SEN00084-07

HYDRAULIC
EXCAVATOR

PC200 -8
PC200LC -8
PC220 -8
PC220LC -8
SERIAL NUMBERS

PC200- 300001
PC200LC- 300001
PC22070001
PC220LC- 70001

and up

SEN00093-07

HYDRAULIC EXCAVATOR
1SHOP MANUAL

PC200-8
PC200LC-8
PC220-8
PC220LC-8
Machine model

Serial number

PC200-8
PC200LC-8
PC220-8
PC220LC-8

300001 and up
300001 and up
70001 and up
70001 and up

00 Index and foreword

1

Index
Composition of shop manual .......................................................................................................................... 2
Table of contents ............................................................................................................................................. 4

PC200, 220-8

1

SEN00093-07

00 Index and foreword

Composition of shop manual

1

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

Form Number

Shop Manual, contents binder, binder label and tabs

SEN00084-07

00 Index and foreword
Index
Foreword and general information

SEN00085-07
SEN00093-07 q
SEN00094-04 q

01 Specification
Specification and technical data

SEN00086-01
SEN00095-01 q

10 Structure, function and maintenance standard
Engine and cooling system
Power train
Undercarriage and frame
Hydraulic system, Part 1
Hydraulic system, Part 2
Hydraulic system, Part 3
Work equipment
Cab and its attachments
Electrical system

SEN00087-01
SEN00096-00
SEN00097-00
SEN00098-00
SEN00099-01
SEN00100-01
SEN00160-01
SEN00101-00
SEN00102-00
SEN00103-01

20 Standard value table
Standard service value table

SEN00088-01
SEN00227-01

30 Testing and adjusting
Testing and adjusting, Part 1
Testing and adjusting, Part 2
Testing and adjusting, Part 3

SEN00089-03
SEN00228-02 q
SEN00229-03 q
SEN00230-01

2

PC200, 220-8

00 Index and foreword

SEN00093-07

40 Troubleshooting
Failure code table and fuse locations
General information on troubleshooting
Troubleshooting by failure code (Display of code), Part 1
Troubleshooting by failure code (Display of code), Part 2
Troubleshooting by failure code (Display of code), Part 3
Troubleshooting by failure code (Display of code), Part 4
Troubleshooting of electrical system (E-mode)
Troubleshooting of hydraulic and mechanical system (H-mode)
Troubleshooting of engine (S-mode)

SEN00090-03
SEN03308-00
SEN00231-03
SEN00240-03
SEN00241-01
SEN00242-03
SEN00243-01
SEN00244-01
SEN00245-01
SEN00246-01

50 Disassembly and assembly
General information on disassembly and assembly
Engine and cooling system
Power train
Undercarriage and frame
Hydraulic system
Work equipment
Cab and its attachments
Electrical system

SEN00658-02
SEN00659-02
SEN00660-02
SEN00661-00
SEN00662-02
SEN00663-02
SEN00664-02
SEN00665-02
SEN00666-02

90 Diagrams and drawings
Hydraulic diagrams and drawings
Electrical diagrams and drawings

SEN00092-05
SEN00112-02 q
SEN00113-05 q

PC200, 220-8

Q
q
q
q

q

q
q
q
q
q
q
q

3

SEN00093-07

00 Index and foreword

Table of contents

1

00 Index and foreword
Index
SEN00093-07
Composition of shop manual ...................................................................................................
2
Table of contents......................................................................................................................
4
Foreword and general information
SEN00094-04
Safety notice ............................................................................................................................
2
How to read the shop manual..................................................................................................
7
Explanation of terms for maintenance standard ......................................................................
9
Handling of electric equipment and hydraulic component ....................................................... 11
Handling of connectors newly used for engines ...................................................................... 20
How to read electric wire code................................................................................................. 23
Precautions when carrying out operation ................................................................................ 26
Method of disassembling and connecting push-pull type coupler ........................................... 29
Standard tightening torque table.............................................................................................. 32
Conversion table...................................................................................................................... 36
01 Specification
Specification and technical data
SEN00095-01
Specification dimension drawings............................................................................................
2
Working range diagram ...........................................................................................................
3
Specifications...........................................................................................................................
4
Weight table .............................................................................................................................
8
Table of fuel, coolant and lubricants ........................................................................................ 12
10 Structure, function and maintenance standard
Engine and cooling system
SEN00096-00
Engine and cooling system .........................................................................................................
2
Engine related parts.................................................................................................................
2
Radiator, oil cooler, aftercooler and fuel cooler........................................................................
3
Power train
SEN00097-00
Power train ..................................................................................................................................
2
Power train...............................................................................................................................
2
Final drive ................................................................................................................................
4
Swing machinery .....................................................................................................................
6
Swing circle.............................................................................................................................. 10
Undercarriage and frame
SEN00098-00
Undercarriage and frame ............................................................................................................
2
Track frame and recoil spring ..................................................................................................
2
Idler..........................................................................................................................................
4
Carrier roller.............................................................................................................................
6
Track roller ...............................................................................................................................
7
Track shoe ...............................................................................................................................
8
Hydraulic system, Part 1
SEN00099-01
Hydraulic system, Part 1 .............................................................................................................
2
Hydraulic equipment layout drawing........................................................................................
2
Hydraulic tank and filter ...........................................................................................................
4
Hydraulic pump........................................................................................................................
6
Pilot oil filter ............................................................................................................................. 28
Hydraulic system, Part 2
SEN00100-01
Hydraulic system, Part 2 .............................................................................................................
2
Control valve............................................................................................................................
2
CLSS ....................................................................................................................................... 15
Functions and operation by valve ............................................................................................ 20

4

PC200, 220-8

00 Index and foreword

SEN00093-07

Hydraulic system, Part 3
SEN00160-01
Hydraulic system, Part 3 .............................................................................................................
3
Swing motor.............................................................................................................................
3
Center swivel joint ................................................................................................................... 12
Travel motor............................................................................................................................. 14
PPC valve................................................................................................................................ 25
Work equipment and swing PPC valve ................................................................................... 25
Travel PPC valve ..................................................................................................................... 31
Service PPC valve (with EPC valve) ....................................................................................... 40
Service PPC valve................................................................................................................... 46
Valve control ............................................................................................................................ 48
Solenoid valve ......................................................................................................................... 50
PPC accumulator..................................................................................................................... 52
Return oil filter ......................................................................................................................... 53
Attachment circuit selector valve ............................................................................................. 54
Hydraulic cylinder .................................................................................................................... 56
Work equipment
SEN00101-00
Work equipment ..........................................................................................................................
2
Dimensions of components .....................................................................................................
2
Cab and its attachments
SEN00102-00
Cab and its attachments..............................................................................................................
2
Air conditioner piping ...............................................................................................................
2
Electrical system
SEN00103-01
Electrical system .........................................................................................................................
1
Engine control..........................................................................................................................
2
Electrical control system.......................................................................................................... 10
Monitor system ........................................................................................................................ 33
Sensor ..................................................................................................................................... 60
KOMTRAX terminal system..................................................................................................... 63
20 Standard value table
Standard service value table
SEN00227-01
Standard service value table .......................................................................................................
2
Standard value table for engine related parts ..........................................................................
2
Standard value table for chassis related parts.........................................................................
4
30 Testing and adjusting
Testing and adjusting, Part 1
SEN00228-02
Testing and adjusting, Part 1.......................................................................................................
3
Tools for testing, adjusting, and troubleshooting .....................................................................
3
Measuring engine speed .........................................................................................................
6
Measuring intake air pressure (boost pressure) ......................................................................
7
Checking exhaust gas color ....................................................................................................
8
Adjusting valve clearance........................................................................................................
9
Measuring compression pressure ........................................................................................... 11
Measuring blow-by pressure ................................................................................................... 13
Measuring engine oil pressure ................................................................................................ 14
Handling fuel system parts ...................................................................................................... 15
Releasing residual pressure from fuel system......................................................................... 15
Measuring fuel pressure .......................................................................................................... 16
Measuring fuel return rate and leakage................................................................................... 18
Bleeding air from fuel circuit .................................................................................................... 20
Checking fuel circuit for leakage.............................................................................................. 22
Checking and adjusting air conditioner compressor belt tension ............................................ 23
Replacing fan belt.................................................................................................................... 24
Measuring swing circle bearing clearance............................................................................... 25
PC200, 220-8

5

SEN00093-07

00 Index and foreword

Checking and adjusting track shoe tension ............................................................................. 26
Measuring and adjusting oil pressure in work equipment, swing, and travel circuits............... 28
Measuring control circuit basic pressure ................................................................................. 31
Measuring and adjusting oil pressure in pump PC control circuit ............................................ 32
Measuring and adjusting oil pressure in pump LS control circuit............................................. 35
Measuring solenoid valve output pressure .............................................................................. 39
Measuring PPC valve output pressure .................................................................................... 42
Adjusting play of work equipment and swing PPC valves ....................................................... 44
Checking parts which cause hydraulic drift of work equipment ............................................... 45
Releasing residual pressure from hydraulic circuit .................................................................. 47
Measuring oil leakage.............................................................................................................. 48
Bleeding air from each part...................................................................................................... 51
Checking cab tipping stopper .................................................................................................. 53
Adjusting mirrors...................................................................................................................... 54
Testing and adjusting, Part 2
SEN00229-03
Testing and adjusting, Part 2 .......................................................................................................
2
Special functions of machine monitor ......................................................................................
2
Testing and adjusting, Part 3
SEN00230-01
Testing and adjusting, Part 3 .......................................................................................................
2
Handling voltage circuit of engine controller ............................................................................
2
Preparation work for troubleshooting of electrical system .......................................................
3
Procedure for testing diodes....................................................................................................
8
Pm Clinic service .....................................................................................................................
9
40 Troubleshooting
Failure code table and fuse locations
SEN03308-00
Failure codes table ..................................................................................................................
2
Fuse locations..........................................................................................................................
7
General information on troubleshooting
SEN00231-03
General information on troubleshooting ......................................................................................
2
Points to remember when troubleshooting ..............................................................................
2
Sequence of events in troubleshooting....................................................................................
3
Check before troubleshooting..................................................................................................
4
Classification and procedures for troubleshooting...................................................................
5
How to read electric wire code.................................................................................................
9
Connection table for connector pin numbers ........................................................................... 12
T- branch box and T- branch adapter table.............................................................................. 46
Troubleshooting by failure code (Display of code), Part 1
SEN00240-03
Failure code [989L00] Engine Controller Lock Caution 1 ........................................................
4
Failure code [989M00] Engine Controller Lock Caution 2 .......................................................
4
Failure code [989N00] Engine Controller Lock Caution 3........................................................
5
Failure code [AA10NX] Air Cleaner Clogging ..........................................................................
5
Failure code [AB00KE] Charge Voltage Low ...........................................................................
6
Failure code [B@BAZG] Eng Oil Press. Low...........................................................................
8
Failure code [B@BAZK] Eng Oil Level Low.............................................................................
8
Failure code [B@BCNS] Eng Water Overheat ........................................................................
9
Failure code [B@BCZK] Eng Water Level Low .......................................................................
9
Failure code [B@HANS] Hydr Oil Overheat ............................................................................ 10
Failure code [CA111] EMC Critical Internal Failure.................................................................. 10
Failure code [CA115] Eng Ne and Bkup Speed Sens Error..................................................... 11
Failure code [CA122] Chg Air Press Sensor High Error .......................................................... 12
Failure code [CA123] Chg Air Press Sensor Low Error........................................................... 14
Failure code [CA131] Throttle Sensor High Error .................................................................... 16
Failure code [CA132] Throttle Sensor Low Error..................................................................... 18
Failure code [CA144] Coolant Temp Sens High Error ............................................................. 20
Failure code [CA145] Coolant Temp Sens Low Error .............................................................. 22

6

PC200, 220-8

00 Index and foreword

SEN00093-07

Failure code [CA153] Chg Air Temp Sensor High Error .......................................................... 24
Failure code [CA154] Chg Air Temp Sensor Low Error ........................................................... 26
Failure code [CA155] Chg Air Temp High Speed Derate......................................................... 28
Failure code [CA187] Sens Supply 2 Volt Low Error ............................................................... 30
Failure code [CA221] Ambient Press Sens High Error............................................................ 32
Failure code [CA222] Ambient Press Sens Low Error............................................................. 34
Failure code [CA227] Sens Supply 2 Volt High Error .............................................................. 36
Failure code [CA234] Eng Overspeed..................................................................................... 37
Failure code [CA238] Ne Speed Sens Supply Volt Error......................................................... 38
Failure code [CA271] IMV/PCV1 Short Error .......................................................................... 39
Failure code [CA272] IMV/PCV1 Open Error .......................................................................... 40
Failure code [CA322] Inj #1 Open/Short Error......................................................................... 42
Failure code [CA323] Inj #5 Open/Short Error......................................................................... 44
Failure code [CA324] Inj #3 Open/Short Error......................................................................... 46
Failure code [CA325] Inj #6 Open/Short Error......................................................................... 48
Failure code [CA331] Inj #2 Open/Short Error......................................................................... 50
Failure code [CA332] Inj #4 Open/Short Error......................................................................... 52
Troubleshooting by failure code (Display of code), Part 2
SEN00241-01
Troubleshooting by failure code (Display of code), Part 2...........................................................
3
Failure code [CA342] Calibration Code Incompatibility ...........................................................
3
Failure code [CA351] Injectors Drive Circuit Error...................................................................
4
Failure code [CA352] Sens Supply 1 Volt Low Error ...............................................................
6
Failure code [CA386] Sens Supply 1 Volt High Error ..............................................................
8
Failure code [CA428] Water in Fuel Sensor High Error........................................................... 10
Failure code [CA429] Water in Fuel Sensor Low Error............................................................ 12
Failure code [CA435] Eng Oil Press Sw Error......................................................................... 14
Failure code [CA441] Battery Voltage Low Error ..................................................................... 15
Failure code [CA442] Battery Voltage High Error .................................................................... 18
Failure code [CA449] Rail Press Very High Error .................................................................... 20
Failure code [CA451] Rail Press Sensor High Error................................................................ 22
Failure code [CA452] Rail Press Sensor Low Error ................................................................ 24
Failure code [CA488] Chg Air Temp High Torque Derate........................................................ 26
Failure code [CA553] Rail Press High Error ............................................................................ 26
Failure code [CA559] Rail Press Low Error............................................................................. 27
Failure code [CA689] Eng Ne Speed Sensor Error ................................................................. 28
Failure code [CA731] Eng Bkup Speed Sens Phase Error...................................................... 30
Failure code [CA757] All Continuous Data Lost Error ............................................................. 32
Failure code [CA778] Eng Bkup Speed Sensor Error.............................................................. 34
Failure code [CA1633] KOMNET Datalink Timeout Error........................................................ 36
Failure code [CA2185] Throt Sens Sup Volt High Error .......................................................... 38
Failure code [CA2186] Throt Sens Sup Volt Low Error ........................................................... 39
Failure code [CA2249] Rail Press Very Low Error................................................................... 40
Failure code [CA2311] IMV Solenoid Error.............................................................................. 42
Failure code [CA2555] Grid Htr Relay Volt High Error............................................................. 44
Failure code [CA2556] Grid Htr Relay Volt Low Error ............................................................. 46
Failure code [D19JKZ] Personal Code Relay Abnormality...................................................... 48
Failure code [D862KA] GPS Antenna Discon ......................................................................... 50
Failure code [DA22KK] Pump Solenoid Power Low Error ....................................................... 51
Failure code [DA25KP] 5V Sensor 1 Power Abnormality ........................................................ 53
Failure code [DA29KQ] Model Selection Abnormality ............................................................. 60
Troubleshooting by failure code (Display of code), Part 3
SEN00242-03
Troubleshooting by failure code (Display of code), Part 3...........................................................
4
Failure code [DA2RMC] CAN Discon (Pump Con Detected) ..................................................
4
Failure code [DAF8KB] Short circuit in camera power supply .................................................
6
Failure code [DAFGMC] GPS Module Error............................................................................
8
Failure code [DAFRMC] CAN Discon (Monitor Detected) ....................................................... 10
Failure code [DGH2KB] Hydr Oil Sensor Short ....................................................................... 12

PC200, 220-8

7

SEN00093-07

00 Index and foreword

Failure code [DHPAMA] F Pump Press Sensor Abnormality................................................... 14
Failure code [DHPBMA] R Pump Press Sensor Abnormality .................................................. 16
Failure code [DHS3MA] Arm Curl PPC Press Sensor Abnormality......................................... 18
Failure code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality .................................... 20
Failure code [DHS8MA] Boom Raise PPC Press Sensor Abnormality ................................... 22
Failure code [DHSAMA] Swing RH PPC Press Sensor Abnormality....................................... 24
Failure code [DHSBMA] Swing LH PPC Press Sensor Abnormality ....................................... 26
Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality................................. 28
Failure code [DHX1MA] Overload Sensor Abnormality (Analog) ............................................ 31
Failure code [DW43KA] Travel Speed Sol Discon ................................................................... 34
Failure code [DW43KB] Travel Speed Sol Short ..................................................................... 36
Failure code [DW45KA] Swing Brake Sol Discon.................................................................... 38
Failure code [DW45KB] Swing Brake Sol Short ...................................................................... 40
Failure code [DW91KA] Travel Junction Sol Discon................................................................ 42
Failure code [DW91KB] Travel Junction Sol Short .................................................................. 44
Failure code [DWA2KA] Service Sol Discon............................................................................ 46
Failure code [DWA2KB] Service Sol Short .............................................................................. 47
Failure code [DWK0KA] 2-stage Relief Sol Discon ................................................................. 48
Failure code [DWK0KB] 2-stage Relief Sol Short.................................................................... 50
Troubleshooting by failure code (Display of code), Part 4
SEN00243-01
Troubleshooting by failure code (Display of code), Part 4...........................................................
4
Failure code [DXA8KA] PC-EPC (F) Sol Discon .....................................................................
4
Failure code [DXA8KB] PC-EPC (F) Sol Short........................................................................
6
Failure code [DXA9KA] PC-EPC (R) Sol Discon .....................................................................
8
Failure code [DXA9KB] PC-EPC (R) Sol Short ....................................................................... 10
Failure code [DXE0KA] LS-EPC Sol Discon............................................................................ 12
Failure code [DXE0KB] LS-EPC Sol Short .............................................................................. 14
Failure code [DXE4KA] Service Current EPC Discon ............................................................. 16
Failure code [DXE4KB] Service Current EPC Short................................................................ 18
Failure code [DXE5KA] Merge-divider Main Sol Discon.......................................................... 20
Failure code [DXE5KB] Merge-divider Main Sol Short ............................................................ 22
Failure code [DXE6KA] Merge-divider LS Sol Discon ............................................................. 24
Failure code [DXE6KB] Merge-divider LS Sol Short................................................................ 26
Failure code [DY20KA] Wiper Working Abnormality................................................................ 28
Failure code [DY20MA] Wiper Parking Abnormality ................................................................ 30
Failure code [DY2CKA] Washer Drive Discon ......................................................................... 32
Failure code [DY2CKB] Washer Drive Short ........................................................................... 34
Failure code [DY2DKB] Wiper Drive (For) Short ..................................................................... 36
Failure code [DY2EKB] Wiper Drive (Rev) Short..................................................................... 38
Troubleshooting of electrical system (E-mode)
SEN00244-01
Troubleshooting of electrical system (E-mode) ...........................................................................
3
Before carrying out troubleshooting of electrical system .........................................................
3
Information in troubleshooting table.........................................................................................
5
E-1 When starting switch turned ON, machine monitor displays nothing ................................
6
E-2 When starting switch turned ON (before starting engine), basic check item lights up ......
8
E-3 Engine does not start (Engine does not turn).................................................................... 11
E-4 Preheater does not operate .............................................................................................. 14
E-5 Automatic warm-up system does not operate (in cold season) ........................................ 16
E-6 All work equipment, swing, and travel mechanism do not move or cannot be locked ...... 18
E-7 Precaution lights up while engine is running ..................................................................... 20
E-8 Emergency stop item lights up while engine is running .................................................... 25
E-9 Engine coolant temperature gauge does not indicate normally ........................................ 26
E-10 Hydraulic oil temperature gauge does not indicate normally .......................................... 27
E-11 Fuel level gauge does not indicate normally ................................................................... 29
E-12 Contents of display by machine monitor are different from applicable machine ............. 31
E-13 Machine monitor does not display some items ............................................................... 31
E-14 Function switch does not work ........................................................................................ 31

8

PC200, 220-8

00 Index and foreword

SEN00093-07

E-15 Auto-decelerator does not operate normally................................................................... 32
E-16 Working mode does not change ..................................................................................... 33
E-17 Travel speed does not change........................................................................................ 34
E-18 Alarm buzzer cannot be stopped .................................................................................... 35
E-19 Windshield wiper and window washer do not operate .................................................... 36
E-20 Power maximizing function does not operate normally................................................... 38
E-21 Swing holding brake does not operate normally ............................................................. 40
E-22 Travel alarm does not sound or does not stop sounding ................................................ 42
E-23 Air conditioner does not operate normally (including air conditioner abnormality record) 44
E-24 While starting switch is in OFF position, service meter is not displayed ......................... 56
E-25 Machine monitor cannot be set in service mode............................................................. 56
E-26 Monitoring function does not display lever control signal normally ................................. 57
E-27 KOMTRAX system does not operate normally ............................................................... 65
Troubleshooting of hydraulic and mechanical system (H-mode)
SEN00245-01
Troubleshooting of hydraulic and mechanical system (H-mode) ................................................
4
System diagram of hydraulic and mechanical system.............................................................
4
Information in troubleshooting table ........................................................................................
6
H-1 Speed or power of whole work equipment, swing, and travel is low.................................
7
H-2 Engine speed lowers extremely or engine stalls...............................................................
9
H-3 Work equipment, swing, and travel systems do not work ................................................. 10
H-4 Abnormal sound comes out from around hydraulic pump ................................................ 10
H-5 Auto-decelerator does not operate ................................................................................... 11
H-6 Fine control performance or response is low.................................................................... 11
H-7 Speed or power of boom is low......................................................................................... 12
H-8 Speed or power of arm is low ........................................................................................... 13
H-9 Speed or power of bucket is low ....................................................................................... 14
H-10 Work equipment does not move singly ........................................................................... 14
H-11 Hydraulic drift of work equipment is large ....................................................................... 15
H-12 Time lag of work equipment is large ............................................................................... 17
H-13 When part of work equipment is relieved singly, other parts of work equipment move .. 17
H-14 Power maximizing function does not work...................................................................... 18
H-15 In compound operation of work equipment, speed of part loaded more is low............... 18
H-16 When machine swings and raises boom simultaneously, boom rising speed is low ...... 19
H-17 When machine swings and travels simultaneously, travel speed lowers largely ............ 19
H-18 Machine deviates during travel ....................................................................................... 20
H-19 Travel speed is low ......................................................................................................... 21
H-20 Machine is not steered well or steering power is low...................................................... 22
H-21 Travel speed does not change or travel speed is low/high ............................................. 23
H-22 Travel system does not move (only one side) ................................................................ 24
H-23 Upper structure does not swing ...................................................................................... 25
H-24 Swing acceleration or swing speed is low ...................................................................... 27
H-25 Upper structure overruns remarkably when it stops swinging ........................................ 28
H-26 Large shock is made when upper structure stops swinging ........................................... 29
H-27 Large sound is made when upper structure stops swinging ........................................... 29
H-28 Hydraulic drift of swing is large ....................................................................................... 30
H-29 Attachment circuit is not changed................................................................................... 31
H-30 Oil flow in attachment circuit cannot be controlled.......................................................... 31
Troubleshooting of engine (S-mode)
SEN00246-01
Troubleshooting of engine (S-mode)...........................................................................................
4
Method of using troubleshooting chart ....................................................................................
4
S-1 Starting performance is poor .............................................................................................
8
S-2 Engine does not start ........................................................................................................
9
S-3 Engine does not pick up smoothly .................................................................................... 12
S-4 Engine stops during operations ........................................................................................ 13
S-5 Engine does not rotate smoothly ...................................................................................... 14
S-6 Engine lack output (or lacks power) .................................................................................. 15
S-7 Exhaust smoke is black (incomplete combustion) ............................................................ 16

PC200, 220-8

9

SEN00093-07

00 Index and foreword

S-8 Oil consumption is excessive (or exhaust smoke is blue).................................................
S-9 Oil becomes contaminated quickly....................................................................................
S-10 Fuel consumption is excessive .......................................................................................
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) ..............................
S-12 Oil pressure drops...........................................................................................................
S-13 Oil level rises (Entry of coolant/fuel)................................................................................
S-14 Coolant temperature becomes too high (overheating)....................................................
S-15 Abnormal noise is made..................................................................................................
S-16 Vibration is excessive......................................................................................................

17
18
19
20
21
22
23
24
25

50 Disassembly and assembly
General information on disassembly and assembly
SEN00659-02
How to read this manual ..........................................................................................................
2
Coating materials list ...............................................................................................................
4
Special tool list .........................................................................................................................
7
Sketches of special tools ......................................................................................................... 12
Engine and cooling system
SEN00660-02
Removal and installation of fuel supply pump assembly .........................................................
2
Removal and installation of fuel injector assembly ..................................................................
5
Removal and installation of engine front seal .......................................................................... 13
Removal and installation of engine rear seal........................................................................... 16
Removal and installation of cylinder head assembly ............................................................... 19
Removal and installation of radiator assembly ........................................................................ 32
Removal and installation of hydraulic oil cooler assembly....................................................... 35
Removal and installation of aftercooler assembly ................................................................... 37
Removal and installation of fuel cooler assembly.................................................................... 39
Removal and installation of engine and hydraulic pump assembly ......................................... 40
Power train
SEN00661-00
Removal and installation of final drive assembly .....................................................................
2
Disassembly and assembly of final drive assembly.................................................................
4
Removal and installation of swing motor and swing machinery assembly .............................. 20
Disassembly and assembly of swing motor and swing machinery assembly.......................... 22
Removal and installation of swing circle assembly .................................................................. 32
Undercarriage and frame
SEN00662-02
Disassembly and assembly of carrier roller assembly.............................................................
2
Disassembly and assembly of track roller assembly ...............................................................
5
Disassembly and assembly of idler assembly .........................................................................
7
Disassembly and assembly of recoil spring assembly............................................................. 10
Removal and installation of sprocket ....................................................................................... 12
Expansion and installation of track shoe assembly ................................................................. 13
Removal and installation of revolving frame assembly ............................................................ 15
Removal and installation of counterweight assembly .............................................................. 17
Hydraulic system
SEN00663-02
Removal and installation of center swivel joint assembly ........................................................
2
Disassembly and assembly of center swivel joint assembly....................................................
4
Removal and installation of hydraulic tank assembly ..............................................................
5
Removal and installation of control valve assembly ................................................................
9
Disassembly and assembly of control valve assembly............................................................ 14
Removal and installation of hydraulic pump assembly ............................................................ 18
Removal and installation of oil seal in hydraulic pump input shaft........................................... 22
Disassembly and assembly of work equipment PPC valve assembly..................................... 23

10

PC200, 220-8

00 Index and foreword

SEN00093-07

Disassembly and assembly of travel PPC valve assembly ..................................................... 24
Disassembly and assembly of hydraulic cylinder assembly .................................................... 25
Work equipment
SEN00664-02
Removal and installation of work equipment assembly ...........................................................
2
Cab and its attachments
SEN00665-02
Removal and installation of operator's cab assembly..............................................................
2
Removal and installation of operator cab glass (stuck glass)..................................................
5
Removal and installation of front window assembly ................................................................ 15
Removal and installation of floor frame assembly ................................................................... 22
Electrical system
SEN00666-02
Removal and installation of air conditioner unit assembly .......................................................
2
Removal and installation of KOMTRAX communication modem assembly ............................
5
Removal and installation of monitor assembly ........................................................................
6
Removal and installation of pump controller assembly ...........................................................
8
Removal and installation of engine controller assembly.......................................................... 10
90 Diagrams and drawings
Hydraulic diagrams and drawings
SEN00112-02
Hydraulic circuit diagram .........................................................................................................
3
Hydraulic circuit diagram .........................................................................................................
5
Electrical diagrams and drawings
SEN00113-05
Electrical circuit diagram..........................................................................................................
3
Connector arrangement diagram.............................................................................................
5
Electrical circuit diagram for air conditioner.............................................................................
7

PC200, 220-8

11

SEN00093-07

PC200, 220(LC)-8 Hydraulic excavator
Form No. SEN00093-07

© 2007 KOMATSU
All Rights Reserved
Printed in Japan 04-07 (01)

12

SEN00094-04

HYDRAULIC EXCAVATOR
1SHOP MANUAL

PC200-8
PC200LC-8
PC220-8
PC220LC-8
Machine model

Serial number

PC200-8
PC200LC-8
PC220-8
PC220LC-8

300001 and up
300001 and up
70001 and up
70001 and up

00 Index and foreword

1

Foreword and general information
Safety notice ................................................................................................................................................... 2
How to read the shop manual ......................................................................................................................... 7
Explanation of terms for maintenance standard ............................................................................................. 9
Handling of electric equipment and hydraulic component .............................................................................11
Handling of connectors newly used for engines ........................................................................................... 20
How to read electric wire code...................................................................................................................... 23
Precautions when carrying out operation...................................................................................................... 26
Method of disassembling and connecting push-pull type coupler................................................................. 29
Standard tightening torque table ................................................................................................................... 32
Conversion table ........................................................................................................................................... 36

PC200, 220-8

1

SEN00094-04

Safety notice

00 Index and foreword

1

(Rev. 2007/03)

Important safety notice
Proper service and repair are extremely important for safe machine operation. The service and repair
techniques recommended by Komatsu and described in this manual are both effective and safe.
Some of these techniques require the use of tools specially designed by Komatsu for the specific
purpose.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The
cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with
the situation.
1.

2

General precautions
k Mistakes in operation are extremely
dangerous. Read the Operation and
Maintenance Manual carefully before
operating the machine.
1) Before carrying out any greasing or
repairs, read all the safety plates stuck to
the machine. For the locations of the
safety plates and detailed explanation of
precautions, see the Operation and Maintenance Manual.
2) Decide a place in the repair workshop to
keep tools and removed parts. Always
keep the 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. Smoke only in the areas
provided for smoking. Never smoke while
working.
3) When carrying out any operation, always
wear safety shoes and helmet. Do not
wear loose work clothes, or clothes with
buttons missing.
q
Always wear safety glasses when hitting parts with a hammer.
q
Always wear safety glasses when
grinding parts with a grinder, etc.
4) When carrying out any operation with 2 or
more workers, always agree on the operating procedure before starting. Always
inform your fellow workers before starting
any step of the operation. Before starting
work, hang UNDER REPAIR warning
signs in the operator's compartment.
5) Only qualified workers must carry out work
and operation which require license or
qualification.
6) Keep all tools in good condition, learn the
correct way to use them, and use the
proper ones of them. Before starting work,
thoroughly check the tools, machine, forklift, service car, etc.

7)

8)

If welding repairs are needed, always
have a trained and experienced welder
carry out the work. When carrying out
weld in g wo rk , al way s wear wel din g
gloves, apron, shielding goggles, cap and
other clothes suited for welding work.
Before starting work, warm up your body
thoroughly to start work under good condition.

Safety points
1 Good arrangement
2 Correct work clothes
3 Following work standard
4 Making and checking signs
5

Prohibition of operation and handling by
unlicensed workers

6 Safety check before starting work
7

Wearing protective goggles
(for cleaning or grinding work)

8

Wearing shielding goggles and protectors
(for welding work)

9 Good physical condition and preparation
10

2.

Precautions against work which you are
not used to or you are used to too much

Preparations for work
1) Before adding oil or making any repairs,
park the machine on hard and level
ground, and apply the parking brake and
block 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 signs on them.

PC200, 220-8

00 Index and foreword

3)
4)

3.

When disassembling or assembling, support the machine with blocks, jacks, or
stands before starting work.
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
m a c h i n e . N e v e r j u m p o n o r o ff t h e
machine. If it is impossible to use the
handrails, ladders or steps, use a stand to
provide safe footing.

Precautions during work
1) Before disconnecting or removing components of 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 stopped, so be careful
not to get scalded. Wait for the oil and
coolant to cool before carrying out any
work on the oil or water circuits.
3) Before starting work, stop the engine.
When working on or around a rotating
part, in particular, stop the engine. When
checking the machine without stopping
the engine (measuring oil pressure,
revolving speed, temperature, etc.), take
extreme care not to get rolled or caught in
rotating parts or moving parts.
4) Before starting work, remove the leads
from the battery. Always remove the lead
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.
6) When removing a cover which is under
internal pressure or under pressure from a
spring, always leave 2 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.

PC200, 220-8

SEN00094-04

8)

9)
10)

11)

12)

13)
14)
15)

16)

When removing piping, stop the fuel or oil
from spilling out. If any fuel or oil drips
onto the floor, wipe it up immediately. Fuel
or oil on the floor can cause you to slip
and can even start fires.
As a general rule, do not use gasoline to
wash parts. Do not use it to clean electrical parts, in particular.
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.
When installing high pressure hoses,
make sure that they are not twisted. Damaged tubes are dangerous, so be
extremely careful when installing tubes for
high pressure circuits. In addition, check
t h a t c o n n e c t i n g pa r ts a r e c o r r e c t l y
installed.
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 speed, be particul a r ly c a r e fu l t o c he c k t h a t t h e y ar e
installed correctly.
When aligning 2 holes, never insert your
fingers or hand. Be careful not to get your
fingers caught in a hole.
When measuring hydraulic pressure,
check that the measuring tools are correctly assembled.
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.
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.

3

SEN00094-04

4.

4

Precautions for sling work and making
signs
1) Only one appointed worker must make
signs and co-workers must communicate
with each other frequently. The appointed
sign maker must make specified signs
clearly at a place where he is seen well
from the operator's seat and where he can
see the working condition easily. The sign
maker must always stand in front of the
load and guide the operator safely.
q
Do not stand under the load.
q
Do not step on the load.
2) Check the slings before starting sling
work.
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 center 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 1 wire rope alone.
If it is slung so, it may rotate and may slip
out of the rope. Install 2 or more wire
ropes symmetrically.
k Slinging with 1 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°, as a rule.
Do not sling a heavy load with ropes forming a wide hanging angle from the hook.
When hoisting a load with 2 or more
ropes, the force subjected to each rope
will increase with the hanging angle. The
table below shows the variation of allowable load in kN {kg} when hoisting is made
with 2 ropes, each of which is allowed to
sling up to 9.8 kN {1,000 kg} vertically, at
various hanging angles. When the 2 ropes
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 2 ropes make a hanging
angle of 120°. If the 2 ropes sling a 19.6
kN {2,000 kg} load at a lifting angle of
150°, each of them is subjected to a force
as large as 39.2 kN {4,000 kg}.

00 Index and foreword

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.

PC200, 220-8

00 Index and foreword

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 slantingly.
13) When lifting down 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.

SEN00094-04

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 electric shock prevention earth
leakage breaker, check that the devices
related to that switch are not in operation
state.
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.

q

5.

6.

Precautions for using mobile crane
a Read the Operation and Maintenance
Manual of the crane carefully in advance
and operate the crane safely.
Precautions for using overhead hoist crane
k When raising a heavy part (heavier
than 25 kg), use a hoist, etc. In Disassembly and assembly, the weight of a
part heavier than 25 kg is indicated
after the mark of 4.
1) Before starting work, inspect the wire
ropes, brake, clutch, controller, rails, over
wind stop device, electric shock prevention earth leakage breaker, crane collision
prevention device, and power application
warning lamp, and check safety.
2) Observe the signs 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 slantingly. 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 on a position
where it will not be an obstacle to work
and passage.
11) After operating the hoist, do not swing the
control switch.
12) Remember the position of the main switch
so that you can turn off the power immediately in an emergency.

PC200, 220-8

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)
Nominal
Allowable load
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 used
(Safety coefficient: 6).

5

SEN00094-04

8.

Precautions for disconnecting and connecting hoses and tubes in air conditioner
circuit
1) Disconnection
k Collect the air conditioner refrigerant (R134a) from the air conditioner circuit in advance.
a Ask professional traders for collecting
and filling operation of refrigerant
(R134a).
a Never release the refrigerant (R134a)
to the atmosphere.
k If the refrigerant gas (R134a) gets
in your eyes, you may lose your
sight. Accordingly, when collecting or filling it, you must be qualified for handling the refrigerant
and put on protective goggles.
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 each O-ring is not damaged or deteriorated.
4] When connecting the refrigerant piping, apply compressor oil for refrigerant (R134a) (DENSO: ND-OIL8,
ZEXEL: ZXL100PG (equivalent to
PAG46)) to its O-rings.

a

Example of O-ring (Fitted to every joint of
hoses and tubes)

a

For tightening torque, see the precautions for
installation in each section of "Disassembly
and assembly".

6

00 Index and foreword

PC200, 220-8

00 Index and foreword

How to read the shop manual
q
q
q

1.

SEN00094-04

1

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.
Composition of shop manual
This shop manual contains the necessary technical information for services performed in a workshop.
For ease of understanding, the manual is divided into the following sections.
00. Index and foreword
This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification
This section explains the specifications of the machine.
10. Structure, function and maintenance standard
This section explains the structure, function, and maintenance standard values of each component.
The structure and function sub-section explains the structure and function of each component. It
serves not only to give an understanding of the structure, but also serves as reference material for
troubleshooting. The maintenance standard sub-section explains the criteria and remedies for disassembly and service.
20. Standard value table
This section explains the standard values for new machine and judgement criteria for testing,
adjusting, and troubleshooting. This standard value table is used to check the standard values in
testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting
This section explains measuring instruments and measuring methods for testing and adjusting, and
method of adjusting each part. The standard values and judgement criteria for testing and adjusting
are explained in Testing and adjusting.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is
divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also
explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly
This section explains the special tools and procedures for removing, installing, disassembling, and
assembling each component, as well as precautions for them. In addition, tightening torque and
quantity and weight of coating material, oil, grease, and coolant necessary for the work are also
explained.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
q
Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q
Engine volume
This section explains the method of reproducing, repairing, and replacing parts.

2.

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

PC200, 220-8

7

Places where oil. 02 …) q Revisions Revised brochures are shown in the shop manual composition table.SEN00094-04 3. Places to be coated with adhesives. must be drained. Places that require special attention for tightening torque during assembly. Caution necessary when selecting hoisting wire. or when working posture is important. q Revised edition mark When a manual is revised. 4. during assembly. (Example: 00. the units are indicated with International System of units (SI). etc. and quantity to be drained. conventionally used Gravitational System of units is indicated in parentheses { }. 00 Index and foreword Filing method File by the brochures in the correct order of the form number printed in the shop manual composition table. Units In this shop manual. etc. coolant 6 Drain Remarks Special safety precautions are necessary when performing work. Symbol Item k Safety a Caution Special technical precautions or other precautions for preserving standards are necessary when performing work. Places where oil. 3 Tightening torque 2 Coat 5 Oil. etc. the ones and tens digits of the form number of each brochure is increased by 1. For reference. 01. 8 PC200. must be added. and capacity. 5. etc. 4 Weight Weight of parts of component or parts. Symbols Important safety and quality portions are marked with the following symbols so that the shop manual will be used practically. 220-8 .

030 +0. the finishing size of parts is a little different from one to another. the size of a hole and the size of the shaft to be fitted to that hole are indicated by the same standard size and different tolerances of the hole and shaft.046 –0. Example) 120 (–0. 1. q The above size set temporarily is called the “standard size” and the range of difference from the standard size is called the “tolerance”.022/–0. q Example: Standard size 120 Tolerance –0.022 –0. a temporary standard size is set and an allowable difference from that size is indicated.076 +0 9 .00 Index and foreword SEN00094-04 Explanation of terms for maintenance standard 1 The maintenance standard values necessary for judgment of products and parts are described by the following terms. 220-8 Tolerance Shaft Hole –0.126) q Usually. q To specify a finishing size of a part.126 a The tolerance may be indicated in the text and a table as [standard size (upper limit of tolerance/lower limit of tolerance)]. q The tolerance with the symbols of + or – is indicated on the right side of the standard size. Standard size and tolerance To be accurate. Indication of size of rotating shaft and hole and relationship drawing of them q Example: Standard size 60 PC200. The tightness of fit is decided by the tolerance.

q If a product is worn to the allowable value. however. the difference between those diameters is called the “interference”. the value of performance/function is set to the standard value. q The range (A – B) from the difference (A) between the minimum size of the shaft and the maximum size of the hole to the difference (B) between the maximum size of the shaft and the minimum size of the hole is the “standard interference”. it must be checked or repaired. q A value of performance and function of new products or equivalent is called the “standard value“. which is indicated by a range or a target value. q When some parts are repaired. 4. they must be replaced or repaired. q When some parts are repaired. q 6. 220-8 . q If the interference between the parts exceeds the interference limit. q If the clearance between the parts exceeds the clearance limit. q After repairing or replacing some parts. q The performance and function of a product lowers while it is used. which is indicated by the range from the minimum clearance to the maximum clearance. Interference limit The allowable maximum interference between the hole of a part and the shaft of another part to be assembled is called the “interference limit”. q 10 PC200. q If a part is worn to the repair limit must be replaced or repaired. Since the permissible value is estimated from various tests or experiences in most cases. they must be replaced or repaired. q The interference limit shows the repair limit of the part of smaller tolerance. Standard clearance and standard value The clearance made when new parts are assembled is called the “standard clearance“. Clearance limit Parts can be used until the clearance between them is increased to a certain limit. q Repair limit and allowable value The size of a part changes because of wear and deformation while it is used. the clearance is generally adjusted to the standard clearance. 00 Index and foreword 5.SEN00094-04 2. Standard interference q When the diameter of a hole of a part shown in the given standard size and tolerance table is smaller than that of the mating shaft. measure the size of their hole and shaft and check that the interference is in the standard range. it must be judged after considering the operating condition and customer's requirement. The limit of changed size is called the “repair limit”. q 3. The limit at which those parts cannot be used is called the “clearance limit”. A value below which the product can be used without causing a problem is called the “allowable value”.

2) Defective crimping or soldering of connectors The pins of the male and female connectors are in contact at the crimped terminal or soldered portion. so they are likely to suffer deformation or damage. or because there is corrosion or oxidization of the contact surfaces. Points to remember when handling electric equipment 1. and protectors or tubes used for protecting the wiring. or because one or both of the connectors is deformed or the position is not correctly aligned. Compared with other electrical components fitted in boxes or cases. “maintenance and inspection“. PC200. For this reason. wiring harnesses are more likely to be affected by the direct effects of rain. 220-8 11 . Main failures occurring in wiring harness 1) Defective contact of connectors (defective contact between male and female) Problems with defective contact are likely to occur because the male connector is not properly inserted into the female connector. it is necessary to be extremely careful when handling wiring harnesses. Furthermore. they are frequently removed and installed again. The corroded or oxidized contact surfaces may become shiny again (and contact may become normal) by connecting and disconnecting the connector about 10 times. Handling wiring harnesses and connectors Wiring harnesses consist of wiring connecting one component to another component. correct “operation“. water. For this purpose. 2. and “repairs” must be carried out. during inspection and repair operations. and to prevent failures or other troubles before they occur. but if there is excessive force brought to bear on the wiring.00 Index and foreword Handling of electric equipment and hydraulic component SEN00094-04 1 To maintain the performance of the machine over a long period. the plating at the joint will peel and cause improper connection or breakage. it gives sections on “Handling electric equipment” and “Handling hydraulic equipment” (particularly gear oil and hydraulic oil). or vibration. This section deals particularly with correct repair procedures for mechatronics and is aimed at improving the quality of repairs. connectors used for connecting and disconnecting one wire from another wire. “troubleshooting“. heat.

water may enter the connector. 4) High-pressure water entering connector The connector is designed to make it difficult for water to enter (drip-proof structure). wipe it off with a dry cloth or blow it dry with compressed air and spray it with a contact restorer. so if any water gets in. or the soldering may be damaged. but if high-pressure water is sprayed directly on the connector. Therefore. or components are lifted with a crane with the wiring still connected. if water should get into the connector. if water does enter. the contacts will become even dirtier. 00 Index and foreword PC200. depending on the direction of the water jet. or the wiring may be broken. The connector is designed to prevent water from entering. a When wiping the mating portion of the connector. the pins will be short-circuited by the water. but at the same time. the crimping of the connector may separate. so there will be defective contact. so remove the oil and water from the compressed air completely before cleaning with compressed air. or a heavy object hits the wiring. 220-8 .SEN00094-04 12 3) Disconnections in wiring If the wiring is held and the connectors are pulled apart. 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 between the male and female pins. the oil will not let the electricity pass. a If there is oil or water in the compressed air. If there is oil or grease stuck to the connector. be careful not to use excessive force or deform the pins. immediately dry the connector or take other appropriate action before passing electricity through it. take care not to splash water over the connector. it is difficult for it to be drained. Accordingly.

When disconnecting the connectors.00 Index and foreword 3. For connectors which have a lock stopper. it is particularly easy for improper contact to occur. hold the connectors. pull the connector in a parallel direction to the clip for removing stoppers. loosen the screw fully. oil. 3] Action to take after removing connectors After removing any connector. or water from getting in the connector portion. For connectors held by a screw. q When removing a connector from a clip. a If the machine is left disassembled for a long time. dirt. press down the stopper with your thumb and pull the connectors apart. the housing may break. SEN00094-04 Removing. PC200. cover it with a vinyl bag to prevent any dust. so always cover the connector. and drying connectors and wiring harnesses 1) Disconnecting connectors 1] Hold the connectors when disconnecting. which are engaged with each other when the connector is installed. 220-8 13 . 2] q When removing from clips Both of the connector and clip have stoppers. a If the connector is twisted up and down or to the left or right. a Never pull with one hand. installing. then hold the male and female connectors in each hand and pull apart.

SEN00094-04 2) 14 00 Index and foreword Connecting connectors 1] Check the connector visually. a If there is any oil. 3] Correct any protrusion of the boot and any misalignment of the wiring harness. 220-8 . but be careful not to make it too hot as this will cause short circuits. q If the connector clamp has been removed. correct any protrusion of the boot. or water stuck to the connector pins (mating portion). Align the position of the connector correctly. a If the connector cannot be corrected easily. warm the inside of the wiring with a dryer. PC200. water. corrosion. a If there is any damage or breakage. Check that there is no damage or breakage to the outside of the connector. adjust it to its correct position. replace the connector. remove the clamp and adjust the position. if the wiring harness is misaligned. and then insert it securely. dirt. Check also that there are no loose clamps. Check that there is no oil. Check that there is no deformation. push in the connector until the stopper clicks into position. In addition. wipe it off with a dry cloth. or the clamp is out of position. defective contact. If any water has got inside the connector. For connectors with the lock stopper. or dirt stuck to the connector. be sure to return it to its original position. For connectors fitted with boots. 2] Fix the connector securely. or damage to the connector pins.

Arrow: 1). push in female connector (2) while moving it up and down until the locks are set normally. 12pole) Disconnection (Left of figure) While pressing both sides of locks (a) and (b). (b): Locks PC200. 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.00 Index and foreword 3) Heavy duty wire connector (DT 8-pole. pull out female connector (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). 220-8 SEN00094-04 q Disconnection q Connection (Example of incomplete setting of (a)) 15 . 2).

3] Carry out a continuity test on the connector. a After completely drying the conn e c t o r. leave the wiring harness disconnected and carry out a continuity test to check for any short circuits between pins caused by water. Avoid washing it in water or using steam. do not use high-pressure water or steam directly on the wiring harness. 220-8 . as this will cause deformation or damage to the connector. use a dryer to dry the connector. If water gets directly on the connector. After drying. so remove all oi l a nd wa ter fr om t he c om pressed air before blowing with air.SEN00094-04 4) 16 00 Index and foreword Drying wiring harness If there is any oil or dirt on the wiring harness. PC200. 1] Disconnect the connector and wipe off the water with a dry cloth. wipe it off with a dry cloth. 2] Dry the inside of the connector with a dryer. b l o w i t w i t h c o n ta c t restorer and reassemble. but regulate the time that the hot air is used in order not to make the connector or related parts too hot. If the connector must be washed in water. do as follows. there is the risk that oil in the air may cause defective contact. If water gets inside the connector. a If the connector is blown dry with compressed air. a Hot air from the dryer can be used.

(Place it on a suitable dry stand). even for a short time. a Disconnect and connect the related connectors several times to check. PC200.00 Index and foreword 4. 5. 3) Cover the control connectors with tape or a vinyl bag. 2) Do not place objects on top of the controller. continuity. disconnect all wiring harness connectors connected to the controller. Points to remember when troubleshooting electric circuits 1) Always turn the power OFF before disconnecting or connecting connectors. Never touch the connector contacts with your hand. a If the power is turned ON with the connectors still disconnected. unnecessary abnormality displays will be generated. 220-8 SEN00094-04 17 . a If there is any change. 3) Always connect any disconnected connectors before going on to the next step. Fit an arc welding ground close to the welding point. or in any hot place. do not leave the controller in a place where it is exposed to rain. These control all of the electronic circuits on the machine. 6) Precautions when carrying out arc welding When carrying out arc welding on the body. there is probably defective contact in that circuit. check that all the related connectors are properly inserted. resistance. 4) During rainy weather. or soil. 4) When carrying out troubleshooting of circuits (measuring the voltage. Handling controller 1) The controller contains a microcomputer and electronic control circuits. water. so be extremely careful when handling the controller. 2) Before carrying out troubleshooting. move the related wiring and connectors several times and check that there is no change in the reading of the tester. 5) Do not place the controller on oil. or current).

and also use clean pumps and oil containers. or places where there is a lot of dust. Do not simply drain oil out onto the ground. 3. 4. but collect it and ask the customer to dispose of it. 220-8 . replacing filters. there is danger of dust entering the equipment. or take it back with you for disposal.SEN00094-04 00 Index and foreword Points to remember when handling hydraulic equipment With the increase in pressure and precision of hydraulic equipment. or when disassembling or assembling hydraulic equipment. 1. Always keep the oil filler and the area around it clean. the most common cause of failure is dirt (foreign material) in the hydraulic circuit. Avoid adding hydraulic oil. so it is desirable to use unit exchange. so this is an even more effective method. and the performance should be checked with special test equipment. 18 PC200. or vinyl bags to prevent any dirt or dust from entering. It is also difficult to check the performance after repairs. it is possible to filter out the dirt that has collected during storage. When adding hydraulic oil. Sealing openings After any piping or equipment is removed. there is danger of dirt entering or of the surrounding area being made dirty by leaking oil so never do this. or repairing the machine in rain or high winds. If an oil cleaning device is used. If the opening is left open or is blocked with a rag. 2. tapes. Disassembly and maintenance work in the field If disassembly or maintenance work is carried out on hydraulic equipment in the field. Disassembly and maintenance of hydraulic equipment should be carried out in a specially prepared dustproof workshop. Do not let any dirt or dust get in during refilling operations Be careful not to let any dirt or dust get in when refilling with hydraulic oil. it is necessary to be particularly careful. the openings should be sealed with caps. Be careful of the operating environment.

and secondary flushing is carried out with the specified hydraulic oil.) If any old oil is left. so it is best to change the oil when it is still warm.) or when running the machine. so it is an extremely effective device. the sludge can also be drained out easily from the circuit together with the oil. and old oil from the hydraulic circuit. control valve. Cleaning operations After repairing the hydraulic equipment (pump.00 Index and foreword 5. 6. (Drain the oil from the hydraulic tank. 7. or changing the oil. PC200. Change hydraulic oil when the temperature is high When hydraulic oil or other oil is warm. Normally. When changing the oil. it flows easily. 220-8 SEN00094-04 19 . use flushing oil to remove the contaminants. The oil cleaning equipment is used to remove the ultra fine (about 3 m) particles that the filter built in the hydraulic equipment cannot remove. sludge. as much as possible of the old hydraulic oil must be drained out. flushing is carried out twice: primary flushing is carried out with flushing oil. etc. also drain the oil from the filter and from the drain plug in the circuit. Flushing operations After disassembling and assembling the equipment. the contaminants and sludge in it will mix with the new oil and will shorten the life of the hydraulic oil. carry out oil cleaning to remove the sludge or contaminants in the hydraulic oil circuit. In addition.

170. if part A does not float. Mainly. float part A with a small screwdriver while press lock (L2). 20 PC200. 12V140 engine q Various temperature sensors Example) Intake air temperature sensor in intake manifold: TIM Fuel temperature sensor: TFUEL Oil temperature sensor: TOIL Coolant temperature sensor: TWTR. 220-8 . following engines are object for following connectors. 1) Slide lock (L1) to the right. 12V140 engines) Ambient pressure sensor: PAMB (125. Disconnect the connector by pulling lock (B) (on the wiring harness side) of connector (2) outward. 12V140 engines) Oil pressure switch (107. 170.SEN00094-04 00 Index and foreword Handling of connectors newly used for engines a 1. q Disconnect connector (1) according to the following procedure. 1 Pull lock type (PACKARD-2) 107 – 170. q 107E-1 q 114E-3 q 125E-5 q 140E-5 q 170E-5 q 12V140E-3 Slide lock type (FRAMATOME-3. a Even if lock (L2) is pressed. 170. In this case. connector (1) cannot be pulled out toward you. FRAMATOME-2) q 107 – 170. pull out connector (1) toward you. 2) While pressing lock (L2). and then pull out connector (1) toward you. 12V140 engines) 2. etc. 12V140 engines) Oil pressure sensor: POIL (125. 12V140 engines q Various pressure sensors and NE speed sensor Examples) Intake air pressure in intake manifold: PIM (125. 114 engines) Ne speed sensor of flywheel housing: NE (107 – 170.

SEN00094-04 Push lock type q 107. 1) While pressing lock (C). pull out connector (4) in the direction of the arrow. PC200. 107 engine a 2) If the lock is on the underside. 114 engine Example) Intake air pressure/temperature sensor in intake manifold (SUMITOMO-04) 3) While pressing lock (D). pull out connector (3) in the direction of the arrow. pull out connector (3) in the direction of the arrow. use flat-head screwdriver [1] since you cannot insert your fingers.00 Index and foreword 3. 220-8 21 . 114 engines Example) Fuel pressure sensor in common rail (BOSCH-03) Disconnect connector (3) according to the following procedure. While pressing up lock (C) of the connector with flat-head screwdriver [1]. q q 114 engine q 107.

SEN00094-04 q 4) 125 – 170. 220-8 . Turn-housing type (Round green connector) 140 engine Example) Intake air pressure sensor in intake manifold (CANNON-04): PIM etc. 1] Insert the connector to the end. housing (H1) becomes heavy to turn. pullout connector (5) in the direction of the arrow. a When connector is unlocked. 22 PC200. q 1) Disconnect connector (6) according to the following procedure. 2] Pull out housing (H1) in the direction of the arrow. 12V140 engine While pressing lock (E) of the connector. (AMP-3) 00 Index and foreword 4. 2] Turn housing (H1) in the direction of the arrow until it “clicks”. 1] Turn housing (H1) in the direction of the arrow. while setting its groove. a Housing (H1) is left on the wiring harness side. Example) Injection pressure control valve of fuel supply pump: PCV (SUMITOMO-2) Example) Speed sensor of fuel supply pump: G (SUMITOMO-3) a Pull the connector straight up. 2) Connect the connector according to the following procedure. Example) Fuel pressure in common rail: PFUEL etc.

85 Indicates color of wire by color code. the material. 3 and below) General wiring in extremely –50 to +110 cold district. The electric wire code is helpful in understanding the electric circuit diagram. Indicates type of wire by symbol. 5 and above) –30 to +60 General wiring (Nominal No. having nominal No. and material of wire are shown in Table 1.Indicates blue. Example: AEX 0.) is shown in Table 2. symbol.. thickness. In the electric circuit diagram. Color codes are shown in Table 3. symbol. (Table 1) Type Low-voltage wire for automobile Thin-cover low-voltage wire for automobile Symbol AV AVS Heat-resistant low-voltAEX age wire for automobile PC200. and color of each electric wire are indicated by symbols.00 Index and foreword SEN00094-04 How to read electric wire code a 1 The information about the wires unique to each machine model is described in Troubleshooting section. wiring at high-temperature place 23 . Size (Nominal No. 220-8 Material Conductor Insulator Conductor Annealed copper for electric appliance Soft polyvinyl chloride Annealed copper for electric appliance Insulator Soft polyvinyl chloride Conductor Annealed copper for electric appliance Heat-resistant crosslinked polyethylene Insulator Using temperature range (°C) Example of use General wiring (Nominal No.). Type.. of 0. and material AV and AVS are different in only thickness and outside diameter of the cover. AEX is similar to AV in thickness and outside diameter of AEX and different from AV and AVS in material of the cover. Relational information of troubleshooting. (Since AV and AVS are classified by size (nominal No. they are not indicated.85 L . Indicates size of wire by nominal No.) 1. low-voltage wire for automobile. Type. heat-resistant.

3 4.32 65/0.2 2.84 84.0 7.5f (0.1 – 3.4 – 13.96 2.6 108/0.4 3.5 1.9 2. 00 Index and foreword Dimensions (Table 2) Nominal No.8 4.2 2.32 eter of strand Conductor Sectional 0.2 8.08 3.8 – 7.45 41/0.0 13.6 – CovAV Standard – – – – – – – 4.30 5.5 5.61 35.23 area (mm2) d (approx.0 10. 24 PC200.4 9.5 3.29 63.80 70/0.1 3. Number of strands/Diameter of strand Conductor Sectional area (mm2) d (approx.73 54.96 109.) AVS Standard CovAV Standard er D AEX Standard 8 15 20 30 40 50 60 85 100 50/0.9 3.7 – 5.0 3. 220-8 .0 2.80 “f” of nominal No.45 84/0.76 0.26 41/0.25) 2f 2 3f 3 5 Number of strands/Diam.6 – 11.0 – 10.18 11/0. 0.6 17.32 37/0.6 12.0 – 8.25f (1.7 3.8 8.80 7.8 10.51 0.32 30/0.6 er D AEX Standard 2.9 1.26 26/0.20/0.18 16/0.0 6.85) 1.0 AVS Standard 2.56 0.80 127/0.5 2.6 13.6 Nominal No.32 50/0.80 85/0.2 1. denotes flexible”.88 1.95 13.) 1.0 16.0 13.SEN00094-04 2.4 11.09 3.9 2.80 217/0.2 8.3 2.8 – 13.27 1.18 7/0.6 – 17.5) 0.36 20.0 – 16.75f (0.0 1.29 1.32 58/0.0 2.80 169/0.19 42.

the first color is the color of the background and the second color is the color of the marking. Types of circuits and color codes (Table 4) Type of wire Charge Ground Start Light Instrument Signal Type of circuit Others PC200. 220-8 AVS or AV R B R RW Y G L Br Lg O Gr P Sb Dg Ch AEX – R B R D Y G L – – WG – – – – – – – – – – – – – – – – RB YR GW LW BrW LgR RY YB GR LR BrR LgY RG YG GY LY BrY LgB RL YL GB LB BrB LgW – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – YW GL – – Gr Br – – 25 .00 Index and foreword 3. SEN00094-04 Color codes table (Table 3) Color Code B Br BrB BrR BrW BrY Ch Dg G GB GL Gr GR GW GY L LB Lg LgB LgR Color of wire Color Code LgW LgY LR LW LY O P R RB RG RL RW RY Sb Y YB YG YL YR YW 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 Color 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 color code consisting of 2 colors. 4. Example: “GW” means that the background is Green and marking is White.

Confirm the match marks showing the installation position.SEN00094-04 00 Index and foreword Precautions when carrying out operation 1 [When carrying out removal or installation (disassembly or assembly) of units. Precautions when handling piping during disassembly Fit the following plugs into the piping after disconnecting it during disassembly operations. and make match marks in the necessary places before removal to prevent any mistake when assembling. q q q q q q q q q q a Precautions when carrying out removal work If the coolant contains antifreeze. When raising components. After disconnecting hoses or tubes. tighten the forcing screws uniformly in turn. dispose of it correctly. 1) Face seal type hoses and tubes Nominal number 02 03 04 05 06 10 12 2) 26 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 Split flange type hoses and tubes Nominal number 04 05 3) Plug (nut end) Flange (hose end) Sleeve head (tube end) Split flange 07379-00400 07379-00500 07378-10400 07378-10500 07371-30400 07371-30500 If the part is not under hydraulic pressure. the following corks can be used. Before removing any unit. When using forcing screws to remove any components.5 18 16 13. always hold the connectors when disconnecting the connectors.] 1. Check the number and thickness of the shims.5 12 12 10 15 14 11.5 28 24 20 30 27 07049-02734 27 22. Do not pull the wires. cover them or fit plugs to prevent dirt or dust from entering. To prevent any excessive force from being applied to the wiring. clean the surrounding area and fit a cover to prevent any dust or dirt from entering after removal.5 34 PC200. be sure to use lifting equipment of ample strength. 220-8 . Fit wires and hoses with tags to show their installation position to prevent any mistake when installing.5 11 10 8.5 20 18 15 22 20 17 25 22 18. be sure to follow the general precautions given below when carrying out the operation. and keep in a safe place. When draining oil. Nominal number Part Number 06 08 10 12 14 16 18 20 22 24 07049-00608 07049-00811 07049-01012 07049-01215 07049-01418 07049-01620 07049-01822 07049-02025 07049-02228 07049-02430 Dimensions D d L 6 5 8 8 6. prepare a container of adequate size to catch the oil.

and the joints for air suction and exhaust gas leakage. If any part is loosened or damaged. Clean all parts. screw them in fully. if there are any. 4) After doing this. If any part is loosened. 2) Operate the work equipment control lever to operate the hydraulic cylinder 4 – 5 times. When using eyebolts. always bleed the air as follows: 1) Start the engine and run at low idle. q Add the specified amount of grease (molybdenum disulphide grease) to the work equipment parts. If any part is loosened or damaged. 3) Checking engine piping for damage and looseness Intake and exhaust system Check the piping for damage. When operating the hydraulic cylinders for the first time after reassembling cylinders. retighten it. Then check the coolant level again. check that there is no dirt or damage. oil and grease q If the coolant has been drained. clean the connector to remove all oil. 220-8 27 . “Bleeding air”. retighten or repair it. check that there is no deformation or deterioration. When coating with adhesive. When press fitting parts. coat the surface with anti-friction compound (LM-P). When connecting wiring connectors. PC200. then connect securely. pumps and other hydraulic equipment removed for repair. a For details. tighten uniformly in turn to prevent excessive tightening on one side. dirt. Precautions when completing the operation 1) Refilling with coolant. When tightening split flanges. and the joints for fuel leakage. dents. tighten the drain valve. O-rings. Cooling system Check the piping for damage. then coat uniformly with gasket sealant. see “Disassembly and assembly”. then coat the threaded portion with 2 – 3 drops of adhesive. Fuel system Check the piping for damage. When coating with gasket sealant. operate the hydraulic cylinder 3 – 4 times to the end of its stroke. burrs. When using the machine for the first time after repair or long storage. Coat rotating parts and sliding parts with engine oil. retighten or repair it. see Testing and adjusting. and align the direction of the hook. q If the piping or hydraulic equipment have been removed. or water. If any part is loosened or damaged. stopping the cylinder 100 mm from the end of its stroke. retighten or repair it. cotter pins. q If the hydraulic equipment has been removed and installed again. the mounting bolts and nuts for looseness. and lock plates with new parts. After fitting snap rings. follow the same procedure. run the engine at normal speed. or rust.00 Index and foreword 2. the mounting bolts and nuts for looseness. clean the part and remove all oil and grease. SEN00094-04 Precautions when carrying out installation work Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque. Then check the oil level again. and the joints for coolant leakage. add engine oil to the specified level. and correct any damage. Bend the cotter pins and lock plates securely. q q q q q q q q q q q q q a a 3. the mounting bolts and nuts for looseness. 3) Next. always bleed the air from the system after reassembling the parts. q For the tightening torque. Install the hoses without twisting or interference and fix them with intermediate clamps. Run the engine to circulate the coolant through the system. Replace all gaskets. clean the surface and remove all oil and grease. check that the snap ring is fitted securely in the ring groove. Run the engine to circulate the oil through the system. 2) Checking cylinder head and manifolds for looseness Check the cylinder head and intake and exhaust manifold for looseness. and add coolant to the specified level.

Checking muffler function Check the muffler for abnormal sound and sound different from that of a new muffler. replace it. If any abnormal sound is heard. repair the muffler. PC200. 220-8 . If any bolt or nut is loosened. 2] Check the mounting bolts and nuts of the muffler. exhaust pipe and their mounting parts for looseness. exhaust pipe and their mounting parts for a crack and damage.SEN00094-04 4) 5) 28 00 Index and foreword Checking muffler and exhaust pipe for damage and looseness 1] Visually check the muffler. If any part is damaged. retighten it. referring to “Troubleshooting” and “Disassembly and assembly”.

Connection 1) Hold hose adapter (1) or hose (5) and insert it in mating adapter (3). 5) a When the hose is pulled back. This does not indicate abnormality. (Fig. PC200. loosen the oil filler cap of the hydraulic tank gradually to release the residual pressure from the hydraulic tank. 2) After inserting the hose in the mating adapter perfectly.5 mm. (Fig. prepare an oil receiving container. Accordingly. 4) a Do not hold rubber cap portion (4). (Fig.00 Index and foreword SEN00094-04 Method of disassembling and connecting push-pull type coupler k k 1 Before carrying out the following work. 1) a The adapter can be pushed in about 3. 2. however. some hydraulic oil flows out when the hose is disconnected. the rubber cap portion moves toward the hose about 3. prepare an oil receiving container. (Fig. pull it back to check its connecting condition. Disconnection 1) Hold adapter (1) and push hose joint (2) into mating adapter (3). press rubber cap portion (4) against adapter (3) until it clicks. 2) After hose joint (2) is pushed into adapter (3). 220-8 29 . aligning them with each other. (Fig. 3) a Since some hydraulic oil flows out.5 mm. Type 1 1. 2) 3) Hold hose adapter (1) or hose (5) and pull it out. a Do not hold rubber cap portion (4). Even if the residual pressure is released from the hydraulic tank.

9) 30 PC200. turn lever (8) to the right (clockwise). pull out whole body (7) to disconnect it. (Fig. (Fig. 7) 3) While holding the condition of Steps 1) and 2). 220-8 .SEN00094-04 00 Index and foreword Type 2 1. 6) 2) While holding the condition of Step 1). 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. 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.

(Fig. 10) 2) While holding the condition of Step 1). (Fig. 13) PC200. 12) 2. 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. 220-8 31 .00 Index and foreword SEN00094-04 Type 3 1. 11) 3) While holding the condition of Steps 1) and 2). pull out whole body (9) to disconnect it. (Fig. (Fig. Connection q Hold the tightening portion and push body (9) straight until the sliding prevention ring contacts contact surface (b) of the hexagonal portion at the male end. push cover (10) straight until it contacts contact surface (b) of the hexagonal portion at the male end.

5 – 19.5 – 29.450 200 – 250 2.5 59 – 74 6.5 34.0 1.5 – 78.0 – 7.960 – 2.8 – 3.450 – 3.6 – 9. A.150 – 1.440 118 – 147 1. 220-8 .7 1. Thread diameter of bolt mm 6 8 10 12 14 16 18 20 22 24 27 30 33 36 39 a a Fig. B PC200.520 – 1.7 – 23. Table of tightening torques for bolts and nuts a Unless there are special instructions.5 – 90.7 7.3 – 46.SEN00094-04 00 Index and foreword Standard tightening torque table 1. Thread diameter of bolt mm 6 8 10 12 32 1 Width across flats mm 10 13 14 27 Tightening torque Nm 5.0 1.5 98 – 123 10.890 – 3.5 – 58.2 – 1.4 3.0 – 41.8 13.2 a Fig.4 – 2.8 – 14.5 235 – 285 23.0 455 – 565 46.2 kgm 0.0 785 – 980 80.0 610 – 765 62.9 – 9.0 – 100.910 155 – 195 1.5 320 – 400 33. A Width across flats mm 10 13 17 19 22 24 27 30 32 36 41 46 50 55 60 Tightening torque Nm kgm 11.5 – 4. (When using torque wrench) a The following table corresponds to the bolts in Fig.5 153 – 190 15. tighten metric nuts and bolts to the torque below.630 295 – 370 The following table corresponds to the bolts in Fig.6 – 1.040 250 – 310 2.1 74. B.5 27 – 34 2.0 – 12.

02 03.4 {13. SEN00094-04 Thread diameter mm 14 20 24 33 42 Width across flats mm Tightening torque Nm {kgm} Range Target 35 – 63 { 3.3} 11.0} 93.0} 68.3 – 240.5} 49. tighten O-ring boss plugs to the torque below.0} Table of tightening torques for O-ring boss plugs a Unless there are special instructions.5} 274.5 – 12.3 {2.0} on type of connec.0} 151.5 – 24.0 – 7.0 – 37.0} 58.0} 127.82 {0. 220-8 Thread diameter mm 8 10 12 14 16 18 20 24 30 33 36 42 52 Width across flats mm 14 17 19 22 24 27 30 32 32 – 36 – – Tightening torque Nm {kgm} Range Target 5.5 Table of tightening torques for O-ring boss piping joints a Unless there are special instructions.8 {11.8 – 78.5 {2.5 98 – 123 10.81 – 12.0 – 8.74 {1.5} 323.5 – 4.6 – 0.2 {4.5} 22.3} 24.0 – 103} 883 {90.0} 34.9 {4.04 05. Thread diameter of bolt mm 10 12 16 3.0} 44.9 {15.5} 103 {10.1 {3.0 {5.5 – 6.0} tor.0} 746 – 1.4 {33.75} 9.5} 181.0 – 2.8 – 147.128 – 186 {13.5 – 2.35 {0.4 {3.27 {1.0} 422 {43.0 – 12.010 {76.0 – 19.0} 17.3 – 44.15} 14.0 {11.1 – 122. 08 10 12 14 16 18 20 24 30 33 36 42 52 PC200.5 – 3.5 235 – 285 23.0} 127.54 {2.5 – 34.0} 33 . tighten split flange bolts to the torque below.5 {28. Table of tightening torques for split flange bolts a Unless there are special instructions.88 – 8.7 {21.1 – 53.5 – 13.0 – 1.0 – 18.5} 29.0 – 49.5} 84 – 132 { 8.9} 7.06 10.5 – 5.4 – 367.5} Varies depending 157 {16.5} 39.1 {18.12 14 4.00 Index and foreword 2.5 – 29.4 {13.64 {1.5} 44 { 4. Width across flats mm 14 17 22 Tightening torque Nm kgm 59 – 74 6.4 – 176.7 – 19.0 – 15.4 {6.6 – 24.5 { 9.5} 107.6 {7. Nominal No.0} 107.8} 19. Nominal No.5} 210. 363 – 480 {37. tighten O-ring boss piping joints to the torque below.6 {1.

5} 59 – 98 { 6.0 – 10.20 2.0} 294 {30.51 PC200.SEN00094-04 5.22 ± 0. type of erence) thread 9/16-18UN 14.4 1-3/16-12UN 30. 00 Index and foreword Table of tightening torques for hoses (taper seal type and face seal type) a Unless there are special instructions. of hose Width across flats 02 19 03 04 05 06 (10) (12) (14) 6.0} Target 44 { 4. 107 and 114 engine series to the torque below. 220-8 .0 – 30. Taper seal Tightening torque Nm 8±2 10 ± 2 12 ± 2 24 ± 4 36 ± 5 kgm 0.0} 246 – 343 {25. Thread size mm 6 8 10 12 14 34 Thread size (mm) Face seal Nominal No. tighten the metric eye joints of the 102.81 ± 0.0} 177 – 245 {18.20 1.45 ± 0.0} 84 – 132 { 8.20 2.0} 177 – 245 {18.38 ± 0.5} 34 – 63 { 3.5 – – 13/16-16UN 20.0} 245 {25.61 7.22 — Table of tightening torques for 102.02 ± 0.02 ± 0. 22 24 27 32 36 41 46 55 Range 34 – 54 { 3.20 1. Tightening torque Nm {kgm} Nominal No. a Apply the following torque when the threads are coated (wet) with engine oil. Thread size 7.2 – – – – – – Table of tightening torques for 102. 107 and 114 engine series (Bolts and nuts) a Unless there are special instructions. tighten the hoses (taper seal type and face seal type) to the torque below.0 – 25.45 ± 0.85 ± 1.0 – 19.5} 128 – 186 {13.0 – 35. 107 and 114 engine series to the torque below.0} mm 6 8 10 12 14 – 14 – 18 22 24 30 33 36 42 Tightening torque Bolts and nuts Nm 10 ± 2 24 ± 4 43 ± 6 77 ± 12 — kgm 1.41 3.67 ± 0.0} 103 {10.6 1-14UNS 25. Thread diameNumber of ter (mm) (Refthreads.0 – 25. 107 and 114 engine series (Eye joints) a Unless there are special instructions.5 – 5.5} 78 { 8.0} 216 {22.0} 197 – 294 {20.5} 74 { 7.5 – 9.5} 157 {16.5 – 13.5 – 6. tighten the metric bolts and nuts of the 102.3 – – 11/16-16UN 17.5} 54 – 93 { 5.0} 216 {22.41 4.

92 35 .10 0.00 Index and foreword 8.53 ± 0. 107 and 114 engine series to the torque below.20 2.20 1.51 6. 107 and 114 engine series (Taper screws) a Unless there are special instructions. 220-8 Tightening torque Nm 3±1 8±2 12 ± 2 15 ± 2 24 ± 4 36 ± 5 60 ± 9 kgm 0.20 1. tighten the taper screws (unit: inch) of the 102.67 ± 0.12 ± 0.31 ± 0.81 ± 0.41 3. Thread size inch 1/16 1/8 1/4 3/8 1/2 3/4 1 PC200.22 ± 0. SEN00094-04 Table of tightening torques for 102.45 ± 0.

787 1.780 2.819 1 mm = 0.102 1. so divide it by 10 (move the decimal point one place to the left) to convert it to 55 mm.063 1.717 3. Convert 55 mm into inches.732 50 60 70 80 90 1. 2) Carry out the same procedure as above to convert 55 mm to 2. 3) Take the point where the 2 lines cross as (C).047 2.480 2.583 2.433 0.536 1.402 2.850 2.748 1.378 1.323 2.504 3.165 inches. 3) The original value (550 mm) was divided by 10.110 3.654 3 0.906 1.520 2.551 0.496 1.189 3.984 1.SEN00094-04 00 Index and foreword Conversion table 1 Method of using the conversion table The conversion table in this section is provided to enable simple conversion of figures.079 0.346 3. 2.039 0. 2) Locate the number 5 in the row across the top.315 0.362 2.709 0.165 2.354 0.559 2.772 (C) 2. This point (C) gives the value when converting from millimeters to inches.03937 in 8 9 0.268 3.913 3. 1) Locate the number 50 in the vertical column at the left side.858 2.386 3.228 3.150 3.543 2. 220-8 .630 1.165 inches. 55 mm = 2. and then draw a horizontal line from (A).598 2.197 0.118 0.299 1.866 1.591 0.929 2.874 3. take this as (B).465 3.276 0.087 2.220 1.032 3.441 2.457 1.614 2 0.236 0.512 0.339 1.394 0.992 3.575 1 0. 1) The number 550 does not appear in the table. Therefore.472 0.945 1.622 2.835 3.126 2.953 3.740 6 0.142 1.283 2. Millimeters to inches (A) 36 (B) 0 10 20 30 40 0 0 0. Example: Method of using the conversion table to convert from millimeters to inches 1. This gives 550 mm = 21. Convert 550 mm into inches.811 7 0.181 1.205 2.244 2.898 PC200.417 1.638 3.756 3.969 2.260 1.661 2.024 1.157 0.65 inches.008 2.669 1.165 inches by 10 (move the decimal point one place to the right) to return to the original value. For details of the method of using the conversion table.890 1. then draw a perpendicular line down from (B).693 4 0.827 1.307 3.795 3. see the example given below.425 3.677 3. take this as (A).071 3.701 5 0. so multiply 2.

41 103.323 2.07 55.512 0.058 17.361 15.604 6.906 3.756 21.907 19.693 4 0.S.076 8.2046 lb 6 7 8 9 13.85 127.605 23.819 1 kg = 2.25 143.077 22. 220-8 13.46 145.669 0.05 141.398 24.96 194.063 1.44 134.480 2.417 1.813 22.34 90.472 0.926 24.925 8.87 149.134 23.774 10.44 123.285 21.624 1 l = 0.84 35.00 Index and foreword SEN00094-04 Millimeters to inches 0 10 20 30 40 0 0 0.66 50.24 121.157 0.709 0.304 14.05 44.559 2.48 156.78 202.152 12.321 1.181 1.662 24.701 2.264 0.220 1.755 5.46 48.379 19.032 3.795 17.283 5.340 8.359 4 1.322 17.48 39.25 46.23 15.61 28.75 94.17 196.698 6.346 3.528 2.529 17.43 17.983 25.62 114.642 2.189 8.625 15.228 20.12 77.64 19.153 37 .64 136.898 Kilogram to pound 0 10 20 30 40 0 0 22.71 169.457 1.28 154.969 2.16 99.227 4.402 2.906 1.133 7.26 Liters to U.717 3.465 3.780 2.680 12.41 26.510 9.661 2.416 12.246 9.677 3.397 7.858 2.03 2.09 66.945 1.992 3.718 11.32 59.307 3.39 209.303 11.378 1.94 182.832 14.53 61.S.64 125.37 198.62 105.473 16.019 6.80 4 8.93 79.189 3.78 85.386 3.441 2.69 158.811 1 mm = 0.39 2 4.869 7.209 15.76 191.454 10.953 3.23 132.888 12.536 1.079 0.795 3.354 0.568 14.91 171.118 0.113 2.12 174.07 152.68 41.700 20.80 213.549 22.98 205.2642 U.433 0.276 0.19 207.548 5.315 0.849 2.126 2.756 3.190 24.520 2.874 3.890 1.21 50 60 70 80 90 110.732 5 0.511 26.866 1.Gal 5 6 7 8 9 1.339 1.03 119.638 3.86 51.165 2.265 16.20 24.740 2.51 167.850 1.73 63.57 83.102 1.944 50 60 70 80 90 13.14 88.748 1.024 1.543 2.583 2.775 14.394 0.37 81.047 2.299 1.228 3.283 2.496 1.434 6.614 2 0.89 57.096 PC200.82 108.586 18.913 3.01 216.32 176.831 11.71 72.170 5.492 21.963 4.10 163.001 16.341 22.98 101.30 68.787 1.268 3.020 21.551 0.630 1.60 211.197 0.82 30.585 1.57 200.654 3 0.96 97.03937 in 7 8 9 0.66 147.00 5 11.812 7.984 1.964 20.110 3. Gallons 0 10 20 30 40 0 1 2 0 0.59 3 6.18 1 2.02 33.247 25.835 3.719 25.205 2.73 180.171 19.260 1.362 2.85 138.737 16.55 92.115 18.150 3.008 2.142 1.491 4.83 116.591 0.455 25.772 6 0.435 20.889 15.378 3.087 2.661 9.827 1.89 160.14 185.095 3 0.071 3.42 112.598 2.504 3.575 1 0.039 0.622 2.27 37.21 218.91 74.50 70.870 23.35 187.567 10.236 0.30 165.982 11.55 189.53 178.850 18.425 3.040 13.244 2.039 10.05 130.057 3.929 50 60 70 80 90 1.643 19.793 3.

4 50 60 70 80 90 361.8 1215.658 13.8 267.0 1439.2 325.0 600.1 100 110 120 130 140 723.6 462.8 564.lb 7 8 9 50.1 1193.8 159.640 4.398 17. Gallons 0 10 20 30 40 0 0 2.2 1070.4 238.7 1 kgm = 7.2 976.2 376.6 1301.0 1345.8 499.339 10.8 745.279 7.0 969.6 1179.778 12.7 94.318 14.9 65.8 593.320 1.6 802.738 16.1 1034.039 9.6 831.21997 U.599 8.9 658.1 665.917 21.9 781.1 817.6 1019.878 14.4 PC200.819 9.037 20.2 354.6 651.740 3.440 2.4 1171.838 18.3 701.1 1352.119 10.8 1309.5 86.337 12.8 1056.5 1048.3 853.059 7.858 16.5 708.4 1388.479 9.5 860.7 1106.378 19.7 217.699 9.0 166.9 535.1 405.899 50 60 70 80 90 10.7 716.2 1164.6 1396.7 390.0 1063.179 5.K.1 260.SEN00094-04 00 Index and foreword Liters to U.557 12.7 622.5 303.3 1323.2 1121.7 868.0 875.6 419.4 1012.3 202.5 954.357 21.2 296.5 1359.2 636.938 19.8 470.2 607.897 1 l = 0.0 846.2 542.200 4.5 180.0 347.5 1236.9 629.0 289.1 123.7 990.3 38 1092.139 8.9 318.6 151.6 1424.9 1374.718 18.7 188.3 1417.499 7.638 15.980 3.4 643.9 441.660 2.618 17.220 2.198 15.9 810.298 16.137 21.3 1 7.0 4 28.459 4 0.3 5 36.679 5 1.4 918.1 911.8 962.7 773.7 1244.0 752.259 9.8 3 21.6 57.978 15.9 1280.7 1367.8 426.117 12.498 18.5 209.178 17.9 101.958 17.4 1294.1 940.4 412.0 130.6 245.359 8.1 1150.719 5.4 1265.Gal 6 7 8 9 1.1 1287.9 1186.797 11.9 1157.4 1128.518 16.7 434.860 5.9 397.6 1207.078 16.237 11.998 13.159 6.058 18.9 1403.5 983.2 513.6 925.4 795.9 1027.3 730.257 20.3 1200.8 253.2 1258.457 11.619 6.399 6.777 kgm to ft.520 3.1 231. 220-8 .5 491.0 1222.100 3.239 3 0.939 6.839 7.559 10.2 882.019 2 0.5 614.4 549.3 484.418 15.2 137.579 10.950 4.6 679.2 788.420 4.5 1077.K.528 14.1 571.3 1041.7 896.4 889.0 694.2 1005.3 144.7 311.0 506.799 1 0.8 1432.5 1099.lb 0 10 20 30 40 0 0 72.5 585.677 12.5 520.8 687.4 332.919 8.477 20.880 3.6 274.300 5.5 766.3 947.379 7.3 1129.017 11.233 ft.6 2 14.598 19.7 1135.5 6 43.2 759.7 528.2 108.0 1113.438 13.4 455.6 556.5 737.9 224.9 904.1 1410.7 1273.3 578.0 368.2 1381.0 1251.540 1.278 18.4 383.4 115.9 998.9 1142.1 1316.7 150 160 170 180 190 1084.2 79.9 282.4 195.8 839.697 20.5 1330.577 21.281 13.758 14.080 5.8 933.3 824.1 477.3 173.3 672.8 1338.1 448.1 340.098 14.760 1.158 19.818 20.

9 1 14.4 3 42.8 896.3 924.044 3.361 2.152 1.115 3.4 355.7 1.166 1.195 1.2 384.731 2.451 1.243 3.607 1.8 640.522 1.1 597.020 1.2 2 28.949 2.920 2.219 2.446 2.470 2.034 1.7 568.048 1.143 3.186 3.489 2.271 3.4 867.119 150 160 170 180 190 2.759 2.286 3.901 3.778 1.129 3.0 654.674 2.6 113.200 3.3 540.318 2.792 1.9 327.574 2.7 953.493 1.479 1.4 995.181 1.001 3. 220-8 39 .1 6 85.0 241.2 981.365 810.877 2.394 839.536 1.038 1.764 1.252 1.2233 lb/in2 7 8 9 99.621 1.2 156.109 1.1 213.134 2.499 2.835 1.7 440.916 3.617 2.337 782.414 2.8 5 71.190 2.158 3.205 2.816 2.9 50 60 70 80 90 711.821 1.721 1.380 825.404 2.650 1.646 2.873 3.660 2.934 2.062 1.294 739.4 1.328 3.105 1.963 2.247 2.460 2.8 512.005 1.745 2.7 696.973 3.058 3.991 1.485 2.015 3.233 2.8 1.229 3.593 1.357 3.418 2.3 1.4 483.849 1.442 2.3 1 kg/cm2 = 14.773 2.072 3.6 497.631 2.223 1.266 1.314 3.806 1.024 1.503 2.432 2.9 199.7 668.237 1.095 1.702 2.2 1.664 1.6 369.067 1.688 2.2 284.4 611.565 1.172 3.693 1.399 3.280 725.579 1.214 3.304 2.5 554.465 1.0 398.347 2.8 128.5 938.9 583.475 2.385 3.5 682.735 1.859 3.1 469.086 3.987 3.845 2.276 2.7 184.1 1.408 100 110 120 130 140 1.3 412.7 312.124 1.977 2.422 1.636 1.603 2.6 4 56.546 2.887 3.010 1.863 2.527 2.1 341.9 455.101 3.437 1.589 2.8 256.5 298.707 1.351 796.091 1.030 3.138 1.518 2.333 2.428 2.0 967.262 2.290 2.5 526.4 170.0 270.958 3.162 2.542 PC200.513 2.5 1.375 2.802 2.309 753.456 2.6 1.944 3.788 2.3 227.209 1.5 426.148 2.053 1.930 3.532 2.077 1.00 Index and foreword SEN00094-04 kg/cm2 to lb/in2 0 10 20 30 40 0 0 142.906 2.343 3.081 1.6 881.678 1.717 2.371 3.6 625.892 2.2 853.323 768.389 2.300 3.550 1.6 1.560 2.749 1.0 1.830 200 210 220 230 240 2.1 910.508 1.257 3.176 2.

4 21.1 73.7 79.2 149.7 31 32 33 34 35 87.3 28.4 102.4 30.1 6.4 48.8 3. When convert from Fahrenheit to Centigrade degrees.4 120.1 16.0 –4.9 34.0 –11.0 –31.3 3.2 50.1 –20.4 138.0 –3.6 73.1 –19 –18 –17 –16 –15 –2.2 185.6 36.8 134.9 9.3 –7.4 174.4 1.8 –12.0 15.6 172.0 320.0 –4.4 147.6 43.6 100.8 18.0 21.0 30.6 –9 –8 –7 –6 –5 15.2 122.9 –18.4 20.2 68.7 22.8 116.7 37.6 11.8 179.2 113.0 338. When convert from Centigrade to Fahrenheit degrees.6 130 135 140 145 150 266.3 8.4 155 160 165 170 175 311. These figures refer to the temperature in either Fahrenheit or Centigrade degrees.8 152.1 36.0 5.8 89.4 10.6 145.4 25.7 –28.6 199.0 –14.1 –5.2 23.0 284.6 0 0.0 54.8 125.6 10.2 32.4 165.0 91 92 93 94 95 195.8°F °F –40.4 36 37 38 39 40 96.4 –31.6 19.2 212.8 161.0 68.2 –34.6 37.6 46.8 26.4 15.2 6 7 8 9 10 42.6 –15.7 –21.2 –1.4 –13.0 329.0 –19.0 –22.7 7.1 11.1 –10.0 5.7 –16.7 –11. consider the center column to be a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.9 51.0 46 47 48 49 50 114.6 109.2 –26.2 194.0 35.9 –23.0 62.2 59.0 302.6 208.4 57.8 –27.8 71.2 17.4 39.7 16 17 18 19 20 60.2 –21.4 3.2 167.6 26.3 46.8 62.9 14.6 82.4 111.9 29.8 23.2 –16.1 1.4 66. consider the center column to be a table of Centigrade values.1 26 27 28 29 30 78.9 4.0 –13.4 129.4 57.6 –25.6 6.2 41.3 61 62 63 64 65 141.0 25.0 40.0 –0.9 19.3 –27.2 37.2 131.0 18.0 7.8 53.0 –28.4 81 82 83 84 85 177.2 86.2 –0.8 –4 –3 –2 –1 0 24.4 183.0 1 2 3 4 5 33.4 12.0 27.0 –20.6 127.1 66 67 68 69 70 150.8 197. 220-8 .8 33.9 71 72 73 74 75 159.2 2.0 16.0 –24.6 –5.0 230.9 76.1 26.0 13.2 60.4 210.8 51 52 53 54 55 123.2 27.7 17.0 10.2 41 42 43 44 45 105.0 –8.0 275.3 –12.6 31.0 40 PC200.8 –2.6 136.2 5.0 257.2 203.3 33.8 44.2 86 87 88 89 90 186.4 11 12 13 14 15 51.6 181.0 –6.0 –17.3 23.6 56 57 58 59 60 132.3 71.7 –1.8 –7.9 –40 –35 –30 –25 –20 –40.8 107.0 20.8 80.SEN00094-04 00 Index and foreword Temperature 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 center (boldface column) of figures.6 163.8 17.2 158.1 31.7 76 77 78 79 80 168.4 35.7 –26.6 64.2 12.2 140.0 293.1 –15.0 30.6 154.8 35.7 32.3 –17.3 –2. and read the corresponding Fahrenheit temperature on the right.9 –13.8 –22.3 –14 –13 –12 –11 –10 6.7 105 110 115 120 125 221.0 248.7 12.6 118.8 96 97 98 99 100 204.0 32.4 75.9 21 22 23 24 25 69.6 1.4 –37.8 98.4 93.8 8.6 28.0 24.8 8.2 176.4 –3.8 206.2 104.8 188.7 65.8 143.2 77. °C °F °C °F °C °F °C 1°C = 33.4 192.6 55.6 21.6 190.2 14.0 –25.0 347.4 156.0 –9.6 91.6 –10.4 –23.4 –18.9 –8.8 28.1 48.3 13.0 –22.0 239.0 2.4 201.4 84.2 22.2 95.2 –6.8 170.

00 Index and foreword PC200. 220-8 SEN00094-04 41 .

SEN00094-04 PC200. SEN00094-04 © 2007 KOMATSU All Rights Reserved Printed in Japan 04-07 (01) 42 . 220(LC)-8 Hydraulic excavator Form No.

...................................SEN00095-01 HYDRAULIC EXCAVATOR 1SHOP MANUAL PC200-8 PC200LC-8 PC220-8 PC220LC-8 Machine model Serial number PC200-8 PC200LC-8 PC220-8 PC220LC-8 300001 and up 300001 and up 70001 and up 70001 and up 01 Specification 1 Specification and technical data Specification dimension drawings .................. 3 Specifications ............................................ coolant and lubricants................................................................. 4 Weight table ......................... 8 Table of fuel............................................................................................................................................................................................................................................................................................................................................... 220-8 1 ........................ 12 PC200................ 2 Working range diagram...........................................................................................

275 3. ground length mm 440 440 440 440 H 2 PC200.055 3.940 2.070 4. PC220-8.885 9.425 9. 220-8 .750 2.040 3.800 3.185 C Overall width mm 2.260 4.655 3.980 3.845 Min.460 3.040 3.640 Length of track on ground mm 3.280 D Shoe width mm 600 700 600 700 E Cab height mm 3. PC220LC-8 Check item A Overall length B Overall height Unit PC200-8 PC200LC-8 PC220-8 PC220LC-8 mm 9.SEN00095-01 01 Specification Specification dimension drawings 1 PC200-8.040 3.040 3.055 F Tail swing radius mm 2.080 2. PC200LC-8.185 3.425 9.750 2.940 G Overall track length mm 4.885 mm 3.450 4.

980 6.980 5.010 6.530 2. PC200LC-8.920 6.020 10.700 9.010 E Max. PC220LC-8 Check item Unit PC200-8 PC200LC-8 PC220-8 PC220LC-8 A Max. digging reach mm 9.110 7. 220-8 3 .700 10.020 PC200.645 2.620 6.530 G Max.180 B Max.875 9. dumping height mm 7.000 10. reach at ground level mm 9. vertical wall digging depth mm 5.875 10.180 10.01 Specification SEN00095-01 Working range diagram 1 PC200-8.000 10.920 C Max. digging depth mm 6.000 10.035 F Min.645 2.620 6. PC220-8. digging height mm 10.035 7.000 D Max. dumping height mm 2.110 7.

swing radius of work equipment mm 8.390 2.100} (149. digging depth mm 6.1 {15.700 Max.800 3.700 9. PC200LC-8 Machine model PC200-8 Serial number 300001 and up Operating weight Working range m Performance Bucket capacity 0.425 Overall width mm 2. ground clearance mm 440 440 Swing operation max.0 Mi: 4.8 0.980 Max.45} 36.620 6. slope angle Travel speed Gradability Ground pressure (Standard shoe) Dimensions PC200LC-8 degree 2 Tail swing radius mm 2.110 7.200}) 138. swing radius mm 3.085 Min.750 2.040 Machine body overall height (*) mm 3.800 3. digging force (when power max. dumping height mm 7. 220-8 .000 Max.040 Top height at min. digging radius mm 9. digging height mm 10.040 3.875 Max. vertical wall digging depth mm 5.3 {14.110 kN {kg} 138.040 3.080 Overall height (During transportation) (*) mm 3.750 Work equipment min.5 Lo: 3.040 3.8 kg 19.390 Width of standard shoe mm 600 700 *: Grouser height (26 mm) included.5 35 35 kPa {kg/cm } 44.1 Hi: 5. function is turned on) Swing speed 3 rpm 12.0 Mi: 4.37} Overall length mm 9.200 2.1 Hi: 5.500 20.080 Overall crawler width mm 2.SEN00095-01 01 Specification Specifications 1 PC200-8. reach at ground level mm 9.875 9.380 Cab height mm 2.425 9.275 3.200}) Max.4 12.005 8.000 10.1 {15.3 {0. 4 PC200.005 Length of track on ground mm 3.620 Max.4 degree 25 25 km/h Lo: 3.980 5.040 Ground clearance of upper structure bottom mm 1.085 1.3 {14.655 Track gauge mm 2.1 {0.100} (149.900 Max.

01 Specification SEN00095-01 Machine model PC200-8 PC200LC-8 Serial number Model SAA6D107E-1 Type 4-cycle.870 2.075 1.5 1.000} Max.334.204. 4. piston type: 1 (with safety valve and parking brake) Type Boom (*1) Arm (*1) (*2) Bucket Double acting piston Double acting piston Double acting piston Cylinder inner diameter mm 120 135 115 Piston rod diameter mm 85 95 80 Stroke mm 1. 220-8 5 .500} rpm 2.000 {148/2.565 2. piston type: 2 (with brake valve and parking brake) Swing motor KMF125ABE-6.5 kW Alternator 24 V.120 Max. torque Nm/rpm {kgm/rpm} 609/1. fuel consumption ratio rpm 1.060 Performance Piston displacement Engine 300001 and up High idle under no load Low idle under no load Min. water-cooled in-line. Variable displacement piston type: 2 l/min Piston: 219.2 {380} Type and number 6-spool type: 1 Operating method Hydraulic Travel motor HMV110ADT-2. direct injection with turbocharger and air-cooled aftercooler Number of cylinders – bore x stroke mm 6 – 107 x 124 l {cc} 6.680 Hydraulic tank Hydraulic oil filter Hydraulic oil cooler Closed type Tank return side CF40-1 (Air-cooling type) *1: Cushion is provided on the head side *2: Cushion is provided on the bottom side PC200.1/1.5 3.050 g/kWh{g/HPh} 215 {155} Starting motor 24 V.500 {62.800 Min. pin-to-pin distance mm 1.690} Rated pressure kW/rpm {HP/rpm} 110/2.5 x 2 MPa {kg/cm2} Piston: 37. pin-to-pin distance mm 3. 110 Ah x 2 Radiator type Alminum wave 4 rows Carrier roller 2 on one side Track roller 7 on one side Hydraulic motor Control valve Hydraulic pump Type and numbers Delivery Set pressure 9 on one side Assembly-type triple grosser Assembly-type triple grosser 45 on one side 49 on one side Track shoe Hydraulic cylinder Hydraulic system Undercarriage Battery HPV95+95. 35 A 12 V.69 {6.490 1.

380 2. PC220LC-8 Machine model PC220-8 Serial number 70001 and up Operating weight Working range m Performance Bucket capacity 1.010 Max.180 10.185 Machine body overall height (*) mm 3.055 3. slope angle Travel speed Gradability Ground pressure (Standard shoe) Dimensions PC220LC-8 degree 2 *: Grouser height (26 mm) included.845 Track gauge mm 2.100 1.020 10.940 Work equipment min.5 35 35 kPa {kg/cm } 50.450 Top height at min.2 {0.920 Max. function is turned on) Swing speed 3 rpm 11.1 Mi: 4.055 Ground clearance of upper structure bottom mm 1.110 Length of track on ground mm 3.885 9.2 Hi: 5.0 {0.110 8. reach at ground level mm 10.5 Lo: 3.500}) Max.2 Hi: 5.200} (171.280 Overall crawler width mm 2.450 3.000 Max.7 degree 25 25 km/h Lo: 3.330 Max.0 1.9 {16. digging radius mm 10.980 3.6 {17.6 {17.980 3.460 3.200} (171. ground clearance mm 440 440 Tail swing radius mm 2. swing radius mm 3.940 2.405 2.580 Cab height mm 2. digging force (when power max.010 6.405 Width of standard shoe mm 600 700 Swing operation max.280 Overall height (during transportation)(*) mm 3.885 Overall width mm 2.920 6.900 24.42} Overall length mm 9.9 {16. swing radius of work equipment mm 8.51} 41.SEN00095-01 01 Specification PC220-8. vertical wall digging depth mm 6. digging height mm 10. dumping height mm 7.035 kN {kg} 158.020 Max.180 Max. 220-8 .500}) 158. 6 PC200.0 kg 22. digging depth mm 6.100 Min.000 10.7 11.035 7.185 3.1 Mi: 4.

fuel consumption ratio rpm 1. PC220LC-8 Serial number 70001 and up Model SAA6D107E-1 Type 4-cycle. pin-to-pin distance mm 1. torque Nm/rpm {kgm/rpm} 686/1.69 {6.690} Rated pressure kW/rpm {HP/rpm} 125/2. 35 A 12 V.635 1.335 1.01 Specification SEN00095-01 Machine model PC220-8.160 Performance Engine Piston displacement High idle under no load Low idle under no load Min.205 2.870 1. Variable displacement piston type: 2 l/min Piston: 219.500 {70/1.5 x 2 MPa {kg/cm2} Piston: 37.000 {168/2.020 Max. piston type: 1 (with safety valve and parking brake) Type Boom (*1) Arm (*1).2 {380} Type and number 6-spool type: 1 Operating method Hydraulic Travel motor HMV110ADT-3. closed type Tank return side CF40-1 (Air-cooling type) *1: Cushion is provided on the head side *2: Cushion is provided on the bottom side PC200. 220-8 7 . 110 Ah x 2 Radiator type Alminum wave 4 rows Carrier roller 2 on one side 8 on one side 10 on one side Track shoe Assembly-type triple grosser 47 on one side Assembly-type triple grosser 51 on one side Hydraulic motor Control valve Hydraulic pump Track roller Hydraulic cylinder Hydraulic system Undercarriage Battery Type and number Delivery Set pressure HPV95+95. (*2) Bucket Double acting piston Double acting piston Double acting piston Cylinder inner diameter mm 130 140 130 Piston rod diameter mm 90 100 90 Stroke mm 1.5 kW Alternator 24 V. pin-to-pin distance mm 3. piston type: 2 (with brake valve and parking brake) Swing motor KMF125ABE-6. water-cooled in-line.235 2. 4.060 g/kWh{g/HPh} 215 {153} Starting motor 24 V.500} rpm 2.605 Hydraulic tank Hydraulic oil filter Hydraulic oil cooler Box-shaped. direct injection with turbocharger and air cooled aftercooler Number of cylinders – bore x stroke mm 6 – 107 x 124 l {cc} 6.625 Min.000} Max.870 3.

649 • Swing circle 273 273 • Idler 101 x 2 101 x 2 • Idler cushion 118 x 2 129 x 2 • Carrier roller 14 x 4 14 x 4 • Track roller 36 x 14 36 x 18 • Final drive (including travel motor) 322 x 2 322 x 2 • Standard triple shoe (600 mm) 1.735 3.405 x 2 1.264 4.600 x 2 Center swivel joint Track shoe assembly 8 PC200. 220-8 .325 x 2 • Standard triple shoe (700 mm) 1.530 x 2 • Wide triple shoe (800 mm) 1.670 x 2 • Road liner (Rubber pad type) (600 mm) 1.721 Cab 480 480 Operator’s seat 35 35 Counterweight 3.5 Travel motor 93 x 2 93 x 2 36 36 Track frame assembly (Not including piping) 4.470 x 2 1.215 x 2 1. PC200-8.862 • Track frame 2.260 2. PC200LC-8 Unit: kg Machine model PC200-8 Serial number PC200LC-8 300001 and up Engine assembly 733 733 • Engine 575 575 • Damper 6 6 152 152 • Hydraulic pump Radiator and oil cooler assembly 115 115 Hydraulic tank and filter assembly (Not including hydraulic oil) 123 123 Fuel tank assembly (Not including fuel) 134 134 1.721 1.SEN00095-01 01 Specification Weight table k 1 This weight table is prepared for your reference when handling or transporting the components.5 51.735 174 174 Revolving frame Swing machinery Control valve 235 235 Swing motor 51.530 x 2 1.

393 Arm assembly 633 633 Bucket assembly 633 633 173 x 2 173 x 2 Arm cylinder assembly 223 223 Bucket cylinder assembly 133 133 Link (large) assembly 83 83 Link (small) assembly 22 x 2 22 x 2 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 Link pin 13 x 2 13 x 2 Boom cylinder assembly Boom pin PC200.393 1. 220-8 9 .01 Specification SEN00095-01 Unit: kg Machine model PC200-8 Serial number Boom assembly PC200LC-8 300001 and up 1.

5 Travel motor 93 x 2 93 x 2 Center swivel joint 36 36 Track frame assembly (Not including piping) 4.595 x 2 • Wide triple shoe (800 mm) 1.SEN00095-01 01 Specification PC220-8.411 • Track frame 2.735 x 2 • Road liner (Rubber pad type) (600 mm) 1.573 3.455 x 2 • Standard triple shoe (700 mm) 1.600 x 2 1.023 2.056 Swing machinery 218 218 Control valve 235 235 Swing motor 51.535 x 2 — Track shoe assembly 10 PC200.470 x 2 1.060 • Swing circle 293 293 • Idler 101 x 2 101 x 2 • Idler cushion 129 x 2 129 x 2 • Carrier roller 14 x 4 14 x 4 • Track roller 36 x 16 36 x 20 • Final drive (including travel motor) 362 x 2 362 x 2 • Standard triple shoe (600 mm) 1. 220-8 . PC220LC-8 Unit: kg Machine model PC220-8 Serial number PC220LC-8 70001 and up Engine assembly 733 733 • Engine 575 575 • Damper 6 6 • Hydraulic pump 152 152 Radiator and oil cooler assembly 115 115 Hydraulic tank and filter assembly (Not including hydraulic oil) 123 123 Fuel tank assembly (Not including fuel) 134 134 Revolving frame 2.023 Cab 480 480 Operator’s seat 35 35 Counterweight 5.5 51.785 5.056 5.340 x 2 1.

220-8 11 .01 Specification SEN00095-01 Unit: kg Machine model PC220-8 Serial number Boom assembly PC220LC-8 70001 and up 1.815 Arm assembly 815 815 Bucket assembly 722 722 200 x 2 200 x 2 Arm cylinder assembly 265 265 Bucket cylinder assembly 160 160 Link (large) assembly 78 78 Link (small) assembly 22 x 2 22 x 2 51 + 10 x 2 + 31 + 10 + 26 51 + 10 x 2 + 31 + 10 + 26 Boom cylinder assembly Boom pin Arm pin 12 + 10 12 + 10 Bucket pin 20 x 2 20 x 2 Link pin 17 x 2 17 x 2 PC200.815 1.

220-8 ... Note 2.) in the table.SEN00095-01 01 Specification Table of fuel. see Operation and Maintenance Manual. PC200. coolant and lubricants a 12 1 For details of the notes (Notes 1.

4 23. PC200(LC)-8 *2.2 *1 3.65 *1 232 135 *2 239 135 400 — *1 21.0 *2 20.4 Engine oil pan Swing machinery case Final drive case (both sides) Damper case Hydraulic oil system Fuel tank Cooling system *1.4 5.2 0.4 20.3 *2 5.01 Specification SEN00095-01 Unit: l PC200(LC)-8.1 7.1 *2 8.5 3.65 0.2 8.1 *1 7. PC220(LC)-8 Refilling points Specified capacity Refill capacity 25. 220-8 13 .0 21. PC220(LC)-8 PC200.

220(LC)-8 Hydraulic excavator Form No. SEN00095-01 © 2007 KOMATSU All Rights Reserved Printed in Japan 05-07 (01) 14 .SEN00095-01 PC200.

................. 220-8 1 . 2 Radiator............................................................................................................................. 3 PC200................... aftercooler and fuel cooler ...............................SEN00096-00 HYDRAULIC EXCAVATOR 1SHOP MANUAL PC200-8 PC200LC-8 PC220-8 PC220LC-8 Machine model Serial number PC200-8 PC200LC-8 PC220-8 PC220LC-8 300001 and up 300001 and up 70001 and up 70001 and up 10 Structure.............. 2 Engine related parts ....................................................................................... oil cooler...... function and maintenance standard 1 Engine and cooling system Engine and cooling system .......................................

4. 220-8 . 2 Drive plate Torsion spring Stopper pin Friction plate Muffler Rear engine mount Front engine mount Damper assembly Outline A damper assembly is wet type. 5. function and maintenance standard Engine and cooling system 1 Engine related parts 1 1. 3. 2. 6. 8. 7. Oil capacity: 0.65 l PC200.SEN00096-00 10 Structure.

aftercooler and fuel cooler 1. 5. 8.10 Structure. Reservoir tank Fan Shroud Radiator cap Radiator inlet hose Net Radiator outlet hose Radiator Oil cooler Aftercooler Fuel cooler PC200. function and maintenance standard SEN00096-00 Radiator. oil cooler. 7. 6. 4. 9. 220-8 1 Specifications Radiator : Aluminum wave type. 11. 3. 2. 4th row Oil cooler : CF40-1 Aftercooler : Aluminum wave type Fuel cooler : Drawn cup type 3 . 10.

SEN00096-00 © 2005 KOMATSU All Rights Reserved Printed in Japan 09-05 (01) 4 .SEN00096-00 PC200. 220(LC)-8 Hydraulic excavator Form No.

............................... 220-8 1 ........................................... 6 Swing circle .......................................................................................SEN00097-00 HYDRAULIC EXCAVATOR 1SHOP MANUAL PC200-8 PC200LC-8 PC220-8 PC220LC-8 Machine model Serial number PC200-8 PC200LC-8 PC220-8 PC220LC-8 300001 and up 300001 and up 70001 and up 70001 and up 10 Structure........... 10 PC200........................................................................................................................... function and maintenance standard 1 Power train Power train............................................................................................................................................................................................................................. 4 Swing machinery.............................................................................................................. 2 Power train ..................................... 2 Final drive....................................

5. 2. 3. 12. function and maintenance standard Power train 1 Power train 1 1. 9.SEN00097-00 10 Structure. 7. 6. 220-8 . 8. 2 Idler Center swivel joint Control valve Final drive Travel motor (HMV110ADT-2) Hydraulic pump (HPV95 + 95) Engine (SAA6D107E-1) Travel speed solenoid valve Swing brake solenoid valve Swing motor (KMF125ABE-6) Swing machinery Swing circle PC200. 4. 11. 10.

220-8 . function and maintenance standard 1 PC200.SEN00097-00 Final drive 4 10 Structure.

57 1. 3.47 1. 2 sun gear (No. of teeth: 95) Sprocket Floating seal Travel motor No. 6. 1 sun gear (No. 1 planetary gear (No. 1 planetary gear and gear hub 0. of teeth: 36) Specifications Reduction ratio: – ((10 + 95)/10) x ((21 + 95)/21) + 1 = –57.10 Structure. 9. 10.46 1. 2 planetary gear and gear hub 0. Check item Criteria Remedy Standard clearance Clearance limit 0.25 — 17 Backlash between No. 1 planetary carrier Cover No. SEN00097-00 Level plug No.00 20 Amount of wear on sprocket tooth 21 Width of sprocket tooth PC200. 2 planetary carrier Gear hub (No.66 1. function and maintenance standard 1. 2 sun gear and No.06 – 0.000 Unit: mm No.38 – 0.13 – 0.1 planetary gear 0. 12.16 – 0.00 14 Backlash between No. of teeth: 10) No.10 16 Backlash between No. 11. 8. of teeth: 42) Drain plug No.56 1. of teeth: 21) No. 4.2 planetary gear 15 Backlash between No.00 18 Backlash between No.17 – 0. 1 sun gear and No.14 – 0. 5. 2 planetary gear (No.10 19 Backlash between No. 220-8 Replace Repair limit: 6 Standard size Repair limit 71 68 Build-up welding or replace 5 . 7. 2 sun gear 0. 2. 1 planetary carrier and No. 13. 2 planetary carrier and motor 0.

220-8 .SEN00097-00 Swing machinery 10 Structure. PC200LC-8 6 PC200. function and maintenance standard 1 PC200-8.

1 sun gear Swing motor Oil level gauge Ring gear Case Specifications Reduction ratio: ((17 + 58)/17) x ((18 + 58)/18) = 18. 3. 11. 2. 2 planetary carrier No.07 – 0. 8. function and maintenance standard 1. 1 planetary gear and ring gear 0. 4.50 0. of teeth: 13) No.39 – 0. 2 sun gear 0.100) — PC200. 5.90 Replace Backlash between No. 2 planetary carrier and swing pinion 0.627 Unit: mm No. 6. 2 sun gear No.22 – 1. 12.28 — 0.94 — Wear of swing pinion surface contacting with oil seal Standard size Repair limit 23 ø125 (0/ – 0.10 16 Backlash between No.66 – 2. 2 plane18 tary gear and ring gear 0.59 1.32 2. 2 planetary carrier 0.59 1.18 – 0. Check item 13 Backlash between swing motor shaft and No.50 1.23 — 20 Backlash between swing pinion and swing circle 0. 1 sun 14 gear and No.71 1.00 21 Clearance between plate and No. 7. SEN00097-00 Drain plug Swing pinion (No.00 15 Backlash between No. 1 sun gear Backlash between No.20 17 Backlash between No.18 – 0.16 – 0. 9. 2 sun gear and No. 2 sun gear and plate 1.1 planetary gear Criteria Remedy Standard clearance Clearance limit 0.66 – 1. 2 planetary gear No.16 – 0. 1 planetary carrier No. 220-8 Apply hard chrome plating or replace 7 .2 planetary gear 0. 1 planetary carrier and No.14 — 22 Clearance between No. 1 planetary gear No.18 – 0.10 Structure. 10.00 19 Backlash between No.

SEN00097-00 10 Structure. PC220LC-8 8 PC200. function and maintenance standard PC220-8. 220-8 .

84 — Wear of swing pinion surface contacting with oil seal Standard size Repair limit 23 125(0/ – 0. 1 sun gear Backlash between No. SEN00097-00 Drain plug Swing pinion (No.56 – 3.2 planetary gear 0.16 – 0.58 – 1. 12. 6. 1 planetary gear No.10 Structure.44 0. 4.37 2.08 – 0.00 19 Backlash between No.12 – 0.18 – 0. 2 plane18 tary gear and ring gear 0. 2 planetary carrier and swing pinion 0. 3.62 — 22 Clearance between No. Check item 13 Backlash between swing motor shaft and No.23 — 20 Backlash between swing pinion and swing circle 0. 1 planetary carrier and No. 7. 1 planetary gear and ring gear 0.90 Replace Backlash between No. 2 planetary gear No. 2.00 15 Backlash between No.18 – 0. 2 planetary carrier 0. 1 sun 14 gear and No.23 – 1. 220-8 Apply hard chrome plating or replace 9 . 10.16 – 0. of teeth: 13) No.35 – 0.689 Unit: mm No. 2 sun gear and plate 2.00 21 Clearance between plate and No. 2 sun gear No.64 1. 2 sun gear 0.10 16 Backlash between No. 9.59 1. 1 sun gear Swing motor Oil level gauge Ring gear Case Specifications Reduction ratio: ((17 + 58)/17) x ((14 + 58)/14) = 22. 2 sun gear and No.28 — 0.56 1. function and maintenance standard 1.50 1.1 planetary gear Criteria Remedy Standard clearance Clearance limit 0. 1 planetary carrier No.20 17 Backlash between No. 5.100) — PC200. 2 planetary carrier No. 11. 8.

3.6 l (G2-LI) Unit: mm No.385 Amount of filled grease: 14. Inner race soft zone “S“ position Outer race soft zone “S“ position Specifications Reduction ratio: –96/13 = –7. 220-8 .SEN00097-00 10 Structure. function and maintenance standard Swing circle 1 PC200-8. 4 10 Check item Axial clearance of bearing (when mounted on chassis) Criteria Remedy Standard clearance Clearance limit 0.2 Replace PC200.6 3.5 – 1. PC200LC-8 1. Swing circle inner race (No. 2. b. of teeth: 96) Ball Swing circle outer race a.

Inner race soft zone “S“ position Outer race soft zone “S“ position Specifications Reduction ratio: –92/13 = –7. 4 Check Item Axial clearance of bearing (when mounted on chassis) PC200. function and maintenance standard SEN00097-00 PC220-8. 220-8 Criteria Remedy Standard clearance Clearance limit 0. of teeth: 92) Ball Swing circle outer race a.8 l (G2-LI) Unit: mm No.077 Amount of filled grease: 15. Swing circle inner race (No.6 3.10 Structure.2 Replace 11 . 2. b. PC220LC-8 1. 3.5 – 1.

SEN00097-00 PC200. 220(LC)-8 Hydraulic excavator Form No. SEN00097-00 © 2005 KOMATSU All Rights Reserved Printed in Japan 09-05 (01) 12 .

............................................................................................................ 220-8 1 .................................................................................................................................................. 2 Idler ........................................................................................................................... 8 PC200.................................................................................................................................... 4 Carrier roller ..............................................SEN00098-00 HYDRAULIC EXCAVATOR 1SHOP MANUAL PC200-8 PC200LC-8 PC220-8 PC220LC-8 Machine model Serial number PC200-8 PC200LC-8 PC220-8 PC220LC-8 300001 and up 300001 and up 70001 and up 70001 and up 10 Structure...................... function and maintenance standard 1 Undercarriage and frame Undercarriage and frame ....................................... 2 Track frame and recoil spring............................................. 7 Track shoe........................................................................................................................................ 6 Track roller ...........

220-8 . 5. Number of track rollers Model Q'ty (One side) PC200-8 7 PC220-8 8 PC200LC-8 9 PC220LC-8 10 PC200. but the basic structure is not different. function and maintenance standard Undercarriage and frame 1 Track frame and recoil spring 1 1. 4.SEN00098-00 10 Structure. 2. 3. 8. 2 Idler Track frame Carrier roller Final drive Track roller Track shoe Center guard Front guard q q The dimensions and the number of track rollers depend on the model. 7. 6.

4 — — Standard size Build-up welding or replace Repair limit Free length Installation Installation Installation x Outside Free length length load load diameter 11 Recoil spring PC200-8 558 x 238 PC200LC-8 PC220-8 561. 220-8 417 109. 9 10 Check item Vertical width of idler guide Horizontal width of idler guide Criteria Remedy Standard size Tolerance Repair limit Track frame 107 — — Idler support 105 — — Track frame 250 — — Idler support 247.920 kg} 433 126.900 kg} 534 101 kN {10.150 kg} 531.300 kg} Replace 3 .3 kN {11. function and maintenance standard SEN00098-00 Standard shoe Models PC200-8 PC220-8 PC200LC-8 PC220LC-8 Shoe width (mm) 600 600 700 700 Link pitch (mm) 190 190 190 190 Q'ty (One side) 45 47 49 51 Item Unit: mm No.10 Structure.4 x 237 PC220LC-8 PC200.5 kN {12.4 kN {8.4 87.

SEN00098-00 Idler 4 10 Structure. 220-8 . function and maintenance standard 1 PC200.

514 — Interference limit — Tolerance Shaft Hole Standard interference +0.008 –0.5 – 1.074 0.170 Standard clearance Clearance limit 0.350 +0.108 +0.164 –0. function and maintenance standard SEN00098-00 Unit: mm No. Check item Criteria Remedy Standard size Repair limit 538 — 1 Outside diameter of protrusion 2 Outside diameter of tread 500 488 3 Thickness of tread 26 20 4 Difference of tread 19 25 5 Total width 159 — 6 Width of tread 37.5 — 7 Clearance between shaft and bushing 8 Interference between idler and bushing Standard size 65 Standard size 72 9 Clearance between bushing and support (Sum of clearance at both sides) PC200.040 – 0.176 – 0.250 –0.062 0. 220-8 Tolerance Build-up welding or replace Shaft Hole Standard clearance Clearance limit –0.10 Structure.032 –0.0 — Replace bushing 5 .

Check item Criteria Standard size Repair limit 1 Outside diameter of flange 145 — 2 Outside diameter of tread 120 106 3 Width of tread 43 — 4 Thickness of tread 23 16 5 Width of flange 14 6 7 Clearance between shaft and bushing Interference between roller and bushing Standard size 40 Standard size 47 8 6 Remedy Axial clearance of roller — Tolerance Shaft Hole Standard clearance Clearance limit –0.061 +0.190 +0.168 0.101 Standard clearance Clearance limit 0. 220-8 .SEN00098-00 10 Structure.76 — Replace PC200.491 — Interference limit — Tolerance Shaft Hole Standard interference +0.000 –0.338 – 0.016 – 0.301 +0. function and maintenance standard Carrier roller 1 Unit: mm No.170 –0.016 –0.44 – 0.040 0.

215 –0.5 38.5 — 7 8 Clearance between shaft and bushing Interference between roller and bushing Standard size 60 Standard size 67 9 Clearance between bushing and collar (Sum of clearance at both sides) PC200.510 — Interference limit — Tolerance Shaft Hole Standard interference +0. 220-8 Tolerance Build-up welding or replace Shaft Hole Standard clearance Clearance limit –0.153 Standard clearance Clearance limit 0.195 –0.5 — 6 Width of flange 25.000 0.5 4 Total width 225 — 5 Width of tread 44.0 — Replace bushing Replace 7 .10 Structure.023 – 0. Check item Criteria Standard size Remedy Repair limit 1 Outside diameter of flange 188 — 2 Outside diameter of tread 156 144 3 Thickness of tread 44.315 +0.030 –0. function and maintenance standard SEN00098-00 Track roller 1 Unit: mm No.215 – 0.5 – 1.053 +0.153 +0.000 0.

function and maintenance standard 1 P portion shows the link of bushing press fitting end.SEN00098-00 Track shoe a 10 Structure. 220-8 . Triple grouser shoe 2. Flat shoe 8 PC200. Swamp shoe 4. Road liner 3. 1.

4 Shoe bolt pitch 9 18 Reverse or replace 160.5 20.4 – 274.5 13 Protrusion of bushing Regular 4.3 10.2 – 245 kN{9 – 25 ton} Regular pin 127.7 16 Thickness of spacer 17 19 (*) Repair or replace 124.0 14 Overall length of pin Regular 212 Master 212 15 Overall length of bushing Regular 138. 220-8 9 .3 Standard size Reverse 59.4 kN{13 – 28 ton} Master pin 78.5 Master 2.3 54.10 Structure.8 Overall width 45.85 Master 0.4 Tread width 39.4 8 10 Remedy Standard size Press-fitting force Adjust or replace — Bushing 88.5 62 Link 11 12 Protrusion of pin Inside width 84.5 Master 128.3 193. function and maintenance standard SEN00098-00 Unit: mm No. 1 Check item Criteria Link pitch 2 Outside diameter of bushing 3 Thickness of bushing metal 4 Link height 5 Thickness of link metal (bushing press-fitting portion) 6 7 Repair limit 190.4 5.6 Regular 2.4 Standard size Repair limit 105 97 28.4 – 147 kN{8 – 15 ton} — * Dry type track link PC200.

220-8 .740 Adjust or replace Standard interference 0.000 Tolerance Shaft Hole –0.200 0.552 – 1. function and maintenance standard Unit: mm No.8 Standard size 38 Tolerance Shaft Hole +0.902 +0. Regular link Shoe bolt 20 b.162 –0.434 38 +0.074 –0.402 Tolerance Shaft Hole +0.902 +0.350 +0. Check item Criteria Tightening torque (Nm {kgm}) a.188 – 0.) Standard size Tolerance — Standard interference Shaft Hole 59 +0.402 Standard clearance 0.SEN00098-00 10 Structure.300 – 0.250 +0.252 * Dry type track link 10 PC200.000 0.222 +0.434 +0.222 +0.280 +0.) Lower limit torque (Nm {kgm}) — — — PC200-8: 45 PC200LC-8: 49 PC220-8: 47 PC220LC-8: 51 No.162 +0. of shoes (each side) 21 Remedy Retightening angle (deg. Master link Triple grouser shoe 490 ± 49 {50 ± 5} 120 ± 10 Road liner (Rubber pad type) 549 ± 59 {56 ± 6} — 22 Interference between bushing and link Interference between regular pin and link Clearance between regular pin 23 and bushing 24 Interference between master (*) pin and link 25 Clearance between master pin (*) and bushing Retighten Tightening torque (Nm {kgm}) Retightening angle (deg.180 – 0.320 – 0.062 –0.138 –0.394 +0.150 –0.422 Standard size 38 Standard size 37.280 Standard clearance 0.

function and maintenance standard Triple grouser shoe Swamp shoe Road liner 12 PC200.SEN00098-00 10 Structure. 220-8 .

function and maintenance standard SEN00098-00 Unit: mm No.10 Structure. PC200LC-8: 600 mm width shoe PC200.5 90. 220-8 13 .5 10 Thickness 17 5 (*) 11 Height 70 Replace *: PC200-8.5 24. Check item Criteria Remedy Standard size Repair limit 26 16 1 Height 2 Thickness 3 Length of base 26 4 Length of base 19 5 Length at tip 20 6 Length at tip 14 7 Length at tip 19 10 (*) 8.5 Build-up welding or replace Standard size Repair limit 36 26 8 Thickness 34.5 9 Height 102.

SEN00098-00 PC200. 220(LC)-8 Hydraulic excavator Form No. SEN00098-00 © 2005 KOMATSU All Rights Reserved Printed in Japan 09-05 (01) 14 .

................................ 6 Pilot oil filter.................................................................................................................. 2 Hydraulic tank and filter.... 28 PC200............................................. 2 Hydraulic equipment layout drawing ................................................................................ function and maintenance standard 1 Hydraulic system...... 220-8 1 ........................SEN00099-01 HYDRAULIC EXCAVATOR 1SHOP MANUAL PC200-8 PC200LC-8 PC220-8 PC220LC-8 Machine model Serial number PC200-8 PC200LC-8 PC220-8 PC220LC-8 300001 and up 300001 and up 70001 and up 70001 and up 10 Structure.. Part 1 Hydraulic system............................ Part 1 .. 4 Hydraulic pump .............................................................................................................................................................................................................................................................................................

function and maintenance standard Hydraulic system. 18. 11. 13. Travel speed solenoid valve 21E. 14. travel motor Multi pattern selector valve Left PPC valve Lock lever Center swivel joint Right PPC valve Travel PPC valve Attachment PPC valve Hydraulic drift prevention valve Accumulator Solenoid valve assembly 21A. 3.H. Travel junction solenoid valve 21F. 2-stage relief solenoid valve 21C. travel motor Swing motor Hydraulic pump Control valve Oil cooler L. Swing brake solenoid valve 21D. ATT selector solenoid valve PC200. 15. Part 1 Hydraulic equipment layout drawing 1. 19. 10. 7. 6. 20. 5.SEN00099-01 10 Structure. 17. 16. 12. 2 1 1 Bucket cylinder Arm cylinder Boom cylinder Hydraulic tank Hydraulic oil filter R. 8. PPC lock solenoid valve 21B. 4. 2. 9. 220-8 . 21.H.

220-8 SEN00099-01 3 .10 Structure. function and maintenance standard PC200.

2. function and maintenance standard Hydraulic tank and filter 1.3 kg/cm2} PC200. 6.9 kPa {0. 5. 7.17 ± 0.SEN00099-01 10 Structure.07 kg/cm2} Suction cracking pressure: 0 – 0.005 kg/cm2} Bypass valve set pressure: 150 ± 30 kPa {1.5 ± 0.7 ± 6. 4 Hydraulic tank Oil filler port cap Filter element Strainer Bypass valve Suction strainer Sight gauge 1 Specifications Tank capacity : 190 l Amount of oil inside tank : 135 l Safety valve Relief cracking pressure: 16.49 kPa {0 – 0. 3. 220-8 . 4.

220-8 SEN00099-01 5 . function and maintenance standard PC200.10 Structure.

function and maintenance standard 1 Type: HPV95+95 6 PC200.SEN00099-01 Hydraulic pump 10 Structure. 220-8 .

6. LS valve. function and maintenance standard SEN00099-01 Outline q This pump consists of 2 variable capacity swash plate piston pumps. and EPC valve. 3. IMF IMR ISIG PAF PAR PBF PD1F PD1R PD2F PD2R PENF PENR PEPC PEPCC PFC : : : : : : : : : : : : : : : PLSF PLSFC PLSR PLSRC PMF : : : : : PMR : PRC : PS PSIG : : 1. 220-8 7 . 2. 4. 5.10 Structure. PC valve. Front PC mode selector current Rear PC mode selector current LS set pressure selector current Front pump delivery port Rear pump delivery port Pump pressure input port Case drain port Air bleeder Drain plug Drain plug Front control pressure detection port Rear control pressure detection port EPC basic pressure port EPC basic pressure detection port Front pump discharge pressure detection port Front load pressure input port Front load pressure detection port Rear load pressure input port Rear load pressure detection port Front PC mode selector pressure detection port Rear PC mode selector pressure detection port Rear pump discharge pressure detection port Pump suction port LS set selector pressure detection port Front pump Rear pump LS valve PC valve LS-EPC valve PC-EPC valve PC200.

8. 6. function and maintenance standard Front shaft Cradle Front case Rocker cam Shoe Piston Cylinder block Valve plate End cap Rear shaft Rear case Servo piston PC valve PC200. 13.SEN00099-01 1. 5. 9. 11. 220-8 . 3. 7. 12. 4. 8 10 Structure. 2. 10.

q Rocker cam (4) has flat surface (A). function and maintenance standard SEN00099-01 Function q The pump converts the engine rotation transmitted to its shaft to oil pressure and delivers pressurized oil corresponding to the load. q Structure q Cylinder block (7) is supported to shaft (1) by spline (14). q Piston (6) and shoe (5) constitute the spherical bearing. This surface is designed so that the oil pressure balance is maintained at a suitable level. 220-8 q q Piston (6) carries out relative movement in the axial direction inside each cylinder chamber of cylinder block (7). Cylinder block (7) seals the pressurized oil to valve plate (8) and carries out relative rotation. q Tip of piston (6) is shaped as a concave ball and shoe (5) is caulked to it to form one unit. which is secured to the case. and shoe (5) is always pressed against this surface while sliding in a circular movement. q PC200.10 Structure. The oil inside the respective cylinder chambers of cylinder block (7) is suctioned and discharged through valve plate (8). q Rocker cam (4) conducts high pressure oil to the cylinder surface (B) with cradle (2). and forms a static pressure bearing when it slides. q Shaft (1) is supported by front and rear bearings (15). q It is possible to change the discharge amount by changing the swash plate angle. 9 .

flat surface (A) acts as a cam in relation to shoe (5). the volume of chamber (F) grows larger and. so a difference between volumes (E) and (F) is created inside cylinder block (7). piston (6) slides on the inside of cylinder block (7). so angle (a) between center line (X) of rocker cam (4) and th e axia l d ir ection of cylinde r bloc k ( 7) changes. rocker cam (4) moves along cylindrical surface (B). the difference between volumes (E) and (F) inside cylinder block (7) becomes 0. On the other hand. q q q q q 10 10 Structure. q (a) is named the swash plate angle. Namely pumping action is not performed. 220-8 . PC200. As cylinder block (7) rotates and the volume of chamber (E) becomes smaller. the pressurized oil is discharged. function and maintenance standard q q As center line (X) of rocker cam (4) matches the axial direction of cylinder block (7) (swash plate angle (a) = 0). A single piston (6) suctions and discharges the oil by the amount (F) – (E). and shoe (5) slides on flat surface (A). (Actually. in this process. however.SEN00099-01 Operation of pump q Cylinder block (7) rotates together with shaft (1). the swash plate angle is not set to 0) With center line (X) of rocker cam (4) at a swash plate angle (a) in relation to the axial direction of cylinder block (7). q When this happens. In this way. the oil is suctioned. Suction and discharge of pressurized oil is not carried out in this state.

q The relationship in the size of pressure (PP) at the small diameter piston end and pressure (PEN) at the large diameter piston end. q Servo piston (12) carries out linear reciprocal movement according to the signal pressure from the PC and LS valves. PC200. q Space of the pressure receiving area of servo piston (12) are not identical on the left side and right side. rocker cam (4) slides on the surface while continuing revolving movement. Main pump discharge pressure (self pressure) (PP) is always brought to the pressure chamber of the small diameter piston side. q Servo piston (12) is used for changing swash plate angle (a). 220-8 11 . q Output pressure (PEN) of the LS valve is brought to the chamber receiving the pressure at the large diameter piston end. function and maintenance standard SEN00099-01 Control of delivery q If the swash plate angle (a) becomes larger.10 Structure. q This linear movement is transmitted to rocker cam (4) through slider (13). q Being supported by cradle (2) on the cylindrical surface. and the ratio between the area receiving the pressure of the small diameter piston and the large diameter piston controls the movement of servo piston (12). the difference between volumes (E) and (F) becomes larger and pump delivery (Q) increases.

27 to 1. LS valve PA PDP PLP PLS PP PPL PSIG : Pump port : Drain port : LS control pressure output port : LS pressure input port : Pump port : Control pressure input port : LS mode selector pilot port 1. the specified median of the pump delivery volume switching point changes as shown in the diagram. setting force the spring changes. 4. 8.7 MPa {2. Sleeve Piston Spool Spring Sheet Sleeve Plug Locknut Function q The LS (load sensing) valve detects the load and controls the discharge amount. 220-8 . too. As the result. 6. function and maintenance standard 1. 5. q Main pump pressure (PP). 3. and pressure (PSIG) (called the LS selector pressure) from the proportional solenoid valve enter this valve.SEN00099-01 10 Structure. q This valve controls main pump delivery (Q) according to differential pressure (dPLS)[= PP — PLS].78 to 17.75 kg/cm2}. q If (ISIG) changes from 0 to 1A. 7. 2. pressure (PLS) (called the LS pressure) coming from the control valve output. called the LS differential pressure (the difference between main pump pressure PP and control valve outlet port pressure PLS). 12 PC200. q The relationship between the LS differential pressure between the main pump pressure (PP) and LS pressure (PLS) (dPLS) [= (PP) — (PLS)] and the pump delivery (Q) changes as shown in the diagram according to LS selector current (ISIG) of the LS-EPC valve. It will change in the range of 0.

Pump pressure (PP) is conducted to the larger diameter end from the port (K). LS pressure (PLS) will be set to 0 MPa {0 kg/cm2}. However. (Setting force of the spring is changed) Before the engine is started. and main pump discharge pressure (PP) brought to port (H) of sleeve (8).10 Structure. servo piston (12) is pushed to the left. force of spring (4) and the pump delivery pressure (self pressure) (PP) determine the position of spool (6). Magnitude of the force resulting from this LS pressure (PLS). 13 . 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). (See the figure) If the control lever is at the neutral position when the engine is started. and port (C) and port (D) will be connected. The same pump pressure (PP) is conducted to the smaller diameter end from the port (J). the pressure moves in such that the swash plate angle may be minimized. According to the difference in the areas on servo piston (12). function and maintenance standard SEN00099-01 Operation 1) When the control valve is situated at neutral q q q q q The LS valve is a 3-way selector valve. (It is interconnected to the drain circuit through the control valve spool) PC200. with pressure (PLS) (LS pressure) from the outlet port of the control valve brought to spring chamber (B). 220-8 q q q q Spool (6) is pushed to the right.

L S d i ffe r e n t i a l p r e s s u r e (dP L S) becomes smaller (for example. so servo piston (12) is pushed to the left side. (The operation of the PC valve is explained later. The PC valve is connected to the drain port. Therefore. so the pressure across circuits (D) and (K) becomes drain pressure (PT). and pump pressure (PP) enters port (J) at the small diameter end. 220-8 . port (D) and port (E) are interconnected and connected to the PC valve. When spool (6) moves. spool (6) is pushed to the left by the combined force of LS pressure (PLS) and the force of spring (4). q q If the output pressure of the EPC valve for the LS valve enters port (G).SEN00099-01 10 Structure. If piston (7) is pushed to the right. in other w o r d s . function and maintenance standard 2) Action for the direction of maximizing the pump delivery q q q q 14 When the difference between the main pump pressure (PP) and LS pressure (PLS). the swash plate is moved in the direction to make the discharge amount larger. changing the LS differential pressure (dPLS) [Difference between oil pressures (PLS) and (PP)] when ports (D) and (E) of spool (6) are connected. setting force of spring (4) is weakened. when the area of opening of the control valve becomes larger and pump pressure PP drops). PC200.) The pressure at the large diameter end of servo piston (12) becomes drain pressure (PT). rightward force is generated on piston (7).

the servo piston (12) moves into the direction of reducing the swash plate angle. setting force of spring (4) is reduced. As the result.10 Structure. Main pump pressure (PP) also enters port (J) of the small diameter end of the piston. it enters the large diameter end of the piston. it is pushed to the right. pump pressure (PP) pushes spool (6) to the right. 220-8 15 . function and maintenance standard SEN00099-01 3) Action for the direction of minimizing the pump delivery q q q q When LS differential pressure (dPLS) becomes larger (for example. main pump pressure (PP) flows from port (C) to port (D) and from port (K). PC200. but because of the difference in area between the large diameter end and the small diameter end on servo piston (12). As LS selector pressure (PSIG) is input to port (G). When spool (6) moves. when the area of opening of the control valve becomes smaller and pump pressure (PP) rises) because of the rightward move (it reduces discharge amount) of servo piston (12).

] At this point. The swash plate of the pump will be held at the intermediate position. If (PSIG) [Output pressure of LS-EPC valve. [Spool (6) will be stopped at a position where the distance of the opening from port (D) to port (E) and the distance from port (C) to port (D) is almost the same. 0 to 2. 220-8 .SEN00099-01 10 Structure. so the pressure applied across the piston when it is balanced becomes (PP) : (PEN) C 5 : 3.75 kg/cm2} at the median of the specified value.75 to 2. PC200. q q Force of spring (4) is adjusted in such that the position of the balanced stop of this spool (6) may be determined when (PP) — (PLS) = 1.9 MPa {0 to 30 kg/cm2}] is input to port (G).27 MPa {17. the relationship between the pressure receiving areas across servo piston (12) is (A0) : (A1) = 3 : 5. the area receiving the pressure at the small diameter end as (A0). the position of the balanced stop is changed in the range of (PP) — (PLS) = 1.7 to 0. If the main pump pressure (PP) of the LS valve and the combined force of spring (4) and LS pressure (PLS) are balanced. function and maintenance standard 4) When servo piston is balanced q q q q 16 Let us take the area receiving the pressure at the large diameter end of the piston as (A1).7 MPa{17. and the relationship is (A0) x (PP) = (A1) x (PEN).78 kg/cm2} in proportion to (PSIG) pressure. and the pressure flowing into the large diameter end of the piston as (PEN). servo piston (12) will stop in that position.

5. PC200. 8. the controller reduces the pump delivery to recover the speed.10 Structure. relation between the mean discharge pressure of the front and rear pumps [(PP1) + (PP2)]/2 and the pump delivery (Q) will becomes as shown in the diagram if the relation is represented as the parameter the current value (X) to be given to PC-EPC valve solenoid. 3. the PC valve controls the pump so that the volume of oil beyond the discharge pressure-based specific flowrate may not be conducted however you may increase the control valve stroke. q The controller continues counting the actual engine speed. function and maintenance standard SEN00099-01 2. PC valve PA PA2 PDP PM PPL : Pump port : Pump pressure pilot port : Drain port : Mode selector pressure pilot port : Control pressure output port (to LS valve) Function q When the pump discharge pressure (PP1) (self-pressure) and (PP2) (other pump pressure) are high. this valve decreases the pump delivery. Namely it is intended at controlling the horse power for the pumps so that it may not exceed the engine hose power. it increases the pump delivery. 220-8 1. 6. the controller sends a command current to PC-EPC valve solenoid in order to reduce the slope angle in proportion to reduction in the engine speed. Plug Servo piston assembly Pin Spool Retainer Sheet Cover Wiring q If the engine speed goes below the specified value because of increased load. 17 . q If the pump discharge pressure increases due to increased load during operation. q If the engine speed is slowed down due to increased load. 2. 4. q And if the pump delivery pressure goes low. q In this case. 7.

q Spool (3) stops at a position where the combined spool-pushing force is balanced by the setting force of springs (4) and (6) as well as the pump pressures (PP1) (self-pressure) and (PP2) (another pump's pressure). And for the rear pump pressure. 18 a Other pump's pressure denotes the pressure of the pump situated on the opposite side. and the set value and actual value of the engine speed.SEN00099-01 10 Structure. PC200. the other pump's pressure is that of the rear pump. q The pressure [port (C) pressure] output from PC valve is changed depending on the above position. the other pump's pressure is that of the front pump. q The size of command current (X) is determined by the nature of the operation (lever operation). 220-8 . function and maintenance standard Operation 1) When pump controller is normal (1) When the load on the actuator is small and pump discharge pressures (PP1) and (PP2) are low Action of PC-EPC valve solenoid (1) q Command current (X) is being sent to PC-EPC valve solenoid (1) from the pump controller. the selected working mode. q This command current acts on PC-EPC valve to output the signal pressure in order to modify the force pushing piston (2). For the front pump pressure.

10 Structure, function and maintenance standard

Action of spring
q
Load of springs (4) and (6) on the PC valve is
determined by the swash plate position.
q
As servo piston (9) moves to right, spring (6) is
retracted.
q
If the servo piston moves further, it will be contacted again seat (5) and spring (6) will be
fixed.
q
After that, spring (4) alone will operate.
q
The spring load is changed by servo piston (9)
as it extends or compresses springs (4) and
(6).
The spring load changes as the servo piston
(9) extends and contracts the springs (4) and
(6).
q
If the command current (X) to PC-EPC valve
solenoid (1) changes, so does the force pushing piston (2).
q
Spring load of springs (4) and (6) is also
affected by the command current (X) to PCEPC valve solenoid.
q
Port (C) of the PC valve is connected to port
(E) of the LS valve.

PC200, 220-8

SEN00099-01

q

q

q

q

q
q

Self pressure (PP1) enters port (B) and the
small diameter end of servo piston (9), and
other pump pressure (PP2) enters port (A).
When pump pressures (PP1) and (PP2) are
small, spool (3) will be positioned in the left
side.
Port (C) and (D) are connected, and the pressure entering the LS valve becomes drain
pressure (PT).
If port (E) and port (G) of the LS valve are connected, the pressure entering the large diameter end of the piston from port (J) becomes
drain pressure (PT), and servo piston (9)
moves to the left side.
The pump delivery will be set to the increasing
trend.
Accompanied with move of servo piston (9),
springs (4) and (6) will be expanded and the
spring force becomes weaker.

19

SEN00099-01

q

q

q

20

10 Structure, function and maintenance standard

As the spring force is weakened, spool (3)
moves to the right, the connecting between
port (C) and port (D) is shut off and the pump
discharge pressure ports (B) and (C) are connected.
As a result, the pressure on port (C) rises and
the pressure on the large diameter end of the
piston also rises. Thus, the leftward move of
servo piston (9) is stopped.
Servo piston (9) stop position (= Pump delivery) is decided by the position where the pushing force generated from the pressures (PP1)
and (PP2) applied to spool (3), the pushing
force of the solenoid in PC-EPC valve generates and the pushing force of springs (4) and
(6) are balanced.

PC200, 220-8

10 Structure, function and maintenance standard

SEN00099-01

(2) When load on actuator is large and pump discharge pressure is high

Outline
q
When the load is large and pump discharge
pressures (PP1) and (PP2) are high, the force
pushing spool (3) to the right becomes larger
and spool (3) will be moved to the position
shown in above figure.
q
Part of the pressure to be conducted from port
(C) to LS valve flows from port (B) to port (C)
and (D) through LS valve. At the end this flow,
level of this pressure becomes approximately
half of the main pump pressure (PP2).

q

Operation
q
When port (E) and port (G) of the LS valve are
connected, this pressure from port (J) enters
the large diameter end of servo piston (9),
stopping servo piston (9).
q
If main pump pressure (PP2) increases further
and spool (3) moves further to the right, main
pump pressure (PP1) flows to port (C) and acts
to make the pump delivery the minimum.

q

PC200, 220-8

q
q

q

When servo piston (9) moves to the right,
springs (4) and (6) are compressed and push
back spool (3).
When spool (3) moves to the left, the opening
of port (C) and port (D) becomes larger.
As a result, the pressure on port (C) (= J) is
decreased and the rightward move servo piston (9) is stopped.
The position in which servo piston (9) stops at
this time is further to the right than the position
when pump pressures (PP1) and (PP2) are
low.
The relationship between the average pump
pressure (PP1 + PP2)/2 and servo piston (9) in
terms of their positions can be represented by
the broken line in the figure springs (4) and (6)
form the double springs.

21

SEN00099-01

q

The relationship between the average pump
pressure (PP1 + PP2)/2 and average pump
delivery (Q) becomes as shown below.

q

If command voltage (X) sent to PC-EPC valve
solenoid (1) increases further, the relationship
between average pump pressure (PP1 + PP2)/
2, and pump delivery (Q) is proportional to the
force of the PC-EPC valve solenoid and moves
in parallel.
Namely, the force of PC-EPC valve solenoid
(1) is added to the pushing force to the right
because of the pump pressure applied to the
spool (3), so the relationship between the average pump pressure (PP1 + PP2)/2 and the
pump delivery (Q) moves from (A) to (B) as the
command current (X) is increased.

q

22

10 Structure, function and maintenance standard

PC200, 220-8

10 Structure, function and maintenance standard

SEN00099-01

2) As the emergency pump drive switch is turned on due to failure on the pump
controller
(1) When the main pump is under light load

q

q

q
q

q

If there is a failure in the pump controller, the
emergency pump drive switch is turned on to
hand the control to the resistor side.
In this case, the power is directly supplied from
the battery. The current, however, is too large
as is, so the resistor is set in between to control the current flowing to PC-EPC valve solenoid (1).
The current becomes constant, so the force
pushing piston (2) is also constant.
If the main pump pressures (PP1) and (PP2)
are low, the combined force of the pump pressure and the PC-EPC valve solenoid (1) is
weaker than the spring set force, so spool (3)
is balanced at a position to the left.
The port (C) is connected to the drain pressure
of the port (D), and the large diameter end of
the servo piston (9) also becomes the drain
pressure (PT) through the LS valve.

PC200, 220-8

q

Since the pressure on the small diameter end
of the piston large, servo piston (9) moves in
the direction to make the discharge amount
larger.

23

SEN00099-01

10 Structure, function and maintenance standard

(2) When the main pump is under heavy load

q

q
q

q

q

24

If the emergency pump drive switch is turned
on in the same way as in above, the command
current (X) sent to PC-EPC valve solenoid (1)
becomes constant.
For this reason, the force of piston (2) pushing
spool (3) is constant.
If main pump pressures (PP1) and (PP2)
increase, spool (3) moves further to the right
than when the main pump load is light, and is
balanced at the position in the figure above.
In this case, the pressure from port (B) flows to
port (C), so servo piston (9) moves to the right
(smaller pump delivery) and stops at a position
to the further to the right then when the load on
the pump is light.
When the emergency pump drive switch is
turned on, too, the pump pressure (PP) and
pump delivery (Q) have a relationship as
shown with the curve in the figure corresponding to the current sent to the PC-EPC valve
solenoid through the resistor.

q

The curve resulting when the emergency pump
drive switch is ON is situated further to the left
(B) than when the pump controller is normal
(A).

PC200, 220-8

10 Structure, function and maintenance standard

SEN00099-01

3. LS (PC)-EPC valve

C : To LS (PC) valve
P : From self pressure reducing valve
T : To tank
1.
2.
3.
4.
5.
6.
7.

Connector
Coil
Body
Spring
Spool
Rod
Plunger

PC200, 220-8

25

SEN00099-01

Function
q
The EPC valve consists of the proportional
solenoid portion and the hydraulic valve portion.
q
When it receives signal current (i) from the
controller, it generates the EPC output pressure in proportion to the size of the signal, and
outputs it to the LS (PC) valve.

10 Structure, function and maintenance standard

Operation

1) When signal current is 0 (coil is deenergized)
q

q
q

q

26

When there is no signal current flowing from
the controller to coil (2), coil (2) is de-energized.
Spool (5) is pushed to the left by spring (4).
Port (P) closes 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 is
drained to the tank through port (C) and port
(T).

PC200, 220-8

10 Structure, function and maintenance standard

2) When signal current is very small
(coil is energized)
q

q
q

q
q
q

q

When a very small signal current flows to coil
(2), coil (2) is energized, and a propulsion force
is generated on the right side of plunger (7).
Rod (6) pushes spool (5) to the right, and pressurized oil flows from port (P) to port (C).
Pressure on port (C) increases and the force to
act on spool (5) surface and the spring load on
spring (4) become larger than the propulsion
force of plunger (7).
Spool (5) is pushed to the left, and port (P) is
shut off from port (C).
Port (C) and port (T) are connected.
Spool (5) moves up and down so that the propulsion force of plunger (7) may be balanced
with pressure of port (C) + spring load of spring
(4).
The circuit pressure between the EPC valve
and the LS (PC) valve is controlled in proportion to the size of the signal current.

PC200, 220-8

SEN00099-01

3) When signal current is maximum
(coil is energized)
q
q

q
q

q

As the signal current flows to coil (2), coil (2) is
energized.
When this happens, the signal current is at its
maximum, so the propulsion force of plunger
(7) is also at its maximum.
Spool (5) is pushed toward right side by rod
(6).
The maximum volume of pressurized oil is
conducted from port (P) to port (C), increasing
the circuit pressure across EPC valve and LS
(PC) valve to the maximum level.
Since port (T) is closed, pressurized oil does
not flow to the tank.

27

SEN00099-01

10 Structure, function and maintenance standard

Pilot oil filter

1

For breaker

1.
2.
3.
4.

28

Filter
Case
Head cover
Relief valve

Specifications
Rated pressure : 6.57 MPa {67 kg/cm2}
Flow rate
: 16 l/min.
Relief valve cracking pressure
: 0.15 MPa {1.5 kg/cm2}
Filter mesh size : 6 mm
Filtering area
: 450 cm2

PC200, 220-8

10 Structure, function and maintenance standard

PC200, 220-8

SEN00099-01

29

SEN00099-01

PC200, 220(LC)-8 Hydraulic excavator
Form No. SEN00099-01

© 2007 KOMATSU
All Rights Reserved
Printed in Japan 01-07 (01)

30

SEN00100-01

HYDRAULIC EXCAVATOR
1SHOP MANUAL

PC200-8
PC200LC-8
PC220-8
PC220LC-8
Machine model

Serial number

PC200-8
PC200LC-8
PC220-8
PC220LC-8

300001 and up
300001 and up
70001 and up
70001 and up

10 Structure, function and
maintenance standard

1

Hydraulic system, Part 2
Hydraulic system, Part 2 ................................................................................................................................. 2
Control valve ........................................................................................................................................ 2
CLSS.................................................................................................................................................. 15
Functions and operation by valve ...................................................................................................... 20

PC200, 220-8

1

SEN00100-01

10 Structure, function and maintenance standard

Hydraulic system, Part 2
Control valve

1
1

Outline
q
This control valve consists of a 6-spool valve
(one body composition) and a set of service
valve. A merge-divider valve, a back pressure
valve and a boom hydraulic drift prevention
valve are installed to it.
q
Since all the valves are assembled together
with connecting bolts and their passes are connected to each other inside the assembly, the
assembly is compact and easy to maintain.
q
With one spool provided for one work equipment, this control valve is simple in construction.
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
A-3: To attachment 3
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
B-3: To attachment 3
BP1: From LS select solenoid valve
BP5: From attachment selector solenoid valve
C: To tank
IS1: From controller
IS2: From controller
P1: From bucket PPC and EPC valves
P2: From bucket PPC and EPC valves
P3: From L.H. Travel PPC valve
P4: From L.H. Travel PPC valve
P5: From boom PPC and EPC valves
P6: From boom PPC and EPC valves

P7: From swing PPC and EPC valves
P8: From swing PPC and EPC valves
P9: From R.H. Travel PPC valve
P10: From R.H. Travel PPC valve
P11: From arm PPC and EPC valves
P12: From arm PPC and EPC valves
P-1: From service 1 and PPC valves
P-2: From service 1 and PPC valves
P-3: From service 2 and PPC valves
P-4: From service 2 and PPC valves
P-5: From service 3 and PPC valves
P-6: From service 3 and PPC valves
PLS1: To rear pump control
PLS2: To front pump control
PLSC: LS pressure detection port
PP1: From front pump
PP2: From rear pump
PP2S: Pressure sensor mounting port
PPC: Pilot basic pressure detection port
PPS1: Pressure sensor mounting port
PPS2: To front pump control
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: To swing motor S-port (suction side)

1.
2.
3.
4.
5.

6.
7.
8.
9.
10.

2

6-spool valve
Cover A
Cover B
Service valve 1
Service valve 2

Service valve 3
Merge-divider valve
Boom hydraulic drift prevention valve
Arm hydraulic drift prevention valve
Arm quick return valve

PC200, 220-8

10 Structure, function and maintenance standard

SEN00100-01

General view
PC200-8

PC200, 220-8

3

SEN00100-01

10 Structure, function and maintenance standard

PC220-8

4

PC200, 220-8

10 Structure, function and maintenance standard

PC200, 220-8

SEN00100-01

5

SEN00100-01

10 Structure, function and maintenance standard

Sectional view
(1/5)

6

PC200, 220-8

10 Structure, function and maintenance standard

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.

SEN00100-01

Pressure compensation valve (Arm OUT)
Pressure compensation valve (R.H. travel REVERSE)
Pressure compensation valve (RIGHT swing)
Pressure compensation valve (Boom RAISE)
Pressure compensation valve (L.H. travel REVERSE)
Pressure compensation valve (Bucket DUMP)
Pressure compensation valve (Service 1)
Pressure compensation valve (Service 2)
Pressure compensation valve (Service 3)
Pressure compensation valve (Bucket CURL)
Pressure compensation valve (L.H. travel FORWARD)
Pressure compensation valve (Boom LOWER)
Pressure compensation valve (LEFT swing)
Pressure compensation valve (R.H. travel FORWARD)
Pressure compensation valve (Arm IN)
Main relief valve
Unload valve
Main relief valve
Spool (Service 3)
Spool (Service 2)
Spool (Service 1)
Spool (Bucket)
Spool (L.H. travel)
Spool (Boom)
Spool (Swing)
Spool (R.H. travel)
Spool (Arm)
Unit: mm

No.

Check item

Criteria
Standard size

28

Spool return spring

Remedy
Repair limit

Free length x
Outside diameter

Installed
length

55.2 x 34.4

51.2

407 N
{41.5 kg}

326 N
{33.2 kg}

Installation
Installation
Free length
load
load

29

Spool return spring

54.5 x 34.8

51.2

393 N
{40.1 kg}

315 N
{32.1 kg}

30

Spool return spring

54.4 x 34.8

51.2

375 N
{38.2 kg}

300 N
{30.6 kg}

31

Spool return spring

54.6 x 34.8

51.2

421 N
{42.9 kg}

336 N
{34.3 kg}

PC200, 220-8

If damaged or
deformed,
replace spring.

7

SEN00100-01

10 Structure, function and maintenance standard

(2/5)

8

PC200, 220-8

10 Structure, function and maintenance standard

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.

SEN00100-01

Suction valve (Arm OUT)
Suction valve (R.H. travel REVERSE)
Suction valve (Boom RAISE)
Suction valve (L.H. travel REVERSE)
Safety-suction valve (Bucket DUMP)
Safety-suction valve (Service 1)
Safety-suction valve (Service 2)
Safety-suction valve (Service 3)
2-stage safety-suction valve (Service)
Safety-suction valve (Bucket CURL)
Suction valve (L.H. travel FORWARD)
Safety-suction valve (Boom LOWER)
Suction valve (R.H. travel FORWARD)
Safety-suction valve (Arm IN)
LS shuttle valve (Arm)
LS shuttle valve (R.H. travel)
LS select valve
LS shuttle valve (Boom)
LS shuttle valve (L.H. travel)
LS shuttle valve (Bucket)
LS shuttle valve (Service 1)
LS shuttle valve (Service 2)
LS shuttle valve (Service 3)
LS check valve
Pressure relief plug
Unit: mm

No.

Check item

Criteria
Standard size

26

27

Suction valve spring

Check valve spring

PC200, 220-8

Remedy
Repair limit

Free length x
Outside diameter

Installed
length

46.8 x 7.5

40.6

5.5 N
{0.56 kg}

4.4 N
{0.45 kg}

11.5 x 4.6

8.5

1.5 N
{0.15 kg}

1.2 N
{0.12 kg}

Installation
Installation
Free length
load
load

If damaged or
deformed,
replace spring.

9

SEN00100-01 10 Structure. function and maintenance standard (3/5) 10 PC200. 220-8 .

94 kg} PC200.4 43 14. Pressure compensation valve (L. SEN00100-01 Unload valve Safety valve (Boom RAISE) Main relief valve Lift check valve Arm valve 5.H.6 kg} — 4.2 x 20 36 170 N {17.3 13.68 kg} — 28.7 N {1.1 N {3.) 23.5 kg} — 11.4 kg} — 11 N {1. Pressure compensation valve (FORWARD) 17.8 kg} 30 Piston return spring 18.3 19. Check item Criteria Standard size 25 Check valve return spring Remedy Repair limit Free length x Outside diameter Installed length 59. Arm check valve 6.8 x 6 29 13.8 N {2. 11 .2 kg} Installation Installation Free length load load 26 Check valve spring 33.10 Structure. Spool 18. 4.48 kg} 29 Piston return spring 88.3 x 14. Pressure compensation valve (IN) 9.8 N {1.8 kg} 28 Check valve spring 31. Suction valve (FORWARD) 19. replace spring.4 65 157 N {16 kg} — 126 N {12.H. LS select valve 22.5 x 10.5 5. Quick return valve 8. Suction valve (REVERSE) 20. 220-8 If damaged or deformed. Regeneration circuit check valve 13. travel valve 15. 3.7 N {1. 2.9 N {0.2 x 28.0 x 9.71 N {0. LS shuttle valve 7. Back pressure valve 12.) Unit: mm No.12 kg} 27 Piston return spring 60. function and maintenance standard 1. Spool 10. Safety-suction valve (IN) 11.H. Pressure compensation valve (R. Spool 24. Pressure compensation valve (OUT) R.3 kg} — 135 N {13. Pressure compensation valve (REVERSE) Swing valve 21. LS shuttle valve 16.4 36. Suction valve (OUT) 14.

SEN00100-01 10 Structure. function and maintenance standard (4/5) 12 PC200. 220-8 .

13 .5 kg} 32 Check valve spring 33.4 x 21. travel valve 15.10 Structure. 2.0 29. Suction valve (REVERSE) 22. Drift prevention valve 8.3 kg} — 96.12 kg} 34 Piston return spring 31. Pressure compensation valve (CURL) 25.H. LS shuttle valve 9.0 35. Pressure compensation valve (RAISE) Bucket valve 23.3 19.3 N {3.0 N {5.0 13. 4.84 kg} Installation Installation Free length load load 30 Check valve spring 70.5 x 10.6 kg} — 4. LS shuttle valve 18.5 N {9.0 N {4. Spool 11.7 N {1.4 kg} — 11.0 26. replace spring. Pressure compensation valve (FORWARD) 19. 220-8 If damaged or deformed. Spool 20. 6. SEN00100-01 L. 3.1 kg} — 142 N {14.6 kg} — 28. Safety-suction valve (LOWER) 12.0 121 N {12.71 N {0. Safety-suction valve (CURL) 27.1 kg} — 40.7 x 20. Suction valve (FORWARD) 21. Pressure compensation valve (DUMP) Unit: mm No.5 5.0 178 N {18. Merge-divider valve (travel junction valve) 16.0 N {1. Regeneration circuit check valve 13. function and maintenance standard 1. Check item Criteria Standard size 29 Spool return spring Remedy Repair limit Free length x Outside diameter Installed length 36.0 250 N {25. Spool 26. Safety-suction valve (DUMP) 28.8 33. Pressure compensation valve (Reverse) Return spring Merge-divider valve (for LS) Valve (Sequence valve) Spring (Sequence valve) Merge-divider valve (Main) Return spring Boom valve 7. LS shuttle valve 24.8 x 6.9 x 18.48 kg} 35 Piston return spring 30.88 kg} 33 Check valve spring 33.0 56. 5.3 63.5 kg} — 200 N {20. Suction valve (RAISE) 14.5 x 32.0 x 12.08 kg} PC200.2 N {2. Return spring 17.4 kg} 31 Spool return spring 64.5 23 50. Pressure compensation valve (LOWER) 10.9 N {0.

Unload valve 11. Main relief valve 12.SEN00100-01 10 Structure. Spool 9. 2-stage safety-suction valve 5. 220-8 . Spool 4. Pressure compensation valve 3. LS shuttle valve 2. LS shuttle valve 7. function and maintenance standard (5/5) Service valve 1 1. Pressure compensation valve 8. Safety-suction valve 10. Safety-suction valve 14 Service valves 2 and 3 6. LS bypass plug PC200.

which has the following characteristics: q q q q Fine control not influenced by load Controllability enabling digging even with fine control Ease of compound operation ensured by flow divider function using area of opening of spool during compound operations Energy saving using variable pump control PC200. and respective actuators. control valves. 15 . q The hydraulic pump is configured with pump body. 220-8 Configuration q CLSS is configured with variable capacity piston pumps. function and maintenance standard SEN00100-01 CLSS 1 Outline of CLSS 1 Features CLSS stands for Closed center Load Sensing System.10 Structure. PC valve and LS valve.

220-8 . see the “Hydraulic pump“ paragraph. Pump swash plate angle control q q The pump swash plate angle (pump delivery) is controlled so that LS differential pressure (dPLS) (the difference between pump pressure PP and control valve outlet port LS pressure PLS) (load pressure of actuator) is constant. [LS differential pressure (dPLS) = Pump discharge pressure (PP) — LS pressure (PLS)] q q The pump swash plate angle shifts toward the maximum position if LS differential pressure (dPLS) is lower than the set pressure of the LS valve (when the actuator load pressure is high). LS differential pressure (dPLS) and pump swash plate angle a 16 For details of functions. function and maintenance standard 1 1. If it becomes higher than the set pressure (when the actuator load pressure is low).SEN00100-01 Basic principle 10 Structure. the pump swash plate angle shifts toward the minimum position. PC200.

function and maintenance standard SEN00100-01 2. PC200. Pressure compensation control q q q A pressure compensation valve is installed to the outlet port side of the control valve to balance the load. 220-8 17 .10 Structure. The flow of oil from the pump is divided (compensated) in proportion to the area of opening (S1) and (S2) of each valve. When actuators are operated together. the pressure difference (dP) between the upstream (inlet port) and downstream (outlet port) of the spool of each valve becomes the same regardless the size of the load (pressure).

8. 2. 10. System diagram a The illustration shows the actuator (6) in the merge mode with stroke end at the time of relief. 6. Front pump Rear pump Main relief valve Unload valve Merge-divider valve Control valve Actuator Pump circuit 18 9. 12.SEN00100-01 10 Structure. 3. 4. LS circuit Tank circuit Valve Spring LS bypass valve LS valve PC valve PC200. 7. 220-8 . 15. function and maintenance standard 3. 5. 11. 1. 13. 14.

220-8 SEN00100-01 19 .10 Structure. function and maintenance standard PC200.

220-8 . function and maintenance standard Functions and operation by valve 1 Hydraulic circuit diagram and the name of valves 1 20 PC200.SEN00100-01 10 Structure.

5 MPa{390 ± 5 kg/cm2} 42.5 MPa{382 ± 5kg/cm2} 36.6 ± 0. 2. Arm check valve (for central safety valve circuit) 30.5 MPa{355.5 ± 0. travel spool Swing spool Boom spool L.2 ± 0. 18. 5. 23.5 ± 0. 3. Safety-suction valve Set pressure: 31. 220-8 SEN00100-01 28. 8.H. 15. Main relief valve (arm side) Set pressure: 34. Unload valve (arm side) Cracking pressure: 2. Arm valve R. Self pressure reducing valve 31.5 ± 0.5 MPa{250 ± 5kg/cm2} 40. 10. 2-stage safety-suction valve Set pressure: 1 stage: 24. 12. Travel junction valve 32.5 MPa{210 ± 5 kg/cm2} 21 .5 MPa{320 ± 5 kg/cm2} 41.H.5 MPa{26 ± 5kg/cm2} 39.5 ± 0. Boom drift prevention valve 35. 11.4 ± 0. 16.5 MPa{382 ± 5kg/cm2} 37. Main relief valve (bucket side) Set pressure: 34.H.9 ± 0.10 Structure. 26.5 MPa{26 ± 5kg/cm2} 38.H. travel spool Bucket spool Service spool 1 Service spool 2 Service spool 3 Pressure compensation valve Suction valve Check valve (for boom regeneration circuit) Check valve (for arm regeneration circuit) EPC valve (for switching main spool of mergedivider valve) EPC valve (for switching LS spool of mergedivider valve) LS shuttle valve LS select valve Merge-divider valve PC200. travel valve Swing valve Boom valve L.5 MPa{250 ± 5 kg/cm2} 2 stage: 20. 4.5 ± 5kg/cm2} When digging force increased: 37. 21. Cooler check valve 34. 17. function and maintenance standard 1. 22. 7. Back pressure valve 33. Unload valve (bucket side) Cracking pressure: 2.5 ± 5kg/cm2} When digging force increased: 37. 20.5 ± 0. 25. travel valve Bucket valve Service valve 1 Service valve 2 Service valve 3 Arm spool R. Safety-suction valve Set pressure: 38.5 MPa{355. Arm quick return valve 29. Safety-suction valve Set pressure: 24. 6. 24. 19. 13.5 ± 0.9 ± 0. 14. 9. 27.

q Pressurized oil of pump circuit (3) stops at valve (2). q Ports (b) and (c) are interconnected and the pump pressure flows to tank circuit (4). 5. q When actuated. q Since the control valve is in neutral position. function and maintenance standard Unload valve 1. and the pressure rises as no relief is available. 220-8 . When the unload valve is actuating 1.SEN00100-01 10 Structure. q Since the pump discharge pressure . q When this pressure becomes larger than the force of spring (5). q The pressurized oil of LS circuit (1) passes from orifice (a) through port (c) and is drained to the tank circuit (4). the signal is output to minimize the pump swash plate angle. 3. pressure of LS circuit (1) is 0 MPa{0 kg/cm2}. LS circuit Valve Pump circuit Function q Drains an oil discharge for the portion of the minimum pump swash plate angle while all control valves are in the holding. valve (2) moves to the left. LS pressure C tank pressure C 0 MPa{0 kg/cm2}. LS pressure C tank pressure. q Since LS pressure is drained from the LS bypass valve. q The pump pressure will correspond to a set load of spring (5) inside the valve (this pressure will be P1). q PC200.LS circuit pressure during unloading is larger than the pump LS control pressure. 22 4. 2. Tank circuit Spring Operation Pressure of pump circuit (3) is received by the end of valve (2).

(See the system diagram) The pump discharge pressure (PP) and LS pressure (PLS) become approximately the same as each has not flow at the upstream and downstream of the spool. and LS differential pressure (dPLS) becomes 0 kg/cm2. LS control differential pressure (dPLS) of discharge for the portion of minimum swash plate angle will be equal to P1 pressure. Mechanically. The pump is held at a minimum swash plate angle by the cut-off function of PC valve. SEN00100-01 2.10 Structure. The pump delivery (Q) is relieved to the tank. operation of PC valve have the prevalence to that of LS valve. the main relief valve opens. 220-8 When the cylinder reaches the stroke end. As LS differential pressure (dPLS) is lower than the LS set pressure of LS valve. LS valve is actuated to maximize the pump swash plate angle. the discharge pressure for the portion of minimum pump swash plate angle is set to LS pressure + P1 pressure. Operation of relief valve q q q q q q PC200. function and maintenance standard q q During operation (a work within a scope of discharge by a minimum swash plate angle). 23 .

check valve (5) opens. Operation When main spool (2) is operated. function and maintenance standard 1 Hydraulic pump Main spool Pressure compensation valve Valve Check valve LS circuit LS shuttle valve Function q Introduces the upstream pressure (downstream pressure of the spool meter-in) of pressure compensation valve (3) and leads to LS shuttle valve (7) as the LS pressure. 6. 4. 5. q 24 PC200. q Connected to actuator port (B) through valve (4). 2. the pump pressure enters port (c) through inlet pore (a) and is led to the LS circuit. 220-8 .SEN00100-01 Introduction of LS pressure 1. 7. q Inlet pore (a) inside main spool (2) has a small diameter concurrently serving as a throttle. 3. and makes LS pressure C actuator load pressure. 10 Structure. q When the pump pressure rises to reach the load pressure of port (B).

220-8 25 . function and maintenance standard LS bypass valve 1. q Bypass flow from LS bypass valve (5) causes a pressure loss to be generated due to the circuit resistance between throttle (c) of main spool (2) and LS shuttle valve (4). SEN00100-01 1 Hydraulic pump Main spool Pressure compensation valve LS shuttle valve LS bypass valve LS circuit Function q Releases the residual pressure in LS pressure circuit (6) from orifices (a) and (b). q Effective LS differential pressure drops to improve a dynamic stability of the actuator.10 Structure. 5. 4. 6. q Slows down the rising rate of LS pressure to prevent a sudden change of hydraulic pressure. 2. 3. PC200.

port (C) and spring chamber (E) are designed to interconnect before valve (7) is seated. Piston Spring LS shuttle valve q As principle. a pressure compensation valve with integrated valve (2) and piston (4) is used. q If the pump pressure (LS pressure) is lower than the load at port (c). shuttle valve (3) in pressure compensation valve piston (4) interconnects spring chamber (E) and port (C). 220-8 . q With the present machine. Hydraulic pump Valve Shuttle valve Function q Pressure compensation valve works as the load check valve.SEN00100-01 10 Structure. q q Integrated pressure compensation valve q High stress may occur when valve (2) collides with valve chamber seat portion (C) if a high peak pressure is generated in the actuator circuit or repetitive peak pressure occurs continuously (example: when using the breaker).. 26 PC200. 4. valve (7) does not collide with the valve chamber. port (C) and spring chamber (E) are not interconnected in an integrated pressure compensation valve. During independent operation and under maximum load pressure (If the load pressure is higher than other work equipment during a combined operation) 1. 2. 3. 5. q To prevent this. etc. With a bucket valve. q The force of spring (5) operates piston (4) and valve (2) to the closing direction. 6. function and maintenance standard Pressure compensation valve 1 1. this device is adopted for the bucket valve (cylinder bottom) and the service valve. If high peak pressure is generated at port (C).

q PC200. and the spool meter-in downstream pressure of port (B) becomes equivalent to the maximum pressure of other work equipment. Operation Spring chamber (E) is interconnected to port (D). q Since the spool meter-in upstream pressure of port (A) is the pump pressure.10 Structure. q Pump flow is divided according to the ratio of the meter-in opening area. the spool meterin differential pressure [upstream pressure port (A) pressure]–downstream pressure [port (B) pressure] becomes equivalent to all the spools in operation. q Piston (4) and valve (2) operate in the closing direction (to the right) under the LS circuit pressure from other work equipment of port (F). q Valve upstream pressure (= spool meter-in downstream pressure) of port (B) is controlled with LS pressure. When compensated (If the load pressure is lower than other work equipment during a combined operation) Function q The pressure compensation valve closes under LS pressure of port (D). function and maintenance standard SEN00100-01 2. 220-8 27 .

q If area ratio = 1 or under: The spool meter-in downstream pressure will be smaller than the maximum load pressure.SEN00100-01 10 Structure. function and maintenance standard 3. q If area ratio = 1 or over: The spool meter-in downstream pressure will be greater than the maximum load pressure. Pressure compensation valve area ratio Function q The state of division changes according to the area ratio of pressure compensation portion (A1) and (A2). 28 PC200. and the pressure will be divided according to the opening area ratio. and the pressure will be divided smaller than the opening area ratio. 220-8 . and the pressure will be divided greater than the opening area ratio. Area ratio = (A2)/(A1) q If area ratio = 1: The spool meter-in downstream pressure will be equal to the maximum load pressure.

2.10 Structure. Hydraulic pump Valve Pressure compensation valve inner shuttle valve Piston Function q Shuttle valve (3) is pushed to the right by port (A) pressure and cuts off interconnection between ports (A) and (C). q Holding pressure at port (A) is led to the spring chamber (B) to push piston (4) to the left so that piston (4) and valve (2) will not be separated. function and maintenance standard SEN00100-01 Pressure compensation valve inner shuttle valve 1 1. 4. 220-8 29 . If holding pressure at port (A) is larger than LS pressure in the spring chamber (B) 1. PC200. 3.

a pressure compensation valve without shuttle valve (3) is adopted. function and maintenance standard 2. In the case of travel Outline q Since no holding pressure is generated at port (A) of the travel circuit. 30 PC200. 220-8 .SEN00100-01 10 Structure.

6. PC200. 7. Hydraulic pump Boom spool Pressure compensation valve Safety-suction valve Function q Provides the regeneration circuit from the cylinder bottom to the cylinder head when the boom is lowered and increases flow to the cylinder bottom. If the cylinder head pressure is lower than the bottom pressure (free fall. remaining oil flows to regeneration circuit (C). 2. 3. etc.) 1. 220-8 5. function and maintenance standard SEN00100-01 Boom regeneration circuit 1 1.10 Structure. opens check valve (6) and flows to the cylinder head through circuit (D). q On the other hand. 31 . 4. q Flow from regeneration circuit (C) and pump (1) merges in circuit (E). Suction valve Check valve LS shuttle valve Operation q If the cylinder head pressure is lower than the bottom pressure. pressurized oil (A) from the cylinder bottom flows to drain circuit (B) from the notch of boom spool (2).

) Function q Check valve (6) provided to regeneration circuit (C) closes to shut off the flow from the cylinder bottom to the head. 32 PC200. etc. If the cylinder head pressure is higher than the bottom pressure (digging work. 220-8 . function and maintenance standard 2.SEN00100-01 10 Structure.

q Flow from regeneration circuit (C) and pump (1) merges in circuit (E). Hydraulic pump Arm spool Pressure compensation valve Safety-suction valve Function q During arm digging. 3.10 Structure. Suction valve Check valve LS shuttle valve Operation q If the cylinder head pressure is lower than the bottom pressure. q On the other hand. If the cylinder head pressure is higher than the bottom pressure 1. 7. 33 . 6. remaining oil flows to regeneration circuit (C). regeneration circuit provided from the cylinder head to the bottom increases the cylinder speed as the cylinder flow involves the pump delivery plus regenerated flow. pressurized oil (A) from the cylinder bottom flows to drain circuit (B) from the notch of arm spool (2). PC200. 4. opens check valve (6) and flows to the cylinder head through circuit (D). 220-8 5. function and maintenance standard SEN00100-01 Arm regeneration circuit 1 1. 2.

220-8 . If the cylinder head pressure is lower than the bottom pressure Function q Check valve (6) provided to regeneration circuit (C) closes to shut off the flow from the cylinder bottom to the head. 34 PC200.SEN00100-01 10 Structure. function and maintenance standard 2.

2. q Merges and divides LS circuit pressure. 5. output pressure from EPC valve is 0 kg/cm2. Operation Since selector signal (IS1) is OFF. 8. LS circuit (bucket side) LS circuit (arm side) LS circuit (arm side) EPC valve (for main spool) EPC valve (for LS spool) q Merges pressurized oil (P1) and (P2) discharged from the two pumps at ports (E) and (F) and sends to necessary control valve. Since selector signal (IS2) is OFF for LS spool (3). it is pressed to the right by spring (4). and ports (A) – (D) and ports (B) – (C) are interconnected. (7) and (8) to all the pressure compensation valves. (6). q PC200. 3. Forwards LS pressure led from respective control valve spools to LS circuits (5). 7. When flows from the pumps merge [if merge-divider selector signals (IS1) and (IS2) are OFF] 1. function and maintenance standard SEN00100-01 Merge-divider valve 1 1. Main spool Spring LS spool Spring LS circuit (bucket side) Function q Merges pressurized oil (P1) and (P2) discharged from the two pumps or divides (to respective control valve group). q q 35 . q Main spool (1) is pressed to the right by spring (2) and ports (E) and (F) are interconnected. 220-8 6.10 Structure. 4. 9. 10.

travel. and arm q When selector signal (IS2) is turned ON. and ports (E) and (F) are divided. (6).H. and boom P2 pressure: To swing. LS spool (3) too shifts to the left under the output pressure from the EPC valve. and output pressure from the EPC valve shifts main spool (1) to the left. interconnects ports (A) and (C) and divides other ports. (7) and (8) to respective control valves. q Forwards LS pressure led from each control valve spool to LS circuits (5). R. travel.H. L. 10 Structure. 220-8 .SEN00100-01 2. q Pressurized oil discharged from the two pumps are sent to respective control valves. P1 pressure: To bucket. function and maintenance standard When flows from the pumps divide [if merge-divider selector signals (IS1) and (IS2) are ON] Operation q Selector signal (IS1) turns ON. 36 PC200.

travel. 2. The illustration shows the state of simultaneous operation of swinging and R.10 Structure. 3. Valve (1) is pressed to the right and interconnection between ports (A) and (B) is closed. swing LS pressure (P1) enters port (A) after passing swing spool (5). 6. Swing LS pressure (P1) stops flowing to LS shuttle valve (8). 2. Valve (1) is pressed to the left and ports (A) and (B) are interconnected. BP pressure contracts spring (2). If pilot pressure (BP) is OFF q q q q Since pilot pressure (BP) is OFF. 7. When swing-operated. 220-8 37 . If pilot pressure (BP) is ON q q q q a 1. other LS circuits are not affected. If pilot pressure (BP) is ON. 1 Operation 1. 4. function and maintenance standard SEN00100-01 LS select valve Function q Prevents high LS pressure from the swinging from entering the LS circuit of work valves while the swinging and work equipment are in combined operation.H. 8. 9. Swing LS pressure (P1) flows to LS shuttle valve (8). travel spool Arm spool LS shuttle valve LS circuit PC200. and piston (3) shifts to the right. [(BP) pressure ON] Valve Spring Piston Piston Swing spool L. If swing LS pressure (P1) rises. 5. q Prevents high pressure generated during swing drive and improves operability of work equipment. piston (3) is pressed to the left by spring (2).H.

EPC valves. Valve (7) is pressed by spring (8) against the left side and port (P2) is closed to (A2). Valve (14) is pressed by spring (13) against the left side and port (P2) is connected to (TS). While engine is stopped q q q 38 Poppet (11) is pressed by spring (12) against the seat and port (PR) is not connected to (TS). 220-8 .SEN00100-01 Self pressure reducing valve 10 Structure. etc. function and maintenance standard 1 Function q Reduces the discharge pressure of the main pump and supplies it as control pressure for the solenoid valves. PC200. Operation 1.

Pressurized oil flows from port (PR) to orifice (a) in spool (14). When pressure (PR) rises above the set pressure. Pressure (P2) is reduced by the opening at this time and adjusted to a constant pressure (the set pressure) and supplied as pressure (PR). 39 . When pressure (PR) rises above the set pressure. Differential pressure is generated before and after orifice (a) in spool (14) and then spool (14) moves to close the pass between ports (P2) and (PR). 220-8 q q q q q Load pressure (A2) increases with the operation of digging. When load pressure (P2) is high q When load pressure (A2) is lower than self pressure reducing valve output pressure (PR) q q q q q q q q Valve (7) is pressed to the closing direction of circuit between ports (P2) and (A2) by spring (8) and under pressure (PR) (which is 0 MPa{0 kg/cm2}).. opening between ports (P2) and (A2) increases. a balance is reached due to [(φd area x P2 pressure) = force of spring (8) + (φd area x PR pressure)]. PC200. Differential pressure is generated before and after orifice (a) in spool (14) and then spool (14) moves to close the pass between ports (P2) and (PR). function and maintenance standard 2. reducing the engine horsepower loss. etc. poppet (11) opens. Pressure (P2) increases to [(φd area x P2 pressure) > force of spring (8) + (φd area x PR pressure)]. When pressurized oil flows in from port (P2).10 Structure. Adjusts valve (7) opening to keep pressure (P2) at a constant level over pressure (PR). then flows to seal drain port (TS) from poppet (11) opening.. and the pass resistance reduces. poppet (11) opens. Pressurized oil flows from port (PR) to orifice (a) in spool (14). and the pump discharge increases accordingly. During neutral and when load pressure (P2) is low a SEN00100-01 3. and valve (7) moves to the right to the stroke end. then flows to seal drain port (TS) from poppet (11) opening. As a result. Pressure (P2) is reduced by the opening at this time and adjusted to a constant pressure (the set pressure) and supplied as pressure (PR).

solenoid valve and other devices from abnormal pressure. function and maintenance standard 4. ball (16) contracts spring (15) and becomes separated from the seat.SEN00100-01 10 Structure. When abnormally high pressure is generated q q q 40 If pressure (PR) of self pressure reducing valve becomes abnormally high. Allows the pressurized oil to (TS) from port (PR) and lowers pressure (PR). PC200. Protects PPC valve. 220-8 .

H.H. travel circuit) and port (PTR) (R. function and maintenance standard Travel junction valve SEN00100-01 1 1. q When the machine is steered. travel circuit) is closed. When pilot pressure is turned ON Function q This valve connects the L. and travel junction spool (2) moves to the left to the stroke end. 41 .H. outside pilot pressure (PST) closes the travel junction valve to improve steering performance. PC200.H. travel circuits through travel junction valve so that the hydraulic oil will be supplied evenly to both travel motors to improve machine's straight travel performance.10 Structure. q Junction circuit between port (PTL) (L. and R. 220-8 Operation q Pilot pressure from the travel junction solenoid valve contracts spring (1).

SEN00100-01 10 Structure. travel junction spool (2) is pressed by the force of spring (1) against the right side and the pass between ports (PTL) and (PTR) is open. and port (PTR) so that the oil flow rates to both motors will be equalized again. PC200. travel junction spool (2). travel motors become different from each other. function and maintenance standard 2. 42 q If the oil flow rates to the L. 220-8 . When pilot pressure is turned OFF Operation q If pilot pressure (PST) from the solenoid valve is 0. and R.H. the oil flows through the route between port (PTL).H.

digging with arm. q When operated for boom raising (or arm digging. bucket digging. dumping.10 Structure. and bucket using the pilot pressure of travel PPC valve while climbing a steep grade. arm and/or bucket. 220-8 Operation q The oil in stroke regulation signal chamber (a) is drained through orifices (5) and (6) of pistons (3) and (4) in the travel spring case and the travel PPC valve. When travel lever is in neutral Function q Regulates flow to each cylinder by controlling the stroke of each spool of the boom. arm. dumping). raising the boom. bucket-digging or operating dump. 43 . spool (1) moves to the left until it makes contact with the end face of spring casing (2) (st0). q When controlling the stroke of the boom. PC200. function and maintenance standard Travel PPC shuttle valve SEN00100-01 1 1. pilot pressure of travel PPC valve passes through the circuit inside the control valves to actuate the system. dumping.

220-8 . dump). 44 q Maximum stroke of the spool is limited to (st1) for the amount of movement (st2) of piston (8) to the right.SEN00100-01 10 Structure. OUT. q When operated for boom raising (or arm IN. When traveling Operation q If the right travel lever is set in the reverse (or forward) direction. q Spool (7) pushes piston (3) to close orifice (5) and shut off stroke regulation signal chamber (a) and the drain circuit of the travel PPC valve. bucket curl. q At this time. pilot pressure from the PPC valve presses spool (7) to the left (or right). spool (1) moves to the left. PC200. PPC pressure is applied through orifice (6) of piston (4) to the left end of piston (8) to push piston (8) to the right. function and maintenance standard 2. the right travel reverse (or forward) lever is set.

q As a result. function and maintenance standard Boom drift prevention valve SEN00100-01 1 1. pressurized oil from the control valve passes through the opening of poppet (5) and flows to the bottom end of the boom cylinder. pressurized oil from the control valve works on the ring-shaped area (S)[= φ (d1) area – φ (d2) area] caused by the difference between outside diameter (d1) of poppet (5) and seat diameter (d2) to move it to the left.10 Structure. PC200. 220-8 45 . q Contracts spring (4) and poppet (5) moves to the left. Operation q When the boom is raised. When raising boom Function q This valve prevents the oil in the boom cylinder bottom from leaking through spool (1) and the boom from lowering under its weight while the boom lever is not operated.

SEN00100-01 10 Structure. q Pressurized oil from the control valve and the holding pressure of the boom cylinder bottom are shut off. When the boom is in neutral Operation q Moves the lever to neutral with the boom raised. q Pressurized oil flown inside poppet (5) from orifice (a) of poppet (5) is closed by pilot piston (2). q The holding pressure of boom cylinder bottom works on the ring-shaped area (S) caused by the difference between outside diameter (d1) of poppet (5) and seat diameter (d2) to move it to the right. q Pressurized oil from the control valve and the holding pressure of the boom cylinder bottom are shut off. function and maintenance standard 2. 46 PC200. 220-8 . q The sum of this force and the force of spring (4) closes poppet (5).

220-8 47 . function and maintenance standard SEN00100-01 3. q Pressurized oil of the boom bottom flows to orifice (a) o chamber (b) o orifice (c) o drain (T). and the pressurized oil in chamber (b) lowers. When lowering boom Operation q When the boom is lowered. pilot pressure from the PPC valve presses pilot spool (2). PC200. poppet (5) opens. q Pressurized oil from port (B) is led to port (A) and then flows to the control valve. q As the pressure of chamber (b) lowers under the pressure of port (B).10 Structure. q Pressurized oil in chamber (b) inside the poppet is drained through orifice (c).

pressurized oil from the control valve passes through the opening of poppet (5) and flows to the arm cylinder head. pressurized oil from the control valve works on the ringshaped area (S)[= φ (d1) area – φ (d2) area] caused by the difference between the outside diameter (d1) of poppet (5) and the seat diameter (d2) to move it to the left. 220-8 . q Contracts spring (4) and poppet (5) moves to the left. function and maintenance standard 1 1. q As a result. When arm OUT Function q This valve prevents the oil in the arm head from leaking through spool (1) and the boom from lowering under its weight while the arm lever is not operated. 48 PC200. Operation q When the arm OUT is operated.SEN00100-01 Arm drift prevention valve (if equipped) 10 Structure.

10 Structure. 220-8 49 . q Pressurized oil from the control valve and the holding pressure of the arm cylinder head are shut off. PC200. q Pressurized oil from the control valve and the holding pressure of the arm cylinder head are shut off. When the arm is in neutral Operation q Moves the lever to neutral with the arm dumped. function and maintenance standard SEN00100-01 2. q The holding pressure of arm cylinder head works on ring-shaped area (S) caused by the difference between outside diameter (d1) of poppet (5) and seat diameter (d2) to move it to the right. q Pressurized oil flown inside poppet (5) from orifice (a) of poppet (5) is closed by pilot piston (2). q The sum of this force and the force of spring (4) closes poppet (5).

q As the pressure of chamber (b) lowers under the pressure of port (B). q Pressurized oil from port (B) is led to port (A) and then flows to the control valve. pilot spool (2) is pushed under the pilot pressure from the PPC valve. q Pressurized oil of the arm head flows to orifice (a) o chamber (b) o orifice (c) o drain (T). poppet (5) opens. 220-8 . and the pressurized oil in chamber (b) lowers. 50 PC200. q Pressurized oil in chamber (b) inside the poppet is drained through orifice (c). When arm IN Operation q When the arm IN is operated.SEN00100-01 10 Structure. function and maintenance standard 3.

then safety valve (3) operates. function and maintenance standard SEN00100-01 When abnormally high pressure is generated q If abnormally high pressure is generated in the boom cylinder bottom circuit. 51 . pushes check valve (6) or (6A) open to actuate safety valve (3).10 Structure. the pressurized oil in port (B) pushes check valve (6) open. the boom cylinder bottom circuit pressure force or arm cylinder head circuit pressure force. whichever having higher pressurized oil. 220-8 q If arm drift prevention valve (if eguipped) is installed to the arm cylinder head circuit. PC200.

large volume of oil returns from the cylinder bottom. When arm OUT Function q When arm OUT. q q 52 q q q If the pressure of chamber (b) drops lower than that of port (A). PC200. function and maintenance standard Quick return valve 1 1. pressure receiving force of the pressure receiving portion [φd2 area (S2) (seat diameter area)] on the side of port (A) increases by the sum of the pressure receiving force of pressure receiving portion[φd1 area (S1)] on the chamber (b) side of valve (2) and the spring force. q Reduces this pressure loss. From port (B). Or (φd2 pressure receiving force > φd1 pressure receiving force + spring force) Valve (2) is pressed to the right and pressurized oil is led from port (A) to (B). q Pressurized oil of the arm bottom side flows to orifice (a) o chamber (b) o orifice (c) o drain (T). Operation When the arm OUT is operated. q Pressurized oil in chamber (b) inside the valve is drained through orifice (c). pressurized oil is drained directly to the tank. pilot spool (1) is pushed under the pilot pressure from the PPC valve. and the pressure in chamber (b) lowers. 220-8 .SEN00100-01 10 Structure.

10 Structure. When the arm is in neutral Operation q Returning the lever to neutral reduces the pilot pressure from the PPC valve to 0 kg/cm2. PC200. function and maintenance standard SEN00100-01 2. 220-8 53 . q Valve (2) is closed by the total of this force and the force of spring (3). q The pressurized oil that has flowed and been drained through orifice (a) in valve (2) is closed by pilot piston (1). so ports (A) and (B) are shut off. q The holding pressure on the arm bottom side works on the difference between areas (S2) and (S1) of valve (2) to the left.

2. While engine is stopped q q Pressurized oil is not fed to the self pressure reducing valve from the pump. Drain circuit (a) of the control valve is connected with port (T) through orifice (b) of valve (1).SEN00100-01 10 Structure. etc. Valve (1) strikes balance to make the back pressure equal to (PA) in the equation below. function and maintenance standard Lift check valve 1 Function q This valve applies back pressure to the drain circuit to prevent generation of negative pressure on each actuator (motors. At this time. q q Output pressure (PR) of the self pressure reducing valve is applied through the control valve to spring chamber (c) of back pressure valve (3). While engine is running Operation q q 1. Output pressure (PR) applied to spring chamber (c) is applied to the left end of valve (1) (area of φd) to push valve (1) to the right. pressure (PA) of drain circuit (a) of the control valve is applied to the right end of valve (1) (area of φd1) to push valve (1) to the left.). cylinders. 220-8 . PA= 54 (Area of ød) x PR + force of spring (2) Area of ød1 PC200. and valve (1) is pressed to the right by the force of spring (2).

Setting the 1st stage completes the setting of the 2nd stage. PC200. function and maintenance standard Main relief valve 1. 1. q When power is needed. pilot pressure (P) is turned ON and the set pressure becomes higher. 2. Operation q The set pressure of relief valve is determined by spring (1) installed load. raising the set pressure to higher level.10 Structure. SEN00100-01 1 Spring Poppet Function q Set pressure of the relief valve is in two stages. 220-8 55 . If pilot pressure (P) is OFF: Low-pressure setting Set pressure is determined by spring (1) installed load. 2. (1st stage) q Respective setting is not required for both the 1st and 2nd stages. If pilot pressure (P) is ON: High-pressure setting Spring (1) installed load is added with pilot pressure (P) applied to the area of poppet diameter (d1).

56 Since pilot pressure (P) is OFF. 220-8 . PC200. Passage (B) is interconnected to the drain circuit through passage (C) and chamber (D). and make the low-pressure setting smaller. 3.SEN00100-01 10 Structure. 1 Spring Piston Spring Holder Function q Enables to provide the safety valve set pressure in two stages. 2. q Improves work efficiency and reduces machine body vibration. q Enables to relieve a load without lever operation if high load is applied to the cylinder. 4. [Spring (1) installed load < spring (3) installed load] Spring (1) installed load becomes maximum and the set pressure rises. function and maintenance standard 2-stage safety-suction valve [Installed to port (B) of the service valve] 1. piston (2) is pressed to the left by spring (3). If pilot pressure is OFF (high-pressure setting) q q q Operation q The safety set pressure is determined by spring (1) installed load. 1.

10 Structure. This pilot pressure contracts spring (3). the pilot pressure is led to section (A) through passage (B). 220-8 57 . If pilot pressure is ON (low-pressure setting) q q q q q If the pilot pressure (P) is ON. function and maintenance standard SEN00100-01 2. Spring (1) stretches. and piston (2) moves to the right until making contact with holder (4). and the set pressure lowers. Piston (2) works on the pressure-receiving bore portion [(d2) — (d1)] of section (A). installed load is reduced. Pressurized oil proportionate to the piston stroke is drained through passage (C) and chamber (D). PC200.

SEN00100-01 © 2007 KOMATSU All Rights Reserved Printed in Japan 01-07 (01) 58 .SEN00100-01 PC200. 220(LC)-8 Hydraulic excavator Form No.

...........................................................SEN00160-01 HYDRAULIC EXCAVATOR 1SHOP MANUAL PC200-8 PC200LC-8 PC220-8 PC220LC-8 Machine model Serial number PC200-8 PC200LC-8 PC220-8 PC220LC-8 300001 and up 300001 and up 70001 and up 70001 and up 10 Structure........................................................................................................................... 52 Return oil filter .............................................................. 220-8 1 ............................................................. 14 PPC valve . 12 Travel motor ....................................................................................................................................................................................................................................................................................... 31 Service PPC valve (with EPC valve)................................................................................................................................................................................................................... 3 Center swivel joint ............................................................. 48 Solenoid valve.................................... 53 PC200........................................................... function and maintenance standard 1 Hydraulic system.............................................. Part 3 Hydraulic system.................... 25 Work equipment and swing PPC valve ......................................... 3 Swing motor ................................................................................................................................................................................................................................ 50 PPC Accumulator............................. Part 3 .............................................................................. 25 Travel PPC valve...................................................................................................................... 40 Service PPC valve ....................................................... 46 Valve control..............................................................................

... 54 Hydraulic cylinder ...SEN00160-01 10 Structure.......................................................... 220-8 ............................................... 56 2 PC200... function and maintenance standard Attachment circuit selector valve........................................................................................................................

220-8 PC200-8 1. Part 3 1 Swing motor 1 Type: KMF125ABE-6 B: From swing brake solenoid valve MA: From control valve MB: From control valve S: From control valve T: To tank 1.879 rpm 1.4 MPa {290 kg/cm 2} Rated engine speed Brake release pressure PC200. Reverse prevention valve 2.694 rpm 1.4 MPa {14 kg/cm 2} 3 . function and maintenance standard SEN00160-01 Hydraulic system.10 Structure. Safety valve Specifications Models Item Type PC220-8 KMF125ABE-6 Theoretical displacement 125 cm3/rev Safety valve set pressure 28.

SEN00160-01 4 10 Structure. 220-8 . function and maintenance standard PC200.

220-8 Repair limit Free length x Outside diameter Installation length Installation load Free length Installation load 57. 5.2 x 20. 10. 9. 14. Check item Criteria Remedy Standard size 16 17 Check valve spring Shuttle valve spring PC200.0 3. 7.12 kg} If damaged or deformed.10 Structure.9 11.53 N {0. 3.5 13. SEN00160-01 Brake spring Drive shaft Spacer Case Disc Plate Brake piston Housing Piston Cylinder block Valve plate Center shaft Center spring Check valve Shuttle valve Unit: mm No. 15.4 x 8.4 kg} — 11. 5 . 4.84 N {0. replace spring.7 N {1.0 30.29 kg} 16. 6.36 kg} — 2. 12. function and maintenance standard 1.0 N {1. 8. 2. 11. 13.

SEN00160-01 10 Structure. releasing the brake. the valve is switched. q Port (B) is connected to tank circuit (T). When solenoid valve is energized Operation q As the swing holding brake is de-energized. q After entering chamber (a). and the brake is applied. the pressurized oil from the self pressure reducing valve is shut off. When solenoid valve is de-energized 2. 6 PC200. q Disc (5) and plate (6) are pushed together. the pressurized oil compresses brake spring (1) and pushes brake piston (7) up. q The pressurized oil from the self pressure reducing valve is conducted brake chamber (a) through port (B). Operation q As the swing brake solenoid valve is energized. q Brake piston (7) is pushed down by brake spring (1). q Disc (5) is separated from plate (6). 220-8 . function and maintenance standard Swing holding brake 1.

thereby stopping the motor. 220-8 2 When swing is stopped q When the swing control lever is returned to neutral. the pressurized oil from the pump is supplied to port (MA) through control valve (6). the relief valve relieves the abnormally high pressure to port (S) from the motor outlet side (high-pressure side) of the motor. Thus. the relieved pressurized oil and the pressurized oil from port (S) are fed to port (MA) through check valve (3). Function q When the machine is in the swing holding mode. shuttle valves (4) and (5). q The motor output. 7 . q The pressurized oil from the motor outlet can't return to the tank since the returning circuit to the tank is closed from control valve (6). the starting torque is generated in the motor. resulting in damaging the motor. but the motor rotation is continued by inertial force. is abnormally increased. Operation 1 When starting swing q When the swing control lever is operated to the right. the supply of pressurized oil from the pump to port (MA) is stopped. q Above prevents cavitation on port (MA). q Shuttle valve (4) is pressed as pressure on port (MB) goes above port (MA). q In order to prevent the motor damages. control valve (6) closes the motor outlet circuit. therefore. q When relief valve (1) is being actuated. q The pressure on chamber (C) is increased to the se t pr es sure of relief va lv e (1) an d becomes the same as that of port (MB). q Rotation resistance is generated on the motor and hence the brake starts working. q A high braking torque works on the motor. pressure on port (MB) increases. function and maintenance standard SEN00160-01 Relief valve portion Outline q The relief valve portion consists of check valves (2) and (3). q The pressure on port (MA) rises. PC200. and relief valve (1). q The pressurized oil from the outlet port of the motor passes from port (MB) through the control valve (6) and returns to the tank.swing.10 Structure. and the motor starts to rotate.

function and maintenance standard Reverse prevention valve 8 PC200. 220-8 .SEN00160-01 10 Structure.

10 Structure. 3. 7. function and maintenance standard MA: MB: T1: T2: 1. 2. 6. 220-8 9 . 5. SEN00160-01 From control valve From control valve To tank To tank Valve body Spool (MA side) Spring (MA side) Plug (MA side) Spool (MB side) Spring (MB side) Plug (MB side) Explanatory drawing of effects PC200. 4.

When motor is stopped temporarily q The motor rotation is reversed by the closing pressure generated at port (MB). q Port (MA) o chamber (b) will be interconnected. q The valve contributes in preventing collapsing 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). the backlash and rigidity of the machinery system. q Port (MB) o chamber (e) will be interconnected. PC200. thereby preventing the reverse rotation of the 2nd time. Operation 1. (1st time: reverse rotation) q Reversing pressure is generated on port (MA). q The pressure compresses spring (3) by use of the difference in areas of circles (φD3 > φD4) of spool (2) and moves spool (2) to the right side. 220-8 . q Since pressure (MA) is lower than the set pressure of spring (3). and the compression of the hydraulic oil when the swing is stopped. 10 10 Structure. Thus the braking force is ensured. When port (MB) brake pressure is generated q Pressure (MB) is conducted to chamber (d) through notch (g). spool (2) does not move and the pressurized oil is kept in. function and maintenance standard 2. q Ports (b) and (f) will be interconnected through the drilled hole (h) on spool (5). This interconnection bypasses the reversing pressure on port (MA) to port (T).SEN00160-01 Function q This valve reduces the swing back generation in the swing body by the inertia of the swing body. Pressure (MA) is conducted to chamber (a). q The pressure compresses spring (6) by use of the difference in areas of circles (φD1 > φD2) of spool (5) and moves spool (5) to the left side.

10 Structure. function and maintenance standard PC200. 220-8 SEN00160-01 11 .

220-8 .SEN00160-01 Center swivel joint 12 10 Structure. function and maintenance standard 1 PC200.

10 Structure, function and maintenance standard

1.
2.
3.
4.
5.

A1
A2
B1
B2
C1
C2
D1
D2
E
T1
T2

SEN00160-01

Cover
Slipper seal
Body
O-ring
Shaft

: To L.H. travel motor port (PB)
: From control valve port (A5)
: To L.H. travel motor port (PA)
: From control valve port (B5)
: To R.H. travel motor port (PA)
: From control valve port (A2)
: To R.H. travel motor port (PB)
: From control valve port (B2)
: To L.H. and R.H. travel motors port (P)
: From L.H. and R.H. travel motors port (T)
: To tank
Unit: mm

No.

6

Check item
Clearance between rotor and shaft

PC200, 220-8

Criteria

Remedy

Standard size

Standard clearance

Clearance limit

80

Replace

13

SEN00160-01

10 Structure, function and maintenance standard

Travel motor

1

Type: HMV110ADT-3

B
MA
MB
P
PA
PB
T

: Brake release pressure port
: MA pressure detection port
: MB pressure detection port
: From travel speed solenoid valve
: From control valve
: From control valve
: To tank

Specifications
Models
Item
Type
Theoretical
displacement Max.
Rated pressure

14

PC220-8

HMV110ADT-3
Min.

Rated speed

PC200-8

78.6 cm3/rev
3

106.2 cm /rev

74 cm3/rev
110.7 cm3/rev

37.3 MPa {380 kg/cm2}

Capacity min.

2,805 rpm

3,046 rpm

Capacity max.

1,842 rpm

1,588 rpm

Brake release pressure

1.18 MPa {12 kg/cm2}

Travel speed
Differential
selector prespressure
sure

0.78 MPa {8 kg/cm2}

PC200, 220-8

10 Structure, function and maintenance standard

PC200, 220-8

SEN00160-01

15

SEN00160-01

16

10 Structure, function and maintenance standard

PC200, 220-8

10 Structure, function and maintenance standard

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.

SEN00160-01

Regulator piston
Spring
Regulator valve
Motor case
Suction safety valve
Check valve
Output shaft
Rocker cam
Retainer guide
Pin
Retainer
Piston
Cylinder block
Valve plate
Counterbalance valve
Ring
Brake piston
Plate
Disc
Ball
Unit: mm

No.

Check item

Criteria

Remedy

Standard size

21

Check valve spring

Repair limit

Free length x
Outside diameter

Installation
length

Installation
load

Free length

Installation
load

32.5 x 6.5

24.2

7.16 N
{0.73 kg}

5.69 N
{0.58 kg}

22

Check valve spring

13.0 x 6.5

9.5

1.96 N
{0.2 kg}

1.57 N
{0.16 kg}

23

Spool return spring

58.4 x 30

42

427 N
{43.5 kg}

341 N
{34.8 kg}

24

Regulator valve spring

21.5 x 11.1

17.1

54.9 N
{5.6 kg}

43.9 N
{4.48 kg}

PC200, 220-8

If damaged or
deformed, replace
spring.

17

SEN00160-01

10 Structure, function and maintenance standard

Operation of motor
1) At slow speed (motor swash plate angle at maximum)

q

q
q

q

18

As the solenoid valve is de-energized, the pilot
pressurized oil from the self pressure reducing
valve does not flow to port (P).
Regulator valve (9) is pushed to the right by
spring (10).
Pressurized oil being conducted from the control valve to end cover (8) by pressing check
valve (22) is shut off by regulator valve (9).
Fulcrum (a) of rocker cam (4) is eccentric to
the working point (b) of the combined force of
the propulsion force of cylinder (6).

q

q

q

The combined force of the piston propulsion
forces works as the moment of inclining rocker
cam (4) toward the maximum swash plate
angle.
The pressurized oil at regulator piston (15)
passes through orifice (c) of regulator valve (9)
and is drained to the motor case.
Rocker cam (4) is inclined in the maximum
swash plate angle direction. The motor capacity becomes maximum, turning on the low
speed travel.

PC200, 220-8

10 Structure, function and maintenance standard

SEN00160-01

2) At high speed (motor swash plate angle at minimum)

q

q
q

q
q

As the solenoid valve is energized, the pilot
pressurized oil from the self pressure reducing
valve flows to port (P).
Regulator valve (9) is pushed to the left.
The pressurized oil from the control valve
passes through passage (d) in regulator valve
(9) and enters regulator piston (15).
Regulator piston (15) is pushed to the right.
Rocker cam (4) is inclined in the minimum
swash plate angle direction. The motor capacity becomes minimum, turning on the high
speed travel.

PC200, 220-8

19

SEN00160-01

10 Structure, function and maintenance standard

Operation of parking brake
1) When starting travel

q

q

q

20

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

PC200, 220-8

10 Structure, function and maintenance standard

SEN00160-01

2) When travel is stopped

q

q

q
q
q
q

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

PC200, 220-8

21

SEN00160-01

10 Structure, function and maintenance standard

Brake valve

Operation when pressurized oil is supplied
q
Operating the travel lever conducts the pressurized oil from the control valve to port (PA).
q
The pressurized oil push-opens suction safety
valve (18A) and then flows to motor outlet port
(MB) through motor inlet port (MA).
q
The motor outlet side is closed by suction
safety valve (18B) and spool (19), so the pressure at the supply side rises.

q
q

The brake valve consists of suction safety
valve (18A) and counterbalance valve (18).
Functions and operations of respective components shall conform to the following.

1) Counterbalance valve and check valve
Function
q
When traveling downhill, the machine travel
speed tends to get faster than the motor
(engine) speed because of the downward force
generated from its own weight.
q
If the machine travels with the engine at low
speed, the motor may rotate without load,
causing the machine to run away; resulting in a
very dangerous situation.
q
These valves are used to prevent above by
controlling the machine to travel according to
the engine speed (pump delivery).

22

PC200, 220-8

10 Structure, function and maintenance standard

q

q

q

The pressurized oil on the supply side flows to
chamber (S1) through orifice (E1) and orifice
(E2) of the spool (19).
As the pressure in chamber (S1) goes above
the spool selector pressure, spool (19) is
pushed toward right.
Port (MB) and port (PB) are connected, opening the motor outlet port side and starting the
motor rotating.

PC200, 220-8

SEN00160-01

Operation of brake during travelling downhill
q
If indication of the machine runaway is sensed
while travelling downhill, the motor will be
caused to rotate without load to decrease the
inlet side oil pressure.
q
Pressure in chamber (S1) is released through
orifices (E1) and (E2).
q
As the pressure in chamber (S1) goes below
the spool selector pressure, spool (19) is
returned to the left by spring (20) and outlet
port (MB) is throttled.
q
The pressure at the outlet port side rises, generating rotation resistance on the motor to prevent the machine from running away.
q
The spool moves to a position where the pressure on outlet port (MB) can be balanced
against the machine's own weight and the inlet
port pressure.
q
Oil flow from the outlet circuit is reduced to
ensure the travel speed corresponded to the
pump delivery.

23

SEN00160-01

10 Structure, function and maintenance standard

2) Safety valve

q

Function
q
As long as the machine travel is stopped (or it
is travelling downhill), the counterbalance
valve closes the inlet and outlet circuits of the
motor.
q
Since the motor is rotated by inertial force,
pressure in the motor outlet port side is abnormally increased, potentially resulting in damages on the motor and piping.
q
The safety valve releases this abnormal pressure to the inlet port side of the motor in order
to prevent damages to the equipment.

q

Operation
(1) When travel is stopped
(or when travelling downhill) (Right swing)
q
Reduction of the pressure at motor inlet (PA)
decreases the pressure in chamber (S1).
q
When it drops beyond the spool switching
pressure, spool (19) is returned to the left by
spring (20), reducing the pressure at outlet
passage (B1).
q
The motor tries to continue rotation resorting to
inertial force, thus pressure on the outlet port
(MB) is increased.

24

q

When the pressure rises above the set pressure
of the suction safety valve, poppet (1) opens.
The pressurized oil passes through notch (A1)
of spool (19) into chamber (MA) of the circuit at
the opposite side.
At the time of counterclockwise rotation, it
makes reverse operation of clockwise rotation.

(2) When starting travel
(or when traveling at a constant speed)
q
As the travel lever is operated, the pressurized
oil from the pump moves spool (19) toward right.
q
The passage to the suction safety valve functions as a circuit which passes through notch
(B2) of spool (19), producing large differential
pressure.
q
The pump pressure rises, providing a large
tractional force to the valve.

PC200, 220-8

10 Structure, function and maintenance standard

PPC valve

SEN00160-01

1

Work equipment and swing PPC valve 1

P:
P1:
P2:
P3:
P4:
T:

From self pressure reducing valve
L.H. PPC valve: Arm OUT port/R.H. PPC valve: Boom LOWER port
L.H. PPC valve: Arm IN port/R.H. PPC valve: Boom RAISE port
L.H. PPC valve: Swing LEFT port/R.H. PPC valve: Bucket CURL port
L.H. PPC valve: Swing RIGHT port/R.H. PPC valve: Bucket DUMP port
To tank

PC200, 220-8

25

SEN00160-01

26

10 Structure, function and maintenance standard

PC200, 220-8

10 Structure, function and maintenance standard

1.
2.
3.
4.
5.
6.
7.
8.
9.

SEN00160-01

Spool
Piston
Disc
Nut (for lever connection)
Joint
Plate
Retainer
Body
Filter
Unit: mm

No.

Check item

Criteria

Remedy

Standard size

10

Centering spring
(for ports P3 and P4)

Repair limit

Free length
x Outside
diameter

Installation
length

Installation
load

Free length

Installation
load

42.5 x 15.5

34.0

17.7 N
{1.80 kg}

14.1 N
{1.44 kg}

11

Centering spring
(for ports P1 and P2)

44.5 x 15.5

34.0

29.4 N
{3.0 kg}

23.5 N
{2.40 kg}

12

Metering spring

26.5 x 8.15

24.9

16.7 N
{1.70 kg}

13.3 N
{1.36 kg}

PC200, 220-8

If damaged or
deformed,
replace spring.

27

SEN00160-01

Operation

10 Structure, function and maintenance standard

q

1. When in neutral
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

The relationship of the position of spool (1) and
body (10) [fine control hole (f) is in the middle
between drain chamber (D) and pump pressure chamber (PP)] does not change until
retainer (9) contacts spool (1).
Metering spring (2) contracts in proportion to
the stroke of the control lever.
Pressure at port (P1) also rises in proportion to
the stroke of the control lever.
In this way, the control valve spool moves to a
position where the pressure of chamber (A)
(same as pressure at port (P1)) and the force
of the return spring of the control valve spool
are balanced.

2. During fine control
(Neutral o fine control)
q

q

q

q

q

28

When piston (4) is pushed by disc (5), retainer
(9) is pushed, spool (1) is also pushed by
metering spring (2), and moves down.
When fine control hole (f) is shut off from drain
chamber (D), it is almost simultaneously interconnected to pump pressure chamber (PP).
Pilot pressurized oil of the control pump is led
to port (A) from port (P1) through fine control
hole (f).
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).
As a result, spool (1) moves up and down until
the force of metering spring (2) is balanced
with the pressure at port (P1).

PC200, 220-8

10 Structure, function and maintenance standard

3. During fine control
(When control lever is returned)
q

q

q

q

q

q

When disc (5) starts to be returned, spool (1) is
pushed up by the force of centering spring (3)
and the pressure at port (P1).
Because of this, fine control hole (f) is connected to drain chamber (D), and the pressurized oil at port (P1) is released.
If the pressure of port (P1) is lowered excessively, spool (1) is pushed down by metering
spring (2).
Fine control hole (f) is shut off from drain
chamber (D), and it is almost simultaneously
interconnected to pump pressure chamber
(PP).
Pump pressure is supplied until the pressure at
port (P1) recovers to the level equivalent to the
lever position.
When the spool of the control valve returns,
the oil in drain chamber (D) flows in from fine
control hole (f') in the valve on the side that is
not working. The oil passes through port (P2)
and enters chamber (B) to replenish the chamber with pressurized oil.

PC200, 220-8

SEN00160-01

4. At full stroke
q
q

q

q

Disc (5) pushes down piston (4), and retainer
(9) pushes down spool (1).
Fine control hole (f) is shut off from drain
chamber (D), and is interconnected to pump
pressure chamber (PP).
Therefore, the pilot pressure oil from the self
pressure reducing valve passes through fine
control hole (f) and flows to chamber (A) from
port (P1) to push the control valve spool.
The oil returning from chamber (B) passes
from port (P2) through fine control hole (f') and
flows to drain chamber (D).

29

SEN00160-01

30

10 Structure, function and maintenance standard

PC200, 220-8

10 Structure, function and maintenance standard

Travel PPC valve

P:
P1:
P2:
P3:
P4:
P5:
P6:
T:

SEN00160-01

1

From self pressure reducing valve
L.H. travel REVERSE port
L.H. travel FORWARD port
R.H. travel REVERSE port
R.H. travel FORWARD port
Travel signal port
Steering signal port
To tank

PC200, 220-8

31

SEN00160-01

32

10 Structure, function and maintenance standard

PC200, 220-8

10 Structure, function and maintenance standard

1.
2.
3.
4.
5.
6.
7.

SEN00160-01

Plate
Body
Piston
Collar
Valve
Damper
Steering signal spool
Unit: mm

No.

Check item

Criteria

Remedy

Standard size

8

9
10

Repair limit

Free length
x Outside
diameter

Installation
length

Installation
load

Free length

Installation
load

48.6 x 15.5

32.5

108 N
{11.0 kg}

86.3 N
{8.8 kg}

Metering spring

26.5 x 8.15

24.9

16.7 N
{1.7 kg}

13.3 N
{1.36 kg}

Steering signal spring

12.8 x 7.3

8.5

8.83 N
{0.9 kg}

7.06 N
{0.72 kg}

Centering spring

PC200, 220-8

If damaged or
deformed,
replace spring.

33

2) During fine control (Neutral o fine control) q When piston (4) is pushed by lever (5). q As a result. q When fine control hole (f) is shut off from drain chamber (D). retainer (9) is pushed. Pressure reducing valve function 10 Structure. and moves down. 220-8 . q Pilot pressurized oil of the control pump is led to port (A) from port (P1) through fine control hole (f). q q q The relationship of the position of spool (1) and body (10) [fine control hole (f) is in the middle between drain chamber (D) and pump pressure chamber (PP)] does not change until retainer (9) contacts spool (1). q When the pressure at port (P1) becomes higher. 34 PC200. Pressure at port (P1) also rises in proportion to the stroke of the control lever. it is connected to drain chamber (D) to release the pressure at port (P1). In this way. spool (1) is also pushed by metering spring (2). it is almost simultaneously interconnected to pump pressure chamber (PP). spool (1) is pushed back and fine control hole (f) is shut off from pump pressure chamber (PP). Metering spring (2) contracts in proportion to the stroke of the control lever. spool (1) moves up and down until the force of metering spool (2) is balanced with the pressure at port (P1). function and maintenance standard q Operation 1) When in neutral 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). the control valve spool moves to a position where the pressure of chamber (A) (same as pressure at port (P1)) and the force of the return spring of the control valve spool are balanced. At almost the same time.SEN00160-01 1.

2. travel levers is operated. The oil returning from chamber (B) passes from port (P2) through fine control hole (f') and flows to drain chamber (D).10 Structure. the oil in drain chamber (D) flows in from fine control hole (f') in the valve on the side that is not working. whether the machine is being steered is judged by the signal of port (P6). Pump pressure is supplied until the pressure at port (P1) recovers to the level equivalent to the lever position. the higher PPC output pressure of both sides is output as the travel signal. Fine control hole (f) is shut off from drain chamber (D). SEN00160-01 q q Therefore. the pilot pressure oil from the self pressure reducing valve passes through fine control hole (f) and flows to chamber (A) from port (P1) to push the control valve spool. q Accordingly. whether the machine is travelling is judged by the signal of port (P5). Travel signal/Steering function Travel signal q If either of the L. or R. The oil passes through port (P2) and enters chamber (B) to replenish the chamber with pressurized oil. 4) At full stroke q q Lever (5) pushes down piston (4). t h e hi g h e r o ne o f t h e P P C o u tp u t pressures of both sides is output as the steering signal. 35 . and it is almost simultaneously interconnected to pump pressure chamber (PP). and is interconnected to pump pressure chamber (PP). and the pressurized oil at port (P1) is released. 220-8 Steering signal q If the operation quantities of both levers are different from each other as in the steering operati o n . q Accordingly. fine control hole (f) is connected to drain chamber (D).H. Because of this.H. When the spool of the control valve returns. and retainer (9) pushes down spool (1). spool (1) is pushed down by metering spring (2). q Any signal is not output from port (P6) while the machine is travelling straight (forward or reverse) or in neutral. If the pressure of port (P1) is lowered excessively. Fine control hole (f) is shut off from drain chamber (D). spool (1) is pushed up by the force of centering spring (3) and pressure at port (P1). function and maintenance standard 3) During fine control (When control lever is returned) q q q q q q When lever (5) starts to be returned. PC200.

travel signal [port (P5)] and steering signal [port (P6)]. PC200. 220-8 . function and maintenance standard Operation 1) When in neutral q 36 No output is made from respective output ports [from port (P1) to (P4)].SEN00160-01 10 Structure.

220-8 37 . function and maintenance standard SEN00160-01 2) During straight travel a The Illustration shows the circuit for travelling straight forward. spring chamber (k) and R. motor forward [port (P2) output] and R. pressure of both L. q When operating L.H. q PC200. Steering signal spool (j) remains at neutral position and does not output a steering signal to port (P6). spring chamber (l) rises high.10 Structure.H. motor forward [port (P4) output].H.H.

whichever having a higher output pressure. the spool is switched to the direction of the arrow.H. is output to port (P6) as the steering signal. q If the operation quantities of both levers are different from each other as in the steering operation (if the difference of the pilot pressure between both sides is higher than a certain level). or R. PPC valves. The pressure in right spring chamber (l) is (P4).SEN00160-01 10 Structure. 220-8 . PC200.H. The pressure in left spring chamber (k) of steering signal spool (j) is (P2). the pilot pressure is output as the steering signal. When the pressure state reaches [(P4 – P2) x (Spool section) > Spring set load]. function and maintenance standard 3) When steered or pivot-turned a The Illustration shows the circuit for travelling left forward (slow) and right forward (fast) operation. q q q 38 q Port (P4) pressure of the L.

Steering signal spool (j) strokes to the left to output the steering signal to port (P6). q When operating L.H. 220-8 39 . motor forward [port (P4) output].H. q PC200. spring chamber (l) only rises high.H.10 Structure. function and maintenance standard SEN00160-01 4) When counter-rotated a The illustration shows the circuit for travelling left reverse and right forward. motor reverse [port (P1) output] and R. pressure of the R.

function and maintenance standard 1 For the details of operation.” PC200. see the paragraph of “Work equipment swing PPC valve. 220-8 .SEN00160-01 Service PPC valve (with EPC valve) a 40 10 Structure.

6. 3. 5.2 kg} 33.4 125 N {12. replace spring.10 Structure. 7.7 kg} — 100 N {10. 4. function and maintenance standard P: P1: P2: T: From self pressure reducing valve To service valve To service valve To tank 1. Spool Piston Lever Plate Retainer Block Body EPC valve SEN00160-01 Unit: mm No.7 x 8.3 22.7 N {1. Check item Criteria Remedy Standard size 9 10 Centering spring Metering spring PC200.0 16. 8.10 22. 2.9 x 15. 41 .36 kg} If damaged or deformed.3 N {1.70 kg} — 13. 220-8 Free length x Outside diameter Repair limit Installation length Installation load Free length Installation load 28.

7. Spool Push pin Coil Plunger Connector Unit: mm No.SEN00160-01 10 Structure. PC200. Check item Criteria Remedy Standard size 8 42 Return spring Repair limit Free length Installation length Installation load Free length Installation load 9. 2.1 N {0.32 kg} — — If damaged or deformed. 5. EPC valve C: P: T: To control valve From self pressure reducing valve To hydraulic tank 1. Body Plug 3. function and maintenance standard 1.4 3. replace EPC valve assembly.0 8. 220-8 . 6. 4.

Spool (11) is pushed to the right by spring (12). The pressurized oil from the control valve is drained to the tank through port (C) and port (T).10 Structure. q When it receives signal current (i) from the pump controller. and outputs it to the control valve. Port (P) closes and the pressurized oil from the front pump does not flow to the control valve. 43 . function and maintenance standard Function q The EPC valve consists of the proportional solenoid portion and the hydraulic valve portion. 220-8 When there is no signal current flowing from the controller to coil (14). it generates the EPC output pressure in proportion to the size of the signal. coil (14) is de-energized. SEN00160-01 Operation 1) When signal current is 0 (coil is de-energized) q q q q PC200.

The circuit pressure between the EPC valve and the control valve is controlled in proportion to the size of the signal current. Spool (2) is pushed to the left by push pin (4). Since port (T) is closed. 220-8 . coil (5) is energized. and pressurized oil flows from port (P) to port (C). Push pin (4) pushes spool (2) to the left. pressurized oil does not flow to the hydraulic tank. coil (5) is energized. Spool (2) moves up and down so that the propulsion force of plunger (6) may be balance with pressure of port (C) + spring load of spring (3). so the propulsion force of plunger (6) is also at its maximum. and a propulsion force is generated on the left side of plunger (6).SEN00160-01 2) When signal current is very small (coil is energized) q q q q q q 44 When a very small signal current flows to coil (5). When this happens. function and maintenance standard 3) When signal current is maximum (coil is energized) q q q q q As the signal current flows to coil (5). Pressures on port (C) increases and the force to act on surface (a) of spool (2) and the spring load on spring (3) become larger than the propulsion force of plunger (6). Spool (2) is pushed to the right. The maximum volume of pressurized oil is conducted from port (P) to port (C). increasing the circuit pressure across EPC valve and the control valve to the maximum level. 10 Structure. PC200. port (P) is shut off from port (C) and ports (C) and (T) are connected. the signal current is at its maximum.

function and maintenance standard PC200. 220-8 SEN00160-01 45 .10 Structure.

220-8 . function and maintenance standard 1 For the details of operation. see the paragraph of “Work equipment and swing PPC valve“. PC200.SEN00160-01 Service PPC valve a 46 10 Structure.

47 . Check item Criteria Remedy Standard size 7 8 Centering spring Metering spring PC200. 5.4 125 N {12.36 kg} Installation length Installation load 33. Spool Piston Lever Plate Retainer Body SEN00160-01 Unit: mm No. 6. replace spring.0 16.10 Structure.10 If damaged or deformed.9 x 15.70 kg} — 13.7 N {1.3 N {1. 4.2 kg} 22. 2. 220-8 Free length x Outside diameter Repair limit Free length Installation load 28. 3.7 kg} — 100 N {10. function and maintenance standard P: P1: P2: T: From self pressure reducing valve To service valve To service valve To tank 1.7 x 8.3 22.

function and maintenance standard 1 PC200. 220-8 .SEN00160-01 Valve control 48 10 Structure.

PPC valve Lever positions A. 10. SEN00160-01 Travel PPC valve Service PPC valve Service pedal L. 6. 220-8 49 . PPC valve R. 11. Travel “FORWARD” PC200. Travel “REVERSE” N. 5. Neutral G. function and maintenance standard 1.H. 3. 14. Bucket “CURL” F. Neutral M. Swing “RIGHT” K. Swing “LEFT” L. 13. 8. 12.H. 4.H.H.10 Structure. Arm “OUT” J. Boom “RAISE” C. travel lever R. 2. 9. travel lever R.H. Bucket “DUMP” E. 7. Boom “LOWER” D. Neutral B. work equipment control lever Solenoid block Accumulator Control valve Hydraulic pump Junction box L. Arm “IN” H.H. work equipment control lever L.

function and maintenance standard 1 PPC lock. travel junction. ATT selector. swing brake. and 2-stage relief solenoid valves 50 PC200. 220-8 .SEN00160-01 Solenoid valve 10 Structure. travel speed.

5. 220-8 51 . the oil from the actuator is drained through ports (A) and (T) into the tank.H. 4. pressurized oil from the main pump does not flow to the actuator. 3. 11. port (T) closes. 8. For this reason. At the same time. solenoid (9) is de-energized. 9. Accordingly. Since port (P) is closed to port (A). via inside spool (10). spool (10) is pushed to the right. 7.10 Structure. PC200.H. to port (A). This operation flows the pressurized oil from the main pump. function and maintenance standard 1. At this time. 6. To tank To PPC valve To main valve (2-stage relief valve) To swing motor To L. travel motors To main valve (Travel junction valve) To ATT selector valve From main pump To accumulator Operation When solenoid is de-energized q Since the signal current does not flow from the controller. spool (10) is pushed to the left by spring (12). and eventually to the actuator. solenoid (9) is energized. and R. 10. 12. PPC lock solenoid valve 2-stage relief solenoid valve Swing brake solenoid valve Travel speed solenoid valve Travel junction solenoid valve ATT selector solenoid valve Connector Moving core Coil Spool Block Spring T: A1: A2: A3: A4: A5: A6: P1: ACC: SEN00160-01 When solenoid is energized q As the signal current flows from the controller to solenoid (9). 2. through port (P). the oil does not flow to the tank.

5. 6. 4. 10 Structure. function and maintenance standard 1 Gas plug Shell Poppet Holder Bladder Oil port Specifications Gas capacity: 300 cc (for PPC) 52 PC200.SEN00160-01 PPC Accumulator 1. 3. 220-8 . 2.

10 Structure. 5.5 kg/cm2} Filter mesh size: 6 mm Filtering area: 4. 220-8 Specifications Rated pressure: 6. Drain plug Filter Case Head cover Relief valve PC200. 4.9 MPa {70 kg/cm2} Flow rate: 200 l/min Relief valve cracking pressure: 0. 3.570 cm2 53 . function and maintenance standard Return oil filter SEN00160-01 1 For breaker 1.34 ± 0.5 ± 0.05 MPa {3. 2.

replace spring.0 kg} If damaged or deformed.5 834 N {85.SEN00160-01 10 Structure. 220-8 .0 kg} — 667 N {68. Check item Criteria Remedy Standard size 2 54 Spool return spring Repair limit Free length x Outside diameter Installation length Installation load Free length Installation load 132 x 29 114. PC200. function and maintenance standard Attachment circuit selector valve ACC: ATT: P1: T: TS: V: 1. 1 To accumulator To attachment From attachment selector solenoid valve To hydraulic tank To hydraulic tank To control valve Spool Unit: mm No.

the return oil from the breaker does not pass through the main valve. Ports (ATT) and (V) are shut off and ports (ATT) and (T) are interconnected. and spool (1) moves to the right to the stroke end. Attachment is thus interconnected to the control valve. 220-8 55 . function and maintenance standard Function q When a breaker is installed. but returns directly to the hydraulic tank. When breaker is installed q q q Operation 1. the attachment and the main valve are interconnected.10 Structure. Pressurized oil returning from the breaker returns directly to the hydraulic tank through port (T) without passing through the control valve. Spool (1) is pressed to the left by the force of spring (2). SEN00160-01 2. etc.) are installed. Ports (ATT) and (V) are interconnected and ports (ATT) and (T) are shut off. PC200. q When other attachments (crusher. When attachment other than breaker is installed q q Pilot pressure from the attachment circuit selector solenoid valve contracts spring (2).

SEN00160-01 Hydraulic cylinder 10 Structure. 220-8 . function and maintenance standard 1 PC200-8 and PC200LC-8 Boom cylinder Arm cylinder Bucket cylinder 56 PC200.

030 –0.222 +0.312 0.030 –0.036 –0.036 –0.070 0.(PC200-8) ton rod and bushing Arm Clearance between piston rod support shaft and bushing Clearance between cylinder bottom support shaft and bushing PC200.100 – 0.083 – 0.047 0.090 +0.10 Structure.090 +0.190 +0. 220-8 Tolerance Shaft Cylinder Standard size Remedy Replace bushing Replace pin or bushing 57 .030 –0.0 Boom 70 –0.076 +0.076 +0.076 +0.060 +0.412 95 –0.170 +0.075 – 0.225 1.077 – 0.047 0.398 Boom 80 –0. Check item Criteria 1 2 Hole Standard clearance Clearance limit 85 –0.298 0.076 +0.060 +0.222 +0.100 – 0. function and maintenance standard SEN00160-01 Unit: mm No.070 0.190 +0.100 – 0.222 +0.030 –0.030 –0.047 0.190 +0.312 0.250 1.045 0.060 +0.0 Boom Clearance between pis.070 0.412 Bucket 80 –0.266 1.165 +0.0 3 Arm 80 –0.225 1.075 – 0.030 –0.100 – 0.0 Arm 80 –0.0 Bucket 70 –0.070 0.045 0.0 Bucket 70 –0.030 –0.083 – 0.165 +0.266 1.246 1.

SEN00160-01 PC220-8 and PC220LC-8 Boom cylinder Arm cylinder Bucket cylinder 58 .

190 +0.090 +0.437 Arm 100 –0.257 +0.246 1.175 +0.257 +0.084 – 0.190 +0.100 – 0.084 – 0.190 +0.447 Bucket 90 –0. function and maintenance standard SEN00160-01 Unit: mm No.0 Arm 80 –0.0 Boom 80 –0.048 0.250 1.347 0.0 Bucket 80 –0.075 – 0.10 Structure.030 –0.100 – 0.076 +0.030 –0. 220-8 Criteria Cylinder Standard size Boom Tolerance Remedy Shaft Hole Standard clearance Clearance limit 90 –0.060 +0.030 –0.0 Bucket 80 –0.047 0.225 1.076 +0. 1 2 3 Check item Clearance between piston rod and bushing Clearance between piston rod support shaft and bushing Clearance between cylinder bottom support shaft and bushing PC200.347 0.048 0.100 – 0.030 –0.030 –0.030 –0.060 +0.070 0.075 0.083 – 0.266 1.036 –0.070 0.347 0.070 0.036 –0.225 1.070 0.100 – 0.075 – 0.070 0.036 –0.190 +0.076 +0.090 +0.0 Replace bushing Replace pin or bushing 59 .0 Arm 80 –0.447 Boom 80 –0.076 +0.257 +0.190 +0.090 +0.266 1.

function and maintenance standard PC200.SEN00160-01 10 Structure. 220-8 . 220(LC)-8 Hydraulic excavator Form No. SEN00160-01 © 2007 KOMATSU All Rights Reserved Printed in Japan 01-07 (01) 60 PC200.

.. 220-8 1 ......... 2 PC200................................................................ 2 Dimensions of components .................................................................................................................................................................SEN00101-00 HYDRAULIC EXCAVATOR 1SHOP MANUAL PC200-8 PC200LC-8 PC220-8 PC220LC-8 Machine model Serial number PC200-8 PC200LC-8 PC220-8 PC220LC-8 300001 and up 300001 and up 70001 and up 70001 and up 10 Structure.. function and maintenance standard 1 Work equipment Work equipment .....................

function and maintenance standard Work equipment Dimensions of components 2 1 1 PC200.SEN00101-00 10 Structure. 220-8 .

213 1.113 – 0.036 –0.0 5 Clearance between pin connecting link and bucket and bushing 80 –0.077 0.076 +0.135 +0.209 1. 220-8 Replace 3 .076 +0.076 +0. function and maintenance standard SEN00101-00 PC200-8. PC200LC-8 Unit: mm No.166 +0.071 +0.116 – 0. PC220LC-8 Unit: mm No.0 2 Clearance between pin connecting boom and arm and bushing 90 –0.242 1.086 0.108 – 0.206 1.137 +0.074 0.208 1. 1 Check item Clearance between pin connecting boom and revolving frame and bushing Criteria Standard size Tolerance Remedy Shaft Hole Standard clearance Clearance limit 100 –0.076 +0.230 1.0 4 Clearance between pin connecting arm and bucket and bushing 80 –0.066 0.071 +0.086 0.078 0.166 +0.074 0.104 – 0.030 –0.154 +0.0 6 Clearance between pin connecting links and bushing 80 –0.074 0.166 +0.071 +0.030 –0.158 +0.030 –0.036 –0.10 Structure.0 4 Clearance between pin connecting arm and bucket and bushing 80 –0.086 0.0 5 Clearance between pin connecting link and bucket and bushing 80 –0.0 Replace PC220-8.074 0.213 1.071 +0.096 – 0.030 –0.234 1.030 –0.030 –0.076 +0.076 +0.166 +0.036 –0.0 6 Clearance between pin connecting links and bushing 70 –0.208 1. 1 Check item Clearance between pin connecting boom and revolving frame and bushing Criteria Standard size Tolerance Remedy Shaft Hole Standard clearance Clearance limit 90 –0.078 0.242 1.0 PC200.104 – 0.036 –0.137 +0.0 2 Clearance between pin connecting boom and arm and bushing 90 –0.114 – 0.0 3 Clearance between pin connecting arm and link and bushing 70 –0.138 +0.104 – 0.242 1.030 –0.0 3 Clearance between pin connecting arm and link and bushing 80 –0.242 1.077 0.116 – 0.110 – 0.113 – 0.137 +0.076 +0.030 –0.116 – 0.076 +0.137 +0.

4 10 Structure.SEN00101-00 1. function and maintenance standard Dimension of arm PC200. 220-8 .

1 +0.3 +1.5 206.5 –0.551.7 — 15 φ80 +0.6 — 9 2.800 — 2.5 4 φ90 +0. function and maintenance standard SEN00101-00 Unit: mm No.5 17 φ80 +0.1 +0.10 Structure.5 –0.2 582.0 φ80 +0.1 ±1 918. 2.5 13 458.919 — 3.5 –0.3 — 14 1.000 φ90 +0. 220LC-8 Standard size Tolerance Standard size Tolerance 1 φ80 +0.1 16 325 ±0.0 φ80 +0.1 ±1 419.5 –0.5 +0.5 –0.5 ±1 2.5 600 ±0.5 311 –0.5 305.0 φ80 +0. 200LC-8 PC220-8.1 Arm itself 311 –0.2 12 600 ±0. 1.5 ±0.1 3 305.8 ±1 10 410 ±1 465 ±1 11 640 ±0.562.605 — Max.054 +0.1 +0.486 — 1.1 +0.625 — 19 PC200.1 2 109.6 ±1 8 2.054 5 402.037.5 325 ±0.054 +0.9 ±1 6 187.1 ±0.5 –0.5 7 829. 220-8 5 .5 When press fitting bushing 325 — 325 — Min. 18 PC200-8.1 — 446.630.5 +0.1 +0.1 +0.3 +1.0 109.2 ±0.680 — 1.

220-8 . function and maintenance standard Dimension of bucket PC200.SEN00101-00 2. 6 10 Structure.

3 — 5 1.1 φ80 +0.5 ±1 326.1 — 446.5 — 15 φ140 — φ140 — 16 φ190 — φ190 — 17 133. 220-8 7 . 220LC-8 Standard size Tolerance Standard size Tolerance 457.6 — 133.3 — 18 131.5 ±1 11 56 — 59 — 12 106 — 104 — 13 470 — 470 — 14 φ23.3 — 1.5 +2 +0 348.10 Structure.1 +0. 200LC-8 PC220-8.5 — φ23.5 3 92° 45’ — 97° 37’ — 4 458.1 — 19 107 — 107 — 20 85 — 82 — 21 348.5 59.6 — 185.4 ±0.2 — 156.6 — 7 — — — — 8 15° 54’ — 7° 48’ — 9 φ80 +0.5 — 6 158.1 10 326. function and maintenance standard SEN00101-00 Unit: mm No.5 2 22 ±0.2 ±0.477.1 +0.6 ±0.5 +2 +0 22 38 — 37 — 1 PC200.540.5 442. PC200-8.

SEN00101-00 © 2005 KOMATSU All Rights Reserved Printed in Japan 09-05 (01) 8 .SEN00101-00 PC200. 220(LC)-8 Hydraulic excavator Form No.

..... 2 PC200...................................................................................................... function and maintenance standard 1 Cab and its attachments Cab and its attachments ..................................... 220-8 1 ............................................. 2 Air conditioner piping..............................................SEN00102-00 HYDRAULIC EXCAVATOR 1SHOP MANUAL PC200-8 PC200LC-8 PC220-8 PC220LC-8 Machine model Serial number PC200-8 PC200LC-8 PC220-8 PC220LC-8 300001 and up 300001 and up 70001 and up 70001 and up 10 Structure.....................

SEN00102-00 10 Structure. 5. 3. 7. 4. 6. 220-8 . 2. function and maintenance standard Cab and its attachments Air conditioner piping 1. 2 Air conditioner unit Hot water pickup piping Air conditioner compressor Refrigerant piping Condenser Hot water return piping Duct 1 1 A : Fresh air B : Recirculated air C: Hot air/cold air PC200.

220(LC)-8 Hydraulic excavator Form No. SEN00102-00 © 2005 KOMATSU All Rights Reserved Printed in Japan 09-05 (01) 4 .SEN00102-00 PC200.

.............................................................................................................. 63 PC200.......................... 60 KOMTRAX terminal system .................................................................................... 10 Monitor system....................................................................................... 2 Engine control ........................................................................................................................................................................SEN00103-01 HYDRAULIC EXCAVATOR 1SHOP MANUAL PC200-8 PC200LC-8 PC220-8 PC220LC-8 Machine model Serial number PC200-8 PC200LC-8 PC220-8 PC220LC-8 300001 and up 300001 and up 70001 and up 70001 and up 10 Structure....................................................................................................................... 33 Sensor..................................... 2 Electrical control system ..................................................................... function and maintenance standard 1 Electrical system Electrical system ........................................................... 220-8 1 .....................

the starting motor turns to start the engine. the engine controller cuts the signal of the supply pump drive solenoid to stop the engine. the starting signal flows to the starting motor.SEN00103-01 10 Structure. q 2 PC200. and eventually controls the engine speed. function and maintenance standard Electrical system 1 Engine control 1 Operation of system 1 Starting engine q When the starting switch is turned to the START position. Engine speed control The fuel control dial sends a signal voltage corresponding to the rotation angle to the engine controller. When it happens. Then. 220-8 . the engine controller checks the signal voltage from the fuel control dial and sets the engine speed to the speed set by the fuel control dial. Stopping engine When detecting that the starting switch is set to the “STOP” position. q The engine controller sends a driving signal to the supply pump depending on the signal voltage to control the fuel injection pump.

function and maintenance standard Component SEN00103-01 1 Fuel control dial 1. 3.10 Structure. Knob Dial Spring PC200. Ball Potentiometer Connector 3 . 6. 2. 220-8 4. 5.

SEN00103-01 10 Structure. 220-8 . the engine is running at low idle. q The hatched area in the right graph is the abnormality detection area. 4 PC200. q Turning knob (1) rotates the shaft of potentiometer (5). function and maintenance standard Function q The fuel control dial is installed under the machine monitor. q The rotation of the shaft changes the resistance of the variable resistor in potentiometer (5). When the throttle voltage is within this area. sending any throttle signal to the engine controller.

function and maintenance standard SEN00103-01 Engine controller CN-CE01 Pin No.10 Structure. 5 . Signal name Title panel 18 NC(*) 19 NC(*) 20 NC(*) 21 NC(*) 22 Engine brake drive D 23 Boost temperature sensor B 24 NC(*) 25 Common rail pressure sensor B 26 G sensor (+) B 27 NE sensor (+) B 28 Engine brake return 29 NC(*) 30 NC(*) 31 NC(*) D 32 IMA return C 33 5V electric power supply for sensor 34 NC(*) *: Never connect to NC or malfunctions or failures will occur. PC200. CN-CE01 Signal name Input/ output 1 Electric power supply for lift pump 2 Electric power supply for IMA 3 Atmosphere sensor 4 NC(*) 5 NC(*) 6 CAN(–) 7 NC(*) 8 CAN(+) 9 NC(*) 10 NC(*) 11 Lift pump return 12 NC(*) 13 NC(*) 14 NC(*) 15 Coolant temperature sensor 16 5V electric power supply for sensor 17 Oil pressure switch *: Never connect to NC or malfunctions or failures will occur. 220-8 Pin No.

PC200. 220-8 . Signal name Input/ output 1 NC(*) 2 NC(*) 3 NC(*) 4 NC(*) 5 NC(*) 6 NC(*) 7 NC(*) 8 NC(*) 9 Fuel control dial (+) 10 NC(*) 11 NC(*) 12 NC(*) 13 NC(*) 14 NC(*) 15 NC(*) 16 NC(*) 17 NC(*) 18 NC(*) 19 NC(*) *: Never connect to NC or malfunctions or failures will occur. CN-CE02 Signal name Title panel A 35 NC(*) 36 NC(*) 37 5V electric power supply for sensor A 38 GND C 39 NC(*) 40 NC(*) 41 NC(*) 42 NC(*) C 43 NC(*) 44 Boost pressure sensor B 45 Injector #1 (+) D 46 Injector #5 (+) D 47 G sensor (–) C 48 Ne sensor (–) C 49 NC(*) 50 NC(*) 51 Injector #2 (–) C 52 Injector #3 (–) C 53 Injector #1 (–) C 54 Injector #2 (+) D 55 Injector #3 (+) D 56 Injector #4 (+) D 57 Injector #6 (+) D 58 Injector #4 (–) C 59 Injector #6 (–) C 60 Injector #5 (–) C *: Never connect to NC or malfunctions or failures will occur. function and maintenance standard CN-CE01 Pin No. Signal name Input/ output 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 NC(*) NC(*) Fuel control dial (+5V) Fuel control dial (–) NC(*) NC(*) NC(*) NC(*) NC(*) NC(*) NC(*) NC(*) NC(*) GND NC(*) NC(*) NC(*) NC(*) NC(*) Key switch (ACC) Electrical intake air heater relay 40 drive 41 NC(*) Electrical intake air heater relay 42 return 43 NC(*) 44 NC(*) 45 NC(*) 46 CAN(+) 47 CAN(–) 48 NC(*) 49 PWM OUTPUT 50 NC(*) *: Never connect to NC or malfunctions or failures will occur. Signal name Input/ output 1 2 GND NC(*) Electric power supply (+24V con3 stantly) 4 NC(*) *: Never connect to NC or malfunctions or failures will occur. CN-CE02 Pin No. CN-CE03 Pin No. 6 Pin No.SEN00103-01 10 Structure.

Sensor O-ring Connector Oil pressure switch 1.10 Structure. function and maintenance standard SEN00103-01 Coolant temperature sensor 1. 2. 220-8 7 . 3. 2. Connector Sensor O-ring PC200. 3.

220-8 . Connector Sensor O-ring Boost pressure and temperature sensor 1. 8 Connector Sensor O-ring PC200. function and maintenance standard Rotation sensor 1. 2. 3.SEN00103-01 10 Structure. 2. 3.

3. 4. 3. Connector Bracket Float Switch PC200. function and maintenance standard SEN00103-01 WIF (water-in-fuel detection) sensor 1. 220-8 9 . 2. 4. Connector Tube Sensor O-ring Engine oil level sensor 1. 2.10 Structure.

220-8 .SEN00103-01 Electrical control system 10 Structure. function and maintenance standard 1 Machine control system diagram 10 PC200.

function and maintenance standard PC200.10 Structure. 220-8 SEN00103-01 11 .

SEN00103-01 10 Structure. 220-8 . Engine and pump composite control function 12 PC200. function and maintenance standard 1.

To select a working mode. q The pump controller controls the pump so that it can absorb all the torque at the output points of the engine depending on the pump absorption torque specified for each mode. L.800 rpm {143 HP/1. engine speed is always controlled so that it is kept around the matching point specified for each mode. and B (three modes of P. engine speed (N) lowers. use the working mode selector switch of the machine monitor. the pump controller continues to increase pump delivery until the engine speed reaches around the matching point. On the contrary. the engine speed is increased to around the matching point.9 kW/1. ATT. E.800 rpm {123 HP/1. If it happens. Five modes of P. allowing the pump controller to decrease pump delivery (Q). E. 13 .800 rpm} E 91. E mode. or ATT mode. rotation set by the fuel control dial. function and maintenance standard Function q This function allows the operator to select engine torque (T) and pump absorption torque d ep en d in g o n t he wo r k c o nt en ts o f th e machine. E. and actual engine speed. the pump load decreases and the pressure lowers. 220-8 SEN00103-01 1) Control method in each mode P mode.800 rpm} In P.0 kW/1. PC200. and ATT mode q Matching point: Models Mode q q PC200-8 P and ATT (Work) 107.10 Structure. If the pump load increases and the pressure rises. and L for machines with “No ATT” specified) are specified as working modes.

SEN00103-01 10 Structure. but the pump absorption torque is increased.780 rpm} L 73. PC200. the working mode and engine speed (N) do not change. 2) q q q Function to control pump during travel Traveling the machine in P or ATT mode increases engine speed (N). 220-8 . but raises the pump absorption torque and engine speed (N) to values same as those in P mode. function and maintenance standard B mode and L mode Mode B L Partial output point 75% 70% Models Mode q q q 14 PC200-8 B 80. 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. Traveling the machine in E or B mode leaves the working mode unchanged. engine output is controlled to a constant level.9 kW/1.6 kW/1.800 rpm {99 HP/1.780 rpm {108 HP/1. If the machine travels in L mode.800 rpm} In B or L mode. The controller controls pump delivery (Q) so that the engine torque can be kept at a constant level along the equal engine horsepower curve.

function and maintenance standard 3) q SEN00103-01 Function to control when emergency pump drive switch is turned on Even if any abnormality occurs in the controller or sensor. 220-8 15 . the oil pressure is sensed by only the EPC valve for PC. setting emergency pump drive switch (1) to the “ON” position activates the machine with an absorption torque approximately equivalent to that in E mode. a constant current flows from the battery to the EPC valve for PC and therefore. In this case.10 Structure. PC200.

220-8 . etc. 16 PC200.SEN00103-01 10 Structure. function and maintenance standard 2. Pump and valve control function Function q The machine is matched to various types of work properly with the 2-stage relief function to increase the digging force.

The cut-off function does not work. function and maintenance standard 1) q q 2) q LS control function Depending on the operation condition of the actuator. however. swing lock switch is in the “ON” position. If the 2-stage relief function is turned on. PC200. By this operation.9 MPa {285 kg/cm2} with the power maximizing function off.2 MPa {380 kg/cm2}. however. the start-up time of the pump discharge is optimized and the composite operation and fine control performance is improved. Operating condition for turning on cut-off function When the average value of the front and rear pressure sensors is above 27.2 MPa {380 kg/cm2} Cut-off function This function increases PC-EPC current (J) to reduce the flow rate in the relief state.8 MPa {355 kg/cm2} O 37.10 Structure. while the machine is travelling in A mode. 220-8 17 . improving fuel consumption. By this operation. the relief pressure rises to about 37. Operating condition for turning on 2stage relief function • During travel • When swing lock switch is turned to the ON position • When boom is lowered • When power maximizing function is turned on • When L mode is operated Relief pressure 34. SEN00103-01 3) q 2-stage relief function The relief pressure in the normal work is 34.8 MPa {355 kg/cm2}. this function changes the pressure output from the LS-EPC valve to LS valve to change the change point (LS set differential pressure (DLS)) of the pump discharge in the LS valve. the hydraulic force is increased further.

8 MPa {355 kg/cm2} O 37..2 MPa {380 kg/cm2} 18 These settings are automatically reset after 8. Function Matching at rated output point 2-stage relief function 34. At this time.H.SEN00103-01 10 Structure. each function is automatically set as shown below. knob switch in P. when digging up a large rock). increasing a digging force.g. E. q Pressing the L. q This function is used to increase digging force for a certain period of time (e. function and maintenance standard 3. Setting Engine and pump control Software cut-off function q Cancel PC200. 220-8 . Power maximizing function Function q The power maximizing function allows the operator to increases power for a certain time by operating the left knob switch.5 seconds when the switch is pressed. or ATT mode increases a hydraulic force by approximately 7% and horsepower by approximately 3%.

Operation When control levers are set in neutral q If all the control levers are kept to NEUTRAL for 4 sec. 220-8 19 . When any control lever is operated q If you operate any control lever while the engine speed is kept at the deceleration operation level.10 Structure. Auto-deceleration function Function q The auto-deceleration function automatically reduces the engine speed to its medium speed range when the all control levers are set in NEUTRAL while waiting for a dump truck or work to reduce the fuel consumption and noise. the engine speed instantly rises to the level set with the fuel control dial.400 rpm) and keeps it until you operate any lever. during operation at a engine speed above a decelerator operation level (approximately 1. function and maintenance standard SEN00103-01 4. this function lowers the engine speed to the deceleration operation level (approximately 1. PC200. the engine speed instantly returns to the speed set with the fuel control dial. q If any lever is operated.400 rpm).

220-8 . function and maintenance standard 5.SEN00103-01 10 Structure. 20 PC200. The overheat prevention function reduces the pump load when coolant or hydraulic oil temperature is too high during operation to protect the engine from overheating. Auto-warm-up and overheat prevention function Function q The engine automatic warm-up function increases the engine speed to warm up the engine if coolant temperature is too low after the engine starts.

(Automatic reset) 21 . 102°C Hydraulic oil temperature: Min. This function starts when coolant temperature reaches 100°C or hydraulic oil temperature reaches 95°C. E.200 rpm Resetting condition (Any one of following conditions) q SEN00103-01 Coolant temperature: Min. Reduce pump delivery. 100°C Working mode: P or E mode Engine speed: Kept as is. hydraulic oil temperature: Below 105°C Fuel control dial: Return to low idle position once.200 rpm Auto Manual 2) q Operated Engine speed: 1. 105°C Working mode: Any mode Engine speed: Low idle Monitor alarm lamp: Lights up Alarm buzzer: Sounds Operating condition Operation/Remedy Coolant temperature: Min. controller is set to condition before operation of function. 95°C PC200. (Automatic reset) Resetting condition Coolant temperature. Resetting condition Coolant temperature.10 Structure. Under above condition. hydraulic oil temperature: Below 100°C Under above condition. 100°C or Hydraulic oil temperature: Min. 1. or longer Reset Engine speed: Any level Overheat prevention function This function reduces the pump load and engine speed when coolant or hydraulic oil temperature is too high to protect the engine and hydraulic components from overheating. Operating condition Operation/Remedy Coolant temperature: Min. Monitor alarm lamp: Lights up Reduce pump delivery. controller is set to condition before operation of function. Operating condition Operation/Remedy or Hydraulic oil temperature: Min. (Manual reset) Resetting condition Coolant temperature. 30°C Auto-warm-up operation time: Min. controller is set to condition before operation of function. 10 minutes Fuel control dial: Kept at 70% of full level or above for 3 sec. Lower travel speed. controller is set to condition before operation of function. function and maintenance standard 1) q Auto-warm-up function After the engine is started. or L mode Engine speed: Kept as is. 220-8 Working mode: Travel Engine speed: Kept as is. B. if the engine coolant temperature is low. (Automatic reset) Resetting condition Hydraulic oil temperature: Below 95°C Under above condition. Operating condition Operation/Remedy Coolant temperature: Min. 105°C or Hydraulic oil temperature: Min. hydraulic oil temperature: Below 102°C Under above condition. 102° Working mode: P. Operating condition (All of following conditions) Coolant temperature: Below 30°C Engine speed: Max. the engine speed is raised automatically to warm up the engine.

22 PC200. Swing control function Function The swing lock and swing holding brake function are provided as a swing control function. 220-8 .SEN00103-01 10 Structure. function and maintenance standard 6.

swing brake operates Swing in about 5 sec. canceled. q Swing holding brake cancel switch Swing lock switch Swing brake q q ON (when controller has trouble) ON OFF OFF (when controller is normaly) ON Swing Swing Swing lock is lock is lock is turned on. function and maintenance standard 1) q q Swing lock and swing holding brake function The swing lock function (manual) is used to lock machine from swinging at any position. Operation of swing lock switch and swing lock/ holding brake Lock switch OFF ON Lock lamp OFF ON Function SEN00103-01 2) q Quick hydraulic oil warm-up function when swing lock switch is turned on If swing lock switch (2) is turned on. Even if swing lever is operated. Note that if swinging is stopped on a slope. 220-8 23 . turned on. The swing holding brake function (automatic) is used to prevent hydraulic drift after the machine stops swinging. the hydraulic oil temperature rises quickly and the warm-up time can be shortened. PC200. Even if the swing holding brake cancel switch is turned on. the swing brake is not released. the swing lock can be reset with the swing holding brake cancel switch. OFF Swing holding brake is turned on. the pump cut-off function is cancelled and the relief pressure rises from 34. Operation If swing lever is set in neutral. brake is brake released and machine can swing freely. the upper structure may swing by its gravity. If the work equipment is relieved under this condition. etc.2 MPa {380 kg/cm2}. If swing holding lever is operated.10 Structure. Swing holding brake cancel switch If the controller. only the hydraulic brake is applied by the safety valve. and the machine cannot swing. Swing lock Swing lock operates and machine is locked from swinging. swing lock is not reset and machine does not swing. If the swing lock is reset. the swing holding brake does not work normally. has a problem. if the swing lock switch is turned on.8 MPa {355 kg/cm2} to 37.

24 PC200.SEN00103-01 10 Structure. function and maintenance standard 7. Travel control function Function q The machine is provided with a function that ensures travel performance best fit to the type of work and jobsite by controlling pumps during travel or allowing operator to change travel speed automatically or manually. 220-8 .

the travel motor capacity automatically switches to the medium speed (Mi) (the travel speed switch stays at Hi)..5 sec. Max.1 5.0 4. 3. Travel speed switch Lo (Low speed) Mi (Medium speed) Hi (High speed) Pump capacity (%) 80 90 100 Max. q The travel speed does not switch to Hi when the machine is traveling in Mi. If the machine starts traveling on level ground or downhill during operation of the above mentioned function and the travel pressure goes below 14. Travel speed change function 1] Manual change with travel speed selector switch Switching the travel speed selector switch from Lo to Mi and Hi causes the pump controller to control the pump capacity and motor capacity at each gear speed as shown below. Automatic change by pump discharge pressure If the travel pressure is kept to 24. switching the travel speed switch to Hi again.7 MPa {150 kg/cm2} and continues such the condition at least 0. switching the travel speed. the travel motor capacity will automatically change. q The travel speed automatically changes to Mi when the machine is travelling in Hi. PC200.5 sec. see Engine and pump composite control function.5 MPa {250 kg/cm 2 } at least 0.10 Structure.500 rpm or less with the fuel control dial. 220-8 25 . Min. due to increased load during traveling in Hi on an uphill.5 Motor capacity Travel speed (km/h) 2] 3] Automatic change by engine speed If you adjust the engine speed to 1. function and maintenance standard 1) q 2) SEN00103-01 Function to control pump during travel For details.

q The function acts as follows according to the flow command and working mode from the monitor. 1) It throttles the attachment PPC pressure and controls the flow when the pedal is depressed fully. function and maintenance standard 8. 220-8 .SEN00103-01 10 Structure. 26 Working mode Attachment operation ATT Double-acting B Single-acting PC200. Attachment flow control circuit selector function (if equipped) Function q This function is available only with the attachment specification. 2) Attachment operation switches depending on the working mode as shown below.

1 MPa {5. 220-8 27 . System component parts 1) PPC oil pressure switch 1.0 ± 0. 2. q PC200.3 ± 0. function and maintenance standard SEN00103-01 9.0 kg/cm2} Resetting (OFF) pressure: 0. 3.05 MPa {3. q This sensor detects the operating condition of each actuator by the PPC pressure and transmit it to the pump controller.5 kg/cm2} Function The junction block has 2 PPC oil pressure switches.0 ± 1. Plug Switch Connector Specifications Type of contacts: Normally open contacts Operating (ON) pressure: 0.10 Structure.5 ± 0.

function and maintenance standard Function q The junction block has 6 PPC oil pressure sensor. which is transmitted to the amplifier (voltage amplifier). Operation The oil pressure is applied to the diaphragm of the oil pressure sensor from the pressure intake part. q The deformation in the diaphragm causes the resistance of the gauge to change. q q 28 q The amplifier magnifies output voltage (E) and transmits it to the pump controller. the diaphragm is deformed. 2. q This sensor detects the operating condition of each actuator by the PPC pressure and transmit it to the pump controller. The relationship between the pressure applied to sensors (P) and output voltage (E) is shown in the figure below. Sensor Connector 10 Structure. 220-8 . This causes a change in the output voltage. PC200.SEN00103-01 2) Oil pressure sensor 1.

Sensor Connector SEN00103-01 Operation q The relationship between the pressure applied to sensors (P) and output voltage (E) is shown in the figure below. 2.10 Structure. 220-8 29 . function and maintenance standard 3) Pump pressure sensor 1. PC200.

SEN00103-01 3) 30 10 Structure. function and maintenance standard Pump controller PC200. 220-8 .

PC200. 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 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 Signal name Power Power GND Washer motor power Power Power GND NC (*) NC (*) Power (+5 V) Power (+5 V) NC (*) NC (*) NC (*) NC (*) Boom down pressure SW Arm dump pressure SW Swing (L) pressure sensor Arm digging pressure sensor Analog GND Swing lock NC (*) Machine select 2 NC (*) NC (*) Key SW (ACC) NC (*) NC (*) NC (*) NC (*) Hydraulic oil temperature NC (*) NC (*) NC (*) NC (*) Bucket dump pressure sensor NC (*) Travel steering SW NC (*) Swing emergency Machine select 5 Machine select 1 Knob SW NC (*) Key SW (ACC) NC (*) CAN_H Analog GND NC (*) NC (*) F pump pressure sensor NC (*) NC (*) Input/output Input Input Output Input Input Input — Output Output Input — Input Input Input Input Input Input Input Input Input Input Input Input Input Input — Output Output Input Input — Input Input Input Input Input Input Input Input Input Input Input Input Input Input/output Input Input Input Input Input Input CN-C01 Pin No. 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 Signal name Input/output Service pressure SW Input Boom up pressure sensor Input NC (*) Input Steering pressure SW Input Wiper (W) Input Window limit SW Input Machine select 4 Input NC (*) Input Key SW (C) Input NC (*) Input External drive signal Input NC (*) — CAN_L Input/output NC (*) Input NC (*) Input NC (*) Input R pump pressure sensor Input NC (*) Input Analog GND Input NC (*) Input Swing (R) pressure sensor Input Bucket digging pressure sensor Input NC (*) Input Wiper (P) Input NC (*) Input Machine select 3 Input NC (*) Input Input NC (*) — NC (*) Input *: Never connect to NC or malfunctions or failures will occur. function and maintenance standard SEN00103-01 Input and output signals CN-C01 Pin No. *: Never connect to NC or malfunctions or failures will occur. 220-8 31 .10 Structure.

function and maintenance standard Input/output — — Output Output Output Output Output Output — — Output — — Output Output Output — — Output Output Output Output Output Output — Output Output Output Output Output Output Output Output Input Input Input Input Output Input Input *: Never connect to NC or malfunctions or failures will occur.SEN00103-01 CN-C02 Pin No. 220-8 . 32 PC200. 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 Signal name NC (*) NC (*) NC (*) NC (*) Service circuit SOL Travel speed SOL LS-EPC Merge-divider LS EPC NC (*) NC (*) NC (*) NC (*) NC (*) NC (*) PC-EPC (F) Service current EPC NC (*) NC (*) NC (*) Swing parking brake SOL NC (*) NC (*) PC-EPC (R) NC (*) NC (*) NC (*) Battery relay 2-step relief SOL Travel junction SOL NC (*) Merge-divider main EPC NC (*) Wiper motor (–) Solenoid GND Solenoid power Solenoid GND Solenoid power Wiper motor (+) Solenoid GND Solenoid power 10 Structure.

etc. fuel level. Contents displayed on the panel are largely divided into the following. the machine monitor is provided with various mode selector switches that function as the operation unit of the machine control system. PC200. Also.) The monitor panel also has various mode selector switches and functions to operate the machine control system. function and maintenance standard Monitor system q q SEN00103-01 1 The monitor system notifies the operator of machine status. Alarm when an abnormality occurs on the machine 2. It monitors the condition of the machine with the sensors mounted on various parts of the machine.10 Structure. Machine condition (Temperature of coolant and hydraulic oil. 1. processes and immediately displays the obtained information on the panel. 220-8 33 .

SEN00103-01

Machine monitor

10 Structure, function and maintenance standard

1

Outline
q
The machine monitor has the functions to display various items and the functions to select
modes and electric parts.
q
The machine monitor has a CPU (Central Processing Unit) in it to process, display, and output the information.
q
The monitor display employs an LCD (Liquid
Crystal Display). The switches are flat sheet
switches.

34

PC200, 220-8

10 Structure, function and maintenance standard

Input and output signals

CN-CM03
Pin No.

CN-CM01
Pin No.
1
2
3
4

SEN00103-01

Signal name
Battery power (+24V constantly)
Battery power (+24V constantly)
Battery power GND
Battery power GND

Input/
output

1

Input

2

Input

3



Input/
5
Wake-up
Output
6
Relay output
Output
7
Chassis signal GND

8
NC(*)

9
Fuel level
Input
10
NC(*)

11
Charge amount
Input
12
Chassis analog signal GND

13
Light switch
Input
14
Key switch (ACC)
Input
15
Key switch (C)
Input
16
Preheating
Input
17
NC(*)

18
NC(*)

*: Never connect to NC or malfunctions or failures
will occur.

Input/
output
1
NC(*)

2
Engine oil level sensor
Input
3
Coolant level sensor
Input
4
Air cleaner clogging sensor
Input
5
Swing lock
Input
6
NC(*)
Input
7
Chassis signal GND

8
CAN terminating resistance

Input/
9
CAN_H
Output
Input/
10
CAN_L
Output
Input/
11
NC(*)
Output
Input/
12
NC(*)
Output
*: Never connect to NC or malfunctions or failures
will occur.

PC200, 220-8

5
6
7
8
9
10
11
12
13
14

CN-CM02
Pin No.

4

Signal name

15
16
17
18

Signal name
RS232C CD for communication terminal
RS232C RXD for communication terminal
RS232C SG for communication terminal
Signal GND for communication
terminal control
Communication terminal selection signal
RS232C RTS for communication terminal
RS232C TXD for communication terminal
RS232C DTR for communication terminal
RS232C DTR for communication terminal
RS232C CTS for communication terminal
RS232C RI for communication
terminal
Power GND for communication
terminal
Input CH1 for communication
terminal status
Output for communication terminal power control
Output CH1 for communication
terminal control
Output CH2 for communication
terminal control
Input CH2 for communication
terminal status
Electric power supply for communication terminal

Input/
output
Input
Input


Input
Output
Output
Output
Input
Input
Input

Input
Output
Output
Output
Input
Output

CN-CM04
Input/
output
1
NC(*)

2
NC(*)

3
NC(*)

4
NC(*)

5
NC(*)

6
NC(*)

7
NC(*)

8
NC(*)

9
NC(*)

10
NC(*)

11
NC(*)

12
NC(*)

*: Never connect to NC or malfunctions or failures
will occur.
Pin No.

Signal name

35

SEN00103-01

10 Structure, function and maintenance standard

CN-CM05
Pin No.

36

Signal name

Input/
output

1

Electric power supply for camera

2

Camera NTSC signal input 1

Input

3

Camera NTSC signal input 2

Input

4

Camera NTSC signal input 3

Input

5

Electric power supply GND for
camera

6

Camera signal GND1

7

Camera signal GND2

8

Camera signal GND3

Output

PC200, 220-8

10 Structure, function and maintenance standard

PC200, 220-8

SEN00103-01

37

SEN00103-01

Monitor control, display portion

38

10 Structure, function and maintenance standard

1

PC200, 220-8

10 Structure, function and maintenance standard

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.

SEN00103-01

Hydraulic oil temperature monitor
Hydraulic oil temperature gauge
Engine coolant temperature monitor
Engine coolant temperature gauge
KOMTRAX message monitor
Air conditioner monitor
Wiper monitor
Swing lock monitor
Engine pre-heating monitor/power maximizing
monitor
Time/service meter
Auto-deceleration monitor
Working mode monitor
Travel speed monitor
ECO indicator
Fuel gauge
Fuel level monitor
Maintenance interval monitor
Engine oil pressure monitor
Charge level monitor
Radiator coolant level monitor
Engine oil level monitor
Air cleaner clogging monitor
Water separator monitor

Precautions on the machine monitor display
q
The liquid crystal display panel may have black
spots (which do not light up) or bright spots
(which stay on).
Products having 10 or less black or bright
spots conform the product specification; such
the condition is quite normal.
q
Battery voltage may suddenly drop at enginestart due to ambient temperature or the condition of the battery. The machine monitor display may temporarily disappear if it happens; it
is quite normal.
q
Continuous operation of the machine monitor
may display blue bright spots on the screen
having a black background; it is quite normal.
The screen normally displayed on the monitor
has a blue or white background. For this reason, blue spots will not cause any problem
(since the liquid crystal lights up red, blue, and
green spots when displaying white).

PC200, 220-8

39

SEN00103-01

10 Structure, function and maintenance standard

Monitor items and display
Symbol

Display item

Swing lock

Display method
Swing lock switch

Swing holding brake
release switch

Display of symbol

OFF

OFF

OFF

ON

OFF

ON

OFF

ON

Flashes

ON

ON

Flashes

Automatic preheating

Preheater operates at low temperature and
symbol keeps lighting up for up to about 30
seconds and then goes off after engine starts.

Preheating
Manual preheating

Power Max.

Time after setting

Display of symbol

0 – 30 sec
30 – 40 sec
After 40 sec

ON
Flashes
OFF

Power Max. switch

Display of symbol

While pressed

Keeps lighting up.
Goes off after about 9 sec. if switch
is kept pressed.

While released

Kept turned OFF.

Engine coolant
temperature
Hydraulic oil
temperature

See gauge display on next page.

Fuel level

40

PC200, 220-8

10 Structure, function and maintenance standard

SEN00103-01

The gauge pointer disappears when information on coolant temperature or hydraulic oil temperature cannot
be obtained due to disconnection of CAN.
Gauge

Engine coolant temperature
(°C)

Hydraulic oil temperature
(°C)

Fuel level (l)

PC200, 220-8

Range

Temperature or volume

Indicator

Buzzer sound

A1

105

Red

Q

A2

102

Red

A3

100

Off

A4

85

Off

A5

60

Off

A6

30

White

B1

105

Red

B2

102

Red

B3

100

Off

B4

85

Off

B5

40

Off

B6

20

White

C1

289

Off

C2

244.5

Off

C3

200

Off

C4

100

Off

C5

60

Off

C6

41

Red

41

SEN00103-01

10 Structure, function and maintenance standard

Checks before starting (all symbols light up), when maintenance interval is exceeded.
If the checks before starting or maintenance interval is exceeded items light up, the display of the hydraulic
oil temperature gauge and the hydraulic oil temperature monitor disappear and the following symbols are
displayed.
Display item

Check before starting
item

While engine is
stopped

While engine is
running

Engine oil pressure

q

Lights up and buzzer
sounds when abnormal.

Battery charge

q

Lights up when
abnormal.

Radiator coolant level

q

Engine oil level

q

Lights up when
abnormal.

Air cleaner clogging

q

Lights up when
abnormal.

Water separator

q

Lights up when
abnormal.

Lights up when
abnormal.

Symbol

Maintenance

Lights up and buzzer
Lights up and buzzer
sounds when abnormal. sounds when abnormal.

Notice lamp (yellow)/Warning lamp (red).
Lights up for only 30 seconds after starting
switch is turned ON.

Symbols appear in the order in which they occur
from the upper left. When symbols are displayed, if
the hydraulic oil temperature is high or low, only its
symbol is displayed.
Condition of hydraulic oil

Color of symbol

Low temperature (below B6 or
equivalent)

Black on white background

Normal (B6 – B2)

No display

High temperature (above B2)

White on red background

42

PC200, 220-8

10 Structure, function and maintenance standard

Display
category

Symbol

Display item
KOMTRAX
message

Display range

Display method

Green:
There is unread message.
Blue:
There is unreturned message.

Air conditioner/
Heater

Wiper

SEN00103-01

ON

INT

Displays operating condition.

OFF

OFF

ON

Displays state of message
(for only machine equipped
with KOMTRAX).

Displays set condition.

Monitor
Working mode

Travel speed

Auto-deceleration

ECO
indicator

ECO indicator

Service
meter

Service meter
indicator

Clock

PC200, 220-8

Clock

P, E, L, B, ATT

Lo

Mi

ON

Displays set mode.

Hi

OFF

Green:
Work load is light – medium.
Orange:
Work load is heavy.

While service meter is working

12-hour display
24-hour display

Displays set speed.

Displays operating condition.

Displays average work load in
1 minute on 10 levels.
(Does not display if ECO
display is set OFF in service
menu.)
Displays operating time.
(Changes to clock if F4 is
depressed.)
Displays time.
(Changes to service meter if
F4 is depressed.)

43

SEN00103-01

Switches

1.
2.
3.
4.
5.
6.
7.
8.
9.

10 Structure, function and maintenance standard

1

Buzzer cancel switch
Auto-deceleration switch
Guidance icon
Function switch
Working mode selector switch
Travel speed selector switch
Window washer switch
Wiper switch
Air conditioner control switch

Buzzer cancel switch
Pressing this switch when the alarm buzzer is making sound stops the alarm buzzer.
If a new abnormality is detected, the alarm buzzer
sounds.
Depending on the alarm buzzer type, it does not
stop even if you press the buzzer cancel switch.

44

Auto-deceleration switch
The auto-deceleration switch toggles the autodeceleration function on and off. When the working
mode is switched, it is automatically set to ON.
When it is set to ON, the auto-deceleration monitor
appears.
a The auto-deceleration function does not work
in L mode.
Guidance icon and function switch
The function switches differ depending on the
screen display. Each guidance icon shows the function of the switch below it.
Switches with no guidance icon are disabled.
The functions shown by the guidance icons are as
shown in the table below.

PC200, 220-8

10 Structure, function and maintenance standard

Symbol

Switch

Item

Function

F6

Enter

Enters selected/set item.

F5

Return

Returns to previous screen.

F3

Select camera screen

Selects camera screen.

F4

Select service meter/clock

Selects service meter and clock alternately.

F5

Select maintenance screen

Selects maintenance screen.

F6

Select user mode screen

Selects user mode screen.

F3

Select item

Selects item on left side (Selects right end item after left
end item).

F4

Select item

Selects item on right side (Selects left end item after right
end item).

F3

Select item

Selects item on lower side (Selects top item after bottom
item)/Resets holding of monitoring.

F4

Select item

Selects item on upper side (Selects bottom item after top
item)/Holds monitoring.

F1

Select item

Selects page on lower side (Selects top page after bottom
page).

F2

Select item

Selects page on upper side (Selects bottom page after top
page).

F1

Display No. 1 camera screen

Selects No. 1 camera screen.

F2

Display No. 2 camera screen

Selects No. 2 camera screen.

F3

Display No. 3 camera screen

Selects No. 3 camera screen.

F4

Display No. 1 and No. 2
camera screens

Displays No. 1 and No. 2 camera screens simultaneously.

F2

Return to default setting

Returns selected item to default setting. (Used for
adjustment of screen.)

F1

Start

Starts operation. (Used to start measurement of split fuel
consumption on fuel consumption display screen.)

F1

Stop

Stops operation. (Used to stop measurement of split fuel
consumption on fuel consumption display screen.)

F1/F2

Clear

Clears selected/displayed item

Set

Executes setting.

F1

PC200, 220-8

SEN00103-01

45

SEN00103-01

Working mode selector switch
Pressing working mode selector switch (5) switches
among working modes.
Check the working mode on the working mode
monitor.

About B mode
q
When you try specifying B mode as a working
mode, the buzzer sounds for safety's sake and
the following confirmation message appears.

F5 : Returns to the working mode selector screen.
F6 : Specifies the breaker mode.
q

If B mode is specified as a working mode when
you start the monitor, the buzzer sounds and
the following message appears.

10 Structure, function and maintenance standard

Travel speed selector switch
Each time you press the travel speed selector
switch, the travel speed setting switches as shown
below.
Lo o Mi o Hi o Lo ….
The travel speed setting is confirmable on the travel
speed monitor.
The relationship between the speed setting and the
monitor display is shown in the table below.
Display

Setting

Crawler symbol + Lo

Low speed (default)

Crawler symbol + Mi

Medium speed

Crawler symbol + Hi

High speed

Window washer switch
While the switch is being pressed, window washer
liquid is sprayed out. There is a time delay before
the wiper starts.
Wiper switch
Each time you press the wiper switch, the wiper
settings switch as follows.
OFF o INT o ON o OFF o ….
The wiper operation setting is confirmable on the
wiper monitor.
The relationship between the wiper setting and the
monitor display is shown in the table below.
Display

Setting

Wiper actuation status

None

OFF

Stowing stopped or now
stowing

Wiper symbol +
INT

INT

Intermittent actuation

Wiper symbol +
ON

ON

Continuous actuation

Air conditioner control switch
To operate the air conditioner, use the air conditioner control switches.

F5 : Starts up in E mode.
F6 : Starts up in B mode.

46

PC200, 220-8

10 Structure, function and maintenance standard

9a : Specifies airflow
9b : Specifies temperature
9c : AUTO
9d : A/C
9e : Switches among air blowing modes
9f : Switches between inside air and outside air
9g : OFF
9a to 9c : Enables entered information simultaneously with switching to the air conditioner control screen below.
9d to 9f : Switches to the air conditioner control
screen below. Another pressing switches
among modes.
9g : Turns OFF the air conditioner function without
switching to the air conditioner screen.

SEN00103-01

Camera screen display function
q

q

q

1

For an optional-camera-equipped machine,
pressing the F3 on the normal screen switches
to the camera image.
For a machine with no camera equipped, the
guidance icon for switching to the camera
screen does not appear; even if you press the
switch, the screen does not switch to the camera image.
Up to three cameras are mountable.

F1 :
F2 :
F3 :
F4 :
If you do no operation at least 5 sec. with the air
conditioner control screen displayed, the window
returns to the normal window.
a When communication with the air conditioner
is disconnected, or “spurting-out damper”,
“A/M damper”, or “refrigerant” has a problem,
the following screen appears.

PC200, 220-8

Displays the image of No. 1 camera full-screen.
Displays the image of No. 2 camera full-screen.
Displays the image of No. 3 camera full-screen.
Displays the images of No. 1 and No. 2 cameras at the same time.
F5 : Returns to the normal screen.
q

Making operation of air conditioner button (1)
with the camera screen displayed may switch
to the air conditioner operation screen.

47

SEN00103-01

10 Structure, function and maintenance standard

Service meter/time selector function
q

1

Pressing F4 on the normal screen when the
service meter is displayed in the top center of
the screen switches the display to the time,
and doing so when the time is displayed
switches the display to the service meter.

F6, or no operation for 5 sec.: Returns to the camera screen.
q

q

q

q

48

Even when the camera screen is displayed,
the working mode selector switch, travel speed
selector switch, auto-deceleration switch,
buzzer cancel switch, wiper switch, and window washer switch are enabled.
If an abnormality corresponding to an alarm
item with the camera screen displayed, the
alarm monitor appears on the upper left of the
screen. If it appears, return to the normal
screen with F5 to check the alarm display.
If an abnormality corresponding to an error
item with the camera screen displayed, the
error monitor appears on the upper left of the
screen. If it appears, you must move the
machine to safe posture immediately and
make inspections.
If you do not operate the lever at least 10 sec.
after the error monitor starts to blink, the
screen switches to the normal screen.

PC200, 220-8

10 Structure, function and maintenance standard

Maintenance function
q

SEN00103-01

1

Pressing F5 on the normal screen switches to
the maintenance screen.

F5 : Cancels the reset to return to the maintenance
table screen.
F6 : Resets the remaining time to return to the normal screen.
No operation at least 30 sec. : Returns to the normal screen.
q

No.

F1 : Displays the next page.
Displays the top page when the last page is
displayed.
F2 : Displays the previous page.
Displays the last page when the top page is
displayed.
F3 : Selects (highlights) an item one down.
F4 : Selects (highlights) an item one up.
F5 : Returns to the normal screen.
F6 : Switches to the maintenance time reset screen.
No operation at least 30 sec. : Returns to the normal screen.
q

q

If the remaining time on the maintenance table
screen is less than 30 hours, the relevant items
are highlighted in yellow, and if 0 hours, they
are done in red.
On the maintenance time reset screen, reset
the remaining time for the selected item to
return to the default.

PC200, 220-8

The table below shows the maintenance items
and replacement intervals. The time remaining
to maintenance is reduced as the machine is
operated.
Item

01 Engine oil
02 Engine oil filter
03 Fuel main filter
41 Fuel prefilter
04 Hydraulic filter
05 Hydraulic tank breather
06 Corrosion resistor
07 Damper case oil
08 Final case oil
09 Machinery case oil
10 Hydraulic oil
*: If equipped (To be determined)
q

Replacement interval
(Hours)
500
500
1000
500
1000
500
1000(*)
1000
2000
1000
5000

The content of the caution display differs
according to the remaining time. The relationship is as shown in the table below.
Display

Condition
Remaining time for mainteNone
nance for all items is more
than 30 hours.
There is one or more items
Notice display (black symwith less than 30-hour
bol displayed on yellow
remaining time for maintebackground)
nance.
There is one or more items
Warning display (white
with less than 0-hour
symbol displayed on red
remaining time for maintebackground)
nance.

49

SEN00103-01

q

You can lock the maintenance time by a password to prevent it from carelessly being reset.

q

The default password is “000000”.
Enabling the password lock on an attachmentequipped machine locks the breaker/attachment setting screen at the same time.
For information on changing the attachment/
maintenance password, see “Attachment/
maintenance password change function” in the
Testing and adjusting section.

q

a

50

10 Structure, function and maintenance standard

PC200, 220-8

10 Structure, function and maintenance standard

User mode
q
q

1

Pressing F6 on the normal screen enters the
user mode, switching to the user menu screen.
In user mode, you can specify items relating to
the machine monitor and machine shown
below.
Breaker/attachment setting
Message display
Screen adjustment
Time adjustment
Language setting
Economy mode adjustment

F3 :
F4 :
F5 :
F6 :

Selects (highlights) an item one down.
Selects (highlights) an item one up.
Returns to the normal screen.
Switches to the setting screen for the selected
item.
No operation at least 30 sec. : Returns to the normal screen.
(In user mode, no switch operation at least 30 sec.
returns to the previous screen.)

SEN00103-01

F3 : Selects (highlights) an item one down.
F4 : Selects (highlights) an item one up.
F5 : Cancels changes you made before confirming
them with F6 to return to the menu screen.
F6 : Moves to the setup items of the selected (highlighted) item.
q

q

Selecting B switches to the breaker setting
menu, and selecting ATT switches to the
attachment setting menu.
You can lock this menu with a password.
Enabling the password lock locks the maintenance reset screen at the same time.

Changing breaker mode setting
Selecting B on the breaker/attachment setting
screen switches to the breaker setting screen.
On this screen, select the breaker setting
selection screen or breaker flow rate setting
screen.

q

Breaker/attachment setting
q

q

For an attachment-equipped machine, this
menu allows you to adjust a flow rate in B
mode and ATT mode.
For a machine with no attachment, this menu
does not appear.

F3 : Selects (highlights) an item one down.
F4 : Selects (highlights) an item one up.
F5 : Returns to the breaker/attachment setting
screen.
F6 : Switches to the setting screen for the selected
(highlighted) item.

PC200, 220-8

51

SEN00103-01

1.

Breaker setting selection screen.
q
On this screen, you can allocate one of
two set flow rates as a flow rate in breaker
mode.
q
The B symbol is displayed before items
specified to breaker mode.
a The defaults of both flow rates are 180 l/
min.

F3 : Selects (highlights) an item one down.
F4 : Selects (highlights) an item one up.
F5 : Returns to the breaker setting menu
screen.
F6 : Specifies the selected (highlighted) item
as a flow rate in breaker mode.
2.

Breaker flow rate setting screen
q
On this screen, you can specify a flow
rate.
q
The B symbol is displayed before items
specified to breaker mode.

F3 : Selects (highlights) an item one down.
F4 : Selects (highlights) an item one up.
F5 : Returns to the breaker setting menu
screen.
F6 : Switches to the flow rate level setting
screen for the selected (highlighted) item.

52

10 Structure, function and maintenance standard

On the flow rate level setting screen,
change the set flow rate.

q

F3 : Decreases the flow rate.
F4 : Increases the flow rate.
F5 : Returns to the flow rate setting screen
without changing the flow rate.
F6 : Returns to the flow rate setting screen
after specifying the flow rate.
Flow level

Flow rate (l/min)

15

210

14

200

13

190

12

180

11

170

10

160

9

150

8

140

7

130

6

120

5

110

4

100

3

90

2

80

1

70

Remarks

Default

Changing attachment mode setting
q
Selecting ATT on the breaker/attachment setting screen switches to the 2-way attachment
setting menu. On this screen, select the
attachment setting screen or breaker flow rate
setting screen.

PC200, 220-8

10 Structure, function and maintenance standard

SEN00103-01

F3 : Selects (highlights) an item one down.
F4 : Selects (highlights) an item one up.
F5 : Returns to the breaker/attachment setting
screen.
F6 : Switches to the setting screen for the selected
(highlighted) item.

F3 : Selects (highlights) an item one down.
F4 : Selects (highlights) an item one up.
F5 : Returns to the breaker setting menu
screen.
F6 : Switches to the flow rate level setting
screen for the selected (highlighted) item.

1.

q

Attachment setting selection screen
On this screen, you can allocate one of
two set flow rates as a flow rate in attachment mode.
q
The ATT symbol is displayed before items
specified to attachment mode.
a The defaults of both flow rates are 430 l/
min.

On the flow rate level setting screen,
change the set flow rate.

q

F3 : Decreases the flow rate.
F4 : Increases the flow rate.
F5 : Returns to the flow rate setting screen
without changing the flow rate.
F6 : Returns to the flow rate setting screen
after specifying the flow rate.
F3 :
F4 :
F5 :
F6 :
q

2.

Selects (highlights) an item one down.
Selects (highlights) an item one up.
Returns to the attachment setting menu.
Specifies the selected (highlighted) item
as a flow rate in attachment mode.
Selecting “No attachment” disables selection of attachment mode on the working
mode selection screen.

Attachment flow rate setting screen
q
On this screen, you can specify a flow
rate.
q
The ATT symbol is displayed before items
specified to attachment mode.

PC200, 220-8

Flow level

Flow (l/min)

Remarks

8

430

Default

7

350

6

250

5

170

4

140

3

115

2

90

1

30

53

SEN00103-01

10 Structure, function and maintenance standard

Message display
q

q
q

For a KOMTRAX-equipped machine, you can
view notification from the sales representative.
When there is a message, the message monitor appears on the upper left of the normal
screen.
The lighting green monitor indicates that there
are messages to be read.
The lighting blue monitor appears when you
have not sent replies yet after opening messages which accept replies.

q
q

q

Messages will be deleted when their validity
expire or a new message is received.
When no message has not been received, “No
message” appears at the blue part of the top of
the screen.
Separately from the message display for users
above, the service menu is provided with message display for service.

Screen adjustment
q
q

Press F6 to enter user mode and select “Message display” and you can view (open) the
messages.

q

q
q

Selecting the Screen adjustment from the user
menu and pressing F6 switches to the screen
adjustment screen.
From this menu, you can adjust the brightness,
contrast, and luminance of the machine monitor screen.
When the light switch is in Night mode ON, the
night mode screen is adjustable.
When the light switch is in Daytime mode ON
or OFF, the daytime mode screen is adjustable.

F6 : Returns to the user mode screen.
q

q

54

Under messages that accept replies, “Value to
be entered with 10-key: [ ]” appears.If it
appears, enter the selected item number provided in the message using the switches of the
machine monitor, and press F6.
“Do you want to transmit the entered value?”
appears under the message. Press F6 and the
entered value will be sent.

F2 : Returns all adjusted values to the defaults.
F3 : Decreases the value indicated by the indicator
one graduation left.
F4 : Increases the value indicated by the indicator
one graduation right.
F5 : Cancels changes you made before confirming
them with F6 to return to the menu screen.
F6 : Confirms the changes and moves to the next
item.

PC200, 220-8

and illuminance of the camera screen are also adjustable. The time display part is highlighted. F3 : Moves to the item one right. 2) F3 : Selects (highlights) an item one down. q q SEN00103-01 Clock adjustment q q Selecting the Clock adjustment from the user menu and pressing F6 switches to the clock adjustment screen. selecting Sc reen adjus tment fro m the us er menu switches to the screen for selecting a screen you want to adjust. F5 : Cancels changes you made before confirming them with F6 to return to the menu screen. If the time setting item is not highlighted. The minute display part is highlighted. contrast. press F6 to highlight it. If the item of 12/24 display mode is not highlighted. 1 camera image. F4 : Set the clock back one min. F6 : Confirms the changes and moves to the 12/24 display mode. F3 : Selects (highlights) an item one down. F4 : Moves to the item one left. F5 : Cancels changes you made before confirming them with F6 to return to the menu screen. the brightness. F6 : Confirms the changes and moves to summer time. F5 : Cancels the changes to return to the user menu. F6 : Moves to the setup items of the selected (highlighted) item. function and maintenance standard q q For a camera-equipped machine. F5 : Cancels changes you made before confirming them with F6 to return to the user menu. The background when adjusting the camera screen is the No. F6 : Confirms the changes and moves to minute setting. F3 : Advances the clock one min. The adjustment methods for the camera screen and normal screen are the same. F3 : Advances the clock one hour. press F6 to highlight it. F4 : Selects (highlights) an item one up. F5 : Cancels changes you made before confirming them with F6 to return to the use menu. you can change the setting of the time displayed on the normal screen. 1) Time setting Set the clock time. F6 : Moves to the setup items of the selected (highlighted) item. 55 . On this screen.10 Structure. F4 : Sets the clock back one hour. PC200. F4 : Selects (highlights) an item one up. 220-8 12/24 display mode Specify time display to 12-hour display (AM/PM) or 24-hour display. For a camera-equipped machine.

Japanese. F3 : Moves to the item one right. The fuel consumption level is specified to one of four levels from E0 to E3. Spanish. Cancels the changes to return to the user menu. but the smaller the work rate. F4 : Moves to the item one left. function and maintenance standard Economy mode adjustment q q q Selecting the Economy mode adjustment from the user menu and pressing F6 switches to the Economy mode setting screen. Selects (highlights) an item one up. From this menu. F5 : Cancels changes you made before confirming them with F6 to return to the user menu screen. German. Setting OFF returns to the ordinary time. Cancels the changes to return to the user menu. Chinese. the better the fuel consumption. PC200. Italian. a 10 Structure. French. Russian. Language setting q q F3 : F4 : F5 : F6 : 56 Selecting the Language from the user menu screen and pressing F6 switches to the language setting screen. English. Selects (highlights) an item one up. you can change the language to be displayed on the monitor. Summer time (daylight saving time) is a system to lead a life according to the one-hour advanced time in order to make efficient use of daylight time. 220-8 . Available languages are as follows. The larger the value. F6 : Confirms the changes and moves to the time setting.SEN00103-01 3) Summer time Selecting ON for this sets the time forward one hour. From this menu. you can adjust engine output to improve fuel consumption in E mode. Cancels the changes to return to the user menu. Cancels the changes to return to the user menu. and Turkish F3 : F4 : F5 : F6 : Selects (highlights) an item one down. Portuguese. Selects (highlights) an item one down.

q When the lever is operated q When F5 is pressed q When an error or caution occurs When you switch to the normal screen by pressing F5. after operating the lever. This screen switches to the normal screen if one of the following conditions occurs. If the engine continues to run at least five min. this screen appears again. q No operation is made at least 5 min. this screen does not appear even if the engine continues to run at idle.10 Structure. and the engine is running at idle. q Energy saving guidance display of the service menu is specified to ON. PC200. q No error or caution (excluding low hydraulic oil temperature) is occurring. 220-8 57 . It is displayed only when all the following conditions are met. function and maintenance standard Idle stop guidance function SEN00103-01 1 This function displays guidance to control unnecessary fuel consumption.

a 58 Display LCD check function 1 q Continuously pressing the buzzer cancel switch (1) and F2 at the same time on the password input screen or normal screen causes the entire LCD to light in white. function and maintenance standard 1 q If you continuously pressing auto-deceleration switch (1) and buzzer cancel switch (2) at the same time when setting the starting switch to the OFF position. PC200. Continuous operation of the machine monitor may display blue bright spots on this screen. q Pressing any function switch returns to the previous screen. Release F2 and buzzer cancel switch in order. If any part of the display is black. q When these switches are released. it is quite normal. the LCD goes out.SEN00103-01 Service meter check function 10 Structure. the service meter will appear on the screen in 3 to 5 sec. 220-8 . the LCD is broken.

10 Structure. user code (1) and failure code (2) are displayed on the portion for the hydraulic oil temperature gauge. (For information on how to input and set the telephone number. q If the telephone number has been set in the service menu.) PC200. The drawing below shows the case two types of user codes and failure codes are displayed. they are displayed alternately every 2 sec. 220-8 59 . function and maintenance standard User code/failure code display function q q q SEN00103-01 1 If there is any problem in machine operation. q If multiple user codes or failure codes are issued. the user code and failure code are displayed on the monitor to advise the operator of the steps to take. These codes appear on the normal screen. see “Special functions of monitor panel” in the Testing and adjusting section. On the normal screen. the screen shows the telephone symbol and telephone number simultaneously with the user code/failure code.

Either side of a sensor of contact type is always connected to the chassis ground. 2. 4. 3. 60 When When normal abnormal ON OFF (Closed) (Open) — — OFF (Closed) ON (Closed) ON (Open) OFF (Open) 1 Connector Bracket Float Switch PC200. 220-8 .SEN00103-01 10 Structure. Sensor name Type of sensor Hydraulic oil level Contact Fuel level Resistance Air cleaner clogging Contact Coolant level Contact Hydraulic oil level sensor 1. function and maintenance standard Sensor q q 1 The signals from the sensors are input to the monitor panel directly.

function and maintenance standard Fuel level sensor 1.10 Structure. 3. 220-8 1 61 . 4. SEN00103-01 1 Float Connector Cover Variable resistor Air cleaner clogging sensor PC200. 2.

62 10 Structure.SEN00103-01 Coolant level sensor 1. 2. 4. function and maintenance standard 1 Reserve tank Float Sensor Connector PC200. 3. 220-8 .

function and maintenance standard KOMTRAX terminal system q q q a SEN00103-01 1 The KOMTRAX terminal system consists of a KOMTRAX communication modem. Error history and others. and GPS antenna. To provide the services. Persons to operate the KOMTRAX can refer to the information at office to provide various kinds of services for customers. Operation map 2. PC200. communication antenna. machine monitor. 1. Service meter 3. 220-8 63 .10 Structure. Information transmittable from the KOMTRAX terminal system includes the following. Position information 4. you need to make an arrangement for starting the KOMTRAX service separately. This system transmits various kinds of machine information wirelessly.

Communication antenna connection Connector A (14 poles) Connector B (10 poles) Outline The KOMTRAX communication modem is a wireless communication device to transmit various kinds of machine information or GPS position information the monitor obtains from n e tw o r k s i gn a l s o r i n pu t s i g n a l s i n t h e machine. *2: Signal used by TH200 Input/ output B-1 Serial signal DCD Output B-2 Serial signal RXD Output B-3 Serial signal TXD Input B-4 Serial signal DTR Input B-5 Serial signal SGND Input B-6 Serial signal DSR Output B-7 Serial signal RTS (*2) Input B-8 Serial signal CTS (*2) Output B-9 Serial signal RI (*2) Output B-10 NC(*1) — *1: Never connect to NC or malfunctions or failures will occur.SEN00103-01 KOMTRAX communication modem 10 Structure. *2: Signal used by TH200 64 Pin No. The communication modem can transmit information via the communication antenna. q Input and output signals Connector A Connector B Input/ Pin No. Signal name PC200. 2. The LED is used for maintenance. q The modem is provided with a LED lamp as a display unit. Signal name output A-1 Electric power supply Input A-2 NC(*1) — A-3 NC(*1) — A-4 Electric power supply switching Output A-5 NC(*1) — A-6 NC(*1) — A-7 GND Input A-8 GND Input A-9 Modem power control 1 (*2) Input A-10 Modem power control 2 (*2) Input A-11 Modem serial control (*2) Input A-12 Electric field intensity 1 (*2) Output A-13 Electric field intensity 2 (*2) Output A-14 NC(*1) — *1: Never connect to NC or malfunctions or failures will occur. function and maintenance standard 1 TH300 1. 220-8 . 3.

10 Structure. function and maintenance standard PC200. 220-8 SEN00103-01 65 .

SEN00103-01 PC200. 220(LC)-8 Hydraulic excavator Form No. SEN00103-01 © 2007 KOMATSU All Rights Reserved Printed in Japan 01-07 (01) 66 .

........................................................................................................ 2 Standard value table for engine related parts.........................SEN00227-01 HYDRAULIC EXCAVATOR 1SHOP MANUAL PC200-8 PC200LC-8 PC220-8 PC220LC-8 Machine model Serial number PC200-8 PC200LC-8 PC220-8 PC220LC-8 300001 and up 300001 and up 70001 and up 70001 and up 20 Standard value table 1 Standard service value table Standard service value table ............................................................. 220-8 1 ........................ 4 PC200..................................................................... 2 Standard value table for chassis related parts ..............

98 N{10 kg} mm 8 6 – 10 Air conditioner compressor belt tension • Between fan pulley and compressor pulley • Deflection when pressed with finger force of approx. 1.060 ± 70 Low idle rpm 1. SAE5W40E0S. 0.0} 0.0} 0.25 {2.381 Exhaust valve mm 0.000 2. 25 35 At high idle % — — Intake valve mm 0. 0. 220-8 .25 0.07 {0.2} Engine speed rpm 250 – 280 250 – 280 kPa {mmH2O} Max.050 ± 50 Rated speed rpm 2.96 {200} MPa {kg/cm2} Min. SAE15W40DH.6} 1.SEN00227-01 20 Standard value table Standard service value table 1 Standard value table for engine related parts 1 PC200.41 {Min.29 {Min.000} 103 {775} At sudden acceleration % Max. Oil pressure • SAE0W30E0S. 1.51 0.98 {Max. 2. 133 {Min. Exhaust gas color • Coolant temperature: operating range Valve clearance 2 Applicable model • Normal temperature Compression pressure • Oil temperature: 40 – 60°C Blow-by pressure • Coolant temperature: operating range • Arm IN relief + power max.381 – 0. 3. 24.000 kPa {mmHg} Min.7} Measurement condition • Coolant temperature: operating range Intake pressure (boost pressure) • Coolant temperature: operating range • Arm IN relief + Power Max.10 {Min. 98 N{10 kg} mm 5–8 5–8 PC200.152 – 0. 100} 1. 200LC-8 Engine SAA6D107E-1 Unit Standard value for new machine Judgement criteria High idle rpm 2.69 {17.5} MPa {kg/cm2} Min.060 ± 70 2. High idle SAE10W30DH.762 Compression pressure MPa {kg/cm2} Min.050 ± 50 1. 200LC-8 Category Item Engine speed Engine PC200. 0. SAE30DH engine oil • Coolant Low idle temperature: operating range Oil temperature • Whole speed range (inside oil pan) °C 80 – 110 120 Fan belt tension • Between fan pulley and alternator pulley • Deflection when pressed with finger force of approx.

220LC-8 Category Item Engine speed PC220. 2. 220-8 3 .381 – 0.25 0. SAE5W40E0S. 1. 0.000} 103 {775} At sudden acceleration % Max.7} Measurement condition • Coolant temperature: operating range Intake pressure (boost pressure) • Coolant temperature: operating range • Arm IN relief + Power Max.0} 0.29 {Min. 98 N{10 kg} mm 8 6 – 10 Air conditioner compressor belt tension • Between fan pulley and compressor pulley • Deflection when pressed with finger force of approx.000 2. 3. 1. 0.0} 0.69 {17. SAE15W40DH.160 ± 70 Low idle rpm 1.51 0. Oil pressure • SAE0W30E0S. Exhaust gas color • Coolant temperature: operating range Valve clearance Engine Applicable model • Normal temperature Compression pressure • Oil temperature: 40 – 60°C Blow-by pressure • Coolant temperature: operating range • Arm IN relief + power max. 24.050 ± 50 Rated speed rpm 2. SAE30DH engine oil • Coolant Low idle temperature: operating range Oil temperature • Whole speed range (inside oil pan) °C 80 – 110 120 Fan belt tension • Between fan pulley and alternator pulley • Deflection when pressed with finger force of approx.10 {Min.96 {200} MPa {kg/cm2} Min.381 Exhaust valve mm 0.152 – 0.6} 1.07 {0.000 kPa {mmHg} Min. 220LC-8 Engine SAA6D107E-1 Unit Standard value for new machine Judgement criteria High idle rpm 2.25 {2.98 {Max.160 ± 70 2.41 {Min. 25 35 At high idle % — — Intake valve mm 0.762 Compression pressure MPa {kg/cm2} Min.5} MPa {kg/cm2} Min.2} Engine speed rpm 250 – 280 250 – 280 kPa {mmH2O} Max. 0. 98 N{10 kg} mm 5–8 5–8 PC200. 100} 1.20 Standard value table SEN00227-01 PC220.050 ± 50 1. High idle SAE10W30DH. 133 {Min.

5 Swing control valve LH.5 mm 85 ± 10 85 ± 10 mm 85 ± 10 85 ± 10 mm 85 ± 10 85 ± 10 mm 85 ± 10 85 ± 10 mm 115 ± 12 115 ± 12 Work equipment mm Max. 200LC-8 Measurement condition Unit Standard value for new machine Judgement criteria 2 pumps at relief • Engine coolant temperature: Within operating range • Hydraulic oil temperature: Within operating range • Engine at high idle • Power mode (P) • Arm IN relief condition rpm 1.5 11. 20 Max.5 OUT mm 9.5 9. see Control valve.5 ± 0.5 Lower mm 9.920 ± 100 1.5 ± 0.5 9. 200LC-8 Applicable model Engine speed Category PC200.5 ± 0.950 ± 100 1.5 ± 0.950 ± 100 Speed when autodeceleration is operated • Engine at high idle • Auto-deceleration switch in ON condition • All control levers in NEUTRAL condition rpm 1. 20 Travel mm Max.400 ± 100 Raise mm 11.5 ± 0.5 9.5 ± 0.5 ± 0.5 ± 0.5 ± 0.5 Travel control valve Forward. DUMP mm 9.5 ± 0.5 IN mm 11.5 ± 0.5 ± 0.SEN00227-01 20 Standard value table Standard value table for chassis related parts 1 PC200. 25 Item Spool stroke Boom control valve Arm control valve Bucket control valve • Engine stopped • For measuring point. RH travel mm 9.5 9.5 9. 15 Max.5 ± 0. 220-8 . Boom control lever Travel of control levers Arm control lever Bucket control lever Swing control lever Travel control lever Play of control lever 4 • Engine stopped • Control lever grip at center • Max.5 ± 0.920 ± 100 At 2-pump relief + power max.400 ± 100 1.5 11. • Engine coolant temperature: Within operating range • Hydraulic oil temperature: Within operating range • Engine at high idle • Working mode: P mode • Arm IN relief + Left knob switch ON rpm 1. reading up to stroke end (except lever play in NEUTRAL position) PC200. Reverse mm 9.5 CURL.

3 ± 1.2 {370 – 400} MPa {kg/cm2} 30. 21. reading up to stroke end Travel control pedal Unload pressure Boom relief Arm relief Bucket relief Hydraulic pressure PC200.8 ± 0.2 {370 – 400} Normal relief MPa {kg/cm2} 34. 4.9 {1.20 Standard value table SEN00227-01 Applicable model Operating force of control levers and pedal Category Unit Standard value for new machine Judgement criteria Boom control lever N {kg} 15.6 ± 0.6 ± 0. 2.9 {2.7 ± 2. 2.6 {Max.0 {380 ± 10} 36.5 {Max.6 ± 1.4} Max.0 {36 ± 10} 3.5 ± 0.5} Arm control lever N {kg} 15.3 – 36.8 ± 1. 39.0 {355 ± 10} 33.0 {380 ± 10} 36.3} Max.8 ± 1.0 {36 ± 10} Normal relief MPa {kg/cm2} 34. 21.7 ± 3.2} N {kg} 12.2 {Max.6 {7.8 {340 – 375} Power max.6 {Max.6 {Max. 220-8 • Hydraulic oil temperature: Within operating range • Engine at high idle • Working mode: P mode • Traveling speed: Hi • Run either track with no load • Hydraulic oil pump pressure – LS pressure 5 .3 ± 0. 2.2} N {kg} 24.6} Max.5 {Max.3 ± 1.5 {310 ± 15} 28.3 – 36.8 {340 – 375} Power max.9 {1. 24.1 {18 ± 1} Item Bucket control lever Swing control lever Travel control lever Measurement condition • Hydraulic oil temperature: Within operating range • Engine at high idle • Control lever grip at center • Pedal at tip • Max.7(+1.5 ± 1. 11} • Hydraulic oil temperature: Within operating range • Engine at high idle • Working mode: P mode • Hydraulic pump output pressure with all control levers in NEUTRAL position MPa {kg/cm2} 3.7 ± 3.0) {395(+10/–20)} 36.3} Max.75 – 3.9 {1.3 – 39.43 {28 – 35} When all control levers in NEUTRAL position MPa {kg/cm2} 3. 107.0 {36 ± 10} When traveling at half stroke MPa {kg/cm2} 1.5 ± 1.4} Max. 24.9 {1. 2.3 – 39.2/–0.3 {290 – 330} MPa {kg/cm2} 38.5 ± 5.3 – 36.9} Max. 200LC-8 Swing relief Travel relief • Hydraulic oil temperature: Within operating range • Engine at high idle • Working mode: P mode • Hydraulic pump output pressure with all measurement circuits relieved • Hydraulic oil temperature: Within operating range • Engine at high idle • Working mode: P mode • Hydraulic pump output pressure with all measurement circuits relieved • Hydraulic oil temperature: Within operating range Control circuit source • Engine running at high idle pressure • Self pressure reducing valve output pressure with all control levers in NEUTRAL position LS differential pressure PC200.2 {375 – 410} MPa {kg/cm2} 3. MPa {kg/cm2} 37.3) {33(+2/–3)} 2.7 ± 2.5} N {kg} 12.8 ± 1.0 {355 ± 10} 33.4 – 32.8 – 40.8 {340 – 375} Power max. MPa {kg/cm2} 37.0/–2. MPa {kg/cm2} 37.5 ± 18.5 ± 1.3 ± 1.1 {18 ± 1} 1.0 {380 ± 10} 36.23(+0.0 {36 ± 10} 3.2 {370 – 400} Normal relief MPa {kg/cm2} 34.3 ± 0.8 ± 0.0 {355 ± 10} 33.3 ± 1.5 ± 1.3 – 39.0} N {kg} 74.

7 Time taken to start swing • Hydraulic oil temperature: Within operating range • Engine running at high idle • Working mode: P mode • Time required for passing points 90° and 180° from starting point • For measuring posture.8 ± 1.8 [PC200] 33.9 ± 5. 24.7 – 48. see Swing 1 sec. sec. 4. 3.2 ± 2. 130 (—) 90° sec.3 [PC200LC] 40. 200LC-8 Lo Mi Hi sec. 3.7 – 45.3 Item Travel Swing Category 6 PC200.1 ± 0.5 Max.2 – 60.4 ± 0. (mm) Max. see Travel 1 [PC200] 37. 220-8 . 30 Hydraulic drift of swing • Hydraulic oil temperature: Within operating range • Engine stopped • Keeping upper structure transverse on slope of 15° • Notching a mating mark on inner and outer races of swing circle • Mating mark misalignment amount during 5 minutes • For measuring posture.1 [PC200LC] 36.SEN00227-01 20 Standard value table Applicable model Measurement condition Unit Standard value for new machine Judgement criteria Swing brake angle • Hydraulic oil temperature: Within operating range • Engine running at high idle • Working mode: P mode • Swing circle misalignment amount when stopping after one turn • For measuring posture. see Swing 2 mm 0 0 Leakage from swing motor • Hydraulic oil temperature: Within operating range • Engine running at high idle • Swing lock switch: ON • Leakage amount for one minute during swing relief l/min Max.8 ± 4. see Swing 1 180° sec.4 Max.5 [PC200LC] 27. 5 Max.3 Max. 100 (—) Max.5 Time taken to swing • Hydraulic oil temperature: Within operating range • Engine running at high idle • Working mode: P mode • Time required for 5 more turns after making initial one turn • For measuring posture. 10 [PC200] 51.5 ± 3.8 [PC200LC] 28.5 ± 1. sec.3 – 32. see Swing 1 deg.2 – 29.6 [PC200LC] 50.3 – 65.9 [PC200] 26. PC200. 5.3 [PC200] 25.4 [PC200LC] 55.3 ± 5.1 [PC200] 46.5 Travel speed (without load) • Hydraulic oil temperature: Within operating range • Engine running at high idle • Working mode: P mode • Time required for track shoes to make 5 turns after making one initial idle turn • For measuring posture.

see Travel 4 mm 0 0 Leakage of travel motor • Hydraulic oil temperature: Within operating range • Engine at high idle • Traveling with sprocket locked • Oil leakage amount for one minute with traveling in relief condition l/min 13.5 14. 13 ± 1.5 – 27.0 Travel deviation • Hydraulic oil temperature: Within operating range • Engine at high idle • Working mode: P mode • Travel speed: Lo • Solid and flat ground • Swerving amount while traveling 20 m (X) after initial 10 m trial run • For measuring posture. 240 mm Max. 250 Hydraulic drift of travel • Hydraulic oil temperature: Within operating range • Engine stopped • Parking machine on slope of 12° with sprocket facing upslope • Sliding distance for 5 minutes • For measuring posture.440kg) • Boom horizontal. see Travel 2 and 3 mm Max. 40 Max.0 12. 58 Category Item Travel Travel speed (actual run) Hydraulic drift of work equipment Measurement condition • Hydraulic oil temperature: Within operating range • Engine running at high idle • Working mode: P mode • Flat ground • Time required for traveling 20 m after 10 m trial run • For measuring posture. 220-8 7 . 17 ± 2. 18 Max.0 – 15. 24 ± 2.5 Hi sec.2 mm Max.8m 3: 1. 600 Max.5 – 20. 900 mm Max. 160 Max. bucket cylinder fully extended • Engine stopped Boom cylinder • Work equipment control lever in NEUTRAL position • Fall amount for 15 minutes as measured every 5 minutes starting immediately after initial setting • Whole work equipment: Lowering distance of tooth tip Arm cylinder • Boom cylinder: Retraction distance of cylinder • Arm cylinder: Extraction distance of cylinder • Bucket cylinder: Retraction distance of cylinder Bucket cylinder • For measuring posture. 27 mm Max. 150 Max. see Work equipment 1 Whole work equipment Work equipment PC200.5 Mi sec.6 27. see Travel 2 • Hydraulic oil temperature: Within operating range • Flat and level ground • Fill bucket with dirt or rated load (0.20 Standard value table SEN00227-01 Applicable model Unit Standard value for new machine Judgement criteria Lo sec. 200LC-8 PC200. arm fully retracted.5 21.

7 IN sec.7 Measurement condition • Hydraulic oil temperature: Within operating range • Engine running at high idle • Working mode: P mode • Time required from raise stroke end till bucket touches ground • For measuring posture.6 ± 0.9 ± 0.3 Max. 1.4 ± 0. 2.SEN00227-01 20 Standard value table Applicable model Category Item Work equipment speed Work equipment Boom Arm Bucket 8 PC200. see Work equipment 2 • Hydraulic oil temperature: Within operating range • Engine running at high idle • Working mode: P mode • Time required from dumping stroke end to digging stroke end • For measuring posture.5 CURL sec. 4.4 Max.3 Max. 3. 3. 2. 2.7 LOWER sec. 2.5 OUT sec.3 Max.2 Max. 200LC-8 Unit Standard value for new machine Judgement criteria RAISE sec. 4.5 ± 0.3 ± 0.3 DUMP sec. see Work equipment 4 PC200. 3. 220-8 .7 ± 0. 3. 3. see Work equipment 3 • Hydraulic oil temperature: Within operating range • Engine running at high idle • Working mode: P mode • Time required from dumping stroke end to digging stroke end • For measuring posture.4 Max.

1.2 ± 0. 1.5 20 cc/min 10 50 Performance in compound operation PC200.0 Max.20 Standard value table SEN00227-01 Measurement condition Unit Standard value for new machine Judgement criteria Boom • Hydraulic oil temperature: Within operating range • Engine running at low idle • Working mode: P mode • Time required from raise stroke end till bucket touches ground and pushes up machine front • For measuring posture. see Work equipment 8 sec. see Work equipment 6 sec. see Work equipment 7 sec.6 cc/min 4.440kg) Time required for • On hard and flat ground. 3.2 Arm • Hydraulic oil temperature: Within operating range • Engine running at low idle • Working mode: P mode • Time required from dumping stroke end till bucket stops momentarily after control lever is tilted to digging and starts to move again • For measuring posture. Max. Time lag Item Internal leakage Work equipment Category — Cylinders Center swivel joint Discharge amount of hydraulic pump PC200.8 Bucket • Hydraulic oil temperature: Within operating range • Engine running at low idle • Working mode: P mode • Time required from dumping stroke end till bucket stops momentarily after control lever is tilted to digging and starts to move again • For measuring posture. 220-8 • Hydraulic oil temperature: Within operating range • Engine running at high idle • Leakage amount for one minute with cylinder or travel to be measured in relief condition 4.220 Characteristics of PC flow control valve Applicable model • Hydraulic oil temperature: Within operating range • Engine at high idle • Working mode: P mode • Rated load applied to bucket (0. 2.8m 3: 1. 1. see Work equipment 5 sec. see Travel 2 and 3 mm Max. make equipment and travel approach run of 10 m and then measure deviation in the travel of 20 m • For measuring posture. Max. 2.200 Max. Max. set arm turning from 0 to 90° vertically and lower back of bucket with boom raised to ground • Time required till passing spot of 90° starting from illustrated posture and with boom raised • For measuring posture.0 Max.0 Max. 200LC-8 • Hydraulic oil temperature: Within operating range • Engine at high idle Swerving amount in • Working mode: P mode simultaneous • Traveling speed: Lo operation of work • On hard and flat ground.4 (Reference value) See performance of hydraulic pump (next page) 9 .

take the pump discharge amount and the engine speed at the point of measurement.SEN00227-01 20 Standard value table Applicable model Hydraulic pump Category a a 10 Item Performance of hydraulic pump PC200. When measuring with the pump mounted on the machine. bring pump discharge pressure P1 and P2 as close as possible to the average pressure when measuring. and use them as a base for calculating the pump discharge amount at the specified speed. 220-8 . PC200.000rpm • PC-EPC current value (mA): 440mA • Discharge pressure of test pump (MPa {kg/cm2}): P1 • Discharge pressure of another pump (MPa {kg/cm2}): P2 • Average discharge pressure (MPa {kg/cm2}): Pp=(P1+P2)÷2 l/min Q (See graph) Q (See graph) As far as possible. 200LC-8 Measurement condition Unit Standard value Standard lower limit of delivery • Pump speed (rpm): 2. if it is impossible to set the engine speed to the specified speed with the fuel control dial.

5 CURL.5 9. 25 Item Spool stroke Boom control valve Arm control valve Bucket control valve • Engine stopped • For measuring point.5 OUT mm 9.5 11.5 ± 0.5 ± 0. 15 Max.5 ± 0.5 ± 0. 20 Max.400 ± 100 1.5 9. 220LC-8 Measurement condition Unit Standard value for new machine Judgement criteria 2 pumps at relief • Engine coolant temperature: Within operating range • Hydraulic oil temperature: Within operating range • Engine at high idle • Power mode (P) • Arm IN relief condition rpm 1.5 ± 0.5 mm 85 ± 10 85 ± 10 mm 85 ± 10 85 ± 10 mm 85 ± 10 85 ± 10 mm 85 ± 10 85 ± 10 mm 115 ± 12 115 ± 12 Work equipment mm Max.950 ± 100 1.5 Travel control valve Forward.5 9. Reverse mm 9. see Control valve.940 ± 100 At 2-pump relief + power max.5 ± 0. 220LC-8 Applicable model Engine speed Category PC220. reading up to stroke end (except lever play in NEUTRAL position) Travel control lever Play of control lever PC200.5 ± 0.5 ± 0.940 ± 100 1.5 ± 0.5 ± 0.5 11.20 Standard value table SEN00227-01 PC220. 20 Travel mm Max.5 9.5 ± 0. Boom control lever Travel of control levers Arm control lever Bucket control lever Swing control lever • Engine stopped • Control lever grip at center • Max.5 ± 0.400 ± 100 Raise mm 11. 220-8 11 .5 ± 0. • Engine coolant temperature: Within operating range • Hydraulic oil temperature: Within operating range • Engine at high idle • Working mode: P mode • Arm IN relief + Left knob switch ON rpm 1.5 ± 0.5 Lower mm 9. DUMP mm 9.5 IN mm 11.950 ± 100 Speed when autodeceleration is operated • Engine at high idle • Auto-deceleration switch in ON condition • All control levers in NEUTRAL condition rpm 1.5 Swing control valve LH.5 9. RH travel mm 9.

5 ± 18.6 {Max.6 {Max.9 {2.2 {Max.43 {28 – 35} When all control levers in NEUTRAL position MPa {kg/cm2} 3.3 ± 1.0 {36 ± 10} 3.75 – 3.2 {370 – 400} Normal relief MPa {kg/cm2} 34.9} Max.5 ± 1.7 ± 3.2} N {kg} 24.0) {395(+10/–20)} 36.8 ± 1.0 {36 ± 10} Normal relief MPa {kg/cm2} 34.SEN00227-01 20 Standard value table Applicable model Operating force of control levers and pedal Category Item Unit Standard value for new machine Judgement criteria N {kg} 15.5 {310 ± 15} 28.0 {355 ± 10} 33. MPa {kg/cm2} 37. 2.9 {1.0 {380 ± 10} 36.6 ± 1. MPa {kg/cm2} 37. 11} • Hydraulic oil temperature: Within operating range • Engine at high idle • Working mode: P mode • Hydraulic pump output pressure with all control levers in NEUTRAL position MPa {kg/cm2} 3.5 ± 0.0 {380 ± 10} 36.9 {1.7(+1.3 – 39.8 ± 0.3} Max. 2.4 – 32.2 {370 – 400} Normal relief MPa {kg/cm2} 34.5 ± 5.1 {18 ± 1} Measurement condition Boom control lever Arm control lever Bucket control lever Swing control lever Travel control lever • Hydraulic oil temperature: Within operating range • Engine at high idle • Control lever grip at center • Pedal at tip • Max.1 {18 ± 1} 1.3) {33(+2/–3)} 2.8 ± 1.3 ± 0.6 ± 0.6 ± 0.8 ± 0. 220-8 . 4. MPa {kg/cm2} 37.3 – 36. reading up to stroke end Travel control pedal Unload pressure Boom relief Arm relief Bucket relief Hydraulic pressure PC220.3 – 39.3 ± 1. 107.8 {340 – 375} Power max.2 {375 – 410} MPa {kg/cm2} 3.5} N {kg} 15.3 {290 – 330} MPa {kg/cm2} 38. 24.4} Max.3 ± 1.6 {7.23(+0.0 {355 ± 10} 33.5 {Max.9 {1.6} Max. 21. 2. 21.2} N {kg} 12. 39.5 ± 1.8 {340 – 375} Power max.0/–2.0} N {kg} 74.8 – 40.7 ± 2.3 – 39.5} N {kg} 12.7 ± 2.7 ± 3.2 {370 – 400} MPa {kg/cm2} 30.3} Max.3 – 36.3 ± 1.0 {36 ± 10} 3. 220LC-8 Swing relief Travel relief • Hydraulic oil temperature: Within operating range • Engine at high idle • Working mode: P mode • Hydraulic pump output pressure with all measurement circuits relieved • Hydraulic oil temperature: Within operating range • Engine at high idle • Working mode: P mode • Hydraulic pump output pressure with all measurement circuits relieved • Hydraulic oil temperature: Within operating range Control circuit source • Engine running at high idle pressure • Self pressure reducing valve output pressure with all control levers in NEUTRAL position LS differential pressure 12 • Hydraulic oil temperature: Within operating range • Engine at high idle • Working mode: P mode • Traveling speed: Hi • Run either track with no load • Hydraulic oil pump pressure – LS pressure PC200.0 {36 ± 10} When traveling at half stroke MPa {kg/cm2} 1.4} Max.5 {Max.5 ± 1.0 {355 ± 10} 33.9 {1. 24.8 {340 – 375} Power max.0 {380 ± 10} 36. 2.5 ± 1.8 ± 1.3 – 36.2/–0.6 {Max.3 ± 0.

4 Time taken to swing • Hydraulic oil temperature: Within operating range • Engine running at high idle • Working mode: P mode • Time required for 5 more turns after making initial one turn • For measuring posture.5 ± 0.6 – 51.9 Item Travel Swing Category PC220. 13 .5 Time taken to start swing • Hydraulic oil temperature: Within operating range • Engine running at high idle • Working mode: P mode • Time required for passing points 90° and 180° from starting point • For measuring posture.4) [PC220LC] 28.3 Max.6(+6. 220-8 Lo Mi Hi sec.9) [PC220LC] 38.6) [PC220] 35.3) [PC220LC] 52. 5. 4.9) [PC220] 48.8 Max. 3.4/–3.6 [PC220LC] 58. 220LC-8 PC200. (mm) Max. sec.8 – 68. 25.7 ± 2.3(+1.5(–4. 3.2(+4.7/–3.6/–1.2 [PC220] 28.0 ± 0. 200 (—) 90° sec.0/–4. see Travel 1 [PC220] 39.5/–1.4 Max. 165 (—) Max. see Swing 1 180° sec. see Swing 1 sec.6 – 47. 5 Max. sec.7 – 63.6 Travel speed (without load) • Hydraulic oil temperature: Within operating range • Engine running at high idle • Working mode: P mode • Time required for track shoes to make 5 turns after making one initial idle turn • For measuring posture.5 [PC220LC] 30.6 [PC220LC] 42.3) [PC220] 26. 31 Hydraulic drift of swing • Hydraulic oil temperature: Within operating range • Engine stopped • Keeping upper structure transverse on slope of 15° • Notching a mating mark on inner and outer races of swing circle • Mating mark misalignment amount during 5 minutes • For measuring posture. 10 [PC220] 53.0(+1. see Swing 2 mm 0 0 Leakage from swing motor • Hydraulic oil temperature: Within operating range • Engine running at high idle • Swing lock switch: ON • Leakage amount for one minute during swing relief l/min Max.7 – 31.20 Standard value table SEN00227-01 Applicable model Measurement condition Unit Standard value for new machine Judgement criteria Swing brake angle • Hydraulic oil temperature: Within operating range • Engine running at high idle • Working mode: P mode • Swing circle misalignment amount when stopping after one turn • For measuring posture.9 – 33.5/–5. see Swing 1 deg.1(+6.

18 Max. see Travel 2 • Hydraulic oil temperature: Within operating range • Flat and level ground • Fill bucket with dirt or rated load (0.0 15. arm fully retracted.8m 3: 1.6 27.0 – 15.0 Travel deviation • Hydraulic oil temperature: Within operating range • Engine at high idle • Working mode: P mode • Travel speed: Lo • Solid and flat ground • Swerving amount while traveling 20 m (X) after initial 10 m trial run • For measuring posture. 160 Max.2 mm Max. see Travel 2 and 3 mm Max. 13 ± 1.5 21. 150 Max.5 Mi sec. 40 Max.SEN00227-01 20 Standard value table Applicable model Unit Standard value for new machine Judgement criteria Lo sec. 220LC-8 PC200.5 – 27.440kg) • Boom horizontal. bucket cylinder fully extended • Engine stopped Boom cylinder • Work equipment control lever in NEUTRAL position • Fall amount for 15 minutes as measured every 5 minutes starting immediately after initial setting • Whole work equipment: Lowering distance of tooth tip Arm cylinder • Boom cylinder: Retraction distance of cylinder • Arm cylinder: Extraction distance of cylinder • Bucket cylinder: Retraction distance of cylinder Bucket cylinder • For measuring posture. 17 ± 2. 900 mm Max. 27 mm Max. 24 ± 2. 220-8 . 600 Max.0 – 20.0 12. 58 Category Item Travel Travel speed (actual run) Hydraulic drift of work equipment Work equipment Measurement condition • Hydraulic oil temperature: Within operating range • Engine running at high idle • Working mode: P mode • Flat ground • Time required for traveling 20 m after 10 m trial run • For measuring posture. see Work equipment 1 Whole work equipment 14 PC220. 240 mm Max. see Travel 4 mm 0 0 Leakage of travel motor • Hydraulic oil temperature: Within operating range • Engine at high idle • Traveling with sprocket locked • Oil leakage amount for one minute with traveling in relief condition l/min 13.0 Hi sec. 250 Hydraulic drift of travel • Hydraulic oil temperature: Within operating range • Engine stopped • Parking machine on slope of 12° with sprocket facing upslope • Sliding distance for 5 minutes • For measuring posture.

9(+0.20 Standard value table SEN00227-01 Applicable model Category Item Work equipment speed Work equipment Boom Arm Bucket PC200.7 ± 0. 4. 4. see Work equipment 4 15 .7 Measurement condition • Hydraulic oil temperature: Within operating range • Engine running at high idle • Working mode: P mode • Time required from raise stroke end till bucket touches ground • For measuring posture.4 Max.9 LOWER sec. 4.3 DUMP sec. 2.3) Max. 220-8 PC220. 3. 220LC-8 Unit Standard value for new machine Judgement criteria RAISE sec.5/–0. 3. 3.4 IN sec.7 ± 0. see Work equipment 3 • Hydraulic oil temperature: Within operating range • Engine running at high idle • Working mode: P mode • Time required from dumping stroke end to digging stroke end • For measuring posture.3 Max. 4. 2. 2.7 OUT sec.1 ± 0.4/–0.2) Max. 2. see Work equipment 2 • Hydraulic oil temperature: Within operating range • Engine running at high idle • Working mode: P mode • Time required from dumping stroke end to digging stroke end • For measuring posture.0 ± 0. 2.4(+0.3 Max.3 Max.5 CURL sec.

200 Max. Max. 220-8 . see Work equipment 5 sec. 2.0 Max. Max. 2.8m 3: 1.6 cc/min 4. 220LC-8 • Hydraulic oil temperature: Within operating range • Engine at high idle Swerving amount in • Working mode: P mode simultaneous • Traveling speed: Lo operation of work • On hard and flat ground. 1. 3.0 Max.0 Max. Max. see Work equipment 6 sec.3 ± 0. see Work equipment 7 sec. see Work equipment 8 sec. set arm turning from 0 to 90° vertically and lower back of bucket with boom raised to ground • Time required till passing spot of 90° starting from illustrated posture and with boom raised • For measuring posture.SEN00227-01 20 Standard value table Measurement condition Unit Standard value for new machine Judgement criteria Boom • Hydraulic oil temperature: Within operating range • Engine running at low idle • Working mode: P mode • Time required from raise stroke end till bucket touches ground and pushes up machine front • For measuring posture.220 Characteristics of PC flow control valve Applicable model • Hydraulic oil temperature: Within operating range • Engine at high idle • Working mode: P mode • Rated load applied to bucket (0.5 20 cc/min 10 50 Performance in compound operation PC220.440kg) Time required for • On hard and flat ground. Time lag Item Internal leakage Work equipment Category — 16 Cylinders Center swivel joint Discharge amount of hydraulic pump • Hydraulic oil temperature: Within operating range • Engine running at high idle • Leakage amount for one minute with cylinder or travel to be measured in relief condition 4.4 (Reference value) See performance of hydraulic pump (next page) PC200. see Travel 2 and 3 mm Max. 1.8 Bucket • Hydraulic oil temperature: Within operating range • Engine running at low idle • Working mode: P mode • Time required from dumping stroke end till bucket stops momentarily after control lever is tilted to digging and starts to move again • For measuring posture. make equipment and travel approach run of 10 m and then measure deviation in the travel of 20 m • For measuring posture. 1.2 Arm • Hydraulic oil temperature: Within operating range • Engine running at low idle • Working mode: P mode • Time required from dumping stroke end till bucket stops momentarily after control lever is tilted to digging and starts to move again • For measuring posture.

000rpm • PC-EPC current value (mA): 440mA • Discharge pressure of test pump (MPa {kg/cm2}): P1 • Discharge pressure of another pump (MPa {kg/cm2}): P2 • Average discharge pressure (MPa {kg/cm2}): Pp=(P1+P2)÷2 l/min Q (See graph) Q (See graph) As far as possible. bring pump discharge pressure P1 and P2 as close as possible to the average pressure when measuring. and use them as a base for calculating the pump discharge amount at the specified speed. When measuring with the pump mounted on the machine. if it is impossible to set the engine speed to the specified speed with the fuel control dial. PC200. take the pump discharge amount and the engine speed at the point of measurement. 220-8 17 .20 Standard value table SEN00227-01 Applicable model Hydraulic pump Category a a Item Performance of hydraulic pump PC220. 220LC-8 Measurement condition Unit Standard value Standard lower limit of delivery • Pump speed (rpm): 2.

220-8 . travel deviation Swing 1: Swing brake angle.SEN00227-01 For all models (Posture of machine for measuring performance and measurement procedure) 20 Standard value table Travel 1: Travel speed (without load) Control valve: spool stroke Travel 2: Travel speed (actual run). time taken to start swing. time taken to swing Travel 3: Travel deviation Swing 2: Hydraulic drift of swing 18 PC200.

220-8 19 .20 Standard value table SEN00227-01 Travel 4: Hydraulic drift of travel Work equipment 3: Arm speed Work equipment 1: Hydraulic drift of work equipment Work equipment 4: Bucket speed Work equipment 5: Boom time lag Work equipment 2: Boom speed PC200.

SEN00227-01 20 Standard value table Work equipment 6: Arm time lag Work equipment 7: Bucket time lag Work equipment 8: Characteristics of PC flow control valve 20 PC200. 220-8 .

SEN00227-01 © 2006 KOMATSU All Rights Reserved Printed in Japan 03-06 (01) 22 .SEN00227-01 PC200. 220(LC)-8 Hydraulic excavator Form No.

....................................... 16 Measuring fuel return rate and leakage ................................................................................. 23 PC200.......................................................................................................................... 220-8 1 ........................ 9 Measuring compression pressure .................................................................................................................................. 15 Measuring fuel pressure...... 22 Checking and adjusting air conditioner compressor belt tension ............................... 8 Adjusting valve clearance ........................................................................................................................ Part 1 Testing and adjusting.......................SEN00228-02 HYDRAULIC EXCAVATOR 1SHOP MANUAL PC200-8 PC200LC-8 PC220-8 PC220LC-8 Machine model Serial number PC200-8 PC200LC-8 PC220-8 PC220LC-8 300001 and up 300001 and up 70001 and up 70001 and up 30 Testing and adjusting 1 Testing and adjusting...................................................................................................................................................11 Measuring blow-by pressure .............................................. 13 Measuring engine oil pressure ............................................................................................................................................................................................... 7 Checking exhaust gas color .............................................................. 3 Measuring engine speed........................................ 3 Tools for testing................................................................................................................................ 15 Releasing residual pressure from fuel system .............................................................................................. 14 Handling fuel system parts .................................................................................................................. 6 Measuring intake air pressure (boost pressure)............ Part 1............................................... 20 Checking fuel circuit for leakage .............................................................................. and troubleshooting ................................................. 18 Bleeding air from fuel circuit........................ adjusting.............................

....................................................... 47 Measuring oil leakage ...........................................................................................SEN00228-02 30 Testing and adjusting Replacing fan belt............................ swing............................................................................................................................................................................................ 24 Measuring swing circle bearing clearance ................ 51 Checking cab tipping stopper ..................................................................................................................................................... 32 Measuring and adjusting oil pressure in pump LS control circuit .......................................................................................................................................................... 26 Measuring and adjusting oil pressure in work equipment................................................. 54 2 PC200........................................................................... 28 Measuring control circuit basic pressure ....................................................................... 53 Adjusting mirrors ........................... and travel circuits ............................................................................. 39 Measuring PPC valve output pressure........... 35 Measuring solenoid valve output pressure............................................................... 220-8 ....................................................................................... 45 Releasing residual pressure from hydraulic circuit........ 31 Measuring and adjusting oil pressure in pump PC control circuit........................................................................................................ 42 Adjusting play of work equipment and swing PPC valves....................................... 48 Bleeding air from each part .................................. 44 Checking parts which cause hydraulic drift of work equipment ............. 25 Checking and adjusting track shoe tension..................................................

25 mm 1 1 3 .0 MPa 1 {10 kg/cm2} 1 1 1 1 F 2 3 799-401-2320 Hydraulic tester 1 795-790-4700 Tester kit 2 795-790-6700 Adapter 6754-71-5340 Connector 3 Measuring fuel return rate 6754-71-5350 Washer G and leakage Commercially 4 Measuring cylinder available Commercially 5 Stopwatch available Measuring swing circle Commercially H Dial gauge bearing clearance available 799-101-5002 Hydraulic tester Measuring and adjusting 1 oil pressure in work equipJ 790-261-1204 Digital hydraulic tester ment. 60 MPa {25. 600 kg/cm2} Pressure gauge: 60 MPa 1 {600 kg/cm2} 1 Size: 10 × 1. 400. 400. 40. 40. swing.5. 6.5. 6. 600 kg/cm2} Pressure gauge: 60 MPa 1 {600 kg/cm2} 2 Size: 10 × 1. 60.25 mm. 6. 400.0 MPa {10 kg/cm2} Pressure gauge: 2. Part 1 Remarks 1 – 101 – 200 kPa {– 760 – 1.0. 40.500 mmHg} Handy smoke checker 1 Smoke meter 1 Gear 1 Thickness gauge 1 Intake: 0. 60 MPa {25.0.25 mm 2 Pressure gauge: 2.5.0 mm o R1/8 1 Pressure gauge: 1. adjusting. 220-8 0 – 6.0. 40. 6. and travel circuits 799-101-5220 Nipple 2 07002-11023 O-ring 799-101-5002 Hydraulic tester Measuring basic pressure K of control circuit 1 790-261-1204 Digital hydraulic tester 2 PC200. 400. and troubleshooting 1 Testing/Adjusting item Symbol Measuring intake air pressure (boost pressure) R Checking exhaust gas color Adjusting valve clearance Measuring compression pressure Measuring blow-by pressure Part No. 60 MPa 1 {25. 600 kg/cm2} Pressure gauge: 60 MPa {600 kg/cm2} 2 799-401-2320 Hydraulic tester 1 Measuring fuel pressure Bosch index: 0 – 9 799-101-5220 Nipple 07002-11023 O-ring 1 1 1 Pressure gauge: 2. 60.9 MPa {0 – 70 kg/cm2} For 107E-1 engine For 107E-1 engine For 107E-1 engine 0 – 5 kPa {0 – 500 mmH2O} For 107E-1 engine Pressure gauge: 2.51 mm Compression gauge Puller Adapter Gasket Blow-by checker Blow-by tool 1 1 1 1 1 1 799-101-5002 Hydraulic tester 1 790-261-1204 Digital hydraulic tester 1 1 1 799-101-5002 Hydraulic tester 1 790-261-1204 Digital hydraulic tester 1 795-790-4430 Adapter 6215-81-9710 O-ring 1 10 × 1. 600 kg/cm2} Pressure gauge: 60 MPa {600 kg/cm2} Pressure gauge: 1. 60.5.0.30 Testing and adjusting SEN00228-02 1 Tools for testing. 799-201-2202 Boost gauge kit 1 799-201-9001 Commercially 2 available 1 795-799-1131 B Commercially 2 available 1 795-502-1590 2 795-799-6700 C 795-790-4410 3 6754-11-3130 1 799-201-1504 D 2 795-790-3300 A Measuring engine oil presE sure Part name Q'ty Testing and adjusting. Exhaust: 0. 60. 60 MPa {25.

220-8 .Testing/Adjusting item 30 Testing and adjusting Symbol Part No. 6.0. 40. 60. 6.5. 400.25 mm 4 Pressure gauge: 2. 60 MPa 1 {25.0. 400. 60.0. 600 kg/cm2} Pressure gauge: 60 MPa 1 {600 kg/cm2} 1 1 49 MPa {500 kg/cm2} 4 Size: 10 × 1. 400. 600 kg/cm2} Pressure gauge: 60 MPa 1 {600 kg/cm2} 1 Size: 02 Pressure gauge: 2.5. 6. 6. 60 MPa 1 {25. 60 MPa 1 {25. 40.25 mm 4 Pressure gauge: 2. 40.5. 60. 40. 60. 600 kg/cm2} Pressure gauge: 60 MPa 1 {600 kg/cm2} 4 Size: 10 × 1. 400.5. 60 MPa {25. 600 kg/cm2} Pressure gauge: 60 MPa 1 {600 kg/cm2} 1 Size: 02 1 Size: 03 1 1 1 1 1 1 1 For DRC60. ECONO (Does not include 799-601-4201) Engine controller Engine controller Engine controller For injector 1 — 799-601-4350 or • Measurement box 799-601-9320 1 — 799-601-9020 • Adapter for DT 1 — 799-601-9030 • Adapter for DT 1 — 799-601-4260 • Adapter for DT 1 For ECONO (Does not include 799-601-4201/ 799-601-9000 and 799-601-9200) For ECONO (Does not include 799-601-4101/ 799-601-4201 and 799-601-9200) For DT2P For DT3P (Does not include 799-601-4101 and 799-601-4201) For DTP4 (Does not include 799-601-9000 and 799-601-9200) PC200.0. 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 Measuring and adjusting oil pressure in pump LS control circuit 790-261-1204 Digital hydraulic tester M Differential pressure gauge 799-101-5220 Nipple 3 07002-11023 O-ring 2 799-401-2701 799-101-5002 Hydraulic tester Measuring solenoid valve output pressure N 1 790-261-1204 Digital hydraulic tester 2 799-401-3100 Adapter 799-101-5002 Hydraulic tester Measuring PPC valve outP put pressure Measuring oil leakage Troubleshooting for engine Controller/sensors/actuators 1 2 799-401-3100 Adapter 3 799-401-3200 Adapter Commercially Q Measuring cylinder available 799-601-4101 — or T-adapter assembly 799-601-4201 — 799-601-4350 • Measurement box — — — — 799-601-4211 799-601-4220 799-601-4260 799-601-9020 799-601-4101 or 799-601-4201 or 799-601-9000 or 799-601-9200 — Troubleshooting for chassis Sensors/wiring harnesses 4 790-261-1204 Digital hydraulic tester • • • • T-adapter T-adapter T-adapter T-adapter T-adapter assembly Q'ty SEN00228-02 Remarks Pressure gauge: 2.

see “Troubleshooting (General information on troubleshooting). of the T-boxes and T-adapters used for troubleshooting for the machine monitor. 4/DTM-2 For pump controller — Commercially Torque wrench available 1 3.26 mm torque wrench (KTC Q4T15 or equivalent) — 795-799-6210 Deep socket 1 27 mm deep socket — Commercially Socket available 1 21 mm deep socket (MITOLOY 4ML-21 or equivalent) For the model names and part Nos. Part name Q'ty 30 Testing and adjusting Remarks — 799-601-7000 or 799-601-7100 or T-adapter assembly 799-601-7400 or 799-601-8000 1 — 799-601-2600 • Measurement box 1 — — — — 799-601-7090 799-601-7110 799-601-7120 799-601-7140 — 799-601-7050 • Adapter for SWP 1 — 799-601-7060 • Adapter for SWP 1 — 799-601-7010 • Adapter for X 1 — — — — — 799-601-7020 799-601-7360 799-601-7310 799-601-9890 799-601-4280 • Adapter for X 1 1 1 1 1 — 799-101-1502 Digital thermometer 1 – 99. 3. sensors.299°C 79A-264-0021 79A-264-0091 Commercially available Commercially available Commercially available Push-pull scale Push-pull scale 1 0 – 294 N {0 – 30 kg} 1 0 – 490 N {0 – 50 kg} Ruler 1 Stopwatch 1 Circuit tester 1 — — — — • • • • Adapter for M Adapter for M Adapter for M Adapter for S Adapter for relay Adapter for SWP Adapter for multiple Measurement box 1 1 1 1 For ECONO (Does not include 799-601-7000) For M2P For M3P For M4P For S8P For SW6P (Does not include 799-601-8000) For SW8P (Does not include 799-601-8000) For X1P (Does not include 799-601-7000 and 799-601-7100) For X2P For REL-5P For SW12P For DT-2.Testing/Adjusting item Troubleshooting for chassis Sensors/wiring harnesses Measuring coolant temperature and oil temperature Measuring operating effort and depressing force Measuring stroke and hydraulic drift Measuring 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 a SEN00228-02 Symbol Part No. PC200. and wiring harnesses. 220-8 5 . List of T-boxes and T-adapters”. electrical equipment.9 – 1. actuators. controllers.

3) While operating the left work equipment control lever to relieve the arm circuit at the IN stroke end and depressing the power maximizing switch. and travel in neutral and measure the engine speed. PC200. measure the engine speed in that period. Measure the engine speed under the following condition. 2) Set all the levers and pedals for work equipment control. see Special functions of machine monitor.) 6. a You may check with the swing lock switch ON (In this case. and travel in neutral and measure the engine speed when the auto-decelerator operates. a For the operating method of the machine monitor. q Engine coolant temperature: Within operating range q Hydraulic oil temperature: Within operating range Preparation work Operate the machine monitor so that the engine speed can be monitored. 3) Set all the levers and pedals for work equipment control. 2) Set the fuel control dial in the high idle (MAX) position and set the working mode in the power mode (P). This level is the auto-deceleration speed. a Monitoring code: 01002 Engine speed Measuring low idle speed 1) Start the engine and set the fuel control dial in the low idle (MIN) position. 2) Set the working mode in the power mode (P) and turn the auto-decelerator OFF. Measuring 2-pump relief and power maximizing speed (near rated speed) 1) Start the engine and operate the arm cylinder to the IN stroke end.5 seconds even if the switch is kept depressed. 2. 2) Set all the levers and pedals for work equipment control. Measuring auto-deceleration speed 1) Start the engine. Measure the engine speed with the monitoring function of the machine monitor. a The power maximizing function is reset automatically in about 8. swing control. swing control. and turn the auto-decelerator ON. 220-8 . 5. 6 30 Testing and adjusting 1 3. swing control. measure the engine speed. 2) Set the fuel control dial in the high idle (MAX) position and set the working mode in the power mode (P). Measuring high idle speed 1) Start the engine and set the fuel control dial in the high idle (MAX) position. and travel in neutral and measure the engine speed. Measuring 2-pump relief speed 1) Start the engine and operate the arm cylinder to the IN stroke end.SEN00228-02 Measuring engine speed a a 1. 3) Operate the left work equipment control lever to relieve the arm circuit at the IN stroke end and measure the engine speed. Accordingly. a The engine speed lowers to a certain level about 5 seconds after all the levers and pedals are set in neutral. set the fuel control dial in the high idle position (MAX). 4. you do not need to operate the power maximizing switch.

you use the airbleeding coupling (790-261-1130) in that kit. a If Pm kit (A) is available. q Engine coolant temperature: Within operating range q Hydraulic oil temperature: Within operating range 1. Part name R 799-201-2202 Boost gauge kit k a 3. After finishing measurement. Open the engine hood and remove intake air pressure pickup plug (1) from the intake air connector. and the oil will be drained. Stop the machine on a level ground and lower the work equipment to the ground. Set the working mode in the power mode (P) and turn the swing lock switch ON. be sure to drain the oil. remove the measuring tools and return the removed parts. the main relief valve is set for high-pressure relief. 220-8 7 . Accordingly. a If the swing lock switch is turned ON. the gauge does not work. 5. 1 Measuring tools for intake air pressure (boost pressure) Symbol Part No. PC200. 6. relieve the arm circuit and measure the intake air pressure. 2. 4. Measure the intake air pressure under the following condition. Install nipple [1] of boost gauge kit R and connect it to gauge [2]. a Insert the connecting parts of the gauge and hose about a half and open the selfseal on the hose side repeatedly. a If oil is left in the hose. While running the engine at high idle.30 Testing and adjusting SEN00228-02 Measuring intake air pressure (boost pressure) a Run the engine at middle or higher speed and bleed oil from the hose.

Be careful not to touch any hot part when removing or installing the checking tools. remove the measuring tools and return the removed parts. remove the checking tools and return the removed parts. Place the contaminated filter paper on the clean filter paper (at least 10 sheets) in the filter paper holder and read the indicated value.SEN00228-02 30 Testing and adjusting Checking exhaust gas color a Checking tools for exhaust gas color Symbol A k k a a 1.2 sec 2) 3) 4) 5) 6) 4) 5) Remove the filter paper and compare it with the attached scale. 2) Insert the exhaust gas intake pipe in exhaust pipe (1). Loosen the cap nut of the suction pump and fit the filter paper. a Fit the filter paper securely so that the exhaust gas will not leak. When recording official data. 8 Checking with smoke meter A2 1) Insert probe [1] of smoke meter A2 in the outlet of the exhaust pipe and fix it to the exhaust pipe with a clip. 1 Part No. Start the engine and accelerate it suddenly or run it at high idle and depress the accelerator pedal of smoke meter A2 and collect the exhaust gas into the filter paper. Check the exhaust gas color under the following condition. Connect the power cable to an AC receptacle. Part name 1 799-210-9001 Handy smoke checker 2 Commercially available Smoke meter Stop the machine on a level ground and lower the work equipment to the ground. check that the power switch of the smoke meter is turned OFF. PC200. a Limit the supplied air pressure to 1. 220-8 . and air hose to smoke meter A2.4 ± 0. Turn on the power switch of smoke meter A2. use handy smoke checker A1. a Before connecting the cable. 8) Connect the probe hose. After finishing checking. q Engine coolant temperature: Within operating range If an air source and an electric power source are not available in the field. After finishing checking. receptacle of the accelerator switch. 7) 2.5 MPa {15 kg/cm2}. a Absorbing time: 1. use smoke meter A2. Measuring with handy smoke checker A1 1) Stick a sheet of filter paper to smoke checker A1. 3) Start the engine and accelerate it suddenly or run it at high idle and operate the handle of smoke checker A1 so that the filter paper will absorb the exhaust gas.

Take care. If you can move the rocker arms of exhaust valves (EX) with the hand by the valve clearance. Valve arrangement drawing 9 . the piston in the No. PC200. Remove cylinder head cover (1). a Projection top (a) must be within the range of wide slit (b) when it is seen from the air conditioner compressor side. 1 cylinder to judge the valve to be adjusted. Remove plug (2) from the top of the starting motor and insert gear B1. a Since the breather connector on the rear side of the cylinder head cover is connected to the flywheel housing through the O-ring. 5. pull it together with the cylinder head cover. Open the engine hood and remove the belt guard from the top of the air conditioner compressor. Rotate the crankshaft forward with gear B1 and set wide slit (b) of the rotation sensor ring to projection top (a) of front cover. k When the crankshaft is set as above. q Engine coolant temperature: Normal temperature 1. a a 3. a If you can see the yellow marks of projection top (a) and wide slit (b). 220-8 a If you can move the rocker arms of air intake valves (IN) with the hand by the valve clearance. adjust the valves marked with Q in the valve arrangement drawing. 2. 6 cylinder is not set to the compression top dead center (TDC). 1 or No. Check the movement of the rocker arm of the No. Measure the valve clearance under the following condition.30 Testing and adjusting SEN00228-02 Adjusting valve clearance a k a 4. Measuring tools for valve clearance Symbol B 1 Part No. you may set them to each other. adjust the valves marked with q in the valve arrangement drawing. Part name 1 795-799-1131 Gear 2 Commercially available Thickness gauge Stop the machine on a level ground and lower the work equipment to the ground.

remove the adjusting tools and return the removed parts. After finishing adjustment. a If the valves marked with Q in the valve arrangement drawing were adjusted in steps (5) and (6). Rotate the crankshaft forward by 1 turn and set wide slit (b) to projection top (a) according to step 4. tighten locknut (4). adjust the valves marked with q. 3 Cylinder head cover mounting nut: 24 ± 4 Nm {2.45 ± 0.41 kgm} 10 30 Testing and adjusting PC200. 9. 220-8 . loosen locknut (4). 1) While fixing adjustment screw (3). k Remove gear B1 without fail. 8. adjust the valves marked with Q. 2) Insert thickness gauge B2 in the clearance between rocker arm (5) and crosshead (6) and adjust the valve clearance with adjustment screw (3). Adjust the other valve clearances according to steps (5) and (6). turn the adjustment screw to a degree that you can move the thickness gauge lightly. 3) While fixing adjustment screw (3).SEN00228-02 6. check the valve clearance again. 7. a With the thickness gauge inserted. a If the valves marked with q in the valve arrangement drawing were adjusted in steps (5) and (6).45 ± 0.41 kgm} a After tightening the locknut. 3 Locknut: 24 ± 4 Nm {2. Adjust the valve clearance according to the following procedure.

Measure the compression pressure under the following condition. air does not leak easily. 4. a Install the gasket to the adapter end without fail.5 ± 0. Using tool C2. pull it together with the cylinder head cover.04 kgm} 2nd time: 75 ± 5 ° (Angle tightening) a If a little quantity of engine oil is applied the joint of the adapter and gauge. 3 Injector clamp mounting bolt: 1st time : 3. Remove the mounting bolts of rocker arm assembly (2) on the exhaust side. Open the engine hood and remove cylinder head cover (1).30 Testing and adjusting SEN00228-02 Measuring compression pressure a Measuring tools for compression pressure Symbol C a 1. remove injector (4). q Engine oil temperature: 40 – 60°C 5.36 ± 0. a When removing the injector. a Since the breather connector on the rear side of the cylinder head cover is connected to the flywheel housing through the O-ring. 3. a See “Adjusting valve clearance”. 220-8 11 .35 Nm {0. Part name 1 795-502-1590 2 795-799-6700 Puller 795-790-4410 Adapter 6754-11-3130 Gasket 3 k 1 Compression gauge Stop the machine on a level ground and lower the work equipment to the ground. Install rocker arm assembly (2) on the exhaust side and adjust the valve clearance. Part No. you do not need to remove the rocker arm assembly on the intake side. and then remove rocker arm assembly (2). Disconnect injector wiring harness. Remove fuel tube (3). Install adapter C3 to the injector mounting part with the injector clamp and connect compression gauge C1. PC200. and then remove inlet connector (7) in the cylinder head. 2. a The inlet connector is connecting the fuel tube to the injector. 6.

41 kgm} 12 PC200. 4) Install inlet connector (7) and tighten inlet connector retainer temporarily. 3 Cylinder head cover mounting nut: 24 ± 4 Nm {2. k If the connector is not disconnected.08 kgm} 6) Tighten inlet connector retainer (8) securely.6 ± 0.4 kgm} 3 Rocker arm assembly mounting bolt: 36 ± 6 Nm {3. remove the measuring tools and return the removed parts.25 Nm {0. 30 Testing and adjusting 9. the engine will start during measurement and it will be dangerous. a Install the injector and inlet connector according to the following procedure.026 kgm} 3 Fuel tube sleeve nut: 35 ± 3. Disconnect CE03 connector (5) of the engine controller. see “Adjusting valve clearance”.5 ± 0. k Since the CE03 connector is a part of the power supply circuit of the engine controller.8 ± 0. 3) Install injector clamp (6) and tighten the mounting bolt by 3 – 4 threads. a Read the gauge when the pointer is stabilized. etc.45 ± 0. cover the connector on the machine side with a vinyl sheet.5 kgm} a Tighten the bolts and nuts other than the injector and inlet connector to the following torque.SEN00228-02 7. 3 Inlet connector retainer: 50 ± 5 Nm {5. Rotate the engine with the starting motor and measure the compression pressure. to prevent electric leakage and ground fault.6 kgm} a Adjust the valve clearance. 3 Injector clamp mounting bolt: 8 ± 0. 220-8 . 3 Injector wiring harness nut: 1.5 Nm {3. 8.15 ± 0.1 ± 0.7 ± 0. For details. 2) Install injector (4) with the fuel inlet hole directed to the air intake manifold. 1) Apply new engine oil (SAE15W-40) to the O-ring of injector (4) and cylinder head. After finishing measurement. 5) Tighten the mounting bolt of injector clamp (6) securely.8 Nm {0.

Install tool and adapter [1] of blow-by checker D1 or blow-by tool D2 to breather hose (1) and connect gauge [2]. Part name 1 799-201-1504 Blow-by checker 2 799-790-3300 Blow-by tool Stop the machine on a level ground and lower the work equipment to the ground. a Read the gauge when the pointer is stabilized. remove the measuring tools and return the removed parts. 3. While running the engine at high idle. Measure the blow-by pressure under the following condition. relieve the arm circuit and measure the blow-by pressure. 2. Remove the undercover of the hydraulic pump. 13 . PC200. After finishing measurement. q Engine coolant temperature: Within operating range q Hydraulic oil temperature: Within operating range 1. and turn the swing lock switch ON. 220-8 5. Start the engine. a If the swing lock switch is turned ON. set the working mode in the power mode (P).30 Testing and adjusting SEN00228-02 Measuring blow-by pressure a Measuring tools for blow-by pressure Symbol D k a 1 Part No. the main relief valve is set for high-pressure relief. 4.

After finishing measurement. 14 5. Open the side cover of the pump room and remove oil pressure pickup plug (1) from the engine oil filter. 3. 4. Install nipple [1] of hydraulic tester E1 and connect hydraulic tester E2. 2.SEN00228-02 30 Testing and adjusting Measuring engine oil pressure a Measuring tools for engine oil pressure Symbol E 1 2 k a 1 Part No. PC200. 220-8 . Start the engine and turn the auto-decelerator OFF. Run the engine and measure the engine oil pressure at high idle and low idle. Part name 799-101-5002 Hydraulic tester 790-261-1204 Digital hydraulic tester 799-401-2320 Hydraulic tester Stop the machine on a level ground and lower the work equipment to the ground. q Engine coolant temperature: Within operating range 1. Measure the engine oil pressure under the following condition. remove the measuring tools and return the removed parts.

Low-pressure circuit: Feed pump – Fuel main filter – Supply pump High-pressure circuit: Supply pump – Common rail – Injector The pressure in both low-pressure circuit and high-pressure circuit lowers to a safety level automatically 30 seconds after the engine is stopped. If a filter other than the genuine one is used. If foreign matter enters this system.30 Testing and adjusting Handling fuel system parts a a SEN00228-02 1 Precautions for checking and maintaining fuel system The common rail fuel injection system (CRI) consists of more precise parts than the conventional fuel injection pump and nozzle. If dust. Before checking the fuel system or removing its parts. the residual pressure in the fuel circuit must be released completely. wait at least 30 seconds after stopping the engine until the residual pressure in the fuel circuit is released. Accordingly. (Do not start the work just after stopping the engine since there is residual pressure. Before the fuel circuit is checked and its parts are removed. 220-8 Releasing residual pressure from fuel system 1 a a a k Pressure is generated in the low-pressure circuit and high-pressure circuit of the fuel system while the engine is running. Since the common rail fuel injection system (CRI) consists of more precise parts than the conventional fuel injection pump and nozzle. Accordingly. observe the following. sticks to any part. take care more than the past.) 15 . wash that part thoroughly with clean fuel. the fuel system may have a trouble. it can cause a trouble. it employs a high-efficiency special filter to prevent foreign matter from entering it. Precautions for replacing fuel filter cartridge Be sure to use the Komatsu genuine fuel filter cartridge. PC200. etc. When checking and maintaining the fuel system. never use such a filter.

3) Measuring pressure in fuel low-pressure circuit 1) Open the engine hood and remove fuel pressure pickup plug (1) from the fuel main filter.1 – 13. you may measure the fuel pressure while rotating the engine with the starting motor. however.3 kg/cm2} If the engine cannot be started.1 MPa {3. it cannot be measured.SEN00228-02 30 Testing and adjusting Measuring fuel pressure a Measuring tools for fuel pressure Symbol 1 F 2 3 k a k 1. Do not rotate for more than 20 seconds continuously.5 – 1. 3 Fuel pressure pickup plug: 10 ± 2 Nm {1 ± 0.3 kg/cm2} During cranking 0.0 mm o R1/8) 6215-81-9710 O-ring 799-401-2320 Hydraulic tester Stop the machine on a level ground and lower the work equipment to the ground. After finishing measurement. Since the pressure in the high-pressure circuit from the supply pump through the common rail to the injector is very high. it is normal. for protection of the starting motor.2 kgm} PC200.5 MPa {25 kg/cm2}.3 – 1.3 MPa {5. Part No. a If the pressure in the fuel low-pressure circuit is in the following range. remove the measuring tools and return the removed parts. Part name 799-101-5002 Hydraulic tester 790-261-1204 Digital hydraulic tester 795-790-4430 Adapter (10 × 1. Run the engine at low idle and measure the pressure in the fuel low-pressure circuit.1 – 11. 220-8 . Measure 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 4) At low idle 0. 2) 16 1 Install adapter F2 and nipple [1] of hydraulic tester F1 and connect them to oil pressure gauge [2] a Use the oil pressure gauge of 2.

3 Fuel pressure pickup plug: 24 ± 4 Nm {2.02 MPa {Max. a If the pressure in the fuel return circuit is in the following range. At low idle During cranking k After finishing measurement. PC200. SEN00228-02 Measuring pressure in fuel return circuit 1) Open the engine hood and remove fuel pressure pickup plug (2) from the fuel return block. remove the measuring tools and return the removed parts. it is normal. 4) 2) Install nipple [3] of hydraulic tester F1 and nipple [1] and connect them to hydraulic tester F3. Do not rotate for more than 20 seconds continuously. 220-8 17 .30 Testing and adjusting 2. 07002-11223 3) Run the engine at low idle and measure the pressure in the fuel return circuit.19 kg/cm2} If the engine cannot be started. you may measure the fuel pressure while rotating the engine with the starting motor.4 kgm} Max.4 ± 0. 0. a Nipple [3]: 790-301-1181. for protection of the starting motor. 0. however.

a When measuring the leakage from the pressure limiter or finishing the measurement: Return the removed parts to their original positions. a The return hose is connected by a quick coupler. After finishing measurement. a If the return rate from the supply pump is in the following range. however.000 cc/min 140 cc/min If the engine cannot be started. Stop the machine on a level ground and lower the work equipment to the ground. Do not rotate for more than 20 seconds continuously. a When measuring the leakage from the injector: Leave the removed parts as they are and keep the hose end in the oil pan.SEN00228-02 30 Testing and adjusting Measuring fuel return rate and leakage a Measuring tools for fuel return rate and leakage Symbol 1. Tester kit 2 795-790-6700 Adapter 6754-71-5340 Connector 6754-71-5350 Washer 4 Commercially available Measuring cylinder 5 Commercially available Stopwatch 4) Since some fuel flows out during check. 1 3 a 1 Install connector G3 and cap nut [1] of tester kit G1 to the return hose to stop the fuel from flowing out. you may measure the fuel return rate while rotating the engine with the starting motor. At low idle During cranking k 5) 1. PC200. remove the measuring tools and return the removed parts. Run the engine at low idle and measure the return rate in 1 minute with measuring cylinder G4. for protection of the starting motor. 2) 3) 18 Part name 795-790-4700 G k Part No. Measuring return rate from supply pump 1) Open the engine hood and disconnect return hose (1) of the supply pump. prepare an oil (receiving) pan of about 20 liters. Connect test hose [2] of tester kit G1 to the supply pump. a Lay the test hose so that it will not slacken and put its end in the oil (receiving) pan. 220-8 . it is normal.

and connect test hose [4]. Run the engine at low idle and measure the return rate in 1 minute with measuring cylinder G4. set the supply pump for testing.4 kgm} Measuring return rate from injector a The leakage from the injector is measured while the return hose of the pressure limiter is connected. 1) Referring to Measuring return rate from supply pump. 220-8 Install connector bolt [3] of adapter G2 instead of the removed connector bolt. a Lay the test hose so that it will not slacken and put its end in the oil (receiving) pan. keep the test hose end in the oil pan. a If the leakage from the pressure limiter is in the following range. At low idle 0 cc (No leakage) 3) PC200. 2) Disconnect return hose (4) of the return block. Accordingly. 5) 3. 3 Joint bolt: 24 ± 4 Nm {2. check that the leakage from the pressure limiter is normal. 19 . it is normal. before measuring the leakage from the injector. 2) 3) 4) Install removed connector bolt (3) and cap nut [1] of tester kit G1 to the return hose to stop the fuel from flowing out. Install connector G3 to the common rail and connect test hose [2] of tester kit G1. Accordingly. a Install the seal washer to the connector bolt. a Lay the test hose so that it will not slacken and put its end in the oil (receiving) pan. remove the measuring tools and return the removed parts. After finishing measurement.30 Testing and adjusting 2. a Install the seal washer to the return hose. k The fuel returning from the supply pump flows out during measurement of the return rate from the injector. SEN00228-02 Measuring leakage from pressure limiter 1) Open the engine hood and disconnect return hose (2) of the pressure limiter.4 ± 0.

you may measure the fuel return rate while rotating the engine with the starting motor. Stop the machine on a level ground and lower the work equipment to the ground.4 ± 0. and then operate it forward and backward. After bleeding air. a After bleeding air. 3. however. a Move the knob until it becomes heavy. 2. for protection of the starting motor. Loosen knob (1) of the feed pump and pull it out. Fill the fuel tank with fuel.SEN00228-02 a 30 Testing and adjusting The shape in the figure is partially different from PC200 and PC220-8. some air may be left in the water separator. it is normal. At low idle 1 If the engine cannot be started. The remaining air is bled naturally while the engine is running for a while. 4. This phenomenon occurs when the fuel in the fuel prefilter is drained too much and does not indicate an abnormality or a trouble. a Add fuel until the float of the sight gauge reaches the maximum position. Run the engine at low idle and measure the return rate in 1 minute with measuring cylinder G4. Open the side cover of the pump room. push in and tighten knob (1). a The plug at the top of the fuel main filter does not need to be removed. 1. the engine can be started. 3 Joint bolt: 24 ± 4 Nm {2. however.4 kgm} PC200. remove the measuring tools and return the removed parts. 220-8 . After finishing measurement. Do not rotate for more than 20 seconds continuously. a If the return rate from the injector is in the following range. bleed air from the fuel circuit according to the following procedure. If the feed pump is operated until it becomes heavy. Bleeding air from fuel circuit a k 4) k 5) 20 180 cc/min During cranking 90 cc/min If fuel is used up or if a fuel circuit part is removed and installed.

30 Testing and adjusting a SEN00228-02 Air bleeding route of fuel circuit Fuel tank o Pre-filter o Feed pump o Main filter o Metering unit o Fuel tank PC200. 220-8 21 .

repair it and check again from step 2. Check the fuel piping and devices for fuel leakage. a If no fuel leakage is detected. Run the engine at speed below 1. a Relieve the arm circuit at the IN stroke end. 3. 22 30 Testing and adjusting 9. After checking the fuel system or removing its parts. Run the engine at high idle and load it.000 rpm and stop it after its speed is stabilized. Run the engine at low idle.SEN00228-02 Checking fuel circuit for leakage 1 k k a Very high pressure is generated in the highpressure circuit of the fuel system. repair it and check again from step 2. a If any fuel leakage is detected. Run the engine at high idle. a If any fuel leakage is detected. If fuel leaks while the engine is running. check it for fuel leakage according to the following procedure. 6. 7. 2. Check the fuel piping and devices for fuel leakage. check is completed. a If any fuel leakage is detected. 1. repair it and check again from step 2. common rail. 220-8 . fuel injector. it is dangerous since it can catch fire. 8. Spray color checker (developer) over the fuel supply pump. and joints of the high-pressure piping. a Check around the high-pressure circuit parts coated with the color checker for fuel leakage. a Check mainly around the high-pressure circuit parts coated with the color checker for fuel leakage. Check the fuel piping and devices for fuel leakage. Check the fuel piping and devices for fuel leakage. a Check mainly around the high-pressure circuit parts coated with the color checker for fuel leakage. a If any fuel leakage is detected. a Check mainly around the high-pressure circuit parts coated with the color checker for fuel leakage. 5. Stop the machine on a level ground and lower the work equipment to the ground. 4. Clean and degrease the engine and the parts around it in advance so that you can check it easily for fuel leakage. repair it and check again from step 2. PC200.

a Check each pulley for breakage. After finishing measurement. adjust their tension again after operating the machine for 1 hour. 3. wear of the V-groove. check the belt tension again according the above procedure. replace it. return the removed parts. 2. Checking 1. a If the V-belt is so lengthened that the adjustment allowance is eliminated or it has a cut or a crack. Press the intermediate point of the belt between fan pulley and compressor pulley with a finger and measure deflection (a) of the belt. adjust it according to the following procedure. a After tightening the bolts. Open the engine hood and remove the belt guard from the top of the air conditioner compressor. a If the belt is replaced. 2. After positioning compressor (3). q Belt pressing force: 98 N {10 kg} PC200. 1.30 Testing and adjusting Checking and adjusting air conditioner compressor belt tension k SEN00228-02 1 Stop the machine on a level ground and lower the work equipment to the ground. Adjusting a If the belt deflection is abnormal. 4. tighten bolts (1) and (2). and contact of the V-belt and V-groove. Loosen bolts (1) and (2). Move compressor (3) and bracket (4) together to adjust the belt tension. 220-8 23 .

Replace the fan belt (2). Check each pulley for breakage and crack. Insert a wrench to the portion (A) (width across flats T 12. the wrench may accidentally come off while being rotated and it is extremely dangerous. Disconnect air conditioner compressor belt before replacing the fan belt. 1. k Make sure that the wrench is secured at the portion (A) of the tensioner assembly (3) before rotating it. return the tensioner assembly (3) slowly with care.) k After removing the fan belt (2). testing and adjustment of the belt is usually not necessary. 2. q PC200.7 mm) of the tensioner assembly (3). If the wrench is loosely inserted. Thus. 220-8 . k Be careful not to get your fingers caught between the pulley and fan belt (2) during work. 24 3. and rotate it to the opposite to the winding-up direction to decrease the fan belt (2) tension. (The spring of the tensioner assembly (3) is strong. Open engine hood and remove fan belt cover (1). Park the machine in a level ground and lower the work equipment to the ground.SEN00228-02 Replacing fan belt a a k 30 Testing and adjusting 1 The auto-tensioner is provided for the fan belt.

a At this time the front of the upper structure lowers and the rear rises. 5. 6. Set dial gauge H to the 0 point. read dial gauge H. see Structure. perform the following procedure.30 Testing and adjusting SEN00228-02 Measuring swing circle bearing clearance 1 a Set the arm almost perpendicular to the ground and lower the boom until the front track shoe floats. Stop the machine on a level ground and lower the work equipment to the ground. repeat steps 2 through 5. Return the machine to the condition of step 2 and check that dial gauge H indicates 0. a If the dial gauge does not indicate 0. 4. PC200. Under this condition. Measuring tools for swing circle bearing clearance Symbol Part No. function and maintenance standard. Set the work equipment to the maximum reach position and set the bucket tip to the height of the under side of the revolving frame. Part name Dial gauge When measuring the swing circle bearing clearance installed to the machine. Do not put your hands or feet under the undercarriage during measurement. 220-8 25 . 2. a For the standard value. “Swing circle”. a At this time the front of the upper structure rises and the rear lowers. 3. a The value indicated by dial gauge H is the clearance of the bearing. H Commercially available a k k 1. Fix dial gauge H to the track frame and apply the probe to the lower end of the outer race.

3. Run the engine at low idle and drive the machine forward by the length of track on ground. which will be deflected less. run the engine at low idle and move the machine forward by the length of track on ground. q Standard maximum clearance (a): 10 – 30 mm Adjusting a If the track shoe tension is abnormal. and then stop slowly.SEN00228-02 Checking and adjusting track shoe tension 30 Testing and adjusting 1 Checking 1. In this case. check the track shoe tension again according to the above procedure. Measure maximum clearance (a) between steel bar [1] and track shoe. reverse or replace the pins and bushings. 2. 1. a 26 You may add grease until dimension (b) between the idler guide and track frame end becomes 0 mm. 2) To check that the tension is normal. a As the steel bar. PC200. Place steel bar [1] on the track shoe between the idler and the 1st carrier roller. adjust it according to the following procedure. use an angle steel. 220-8 . etc. the pins and bushings are worn much. If the tension is still low. 3) After adjusting. then stop slowly. Increasing tension 1) Add grease through grease fitting (1) with a grease gun.

and then tighten it. If it is loosened more. SEN00228-02 Decreasing tension 1) Loosen valve (2) to discharge grease. k Do not loosen the valve more than 1 turn. 3) After adjusting. PC200. 220-8 27 . then stop slowly. run the engine at low idle and move the machine forward by the length of track on ground. 2) To check that the tension is normal. it may jump out because of the highpressure grease in it. check the track shoe tension again according to the above procedure.30 Testing and adjusting 2.

q Monitoring code: 01100 F pump pressure q Monitoring code: 01101 R pump pressure a Measure the oil pressure in the work equipment. the oils of the pumps are divided. swing. 220-8 . Measuring and adjusting tools for oil pressure in work equipment. see "Releasing residual pressure from hydraulic circuit". swing. and travel circuits 1 J 2 Part No. and travel circuits under the following condition. Note that different actuators relieve different valves. a When the work equipment circuit or swing circuit is relieved singly. Actuator Valve relieved (R unload valve) (R main relief valve) Rear pump a 2) Service Safety-suction valve Bucket R main relief valve Left travel R main relief valve Boom Raise: R main relief valve Lower: Safety-suction valve (Pump merge-divider valve) (Travel junction valve) Front pump (Self pressure reducing valve) 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) 28 PC200. When the travel circuit is relieved singly. too (For details.25 mm) 07002-11023 O-ring Stop the machine on a level ground and lower the work equipment to the ground. Install nipples J2 and connect oil pressure gauges [1] of hydraulic tester J1.8 MPa {600 kg/cm2}. Part name 799-101-5002 Hydraulic tester 790-261-1204 Digital hydraulic tester 799-101-5220 Nipple (10 × 1. the oils of the pumps are merged.SEN00228-02 30 Testing and adjusting Measuring and adjusting oil pressure in work equipment. Combination of pump. and travel circuits Symbol k 1 Preparation work 1) Open the side cover of the pump room and remove oil pressure pickup plugs (1) and (2). q Hydraulic oil temperature: Within operating range 1. swing. see “Special functions of machine monitor”). q (1): Front pump discharge pressure pickup plug q (2): Rear pump discharge pressure pickup plug 2. For details. and valve a When the oil from the pumps is divided. swing. Then. release the residual pressure from the hydraulic circuit. and travel circuits (pump discharge pressure) can be checked with monitoring function of the machine monitor. Measuring a The oil pressure in the work equipment. a Use the oil pressure gauges of 58. a The actuators in the table are arranged in the order when the control valve is seen from the front of the machine (and an attachment is installed to the service valve). the front pump and rear pump act independently on each actuator. actuator.

set the working mode in the power mode (P). the latter is relieved at high pressure. a The swing relief pressure is lower than the main relief pressure. and measure the oil pressure.30 Testing and adjusting 3. Measuring swing relief pressure 1) Start the engine. check the position and locking direction of the locked sprocket again. k Before operating the travel lever and pedal. and turn the swing lock switch ON. and measure the oil pressure. 2) 3) 7. the safety-suction valve of the control valve for lowering the boom is relieved). the main relief valve is relieved at low pressure. remove the measuring tools and return the removed parts. operate the left work equipment control lever to relieve the swing motor. a The pressure measured when the unload valve is unloaded is indicated. Set the working mode in the power mode (P). Measuring work equipment relief pressure 1) Start the engine and move the cylinder to be measured to the stroke end. k Put pin [2] between the sprocket and track frame to lock the travel mechanism securely. keep the swing lock switch turned OFF. operate the right and left work equipment control levers to relieve the cylinder. a The pressure measured when the main relief valve is relieved is indicated (If the boom is lowered singly. 6. the 2-stage relief solenoid valve is kept turned ON and the relief valve is relieved at high pressure. 3) Run the engine at high idle. 5.0 – 2. 29 . and travel in neutral. set the working mode in the power mode (P). If the former is pressed. 4. a The pressure measured when the swing motor relief valve is relieved is indicated. Run the engine at high idle. 2) Set the working mode in the power mode (P). Accordingly. SEN00228-02 2) Measuring unload pressure 1) Start the engine. swing control. and turn the autodecelerator OFF. 220-8 Measuring travel relief pressure 1) Run the engine and lock the travel mechanism. Run the engine at high idle. set all the levers and pedals for work equipment control. a If the swing lock switch is set in turned ON.8 kgm} Adjusting a The unload valve and safety-suction valve for lowering the boom cannot be adjusted. and measure the oil pressure. Work after finishing measurement After finishing measurement. and measure the oil pressure. The travel circuit is always relieved at high pressure. 2) Run the engine at high idle. a If the power maximizing switch is released. a The pressure measured when the main relief valve of the control valve is relieved is indicated. 3 Oil pressure pickup plug: 20 – 27 Nm {2. PC200. operate the travel lever and pedal to relieve the travel motor.

8 Nm {5 – 6 kgm} 3) 4) 30 Connect pilot hose (5).7 MPa {Approx. q (3): Front (F) main relief valve q (4): Rear (R) main relief valve a When adjusting the main relief valves. a If the holder is q Turned to the right. the set pressure is decreased. q Turned to the left. 220-8 . 209 kg/cm2} While fixing holder (6). 6. the set pressure is decreased. While fixing adjustment screw (9). After finishing adjustment. the set pressure is increased. Turn adjustment screw (9) to adjust the pressure. 68. Adjusting swing relief pressure a If the swing relief pressure is abnormal. a Adjust only the low relief pressure of the main relief valve. 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. 3 Locknut: 78 – 103 Nm {8 – 10. 20. loosen locknut (10).4 kg/cm2} While fixing adjustment screw (9). adjust safety valve (8) of the swing motor according to the following procedure. check again that the oil pressure is normal according to the above described measurement procedure. 1) 2) 1) 2) 3) 4) Disconnect pilot hose (5). 3 Locknut: 49 – 58. adjust main relief valves (3) and (4) according to the following procedure. q Turned to the left.SEN00228-02 1. While fixing holder (6). tighten locknut (7).5 MPa {Approx. a If the adjustment screw is q Turned to the right. a Quantity of adjustment per turn of holder: Approx. a Quantity of adjustment per turn of adjustment screw: Approx. Turn holder (6) to adjust the set pressure. remove the top cover of the control valve. If the low repair procedure is adjusted. PC200. the set pressure is increased. 30 Testing and adjusting 5) 6) 2. the high repair procedure is set automatically. check again that the oil pressure is normal according to the above described measurement procedure. tighten locknut (10). Adjusting work equipment and travel relief pressure a If the relief pressure of the work equipment circuit and travel circuit is abnormal.5 kgm} After finishing adjustment. loosen locknut (7).

5. 2. and turn the auto-decelerator OFF. a Do not adjust the relief valve for control circuit basic pressure. remove the measuring tools and return the removed parts. set all the levers and pedals for work equipment control.9 MPa {60 kg/cm2}. 220-8 31 . Measure the control circuit basic pressure under the following condition. swing control. 4. and measure the oil pressure. Part name Hydraulic tester 790-261-1204 Digital hydraulic tester 799-101-5220 Nipple (10 × 1. a Use the oil pressure gauge of 5. 799-101-5002 3. Run the engine at high idle. a The control circuit basic pressure may be measured with oil pressure pickup plug (2) on the hydraulic pump side. release the residual pressure from the hydraulic circuit. Part No. set the working mode in the power mode (P). For details. Then.25 mm) 07002-11023 O-ring Stop the machine on a level ground and lower the work equipment to the ground. After finishing measurement. and travel in neutral. q Hydraulic oil temperature: Within operating range Remove the control valve top cover and oil pressure pickup plug (1).30 Testing and adjusting SEN00228-02 Measuring control circuit basic pressure 1 a Measuring tools for control circuit basic pressure Symbol 1 K 2 k a 1. Install nipple K2 and connect oil pressure gauge [1] of hydraulic tester K1. see “Releasing residual pressure from hydraulic circuit”. PC200. Start the engine.

swing. 2) Install nipples L2 and nipples [1] of hydraulic tester L1 and connect them to oil pressure gauges [2]. 220-8 . For details. (3).SEN00228-02 30 Testing and adjusting Measuring and adjusting oil pressure in pump PC control circuit a Measuring and adjusting tools for oil pressure in pump PC control circuit Symbol 1 L 2 k 1 Part No. release the residual pressure from the hydraulic circuit. a Connect the measuring part of plug (3) by using joint (790-301-1271) and elbow (790-301-1530) of hydraulic tester L1 and nipple [1] so that it will not interfere with the drain piping. Set the working mode in the power mode (P) and turn the swing lock switch ON. Then. Measuring a Before measuring the oil pressure in the PC control circuit. a Use the oil pressure gauges of 58. check that the oil pressure in the work equipment. q (1): Front pump discharge pressure pickup plug q (2): Rear pump discharge pressure pickup plug q (3): Front PC valve output pressure pickup plug q (4): Rear PC valve output pressure pickup plug 4) PC200. Part name 799-101-5002 Hydraulic tester 790-261-1204 Digital hydraulic tester 799-101-5220 Nipple (10 × 1. q Hydraulic oil temperature: Within operating range 1. 3) Start the engine and move the arm cylinder to the IN stroke end. see “Releasing residual pressure from hydraulic circuit”. a If the swing lock switch is turned ON. 1) Open the side cover of the pump room and remove oil pressure pickup plugs (1). 32 Measuring 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. a Measure the oil pressure in the pump PC control circuit under the following condition. (2). and (4). and travel circuits and the basic pressure of the control circuit are normal. the main relief valve is set for highpressure relief.25 mm) 07002-11023 O-ring Stop the machine on a level ground and lower the work equipment to the ground.8 MPa {600 kg/cm2}.

After finishing measurement. remove the measuring tools and return the removed parts.9 MPa {60 kg/cm2}. If the PC valve or the servo piston is abnormal. the PC valve is normal. a 2) Install nipples L2 and connect them to oil pressure gauges [2]. set all the levers and pedals for work equipment control. and measure the oil pressure. Measuring condition and method of judgment: If the pressures are in the following ratio. and travel in neutral. Run the engine at high idle and low idle. (5): Front PC-EPC valve output pressure pickup plug (6): Rear PC-EPC valve output pressure pickup plug PC200. Measuring PC-EPC valve output pressure 1) Open the side cover of the pump room and remove oil pressure pickup plugs (5) and (6).6 (Approx. 3/5) a 6) 2. a Use the oil pressure gauges of 5. operate the left work equipment control lever to relieve the arm circuit at the IN stroke end. swing control. and measure the oil pressure at each speed.30 Testing and adjusting 5) SEN00228-02 Run the engine at high idle. 3) Start the engine and set the working mode in the power mode (P). Measured oil pressure Pump discharge pressure PC valve output pressure Operation of lever Ratio of oil pressures 1 Arm IN relief Approx. 220-8 4) 33 . 0. the PC valve output pressure (servo piston inlet pressure) is "the same as the pump discharge pressure" or "almost 0".

q The engine speed is normal but the work equipment speed is low. Tighten locknut (9). Do not turn any other locknuts or adjustment screws since they affects the hydraulic pump performance.5 kgm} 4. q As the working load increases. the PC-EPC valve is normal.8 – 3. adjust PC valves (7) and (8) according to the procedure shown below. 3. PC200. remove the measuring tools and return the removed parts. check again that the PC valve output pressure (servo piston inlet pressure) is normal according to the above described measurement procedure. make counter mark at the adjustment screw end so that you can see the position of the locknut before the adjustment (and you can return the locknut to its original position after turning it in reverse). 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 of the adjustment screw (inside width) is 4 mm. a Turn the adjustment screw q Clockwise when the work equipment speed is low (to in crease pu mp absorption torque) and q Counterclockwise when the engine speed lowers (to decrease pump absorption torque). 34 1.SEN00228-02 a Measuring condition and method of judgment: If the output pressures are in the following ratio. 2. Adjusting Adjusting pump PC valve a If either of the following phenomena occurs and the PC valve seems to be defective.9 MPa {Approx. 3 Locknut: 27 – 34 Nm {2. 30 kg/cm2} 0 MPa {0 kg/cm2} After finishing measurement. Output pressure Approx. Turn adjustment screw (10) clockwise or counterclockwise to adjust. the engine speed lowers remarkably. Engine Low idle High idle 5) 30 Testing and adjusting Operation of lever All control levers and pedals in neutral Loosen locknut (9). 220-8 . 2. a Before loosening the locknut. After finishing adjustment.

Measuring a Before measuring the oil pressure in the PC control circuit. Set the working mode in the power mode (P) and set the travel speed in the High position. see “Releasing residual pressure from hydraulic circuit”.30 Testing and adjusting SEN00228-02 Measuring and adjusting oil pressure in pump LS control circuit a Measuring and adjusting tools for oil pressure in pump LS control circuit Symbol 1 M 2 3 k 1 Part No. Part name 799-101-5002 Hydraulic tester 790-261-1204 Digital hydraulic tester 799-401-2701 Differential pressure gauge 799-101-5220 Nipple (10 × 1. release the residual pressure from the hydraulic circuit. For details. check that the oil pressure in the work equipment.8 MPa {600 kg/cm2}. and (4). a Use the oil pressure gauges of 58. 3) Start the engine and push up the track shoe on the side to be measured with the work equipment and prepare for running the track shoe idle. 1) Open the side cover of the pump room and remove oil pressure pickup plugs (1). q When measuring front circuit: Right track shoe q When measuring rear circuit: Left track shoe k Since the raised track shoe will be run idle during measurement. swing. 2) Install nipples M3 and nipples [1] of hydraulic tester M1 and connect them to oil pressure gauges [2].25 mm) 07002-11023 O-ring Stop the machine on a level ground and lower the work equipment to the ground. (3). q (1): Front pump discharge pressure pickup plug q (2): Rear pump discharge pressure pickup plug q (3): Front LS valve output pressure pickup plug q (4): Rear LS valve output pressure pickup plug 4) PC200. Then. q Hydraulic oil temperature: Within operating range 1. and travel circuits and the basic pressure of the control circuit are normal. secure a sufficient working area. a Measure the oil pressure in the pump LS control circuit under the following condition. a Connect the measuring part of plug (3) by using joint (790-301-1271) and elbow (790-301-1530) of hydraulic tester M1 and nipple [1] so that it will not interfere with the drain piping. Measuring LS valve output pressure (servo piston inlet pressure) a Measure the LS valve output pressure (servo piston inlet pressure) and pump discharge pressure simultaneously and compare them. (2). 220-8 35 .

98 MPa {10 kg/cm2}.way (Track tral shoe run idle) 1 Almost same Approx. q q a Measuring condition and method of judgment: If the pressures are in the following ratio. Since the differential pressure gauge needs a 12V power source.SEN00228-02 5) 30 Testing and adjusting Run the engine at high idle. set all the levers and pedals for work equipment control. and travel in neutral.6 (Approx. Operation of lever and ratio of oil pressures Measured oil pressure Pump discharge pressure LS valve output pressure 6) 2. 36 (5): Front LS pressure pickup plug (6): Rear LS pressure pickup plug All control Travel lever levers and moved halfpedals in neu. Measuring LS differential pressure a Measure the pump discharge pressure and LS pressure (actuator load pressure) simultaneously and calculate the difference between them. 3/5) After finishing measurement. and (6).8 MPa {600 kg/cm2} having the unit of 0. run the track shoe pushed up idle.9 MPa {40 kg/cm2} at maximum. 220-8 . PC200. Since the differential pressure is about 3. and measure the oil pressure at each speed. operate the travel lever to run the track shoe idle and measure the oil pressure. q (1): Front pump discharge pressure pickup plug q (2): Rear pump discharge pressure pickup plug 2) Install nipples M3 and connect it to differential pressure gauge M2 or the oil pressure gauge of hydraulic tester M1. 0. Then. remove the measuring tools and return the removed parts. connect it to a battery. a When using differential pressure gauge M2: Connect the pump discharge pressure to the high pressure side (back side) and connect the LS pressure to the low pressure side (lower side). measure it by installing the same gauge to the pickup plugs alternately. 1) Open the side cover of the pump room and remove oil pressure pickup plugs (1). k While checking the safety around the machine extremely. a Do not operate the travel lever to the stroke end (but stop it halfway). swing control. (5). (2). a When using oil pressure gauge (in M1): Use the oil pressure gauge of 58. the LS valve is normal.

and measure the oil pressure at each speed. Then. secure a sufficient working area. k While checking the safety around the machine extremely. set all the levers and pedals for work equipment control. operate the travel lever to run the track shoe idle and measure the oil pressure. 3) 4) 5) Run the engine. Set the working mode in the power mode (P) and set the travel speed in the High position.30 Testing and adjusting SEN00228-02 q The figure shows the pump discharge pressure side. push up the track shoe on the side to be measured with the work equipment. Operation of levers LS differential pressure All control levers and pedals Specified LS difin neutral ferential pressure (See Travel lever moved halfway standard values (Track shoe run idle) table) 6) 3. Run the engine at high idle. swing control. and prepare for running track shoe idle. and travel in neutral. the LS valve is normal. remove the measuring tools and return the removed parts. 37 . run the track shoe pushed up idle. a Measuring condition and method of judgment: If the pressures are in the following ratio. q When measuring front circuit: Right track shoe q When measuring rear circuit: Left track shoe k Since the raised track shoe will be ru n idle during measurement. PC200. 220-8 After finishing measurement. Measuring LS-EPC valve output pressure 1) Open the side cover of the pump room and remove oil pressure pickup plug (7). q The figure shows the LS pressure side. a Do not operate the travel lever to the stroke end (but stop it halfway).

the LS-EPC valve is normal.9 MPa {60 kg/cm2}. 5) Adjusting Adjusting LS valve a If the LS differential pressure is abnormal. 10. 2. the differential pressure is increased. Turn adjustment screw (10) to adjust the differential pressure. 220-8 . 2.8 kg/cm2} 3. tighten locknut (11).SEN00228-02 30 Testing and adjusting 2) Install nipple M3 and connect them to oil pressure gauge [2]. a Quantity of adjustment (LS differential pressure) per turn of adjustment screw: Approx. and measure the output pressure in each case. q (8): Front pump LS valve q (9): Rear pump LS valve After finishing measurement.6 Nm {5 – 7 kgm} 4. q Turned to the left. PC200. Output pressure Lo Approx. While fixing adjustment screw (10).9 MPa Travel lever in neutral {Approx. remove the measuring tools and return the removed parts. a Measuring condition and method of judgment: If the output pressures are in the following ratio.1 MPa {Approx. adjust the LS valve according to the following procedure. Run the engine at high idle. a If the adjustment screw is q Turned to the right. a Use the oil pressure gauges of 5. 3) 4) Start the engine. While fixing adjustment screw (10). 30 kg/cm2} Hi Travel lever operated a little (Note) 0 MPa {0 kg/cm2} Note: Move the travel lever to a degree that the PPC oil pressure switch is turned ON (before the track starts moving). After finishing adjustment. the differential pressure is decreased. check again that the LS differential pressure is normal according to the above described measurement procedure. 3 Locknut: 49 – 68. Travel speed Operation of lever 38 1. loosen locknut (11). operate the travel speed switch and travel lever. 1.

9 MPa {60 kg/cm2}. a The figure shows the measuring tools connected to outlet hose (1) of the PPC lock solenoid valve. Solenoid valve to be measured 1 PPC lock solenoid valve 2 2-stage relief solenoid valve 3 Swing holding brake solenoid valve 4 Travel speed shifting solenoid valve 5 Travel junction solenoid valve 6 ATT return selector solenoid valve (Attachment installation specification) a When measuring with hoses (2) – (6). a For the conditions for turning the solenoid valve ON and OFF. PC200. see “Special functions of machine monitor”). remove the undercover of the control valve. Before measuring the solenoid valve output pressure. Measure the solenoid valve output pressure under the following condition. Part name 799-101-5002 Hydraulic tester 790-261-1204 Digital hydraulic tester 799-401-3100 Adapter (Size 02) Stop the machine on a level ground and lower the work equipment to the ground. Install nipple [1] of hydraulic tester N1 and connect it to oil pressure gauge [2]. see the operation table of each solenoid valve.30 Testing and adjusting SEN00228-02 a Measuring solenoid valve output pressure 1 a Measuring tools for solenoid valve output pressure Symbol 1 N 2 k a a 1. Part No. 5. Start the engine. q Hydraulic oil temperature: Within operating range 2. Install adapter N2 and connect the disconnected hose again. For details. Run the engine at high idle. and measure the oil pressure. check that the basic pressure of the control circuit is normal. Then. 4. 220-8 39 . No. q Monitoring code: 02300 Solenoid 1 q Monitoring code: 02301 Solenoid 2 Disconnect outlet hoses (1) – (6) of the solenoid valves to be measured. remove the undercover (rear side) of the operator's cab. release the residual pressure from the hydraulic circuit. a The operating condition of the solenoid valve can be checked with the monitoring function of the machine monitor (For details. see “Releasing residual pressure from hydraulic circuit”. 3. When measuring with hose (1). a Use the oil pressure gauge of 5. operate the control levers and switches to turn the solenoid valve ON or OFF.

PC200. remove the measuring tools and return the removed parts. 220-8 .SEN00228-02 a 6. the solenoid valve is normal.9 MPa {30 kg/cm2} After finishing measurement. Solenoid valve Output pressure OFF (Demagnetization) 0 MPa {0 kg/cm2} ON (Excitation) 2. 40 30 Testing and adjusting If the output pressure is as follows.

swing. 220-8 41 . and travel signals are OFF Swing lock switch is ON Travel signal is ON L mode is selected ON Boom LOWER signal is ON P/E mode is selected Left knob switch is ON Signals other than swing single signal are ON Swing single signal is ON Other than above condition OFF Operation table of swing holding brake solenoid valve Operating condition Work equipment. swing.5 MPa {250 kg/cm2} or higher Other than above condition Operation ON OFF Operation table of ATT return selector solenoid valve (Attachment installation specification) Operating condition Operation Working mode: Other than B OFF Working mode: B ON PC200.3 MPa {150 kg/cm2} or higher ON Other than above condition Operation table of travel junction solenoid valve Operating condition Travel steering signal is ON Travel steering signal is OFF Travel lever is operated singly F or R pump pressure is 24. and travel signals Operation All are OFF OFF Any one is ON ON Operation table of travel speed shifting solenoid valve Operating condition Operation Overheat 2nd setting is ON Fuel control dial is at 1.30 Testing and adjusting SEN00228-02 Operation table of PPC lock solenoid valve Operating condition Lock lever Operation Lock OFF Free ON Operation table of 2-stage relief solenoid valve Operating condition Operation Overheat 1st setting is ON Overheat 2nd setting is ON OFF All of work equipment.5 MPa {250 kg/cm2} Travel speed switch is at Hi (PC200-8) or higher Travel speed switch is at Mi/Hi (PC220-8) Travel signal is ON F or R pump pressure is 15.500 rpm or below Travel speed switch is at Lo/Mi (PC200-8) Travel speed switch is at Lo (PC220-8) OFF Travel signal is OFF F or R pump pressure is 24.

220-8 . The colors in ( ) are the colors of the bands installed for distinction of the pipes. When measuring the steering signal voltage. The figure at right shows the check points of the steering signal voltage of the travel PPC valve.SEN00228-02 Measuring PPC valve output pressure 30 Testing and adjusting 1 Connecting points of PPC piping a a 42 The above figure shows the connecting points of the PPC piping on the control valve of 1 attachment installation specification. remove the undercover of the operator's cab (front side). PC200.

PC200. 4. a For the hose to be disconnected. 3. remove the measuring tools and return the removed parts. Install nipple [1] of hydraulic tester P1 and connect it to oil pressure gauge [2]. release the residual pressure from the hydraulic circuit. see “Releasing residual pressure from hydraulic circuit”. a The figure shows the measuring tools connected to the hose of the bucket dump PPC circuit. check that the basic pressure of the control circuit is normal. For details. Part name 799-101-5002 Hydraulic tester 790-261-1204 Digital hydraulic tester 2 799-401-3100 Adapter (Size 02) 3 799-401-3200 Adapter (Size 03) 1 P SEN00228-02 Stop the machine on a level ground and lower the work equipment to the ground.9 MPa {60 kg/cm2}. Measure the solenoid valve output pressure under the following condition. Before measuring the PPC valve output pressure. If the output pressure is as follows. Run the engine at high idle and measure the oil pressure with the control lever in neutral and moved to the stroke end. q Hydraulic oil temperature: Within operating range Disconnect the hose of the PPC circuit to be measured. see “Connecting points of PPC piping”. the PPC valve is normal.30 Testing and adjusting a Measuring tools for PPC valve output pressure Symbol k a a 1. Install adapter P2 and connect the disconnected hose again. a Use the oil pressure gauge of 5. Operation of lever Output pressure Neutral 0 MPa {0 kg/cm2} Stroke end Almost same as control circuit basic pressure (See standard values table) After finishing measurement. 43 . 220-8 a 6. Then. 2. Start the engine and set the working mode in the power mode (P). Part No. 5.

2. 3. 44 PC200.SEN00228-02 30 Testing and adjusting Adjusting play of work equipment and swing PPC valves 1 a If the right and left work equipment levers have large play. Remove bellows (1). Install the work equipment and swing PPC valve assembly. Install bellows (1). a Do not move the piston at this time. 6. 220-8 . adjust them according to the following procedure. 3 Locknut: 98 – 127 Nm {10 – 13 kgm} 5. 4. 1. Loosen locknut (2) and tighten disc (3) until it touches the heads of 4 pistons (4). Fix disc (3) and tighten locknut (2) to the specified torque. Remove the work equipment and swing PPC valve assembly.

q If the lowering speed does not change at this time. 45 . [Reference] Reason why the lowering speed is increased by the above operation when the cylinder packing is the cause of the hydraulic drift: 1) If the machine is set in the above position (where the holding pressure is applied to the bottom side). 2) 2) When checking the boom cylinder. Checking arm cylinder 1) Stop the arm cylinder about 100 mm before the IN stroke end and stop the engine. 1. the control valve is defective. the oil leaks from the bottom side to the head side. check to see if the cause is on the cylinder packing side or control valve side according to the following procedure. Since the volume on the head side is less than that on the bottom side by the volume of the rod. the cylinder packing is defective. 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).30 Testing and adjusting Checking parts which cause hydraulic drift of work equipment SEN00228-02 2. run the engine for about 5 seconds to heighten the pressure in the accumulator. set the boom control lever in the RAISE position. q If the lowering speed is increased at this time. the cylinder packing is defective. When checking the bucket cylinder. 2) As the pressure in the head side is increased. a If the pressure in the accumulator is lost. q If the lowering speed is increased at this time. and then the lowering speed is lowered. a Fill the bucket with a rated load or with dirt and sand. it is balanced at a certain level (which depends on the leakage). run the engine for about 5 seconds to heighten the pressure in the accumulator. the pressure in the head side is increased by the oil flowing in from the bottom side. a Operate the control lever while the starting switch is in the ON position. 220-8 Operate the arm control lever in the IN position. a Operate the control lever while the starting switch is in the ON position. set the bucket control lever in the CURL position. a If the pressure in the accumulator is lost. PC200. q If the lowering speed does not change at this time. the control valve is defective. As a result. 1 a If the work equipment (cylinder) drifts hydraulically. Checking boom cylinder and bucket cylinder 1) Set the machine in the position for measuring hydraulic drift and stop the engine. the oil on the head side flows in the drain circuit. the pressure is unbalanced and the lowering speed is increased.

SEN00228-02 3. 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). PC200. 220-8 . a If the pressure in the accumulator is lost. set the lock lever in the LOCK/FREE position and measure the lowering distance. 46 30 Testing and adjusting Checking PPC valve While the pressure in the accumulator is high. a Operate the control lever while the starting switch is in the ON position. run the engine for about 5 seconds to heighten the pressure in the accumulator.

Releasing residual pressure from hydraulic tank k Since the hydraulic tank is enclosed and pressurized. 4) Repeat steps 2) and 3) above 2 – 3 times. For details. release the residual pressure from the piping according to the following procedure. a Keep the oil filler cap of the hydraulic tank removed. 4. however). 2) Loosen oil filler cap (1) of the hydraulic tank gradually to release the air in the tank. after the control valve is operated 2 – 3 times. The pressure in the accumulator is used up. the pressure in this circuit can be released by performing “Releasing residual pressure from hydraulic tank”. see “Releasing residual pressure from hydraulic tank”. 220-8 47 . a The engine does not start until the lock lever is set in the LOCK position once. 1) Lower the work equipment and release the residual pressure from the hydraulic tank. 2. and to the left. a The control valve is operated by the pressure in the accumulator. backward. release the residual pressure from it when removing a hose or a plug connected to it. 1) Lower the work equipment to the ground in a stable position and stop the engine. Releasing residual pressure from swing motor circuit The residual pressure in the swing motor circuit can be released by performing the operation for “Releasing residual pressure from hydraulic cylinder circuit” (Operate the lever in the swing direction only. 3. however. and then operate the right and left work equipment control levers forward. and the residual pressure in the piping is released completely. PC200. 3) Run the engine at low idle for 5 seconds to heighten the pressure in the accumulator. 2) Turn the starting switch ON and set the lock lever in the FREE position. to the right.30 Testing and adjusting SEN00228-02 Releasing residual pressure from hydraulic circuit 1 1. Releasing residual pressure from hydraulic cylinder circuit k When disconnecting a pipe between a hydraulic cylinder and the control valve. Releasing residual pressure from travel motor circuit Since the control valve spool of the travel motor circuit is open.

2) Disconnect hose (1) on the cylinder head side and block the hose side with a flange. After finishing measurement. return the removed parts. PC200. return the removed parts. Q Commercially available Part name Measuring cylinder a Measure the oil leakage under the following condition. a Use the following part to block the hose side. see Releasing residual pressure from hydraulic circuit (Operate the lever in the arm IN direction only. For details. k Take care not to "lower the boom". Measuring oil leakage from arm cylinder 1) Move the arm cylinder to the IN stroke end and stop the engine. q Hydraulic oil temperature: Within operating range 1. k Release the residual pressure from the piping on the boom cylinder head side. After finishing measurement. however). 07379-00640 (Flange #06) 2.SEN00228-02 30 Testing and adjusting Measuring oil leakage a 1 Measuring tools for oil leakage Symbol Part No. Run the engine at high idle and relieve the boom circuit by raising the boom. For details. k Take care not to "move the arm OUT". see “Releasing residual pressure from hydraulic circuit” (Operate the lever in the boom RAISE direction only. Start measuring the oil leakage 30 seconds after relieving is started and measure for 1 minute. 2) Disconnect hose (2) on the cylinder head side and block the hose side with a flange. 07379-00640 (Flange #06) 3) 4) 5) 3) 4) 5) 48 Run the engine at high idle and relieve the arm circuit by moving the arm IN. k Take care not to disconnect the hose on the cylinder bottom side. k Take care not to disconnect the hose on the cylinder bottom side. a Use the following part to block the hose side. Measuring oil leakage from boom cylinder 1) Move the boom cylinder to the RAISE stroke end and stop the engine. however). Start measuring the oil leakage 30 seconds after relieving is started and measure for 1 minute. k Release the residual pressure from the piping on the arm cylinder head side. 220-8 .

a Use the following parts to block the hose side. 2) Disconnect hose (3) on the cylinder head side and block the hose side with a flange. 07379-00640 (Flange #06) SEN00228-02 4. see Releasing residual pressure from hydraulic circuit (Operate the lever in the bucket CURL direction only. swing 180°. k Take care not to disconnect the hose on the cylinder bottom side. return the removed parts. Measuring oil leakage from bucket cylinder 1) Move the bucket cylinder to the CURL stroke end and stop the engine. Run the engine at high idle and relieve the bucket circuit by curling the bucket. For details. and then measure again. After finishing measurement. Run the engine at high idle and relieve the swing circuit by swinging. 07376-70522 (Plug #05) 2) 3) 4) 3) 4) 5) Turn the swing lock switch ON. k Release the residual pressure from the piping on the bucket cylinder head side. a Use the following part to block the hose side.30 Testing and adjusting 3. After finishing measurement. however). PC200. 220-8 49 . Measuring oil leakage from swing motor 1) Disconnect 2 drain hoses (4) and block the hose side with plugs. return the removed parts. a Start measuring the oil leakage 30 seconds after relieving is started and measure for 1 minute. Start measuring the oil leakage 30 seconds after relieving is started and measure for 1 minute. a After measuring 1 time. k Take care not to “dump the bucket”.

SEN00228-02 5. a Use the following part to block the hose side. k Put pin [1] between the sprocket and track frame to lock the travel mechanism securely. Accordingly. lock the travel mechanism. return the removed parts. 07376-70422 (Plug #04) 4) Run the engine at high idle. a Start measuring the oil leakage 30 seconds after relieving is started and measure for 1 minute. 220-8 . 50 Measuring oil leakage from travel motor 1) Remove the travel motor cover. and stop the engine. 2) Run the engine. check the position and locking direction of the locked sprocket again. moving the motor a little (changing the position of the valve plate and cylinder and that of the cylinder and piston) each time. make signs and checks securely. k Before operating the travel lever. and measure the oil leakage. k Wrong operation of the lever can cause an accident. PC200. relieve the travel circuit. 30 Testing and adjusting 5) After finishing measurement. 3) Disconnect drain hose (5) of the travel motor and block the hose side with a plug. a Measure several times.

In particular. the boom cylinder does not move to the lowering stroke end. PC200. bleed air from it before connecting the work equipment. keep its speed at low idle for 10 minutes. 3 Air bleeder: 7.8 – 9. 2) After the oil oozes out. 51 . D o n o t relieve the oil. tighten air bleeder (1). 1) Run the engine at low idle for about 5 minutes.30 Testing and adjusting SEN00228-02 Bleeding air from each part Air bleeding item 1 Air bleeding procedure 1 2 3 Bleeding air from hydraulic pump Starting engine q q 4 5 6 Bleeding air Bleeding air Bleeding air from swing from travel from cylinder motor motor Checking oil level and starting operation q q (See note) q (See note) q q o o o q q q o o q • Replacing and repairing control valve • Removing control valve piping q q o o q • Replacing and repairing cylinder • Removing cylinder piping q q o o q • Replacing and repairing swing motor • Removing swing motor piping q o q o q • Replacing and repairing travel motor • Removing travel motor piping q o o q q • Replacing and repairing swivel joint • Removing swivel joint piping q o o o q Contents of work • Replacing hydraulic oil • Cleaning strainer • Replacing return filter element • Replacing and repairing hydraulic pump • Removing suction piping q Note: Bleed air from the swing motor and travel motor only when the oil in the motor cases is drained. and the automatic warm-up operation is reset). if it is installed to the work equipment. 2) While running the engine at low idle. 3. Bleeding air from cylinder a If a cylinder is replaced. a Stop the piston rod about 100 mm be f or e e a c h s t r ok e e nd . a If the engine coolant temperature is low and the automatic warm-up operation is started. Bleeding air from hydraulic pump 1) Loosen air bleeder (1) and check that oil oozes out through the air bleeder. 1. Starting engine When running the engine after performing step 1.8 Nm {0. stop the engine temporarily and reset the automatic warm-up operation with the fuel control dial (Set the starting switch in the ON position and hold the fuel control dial in the MAX position for 3 seconds. 220-8 2.8 – 1. raise and lower the boom 4 – 5 times.0 kgm} a Do not use an impact wrench to tighten the air bleeder.

8 – 3. Add oil when the oil level is out of the following standard ranges. it is insufficient. Bleeding air from travel motor 1) Run the engine at low idle. 2) Loosen air bleeder (2) and check that oil oozes out through the air bleeder. and stop the engine.6 kgm} 6. tighten air bleeder (2). Add oil. 3 Air bleeder: 27. 4. Bleeding air from swing motor 1) Run the engine at low idle. 5. move the piston rod to the stroke end and relieve the oil. retract the arm cylinder and bucket cylinder to the stroke ends. q When oil temperature is 10 – 30°C: Between line H and line L q When oil temperature is 50 – 80°C: Near line H PC200. Bleed air from the arm cylinder and bucket cylinder according to steps 2) – 4). Checking oil level and starting work 1) Run the engine.5 – 35.3 Nm {2. While running the engine at low idle. a The oil level changes according to the oil temperature. 3) After the oil oozes out. perform step 2). 52 30 Testing and adjusting 2) Check the oil level by sight gauge (3) on the rear side of the hydraulic tank. 2) Swing slowly to bleed air. a If the oil level is below line L. lower the work equipment to the ground. 220-8 .SEN00228-02 3) 4) 5) While running the engine at high idle.

5 kgm} [Reference] q The tightening torque of mounting bolt (4) of cab tipping stopper (3) is different from that of a common bolt 30 mm in diameter. 220-8 53 . 2. Remove the additional undercover from the rear of the operator's cab. 3 Bolt (2): 98 – 123 Nm {10 – 12. 1. 3 Bolt (4): 245 – 309 Nm {25 – 31.30 Testing and adjusting Checking cab tipping stopper SEN00228-02 1 a Check the cab tipping stopper according to the following procedure. a Perform this step only when the additional undercover is installed.5 kgm} PC200. Take care. Check the tightening torque of the mounting bolt (2) of the lock plate (1).

SEN00228-02 Adjusting mirrors 54 30 Testing and adjusting 1 PC200. 220-8 .

a If a mirror is hard to move.30 Testing and adjusting SEN00228-02 Installing positions of mirrors Install mirrors (a1) and (b1) as shown in the figure. 220-8 55 .500 mm q Mirror (a1) : Hatched part (a2) must be seen q Mirror (b1) : Hatched part (b2) must be seen q Mirror (c1) : Hatched part (c2) must be seen q Mirror (d1) : Hatched part (d2) must be seen PC200. Adjusting mirrors (c1) and (d1) Adjust the mirrors so that the operator can see the ground at 1 m around the machine from the operator's seat. q Visibility (Left) :1.830 mm q Visibility (Right) :1. q Mirror (a1): 120 mm (from stay top) q Mirror (b1): 100 mm (from stay bottom) Adjusting mirrors (a1) and (b1) Loosen bolts (1) and (2) of the mirrors and adjust the mirrors so that the operator can see the right and left rear views best which are blind corners from the operator's seat. Adjusting view Adjust each mirror so that the operator can see the following ranges. a Adjust the mirrors so that the operator can see persons (or things 1 m high and about 30 cm in diameter) at the right and left rear of the machine. loosen screw (3).

220(LC)-8 Hydraulic excavator Form No.SEN00228-02 PC200. SEN00228-02 © 2007 KOMATSU All Rights Reserved Printed in Japan 04-07 (01) 56 .

............................SEN00229-03 HYDRAULIC EXCAVATOR 1SHOP MANUAL PC200-8 PC200LC-8 PC220-8 PC220LC-8 Machine model Serial number PC200-8 PC200LC-8 PC220-8 PC220LC-8 300001 and up 300001 and up 70001 and up 70001 and up 30 Testing and adjusting 1 Testing and adjusting............ 2 PC200................................. 2 Special functions of machine monitor.... 220-8 1 .................................................................................... Part 2 Testing and adjusting.................................................. Part 2...............

SEN00229-03 30 Testing and adjusting Testing and adjusting. 220-8 . Part 2 1 Special functions of machine monitor 1 Air conditioner specification 2 PC200.

the machine monitor goes off for a moment. This phenomenon is not a failure. that function switch is not working.30 Testing and adjusting Heater specification SEN00229-03 Upper section of machine monitor (Display section) (a): Multi-display a When the engine is started. and heaterless specification is only the functions of the switches in this section. according to the display condition of multidisplay. however. a The machine monitor automatically judges which function of each switch is currently effective. Upper section of machine monitor (Switch section) [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. 3 . a If the graphic mark of a function switch is not displayed. heater specification. depending on the ambient temperature and the condition of the battery. the battery voltage may lower suddenly. a The difference between the air conditioner specification. In this case. 220-8 Lower section of machine monitor (Switch section) [1]: Numeral 1 input switch/Auto-decelerator switch [2]: Numeral 2 input switch/Working mode selector switch [3]: Numeral 3 input switch/Travel speed shifting switch [4]: Numeral 4 input switch/Alarm buzzer cancel switch [5]: Numeral 5 input switch/Wiper switch [6]: Numeral 6 input switch/Windshield 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. Heaterless specification PC200.

or troubleshooting. This mode is used for special setting. 2. adjusting. testing. Each serviceman can display them by operating the switches specially. Special functions: Service mode The items in this mode are not displayed ordinarily. t Operator mode (Outline) Page Page Service mode 6p 20p 6p Monitoring A Display of inputting password 7p A Display of check of breaker mode 7p A Display of check before starting 7p Mechanical Systems 26p Abnormality Electrical Systems 27p Record Air-conditioning System/Heater System 33p A Display of warning after check before starting 8p Maintenance Record 34p A Display of ending of maintenance interval 8p Maintenance Mode Change 35p A Display of check of working mode and travel speed 8p Phone Number Entry 37p A Display of ordinary screen 8p Key-on Mode 38p A Display of end screen 9p Unit 39p B Selection of auto-deceleration 9p B Selection of working mode 9p B Selection of travel speed 10p B Operation to stop alarm buzzer 10p B Operation of windshield wiper 11p B Operation of window washer 11p B Operation of air conditioner/heater 11p Operation to display camera mode (if camera is installed) 12p B 12p B Check of maintenance information 13p Setting and display of user mode B (Including KOMTRAX messages for user) 13p C Display of energy-saving guidance 14p C Display of caution monitor 14p C Display of automatic judgment of breaker 15p C Display of user code and failure code 15p 40p Attachment/Maintenance Password 41p Camera 42p ECO Display 43p Breaker Detect 44p Pump Absorption Torque (F) 45p Pump Absorption Torque (R) 46p Low Speed 47p 48p Cylinder Cut-Out 49p No Injection 50p Fuel Consumption 52p Terminal Status 53p KOMTRAX GPS & Communication Status Settings MODEM S/N (TH300) MODEM IP Address (TH200) 54p 55p 56p 57p 17p D Function of checking service meter 17p Function of changing attachment/maintenance D password 18p 4 Adjustment With/Without Attachment Display of KOMTRAX message O (Special operation) Function of checking display of LCD (Liquid Crystal Display) Default 21p Attachment Flow Adjustment B Operation to display clock and service meter D O (Special operation) A Display of KOMATSU logo PC200. The operator can display and set them by operating the switches (Display and setting of some items need special operations of the switches). 1. Ordinary functions: Operator mode The items in this mode are displayed ordinarily.SEN00229-03 30 Testing and adjusting t Ordinary functions and special functions of machine monitor The machine monitor has the ordinary function and special functions and displays information of various types on the multi-display. 220-8 . 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.

220-8 5 .30 Testing and adjusting a SEN00229-03 Classification of operator mode A: Display/Function from time when starting switch is turned ON to time when screen changes to ordinary screen and display after starting switch is turned OFF B: Display/Function when switch of machine monitor is operated C: Display/Function when certain condition is satisfied D: Display/Function which needs special operation of switch PC200.

the KOMATSU logo is displayed for 2 seconds. or Operation and Maintenance Manual. a Display pattern A B C D E Display of KOMATSU logo 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. or “Display of check before starting”. the screen changes to “Display of inputting password”. function and maintenance standard. call the person responsible to operation of KOMTRAX in your Komatsu distributor and ask for remedy. If this screen is displayed. “Display of check of breaker mode (if B mode is set)”.SEN00229-03 t a a 30 Testing and adjusting Operator mode (Outline) Only outline of the operator mode is described in this section. 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 checkbefore-starting items E : When there is maintenance item which is not maintained after specified interval 1 1 1 1 1 Display of inputting password 2 — — — — Display of check of breaker mode — — 2 — — Display of check before starting 3 2 3 2 2 Display of warning after check before starting — — — 3 — Display of ending of maintenance interval — — — — 3 Display of check of working mode and travel speed 4 3 4 4 4 Display of ordinary screen 5 4 5 5 5 Display of KOMATSU logo When the s tarting switch is turned ON. For details of contents/operation of each function/display. The following are the displays or functions of the operator mode explained in this section (including some items which need special operations). 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/heater Operation to display camera mode (if camera is installed) Operation to display clock and service meter Check of maintenance information Setting and display of user mode (including KOMTRAX messages for user) Display of energy-saving guidance Display of caution monitor Display of automatic judgment of breaker a a The following screen may be displayed instead of the above Display of inputting password screen. Display of 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 6 PC200. see the Structure. 220-8 . a After the KOMATSU logo is displayed for 2 seconds.

the screen changes to “Display of warning after check before starting” or “Display of ending of maintenance interval”. the machine may move unexpectedly or may not operate normally or the hydraulic components may be damaged. a After operation to check of the breaker mode is finished. a If no abnormality is detected by the check before starting. a If any abnormality is detected by the check before starting. the screen changes to “Display of check of working mode and travel speed”. a The machine monitor has some password functions other than the engine start lock. Those functions are independent from one another. If No is selected: Working mode is set to economy mode [E] If Yes is selected: Working mode is set to breaker mode [B] PC200. the screen changes to “Display of check of breaker mode (if B mode is set)” or “Display of check before starting”. a This screen is displayed only when the engine start lock function is set effective. Display of check before starting When the screen changes to the check-beforestarting screen.30 Testing and adjusting SEN00229-03 Display of inputting password After the KOMATSU logo is displayed. k If an attachment other than the breaker is used while the working mode is set to the breaker mode [B]. the screen to input the engine start lock password is displayed. a message to inform the operator of starting in the breaker mode is displayed on the screen. the screen changes to “Display of check before starting”. a The monitors (6 pieces) displayed on the screen are the items under the check before starting. the check before starting is carried out for 2 seconds. Display of check of breaker mode When the starting switch is turned ON. a If the password is input normally. if the working mode is set to the breaker mode [B]. 220-8 7 .

the maintenance monitor is displayed for 30 seconds to urge the operator to maintenance. if a maintenance item is near or after the end of the set interval. the warning monitor is displayed on the screen. a After display of this screen is finished. 8 30 Testing and adjusting Display of check of working mode and travel speed If the check before starting is finished normally. a Set or change the maintenance function in the service mode. the screen changes to “Display of ordinary screen”. Display of ordinary screen If the machine monitor starts normally. PC200. a The following figure shows that the engine oil level monitor (a) is warning of low of engine oil level. the ordinary screen is displayed. a ECO gauge (b) is displayed at the right end of the screen (It is turned ON and OFF in the service mode). The color of the maintenance monitor (yellow or red) indicates the length of the time after the maintenance interval.SEN00229-03 Display of warning after check before starting If any abnormality is detected by the check before starting. the screen to check the working mode and travel speed is displayed for 2 seconds. Display of ending of maintenance interval When the check before starting is carried out. a After display of check of the working mode and travel speed is finished. a This screen is displayed only when the maintenance function is effective. 220-8 . the screen changes to “Display of check of working mode and travel speed”. a Service meter (a) or a clock is displayed at the center upper section of the screen (The service meter or clock is selected with [F4]).

a If the auto-deceleration is turned OFF. PC200. 9 . the end screen is displayed for 5 seconds. Selection of auto-deceleration While the ordinary screen is displayed. 1. Operate the function switches or working mode selector switch to select and confirm the working mode which you will use. a The following figure is the working mode selection screen displayed when "With attachment" is set (If "With attachment" is not set in the service mode. large auto-deceleration monitor (a) is displayed for 2 seconds and the setting of the auto-deceleration is changed. a Another message may be displayed on the end screen. if the autodeceleration switch is pressed. depending on the message display function of KOMTRAX. 220-8 SEN00229-03 Selection of working mode Select a working mode according to the following procedure. 2. the selection is confirmed and the screen changes to the ordinary screen. the attachment mode [ATT] is not displayed). Function switches q [F3]: Move to lower working mode q [F4]: Move to upper working mode q [F5]: Cancel selection and return to ordinary screen q [F6]: Confirm selection and return to ordinary screen Working mode selector switch q Press: Move to lower working mode q Hold down:Confirm selection and return to ordinary screen a If you do not touch any of the function switches and working mode selector switch for 5 seconds. a If the auto-deceleration is turned ON.30 Testing and adjusting Display of end screen When the starting switch is turned OFF. a Each time the auto-deceleration switch is pressed. While the ordinary screen is displayed. the auto-deceleration is turned ON and OFF alternately. and the working mode selection screen is displayed. autodeceleration monitor (b) goes off. press the working mode selector switch. large monitor (a) and auto-deceleration monitor (b) are displayed simultaneously.

q If an attachment other than the breaker is used. Hi. PC200. too. if the travel speed shifting switch is pressed. q If the setting is confirmed on this screen. When the ordinary screen is displayed again. the alarm buzzer stops. q After the breaker mode is selected. both of the control of the hydraulic pump and the setting of the hydraulic circuit are changed. the machine may move unexpectedly or may not operate normally or the hydraulic components may be damaged. Mi. large travel speed monitor (a) is displayed for 2 seconds and the setting of the travel speed is changed. If Yes is selected: Working mode is set to breaker mode [B] 10 30 Testing and adjusting Selection of travel speed While the ordinary screen is displayed. the travel speed is changed to Lo. the display of travel speed monitor (b) is changed. and Lo again in order. a Each time the travel speed shifting switch is pressed. If No is selected: Screen returns to screen to select working mode. a When large monitor (a) is displayed. <Precautions for selecting breaker mode [B]> q If breaker mode [B] is selected. and then the setting of the working mode is changed.SEN00229-03 3. the screen to confirm the selection of the breaker mode is displayed (The buzzer sounds intermittently while this screen is displayed). the display of working mode monitor (b) is changed. a Even if the alarm buzzer cancel switch is pressed. a When large monitor (a) is displayed. Operation to stop alarm buzzer While the alarm buzzer is sounding. the screen changes to the ordinary screen. large working mode monitor (a) is displayed for 2 seconds. the screen does not change. too. 220-8 . if the alarm buzzer cancel switch is pressed.

a When large monitor (a) is displayed. a Even if the window washer switch is pressed. 220-8 11 . the windshield wiper setting is changed to INT. if the window washer switch is pressed. a While the air conditioner adjustment screen or heater adjustment screen is displayed. a Air conditioner specification a Heater specification Operation of window washer While the ordinary screen is displayed. and INT again in order. large monitor (a) is not displayed.30 Testing and adjusting Operation of windshield wiper While the ordinary screen is displayed. if you do not touch any switch for 5 seconds. the washing liquid is splashed only while the switch is held down. if the wiper switch is pressed. PC200. the screen changes to the ordinary screen. OFF. a Each time the wiper switch is pressed. a If the windshield wiper is turned OFF. press the air conditioner switch or heater switch. large wiper monitor (a) is displayed for 2 seconds and the windshield wiper starts or stops. too. the screen does not change. ON. the display of wiper monitor (b) is changed or turned OFF. SEN00229-03 Operation of air conditioner/heater While the ordinary screen is displayed. and the air conditioner adjustment screen or heater adjustment screen is displayed.

When two or more cameras are connected. the caution monitor is displayed at the left upper of the screen (The low hydraulic oil temperature caution is not displayed there. a When the clock is selected. a a a 12 30 Testing and adjusting Operation to display clock and service meter While the ordinary screen is displayed. press [F4]. PC200.SEN00229-03 Operation to display camera mode (if camera is installed) When a camera is installed. however). images are displayed at intervals of 1 second on the right and left screen. only the image of camera 1 is always displayed. if you do not touch any control lever for 10 seconds. the image of one of them or the images of two of them can be displayed. 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. 220-8 . a If a caution is generated in the camera mode. and set the summer time with the user mode function. set 12-hour or 24-hour display. the multi-display changes to the camera image (Set the connection of the camera in the service mode). If 2-camera image display [F4] is selected. The image of camera 3 is displayed only singly. and section (a) changes to the service meter and clock alternately. if [F3] is pressed. a Up to 3 cameras can be connected. If the camera mode is selected. however. When an error that there is a user code occurs in the camera mode. the screen changes to the ordinary screen and displays the error information. If the images of 2 cameras are displayed simultaneously. adjust the time.

press [F6]. The breaker/attachment setting menu is displayed only when "With attachment" is set in the service mode. more operations are necessary. and the user menu screen is displayed. press [F5]. Setting and display of user mode (Including KOMTRAX messages for user) While the ordinary screen is displayed. a a To reset the time left after finishing maintenance. 13 .30 Testing and adjusting SEN00229-03 Check of maintenance information While the maintenance monitor or ordinary screen is displayed. 220-8 There are following items in the user menu. Breaker/Attachment Settings User Message Screen Adjustment Clock Adjustment Language Economy Mode Adjustment a PC200. and the maintenance table screen is displayed.

the caution monitor is displayed large for a moment and then displayed at (a) in the screen. q For service: A message transmitted from the KOMTRAX base station for the service. 14 PC200. 220-8 . operate "KOMTRAX message" display in the service menu. the energy-saving guidance screen is displayed automatically to urge the operator to the energy-saving operation. a Condition for display: Engine is running + All levers have been in neutral for 5 minutes + Caution (Note) or user code is not generated (Note) Note: Excluding hydraulic oil low temperature caution a If any lever or pedal is operated. a The energy-saving guidance is displayed when the following condition is satisfied while the display setting is set effective in the service mode. Even if it is received. operate "User Message" in the above user menu. nothing is displayed on the ordinary screen. or [F5] is pressed. the message monitor is displayed on the ordinary screen. If it is received. To see the contents of the message. q For user: A message transmitted from the KOMTRAX base station for the user.SEN00229-03 [KOMTRAX message] q There are 2 types of KOMTRAX message. a On the camera mode screen. 30 Testing and adjusting Display of energy-saving guidance When the machine is set in a certain operating condition. the caution monitor flashes at the left upper of the screen when the caution is generated. the screen returns to the ordinary screen. Display of caution monitor If an abnormality which displays a caution monitor occurs on the ordinary screen or camera mode screen. To see the contents of the message. 1 is for the user and the other is for the service.

all the information of the abnormality is displayed. a To return to the ordinary screen. a PC200. check the setting of the working mode. a Condition for display: When the pump controller measures the rear pump pressure for a certain time. 220-8 When the caution monitor is also displayed. are displayed only when the telephone No. a This screen is displayed only when an abnormality (failure code) for which a user code is set occurs. select the breaker mode [B]. a If multiple abnormalities occur simultaneously.30 Testing and adjusting Display of automatic judgment of breaker If the operator performs breaker work in an improper working mode. SEN00229-03 Display of user code and failure code If an abnormality which displays a user code and a failure code occurs on the ordinary screen or camera mode screen. (a): User code (3 digits) (b): Failure code (5 or 6 digits) (c): Telephone mark (d): Telephone No. check the details in the service mode. the breaker automatic judgment screen is displayed to urge the operator to select a proper working mode. 15 . press [F5]. is registered in the service mode. all the codes are displayed repeatedly in order. a If this screen is displayed. the obtained value is similar to the pulsation wave form of breaker operation which is held in the controller in advance. the telephone mark is not displayed. a Since the information of the displayed failure code is recorded in the abnormality record in the service mode. a The telephone mark and telephone No. If the breaker is being used. a The breaker automatic judgment function is set to Not used (Not displayed) when delivered. a The breaker automatic judgment is displayed when the following condition is satisfied while the display setting is set effective in the service mode.

but have inspection carried out immediately.SEN00229-03 a Remedies given by displayed user codes to operator to take (The following table is an excerpt from the Operation and Maintenance Manual) User code Failure mode Action Pump control system error When emergency pump drive switch is at the up (emergency) position. oil pressure) system error Operations are possible. normal operations become possible. have inspection carried out immediately. 220-8 . operate the swing lock switch manually. In any case. E0E Network error Operate machine to a safe posture and have inspection carried out immediately. (engine stopped) E11 Engine controller system error Output reduced to protect engine Operate machine to a safe posture and have inspection carried out immediately. it may not be possible to release it. E15 Engine sensor (coolant temperature. Depending on the cause of the problem. fuel pressure. E02 16 30 Testing and adjusting PC200. but have inspection carried out immediately. E10 Engine controller power source error Engine controller drive system circuit error Have inspection carried out immediately. E14 Abnormality in throttle system Operate machine to a safe posture and have inspection carried out immediately. E03 Swing brake system error Move the swing brake cancel switch up to release the brake. When applying the swing brake.

PC200. those points are not a failure or a defect. At this time. all the LCD (Liquid Crystal Display) lights up in white. 17 . only the service meter section displays. 220-8 SEN00229-03 Function of checking service meter To check the service meter while the starting switch is turned OFF. hold down the switches until the LCD displays normally. q Operation of switches (simultaneous): [4] + [F2] a When finishing the operation of the switches. q Operation of switches (simultaneous): [4] + [1] a Since there is some time lag in start of the LCD. a To return to the former screen. only that part is indicated in black.30 Testing and adjusting Function of checking display of LCD (Liquid Crystal Display) While the ordinary screen is displayed. press the function switch. This phenomenon does not indicate a failure or a defect. if the following numeral input switch and function switch are operated as follows. a After the machine monitor is used continuously. a If there is a display error in the LCD. If the number of the bright points and black points does not exceed 10. 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. operate the numeral input switches as follows. release [F2] first. blue points (points which do not go off) may be seen on this screen.

After the New password input screen is displayed. input the current password with the numeral input switches and confirm it with the function switch. While the ordinary screen is displayed. perform the following operation with the numeral input switches. 1. 2. a If the input password is incorrect. q [F5]: Reset input numeral/Return to ordinary screen q [F6]: Confirm input numeral a Default password: [000000] a If the input password is correct. the message to input the password again is displayed. After the New password input screen is displayed again. q Operation of switches (While pressing [4]. q [F5]: Reset input numeral/Return to ordinary screen q [F6]: Confirm input numeral 4. follow these procedures. input a new password with the numeral input switches and confirm it with the function switch. PC200. the message to input again is displayed. a Set a new password of 4 – 6 digits (If it has only 3 or less digits or has 7 or more digits. 30 Testing and adjusting 3. q [F5]: Reset input numeral/Return to ordinary screen q [F6]: Confirm input numeral a If a password different from the password input before is input.SEN00229-03 Function of changing attachment/maintenance password When changing the attachment/maintenance password used for the attachment setting function and maintenance setting function. the screen changes to the next screen. input a new password again with the numeral input switches and confirm it with the function switch. it is not accepted). 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 on. 18 After the Attachment/Maintenance PASSWORD screen is displayed. 220-8 .

the password is changed successfully. SEN00229-03 If the screen to notify completion of setting is displayed and then the ordinary screen is displayed. PC200.30 Testing and adjusting 5. 220-8 19 .

q [F3]: Move to lower menu q [F4]: Move to upper menu q [F5]: Return to ordinary 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]. Select a service menu you use with the function switches or numeral input switches. perform the following operation with the numeral input switches. 09 No Injection 10 Fuel Consumption Terminal Status 11 KOMTRAX GPS & Communication Status Settings MODEM S/N (TH300) MODEM IP Address (TH200) PC200. Check of display of screen and operation of switches While the ordinary screen is displayed. 220-8 .SEN00229-03 t Service mode To change the operator mode to the service mode. perform the following operation. 01 Monitoring Mechanical Systems 02 Abnormality Electrical Systems Record Air-conditioning System/Heater System 03 Maintenance Record 04 Maintenance Mode Change 05 Phone Number Entry Key-on Mode Unit With/Without Attachment 06 Default Attachment/Maintenance Password Camera ECO Display Breaker Detect Pump Absorption Torque (F) 07 Adjustment Pump Absorption Torque (R) Low Speed Attachment Flow Adjustment 08 Cylinder Cut-Out 2. 1. 20 Selection of service menu When the Service menu screen is displayed. q Operation of switches (While pressing [4]. This operation is always required when you use the service mode. 30 Testing and adjusting a The items which can be selected in the service menu are as follows (including some items which need special operations). 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. the service mode is selected.

Selecting menu Select “Monitoring” on the service menu screen. 3. 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]: Reset input numeral/Return to service menu screen q [F6]: Confirm selection a Selection with function switches: Select an item with [F3] or [F4] and confirm it with [F6]. selection of the item of that box is confirmed. a If monitoring items are selected up to the limit number. If [F6] is pressed once more at this time. 220-8 Deciding monitoring items After selecting monitoring items. a Execution with numeral input switch: Input [99999] and press [F6]. select items to be monitored with t he f u nc t i o n s wi t c h e s or nu m e r a l i np u t switches. etc. a When monitoring only 2 items. a If the color of the selected box changes from yellow to red. PC200. depending on the display form of those items. Confirm that item with [F6]. Selecting monitoring items After the “Monitoring selection menu screen” is displayed. execute monitoring with the function switch or numeral input switch. a Execution with function switch: Doubleclick or hold down [F6] (about 2 seconds). however. 2. for example.30 Testing and adjusting SEN00229-03 Monitoring The machine monitor can monitor the condition of the machine in real time by receiving signals from various switches. a Selection with numeral input switches: Enter a 5-digit code. and actuators installed to many parts of the machine and the information from the controllers which are controlling switches. monitoring is executed. 1. 21 . sensors. a Up to 6 monitoring items can be selected at a time. monitoring is executed automatically. and the item of that code is selected directly. You may not able to set up to 6 items. select them and confirm with [F6].

a After finishing changing the setting. 5. a Monitoring information is indicated by value. the corresponding mode is changed. travel speed. perform the necessary operation of the machine and check the monitoring information. metric unit. or special display. a The unit of display can be set to SI unit.SEN00229-03 4. 220-8 . Holding monitoring information The monitoring information can be held and reset with the function switches. While this screen is displayed. or auto-deceleration during monitoring. the screen to confirm the change of the setting is displayed as in changing the working mode on the ordinary screen. q [F3]: Reset holding q [F4]: Hold information (displayed data) q [F5]: Return to monitoring selection menu screen 22 30 Testing and adjusting 6. Changing machine setting mode To change the setting of the working mode. the new setting is held even after the screen returns to the ordinary screen after monitoring is finished. if the corresponding switch is operated further. Executing monitoring After the “Executing monitoring screen” is displayed. press [F6] to return to the monitoring information screen. a If the working mode is changed to breaker mode [B]. a If the setting is changed during monitoring. operate the corresponding switch under the current condition. PC200. or inch unit with the Initialization function in the service mode. ON/OFF. and the mode setting screen is displayed.

Ambient Press Sens Volt Charge Temp Sens Volt Charge Press Sens Volt Rail Pressure Sens Volt Engine Power Mode Throttle Position Final Throttle Position Inject Fueling Command Rail Press Command Injection Timing Command Fuel Rate 2nd Eng. Lo Hydr. Oil Temperature PC-EPC Sol. Curr.(F) PC-EPC Sol.(R) LS-EPC Sol. Battery Voltage Battery Power Supply Battery Charge Vol. Merge-divider Sol. 220-8 % % mg/st MPa CA l/h % Nm MPa % % mg/st psi CA gal/h % lbft psi Remarks Absolute value indication (including atmospheric pressure) 23 . Curr. Monitoring item (Display on screen) ISO meter inch rpm rpm psi psi psi psi psi psi psi psi °F °F mA mA mA mA mA mA V V V psi psi °F Component in charge PUMP ENG ENG PUMP PUMP PUMP PUMP PUMP PUMP PUMP PUMP PUMP ENG PUMP PUMP PUMP PUMP PUMP PUMP PUMP PUMP ENG MON ENG ENG ENG 00200 00201 01002 01601 01100 01101 07400 07200 07300 07301 09001 09002 04107 04401 01300 01302 01500 08000 08001 01700 03200 03203 04300 36400 37400 18500 Controller Model Select Machine ID Engine speed 2nd Eng. Water Temp. Curr.30 Testing and adjusting SEN00229-03 Monitoring items table Unit (Initial setting: ISO) Code No. Eng. Vol. Sonser Vol. Speed Command Main Pump Absorb Torque Boom Bottom Pressure % Nm V V V V V V V V % kgm V V V V V V V V — % % mg/st kg/cm2 CA l/h % kgm kg/cm2 % lbft V V V V V V V V ENG ENG ENG MON ENG PUMP ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG ENG PUMP PUMP PUMP PC200. Speed Command F Pump Pressure R Pump Pressure Boom Raise PPC Pressure Arm Curl PPC Pressure Bucket Curl PPC Pressure Bucket Dump PPC Pressure Swing left PPC Pressure Swing right PPC Pressure Coolant Temperature Hydr. Curr. Rail Pressure Ambient Pressure Charge Temperature r/min r/min MPa MPa MPa MPa MPa MPa MPa MPa °C °C mA mA mA mA mA mA V V V MPa kPa °C — — rpm rpm kg/cm2 kg/cm2 kg/cm2 kg/cm2 kg/cm2 kg/cm2 kg/cm2 kg/cm2 °C °C mA mA mA mA mA mA V V V kg/cm2 kg/cm2 °C 36500 Boost Pressure kPa kg/cm2 psi ENG 36700 18700 03000 04200 04105 04402 37401 18501 36501 36401 17500 31701 31706 18600 36200 36300 37300 01602 13113 15900 Engine Torque Ratio Engine Output Torque Fuel Dial Pos Sens Volt Fuel Level Sensor Vol.(Main) Merge-divider Sol. Temp. Curr.(LS) Service Sol. Curr.

Key Switch Start Preheat Monitor input 1 Light Rad. Oil Level Battery Charge Monitor Input 3 Swing Brake Sw. Swing Brake Sw. Model Select 1 Model Select 2 Model Select 3 Switch Input 2 Model Select 4 Model Select 5 Overload Alarm Switch Input 3 Key Switch (ACC) Window Limit SW. Switch Input 5 P Limit SW. Switch Input 1 Swing Release Sw. Level Air cleaner Monitor Input 2 Eng. F1 F2 Monitor Function F3 Switches F4 F5 F6 SW1 SW2 Monitor 1st & 2nd SW3 Row Switches SW4 SW5 SW6 ISO meter ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF inch Component in charge PUMP PUMP PUMP PUMP PUMP PUMP PUMP PUMP PUMP PUMP PUMP PUMP PUMP PUMP PUMP PUMP PUMP PUMP PUMP PUMP PUMP PUMP PUMP PUMP PUMP PUMP PUMP PUMP PUMP MON MON MON MON MON MON MON MON MON MON MON MON MON MON MON MON MON MON MON MON MON Remarks PC200. W Limit SW.SEN00229-03 30 Testing and adjusting Unit (Initial setting: ISO) Code No. 01900 01901 02300 02301 02200 02201 02202 02204 04500 04501 04502 04503 04504 24 Monitoring item (Display on screen) Swing Travel Boom Lower Pressure Switch 1 Boom Raise Arm Curl Arm Dump Bucket Curl Bucket Dump Pressure Switch 2 Service Travel Steering Travel Junction Swing Brake Solenoid Valve 1 Merge-divider 2-Stage Relief Travel Speed Solenoid Valve 2 Service Return Lever Sw. 220-8 .

Serial No Pump Con. meter. P/N a a a ISO °C meter ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF ON•OFF — — °C — — — — — — — inch °F Component in charge MON MON MON MON MON MON MON MON MON ENG ENG ENG ENG ENG MON MON MON PUMP PUMP PUMP Remarks WIF: Water In Fuel Entry order of items in table The items are entered in the order of display on the monitoring selection menu screen. ENG: The engine controller is in charge of detection of monitoring information.30 Testing and adjusting SEN00229-03 Unit (Initial setting: ISO) Code No. Prog. PC200. "mg/st" in the display unit is an abbreviation for milligram/stroke. "CA" in the display unit is an abbreviation for crankshaft angle. or inch freely (Set it with Unit selecting in Initialization of the service menu). Ass'y P/N Pump Con. 220-8 25 . PUMP: The pump controller is in charge of detection of monitoring information. P/N Pump Con. Unit The display unit can be set to ISO. Component in charge MON: The machine monitor is in charge of detection of monitoring information. Monitoring item (Display on screen) SW7 SW8 SW9 SW10 SW11 SW12 SW13 SW14 SW15 04505 Monitor 3rd & 4th Row Switches 04506 Monitor 5th Row Switches 18800 20216 20217 18900 20400 20227 20402 20228 20229 20403 20230 Water In Fuel ECM Build Version ECM CAL Data Ver ECM Internal Temp ECM Serial No Monitor Ass'y P/N Monitor Serial No Monitor Prog.

electrical systems. and air-conditioning system or heater system. 2. Selecting menu Select “Abnormality Record” on the “Service Menu” screen. which may not be displayed in the heaterless specification. a If [E] is displayed on the left of a failure code. Information displayed on “abnormality record” screen On the “Mechanical Systems” screen. Selecting sub menu After the “Abnormality Record” screen is displayed. a The following figure shows the display of the air conditioner specification. The heater specification and heaterless specification are different from each other in the display of "03 Air-conditioning System". 220-8 . select “Mechanical Systems” with the function switches or numeral input switches. 26 30 Testing and adjusting 3. 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 record of that code and confirm it with [F6]. the following information is displayed. To check the mechanical system abnormality record. (a) : Occurrence order of abnormalities from latest one/Total number of records (b) : Failure code (c) : Contents of trouble (d) : Number of occurrence time (Displayable range: 0 – 65. perform the following procedures. the service meter reading at the first occurrence and that at the last occurrence are the same.SEN00229-03 Abnormality Record (Mechanical Systems) The machine monitor classifies and records the abnormalities which occurred in the past or which are occurring at present into the mechanical systems. "No abnormality record" is displayed. see the failure codes table in “Abnormality Record (Electrical Systems)”. a If the number of occurrence time is 1 (first occurrence). a For all the failure codes that the machine monitor can record. the abnormality is still occurring or resetting of it has not been confirmed.535 times) (e) : Service meter reading at first occurrence (f) : Service meter reach 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 record is recorded. 1. PC200.

a If the number of occurrence time is 1 (first occurrence). and air-conditioning system. To check the electrical system abnormality record. the following information is displayed. Information displayed on “abnormality record” screen On the “Electrical Systems” screen. perform the following procedures. a The following figure shows the display of the air conditioner specification. Selecting menu Select “Abnormality Record” on the “Service Menu” Screen. 2. "No abnormality record" is displayed. electrical systems. 220-8 3. 27 . 1. SEN00229-03 Resetting abnormality record The contents of the mechanical system abnormality record cannot be reset. PC200. a If [E] is displayed on the left of a failure code. the abnormality is still occurring or resetting of it has not been confirmed. a For all the failure codes that the machine monitor can record. Abnormality Record (Electrical Systems) The machine monitor classifies and records the abnormalities which occurred in the past or which are occurring at present into the mechanical systems. see the failure codes table. (a) : Occurrence order of abnormalities from latest one/Total number of records (b) : Failure code (c) : Contents of trouble (d) : Number of occurrence time (Displayable range: 0 – 65.535 times) (e) : Service meter reading at first occurrence (f) : Service meter reach 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 record is recorded. 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 record of that code and confirm it with [F6]. Selecting sub menu After the “Abnormality Record” screen is displayed.30 Testing and adjusting 4. the service meter reading at the first occurrence and that at the last occurrence are the same. select “Electrical Systems” with the function switches or numeral input switches. The heater specification and heaterless specification are different from each other in the display of "03 Air-conditioning System". which may not be displayed in the heaterless specification.

and then reset the items one by one or together with the function switches. the resetting operation is accepted but the information is not reset. q [F2]: Reset all items q [F3]: Move to lower item q [F4]: Move to upper item q [F5]: Return to abnormality record screen q [F6]: Reset selected item a To reset items one by one: Select the item to be reset with [F3] or [F4] and press [F6]. 30 Testing and adjusting 3) After the “Electrical Sys. 220-8 . perform the operation in order): [4] + [1] o [2] o [3] 2) 28 Check that the screen is set in the reset mode. and all the items are reset. operate the function switches. a To reset all items together: Press [F2]. a If [E] is displayed on the left of a failure code. a If the screen is set in the reset mode. q Operation of switches (While pressing [4]. [CLEAR] graphic mark is indicated at [F2]. the reset of the abnormality record is completed. perform the following operation with the numeral input switches. Error Reset” screen is displayed. 4) If the screen to notify completion of reset is displayed and then the “Electrical Systems” (reset mode) screen is displayed. the screen returns to the “Electrical Systems” screen. PC200. Resetting abnormality record 1) While the “Electrical Systems” screen is displayed. q [F5]: Return to “Electrical systems” screen (Reset mode) q [F6]: Execute reset a The following figure shows the screen displayed when the items are reset one by one (which is a little different from the screen displayed when all the items are reset together). a After a while.SEN00229-03 4. regardless of selection of the items.

30 Testing and adjusting SEN00229-03 Failure codes table User code Failure code Trouble (Displayed on screen) Alarm buzzer Component Category of 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 B@BAZK Eng Oil Level Low B@BCNS Eng Water Overheat e ENG B@BCZK Eng Water Level Low e MON B@HANS Hydr Oil Overheat e PUMP e ENG MON E10 CA111 EMC Critical Internal Failure q ENG E10 CA115 Eng Ne and Bkup Speed Sens Error q ENG E11 CA122 Chg Air Press Sensor High Error q ENG E11 CA123 Chg Air Press Sensor Low Error q ENG E14 CA131 Throttle Sensor High Error q ENG E14 CA132 Throttle Sensor Low Error q ENG E15 CA144 Coolant Temp Sens High Error q ENG E15 CA145 Coolant Temp Sens Low Error q ENG E15 CA153 Chg Air Temp Sensor High Error q ENG E15 CA154 Chg Air Temp Sensor Low Error q ENG E11 CA155 Chg Air Temp High Speed Derate q ENG E15 CA187 Sens Supply 2 Volt Low Error q ENG E11 CA221 Ambient Press Sens High Error q ENG E11 CA222 Ambient Press Sens Low Error q ENG E15 CA227 Sens Supply 2 Volt High Error q ENG CA234 Eng Overspeed E15 CA238 Ne Speed Sens Supply Volt Error q ENG E10 CA271 IMV/PCV1 Short Error q ENG E10 CA272 IMV/PCV1 Open Error q ENG E11 CA322 Inj #1 Open/Short Error q ENG PC200. 220-8 ENG 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 Mechanical system Electrical system Electrical system Electrical system Electrical system 29 .

SEN00229-03 30 Testing and adjusting User code Failure code E11 CA323 Inj #5 Open/Short Error q E11 CA324 Inj #3 Open/Short Error q E11 CA325 Inj #6 Open/Short Error q E11 CA331 Inj #2 Open/Short Error q E11 CA332 Inj #4 Open/Short Error q E10 CA342 Calibration Code Incompatibility q E10 CA351 Injectors Drive Circuit Error q E15 CA352 Sens Supply 1 Volt Low Error q E15 CA386 Sens Supply 1 Volt High Error q E15 CA428 Water in Fuel Sensor High Error q E15 CA429 Water in Fuel Sensor Low Error q E15 CA435 Eng Oil Press Sw Error q E10 CA441 Battery Voltage Low Error q E10 CA442 Battery Voltage High Error q E11 CA449 Rail Press Very High Error q E11 CA451 Rail Press Sensor High Error q E11 CA452 Rail Press Sensor Low Error q E11 CA488 Chg Air Temp High Torque Derate q E15 CA553 Rail Press High Error q E15 CA559 Rail Press Low Error q E15 CA689 Eng Ne Speed Sensor Error q E15 CA731 Eng Bkup Speed Sens Phase Error q E10 CA757 All Continuous Data Lost Error q E15 CA778 Eng Bkup Speed Sensor Error q E0E CA1633 KOMNET Datalink Timeout Error q E14 CA2185 Throt Sens Sup Volt High Error q E14 CA2186 Throt Sens Sup Volt Low Error q E11 CA2249 Rail Press Very Low Error q E11 CA2311 IMV Solenoid Error q E15 CA2555 Grid Htr Relay Volt High Error q 30 Trouble (Displayed on screen) Alarm buzzer Component Category of in charge record Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system Electrical ENG system PC200. 220-8 .

30 Testing and adjusting SEN00229-03 User code Failure code E15 CA2556 Grid Htr Relay Volt Low Error q E01 D19JKZ Personal Code Relay Abnormality q D862KA GPS Antenna Discon DA22KK Pump Solenoid Power Low Error DA25KP 5 V Sensor 1 Power Abnormality DA29KQ Model Selection Abnormality DA2RMC CAN Discon (Pump Con Detected) DAF8KB Short circuit in camera power supply DAFGMC GPS Module Error DAFRMC CAN Discon (Monitor Detected) DGH2KB Hydr Oil Sensor Short DHPAMA F Pump Press Sensor Abnormality DHPBMA R Pump Press Sensor Abnormality DHS3MA Arm Curl PPC Press Sensor Abnormality DHS4MA Bucket Curl PPC Press Sensor Abnormality DHS8MA Boom Raise PPC Press Sensor Abnormality DHSAMA Swing RH PPC Press Sensor Abnormality DHSBMA Swing LH PPC Press Sensor Abnormality DHSDMA Bucket Dump PPC Press Sensor Abnormality DHX1MA Overload Sensor Abnormality (Analog) DW43KA Travel Speed Sol Discon DW43KB Travel Speed Sol Short E03 DW45KA Swing Brake Sol Discon q E03 DW45KB Swing Brake Sol Short q DW91KA Travel Junction Sol Discon DW91KB Travel Junction Sol Short DWA2KA Service Sol Discon DWA2KB Service Sol Short DWK0KA 2-stage Relief Sol Discon DWK0KB 2-stage Relief Sol Short E0E E0E E0E PC200. 220-8 Trouble (Displayed on screen) Alarm buzzer q q q Component Category of in charge record Electrical ENG system Electrical MON2 system Electrical MON2 system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical MON system Electrical MON2 system Electrical MON system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system 31 .

Category of record Mechanical system: Abnormality information is recorded in the mechanical system abnormality record. PC200. Alarm buzzer q : When occurrence of an error is notified to the operator. the buzzer sounds (The operator can stop the buzzer with the alarm buzzer cancel switch). User code Attached : If the failure code is detected. failure code. e: Since the caution monitor is also turned ON. the user code. 220-8 . the machine monitor does not notify the operator of the abnormality. ENG: The engine controller is in charge of detection of abnormality. Not attached: Even if the failure code is detected. and telephone No. its function sounds the buzzer. MON2: The KOMTRAX section of the machine monitor is in charge of detection of abnormality. (if registered) are displayed on the ordinary screen to notify the operator of the abnormality.SEN00229-03 30 Testing and adjusting User code Failure code E02 DXA8KA PC-EPC (F) Sol Discon q E02 DXA8KB PC-EPC (F) Sol Short q E02 DXA9KA PC-EPC (R) Sol Discon q E02 DXA9KB PC-EPC (R) Sol Short q DXE0KA LS-EPC Sol Discon DXE0KB LS-EPC Sol Short DXE4KA Service Current EPC Discon DXE4KB Service Current EPC Short DXE5KA Merge-divider Main Sol Discon DXE5KB Merge-divider Main Sol Short DXE6KA Merge-divider LS Sol Discon DXE6KB Merge-divider LS Sol Short DY20KA Wiper Working Abnormality DY20MA Wiper Parking Abnormality DY2CKA Washer Drive Discon DY2CKB Washer Drive Short DY2DKB Wiper Drive (For) Short DY2EKB Wiper Drive (Rev) Short a a a a a 32 Trouble (Displayed on screen) Alarm buzzer Component Category of in charge record Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Electrical PUMP system Entry order of items in table The items are entered in the order of their failure codes (incremental order). PUMP: The pump controller is in charge of detection of abnormality. Component in charge MON: The machine monitor is in charge of detection of abnormality. Electrical system: Abnormality information is recorded in the electrical system abnormality record.

Information displayed on “abnormality record” screen On the “Air-conditioning System” or “Heater System” screen. select “Air-conditioning System” or “Heater System” with the function switches or numeral input switches. perform the following procedures. communication cannot be carried out normally. Heaterless specification In the heaterless specification. 1. the abnormality is still occurring or resetting of it has not been confirmed. Accordingly. SEN00229-03 3. (a): System/Component name (b): Number of occurrence time (c): Condition (Normal or abnormal) q [F2]: Reset abnormality record q [F5]: Return to abnormality record screen a If [E] is displayed on the left of a condition. a Heater specification In the heater specification. and the number of occurrence time of abnormality is reset. Selecting menu Select “Abnormality Record” on the “Service Menu” screen. a If CAN disconnection is displayed in Communication condition. the abnormality record menu and screen are not displayed. 2. the following information is displayed. 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 record of that code and confirm it with [F6]. 4.30 Testing and adjusting Abnormality Record (Air-conditioning System/ Heater System) The machine monitor classifies and records the abnormalities which occurred in the past or which are occurring at present into the mechanical systems. Selecting sub menu After the “Abnormality Record” screen is displayed. a All the following figures show the air conditioner specification. 220-8 33 . Resetting abnormality record While the “abnormality record” screen is displayed. electrical systems. the display of “Airconditioning” is replaced with “Heater” and the items which are not related to the heater are not displayed. To check the air-conditioning abnormality record or heater abnormality record. and air-conditioning abnormalities or heater abnormalities. the display changes to Normal. a PC200. press [F2]. the conditions of other items are turned OFF. If it is confirmed at this time that the abnormality has been reset.

. 2. 220-8 . the number of the times of maintenance is recorded in this section. 34 The following items can be selected in the maintenance record. 3. if the data are reset in the operator mode. which the operator can display and check by the following operations. Items displayed on maintenance record screen The following items are displayed. 01 Engine oil change 02 Engine oil filter change 03 Fuel main filter change 41 Fuel pre-filter change 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 Selecting menu Select “Maintenance Record” on the “Service Menu” screen.SEN00229-03 30 Testing and adjusting a Maintenance Record The machine monitor records the maintenance information of the filters. (a) : Maintenance items (b) : Number of times of replacement up to now (c) : Service meter reading (SMR) at previous replacement Selecting maintenance record item After the “Maintenance Record” screen is displayed. 1. 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. oils. When maintenance is carried out. select an item to be checked with the function switches or numeral input switches. PC200. etc.

06 Corrosion resistor change int. q ON: Functions of all maintenance items are set effective in operator mode q OFF: Functions of all maintenance items are set ineffective 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. 02 Engine oil filter change int. Selecting sub menu After the “Maintenance Mode Change” screen is displayed. 10 Hydraulic oil change int. 3. if the screen is displayed. 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 and confirm it with [F6]. q Set function effective or ineffective q Change set replacement interval (by items) q Initialize all set replacement intervals 1. if the above setting is changed. 07 Damper case service int. 35 . select an item to change the setting with the function switches or numeral input switches. 08 Final drive case oil change int. PC200. 09 Machinery case change int. 220-8 The following items can be selected on the Change of maintenance mode screen. set ON or OFF with the function switches. 00 Maintenance mode on/off 01 Engine oil change int. 2. 04 Hyd oil filter change int.30 Testing and adjusting SEN00229-03 a Maintenance Mode Change The operating condition for maintenance function in the operation mode can be set and changed with this menu. 03 Fuel main filter change int. Contents of setting of Maintenance mode on/ off After selecting “Maintenance Mode On/Off”. 41 Fuel pre filter change int. it is applied. 05 Hyd tank breather change int. 99 Initialize all items Selecting menu Select of “Maintenance Mode Change” on the “Service Menu” screen.

q ON: Maintenance function of this item is set effective in operator mode. q [F3]: Select Reduce set value (Upper) or OFF (Lower). if the screen is displayed. Maintenance functions in operator mode operate on basis of this set time (which is increased or decreased by 50 hours). q [F6]: Confirm setting of upper or lower line. initialization is completed. if the screen is displayed. the change is recognized as a resetting operation. 30 Testing and adjusting 5. 220-8 . the setting is effective. PC200. q Initial value: Maintenance interval set in machine monitor (Recommended by manufacturer and not changeable). a If the set value of an item set to “ON” is changed after 1 or more operating hours since the start of setting. q Set value: Maintenance interval which can be set freely.SEN00229-03 4. a After the setting of the upper and lower lines is confirmed with [F6] and the screen changes to the Maintenance mode change screen with [F5]. q [F4]: Select Increase set value (Upper) or ON (Lower). if the “Maintenance Mode Change” screen is displayed. the initialization completion screen is displayed. Then. q [F5]: Return to Maintenance mode change screen q [F6]: Execute initialization a A while after [F6] is pressed. set with the function switches. 36 Contents of setting of each maintenance item After selecting each maintenance item. Function of initializing all items After selecting “All Default Value”. the set values of all the maintenance items are initialized. q [F5]: Cancel setting before confirmation and return to Maintenance mode change screen. set the item with the function switches. q If this operation is executed. q OFF: Maintenance function of this item is set ineffective in operator mode.

displayed when the user code/ failure code is displayed in the operator mode can be input and changed according to the following procedure. is not input with this function. Accordingly. Selecting menu Select “Phone Number Entry” on the “Service Menu” screen. 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 q [F6]: Confirm input a a SEN00229-03 a If [F6] is pressed without inputting a digit. Input nothing in the surplus positions. After the “Phone Number Entry” screen is displayed. Registering and changing telephone No. no telephone No. If a telephone No. q [F2]: Reset all input No. no telephone No. register or change the telephone No. move to that digit (orange background) and overwrite it with the correct digit. PC200. If one of the input digits is wrong. is displayed in the operator mode.30 Testing and adjusting Phone Number Entry The telephone No. 2. 220-8 37 . is displayed in the operator mode. there is not information of telephone No. 1. Up to 14 digits can be input from the left.

PC200. If "With attachment" is not set. Selecting sub menu After the “Default” screen is displayed. Breaker mode [B] is always displayed. The function of working mode with key ON is used to set the working mode displayed on the machine monitor when the starting switch is turned ON.SEN00229-03 30 Testing and adjusting Default (Key-on Mode) Check or change various settings related to the machine monitor and machine by "Default". Selecting mode After the “Key-on Mode” screen is displayed. q Power Mode: [P] is displayed when key is ON q Economy Mode: [E] is displayed when key is ON q Lifting Mode: [L] is displayed when key is ON q Breaker Mode: [B] is displayed when key is ON q Attachment Mode: [ATT] is displayed when key is ON 38 Mode at Previous Key-off: Final mode in previous operation is displayed when key is ON [F3]: Move to lower item [F4]: Move to upper item [F5]: Cancel selection and return to “Default” screen [F6]: Confirm selection and return to “Default” screen When the machine is delivered. select “Key-on Mode” with the function switches or numeral input switches. q 1. 3. q Selecting menu Select “Default” on the “Service Menu” screen. select the mode to be set with the function switches. q q q a a a a 2. if "Without attachment" is set. While Attachment mode [ATT] is selected. Power mode [P] is displayed when the key is turned ON. a Select this item similarly to an item on the “Service Menu” screen. the attachment mode cannot be selected. 220-8 . If the engine is stopped while breaker mode [B] is selected in the operator mode. regardless of the above setting. Mode at previous key-OFF is set.

Selecting unit After the “Unit” screen is displayed. 220-8 SEN00229-03 a When the machine is delivered. Selecting menu Select “Default” on the “Service Menu” screen.30 Testing and adjusting Default (Unit) Check or change various settings related to the machine monitor and machine by "Default". q [F3]: Move to lower unit q [F4]: Move to upper unit q [F5]: Cancel selection and return to “Default” screen q [F6]: Confirm selection and return to “Default” screen PC200. a Select this item similarly to an item on the “Service Menu” screen. 3. 1. etc. select “Unit” with the function switches or numeral input switches. 39 . select the unit to be set with the function switches. Selecting sub menu After the “Default” screen is displayed. 2. The unit selecting function is used to select the unit of the data displayed for monitoring. the SI unit system is set.

select “With/Without Attachment” with the function switches or numeral input switches. the attachment may not work normally or the hydraulic components may have trouble. The "With/Without attachment" function is used to set an installed or a remove attachment. Selecting menu Select "Default" on the “Service Menu” screen. if this setting is not carried out normally. Selecting With/Without After the “With/Without Attachment” screen is displayed. PC200. Selecting sub menu After the "Default" screen is displayed. 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 40 30 Testing and adjusting a When an attachment is installed. a Select this item similarly to an item on the “Service Menu” screen.SEN00229-03 Default (With/Without Attachment) Check or change various settings related to the machine monitor and machine by "Default". the attachment cannot be set in the operator mode. 3. 220-8 . 1. 2. select the setting with the function switches. As a result.

a See Attachment/Maintenance password changing function in the operator mode. q User mode: On the User menu screen. q Maintenance mode: The Maintenance table screen is changed to the Maintenance interval reset screen. the Breaker/Attachment setting menu is selected and the screen is changed to the Attachment setting menu screen. 220-8 SEN00229-03 3. Displaying attachment/maintenance password screen When the following operation is performed. the password screen is displayed in the operator mode. Changing attachment/maintenance password The password can be changed by operating the switches specially in the operator mode. a Default password: [000000] a If the password setting is changed from Enable to Disable. 41 . be sure to set a new password. 2. 1. PC200. select the setting with the function switches. 5. the password is reset to the default. When Enable is set again.30 Testing and adjusting Default (Attachment/Maintenance Password) Check or change various settings related to the machine monitor and machine by "Default". Selecting menu Select “Default” on the “Service Menu” screen. select “Attachment/Maintenance Password” with the function switches or numeral input switches. Selecting Disable/Enable After the Attachment/Maintenance Password screen is displayed. a The attachment/maintenance password is different from the engine start lock password. 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. a Select this item similarly to an item on the “Service Menu” screen. Selecting sub menu After the “Default” screen is displayed. The function of setting attachment/maintenance password is used to set the display of the password screen when the functions related to the attachment and maintenance are used in the operator mode.

used as back monitor) q Reverse Image: Image of connected camera is displayed in reverse position (as seen directly. 2. select “Came ra ” wi th t he func tio n swi tch es or numeral input switches. the screen changes to setting of camera 2 automatically. Accordingly. 1. a When a camera is installed. 220-8 . a If 2 or more cameras are connected. check that the displayed image is not inverted horizontally. be sure to set the use of them from camera 1 in order. The camera setting function is used to set installation and removal of a camera. Selecting menu Select “Default” on the “Service Menu” screen. and the setting is effective. select the setting with the function switches. PC200. if camera 1 is set. q OFF: Camera is not used q Original Image: Image of connected camera is displayed in original position (as in mirror. camera 1 can be always set. the graphic mark of camera is not displayed at [F3] in the operator mode. return to the "Default" screen with [F5]. 42 30 Testing and adjusting 3. a If a camera is connected but not set normally with this function. a Select this item similarly to an item on the “Service Menu” Screen. a After confirming the setting of each line with [F6]. Selecting camera setting After the “Camera” setting screen is displayed.SEN00229-03 Default (Camera) Check or change various settings related to the machine monitor and machine by "Default". the image of the camera cannot be used. Selecting sub menu After the “Default” screen is displayed. used as front or side monitor) q [F3]: Move to left item q [F4]: Move to right item q [F5]: Cancel setting before confirmation and return to “Default” screen q [F6]: Confirm selection in each line a After “Camera” screen is displayed. When 2 or more cameras are connected. a The function of displaying 2 images simultaneously is effective when use of camera 1 and camera 2 is set.

and the setting is effective. it is not displayed if the condition for display is not satisfied on the ordinary screen. a Select this item similarly to an item on the “Service Menu” screen. however. a Display of ECO gauge (a) a Display of energy saving guidance Selecting menu Select “Default” on the “Service Menu” screen. Selecting sub menu After the “Default” screen is displayed. Even if the energy saving guidance is turned ON. 3. The ECO display setting function is used to set the display of the ECO gauge and energy saving guidance. SEN00229-03 a If ECO display is turned ON. select the setting with the function switches. 2. 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 setting before confirmation and return to "Default" screen q [F6] : Confirm selection in each line a After confirming the setting of the upper and lower lines with [F6].30 Testing and adjusting Default (ECO Display) Check or change various settings related to the machine monitor and machine by "Default". 1. ECO is displayed when the screen changes to the ordinary screen. return to the "Default" screen with [F5]. select “ECO Display” with the function switches or numeral input switches. Selecting display setting After the “ECO Display” screen is displayed. PC200. 220-8 43 .

Selecting display setting After the "Breaker Detect" screen is displayed. a Display of "Breaker Detect" PC200. 1. The function of setting breaker automatic judgment is used to set the display to give warning when the breaker is used in an improper working mode. 44 30 Testing and adjusting 3.SEN00229-03 Default (Breaker Detect) Check or change various settings related to the machine monitor and machine by "Default". select "Breaker Detect" with the function switches or numeral input switches. Selecting menu Select “EDefault” on the “Service Menu” screen. Disable is set. 220-8 . 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 the machine is delivered. select the setting with the function switches. Selecting sub menu After the “Default” screen is displayed. a Select this item similarly to an item on the “Service menu” screen. 2.

SEN00229-03 3. Selecting absorption torque After the "Pump Absorption Torque (F)" screen is displayed.6 Nm {+2 kgm} +9.8 Nm {+1 kgm} 0 Nm {0 kgm} –9. 1. 220-8 Set value 000 001 002 003 004 005 006 007 008 and Torque adjustment value +39. see table q [F3]: Increase set value q [F4]: Decrease set value q [F6]: Confirm setting and return to Adjustment menu screen a The 3 digits on the left side do not vary since they are the code of this function.4 Nm {–3 kgm} –39. select a set value on the right side with the function switches. q Set value: For actual torque adjustment value.2 Nm {+4 kgm} +29. Selecting sub menu After the “Adjustment” screen is displayed.2 Nm {–4 kgm} 45 . The pump absorption torque (F) function is used to finely adjust the absorption torque on the front side of the hydraulic pump.6 Nm {–2 kgm} –29. a Relationship between set value torque adjustment value Code 021 PC200. 2. a Select this item similarly to an item on the “Service Menu” screen. select “Pump Absorption Torque (F)” with the function switches or numeral input switches.4 Nm {+3 kgm} +19. Selecting menu Select “Adjustment” on the “Service Menu” screen.8 Nm {–1 kgm} –19.30 Testing and adjusting Adjustment (Pump Absorption Torque (F)) The operator can adjust various items related to the machine with the machine monitor.

4 Nm {+3 kgm} +19.8 Nm {+1 kgm} 0 Nm {0 kgm} –9. Selecting absorption torque After the "Pump Absorption Torque (R)" screen is displayed. q Set value: For actual torque adjustment value.8 Nm {–1 kgm} –19.6 Nm {+2 kgm} +9.SEN00229-03 Adjustment (Pump Absorption Torque (R)) The operator can adjust various items related to the machine with the machine monitor.2 Nm {–4 kgm} PC200. select “Pump Absorption Torque (R)” with the function switches or numeral input switches.4 Nm {–3 kgm} –39.6 Nm {–2 kgm} –29. 30 Testing and adjusting 3. Selecting sub menu After the “Adjustment” screen is displayed. see table q [F3]: Increase set value q [F4]: Decrease set value q [F6]: Confirm setting and return to Adjustment menu screen a The 3 digits on the left side do not vary since they are the code of this function. 1. a Relationship between set value and torque adjustment value Code 022 46 Set value 000 001 002 003 004 005 006 007 008 Torque adjustment value +39. The pump absorption torque (R) function is used to finely adjust the absorption torque on the rear side of the hydraulic pump. Selecting menu Select “Adjustment” on the “Service Menu” screen.2 Nm {+4 kgm} +29. a Select this item similarly to an item on the “Service Menu” screen. 2. select a set value on the right side with the function switches. 220-8 .

30 Testing and adjusting

Adjustment (Low speed)
The operator can adjust various items related to the
machine with the machine monitor.
The travel Low speed setting function is used to
finely adjust the travel Low speed.
1.

Selecting menu
Select “Adjustment” on the “Service Menu” screen.

2.

Selecting sub menu
After the “Adjustment” screen is displayed,
select “Low speed” with the function switches
or numeral input switches.
a Select this item similarly to an item on the
“Service Menu” screen.

SEN00229-03

3.

Selecting travel Low speed
After the "Low Speed" setting screen is displayed, select a set value on the right side with
the function switches.
q
Set value: For actual travel Low speed
value, see table
q
[F3]: Increase set value
q
[F4]: Decrease set value
q
[F6]: Confirm setting and return to Adjustment menu screen
a The 3 digits on the left side do not vary
since they are the code of this function.

a

Relationship between set value and travel
Low speed value
Code

020

PC200, 220-8

Set
value
000
001
002
003

Travel Low speed value
3.0 km/h
2.8 km/h
3.2 km/h
3.4 km/h

47

SEN00229-03

Adjustment (Attachment Flow Adjustment)
The operator can adjust various items related to the
machine with the machine monitor.
The function of "Attachment Flow Adjustment" is
used to finely adjust the oil flow to the attachment in
compound operation.
1. Selecting menu
Select “Adjustment” on the “Service Menu”
screen.

2.

Selecting sub menu
After the “Adjustment” screen is displayed,
select “Attachment Flow Adjustment” with the
function switches or numeral input switches.
a Select this item similarly to an item on the
“Service Menu” screen.

30 Testing and adjusting

3.

Selecting distribution of oil flow
After the screen of "Attachment Flow Adjustment" is displayed, select a set value on the
right side with the function switches.
q
Set value: For actual distribution of flow,
see table
q
[F3]: Increase set value
q
[F4]: Decrease set value
q
[F6]: Confirm setting and return to Adjustment menu screen
a The 3 digits on the left side do not vary
since they are the code of this function.

a

Relationship between set value and distribution of flow to attachment
Code

044

48

Set
value
000
001
002
003

Distribution of flow to
attachment
50 %
70 %
100 %
40 %

PC200, 220-8

30 Testing and adjusting

SEN00229-03

Cylinder Cut-Out
The operator can perform "Cylinder Cut-Out" operation with the machine monitor.
"Cylinder Cut-Out" operation means to run the
engine with 1 or more fuel injectors disabled electrically to reduce the number of effective cylinders.
This operation is used to find out a cylinder which
does not output power normally (combustion in it is
abnormal).
1.

2.

Selecting menu
Select “Cylinder Cut-Out” on the “Service
Menu” screen.

Selecting cylinder to be disabled
After the "Cylinder Cut-Out" screen is displayed, select a cylinder to be Cut-Out with 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 Cut-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 In the cylinder Cut-Out operation, the
auto-deceleration function can be
selected. If the auto-deceleration is turned
ON, auto-deceleration monitor (b) is displayed.

PC200, 220-8

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 operation is not automatically
reset after the screen returns 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
If [F4] is pressed during the cylinder Cut-Out
operation, the displayed information is newly
held (c) (The real-time information is kept displayed on the left side).
While the information is held, if [F3] is pressed,
the holding function is reset.
a The holding function is effective, regardless of setting of the reduced cylinder
mode operation.

49

SEN00229-03

[Reference]
q
If a normally operating 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.

50

30 Testing and adjusting

No Injection
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
function to lubricate the engine before starting it by
cranking it without injecting fuel is installed.
Set the no-injection cranking while the engine is
stopped.
1.

Selecting menu
Select “No Injection” on the “Service Menu”
screen.

2.

Displaying check screen
If the "No injection" screen is displayed, the
machine monitor asks the operator if no injection cranking should be performed. Answer
with the function switch.
q
[F5]: Do not perform (Return to Service
menu screen)
q
[F6]: Perform
a While the screen is changing to the following screen, the screen of "Communication
between controllers is being checked" is
displayed.

PC200, 220-8

30 Testing and adjusting

3.

Starting no injection cranking
If no injection cranking (Fuel injection in no cylinders) becomes effective, that is displayed on
the screen. Under this condition, crank the
engine with the starting motor.
a While the screen is changing to the following screen, the screen of "Setting is being
prepared" is displayed.
a Limit the cranking time to 20 seconds to
protect the starting motor.

4.

Finishing no injection cranking
After completing the no injection cranking
operation, press [F6], and finish of no injection
cranking is displayed and the screen returns to
the “Service Menu” screen automatically.

PC200, 220-8

SEN00229-03

5.

Prohibiting no injection cranking
If the operator tries to perform the no injection
cranking while the engine is running, the message that the engine is running is displayed
and the no injection cranking is not set effective.
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.

51

SEN00229-03

Fuel Consumption
This function calculates the hourly fuel consumption from the actual fuel consumption in a measuring period and indicates it.
1. Selecting menu
Select “Fuel Consumption” on the “Service
Menu” screen.

2.

Starting measurement
After the screen of “Fuel Consumption” is displayed, start measurement with 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 reset by pressing [F2].
a If [F1] is pressed, the data is displayed on
the starting date and time side and measurement starts.

a

52

30 Testing and adjusting

3.

Display and function during measurement
Clock mark (a) flashes during measurement.
a While the fuel consumption is being measured, the operator can work with the
operator mode and other functions. Measurement is not finished until this screen is
displayed again and [F1] is pressed (Even
if the starting switch is turned OFF, this
function is kept effective, although fuel
consumption is measured only while the
engine is running).

4.

Finishing measurement
Press [F1], and measurement is finished and
the data are displayed on the finishing date
and time side.

5.

Displaying fuel consumption
If the measurement is finished, the hourly fuel
consumption calculated from the fuel consumption calculated by the engine controller
and the elapsed time are displayed.

The display unit of the fuel changes
according to the unit set with the default
(unit setting) function.
SI and meter: l/h
inch: gal/h

PC200, 220-8

30 Testing and adjusting

KOMTRAX Settings (Terminal Status)
The setting condition and operating condition of
K O MTRA X c an be c hec k ed wi th Di sp lay of
KOMTRAX setting.
Setting condition of terminal is used to check the
setting condition of the KOMTRAX terminal.
1.

Selecting menu
Select “KOMTRAX Settings” on the “Service
Menu” screen.

2.

Selecting sub menu
After the “KOMTRAX Settings” screen is displayed, select “Terminal Status” with the function switches or numeral input switches.
a Select this item similarly to an item on the
Service menu screen.
a The following figure shows the display when
Model TH300 KOMTRAX is installed. When
TH200 is installed, “03 IP Adress” is displayed.

PC200, 220-8

SEN00229-03

3.

Contents of display of terminal status
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 Meant Time
q
[F5]: Return to KOMTRAX settings screen

53

SEN00229-03

KOMTRAX Settings (GPS & Communication Status)
The setting condition and operating condition of
KOMTRAX can be checked with “KOMTRAX Settings”.
GPS & communication status is used to check the
condition of positioning and communication of the
KOMTRAX terminal.
1.

Selecting menu
Select “KOMTRAX Settings” on the “Service
Menu” 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.
a The following figure shows the display when
Model TH300 KOMTRAX is installed. When
TH200 is installed, “03 IP Adress” is displayed.

54

30 Testing and adjusting

3.

Contents of display of GPS & communication
status
On the screen of “GPS & Communication Status”, the following items are displayed.
q
Positioning: Positioning condition of GPS
q
Communication: Communication environment of communication MODEM and connecting condi tion of c ommunication
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

PC200, 220-8

30 Testing and adjusting

KOMTRAX Setting (MODEM S/N: TH300)
The setting condition and operating condition of
K O MTRA X c an be c hec k ed wi th Di sp lay of
KOMTRAX setting.
MODEM S/N is used to check the serial No. of the
KOMTRAX communication MODEM.
1.

Selecting menu
Select “KOMTRAX Settings” on the “Service
Menu” screen.

2.

Selecting sub menu
After the “KOMTRAX Settings” screen is displayed, select “Modem S/N” with the function
switches or numeral input switches.
a Select this item similarly to an item on the
“Service Menu” screen.

PC200, 220-8

SEN00229-03

3.

Contents of display of Modem S/N
The serial No. of TH300 Modem is displayed.
q
[F5]: Return to KOMTRAX settings screen

55

SEN00229-03

KOMTRAX Settings (IP Address: TH200)
The setting condition and operating condition of
K O MTRA X c an be c hec k ed wi th Di sp lay of
KOMTRAX settings.
IP address is used to check the IP address of the
KOMTRAX communication MODEM.
1.

Selecting menu
Select "KOMTRAX Settings" on the service
menu screen.

2.

Selecting sub menu
After the “KOMTRAX Settings” screen is displayed, select “IP Address” with the function
switches or numeral input switches.
a Select this item similarly to an item on the
“Service Menu” screen.

56

30 Testing and adjusting

3.

Contents of display of IP address
The telephone No. and IP address (2 systems)
of TH200 MODEM are displayed.
q
[F5]: Return to KOMTRAX setting screen
a The IP address is a No. specific to each
MODEM which is required when communication is made between the MODEM
and the server.

PC200, 220-8

30 Testing and adjusting

Display of KOMTRAX message
Special messages for the serviceman sent from the
KOMTRAX base station (a distributor, etc.) can be
checked with this function.
If there is setting in a message, a return mail can be
sent by using numeral input switches.
1.

Operation to display menu
Select "Service message" on the service menu
screen.

2.

Display of message (Read-only)
If there is a message, its contents are displayed. If there is not a message, "No message" is displayed.
q
[F5]: Return to service menu screen
a This message is different from a message
transmitted to the operator in the operator
mode.
a Since this message is special for the serviceman, the message monitor is not displayed when it is received as in the
operator mode.

PC200, 220-8

SEN00229-03

3.

Display of message (with return mail function)
If a box to enter a value with the numeral keys
is displayed under the message, enter a
proper number with the numeral input switches
and function switches and confirm it, and the
information is returned to the KOMTRAX base
station.
q
[F5]: Return to service menu screen
q
[F6]: Confirm and return input value
a This message is different from a message
transmitted to the operator in the operator
mode.
a Since this message is special for the serviceman, the message monitor is not displayed when it is received as in the
operator mode.

57

SEN00229-03

PC200, 220(LC)-8 Hydraulic excavator
Form No. SEN00229-03

© 2007 KOMATSU
All Rights Reserved
Printed in Japan 04-07 (01)

58

SEN00230-01

HYDRAULIC EXCAVATOR
1SHOP MANUAL

PC200-8
PC200LC-8
PC220-8
PC220LC-8
Machine model

Serial number

PC200-8
PC200LC-8
PC220-8
PC220LC-8

300001 and up
300001 and up
70001 and up
70001 and up

30 Testing and adjusting

1

Testing and adjusting, Part 3
Testing and adjusting, Part 3........................................................................................................................... 2
Handling voltage circuit of engine controller ........................................................................................ 2
Preparation work for troubleshooting of electrical system.................................................................... 3
Procedure for testing diodes ................................................................................................................ 8
Pm Clinic service.................................................................................................................................. 9

PC200, 220-8

1

SEN00230-01

Testing and adjusting, Part 3

30 Testing and adjusting

1

Handling voltage circuit of engine
controller
1
1.

Before disconnecting or connecting a connector between the engine controller and engine,
be sure to turn the starting switch OFF.

2.

If a T-adapter is inserted in or connected to a
connector between the engine controller and
engine 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.

2

PC200, 220-8

30 Testing and adjusting

Preparation work for
troubleshooting of electrical
system
a

a

1.

SEN00230-01

4)

1

When carrying out troubleshooting of an electric circuit related to the machine monitor,
e n g i n e c o n t r o l l e r, p u m p c o n t r o l l e r, o r
KOMTRAX communication MODEM, expose
the related connectors according to the following procedure.
Disconnect and connect the connectors having
special locking mechanisms according to the
procedure shown below.
Machine monitor
1) Remove 2 mounting bolts and cover (1).
a One of the mounting bolts is installed
in the cover on the right of the daylight sensor.
a While removing the mounting bolts,
disconnect connector P31 of the daylight sensor.
2) Remove cover (2).
a The cover is fixed with clips. Remove
it by pull it up.
a While removing the cover, disconnect connector M04 of the cigarette
lighter.

3)

2.

Insert or connect troubleshooting T-adapters in or to connectors CM01, CM02, and
CM03 of machine monitor (4).
a Connectors CM02 and CM03 are of
the same type. When returning them,
check the mark plates of the mounting brackets and take care not to
make a wrong connection.

Engine controller
1) Open the engine hood.
a The engine controller is mounted on
the engine (on the counterweight
side).
2) Insert or connect troubleshooting T-adapters in or to connectors CE01, CE02, and
CE03 of engine controller (5).
a Connectors CE01 and CE02 are fixed
with 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}

Remove 1 mounting bolt and duct (3).

PC200, 220-8

3

SEN00230-01

3.

30 Testing and adjusting
a

Pump controller
1) Slide the operator's seat and seat stand to
the forward end.
2) Remove the 5 mounting bolts and cool &
hot box (6).
a While removing the cool & hot box,
disconnect the drain hose.
3) Remove the 2 mounting bolts, 1 fastener,
and magazine box (7).
4) Remove the 3 mounting bolts and cover
(8).
5) Remove fuse box cover (9) and cover
(10).
a Since the underside of cover (10) is
clamped, pull it up.
6) Remove the 7 mounting bolts and cover
(11).

4.

7)

4

Connect the troubleshooting adapters to
connectors C01 and C02 of pump controller (12).
a Install the adapters to only the wiring
harness side.

The connectors of the pump controller have a special locking mechanism. Disconnect them according to
steps (a) – (c) and connect them
according to steps (d) – (f) as shown
below.
Disconnection: (a) Unlock – (b)
Slide lever – (c) Disconnect connector.
Connection: (d) Position connector –
(e) Slide lever – (f) Lock.

KOMTRAX communication module
1) Slide the operator's seat and seat stand to
the forward end.
2) Remove the 5 mounting bolts and cool &
hot box (6).
a While removing the cool & hot box,
disconnect the drain hose.
3) Remove the 2 mounting bolts, 1 fastener,
and magazine box (7).
4) Remove the 3 mounting bolts and cover
(8).
5) Remove fuse box cover (9) and cover
(10).
a Since the underside of cover (10) is
clamped, pull it up.
6) Remove the 7 mounting bolts and cover
(11).

PC200, 220-8

30 Testing and adjusting

7)

SEN00230-01
a

Connect troubleshooting T-adapters to connectors CK01 and CK02 of KOMTRAX
communication module (13).
a Cable (14) is for the communication
antenna.
6.

5.

Atmospheric pressure sensor (AMBAIR
PRESSURE)
Engine Ne speed sensor (CRANK SENSOR)
Engine Bkup speed sensor (CAM SENSOR)
Engine oil pressure switch (OIL PRESSURE
SWITCH)
a Disconnection and connection of connectors
The connectors of the atmospheric pressure sensor, engine Ne speed sensor,
engine Bkup speed sensor, engine oil
pressure switch have a special locking
mechanism. Disconnect them according
to steps (a) – (c) and connect them
according to steps (d) – (f) as shown
below.
Disconnection: (a) Slide lever – (b)
Unlock – (c) Disconnect connector.
Connection: (d) Connect connector – (e)
Lock – (f) Slide lever.

PC200, 220-8

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".

Boost pressure and temperature sensor
(BOOST PRESS & IMT)
a Disconnection and connection of connector
The connector of the boost pressure and
temperature sensor has a special locking
mechanism. Disconnect it according to
steps (a) – (b) and connect it according to
steps (c) – (d) as shown below.
Disconnection: (a) Unlock – (b) Disconnect connector.
Connection: (c) Connect connector – (d)
Lock.

a

Removal and installation of sensor
A torque wrench is necessary for removal
and installation of the boost pressure and
temperature sensor. See "Tools for testing, adjusting, and troubleshooting".

5

SEN00230-01

7.

30 Testing and adjusting
a

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)
– (b) and connect it according to steps (c)
– (d) as shown below.
Disconnection: (a) Unlock – (b) Disconnect connector.
Connection: (c) Connect connector – (d)
Lock.

8.

a

6

Precautions for disconnecting connector
The direction of the lock of the connector
varies with the tightened position of the
sensor and the lock may be in a direction
in which it is difficult to reset (on the underside or engine side).
In this case, pinch the lock in direction (a)
with bent-nose nippers [1] (commercially
available), and the lock is reset.
Since the lock clicks when it is reset, disconnect the connector after a click is heard.

Precautions for connecting connector
Take care not to connect the connector
reversely.
Engage lock (e) on the wiring harness side
with triangular notch (f) on the sensor side
(Do not engage lock (e) with square guide
(g) on the opposite side of triangular notch
(f)).

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)
– (b) and connect it according to steps (c)
– (d) as shown below.
Disconnection: (a) Unlock – (b) Disconnect connector.
Connection: (c) Connect connector – (d)
Lock.

PC200, 220-8

30 Testing and adjusting

9.

SEN00230-01

Engine coolant temperature sensor (COOLANT TEMP)
a Disconnection and connection of connector
The connector of the engine coolant temperature sensor has a special locking
mechanism. Disconnect it according to
steps (a) – (b) and connect it according to
steps (c) – (d) as shown below.
Disconnection: (a) Unlock – (b) Disconnect connector.
Connection: (c) Connect connector – (d)
Lock.

a

Removal and installation of sensor
A deep socket is necessary for removal
and installation of the engine coolant temperature sensor. See "Tools for testing,
adjusting, and troubleshooting".

PC200, 220-8

7

SEN00230-01

Procedure for testing diodes
a
a

30 Testing and adjusting

1

Test the assembled-type diode (8-pin) and the
single diode (2-pin) according to the following
procedure.
The conductive directions of the assembledtype diode are as follows.

2.

a

The conductive direction of the single diode is
indicated on the surface of the diode.

1.

When using digital circuit tester
1) Set the tester in the diode range and
check 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 tester to the
anode (P) side of the diode and apply the
black (–) lead to the cathode (N) side and
check the indicated value.
3) Judge the condition of the diode by the
indicated value.
q
The indicated value does not change:
The diode does not have conductivity
(Defective).
q
The indicated value changes:
The diode has conductivity (Normal).
Note: In the case of a silicon diode, a
value in the range from 460 to 600 is indicated.

8

When using analog circuit tester
1) Set the tester in the resistance range.
2) Apply the leads of the tester as explained
below and check the movement of the
pointer.
i) Apply the red (+) lead of the tester to
the anode (P) side of the diode and
apply the black (–) lead to the cathode (N) side.
ii) Apply the red (+) lead of the tester to
the cathode (N) side of the diode and
apply the black (–) lead to the anode
(P) side.
3) Judge 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
tester, 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
disconnection).

PC200, 220-8

30 Testing and adjusting

SEN00230-01

Pm Clinic service

1

Model name

Serial No.

Service meter

T PC200-8
T PC220-8 T LC

h

User's name

Date of execution
/

Inspector

/

Specifications
Main components
Boom
Arm
Bucket

T Standard T (
T Standard T (
T Standard T (

Attachments
)
)
)

Shoe width

T Breaker
T(
T(

)
)

T 600 mm
T 700 mm
T(

)

Check of oil/coolant level
T Radiator coolant
T Engine oil
T Hydraulic oil

When necessary
T Damper case oil
T Final drive case oil

T Machinery case oil
T(

Ambient temperature

)

Altitude

°C

m
Operator's opinion

Result of visual inspection

Mechanical equipment system fault history

Electrical equipment system fault history

989EKX

times/1st time

h/last

h

times/1st time

h/last

h

AA10NX

times/1st time

h/last

h

times/1st time

h/last

h

AB00KE

times/1st time

h/last

h

times/1st time

h/last

h

B@BAZG

times/1st time

h/last

h

times/1st time

h/last

h

B@BAZK

times/1st time

h/last

h

times/1st time

h/last

h

B@BCNS

times/1st time

h/last

h

times/1st time

h/last

h

B@BCZK

times/1st time

h/last

h

times/1st time

h/last

h

B@HANS

times/1st time

h/last

h

times/1st time

h/last

h

CA234

times/1st time

h/last

h

times/1st time

h/last

h

Max. range of engine coolant temperature gauge

PC200, 220-8

Max. range of hydraulic oil temperature gauge

9

SEN00230-01 30 Testing and adjusting Items related to engine 10 PC200. 220-8 .

220-8 11 .30 Testing and adjusting SEN00230-01 Items related to oil pressure PC200.

Work equipment extended fully Min.850 – 2.7 Max.130 1.500 1. Work.990 – 2.07 {0.2 – 56. 3.4 50. Inspector STD LC STD LC STD LC sec sec sec 46.130 MPa {kg/cm2} rpm MPa {kg/cm2} rpm ON Arm IN relief OFF All levers in neutral MAX ON kPa {mmH2O} Check item Boom RAISE 2 Arm IN Fuel control dial Working mode P E L 3 Arm OUT 4 Bucket CURL 5 Swing (5 turns) MAX Checking posture.5 sec 6.9 36.5 50.050 Max.4 Max.3 – 2.7 Max.7 sec 3. Min.3 27.7 – 41.8 27.5 Boom top horizontal Arm cylinder retracted fully sec 2.7} 1.96 {200} 1.98 {Max.300 – 1.9 – 3.0} 0.SEN00230-01 30 Testing and adjusting Check sheet (PC200/200LC-8) Model Serial No.9 25.3 – 30.2 – 60.000 – 1.3 – 32. 4.10 {Min. 0.1 – 3.7 sec 2.25 {2. 30 Boom top horizontal P Travel (5 idle turns) LO One side of track pushed up and turned forward and backward MI HI 12 Measured value 1.AutoLeft knob ing decelswitch mode eration Operation of work equipment All levers in neutral MAX OFF MIN All levers in neutral OFF P Unit Standard value for new machine rpm 1.3 – 61.3 PC200. etc.3 33. 220-8 .3 Work equipment extended fully Swing right and left sec 21.5 33.2 – 29. 3. / Good 1.7 – 44.1 – 3.5} rpm Checking condition No.300 – 1.7 – 45.990 – 2.850 – 2.5 sec 3.0 Max.3 36.7 – 48. 4.000 – 1.9 Max.0 – 7.3 – 65.4 46. 7.9 Max.4 – 3. Service meter User's name Date of execution / Engine speed 2 Engine oil pressure 3 Engine speed 4 Engine oil pressure 5 Engine speed 6 Blow-by pressure 7 Engine oil pressure 2. 4. 100} 1. 0.29 {Min. 1.050 1.7 – 26.500 Unit Standard value for new machine Service limit value sec 2.2 – 27.100 Work equipment speed 1 6 Measured value 0.0} Service limit value Bad 1 Fuel control dial Bad Check item Good Engine Checking condition No. 0. 3.9 Max.8 25.100 1.

3 {290 – 330} G (Travel relief pressure) 36. Good Checking condition Bad Hydraulic drift of work equipment Good 3.8 – 40. Checking condition No.3 – 39.5 – 4.30 Testing and adjusting 1 4.8 {340 – 375} 36.2 {370 – 400} D1 – D2 = 2.9 {17 – 19} F (Swing relief pressure) 28.7 – 1.7 {375 – 405} 36. high) D (Unload pressure) E (LS differential pressure) MPa {kg/cm2} — — E1 Swing lock Right swing relief F F Swing lock Left swing relief F F E2 — — — — — A E2 — — — — — — — — Right travel lock G Right forward relief — — — — Right travel lock G Right reverse relief — — — — — — — — — — Left travel lock Left forward relief — Left travel lock Left reverse relief — G G Standard value for new machine Service limit value 2. etc.8 {295 – 325} 28.5 {26 – 46} D1 – D2 = 2.2 {375 – 410} PC200. 220-8 13 .74 – 3. Check item Fuel control dial Working mode Hydraulic drift of Engine stopped bucket tip Checked part Self pressure reducing valve 2 Main relief valve (Low pressure) 3 Main relief valve (Low pressure) 4 Unload valve Fuel control dial Boom top horizontal Arm cylinder retracted fully Bucket loaded 7 WorkLeft knob ing switch mode Max.43 {30 – 35} 2. 900 [2] [3] [4] [5] 600K 600K 600K 600K 60K Operation of work equipment F pump main R pump main F pump LS R pump LS Control All lever in neutral — — — — Arm out relief ON All levers in neutral B B B B C C C C D1 D1 D2 D2 Right track driven idle E1 Lever moved halfway LS valve Left track driven idle Lever moved halfway P Swing motor safety valve OFF Main relief valve Travel motor Safety valve Travel junction valve Checked oil pressure Unit A (Control circuit basic pressure) Standard value mm/ 15 min Measured value [1] OFF MAX 6 Service limit value Hydraulic circuit 1 5 Standard value for new machine Checking posture.9 {17 – 19} E1 – E2 = 1. Unit Bad No.4 – 32.8 – 35. SEN00230-01 B (Work equipment relief pressure.8 {345 – 365} 33.3 – 36.8 – 31. 600 Max.3 – 38.5 {26 – 46} E1 – E2 = 1.7 – 1.3 {370 – 380} 36.7 – 39.43 {28 – 35} 33.5 – 4.93 – 3. low) C (Work equipment relief pressure.

2. 0. 1.45 {Approx. 25} K2 (LS-EPC valve output pressure 2) Approx.7 {Approx.9 {Approx. 220-8 . 7} J3 (PC-EPC valve output pressure 3) Approx. 30} J1 (PC-EPC valve output pressure 1) J4 (PC-EPC valve output pressure 4) — MPa {kg/cm2} Approx.5} K3 (LS-EPC valve output pressure 3) 0 {0} PC200.7 {Approx. 17. and [5]. 7.78 {Approx. [1] [2] [3b] [4b] [5a] 600K 600K 60K 60K 60K F pump main R pump main F pump (F) R pump (R) LS-EPC — — J1 J1 — — J2 J2 — — J3 J3 — — J4 J4 — — J5 J5 Travel speed: Lo travel lever in neutral — — — — Travel speed: Mi Travel lever operated — — — — Travel speed: Hi Travel lever operated — — — — Checking condition No. [4]. 2.74 {Approx. — Service limit value H1 : H2 = 1 : 0. 0.SEN00230-01 30 Testing and adjusting Servo piston Fuel control dial WorkLeft knob ing switch mode MAX P OFF Checked oil pressure Unit H (Servo control pressure) — Operation of work equipment Arm out relief [3a] [4a] [5] 600K 600K 600K 600K 60K F pump main R pump main F pump servo R pump servo Control H1 H1 H2 H2 Standard value for new machine Bad Standard value 8 Check item [2] Bad No.6 (Oil pressure ratio) * Gauge changing work: Change [3] and [4] to 60K and change hoses of [3]. 0. 1. 8} J5 (PC-EPC valve output pressure 5) — Approx.5} Approx.57 {Approx. Check item Fuel control dial WorkLeft knob ing switch mode Operation of work equipment MIN P 9 PC-EPC (F) valve PC-EPC (R) valve E All levers in neutral L B OFF MAX 10 LS-EPC valve P Checked oil pressure Unit Standard value 14 — — — K1 K2 K3 Standard value for new machine Service limit value J2 (PC-EPC valve output pressure 2) Approx. [1] Good Checking condition Good * Gauge changing work: Change hoses of gauges [3] and [4]. 16} K1 (LS-EPC valve output pressure 1) Approx.

3.4 – 3.5 2.7 – 31.96 {200} 1.3 Work equipment extended fully Swing right and left sec 22.500 1.850 – 2. 4.850 – 2.100 Work equipment speed L 5 Measured value 0.6 – 46.6 – 47.3 Max.5 28. Work. 3.5 sec 2.6 38. Inspector STD LC STD LC STD LC sec sec sec 48. Work equipment extended fully E Arm IN 3 Min.7 – 59.9 38.7 – 63.9 – 31.0 Max.5 Max.090 – 2. 31 LO One side of track pushed up and turned forward and backward MI HI PC200.3 52.9 28.230 MPa {kg/cm2} rpm MPa {kg/cm2} rpm ON Arm IN relief OFF All levers in neutral MAX ON kPa {mmH2O} 1 2 Check item Fuel control dial Boom RAISE Working mode P Arm OUT 4 Bucket CURL Checking posture. 100} 1.25 {2.6 7.0} 0.5} rpm Checking condition No. Min.050 1.4 Max. 220-8 3.9 – 28. 4.8 – 64.6 35. 0. Service meter User's name Date of execution / Engine speed 2 Engine oil pressure 3 Engine speed 4 Engine oil pressure 5 Engine speed 6 Blow-by pressure 7 Engine oil pressure 2. etc.9 15 .07 {0.1 – 3.000 – 1.090 – 2.0} Service limit value Bad 1 Fuel control dial Good Check item Bad Engine Checking condition No.5 26.6 – 4.30 Testing and adjusting SEN00230-01 Check sheet (PC220/220LC-8) Model Serial No.6 35.29 {Min.6 48.9 Max.8 – 3.300 – 1. 0. 1.9 – 33.4 Max.8 – 4.7 – 29.6 Boom top horizontal Arm cylinder retracted fully P Travel (5 idle turns) sec sec sec MAX 6 Measured value 1.0 2. 0.000 – 1.AutoLeft knob ing decelswitch mode eration Operation of work equipment All levers in neutral MAX OFF All levers in neutral OFF MIN P Unit Standard value for new machine rpm 2.7} 1.6 52. 4.9 Max.100 1.500 Unit Standard value for new machine Service limit value sec 3.6 – 51.2 26.300 – 1.7 – 3.8 – 68.10 {Min. 3.7 Boom top horizontal Swing (5 turns) Max.6 – 43. 9. 3. / Good 1.050 Max.98 {Max.9 sec 3.230 2.0 – 8.

high) D (Unload pressure) E (LS differential pressure) MPa {kg/cm2} PC200.5 – 4. Check item Fuel control dial Working mode Hydraulic drift of Engine stopped bucket tip Checked part Self pressure reducing valve 2 Main relief valve (Low pressure) 3 Main relief valve (Low pressure) 4 Unload valve Fuel control dial Boom top horizontal Arm cylinder retracted fully Bucket loaded 7 WorkLeft knob ing switch mode Max.4 – 32. 600 [2] Arm out relief Unit — — E1 Swing lock Right swing relief F F Swing lock Left swing relief F F E2 — — — — — A E2 — — — — — — — — Right travel lock G Right forward relief — — — — Right travel lock G Right reverse relief — — — — — — — — — — Left travel lock Left forward relief — Left travel lock Left reverse relief — G G Standard value for new machine Service limit value 2.93 – 3.3 – 39.7 – 1.8 {295 – 325} 28.8 {340 – 375} 36. Bad Checking condition Good Hydraulic drift of work equipment Good 3. low) C (Work equipment relief pressure.3 – 36.43 {30 – 35} 2.3 {290 – 330} G (Travel relief pressure) 36.8 – 40.7 – 1.5 {26 – 46} E1 – E2 = 1.2 {370 – 400} D1 – D2 = 2.3 {370 – 380} 36.SEN00230-01 1 4.3 – 38.9 {17 – 19} E1 – E2 = 1.7 – 39.74 – 3.7 {375 – 405} 36. 30 Testing and adjusting B (Work equipment relief pressure.8 {345 – 365} 33. Unit Bad No.2 {375 – 410} A (Control circuit basic pressure) 16 mm/ 15 min Measured value [1] OFF MAX 6 Service limit value Hydraulic circuit 1 5 Standard value for new machine Checking posture. etc. Checking condition No.43 {28 – 35} 33.9 {17 – 19} F (Swing relief pressure) 28.5 {26 – 46} D1 – D2 = 2. 220-8 .5 – 4.8 – 35.8 – 31. 900 [3] [4] [5] 600K 600K 600K 600K 60K Operation of work equipment F pump main R pump main F pump LS R pump LS Control All lever in neutral — — — — ON All levers in neutral B B B B C C C C D1 D1 D2 D2 Right track driven idle E1 Lever moved halfway LS valve Left track driven idle Lever moved halfway P Swing motor safety valve OFF Main relief valve Travel motor Safety valve Travel junction valve Checked oil pressure Standard value Max.

25} K2 (LS-EPC valve output pressure 2) Approx.7 {Approx. 17. [4]. 220-8 — Service limit value J3 (PC-EPC valve output pressure 3) J5 (PC-EPC valve output pressure 5) — Approx. 0.9 {Approx. 2. 16} K1 (LS-EPC valve output pressure 1) Approx.57 {Approx. 7} Approx.78 {Approx. Standard value 8 Check item Servo piston Fuel control dial WorkLeft knob ing switch mode 600K 600K 600K 600K 60K Operation of work equipment F pump main R pump main F pump servo R pump servo Control MAX P OFF Arm out relief H1 H1 H2 H2 — Checked oil pressure Unit H (Servo control pressure) — Standard value for new machine Bad [3a] Good [2] Bad [1] Checking condition Good * Gauge changing work: Change hoses of gauges [3] and [4]. 1. [1] [2] [3b] [4b] [5a] 600K 600K 60K 60K 60K F pump main R pump main PC-EPC (F) PC-EPC (R) LS-EPC — — J1 J1 — — J2 J2 — — J3 J3 — — J4 J4 — — J5 J5 Travel speed: Lo travel lever in neutral — — — — Travel speed: Mi Travel lever operated — — — — Travel speed: Hi Travel lever operated — — — — Checking condition No. 30} J2 (PC-EPC valve output pressure 2) J4 (PC-EPC valve output pressure 4) — 17 . 2.7 {Approx.45 {Approx. Service limit value H1 : H2 = 1 : 0. Check item Fuel control dial WorkLeft knob ing switch mode Operation of work equipment MIN P 9 PC-EPC (F) valve PC-EPC (R) valve E All levers in neutral L OFF MAX 10 LS-EPC valve B P Checked oil pressure Unit Standard value J1 (PC-EPC valve output pressure 1) Standard value for new machine Approx. 0.5} K3 (LS-EPC valve output pressure 3) 0 {0} PC200. 1. and [5].30 Testing and adjusting SEN00230-01 [4a] [5] No.01 {21} Approx.6 (Oil pressure ratio) * Gauge changing work: Change [3] and [4] to 60K and change hoses of [3]. 8} MPa {kg/cm2} — — K1 K2 K3 2.

220(LC)-8 Hydraulic excavator Form No.SEN00230-01 30 Testing and adjusting PC200. SEN00230-01 © 2006 KOMATSU All Rights Reserved Printed in Japan 03-06 (01) 18 PC200. 220-8 .

......................................................................... 2 Fuse locations ...........................................................................................................SEN03308-00 HYDRAULIC EXCAVATOR 1SHOP MANUAL PC200-8 PC200LC-8 PC220-8 PC220LC-8 Machine model Serial number PC200-8 PC200LC-8 PC220-8 PC220LC-8 300001 and up 300001 and up 70001 and up 70001 and up 40 Troubleshooting 1 Failure code table and fuse locations Failure code table and fuse locations .............................................................. 7 PC200........................... 220-8 1 ........................ 2 Failure codes table ...............................................................................

SEN03308-00 40 Troubleshooting Failure code table and fuse locations Failure codes table a 1 This failure codes table is the same as that in Testing and adjusting. Special functions of machine monitor. Low ENG Mechanical system B@BAZK Eng Oil Level Low MON Mechanical system B@BCNS Eng Water Overheat e ENG Mechanical system B@BCZK Eng Water Level Low e MON Mechanical system B@HANS Hydr Oil Overheat e PUMP Mechanical system EMC Critical Internal Failure q ENG Electrical system CA111 e E10 CA115 Eng Ne and Bkup Speed Sens Error q ENG Electrical system E11 CA122 Chg Air Press Sensor High Error q ENG Electrical system E11 CA123 Chg Air Press Sensor Low Error q ENG Electrical system E14 CA131 Throttle Sensor High Error q ENG Electrical system E14 CA132 Throttle Sensor Low Error q ENG Electrical system E15 CA144 Coolant Temp Sens High Error q ENG Electrical system E15 CA145 Coolant Temp Sens Low Error q ENG Electrical system E15 CA153 Chg Air Temp Sensor High Error q ENG Electrical system E15 CA154 Chg Air Temp Sensor Low Error q ENG Electrical system E11 CA155 Chg Air Temp High Speed Derate q ENG Electrical system E15 CA187 Sens Supply 2 Volt Low Error q ENG Electrical system E11 CA221 Ambient Press Sens High Error q ENG Electrical system Troubleshooting by failure code. Part 1 SEN00240-02 PC200. User code E10 2 1 Failure code Trouble (Displayed on screen) Alarm buzzer Device in charge Category Reference of history documents No. 220-8 . 989L00 Engine Controller Lock Caution 1 MON Electrical system 989M00 Engine Controller Lock Caution 2 MON Electrical system 989N00 Engine Controller Lock Caution 3 MON Electrical system AA10NX Air Cleaner Clogging MON Mechanical system AB00KE Charge Voltage Low MON Mechanical system B@BAZG Eng Oil Press.

220-8 Troubleshooting by failure code.40 Troubleshooting SEN03308-00 Alarm buzzer Device in charge Ambient Press Sens Low Error q ENG Electrical system CA227 Sens Supply 2 Volt High Error q ENG Electrical system CA234 Eng Overspeed ENG Mechanical system E15 CA238 Ne Speed Sens Supply Volt Error q ENG Electrical system E10 CA271 IMV/PCV1 Short Error q ENG Electrical system E10 CA272 IMV/PCV1 Open Error q ENG Electrical system E11 CA322 Inj #1 Open/Short Error q ENG Electrical system E11 CA323 Inj #5 Open/Short Error q ENG Electrical system E11 CA324 Inj #3 Open/Short Error q ENG Electrical system E11 CA325 Inj #6 Open/Short Error q ENG Electrical system E11 CA331 Inj #2 Open/Short Error q ENG Electrical system E11 CA332 Inj #4 Open/Short Error q ENG Electrical system E10 CA342 Calibration Code Incompatibility q ENG Electrical system E10 CA351 Injectors Drive Circuit Error q ENG Electrical system E15 CA352 Sens Supply 1 Volt Low Error q ENG Electrical system E15 CA386 Sens Supply 1 Volt High Error q ENG Electrical system E15 CA428 Water in Fuel Sensor High Error q ENG Electrical system E15 CA429 Water in Fuel Sensor Low Error q ENG Electrical system User code Failure code E11 CA222 E15 Trouble (Displayed on screen) Category Reference of history documents No. Part 1 SEN00240-02 Troubleshooting by failure code. E15 CA435 Eng Oil Press Sw Error q ENG Electrical system E10 CA441 Battery Voltage Low Error q ENG Electrical system E10 CA442 Battery Voltage High Error q ENG Electrical system E11 CA449 Rail Press Very High Error q ENG Electrical system E11 CA451 Rail Press Sensor High Error q ENG Electrical system E11 CA452 Rail Press Sensor Low Error q ENG Electrical system E11 CA488 Chg Air Temp High Torque Derate q ENG Electrical system PC200. Part 2 SEN00241-01 3 .

SEN03308-00 User code Failure code E15 CA553 E15 Alarm buzzer Device in charge Rail Press High Error q ENG Electrical system CA559 Rail Press Low Error q ENG Electrical system E15 CA689 Eng Ne Speed Sensor Error q ENG Electrical system E15 CA731 Eng Bkup Speed Sens Phase Error q ENG Electrical system E10 CA757 All Continuous Data Lost Error q ENG Electrical system E15 CA778 Eng Bkup Speed Sensor Error q ENG Electrical system E0E CA1633 KOMNET Datalink Timeout Error q ENG Electrical system E14 CA2185 Throt Sens Sup Volt High Error q ENG Electrical system E14 CA2186 Throt Sens Sup Volt Low Error q ENG Electrical system E11 CA2249 Rail Press Very Low Error q ENG Electrical system E11 CA2311 IMV Solenoid Error q ENG Electrical system E15 CA2555 Grid Htr Relay Volt High Error q ENG Electrical system E15 CA2556 Grid Htr Relay Volt Low Error q ENG Electrical system E01 D19JKZ Personal Code Relay Abnormality q MON2 Electrical system D862KA GPS Antenna Discon MON2 Electrical system DA22KK Pump Solenoid Power Low Error PUMP Electrical system DA25KP 5V Sensor 1 Power Abnormality PUMP Electrical system DA29KQ Model Selection Abnormality PUMP Electrical system DA2RMC CAN Discon (Pump Con Detected) PUMP Electrical system DAF8KB Short circuit in camera power supply MON Electrical system DAFGMC GPS Module Error MON2 Electrical system MON Electrical system E0E E0E E0E 4 40 Troubleshooting Trouble (Displayed on screen) q q q Category Reference of history documents No. Part 2 SEN00241-01 Troubleshooting by failure code. DAFRMC CAN Discon (Monitor Detected) DGH2KB Hydr Oil Sensor Short PUMP Electrical system DHPAMA F Pump Press Sensor Abnormality PUMP Electrical system DHPBMA R Pump Press Sensor Abnormality PUMP Electrical system Troubleshooting by failure code. 220-8 . Part 3 SEN00242-02 PC200.

DHS3MA Arm Curl PPC Press Sensor Abnormality PUMP Electrical system DHS4MA Bucket Curl PPC Press Sensor Abnormality PUMP Electrical system DHS8MA Boom Raise PPC Press Sensor Abnormality PUMP Electrical system DHSAMA Swing RH PPC Press Sensor Abnormality PUMP Electrical system DHSBMA Swing LH PPC Press Sensor Abnormality PUMP Electrical system DHSDMA Bucket Dump PPC Press Sensor Abnormality PUMP Electrical system DHX1MA Overload Sensor Abnormality (Analog) PUMP Electrical system DW43KA Travel Speed Sol Discon PUMP Electrical system PUMP Electrical system DW43KB Travel Speed Sol Short E03 DW45KA Swing Brake Sol Discon q PUMP Electrical system E03 DW45KB Swing Brake Sol Short q PUMP Electrical system DW91KA Travel Junction Sol Discon PUMP Electrical system DW91KB Travel Junction Sol Short PUMP Electrical system DWA2KA Service Sol Discon PUMP Electrical system DWA2KB Service Sol Short PUMP Electrical system DWK0KA 2-stage Relief Sol Discon PUMP Electrical system DWK0KB 2-stage Relief Sol Short PUMP Electrical system E02 DXA8KA PC-EPC (F) Sol Discon q PUMP Electrical system E02 DXA8KB PC-EPC (F) Sol Short q PUMP Electrical system E02 DXA9KA PC-EPC (R) Sol Discon q PUMP Electrical system E02 DXA9KB PC-EPC (R) Sol Short q PUMP Electrical system DXE0KA LS-EPC Sol Discon PUMP Electrical system DXE0KB LS-EPC Sol Short PUMP Electrical system DXE4KA Service Current EPC Discon PUMP Electrical system DXE4KB Service Current EPC Short PUMP Electrical system PC200. Part 3 SEN00242-02 Troubleshooting by failure code. 220-8 Troubleshooting by failure code.40 Troubleshooting User code Failure code SEN03308-00 Trouble (Displayed on screen) Alarm buzzer Device in charge Category Reference of history documents No. Part 4 SEN00243-01 5 .

failure code. User code Attached : If the failure code is detected. the buzzer sounds (The operator can stop the buzzer with the alarm buzzer cancel switch). PUMP: The pump controller is in charge of detection of abnormality. the machine monitor does not notify the operator of the abnormality.SEN03308-00 User code a a a a a 6 Failure code 40 Troubleshooting Trouble (Displayed on screen) Alarm buzzer Device in charge Category Reference of history documents No. its function sounds the buzzer. ENG: The engine controller is in charge of detection of abnormality. Alarm buzzer q : When occurrence of an error is notified to the operator. (if registered) are displayed on the ordinary screen to notify the operator of the abnormality. the user code. Component in charge MON: The machine monitor is in charge of detection of abnormality. MON2: The KOMTRAX section of the machine monitor is in charge of detection of abnormality. DXE5KA Merge-divider Main Sol Discon PUMP Electrical system DXE5KB Merge-divider Main Sol Short PUMP Electrical system DXE6KA Merge-divider LS Sol Discon PUMP Electrical system DXE6KB Merge-divider LS Sol Short PUMP Electrical system DY20KA Wiper Working Abnormality PUMP Electrical system DY20MA Wiper Parking Abnormality PUMP Electrical system DY2CKA Washer Drive Discon PUMP Electrical system DY2CKB Washer Drive Short PUMP Electrical system DY2DKB Wiper Drive (For) Short PUMP Electrical system DY2EKB Wiper Drive (Rev) Short PUMP Electrical system Troubleshooting by failure code. 220-8 . PC200. Part 4 SEN00243-01 Entry order of items in table The items are entered in the order of their failure codes (incremental order). Category of record Mechanical system: Abnormality information is recorded in the mechanical system abnormality record. e: Since the caution monitor is also turned ON. Not attached: Even if the failure code is detected. and telephone No. Electrical system: Abnormality information is recorded in the electrical system abnormality record.

working lamp (rear) 9 10 A 10 10 A 11 20 A 12 10 A (Spare) 13 10 A Headlamp 14 10 A Optional power supply (1) 15 10 A 16 10 A 17 20 A Windshield washer motor Radio Left knob switch (pump controller input) (Spare) Air conditioner unit Air conditioner compressor electromagnetic clutch Travel alarm Optional power supply (2) Radio (backup power supply) Room lamp Starting switch Machine monitor Pump controller 18 10 A (Spare) 19 30 A Engine controller 20 5A Engine controller (ACC signal) 7 .40 Troubleshooting SEN03308-00 Fuse locations 1 Connection table of fuse box a This connection table shows the devices to which each power supply of the fuse box supplies power (A switch power supply is a device which supplies power while the starting switch is in the ON position and a constant power supply is a device which supplies power while the starting switch is in the OFF and ON positions). 220-8 Cigarette lighter 4 10 A 5 10 A Horn relay. Fuse capacity Destination of power Lamp relay. rear lamp relay. horn 6 10 A Electrical intake air heater relay 7 10 A Rotary lamp 8 20 A Right headlamp. PC-EPC (R) solenoid valve [When pump drive switch is operated in emergency] Swing holding brake solenoid valve [When swing holding brake release switch is operated] Switch power supply F04 (60 A) 2 30 A Pump controller (Solenoid power supply) PPC oil pressure lock solenoid valve 3 10 A Starting motor cut-out relay (PPC lock) Starting motor cut-out relay (Personal code) Switch power supply Switch power supply Constant power supply F04 (60 A) F04 (60 A) F05 (30 A) Switch power Starting switch supply ACC PC200. you should check the fuses and fusible links to see if the power is supplied normally. working lamp (boom). a When carrying out troubleshooting related to the electrical system. cab lamp relay 1 10 A PC-EPC (F) solenoid valve. Type of power supply Fusible link Fuse No.

SEN03308-00 40 Troubleshooting Locations of fusible links Location of fuse box and fuse Nos. 220-8 . 8 PC200.

check the related fuse (F01-17) and "green LED" of the pump controller to see if the power is supplied normally. the controller cannot control the system and the troubles shown below occur simultaneously (The following is an example of the troubles).40 Troubleshooting SEN03308-00 Troubles that occur when power supply of pump controller is defective a The controller power supply (F01-17) of the pump controller drives the controller system. q The swing holding brake cannot be reset automatically. a If the above problems occur. if it is turned off. q The travel speed does not change. Accordingly. q The working mode cannot be changed. q The power maximizing function does not work. q Flashing: The controller power is supplied (There is an error). q Lighting: The controller power is supplied (There is not an error and the power supply is normal). q Put out: The controller power is not supplied. 220-8 9 . a Green LED of pump controller (a) PC200. q The machine deviates during travel. q The auto-decelerator does not work or is not reset.

if the solenoid power supply is turned off. 220-8 . check the related fuse (F01-2) and inlet voltage of the pump controller. and (121) and each of pins C01 (2) and (5). it is normal. [DXE0KB]: LS-EPC solenoid system q [DXE4KA]. [DXE5KB]: Merge-divider main solenoid system q [DXE6KA]. 1) Disconnect connectors C01 and C02 of the controller and connect a T-adapter box to the wiring harness side. [DWK0KB]: 2-stage relief solenoid system q [DXA8KA]. 3) Measure the voltage between each of pins C02 (116). (118). [DW45KB]: Swing holding brake solenoid system q [DW91KA]. [DW91KB]: Travel junction solenoid system q [DWA2KA]. [DXE6KB]: Merge-divider LS solenoid system a If the above problems occur. q [DW43KA]. 2) Turn the starting switch ON. a If the voltage is 20 – 30 V. when the controller outputs the power to the solenoids or relays. [DXA9KB]: PC-EPC (R) solenoid system q [DXE0KA]. (118). [DXA8KB]: PC-EPC (F) solenoid system q [DXA9KA]. [DW43KB]: Travel speed solenoid system q [DW45KA]. and (121) are the power supply and pins C01 (2) and (5) are the chassis ground. Accordingly. [DWA2KB]: Service solenoid system q [DWK0KA]. [DXE4KB]: Service current EPC system (if attachment is installed) q [DXE5KA]. the power is not supplied to any of the solenoids and relays and all or some of the following failure codes are displayed simultaneously.SEN03308-00 40 Troubleshooting Troubles that occur when power supply of pump controller is defective a The solenoid power supply (F01-2) of the pump controller is used by the controller to drive the solenoids and relays. a Pins C02 (116). C02) of pump controller PC200. a 10 Power supply connectors (C01.

220-8 SEN03308-00 11 .40 Troubleshooting PC200.

220(LC)-8 Hydraulic excavator Form No. SEN03308-00 © 2007 KOMATSU All Rights Reserved Printed in Japan 04-07 (01) 12 .SEN03308-00 PC200.

..... 5 How to read electric wire code ........................................................................................................ 2 Sequence of events in troubleshooting ............................................................................. 46 PC200........................................................................................................................................ 9 Connection table for connector pin numbers ..... 3 Check before troubleshooting ........ 4 Classification and procedures for troubleshooting ...................................................................................................................................................................SEN00231-03 HYDRAULIC EXCAVATOR 1SHOP MANUAL PC200-8 PC200LC-8 PC220-8 PC220LC-8 Machine model Serial number PC200-8 PC200LC-8 PC220-8 PC220LC-8 300001 and up 300001 and up 70001 and up 70001 and up 40 Troubleshooting 1 General information on troubleshooting General information on troubleshooting................................................................................... 220-8 1 .................................. 12 T..........branch box and T................................... 2 Points to remember when troubleshooting................................................................................branch adapter table ............................

Then. When carrying out troubleshooting. and judge whether to handle it as a real failure or as a problem with the method of operation. hot coolant may spurt out and cause burns. and important point is of course to understand the structure and function. Confirming failure q Confirm the extent of the failure yourself. be sure to connect it properly. When removing the plug or cap from a location which is under pressure from oil. For this reason. 3) Investigate other related parts or information. When carrying out the operation with two or more workers. However. Other maintenance items can be checked externally. remove the root cause. To prevent this. blocks. keep strictly to the agreed signals. always disconnect the negative (–) terminal of the battery first. 2) Start from the most likely points. always release the internal pressure first. and check that the lock pin. 2. if the root cause of the failure is not repaired. The aim of troubleshooting is to pinpoint the basic cause of the failure. 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. and to prevent reoccurrence of the failure. 2 When carrying out troubleshooting. When disconnecting wiring. 3.SEN00231-03 40 Troubleshooting General information on troubleshooting 1 Points to remember when troubleshooting 1 k k k k k k Stop the machine in a level ground. parts. etc. water. or air. 1) Start from the simple points. 6. Be extremely careful not to touch any hot parts or to get caught in any rotating parts. it is necessary to carry out thorough prior investigation and to carry out troubleshooting in accordance with the fixed procedure. 1. 5. to carry out repairs swiftly. or were there problems with the machine condition before this? 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? Check before troubleshooting 1) Check the oil level 2) Check for any external leakage of oil from the piping or hydraulic equipment. 220-8 . Measures to remove root cause of failure q Even if the failure is repaired. Check the stroke of the control valve spool. It will also cause a waste of manhours. and parking brake are securely fitted. Points to ask 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. 3) 4) 5) Check the travel of the control levers. Troubleshooting q Use the results of the investigation and inspection in Items 2 – 4 to narrow down the causes of failure. do not hurry to disassemble the components. When installing measuring equipment. PC200. and do not allow any unauthorized person to come near. a The basic procedure for troubleshooting is as follows. or oil or grease. do not carry out any investigation or measurement that may make the problem worse. when carrying out troubleshooting. so check any item that is considered to be necessary. then use the troubleshooting flowchart to locate the position of the failure exactly. If the radiator cap is removed when the engine is hot. will also lose the confidence of the user or operator. so wait for the engine to cool down before starting troubleshooting. and at the same time. If components are disassembled immediately any failure occurs: q Parts that have no connection with the failure or other unnecessary parts will be disassembled. a When operating the machine to reenact the troubleshooting symptoms. q It will become impossible to find the cause of the failure. the same failure will occur again. 4. always investigate why the problem occurred.

220-8 3 .40 Troubleshooting SEN00231-03 Sequence of events in troubleshooting 1 PC200.

in particular) — Dry 4. Check of wires for wetness (Check connectors and terminals for wetness. Check of battery voltage (with engine stopped) 20 – 30 V Charge or replace Between H – L Add or replace 6. 220-8 . Check of level and type of engine oil (in oil pan) Between H – L Add oil 7. Check of fuel for foreign matter Hydraulic/ Mechanical equipment Electric. Check of swing machinery oil level Between H – L Add oil 6. burn. Check for abnormal noise/smell — Repair 2. Bleeding air — Bleed air 1. Check of coolant level (in sub tank) Between H – L Add coolant 8. Check of hydraulic oil level Lubricating oil/Coolant 1 — Replace 10. Check for released wire clamp and drooping wire — Repair 8.SEN00231-03 40 Troubleshooting Check before troubleshooting Item 1. Check of dust indicator for clogging No red part Clean or replace 9. Check of alternator terminals and wiring for looseness and corrosion — Retighten or replace 3. Check of level and type of fuel 2. Check of wires for discoloration.5 – 29.5 V Replace 11. electrical equipment Remedy — Add fuel — Clean and drain Add oil — Clean and drain 5. Check of battery relay for operating sound (when starting switch is turned ON or OFF) — Replace PC200. Check of alternator voltage (while engine speed is at middle or higher) After operating for several minutes: 27. Check of battery terminals and wiring for looseness and corrosion — Retighten or replace 2. Check for oil leakage — Repair 3. Check of starting motor terminals and wiring for looseness and corrosion — Retighten or replace 4. Check of electrolyte level 9. Check of hydraulic oil filter — Replace 1. Check of fuse for disconnection and corrosion 4 Criterion Between H – L 3. and removal of cover — Repair or replace 7. Check of hydraulic oil strainer 5.

a If an electrical system failure code is recorded. In this case. When electrical system error code or mechanical system error code is recorded in abnormality record: If a user code and a failure code are not displayed on the machine monitor. Procedure for troubleshooting to be taken 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. 3. or "S-mode". PC200. When user code and failure code is not displayed and no failure code is recorded in abnormality record: If a user code and failure code are not displayed on the machine monitor and no failure code is recorded in the abnormality record. and then see if the trouble is still detected. a An error code of the mechanical system cannot be deleted. and then go to the corresponding troubleshooting section. according to the following procedure. carry out the troubleshooting for the corresponding "Display of code" according to the displayed failure code. If a code is recorded. carry out the corresponding troubleshooting in E-mode. "H-mode". select a proper troubleshooting No.". check a mechanical system failure code and an electrical system failure code with the abnormality record function of the machine monitor. delete all the codes and reproduce them. carry out troubleshooting for the corresponding "Display of code" according to the recorded code. check the phenomenon looking like a trouble again and select the same phenomenon from the table of "Phenomena looking like troubles and troubleshooting Nos. 2. a If a trouble is displayed in the air conditioner abnormality record or heater abnormality record by the abnormality record function. and then carry out troubleshooting corresponding to that phenomenon in the "E-mode". 1.40 Troubleshooting SEN00231-03 Classification and procedures for troubleshooting 1 Classification for troubleshooting Mode Display of code Contents Troubleshooting by failure code E-mode Troubleshooting of electrical system H-mode Troubleshooting of hydraulic and mechanical system S-mode Troubleshooting of engine Procedure for troubleshooting If a phenomenon looking like a trouble occurs in the machine. 220-8 5 . a trouble that the machine cannot find out by itself may have occurred in the electrical system or hydraulic and mechanical system.

failure code is displayed in air conditioner or heater abnormality record E-23 Phenomena related to engine 5 Starting performance is poor S-1 6 Engine does not start E-3 S-2 7 Engine does not pick up smoothly S-3 8 Engine stops during operations S-4 9 Engine does not rotate smoothly S-5 10 Engine lacks output (or lacks power) S-6 11 Exhaust smoke is black (incomplete combustion) S-7 12 Oil consumption is excessive (or exhaust smoke is blue) S-8 13 Oil becomes contaminated quickly S-9 14 Fuel consumption is excessive S-10 15 Oil is in coolant (or coolant spurts back or coolant level goes down) S-11 16 Oil pressure drops S-12 17 Oil level rises (Entry of coolant/fuel) S-13 18 Coolant temperature becomes too high (overheating) S-14 19 Abnormal noise is made S-15 20 Vibration is excessive S-16 21 Preheater does not operate E-4 22 Automatic warm-up system does not operate (in cold season) E-5 23 Auto-decelerator does not operate normally E-15 H-5 E-6 H-3 Phenomena related to work equipment/swing/travel 24 Work equipment. 220-8 . and travel is low H-1 26 Engine speed lowers extremely or engine stalls H-2 27 Working mode does not change S-6 E-16 28 Abnormal sound comes out from around hydraulic pump H-4 29 Fine control performance or response is low H-6 Phenomena related to work equipment 30 Speed or power of boom is low H-7 31 Speed or power of arm is low H-8 32 Speed or power of bucket is low H-9 33 Work equipment does not move singly H-10 34 Hydraulic drift of work equipment is large H-11 6 PC200. failure code is displayed in 3 electrical system abnormality record 4 When abnormality record is checked.SEN00231-03 40 Troubleshooting Phenomena looking like troubles and troubleshooting Nos. failure code is displayed in 2 played mechanical system abnormality record code When abnormality record is checked. Troubleshooting No. swing. swing. Phenomena looking like troubles Display of code E-mode H-mode S-mode Phenomena related to user code/failure code User code and failure code are displayed on ordinary screen of machine 1 monitor According to disWhen abnormality record is checked. and travel mechanism do not move or cannot be locked 25 Speed or power of whole work equipment.

basic check 56 item lights up E-2 57 Precaution lights up while engine is running E-7 58 Emergency stop item lights up while engine is running E-8 59 Engine coolant temperature gauge does not indicate normally E-9 60 Hydraulic oil temperature gauge does not indicate normally E-10 61 Fuel level gauge does not indicate normally E-11 62 Contents of display by machine monitor are different from applicable machine E-12 63 Machine monitor does not display some items E-13 64 Function switch does not work E-14 65 Alarm buzzer cannot be stopped E-18 66 Windshield wiper and window washer do not operate E-19 67 Air conditioner does not operate normally E-23 68 When starting switch is turned OFF.40 Troubleshooting SEN00231-03 Troubleshooting No. speed of part loaded more is low H-15 41 When machine swings and raises boom simultaneously. Phenomena looking like troubles Display of code E-mode 35 Time lag of work equipment is large 36 S-mode H-12 When part of work equipment is relieved singly. boom rising speed is low H-16 42 When machine swings and travels simultaneously. machine monitor displays nothing E-1 When starting switch turned ON (before starting engine). other parts of work equipment move 37 Power maximizing function does not work H-13 E20 38 Attachment circuit is not changed (when attachment is installed) 39 H-mode H-14 H-29 Oil flow in attachment circuit cannot be controlled (when attachment is installed) H-30 Phenomena related to compound operation 40 In compound operation of work equipment. 220-8 7 . service meter is not displayed E-24 PC200. travel speed lowers largely H-17 Phenomena related to travel 43 Machine deviates during travel H-18 44 Travel speed is low H-19 45 Machine is not steered well or steering power is low H-20 46 Travel speed does not change or travel speed is low/high E-17 47 Travel system does not move (only one side) 48 Travel alarm does not sound or does not stop sounding H-21 H-22 E-22 Phenomena related to swing 49 Upper structure does not swing H-23 50 Swing acceleration or swing speed is low H-24 51 Upper structure overruns remarkably when it stops swinging H-25 52 Large shock is made when upper structure stops swinging H-26 53 Large sound is made when upper structure stops swinging H-27 Swing holding brake does not operate normally 54 Hydraulic drift of swing is large E-21 H-28 Phenomena related to machine monitor 55 When starting switch turned ON.

SEN00231-03 40 Troubleshooting Troubleshooting No. 220-8 . Phenomena looking like troubles Display of code E-mode 69 Machine monitor cannot be set in service mode E-25 70 Monitoring function does not display lever control signal normally E-26 H-mode S-mode Other phenomena 71 KOMTRAX system does not operate normally 8 E-27 PC200.

they are not indicated. electric wire codes specific to PC200/200LC-8 and PC220/220LC-8 are explained.25) 9 . circularly compressed wire for automobile PC200. AEX is similar to AV in thickness and outside diameter of AEX and different from AV.85 L . 220-8 Symbol Material Conductor Annealed copper for electric appliance Insulator Soft polyvinyl chloride Conductor Annealed copper for electric appliance Insulator Soft polyvinyl chloride Conductor Annealed copper for electric appliance AV AVS AVSS AEX Insulator Heat-resistant crosslinked polyethylene Conductor Annealed copper for electric appliance CAVS Insulator Soft polyvinyl chloride Using temperature range (°C) Example of use for reference General wiring (Nominal No. AVS. and material AV. and AVSS in material of the cover. low-voltage wire for automobile Thin-cover. 3 – 5) AVSS: General wiring (Nominal No. 2) –50 to +110 General wiring in extremely cold district. 8 and above) –30 to +60 AVS: General wiring (Nominal No. of 0.) is shown in Table 2 and Table 3.40 Troubleshooting SEN00231-03 How to read electric wire code a 1 In this section. Example: AEX 0.. Indicates size of wire by nominal No. In the electric circuit diagram. heat-resistant. low-voltage. having nominal No. AVSS. thickness.5 – 1. AVS. symbol. (Table 1) Type Low-voltage wire for automobile Thin-cover. and color of each electric wire are indicated by symbols. wiring at hightemperature place –30 to +60 General wiring (Nominal No. symbol. AVS. (Since AV. and CAVS are classified by size (nominal No. Type. Color codes are shown in Table 4. Indicates type of wire by symbol. CAVS has circularly compressed conductor and is different from AV and AVS in outside diameter. low-voltage wire for automobile Heat-resistant. Type.) 1..85 Indicates color of wire by color code.Indicates blue. and AVSS are different in only thickness and outside diameter of the cover. and material of wire are shown in Table 1. the material. Size (Nominal No. 0.). The electric wire code is helpful in understanding the electric circuit diagram. low-voltage wire for automobile.

7 2.7 4.1 1.5 3.80 169/0.5) 0.51 AV Standard 5.36 20.56 0.1 d (Approx.5 1.0 17.6 AVSS Standard — — — — — — — — — CAVS (Table 3) Nominal No.85 1.8 11.56 0.6 AVSS Standard — — — 2.6 16.0 8.85) 1.4 AV Standard — — — — — — — — AEX Standard 2.0 8.95 13.4 Standard 1.75f (0.76 d (Approx.88 1.9 2.0 13.25) 2f 2 3f 3 5 Number of strands/ 20/0.2 10.SEN00231-03 2.0 1.6 16.0 13.61 35.3 2.8 10.4 12.0 8.9 2.0 13.) 0.9 1. denotes "flexible".) AVS Cover D 0.45 Diameter of strand Conductor 15 20 30 40 50 84/0.8 6.7 — — — Nominal No.18 7/0. 40 Troubleshooting Dimensions AVS.3 7.2 10.80 217/0.7 3.84 84.18 11/0.26 41/0.6 4.8 11.80 Sectional area (mm2) 7.80 70/0.) 3. AVSS (Table 2) Nominal No.29 d (Approx.6 Standard — — — — — — — — — AVS Cover D 0. 8 Number of strands/ 50/0.96 2.0 2.5 0.32 Diameter of strand Sectional area (mm2) Conductor 0.32 58/0.27 1.2 1.23 1.7 1.6 9.32 30/0.80 60 85 100 108/0.6 AEX Standard 5.2 "f" of nominal No.32 37/0.5f (0.73 54.5 7.25f (1.4 13.1 — 3.08 3.19 42. 0.18 16/0.8 4.25 Number of strands/ Diameter of strand 7/Compressed circularly 11/Compressed circularly 16/Compressed circularly Sectional area (mm2) 0.0 3. Conductor Cover D CAVS 0.9 1.4 3.45 41/0.29 63.32 50/0.2 2.88 1. 10 PC200.30 5.0 17.32 65/0.80 85/0.96 109. AV. 220-8 .09 3.26 26/0.4 13.80 127/0.0 Standard — — — — — 3.0 8. AEX.29 1.

40 Troubleshooting 3. 4. Types of circuits and color codes (Table 5) Type of wire Charge Ground Start Light Instrument Signal Type of circuit Others PC200. SEN00231-03 Color codes table (Table 4) Color Code B Br BrB BrR BrW BrY Ch Dg G GB GL Gr GR GW GY L LB Lg LgB LgR Color 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 Color Code LgW LgY LR LW LY O P R RB RG RL RW RY Sb Y YB YG YL YR YW Color 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 color code consisting of 2 colors. Example: “GW” means that the background is Green and marking is White. the first color is the color of the background and the second color is the color of the marking. 220-8 R B R RW Y G L Br Lg O Gr P Sb Dg Ch WG — — RB YR GW LW BrW LgR — — — — — — AVS or AV — — — — — — RY RG YB YG GR GY LR LY BrR BrY LgY LgB — — — — — — — — — — — — AEX — — — RL YL GB LB BrB LgW — — — — — — — — — — YW GL — — — — — — — — — R B R D Y G L — — — — — — — — — — — — Gr Br — — — — — — — — — 11 .

2007. while the terms of male housing and female housing refer to the mating portion of the housing. PC200.SEN00231-03 Connection table for connector pin numbers a 12 40 Troubleshooting (Rev. 220-8 .5) The terms of male and female refer to the pins.

40 Troubleshooting PC200. 220-8 SEN00231-03 13 .

SEN00231-03 14 40 Troubleshooting PC200. 220-8 .

220-8 SEN00231-03 15 .40 Troubleshooting PC200.

220-8 .SEN00231-03 16 40 Troubleshooting PC200.

220-8 SEN00231-03 17 .40 Troubleshooting PC200.

SEN00231-03 18 40 Troubleshooting PC200. 220-8 .

40 Troubleshooting PC200. 220-8 SEN00231-03 19 .

220-8 .SEN00231-03 20 40 Troubleshooting PC200.

40 Troubleshooting PC200. 220-8 SEN00231-03 21 .

220-8 .SEN00231-03 22 40 Troubleshooting PC200.

220-8 SEN00231-03 23 .40 Troubleshooting PC200.

220-8 .SEN00231-03 24 40 Troubleshooting PC200.

40 Troubleshooting PC200. 220-8 SEN00231-03 25 .

SEN00231-03 26 40 Troubleshooting PC200. 220-8 .

40 Troubleshooting PC200. 220-8 SEN00231-03 27 .

220-8 .SEN00231-03 28 40 Troubleshooting PC200.

220-8 SEN00231-03 29 .40 Troubleshooting PC200.

220-8 .SEN00231-03 30 40 Troubleshooting PC200.

220-8 SEN00231-03 31 .40 Troubleshooting PC200.

SEN00231-03 32 40 Troubleshooting PC200. 220-8 .

220-8 SEN00231-03 33 .40 Troubleshooting PC200.

220-8 .SEN00231-03 34 40 Troubleshooting PC200.

220-8 SEN00231-03 35 .40 Troubleshooting PC200.

SEN00231-03 36 40 Troubleshooting PC200. 220-8 .

40 Troubleshooting PC200. 220-8 SEN00231-03 37 .

SEN00231-03 38 40 Troubleshooting PC200. 220-8 .

40 Troubleshooting PC200. 220-8 SEN00231-03 39 .

SEN00231-03 40 40 Troubleshooting PC200. 220-8 .

220-8 SEN00231-03 41 .40 Troubleshooting PC200.

220-8 .SEN00231-03 42 40 Troubleshooting PC200.

220-8 SEN00231-03 43 .40 Troubleshooting PC200.

220-8 .SEN00231-03 44 40 Troubleshooting PC200.

220-8 SEN00231-03 45 .40 Troubleshooting PC200.

2007.branch box and T. Number of pins 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 799-601-2600 T-box (for ECONO) 21 799-601-3100 T-box (for MS) 37 q 799-601-3200 T-box (for MS) 37 q q 799-601-3380 • Plate for MS (14-pin) 799-601-3410 Adapter for BENDIX (MS) 24 MS-24P q 799-601-3420 Adapter for BENDIX (MS) 24 MS-24P q 799-601-3430 Adapter for BENDIX (MS) 17 MS-17P q 799-601-3440 Adapter for BENDIX (MS) 17 MS-17P q 799-601-3450 Adapter for BENDIX (MS) 5 MS-5P q 799-601-3460 Adapter for BENDIX (MS) 10 MS-10P q 799-601-3510 Adapter for BENDIX (MS) 5 MS-5S q 799-601-3520 Adapter for BENDIX (MS) 17 MS-17P q 799-601-3530 Adapter for BENDIX (MS) 19 MS-19P q 799-601-2910 Adapter for BENDIX (MS) 14 MS-14P q 799-601-2710 Adapter for MIC 5 MIC-5P q q 799-601-2720 Adapter for MIC 13 MIC-13P q q 799-601-2730 Adapter for MIC 17 MIC-17P q q q 799-601-2740 Adapter for MIC 21 MIC-21P q q q 799-601-2950 Adapter for MIC 9 MIC-9P 799-601-2750 Adapter for ECONO 2 ECONO2P q q 799-601-2760 Adapter for ECONO 3 ECONO3P q q 799-601-2770 Adapter for ECONO 4 ECONO4P q q 799-601-2780 Adapter for ECONO 8 ECONO8P q q 799-601-2790 Adapter for ECONO 12 ECONO12P q q q 799-601-3470 Case 799-601-2810 Adapter for DLI 8 DLI-8P q q 799-601-2820 Adapter for DLI 12 DLI-12P q q 799-601-2830 Adapter for DLI 16 DLI-16P q q 799-601-2840 Extension cable (ECONO type) 12 ECONO12P q q q q q q q q q q q q q q q 799-601-2850 Case 799-601-4350 T-box (for DRC 60.SEN00231-03 40 Troubleshooting T. 220-8 .5-1) 1 q q q q Out of kit 799-601-4201 799-601-4101 799-601-9300 799-601-9200 799-601-9100 799-601-9000 799-601-8000 799-601-7500 799-601-7400 799-601-7100 799-601-7000 799-601-2800 Identification symbol 799-601-2700 Part name T-adapter kit 799-601-2500 Part No.branch adapter table a (Rev. ECONO) q q 60 q 799-601-4360 Case 799-601-7010 Adapter for X (T-adapter) 1 q q 799-601-7020 Adapter for X 2 X2P q q q q 799-601-7030 Adapter for X 3 X3P q q q q 799-601-7040 Adapter for X 4 X4P q q q q 799-601-7050 Adapter for SWP 6 SW6P q q q 799-601-7060 Adapter for SWP 8 SW8P q q q 799-601-7310 Adapter for SWP 12 SW12P 799-601-7070 Adapter for SWP 14 SW14P 799-601-7320 Adapter for SWP 16 SW16P 799-601-7080 Adapter for M (T-adapter) 1 799-601-7090 Adapter for M 2 799-601-7110 Adapter for M 3 46 q q q q q M2P q q q q M3P q q q q q PC200.

220-8 24 q q q q q q q q q q 47 .40 Troubleshooting SEN00231-03 q q q q 799-601-7150 Adapter for S (White) 10 S10P q q q q 799-601-7160 Adapter for S (Blue) 12 S12P q q q 799-601-7170 Adapter for S (Blue) 16 S16P q q q 799-601-7330 Adapter for S (White) 16 S16PW 799-601-7350 Adapter for S (White) 12 S12PW Out of kit S8P 799-601-4201 8 799-601-4101 799-601-7140 Adapter for S 799-601-9300 q 799-601-9200 q q q M8P 799-601-9100 M6P 8 799-601-9000 6 799-601-7340 Adapter for M 799-601-8000 799-601-7130 Adapter for M 799-601-7500 q 799-601-7400 q q q 799-601-7100 M4P 799-601-7000 4 799-601-2800 799-601-7120 Adapter for M Part name 799-601-2700 Identification symbol Part No. 799-601-2500 Number of pins T-adapter kit q q q q q 799-601-7180 Adapter for AMP040 8 A8P 799-601-7190 Adapter for AMP040 12 A12P q q 799-601-7210 Adapter for AMP040 16 A16P q q q q 799-601-7220 Adapter for AMP040 20 A20P q q q q 799-601-7230 Short connector for X 2 — q q q q q q 799-601-7240 Case q 799-601-7270 Case 799-601-7510 Adapter for 070 10 07-10 q 799-601-7520 Adapter for 070 12 07-12 q 799-601-7530 Adapter for 070 14 07-14 q 799-601-7540 Adapter for 070 18 07-18 q 799-601-7550 Adapter for 070 20 07-20 q 799-601-7360 Adapter for relay 5 REL-5P q 799-601-7370 Adapter for relay 6 REL-6P q 799-601-7380 Adapter for JFC 2 — 799-601-9010 Adapter for DTM 2 DTM2 q q 799-601-9020 Adapter for DT 2 DT2 q q 799-601-9030 Adapter for DT 3 DT3 q q 799-601-9040 Adapter for DT 4 DT4 q q 799-601-9050 Adapter for DT 6 DT6 q q 799-601-9060 Adapter for DT (Gray) 8 DT8GR q q q 799-601-9070 Adapter for DT (Black) 8 DT8B q q 799-601-9080 Adapter for DT (Green) 8 DT8G q q 799-601-9090 Adapter for DT (Brown) 8 DT8BR q q 799-601-9110 Adapter for DT (Gray) 12 DT12GR q q 799-601-9120 Adapter for DT (Black) 12 DT12B q q 799-601-9130 Adapter for DT (Green) 12 DT12G q q 799-601-9140 Adapter for DT 12 DT12BR q q 799-601-9210 Adapter for HD30-18 8 D18-8 q q 799-601-9220 Adapter for HD30-18 14 D18-14 q q 799-601-9230 Adapter for HD30-18 20 D18-20 q q 799-601-9240 Adapter for HD30-18 21 D18-21 q q 799-601-9250 Adapter for HD30-24 9 D24-9 q q 799-601-9260 Adapter for HD30-24 16 D24-16 q q 799-601-9270 Adapter for HD30-24 21 D24-21 q q 799-601-9280 Adapter for HD30-24 23 D24-23 q q 799-601-9290 Adapter for HD30-24 31 D24-31 q q 799-601-9310 Plate for HD30 (24-pin) 799-601-9320 T-box (for ECONO) PC200.

220-8 . 40 Troubleshooting Number of pins SEN00231-03 q 799-601-9330 Case q 799-601-9340 Case 799-601-9350 Adapter for DRC 40 DRC-40 q 799-601-9360 Adapter for DRC 24 DRC-24 q 799-601-9410* Socket for engine (CRI-T2) 2 G q 799-601-9420 Adapter for engine (CRI-T2) Adapter for engine (CRI-T3) PFUEL 3 A3 q q 799-601-9430* Socket for engine (CRI-T2) Socket for engine (CRI-T3) PCV 2 P q q 799-601-9440* Socket for engine (CRI-T2) 3 1.4C q q 799-601-4240* Socket for engine (CRI-T3) PAMB 3 1.3.2.4T 799-601-4260 Adapter for controller (ENG) 4 DTP4 q q q 799-601-4211 Adapter for controller (ENG) 50 DRC50 q 799-601-4220 Adapter for controller (ENG) 60 DRC60 q 799-601-4390* Socket for controller (95 ENG) 60 — q 799-601-4280 Box for controller (PUMP) 121 — q 799-601-9720 Adapter for controller (HST) 16 HST16A q 799-601-9710 Adapter for controller (HST) 16 HST16B q 799-601-9730 Adapter for controller (HST) 26 HST26A q 2.2. 48 PC200.2.2.2. CAM 3 FCIN q q Adapter for engine (CRI-T3) 799-601-4140 Atomosphere pressure 3 FCIG q q 799-601-4150 Adapter for engine (CRI-T3) POIL 3 FCIB q q Adapter for engine (CRI-T3) 799-601-4160 Oil pressure switch 2 4160 q q 799-601-4180 Adapter for engine (CRI-T3) PEVA 3 4180 q q Socket for engine (CRI-T3) 799-601-4190* Commonrail pressure 3 1.3 q 795-799-5520* Socket for engine (HPI-T2) 2 S q Socket for engine (HPI-T2) 795-799-5530* Socket for engine (CRI-T3) Temperature sensor 2 C q q 2 A q q 795-799-5460 Cable for engine (HPI-T2) 3 — q 795-799-5470 Cable for engine (HPI-T2) 3 — q 795-799-5480 Cable for engine (HPI-T2) 3 — q 795-799-5540* Socket for engine (HPI-T2) Socket for engine (CRI-T3) TIM 799-601-4110 Adapter for engine (140-T3) PIM 4 ITT3N q q 799-601-4130 Adapter for engine (CRI-T3) NE.3B q q 799-601-4330* Socket for engine (CRI-T3) G 3 1.PA 799-601-4380* Socket for engine (CRI-T3)(95) Air intake pressure/temperature 4 1.2. 3. — q 799-601-9890 Multi-adapter for DT2 – 4 and DTM2 “*” Shows not T-adapter but socket.3.2. 4.3A q q 799-601-4250* Socket for engine (CRI-T3) PIM 3 1.3L q q 4 1.Out of kit 799-601-4201 799-601-4101 799-601-9300 799-601-9200 799-601-9100 799-601-9000 799-601-8000 799-601-7500 799-601-7400 799-601-7100 799-601-7000 799-601-2800 Identification symbol 799-601-2700 Part name T-adapter kit 799-601-2500 Part No.3.G q q q q 799-601-4230* Socket for engine (CRI-T3) Air intake pressure/temperature 799-601-4340* Socket for engine (CRI-T3) Pump actuator 2 2.

220-8 SEN00231-03 49 .40 Troubleshooting PC200.

SEN00231-03 PC200. 220(LC)-8 Hydraulic excavator Form No. SEN00231-03 © 2007 KOMATSU All Rights Reserved Printed in Japan 04-07 (01) 50 .

5 Failure code [AB00KE] Charge Voltage Low .................... 6 Failure code [B@BAZG] Eng Oil Press........................................................................................ 220-8 1 ............................................................................................. 10 Failure code [CA115] Eng Ne and Bkup Speed Sens Error ................................................................... 9 Failure code [B@BCZK] Eng Water Level Low................... 4 Failure code [989M00] Engine Controller Lock Caution 2.......... 8 Failure code [B@BAZK] Eng Oil Level Low ........................................................ 9 Failure code [B@HANS] Hydr Oil Overheat......................................................................................................................... 4 Failure code [989N00] Engine Controller Lock Caution 3 ....................... Part 1 Failure code [989L00] Engine Controller Lock Caution 1...........................................................................................................................SEN00240-03 HYDRAULIC EXCAVATOR 1SHOP MANUAL PC200-8 PC200LC-8 PC220-8 PC220LC-8 Machine model Serial number PC200-8 PC200LC-8 PC220-8 PC220LC-8 300001 and up 300001 and up 70001 and up 70001 and up 40 Troubleshooting 1 Troubleshooting by failure code (Display of code)............................................ 5 Failure code [AA10NX] Air Cleaner Clogging ..................................................................... 8 Failure code [B@BCNS] Eng Water Overheat................................................................... Low ........................... 12 Failure code [CA123] Chg Air Press Sensor Low Error .................................................................................................................................................................11 Failure code [CA122] Chg Air Press Sensor High Error .......... 14 PC200................................................................................... 10 Failure code [CA111] EMC Critical Internal Failure ..........

..................................................................................................... 22 Failure code [CA153] Chg Air Temp Sensor High Error ....................................................................................................................................................................................... 39 Failure code [CA272] IMV/PCV1 Open Error .................................... 36 Failure code [CA234] Eng Overspeed............................ 38 Failure code [CA271] IMV/PCV1 Short Error ............................ 50 Failure code [CA332] Inj #4 Open/Short Error ..................................................................................................................................................................................................................................................................................................... 34 Failure code [CA227] Sens Supply 2 Volt High Error .. 30 Failure code [CA221] Ambient Press Sens High Error... 28 Failure code [CA187] Sens Supply 2 Volt Low Error........................... 42 Failure code [CA323] Inj #5 Open/Short Error .................................................................................................................................................... 37 Failure code [CA238] Ne Speed Sens Supply Volt Error..... 44 Failure code [CA324] Inj #3 Open/Short Error ...... 48 Failure code [CA331] Inj #2 Open/Short Error .................... 16 Failure code [CA132] Throttle Sensor Low Error ......................................................................... 26 Failure code [CA155] Chg Air Temp High Speed Derate ......................................................................................................................... 32 Failure code [CA222] Ambient Press Sens Low Error ......................... 52 2 PC200............ 18 Failure code [CA144] Coolant Temp Sens High Error..................................................... 220-8 ..................................................... 46 Failure code [CA325] Inj #6 Open/Short Error .............................................................. 24 Failure code [CA154] Chg Air Temp Sensor Low Error......................................................................SEN00240-03 40 Troubleshooting Failure code [CA131] Throttle Sensor High Error............................................................................................................................................................... 40 Failure code [CA322] Inj #1 Open/Short Error ...................................................................... 20 Failure code [CA145] Coolant Temp Sens Low Error......................................................

40 Troubleshooting PC200. 220-8 SEN00240-03 3 .

) PC200. If this failure code is displayed while machine monitor is not replaced. machine monitor • If cause of failure disappears. machine monitor • If cause of failure disappears. Related information • If this failure code is displayed after machine monitor is replaced. Problem that appears on machine • Engine cannot be started. • Method of reproducing failure code: Turn starting switch ON. Action of • None in particular. Cause Possible causes and standard value in normal state 4 1 Replacement of machine monitor 2 Defective machine monitor Standard value in normal state/Remarks on troubleshooting This trouble may be caused by replacement of machine monitor. system resets itself. 220-8 . system resets itself. user password must be changed to one before replacement. Failure code [989M00] Engine Controller Lock Caution 2 User code Failure code — 989M00 Contents of trouble Trouble 1 Engine controller lock caution 2 (Machine monitor system) • Engine controller lock is detected (Factor 2). user password must be changed to one before replacement. (Since trouble is in system. Possible causes and standard value in normal state Cause 1 Standard value in normal state/Remarks on troubleshooting Replacement of machine monitor This trouble may be caused by replacement of machine monitor. • Method of reproducing failure code: Turn starting switch ON.SEN00240-03 40 Troubleshooting Failure code [989L00] Engine Controller Lock Caution 1 User code Failure code — 989L00 Contents of trouble Trouble 1 Engine controller lock caution 1 (Machine monitor system) • Engine controller lock is detected (Factor 1). Problem that appears on machine • Engine cannot be started. Related information • If this failure code is displayed after machine monitor is replaced. Action of • None in particular. machine monitor may be defective. troubleshooting cannot be carried out.

Action of • Tries automatic resetting. engine controller may be defective. Cause Standard value in normal state/Remarks on troubleshooting 1 Defective engine controller If this failure code is displayed repeatedly. machine monitor • If cause of failure disappears. signal circuit of air cleaner clogging switch detected clogging of air cleaner (sensor contact opened). machine monitor • If cause of failure disappears. (Code: 04501 Monitor input 2) • Method of reproducing failure code: Start engine. troubleshooting cannot be carried out. 2 Defective air cleaner clogging monitor system If cause 1 is not detected. Problem that appears on machine • If machine is operated as it is. Action of • Displays air cleaner clogging monitor on machine monitor. 220-8 Standard value in normal state/Remarks on troubleshooting 1 Clogging of air cleaner (when Air cleaner may be clogged. engine may be damaged.40 Troubleshooting SEN00240-03 Failure code [989N00] Engine Controller Lock Caution 3 User code Failure code — 989N00 Contents of trouble Trouble 1 Engine controller lock caution 3 (Machine monitor system) • Engine controller lock is detected (Factor 3).) Failure code [AA10NX] Air Cleaner Clogging User code Failure code — AA10NX Contents of trouble Trouble 1 Air cleaner clogging (Machine monitor system) • While engine was running. system resets itself. Problem that appears on machine Related information Possible causes and standard value in normal state • Method of reproducing failure code: Failure code is not reproduced since system is reset automatically. system resets itself. Check it for clogging and then clean or system is normal) replace if clogged. air cleaner clogging monitor system may be defective. Cause Possible causes and standard value in normal state PC200. Carry out troubleshooting for "E-7 Caution item flashes while engine is running" in E-mode. 5 . Related information • Condition of air cleaner clogging switch signal can be checked with monitoring function. (Since trouble is in system.

PC200. Action of • Displays charge level monitor on machine monitor. charge level monitor system may be Defective charge level monidefective. 220-8 .5 – 29. signal circuit of alternator detected low charge voltage (below 7. Related information • Signal voltage of alternator can be checked with monitoring function. then start engine and carry out troubleshooting. system does not reset itself until starting switch is turned OFF. machine monitor • Even if cause of failure disappears. Problem that appears on machine • If machine is operated as it is. medium speed 27. E12 (male) Engine speed Voltage Between (1) – chassis ground Min. Cause Possible causes and standard value in normal state 1 2 6 Defective charge of alternator (when system is normal) Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF. Carry out troubleshooting for "E-7 Caution item flashes tor while engine is running" in E-mode. battery may not be charged.5 V If cause 1 is not detected. (Code: 04300 Charge voltage) • Method of reproducing failure code: Start engine.SEN00240-03 40 Troubleshooting Failure code [AB00KE] Charge Voltage Low User code Failure code — AB00KE Contents of trouble Trouble 1 Charge voltage low (Machine monitor system) • While engine is running.8 V).

40 Troubleshooting SEN00240-03 Circuit diagram related to preheating/starting of engine and charge of battery PC200. 220-8 7 .

machine monitor • Even if cause of failure disappears. • Displays engine oil pressure monitor on machine monitor. 2 If cause 1 is not detected. Cause Possible causes and standard value in normal state 8 1 Lowering of engine oil level (when system is normal) Defective engine oil level 2 monitor system Standard value in normal state/Remarks on troubleshooting Engine oil level may be low. engine oil pressure monitor system may Defective engine oil pressure be defective. Action of • Displays engine oil level monitor on machine monitor. Related information • Engine oil level switch signal can be checked with monitoring function. • If cause of failure disappears. Possible causes and standard value in normal state Cause Standard value in normal state/Remarks on troubleshooting Lowering of engine oil pres1 sure (when system is normal) Engine oil pressure may be low.SEN00240-03 40 Troubleshooting Failure code [B@BAZG] Eng Oil Press. engine may be damaged. Carry out troubleshooting for "E-8 Emergency stop monitor system item lights up while engine is running" in E-mode. Check it and add new oil if it is low. Failure code [B@BAZK] Eng Oil Level Low User code Failure code — Contents of trouble B@BAZK Trouble 1 Engine oil level low (Machine monitor system) • When starting switch is turned ON (but engine is not started). 220-8 . (Code: 04501 Monitor input 2) • Method of reproducing failure code: Turn starting switch ON. system resets itself. Problem that appears on machine • If machine is operated as it is. Low User code Failure code — Contents of trouble Action of controller B@BAZG Trouble 1 Engine oil pressure low (Engine controller system) • While engine was running. Problem that appears on machine • If machine is operated as it is. Carry out troubleshooting for "E-2 Basic check item lights up when starting switch is turned ON (but engine is not started)" in E-mode. engine may be damaged. system does not reset itself until starting switch is turned OFF. • Method of reproducing failure code: Start engine. If cause 1 is not detected. engine oil level monitor system may be defective. signal circuit of engine oil level switch detected low engine oil level (sensor contact opened). Check it and remove cause if it is low. PC200. signal circuit of engine oil pressure switch detected low engine oil pressure (sensor contact opened). Related information • Engine oil pressure switch signal is input to engine controller and then transmitted to machine monitor.

Cause Possible causes and standard value in normal state Standard value in normal state/Remarks on troubleshooting Overheating of engine Engine coolant may be overheating. mal) 2 Defective engine coolant temperature gauge system If cause 1 is not detected. • If cause of failure disappears. engine coolant temperature gauge system may be defective. Problem that appears on machine • If machine is operated as it is. Failure code [B@BCZK] Eng Water Level Low User code Failure code — B@BCZK Contents of trouble 1 Trouble 1 Engine coolant level low (Machine monitor system) • When starting switch is turned ON. engine may seize up. signal circuit of engine coolant temperature sensor detected overheating of engine coolant (above about 102°C). Check it and remove cause if it 1 coolant (when system is noris overheating. • Engine coolant temperature can be checked with monitoring function (Code: 04107 Engine coolant temperature) • Method of reproducing failure code: Start engine. Related information • Engine coolant temperature sensor signal is input to engine controller and then transmitted to machine monitor. 220-8 Standard value in normal state/Remarks on troubleshooting Lowering of radiator coolant 1 level (when system is normal) Radiator coolant level may be low. Action of • Displays radiator coolant level monitor on machine monitor. Related information • Condition of radiator coolant level switch can be checked with monitoring function (Code: 04500 Monitor input 1) • Method of reproducing failure code: Turn starting switch ON. Check it and add coolant if it is low. system resets itself. Cause Possible causes and standard value in normal state PC200. system does not reset itself until starting switch is turned OFF. signal circuit of radiator coolant level sensor detected low radiator coolant level (sensor contact opened). 9 . engine may overheat.40 Troubleshooting SEN00240-03 Failure code [B@BCNS] Eng Water Overheat User code Failure code — Contents of trouble Action of controller B@BCNS Trouble Engine coolant overheat (Engine controller system) • While engine was running. Problem that appears on machine • If machine is operated as it is. machine monitor • Even if cause of failure disappers. Defective radiator coolant 2 level monitor system If cause 1 is not detected. • Displays engine coolant temperature monitor with red on machine monitor. radiator coolant level monitor system may be defective. Carry out troubleshooting for "E-2 Basic check item lights up when starting switch is turned ON (but engine is not started)" in E-mode. Carry out troubleshooting for "E-9 Engine coolant temperature gauge does not work normally" in E-mode.

Failure code [CA111] EMC Critical Internal Failure User code Failure code E10 CA111 Contents of trouble Action of controller Problem that appears on machine Trouble 1 Critical internal failure (Engine controller system) • Memory or power supply circuit in engine controller is defective. Related information • Hydraulic oil temperature sensor signal is input to engine controller and then transmitted to machine monitor. Check it and remove cause if it is overheating. • If cause of failure disappears. signal circuit of hydraulic oil temperature sensor detected overheating of hydraulic oil (above about 102°C). Related information Possible causes and standard value in normal state 10 Cause Standard value in normal state/Remarks on troubleshooting 1 Defective engine controller Engine controller may be defective. 220-8 . hydraulic oil temperature gauge system may be defective. Carry out troubleshooting for "E-10 Hydraulic oil temperature gauge does not work normally" in E-mode. • None in particular. • Displays hydraulic oil temperature monitor with red on machine monitor. • Engine does not start. system resets itself.) PC200.SEN00240-03 40 Troubleshooting Failure code [B@HANS] Hydr Oil Overheat User code Failure code — Contents of trouble Action of controller B@HANS Trouble 1 Hydraulic oil overheat (Pump controller system) • While engine was running. 2 Defective hydraulic oil temperature gauge system If cause 1 is not detected. (Since trouble is in system. Cause Possible causes and standard value in normal state Standard value in normal state/Remarks on troubleshooting 1 Overheating of hydraulic oil (when system is normal) Hydraulic oil may be overheating. troubleshooting cannot be carried out. Problem that appears on machine • If machine is operated as it is. engine may be seized. • Hydraulic oil temperature can be checked with monitoring function (Code: 04401 Hydraulic oil temperature) • Method of reproducing failure code: Start engine.

40 Troubleshooting SEN00240-03 Failure code [CA115] Eng Ne and Bkup Speed Sens Error User code Failure code E10 CA115 Contents of trouble Action of controller Trouble Engine Ne and Bkup speed sensor error (Engine controller system) • Both signals of engine Ne speed sensor and engine Bkup speed sensor are abnormal. Possible causes and standard value in normal state PC200. 11 . • Engine does not start. Check them sor connector directly. • None in particular. Problem that appears on machine • Engine stops. Related information • Method of reproducing failure code: Start engine. 220-8 1 Cause 1 Standard value in normal state/Remarks on troubleshooting Connectors of Ne speed sensor and Bkup speed sensor may be Defective connection of senconnected defectively (or connected to wrong parts).

100 kz Connecting parts between boost pressure/temperature sensor – engine wiring harness – engine controller may be defective. bend. then turn starting switch ON and carry out troubleshooting. • Fixes charge pressure value and continues operation.SEN00240-03 40 Troubleshooting Failure code [CA122] Chg Air Press Sensor High Error User code Failure code E11 CA122 Contents of trouble Action of controller Trouble 1 Charge air pressure sensor high error (Engine controller system) • Pressure signal circuit of boost pressure/temperature sensor detected high voltage. or expansion of pin • Moisture or dirt in connector or defective insulation a Prepare with starting switch OFF. for another cause of trouble. carry out troubleshooting 1 ply 2 system for it first. Cause Standard value in normal state/Remarks on troubleshooting Defective sensor power sup. check wiring harness and controller. breakage. a Prepare with starting switch OFF. Wiring harness between CE01 (female) (44) – BOOST PRESS & IMT (female) (4) and between CE01 (female) (37) – JC01 – BOOST PRESS & IMT (female) (3) Resistance Min. CE01 Between (37) – (47) 12 Power supply Voltage Voltage Power supply 4.75 – 5. or breakage of seal • Corrosion. if voltage is abnormal. Related information • Signal voltage on boost pressure side of boost pressure/temperature sensor can be checked with monitoring function. Accordingly. then turn starting switch ON Hot short (Short circuit with 5 and carry out troubleshooting.If failure code [CA227] is also indicated. Defective boost pressure/ 2 temperature sensor [pressure signal system] Possible causes and standard value in normal state BOOST PRESS & IMT Between (3) – (1) 4.75 – 5. breakage of lock. 3 V/24 V circuit) in wiring harWiring harness between CE01 (female) (44) ness Voltage Max. a Prepare with starting switch OFF. Problem that appears on machine • Engine output lowers. then carry out troubleshooting without turning starting switch ON.25 V PC200. too. • Looseness of connector. push-in. and then judge. then turn starting switch ON and carry out troubleshooting. (Code: 36501 Boost pressure sensor voltage) • Method of reproducing failure code: Turn starting switch ON. Check them directly. 1 V – BOOST PRESS & IMT (female) (4) Short circuit in wiring har4 ness (with another wiring harness) 5 Defective wiring harness connector 6 Defective engine controller a Prepare with starting switch OFF. 220-8 .25 V Voltage is measured with wiring harness connected.

40 Troubleshooting SEN00240-03 Circuit diagram related to boost pressure/temperature sensor (Combination sensor) PC200. 220-8 13 .

then turn starting switch ON and carry out troubleshooting. or expansion of pin • Moisture or dirt in connector or defective insulation a Prepare with starting switch OFF. (Code: 36501 Boost pressure sensor voltage) • Method of reproducing failure code: Turn starting switch ON.25 V PC200. Defective boost pressure/ 2 temperature sensor [pressure signal system] Possible causes and standard value in normal state BOOST PRESS & IMT Between (3) – (1) 4. for another cause of trouble. Accordingly. Problem that appears on machine • Engine output lowers. or breakage of seal • Corrosion.75 – 5. if voltage is abnormal. 100 kz Connecting parts between boost pressure/temperature sensor – engine wiring harness – engine controller may be defective. 100 circuit) – BOOST PRESS & IMT (female) (4) tance kz Short circuit in wiring har4 ness (with another wiring harness) 5 Defective wiring harness connector 6 Defective engine controller a Prepare with starting switch OFF.If failure code [CA187] is also indicated.75 – 5. Cause Standard value in normal state/Remarks on troubleshooting Defective sensor power sup. Wiring harness between CE01 (female) (44) – BOOST PRESS & IMT (female) (4) and between CE01 (female) (47) – JC02 – BOOST PRESS & IMT (female) (1) Resistance Min.25 V Voltage is measured with wiring harness connected. too. carry out troubleshooting 1 ply 2 system for it first. • Looseness of connector. Check them directly. then carry out troubleshooting Ground fault in wiring harwithout turning starting switch ON. and then judge.SEN00240-03 40 Troubleshooting Failure code [CA123] Chg Air Press Sensor Low Error User code Failure code E11 CA123 Contents of trouble Action of controller Trouble 1 Charge air pressure sensor low error (Engine controller system) • Pressure signal circuit of boost pressure/temperature sensor detected low voltage. a Prepare with starting switch OFF. • Fixes charge pressure value and continues operation. 3 ness (Short circuit with GND Wiring harness between CE01 (female) (44) ResisMin. breakage of lock. then carry out troubleshooting without turning starting switch ON. 220-8 . Related information • Signal voltage on boost pressure side of boost pressure/temperature sensor can be checked with monitoring function. CE01 Between (37) – (47) 14 Power supply Voltage Voltage Power supply 4. bend. then turn starting switch ON and carry out troubleshooting. check wiring harness and controller. push-in. a Prepare with starting switch OFF. breakage.

220-8 15 .40 Troubleshooting SEN00240-03 Circuit diagram related to boost pressure/temperature sensor (Combination sensor) PC200.

• Looseness of connector. 220-8 . carry out troubleshooting for it first. controller continues operation with voltage at 100% value. 3 V/24 V circuit) in wiring harWiring harness between CE02 (female) (9) – ness Voltage Max. controller fixes voltage value to level just before detection of trouble and continues operation.25 V Voltage is measured with wiring harness connected. Wiring harness between CE02 (female) (9) – P20 (female) (2) and between CE02 (female) (22) – P20 (female) (1) Min. 1 V P20 (female) (2) Short circuit in wiring har4 ness (with another wiring harness) 5 Defective wiring harness connector 6 Defective engine controller a Prepare with starting switch OFF. Possible causes and standard value in normal state a Prepare with starting switch OFF. 1 Cause Standard value in normal state/Remarks on troubleshooting Defective throttle sensor power supply system If failure code [CA2185] is also indicated. if voltage is abnormal. then turn starting switch ON Hot short (Short circuit with 5 and carry out troubleshooting. for another cause of trouble.SEN00240-03 40 Troubleshooting Failure code [CA131] Throttle Sensor High Error User code Failure code E14 CA131 Contents of trouble Action of controller Trouble 1 Throttle sensor high error (Engine controller system) • Signal circuit of fuel control dial detected high voltage. breakage. breakage of lock. a Prepare with starting switch OFF. then turn starting switch ON and carry out troubleshooting. Check them directly.75 – 5. push-in. P20 2 Defective fuel control dial Between (1) – (3) Voltage Power supply 4. check wiring harness and controller.25 V PC200. • If starting switch is turned ON while voltage is abnormally high. Accordingly. (Code: 03000 Fuel control dial voltage) • Method of reproducing failure code: Turn starting switch ON. then turn starting switch ON and carry out troubleshooting.75 – 5. Related information • Signal voltage of fuel control dial can be checked with monitoring function. then carry out troubleshooting without turning starting switch ON. or breakage of seal • Corrosion. too. • If trouble occurs while starting switch is in ON position. 100 kz Connecting parts between fuel control dial – machine wiring harness – engine controller may be defective. or expansion of pin • Moisture or dirt in connector or defective insulation a Prepare with starting switch OFF. Problem that appears on machine • Engine speed cannot be controlled with fuel control dial. bend. and then judge. CE02 Between (22) – (23) 16 Resistance Voltage Power supply 4.

220-8 17 .40 Troubleshooting SEN00240-03 Circuit diagram related to fuel control dial PC200.

for another cause of trouble. and then judge. controller fixes voltage value to level just before detection of trouble and continues operation. push-in. Related information • Signal voltage of fuel control dial can be checked with monitoring function. then turn starting switch ON and carry out troubleshooting. 1 Cause Standard value in normal state/Remarks on troubleshooting Defective throttle sensor power supply system If failure code [CA2186] is also indicated. Accordingly. Possible causes and standard value in normal state a Prepare with starting switch OFF. • If trouble occurs while starting switch is in ON position. Wiring harness between CE02 (female) (9) – P20 (female) (2) and between CE02 (female) (23) – P20 (female) (3) Min.25 V Voltage is measured with wiring harness connected. Check them directly. then carry out troubleshooting without turning starting switch ON. if voltage is abnormal. 100 kz Connecting parts between fuel control dial – machine wiring harness – engine controller may be defective. a Prepare with starting switch OFF.SEN00240-03 40 Troubleshooting Failure code [CA132] Throttle Sensor Low Error User code Failure code E14 CA132 Contents of trouble Action of controller Trouble 1 Throttle sensor low error (Engine controller system) • Signal circuit of fuel control dial detected low voltage. 220-8 . carry out troubleshooting for it first.25 V PC200. Problem that appears on machine • Engine speed cannot be controlled with fuel control dial. breakage of lock. or expansion of pin • Moisture or dirt in connector or defective insulation a Prepare with starting switch OFF. CE02 Between (22) – (23) 18 Resistance Voltage Power supply 4. 100 circuit) P20 (female) (2) tance kz Short circuit in wiring har4 ness (with another wiring harness) 5 Defective wiring harness connector 6 Defective engine controller a Prepare with starting switch OFF. • If starting switch is turned ON while voltage is abnormally high. then turn starting switch ON and carry out troubleshooting. check wiring harness and controller. 3 ness (Short circuit with GND Wiring harness between CE02 (female) (9) – ResisMin.75 – 5. (Code: 03000 Fuel control dial voltage) • Method of reproducing failure code: Turn starting switch ON. then carry out troubleshooting Ground fault in wiring harwithout turning starting switch ON. P20 2 Defective fuel control dial Between (1) – (3) Voltage Power supply 4. bend. controller continues operation with voltage at 100% value. too.75 – 5. or breakage of seal • Corrosion. breakage. • Looseness of connector.

40 Troubleshooting SEN00240-03 Circuit diagram related to fuel control dial PC200. 220-8 19 .

then carry out troubleshooting without turning starting switch ON.SEN00240-03 40 Troubleshooting Failure code [CA144] Coolant Temp Sens High Error User code Failure code E15 CA144 Contents of trouble Action of controller Trouble 1 Coolant temperature sensor high error (Engine controller system) • Signal circuit of coolant temperature sensor detected high voltage.18 – 160 kz a Prepare with starting switch OFF.– COOLANT TEMP (female) (B) nector) Wiring harness between CE01 (female) (38) – JC03 – COOLANT TEMP (female) (A) Possible causes and standard value in normal state Short circuit in wiring har3 ness (with another wiring harness) 4 Defective wiring harness connector 5 Defective engine controller 20 Resistance Max. (Code: 04105 Coolant temperature sensor voltage) • Method of reproducing failure code: Turn starting switch ON. 220-8 . or expansion of pin • Moisture or dirt in connector or defective insulation a Prepare with starting switch OFF. • Overheat prevention function does not work. 10 z Resistance Max. COOLANT TEMP (male) Resistance Between (A) – (B) 0. push-in.18 – 160 kz PC200. 100 kz Connecting parts between coolant temperature sensor – engine wiring harness – engine controller may be defective. or breakage of seal • Corrosion. Wiring harness between CE01 (female) (15) – each of CE01 (female) pins (With all wiring harness connectors disconnected) Resistance Min. then carry out troubleshooting without turning starting switch ON. Check them directly. Cause 1 Defective coolant temperature sensor Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF. • Looseness of connector. then carry out troubleshooting without turning starting switch ON. Problem that appears on machine • Exhaust gas becomes white. 10 z a Prepare with starting switch OFF. bend. • Fixes coolant temperature value and continues operation. then carry out troubleshooting without turning starting switch ON. Related information • Signal voltage of coolant temperature sensor can be checked with monitoring function. breakage of lock. Disconnection in wiring harness (Disconnection in wiring Wiring harness between CE01 (female) (15) 2 or defective contact in con. breakage. CE01 (female) Resistance Between (15) – (38) 0.

220-8 21 .40 Troubleshooting SEN00240-03 Circuit diagram related to coolant temperature sensor PC200.

Problem that appears on machine • Exhaust gas becomes white. 220-8 . then carry out troubleshooting without turning starting switch ON. • Overheat prevention function does not work.18 – 160 kz Between (15) – chassis ground Min. 2 ness (Short circuit with GND Wiring harness between CE01 (female) (15) ResisMin. Cause Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF. (Code: 04105 Coolant temperature sensor voltage) • Method of reproducing failure code: Turn starting switch ON. Check them directly. or breakage of seal • Corrosion. 100 circuit) – COOLANT TEMP (female) (B) tance kz Possible causes and standard value in normal state Short circuit in wiring har3 ness (with another wiring harness) 4 Defective wiring harness connector a Prepare with starting switch OFF. • Looseness of connector. then carry out troubleshooting Ground fault in wiring harwithout turning starting switch ON. 5 Defective engine controller 22 CE01 (female) Resistance Between (15) – (38) 0. breakage of lock. 100 kz Connecting parts between coolant temperature sensor – engine wiring harness – engine controller may be defective. bend.18 – 160 kz Between (B) – chassis ground Min. or expansion of pin • Moisture or dirt in connector or defective insulation a Prepare with starting switch OFF. 100 kz a Prepare with starting switch OFF.SEN00240-03 40 Troubleshooting Failure code [CA145] Coolant Temp Sens Low Error User code Failure code E15 CA145 Contents of trouble Action of controller Trouble 1 Coolant temperature sensor low error (Engine controller system) • Signal circuit of coolant temperature sensor detected low voltage. Wiring harness between CE01 (female) (15) – each of CE01 (female) pins (With all wiring harness connectors disconnected) Resistance Min. Related information • Signal voltage of coolant temperature sensor can be checked with monitoring function. then carry out troubleshooting without turning starting switch ON. push-in. 1 Defective coolant temperature sensor COOLANT TEMP (male) Resistance Between (A) – (B) 0. then carry out troubleshooting without turning starting switch ON. • Fixes coolant temperature value and continues operation. breakage. 100 kz PC200.

40 Troubleshooting SEN00240-03 Circuit diagram related to coolant temperature sensor PC200. 220-8 23 .

breakage of lock. or expansion of pin • Moisture or dirt in connector or defective insulation a Prepare with starting switch OFF.– BOOST PRESS & IMT (female) (2) nector) Wiring harness between CE01 (female) (47) – JC02 – BOOST PRESS & IMT (female) (1) Possible causes and standard value in normal state Short circuit in wiring har3 ness (with another wiring harness) 4 Defective wiring harness connector 5 Defective engine controller 24 Resistance Max. • Engine protection function based on boost temperature does not work Related information • Signal voltage on boost temperature side of boost pressure/temperature sensor can be checked with monitoring function. CE01 (female) Resistance Between (23) – (47) 0. 220-8 .SEN00240-03 40 Troubleshooting Failure code [CA153] Chg Air Temp Sensor High Error User code Failure code E15 CA153 Contents of trouble Action of controller Trouble 1 Charge air temperature sensor high error (Engine controller system) • Temperature signal circuit of boost pressure/temperature sensor detected high voltage. Disconnection in wiring harness (Disconnection in wiring Wiring harness between CE01 (female) (23) 2 or defective contact in con. then carry out troubleshooting without turning starting switch ON. Cause Defective boost pressure/ 1 temperature sensor [temperature signal system] Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF. 100 kz Connecting parts between boost pressure/temperature sensor – engine wiring harness – engine controller may be defective. • Fixes charge temperature value and continues operation. or breakage of seal • Corrosion. Problem that appears on machine • Exhaust gas becomes white. push-in. then carry out troubleshooting without turning starting switch ON. 10 z a Prepare with starting switch OFF. 10 z Resistance Max.18 – 160 kz a Prepare with starting switch OFF. then carry out troubleshooting without turning starting switch ON.18 – 160 kz PC200. bend. Wiring harness between CE01 (female) (23) – each of CE01 (female) pins (With all wiring harness connectors disconnected) Resistance Min. • Looseness of connector. Check them directly. BOOST PRESS & IMT (male) Resistance Between (2) – (1) 0. breakage. then carry out troubleshooting without turning starting switch ON. (Code: 18501 Boost temperature sensor voltage) • Method of reproducing failure code: Turn starting switch ON.

40 Troubleshooting SEN00240-03 Circuit diagram related to boost pressure/temperature sensor (Combination sensor) PC200. 220-8 25 .

breakage of lock. 100 kz Connecting parts between boost pressure/temperature sensor – engine wiring harness – engine controller may be defective. then carry out troubleshooting Ground fault in wiring harwithout turning starting switch ON. 100 Wiring harness between CE01 (female) (23) circuit) – BOOST PRESS & IMT (female) (2) tance kz Possible causes and standard value in normal state Short circuit in wiring har3 ness (with another wiring harness) 4 Defective wiring harness connector a Prepare with starting switch OFF. 5 Defective engine controller 26 CE01 (female) Resistance Between (23) – (47) 0. 100 kz PC200. push-in. Cause Defective boost pressure/ 1 temperature sensor [temperature signal system] Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF.18 – 160 kz Between (2) – chassis ground Min. • Looseness of connector. BOOST PRESS & IMT (male) Resistance Between (2) – (1) 0. (Code: 18501 Boost temperature sensor voltage) • Method of reproducing failure code: Turn starting switch ON.18 – 160 kz Between (23) – chassis ground Min. 2 ness (Short circuit with GND ResisMin. then carry out troubleshooting without turning starting switch ON. or expansion of pin • Moisture or dirt in connector or defective insulation a Prepare with starting switch OFF. bend. 100 kz a Prepare with starting switch OFF. then carry out troubleshooting without turning starting switch ON. Wiring harness between CE01 (female) (23) – each of CE01 (female) pins (With all wiring harness connectors disconnected) Resistance Min. • Engine protection function based on boost temperature does not work Related information • Signal voltage on boost temperature side of boost pressure/temperature sensor can be checked with monitoring function.SEN00240-03 40 Troubleshooting Failure code [CA154] Chg Air Temp Sensor Low Error User code Failure code E15 CA154 Contents of trouble Action of controller Trouble 1 Charge air temperature sensor low error (Engine controller system) • Temperature signal circuit of boost pressure/temperature sensor detected low voltage. • Fixes charge temperature value and continues operation. breakage. 220-8 . or breakage of seal • Corrosion. Problem that appears on machine • Exhaust gas becomes white. then carry out troubleshooting without turning starting switch ON. Check them directly.

220-8 27 .40 Troubleshooting SEN00240-03 Circuit diagram related to boost pressure/temperature sensor (Combination sensor) PC200.

• Looseness and breakage of fan belt. 3 Defective engine controller If causes 1 – 2 are not detected.) PC200. troubleshooting cannot be carried out. • Engine stops. Problem that appears on machine • Engine output lowers. Check related parts directly. • Limits output and continues operation. (Since trouble is in system. Related information • Boost temperature can be checked with monitoring function. 220-8 .SEN00240-03 40 Troubleshooting Failure code [CA155] Chg Air Temp High Speed Derate User code Failure code E11 CA155 Contents of trouble Action of controller Trouble 1 Charge air temperature high speed derate (Engine controller system) • Temperature signal of boost pressure/temperature sensor exceeded control upper temperature limit. • Insufficiency of cooling air • Clogging of aftercooler fins 2 Abnormal rise of turbocharger outlet temperature Outlet temperature of turbocharger may be abnormally high. (Code: 18500 Boost temperature) • Method of reproducing failure code: Start engine Cause Possible causes and standard value in normal state 28 Standard value in normal state/Remarks on troubleshooting 1 Lowering of cooling performance of aftercooler Cooling performance of aftercooler may be low. engine controller may be defective. Check following points directly.

40 Troubleshooting PC200. 220-8 SEN00240-03 29 .

breakage. Problem that appears on machine • Engine output lowers. (Since trouble is in system. or expansion of pin • Moisture or dirt in connector or defective insulation 3 Defective engine controller If causes 1 – 2 are not detected. If "E" of failure code goes off when a sensor or wiring harness is disconnected. Related information • Method of reproducing failure code: Turn starting switch ON. or breakage of seal • Corrosion. 1 Defective sensor or wiring harness Possible causes and standard value in normal state Boost pressure/temperature sensor BOOST PRESS & IMT Common rail pressure sensor FUEL RAIL PRESS Bkup sensor CAM SENSOR Engine wiring harness CE01 Defective wiring harness connector Connecting parts between each sensor – engine wiring harness – engine controller may be defective. push-in. troubleshooting cannot be carried out. • Limits output and continues operation. that sensor or wiring harness is defective. bend. • Fixes boost pressure value and continues operation. engine controller may be defective. Check them directly. Cause Standard value in normal state/Remarks on troubleshooting a Disconnect connector with starting switch OFF. • Fixes charge temperature value and continues operation. then turn starting switch ON and carry out troubleshooting. PC200.) 2 30 Disconnect sensors and wiring harness at right in order and carry out operation to reproduce trouble. breakage of lock. • Looseness of connector.SEN00240-03 40 Troubleshooting Failure code [CA187] Sens Supply 2 Volt Low Error User code Failure code E15 CA187 Contents of trouble Action of controller Trouble 1 Sensor power supply 2 voltage low error (Engine controller system) • Low voltage was detected in sensor power supply 2 circuit. 220-8 .

220-8 31 .40 Troubleshooting SEN00240-03 Circuit diagram related to sensor power supply 2 PC200.

then turn starting switch ON and carry out troubleshooting. Wiring harness between CE01 (female) (3) – AMBAIR PRESSURE (female) (3) and between CE01 (female) (33) – AMBAIR PRESSURE (female) (1) Min. 100 kz Connecting parts between ambient pressure sensor – engine wiring harness – engine controller may be defective. then carry out troubleshooting without turning starting switch ON.SEN00240-03 40 Troubleshooting Failure code [CA221] Ambient Press Sens High Error User code Failure code E11 CA221 Contents of trouble Action of controller Trouble 1 Ambient pressure sensor high error (Engine controller system) • High voltage was detected in signal circuit of ambient pressure sensor. 1 V AMBAIR PRESSURE (female) (3) Short circuit in wiring har4 ness (with another wiring harness) 5 Defective wiring harness connector 6 Defective engine controller a Prepare with starting switch OFF. • Looseness of connector. for another cause of trouble. Related information • Signal voltage of ambient pressure sensor can be checked with monitoring function. (Code: 37401 Ambient pressure sensor voltage • Method of reproducing failure code: Turn starting switch ON. or breakage of seal • Corrosion.75 – 5. CE01 Between (33) – (38) 32 Resistance Voltage Voltage 4. Accordingly. and then judge. carry out troubleshooting 1 ply 1 system for it first. too. Possible causes and standard value in normal state a Prepare with starting switch OFF. if voltage is abnormal. Cause Standard value in normal state/Remarks on troubleshooting Defective sensor power sup. breakage. • Fixes ambient pressure value and continues operation. push-in. 3 5V/24V circuit) in wiring harWiring harness between CE01 (female) (3) – ness Voltage Max. Defective ambient pressure 2 sensor AMBAIR PRESURE Between (1) – (2) Power supply Voltage 4. Problem that appears on machine • Engine does not start easily. Check them directly. then turn starting switch ON and carry out troubleshooting.25V Voltage is measured with wiring harness connected. bend. then turn starting switch ON Hot short (Short circuit with and carry out troubleshooting. check wiring harness and controller.25 V PC200.If failure code [CA386] is also indicated. • Engine output lowers. or expansion of pin • Moisture or dirt in connector or defective insulation a Prepare with starting switch OFF. a Prepare with starting switch OFF. 220-8 . breakage of lock.75 – 5.

220-8 33 .40 Troubleshooting SEN00240-03 Circuit diagram related to ambient pressure sensor PC200.

(Code: 37401 Ambient pressure sensor voltage • Method of reproducing failure code: Turn starting switch ON. • Looseness of connector. carry out troubleshooting 1 ply 1 system for it first. bend. then turn starting switch ON and carry out troubleshooting. and then judge. Cause Standard value in normal state/Remarks on troubleshooting Defective sensor power sup. Related information • Signal voltage of ambient pressure sensor can be checked with monitoring function. 220-8 . then carry out troubleshooting without turning starting switch ON. then carry out troubleshooting Ground fault in wiring harwithout turning starting switch ON. Possible causes and standard value in normal state a Prepare with starting switch OFF. or breakage of seal • Corrosion. Accordingly.75 – 5.25 V PC200. 100 circuit) AMBAIR PRESSURE (female) (3) tance kz Short circuit in wiring har4 ness (with another wiring harness) 5 Defective wiring harness connector 6 Defective engine controller a Prepare with starting switch OFF. 3 ness (Short circuit with GND Wiring harness between CE01 (female) (3) – ResisMin. • Engine output lowers. or expansion of pin • Moisture or dirt in connector or defective insulation a Prepare with starting switch OFF. if voltage is abnormal. 100 kz Connecting parts between ambient pressure sensor – engine wiring harness – engine controller may be defective. then turn starting switch ON and carry out troubleshooting. • Fixes ambient pressure value and continues operation. breakage of lock. Check them directly. Wiring harness between CE01 (female) (3) – AMBAIR PRESSURE (female) (3) and between CE01 (female) (38) – JC03 – AMBAIR PRESSURE (female) (2) Min. a Prepare with starting switch OFF. Problem that appears on machine • Engine does not start easily. too.75 – 5. push-in.25V Voltage is measured with wiring harness connected. check wiring harness and controller.SEN00240-03 40 Troubleshooting Failure code [CA222] Ambient Press Sens Low Error User code Failure code E11 CA222 Contents of trouble Action of controller Trouble 1 Ambient pressure sensor low error (Engine controller system) • Low voltage was detected in signal circuit of ambient pressure sensor. CE01 Between (33) – (38) 34 Resistance Voltage Voltage 4.If failure code [CA352] is also indicated. breakage. Defective ambient pressure 2 sensor AMBAIR PRESURE Between (1) – (2) Power supply Voltage 4. for another cause of trouble.

40 Troubleshooting SEN00240-03 Circuit diagram related to ambient pressure sensor PC200. 220-8 35 .

• Limits output and continues operation. Check them directly. Related information • Method of reproducing failure code: Turn starting switch ON. troubleshooting cannot be carried out. • Fixes boost pressure value and continues operation. engine controller may be defective. or breakage of seal • Corrosion. Problem that appears on machine • Engine output lowers. push-in. breakage. • Fixes charge temperature value and continues operation. • Looseness of connector.) 1 Circuit diagram related to sensor power supply 2 36 PC200.SEN00240-03 40 Troubleshooting Failure code [CA227] Sens Supply 2 Volt High Error User code Failure code E15 CA227 Contents of trouble Action of controller Trouble Sensor power supply 2 voltage high error (Engine controller system) • High voltage was detected in sensor power supply 2 circuit. 220-8 . bend. breakage of lock. or expansion of pin • Moisture or dirt in connector or defective insulation 2 Defective engine controller If cause 1 is not detected. Cause Possible causes and standard value in normal state 1 Standard value in normal state/Remarks on troubleshooting Defective wiring harness connector Connecting parts between each sensor – engine wiring harness – engine controller may be defective. (Since trouble is in system.

Teach operator proper using method. 2 Improper use Machine may be used improperly. Problem that appears on machine • Engine speed fluctuates. 3 Defective engine controller If causes 1 – 2 are detected. Related information • Engine speed can be checked with monitoring function. (Since trouble is in system.40 Troubleshooting SEN00240-03 Failure code [CA234] Eng Overspeed User code Failure code — CA234 Contents of trouble Action of controller Trouble Engine overspeed (Engine controller system) • Engine speed exceeded control upper speed limit. 220-8 1 Standard value in normal state/Remarks on troubleshooting 1 Use of improper fuel Fuel used may be improper. • Stops injection until engine speed lowers to normal level. Cause Possible causes and standard value in normal state PC200.) 37 . engine controller may be defective. (Code: 01002 Engine speed) • Method of reproducing failure code: Run engine at high idle. troubleshooting cannot be carried out. Check it directly.

that ness sensor or wiring harness is defective. or breakage of seal • Corrosion. Check them directly. or expansion of pin • Moisture or dirt in connector or defective insulation Circuit diagram related to engine Ne speed sensor 38 PC200. Cause Standard value in normal state/Remarks on troubleshooting a Disconnect connector with starting switch OFF. breakage of lock. breakage.SEN00240-03 40 Troubleshooting Failure code [CA238] Ne Speed Sens Supply Volt Error User code Failure code E15 CA238 Contents of trouble Action of controller Trouble 1 Ne speed sensor power supply voltage error (Engine controller system) • Low voltage was detected in power supply circuit of engine Ne speed sensor. bend. push-in. • Engine hunts. • Continues control with signal from engine Bkup speed sensor. Possible causes and standard value in normal state Defective sensor or wiring 1 harness 2 Defective wiring harness connector Disconnect sensor and wiring harness at right in order and Ne speed sensor carry out operation to reproduce trouble. then turn starting switch ON and carry out troubleshooting. Problem that appears on machine • Engine does not start easily. • Looseness of connector. If "E" of failure code goes off when sensor or wiring harness is Engine wiring hardisconnected. Related information • Method of reproducing failure code: Turn starting switch ON. 220-8 . CRANK SENSOR CE01 Connecting parts between each sensor – engine wiring harness – engine controller may be defective.

• None in particular. then carry out troubleshooting without turning starting switch ON. then carry out troubleshooting Ground fault in wiring harwithout turning starting switch ON. bend. 100 kz a Prepare with starting switch OFF. 100 circuit) CP3 PUMP REGULATOR (female) (1) tance kz Possible causes and standard value in normal state Short circuit in wiring har3 ness (with another wiring harness) 4 Defective wiring harness connector 5 Defective engine controller a Prepare with starting switch OFF. Check them directly. 100 kz Connecting parts between supply pump actuator – engine wiring harness – engine controller may be defective. Problem that appears on machine • Engine speed does not rise from low idle. 2 ness (Short circuit with GND Wiring harness between CE01 (female) (2) – ResisMin. push-in. CE01 (female) Resistance Between (2) – chassis ground Min. • Looseness of connector.40 Troubleshooting SEN00240-03 Failure code [CA271] IMV/PCV1 Short Error User code Failure code E10 CA271 Contents of trouble Action of controller Trouble 1 IMV/PCV1 short circuit error (Engine controller system) • Short circuit was detected in drive circuit of supply pump actuator. • Common rail fuel pressure rises above command value. 220-8 39 . • Engine output lowers. 100 kz Circuit diagram related to supply pump actuator (metering unit) PC200. or breakage of seal • Corrosion. breakage of lock. Cause Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF. then carry out troubleshooting without turning starting switch ON. then carry out troubleshooting without turning starting switch ON. Wiring harness between CE01 (female) (2) – each of CE01 (female) pins (With all wiring harness connectors disconnected) Resistance Min. or expansion of pin • Moisture or dirt in connector or defective insulation a Prepare with starting switch OFF. breakage. Defective supply pump actu1 ator CP3 PUMP REGULATOR (male) Resistance Between (1) – chassis ground Min. Related information • Method of reproducing failure code: Turn starting switch ON.

220-8 . • Engine runs but its operation is unstable. 5 z Circuit diagram related to supply pump actuator (metering unit) 40 PC200. Cause 1 Defective supply pump actuator Disconnection in wiring harness (Disconnection in wiring 2 or defective contact in connector) Possible causes and standard value in normal state 1 3 Hot short (Short circuit with 24V circuit) in wiring harness 4 Short circuit in wiring harness (with another wiring harness) 5 Defective wiring harness connector 6 Defective engine controller Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF. 100 each of CE01 (female) pins (With all wiring tance kz harness connectors disconnected) Connecting parts between supply pump actuator – engine wiring harness – engine controller may be defective.SEN00240-03 40 Troubleshooting Failure code [CA272] IMV/PCV1 Open Error User code E10 Contents of trouble Action of controller Problem that appears on machine Related information Failure code CA272 Trouble IMV/PCV1 open error (Engine controller system) • Opening was detected in drive circuit of supply pump actuator. Wiring harness between CE01 (female) (2) – Voltage Max. CE01 (female) Resistance Between (2) – (32) Max. CP3 PUMP REGULATOR (male) Resistance Between (1) – (2) Max. • Looseness of connector. then carry out troubleshooting without turning starting switch ON. then carry out troubleshooting without turning starting switch ON. then carry out troubleshooting without turning starting switch ON. Wiring harness between CE01 (female) (2) – ResisMax. or breakage of seal • Corrosion. bend. 10 z – CP3 PUMP REGULATOR (female) (2) tance a Prepare with starting switch OFF. then turn starting switch ON and carry out troubleshooting. then carry out troubleshooting without turning starting switch ON. push-in. • Common rail fuel pressure rises above command value. • None in particular. breakage of lock. Check them directly. 10 z CP3 PUMP REGULATOR (female) (1) tance Wiring harness between CE01 (female) (32) ResisMax. • Method of reproducing failure code: Turn starting switch ON. 5 z a Prepare with starting switch OFF. 3 V CP3 PUMP REGULATOR (female) (1) a Prepare with starting switch OFF. Wiring harness between CE01 (female) (2) – ResisMin. or expansion of pin • Moisture or dirt in connector or defective insulation a Prepare with starting switch OFF. breakage.

220-8 SEN00240-03 41 .40 Troubleshooting PC200.

2 z – INJ CYL 1 (1) tance Possible causes and standard value in normal state a Prepare with starting switch OFF. then carry out troubleshooting Ground fault in wiring harwithout turning starting switch ON. 100 kz 5 Defective wiring harness connector Connecting parts between No. then carry out troubleshooting without turning starting switch ON. breakage. 220-8 . • Looseness of connector. 7 Defective engine controller 42 CE01 (female) Resistance Between (45) – (53) Max. a Prepare with starting switch OFF. too. 2 z Resistance Max. Related information • Method of reproducing failure code: Start engine. 2 z Between (1) – chassis ground Min. 3 ness (Short circuit with GND Wiring harness between CE01 (female) (45) Resiscircuit) Max.SEN00240-03 40 Troubleshooting Failure code [CA322] Inj #1 Open/Short Error User code Failure code E11 CA322 Contents of trouble Action of controller Trouble 1 Injector #1 open/short circuit error (Engine controller system) • Opening or short circuit was detected in drive circuit of No.– INJ CYL 1 (1) nector) Wiring harness between CE01 (female) (53) – INJ CYL 1 (2) Resistance Max. • None in particular. bend. or breakage of seal • Corrosion. • Engine output lowers. Wiring harness between CE01 (female) (45) Short circuit in wiring harness – each of CE01 (female) pins (With all wiring 4 (with another wiring harness) harness connectors disconnected) Resistance Min. then carry out troubleshooting without turning starting switch ON. 100 kz Wiring harness between CE01 (female) (53) – each of CE01 (female) pins (With all wiring harness connectors disconnected) Resistance Min. 2 z a Prepare with starting switch OFF. 1 injector – engine wiring harness – engine controller may be defective. carry out troubleshooting of them. Disconnection in wiring harness (Disconnection in wiring Wiring harness between CE01 (female) (45) 2 or defective contact in con. Problem that appears on machine • Combustion becomes irregular or engine hunts. 100 kz a Prepare with starting switch OFF. or expansion of pin • Moisture or dirt in connector or defective insulation 6 Defective other cylinder injectors or wiring harness If the failure codes of other injectors are displayed. then carry out troubleshooting without turning starting switch ON. Check them directly. breakage of lock. 100 kz PC200. 1 injector. 2 z Between (45) – chassis ground Min. 1 Defective No. 1 injector INJ CYL 1 Resistance Between (1) – (2) Max. push-in. Cause Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF. then carry out troubleshooting without turning starting switch ON.

1 injector PC200.40 Troubleshooting SEN00240-03 Circuit diagram related to No. 220-8 43 .

100 kz a Prepare with starting switch OFF. Related information • Method of reproducing failure code: Start engine. Disconnection in wiring harness (Disconnection in wiring Wiring harness between CE01 (female) (46) 2 or defective contact in con. too. 3 ness (Short circuit with GND Wiring harness between CE01 (female) (46) Resiscircuit) Max. carry out troubleshooting of them. then carry out troubleshooting Ground fault in wiring harwithout turning starting switch ON. then carry out troubleshooting without turning starting switch ON. then carry out troubleshooting without turning starting switch ON.SEN00240-03 40 Troubleshooting Failure code [CA323] Inj #5 Open/Short Error User code Failure code E11 CA323 Contents of trouble Action of controller Trouble 1 Injector #5 open/short circuit error (Engine controller system) • Opening or short circuit was detected in drive circuit of No. 100 kz PC200. 5 injector INJ CYL 5 Resistance Between (1) – (2) Max. bend. 2 z Between (46) – chassis ground Min. a Prepare with starting switch OFF. 220-8 .– INJ CYL 5 (1) nector) Wiring harness between CE01 (female) (60) – INJ CYL 5 (2) Resistance Max. then carry out troubleshooting without turning starting switch ON. • Engine output lowers. push-in. 2 z Between (1) – chassis ground Min. breakage. 5 injector. Problem that appears on machine • Combustion becomes irregular or engine hunts. breakage of lock. 100 kz Wiring harness between CE01 (female) (60) – each of CE01 (female) pins (With all wiring harness connectors disconnected) Resistance Min. then carry out troubleshooting without turning starting switch ON. 100 kz 5 Defective wiring harness connector Connecting parts between No. 2 z – INJ CYL 5 (1) tance Possible causes and standard value in normal state a Prepare with starting switch OFF. 7 Defective engine controller 44 CE01 (female) Resistance Between (46) – (60) Max. or breakage of seal • Corrosion. Wiring harness between CE01 (female) (46) Short circuit in wiring harness – each of CE01 (female) pins (With all wiring 4 (with another wiring harness) harness connectors disconnected) Resistance Min. Cause Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF. • Looseness of connector. 2 z Resistance Max. • None in particular. 1 Defective No. Check them directly. or expansion of pin • Moisture or dirt in connector or defective insulation 6 Defective other cylinder injectors or wiring harness If the failure codes of other injectors are displayed. 2 z a Prepare with starting switch OFF. 5 injector – engine wiring harness – engine controller may be defective.

5 injector PC200.40 Troubleshooting SEN00240-03 Circuit diagram related to No. 220-8 45 .

or breakage of seal • Corrosion. then carry out troubleshooting Ground fault in wiring harwithout turning starting switch ON. 3 injector. 3 injector INJ CYL 3 Resistance Between (1) – (2) Max. carry out troubleshooting of them. 2 z Between (55) – chassis ground Min. 1 Defective No. too.– INJ CYL 3 (1) nector) Wiring harness between CE01 (female) (52) – INJ CYL 3 (2) Resistance Max. 2 z a Prepare with starting switch OFF. 2 z Resistance Max.SEN00240-03 40 Troubleshooting Failure code [CA324] Inj #3 Open/Short Error User code Failure code E11 CA324 Contents of trouble Action of controller Trouble 1 Injector #3 open/short circuit error (Engine controller system) • Opening or short circuit was detected in drive circuit of No. 220-8 . Check them directly. breakage. then carry out troubleshooting without turning starting switch ON. a Prepare with starting switch OFF. 100 kz PC200. bend. then carry out troubleshooting without turning starting switch ON. 3 injector – engine wiring harness – engine controller may be defective. Problem that appears on machine • Combustion becomes irregular or engine hunts. 3 ness (Short circuit with GND Wiring harness between CE01 (female) (55) Resiscircuit) Max. 100 kz 5 Defective wiring harness connector Connecting parts between No. 7 Defective engine controller 46 CE01 (female) Resistance Between (55) – (52) Max. • None in particular. 2 z Between (1) – chassis ground Min. then carry out troubleshooting without turning starting switch ON. Related information • Method of reproducing failure code: Start engine. 100 kz Wiring harness between CE01 (female) (52) – each of CE01 (female) pins (With all wiring harness connectors disconnected) Resistance Min. or expansion of pin • Moisture or dirt in connector or defective insulation 6 Defective other cylinder injectors or wiring harness If the failure codes of other injectors are displayed. 2 z – INJ CYL 3 (1) tance Possible causes and standard value in normal state a Prepare with starting switch OFF. push-in. Disconnection in wiring harness (Disconnection in wiring Wiring harness between CE01 (female) (55) 2 or defective contact in con. then carry out troubleshooting without turning starting switch ON. • Engine output lowers. • Looseness of connector. breakage of lock. Cause Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF. 100 kz a Prepare with starting switch OFF. Wiring harness between CE01 (female) (55) Short circuit in wiring harness – each of CE01 (female) pins (With all wiring 4 (with another wiring harness) harness connectors disconnected) Resistance Min.

40 Troubleshooting SEN00240-03 Circuit diagram related to No. 3 injector PC200. 220-8 47 .

7 Defective engine controller 48 CE01 (female) Resistance Between (57) – (59) Max. breakage. 6 injector – engine wiring harness – engine controller may be defective. Disconnection in wiring harness (Disconnection in wiring Wiring harness between CE01 (female) (57) 2 or defective contact in con. • Engine output lowers. then carry out troubleshooting without turning starting switch ON. 100 kz PC200. 1 Defective No. Wiring harness between CE01 (female) (57) Short circuit in wiring harness – each of CE01 (female) pins (With all wiring 4 (with another wiring harness) harness connectors disconnected) Resistance Min. 6 injector. 2 z Between (1) – chassis ground Min.SEN00240-03 40 Troubleshooting Failure code [CA325] Inj #6 Open/Short Error User code Failure code E11 CA325 Contents of trouble Action of controller Trouble 1 Injector #6 open/short circuit error (Engine controller system) • Opening or short circuit was detected in drive circuit of No. 6 injector INJ CYL 6 Resistance Between (1) – (2) Max.– INJ CYL 6 (1) nector) Wiring harness between CE01 (female) (59) – INJ CYL 6 (2) Resistance Max. 3 ness (Short circuit with GND Wiring harness between CE01 (female) (57) Resiscircuit) Max. or breakage of seal • Corrosion. then carry out troubleshooting without turning starting switch ON. • Looseness of connector. 2 z – INJ CYL 6 (1) tance Possible causes and standard value in normal state a Prepare with starting switch OFF. 220-8 . 100 kz a Prepare with starting switch OFF. 2 z a Prepare with starting switch OFF. then carry out troubleshooting Ground fault in wiring harwithout turning starting switch ON. or expansion of pin • Moisture or dirt in connector or defective insulation 6 Defective other cylinder injectors or wiring harness If the failure codes of other injectors are displayed. Problem that appears on machine • Combustion becomes irregular or engine hunts. bend. 2 z Between (57) – chassis ground Min. then carry out troubleshooting without turning starting switch ON. then carry out troubleshooting without turning starting switch ON. • None in particular. too. Cause Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF. carry out troubleshooting of them. 100 kz 5 Defective wiring harness connector Connecting parts between No. 2 z Resistance Max. Related information • Method of reproducing failure code: Start engine. 100 kz Wiring harness between CE01 (female) (59) – each of CE01 (female) pins (With all wiring harness connectors disconnected) Resistance Min. a Prepare with starting switch OFF. breakage of lock. push-in. Check them directly.

6 injector PC200.40 Troubleshooting SEN00240-03 Circuit diagram related to No. 220-8 49 .

Problem that appears on machine • Combustion becomes irregular or engine hunts. Related information • Method of reproducing failure code: Start engine.SEN00240-03 40 Troubleshooting Failure code [CA331] Inj #2 Open/Short Error User code Failure code E11 CA331 Contents of trouble Action of controller Trouble 1 Injector #2 open/short circuit error (Engine controller system) • Opening or short circuit was detected in drive circuit of No. breakage of lock.– INJ CYL 2 (1) nector) Wiring harness between CE01 (female) (51) – INJ CYL 2 (2) Resistance Max. Wiring harness between CE01 (female) (54) Short circuit in wiring harness – each of CE01 (female) pins (With all wiring 4 (with another wiring harness) harness connectors disconnected) Resistance Min. 3 ness (Short circuit with GND Wiring harness between CE01 (female) (54) Resiscircuit) Max. 2 injector. Disconnection in wiring harness (Disconnection in wiring Wiring harness between CE01 (female) (54) 2 or defective contact in con. 100 kz 5 Defective wiring harness connector Connecting parts between No. then carry out troubleshooting without turning starting switch ON. too. or expansion of pin • Moisture or dirt in connector or defective insulation 6 Defective other cylinder injectors or wiring harness If the failure codes of other injectors are displayed. 100 kz a Prepare with starting switch OFF. breakage. 2 z Resistance Max. • None in particular. bend. 2 injector INJ CYL 2 Resistance Between (1) – (2) Max. then carry out troubleshooting without turning starting switch ON. a Prepare with starting switch OFF. Check them directly. 1 Defective No. 2 z – INJ CYL 2 (1) tance Possible causes and standard value in normal state a Prepare with starting switch OFF. 220-8 . push-in. • Looseness of connector. then carry out troubleshooting Ground fault in wiring harwithout turning starting switch ON. 2 z a Prepare with starting switch OFF. then carry out troubleshooting without turning starting switch ON. 100 kz PC200. then carry out troubleshooting without turning starting switch ON. carry out troubleshooting of them. Cause Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF. 2 injector – engine wiring harness – engine controller may be defective. 7 Defective engine controller 50 CE01 (female) Resistance Between (54) – (51) Max. or breakage of seal • Corrosion. • Engine output lowers. 2 z Between (1) – chassis ground Min. 2 z Between (54) – chassis ground Min. 100 kz Wiring harness between CE01 (female) (51) – each of CE01 (female) pins (With all wiring harness connectors disconnected) Resistance Min.

40 Troubleshooting SEN00240-03 Circuit diagram related to No. 2 injector PC200. 220-8 51 .

2 z – INJ CYL 4 (1) tance Possible causes and standard value in normal state a Prepare with starting switch OFF. • Looseness of connector. then carry out troubleshooting without turning starting switch ON.SEN00240-03 40 Troubleshooting Failure code [CA332] Inj #4 Open/Short Error User code Failure code E11 CA332 Contents of trouble Action of controller Trouble 1 Injector #4 open/short circuit error (Engine controller system) • Opening or short circuit was detected in drive circuit of No. 4 injector – engine wiring harness – engine controller may be defective. 2 z Between (1) – chassis ground Min. then carry out troubleshooting without turning starting switch ON. Check them directly. Problem that appears on machine • Combustion becomes irregular or engine hunts. 7 Defective engine controller 52 CE01 (female) Resistance Between (56) – (58) Max. • Engine output lowers. then carry out troubleshooting without turning starting switch ON. carry out troubleshooting of them. Related information • Method of reproducing failure code: Start engine. breakage of lock.– INJ CYL 4 (1) nector) Wiring harness between CE01 (female) (58) – INJ CYL 4 (2) Resistance Max. then carry out troubleshooting without turning starting switch ON. 220-8 . or expansion of pin • Moisture or dirt in connector or defective insulation 6 Defective other cylinder injectors or wiring harness If the failure codes of other injectors are displayed. then carry out troubleshooting Ground fault in wiring harwithout turning starting switch ON. 1 Defective No. Disconnection in wiring harness (Disconnection in wiring Wiring harness between CE01 (female) (56) 2 or defective contact in con. 3 ness (Short circuit with GND Wiring harness between CE01 (female) (56) Resiscircuit) Max. a Prepare with starting switch OFF. 4 injector INJ CYL 4 Resistance Between (1) – (2) Max. 100 kz a Prepare with starting switch OFF. breakage. 100 kz PC200. 2 z Resistance Max. Wiring harness between CE01 (female) (56) Short circuit in wiring harness – each of CE01 (female) pins (With all wiring 4 (with another wiring harness) harness connectors disconnected) Resistance Min. 4 injector. too. or breakage of seal • Corrosion. bend. 100 kz Wiring harness between CE01 (female) (58) – each of CE01 (female) pins (With all wiring harness connectors disconnected) Resistance Min. 2 z Between (56) – chassis ground Min. 2 z a Prepare with starting switch OFF. push-in. Cause Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF. 100 kz 5 Defective wiring harness connector Connecting parts between No. • None in particular.

220-8 53 . 4 injector PC200.40 Troubleshooting SEN00240-03 Circuit diagram related to No.

220(LC)-8 Hydraulic excavator Form No. SEN00240-03 © 2007 KOMATSU All Rights Reserved Printed in Japan 04-07 (01) 54 .SEN00240-03 PC200.

.................................................................. 12 Failure code [CA435] Eng Oil Press Sw Error ........ 18 Failure code [CA449] Rail Press Very High Error .................................................................................. 15 Failure code [CA442] Battery Voltage High Error.......... 4 Failure code [CA352] Sens Supply 1 Volt Low Error...................................... 14 Failure code [CA441] Battery Voltage Low Error .................................................... 3 Failure code [CA342] Calibration Code Incompatibility ..................................................................................................................................................... 26 PC200.......................................................................... 220-8 1 ..................................................................................... 10 Failure code [CA429] Water in Fuel Sensor Low Error ............................................... 8 Failure code [CA428] Water in Fuel Sensor High Error ......................................................... 6 Failure code [CA386] Sens Supply 1 Volt High Error......................... 22 Failure code [CA452] Rail Press Sensor Low Error ................................................................................................................................................................................ 24 Failure code [CA488] Chg Air Temp High Torque Derate .......SEN00241-01 HYDRAULIC EXCAVATOR 1SHOP MANUAL PC200-8 PC200LC-8 PC220-8 PC220LC-8 Machine model Serial number PC200-8 PC200LC-8 PC220-8 PC220LC-8 300001 and up 300001 and up 70001 and up 70001 and up 40 Troubleshooting 1 Troubleshooting by failure code (Display of code)................... 20 Failure code [CA451] Rail Press Sensor High Error ................................................... Part 2 .................... Part 2 Troubleshooting by failure code (Display of code)............................................................................. 3 Failure code [CA351] Injectors Drive Circuit Error ..............

.................................................................................................................................... 51 Failure code [DA25KP] 5V Sensor 1 Power Abnormality................................... 36 Failure code [CA2185] Throt Sens Sup Volt High Error .. 48 Failure code [D862KA] GPS Antenna Discon .. 30 Failure code [CA757] All Continuous Data Lost Error ........ 28 Failure code [CA731] Eng Bkup Speed Sens Phase Error ..........................SEN00241-01 40 Troubleshooting Failure code [CA553] Rail Press High Error..................................................................................................................................................... 220-8 ........ 50 Failure code [DA22KK] Pump Solenoid Power Low Error........................................ 46 Failure code [D19JKZ] Personal Code Relay Abnormality..................................................... 39 Failure code [CA2249] Rail Press Very Low Error .......................................................................... 53 Failure code [DA29KQ] Model Selection Abnormality.................................. 27 Failure code [CA689] Eng Ne Speed Sensor Error ................................ 32 Failure code [CA778] Eng Bkup Speed Sensor Error ...................................... 60 2 PC200.................................................................................................................................................................................................................. 38 Failure code [CA2186] Throt Sens Sup Volt Low Error .............. 40 Failure code [CA2311] IMV Solenoid Error .................................................................................................... 44 Failure code [CA2556] Grid Htr Relay Volt Low Error ........................................................................................................................................................................... 26 Failure code [CA559] Rail Press Low Error.............................................. 42 Failure code [CA2555] Grid Htr Relay Volt High Error ....................................................................... 34 Failure code [CA1633] KOMNET Datalink Timeout Error ...................................................................................

(Troubleshooting cannot be carried out. • Engine stops or does not start. Part 2 1 Failure code [CA342] Calibration Code Incompatibility 1 User code Failure code E10 CA342 Contents of trouble Action of controller Trouble Calibration code incompatibility (Engine controller system) • Incompatibility of data occurred in engine controller.40 Troubleshooting SEN00241-01 Troubleshooting by failure code (Display of code). Possible causes and standard value in normal state PC200. Related information • Method of reproducing failure code: Turn starting switch ON.) 3 . 2 Defective engine controller Engine controller may be defective. 220-8 Cause Standard value in normal state/Remarks on troubleshooting 1 Defect in related system If another failure code is displayed. • None in particular. Problem that appears on machine • Continues normal operation. carry out troubleshooting for it.

10 z If causes 1 – 4 are not detected. • Limits output and continues operation. then carry out troubleshooting without turning starting switch ON. circuit probably has ground fault.5 z Wiring harness between R23. Cause If another failure code is displayed. Engine cannot be started. engine controller may be defective. R24 (female) (3) Resistance Max. R24 (female) (5) – CE03 (female) (3) Resistance Max. (Since trouble is in system. Engine output lowers. 19 If fuse is broken. 0.5 z Wiring harness between CE03 (female) (1) – chassis ground (T12) Resistance Max. If "E" of failure code goes off at this time. Problem that appears on machine • • • • Related information • Method of reproducing failure code: Start engine. R24) for engine controller with another relay and perform reproducing operation.) PC200. 2 Defective fuse No.SEN00241-01 40 Troubleshooting Failure code [CA351] Injectors Drive Circuit Error User code Failure code E10 CA351 Contents of trouble Action of controller Trouble Injectors Drive Circuit Error (Engine controller system) • There is error in drive power circuit of injector. Defective relay for engine controller power supply a Prepare with starting switch OFF. Disconnection in wiring harness (Disconnection in wiring 4 or defective contact in connector) 5 Defective engine controller 4 Standard value in normal state/Remarks on troubleshooting 1 Defect in related system 3 Possible causes and standard value in normal state 1 Wiring harness between F01-19 – R23. carry out troubleshooting for it. Exhaust gas becomes black. Combustion becomes irregular. troubleshooting cannot be carried out. replaced relay is defective. a Prepare with starting switch OFF. Replace relay (R23. then turn starting switch ON and carry out troubleshooting. 0. 220-8 .

220-8 5 .40 Troubleshooting SEN00241-01 Circuit diagram related to engine controller PC200.

troubleshooting cannot be carried out.SEN00241-01 40 Troubleshooting Failure code [CA352] Sens Supply 1 Volt Low Error User code Failure code E15 CA352 Contents of trouble Action of controller Trouble 1 Sensor power supply 1 voltage low error (Engine controller system) • Low voltage was detected in sensor power supply 1 circuit. breakage. • Looseness of connector. that sensor or wiring harness is defective. or breakage of seal • Corrosion. If "E" of failure code goes off when sensor or wiring harness is disconnected. Defective sensor or wiring 1 harness Possible causes and standard value in normal state Ambient pressure sensor AMBAIR PRESURE Engine wiring harness CE01 Defective wiring harness connector Connecting parts between ambient pressure sensor – engine wiring harness – engine controller may be defective. Cause Standard value in normal state/Remarks on troubleshooting a Disconnect connector with starting switch OFF. bend. engine controller may be defective. breakage of lock. or expansion of pin • Moisture or dirt in connector or defective insulation 3 Defective engine controller If causes 1 – 2 are not detected. Check them directly.) 2 6 Disconnect sensor and wiring harness at right in order and carry out operation to reproduce trouble. PC200. 220-8 . then turn starting switch ON and carry out troubleshooting. (Since trouble is in system. • Engine output lowers. push-in. • Fixes ambient pressure value and continues operation. Problem that appears on machine • Engine does not start easily. Related information • Method of reproducing failure code: Turn starting switch ON.

40 Troubleshooting SEN00241-01 Circuit diagram related to sensor power supply 1 PC200. 220-8 7 .

or breakage of seal • Corrosion.SEN00241-01 40 Troubleshooting Failure code [CA386] Sens Supply 1 Volt High Error User code Failure code E15 CA386 Contents of trouble Action of controller Trouble Sensor power supply 1 voltage high error (Engine controller system) • High voltage was detected in sensor power supply 1 circuit.) 1 Circuit diagram related to sensor power supply 1 8 PC200. breakage. push-in. engine controller may be defective. (Since trouble is in system. • Fixes ambient pressure value and continues operation. • Looseness of connector. Related information • Method of reproducing failure code: Turn starting switch ON. 220-8 . breakage of lock. • Engine output lowers. Check them directly. Possible causes and standard value in normal state 1 Cause Standard value in normal state/Remarks on troubleshooting Defective wiring harness connector Connecting parts between ambient pressure sensor – engine wiring harness – engine controller may be defective. or expansion of pin • Moisture or dirt in connector or defective insulation 2 Defective engine controller If cause 1 is not detected. Problem that appears on machine • Engine does not start easily. troubleshooting cannot be carried out. bend.

(Code: 18800 Condition of WIF sensor) • Method of reproducing failure code: Turn starting switch ON. breakage of lock. • None in particular. CE01 (female) Resistance Between (14) – (47) Max. or breakage of seal • Corrosion. bend. 220-8 . Cause 1 Defective water-in-fuel sensor Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF. 10 z a Prepare with starting switch OFF. • Looseness of connector. then carry out troubleshooting without turning starting switch ON. breakage. then carry out troubleshooting without turning starting switch ON. P47 (female) Resistance Between (1) – (2) Max. or expansion of pin • Moisture or dirt in connector or defective insulation a Prepare with starting switch OFF. push-in.SEN00241-01 40 Troubleshooting Failure code [CA428] Water in Fuel Sensor High Error User code Failure code E15 CA428 Contents of trouble Action of controller Trouble 1 Water-in-fuel sensor high error (Engine controller system) • High voltage was detected in signal circuit of water-in-fuel sensor. Problem that appears on machine • Water separator monitor does not display normally. Check them directly. 10 z Resistance Max.– P47 (male) (1) nector) Wiring harness between CE01 (female) (47) – JC02 – P47 (male) (2) Short circuit in wiring har3 ness (with another wiring harness) 4 Defective wiring harness connector 5 Defective engine controller 10 Resistance Max. 10 z PC200. then carry out troubleshooting without turning starting switch ON. then carry out troubleshooting without turning starting switch ON. Wiring harness between CE01 (female) (14) – each of CE01 (female) pins (With all wiring harness connectors disconnected) Resistance Min. Possible causes and standard value in normal state Disconnection in wiring harness (Disconnection in wiring Wiring harness between CE01 (female) (14) 2 or defective contact in con. 100 kz Connecting parts between water-in-fuel sensor – engine wiring harness – engine controller may be defective. Related information • Condition water-in-fuel sensor signal can be checked with monitoring function. 10 z a Prepare with starting switch OFF.

40 Troubleshooting SEN00241-01 Circuit diagram related to water-in-fuel sensor PC200. 220-8 11 .

bend. 10 z Between (14) – chassis ground Min. 10 z Between (1) – chassis ground Min. breakage. Check them directly.SEN00241-01 40 Troubleshooting Failure code [CA429] Water in Fuel Sensor Low Error User code Failure code E15 CA429 Contents of trouble Action of controller Trouble 1 Water-in-fuel sensor low error (Engine controller system) • Low voltage was detected in signal circuit of water-in-fuel sensor. then carry out troubleshooting without turning starting switch ON. 100 circuit) – P47 (male) (1) tance kz Possible causes and standard value in normal state Short circuit in wiring har3 ness (with another wiring harness) 4 Defective wiring harness connector a Prepare with starting switch OFF. then carry out troubleshooting without turning starting switch ON. Related information • Condition water-in-fuel sensor signal can be checked with monitoring function. 1 Defective water-in-fuel sensor P47 (female) Resistance Between (1) – (2) Max. (Code: 18800 Condition of WIF sensor) • Method of reproducing failure code: Turn starting switch ON. or breakage of seal • Corrosion. then carry out troubleshooting Ground fault in wiring harwithout turning starting switch ON. • Looseness of connector. breakage of lock. 100 kz Connecting parts between water-in-fuel sensor – engine wiring harness – engine controller may be defective. 220-8 . Problem that appears on machine • Water separator monitor does not display normally. 100 kz a Prepare with starting switch OFF. 100 kz PC200. push-in. 2 ness (Short circuit with GND Wiring harness between CE01 (female) (14) ResisMin. Wiring harness between CE01 (female) (14) – each of CE01 (female) pins (With all wiring harness connectors disconnected) Resistance Min. then carry out troubleshooting without turning starting switch ON. Cause Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF. 5 Defective engine controller 12 CE01 (female) Resistance Between (14) – (47) Max. or expansion of pin • Moisture or dirt in connector or defective insulation a Prepare with starting switch OFF. • None in particular.

220-8 13 .40 Troubleshooting SEN00241-01 Circuit diagram related to water-in-fuel sensor PC200.

100 kz Connecting parts between engine oil pressure switch – engine wiring harness – engine controller may be defective.a Prepare with starting switch OFF. breakage of lock. 220-8 . push-in. Problem that appears on machine • Engine protection function based on engine oil pressure does not work. breakage. then carry out troubleshooting without turning starting switch ON. ness (Disconnection in wiring 2 or defective contact in con. • Engine oil pressure monitor does not display normally Related information • Method of reproducing failure code: Turn starting switch ON or start engine. • None in particular.SEN00241-01 40 Troubleshooting Failure code [CA435] Eng Oil Press Sw Error User code Failure code E15 CA435 Contents of trouble Action of controller Trouble 1 Engine oil pressure switch error (Engine controller system) • There is error in signal circuit of engine oil pressure switch. • Looseness of connector. 10 z Disconnection in wiring har. then carry out troubleshooting without turning starting switch ON. or breakage of seal • Corrosion.Wiring harness between CE01 (female) (17) ResisMax. bend. Check them directly. CE01 (female) Resistance Between (17) – chassis ground Max. 10 z nector) – OIL PRESSURE SWITCH (male) (1) tance Possible causes and standard value in normal state Short circuit in wiring har3 ness (with another wiring harness) 4 Defective wiring harness connector 5 Defective engine controller a Prepare with starting switch OFF. Defective engine oil pressure 1 switch OIL PRESSURE SWITCH (male) Between (1) – chassis ground Resistance Max. then carry out troubleshooting without turning starting switch ON. Cause Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF. 10 z Circuit diagram related to engine oil pressure switch 14 PC200. or expansion of pin • Moisture or dirt in connector or defective insulation a Prepare with starting switch OFF. Wiring harness between CE01 (female) (17) – each of CE01 (female) pins (With all wiring harness connectors disconnected) Resistance Min. then carry out troubleshooting without turning starting switch ON.

10 z Wiring harness between CE03 (female) (1) – chassis ground (T12) Resistance Max. • None in particular. a Prepare with starting switch OFF. 10 z Wiring harness between R23. then carry out troubleshooting without turning starting switch ON. 100 kz Resistance Max. Cause 1 Looseness or corrosion of battery terminal Standard value in normal state/Remarks on troubleshooting Battery terminal may be loosened or corroded.40 Troubleshooting SEN00241-01 Failure code [CA441] Battery Voltage Low Error User code Failure code E10 CA441 Contents of trouble Action of controller Trouble 1 Battery voltage low error (Engine controller system) • There is low voltage in controller power supply circuit. 10 z a Prepare with starting switch OFF. R24 (female) (3) Resistance Max. R24 (female) (5) – CE03 (female) (3) Resistance Min. R24 6 ness (Short circuit with GND (female) (3) circuit) Wiring harness between R23. 12 V START Min. 220-8 Wiring harness between CE03 (female) (3) – CE03 (female) (1) pin (with battery terminal disconnected) Resistance Min. then carry out troubleshooting without turning starting switch ON. 100 kz Wiring harness between CE03 (female) (3) – each of CE02 (female) pins (With battery terminal disconnected) Resistance Min. 100 kz 15 . 2 Low battery voltage 3 Defective fuse No. Check it directly. then keep starting switch OFF and start engine and carry out troubleshooting in each case. If "E" of failure code goes off at this time.2 V If fuse is broken. Ground fault in wiring harWiring harness between F01-19 – R23. 19 4 Defective relay for engine controller power supply Battery (1 piece) Starting switch Voltage Between (+) – (–) terminals OFF Min. Problem that appears on machine • Engine stops. circuit probably has ground fault. 10 z a Prepare with starting switch OFF. (See Cause 6) a Prepare with starting switch OFF. 6. • Engine does not start easily. R24 (female) (5) – CE03 (female) (3) Resistance Max. Possible causes and standard value in normal state Disconnection in wiring harness (Disconnection in wiring 5 or defective contact in connector) Wiring harness between F01-19 – R23. replaced relay is defective. Replace relay (R23. 100 kz Wiring harness between CE03 (female) (1) – each of CE02 (female) pins (With battery terminal disconnected) Resistance Min. Short circuit in wiring har7 ness (with another wiring harness) PC200. then carry out troubleshooting without turning starting switch ON. Related information • Method of reproducing failure code: Turn starting switch ON. then turn starting switch ON and carry out troubleshooting. R24) for engine controller with another relay and perform reproducing operation. a Prepare with starting switch OFF.

bend. breakage of lock. or breakage of seal • Corrosion. or expansion of pin • Moisture or dirt in connector or defective insulation a Prepare with starting switch OFF. then turn starting switch ON and start engine and carry out troubleshooting in each case. 19 – machine wiring harness – engine controller may be defective. push-in.SEN00241-01 40 Troubleshooting 8 Possible causes and standard value in normal state Cause Standard value in normal state/Remarks on troubleshooting Defective wiring harness connector Connecting parts between fuse No. 12 V PC200. Check them directly. breakage. 220-8 . 9 Defective engine controller CE03 (female) Between (3) – (1) 16 Starting switch Voltage ON Min. 24 V START Min. • Looseness of connector.

220-8 17 .40 Troubleshooting SEN00241-01 Circuit diagram related to engine controller power supply PC200.

32 V a Prepare with starting switch OFF. Battery Voltage Between (+) – (–) terminals Max. 32 V PC200. then carry out troubleshooting without turning starting switch ON. Related information • Method of reproducing failure code: Turn starting switch ON. 220-8 . Cause 1 Defective battery voltage Possible causes and standard value in normal state Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF. then turn starting switch ON and carry out troubleshooting. Action of controller • None in particular.5 V a Prepare with starting switch OFF. then start engine and carry out troubleshooting.SEN00241-01 40 Troubleshooting Failure code [CA442] Battery Voltage High Error User code Failure code E10 CA442 Contents of trouble Trouble Battery voltage high error (Engine controller system) • There is high voltage (36 V or higher) in controller power supply circuit. 2 Defective alternator 3 Defective engine controller 18 1 E12 (male) Engine speed Voltage Between (1) – chassis ground Medium or higher 27. Problem that appears on machine • Engine may stop. CE03 (female) Voltage Between (3) – (1) Max.5 – 29.

220-8 19 .40 Troubleshooting SEN00241-01 Circuit diagram related to engine controller power supply PC200.

Leakage through pressure limiter During low idle 0 cc (No leakage) If causes 1 – 5 are not detected. Cause Standard value in normal state/Remarks on troubleshooting 1 Defect in related system If another failure code is displayed. 220-8 . carry out troubleshooting for it. Checking fuel return rate and leakage. 0. 2 Air in low pressure circuit There may be air in low pressure circuit. 4 Defective common rail pressure sensor 5 Defective pressure limiter 6 Defective supply pump 20 1 Monitoring code (Machine monitor) 36400 Common rail pressure Monitoring information While engine is stopped 0 ± 0. Checking fuel pressure.02 MPa {Max. Problem that appears on machine • Engine sound becomes large when no or light load is applied. 0. Fuel return circuit pressure Low idle running or cranking Max. Check it directly according to the following procedure.39 MPa {0 ± 4 kg/cm2} a For check of leakage through pressure limiter. Defect in fuel return circuit 3 parts Possible causes and standard value in normal state a For check of fuel return circuit pressure. PC200. (Code: 36400 Common rail pressure) • Method of reproducing failure code: Start engine. supply pump may be defective.SEN00241-01 40 Troubleshooting Failure code [CA449] Rail Press Very High Error User code Failure code E11 CA449 Contents of trouble Action of controller Trouble Common rail pressure very high error (Engine controller system) • There is high pressure error in common rail circuit. 3) Check pressure pickup plug for leakage of fuel and air. Related information • Common rail pressure can be checked with monitoring function. • Engine output lowers. see Testing and adjusting. 2) Operate feed pump of fuel pre-filter. 1) Remove pressure pickup plug (outlet side) of fuel main filter. see Testing and adjusting. then keep starting switch ON and carry out troubleshooting in each case. • Limits output and continues operation.19 kg/cm2} a Prepare with starting switch ON.

push-in. Accordingly. 3 5V/24V circuit) in wiring harWiring harness between CE01 (female) (25) ness Voltage Max. CE01 Between (37) – (47) 22 Resistance Voltage Power supply 4. (Code: 36401 Common rail pressure sensor voltage) • Method of reproducing failure code: Turn starting switch ON. then turn starting switch ON Hot short (Short circuit with and carry out troubleshooting. Problem that appears on machine • Engine does not start. bend. or expansion of pin • Moisture or dirt in connector or defective insulation a Prepare with starting switch OFF. Check them directly. check wiring harness and controller. 220-8 . then turn starting switch ON and carry out troubleshooting. breakage of lock. Wiring harness between CE01 (female) (25) – FUEL RAIL PRESS (female) (2) and between CE01 (female) (37) – JC01 – FUEL RAIL PRESS (female) (3) Min.75 – 5. breakage.25 V Voltage is measured with wiring harness connected. carry out troubleshooting 1 ply 2 system for it first. • Looseness of connector. and then judge. 100 kz Connecting parts between common rail pressure sensor – engine wiring harness – engine controller may be defective. or breakage of seal • Corrosion. 1 V – FUEL RAIL PRESS (female) (2) Short circuit in wiring har4 ness (with another wiring harness) 5 Defective wiring harness connector 6 Defective engine controller a Prepare with starting switch OFF.SEN00241-01 40 Troubleshooting Failure code [CA451] Rail Press Sensor High Error User code Failure code E11 CA451 Contents of trouble Action of controller Trouble 1 Common rail pressure sensor high error (Engine controller system) • There is high voltage in signal circuit of common rail pressure sensor.25 V PC200. Related information • Signal voltage of common rail pressure sensor can be checked with monitoring function. for another cause of trouble. if voltage is abnormal. • Limits output and continues operation. Defective common rail pres2 sure sensor FUEL RAIL PRESS Between (3) – (1) Power supply Voltage 4. then carry out troubleshooting without turning starting switch ON. Cause Standard value in normal state/Remarks on troubleshooting Defective sensor power sup.75 – 5. Possible causes and standard value in normal state a Prepare with starting switch OFF. • Engine speed or output lowers. a Prepare with starting switch OFF. then turn starting switch ON and carry out troubleshooting.If failure code [CA227] is also displayed. too.

220-8 23 .40 Troubleshooting SEN00241-01 Circuit diagram related to common rail pressure sensor PC200.

Wiring harness between CE01 (female) (25) – FUEL RAIL PRESS (female) (2) and between CE01 (female) (47) – JC02 – FUEL RAIL PRESS (female) (1) Min.75 – 5. 220-8 . Check them directly. bend. Accordingly. or breakage of seal • Corrosion. • Engine speed or output lowers. then carry out troubleshooting without turning starting switch ON. Defective common rail pres2 sure sensor FUEL RAIL PRESS Between (3) – (1) Power supply Voltage 4. Cause Standard value in normal state/Remarks on troubleshooting Defective sensor power sup. a Prepare with starting switch OFF. check wiring harness and controller. • Limits output and continues operation. then turn starting switch ON and carry out troubleshooting. • Looseness of connector. Problem that appears on machine • Engine does not start.SEN00241-01 40 Troubleshooting Failure code [CA452] Rail Press Sensor Low Error User code Failure code E11 CA452 Contents of trouble Action of controller Trouble 1 Common rail pressure sensor low error (Engine controller system) • There is low voltage in signal circuit of common rail pressure sensor. 100 kz Connecting parts between common rail pressure sensor – engine wiring harness – engine controller may be defective. Possible causes and standard value in normal state a Prepare with starting switch OFF. then turn starting switch ON and carry out troubleshooting. 100 circuit) – FUEL RAIL PRESS (female) (2) tance kz Short circuit in wiring har4 ness (with another wiring harness) 5 Defective wiring harness connector 6 Defective engine controller a Prepare with starting switch OFF.25 V PC200. breakage.25 V Voltage is measured with wiring harness connected. breakage of lock. for another cause of trouble. Related information • Signal voltage of common rail pressure sensor can be checked with monitoring function. (Code: 36401 Common rail pressure sensor voltage) • Method of reproducing failure code: Turn starting switch ON.If failure code [CA187] is also displayed. too. CE01 Between (37) – (47) 24 Resistance Voltage Power supply 4. then turn starting switch ON Ground fault in wiring harand carry out troubleshooting. if voltage is abnormal. 3 ness (Short circuit with GND Wiring harness between CE01 (female) (25) ResisMin.75 – 5. carry out troubleshooting 1 ply 2 system for it first. and then judge. or expansion of pin • Moisture or dirt in connector or defective insulation a Prepare with starting switch OFF. push-in.

220-8 25 .40 Troubleshooting SEN00241-01 Circuit diagram related to common rail pressure sensor PC200.

Problem that appears on machine • Engine output lowers. troubleshooting cannot be carried out. Check following terminals directly. Related information • Common rail pressure can be checked with monitoring function. machine monitor Problem that appears on machine • Engine sound becomes large when no or light load is applied. • Ground terminal of machine ((–) terminal of battery) • Ground terminal of engine • Ground terminal of engine controller • Ground terminal of starting motor 2 Defective connection of ground terminal 3 Breakage of O-ring of supply O-ring of supply pump actuator may be broken. carry out troubleshooting for it. Check following points directly. Action of • None in particular. (Since trouble is in system. • Insufficiency of cooling air • Clogging of aftercooler fins 2 Abnormal rise of turbocharger outlet temperature Outlet temperature of turbocharger may be abnormally high. • Looseness and breakage of fan belt. (Code: 18500 Boost temperature) • Method of reproducing failure code: Start engine. engine controller may be defective. Cause Possible causes and standard value in normal state Standard value in normal state/Remarks on troubleshooting 1 Lowering of cooling performance of aftercooler Cooling performance of aftercooler may be low. • Engine output lowers. Related information • Boost temperature can be checked with monitoring function. (Code: 36400 Common rail pressure) • Method of reproducing failure code: Start engine. 3 Defective engine controller If causes 1 – 2 are not detected.) Failure code [CA553] Rail Press High Error User code Failure code E15 CA553 Contents of trouble Trouble 1 Common rail pressure high error (Engine controller system) • There is high pressure error in common rail circuit. 220-8 . Ground terminal may be connected defectively.SEN00241-01 40 Troubleshooting Failure code [CA488] Chg Air Temp High Torque Derate User code Failure code E11 CA488 Contents of trouble Action of controller Trouble 1 Charge air temperature high torque derate (Engine controller system) • Temperature signal of boost pressure/temperature sensor exceeded control upper temperature limit. Check related parts directly. • Limits output and continues operation. Cause 1 Defect in related system Possible causes and standard value in normal state 26 Standard value in normal state/Remarks on troubleshooting If another failure code is displayed. pump actuator PC200. Check it directly.

Related information • Common rail pressure can be checked with monitoring function. • None in particular. 90 cc/min. Checking fuel return rate and leakage.1 – 13. (Code: 36400 Common rail pressure) • Method of reproducing failure code: Start engine. Checking fuel return rate and leakage. Checking fuel pressure. • Exhaust gas becomes black.3 kg/cm2} a For check of leakage through pressure limiter. 27 . see Testing and adjusting. 180 cc/min. see Testing and adjusting.3 – 1. Checking fuel return rate and leakage.1 MPa {3. 1. During low idle (if engine can be started) Max. a For check of return rate from supply pump.1 – 11. During low idle (if engine can be started) Max.3 kg/cm2} During low idle (if engine can be started) 0. Defect in low pressure cir2 cuit parts 3 Defective pressure limiter Possible causes and standard value in normal state Pressure in fuel lowpressure circuit During cranking (if engine cannot be started) 0. 220-8 Return rate from supply pump During cranking (if engine cannot be started) Max. a For check of pressure in fuel low pressure circuit. Cause 1 Fuel leakage to outside Standard value in normal state/Remarks on troubleshooting Fuel may be leaking to outside.5 – 1. Problem that appears on machine • Engine does not start at all or does not start easily.40 Troubleshooting SEN00241-01 Failure code [CA559] Rail Press Low Error User code Failure code E15 CA459 Contents of trouble Action of controller Trouble 1 Common rail pressure low error (Engine controller system) • There is low pressure error in common rail circuit. see Testing and adjusting.3 MPa {5. Defective injector (including 4 high pressure piping in head) Return rate from injector During cranking (if engine cannot be started) Max. 5 Defective supply pump PC200.000 cc/min. 140 cc/min. Leakage through pressure limiter During low idle 0 cc (No leakage) a For check of return rate from injector. Check it directly (Check visually while running engine at low idle). see Testing and adjusting. • Engine output lowers.

a Prepare with starting switch OFF. Check it directly. carry out troubleshooting for it first.25 V Voltage is measured with wiring harness connected. Related information • Method of reproducing failure code: Start engine. Breakage or improper clearEngine Ne speed sensor may be broken or may have improper 3 ance of engine Ne speed clearance. then carry out troubleshooting without turning starting switch ON. then turn starting switch ON Hot short (Short circuit with and carry out troubleshooting. • Engine output lowers. 100 kz Wiring harness between CE01 (female) (27) – CRANK SENSOR (female) (3) or between CE01 (female) (48) – CRANK SENSOR (female) (2) Resistance Min. 2 Defective engine Ne speed sensor CRANK SENSOR Between (1) – (2) Power supply Voltage 4. • Continues control with signal from engine Bkup speed sensor.a Prepare with starting switch OFF. check wiring harness and controller. Check it directly. 100 kz PC200. Cause 1 Defective Ne speed sensor power supply system Standard value in normal state/Remarks on troubleshooting If failure code [CA238] is also displayed. then carry out troubleshooting Ground fault in wiring harwithout turning starting switch ON. 1 V – CRANK SENSOR (female) (3) a Prepare with starting switch OFF. • Engine does not start easily. Disconnection in wiring har. then carry out troubleshooting without turning starting switch ON. for another cause of trouble. then turn starting switch ON and carry out troubleshooting. and then judge. Short circuit in wiring har8 ness (with another wiring harness) 28 Wiring harness between CE01 (female) (27) – CRANK SENSOR (female) (3) or between CE01 (female) (16) – CRANK SENSOR (female) (1) Resistance Min. 10 z nector) – CRANK SENSOR (female) (3) tance a Prepare with starting switch OFF. if voltage is abnormal. 6 ness (Short circuit with GND Wiring harness between CE01 (female) (27) ResisMin. ness (Disconnection in wiring 5 or defective contact in con. sensor 4 Possible causes and standard value in normal state Breakage of rotation sensor wheel Rotation sensor wheel may be broken.75 – 5.Wiring harness between CE01 (female) (27) ResisMax. Accordingly. Problem that appears on machine • Engine hunts. 7 5V/24V circuit) in wiring harWiring harness between CE01 (female) (27) ness Voltage Max. 100 circuit) – CRANK SENSOR (female) (3) tance kz a Prepare with starting switch OFF. too.SEN00241-01 40 Troubleshooting Failure code [CA689] Eng Ne Speed Sensor Error User code Failure code E15 CA689 Contents of trouble Action of controller Trouble 1 Engine Ne speed sensor error (Engine controller system) • There is error in signal from engine Ne speed sensor. 220-8 .

push-in. breakage of lock. CE01 Between (16) – (48) Voltage Power supply 4.40 Troubleshooting Possible causes and standard value in normal state 9 SEN00241-01 Cause Standard value in normal state/Remarks on troubleshooting Defective wiring harness connector Connecting parts between engine Ne speed sensor – engine wiring harness – engine controller may be defective.75 – 5. or breakage of seal • Corrosion. breakage. or expansion of pin • Moisture or dirt in connector or defective insulation 10 Defective engine controller a Prepare with starting switch OFF. 220-8 29 .25 V Circuit diagram related to engine Ne speed sensor PC200. then turn starting switch ON and carry out troubleshooting. bend. • Looseness of connector. Check them directly.

rotation sensor ring is installed normally. 3) If 2 grooves (1 crest) of rotation sensor ring are seen through sensor mounting hole. Check following terminals directly. Cause Possible causes and standard value in normal state Standard value in normal state/Remarks on troubleshooting 1 Breakage of engine Ne speed sensor Engine Ne speed sensor may be broken. 1 cylinder at compression top dead center (Match stamped mark). • Exhaust gas becomes black. • Idle speed is unstable. Problem that appears on machine • Engine does not start at all or does not start easily. • Ground terminal of machine ((–) terminal of battery) • Ground terminal of engine • Ground terminal of engine controller • Ground terminal of starting motor PC200. Defective installation or 3 breakage of rotation sensor wheel on crankshaft side Rotation sensor wheel on crankshaft side may be installed defectively or broken. 2 Breakage of engine Bkup speed sensor Engine Bkup speed sensor may be broken. Check it according to the following procedure. Check it according to the following procedure. 2) If center of oblong hole of rotation sensor wheel is at tip of Ne speed sensor. Check it directly. 5 6 30 1 Defective timing of crankshaft and camshaft Timing of crankshaft and camshaft may be defective. Defective installation or 4 breakage of rotation sensor ring on camshaft side Rotation sensor ring on camshaft side may be installed defectively or broken. 1) Set No.SEN00241-01 40 Troubleshooting Failure code [CA731] Eng Bkup Speed Sens Phase Error User code Failure code E15 CA731 Contents of trouble Action of controller Trouble Engine Bkup speed sensor phase error (Engine controller system) • Phase error was detected in signals from engine Ne speed sensor and engine Bkup speed sensor • Continues control with signal from engine Ne speed sensor. rotation sensor wheel is installed normally. 2) Remove Bkup speed sensor. 1 cylinder at compression top dead center (Match stamped mark). Check it directly. Defective connection of ground terminal Ground terminal may be connected defectively. Related information • Method of reproducing failure code: Start engine. 1) Set No. 220-8 . Check it directly.

SEN00241-01 40 Troubleshooting Failure code [CA757] All Continuous Data Lost Error User code Failure code E10 CA757 Contents of trouble Action of controller Trouble 1 All continuous data lost error (Engine controller system) • All data in engine controller are lost. replaced relay is defective. 220-8 . carry out troubleshooting for it. 6. then keep starting switch OFF and start engine and carry out troubleshooting in each case. breakage. Looseness or corrosion of 2 battery terminal Battery terminal may be loosened or corroded. 10 z Wiring harness between R23. a Prepare with starting switch OFF. a Prepare with starting switch OFF. a Prepare with starting switch OFF. • Monitoring function of machine monitor (engine controller system) may not work normally. 3 Low battery voltage 4 Defective fuse No. Replace relay (R23. Check them directly. then turn starting switch ON and carry out troubleshooting. Disconnection in wiring harness (Disconnection in wiring 6 or defective contact in connector) 7 Defective wiring harness connector Wiring harness between F01-19 – R23. push-in. or breakage of seal • Corrosion. 10 z Connecting parts between fuse No. breakage of lock. then carry out troubleshooting without turning starting switch ON. R24 (female) (5) – CE03 (female) (3) Resistance Max. • None in particular. R24 (female) (3) Resistance Max. Cause Standard value in normal state/Remarks on troubleshooting 1 Defect in related system If another failure code is displayed. 24 V START Min. bend. 8 Defective engine controller CE03 (female) Between (3) – (1) 32 Starting switch Voltage ON Min. 12 V PC200. circuit probably has ground fault. If "E" of failure code goes off at this time. or expansion of pin • Moisture or dirt in connector or defective insulation a Prepare with starting switch OFF. R24) for engine controller with another relay and perform reproducing operation. then turn starting switch ON and start engine and carry out troubleshooting in each case. 10 z Wiring harness between CE03 (female) (1) – chassis ground (T12) Resistance Max. 12 V START Min. Problem that appears on machine • Engine may stop and may not be started again. Related information • Method of reproducing failure code: Turn starting switch ON. Check it directly. • Looseness of connector. 19 5 Possible causes and standard value in normal state Defective relay for engine controller power supply Battery (1 piece) Starting switch Voltage Between (+) – (–) terminals OFF Min.2 V If fuse is broken. 19 – machine wiring harness – engine controller may be defective.

40 Troubleshooting SEN00241-01 Circuit diagram related to engine controller power supply PC200. 220-8 33 .

and then judge. Short circuit in wiring har8 ness (with another wiring harness) 34 Wiring harness between CE01 (female) (26) – JC03 – CAM SENSOR (female) (3) or between CE01 (female) (37) – JC01 – CAM SENSOR (female) (1) Resistance Min.If failure code [CA187] is also displayed. 100 circuit) – JC03 – CAM SENSOR (female) (3) tance kz a Prepare with starting switch OFF. ness (Disconnection in wiring 5 or defective contact in con. Disconnection in wiring har. sensor 4 Possible causes and standard value in normal state Breakage of rotation sensor ring Rotation sensor ring may be broken. if voltage is abnormal. 7 5V/24V circuit) in wiring harWiring harness between CE01 (female) (26) ness Voltage Max. a Prepare with starting switch OFF. 100 kz Wiring harness between CE01 (female) (26) – JC03 – CAM SENSOR (female) (3) or between CE01 (female) (47) – JC02 – CAM SENSOR (female) (2) Resistance Min. then carry out troubleshooting Ground fault in wiring harwithout turning starting switch ON.Wiring harness between CE01 (female) (26) ResisMax. then carry out troubleshooting without turning starting switch ON. 6 ness (Short circuit with GND Wiring harness between CE01 (female) (26) ResisMin. Check it directly. 2 Defective engine Bkup speed sensor CAM SENSOR Between (1) – (2) Power supply Voltage 4. 100 kz PC200.SEN00241-01 40 Troubleshooting Failure code [CA778] Eng Bkup Speed Sensor Error User code Failure code E15 CA778 Contents of trouble Action of controller Trouble 1 Engine Bkup speed sensor error (Engine controller system) • There is error in signal from engine Bkup speed sensor. Accordingly.a Prepare with starting switch OFF. for another cause of trouble.25 V Voltage is measured with wiring harness connected. too. then turn starting switch ON Hot short (Short circuit with and carry out troubleshooting. Breakage or improper clearEngine Bkup speed sensor may be broken or may have improper 3 ance of engine Bkup speed clearance.75 – 5. then carry out troubleshooting without turning starting switch ON. Problem that appears on machine • Engine does not start easily. Check it directly. 10 z nector) – JC03 – CAM SENSOR (female) (3) tance a Prepare with starting switch OFF. 1 V – JC03 – CAM SENSOR (female) (3) a Prepare with starting switch OFF. carry out troubleshooting ply 2 system for it first. then turn starting switch ON and carry out troubleshooting. check wiring harness and controller. 220-8 . Related information • Method of reproducing failure code: Start engine. Cause 1 Standard value in normal state/Remarks on troubleshooting Defective sensor power sup. • Continues control with signal from engine Ne speed sensor. • Engine output lowers.

75 – 5. or breakage of seal • Corrosion.40 Troubleshooting Possible causes and standard value in normal state 9 SEN00241-01 Cause Standard value in normal state/Remarks on troubleshooting Defective wiring harness connector Connecting parts between engine Bkup speed sensor – engine wiring harness – engine controller may be defective. then turn starting switch ON and carry out troubleshooting. CE01 Between (37) – (47) Voltage Power supply 4. breakage. 220-8 35 . bend. breakage of lock. push-in. • Looseness of connector.25 V Circuit diagram related to engine Bkup speed sensor PC200. Check them directly. or expansion of pin • Moisture or dirt in connector or defective insulation 10 Defective engine controller a Prepare with starting switch OFF.

– K02 (female) (B). – CE02 (female) 3 24V circuit) in wiring harness (46). (9) – C01 (female) (45). 5.5 V Wiring harness between CM02 (female) (10) – C01 (female) (64). K02 (male) Resistance Between (A) – (B) 120 ± 12 z If causes 1 – 4 are not detected. – K02 (female) (A). (Since trouble is in system. Cause Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF.) PC200.5 V Defective CAN terminal 4 resistance (Internal short circuit or disconnection) 5 Defective pump controller 36 Resistance a Prepare with starting switch OFF. 1 z a Prepare with starting switch OFF. Possible causes and standard value in normal state Wiring harness between CM02 (female) (8). – K02 (female) (B). troubleshooting cannot be carried out. – CE02 (female) (47). – N08 (male) (10) Min. 1 Mz Resistance Min. then carry out troubleshooting without turning starting switch ON. 220-8 .) Related information • Method of reproducing failure code: Turn starting switch ON. – CE02 (female) (47). • Continues operation in default mode. then carry out troubleshooting without turning starting switch ON. – CE02 (female) (47). Ground fault in wiring har(9) – C01 (female) (45). (Trouble phenomenon depends on failed section. Problem that appears on machine • Information may not transmitted normally by KOMNET communication and machine may not operate normally. Wiring harness between CM02 (female) (8). system resets itself. then turn starting switch ON and carry out troubleshooting. – N08 (male) (10) Voltage Max. – CE02 (female) 2 ness (Short circuit with GND (46).SEN00241-01 40 Troubleshooting Failure code [CA1633] KOMNET Datalink Timeout Error User code E0E Contents of trouble Action of controller Failure code CA1633 Trouble 1 KOMNET Datalink timeout error (Engine controller system) • Engine controller detected communication error in KOMNET communication circuit between pump controller and machine monitor. 1 z Wiring harness between CM02 (female) (10) – C01 (female) (64). then carry out troubleshooting without turning starting switch ON. – CE02 (female) (46). – K02 (female) (A) Resistance Max. – K02 (female) (A). • If cause of failure disappears. 1 Mz a Prepare with starting switch OFF. Disconnection in wiring harness (Disconnection in wiring 1 or defective contact in connector) Wiring harness between CM02 (female) (8). Hot short (Short circuit with (9) – C01 (female) (45). engine controller may be defective. 5. – K02 (female) (B) Resistance Max. – N08 (male) (3) Voltage Max. – N08 (male) (3) circuit) Wiring harness between CM02 (female) (10) – C01 (female) (64).

40 Troubleshooting SEN00241-01 Circuit diagram related to CAN communication PC200. 220-8 37 .

(Since trouble is in system. 220-8 . bend. • If starting switch is turned ON while voltage is abnormally high. or expansion of pin • Moisture or dirt in connector or defective insulation If causes 1 – 2 are not detected.25 V or higher) was detected in throttle sensor power supply circuit. or breakage of seal • Corrosion. Related information • Method of reproducing failure code: Turn starting switch ON. • If trouble occurs while starting switch is in ON position. push-in. Check them directly. • Looseness of connector. Cause Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF. engine controller may be defective. controller continues operation with voltage at 100% value. Possible causes and standard value in normal state Short circuit in wiring har1 ness (with another wiring harness) 2 Defective wiring harness connector 3 Defective engine controller Wiring harness between CE02 (female) (22) – each of CE02 (female) pins (With P20 disconnected) Resistance Min. breakage. troubleshooting cannot be carried out.SEN00241-01 40 Troubleshooting Failure code [CA2185] Throt Sens Sup Volt High Error User code Failure code E14 CA2185 Contents of trouble Action of controller Trouble 1 Throttle sensor supply voltage high error (Engine controller system) • High voltage (5.) Circuit diagram related to fuel control dial 38 PC200. controller fixes voltage value to level just before detection of trouble and continues operation. breakage of lock. Problem that appears on machine • Engine speed cannot be controlled with fuel control dial. then carry out troubleshooting without turning starting switch ON. 100 kz Connecting parts between fuel control dial – machine wiring harness – engine controller may be defective. 100 kz Wiring harness between CE02 (female) (22) – CE03 (female) (3) (With P20 disconnected) Resistance Min.

then carry out troubleshooting Ground fault in wiring harwithout turning starting switch ON. (Since trouble is in system. • Looseness of connector. 1 ness (Short circuit with GND Wiring harness between CE02 (female) (22) ResisMin.) Circuit diagram related to fuel control dial PC200. then carry out troubleshooting without turning starting switch ON. Cause Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF. or expansion of pin • Moisture or dirt in connector or defective insulation If causes 1 – 3 are not detected. troubleshooting cannot be carried out. Related information • Method of reproducing failure code: Turn starting switch ON. Check them directly. engine controller may be defective. • If trouble occurs while starting switch is in ON position. push-in. 100 circuit) – P20 (female) (1) tance kz Possible causes and standard value in normal state Short circuit in wiring har2 ness (with another wiring harness) 3 Defective wiring harness connector 4 Defective engine controller a Prepare with starting switch OFF. 100 kz Connecting parts between fuel control dial – machine wiring harness – engine controller may be defective. bend. controller continues operation with voltage at 100% value. or breakage of seal • Corrosion.40 Troubleshooting SEN00241-01 Failure code [CA2186] Throt Sens Sup Volt Low Error User code Failure code E14 CA2186 Contents of trouble Action of controller Trouble 1 Throttle sensor supply voltage low error (Engine controller system) • Low voltage was detected in throttle sensor power supply circuit. Problem that appears on machine • Engine speed cannot be controlled with fuel control dial. breakage. Wiring harness between CE02 (female) (9) – each of CE02 (female) pins (With P20 disconnected) Resistance Min. breakage of lock. 220-8 39 . controller fixes voltage value to level just before detection of trouble and continues operation. • If starting switch is turned ON while voltage is abnormally high.

SEN00241-01 40 Troubleshooting Failure code [CA2249] Rail Press Very Low Error User code Failure code E11 CA2249 Contents of trouble Action of controller Trouble Common rail pressure very low error (Engine controller system) • There is low pressure error in common rail circuit. (Code: 36400 Common rail pressure) • Method of reproducing failure code: Start engine. • Exhaust gas becomes black. Related information • Common rail pressure can be checked with monitoring function. 220-8 . Possible causes and standard value in normal state 40 1 Cause Standard value in normal state/Remarks on troubleshooting 1 Carry out troubleshooting for failure code [CA559]. PC200. Problem that appears on machine • Engine does not start easily. • Limits output and continues operation. • Engine output lowers.

5 z Min. then carry out troubleshooting without turning starting switch ON. 5 z Resistance Max. • Looseness of connector. Possible causes and standard value in normal state Disconnection in wiring harness (Disconnection in wiring Wiring harness between CE01 (female) (2) – 3 or defective contact in con. Cause 1 Defect in related system Standard value in normal state/Remarks on troubleshooting If another failure code is displayed. 100 kz a Prepare with starting switch OFF. then carry out troubleshooting without turning starting switch ON. breakage of lock. Check them directly. push-in.CP3 PUMP REGULATOR (male) ator Between (1) – (2) Between (1) – chassis ground Resistance Max. 6 Defective engine controller 42 CE01 (female) Resistance Between (2) – (32) Max. breakage. • None in particular.SEN00241-01 40 Troubleshooting Failure code [CA2311] IMV Solenoid Error User code Failure code E11 CA2311 Contents of trouble Action of controller Trouble 1 IMV solenoid error (Engine controller system) • Resistance of supply pump actuator circuit is abnormally high or low. bend. or breakage of seal • Corrosion. 100 kz PC200. a Prepare with starting switch OFF. then carry out troubleshooting Ground fault in wiring harwithout turning starting switch ON. 2 Defective supply pump actu. 5 z Between (2) – chassis ground Min. 220-8 . 4 ness (Short circuit with GND Wiring harness between CE01 (female) (2) – ResisMin. 100 circuit) CP3 PUMP REGULATOR (female) (1) tance kz 5 Defective wiring harness connector Connecting parts between supply pump actuator – engine wiring harness – engine controller may be defective. 5 z a Prepare with starting switch OFF. carry out troubleshooting for it. or expansion of pin • Moisture or dirt in connector or defective insulation a Prepare with starting switch OFF. Problem that appears on machine • Engine output lowers.CP3 PUMP REGULATOR (female) (1) nector) Wiring harness between CE01 (female) (32) – CP3 PUMP REGULATOR (female) (2) Resistance Max. Related information • Method of reproducing failure code: Start engine. then carry out troubleshooting without turning starting switch ON.

220-8 43 .40 Troubleshooting SEN00241-01 Circuit diagram related to supply pump actuator (metering unit) PC200.

or breakage of seal • Corrosion. then turn starting switch ON nection) and carry out troubleshooting.SEN00241-01 40 Troubleshooting Failure code [CA2555] Grid Htr Relay Volt High Error User code Failure code E15 CA2555 Contents of trouble Action of controller Trouble 1 Grid heater relay volt high error (Engine controller system) • Disconnection was detected in drive circuit of intake air heater relay. Related information • Method of reproducing failure code: Turn starting switch ON when engine coolant temperature is below –4°C. 10 z a Prepare with starting switch OFF. then carry out troubleshooting without turning starting switch ON. bend. 100 kz Connecting parts between automatic preheater relay – machine wiring harness – engine controller may be defective. • Looseness of connector. push-in. breakage of lock. Problem that appears on machine • Intake air heater does not work (Engine does not start easily and exhaust gas becomes white at low temperature). then carry out troubleshooting without turning starting switch ON. 10 z Resistance Max. 220-8 . replaced relay is defective. Possible causes and standard value in normal state Disconnection in wiring harness (Disconnection in wiring Wiring harness between CE02 (female) (40) 2 or defective contact in con. then carry out troubleshooting without turning starting switch ON. breakage.– R18 (female) (1) nector) Wiring harness between CE02 (female) (42) – R18 (female) (2) Short circuit in wiring har3 ness (with another wiring harness) 4 Defective wiring harness connector 5 Defective engine controller 44 Resistance Max. then carry out troubleshooting without turning starting switch ON. a Prepare with starting switch OFF. (Troubleshooting for relay unit) R18 (male) Resistance Defective automatic preBetween (1) – (2) 300 – 600 z 1 heater relay (Internal discona Prepare with starting switch OFF. CE02 (female) Resistance Between (40) – (42) 300 – 600 z PC200. • None in particular. (Troubleshooting by replacement) Replace automatic preheater relay (R18)) with another relay and perform reproducing operation. Check them directly. Cause Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF. If "E" of failure code goes off at this time. Wiring harness between CE02 (female) (40) – each of CE02 (female) pins (With R18 disconnected) Resistance Min. or expansion of pin • Moisture or dirt in connector or defective insulation a Prepare with starting switch OFF.

40 Troubleshooting SEN00241-01 Circuit diagram related to engine preheater/starting motor/charging system PC200. 220-8 45 .

push-in. then carry out troubleshooting without turning starting switch ON. 100 circuit) – R18 (female) (1) tance kz Short circuit in wiring har3 ness (with another wiring harness) 4 Defective wiring harness connector 5 Defective engine controller 46 a Prepare with starting switch OFF. CE02 (female) Resistance Between (40) – (42) 300 – 600 z PC200. Related information • Method of reproducing failure code: Turn starting switch ON when engine coolant temperature is below –4°C. 100 kz Connecting parts between automatic preheater relay – machine wiring harness – engine controller may be defective. Possible causes and standard value in normal state a Prepare with starting switch OFF.SEN00241-01 40 Troubleshooting Failure code [CA2556] Grid Htr Relay Volt Low Error User code Failure code E15 CA2556 Contents of trouble Action of controller Trouble 1 Grid heater relay volt low error (Engine controller system) • Short circuit was detected in drive circuit of intake air heater relay. If "E" of failure code goes off at this time. then carry out troubleshooting Ground fault in wiring harwithout turning starting switch ON. breakage of lock. • Looseness of connector. or expansion of pin • Moisture or dirt in connector or defective insulation a Prepare with starting switch OFF. then carry out troubleshooting without turning starting switch ON. replaced relay is defective. then carry out troubleshooting without turning starting switch ON. Check them directly. 220-8 . • None in particular. or breakage of seal • Corrosion. Cause Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF. bend. then turn starting switch ON nection) and carry out troubleshooting. 2 ness (Short circuit with GND Wiring harness between CE02 (female) (40) ResisMin. (Troubleshooting by replacement) Replace automatic preheater relay (R18)) with another relay and perform reproducing operation. breakage. Problem that appears on machine • Intake air heater does not work (Engine does not start easily and exhaust gas becomes white at low temperature). Wiring harness between CE02 (female) (40) – each of CE02 (female) pins (With R18 disconnected) Resistance Min. (Troubleshooting for relay unit) R18 (male) Resistance Defective automatic preBetween (1) – (2) 300 – 600 z 1 heater relay (Internal discona Prepare with starting switch OFF.

220-8 47 .40 Troubleshooting SEN00241-01 Circuit diagram related to engine preheater/starting motor/charging system PC200.

• Method of reproducing failure code: Turn starting switch ON (Disconnection).SEN00241-01 40 Troubleshooting Failure code [D19JKZ] Personal Code Relay Abnormality User code Failure code E01 D19JKZ Contents of trouble Action of controller Trouble 1 Personal code relay abnormality (KOMTRAX system in machine monitor) • Disconnection or short circuit was detected in personal code relay circuit. 1 Mz If causes 1 – 4 are not detected. 3 Standard value in normal state/Remarks on troubleshooting If fuse is broken. Disconnection in wiring harness (Disconnection in wiring Wiring harness between F01 (3) – R07 3 or defective contact in con. (Troubleshooting for relay unit) R07 (male) Resistance Defective personal code Between (1) – (2) (300 – 600 z) 2 relay (Internal disconnection a Prepare with starting switch OFF. Even if cause of failure disappears. 1 Mz Resistance Min. Trouble cannot be reproduced on machine (Short circuit). Turns output to personal code relay OFF (when short circuit is detected). a Prepare with starting switch OFF. then carry out troubleshooting without turning starting switch ON. machine monitor (KOMTRAX) may be defective. 220-8 . Cause 1 Defective fuse No. Ground fault in wiring harWiring harness between F01 (3) – R07 4 ness (Short circuit with GND (female) (1) circuit) Wiring harness between R07 (female) (2) – CM01 (female) (6) 5 48 Defective machine monitor (KOMTRAX section) Resistance Min. replaced relay is defective. system resets itself (when disconnection is detected).(female) (1) nector) Wiring harness between R07 (female) (2) – CM01 (female) (6) Resistance Max. a Prepare with starting switch OFF. (Since trouble is in system. If cause of failure disappears. system does not reset itself until starting switch is turned OFF (when disconnection is detected). Problem that appears on machine Related information • This failure code is displayed only when engine lock function is effective. 1 z Resistance Max. troubleshooting cannot be carried out. If "E" of failure code goes off at this time. then carry out troubleshooting without turning starting switch ON. 1 z a Prepare with starting switch OFF. then turn starting switch ON or short circuit) and carry out troubleshooting. (Troubleshooting by replacement) Possible causes and standard value in normal state Replace personal code relay (R07)) with another relay and perform reproducing operation.) PC200. then carry out troubleshooting without turning starting switch ON. circuit probably has ground fault (See cause 4). • • • • None in particular (when disconnection is detected).

40 Troubleshooting SEN00241-01 Circuit diagram related to engine preheater/starting motor/charging system PC200. 220-8 49 .

system resets itself. 220-8 . Problem that appears on machine • GPS cannot measure position. disconnection or short circuit in antenna cable. and defective connection of antenna cable connector (GPS). Possible causes and standard value in normal state 1 Cause 1 Defective GPS antenna or antenna cable Standard value in normal state/Remarks on troubleshooting Possible causes are defective GPS antenna. • If cause of failure disappears. • None in particular.SEN00241-01 40 Troubleshooting Failure code [D862KA] GPS Antenna Discon User code Failure code — D862KA Contents of trouble Action of controller Trouble GPS antenna disconnection (KOMTRAX system in machine monitor) • Disconnection was detected in GPS antenna circuit. Configuration drawing 50 PC200. Related information • Method of reproducing failure code: Turn starting switch ON.

circuit probably has ground fault. 1 Mz Resistance Min. – circuit branch end Wiring harness between F04 (male) (1) – R03 Resistance Min. Disconnection in wiring harness (Disconnection in wiring 2 or defective contact in connector) Possible causes and standard value in normal state Wiring harness between C02 (female) (116). detection of failure codes (disconnection/short circuit) of all the solenoid systems is stopped. Wiring harness between C02 (female) (116). (See Cause 3. 220-8 C01 (female). 2 Standard value in normal state/Remarks on troubleshooting If fusible link or fuse is broken. (121) – F01-2 Resistance Max. (118). Problem that appears on machine • Since no solenoid valve is driven normally. Cause Defective fusible link F04 or 1 fuse No. system does not reset itself until starting switch is turned OFF.) a Prepare with starting switch OFF. 1 Mz Resistance Min. 1 Mz a Prepare with starting switch OFF. 1 z a Prepare with starting switch OFF. (121) – C01 (2). • While this failure code is displayed. then carry out troubleshooting without turning starting switch ON. • Even if cause of failure disappears. Ground fault in wiring har(118). then carry out troubleshooting without turning starting switch ON. then turn starting switch ON and carry out troubleshooting. 1 z Wiring harness between F04 (male) (1) – R03 Resistance Max. C02 (female) Voltage Between C02 (116). 4 Defective pump controller PC200. 1 z Wiring harness between F01-1A – F04 (male) (2) Resistance Max. machine does not operate normally.40 Troubleshooting SEN00241-01 Failure code [DA22KK] Pump Solenoid Power Low Error User code Failure code E0E DA22KK Contents of trouble Action of controller Trouble 1 Lowering of solenoid power supply voltage (Pump controller system) • Solenoid power supply voltage of controller is below 20 V. (121) – F01-2 3 ness (Short circuit with GND Wiring harness between F01-1A – F04 circuit) (male) (2). (5) 20 – 30 V 51 . (118). Related information • Method of reproducing failure code: Turn starting switch ON.

220-8 .SEN00241-01 40 Troubleshooting Circuit diagram related to pump controller power supply 52 PC200.

that sensor is defective. 1 Mz Wiring harness between C01 (female) (9) – J06 – P03 (female) (3) [Swing LEFT PPC pressure sensor system] Resistance Min. 1 Mz Wiring harness between C01 (female) (9) – J06 – P06 (female) (3) [Boom RAISE PPC pressure sensor system] Resistance Min. 1 Mz Ground fault in wiring har2 ness (Short circuit with GND Wiring harness between C01 (female) (9) – J06 – P04 (female) (3) circuit) [Arm IN PPC pressure sensor system] Resistance Min. system does not reset itself until starting switch is turned OFF. 1 Mz Wiring harness between C01 (female) (9) – J06 – P05 (female) (3) [Bucket DUMP PPC pressure sensor system] Resistance Min. Wiring harness between C01 (female) (9) – J06 – P01 (female) (3) [Bucket CURL PPC pressure sensor system] Resistance Min. then carry out troubleshooting without turning starting switch ON. • Even if cause of failure disappears. Bucket CURL PPC pressure sensor P01 Swing LEFT PPC pressure sensor P03 Arm IN PPC pressure sensor P04 Bucket DUMP PPC pressure sensor P05 Boom RAISE PPC pressure sensor P06 Swing RIGHT PPC pressure sensor P07 F pump pressure sensor P25 R pump pressure sensor P26 a Prepare with starting switch OFF. • Auto-decelerator keeps working and is not reset or fine control performance of work equipment is lowered (PPC pressure sensor system). Related information • Method of reproducing failure code: Turn starting switch ON.0 V.40 Troubleshooting SEN00241-01 Failure code [DA25KP] 5V Sensor 1 Power Abnormality 1 Overload alarm monitor non-display specification User code Failure code — DA25KP Contents of trouble Trouble 5V sensor power supply output 1 abnormality (Pump controller system) • Voltage of 5V sensor power supply output 1 circuit is below 2. If "E" of failure code goes off when a sensor is disconnected. Problem that appears on machine • Automatic gear shifting function does not work (pump pressure sensor system). Cause Standard value in normal state/Remarks on troubleshooting a Disconnect connector with starting switch OFF. then turn starting switch ON and carry out troubleshooting. Action of controller • Turns output of 5V sensor power supply output 1 OFF.5 V or above 6. 1 Possible causes and standard value in normal state PC200. 220-8 Defective pressure sensor (Internal short circuit) Disconnect sensors at right in order and carry out operation to reproduce trouble. 1 Mz 53 .

1 V Possible causes and standard value in normal state 4 Defective pump controller 54 If causes 1 – 3 are not detected.SEN00241-01 40 Troubleshooting Cause Standard value in normal state/Remarks on troubleshooting Wiring harness between C01 (female) (9) – J06 – P07 (female) (3) [Swing RIGHT PPC pressure sensor system] Resistance Min. 1 V Wiring harness between C01 (female) (9) – J06 – P06 (female) (3) [Boom RAISE PPC pressure sensor system] Voltage Max. 1 V Wiring harness between C01 (female) (9) – J06 – P03 (female) (3) [Swing LEFT PPC pressure sensor system] Voltage Max. 1 V Wiring harness between C01 (female) (9) – J06 – P25 (female) (3) [F pump pressure sensor system] Voltage Max. 1 Mz Wiring harness between C01 (female) (9) – J06 – P26 (female) (3) [R pump pressure sensor system] Resistance Min. 1 Mz a Prepare with starting switch OFF. 1 V Wiring harness between C01 (female) (9) – J06 – P04 (female) (3) [Arm IN PPC pressure sensor system] Voltage Max. 220-8 .) PC200. 1 Mz Ground fault in wiring harWiring harness between C01 (female) (9) – 2 ness (Short circuit with GND J06 – P25 (female) (3) circuit) [F pump pressure sensor system] Resistance Min. (Since trouble is in system. 1 V Wiring harness between C01 (female) (9) – J06 – P07 (female) (3) [Swing RIGHT PPC pressure sensor system] Voltage Max. troubleshooting cannot be carried out. Wiring harness between C01 (female) (9) – J06 – P01 (female) (3) [Bucket CURL PPC pressure sensor system] Voltage Max. then turn starting switch ON and carry out troubleshooting. 1 V Wiring harness between C01 (female) (9) – P05 (female) (3) Hot short (Short circuit with 3 [Bucket DUMP PPC pressure sensor sys24V circuit) in wiring harness tem] Voltage Max. pump controller may be defective. 1 V Wiring harness between C01 (female) (9) – J06 – P26 (female) (3) [R pump pressure sensor system] Voltage Max.

40 Troubleshooting SEN00241-01 Circuit diagram related to pump controller 5V sensor power supply output 1 (Overload alarm monitor non-display specification) PC200. 220-8 55 .

1 Mz Wiring harness between C01 (female) (9) – J06 – P06 (female) (3) [Boom RAISE PPC pressure sensor system] Resistance Min. 56 Wiring harness between C01 (female) (9) – J06 – P01 (female) (3) [Bucket CURL PPC pressure sensor system] Resistance Min.5 V or above 6. If "E" of failure code goes off when a sensor is disconnected. 220-8 . • Even if cause of failure disappears. machine does not operate normally. • Turns output of 5V sensor power supply output 1 OFF. 1 Mz Wiring harness between C01 (female) (9) – J06 – P03 (female) (3) [Swing LEFT PPC pressure sensor system] Resistance Min. that sensor is defective. • Overload alarm monitor does not display normally (Overload alarm pressure sensor system) Related information • Method of reproducing failure code: Turn starting switch ON.0 V. Problem that appears on machine • Automatic gear shifting function does not work (pump pressure sensor system). then carry out troubleshooting without turning starting switch ON. 1 Mz Ground fault in wiring har2 ness (Short circuit with GND Wiring harness between C01 (female) (9) – J06 – P04 (female) (3) circuit) [Arm IN PPC pressure sensor system] Resistance Min. 1 Mz Wiring harness between C01 (female) (9) – J06 – P05 (female) (3) [Bucket DUMP PPC pressure sensor system] Resistance Min. Defective pressure sensor 1 (Internal short circuit) Possible causes and standard value in normal state Disconnect sensors at right in order and carry out operation to reproduce trouble. Bucket CURL PPC pressure sensor P01 Swing LEFT PPC pressure sensor P03 Arm IN PPC pressure sensor P04 Bucket DUMP PPC pressure sensor P05 Boom RAISE PPC pressure sensor P06 Swing RIGHT PPC pressure sensor P07 F pump pressure sensor P25 R pump pressure sensor P26 Overload alarm pressure sensor P46 a Prepare with starting switch OFF.SEN00241-01 40 Troubleshooting Overload alarm monitor display specification User code Failure code — DA25KP Contents of trouble Action of controller Trouble 5V sensor power supply output 1 abnormality (Pump controller system) • Voltage of 5V sensor power supply output 1 circuit is below 2. system does not reset itself until starting switch is turned OFF. • Since no solenoid valve is driven normally. 1 Mz PC200. then turn starting switch ON and carry out troubleshooting. Cause Standard value in normal state/Remarks on troubleshooting a Disconnect connector with starting switch OFF.

1 Mz Wiring harness between C01 (female) (9) – J06 – P25 (female) (3) [F pump pressure sensor system] Resistance Min. pump controller may be defective. 220-8 Wiring harness between C01 (female) (9) – J06 – P01 (female) (3) [Bucket CURL PPC pressure sensor system] If causes 1 – 3 are not detected. 1 V Voltage Max. 1 Mz Resistance Min. 1 V Wiring harness between C01 (female) (9) – J06 – P04 (female) (3) [Arm IN PPC pressure sensor system] Voltage Max. 1 V Hot short (Short circuit with 24V circuit) in wiring harness Wiring harness between C01 (female) (9) – J06 – P06 (female) (3) [Boom RAISE PPC pressure sensor system] 4 Defective pump controller PC200. Possible causes and standard value in normal state 3 Voltage Max. 1 Mz Ground fault in wiring har2 ness (Short circuit with GND Wiring harness between C01 (female) (9) – circuit) J06 – P26 (female) (3) [R pump pressure sensor system] Wiring harness between C01 (female) (9) – J06 – P46 (female) (3) [Overload alarm pressure sensor system] a Prepare with starting switch OFF. 1 Mz Resistance Min. 1 V Wiring harness between C01 (female) (9) – J06 – P25 (female) (3) [F pump pressure sensor system] Voltage Max. (Since trouble is in system. 1 V Wiring harness between C01 (female) (9) – J06 – P26 (female) (3) [R pump pressure sensor system] Voltage Max. 1 V Wiring harness between C01 (female) (9) – J06 – P03 (female) (3) [Swing LEFT PPC pressure sensor system] Voltage Max. then turn starting switch ON and carry out troubleshooting. 1 V Wiring harness between C01 (female) (9) – J06 – P07 (female) (3) [Swing RIGHT PPC pressure sensor system] Voltage Max. troubleshooting cannot be carried out. 1 V Wiring harness between C01 (female) (9) – J06 – P46 (female) (3) [Overload alarm pressure sensor system] Voltage Max.40 Troubleshooting SEN00241-01 Cause Standard value in normal state/Remarks on troubleshooting Wiring harness between C01 (female) (9) – J06 – P07 (female) (3) [Swing RIGHT PPC pressure sensor system] Resistance Min. 1 V Wiring harness between C01 (female) (9) – P05 (female) (3) [Bucket DUMP PPC pressure sensor system] Voltage Max.) 57 .

SEN00241-01 40 Troubleshooting Circuit diagram related to pump controller 5V sensor power supply output 1 (Overload alarm monitor display specification) 58 PC200. 220-8 .

Problem that appears on machine • Since control is carried out on assumption that model is PC200. (2). (40). 1 z Resistance Max. no particular problem occur. 1 Mz Resistance Min. 220-8 . then carry out troubleshooting without turning starting switch ON. Cause Defective model selection 1 connector (Internal disconnection or short circuit) Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF. Related information • Model code of pump controller can be checked with monitoring function. • Changes input model code to code of default model (PC200) and continues control. (58) – chassis ground Min. (39). 1 Mz Between (77) – chassis ground Max. 1 z a Prepare with starting switch OFF. then carry out troubleshooting without turning starting switch ON. (7) – (8) Min. 1 Mz Between (3) – (8) Max.SEN00241-01 40 Troubleshooting Failure code [DA29KQ] Model Selection Abnormality 1 PC200. 1 z PC200. 1 Mz Resistance Min.S30 (male) (3) nector) Wiring harness between S30 (male) (8) – J05 – chassis ground (T07) Resistance Max. (4). (Code: 02201 Switch input 2) • Method of reproducing failure code: Turn starting switch ON. then carry out troubleshooting without turning starting switch ON. system does not reset itself until starting switch is turned OFF. 1 Mz Resistance Min. S30 (female) Resistance Between (1). Possible causes and standard value in normal state iring harness between C01 (female) (40) – S30 (male) (1) Ground fault in wiring harWiring harness between C01 (female) (21) – 3 ness (Short circuit with GND S30 (male) (2) circuit) Wiring harness between C01 (female) (58) – S30 (male) (4) Wiring harness between C01 (female) (39) – S30 (male) (7) Resistance Min. Disconnection in wiring harness (Disconnection in wiring Wiring harness between C01 (female) (77) – 2 or defective contact in con. 4 Defective pump controller 60 C01 (female) Resistance Between (21). then carry out troubleshooting without turning starting switch ON. • Even if cause of failure disappears. 1 Mz a Prepare with starting switch OFF. 1 z a Prepare with starting switch OFF. 200LC-8 User code Failure code — DA29KQ Contents of trouble Action of controller Trouble Model selection abnormality (Pump controller system) • Model code signal for model which is not registered in controller is input. (Code: 00200 Controller model code) • Condition of model selection signal can be checked with monitoring function.

220-8 61 .40 Troubleshooting SEN00241-01 Circuit diagram related to model selection connector (PC200. 200LC-8) PC200.

power or speed is low. 4 Defective pump controller 62 C01 (female) Resistance Between (21). Disconnection in wiring harness (Disconnection in wiring 2 or defective contact in connector) Possible causes and standard value in normal state Wiring harness between C01 (female) (40) – S30 (male) (1) Resistance Max. (58) – chassis ground Min. 1 z Wiring harness between C01 (female) (77) – S30 (male) (3) Resistance Max. 220-8 . then carry out troubleshooting without turning starting switch ON. Cause Defective model selection 1 connector (Internal disconnection or short circuit) Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF. Problem that appears on machine • Since control is carried out on assumption that model is PC200. 220LC-8 User code Failure code — DA29KQ Contents of trouble Action of controller Trouble Model selection abnormality (Pump controller system) • Model code signal for model which is not registered in controller is input. • Changes input model code to code of default model (PC200) and continues control. (Code: 02201 Switch input 2) • Method of reproducing failure code: Turn starting switch ON. system does not reset itself until starting switch is turned OFF. 1 Mz Resistance Min. then carry out troubleshooting without turning starting switch ON. 1 Mz Between (1). then carry out troubleshooting without turning starting switch ON. then carry out troubleshooting without turning starting switch ON.SEN00241-01 40 Troubleshooting PC220. 1 z Wiring harness between S30 (male) (8) – J05 – chassis ground (T07) Resistance Max. 1 z PC200. 1 z a Prepare with starting switch OFF. (77) – chassis ground Max. 1 z a Prepare with starting switch OFF. 1 Mz a Prepare with starting switch OFF. (7) – (8) Min. 1 Mz Between (40). (3) – (8) Max. S30 (female) Resistance Between (2). (4). • Even if cause of failure disappears. Related information • Model code of pump controller can be checked with monitoring function. (39). 1 Mz Wiring harness between C01 (female) (39) – S30 (male) (7) Resistance Min. (Code: 00200 Controller model code) • Condition of model selection signal can be checked with monitoring function. Wiring harness between C01 (female) (21) – Ground fault in wiring harS30 (male) (2) 3 ness (Short circuit with GND Wiring harness between C01 (female) (58) – circuit) S30 (male) (4) Resistance Min.

220LC-8) PC200. 220-8 63 .40 Troubleshooting SEN00241-01 Circuit diagram related to model selection connector (PC220.

SEN00241-01 © 2006 KOMATSU All Rights Reserved Printed in Japan 03-06 (01) 64 . 220(LC)-8 Hydraulic excavator Form No.SEN00241-01 PC200.

................................ Part 3 Troubleshooting by failure code (Display of code).......................................................................................................................................................... 6 Failure code [DAFGMC] GPS Module Error ..... 4 Failure code [DA2RMC] CAN Discon (Pump Con Detected) ..................... 4 Failure code [DAF8KB] Short circuit in camera power supply ............................................................................................................. Part 3 .......... 16 Failure code [DHS3MA] Arm Curl PPC Press Sensor Abnormality ................. 10 Failure code [DGH2KB] Hydr Oil Sensor Short................ 14 Failure code [DHPBMA] R Pump Press Sensor Abnormality ................................SEN00242-03 HYDRAULIC EXCAVATOR 1SHOP MANUAL PC200-8 PC200LC-8 PC220-8 PC220LC-8 Machine model Serial number PC200-8 PC200LC-8 PC220-8 PC220LC-8 300001 and up 300001 and up 70001 and up 70001 and up 40 Troubleshooting 1 Troubleshooting by failure code (Display of code)..................... 22 Failure code [DHSAMA] Swing RH PPC Press Sensor Abnormality ............................................................................................................................................................ 24 Failure code [DHSBMA] Swing LH PPC Press Sensor Abnormality.......................................... 20 Failure code [DHS8MA] Boom Raise PPC Press Sensor Abnormality.............................................. 220-8 1 ............................ 12 Failure code [DHPAMA] F Pump Press Sensor Abnormality ....................................................... 8 Failure code [DAFRMC] CAN Discon (Monitor Detected)..... 28 PC200.............................. 26 Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality ........................... 18 Failure code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality ...........................................

................................................ 50 2 PC200....................................................SEN00242-03 40 Troubleshooting Failure code [DHX1MA] Overload Sensor Abnormality (Analog) .................................................................... 44 Failure code [DWA2KA] Service Sol Discon ........................................................................ 36 Failure code [DW45KA] Swing Brake Sol Discon ....... 48 Failure code [DWK0KB] 2-stage Relief Sol Short .................................................................... 220-8 ........................... 42 Failure code [DW91KB] Travel Junction Sol Short.................................................................................................................................................................................................................................................................. 34 Failure code [DW43KB] Travel Speed Sol Short ................................. 38 Failure code [DW45KB] Swing Brake Sol Short.................................................. 47 Failure code [DWK0KA] 2-stage Relief Sol Discon ................................... 31 Failure code [DW43KA] Travel Speed Sol Discon ...................................................... 40 Failure code [DW91KA] Travel Junction Sol Discon ..................... 46 Failure code [DWA2KB] Service Sol Short............................................................

40 Troubleshooting PC200. 220-8 SEN00242-03 3 .

SEN00242-03 40 Troubleshooting Troubleshooting by failure code (Display of code). – K02 (female) (A). – K02 (female) (B) Resistance Max. pump controller may be defective. – CE02 (female) 3 24V circuit) in wiring harness (46). – N08 (male) (10) Voltage Max. 1 Mz a Prepare with starting switch OFF. • Continues operation with information of CAN communication just before detection of error. – CE02 (female) (47). Possible causes and standard value in normal state Wiring harness between CM02 (female) (8). Wiring harness between CM02 (female) (8). (9) – C01 (female) (45). then carry out troubleshooting without turning starting switch ON. K02 (male) Resistance Between (A) – (B) 120 ± 12 z If causes 1 – 4 are not detected. (Since trouble is in system. – N08 (male) (3) circuit) Wiring harness between CM02 (female) (10) – C01 (female) (64). – CE02 (female) (46). • If cause of failure disappears. – CE02 (female) (47). – CE02 (female) 2 ness (Short circuit with GND (46). Disconnection in wiring harness (Disconnection in wiring 1 or defective contact in connector) Wiring harness between CM02 (female) (8). Hot short (Short circuit with (9) – C01 (female) (45). troubleshooting cannot be carried out. (Trouble phenomenon depends on failed section.5 V Defective CAN terminal 4 resistance (Internal short circuit or disconnection) 5 Defective pump controller 4 Resistance a Prepare with starting switch OFF. – K02 (female) (B). 1 z a Prepare with starting switch OFF. – N08 (male) (3) Voltage Max. – K02 (female) (A) Resistance Max. Part 3 1 Failure code [DA2RMC] CAN Discon (Pump Con Detected) 1 User code E0E Contents of trouble Action of controller Failure code DA2RMC Trouble CAN disconnection (Pump controller detected) (Pump controller system) • Pump controller detected communication error in CAN communication circuit between machine monitor and engine controller. Problem that appears on machine • Information may not transmitted normally by CAN communication and machine may not operate normally. 5.) Related information • Method of reproducing failure code: Turn starting switch ON. 1 z Wiring harness between CM02 (female) (10) – C01 (female) (64).5 V Wiring harness between CM02 (female) (10) – C01 (female) (64). 5. system resets itself. – K02 (female) (A). 1 Mz Resistance Min. – CE02 (female) (47). then carry out troubleshooting without turning starting switch ON. 220-8 . Cause Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF. – N08 (male) (10) Min. then turn starting switch ON and carry out troubleshooting. Ground fault in wiring har(9) – C01 (female) (45).) PC200. then carry out troubleshooting without turning starting switch ON. – K02 (female) (B).

220-8 5 .40 Troubleshooting SEN00242-03 Circuit diagram related to CAN communication PC200.

10 V If causes 1 – 3 are not detected. Action of • Turns output power supply voltage (Rating: 8 V) to camera OFF. machine monitor may be detective. system does not reset itself until starting switch is turned OFF. Cause Defective camera (Internal 1 short circult) Possible causes and standard value in normal state Standard value in normal state/Remarks on troubleshooting a Disconnect camera with starting switch OFF. machine monitor • Even if cause of failure disappears.) PC200. Ground fault in wiring har(Disconnect camera and check that it is not defective in 2 ness (Contact with GND ciradvance. Related information • Method of reproducing failure code: Turn starting switch ON.) cuit) Between CM05 (female) (1) – CAMERA Voltage Min. 220-8 .0 V or above 10 V. camera is defective. (Disconnect camera and check that it is not defective in advance. 6 V (female) (F) wiring harness and ground 3 Hot short (Contact with 24V circuit) in wiring harness a Disconnect camera with starting switch OFF. (Since trouble is in system. If failure code disappears at this time. a Disconnect camera with starting switch OFF. then turn starting switch ON and carry out troubleshooting.SEN00242-03 40 Troubleshooting Failure code [DAF8KB] Short circuit in camera power supply 1 Serial number 310001 and up User code Failure code — DAF8KB Contents of trouble Trouble Short circuit in camera power supply (Machine monitor system) • Output power supply voltage (Rating: 8 V) from machine monitor to camera is below 6.) Between CM05 (female) (1) – CAMERA (female) (F) wiring harness and ground 4 Defective machine monitor 6 Voltage Max. troubleshooting cannot be carried out. Disconnect camera and perform failure reproduction operation. Problem that appears on machine • Camera image is not displayed on monitor screen. then turn starting switch ON and carry out troubleshooting. then turn starting switch ON and carry out troubleshooting.

220-8 7 .40 Troubleshooting SEN00242-03 Circuit diagram related to camera PC200.

troubleshooting cannot be carried out. system resets itself. machine monitor • If cause of failure disappears.) PC200. (Since trouble is in system. Cause Standard value in normal state/Remarks on troubleshooting 1 Defective machine monitor GPS module of machine monitor may be defective. 220-8 . Action of • None in particular. Problem that appears on machine Related information Possible causes and standard value in normal state 8 • Method of reproducing failure code: Turn starting switch ON (At least 50 seconds after starting switch is turned ON).SEN00242-03 40 Troubleshooting Failure code [DAFGMC] GPS Module Error User code — Contents of trouble Failure code DAFGMC Trouble 1 GPS module operation 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 is started.

40 Troubleshooting PC200. 220-8 SEN00242-03 9 .

system resets itself. (Trouble phenomenon depends on failed section. (9) – C01 (female) (45). Cause Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF. Ground fault in wiring har(9) – C01 (female) (45).) Related information • Method of reproducing failure code: Turn starting switch ON. – CE02 (female) (47). Action of • If cause of failure disappears. – K02 (female) (A). – K02 (female) (B) Resistance Max. – CE02 (female) 2 ness (Short circuit with GND (46). K02 (male) Resistance Between (A) – (B) 120 ± 12 z If causes 1 – 4 are not detected. 1 Mz Resistance Min. Hot short (Short circuit with (9) – C01 (female) (45). Possible causes and standard value in normal state Wiring harness between CM02 (female) (8). machine monitor may be defective. 220-8 . – N08 (male) (10) Voltage Max.5 V Wiring harness between CM02 (female) (10) – C01 (female) (64). troubleshooting cannot be carried out. – K02 (female) (A). – N08 (male) (3) circuit) Wiring harness between CM02 (female) (10) – C01 (female) (64). 1 Mz a Prepare with starting switch OFF. 5. 1 z a Prepare with starting switch OFF. – CE02 (female) (46). then carry out troubleshooting without turning starting switch ON. then carry out troubleshooting without turning starting switch ON. – N08 (male) (3) Voltage Max.SEN00242-03 40 Troubleshooting Failure code [DAFRMC] CAN Discon (Monitor Detected) User code E0E Contents of trouble Failure code DAFRMC Trouble 1 CAN disconnection (Monitor detected) (Machine monitor system) • Machine monitor detected communication error in CAN communication circuit between pump controller and engine controller. – N08 (male) (10) Min.) PC200. – K02 (female) (A) Resistance Max. then turn starting switch ON and carry out troubleshooting.5 V Defective CAN terminal 4 resistance (Internal short circuit or disconnection) 5 Defective machine monitor 10 Resistance a Prepare with starting switch OFF. Wiring harness between CM02 (female) (8). – CE02 (female) 3 24V circuit) in wiring harness (46). 1 z Wiring harness between CM02 (female) (10) – C01 (female) (64). 5. – CE02 (female) (47). – K02 (female) (B). (Since trouble is in system. Disconnection in wiring harness (Disconnection in wiring 1 or defective contact in connector) Wiring harness between CM02 (female) (8). then carry out troubleshooting without turning starting switch ON. – K02 (female) (B). machine monitor Problem that appears on machine • Information may not transmitted normally by CAN communication and machine may not operate normally. – CE02 (female) (47).

40 Troubleshooting SEN00242-03 Circuit diagram related to CAN communication PC200. 220-8 11 .

5 – 90 kz Between (29) – chassis ground Min. (Code: 04402 Hydraulic oil temperature sensor voltage) • Method of reproducing failure code: Start engine. 2 ness (Short circuit with GND ResisWiring harness between C01 (female) (29) – circuit) Min. then carry out troubleshooting without turning starting switch ON. then carry out troubleshooting without turning starting switch ON. Problem that appears on machine • While hydraulic oil temperature rises normally. 1 Mz Circuit diagram related to hydraulic oil temperature sensor 12 PC200. hydraulic oil temperature gauge does not move from top of white range (bottom of green range). 1 Mz P22 (female) (2) tance a Prepare with starting switch OFF. system resets itself. 3 Defective pump controller C01 (female) Resistance Between (29) – (46) 3. Related information • Signal voltage of hydraulic oil temperature sensor can be checked with monitoring function. then carry out troubleshooting Ground fault in wiring harwithout turning starting switch ON. • Fixes hydraulic oil temperature value at 40°C and continues operation. P22 (male) Resistance Between (1) – (2) 3. 1 Mz a Prepare with starting switch OFF. 220-8 . • If cause of failure disappears.SEN00242-03 40 Troubleshooting Failure code [DGH2KB] Hydr Oil Sensor Short User code Failure code — DGH2KB Contents of trouble Action of controller Trouble 1 Hydraulic oil temperature sensor short (Pump controller system) • Ground fault was detected in hydraulic oil temperature sensor circuit. Cause Defective hydraulic oil tem1 perature sensor (Internal disconnection or short circuit) Possible causes and standard value in normal state Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF.5 – 90 kz Between (2) – chassis ground Min.

220-8 SEN00242-03 13 .40 Troubleshooting PC200.

then turn starting switch ON and carry out troubleshooting.3 – 4. pump controller may be defective.) PC200. troubleshooting cannot be carried out.SEN00242-03 40 Troubleshooting Failure code [DHPAMA] F Pump Press Sensor Abnormality User code Failure code — DHPAMA Contents of trouble Action of controller Trouble 1 F pump pressure sensor abnormality (Pump controller system) • Signal voltage of F pump pressure sensor circuit is below 0. (Code: 01100 F pump pressure) • Method of reproducing failure code: Turn starting switch ON or start engine.5 V Between (2) – (1) Signal 0. system resets itself. carry out troubleshooting for it first. 1 Mz P25 (female) (2) tance a Prepare with starting switch OFF. a Prepare with starting switch OFF. then turn starting switch ON or start engine and carry out troubleshooting in each case. (If "E" of failure code goes off at this time. 4 ness (Short circuit with GND Wiring harness between C01 (female) (49) – Resiscircuit) Min. • If cause of failure disappears. 1 z Wiring harness between C01 (female) (49) – P25 (female) (2) Resistance Max. • Fixes F pump pressure at 0 MPa {0 kg/cm2} and continues control. then carry out troubleshooting without turning starting switch ON. • F pump pressure can be checked with monitoring function. F pump pressure sensor is defective. then carry out troubleshooting Ground fault in wiring harwithout turning starting switch ON. replace F pump pressure sensor with R pump pressure sensor and check failure code. Cause Standard value in normal state/Remarks on troubleshooting Defective 5V sensor power 1 supply 1 system a If failure code [DA25KP] is also displayed. take extreme care when checking. P25 2 Defective F pump pressure sensor (Internal defect) Voltage Between (3) – (1) Power supply 4.5 V If voltage is abnormal. Hot short (Short circuit with 5 24V circuit) in wiring harness Wiring harness between C01 (female) (49) – Voltage Max.3 V or above 4. • Straight travel performance or steering performance lowers. Disconnection in wiring harness (Disconnection in wiring 3 or defective contact in connector) Wiring harness between C01 (female) (18) – P25 (female) (1) Resistance Max. 1 z Wiring harness between C01 (female) (9) – J06 – P25 (female) (3) Resistance Max. pressure sensor will be broken. Accordingly. 1 V P25 (female) (2) 6 Defective pump controller 14 If causes 1 – 5 are not detected.) Possible causes and standard value in normal state a Prepare with starting switch OFF. 1 z a Prepare with starting switch OFF. 220-8 . (Since trouble is in system.5 V.5 – 5. Problem that appears on machine • Automatic gear shifting function does not work. Related information a If 5V circuit (3) and ground circuit (1) of pressure sensor are connected inversely.

40 Troubleshooting SEN00242-03 Circuit diagram related to F pump pressure sensor PC200. 220-8 15 .

220-8 . 1 V P26 (female) (2) 6 Defective pump controller 16 If causes 1 – 5 are not detected. a Prepare with starting switch OFF.5 V If voltage is abnormal. Problem that appears on machine • Automatic gear shifting function does not work. 1 Mz P26 (female) (2) tance a Prepare with starting switch OFF. pump controller may be defective. Related information a If 5V circuit (3) and ground circuit (1) of pressure sensor are connected inversely. 1 z a Prepare with starting switch OFF. • Fixes R pump pressure at 0 MPa {0 kg/cm2} and continues control.5 V Between (2) – (1) Signal 0.5 – 5. troubleshooting cannot be carried out.3 – 4. replace R pump pressure sensor with F pump pressure sensor and check failure code. Disconnection in wiring harness (Disconnection in wiring 3 or defective contact in connector) Wiring harness between C01 (female) (18) – P26 (female) (1) Resistance Max. 1 z Wiring harness between C01 (female) (9) – J06 – P26 (female) (3) Resistance Max.) Possible causes and standard value in normal state a Prepare with starting switch OFF.5 V. then carry out troubleshooting Ground fault in wiring harwithout turning starting switch ON. (Code: 01101 R pump pressure) • Method of reproducing failure code: Turn starting switch ON or start engine. 4 ness (Short circuit with GND Wiring harness between C01 (female) (68) – Resiscircuit) Min. take extreme care when checking. P26 2 Defective R pump pressure sensor (Internal defect) Voltage Between (3) – (1) Power supply 4. then turn starting switch ON or start engine and carry out troubleshooting in each case. • If cause of failure disappears.) PC200. system resets itself. • Straight travel performance or steering performance lowers. pressure sensor will be broken.3 V or above 4. Cause Standard value in normal state/Remarks on troubleshooting Defective 5V sensor power 1 supply 1 system If failure code [DA25KP] is also displayed. R pump pressure sensor is defective. (If "E" of failure code goes off at this time.SEN00242-03 40 Troubleshooting Failure code [DHPBMA] R Pump Press Sensor Abnormality User code Failure code — DHPBMA Contents of trouble Action of controller Trouble 1 R pump pressure sensor abnormality (Pump controller system) • Signal voltage of R pump pressure sensor circuit is below 0. Hot short (Short circuit with 5 24V circuit) in wiring harness Wiring harness between C01 (female) (68) – Voltage Max. carry out troubleshooting for it first. • R pump pressure can be checked with monitoring function. 1 z Wiring harness between C01 (female) (68) – P26 (female) (2) Resistance Max. then turn starting switch ON and carry out troubleshooting. Accordingly. then carry out troubleshooting without turning starting switch ON. (Since trouble is in system.

220-8 17 .40 Troubleshooting SEN00242-03 Circuit diagram related to R pump pressure sensor PC200.

1 Mz P04 (female) (2) tance 5 Hot short (Short circuit with 24V circuit) in wiring harness Wiring harness between C01 (female) (17) – P04 (female) (2) 6 Defective pump controller 18 a Prepare with starting switch OFF. P04 2 Defective arm curl PPC pressure sensor (Internal defect) Voltage Between (3) – (1) Power supply 4. troubleshooting cannot be carried out. 1 z a Prepare with starting switch OFF. • If cause of failure disappears.) Possible causes and standard value in normal state a Prepare with starting switch OFF. • Arm curl performance lowers. then turn starting switch ON or start engine and carry out troubleshooting in each case. then carry out troubleshooting Ground fault in wiring harwithout turning starting switch ON.3 – 4.3 V or above 4.5 – 5. (Since trouble is in system. 1 V If causes 1 – 5 are not detected.5 V. (If "E" of failure code goes off at this time. then carry out troubleshooting without turning starting switch ON. carry out troubleshooting for it first.5 V If voltage is abnormal. Related information a If 5V circuit (3) and ground circuit (1) of pressure sensor are connected inversely.) PC200. 1 z Wiring harness between C01 (female) (17) – P04 (female) (2) Resistance Max. pump controller may be defective. arm curl PPC pressure sensor is defective. Voltage Max. Accordingly. • Arm curl PPC pressure can be checked with monitoring function. pressure sensor will be broken. then turn starting switch ON and carry out troubleshooting. a Prepare with starting switch OFF. (Code: 07200 Arm curl PPC pressure) • Method of reproducing failure code: Turn starting switch ON or start engine. • Fixes arm curl PPC pressure at 0 MPa {0 kg/cm2} and continues control. Disconnection in wiring harness (Disconnection in wiring 3 or defective contact in connector) Wiring harness between C01 (female) (18) – P04 (female) (1) Resistance Max. replace arm curl PPC pressure sensor with another PPC pressure sensor and check failure code.5 V Between (2) – (1) Signal 0. system resets itself. Problem that appears on machine • Automatic decelerator cannot be reset. take extreme care when checking. Cause 1 Defective 5V sensor power supply 1 system Standard value in normal state/Remarks on troubleshooting If failure code [DA25KP] is also displayed.SEN00242-03 40 Troubleshooting Failure code [DHS3MA] Arm Curl PPC Press Sensor Abnormality User code Failure code — DHS3MA Contents of trouble Action of controller Trouble 1 Arm curl PPC pressure sensor abnormality (Pump controller system) • Signal voltage of arm curl PPC pressure sensor circuit is below 0. 220-8 . 4 ness (Short circuit with GND Wiring harness between C01 (female) (17) – Resiscircuit) Min. 1 z Wiring harness between C01 (female) (9) – J06 – P04 (female) (3) Resistance Max.

40 Troubleshooting SEN00242-03 Circuit diagram related to arm curl PPC pressure sensor PC200. 220-8 19 .

carry out troubleshooting for it first. 1 z Wiring harness between C01 (female) (9) – J06 – P01 (female) (3) Resistance Max. • Fixes bucket curl PPC pressure at 0 MPa {0 kg/cm2} and continues control.5 – 5. a Prepare with starting switch OFF. Voltage Max. 1 z Wiring harness between C01 (female) (73) – P01 (female) (2) Resistance Max. replace bucket curl PPC pressure sensor with another PPC pressure sensor and check failure code. (If "E" of failure code goes off at this time. (Code: 07300 Bucket curl PPC pressure) • Method of reproducing failure code: Turn starting switch ON or start engine. 4 ness (Short circuit with GND Wiring harness between C01 (female) (73) – Resiscircuit) Min.) PC200. Problem that appears on machine • Automatic decelerator cannot be reset. • If cause of failure disappears.SEN00242-03 40 Troubleshooting Failure code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality User code Failure code — DHS4MA Contents of trouble Action of controller Trouble 1 Bucket curl PPC pressure sensor abnormality (Pump controller system) • Signal voltage of bucket curl PPC pressure sensor circuit is below 0. pressure sensor will be broken. pump controller may be defective.5 V Between (2) – (1) Signal 0. 1 z a Prepare with starting switch OFF.5 V.5 V If voltage is abnormal. bucket curl PPC pressure sensor is defective. Cause 1 Defective 5V sensor power supply 1 system Standard value in normal state/Remarks on troubleshooting If failure code [DA25KP] is also displayed. take extreme care when checking. 1 V If causes 1 – 5 are not detected.) a Prepare with starting switch OFF. system resets itself. 1 Mz P01 (female) (2) tance 5 Hot short (Short circuit with 24V circuit) in wiring harness Wiring harness between C01 (female) (73) – P01 (female) (2) 6 Defective pump controller 20 a Prepare with starting switch OFF.3 – 4. troubleshooting cannot be carried out. then carry out troubleshooting Ground fault in wiring harwithout turning starting switch ON. (Since trouble is in system. • Bucket curl performance lowers. Accordingly. then carry out troubleshooting without turning starting switch ON. 220-8 . • Bucket curl PPC pressure can be checked with monitoring function. Disconnection in wiring harness (Disconnection in wiring 3 or defective contact in connector) Wiring harness between C01 (female) (18) – P01 (female) (1) Resistance Max. then turn starting switch ON or start engine and carry out troubleshooting in each case.3 V or above 4. Related information a If 5V circuit (3) and ground circuit (1) of pressure sensor are connected inversely. then turn starting switch ON and carry out troubleshooting. P01 Defective bucket curl PPC 2 pressure sensor (Internal defect) Possible causes and standard value in normal state Voltage Between (3) – (1) Power supply 4.

220-8 21 .40 Troubleshooting SEN00242-03 Circuit diagram related to bucket curl PPC pressure sensor PC200.

) a Prepare with starting switch OFF. • If cause of failure disappears. replace boom raise PPC pressure sensor with another PPC pressure sensor and check failure code.SEN00242-03 40 Troubleshooting Failure code [DHS8MA] Boom Raise PPC Press Sensor Abnormality User code Failure code — DHS8MA Contents of trouble Action of controller Trouble 1 Boom raise PPC pressure sensor abnormality (Pump controller system) • Signal voltage of boom raise PPC pressure sensor circuit is below 0. carry out troubleshooting for it first. (Since trouble is in system. Voltage Max. Accordingly.5 V If voltage is abnormal.3 – 4. pressure sensor will be broken. • Fixes boom raise PPC pressure at 0 MPa {0 kg/cm2} and continues control. system resets itself. 1 z Wiring harness between C01 (female) (9) – J06 – P06 (female) (3) Resistance Max. Cause 1 Defective 5V sensor power supply 1 system Standard value in normal state/Remarks on troubleshooting If failure code [DA25KP] is also displayed. a Prepare with starting switch OFF. • Boom raise PPC pressure can be checked with monitoring function.3 V or above 4. troubleshooting cannot be carried out. then carry out troubleshooting without turning starting switch ON.) PC200. then carry out troubleshooting Ground fault in wiring harwithout turning starting switch ON. 4 ness (Short circuit with GND Wiring harness between C01 (female) (53) – Resiscircuit) Min. take extreme care when checking. Related information a If 5V circuit (3) and ground circuit (1) of pressure sensor are connected inversely. 1 Mz P06 (female) (2) tance 5 Hot short (Short circuit with 24V circuit) in wiring harness Wiring harness between C01 (female) (53) – P06 (female) (2) 6 Defective pump controller 22 a Prepare with starting switch OFF.5 V. 1 z a Prepare with starting switch OFF. then turn starting switch ON and carry out troubleshooting. boom raise PPC pressure sensor is defective. • Boom raise performance lowers. Problem that appears on machine • Automatic decelerator cannot be reset. (Code: 07400 Boom raise PPC pressure) • Method of reproducing failure code: Turn starting switch ON or start engine. Disconnection in wiring harness (Disconnection in wiring 3 or defective contact in connector) Wiring harness between C01 (female) (18) – P06 (female) (1) Resistance Max.5 – 5. P06 Defective boom raise PPC 2 pressure sensor (Internal defect) Possible causes and standard value in normal state Voltage Between (3) – (1) Power supply 4. 220-8 . then turn starting switch ON or start engine and carry out troubleshooting in each case. 1 V If causes 1 – 5 are not detected. pump controller may be defective. 1 z Wiring harness between C01 (female) (53) – P06 (female) (2) Resistance Max.5 V Between (2) – (1) Signal 0. (If "E" of failure code goes off at this time.

40 Troubleshooting SEN00242-03 Circuit diagram related to boom raise PPC pressure sensor PC200. 220-8 23 .

then turn starting switch ON and carry out troubleshooting.3 V or above 4. Cause 1 Defective 5V sensor power supply 1 system Standard value in normal state/Remarks on troubleshooting If failure code [DA25KP] is also displayed. • If cause of failure disappears. Voltage Max. then turn starting switch ON or start engine and carry out troubleshooting in each case. P07 Defective swing right PPC 2 pressure sensor (Internal defect) Possible causes and standard value in normal state Voltage Between (3) – (1) Power supply 4. 1 z a Prepare with starting switch OFF. pump controller may be defective. replace swing right PPC pressure sensor with another PPC pressure sensor and check failure code. take extreme care when checking. 1 z Wiring harness between C01 (female) (72) – P07 (female) (2) Resistance Max. 1 V If causes 1 – 5 are not detected. carry out troubleshooting for it first. Related information a If 5V circuit (3) and ground circuit (1) of pressure sensor are connected inversely. then carry out troubleshooting without turning starting switch ON.5 V. Disconnection in wiring harness (Disconnection in wiring 3 or defective contact in connector) Wiring harness between C01 (female) (18) – P07 (female) (1) Resistance Max. 220-8 . • Fixes swing right PPC pressure at 0 MPa {0 kg/cm2} and continues control.SEN00242-03 40 Troubleshooting Failure code [DHSAMA] Swing RH PPC Press Sensor Abnormality User code Failure code — DHSAMA Contents of trouble Action of controller Trouble 1 Swing right PPC pressure sensor abnormality (Pump controller system) • Signal voltage of swing right PPC pressure sensor circuit is below 0. (Code: 09002 Swing right PPC pressure) • Method of reproducing failure code: Turn starting switch ON or start engine. swing right PPC pressure sensor is defective. • Swing right PPC pressure can be checked with monitoring function.3 – 4. (If "E" of failure code goes off at this time.) PC200. Problem that appears on machine • Automatic decelerator and swing holding brake cannot be reset. • Swing right performance lowers. (Since trouble is in system.5 V Between (2) – (1) Signal 0. pressure sensor will be broken. a Prepare with starting switch OFF.5 V If voltage is abnormal. system resets itself. then carry out troubleshooting Ground fault in wiring harwithout turning starting switch ON. 1 Mz P07 (female) (2) tance 5 Hot short (Short circuit with 24V circuit) in wiring harness Wiring harness between C01 (female) (72) – P07 (female) (2) 6 Defective pump controller 24 a Prepare with starting switch OFF. 4 ness (Short circuit with GND Wiring harness between C01 (female) (72) – Resiscircuit) Min.5 – 5. troubleshooting cannot be carried out. 1 z Wiring harness between C01 (female) (9) – J06 – P07 (female) (3) Resistance Max.) a Prepare with starting switch OFF. Accordingly.

40 Troubleshooting SEN00242-03 Circuit diagram related to swing right PPC pressure sensor PC200. 220-8 25 .

pump controller may be defective. Voltage Max. 1 z a Prepare with starting switch OFF. Related information a If 5V circuit (3) and ground circuit (1) of pressure sensor are connected inversely.5 V Between (2) – (1) Signal 0. replace swing left PPC pressure sensor with another PPC pressure sensor and check failure code. 1 V If causes 1 – 5 are not detected. • Swing left PPC pressure can be checked with monitoring function. Cause 1 Defective 5V sensor power supply 1 system Standard value in normal state/Remarks on troubleshooting If failure code [DA25KP] is also displayed. then carry out troubleshooting without turning starting switch ON. (Since trouble is in system. • Fixes swing left PPC pressure at 0 MPa {0 kg/cm2} and continues control.SEN00242-03 40 Troubleshooting Failure code [DHSBMA] Swing LH PPC Press Sensor Abnormality User code Failure code — DHSBMA Contents of trouble Action of controller Trouble 1 Swing left PPC pressure sensor abnormality (Pump controller system) • Signal voltage of swing left PPC pressure sensor circuit is below 0. then turn starting switch ON or start engine and carry out troubleshooting in each case. 220-8 . • Swing left performance lowers. • If cause of failure disappears. troubleshooting cannot be carried out. Disconnection in wiring harness (Disconnection in wiring 3 or defective contact in connector) Wiring harness between C01 (female) (18) – P03 (female) (1) Resistance Max. Problem that appears on machine • Automatic decelerator and swing holding brake cannot be reset. Accordingly. 1 Mz P03 (female) (2) tance 5 Hot short (Short circuit with 24V circuit) in wiring harness Wiring harness between C01 (female) (16) – P03 (female) (2) 6 Defective pump controller 26 a Prepare with starting switch OFF. a Prepare with starting switch OFF.5 V.3 – 4. 4 ness (Short circuit with GND Wiring harness between C01 (female) (16) – Resiscircuit) Min. (If "E" of failure code goes off at this time. swing left PPC pressure sensor is defective. 1 z Wiring harness between C01 (female) (16) – P03 (female) (2) Resistance Max. pressure sensor will be broken. take extreme care when checking.) PC200.5 – 5. carry out troubleshooting for it first. 1 z Wiring harness between C01 (female) (9) – J06 – P03 (female) (3) Resistance Max. P03 Defective swing left PPC 2 pressure sensor (Internal defect) Possible causes and standard value in normal state Voltage Between (3) – (1) Power supply 4.) a Prepare with starting switch OFF. (Code: 09002 Swing left PPC pressure) • Method of reproducing failure code: Turn starting switch ON or start engine.3 V or above 4.5 V If voltage is abnormal. system resets itself. then turn starting switch ON and carry out troubleshooting. then carry out troubleshooting Ground fault in wiring harwithout turning starting switch ON.

220-8 27 .40 Troubleshooting SEN00242-03 Circuit diagram related to swing left PPC pressure sensor PC200.

5 V. 220-8 . Cause 1 Defective 5V sensor power supply 1 system Standard value in normal state/Remarks on troubleshooting If failure code [DA25KP] is also displayed. 4 ness (Short circuit with GND Wiring harness between C01 (female) (34) – Resiscircuit) Min. take extreme care when checking. Accordingly. carry out troubleshooting for it first. system resets itself. troubleshooting cannot be carried out. 1 z Wiring harness between C01 (female) (34) – P05 (female) (2) Resistance Max. then carry out troubleshooting without turning starting switch ON.5 V Between (2) – (1) Signal 0. (If "E" of failure code goes off at this time. pump controller may be defective. then carry out troubleshooting Ground fault in wiring harwithout turning starting switch ON.3 – 4. then turn starting switch ON and carry out troubleshooting. • Bucket dump PPC pressure can be checked with monitoring function. a Prepare with starting switch OFF. then turn starting switch ON or start engine and carry out troubleshooting in each case.5 V If voltage is abnormal. Related information a If 5V circuit (3) and ground circuit (1) of pressure sensor are connected inversely.SEN00242-03 40 Troubleshooting Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality 1 User code Failure code — DHSDMA Contents of trouble Action of controller Trouble Bucket dump PPC pressure sensor abnormality (Pump controller system) • Signal voltage of bucket dump PPC pressure sensor circuit is below 0.) a Prepare with starting switch OFF. 1 z Wiring harness between C01 (female) (9) – J06 – P05 (female) (3) Resistance Max. 1 Mz P05 (female) (2) tance 5 Hot short (Short circuit with 24V circuit) in wiring harness Wiring harness between C01 (female) (34) – P05 (female) (2) 6 Defective pump controller 28 a Prepare with starting switch OFF. • Fixes bucket dump PPC pressure at 0 MPa {0 kg/cm2} and continues control.3 V or above 4. (Since trouble is in system. bucket dump PPC pressure sensor is defective. 1 z a Prepare with starting switch OFF. P05 Defective bucket dump PPC 2 pressure sensor (Internal defect) Possible causes and standard value in normal state Voltage Between (3) – (1) Power supply 4.5 – 5. Problem that appears on machine • Automatic decelerator cannot be reset.) PC200. 1 V If causes 1 – 5 are not detected. Disconnection in wiring harness (Disconnection in wiring 3 or defective contact in connector) Wiring harness between C01 (female) (18) – P05 (female) (1) Resistance Max. • Bucket dump performance lowers. Voltage Max. • If cause of failure disappears. (Code: 07301 Bucket dump PPC pressure) • Method of reproducing failure code: Turn starting switch ON or start engine. replace bucket dump PPC pressure sensor with another PPC pressure sensor and check failure code. pressure sensor will be broken.

220-8 29 .40 Troubleshooting SEN00242-03 Circuit diagram related to bucket dump PPC pressure sensor PC200.

SEN00242-03 30 40 Troubleshooting PC200. 220-8 .

220-8 Method of reproducing failure code: Turn starting switch ON.) 31 . • None in particular. Cause 1 Defective pump controller Standard value in normal state/Remarks on troubleshooting Pump controller may be defective.40 Troubleshooting SEN00242-03 Failure code [DHX1MA] Overload Sensor Abnormality (Analog) 1 Overload alarm monitor non-display specification User code Failure code — DHX1MA Contents of trouble Action of controller Trouble Overload sensor (analog) (Pump controller system) • Monitor which is not set to be displayed (Overload alarm monitor) is displayed. troubleshooting cannot be carried out. system resets itself. Problem that appears on machine Related information Possible causes and standard value in normal state PC200. (Since trouble is in system. • If cause of failure disappears.

) PC200.5 – 5. pump controller may be defective. 220-8 . a If 5V circuit (3) and ground circuit (1) of pressure sensor are connected inversely. Cause 1 Defective 5V sensor power supply 1 system Standard value in normal state/Remarks on troubleshooting If failure code [DA25KP] is also displayed. overload alarm monitor is displayed constantly. • Outputs overload alarm constantly. Problem that appears on machine • If display of overload alarm monitor is set. then carry out troubleshooting Ground fault in wiring harwithout turning starting switch ON. 1 z a Prepare with starting switch OFF. 1 Mz P46 (female) (2) tance a Prepare with starting switch OFF. (Since trouble is in system.) a Prepare with starting switch OFF.4 V. take extreme care when checking. Hot short (Short circuit with 5 24V circuit) in wiring harness Wiring harness between C01 (female) (9) – Voltage Max. • If cause of failure disappears. then turn starting switch ON and carry out troubleshooting. Accordingly.3 – 4. then turn starting switch ON or start engine and carry out troubleshooting in each case. 1 z Wiring harness between C01 (female) (74) – P46 (female) (2) Resistance Max.SEN00242-03 40 Troubleshooting Overload alarm monitor display specification User code Failure code — DHX1MA Contents of trouble Action of controller Trouble Overload sensor (analog) (Pump controller system) • Signal voltage of overload alarm pressure sensor circuit is below 0. Related information • Overload alarm pressure sensor is installed to only machine on which display of overload alarm monitor is set. troubleshooting cannot be carried out. 1 V P46 (female) (2) 6 Defective pump controller 32 If causes 1 – 5 are not detected. then carry out troubleshooting without turning starting switch ON. P46 Defective overload alarm 2 pressure sensor (Internal defect) Possible causes and standard value in normal state Voltage Between (3) – (1) Power supply 4. system resets itself. replace overload alarm pressure sensor with F pump pressure sensor or R pump pressure sensor and check failure code. (If "E" of failure code goes off at this time. pressure sensor will be broken. 1 z Wiring harness between C01 (female) (9) – J06 – P46 (female) (3) Resistance Max.3 V or above 4. (Code: 15900 Boom bottom pressure) • Method of reproducing failure code: Turn starting switch ON or start engine. carry out troubleshooting for it first. • Overload alarm pressure (Boom cylinder bottom pressure) can be checked with monitoring function. 4 ness (Short circuit with GND Wiring harness between C01 (female) (9) – Resiscircuit) Min. overload alarm pressure sensor is defective. Disconnection in wiring harness (Disconnection in wiring 3 or defective contact in connector) Wiring harness between C01 (female) (18) – P46 (female) (1) Resistance Max. a Prepare with starting switch OFF.5 V Between (2) – (1) Signal 0.4 V If voltage is abnormal.

220-8 33 .40 Troubleshooting SEN00242-03 Circuit diagram related to overload alarm pressure sensor PC200.

(Since no current flows. Problem that appears on machine • PC200: Speed is low at High travel speed position (Machine monitor is set to High but actual speed is about Middle). (117). disconnection was detected in circuit. Disconnection in wiring harness (Disconnection in wiring Wiring harness between C02 (female) (87) – 2 or defective contact in con.) • If cause of failure disappears. (120) 20 – 60 z PC200. 1 z a Prepare with starting switch OFF. 3 Defective pump controller 34 C01 (female) Resistance Between (87) – (115). (117). (120) – V04 (female) (2) Resistance Max. 220-8 . V04 (male) Resistance Between (1) – (2) 20 – 60 z a Prepare with starting switch OFF. Cause Defective travel speed shift1 ing solenoid (Internal disconnection) Possible causes and standard value in normal state Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF.V04 (female) (1) nector) Wiring harness between C02 (female) (115). then carry out troubleshooting without turning starting switch ON. solenoid does not operate. (Code: 02300: Solenoid 1) • Method of reproducing failure code: Start engine + Set travel speed to High + Operate travel lever. • None in particular. Related information • Operating condition of travel speed shifting solenoid can be checked with monitoring function. 1 z Resistance Max. then carry out troubleshooting without turning starting switch ON.SEN00242-03 40 Troubleshooting Failure code [DW43KA] Travel Speed Sol Discon User code Failure code — DW43KA Contents of trouble Action of controller Trouble 1 Travel speed solenoid system disconnection (Pump controller system) • When output to travel speed shifting solenoid was turned ON. • PC220: Speed is low at High and Middle travel speed position (Machine monitor is set to High or Middle but actual speed is about Low). system resets itself. then carry out troubleshooting without turning starting switch ON.

220-8 35 .40 Troubleshooting SEN00242-03 Circuit diagram related to travel speed shifting solenoid PC200.

then carry out troubleshooting without turning starting switch ON. short circuit was detected in circuit. then carry out troubleshooting Ground fault in wiring harwithout turning starting switch ON. system does not reset itself until starting switch is turned OFF. Action of controller • Turns output to travel speed shifting solenoid OFF. • Even if cause of failure disappears. 220-8 . Related information • Operating condition of travel speed shifting solenoid can be checked with monitoring function. 1 Mz V04 (female) (1) tance a Prepare with starting switch OFF. Cause Defective travel speed shift1 ing solenoid (Internal disconnection) Possible causes and standard value in normal state Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF. (117). V04 (male) Resistance Between (1) – (2) 20 – 60 z Between (1) – chassis ground Min. • PC220: Speed is low at High and Middle travel speed position (Machine monitor is set to High or Middle but actual speed is about Low).SEN00242-03 40 Troubleshooting Failure code [DW43KB] Travel Speed Sol Short User code Failure code — DW43KB Trouble 1 Travel speed solenoid system short (Pump controller system) Contents of trouble • When output to travel speed shifting solenoid was turned ON. 1 Mz PC200. then carry out troubleshooting without turning starting switch ON. 1 Mz a Prepare with starting switch OFF. (120) 20 – 60 z Between (87) – chassis ground Min. (Code: 02300: Solenoid 1) • Method of reproducing failure code: Start engine + Set travel speed to High + Operate travel lever. 3 Defective pump controller 36 C02 (female) Resistance Between (87) – (115). 2 ness (Short circuit with GND Wiring harness between C02 (female) (87) – Resiscircuit) Min. Problem that appears on machine • PC200: Speed is low at High travel speed position (Machine monitor is set to High but actual speed is about Middle).

220-8 37 .40 Troubleshooting SEN00242-03 Circuit diagram related to travel speed shifting solenoid PC200.

(Code: 02300: Solenoid 1) • Method of reproducing failure code: Turn starting switch ON. then carry out troubleshooting without turning starting switch ON.SEN00242-03 40 Troubleshooting Failure code [DW45KA] Swing Brake Sol Discon User code Failure code E03 DW45KA Contents of trouble Action of controller Trouble 1 Swing holding brake solenoid system disconnection (Pump controller system) • When output to swing holding brake solenoid was turned OFF. 3 Defective swing lock switch (Internal disconnection) S04 (male) Between (3) – (4) Possible causes and standard value in normal state Swing lock switch Resistance OFF Max. then carry out troubleshooting without turning starting switch ON. 220-8 . Related information • If solenoid and wiring harness are normal. 1 z Resistance Max. 1 z ON Min. 5 Defective pump controller C02 (female) Between (101) – (115). • Keep swing lock switch in OFF position and swing holding brake release switch in release position during troubleshooting. 1 z Resistance Max. Wiring harness between C02 (female) (101) – D01 (female) (7) Disconnection in wiring harness (Disconnection in wiring Wiring harness between D01 (female) (3) – 4 or defective contact in con. then carry out troubleshooting without turning starting switch ON. D01 (male) Digital circuit tester Continuity Between (7) – (3) Diode mode There is continuity a Prepare with starting switch OFF. (Since no current flows.) • If cause of failure disappears. disconnection was detected in circuit. • Operating condition of swing holding brake solenoid can be checked with monitoring function. (120) 38 Disconnect D01 and connect pins (3) and (7) on female side directly. then carry out troubleshooting without turning starting switch ON. 1 z a Prepare with starting switch OFF. system resets itself. operator can swing machine by setting swing holding brake release switch in release position (Swing holding brake does not work. (120) – V03 (female) (2) Resistance Max.J02 – S04 (female) (3) nector) Wiring harness between S04 (female) (4) – V03 (female) (1) Wiring harness between C02 (female) (115). then carry out troubleshooting without turning starting switch ON. when machine stops). (117). 1 Mz a Prepare with starting switch OFF. Cause Defective swing holding 1 brake solenoid (Internal disconnection) Defective assembled-type 2 diode D01 (Internal disconnection) Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF. 1 z Resistance Max. • None in particular. (117). Problem that appears on machine • Machine cannot swing (Swing holding brake is not reset). Resistance 20 – 60 z PC200. solenoid does not operate. V03 (male) Resistance Between (1) – (2) 20 – 60 z a Prepare with starting switch OFF. however.

40 Troubleshooting SEN00242-03 Circuit diagram related to swing holding brake solenoid PC200. 220-8 39 .

then carry out troubleshooting without turning starting switch ON. when machine stops). 220-8 . then carry out troubleshooting without turning starting switch ON. C02 (female) 3 Defective pump controller Between (101) – (115). Related information • If solenoid and wiring harness are normal. Problem that appears on machine • Machine cannot swing (Swing holding brake is not reset). 1 Mz a Prepare with starting switch OFF. (117). short circuit was detected in circuit. ness (Disconnection in wiring 2 Wiring harness between C02 (female) (101) or defective contact in conResisMin. however. V03 (male) Resistance Between (1) – (2) 20 – 60 z Between (1) – chassis ground Min. Cause Defective swing holding 1 brake solenoid (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. 1 Mz – D01 – J02 – S04 – V03 (female) (1). operator can swing machine by setting swing holding brake release switch in release position (Swing holding brake does not work. • Operating condition of swing holding brake solenoid can be checked with monitoring function. (120) Between (101) – chassis ground 40 Disconnect D01 and connect pins (3) and (7) on female side directly. (Code: 02300: Solenoid 1) • Method of reproducing failure code: Start engine + Swing with left work equipment control lever. – S25 nector) tance (female) (14) a Prepare with starting switch OFF. • Keep swing lock switch in OFF position and swing holding brake release switch in release position during troubleshooting. then carry out troubleshooting Ground fault in wiring harwithout turning starting switch ON. Action of controller • Turns output to swing holding brake solenoid OFF. • Even if cause of failure disappears. 1 Mz PC200. Resistance 20 – 60 z Min. system does not reset itself until starting switch is turned OFF.SEN00242-03 40 Troubleshooting Failure code [DW45KB] Swing Brake Sol Short User code Failure code E03 DW45KB Trouble 1 Swing holding brake solenoid system short (Pump controller system) Contents of trouble • When output to swing holding brake solenoid was turned ON.

40 Troubleshooting SEN00242-03 Circuit diagram related to swing holding brake solenoid PC200. 220-8 41 .

Related information • Operating condition of travel junction solenoid can be checked with monitoring function. 220-8 .– V05 (female) (1) nector) Wiring harness between C02 (female) (115). (Since no current flows. 3 Defective pump controller 42 C02 (female) Resistance Between (110) – (115). (117). disconnection was detected in circuit. (120) – V05 (female) (2) Resistance Max. system resets itself. solenoid does not operate. Cause Defective travel junction 1 solenoid (Internal disconnection) Possible causes and standard value in normal state Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF. (117). • None in particular. then carry out troubleshooting without turning starting switch ON.SEN00242-03 40 Troubleshooting Failure code [DW91KA] Travel Junction Sol Discon User code Failure code — DW91KA Contents of trouble Action of controller Trouble 1 Travel junction solenoid system disconnection (Pump controller system) • When output to travel junction solenoid was turned ON. then carry out troubleshooting without turning starting switch ON. (120) 20 – 60 z PC200.) • If cause of failure disappears. Disconnection in wiring harness (Disconnection in wiring Wiring harness between C02 (female) (110) 2 or defective contact in con. 1 z a Prepare with starting switch OFF. Problem that appears on machine • Machine is not steered easily during travel. (Code: 02300 Solenoid 1) • Method of reproducing failure code: Start engine + Steer machine with right and left travel levers. then carry out troubleshooting without turning starting switch ON. V05 (male) Resistance Between (1) – (2) 20 – 60 z a Prepare with starting switch OFF. 1 z Resistance Max.

40 Troubleshooting SEN00242-03 Circuit diagram related to travel junction solenoid PC200. 220-8 43 .

Cause Defective travel junction 1 solenoid (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. 3 Defective pump controller 44 C02 (female) Resistance Between (110) – (115). 1 Mz PC200. (120) 20 – 60 z Between (110) – chassis ground Min. V05 (male) Resistance Between (1) – (2) 20 – 60 z Between (1) – chassis ground Min. then carry out troubleshooting Ground fault in wiring harwithout turning starting switch ON. • Even if cause of failure disappears. Problem that appears on machine • Machine is not steered easily during travel.SEN00242-03 40 Troubleshooting Failure code [DW91KB] Travel Junction Sol Short User code Failure code — DW91KB Contents of trouble Action of controller Trouble 1 Travel junction solenoid system short (Pump controller system) • When output to travel junction solenoid was turned ON. • Turns output to travel junction solenoid OFF. (117). short circuit was detected in circuit. (Code: 02300 Solenoid 1) • Method of reproducing failure code: Start engine + Steer machine with right and left travel levers. then carry out troubleshooting without turning starting switch ON. then carry out troubleshooting without turning starting switch ON. system does not reset itself until starting switch is turned OFF. 1 Mz a Prepare with starting switch OFF. 2 ness (Short circuit with GND ResisWiring harness between C02 (female) (110) circuit) Min. Related information • Operating condition of travel junction solenoid can be checked with monitoring function. 1 Mz – V05 (female) (1) tance a Prepare with starting switch OFF. 220-8 .

220-8 45 .40 Troubleshooting SEN00242-03 Circuit diagram related to travel junction solenoid PC200.

then carry out troubleshooting without turning starting switch ON. • None in particular. Problem that appears on machine • Hydraulic circuit for attachment does not change to single operation circuit. C02 (female) Resistance Between (86) – chassis ground 20 – 60 z Circuit diagram related to service solenoid 46 PC200. 1 z a Prepare with starting switch OFF.) • If cause of failure disappears. 220-8 . Cause 1 Possible causes and standard value in normal state Defective service solenoid (Internal disconnection) Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF. then carry out troubleshooting without turning starting switch ON. system resets itself.V06 (female) (1) nector) Wiring harness between V06 (female) (2) – chassis ground (T09) 3 Defective pump controller Resistance Max. solenoid does not operate. V06 (male) Resistance Between (1) – (2) 20 – 60 z a Prepare with starting switch OFF. Disconnection in wiring harness (Disconnection in wiring Wiring harness between C02 (female) (86) – 2 or defective contact in con.SEN00242-03 40 Troubleshooting Failure code [DWA2KA] Service Sol Discon User code Failure code — DWA2KA Contents of trouble Action of controller Trouble 1 Service solenoid disconnection (Pump controller system) • When output to service solenoid is turned OFF. disconnection was detected in circuit. (Since no current flows. (Code: 02301 Solenoid 2) • Method of reproducing failure code: Turn starting switch ON + Set machine in mode other than breaker mode (B). Related information • Operating condition of service solenoid can be checked with monitoring function. then carry out troubleshooting without turning starting switch ON. 1 z Resistance Max.

• Turns output to service solenoid OFF • Even if cause of failure disappears. Related information • Operating condition of service solenoid can be checked with monitoring function. Problem that appears on machine • Hydraulic circuit for attachment is not does not change to single operation circuit. 1 Mz V06 (female) (1) tance 3 Defective pump controller a Prepare with starting switch OFF. 220-8 47 . short circuit was detected in circuit. 1 Mz a Prepare with starting switch OFF. Cause Defective service solenoid 1 (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. 2 ness (Short circuit with GND Wiring harness between C02 (female) (86) – Resiscircuit) Min. (Code: 02301 Solenoid 2) • Method of reproducing failure code: Turn starting switch ON + Set machine in breaker mode (B). then carry out troubleshooting Ground fault in wiring harwithout turning starting switch ON.40 Troubleshooting SEN00242-03 Failure code [DWA2KB] Service Sol Short User code Failure code — DWA2KB Contents of trouble Action of controller Trouble 1 Service solenoid short (Pump controller system) • When output to service solenoid is turned ON. system does not reset itself until starting switch is turned OFF. C02 (female) Resistance Between (86) – chassis ground 20 – 60 z Circuit diagram related to service solenoid PC200. V06 (male) Resistance Between (1) – (2) 20 – 60 z Between (1) – chassis ground Min. then carry out troubleshooting without turning starting switch ON. then carry out troubleshooting without turning starting switch ON.

solenoid does not operate. Related information • Operating condition of 2-stage relief solenoid can be checked with monitoring function. disconnection was detected in circuit. 3 Defective pump controller 48 C02 (female) Resistance Between (109) – (115). Problem that appears on machine • Power maximizing function does not work. (Since no current flows. (Code: 02300 Solenoid 1) • Method of reproducing failure code: Turn starting switch ON + Set machine in mode other than (L). 220-8 . (117). then carry out troubleshooting without turning starting switch ON. • Travel power is low.) • If cause of failure disappears. then carry out troubleshooting without turning starting switch ON. 1 z a Prepare with starting switch OFF. (117). • None in particular. 1 z Resistance Max. Defective 2-stage relief sole1 noid (Internal disconnection) V02 (male) Resistance Between (1) – (2) Possible causes and standard value in normal state 20 – 60 z a Prepare with starting switch OFF. Cause Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF.SEN00242-03 40 Troubleshooting Failure code [DWK0KA] 2-stage Relief Sol Discon User code Failure code — DWK0KA Contents of trouble Action of controller Trouble 1 2-stage relief solenoid disconnection (Pump controller system) • When output to 2-stage relief solenoid is turned OFF. (120) 20 – 60 z PC200. Disconnection in wiring harness (Disconnection in wiring Wiring harness between C02 (female) (109) 2 or defective contact in con.– V02 (female) (1) nector) Wiring harness between C02 (female) (115). then carry out troubleshooting without turning starting switch ON. system resets itself. (120) – V02 (female) (2) Resistance Max.

220-8 49 .40 Troubleshooting SEN00242-03 Circuit diagram related to 2-stage relief solenoid PC200.

2 ness (Short circuit with GND ResisWiring harness between C02 (female) (109) circuit) Min. V02 (male) Resistance Between (1) – (2) 20 – 60 z Between (1) – chassis ground Min. 1 Mz a Prepare with starting switch OFF. • Turns output to 2-stage relief solenoid OFF. (Code: 02300 Solenoid 1) • Method of reproducing failure code: Turn starting switch ON + Set machine in working mode (L). Cause Defective 2-stage relief 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. (117). then carry out troubleshooting without turning starting switch ON. then carry out troubleshooting Ground fault in wiring harwithout turning starting switch ON. short circuit was detected in circuit. (120) 20 – 60 z Between (109) – chassis ground Min. 3 Defective pump controller 50 C02 (female) Resistance Between (109) – (115). Related information • Operating condition of 2-stage relief solenoid can be checked with monitoring function. 1 Mz – V02 (female) (1) tance a Prepare with starting switch OFF. 220-8 . • Travel power is low. • Even if cause of failure disappears. Problem that appears on machine • Power maximizing function does not work. 1 Mz PC200.SEN00242-03 40 Troubleshooting Failure code [DWK0KB] 2-stage Relief Sol Short User code Failure code — DWK0KB Contents of trouble Action of controller Trouble 1 2-stage relief solenoid short (Pump controller system) • When output to 2-stage relief solenoid is turned ON. then carry out troubleshooting without turning starting switch ON. system does not reset itself until starting switch is turned OFF.

220-8 51 .40 Troubleshooting SEN00242-03 Circuit diagram related to 2-stage relief solenoid PC200.

SEN00242-03 © 2007 KOMATSU All Rights Reserved Printed in Japan 04-07 (01) 52 .SEN00242-03 PC200. 220(LC)-8 Hydraulic excavator Form No.

........... 220-8 1 ................... 8 Failure code [DXA9KB] PC-EPC (R) Sol Short.......................................................... Part 4 Troubleshooting by failure code (Display of code)............................................................... 24 Failure code [DXE6KB] Merge-divider LS Sol Short ............................................. 16 Failure code [DXE4KB] Service Current EPC Short ............................. 26 Failure code [DY20KA] Wiper Working Abnormality ......................................................................................................................................................................... 18 Failure code [DXE5KA] Merge-divider Main Sol Discon .......................................................................................................................SEN00243-01 HYDRAULIC EXCAVATOR 1SHOP MANUAL PC200-8 PC200LC-8 PC220-8 PC220LC-8 Machine model Serial number PC200-8 PC200LC-8 PC220-8 PC220LC-8 300001 and up 300001 and up 70001 and up 70001 and up 40 Troubleshooting 1 Troubleshooting by failure code (Display of code)................................................................................................ 10 Failure code [DXE0KA] LS-EPC Sol Discon .................. 6 Failure code [DXA9KA] PC-EPC (R) Sol Discon . 20 Failure code [DXE5KB] Merge-divider Main Sol Short................ 14 Failure code [DXE4KA] Service Current EPC Discon............. 12 Failure code [DXE0KB] LS-EPC Sol Short ................................................................................................................................................................................... 4 Failure code [DXA8KB] PC-EPC (F) Sol Short ....................................... 28 PC200......................................................... Part 4 ................................................................................................................ 4 Failure code [DXA8KA] PC-EPC (F) Sol Discon....... 22 Failure code [DXE6KA] Merge-divider LS Sol Discon.......................................

.. 220-8 ................................................................................................................................................................................................... 30 Failure code [DY2CKA] Washer Drive Discon..............................SEN00243-01 40 Troubleshooting Failure code [DY20MA] Wiper Parking Abnormality................................................................................................. 36 Failure code [DY2EKB] Wiper Drive (Rev) Short .................... 38 2 PC200....... 34 Failure code [DY2DKB] Wiper Drive (For) Short ................ 32 Failure code [DY2CKB] Washer Drive Short .......................................

(Code: 01300 PC-EPC solenoid current (F)) • Method of reproducing failure code: Turn starting switch ON. (117). 1 Mz Normal Max. disconnection was detected in circuit. system resets itself. Problem that appears on machine • If pump load increases. then carry out troubleshooting without turning starting switch ON. 4 Defective pump controller 4 C02 (female) Resistance Between (96) – (115).V11 (female) (1) nector) Wiring harness between C02 (female) (115). 1 z a Prepare with starting switch OFF. Defective emergency pump 2 drive switch (Internal disconnection) S25 (male) Between (3) – (2) Between (6) – (5) Possible causes and standard value in normal state Emergency pump drive switch Resistance Normal Max. • None in particular (Since no current flows. (120) 7 – 14 z PC200. Wiring harness between C02 (female) (96) – S25 (female) (3) Disconnection in wiring harness (Disconnection in wiring Wiring harness between S25 (female) (2) – 3 or defective contact in con. 1 z Resistance Max. (120) – S25 (female) (6) Wiring harness between S25 (female) (5) – V11 (female) (2) Resistance Max. then carry out troubleshooting without turning starting switch ON. then carry out troubleshooting without turning starting switch ON. then carry out troubleshooting without turning starting switch ON. Part 4 1 Failure code [DXA8KA] PC-EPC (F) Sol Discon 1 User code Failure code E02 DXA8KA Contents of trouble Action of controller Trouble PC-EPC (F) solenoid system disconnection (Pump controller system) • When PC-EPC (F) solenoid was driven. engine speed lowers largely and engine may stall. 1 z Resistance Max. • If cause of failure disappears. Cause 1 Defective PC-EPC (F) solenoid (Internal disconnection) Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF. V11 (male) Resistance Between (1) – (2) 7 – 14 z a Prepare with starting switch OFF. solenoid does not operate). 1 Mz a Prepare with starting switch OFF. 1 z Emergency Min. 1 z Emergency Min. 1 z Resistance Max. Related information • Drive current of PC-EPC (F) solenoid can be checked with monitoring function.SEN00243-01 40 Troubleshooting Troubleshooting by failure code (Display of code). (117). 220-8 .

40 Troubleshooting SEN00243-01 Circuit diagram related to PC-EPC (F) solenoid and PC-EPC (R) solenoid PC200. 220-8 5 .

• Even if cause of failure disappears. engine speed lowers largely and engine may stall. Related information • Drive current of PC-EPC (F) solenoid can be checked with monitoring function. 220-8 . 1 Mz a Prepare with starting switch OFF. (Code: 01300 PC-EPC solenoid current (F)) • Method of reproducing failure code: Turn starting switch ON. (117). Ground fault in wiring harWiring harness between C02 (female) (96) – 3 ness (Contact with GND cirS25 (female) (3) cuit) Wiring harness between S25 (female) (5) – V11 (female) (2) Resistance Min. then carry out troubleshooting without turning starting switch ON. (120) 7 – 14 z Between (96) – chassis ground Min.SEN00243-01 40 Troubleshooting Failure code [DXA8KB] PC-EPC (F) Sol Short User code Failure code E02 DXA8KB Contents of trouble Action of controller Trouble 1 PC-EPC (F) solenoid system short (Pump controller system) • When PC-EPC (F) solenoid was driven. 1 Mz Resistance Min. then carry out troubleshooting without turning starting switch ON. • Turns output to PC-EPC (F) solenoid OFF. system does not reset itself until starting switch is turned OFF. short circuit was detected in circuit. (3) – (4) Between (2). then carry out troubleshooting without turning starting switch ON. (3) – chassis ground Resistance Min. 1 Mz Normal Min. 4 Defective pump controller 6 C02 (female) Resistance Between (96) – (115). Cause Defective PC-EPC (F) sole1 noid (Internal short circuit or ground fault) Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF. 1 Mz a Prepare with starting switch OFF. V11 (male) Resistance Between (1) – (2) 7 – 14 z Between (1) – chassis ground Min. Possible causes and standard value in normal state Defective emergency pump 2 drive switch (Internal short circuit or ground fault) S25 (male) Emergency pump drive switch Between (2). then carry out troubleshooting without turning starting switch ON. 1 Mz PC200. 1 Mz a Prepare with starting switch OFF. Problem that appears on machine • If pump load increases.

40 Troubleshooting SEN00243-01 Circuit diagram related to PC-EPC (F) solenoid and PC-EPC (R) solenoid PC200. 220-8 7 .

(117). (Code: 01302 PC-EPC solenoid current (R)) • Method of reproducing failure code: Turn starting switch ON. Cause Defective PC-EPC (R) sole1 noid (Internal disconnection) Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF. disconnection was detected in circuit. V12 (male) Resistance Between (1) – (2) 7 – 14 z a Prepare with starting switch OFF. (117). Related information • Drive current of PC-EPC (R) solenoid can be checked with monitoring function. then carry out troubleshooting without turning starting switch ON. • None in particular (Since no current flows. system resets itself. Defective emergency pump 2 drive switch (Internal disconnection) S25 (male) Between (9) – (8) Between (12) – (11) Possible causes and standard value in normal state Emergency pump drive switch Resistance Normal Max. (120) – S25 (female) (12) Wiring harness between S25 (female) (11) – V12 (female) (2) Resistance Min. 1 Mz Resistance Min. 1 Mz Resistance Min. then carry out troubleshooting without turning starting switch ON. 1 Mz Normal Max. Wiring harness between C02 (female) (104) – S25 (female) (9) Disconnection in wiring harness (Disconnection in wiring Wiring harness between S25 (female) (8) – 3 or defective contact in con. solenoid does not operate).SEN00243-01 40 Troubleshooting Failure code [DXA9KA] PC-EPC (R) Sol Discon User code Failure code E02 DXA9KA Contents of trouble Action of controller Trouble 1 PC-EPC (R) solenoid system disconnection (Pump controller system) • When PC-EPC (R) solenoid was driven. 1 z Emergency Min. 1 Mz Resistance Min. • If cause of failure disappears. 1 Mz a Prepare with starting switch OFF. (120) 7 – 14 z PC200. then carry out troubleshooting without turning starting switch ON. 4 Defective pump controller 8 C02 (female) Resistance Between (104) – (115).V12 (female) (1) nector) Wiring harness between C02 (female) (115). 1 z Emergency Min. Problem that appears on machine • If pump load increases. then carry out troubleshooting without turning starting switch ON. engine speed lowers largely and engine may stall. 220-8 . 1 Mz a Prepare with starting switch OFF.

220-8 9 .40 Troubleshooting SEN00243-01 Circuit diagram related to PC-EPC (F) solenoid and PC-EPC (R) solenoid PC200.

(9) – chassis ground Emergency pump drive switch Resistance Min. 220-8 . • Even if cause of failure disappears. 4 Defective pump controller 10 C02 (female) Resistance Between (104) – (115). (Code: 01302 PC-EPC solenoid current (R)) • Method of reproducing failure code: Turn starting switch ON.SEN00243-01 40 Troubleshooting Failure code [DXA9KB] PC-EPC (R) Sol Short User code Failure code E02 DXA9KB Contents of trouble Action of controller Trouble 1 PC-EPC (R) solenoid system short (Pump controller system) • When PC-EPC (R) solenoid was driven. then carry out troubleshooting without turning starting switch ON. then carry out troubleshooting without turning starting switch ON. V12 (male) Resistance Between (1) – (2) 7 – 14 z Between (1) – chassis ground Min. 1 Mz PC200. (9) – (10) Between (8). then carry out troubleshooting without turning starting switch ON. • Turns output to PC-EPC (R) solenoid OFF. then carry out troubleshooting without turning starting switch ON. Possible causes and standard value in normal state Defective emergency pump 2 drive switch (Internal short circuit or ground fault) S25 (male) Between (8). engine speed lowers largely and engine may stall. 1 Mz a Prepare with starting switch OFF. Cause Defective PC-EPC (R) sole1 noid (Internal short circuit or ground fault) Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF. (120) 7 – 14 z Between (104) – chassis ground Min. 1 Mz a Prepare with starting switch OFF. 1 Mz Normal Min. Problem that appears on machine • If pump load increases. system does not reset itself until starting switch is turned OFF. short circuit was detected in circuit. 1 Mz a Prepare with starting switch OFF. (117). Related information • Drive current of PC-EPC (R) solenoid can be checked with monitoring function. Ground fault in wiring harWiring harness between C02 (female) (104) 3 ness (Contact with GND cir– S25 (female) (9) cuit) Wiring harness between S25 (female) (8) – V12 (female) (1) Resistance Min. 1 Mz Resistance Min.

220-8 11 .40 Troubleshooting SEN00243-01 Circuit diagram related to PC-EPC (F) solenoid and PC-EPC (R) solenoid PC200.

Disconnection in wiring harness (Disconnection in wiring Wiring harness between C02 (female) (88) – Resis2 Max. then carry out troubleshooting without turning starting switch ON. (120) 7 – 14 z PC200. system resets itself. Related information • Drive current of LS-EPC solenoid can be checked with monitoring function. disconnection was detected in circuit. Cause Defective LS-EPC solenoid 1 (Internal disconnection) Possible causes and standard value in normal state 1 Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF. 1 z or defective contact in con. 3 Defective pump controller 12 C02 (female) Resistance Between (88) – (115). • Work equipment speed and swing speed are high in lifting mode (L). ResisMax. • None in particular (Since no current flows.V19 (female) (1) tance nector) Wiring harness between C02 (female) (115). then carry out troubleshooting without turning starting switch ON. • If cause of failure disappears. 220-8 . Problem that appears on machine • Travel speed is high at Lo and Mi. (Code: 01500 LS-EPC solenoid current) • Method of reproducing failure code: Turn starting switch ON. (120) – V19 (female) (2) tance a Prepare with starting switch OFF. then carry out troubleshooting without turning starting switch ON. 1 z (117). V19 (male) Resistance Between (1) – (2) 7 – 14 z a Prepare with starting switch OFF. (117).SEN00243-01 40 Troubleshooting Failure code [DXE0KA] LS-EPC Sol Discon User code Failure code — DXE0KA Contents of trouble Action of controller Trouble LS-EPC solenoid system disconnection (Pump controller system) • When LS-EPC solenoid was driven. solenoid does not operate).

40 Troubleshooting SEN00243-01 Circuit diagram related to LS-EPC solenoid PC200. 220-8 13 .

• Even if cause of failure disappears. short circuit was detected in circuit. then carry out troubleshooting without turning starting switch ON. 1 Mz a Prepare with starting switch OFF. 1 Mz a Prepare with starting switch OFF. Related information • Drive current of LS-EPC solenoid can be checked with monitoring function. then carry out troubleshooting without turning starting switch ON. 3 Defective pump controller 14 C02 (female) Resistance Between (88) – (115). (120) 7 – 14 z Between (88) – chassis ground Min. (Code: 01500 LS-EPC solenoid current) • Method of reproducing failure code: Turn starting switch ON. • Work equipment speed and swing speed are high in lifting mode (L). then carry out troubleshooting without turning starting switch ON. 220-8 . • Turns output to LS-EPC solenoid OFF.SEN00243-01 40 Troubleshooting Failure code [DXE0KB] LS-EPC Sol Short User code Failure code — DXE0KB Contents of trouble Action of controller Trouble LS-EPC solenoid system short (Pump controller system) • When LS-EPC solenoid was driven. V19 (male) Resistance Between (1) – (2) 7 – 14 z Between (1) – chassis ground Min. Cause Defective LS-EPC solenoid 1 (Internal short circuit or ground fault) Possible causes and standard value in normal state 1 Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF. (117). 1 Mz PC200. Ground fault in wiring har2 ness (Short circuit with GND Wiring harness between C02 (female) (88) – circuit) V19 (female) (1) Resistance Min. system does not reset itself until starting switch is turned OFF. Problem that appears on machine • Travel speed is high at Lo and Mi.

40 Troubleshooting SEN00243-01 Circuit diagram related to LS-EPC solenoid PC200. 220-8 15 .

solenoid does not operate). 220-8 . 1 z (117). system resets itself. Disconnection in wiring harness (Disconnection in wiring Wiring harness between C02 (female) (97) – Resis2 Max. Related information • Drive current of service EPC solenoid can be checked with monitoring function.SEN00243-01 40 Troubleshooting Failure code [DXE4KA] Service Current EPC Discon User code Failure code — DXE4KA Contents of trouble Action of controller Trouble 1 Service current EPC solenoid disconnection (Pump controller system) • When service EPC solenoid was driven. (120) – V30 (female) (2) tance a Prepare with starting switch OFF. ResisMax.V30 (female) (1) tance nector) Wiring harness between C02 (female) (115). • If cause of failure disappears. then carry out troubleshooting without turning starting switch ON. 3 Defective pump controller 16 C02 (female) Resistance Between (97) – (115). then carry out troubleshooting without turning starting switch ON. 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. (117). (120) 7 – 14 z PC200. disconnection was detected in circuit. 1 z or defective contact in con. Problem that appears on machine • Attachment does not operate. then carry out troubleshooting without turning starting switch ON. (Code: 01700 service solenoid current) • Method of reproducing failure code: Turn starting switch ON + Set in attachment mode (ATT). V30 (male) Resistance Between (1) – (2) 7 – 14 z a Prepare with starting switch OFF. • None in particular (Since no current flows.

220-8 17 .40 Troubleshooting SEN00243-01 Circuit diagram related to service EPC solenoid PC200.

Ground fault in wiring har3 ness (Short circuit with GND Wiring harness between C02 (female) (97) – circuit) V30 (female) (1) Resistance Min. system does not reset itself until starting switch is turned OFF. Problem that appears on machine • Attachment does not operate. (Code: 01700 service EPC solenoid current) • Method of reproducing failure code: Turn starting switch ON + Set in attachment mode (ATT). 220-8 . 1 Mz a Prepare with starting switch OFF. V30 (male) Resistance Between (1) – (2) 7 – 14 z Between (1) – chassis ground Min. 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. • Even if cause of failure disappears. • Turns output to service EPC solenoid OFF. (117).SEN00243-01 40 Troubleshooting Failure code [DXE4KB] Service Current EPC Short User code Failure code — DXE4KB Contents of trouble Action of controller Trouble 1 Service current EPC solenoid short (Pump controller system) • When service EPC solenoid was driven. then carry out troubleshooting without turning starting switch ON. short circuit was detected in circuit. then carry out troubleshooting without turning starting switch ON. 1 Mz PC200. 4 Defective pump controller 18 C02 (female) Resistance Between (97) – (115). 1 Mz a Prepare with starting switch OFF. Related information • Drive current of service EPC solenoid can be checked with monitoring function. (120) 7 – 14 z Between (97) – chassis ground Min. then carry out troubleshooting without turning starting switch ON.

40 Troubleshooting SEN00243-01 Circuit diagram related to service EPC solenoid PC200. 220-8 19 .

SEN00243-01 40 Troubleshooting Failure code [DXE5KA] Merge-divider Main Sol Discon User code Failure code — DXE5KA Contents of trouble Action of controller Trouble 1 Merge-divider main solenoid disconnection (Pump controller system) • When merge-divider main EPC solenoid was driven. Related information • Drive current of merge-divider main EPC solenoid can be checked with monitoring function. Cause Defective merge-divider 1 main EPC solenoid (Internal disconnection) Possible causes and standard value in normal state Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF. (117). (120) – V23 (female) (2) tance a Prepare with starting switch OFF. Problem that appears on machine • Single operation speed of work equipment and swing is high in lifting mode (L).– V23 (female) (1) tance nector) Wiring harness between C02 (female) (115). V23 (male) Resistance Between (1) – (2) 7 – 14 z a Prepare with starting switch OFF. 1 z or defective contact in con. then carry out troubleshooting without turning starting switch ON. disconnection was detected in circuit. • None in particular (Since no current flows. (120) 7 – 14 z PC200. system resets itself. ResisMax. (Code: 08000 merge-divider main solenoid current) • Method of reproducing failure code: Turn starting switch ON. 3 Defective pump controller 20 C02 (female) Resistance Between (112) – (115). then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wiring Wiring harness between C02 (female) (112) Resis2 Max. then carry out troubleshooting without turning starting switch ON. 220-8 . 1 z (117). • If cause of failure disappears. solenoid does not operate).

40 Troubleshooting SEN00243-01 Circuit diagram related to merge-divider main EPC solenoid PC200. 220-8 21 .

SEN00243-01 40 Troubleshooting Failure code [DXE5KB] Merge-divider Main Sol Short User code Failure code — DXE5KB Contents of trouble Action of controller Trouble 1 Merge-divider main solenoid short (Pump controller system) • When merge-divider main EPC solenoid was driven. short circuit was detected in circuit. 1 Mz PC200. Cause Defective merge-divider 1 main EPC solenoid (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. 1 Mz a Prepare with starting switch OFF. 220-8 . (120) 7 – 14 z Between (112) – chassis ground Min. 1 Mz a Prepare with starting switch OFF. then carry out troubleshooting without turning starting switch ON. 3 Defective pump controller 22 C02 (female) Resistance Between (112) – (115). • Turns output to merge-divider main EPC solenoid OFF. then carry out troubleshooting without turning starting switch ON. Problem that appears on machine • Single operation speed of work equipment and swing is high in lifting mode (L). Related information • Drive current of merge-divider main EPC solenoid can be checked with monitoring function. V23 (male) Resistance Between (1) – (2) 7 – 14 z Between (1) – chassis ground Min. then carry out troubleshooting without turning starting switch ON. (Code: 08000 merge-divider main EPC solenoid current) • Method of reproducing failure code: Turn starting switch ON. (117). system does not reset itself until starting switch is turned OFF. Ground fault in wiring har2 ness (Short circuit with GND Wiring harness between C02 (female) (112) circuit) – V23 (female) (1) Resistance Min. • Even if cause of failure disappears.

40 Troubleshooting SEN00243-01 Circuit diagram related to merge-divider main EPC solenoid PC200. 220-8 23 .

disconnection was detected in circuit. Related information • Drive current of merge-divider LS EPC solenoid can be checked with monitoring function. solenoid does not operate). (117). then carry out troubleshooting without turning starting switch ON. then carry out troubleshooting without turning starting switch ON. then carry out troubleshooting without turning starting switch ON. (120) 7 – 14 z PC200. Disconnection in wiring harness (Disconnection in wiring Wiring harness between C02 (female) (89) – Resis2 Max. (120) – V24 (female) (2) tance a Prepare with starting switch OFF. (Code: 08001 merge-divider LS solenoid current) • Method of reproducing failure code: Turn starting switch ON. 3 Defective pump controller 24 C02 (female) Resistance Between (89) – (115). 1 z or defective contact in con.SEN00243-01 40 Troubleshooting Failure code [DXE6KA] Merge-divider LS Sol Discon User code Failure code — DXE6KA Contents of trouble Action of controller Trouble 1 Merge-divider LS solenoid disconnection (Pump controller system) • When merge-divider LS EPC solenoid was driven. 1 z (117). • If cause of failure disappears. V24 (male) Resistance Between (1) – (2) 7 – 14 z a Prepare with starting switch OFF. • None in particular (Since no current flows. system resets itself. 220-8 . Cause Defective merge-divider LS 1 EPC solenoid (Internal disconnection) Possible causes and standard value in normal state Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF. ResisMax. Problem that appears on machine • Single operation speed of work equipment and swing is high in lifting mode (L).V24 (female) (1) tance nector) Wiring harness between C02 (female) (115).

220-8 25 .40 Troubleshooting SEN00243-01 Circuit diagram related to merge-divider LS EPC solenoid PC200.

• Even if cause of failure disappears. Problem that appears on machine • Single operation speed of work equipment and swing is re high in lifting mode (L). • Turns output to merge-divider LS EPC solenoid OFF. 3 Defective pump controller 26 C02 (female) Resistance Between (89) – (115). then carry out troubleshooting without turning starting switch ON.SEN00243-01 40 Troubleshooting Failure code [DXE6KB] Merge-divider LS Sol Short User code Failure code — DXE6KB Contents of trouble Action of controller Trouble 1 Merge-divider LS solenoid short (Pump controller system) • When merge-divider LS EPC solenoid was driven. (Code: 08000 merge-divider LS EPC solenoid current) • Method of reproducing failure code: Turn starting switch ON. 1 Mz a Prepare with starting switch OFF. 220-8 . Cause Defective merge-divider LS 1 EPC solenoid (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. 1 Mz PC200. (120) 7 – 14 z Between (89) – chassis ground Min. short circuit was detected in circuit. Ground fault in wiring har2 ness (Short circuit with GND Wiring harness between C02 (female) (89) – circuit) V24 (female) (1) Resistance Min. V24 (male) Resistance Between (1) – (2) 7 – 14 z Between (1) – chassis ground Min. 1 Mz a Prepare with starting switch OFF. Related information • Drive current of merge-divider LS EPC solenoid can be checked with monitoring function. then carry out troubleshooting without turning starting switch ON. (117). system does not reset itself until starting switch is turned OFF. then carry out troubleshooting without turning starting switch ON.

220-8 27 .40 Troubleshooting SEN00243-01 Circuit diagram related to merge-divider LS EPC solenoid PC200.

then carry out troubleshooting without turning starting switch ON. 1 z Resistance Max. 20 z PC200. Cause Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF. 1 Mz Max. then carry out troubleshooting without turning starting switch ON. 1 z Min. 220-8 . 1 Mz Between (1) – (3) All range Max. C01 (female) 3 Defective pump controller Operating range top Between (56) – chasOther than operating sis ground range top Between (114) – (119) 28 Wiper blade All range Resistance Max.SEN00243-01 40 Troubleshooting Failure code [DY20KA] Wiper Working Abnormality User code Failure code — DY20KA Contents of trouble Action of controller Trouble 1 Wiper working abnormality (Pump controller system) • When windshield wiper works. W signal of working ends is not input. Problem that appears on machine • Wiper motor does not work. 1 z Resistance Max.J04 – chassis ground (T05. Defective wiper motor (Inter1 nal disconnection) M05 (female) Wiper blade Resistance Operating range top Max. Possible causes and standard value in normal state Wiring harness between C01 (female) (56) – M05 (male) (6) Disconnection in wiring harness (Disconnection in wiring Wiring harness between M05 (female) (5) – 2 or defective contact in con. 1 z a Prepare with starting switch OFF. 20 z a Prepare with starting switch OFF. (Code: 02204 switch 5) • Method of reproducing failure code: Turn starting switch ON + Set wiper switch to INT or ON. • Turns working output to wiper motor OFF. T06) nector) Wiring harness between C02 (female) (114) – M05 (male) (1) Wiring harness between C02 (female) (119) – M05 (male) (3) Resistance Max. 1 z Between (6) – (5) Other than operating range top Min. then carry out troubleshooting without turning starting switch ON. 1 z Resistance Max. system resets itself. Related information • Condition of W contact signal of wiper working area can be checked with monitoring function. • If cause of failure disappears.

40 Troubleshooting SEN00243-01 Circuit diagram related to windshield wiper and window washer PC200. 220-8 29 .

P signal of storage area is not input. 1 z a Prepare with starting switch OFF. (Code: 02204 switch 5) • Method of reproducing failure code: Turn starting switch ON + Set wiper switch to INT/ON to OFF.SEN00243-01 40 Troubleshooting Failure code [DY20MA] Wiper Parking Abnormality User code Failure code — DY20MA Contents of trouble Action of controller Trouble 1 Wiper parking abnormality (Pump controller system) • When windshield wiper parks. Related information • Condition of P contact signal of wiper parking area can be checked with monitoring function. 1 z a Prepare with starting switch OFF. 1 Mz All range Max. 220-8 . T06) Resistance Max. 20 z PC200. then carry out troubleshooting without turning starting switch ON. 1 z Wiring harness between M05 (female) (5) – J04 – chassis ground (T05. • Turns parking output to wiper motor OFF. 4 Defective pump controller 30 C01 (female) Wiper blade Resistance Between (75) – chassis ground Storage area Max. 20 z Wiring harness between C02 (female) (114) – M05 (male) (1) Resistance Max. Problem that appears on machine • Wiper motor does not park. then carry out troubleshooting without turning starting switch ON. 1 z Working area Min. 1 z Wiring harness between C02 (female) (114) – M05 (male) (1) Resistance Max. system resets itself. Cause Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF. Disconnection in wiring harness (Disconnection in wiring 3 or defective contact in connector) Wiring harness between C01 (female) (75) – M05 (male) (4) Resistance Max. then carry out troubleshooting without turning starting switch ON. 1 Mz Between (114) – (119) All range Max. • If cause of failure disappears. M05 (female) 1 Possible causes and standard value in normal state Defective wiper motor (Internal disconnection) Between (4) – (5) Between (1) – (3) Wiper blade Resistance Storage area Max. 1 z Wiring harness between C02 (female) (119) – M05 (male) (3) Resistance Max. 1 z Wiring harness between C02 (female) (119) – M05 (male) (3) Resistance Max. 1 z Working area Min.

220-8 31 .40 Troubleshooting SEN00243-01 Circuit diagram related to windshield wiper and window washer PC200.

– D02 (female) (3) circuit) Wiring harness between C01 (female) (3) – J04 – M06 (female) (2). circuit probably has ground fault. 4 Standard value in normal state/Remarks on troubleshooting If fuse is broken. (2) – chassis ground Min. Defective washer motor 2 (Internal short circuit or ground fault) Defective assembled-type 3 diode D02 (Internal short circuit) Possible causes and standard value in normal state M06 (male) Resistance Between (1) – (2) 5 – 20 z Between (1). Ground fault in wiring harWiring harness between F01 (4) – J03 – M06 5 ness (Short circuit with GND (female) (1). 1 Mz Resistance Min. – D02 (female) (7) 6 Defective pump controller 32 Resistance Min. 1 z a Prepare with starting switch OFF.(female) (1) nector) Wiring harness between C01 (female) (3) – J04 – M06 (female) (2) Resistance Max.) a Prepare with starting switch OFF. then carry out troubleshooting without turning starting switch ON. system resets itself. 1 Mz) a Prepare with starting switch OFF. disconnection was detected in circuit. 220-8 . Problem that appears on machine • Window washer does not operate. then turn starting switch ON and carry out troubleshooting. then carry out troubleshooting without turning starting switch ON. 1 Mz a Prepare with starting switch OFF. Disconnection in wiring harness (Disconnection in wiring Wiring harness between F01 (4) – J03 – M06 4 or defective contact in con. then carry out troubleshooting without turning starting switch ON.SEN00243-01 40 Troubleshooting Failure code [DY2CKA] Washer Drive Discon User code Failure code — DY2CKA Contents of trouble Action of controller Trouble 1 Window washer drive system disconnection (Pump controller system) • When output to window washer drive system was turned OFF (when ground circuit was connected). then carry out troubleshooting without turning starting switch ON. washer motor does not operate). Cause 1 Defective fuse No. C01 (female) Voltage Between (3) – chassis ground 20 – 30 V PC200. 1 z Resistance Max. 1 Mz a Prepare with starting switch OFF. • If cause of failure disappears. Related information • Method of reproducing failure code: Turn starting switch ON. D02 (female) Continuity (Resistance) Between (3) – (7) No continuity (Min. (See cause 5. • None in particular (Since no current flows.

220-8 33 .40 Troubleshooting SEN00243-01 Circuit diagram related to windshield wiper and window washer PC200.

then turn starting switch ON and carry out troubleshooting. 220-8 . (Since trouble is in system. system does not reset itself until starting switch is turned OFF. M06 (male) Resistance Between (1) – (2) 5 – 20 z a Prepare with starting switch OFF. troubleshooting cannot be carried out. short circuit was detected in circuit. Related information • Method of reproducing failure code: Turn starting switch ON + Turn washer switch ON.) PC200. 1 V J04 – M6 (female) (2). • Turns output to washer motor OFF. • Even if cause of failure disappears. Hot short (Short circuit with 2 24V circuit) in wiring harness Wiring harness between C01 (female) (3) – Voltage Max. Problem that appears on machine • Window washer does not operate. – D02 (female) (7) 3 Defective pump controller 34 Standard value in normal state/Remarks on troubleshooting If causes 1 and 2 are not detected.SEN00243-01 40 Troubleshooting Failure code [DY2CKB] Washer Drive Short User code Failure code — DY2CKB Contents of trouble Action of controller Trouble 1 Window washer drive system short (Pump controller system) • When output to window washer drive system was turned ON (ground circuit was disconnected). pump controller may be defective. Cause 1 Possible causes and standard value in normal state Defective washer motor (Internal short circuit) a Prepare with starting switch OFF. then carry out troubleshooting without turning starting switch ON.

220-8 35 .40 Troubleshooting SEN00243-01 Circuit diagram related to windshield wiper and window washer PC200.

) PC200. system does not reset itself until starting switch is turned OFF. 1 Mz – M05 (male) (3) tance 4 Defective pump controller 36 Standard value in normal state/Remarks on troubleshooting If causes 1 and 2 are not detected.SEN00243-01 40 Troubleshooting Failure code [DY2DKB] Wiper Drive (For) Short User code Failure code — DY2DKB Trouble 1 Wiper motor drive forward system short (Pump controller system) Contents of trouble • When output to wiper motor drive forward side was turned ON. Problem that appears on machine • Windshield wiper does not operate. then carry out troubleshooting without turning starting switch ON. short circuit was detected in circuit. Cause Possible causes and standard value in normal state Defective wiper motor (Inter1 nal short circuit or ground fault) a Prepare with starting switch OFF. 1 Mz a Prepare with starting switch OFF. M05 (female) Resistance Between (3) – (1) There is continuity Between (3) – chassis ground Min. pump controller may be defective. troubleshooting cannot be carried out. (Since trouble is in system. • Even if cause of failure disappears. 220-8 . Action of controller • Turns output to wiper motor drive forward side OFF. Related information • Method of reproducing failure code: Turn starting switch ON + Set wiper switch to INT or ON. then carry out troubleshooting Ground fault in wiring harwithout turning starting switch ON. 3 ness (Short circuit with GND Wiring harness between C02 (female) (119) Resiscircuit) Min.

220-8 37 .40 Troubleshooting SEN00243-01 Circuit diagram related to windshield wiper and window washer PC200.

1 Mz a Prepare with starting switch OFF. troubleshooting cannot be carried out. 220-8 . short circuit was detected in circuit. Cause Possible causes and standard value in normal state Defective wiper motor (Inter1 nal short circuit or ground fault) a Prepare with starting switch OFF. 3 ness (Short circuit with GND Wiring harness between C02 (female) (114) Resiscircuit) Min. (Since trouble is in system. system does not reset itself until starting switch is turned OFF. M05 (female) Continuity/Resistance Between (1) – (3) There is continuity Between (1) – chassis ground Min. • Even if cause of failure disappears. then carry out troubleshooting without turning starting switch ON.) PC200. then carry out troubleshooting Ground fault in wiring harwithout turning starting switch ON. pump controller may be defective.SEN00243-01 40 Troubleshooting Failure code [DY2EKB] Wiper Drive (Rev) Short User code Failure code — DY2EKB Trouble 1 Wiper motor drive reverse system short (Pump controller system) Contents of trouble • When output to wiper motor drive reverse side was turned ON. Related information • Method of reproducing failure code: Turn starting switch ON + Set wiper switch to INT or ON. 1 Mz – M05 (male) (1) tance 4 Defective pump controller 38 Standard value in normal state/Remarks on troubleshooting If causes 1 and 2 are not detected. Problem that appears on machine • Windshield wiper does not operate. Action of controller • Turns output to wiper motor drive reverse side OFF.

220-8 39 .40 Troubleshooting SEN00243-01 Circuit diagram related to windshield wiper and window washer PC200.

SEN00243-01 PC200. SEN00243-01 © 2006 KOMATSU All Rights Reserved Printed in Japan 03-06 (01) 40 . 220(LC)-8 Hydraulic excavator Form No.

............................................... 220-8 1 ...... 20 E-8 Emergency stop item lights up while engine is running ..................... 3 Information in troubleshooting table ........................ 18 E-7 Precaution lights up while engine is running .............................................................................................................................................................................................................................. 26 E-10 Hydraulic oil temperature gauge does not indicate normally...... 8 E-3 Engine does not start (Engine does not turn) .......................................... 25 E-9 Engine coolant temperature gauge does not indicate normally............................................................................11 E-4 Preheater does not operate.................SEN00244-01 HYDRAULIC EXCAVATOR 1SHOP MANUAL PC200-8 PC200LC-8 PC220-8 PC220LC-8 Machine model Serial number PC200-8 PC200LC-8 PC220-8 PC220LC-8 300001 and up 300001 and up 70001 and up 70001 and up 40 Troubleshooting 1 Troubleshooting of electrical system (E-mode) Troubleshooting of electrical system (E-mode)........................ 14 E-5 Automatic warm-up system does not operate (in cold season)................................................ 16 E-6 All work equipment........................................... machine monitor displays nothing ............ swing................... basic check item lights up.................... 6 E-2 When starting switch turned ON (before starting engine)...................................................................................................................................... 27 E-11 Fuel level gauge does not indicate normally........................................... 5 E-1 When starting switch turned ON..................... 3 Before carrying out troubleshooting of electrical system............................... and travel mechanism do not move or cannot be locked.................. 29 PC200.....................................

.... 32 E-16 Working mode does not change ................................... 57 E-27 KOMTRAX system does not operate normally ..................... 36 E-20 Power maximizing function does not operate normally ....... 31 E-13 Machine monitor does not display some items....... 44 E-24 While starting switch is in OFF position.......................................................................................... 33 E-17 Travel speed does not change............................................................... 220-8 .................... 56 E-25 Machine monitor cannot be set in service mode ............... service meter is not displayed...................................................................................................... 35 E-19 Windshield wiper and window washer do not operate....................................................................................... 31 E-14 Function switch does not work...................... 65 2 PC200................................................................................................... 40 E-22 Travel alarm does not sound or does not stop sounding ............................................................................................................. 31 E-15 Auto-decelerator does not operate normally.............................SEN00244-01 40 Troubleshooting E-12 Contents of display by machine monitor are different from applicable machine.................................................................................... 34 E-18 Alarm buzzer cannot be stopped ....................... 56 E-26 Monitoring function does not display lever control signal normally........... 42 E-23 Air conditioner does not operate normally (including air conditioner abnormality record) ........................................................................................................................................................................................... 38 E-21 Swing holding brake does not operate normally..........................................

rear lamp relay. 220-8 Cigarette lighter 4 10 A 5 10 A Horn relay. working lamp (rear) 9 10 A 10 10 A 11 20 A 12 10 A 13 10 A Headlamp 14 10 A Optional power supply (1) 15 10 A 16 10 A Radio Left knob switch (pump controller input) (Spare) Air conditioner unit Air conditioner compressor electromagnetic clutch (Spare) Travel alarm Optional power supply (2) Radio (backup power supply) Room lamp Starting switch 17 20 A Machine monitor 18 10 A (Spare) 19 30 A Engine controller 20 5A Engine controller (ACC signal) Pump controller 3 . a When carrying out troubleshooting related to the electrical system. cab lamp relay 1 10 A PC-EPC (F) solenoid valve. Fuse capacity Destination of power Lamp relay. you should check the fuses and fusible links to see if the power is supplied normally. PC-EPC (R) solenoid valve [When pump drive switch is operated in emergency] Swing holding brake solenoid valve [When swing holding brake release switch is operated] Switch power supply F04 (60 A) 2 30 A Pump controller (Solenoid power supply) PPC oil pressure lock solenoid valve 3 10 A Starting motor cut-out relay (PPC lock) Starting motor cut-out relay (Personal code) Switch power supply Switch power supply Constant power supply F04 (60 A) F04 (60 A) F05 (30 A) Switch power Starting switch supply ACC PC200.40 Troubleshooting SEN00244-01 Troubleshooting of electrical system (E-mode) 1 Before carrying out troubleshooting of electrical system 1 1 Connection table of fuse box a This connection table shows the devices to which each power supply of the fuse box supplies power (A switch power supply is a device which supplies power while the starting switch is in the ON position and a constant power supply is a device which supplies power while the starting switch is in the OFF and ON positions). horn 6 10 A Electrical intake air heater relay Windshield washer motor 7 10 A Rotary lamp 8 20 A Right headlamp. Type of power supply Fusible link Fuse No. working lamp (boom).

SEN00244-01 40 Troubleshooting Locations of fusible links Location of fuse box and fuse Nos. 220-8 . 4 PC200.

• If connector No.<Precautions for troubleshooting> ence numbers. • Short circuit Independent wiring harnesses are in contact with each other abnormally. 220-8 5 . Before carrying out troubleshooting. and pin No. dis3 connect connector and insert T-adapters in both male side and female side. Trouble Related information Trouble which occurred in the machine Information related to detected trouble or troubleshooting Cause Standard value in normal state/Remarks on troubleshooting <Contents of description> • Standard value in normal state to judge possible causes • Remarks on judgment 1 Possible causes and standard value in normal state <Troubles in wiring harness> • Disconnection Connector is connected imperfectly or wiring harness is broken. unless otherwise specified. • Connector No. • “Connector No. • Ground fault Wiring harness which is not connected to chassis ground circuit is in contact with chassis ground circuit.40 Troubleshooting SEN00244-01 Information in troubleshooting table a 1 The following information is summarized in the troubleshooting table and the related electrical circuit diagram.: Indicates (Model – Number of pins) and (Color). has marks of “male” and “female”. • If connector No. understand that information fully. Possible causes of trouble (Given numbers are refer.” from each branching/merging point: Shows the ends of branch or source of merging within the parts of the same wiring harness. disconnect connector and connect T-adapter to only male side or female side. or harness entered on rear side. or wiring harness entered on front side. PC200. • Connect negative (–) lead to pin No. which do 1) Method of indicating connector No. and handling of tester leads Connect positive (+) lead and negative (–) lead of tester as explained below for troubleshooting. unless otherwise specified. 2) Entry order of pin Nos. • Hot short Wiring harness which is not connected to power source (24 2 V) circuit is in contact with power source (24 V) circuit. 4 • Connect positive (+) lead to pin No. has no marks of “male” and “female”. and handling of Tnot indicate priority) adapter Insert or connect T-adapter as explained below for troubleshooting. Related circuit diagram This drawing is a part of the circuit diagram related to troubleshooting. • Arrow ( ): Roughly shows the location on the machine.

) a Prepare with starting switch OFF. (4) – chassis ground (T05) Resistance Max. 1 z Wiring harness between F01-17 – H15 (female) (1) Resistance Max. depending on the ambient temperature and the condition of the battery. 1 z Wiring harness between H15 (female) (5) – J03 – CM01 (female) (14) Resistance Max. circuit probably has ground fault.SEN00244-01 40 Troubleshooting E-1 When starting switch turned ON. screen of check before starting. then hold starting switch OFF and ON and carry out troubleshooting in each case. 24 V Min. 1. 220-8 . 1 z Wiring harness between F05 (male) (2) – F01-16D Resistance Max. 1 Mz Wiring harness between H15 (female) (5) – J03 – CM01 (female) (14) Resistance Min. (4) OFF 20 – 30 V Between (14) – (3). then carry out troubleshooting without turning starting switch ON. (See Cause 5. (2) – (3). screen to input password (if set). 1 z Wiring harness between battery (+) – R04 – F05 (male) (1) Resistance Max. 1 Mz Resistance Min. and ordinary screen in order. 1 z Wiring harness between CM01 (female) (3). machine monitor displays nothing. • When starting switch is turned ON. Cause Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF. screen to check breaker mode (if set). • When the engine is started. 1 Mz Wiring harness between F01-17 – H15 (female) (1) Resistance Min. (Check mounting bracket plate with connector. then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wiring 4 or defective contact in connector) Possible causes and standard value in normal state Wiring harness between battery (–) – chassis ground Resistance Max. (2) Resistance Max.) Wrong connection of connec. 1 Mz Resistance Min. 1 Mz Wiring harness between F05 (male) (2) – Ground fault in wiring harF01-16D 5 ness (Short circuit with GND Wiring harness between F01-17 – J06 – circuit) CM01 (female) (1). machine monitor displays KOMATSU logo. screen to check working mode and travel speed. machine monitor displays nothing1 Trouble Related information • When starting switch turned ON.26 If fusible link or fuse is broken. 1 Low charge level of battery Defective fusible link F05 or 2 fuse No. the battery voltage may lower suddenly. 6 Defective machine monitor 6 CM01 Starting switch Voltage Between (1). 1 z a Prepare with starting switch OFF. 17 3 Battery voltage (2 pieces) Electrolyte specific gravity (1 piece) Min.Machine monitor connector may be connected wrongly. 1 z Wiring harness between F01-17 – J06 – CM01 (female) (1). then carry out troubleshooting without turning starting switch ON. (2) a Prepare with starting switch OFF. Wiring harness between battery (+) – R04 – F05 (male) (1) Resistance Min. Check it tor directly. (4) ON 20 – 30 V PC200.

40 Troubleshooting SEN00244-01 Circuit diagram related to machine monitor power supply PC200. 220-8 7 .

1 z chassis ground (T10) tance a Prepare with starting switch OFF. (Code: 04500 Monitor input 1) Cause Lowering of radiator coolant 1 level (When system is normal) Standard value in normal state/Remarks on troubleshooting Coolant level in radiator sub tank may be low. 1 z Below LOW Min.P24 (female) (1) tance nector) Wiring harness between P24 (female) (2) – ResisMax. basic check item lights up Trouble Related information 1 (1) Radiator coolant level monitor lights up red. 4 Defective machine monitor CM02 Between (3) – chassis ground 8 Sub tank coolant level Voltage Between FULL – LOW Max. (If monitor lights up red while engine is running. it is also checked while engine is running. 220-8 . then carry out troubleshooting without turning starting switch ON.SEN00244-01 40 Troubleshooting E-2 When starting switch turned ON (before starting engine). then carry out troubleshooting without turning starting switch ON. 1 V Below LOW 20 – 30 V PC200. Defective radiator coolant 2 level switch (Internal disconnection) P24 (male) Between (1) – (2) Possible causes and standard value in normal state Sub tank coolant level Resistance Between FULL – LOW Max. Check it and add coolant if necessary. then turn starting switch ON and carry out troubleshooting. carry out this troubleshooting. • Although radiator coolant level monitor is basic check item. too.) • Condition of radiator coolant level switch signal can be checked with monitoring function. 1 z or defective contact in con. 1 Mz a Prepare with starting switch OFF. Disconnection in wiring harness (Disconnection in wiring Wiring harness between CM02 (female) (3) – Resis3 Max. a Prepare with starting switch OFF.

220-8 9 .40 Troubleshooting SEN00244-01 Circuit diagram related to radiator coolant level switch PC200.

1 z nector) P44 (female) (1) tance a Prepare with starting switch OFF. 1 V Below L 20 – 30 V 4 Defective machine monitor Circuit diagram related to engine oil level switch 10 PC200. (Code: 04501 Monitor input 2) Cause 1 Lowering of engine oil level (When system is normal) Defective engine oil level 2 switch (Internal disconnection) Possible causes and standard value in normal state Standard value in normal state/Remarks on troubleshooting Engine oil level may be low. 1 Mz Disconnection in wiring har. then turn starting switch ON and carry out troubleshooting.SEN00244-01 Trouble Related information 40 Troubleshooting (2) Engine oil level monitor lights up red. ness (Disconnection in wiring 3 or defective contact in con. CM02 Engine oil level Voltage Between (2) – chassis ground Between H – L Max. P44 (male) Engine oil level Resistance Between (1) – chassis ground Between H – L Max. Check it and add oil if necessary.Wiring harness between CM02 (female) (2) – ResisMax. 1 z Below L Min.a Prepare with starting switch OFF. a Prepare with starting switch OFF. • Condition of engine oil level switch signal can be checked with monitoring function. 220-8 . then carry out troubleshooting without turning starting switch ON. then carry out troubleshooting without turning starting switch ON.

• Engine starting circuit has following 2 start lock mechanisms. then carry out troubleshooting without turning starting switch ON. 3 Battery voltage (2 pieces) Electrolyte specific gravity (1 piece) Min. 1. S14 (female) Between (1) – (3) Defective starting motor cutout relay R06 or R07 (Inter5 nal disconnection or short circuit) Lock lever Resistance Free Min. 1 z Between (3) – (5) Min. generation input. Safety relay terminal 6 Defective starting motor safety relay (Internal defect) Voltage Between B – E Power supply 20 – 30 V Between R (R17-2) – E Generation input Max. 1 z a Prepare with starting switch OFF. starting motor safety relay is defective. 1 z Between (1) – (4) 4 Possible causes and standard value in normal state Defective lock lever switch (Internal disconnection) a Prepare with starting switch OFF. R07 (male) Resistance Between (1) – (2) 300 – 600 z Between (3) – (4) Max.) a Prepare with starting switch OFF. 24 V Min. then keep starting switch OFF and turn it to START and carry out troubleshooting in each case. 1 Mz a Prepare with starting switch OFF (with only terminal C disconnected). 1 Mz START Max.26 If fuse is broken. then carry out troubleshooting without turning starting switch ON. 1 Mz Lock Max. circuit probably has ground fault. PC200. (See cause 10. 1 V Between S (R17-1) – E Starting input 20 – 30 V Between C (R18) – E Starting output 20 – 30 V If power supply.40 Troubleshooting SEN00244-01 E-3 Engine does not start (Engine does not turn) Trouble Related information 1 • Engine does not start (Engine does not turn). and starting input are normal but starting output is not normal. 1) Start lock with password of machine monitor 2) Start lock with lock lever Cause Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF. 220-8 11 . then carry out troubleshooting without turning starting switch ON. then turn starting switch to START and carry out troubleshooting. R06 (male). 3 Defective starting switch (Internal disconnection) H15 (male) Starting switch Resistance OFF Min. 1 Low charge level of battery 2 Defective fuse No.

1 z Wiring harness between starting motor safety relay C – starting motor C (SC) Resistance Max. Wiring harness between H15 (female) (4) – J01 – R06 (female) (5). then turn starting switch to START and carry out troubleshooting. then carry out troubleshooting without turning starting switch ON. then turn starting switch ON and carry out troubleshooting. 1 z Wiring harness between starting motor safety relay B – heater relay – battery relay B Resistance Max. 1 z Wiring harness between starting motor safety relay E – chassis ground Resistance Max. – circuit branch end Resistance Min. Possible causes and standard value in normal state Disconnection in wiring harness (Disconnection in wiring 9 or defective contact in connector) Wiring harness between H15 (female) (4) – J01 – R06 (female) (5) Resistance Max. 1 Mz Resistance Min. 1 z Wiring harness between S14 (male) (3) – R06 (female) (1) Resistance Max. 1 Mz Wiring harness between R06 (female) (3) – R07 (female) (4) Resistance Min. 1 Mz Wiring harness between starting motor safety relay C – starting motor C (SC) Resistance Min. Alternator Between L – chassis ground Generation output Voltage Max. 1 V alternator L. 8 Defective alternator (Internal short circuit) a Prepare with starting switch OFF. – circuit branch end PC200. 1 V a Prepare with starting switch OFF. 1 Mz Wiring harness between F01-3 – S14 (male) (1) Resistance Min. then carry out troubleshooting without turning starting switch ON. then turn starting switch ON and carry out troubleshooting. 220-8 .SEN00244-01 40 Troubleshooting Cause Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF. 1 z Wiring harness between R07 (female) (3) – R17 (female) (1) Resistance Max. 1 Mz Wiring harness between S14 (male) (3) – R06 (female) (1) Resistance Min. 1 Mz Wiring harness between R07 (female) (3) – Ground fault in wiring harR17 (female) (1) 10 ness (Short circuit with GND Wiring harness between starting motor circuit) safety relay B – heater relay – battery relay B 11 12 a Prepare with starting switch OFF. 1 z Wiring harness between R06 (female) (2) – J04 – chassis ground (T04) Resistance Max. Hot short (Short circuit with 24V circuit) in wiring harness Wiring harness between R17 (female) (2) – Voltage Max. 1 Mz Resistance Min. 1 z Wiring harness between F01-3 – S14 (male) (1) Resistance Max. starting motor is defective. 1 z Wiring harness between R06 (female) (3) – R07 (female) (4) Resistance Max. Starting motor terminals 7 Defective starting motor (Internal defect) Voltage Between B (SB) – chassis ground Power supply 20 – 30 V Between C (SC) – chassis ground Starting input 20 – 30 V If power supply and starting input are normal but starting motor does not turn. 1 z a Prepare with starting switch OFF.

220-8 13 .40 Troubleshooting SEN00244-01 Circuit diagram related to preheating/starting of engine and charge of battery PC200.

• If engine coolant temperature is below 20°C. 2 Defective intake air heater (Internal disconnection) E01 Starting switch Voltage Between terminal – chassis ground HEAT 20 – 30 V If voltage is normal but heater mounting part does not become warm.Wiring harness between CM01 (female) ResisMax. 1 z Wiring harness between battery relay R03 – heater relay contact terminal Resistance Max.• Check that engine can be turned with starting motor (If engine cannot be turned. 1 V HEAT 20 – 30 V (2) When starting switch is turned to HEAT position. Cause Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF (with wiring harness connected). (Code: 04500 Monitor input 1) Cause 1 Defective starting switch (Internal disconnection) Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF. then keep starting switch OFF and turn it to HEAT and carry out troubleshooting in each case. 1 z a Prepare with starting switch OFF. 1 z PC200. 1 Mz HEAT Max. • Condition of starting switch (preheating) signal can be checked with the monitoring function. Related informa. H15 (male) Between (1) – (3) Possible causes and standard value in normal state 2 Starting switch Resistance OFF Min. 220-8 . 3 14 Disconnection in wiring harness (Disconnection in wiring or defective contact in connector) Wiring harness between H15 (female) (3) – J02 – heater relay R15 Resistance Max. a Prepare with starting switch OFF. then turn starting switch to HEAT and carry out troubleshooting in each case.SEN00244-01 40 Troubleshooting E-4 Preheater does not operate Trouble 1 (1) When starting switch is turned to HEAT position. preheating monitor does not light up or flash. then carry out troubleshooting Disconnection in wiring harwithout turning starting switch ON. Related informa. 3 Trouble Defective machine monitor CM01 Starting switch Voltage Between (16) – chassis ground OFF Max. carry out troubleshooting tion for E-1 Engine does not start (Engine does not turn)). automatic warm-up system operates and preheating monitor tion lights up for up to 30 seconds. intake air heater is defective. • Preheater monitor lights up when starting switch is turned to HEAT and starts flashing about 30 seconds after to notify completion of preheating (It stops flashing about 10 seconds after). then keep starting switch OFF and turn it to HEAT and carry out troubleshooting in each case. intake air heater mounting part does not become warm. then carry out troubleshooting without turning starting switch ON. then keep starting switch OFF and turn it to HEAT and carry out troubleshooting in each case. 1 Possible causes and standard value in normal state Defective heater relay (Internal disconnection) Heater relay Starting switch Continuity/Resistance Between R15 – chassis ground OFF There is continuity Between power supply terminal – R16 HEAT Max. 1 z Wiring harness between heater relay R16 – intake air heater E01 Resistance Max. ness (Disconnection in wiring or defective contact in connec. 1 z a Prepare with starting switch OFF (with wiring harness connected). 1 z tor) (16) – J02 – H15 (female) (3) tance a Prepare with starting switch OFF.

220-8 15 .40 Troubleshooting SEN00244-01 Circuit diagram related to preheating/starting of engine and charge of battery PC200.

) • If engine coolant temperature is below 10°C turbocharger protection function operates to keep the engine speed at low idle. • If fuel control dial is opened more than 70% for 3 seconds when starting switch is turned ON or after engine is started.200 rpm. Monitoring code Possible causes and standard value in normal state 1 Defective engine coolant temperature signal system 04107 Engine coolant temperature Engine coolant temperature Coolant temperature level 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 level of coolant temperature gauge is different from actual coolant temperature. carry out troubleshooting for E-9 Engine coolant temperature gauge does not indicate normally. 2 Defective engine controller If cause 1 is not detected. (Automatic warm-up system stops automatically after operating for 10 minutes. • When engine coolant temperature is below 30°C automatic warm-up system raises engine speed to 1. troubleshooting cannot be carried out. automatic warm-up system is turned OFF.SEN00244-01 40 Troubleshooting E-5 Automatic warm-up system does not operate (in cold season) Trouble Related information 1 • Automatic warm-up system does not operate (in cold season). (Since trouble is in system. Cause Standard value in normal state/Remarks on troubleshooting a Turn starting switch ON or start engine and carry out troubleshooting.) Engine coolant temperature gauge and engine coolant temperature monitor 16 PC200. engine controller may be defective. 220-8 .

Related information Cause 1 Defective fuse No. 1 Mz Resistance Min. – D01 (female) (4) 18 Resistance Min. then carry out troubleshooting without turning starting switch ON. 1 z Wiring harness between S14 (male) (2) – V01 (female) (1) Resistance Max. D01 (male) Resistance (Continuity) Between (4) – (8) Min. and travel mechanism do not move or cannot be locked 1 Trouble (1) All work equipment. 1 Mz a Prepare with starting switch OFF. 220-8 . swing. Ground fault in wiring harWiring harness between F01-3 – S14 (male) 6 ness (Short circuit with GND (1). 2 Defective lock lever switch (Internal disconnection) S14 (female) Between (1) – (2) Defective PPC lock solenoid 3 (Internal disconnection or short circuit) Possible causes and standard value in normal state Defective assembled-type 4 diode D01 (Internal short circuit) Lock lever Resistance Lock Min. 1 Mz (No continuity) a Prepare with starting switch OFF. then carry out troubleshooting without turning starting switch ON. 1 z a Prepare with starting switch OFF. 1 Mz Free Max. 3 Standard value in normal state/Remarks on troubleshooting If fuse is broken. swing.) a Prepare with starting switch OFF. 1 z Wiring harness between V01 (female) (2) – chassis ground (T09) Resistance Max. 1 Mz PC200. then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness (Disconnection in wiring 5 or defective contact in connector) Wiring harness between F01-3 – S14 (male) (1) Resistance Max. then carry out troubleshooting without turning starting switch ON. circuit probably has ground fault. – circuit branch end circuit) Wiring harness between S14 (male) (2) – V01 (female) (1). then carry out troubleshooting without turning starting switch ON. (See cause 6. 1 z a Prepare with starting switch OFF. V01 (male) Resistance Between (1) – (2) 20 – 60 z Between (1) – chassis ground Min.SEN00244-01 40 Troubleshooting E-6 All work equipment. and travel mechanism do not move.

then turn starting switch ON and carry out troubleshooting. Possible causes and standard value in normal state 1 Defective lock lever switch (Internal short circuit) S14 (female) Between (1) – (2) Lock lever Resistance Lock Min. 1 V V01 (female) (1).40 Troubleshooting Trouble SEN00244-01 (2) All work equipment. swing. – D01 (female) (4) Circuit diagram related to PPC lock solenoid PC200. Hot short (Short circuit with 2 24V circuit) in wiring harness Wiring harness between S14 (male) (2) – Voltage Max. Related information Cause Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF. 1 z a Prepare with starting switch OFF. and travel mechanism cannot be locked. then carry out troubleshooting without turning starting switch ON. 220-8 19 . 1 Mz Free Max.

5 – 29. then carry out troubleshooting without turning starting switch ON. Ground fault in wiring har3 ness (Short circuit with GND Wiring harness between CM01 (female) Resiscircuit) (11) – J02 – E12 (female) (1). then start engine and carry out troubleshooting.5 V Disconnection in wiring har. then carry out troubleshooting without turning starting switch ON.8 V PC200. ness (Disconnection in wiring 2 or defective contact in con.SEN00244-01 40 Troubleshooting E-7 Precaution lights up while engine is running Trouble Related information (1) Charge level monitor lights up red. 7. 220-8 .Wiring harness between CM01 (female) ResisMax. 1 z nector) (11) – J02 – E12 (female) (1) tance a Prepare with starting switch OFF. – circuit Min. E12 (male) Engine speed Voltage Between (1) – chassis ground Middle or higher 27. then start engine and carry out troubleshooting. • Signal voltage of alternator can be checked with monitoring function. 1 Mz tance branch end a Prepare with starting switch OFF. 4 Defective machine monitor 20 CM02 Engine Voltage Between (11) – chassis ground Running Min.a Prepare with starting switch OFF. (Code: 04300 Charge voltage) Cause Defective generation by 1 alternator (when system is normal) Possible causes and standard value in normal state 1 Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF.

40 Troubleshooting SEN00244-01 Circuit diagram related to preheating/starting of engine and charge of battery PC200. 220-8 21 .

(Code: 04501 Monitor input 2) Cause 1 Standard value in normal state/Remarks on troubleshooting Clogging of air cleaner (when Air cleaner may be clogged.P23 (female) (1) nector) Wiring harness between P23 (female) (2) – chassis ground (T09) Resistance Max. then carry out troubleshooting without turning starting switch ON. fuel level gauge system may be defective. 1 z Resistance Max. Carry out troubleshooting for E-11 Fuel level gauge does not indicate normally. 1 z a Prepare with starting switch OFF. then clean or replace if necsystem is normal) essary. Check it. Disconnection in wiring harness (Disconnection in wiring Wiring harness between CM02 (female) (4) – 3 or defective contact in con. –350 mmH2O} *2: –7. 1 V When clogged (Air intake resistance: *2) 20 – 30 V *1: Max. P23 (male) Defective air cleaner clog2 ging switch (Internal disconnection) Possible causes and standard value in normal state Between (1) – (2) Air cleaner Resistance When normal (Air intake resistance: *1) Max. • Condition of signal of air cleaner clogging switch can be checked with monitoring function. Check it and add fuel if is normal) necessary. 1 z When clogged (Air intake resistance: *2) Min. (3) Air cleaner clogging monitor lights up red.470 ± 490 Pa {–762 ± 50 mmH2O} 22 PC200. (Code: 04200 Fuel sensor voltage) Cause Possible causes and standard value in normal state Trouble Related information Standard value in normal state/Remarks on troubleshooting 1 Low fuel level (when system Fuel level may be low (below about 41 l).430 Pa {Max. 2 Defective fuel level gauge system If cause 1 is not detected. • Signal voltage of fuel sensor can be checked with monitoring function. then start engine and carry out troubleshooting. 220-8 . 1 Mz a Prepare with starting switch OFF. –3.SEN00244-01 Trouble Related information 40 Troubleshooting (2) Fuel level monitor lights up red. then start engine and carry out troubleshooting. a Prepare with starting switch OFF. CM02 4 Defective machine monitor Between (4) – chassis ground Air cleaner Voltage When normal (Air intake resistance: *1) Max.

40 Troubleshooting SEN00244-01 Circuit diagram related to air cleaner clogging switch PC200. 220-8 23 .

If cause 1 is not detected. then drain if full. system is normal) Cause Possible causes and standard value in normal state If cause 1 is not detected. Check it. (6) Hydraulic oil temperature monitor lights up white. • Lighting up white: Hydraulic oil temperature is low. (5) Water separator monitor lights up red. • Engine coolant temperature can be checked with monitoring function. Defective hydraulic oil temperature gauge system Standard value in normal state/Remarks on troubleshooting If monitor lights up white. Cause Possible causes and standard value in normal state Standard value in normal state/Remarks on troubleshooting If monitor lights up white. hydraulic oil temperature may be low (below about 20°C). PC200. (Code: 18800 WIF sensor condition) 2 Defective water-in-fuel sensor system If cause 1 is not detected.SEN00244-01 Trouble Related information 40 Troubleshooting (4) Engine coolant temperature monitor lights up white. hydraulic oil temperature gauge system may be defective. • Lighting up blue: Engine coolant temperature is proper. 220-8 . (Code: 04107 Engine coolant temperature) Cause Possible causes and standard value in normal state Insufficient warm-up of 1 machine (when system is normal) 2 Trouble Related information Defective engine coolant temperature gauge system Trouble Related information • Condition of signal of water-in-fuel sensor switch can be checked with monitoring function. • Hydraulic oil temperature can be checked with monitoring function. Warm up engine. • Signals of hydraulic oil temperature sensor are input to pump controller and then transmitted to machine monitor through communication system. (Code: 04401 Hydraulic oil temperature) Insufficient warm-up of 1 machine (when system is normal) 2 24 Standard value in normal state/Remarks on troubleshooting Water separator is full (when 1 Water separator may be full of water. Carry out troubleshooting for failure codes [CA428] and [CA429]. Carry out troubleshooting for E-10 Hydraulic oil temperature gauge does not indicate normally. • Lighting up blue: Hydraulic oil temperature is proper. engine coolant temperature gauge system may be defective. • Lighting up white: Engine coolant temperature is low. engine coolant temperature may be low (below about 30°C). water-in-fuel sensor system may be defective. Carry out troubleshooting for E-9 Engine coolant temperature gauge does not indicate normally. Warm up engine. • Signals of engine coolant temperature sensor are input to engine controller and then transmitted to machine monitor through communication system.

(2) Hydraulic oil temperature monitor lights up red. 1 ant (when system is normal) • Lighting up red: Engine coolant temperature is high (overheating). 25 . engine coolant temperature gauge system may be defective. If it is low. (Code: 04107 Engine coolant temperature) Cause Possible causes and standard value in normal state Related information Defective engine coolant temperature gauge system Trouble Related information Possible causes and standard value in normal state PC200. engine oil pressure gauge system may be switch system defective. • Signals of engine coolant temperature sensor are input to engine controller and then transmitted to machine monitor through communication system. Carry out troubleshooting for E-9 Engine coolant temperature gauge does not indicate normally. 2 Defective engine oil pressure If cause 1 is not detected. engine coolant temperature may be high (above about 102°C). 2 Trouble 1 Standard value in normal state/Remarks on troubleshooting 1 Overheating of hydraulic oil (when system is normal) If monitor lights up red. Cause Standard value in normal state/Remarks on troubleshooting Lowering of engine oil pres1 sure (when system is normal) Engine oil pressure may be low. • Lighting up blue: Engine coolant temperature is proper. • Lighting up blue: Hydraulic oil temperature is proper.idle).40 Troubleshooting SEN00244-01 E-8 Emergency stop item lights up while engine is running Trouble Related information (1) Engine coolant temperature monitor lights up red. hydraulic oil temperature may be high (above about 102°C). • Engine coolant temperature can be checked with monitoring function. 220-8 If cause 1 is not detected. (3) Engine oil pressure monitor lights up red. 2 Defective hydraulic oil temperature gauge system If cause 1 is not detected. carry out troubleshooting for S-12 Oil pressure lowers. • Signals of engine oil pressure switch are input to engine controller and then transmitted to machine monitor through communication system. Cool down engine coolant (Run engine at low Overheating of engine cool. Carry out troubleshooting for E-10 Hydraulic oil temperature gauge does not indicate normally. • Hydraulic oil temperature can be checked with monitoring function. Cool down hydraulic oil (Run engine at low idle). hydraulic oil temperature gauge system may be defective. Carry out troubleshooting for failure code [CA435]. (Code: 04401 Hydraulic oil temperature) Cause Possible causes and standard value in normal state Standard value in normal state/Remarks on troubleshooting If monitor lights up red. • Lighting up red: Hydraulic oil temperature is high (overheating). • Signals of hydraulic oil temperature sensor are input to pump controller and then transmitted to machine monitor through communication system.

SEN00244-01 40 Troubleshooting E-9 Engine coolant temperature gauge does not indicate normally 1 Trouble (1) While engine coolant temperature is rising normally. temperature gauge rises to red range (H). (Since trouble is in system. troubleshooting cannot be carried out. Possible causes and standard value in normal state Engine coolant temperature 1 Defective machine monitor Coolant temperature Color of monitor light level (a) 105°C 6 102°C 5 100°C 4 85°C 3 60°C 2 30°C 1 Red Blue White Engine coolant temperature gauge and engine coolant temperature monitor 26 PC200. (Code: 04107 Engine coolant temperature) Cause Standard value in normal state/Remarks on troubleshooting a Turn starting switch ON or start engine and carry out troubleshooting. machine monitor may be defective. Related information • Signals of engine coolant temperature sensor are input to engine controller and then transmitted to machine monitor through communication system. (4) Display of engine coolant temperature gauge is different from display of engine coolant temperature monitor. (2) While engine coolant temperature is stabilized normally. (Code: 04107 Engine coolant temperature) Cause Possible causes and standard value in normal state Standard value in normal state/Remarks on troubleshooting Defective engine coolant temperature sensor system If cause 1 is not detected. • Engine coolant temperature can be checked with monitoring function. Carry out troubleshooting for failure codes [CA144] and [CA145]. 2 Defective machine monitor If cause 1 is not detected. temperature gauge does not rise from white range (C). • Engine coolant temperature can be checked with monitoring function. 220-8 .) 1 Trouble (3) Display of coolant temperature gauge is different from actual engine coolant temperature. engine coolant temperature sensor system may be defective. Related information • Signals of engine coolant temperature sensor are input to engine controller and then transmitted to machine monitor through communication system.

40 Troubleshooting SEN00244-01 E-10 Hydraulic oil temperature gauge does not indicate normally Trouble Related information (1) While hydraulic oil temperature is rising normally. 1 Mz If causes 1 – 5 are not detected. • Signals of hydraulic oil temperature sensor are input to pump controller and then transmitted to machine monitor through communication system. P22 (male) Resistance Between (1) – (2) 3. troubleshooting cannot be carried out. 1 z P22 (female) (1) tance a Prepare with starting switch OFF. (2) While hydraulic oil temperature is stabilized normally. 1 Mz P22 (female) (2) tance a Prepare with starting switch OFF. 5 Defective pump controller 6 Defective machine monitor C01 (female) Resistance Between (29) – (46) 3. then turn starting switch ON and carry out troubleshooting. Hot short (Short circuit with 4 24V circuit) in wiring harness Wiring harness between C01 (female) (29) – Voltage Max. temperature gauge rises to red range (H). • Hydraulic oil temperature can be checked with monitoring function. 220-8 27 . 1 Mz a Prepare with starting switch OFF. then carry out troubleshooting without turning starting switch ON.5 – 90 kz Between (29) – chassis ground Min. temperature gauge does not rise from white range (C).P22 (female) (2) tance nector) Wiring harness between C01 (female) (46) – ResisMax.) Circuit diagram related to hydraulic oil temperature sensor PC200. 1 V P22 (female) (2) 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 C01 (female) (29) – Resis2 Max. 3 ness (Short circuit with GND Wiring harness between C01 (female) (29) – Resiscircuit) Min. machine monitor may be defective. 1 z or defective contact in con. (Code: 04401 Hydraulic oil temperature) Cause Defective hydraulic oil tem1 perature sensor (Internal disconnection or short circuit) Possible causes and standard value in normal state 1 Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF. then carry out troubleshooting without turning starting switch ON. (Since trouble is in system. then carry out troubleshooting Ground fault in wiring harwithout turning starting switch ON.5 – 90 kz Between (2) – chassis ground Min.

• Hydraulic oil temperature can be checked with monitoring function. (4) Display of hydraulic oil temperature gauge is different from display of hydraulic oil temperature monitor. 220-8 . • Signals of hydraulic oil temperature sensor are input to pump controller and then transmitted to machine monitor through communication system. (Code: 04401 Hydraulic oil temperature) Cause Standard value in normal state/Remarks on troubleshooting a Turn starting switch ON or start engine and carry out troubleshooting.SEN00244-01 Trouble Related information 40 Troubleshooting (3) Display of hydraulic oil temperature gauge is different from actual hydraulic oil temperature.Color of monitor light ture level (a) 105°C 6 102°C 5 100°C 4 85°C 3 40°C 2 20°C 1 Red Blue White Hydraulic oil temperature gauge and hydraulic oil temperature monitor 28 PC200. Possible causes and standard value in normal state Hydraulic oil temperature 1 Defective machine monitor Hydraulic oil tempera.

(Code: 04200 Fuel level sensor voltage) Cause Defective fuel level sensor 1 (Internal disconnection or short circuit) Possible causes and standard value in normal state 1 Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF.Wiring harness between CM01 (female) (9) – ResisMax. 5 Defective machine monitor CM01 (female) Fuel level Resistance Between (9) – chassis ground FULL 7 – 11 z EMPTY 85 – 95 z Circuit diagram related to fuel level sensor PC200. 1 V P21 (female) (1) a Prepare with starting switch OFF. fuel level gauge does not lower from green range top (F) • Signal voltage of fuel level sensor can be checked with monitoring function. 1 z nector) P21 (female) (1) tance a Prepare with starting switch OFF. then carry out troubleshooting without turning starting switch ON. then carry out troubleshooting without turning starting switch ON. fuel level gauge does not rise from red range (E). (2) While fuel level is low. then carry out troubleshooting Ground fault in wiring harwithout turning starting switch ON.40 Troubleshooting SEN00244-01 E-11 Fuel level gauge does not indicate normally Trouble Related information (1) While fuel is added. 3 ness (Short circuit with GND Wiring harness between CM01 (female) (9) – Resiscircuit) Min. then turn starting switch ON and carry out troubleshooting.a Prepare with starting switch OFF. then carry out troubleshooting without turning starting switch ON. 1 Mz P21 (female) (1) tance a Prepare with starting switch OFF. P21 (male) Fuel level Resistance Between (1) – chassis ground FULL 7 – 11 z EMPTY 85 – 95 z Disconnection in wiring har. Hot short (Short circuit with 4 24V circuit) in wiring harness Wiring harness between CM01 (female) (9) – Voltage Max. 220-8 29 . ness (Disconnection in wiring 2 or defective contact in con.

• Signal voltage of fuel level sensor can be checked with monitoring function.SEN00244-01 Trouble Related information 40 Troubleshooting (3) Display of fuel level gauge is different from actual fuel level. 220-8 .5 l 5 200 l 4 100 l 3 60 l 2 41 l 1 Blue Red Fuel level gauge and fuel level monitor 30 PC200. Possible causes and standard value in normal state Quantity of fuel 1 Defective machine monitor Reading of fuel level Color of monitor light gauge (a) 289 l 6 244. (Code: 04200 Fuel level sensor voltage) Cause Standard value in normal state/Remarks on troubleshooting a Turn starting switch ON or start engine and carry out troubleshooting. (4) Display of fuel level gauge is different from display of fuel level monitor.

) E-13 Machine monitor does not display some items Trouble Related information • Machine monitor does not display some items. machine monitor may be defective. Cause Possible causes and standard value in normal state 1 Standard value in normal state/Remarks on troubleshooting a Turn starting switch ON and carry out troubleshooting.) 31 . Possible causes and standard value in normal state 1 Defective model code signal Monitoring code Normal display 00200 Controller model code PC200-8: PC200-8 PC220-8: PC220-8 If display of monitoring is abnormal. machine monitor may be defective. (Since trouble is in system. troubleshooting cannot be carried out. if all LCD panel is lighted up (all surface becomes white). 2 Defective machine monitor If cause 1 is not detected.) E-14 Function switch does not work Trouble Related information Possible causes and standard value in normal state PC200. troubleshooting cannot be carried out. troubleshooting cannot be carried out.40 Troubleshooting SEN00244-01 E-12 Contents of display by machine monitor are different from applicable machine Trouble 1 Contents of display by machine monitor are different from applicable machine. (Code: 04503 Monitor function switch) Cause Standard value in normal state/Remarks on troubleshooting 1 Defective machine monitor Machine monitor may be defective. If the number of the bright points and black points does not exceed 10. (Since trouble is in system. 220-8 1 • Function switch does not work. • Operation of switches: [4] + [F2] (Press simultaneously) If cause 1 is not detected. (Since trouble is in system. • 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. LCD panel is normal. Defective machine monitor 1 (LCD panel) 2 Defective machine monitor (body) When following switches are operated. • Condition of signal of function switch can be checked with monitoring function. carry out troubleshooting for failure code [DA29KQ]. those points are not a failure or a defect. Related information Cause Standard value in normal state/Remarks on troubleshooting a Turn starting switch ON and carry out troubleshooting (with monitoring function).

) 4 Defective engine controller If cause 1 is not detected. troubleshooting cannot be carried out. • Set speed of auto-decelerator is 1.SEN00244-01 40 Troubleshooting E-15 Auto-decelerator does not operate normally Trouble Related information Possible causes and standard value in normal state Trouble Related information 1 (1) When auto-decelerator switch is operated. (Since trouble is in system. machine monitor may be defective. (Since trouble is in system. engine controller may be defective. autodecelerator is not operated or reset. 32 2 Defective machine monitor If cause 1 is not detected. If fuel control dial is not set above this speed.) (2) Auto-decelerator is not operated or reset with lever. Cause Standard value in normal state/Remarks on troubleshooting a Start engine and carry out troubleshooting (with monitoring function). (Since trouble is in system. Monitoring code Item Normal display Swing Travel 01900 Pressure switch 1 Possible causes and standard value in normal state Defective PPC pressure sig1 nal Boom lower Boom raise Arm curl When lever is operated: ON When lever is in neutral: OFF Arm dump Bucket curl 01901 Pressure switch 2 Bucket dump Service When lever is operated: ON When lever is in neutral: OFF If display of monitoring is abnormal. 2nd line switches) Cause 1 Defective machine monitor Standard value in normal state/Remarks on troubleshooting Machine monitor may be defective. • Condition of signal of auto-decelerator switch can be checked with monitoring function. troubleshooting cannot be carried out. (Since trouble is in system. troubleshooting cannot be carried out.) 3 Defective pump controller If cause 1 is not detected. troubleshooting cannot be carried out. 220-8 . pump controller may be defective. carry out troubleshooting for E-26 Monitoring function does not display lever control signal normally.400 rpm.) PC200. auto-decelerator monitor does not light up or does not go off. (Code: 04504 Monitor 1st.

setting of engine and hydraulic pump is not changed. troubleshooting cannot be carried out. (Since trouble is in system.) 33 . troubleshooting cannot be carried out.) 2 Defective pump controller Pump controller may be defective. • Condition of signal of working mode switch can be checked with monitoring function. (Code: 04504 Monitor 1st. troubleshooting cannot be carried out. 2nd line switches) Cause 1 Defective machine monitor Standard value in normal state/Remarks on troubleshooting Machine monitor may be defective. Related information Possible causes and standard value in normal state PC200. working mode selection screen is not displayed. (Since trouble is in system. (Since trouble is in system.40 Troubleshooting SEN00244-01 E-16 Working mode does not change Trouble Related information Possible causes and standard value in normal state Trouble 1 (1) When working mode switch is operated. 220-8 Cause Standard value in normal state/Remarks on troubleshooting 1 Defective machine monitor Machine monitor may be defective.) (2) When working mode is changed.

troubleshooting cannot be carried out. • If cause 1 occurs. machine monitor may be defective. actual travel speed does not change. travel speed monitor does not change. 220-8 . troubleshooting cannot be carried out. pump controller may be defective. troubleshooting cannot be carried out. 2nd line switches) Cause 1 Defective machine monitor Standard value in normal state/Remarks on troubleshooting Machine monitor may be defective. (Since trouble is in system.) 3 Defective pump controller If cause 1 is not detected.) Circuit diagram related to travel speed shifting solenoid 34 PC200. Cause Possible causes and standard value in normal state 1 Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF.SEN00244-01 40 Troubleshooting E-17 Travel speed does not change Trouble Related information Possible causes and standard value in normal state Trouble Related information (1) When travel speed switch is operated. • Condition of signal of travel speed switch can be checked with monitoring function. actual travel speed does not lower when travel speed is shifted to Lo. then turn starting switch ON and carry out troubleshooting.) (2) When travel speed is shifted. (Code: 04504 Monitor 1st. 1 V V04 (female) (1) 2 Defective machine monitor If cause 1 is not detected. Hot short (Short circuit with 1 24V circuit) in wiring harness Wiring harness between C02 (female) (87) – Voltage Max. (Since trouble is in system. (Since trouble is in system.

2nd line switches) Cause 1 Defective machine monitor Standard value in normal state/Remarks on troubleshooting Machine monitor may be defective. • Condition of signal of alarm buzzer cancel switch can be checked with monitoring function. (Since trouble is in system. (Code: 04503 Monitor 1st.40 Troubleshooting SEN00244-01 E-18 Alarm buzzer cannot be stopped Trouble Related information Possible causes and standard value in normal state PC200. 220-8 1 • Alarm buzzer cannot be stopped. troubleshooting cannot be carried out.) 35 .

then carry out troubleshooting without turning starting switch ON. 220-8 . • Condition of window rear limit switch signal can be checked with monitoring function. Defective wiper motor (Inter2 nal disconnection) M05 (female) Continuity Between (1) – (3) There is continuity a Prepare with starting switch OFF. 1 Mz tance a Prepare with starting switch OFF. then carry out troubleshooting without turning starting switch ON. 1 z Resistance Max. then carry out troubleshooting Ground fault in wiring harwithout turning starting switch ON.– M05 (male) (3) nector) Wiring harness between C02 (female) (114) – M05 (male) (1) Resistance Max.) (2) When wiper switch is operated. 1 z a Prepare with starting switch OFF. 1 z a Prepare with starting switch OFF. Related information • Condition of wiper switch signal can be checked with monitoring function.SEN00244-01 40 Troubleshooting E-19 Windshield wiper and window washer do not operate Trouble (1) When wiper switch is operated. then carry out troubleshooting without turning starting switch ON. 1 z a Prepare with starting switch OFF. Possible causes and standard value in normal state Disconnection in wiring harness (Disconnection in wiring Wiring harness between C02 (female) (119) 3 or defective contact in con. C02 (female) Continuity Between (119) – (114) There is continuity PC200. (Code: 02204 Switch 5) Cause Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF. then carry out troubleshooting without turning starting switch ON. (Code: 04504 Monitor 1st. wiper does not operate. 2nd line switches) Possible causes and standard value in normal state Trouble Related information Cause 1 Defective machine monitor 1 Standard value in normal state/Remarks on troubleshooting Machine monitor may be defective. Defective pump controller (Rear limit switch system) 5 Defective pump controller (Wiper motor system) 36 C01 (female) Between (57) – chassis ground Front window Resistance When installed to front Min. 1 Mz When retracted to rear Max. troubleshooting cannot be carried out. 1 Defective window rear limit switch (Internal short circuit) W03 (male) Between (1) – (2) Front window Resistance When installed to front Min. wiper monitor does not light up or go off. 4 ness (Short circuit with GND Resiscircuit) C01 (female) (57) – W03 (female) (1) Min. then carry out troubleshooting without turning starting switch ON. (Since trouble is in system. 1 Mz When retracted to rear Max.

220-8 (3) When window washer switch is operated. • Condition of window washer switch signal can be checked with monitoring function. (Since trouble is in system. 2nd line switches) Cause 1 Defective machine monitor Standard value in normal state/Remarks on troubleshooting Machine monitor may be defective.40 Troubleshooting SEN00244-01 Circuit diagram related to windshield wiper and window washer Trouble Related information Possible causes and standard value in normal state PC200. troubleshooting cannot be carried out. window washer does not operate.) 37 . (Code: 04504 Monitor 1st.

(2) When left knob switch is pressed. 1 z a Prepare with starting switch OFF. 5 Defective pump controller C01 (female) Between (41) – chassis ground 6 Defective machine monitor Left knob switch Released Resistance Min.) a Prepare with starting switch OFF.) Circuit diagram related to left knob switch 38 PC200. then carry out troubleshooting without turning starting switch ON.(female) (1) tance nector) Wiring harness between S11 (female) (2) – ResisMax. 1 Mz Pressed Max. then carry out troubleshooting without turning starting switch ON. (Since trouble is in system. Ground fault in wiring harWiring harness between F01-9 – S11 Resis4 ness (Short circuit with GND Min. Possible causes and standard value in normal state Disconnection in wiring harness (Disconnection in wiring Wiring harness between F01-9 – S11 Resis3 Max. 220-8 . troubleshooting cannot be carried out. then carry out troubleshooting without turning starting switch ON. circuit probably has ground fault. • One-touch power maximizing function does not work when working mode is not power mode (P) or economy mode (E). • Condition of left knob switch signal can be checked with monitoring function. then carry out troubleshooting without turning starting switch ON. S11 (male) Between (1) – (2) Left knob switch Released Resistance Min. 1 z or defective contact in con. (See cause 4. 1 Mz (female) (1) tance circuit) Wiring harness between S11 (female) (2) – ResisMin. (Code: 02200 Switch input 1) Cause 1 Defective fuse No.SEN00244-01 40 Troubleshooting E-20 Power maximizing function does not operate normally Trouble Related information 1 (1) When left knob switch is pressed. one-touch power maximizing monitor is not displayed. 1 Mz Pressed Max. work equipment power is not increased. 1 z C01 (female) (41) tance a Prepare with starting switch OFF. 1 Mz C01 (female) (41) tance a Prepare with starting switch OFF. 1 z Machine monitor may be defective. 9 2 Defective left knob switch (Internal disconnection) Standard value in normal state/Remarks on troubleshooting If fuse is broken.

40 Troubleshooting Trouble Related information SEN00244-01 (3) When left knob switch is released. work equipment power does not return to normal level. Hot short (Short circuit with 1 24V circuit) in wiring harness Wiring harness between C02 (female) (109) Voltage Max. (Code: 02200 Switch input 1) Cause Possible causes and standard value in normal state Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF. pump controller may be defective. 1 V – V02 (female) (1) 2 Defective pump controller If cause 1 is not detected. 220-8 39 . then turn starting switch ON and carry out troubleshooting. • Condition of left knob switch signal can be checked with monitoring function.) Circuit diagram related to 2-stage relief solenoid PC200. troubleshooting cannot be carried out. (Since trouble is in system.

J02 – S04 (female) (5) tance nector) Wiring harness between S04 (female) (6) – ResisMax. – C01 (female) (19) tance a Prepare with starting switch OFF. swing lock does not operate.) Related information Cause 1 Defective swing lock switch (Internal short circuit) Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF. (Machine monitor system code: 04502 Monitor input 3) (Pump controller system code: 02200 Switch input 1) Cause Defective swing lock switch 1 (Internal disconnection or short circuit) Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF. then carry out troubleshooting without turning starting switch ON. then turn starting switch ON and carry out troubleshooting. • Condition of swing lock switch signal can be checked with monitoring function. 1 z a Prepare with starting switch OFF. S04 (male) Swing lock switch Resistance Between (5) – (6) OFF ON Min. 4 Defective machine monitor CM02 Between (5) – chassis ground Trouble Swing lock switch OFF Voltage 20 – 30 V ON Max. then carry out troubleshooting without turning starting switch ON. 220-8 . 1 V 24V circuit) in wiring harness J02 – S04 (female) (3). 1 Mz Max. 1 Mz J02 – S04 (female) (5). then carry out troubleshooting without turning starting switch ON. 3 ness (Short circuit with GND Wiring harness between CM02 (female) (5) – Resiscircuit) Min. then carry out troubleshooting without turning starting switch ON. – D03 (female) (3) 40 Min. swing lock monitor does not light up or go off. – S25 (female) (14) Wiring harness between S04 (female) (4) – V03 (female) (1). Defective swing holding Swing holding brake S25 (male) Resistance 2 brake release switch (Interrelease switch nal short circuit) Lock Min. 1 z or defective contact in con. then carry out troubleshooting Ground fault in wiring harwithout turning starting switch ON. 1 V PC200. Hot short (Short circuit with Wiring harness between D01 (female) (3) – 3 Voltage Max. then turn starting switch ON and carry out troubleshooting. (Hydraulic drift of swing occurs on slope. 1 z Voltage Max.SEN00244-01 40 Troubleshooting E-21 Swing holding brake does not operate normally Trouble Related information 1 (1) When swing lock switch is operated. S04 (male) Swing lock switch Resistance Between (3) – (4) Possible causes and standard value in normal state OFF ON a Prepare with starting switch OFF. 1 V (2) When swing lock switch is turned ON. Possible causes and standard value in normal state Disconnection in wiring harness (Disconnection in wiring Wiring harness between CM02 (female) (5) – Resis2 Max. 1 Mz Max. 1 z a Prepare with starting switch OFF. 1 Mz Between (13) – (14) Release Max. 1 z J05 – chassis ground (T07) tance a Prepare with starting switch OFF.

40 Troubleshooting SEN00244-01 Circuit diagram related to swing holding brake solenoid PC200. 220-8 41 .

D02 (male) Continuity Between (4) – (8) No continuity a Prepare with starting switch OFF. Monitoring code Item Possible causes and standard value in normal state 1 Normal display When lever is operated: ON 01900 Defective travel signal sysTravel 2 Pressure switch 1 When lever is in tem neutral: OFF If display of monitoring is abnormal. 15 Standard value in normal state/Remarks on troubleshooting If fuse is broken. (See cause 4. a Prepare with starting switch OFF. nal defect) Trouble (2) Alarm does not stop sounding while machine is stopped. 1 z or defective contact in con. 1 z J01 (19) – P09 (female) (2) tance a Prepare with starting switch OFF. then carry out troubleshooting Ground fault in wiring harwithout turning starting switch ON. travel alarm is defective. 3 ness (Short circuit with GND Wiring harness between M14 (female) (2) – Resiscircuit) Min. 1 Mz (female) (1).(female) (1) tance nector) Wiring harness between M14 (female) (2) – ResisMax. 1 Mz J01 – P09 (female) (2). Monitoring code Item 1 Possible causes and standard value in normal state Defective travel signal system Defective assembled-type 2 diode D02 (Short circuit with GND circuit) Normal display When lever is operated: ON Pressure switch 1 Travel When lever is in neutral: OFF If display of monitoring is abnormal. a Prepare with starting switch OFF. 4 ness (Short circuit with GND Wiring harness between F01-15 – J03 – M14 Resiscircuit) Min. circuit probably has ground fault. carry out troubleshooting for E26 Monitoring function does not display lever control signal normally. Related information Cause Standard value in normal state/Remarks on troubleshooting a Start engine and carry out troubleshooting. Disconnection in wiring harness (Disconnection in wiring Wiring harness between F01-15 – J03 – M14 Resis3 Max. 220-8 . then carry out troubleshooting without turning starting switch ON. – D02 (female) (4) tance 42 PC200. – circuit branch end tance Defective travel alarm (Inter5 If causes 1 – 4 are not detected.) a Start engine and carry out troubleshooting. then carry out troubleshooting without turning starting switch ON.SEN00244-01 40 Troubleshooting E-22 Travel alarm does not sound or does not stop sounding Trouble Related information (1) Alarm does not sound during travel. then carry out troubleshooting Ground fault in wiring harwithout turning starting switch ON. carry out troubleshooting for E-26 Monitoring function does not display lever control signal normally. Cause 1 Defective fuse No.

220-8 43 .40 Troubleshooting SEN00244-01 Circuit diagram related to travel alarm and travel PPC oil pressure switch PC200.

1 z Resistance Max.) 2 Defective fuse in unit If fuse in unit is broken. (Code: 04505 Monitor 3rd. then turn starting switch ON and carry out troubleshooting. machine monitor may be defective. circuit in unit probably has ground fault. 1 z a Prepare with starting switch OFF. Related information Cause Standard value in normal state/Remarks on troubleshooting 1 Defective fuse No. (Since trouble is in system.SEN00244-01 40 Troubleshooting E-23 Air conditioner does not operate normally (including air conditioner abnormality record) Trouble Related information Possible causes and standard value in normal state Trouble 1 (1) When air conditioner switch is operated. troubleshooting cannot be carried out. troubleshooting cannot be carried out. (See cause 4.) (2) When air conditioner switch is operated. (Since trouble is in system. then carry out troubleshooting without turning starting switch ON. 04506 Monitor 5th line switch) Cause 1 Defective machine monitor Standard value in normal state/Remarks on troubleshooting Machine monitor may be defective. 1 Mz a Prepare with starting switch OFF. Possible causes and standard value in normal state Disconnection in wiring harness (Disconnection in wiring Wiring harness between F01-11 – fuse in 3 or defective contact in con. air conditioner controller may be defective. • Condition of air conditioner switch signal can be checked with monitoring function. – circuit branch end Resistance Min. air conditioner does not operate at all. 6 Defective machine monitor 44 If causes 1 – 5 are not detected. 220-8 .) a Prepare with starting switch OFF. circuit probably has ground fault. (See cause 4. 11 If fuse is broken. air conditioner control screen is not displayed. Ground fault in wiring har4 ness (Short circuit with GND Wiring harness between F01-11 – fuse in circuit) unit – ACW (wiring side) (6). 5 Defective air conditioner controller ACW (wiring side) Voltage Between (6) – (16) 20 – 30 V If above voltage is normal.unit – ACW (wiring side) (6) nector) Wiring harness between ACW (wiring side) (16) – chassis ground (T07) Resistance Max. 4th line switches.) PC200. then carry out troubleshooting without turning starting switch ON.

then carry out troubleshooting without turning starting switch ON (coil side). 1 z Wiring harness between F01-11 – R20 (female) (5) Resistance Max. 1 z Resistance Max. Fan switch Operate between Low and Medium and High. 1 z Wiring harness between R20 (female) (3) – ACW (wiring side) (36) Resistance Max. 220-8 45 . 1 z Wiring harness between PTR (wiring side) (1) – chassis ground (T07) Resistance Max. then turn starting switch ON and carry out troubleshooting.40 Troubleshooting Trouble SEN00244-01 (3) Air does not come out (Air flow is insufficient). Possible causes and standard value in normal state 3 Defective blower motor (Internal defect) MB (wiring side) Air conditioner switch Voltage Between (1) – (2) Air blow position 20 – 30 V If above voltage is normal and blower motor does not revolve. R20 (male) 1 2 Resistance Between (1) – (3) 140 – 340 z Defective blower relay (Intera Prepare with starting switch OFF. 1 z Wiring harness between PTR (wiring side) (4) – ACW (wiring side) (7) Resistance Max.MB (wiring side) (1) nector) Wiring harness between MB (wiring side) (2) – PTR (wiring side) (3) PC200. If air flow changes according to operation of fan switch. a Prepare with starting switch OFF. then turn starting switch ON and carry out troubleshooting. Wiring harness between F01-11 – fuse in unit – R20 (female) (1) Resistance Max. blower motor is defective. 1 z Disconnection in wiring harness (Disconnection in wiring Wiring harness between R20 (female) (4) – 4 or defective contact in con. Related information Cause Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF. Defective power transistor (Internal defect) R20 Air conditioner switch Voltage Between (4) – chassis ground Air blow position 20 – 30 V a Prepare with starting switch OFF. then turn starting switch ON nal disconnection) and carry out troubleshooting (contact side). then carry out troubleshooting without turning starting switch ON. 1 z Wiring harness between PTR (wiring side) (2) – ACW (wiring side) (8) Resistance Max. a Prepare with starting switch OFF. power transistor is normal. 1 z Resistance Max.

PC200. Wiring harness between R20 (female) (3) – ACW (wiring side) (36) Possible causes and standard value in normal state 46 Ground fault in wiring harWiring harness between R20 (female) (4) – 5 ness (Short circuit with GND MB (wiring side) (1) circuit) Wiring harness between MB (wiring side) (2) – PTR (wiring side) (3) Wiring harness between PTR (wiring side) (2) – ACW (wiring side) (8) Resistance Min. Troubleshooting. air conditioner controller may be Defective air conditioner condefective. air conditioner system may be Defective air conditioner sysdefective. (Since trouble is in system. 1 Mz Resistance Min.SEN00244-01 40 Troubleshooting Cause Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF. 1 Mz Resistance Min.) 7 If causes 1 – 5 are not detected. See Machine Component Volume of Shop Manual. 1 Mz 6 If causes 1 – 5 are not detected. Air tem conditioner. troubleshooting cannot be troller carried out. 220-8 . 1 Mz Resistance Min. then carry out troubleshooting without turning starting switch ON.

1 z Resistance Max. 1 Mz Resistance Min. 1 z Resistance Max. Carry out trousure switches bleshooting for “Abnormality in refrigerant”. 3 Defective high and low pres. Check it directly. troubleshooting cannot be troller carried out. then carry out troubleshooting without turning starting switch ON. air conditioner controller may be Defective air conditioner condefective. then turn starting switch ON and carry out troubleshooting (contact side). then carry out troubleshooting without turning starting switch ON (coil side). 1 z a Prepare with starting switch OFF. nal defect) Possible causes and standard value in normal state a Prepare with starting switch OFF. air conditioner system may be Defective air conditioner sysdefective. Check it directly.40 Troubleshooting Trouble SEN00244-01 (4) Air is not cooled (Cooling performance is insufficient). Ground fault in wiring harWiring harness between R21 (female) (3) – 7 ness (Short circuit with GND ACW (wiring side) (35) circuit) Wiring harness between R21 (female) (2) – AC02 (female) (1) PC200. Related information Cause Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF.) 9 If causes 1 – 7 are not detected. Wiring harness between F01-11 – fuse in unit – R21 (female) (1) Disconnection in wiring harness (Disconnection in wiring Wiring harness between R21 (female) (3) – 6 or defective contact in con. Carry out troubleshooting for Abnormality in internal air sensor.High and low pressure switches may be defective. Air tem conditioner. 1 Defective compressor relay (Internal disconnection) 2 Defective internal air sensor R21 (male) Resistance Between (1) – (3) 140 – 340 z a Prepare with starting switch OFF. (Internal defect) 5 Defective compressor (InterCompressor may be defective. 4 Defective compressor clutch Compressor clutch may be defective. See Machine Component Volume of Shop Manual. R21 Air conditioner switch Voltage Between (2) – chassis ground Cooling position 20 – 30 V Internal air sensor may be defective. 220-8 Resistance Min. 47 . (Since trouble is in system. 1 z Resistance Max. then carry out troubleshooting without turning starting switch ON.ACW (wiring side) (35) nector) Wiring harness between F01-11 – R21 (female) (4) Wiring harness between R21 (female) (2) – AC02 (female) (1) Resistance Max. 1 Mz 8 If causes 1 – 7 are not detected. Troubleshooting.

troubleshooting cannot be carried out. – N08 (male) (10) Min. Ground fault in wiring har– CE02 (female) (46). “CAN disconnection” is displayed. – C01 (female) (45). – K02 (female) (A). condition of other items is not displayed. – CE02 (female) (47). – 2 ness (Short circuit with GND N08 (male) (3) circuit) Wiring harness between N10 (female) (1) – CM02 (female) (10). 3 Hot short (Short circuit with 24V circuit) in wiring harness Defective CAN terminal 4 resistance (Internal short circuit or disconnection) 5 N10 (male) (2) – CM02 (female) (8). 1 z Resistance Max. – C01 (female) (45). Cause Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF. • If abnormality in communication has been detected and reset.CM02 (female) (8). Accordingly. (9). Possible causes and standard value in normal state Wiring harness between N10 (male) (2) – CM02 (female) (8). “Abnormality” is displayed.) PC200. (9) nector) Wiring harness between N10 (female) (1) – CM02 (female) (10) Resistance Max. – C01 (female) (64).SEN00244-01 40 Troubleshooting Trouble (5) Air conditioner abnormality record: Communication condition “CAN disconnection”. • Method of reproducing abnormality record: Turn starting switch ON. – K02 (female) (B).) 6 Defective machine monitor 48 Resistance If causes 1 – 4 are not detected. then carry out troubleshooting without turning starting switch ON. 5. (Since trouble is in system. – C01 (female) (64). (Since trouble is in system. then turn starting switch ON and carry out troubleshooting. troubleshooting cannot be troller carried out. then carry out troubleshooting without turning starting switch ON. 1 Mz Resistance Min. K02 (male) Resistance Between (A) – (B) 47 – 67 z If causes 1 – 4 are not detected. – N08 (male) (3) Voltage Max. 220-8 . communication cannot be carried out normally. Disconnection in wiring harness (Disconnection in wiring Wiring harness between N10 (female) (2) – 1 or defective contact in con. – CE02 (female) (46). 1 z a Prepare with starting switch OFF. machine monitor may be defective. – K02 (female) (A). – K02 (female) (B).5 V a Prepare with starting switch OFF. – CE02 (female) (47). (9).5 V Wiring harness between N10 (female) (1) – CM02