnormality is found by above checks, pump controller is defective. (Since this is an internal failure, troubleshooting cannot be performed.)
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [DWA2KA] Attachment Sol Open Circuit
Circuit diagram related to ATT single/multiple selector solenoid
PC228US-8,PC228USLC-8
40-293
40-293
Troubleshooting by failure code Failure code [DWA2KB] Attachment Sol Short Circuit
Failure code [DWA2KB] Attachment Sol Short Circuit User code
Failure code Failure
– Detail of failure Action of controller Problem on machine
DWA2KB
Attachment single/multiple selector solenoid short circuit (Pump controller system)
q
When outputting current to attachment return selector solenoid, abnormal current flows in circuit and short circuit is detected.
q q
Stops outputting current to attachment return selector solenoid. Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position.
q
Hydraulic circuit for attachment does not change to single-acting circuit.
q
Controller's command (ON/OFF) to attachment return selector solenoid can be checked with monitoring function. (If controller sends solenoid ON command, monitoring display is ON even if solenoid is not switched ON due to short circuit.) (Code: 02301 Solenoid 2) Method of reproducing failure code: Turn starting switch ON and set machine in breaker mode (B).
Related information q
Cause
Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position. Defective attachment return selec- 2. Disconnect connector V06, and connect T-adapter to male side. 1 tor solenoid (Internal short circuit, Between V06 (male) (1) and (2) Resistance 20 – 60 z ground fault) Between V06 (male) (1) and ground Resistance Min. 1 Mz 1. Turn starting switch to OFF position. Open circuit or ground fault in wir- 2. Disconnect connector C02 and connect T-adapter to female side. 2 ing harness Between C02 (female) (86) and (115) or (117) or Resistance 20 – 60 z (120) a If no abnormality is found in checks on cause 2, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors C02 and V06, and connect T-adapter to female side Ground fault in wiring harness 3 of either of them. (Contact with ground circuit) Between C02 (female) (86) or V06 (female) (1) and Resistance Min. 1 Mz ground 4 Defective pump controller
40-294
If no abnormality is found by above checks, pump controller is defective. (Since this is an internal failure, troubleshooting cannot be performed.)
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [DWA2KB] Attachment Sol Short Circuit
Circuit diagram related to ATT single/multiple selector solenoid
PC228US-8,PC228USLC-8
40-295
40-295
Troubleshooting by failure code Failure code [DWK0KA] 2-stage Relief Sol Open Circuit
Failure code [DWK0KA] 2-stage Relief Sol Open Circuit User code
Failure code Failure
–
DWK0KA
2-stage relief solenoid open circuit (Pump controller system)
q
When stop outputting current to 2-stage relief solenoid circuit, controller solenoid output voltage is above standard value and open circuit is detected.
Action of controller
q
None in particular (Since no current flows, solenoid does not operate). If cause of failure disappears, machine becomes normal by itself.
Problem on machine
q
Detail of failure
q
q q
Related information
q q q
Travel power is low (The main relief valve is not set in the HIGH PRESSURE position) One-touch power maximizing function does not work. Controller's command (ON/OFF) to 2-stage relief solenoid can be checked with monitoring function. (If controller sends solenoid ON command, monitoring display is ON even if solenoid is not switched ON due to open circuit.) (Code: 02300 Solenoid 1) As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be measured at pump controller connector. Controller detects open circuit when no current is output to solenoid. Method of reproducing failure code: Turn starting switch to ON position.
Cause 1
Defective 2-stage relief solenoid (Internal open circuit)
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector V05, and connect T-adapter to male side. Between V05 (male) (1) and (2)
Resistance
20 – 60 z
1. Turn starting switch to OFF position. 2. Disconnect connector C02 and connect T-adapter to female side. Open or short circuit in wiring har- a If resistance is above 1 Mz, wiring harness has open circuit. If resistance is 2 below 1 z, wiring harness has short circuit. ness Between C02 (female) (109) and (115) or Resistance 20 – 60 z (117) or (120) a If cause 2 is not the cause for the trouble, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors C02 and V05, and connect T-adapters to each Open circuit in wiring harness female side of them. 3 (Wire breakage or defective con- Between C02 (female) (109) and V05 Resistance Max. 1 z tact of connector) (female) (1) Between V05 (female) (2) and C02 (female) (115) or (117) or (120) 4 Defective pump controller
40-296
Resistance
Max. 1 z
If no abnormality is found by the above checks, pump controller may be defective. (Since this is an internal failure, troubleshooting cannot be performed.)
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [DWK0KA] 2-stage Relief Sol Open Circuit
Circuit diagram related to 2-stage relief solenoid
PC228US-8,PC228USLC-8
40-297
40-297
Troubleshooting by failure code Failure code [DWK0KB] 2-stage Relief Sol Short Circuit
Failure code [DWK0KB] 2-stage Relief Sol Short Circuit User code
Failure code Failure
– Detail of failure Action of controller Problem on machine
DWK0KB q
When outputting current to drive 2-stage relief solenoid circuit, abnormal current flows in circuit and short circuit is detected.
q
Stop outputting current to 2-stage relief solenoid circuit. Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position.
q
q q q
Related information
q q q
Travel power is low (The main relief valve is not set in the HIGH PRESSURE position) One-touch power maximizing function does not work. Controller's command (ON/OFF) to 2-stage relief solenoid can be checked with monitoring function. (If controller sends solenoid ON command, monitoring display is ON even if solenoid is not switched ON due to short circuit.) (Code: 02300 Solenoid 1) As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be measured at pump controller connector. Controller detects open circuit when no current is output to solenoid. Method of reproducing failure code: Turn starting switch to ON position.
Cause Defective 2-stage relief solenoid 1 (Internal short circuit or ground fault)
2
2-stage relief solenoid short circuit (Pump controller system)
Ground fault in wiring harness (Contact with ground circuit)
3 Short circuit in wiring harness
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector V05, and connect T-adapter to male side. Between V05 (male) (1) and (2)
Resistance
20 – 60 z
Between V05 (female) (1) and ground
Resistance
Min. 1 Mz
1. Turn starting switch to OFF position. 2. Disconnect connectors C02 and V05, and connect T-adapter to female side of V05. Between C02 (female) (109) or V05 (female) (1) and ground
40-298
Min. 1 Mz
1. Turn starting switch to OFF position. 2. Disconnect connectors C02 and V05, and connect T-adapter to female side of V05. Between V05 (female) (1) and (2)
4 Defective pump controller
Resistance
Resistance
Min. 1 Mz
If no abnormality is found by the above checks, pump controller may be defective. (Since this is an internal failure, troubleshooting cannot be performed.)
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [DWK0KB] 2-stage Relief Sol Short Circuit
Circuit diagram related to 2-stage relief solenoid
PC228US-8,PC228USLC-8
40-29
40-299
Troubleshooting by failure code Failure code [DXA8KA] PC-EPC (F) Sol Open Circuit
Failure code [DXA8KA] PC-EPC (F) Sol Open Circuit User code
Failure code Failure
E02
DXA8KA
Detail of failure q Action of controller Problem on machine Related information
q
F-PC-EPC solenoid system open circuit (Pump controller system)
When F-PC-EPC solenoid is driven, no current flows and open circuit is detected.
q
None in particular (Since no current flows, solenoid does not operate). If cause of failure disappears, machine becomes normal by itself.
q
If the pump load increases, the engine speed lowers sharply and may cause engine stall.
q
When solenoid and wiring harness are normal, engine can be prevented from stalling by turning emergency pump drive switch to ON. Drive current of F-PC-EPC solenoid can be checked with monitoring function. (Code: 01300 PC-EPC solenoid current (F)) Method of reproducing failure code: Turn starting switch to ON position.
q q
Cause Defective F-PC-EPC solenoid 1 (Internal open circuit)
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector V11, and connect T-adapter to male side. Between V11 (male) (1) and (2)
Resistance
3 – 14 z
1. Turn starting switch to OFF position. 2. Disconnect connector S25, and connect T-adapter to male side. Emergency pump drive switch 2 defective (Internal open circuit in wiring)
Between S25 (male) (3) and (2)
Between S25 (male) (6) and (5)
Switch position: Normal
Resistance
Max. 1 z
Switch position: Emergency
Resistance
Min. 1 Mz
Switch position: Normal
Resistance
Max. 1 z
Switch position: Emergency
Resistance
Min. 1 Mz
1. Turn starting switch to OFF position. 2. Disconnect connector C02 and connect T-adapter to female side. Open or short circuit in wiring har- a Check that emergency pump drive switch is at normal position (lower side). 3 ness Between C02 (female) (96) and (115) or (117) or Resistance 3 – 14 z (120) a If no abnormality is found in checks on cause 3, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors C02, S25 and V11, and connect T-adapters to each female side of them. Open circuit in wiring harness Between C02 (female) (96) and S25 (female) (3) Resistance Max. 1 z 4 (Wire breakage or defective conBetween S25 (female) (2) and V11 (female) (1) Resistance Max. 1 z tact of connector)
5 Defective pump controller
40-300
Between S25 (female) (6) and C02 (female) (115) or (117) or (120)
Resistance
Max. 1 z
Between S25 (female) (5) and V11 (female) (2)
Resistance
Max. 1 z
If no abnormality is found by above checks, pump controller is defective. (Since this is an internal failure, troubleshooting cannot be performed.)
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [DXA8KA] PC-EPC (F) Sol Open Circuit
Circuit diagram related to PC-EPC solenoid
PC228US-8,PC228USLC-8
40-301
40-301
Troubleshooting by failure code Failure code [DXA8KB] PC-EPC (F) Sol Short Circuit
Failure code [DXA8KB] PC-EPC (F) Sol Short Circuit User code
Failure code Failure
E02
DXA8KB
F-PC-EPC solenoid system short circuit (Pump controller system)
Detail of failure q
When F-PC-EPC solenoid is driven, abnormal current flows in circuit and short circuit is detected.
q q
Stops outputting current to F-PC-EPC solenoid. Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position.
q
If the pump load increases, the engine speed lowers sharply and may cause engine stall.
q
When solenoid and wiring harness are normal, engine can be prevented from stalling by turning emergency pump drive switch to ON. Drive current of F-PC-EPC solenoid can be checked with monitoring function. (Code: 01300 PC-EPC solenoid current (F)) Method of reproducing failure code: Turn starting switch to ON position.
Action of controller Problem on machine Related information
q q
Cause Defective F-PC-EPC solenoid 1 (Internal short circuit or ground fault)
Defective emergency pump drive 2 switch (Internal short circuit or ground fault)
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector V11, and connect T-adapter to male side. Between V11 (male) (1) and (2)
Resistance
3 – 14 z
Between V11 (male) (1) and ground
Resistance
Min. 1 Mz
1. Turn starting switch to OFF position. 2. Disconnect connector S25, and connect T-adapter to male side. Between S25 (male) (2) or (3) and (5) Between S25 (male) (2) or (3) and ground
Resistance Switch position: Normal Resistance
Min. 1 Mz Min. 1 Mz
1. Turn starting switch to OFF position. 2. Disconnect connector C02 and connect T-adapter to female side. a Check that emergency pump drive switch is at normal position (lower side).
3
Short circuit or ground fault in wirBetween C02 (female) (96) and (115) or (117) or ing harness (120) Between C02 (female) (96) and ground
4
Ground fault in wiring harness (Contact with ground circuit)
40-302
3 – 14 z
Resistance
Min. 1 Mz
a If no abnormality is found in checks on cause 3, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors C02, S25 and V11, and connect T-adapter to female side of either connector. Between C02 (female) (96) or S25 (female) (3) and Resistance Min. 1 Mz ground Between S25 (female) (5) or V11 (female) (2) and ground
5 Defective pump controller
Resistance
Resistance
Min. 1 Mz
If no abnormality is found by above checks, pump controller is defective. (Since this is an internal failure, troubleshooting cannot be performed.)
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [DXA8KB] PC-EPC (F) Sol Short Circuit
Circuit diagram related to PC-EPC solenoid
PC228US-8,PC228USLC-8
40-303
40-303
Troubleshooting by failure code Failure code [DXA9KA] PC-EPC (R) Sol Open Circuit
Failure code [DXA9KA] PC-EPC (R) Sol Open Circuit User code
Failure code Failure
E02
DXA9KA
Detail of failure q Action of controller Problem on machine Related information
q
R-PC-EPC solenoid system open circuit (Pump controller system)
When R-PC-EPC solenoid is driven, no current flows and open circuit is detected.
q
None in particular (Since no current flows, solenoid does not operate). If cause of failure disappears, machine becomes normal by itself.
q
If the pump load increases, the engine speed lowers sharply and may cause engine stall.
q
When solenoid and wiring harness are normal, engine can be prevented from stalling by turning emergency pump drive switch to ON. Drive current of R-PC-EPC solenoid can be checked with monitoring function. (Code: 01300 PC-EPC solenoid current (R)) Method of reproducing failure code: Turn starting switch to ON position.
q q
Cause Defective R-PC-EPC solenoid 1 (Internal open circuit)
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector V12, and connect T-adapter to male side. Between V12 (male) (1) and (2)
Resistance
3 – 14 z
1. Turn starting switch to OFF position. 2. Disconnect connector S25, and connect T-adapter to male side. Emergency pump drive switch 2 defective (Internal open circuit)
Between S25 (male) (3) and (2)
Between S25 (male) (6) and (5)
Switch position: Normal
Resistance
Max. 1 z
Switch position: Emergency
Resistance
Min. 1 Mz
Switch position: Normal
Resistance
Max. 1 z
Switch position: Emergency
Resistance
Min. 1 Mz
1. Turn starting switch to OFF position. 2. Disconnect connector C02 and connect T-adapter to female side. Open or short circuit in wiring har- a Check that emergency pump drive switch is at normal position (lower side). 3 ness Between C02 (female) (96) and (115) or (117) or Resistance 3 – 14 z (120) a If no abnormality is found in checks on cause 3, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors C02, S25 and V12, and connect T-adapters to each female side of them. Open circuit in wiring harness Between C02 (female) (96) and S25 (female) (3) Resistance Max. 1 z 4 (Wire breakage or defective conBetween S25 (female) (2) and V12 (female) (1) Resistance Max. 1 z tact of connector)
5 Defective pump controller
40-304
Between S25 (female) (6) and C02 (female) (115) or (117) or (120)
Resistance
Max. 1 z
Between S25 (female) (5) and V12 (female) (2)
Resistance
Max. 1 z
If no abnormality is found by above checks, pump controller is defective. (Since this is an internal failure, troubleshooting cannot be performed.)
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [DXA9KA] PC-EPC (R) Sol Open Circuit
Circuit diagram related to PC-EPC solenoid
PC228US-8,PC228USLC-8
40-305
40-305
Troubleshooting by failure code Failure code [DXA9KB] PC-EPC (R) Sol Short Circuit
Failure code [DXA9KB] PC-EPC (R) Sol Short Circuit User code
Failure code Failure
E02
DXA9KB
Detail of failure q Action of controller Problem on machine Related information
q
R-PC-EPC solenoid system short circuit (Pump controller system)
When R-PC-EPC solenoid is driven, abnormal current flows and short circuit is detected.
q
Stops outputting current to R-PC-EPC solenoid. Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position.
q
If the pump load increases, the engine speed lowers sharply and may cause engine stall.
q
When solenoid and wiring harness are normal, engine can be prevented from stalling by turning emergency pump drive switch to ON. Drive current of R-PC-EPC solenoid can be checked with monitoring function. (Code: 01300 PC-EPC solenoid current (R)) Method of reproducing failure code: Turn starting switch to ON position.
q q
Cause Defective R-PC-EPC solenoid 1 (Internal short circuit or ground fault)
Defective emergency pump drive 2 switch (Internal short circuit or ground fault)
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector V12, and connect T-adapter to male side. Between V12 (male) (1) and (2)
Resistance
3 – 14 z
Between V12 (male) (1) and ground
Resistance
Min. 1 Mz
1. Turn starting switch to OFF position. 2. Disconnect connector S25, and connect T-adapter to male side. Between S25 (male) (2) or (3) and (5) Between S25 (male) (2) or (3) and ground
Resistance Switch position: Normal Resistance
Min. 1 Mz Min. 1 Mz
1. Turn starting switch to OFF position. 2. Disconnect connector C02 and connect T-adapter to female side. a Check that emergency pump drive switch is at normal position (lower side).
3
Short circuit or ground fault in wirBetween C02 (female) (96) and (115) or (117) or ing harness (120) Between C02 (female) (96) and ground
4
Ground fault in wiring harness (Contact with ground circuit)
40-306
3 – 14 z
Resistance
Min. 1 Mz
a If no abnormality is found in checks on cause 3, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors C02, S25 and V12, and connect T-adapter to female side of either connector. Between C02 (female) (96) or S25 (female) (3) and Resistance Min. 1 Mz ground Between S25 (female) (5) or V12 (female) (2) and ground
5 Defective pump controller
Resistance
Resistance
Min. 1 Mz
If no abnormality is found by above checks, pump controller is defective. (Since this is an internal failure, troubleshooting cannot be performed.)
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [DXA9KB] PC-EPC (R) Sol Short Circuit
Circuit diagram related to PC-EPC solenoid
PC228US-8,PC228USLC-8
40-307
40-307
Troubleshooting by failure code Failure code [DXE0KA] LS-EPC Sol Open Circuit
Failure code [DXE0KA] LS-EPC Sol Open Circuit User code
Failure code Failure
–
DXE0KA
Detail of failure q Action of controller
q
Problem on machine
q
Related information
q
q q q
When LS-EPC solenoid is driven, no current flows and open circuit is detected . None in particular (Since no current flows, solenoid does not operate). If cause of failure disappears, machine becomes normal by itself. Travel speed is high at Lo and Mi. Work equipment speed and swing speed are high in fine control mode (L). Drive current of LS-EPC solenoid can be checked with monitoring function. (Code: 01500 LS-EPC solenoid current) Method of reproducing failure code: Turn starting switch to ON position.
Cause 1
LS-EPC solenoid system open circuit (Pump controller system)
Defective LS-EPC solenoid (Internal open circuit)
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector V19, and connect T-adapter to male side. Between V19 (male) (1) and (2)
Resistance
3 – 14 z
1. Turn starting switch to OFF position. Open or short circuit in wiring har- 2. Disconnect connector C02 and connect T-adapter to female side. 2 ness Between C02 (female) (88) and (115) or (117) or Resistance 3 – 14 z (120) a If cause 2 is not the cause of failure, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors C02 and V19, and connect T-adapters to each Open circuit in wiring harness female side of them. 3 (Wire breakage or defective conBetween C02 (female) (88) and V19 (female) (1) Resistance Max. 1 z tact of connector) Between V19 (female) (2) and C02 (female) (115) or (117) or (120) 4 Defective pump controller
40-308
Resistance
Max. 1 z
If no abnormality is found by above checks, pump controller is defective. (Since this is an internal failure, troubleshooting cannot be performed.)
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [DXE0KA] LS-EPC Sol Open Circuit
Circuit diagram related to LS-EPC solenoid
PC228US-8,PC228USLC-8
40-309
40-309
Troubleshooting by failure code Failure code [DXE0KB] LS-EPC Sol Short Circuit
Failure code [DXE0KB] LS-EPC Sol Short Circuit User code
Failure code Failure
–
DXE0KB
Detail of failure q Action of controller Problem on machine Related information
q q
q q q q
LS-EPC solenoid system short circuit (Pump controller system)
When LS-EPC solenoid is driven, abnormal current flows and short circuit is detected . Stops outputting current to LS-EPC solenoid. Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position. Travel speed is high at Lo and Mi. Work equipment speed and swing speed are high in fine control mode (L). Drive current of LS-EPC solenoid can be checked with monitoring function. (Code: 01500 LS-EPC solenoid current) Method of reproducing failure code: Turn starting switch to ON position.
Cause Defective LS-EPC solenoid 1 (Internal short circuit or ground fault)
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector V19 and connect T-adapter to male side. Between V19 (male) (1) and (2)
Resistance
3 – 14 z
Between V19 (male) (2) and ground
Resistance
Min. 1 Mz
1. Turn starting switch to OFF position. 2. Disconnect connector C02 and connect T-adapter to female side. 2
Short circuit or ground fault in wirBetween C02 (female) (88) and (115) or (117) or ing harness (120) Between C02 (female) (88) and ground
3
Ground fault in wiring harness (Contact with ground circuit)
4 Defective pump controller
40-310
Resistance
3 – 14 z
Resistance
Min. 1 Mz
a If cause 2 is not the cause of failure, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors C02 and V19, and connect T-adapter to female side of either of them. Between C02 (female) (88) or V19 (female) (1) and Resistance Min. 1 Mz ground If no abnormality is found by above checks, pump controller is defective. (Since this is an internal failure, troubleshooting cannot be performed.)
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [DXE0KB] LS-EPC Sol Short Circuit
Circuit diagram related to LS-EPC solenoid
PC228US-8,PC228USLC-8
40-31
40-311
Troubleshooting by failure code Failure code [DXE4KA] Service Current EPC Disc.
Failure code [DXE4KA] Service Current EPC Disc. User code
Failure code Failure
–
DXE4KA
Detail of failure q Action of controller Problem on machine Related information
q
Service flow throttle EPC open circuit (Pump controller system)
When service flow throttle EPC solenoid is driven, no current flows and open circuit is detected.
q
None in particular (Since no current flows, solenoid does not operate). If cause of failure disappears, machine becomes normal by itself.
q
Attachment does not move.
q
Drive current of service current EPC solenoid can be checked with monitoring function. (Code: 01700 Service solenoid current) Method of reproducing failure code: Turn starting switch ON and set machine in breaker mode (B).
q
Cause Defective service current EPC 1 solenoid for attachment (Internal open circuit)
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector V30, and connect T-adapter to male side. Between V30 (male) (1) and (2)
Resistance
3 – 14 z
1. Turn starting switch to OFF position. Open or short circuit in wiring har- 2. Disconnect connector C02 and connect T-adapter to female side. 2 ness Between C02 (female) (97) and (115) or (117) or Resistance 3 – 14 z (120) a If cause 2 is not the cause of failure, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors C02 and V30, and connect T-adapters to each Open circuit in wiring harness female side of them. 3 (Wire breakage or defective conBetween C02 (female) (97) and V30 (female) (1) Resistance Max. 1 z tact of connector) Between V30 (female) (2) and C02 (female) (115) or (117) or (120) 4 Defective pump controller
40-312
Resistance
Max. 1 z
If no abnormality is found by above checks, pump controller is defective. (Since this is an internal failure, troubleshooting cannot be performed.)
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [DXE4KA] Service Current EPC Disc.
Circuit diagram related to service flow throttle EPC
PC228US-8,PC228USLC-8
40-313
40-313
Troubleshooting by failure code Failure code [DXE4KB] Service Current EPC S/C
Failure code [DXE4KB] Service Current EPC S/C User code
Failure code Failure
– Detail of failure Action of controller Problem on machine Related information
DXE4KB q q q
Service flow throttle EPC short circuit (Pump controller system)
When service flow throttle EPC solenoid is driven, abnormal current flows and short circuit is detected . Stops outputting current to service EPC solenoid. Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position.
q
Attachment does not move.
q
Drive current of service flow adjust EPC solenoid can be checked with monitoring function. (Code: 01700 Service solenoid current) Method of reproducing failure code: Turn starting switch ON and set machine in breaker mode (B).
q
Cause Defective service EPC solenoid 1 (Internal short circuit or ground fault)
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector V30, and connect T-adapter to male side. Between V30 (male) (1) and (2)
Resistance
3 – 14 z
Between V30 (male) (1) and ground
Resistance
Min. 1 Mz
1. Turn starting switch to OFF position. 2. Disconnect connector C02 and connect T-adapter to female side. 2
Short circuit or ground fault in wirBetween C02 (female) (97) and (115) or (117) or ing harness (120) Between C02 (female) (97) and ground
3
Ground fault in wiring harness (Contact with ground circuit)
4 Defective pump controller
40-314
Resistance
3 – 14 z
Resistance
Min. 1 Mz
a If cause 2 is not the cause of failure, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors C02 and V30, and connect T-adapter to female side of either connector. Between C02 (female) (97) or V30 (female) (1) and Resistance Min. 1 Mz ground If no abnormality is found by above checks, pump controller is defective. (Since this is an internal failure, troubleshooting cannot be performed.)
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [DXE4KB] Service Current EPC S/C
Circuit diagram related to service flow throttle EPC
PC228US-8,PC228USLC-8
40-315
40-315
Troubleshooting by failure code Failure code [DXE5KA] Merge-divider Main Sol Open Circuit
Failure code [DXE5KA] Merge-divider Main Sol Open Circuit User code
Failure code Failure
– Detail of failure
DXE5KA q q
Action of controller Problem on machine Related information
q q q q q
Merge-divider main solenoid open circuit (Pump controller system)
When pump merge-divider (main) EPC solenoid is driven, no current flows and open circuit is detected . None in particular (Since no current flows, merge-divider main solenoid does not operate. Since no current flows, merge-divider LS solenoid does not operate, either.) Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position. Single operation speed of work equipment and swing is high in fine control mode (L). Machine cannot be steered easily during travel. Drive current of merge-divider main EPC solenoid can be checked with monitoring function. (Code: 08000 Merge-divider (main) solenoid current) Method of reproducing failure code: Turn starting switch to ON position.
Cause
Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position. Defective merge-divider main EPC 2. Disconnect connector V23, and connect T-adapter to male side. 1 solenoid (internal open circuit) Between V23 (male) (1) and (2) Resistance 3 – 14 z 1. Turn starting switch to OFF position. Open or short circuit in wiring har- 2. Disconnect connector C02 and connect T-adapter to female side. 2 ness Between C02 (female) (112) and (115) or (117) or Resistance 3 – 14 z (120) a If cause 2 is not the cause of failure, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors C02 and V23, and connect T-adapters to each Open circuit in wiring harness female side of them. 3 (Wire breakage or defective conBetween C02 (female) (112) and V23 (female) (1) Resistance Max. 1 z tact of connector) Between V23 (female) (2) and C02 (female) (115) or (117) or (120) 4 Defective pump controller
40-316
Resistance
Max. 1 z
If no abnormality is found by above checks, pump controller is defective. (Since this is an internal failure, troubleshooting cannot be performed.)
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [DXE5KA] Merge-divider Main Sol Open Circuit
Circuit diagram related to pump merge-divider main solenoid
PC228US-8,PC228USLC-8
40-317
40-317
Troubleshooting by failure code Failure code [DXE5KB] Merge-divider Main Sol Short Circuit
Failure code [DXE5KB] Merge-divider Main Sol Short Circuit User code
Failure code Failure
– Detail of failure
DXE5KB q q
Action of controller Problem on machine Related information
q q q q q
Merge-divider main solenoid short circuit (Pump controller system)
When pump merge-divider (main) EPC solenoid is driven, abnormal current flows and short circuit is detected. Stops outputting current to merge-divider (main) EPC solenoid. (Since no current flows, merge-divider LS solenoid does not operate, either.) Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position. Single operation speed of work equipment and swing is high in fine control mode (L). Machine cannot be steered easily during travel. Drive current of merge-divider main EPC solenoid can be checked with monitoring function. (Code: 08000 Merge-divider (main) solenoid current) Method of reproducing failure code: Turn starting switch to ON position.
Cause
Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position. Defective merge-divider main EPC 2. Disconnect connector V23, and connect T-adapter to male side. 1 solenoid (internal short circuit or Between V23 (male) (1) and (2) Resistance 3 – 14 z ground fault) Between V23 (male) (1) and ground Resistance Min. 1 Mz 1. Turn starting switch to OFF position. 2. Disconnect connector C02 and connect T-adapter to female side. Short circuit or ground fault in wirBetween C02 (female) (112) and (115) or (117) or 2 Resistance 3 – 14 z ing harness (120) Between C02 (female) (112) and ground
3
Ground fault in wiring harness (Contact with ground circuit)
4 Defective pump controller
40-318
Resistance
Min. 1 Mz
a If cause 2 is not the cause of failure, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors C02 and V23, and connect T-adapter to female side of either of them. Between C02 (female) (112) or V23 (female) (1) Resistance Min. 1 Mz and ground If no abnormality is found by above checks, pump controller is defective. (Since this is an internal failure, troubleshooting cannot be performed.)
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [DXE5KB] Merge-divider Main Sol Short Circuit
Circuit diagram related to pump merge-divider main solenoid
PC228US-8,PC228USLC-8
40-319
40-319
Troubleshooting by failure code Failure code [DXE6KA] Merge-divider LS Sol Open Circuit
Failure code [DXE6KA] Merge-divider LS Sol Open Circuit User code
Failure code Failure
– Detail of failure
DXE6KA q q
Action of controller Problem on machine Related information
q q q q q
Merge-divider LS solenoid open circuit (Pump controller system)
When pump merge-divider (LS) EPC solenoid is driven, no current flows and open circuit is detected. None in particular (Since no current flows, merge-divider LS solenoid does not operate. Since no current flows, merge-divider main solenoid does not operate, either.) Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position. Single operation speed of work equipment and swing is high in fine control mode (L). Machine cannot be steered easily during travel. Drive current of merge-divider LS EPC solenoid can be checked with monitoring function. (Code: 08001 Merge-divider (LS) solenoid current) Method of reproducing failure code: Turn starting switch to ON position.
Cause Defective merge-divider LS EPC 1 solenoid (internal open circuit)
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector V24, and connect T-adapter to male side. Between V24 (male) (1) and (2)
Resistance
3 – 14 z
1. Turn starting switch to OFF position. Open or short circuit in wiring har- 2. Disconnect connector C02 and connect T-adapter to female side. 2 ness Between C02 (female) (89) and (115) or (117) or Resistance 3 – 14 z (120) a If cause 2 is not the cause of failure, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors C02 and V24, and connect T-adapters to each Open circuit in wiring harness female side of them. 3 (Wire breakage or defective conBetween C02 (female) (89) and V24 (female) (1) Resistance Max. 1 z tact of connector) Between V24 (female) (2) and C02 (female) (115) or (117) or (120) 4 Defective pump controller
40-320
Resistance
Max. 1 z
If no abnormality is found by above checks, pump controller is defective. (Since this is an internal failure, troubleshooting cannot be performed.)
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [DXE6KA] Merge-divider LS Sol Open Circuit
Circuit diagram related to pump merge-divider LS solenoid
PC228US-8,PC228USLC-8
40-321
40-321
Troubleshooting by failure code Failure code [DXE6KB] Merge-divider LS Sol Short Circuit
Failure code [DXE6KB] Merge-divider LS Sol Short Circuit User code
Failure code Failure
– Detail of failure
DXE6KB q q
Action of controller Problem on machine Related information
q q q q q
Merge-divider LS solenoid short circuit (Pump controller system)
When pump merge-divider (LS) EPC solenoid is driven, abnormal current flows and short circuit is detected. Stops outputting current to merge-divider (LS) EPC solenoid. (Since no current flows, merge-divider main solenoid does not operate, either.) Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position. Single operation speed of work equipment and swing is high in fine control mode (L). Machine cannot be steered easily during travel. Drive current of merge-divider LS EPC solenoid can be checked with monitoring function. (Code: 08000 Merge-divider (LS) solenoid current) Method of reproducing failure code: Turn starting switch to ON position.
Cause Defective merge-divider LS EPC 1 solenoid (internal short circuit or ground fault)
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector V24, and connect T-adapter to male side. Between V24 (male) (1) and (2)
Resistance
3 – 14 z
Between V24 (male) (1) and ground
Resistance
Min. 1 Mz
1. Turn starting switch to OFF position. 2. Disconnect connector C02 and connect T-adapter to female side. Short circuit or ground fault in wirBetween C02 (female) (89) and (115) or (117) or 2 Resistance 3 – 14 z ing harness (120) Between C02 (female) (89) and ground
3
Ground fault in wiring harness (Contact with ground circuit)
4 Defective pump controller
40-322
Resistance
Min. 1 Mz
a If cause 2 is not the cause of failure, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors C02 and V24, and connect T-adapter to female side of either of them. Between C02 (female) (89) or V24 (female) (1) and Resistance Min. 1 Mz ground If no abnormality is found by above checks, pump controller is defective. (Since this is an internal failure, troubleshooting cannot be performed.)
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [DXE6KB] Merge-divider LS Sol Short Circuit
Circuit diagram related to pump merge-divider LS solenoid
PC228US-8,PC228USLC-8
40-323
40-323
Troubleshooting by failure code Failure code [DY20KA] Wiper Working Abnormality
Failure code [DY20KA] Wiper Working Abnormality User code
Failure code Failure
–
DY20KA
Detail of failure q Action of controller Problem on machine
q
Wiper working abnormality (Pump controller system)
When windshield wiper works, W signal of working ends is not input.
q
Stops outputting current to wiper motor. If cause of failure disappears, machine becomes normal by itself.
q
Wiper motor does not work.
q
Signal input (ON/OFF) of W contact signal that indicates wiper working area end can be checked with monitoring function. (Code: 02204 Switch input 5) Related infor- q As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be mation measured at pump controller connector. a Single wiper does not have lower wiper of double wiper (Upper wiper is called wiper). q Method of reproducing failure code: Turn starting switch to ON position and set wiper switch to INT or ON. Cause
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector M05 and connect T-adapter to female side.
1
Defective wiper motor (Internal open circuit)
Between M05 (female) (6) and (5) Between M05 (female) (1) and (3)
Wiper position: working area end
Resistance
Max. 1 z
Wiper position: other than Resistance working area end
Min. 1 Mz
Wiper position: whole range
Max. 20 z
Resistance
1. Turn starting switch to OFF position. 2. Disconnect connectors C01 and C02 and connect T-adapters to female side of them. Open or short circuit in wiring harBetween C01 (female) 2 ness (56) and ground
Open circuit in wiring harness 3 (Wire breakage or defective contact of connector)
4 Defective pump controller
40-324
Wiper position: working area end
Resistance
Max. 1 z
Wiper position: other than Resistance working area end
Min. 1 Mz
Between C02 (female) Wiper position: whole Resistance Max. 20 z (114) and (119) range a If cause 2 is not the cause of failure, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors CP01, CP02, and M05. 3. Connect T-adapters to female sides of connector CP01 and CP02 and male side of M05. Between C01 (female) (56) and M05 (male) (6)
Resistance
Max. 1 z
Between M05 (male) (5) and ground (T05)
Resistance
Max. 1 z
Between C02 (female) (114) and M05 (male) (1)
Resistance
Max. 1 z
Between C02 (female) (119) and M05 (male) (3)
Resistance
Max. 1 z
If no abnormality is found by above checks, pump controller is defective. (Since this is an internal failure, troubleshooting cannot be performed.)
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [DY20KA] Wiper Working Abnormality
Circuit diagram related to wiper
PC228US-8,PC228USLC-8
40-325
40-325
Troubleshooting by failure code Failure code [DY20MA] Wiper Parking Abnormality
Failure code [DY20MA] Wiper Parking Abnormality User code
Failure code Failure
–
DY20MA
Detail of failure q Action of controller Problem on machine
Related information
q
Wiper resting abnormality (Pump controller system)
When windshield wiper rests, P signal for rest area is not input.
q
Stops outputting current to rest wiper motor. If cause of failure disappears, machine becomes normal by itself.
q
Wiper motor does not rest.
q
Condition of P contact signal of wiper resting area can be checked with monitoring function. (Code: 02204 Switch input 5) As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be measured at pump controller connector. Method of reproducing failure code: Turn starting switch to ON position and set wiper switch from INT/ON to OFF.
q q
Cause
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector M05 and connect T-adapter to female side.
1
Defective wiper motor (Internal open circuit)
2
Open or short circuit in wiring harBetween C01 (female) ness (75) and ground
Open circuit in wiring harness 3 (Wire breakage or defective contact of connector)
4 Defective pump controller
40-326
Between M05 (female) (4) and (5)
Wiper position: rest area
Resistance
Max. 1 z
Wiper position: working Resistance Min. 1 Mz area Between M05 (female) Wiper position: whole Resistance Max. 20 z (1) and (3) range 1. Turn starting switch to OFF position. 2. Disconnect diode arrays C01 and C02 and connect T-adapters to each female side of them. Wiper position: rest area
Resistance
Max. 1 z
Wiper position: working Resistance Min. 1 Mz area Between C02 (female) Wiper position: whole Resistance Max. 20 z (114) and (119) range a If cause 2 is not the cause of failure, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors C01, C02, and M05. 3. Connect T-adapters to female sides of connector C01 and C02 and male side of M05. Between C01 (female) (75) and M05 (male) (4)
Resistance
Max. 1 z
Between M05 (male) (5) and ground (T05)
Resistance
Max. 1 z
Between C02 (female) (114) and M05 (male) (1)
Resistance
Max. 1 z
Between C02 (female) (119) and M05 (male) (3)
Resistance
Max. 1 z
If no abnormality is found by above checks, pump controller is defective. (Since this is an internal failure, troubleshooting cannot be performed.)
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [DY20MA] Wiper Parking Abnormality
Circuit diagram related to wiper
PC228US-8,PC228USLC-8
40-327
40-327
Troubleshooting by failure code Failure code [DY2CKA] Washer drive discon
Failure code [DY2CKA] Washer drive discon User code
Failure code Failure
–
DY2CKA
Window washer drive system open circuit (Pump controller system)
q
When stop outputting current to window washer drive, no voltage is applied to output pin (pin No. 3) of controller and open circuit is detected.
q q
None in particular (Washer motor does not work because no current flows to it). If cause of failure disappears, machine becomes normal by itself.
Problem on machine
q
Window washer does not operate.
Related information
q
Method of reproducing failure code: Turn starting switch to ON position.
Detail of failure Action of controller
Cause 1 Defective fuse No.4
Defective washer motor 2 (internal open circuit or ground fault)
3
Defective diode array D02 (Internal short circuit)
Procedure, measuring location, criteria and remarks If the fuse is broken, the circuit probably has a grounding fault, etc. (See Cause 6.) 1. Turn starting switch to OFF position. 2. Disconnect diode array M06 and connect T-adapter to male side. Between M06 (male) (1) and (2)
Resistance
5 – 20 z
Between ground and M06 (male) (1) or (2)
Resistance
Min. 1 Mz
1. Turn starting switch to OFF position. 2. Disconnect connector D02 and connect T-adapter to male side. Between D02 (male) (7) (+) and (3) (-)
Continuity
Between D02 (male) (3) (+) and (7) (-)
No continuity
1. Turn starting switch to OFF position. 2. Disconnect connector C01 and connect T-adapter to female side. Open circuit or ground fault in wir- 3. Turn starting switch to ON position. 4 ing harness a Ignore failure code displayed on machine monitor. Between C01 (female) (3) and ground
Open circuit in wiring harness 5 (Wire breakage or defective contact of connector)
6
Ground fault in wiring harness (Contact with ground circuit)
40-328
20 – 30 V
Between F01 (4) and M06 (female) (1)
Resistance
Max. 1 z
Between C01 (female) (3) and M06 (female) (2)
Resistance
Max. 1 z
a If no abnormality is found by check on cause 4, this check is not required. 1. Turn starting switch to OFF position. 2. Remove fuse F01 (4). 3. Disconnect connectors M06, C01, and D02, and connect T-adapter to female side of either connector. Between F01 (4) or M06 (female) (1) or D02 Resistance Min. 1 Mz (female) (3) and ground Between C01 (female) (3) or M06 (female) (2) or D02 (female) (7) and ground
7 Defective pump controller
Voltage
a If no abnormality is found by check on cause 4, this check is not required. 1. Turn starting switch to OFF position. 2. Remove fuse F01 (4). 3. Disconnect connectors M06 and C01 and connect T-adapter to each female side of them.
Resistance
Min. 1 Mz
If no abnormality is found by above checks, pump controller is defective. (Since this is an internal failure, troubleshooting cannot be performed.)
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [DY2CKA] Washer drive discon
Circuit diagram related to window washer motor
PC228US-8,PC228USLC-8
40-329
40-329
Troubleshooting by failure code Failure code [DY2CKB] Washer drive short
Failure code [DY2CKB] Washer drive short User code
Failure code Failure
– Detail of failure Action of controller Problem on machine Related information
DY2CKB q
When outputting current to window washer motor, abnormal current flows and short circuit is detected.
q q
Stops outputting current to washer motor. Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position.
q
Window washer does not operate.
q
Method of reproducing failure code: Turn starting switch to ON position and turn washer switch to ON position.
Cause 1 Defective fuse No.4
Defective washer motor 2 (internal open circuit or ground fault)
3
4
Window washer drive system short circuit (Pump controller system)
Defective diode array D02 (Internal short circuit)
Hot short circuit in wiring harness (Contact with 24 V circuit)
Procedure, measuring location, criteria and remarks If the fuse is broken, the circuit probably has a grounding fault, etc. (See failure code [DY2CKA].) 1. Turn starting switch to OFF position. 2. Disconnect diode array M06 and connect T-adapter to male side. Between M06 (male) (1) and (2)
Resistance
5 – 20 z
Between ground and M06 (male) (1) or (2)
Resistance
Min. 1 Mz
1. Turn starting switch to OFF position. 2. Disconnect connector D02 and connect T-adapter to male side. a Check the continuity in diode range. Between D02 (male) (7) (+) and (3) (-)
Continuity
Between D02 (male) (3) (+) and (7) (-)
No continuity
1. Turn starting switch to OFF position. 2. Disconnect connectors C01 and M06 and connect T-adapter to female side of C01. 3. Remove fuse No. 4. 4. Turn starting switch to ON position. a Ignore failure code displayed on machine monitor. Between C01 (female) (3) and ground
5 Defective pump controller
40-330
Voltage
Max. 1 V
If no abnormality is found by above checks, pump controller is defective. (Since this is an internal failure, troubleshooting cannot be performed.)
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [DY2CKB] Washer drive short
Circuit diagram related to window washer motor
PC228US-8,PC228USLC-8
40-3 1
40-331
Troubleshooting by failure code Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit
Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit User code
Failure code Failure
– Detail of failure Action of controller Problem on machine Related information
DY2DKB
Wiper motor drive normal rotation system short circuit (Pump controller system)
q
When outputting current to normal rotation side of wiper motor drive, abnormal current flows in circuit and short circuit is detected.
q q
Stops outputting current to wiper motor drive forward side. Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position.
q
Windshield wiper does not operate.
q
As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be measured at pump controller connector. Method of reproducing failure code: Turn starting switch to ON position and set wiper switch to INT or ON.
q
Cause Defective wiper motor 1 (Internal short circuit or ground fault)
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector M05 and connect T-adapter to female side. Between M05 (female) (3) and (1)
Continuity
Between M05 (female) (3) and ground
2 Short circuit in wiring harness
3
Ground fault in wiring harness (Contact with ground circuit)
Resistance
Min. 1 Mz
1. Turn starting switch to OFF position. 2. Disconnect connectors CP02 and M05 and connect T-adapter to wiring harness side of either of them. Between C02 (female) (119) and (114), or between Resistance Min. 1 Mz M05 (male) (1) and (3) 1. Turn starting switch to OFF position. 2. Disconnect connectors C02 and M05 and connect T-adapter to wiring harness side of either of them. Between C02 (female) (119) or M05 (male) (3) and Resistance Min. 1 Mz ground If no abnormality is found by above checks, pump controller is defective. (Since this is an internal failure, troubleshooting cannot be performed.) q
4 Defective pump controller
1. 2. 3. 4.
Reference Turn starting switch to OFF position. Insert T-adapter into connector M05. Turn starting switch to ON position. Turn wiper switch ON and OFF, and troubleshoot.
Between M05 (3) and (5)
40-332
Wiper switch: OFF
Voltage
Max. 3 V
Wiper switch: ON
Voltage
Pulse below 3 V io above 20 V
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit
Circuit diagram related to wiper
PC228US-8,PC228USLC-8
40-3 3
40-333
Troubleshooting by failure code Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit
Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit User code
Failure code Failure
– Detail of failure Action of controller Problem on machine Related information
DY2EKB
Wiper motor drive reverse rotation system short circuit (Pump controller system)
q
When outputting current to reverse rotation side of wiper motor drive is turned ON, abnormal current flows in circuit and short circuit is detected.
q q
Stops outputting current to wiper motor drive reverse rotation side. Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position.
q
Windshield wiper does not operate.
q
As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be measured at pump controller connector. Method of reproducing failure code: Turn starting switch to ON position and set wiper switch to INT or ON.
q
Cause Defective wiper motor 1 (Internal short circuit or ground fault)
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector M05 and connect T-adapter to female side. Between M05 (female) (1) and (3)
Continuity
Between M05 (female) (1) and ground
2 Short circuit in wiring harness
Resistance Min. 1 Mz
1. Turn starting switch to OFF position. 2. Disconnect connectors C02 and M05 and connect T-adapter to wiring harness side of either of them. Between C02 (female) (119) and (114), or between M05 (male) (1) and (3)
3
Ground fault in wiring harness (Contact with ground circuit)
Resistance Min. 1 Mz
1. Turn starting switch to OFF position. 2. Disconnect connectors C02 and M05 and connect T-adapter to wiring harness side of either of them. Between C02 (female) (114) or M05 (male) (1) and ground
Resistance Min. 1 Mz
If no abnormality is found by above checks, pump controller is defective. (Since this is an internal failure, troubleshooting cannot be performed.) q
4 Defective pump controller
1. 2. 3. 4.
Reference Turn starting switch to OFF position. Insert T-adapter into connector M05. Turn starting switch to ON position. Turn wiper switch ON and OFF, and troubleshoot.
Between M05 (1) and (5)
40-334
Wiper switch: OFF
Voltage
Max. 3 V
Wiper switch: ON
Voltage
Pulse below 3 V io above 20 V
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit
Circuit diagram related to wiper
PC228US-8,PC228USLC-8
40-3 5 40-3 5
40-335
Troubleshooting by failure code Failure code [DXEAKA] Service Current EPC1 Discon
Failure code [DXEAKA] Service Current EPC1 Discon User code
Failure code
—
DXEAKA
Trouble
Service current EPC1 solenoid disconnection (Pump controller system)
Contents of trouble
• When service EPC1 solenoid was driven, disconnection was detected in circuit.
Action of controller
• None in particular (Since no current flows, solenoid does not operate). • If cause of failure disappears, system resets itself.
Problem that appears on machine
• Attachment does not operate.
Related information
• Drive current of service EPC1 solenoid can be checked with monitoring function. (Code: 01701 service solenoid current) • Method of reproducing failure code: Turn starting switch ON + Set in attachment mode (ATT). Cause Defective service EPC sole1 noid (Internal disconnection)
Possible causes and standard value in normal state
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. V91 (male)
Resistance
Between (1) – (2)
7 – 14 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wiring Wiring harness between C02 (female) (95) – Resist2 Max. 1 z or defective contact in con- V91 (female) (1) ance nector) Wiring harness between C02 (female) (115), ResistMax. 1 z (117), (120) – V91 (female) (2) ance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 3 Defective pump controller
40-336
C02 (female)
Resistance
Between (95) – (115), (117), (120)
7 – 14 z
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [DXEAKB] Service Current EPC1 Short
Failure code [DXEAKB] Service Current EPC1 Short User code
Failure code
—
DXEAKB
Trouble
Service current EPC1 solenoid short (Pump controller system)
Contents of trouble
• When service EPC1 solenoid was driven, short circuit was detected in circuit.
Action of controller
• Turns output to service EPC1 solenoid OFF. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears on machine
• Attachment does not operate.
Related information
• Drive current of service EPC solenoid can be checked with monitoring function. (Code: 01701 service EPC solenoid current) • Method of reproducing failure code: Turn starting switch ON + Set in attachment mode (ATT). Cause
Defective service EPC sole1 noid (Internal short circuit or ground fault)
Possible causes and standard value in normal state
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. V91 (male)
Resistance
Between (1) – (2)
7 – 14 z
Between (1) – chassis ground
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Ground fault in wiring har3 ness (Short circuit with GND Wiring harness between C02 (female) (95) – circuit) V91 (female) (1)
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4 Defective pump controller
PC228US-8,PC228USLC-8
C02 (female)
Resistance
Between (95) – (115), (117), (120)
7 – 14 z
Between (95) – chassis ground
Min. 1 Mz
40-337
Troubleshooting by failure code Failure code [DXE7KA] Service Current EPC2 Discon
Failure code [DXE7KA] Service Current EPC2 Discon User code
Failure code
—
DXE7KA
Trouble
Service current EPC2 solenoid disconnection (Pump controller system)
Contents of trouble
• When service EPC2 solenoid was driven, disconnection was detected in circuit.
Action of controller
• None in particular (Since no current flows, solenoid does not operate). • If cause of failure disappears, system resets itself.
Problem that appears on machine
• Attachment does not operate.
Related information
• Drive current of service EPC2 solenoid can be checked with monitoring function. (Code: 01702 service solenoid current) • Method of reproducing failure code: Turn starting switch ON + Set in attachment mode (ATT). Cause
Standard value in normal state/Remarks on troubleshooting
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective service EPC sole1 V92 (male) Resistance noid (Internal disconnection) 7 – 14 z
Between (1) – (2) Possible causes and standard value in normal state
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wiring Wiring harness between C02 (female) (103) 2 or defective contact in con- – V92 (female) (1) nector) Wiring harness between C02 (female) (115), (117), (120) – V92 (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 3 Defective pump controller
40-338
C02 (female)
Resistance
Between (103) – (115), (117), (120)
7 – 14 z
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [DXE7KB] Service Current EPC2 Short
Failure code [DXE7KB] Service Current EPC2 Short User code
Failure code
—
DXE7KB
Trouble
Service current EPC2 solenoid short (Pump controller system)
Contents of trouble
• When service EPC2 solenoid was driven, short circuit was detected in circuit.
Action of controller
• Turns output to service EPC2 solenoid OFF. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears on machine
• Attachment does not operate.
Related information
• Drive current of service EPC2 solenoid can be checked with monitoring function. (Code: 01702 service EPC solenoid current) • Method of reproducing failure code: Turn starting switch ON + Set in attachment mode (ATT). Cause
Defective service EPC sole1 noid (Internal short circuit or ground fault)
Possible causes and standard value in normal state
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. V92 (male)
Resistance
Between (1) – (2)
7 – 14 z
Between (1) – chassis ground
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Ground fault in wiring har3 ness (Short circuit with GND Wiring harness between C02 (female) (103) circuit) – V92 (female) (1)
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4 Defective pump controller
PC228US-8,PC228USLC-8
C02 (female)
Resistance
Between (103) – (115), (117), (120)
7 – 14 z
Between (103) – chassis ground
Min. 1 Mz
40-339
Troubleshooting by failure code Failure code [DXE8KA] Service Current EPC3 Discon
Failure code [DXE8KA] Service Current EPC3 Discon User code
Failure code
—
DXE8KA
Trouble
Service current EPC3 solenoid disconnection (Pump controller system)
Contents of trouble
• When service EPC3 solenoid was driven, disconnection was detected in circuit.
Action of controller
• None in particular (Since no current flows, solenoid does not operate). • If cause of failure disappears, system resets itself.
Problem that appears on machine
• Attachment does not operate.
Related information
• Drive current of service EPC3 solenoid can be checked with monitoring function. (Code: 01703 service solenoid current) • Method of reproducing failure code: Turn starting switch ON + Set in attachment mode (ATT). Cause Defective service EPC sole1 noid (Internal disconnection)
Possible causes and standard value in normal state
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. V93 (male)
Resistance
Between (1) – (2)
7 – 14 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wiring Wiring harness between C02 (female) (111) Resist2 Max. 1 z or defective contact in con- – V93 (female) (1) ance nector) Wiring harness between C02 (female) (115), ResistMax. 1 z (117), (120) – V93 (female) (2) ance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 3 Defective pump controller
40-340
C02 (female)
Resistance
Between (111) – (115), (117), (120)
7 – 14 z
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [DXE8KB] Service Current EPC3 Short
Failure code [DXE8KB] Service Current EPC3 Short User code
Failure code
—
DXE8KB
Trouble
Service current EPC3 solenoid short (Pump controller system)
Contents of trouble
• When service EPC3 solenoid was driven, short circuit was detected in circuit.
Action of controller
• Turns output to service EPC3 solenoid OFF. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears on machine
• Attachment does not operate.
Related information
• Drive current of service EPC3 solenoid can be checked with monitoring function. (Code: 01703 service EPC solenoid current) • Method of reproducing failure code: Turn starting switch ON + Set in attachment mode (ATT). Cause
Defective service EPC sole1 noid (Internal short circuit or ground fault)
Possible causes and standard value in normal state
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. V93 (male)
Resistance
Between (1) – (2)
7 – 14 z
Between (1) – chassis ground
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Ground fault in wiring har3 ness (Short circuit with GND Wiring harness between C02 (female) (111) circuit) – V93 (female) (1)
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4 Defective pump controller
PC228US-8,PC228USLC-8
C02 (female)
Resistance
Between (111) – (115), (117), (120)
7 – 14 z
Between (111) – chassis ground
Min. 1 Mz
40-341
Troubleshooting by failure code Failure code [DXE9KA] Service Current EPC4 Discon
Failure code [DXE9KA] Service Current EPC4 Discon User code
Failure code
—
DXE9KA
Trouble
Service current EPC4 solenoid disconnection (Pump controller system)
Contents of trouble
• When service EPC4 solenoid was driven, disconnection was detected in circuit.
Action of controller
• None in particular (Since no current flows, solenoid does not operate). • If cause of failure disappears, system resets itself.
Problem that appears on machine
• Attachment does not operate.
Related information
• Drive current of service EPC4 solenoid can be checked with monitoring function. (Code: 01704 service solenoid current) • Method of reproducing failure code: Turn starting switch ON + Set in attachment mode (ATT). Cause Defective service EPC sole1 noid (Internal disconnection)
Possible causes and standard value in normal state
Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. V94 (male)
Resistance
Between (1) – (2)
7 – 14 z
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wiring Wiring harness between C02 (female) (102) Resist2 Max. 1 z or defective contact in con- – V94 (female) (1) ance nector) Wiring harness between C02 (female) (115), ResistMax. 1 z (117), (120) – V94 (female) (2) ance a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 3 Defective pump controller
40-342
C02 (female)
Resistance
Between (102) – (115), (117), (120)
7 – 14 z
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [DXE9KA] Service Current EPC4 Discon
PC228US-8,PC228USLC-8
40-343
Troubleshooting by failure code Failure code [DXE9KB] Service Current EPC4 Short
Failure code [DXE9KB] Service Current EPC4 Short User code
Failure code
—
DXE9KB
Trouble
Service current EPC4 solenoid short (Pump controller system)
Contents of trouble
• When service EPC4 solenoid was driven, short circuit was detected in circuit.
Action of controller
• Turns output to service EPC4 solenoid OFF. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears on machine
• Attachment does not operate.
Related information
• Drive current of service EPC4 solenoid can be checked with monitoring function. (Code: 01704 service EPC solenoid current) • Method of reproducing failure code: Turn starting switch ON + Set in attachment mode (ATT). Cause
Standard value in normal state/Remarks on troubleshooting a
Defective service EPC sole1 noid (Internal short circuit or ground fault)
Possible causes and standard value in normal state
V94 (male)
Resistance
Between (1) – (2)
7 – 14 z
Between (1) – chassis ground
Min. 1 Mz
a
Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Ground fault in wiring har3 ness (Short circuit with GND Wiring harness between C02 (female) (102) circuit) – V94 (female) (1) a
4 Defective pump controller
40-344
Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Resistance
Min. 1 Mz
Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. C02 (female)
Resistance
Between (102) – (115), (117), (120)
7 – 14 z
Between (102) – chassis ground
Min. 1 Mz
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [DXE9KB] Service Current EPC4 Short
S e r v i c e EPC 1 1st S e r v i c e LH EPC
Att ( 1LHs tEPC )
2nd S e r v i c e RH EPC 1st S e r v i c e RH EPC S e r v i c e EPC 2
2nd S e r v i c e LH EPC S o l e n o i d GND S o l e n o i d GND
Att ( 1RHs t EPC )
S o l e n o i d GND S e r v i c e EPC 3 Att ( 2LHn dEPC )
TA
S e r v i c e EPC 4 Att ( 2RHn dEPC )
TB
J07
PC228US-8,PC228USLC-8
40-345
Troubleshooting by failure code Failure code [DFB1KZ] Service Lever Potentio 1 Abnormality
Failure code [DFB1KZ] Service Lever Potentio 1 Abnormality User code
Failure code
—
DFB1KZ
Trouble
RH Lever main potentiometer (for 1st Att.) has failure
Contents of trouble
• Potentiometer’s output voltage is out of range (below 0.4 volts or above 4.6 volts)
Action of controller
• Turns output to service EPC solenoids (EPC1 & EPC2) OFF. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears on machine
• 1st Attachment does not operate.
Related information
• Main potentio output voltage can be checked with monitoring function. (Code: 42008 Lever potentio 1 volt (Main)) • Sub potentio output voltage can be checked with monitoring function. (Code 42009 Lever potentio 1 volt (Sub)) • Potentiometer stroke can be checked with monitoring function. (Code 42012 Lever potentio 1 stroke) • Method of reproducing failure code : Turn starting switch to ON + set in attachment mode (ATT). Cause
Standard value in normal state/Remarks on troubleshooting a
Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Lever slide sw Neutral
2.5 ± 0.3 V
Lever slide sw Upper max.
1
Defective RH lever assembly
4.0 ~ 4.6 V Monitoring function code : Lever slide sw Lower 42008 0.4 ~ 1.0 V max. Lever potentio 1 Volt (Main) If voltage is 0V and no movement, disconnection or ground short may be the cause. If voltage is 5V and no movement, hot short may be the cause. M22 (female) Between (6) - (7)
Possible causes and standard value in normal state
Between (9) - (17) Potentio output
Voltage
Potentio 5V supply
4.5 ~ 5.5 V
Lever slide sw Neutral
2.5 ± 0.3 V
Lever slide sw Upper max.
4.0 ~ 4.6 V
Lever slide sw Lower max.
0.4 ~ 1.0 V
If M22 (6) - (7) voltage 0V, disconnection may be the cause. a Disconnection in wiring harness. (Disconnection in 2 wiring or defective contact in connector).
Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between M22 (female) (6) - C01 (female) (9)
Resistance
Max.1 z
Wiring harness between M22 (female) (7) - C01 (female) (18)
Resistance
Max.1 z
Wiring harness between M22 (female) (9) - C01 (female) (69)
Resistance
Max.1 z
a
Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Ground fault in wiring harness. Wiring harness between M22 (female) (6) - C01 3 (Short circuit with (female) (9) GND circuit) Wiring harness between M22 (female) (9) - C01 (female) (69)
40-346
Resistance
Min.100 kz
Resistance
Min.100 kz
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [DFB1KZ] Service Lever Potentio 1 Abnormality
Cause
Possible causes and standard value in normal state
Standard value in normal state/Remarks on troubleshooting
a Prepare with starting switch OFF, then carry out troubleshooting without Hot short turning starting switch ON. (Short circuit with 4 5 Volts circuit) in Wiring harness between M22 (female) (9) - M22 (female) (6). Resistance Min.100 kz wiring harness. (Measure it disconnecting M22 connector). Ground fault in a Prepare with starting switch OFF, then carry out troubleshooting without wiring harness . turning starting switch ON. 5 (No secure GND from pump con- Wiring harness between M22 (female (7) - chassis Resistance Max.30 z GND troller). 6
Defective pump controller.
PC228US-8,PC228USLC-8
If cause 1 -5 are not detected, pump controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out).
40-347
Troubleshooting by failure code Failure code [DFB2KZ] Service Lever Potentio 2 Abnormality
Failure code [DFB2KZ] Service Lever Potentio 2 Abnormality User code
Failure code
—
DFB2KZ
Trouble
LH Lever main potentiometer (for 2nd Att.) has failure
Contents of trouble
• Potentiometer’s output voltage is out of range (below 0.4 volts or above 4.6 volts)
Action of controller
• Turns output to service EPC solenoids (EPC3 & EPC4) OFF. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears on machine
• 2nd Attachment does not operate.
Related information
• Main potentio output voltage can be checked with monitoring function. (Code: 42010 Lever potentio 2 volt (Main)) • Sub potentio output voltage can be checked with monitoring function. (Code 42011 Lever potentio 2 volt (Sub)) • Potentiometer stroke can be checked with monitoring function. (Code 42013 Lever potentio 2 stroke) • Method of reproducing failure code : Turn starting switch to ON + set in attachment mode (ATT). Cause
Standard value in normal state/Remarks on troubleshooting a
Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Lever slide sw Neutral
2.5 ± 0.3 V
Lever slide sw Upper max.
1
Defective LH lever assembly
4.0 ~ 4.6 V Monitoring function code : Lever slide sw Lower 42010 0.4 ~ 1.0 V max. Lever potentio 2 Volt (Main) If voltage is 0V and no movement, disconnection or ground short may be the cause. If voltage is 5V and no movement, hot short may be the cause. M23 (female) Between (6) - (7)
Possible causes and standard value in normal state
Between (9) - (17) Potentio output
Voltage
Potentio 5V supply
4.5 ~ 5.5 V
Lever slide sw Neutral
2.5 ± 0.3 V
Lever slide sw Upper max.
4.0 ~ 4.6 V
Lever slide sw Lower max.
0.4 ~ 1.0 V
If M23 (6) - (7) voltage 0V, disconnection may be the cause. a Disconnection in wiring harness. (Disconnection in 2 wiring or defective contact in connector).
Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between M23 (female) (6) - C01 (female) (9)
Resistance
Max.1 z
Wiring harness between M23 (female) (7) - C01 (female) (18)
Resistance
Max.1 z
Wiring harness between M23 (female) (9) - C01 (female) (32)
Resistance
Max.1 z
a
Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Ground fault in wiring harness. Wiring harness between M23 (female) (6) - C01 3 (Short circuit with (female) (9) GND circuit) Wiring harness between M23 (female) (9) - C01 (female) (32)
40-348
Resistance
Min.100 kz
Resistance
Min.100 kz
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [DFB2KZ] Service Lever Potentio 2 Abnormality
Cause
Possible causes and standard value in normal state
Standard value in normal state/Remarks on troubleshooting
a Prepare with starting switch OFF, then carry out troubleshooting without Hot short turning starting switch ON. (Short circuit with 4 5 Volts circuit) in Wiring harness between M23 (female) (9) - M23 (female) (6). Resistance Min.100 kz wiring harness. (Measure it disconnecting M23 connector). Ground fault in a Prepare with starting switch OFF, then carry out troubleshooting without wiring harness . turning starting switch ON. 5 (No secure GND from pump con- Wiring harness between M23 (female (7) - chassis Resistance Max.30 z GND troller). 6
Defective pump controller.
PC228US-8,PC228USLC-8
If cause 1 -5 are not detected, pump controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out).
40-349
Troubleshooting by failure code Failure code [DFB5KZ] Service Lever Sub Potentio 1 Abnormality
Failure code [DFB5KZ] Service Lever Sub Potentio 1 Abnormality User code
Failure code
—
DFB5KZ
Trouble
RH Lever main potentiometer (for 1st Att.) has failure
Contents of trouble
• Potentiometer’s output voltage is out of range (below 0.4 volts or above 4.6 volts)
Action of controller
• Turns output to service EPC solenoids (EPC1 & EPC2) OFF. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears on machine
• 1st Attachment does not operate.
Related information
• Main potentio output voltage can be checked with monitoring function. (Code: 42008 Lever potentio 1 volt (Main)) • Sub potentio output voltage can be checked with monitoring function. (Code 42009 Lever potentio 1 volt (Sub)) • Potentiometer stroke can be checked with monitoring function. (Code 42012 Lever potentio 1 stroke) • Method of reproducing failure code : Turn starting switch to ON + set in attachment mode (ATT). Cause
Standard value in normal state/Remarks on troubleshooting a
Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Lever slide sw Neutral
2.5 ± 0.3 V
Lever slide sw Upper max.
1
Defective RH lever assembly
0.4 ~ 1.0 V Monitoring function code : Lever slide sw Lower 42009 4.0 ~ 4.6 V max. Lever potentio 1 Volt (Main) If voltage is 0V and no movement, disconnection or ground short may be the cause. If voltage is 5V and no movement, hot short may be the cause. M22 (female) Between (6) - (7)
Possible causes and standard value in normal state
Between (8) - (17) Potentio output
Voltage
Potentio 5V supply
4.5 ~ 5.5 V
Lever slide sw Neutral
2.5 ± 0.3 V
Lever slide sw Upper max.
0.4 ~ 1.0 V
Lever slide sw Lower max.
4.0 ~ 4.6 V
If M22 (6) - (7) voltage 0V, disconnection may be the cause. a Disconnection in wiring harness. (Disconnection in 2 wiring or defective contact in connector).
Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between M22 (female) (6) - C01 (female) (9)
Resistance
Max.1 z
Wiring harness between M22 (female) (7) - C01 (female) (18)
Resistance
Max.1 z
Wiring harness between M22 (female) (8) - C01 (female) (13)
Resistance
Max.1 z
a
Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Ground fault in wiring harness. Wiring harness between M22 (female) (6) - C01 3 (Short circuit with (female) (9) GND circuit) Wiring harness between M22 (female) (8) - C01 (female) (13)
40-350
Resistance
Min.100 kz
Resistance
Min.100 kz
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [DFB5KZ] Service Lever Sub Potentio 1 Abnormality
Cause
Possible causes and standard value in normal state
Standard value in normal state/Remarks on troubleshooting
a Prepare with starting switch OFF, then carry out troubleshooting without Hot short turning starting switch ON. (Short circuit with 4 5 Volts circuit) in Wiring harness between M22 (female) (8) - M22 (female) (6). Resistance Min.100 kz wiring harness. (Measure it disconnecting M22 connector). Ground fault in a Prepare with starting switch OFF, then carry out troubleshooting without wiring harness . turning starting switch ON. 5 (No secure GND from pump con- Wiring harness between M22 (female (7) - chassis Resistance Max.30 z GND troller). 6
Defective pump controller.
PC228US-8,PC228USLC-8
If cause 1 -5 are not detected, pump controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out).
40-351
Troubleshooting by failure code Failure code [DFB6KZ] Service Lever Sub Potentio 2 Abnormality
Failure code [DFB6KZ] Service Lever Sub Potentio 2 Abnormality User code
Failure code
—
DFB6KZ
Trouble
LH Lever main potentiometer (for 2nd Att.) has failure
Contents of trouble
• Potentiometer’s output voltage is out of range (below 0.4 volts or above 4.6 volts)
Action of controller
• Turns output to service EPC solenoids (EPC3 & EPC4) OFF. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears on machine
• 2nd Attachment does not operate.
Related information
• Main potentio output voltage can be checked with monitoring function. (Code: 42010 Lever potentio 2 volt (Main)) • Sub potentio output voltage can be checked with monitoring function. (Code 42011 Lever potentio 2 volt (Sub)) • Potentiometer stroke can be checked with monitoring function. (Code 42013 Lever potentio 2 stroke) • Method of reproducing failure code : Turn starting switch to ON + set in attachment mode (ATT).
Cause
Standard value in normal state/Remarks on troubleshooting a
Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Lever slide sw Neutral
2.5 ± 0.3 V
Lever slide sw Upper max.
1
Defective LH lever assembly
0.4 ~ 1.0 V Monitoring function code : Lever slide sw Lower 42011 4.0 ~ 4.6 V max. Lever potentio 2 Volt (Main) If voltage is 0V and no movement, disconnection or ground short may be the cause. If voltage is 5V and no movement, hot short may be the cause. M23 (female) Between (6) - (7)
Possible causes and standard value in normal state
Between (8) - (17) Potentio output
Voltage
Potentio 5V supply
4.5 ~ 5.5 V
Lever slide sw Neutral
2.5 ± 0.3 V
Lever slide sw Upper max.
0.4 ~ 1.0 V
Lever slide sw Lower max.
4.0 ~ 4.6 V
If M23 (6) - (7) voltage 0V, disconnection may be the cause. a Disconnection in wiring harness. (Disconnection in 2 wiring or defective contact in connector).
Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between M23 (female) (6) - C01 (female) (9)
Resistance
Max.1 z
Wiring harness between M23 (female) (7) - C01 (female) (18)
Resistance
Max.1 z
Wiring harness between M23 (female) (8) - C01 (female) (51)
Resistance
Max.1 z
a
Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Ground fault in wiring harness. Wiring harness between M23 (female) (6) - C01 3 (Short circuit with (female) (9) GND circuit) Wiring harness between M23 (female) (8) - C01 (female) (51)
40-352
Resistance
Min.100 kz
Resistance
Min.100 kz
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [DFB6KZ] Service Lever Sub Potentio 2 Abnormality
Cause
Possible causes and standard value in normal state
Standard value in normal state/Remarks on troubleshooting
a Prepare with starting switch OFF, then carry out troubleshooting without Hot short turning starting switch ON. (Short circuit with 4 5 Volts circuit) in Wiring harness between M23 (female) (8) - M23 (female) (6). Resistance Min.100 kz wiring harness. (Measure it disconnecting M23 connector). Ground fault in a Prepare with starting switch OFF, then carry out troubleshooting without wiring harness . turning starting switch ON. 5 (No secure GND from pump con- Wiring harness between M23 (female (7) - chassis Resistance Max.30 z GND troller). 6
Defective pump controller.
PC228US-8,PC228USLC-8
If cause 1 -5 are not detected, pump controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out).
40-353
Troubleshooting by failure code Failure code [DFB3L8] Service Lever 1 Potentio Error
Failure code [DFB3L8] Service Lever 1 Potentio Error User code
Failure code
—
DFB3L8
Trouble
RH Lever main potentiometer (for 1st Att.) has failure
Contents of trouble
• Summation of Potentiometer’s output voltage is out of range (below 4.5 volts or above 5.5 volts)
Action of controller
• Turns output to service EPC solenoids (EPC1 & EPC2) OFF. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears on machine
• 1st Attachment does not operate.
Related information
• Main potentio output voltage can be checked with monitoring function. (Code: 42008 Lever potentio 1 volt (Main)) • Sub potentio output voltage can be checked with monitoring function. (Code 42009 Lever potentio 1 volt (Sub)) • Potentiometer stroke can be checked with monitoring function. (Code 42012 Lever potentio 1 stroke) • Method of reproducing failure code : Turn starting switch to ON + set in attachment mode (ATT).
q
For troubleshooting, carry out [DFB1KZ] and [DFB5KZ]
Information <Potentiometer’s output voltage> As shown below, summation of Main and Sub Potentiometer output to be constant. If this value exceeded 5 ± 0.5 V, this Failure code [DFB3L8] is displayed.
q
The cause to be Main or Sub potentiometer’s output error, so need to carry out troubleshooting in [DFB1KZ] and [DFB5KZ].
Output Voltage (V) 4.3 Main Potentio Output 2.5 Sub Potentio Output 0.7
Lower max
Neutral (V) 5 ± 0.5
40-354
Upper max Summation of Main & Sub Potentio Output
PC228US-8,PC228USLC-8
Troubleshooting by failure code Failure code [DFB4L8] Service Lever 2 Potentio Error
Failure code [DFB4L8] Service Lever 2 Potentio Error User code
Failure code
—
DFB4L8
Trouble
LH Lever main potentiometer (for 2nd Att.) has failure
Contents of trouble
• Summation of Potentiometer’s output voltage is out of range (below 4.5 volts or above 5.5 volts)
Action of controller
• Turns output to service EPC solenoids (EPC3 & EPC4) OFF. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears on machine
• 2nd Attachment does not operate.
Related information
• Main potentio output voltage can be checked with monitoring function. (Code: 42010 Lever potentio 2 volt (Main)) • Sub potentio output voltage can be checked with monitoring function. (Code 42011 Lever potentio 2 volt (Sub)) • Potentiometer stroke can be checked with monitoring function. (Code 42013 Lever potentio 2 stroke) • Method of reproducing failure code : Turn starting switch to ON + set in attachment mode (ATT).
q
For troubleshooting, carry out [DFB2KZ] and [DFB6KZ]
Information <Potentiometer’s output voltage> As shown below, summation of Main and Sub Potentiometer output to be constant. If this value exceeded 5 ± 0.5 V, this Failure code [DFB4L8] is displayed.
q
The cause to be Main or Sub potentiometer’s output error, so need to carry out troubleshooting in [DFB2KZ] and [DFB6KZ].
Output Voltage (V) 4.3 Main Potentio Output 2.5 Sub Potentio Output 0.7
Lower max
Neutral (V) 5 ± 0.5
PC228US-8,PC228USLC-8
Upper max Summation of Main & Sub Potentio Output
40-355
Troubleshooting by failure code Failure code [DFB4L8] Service Lever 2 Potentio Error
LEVER LH (2nd ATT)
LEVER RH (1st ATT)
Sub Potentio 2
Sub Potentio 1
Main Potentio 2
Main Potentio 1
M23
M22
H19
H14
J06
Pump Controller C01 Potentio Power (+5 V) DX SI
1st Service Potentio (Sub) ANALOG GND 2nd Service Potentio (Main) 2nd Service Potentio (Sub) 1st Service Potentio (Main)
40-356
PC228US-8,PC228USLC-8
Troubleshooting of electrical system (E-mode) E-1 Engine does not start (Engine does not crank)
Troubleshooting of electrical system (E-mode) E-1 Engine does not start (Engine does not crank) Failure Related information
q
Engine does not start (Engine does not crank).
q
Engine starting circuit has following two start lock mechanisms. 1) Start lock by using password of machine monitor 2) Start lock by using lock lever In the case that "Battery relay does not make operating sound" when starting switch is turned to ON position, perform troubleshooting for E-1 also.
q
Cause
Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position. 1 Defective fusible links F04 or F05 2. Remove fusible links F04 and F05 Between terminals F04 and F05 2
Defective fuses Nos. 3 and 17 in fuse box F01
Resistance
Max. 1 z
If fuse is broken, circuit probably has ground fault. (See Cause 16.)
1. Turn starting switch to OFF position. Loose terminal connection or open 3 Check terminals of starting motor, alternator, battery relay, grounds T04 and circuit at terminal T08, etc. 1. Turn starting switch to OFF position. 4
Defective contact (ground) between battery relay and frame
5 Insufficient battery capacity
Between battery relay terminal R01 and ground a Check grounding at machine frame. a Loosened or rusted terminal T08 Resistance Max. 1 z a Rusted contact faces of battery bracket and frame a Be ready with starting switch OFF, then perform troubleshooting without turning starting switch ON. Battery voltage (two pieces)
Min. 24 V
Electrolyte specific gravity (one piece)
Min. 1.26
Engine controller power supply and ACC signal are diagnosed with proce6 Defective engine controller system dures for failure codes [DA2RMC] and [DAFRMC]. If these codes are displayed, perform troubleshooting for them first. 1. Turn starting switch to OFF position. 2. Disconnect connector H15 and connect T-adapter to male side. 3. After troubleshooting, turn starting switch to ON/START position and perform troubleshooting again. Turn starting switch to Resistance Min. 1 Mz Between H15 (male) (1) OFF position. Turn starting switch to and (2) Resistance Max. 1 z Defective starting switch ON position. 7 (Open circuit in internal wiring) Turn starting switch to Resistance Min. 1 Mz Between H15 (male) (1) OFF position. Turn starting switch to and (5) Resistance Max. 1 z ON position. Turn starting switch to Resistance Min. 1 Mz Between H15 (male) (1) OFF position. Turn starting switch to and (4) Resistance Max. 1 z START position 1. Turn starting switch to OFF position. 2. Disconnect connector S14 and connect T-adapter to female side. Defective lock lever switch 8 (Open circuit in internal wiring) Between S14 (female) (1) Lock lever FREE position Resistance Min. 1 Mz and (3) Lock lever LOCK position Resistance Max. 1 z
PC228US-8,PC228USLC-8
40-357
Troubleshooting of electrical system (E-mode) E-1 Engine does not start (Engine does not crank)
Cause
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connectors R06 and R07 and connect T-adapter to male side. 200 to Between R06 (male) (1) and (2) Resistance 600 z
Defective starting motor cutout relay R06 or personal code relay 9 R07 (Open circuit in internal wiring)
Max. 1 z
Between R06 (male) (3) and (4)
Resistance
Between R06 (male) (3) and (5)
Resistance Min. 1 Mz
Between R07 (male) (1) and (2)
Resistance
200 to 600 z
Between R07 (male) (3) and (4)
Resistance
Max. 1 z
Between R07 (male) (3) and (5)
Resistance Min. 1 Mz
1. 2. 3. 4.
Defective starting motor safety 10 relay (Internal defect)
11
Defective starting motor (Internal defect)
12
Defective alternator (Internal short circuit)
Defective diode D01 13 (open or short circuit in internal wiring)
40-358
Turn starting switch to OFF position. Disconnect cable only from C terminal on starting motor safety relay. Insert T-adapter between male and female sides of connector R17. Turn starting switch to START position and perform troubleshooting. Power supBetween safety relay terminal B and E Voltage 20 to 30 V ply Command power input Between safety relay terminal R from alterVoltage Max. 1 V (R17-2) and safety relay terminal E nator generation Starting Between safety relay terminal S command Voltage 20 to 30 V (R17-1) and safety relay terminal E input Starting Between safety relay terminal C (R28) power outVoltage 20 to 30 V and safety relay terminal E put If power supply, command power input, and starting command input are normal but starting command output is not normal, starting motor safety relay is defective. 1. Turn starting switch to OFF position. 2. Turn starting switch to START position and perform troubleshooting. Between starting motor terminal B Power supVoltage 20 to 30 V (SB) and ground ply Starting Between starting motor terminal C command Voltage 20 to 30 V (SC) and ground input If power supply and starting command input are normal but starting motor does not rotate, starting motor is defective. a Be ready with starting switch OFF, then perform troubleshooting with starting switch in ON position and perform troubleshooting. Command power outBetween alternator terminal L and put from Voltage Max. 1 V ground alternator generation 1. Turn starting switch to OFF position. 2. Disconnect connector D01 and connect T-adapter to diode. a Measure by using multimeter in diode range. Between D01 (male) (1) (+) and (5) (-)
No continuity
Between D01 (male) (5) (+) and (1) (-)
Continuity
Between D01 (male) (2) (+) and (6) (-)
No continuity
Between D01 (male) (6) (+) and (2) (-)
Continuity
PC228US-8,PC228USLC-8
Troubleshooting of electrical system (E-mode) E-1 Engine does not start (Engine does not crank)
Cause
Procedure, measuring location, criteria and remarks q
Battery relay 1. Turn starting switch to OFF position. Between terminal B02 and H15 (female) (2)
Resistance
Max. 1 z
q
Battery relay 1. Turn starting switch to OFF position. 2. Turn starting switch to ON position. a Check to where 24 V is supplied to isolate open section. Between terminals R04 and R01
Voltage
20 to 30 V
Between terminals R02 and R01
Voltage
20 to 30 V
Between terminals R03 and R01
Voltage
20 to 30 V
Between terminal R01 and ground
Voltage
Max. 1 V
q Alternator and starting motor 1. Turn starting switch to OFF position. 2. Disconnect battery ground cable. 3. Insert T-adapters into connectors H15, S14, R07, R17, E10, and E12. 4. Connect ground strap. 5. Turn starting switch to START position and troubleshoot. a Check to where 24 V power is supplied to isolate open section.
Open circuit in wiring harness 14 (Wire breakage or defective contact of connector)
Between H15 (4) and ground
Voltage
20 to 30 V
Between S14 (1) and ground
Voltage
20 to 30 V
Between S14 (3) and ground
Voltage
20 to 30 V
Between R07 (4) and ground
Voltage
20 to 30 V
Between R17 (1) and ground
Voltage
20 to 30 V
Between R17 (2) and ground
Voltage
20 to 30 V
Between E10 (1) and ground
Voltage
20 to 30 V
Between E12 (1) and ground
Voltage
20 to 30 V
Between alternator B terminal and ground
Voltage
20 to 30 V
Between starting motor terminal B and ground
Voltage
20 to 30 V
a If fuse or fusible link is broken, replace it. 1. Turn starting switch to OFF position. 2. Disconnect H15, S14, R06 and R07. 3. Connect T-adapter to female sides of H15, R06 and R07, and to male side of S14. 4. Remove fuse F01-3.
PC228US-8,PC228USLC-8
Between H15 (female) (4) and R06 (female) (5)
Resistance
Max. 1 z
Between R06 (female) (3) and R07 (female) (4)
Resistance
Max. 1 z
Between R07 (female) (1) and S14 (male) (1)
Resistance
Max. 1 z
Between R07 (female) (2) and CM01 (female) (6)
Resistance
Max. 1 z
Between R07 (female) (3) and starting motor termiResistance nal S
Max. 1 z
Between alternator B and starting motor B
Resistance
Max. 1 z
Between starting motor B and battery relay R03
Resistance
Max. 1 z
Between alternator R and starting motor L
Resistance
Max. 1 z
Between alternator R and D01 (female) (6)
Resistance
Max. 1 z
Between F01-3 and S14 (male) (1)
Resistance
Max. 1 z
Between S14 (male) (3) and R06 (male) (1)
Resistance
Max. 1 z
Between R06 (male) (2) and ground (T04)
Resistance
Max. 1 z
40-359
Troubleshooting of electrical system (E-mode) E-1 Engine does not start (Engine does not crank)
Cause 15
Defective battery relay (Does not activate)
16
Ground fault in wiring harness (Contact with ground circuit)
Procedure, measuring location, criteria and remarks If only terminal R03 voltage is abnormal during battery relay check for cause 14, battery relay is defective. 1. Turn starting switch to OFF position. 2. Disconnect H15, S14, R06 and R07. 3. Connect T-adapter to female sides of H15, R06 and R07, and to male side of S14. 4. Remove fuse F01-3. Between H15 (female) (4) and ground, or between Resistance Min. 1 Mz R06 (female) (5) and ground Between R06 (female) (3) and ground, or between Resistance Min. 1 Mz R07 (female) (4) and ground Between R07 (female) (3) and ground, or between Resistance Min. 1 Mz R17 (female) (1) and ground Between starting motor safety relay B or battery Resistance Min. 1 Mz relay R03 and ground Between starting motor safety relay C or starting motor C (SC) and ground
Resistance Min. 1 Mz
Between F01-3 or S14 (male) (1) and ground
Resistance Min. 1 Mz
Between S14 (male) (3) and ground, or between Resistance Min. 1 Mz R06 (female) (1) and ground 1. Turn starting switch to OFF position. Hot short circuit in wiring harness 2. Insert T-adapter between male and female sides of connector R17 or E08. 17 3. Turn starting switch to ON position. (Contact with 24 V circuit) Between R17 (female) (2) or E08 (1) and ground Voltage Max. 1 V
40-360
PC228US-8,PC228USLC-8
Troubleshooting of electrical system (E-mode) E-1 Engine does not start (Engine does not crank)
Circuit diagram related to engine start circuit
PC228US-8,PC228USLC-8
40-341
40-361
Troubleshooting of electrical system (E-mode) E-2 Preheater does not operate
E-2 Preheater does not operate Failure
1)Manual preheater does not operate.
a This troubleshooting describes the procedures to be followed when manual preheating does not function to heat the electrical intake air heater mounting section. q There are "Automatic preheater" and "Manual preheater" installed. When either function is operated, preheating monitor lights up. (When only preheating does not light up, troubleshoot "3) While preheater is operating, preheating monitor does not light up") Related information q If "the machine monitor does not light up" or " battery relay does not make operating sound" when turning starting switch ON, main electric power supply system is supposed to be defective. So, troubleshoot E-3 and E-1. q Before performing out troubleshooting, check that no related failure code is displayed. (If failure codes [D110KB] is displayed, troubleshoot it first.) Cause
Procedure, measuring location, criteria and remarks
1
Defective fuse No. 17 in fuse box F01
If fuse No. 17 in fuse box F01 is broken, circuit probably has ground fault. In this case, perform troubleshooting for cause 8 first.
2
Loose terminal or disconnection at 1. Turn starting switch to OFF position. terminal Check terminals of heater relay, battery relay, electrical intake air heater, etc.
Defective diode D02 3 (open or short circuit in internal wiring)
Defective electrical intake air 4 heater (open circuit in internal wiring)
5 Defective starting switch
1. Turn starting switch to OFF position. 2. Disconnect connector D02 and connect T-adapter to diode. a Measure by using multimeter in diode range. Between D02 (male) (1) (+) and (5) (-)
No continuity
Between D02 (male) (5) (+) and (1) (-)
Continuity
1. Turn starting switch to OFF position. 2. Disconnect terminal E01. Between E01 terminal and ground 1. 2. 3. 4.
Continuity
Turn starting switch to OFF position. Disconnect battery ground cable. Disconnect connector H15 and connect T-adapter to male side. Turn starting switch to OFF/HEAT position and troubleshoot. OFF
Resistance
Min. 1 Mz
HEAT
Resistance
Max. 1 z
Between H15 (male) (1) and (3)
1. Turn starting switch to OFF position. 2. Disconnect connectors CM01 and H15, and connect T-adapter to female side of H15. Between H15 (female) (3) and ground
Continuity
1. Turn starting switch to OFF position. 2. Turn starting switch to ON position. Open or short circuit in wiring har- Between input terminal on contact side of heater 6 Voltage 20 to 30 V ness relay and ground 1. Turn starting switch to OFF position. 2. Disconnect heater relay terminal R16. a Disconnect so that current does not flow in heater when starting switch is turned to HEAT position. 3. Turn starting switch to HEAT position (Connect R1). Between heater relay terminal R15 and ground 7
Defective heater relay (Does not work) (Terminal R16)
40-362
Voltage
20 to 30 V
If no failure is found by check on cause 6 and heater relay operation sound is not heard, heater relay is defective.
PC228US-8,PC228USLC-8
Troubleshooting of electrical system (E-mode) E-2 Preheater does not operate
8
Cause
Procedure, measuring location, criteria and remarks
Ground fault in wiring harness (contact with ground circuit)
a If cause 6 is not cause for trouble, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors H15 and CM01, terminals R15 and E01, and starting motor terminal B. Between heater relay terminal R15 (wiring harness Resistance Min. 1 Mz side) and ground Between input terminal on contact side of heater Resistance Min. 1 Mz relay and ground Between heater relay terminal E01 (wiring harness Resistance Min. 1 Mz side) and ground
Failure
2) Automatic preheater does not operate. q q
Related informaq tion q
1
Automatic preheater operates when boosted air temperature is below -4 °C. (Monitoring code Boost temperature: 18500) If automatic preheater does not operate, check if manual preheater operates. Engine controller troubleshoots primary (coil) side of preheater relay (connector R18) for failure codes [CA2555] and [CA2556]. Engine controller troubleshoots charged (boosted) air temperature sensor for failure codes [CA153] and [CA154].
Cause
Procedure, measuring location, criteria and remarks
Defective fuse No. 6 in fuse box 01
If fuse No. 6 in fuse box 01 is broken, circuit probably has ground fault. In this case, troubleshoot cause 5 first.
1. Turn starting switch to OFF position. 2. Replace preheater relay (connector R18) with horn relay (connector R08), for Defective preheater relay example. R18 2 (open or short circuit in inter- 3. Turn starting switch to ON position. nal wiring) If automatic preheater operates when charged (boosted) air temperature is below -4 °C, original preheater relay is defective. 1. Turn starting switch to OFF position. 2. Disconnect connectors CM01 and R18, and then connect T-adapter to female side of R18. Open circuit or ground fault a If resistance is above 1 Mz, wiring harness has open circuit. If resistance is be3 of wiring harness low 1 z, wiring harness has short circuit. a Heater relay coil resistance Between R18 (female) (5) and ground
Open circuit in wiring harness 4 (Wire breakage or defective contact)
Ground fault in wiring har5 ness (contact with ground circuit)
1. Turn starting switch to OFF position. 2. Disconnect connectors R18 and CM01, and then connect T-adapter to female side of R18. 3. Remove fuse No. 6 in fuse box F01. Between R18 (female) (3) and F01-6
Resistance
Max. 1 z
Between R18 (female) (5) and heater relay terminal Resistance Max. 1 z R15 If fuse is not blown, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors CM01, R18, and starting motor terminal B, and then connect T-adapter to female side of R18. Between R18 (female) (3) and ground
PC228US-8,PC228USLC-8
Resistance Approx. 20 z
Resistance
Min. 1 Mz
40-363
Troubleshooting of electrical system (E-mode) E-2 Preheater does not operate
Failure
3) While preheater is operating, preheating monitor does not light up.
Related information
q q
There are "Automatic preheater" and "Manual preheater" installed. When either function is operated, preheating lamp lights up. Check that manual preheater operates first.
Cause Open circuit in wiring harness 1 (Wire breakage or defective contact)
2 Defective machine monitor
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connectors H15, CM01, and R18, and connect T-adapters to their female sides. Between H15 (female) (3) and CM01 (female) (16)
Resistance
Max. 1 z
Between R18 (female) (5) and CM01 (female) (16)
Resistance
Max. 1 z
If cause is not found by above checks, machine monitor is defective. q Reference 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector CM01. 3. Disconnect heater relay terminal R16. a Disconnect so that current does not flow in heater when starting switch is turned to HEAT position. 4. Turn the starting switch to HEAT position. Between CM01 (16) and (3)
40-364
Resistance
20 to 30 V
PC228US-8,PC228USLC-8
Troubleshooting of electrical system (E-mode) E-2 Preheater does not operate
Circuit diagram related to preheating of engine
PC228US-8,PC228USLC-8
40-345
40-365
Troubleshooting of electrical system (E-mode) E-2 Preheater does not operate
40-366
PC228US-8,PC228USLC-8
Troubleshooting of electrical system (E-mode) E-3 When starting switch is turned to ON position, machine monitor displays nothing
E-3 When starting switch is turned to ON position, machine monitor displays nothing Failure
Related information
q
When starting switch is turned to ON position, machine monitor displays nothing.
q
When starting switch is turned to ON position, machine monitor displays KOMATSU logo, screen to input password (if set), screen to check breaker mode (if set), screen of check before starting, screen to check working mode and travel speed, and standard screen in order. When engine is started, battery voltage may lower suddenly, depending on the ambient temperature and condition of battery. In this case, machine monitor goes off for a moment. This phenomenon is not a failure, however.
q
Cause
Procedure, measuring location, criteria and remarks a Be ready with starting switch in OFF position, then perform troubleshooting without turning starting switch ON.
1 Insufficient battery capacity
2
Defective fusible link F05 Defective fuse F01-17
Wrong connection of con3 nector
Defective wiring harness, 4 starting switch, or machine monitor
Defective starting switch 5 (open circuit in internal wiring)
Battery voltage (two pieces)
Min. 24 V
Electrolyte specific gravity (one piece)
Min. 1.26
If fusible link or fuse is blown, circuit probably has ground fault. (See Cause 7.) a If machine monitor is not replaced, this check is not required. Machine monitor connector may be connected wrongly. Check it directly. a Connector CM02 and CM03 can be installed even if they are exchanged. Since both male and female parts of CM03 are green, check their colours. 1. Turn starting switch to OFF position and disconnect ground cable. 2. Insert T-adapter into connector CM01. 3. Connect battery ground cable, and turn starting switch to ON position (connect ACC). Between CM01 (1) and (3)
Voltage
20 to 30 V
Between CM01 (2) and (4)
Voltage
20 to 30 V
Between CM01 (14) and (4)
Voltage
20 to 30 V
1. Turn starting switch to OFF position. 2. Disconnect connector H15 and connect T-adapter to male side. 3. Turn starting switch to ON position and troubleshoot again. Turn starting switch to OFF Resistance Min. 1 Mz Between H15 (male) (1) position. Turn starting switch to ON and (5) Resistance Max. 1 z position. If check result on cause 4 is normal, this check is not required. 1. Turn starting switch to OFF position and disconnect ground cable. 2. Disconnect fusible link F05, No. 17 of fuse F01, and connectors H15 and CM01. 3. Connect T-adapters to male side of connector F05 and female side of H15 and CM01. Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Between CM01 (female) (3), (4) and ground (T09)
Resistance
Max. 1 z
Between F01-17 and H15 (female) (1)
Resistance
Max. 1 z
Between H15 (female) (5) and CM01 (female) (14)
Resistance
Max. 1 z
Between battery (-) and ground Open circuit in wiring harBetween battery (+) and F03 (male) (1) ness 6 (Wire breakage or defective Between F03 (male) (2) and F01-16D contact of connector) Between F01-17 and CM01 (female) (1), (2)
PC228US-8,PC228USLC-8
40-367
Troubleshooting of electrical system (E-mode) E-3 When starting switch is turned to ON position, machine monitor displays nothing
Cause
Procedure, measuring location, criteria and remarks
If check result on cause 4 is normal, this check is not required. 1. Turn starting switch to OFF position and disconnect ground cable. 2. Disconnect fusible link F05, No. 17 of fuse F01, terminal 20E, and connectors H15, CM01, and C01. 3. Connect T-adapters to male side of connector F05 and female side of H15 and CM01. Ground fault in wiring harBetween battery (+) and ground, or between F03 Resistance Min. 1 Mz 7 ness (male) (1) and ground (contact with ground circuit) Between F05 (male) (2) and ground, or between Resistance Min. 1 Mz F01-16D and ground Between F01-17 and ground, or between CM01 (female) (1), (2) and ground, or between H15 (female) Resistance Min. 1 Mz (1) and ground Between H15 (female) (5) and ground, or between Resistance Min. 1 Mz CM01 (female) (14) and ground If no failure is found by above checks, machine monitor is defective. (Since failure is 8 Defective machine monitor in monitor, troubleshooting cannot be performed.)
40-368
PC228US-8,PC228USLC-8
Troubleshooting of electrical system (E-mode) E-3 When starting switch is turned to ON position, machine monitor displays nothing
Circuit diagram related to machine monitor power supply
PC228US-8,PC228USLC-8
40-349
40-369
Troubleshooting of electrical system (E-mode) E-4 When starting switch is turned to ON position (before starting engine), basic check monitor lights up.
E-4 When starting switch is turned to ON position (before starting engine), basic check monitor lights up. 1) When starting switch is turned to ON position (with engine stopped), engine oil level monitor lights up in red.
Failure Related information
Cause 1
Procedure, measuring location, criteria and remarks
Defective engine oil level switch Perform troubleshooting for failure code [B@BAZK]. system (machine monitor system)
2 Defective machine monitor Failure
If cause 1 is not detected, machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be performed.)
2) Radiator coolant level monitor lights up in red.
Related information Cause
Procedure, measuring location, criteria and remarks
1
Low radiator coolant level (When system works properly)
Coolant level may be low. Check coolant level and add coolant if necessary.
2
Radiator sub tank coolant level switch system
Perform troubleshooting for failure code [B@BCZK].
40-370
PC228US-8,PC228USLC-8
Troubleshooting of electrical system (E-mode) E-5 Precaution monitor lights up while engine is running
E-5 Precaution monitor lights up while engine is running Failure
1) Engine coolant temperature monitor lights up in white. q
Related information
q
Signal of engine coolant temperature sensor is input to engine controller and then data is transmitted to machine monitor through CAN communication system. Engine coolant temperature can be checked with monitoring function (Code: 04107 Engine coolant temperature)
Cause
Procedure, measuring location, criteria and remarks
If monitor lights up in white, engine coolant temperature may be low (below approximately 30 °C). Warm up engine. q Lighting up in white: Engine coolant temperature is low. q Lighting up in blue: Engine coolant temperature is proper. If cause 1 is not cause for trouble, engine coolant temperature gauge system Defective engine coolant tempera2 may be defective. Perform troubleshooting for "E-8 Engine coolant temperature gauge system ture gauge does not display properly". Insufficient warm-up of machine 1 (When system works properly)
Failure
2) Hydraulic oil temperature monitor lights up in white. q
Related information
q
Signal of hydraulic oil temperature sensor is input to pump controller and then data is transmitted to machine monitor through CAN communication system. Hydraulic oil temperature can be checked with monitoring function (Code: 04401 Hydraulic oil temperature)
Cause
Procedure, measuring location, criteria and remarks
If monitor lights up in white, hydraulic oil temperature may be low (below approximately 20 °C). Warm up engine. q Lighting up in white: Hydraulic oil temperature is low. q Lighting up in blue: Hydraulic oil temperature is proper. If cause 1 is not the cause for trouble, hydraulic oil temperature gauge system Defective hydraulic oil temperature 2 may be defective. Perform troubleshooting for "E-9 hydraulic oil temperature gauge system gauge does not display properly". Insufficient warm-up of machine 1 (When system works properly)
Failure
3) Charge level monitor lights up while engine is running.
Related information
q
Condition of generation signal of alternator can be checked with monitoring function. (Code: 04300 Charge voltage)
Cause
Procedure, measuring location, criteria and remarks
1 Defective alternator system
Failure
4) Fuel level monitor lights up in red.
Related information
q
Signal voltage of fuel sensor can be checked with monitoring function. (Code: 04200 Fuel sensor voltage)
Cause 1
Perform troubleshooting for failure code [AB00KE].
Low fuel level (When system works properly)
2 Defective fuel level gauge system
PC228US-8,PC228USLC-8
Procedure, measuring location, criteria and remarks Fuel level may be low. Check it and add fuel if necessary. If cause 1 is not cause for trouble, fuel level gauge system may be defective. Perform troubleshooting for "E-7 Fuel level gauge does not display properly".
40-371
Troubleshooting of electrical system (E-mode) E-5 Precaution monitor lights up while engine is running
Failure
5) Air cleaner clogging monitor lights up in red.
Related information
q
Condition of air cleaner clogging switch signal can be checked with monitoring function. (Code: 04501 Monitor input 2)
Cause
Procedure, measuring location, criteria and remarks
Clogging of air cleaner (When system works properly) Defective air cleaner clogging 2 switch system 1
Failure
Air cleaner may be clogged. Check it, then clean or replace if necessary. Perform troubleshooting for failure code [AA10NX].
6) Water separator monitor (Water level in water separator is high) q
Detection of water by fuel filter sensor can be checked with monitoring function. (Code: 18800 Condition of WIF sensor)
Cause
Procedure, measuring location, criteria and remarks
Related information
1
High water level in water separator Water is detected in water separator. Check and drain water separator. (When system works properly)
2
Defective fuel filter sensor system If cause 1 is not cause for trouble, fuel filter system may be defective. Perform (engine controller circuit) troubleshooting for failure codes [CA428] and [CA429].
3 Defective machine monitor
40-372
If causes 1 and 2 are not cause for trouble, machine monitor may be defective (Since failure is in monitor, troubleshooting cannot be performed.)
PC228US-8,PC228USLC-8
Troubleshooting of electrical system (E-mode) E-6 Emergency stop monitor lights up while engine is running
E-6 Emergency stop monitor lights up while engine is running Failure
1) Engine coolant temperature monitor lights up in red. q
Related information
q
Signal of engine coolant temperature sensor is input to engine controller and then data is transmitted to machine monitor through CAN communication system. Engine coolant temperature can be checked with monitoring function (Code: 04107 Engine coolant temperature)
Cause
Procedure, measuring location, criteria and remarks
If monitor lights up in red, engine coolant temperature may be high (above approximately 102 °C). Cool down engine coolant (Run engine at low idle). Overheating of engine coolq Lighting up in red: Engine coolant temperature is high (overheating). 1 ant (when system works q Lighting up in blue: Engine coolant temperature is proper. properly) Perform troubleshooting for "S-14 Coolant temperature becomes too high (overheating)". If cause 1 is not cause for trouble, engine coolant temperature gauge system may Defective engine coolant 2 be defective. Perform troubleshooting for "E-8 Engine coolant temperature gauge temperature gauge system does not display properly".
Failure
2) Hydraulic oil temperature monitor lights up in red. q
Related information
q
Signal of hydraulic oil temperature sensor is input to pump controller and then the data is transmitted to machine monitor through CAN communication system. Hydraulic oil temperature can be checked with monitoring function (Code: 04401 Hydraulic oil temperature)
Cause
Procedure, measuring location, criteria and remarks
Overheating of hydraulic oil 1 (When system works properly) 2
Defective hydraulic oil temperature gauge system
Failure
If monitor lights up in red, hydraulic oil temperature may be high (above approximately 102 °C). Cool down hydraulic oil (Run engine at low idle). q Lighting up in red: Hydraulic oil temperature is high (overheating). q Lighting up in blue: Hydraulic oil temperature is proper. If cause 1 is not cause for trouble, hydraulic oil temperature gauge system may be defective. Perform troubleshooting for "E-9 hydraulic oil temperature gauge does not display properly".
3) Engine oil pressure monitor lights up in red.
Related information
q
Signal of engine oil pressure switch is input to engine controller. If engine oil pressure switch is turned ON while engine is running, failure code [B@BAZG] is transmitted from engine controller to machine monitor through CAN communication.
Cause Low engine oil pressure 1 (When system works properly) Defective engine oil pres2 sure switch system
PC228US-8,PC228USLC-8
Procedure, measuring location, criteria and remarks Since engine oil pressure may be low, check it. If it is low, perform troubleshooting for "S-12 Oil pressure decreases". If cause 1 is not cause for trouble, engine oil pressure switch system may be defective. Perform troubleshooting for failure code [CA435].
40-373
Troubleshooting of electrical system (E-mode) E-7 Fuel level gauge does not indicate correctly
E-7 Fuel level gauge does not indicate correctly 1) While fuel is added, fuel level gauge indicator does not rise from red range (E). 2) While fuel level is low, fuel level gauge indicator does not lower from green range top (F)
Failure Related information
q
Signal voltage of fuel sensor can be checked with monitoring function. (Code: 04200 Fuel sensor voltage)
Cause Defective fuel level sensor 1 (Open or short circuit in internal wiring)
2
Open or short circuit in wiring harness
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector P21 and connect T-adapter to male side. Between P21 (male) (1) and ground
Fuel level: FULL
Resistance Approx. 12 z
Fuel level: EMPTY
Resistance
85 to 110 z
1. Turn starting switch to OFF position. 2. Disconnect connector CM01 and connect T-adapter to female side. Between CM01 (female) (9) and ground
Fuel level: FULL
Resistance Approx. 12 z
Fuel level: EMPTY
Resistance
85 to 110 z
a If check result on cause 2 is normal, this check is not required. Open circuit in wiring har1. Turn starting switch to OFF position. ness 2. Disconnect connectors CM01 and P21, and connect T-adapter on each female 3 (Wire breakage or defective side. contact of connector) Between CM01 (female) (9) and P21 (female) (1) Resistance Max. 1 z 1. Turn starting switch to OFF position. Ground fault in wiring har2. Disconnect connectors CM01 and P21, and connect T-adapter to female side of 4 ness either one. (contact with ground circuit) Between CM01 (female) (9) and ground, or between Resistance Min. 1 Mz P21 (female) (1) and ground 1. Turn starting switch to OFF position. 2. Disconnect connector P21. Hot short circuit in wiring 3. Insert T-adapter between male and female sides of connector CM01 or connect 5 harness T-adapter to female side of connector P21. (contact with 24 V circuit) 4. Turn starting switch to ON position. Approx. 3.3 Between CM01 (9) and ground, or between P21 Voltage V (female) (1) and ground If no failure is found by above checks, machine monitor is defective. (Since failure is 6 Defective machine monitor in monitor, troubleshooting cannot be performed.)
Circuit diagram related to fuel level sensor
40-374
40-354
PC228US-8,PC228USLC-8
Troubleshooting of electrical system (E-mode) E-7 Fuel level gauge does not indicate correctly
3) Indication of fuel level gauge is different from actual fuel level. 4) Indication of fuel level gauge is different from display of fuel level monitor.
Failure Related information
q
Signal voltage of fuel sensor can be checked with monitoring function. (Code: 04200 Fuel sensor voltage)
Cause
Procedure, measuring location, criteria and remarks a Turn starting switch to ON position or start engine and perform troubleshooting. Fuel level
1 Defective machine monitor
230 l
6
195 l
5
160 l
4
80 l
3
60 l
2
40 l
1
Fuel level gauge and fuel level monitor
PC228US-8,PC228USLC-8
Reading of fuel level gauge Colour of monitor light (a)
Blue
Red
40-35
40-375
Troubleshooting of electrical system (E-mode) E-8 Engine coolant temperature gauge does not indicate correctly
E-8 Engine coolant temperature gauge does not indicate correctly 1) While engine coolant temperature is rising properly, temperature gauge does not rise from white range (C). 2) While engine coolant temperature is stabilized normally, temperature gauge rises to red range (H). q Signal of engine coolant temperature sensor is input to engine controller and then data is transmitted to machine monitor through CAN communication system. Related inforq Engine coolant temperature can be checked with monitoring function mation (Code: 04107 Engine coolant temperature) Failure
1
Cause
Procedure, measuring location, criteria and remarks
Defective engine coolant temperature sensor system
Engine coolant temperature sensor system may be defective. Perform troubleshooting for failure codes [CA144] and [CA145].
2 Defective machine monitor
If cause 1 is not detected, machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be performed.)
3) Indication of the coolant temperature gauge is different from actual engine coolant temperature. 4) Indication of engine coolant temperature gauge is different from display of engine coolant temperature monitor. q Signal voltage of engine coolant temperature sensor is input to engine controller and then data is transmitted to machine monitor through CAN communication system. Related inforq Engine coolant temperature can be checked with monitoring function. mation (Code: 04107 Engine coolant temperature) Failure
Cause
Procedure, measuring location, criteria and remarks a Turn starting switch to ON position or start engine and perform troubleshooting. Engine coolant temperature
Coolant temperature level
105 °C
6
102 °C
5
100 °C
4
85 °C
3
60 °C
2
30°C
1
Colour of monitor light (a) Red
1 Defective machine monitor
Blue
White
Engine coolant temperature gauge and coolant temperature monitor 40-356
40-376
PC228US-8,PC228USLC-8
Troubleshooting of electrical system (E-mode) E-8 Engine coolant temperature gauge does not indicate correctly
PC228US-8,PC228USLC-8
40-377
Troubleshooting of electrical system (E-mode) E-9 Hydraulic oil temperature gauge does not indicate correctly
E-9 Hydraulic oil temperature gauge does not indicate correctly Failure
Related information
(1) While hydraulic oil temperature is rising properly, temperature gauge does not rise from white range (C). (2) Although hydraulic oil temperature is stabilized normally, temperature gauge rises to red range (H). q Signal of hydraulic oil temperature sensor is input to pump controller and then data is transmitted to machine monitor through CAN communication system. q Hydraulic oil temperature can be checked with monitoring function. (Code: 04401 Hydraulic oil temperature)
Cause 1 Defective machine monitor
Procedure, measuring location, criteria and remarks See the next page. 1. Turn starting switch to OFF position. 2. Disconnect connector P22 and connect T-adapter to male side.
Defective hydraulic oil temperature sensor Between P22 (male) (1) and (2) 2 (open or short circuit in inter- a Temperature characteristics of oil nal wiring) temperature sensor
Between P22 (male) (2) and ground
3
4
5
6
7
10°C
Resistance
30°C
Resistance
80°C
Resistance
100°C
Resistance Resistance
Approx. 90 kz Approx. 35 kz Approx. 6.5 kz Approx. 3.5 kz Min. 1 Mz
1. Turn starting switch to OFF position. 2. Disconnect connector C01 and connect T-adapter to female side. Open circuit or ground fault Between C01 (female) (29) and (46) in wiring harness a Resistance accords with value on temperature char- Resistance 3.5 to 90 kz acteristics table in cause 2. Between C01 (female) (29) and ground Resistance Min. 1 Mz a If no failure is found in checks on cause 3, this check is not required. 1. Turn starting switch to OFF position. Open circuit in wiring har2. Disconnect connectors C01 and P22, and connect T-adapters to each female ness side. (Wire breakage or defective Between C01 (female) (29) and P22 (female) (2) Resistance Max. 1 z contact of connector) Between C01 (female) (46) and P22 (female) (1) Resistance Max. 1 z a If no failure is found in checks on cause 3, this check is not required. 1. Turn starting switch to OFF position. Ground fault in wiring har2. Disconnect connectors C01 and P22, and connect T-adapter to female side of ness either one. (contact with ground circuit) Between C01 (female) (29) and ground, or between Resistance Min. 1 Mz P22 (female) (2) and ground 1. Turn starting switch to OFF position. 2. Disconnect connector P22. Hot short circuit in wiring har- 3. Insert T-adapter between male and female sides of connector C01 or connect ness T-adapter to female side of connector P22. (contact with 24 V circuit) 4. Turn starting switch to ON position. Between C01 (29) and ground, or between P22 Voltage Approx. 5 V (female) (2) and ground If no failure is found by above checks, pump controller is defective. (Since failure is Defective pump controller in controller, troubleshooting cannot be performed.)
40-378
PC228US-8,PC228USLC-8
Troubleshooting of electrical system (E-mode) E-9 Hydraulic oil temperature gauge does not indicate correctly
Circuit diagram related to hydraulic oil temperature sensor
PC228US-8,PC228USLC-8
40-359
40-379
Troubleshooting of electrical system (E-mode) E-9 Hydraulic oil temperature gauge does not indicate correctly
(3) Indication of hydraulic oil temperature gauge is different from actual hydraulic oil temperature. (4) Indication of hydraulic oil temperature gauge is different from display of hydraulic oil temperature monitor. q Signal of hydraulic oil temperature sensor is input to pump controller and then data is transmitted to machine monitor through CAN communication system. Related inforq Hydraulic oil temperature can be checked with monitoring function mation (Code: 04401 Hydraulic oil temperature) Failure
Cause
Procedure, measuring location, criteria and remarks a Turn starting switch to ON position or start engine and perform troubleshooting. Hydraulic oil temperature
Hydraulic oil temperature level
105°C
6
102°C
5
100°C
4
85°C
3
40°C
2
20°C
1
Colour of monitor light (a) Red
1 Defective machine monitor
Blue
White
Hydraulic oil temperature gauge and hydraulic oil temperature monitor 40-360
40-380
PC228US-8,PC228USLC-8
Troubleshooting of electrical system (E-mode) E-10 Displays on machine monitor are different from those for actual machine
E-10 Displays on machine monitor are different from those for actual machine q
Failure
Display on machine monitor are different from those for applicable model.
Related information Cause
Procedure, measuring location, criteria and remarks a Turn starting switch to ON position and perform troubleshooting (with monitoring function).
1 Defective model code signal
Monitoring code
Correct display
00200 Controller model code
PC228US-8
If display on monitor is incorrect, perform troubleshooting for failure code [DA29KQ]. 2 Defective machine monitor
If no failure is found in check on cause 1, machine monitor is defective. (Since failure is in monitor, troubleshooting cannot be performed.)
E-11 Some areas of machine monitor screen are not displayed Failure
q
Machine monitor does not display some items
q
The LCD panel may have black pixels (that do not light up) or bright pixels (that stay on). If the number of the bright pixels and black pixels does not exceed ten, it does not indicate a failure or a defect.
Related information
Cause
Procedure, measuring location, criteria and remarks a Turn starting switch ON and performed troubleshooting.
Defective machine monitor 1 (LCD panel)
2
Defective machine monitor (body)
When following switches are operated, if all LCD panel is lighted up (all surface becomes white), LCD panel is normal. q Operation of switches: [4] + [F2] (Press simultaneously) If cause 1 is not detected, machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be performed.)
E-12 Function switch does not operate Failure Related information
q
The function switch does not work.
q
The condition of signal of function switch can be checked with the monitoring function. (Code: 04503 Monitor function switch)
Cause 1 Defective machine monitor
PC228US-8,PC228USLC-8
Procedure, measuring location, criteria and remarks Machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be performed.)
40-381
Troubleshooting of electrical system (E-mode) E-13 Automatic warm-up system does not operate (in cold season)
E-13 Automatic warm-up system does not operate (in cold season) Failure
q
Automatic warm-up system does not operate (in cold weather).
q
Automatic warm-up function increases engine speed to 1,200 rpm when engine coolant temperature is below 30 °C. With starting switch at ON position or after engine is started, if fuel control dial is kept at 70% of full open range or more for 3 seconds, automatic warm-up operation is cancelled. If machine is equipped with air conditioner, when blower is operated, ambient temperature is below 5 °C and engine coolant temperature is below 55 °C, automatic warm-up function increases engine speed to 1,300 rpm. If engine coolant temperature reaches 60 °C, automatic warm-up function is cancelled. If engine coolant temperature is below 10 °C, turbocharger protection function operates to keep engine speed below 1,000 rpm for up to 5 seconds after engine is started.
q
Related information
q
q
Cause
Procedure, measuring location, criteria and remarks a Turn starting switch to ON position or start engine and perform troubleshooting. Engine coolant temperaCoolant temperature Monitoring code ture gauge level
04107 Defective engine coolant tempera1 Engine coolant temperature signal system ture
2 Defective engine controller
105 °C
6 (a: Red)
102 °C
5 (a: Red)
100 °C
4 (a: Blue)
85 °C
3 (a: Blue)
60 °C
2 (a: Blue)
30 °C
1 (a: White)
If engine coolant temperature does not match with coolant temperature gauge level, perform troubleshooting for "E-8 Engine coolant temperature gauge does not indicate correctly". If no failure is found in cause 1, the engine controller is defective. (Since failure is in controller, troubleshooting cannot be performed.)
Engine coolant temperature gauge and engine coolant temperature monitor 40-362
40-382
PC228US-8,PC228USLC-8
Troubleshooting of electrical system (E-mode) E-14 Auto-decelerator does not operate properly
E-14 Auto-decelerator does not operate properly 1) When auto-decelerator switch is operated, auto-decelerator monitor does not light up or does not go off. q Condition of signal of auto-decelerator switch can be checked with monitoring function. Related information (Code: 04504 Monitor 1st, 2nd line switches) Failure
Cause
Procedure, measuring location, criteria and remarks
1 Defective machine monitor Failure
Machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be performed.)
2) Auto-decelerator is not operated or cancelled with lever. q
Related information q
Since set speed of auto-decelerator is 1,050 rpm, it is not operated or cancelled if fuel control dial is set below this speed. Auto-deceleration does not function in arm crane mode (L) for machines with arm crane.
Cause
Procedure, measuring location, criteria and remarks a Start engine and perform troubleshooting (with monitoring function). Monitoring code
Item
Correct display
Swing Travel 01900 Pressure switch 1 1 Defective PPC oil pressure signal
Boom LOWER Boom RAISE
When lever is operated: ON When lever is in neutral: OFF
Arm IN Arm OUT Bucket CURL 01901 Pressure Switch 2
Bucket DUMP Service
When lever is operated: ON When lever is in neutral: OFF
If display of monitor is incorrect, perform troubleshooting for "E-26 - 34 Monitoring function does not display *** properly". 2 Defective machine monitor
If no failure is found in check on cause 1, machine monitor may be defective. (Since failure is in monitor, troubleshooting cannot be performed.)
3 Defective pump controller
If no failure is found in checks on causes 1 and 2, pump controller may be defective (Since failure is in controller, troubleshooting cannot be performed.)
4 Defective engine controller
If no failure is found in checks on causes 1 and 3, engine controller may be defective. (Since failure is in controller, troubleshooting cannot be performed.)
PC228US-8,PC228USLC-8
40-383
Troubleshooting of electrical system (E-mode) E-15 Working mode does not change
E-15 Working mode does not change Failure
1) When working mode switch is operated, working mode selection screen is not displayed.
Related information
q
Condition of signal of working mode switch can be checked with monitoring function. (Code: 04504 Monitor 1st, 2nd line switches)
Cause 1 Defective machine monitor
Failure
Procedure, measuring location, criteria and remarks Machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be performed.)
2) When working mode is changed, setting of engine and hydraulic pump is not changed.
Related information Cause 1 Defective machine monitor 2 Defective pump controller
40-384
Procedure, measuring location, criteria and remarks Machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be performed.) Pump controller may be defective. (Since failure is in controller, troubleshooting cannot be performed.)
PC228US-8,PC228USLC-8
Troubleshooting of electrical system (E-mode) E-16 Travel speed does not change
E-16 Travel speed does not change Failure
1) When travel speed switch is operated, travel speed monitor does not change.
Related information
q
Condition of signal of travel speed switch can be checked with monitoring function. (Code: 04504 Monitor 1st, 2nd line switches)
Cause
Procedure, measuring location, criteria and remarks
1 Defective machine monitor
Failure
2) When travel speed selection is changed, actual travel speed does not change. q
Related information
q
If cause 1 occurs, actual travel speed does not lower when travel speed selection is changed to Lo. As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be measured at pump controller connector.
Cause
1
Machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be performed.)
Hot short circuit in wiring harness (contact with 24 V circuit)
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector V04 and connect T-adapter to female side. 3. Turn starting switch to ON position. Between V04 (female) (2) and ground
Voltage
Max. 1 V
2 Defective machine monitor
If no failure is found in checks on cause 1, machine monitor may be defective. (Since failure is in monitor, troubleshooting cannot be performed.)
3 Defective pump controller
If no failure is found in checks on cause 1 and 2, pump controller may be defective (Since failure is in controller, troubleshooting cannot be performed.)
Circuit diagram related to travel speed solenoid
PC228US-8,PC228USLC-8
40-365
40-385
Troubleshooting of electrical system (E-mode) E-17 Alarm buzzer cannot be cancelled
E-17 Alarm buzzer cannot be cancelled q
Failure
Alarm buzzer cannot be cancelled
q
Related information
Condition of signal of alarm buzzer cancel switch can be checked with monitoring function. (Code: 04504 Monitor 1st, 2nd line switches) a Alarm buzzer related to failure of arm crane cannot be cancelled.
Cause
Procedure, measuring location, criteria and remarks
1 Defective machine monitor
Machine monitor may be defective. (Since failure is in monitor, troubleshooting cannot be performed.)
E-18 When starting switch is turned OFF, service meter is not displayed Failure
q
When starting switch is turned OFF, service meter is not displayed.
q
While starting switch is at OFF position, if following switches are operated, service meter is displayed at top centre of screen. Operation of switches: [4] + [1] (Press simultaneously)
Related information
Cause Defective backup power supply 1 system 2 Defective machine monitor
40-386
Procedure, measuring location, criteria and remarks When starting switch is turned ON, if machine monitor displays nothing, backup power supply system may be defective. In this case, perform troubleshooting for "E-3 When starting switch is turned ON, machine monitor displays nothing". If cause 1 is not detected, machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be performed.)
PC228US-8,PC228USLC-8
Troubleshooting of electrical system (E-mode) E-19 Service mode cannot be selected
E-19 Service mode cannot be selected Failure Related information
q
Machine monitor cannot be set in service mode
q
Following switch operation sets the machine monitor in service mode. Switch operation: [4] + [1] o [2] o [3] (While pressing [4], press [1], [2], and [3] in order)
Cause 1 Defective machine monitor
PC228US-8,PC228USLC-8
Procedure, measuring location, criteria and remarks Machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be performed.)
40-387
Troubleshooting of electrical system (E-mode) E-20 Any of work equipment, swing and travel do not operate or cannot be locked
E-20 Any of work equipment, swing and travel do not operate or cannot be locked Failure
1) All of work equipment, swing, and travel mechanism do not move.
Related information Cause 1 Defective fuse F01-3
Defective lock lever 2 switch (open circuit in internal wiring)
Procedure, measuring location, criteria and remarks If the fuse is blown, the circuit probably has a ground fault. (See cause 6.) 1. Turn starting switch to OFF position. 2. Disconnect connector S14 and connect T-adapter to female side. Lock lever: LOCK
Resistance
Min. 1 Mz
Lock lever: FREE
Resistance
Max. 1 z
1. Turn starting switch to OFF position. Defective PPC lock sole- 2. Disconnect connector V01 and connect T-adapter to male side. 3 noid (open or short circuit Between V01 (male) (1) and (2) Resistance in internal wiring) Between V01 (male) (1) and ground Resistance
20 – 60 z
Between S14 (male) (1) and (2)
Min. 1 Mz
1. Turn starting switch to OFF position. 2. Remove diode array D01 and connect T-adapter to male side. Defective diode array D01 a Check the continuity in diode range. 4 (internal short circuit) Between D01 (male) (8) (+) and (4) (-) Continuity Between D01 (male) (4) (+) and (8) (-)
No continuity
1. Turn starting switch to OFF position. 2. Set lock lever to FREE position. 3. Remove fuse F01-3. Between F01-3 and ground (coil resistance of PPC lock Resistance 20 – 60 z solenoid) Open circuit in wiring har- a If above check result is normal, this check is not required. 1. Turn starting switch to OFF position. ness 5 (Wire breakage or defec- 2. Remove fuse F01-3. tive contact of connector) 3. Disconnect connectors S14 and V01 and then connect T-adapters to male side of S14 and female side of V01. Between F01-3 and S14 (male) (1)
Resistance
Max. 1 z
Between S14 (male) (2) and V01 (female) (1)
Resistance
Max. 1 z
Between V01 (female) (2) and ground (T09)
Resistance
Max. 1 z
1. Turn starting switch to OFF position. 2. Remove fuse F01-3. Ground fault in wiring har- 3. Disconnect connectors S14, V01, and D01, and then connect T-adapter to male ness side of S14 or female side of V01 or D01. 6 (Contact with ground cir- Between F01-3 or S14 (male) (1) and ground Resistance Min. 1 Mz cuit) Between ground and S14 (male) (2), V01 (female) (1) or Resistance Min. 1 Mz D01 (female) (4)
40-388
PC228US-8,PC228USLC-8
Troubleshooting of electrical system (E-mode) E-20 Any of work equipment, swing and travel do not operate or cannot be locked
Failure
2) All of work equipment, swing, and travel mechanism do not lock.
Related information Cause Defective lock lever switch 1 (short circuit in internal wiring)
Hot short circuit in wiring 2 harness (contact with 24 V circuit)
Related circuit diagram
PC228US-8,PC228USLC-8
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector S14, and connect T-adapter to male side. Between S14 (male) (1) and (2)
Lock lever: LOCK
Resistance
Min. 1 Mz
Lock lever: FREE
Resistance
Max. 1 z
Voltage
Max. 1 V
1. Turn starting switch to OFF position. 2. Connect T-adapter to connector V01. 3. Turn starting switch to ON position. Between V01 (male) (1) and (2)
40-369
40-389
Troubleshooting of electrical system (E-mode) E-20 Any of work equipment, swing and travel do not operate or cannot be locked
40-390
PC228US-8,PC228USLC-8
Troubleshooting of electrical system (E-mode) E-21 Swing brake does not operate properly
E-21 Swing brake does not operate properly Failure
1) When swing brake cancel switch is set to CANCEL position, machine cannot swing.
Related information
q
Condition of swing lock switch signal can be checked with monitoring function. (Pump controller system code: 02200 Switch input 1)
Cause 1 Defective fuse F01-1
Procedure, measuring location, criteria and remarks If fuse F01-1 is broken, circuit probably has ground fault. In this case, troubleshoot cause 6 first. 1. Turn starting switch to OFF position. 2. Disconnect connector S25, and connect T-adapter to male side.
Defective swing brake can2 cel switch (internal short circuit)
Swing brake cancel switch: Between S25 (male) (13) LOCK and (14) Swing brake cancel switch: CANCEL
Resistance
Min. 1 Mz
Resistance
Max. 1 z
1. Turn starting switch to OFF position. 2. Remove diode arrays D01 and D03, and connect T-adapters to male side. a Check the continuity in diode range. 3
Defective diode array D01 or Between D01 (male) (7) (+) and (3) (-) D03 (internal short circuit) Between D01 (male) (3) (+) and (7) (-)
Continuity No continuity
Between D03 (male) (7) (+) and (3) (-)
Continuity
Between D03 (male) (3) (+) and (7) (-)
No continuity
1. Turn starting switch to OFF position. 2. Disconnect connector V03 and connect T-adapter to female side. 3. Turn starting switch to ON position. 4 Defective wiring harness
Swing brake cancel switch: Voltage 20 to 30 V Between V03 (female) (1) CANCEL and (2) Swing brake cancel switch: Voltage Max. 1 V LOCK a If no failure is found in checks on cause 4, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors V03 and S25, and connect T-adapters to female sides of them.
Open circuit in wiring harness 5 (Wire breakage or defective Between V03 (female) (1) and S25 (female) (14) contact of connector)
Resistance
Max. 1 z
Between V03 (female) (2) and C02 (female) (115)
Resistance
Max. 1 z
a If no failure is found in checks on cause 3, this check is not required. 1. Turn starting switch to OFF position. Ground fault in wiring har2. Disconnect connectors S25, V03, D01 and D03, and connect T-adapter to 6 ness female side of V03. (contact with ground circuit) Between V03 (female) (1) and ground Resistance Min. 1 Mz
Failure
2) When swing brake cancel switch is set to LOCK position, swing brake does not operate.
Related information Cause
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector S25, and connect T-adapter to male side.
Defective swing brake can1 cel switch (internal short circuit)
PC228US-8,PC228USLC-8
Swing brake cancel switch: Between S25 (male) (13) LOCK and (14) Swing brake cancel switch: CANCEL
Resistance
Min. 1 Mz
Resistance
Max. 1 z
40-391
Troubleshooting of electrical system (E-mode) E-21 Swing brake does not operate properly
Cause Hot short circuit in wiring 2 harness (contact with 24 V circuit)
Procedure, measuring location, criteria and remarks 1. 2. 3. 4.
Turn starting switch to OFF position. Disconnect connector V03 and connect T-adapter to female side. Turn starting switch to ON position. Swing lock switch: ON
Between V03 (female) (1) and ground
40-392
Voltage
Max. 1 V
PC228US-8,PC228USLC-8
Troubleshooting of electrical system (E-mode) E-21 Swing brake does not operate properly
Circuit diagram related to swing brake solenoid
PC228US-8,PC228USLC-8
40-373
40-393
Troubleshooting of electrical system (E-mode) E-22 One-touch power maximizing function does not operate properly
E-22 One-touch power maximizing function does not operate properly 1) When L.H. knob switch is pressed, one-touch power maximizing monitor is not displayed. 2) When L.H. knob switch is pressed, work equipment power is not increased.
Failure
q
Related information
q
One-touch power maximizing function does not operate when working mode is not power mode (P) or economy mode (E). Condition of L.H. knob switch signal can be checked with monitoring function. (Code: 02200 Switch Input 1)
Cause 1
When L.H. knob switch is pressed, if work equipment power is increased but fact is not Defective machine monidisplayed on monitor, machine monitor may be defective (Since trouble is in monitor, tor troubleshooting cannot be performed.)
2 Defective fuse No. 9
3
Procedure, measuring location, criteria and remarks
Defective left knob switch (internal open circuit)
If fuse is blown, circuit probably has a ground fault. (See cause 6.) 1. Turn starting switch to OFF position. 2. Disconnect connector S11, and connect T-adapter to male side. L.H. knob switch: Released
Resistance
Min. 1 Mz
L.H. knob switch: Pressed
Resistance
Max. 1 z
1. Turn starting switch to OFF position. Defective PPC lock sole- 2. Disconnect connector V01 and connect T-adapter to male side. 4 noid (open or short circuit Between V01 (male) (1) and (2) Resistance in internal wiring) Between V01 (male) (1) and ground Resistance
20 – 60 z
Between S11 (female) (1) and (2)
1. Turn starting switch to OFF position. 2. Disconnect connector C01 and connect T-adapter to female side. 3. Turn starting switch to ON position. Open circuit in or ground a Ignore displayed failure code. 5 fault of wiring harness Voltage Between C01 (female) (41) L.H. knob switch: Released and ground L.H. knob switch: Pressed Voltage
Min. 1 Mz
Max. 1 V 20 – 30 z
a If no failure is found in checks on cause 4, this check is not required. 1. Turn starting switch to OFF position. Open circuit in wiring har2. Remove fuse F01-9. ness 3. Disconnect connectors C01 and S11 and connect T-adapters to their female sides. 6 (Wire breakage or defecBetween F01-9 and S11 (female) (1) Resistance Max. 1 z tive contact of connector) Between S11 (female) (2) and C01 (female) (41)
Resistance
Max. 1 z
a If no failure is found in checks on cause 4, this check is not required. 1. Turn starting switch to OFF position. Ground fault in wiring har- 2. Remove fuse F01-9. ness 3. Disconnect connectors C01 and S11 and connect T-adapter to female side of S11. 7 (contact with ground cirBetween F01-9 or S11 (female) (1) and ground Resistance Min. 1 Mz cuit) Between S11 (female) (2) or C01 (female) (41) and Resistance Min. 1 Mz ground If no failure is found by above checks, pump controller is defective. (Since failure is in 8 Defective pump controller controller, troubleshooting cannot be performed.)
40-394
PC228US-8,PC228USLC-8
Troubleshooting of electrical system (E-mode) E-22 One-touch power maximizing function does not operate properly
Circuit diagram related to one-touch power maximizing switch
PC228US-8,PC228USLC-8
40-375
40-395
Troubleshooting of electrical system (E-mode) E-22 One-touch power maximizing function does not operate properly
Failure
3) When L.H. knob switch is released, work equipment power is not returned to normal.
Related information
q
Condition of L.H. knob switch signal can be checked with monitoring function. (Code: 02200 Switch Input 1)
Cause Hot short circuit in wiring 1 harness (contact with 24 V circuit) 2 Defective pump controller
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector V02 and connect T-adapter to female side. 3. Turn starting switch to ON position. Between V02 (female) (1) and (2)
Max. 1 V
If no failure is found in check on cause 1, pump controller is defective. (Since failure is in controller, troubleshooting cannot be performed.)
Circuit diagram related to 2-stage relief solenoid
40-396
Voltage
40-376
PC228US-8,PC228USLC-8
Troubleshooting of electrical system (E-mode) E-23 Travel alarm does not sound or does not stop sounding
E-23 Travel alarm does not sound or does not stop sounding Failure
1) Alarm does not sound during travel.
Related information
q
Output to travel alarm can be checked with monitoring function. (Code: 03701 Controller output 2)
Cause 1
Defective travel alarm (internal defect)
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector M14 and connect T-adapter to male side. Between M14 (male) (1) and (2)
Continuity
1. Turn starting switch to OFF position. 2. Disconnect connectors M14 and C02 and connect T-adapters to their female sides.
Open circuit in wiring harness 2 (Wire breakage or defective Between C02 (female) (107) and M14 (female) (1) contact of connector) Between C02 (female) (115) and M14 (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z
1. Turn starting switch to OFF position. Ground fault in wiring har2. Disconnect connectors C02 and M14, and connect T-adapter to female side of 3 ness either connector. (contact with ground circuit) Between C02 (female) (107) or M14 (female) (1) and Resistance Min. 1 Mz ground
Failure
2) Alarm does not stop sounding while machine is stopped.
Related information Cause Hot short circuit in wiring 1 harness (contact with 24 V circuit)
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector M14 and connect T-adapter to female side. 3. Turn starting switch to ON position. Between M14 (female) (1) and ground
Circuit diagram related to travel alarm
PC228US-8,PC228USLC-8
Voltage
Max. 1 V
40-37
40-397
Troubleshooting of electrical system (E-mode) E-24 Horn does not sound or does not stop
E-24 Horn does not sound or does not stop Failure
1) Horn does not sound.
Related information Cause 1 Defective fuse F01-5
Defective horn relay 2 (open or short circuit in internal wiring)
Procedure, measuring location, criteria and remarks If fuse F01-5 is broken, circuit probably has ground fault. In this case, troubleshoot cause 7 first. 1. 2. 3. 4.
Turn starting switch to OFF position. Replace horn relay (connector: R08) with another relay. Turn starting switch to ON position. Press L.H. knob switch.
If horn sounds, original horn relay is defective.
3
Defective horn switch (internal open or short circuit)
1. Turn starting switch to OFF position. 2. Disconnect connector S10 and connect T-adapter to male side. Between S10 (male) (1) and (2)
Switch: OFF
Resistance
Min. 1 Mz
Switch: ON
Resistance
Max. 1 z
1. Turn starting switch to OFF position. Defective high-tone horn (M07) 2. Disconnect connectors M07 and M08 and connect T-adapters to their male sides. or low-tone horn (M08) (open 4 circuit or short circuit in internal Between M07 (male) (1) and (2) Continuity wiring) Between M08 (male) (1) and (2) Continuity
5 Defective wiring harness
1. 2. 3. 4.
Turn starting switch to OFF position. Disconnect connector R08 and connect T-adapter to female side. Turn starting switch to ON position. Press L.H. knob switch.
Between R08 (female) (1) and (2)
Voltage
20 to 30 V
Between R08 (female) (3) and (2)
Voltage
20 to 30 V
1. Turn starting switch to OFF position. 2. Disconnect connector R08 and connect T-adapter to female side. Between R08 (female) (5) and ground
Continuity
Between R08 (female) (1) and ground
Continuity
a If no failure is found in above checks, this check is not required. 1. Turn starting switch to OFF position. Open circuit in wiring harness 6 (Wire breakage or defective con- 2. Remove fuse F01-5. 3. Disconnect connectors R08 and S10, and connect T-adapters to female sides tact) of them.
7
Ground fault in wiring harness (contact with ground circuit)
40-398
Between F01-5 and S10 (female) (1)
Resistance
Max. 1 z
Between S10 (female) (2) and R08 (female) (1)
Resistance
Max. 1 z
Between R08 (female) (2) and ground
Resistance
Max. 1 z
Between R08 (female) (3) and F01-5
Resistance
Max. 1 z
a If fuse is not blown, this check is not required. 1. Turn starting switch to OFF position. 2. Remove fuse F01-5. 3. Disconnect connectors R08, M07, and M08, and connect T-adapter to female side of R08. Between R08 (female) (1) and ground
Resistance
Min. 1 Mz
Between R08 (female) (3) and ground
Resistance
Min. 1 Mz
Between R08 (female) (5) and ground
Resistance
Min. 1 Mz
PC228US-8,PC228USLC-8
Troubleshooting of electrical system (E-mode) E-24 Horn does not sound or does not stop
Cause 8
Defective horn (internal defect)
Failure
Procedure, measuring location, criteria and remarks If cause cannot be found by above checks, horn may be defective.
2) Horn does not stop sounding.
Related information Cause Defective horn relay (R08) 1 (open or short circuit in internal wiring)
2
Hot short circuit in wiring harness (contact with 24 V circuit)
Circuit diagram related to horn
PC228US-8,PC228USLC-8
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Remove horn relay (connector R08). 3. Turn starting switch to ON position. If horn stops sounding, original horn relay is defective. 1. Turn starting switch to OFF position. 2. Disconnect connectors M07 and M08 and connect T-adapters to their female sides. 3. Turn starting switch to ON position. Between M07 (female) (2) and (1)
Voltage
Max. 1 V
Between M08 (female) (2) and (1)
Voltage
Max. 1 V
40-379
40-399
Troubleshooting of electrical system (E-mode) E-25 Windshield wiper and window washer do not operate
E-25 Windshield wiper and window washer do not operate Failure
1) When wiper switch is operated, wiper monitor does not light up or go off.
Related information
q
Condition of wiper switch signal can be checked with monitoring function. (Code: 04504 Monitor 1st, 2nd line switches)
Cause
Procedure, measuring location, criteria and remarks
1 Defective machine monitor
Machine monitor may be defective. (Since failure is in monitor, troubleshooting cannot be performed.)
Failure
2) When wiper switch is operated, wiper does not operate.
Related information
q q
Condition of window rear limit switch signal can be checked with monitoring function. (Code: 02204 Switch input 5) Wiper motor is troubleshoot for failure codes [DY20KA], [DY20MA], [DY2DKB], and [DY2EKB].
Cause
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector W03.
Defective rear limit switch for 1 window (internal short cirBetween W03 (male) (1) cuit) and (2)
Defective wiper motor 2 (internal open circuit in wiring)
Front window: when closed Resistance
Min. 1 Mz
Front window: when pulled up
Max. 1 z
Resistance
1. Turn starting switch to OFF position. 2. Disconnect connector M05 and connect T-adapter to female side. Between M05 (female) (1) and (3)
Continuity
a Wiper motor system See troubleshooting for [DY20KA], [DY20MA], [DY2DKB], and [DY2EKB].
Open circuit in wiring hara Rear limit switch system ness 3 (Wire breakage in wiring or 1. Turn starting switch to OFF position. defective contact of connec- 2. Disconnect connector C01 and connect T-adapter to female side. 3. Pull up front window. tor) Resistance
Max. 1 z
1. Turn starting switch to OFF position. Ground fault in wiring har2. Disconnect connector C01 and connect T-adapter to female side. 4 ness 3. Close front window. (contact with ground circuit) Between C01 (female) (57) and ground Resistance
Min. 1 Mz
Between C01 (female) (57) and ground
5 Defective pump controller
Failure
If no failure is found by above checks, pump controller is defective. (Since failure is in controller, troubleshooting cannot be performed.)
3) When window washer switch is operated, window washer does not operate.
Related information
q q
Condition of window washer switch signal can be checked with monitoring function. (Code: 04504 Monitor 1st, 2nd line switches) Window washer is troubleshoot for failure codes [DY2CKA] and [DY2CKB].
Cause
Procedure, measuring location, criteria and remarks
1 Defective machine monitor
Machine monitor may be defective. (Since failure is in monitor, troubleshooting cannot be performed.)
40-400
PC228US-8,PC228USLC-8
Troubleshooting of electrical system (E-mode) E-25 Windshield wiper and window washer do not operate
Circuit diagram related to wiper
PC228US-8,PC228USLC-8
40-381
40-401
Troubleshooting of electrical system (E-mode) E-26 BOOM LOWER indicator is not displayed properly with monitoring function
E-26 BOOM LOWER indicator is not displayed properly with monitoring function Failure
Boom LOWER operation is not displayed properly with monitoring function. q
Related information
q q
Monitoring code: 01900 Pressure switch 1 Use "short connector": 799-601-7230 for 2-pin X connector in test for Cause 6. As pump controller connector uses "socket-type box" T-adapter, operating voltage cannot be measured at pump controller connector.
Cause
Defective boom lower PPC pres1 sure switch (open or short circuit in internal wiring)
2
Defective harness or pump controller
Open circuit in wiring harness 3 (Wire breakage or defective contact of connector)
4
Ground fault of harness (contact with ground circuit)
5
Hot short circuit in wiring harness (contact with 24 V circuit)
Procedure, measuring location, criteria and remarks 1. 2. 3. 4.
Turn starting switch to OFF position. Disconnect connector P02 and connect T-adapter to male side. Start engine Operate R.H. work equipment control lever and perform troubleshooting.
R.H. work equipment Resistance Min. 1 Mz control lever: NEUTRAL Between P02 (male) (1) R.H. work equipment and (2) control lever: Boom Resistance Max. 1 z LOWER 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector P02. 3. Start engine 4. Operate R.H. work equipment control lever and perform troubleshooting. R.H. work equipment Voltage Approx. 7 V control lever: NEUTRAL Between P02 (2) and (1) R.H. work equipment control lever: Boom Voltage Max. 1 V LOWER a If no failure is found in checks on cause 2, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors C01 and P02 and connect T-adapters to each female side. Between C01 (female) (14) and P02 (female) (1)
Resistance
Max. 1 z
Between P02 (female) (2) and ground (T10)
Resistance
Max. 1 z
a If no failure is found in checks on cause 2, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors C01 and P02 and connect T-adapter to female side of either of them. Between ground and C01 (female) (14) or P02 Resistance Min. 1 Mz (female) (1) a If no failure is found in checks on cause 2, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connector P02 and connect T-adapter to female side. 3. Turn starting switch to ON position. Between P02 (female) (1) and ground
6 Defective pump controller
1. 2. 3. 4.
Voltage
Approx. 7 V
Turn starting switch to OFF position. Disconnect connector P02 and connect T-adapter to female side. Connect "short connector" to male side of T-adapter. Turn starting switch to ON position.
If voltage between P02 (1) and (2) is below 1 V but "Boom LOWER" is displayed "OFF", pump controller is defective. a After finishing test, restore connector.
40-402
PC228US-8,PC228USLC-8
Troubleshooting of electrical system (E-mode) E-26 BOOM LOWER indicator is not displayed properly with monitoring function
Circuit diagram related to boom LOWER oil pressure switch
PC228US-8,PC228USLC-8
40-383
40-403
Troubleshooting of electrical system (E-mode) E-27 ARM OUT indicator is not displayed properly with monitoring function
E-27 ARM OUT indicator is not displayed properly with monitoring function Failure
Arm OUT operation is not displayed properly with monitoring function. q
Related information
q q
Monitoring code: 01900 Pressure switch 1 Use "short connector": 799-601-7230 for 2-pin X connector in test for Cause 6. As pump controller connector uses "socket-type box" T-adapter, operating voltage cannot be measured at pump controller connector.
Cause
Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position. 2. Disconnect connector P08 and connect T-adapter to male side. 3. Start engine Defective Arm OUT PPC oil pres- 4. Operate L.H. work equipment control lever and perform troubleshooting. 1 sure switch (internal open or short L.H. work equipment Resistance Min. 1 Mz circuit) Between P08 (male) (1) control lever: NEUTRAL and (2) L.H. work equipment Resistance Max. 1 z control lever: Arm OUT
2
Defective harness or pump controller
1. 2. 3. 4.
Turn starting switch to OFF position. Insert T-adapter into connector P08. Start engine. Operate L.H. work equipment control lever and perform troubleshooting.
Between P08 (2) and (1)
Open circuit in wiring harness 3 (Wire breakage or defective contact of connector)
4
Ground fault in wiring harness (contact with ground circuit)
5
Hot short circuit in wiring harness (contact with 24 V circuit)
L.H. work equipment control lever: NEUTRAL
Approx. 7 V
L.H. work equipment Voltage Max. 1 V control lever: Arm OUT a If no failure is found in checks on cause 2, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors C01 and P08 and connect T-adapters to each female side. Between C01 (female) (15) and P08 (female) (1)
Resistance
Max. 1 z
Between P08 (female) (1) and ground (T10)
Resistance
Max. 1 z
a If no failure is found in checks on cause 2, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors C01 and P08 and connect T-adapter to female side of either one. Between ground and C01 (female) (15) or P08 Resistance Min. 1 Mz (female) (1) a If no failure is found in checks on cause 2, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connector P08, and connect T-adapter to female side. 3. Turn starting switch to ON position. Between P08 (female) (1) and ground
6 Defective pump controller
Voltage
1. 2. 3. 4.
Voltage
Approx. 7 V
Turn starting switch to OFF position. Disconnect connector P08, and connect T-adapter to female side. Connect "short connector" to male side of T-adapter. Turn starting switch to ON position.
If voltage between P08 (1) and (2) is below 1 V but "OFF" is displayed for "Arm OUT", pump controller is defective.
40-404
PC228US-8,PC228USLC-8
Troubleshooting of electrical system (E-mode) E-27 ARM OUT indicator is not displayed properly with monitoring function
Circuit diagram related to arm OUT oil pressure switch
PC228US-8,PC228USLC-8
40-385
40-405
Troubleshooting of electrical system (E-mode) E-28 ARM IN indicator is not displayed properly with monitoring function
E-28 ARM IN indicator is not displayed properly with monitoring function Failure
Arm IN operation is not displayed properly with monitoring function.
Related information
q
Monitoring code: 01900 Pressure switch 1
Cause
Procedure, measuring location, criteria and remarks
Defective arm IN PPC oil pressure 1 sensor system (internal open cir- Perform troubleshooting for failure code [DHS3MA]. cuit or short circuit)
E-29 BOOM RAISE indicator is not displayed properly with monitoring function Failure
Boom RAISE operation is not displayed properly with monitoring function.
Related information
q
Monitoring code: 01900 Pressure switch 1
Cause
Procedure, measuring location, criteria and remarks
Defective boom RAISE PPC oil pressure sensor system 1 Perform troubleshooting for failure code [DHS8MA]. (internal open circuit or short circuit)
E-30 BUCKET CURL indicator is not displayed properly with monitoring function Failure
Bucket CURL operation is not displayed properly with monitoring function.
Related information
q
Monitoring code: 01901 Pressure switch 2
Cause 1
Defective bucket CURL PPC oil pressure sensor system
40-406
Procedure, measuring location, criteria and remarks Perform troubleshooting for failure code [DHS4MA].
PC228US-8,PC228USLC-8
Troubleshooting of electrical system (E-mode) E-31 BUCKET DUMP indicator is not displayed properly with monitoring function
E-31 BUCKET DUMP indicator is not displayed properly with monitoring function Failure
Bucket DUMP operation is not displayed properly with monitoring function.
Related information
q
Monitoring code: 01901 Pressure switch 2
Cause 1
Procedure, measuring location, criteria and remarks
Defective bucket DUMP PPC oil pressure sensor system
Perform troubleshooting for failure code [DHSDMA].
E-32 SWING indicator is not displayed properly with monitoring function Failure
Swing operation is not displayed properly with monitoring function.
Related information
q
Monitoring code: 01901 Pressure switch 2
Cause
Procedure, measuring location, criteria and remarks
Defective swing PPC oil pressure sensor system 1 Perform troubleshooting for failure codes [DHSAMA] and [DHSBMA]. (internal open circuit or short circuit)
E-33 TRAVEL indicator is not displayed properly with monitoring function Failure
Travel operation is not displayed properly with monitoring function.
Related information
q
Monitoring code: 01901 Pressure switch 2
Cause
Procedure, measuring location, criteria and remarks
Defective travel PPC oil pressure sensor system 1 (internal open circuit or short circuit)
Perform troubleshooting for failure codes [DHSFMA], [DHSGMA], [DHSHMA] and [DHSJMA].
PC228US-8,PC228USLC-8
40-407
Troubleshooting of electrical system (E-mode) E-34 ATTACHMENT indicator is not displayed properly with monitoring function
E-34 ATTACHMENT indicator is not displayed properly with monitoring function Failure
Attachment is not displayed properly with monitoring function. q
Monitoring code: 01901 Pressure switch 2 For safety, use "short connector" 799-601-7230 for 2-pin X connector in tests for Causes 1 Related information and 2. k Do not check oil pressure switch connector while engine is running. q
Cause
Procedure, measuring location, criteria and remarks
A. If monitoring function does not indicate that attachment control pedal is operated when engine is started and attachment control pedal is depressed at front end 1. Turn starting switch to OFF position. 2. Disconnect connector P14 and connect "short connector" to male side. 3. Turn starting switch to ON position. a After finishing test, restore connectors. If monitoring function indicates that "attachment control pedal" is "operated", Defective PPC oil pressure switch PPC oil pressure switch (P14) for front end of attachment control pedal is 1 (P14) for front end of attachment defective (Note 1). control pedal B. If monitoring function indicates that attachment control pedal is operated when starting switch is turned to ON position 1. Turn starting switch to OFF position. 2. Disconnect connector P14. 3. Turn starting switch to ON position. If monitoring function indicates that "attachment control pedal" is "released", PPC oil pressure switch (P14) for front end of attachment control pedal is defective (Note 2). A. If monitoring function does not indicate that attachment control pedal is operated when engine is started and attachment control pedal is depressed at rear end 1. Turn starting switch to OFF position. 2. Disconnect connector P15 and connect "short connector" to male side. 3. Turn starting switch to ON position. a After finishing test, restore connectors. If monitoring function indicates that "attachment control pedal" is "operated", Defective PPC oil pressure switch PPC oil pressure switch (P15) for rear end of attachment control pedal is defective (Note 1). 2 (P15) for rear end of attachment control pedal B. If monitoring function indicates that attachment control pedal is operated when starting switch is turned to ON position 1. Turn starting switch to OFF position. 2. Disconnect connector P15. 3. Turn starting switch to ON position. If monitoring function indicates that "attachment control pedal" is "released", PPC oil pressure switch (P15) for rear end of attachment control pedal is defective (Note 2). 1. Turn starting switch to OFF position. 2. Insert T-adapter into P13. 3. Start engine. Defective wiring harness or pump 4. Operate attachment control pedal, and perform troubleshooting. 3 attachment control pedal: controller Between P13 (1) and (2) Voltage Approx. 7 V Neutral attachment control pedal: Between P13 (1) and (2) Voltage Max. 1 V front end or rear end
40-408
PC228US-8,PC228USLC-8
Troubleshooting of electrical system (E-mode) E-34 ATTACHMENT indicator is not displayed properly with monitoring function
Cause
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connectors C01, P14, and P15, and connect T-adapters to their female sides.
Open circuit in wiring harness 4 (Wire breakage or defective contact of connector)
5
Ground fault in wiring harness (contact with ground circuit)
6 Short circuit in wiring harness
7 Defective pump controller
Between C01 (female) (52) and P14 (female) (1)
Resistance
Max. 1 z
Between C01 (female) (52) and P15 (female) (1)
Resistance
Max. 1 z
Between P14 (female) (2) and ground (T06)
Resistance
Max. 1 z
Between P15 (female) (2) and ground (T06)
Resistance
Max. 1 z
1. Turn starting switch to OFF position. 2. Disconnect connectors C01, P14, and P15, and connect T-adapter to female side of either one. Between ground and C01 (female) (52), P14 Resistance Min. 1 Mz (female) (1) or P15 (female) (1) 1. Turn starting switch to OFF position. 2. Disconnect connectors P14 and P15, and connect T-adapter to female side of either one. 3. Turn starting switch to ON position. Between P14 (female) (1) and ground, or between Voltage Approx. 7 V P15 (female) (1) and ground If no failure is found by above checks, pump controller is defective. (Since failure is in controller, troubleshooting cannot be performed.)
Note 1: If monitoring function indicates that "attachment control pedal" is "released" while voltage between C01 (52) and ground is below 1 V, pump controller is defective. Note 2: If monitoring function indicates that "attachment control pedal" is "operated" while voltage between C01 (52) and ground is approximately 7 V, pump controller is defective. Circuit diagram related to attachment control pedal PPC oil pressure switch (service pressure switch)40-389
PC228US-8,PC228USLC-8
40-409
Troubleshooting of electrical system (E-mode) E-35 Attachment hydraulic circuit cannot be changed
E-35 Attachment hydraulic circuit cannot be changed Failure Related information
q Attachment circuit is not changed 1) When working mode P or E is selected, crusher circuit (two-way circuit) is not selected. 2) When working mode B is selected, breaker circuit (one-way circuit) is not selected. q
Failures (open circuit/short circuit) of attachment oil return selector solenoid are troubleshoot for failure codes [DWA2KA] and [DWA2KB].
Cause Defective attachment oil return 1 selector solenoid (internal short circuit)
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector SSTC and connect T-adapter to male side. Between V06 (male) (1) and (2)
Resistance
20 – 60 z
Between V06 (male) (1) and ground
Resistance
Min. 1 Mz
1. Turn starting switch to OFF position. Hot short circuit in wiring harness 2. Disconnect connector V06 and connect T-adapter to female side. 2 3. Turn starting switch to ON position. (contact with 24 V circuit) Between V06 (female) (1) and ground Voltage Max. 1 V
Circuit diagram related to attachment oil return selector solenoid
40-410
40-390
PC228US-8,PC228USLC-8
Troubleshooting of electrical system (E-mode) E-36 KOMTRAX system does not operate properly
E-36 KOMTRAX system does not operate properly Failure Related information
q
KOMTRAX system does not operate properly.
q
Perform following troubleshooting if administrator of KOMTRAX system requests to check whether failure is occurring in system on machine. Even when KOMTRAX system is defective, no problem appears on machine. Check all of results of troubleshooting on service menu display of machine monitor.
q q
Cause
1 Defective communication 1
Procedure, measuring location, criteria and remarks 1. Turn starting switch to ON position. 2. Display “Terminal status” screen. Check item: To be completed Station set-up check 1. Turn starting switch to ON position. 2. Display “GPS & Communication Status” screen. N ###.##.## (Latitude)
2 Defective positioning by GPS
Check item: Positioning
E ###.##.## (Longitude) In positioning
3
Defective communication environment
4 Defective communication 2
If latitude and longitude are not displayed within 5 minutes with machine stayed outdoor which opens clearly for sky, contact KOMTRAX service hot line. 1. Turn starting switch to ON position. 2. Display “GPS & Communication Status” screen. Check item: Satellite in View or No Satellite in Communication View If Communication Status does never display “Satellite in View” within 15 minutes with machine stayed outdoor which opens clearly for sky, check if connector of TH300 or antenna on top of cab are properly connected. 1. Turn starting switch to ON position. 2. Display “GPS & Communication Status” screen. Check item: 0 to 60 (normally 0) Number of message not yet sent
a Select “Terminal Status” from “12 Display of KOMTRAX setting” in service menu of machine monitor.
PC228US-8,PC228USLC-8
a Select “GPS & Communication Status” from “12 Display of KOMTRAX setting” in service menu of machine monitor.
40-411
Troubleshooting of electrical system (E-mode) E-36 KOMTRAX system does not operate properly
40-412
PC228US-8,PC228USLC-8
Troubleshooting of hydraulic and mechanical system (H-mode) Information in troubleshooting table
Troubleshooting of hydraulic and mechanical system (H-mode) Information in troubleshooting table (Rev. 2010/03) a The following information is summarized in the troubleshooting table. Before carrying out troubleshooting, understand that information fully. Failure
Description of failure code
Related inforInformation related to the detected failure or troubleshooting mation Cause
Criteria and troubleshooting procedure
1
Probable causes and criteria
2 Probable causes for trou- <Contents of description> ble (Each number is serial q Standard value in normal condition to judge probable caus3 es number, not priority q Remarks on judgment sequence.) 4 5
PC228US-8,PC228USLC-8
40-413
Troubleshooting of hydraulic and mechanical system (H-mode) System chart for hydraulic and mechanical systems
System chart for hydraulic and mechanical systems
40-414
PC228US-8,PC228USLC-8
Troubleshooting of hydraulic and mechanical system (H-mode) System chart for hydraulic and mechanical systems
a This is a system chart that is drawn up by simplifying the whole hydraulic circuit chart. Use it as a reference material when troubleshooting the hydraulic and mechanical systems.
PC228US-8,PC228USLC-8
40-415
Troubleshooting of hydraulic and mechanical system (H-mode) Failure mode and cause table
Failure mode and cause table
Any of work equipment, swing and travel
Fine control performance or response is poor
QQQQQQQQ Q QQQQQQQ Q QQ QQQQ Q
Swing Swing and travel and boom
Work equipment
Speed or power of bucket is low Work equipment does not move in single operation Boom Arm Bucket
Q
Boom lock valve
Boom regeneration valve
Boom throttle EPC solenoid
Pump merge-divider LS valve
Pump merge-divider main valve
Pump merge-divider LS-EPC valve
Pump merge-divider main EPC valve
LS line throttle
Self-pressure reducing valve
Pressure compensation valve
Main relief valve
Unload valve
Q Q Q Q Q Q Q Q Q
Q Q Q
QQQQQQQ QQQQ Q
Q Q Q Q
Q
Q
In combined operations of swing and boom RAISE, boom rising speed is low
Travel speed drops largely in combined operation of swing and travel
Q
Travel speed is low. Travel
Q
Q
Machine does not travel straight
Swing
Speed or power of arm is low
Time lag of work equipment operation is large Other work equipment moves when one of work equipment is relieved One-touch power maximizing function does not work. In combined operation of work equipment, equipment having heavier load moves slower
Spool
Q
Speed or power of boom is low
Hydraulic drift of work equipment is large
Control valve
LS valve
LS-EPC valve
PC valve
PC-EPC valve
Pump swash plate sensor
Servo piston
Piston pump
Hydraulic pump
Strainer
Cap
Hydraulic oil
Failure mode All of work equipment, swing and travel work slow or lack power Engine speed lowers extremely or engine stalls Any of work equipment, swing and travel systems does not work. Unusual sound is heard from around hydraulic pump
Tank
Engine system Damper
Failed parts
Machine is hard to steer or travel power is low Travel speed does not change or travel speed is too low or high One of tracks does not run Upper structure swings neiUpper structure does not ther to the right nor left swing Upper structure does not swing in only one direction Poor or low for both of the Swing acceleration is poor right and left or swing speed is low Poor or low for only in one direction Largely for both of the right Upper structure overruns and left considerably when it stops Largely for only in one direcswinging tion
QQ Q Q
Q QQ Q
Q
Q
QQQQ
Q Q Q Q Q
Q
Q
Shock is larger when upper structure stops swinging Large sound is made when upper structure stops swinging
Attachment
Swing drift on a slope is large
When swing brake works When swing brake works
Q
Q
Attachment circuit is not changed Oil flow in attachment circuit cannot be changed
40-416
PC228US-8,PC228USLC-8
Q Q Q Q
Q Q Q Q
QQ Q QQ Q Q Q Q QQ Q
PC228US-8,PC228USLC-8 Q
Q
Q
Q Q
Q
Control valve
Q Q Q
Q
Q
Q
Q
Q
Q
Q
Q
Q
Q Q
Q
Q Q
Q Q
Q Q QQ
Q
Q
Q
Q Q
Q
Q Q
Q Q
Q Q
Q
Q
Q
Q QQ Q
Q Q Q
Q
Q Q Q Q
Q
Q
Q
Q QQ Q Q Q Q Q Q Q Q Q Q Q Q Q Q
Diagnosis codes
Final drive Hydraulic cylinder
Parking brake
Safety valve
Check valve
Swing electric motor
Counterbalance valve
Piston motor
Centre swivel joint
Swing machinery
Parking brake
Shockless valve
Suction valve
Check valve
Safety valve
Solenoid valve
Piston motor
ATT return selector solenoid
Swing parking brake solenoid
Travel speed selector solenoid
Travel interconnection solenoid
2-stage relief solenoid
Work equipment lock solenoid
Oil flow adjuster EPC valve for attachment
Swing PPC slow return valve
PPC valve (service)
PPC valve (travel lever)
PPC valve (left lever)
PPC valve (right lever)
Service valve (safety valve)
Back pressure valve
Travel inter-connection valve
Swing LS select valve
Arm lock valve
Arm quick return valve
Arm regeneration valve
LS shuttle valve
Suction valve
Safety valve
Troubleshooting of hydraulic and mechanical system (H-mode) Failure mode and cause table
Travel motor
H-1
H-2
H-3
H-4
H-5
H-6
H-7
H-8
H-9
H-10 H-11
H-12 H-13
H-14
H-15
H-16
H-17
H-18
H-19
H-20
H-21
Q Q
H-22
Q Q
H-23
Q Q
H-24
H-25
H-26
H-27
H-28
H-29
40-417
Troubleshooting of hydraulic and mechanical system (H-mode) H- 1 All of work equipment, swing and travel work slow or lack power
H- 1 All of work equipment, swing and travel work slow or lack power Failure Related information
q
Speed or power of all work equipment, swing, and travel is low.
q
Perform all troubleshooting with working mode in POWER (P) mode. For items other than swing, check whether speed becomes normal when swing lock switch is turned to ON position. If speed becomes normal, check swash plate sensor of No. 1 pump for malfunction. If speed does not become normal, perform troubleshooting No. 2 and after.
q
Cause
Criteria and troubleshooting procedure a Prepare with engine stopped, then troubleshoot with engine at full speed.
1
Malfunction of swash plate sensor of pump
Measurement conditions
Sensor output voltage
All levers in NEUTRAL
1.57 ± 0.63 V
Run one track idle off ground 3.75 ± 0.63 V Swing lock switch: ON a Prepare with engine stopped, then troubleshoot with engine at full speed. 2 Malfunction of unload valve
Control lever
Unload pressure
3.5 ± 1.0 MPa {6 ± 10 kg/cm2} a Prepare with engine stopped, then troubleshoot with engine at full speed. All levers in NEUTRAL
Defective adjustment or mal3 function of main relief valve
Probable causes and criteria
Left work equipment control lever
Main relief pressure
Arm IN to hydraulic relief
33.3 – 36.8 MPa {340 – 375 kg/cm2}
If normal oil pressure is not obtained by adjustment, main relief valve may malfunction or have internal defect. Check it directly. a Prepare with engine stopped, then troubleshoot with engine at full speed. 4
Malfunction of self-pressure reducing valve
Control lever
Control circuit source pressure
All levers in NEUTRAL
2.84 – 3.4 MPa {29 – 35 kg/cm2}
a Prepare with engine stopped, and then run engine at full speed and low speed to perform troubleshooting at each speed. Malfunction of PC-EPC 5 valve
Engine
Control lever
PC-EPC valve output pressure
2.9 MPa {30 kg/cm2} All levers in NEUTRAL 0.52 – 0.91 MPa At high idle {5.3 – 9.3 kg/cm2} a Prepare with engine stopped, then troubleshoot with engine at full speed. Measured oil pres- Measurement condiRatio of oil pressures sure tions Defective adjustment or mal- Pump delivery pres- Swing lock 1 6 sure switch: ON function of PC valve PC valve output pres- Arm IN to hydraulic Approx. 0.6 (Approx. sure 3/5) relief If normal oil pressure is not obtained after adjustment, PC valve may malfunction or internal defect. Check PC valve.
40-418
At low idle
PC228US-8,PC228USLC-8
Troubleshooting of hydraulic and mechanical system (H-mode) H- 1 All of work equipment, swing and travel work slow or lack power
Cause
Criteria and troubleshooting procedure a Prepare with engine stopped, then troubleshoot with engine at full speed. LS-EPC valve Travel speed setting Travel lever output pressure
7 Malfunction of LS-EPC valve
Approx. 2.9 MPa {30 kg/cm2} 0 MPa FORWARD or High REVERSE {0 kg/cm2} a Prepare with engine stopped, then troubleshoot with engine at full speed. Low
Probable causes and criteria
NEUTRAL
Operation of levers and oil pressure ratio Measured oil pressure 8
Defective adjustment or malfunction of LS valve
9 Malfunction of servo piston 10 Defective piston pump
PC228US-8,PC228USLC-8
All levers in NEUTRAL
Run track idle off ground (lever at half stroke)
Pump delivery pres1 Almost same pressure LS valve out put Approx. 0.6 (Approx. sure pressure 3/5) If normal oil pressure is not obtained by adjustment, the LS valve may malfunction or have internal defect. Check LS valve. Servo piston may malfunction. Check change in voltage from swash plate sensor by using monitoring function. Piston pump may have performance deterioration, malfunction or internal failure.
40-419
Troubleshooting of hydraulic and mechanical system (H-mode) H- 2 Engine speed lowers significantly or engine stalls
H- 2 Engine speed lowers significantly or engine stalls Failure Related information
q
Engine speed lowers significantly or engine stalls.
q
Perform all troubleshooting with working mode in POWER (P) mode. Check whether speed becomes normal when swing lock switch is turned to ON position. If speed becomes normal, check swash plate sensor of No. 1 pump for malfunction. If speed does not become normal, perform troubleshooting No. 2 and after.
q
Cause
1
Malfunction of swash plate sensor of pump
Defective adjustment or mal2 function of main relief valve
Criteria and troubleshooting procedure a Prepare with engine stopped, then troubleshoot with engine at full speed. Measurement conditions Sensor output voltage All levers in NEUTRAL 1.57 ± 0.63 V Run one track idle off ground 3.75 ± 0.63 V Swing lock switch: ON a Prepare with engine stopped, then troubleshoot with engine at full speed. Left work equipment control lever
Main relief pressure
Arm IN to hydraulic relief
33.3 – 36.8 MPa {340 – 375 kg/cm2}
If normal oil pressure is not obtained by adjustment, main relief valve may malfunction or have internal defect. Check main relief valve. a Prepare with engine stopped, and then run engine at full speed and low speed to perform troubleshooting at each speed. Malfunction of PC-EPC 3 valve
Probable causes and criteria
Engine
Control lever
PC-EPC valve Output pressure
2.9MPa {30 kg/cm2} All levers in NEUTRAL 0.52 – 0.91MPa At high idle {5.3 – 9.3 kg/cm2} a Prepare with engine stopped, then troubleshoot with engine at full speed. Measured oil pres- Measurement condiRatio of oil pressures sure tion Defective adjustment or mal- Pump delivery pres- Swing lock 1 4 sure switch: ON function of PC valve PC valve output pres- Arm IN to hydraulic Approx. 0.6 (Approx. sure 3/5) relief If normal oil pressure is not obtained after adjustment, PC valve may malfunction or have internal defect. Check PC valve. a Prepare with engine stopped, then troubleshoot with engine at full speed. At low idle
Operation of levers and oil pressure ratio Measured oil pressure 5
Run track idle off ground (lever at half stroke)
Defective adjustment or malfunction of LS valve Pump delivery pres1 Almost same pressure LS valve out put presApprox. 0.6 (Approx. sure sure 3/5) If normal oil pressure is not obtained by adjustment, the LS valve may malfunction or have internal defect. Check LS valve. Clogged orifice or filter in servomechanism
Orifice or filter in pump servomechanism may be clogged. Check them directly.
7 Malfunction of servo piston
Servo piston may malfunction. Check change in voltage from swash plate sensor by using monitoring function.
6
40-420
All levers in NEUTRAL
PC228US-8,PC228USLC-8
Troubleshooting of hydraulic and mechanical system (H-mode) H- 3 Any of work equipment, swing and travel does not work
H- 3 Any of work equipment, swing and travel does not work Failure
q
Any of work equipment, swing and travel systems does not work.
Related information
q
Perform all troubleshooting with working mode in POWER (P) mode. Cause
Criteria and troubleshooting procedure a Prepare with engine stopped, then troubleshoot with engine at full speed.
1
Malfunction of PPC lock solenoid valve
Work equipment lock lever
Solenoid output pressure
LOCK
0 MPa {0 kg/cm2}
2.9 MPa {30 kg/cm2} a Prepare with engine stopped, then troubleshoot with engine at full speed. FREE
Probable causes and criteria
2
Malfunction of self-pressure reducing valve
Control lever
Control circuit source pressure
2.84 – 3.43 MPa {29 – 35 kg/cm2} Piston pump may malfunction or have internal defect. Check it by following method. q Crank the engine with main oil pressure pickup port plug removed. If any oil flows out, piston pump is normal. Pump shaft may not rotate due to some internal failure of damper. Check the damper. All levers in NEUTRAL
3 Defective piston pump
4 Defective damper
H- 4 Unusual sound is heard from around hydraulic pump Failure
q
Unusual sound is heard from around hydraulic pump.
Related infor– mation Cause
Probable causes and criteria
Criteria and troubleshooting procedure
1 Lowered hydraulic oil level
Make a visual check.
2 Defective hydraulic oil
Air may mix in hydraulic oil. Check it directly.
3
Clogging of hydraulic tank cap
Breather in cap of the hydraulic tank may be clogged, causing negative pressure inside tank. Check cap directly.
4
Clogging of hydraulic tank strainer
Strainer in hydraulic tank may be clogged, causing negative pressure in suction circuit. Check strainer directly.
5 Defective piston pump
PC228US-8,PC228USLC-8
Piston pump may have internal defect. Check it.
40-421
Troubleshooting of hydraulic and mechanical system (H-mode) H- 5 Fine control performance or response is poor
H- 5 Fine control performance or response is poor Failure
q
Fine control performance or response is poor.
Related information
q
Perform all troubleshooting with working mode in POWER (P) mode. Cause
Criteria and troubleshooting procedure
a Prepare with engine stopped, then troubleshoot with engine at full speed. LS-EPC valve output Travel speed setting Travel lever pressure 1 Malfunction of LS-EPC valve Approx. 2.9 MPa Low NEUTRAL {Approx. 30 kg/cm2} FORWARD or High 0 MPa {0 kg/cm2} REVERSE 2 Clogging of LS circuit orifice Orifice in LS circuit may be clogged. Check orifice . a Prepare with engine stopped, then troubleshoot with engine at full speed.
Probable causes and criteria
Ratio of oil pressures Measured oil pressure 3
Defective adjustment or malfunction of LS valve
4 Malfunction of servo piston
40-422
All levers in NEUTRAL
Run track idle off ground (lever at half stroke)
Pump delivery pres1 Almost same pressure LS valve out put Approx. 0.6 (Approx. sure pressure 3/5) If normal oil pressure is not obtained by adjustment, the LS valve may malfunction or have internal defect. Check LS valve. Servo piston may malfunction. Check change in voltage from swash plate sensor by using monitoring function.
PC228US-8,PC228USLC-8
Troubleshooting of hydraulic and mechanical system (H-mode) H- 6 Boom operation lacks speed or power
H- 6 Boom operation lacks speed or power Failure
q
Speed or power of boom is low.
Related information
q
Perform all troubleshooting with working mode in POWER (P) mode . Cause
1
NEUTRAL
0 MPa {0 kg/cm2}
Boom RAISE Boom LOWER
2.84 – 3.43 MPa {29 – 35 kg/cm2}
2
Malfunction of merge-divider Merge-divider main EPC valve may malfunction. Check it directly. main EPC valve
3
Malfunction of merge-divider Merge-divider LS-EPC valve may malfunction. Check it directly. LS-EPC valve
4
Malfunction of merge-divider Merge-divider main valve may malfunction. Check it directly. main valve
5 6 7 Probable causes and criteria
Malfunction of right PPC valve (boom circuit)
Criteria and troubleshooting procedure a Prepare with engine stopped, then troubleshoot with engine at full speed. Right work equipment control PPC valve output pressure lever
8 9 10
Malfunction of merge-divider Merge-divider LS valve may malfunction. Check it directly. LS valve Defective operation of boom throttle EPC solenoid valve Boom throttle EPC solenoid may malfunction. Check it directly. (raise side only) Malfunction of boom control Spool of boom control valve may malfunction. Check it directly. valve (spool) Malfunction of boom control Pressure compensation valve of boom control valve may malfuncvalve (pressure compensation. Check it directly. tion valve) Malfunction of boom control Regeneration valve of boom control valve may malfunction or sealvalve (regeneration valve) ing may be defective. Check it directly. Malfunction of boom control Lock valve of boom control valve may malfunction. Check it valve (lock valve) directly.
Malfunction or defective 11 sealing of safety valve for lock valve
Safety valve for lock valve may malfunction or sealing may be defective. Check it directly.
Malfunction or defective 12 sealing of boom control valve (suction valve)
Suction valve (bottom side) of boom control valve may malfunction or sealing may be defective. Check it directly.
Malfunction or defective 13 sealing of boom control valve (suction-safety valve)
Suction-safety valve (head side) of boom control valve may malfunction or sealing may be defective. Check it directly.
Malfunction of LS shuttle LS shuttle valve of left travel , bucket or service valve may malfunc14 valve (left travel, bucket and tion.Check it directly. service valves) a Prepare with engine stopped, then troubleshoot with engine at full speed. 15 Defective boom cylinder Boom cylinder Leakage from cylinder Boom RAISE to hydraulic relief
PC228US-8,PC228USLC-8
20 cc/min
40-423
Troubleshooting of hydraulic and mechanical system (H-mode) H- 7 Arm operation lacks speed or power
H- 7 Arm operation lacks speed or power Failure
q
Speed or power of arm is low.
Related information
q
Perform all troubleshooting with working mode in POWER (P) mode . Cause
Criteria and troubleshooting procedure
a Prepare with engine stopped, then troubleshoot with engine at full speed. Left work equipment control PPC valve output pressure lever Malfunction of left PPC valve 1 0 MPa (arm circuit) NEUTRAL {0 kg/cm2} 2.84 – 3.43 MPa Arm IN Arm OUT {29 – 35 kg/cm2} 2
Malfunction of merge-divider Merge-divider main EPC valve may malfunction. Check it directly. main EPC valve
3
Malfunction of merge-divider Merge-divider LS-EPC valve may malfunction. Check it directly. LS-EPC valve
4
Malfunction of merge-divider Merge-divider main valve may malfunction. Check it directly. main valve
5
Malfunction of merge-divider Merge-divider LS valve may malfunction. Check it directly. LS valve
Malfunction of arm control valve (spool) Malfunction of arm control 7 valve (pressure compensation valve) 6
Probable causes and criteria
8
Malfunction of arm control valve (regeneration valve)
9
Malfunction of arm control valve (quick return valve)
Malfunction or defective 10 sealing of safety valve for lock valve
Spool of arm control valve may malfunction. Check it directly. Pressure compensation valve of boom control valve may malfunction. Check it directly. Regeneration valve of arm control valve may have malfunction. Check it directly. Quick return valve of arm control valve may malfunction. Check it directly. Safety valve for lock valve may malfunction or sealing may be defective. Check it directly.
Malfunction or defective Suction valve of arm control valve may malfunction. Check it 11 sealing of arm control valve directly. (suction valve) Malfunction or defective Suction-safety valve of arm control valve may malfunction or seal12 sealing of arm control valve ing may be defective. Check it directly. (suction-safety valve) Malfunction of each control 13 valve (LS shuttle valve)
14 Defective arm cylinder
LS shuttle valve of right travel , boom , left travel , bucket , or service valve may malfunction. Check them directly. a Prepare with engine stopped, then troubleshoot with engine at full speed . Left work equipment control Leakage from arm cylinder lever Arm IN to hydraulic relief
40-424
20 cc/min
PC228US-8,PC228USLC-8
Troubleshooting of hydraulic and mechanical system (H-mode) H- 8 Bucket operation lacks speed or power
H- 8 Bucket operation lacks speed or power Failure
q
Speed or power of bucket is low.
Related information
q
Perform all troubleshooting with working mode in POWER (P) mode.
1
Cause
Criteria and troubleshooting procedure
Malfunction of right PPC valve (bucket circuit)
a Prepare with engine stopped, then troubleshoot with engine at full speed. Right work equipment control PPC valve output pressure lever 0 MPa NEUTRAL {0 kg/cm2} 2.84 – 3.43 MPa Bucket CURL Bucket DUMP {29 – 35 kg/cm2}
Malfunction of bucket control Spool of bucket control valve may malfunction. Check it directly. valve (spool) Malfunction of bucket control Pressure compensation valve of bucket control valve may malfunc3 valve (pressure compensation. Check it directly. tion valve) Malfunction or defective Suction-safety valve of bucket control valve may malfunction or 4 sealing of bucket control sealing may be defective . Check it directly. valve (suction-safety valve) 2
Probable causes and criteria
5
Malfunction of LS shuttle valve (service valve)
6 Defective bucket cylinder
LS shuttle valve of service control valve may have malfunction. Check it directly.(If service valve is installed) a Prepare with engine stopped, then troubleshoot with engine at full speed. Right work equipment control Leakage from bucket cylinder lever Bucket CURL to hydraulic relief
20 cc/min
H- 9 Work equipment does not move in single operation Failure Related information
(1) Boom does not move when it is operated independently. (2) Arm does not move when it is operated independently. (3) Bucket does not move when it is operated independently. q
Perform all troubleshooting with working mode in POWER (P) mode . Cause
Criteria and troubleshooting procedure a Prepare with engine stopped, then troubleshoot with engine at full speed.
Probable causes and criteria
1 Malfunction of PPC valve
2
Malfunction of control valve (spool)
PC228US-8,PC228USLC-8
Work equipment control lever
PPC valve output pressure
NEUTRAL
0 MPa {0 kg/cm2}
Operation
2.84 – 3.43 MPa {29 – 35 kg/cm2}
Spool of control valve may malfunction. Check it directly.
40-425
Troubleshooting of hydraulic and mechanical system (H-mode) H-10 Hydraulic drift of work equipment is large
H-10 Hydraulic drift of work equipment is large Failure Related information
(1) Hydraulic drift of boom is large. q
Perform all troubleshooting with working mode in POWER (P) mode . Cause
Probable causes and criteria
Failure Related information
1 Defective boom cylinder
Criteria and troubleshooting procedure a Prepare with engine stopped, then troubleshoot with engine at full speed. Right work equipment control Leakage from boom cylinder lever Boom RAISE to hydraulic relief
2
Defective sealing for boom control valve (lock valve)
Sealing for lock valve in boom control valve may be defective. Check it directly.
3
Defective sealing for safety valve for lock valve
Sealing for safety valve for lock valve may be defective. Check it directly.
(2) Hydraulic drift of arm is large. q
Perform all troubleshooting with working mode in POWER (P) mode . Cause
1 Defective arm cylinder
Criteria and troubleshooting procedure a Prepare with engine stopped, then troubleshoot with engine at full speed. Left work equipment control Leakage from arm cylinder lever Arm IN to hydraulic relief
Probable causes and criteria
40-426
20 cc/min
20 cc/min
Sealing for suction-safety valve (bottom side) in arm control valve Defective sealing for arm may be defective. Check it directly. 2 control valve (suction-safety * This defect can be judged by replacing it with another valve) suction-safety valve and watching how condition changes. Defective sealing for arm Sealing for spool of arm control valve may be defective .Check it 3 control valve (spool) directly. Defective sealing for arm Sealing for pressure compensation valve (bottom side) in arm con4 control valve (pressure comtrol valve may be defective. Check it directly. pensation valve)
PC228US-8,PC228USLC-8
Troubleshooting of hydraulic and mechanical system (H-mode) H-10 Hydraulic drift of work equipment is large
Failure Related information
(3) Hydraulic drift of bucket is large. q
Perform all troubleshooting with working mode in POWER (P) mode . Cause
1 Defective bucket cylinder
Criteria and troubleshooting procedure a Prepare with engine stopped, then troubleshoot with engine at full speed. Right work equipment control Leakage amount from bucket lever cylinder Bucket CURL to hydraulic relief
Probable causes and criteria
20 cc/min
Sealing for suction-safety ( bottom side) in bucket control valve Defective sealing for bucket may be defective. Check it directly. 2 control valve (suction-safety * This defect can be judged by replacing it with another valve) suction-safety valve and watching how condition changes. Defective sealing for bucket Sealing for spool of bucket control valve may be defective. Check it 3 control valve (spool) directly. Defective sealing for bucket Sealing for pressure compensation valve (bottom side) in bucket 4 control valve (pressure comcontrol valve may be defective. Check it directly. pensation valve)
PC228US-8,PC228USLC-8
40-427
Troubleshooting of hydraulic and mechanical system (H-mode) H-11 Time lag of work equipment is large
H-11 Time lag of work equipment is large Failure
q
Time lag of work equipment is large.
Related information
q
Perform all troubleshooting with working mode in POWER (P) mode. Cause
Criteria and troubleshooting procedure
a Prepare with engine stopped, then troubleshoot with engine at full speed. LS-EPC valve output Travel speed setting Travel lever pressure 1 Malfunction of LS-EPC valve Approx. 2.9 MPa Low NEUTRAL {Approx. 30 kg/cm2} Probable causes and criteria
High
Operation
0 MPa {0 kg/cm2}
Malfunctioning of control 2 valve (regeneration valve) [only boom and arm]
Regeneration valve in control valve may malfunction. Check it directly.
Malfunction of control valve 3 (suction-safety valve)
Suction-safety valve in control valve (boom: head side, arm and bucket: bottom side) may malfunction. Check it directly. * This defect can be judged by replacing it with another suction-safety valve and watching how condition changes.
Malfunction of control valve 4 (pressure compensation valve)
Pressure compensation valve of control valve may malfunction. Check it directly.
H-12 Other work equipment moves when one of work equipment is relieved Failure
q
When performing hydraulic relief of a work equipment, other work equipment move.
Related information Probable causes and criteria
40-428
Cause
Criteria and troubleshooting procedure
Defective sealing for control Sealing for pressure compression valve in control valve may be 1 valve (pressure compensadefective. Check it directly. tion valve)
PC228US-8,PC228USLC-8
Troubleshooting of hydraulic and mechanical system (H-mode) H-13 One-touch power maximizing function does not work
H-13 One-touch power maximizing function does not work Failure
q
Power maximizing function does not work.
Related information
q
Perform all troubleshooting with working mode in POWER (P) mode . Cause
Criteria and troubleshooting procedure a Prepare with engine stopped, then troubleshoot with engine at full speed.
Probable causes and criteria
1
2
Malfunction of 2-stage relief solenoid valve
Malfunction of main relief valve
Swing lock switch
Solenoid output pressure
OFF
0 MPa {0 kg/cm2}
ON
2.9 MPa {30 kg/cm2}
Main relief valve of control valve may malfunction. Check it directly.
H-14 In combined operation of work equipment , equipment having heavier load moves slower. Failure
q
Work equipment on large load side moves slower during combined operation
Related information Cause
Criteria and troubleshooting procedure Pressure compensation valve for work equipment on low load side may malfunction. Check the valve directly.
Probable causes and criteria
Malfunction of control valve 1 (pressure compensation valve) on low load side
PC228US-8,PC228USLC-8
Combined operation
Large load side
Low load side
Boom RAISE + Arm IN
Boom RAISE
Arm IN
Boom RAISE + Arm OUT
Arm OUT
Boom RAISE
Boom RAISE + Bucket CURL
Boom RAISE
Bucket CURL
Arm OUT + Bucket CURL
Arm OUT
Bucket CURL
Boom LOWER + Arm OUT
Arm OUT
Boom LOWER
40-429
Troubleshooting of hydraulic and mechanical system (H-mode) H-15 In combined operation of swing and boom RAISE, boom rising speed is low
H-15 In combined operation of swing and boom RAISE, boom rising speed is low Failure
q
When performing combined operation of swing and boom RAISE , boom RAISE speed is slow.
Related information
q
If boom RAISE speed is also low when it is operated singly, perform troubleshooting for "H- 6 Boom operation lacks speed or power".
Probable causes and criteria
Cause Malfunction or defective 1 sealing of swing control valve (LS select valve)
Criteria and troubleshooting procedure LS select valve of swing control valve may malfunction or sealing may be defective. Check it directly.
H-16 Travel speed drops largely in combined operation of swing and travel Failure
q
When performing combined operation of swing and travel , travel speed lowers significantly.
Related information
q
If travel speed is also low when machine is operated only to travel, perform troubleshooting for "H-18 Travel speed is low" first.
Probable causes and criteria
40-430
1
Cause
Criteria and troubleshooting procedure
Malfunction of each control valve (LS shuttle valve)
LS shuttle valve of left travel control valve or swing control valve may malfunction. Check it directly.
PC228US-8,PC228USLC-8
Troubleshooting of hydraulic and mechanical system (H-mode) H-17 Machine does not travel straight
H-17 Machine does not travel straight Failure
q
Machine deviates during travel
Related information
q
Perform all troubleshooting with working mode in POWER (P) mode . Cause
Criteria and troubleshooting procedure a Prepare with engine stopped, then troubleshoot with engine at full speed.
1
2
Malfunction of travel PPC valve
Malfunction of self-pressure reducing valve
Travel lever
PPC valve output pressure
2.84 – 3.43 MPa FORWARD REVERSE {29 – 35 kg/cm2} a Prepare with engine stopped, then troubleshoot with engine at full speed . Control lever
Control circuit source pressure
2.84 – 3.43 MPa {29 – 35 kg/cm2} a Prepare with engine stopped, then troubleshoot with engine at full speed. All levers in NEUTRAL
Ratio of oil pressures Measured oil pressure 3
Defective adjustment or malfunction of LS valve
4
Malfunction of travel junction solenoid valve
Probable causes and criteria
All levers in NEUTRAL
Run track idle off ground (lever at half stroke)
Pump delivery pres1 Almost same pressure LS valve out put Approx. 0.6 (Approx. sure pressure 3/5) If normal oil pressure is not obtained by adjustment, LS valve may malfunction or may have internal defect. Check it directly a Prepare with engine stopped, then troubleshoot with engine at full speed. Travel lever
Solenoid output pressure
NEUTRAL
0 MPa {0 kg/cm2}
When either lever is operated
2.9 MPa {30 kg/cm2}
Malfunction of travel juncTravel junction valve may malfunction. Check it directly. tion valve Malfunction of travel control 6 Spool of travel control valve may malfunction. Check it directly. valve (spool) Interchange connection ports of right and left hoes connecting 7 Defective centre swivel joint swivel joint and travel motors and check if deviation direction changes. a Prepare with engine stopped, then troubleshoot with engine at full speed. 8 Defective travel motor Travel lever Leakage from travel motor 5
F or R to hydraulic relief 9 Defective final drive
PC228US-8,PC228USLC-8
27.2 l/min
Final drive may have internal failure. Check it directly. * (This defect can be judged by unusual sound, unusual heat, metal chips in drained oil, etc.)
40-431
Troubleshooting of hydraulic and mechanical system (H-mode) H-18 Travel speed is low
H-18 Travel speed is low Failure
q
Travel speed is low.
Related information
q
Perform all troubleshooting with working mode in POWER (P) mode . Cause
Criteria and troubleshooting procedure a Prepare with engine stopped, then troubleshoot with engine at full speed. Travel lever
Malfunction of travel PPC 1 valve
2
Malfunction of self-reducing pressure valve
PPC valve output pressure
0 MPa {0 kg/cm2} 2.84 – 3.43 MPa FORWARD REVERSE {29 – 35 kg/cm2} a Prepare with engine stopped, then troubleshoot with engine at full speed. NEUTRAL
Control lever
Control circuit source pressure
2.84 – 3.43 MPa {29 – 35 kg/cm2} a Prepare with engine stopped, then troubleshoot with engine at full speed. LS-EPC valve Travel speed setting Travel lever output pressure All levers in NEUTRAL
Probable causes and criteria
3 Malfunction of LS-EPC valve
Malfunction of travel control valve (spool) Malfunction of travel control 5 valve (pressure compensation valve) Malfunction of travel control 6 valve (suction valve) 4
7
Malfunction of LS shuttle valve (bucket)
8 Defective travel motor
9 Defective final drive
40-432
Low
NEUTRAL
Approx. 2.9 MPa {Approx. 30 kg/cm2}
High
FORWARD or REVERSE
0 MPa {0 kg/cm2}
Spool of travel control valve may malfunction. Check it directly. Pressure compensation valve of travel control valve may malfunction. Check it directly. Suction valve of travel control valve may malfunction. Check it directly. LS shuttle valve of bucket control valve may malfunction. Check it directly. a Prepare with engine stopped, then troubleshoot with engine at full speed. Travel lever
Leakage from travel motor
F or R to hydraulic relief
27.2 l/min
Final drive may have internal failure. Check it directly. * (This defect can be judged by unusual sound, unusual heat, metal chips in drained oil, etc.)
PC228US-8,PC228USLC-8
Troubleshooting of hydraulic and mechanical system (H-mode) H-19 Machine is hard to steer or travel power is low
H-19 Machine is hard to steer or travel power is low Failure
q
Machine is not steered well or steering power is low
Related information
q
Perform all troubleshooting with working mode in POWER (P) mode. Cause
Criteria and troubleshooting procedure a Prepare with engine stopped, then troubleshoot with engine at full speed.
1
Malfunction of travel PPC valve
Travel lever
PPC valve output pressure
Both levers in NEUTRAL
0 MPa {0 kg/cm2}
2.84 – 3.43 MPa {29 – 35 kg/cm2} a Prepare with engine stopped, then troubleshoot with engine at full speed. When either lever is operated
2
Malfunction of travel junction solenoid valve
Travel lever
Solenoid valve output pressure
NEUTRAL
0 MPa {0 kg/cm2}
2.9 MPa {30 kg/cm2} Travel junction valve of control valve may malfunction. Check it directly. When either lever is operated
Malfunction of travel junction valve Malfunction of merge-divider 4 Merge-divider main EPC valve may malfunction. Check it directly. main EPC valve 3
5
Malfunction of merge-divider Merge-divider LS-EPC valve may malfunction. Check it directly. LS-EPC valve
Malfunction of merge-divider Merge-divider main valve may malfunction. Check it directly. main valve Probable Malfunction of merge-divider Merge-divider LS valve may malfunction. Check it directly. causes and cri- 7 LS valve teria Malfunction of travel control 8 Spool of travel control valve may malfunction. Check it directly. valve (spool) Malfunction of travel control Pressure compensation valve of travel control valve may malfunc9 valve (pressure compensation. Check it directly. tion valve) Malfunction of travel control Suction valve of travel control valve may malfunction. Check it 10 valve (suction valve) directly. 6
Malfunction of LS shuttle valve (bucket) Defective sealing for check 12 valve at LS oil pressure pickup port 11
LS shuttle valve of bucket control valve may malfunction. Check it directly. Sealing for check valve at LS oil pressure pickup port may be defective. Check it directly.
Interchange connection ports of right and left hoses connecting 13 Defective centre swivel joint swivel joint and travel motors and check if turning direction changes. Sealing for safety valve of travel motor may be defective. Check it directly. Malfunctioning of travel * This failure can be checked by interchanging valves from for14 motor (safety valve) ward and reverse circuits of motor or those from right and left motors and watching how condition changes. Sealing for check valve of travel motor may be defective. Check it directly. Malfunctioning of travel 15 * This failure can be checked by interchanging valves from formotor (check valve) ward and reverse circuits of motor or those from right and left motors and watching how condition changes.
PC228US-8,PC228USLC-8
40-433
Troubleshooting of hydraulic and mechanical system (H-mode) H-20 Travel speed does not change, or travel speed is too low or high
H-20 Travel speed does not change, or travel speed is too low or high Failure
q
Travel speed does not switch or travel speed is too low or high.
Related information
q
Perform all troubleshooting with working mode in POWER (P) mode . Cause
Criteria and troubleshooting procedure a Prepare with engine stopped, then troubleshoot with engine at full speed . Travel speed Travel lever Monitoring code: 01500 setting Low Medium
1 Malfunction of LS-EPC valve
Probable causes and criteria
2
Malfunction of travel speed solenoid valve
617 mA (See *) FORWARD or REVERSE
High
679 mA 0 mA
a Prepare with engine stopped, then troubleshoot with engine at full speed. Travel speed Travel lever LS-EPC valve output pressure setting Approx. 2.9 MPa Low NEUTRAL {Approx. 30 kg/cm2} FORWARD or High 0 MPa {0 kg/cm2} REVERSE a Prepare with engine stopped, then troubleshoot with engine at full speed. Travel speed Travel lever Solenoid valve output pressure setting Low
NEUTRAL
0 MPa {0 kg/cm2}
High
FORWARD or REVERSE
Approx. 2.9 MPa {Approx. 30 kg/cm2}
Malfunction of travel motor Speed-select unit of travel motor may malfunction. Check it (speed-select unit) directly. * : Travel speed: Speed of Low can be adjusted with adjustment function of machine monitor. Therefore, if it has been changed from initial set value, indicated value changes more or less. 3
40-434
PC228US-8,PC228USLC-8
Troubleshooting of hydraulic and mechanical system (H-mode) H-21 One of tracks does not run
H-21 One of tracks does not run Failure
q
Track does not move (only track on one side)
Related information
q
Perform all troubleshooting with working mode in POWER (P) mode . Cause
1
2
Probable causes and criteria
3
4
5
Criteria and troubleshooting procedure
Defective sealing for travel Sealing for suction valve of travel motor may be defective. Check it control valve (suction valve) directly. Sealing for safety valve of travel motor may be defective. Check it directly. Defective sealing for travel * This failure can be checked by interchanging safety valves from motor (safety valve) forward and reverse circuits of motor or those from right and left motors and watching how condition changes. Sealing for check valve of travel motor may be defective. Check it directly. Defective sealing for travel * This failure can be checked by interchanging check valves from motor (check valve) forward and reverse circuits of motor or those from right and left motors and watching how condition changes. Malfunction of travel motor Parking brake of travel motor may malfunction. Check it directly. (parking brake) a Prepare with engine stopped, then troubleshoot with engine at full speed. Defective travel motor Travel lever Leakage from travel motor F or R to hydraulic relief
6 Defective final drive
PC228US-8,PC228USLC-8
27.2 l/min
Final drive may have internal failure. Check it directly. * (This defect can be judged by unusual sound, unusual heat, metal chips in drained oil, etc.)
40-435
Troubleshooting of hydraulic and mechanical system (H-mode) H-22 Upper structure does not swing
H-22 Upper structure does not swing Failure Related information
(1) Upper structure swings neither to right nor left q
Perform all troubleshooting with working mode in POWER (P) mode . Cause
1
Malfunction of swing brake solenoid valve
Criteria and troubleshooting procedure a Prepare with engine stopped, then troubleshoot with engine at full speed. Left work equipment control Output pressure of swing brake lever solenoid valve NEUTRAL Left swing Right swing
Probable causes and criteria
40-436
0 MPa {0 kg/cm2} 2.9 MPa {30 kg/cm2}
2
Malfunction of swing control Spool of swing control valve may malfunction. Check it directly. valve (spool)
3
Malfunction of swing motor (swing brake)
Swing brake of swing motor may malfunction. check it directly.
a Prepare with engine stopped, then troubleshoot with engine at full speed. Swing lock Left work equipment Swing switch control lever Improper adjustment or mal4 function of swing motor 28.9 – 3 2.9 MPa Swing to hydraulic ON (safety valve) relief {295 – 335 kg/cm2} If normal oil pressure is not obtained by adjustment, swing motor safety valve may malfunction or may internal defect. Check it directly. a Prepare with engine stopped, then troubleshoot with engine at full speed. Swing lock Left work equipment Leakage from swing 5 Defective swing motor switch control lever motor Swing to hydraulic ON Below 10 l/min relief Swing machinery may internal failure. Check it directly. 6 Defective swing machinery * (This defect can be judged by unusual sound, unusual heat, metal chips in drained oil, etc.)
PC228US-8,PC228USLC-8
Troubleshooting of hydraulic and mechanical system (H-mode) H-22 Upper structure does not swing
Failure Related information
Probable causes and criteria
(2) Upper structure does not swing in only one direction. q
Perform all troubleshooting with working mode in POWER (P) mode . Cause
Criteria and troubleshooting procedure
1
Malfunction of swing PPC valve
a Prepare with engine stopped, then troubleshoot with engine at full speed. Left work equipment control PPC valve output pressure lever 0 MPa NEUTRAL {0 kg/cm2} 2.84 – 3.43 MPa Left swing Right swing {29 – 35 kg/cm2}
2
Malfunction of swing control Spool of swing control valve may malfunction. Check it directly. valve (spool)
Malfunction of swing motor 3 (suction valve)
Suction valve of swing motor may malfunction. Check it directly. * This failure can be checked by interchanging right and left suction valves of swing motor and watching how condition changes.
Malfunction of swing motor 4 (check valve)
Check valve of swing motor may malfunction. Check it directly. * This failure can be checked by interchanging right and left check valves of swing motor and watching how condition changes.
PC228US-8,PC228USLC-8
40-437
Troubleshooting of hydraulic and mechanical system (H-mode) H-23 Swing acceleration is poor or swing speed is low
H-23 Swing acceleration is poor or swing speed is low Failure Related information
(1) Swing acceleration is poor or swing speed is slow in both right and left directions. q
Perform all troubleshooting with working mode in POWER (P) mode . Cause
Probable causes and criteria
40-438
Criteria and troubleshooting procedure
1
Malfunction of swing control Spool of swing control valve may malfunction. Check it directly. valve (spool)
2
Malfunction of all control valves (LS shuttle valves)
LS shuttle valves for all control valves may malfunction. Check them directly.
3
Malfunction of swing motor (swing brake)
Swing brake of swing motor may malfunction, check it directly.
a Prepare with engine stopped, then troubleshoot with engine at full speed. Swing lock Left work equipment Swing relief pressure switch control lever Improper adjustment or mal4 function of swing motor 28.9 – 32.9 MPa Swing to hydraulic ON (safety valve) relief {295 – 335 kg/cm2} If normal oil pressure is not obtained by adjustment, swing motor safety valve may malfunction or may internal defect. Check it directly. a Prepare with engine stopped, then troubleshoot with engine at full speed. Swing lock Left work equipment Leakage from swing 5 Defective swing motor switch control lever motor Swing to hydraulic ON Below 10 l/min relief Swing machinery may be defective. check it directly. 6 Defective swing machinery * (This failure can be checked by unusual sound, unusual heat, metal chips in drained oil, etc.)
PC228US-8,PC228USLC-8
Troubleshooting of hydraulic and mechanical system (H-mode) H-23 Swing acceleration is poor or swing speed is low
Failure Related information
(2) Swing acceleration performance is poor or swing speed is slow in only one direction. q
1
Possible causes and standard value for judgment
Perform all troubleshooting with working mode in POWER (P) mode. Cause
Standard value in normal condition/Remarks on troubleshooting
Malfunction of swing PPC valve
a Prepare with engine stopped, then troubleshoot with engine at full speed. Left work equipment control PPC valve output pressure lever 0 MPa NEUTRAL {0 kg/cm2} 2.84 – 3.43 MPa Left swing Right swing {29 – 35 kg/cm2}
Malfunction of swing control Spool of swing control valve may malfunction. Check it directly. valve (spool) Malfunction of swing control Pressure compensation valve of swing control valve may malfunc3 valve (pressure compensation. Check it directly. tion valve) Suction valve of swing motor may malfunction. Check it directly. Malfunction of swing motor * This failure can be checked by interchanging right and left suc4 (suction valve) tion valves of swing motor and watching how condition changes. 2
Malfunction of swing motor 5 (check valve)
PC228US-8,PC228USLC-8
Check valve of swing motor may malfunction. Check it directly. * This failure can be checked by interchanging right and left suction valves of swing motor and watching how condition changes.
40-439
Troubleshooting (S-mode) Troubleshooting of of engine hydraulic and mechanical system (H-mode) H-24 Oil Upper overruns when itlevel stops swinging S-11 is instructure coolant (or coolantexcessively spurts or coolant goes down)
H-24 Upper structure overruns excessively when it stops swinging Failure Related information
(1) Upper structure overruns excessively when it stops swinging in both right and left directions. q
Perform all troubleshooting with working mode in POWER (P) mode. Cause
Probable causes and criteria
Failure Related information
(2) Upper structure overruns excessively when it stops swinging in only one direction. q
Perform all troubleshooting with working mode in POWER (P) mode. Cause
Probable causes and criteria
40-440
Criteria and troubleshooting procedure
a Prepare with engine stopped, then troubleshoot with engine at full speed. Swing lock Left work equipment Swing switch control lever Improper adjustment or mal1 functioning of swing motor 28.9 – 32.9 MPa Swing to hydraulic ON (safety valve) relief {295 – 335 kg/cm2} If normal oil pressure is not obtained by adjustment, swing motor safety valve may malfunction or may have internal defect. Check it directly. a Prepare with engine stopped, then troubleshoot with engine at full speed. Swing lock Left work equipment Leakage from swing 2 Defective swing motor switch control lever motor Swing to hydraulic ON Below 10 l/min relief
Criteria and troubleshooting procedure a Prepare with engine stopped, then troubleshoot with engine at full speed. Left work equipment control PPC valve output pressure lever 0 MPa NEUTRAL {0 kg/cm2} 2.84 – 3.43 MPa Left swing Right swing {29 – 35 kg/cm2} Swing PPC slow return valve may malfunction. Check it directly. * This failure can be checked by interchanging right and left swing PPC slow return valves and watching how condition changes.
1
Malfunction of swing PPC valve
2
Clogged swing PPC slow return valve
3
Malfunction of swing control Spool of swing control valve may malfunction. Check it directly. valve (spool)
Malfunction of swing motor 4 (suction valve)
Suction valve of swing motor may malfunction. Check it directly. * This failure can be checked by interchanging right and left suction valves of swing motor and watching how condition changes.
Malfunction of swing motor 5 (check valve)
Check valve of swing motor malfunction. Check it directly. * This failure can be checked by interchanging right and left check valves of swing motor and watching how condition changes.
PC228US-8,PC228USLC-8
Troubleshooting of hydraulic and mechanical system (H-mode) H-25 Shock is large when upper structure stops swinging
H-25 Shock is large when upper structure stops swinging Failure
q
Large shock is made when upper structure stops swinging.
Related information
q
Perform all troubleshooting with working mode in POWER (P) mode . Cause
1
Malfunction of swing PPC valve
Probable causes and criteria Clogged swing PPC slow 2 return valve
3
Malfunction of swing motor (shockless valve)
Criteria and troubleshooting procedure a Prepare with engine stopped, then troubleshoot with engine at full speed. Left work equipment control PPC valve output pressure lever NEUTRAL
0 MPa {0 kg/cm2}
Right swing Left swing
2.84 – 3.43 MPa {29 – 35 kg/cm2}
Swing PPC slow return valve may malfunction. Check it directly. * This failure can be checked by interchanging right and left swing PPC slow return valves and watching how condition changes. Shockless valve of swing motor may malfunction. Check it directly.
H-26 Large unusual noise is heard when upper structure stops swinging Failure
q
Large sound is made when upper structure stops swinging
Related information
q
Perform all troubleshooting with working mode in POWER (P) mode . Cause
Criteria and troubleshooting procedure
Malfunctioning of back pres- Back pressure valve of control valve may malfunction. Check it sure valve directly. Malfunction of swing motor 2 Safety valve of swing motor may malfunction. Check it directly. (safety valve) Suction valve of swing motor may malfunction. Check it directly. Malfunction of swing motor * This failure can be checked by interchanging right and left 3 (suction valve) swing motor suction valves and watching how condition changes. Swing machinery may be defective .Check it directly. 4 Defective swing machinery * (This failure can be checked by unusual sound, unusual heat, metal chips in drained oil, etc.) 1
Probable causes and criteria
PC228US-8,PC228USLC-8
40-441
Troubleshooting of hydraulic and mechanical system (H-mode) H-27 Swing drift on a slope is large
H-27 Swing drift on a slope is large Failure Related information
q
Swing drift on a slope is excessive. (While swing brake is applied)
q
When swing lock switch is in ON position, or swing brake release switch is in normal position, swing brake is applied and disc brake holds upper structure. Perform all troubleshooting with working mode in POWER (P) mode .
q
Cause
Probable causes and criteria
1
2
Failure Related information
q q q
Malfunction of swing brake solenoid valve
Malfunction of swing motor (swing brake part)
40-442
NEUTRAL
0 MPa {0 kg/cm2}
Right swing Left swing
2.9 MPa {30 kg/cm2}
Swing brake of swing motor may malfunction or may have internal defect. Check it directly.
Swing drift on a slope is excessive. (While swing brake is released) When swing brake release switch is in emergency position, swing brake is released and upper structure is held with only hydraulic pressure. Perform all troubleshooting with working mode in POWER (P) mode . Cause
Criteria and troubleshooting procedure
Malfunction of swing control valve (spool) Malfunction of swing control 2 valve (pressure compensation valve) Defective swing motor 3 (safety valve)
Sealing for spool of swing control valve may be defective . Check it directly.
1
Probable causes and criteria
Criteria and troubleshooting procedure a Prepare with engine stopped, then troubleshoot with engine at full speed. Left work equipment control Solenoid valve output pressure lever
Sealing for pressure compensation valve of swing control valve may be defective . Check it directly. Sealing for safety valve of swing motor may be defective .Check the valve directly.
4
Defective swing motor (suc- Sealing for suction valve of swing motor may be defective. Check tion valve) it directly.
5
Defective swing motor (check valve)
Sealing for check valve of swing motor may be defective . Check it directly.
6
Defective sealing for swing motor (shockless valve)
Sealing for shockless valve of swing motor may be defective. Check it directly.
PC228US-8,PC228USLC-8
Troubleshooting of hydraulic and mechanical system (H-mode) H-28 Attachment circuit cannot be changed
H-28 Attachment circuit cannot be changed For machines with provision for attachment Failure
q
Attachment circuit is not switched to desired one.
q
For machines with provision for attachment, service circuit changes as shown below according to selected working mode. 1) ATT mode: Double-acting circuit (2-WAY) is selected and safety valve is set to low-pressure setting. 2)B mode : Single acting (1-WAY) circuit is selected and safety valve is set to high-pressure setting. q Setting of safety valve is changed on only port B side. Setting on port A side is kept to low-pressure setting.
Related information
Cause
Probable causes and criteria
40-423
1
Malfunction of ATT return selector solenoid valve
Criteria and troubleshooting procedure a Prepare with engine stopped, then troubleshoot with engine at full speed. ATT return selector solenoid Working mode valve output pressure ATT mode
0 MPa {0 kg/cm2}
B mode
2.9 MPa {30 kg/cm2}
2
Malfunction of ATT return selector valve
3
Malfunction of service valve Safety valve (port B side) of service valve may malfunction. Check (safety valve) it directly.
ATT return selector valve may malfunction. Check it directly.
H-29 Oil flow in attachment circuit cannot be controlled For machines with provision for attachment Failure Related information
q
Flow rate of attachment circuit cannot be adjusted
q
For machines with provision for attachment, flow rate of service circuit changes according to setting selected in user mode. How to adjust flow rate in ATT mode is different from that in B mode. For details, see Operation and Maintenance Manual.
q
Cause Probable causes and criteria
40-423
Malfunction of attachment 1 flow rate adjustment EPC valve Malfunction of service PPC 2 valve
PC228US-8,PC228USLC-8
Criteria and troubleshooting procedure Attachment flow rate adjustment EPC valve may malfunction. Check it directly. Service PPC valve may malfunction. Check it directly.
40-443
Troubleshooting of engine (S-mode) Method of using troubleshooting chart
Troubleshooting of engine (S-mode) Method of using troubleshooting chart The troubleshooting chart consists of the "Questions", "Check items", "Causes", and "Troubleshooting" blocks. The Questions and Check items are used to narrow down high probability causes by simple inspection or from symptoms without using troubleshooting tools. Next, use troubleshooting tools or perform direct inspection to check the selected Causes in the order of probability to determine the real cause. Questions: Questions placed in the sections A and B in the table on the next page are those to be answered by the customer or operator. Questions in section A are for basic information about the failure. Depth and accuracy of their answers to the questions in section B may depend on their concerns on the machine condition. Check items: Check items placed in the section C in the table on the right are to be simply checked by the technician to select highly probable causes. [Causes]: Various causes are listed is this block. The technician will be able to narrows down the probable causes by taking the actions listed in the blocks A, B, and C. [Troubleshooting]: This section includes various items of troubleshooting that are performed in order to verify the results of the diagnosis made by asking the questions and inspecting the machine. The troubleshooting is performed in order from the most probable one by applying troubleshooting tools or direct inspection.
40-444
PC228US-8,PC228USLC-8
Troubleshooting of engine (S-mode) Method of using troubleshooting chart
This troubleshooting chart marks the content of the questions and check items with E, Q or w according to their closer relationship with the causes. E: Reference information for estimation of the cause Q: Information and inspection result that indicate the cause of the failure w: A cause particularly probable among those marked with Q above. a Count the priority level of each marking as w > Q when determining the cause. Don't count E when determining the cause. The item with this marking may be counted, however, if no difference is present than this and the cause cannot be determined.
PC228US-8,PC228USLC-8
40-445
Troubleshooting of engine (S-mode) Method of using troubleshooting chart
<Example of troubleshooting> Exhaust smoke is black (Incomplete combustion) 40-426 a The following legend contains items which are not applicable to this machine. Let us assume that a trouble of “Exhaust smoke is black” occurred and we checked the [Questions] and [Check items] and found the following 3 items to be the causal symptoms; [Colour of exhaust smoke gradually became black], [Power was lost gradually], and [Dust indicator indicates a red zone].
40-446
PC228US-8,PC228USLC-8
Troubleshooting of engine (S-mode) Method of using troubleshooting chart
There is a causal relationship between 3 items in the [Questions] and [Check items] sections and 6 items in the [Causes] sections. The method of pinpointing the [cause] from the causal relationship and approaching the [troubleshooting] is explained according to Step 1 – Step 3 shown below.
PC228US-8,PC228USLC-8
40-447
Troubleshooting of engine (S-mode) S-1 Startability is poor
S-1 Startability is poor Cause
q
Defective electrical system Insufficient supply of fuel q Insufficient intake of air q Improper selection of fuel a The common rail fuel injection system (CRI) controls the fuel injection timing electrically. Accordingly, even if the engine is cranked properly, the engine may not start until the crankshaft rotates two turns under the most disadvantageous condition. This phenomenon does not mean a problem, however.
Check recent repair history. Machine operaOperated for long period E E E tion hours Starting perform- Became worse gradually Q w w Q Engine starts easily when warm. w w ance Fuel other than specified one is used. Q Q Q The filter was not replaced as specified by the operation and Maintenance w w Q Q Manual. Engine oil must be added more frequently. w When engine is preheated or when temperature is low, preheating monitor w does not indicate proper functioning of preheating system. During operation, charge level monitor indicates abnormal charge. w w Dust indicator indicate a red zone. w Air breather hole in fuel tank cap is clogged. w Fuel leaks from fuel piping. w Q If priming pump is operated, no resistance is felt or it is heavy. w Q Starting motor cranks engine slowly. w When engine is Even if air bleeding plug in fuel filter head is removed, fuel w cranked with does not flow out. If spill hose from injector is disconnected, little fuel spills. w starting motor, When exhaust manifold is touched immediately after starting engine, temperw ature of some cylinders is low. Engine does not pick up smoothly and combustion is irregular. Q Q w Engine hunts. Q w Q Blowby gas is excessive. w Check air cleaner. When compression pressure is measured, it is found to be low. When air is bled from fuel system, air comes out. Check fuel filter. Perform troubleshooting for "Supply pump pressure low error” according to failure code (*1). Even if a cylinder is cut out, engine speed does not change. Even if starting switch is turned to HEAT, intake air heater mount does not become warm. Is voltage 20 – 30 V between alternator terminal B and terminal E Yes when engine is running at low idle speed? None Specific gravity of electrolyte and voltage of battery are low. Remedy
q
q q
q
q q q q q
q
q
Clean Replace Replace Clean Repair Replace Replace Replace Replace Replace Replace Replace
Troubleshooting
Check items
Questions
q
Clogged air cleaner element Defective contact of valve with valve seat Worn piston ring or cylinder Clogged air breather hole in fuel tank cap Leakage or clogging of fuel piping or air in the fuel piping Clogging of fuel filter Stuck or seized supply pump plunger Defective injector Defective intake air heater system Defective alternator (regulator section) Defective alternator (generator section) Defective or deteriorated battery
General causes why startability is poor
*1: Failure codes [CA559] and [CA2249] 40-448
PC228US-8,PC228USLC-8
Troubleshooting of engine (S-mode) S-2 Engine does not start
S-2 Engine does not start Cause
a) Engine does not crank
q
Troubleshooting
Check items
Questions
q
Internal parts of engine seized. oSee "S-4 Engine stops during operations" Defective electrical system Defect in hydraulic pump
Check recent repair history. Machine operation Operated for long period EE hours Condition of horn Horn does not sound. Q Q w when starting switch Horn volume is low. w is turned ON Battery electrolyte level is low. w Battery cable terminal is loose w When starting switch is turned ON, no operating sound is heard from battery relay. Q w When starting switch is turned to START, starter pinion does not plunge. Q Q w w When starting switch Rotation speed is low. w w is turned to START, Unusual noise is heard around ring gear. starter pinion Pinion returns halfway. w plunges, but: Unusual noise is heard around relay and engine does not rotate. Q QQ Q Check flywheel ring gear. q Specific gravity of electrolyte and voltage of battery are low. q Voltage (20 – 30 V) between battery relay terminal B and terminal E is not found. Turn starting switch to When terminal B and terminal C of starting switch are connected, engine cranks. OFF position and When terminal B at safety relay outlet and terminal C are conconnect cable, and perform troubleshoot- nected, engine cranks. Even if terminal B at safety relay outlet and terminal C are coning with starting nected, engine will not crank. switch at ON. When terminal at safety switch and terminal B at starting motor are connected, engine cranks. Remedy
PC228US-8,PC228USLC-8
Replace Replace Repair Replace Replace Replace Replace – Perform E-mode troubleshooting – Perform H-mode troubleshooting
q
Broken flywheel ring gear Defective or deteriorated battery Defective connection of battery cable terminal Defective battery relay Defective starting switch Defective safety relay Defective starting motor (motor section) Defective starting circuit wiring Defective hydraulic pump
General causes why engine does not crank
q
q
q
q q
40-449
Troubleshooting of engine (S-mode) S-2 Engine does not start
Cause Use of improper fuel Insufficient fuel in tank Clogged air breather hole in fuel tank cap Leakage or clogging of fuel piping or air in the fuel piping Clogging of fuel filter Seized or prematurely worn feed pump Broken supply pump shaft Stuck or seized supply pump plunger Defective IMV for supply pump Malfunction of overflow valve (Does not close) Defective common rail pressure limitter Defective fuel injector
b) Engine cranks but no exhaust smoke comes out General causes why engine cranks but no exhaust smoke comes out
q
Troubleshooting
Check items
Questions
q
Fuel is not being supplied. Supply of fuel is extremely small. Improper selection of fuel (particularly in winter)
Check recent repair history. Machine operaOperated for long period EE tion hours Exhaust smoke suddenly stopped coming out (at restarting after short time w Q w w stoppage). Fuel other than specified fuel one is used. w The filter was not replaced as specified by the Operation and Maintenance w E Manual. Fuel tank is found to be empty. w Air breather hole in fuel tank cap is clogged. w Rust and water are found when fuel tank is drained. QE EE There is no fuel in the removal fuel filter. w w Fuel is leaking from fuel piping. w When priming pump is operated, no resistance is felt or it is heavy. w Q Even if air bleeding plug in fuel filter head is removed, fuel When engine is Q Q w Q does not flow out. cranked with Even if spill hose from injector is disconnected, little fuel Q w w w starting motor, spills. When air is bled from fuel system, air comes out. Check fuel filter. Check feed pump. Perform troubleshooting for "Supply pump pressure low error” according to failure code (*1). Perform troubleshooting for the error "IMV/IMA short or open circuit" according to failure code (*2). Check pressure relief valve. Fuel flows out when pressure limitter return piping is disconnected. Remedy
q
q
Q
q q q q q
q
Replace Add Clean Repair Replace Replace Replace Replace Replace Replace Replace Replace
q
*1: Failure codes [CA559] and [CA2249] *2: Failure codes [CA271] and [CA272]
40-450
PC228US-8,PC228USLC-8
Troubleshooting of engine (S-mode) S-2 Engine does not start
Cause
General causes why exhaust smoke comes out but engine does not start
q q
Troubleshooting
Check items
Questions
q
Lack of cranking force due to defective electrical system Insufficient supply of fuel Insufficient intake of air Improper selection of fuel
Check recent repair history. Machine operation Operated for long period E E E hours Suddenly become un-startable. w w Q Fuel other than specified one is used. Q Q The filter was not replaced as specified by the Operation and Maintenance w w Manual. Oil must be added more frequently w When engine is preheated or when temperature is low, preheating monitor w does not indicate proper function of preheating system. Dust indicator indicates a red zone. w Air breather hole of fuel tank cap is clogged. Q Rust and water are found when fuel tank is drained. w There is no fuel in the removal fuel filter. w Fuel is leaking from fuel piping. w When priming pump is operated, no resistance is felt or it is heavy. wQ Starting motor cranks engine slowly. w When engine is running, unusual noise is heard around cylinder head. w Even if air bleeding plug in fuel filter head is removed, fuel When engine is Q w does not flow out. cranked with startEven if spill hose from injector is disconnected, little fuel w ing motor, spills. When exhaust manifold is touched immediately after starting engine, temperaw ture of some cylinders is low. Check air cleaner. Check valve system. When compression pressure is measured, it is found to be low. When air is bled from fuel system, air comes out. Check fuel filter. Perform troubleshooting for "Supply pump pressure low error” according to failure code (*1). Specific gravity of electrolyte and voltage of battery are low. Coolant temperature gauge indication is not correct. Even if starting switch is turned to HEAT, intake air heater mount does not become warm. Remedy
q
q
q
q
q q q
q q
Clean Replace Replace Replace Clean Repair Replace Replace Replace Replace Replace Replace
q
Clogged air cleaner element Worn valve system (valve, rocker lever, etc.) Worn piston ring or cylinder Use of improper fuel Clogged air breather hole in fuel tank cap Leakage or clogging of fuel piping or air in the fuel system Clogging of fuel filter Stuck or seized supply pump plunger Clogged injection nozzle, or defective spray Defective or deteriorated battery Defective coolant temperature sensor or wiring harness Defective intake air heater system
c) Exhaust smoke comes out but engine will not start (fuel is injected)
*1: Failure codes [CA559] and [CA2249] PC228US-8,PC228USLC-8
40-451
Troubleshooting of engine (S-mode) S-3 Engine does not pick up smoothly
S-3 Engine does not pick up smoothly Cause
q q q
Troubleshooting
Check items
Questions
q
Insufficient intake of air Insufficient supply of fuel Improper of fuel injection Improper selection of fuel Controller is controlling in derate mode (limiting injection rate (power) because of an error in electrical system)
Check recent repair history. Machine operaOperated for long period EE E E tion hours Engine pickup suddenly became worse. w QQ Q Fuel other than specified one is used. www The filter was not replaced as specified by the Operation and Maintenance Manual. w w Engine oil must be added more frequently. w Dust indicator indicates a red zone. w Air breather hole in fuel tank cap is clogged. w Rust and water are found when fuel tank is drained. w Fuel is leaking from fuel piping. w When priming pump is operated, no resistance is felt or it is heavy. wQ When exhaust manifold is touched immediately after starting engine, temperature of Qw some cylinders is low. w Colour of exhaust Blue under light load. smoke Black. wQ w w While engine is running, unusual noise is heard around cylinder head. w While engine is running, interference sound is heard around turbocharger. w High idle speed is normal, but speed suddenly drops when load is applied. Q w Engine hunts. Q Q Q Blowby gas is excessive. w Check air cleaner. When compression pressure is measured, it is found to be low. Check valve clearance. When turbocharger is rotated by hand, it is found to be heavy. When air is bled from fuel system, air comes out. Check fuel filter. Perform troubleshooting for "Supply pump pressure low error” according to failure code (*1). Even if a cylinder is cut out, engine speed does not change. Remedy
q
q
q
q q
q
q q q
Clean Repair Adjust Replace Replace Clean Repair Replace Replace Replace
q
Clogged air cleaner element Defective contact of valve with valve seat Improper valve clearance Seizure or interference at turbocharger Worn piston ring or cylinder Clogged air breather hole in fuel tank cap Leaking or clogging of fuel piping or air in the fuel Clogging of fuel filter Stuck or seized supply pump plunger Clogged injection nozzle, or defective spray
General causes why engine will not pick up smoothly
*1: Failure codes [CA559] and [CA2249]
40-452
PC228US-8,PC228USLC-8
Troubleshooting of engine (S-mode) S-4 Engine stops during operation
S-4 Engine stops during operation
Check valve system. Check piston and connecting rod. Check crankshaft bearing. Check gear train. Check fuel filter. Check feed pump gauze filter. Check the feed pump. Perform troubleshooting for "Supply pump pressure low error” according to failure code (*1). Engine operates if auxiliary equipment (pump, air compressor, etc.) is removed. Check engine controller power supply wiring. Check starting switch wiring. Remedy
Defective hydraulic pump
EE wwww wQ
QwQw w w wQ
w w
w
ww ww
w
Q
QQ QQQ QQQ ww
Q
w wQQ ww QQ
w
w w
q
q
q
q
QQ QQ
q
q
w
q qq q
q
q
Repair Repair
Check recent repair history. Machine operation Operated for long period. hours Unusual noise was heard and engine stopped suddenly. Condition when Engine overheated and stopped. engine stopped Engine stopped slowly. Engine hunted and stopped. Fuel other than specified one is used. The filter was not replaced as specified by the Operation and Maintenance Manual. Fuel level monitor indicates low level. Fuel tank is found to be empty. Air breather hole in fuel tank cap is clogged. Fuel is leaking from fuel piping. When priming pump is operated, no resistance is felt or it is Rust and water are found when fuel tank is drained. Metal particles are found in oil drained from oil pan. It does not rotate at all. It rotates only in opposite direction. When engine is Crankshaft moves by amount of gear rotated by hand: backlash. Supply pump shaft does not turn. Engine operates, but stops when load is applied from machine.
Perform H-mode troubleshooting
Troubleshooting
Check items
Questions
q
Internal parts of engine seized Insufficient supply of fuel Engine overheating Defect in hydraulic pump
–
q
Damage of valve system (valve, rocker lever, etc.) Broken or seized piston connecting rod Broken or seized crankshaft bearing Broken or seized gear train Insufficient fuel in tank Clogged air breather hole in fuel tank cap Clogged or leaking fuel piping Clogging of fuel filter Clogging of feed pump gauze filter Broken or seized feed pump Broken supply pump shaft Stuck or seized supply pump plunger Broken auxiliary equipment (pump or air compressor, etc.)
q
Replace Replace Replace Replace Add Clean Repair Replace Clean Replace Replace Replace Replace
q
Defective engine controller power supply wiring Defective starting switch wiring
Cause
General causes why engine stops during operation
*1: Failure codes [CA559] and [CA2249] PC228US-8,PC228USLC-8
40-453
Troubleshooting of engine (S-mode) S-5 Engine runs rough or is unstable
S-5 Engine runs rough or is unstable Cause
Troubleshooting Check items
Questions
q
Air in fuel system Defective engine speed sensor (error at degree that does not generate failure code)
Check recent repair history. Machine operation Operated for long period hours Occurs at a certain speed range. Occurs at low idle. Hunting: Occurs even when speed is raised. Occurs on slope. The filter was not replaced as specified by the Operation and Maintenance Manual. Fuel tank is found to be empty. Air breather hole in fuel tank cap is clogged. Rust and water are found when fuel tank is drained. Fuel is leaking from fuel piping.
E
w w
Q Q Q Q Q Q Q Q Q Q w w w
Q
When priming pump is operated, no resistance is felt or it is heavy.
w Q
When air is bled from fuel system, air comes out. Check fuel filter. Even if a cylinder is cut out, engine speed does not change. Perform troubleshooting for "Eng Ne Speed Sensor Error" according to failure code (*1).
q
q
q
q
Perform troubleshooting for "Eng Backup Speed Sensor Error" according to failure code (*2).
q
Remedy
Add Clean Replace Replace Replace Replace Replace
q
Insufficient fuel in tank Clogged air breather hole in fuel tank cap Leakage or clogging of fuel piping or air in the fuel piping Clogging of fuel filter Clogged injector or defective spray (dirt in injector) Defective Ne speed sensor, or wiring harness Defective Ne speed sensor, or wiring harness
General causes why engine runs rough or is unstable
*1: Failure code [CA689] *2: Failure code [CA778]
40-454
PC228US-8,PC228USLC-8
Troubleshooting of engine (S-mode) S-6 Engine lacks power
S-6 Engine lacks power Causes
E
E
E
Q
Q
Q Q QQ Q
Q Q Q
Q Q
w Q
Q w
w
w
w
w w w
w w Q Q w w q
w
q
q
wQ Q
QQ QQQ
w Q Q
q q
q
q q q q
q q Replace
Remedy
w
Replace
Check recent repair history. Machine operaOperated for long period E tion hours suddenly Q Power was lost gradually Q Fuel other than specified one is used. The filter was not replaced as specified by the Operation and w Maintenance Manual. Oil must be added more frequently. Dust indicator indicates a red zone. w w Air breather hole in fuel tank cap is clogged. Fuel is leaking from fuel piping. Power becomes insufficient after short stop of operation. w Colour of black exhaust smoke blue under light load When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low. While engine is running, interference sound is heard around turbocharger. While engine is running, unusual noise is heard around cylinder head. High idle speed is too high. High idle speed is normal, but speed suddenly drops when load is applied. Engine does not pick up smoothly and combustion is irregular. w Engine hunts. Blowby gas is excessive. Check air cleaner. q Check air intake piping. q When boost pressure is measured, it is found to be low. q q When compression pressure is measured, it is found to be low. Check valve clearance. Check fuel piping. Check fuel filter. Check spill port check valve. Perform troubleshooting for "Supply pump pressure low error” according to failure code (*1). Even if a cylinder is cut out, engine speed does not change. Check boost air pressure sensor mount. Perform troubleshooting for "Charge pressure sensor error" according to failure code (*2).
Repair
Troubleshooting
Check items
Questions
q
Replace
q
Replace
q
Replace Repair Adjust Replace Clean Repair Replace Replace
q
Insufficient intake of air Insufficient supply of fuel Improper fuel injection Improper selection of fuel Engine overheating oSee “S-14 Coolant temperature becomes too high (overheating)“. Controller is controlling in derate mode. (limiting injection rate (power) because of an error in electrical system)
Repair
q
Clean
q
Clogged air cleaner element Air leakage from air intake piping and aftercooler Seizure or interference at turbocharger Defective contact of valve with valve seat Improper valve clearance Worn piston ring or cylinder Clogged air breather hole in fuel tank cap Clogged or leaking fuel piping Clogging of fuel filter Stuck or seized supply pump plunger Clogged injector nozzle, or defective spray (dirt in injector) Defective injector drive (signal or solenoid) Defective installation of boost pressure sensor (air leak) Defective boost pressure sensor or wiring harness Clogged fuel spill piping
General causes why engine lacks power
*1: Failure codes [CA559] and [CA2249] *2: Failure codes [CA122] and [CA123] PC228US-8,PC228USLC-8
40-455
Troubleshooting of engine (S-mode) S-7 Exhaust smoke is black (incomplete combustion)
S-7 Exhaust smoke is black (incomplete combustion)
q q q
Troubleshooting
Check items
Questions
q
Insufficient intake of air Improper fuel injection Improper selection of fuel Engine overheating oSee “S-14 Coolant temperature becomes too high (overheating)“. Controller is controlling in derate mode. (limiting injection rate (power) because of an error in electrical system)
Check recent repair history. Machine operaOperated for long period tion hours Suddenly became black. Colour of Gradually became black. exhaust smoke Is blue under light load. Fuel other than specified one is used. Engine oil must be added more frequently. Suddenly Power was lost Gradually Dust indicator indicates a red zone. Muffler is crushed. Air leaks at tubing between turbocharger and cylinder head, and loose clamp. Engine is operated in low-temperature mode at normal temperature. When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low. While engine is running, interference sound is heard around turbocharger. While engine is running, unusual noise is heard around cylinder head. Torque converter stall speed or pump relief speed is high (Fuel is injected excessively). Exhaust noise is unusual. Engine does not pick up smoothly and combustion is irregular. Blowby gas is excessive. When spill hose from injector is disconnected, fuel spills excessively.
E w
Q w
E
E
w
w
w Q
Q
Q
Q
w Q
QQQ Q QQ QQ
w w QQQ Qw w
w Q
Q Q
w QQQ
Check air cleaner. q When turbocharger is rotated by hand, it is fount to be heavy. q When compression pressure is measured, it is found to be low. q Check valve clearance. q If muffler is removed, exhaust sound improves. Perform troubleshooting for "Supply pump pressure low error” according to failure code (*1). Even if a cylinder is cut out, engine speed does not change. Perform troubleshooting for "Coolant sensor error" according to failure code (*2). Check the condition by using monitoring function of the machine monitor. Remedy
w
E
w
Q Qw w
q q q
q q q qq
Clean Replace Repair Adjust Repair Replace Replace Replace Replace Replace Replace Replace Replace
q
Clogged air cleaner element Seizure or interference at turbocharger Defective contact of valve with valve seat Improper valve clearance Air leak at tubing between turbocharger and cylinder head Crushed or clogged muffler Worn piston ring or cylinder Stuck or seized supply pump plunger Clogged or seized injector Prematurely worn injector Improper fuel injection timing Improper fuel injection pressure Defective coolant temperature sensor or wiring harness
Cause
General causes why exhaust smoke is black
*1: Failure codes [CA559] and [CA2249] *2: Failure codes [CA144] and [CA145] 40-456
PC228US-8,PC228USLC-8
Troubleshooting of engine (S-mode) S-8 Oil consumption is excessive (or exhaust smoke is blue)
S-8 Oil consumption is excessive (or exhaust smoke is blue)
Check recent repair history. Machine operation Operated for long period hours Oil consumption suddenly increased. Engine oil must be added more frequently. Oil becomes contaminated quickly. Outside of engine is dirty with oil. Loose hose clamps are found in air intake system. Inside of air outlet pipe at turbo compressor side is dirty with oil. Inside of turbo exhaust outlet pipe is dirty with oil. Oil in coolant Oil level in damper chamber is increasing. Exhaust smoke is blue under light load. Excessive Amount of blowby gas None When intake manifold is removed, dust is found inside. When intake manifold is removed, inside is abnormally dirty. Excessive play of turbocharger shaft Check breather or breather hose. When compression pressure is measured, it is found to be low. Check rear oil seal. Pressure tightness test result of oil cooler shows oil leakage. External leakage of oil from engine Remedy
PC228US-8,PC228USLC-8
Dust sucked in at air intake system Worn/damaged valve (stem, guide, seal) Worn seal at turbine end Turbocharger Worn seal at blower end Clogged breather or breather hose Broken piston ring Worn piston ring or cylinder Worn or damaged rear oil seal Broken oil cooler Oil leakage from oil cooler Oil leakage from oil filter Oil leakage from oil piping Oil leakage from oil drain plug Oil leakage from oil pan, cylinder head, etc.
Cause
EEE
E w
Q Q
w Q Q w w Q w
Q q
q
w w w w w
w
Q
q q
w
q
w w w w
q q
w
q
w
q q
q q q q
Repair Repair Replace Replace Clean Replace Replace Replace Replace Replace Repair Repair Repair Repair
Troubleshooting
Check items
Questions
General causes why oil consumption is excessive q Excessive oil carry-over q Long-time operation of engine at low idle or high idle (Do not idle the engine for more than 20 minutes continuously) q External leakage of oil q Wear of parts in lubrication system
40-457
Troubleshooting of engine (S-mode) S-9 Oil becomes contaminated early
S-9 Oil becomes contaminated early Cause
q q
Troubleshooting
Check items
Questions
q
Entry of exhaust gas into oil due to internal wear Clogging of lubrication passage Use of improper fuel Use of improper oil Operation under excessive load
Check recent repair history. Machine operation hours Operated for long period Fuel other than specified one is used. Oil must be added more frequently. Metal particles are found in the removed oil filter. Inside of exhaust pipe is dirty with oil. Engine oil temperature rises quickly. Blue under light load Colour of exhaust smoke Black Excessive Amount of blowby gas None
EEE Q w Q Q w
Excessive play of turbocharger shaft When compression pressure is measured, it is found to be low. Check breather or breather hose. Check oil cooler. Check oil filter. Spring of oil filter safety valve is stuck or broken. Check turbocharger lubrication oil drain tube.
q
w w
w Q Q w
Q
w
w
Remedy
40-458
Q
q q
q
q
q
q
See S-7
q
q
Replace Replace Replace Clean Clean Replace Replace Clean –
q
Defective sealing at turbocharger turbine end Worn valve or valve guide Worn piston ring or cylinder Clogged breather or breather hose Clogged oil cooler Clogged oil filter Defective oil filter safety valve Clogged turbocharger lubrication oil drain tube Exhaust smoke is bad
General causes why oil becomes contaminated early
PC228US-8,PC228USLC-8
Troubleshooting of engine (S-mode) S-10 Fuel consumption is excessive
S-10 Fuel consumption is excessive Cause
q
Troubleshooting
Check items
Questions
q
Leakage of fuel Improper fuel injection (fuel pressure or injection timing) Excessive injection of fuel
Check recent repair history. Machine operaOperated for long period tion hours is more than that on other machines of same model. Fuel consumpGradually increased. tion: Suddenly increased. External leakage of fuel from engine Combustion is irregular. Engine oil level rises and oil smells of diesel fuel. When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low. Low idle speed is high. Pump relief speed is high. Black Colour of exhaust smoke White Remove head cover and check for fuel leak. Check oil seal of feed pump. Perform troubleshooting for "Supply pump pressure low error” according to failure code (*1). Even if a cylinder is cut out, engine speed does not change. Too much fuel is returned from injector. Perform troubleshooting for "Coolant sensor error" according to failure code (*2). Check the condition by using monitoring function of machine monitor. Remedy
EE Q
QQ w w
E Q
Q
QQQ
w
w
w
Q q
Q Q
q q q q
q q
q
Repair Repair Replace Replace Repair Replace Replace Replace Replace
q
Fuel leakage at cylinder head Fuel leakage from fuel filter, piping, etc. Defective feed pump oil seal Defective supply pump plunger Improper common rail pressure Defective atomization by injector Defective operation of injector Improper injection timing Defective coolant temperature sensor or wiring harness
General causes why fuel consumption is excessive
*1: Failure codes [CA559] and [CA2249] *2: Failure codes [CA144] and [CA145]
PC228US-8,PC228USLC-8
40-459
Troubleshooting of engine (S-mode) S-11 Oil is in coolant (or coolant spurts or coolant level goes down)
S-11 Oil is in coolant (or coolant spurts or coolant level goes down) Cause
Troubleshooting
Check items
Questions
q
Internal leakage in lubrication system Internal leakage in cooling system
Check recent repair history. Machine operation Operated for long period hours suddenly Oil level rose: gradually Hard water is being used as coolant. Oil level has risen and oil is milky.
Q
Unusual air bubbles are found in radiator, or coolant spurts.
w
Pressure tightness test result of cylinder head shows oil leakage.
q
EE Q Q Q Q Q Q w
q q
Check cylinder block.
q
Pressure tightness test result of oil cooler shows oil leakage. Remedy
40-460
Q
Replace Replace Replace Replace
q
Broken cylinder head or cylinder head gasket Internal cracks in cylinder block Holes caused by pitting Broken oil cooler core or O-ring
General causes why oil is present in coolant
PC228US-8,PC228USLC-8
Troubleshooting of engine (S-mode) S-12 Oil pressure drops
S-12 Oil pressure drops Worn main hearing Lack of oil in oil pan Coolant or fuel in oil Clogged strainer in oil pan Clogged or broken pipe in oil pan Defective oil pump Defective regulator valve Clogged oil filter Leaking, crushed, clogged oil piping Defective coolant temperature sensor or wiring harness
Cause
Check recent repair history. Machine operaOperated for long period E E E tion hours Oil pressure monitor indicates low oil pressure. Qw Non-specified oil is being used. Q Q The filter was not replaced as specified by the Operation and Maintenance Manual. w Indicates pressure drop at low idle. w Oil pressure Indicates pressure drop at low and high idle. Q wwwQ monitor: Indicates pressure drop on slope. w (if installed) Sometimes indicates pressure drop. w Q Oil pressure monitor indicates low oil pressure. w w Oil level in oil pan is low. w External lubrication piping is leaking or crushed. w Oil is milky or smells of diesel fuel. w Metal particles are found in oil drained from oil pan. w
w
Metal particles are found in oil filter. Inspect oil pan strainer and pipe. Oil pump rotation is heavy or there is play in oil pump. Valve and spring of regulator valve are fatigued or damaged. Check oil filter. If oil level sensor is replaced, oil level monitor indicates correct oil level.
q
Remedy
PC228US-8,PC228USLC-8
Q See S-13
Metal particles are found in the removed oil filter.
q
q
q
q
Replace Add – Clean Clean Replace Adjust Adjust Repair Replace
Troubleshooting Check items
Questions
General causes why oil pressure drops q Leakage, clogging, or wear on lubrication system q Defective oil pressure control q Selection of oil by the temperature etc. specified in the Operation and Maintenance Manual is not observed. q Deterioration of oil due to overheating
40-461
Troubleshooting of engine (S-mode) S-13 Oil level rises (coolant or fuel in oil)
S-13 Oil level rises (coolant or fuel in oil) Causes Broken cylinder head or cylinder head gasket Broken injector O-ring Internal cracks in cylinder block Holes caused by pitting Worn or damaged rear oil seal Broken oil cooler core or O-ring Defects in supply pump Defective seal of auxiliaries (water pump or air compressor)
General causes why oil level rises q
Coolant in oil (milky) Fuel in oil (oil smell of diluted diesel fuel) a If oil is in coolant, perform troubleshooting for “S-11 Oil is in coolant”.
Check recent repair history. Machine operaOperated for long period tion hours Fuel must be added more frequently. Coolant must be added more frequently. Oil in coolant Oil smells of diesel fuel Oil is milky. While engine is running, drops of water come from muffler. If radiator cap is removed and engine is run at low idle, an unusual number of bubbles appears, or coolant spurts. Exhaust smoke is white.
E
EE
w Q Q QQQQ w Q Q Q w
w w
w
Q Q w
Oil level in damper chamber decreases.
q
When compression pressure is measured, it is found to be low. Remove injector and check O-ring. Check cylinder block. Check rear oil seal. Pressure tightness test result of oil cooler shows oil leakage. Remove and check supply pump. Check seal of auxiliaries. Remedy
40-462
E
q
q
q
q
q
Replace Replace Replace Replace Replace Replace Replace Replace
Troubleshooting
Check items
Questions
q
PC228US-8,PC228USLC-8
Troubleshooting of engine (S-mode) S-14 Coolant temperature rises too high (overheating)
S-14 Coolant temperature rises too high (overheating) Causes
Broken cylinder head or cylinder head gasket Holes caused by pitting Clogged or broken oil cooler Lack of coolant Malfunction of water pump Defective thermostat Clogged or crushed radiator fins Clogged radiator core Defective radiator cap (pressure valve) Slipping fan belt or worn fan pulley Defective coolant temperature gauge Rise in hydraulic oil temperature
Check recent repair history. Machine operaOperated for long period EE EE tion hours Suddenly occurred. Q w Q Overheating Tends to occur always. Q w w Q Q w Coolant temper- Indicates quick temperature rise. ature gauge: Does not go down from red range. w Radiator coolant level monitor indicates drop of coolant level. w Engine oil level has risen and oil is milky. w Q Fan belt tension is low. w When fan pulley is turned, it has play. w Milky oil is floating on coolant. w Unusual air bubbles are found in radiator or coolant spurts. w When light bulb is held behind radiator core, no light passes through. w Radiator shroud and inside of underguard are clogged with dirt or mud. w w Coolant is leaking because of cracks in hose or loose clamps. w Coolant flows out from radiator overflow hose. w Fan belt whines under sudden acceleration. w Hydraulic oil temperature gauge enters red range faster than engine coolant w temperature gauge.
q
When compression pressure is measured, it is found to be low.
q
Troubleshooting
Check oil cooler. Temperature difference between upper and lower tanks of radiator is large. When operation of thermostat is tested, it does not open at specified opening temperature. Temperature difference between upper and lower tanks of radiator is slight.
q q q q
Check radiator core. When operation of radiator cap is tested, its opening pressure is low.
q q
Check fan belt and pulley.
q
When coolant temperature is measured, it is found to be normal. Remedy
PC228US-8,PC228USLC-8
Perform H-mode troubleshooting.
q
Check cylinder.
Replace Replace Replace Add Replace Replace Repair Repair Replace Repair Replace –
Check items
Questions
General causes why coolant temperature rises too high q Lack of cooling air (deformation or damage of fan) q Drop in heat dissipation efficiency q Problem in coolant circulation system
40-463
Troubleshooting of engine (S-mode) S-15 Unusual noise is made
S-15 Unusual noise is made Cause
Questions Check items Troubleshooting
Check recent repair history. Machine operaOperated for long period tion hours Gradually occurred. Abnormal noise Sudden occurred. Fuel other than specified one is used. Engine oil must be added more frequently. Metal particles are found in the removed oil filter. Air leaks at tubing between turbocharger and cylinder head. While engine is running, interference sound is heard from turbocharger. While engine is running, unusual noise is heard around cylinder head. While engine is running, beat noise is heard around muffler. When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low. Blue under light load Colour of exhaust smoke: Black Engine does not pick up smoothly and combustion is irregular. Unusual noise is loud when engine is accelerated Blowby gas is excessive. When turbocharger is rotated by hand, it is found to be heavy. Check valve system. If muffler is removed, unusual noise disappears. Check valve clearance. When compression pressure measured, it is found to be low. Check gear train. Check fan and fan belt. Even if a cylinder is cut out, engine speed does not change. Unusual noise is heard only when engine is cranked. Check the condition by using monitoring function of machine monitor. Remedy
40-464
E Q
w
Q
w w w
w
w
Q Q
w
w wQ
Qw
Q Q
q
q
q
q
w
w
q
Q
w QQ
q
qq q
q Replace
Abnormality due to defective parts Abnormal combustion q Air sucked in from air intake system a Judge if the noise is an internal noise or an external noise before starting troubleshooting. a The engine is operated in the low-temperature mode while it is not warmed up sufficiently. Accordingly, the engine sound becomes a little larger. This does not indicate abnormality, however. a When the engine is accelerated, it is operated in the acceleration mode and its sound becomes a little larger for up to about three seconds. This does not indicate abnormality, however. q
Replace Replace Replace Replace Adjust Replace Replace Replace Repair Replace Replace
q
Air leak at tubing between turbocharger and cylinder head Seizure or interference at turbocharger Damage of valve system (valve or rocker lever) Defective inside of muffler (partition board out of position) Improper valve clearance Excessively worn piston ring or cylinder Improper gear train backlash Dislocated or seized bushing Deformed cooling fan, loose fan belt, interference of fan belt Clogged or seized injector Dirt caught in injector Improper fuel injection timing (defect in low coolant temperature sensor or boost temperature sensor)
General causes why unusual noise is heard
PC228US-8,PC228USLC-8
Troubleshooting of engine (S-mode) S-16 Vibration is excessive
S-16 Vibration is excessive Cause Stuck valve system (valve, rocker arm, etc.) Worn main bearing and connecting rod bearing Improper gear train backlash Worn camshaft bushing Improper injection timing (Problem with coolant or boost temperature sensor) Loose engine mount bolts or broken cushions Misalignment of engine and hydraulic pump Broken parts in damper chamber
General causes why vibration is excessive q
Defective parts (premature wear or breakage) Misalignment between engine and hydraulic pump q Abnormal combustion a If unusual noise is made and vibration is excessive, perform troubleshooting also for “S-15 Unusual noise is made”.
Check recent repair history. Machine operaOperated for long period tion hours Suddenly increased. Vibration Gradually increased. Non-specified oil is being used. Metal particles are found in the removed oil filter. Metal particles are found in oil drained from oil pan. Oil pressure is low at low idle. Vibration occurs at mid-range speed. Vibration follows engine speed.
Q
E
E
Q Q w w Q
Q Q w w Q
Q
w
Check valve system. Check main bearing and connecting rod bearing. Check gear train. Check camshaft bushing. Check the condition by using monitoring function of machine monitor. Check engine mounting bolts and cushions. When radial runout and facial runout are checked, misalignment is found. Check inside of damper chamber.
q
Remedy
Q
Q Q Q Q Q
Q
Exhaust smoke is black.
PC228US-8,PC228USLC-8
E
Q q
q
q
q
q
q
q
Replace Replace Replace Replace Replace Replace Adjust Replace
Troubleshooting
Check items
Questions
q
40-465
Quick coupler troubleshooting Quick coupler
Quick coupler troubleshooting Quick coupler 1 Trouble
(1) Quick coupler cylinder will not extend or Retract
Related information
Quick coupler block assembly has 3 cartridge valves in it, two 3 port pressure reducers to regulate the pressure to both the solenoid valve and both sides of the quick coupler cylinder and a 4/2 solenoid operated directional control valve, this functions as follows: -Default position allows oil to flow to extend quick coupler cylinder [Lock]. Cause
1
Remarks on troubleshooting
If there is insufficient pressure achieved at the quick coupler Pressure setting too low for cylinder, then it wont move. Adjust pressure according to particular quick coupler quick coupler specification (refer to Testing and Adjusting Section 30 for measuring and adjustment procedure) This will result in solenoid coil being energised and oil being directed to retract the quick coupler cylinder
2 Possible causes and standard value in normal state
a
Power supply to solenoid coil not removed
Prepare with starting switch OFF, then turn starting switch ON (but quick coupler switch OFF) and carry out troubleshooting.
V40 (female) between (1) - (2). Voltage below 1V. 3
4
Directional control valve malfunction
Directional control valve may have a malfunction (eg. sticking spool). Check it directly and replace complete directional control valve if necessary.
Malfunction of pressure reducer
This may result in insufficient pressure being available. Measure pressure as explained in "Testing and Adjusting Section 30" then check if pressure can be adjusted, if it can’t replace complete pressure reducer. NOTE: one pressure reducer regulates extend pressure, one regulates retract pressure
1 Trouble
(2) Quick coupler cylinder will not extend (but buzzer does not sound)
Related information
Quick coupler block assembly has 3 cartridge valves in it, two 3 port pressure reducers to regulate the pressure to both the solenoid valve and both sides of the quick coupler cylinder and a 4/2 solenoid operated directional control valve, this functions as follows: Default position allows oil to flow to extend Quick Coupler [Lock]. -When operation switch in operators cab is in "ON" position solenoid is energised switching valve which allows oil to flow to retract quick coupler cylinder [UNLOCK]. At the same time a warning buzzer sounds and the lamp on the switch comes on.
40-466
PC228US-8,PC228USLC-8
Quick coupler troubleshooting Quick coupler
Cause
Remarks on troubleshooting Valve will not switch a
1
Defective solenoid coil
Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. V40 (male) between (1) (+ positive) and (2) ( - negative) resistance 30+/-1.5Ω V40 (male) between (1) (+ positive) and chassis ground resistance Min 1MΩ
Valve will not switch a 2
No power supply to solenoid coil
Possible causes and standard value in normal state
Prepare with starting switch OFF, then turn starting switch ON and quick coupler RH console switch ON and LH lever switch ON and carry out troubleshooting without starting engine.
V40 (female) between (1) - (2). Voltage 20-30 V. a
Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
3
Defective LH lever switch
4
Directional control valve malfunction
Directional control valve may have a malfunction (eg sticking spool). Check it directly and replace the complete directional control valve if necessary.
5
Malfunction of pressure reducer
This may result in insufficient pressure being available. Measure pressure as explained in "Testing and Adjusting Section 30" then check if pressure can be adjusted, if it can’t replace complete pressure reducer.
6
Pilot operated check in Consult specific quick coupler manufacturer for the specificaquick coupler falling to opertion. ate
H16 (male) (16) - (21) SW : ON continuity, SW : OFF no continuity
Trouble
(3) Buzzer does not sound (but quick coupler cylinder does retract)
Related information
When operation switch in operators cab is in "ON" position a buzzer sounds and light on the switch comes on to warn the operator. Cause
Remarks on troubleshooting a
Possible causes and standard value in normal state
1
CM02 (female) (6) - H16 (male) (4) H16 (female) (4) - ground. 2
Trouble Possible causes and standard value in normal state
No continuity of wire
Prepare with starting switch OFF, then turn starting switch ON, then turn LH console quick coupler switch ON and carry out troubleshooting without starting engine.
Monitor malfunction
If (1) above is OK then check monitor panel.
(4) Quick coupler cylinder extends and retracts slowly Cause
Remarks on troubleshooting
1
Restriction in tank line
Check that hose is not crushed or kinked.
2
Hydraulic system pressure too low
Depending on the design of the quick coupler it may be necessary to operate the swing lever to raise the pressure in the hydraulic system.
PC228US-8,PC228USLC-8
40-467
40-468
Power Supply
7
9
FUSE BOX
F01
CAB
1
T06
2 3
4
5
R40 2
P50
2
1
V40
T09
REVOLVING FRAME
Hydraulic Pressure
Quick Coupler Circuit Low Pressure SW
1
Quick Coupler Solenoid
T01
4
1
5
5
4
9
9
8
CAB
16
10
LH CONSOLE Quick Coupler SW
21
H16
D20
D03
S42
59
6
Pump Controller
CAN Network
Monitor Panel 1
Quick Coupler Circuit Low Pressure SW
C01
BUZZER ON SIGNAL
CM02
LH LEVER Quick Coupler SW
Quick coupler troubleshooting Quick coupler
1
PC228US-8,PC228USLC-8
SEN0533427-00
50-1
PC228US-8, PC228USLC-8
HYDRAULIC EXCAVATOR PC228US-8 PC228USLC-8 Shop Manual
Machine model
Serial number
PC228US-8 PC228USLC-8
50001 and up 50001 and up
50 Disassembly and assembly 50-1
PC228US-8, PC228USLC-8
50-1
Table of contents
Table of contents 50 Disassembly and assembly General information on disassembly and assembly ...................................................................... 50-4 How to read Disassembly and Assembly.................................................................................... 50-4 Coating materials list................................................................................................................... 50-6 Special tools list .......................................................................................................................... 50-9 Sketches of special tools ............................................................................................................ 50-13 Engine and cooling system ............................................................................................................ 50-18 Removal and installation of fuel supply pump assembly ............................................................ 50-18 Removal and installation of fuel injector assembly ..................................................................... 50-22 Removal and installation of cylinder head assembly .................................................................. 50-29 Removal and installation of radiator assembly ........................................................................... 50-44 Removal and installation of hydraulic oil cooler assembly.......................................................... 50-47 Removal and installation of aftercooler assembly....................................................................... 50-49 Removal and installation of engine assembly............................................................................. 50-52 Removal and installation of engine front seal ............................................................................. 50-56 Removal and installation of engine rear seal .............................................................................. 50-58 Removal and installation of fuel cooler assembly ....................................................................... 50-61 Removal and installation of fuel tank assembly .......................................................................... 50-63 Power train..................................................................................................................................... 50-66 Removal and installation of travel motor and final drive assembly ............................................. 50-66 Disassembly and assembly of final drive assembly.................................................................... 50-67 Removal and installation of swing motor and swing machinery assembly ................................. 50-75 Disassembly and assembly of swing machinery assembly ........................................................ 50-77 Removal and installation of swing circle assembly ..................................................................... 50-85 Undercarriage and frame ............................................................................................................... 50-86 Separation and connection of track shoe assembly ................................................................... 50-86 Removal and installation of idler and idler cushion assembly..................................................... 50-88 Disassembly and assembly of idler assembly ............................................................................ 50-89 Disassembly and assembly of idler cushion assembly ............................................................... 50-92 Disassembly and assembly of track roller assembly .................................................................. 50-94 Disassembly and assembly of carrier roller assembly ................................................................ 50-96 Removal and installation of revolving frame assembly ............................................................... 50-99 Removal and installation of counterweight assembly ................................................................. 50-101 Removal and installation of maintenance counterweight assembly............................................ 50-103 Hydraulic system............................................................................................................................ 50-106 Removal and installation of centre swivel joint assembly ........................................................... 50-106 Disassembly and assembly of centre swivel joint assembly....................................................... 50-109 Removal and installation of hydraulic tank assembly ................................................................. 50-111 Removal and installation of main pump assembly...................................................................... 50-113 Removal and installation of main pump input shaft oil seal ........................................................ 50-117 Removal and installation of control valve assembly ................................................................... 50-118 Disassembly and assembly of control valve assembly ............................................................... 50-123 Disassembly and assembly of work equipment PPC valve assembly ........................................ 50-127 Disassembly and assembly of travel PPC valve assembly......................................................... 50-129 Work equipment............................................................................................................................. 50-132 Removal and installation of work equipment assembly .............................................................. 50-132 Disassembly and assembly of work equipment cylinder assembly ............................................ 50-135 Cab and its attachments ................................................................................................................ 50-142 Removal and installation of operator's cab assembly ................................................................. 50-142 Removal and installation of operator's cab glass (adhered window glass)................................. 50-146 Removal and installation of front window assembly ................................................................... 50-156
50-2
PC228US-8, PC228USLC-8
Table of contents
Removal and installation of floor frame assembly ...................................................................... 50-157 Removal and installation of air conditioner unit assembly .......................................................... 50-164 Electrical system ............................................................................................................................ 50-170 Removal and installation of air conditioner compressor assembly ............................................. 50-170 Removal and installation of air conditioner condenser assembly ............................................... 50-172 Removal and installation of engine controller assembly............................................................. 50-173 Removal and installation of pump controller assembly............................................................... 50-175 Removal and installation of machine monitor assembly............................................................. 50-178 Removal and installation of pump swash plate sensor............................................................... 50-180 Removal and installation of KOMTRAX terminal assembly ........................................................ 50-181 Disassembly and Assembly of Quick Coupler Valve .................................................................. 50-182
PC228US-8, PC228USLC-8
50-3
General information on disassembly and assembly How to read Disassembly and Assembly
General information on disassembly and assembly How to read Disassembly and Assembly 1. Removal and installation of assemblies Special tools 50-4 q Special tools which are necessary for removal or installation of parts are described as A1 ••• X1 etc. and their part numbers, part names and quantities are described in the special tool list. q In the special tools table, the following information is described, as well as the above items. 1) 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. 2) New/redesign N : Tools newly developed for this model. They have a new part number respectively. 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 forward the part number of the existing tool. Blank :Tools already available for other models. They can be used without any modification. 3) Circle mark Q in sketch column: q The sketch of the special tool is presented in the section of “Sketches of special tools”. q Part No. of special tools starting with 79*T-***-****: means that they are not available from Komatsu Ltd. (i.e. tools to be made locally).
(Rev. 2009. 01) 50-4 Removal 50-4 q In “Removal” section, the work procedures, precautions and know-how to do the work, and the amount of oil and coolant to be drained are described. q Common tools that are necessary for removal are described as [1], [2]••• etc. and their part numbers, part names and quantities are not described. q Various symbols used in “Removal” section are explained and listed below. k : Precautions related to work safety a : Know-how or precautions for work [*1] : This mark shows that instructions or precautions for parts installation work are given in “Installation” section. 6 : This mark shows the amount of oil or coolant to be drained 4 : Weight of part or component Installation 50-4 q Unless otherwise instructed, installation of parts is to be done in the reverse order to removal. q Instructions and precautions for parts installation is shown with the mark ([*1], [*2]...) which corresponds to the mark in “Removal” section. q Common tools that are necessary for installation are described as [1], [2]••• etc. and their part numbers, part names and quantities are not described. q Marks shown in the "Installation" section stand for the following. k : Precautions related to work safety a : Know-how or precautions for work 2 : Type of coating material 3 : Tightening torque 5 : Amount of oil or coolant to be replenished Sketches of special tools 50-4 q Various special tools are illustrated for the local manufacture.
50-4
PC228US-8, PC228USLC-8
General information on disassembly and assembly How to read Disassembly and Assembly
2. Disassembly and assembly of assemblies Special tools 50-5 q Special tools which are necessary for disassembly and assembly of parts are described as A1•••X1 etc. and their part numbers, part names and quantities are described in the special tool list. q In the special tools table, the following information is described, as well as the above items. 1) 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. 2) New/redesign N : Tools newly developed for this model. They have a new part number respectively. 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 forward the part number of the existing tool. Blank :Tools already available for other models. They can be used without any modification. 3) Circle mark Q in sketch column: q The sketch of the special tool is presented in the section of “Sketches of special tools”. q Part No. of special tools starting with 79*T-***-****: means that they are not available from Komatsu Ltd. (i.e. tools to be made locally).
50-5 Assembly 50-5 q In “Assembly” section, the work procedures, precautions and know-how to do the work, and the amount of oil and coolant to be replenished are described. q Common tools that are necessary for assembly are described as [1], [2]••• etc. and their part numbers, part names and quantities are not described. q The meanings of the symbols used in "Assembly" section are as follows. k : Precautions related to work safety a : Know-how or precautions for work 2 : Type of coating material 3 : Tightening torque 5 : Amount of oil or coolant to be replenished Sketches of special tools 50-5 q Various special tools are illustrated for the local manufacture.
Disassembly 50-5 q In “Disassembly” section, the work procedures, precautions and know-how to do the work, and the amount of oil and coolant to be drained are described. q Common tools that are necessary for disassembly are described as [1], [2]••• etc. and their part numbers, part names and quantities are not described. q The meanings of the symbols used in "Disassembly" section are as follows. k : Precautions related to work safety a : Know-how or precautions for work 6 : Amount of oil or coolant drained.
PC228US-8, PC228USLC-8
50-5
General information on disassembly and assembly Coating materials list
Coating materials list (Rev. 2009. 08) a The recommended coating materials such as adhesives, liquid gaskets, and greases used for disassembly and assembly are listed below. a For coating materials not listed below, use the equivalent of products shown in this manual.
Adhesive
CateKomatsu code gory
Part number
capacity
Container
LT-1A
790-129-9030
150 g
Tube
LT-1B
20 g Polyethyl790-129-9050 (2 pcs. ene concontained ) tainer
LT-2
09940-00030
50 g
Polyethylene container
LT-3
790-129-9060 (Set of adhesive and hardener)
Adhesive: 1 kg Hardener: 500 g
LT-4
790-129-9040
Holtz MH 705
790-129-9120
ThreeBond 1735
Aron-alpha 201
Loctite 648-50
LG-5
790-129-9140
790-129-9130
79A-129-9110
790-129-9080
Main features and applications q q
q q
Features: Resistance to heat and chemicals Use to fix and seal bolts and plugs.
Can
q
Use to bond and seal metal, glass and plastics.
250 g
Polyethylene container
q
Use to seal plugs for blank holes
75 g
Tube
q
Heat-resistant seal used to repair engines.
q
50 g
Polyethylene container
2g
Polyethylene container
Instantaneous adhesive. Curing time: From 5 sec. to 3 min. Use mainly to bond metals, rubbers, plastics, and woods. Instantaneous adhesive. Quick-curing type (max. strength is obtained after 30 minutes) Use mainly to bond rubbers, plastics, and metals.
50 cc
Polyethylene container
1 kg
Polyethylene container
q q q q q q q q q q
Liquid gasket
LG-6
200 g
Tube
q q q
LG-7
790-129-9170
1 kg
Tube
LG-8 ThreeBond 1207B
419-15-18131
100 g
Tube
LG-9 ThreeBond 1206D
50-6
790-129-9160
q q q q
790-129-9310
Use to prevent rubber gaskets, rubber cushions, and cork plugs from coming out. Use for plastic (except polyethylene, polypropylene, tetrafluoroethylene and vinyl chloride), rubber, metal, and non-metal parts which require immediate and strong adhesion.
200 g
Tube q
Features: Resistance to heat and chemicals Used for fitted portions used at high temperatures. Use to seal various threaded portions, pipe joints, and flanges. Use to seal taper plugs, elbows, and nipples for hydraulic piping. Features: Silicon-based heat and cold-resistant sealant To be used to seal threaded portions on flange surface Use to seal oil pan, final drive case, etc. Features: Silicon-based quick-curing sealant Use to seal flywheel housing, intake manifold, thermostat old, oil pan, thermostat housing, etc. Features: Silicon-based, heat-resistant, vibration-resistant, impact-resistant sealant Use to seal transfer case, etc. Use for rough surfaces such as the circle gear top seal which is not clamped by bolts, gaps in the weld which must be caulked, etc. Can be coated with paint.
PC228US-8, PC228USLC-8
General information on disassembly and assembly Coating materials list
Seizure Molybdenum disulphide prevention compound lubricant
Liquid gasket
CateKomatsu code gory LG-10 ThreeBond 1206E LG-11 ThreeBond 1121 ThreeBond 1211 LM-P
Part number
capacity
Container
790-129-9320
200 g
Tube
q q q
200 g
Tube
q
790-129-9090
100 g
Tube
q
Liquid gasket used to repair engine.
q
Use to prevent galling and seizure of press-fitted portions, shrinkage-fitted portions, and threaded portions. Use to lubricate linkages, bearings, etc. Spray type Thin molybdenum disulphide films are made on metal surfaces to prevent the metals from galling. Use for the drive shaft splines, needle bearings, various link pins, bolts, etc.
09940-00040
200 g
Tube q q q
–
09995-00250
190 g
Can q
q
LC-G NEVER-SEEZ
Molybdenum disulphide grease LM-G (G2-M)
–
SYG2-400M SYG2-400M-A SYGA-16CNM
SYG2-400T-A Hyper White SYG2-16CNT G2-T SYG0-400T-A G0-T (*) (*) *: For cold disSYG0-16CNT trict (*) Biogrease SYG2-400B G2-B SYGA-16CNB G2-BT (*) SYG2-400BT *: For use at (*) high temperaSYGA-16CNBT ture and under (*) high load G2-S ThreeBond 1855
Use as lubricant/sealant when installing the radiator hoses to the water tubes. Can be coated with paint. Feature: Can be used together with solid gaskets. Use for covers of the transmission case and steering case etc.
790-129-9330
SYG2-400LI SYG2-350LI SYG2-400LI-A G2-LI SYG2-160LI G0-LI (*) SYGA-160CNLI *: For cold disSYG0-400LI-A trict (*) SYG0-16CNLI (*)
Grease
Main features and applications
–
–
Can
Various
Various
q
q
Feature: Lithium grease with extreme pressure lubrication performance, general purpose type.
q
Used for parts under heavy load. Caution: q Do not use this grease for rolling bearings like swing circle bearings, etc. and spline. q Use this grease for work equipment pins only when installing them, but do not use it afterward.
q
Seizure resistance, heat resistance and water resistance higher than molybdenum disulphide grease. Not conspicuous on machine since colour is white.
Bel400 g × 10 lows-type 400 g × 20 container 16 kg Can
400 g 16 kg
400 g 16 kg
200 g
Bellows-type container Can
Bellows-type container Can
q
q
Since this grease is biodegradable in short period, it has less impact on microorganisms, animals, and plants.
q
Feature: Silicone grease with wide usable temperature range, high resistance to thermal-oxidative degradation and performance to prevent deterioration of rubber and plastic parts Use for oil seals of the transmission, etc.
Tube q
PC228US-8, PC228USLC-8
Feature: Seizure and galling prevention compound with metallic super-fine-grain, etc. Use for the mounting bolt in the high temperature area of the exhaust manifold and the turbocharger, etc.
50-7
General information on disassembly and assembly Coating materials list
CateKomatsu code gory
Part number
capacity
Container
Main features and applications
SUNSTAR PAINT PRIMER580 SUPER SUNSTAR GLASS PRIMER 580 SUPER SUNSTAR PAINT PRIMER 435-95
Caulking material
Adhesive
SUNSTAR GLASS PRIMER 435-41
50-8
427-12-11871
Can q
20 ml
Glass container
20 ml
Glass container
20 ml
Glass container
417-926-3910
22M-54-27230
22M-54-27240
SUNSTAR SASH 22M-54-27250 PRIMER GP-402 SUNSTAR PENGUINE SEAL580 417-926-3910 SUPER “ S" or “ W" Sika Japan, Sikaflex 20Y-54-39850 256HV SUNSTAR PENGUINE 22M-54-27210 SUPER 560 SUNSTAR PENGUINE 417-926-3920 SEAL No. 2505 SEKISUI SILICONE SEAL- 20Y-54-55130 ANT GE TOSHIBA SILICONES TOSSEAL381
2 kg
150 ml
Can
20 ml
Glass container
320 ml
Polyethylene container
For adhered window glass
G2-U-S ENS grease
Feature: Urea (organic system) grease with heat resistance and long life, can be packed into the confined space and left intact until next overhaul. Use for rubber, bearing and oil seal in damper. Caution: Do not mix with lithium grease. q Use as primer for painted cab sheet metal surface. (Effective period: 4 months after date of manufacture) q
Use as primer for glass. (Effective period: 4 months after date of manufacture)
q
Use as primer for painted cab sheet metal surface. (Effective period: 4 months after date of manufacture) Use as primer for black ceramic-coated glass surface and for hard polycarbonate-coated surface. (Effective period: 4 months after date of manufacture) Use as primer for sash (anodized aluminium surface). (Effective period: 4 months after date of manufacture) Use “S" in high-temperature season and “W" in low-temperature season as adhesive for glass. (Effective period: 4 months after date of manufacture) Use as adhesive for glass. (Effective period: 6 months after date of manufacture) Use as adhesive for glass. (Effective period: 6 months after date of manufacture)
q
q
q
310 ml
320 ml
Polyethylene container Ecocart (Special container)
320 ml
Polyethylene container
333 ml
Polyethylene container
q
For adhered window glass
Primer
Grease
q
q
q
Use to seal glass-to-glass joints. (Effective period: 4 months after date of manufacture)
q
Use to seal front window. (Effective period: 6 months after date of manufacture) Use to seal glass-to-glass joint. Translucent white seal. (Effective period: 12 months after date of manufacture)
q
22M-54-27220
333 ml
Cartridge
PC228US-8, PC228USLC-8
General information on disassembly and assembly Special tools list
Special tools list
Work
Sym -bol
Part number
Part name
Removal and installation of fuel supply pump 1 795-799-6130 Support assembly Removal and installa2 795-799-6700 Puller tion of fuel injector 3 795-799-1131 Gear assembly and cylinder 4 795-799-8150 Remover head assembly A 5 790-331-1120 Wrench (angle) Removal and installation of cylinder head assembly and engine 6 795-799-8150 Remover front seal Removal and installa7 795-799-6400 Seal puller tion of engine front seal Removal and installa8 795-799-6500 Seal puller tion of engine rear seal 1 796-427-1200 Wrench
Disassembly and assembly of final drive assembly
Disassembly and assembly of swing machinery assembly Disassembly and assembly of idler assembly Disassembly and assembly of track roller assembly Disassembly and assembly of carrier roller assembly
2 791-545-1510 Installer 796T-427-1220 Push tool 790-101-2510 Block 792-104-3940 Bolt F 3 05180-11613 Nut 01613-31645 Washer 790-105-2100 Jack 790-101-1102 Hydraulic pump 4 790-331-1110 Wrench 1 796T-426-1410 Push tool 2 796-426-1120 Push tool G 796T-426-1130 Plate 3 790-101-5241 Grip 01010-81240 Bolt
Necessity Q'ty New/redesign Sketch
a A tool number in the format 79*T-***-**** indicates a non-supplied (locally made) item. a Necessity: t … … Special tools that cannot be substituted and should always be used. q …… Special tools that will be useful if available and are substitutable with tools available on the market. a New/Remodel : N:Tools newly developed for this model. They have a new part number respectively. R……Tools made available by redesigning the existing tools which were developed for other models. Blank: Tools already available for other models, can be used without any modification. a Tools marked Q in the Sketch column are tools introduced in the sketches of the special tools (See Sketches of special tools)
Contents of work and remarks
t 1
Holding of fuel supply pump gear
t 1
Removal of fuel injector assembly Adjustment of valve clearance Removal of inlet connector
t 1 q 1 q 1
Angle tightening of bolt
q 1
Judgment of cylinder head bolt length
t 1
Installation of engine front seal
t 1
Installation of engine rear seal
t 1
Removal and installation of round nut Installation of floating seal
t 1 t 1 t 1 t 2 t 2 t 2 t 1 t 1 t 1 t 1 t 1 t 1 t 1 t 1
Q
Installation of hub assembly
Installation of cover
Q Press fit of main bearing Q
Press fitting of sub bearing Press fit of oil seal
J
791-530-1510 Installer
t 1
Installation of floating seal
K
796-670-1020 Installer
t 1
Installation of floating seal
L
790-434-1660 Installer
t 1
Installation of floating seal
PC228US-8, PC228USLC-8
50-9
Work
Sym -bol
Part number
791-600-2001 or 791-685-8006 790-201-2780 1 791-635-3160
Part name
Compressor (A)
Compressor (B) Spacer Extension Cylinder 790-101-1600 (686 kN {70 ton}) Disassembly and 790-101-1102 Pump assembly of idler cush- M 790-640-2180 Guide bolt ion assembly 790-101-5201 Push tool kit (B) 790-101-5241 q Plate 2 790-101-5221 q Grip 01010-51225 q Bolt 790-201-1500 Push tool kit 790-201-1620 q Plate 3 790-101-5021 q Grip 01010-50816 q Bolt 791-630-3000 Remover Separation and connecCylinder (980 kN {100 tion of track shoe N 790-101-1300 ton}) assembly 790-101-1102 Hydraulic pump 1 796T-416-1010 Push tool Disassembly and assembly of travel PPC Q 2 796T-416-1030 Push tool valve 3 796T-416-1020 Push tool Removal and installa1 796-460-1210 Oil stopper tion of main pump R 2 796T-460-1230 Adapter assembly Removal and installation of main pump input shaft oil seal
S
Disassembly and assembly of centre swivel joint assembly
790-101-2501 Push-puller 790-101-2510 q Block 790-101-2520 q Screw 791-112-1180 q Nut T 1 790-101-2540 q Washer 790-101-2630 q Leg 790-101-2570 q Plate 790-101-2560 q Nut 790-101-2650 q Adapter
50-10
796T-467-2410 Push tool
Necessity Q'ty New/redesign Sketch
General information on disassembly and assembly Special tools list
Contents of work and remarks
t 1 t 1 t 1 t 1
Disassembly and assembly of idler cushion assembly
t 1 t 1 q 1 1 1 2 q 1 1 1 2 t 1
t 1 t 1 t 1 t 1 t 1 q 1
Press fit of bushing
Press fit of dust seal
Removal and installation of master pin
Q Press fit of bushing Q Press fit of bushing Q Press fit of pin
q 1
To stop flow of oil from hydraulic Q tank
t 1
Q Press fit of input shaft oil seal
q 1 1 1 1 1 2 4 2 2
Removal of rotor and ring
PC228US-8, PC228USLC-8
Work
Disassembly and assembly of control valve assembly
Sym -bol
Part number
Part name
796-946-1310 Guide φ 21.8 (For 723-46-40100) 796-946-1610 Guide φ 21.4 (For 723-46-41100) 796-946-1810 Guide φ 21.2 2 (For 723-46-43100 and 723-46-43400) 796-946-1910 Guide φ 21.0 (For 723-46-46101 and 723-46-46300) 796-946-2210 Guide φ 20.6 (For 723-46-45100 and 723-46-45700) 796-946-1320 Guide φ 21.8 (For 723-46-40100) 796-946-1620 Guide φ 21.4 (For 723-46-41100) 796-946-1820 Guide φ 21.2 (For 723-46-43100 and 723-46-43400) 3 796-946-1920 Guide φ 21.0 T (For 723-46-46101 and 723-46-46300) 796-946-2220 Guide φ 20.6 (For 723-46-45100) 796-946-1420 Guide φ 21.6 (For 723-46-42700) 796-946-1330 Sleeve (For 723-46-40100) 796-946-1630 Sleeve (For 723-46-41100) 796-946-1830 Sleeve (For 723-46-43100 and 723-46-43400) 4 796-946-1930 Sleeve (For 723-46-46101 and 723-46-46300) 796-946-2230 Sleeve (For 723-46-45100) 796-946-1430 Sleeve (For 723-46-42700) 790-502-1003 Cylinder repair stand 1 790-101-1102 Pump 790-102-4300 Wrench assembly 2 790-102-4310 Pin 3 790-720-1000 Expander 796-720-1660 Ring 07281-01159 Clamp 4 796-720-1670 Ring 07281-01279
Disassembly and assembly of work equip- U ment cylinder assembly
790-201-1702 790-101-5021 01010-50816 5 790-201-1831 790-201-1940 790-201-1841 790-201-1930 790-201-1500 790-201-5021 01010-50816 6 790-201-1620 790-101-1630 790-201-1640 790-201-1650
PC228US-8, PC228USLC-8
Necessity Q'ty New/redesign Sketch
General information on disassembly and assembly Special tools list
Contents of work and remarks
t 1 t 1 t 1 t 1 t 1 t 1 t 1 t 1 t 1
Replacement of pressure compensation valve seal
t 1 t 1 t 1 t 1 t 1 t 1 t 1 t 1 q 1 q 1 t 1 t 1 t 1 t 1 t 1
Disassembly and assembly of piston rod assembly Removal and installation of piston Expansion of piston ring Installation of piston ring (for piston dia. φ 115 mm)
t 1
Installation of piston ring (for piston dia. φ120 mm, 130 mm, φ135 mm)
Clamp
t 1
Push tool kit Grip Bolt Push tool Push tool Push tool Push tool Push tool kit Grip Bolt Push tool Push tool Push tool Push tool
t 1 1 1 1 1 1 1 t 1 1 1 1 1 1 1
Press fit of cylinder head bushing (For rod dia. 80 mm) (For rod dia. 85 mm) (For rod dia. 90 mm) (For rod dia. 95 mm) Press fit of cylinder head dust seal (For rod dia. 80 mm) (For rod dia. 85 mm) (For rod dia. 90 mm) (For rod dia. 95 mm)
50-11 (03)
Necessity Q'ty New/redesign Sketch
General information on disassembly and assembly Special tools list
Work
Sym -bol
Part number
Removal and installation of work equipment assembly
V
796-900-1200 Remover 790-101-4000 Puller (50 ton) 790-101-1102 Hydraulic pump
t 1 t 1 t 1
Removal of boom foot pin
Removal and installation of operator's cab glass
1 793-498-1210 Lifter (Suction cup)
t 2
Holding of glass
X 2 20Y-54-13180 Stopper rubber
t 2
Fixing of glass
Removal and installation of counterweight assembly
50-12
Z
Part name
Commercially Impact wrench q 1 available Commercially Socket wrench q 1 available (width across flats: 65 mm)
Contents of work and remarks
Removal and installation of counterweight assembly mounting bolt
PC228US-8, PC228USLC-8
General information on disassembly and assembly Sketches of special tools
Sketches of special tools Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches. F3: Push tool 50-13
G1: Push tool
PC228US-8, PC228USLC-8
50-13
50-13
General information on disassembly and assembly Sketches of special tools
Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches. G3: Plate 50-14
Q1: Push tool
50-14
50-14
PC228US-8, PC228USLC-8
General information on disassembly and assembly Sketches of special tools
Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches. Q2: Push tool 50-15
Q3: Push tool
PC228US-8, PC228USLC-8
50-15
50-15
General information on disassembly and assembly Sketches of special tools
Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches. R2: Adapter 50-16
S: Push tool
50-16
50-16
PC228US-8, PC228USLC-8
General information on disassembly and assembly Sketches of special tools
PC228US-8, PC228USLC-8
50-17
Engine and cooling system Removal and installation of fuel supply pump assembly
Engine and cooling system Removal and installation of fuel supply pump assembly
Part name
A
795-799-6130
Support
t
1
1
3. Loosen two clamps (4) for high-pressure pipe (3).
Sketch
Part number
New/redesign
Symbo l
Q'ty
50-18 Necessity
Special tools
Removal 50-18 k Swing the upper structure 90 °, stop the engine, and disconnect the cable from the negative (-) terminal of the battery. 1. Through the inspection window in cover (1), close fuel stop valve (2). 4. Disconnect fuel supply hose (5). 5. Disconnect fuel filter hoses (7) and (8) from fuel supply pump (6). [*1] a Remove any dirt from the fitting. (Dirt on the fitting may cause lock (L) to be stuck.) a Pull out the hose while pressing lock L from both sides. a When disconnecting the hoses, fuel will flow out. Plug the fittings, to prevent fuel from flowing out. a Do not use a wooden plug because wooden chips may enter the fuel line. 6. Disconnect connector (9).
2. Remove the maintenance counterweight assembly. For details, see "Removal and installation of maintenance counterweight assembly".
50-18
PC228US-8, PC228USLC-8
Engine and cooling system Removal and installation of fuel supply pump assembly
9. Disconnect high-pressure pipe (3) from pump (6). [*3]
11. Remove the gear from the fuel supply pump according to the following procedure. [*5] 1) While locking the gear using support A1 and 1/2-inch spin handle (12), loosen nut (13). a At this stage, loosen nut (13) partially so that it stays on the shaft.
10. Remove mounting nuts (A) and remove fuel supply pump assembly (6). [*4]
2) Install puller [1] between the flange and gear (14).
7. Disconnect fuel return tube (10).
[*2]
8. Disconnect fuel return hose (11).
a Fuel supply pump assembly (6) comes off with the gear. The gear is not worked on its teeth (no missing tooth) to show the mark for 1.6 TDC adjustment.
PC228US-8, PC228USLC-8
50-19
Engine and cooling system Removal and installation of fuel supply pump assembly
3) Install puller [2] on puller [1] and the shaft. 4) Turn centre bolt (15) until the gear comes off the shaft. 5) Remove pullers [1] and [2].
Installation 50-20 q Perform installation in the reverse order to removal. a Drawing: See Removal [*1] q
6) Remove nut (13), lock washer (17), and gear (18) from shaft (16).
When installing a connector of quick coupler type, observe the following points. a The internal parts of the fitting may be damaged when the hose or tube is removed. Accordingly, do not reuse the hose or tube. When installing, replace it with a new one. a Ensure that mud or dirt is not sticking to the hose joint portions in advance. a Push the connector straight (in the direction of (b)). Do not pry it in or wobble it. If it is difficult to insert the connector, do not push it in forcibly but pull it out. Then, check the male and female couplings for damage and sticking mud.
[*2]
3 Joint bolt for fuel return tube:
24 ± 4 Nm {2.45 ± 0.41 kgm}
50-20
PC228US-8, PC228USLC-8
Engine and cooling system Removal and installation of fuel supply pump assembly
[*3] Install high-pressure pipe (3) according to the following procedure. 1. Tighten the sleeve nuts on the pump side and then on the common rail side. 3 Sleeve nut: 35 ± 3.5 Nm {3.57 ± 0.36 kgm} 2. Install two tube clamps (4). 3 Clamp mounting bolt: 24 ± 4 Nm {2.45 ± 0.41 kgm} 3. Install the fuel spray prevention cap. a Install each cap with its slit outward and down. a The caps are installed so that fuel will not spout over the hot parts of the engine and catch fire if it leaks for some reason. q
[*4]
q
Bleeding air Bleed air from the fuel system. a Refer to the Testing and adjusting.
3 Fuel supply pump mounting nut:
10 ± 2 Nm {1.0 ± 0.2 kgm} [*5] q Install gear (18) according to the following procedure. a Clean and dry the mating surfaces on shaft (16) and gear (18) so that the surfaces are free of dirt and foreign material. 1. Install gear (18) to shaft (16). 2. Install lock washer (17) and nut (13) and finger-tighten the nut.
3. While locking the gear by using support A1 and 1/2-inch spin handle (12), tighten nut (13) to the specified torque. 3 Fuel supply pump gear mounting nut: 105 ± 5 Nm {10.7 ± 0.51 kgm}
PC228US-8, PC228USLC-8
50-21
Engine and cooling system Removal and installation of fuel injector assembly
Removal and installation of fuel injector assembly
Symbol
A
Part number
2 795-799-6700 3 795-799-1131 4 795-799-8150
50-2
Part name
Puller Gear Remover
Necessity Q'ty New/redesign Sketch
Special tools
t 1 t 1 q 1
6. Loosen two harness mounting nuts (9) on fuel injector assembly (8). Harness colour White Black
Cylinder No. 1, 3, 5 2, 4, 6
a Do not remove injector harness connector (10) from the rocker housing unless needed.
Removal 50-2 k Disconnect the cable from the negative (-) terminal of the battery. 1. Open engine hood (3) and keep it open with a lock bar. 2. Remove cover (4).
7. Remove two mounting bolts (11) and remove rocker arm assembly (12). a Loosen lock nut (13) and loosen adjustment screw (14) two or three turns so that the push rod is not subjected to excessive force when the rocker arm is installed.
3. Remove two mounting bolts for blowby duct (5) on the head cover side [*1] 4. Remove six head cover bolts (6). 5. Remove head cover (7).
50-22
[*2]
8. Remove crosshead (15). a Note the installed positions and orientation (the shapes of the holes at parts a and b) of the crossheads. (Install it in the same direction when assembling.) 9. Disconnect three connectors (40). a As you cannot hold the connector, remove it as follows, using two flat-head screwdrivers. 1) Keep the lock of each connector (40) pushed with flat head screwdriver [1]. 2) Inserting another flat-head screwdriver [2] in one and the other gaps on both sides of the connector's lock alternately, pry the connector in both directions to disconnect the connector little by little.
PC228US-8, PC228USLC-8
Engine and cooling system Removal and installation of fuel injector assembly
10. Disconnect connector (41). a While pushing up the lock of connector (41) with flat-head screwdriver [1], pull the connector in the direction of the arrow to disconnect it.
12. Remove fuel injection pipe (17). [*3] a Clean the surrounding area and remove dirt etc. in advance to prevent them from entering the connector hole.
13. Remove retaining nut (18) and remove inlet connector (19). a Remove dirt from the inlet connector in advance so that it does not enter the connector hole. a Use tool A4 to remove inlet connector (19). 14. Remove mounting bolts (20) of fuel injector assembly (8).
11. Remove fuel spray prevention caps (16) on the cylinder head and common rail sides.
PC228US-8, PC228USLC-8
50-23
Engine and cooling system Removal and installation of fuel injector assembly
15. Using tool A2, remove fuel injector assembly (8). a Take care so that dirt and foreign material do not enter the fuel injector assembly mounting area.
Installation 50-24 1. Fuel injector assembly a When replacing the fuel injector assembly with a new one, be sure to replace the inlet connector as well. a Ensure that fuel injector mounting bore (21) is free of damage or dirt.
1) Install O-ring (23) and gasket (24) to fuel injector (22). a Replace the O-ring and gasket with new ones. 2) Apply engine oil to O-ring (23) of fuel injector (22) and the fuel injector mounting bore. 2 O-ring (23) and fuel injector mounting bore: Engine oil (EO15W-40) 3) Engage the male and female parts at (A) to install holder (25) to fuel injector (22).
4) When installing, direct the fuel inlet hole (inlet connector mounting hole) toward the air intake manifold.
50-24
PC228US-8, PC228USLC-8
Engine and cooling system Removal and installation of fuel injector assembly
5) Install fuel injector assembly (8) to fuel injector sleeve. Finger-tighten mounting bolts (20) at least three or four turns.
6) Apply engine oil to O-ring (26) of inlet connector (19) and to the inlet connector mounting bore (in the cylinder head). a Check the inlet connector visually for the following defects. If it has any of those defects, replace it and fuel injector assembly with new ones. q Front end (a) or rear end (b) of the inlet connector is burred or worn. q Foreign material is trapped by the edge filter at rear end (c) of the inlet connector. q Cracks or deterioration is recognizable in O-ring of the inlet connector upper (d) portion. q Sealing surface (e) on the edge of the inlet connector is worn or has uneven contact pattern. a If high-pressure fuel leaks through the inlet connector, the sealing surface has fine streaks or cracks. 7) Fully insert inlet connector (19) aligning parts (B) of inlet connector (19) with the groove in the cylinder head (upper part of the bore). 2 O-ring (26) and inlet connector mounting bore: Engine oil (EO15W-40)
PC228US-8, PC228USLC-8
8) Install inlet connector (19) and tighten retaining nut (18) lightly. 3 Retaining nut (lightly): 15 ± 5 Nm {1.5 ± 0.5 kgm} 9) Alternately tighten mounting bolts (20) of fuel injector assembly (8). 3 Fuel injector mounting bolt (20): 8 ± 0.8 Nm {0.8 ± 0.08 kgm} 10)Tighten retaining nut (18) to the specified torque. 3 Retaining nut (18): 50 ± 5 Nm {5.1 ± 0.51 kgm}
50-25
Engine and cooling system Removal and installation of fuel injector assembly
2. Install the rocker arm assembly according to the following procedure. 1) Install crossheads (15). a Installed position and orientation of crossheads Install them to the same positions and the same orientation (hole shapes of (a) and (b)) as those when they were removed.
5) Install harness mounting nuts (9) of fuel injector assembly (8). a Check that the harness does not interfere with the rocker arm. a Installed positions of harnesses Harness colour
Cylinder No.
White
1, 3, 5
Black
2, 4, 6
3 Mounting nut:
1.5 ± 0.25 Nm {0.15 ± 0.03 kgm}
2) Install rocker arm assembly (12) and tighten mounting bolts (11). a Ensure that adjustment screw (14) is sufficiently loose. a Ensure that the ball of adjustment screw (14) is fitted in the socket of the push rod before tightening mounting bolt (11). 3 Rocker arm mounting bolt (11): 36 ± 5 Nm {3.7 ± 0.51 kgm} 3) Adjust the valve clearance. For details, see Testing and adjusting, “Testing and adjusting valve clearance”. a Use tool A3 to turn the crankshaft. 4) After valve clearance adjustment, ensure that lock nut (13) is tightened to the specified torque. 3 Lock nut (13): 24 ± 4 Nm {2.4 ± 0.4 kgm}
50-26
a If injector harness connector (10) is removed, apply liquid gasket LG-7 to O-ring (27) and flange (28) of the connector. Apply a bead of LG-7 3 mm in diameter to the O-ring so that the ring groove is completely sealed. If the O-ring is damaged, replace it and the harness assembly as a unit. 3 Connector flange mounting bolt (29): 10 ± 2 Nm {1 ± 0.2 kgm}
PC228US-8, PC228USLC-8
Engine and cooling system Removal and installation of fuel injector assembly
q
Perform the subsequent installation in the reverse order to removal.
[*1] a When installing the blowby duct, check that the O-ring is fitted. 3 Blowby duct mounting bolt: 7 ± 2 Nm {0.71 ± 0.2 kgm} [*2]
3 Cylinder head cover mounting nut:
24 ± 4 Nm {2.4 ± 0.4 kgm} a If the stud bolt is removed, install it and tighten to the following torque. 3 Stud bolt: 24 ± 4 Nm {2.4 ± 0.4 kgm} [*3] a Precautions for installing fuel injection pipe k Do not reuse the fuel injection pipe by bending it. k Be sure to use genuine fuel injection pipe clamps and tighten them to the specified torque. k After installing the fuel injection pipe, be sure to install the fuel spray prevention cap to cover the sleeve nut. k Ensure that the fuel spray prevention cap faces out and down. a Before installing the fuel injection pipe, check the following. q If the fuel injection pipe has a fault, it may leak the fuel. Accordingly, replace it with a new one. q Taper seal section (j) at the connecting end: Check that there is no visible streaky slits (k) or spotty dimples (l) in the 2 mm distance area from the end. q Check that portion (m) (the end of the taper seal section: 2 mm from the end) Check that there is no steps (deformation) that your nail can feel.
PC228US-8, PC228USLC-8
a Install the high-pressure pipe according to the following procedure. 1) Connect the high-pressure pipe to both the cylinder head and common rail. 3 Sleeve nut: 0.2 – 0.8 Nm {0.02 – 0.08 kgm} 2) Tighten the sleeve nut on the cylinder head end, and then one on the common rail end to the specified torque. 3 Sleeve nut: 35 ± 3.5 Nm {3.6 ± 0.4 kgm} 1] Cylinder head ends of high-pressure pipes (42) and (47). 2] Common rail ends of high-pressure pipes (47) and (42). 3] Cylinder head ends of high-pressure pipes (43), (44), (45) and (46). 4] Common rail ends of high-pressure pipes (43), (44), (45) and (46). 3) Install a fuel spray prevention cap (48) on both the cylinder head and common rail ends.
k Install the fuel spray prevention cap with the
slit out and down. The caps are installed so that fuel will not spout over the hot parts of the engine and catch fire if it leaks for some reason.
50-27
Engine and cooling system Removal and installation of fuel injector assembly
a If all of the fuel injector assemblies have been removed, see [*7] and [*8], "Removal and installation of cylinder head assembly" for assembly procedure. q
Bleeding air Bleed air from the fuel system. For details, see the Testing and adjusting "Air bleeding of fuel circuit".
50-28
PC228US-8, PC228USLC-8
Engine and cooling system Removal and installation of cylinder head assembly
Removal and installation of cylinder head assembly
Symbol Part number
A
50-29
Part name
Necessity Q'ty New/redesign Sketch
Special tools
2 795-799-6700 Puller
t 1
3 795-799-1131 Gear
t 1
4 795-799-8150 Remover
q 1
5 790-331-1120 Wrench (angle)
q 1
6 795-790-4510 Gauge
q 1
Removal 50-29 k Disconnect the cable from the negative (-) terminal of the battery. 1. Remove cover (1).
2. Open drain valve (2) to drain coolant. 6 Coolant:
3. Remove the rear right inspection cover and remove partition plate (3).
4. Remove the following components. For details, see "Removal and installation of maintenance counterweight assembly". 1) Engine hood (4) 2) Covers (5), (6) and (7) 3) Frame (8) 4) Fuel filter and bracket assembly (9) 5) Maintenance counterweight assembly (10)
21 l 5. Remove partition plate (11).
PC228US-8, PC228USLC-8
50-29
Engine and cooling system Removal and installation of cylinder head assembly
6. Remove clamp (12). [*1] a When removing the clamp bolt, fix the nut on the opposite side by using a spanner so that the force is not applied to the bracket.
9. Remove drive belt (15) of the air conditioner compressor. [*2] 10. Disconnect radiator hose (16) and aeration hose (17). [*3] 11. Loosen two clamps (18) and disconnect aftercooler hose (19). 12. Disconnect connector E01 (20) of the electric intake air heater. 13. Detach bracket (21).
[*4]
14. Disconnect tube (22). 15. Remove electric intake air heater (23). 7. Remove mounting bolts (13) of the muffler mounting bracket.
16. Disconnect heater hose (24). 17. Remove three mounting bolts (25). a Do not loosen four mounting bolts (26) of the air conditioner compressor. [*5] 18. Remove air conditioner compressor assembly (27). a Remove the air conditioner compressor assembly and the bracket as a unit and put them aside.
8. Sling and remove muffler (14). a Space for winding the lifting tool is small. 4 Muffler: 35 kg
50-30
PC228US-8, PC228USLC-8
Engine and cooling system Removal and installation of cylinder head assembly
19. Remove the alternator according to the following procedure. 1) Disconnect wiring (28) and (29). 2) Slacken fan belt (31) by inserting wrench [1] in hole (A) (width across flats:12.7 mm) in tensioner assembly (30) and turning the wrench counter clockwise (R) as viewed from the front of the engine. 3) Remove fan belt (31) from alternator assembly (32). k Turn the tensioner assembly only after making sure that wrench [1] is fitted completely in hole (A) in tensioner assembly (30). (The tensioner assembly is loaded with strong spring tension. If the wrench [1] is incompletely fitted in the hole, the wrench could disengage from the hole while the tensioner is being turned, possibly leading to a very dangerous consequence.) k After removing fan belt (31), be sure to release wrench [1] slowly and carefully. k During the fan belt removal operation, be fully careful so as not to pinch your fingers between the pulley and fan belt (31). 4) Remove the mounting bolts of the alternator to remove alternator assembly (32). 20. Remove fan (33). a Put the fan down.
21. Disconnect fuel supply hose (34). 22. Disconnect fuel filter hoses (36) and (37) from fuel supply pump assembly (35). a Before disconnecting each hose, be sure to remove dirt from its fitting. (Dirt on the fitting may cause lock (L) to be stuck.) a Disconnect each hose while pressing lock (L) from both sides.
[*6]
23. Remove clamps (38) and (39) from the cylinder block. 24. Remove fuel spray prevention cap (40) on the supply pump side.
PC228US-8, PC228USLC-8
50-31
Engine and cooling system Removal and installation of cylinder head assembly
25. Disconnect high-pressure pipe (41) from the supply pump.
36. Disconnect boost pressure and temperature sensor connector (50). a Place the harness aside. [*12]
26. Disconnect three connectors (42). a As you cannot hold the connector, remove it as follows, using two flat-head screwdrivers. 1) Keep the lock of each connector (42) pushed with flat head screwdriver [2]. 2) Inserting another flat-head screwdriver [3] in one and the other gaps on both sides of the connector's lock alternately, pry the connector in both directions to disconnect the connector little by little. 27. Disconnect connector (43). a While pushing up the lock of connector (43) with flat-head screwdriver [2], pull the connector in the direction of the arrow to disconnect it. 28. Remove six fuel spray prevention caps (40). a Cylinder head side only 29. Disconnect six high-pressure pipes (44) from the cylinder head. [*7] 30. Remove common rail and high-pressure pipe assembly (45). [*8] 31. Disconnect high-pressure pipe (41) from the common rail. 32. Disconnect fuel return hose (46).
[*9]
33. Disconnect fuel return hose (47). 34. Remove bracket (48).
[*10]
35. Remove fuel block (49).
[*11]
50-32
PC228US-8, PC228USLC-8
Engine and cooling system Removal and installation of cylinder head assembly
37. Remove blowby duct (51).
42. Remove mounting bolts (61) of exhaust manifold (60), leaving some of the bolts unremoved. [*16]
38. Disconnect fuel drain hose (52).
39. Loosen air hose clamp (53) and disconnect hose (54). [*13] 40. Loosen air tube clamp (55) and disconnect tube (56). [*14] 41. Disconnect lubrication inlet hose (57) and lubrication outlet hose (58). [*15] a When disconnecting the lubrication inlet hose, hold connector (59) on the turbocharger side with a wrench to prevent the connector from turning.
PC228US-8, PC228USLC-8
43. Sling exhaust manifold and turbocharger assembly (62), then remove the remaining mounting bolts. 44. Sling and remove exhaust manifold and turbocharger assembly (62). 4 Exhaust manifold and turbocharger assembly: 25 kg
50-33
Engine and cooling system Removal and installation of cylinder head assembly
45. Disconnect clamp (63). 46. Disconnect the connectors of coolant temperature sensor (64) and ambient pressure sensor (65). a Coolant temperature sensor (64): Pull the lock (female half) outward. a Ambient pressure sensor (65): 1] Slide lock (L1) by pushing it. 2] While pressing lock (L2), pull out the connector.
48. Remove nuts (67) of the harness from the injector. Harness colour
Cylinder No.
White
1, 3, 5
Black
2, 4, 6
49. Remove the 12 mounting bolts to remove six rocker arm assemblies (68). a Loosen lock nuts (69) and then adequately loosen adjustment screws (70) to avoid excessive forces that would otherwise work on the push rods when the rocker arms are reinstalled. a Note of the installed positions and orientation (the shapes of the holes at parts a and b) of the crossheads (to assure that the crossheads can be reinstalled in the original position). 50. Remove crossheads (71). 51. Remove retaining nuts (72), then remove six inlet connectors (73). a Clean the surrounding area and remove dirt etc. in advance to prevent them from entering the connector hole. a Use Tool A4: Remover for removing inlet connectors (73). (See Tool Table.)
47. Remove cylinder head cover (66).
50-34
PC228US-8, PC228USLC-8
Engine and cooling system Removal and installation of cylinder head assembly
52. Remove two mounting bolts (75) of injector assembly (74). 53. Using tool A2, remove fuel injector assembly (74). a Take care so that dirt and foreign material do not enter the fuel injector assembly mounting area.
57. Remove 26 mounting bolts (79) and sling and remove cylinder head assembly (80). 4 Cylinder head assembly: 75 kg 58. Remove cylinder head gasket (81).
54. Remove push rods (76). 55. Remove rocker arm support (77). 56. Remove rocker housing assembly (78).
PC228US-8, PC228USLC-8
50-35
Engine and cooling system Removal and installation of cylinder head assembly
Installation 50-36 1. Cylinder head assembly 1) Using Tool A6, measure stem length (a) of every cylinder head mounting bolt to make sure that the length is within the service limit. (See Special Tool Table.) q Service limit length of bolt: Less than 132.1 mm a If the stem length of a bolt is longer than the service limit, do not reuse that bolt but replace it with a new one.
2) Set cylinder head gasket (81) in position on the cylinder block. a Check that the cylinder head mounting face and inside of the cylinders are free from dirt and foreign matter. a Check that the holes in cylinder head gasket (81) are aligned with the holes in the cylinder head. 3) Sling cylinder head assembly (80), set the assembly in position on the cylinder block, and finger-tighten mounting bolts (79) more than two to three turns. 4) Tighten the cylinder head mounting bolts according to the following procedure in sequence, beginning with [1] and ending with [26]. 2 Apply engine oil (EO15W-40) to the threaded portion and seat surface of each cylinder head mounting bolt. 3 Mounting bolt: a Tighten the bolts 3 times in the order shown in the figure. 1] 90 ± 3 Nm {9.2 ± 0.3 kgm} 2] 90 ± 3 Nm {9.2 ± 0.3 kgm} 3] 90°± 5° (When tightened with angle tightening tool A5)
50-36
q
Method without using angle tightening wrench A5. Put a mark across the cylinder head and bolt with a marker pen, then re tighten the bolt by 90 ± 5 °.
PC228US-8, PC228USLC-8
Engine and cooling system Removal and installation of cylinder head assembly
2. Install the rocker housing assembly according to the following procedure. 1) Install rocker housing assembly (78) and tighten seven rocker housing mounting bolts (82). a Replace the gasket with new one. 3 Mounting bolt: 24 ± 4 Nm {2.4 ± 0.4 kgm} 2) Install push rods (76). 3) Install rocker arm support (77). 3. Install each fuel injector and the inlet connector according to the following procedure. a When replacing the fuel injector assembly with a new one, be sure to replace the inlet connector as well. a Check that fuel injector mounting bore (83) is free from dirt or other particles.
a Be sure to replace all O-rings and gaskets with new ones. 1) Install O-ring (85) and gasket (86) to fuel injector (84). 2) Apply engine oil (EO15W-40) to O-ring (85) and cylinder head side surface of fuel injector (84). 2 O-ring (85) and cylinder head side surface of fuel injector (84): Engine oil (EO15W-40) 3) Engage the male and female parts at (A) to install holder (87) to fuel injector (84).
PC228US-8, PC228USLC-8
4) Install fuel injector assembly (84) into the cylinder head with the fuel inlet hole toward the air intake manifold. 5) Screw in mounting bolts (75) by three to four threads. 6) Apply engine oil (EO15W-40) to the cylinder head side threads (section B) of inlet connector (73). 7) Apply engine oil (EO15W-40) to O-ring (C) of inlet connector (73). Align part D with the groove in the cylinder head and inlet connector (73) with the fuel inlet hole of the fuel injector assembly. Insert inlet connector (73) fully into the cylinder head. a Visually check the inlet connector. If any of the following defects is found, replace the fuel injector and inlet connector with new ones as a unit. q Burrs or wear is recognizable in the inlet connector front-end (a) and back-end (b) portions. q Foreign material is collected in the edge filter at rear end (c) of the inlet connector. q Cracks or deterioration is recognizable in O-ring of the inlet connector upper (d) portion. q Sealing surface (e) at the front end of the inlet connector is worn or seated unevenly. a If high-pressure fuel leaks through the inlet connector, the sealing surface has fine streaks or cracks.
50-37
Engine and cooling system Removal and installation of cylinder head assembly
4. Install the rocker arm assembly and crosshead according to the following procedure. 1) Install crosshead (71). 2) Install rocker arm assembly (68). a The shape of the hole at part a of the crosshead is different from that at part b. When reusing a crosshead, be sure to use it for the same intake and exhaust valves for which the crosshead was used before removal, and also, its ends should be pointed in the original directions. a Check that the spherical portion of adjustment screw (70) is fitted properly in the socket of the push rod and then tighten the mounting bolt. 3 Mounting bolt: 36 ± 5 Nm {3.7 ± 0.5 kgm} 3) Adjust the valve clearances. a For details, see Testing and adjusting, "Testing and adjusting valve clearance". 3 Lock nut (69) 24 ± 4 Nm {2.4 ± 0.4 kgm}
8) Install inlet connector (73) and tighten retaining nut (72) lightly (to force the inlet connector into the injector hole). 3 Retaining nut (lightly): 15 ± 5 Nm {1.5 ± 0.5 kgm} 9) Alternately tighten mounting bolts (75) of fuel injector assembly (74). 3 Fuel injector mounting bolt: 8 ± 0.8 Nm {0.8 ± 0.08 kgm} 10)Tighten retaining nut (72) to the specified torque. 3 Retaining nut: 50 ± 5 Nm {5.1 ± 0.51 kgm}
50-38
PC228US-8, PC228USLC-8
Engine and cooling system Removal and installation of cylinder head assembly
5. Install the harness using harness mounting nuts (67). a Harness installation position Harness colour
Cylinder No.
White
1, 3, 5
Black
2, 4, 6
3 Mounting nut:
1.5 ± 0.25 Nm {0.15 ± 0.03 kgm}
6. Install the gasket and then cylinder head cover (66). 3 Mounting nut: 24 ± 4 Nm {2.4 ± 0.4 kgm} 7. Install blowby duct (51). 3 Blowby duct mounting bolt: 7 ± 2 Nm {0.71 ± 0.2 kgm}
q
Perform the subsequent installation in the reverse order to removal.
[*1] a Install muffler (14) to the exhaust pipe after applying thermosetting sealant to the entire external surfaces of both the end of the exhaust pipe and the exhaust pipe fitting end (E) of the muffler. 2 Muffler's surface E: Thermosetting sealant (Musashi Holts FIREGUM or equivalent)
a Replace clamp (12) with a new one. 3 Clamp bolt First time: 39.2 – 49 Nm {4.0 – 5.0 kgm} 2nd time: 68.6 – 122.5 Nm {7.0 – 12.49 kgm}
8. Install fuel drain hose (52). 3 Joint bolt: 24 ± 4 Nm {2.4 ± 0.4 kgm}
[*2] a For details, see Testing and adjusting, "Testing and adjusting tension of air conditioner compressor belt". [*3] 3 Radiator hose clamp: 10.8 – 11.8 Nm {1.1 – 1.2 kgm} [*4] 3 Bracket mounting bolt: 43 ± 6 Nm {4.4 ± 0.6 kgm}
PC228US-8, PC228USLC-8
50-39
Engine and cooling system Removal and installation of cylinder head assembly
[*5] q If four mounting bolts (26) of the air conditioner compressor are loosened, tighten them to the torque indicated below. a If the bolts are tightened to a torque greater than the specified, problems may occur with the internal components of the air conditioner compressor. 3 Air compressor mounting bolt :
27 – 34 Nm {2.8 – 3.5 kgm} [*6] q Install fan belt (31) according to the following procedure. 1. Install fan belt (31) on each of the pulleys. 2. Loosen tensioner assembly (30), then install fan belt (31) on the pulley of alternator assembly (32). a Insert a wrench in hole (A) (width across flats: 12.7 mm) in tensioner assembly (30) and turn the wrench counter clockwise (R) as viewed from the front of the engine. 3. Install fan belt (31) and return tensioner assembly (30) to the working position. k Turn the tensioner assembly only after mak-
ing sure that the wrench is fitted completely in hole (A) in tensioner assembly (30). (The tensioner assembly is loaded with strong spring tension. If the wrench is turned when it is incompletely fitted in the hole, the wrench could disengage from the hole, possibly leading to a very dangerous consequence.) k When returning tensioner assembly (30) to the working position after installing fan belt (31), be sure to return the tensioner assembly slowly and carefully. k During the fan belt installation operation, be fully careful so as not to pinch your fingers between the pulley and fan belt.
50-40
[*7] [*8] Installation of high-pressure pipes and common rail k Do not reuse the fuel injection pipe by bending it. k Be sure to use genuine fuel injection pipe clamps and tighten them to the specified torque. k After installing the fuel injection pipe, be sure to install the fuel spray prevention cap to cover the sleeve nut. k Ensure that the fuel spray prevention cap faces outward and downward. a Before installing the fuel injection pipe, check the following. q If the fuel injection pipe has a fault, it may leak the fuel. Accordingly, replace it with a new one. q Taper seal section (j): Check that there is no visible streaky slits (k) and spotty dimples (l) in the 2 mm distance area from the end. q Portion (m): Check that there is no steps (deformation) that your nail can feel in the 2 mm distance area from the end of the taper seal section. q
1) Install common rail and high-pressure pipe assembly (45) partially. 3 Sleeve nut and mounting bolt: 0.2 – 0.8 Nm {0.02 – 0.08 kgm} 2) Tighten high-pressure pipes (88) to (93) according to the following procedure. 3 Sleeve nut: 35 ± 3.5 Nm {3.6 ± 0.4 kgm} 1] Cylinder head ends of high-pressure pipes (88) and (93) 2] Common rail ends of high-pressure pipes (93) and (88) 3] Cylinder head ends of high-pressure pipes (89), (90), (91) and (92) 4] Common rail ends of high-pressure pipes (89), (90), (91) and (92)
PC228US-8, PC228USLC-8
Engine and cooling system Removal and installation of cylinder head assembly
3) Tighten the sleeve nut of high-pressure pipe (41) lightly. 4) Tighten the pump (35) end of high-pressure pipe first and then tighten its common rail end. 3 Sleeve nut: 35 ± 3.5 Nm {3.6 ± 0.4 kgm} 5) Tighten clamps (38) and (39) of high-pressure pipe (41). 3 Mounting bolt: 10 ± 2 Nm {1.0 ± 0.2 kgm} 6) Install the common rail by tightening four mounting bolts. a Coat the two bolt threads on the inner side of the engine with sealant (LG-7). 3 Mounting bolt: 24 ± 4 Nm {2.4 ± 0.4 kgm} 7) Install fuel spray prevention cap (40) on each high-pressure pipe. (14 caps) a Set the slit of each cap out and down. a The caps are installed so that fuel will not spout over the hot parts of the engine and catch fire if it leaks for some reason.
a Be sure to replace the sensor removed from the common rail with a new sensor. 1) Before removing the sensor, clean the area around it to remove dirt, etc. thoroughly 2) Remove the sensor. 3) Check the sensor connector for crack, damage, damaged seal, foreign matter at pin, corroded, bent or damaged pin, etc. 4) Install a new sensor. 2 Threaded part of fuel pressure sensor: Gear oil (#90) 3 Tightening torque: 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 there are no leaks. For details, see Testing and adjusting in the Engine Shop Manual. 2. If necessary, replace relief valve (3) according to the following procedure. 1) Before removing the relief valve, remove dirt the area surrounding the valve. 2) Remove the relief valve. 3) If the leakage through the relief valve exceeds the specified value, do not reuse that relief valve. 4) Check that there is no damage on high-pressure fuel sealing surfaces (A) on the relief valve and common rail. 5) Install the new relief valve. 2 Relief valve: Gear oil (#90) 3 Tightening torque: 100 ± 4 Nm {10.2 ± 0.4 kgm} Tightening too strongly can cause leakage. 6) Start the engine and check that there are no leaks. For details, see Testing and adjusting in the Shop Manual.
Handling of fuel pressure sensor and relief valve 1. If necessary, replace fuel pressure sensor (2) according to the following procedure. a Do not remove fuel pressure sensor (2) from common rail (1) unless replacement of the sensor is necessary.
q
PC228US-8, PC228USLC-8
50-41
Engine and cooling system Removal and installation of cylinder head assembly
q
When using a new hose Tighten the clamp so that BDG dimension is as follows. BDG: 7 – 10 mm
[*9]
3 Joint bolt:
24 ± 4 Nm {2.4 ± 0.4 kgm} [*10]
3 Mounting bolt:
24 ± 4 Nm {2.4 ± 0.4 kgm} [*11]
3 Fuel block mounting bolt:
32 ± 4 Nm {3.3 ± 0.4 kgm} [*12] k Install each high-pressure pipe and harness at least 10 mm apart from each other. [*13] 3 Air hose clamp: 10.0 – 11.0 Nm {1.02 – 1.12 kgm} [*14] q Reconnect the disconnected air tubes according to the following procedure. a Use a new MIKALOR clamp. 1) Set the hose to the original position (marked position). (Reference) Air hose fitting depth: 40 mm (turbocharger end) 65 mm (aftercooler end) 2) With bridge (BR) set under the clamp bolt, tighten the bolt so that bridge (BR) overlaps with the band by dimension (b) indicated below. Dimension (b): 5 mm or more 2 Threaded portion of clamp bolt (BC): Lubricating oil (THREEBOND PANDO 18B) a Do not use an impact wrench. q
[*15]
3 Mounting nut of lubricating oil inlet hose
for turbocharger 35 ± 5 Nm {3.57 ± 0.5 kgm} a When tightening the hose mounting nut, fix the connector on the turbocharger side securely by using a wrench since its tightening is low. a If the connector had been loosened with the nut, tighten the connector the following torque. 3 Connector: 36 ± 5 Nm {3.7 ± 0.5 kgm} (turbocharger side) 24 ± 4 Nm {2.4 ± 0.4 kgm} (oil cooler side) a If the stud bolt is removed, install it and tighten to the following torque. 3 Stud bolt: 24 ± 4 Nm {2.4 ± 0.4 kgm} 3 Mounting bolt of lubricating oil return tube for turbocharger: 24 ± 4 Nm {2.4 ± 0.4 kgm}
When reusing the hose Install the clamp to the clamp mark made on the hose. 2 Clamp bolt: 6 Nm {0.6 kgm}
50-42
PC228US-8, PC228USLC-8
Engine and cooling system Removal and installation of cylinder head assembly
[*16] a Tighten the bolts in the order shown below. 3 Exhaust manifold mounting bolt: First time: Tighten the bolts in the order of [1] to [12] to 24 ± 4 Nm {2.4 ± 0.4 kgm}. 2nd time: Tighten the bolts in the order of [1] to [12] to 53 ± 6 Nm {5.4 ± 0.6 kgm}. 3rd time: Tighten only bolts [1] to [4] in this order to 53 ± 6 Nm {5.4 ± 0.6 kgm}.
a Refilling with coolant Supply coolant through the coolant filler to the specified level. Run the engine to circulate the coolant through the system. Then, check the coolant level again. 5 Coolant: 21 l
PC228US-8, PC228USLC-8
50-43
Engine and cooling system Removal and installation of radiator assembly
Removal and installation of radiator assembly Removal 50-4 k Swing the upper structure 90 °, lower the work equipment to the ground and stop the engine. Gradually loosen the hydraulic oil tank cap to release the pressure inside the hydraulic oil tank. k Disconnect the cable from the negative (-) terminal of the battery.
3. Disconnect radiator hose (3).
[*1]
1. Remove cover (1).
4. Remove mounting bolt (5) of cover (4).
2. Drain the coolant through drain valve (2). 6 Coolant:
21 l
5. Remove aftercooler hose (6).
50-44
PC228US-8, PC228USLC-8
Engine and cooling system Removal and installation of radiator assembly
6. Disconnect clamp (7).
13. Remove radiator mounting bolts (15).
7. Remove mounting bolt (8) of cover (4). 8. Change the position of cover (4) upward.
(example of marking)
9. Open engine hood (9) and cover (10). 10. Remove cover (11).
14. Sling and remove radiator assembly (16). [*3] a Carefully lift the radiator assembly so that its lower part is not caught. 4 Radiator assembly: 15 kg
11. Disconnect reservoir tank hose (12). 12. Disconnect radiator hose (13) and aeration hose (14). [*2] a In order to show the original position of the hose, put a mark of the hose-end on the radiator. (See figure bottom)
PC228US-8, PC228USLC-8
50-45
Engine and cooling system Removal and installation of radiator assembly
Installation 50-46 q Perform installation in the reverse order to removal. [*1][*2] a Reference Hose installation depth: 45 mm (both upper and lower hoses) 3 Radiator hose clamp: 10.5 ± 0.5 Nm {1.07 ± 0.05 kgm} [*3] a Make sure that the insulation seal (sponge) at the radiator periphery is not damaged. a If the heat insulation seal (sponge) is damaged, replace it. a When installing the radiator assembly, carefully lower it to avoid the insulation seal (sponge) at the periphery from being damaged. a Check that the convex parts (A) at the bottom of the radiator properly fits with the concaved parts (B) of the machine from the undercover side.
q
Refilling with coolant Supply coolant through the coolant filler to the specified level. Run the engine to circulate the coolant through the system. Then, check the coolant level again. 5 Coolant: 21 l
50-46
PC228US-8, PC228USLC-8
Engine and cooling system Removal and installation of hydraulic oil cooler assembly
Removal and installation of hydraulic oil cooler assembly Removal 50-47 k Swing the upper structure 90 °, lower the work equipment to the ground and stop the engine. Gradually loosen the hydraulic oil tank cap to release the pressure inside the hydraulic oil tank. k Disconnect the cable from the negative (-) terminal of the battery.
4. Remove plug (6) to drain the remaining oil in the hydraulic oil cooler.
1. Open the inspection cover at the left rear and remove battery cover (2).
5. Disconnect hydraulic oil cooler tube block (7) from hydraulic oil cooler (8).
2. Remove batteries (3).
6. Open engine hood (9) and cover (10). 7. Remove cover (11).
3. Remove cover (5).
8. Disconnect tube block (12).
PC228US-8, PC228USLC-8
50-47
Engine and cooling system Removal and installation of hydraulic oil cooler assembly
9. Remove two hydraulic oil cooler mounting bolts (13). 10. Remove butterfly nut (14), then disconnect net (15) from the hydraulic oil cooler.
Installation 50-48 q Perform installation in the reverse order to removal. [*1] a Make sure that the insulation seal (sponge) at the hydraulic oil cooler periphery is not damaged. a If the heat insulation seal (sponge) is damaged, replace it. a When installing the hydraulic oil cooler assembly, carefully lower it to avoid the insulation seal (sponge) at the periphery from being damaged. a Check that the convex parts (A) at the bottom of the hydraulic oil cooler properly fits with the concaved parts (B) of the machine from the undercover side.
11. Sling and remove hydraulic oil cooler assembly (16). [*1] 4 Hydraulic oil cooler assembly: 22 kg
Refilling with oil (Hydraulic tank) a Before supplying oil, make sure that the oil cooler drain plug is securely tightened. a Supply hydraulic oil through the oil filler port to the specified level. Run the engine to circulate the oil through the piping. Then, check the oil level again.
q
50-48
PC228US-8, PC228USLC-8
Engine and cooling system Removal and installation of aftercooler assembly
Removal and installation of aftercooler assembly Removal k Swing the upper structure 90 °, lower the work equipment to the ground, then stop the engine. k Disconnect the cable from the negative (-) terminal of the battery.
50-49 5. Change the position of cover (5) upward.
1. Remove cover (1).
6. Open engine hood (7). 7. Remove covers (8) and (9). 8. Remove cover (10). 2. Remove aftercooler hose (3).
[*1]
9. Remove frame (11), and covers (12) and (13). 3. Disconnect clamp (4). 4. Remove mounting bolt (6) of cover (5).
PC228US-8, PC228USLC-8
50-49
Engine and cooling system Removal and installation of aftercooler assembly
10. Open cover (14).
15. Reposition hoses (23) to the radiator side.
11. Remove cover (15), and remove rubber (16).
16. Remove air hose (24).
12. Remove covers (17) and (18), and remove the hose clamp.
17. Remove two aftercooler mounting bolts (25).
13. Remove clamps (19) and (20).
18. Sling and remove aftercooler assembly (26). [ *2] 4 Aftercooler assembly: 12 kg
14. Remove hose clamps (21) and (22).
50-50
PC228US-8, PC228USLC-8
Engine and cooling system Removal and installation of aftercooler assembly
Installation Perform installation in the reverse order to removal.
q
[*1] a Install aftercooler hose (3) to the aftercooler assembly first, then install clamps (19) and (20).
PC228US-8, PC228USLC-8
50-51 [*2] a Make sure that the insulation seal (sponge) at the aftercooler periphery is not damaged. a If the heat insulation seal (sponge) is damaged, replace it. a When installing the aftercooler assembly, carefully lower it to avoid the insulation seal (sponge) at the periphery from being damaged. a Check that the convex parts (A) at the bottom of the aftercooler properly fits with the concaved parts (B) of the machine from the undercover side.
50-51
Engine and cooling system Removal and installation of engine assembly
Removal and installation of engine assembly Removal 50-52 k Lower the work equipment completely to the ground. After stopping the engine, gradually loosen the hydraulic oil tank cap to release the pressure inside the hydraulic oil tank. k Disconnect the cable from the negative (-) terminal of the battery. k Close the fuel stop valve. 1. Remove the main pump assembly. For details, see "Removal and installation of main pump assembly". 2. Remove cover (1), and remove rubber (2).
3. Remove drive belt (3) of the air conditioner compressor. [*1] 4. Disconnect radiator hose (4) and aeration hose (5). [*2] 5. Loosen two clamps (6) and disconnect aftercooler hose (2). 6. Disconnect heater hose (8). 7. Disconnect wiring connector AC02(9) from the air conditioner compressor. 8. Disconnect wiring clamp (10). 9. Remove three mounting bolts (11). [*3] a Do not loosen four air conditioner compressor mounting bolts (12). [*4] 10. Remove air conditioner compressor assembly (13). a Remove the air conditioner compressor assembly and the bracket as a unit and put them aside.
50-52
11. Remove the alternator according to the following procedure. 1) Disconnect wiring (14) and (15). 2) Slacken fan belt (17) by inserting wrench [1] in hole (A) (width across flats: 12.7 mm) in tensioner assembly (16) and turning the wrench counter clockwise (R) as viewed from the front of the engine. 3) Remove fan belt (17) from alternator assembly (18). k Turn the tensioner assembly only after making sure that wrench [1] is fitted completely in hole (A) in tensioner assembly (16). (The tensioner assembly is loaded with strong spring tension. If the wrench [1] is incompletely fitted in the hole, the wrench could disengage from the hole while the tensioner is being turned, possibly leading to a very dangerous consequence.)) k After removing fan belt (17), be sure to release wrench [1] slowly and carefully. k During the fan belt removal operation, be fully careful so as not to pinch your fingers between the pulley and fan belt (17).
PC228US-8, PC228USLC-8
Engine and cooling system Removal and installation of engine assembly
4) Remove the mounting bolts of the alternator to remove alternator assembly (18). 12. Remove fan (19). a Put the fan down.
[*5]
19. Disconnect fuel supply hose (32). 20. Disconnect two fuel filter hoses (33) and (34). a Press locks (L) on both sides of the connector to disconnect the hose. 21. Disconnect fuel return hose (35).
13. Loosen air hose clamp (20) and disconnect hose (21). [*6] 14. Loosen air tube clamp (22) and disconnect tube (23). [*7] 15. Loosen air hose clamp (24) and disconnect radiator hose (25). [*8]
22. Disconnect wiring connector CE02 (37) from engine controller (36). a Connector (37) is locked with a hexagonal socket head bolt L1(4 mm). 23. Press the locks to disconnect wiring connector CE03 (38). 24. Remove four grounding cables (39).
16. Disconnect hoses (26) and (27). 17. Disconnect engine ground cable (28). 18. Disconnect wiring connectors E08 (29), E10 (30) and (31).
PC228US-8, PC228USLC-8
50-53
Engine and cooling system Removal and installation of engine assembly
25. Disconnect hoses (40) and (41). 26. Separate elbows (42) and (43). 27. Remove four mounting bolts (44).
[*9] [*10]
28. Sling and remove engine assembly (45). a After checking that all wiring and piping connections are disconnected, lift the engine. a Using 3-point lifting method that allows for angle adjustment, slowly lift the engine while adjusting its position. 4 Engine assembly: 580 kg
Installation 50-54 q Perform installation in the reverse order to removal. [*1] a For details, see Testing and adjusting, "Testing and adjusting tension of air conditioner compressor belt". [*2] 3 Radiator hose clamp: 10.8 – 11.8 Nm {1.1 – 1.2 kgm} [*3] 3 Bracket mounting bolt: 43 ± 6 Nm {4.4 ± 0.6 kgm} [*4] q If four mounting bolts (12) of the air conditioner compressor are loosened, tighten them to the torque indicated below. a If the bolts are tightened to a torque greater than the specified, problems may occur with the internal components of the air conditioner compressor. 3 Air compressor mounting bolt :
27 – 34 Nm {2.8 – 3.5 kgm} [*5] Install fan belt (17) according to the following procedure. 1. Install fan belt (17) on each of the pulleys. 2. Loosen tensioner assembly (16), then install fan belt (17) on the pulley of alternator assembly (18). a Insert a wrench in hole (A) (width across flats: 12.7 mm) in the tensioner assembly (16), and turn it counter clockwise (R) viewed from the front of the engine. 3. Install fan belt (17) and return tensioner assembly (16) to the working position. k Turn the tensioner assembly only after making sure that the wrench is fitted completely in hole (A) in tensioner assembly (16). (Tensioner assembly (16) is loaded with large spring tension. If the wrench is turned when it is incompletely fitted in the hole, the wrench could disengage from the hole, possibly leading to a very dangerous consequence.) k When returning tensioner assembly (16) to the working position after installing fan belt (17), be sure to return the tensioner assembly slowly and carefully. k During the fan belt installation operation, be fully careful so as not to pinch your fingers between the pulley and fan belt. q
50-54
PC228US-8, PC228USLC-8
Engine and cooling system Removal and installation of engine assembly
[*6]
3 Air hose clamp:
[*9]
3 Hydraulic oil hose clamp:
10.0 – 11.0 Nm {1.02 – 1.12 kgm} [*7][*8] q Reconnect the disconnected air tubes according to the following procedure. a Use a new MIKALOR clamp. 1) Set the hose to the original position (marked position). (Reference) Air hose fitting depth: 40 mm (turbocharger end) 65 mm (aftercooler end) 2) With bridge (BR) set under the clamp bolt, tighten the bolt so that bridge (BR) overlaps with the band by dimension (b) indicated below. Dimension (b): 5 mm or more 2 Threaded portion of clamp bolt (BC): Lubricant (THREEBOND PANDO 18B) a Do not use an impact wrench. q
q
When reusing the hose Install the clamp to the clamp mark made on the hose. 3 Clamp bolt: 6 Nm {0.6 kgm}
128 – 186 Nm {13.0 – 19.0 kgm} [*10] a The bolt length of the engine front side is shorter than that of the rear side. a The engine mounting rubber size on the front side is smaller than that on the rear side.
3 Engine mount mounting bolt:
245 – 308.9 Nm {25 – 31.5 kgm} q
When using a new hose Tighten the clamp so that BDG dimension is as follows. BDG: 7 - 10 mm
Refilling with coolant Supply coolant through the coolant filler port to the specified level. Run the engine to circulate the coolant through the system. Then, check the coolant level again. 5 Coolant: 21 l
Refilling with oil (Hydraulic tank) Supply oil through the oil filter port to the specified level. Run the engine to circulate the oil through the piping. Then, check the oil level again. 5 Hydraulic tank: 126 l 3 Hydraulic tank drain plug: 58.8 – 78.5 Nm {6.0 – 8.0 kgm}
q
PC228US-8, PC228USLC-8
50-55
Engine and cooling system Removal and installation of engine front seal
Removal and installation of engine front seal
Symbol Part number
50-56
Part name
Necessity Q'ty New/redesign Sketch
Special tools
5 790-331-1120 Wrench (angle)
q 1
7 795-799-6400 Seal puller
t 1
A
Installation
50-56
1. By using tool A7, install front seal (3). a Before installing the seal, check that the end corners and lip sliding surfaces of the crankshaft are free from flaw, burr, and rust. a When installing the seal, do not apply oil or grease to the crankshaft and seal lip. Wipe off the oil from the crankshaft.
Removal 50-56 1. Remove the engine assembly. For details, see "Removal and installation of engine assembly". 2. Remove vibration damper mounting bolts (1), and remove vibration damper(2).
a Protrusion and facial runout of seal (3) from cover (C): q Protrusion x: 0.38 mm or less q Facial runout (TIR: Total Indicator Reading) y: 0.25 mm or less
3. Remove seal (3).
50-56
PC228US-8, PC228USLC-8
Engine and cooling system Removal and installation of engine front seal
2. Vibration damper 1) Align the hole in vibration damper (2) with dowel pin [a] on the crankshaft when installing the damper. 2) Bolts (1) tightening sequence: 1] Tighten diagonally to a torque of 55 ± 5 Nm {5.6 ± 0.5 kgm}. 2] Loosen bolts 180 °. 3] Tighten diagonally to a torque of 55 ± 5 Nm {5.6 ± 0.5 kgm}. 4] Re tighten the bolts 90 ± 5 ° For angle tightening, tool A5: wrench is available. (See the special tool list)
PC228US-8, PC228USLC-8
q
When an angle tightening tool is not used: Place marks on the vibration damper and the bolts using a marker pen, etc. Then re tighten the bolts 90 ° ± 5 °.
q
Perform the subsequent installation in the reverse order to removal.
50-57
Engine and cooling system Removal and installation of engine rear seal
Removal and installation of engine rear seal
Symbol Part number
A
50-58
Part name
8 795-799-6500 Seal puller
Necessity Q'ty New/redesign Sketch
Special tools
6. Sling and remove flywheel assembly (4). 4 Flywheel assembly:
[*2] 35 kg
t 1
Removal 50-58 1. Remove the main pump assembly. For details, see "Removal and installation of main pump assembly". 2. Remove mounting bolt (1) and set guide bolt [1]. 3. Remove damper assembly (2). 7. Remove the rear oil seal according to the following procedure. 1) Mount tool A8 on the crankshaft. 2) Screw-in tapping screw [1] of tool A8 into the seal carrier part of rear oil seal (5). 3) Turn the handle clockwise to remove rear oil seal (5).
4. Remove mounting bolts (3) and insert guide bolts [2]. [*1] a Width across flats: 18 mm 5. Sling flywheel assembly (4) and pull out it. a Be careful not to let the guide bolts drop out. a Take care in the removal so that the crankshaft is not damaged.
50-58
PC228US-8, PC228USLC-8
Engine and cooling system Removal and installation of engine rear seal
Installation 1. Install the oil seal according to the following procedure. a Do not remove pilot [5] attached to rear oil seal (5) until the seal is installed to the crankshaft. a Before installing the rear seal, degrease, clean and dry the seal contact surface on the crankshaft and the seal lip face to prevent oil leakage.
50-59 4. Using tool A8 to install rear oil seal (5) to an appropriate depth of flywheel housing (7). a Push in oil seal (5) while checking it for any bend. a Protrusion of rear oil seal from flywheel housing (7) X: 0.38 mm or less
2. Install pilot [5] to crankshaft (6), and push rear oil seal (5) into flywheel housing (7). 3. Push rear oil seal (5) further in and remove pilot [5].
q
PC228US-8, PC228USLC-8
Perform the subsequent installation in the reverse order to removal.
50-59
Engine and cooling system Removal and installation of engine rear seal
[*1] a Tighten the eight 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}
[*2] q
q
a Use plate [3] to prevent the flywheel assembly from rotating when tightening the bolts.
50-60
Measurement of radial runout a Radial runout: Max. 0.13 mm 1) Install dial gauge [4] on the stand, and set the stand on flywheel housing (7). 2) Make the probe of dial gauge contact with spigot joint portion (a) or outer circumference of the flywheel at a right angle. 3) Rotate the flywheel 360° and measure the maximum swing width of the dial gauge indicator. a Check that the dial gauge indicator is back in the original position after the flywheel is rotated 360 °. Measuring facial runout a Facial runout: 0.20 mm or less 1) Similarly to measurement of radial runout, make the probe of dial gauge contact at a right angle with the end face (b) near the outer circumference of the flywheel. a Conduct measurement pulling the crankshaft to either the front or rear side of the engine to prevent errors caused by backlash. 2) Rotate the flywheel 360° and measure the maximum swing width of the dial gauge indicator.
PC228US-8, PC228USLC-8
Engine and cooling system Removal and installation of fuel cooler assembly
Removal and installation of fuel cooler assembly Removal 50-61 k Disconnect the cable from the negative (-) terminal of the battery. a If the fuel is too much, drain the fuel in order to stop the fuel flow from the fuel tank return hose.
6. Remove fuel cooler (6).
1. Remove four mounting bolts (1) for the air conditioner condenser. 2. Put aside air conditioner condenser (2).
3. Remove rubber cover (3).
4. Disconnect two hoses (4). [*1] a Make sure to hold elbow [L] on the fuel cooler by using another spanner while disconnecting the hoses to avoid stressing the cooler. a If a spanner [1] is not used, stress will be applied to the cooler and the welded portions (M) may come apart. 5. Remove four fuel cooler mounting bolts (5).
PC228US-8, PC228USLC-8
50-61
Engine and cooling system Removal and installation of fuel cooler assembly
Installation 50-62 q Perform installation in the reverse order to removal. [*1] a Make sure to hold elbow [L] on the fuel cooler by using another spanner while connecting the hoses to avoid stressing the cooler. a If a spanner [1] is not used, stress will be applied to the cooler and the welded portions (M) may come apart.
50-62
PC228US-8, PC228USLC-8
Engine and cooling system Removal and installation of fuel tank assembly
Removal and installation of fuel tank assembly Removal 50-63 k When removing and installing the fuel tank assembly, lower the work equipment completely to the ground. k Disconnect the cable from the negative (-) terminal of the battery.
7. Disconnect fuel tank lower hoses (9), (10) and (11). [*1]
1. Remove the undercover of the fuel tank and drain the fuel from the fuel tank. 6 Fuel tank: 320 l (when tank is full) 2. Remove handrails (1) and (2). 3. Remove mirror (3). 4. Remove covers (4) and (5).
8. Remove additional pilot filter (12) for breaker.
5. Disconnect fuel level sensor connector P21 (6). 6. Remove fuel pre-filter (7) and bracket (8). a Reposition the fuel pre-filter and bracket toward the main pump so that they will not interfere with the fuel tank when removing the tank.
PC228US-8, PC228USLC-8
9. Remove hose clamps (13) and (14).
50-63
Engine and cooling system Removal and installation of fuel tank assembly
10. Remove the six mounting bolts. Sling and remove fuel tank assembly (15). [*2] 4 Fuel tank assembly: 130 kg
Installation 50-64 q Perform installation in the reverse order to removal. [*1]
2 Fuel tank hose (9) threads: 3 Fuel tank hose (9):
Liquid gasket (LG-5)
3.9 – 7.8 Nm {0.4 – 0.8 kgm}
3 Fuel tank hose (11):
54 – 93 Nm {5.5 – 9.5 kgm} [*2]
3 Fuel tank mounting bolt:
245 – 309 Nm {25.0 – 31.5 kgm}
50-64
PC228US-8, PC228USLC-8
Engine and cooling system Removal and installation of fuel tank assembly
PC228US-8, PC228USLC-8
50-65
Power train Removal and installation of travel motor and final drive assembly
Power train Removal and installation of travel motor and final drive assembly Removal 50-6 k Lower the work equipment completely to the ground. Referring to “Releasing residual pressure in hydraulic circuit” , release the residual pressure in the hydraulic circuit.
5. Sling and remove travel motor and final drive assembly (3). 4 Travel motor and final drive assembly: 380 kg
1. Remove the track shoe assembly. For details, see "Separation and connection of track shoe assembly". 2. Remove cover (1).
Installation 50-6 q Perform installation in the reverse order to removal. 3 Travel motor and final drive assembly mounting bolt: 265 – 309 Nm {27 – 31.5 kgm} (Average torque: Min. 275 Nm {28 kgm}) 3. Disconnect four travel motor hoses (2). q
Bleeding air Bleed air from the travel motor circuit. For details, see Testing and adjusting, “Bleeding air from each part” .
q
Refilling with oil Supply oil through the oil filler port to the specified level. Run the engine to circulate the oil through the system. Then, check the oil level again.
4. Sling travel motor and final drive assembly and remove eighteen mounting bolts (4) to remove the assembly.
50-66
PC228US-8, PC228USLC-8
Power train Disassembly and assembly of final drive assembly
Disassembly and assembly of final drive assembly
1 796-427-1200
Push tool
t 1
2 791-545-1510
Installer
t 1
796T-427-1220 Push tool
t 1
790-101-2510
Block
t 1
792-104-3940
Bolt
t 1
05180-11613
Nut
t 1
01613-31645
Washer
t 1
790-105-2100
Jack
t 1
790-101-1102
Hydraulic pump t 1
F 3
4 790-331-1110
Wrench
4. Washer Remove washer (2).
Sketch
Part name
Q'ty
Part number
New/redesign
Symbol
50-67 Necessity
Special tools
Q
5. No. 1 carrier assembly 1) Remove No. 1 carrier assembly (3).
t 1
Disassembly 50-67 1. Sprocket Remove 20 mounting bolts of the travel motor and final drive assembly to remove the sprocket. 4 Sprocket: 40 kg 2. Draining oil
Remove the drain plug to drain the oil from the final drive case. 6 Final drive: 5.4 l 3. Cover Remove 20 mounting bolts. Using eyebolts [1], sling and remove cover (1). a If ring gear (12) lifts off together with the cover, gently tap the ring gear off the cover by using a plastic hammer.
PC228US-8, PC228USLC-8
2) Disassemble the No. 1 carrier assembly according to the following procedure. 1] Drive pin (4) into pin (5) to remove pin (5) from carrier (6). a After removing pin (5), remove pin (4) from pin (5). 2] Remove thrust washer (7), No. 1 planetary gear (8), needle bearing (9), and thrust washer (10).
50-67
Power train Disassembly and assembly of final drive assembly
6. No. 1 sun gear shaft Remove No. 1 sun gear shaft (11).
7. No.1 & No. 2 ring gear Remove No. 1 & No. 2 ring gear (12). 8. Thrust washer Remove thrust washer (13). 9. No. 2 sun gear Remove No. 2 sun gear (14).
10. Washer Remove washer (15).
50-68
11. No. 2 carrier assembly 1) Remove No. 2 carrier assembly (16).
2) Disassemble the No. 2 carrier assembly 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 bearing (22), and thrust washer (23).
12. Lock 1) Remove lock (24). 2) Use tool F1 to remove lock (25).
PC228US-8, PC228USLC-8
Power train Disassembly and assembly of final drive assembly
13. Hub assembly 1) Using eyebolts [2], remove hub assembly (26).
Assembly 50-69 a Before assembly, clean the parts and ensure that they are free of dirt and damage and apply oil (T030) on their sliding surfaces. 1. Travel motor assembly 1) Install floating seal (31) to tool F2. a Install the floating seal after degreasing and drying the O-ring and O-ring contact surface completely.
2) Disassemble the hub assembly according to the following procedure. 1] Remove floating seal (27). 2] Remove ball bearings (28) and (29) from hub (30). 2) Install floating seal (31) to travel motor (32). a After installing the floating seal, check that its leaning is less than 1 mm. a After installing the floating seal, check that the sliding surface is free of dirt, and apply a thin film of oil (T030) to the surface.
14. Travel motor assembly Remove floating seal (31) from travel motor (32).
PC228US-8, PC228USLC-8
50-69
Power train Disassembly and assembly of final drive assembly
1) Assemble the hub assembly according to the following procedure. 1] Using the push tool, press fit ball bearings (29) and (28) into hub (30).
2) Using eyebolts [2], place hub assembly (26) on the travel motor. a If the hub assembly is difficult to install, use the push tool and lightly tap the bearing inner race to install.
2] Install floating seal (27) to tool F2. a Install the floating seal after degreasing and drying the O-ring and O-ring contact surface completely. 3] Install floating seal (27) on hub (30). a After installing the floating seal, check that its leaning is less than 1 mm. a After installing the floating seal, check that the sliding surface is free of dirt, and apply a thin film of oil (T030) to the surface.
3. Lock 1) Using tool F3, push the inner race of the ball bearing. q Specified pressing force: 8.8 – 12.7 N {0.9 – 1.3 tons} 2) While pressing the bearing, turn hub assembly (26) 2 to 3 turns. 3) In this state, measure distance a from the top face of the travel motor to the top face of the bearing inner race. a After measurement, remove tool F3.
2. Hub assembly
50-70
PC228US-8, PC228USLC-8
Power train Disassembly and assembly of final drive assembly
4) Measure thickness (b) of lock (25). 5) Based on measured values (a) and (b), calculate screw-in depth (c) for lock (25). q c = a - b - (0 to 0.1) 6) Using tool F1, screw in lock (25) to calculated depth (c). a Screw-in depth (c) corresponds to the distance from the upper face of the travel motor to the upper face of the lock.
7) Using push-pull scale [3], measure the tangential (starting) force of hub assembly (26). a Use a hole for a sprocket mounting bolt to measure the tangential (starting) force. q Tangential (starting) force: 294 N {30 kg} or less a If the measured tangential (starting) force is not to specification, disassemble the assembly and locate the cause.
8) Install lock (24). 2 Mounting bolt: Adhesive (LT-2) a Do not apply liquid adhesive to the screw holes for the lock. a Install the lock so that its splines are engaged with the splines of the travel motor.
4. No. 2 carrier assembly 1) Assemble the No. 2 carrier assembly according to the following procedure. 1] Install thrust washer (23), needle bearing (22), No. 2 planetary gear (21), and thrust washer (20) to carrier (19). a If a disassembled carrier is reused, the crimping damage left in pin hole (d) in the carrier must be repaired before reassembly. a Replace the thrust washer with a new part.
2] Install pin (18). a Before inserting the pin fully, align its hole with the hole of the carrier. a Install the shaft while turning the planetary gear and taking care not to damage the thrust washer.
PC228US-8, PC228USLC-8
50-71
Power train Disassembly and assembly of final drive assembly
3] Install pin (17). a Replace the pin with a new one. a Before inserting the pin, ensure that the pin is oriented such that three tabs (e) on the periphery of the pin do not catch the thin wall part of the carrier. a After inserting the pin, crimp the periphery of the pin hole at two places to prevent the pin from coming out. a After assembling the No. 2 carrier assembly, ensure that all gears can be turned smoothly.
2) Install No. 2 carrier assembly (16). a Position the No. 2 carrier assembly so that the four protrusions on the bottom of the pin engage with the four recesses in the motor case.
50-72
5. Washer Install washer (15). 6. No. 2 sun gear Install No. 2 sun gear (14). 7. Thrust washer Install thrust washer (13). 8. No. 1 sun gear shaft Install No. 1 sun gear shaft (11).
9. No.1 & No. 2 ring gear 1) Install the O-ring to the hub. 2) Using eyebolts [4], place No. 1 & No. 2 ring gear (12) on the hub. a Degrease the mating faces of the ring gear and hub. Do not apply liquid gasket on the mating faces. a Align the bolt holes of the ring gear with those of the hub.
PC228US-8, PC228USLC-8
Power train Disassembly and assembly of final drive assembly
10. No. 1 carrier assembly 1) Assemble the No. 1 carrier assembly according to the following procedure. 1] Install thrust washer (10), needle bearing (9), No. 2 planetary gear (8), and thrust washer (7) to carrier (6). a If a disassembled carrier is reused, the crimping damage left in pin hole (g) in the carrier must be repaired before reassembly. a Replace the thrust washer with a new one.
2) Install No. 1 carrier assembly (3). a Ensure that all gears are engaged correctly. If not, engage the gears correctly by wobbling the hub in the direction of rotation and back several times.
2] Install pin (5). a Before inserting the pin fully, align its hole with the hole of the carrier. a Install the shaft while turning the planetary gear and taking care not to damage the thrust washer. 3] Install pin (4). a Replace the pin with a new one. a Before inserting the pin, ensure that the pin is oriented such that three tabs (h) on the periphery of the pin do not catch the thin wall part of the carrier. a After inserting the pin, crimp the periphery of the pin hole at two places (i) to prevent the pin from coming out. a After assembling the No. 1 carrier assembly, ensure that all gears can be turned smoothly.
PC228US-8, PC228USLC-8
11. Washer Install washer (2). a Measure distance (j) from the top face of planetary gear (8) to the top face of ring gear (12). a If measurement (j) is not between 1.0 ± 0.51 mm, the assembly is assembled incorrectly.
50-73
Power train Disassembly and assembly of final drive assembly
12. Cover 1) Using eyebolts [1], install cover (1). 2 Mating faces of cover and ring gear: Liquid gasket (LG-6)
13. Refilling with oil Tighten the drain plug and supply power train oil (TO30) through the oil filler port. 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 mounting bolts. 2 Mounting bolt: Adhesive (LT-2) 3 Mounting bolt: 441 – 490 Nm {45 – 50 kgm}
2) Using tool F4, install the 20 mounting bolts. 3 Mounting bolt: 1st time: 147 Nm {15 kgm} 2nd time: 85 – 95° (re tightening angle)
50-74
PC228US-8, PC228USLC-8
Power train Removal and installation of swing motor and swing machinery assembly
Removal and installation of swing motor and swing machinery assembly Removal 50-75 k Lower the work equipment completely to the ground. Referring to “Releasing residual pressure in hydraulic circuit” , release the residual pressure in the hydraulic circuit. k Disconnect the cable from the negative (-) terminal of the battery. k Note the connector numbers and installed positions before disconnecting wiring and hoses.
4. Remove rubber partition plate (7) and frame (8).
1. Open engine hood (1). 2. Remove covers (2), (3) and frame (4).
5. Disconnect swing motor hoses (9) to (14). a Hoses are connected to the following ports: q (9) and (10): Main circuit (Ports MA and MB) q (11): Suction circuit (port S) q (12): Parking brake circuit (port B) q (13) and (14): Drain circuit (port T) a After suction and drain circuit hoses are disconnected, plug the hoses.
3. Remove covers (5) and (6).
PC228US-8, PC228USLC-8
50-75
Power train Removal and installation of swing motor and swing machinery assembly
6. Loosen the 12 mounting bolts. Sling and remove swing motor and swing machinery assembly (15). [*1] 4 Swing motor and swing machinery assembly: 240 kg
50-76
50-76 Installation q Perform installation in the reverse order to removal. [*1]
3 Swing motor and swing machinery
assembly mounting bolt: 490 – 608 Nm {50 – 62 kgm} q
Bleeding air Bleed air from the swing motor circuit. For details, see Testing and adjusting, “Bleeding air from each part” .
q
Refilling with oil Supply oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then, check the oil level again.
PC228US-8, PC228USLC-8
Power train Disassembly and assembly of swing machinery assembly
Disassembly and assembly of swing machinery assembly
1 796T-426-1410 Push tool 2 796-426-1120 Push tool G 796T-426-1130 Plate 3 790-101-5241 Grip 01010-81240 Bolt
t t t t t
1 1 1 1 1
3. No. 1 sun gear Remove No. 1 sun gear (2).
Sketch
Part name
New/redesign
Part number
Q'ty
Symbol
50-7 Necessity
Special tools
Q Q
Disassembly 50-7 1. Draining oil Remove the drain plug to drain the oil in the swing machinery case. 6 Swing machinery: 7.1 l
4. No. 1 carrier assembly 1) Remove No. 1 carrier assembly (3).
2. Swing motor assembly 1) Place the swing motor and swing machinery assembly on block [1]. 2) Remove the six mounting bolts to remove swing motor assembly (1). 4 Swing motor assembly: 70 kg
2) Disassemble the No. 1 carrier assembly according to the following procedure.
1] Remove snap ring (4). Remove thrust washer (5), No. 1 planetary gear (6), needle bearing (7), and thrust washer (8) from carrier (30). 2] Remove washer (9). 3] Remove snap ring (31). Using a press, remove pin (32). q Pin pressing force for assembly (reference): 11.2 – 25.8 kN {1,140 – 2,630 kg}
PC228US-8, PC228USLC-8
50-77
Power train Disassembly and assembly of swing machinery assembly
7. No. 2 carrier assembly 1) Loosen mounting bolt (12) for the No. 2 carrier assembly. 2) Remove No. 2 carrier assembly (13).
5. No.1 & No. 2 ring gear Loosen the 18 mounting bolts and remove No. 1 & No. 2 ring gear (10). 3) Disassemble the No. 2 carrier assembly according to the following procedure. 1] Drive pin (14) into pin (15) to remove pin (15) from carrier (16). a After removing pin (15), remove pin (14) from pin (15). 2] Remove thrust washer (17), No. 2 planetary gear (18), needle bearing (19), and thrust washer (20). 3] Remove plate (21).
6. No. 2 sun gear Remove No. 2 sun gear (11).
50-78
PC228US-8, PC228USLC-8
Power train Disassembly and assembly of swing machinery assembly
8. Shaft and case assembly 1) Remove mounting bolts (23). 2) Install the shaft and case assembly on the press. Using push tool [2], remove shaft assembly (24) from case assembly (25).
3) Disassemble the shaft assembly according 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-8, PC228USLC-8
9. Bearing Using the push tool, remove bearing (35) from case (36).
Assembly 50-79 a Before assembly, clean the parts and ensure that they are free of dirt and damage and apply engine oil on their sliding surfaces. a Do not reuse the disassembled bearings and oil seals. 1. Bearing Using push tool [5], press fit bearing (27) to case (36). a Use new bearing (27).
50-79
Power train Disassembly and assembly of swing machinery assembly
2. Cover assembly 1) Set oil seal (29) horizontally on cover (34). 2) Using push toolG3, press fit oil seal (29) to cover (34). a Use new oil seal (29). 2 Outer periphery of oil seal: Liquid gasket (LG-6) a Take care not to stick the liquid gasket (LG-6) to the oil seal lip at the time of press fitting. a If push tool G3 is not available, use a push tool that can evenly push periphery A of the oil seal. a Check that oil seal (29) is not leaned.
3) Install cover assembly (26) to case (36) and tighten mounting bolts (23). a Match the drain ports. 2 Cover mounting face: Liquid gasket (LG-6) a When applying the liquid gasket, 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)
3. Shaft and case assembly 1) Set case assembly (25) on shaft (28). a Take care not to damage the oil seal.
50-80
PC228US-8, PC228USLC-8
Power train Disassembly and assembly of swing machinery assembly
2) Using push Tool G1 and tool [8], tap while taking care not to drop the shaft. a Keep sling [9] loose.
3) Set the assembly to the press. 4) Using push tool G1 and tools [8] and [10], press fit the bearing inner race. a Press-fit force: Several tons a Keep push tool [10] so that it can be used in the event that case assembly (25) tilts severely. a Keep case assembly (25) in a horizontal position by lightly tapping the case flange as required. a Bring case assembly (25) to a horizontal position so that oil seal lip contact surface B of shaft (28) is located in the centre of oil seal (29).
PC228US-8, PC228USLC-8
4. Sub-bearing Using tool G2, press fit bearing (35). a Use new bearing (35). a Press the bearing inner race and outer race simultaneously. q Bearing press fit force (reference): Inner race: 9.4 - 26.6 kN {960 - 2,710 kg} Outer race: 0 - 8.9 kN {0 - 910 kg} a After press-fitting the bearing, check that the case rotates smoothly.
50-81
Power train Disassembly and assembly of swing machinery assembly
5. No. 2 carrier assembly 1) Assemble No. 2 carrier assembly according to the following procedure. 1] Install plate (21) to carrier (16). a If a disassembled carrier is reused, the crimping damage left in pin hole (b) in the carrier must be repaired before reassembly. 2] Install thrust washer (20), needle bearing (19), No. 2 planetary gear (18), and thrust washer (17). a Install the shaft while turning the planetary gear and taking care not to damage the thrust washer.
2) Install No. 2 carrier assembly (13). 3) Tighten mounting bolt (12) for No. 2 carrier assembly (13). 2 Mounting bolt: Adhesive (LT-2) 3 Mounting bolt: 157 - 196 Nm {16 – 20 kgm}
6. No. 2 sun gear 1) Install No. 2 sun gear (11). 2) Install the O-ring to the case.
3] Install pin (15). a Before inserting the pin fully, align its hole with the hole of the carrier. a Install the shaft while turning the planetary gear and taking care not to damage the thrust washer. 4] Install pin (14). a After inserting the pin, crimp the periphery of the pin hole at two places (c) to prevent the pin from coming out.
50-82
PC228US-8, PC228USLC-8
Power train Disassembly and assembly of swing machinery assembly
7. No.1 & No. 2 ring gear Using eyebolts, install No. 1 & No. 2 ring gear (10). a Degrease the mating faces of the ring gear and case. a Do not stick liquid gasket to the mating faces of the ring gear and case. a Ensure that concave (d) on the top face of ring gear (10) is engaged with cast convex (e) on the case periphery. a Install the washer. 3 Mounting bolt: 157 – 196 Nm {16 – 20 kgm}
3] Press pin (32) in the direction opposite to that in Step 1]. a Push back the pin until the snap ring is tight on the end face of the carrier. Use care not to push back the pin too much.
4] Install washer (9) to carrier (30). 5] Install thrust washer (8), needle bearing (7), planetary gear (6), and thrust washer (5). Install snap ring (4) to fix them in position.
2) Install No. 1 carrier assembly (3). 8. No. 1 carrier assembly 1) Assemble the No. 1 carrier assembly according to the following procedures. 1] Using the press, press fit pin (32) into carrier (30). a Press fit the pin until the snap ring groove on the one side comes out of the opposite side of the carrier. q Press fit force of pin (reference): 11.2 - 25.8 kN {1,140 - 2,630 kg} 2] Install snap ring (31).
PC228US-8, PC228USLC-8
50-83
Power train Disassembly and assembly of swing machinery assembly
9. No. 1 sun gear Install No. 1 sun gear (2). a Install the No. 1 sun gear with longer stepped portion (g) up.
11. Oil level gauge a Observe the following points when installing the oil level gauge. 1) Make adjustments so that the end of the gauge is located as shown in the figure below. 2) If the oil level gauge interferes with other parts after installation on the machine, loosen the clip and tube sleeve nuts and reposition the gauge to avoid interference. 3 Clip nut: 59 – 74 Nm {6.0 – 7.5 kgm} 3 Tube sleeve nut: 42.1 – 70.6 Nm {4.3 – 7.2 kgm}
10. Swing motor assembly Install the O-ring to ring gear (10), then install swing motor assembly (1). a Degrease the mating faces of the swing motor and ring gear. a Install the swing motor assembly with face (f) having ports MA and MB facing cast convex (e) on the case periphery. 3 Mounting bolt: 59 – 74 Nm {6.0 – 7.5 kgm} q
50-84
Refilling with oil Tighten the drain plug and supply power train oil through the oil filler. 5 Swing machinery: 7.1 l
PC228US-8, PC228USLC-8
Power train Removal and installation of swing circle assembly
Removal and installation of swing circle assembly Removal 50-85 1. Remove the revolving frame assembly. For details, see "Removal and installation of revolving frame assembly".
Installation 50-85 q Perform installation in the reverse order to removal. [*1]
2. Remove swing circle assembly mounting bolts (1) and sling swing circle assembly (2). [*1] a Leaving one mounting bolt each at the front and rear parts, sling the swing circle assembly by 3-point lifting method. 3. Remove the remaining mounting bolts to remove swing circle assembly (2). [*2] 4 Swing circle assembly: 270 kg
PC228US-8, PC228USLC-8
2 Mounting bolt of swing circle assembly:
Adhesive (LT-2)
3 Revolving frame assembly mounting bolt:
1st time: 191.2 ± 19.6 Nm {19.5 ± 2 kgm} 2nd time: 48 ± 5° (re tightening angle) [*2] a When installing the swing circle assembly, position the outer race to the track frame by aligning the dowel pin and hole. a After installing the swing circle assembly, align the inner race soft zone position (stamped "S" on top surface) with the outer race soft zone position (at a where the ball is inserted).
50-85
Undercarriage and frame Separation and connection of track shoe assembly
Undercarriage and frame Separation and connection of track shoe assembly
Symbol 1 N
2 3
Part number
50-86
Part name
791-630-3000 Remover Cylinder 790-101-1300 (980 kN {100 tons}) 790-101-1102 Hydraulic pump
Necessity Q'ty New/redesign Sketch
Special tools
[*2] a After removing the pin, leave the temporary pin, and remove tool N.
t 1 t 1 t 1
Separation 50-86 1. Position the track with the master pin at a position between the idler and front track roller so that the separated track can be spread toward the front and rear. Swing the upper structure 90° and stop the engine. a Each track has two master pins and each master pin has a hole in its end face. 2. Loosen valve (1) to loosen the track tension. [*1]
k Since the internal pressure of the adjust-
ment cylinder is very high, do not loosen the valve more than one turn. If the grease does not come out sufficiently, start the engine and move the machine forward and in reverse.
50-86
3. By using tool N, remove master pin (2).
4. Run the engine and move the machine forward until the temporary pin [1] is positioned in front of the idler. Place blocks [2] under the track. 5. Remove temporary pin [1] and remove the dust seal. [*3] 6. Move the machine slowly in reverse to spread track assembly (3).
PC228US-8, PC228USLC-8
Undercarriage and frame Separation and connection of track shoe assembly
Connection 50-87 Perform connection in the reverse order to separation.
q
[*1] a For details, see Testing and adjusting, “Testing and adjusting track tension”. [*2] a By using tool N, press fit the master pin until the pin protrusion (a) reaches the specified dimension. q Pin protrusion (a): 2.5 ± 1 mm (each side)
[*3] a When installing the dust seal, apply grease (G2-LI) to the contact surfaces on the dust seal and bushing (do not apply grease to the mounting face on the bushing to the link). a Precaution for road liner type track shoe: If the rubber of road liner type track shoe (rubber pad type) is worn and broken to damage the mounting bolt heads, replace the shoe with new one immediately. If the bolt heads are crushed, the bolts cannot be replaced.
PC228US-8, PC228USLC-8
50-87
Undercarriage and frame Removal and installation of idler and idler cushion assembly
Removal and installation of idler and idler cushion assembly Removal 50-8 1. Remove the track shoe assembly. For details, see "Separation and connection of track shoe assembly". 2. By using a prybar [1], move the idler and idler cushion assembly (1) forward to a position where it can be lifted.
3. Sling the idler and idler cushion assembly (1), pull it forward to remove from track frame (2). 4 Idler and idler cushion assembly: Approx. 240 kg
50-88
4. Disconnect idler cushion assembly (4) from idler assembly (3). 4 Idler assembly: 110 kg 4 Idler cushion assembly: 130 kg
Installation 50-8 q Perform installation in the reverse order to removal.
PC228US-8, PC228USLC-8
Undercarriage and frame Disassembly and assembly of idler assembly
Disassembly and assembly of idler assembly
Symbol
Part number
J
791-530-1510
50-89
Part name
Installer
Necessity Q'ty New/redesign Sketch
Special tools
t 1
Disassembly q Structural illustration
50-89
3. Remove idler (4) from the assembly of shaft (5) and support (7). a Since 250 ml of oil is charged in the idler, drain the oil at this time point or lay rags to prevent contamination. 4. Remove floating seals (6) on the opposite side from idler (4) and the assembly of shaft (5) and support (7).
5. Remove dowel pin (8) to remove support (7) from shaft (5). 6. Remove bushings (9) and (10) from idler (4).
1. Remove dowel pin (1) to dismount support (2). 2. Remove floating seals (3) from support (2) and idler (4).
PC228US-8, PC228USLC-8
50-89
Undercarriage and frame Disassembly and assembly of idler assembly
Assembly q Structural illustration
50-90
2. Install support (7) with the O-ring to shaft (5) by using dowel pin (8).
3. By using tool J, install floating seals (6) to idler (4) and the assembly of shaft (5) and support (7). a Completely clean, degrease and dry the contact surfaces (hatched area in the drawing) of the floating seal and the O-ring. a Apply oil to the sliding surface of the floating seal, and take care not to have any dirt stuck on it. a After inserting the floating seal, check that the leaning of the seal is less than 1 mm and that the protrusion (a) is within the range of 7 – 11 mm.
1. Press fit bushings (9) and (10) to idler (4).
50-90
PC228US-8, PC228USLC-8
Undercarriage and frame Disassembly and assembly of idler assembly
4. Install the assembly of shaft (5) and support (7) to idler (4).
6. Install support (2) with the O-ring to the shaft by using dowel pin (1). a See structural illustration. 7. Supply oil and tighten the plug. 5 Quantity of oil: 245 – 255 cc (EO30-DH) 3 Plug: 205.8 ± 49 Nm {21 ± 5 kgm}
5. By using tool J (above-mentioned), install floating seals (3) to idler (4) and support (2). a Completely clean, degrease and dry the contact surfaces (hatched area shown in the drawing) of the floating seal and the O-ring. a Apply oil to the sliding surface of the floating seal, and take care not to have any dirt stuck on it. a After inserting the floating seals, check that the leaning of the seal is less than 1 mm and protrusion (a) is within the range of 7 - 11 mm.
PC228US-8, PC228USLC-8
50-91
Undercarriage and frame Disassembly and assembly of idler cushion assembly
Disassembly and assembly of idler cushion assembly
791-600-2001 Compressor (A) or 791-685-8006 Compressor (B) 790-201-2780 Spacer 1 791-635-3160 Extension Cylinder 790-101-1600 (686 kN {70 ton}) 790-101-1102 Pump M 790-640-2180 Guide bolt 790-101-5201 Push tool kit (B) 790-101-5241 q Plate 2 790-101-5221 q Grip 01010–51225 q Bolt 790-201-1500 Push tool kit 790-201-1620 q Plate 3 790-101-5021 q Grip 01010-50816 q Bolt
Disassembly q Structural illustration
t 1
Sketch
New/redesign
Part name
Q'ty
SymPart number bol
50-92 Necessity
Special tools
1. Remove piston assembly (2) from idler cushion assembly (1). 2. Disassembling idler cushion assembly 1) Install tool M1 to idler cushion assembly (1). k The tool must be installed correctly as the load at installed length of the spring is large and dangerous. a Load at installed length: 126 kN {12,900 kg}
t 1 t 1 t 1 t 1 t 1 q 1 1 1 2 q 1 1 1 2
50-92 2) Apply hydraulic pressure gradually to compress the spring and remove lock plate (3) and nut (4). a Compress the spring up to the point where the nut gets loose. a Release the hydraulic pressure slowly to release the tension of the spring. a Free length of spring: 561 mm 3) Remove yoke (6) and cylinder (7) from spring (5). 4) Remove snap ring (8), dust seal (9) and bushing (10), in turn from cylinder (7). 3. Disassembling piston assembly (2) 1) Remove lock plate (12) from piston (11), and then valve (13). 2) Remove snap ring (14), then remove U-packing (15) and ring (16).
50-92
PC228US-8, PC228USLC-8
Undercarriage and frame Disassembly and assembly of idler cushion assembly
Assembly Structural illustration
50-93
q
1. Assembling piston assembly (2) 1) Install ring (16) and U-packing (15) to piston (11), and secure them with snap ring (14). 2) Tighten valve (13) lightly, and secure it with lock plate (12). 2. Assembling idler cushion assembly 1) Using tool M2, press fit bushing (10) into cylinder (7). 2) Using tool M3, install dust seal (9) to cylinder (7). 3) Secure them by using snap ring (8).
4) Install cylinder (7) and yoke (6) to spring (5). Install the assembly to tool M1. 2 Sliding surface of cylinder: Grease (G2-LI)
5) Slowly apply hydraulic pressure to compress the spring. Tighten nut (4) until the installed length of the spring reaches dimension (a). Install lock plate (3). a Installed length (a) of spring: 433 mm
6) Remove idler cushion assembly (1) from tool M1. 3. Install piston assembly (2) to the idler cushion assembly (1). 2 Sliding surface of cylinder: : Grease (G2-LI) 2 Wear ring: Grease (G2-LI) a Install the piston assembly with the valve installed position outward. a Pump 300 cc of grease (G2-LI) into the cylinder and bleed air. Check that grease comes out of the grease hole.
PC228US-8, PC228USLC-8
50-93
Undercarriage and frame Disassembly and assembly of track roller assembly
Disassembly and assembly of track roller assembly
Symbol K
Part number
50-94
Part name
796-670-1020 Installer
Necessity Q'ty New/redesign Sketch
Special tools
2. Install collar (8) with the O-ring to shaft (5), and install pin (7).
t 1
Disassembly 1. Remove pin (1), then remove collar (2).
Assembly 50-94 1. Using push tool [1], press fit bushings (9) and (10) to roller (4).
50-94
2. Remove floating seals (3) from collar (2) and roller (4). 3. Remove roller (4) from the assembly of shaft (5) and collar (8). a Since 195 ml of oil is charged in the roller, drain the oil at this time point or lay rags to prevent contamination. 4. Remove floating seals (6) on the opposite side from roller (4), and the assembly of shaft (5) and collar (8). 5. Remove pin (7) and then collar (8) from shaft (5). 6. Remove bushings (9) and (10) from roller (4).
50-94
PC228US-8, PC228USLC-8
Undercarriage and frame Disassembly and assembly of track roller assembly
3. By using tool K, install floating seal (6a) to collar (8). a Completely clean, degrease and dry the contact surfaces (hatched area in the drawing). And take care not to have any dirt stuck on the contact surfaces. a After inserting the floating seals, check that the leaning is less than 1 mm and the protrusion (a) is within the range of 7 - 11 mm.
5. Install shaft (5) to roller (4). 6. Turn over the assembly of roller (4) and shaft (5).
4. By using tool K, install floating seals (6b) and (3b) to roller (4). a As to precautions for installation of floating seals (6b) and (3b), refer to a marked comments in step 3.
7. By using tool K, install floating seal (3a) to collar (2). a As to precautions for installation of floating seal (3a), refer to a marked comments in step 3. a Apply oil to the sliding surface of the floating seal, and take care not to have any dirt stuck on it. 8. Install collar (2) with the O-ring to the shaft with pin (1).
9. Supply oil and tighten the plug. 5 Quantity of oil: 190 – 200 cc (E030-DH) 3 Plug: 15 ± 1.5 Nm {1.5 ± 0.5 kgm}
PC228US-8, PC228USLC-8
50-95
Undercarriage and frame Disassembly and assembly of carrier roller assembly
Disassembly and assembly of carrier roller assembly
Symbol L
Part number
50-96
Part name
790-434-1660 Installer
Necessity Q'ty New/redesign Sketch
Special tools
a Shaft (2) and cover (3) under the shaft are removed as a unit.
t 1
Sectional view a A number in the drawing is the number shown in the text.
q
3. Remove ring (5) from roller (4). 4. Remove floating seal (6) from ring (5). a Take care not to damage the sealing surface.
Disassembly 50-96 1. Remove plug (9) and drain the oil from carrier roller (1). 6 Carrier roller : 75 – 85 ml
5. Remove floating seal (7) from roller (4). a Take care not to damage the sealing surface.
2. Using push tool [1], push the end surface of the shaft to remove shaft (2) from carrier roller (1) to separate followings. q The assembly of roller (4) and ring (5), shaft (2) and cover (3). q Press fit force (reference): 59 kN {6,000 kg} or more. a The press fit between shaft (2) and ring (5), and also between roller (4) and cover (3) are disengaged.
50-96
PC228US-8, PC228USLC-8
Undercarriage and frame Disassembly and assembly of carrier roller assembly
6. Using push tools [2] and [3], remove bushing (8) from roller (4).
Assembly 50-97 1. Using push tools [3] and [4], press fit bushing (8) to roller (4). a Press fit it from the side of cover (3)
2. Floating seal 1) By using tool L, install floating seal (7) to roller (4). 2) By using tool L, install floating seal (6) to ring (5). a Completely clean, degrease and dry the contact surfaces (hatched area in the drawing) of the floating seal and the O-ring. And take care not to have any dirt stuck on the contact surfaces. a When installing floating seals, use tool L and make sure to press the O-ring. a After inserting the floating seal, check that the leaning is less than 1 mm and that the protrusion (a) is within the range of 7 – 11 mm.
PC228US-8, PC228USLC-8
50-97
Undercarriage and frame Disassembly and assembly of carrier roller assembly
3. Install roller (4) and ring (5) to shaft (2). a Apply oil to the sliding surface of the floating seal, and take care not to have any dirt stuck on it.
4. Place washers [7] between push tool [6] and roller (4). Press fit ring (5) to shaft (2) until the height difference of roller (4) and ring (6) becomes 1.8 ± 0.2 mm. a Thickness of washer [7] = 1.8 ± 0.2 mm a Use push tool [5] to support shaft (2) on it.
50-98
5. Using push tool [8], press fit cover (3) to roller (4). a Degrease, wash and dry the surfaces where roller (4) and cover (3) fit tight. q Press-fit force (reference) 59 kN {6,000 kg} or more.
6. Fill carrier roller assembly (1) with oil and tighten plug (9). 5 Carrier roller : 75 – 85 cc (E030-DH) 3 Plug: 15 ± 5 Nm {1.5 ± 0.5 kgm}
PC228US-8, PC228USLC-8
Undercarriage and frame Removal and installation of revolving frame assembly
Removal and installation of revolving frame assembly Removal 50-9 1. Remove the counterweight assembly. For details, see "Removal and installation of counterweight assembly".
5. Remove boom cylinder assembly (3). 4 Boom cylinder assembly (x1): 70 kg (Standard specification) 190 kg (Demolition specification)
2. Remove the work equipment assembly. For details, see Removal and installation of work equipment assembly. 3. Disconnect four boom cylinder hoses (1).
6. Disconnect upper hoses (4) - (9) from the swivel joint. [*1] a Before disconnecting the hoses, put tags to them and write the mounting positions.
4. Remove bottom pin (2).
7. Remove the pin from stopper plate (10) and disconnect the stopper plate from the swivel joint.
PC228US-8, PC228USLC-8
50-99
Undercarriage and frame Removal and installation of revolving frame assembly
8. Sling revolving frame assembly (11). a Use two counterweight mounting bolt holes and two boom foot pin holes as lifting points to sling the revolving frame assembly by 4-point lifting method. 9. Remove the 36 mounting bolts to remove revolving frame assembly (11). [*2] a All the mounting bolts are installed from underside of the outer race of the swing circle. a Leaving two or three mounting bolts at the front and rear parts, adjust the balance of the revolving frame by using lever blocks, etc. Then, remove those mounting bolts. k When removing the revolving frame assembly, take care so that it does not interfere with the centre swivel joint. 4 Revolving frame assembly: 4,700 kg (Standard specification) 4,900 kg (Demolition specification)
Installation 50-10 q Perform installation in the reverse order to removal. [*1] a Before installing the swivel joint on the machine, connect the drain hose between swivel joint and swing motor to the swivel joint side. [*2]
2 Revolving frame assembly mounting bolt:
Adhesive (LT-2)
3 Revolving frame assembly mounting bolt:
1st time: 294.2 ± 29.4Nm {30 ± 3kgm} 2nd time: 60 ± 6°(retightening angle) q
Bleeding air
Bleed air from the travel motor circuit. For details, see Testing and adjusting , "Air bleeding from each part". q
Refilling with oil
Supply oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then, check the oil level again.
50-100
PC228US-8, PC228USLC-8
Undercarriage and frame Removal and installation of counterweight assembly
Removal and installation of counterweight assembly
Z
Commercially Impact wrench available Socket wrench Commercially (Width across flats: available 65 mm)
Sketch
New/redesign
Part name
Q'ty
Sym Part number bol
50-101 Necessity
Special tools
q 1 q 1
a Use the impact wrench and socket wrench with a torque enough for tightening the counterweight mounting bolts.
5. Disconnect rear camera wiring connector A40 (8). 6. Remove wiring clamp (9). 7. Remove radiator hose clamps (10). 8. Remove air conditioner compressor hose clamp (11). 9. Remove fuel filter and bracket assembly (12), and reposition it forward so that it does not interfere with the maintenance counterweight assembly.
Removal 50-101 k Perform removal work with the machine parked on a flat surface and the work equipment completely lowered on the ground. 1. Open engine hood (1). 2. Remove cover (2). 3. Remove cover (3). 4. Remove frame (4). 10. Disconnect rear lamp wiring connector A15 (13).
PC228US-8, PC228USLC-8
50-101
Undercarriage and frame Removal and installation of counterweight assembly
11. Open the right rear inspection cover and remove hose connector (14).
Installation 50-102 q Perform installation in the reverse order to removal. [*1]
2 Mounting bolt: 3 Mounting bolt:
Adhesive (LT-2)
3,430 – 4,217 Nm {350 – 430 kgm}
12. Sling counterweight assembly (15). 13. Using tool Z, remove the mounting bolts. Remove counterweight assembly (15). [*1] a Remove the counterweight assembly carefully so that it does not hit the machine. 4 Counterweight (15): 6,040 kg (Standard specification) 7,360 kg (Demolition specification)
50-102
PC228US-8, PC228USLC-8
Undercarriage and frame Removal and installation of maintenance counterweight assembly
Removal and installation of maintenance counterweight assembly Removal 50-103 k Perform removal work with the machine parked on a flat surface and the work equipment completely lowered on the ground.
8. Remove fuel filter and bracket assembly (12), and reposition it forward so that it does not interfere with the maintenance counterweight.
1. Open engine hood (1). 2. Remove cover (2). 3. Remove cover (3).
9. Disconnect rear lamp wiring connector A15 (13). 10. Sling engine hood (14) and remove mounting bolts (15). 11. Sling and remove engine hood (14). 4 Engine hood: 35 kg 4. Disconnect rear camera wiring connector A40 (8). 5. Remove wiring clamps (9). 6. Remove radiator hose clamp (10). 7. Remove air conditioner compressor hose clamp (11).
PC228US-8, PC228USLC-8
50-103
Undercarriage and frame Removal and installation of maintenance counterweight assembly
12. Disconnect air conditioner compressor wiring connector AC02 (16).
Installation 50-104 q perform installation in the reverse order to removal.
13. Loosen mounting bolts (19) and reposition air conditioner compressor assembly (17) forward so that it does not interfere with maintenance counterweight assembly (18).
14. Remove cushion (20). 15. Remove maintenance counterweight assembly mounting bolts (21).
16. Sling and remove maintenance counterweight assembly (18). 4 Maintenance counterweight assembly: 500 kg
50-104
PC228US-8, PC228USLC-8
Undercarriage and frame Removal and installation of maintenance counterweight assembly
PC228US-8, PC228USLC-8
50-105
Hydraulic system Removal and installation of centre swivel joint assembly
Hydraulic system Removal and installation of centre swivel joint assembly Removal 50-106 k Lower the work equipment completely to the ground. Referring to “Releasing residual pressure in hydraulic circuit” , release the residual pressure in the hydraulic circuit. k Disconnect the cable from the negative (-) terminal of the battery. k Note connector numbers and installed positions before disconnecting wiring and hoses.
4. Remove rubber partition plate (7) and frame (8).
1. Open engine hood (1). 2. Remove covers (2) and (3), and frame (4).
5. Disconnect swing motor hoses (9) to (14). a Hoses are connected to the following ports: q (9) and (10): Main circuit (ports MA and MB) q (11): Suction circuit (port S) q (12): Parking brake circuit (port B) (13) and (14): Drain circuit (port T) a After suction and drain circuit hoses are disconnected, plug the hose.
3. Remove covers (5) and (6).
50-106
PC228US-8, PC228USLC-8
Hydraulic system Removal and installation of centre swivel joint assembly
6. Remove six mounting bolts. Sling and remove swing motor assembly (7). [*1] 4 Swing motor assembly: 60 kg
7. Disconnect upper hoses (16) to (21) from the swivel joint. [*2] a Before disconnecting the hoses, put tags to them and write the installed positions. 8. Remove the pin from stopper plate (22) and disconnect the stopper plate from the swivel joint.
PC228US-8, PC228USLC-8
9. Disconnect lower hoses (23) to (30) from the swivel joint.
10. Remove four mounting bolts and remove centre swivel joint assembly (31). [*3] 4 Centre swivel joint assembly: 40 kg
50-107
Hydraulic system Removal and installation of centre swivel joint assembly
Installation 50-108 q Perform installation in the reverse order to 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 drain hose between the swivel joint and swing motor to the swivel joint side. [*3]
3 Centre
swivel joint assembly mounting
bolt: 98.1 – 122.6 Nm {10 – 12.5 kgm} q
Bleeding air Bleed air from the travel motor circuit. For details, see Testing and adjusting, “Bleeding air from each part” .
q
Refilling with oil Supply oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then, check the oil level again.
50-108
PC228US-8, PC228USLC-8
Hydraulic system Disassembly and assembly of centre swivel joint assembly
Disassembly and assembly of centre swivel joint assembly
Symbol
Part number
50-109
Part name
790-101-2501 Push-puller 790-101-2510 q Block 790-101-2520 q Screw 791-112-1180 q Nut T 1 790-101-2540 q Washer 790-101-2630 q Leg 790-101-2570 q Plate 790-101-2560 q Nut 791-101-2650 q Adapter
Necessity Q'ty New/redesign Sketch
Special tools
q 1 1 1 1 1 2 4 2 2
Disassembly 50-109 1. Remove four mounting bolts to remove cover (1). 2. Remove snap ring (2) and ring (3). a If the ring is difficult to remove, remove it together with the swivel rotor in step 3. 3. By using tool T1, pull out rotor (4) from shaft (5).
4. Remove six slipper seals (6) and O-ring (7) from rotor (4). 5. Remove seal (8) from shaft (5). 6. Remove plug (9) from shaft (5).
PC228US-8, PC228USLC-8
50-109
Hydraulic system Disassembly and assembly of centre swivel joint assembly
Assembly 50-1 0 1. Install plug (9) to shaft (5). a Before installing the plug, clean, degrease, and dry it. a After installing the plug, check that it is sunk lower than the shaft end face. 3 Plug: 33.3 ± 3.9 Nm {3.4 ± 0.4 kgm} 2. Install seal (8) to shaft (5). 3. Install six slipper seals (6) and O-ring (7) to rotor (4). 4. Install rotor (4) to shaft (5). 2 Contact surfaces on rotor and shaft: Grease (G2-LI) a Set the rotor to the top of the shaft and lightly hit it with a plastic hammer to install it to the shaft. a When installing the rotor, take extreme care not to damage the slipper seals and O-ring. 5. Install ring (3) and secure with snap ring (2). 6. Install cover (1) with the O-ring. 3 Plug: 31.4 ± 2.9 Nm {3.2 ± 0.3 kgm}
50-110
PC228US-8, PC228USLC-8
Hydraulic system Removal and installation of hydraulic tank assembly
Removal and installation of hydraulic tank assembly Removal 50-1 1 k Lower the work equipment completely to the ground. Referring to “Releasing residual pressure in hydraulic circuit” , release the residual pressure in the hydraulic circuit. k Disconnect the cable from the negative (-) terminal of the battery. k Note the connector numbers and installed positions before disconnecting wiring and hoses.
2. Remove cover (3).
1. Drain oil from the hydraulic tank. 1) Remove cover (1).
3. Remove covers (4) and (5).
2) Remove drain plug (2) to drain the hydraulic oil. 6 Hydraulic tank: 126 l
4. Remove filter bracket (6). 5. Disconnect three drain hoses (7) to (9). q (7) and (8) : From control valve q (9) : From upper side of oil cooler
PC228US-8, PC228USLC-8
50-111
Hydraulic system Removal and installation of hydraulic tank assembly
6. Disconnect hydraulic tank return hoses (10) and (11).
9. Remove four bolts (18) and disconnect suction hose (19).
7. Remove clamp bracket (12).
10. Remove six mounting bolts (20).
8. Disconnect five drain hoses (13) to (17). q (13): Main valve drain q (14): PPC valve drain q (15): 6-spool solenoid valve drain q (16): Boom RAISE EPC valve drain q (17): ATT selector valve drain
11. Sling and remove hydraulic tank assembly (21). 4 Hydraulic tank assembly: 120 kg
a Use multi eyebolts [1] to remove hydraulic tank assembly (21). q Multi eye bolt: M12 x 1.75 Installation 50-1 2 Perform installation in the reverse order to removal.
q
50-112
q
Bleeding air Bleed air from the hydraulic pump circuit. For details, see Testing and adjusting, “ Bleeding air from each part” .
q
Refilling with oil Supply oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then, check the oil level again.
PC228US-8, PC228USLC-8
Hydraulic system Removal and installation of main pump assembly
Removal and installation of main pump assembly
Sym bol
Part number
1 796-460-1210
50-1 3
Part name
Oil stopper
R 2 796T-460-1230 Adapter
Necessity Q'ty New/redesign Sketch
Special tools
a If using tool R1 and R2, remove the hydraulic tank strainer and stop oil with tool R1 and R2.
q 1 q 1
Q
Removal 50-1 3 k Swing the upper structure 45 ° and lower the work equipment completely to the ground. Stop the engine. Slowly open the hydraulic tank cap to release pressure in the tank. Set the lock lever to LOCK position. k Disconnect the cable from the negative (-) terminal of the battery. k Note the connector numbers and installed positions before disconnecting wiring and hoses. a Attach tags to the hoses to show their installed positions to prevent any mistake when installing.
3. Drain damper oil through drain plug (3). 6 Damper case: Approx. 0.65 l
1. Remove under cover (1).
2. Remove drain plug (2) to drain hydraulic oil from the hydraulic oil tank. 6 Hydraulic tank: 126 l
PC228US-8, PC228USLC-8
50-113
Hydraulic system Removal and installation of main pump assembly
4. Open engine hood (4) and remove covers (5), (6), and frame (7).
7. Remove mounting bolts (13) of the muffler mounting bracket.
5. Remove partition plate (11).
8. Sling and remove muffler (14). a Space for winding the lifting tool is small. 4 Muffler assembly 35 kg
6. Remove clamp (12). [* 1 ] a When removing the clamp mounting bolt, fix the nut on the opposite side by using a spanner so that the force is not applied to the bracket.
50-114
9. Remove pre-filter bracket (15).
PC228US-8, PC228USLC-8
Hydraulic system Removal and installation of main pump assembly
10. Remove filter bracket (16).
13. Disconnect two hoses (27).
11. Disconnect hoses (17) to (21). q (17): Rear pump discharge port q (18): Front pump discharge port q (19): Rear load pressure pick-up port q (20): Front load pressure pick-up port q (21): Pump suction port
14. Disconnect connector (28).
15. Loosen 12 mounting bolts (29) for the work equipment pump. a Sling work equipment pump assembly (30). 12. Disconnect hoses (22) to (25). q (22): Case drain port q (23): Rear load pressure input port q (24): EPC source pressure port q (25): Pump pressure input port q (26): Front load pressure input port
16. Sling and remove main pump assembly (30). 4
Main pump assembly: 170 kg
PC228US-8, PC228USLC-8
50-115
Hydraulic system Removal and installation of main pump assembly
Installation 50-1 6 q Perform installation in the reverse order to removal.
q
Oil filling (damper case) Supply oil through the oil filler to the specified level. 5 Damper case: 0.65 l(EO30-DH)
q
Oil filling (hydraulic tank) Supply oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then, check the oil level again. 5 Hydraulic tank: 126 l 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”.
[*1] a Install muffler (14) to the exhaust pipe after applying thermosetting sealant to the entire external surfaces of both the end of the exhaust pipe and the exhaust pipe fitting end (E) of the muffler. 2 Entire periphery of E: Thermosetting sealant (Musashi Holts FIREGUM or equivalent)
a Replace clamp (12) with a new one. 3 Clamp bolt First time: 39.2 – 49 Nm {4.0 – 5.0 kgm} 2nd time: 68.6 – 122.5 Nm {7.0 – 12.49 kgm}
50-116
PC228US-8, PC228USLC-8
Hydraulic system Removal and installation of main pump input shaft oil seal
Removal and installation of main pump input shaft oil seal
Symbol
Part number
S
796T-467-2410
50-1 7
Part name
Push tool
Necessity Q'ty New/redesign Sketch
Special tools
t 1
Q
Removal 50-1 7 1. Remove the main pump assembly. For details, see "Removal and installation of main pump assembly".
Installation 50-1 7 Perform installation in the reverse order to removal.
q
[*1]
2 Oil seal lip: 2 Oil seal outer periphery:
Grease (G2-LI)
Grease (G2-LI) a Apply a thin film of the grease on the oil seal outer circumference. a By using tool S and tools [1] and [2], press fit oil seal (3).
2. Remove snap ring (1) and then remove spacer (2). 3. By using a screwdriver, pry off oil seal (3). [*1] a Take care not to damage the shaft when removing the oil seal.
PC228US-8, PC228USLC-8
50-117
Hydraulic system Removal and installation of control valve assembly
Removal and installation of control valve assembly Removal 50-1 8 k Lower the work equipment completely to the ground. Referring to “Releasing residual pressure in hydraulic circuit” , release the residual pressure in the hydraulic circuit. k Disconnect the cable from the negative (-) terminal of the battery. k Note the connector numbers and installed positions before disconnecting wiring and hoses.
3. Open right rear inspection cover (56) and disconnect tube (57) of the window washer tank and connector CN-M06 (3). a Disconnect the clamp on the frame as well.
1. Remove under cover (1).
4. Remove handrails (4) and (5) and mirror (6). 5. Remove covers (7) and (8). 6. Remove cover (9) and the frame as a unit.
2. Remove drain plug (2) to drain hydraulic oil from the hydraulic oil tank. 6 Hydraulic tank: 126 l
50-118
PC228US-8, PC228USLC-8
Hydraulic system Removal and installation of control valve assembly
7. Disconnect hoses (10) to (12).
11. Disconnect solenoid valve hoses (18) to (23). q q q q q q
(18): Relief solenoid valve (19): Travel solenoid valve (20): Swing brake solenoid valve (21): Merge-divider solenoid valve (22): Swing brake solenoid outlet hose (23): Travel interconnection solenoid outlet hose
12. Disconnect rear pump hose (24) and front pump hose (25). 13. Disconnect solenoid valve, PPC and EPC hose (26), and front pump control hose (27). 8. Disconnect hoses (13) to (15). 9. Remove bolt (16).
14. Disconnect attachment hose (28) and hydraulic tank hose (29). 10. Sling and remove attachment selector valve assembly (17). 4
Attachment selector valve assembly: 50 kg
PC228US-8, PC228USLC-8
50-119
Hydraulic system Removal and installation of control valve assembly
15. Disconnect 17 connectors (30). a Before disconnecting the connectors, note their installed positions (connector numbers).
18. Disconnect hoses (36) to (43). q q q q q q q q
(36): Rear pump control valve (37): Front pump control valve (38): Bucket cylinder head (39): Left travel motor (40): Boom cylinder bottom (41): Swing motor (42): Right travel motor (43): Arm cylinder head
16. Disconnect hose (31) of the attachment selector solenoid valve.
19. Disconnect hoses (44) to (49). q q q q q q
(44): Bucket cylinder bottom (45): Left travel motor (46): Boom cylinder bottom (47): Swing motor (48): Right travel motor (49): LS select solenoid valve
17. Disconnect hoses (32) to (35). q q q q
(32): PPC valve (33): Left travel PPC valve (34): Right travel PPC valve (35): Swing motor S port
50-120
PC228US-8, PC228USLC-8
Hydraulic system Removal and installation of control valve assembly
20. Disconnect arm cylinder bottom hose (51) and hydraulic tank hose (50).
23. Remove four mounting bolts (54) for the control valve assembly.
21. Disconnect hose (52).
22. Disconnect main valve drain hose (53).
PC228US-8, PC228USLC-8
24. Remove control valve assembly (55) and the solenoid valve assembly as a unit. 4 Control valve assembly: 330 kg
50-121
Hydraulic system Removal and installation of control valve assembly
Installation 50-12 q Perform out installation in the reverse order to removal. q
Refilling with oil (Hydraulic tank) Supply oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then, check the oil level again.
q
Bleeding air Bleed air from the hydraulic cylinder, swing motor, and travel motor circuits. For details, see Testing and adjusting, "Air bleeding" from each part.
50-122
PC228US-8, PC228USLC-8
Hydraulic system Disassembly and assembly of control valve assembly
Disassembly and assembly of control valve assembly
Symbol
Part number
Part name
796-946-1310 Guide φ21.8 (For 723-46-40100) 796-946-1610 Guide φ21.4 (For 723-46-41100) 796-946-1810 Guide φ21.2 (For 723-46-43100 and 2 723-46-43400) 796-946-1910 Guide φ21.0 (For 723-46-46101 and 723-46-46300) 796-946-2210 Guide φ20.6 (For 723-46-45100 and 723-46-45700) 796-946-1320 Guide φ21.8 (For 723-46-40100) 796-946-1620 Guide φ21.4 (For 723-46-41100) 796-946-1820 Guide φ21.2 (For 723-46-43100 and 723-46-43400) 3 T 796-946-1920 Guide φ21.0 (For 723-46-46101 and 723-46-46300) 796-946-2220 Guide φ20.6 (For 723-46-45100) 796-946-1420 Guide φ21.6 (For 723-46-42700) 796-946-1330 Sleeve (For 723-46-40100) 796-946-1630 Sleeve (For 723-46-41100) 796-946-1830 Sleeve (For 723-46-43100 and 723-46-43400) 4 796-946-1930 Sleeve (For 723-46-46101 and 723-46-46300) 796-946-2230 Sleeve (For 723-46-45100) 796-946-1430 Sleeve (For 723-46-42700)
PC228US-8, PC228USLC-8
Necessity Q'ty New/redesign Sketch
a This section explains only the precautions for assembling the control valve assembly. Special tools 50-123
t 1
Replacement of pressure compensation valve seal 50-123 a Since there are many types of pressure compensation valve, put a mark and note the installed position when removing it. 1. Remove piston (2), plug (3) and spring (4) from pressure compensation valve (1). 2. Remove seals (5) and (6) from piston (2).
t 1 t 1 t 1 t 1 t 1 t 1 t 1 t 1 t 1 t 1 t 1
a There are many types of pistons. 3. Install tool T2 on piston (2), put the seal on the tool and slowly push seal (5) down by hand so that it evenly expands. a You may put the seal on the tool and push it down to the flat part of the tool, and them install the tool to the pistion to install the seal in position.
t 1 t 1 t 1 t 1 t 1
50-123 (03)
Hydraulic system Disassembly and assembly of control valve assembly
4. Repeat the same process to install another seal (6). Install tool T3 on the same end of piston (2). Slowly push seal (6) down so that it evenly expands. a You may put the seal on the tool and push it down to the flat part of the tool, and them install the tool to the pistion to install the seal in position.
5. Install settling tool T4 on piston (2) for approx. one minute to make seals (5) and (6) settle. a Check that there is no protrusion or cut on the seal.
6. Fit plug (3) and spring (4) to piston (2), then install pressure compensation valve (1). a After the installation, push the piston by hand and check that the piston returns only with spring force.
50-124
PC228US-8, PC228USLC-8
Hydraulic system Disassembly and assembly of control valve assembly
Assembly of control valve
50-125
Apply engine oil to the sliding surfaces before assembling. q Install spools (7) and (8) into the valve chamber, with drill holes (H1) and (H2) facing the directions as shown in the drawing respectively. a The same applies to cross sections H-H, K-K, L-L, and M-M. q
q
Install filters (13) in PLS1 and PLS2 PORTs as shown in the drawing. (Check the positions of the crimped parts*.) TRUE: Correct ERROR: Incorrect
PC228US-8, PC228USLC-8
50-125
Hydraulic system Disassembly and assembly of control valve assembly
Upper and lower control valve cover blocks face of upper and lower control valve cover blocks (SE): Loctite 242 or equivalent q Tighten the mounting bolts for the upper and lower control valve covers in order of figure. (AoDoCoB) 3 Mounting bolt for upper and lower control covers: 156.9 – 176.5 Nm {16 – 18 kgm} q
2 Mating
q
Merge-divider valve
2 Merge valve mating face (SE2):
Loctite 242 or equivalent Tighten the mounting bolts for the merge-divider valve in the same sequence as that for the control valve cover mounting bolts. 3 Merge-divider valve mounting bolt: 156.9 – 176.5 Nm {16 – 18 kgm} q Tighten the mounting bolts of the back pressure valve, boom lock valve, arm quick return valve, and arm check valve in the same order as that for the control valve cover. 3 Mounting bolts of back pressure valve, boom lock valve, and arm quick return valve, and arm check valve: 58.8 – 73.6 Nm {6 – 7 kgm} q After assembling, put stoppers (CAP) to prevent oil and detergent liquid from entering through φ12 holes. q Pressure compensation valve a Install each pressure compensation valve, checking the mark that was put when removing it. Especially, do not install BKC1 and BKC2 adversely. q Main relief valve assembly After installing the main relief valve assembly in the control valve, see Testing and adjusting, "Testing and adjusting of work equipment, swing, and travel circuit pressure" to perform the check and adjustment. q
50-126 (03)
PC228US-8, PC228USLC-8
Hydraulic system Disassembly and assembly of work equipment PPC valve assembly
Disassembly and assembly of work equipment PPC valve assembly
a Only precautions for assembling the work equipment PPC valve assembly are explained below. Disassembly 50-127 a Each of springs (6) and (7), consists of two springs having different load at installed length. Note their installed positions (hydraulic ports) and identify them with tags to ensure correct installation. Assembly 50-127 a Before assembly, thoroughly clean the parts and check them for any dirt, rust or damage to prevent failures. a The head of plug (2) must not be projected from the surface of valve body (1). 3 Plug (2): 6 – 11 Nm {0.6 – 1.1 kgm}
a Install spring (5) with its small diameter end toward the shim (4). q Diameter of spring (inside diameter) Small end: φ 4.9 mm Large end: φ 5.55 mm a When installing springs (6) and (7), note that they are different by hydraulic port to install. q Installed height 31.9 mm (all) q Load at installed length Spring (6)(P1, P2): 35.3 N {3.6 kg} Spring (7)(P3, P4): 21.6 N {2.2 kg} a Before installing piston (8), apply grease (G2-LI) to the periphery of the piston and the bore in the valve body. 3 Bolt (11): 11.8 – 14.7 Nm {1.2 – 1.5 kgm}
a When installing plug (3) to valve body (1), check the insertion depth so that the tip of plug does not protrudes from the φ 20 hole bottom surface of the valve body. 3 Plug (3): 4 – 9 Nm {0.4 – 0.9 kgm}
PC228US-8, PC228USLC-8
50-127 (03)
Hydraulic system Disassembly and assembly of work equipment PPC valve assembly
a When installing joint (12) to valve body (1), apply LOCTITE according to the following procedure. 1) Before installing the joint, apply one drop (approx. 0.02 g) of Loctite (No. 262) to two locations of the threaded portion (A) of the valve body. Before installation, thoroughly degrease and dry the threaded portions of the joint and valve body with Drysol. 2) Drop LOCTITE to the following positions. 2 Female threads of valve body (A): Loctite No. 262 3 Joint (12): 39 – 49 Nm {4 – 5 kgm}
a Apply grease (G2-LI) to the sliding surface of joint (12) and to the contact surfaces of disc (13) and piston (8). 2 Quantity of grease (G2-LI) 1) Sliding surface of joint: 2 – 4 cc/circumference 2) Contact parts of disc and piston: 0.3 – 0.8 cc/part a Install disc (13) according to the following procedure. Adjust the disc so that the play at the lever end is within the following range. Lever play: 0.5 – 3 mm (at 200 mm from lever pivot point) a For details, see Testing and adjusting "Adjustment of play in work equipment & swing PPC valve". a Tighten nut (14) to the following torque. 3 Nut (14): 69 – 88 Nm {7 – 9 kgm}
50-128
PC228US-8, PC228USLC-8
Hydraulic system Disassembly and assembly of travel PPC valve assembly
Disassembly and assembly of travel PPC valve assembly
Symbol
Part number
50-129
Part name
1 796T-416-1010 Push tool Q 2 796T-416-1030 Push tool 3 796T-416-1020 Push tool
Necessity Q'ty New/redesign Sketch
Special tools
t 1 t 1 t 1
Q Q Q
a Remove pin (24) from valve body (1). 6. Remove seal (9) and collar (8). 7. Remove pistons (7) to remove retainers (6), springs (5) and (4) and shims (3). a Note the installed position, quantity and thickness of each pack of shims (3) and keep them. 8. Remove valves (2) from valve body (1).
Disassembly 50-129 1. Remove screws (22) and remove damper assemblies (21). 2. Remove mounting bolt (19) and remove case (18), shafts (16) and levers (13) as a unit. 3. Remove pins (17). 4. Remove levers (13), bushings (14) and (14a), and shafts (16) from the case. 5. Remove mounting bouts (11) to remove plate (10). a Note the thickness and installed position of each washer (12).
PC228US-8, PC228USLC-8
50-129
Hydraulic system Disassembly and assembly of travel PPC valve assembly
Assembly Only precautions for assembly are described.
50-130
a Before assembly, thoroughly clean the part and check them for dirt, rust, or damage to prevent failure. a When installing piston (7), apply grease (G2-LI) to its periphery and the inside of the valve body hole. a Install spring (4) with its small diameter end toward shim (3). q Diameter of spring (inside diameter) Small end: φ 4.9 Large end: φ 5.55 a Install shaft (16) according to the following procedure. 1) Using tool Q1, install bushing (14) to the case. a Install bushing with 10 ° chamfered end ahead. a Install the bushing so that distance A is as follows. q Distance A: 20.4 ± 0.3 mm a Do not hit it with a hammer directly.
2) Using tool Q2, install bushing (14a) to the case. a Install bushing with 10 ° chamfered end ahead. a Install the bushing so that distance B is as follows (bushing end face flush is with case end face). q Distance B: 0 mm a Do not hit it with a hammer directly.
50-130 (03)
3) Install lever (13). 4) Install shaft (16). 5) Using tool Q3, install pin (17). a Install the pin so that distance C is as follows. q Distance C: 0 – 0.5 mm a Do not hit it with a hammer directly.
a Apply grease (G2-LI) to the sliding surfaces of shaft (16), contact parts of lever (13) and piston (7), and contact parts of damper (21) and pin (20). 2 Quantity of grease (G2-LI) Sliding surfaces of shaft: 4 – 8 cc/circumference Contact parts of lever and piston: 0.3 – 0.8 cc/part Contact parts of damper and pin: 0.3 – 0.8 cc/part
a Install washer (12) of t=1.6. If the difference in lever angle between left and right travel control levers at full lever stroke is more than 0.7 °, adjust the washer thickness to keep the difference within 0.7 °. (Decreasing the thickness of washer by 0.3 mm increases the lever angle at full stroke by 0.39°.) q Available washer: t= 1.0, 1.3, 1.6, 1.9, 2.2
PC228US-8, PC228USLC-8
Hydraulic system Disassembly and assembly of travel PPC valve assembly
1. Tighten each part to the following torque. q Plug (26): 6 – 11 Nm {0.6 – 1.1 kgm} q Plug (25): 4 – 9 Nm {0.4 – 0.9 kgm} q Screw (22): 7.8 – 9.8 Nm {0.8 – 1.0 kgm} q Bolt (19): 25 – 30 Nm {2.5 – 3.2 kgm} q Bolt (11): 27 – 34 Nm {2.8 – 3.5 kgm}
PC228US-8, PC228USLC-8
50-131
Work equipment Removal and installation of work equipment assembly
Work equipment Removal and installation of work equipment assembly 50-132
Symbol
Part number
Part name
V
796-900-1200 790-101-4000 790-101-1102
Remover Puller (50 ton) Hydraulic pump
Necessity Q'ty New/redesign Sketch
Special tools
4. Remove head side pin (5). [*2] a Shims are installed, so note the quantity and thickness.
t 1 t 1 t 1
Removal 50-132 k Fully extend the arm and bucket and completely lower the work equipment to the ground. Set the lock lever to LOCK position. k Disconnect the cable from the negative (-) terminal of the battery. 1. Disconnect grease hose (1). 2. Sling boom cylinder assembly (2) and remove lock bolt (3). [*1] 3. Remove plate (4).
5. Start the engine, retract the piston rod of the boom cylinder, and place the boom cylinder on the stand. a Wire the rod to prevent it from extending. a Perform the same steps 1 to 5 for the boom cylinder of the other side. k Relieve the remaining pressure in the boom cylinder circuit. See Testing and adjusting, "Relieving remaining pressure in hydraulic circuits". 6. Disconnect hoses (6) (four in total) of the arm and bucket cylinders and plug them. 7. Disconnect work lamp connector A13. 8. Remove covers (7) and (8) and remove boom angle potentiometer (9). [*3] a See Testing and adjusting, "Replacement procedure for boom angle potentiometer".
50-132
PC228US-8, PC228USLC-8
Work equipment Removal and installation of work equipment assembly
Installation 50-13 Perform installation in the reverse order to removal.
q
[*1] a Tighten the lock nut so that the clearance (a) between the plate and the nut is 0.5 to 1.5 mm.
9. Sling work equipment assembly (10), remove foot pin (11) by using tool V, and remove work equipment assembly (10). [*4] 4 Work equipment assembly (10) 3,400 kg (Standard specification) 3,900 kg (Demolition specification)
[*2]
2 Inside surface of bushing when installing
pin: Molybdenum disulphide lubricant (LM-P) 2 Greasing after installing pin: Grease (LM-G) k When aligning the pin holes, never insert your fingers in them. a st1: Resin shim (1.0 mm in thickness) a Set the clearance (b) between cylinder rod (12) and plate (4) to 1.5 mm or less by shimming. Available shims: 1.0, 2.0 mm a Install one shim or more on each end face.
PC228US-8, PC228USLC-8
50-133
Work equipment Removal and installation of work equipment assembly
Demolition specification a Insert resin shim (1.0 mm in thickness) in the same manner as that for standard specification machine. 1) Operation
q
[*3] a Perform the initial setting of the boom potentiometer. See Testing and adjusting, "Special functions of machine monitor (EMMS)". [*4]
2 Inside surface of bushing when installing
pin: Molybdenum disulphide lubricant (LM-P) 2 Greasing after installing pin: Grease (LM-P) k When aligning the pin holes, never insert your fingers in them. a Set the clearance (c) between the foot end face of boom (13) and bracket (14) to 1 mm or less by shimming. Available shims: 2.0, 2.5, 3.0, 3.5 mm a Install one shim or more on each end face. 2) When lifting the machine (e.g. when loading the machine on a vessel)
50-134
q
Bleeding air Bleed air. See Testing and adjusting "Air bleeding from each part".
q
Refilling with oil (Hydraulic tank) Supply oil through oil filler port to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again.
PC228US-8, PC228USLC-8
Work equipment Disassembly and assembly of work equipment cylinder assembly
Disassembly and assembly of work equipment cylinder assembly
Symbol
50-135 Necessity Q'ty New/redesign Sketch
Special tools
Part number
Part name
790-502-1003
Cylinder repair stand
q 1
790-102-1102
Pump
q 1
790-102-4300
Wrench assembly
t 1
790-102-4310
Pin
t 1
Expander
t 1
796-720-1660
Ring
t 1
07281-01159
Clamp
t 1
796-720-1670
Ring
t 1
07281-01279
Clamp
t 1
790-201-1702
Push tool kit
t 1
790-101-5021
Grip
1
01010-50816
Bolt
1
5 790-201-1831
Push tool
1
790-201-1940
Push tool
1
790-201-1841
Push tool
1
790-201-1930
Push tool
1
790-201-1500
Push tool kit
790-201-5021
Grip
1
01010-50816
Bolt
1
790-201-1620
Push tool
1
790-101-1630
Push tool
1
790-201-1640
Push tool
1
790-201-1650
Push tool
1
1
2 3 790-720-1000
4
U
6
PC228US-8, PC228USLC-8
Disassembly 50-135 1. Disconnecting the cylinder assembly from the piston rod assembly 1) Remove piping from the cylinder assembly. 2) Loosen the 12 mounting bolts and disconnect head assembly (1) from the cylinder. 3) Pull out piston rod assembly (2). a Place an oil pan or other appropriate container under the cylinder to collect oil from the cylinder.
2. Disassembling the cylinder and piston rod assemblies 1) Install piston rod assembly (2) on tool U1.
t 1
50-135
Work equipment Disassembly and assembly of work equipment cylinder assembly
2) Using a hexagonal wrench, loosen locking screw (3) on the end of the piston assembly. q Screw size: 12x1.75 mm (16 mm in length) a If screw (3) has been crimped too firmly to be loosened, tighten the screw further in and tap on the screw before removing the crimp.
3) Using tool U2, remove piston assembly (4).
6) Remove cap (8) and twelve balls (9) before removing plunger (10). q Arm cylinder only
3. Disassembling the piston assembly 1) Remove two rings (11). 2) Remove two wear rings (12). 3) Remove piston ring (13). 4) Remove the O-ring and two backup rings (14).
4) Remove plunger (5) and collar (6). q Arm cylinder only 5) Remove cylinder head assembly (7).
50-136
PC228US-8, PC228USLC-8
Work equipment Disassembly and assembly of work equipment cylinder assembly
4. Disassembling the cylinder head assembly 1) Remove the O-ring and backup ring (15). 2) Remove snap ring (16), then remove dust seal (17). 3) Remove rod packing (18) and buffer ring (19). 4) Remove snap ring (30). 5) Remove bushing (20).
assembly 50-137 a Be careful not to damage the packings, dust seals, O-rings, etc. a Clean each part. After installing them, cover the piping ports and pin holes to prevent entering of dirt. a Before installing the buffer ring, warm it in hot water of approx. 50-60 °C. Do not attempt to insert it forcibly. 1. Assembly of cylinder assembly (for only arm cylinder) 1) Assemble valve (23) and spring (22). 2) Install the O-ring and plug (21). a Clean and dry the threads of the plug, and then apply liquid gasket (LG-5) to all the periphery of the threaded part. 3 Plug: 83.4–102.9 Nm {8.5–10.5 kgm}
5. Disassembling the cylinder assembly (arm cylinder only) 1) Remove plug (21). 2) Remove spring (22) and valve (23).
PC228US-8, PC228USLC-8
50-137
Work equipment Disassembly and assembly of work equipment cylinder assembly
2. Assembling the cylinder head assembly 1) Using tool U5, press fit bushing (20). 2) Install snap ring (30). 3) Assemble buffer ring (19) and rod packing (18). 4) Install dust seal (17) using tool U6, and install snap ring (16). 5) Install backup ring (15) and the O-ring.
3. Assembling the piston assembly 1) Install piston ring (13) on tool U3. Expand piston ring (13) by turning the crank handle 8-10 turns. 2) Remove piston ring (13) from tool U3. Assemble the ring on the piston. 3) Using tool U4, compress piston ring (13).
4) Install two backup rings (14) and the O-ring. a Install the backup rings and O-ring as shown in the figure. 5) Assemble wear ring (12). 6) Install ring (11). a Be careful not to open the end gap of the ring too wide.
50-138
PC228US-8, PC228USLC-8
Work equipment Disassembly and assembly of work equipment cylinder assembly
4. Assembling the piston rod assembly 1) Set piston rod assembly (2) to tool U1.
2) Assemble cylinder head assembly (7). 3) Install the O-ring and the backup ring on collar (6) and install the sub assembly on the piston rod. a Install the two backup rings, one each in the front and rear of the O-ring. q Arm cylinder only 4) Assemble plunger (5). q Arm cylinder only
5) Place plunger (10) on piston rod assembly (2). Install 12 balls (9) and then cap (8). a After installing the plunger, check that it has a little play at its end. q Arm cylinder only
6) If both piston rod assembly (2) and piston assembly (4) are reused, assemble them in the following sequence. (If one or both of them is (are) replaced with a new one (new ones), go to Step 7.) 1] Using tool U2, install piston assembly (4) on piston rod assembly (2). a Any burrs or sharp edges on threaded portions must be removed using files before installation.
a Fully screw in piston assembly (4) until it comes into contact with the rod end face b. Then, screw out the assembly until the screw holes H in the piston and the rod end face become aligned with each other.
PC228US-8, PC228USLC-8
50-139
Work equipment Disassembly and assembly of work equipment cylinder assembly
a On a cylinder with head cushion, ensure that plunger (5) has play with piston assembly (4) installed.
a On a cylinder with head cushion, ensure that plunger (5) has play with piston assembly (4) installed.
2] Install screw (3) to lock piston assembly (4) and piston rod assembly (2). 2 Screw: Adhesive (LOCTITE #262) 3 Screw: 58.9–73.6 Nm {6–7.5 kgm} a With screw (3) installed, crimp the screw at four peripheral places (a).
2] Drill a screw hole in the threaded portions of piston rod assembly (2) and piston assembly (4). a With a drill aligned with V groove in piston assembly (4) and piston rod assembly (2), drill the groove into a square one. a The cylinder with bottom cushion must not be machined in the cap machining hole position. q Dimensions of a screw hole (mm): Tap drill diameter Bottom hole depth Screw hole size Screw hole depth
10.3 27 12x1.75 20
a After tapping the screw hole, remove chips and other dirt and thoroughly clean the area.
7) When replacing either or both of piston rod assembly (2) and piston assembly with new ones, assemble the new ones according to the following procedure. 1] Using tool U2, screw in piston assembly (4) until it comes into contact with end face (b) of the rod. a If the cylinder has the bottom cushion, put a mark to indicate the tightening position of the ball cap at the rod end. 3 Piston assembly (4): 294 ± 29.4 Nm {30 ± 3.0 kgm}
50-140
PC228US-8, PC228USLC-8
Work equipment Disassembly and assembly of work equipment cylinder assembly
3] Install screw (3) to lock piston assembly (4) and piston rod assembly (2). 2 Screw: Liquid adhesive compound (Loctite #262) 3 Screw: 58.9–73.6 Nm {6–7.5 kgm} a With screw (3) installed, crimp the screw at four peripheral places (a).
2) Tighten the mounting bolt for cylinder head assembly (1). 3 Mounting bolt: Boom cylinder: 270 ± 39 Nm {27.5 ± 4.0 kgm} Arm cylinder: 373 ± 54 Nm {38.0 ± 5.5 kgm} Bucket cylinder: 270 ± 39 Nm {27.5 ± 4.0 kgm}
5. Assembling the cylinder assembly onto the piston rod assembly 1) Assemble piston rod assembly (2) onto the cylinder assembly. a Align ring gaps (c) in a horizontal line. Align the axis of the cylinder tube with that of the piston rod assembly before inserting the assembly into the tube. a Insert the piston fully while ensuring that the rings are not damaged or dislocated.
3) Install piping. a Tighten the mounting bolt of the piping band to the following torque. 3 Band mounting bolt: 27 ± 7 Nm {2.8 ± 0.7 kgm}
PC228US-8, PC228USLC-8
50-141
Cab and its attachments Removal and installation of operator's cab assembly
Cab and its attachments Removal and installation of operator's cab assembly Removal 50-142 k Park the machine on level ground, lower the work equipment to the ground completely, stop the engine, and set the lock lever to LOCK position. k Disconnect the cable from the negative (-) terminal of the battery. a Note the installed positions of disconnected wires and connectors. 1. Remove front window assembly (1). For details, see "Removal and installation of front window assembly". 2. Remove floor mat (2) and cover (3). 3. Remove machine monitor (4). For details, see "Removal and installation of machine monitor assembly". 4. Remove right covers (5) and (6).
5. Remove machine monitor cover (7) and duct (8). 6. Remove two clips (9) and pull ducts (10) and (11) downward in the direction of the arrow to remove the ducts. [*1]
50-142
7. Remove duct (12). 8. Disconnect connector M05 (13) of the wiper wiring harness.
9. Remove wiring harness clamp (14). 10. Disconnect wiper washer hose (15).
11. Remove rear joint duct (16). 12. Remove rear right clip (17) to unclamp harness.
PC228US-8, PC228USLC-8
Cab and its attachments Removal and installation of operator's cab assembly
13. Remove cable clip (19) on right side duct (18) to disconnect cable (20) from duct lever (21). a Remove cable clip (19) by lowering it with a flat-head screwdriver that is inserted in the gap between the cable and clip. 14. Remove two mounting bolts (22) at the front and rear of right side duct (18).
15. Remove right side duct (18) by pulling it in the direction of the arrow.
16. Remove cover (23) after tilting the operator's seat forward and down. 17. Remove cover (24).
PC228US-8, PC228USLC-8
18. Open cover (25) on the left side of the machine and remove fresh air filter (26) of the air conditioner.
19. Remove fresh air duct (27) of the air conditioner. 20. Remove rear left clip (28) and clamp (29). 21. Remove four mounting bolts (31) of bracket (30), and place the bracket beside the operator's seat together with the harness.
22. Disconnect wiring harness connector H15 (32). 23. Disconnect wiring harness connector H16 (33).
50-143
Cab and its attachments Removal and installation of operator's cab assembly
24. Remove clamp (34), clip (35) and band (36). 25. Disconnect wiring harness connectors H08 (37), H09 (38) and H20 (39). 26. Disconnect wiring harness connector H16 (40).
27. Remove mounting bolts (41) (seven bolts marked A) and mounting nuts (42) (four nuts marked B) inside the operator cab. a Note the lengths of the removed bolts. a Nuts (42) are also used for fastening the floor frame.
29. Remove lock plate mounting bolt (44) to remove lock plate (45) from the underside of the cab. [*2] 30. Remove mounting bolt of cab tipping stopper (46). [*3]
31. Sling and remove operator's cab assembly (47). a Before removing the operator is cap assembly, make sure that all wiring and piping are disconnected. [*4] a Before lifting off the operator's cab assembly, keep harnesses from moving away from the cab with cable ties or other suitable means to prevent the harnesses from being damaged. 4 Operator's cab assembly: 440 kg
28. Remove cover (43) from the underside of the cab.
50-144
PC228US-8, PC228USLC-8
Cab and its attachments Removal and installation of operator's cab assembly
Installation 50-145 q Perform installation in the reverse order to removal. [*1] Install ducts (10) and (11) according to the following procedure. 1) Install machine monitor cover (7). 2) Install ducts (10) and (11) to the base of right side duct (18) in advance. 3) Pull ducts (10) and (11) upward in the direction of the arrow to install them.
q
[*2]
3 Lock plate mounting bolt:
98 – 123 Nm {10 – 12.5 kgm} [*3]
3 Cab tipping stopper mounting bolt:
245 – 309 Nm {25 – 31. 5kgm} [*4] a When installing the operator's cab assembly, be careful to prevent the harnesses from getting caught between the cab and other parts.
PC228US-8, PC228USLC-8
50-145
Cab and its attachments Removal and installation of operator's cab glass (adhered window glass)
Removal and installation of operator's cab glass (adhered window glass)
a Among the panes of window glass on the four sides of the operator’s cab, five panes (1) – (5) are adhered. This section describes the replacement procedure of adhered glass. Replace front glass (5) with front window assembly (6) removed. (It is impossible to replace only the front window glass while the front window assembly is installed to the operator’s cab.) For the procedure for replacing the front window assembly, see "Removal and installation of front window assembly".
50-146
(1): Right side window glass (2): Left side rear window glass (3): Door upper window glass (4): Door lower window glass (5): Front window glass (6): Front window assembly (front window glass + front frame) (7): Dam rubber (16):Centre trim seal
PC228US-8, PC228USLC-8
Cab and its attachments Removal and installation of operator's cab glass (adhered window glass)
50-147
Special tools
50-147
Symbol
X
Part number
Part name
1 793–498–1210 Lifter (Suction cup) 2 20Y-54-13180 Stopper rubber
Necessity Q'ty New/redesign Sketch
Removal
t 2 t 2
a If the window glass is broken finely, it may be removed with knife [4] and a flat-head screwdriver. a While widening the cut-opening with a flat-head screwdriver, separate the dam rubber and adhesive layer using a utility knife [4]. (The figure shows the operator’s cab of a wheel loader.)
a Remove the window glass to be replaced according to the following procedure. 1. Using seal cutter [1], cut the adhesive between broken window glass (9) and operator’s cab (metal sheet) (8).
2. Remove the window glass.
a When a seal cutter is not available, an alternative method can be used: Drill a hole in the adhesive and dam rubber layer and let an extra-fine wire (piano wire), etc. [2] go through the hole. Hold or reel each end of this extra-fine wire with two pliers [3] etc. Saw through the adhesive and dam rubber using this wire. (The figure shows the operator’s cab of a wheel loader.)
PC228US-8, PC228USLC-8
50-147
Cab and its attachments Removal and installation of operator's cab glass (adhered window glass)
Installation 50-148 1. Use a utility knife and scraper [5] to remove the remaining adhesive and dam rubber on the sheet metal (adhesion surface) of the operator’s cab. a A small amount of adhesive or dam rubber can remain on the sheet metal surface as far as they do not affect the adhesion performance of new adhesive. Avoid excessive scraping to prevent damage on the painted surface. (damaging the painted surface may cause the adhesive strength to be weakened.) (The figure shows the operator’s cab of a wheel loader.)
2. Remove oil, dust, dirt, etc. from the adhesion surfaces on cab (8) and window glass (9) with white gasoline. a If the adhesion surfaces are not cleaned well, the glass may not be stuck perfectly. a Clean the all black part on the back side of the window glass. a After cleaning the adhesion surfaces, leave them for at lease 5 minutes to dry.
50-148
3. Apply primer (10). a The using limit of primer is 4 months after the date of manufacture. Do not use the primer after this limit. a Use the primer within two hours after opening the container. a Even if the primer is packed again just after it is unpacked, use it within 24 hours after it is unpacked for the first time. (Discard the primer 24 hours after it is packed.) 1) Stir the primer for painted surface and glass sufficiently before using it. a If the primer is stored in a refrigerator, leave it at the room temperature for at least half a day before stirring it. (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) Before reusing brush (11) for applying primer, wash it clean in white gasoline. a After washing the brush, check it again for dirt and contaminant. a Prepare respective brushes for the painted surface primer and glass primer.
PC228US-8, PC228USLC-8
Cab and its attachments Removal and installation of operator's cab glass (adhered window glass)
3) Evenly apply the painted surface primer over the dam rubber mounting position of operator’s cab (8) and its outside areas to be coated with the adhesive. 2 Primer for painted surface: SUNSTAR PAINT PRIMER 580 SUPER a The maximum times of primer application must be limited to two. (If it is applied more than two times, its performance will be lowered.) a Places to apply: Apply over the entire circumferential area of dimension (a). q Primer applying dimension (a): 30 mm 4) Evenly apply the glass primer on the adhesion surfaces of window glass (9). 2 Primer for glass: SUNSTAR GLASS PRIMER 435-41 a The maximum times of primer application must be limited to two. (If it is applied more than two times, its performance will be lowered.)
a For right side window glass (1), it is enough to apply the primer only on the outer dam rubber mounting position and its outside area to be coated with the adhesive. q (b) area a After applying the primer, leave it in air for at least five minutes (maximum eight hours ) to dry. a Never apply wrong primer. If the glass primer, etc. is applied by mistake, wipe it off with white gasoline.
PC228US-8, PC228USLC-8
a Places to apply: Apply the primer on the entire circumferential area of window glass (9) mounting position (d) that is relative to dam rubber (7) in stalled on operator’s cab (8). a Do not apply over the strip area (width: approx. 5 mm) bordering to the transparent portion of the dark part of glass. a After applying the primer, leave it in air for at least five minutes (maximum eight hours ) to dry. a Never apply wrong primer. If the painted surface primer, etc. is applied by mistake, wipe it off with white gasoline.
50-149
Cab and its attachments Removal and installation of operator's cab glass (adhered window glass)
4. Install dam rubber (7) along the inside edge of the glass sticking section. a Do not remove the release tape of dam rubber on the glass sticking side before sticking the glass. a When installing the dam rubber, do not touch the cleaned surface. a Take extra care so that the dam rubber does not float at each corner of the window frame.
a When installing dam rubber (7) around the window frame, the ends must not overlap at the joint. Instead, leave a clearance of approximately 5 mm at the joint (e). 1) Install dam rubber (7) for right side window glass (1) to the position as shown in the figure.
50-150
a Install additional dam rubber (7a) for right side window glass (1). q Additional dam rubber for the right side window glass Installed position: (f): 140 mm (g): 500 mm
2) Install dam rubber (7) for left side rear window glass (2) to the position as shown in the figure.
PC228US-8, PC228USLC-8
Cab and its attachments Removal and installation of operator's cab glass (adhered window glass)
3) Install dam rubber (7) for door upper window glass (3) and door lower window glass (4) to the position as shown in the figure. (The figure shows the door upper window glass.)
q
Details of the sticking positions are as follows. (h): Install the dam rubber along each inner edge of right and left front frames (17). (j): Install the dam rubber "3.0 mm" short from the edge of front frame (17).
(The figure shows the door lower window glass.)
4) Install dam rubber (7) for front window glass (5) at the position shown in the figure. a Dam rubber: 1,004 mm x 2
PC228US-8, PC228USLC-8
5. Position the new window glass. 1) Check the clearances between the window glass and the operator cab on the right, left, upper, and lower sides, and then position the window glass with the clearance evenly. 2) Stick tapes [6] between window glass (9) and operator cab (8) and draw positioning line (n). a Stick tapes [6] to three points, that is, the right, left, and lower portions of the right side window glass, left side rear window glass, and door window glasses (upper and lower) for accurate positioning. 3) Use a utility knife, etc. to cut the tape between window glass (9) and operator cab (8), and remove the window glass. a Do not remove the tapes left on the window glass and the operator's cab before installing the window glass.
50-151
Cab and its attachments Removal and installation of operator's cab glass (adhered window glass)
a The right-and-left and top-and-bottom installed positions for positioning front window glass (5) are as follows: (m) portion (right side): Project "3.8 mm" from the frame end face. (o) portion (top side): Make "3.0 mm" short from the frame end face.
1) Break aluminium dehumidification membrane (13) at the mouth of adhesive cartridge (12) and attach there the dedicated nozzle.
2) Cut the tip of the adhesive cartridge nozzle (14) to dimensions (q) and (r) shown in the figure. q Dimension (q): 10 mm q Dimension (r): 15 mm
6. Apply adhesive. a Use either of two types of adhesives according to the season. 2 Adhesive (summer season): SUNSTAR penguine seal 580 super "S" 2 Adhesive (winter season): SUNSTAR penguine seal 580 super "W" a The effective period of the adhesive is 4 months after the date of manufacture. Do not use the adhesive after this limit. a Keep the adhesive in a dark place where the temperature is below 25 °C. a Never heat the adhesive higher than 30 °C. a When reusing the adhesive, remove the all hardened part form the nozzle tip.
50-152
3) Set adhesive cartridge (12) to caulking gun [7].
PC228US-8, PC228USLC-8
Cab and its attachments Removal and installation of operator's cab glass (adhered window glass)
4) Remove the release tape of the dam rubber on the glass side. 5) Apply adhesive (15) on the outside of dam rubber (7) on the operator’s cab.
a Apply adhesive (15) to dimensions (s) and (t) relative to dam rubber (7) on operator’s cab (8) shown in the figure. q Dimension (s): 10 mm q Dimension (t): 15 mm a The bead of adhesive (15) must be higher than dam rubber (7). a Apply the adhesive evenly with same height level. a As for the right side window, apply the adhesive to the outside area of the outside dam rubber.
PC228US-8, PC228USLC-8
7. Install the window glass. 1) Install window glass (9) while aligning it with the positioning tape mentioned in Step 5 above. a Since the window glass is not allowed to be removed and adhered again, adhere it very carefully. a Adhere the glass within five minutes after applying the adhesive.
2) After sticking window glass (9), press all around it until it sticks to the dam rubber. a Press the corners of the window glass firmly. a The work efficiency can be improved by pulling window glass (9) using suckers X1 from the inside of the operator’s cab. (The figure shows the operator’s cab of PC200-7.)
50-153
Cab and its attachments Removal and installation of operator's cab glass (adhered window glass)
a For front window glass (5), install the centre trim seal to the lower part of the glass after mounting it. In addition, apply caulking for the entire circumference to avoid producing a gap at the portion U between the glass and centre trim seal. a When caulking, neatly arrange the form of the adhesive at the right and left ends with a rubber spatula. 2 Adhesive: Sika Ltd., Japan Sikaflex 256HV
8. Fix the window glass. 1) For right window glass (1) after installing it in the operator’s cab, install stopper rubber X2 for fixation in two (v) portions at the bottom of the glass. (The figure shows the operator’s cab of PC200-7.)
(The figure shows the operator’s cab of PC200-7.)
2) In order to make the window glass and dam rubber closely adhered to each other, use styrene foam [9] and rubber bands [10] to fix them for curing. (The figure shows the operator’s cab of PC200-7.)
50-154
PC228US-8, PC228USLC-8
Cab and its attachments Removal and installation of operator's cab glass (adhered window glass)
9. Clean the remaining primer and adhesive on the window glass and operator’s cab after completing the installation of the window glass. a Use white gasoline to wipe the remaining adhesive before it dries up. a After cleaning, take care not to impact the window glass. 10. Protect the adhered window glass. 1) Keep the window glass fixed for ten hours without removing the stopper rubber, styrene foam and rubber bands. (ambient temperature 20 °C / humidity 60%) 2) Keep curing the adhered glass for 14 hours after removing the stopper rubber, styrene foam and rubber bands, and 24 hours after applying the adhesive before operating the machine.
PC228US-8, PC228USLC-8
50-155
Cab and its attachments Removal and installation of front window assembly
Removal and installation of front window assembly Removal 50-156 k Lower the work equipment to 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. 1. Raise the front window assembly to the ceiling and fix it with the rear locks (on both sides). 2. Remove left lower block (1) and right lower block (2).
3. Release the rear locks of the cab. 4. Lower front window assembly (3) carefully a little. Put out rollers (4) and (5) under the right and left sides of the front window through the portion from which the right and left lower blocks were removed in step 2 (the bottom of the rails). 5. Remove front window assembly (3) by twisting it to the left and right to release left and right upper rollers (6) and (7) from the rail. a See figure in the right for (6) and (7). Installation 50-156 q Perform installation in the reverse order to removal.
50-156
PC228US-8, PC228USLC-8
Cab and its attachments Removal and installation of floor frame assembly
Removal and installation of floor frame assembly 50-157 Removal 50-157 k Park the machine on level ground, lower the work equipment to the ground completely, stop the engine, and set the lock lever to LOCK position. k Disconnect the cable from the negative (-) terminal of the battery. k To prevent burn injury, disconnect the heater hose after the radiator coolant temperature lowers. k Loosen the cap of the hydraulic tank gradually to release the internal pressure of the hydraulic tank. 1. Collect the refrigerant (gas for air conditioner: R134a) from the air conditioner circuit. [*1] a Ask a qualified person for collecting, adding and filling operation of refrigerant (R134a). a Never release the refrigerant (R134a) to the atmosphere. k If refrigerant gets in your eyes, you may lose your sight. And if it touches your skins, you may suffer from frostbite. Accordingly, put on protective eyeglasses, gloves and working suits with long sleeves while you are collecting the refrigerant or filling the air conditioner circuit with the refrigerant. Collecting and filling work must be conducted by a qualified person. q Amount of refrigerant to be collected: 790 ± 50 g
5. Removal of exterior parts 1) Remove handrails (3) and (4). 2) Remove mirror (5). 3) Remove covers (6), (7), and (8).
4) Remove covers (9) and (10).
2. Remove cover (1).
3. Swing the upper structure 90 ° . 4. Open drain valve (2) to drain the coolant. 6 Coolant:
PC228US-8, PC228USLC-8
21 l
50-157
Cab and its attachments Removal and installation of floor frame assembly
5) Remove cover (11) under the operator’s cab.
(27): P08 (arm OUT) (28): P25 (front pump) (29): P26 (rear pump) a In the figure hoses are disconnected for easy understanding.
6. Remove the operator’s cab assembly. For details, see "Removal and installation of operator’s cab assembly." 7. Removal of wiring and hoses around the control valve assembly a Remove the clamps, clips and bands that are fixing the wiring and hoses at the same time. 1) Disconnect connectors (12) to (19) around the solenoid valves. (12): V01 (PPC source pressure lock solenoid valve) (13): V02 (travel interconnection valve solenoid valve) (14): V03 (swing brake) (15): V04 (travel HI-LO solenoid valve) (16): V05 (2-stage relief solenoid valve) (17): V06 (ATT return selector solenoid valve) (18): V23 (merge-divider EPC valve (main)) (19): V24 (merge-divider EPC valve (LS))
3) Disconnect boom RAISE throttle EPC valve connector V09 (30).
4) Open the rear right inspection cover and disconnect washer motor connector M06 (31) and washer hose (32).
2) Disconnect connectors (20) to (29) around the control valve assembly. (20): P01 (bucket CURL) (21): P02 (boom LOWER) (22): P03 (swing LEFT) (23): P04 (arm IN) (24): P05 (bucket DUMP) (25): P06 (boom RAISE) (26): P07 (swing RIGHT)
50-158
PC228US-8, PC228USLC-8
Cab and its attachments Removal and installation of floor frame assembly
5) Disconnect hoses (33) to (40) from the PPC valves for the work equipment and swing. a Each PPC hose is attached with the following ID band in the order from top to bottom. (33): white (bucket CURL) (34): brown (boom LOWER) (35): none (swing LEFT) (36): blue (arm IN) (37): black (bucket DUMP) (38): green (boom RAISE) (39): red (swing RIGHT) (40): yellow (arm OUT) 10)Disconnect PPC drain hose (47).
6) Disconnect hose (41) to the attachment. (Machine with the attachment) (ID band colour: yellow) 7) Disconnect hoses (42) and (43). (42): red (L.H. travel FORWARD) (43): green (R.H. travel FORWARD)
8. Disconnection of wiring around the boom mounting section. a Remove the clamps, clips and bands that are fixing the wiring at the same time. 1) Disconnect horn connectors M07 (48) and M08 (49). 2) Disconnect work equipment harness connector A13 (50).
8) Disconnect hose (44) to the attachment. (Machine with the attachment) (ID band colour: none) 9) Disconnect hoses (45) and (46). (45): none (L.H. travel REVERSE) (46): blue (R.H. travel REVERSE)
PC228US-8, PC228USLC-8
50-159
Cab and its attachments Removal and installation of floor frame assembly
3) Disconnect boom connector A53 (51).
angle
potentiometer
2) Disconnect rear camera wiring connector A40 (64). 4) Disconnect air cleaner clogging sensor connector P23 (52). 5) Disconnect air conditioner outer sensor connector P32 (53). 6) Disconnect radiator coolant level sensor connector P24 (54). 7) Disconnect fusible link connectors F04 (55) and F05 (56).
3) Disconnect rear lamp wiring connector A15 (65).
9. Removal of wiring for the engine assembly a Remove the clamps, clips and bands that are fixing the wiring at the same time. 1) Disconnect connectors (57) to (65) at the left side of the engine assembly. (57): AC02 (air conditioner compressor) (58): E01 (electrical intake air heater) (59): K02 (terminating resistor) (60): CE02 (engine controller (CM850)) (61): CE03 (engine controller (CM850)) (62): T12 (engine controller ground (GND)) (63): E06 (engine harness)
50-160
PC228US-8, PC228USLC-8
Cab and its attachments Removal and installation of floor frame assembly
4) Disconnect connectors (66) to (68) at the right side of the engine assembly. (66): E08 (engine harness) (67): P44 (engine oil level sensor) (68): E10 (starting motor)
10. Removal of wiring for the main pump assembly a Remove the clamps, clips and bands that are fixing the wiring at the same time. 1) Disconnect connectors (69) to (71) around the main pump assembly. (69): P21 (fuel level sensor) (70): P47 (water-in-fuel sensor) (71): M14 (travel alarm)
11. Disconnection of wiring and hoses under the floor 1) Disconnect harnesses T04 (78), T05 (79), T06 (80), T07 (81), T08 (82), T09 (83) and T10 (84). 2) Disconnect battery relays R3 (85) and R4 (86). 3) Remove clips (87) and (88), and clamps (89), (90), (91) and (92).
4) Disconnect floor harnesses T01 (93) and T14 (94). 5) Remove clamps (95) and (96). 2) Disconnect connectors (72) to (77) for the main pump assembly. (72): P22 (hydraulic oil temperature sensor) (73): V12 (R-PC_EPC) (74): V11 (F-PC_EPC) (75): V19 (LS_EPC) (76): A54 (front pump swash plate sensor) (77): A55 (rear pump swash plate sensor)
PC228US-8, PC228USLC-8
50-161
Cab and its attachments Removal and installation of floor frame assembly
6) Disconnect electrical intake air heater relays R15 (97) and R16 (98). 7) Disconnect starting motor safety relays R17 (99) and R28 (100). 8) Disconnect battery relays R1 (101) and R2 (102). 9) Disconnect L.H. travel forward connector P10 (103) and L.H. travel reverse connector P28 (104). 10)Disconnect R.H. travel forward connector P9 (105) and R.H. travel reverse connector P27 (106). 11)Remove clips (107), (108) and (109), and clamp (110).
15)Disconnect wiring connector P17(119) for the air conditioner high/low pressure switch. 16)Disconnect air conditioner hoses (120) and (121). [*1] 17)Disconnect heater hose (122).
12. Disconnect ground cable (123).
12)Disconnect attachment pressure switch connector P13 (111) and ATT_EPC connector V30 (112). 13)Disconnect hoses (113) to (116) from the travel PPC valve. (113): red (L.H. travel FORWARD) (114): none (L.H. travel REVERSE) (115): green (R.H. travel FORWARD) (116): blue (R.H. travel REVERSE) 14)Disconnect hoses (117) and (118).
50-162
13. Remove wiring fixing pad (124) and draw out wiring (125).
PC228US-8, PC228USLC-8
Cab and its attachments Removal and installation of floor frame assembly
14. Sling and remove floor frame assembly (126). a Before lifting the floor frame assembly, check that every wiring connector and clamp is disconnected. a While gradually lifting up floor frame assembly (126), pull out the wiring on the control valve side. a When pulling out wiring on the control valve side, it may catch obstacles on the way to resist smooth removal. Do not pull the wire forcibly. Manage to evade obstacles patiently. 4 Floor frame assembly: Approx. 220 kg
Installation 50-163 q Perform installation in the reverse order to removal. [*1] a When installing the air conditioner hose, take care so that dust, dirt or water does not enter the hose. a Install the air conditioner hose after checking that O-ring (127) is installed in the coupler. a Check O-ring (127) for any damage or deterioration. a When connecting refrigerant piping, apply compressor oil for R134a system (DENSO: ND-OIL8 equivalent) to O-ring (127), and tighten the coupler using a double-wrench method. 3 Hose clamp (M6 bolt): 9.8 ± 1.96 Nm {1. 0± 0.2 kgm} 3 Air conditioner hose mounting bolt: 8 – 12 Nm {0.8 – 1.2 kgm}
Refilling with oil Run the engine to circulate the oil through the system. Then, supply the oil to the specified level.
q
Refilling with refrigerant Refill the air conditioner circuit with refrigerant (R134a). a Refrigerant refilling volume: 790 ± 50 g
q
Refilling with coolant Supply coolant through the coolant filler port to the specified level. Run the engine to circulate the coolant, and then check the coolant level. 5 Coolant: 21 l
q
PC228US-8, PC228USLC-8
50-163
Cab and its attachments Removal and installation of air conditioner unit assembly
Removal and installation of air conditioner unit assembly Removal 50-164 k Park the machine on level ground, lower the work equipment to the ground completely, stop the engine, and set the lock lever to LOCK position. k Disconnect the cable from the negative (-) terminal of the battery. k To prevent burn injury, disconnect the heater hose after the radiator coolant temperature lowers. a Note the installed positions of disconnected wires and connectors. 1. Collect the refrigerant (R134a) from the air conditioner circuit. a Ask a qualified person for collecting, adding and filling operation of refrigerant (R134a). a Never release the refrigerant (R134a) to the atmosphere. k If refrigerant gets in your eyes, you may lose your sight. And if it touches your skins, you may suffer from frostbite. Accordingly, put on protective eyeglasses, gloves and working suits with long sleeves while you are collecting the refrigerant or filling the air conditioner circuit with the refrigerant. Collecting and filling work must be conducted by a qualified person. q Amount of refrigerant to be collected: 790 ± 50 g 2. Remove cover (1).
4. Open drain valve (2) to drain the coolant. 6 Coolant:
21 l
5. Remove cover (3) under the operator’s cab.
6. Disconnect wiring connector P17 (4) for the air conditioner high/low pressure switch. 7. Disconnect air conditioner hoses (5) and (6).[*1] 8. Disconnect heater hose (7).
3. Swing the upper structure 90 ° .
50-164
PC228US-8, PC228USLC-8
Cab and its attachments Removal and installation of air conditioner unit assembly
9. Remove front window assembly (8). For details, see "Removal and installation of front window assembly". 10. Remove floor mat (9) and cover (10). 11. Remove machine monitor (11). For details, see "Removal and installation of machine monitor assembly." 12. Remove front cover (12) of the air conditioner unit assembly. 13. Remove right side covers (13) and (14).
17. Open cover (20) on the left side of the machine and remove fresh air filter (21) of the air conditioner.
18. Remove fresh air duct (22) of the air conditioner. 19. Remove rear left clip (23) and clamp (24). 20. Remove four mounting bolts (26) of bracket (25), and reposition the bracket and the harness as a unit beside the operator's seat.
14. Remove two clips (15) and draw ducts (23) and (24) down in the direction of arrow. [*2]
21. Remove rear joint duct (27). 22. Remove clip (28) and the clamp at the rear right of the unit. 15. Remove cover (18) after tilting the operator's seat forward and down. 16. Remove cover (19).
PC228US-8, PC228USLC-8
50-165
Cab and its attachments Removal and installation of air conditioner unit assembly
23. Remove band (29). 24. Disconnect harness connectors AC01 (30) and N10 (31). 25. Disconnect harness connectors (33) and (34) from engine controller (32).
29. Using mounting bolt (42) as a fulcrum, turn machine monitor cover (40) in the direction of the arrow. a Secure it at a position where it does not interfere right side duct (35).
26. Remove cable clip (36) on right side duct (35) to disconnect cable (37) from duct lever (38). a Remove cable clip (36) by lowering it with a flat-head screwdriver that is inserted in the gap between the cable and clip. 27. Remove two mounting bolts (39) at the front and rear of right side duct (35).
30. Remove right side duct (35) by pulling it in the direction of the arrow.
31. Remove left cover (44) from seat mounting bracket (43).
28. Remove three mounting bolts (41) of machine monitor cover (40) and loosen mounting bolt (42) a little.
50-166
PC228US-8, PC228USLC-8
Cab and its attachments Removal and installation of air conditioner unit assembly
32. Remove wiring harness clamp (45). 33. Remove three mounting bolts (46) for each right and left of seat mounting bracket (43).
36. Screw in the forcing screws [1] evenly on the right and left sides to raise seat mounting bracket (43) for producing clearance (a) from the floor. Clearance (a): Approx. 100 mm a Secure clearance (a) for preventing any interference when drawing out the air conditioner unit assembly.
34. Remove air conditioner unit assembly mounting bolts (4), three front mounting bolts, and two rear mounting bolts.
37. Pull out air conditioner unit assembly (48) in the direction of the arrow to remove it. a Check that all the wiring and piping are disconnected before removing the air conditioner unit.
35. Install forcing screws (M12, L=130 mm) [1]; two at the left side and one at the right side, respectively.
PC228US-8, PC228USLC-8
50-167
Cab and its attachments Removal and installation of air conditioner unit assembly
Installation 50-168 q Perform installation in the reverse order to removal.
[*2] q
Install ducts (16) and (17) according to the following procedure. 1) Insert ducts (16) and (17) beforehand to the base of right side duct (35). 2) Using mounting bolt (42) as a fulcrum, turn machine monitor cover (40) in the direction of the arrow to restore it to the original position. 3) Pull ducts (16) and (17) upward in the direction of the arrow to install them.
q
Refilling with refrigerant (R134a) Refill the air conditioner circuit with refrigerant (R134a). a Refrigerant refilling volume: 790 ± 50 g
q
Addition of air compressor oil See Air conditioner, "Handling of compressor oil".
q
Refilling with coolant Supply coolant through the coolant filler port to the specified level. Run the engine to circulate the coolant, and then check the coolant level again.
[*1] a When installing the air conditioner hose, take care so that dust, dirt or water does not enter the hose. a Install the air conditioner hose, after checking that O-ring (70) is installed in the coupler. a Check O-ring (70) for any damage or deterioration. a When connecting refrigerant piping, apply compressor oil for R134a system (DENSO: ND-OIL8) to O-ring (70), and tighten the coupler using a double-wrench method. 3 Hose clamp (M6 bolt): 9.8 ± 1.96 Nm {1.0 ± 0.2 kgm} 3 Air conditioner hose mounting bolt: 8 – 12 Nm {0.8 – 1.2 kgm}
5
50-168
Coolant:
21 l
PC228US-8, PC228USLC-8
Cab and its attachments Removal and installation of air conditioner unit assembly
PC228US-8, PC228USLC-8
50-169
Electrical system Removal and installation of air conditioner compressor assembly
Electrical system Removal and installation of air conditioner compressor assembly Removal 50-170 k Disconnect the cable from the negative (-) terminal of the battery. 1. Collect the refrigerant (R134a) from the air conditioner circuit. a Ask a qualified person for collecting, adding and filling operation of refrigerant (R134a). a Never release the refrigerant (R134a) to the atmosphere. k If refrigerant gets in your eyes, you may lose your sight. And if it touches your skins, you may suffer from frostbite. Accordingly, put on protective eyeglasses, gloves and working suits with long sleeves while you are collecting the refrigerant or filling the air conditioner circuit with the refrigerant. Collecting and filling work must be conducted by a qualified person. q Amount of refrigerant to be collected: 790 ± 50 g 2. Open engine hood (1) and remove cover (2).
50-170
3. Disconnect rear camera wiring connector A40 (8). 4. Remove wiring clamp (9). 5. Remove radiator hose clamp (10). 6. Remove air conditioner compressor hose clamp (11). 7. Remove fuel filter and bracket assembly (12), and reposition them forward so that it does not interfere with the maintenance counterweight assembly.
8. Disconnect rear lamp wiring connector A15 (13). 9. Sling engine hood (14) and remove mounting bolts (15). 10. Sling and remove engine hood (14). 4 Engine hood: 35 kg
PC228US-8, PC228USLC-8
Electrical system Removal and installation of air conditioner compressor assembly
11. Disconnect wiring connector AC02 (16) for the air conditioner compressor. 12. Disconnect two air conditioner compressor hoses (17) and (18). [*1] a Plug the hose to prevent any dirt, dust and water from entering. a Take care not to damage or lose the O-rings. 13. Loosen mounting bolts (19) and (20), and remove air conditioner compressor belt (21) from pulleys. [*2] 14. Remove wiring clamp (22). 15. Remove four air conditioner mounting bolts (23). 16. Disconnect air conditioner assembly (24) from the bracket.
compressor [*3] compressor
Installation 50-171 q Perform installation in the reverse order to removal. [*1] a When installing the air conditioner hose, take care so that dust, dirt or water does not enter the hose. a Install the air conditioner hose after checking that O-ring (70) is installed in the coupler. a Check O-ring (70) for any damage or deterioration. a When connecting refrigerant piping, apply compressor oil for R134a system (DENSO: ND-OIL8 equivalent) to O-ring (70) before tightening. 3 Hose fitting mounting bolt (M6 bolt): 8 – 12 Nm {0.8 – 1.2 kgm}
[*2] a Adjust air conditioner compressor belt tension. For details, see Testing and adjusting, "Testing and adjusting tension of air conditioner compressor belt". [*3]
3 Air
conditioner compressor mounting bolt (23): 24.5 – 29 Nm {2.5 – 3.0 kgm}
Refilling with refrigerant Refill the air conditioner circuit with refrigerant (R134a). a Refrigerant refilling volume: 790 ± 50 g
q
PC228US-8, PC228USLC-8
50-171
Electrical system Removal and installation of air conditioner condenser assembly
Removal and installation of air conditioner condenser assembly Removal 50-172 k Disconnect the cable from the negative (-) terminal of the battery. 1. Collect the refrigerant (R134a) from the air conditioner circuit. a Ask a qualified person for collecting, adding and filling operation of refrigerant (R134a). a Never release the refrigerant (R134a) to the atmosphere. k If refrigerant gets in your eyes, you may lose your sight. And if it touches your skins, you may suffer from frostbite. Accordingly, put on protective eyeglasses, gloves and working suits with long sleeves while you are collecting the refrigerant or filling the air conditioner circuit with the refrigerant. Collecting and filling work must be conducted by a qualified person. q Amount of refrigerant to be collected: 790 ± 50 g 2. Disconnect hoses (1) and (2) from the air conditioner condenser. [*1]
3. Remove four air conditioner condenser mounting bolts (3) and remove air conditioner condenser assembly (4). [*2] a In this removal operation, take care so as not to damage the core part.
50-172
Installation 50-172 q Perform installation in the reverse order to removal. [*1] a When installing the air conditioner circuit hose, take care so that dust, dirt or water does not enter the hose. a When installing the air conditioner hose, check that O-ring (70) is installed in the coupler. a Check O-ring (70) for any damage and deterioration. a When connecting refrigerant piping, apply compressor oil for R134a system (DENSO: ND-OIL8) to O-ring (70) and then tighten the connector using a double-wrench method. 3 Hose mounting bolt (M6): 9.8 ± 1.96 Nm {1.0 ± 0.2 kgm}
[*2] a Mount the air conditioner condenser assembly by inserting cushions in place. 3 Air conditioner condenser assembly mounting bolt: 12.5 ± 2.5 Nm {1.27 ± 0.25 kgm} Refilling with refrigerant q Refill the air conditioner circuit with refrigerant (R134a) . a Refrigerant refilling volume: 790 ± 50 g PC228US-8, PC228USLC-8
Electrical system Removal and installation of engine controller assembly
Removal and installation of engine controller assembly Removal 50-173 k Disconnect the cable from the negative (-) terminal of the battery. 1. Remove the maintenance counterweight assembly. For details, see "Removal and installation of maintenance counterweight assembly". 2. Disconnect wiring connectors CE02 (2) and (3) from engine controller (1). a Connectors (2) and (3) are locked with a hexagonal socket head bolt L1(4 mm). 3. Press the locks to disconnect wiring connector E03 (4) from engine controller (1).
4. Remove three engine controller mounting bolts (5). [*1] a The harness clamp is tightened with blot (5). 5. Remove engine controller mounting bolts (6) and (7). [*2] a Ground cable (8) is tightened with bolt (6). 6. Remove engine controller (1).
PC228US-8, PC228USLC-8
50-173
Electrical system Removal and installation of engine controller assembly
Installation 50-174 q Perform installation in the reverse order to removal.
[*1] When installing mounting bolts (5), tighten the harness clamps together.
a Reference Method of replacing the O-ring of power supply connector (9). O-ring seal: 1010-074-0406 (Deutsch Japan Ltd.) 1) Remove the cover (10) by holding down the tabs with tweezers [1].
[*2] When installing mounting bolt (6), tighten the ground cable (8) together.
q
2) Use tweezers [1] to pick out O-ring (11).
50-174
PC228US-8, PC228USLC-8
Electrical system Removal and installation of pump controller assembly
Removal and installation of pump controller assembly Removal 50-175 k Disconnect the cable from the negative (-) terminal of the battery. 1. Remove cover (1) after tilting the operator's seat forward and down. 2. Remove cover (2).
6. Disconnect harness connectors C01 (8) and C02 (9) at the back of bracket (6). a For disconnecting harness connectors C01 (8) and C02 (9) of the pump controller assembly, press the connector locks (a) and pull each lever (13) to the inside. 7. Remove bracket (10). 8. Remove four mounting bolts (11) and remove pump controller assembly (12).
3. Remove fresh air duct (3) of the air conditioner. 4. Remove rear left clip (4) and clamp (5). 5. Remove four mounting bolts (7) of bracket (6), and place the bracket and the harness, as a unit beside the operator's seat.
PC228US-8, PC228USLC-8
50-175
Electrical system Removal and installation of pump controller assembly
Installation 50-176 q Perform installation in the reverse order to removal.
a Connector cover (1) removed
a Reference 1. How to remove connector cover (1) 1) Cut and remove cable tie (2). 2) Move lever (3) upward.
2. How to install connector covers 1) Push right and left sliders (4) in all the way.
3) Lightly press part (A) of connector cover (1) to release tabs (B). 4) To escape tab (C), remove connector cover (1) while swinging it just like drawing an arc.
a Right and left sliders (4) pushed in all the way (left figure) 2) Move lever (3) on connector cover (1) from the top position to the left position in the figure (locked position). a (B) , (C) : Tabs a If the sliders and lever are not set as shown in the following figure, the connector is not disconnected or locked securely with the lever. Accordingly, check their positions again
50-176
PC228US-8, PC228USLC-8
Electrical system Removal and installation of pump controller assembly
3) Set tab (C) on the connector and place connector cover (1) in position. a Take care so as not to let harness (5) be caught in.
4) Install connector cover (1) with the tabs (B) set in position.
5) Replace the cut cable tie with a new one and fasten connector cover (1) and harness with the new cable tie. (See 1.1.)
PC228US-8, PC228USLC-8
50-177
Electrical system Removal and installation of machine monitor assembly
Removal and installation of machine monitor assembly Removal 50-178 k Disconnect the cable from the negative (-) terminal of the battery. k Park the machine on level ground, lower the work equipment to the ground completely, stop the engine, and set the lock lever to LOCK position.
3. Disconnect harness connectors CM01 (3), CM02 (4) and CM03 (5). 4. Remove four mounting bolts (6) and draw out machine monitor assembly (7) a little. [*1]
1. Remove the three mounting bolts and two clips, then remove cover (1). a One of the mounting bolts is installed in the cap on the right of the sunlight sensor. a When removing cover (1), disconnect also wiring connector P31 for the sunlight sensor at the same time.
5. Remove mounting bolt (8) and remove cover (9).
2. Remove duct (2).
6. Turn cover (9), and disconnect cigarette lighter harness connector M04 (10).
50-178
PC228US-8, PC228USLC-8
Electrical system Removal and installation of machine monitor assembly
7. With machine monitor assembly (7) drawn out a little, disconnect rear camera harness connector A43 (11) and GPS antenna harness connector (12). 8. Remove machine monitor assembly (7).
Installation 50-179 q Perform installation in the reverse order to removal. q For the setup procedure after replacing the machine monitor assembly, see Service News (AT07196.) [*1] a Since cover (9) may not be properly set if the installation is performed in the reverse order to removal, follow the steps below: 1. Temporarily fasten machine monitor assembly (7) with four mounting bolts (6). 2. Install cigarette lighter harness connector M04 (10) to cover (9). 3. Install cover (9) to the machine monitor assembly. 4. With cover (9) in place, fully tighten the machine monitor assembly mounting bolt (6).
PC228US-8, PC228USLC-8
50-179
Electrical system Removal and installation of pump swash plate sensor
Removal and installation of pump swash plate sensor Removal 50-180 k Disconnect the cable from the negative (-) terminal of the battery. 1. Open the rear right inspection cover and remove partition plate (1).
2. Disconnect front pump swash plate sensor harness connector A54 (2) and rear pump swash plate sensor harness connector A55 (3). a Front pump swash plate sensor harness connector A54 (2) is installed on the left side of the main pump. 3. Disconnect front pump swash plate sensor harness clamp (4) and rear pump swash plate sensor harness clamp (5). 4. Remove mounting bolts (6), then remove front pump swash plate sensor (7) and rear pump swash plate sensor (8). [*1]
50-180
Installation 50-180 q Perform installation in the reverse order to removal. [*1] a Adjust the pump swash plate sensor. For details, see Testing and adjusting "Testing and adjustment of pump swash plate sensors". 3 Pump swash plate sensor mounting bolt: 11.8 – 14.7 Nm {1.2 – 1.5 kgm}
PC228US-8, PC228USLC-8
Electrical system Removal and installation of KOMTRAX terminal assembly
Removal and installation of KOMTRAX terminal assembly Removal 50-181 k Disconnect the cable from the negative (-) terminal of the battery. 1. Fold the operator's seat forward and remove cover (1). 2. Remove cover (2).
6. Disconnect wiring connectors CK01 (8), CK02 (9) and antenna cable (10). 7. Remove four mounting bolts (11) and remove KOMTRAX terminal assembly (12).
Installation 50-181 Perform installation in the reverse order to removal.
q
3. Remove air conditioner fresh air duct (3). 4. Remove clip (4) and clamp (5) from the rear left side. 5. Remove four mounting bolts (7) for bracket (6). Move the bracket and harness toward the operator's seat.
PC228US-8, PC228USLC-8
50-181
Electrical system Disassembly and Assembly of Quick Coupler Valve
Disassembly and Assembly of Quick Coupler Valve INSTALLATION REMOVAL OF PRESSURE REGULATING VALVE q
1.
q
The pressure regulating valves (1) + (5) can be removed as a complete unit using 26mm spanner. In case of malfunction of regulating valve replace the unit.
Install in reverse order to removal.
Tightening torque values for: Directional control valve (3/4" - 16UNF) - 24 - 36Nm Solenoid (3/4" hex) - 3.3 - 4.9Nm Pressure regulating valve (7/8" - 14 UNF, 26A/F) 40 - 60Nm
REMOVAL OF SOLENOID AND DIRECTIONAL CONTROL VALVE 1. 2. q
Remove nut 2a using 3/4" spanner. Remove directional control valve (3) using 7/8" spanner. In case of malfunction of the coil or the directional control valve replace them as complete units.
1a 2a
2 1b
1 4
3
5 5a 5b
1 1a 1b 2 2a 3 4 5
50-182
Pressure regulating valve Lock nut Adjustment screw Solenoid Nut Directional control valve Block Pressure regulating valve
5a 5b
Lock nut Adjustment screw
PC228US-8, PC228USLC-8
SEN0533429-00
60-1
PC228US-8,PC228USLC-8
HYDRAULIC EXCAVATOR PC228US-8 PC228USLC-8 Shop Manual
Machine model
Serial number
PC228US-8 PC228USLC-8
50001 and up 50001 and up
60 Maintenance standard
PC228US-8,PC228USLC-8
60-1
60-1
Contents
Contents 60 Maintenance standard Engine and cooling system ............................................................................................................ 60-4 Engine mount.............................................................................................................................. 60-4 Cooling system ........................................................................................................................... 60-5 Power train..................................................................................................................................... 60-6 Swing circle................................................................................................................................. 60-6 Swing machinery......................................................................................................................... 60-8 Final drive ................................................................................................................................... 60-10 Sprocket...................................................................................................................................... 60-12 Undercarriage and frame ............................................................................................................... 60-14 Track frame and idler cushion..................................................................................................... 60-14 Idler ............................................................................................................................................. 60-16 Track roller .................................................................................................................................. 60-18 Carrier roller ................................................................................................................................ 60-19 Track shoe .................................................................................................................................. 60-20 Hydraulic system............................................................................................................................ 60-26 Hydraulic tank ............................................................................................................................. 60-26 Main pump .................................................................................................................................. 60-27 Control valve ............................................................................................................................... 60-29 Swing motor ................................................................................................................................ 60-39 Travel motor................................................................................................................................ 60-41 PPC valve ................................................................................................................................... 60-45 Solenoid valve............................................................................................................................. 60-53 Attachment circuit selector valve ................................................................................................ 60-55 Anti-drop valve ............................................................................................................................ 60-58 Centre swivel joint....................................................................................................................... 60-60 Work equipment............................................................................................................................. 60-62 Work equipment.......................................................................................................................... 60-62 Dimensions of components......................................................................................................... 60-64 Work equipment cylinder ............................................................................................................ 60-68
60-2
PC228US-8,PC228USLC-8
Contents
PC228US-8,PC228USLC-8
60-3
Engine and cooling system Engine mount
Engine and cooling system Engine mount
60-4
PC228US-8,PC228USLC-8
Engine and cooling system Cooling system
Cooling system
PC228US-8,PC228USLC-8
60-5
Power train Swing circle
Power train Swing circle Standard specification
60-6
Unit: mm
No. 1
60-6
Item Axial clearance of bearing (when installed on machine)
Criteria
Remedy
Standard clearance
Allowable clearance
0.5 – 1.6
3.2
Replace
PC228US-8,PC228USLC-8
Power train Swing circle
North America specification
60-7
Unit: mm
No. 1
Item Axial clearance of bearing (when installed on machine)
PC228US-8,PC228USLC-8
Criteria
Remedy
Standard clearance
Allowable clearance
0.5 – 1.6
3.2
Replace
60-7
Power train Swing machinery
Swing machinery
60-8
PC228US-8,PC228USLC-8
Power train Swing machinery
Unit: mm
No. 1
Item Backlash between swing motor shaft and No. 1 sun gear
Criteria Standard clearance
Allowable clearance
0.18 – 0.28
–
0.16 – 0.50
1.0
0.18 – 0.59
1.1
0.39 – 0.71
1.2
0.16 – 0.50
0.9
0.18 – 0.59
1.0
0.07 – 0.23
–
0.22 – 1.32
2.0
0.9 ± 0.24
–
2.3 ± 0.64
–
Backlash between No. 1 sun gear and No. 1 planetary gear Backlash between No. 1 planetary 3 gear and ring gear Backlash between No. 1 planetary 4 carrier and No. 2 sun gear Backlash between No. 2 sun gear 5 and No. 2 planetary gear Backlash between No. 2 planetary 6 gear and ring gear Backlash between No. 2 planetary 7 carrier and swing pinion Backlash between swing pinion and 8 swing circle Clearance between plate and No. 2 9 planetary carrier Clearance between plate and No. 2 10 sun gear
2
11
Outside diameter of oil seal contact surface on swing pinion collar
PC228US-8,PC228USLC-8
Remedy
Standard dimension 125
Tolerance 0 -0.100
Repair limit –
Replace
Repair by hard chrome-plating or replace
60-9
Power train Final drive
Final drive
60-10
PC228US-8,PC228USLC-8
Power train Final drive
Unit: mm
No.
Item
1
Backlash between No. 2 planetary carrier and travel motor
2 3 4 5 6
Backlash between No. 2 planetary gear and ring gear Backlash between No. 2 planetary gear and No. 2 sun gear Backlash between No.1 planetary gear and ring gear Backlash between No. 1 planetary gear and No. 1 sun gear Backlash between No.1 planetary carrier and No.2 sun gear
Criteria Standard clearance
Allowable clearance
0.16 – 0.53
–
0.16 – 0.57
1.00
0.15 – 0.49
1.00
0.16 – 0.53
1.00
0.14 – 0.44
1.00
0.36 – 0.65
1.00
7 Amount of wear on sprocket tooth 8 Width of sprocket tooth
PC228US-8,PC228USLC-8
Remedy
Repair limit: 6 Standard dimension
Repair limit
71
68
Replace
Build-up welding for rebuilding or replace
60-11
Power train Sprocket
Sprocket
Unit: mm
No.
Item
Criteria
Remedy
Standard dimension
Repair limit
294.5
282.5
2 Thickness of tooth root
17
11
3 Width of tooth
71
68
1 Wear of tooth tip
4 Wear of tooth shape
60-12
Build-up welding for rebuilding or replace
Repair limit: 6 (use a full-size drawing of sprocket tooth shape to judge)
PC228US-8,PC228USLC-8
Power train Sprocket
Full-size drawing of sprocket tooth shape 60-13 a Duplicate the drawing onto an OHP viewgraph at a magnification that restores the scale to the full-size.
PC228US-8,PC228USLC-8
60-13
Undercarriage and frame Track frame and idler cushion
Undercarriage and frame Track frame and idler cushion a The following figure shows PC228US-8.
60-14
PC228US-8,PC228USLC-8
Undercarriage and frame Track frame and idler cushion
Unit: mm
No.
1
2
Item
Vertical width of idler guide
Horizontal width of idler guide
Criteria Standard dimension
Tolerance
Repair limit
Track frame
107
–
–
Idler support
105
–
–
Track frame
250
–
–
Idler support
247.4
–
–
Standard dimension
3 Recoil spring
Remedy
Standard specification North America specification and KUK specification
PC228US-8,PC228USLC-8
Build-up welding for rebuilding or replace
Repair limit Load at Free installed length length
Free length x Outside diameter
Installed length
Installed load
561 x 237
433
126.3 kN {12,890 kg}
534
101 kN {10,300 kg}
556 x 241
433
137.3 kN {14,010 kg}
532
109.8 kN {11,200 kg}
Replace
60-15
Undercarriage and frame Idler
Idler
60-16
PC228US-8,PC228USLC-8
Undercarriage and frame Idler
Unit: mm
No.
Item
Criteria
Remedy
Standard dimension
Repair limit
538
–
2 Outside diameter of tread
500
488
3 Thickness of tread
26
20
4 Difference of tread
19
25
5 Overall width
159
–
6 Width of tread
37.5
–
1 Outside diameter of protrusion
7
8
Clearance between shaft and bushing
Interference between idler and bushing Clearance between bushing and
9 support (Total of both sides)
PC228US-8,PC228USLC-8
Tolerance Shaft Hole - 0.250 + 0.164 65 - 0.350 - 0.074 Tolerance Standard dimension Shaft Hole + 0.108 - 0.032 72 + 0.008 - 0.062 Standard size Standard dimension
0.5 – 1.0
Build-up welding for rebuilding or replace
Standard clearance
Allowable clearance
0.176 – 0.514
–
Standard Allowable interference interference 0.040 – 0.170 Repair limit
Replace bushing
–
–
60-17
Undercarriage and frame Track roller
Track roller
Unit: mm
No.
Item
Criteria
Remedy
Standard dimension
Repair limit
188
–
2 Outside diameter of tread
156
144
3 Thickness of tread
44.5
38.5
4 Overall width
225
–
5 Width of tread
44.5
–
6 Width of flange
25.5
–
1 Outside diameter of flange
7
8
Clearance between shaft and bushing
Interference between roller and bushing Clearance between bushing and
9 collar (Total of both sides)
60-18
Tolerance Shaft Hole - 0.215 + 0.195 60 - 0.315 0 Tolerance Standard dimension Shaft Hole + 0.153 + 0.030 67 + 0.053 0 Standard size Standard dimension
0.5 – 1.0
Build-up welding for rebuilding or replace
Standard clearance
Allowable clearance
0.215 – 0.510
–
Standard Allowable interference Interference 0.023 – 0.153 Repair limit –
Replace bushing
– Replace
PC228US-8,PC228USLC-8
Undercarriage and frame Carrier roller
Carrier roller
Unit: mm
No.
Item
Criteria
Remedy
Standard dimension
Repair limit
145
–
2 Outside diameter of tread
120
106
3 Width of tread
43
–
4 Thickness of tread
23
16
5 Width of flange
14
–
1 Outside diameter of flange
6
7
Clearance between shaft and bushing
Interference between roller and bushing
8 End play in axial direction
PC228US-8,PC228USLC-8
Tolerance Shaft Hole - 0.170 + 0.301 40 - 0.190 + 0.168 Tolerance Standard dimension Shaft Hole + 0.061 0 47 + 0.016 - 0.040 Standard clearance Standard dimension
0.44 – 0.76
Standard clearance
Allowable clearance
0.338 – 0.491
–
Replace
Standard Allowable interference interference 0.016 – – 0.101 Allowable clearance –
60-19
Undercarriage and frame Track shoe
Track shoe
a P portion shows the link of bushing press-fitting end. *1. Triple grouser shoe *2. Road liner shoe [PC228USLC-8 (North America specification only)]
60-20
PC228US-8,PC228USLC-8
Undercarriage and frame Track shoe
Unit: mm
No.
Item
Criteria Standard dimension
1 Link pitch
2 Outside diameter of bushing 3 Thickness of bushing 4 Link height 5
Thickness of link (bushing press-fit part)
Repair limit
190.3
193.3
Standard dimension
Reverse
59.3
54.3
10.4
5.4
Standard dimension
Repair limit
105
97
28.5
20.5
6
160.4
7 Shoe bolt pitch
124.4
8
62
9 10 Link 11
Remedy
Inside width
84.8
Overall width
45.4
Tread width
39.6
Regular
2.5
Master
2.5
Regular
4.85
Master
0.0
Regular
212
Master
212
Regular
138.5
Master
128.7
Reverse or replace
Repair or replace
12 Protrusion of pin Adjust or replace
13 Protrusion of bushing
14 Overall length of pin
15
Overall length of bushing
16 Thickness of spacer 17
– Bushing
88.2 – 245 kN {9 – 25 ton}
18 Press-fitting force
Regular pin
127.4 – 274.4 kN {13 – 28 ton}
19 (*)
Master pin
78.4 – 147 kN {8 – 15 ton}
–
* Dry type track link
PC228US-8,PC228USLC-8
60-21
Undercarriage and frame Track shoe
Unit: mm
No.
Item
Criteria
a. Regular link
20 Shoe bolt b. Master link
Interference between bushing and 21 link
22
Interference between regular pin and link
23
Clearance between regular pin and bushing
24 Interference between master pin (*) and link
Remedy
Tightening torque Re tightening angle (Nm {kgm}) (deg.) 490 ± 49 120 ± 10 Triple grouser shoe {50 ± 5} Road liner 549 ± 59 – (Rubber pad type) {56 ± 6} Tightening torque Re tightening angle Lower limit torque (Nm {kgm}) (deg.) (Nm {kgm}) – Standard dimension 59 38 Standard dimension 38 Standard dimension 37.8
25 Clearance between master pin and Standard dimension (*) bushing 38
–
–
Tolerance Shaft Hole + 0.434 + 0.074 + 0.394 0 + 0.222 - 0.138 + 0.162 - 0.200 Tolerance Shaft Hole + 0.222 + 0.902 + 0.162 + 0.402 Tolerance Shaft Hole + 0.280 + 0.062 + 0.250 0 Tolerance Shaft Hole - 0.150 + 0.902 - 0.350 + 0.402
Standard interference
Re tighten
0.320 – 0.434 0.300 – 0.422 Standard clearance 0.180 – 0.740
Adjust or replace
Standard interference 0.188 – 0.280 Standard clearance 0.552 – 1.252
* Dry type track link
60-22
PC228US-8,PC228USLC-8
Undercarriage and frame Track shoe
Triple grouser shoe
60-23
Unit: mm
No.
Item
Criteria
1 Grouser overall height
Remedy
Standard dimension
Repair limit
26
16
36
26
34.5
24.5
2 Shoe overall height (*)
10
3 Plate thickness (*)
4
8.5 26
Build-up welding for rebuilding or replace
Grouser bottom length
5
19
6
20
7 Grouser tip length
14
8
19
*: The 600 mm wide triple shoe for the PC228US-8 (standard specification) is shown.
PC228US-8,PC228USLC-8
60-23
Undercarriage and frame Track shoe
Road liner
60-24
Unit: mm
No. 1 Shoe height
60-24
Item
Criteria
Remedy
70
Replace
PC228US-8,PC228USLC-8
Undercarriage and frame Track shoe
PC228US-8,PC228USLC-8
60-25
Hydraulic system Hydraulic tank
Hydraulic system Hydraulic tank
60-26
PC228US-8,PC228USLC-8
Hydraulic system Main pump
Main pump Type: HPV95+95
PC228US-8,PC228USLC-8
60-27
Hydraulic system Main pump
60-28
PC228US-8,PC228USLC-8
Hydraulic system Control valve
Control valve General view
PC228US-8,PC228USLC-8
60-29
60-29
Hydraulic system Control valve
Sectional view (1/5)
60-30
60-30
PC228US-8,PC228USLC-8
Hydraulic system Control valve
Unit: mm
No.
Item
1 Spool return spring
2 Spool return spring 3 Spool return spring 4 Spool return spring
PC228US-8,PC228USLC-8
Criteria Standard dimension Load at Free length x Installed installed Outside length length diameter 407 N 55.2 x 34.4 51.2 {41.5 kg} 393 N 54.5 x 34.8 51.2 {40.1 kg} 375 N 54.4 x 34.8 51.2 {38.2 kg} 421 N 54.6 x 34.8 51.2 {42.9 kg}
Remedy Repair limit Load at Free installed length length 326 N – {33.2 kg} 315 N – {32.1 kg} 300 N – {30.6 kg} 336 N – {34.3 kg}
If damaged or deformed, replace spring.
60-31
Hydraulic system Control valve
(2/5)
60-32
PC228US-8,PC228USLC-8
Hydraulic system Control valve
Unit: mm
No.
Item
1 Suction valve spring
2 Check valve spring
PC228US-8,PC228USLC-8
Criteria Standard dimension Load at Free length x Installed installed Outside length length diameter 5.5 N 46.8 x 7.5 40.6 {0.56 kg} 1.5 N 11.5 x 4.6 8.5 {0.15 kg}
Remedy Repair limit Load at Free installed length length 4.4 N – {0.45 kg} 1.2 N – {0.12 kg}
If damaged or deformed, replace spring.
60-33
Hydraulic system Control valve
(3/5)
60-34
PC228US-8,PC228USLC-8
Hydraulic system Control valve
Unit: mm
No.
Item
1 Check valve return spring
2 Check valve spring 3 Piston return spring 4 Check valve spring 5 Piston return spring 6 Piston return spring
PC228US-8,PC228USLC-8
Criteria Standard dimension Load at Free length x Installed installed Outside length length diameter 14.7 N 59.3 x 14.4 43 {1.5 kg} 13.7 N 33.8 x 6 29 {1.4 kg} 170 N 60.2 x 20 36 {17.3 kg} 5.9 N 31.5 x 10.3 19.5 {0.6 kg} 157 N 88.2 x 28.4 65 {16 kg} 52.7 N 22.35 x 9.3 13.4 {5.37 kg}
Remedy Repair limit Load at Free installed length length 11.8 N – {1.2 kg} 11 N – {1.12 kg} 135 N – {13.8 kg} 4.71 N – {0.48 kg} 126 N – {12.8 kg} 42.2 N – {4.30 kg}
If damaged or deformed, replace spring.
60-35
Hydraulic system Control valve
(4/5)
60-36
PC228US-8,PC228USLC-8
Hydraulic system Control valve
Unit: mm
No.
Item
1 Spool return spring
2 Check valve spring 3 Spool return spring 4 Check valve spring 5 Check valve spring 6 Check valve return spring 7 Piston return spring
PC228US-8,PC228USLC-8
Criteria Standard dimension Load at Free length x Installed installed Outside length length diameter 121 N 36.4 x 21.8 33.0 {12.3 kg} 250 N 70.9 x 18.0 56.0 {25.5 kg} 178 N 64.5 x 32.3 63.0 {18.1 kg} 35.3 N 33.0 x 12.0 26.0 {3.6 kg} 13.7 N 33.8 x 6.0 29.0 {1.4 kg} 5.9 N 31.5 x 10.3 19.5 {0.6 kg} 50.0 N 30.7 x 20.5 23 {5.1 kg}
Remedy Repair limit Load at Free installed length length 96.5 N – {9.84 kg} 200 N – {20.4 kg} 142 N – {14.5 kg} 28.2 N – {2.88 kg} 11.0 N – {1.12 kg} 4.71 N – {0.48 kg} 40.0 N – {4.08 kg}
If damaged or deformed, replace spring.
60-37
Hydraulic system Control valve
(5/5)
60-38
PC228US-8,PC228USLC-8
Hydraulic system Swing motor
Swing motor Type: KMF125AB-5
PC228US-8,PC228USLC-8
60-39
Hydraulic system Swing motor
Unit: mm
No.
Item
1 Check valve spring
2 Shuttle valve spring
60-40
Criteria Standard dimension Load at Free length x Installed installed Outside diamlength length eter 3.53 N 57.2 x 20.0 30.0 {0.36 kg} 13.7 N 16.4 x 8.9 11.5 {1.4 kg}
Remedy Repair limit Load at Free installed length length 2.84 N – {0.29 kg} 11.0 N – {1.12 kg}
If damaged or deformed, replace spring.
PC228US-8,PC228USLC-8
Hydraulic system Travel motor
Travel motor Type: HMV110-2
PC228US-8,PC228USLC-8
60-41
Hydraulic system Travel motor
60-42
PC228US-8,PC228USLC-8
Hydraulic system Travel motor
Unit: mm
No.
Item
1 Regulator piston spring
2 Regulator piston spring 3 Check valve spring 4 Check valve spring 5 Check valve spring
PC228US-8,PC228USLC-8
Criteria Standard dimension Load at Free length x Installed installed Outside diamlength length eter 147 N 52.6 x 20.3 36.0 {15.0 kg} 54.9 N 21.5 x 11.1 17.1 {5.6 kg} 1.96 N 13.0 x 6.5 9.5 {0.2 kg} 7.16 N 32.5 x 6.5 24.2 {0.73 kg} 427 N 58.4 x 30.0 42.0 {43.5 kg}
Remedy Repair limit Load at Free installed length length 118 N – {12.0 kg} 43.9 N – {4.48 kg} 1.57 N – {0.16 kg} 5.69 N – {0.58 kg} 341 N – {34.8 kg}
If damaged or deformed, replace spring.
60-43
Hydraulic system Travel motor
60-44
PC228US-8,PC228USLC-8
Hydraulic system PPC valve
PPC valve a PPC: Abbreviation for Proportional Pressure Control Work equipment and swing PPC valve
PC228US-8,PC228USLC-8
60-45
60-45
Hydraulic system PPC valve
60-46
PC228US-8,PC228USLC-8
Hydraulic system PPC valve
Unit: mm
No.
1
2
Item
Centring spring (for ports P3 and P4)
Centring spring (for ports P1 and P2)
3 Metering spring
PC228US-8,PC228USLC-8
Criteria Standard dimension Load at Free length x Installed installed Outside diamlength length eter 17.7 N 42.5 x 15.5 34.0 {1.80 kg} 29.4 N 44.5 x 15.5 34.0 {3.0 kg} 16.7 N 26.5 x 8.15 24.9 {1.70 kg}
Remedy Repair limit Load at Free installed length length 14.1 N – {1.44 kg} 23.5 N – {2.40 kg} 13.3 N – {1.36 kg}
If damaged or deformed, replace spring
60-47
Hydraulic system PPC valve
Travel PPC valve
60-48
60-48
PC228US-8,PC228USLC-8
Hydraulic system PPC valve
Unit: mm
No.
Item
1 Centring spring
2 Metering spring
PC228US-8,PC228USLC-8
Criteria Standard dimension Load at Free length x Installed installed Outside diamlength length eter 108 N 48.57 x 15.5 32.5 {11 kg} 16.7 N 26.53 x 8.15 24.9 {1.7 kg}
Remedy Repair limit Load at Free installed length length 86.3 N – {8.8 kg} 13.3 N – {1.36 kg}
If damaged or deformed, replace spring
60-49
Hydraulic system PPC valve
R.H. attachment PPC valve (with EPC valve)
60-50 60-50
Unit: mm
No.
Item
1 Centring spring
2 Metering spring
60-50
Criteria Standard dimension Load at Free length x Installed installed Outside diamlength length eter 125 N 33.9 x 15.3 28.4 {12.7 kg} 16.7 N 22.7 x 8.10 22.0 {1.70 kg}
Remedy Repair limit Load at Free installed length length 100 N – {10.2 kg} 13.3 N – {1.36 kg}
If damaged or deformed, replace spring
PC228US-8,PC228USLC-8
Hydraulic system PPC valve
EPC valve
60-51
Unit: mm
No.
Item
1 Metering spring
PC228US-8,PC228USLC-8
Criteria Standard dimension Load at Free length x Installed installed Outside diamlength length eter 3.24 N 9.5 8.4 {0.33 kg}
Remedy Repair limit Load at installed length
Free length –
–
If damaged or deformed, replace the EPC valve assembly
60-51
Hydraulic system PPC valve
L.H. attachment PPC valve (if equipped)
60-52 60-52
Unit: mm
No.
Item
1 Centring spring
2 Metering spring
60-52
Criteria Standard dimension Load at Free length x Installed installed Outside diamlength length eter 125 N 33.9 x 15.3 28.4 {12.7 kg} 16.7 N 22.7 x 8.10 22.0 {1.70 kg}
Remedy Repair limit Load at Free installed length length 100 N – {10.2 kg} 13.3 N – {1.36 kg}
If damaged or deformed, replace spring
PC228US-8,PC228USLC-8
Hydraulic system Solenoid valve
Solenoid valve a The figure shows the type for a machine ready for attachments.
PC228US-8,PC228USLC-8
60-53
Hydraulic system Solenoid valve
Boom RAISE cushion EPC valve
60-54
Unit: mm
No.
1 Return spring
Item
Criteria Free length 9.5
60-54
Standard dimension Installed Load at length installed length 3.24 N 8.4 {0.33 kg}
Remedy Repair limit If damaged or Free Load at deformed, replace length installed length the EPC valve assembly – –
PC228US-8,PC228USLC-8
Hydraulic system Attachment circuit selector valve
Attachment circuit selector valve High-pressure side
Unit: mm
No.
Item
Criteria
1 Spool return spring
Standard dimension Load at Free length x Installed installed Outside diamlength length eter 834 N 132 x 29 114.5 {85.0 kg}
PC228US-8,PC228USLC-8
Remedy Repair limit Load at Free installed length length 667 N – {68.0 kg}
If damaged or deformed, replace spring.
60-55
Hydraulic system Attachment circuit selector valve
Low-pressure side
Unit: mm
No.
Item
Criteria
1 Spool return spring
Standard dimension Load at Free length x Installed installed Outside diamlength length eter 28.7 N 33.4 x 11.2 27.3 {2.93 kg}
60-56
Remedy Repair limit Load at Free installed length length 22.9 N – {2.34 kg}
If damaged or deformed, replace spring.
PC228US-8,PC228USLC-8
Hydraulic system Attachment circuit selector valve
PC228US-8,PC228USLC-8
60-57
Hydraulic system Anti-drop valve
Anti-drop valve For boom and arm cylinder (if equipped)
60-58
60-58
PC228US-8,PC228USLC-8
Hydraulic system Anti-drop valve
Unit: mm
No.
Item
1 Check valve spring
2 Spool return spring 3 Spool return spring 4 Spool return spring
PC228US-8,PC228USLC-8
Criteria Standard dimension Load at Free length x Installed installed Outside length length diameter 12.7 N 20.8 x 12.2 13.5 {1.3 kg} 58.8 N 41.1 x 9.6 35.0 {6.0 kg} 78.5 N 41.9 x 25.8 41.0 {8.0 kg} 181 N 44.6 x 25.6 41.0 {18.5 kg}
Remedy Repair limit Load at Free installed length length 10.2 N – {1.04 kg} 47.1 N – {4.8 kg} 62.8 N – {6.4 kg} 145 N – {14.8 kg}
If damaged or deformed, replace spring.
60-59
Hydraulic system Centre swivel joint
Centre swivel joint
Unit: mm
No.
Item
1 Clearance between rotor and shaft
60-60
Criteria
Remedy
Standard dimension
Standard clearance
Allowable clearance
80
0.056 - 0.105
0.111
Replace
PC228US-8,PC228USLC-8
Hydraulic Hydraulic system system Centre swivel swivel joint joint Centre
PC228US-8,PC228USLC-8
60-61
Work equipment Work equipment
Work equipment Work equipment
Unit: mm
No.
Item
1
Clearance between connecting pin and bushing of revolving frame and boom
2 3 4 5 6
Clearance between connecting pin and bushing of boom and arm Clearance between connecting pin and bushing of arm and link Clearance between connecting pin and bushing of arm and bucket Clearance between connecting pin and bushing of link and bucket Clearance between connecting pin and bushing of link and link
60-62
Criteria Standard dimension 90 90 70 80 80 70
Tolerance Shaft Hole -0.036 +0.135 -0.071 +0.074 -0.036 +0.137 -0.071 +0.077 -0.030 +0.335 –0.076 +0.275 -0.030 +0.324 –0.076 +0.270 -0.030 +0.337 –0.076 +0.273 -0.030 +0.335 –0.076 +0.275
Remedy Standard clearance
Allowable clearance
0.110 – 0.206
1.0
0.113 – 0.208
1.0
0.305 – 0.411
1.0
0.300 – 0.400
1.0
0.303 – 0.413
1.0
0.305 – 0.411
1.0
Replace pin or bushing
PC228US-8,PC228USLC-8
Work equipment Work equipment
PC228US-8,PC228USLC-8
60-63
Work equipment Dimensions of components
Dimensions of components Arm
60-64
PC228US-8,PC228USLC-8
Work equipment Dimensions of components
Unit: mm
PC228US-8, PC228USLC-8 No. Measurement point
Standard dimension
–
80
1
Tolerance Shaft - 0.030 - 0.076
Hole + 0.100 0
Arm side
109.3
+ 1.5 0
Cylinder head side
106
±1.2
Boom side
310
Arm side
305.5
2
+ 0.5 0 0 - 0.5
3 - 0.036 - 0.071
+ 0.054 0
4
–
90
5
–
402.1
±1.0
6
–
187.2
±0.5
7
–
829.1
±1.0
8
–
2,919
–
9
–
2,630.5
±1.0
10
–
410
±1.0
11
–
640
±0.2
12
–
600
±0.5
13
–
458.1
–
14
–
1,486
–
15
–
80
- 0.030 - 0.076
+ 0.100 0
Link side
325
±0.5
Bucket side
326.5
±1.0
16 17 18
- 0.030 - 0.076
+ 0.100 0
–
80
Arm boss (without bushing)
311
0 - 0.5
When press-fitting bushing (with bushing)
325
±2.5
Min.
1,680
–
Max.
2,800
–
19
PC228US-8,PC228USLC-8
60-65
Work equipment Dimensions of components
Bucket
60-66
PC228US-8,PC228USLC-8
Work equipment Dimensions of components
Unit: mm
PC228US-8, PC228USLC-8
No. Measurement point
Standard dimension
Tolerance
1
–
457.6
± 0.5
2
–
22
± 0.5
3
–
92 °45 ´
–
4
–
458.1
–
5
–
1,477.3
–
6
–
158.6
–
7
–
45 °
–
8
–
15 °54 ´
–
9
–
80
+ 0.1 0
10
–
90
–
11
–
110
+ 0.1 0
12
–
326.5
±1.0
13
–
56
–
14
–
106
–
15
–
470
–
16
–
23.5
–
17
–
140
–
18
–
150
–
19
–
190
–
20
–
146
–
21
–
150
–
22
–
348.5
+ 2.0 0
23
–
56
–
24
–
38
–
25
–
131.6
–
26
–
137.4
–
27
–
107
–
28
–
85
–
PC228US-8,PC228USLC-8
60-67
Work equipment Work equipment cylinder
Work equipment cylinder Boom cylinder
Arm cylinder
Bucket cylinder
60-68
PC228US-8,PC228USLC-8
Work equipment Work equipment cylinder
Unit: mm
No.
1
2
3
4
5
Item
Clearance between piston rod and bushing
Clearance between piston rod supporting shaft and bushing
Clearance between cylinder bottom support shaft and bushing
Tightening torque for cylinder head
Tightening torque for cylinder piston
Tightening torque for
6 cylinder piston lock screw
Criteria Cylinder name
Standard dimension
Boom (Standard) Boom (large diameter)
85
Arm
95
Bucket
80
Boom (Standard)
80
Boom (large diameter)
80
Arm
80
Bucket
70
Boom (Standard) Boom (large diameter)
70
Arm
80
Bucket
70
90
70
Tolerance Shaft Hole - 0.036 + 0.222 - 0.090 + 0.047 - 0.036 - 0.090
+ 0.257 + 0.048
- 0.036 - 0.090 - 0.030 - 0.076 - 0.030 - 0.060
+ 0.222 + 0.047 + 0.258 + 0.048 + 0.190 + 0.070
- 0.030 - 0.060
+ 0.190 + 0.070
- 0.030 - 0.076 - 0.030 - 0.076 - 0.030 - 0.060
+ 0.190 + 0.070 + 0.424 + 0.350 + 0.165 + 0.045
- 0.030 - 0.060
+ 0.165 + 0.045
- 0.030 - 0.076 - 0.030 - 0.060
+ 0.190 + 0.070 + 0.165 + 0.045
Remedy Standard clearance
Allowable clearance
0.083 – 0.312
0.412
0.084 – 0.347
0.447
0.083 – 0.312
0.412
0.078 – 0.334
0.434
0.100 – 0.250
1.0
0.100 – 0.250
1.0
0.100 – 0.266
1.0
0.380 – 0.500
1.0
0.075 – 0.225
1.0
0.075 – 0.225
1.0
0.100 – 0.266
1.0
0.075 – 0.225
1.0
Boom (Standard) Boom (large diameter)
270 ± 39.2 Nm {27.5 ± 4.0 kgm}
Arm
373 ± 53.9 Nm {38.0 ± 5.5 kgm}
Bucket
270 ± 39.2 Nm {27.5 ± 4.0 kgm}
Boom (Standard) Boom (large diameter)
294 ± 29.4 Nm {30.0 ± 3.0 kgm}
Replace pin or bushing
270 ± 39.2 Nm {27.5 ± 4.0 kgm}
294 ± 29.4 Nm {30.0 ± 3.0 kgm} Re tighten
Arm
294 ± 29.4 Nm {30.0 ± 3.0 kgm}
Bucket
294 ± 29.4 Nm {30.0 ± 3.0 kgm}
Boom (Standard)
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
Boom (large diameter)
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
Arm
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
Bucket
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
PC228US-8,PC228USLC-8
Replace bushing
60-69
Work equipment Work equipment cylinder
60-70
PC228US-8,PC228USLC-8
SEN0533431-00
80-1
PC228US-8,PC228USLC-8
HYDRAULIC EXCAVATOR PC228US-8 PC228USLC-8 Shop Manual
Machine model
Serial number
PC228US-8 PC228USLC-8
50001 and up 50001 and up
80 Appendix
PC228US-8,PC228USLC-8
80-1
80-1
Contents
Contents 80 Appendix Air conditioner ................................................................................................................................ 80-3 Precautions for refrigerant .......................................................................................................... 80-3 Air conditioner component .......................................................................................................... 80-4 Configuration and function of refrigeration cycle......................................................................... 80-5 Outline of refrigeration cycle ....................................................................................................... 80-8 Air conditioner unit ...................................................................................................................... 80-10 Air conditioner controller ............................................................................................................. 80-15 Compressor ................................................................................................................................ 80-16 Condenser and Modulator .......................................................................................................... 80-17 Sensor......................................................................................................................................... 80-17 Procedure for testing and troubleshooting .................................................................................. 80-20 Circuit diagram and arrangement of connector pins ................................................................... 80-22 System diagram .......................................................................................................................... 80-23 Detail of air conditioner unit ........................................................................................................ 80-27 Parts and connectors layout ....................................................................................................... 80-28 Testing air leakage (duct) ........................................................................................................... 80-32 Testing with self-diagnosis function ............................................................................................ 80-33 Testing vent (mode) changeover ................................................................................................ 80-37 Testing FRESH/RECIRC air changeover ................................................................................... 80-37 Testing inner sensor ................................................................................................................... 80-38 Testing outer sensor ................................................................................................................... 80-38 Testing sunlight sensor ............................................................................................................... 80-39 Testing (dual) pressure switch for refrigerant ............................................................................. 80-40 Testing relays.............................................................................................................................. 80-41 Troubleshooting chart 1 .............................................................................................................. 80-44 Troubleshooting chart 2 .............................................................................................................. 80-45 Information in troubleshooting table............................................................................................ 80-47 Troubleshooting for power supply and CAN communication system (Air conditioner does not operate) 80-50 Troubleshooting for compressor and refrigerant system (Air is not cooled) ............................... 80-53 Troubleshooting for blower motor system (No air comes out or air flow is abnormal) ................ 80-56 Troubleshooting for temperature control..................................................................................... 80-59 Troubleshooting for vent (mode) changeover ............................................................................. 80-61 Troubleshooting for FRESH/RECIRC air changeover ................................................................ 80-63 Troubleshooting for temperature sensor system ........................................................................ 80-65 Troubleshooting with gauge pressure......................................................................................... 80-67 Connection of service tool........................................................................................................... 80-69 Precautions for disconnecting and connecting air conditioner piping ......................................... 80-70 Handling of compressor oil ......................................................................................................... 80-72 Desiccant replacement procedure .............................................................................................. 80-74
80-2
PC228US-8,PC228USLC-8
Air conditioner Precautions for refrigerant
Air conditioner Precautions for refrigerant k Collect the refrigerant (Air conditioner gas:
R134a) from air conditioner circuit before disconnecting air conditioner hose to replace air conditioner unit, air conditioner compressor or air conditioner condenser and so on. a Ask a qualified person for collecting, adding and filling operations of the refrigerant (R134a). a Never release the refrigerant (R134a) to the atmosphere.
k If refrigerant gas (R134a) gets in your eyes,
you may lose your sight. And if it touches your skins, you may suffer from frostbite. Accordingly, put on the safety glasses, gloves and working suits with long sleeves while you are collecting the refrigerant (R134a) or filling the air conditioner circuit with the refrigerant (R134a). Collecting and filling work must be conducted by a qualified person.
PC228US-8,PC228USLC-8
80-3
Air conditioner Air conditioner component
Air conditioner component
80-4
PC228US-8,PC228USLC-8
Air conditioner Configuration and function of refrigeration cycle
A: Front warm/cool air vent B: Rear warm/cool air vent C: Foot warm/cool air vent D: Defroster warm E: RECIRC inlet F: FRESH inlet
1. Compressor 2. Condenser 3. Modulator* 4. Hot water piping 5. Hot water return piping 6. Refrigerant piping 7. Dual pressure switch 8. Sight glass 9. Outside air temperature sensor 10. Air conditioner unit 11. Recirculation air filter 12. Fresh air filter 13. Machine monitor 14. Sunlight sensor 15. Air conditioner controller
Specification Refrigerant Refrigerant refilling level (g)
80-5 R134a 790 ± 50
*: Receiver drier and condenser are integrated on this product. The existing receiver drier unit is called "modulator" here.
Configuration and function of refrigeration cycle Cycle (Component)
Compression (Compressor)
Condensation (Condenser)
Location
Engine compartment
Front of radiator
PC228US-8,PC228USLC-8
Expansion (Expansion valve) In operator cab (In air conditioner unit)
Evaporation (Evaporator) In operator cab (In air conditioner unit)
80-5
Air conditioner Configuration and function of refrigeration cycle
Function
State of refrigerant
80-6
Circulates refrigerant gas and increases its Lowers temperature and Evaporates refrigerant to Condenses refrigerant temperature and prespressure of refrigerant liq- absorb heat from air to discharge heat sure so that it can be uid and gas for easy evap- around evaporator, and absorbed in evaporator. liquefied easily in conoration with throttle. cool the air. (condensation of refrigdenser. Controls flow rate, too. (Evaporation of refrigererant) (Compression of (Throttle of refrigerant) ant) refrigerant) GasoGas GasoLiquid Liquid and gas oGas LiquidoLiquid and gas Adiabatic compression
Constant pressure change
Adiabatic expansion
Constant pressure change
PC228US-8,PC228USLC-8
Air conditioner Configuration and function of refrigeration cycle
PC228US-8,PC228USLC-8
80-7
Air conditioner Outline of refrigeration cycle
Outline of refrigeration cycle The refrigeration cycle is comprised of 4 cycles. The refrigerant is circulated while repeatedly vaporizing and liquefying. 1. Compression (Compressor) The compressor sucks in the refrigerant that has been vaporized in the evaporator and compresses it into a state where it can be easily liquefied at the ambient temperature. The gaseous refrigerant sucked into the compressor cylinder is compressed to a temperature and pressure at which it can be easily liquefied when cooled to the ambient temperature. 2. Condensation (Condenser) The condenser cools and liquefies the high pressure and high-temperature gaseous refrigerant sent from the compressor. The heat released to the outside from the condenser is called condensation heat. The amount of condensation heat is the sum total of the heat absorbed by the evaporator from the air in the cab and the quantity of the work applied (the value converted into a heat quantity) by compression of the compressor. The refrigerant liquefied in the condenser is sent to the receiver drier, where moisture is removed. In the compression cycle, the gaseous refrigerant and liquid refrigerant coexist. The temperature (condensation temperature) and the pressure (condensation pressure) at which the gaseous refrigerant is liquefied are proportional to each other. Reference: The pressure varies depending on the condensation temperature of the refrigerant. 3. Expansion (Expansion valve)
The expansion valve reduces the liquid refrigerant pressure to a level where liquid refrigerant can be easily evaporated by the throttle action (*1). The action of reducing the liquid refrigerant pressure to a level where it can be easily evaporated before it is sent to the evaporator is called expansion. The expansion valve, which reduces the refrigerant pressure, also adjusts the refrigerant flow rate simultaneously. The quantity of the liquid refrigerant that can be evaporated in the evaporator depends on the amount of heat (refrigeration load) to be removed under the specific evaporation temperature (evaporation pressure).
80-8
The expansion valve controls the refrigerant feed rate so that the optimum quantity of liquid refrigerant is supplied to the evaporator. (*1) Throttle action If there is a narrow section in the passage through which liquid is flowing at a constant rate, a resistance to the flow will be generated. The liquid expands when it passes through the narrow section and rushes into the passage where the sectional area is larger, and consequently, its pressure and temperature are reduced. No heat is transferred from or to the outside during the throttle action. 4. Evaporation (Evaporator) The evaporator evaporates the liquid refrigerant (superheated vapour). The refrigerant evaporates, while absorbing an amount of heat necessary for evaporation (evaporation heat) from the air around the cooling fins (air in the cab). After the heat has been removed, the cooled air is sent into the cab by the blower fan, reducing the temperature inside the cab. The mist refrigerant that has been sent from the expansion valve coexists with the evaporated refrigerant in the evaporator The temperature (evaporation temperature) and the pressure (evaporation pressure) at which the liquid refrigerant is evaporated are proportional to each other. The compressor sucks in the evaporated refrigerant in order to keep the pressure level in the evaporator as low as possible so that the liquid refrigerant can be evaporated at a much lower temperature. Relationship between refrigerant and defective air conditioning 80-8 q The refrigerant circulates in the refrigeration circuit while repeating the refrigeration cycle to expel the heat from inside the cab. q If there is an insufficient quantity of refrigerant, all of it will be evaporated while it is passing through the evaporator. This causes evaporator efficiency to deteriorate, which will result in defective air conditioning.
PC228US-8,PC228USLC-8
Air conditioner Outline of refrigeration cycle
q
q
If there is excessive refrigerant, not all of it will be evaporated and part of it will be sucked into the compressor in liquid form, which will cause the compressor to compress the liquid and may damage the components. If water gets into the refrigeration circuit, it will freeze at a small hole in the expansion valve, lower the refrigerant flow, and may result in defective air conditioning.
PC228US-8,PC228USLC-8
80-9
Air conditioner Air conditioner unit
Air conditioner unit
80-10
PC228US-8,PC228USLC-8
Air conditioner Air conditioner unit
A: Refrigerant inlet (from condenser) B: Refrigerant outlet (to compressor) C: Hot water inlet D: Hot water outlet 1. Evaporator 2. Heater core 3. Expansion valve 4. Blower fan, blower motor 5. Air mix servomotor 6. Air mix door 7. Mode changeover servomotor 8. Mode changeover door 9. FRESH/RECIRC air changeover servo motor 10. FRESH/RECIRC air changeover door 11. Power transistor 12. Evaporator temperature sensor 13. Inside air temperature sensor 14. Recirculation air filter Outline 80-1 The air conditioner unit consists of the evaporator (1) and heater core (2), and is used to cool down or warm up the air in the cab.
q
Temperature control 80-1 Whenever a temperature control switch is operated on the machine monitor, temperature setting data is sent to the air conditioner controller, which is located behind the operator seat. The air conditioner controller controls the air mix servomotor (5) and changes the angle of the air mix door (6) in order to adjust the temperature.
q
Overcooling (freezing) prevention 80-1 The resistance of the evaporator temperature sensor (12) changes in response to temperature. q The air conditioner controller detects the temperature of the evaporator (1) by converting the changes in the resistance of the evaporator temperature sensor (12) into voltage changes. q The air conditioner controller performs control to prevent freezing of the evaporator (1) by operating the compressor clutch relay (*) to stop the compressor. *: See "Parts and connectors layout" for details regarding the compressor clutch relay. q
Vent (mode) changeover 80-1 Whenever a vent switch is operated on the machine monitor, mode data is sent to the air conditioner controller. The air conditioner controller controls the mode changeover servomotor (7) to adjust the opening angle of the door (8) and thus perform vent changeover. a The defroster/face changeover door is located inside the duct. (See "Testing vent (mode) changeover.")
q
FRESH/RECIRC air changeover 80-1 Whenever a FRESH/RECIRC air changeover switch is operated on the machine monitor, FRESH/RECIRC air changeover setting data is sent to the air conditioner controller. The air conditioner controller controls FRESH/RECIRC air changeover servomotor (9) to open and close FRESH/RECIRC air changeover door (10).
q
Automatic air conditioning 80-1 The inside air temperature sensor (13) detects the room temperature based on changes in resistance. The air conditioner controller detects the room temperature by converting the changes in the resistance of the inside air temperature sensor (13) into voltage changes. The air conditioner controller checks the voltage of the inside air temperature sensor (13) and controls the room temperature so that it matches the setting made on the machine monitor. Data from the outside air temperature sensor and the sunlight sensor is also taken into consideration when adjusting the inside temperature.
q
a Two fuses (5 A) for the air conditioner unit are attached to the harness. a The door is the same as the damper.
Air flow control 80-1 Whenever an air flow control switch is operated on the machine monitor, air flow setting data is sent to the air conditioner controller. The air conditioner controller controls the blower motor using the power transistor (11) in order to adjust the air flow.
q
PC228US-8,PC228USLC-8
80-11
Air conditioner Air conditioner unit
Functions of main component parts 80-12 Evaporator 80-12 q Evaporator (1) is cooled by the low-pressure, low-temperature refrigerant gas being sent from expansion valve (3). Air from the blower fan is cooled and dehumidified when passing through the evaporator fins. Heater core 80-12 Heater core (2) is warmed by the hot water (engine coolant) being sent from the engine. Air from the blower fan is warmed when passing through the heater core fins.
q
When the potential difference fails to reach a predefined voltage for control of the servomotor, the air conditioner controller notifies the machine monitor of an abnormality. A red "Air conditioner Error" is displayed on the air conditioner control screen of the machine monitor. a FRESH/RECIRC air changeover servo motor does not feature a variable resistance, and therefore, does not have a self-diagnosis function. a If attempting to operate a servomotor during inspecting, do not supply power directly between servomotor terminals (6) and (7).
q
Evaporator temperature sensor 80-12 In order to prevent freezing of the evaporator, the air conditioner controller detects the temperature of the evaporator based on changes in the resistance of the evaporator temperature sensor.
q
Servomotors
80-12
a Servomotors are used to adjust the temperature (air mix) and to perform vent (mode) changeover. q
Whenever a switch on the machine monitor is operated, the air conditioner controller delivers power to the servomotor by raising the voltage between terminals (6) and (7) to 24 V. (The rotation direction changes based on the supply polarity.)
q
The servomotor contains a variable resistance, and its resistance value changes as the motor turns. The air conditioner controller delivers voltage at 5 V to the variable resistance and detects motor rotation based on the potential difference. When the door (damper) reaches the position specified by each switch, the air conditioner controller stops the supply of current to the servomotor, then the corresponding door stops.
q
q
80-12
PC228US-8,PC228USLC-8
Air conditioner Air conditioner unit
Expansion valve
80-13
A: When evaporator outlet temperature is high B: When evaporator outlet temperature is low C: From receiver drier (high-pressure refrigerant) D: To compressor (low-pressure refrigerant) 1. Expansion valve la. Needle valve la-1. Diaphragm 1a-2. Thermoprobe 1b. Spring 2. Refrigerant gas 3. Evaporator Outline 80-13 q The expansion valve converts high-pressure and high-temperature liquid refrigerant from the receiver drier to low-pressure, low-temperature misty refrigerant through the throttle action. q It controls the flow rate of refrigerant by changing the level of throttling depending on the temperature in the cab. q The temperature of the air blown out of the air vent is adjusted depending on the volume of refrigerant circulating in the evaporator (3).
PC228US-8,PC228USLC-8
80-13 Structure The box-type expansion valve (1) consists of needle valve (1a), spring (1b), etc. q Refrigerant gas (2) is sealed in the diaphragm chamber (hatched area) outside diaphragm (1a-1) of needle valve (1a). q The opening angle of needle valve (1a) is determined based on the balance between the reaction force exerted by spring (1b) in a rightward direction, and force (Fg) of refrigerant gas (2) pushing needle valve (1a) through diaphragm (1a-1) in a leftward direction. q The refrigerant flow rate flowing from the receiver drier to evaporator (3) is determined based on the opening angle of needle valve (1a). q
80-13
Air conditioner Air conditioner unit
Operation 80-14 q Thermoprobe (1a-2) senses the refrigerant temperature after it passes through the evaporator (3). q After the refrigerant passes through evaporator (3), its temperature is transferred to the refrigerant gas (2) in the diaphragm chamber (hatched area) through the thermoprobe (1a-2). q The pressure of the refrigerant gas (2) sealed in the diaphragm chamber (hatched area) changes in response to the temperature change of the thermoprobe (1a-2), which therefore changes the force (Fg) pushing the needle valve (1a). q The opening angle of the needle valve (1a) is determined based on the balance between the reaction force exerted by the spring (1b) in a rightward direction, and the force (Fg) of the refrigerant gas (2) pushing the needle valve (1a) through the diaphragm (1a-1) in a leftward direction. When evaporator (3) outlet temperature is high: 80-14 [Air in the cab is not cooled: condition (A) in the figure] 80-14 q The pressure of the refrigerant gas (2) in the diaphragm chamber is high and the volume is increased. q The force (Fg) of the refrigerant gas (2) pushing the needle valve (1a) is increased, and the needle valve (1a) moves leftward. q As a result, the opening angle of the needle valve (1a) is increased and the refrigerant flow rate to the evaporator (3) is increased to improve cooling capacity. When evaporator (3) outlet temperature is low: 80-14 [Air in the cab is already cooled: condition (B) in the figure] 80-14 q The pressure of the refrigerant gas (2) in the diaphragm chamber is low and the volume is decreased. q The force (Fg) of the refrigerant gas (2) pushing the needle valve (1a) is reduced, and the needle valve (1a) is moved rightward by the spring force (1b). q The opening angle of the needle valve (1a) is reduced and the refrigerant flow rate to the evaporator (3) is reduced to lower the cooling capacity.
80-14
PC228US-8,PC228USLC-8
Air conditioner Air conditioner controller
Dual pressure switch 80-14 a The dual pressure switch is mounted on the air conditioner hose under the floor. q The dual pressure switch turns "OFF" when the refrigerant circuit pressure becomes abnormally low or abnormally high. q When the dual pressure switch turns "OFF", the air conditioner controller turns the compressor clutch relay "OFF". As a result, the compressor's magnet clutch is released and air conditioner components are protected.
a LA or low: Abnormally low pressure a HA or high: Abnormally high pressure LA: 0.20 MPa {2 kg/cm2} LB: 0.02 MPa {0.2 kg/cm2} HA: 3.14 MPa {32 kg/cm2} HB: 0.59 MPa {6 kg/cm2}
Air conditioner controller
a See "System Diagrams" for details regarding input/output signals.
PC228US-8,PC228USLC-8
80-15
Air conditioner Compressor
Compressor
A: Refrigerant inlet (from air conditioner unit) B: Refrigerant outlet (to condenser) C: Pulley D: Relief valve
Function 80-16 Other than circulating the refrigerant, compressor compresses the refrigerant gas from the evaporator to a high-pressure, high-temperature misty refrigerant so that it may be easily regenerated (liquefied) at normal temperature. q The magnetic clutch is built in and the clutch is engaged by the evaporator temperature and refrigerant pressure. By the engagement of the clutch, the shaft in the compressor rotates to operate the compressor. Specification 80-16 q
Piston capacity (cc/rev) Allowable maximum speed (rpm)
80-16
157.3 6,000
Refrigerant oil used
Denso: ND-OIL8 (For R134a)
Refrigerant oil refilling volume (cc)
180
PC228US-8,PC228USLC-8
Air conditioner Condenser and Modulator
Condenser and Modulator
A: Refrigerant inlet (from compressor) B: Refrigerant outlet (to air conditioner unit) Function 80-17 q Condenser (1) It cools and liquefies the high-pressure, high-temperature misty refrigerant from the compressor. a If the fin is crushed or is clogged with dust, heat exchange efficiency is reduced and complete liquefaction of refrigerant becomes impossible. As a result, pressure in refrigerant circulation circuit is increased, applying extra load to the engine or reducing cooling effect. Take extreme care not to crush or damage the fins when handling them or checking them in daily inspection. Specification Fin pitch (mm) Height x Width x Thickness (mm)
80-17 4.0 421 x 540 x 16
Weight (kg)
3.2
Function 80-17 q Modulator (2) a This has desiccant in it. See "Desiccant replacement procedure". It is used to store liquefied high-pressure, high-temperature misty refrigerant from the condenser. It is capable of completely liquefying the refrigerant even when bubbles are contained in the refrigerant due to the condenser condition in heat dissipation. It eliminates foreign substances in the circulation line and moisture in the refrigerant by use of the built-in filter and desiccant. Specification Weight of desiccating agent (g)
80-17 290
Sensor
PC228US-8,PC228USLC-8
80-17
Air conditioner Sensor
Sunlight sensor
80-18
Outside air temperature sensor
80-18
1. Connector 2. Sensor
1. Connector 2. Sensor
Outline 80-18 q The sunlight sensor is mounted on top of the machine monitor. q It detects the strength of incident sunlight and sends signals to the air conditioner controller. q When performing automatic air conditioning, the air conditioner controller controls the blower motor and the air mix servomotor in order to adjust the temperature and air flow.
Outline 80-18 q The outside air temperature sensor is installed in the battery room at the rear left of the machine. q The outside air temperature sensor has feature of change in resistance by temperature change, therefore, can detect the ambient temperature. q The air conditioner controller detects the ambient temperature by converting the changes in the resistance of the outside air temperature sensor into voltage changes. q When performing automatic air conditioning, the air conditioner controller controls the blower motor and the air mix servomotor in order to adjust the temperature and air flow.
Output characteristics
80-18
80-18
PC228US-8,PC228USLC-8
Air conditioner Sensor
PC228US-8,PC228USLC-8
80-19
Air conditioner Procedure for testing and troubleshooting
Procedure for testing and troubleshooting The air conditioner is provided with self-diagnosis functionality in order to provide for inspection of its main components. Specifically, the operation of sensors and servomotors can be examined. If a troubled section is detected, every part of that section must be inspected. 1. After basic check, find the troubled section according to the detected trouble of the air conditioner. 2. Narrow down the sections with the self-diagnosis function (See “Check with self-diagnosis”). If, however, the entire air conditioner unit fails to operate, inspect for problems with the supply of power to the air conditioner controller and with CAN communication between the machine monitor and the air conditioner controller. If any part of the air conditioner unit can operate, it will indicate that the air conditioner controller is receiving power normally and that CAN communication between the machine monitor and the air conditioner controller is normal. 3. After finding out the troubled section, inspect the component parts in that section and repair the troubled part. Basic check and troubleshooting sequence
80-20
PC228US-8,PC228USLC-8
Air conditioner Procedure for testing and troubleshooting
*1: By error display or abnormal display on “Abnormality Record” screen on machine monitor. *2: Simple checking of refrigerant volume by sight glass. Start up the engine, set the air conditioner switch to ON, and then wait for five minutes before proceeding with the inspection. A) If the continuous stream of bubbles can be seen, the system contains insufficient refrigerant. B) If the bubbles can be seen intermittently, the refrigerant volume is sufficient. C) If no bubbles can be seen (i.e., the liquid is perfectly clear), the system contains too much refrigerant or no refrigerant at all. The above should be treated as general guidelines as certain exceptions do exist. See "Troubleshooting with gauge pressure" and use gauge pressure to determine whether or not the condition is normal. S: Sight glass condition R: Receiver drier internal condition LR: Liquid refrigerant
*3: If any leakage of refrigerant is occurring, the compressor oil circulating within the air conditioner circuit will definitely be leaking from the same point. In such a case, re tighten in accordance with the table of re tightening torques from "Precautions for disconnecting and connecting air conditioner piping." *4: Start the engine and perform the check with the air conditioner switch set to ON.
PC228US-8,PC228USLC-8
80-21
Air conditioner Circuit diagram and arrangement of connector pins
Circuit diagram and arrangement of connector pins
80-22
PC228US-8,PC228USLC-8
Air conditioner System diagram
System diagram a This air conditioner has automatic temperature control.
PC228US-8,PC228USLC-8
80-23
Air conditioner System diagram
80-24
PC228US-8,PC228USLC-8
Air conditioner System diagram
Input and output signals of the air conditioner controller Controller side connector: AMP 040-36PM Harness side connectors: [1], [2] [1]AMP 040-16PF Pin Symbol No. 1 – 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
CAN_H CAN communication (H)
18
CAN_L
20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 q q
Signal name
17
19
Input/o utput –
– A/M servo potentiometer voltA/M P Input age Servo potentiometer 5 V POT 5 V Output power supply (Dual) pressure switch PRESS Input (Refrigerant pressure) – – – +24 V bk Backup power supply Input BLOW F/B Blower feedback signal Input Power transistor control sigPTR B Output nal Blow out (mode) servo potenMODE P Input tiometer voltage – – – THI Inside air temperature sensor Input Evaporator temperature senTHEVA Input sor Outside air temperature senTHO Input sor – – – SS Sunlight sensor Input GND GND Input
[2]AMP 040-20PF Pin Symbol No.
q
Signal name
CAN communication (L)
Recirculated air and fresh air servo terminal A Recirculated air and fresh air R/F B servo terminal B A/M A A/M servo terminal A A/M B A/M servo terminal B Blow out (mode) servo termiMODE A nal A Blow out (mode) servo termiMODE B nal B +24 V Power supply – – GND S Sensor GND – – – – – – – – – – – – – – CCRL Compressor clutch relay BLOW RL Blower main relay R/F A
Input/o utput Input/ output Input/ output Output Output Output Output Output Output Input – Input – – – – – – – Output Output
A/M: Air mix F/B: Feed back R/F: Recirculation/Fresh
PC228US-8,PC228USLC-8
80-25
Air conditioner System diagram
Operation of air conditioner controller 1. Performing CAN communication with the machine monitor, the air conditioner controller controls the air conditioner unit by inputting switches associated with air conditioning. 2. The air conditioner controller controls three servomotors located inside the air conditioner unit in order to adjust the temperature (airmix), perform vent (mode) changeover, and perform FRESH/RECIRC air changeover. 3. The air conditioner controller controls the ON/OFF condition of the blower main relay (i.e., a switch for blowing air) and of the compressor clutch relay (i.e., a switch for activating the compressor). 4. The air conditioner controller controls the air flow volume using the power transistor. a The power transistor has an overcurrent prevention fuse in it. 5. The air conditioner controller detects the evaporator temperature using the evaporator temperature sensor. 6. In order to prevent freezing of the evaporator, the air conditioner controller controls the compressor by turning the compressor clutch relay ON and OFF. a When the dual pressure switch detects a pressure abnormality (i.e., turns OFF), the air conditioner controller turns the compressor clutch relay OFF, and therefore, the compressor stops operating. 7. When performing automatic air conditioning, the air conditioner controller controls the inside air temperature to the set temperature based on data from the sunlight sensor, the outside air temperature sensor, and the inside air temperature sensor. 8. The air conditioner controller has the self-diagnosis function. If any abnormality is detected, the control amplifier notifies it to the machine monitor by the CAN communication. Then, the letters of "A/C Controller Error" are displayed red on the air conditioner operation screen of the machine monitor.
q
80-26
PC228US-8,PC228USLC-8
Air conditioner Detail of air conditioner unit
Detail of air conditioner unit
PC228US-8,PC228USLC-8
80-27
Air conditioner Parts and connectors layout
1. Foot door 2. FRESH/RECIRC air changeover door 3. Inside air temperature sensor 4. Expansion valve 5. Fuse (5 A) 6. FRESH/RECIRC air changeover servomotor A: Recirculation air port B: Fresh air port [1], [2]: Control amplifier connectors [3]: Blower (fan) motor connector [4]*: Power transistor (PTR) connector
[5]*: Vent (mode) servomotor connector [6]*: Temperature adjustment (air mix) servomotor connector [7]: FRESH/RECIRC air changeover servomotor connector [8]: Inner sensor connector [9]: Evaporator temperature sensor connector *: Although shown in the circuit diagram, these connectors cannot be seen from outside. a Connectors [3], [7], and [9] also cannot be seen with the air conditioner unit assembled.
Parts and connectors layout a There are five fuses in total. Three are located inside the fuse box behind the left side of the operator's seat. The remaining two are mounted on the harness between the air conditioner unit and the controller. a The air conditioner unit is located below the operator's seat. a Rotate the unit 90 degrees. 1. Open the cover of the fuse box located behind the left side of the operator's seat. (See fuse mounting positions in "Troubleshooting.") q No. 11 (20 A) from fuse box: For supply of power to blower (fan) and air conditioner compressor q No. 18 (5 A) from fuse box: For supply of power to air conditioner controller (i.e., backup power source) q No. 10 (5 A) from fuse box: For supply of primary power to air conditioner unit, air conditioner controller, and relays R20 and R21 q Part No. of fuse 20 A: 080-041-02000 5 A: 080-041-00500
2. Remove holder cup (1). 3. Remove bracket (2). 4. Remove cover (3).
80-28
PC228US-8,PC228USLC-8
Air conditioner Parts and connectors layout
a Condition with cover removed q R20: Blower main relay q R21: Compressor clutch relay q (4): Air conditioner controller q (5): Fuse 5 A For supply of power to air conditioner unit and air conditioner controller (including primary power for the blower main relay and the air conditioner compressor relay, and power for FRESH/RECIRC air changeover servo motor ) q Part No. of fuse ND93940-05002 q [1] and [2]: Connector of air conditioner controller q N10: Air conditioner unit connector for 24 V power supply and CAN communication with the machine monitor (communication lines shared with engine controller and pump controller) q AC01: Air conditioner unit connector for GND, compressor, pressure switch, relays, sunlight sensor, and outside (air) temperature sensor
PC228US-8,PC228USLC-8
80-29
Air conditioner Parts and connectors layout
5. Remove floor mat (6). 6. Remove covers (7) to (9).
9. Remove cover (15).
q
P17: Pressure switch connector
7. Remove pin (P1) and remove ducts 10) to (13). a Pin (P1) is also provided under duct (11).
8. Using bolt (B), raise seat bracket (14). q A/C U: Air conditioner unit [8]: Inside air temperature sensor connector
80-30
10. Open the engine hood. q ACC: Air conditioner compressor q AC02: Air conditioner compressor connector q E: Ground
PC228US-8,PC228USLC-8
Air conditioner Parts and connectors layout
11. Remove air cleaner (16).
a Condition with air cleaner removed q P32: Outside (air) temperature sensor connector
1] Insert a flat-head screwdriver into the slit (SL) and lift up. 2] Release lock (L) and remove cover (5). 3] At the rear of cover (5), disconnect the connector (M04) for the cigarette lighter.
12. Testing sunlight sensor connector P31 and machine monitor connector CM02 (CAN communication connector) a If the connector CM02 for the machine monitor is disconnected, CAN communication with the engine controller and the pump controller is not be possible, and therefore, the error code [DAFRMC] is displayed. Furthermore, a red "Air conditioner Error" is displayed on the air conditioner control screen. Inspection is only required when this error is displayed. Note: An "Air conditioner Error" is also displayed on the air conditioner control screen when vent changeover is not possible, when a temperature adjustment abnormality occurs, or when the refrigerant's pressure switch is set to OFF. 1) Remove cap (1). 2) Remove cover (2), and disconnect connector P31 for the air conditioner sunlight sensor (S). 3) Remove duct (4). 4) Remove cover (5) as shown in the following. [*1]
PC228US-8,PC228USLC-8
80-31
Air conditioner Testing air leakage (duct)
5) Remove 4 mounting bolts and lift up machine monitor (6). [*2] 6) Check connectors CM02. a CM02 and CM03 can be assembled in reverse, take care not to assemble them in reverse. CM03 is the green connector. a The connector CN-5 is connected on models with rear view camera specification.
Caution about installation [*1], [*2] 1. Tighten lightly the four mounting bolts for the machine monitor (6), and assemble cover (5). 2. With cover (5) in place, fully tighten the machine monitor's mounting bolts. q Carry out the rest of installation in the reverse order to removal.
Testing air leakage (duct) 1. Remove front window (1). 2. Remove floor mat (2). 3. Remove cover [3] from the machine monitor in accordance with item 12 of "Part and connector locations." 4. Remove covers (4) and (5).
5. Remove cup holder (6). 6. Remove bracket (7). 7. Remove rear cover (8). 8. Remove duct cover (9).
80-32
PC228US-8,PC228USLC-8
Air conditioner Testing with self-diagnosis function
9. Check the following ducts. 1) Rear duct Check duct (10) for disconnection. 2) Defroster duct (11), face duct (12) 1] Check pin (P1) and ducts (11), (12) for disconnection. a Pin (P1) is also provided under duct (11).
3) Fresh air duct Check pin (P) and duct (14) for disconnection.
2] Check defroster duct (13) for disconnection.
Testing with self-diagnosis function Outline 80-3 On the air conditioner operation screen of the machine monitor, the system performs self-diagnosis for the communication with the air conditioner unit, temperature control, vent (mode) changeover and refrigerant pressure with the pressure switch, and if a problem is detected, the failure is displayed in red as "A/C Controller Error"
a On the air-conditioning system abnormality record screen that appears in service mode of the machine monitor, the system performs self-diagnosis for various sensors in addition to the above items, and if a problem is detected, screen displays it in red as "Abnormal." a FRESH/RECIRC air changeover servomotor is not checked with self-diagnosis function.
a Even if the cause of a detected problem is restored to normal, the self-diagnosis failure condition will not automatically be reset. To reset the failure condition, the starter switch must be set to OFF. PC228US-8,PC228USLC-8
80-33
Air conditioner Testing with self-diagnosis function
How to enter air conditioner “Abnormality Record” screen in service mode of machine monitor. 80-3 q
Overview of machine monitor operating procedure Normal screen O While pressing [4], press [1], [2], and [3] in this order. Service menu (Mode) O Press [F3] once. Press [F6]. 02Abnormality Record O Press [F3] twice. Press [F6]. 03Air-conditioning System "Abnormality Record" screen
Detailed description of machine monitor operating procedure 1. On the normal operation screen, while pressing number key [4], press [1], [2], and [3] in this order.
q
2. On the service menu screen, press [F3] (R) once, and then select "02 Abnormality Record." 3. Press [F6] ( ) to confirm.
80-34
PC228US-8,PC228USLC-8
Air conditioner Testing with self-diagnosis function
4. On the Abnormality Record screen, press [F3] (R) twice, and then select "03 Air conditioning System." 5. Press [F6] ( ) to confirm.
q
Air Conditioning System Abnormality Record screen: Information displayed in "03 Air Conditioning System" (a): System or Component name (b): Number of abnormality occurrence time (c): Condition (Normal or abnormal) (d): If the CAN communication condition is displayed as being abnormal, it will indicate that the air conditioner unit is disconnected and CAN communication is not possible. Accordingly, the display for the other (d) items will be cleared. (e): If [E] is displayed to the left of the condition, it indicates that the abnormality is ongoing or that restoration to normal has not yet been detected. [F2]: Clear "Abnormality Record" [F5]: Return to Abnormality Record screen
Caution Inner Sensor means "inside temp. sensor" on "system diagram " or "circuit diagram". "Ventilating Sensor is abnormal" means that evaporator temperature sensor is short circuit or disconnected. “Sunlight Sensor is abnormal" means that Sunlight Sensor is short circuit only. "Ventilation is abnormal" means servomotor for vent changeover (mode) damper does not rotate judging from the servomotor potentiometer voltage. a Damper is the same as door. "Air Mix is abnormal" means servomotor for Air Mix (temperature adjustment) damper does not rotate judging from the servomotor potentiometer voltage. "Refrigerant" means refrigerant pressure from dual pressure switch. Namely, "refrigerant is abnormal" means that dual pressure switch of refrigerant is OFF. 1. CAN status: Abnormal Normal communication is not possible between the machine monitor and air conditioner controller. a Display of failure code [DAFRMC] CAN communication failure (with engine controller) indicates that the entire communication line has failed. In this case, see failure code [DAFRMC] in Chapter 40. If failure code [DAFRMC] is not displayed, communication failure is limited to between the controller and the machine monitor alone. In such a case, confirm whether connectors AC01, CN-N10, [1], and [2] have been disconnected. See item 2 from "Parts and connectors layout." Alternatively, see "Troubleshooting for power supply and CAN communication system." 2. Setting : Abnormal The air conditioner controller software and the monitor software are not compatible. Confirm the part number of each.
q
Clearing "Abnormality Record" on machine monitor While the "Abnormality Record " screen is displayed, press [F2], and the number of occurrence time of abnormality is reset. If it is confirmed at this time that the abnormality has been reset, the trouble was resolved.
PC228US-8,PC228USLC-8
3. Inner sensor: Abnormal a Inner Sensor is the same as inside temp. sensor on "System diagram" or "circuit diagram". An open circuit or short circuit has been detected between the air conditioner controller and the inner sensor. a Air conditioner controller remedy: As it is not possible to use data from inner sensor, control the air conditioner using only the temperature setting in automatic air conditioning mode.
80-35
Air conditioner Testing with self-diagnosis function
a Trouble: Automatic air conditioner functions do not work, but manual operations do. a If an abnormality is detected in inner sensor, see "Testing inner sensor." 4. Outer sensor: Abnormal a Outer sensor is the same as outside temp. sensor on "System diagram" or "Circuit diagram". An open circuit or short circuit has been detected between the air conditioner controller and the outer sensor. a Air conditioner controller remedy: As it is not possible to use data from outer sensor, control the air conditioner using only the inside air temperature sensor and the sunlight sensor in automatic air conditioning mode. a Trouble: Automatic air conditioner functions operate without referencing the outside air temperature. Manual operations function normally. a If an abnormality is detected in outer sensor, see "Testing outer sensor." 5. Ventilating sensor: Abnormal a Ventilating sensor means the evaporator temperature sensor. An open circuit or short circuit has been detected between the air conditioner controller and the evaporator temperature sensor. a Air conditioner controller remedy: Output to the compressor is stopped. a Trouble: The air conditioner does not work. a If an abnormality is detected in the ventilating sensor, see "Troubleshooting for temperature sensor system." 6. Sunlight sensor: Abnormal A short circuit has been detected between the air conditioner controller and the sunlight sensor. a Air conditioner controller remedy: Control is carried out without referencing sunlight sensor. a Trouble: The automatic air conditioner does not work when the machine is exposed to the direct sunlight in the automatic air conditioner mode. a If an abnormality is detected in the sunlight sensor, see "Testing sunlight sensor."
a Damper is the same as door. a Trouble: Vent is not changed over. a Air conditioner controller remedy: Output to the vent (mode) selection servomotor is stopped. a Even if the link is disconnected and the damper does not rotate, the self-diagnosis system judges the damper normal since the servomotor potentiometer voltage changes normally. a In the case of "Ventilation: Abnormal", see "Testing vent (mode) changeover." 8. Air Mix: Abnormal It has been determined based on the servomotor's potentiometer voltage that the servomotor for the air mix (temperature adjustment) damper is not operating. a Damper is the same as door. a Trouble: The temperature control system does not work. a Air conditioner controller remedy: Output to the air mix servomotor is stopped. a Even if the link is disconnected and the damper does not rotate, the self-diagnosis system judges the damper normal since the servomotor potentiometer voltage changes normally. a If an abnormality is detected in the Air Mix (A/M) damper, repeat the temperature setting 18.0 °C (Max. cooling)io32.0 °C (Max. heating) several times. If the A/M damper abnormality count does not increase, A/M damper is normal. (This abnormality potentially happens at low temperature) When the A/M damper abnormality count increases, see "Troubleshooting for temperature control." 9. Refrigerant: Abnormal (Dual) pressure switch signal for refrigerant is abnormal. Namely pressure switch for refrigerant is OFF. a Trouble: The air conditioner does not work. a Air conditioner controller remedy: Output to the compressor is stopped. k When replacing a pressure switch, refrigerant must be collected in advance. See "Caution about refrigerant" a If an abnormality is detected in the refrigerant, see "Testing (dual) pressure switch for refrigerant."
7. Ventilation: Abnormal It has been determined based on the servomotor's potentiometer voltage that the servomotor for the vent (mode) changeover damper is not operating. 80-36
PC228US-8,PC228USLC-8
Air conditioner Testing vent (mode) changeover
Testing vent (mode) changeover Outline 80-36 The vent (mode) is selected by changing the angles of the two doors (dampers) in the air conditioner unit and the door (damper) in the duct. The angles of the doors (dampers) are changed with the mode changeover servomotor and all the doors (dampers) are not seen from the outside. Even if the air conditioner unit is removed, the mode changeover servomotor is not seen from the outside. Visually check opening and closing of the foot door (damper) and the angle of the lever of the defroster-face selector door (damper) inside the duct to see these doors from the outside. a To reset the self-diagnosis system (to clear the "A/C Controller Error" displayed on the air conditioner screen of the machine monitor), the starting switch must be turned OFF (While "A/C Controller Error" is displayed with self-diagnosis system, no signals are output to the servomotor). 1. Remove front window (1). 2. Remove floor mat (2). 3. Remove covers (3) - (5).
4. Check the connection of cable (6) and lever (L). (Check whether the connector has been partially removed.) 5. Check clip (7) for coming off. 6. Start the engine and turn the air conditioner power ON. 7. Press the face and defroster selector switch on the air conditioner screen of the machine monitor and visually check that lever (L) moves smoothly between the face mode (F) and
Testing FRESH/RECIRC air changeover Outline 80-37 FRESH/RECIRC air changeover servo motor performs switching between fresh and recirculated air by changing the angle of the FRESH/RECIRC air changeover door (damper) located inside the air conditioner unit. Check visually opening and closing of this door . a The system does not have self-diagnosis function for FRESH/RECIRC air changeover servo motor. 1. Open cover (1) and remove outside air filter (2).
3. Press the FRESH/RECIRC selector switch on the machine monitor's air conditioner control screen, and then check the opening and closing operation of FRESH/RECIRC air changeover door (4) using mirror (3). a As the connector for FRESH/RECIRC air changeover servo motor is located on the floor of the air conditioner unit, its connection condition cannot be checked.
2. Start the engine and turn the air conditioner power ON.
PC228US-8,PC228USLC-8
80-37
Air conditioner Testing inner sensor
Testing inner sensor a Inner sensor means inside (air) temperature sensor. q If "Inner sensor Abnormal" is displayed with self-diagnosis (on "03 Air conditioning System" screen of "Abnormality Record" in the machine monitor), test the following. q To reset the self-diagnosis system (detection of abnormalities), the starting switch must be turned OFF. 1. Referring to "Parts and connectors layout", raise seat bracket (9) by using bolt (B). a Prepare bolt (B) in advance. 2. Check the contact of inner sensor connector [8]. (Check whether the connector has been partially disconnected.) 3. Standard resistance between terminals on sensor side of connector [8]: 1.6 kz (at 0 °C) 5 kz (at 25 °C) a If the resistance is not the above value, replace the inner sensor.
4. Referring to item 2. in "Parts and connectors layout", disconnect connectors [1] and [2]. 5. Ensure that the female terminals (on the wiring harness side) of connector [8] are not being shorted by each other. a If the terminals are shorted, the wiring harness is defective. 6. Between connector [8] (female: wiring harness side) (2) (PB) and connector [1] (wiring harness side) (11) (PB): Ensure Max. 1 z. a If the resistance is not the above value, the wiring harness is defective. 7. Between connector [8] (female: wiring harness side) (1) (BrR) and connector [2] (wiring harness side) (27) (BrR): Max. 1 z a If the resistance is not the above value, the wiring harness is defective. 8. Connect all the connectors. 9. Turn the starting switch to ON position and if "Inner sensor Abnormal" is still displayed with self-diagnosis (on "03 Air conditioning System" screen of "Abnormality Record" in the machine monitor), replace the air conditioner controller.
Testing outer sensor a Outer sensor means outside (air) temperature sensor. q If an "Outer Sensor Abnormal" is displayed with self-diagnosis (on "03 Air-conditioning System" screen of "Abnormality Record" in the machine monitor), test the following.
80-38
q
To reset the self-diagnosis system (detection of abnormalities), the starting switch must be turned OFF.
PC228US-8,PC228USLC-8
Air conditioner Testing sunlight sensor
1. Check contact of the outer sensor connector (P32) in accordance with item 11 of "Parts and connectors layout." (Check whether the connector has been partially disconnected.) 2. Standard resistance between terminals on the sensor side of connector (P32): 1.7 kz (at 25 °C) a If the resistance is not the above value, replace the outer sensor.
3. Referring to items 2. to 4 in "Parts and connectors layout", disconnect connectors [1] and [2]. 4. Ensure that the female terminals on the harness side of the connector (P32) are not being shorted. a If the terminals are shorted, the wiring harness is defective. 5. Condition between female (2) (RW) from the harness side of the connector (P32) and (13) (RW) from the harness side of connector [1]: Ensure Max. 1 z. a If the resistance is not the above value, the wiring harness is defective. 6. Condition between female (1) (BrR) from the harness side of the connector (P32) and (27) (BrW) from the harness side of connector [2]: Max. 1 z a If the resistance is not the above value, the wiring harness is defective. 7. Connect all the connectors. 8. Turn the starting switch to ON position, and if "Outer Sensor Abnormal" is still displayed with self-diagnosis (On the air-conditioning system abnormality record screen in the machine monitor), replace the air conditioner controller.
Testing sunlight sensor If "Sunlight Sensor Abnormal" is displayed by the self-diagnosis (on "03 Air conditioning System" screen of "Abnormality Record" in the machine monitor), test sunlight sensor connector P31. q To reset the self-diagnosis system (detection of abnormality), the starting switch must be turned OFF. a If sunlight sensor (S) is measured with resistance range of tester, sunlight sensor may be destroyed, so do not measure with resistance range of tester. 1. Remove cap (1). 2. Remove cover (2) and inspect the connector P31 (3) for the sunlight sensor (S), which is located on back side of the cover. (Check whether the connector has been partially disconnected.) 3. Disconnect connector P31, and using a tester set to the voltage range, measure the voltage between the male side terminals on the sunlight sensor (S). q Approximate voltage of sunlight sensor unit 0.55 V: Direct sunlight 0.45 V: Cloudy 0.4 V: Indoors q
PC228US-8,PC228USLC-8
80-39
Air conditioner Testing (dual) pressure switch for refrigerant
4. Disconnect connector [1] from the air conditioner controller in line with item 2 from "Parts and connectors layout". 5. Ensure that the female terminals of the connector P31 (harness side) are not being shorted. (If the terminals are shorted, the harness is defective.) 6. Confirm whether the condition between the female terminal of the connector P31 (harness side) (2) (YW) and the terminal of connector [1] (harness side) (15) (YW) is 1 z or less. (If not, the wiring harness is defective.) a If the result of item 6 or item 7 is abnormal, check the contact of connector CN-AC01.
(See "Parts and connectors layout".) 7. Confirm whether the condition between the female terminal of connector P31 (harness side) (1) (RB) and the terminal of connector [1] (harness side) (3) (RB) is 1 z or less. (If this is not the case, the harness is defective.) 8. Connect all the connectors. 9. Turn the starting switch to ON position, and if "Sunlight Sensor Abnormal" is still displayed with self-diagnosis (on "03 Air conditioning System" screen of "Abnormal Record" in the machine monitor), replace the air conditioner controller.
Testing (dual) pressure switch for refrigerant If "Refrigerant Abnormal" is displayed by the self-diagnosis (on "03 Air-conditioning System" screen of "Abnormality Record" in the machine monitor), test the dual pressure switch connector P17. q To reset the self-diagnosis system (detection of abnormality), the starting switch must be turned OFF. q The dual pressure switch is ON when the refrigerant pressure is normal and OFF when it is abnormal. a As the refrigerant pressure will drop when the ambient temperature is below 0 °C, there is a possibility that the dual pressure switch is OFF. In such a case, the dual pressure switch is actually normal (i.e., not defective). 1. Remove undercover in operator cab by referring to item 9 of "Parts and connectors layout." 2. Disconnect the dual pressure switch connector P17. q
a When the pressure switch is OFF, connect a pressure gauge to the high pressure side of the air conditioner compressor and check the refrigerant pressure. See "Connection of service tool" and "Troubleshooting with gauge pressure." a If refrigerant pressure is normal, the pressure switch is defective.
3. Ensure that the resistance between the switch-side terminals from connector P17 is shorted (ON). (If not shorted (OFF), the dual pressure switch will detect a refrigerant pressure abnormality.)
80-40
PC228US-8,PC228USLC-8
Air conditioner Testing relays
q
Dual pressure switch
LA: 0.20 MPa {2 kg/cm2} LB: 0.02 MPa {0.2 kg/cm2} HA: 3.14 MPa {32 kg/cm2} HB: 0.59 MPa {6 kg/cm2} k If the pressure switch is to be replaced, refrigerant must be collected in advance. q If resistance between the switch-side terminals from connector P17 is shorted (ON): (See "Troubleshooting for the compressor and refrigerant system" for the circuit diagram.)
1. Disconnect connector [1] from the controller in line with item 2 from "Parts and connectors layout". 2. Confirm whether the condition between the female terminal of the connector P17 (harness side) (2) (B) and the machine ground is 1 z or less. (If this is not the case, the harness is defective.) 3. Confirm whether the condition between the female terminal of the connector P17 (harness side) (1) (GB) and the terminal of connector [1] (harness side) (4) (GB) is 1 z or less.(If this is not the case, the harness is defective.) a If the result of item 3 is abnormal, check contact of connector CN-AC01. (See "Parts and connectors layout".) 4. Connect all the connectors. 5. Turn the starting switch ON and if "Refrigerant Abnormal" is still displayed with self-diagnosis (On the air-conditioning system abnormality record screen in the machine monitor), replace the air conditioner controller.
Testing relays a If the air conditioner compressor is normal (cooling) and air is being discharged, the test can be omitted. a Listen closely to the relay to determine whether or not it is defective. There are two relays. q Blower main relay R20: Turning the fan motor ON/OFF q Compressor clutch relay R21: Used to turn the compressor (clutch) ON/OFF. 1. Remove rear cover in operator cab by referring to items 2 to 4 of "Parts and connectors layout." 2. Check the connections of connectors R20 and R21. (Check whether the connectors have been partially disconnected.) 3. Turn the starting switch ON (do not start the engine) and turn the main power of the air conditioner ON. If the blower off relay is normal, it is turned ON. Check its click. 4. If the air conditioner switch is turned ON at this time, the compressor relay is turned ON if it is normal. Check its click. a The air conditioner controller will not turn on the compressor relay in the following cases. 1) When the evaporator temperature is below 3 °C (depending on the input voltage from the evaporator temperature sensor). 2) When the pressure switch detects abnormality (it is turned OFF).
PC228US-8,PC228USLC-8
a If the sound produced by the compressor relay cannot be heard due to the sound of the fan, turn the starter switch off temporarily and disconnect the connector R20.
80-41
Air conditioner Testing relays
Checking relay unit Blower main relay (R20) Compressor clutch relay (R21) 1) The coil resistance between terminals (1) and (3) is 140 – 340 z. 2) The condition between terminals (2) and (4) is OFF when no voltage (20-30 V DC) is being applied between terminals (1) (+) and (3). 3) The condition between terminals (2) and (4) is ON when voltage (20-30 V DC) is being applied between terminals (1) (+) and (3).
q
80-42
PC228US-8,PC228USLC-8
Air conditioner Testing relays
PC228US-8,PC228USLC-8
80-43
Air conditioner Troubleshooting chart 1
Troubleshooting chart 1 The numbers in the boxes are the item numbers in the troubleshooting table. 1. Cooling trouble
80-44
80-4
PC228US-8,PC228USLC-8
Air conditioner Troubleshooting chart 2
2. Heating trouble
80-45
Troubleshooting chart 2 1. During cooling, the blower fan motor does not operate or the rotation speed does not match the air flow setting. a See "Troubleshooting of blower motor system (Air does not come out or air flow is abnormal)". Probable cause Defective blower main relay
Check method See "Testing relays" Check connector of blower fan motor for disconnection. Wire breakage or defective conSee "Detail of air conditioner unit" and "Parts and connectors nection layout." See "Troubleshooting of blower motor system" and "Parts and Defective blower fan motor connectors layout". Operate the fan switches in order and check the fan speed. Defective power transistor (PTR) See "Troubleshooting the blower motor system."
Remedy Replace Repair broken parts and connect correctly Replace Replace
2. During cooling, the blower fan motor is normal but the flow of air is very light. Probable cause Large duct resistance Air leakage through duct joints Obstruction at evaporator inlet
Check method Check the filter for clogging and the duct for crushing. Check duct joints. Check for defective duct seal and disconnection of duct Check evaporator for stain and obstruction
Remedy Repair Repair Remove obstruction and clean
Evaporator is frozen. Sensor fixing clip inspection, sensor contaminated Inspect the air conditioner hose around the pressure switch for Repair or replace frost. (when freezing has advanced even further) *: The evaporator temperature sensor and expansion valve are located inside the air conditioner unit. Defective evaporator temperature sensor Defective expansion valve*
3. Pressure abnormality (high-pressure / low-pressure) during cooling. Probable cause
Check method
Insufficient refrigerant Check the refrigerant volume through sight glass. Specifically, perform checking with the gauge manifold connected. Overcharge with refrigerant
PC228US-8,PC228USLC-8
Remedy Repair leaking part, then charge with proper quantity of refrigerant again Collect refrigerant, then fill up with proper quantity of refrigerant again
80-45
Air conditioner Troubleshooting chart 2
Judgment by pressure at inlet/outlet of compressor
80-46
Normal pressure range Low pressure: Approx. 0.13 - 0.2 MPa {1.3 - 2.0 kg/cm2} High pressure: Approx. 1.5 - 1.7 MPa {15 - 17 kg/cm2} Temperature in operator's cab: 30 – 35 °C, Engine speed: Approx. 1,500 rpm
See Troubleshooting with gauge pressure
PC228US-8,PC228USLC-8
Air conditioner Information in troubleshooting table
4. During cooling, the compressor cannot operate easily or at all. a See "Troubleshooting of compressor system (Air is not cooled)". Troubled part Probable cause Compressor Slack of belt belt Trouble in compressor Compressor Insufficient compressor oil Seizing on compressor Drop of battery voltage Open or short circuit in coil Magnet clutch Wire breakage or defective connection of ground wire Relay Refrigerant pressure Pressure switch
Check method
Remedy
Deflection of belt is large.
Adjust tension
Slip of belt
Repair or replace See "Handling compressor oil". Charge battery Replace
Heating of compressor
Slip of clutch Inspect with circuit tester (10 - 20 z) Check ground wire and connections See "Troubleshooting for compressor and Repair refrigerant system". Defective compressor clutch relay See "Testing relays" Replace Low/high pressure (Operation of See "Troubleshooting See "Troubleshooting with gauge pressure". pressure switch) with gauge pressure". See "Troubleshooting for compressor and Defective pressure switch Replace refrigerant system".
5. During cooling, the blower fan motor is normal and the flow of air is very light. Probable cause Large duct resistance
Check method Check the filter for clogging and the duct for crushing. Check duct joints for defective duct seal and disconnection of Air leakage through duct joints duct Clogging of heater core fins Check heater core fins for clogging
Remedy Repair Repair Clean
6. Engine coolant temperature or volume abnormalities during heating or cooling Probable cause Check method Low engine coolant temperaWarm up engine, and then check engine coolant temperature ture Low engine coolant level Check coolant level in radiator Insufficient circulation of engine Check engine coolant piping for clogging coolant (Hose, pipe, and core) The connection of IN and OUT Check the destination of heater hoses heater hoses is in reverse.
Remedy Find out cause Add coolant Bleed air and correct Correct
7. Fan speed abnormalities during cooling Probable cause
Check method See "Testing and adjusting of Air conditioner compressor belt tension" in the "Testing and adjusting" of Chapter 30 of the shop manual.
Fan speed is low
Remedy Correct
8. Other abnormalities Probable cause Check method Temperature cannot be con(See "Troubleshooting the temperature adjustment system.") trolled Vent (mode) changeover is not "Testing vent (mode) changeover" possible. See "Troubleshooting vent (mode) changeover." FRESH/RECIRC air cannot be See "Testing FRESH/RECIRC air changeover" and "Troublechanged over shooting for FRESH/RECIRC air changeover" Excessive compressor oil See "Handling compressor oil". Water leakage into the cab Clogging of drain hole
Remarks
Common to cooling and heating
Cooling only
Information in troubleshooting table Information in troubleshooting table 80-48 a The following information is summarized in the troubleshooting table and the related electrical circuit diagram. Before performing troubleshooting, understand that information fully. Failure Related information
Problem on machine Information related to detected failure or troubleshooting
PC228US-8,PC228USLC-8
80-47
Air conditioner Information in troubleshooting table
Cause
1 Probable causes of trouble (Perform troubleshooting according to these.) 2
3 - defective
Procedure, measuring location, criteria and remarks <Information described> q Procedure q Measuring location a "Between A – B" means “Measure voltage or resistance and so on between A and B". q Standard value in normal condition to judge probable causes q Remarks required for judgement <Notes on troubleshooting> (1) Pin number description sequence and tester lead handling For troubleshooting, connect the plus (+) and minus (–) tester leads as shown below unless otherwise specified. q Connect the plus (+) lead to a pin or harness indicated in the front. q Connect the minus(–) lead to a pin or harness indicated in the rear. (2) Example of troubleshooting by inspection of multiple items a Normal in 1 but abnormal in 2 At this time“ - defective” shown at left is applied
a If a wiring harness is burnt, replace it. <Defective wiring harness> q Open circuit Connector is connected imperfectly or wiring harness is disconnected. q Ground fault A harness not to be connected to the ground (earth) circuit comes into contact with the ground (earth) circuit or chassis accidentally. q Hot short circuit A harness not to be connected to the power (24 V) circuit comes into contact with the power (24 V) circuit accidentally. q Short circuit An independent wire in the harness abnormally comes into contact with one of another wire. (Defective insulation in connector or others) Related circuit diagram
80-48
This is the excerpted circuit diagram related to troubleshooting q Indicates connector No., and pin No. q See "Circuit diagram and arrangement of connector pins" and "Parts and connector locations" for connector location q The circuit diagram shows the size and colours of wires. W: White, B: Black, R: Red, G: Green, Y: Yellow, L: Blue, V: Purple, P: Pink, O: Orange, Br: Brown, Gr: Gray, Sb: Sky blue, Lg: Light green, Dg: Dark green, Ch: Dark brown a When there are two colours Example: WY: Yellow line on white background a The number before the wire colour indicates the wire size. q N.C.: Normally closed (Normally ON) q [1], [2],··· are numbers of unlabelled connectors. q Arrow (io): Roughly indicates their mounting place on the machine.
80-48
PC228US-8,PC228USLC-8
Air conditioner Information in troubleshooting table
PC228US-8,PC228USLC-8
80-49
Air conditioner Troubleshooting for power supply and CAN communication system (Air conditioner does not operate)
Troubleshooting for power supply and CAN communication system (Air conditioner does not operate) Air conditioner does not operate due to failure on power supply system or CAN communication system. Problem on q "A/C Controller Error" is displayed in red on air conditioner screen of machine monitor. machine q No air blows out (Blower motor does not rotate). q If a failure code or [DAFRMC] error is displayed on the machine monitor, see first of all Chapter 40 and troubleshoot it. a The machine monitor, engine controller, pump controller, and air conditioner controller are connected via CAN communication. q In the following cases, "A/C Controller Error" will be displayed in red on the machine monitor's air conditioner control screen. Of these, 1), 2), and 3) will be covered below. 1) The air conditioner controller is receiving no power. 2) The air conditioner controller is malfunctioning. 3) No communication is possible between the air conditioner controller and the machine monitor. 4) Vent (mode) door (damper) servomotor does not rotate. 5) Temperature control (Air Mix) door (damper) servomotor does not rotate. 6) Refrigerant pressure is abnormal. Related infor- q Referring to "Testing with self-diagnosis function", display the air conditioning system abnormality record screen on the machine monitor and check condition of CAN communication. Abnormality in mation CAN communication denotes that CAN communication is disabled between the air conditioner controller behind the air conditioner unit and the machine monitor. CAN Status is indicated as abnormal in any case of 1), 2) and 3) above. q Referring to "Parts and connectors locations", ensure that the No. 10 fuse (5 A) from fuse box F01 and the Fu5A fuse from the air conditioner harness have not blown. q Ground cable of air conditioner is connected in machine wiring harness together with electrical equipment of machine. q For each connector, see "Parts and connectors layout". q In cases where fuses are blown when the A/C switch is pressed, see "Troubleshooting for compressor and refrigerant system." q T-adapter for connector [1]: 799-601-7210, T-adapter for connector [2]: 799-601-7220 a T-adapter is not prepared for other connectors. Failure
Cause
Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position. 2. Disconnect the cable from the negative (–) terminal of the battery. 3. Disconnect connector [1] from the air conditioner controller, and connect 1 Defective wiring harness (ground) the T-adapter to the harness side. Between (16) (black) on the harness side of connector Resistance Max. 1 z [1] and the machine ground 1. Turn starting switch to OFF position. 2 Blown fuse 2. Referring to "Parts and connectors layout", inspect the No. 10 fuse (5 A) from fuse box F01 and the Fu5A fuse on the air conditioner harness.
80-50
PC228US-8,PC228USLC-8
Air conditioner Troubleshooting for power supply and CAN communication system (Air conditioner does not operate)
Cause
3 Defective wiring harness
4
Ground fault in wiring harness (Contact with ground circuit)
5 Open circuit in wiring harness
PC228US-8,PC228USLC-8
Procedure, measuring location, criteria and remarks a If fuse described in related information is broken, replace it. 1) Turn starting switch to OFF position. 2) Disconnect the cable from the negative (–) terminal of the battery. 3) Disconnect connectors [1] and [2] from the air conditioner controller, and connect the T-adapter to the harness side. 4) Turn starting switch to ON position. Between connector [2] (25) (red) and connector [1] (16) (B), both on the harness Voltage 20 – 30 V A side. a If fuse is broken again in test A above, perform following procedure. (Replace blown fuse ) 1. Turn starting switch to OFF position. 2. Disconnect the cable from the negative (–) terminal of the battery. 3. Disconnect connectors [1] and [2] from the air conditioner controller, and connect the T-adapter to the harness side. a If the fuse is blown again in the above test A and both B and C below are normal, it is likely that the cause of the problem lies within the blower motor circuit. In such a case, see "Troubleshooting the blower motor system." Between connector [2] (25) (red) and connector [1] (16) (black), both on the harResistance Min. 1 Mz B ness side. Between (25) (red) on the harness side of Resistance Min. 1 Mz C connector [2] and the machine ground a If fuse is broken again in test A for cause 3 and result of B or C is abnormal, identify wiring harness having ground fault. 1. Turn starting switch to OFF position. 2. Disconnect the cable from the negative (–) terminal of the battery. 3. Disconnect connectors AC01, N10, and [1]. 4. Connect the T-adapter to the harness side of connector [1], and connect the T-adapter to the harness side. a Abnormality in D or E below: Short circuit in air conditioner harness a Abnormality in F or G below: Short circuit in machine harness Between connector [2] (25) (red) and connector [1] (16) (black), both on the harResistance Min. 1 Mz D ness side. Between (25) (red) on the harness side of Resistance Min. 1 Mz E connector [2] and the machine ground Between connector N10 (female) (4) and Resistance Min. 1 Mz F AC01 (female) (6) (black) Between connector AC01 (female) (9) Resistance Min. 1 Mz G (red) and (6) (black) a If none of the fuses described in the related information have blown and an abnormality is recorded for Cause 3 A, inspect the circuit with respect to circuit diagrams.
80-51
Air conditioner Troubleshooting for power supply and CAN communication system (Air conditioner does not operate)
Cause
Procedure, measuring location, criteria and remarks
a Short circuit in CAN communication lines, or if a ground fault has occurred, a [DAFRMC] error is displayed. a Terminating resistors of approximately 120 z are in machine monitor and on engine. Since they are connected in parallel, combined resistance is approximately 60 z. 1. Turn starting switch to OFF position. 2. Disconnect the cable from the negative (–) terminal of the battery. 3. Disconnect connectors [1] and [2] from the air conditioner controller, and connect the T-adapter on the harness side. Between (17) and (18) on the harness Approx. Resistance H Disconnection in CAN communi- side connector [2] 60 z a If result H above is abnormal, perform following procedure. cation circuit a If an abnormality is recorded for H above and J below, the cab harness has 6 (communication is not possible failed. between the machine monitor and a If an abnormality is recorded for H above but J below is normal, the air conthe air conditioner controller) ditioner harness has failed. a Terminating resistors of approximately 120 z are in machine monitor and on engine. Since they are connected in parallel, combined resistance is approximately 60 z. 1. Turn starting switch to OFF position. 2. Disconnect the cable from the negative (–) terminal of the battery. 3. Disconnect connectors [1] and [2] from the air conditioner controller, and connect the T-adapter to the harness side. Between (male) (1) and (2) of connector Approx. Resistance J N10 60 z If results of Cause 1 and Cause 2, 3 A, and 6 H are normal, the air conditioner 7 Defective air conditioner controller controller must be replaced. 8 Defective machine monitor
80-52
When test results for causes 1 – 7 are normal, machine monitor is defective.
PC228US-8,PC228USLC-8
Air conditioner Troubleshooting for compressor and refrigerant system (Air is not cooled)
Circuit diagram related to power supply and CAN communication
80-53
Troubleshooting for compressor and refrigerant system (Air is not cooled) Failure
Air is not cooled due to compressor or refrigerant system failure. q
When engine is started and A/C switch is pressed on air conditioner screen of machine monitor, air is not cooled as displayed on screen. q Air conditioner compressor does not operate. Problem on q A/C Controller Error may be displayed in red on air conditioner screen of machine monitor. machine There are 6 cases, items 1) to 6), of the information relevant to "Troubleshooting for power supply and CAN communication system". As for 1) through 3), see "Troubleshooting for the power supply and CAN communication system." The following description deals with item 6), refrigerant pressure abnormality. q Referring to "Testing with self-diagnosis function", display air conditioner fault history screen on machine monitor and check to see if refrigerant pressure is abnormal. If refrigerant pressure is abnormal, compressor is not turned ON and air is not cooled consequently. Related infor- a Abnormal refrigerant pressure indicates that "Signal (connector [1] (4)) from pressure switch is not mation grounded". q In certain cases, the air conditioner will not turn on at 3 °C or lower (normal). q For each connector and fuse, see "Parts and connectors layout". q T-adapter for connector [1]: 799-601-7210, T-adapter for connector [2]: 799-601-7220 a T-adapter is provided only for connectors [1], [2], and AC02.
PC228US-8,PC228USLC-8
80-53
Air conditioner Troubleshooting for compressor and refrigerant system (Air is not cooled)
Cause
1 Defective pressure switch
Procedure, measuring location, criteria and remarks a If "A/C Controller Error" is displayed in red on air conditioner operation screen of machine monitor, perform following procedure. 1. Turn starting switch to OFF position. 2. Disconnect the cable from the negative (–) terminal of the battery. 3. Disconnect the pressure switch connector P17. a In certain cases, the pressure switch may be operating normally and set to OFF; therefore, if a failure is recorded for the following (i.e., switch OFF), attach a pressure gauge to the air conditioner compressor and check the refrigerant pressure. (See "Troubleshooting with gauge pressure.") Between (1) and (2) of connector P17 (male)
Resistance
k Before replacing pressure switch, collect refrigerant.
2
3
4
5
6
Max. 1 z
1. Turn starting switch to OFF position. 2. Disconnect the connector AC02 from the air conditioner compressor and connect a T-adapter to the male side. Defective air conditioner compres- a Ensure connection of air conditioner compressor ground cable (E). sor (See "Parts and connectors layout".) Between connector AC02 (male) (1) and the Approx. machine ground (i.e., air conditioner compressor Resistance 15 z coil resistance) 1. Turn starting switch to OFF position. 2. Disconnect connectors [1] and R21, and troubleshoot in that condition. a Ensure that the result of checking for Cause 1 (pressure switch ON) and Cause 2 (air conditioner compressor normal) are both normal. Open circuit in wiring harness Between connector [1] (4) and the machine ground Resistance Max. 1 z (Pressure switch is turned ON) Between connector R21 (female) (2) and the Approx. machine ground Resistance 15 z (Air conditioner compressor coil resistance) q Referring to "Testing relays", check sound made when compressor clutch relay is turned ON. a If the sound produced when the compressor Click A clutch relay turns ON cannot be heard due to the is heard. sound of the blower, turn the starter switch off temporarily and disconnect the connector R20. a If A above and B below are abnormal and C is normal (relay is normal), go to causes 7 and 8. 1. Turn starting switch to OFF position. Defective compressor clutch relay 2. Disconnect connector R21. 3. Use a wire to short-circuit (2) (white) and (4) (Does not turn ON) Air is (blue on red) of connector R21 (harness side) . B cooled. (This forces the compressor to operate without using the relay.) 4. Turn starting switch to ON position. 1. Turn starting switch to OFF position. 2. Disconnect connector R21 and troubleshoot in that condition. Approx. 140 Between (1) and (3) of connector R21 Resistance C (male) (i.e., coil resistance) 340 z a If the fuse is not blown, skip troubleshooting. 1. Turn starting switch to OFF position. Ground fault in wiring harness 2. Disconnect connectors R21 and AC02, and connect a T-adapter to the (Contact with ground circuit) female side of AC02. Between (1) of connector AC02 (female) and the Resistance Min. 1 Mz machine ground 1. Turn starting switch to OFF position. 2. Disconnect connectors R21 and [2], and then connect the T-adapter to [2] on the harness side. Short circuit in wiring harness a Ensure that test result for cause 2 is normal. Between (25) and (35) on the harness side of conResistance Min. 1 Mz nector [2]
80-54
PC228US-8,PC228USLC-8
Air conditioner Troubleshooting for compressor and refrigerant system (Air is not cooled)
Cause
Procedure, measuring location, criteria and remarks
a See circuit diagram and inspect. 1. Turn starting switch to OFF position. 2. Disconnect connectors [1] and [2] and insert the T-adapter to the harness side. 8 Defective air conditioner controller 3. Turn starting switch to ON position. 4. Display the air conditioner control screen on the machine monitor and press the A/C switch. 7 Open circuit in wiring harness
Between connector [2] (35) and connector [1] (16) Defective machine monitor 9 (Defective switch)
PC228US-8,PC228USLC-8
Voltage
Max. 1 V
1. Turn starting switch to ON position. 2. Display the air conditioner control screen on the machine monitor. Press A/C switch.
"A/C ON" is displayed
80-55
Air conditioner Troubleshooting for blower motor system (No air comes out or air flow is abnormal)
Circuit diagram related to compressor and refrigerant system
80-56
Troubleshooting for blower motor system (No air comes out or air flow is abnormal) Failure
80-56
q
No air comes out or air flow is abnormal due to blower motor system failure.
PC228US-8,PC228USLC-8
Air conditioner Troubleshooting for blower motor system (No air comes out or air flow is abnormal)
q
The machine monitor shows air flow as normal on the air conditioner control screen, but no air is blown out. q Air flow does not match fan switch setting on air conditioner operation screen. q This failure is not checked with self-diagnosis function. q In cases where the blown-air volume begins to behave in an unpredictable manner after a certain while during cooling, freezing of the evaporator is a likely cause. This may be due to the following. 1) Defective compressor clutch relay (i.e., stuck in ON position) (see item 4 A from "Troubleshooting for compressor and refrigerant system") 2) Detachment of the evaporator temperature sensor's mounting holder Related infor3) Incorrect adjustment of the expansion valve mation a In the case of 2) and 3) above, the air conditioner unit must be replaced. q If air comes out, fuse and relay are normal and wiring harness is seldom abnormal. q In cases where air is discharged but with unpredictable volumes even during heating, the power transistor has failed, and therefore, the air conditioner unit must be replaced. a The power transistor and the blower motor cannot be replaced. q For details regarding connectors and relays, see "Parts and connectors layout." q T-adapter for connector [1]: 799-601-7210, T-adapter for connector [2]: 799-601-7220 a T-adapter is not prepared for other connectors. Problem on machine
Cause
Procedure, measuring location, criteria and remarks q
1
Defective blower main relay (Does not turn ON)
Referring to “Testing relays”, check turn-on sound of blower main relay.
Click is heard.
A
a If A above is B below are abnormal and C is normal (relay is normal), go to cause 2. 1. Turn starting switch to OFF position. 2. Disconnect connector R20. 3. Use a wire to short-circuit (2) (red/yellow) and (4) (red/blue) from connector R20 (harness side). (This forces ON without using the relay.) 4. Turn starting switch to ON position. Air comes Operate fan on air conditioner operation screen. B out. a If air does not come out even when blower motor is turned ON forcibly without using relay, cause is part other than relay.
2 Open circuit in wiring harness
Open circuit in harness, power transistor is defective, or blower 3 (fan) motor is defective. (Replacement of air conditioner unit)
4 Short circuit in wiring harness
PC228US-8,PC228USLC-8
1. Turn starting switch to OFF position. 2. Disconnect connector R20 and troubleshoot in that condition. Approx. Between (1) and (3) from R20 (relay side) Resist140 – C (coil resistance) ance 340 z 1. Turn starting switch to OFF position. 2. Disconnect connector [2] and connect the T-adapter to the wiring harness side. 3. Remove fuse No. 10 of fuse box F01. Approx. Between F01 (10) and [2] on wiring harness side (36) Resistance 140 – (R20 coil resistance) 340 z 1. Turn starting switch to OFF position. 2. Disconnect connectors [1], [2], and AC01, and then connect the T-adapter to [1] and [2] on the harness side. Between (8) and (16) on the harness side of connecApprox. 11 kz or below tor [1] (power transistor's internal resistance) Between (7) on the harness side of connector [1] and AC01 (male) (10) (power transistor’s internal resist- Approx. 2.2 kz or below ance) 1. Turn starting switch to OFF position. 2. Disconnect connectors R20, [1] and [2], and then connect the T-adapter to [1] and [2] on the wiring harness side. Between (16) and (7) on the harness side ResistMin. 1 Mz of connector [1] ance Between (25) and (36) on the harness ResistMin. 1 Mz side of connector [2] ance
80-57
Air conditioner Troubleshooting for blower motor system (No air comes out or air flow is abnormal)
Cause
Procedure, measuring location, criteria and remarks 1. 2. 3. 4.
Turn starting switch to OFF position. Disconnect connectors [1] and [2] and insert the T-adapter. Turn starting switch to ON position. Press fan switch on air conditioner operation screen. (Air flow may be set 5 Defective air conditioner controller to any position.) Between (36) of connector [2] and (16) of Voltage Max. 1 V connector [1] Between (8) and (16) of connector [1]
6
Defective machine monitor (Defective switch)
80-58
Voltage
Max. 2 V
1. Turn starting switch to ON position. 2. Display the air conditioner control screen on the machine monitor. The air volume display Press the fan switches from MIN to MAX moves between MIN and MAX.
PC228US-8,PC228USLC-8
Air conditioner Troubleshooting for temperature control
Circuit diagram related to blower motor system
80-59
Troubleshooting for temperature control Failure Problem on machine
q
Temperature cannot be controlled
q
"A/C Controller Error" may be displayed in red on air conditioner control screen of the machine monitor. (See "Troubleshooting for power supply and CAN communication system.") While air conditioner operation screen of machine monitor is displayed, temperature does not change even if temperature control switch is operated.
q
PC228US-8,PC228USLC-8
80-59
Air conditioner Troubleshooting for temperature control
a Temperature control is achieved by mixing cold and warm air. q Referring to "Testing with self-diagnosis function", display "03 Air conditioning system" screen of "Abnormality Record" of the machine monitor and check whether an "Air mix", "Outer sensor", or "Inner sensor" abnormality has occurred. q In the case of "Air Mix (damper) abnormal", repeat the temperature setting 18.0 °C (Max. cooling)io32.0 °C (Max. heating) several times. If the Air Mix (damper) abnormal count does not Related inforincrease, Air Mix damper is normal. (This abnormality potentially happens only at low temperature.) mation q In the case of "Inner sensor Abnormal", see "Testing inner sensor". q Air mix servomotor and vent (mode) servomotor use the same servomotor. However, since connectors [5] and [6] are not visible from outside, you cannot judge whether servomotor is defective. q T-adapter for connector [1]: 799-601-7210, T-adapter for connector [2]: 799-601-7220 q For each connector, see "Parts and connectors layout". a Connectors [5] and [6] cannot be seen from the outside, therefore, signals must be monitored at air conditioner controller during operation. Cause
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connectors [1] and [2] and insert the T-adapter. 3. Turn starting switch to ON position. Between connector [1] (3) and connector [2] (27)
Voltage
5V
1. 2. 3. 4.
1
2 3
4
Turn starting switch to OFF position. Disconnect connectors [1] and [2] and insert the T-adapter. Turn starting switch to ON position. Operate the temperature adjustment switch on the air conditioner controller screen and prepare by setting to COOL MAX. 5. Operate the temperature adjustment switch on the air conditioner controller screen and set to HOT MAX. Defective air conditioner unit or air a Voltage appears across (21) and (22) of connector [2] for approximately 3 conditioner controller seconds (only while door moves). a The voltage will be vary between connectors [1](2) and [2](27) for approximately 3 seconds (only while door moves). (When the door stops, the voltage will stabilize.) Between (21) (+) and (22) (–) of connector [2] Approx. 24 a If temperature is changed from Voltage A V HOT MAX to COOL MAX, voltage polarities are reversed. Between connector [1] (2) (+) and conVariable Voltage B nector [2] (27) (-) max. 5 V a If the results of checking for Cause 1 A are normal and for Cause 1 B are Defective air conditioner unit abnormal, the air conditioner unit is defective. a If the results of checking for Cause 1 A are abnormal, the air conditioner Defective air conditioner controller controller is defective. 1. Turn starting switch to ON position. 2. Display the air conditioner control screen on the machine monitor. Defective machine monitor (Defective switch) display changes Press temperature control switch. between 18 and 32 °C
80-60
PC228US-8,PC228USLC-8
Air conditioner Troubleshooting for vent (mode) changeover
Circuit diagram related to temperature adjustment
80-61
a Servomotors are common.
Troubleshooting for vent (mode) changeover Failure Problem on machine
q
Vent (mode) changeover is not possible.
q
"A/C Controller Error" is displayed in red on air conditioner control screen of the machine monitor. (See "Troubleshooting for power supply and CAN communication system.") When vent selector switch on air conditioner operation screen of machine monitor is operated, vent does not change.
q
PC228US-8,PC228USLC-8
80-61
Air conditioner Troubleshooting for vent (mode) changeover
q
As described in "Testing with self-diagnosis function", display "03 Air-conditioning system" screen of "abnormality record" in the machine monitor and check whether a "Ventilation Abnormal" has occurred. q Even in cases where cables, etc. have been disconnected (see "Testing the vent (mode) changeover"), self-diagnosis will determine the condition to be normal if the vent (mode) servomotor's potentiometer reaches the correct voltage when current is sent to the vent (mode) servomotor as a Related inforresult of switch operation. mation q Although the air mix servomotor and the vent (mode) servomotor are identical, connectors [5] and [6] cannot be seen from the outside, and therefore, it is not possible to determine whether this servomotor is defective. q T-adapter for connector [1]: 799-601-7210, T-adapter for connector [2]: 799-601-7220 q For each connector, see "Parts and connectors layout". a Connectors [5] and [6] cannot be seen from the outside, therefore, signals must be monitored at air conditioner controller during operation. Cause
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connectors [1] and [2] and insert the T-adapter. 3. Turn starting switch to ON position. Between connector [1] (3) and connector [2] (27)
Voltage
5V
1. 2. 3. 4.
1
2 3
4
Turn starting switch to OFF position. Disconnect connectors [1] and [2] and insert the T-adapter. Turn starting switch to ON position. Operate the vent switch on the air conditioner controller screen and prepare by setting to face mode. 5. Operate the vent switch on the air conditioner controller screen and set to defrost mode. Defective air conditioner unit a Voltage will be output between connectors [2] (24) and [2] (23) for approxor air conditioner controller imately 3 seconds (only while door moves). a The voltage will be vary between connectors [1] (9) and [2] (27) for approximately 3 seconds (only while door moves). (When the door stops, the voltage will stabilize.) Between (24) (+) and (23) (–) of connector [2] Approx. 24 a If vent is changed from DEFROST Voltage A V to FACE, voltage polarities are reversed. Between connector [1] (9) (+) and conVariable Voltage B nector [2] (27) (-) max. 5 V a If the results of checking for Cause 1 A are normal and for Cause 1 B are Defective air conditioner unit abnormal, the air conditioner unit is defective. a If the results of checking for Cause 1 A are abnormal, the air conditioner Defective air conditioner controller controller is defective. 1. Turn starting switch to ON position. 2. Display the air conditioner control screen on the machine monitor. Defective machine monitor Operate the vent switch to display face, face and The display will switch (Defective switch) rear, foot and face and rear, foot, foot and defroster, between the various and defroster. modes.
80-62
PC228US-8,PC228USLC-8
Air conditioner Troubleshooting for FRESH/RECIRC air changeover
Circuit diagram related to vent (mode) changeover
80-63
a Servomotors are common.
Troubleshooting for FRESH/RECIRC air changeover Failure
q
FRESH/RECIRC air cannot be changed over
q
When FRESH/RECIRC selector switch of machine monitor is operated, recirculated or fresh air does not changeover. (FRESH/RECIRC air changeover door (damper) does not rotate) q FRESH/RECIRC air changeover is not checked with self-diagnosis function. q Referring to "Testing FRESH/RECIRC air changeover", operate the FRESH/RECIRC air selector switch and confirm whether or not the FRESH/RECIRC air changeover door (damper) opens and closes. Related inforq FRESH/RECIRC air changeover servo motor cannot be seen from the outside. mation q T-adapter for connector [1]: 799-601-7210, T-adapter for connector [2]: 799-601-7220 q For each connector, see "Parts and connectors layout". a T-adapters for connectors AC02 and [7] are not prepared, and therefore, signals must be monitored at air conditioner controller during operation. Problem on machine
Cause
PC228US-8,PC228USLC-8
Standard value in normal condition/Remarks on troubleshooting
80-63
Air conditioner Troubleshooting for FRESH/RECIRC air changeover
1. 2. 3. 4.
1
2 3
4
Turn starting switch to OFF position. Disconnect connector [2] and insert the T-adapter. Turn starting switch to ON position. Operate the FRESH/RECIRC selector switch on the air conditioner control screen, and set to recirculated air. 5. Operate the FRESH/RECIRC selector switch on the air conditioner control screen, and set to fresh air. a Voltage will be output between connectors [2] (25) and [2] (20) for approximately 3 seconds (only while door moves to the fresh air position). Defective air conditioner controller Between connector [2] (25) (+) and connector [2] Approx. 24 Voltage or air conditioner unit (20) (-) V See1. – 3. above. 4. Set FRESH/RECIRC selector switch on air conditioner operation screen to FRESH. 5. Set FRESH/RECIRC selector switch on air conditioner operation screen to RECIRC. a Voltage will be output between connectors [2] (25) and [2] (19) for approximately 3 seconds (only while door moves to the recirculated air position). Between connector [2] (25) (+) and connector [2] Approx. 24 Voltage (19) (-) V a If the results of checking for Cause 1 are normal and the FRESH/RECIRC Defective air conditioner unit air changeover door does not operate, the air conditioner unit is defective. a If the results of checking for Cause 1 are abnormal, the air conditioner conDefective controller troller is defective. 1. Turn starting switch to ON position. 2. Display the air conditioner control screen on the machine monitor. Defective machine monitor (Defective switch) Display of Recirc/Fresh Press FRESH/RECIRC air selector switch. changes.
80-64
PC228US-8,PC228USLC-8
Air conditioner Troubleshooting for temperature sensor system
Circuit diagram related to FRESH/RECIRC air changeover
80-65
Troubleshooting for temperature sensor system Air is not cooled or automatic air conditioner mode does not operate due to the failure of temperature sensor system. Problem on q Air conditioner does not operate even when its activation switch is pressed, or automatic air conditioner mode does not operate even when the AUTO switch is pressed. machine q The system has three temperature sensors: evaporator temperature sensor, inside (air) temperature sensor, and outside (air) temperature sensor. q See "Testing with self-diagnostic function" and troubleshoot the system if any of the following abnormalities is found. Ventilating sensor (evaporator temperature sensor) Abnormal, Inner sensor (inside Related infor(air) temperature sensor) Abnormal, or Outer sensor (outside (air) temperature sensor) Abnormal mation q The connector of evaporator temperature sensor cannot be inspected when it is mounted on the machine. q T-adapter for connector [1]: 799-601-7210, T-adapter for connector [2]: 799-601-7220 q For each connector and other parts, see "Parts and connectors layout". Failure
Cause
Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connectors [1] and [2] from air conditioner controller, and connect Defective evaporator temperaT-adapter to each connector on the wiring harness side. ture sensor Between connector [1] (12) and connecApprox. 1 0°C Resistance (Replacement of air conditioner tor [2] (27) 4.8 kz unit) Approx. (Resistance of evaporator temperature 15°C Resistance 2.3 kz sensor) 1. Turn starting switch to OFF position. 2. Disconnect connectors [1] and [2] from air conditioner controller, and connect Defective inside air temperature T-adapter to each connector on the wiring harness side. sensor Between connector [1] (11) and connecApprox. 2 0°C Resistance (Replacement of air conditioner tor [2] (27) 1.6 kz unit) Approx. (Resistance of inside air temperature 25°C Resistance 5 kz sensor)
PC228US-8,PC228USLC-8
80-65
Air conditioner Troubleshooting for temperature sensor system
Defective outside air tempera3 ture sensor
1. Turn starting switch to OFF position. 2. Disconnect connector P32. Between P32 (male) (1) and (2)
25°C
Resistance
Approx. 1.7 kz
4 Open circuit in wiring harness
1. Turn starting switch to OFF position. 2. Disconnect connectors [1] and [2] from air conditioner controller, and connect T-adapter to each connector on the wiring harness side. Between connector [1] (13) and connector [2] (27) Approx. 25°C Resistance (Resistance of outside air temperature 1.7 kz sensor)
5 Defective air conditioner controller
If cause is not found by above checks, air conditioner controller is defective.
80-66
PC228US-8,PC228USLC-8
Air conditioner Troubleshooting with gauge pressure
Circuit diagram related to temperature sensors
80-67
Troubleshooting with gauge pressure Perform troubleshooting according to the high and low gauge pressures of the cooling cycle. For details, see "Connection of service tool". a The gauge pressure varies largely with the weather condition and operating condition of the machine. Check the gauge pressure under the pressure measurement conditions. q High-pressure line pressure is too high: Above approx. 2.5 MPa {25 kg/cm2} q High-pressure line pressure is too low: Below approx. 1 MPa {10 kg/cm2} q Low-pressure line pressure is too high: Above approx. 0.3 MPa {3 kg/cm2} q Low-pressure line pressure is too low: Below approx. 0.05 MPa {0.5 kg/cm2} a Dual pressure switch turns "OFF" to protect the air conditioner circuit if the pressure of the high-pressure or low-pressure line is abnormal.
<Measurement condition for pressure> Item Condition value Ambient temperature 25 – 50 °C Engine speed 1,500 rpm Air conditioner switch ON Fan switch HI Set temperature Full cool
Dual pressure switch a The switch is normally "ON", and becomes "OFF" for compressor operation when it detects abnormal pressure.
q
LA: 0.20 MPa {2 kg/cm2} LB: 0.02 MPa {0.2 kg/cm2} HA: 3.14 MPa {32 kg/cm2} HB: 0.59 MPa {6 kg/cm2}
PC228US-8,PC228USLC-8
80-67
Air conditioner Troubleshooting with gauge pressure
Indicated gauge pressure Pressure is normal
Cause
Check method
Air conditioner cycle is operating normally. If there is any trouble (cooling trouble), there is another cause. High- pressure: Approx 1.5 - 1.7 MPa {15 – 17 kg/cm2}
Remedy
–
2
Low-pressure: Approx 0.13 - 0.2 MPa {1.3 - 2.0 kg/cm } Collect refrigerant, then fill up Bubble can be seen through sight glass. *1, with proper quantity of refrigerInsufficient refrigerant ant again *3 *2 There is a temperature difference between Replace Clogging of receiver drier inlet and outlet pipes of receiver drier. *2 Tank is frosty Clean or replace Both high-pressure Clogging of expansion valve Expansion valve is frosted *2 and low-pressure Replace Gas leakage at heat sensing tube of Low-pressure gauge reads vacuum are too low> *2 expansion valve Repair or replace Evaporator is frozen Low-pressure gauge Replace receiver drier Defective evaporator temperature Flow rate of refrigerant is reduced due to reads vacuum Collect refrigerant, then fill up sensor or defective contact of sen- freezing. with proper quantity of refriger(At cool max. and HI speed of fan, later it sor (coming off of mounting clip) ant again becomes not to cold.) *2 Piping between receiver drier and comClean or replace pressor is clogged or crushed. Clogged or crushed piping *2 If clogged completely, low-pressure gauge reads vacuum Collect refrigerant, then fill up with proper quantity of refrigerFilling too much with refrigerant Connect gauge manifold ant again *2 Clean, repair fins, or repair or Dirty condenser, clogging or crushing of <Both high-presreplace condenser Defective cooling of condenser fins, or defective revolution of cooling fan sure and low-pres*2 Replace sure are too high> Improper adjustment of expansion Bubble can be seen through sight glass. *3 *2 valve (Valve is opened too wide) Evacuate and then fill up with proper quantity of refrigerant Air in cycle parts Bubble can be seen through sight glass. *3 again *2 Clean inside of cycle or <High-pressure is Clogged or crushed piping between There is a remarkable temperature differreplace too high and low compressor and condenser ence across clogged part *2 pressure is too low> Both high-pressure and low-pressure are <High-pressure is balanced while compressor is in operation. Replace Defective compressor (Comprestoo low and *2 Compressor has seized and is extremely low-pressure is too sion trouble of compressor) hot. high>
*1 If refrigerant leaks, compressor oil in the air conditioner circuit always leaks, too. So perform the check mainly on pipe joints and dirty parts with oil. *2 k When replacing a cooling cycle part, see “Caution about refrigerant” and collect refrigerant. After replacing it, fill up the air conditioner system with refrigerant again. *3 Sight glass (1) is placed near condenser.
80-68
PC228US-8,PC228USLC-8
Air conditioner Connection of service tool
Connection of service tool Symbol X
Part number
Part name
799 - 703 - 1200
Service tool kit
a Use the service tool kit for R134a. Service tool kit X (1): Gauge manifold (2): High-pressure charging hose (red) (3): Low pressure charging hose (blue) (4): Quick joint for HI side (large diameter) (5): Quick joint for LO side (small diameter)
Connect the gauge manifold, hoses and other service tools according to the following procedure. 1. Close high-pressure valve (6) and low-pressure valve (7) of gauge manifold (1). 2. Connect the red charging hose (2) to the HI side of the gauge manifold and the blue charging hose (3) to the LO side. 3. Connect quick joints (4) and (5) to each hose. 4. Connect quick joints (4) and (5) to service valves (8) and (9) of high- and low-pressure pipes respectively.
(a): As the thread is coarse, care should be taken with regard to loosening.
PC228US-8,PC228USLC-8
80-69
Air conditioner Precautions for disconnecting and connecting air conditioner piping
A: From Cab
B: To Condenser
Precautions for disconnecting and connecting air conditioner piping Precautions for disconnecting
80-72
k Collect the refrigerant (Air conditioner gas:
R134a) from air conditioner circuit before disconnecting air conditioner hose to replace air conditioner unit, air conditioner compressor or receiver drier and so on. a Ask a qualified person for collecting, adding and filling operations of the refrigerant (R134a). a Never release the refrigerant (R134a) to the atmosphere. k If refrigerant gas (R134a) gets in your eyes, you may lose your sight. And if it touches your skins, you may suffer from frostbite. Accordingly, put on the safety glasses, gloves and working suits with long sleeves while you are collecting the refrigerant (R134a) or filling the air conditioner circuit with the refrigerant (R134a). Collecting and filling work must be conducted by a qualified person.
80-70
q
When loosening the air conditioner hose nuts after collecting the refrigerant, be sure to use 2 wrenches; use one wrench to fix and use the other one to loosen the nuts.
PC228US-8,PC228USLC-8
Air conditioner Precautions for disconnecting and connecting air conditioner piping
Precautions for connecting q
q
q q
80-72
When connecting piping, apply compressor oil (ND-OIL8) for R134a to its O-rings. (See item 4 of "Handling compressor oil") Do not apply oil to the threads of a bolt, nut or union, however. Once an O-ring is used, it is deformed and deteriorated. Accordingly, do not reuse it. When removing it, use a soft tool (such as a toothpick) so that the piping will not be damaged. Push in each pipe to the stopper and tighten the bolt or nut fully with your fingers. Be sure to use two wrenches to tighten each nut. Use one wrench to fix and tighten the nut with the other wrench to the specified torque (Use a torque wrench for tightening).
PC228US-8,PC228USLC-8
80-71
Air conditioner Handling of compressor oil
Table of tightening torque for refrigerant pipe joint. Thread size M6 x 1.0
Tightening torque Nm {kgm} 8 to 12 {0.8 to 1.2}
1. Engine 2. Compressor 3. Condenser 4. Modulator 5. Air conditioner unit
Handling of compressor oil 1. Compressor oil management (DENSO: ND-OIL8 for R134a)
2. Filling compressor oil 80-74
Although compressor oil differs from engine oil in that it does not need regular checking or filling, the following types of problem can occur if the amount in the system is too high or too low. Condition Content Insufficiency of Lubrication trouble and seizure of comoil pressor Cooling trouble Excess of oil (Excessive oil stick to parts and lower heat exchange performance)
Accordingly, compressor oil must be filled to the specified level, similarly to refrigerant.
80-72
80-74
k Refrigerant is potentially hazardous to health
and to the environment. Before disconnecting air conditioner hoses, therefore, this liquid should be collected in accordance with "Precautions for connecting air conditioner piping." a If oil for CFC-12 (R-12) is used, lubrication trouble will occur and the compressor may be broken or seized. Be sure to use an oil suitable for R134a ( DENSO: ND-OIL8). a Oil for use with R134a is extremely hygroscopic, and therefore, the cap must be immediately closed after use to limit contact with air. Store the oil can in a dry and ventilated place. a Precautions for using oil Do not allow oil for use with R134a to come into contact with acrylic plastic or polystyrene surfaces (without a baked finish) as it may dissolve these plastics. Check compressor oil in the following cases, and then add new oil if necessary. q When much refrigerant is discharged because of leakage. q When the compressor is troubled and replaced. (See 3 below) PC228US-8,PC228USLC-8
Air conditioner Handling of compressor oil
q
When a cycle parts such as the air conditioner unit, condenser, receiver drier, evaporator unit, etc. is replaced.
q
Quantity of oil to be added when cycle part is replaced Air conditioner part Air conditioner unit, evaporator Condenser Receiver drier Hose (Compressor – Cab) Hose (Compressor – Condenser) Hose (Cab - Condenser)
PC228US-8,PC228USLC-8
Quantity to be added (cc) Approx. 40 Approx. 40 Approx. 20 Approx. 35 Approx. 20 Approx. 5
80-73
Air conditioner Desiccant replacement procedure
3. Replacement of compressor q
80-75
In case of compressor seizure or breakage. Metal chips will circulate through the air conditioner circuit and contaminate the compressor oil extremely. In this case, flush the air conditioner circuit and replace the compressor and receiver drier. The compressor oil is removed from the air conditioner circuit by flushing. Accordingly, install a new compressor with the oil of the specified quantity (180 cc) filled in it.
Other cases a New compressor contains compressor oil of 180 cc in it. 1) Prepare an oil container and drain oil from the old compressor. 2) Measure the quantity of the drained oil with a measuring cylinder, and note the quantity or mark the level.
q
Desiccant replacement procedure a Prepare desiccant (20Y-810-1250).
80-74
replacement
kit
3) Drain below-mentioned quantity of oil from the new compressor. Quantity to be drained= 180 cc - "Noted quantity" Example: If 30 cc was drained from the removed compressor, the quantity to be drained from the new compressor would be 150 cc (i.e., 180 - 30 cc). k When replacing the desiccant, be sure to col-
lect the refrigerant from the air conditioning cycle. If the desiccant is replaced without collecting the refrigerant, the refrigerant may blind you or cap (C) may fly out and injure you because of the refrigerant pressure in the cycle. 1. Condenser 2. Receiver drier a The desiccant is in receiver drier (2).
PC228US-8,PC228USLC-8
Air conditioner Desiccant replacement procedure
Taking out desiccant (D) 80-76 1. Remove snap ring (SR) from receiver drier (2). 2. Remove cap (C) from receiver drier (2). Hold boss (B) of cap (C) with pliers etc. to remove. a Cap (C) may be hard to remove. When removing it, take care not to damage or deform the seal or receiver drier (2). 3. Remove filter (F) from receiver drier (2) 4. Take desiccant (D) out of receiver drier (2). a Removed snap ring (SR), cap (C), filter (F), desiccant (D) will be replaced with the parts of the drier (desiccant replacement kit) and will not be necessary any more.
Installing new desiccant (D) 80-7 1. Apply ND-OIL 8 to the periphery of O-ring (OR) of cap (C). 2. Install filter (F) to cap (C).
3. Insert desiccant (D) in receiver drier (2). 4. Install cap (C) with filter (F) to receiver drier (2). 5. Install snap ring (SR) to receiver drier (2). a Install snap ring (SR) to the groove in receiver drier (2) securely. If it is not installed securely, cap (C) may come off.
PC228US-8,PC228USLC-8
80-75
Air conditioner Desiccant replacement procedure
80-76
PC228US-8,PC228USLC-8
SEN0533433-00
90-1
PC228US-8,PC228USLC-8
HYDRAULIC EXCAVATOR PC228US-8 PC228USLC-8 Shop Manual
Machine model
Serial number
PC228US-8 PC228USLC-8
50001 and up 50001 and up
90 Diagrams and drawings
PC228US-8,PC228USLC-8
90-1
90-1 (03)
Contents
Contents 90 Diagrams and drawings Hydraulic circuit diagram................................................................................................................ 90-3 Symbols used in hydraulic circuit diagrams ................................................................................ 90-3 Hydraulic circuit diagram (1/3) .................................................................................................... 90-7 Hydraulic circuit diagram (2/3) .................................................................................................... 90-9 Hydraulic circuit diagram (3/3) .................................................................................................... 90-11 Electrical circuit diagram ................................................................................................................ 90-13 Symbols used in electric circuit diagrams ...................................................................................... 90-13 Electrical circuit diagram (1/6)..................................................................................................... 90-17 Electrical circuit diagram (2/6)..................................................................................................... 90-19 Electrical circuit diagram (3/6)..................................................................................................... 90-21 Electrical circuit diagram (4/6)..................................................................................................... 90-23 Electrical circuit diagram (5/6)..................................................................................................... 90-25 Electrical circuit diagram (6/6)..................................................................................................... 90-27 Air conditioner electrical circuit diagram ..................................................................................... 90-29
90-2 (03)
PC228US-8,PC228USLC-8
Hydraulic circuit diagram Symbols used in hydraulic circuit diagrams
Hydraulic circuit diagram Symbols used in hydraulic circuit diagrams (Rev. 2010/03)
PC228US-8,PC228USLC-8
90-3 (03)
Hydraulic circuit diagram Symbols used in hydraulic circuit diagrams
90-4 (03)
PC228US-8,PC228USLC-8
Hydraulic circuit diagram Symbols used in hydraulic circuit diagrams
PC228US-8,PC228USLC-8
90-5 (03)
Hydraulic circuit diagram Symbols used in hydraulic circuit diagrams
90-6 (03)
PC228US-8,PC228USLC-8
Hydraulic circuit diagram (1/3) PC228US-8,PC228USLC-8
PC228US-8,PC228USLC-8
Hydraulic circuit diagram PC228US-8,PC228USLC-8
90-7 (03)
Hydraulic circuit diagram (2/3) PC228US-8,PC228USLC-8
PC228US-8,PC228USLC-8
Hydraulic circuit diagram PC228US-8, PCUSLC-8
90-9 (03)
Hydraulic circuit diagram (3/3)
Hydraulic circuit diagram PC228US-8, PCUSLC-8
PC228US-8,PC228USLC-8
PC228US-8,PC228USLC-8
90-11 (03)
Electrical circuit diagram Symbols used in electric circuit diagrams PC228US-8,PC228USLC-8
Electrical circuit diagram Symbols used in electric circuit diagrams (Rev. 2011/02)
PC228US-8,PC228USLC-8
90-13 (03)
Electrical circuit diagram Symbols used in electric circuit diagrams
90-14 (03)
PC228US-8,PC228USLC-8
Electrical circuit diagram Symbols used in electric circuit diagrams
PC228US-8,PC228USLC-8
90-15 (03)
Electrical circuit diagram Symbols used in electric circuit diagrams
90-16 (03)
PC228US-8,PC228USLC-8
Electrical circuit diagram (1/6) (KUK specification)
Electrical circuit diagram (1/6) (KUK specification) PC228US-8,PC228USLC-8
PC228US-8,PC228USLC-8 a This figure covers the equipment and devices that are unavailable as optional items in some areas.
KSP00228
PC228US-8,PC228USLC-8
90-17 (03)
Electrical circuit diagram (2/6) (KUK specification)
Electrical circuit diagram (2/6) (KUK specification) PC228US-8,PC228USLC-8
PC228US-8,PC228USLC-8 a This figure covers the equipment and devices that are unavailable as optional items in some areas.
PC228US-8,PC228USLC-8
90-19 (03)
Electrical circuit diagram (3/6) (KUK specification)
Electrical circuit diagram (3/6) (KUK specification) PC228US-8,PC228USLC-8
PC228US-8,PC228USLC-8 a This figure covers the equipment and devices that are unavailable as optional items in some areas.
PC228US-8,PC228USLC-8
90-21 (03)
Electrical circuit diagram (4/6) (KUK specification)
Electrical circuit diagram (4/6) (KUK specification) PC228US-8,PC228USLC-8
PC228US-8,PC228USLC-8 a This figure covers the equipment and devices that are unavailable as optional items in some areas.
KSP00229
PC228US-8,PC228USLC-8
90-23 (03)
Electrical circuit diagram (5/6) (KUK specification)
Electrical circuit diagram (5/6) (KUK specification) PC228US-8,PC228USLC-8
PC228US-8,PC228USLC-8 a This figure covers the equipment and devices that are unavailable as optional items in some areas.
PC228US-8,PC228USLC-8
90-25 (03)
Electrical circuit diagram (6/6) (KUK specification)
Electrical circuit diagram (6/6) (KUK specification) PC228US-8,PC228USLC-8
PC228US-8,PC228USLC-8 a This figure covers the equipment and devices that are unavailable as optional items in some areas.
PC228US-8,PC228USLC-8
90-27 (03)
Air conditioner electrical circuit diagram PC228US-8,PC228USLC-8 a This figure covers the equipment and devices that are unavailable as optional items in some areas.
PC228US-8, PC228USLC-8
Air conditioner electrical circuit diagram PC228US-8,PC228USLC-8
90-29 (03)
Shop Manual
PC228US-8,PC228USLC-8 HYDRAULIC EXCAVATOR Form Number: UEN05331-03
©2011 KOMATSU All Rights Reserved Printed in Belgium 03-11