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GENERAL
STRUCTURE,
STRUCTURE,FUNCTION,
FUNCTIONAND
& MAINTENANCE
MAINTENANCESTANDARD
STANDARD
TESTINGGENERAL
AND ADJUSTING
STRUCTURE, FUNCTION,OTHERS
AND MAINTENANCE STANDARD
© 2005
All Rights Reserved 00-1
Printed in Japan 10-05 (01) (12)
GENERAL
Specifications
PC200-7, PC200LC-7 . . . . . . . . . . . 01-6
PC220-7, PC220LC-7 . . . . . . . . . . . 01-8
Weight Table
PC200-7, PC200LC-7 . . . . . . . . . . 01-10
PC220-7, PC220LC-7 . . . . . . . . . . 01-12
PC200-7 01-1
BACK
GENERAL SPECIFICATION DIMENSION DRAWINGS
12
SPECIFICATION DIMENSION DRAWINGS
PC200-7, PC200LC-7
DIMENSIONS
WORKING RANGES
01-2 PC200-7
BACK
GENERAL SPECIFICATION DIMENSION DRAWINGS
12
DIMENSIONS
WORKING RANGES
PC200/220(LC)-7 01-3
(11)
BACK
GENERAL SPECIFICATION DIMENSION DRAWINGS
PC220-7, PC220LC-7
DIMENSIONS
WORKING RANGES
01-4 PC200/220(LC)-7
(11)
BACK
GENERAL SPECIFICATION DIMENSION DRAWINGS
12
DIMENSIONS
WORKING RANGES
PC200/220(LC)-7 01-5
(11)
BACK
GENERAL SPECIFICATIONS
SPECIFICATIONS
PC200-7, PC200LC-7
Machine model PC200-7 PC200LC-7
Travel speed km/h Lo: 3.0 ( Mi: 4.1) Lo: 3.0 ( Mi: 4.1)
Hi: 5.5 Hi: 5.5
Gradeability deg. 35 35
01-6 PC200-7
BACK
GENERAL SPECIFICATIONS
12
Model SAA6D102E-2-A
Type 4-cycle, water-cooled, in-line, vertical, direct
injection, with turbo charger
No. of cylinders - bore x stroke mm 6 - 102 x 120
Piston displacement l {cc} 5.883 {5,883}
Type x No.
pump
Delivery
l/min Piston type: 214 x 2
Set pressure
MPa (kg/cm²) Piston type: 37.2 {380}
Control
PC200/220(LC)-7 01-7
(11)
BACK
GENERAL SPECIFICATIONS
PC220-7, PC220LC-7
Travel speed km/h Lo: 3.1 ( Mi: 4.2) Lo: 3.1 ( Mi: 4.2)
Hi: 5.5 Hi: 5.5
Gradeability deg. 35 35
01-8 PC200-7
BACK
GENERAL SPECIFICATIONS
Model SAA6D102E-2-C
Type 4-cycle, water-cooled, in-line, vertical, direct
injection, with turbo charger
No. of cylinders - bore x stroke mm 6 - 102 x 120
Piston displacement l {cc} 5.883 {5,883}
Type x No.
pump
Delivery
l/min Piston type: 214 x 2
Set pressure
MPa (kg/cm²) Piston type: 37.2 {380}
Control
PC200/220(LC)-7 01-9
(11)
BACK
GENERAL WEIGHT TABLE
12
WEIGHT TABLE
PC200-7, PC200LC-7
This weight table is for use when handling components or when transporting the machine.
Unit: kg
• Damper 6 6
• Idler 99 x 2 99 x 2
• Carrier roller 16 x 4 16 x 4
• Track roller 36 x 14 36 x 18
01-10 PC200-7
BACK
GENERAL WEIGHT TABLE
12
Unit: kg
Boom pin 48 + 8 x 2 + 31 + 10 + 26 48 + 8 x 2 + 31 + 10 + 26
Arm pin 11 + 8 11 + 8
Bucket pin 20 x 2 20 x 2
Link pin 13 x 2 13 x 2
PC200-7 01-11
BACK
GENERAL WEIGHT TABLE
PC220-7, PC220LC-7
Unit: kg
• Damper 6 6
• Idler 99 x 2 99 x 2
• Carrier roller 16 x 4 16 x 4
• Track roller 36 x 16 36 x 20
01-12 PC200-7
BACK
GENERAL WEIGHT TABLE
12
Unit: kg
Boom pin 50 + 10 x 2 + 31 + 10 + 26 50 + 10 x 2 + 31 + 10 + 26
Arm pin 11 + 10 11 + 10
Bucket pin 20 x 2 20 x 2
Link pin 17 x 2 17 x 2
PC200-7 01-13
BACK
GENERAL FUEL, COOLANT, AND LUBRICANTs
12
FUEL, COOLANT, AND LUBRICANTS
SAE 30
SAE 10W
Engine oil pan 26.3 24
SAE 10W-30
SAE 15W-40
PC200, PC200,
PC200LC-7 PC200LC-7
22.8 22.4
Cooling system Coolant Add antifreeze
PC220, PC220,
PC220LC-7 PC220LC-7
30.9 30.9
01-14 PC200/220(LC)-7
(4)
STRUCTURE, FUNCTION & MAINTENANCE STANDARD
PC200/220(LC)-7 10-1
(4)
BACK
HYDRAULIC EQUIPMENT LAYOUT
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD DRAWING
12
HYDRAULIC EQUIPMENT LAYOUT DRAWING
1. Bucket cylinder
2. Arm cylinder
3. Boom cylinder
4. Hydraulic tank
5. Hydraulic filter
6. R.H. travel motor
7. Swing motor
8. Hydraulic pump
9. Control valve
10. Oil cooler
11. L.H. travel motor
12. Multi-pattern selector valve
13. L.H. PPC valve
14. Lock lever (electric type)
15. Center swivel joint
16. R.H. PPC valve
17. Travel PPC valve
18. Attachment circuit selector valve
19. Holding valve
20. Accumulator
21. Solenoid valve assembly
21A PPC lock solenoid
21B Travel junction solenoid
21C Pump merge/divider solenoid
21D Travel speed solenoid
21E Swing brake solenoid
21F 2-stage relief solenoid
10-24 PC200/220(LC)-7
(11)
BACK
HYDRAULIC EQUIPMENT LAYOUT
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD DRAWING
12
PC200-7 10-25
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP
12
HYDRAULIC PUMP
HPV95 + 95
1. Front main pump IM : PC mode selector current PENR : Rear pump control pressure detec-
2. Rear main pump ISIG : LS set selector current tion port
3. LS valve PAF : Front pump delivery port PLSF : Front load pressure input port
4. PC valve PFC : Front pump delivery pres- PLSFC: Front load pressure detection port
5. LS-EPC valve sure detection port PLSR : Rear load pressure input port
PAR : Rear pump delivery port PLSRC: Rear load pressure detection port
6. PC-EPC valve
PRC : Rear pump delivery pressure PS : Pump suction port
detection port PSIG : LS set selector pressure detection
PBF : Pump pressure input port port
PD1F: Case drain port PM : PC set selector pressure detection
PENF: Front pump control pressure port
detection port PEPC : EPC basic pressure input port
Outline
• This pump consists of 2 variable capacity swash plate
piston pumps, PC valve, LS valve, and EPC valve.
10-28 PC200-7
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP
12
PC200-7 10-29
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP
12
Function
• The rotation and torque transmitted to the • Rocker cam (4) has flat surface A, and shoe
pump shaft are converted into hydraulic (5) is always pressed against this surface
energy, and pressurized oil is discharged while sliding in a circular movement.
according to the load. Rocker cam (4) brings high pressure oil at cyl-
• It is possible to change the discharge amount inder surface B with cradle (2), which is
by changing the swash plate angle. secured to the case, and forms a static pres-
Structure sure bearing when it slides.
• Cylinder block (7) is supported to shaft (1) by • Piston (6) carries out relative movement in
a spline, and shaft (1) is supported by the the axial direction inside each cylinder cham-
front and rear bearings. ber of cylinder block (7).
• The tip of piston (6) is a concave ball, and • The cylinder block seals the pressure oil to
shoe (5) is caulked to it to form one unit. Pis- valve plate (8) and carries out relative rota-
ton (6) and shoe (5) form a spherical bearing. tion. This surface is designed so that the oil
pressure balance is maintained at a suitable
level. The oil inside each cylinder chamber of
cylinder block (7) is sucked in and discharged
through valve plate (8).
10-30 PC200-7
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP
12
Operation
1) Operation of pump
i Cylinder block (7) rotates together with
shaft (1), and shoe (5) slides on flat surface
A.
When this happens, rocker cam (4) moves
along cylindrical surface B, so angle α
between center line X of rocker cam (4) and
the axial direction of cylinder block (7)
changes. (Angle α is called the swash plate
angle.)
ii Center line X of rocker cam (4) maintains
swash plate angle α in relation to the axial
direction of cylinder block (7), and flat sur-
face A moves as a cam in relation to shoe
(5).
In this way, piston (6) slides on the inside of
cylinder block (7), so a difference between
volumes E and F is created inside cylinder
block (7). The suction and discharge is car-
ried out by this difference F - E.
In other words, when cylinder block (7)
rotates and the volume of chamber E
becomes smaller, the oil is discharged dur-
ing that stroke. On the other hand, the vol-
ume of chamber F becomes larger, and as
the volume becomes bigger, the oil is
sucked in.
iii If center line X of rocker cam (4) is in line
with the axial direction of cylinder block (7)
(swash plate angle = 0), the difference
between volumes E and F inside cylinder
block (7) becomes 0, so the pump does not
carry out any suction or discharge of oil.
(In actual fact, the swash plate angle never
becomes 0.)
PC200-7 10-31
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP
12
2) Control of discharge amount
• If the swash plate angle α becomes larger,
the difference between volumes E and F
becomes larger and discharge amount Q
increases.
• Swash plate angle α is changed by servo
piston (12).
• Servo piston (12) moves in a reciprocal
movement (↔) according to the signal
pressure from the PC and LS valves. This
straight line movement is transmitted
through rod (13) to rocker cam (4), and
rocker cam (4), which is supported by the
cylindrical surface to cradle (2), slides in a
rotating movement in direction of arrow.
• With servo piston (12), the area receiving
the pressure is different on the left and
the right, so main pump discharge pres-
sure (self pressure) PP is always brought
to the chamber receiving the pressure at
the small diameter piston end.
• Output pressure Pen of the LS valve is
brought to the chamber receiving the
pressure at the large diameter end. The
relationship in the size of pressure PP at
the small diameter piston end and pres-
sure Pen at the large diameter end, and
the ratio between the area receiving the
pressure of the small diameter piston and
the large diameter piston controls the
movement of servo piston (12).
10-32 PC200-7
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP
12
LS VALVE
PC VALVE
PC200-7 10-33
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP
12
Function
(1) LS valve
The LS valve detects the load and controls the
discharge amount.
This valve controls main pump discharge
amount Q according to differential pressure
∆PLS (=PP - PLS) [called the LS differential
pressure] (the difference between main pump
pressure PP and control valve outlet port
pressure PLS).
Main pump pressure PP, pressure PLS {called
the LS pressure} coming from the control
valve output, and pressure Psig {called the
LS selector pressure} from the proportional
solenoid valve enter this valve. The relation-
ship between discharge amount Q and differ-
ential pressure ∆PLS, (the difference between
main pump pressure PP and LS pressure
PLS) (= PP - PLS) changes as shown in the
diagram at the right according to LS pressure
selector current isig of the LS-EPC valve.
When isig changes between 0 and 1A, the set
pressure of the spring changes according to
this, and the selector point for the pump dis-
charge amount changes at the rated central
valve between 0.69 ↔ 2.2 MPa {7 ↔ 22 kg/
cm²}.
(2) PC valve
When the pump discharge pressure PP1
(self-pressure) and PP2 (other pump pres-
sure) are high, the PC valve controls the
pump so that no more oil than the constant
flow (in accordance with the discharge pres-
sure) flows even if the stroke of the control
valve becomes larger. In this way, it carries
out equal horsepower control so that the
horsepower absorbed by the pump does not
exceed the engine horsepower.
In other words, If the load during the opera-
tion becomes larger and the pump discharge
pressure rises, it reduces the discharge
amount from the pump; and if the pump dis-
charge pressure drops, it increases the dis-
charge amount from the pump. The
relationship between the average of the front
and rear pump discharge pressures (average
discharge amount of F, R pumps (PP1 +
PP2)/2) and pump discharge amount Q is
shown on the right, with the current given to
the PC-EPC valve solenoid shown as a param-
eter. The controller senses the actual speed of
the engine, and if the speed drops because of
an increase in the load, it reduces the pump the set value, the command current to the PC-
discharge amount to allow the speed to EPC valve solenoid from the controller
recover. In other words, when the load increases according to the drop in the engine
increases and the engine speed drops below speed to reduce the pump swash plate angle.
10-34 PC200-7
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP
12
OPERATION
SDP08884
PC200/220(LC)-7 10-35
(11)
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP
12
SDP08885
2) Operation in increase direction for pump • For this reason, the pressure at the large
discharge amount diameter end of servo piston (12) becomes
• When the difference between the main pump drain pressure PT, and pump pressure PP
pressure PP and LS pressure PLS, in other enters port J at the small diameter end, so
words, LS differential pressure ∆PLS, servo piston (12) is pushed to the right. There-
becomes smaller (for example, when the area fore, the swash plate moves in the direction
of opening of the control valve becomes to make the discharge amount larger. If the
larger and pump PP drops), spool (6) is output pressure of the EPC valve for the LS
pushed to the right by the combined force of valve enters port G, this pressure creates a
LS pressure PLS and the force of spring (4). force to move piston (7) to the left. If piston
• When spool (6) moves, port D and port E are (7) is pushed to the left, it acts to make the set
joined and connected to the PC valve. When pressure of spring (4) weaker, and the differ-
this happens, the PC valve is connected to the ence between PLS and PP changes when
drain port, so circuit D - K becomes drain ports D and E of spool (6) are connected.
pressure PT. (The operation of the PC valve is
explained later).
10-36 PC200/220(LC)-7
(11)
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP
12
SDP08886
PC200/220(LC)-7 10-37
(11)
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP
12
SDP08887
10-38 PC200/220(LC)-7
(11)
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP
12
(2) PC Valve
1) When pump controller is normal
a. When the load on the actuator is small
and pump pressures PP1 and PP2 are
low
1 Movement of PC-EPC solenoid (1)
• The command current from the pump • the pressure (pressure of port C) output
controller flows to PC-EPC solenoid from the PC valve changes according to
(1).This command current acts on the PC- this position.
EPC valve and outputs the signal pres- • The size of command current X is deter-
sure. When this signal pressure is mined by the nature of the operation
received, the force pushing piston (2) is (lever operation), the selection of the
changed. working mode, and the set value and
• On the opposite side to the force pushing actual value for the engine speed.
this piston (2) is the spring set pressure of a Other pump pressure
springs (4) and (6) and pump pressure This is the pressure of the pump at the
PP1 (self pressure) and PP2 (other pump opposite end.
pressure) pushing spool (3). Piston (2) For the F pump, it is the R pump pressure
stops at a position where the combined For the R pump, it is the F pump pressure
force pushing spool (3) is balanced, and
PC200/220(LC)-7 10-39
(11)
BACK
12
SDP08889
2 Action of spring
• The spring load of springs (4) and (6) in the • If the command circuit input to PC-EPC valve
PC valve is determined by the swash plate solenoid (1) changes further, the force push-
position. ing piston (2) changes, and the spring load of
• If piston (9) moves to the left, spring (6) is springs (4) and (6) also changes according to
compressed, and if it moves further to the left, the value of the PC-EPC valve solenoid com-
spring (6) contacts seat (5) and is fixed in mand current.
position. In other words, the spring load is
changed by piston (9) extending or compress-
ing springs (4) and (6).
10-40 PC200/220(LC)-7
(11)
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP
12
PC200/220(LC)-7 10-41
(4)
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP
12
10-42 PC200/220(LC)-7
(11)
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP
12
PC200/220(LC)-7 10-43
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP
12
10-44 PC200/220(LC)-7
(11)
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP
12
PC200/220(LC)-7 10-45
(11)
BACK
12
LS(PC)-EPC VALVE
10-46 PC200/220(LC)-7
(11)
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP
12O
FUNCTION
OPERATION
PC200-7 10-47
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP
10-48 PC200-7
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CONTROL VALVE
12
CONTROL VALVE
PC200-7, PC200LC-7
1. 6-spool valve OUTLINE
2. Cover 1
• This control valve consists of a 6-spool
3. Cover 2 valve (unit type), 1 service valves, a pump
merge-divider valve, a back pressure valve,
4. Pump merge-divider valve
and a boom hydraulic drift prevention
5. Back pressure valve valve.
6. Boom lock valve • Since all the valves are assembled together
with connecting bolts and their passes are
7. Service valve connected to each other inside the assem-
bly, the assembly is small in size and easy
to maintain.
• Since one spool of this control valve is
used for one work equipment unit, its struc-
ture is simple.
10-50 PC200-7
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CONTROL VALVE
12
7-spool valve
(6-spool valve + 1 service valve)
(1/9)
7 3
2 1
PC200/220(LC)-7 10-51
(11)
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CONTROL VALVE
12
(2/9)
S*P09099
10-52 PC200-7
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CONTROL VALVE
12
(3/9)
PC200-7 10-53
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CONTROL VALVE
12
(4/9)
Unit: mm
10-54 PC200-7
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CONTROL VALVE
12
(5/9)
Unit: mm
PC200-7 10-55
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CONTROL VALVE
12
(6/9)
10-56 PC200-7
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CONTROL VALVE
Unit: mm
PC200-7 10-57
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CONTROL VALVE
(7/9)
Unit: mm
10-58 PC200-7
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CONTROL VALVE
12
(8/9)
10-60 PC200-7
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CONTROL VALVE
Unit: mm
PC200-7 10-61
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CONTROL VALVE
12
(9/9)
10-62 PC200-7
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CONTROL VALVE
Unit: mm
PC200-7 10-63
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CONTROL VALVE
CONTROL VALVE
PC220-7, PC220LC-7
1. 6-spool valve OUTLINE
2. Cover 1
• This control valve consists of a 6-spool
3. Cover 2 valve (unit type), 1 service valves, a pump
merge-divider valve, a back pressure valve,
4. Pump merge-divider valve
and a boom hydraulic drift prevention
5. Back pressure valve valve.
6. Boom lock valve • Since all the valves are assembled together
with connecting bolts and their passes are
7. Service valve connected to each other inside the assem-
bly, the assembly is small in size and easy
to maintain.
• Since one spool of this control valve is
used for one work equipment unit, its struc-
ture is simple.
10-64 PC200-7
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CONTROL VALVE
12
7-spool valve
(6-spool valve + 1 service valves)
(1/9)
7 3
2 1
PC200-7 10-65
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CONTROL VALVE
12
(2/9)
S*P09102
10-66 PC200-7
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CONTROL VALVE
12
(3/9)
PC200-7 10-67
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CONTROL VALVE
12
(4/9)
S*P09104
Unit: mm
10-68 PC200-7
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CONTROL VALVE
12
(5/9)
Unit: mm
PC200-7 10-69
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CONTROL VALVE
12
(6/9)
10-70 PC200/220(LC)-7
(11)
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CONTROL VALVE
Unit: mm
PC200-7 10-71
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CONTROL VALVE
(7/9)
Unit: mm
10-72 PC200-7
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CONTROL VALVE
12
(8/9)
10-74 PC200/220(LC)-7
(11)
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CONTROL VALVE
Unit: mm
PC200-7 10-75
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CONTROL VALVE
12
(9/9)
10-76 PC200-7
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CONTROL VALVE
Unit: mm
PC200-7 10-77
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CONTROL VALVE
1. Spring
2. Poppet
FUNCTION
OPERATION
• The relief valve set pressure is determined by the installed load of spring (1). (First stage)
• It is unnecessary to set the first and second stage individually.
The second stage is set when the first stage is set.
10-78 PC200-7
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CONTROL VALVE
12
1. Valve FUNCTION
2. Spring
3. Sleeve • It is possible to adjust the division of the oil
4. Poppet flow to the service valve when the service
5. Spring valve (for attachment) is operated together
6. Screw with the main control valve (boom RAISE,
7. Locknut etc.).
8. Plastic cap (Variable in proportion to surface area)
• The pump pressure leaving the service valve
SS. From service valve spool spool acts on the left end of valve (1), and at
CP. Cylinder port the same time passes through throttle a and
LS. Load pressure from other work equipment enters chamber g.
The maximum LS pressure passes through
throttle d and enters chamber e. At the same
time, the cylinder port pressure passes
through passage c and throttle f, and goes to
chamber h.
In addition, the force of spring (2) acts on
valve (1), and the force of spring (5) acts on
poppet (4). The force of spring (5) can be
adjusted with screw (6).
PC200/220(LC)-7 10-79
(4)
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CONTROL VALVE
OPERATION
10-79-1 PC200/220(LC)-7
(4)
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CLSS
12
CLSS
OUTLINE OF CLSS
FEATURES STRUCTURE
• CLSS stands for Closed center Load Sensing • The CLSS consists of a main pump (2
System, and has the following features. pumps), control valve, and actuators for the
work equipment.
1) Fine control not influenced by load • The main pump body consists of the pump
2) Control enabling digging even with fine con- itself, the PC valve and LS valve.
trol
3) Ease of compound operation ensured by flow
divider function using area of opening of
spool during compound operations
4) Energy saving using variable pump control
10-80 PC200/220(LC)-7
(4)
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CLSS
Basic principle
1) Control of pump swash plate
• The pump swash plate angle (pump dis-
charge amount) is controlled so that LS dif-
ferential pressure ∆PLS (the difference
between pump pressure PP and control
valve outlet port LS pressure PLS) (load
pressure of actuator) is constant.
(LS pressure ∆PLS = Pump discharge pres-
sure PP – LS pressure PLS)
PC200/220(LC)-7 10-81
(4)
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CLSS
2) Pressure compensation
• A pressure compensation valve is installed to In this way, the flow of oil from the pump is
the outlet port side of the control valve to bal- divided (compensated) in proportion to the
ance the load. area of opening S1 and S2 of each valve.
• When two actuators are operated together,
this valve acts to make pressure difference ∆P
between the upstream (inlet port) and down-
stream (outlet port) of the spool of each valve
the same regardless of the size of the load
(pressure).
10-82 PC200/220(LC)-7
(4)
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SELF PRESSURE REDUCING VALVE
OPERATION
PC200/220(LC)-7 10-83
(4)
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SELF PRESSURE REDUCING VALVE
10-84 PC200/220(LC)-7
(4)
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SELF PRESSURE REDUCING VALVE
12
PC200-7 10-85
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SWING MOTOR
12
SWING MOTOR
KMF125ABE-5
10-86 PC200-7
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SWING MOTOR
12
PC200-7 10-87
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SWING MOTOR
12
Unit: mm
10-88 PC200-7
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SWING MOTOR
12
PC200-7 10-89
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SWING MOTOR
12
1) Outline
The relief portion consists of check valves
(2) and (3), shuttle valves (4) and (5), and
relief valve (1).
2. Function
When the swing is stopped, the outlet port
circuit of the motor from the control valve
is closed, but the motor continues to rotate
under inertia, so the pressure at the output
side of the motor becomes abnormally
high, and this may damage the motor.
To prevent this, the abnormally high pres-
sure oil is relieved to port S from the outlet
port of the motor (high-pressure side) to
prevent any damage.
3. Operation
1) When starting swing
• When the swing control lever is operated
to swing right, the pressure oil from the
pump passes through the control valve and
is supplied to port MA. As a result, the
pressure at port MA rises, the starting
torque is generated in the motor, and the
motor starts to rotate. The oil from the out-
let port of the motor passes from port MA
through the control valve and returns to
the tank. (Fig. 1)
2) When stopping swing
• When the swing control lever is returned to
neutral, the supply of pressure oil from the
pump to port MA is stopped. With the oil
from the outlet port of the motor, the return
circuit to the tank is closed by the control
valve , so the pressure at port MB rises. As
a result, rotation resistance is generated in
the motor, so the braking effect starts.
• If the pressure at port MB becomes higher
than the pressure at port MA, it pushes
shuttle valve A (4) and chamber C
becomes the same pressure as port MB.
The oil pressure rises further until it
reaches the set pressure of relief valve (1).
As a result, a high braking torque acts on
the motor and stops the motor. (Fig.2)
• When relief valve (1) is being actuated, the
relief oil and oil from port S passes
through check valve B (3) and is supplied to
port MA. This prevents cavitation at port
MA.
10-90 PC200-7
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD REVERSE PREVENTION VALVE
12
REVERSE PREVENTION VALVE
Operation diagram
1. Valve body
2. Spool (MA side)
3. Spring (MA side)
4. Plug
5. Spool (MB side)
6. Spring (MB side)
7. Plug
Explanation of effect
PC200-7 10-91
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD REVERSE PREVENTION VALVE
12
Outline
This valve reduces the swing back genera-
tion in the swing body by the inertia of the
swing body, the backlash and rigidity of the
machinery system, and the compression of
the hydraulic oil when the swing is
stopped. This is effective in preventing
spillage of the load and reducing the cycle
time when stopping the swing (the posi-
tioning ability is good and it is possible to
move swiftly to the next job.
Operation
1) When brake pressure is being gener-
ated at port MB
• Pressure MB passes through the notch and
goes to chamber d, spool (5) pushes spring
(6) according to the difference in area D1 >
D2, moves to the left, and MB is connected
to e.
When this happens, pressure MA is below
the set pressure of spring (3), so spool (2)
does not move. For this reason, the pres-
sure oil is closed by spool (2), and the brak-
ing force is ensured.
10-92 PC200-7
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CENTER SWIVEL JOINT
12
CENTER SWIVEL JOINT
PC200-7 10-93
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRAVEL MOTOR
TRAVEL MOTOR
HMV110-2
10-94 PC200-7
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRAVEL MOTOR
12
PC200-7 10-95
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRAVEL MOTOR
12
Unit: mm
10-96 PC200-7
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRAVEL MOTOR
OPERATION OF MOTOR
1) Motor swash plate angle at maximum
SJP08742
OR
08893
• The solenoid valve is deactivated, so the pilot • At the same time, the pressurized oil at regu-
pressure oil from the main pump does not lator piston (15) passes through orifice c in
flow to port P. regulator valve (9) and is drained to the motor
For this reason, regulator valve (9) is pushed case.
to the right in the direction of the arrow by • As a result, rocker cam (4) moves in the maxi-
spring (10). mum swash plate angle direction, the motor
• Because of this, it pushes check valve (22), capacity becomes maximum.
and the main pressure oil from the control
valve going to end cover (8) is shut off by reg-
ulator valve (9).
• Fulcrum a of rocker cam (4) is eccentric to
point of force b of the combined force of the
propulsion force of cylinder (6), so the com-
bined force of the piston propulsion force acts
as a moment to angle rocker cam (4) in the
direction of the maximum swash plate angle.
PC200/220(LC)-7 10-97
(11)
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRAVEL MOTOR
12
SJP08743
OR
08894
10-98 PC200/220(LC)-7
(11)
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRAVEL MOTOR
12
PC200-7 10-99
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRAVEL MOTOR
10-100 PC200-7
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRAVEL MOTOR
PC200-7 10-101
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRAVEL MOTOR
10-102 PC200-7
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRAVEL JUNCTION VALVE
Function Operation
• This valve connects both travel circuits to each When pilot pressure is turned ON
other so that the hydraulic oil will be supplied • If the pilot pressure from the travel junction sole-
evenly to both travel motors and the machine will noid valve becomes higher than the force of
travel straight. spring (14), travel junction spool (13) moves to the
• When the machine is steered, outside pilot pres- left stroke end and the junction circuit between
sure PST closes the travel junction valve to secure port PTL (Left travel circuit) and PTR (Right travel
high steering performance. circuit) is closed.
SU(V)P08730
OR
08898
PC200/220(LC)-7 10-103
(4)
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRAVEL JUNCTION VALVE
SU(V)P08731
OR
08899
10-104 PC200/220(LC)-7
(4)
BACK
STROKE REGULATION WHEN
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRAVELLING
PC200/220(LC)-7 10-105
(4)
BACK
STROKE REGULATION WHEN
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRAVELLING
12
2. When travel lever is operated
• If the right travel lever is set in the reverse (or • At this time, the right travel reverse (or for-
forward) direction, the right travel reverse (or ward) PPC pressure is applied through orifice
forward) PPC pressure pushes spool (7) to the (6) of piston (4) to the left end of piston (8) to
left (or right). push piston (8) to the right.
• Spool (7) pushes piston (3) to close orifice (5) • When boom RAISE, arm IN, OUT, bucket
and shut off stroke regulation signal chamber CURL, DUMP are operated, spool (1) moves
"a" from the drain circuit of the travel PPC to the left, but the maximum stroke of the
valve. spool is limited to st1, the amount of move-
ment (st2) of piston (8).
10-106 PC200/220(LC)-7
(4)
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD VALVE CONTROL
VALVE CONTROL
Lever positions
1. Travel PPC valve 8. Solenoid valve (1) Hold (9) Swing "RIGHT"
2. Service PPC valve 9. Accumulator (2) Boom "RAISE" (10) Swing "LEFT"
3. Service pedal 10. Control valve (3) Boom "LOWER" (11) Neutral
4. L.H. travel lever 11. Hydraulic pump (4) Bucket "DUMP" (12) Travel "REVERSE"
5. R.H. travel lever 12. Junction box (5) Bucket "CURL" (13) Travel "FORWARD"
6. R.H. PPC valve 13. L.H. work equip- (6) Hold
7. R.H. work equipment con- ment control lever (7) Arm "IN"
trol lever 14. L.H. PPC valve (8) Arm "OUT"
PC200-7 10-107
BACK
BOOM HYDRAULIC DRIFT
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD PREVENTION VALVE
08900
10-128 PC200-7
BACK
BOOM HYDRAULIC DRIFT
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD PREVENTION VALVE
PC200/220(LC)-7 10-129
(9)
BACK
BOOM HYDRAULIC DRIFT
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD PREVENTION VALVE
10-130 PC200-7
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD LIFT CHECK VALVE
Function
Operation
PC200/220(LC)-7 10-131
(11)
BACK
ATTACHMENT CIRCUIT SELECTOR
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD VALVE
Unit: mm
10-132 PC200/220(LC)-7
(11)
BACK
ATTACHMENT CIRCUIT SELECTOR
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD VALVE
Function
Operation
PC200/220(LC)-7 10-133
(4)
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ENGINE CONTROL
ENGINE CONTROL
OUTLINE
1. Battery relay
2. Battery • The engine can be started and stopped with
3. Starting switch only starting switch (3).
4. Fuel control dial • The engine throttle and pump controller(7)
5. Linkage reveives the signal of fuel control dial (4) and
6. Starting motor transmits the drive signal to governor motor
7. Engine throttle and pump controller (9) to control the governor lever angle of fuel
8. Fuel injection pump injection pump (8) and control the engine
9. Governor motor speed.
PC200-7 10-147
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ENGINE CONTROL
12
1. OPERATION OF SYSTEM
Starting engine
• When the starting switch is turned to the
START position, the starting signal flows to
the starting motor, and the starting motor
turns to start the engine. 08903
When this happens, the engine throttle and
pump controller checks the signal from the
fuel control dial and sets the engine speed
to the speed set by the fuel control dial.
Stopping engine
• When the starting switch is turned to the
STOP position, the engine throttle and
pump controller drives the governor motor
so that the governor lever is set to the NO 08905
INJECTION position.
• When this happens, to maintain the electric
power in the system until the engine stops
completely, the engine throttle and pump
controller itself drives the battery relay.
10-148 PC200-7
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ENGINE CONTROL
12
1. COMPONENT
Fuel control dial
1. Knob
2. Dial
3. Spring
4. Ball
5. Potentiometer
6. Connector
Function
• The fuel control dial is installed under the
monitor panel, and a potentiometer is
installed under the knob. The potentiome-
ter shaft is turned by turning the knob.
• As the potentiometer shaft is turned, the
resistance of the variable resistor in the
potentiometer changes and a throttle sig-
nal is sent to the engine throttle and pump
controller.
The hatched area in the graph shown at
right is the abnormality detection area.
PC200-7 10-149
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ENGINE CONTROL
Governor motor
10-150 PC200-7
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ENGINE CONTROL
10-152 PC200-7
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ENGINE CONTROL
12
Input and output signals
PC200/220(LC)-7 10-153
(10)
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
Control function 1
3
One-touch power maximizing function
4
Auto-deceleration function
5
Auto-warm-up/Overheat prevention function
Electronic control system
6
8
ATT flow control, circuit selector function (if equipped)
Self-diagnosis function
PC200/220(LC)-7 10-155
(11)
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
10-156 PC200/220(LC)-7
(4)
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
PC200/220(LC)-7 10-157
(11)
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
SJP08754
OR
08908
10-158 PC200-7
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
FUNCTION
PC200/220(LC)-7 10-159
(4)
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
12
08912
• If the pump load increases and the pressure
rises, the engine speed lowers.
At this time, the controller lowers the pump
discharge so that the engine speed will be
near the full output point. If the pressure low-
ers, the controller increases the pump dis-
charge so that the engine speed will be near
the full output point. SJP08759
By repeating these operations, the controller
OR
constantly uses the engine near the full out-
put point. 08913
SJP08760
OR
08914
10-160 PC200/220(LC)-7
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
12
PC200/220(LC)-7 10-161
(4)
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
12
10-162 PC200/220(LC)-7
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
12
2. Pump/Valve control function
SJP08765
OR
08921
Function
• The machine is matched to various types of
work properly with the 2-stage relief function
to increase the digging force, etc.
PC200/220(LC)-7 10-163
(11)
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
12
1) LS control function
• The change point (LS set differential pressure)
of the pump discharge in the LS valve is
changed by changing the output pressure
from the LS-EPC valve to the LS valve accord-
ing to the operating condition of the actuator.
• By this operation, the start-up time of the 08922
pump discharge is optimized and the com-
posite operation and fine control perfor-
mance is improved.
2) Cut-off function
• When the cut-off function is turned on, the
PC-EPC current is increased to near the maxi-
mum value.
By this operation, the flow rate in the relief
state is lowered to reduce fuel consumption.
• Operating condition for turning on cut-off
function
Condition
• During travel
• When swing lock switch is 34.8 MPa
turned on {355 kg/cm²}
• When boom is lowered ⇓
• When one-touch power maxi- 37.2 MPa
mizing function is turned on {380 kg/cm²}
• When L mode is operated
10-164 PC200/220(LC)-7
(4)
BACK
12
SJP08766
OR
08923
FUNCTION
PC200/220(LC)-7 10-165
(11)
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
12
⇓
Working mode Engine/Pump control 2-stage relief function Operation time Software cut-off function
34.8 MPa {355 kg/cm²}
Matching at rated out- Automatically
A, E ⇓ Cancel
put point reset at 8.5 sec
37.2 MPa {380 kg/cm²}
10-166 PC200/220(LC)-7
(4)
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
12
4. Auto-deceleration function
SJP08767
OR
08924
FUNCTION
PC200-7 10-167
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
12
OPERATION
10-168 PC200-7
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
12
1. Auto-warm-up/Overheat prevention
function
SJP08768
OR
08925
FUNCTION
PC200/220(LC)-7 10-169
(11)
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
12
1) Auto-warm-up function
• After the engine is started, if the engine cool-
ant temperature is low, the engine speed is
raised automatically to warm up the engine.
⇓
Resetting condition (Any one) Reset
⇒
Coolant temperature: Above 30°C
Auto
Auto-warm-up operation time: Min. 10 minutes
Engine speed: Any level
Fuel control dial: Kept at 70% of full level for 3 sec.
Manual
or longer
⇒ ⇒
Work mode: Any mode Fuel control dial: Return to low idle
Coolant tempera- Engine speed: Low idle position once.
ture: Above 105°C Monitor alarm lamp: Lights up • Under above condition, controller
Alarm buzzer: Sounds is set to condition before operation
of function. (Manual reset)
⇒ ⇒
Work mode: Mode A, E, OR B Coolant temperature: Below 102°C
Coolant tempera- Engine speed: Keep as is. • Under above condition, controller
ture: Above 102°C Monitor alarm lamp: Lights up. is set to condition before operation
Lower pump discharge. of function. (Automatic reset)
⇒ ⇒
Coolant temperature: Below 100°C
Work mode: Mode A
Coolant tempera- • Under above condition, controller
Engine speed: Keep as is.
ture: Above 100°C is set to condition before operation
Lower pump discharge.
of function. (Automatic reset)
⇒ ⇒
Coolant temperature: Below 95°C
Work mode: Travel
Coolant tempera- • Under above condition, controller
Engine speed: Keep as is.
ture: Above 95°C is set to condition before operation
Lower travel speed.
of function. (Automatic reset)
10-170 PC200/220(LC)-7
(11)
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
12
SJP08769
OR
08926
FUNCTION
PC200/220(LC)-7 10-171
(11)
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
12
1) Swing lock and swing holding brake 2) Quick hydraulic oil warm-up function
functions when swing lock switch is turned on
• The swing lock function (manual) is used to • If swing lock switch (4) is turned on, the
lock machine from swinging at any position. pump-cut function is cancelled and the relief
The swing holding brake function (automatic) pressure rises from 34.8 MPa {355 kg/cm²} to
is used to prevent hydraulic drift after the 37.2 MPa {380 kg/cm²}. If the work equipment
machine stops swinging. is relieved under this condition, the hydraulic
• Swing lock switch and swing lock/holding oil temperature rises quickly and the warm-up
brake time can be shortened.
Lock Lock
Function Operation
switch lamp
10-172 PC200/220(LC)-7
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
12
SJP08770
OR
08927
FUNCTION
PC200/220(LC)-7 10-173
(11)
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
12
1) Pump control function during travel
• If the machine travels in a work mode other
than mode A, the work mode and the engine
speed are kept as they are and the pump
absorption torque is increased.
a For details, see ENGINE/PUMP COMPOSITE
CONTROL FUNCTION.
Pump capac-
60 90 100
ity (%)
Travel speed
3.0 4.1 5.5
(km/h)
10-174 PC200/220(LC)-7
(4)
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
FUNCTION
PC200/220(LC)-7 10-175
(11)
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
1. Sensor
2. Locknut
3. Wiring harness
4. Connector
FUNCTION
10-176 PC200/220(LC)-7
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
12
1. Plug
2. Switch
3. Connector
SPECIFICATIONS
FUNCTION
PC200-7 10-177
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
12
1. Sensor
2. Connector
FUNCTION
10-178 PC200-7
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD MULTI MONITOR SYSTEM
SJP08775
OR
08931
• The monitor system monitors the condition • The monitor panel also has various mode
of the machine with sensors installed on vari- selector switches and functions to operate the
ous parts of the machine. It processes and machine control system.
immediately displays the obtained informa-
tion on the panel notifying the operator of the
condition of the machine.
The panel is roughly divided as follows.
1. Monitor section to output alarms when
the machine has troubles
2. Gauge section to display the condition
constantly (Coolant temperature, hydrau-
lic oil temperature, fuel level, etc.)
10-180 PC200/220(LC)-7
(11)
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD MULTI MONITOR SYSTEM
12
1. Monitor panel
OUTLINE
PC200-7 10-181
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD MULTI MONITOR SYSTEM
10-182 PC200/220(LC)-7
(11)
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD MULTI MONITOR SYSTEM
MONITOR PORTION
08932
PC200/220(LC)-7 10-183
(11)
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD MULTI MONITOR SYSTEM
OFF ON Flashes
ON ON ON
Up to 30 sec. ON
Preheating
SAP00526 From 30 sec. to 40 sec. Flashes
Engine
coolant
temperature
See gauge display on the next page
Hydraulic oil
temperature
Fuel level
10-184 PC200/220(LC)-7
(11)
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD MULTI MONITOR SYSTEM
Temperature, vol-
Gauge Range Indicator Buzzer sound
ume
A1 105 Red ❍
A2 102 Red
A5 60 Green
A6 30 White
B1 105 Red
B2 102 Red
B5 40 Green
B6 20 White
C1 289 Green
C2 244.5 Green
C3 200 Green
Fuel level (L)
C4 100 Green
C5 60 Green
C6 41 Red
PC200/220(LC)-7 10-185
(11)
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD MULTI MONITOR SYSTEM
When abnormal,
Engine oil pressure ● -- lights up and buzzer
sounds
When abnormal,
Radiator coolant Lights up when abnor-
● lights up and buzzer
level mal
sounds
10-186 PC200/220(LC)-7
(11)
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD MULTI MONITOR SYSTEM
ON INT OFF
Displays set con-
Wiper
dition
Monitor
Displays set
Travel speed
speed
PC200-7 10-187
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD MULTI MONITOR SYSTEM
SWITCHES
10-188 PC200-7
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD MULTI MONITOR SYSTEM
• Maintenance switch
Check the condition of the maintenance
items. (For details, see MAINTENANCE FUNC-
TION.)
• Auto-deceleration switch
Each time the auto-deceleration switch is
pressed, the auto-deceleration function is
switched ON/OFF.
Use the auto-deceleration monitor display to
check the present condition.
When the working mode switch is operated to
switch the working mode, it is automatically
set to ON.
• Wiper switch
Each time the wiper switch is pressed, the
wiper setting changes OFF → INT → ON → Wiper actuation
OFF → . . . . . . Display Setting
status
Use the wiper monitor display to check the
Stowing stopped
present condition. None OFF
or now stowing
The relationship between the wiper setting
and the monitor display is as shown in the Intermittent actu-
Wiper symbol + INT INT
table on the right. ation
Continuous actu-
Wiper symbol + ON ON
ation
PC200-7 10-189
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD MULTI MONITOR SYSTEM
• Control switch
This is used for control when using the main-
tenance function or select function.
(For details, see each function.)
10-190 PC200-7
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD MULTI MONITOR SYSTEM
METHOD OF USE
PC200/220(LC)-7 10-191
(11)
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD MULTI MONITOR SYSTEM
2. B mode
1) Press select switch (1) on the monitor to
move to the screen for selecting the 3-
stage flow level.
2) Press control switch (2), or input [01] - [03]
with the numeral 10-key pad to choose
one on the three flow levels.
01
02
03
10-192 PC200/220(LC)-7
(11)
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD MULTI MONITOR SYSTEM
5 140 or 150
4 120 or 130
3 100 or 110
2 80 or 90
1 70
PC200/220(LC)-7 10-193
(4)
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD MULTI MONITOR SYSTEM
MAINTENANCE FUNCTION
a Maintenance items
Replacement
No. Item
interval (hours)
Display Condition
10-194 PC200/220(LC)-7
(4)
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD MULTI MONITOR SYSTEM
MAINTENANCE OPERATION
PC200/220(LC)-7 10-195
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD MULTI MONITOR SYSTEM
ADJUSTMENT METHOD
01 Contrast
02 Brightness
10-196 PC200/220(LC)-7
(4)
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD MULTI MONITOR SYSTEM
PC200-7 10-197
3
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD MULTI MONITOR SYSTEM
10-198 PC200-7
3
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD MULTI MONITOR SYSTEM
PC200/220(LC)-7 10-199
(9)
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD 7-SEGMENT MONITOR SYSTEM
SJP08775
OR
08931
• The monitor system monitors the condition • The monitor panel also has various mode
of the machine with sensors installed on vari- selector switches and functions to operate the
ous parts of the machine. It processes and machine control system.
immediately displays the obtained informa-
tion on the panel notifying the operator of the
condition of the machine.
The panel is roughly divided as follows.
1. Monitor section to output alarms when
the machine has troubles
2. Gauge section to display the condition
constantly (Coolant temperature, hydrau-
lic oil temperature, fuel level, etc.)
10-200 PC200-7
3
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD 7-SEGMENT MONITOR SYSTEM
12
1. Monitor panel
PC200/220(LC)-7 10-201
(11)
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD 7-SEGMENT MONITOR SYSTEM
10-202 PC200-7
3
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD 7-SEGMENT MONITOR SYSTEM
Air cleaner clogging When clogged Goes off. Flashes when abnormal.
SAP00521
PC200-7 10-203
3
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD 7-SEGMENT MONITOR SYSTEM
12
10-204 PC200-7
3
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD 7-SEGMENT MONITOR SYSTEM
12
5. Demo-mode
1) In the demo-mode, the time is set to 250h,
the elapsed time is set to 240h, and
replacement of oil is displayed when the
key is turned on. The elapsed time does
not increase, however. The time can be
reset in this mode. Turn on the key 3
times in this mode, and the time interval
is automatically set to "Not set" at the 4th
time and after. The elapsed time is set to
"0h" and counting of elapsed time is
started.
PC200-7 10-205
3
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD 7-SEGMENT MONITOR SYSTEM
12
Mode selector switches
• There are 4 sets of the mode selector Operations table of switch section
switches on the switch section. Each time one
switch is pressed, the machine condition ★ The bold letters are the positions of the
changes. The current condition is indicated switches reset when the starting switch is
by the lighting of the LED above the switch. turned on.
• The initial setting of only the work mode after Item Operation
the starting switch is turned on can be
changed. Work mode A↔E↔B
★ For how to change the setting, see "Work Auto-deceleration ON↔OFF
mode default setting mode" in TROUBLE-
SHOOTING-Display and special functions of Wiper OFF↔Intermittent↔ON
monitor panel.
Travel speed Hi↔Lo
10-206 PC200-7
3
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SENSOR
SENSOR
• The signals from the sensors are input to the
panel directly. Either side of a sensor of con-
tact type is always connected to the chassis
ground.
Hydraulic
oil tempera- Resistance — —
ture
Coolant
Resistance — —
temperature
PC200-7 10-207
3
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SENSOR
12
1. Connector
2. Bracket
3. Float
4. Switch
1. Plug
2. Contact ring
3. Contact
4. Diaphragm
5. Spring
6. Terminal
1. Thermistor 4. Tube
2. Body 5. Wire
3. Tube 6. Connector
10-208 PC200-7
3
BACK
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SENSOR
12
1. Float
2. Connector
3. Cover
4. Variable resistor
PC200-7 10-209
3
TESTING AND ADJUSTING
★ Note the following when making judgements using the standard value tables for testing, adjusting, or trou-
bleshooting.
1. The standard value for a new machine given in the table is the value used when shipping the machine from
the factory and is given for reference. It is used as a guideline for judging the progress of wear after the
machine has been operated, and as a reference value when carrying out repairs.
2. The service limit value given in the tables is the estimated value for the shipped machine based on the
results of various tests. It is used for reference together with the state of repair and the history of operation
to judge if there is a failure.
3. These standard values are not the standards used in dealing with claims.
k When carrying out testing, adjusting, or troubleshooting, park the machine on level ground, insert the safety
pins, and use blocks to prevent the machine from moving.
k When carrying out work together with other workers, always use signals and do not let unauthorized people
near the machine.
k When checking the coolant level, always wait for the coolant to cool down. If the radiator cap is removed
when the coolant is still hot, the coolant will spurt out and cause burns.
k Be careful not to get caught in the fan, fan belt or other rotating parts.
PC200/220(LC)-7 20-1
(11)
BACK
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE RELATED PARTS
Engine SAA6D102E-2
Difference
Oil temperature: 40–60ºC MPa Min. 2.4 between cyinders
Compression pressure
Engine speed: 250rpm {kg/cm2} {Min. 24.6} Min. 1.0
{Min. 10.3}
Oil temperature Whole speed range (inside oil pan) ºC 80–110 120
Fuel injection timing Before Top Dead Center °(degree) 11±1 11±1
20-2 PC200/220(LC)-7
(11)
BACK
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE RELATED PARTS
PC220, 220LC-7
SAA6D102E-2
2,200±70 2,200±70
1,030±50 1,030±50
2,000 2,000
0.25 —
0.51 —
Difference
Min. 2.4 between cyinders
{Min. 24.6} Min. 1.0
{Min. 10.3}
0.39–0.64 0.25
{4.0–6.5} {2.6}
Min. 0.15 0.09
{Min. 1.5} {0.9}
80–110 120
11±1 11±1
8 Min. 6, Max. 10
5–8 5–8
PC200/220(LC)-7 20-3
(1)
BACK
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
20-4 PC200/220(LC)-7
(11)
BACK
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
PC220, 220LC-7
2,050±100 2,050±100
1,950±100 1,950±100
1,400±100 1,400±100
9.5±0.5 9.5±0.5
85±10 85±10
85±10 85±10
85±10 85±10
85±10 85±10
115±12 115±12
Max. 10 Max. 15
15.7±3.9 Max. 24.5
{1.6±0.4} {Max. 2.5}
15.7±3.9 Max. 24.5
{1.6±0.4} {Max. 2.5}
12.7±2.9 Max. 21.6
{1.3±0.3} {Max. 2.2}
12.7±2.9 Max. 21.6
{1.3±0.3} {Max. 2.2}
24.5±5.9 Max. 39.2
{2.5±0.6} {Max. 4.0}
74.5±18.6 Max. 107.6
{7.6±1.9} {Max. 11}
PC200/220(LC)-7 20-5
(1)
BACK
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
20-6 PC200/220(LC)-7
(11)
BACK
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
PC220, 220LC-7
3.9±1.0 3.9±1.0
{40±10} {40±10}
34.8±1.0 33.3–36.8
{355±10} {340–375}
( 37.3±1.0
{380±10} ) ( 36.3–39.2
{370–400} )
30.9±1.5 28.9–32.9
{315±15} {295–335}
38.7±1.0 37.3–40.2
{395±10} {380–410}
3.23±0.2 2.84–3.43
{33±2} {29–35}
3.9±1.0 3.9±1.0
{40±10} {40±10}
2.2±0.1 2.2±0.1
{22±1} {22±1}
PC200/220(LC)-7 20-7
(5)
BACK
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
Time taken to
• Hydraulic oil temperature: Within operation sec. 24.2±2.5 Max. 30
swing
range
• Engine running at high idle
• Working mode: A mode
• Time required for 5 more turns after making
initial one turn
15
Swing
BKP00103
PC200: 46.2–60.4
PC200: 51.3±5.1
Lo PC200LC:
PC200LC: 55.9±5.6
50.3–65.5
PC200: 33.7–45.3
BKP00104
PC200: 37.5±3.8
Travel speed (1) • Hydraulic oil temperature: Within ( Mi) PC200LC:
PC200LC: 40.8±4.1
operation range 36.7–48.9
• Engine running at high idle
• Working mode: A mode PC200: 26.6–31.4
• Time required for track shoes to PC200: 28.0±1.4
Hi PC200LC:
make 5 turns after making one ini- PC200LC: 30.5±1.5
29.0–34.0
tial idle turn
Travel
sec.
45˚
Lo 24±2.5 21.5–27.5
BKP00105
Travel speed (2) • Hydraulic oil temperature: Within ( Mi) 17±2.5 14.5–20.5
operation range
• Engine running at high idle
• Working mode: A mode
• Flat ground Hi 13±1.0 12.0–15.0
• Time required for traveling 20 m
after 10 m trial run
: The “Mi” mode is on the multi-monitor specification machine only.
20-8 PC200/220(LC)-7
(11)
BACK
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
PC220, 220LC-7
Standard value Permissible value
25.7 +2.8
–2.4
Max. 31
0 0
Max. 5 Max. 10
+1.5
PC220: 28.0 –1.3 PC220: 26.7–31.5
PC220LC: PC220LC:
30.3 +1.6 28.9–33.9
–1.4
24±2.5 21.5–27.5
17±2.0 15.0–20.0
13±1.0 12.0–15.0
PC200/220(LC)-7 20-9
(1)
BACK
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
BKP00105
• Hydraulic oil temperature: Within
operation range
• Engine at high idle
• Working mode: A mode
Travel deviation • Travel speed: Lo mm Max. 150 Max. 250
• Solid and flat ground
• Swerving amount while traveling
20 m (X) after initial 10 m trial run
20m
10m
Travel
BKP00107
12˚
BKP00108
BKP00110
Boom cylinder (cylin-
Work equipment
20-10 PC200/220(LC)-7
(11)
BACK
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
PC220, 220LC-7
Standard value Permissible value
0 0
13.6 27.2
Max. 18 Max. 27
Max. 40 Max. 58
PC200/220(LC)-7 20-11
(1)
BACK
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
RAISE
3.3±0.4 Max. 4.7
LOWER
• Engine running at high idle
2.4±0.3 Max. 3.7
• Working mode: A mode
• Time required from raise stroke
end till bucket touches ground
IN
Work equipment speed
Arm
sec.
• Hydraulic oil temperature: Within
operation range
OUT
Bucket
• Hydraulic oil temperature: Within
operation range
DUMP
BKP00114
Boom sec. Max. 1.0 Max. 1.2
• Hydraulic oil temperature: Within operation
range
• Engine running at low idle
• Working mode: A mode
• Time required from raise stroke end till
bucket touches ground and pushes up
machine front
20-12 PC200/220(LC)-7
(11)
BACK
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
PC220, 220LC-7
PC200/220(LC)-7 20-13
(1)
BACK
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
BKP00115
Arm • Hydraulic oil temperature: Within operation Max. 2.0 Max. 2.8
range
• Engine running at low idle
• Working mode: A mode
• Time required from dumping stroke end till
bucket stops momentarily after control
lever is tilted to digging and starts to move
Time lag
again sec.
Work equipment
BKP00116
Bucket • Hydraulic oil temperature: Within operation Max. 1.0 Max. 3.6
range
• Engine running at low idle
• Working mode: A mode
• Time required from dumping stroke end till
bucket stops momentarily after control
lever is tilted to digging and starts to move
again
• Hydraulic oil temperature: Within operation
Cylinders range 4.5 20
leackage
Internal
10m BKP00107
Performance of
hydraulic pump
Hydraulic pump
See next page ¶/min See next page
delivery
20-14 PC200/220(LC)-7
(11)
BACK
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
PC220, 220LC-7
4.5 20
10 50
PC200/220(LC)-7 20-15
(1)
BACK
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
★ As far as possible, bring pump discharge pressure P1 and P2 as close as possible to the average pressure
when measuring.
★ When measuring with the pump mounted on the machine, if it is impossible to set the engine speed to the spec-
ified speed with the fuel control dial, take the pump discharge amount and the engine speed at the point of
measurement, and use them as a base for calculating the pump discharge amount at the specified speed.
20-16 PC200/220(LC)-7
(11)
BACK
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
★ As far as possible, bring pump discharge pressure P1 and P2 as close as possible to the average pressure
when measuring.
★ When measuring with the pump mounted on the machine, if it is impossible to set the engine speed to the spec-
ified speed with the fuel control dial, take the pump discharge amount and the engine speed at the point of
measurement, and use them as a base for calculating the pump discharge amount at the specified speed.
PC200/220(LC)-7 20-17
(11)
BACK
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
20-18 PC200/220(LC)-7
(11)
TESTING AND ADJUSTING
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING........................................................ 20-101-1
INSPECTION AND ADJUSTMENT OF ENGINE SPEED .......................................................................... 20-102
MEASUREMENT OF EXHAUST GAS COLOR.......................................................................................... 20-104
ADJUSTMENT OF VALVE CLEARANCE.................................................................................................. 2 0 - 1 0 5
MEASUREMENT OF COMPRESSION PRESSURE ................................................................................. 20-107
MEASUREMENT OF BLOW-BY PRESSURE............................................................................................ 20-108
INSPECTION AND ADJUSTMENT OF FUEL INJECTION TIMING........................................................... 20-109
MEASUREMENT OF ENGINE OIL PRESSURE........................................................................................ 20- 111
ADJUSTMENT OF ENGINE SPEED SENSOR.......................................................................................... 20-112
INSPECTION AND ADJUSTMENT OF AIR COMPRESSOR BELT TENSION.......................................... 20-112
EMERGENT ESCAPE FROM FAILURE IN ENGINE CONTROL SYSTEM............................................... 20-113
MEASUREMENT OF CLEARANCE IN SWING CIRCLE BEARINGS........................................................ 20-114
INSPECTION AND ADJUSTMENT OF TRACK SHOE TENSION............................................................. 20-115
INSPECTION AND ADJUSTMENT OF HYDRAULIC OIL PRESSURE
IN HYDRAULIC CIRCUIT FOR WORK EQUIPMENT, SWING AND TRAVEL .................................... 20-116
INSPECTION AND ADJUSTMENT OF CONTROL CIRCUIT OIL PRESSURE......................................... 20-120
INSPECTION AND ADJUSTMENT OF PUMP PC CONTROL CIRCUIT OIL PRESSURE ....................... 20-121
INSPECTION AND ADJUSTMENT OF PUMP LS CONTROL CIRCUIT OIL PRESSURE........................ 20-124
MEASUREMENT OF SOLENOID VALVE OUTPUT PRESSURE.............................................................. 20-128
MEASUREMENT OF PPC VALVE OUTPUT PRESSURE ......................................................................... 20-131
ADJUSTMENT OF WORK EQUIPMENT AND SWING PPC VALVE ......................................................... 20-132
INSPECTION OF LOCATIONS OF HYDRAULIC DRIFT OF WORK EQUIPMENT................................... 20-133
RELEASE OF REMAINING PRESSURE IN HYDRAULIC CIRCUIT ......................................................... 20-134
MEASUREMENT OF OIL LEAKAGE AMOUNT......................................................................................... 20-135
AIR BLEEDING OF VARIOUS PARTS ....................................................................................................... 20-137
INSPECTION PROCEDURES FOR DIODE............................................................................................... 20-139
SPECIAL FUNCTION OF MULTI-MONITOR PANEL ................................................................................. 20-140
SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL .................................................................. 20-164
PREPARATIONS FOR TROUBLESHOOTING ELECTRICAL SYSTEM.................................................... 20-177
PC200/220(LC)-7 20-101
(12)
BACK
Symbol
Q’ty
Test, measurement item Part No. Part name Remarks
20-101-1 PC200/220(LC)-7
(12)
BACK
Symbol
Q’ty
Test, measurement item Part No. Part name Remarks
Oil pressure gauge Pressure gauge: 2.5, 5.9, 39.2, 58.8 MPa
799-101-5002 1
PPC valve output pres- kit (analog type) {25, 60, 400, 600 kg/cm2}
M
sure Oil pressure gauge
799-261-1204 1 Pressure gauge: 58.8MPa {600 kg/cm2}
kit (digital type)
Oil leakage inside Commercially
N Cylinder 1
hydraulic cylinder available
Coolant temperature,
P 799-101-1502 Digital thermometer 1 – 99.9 – 1,299°C
oil temperature
79A-264-0021 Push-pull scale 1 0 – 294 N {0 – 30 kg}
Operating force Q
79A-264-0091 Push-pull scale 1 0 – 490 N {0 – 50 kg}
Commercially
Stroke, hydraulic drift R Scale 1
available
Commercially
Work equipment speed S Stopwatch 1
available
Commercially
Voltage, resistance T Tester 1
available
a For the model names and part Nos. of the T-adapters and boxes used for troubleshooting for the monitor
panel, controllers, sensors, actuators, and wiring harnesses, see TROUBLESHOOTING, Layout of connec-
tors and electric circuit diagram of each system.
PC200/220(LC)-7 20-101-2
(11)
BACK
20-102 PC200/220(LC)-7
(12)
BACK
Adjustment
1. Adjustment of engine speed at low idle
a If the rpm at low idle deviates from the stand-
ard value, make adjustment using the adjust-
ment function provided in the monitor panel.
a For the adjustment procedures, refer to the
section, "Special function of monitor panel"
PC200/220(LC)-7 20-103
(12)
BACK
20-104 PC200/220(LC)-7
(12)
BACK
PC200/220(LC)-7 20-105
(5)
BACK
20-106 PC200/220(LC)-7
(1)
BACK
2. Make preparations for measuring the engine 7. Fasten governor lever (3) of the fuel injection
speed. pump, as it is in contact with the stopper on the
a For the preparations, refer to the section, "In- STOP side.
spection and adjustment of engine speed".
2 Nozzle holder:
back to normal condition.
3 Nozzle holder:
Seizure preventive (Molycoat 1000)
PC200/220(LC)-7 20-107
(12)
BACK
20-108 PC200/220(LC)-7
(12)
BACK
PC200/220(LC)-7 20-109
(11)
BACK
7. Detach the measurement tools after the mea- 3. Reverse and push in timing pin (5) of the fuel
surement, and make sure that the machine is injection pump, then match the pin cut-out por-
Adjustment
a If fuel injection timing is found incorrect, adjust it
in the following manner.
1. Confirm that drive gear injection timing is fixed
with driving gear timing pin (3).
a If timing pin (3) was pulled back after the in-
spection had been completed, push it in
again following the foregoing inspection pro-
cedures.
4. Mount the fuel injection pump.
a For mounting the pump, refer to the same
section mentioned in Item 2 above.
20-110 PC200/220(LC)-7
(1)
BACK
PC200/220(LC)-7 20-111
(12)
BACK
ADJUSTMENT OF ENGINE SPEED SENSOR
TESTING AND ADJUSTING INSPECTION AND ADJUSTMENT OF AIR COMPRESSOR BELT TENSION
3 Threaded portion:
with the tip of flywheel ring gear teeth (2).
20-112 PC200/220(LC)-7
(5)
BACK
TESTING AND ADJUSTING EMERGENT ESCAPE FROM FAILURE IN ENGINE CONTROL SYSTEM
PC200/220(LC)-7 20-113
(11)
BACK
a Follow the steps explained below, when measur- 5. Read off the value in dial gauge H in this condi-
ing clearance in the swing circle bearing in the tion.
a The value indicated in dial gauge H express-
k Be careful not to put a hand or foot under the un-
actual machine.
es clearance in the bearings.
dercarriage, while taking measurement.
20-114 PC200/220(LC)-7
(1)
BACK
PC200/220(LC)-7 20-115
(11)
BACK
INSPECTION AND ADJUSTMENT OF HYDRAULIC OIL PRESSURE IN
TESTING AND ADJUSTING HYDRAULIC CIRCUIT FOR WORK EQUIPMENT, SWING AND TRAVEL
20-116 PC200/220(LC)-7
(11)
BACK
INSPECTION AND ADJUSTMENT OF HYDRAULIC OIL PRESSURE IN
TESTING AND ADJUSTING HYDRAULIC CIRCUIT FOR WORK EQUIPMENT, SWING AND TRAVEL
2. Combination of pump, actuator, and valve a Hydraulic oil pressure when the main relief
a When the oil from the pumps is divided, the valve is in relief condition is displayed.
front pump and rear pump act independently a If one-touch power max. switch is de-
on each actuator. Note that different actua- pressed, the oil pressure is turned to high re-
tors relieve different valves. lief pressure, and if released, it is turned to
a When the work equipment circuit or swing low relief pressure.
circuit is relieved singly, the oils of the pumps a Keep the swing lock switch in the OFF posi-
are merged. When the travel circuit is re- tion during the inspection. If it is moved to the
lieved singly, the oils of the pumps are divid- ON position, hydraulic oil pressure is turned to
ed. high relief pressure, as the constant 2-stage
a The actuators in the table are arranged in the relief valve is moved to the ON position.
order when the control valve is seen from the
front of the machine (and an attachment is 5. Measurement of swing relief pressure
installed to the service valve). 1) Start the engine and move the swing lock
switch to the ON position.
Pump Actuator Valve relieved 2) Measure hydraulic oil pressure when the
(R unload valve) (R main relief valve) engine is running at high idle and the swing
Service Safety valve circuit is relieved.
Rear Bucket R main relief valve a Hydraulic oil pressure when the swing motor
safety valve is relieved is displayed.
Left travel R main relief valve
a The swing motor relief pressure is lower than
Boom R main relief valve the main relief pressure.
(Pump merge-divider valve) (Travel junction valve)
(Self-pressure reducing valve) 6. Measurement of travel circuit relief pressure
Swing Swing motor safety valve 1) Start the engine and lock travel.
Front Right travel F main relief valve k Put pin [2] in between the sprocket and the
Arm F main relief valve track frame to make sure locking travel.
(F unload valve) (F main relief valve)
(Centralized safety valve) (Back pressure valve)
PC200/220(LC)-7 20-117
(11)
BACK
ADJUSTMENT OF ENGINE SPEED SENSOR
TESTING AND ADJUSTING INSPECTION AND ADJUSTMENT OF HYDRAULIC OIL PRESSURE IN HY-
3 Lock nut:
4) Fixing holder (8), tighten locknut (7).
3 Locknut:
4) Fixing holder (6), tighten locknut (5).
20-118 PC200/220(LC)-7
(5)
BACK
INSPECTION AND ADJUSTMENT OF HYDRAULIC OIL PRESSURE IN
TESTING AND ADJUSTING HYDRAULIC CIRCUIT FOR WORK EQUIPMENT, SWING AND TRAVEL
3 Locknut:
nut (10).
PC200/220(LC)-7 20-119
(8)
BACK
TESTING AND ADJUSTING INSPECTION AND ADJUSTMENT OF CONTROL CIRCUIT OIL PRESSURE
Measurement
k Lower the work equipment to the ground and
stop the engine. After the engine stops, operate
the control lever several times to release the re-
maining pressure in the piping. Then loosen the
oil filler cap to release the pressure inside the hy-
draulic tank.
20-120 PC200/220(LC)-7
(11)
BACK
INSPECTION AND ADJUSTMENT OF PUMP PC CONTROL CIRCUIT OIL
TESTING AND ADJUSTING PRESSURE
Measurement
a Implement measuring the pump PC control cir-
cuit oil pressure after confirming that the work
equipment, swing and travel circuit oil pressure
as well as the control circuit original oil pressure
PC200/220(LC)-7 20-121
(11)
BACK
INSPECTION AND ADJUSTMENT OF PUMP PC CONTROL CIRCUIT OIL
TESTING AND ADJUSTING PRESSURE
3) Start the engine and keep it running until the 2. Measurement of PC-EPC output pressure
hydraulic oil temperature rises to the operat- 1) Remove oil pressure measurement plug (5).
ing range.
20-122 PC200/220(LC)-7
(11)
BACK
INSPECTION AND ADJUSTMENT OF PUMP PC CONTROL CIRCUIT OIL
TESTING AND ADJUSTING PRESSURE
4) Measure the hydraulic oil pressure with all 1. Loosen locknut (8).
the control levers kept in the NEUTRAL a Before loosening the locknut, make match
position and the engine running at high idle marks at the adjustment screw end so that
and at low idle. you can see the position of the locknut be-
a If PC-EPC valve output pressure chang- fore the adjustment (and you can return the
es to the following values, it is judged locknut to its original position after turning it
normal. in reverse).
Engine Control Hydraulic oil 2. Turn adjustment screw (9) to the right or left to
speed lever pressure adjust.
2.9 MPa a Turn the adjustment screw in the following
Low idle
{30 kg/cm2} directions.
Neutral • If the work equipment speed is low, turn
0 MPa
High idle the adjustment screw to the right (to in-
{0 kg/cm2}
crease the pump absorption torque).
• If the engine speed lowers, turn the ad-
justment screw to the left (to decrease
Adjustment
the pump absorption torque).
a If any of the phenomena mentioned below oc-
curs and PC valve malfunctioning is suspected,
3 Locknut:
3. Tighten locknut (8).
adjust PC valves (6) and (7) in the following man-
ner.
27.5 – 34.3 Nm {2.8 – 3.5 kgm}
• As workload increases, the engine rpm
sharply drops.
• While the engine rpm is normal, the work
equipment moves slowly.
• (6): Front pump PC valve
• (7): Rear pump PC valve
a The width across flats of the locknut for the PC
valve is 13 mm and that of the adjustment screw
(inside width) is 4 mm. Do not turn any other
locknut or adjustment screw since it has effects
on the performance of the hydraulic pumps.
PC200/220(LC)-7 20-123
(11)
BACK
INSPECTION AND ADJUSTMENT OF PUMP LS CONTROL CIRCUIT OIL
TESTING AND ADJUSTING PRESSURE
Measurement
a Measure pump LS control circuit oil pressure af-
ter confirming that the work equipment, swing
and travel circuit oil pressure as well as control
20-124 PC200/220(LC)-7
(11)
BACK
INSPECTION AND ADJUSTMENT OF PUMP LS CONTROL CIRCUIT OIL
TESTING AND ADJUSTING PRESSURE
3) Run the engine and raise the hydraulic oil 5) Detach all the measurement tools after the
temperature to the operating range and measurement and make sure that the
push up the track shoe on the side to be machine is back to normal condition.
measured with the work equipment.
• For measuring oil pressure in front cir- 2. Measurement of LS differential pressure
cuit: Right track shoe a LS differential pressure can be obtained by
• For measuring oil pressure in rear cir- measuring pump delivery pressure and LS
PC200/220(LC)-7 20-125
(11)
BACK
INSPECTION AND ADJUSTMENT OF PUMP LS CONTROL CIRCUIT OIL
TESTING AND ADJUSTING PRESSURE
2) Fit nipple K2 and connect it to oil pressure kProvide a working area of sufficient
gauge [1] of hydraulic tester K1 or differen- space, as the raised track shoe will be
tial pressure gauge K3. idly rotated.
a When using a differential pressure
gauge:
Connect pump delivery pressure to the
high pressure side and LS pressure to
the low pressure side.
A differential pressure gauge requires
DC 12V power. Connect it with one bat-
tery.
a When using an oil pressure gauge:
Use an oil pressure gauge with the ca-
pacity of 58.5 MPa {600 kg/cm2}.
The max. differential pressure is no
more than approx. 40 MPa {408 kg/cm2}.
The same gauge may be used through-
out the measurement. 4) Measure pump delivery pressure and LS
• Photo shows pump delivery pressure pressure (actuator loaded pressure)
side together with the machine set at the follow-
ing conditions and the engine running at
high idle.
• Working mode: A mode
• Traveling speed: Hi
• All the control levers of the work equip-
ment, swing and travel are kept in the
NEUTRAL position and the travel control
lever is kept at half stroke (one side of
the track shoes idly rotates).
a Let the raised track shoe idly rotate, pay-
ing enough attention to the surroundings
for safety.
a Calculation of LS differential pressure:
LS differential pressure = Pump delivery
• Photo shows LS pressure side pressure – LS pressure
a If LS differential pressure is in the follow-
ing conditions, it is judged normal.
20-126 PC200/220(LC)-7
(12)
BACK
INSPECTION AND ADJUSTMENT OF PUMP LS CONTROL CIRCUIT OIL
TESTING AND ADJUSTING PRESSURE
3. Measurement of LS-EPC valve output pres- 4) Measure the oil pressure when the engine is
sure running at high idle and the travel speed
1) Remove oil pressure measurement plug (5). switch and travel lever are operated.
a If LS-EPC valve output pressure chang-
es to the following values, the pressure
is normal.
Adjustment
a When LS differential pressure is not normal, ad-
just it with LS valves (6) and (7).
(6): Front pump LS valve
(7): Rear pump LS valve
PC200/220(LC)-7 20-127
(11)
BACK
INSPECTION AND ADJUSTMENT OF PUMP LS CONTROL CIRCUIT OIL
TESTING AND ADJUSTING PRESSURE
20-127-1 PC200/220(LC)-7
(5)
BACK
20-128 PC200/220(LC)-7
(11)
BACK
Table for Functioning Conditions - PPC lock Table for Functioning Conditions - Swing and
solenoid valve parking brake solenoid
Functioning condition Functioning Functioning condition Functioning
Locked OFF When all of them
Safety lock lever Work equipment, OFF
Released ON is OFF
swing, travel,
signaling When any of them
ON
is ON
PC200/220(LC)-7 20-129
(12)
BACK
20-130 PC200/220(LC)-7
(12)
BACK
PC200/220(LC)-7 20-131
(12)
BACK
TESTING AND ADJUSTING ADJUSTMENT OF WORK EQUIPMENT AND SWING PPC VALVE
20-132 PC200/220(LC)-7
(10)
BACK
INSPECTION OF LOCATIONS OF HYDRAULIC DRIFT OF WORK
TESTING AND ADJUSTING EQUIPMENT
PC200/220(LC)-7 20-133
(11)
BACK
INSPECTION OF LOCATIONS OF HYDRAULIC DRIFT OF WORK EQUIPMENT
TESTING AND ADJUSTING RELEASE OF REMAINING PRESSURE IN HYDRAULIC CIRCUIT
RELEASE OF REMAINING
PRESSURE IN HYDRAULIC
CIRCUIT
3. Inspection of boom lock valve k If the piping between the hydraulic cylinders or
1) Set the work equipment at the maximum the hydraulic motor and control valves is to be
reach and the boom top horizontal. Then disconnected, release the remaining pressure in
20-134 PC200/220(LC)-7
(11)
BACK
PC200/220(LC)-7 20-135
(11)
BACK
4. Measurement of oil leakage amount from 3) Disconnect drain hose (6) of the travel
swing motor motor and fit a blind plug in the hose end.
1) Disconnect drain hoses (4) and (5) and fit a 4) Start the engine and apply the travel relief
blind plug in the hoses. pressure with the engine running at high
2) Turn the swing lock switch to the ON posi- idle, then measure an oil leakage amount
5. Measurement of oil leakage amount from 5) After the measurement, make sure that the
travel motor machine is back to normal condition.
1) Take off the travel motor cover.
2) Start the engine and lock the travel.
k Put pin [1] in between the sprocket and the
track frame to block the travel.
20-136 PC200/220(LC)-7
(11)
BACK
1. Air bleeding from hydraulic pump 2. Air bleeding from hydraulic cylinder
1) Loosen air bleeding plug (1) and confirm 1) Start the engine and kept it running at low
that oil seeps out from the plug. idle for 5 minutes.
2) If the oil seepage is confirmed, tighten air 2) Raise and lower the boom 4 to 5 times with
bleeding plug (1). the engine running at low idle.
3 Air bleeding plug: a Be careful not to apply the relief pres-
7.8–9.8 Nm{0.8–1.0 kgm} sure, stopping the piston rod approx.
a Precautions for starting engine 100 mm before its stroke end.
When starting the engine after the air bleed- 3) Repeat the steps in Item 2) above, but this
ing work explained above, run the engine at time with the engine running at high idle.
low idle for 10 minutes. 4) Apply the relief pressure by extending the
If the engine coolant temperature is low and piston rod to its stroke end and with the
an automatic engine warming-up function is engine running at low idle.
relied on, use the fuel dial, when it becomes 5) For bleeding air from the arm cylinder and
necessary to cancel it. bucket cylinder, follow the same steps
explained in Item 2) through 4) above.
a In case a cylinder is replaced with new one,
it is advised to bleed air from the new one be-
fore mounting the work equipment. It is es-
pecially so with the boom cylinder, because
its rod does not extend to the stroke end of
LOWER side, after the work equipment is
mounted.
PC200/220(LC)-7 20-137
(11)
BACK
20-138 PC200/220(LC)-7
(11)
BACK
PC200/220(LC)-7 20-139
(12)
BACK
[1] Figure input switch 1 [6] Figure input switch 6 [ ] Return switch
[2] Figure input switch 2 [7] Figure input switch 7 [ ] Upward move switch
[3] Figure input switch 3 [8] Figure input switch 8 [ ] Downward move switch
[4] Figure input switch 4 [9] Figure input switch 9 [ ] Input confirmation switch
[5] Figure input switch 5 [0] Figure input switch 0
20-140 PC200/220(LC)-7
BACK
PC200/220(LC)-7 20-141
(11)
BACK
20-142 PC200/220(LC)-7
(1)
BACK
PC200/220(LC)-7 20-143
BACK
20-144 PC200/220(LC)-7
BACK
User
Failed System Action Directed to Operator
Code
Ordinary work may be resumed by turning the emergency pump drive switch ON,
E02 PC-EPC Valve
but call for the inspection service immediately.
Release the brake after turning emergency swing and parking brake switch ON.
When applying the swing brake, operate the swing lock switch manually. The
E03 Swing Brake
swing brake may not be released depending on the nature of the trouble. In either
case, call for the inspection service immediately.
The governor control has become inoperable. Operate the governor control lever
E05 Governor manually. For fixing the lever at full throttle position, use a fixing bolt provided at
the bracket. In this case, call for the inspection service immediately.
PC200/220(LC)-7 20-145
(1)
BACK
20-146 PC200/220(LC)-7
(10)
BACK
Classification
User Code
Failure
No.
Code
Content Code No. Location Phenomenon
No.
Abnormality
– E101 Abnormal data in error history DAF0KT Failure history
in data
Short circuit in wiper motor drive, normal rota- Windshield wiper motor (nor-
– E112 DY2DKB Short circuit
tion system mal rotation)
Short circuit in wiper motor drive, reverse rota-Windshield wiper motor
– E113 DY2EKB Short circuit
tion system (reverse rotation)
– E114 Short circuit in windshield washer drive DY2CKB Windshield washer motor Short circuit
– E115 Abnormality of windshield wiper in motion DY20KA Windshield wiper motor Disconnection
– E116 Abnormality of windshield wiper in retraction
DY20MA Windshield wiper motor Malfunctioning
Travel interlocking solenoid
– E201 Short circuit in travel interconnection solenoid DW91KB Short circuit
valve
E03 E203 Short circuit in swing holding brake solenoid DW45KB Swing holding solenoid valve Short circuit
– E204 Short circuit in merge/divide solenoid DWJ0KB Merge solenoid valve Short circuit
– E205 Short circuit in 2-stage relief solenoid DWK0KB 2-stage relief solenoid valve Short circuit
Travel Hi-Lo shifting solenoid
– E206 Short circuit in travel speed shifting solenoid DW43KB Short circuit
valve
Travel interlocking solenoid
– E211 Disconnection in travel interlocking solenoid DW91KA Disconnection
valve
E03 E213 Disconnection in swing holding brake solenoid DW45KA Swing holding solenoid valve Disconnection
– E214 Disconnection in merge/divide solenoid DWJ0KA Merge solenoid valve Disconnection
– E215 Disconnection in 2-stage relief solenoid DWK0KA 2-stage relief solenoid valve Disconnection
Travel Hi-Lo shifting solenoid
– E216 Disconnection in travel speed shifting solenoid DW43KA Disconnection
Electrical system
valve
Nonconfor-
– E217 Abnormality in model code input DA2SKQ S_NET mance in model
selecting signal
– E218 Disconnection in S_NET signal DA2SKA S_NET Disconnection
– E222 Short circuit in LS-EPC solenoid DXE0KB LS-EPC solenoid valve Short circuit
– E223 Disconnection in LS-EPC solenoid DXE0KA LS-EPC solenoid valve Disconnection
– E224 Abnormality in F pump pressure sensor DHPAMA F pump pressure sensor Malfunctioning
– E225 Abnormality in R pump pressure sensor DHPBMA R pump pressure sensor Malfunctioning
Lowering in out-
– E226 Abnormality in pressure sensor power source DA25KP Governor pump controller
put voltage
– E227 Abnormality in engine revolution sensor DLE2MA Engine revolution sensor Malfunctioning
– E228 Short circuit in ATT return switching relay D196KB ATT switching relay Short circuit
E02 E232 Short circuit in PC-EPC solenoid DXA0KB TVC solenoid valve Short circuit
E02 E233 Disconnection in PC-EPC solenoid DXA0KA TVC solenoid valve Disconnection
– E238 Disconnection in ATT return switching relay D196KA ATT switching relay Disconnection
ATT flow rate throttling EPC
– E245 Short circuit in ATT flow rate adjusting EPC DXE4KB Short circuit
valve
ATT flow rate throttling EPC
– E246 Disconnection in ATT flow rate adjusting EPC DXE4KA Disconnection
valve
Abnormality in
– E256 Incorrect nonvolatile memory data DA20KT Nonvolatile memory
data
Governor motor feedback
– E306 Abnormality in governor potentiometer DK54KZ Malfunctioning
potentiometer
E05 E308 Abnormality in fuel dial DK10KZ Throttle potentiometer Malfunctioning
– E315 Short circuit in battery relay output D110KB Battery relay Short circuit
– E316 Abnormality in governor motor step-out DY10K4 Governor motor Out of control
PC200/220(LC)-7 20-147
(1)
BACK
Classification
User Code
Failure
No.
Code
Content Code No. Location Phenomenon
No.
E05 E317 Disconnection in both governor motors A and B DY10KA Governor motor Disconnection
E05 E318 Short circuit in both governor motors A and B DY10KB Governor motor Short circuit
Electrical system
Error in operation
E50 E501 No setting in model selection DA2AKM Governor pump controller
or setting
Abnormality in
E50 E502 Malfunction in model selecting signal DA20KT Governor pump controller
data
Abnormality in boom angle sensor (short circuit
E50 E511 DKA0KB Boom angle sensor Short circuit
in power source)
– None Engine high idle out of rate A000N1 Engine Overrunning
Low idle out of
– None Engine low idle out of rate A000N2 Engine
rate
– None Air cleaner clogged AA10NX Air cleaner element Clogging
Insufficient
Mechanical system
– None Charging voltage abnormally low AB00KE Alternator
charging
Oil pressure low-
– None Engine oil pressure abnormally low B@BAZG Engine oil
ered
– None Engine oil level abnormally low B@BAZK Engine oil Oil level lowered
– None Engine cooling water overheated B@BCNS Engine cooling water Overheating
Cooling water
– None Radiator water level abnormally low B@BCZK Engine cooling water
level lowered
– None Hydraulic oil overheated B@HANS Hydraulic oil Overheating
Auto-lubrication system con-
– None Auto-lubrication system abnormal DA80MA Malfunction
troller
20-148 PC200/220(LC)-7
(11)
BACK
2) Switch operation
Operate the switch as instructed below.
• Switch operation: [ ] + [1] ➝ [2] ➝ [3]
(Enter a figure, depressing [ ])
PC200/220(LC)-7 20-149
BACK
1) Selection of menu
Select "01 Monitoring" in the initial display of
Service Menu and depress [ ] switch.
20-150 PC200/220(LC)-7
BACK
3) Monitoring operation
Call the monitoring information display and
confirm the monitored information, while
operating the machine.
PC200/220(LC)-7 20-151
BACK
20-152 PC200/220(LC)-7
BACK
★ Select the most favorite display unit from among the prepared three kinds, i.e. ISO, meter and inch. When
changing one display unit for another, refer to "Unit" in the initial value setting of Service Menu.
★ Abbreviations, ABN and NOR, stand for the following conditions.
ABN: Abnormal, NOR: Normal
PC200/220(LC)-7 20-153
BACK
1) Selection of menu
Select 02 Abnormality Record in the initial
display of Service Menu and depress [ ]
switch.
2) Selection of Submenu
Select an appropriate item from Submenu in
the Abnormality Record display and depress
[ ] switch.
No. Abnormality Record Submenu
Return
00
(termination of Abnormality Record)
01 Electrical System
02 Mechanical Systems
20-154 PC200/220(LC)-7
BACK
PC200/220(LC)-7 20-155
(12)
BACK
1) Selection of menu
Select 03 Maintenance Record in Service
Menu and depress [ ] switch.
2) Information to be displayed
: Name of oils and filters
: Times of replacement to date
: Service meter reading at the latest
replacement
20-156 PC200/220(LC)-7
BACK
1) Selection of menu
Select 04 Maintenance Mode Change in the
initial display of Service Menu, and depress
[ ] switch.
PC200/220(LC)-7 20-157
BACK
20-158 PC200/220(LC)-7
BACK
1) Selection of menu
Select 05 Phone Number Entry menu in the
display of Service Menu, and depress [ ]
switch.
PC200/220(LC)-7 20-159
BACK
1) Selection of menu
Select 06 "✩✩✩✩✩/Default menu" in the
initial display of Service Menu, and depress
[ ] switch.
2) Selection of submenu
Select an item to change from the submenu,
and depress [ ] switch.
No. ✩✩✩✩✩/Default submenu
00 Return (termination of ✩✩✩✩✩/Default)
01 Key-on Mode
02 ✩✩/Language
03 Unit
04 With/Without Service Cir.
20-160 PC200/220(LC)-7
BACK
PC200/220(LC)-7 20-161
(1)
BACK
2) Selection of submenu
Select an item to change from the submenu
and depress [ ] switch.
No. Adjustment submenu
00 Return (termination of adjustment)
01 Governor Motor Adjustment
02 Pump Absorption Torque
03 Low Idle Speed
04 Service Current Adjust.
20-162 PC200/220(LC)-7
(11)
BACK
3 Nut:
governor spring is directed down.
PC200/220(LC)-7 20-163
(11)
BACK
20-163-1 PC200/220(LC)-7
(11)
BACK
20-164 PC200/220(LC)-7
(10)
BACK
a Each number in [ ] is a code No. displayed in the service meter section when the menu is selected.
PC200/220(LC)-7 20-165
(10)
BACK
<Reference>
A user code is displayed only when a serious
trouble occurs.
Even if a user code is not displayed, a trouble
may have occurred. If you feel any abnormality,
be sure to check for a service code with the
"Function of displaying service code [01]" in the
service menu.
User Caution
Error mode Remedy (shown to operator)
code buzzer
If the emergency pump drive switch is set in the upper position, the
Error in pump
E02 machine can operate normally. Have the machine inspected immediately, q
control system
however.
Set the swing holding brake release switch in the upper position to release
Error in swing the brake. When applying the swing brake, operate the swing lock switch
E03 q
brake system manually. The brake may not be released, depending on the cause of the
failure. In this case, have the machine inspected immediately.
Error in governor
E05 Have the machine inspected immediately. q
system
20-166 PC200/220(LC)-7
(10)
BACK
1) Operating switches
While holding caution buzzer stop switch (3),
hold auto decelerator switch (4) for 2.5 seconds.
3) Selecting menu
While holding caution buzzer stop switch (3),
operate working mode selector switches (7) and
(8) to select a menu you will use.
• UP switch (7): Increase Menu No.
• DOWN switch (8): Decrease Menu No.
4) Executing menu
Select a menu you will use and press set switch
(5), and the menu is executed.
PC200/220(LC)-7 20-167
(10)
BACK
20-168 PC200/220(LC)-7
(10)
BACK
PC200/220(LC)-7 20-169
(10)
BACK
a For troubleshooting for a service code having the description of (Equivalent to error code [******]), see the
section of the corresponding "Error code of mechanical system".
a "E" at the head of each service code indicates the following condition.
• With E: The trouble has not been repaired.
• Without E: The trouble has been repaired.
20-170 PC200/220(LC)-7
(10)
BACK
PC200/220(LC)-7 20-171
(10)
BACK
20-172 PC200/220(LC)-7
(10)
BACK
PC200/220(LC)-7 20-173
(10)
BACK
a When the wiper is stopped, (d) and (f) of code No. [048] light up. When the wiper is operated, (c) and (f) or
(d) and (e) light up.
20-174 PC200/220(LC)-7
(10)
BACK
PC200/220(LC)-7 20-175
(11)
BACK
3 Locknut:
governor spring is directed down.
20-176 PC200/220(LC)-7
(10)
BACK
PC200/220(LC)-7 20-176-1
(10)
BACK
20-176-2 PC200/220(LC)-7
(10)
BACK
PC200/220(LC)-7 20-176-3
(10)
BACK
20-176-4 PC200/220(LC)-7
(10)
BACK
PC200/220(LC)-7 20-177
(7)
BACK
1. Monitor panel
1) Take off cover (1).
a The cover is fixed with two upper and
lower clips. Pull it up for the removal.
a If a sunlight sensor is equipped for an air
conditioner, detach P15 connector at the
cover rear side.
20-177-1 PC200/220(LC)-7
(5)
BACK
20-178 PC200/220(LC)-7
Engine (PC200, 200LC) Hydraulic system (PC200, 200LC)
PC200/220(LC)-7
20-179
BACK
Model Serial No. Service meter reading Client user's name Implemented on: Inspected by:
20-180
1. Engine (PC200, 200LC-7)
Condition setting Standard value
No. Working Auto One-touch po- Measurement item Unit Measured value Judgement
Fuel dial mode decelerator wer max. switch Work equipment operation New machine Failure judgement
1 Operating travel control lever Engine rotation rpm 2,080 – 2,220 — Good / No good
Full (Do not travel machine)
2 Engine oil pressure MPa{kg/cm2} 0.39 – 0.64{4.0 – 6.5} 0.25{2.6} Good / No good
OFF
3 Engine rotation rpm 980 – 1,080 — Good / No good
Low A OFF All control levers in NEUTRAL
4 Engine oil pressure MPa{kg/cm2} Min. 0.15{Min. 1.5} 0.09{2.9} Good / No good
5 Engine rotation rpm 1,800 – 2,000 — Good / No good
ON Arm (extended) relief
6 Full Blow-by pressure kPa{mmH2O} Max. 1.2{Max. 123} 5.1{520} Good / No good
7 ON OFF All control levers in NEUTRAL Engine rotation rpm 1,300 – 1,500 — Good / No good
PC200/220(LC)-7
BACK
4. Inspection of hydraulic circuit (PC200, 200LC-7) ➀ ➁ ➂ ➃ ➄
Condition setting 600 kg/cm2 600 kg/cm2 600 kg/cm2 600 kg/cm2 60 kg/cm2
No. Part to be checked Remarks
Working Auto-dece- One-touch po- F main pump R main pump F pump LS R pump LS Control circuit
Fuel dial Work equipment operation pressure
mode lerator wer max. switch
1 Self-decompression valve Circuit pressure 3.2 MPa {33 kg/cm2}
OFF Arm dumping relief
2 Main relief valve
PC200/220(LC)-7
34.8 → 37.3 MPa
3 (When power increased) ON {355 → 380 kg/cm2}
Neutral Main–LS=3.9 MPa{40 kg/cm2}
LS valve (LS differential pressure = Unload pressure)
4 (LS differential Travel without load, Right
pressure valve) Full A OFF engine at Hi idle and Main–LS=2.2 MPa{22.0 kg/cm2} (LS pressure)
control lever at half stroke Left
➀ ➁ ➂ ➃ ➄
Condition setting 600 kg/cm2 600 kg/cm2 600 kg/cm2 600 kg/cm2 60 kg/cm2
No. Part to be checked Working Auto- One-touch po- circuit Remarks
Fuel dial mode decelerator wer max. switch Work equipment operation F main pump R main pump F pump servo R pump servo Control
pressure
(11)
20-181
BACK
BACK
20-182 PC200/220(LC)-7
(1)
Engine (PC220, 220LC) Hydraulic system (PC220, 220LC)
PC200/220(LC)-7
20-183
BACK
Model Serial No. Service meter reading Client user's name Implemented on: Inspected by:
20-184
1. Engine (PC220, 220LC-7)
Condition setting Standard value
No. Working Auto One-touch po- Measurement item Unit Measured value Judgement
Fuel dial mode decelerator wer max. switch Work equipment operation New machine Failure judgement
1 Operating travel control lever Engine rotation rpm 2,130 – 2,270 — Good / No good
Full (Do not travel machine)
2 Engine oil pressure MPa{kg/cm2} 0.39 – 0.64{4.0 – 6.5} 0.25{2.6} Good / No good
OFF
3 Engine rotation rpm 980 – 1,080 — Good / No good
Low A OFF All control levers in NEUTRAL
4 Engine oil pressure MPa{kg/cm2} Min. 0.15{Min. 1.5} 0.09{2.9} Good / No good
5 Engine rotation rpm 1,850 – 2,050 — Good / No good
ON Arm (extended) relief
6 Full Blow-by pressure kPa{mmH2O} Max. 1.2{Max. 123} 5.1{520} Good / No good
7 ON OFF All control levers in NEUTRAL Engine rotation rpm 1,300 – 1,500 — Good / No good
PC200/220(LC)-7
BACK
4. Inspection of hydraulic circuit (PC220, 220LC-7) ➀ ➁ ➂ ➃ ➄
Condition setting 600 kg/cm2 600 kg/cm2 600 kg/cm2 600 kg/cm2 60 kg/cm2
No. Part to be checked Remarks
Working Auto-dece- One-touch po- F main pump R main pump F pump LS R pump LS Control circuit
Fuel dial Work equipment operation pressure
mode lerator wer max. switch
1 Self-decompression valve Circuit pressure 3.2 MPa {33 kg/cm2}
OFF Arm dumping relief
2 Main relief valve
PC200/220(LC)-7
34.8 → 37.3 MPa
3 (When power increased) ON {355 → 380 kg/cm2}
Neutral Main–LS=3.9 MPa{40 kg/cm2}
LS valve (LS differential pressure = Unload pressure)
4 (LS differential Travel without load, Right
pressure valve) Full A OFF engine at Hi idle and Main–LS=2.2 MPa{22.0 kg/cm2} (LS pressure)
control lever at half stroke Left
➀ ➁ ➂ ➃ ➄
Condition setting 600 kg/cm2 600 kg/cm2 600 kg/cm2 600 kg/cm2 60 kg/cm2
No. Part to be checked Working Auto- One-touch po- circuit Remarks
Fuel dial mode decelerator wer max. switch Work equipment operation F main pump R main pump F pump servo R pump servo Control
pressure
(11)
20-185
BACK
TROUBLESHOOTING
PC200/220(LC)-7 20-201
BACK
Mode Content
Troubleshooting when Service Code (electrical system) and Failure Code (mechanical
Code display
system) are displayed.
E mode Troubleshooting of electrical system
H mode Troubleshooting of hydraulic and mechanical systems
S mode Troubleshooting of engine assembly
1. Troubleshooting steps when calling User Code display in the monitor panel
In the User Code display, select and depress [ ] switch to display Service Code. Following displayed Ser-
vice Code for the electrical system, carry out the troubleshooting along the corresponding code display.
2. Troubleshooting steps when the electrical system Service Code or mechanical system Failure Code
is recorded in the failure history:
If not calling User Code in the monitor panel, check the electrical system Service Code or mechanical sys-
tem Failure Code, using the failure history function of the monitor panel.
a If Service Code in the electrical system is recorded, delete the all codes once and revive the code in the
display again to check if the same abnormality still persists.
a Failure Code in the mechanical system cannot be deleted.
3. Troubleshooting steps without User Code display and no failure history is available
If there is no display of User Code nor the failure history in the monitor panel, it is possible that a failure that
the monitor panel cannot diagnose by itself may have occurred in any of the electrical, hydraulic or mechan-
ical system. In such a case, reexamine the phenomenon, find out the most similar phenomenon from
among "Failure like Phenomena and Troubleshooting No." and carry out E mode or H mode troubleshooting
related to the phenomenon in question.
PC200/220(LC)-7 20-213
(5)
BACK
Troubleshooting
No. Failure-looking phenomenon Code
E mode H mode S mode
display
Action to be taken concerning Service Code, User Code and Failure Code
1 Display User Code in monitor panel Accord-
Display Service Code in electrical system after checking failure ing to
2
history dis-
Display Failure Code in mechanical system after checking failure played
3 code
history
Engine-related failure
Engine does not start up easily. (It always takes some time to start
4 S-1
up the engine)
5 Engine does not rotate E-1 S-2 (1)
6 Engine rotates, but there is no exhaust gas S-2 (2)
Engine does not start
There is exhaust gas, but engine does not
7 S-2 (3)
start
8 Engine pickup is poor. (Engine does not follow acceleration) S-3
9 Engine stops while in operation E-2 H-2 S-4
10 Engine rotation is irregular. (There is hunting) E-3 S-5
11 Engine is short of output, or lacks power H-1 S-6
12 Color of exhaust gas is too dark. (Incomplete combustion) S-7
13 Excessive engine oil consumption, or color of exhaust gas is blue S-8
14 Premature engine oil contamination S-9
15 Excessive fuel consumption S-10
16 Engine coolant is mixed with engine oil, spurts out or decreases S-11
17 Engine oil amount increases. (Water or fuel gets in) S-13
18 Abnormal noises are heard S-15
19 Excessive vibrations are caused S-16
20 Engine does not stop E-4
21 Auto-decelerator does not work E-5 H-5
22 Engine auto warming-up device does not work E-6
23 Engine preheater does not work E-7
Failure related to work equipment, swing and travel
Speeds of all work equipment, travel and swing are slow, or they
24 H-1 S-6
lack power
25 Engine rotation drops sharply or stalls H-2 S-4
26 All work equipment, travel and swing do not move E-8 H-3
27 There are abnormal noises from around hydraulic pump H-4
28 Fine control mode function works poorly, or shows slow response H-6
20-214 PC200/220(LC)-7
(11)
BACK
Troubleshooting
No. Failure-looking phenomenon Code
E mode H mode S mode
display
Work equipment-related failure
29 Boom moves slowly or lacks power E-21, 22 H-7
30 Arm moves slowly or lacks power E-23, 24 H-8
31 Bucket moves slowly or lacks power E-25, 26 H-9
32 Work equipment does not move when individual operation H-10
33 Natural drift of work equipment is too fast H-11
34 Work equipment time lag is too big H-12
Other work equipment moves, when specific work equipment is
35 H-13
relieved
36 One-touch power max. switch does not work E-9, 21–26 H-14
Compound operation-related failure
In compound operation, work equipment receiving larger load
37 H-15
moves slowly.
38 In swing + boom RAISE operation, boom moves slowly H-16
39 In swing + travel operation, travel speed drops sharply H-17
Travel-related failure
40 Machine tends to swerve while in travel H-18
41 Travel speed is slow E-28 H-19
42 Machine is difficult to steer, or lacks power E-28, 29 H-20
43 Travel speed cannot be shifted or is slow or fast E-28 H-21
44 Track shoe does not move (only on one side) H-22
Swing-related failure
45 Machine does not swing E-27 H-23
46 Swing acceleration is poor, or swing speed is slow H-24
47 Upper structure overruns excessively, when stopping swing H-25
48 There is a big shock caused when stopping swing H-26
49 There is abnormal noise generated when stopping swing H-27
50 Hydraulic drift of swing is large. H-28
Monitor panel-related failure (Operator's Menu: ordinary display)
51 No display appears in monitor panel at all E-10
52 Part of display is missing in monitor panel E-11
53 Descriptions on monitor panel do not apply to the machine model E-12
In startup inspection, radiator coolant level monitor lamp lights up
54 B@BCZK
red ( )
55 In startup inspection, engine oil level monitor lamp lights up red B@BAZK
: The multi-monitor specification machine only.
PC200/220(LC)-7 20-215
(11)
BACK
Troubleshooting
No. Failure-looking phenomenon Code
E mode H mode S mode
display
Refer to Operation and Maintenance
56 In startup inspection, maintenance hour monitor lamp lights up red
Manual
While engine is running, battery charging level monitor lamp lights
57 AB00KE
up red
58 While engine is running, fuel level monitor lamp lights up red E-13
While engine is running, air cleaner clogging monitor lamp lights up
59 AA10NX
red
While engine is running, engine coolant temperature monitor lamp
60 B@BCNS
lights up red
While engine is running, hydraulic oil temperature monitor lamp
61 B@HANS
lights up red ( )
62 Engine coolant temperature gauge does not display correctly E-14
63 Hydraulic oil temperature gauge does not display correctly ( ) E-15
64 Fuel gauge does not display correctly E-16
65 Swing lock monitor does not display correctly E-17
66 When operating monitor switch, no display appears E-18
67 Windshield wiper does not work E-19
68 Warning buzzer cannot be stopped E-20
Monitor panel-related failure (Service Menu: Special Function Display)
In monitoring function, "Boom RAISE" cannot be displayed cor-
69 E-21
rectly
In monitoring function, "Boom LOWER" cannot be displayed cor-
70 E-22
rectly
In monitoring function, "Arm DIGGING" cannot be displayed cor-
71 E-23
rectly
In monitoring function, "Arm DUMPING" cannot be displayed cor-
72 E-24
rectly
In monitoring function, "Bucket DIGGING" cannot be displayed
73 E-25
correctly
In monitoring function, "Bucket DUMPING" cannot be displayed
74 E-26
correctly
75 In monitoring function, "Swing" cannot be displayed correctly E-27
76 In monitoring function, "Travel" cannot be displayed correctly E-28
In monitoring function, "Travel Differential Pressure" cannot be dis-
77 E-29
played correctly
78 In monitoring function, "Service" cannot be displayed correctly E-30
Other failure
79 Air conditioner does not work E-31
80 Travel alarm does not sound E-32
: The multi-monitor specification machine only.
20-216 PC200/220(LC)-7
(11)
BACK
CONNECTOR LOCATION CHART AND ELECTRICAL
TROUBLESHOOTING CIRCUIT DIAGRAM BY SYSTEM
Address
Connector No. of
Type Name of device Stereo M G P
No. pin
-gram circuit circuit circuit
A01 X 4 Intermediate connector T-1 H-6 I-5 I-8
A02 X 4 Intermediate connector T-1 H-6 I-4
A03 D 12 Intermediate connector N-1 H-6 I-2 I-8
A04 SWP 12 Intermediate connector O-1 I-7
A05 SWP 14 Intermediate connector T-1 H-5 I-6
A06 SWP 14 Intermediate connector N-1 H-5 I-5
A07 SWP 16 Intermediate connector S-1 H-3 I-1 I-4
A08 SWP 12 Intermediate connector N-2
A09 SWP 8 Intermediate connector N-2 I-3
A10 Terminal 1 Revolving frame grounding H-1 H-1 J-5 J-4
A11 Terminal 1 Revolving frame grounding H-1 I-1
A12 Terminal 1 Revolving frame grounding H-2 I-1
A13 Terminal 1 Revolving frame grounding I-2 I-1 J-4 J-8
A14 Terminal 1 Revolving frame grounding K-2 I-1
A15 Terminal 1 Revolving frame grounding I-2 I-1 J-4
A16 Terminal 1 Revolving frame grounding I-2 I-1 J-1
A20 Terminal 1 Battery relay (E terminal) J-1 I-2 J-4
A21 Terminal 1 Battery relay (BR terminal) J-1 I-1 J-4
A22 Terminal 1 Battery relay (M terminal) J-1 J-2 K-4
A23 Terminal 1 Battery relay (B terminal) J-2 J-1 K-4
A25 Terminal 1 Heater relay (coil) L-3 K-6
A26 Terminal 1 Heater relay (contact) L-3 K-2
A27 X 2 Starter safety relay (S and R terminals) K-2 J-2
A29 Terminal 1 Starter safety relay (C terminal) L-3
A30 YAZAKI 2 Air conditioner outside air temperature sensor L-4
A31 D 2 Air cleaner clogging sensor L-4 K-4
A33 X 2 Radiator coolant level sensor L-4 K-5
A34 L 2 Fusible link (65A) A-4 K-6 K-5
A35 M 2 Fusible link (30A) A-5 K-6 K-4
A40 AMP 1 Alarm horn (low tone) H-1
A41 AMP 1 Alarm horn (high tone) H-1
A42 X 1 Intermediate connector I-9 J-7
A43 X 2 Travel alarm I-2 K-4
A44 M 1 Front right lamp A-6 K-7
20-218 PC200/220(LC)-7
(11)
BACK
CONNECTOR LOCATION CHART AND ELECTRICAL
TROUBLESHOOTING CIRCUIT DIAGRAM BY SYSTEM
Address
Connector No. of
Type Name of device Stereo M G P
No. pin
-gram circuit circuit circuit
A50 KES0 2 Window washer monitor (tank) K-3 K-5
A51 D 3 F pump hydraulic oil pressure sensor K-3 K-5
A52 D 3 R pump hydraulic oil pressure sensor J-9 K-5
A60 X 1 Fuel level sensor D-9 K-4
A61 D 2 Hydraulic oil temperature sensor H-9 K-5
C01 DRC 24 Governor pump controller V-9 A-3 A-8 A-8
C02 DRC 40 Governor pump controller W-9 A-3 A-7 A-7
C03 DRC 40 Governor pump controller W-9 A-2 A-4 A-4
C09 S 8 Model selection connector W-6 C-9
D01 SWP 8 Assembled type diode W-7 A-9 D-1 G-1
D02 SWP 8 Assembled type diode W-7 A-8 D-1
D03 SWP 8 Assembled type diode P-1 H-1
D04 SWP 8 Assembled type diode Q-1 A-8 F-1 I-1
Suction type air heater
E01 Terminal 1 J-9 L-2 L-6
(electrical intake air heater)
E02 Terminal 1 Engine hydraulic switch L-8 K-6
E03 D 2 Engine oil level switch L-6 K-5
E04 D 2 Engine rotation sensor K-9 K-8
E05 D 2 Engine coolant temperature sensor J-9 K-4
E06 M 3 Fuel dial K-8
Air conditioner compressor electromagnetic
E06 X 1 O-8
switch
E08 X 1 Intermediate connector L-7 J-3 J-5
E10 D 3 Governor potentiometer J-9 K-3
E11 D 4 Governor motor K-9 K-2
E12 X 2 Alternator L-7 K-3 K-5
F02 YAZAKI 2 Revolving warning lamp AA-9
FB1 – – Fuse box W-5 I-9 C-4 F-9
G01 – – – V-2
G02 – – – V-3
G03 – – – V-3
G04 – – – V-2
G05 – – – V-3
H08 M 8 Intermediate connector W-4 K-8
H09 S 8 Intermediate connector W-4 J-8
H10 S 16 Intermediate connector T-9 D-6 I-8
H11 S 16 Intermediate connector S-9 D-5 I-8 B-9
H12 S 12 Intermediate connector S-9 D-5 I-7
H15 S090 20 Intermediate connector N-7 C-2 E-2 C-2
PC200/220(LC)-7 20-219
(11)
BACK
CONNECTOR LOCATION CHART AND ELECTRICAL
TROUBLESHOOTING CIRCUIT DIAGRAM BY SYSTEM
Address
Connector No. of
Type Name of device Stereo M G P
No. pin
-gram circuit circuit circuit
J01 J 20 Junction connector (black) W-8 C-9 D-9 C-9
J02 J 20 Junction connector (black) W-8 D-9 D-9 D-9
J03 J 20 Junction connector (green) W-8 D-9 D-9
J04 J 20 Junction connector (green) W-7 E-9 E-9 E-9
J05 J 20 Junction connector (pink) W-6 E-9 E-9 E-9
J06 J 20 Junction connector (orange) W-6 F-9 H-9
J07 J 20 Junction connector (orange) U-9 F-9 F-9 H-9
J08 J 20 Junction connector (pink) U-9 I-9
K19 M 2 Pump resistor (for driving emergency pump) U-2 E-3
K30 D 3 CAN terminating resistor T-9 A-2 C-1
K31 D 3 CAN terminating resistor N-4 A-4 K-7
M07 M 3 Lamp switch P-8 C-2
M09 M 1 Working lamp (front right) E-9 K-7
M13 KES0 2 Speaker (right) AC-8
M19 YAZAKI 2 Cigarette lighter N-3
M21 PA 9 Radio U-2
M22 Y090 2 Horn switch N-7
M23 Y090 2 Knob switch T-1
M26 S 12 Air conditioner unit W-5
M27 SWP 16 Air conditioner unit W-5
M28 SWP 12 Air conditioner unit W-4
M29 040 20 Air control panel W-3
M30 040 16 Air control panel W-3
M31 M 2 Option power source (2) U-2
M32 M 2 Option power source (1) S-9
M33 M 2 Option power source (3) –
M33 SWP 8 Air conditioner unit S-9
M34 YAZAKI 2 Air conditioner inside air sensor W-8
M40 YAZAKI 2 Working lamp Z-8 K-8
M41 YAZAKI 2 Working lamp (additional) Y-7 K-8
M42 M 1 Intermediate connector K-3 J-7
M43 M 1 Working lamp (rear) – K-7
M45 D 12 Intermediate connector U-2
M46 S090 4 RS232C relaying connector U-9 B-9
M71 M 2 Room lamp Z-8
M72 M 4 DC/AC converter U-2
M73 KES0 2 Speaker (left) AD-8
M79 YAZAKI 2 12V electrical equipment socket V-9
20-220 PC200/220(LC)-7
(11)
BACK
CONNECTOR LOCATION CHART AND ELECTRICAL
TROUBLESHOOTING CIRCUIT DIAGRAM BY SYSTEM
Address
Connector No. of
Type Name of device Stereo M G P
No. pin
-gram circuit circuit circuit
P01 070 12 Monitor panel N-6 A-7 K-8
P02 040 20 Monitor panel N-5 A-6 K-8 A-9
P03 M 2 Buzzer canceling switch P-9 D-1
P05 M 2 Revolving warning lamp switch W-3
P15 Y050 2 Air conditioner sun light sensor N-6
P70 040 16 Monitor panel N-4 A-5 K-7
R10 R 5 Lamp relay O-8 E-1
R11 R 5 Engine starting motor cutting relay (PPC lock) P-8 E-1
Engine starting motor cutting relay (personal
R13 R 5 Q-9 F-1
code)
R20 R 5 Attachment circuit switching relay W-6 C-9
R21 – – – W-7
S01 X 2 Bucket digging oil pressure switch S-8 K-2
S02 X 2 Boom lowering oil pressure switch L-7 K-3
S03 X 2 Swing oil pressure switch, left L-7 K-2
S04 X 2 Arm digging oil pressure switch L-6 K-3
S05 X 2 Bucket dumping oil pressure switch L-5 K-2
S06 X 2 Boom raise oil pressure switch L-5 K-3
S07 X 2 Swing oil pressure switch, right L-5 K-2
S08 X 2 Arm dumping oil pressure switch L-4 K-3
Service oil pressure switch (intermediate con-
S09 X 2 K-3 K-1
nector)
S10 X 2 Service oil pressure switch, front – K-1
S11 X 2 Service oil pressure switch, rear – K-1
S14 M 3 Lever lock switch S-1 K-9 F-8
S21 Terminal 6 Pump emergency driving switch R-9 E-2
Swing and parking brake emergency releasing
S22 Terminal 6 R-9 F-2
switch
S25 S090 16 Intermediate connector Q-9 E-3
S30 X 2 Travel hydraulic switch O-1 A-1
S31 X 2 Travel steering hydraulic switch P-1 A-1
SC Terminal 1 Engine starting motor (C terminal) K-8
SSW Terminal 5 Engine starting switch N-7
T05 Terminal 1 Floor frame grounding W-3 J-8
T06 Terminal 1 Radio body grounding –
T06A M 1 Intermediate connector T-2
T11 Terminal 1 Operator's cab grounding AD-3
T13 D 1 Engine starting motor (C terminal) L-6 J-3
PC200/220(LC)-7 20-221
(11)
BACK
CONNECTOR LOCATION CHART AND ELECTRICAL
TROUBLESHOOTING CIRCUIT DIAGRAM BY SYSTEM
Address
Connector No. of
Type Name of device Stereo M G P
No. pin
-gram circuit circuit circuit
V01 D 2 PPC hydraulic lock solenoid valve J-2 K-6
V02 D 2 Travel interlocking solenoid valve J-2 K-6
V03 D 2 Merge/divide valve solenoid valve J-2 K-6
V04 D 2 Travel speed solenoid valve J-3 K-5
V05 D 2 Swing and parking brake solenoid valve J-3 K-5
V06 D 2 2-stage relief solenoid valve K-3 K-6
V12 D 2 Attachment return switching solenoid valve I-9 K-4
V21 D 2 PC-EPC solenoid valve I-9 K-7
V22 D 2 LS-EPC solenoid valve I-9 K-7
Attachment oil flow rate adjusting EPC solenoid
V30 X 2 P-1 A-1
valve
W03 X 2 Rear limit switch (window) AB-9 L-8
W04 M 6 Windshield wiper motor Y-4 B-9
X05 M 4 Swing lock switch Q-9 D-2 C-2
Y08 – – – G-9
Y09 – – – G-1
Y10 – – – G-9
Y11 – – – A-6
Y12 – – – G-9
Y13 – – – G-1
Y16 – – – G-9
20-222 PC200/220(LC)-7
(1)
BACK
CONNECTOR LOCATION CHART AND ELECTRICAL
TROUBLESHOOTING CIRCUIT DIAGRAM BY SYSTEM
PC200/220(LC)-7 20-223
(5)
BACK
CONNECTOR LOCATION CHART AND ELECTRICAL
TROUBLESHOOTING CIRCUIT DIAGRAM BY SYSTEM
Connector table
PC200, 200LC-7 Serial No. 250001 and up
PC220, 220LC-7 Serial No. 65001 and up
Address
Connector No. of
Type Name of device Stereo M G P
No. pin
-gram circuit circuit circuit
A01 X 4 Intermediate connector M-8 H-6 I-5 I-8
A02 X 4 Intermediate connector M-9 H-6 I-4
A03 D 12 Intermediate connector M-9 H-6 I-2 I-8
A04 SWP 6 Intermediate connector O-8 I-7
A05 SWP 14 Intermediate connector M-8 H-5 I-7
A06 SWP 14 Intermediate connector O-9 H-5 I-5
A07 SWP 16 Intermediate connector M-8 H-4 I-5 I-4
A08 SWP 12 Intermediate connector O-9
A09 SWP 8 Intermediate connector O-9 I-4
A10 Terminal 1 Revolving frame grounding H-1 H-1 J-5 J-4
A11 Terminal 1 Revolving frame grounding H-1 I-1
A12 Terminal 1 Revolving frame grounding H-2 I-1
A13 Terminal 1 Revolving frame grounding I-2 I-1 J-4 J-8
A14 Terminal 1 Revolving frame grounding K-2 I-1 J-4
A15 Terminal 1 Revolving frame grounding I-2 I-1 J-4
A16 Terminal 1 Revolving frame grounding I-2 I-1 J-1
A20 Terminal 1 Battery relay (E terminal) J-1 I-2 J-4
A21 Terminal 1 Battery relay (BR terminal) J-2 I-1 J-4
A22 Terminal 1 Battery relay (M terminal) J-1 J-2 K-4
A23 Terminal 1 Battery relay (B terminal) J-2 J-2 K-4
A25 Terminal 1 Heater relay (coil) L-3 K-6
A26 Terminal 1 Heater relay (contact) L-3 K-2
A27 X 2 Starter safety relay (S and R terminals) K-2 J-2
A29 Terminal 1 Starter safety relay (C terminal) L-3 K-2
A31 D 2 Air cleaner clogging sensor L-4 K-4
A33 X 2 Radiator coolant level sensor L-4 K-5
A34 L 2 Fusible link (65A) A-4 K-6 K-5
A35 M 2 Fusible link (30A) A-5 K-6 K-4
A40 AMP 1 Alarm horn (low tone) H-1
A41 AMP 1 Alarm horn (high tone) H-1
A42 X 1 Intermediate connector I-9
A43 X 2 Travel alarm I-2 K-4
A44 M 1 Front right lamp A-6 K-7
A50 KES0 2 Window washer monitor (tank) K-3 K-5
A51 D 3 F pump hydraulic oil pressure sensor K-3 K-5
A52 D 3 R pump hydraulic oil pressure sensor J-9 K-5
A60 X 1 Fuel level sensor D-9 K-4
A61 D 2 Hydraulic oil temperature sensor H-9 K-5
20-223-1 PC200/220(LC)-7
(11)
BACK
CONNECTOR LOCATION CHART AND ELECTRICAL
TESTING AND ADJUSTING CIRCUIT DIAGRAM BY SYSTEM
Address
Connector No. of
Type Name of device Stereo M G P
No. pin
-gram circuit circuit circuit
P01 070 12 Monitor panel N-6 A-7 K-8
P02 040 20 Monitor panel N-5 A-6 K-8 A-9
P03 M 2 Buzzer canceling switch P-9 D-1
P05 M 2 Revolving warning lamp switch W-3
P15 Y050 2 Air conditioner sun light sensor N-6
P70 040 16 Monitor panel N-4 A-5 K-7
R10 R 5 Lamp relay O-8 E-1
R11 R 5 Engine starting motor cutting relay (PPC lock) P-8 E-1
Engine starting motor cutting relay (personal
R13 R 5 Q-9 F-1
code)
R20 R 5 Attachment circuit switching relay W-6 C-9
R21 – – – W-7
S01 X 2 Bucket digging oil pressure switch S-8 K-2
S02 X 2 Boom lowering oil pressure switch L-7 K-3
S03 X 2 Swing oil pressure switch, left L-7 K-2
S04 X 2 Arm digging oil pressure switch L-6 K-3
S05 X 2 Bucket dumping oil pressure switch L-5 K-2
S06 X 2 Boom raise oil pressure switch L-5 K-3
S07 X 2 Swing oil pressure switch, right L-5 K-2
S08 X 2 Arm dumping oil pressure switch L-4 K-3
Service oil pressure switch (intermediate con-
S09 X 2 K-3 K-1
nector)
S10 X 2 Service oil pressure switch, front – K-1
S11 X 2 Service oil pressure switch, rear – K-1
S14 M 3 Safety lever lock switch S-1 K-9 F-8
S21 Terminal 6 Pump emergency driving switch R-9 E-2
Swing and parking brake emergency releasing
S22 Terminal 6 R-9 F-2
switch
S25 S090 16 Intermediate connector Q-9 E-3
S30 X 2 Travel hydraulic switch O-1 A-1
S31 X 2 Travel steering hydraulic switch P-1 A-1
SC Terminal 1 Engine starting motor (C terminal) K-8
SSW Terminal 5 Engine starting switch N-7
T05 Terminal 1 Floor frame grounding W-3 J-8
T06 Terminal 1 Radio body grounding –
T06A M 1 Intermediate connector T-2
T11 Terminal 1 Operator's cab grounding AD-3
T13 D 1 Engine starting motor (C terminal) L-6 J-3
PC200/220(LC)-7 20-221
BACK
CONNECTOR LOCATION CHART AND ELECTRICAL
TESTING AND ADJUSTING CIRCUIT DIAGRAM BY SYSTEM
Address
Connector No. of
Type Name of device Stereo M G P
No. pin
-gram circuit circuit circuit
V01 D 2 PPC hydraulic lock solenoid valve J-2 K-6
V02 D 2 Travel interlocking solenoid valve J-2 K-6
V03 D 2 Merge/divide valve solenoid valve J-2 K-6
V04 D 2 Travel speed solenoid valve J-3 K-5
V05 D 2 Swing and parking brake solenoid valve J-3 K-5
V06 D 2 2-stage relief solenoid valve K-3 K-6
V12 D 2 Attachment return switching solenoid valve I-9 K-4
V21 D 2 PC-EPC solenoid valve I-9 K-7
V22 D 2 LS-EPC solenoid valve I-9 K-7
Attachment oil flow rate adjusting EPC solenoid
V30 X 2 P-1 A-1
valve
W03 X 2 Rear limit switch (window) AB-9 L-8
W04 M 6 Windshield wiper motor Y-4 B-9
X05 M 4 Swing lock switch Q-9 D-2 C-2
Y08 – – – G-9
Y09 – – – G-1
Y10 – – – G-9
Y11 – – – A-6
Y12 – – – G-9
Y13 – – – G-1
Y16 – – – G-9
20-222 PC200/220(LC)-7
BACK
CONNECTOR LOCATION CHART AND ELECTRICAL
TROUBLESHOOTING CIRCUIT DIAGRAM BY SYSTEM
PC200/220(LC)-7 20-223
(5)
BACK
CONNECTOR LOCATION CHART AND ELECTRICAL
TROUBLESHOOTING CIRCUIT DIAGRAM BY SYSTEM
Connector table
PC200, 200LC-7 Serial No. 250001 and up
PC220, 220LC-7 Serial No. 65001 and up
Address
Connector No. of
Type Name of device Stereo M G P
No. pin
-gram circuit circuit circuit
A01 X 4 Intermediate connector M-8 H-6 I-5 I-8
A02 X 4 Intermediate connector M-9 H-6 I-4
A03 D 12 Intermediate connector M-9 H-6 I-2 I-8
A04 SWP 6 Intermediate connector O-8 I-7
A05 SWP 14 Intermediate connector M-8 H-5 I-7
A06 SWP 14 Intermediate connector O-9 H-5 I-5
A07 SWP 16 Intermediate connector M-8 H-4 I-5 I-4
A08 SWP 12 Intermediate connector O-9
A09 SWP 8 Intermediate connector O-9 I-4
A10 Terminal 1 Revolving frame grounding H-1 H-1 J-5 J-4
A11 Terminal 1 Revolving frame grounding H-1 I-1
A12 Terminal 1 Revolving frame grounding H-2 I-1
A13 Terminal 1 Revolving frame grounding I-2 I-1 J-4 J-8
A14 Terminal 1 Revolving frame grounding K-2 I-1 J-4
A15 Terminal 1 Revolving frame grounding I-2 I-1 J-4
A16 Terminal 1 Revolving frame grounding I-2 I-1 J-1
A20 Terminal 1 Battery relay (E terminal) J-1 I-2 J-4
A21 Terminal 1 Battery relay (BR terminal) J-2 I-1 J-4
A22 Terminal 1 Battery relay (M terminal) J-1 J-2 K-4
A23 Terminal 1 Battery relay (B terminal) J-2 J-2 K-4
A25 Terminal 1 Heater relay (coil) L-3 K-6
A26 Terminal 1 Heater relay (contact) L-3 K-2
A27 X 2 Starter safety relay (S and R terminals) K-2 J-2
A29 Terminal 1 Starter safety relay (C terminal) L-3 K-2
A31 D 2 Air cleaner clogging sensor L-4 K-4
A33 X 2 Radiator coolant level sensor L-4 K-5
A34 L 2 Fusible link (65A) A-4 K-6 K-5
A35 M 2 Fusible link (30A) A-5 K-6 K-4
A40 AMP 1 Alarm horn (low tone) H-1
A41 AMP 1 Alarm horn (high tone) H-1
A42 X 1 Intermediate connector I-9
A43 X 2 Travel alarm I-2 K-4
A44 M 1 Front right lamp A-6 K-7
A50 KES0 2 Window washer monitor (tank) K-3 K-5
A51 D 3 F pump hydraulic oil pressure sensor K-3 K-5
A52 D 3 R pump hydraulic oil pressure sensor J-9 K-5
A60 X 1 Fuel level sensor D-9 K-4
A61 D 2 Hydraulic oil temperature sensor H-9 K-5
20-223-1 PC200/220(LC)-7
(11)
BACK
CONNECTOR LOCATION CHART AND ELECTRICAL
TROUBLESHOOTING CIRCUIT DIAGRAM BY SYSTEM
Address
Connector No. of
Type Name of device Stereo M G P
No. pin
-gram circuit circuit circuit
Boom cylinder bottom pressure sensor for over-
A70 D 3 G-1 K-4
load alarm
C01 DRC 24 Governor pump controller U-9 A-3 A-8 A-8
C02 DRC 40 Governor pump controller V-9 A-3 A-7 A-7
C03 DRC 40 Governor pump controller W-9 A-2 A-4 A-4
C09 S 8 Model selection connector U-9 C-9
D01 SWP 8 Assembled type diode W-9 A-9 D-1 G-1
D02 SWP 8 Assembled type diode W-7 A-8 D-1
Suction type air heater
E01 Terminal 1 J-9 L-2 L-6
(electrical intake air heater)
E02 Terminal 1 Engine hydraulic switch L-8 K-6
E03 D 2 Engine oil level switch L-6 K-6
E04 D 2 Engine rotation sensor K-9 K-8
E05 D 2 Engine coolant temperature sensor J-9 K-4
E06 M 3 Fuel dial O-8 F-1
Air conditioner compressor electromagnetic
E06 X 1 K-8
switch
E08 X 1 Intermediate connector L-8 J-3 J-5
E10 D 3 Governor potentiometer J-9 K-3
E11 D 4 Governor motor K-9 K-2
E12 X 2 Alternator L-7 K-3 K-5
F02 YAZAKI 2 Revolving warning lamp AA-9
FB1 – – Fuse box U-2 I-9 C-4 F-9
G01 – – –
G02 – – –
G03 – – –
G04 – – –
G05 – – –
H08 M 8 Intermediate connector W-6 K-8
H09 S 8 Intermediate connector W-6 J-8
H10 S 16 Intermediate connector S-9 D-6 I-8
H11 S 16 Intermediate connector S-9 D-5 I-8 B-9
H12 S 12 Intermediate connector S-9 D-5 I-7
H15 S090 20 Intermediate connector N-7 C-2 E-2 C-2
J01 J 20 Junction connector (black) T-9 C-9 D-9 C-9
J02 J 20 Junction connector (black) V-2 D-9 D-9 D-9
J03 J 20 Junction connector (green) V-2 D-9 D-9
J04 J 20 Junction connector (green) V-3 E-9 E-9 E-9
J05 J 20 Junction connector (pink) V-3 E-9 E-9 E-9
J06 J 20 Junction connector (orange) V-3 F-9
J07 J 20 Junction connector (orange) W-3 F-9 F-9 H-9
K19 M 2 Pump resistor (for driving emergency pump) W-3 E-3
PC200/220(LC)-7 20-223-2
(11)
BACK
CONNECTOR LOCATION CHART AND ELECTRICAL
TROUBLESHOOTING CIRCUIT DIAGRAM BY SYSTEM
Address
Connector No. of
Type Name of device Stereo M G P
No. pin
-gram circuit circuit circuit
K30 D 3 CAN terminating resistor T-9 A-2 C-1
K31 D 3 CAN terminating resistor N-4 A-4 K-7
M07 M 3 Lamp switch P-8 C-1
M09 M 1 Working lamp (front right) E-9 K-7
M13 KES0 2 Speaker (right) AC-8
M19 YAZAKI 2 Cigarette lighter N-3
M21 PA 9 Radio T-1
M22 Y090 2 Horn switch N-7
M23 Y090 2 One-touch power max. switch S-1
M26 S 12 Intermediate connector W-3
M27 SWP 18 Air conditioner unit W-5
M29 040 20 Air control panel T-2
M30 040 16 Air control panel U-2
M31 M 2 Option power source (2) W-6
M32 M 2 Option power source (1) W-5
M33 M 2 Option power source (3) W-7
SUMIT-
M33 4 Air conditioner unit W-5
OMO
M40 YAZAKI 2 Working lamp Z-8 K-8
M41 YAZAKI 2 Working lamp (additional) Y-7 K-8
M42 M 1 Intermediate connector K-3 K-7
M43 M 1 Working lamp (rear) – K-7
M45 D 12 Intermediate connector W-7
M46 S090 4 RS232C relaying connector V-9 B-9
M71 M 2 Room lamp Z-8
M72 M 4 DC/AC converter W-7
M73 KES0 2 Speaker (left) AD-8
M79 YAZAKI 2 12V electrical equipment socket W-8
P01 070 12 Monitor panel N-6 A-7 K-8
P02 040 20 Monitor panel N-5 A-6 K-8 A-9
P03 M 2 Buzzer canceling switch P-9 D-1
P05 M 2 Revolving warning lamp switch U-2
P15 Y050 2 Air conditioner sun light sensor N-6
P17 S09 2 Air conditioner high/low pressure switch –
P70 040 16 Monitor panel N-4 A-5 K-8
R10 R 5 Lamp relay O-8 E-1
R11 R 5 Engine starting motor cutting relay (PPC lock) P-8 E-1
Engine starting motor cutting relay
R13 R 5 Q-9 F-1
(personal code)
R20 R 5 Attachment circuit switching relay U-9 C-9
R21 – – –
20-223-3 PC200/220(LC)-7
(5)
BACK
CONNECTOR LOCATION CHART AND ELECTRICAL
TROUBLESHOOTING CIRCUIT DIAGRAM BY SYSTEM
Address
Connector No. of
Type Name of device Stereo M G P
No. pin
-gram circuit circuit circuit
R30 R 5 Air conditioner blower relay W-4
R31 R 4 Air conditioner compressor relay W-4
S01 X 2 Bucket digging oil pressure switch L-8 K-3
S02 X 2 Boom lowering oil pressure switch L-7 K-3
S03 X 2 Swing oil pressure switch, left L-7 K-2
S04 X 2 Arm digging oil pressure switch L-6 K-3
S05 X 2 Bucket dumping oil pressure switch L-5 K-2
S06 X 2 Boom raise oil pressure switch L-5 K-3
S07 X 2 Swing oil pressure switch, right L-5 K-2
S08 X 2 Arm dumping oil pressure switch L-5 K-3
Service oil pressure switch
S09 X 2 K-3 K-2
(intermediate connector)
S10 X 2 Service oil pressure switch, front – K-2
S11 X 2 Service oil pressure switch, rear – K-1
S14 M 3 Lever lock switch S-1 K-9 F-8
S21 Terminal 6 Pump emergency driving switch R-9 E-1
Swing and parking brake emergency releasing
S22 Terminal 6 R-9 F-1
switch
S25 S090 16 Intermediate connector Q-9 E-3
S30 X 2 Travel hydraulic switch O-1 A-1
S31 X 2 Travel steering hydraulic switch P-1 A-1
SC Terminal 1 Engine starting motor (C terminal) K-8 K-3
SSW Terminal 5 Engine starting switch N-7
T05 Terminal 1 Floor frame grounding U-2
T06 Terminal 1 Radio body grounding T-1
T06A M 1 Intermediate connector T-1
T11 Terminal 1 Operator's cab grounding AD-3
T13 D 1 Engine starting motor (C terminal) L-6 J-3
V01 D 2 PPC hydraulic lock solenoid valve I-2 K-6
V02 D 2 Travel interlocking solenoid valve J-2 K-6
V03 D 2 Merge/divide valve solenoid valve J-3 K-7
V04 D 2 Travel speed solenoid valve J-3 K-5
V05 D 2 Swing and parking brake solenoid valve J-3 K-6
V06 D 2 2-stage relief solenoid valve K-3 K-6
V12 D 2 Attachment return switching solenoid valve I-9 K-4
V21 D 2 PC-EPC solenoid valve I-9 K-7
V22 D 2 LS-EPC solenoid valve I-9 K-7
Attachment oil flow rate adjusting EPC solenoid
V30 X 2 P-1 A-1
valve
W03 X 2 Rear limit switch (window) AB-9 L-8
W04 M 6 Windshield wiper motor Y-3 B-9
PC200/220(LC)-7 20-223-4
(11)
BACK
CONNECTOR LOCATION CHART AND ELECTRICAL
TROUBLESHOOTING CIRCUIT DIAGRAM BY SYSTEM
Address
Connector No. of
Type Name of device Stereo M G P
No. pin
-gram circuit circuit circuit
X05 M 4 Swing lock switch Q-9 D-1 C-2
Y08 – – –
Y09 – – –
Y10 – – –
Y11 – – –
Y12 – – –
Y13 – – –
Y16 – – –
Y27 – – –
20-223-5 PC200/220(LC)-7
(5)
BACK
CONNECTOR LOCATION CHART AND ELECTRICAL
TROUBLESHOOTING CIRCUIT DIAGRAM BY SYSTEM
PC200/220(LC)-7 20-223-6
(5)
BACK
CONNECTOR LOCATION CHART AND ELECTRICAL
TROUBLESHOOTING CIRCUIT DIAGRAM BY SYSTEM
20-224 PC200/220(LC)-7
(7)
BACK
CONNECTOR LOCATION CHART AND ELECTRICAL
TROUBLESHOOTING CIRCUIT DIAGRAM BY SYSTEM
PC200/220(LC)-7 20-225
(9)
BACK
CONNECTOR LOCATION CHART AND ELECTRICAL
TROUBLESHOOTING CIRCUIT DIAGRAM BY SYSTEM
20-226 PC200/220(LC)-7
(1)
BACK
CONNECTOR LOCATION CHART AND ELECTRICAL
TESTING AND ADJUSTING CIRCUIT DIAGRAM BY SYSTEM
PC200/220(LC)-7 20-227
BACK
CONNECTOR LOCATION CHART AND ELECTRICAL
TESTING AND ADJUSTING CIRCUIT DIAGRAM BY SYSTEM
20-228 PC200/220(LC)-7
BACK
CONNECTOR LOCATION CHART AND ELECTRICAL
TROUBLESHOOTING CIRCUIT DIAGRAM BY SYSTEM
20-229-1 PC200/220(LC)-7
(7)
BACK
CONNECTOR LOCATION CHART AND ELECTRICAL
TROUBLESHOOTING CIRCUIT DIAGRAM BY SYSTEM
PC200/220(LC)-7 20-229-2
(9)
BACK
CONNECTOR LOCATION CHART AND ELECTRICAL
TROUBLESHOOTING CIRCUIT DIAGRAM BY SYSTEM
20-229-3 PC200/220(LC)-7
(5)
BACK
CONNECTOR LOCATION CHART AND ELECTRICAL
TROUBLESHOOTING CIRCUIT DIAGRAM BY SYSTEM
PC200/220(LC)-7 20-229-4
(5)
BACK
CONNECTOR LOCATION CHART AND ELECTRICAL
TROUBLESHOOTING CIRCUIT DIAGRAM BY SYSTEM
20-229-5 PC200/220(LC)-7
(5)
BACK
CONNECTOR LOCATION CHART AND ELECTRICAL
TROUBLESHOOTING CIRCUIT DIAGRAM BY SYSTEM
20-230 PC200/220(LC)-7
(7)
BACK
CONNECTOR LOCATION CHART AND ELECTRICAL
TROUBLESHOOTING CIRCUIT DIAGRAM BY SYSTEM
a This circuit diagram has been compiled by extracting the monitor panel system and engine starting system
from the overall electrical circuit diagram.
PC200/220(LC)-7 20-231
(5)
BACK
CONNECTOR LOCATION CHART AND ELECTRICAL
TROUBLESHOOTING CIRCUIT DIAGRAM BY SYSTEM
20-231-1 PC200/220(LC)-7
(7)
BACK
CONNECTOR LOCATION CHART AND ELECTRICAL
TROUBLESHOOTING CIRCUIT DIAGRAM BY SYSTEM
a This circuit diagram has been compiled by extracting the monitor panel system and engine starting system
from the overall electrical circuit diagram.
PC200/220(LC)-7 20-231-2
(5)
BACK
CONNECTOR LOCATION CHART AND ELECTRICAL
TROUBLESHOOTING CIRCUIT DIAGRAM BY SYSTEM
20-232 PC200/220(LC)-7
(5)
BACK
CONNECTOR LOCATION CHART AND ELECTRICAL
TROUBLESHOOTING CIRCUIT DIAGRAM BY SYSTEM
a This circuit diagram has been compiled by extracting the governor•pump controller system (power source,
governor control, model selection and communication) from the overall electrical circuit diagram.
PC200/220(LC)-7 20-233
(5)
BACK
CONNECTOR LOCATION CHART AND ELECTRICAL
TROUBLESHOOTING CIRCUIT DIAGRAM BY SYSTEM
20-233-1 PC200/220(LC)-7
(7)
BACK
CONNECTOR LOCATION CHART AND ELECTRICAL
TROUBLESHOOTING CIRCUIT DIAGRAM BY SYSTEM
a This circuit diagram has been compiled by extracting the governor•pump controller system (power source,
governor control, model selection and communication) from the overall electrical circuit diagram.
PC200/220(LC)-7 20-233-2
(5)
BACK
CONNECTOR LOCATION CHART AND ELECTRICAL
TROUBLESHOOTING CIRCUIT DIAGRAM BY SYSTEM
20-234 PC200/220(LC)-7
(7)
BACK
CONNECTOR LOCATION CHART AND ELECTRICAL
TROUBLESHOOTING CIRCUIT DIAGRAM BY SYSTEM
a This circuit diagram has been compiled by extracting the governor•pump controller system (pump control),
PPC lock system and backup alarm system from the overall electrical circuit diagram.
PC200/220(LC)-7 20-235
(5)
BACK
CONNECTOR LOCATION CHART AND ELECTRICAL
TROUBLESHOOTING CIRCUIT DIAGRAM BY SYSTEM
20-235-1 PC200/220(LC)-7
(9)
BACK
CONNECTOR LOCATION CHART AND ELECTRICAL
TROUBLESHOOTING CIRCUIT DIAGRAM BY SYSTEM
a This circuit diagram has been compiled by extracting the governor•pump controller system (pump control),
PPC lock system and backup alarm system from the overall electrical circuit diagram.
PC200/220(LC)-7 20-235-2
(9)
BACK
X type connector
No.of
pins T-adapter
Male (female housing) Female (male housing)
Part No.
1 Part No.: 08055-00181 Part No.: 08055-00191 799-601-7010
2 799-601-7020
3 799-601-7030
4 799-601-7040
20-236 PC200/220(LC)-7
BACK
6 799-601-7050
8 799-601-7060
12 799-601-7310
14 799-601-7070
PC200/220(LC)-7 20-237
BACK
16 799-601-7320
20-238 PC200/220(LC)-7
BACK
M type connector
No.of
pins T-adapter Part
Male (female housing) Female (male housing)
No.
1 Part No.: 08056-00171 Part No.: 08056-00181 799-601-7080
2 799-601-7090
3 799-601-7110
4 799-601-7120
6 799-601-7130
8 799-601-7340
PC200/220(LC)-7 20-239
(5)
BACK
S type connector
No.of
pins T-adapter
Male (female housing) Female (male housing)
Part No.
8 799-601-7140
10
799-601-7150
(White)
12
799-601-7350
(White)
16
799-601-7330
(White)
20-240 PC200/220(LC)-7
(1)
BACK
S type connector
No.of
pins T-adapter
Male (female housing) Female (male housing)
Part No.
10
—
(Blue)
— —
12
799-601-7160
(Blue)
16
799-601-7170
(Blue)
PC200/220(LC)-7 20-241
BACK
5 799-601-2710
Body part No.: 79A-222-2620 (Q’ty: 5) Body part No.: 79A-222-2610 (Q’ty: 5)
9 799-601-2950
Body part No.: 79A-222-2660 (Q’ty: 5) Body part No.: 79A-222-2650 (Q’ty: 5)
13 799-601-2720
Body part No.: 79A-222-2710 (Q’ty: 2) Body part No.: 79A-222-2690 (Q’ty: 2)
20-242 PC200/220(LC)-7
BACK
17 799-601-2730
Body part No.: 79A-222-2730 (Q’ty: 2) Body part No.: 79A-222-2720 (Q’ty: 2)
21 799-601-2740
Body part No.: 79A-222-2750 (Q’ty: 2) Body part No.: 79A-222-2740 (Q’ty: 2)
Terminal part No.: 79A-222-2770 Terminal part No.: 79A-222-2760
—
(Q’ty: 50) (Q’ty: 50)
PC200/220(LC)-7 20-243
BACK
8 799-601-7180
12 799-601-7190
16 799-601-7210
20 799-601-7220
20-244 PC200/220(LC)-7
BACK
10 799-601-7510
12 799-601-7520
14 799-601-7530
18 799-601-7540
20 799-601-7550
PC200/220(LC)-7 20-245
(12)
BACK
L type connector
No.of
pins T-adapter Part
Male (female housing) Female (male housing)
No.
2 —
— —
Connector for PA
No.of
pins T-adapter Part
Male (female housing) Female (male housing)
No.
9 —
— —
Bendix MS connector
No.of
pins T-adapter Part
Male (female housing) Female (male housing)
No.
10 799-601-3460
— —
20-246 PC200/220(LC)-7
BACK
2 —
Part No.: 08027-10210 (Natural color) Part No.: 08027-10260 (Natural color)
08027-10220 (Black) 08027-10270 (Black)
3 —
4 —
Part No.: 08027-10410 (Natural color) Part No.: 08027-10460 (Natural color)
08027-10420 (Black) 08027-10470 (Black)
6 —
Part No.: 08027-10610 (Natural color) Part No.: 08027-10660 (Natural color)
08027-10620 (Black) 08027-10670 (Black)
PC200/220(LC)-7 20-247
BACK
8 —
Part No.: 08027-10810 (Natural color) Part No.: 08027-10860 (Natural color)
08027-10820 (Black) 08027-10870 (Black)
5 799-601-7360
— —
6 799-601-7370
— —
20-248 PC200/220(LC)-7
BACK
F type connector
No.of
pins T-adapter
Male (female housing) Female (male housing)
Part No.
4 —
— —
PC200/220(LC)-7 20-249
BACK
[The pin No. is also marked on the connector (electric wire insertion end)]
799-601-9210
799-601-9210
799-601-9220
799-601-9220
20-250 PC200/220(LC)-7
BACK
[The pin No. is also marked on the connector (electric wire insertion end)]
799-601-9230
799-601-9230
799-601-9240
799-601-9240
PC200/220(LC)-7 20-251
BACK
[The pin No. is also marked on the connector (electric wire insertion end)]
799-601-9250
799-601-9250
799-601-9260
799-601-9260
20-252 PC200/220(LC)-7
BACK
[The pin No. is also marked on the connector (electric wire insertion end)]
799-601-9270
799-601-9270
799-601-9280
799-601-9280
PC200/220(LC)-7 20-253
(5)
BACK
[The pin No. is also marked on the connector (electric wire insertion end)]
799-601-9290
799-601-9290
20-254 PC200/220(LC)-7
(1)
BACK
[The pin No. is also marked on the connector (electric wire insertion end)]
DT Series connector
No.of
pins Body (receptacle) T-adapter
Body (plug)
Part No.
2 799-601-9020
Part No.: 08192-12200 (normal type) Part No.: 08192-12100 (normal type)
08192-22200 (fine wire type) 08192-22100 (fine wire type)
3 799-601-9030
Part No.: 08192-13200 (normal type) Part No.: 08192-13100 (normal type)
08192-23200 (fine wire type) 08192-23100 (fine wire type)
4 799-601-9040
Part No.: 08192-14200 (normal type) Part No.: 08192-14100 (normal type)
08192-24200 (fine wire type) 08192-24100 (fine wire type)
6 799-601-9050
Part No.: 08192-16200 (normal type) Part No.: 08192-16100 (normal type)
08192-26200 (fine wire type) 08192-26100 (fine wire type)
PC200/220(LC)-7 20-255
(1)
BACK
[The pin No. is also marked on the connector (electric wire insertion end)]
8GR: 799-601-9060
8B: 799-601-9070
8
8G: 799-601-9080
8BR: 799-601-9090
Part No.: 08192-1820 (normal type) Part No.: 08192-1810 (normal type)
08192-2820 (fine wire type) 08192-2810 (fine wire type)
12GR: 799-601-9110
12B: 799-601-9120
12
12G: 799-601-9130
12BR: 799-601-9140
Part No.: 08192-1920 (normal type) Part No.: 08192-1910 (normal type)
08192-2920 (fine wire type) 08192-2910 (fine wire type)
20-256 PC200/220(LC)-7
(5)
BACK
[The pin No. is also marked on the connector (electric wire insertion end)]
799-601-9010
2
[The pin No. is also marked on the connector (electric wire insertion end)]
2 —
Part No.: 08192-31200 (Contact size#12) Part No.: 08192-31100 (Contact size#12)
08192-41200 (Contact size #8) 08192-41100 (Contact size #8)
08192-51200 (Contact size #4) 08192-51100 (Contact size #4)
PC200/220(LC)-7 20-257
BACK
[The pin No. is also marked on the connector (electric wire insertion end)]
DT Series connector
No.of
pins T-adapter
Body (plug) Body (receptacle)
Part No.
24 799-601-9360
— Part No.:7821-93-3110
40
799-601-9350
(A)
— Part No.:7821-93-3120
40
799-601-9350
(B)
— Part No.:7821-93-3130
20-258 PC200/220(LC)-7
(7)
BACK
a This connection table shows the devices to which each power supply of the fuse box supplies power directly
(A switch power supply is a device which supplies power while the starting switch is at the ON position and
a constant power supply is a device which supplies power while the starting switch is at the OFF position).
a When carrying out troubleshooting for an electric system, you should check its fuse box and fusible link to
see if the power is supplied normally.
Type of power
Fuse No. Fuse capacity Destination of power
supply
Engine throttle and pump controller (Controller power supply)
1 10A Emergency pump drive resistor
Swing holding brake release switch
Switch power Engine throttle and pump controller (Solenoid power supply)
supply 2 20A
Attachment return switching relay (Coil side and contact side)
(Fusible link:
A34) 3 10A Lock switch
Cigarette lighter
4 10A
Windshield washer motor
5 10A Horn switch
6 10A (Spare)
Rotary lamp switch
7 10A
Switch power Additional relay (Coil side and contact side)
supply
8 10A Light relay (Contact side)
(Fusible link:
A34) One-touch power maximizing switch
9 10A
Radio
10 10A (Spare)
11 20A Air conditioner unit
Starting motor cut-out (Personal code) relay (Coil side)
12 20A
Switch power Monitor panel
supply
13 20A Light switch
(Fusible link:
A34) 14 10A Service power supply (M32 connector)
Travel alarm
15 10A
DC/DC converter
Radio
16 10A
Air conditioner unit
Constant power
supply 17 20A Monitor panel
(Fusible link: 18 10A Starting switch
A35)
19 10A Room lamp
20 10A (Spare)
20-266 PC200/220(LC)-7
(11)
BACK
Problems which occur when controller power supply of engine throttle and pump controller is defective
a The controller power supply (FB1-1) of the engine throttle and pump controller drives the controller system.
a Accordingly, if the controller power supply is turned off, the controller cannot control the governor motor and
battery relay and the following problems occur.
1) The engine can be started but cannot be stopped.
2) The engine speed cannot be controlled with the fuel control dial.
a If the above problems occur, check the related fuse (FB1-1) and "green LED" of the engine throttle and pump
controller to see if the power is supplied normally.
• Lighting: The controller power is supplied (There is not an error and the power supply is normal).
• Flashing: The controller power is supplied (There is an error).
• Put out: The controller power is not supplied.
PC200/220(LC)-7 20-267
(5)
BACK
Problems which occur when solenoid power supply of engine throttle and pump controller is defective
a The solenoid power supply (FB1-2) of the engine throttle and pump controller is used by the controller to drive
the solenoids and relays.
a Accordingly, if the solenoid power supply is turned off, when the controller outputs the power to the solenoids
or relays, the power is not supplied to any of the solenoids and relays and all or some of the following error
codes are displayed simultaneously.
• [E212]: Disconnection in travel junction solenoid
• [E213]: Disconnection in swing holding brake solenoid
• [E214]: Disconnection in pump merge-divider solenoid
• [E215]: Disconnection in 2-stage relief solenoid
• [E216]: Disconnection in travel speed shifting solenoid
• [E223]: Disconnection in LS-EPC solenoid
• [E233]: Disconnection in PC-EPC solenoid
• [E248]: Disconnection in attachment flow rate adjustment EPC solenoid (when attachment is installed)
a If the above problems occur, check the related fuse (FB1-2) and inlet voltage of the engine throttle and pump
controller.
1) Disconnect connector C03 of the controller and connect a T-adapter to the wiring harness side.
2) Turn the starting switch ON.
3) Measure the voltage between each of pins (2) and (12) and each of pins (31), (32), and (33).
Pins (2) and (3) are the power supply pins and pins (31), (32), and (33) are the ground pins.
If the voltage is 20 – 30 V, it is normal.
20-268 PC200/220(LC)-7
(5)
TROUBLESHOOTING WHEN SERVICE CODE
"ELECTRICAL SYSTEM" AND FAILURE
CODE "MECHANICAL SYSTEM" ARE
INDICATED
PC200/220(LC)-7 20-301
(5)
BACK
TROUBLESHOOTING
Service Code in Electrical System E317 (Disconnection in governor motor Phase A and B) .................... 20-372
Service Code in Electrical System E318 (Short-circuiting in governor motor Phase A and Phase B) ....... 20-374
Service Code in Electrical System E501 ("Model Selection" function not provided yet) ............................ 20-376
Service Mode in Electrical System E502 (Model selecting signal fault) ..................................................... 20-377
Failure Code in Mechanical System A000N1 (Out-of-rate engine rotation at high idle) ............................. 20-378
Failure Code in Mechanical System A000N2 (Out-of-rate engine rotation at low idle) .............................. 20-378
Failure Code in Mechanical System AA10NX (Air cleaner clogging) ......................................................... 20-379
Failure Code in Mechanical System AB00KE (Abnormally lowered charging voltage).............................. 20-380
Failure Code in Mechanical System B@BAZG (Abnormally lowered engine oil pressure) ........................ 20-382
Failure Code in Mechanical System B@BAZK (Abnormally lowered engine oil level)............................... 20-383
Failure Code in Mechanical System B@BCNS (Engine coolant overheating) ........................................... 20-384
Failure Code in Mechanical System B@BCZK (Abnormally lowered radiator coolant level) ..................... 20-385
Failure Code in Mechanical System B@HANS (Hydraulic oil overheating)................................................ 20-386
20-302 PC200/220(LC)-7
(11)
BACK
20-304 PC200/220(LC)-7
BACK
TROUBLESHOOTING E101
User Code Service Code Failure Code Failure Abnormal data in the error history
— E101 DAF0KT phenomenon (in Monitor Panel system)
• The voltage in the firm power source circuit for Monitor Panel (battery) has dropped below 12 V or
Failure content
exceeded 36 V.
Response from
• None in particular
Monitor Panel
Phenomenon
occurring on • A display for information on the failure history (in the electrical system) cannot be called.
machine
20-306 PC200/220(LC)-7
(5)
BACK
PC200/220(LC)-7 20-307
BACK
User Code Service Code Failure Code Failure Short-circuiting in normal rotation system of wind-
— E112 DY2DKB phenomenon shield wiper motor drive (in monitor panel system)
Failure content • Abnormal current flew to the windshield wiper motor normal rotation circuit, when power is provided.
Response from
• Power supply to the windshield wiper motor normal rotation circuit is turned OFF.
Monitor Panel
Phenomenon
occurring on • The windshield wiper stops moving.
machine
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Windshield wiper motor for the troubleshooting.
defective W04 (female) Continuity and resistance value
1
(Internal short-circuiting
or grounding fault) Between and Continued
Between and grounding Above 1 MΩ
Grounding fault of wiring ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
harness for the troubleshooting.
2
(Contact with grounding Between wiring harness between P01 (female) and Resistance
circuit) Above 1 MΩ
W04 (male) and grounding value
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position
for the troubleshooting.
P01 Windshield wiper switch Voltage
3 Monitor panel defective
OFF Below 3 V
Between and grounding Below 3 V⇔20 – 30 V
ON
(at constant cycle)
20-308 PC200/220(LC)-7
BACK
PC200/220(LC)-7 20-309
BACK
User Code Service Code Failure Code Failure Short-circuiting in reverse rotation system of wind-
— E113 DY2EKB phenomenon shield wiper motor drive (in Monitor Panel system)
• Abnormal current flew to the reverse rotation circuit of the windshield wiper motor drive, when the
Failure content
windshield wiper was set in motion.
Response from
• Power supply to the reverse rotation circuit of the windshield wiper motor drive was switched OFF.
Monitor Panel
Phenomenon
occurring on • The windshield wiper stopped moving.
machine
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Windshield wiper motor for the troubleshooting.
defective W04 (female) Continuity and resistance value
1
(Internal short-circuiting
or grounding fault) Between and Continued
Between and grounding Above 1 MΩ
Grounding fault of wiring ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
harness for the troubleshooting.
2
(Contact with grounding Between wiring harness between P01 (female) and Resistance
circuit) Above 1 MΩ
W04 (male) and grounding value
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position
for the troubleshooting.
P01 Windshield wiper switch Voltage
3 Monitor panel defective
OFF Below 3 V
Between and grounding Below 3 V⇔20 – 30 V
ON
(at constant cycle)
20-310 PC200/220(LC)-7
BACK
TROUBLESHOOTING E113
PC200/220(LC)-7 20-311
(1)
BACK
TROUBLESHOOTING E114
User Code Service Code Failure Code Failure Short-circuiting in window washer drive system
— E114 DY2CKB phenomenon (in Monitor Panel system)
• Abnormal current flew to the window washer drive circuit, when the circuit was grounded and power was
Failure content
switched ON.
Response from
• Power supply to the grounding in the window washer motor circuit was switched OFF.
Monitor Panel
Phenomenon
occurring on • The window washer stopped moving.
machine
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
Window washer drive tion for the troubleshooting.
1 motor defective
A50 (male) Resistance value
(Internal short-circuiting)
Between (1) and (2) 5 – 20 z
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position
Short-circuiting of wiring for the troubleshooting.
harness Between wiring harness from P01 (female) (3) to J04 to
2
(Contact with 24 V A50 (female) (2) and grounding, or between wiring har-
circuit) Voltage Below 1 V
ness between P01 (female) (3) and D04 (female) (8) and
grounding
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position
for the troubleshooting.
3 Monitor panel defective P01 Window washer switch Voltage
OFF 20 – 30 V
Between (3) and grounding
ON Below 1 V
20-312 PC200/220(LC)-7
(7)
BACK
TROUBLESHOOTING E114
PC200/220(LC)-7 20-313
(1)
BACK
TROUBLESHOOTING E114
User Code Service Code Failure Code Failure Short-circuiting in window washer drive system
— E114 DY2CKB phenomenon (in Monitor Panel system)
• Abnormal current flew to the window washer drive circuit, when the circuit was grounded and power was
Failure content
switched ON.
Response from
• Power supply to the grounding in the window washer motor circuit was switched OFF.
Monitor Panel
Phenomenon
occurring on • The window washer stopped moving.
machine
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
Window washer drive tion for the troubleshooting.
1 motor defective
A50 (male) Resistance value
(Internal short-circuiting)
Between (1) and (2) 5 – 20 z
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position
Short-circuiting of wiring for the troubleshooting.
harness Between wiring harness from P01 (female) (3) to J04 to
2
(Contact with 24 V A50 (female) (2) and grounding, or between wiring har-
circuit) Voltage Below 1 V
ness between P01 (female) (3) and D02 (female) (7) and
grounding
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position
for the troubleshooting.
3 Monitor panel defective P01 Window washer switch Voltage
OFF 20 – 30 V
Between (3) and grounding
ON Below 1 V
20-313-1 PC200/220(LC)-7
(11)
BACK
TROUBLESHOOTING E114
PC200/220(LC)-7 20-313-2
(5)
BACK
TROUBLESHOOTING E115
User Code Service Code Failure Code Failure Abnormal operation of windshield wiper
— E115 DY20KA phenomenon (in Monitor Panel system)
Failure content • A W signal is not inputted at both ends of movement, when it is in motion.
Response from
• Power to the windshield wiper motor is turned OFF.
Monitor Panel
Phenomenon
occurring on • The windshield wiper motor does not work.
machine
Relative • Input of W signal at both ends of movement (ON or OFF) can be confirmed in the monitor function.
information (Code No. 049: Monitor input 3)
Windshield wiper motor W04 (female) Windshield wiper blade Resistance value
1 defective At upper end of operation
(Internal disconnection) Below 1 z
range
Between (6) and (5)
Outside upper end of
Above 1 Mz
operation range
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
Disconnection of wiring tion for the troubleshooting.
harness Wiring harness between P01 (female) (5) and W04 (male) Resistance
2 Below 1 z
(Disconnection or faulty (6) value
contact with connector) Resistance
Wiring harness between W04 (male) (5) and grounding Below 1 z
value
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position
for the troubleshooting.
P01 Windshield wiper blade Voltage
3 Monitor panel defective At upper end of operation
Below 1 V
range
Between (5) and grounding
Outside upper end of
20 – 30 V
operation range
20-314 PC200/220(LC)-7
(5)
BACK
PC200/220(LC)-7 20-315
BACK
User Code Service Code Failure Code Failure Abnormal operation of retracting windshield wiper
— E116 DY20MA phenomenon (in Monitor Panel system)
Failure content • P signal in the retraction range is not inputted, when the wiper is retracted.
Response from • Power supply to the windshield wiper motor is switched OFF, when the wiper is
Monitor Panel retracted.
Phenomenon
occurring on • The windshield wiper cannot be retracted completely.
machine
Relative • It can be checked in the monitoring function whether P signal (ON or OFF) in the retraction operation
information range is inputted or not. (Code No. 049: Monitor Input 3)
20-316 PC200/220(LC)-7
BACK
TROUBLESHOOTING E116
PC200/220(LC)-7 20-317
(1)
BACK
TROUBLESHOOTING E201
User Code Service Code Failure Code Failure Short-circuiting in travel interlocking solenoid
— E201 DW91KB phenomenon (in governor • pump controller system)
Failure content • Abnormal current flew to the travel interlocking circuit, when power was supplied to the circuit.
• Power supply to the travel interlocking circuit is switched OFF.
Response from
• Even if the failure cause disappears of itself, the solenoid circuit does not return to normalcy, unless the
controller
engine starting switch is once turned OFF.
Phenomenon
• It is difficult to steer the machine at turns.
occurring on
(The right and left travel circuits are not separated from each other)
machine
Relative • Operation of the travel interlocking solenoid (ON or OFF) can be checked in the monitoring function.
information (Code No. 023: Solenoid)
(Internal short-circuiting
or grounding fault) Between (1) and (2) 20 – 60 z
Between (1) and grounding Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
Assembled-type diode tion during the troubleshooting.
2 D03 defective
D03 (male) Resistance value
(Internal short-circuiting)
Between (3) and (7) Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
Grounding fault of wiring tion during the troubleshooting.
harness Between wiring harness from C03 (female) (7) to J06 to
3
(Contact with grounding V02 (female) (1) and grounding, or between wiring har- Resistance
circuit) Above 1 Mz
ness between C03 (female) (7) and D03 (female) (3) and value
grounding
a Turn the engine starting switch OFF for the preparations, and hold it running during the
troubleshooting.
Governor • pump C03 Travel control lever Voltage
4
controller defective
Straight forward Below 1 V
Between (7) and grounding
Steering 20 – 30 V
20-318 PC200/220(LC)-7
(7)
BACK
TROUBLESHOOTING E201
PC200/220(LC)-7 20-319
(1)
BACK
TROUBLESHOOTING E201
User Code Service Code Failure Code Failure Short-circuiting in travel interlocking solenoid
— E201 DW91KB phenomenon (in governor • pump controller system)
Failure content • Abnormal current flew to the travel interlocking circuit, when power was supplied to the circuit.
• Power supply to the travel interlocking circuit is switched OFF.
Response from
• Even if the failure cause disappears of itself, the solenoid circuit does not return to normalcy, unless the
controller
engine starting switch is once turned OFF.
Phenomenon
• It is difficult to steer the machine at turns.
occurring on
(The right and left travel circuits are not separated from each other)
machine
Relative • Operation of the travel interlocking solenoid (ON or OFF) can be checked in the monitoring function.
information (Code No. 023: Solenoid)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
Travel interlocking sole- tion during the troubleshooting.
noid defective V02 (male) Resistance value
1
(Internal short-circuiting
or grounding fault) Between (1) and (2) 20 – 60 z
Between (1) and grounding Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
Grounding fault of wiring tion during the troubleshooting.
harness
2 Between wiring harness from C03 (female) (7) to V02
(Contact with grounding Resistance
circuit) (female) (1) and grounding, or between wiring harness Above 1 Mz
value
between C03 (female) (7) and grounding
a Turn the engine starting switch OFF for the preparations, and hold it running during the
troubleshooting.
Governor • pump C03 Travel control lever Voltage
3
controller defective
Straight forward Below 1 V
Between (7) and grounding
Steering 20 – 30 V
20-319-1 PC200/220(LC)-7
(7)
BACK
TROUBLESHOOTING E201
PC200/220(LC)-7 20-319-2
(5)
BACK
TROUBLESHOOTING E203
User Code Service Code Failure Code Failure Short-circuiting in swing holding brake solenoid (in
E03 E203 DW45KB phenomenon governor • pump controller system)
• Abnormal current flew to the swing holding brake solenoid circuit, when power was supplied to the cir-
Failure content
cuit.
• Power supply to the swing holding brake solenoid circuit is switched OFF.
Response from
• Even after the failure cause disappears of itself, the swing holding brake does not return to normalcy,
controller
unless the engine starting switch is once turned OFF.
Phenomenon
occurring on • The upper structure cannot swing. (The swing holding brake is not released)
machine
• Operation of the swing holding brake solenoid (ON or OFF) can be checked in the monitoring function.
(Code No. 023: Solenoid 1)
Relative
• If there is no abnormality with the solenoid or wiring harness, the upper structure can swing by turning
information
the emergency swing brake releasing switch to the FREE position.
(In this case, however, the swing holding brake does not work, when stopping the machine)
(Internal short-circuiting
or grounding fault) Between (1) and (2) 20 – 60 z
Between (1) and grounding Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
Assembled-type diode tion during the troubleshooting.
2 D03 defective
D03 (male) Resistance value
(Internal short-circuiting)
Between (4) and (8) Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
Grounding fault of wiring tion during the troubleshooting.
harness Wiring harness from C03 (female) (37) to D01 to J02 to
3
(Contact with grounding X05 to J06 to V05 (female) (1), or between wiring harness Resistance
circuit) Above 1 Mz
between C03 (female) (37) and D03 (female) (4) and value
grounding
a Turn the engine starting switch OFF for the preparations, and hold it running during the
troubleshooting.
Governor • pump C03 Swing control lever Voltage
4
controller defective
NEUTRAL Below 1 V
Between (37) and grounding
Swing 20 – 30 V
20-320 PC200/220(LC)-7
(7)
BACK
TROUBLESHOOTING E203
Electrical Circuit Diagram for Swing Holding Brake of Governor • Pump Controller
PC200/220(LC)-7 20-321
(1)
BACK
TROUBLESHOOTING E203
User Code Service Code Failure Code Failure Short-circuiting in swing holding brake solenoid (in
E03 E203 DW45KB phenomenon governor • pump controller system)
• Abnormal current flew to the swing holding brake solenoid circuit, when power was supplied to the cir-
Failure content
cuit.
• Power supply to the swing holding brake solenoid circuit is switched OFF.
Response from
• Even after the failure cause disappears of itself, the swing holding brake does not return to normalcy,
controller
unless the engine starting switch is once turned OFF.
Phenomenon
occurring on • The upper structure cannot swing. (The swing holding brake is not released)
machine
• Operation of the swing holding brake solenoid (ON or OFF) can be checked in the monitoring function.
(Code No. 023: Solenoid 1)
Relative
• If there is no abnormality with the solenoid or wiring harness, the upper structure can swing by turning
information
the emergency swing brake releasing switch to the FREE position.
(In this case, however, the swing holding brake does not work, when stopping the machine)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
Swing holding brake tion during the troubleshooting.
solenoid defective V05 (male) Resistance value
1
(Internal short-circuiting
or grounding fault) Between (1) and (2) 20 – 60 z
Between (1) and grounding Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
Grounding fault of wiring tion during the troubleshooting.
harness
2 Wiring harness from C03 (female) (37) to D01 to J02 to
(Contact with grounding Resistance
circuit) X05 to V05 (female) (1), or between wiring harness Above 1 Mz
value
between C03 (female) (37) and grounding
a Turn the engine starting switch OFF for the preparations, and hold it running during the
troubleshooting.
Governor • pump C03 Swing control lever Voltage
3
controller defective
NEUTRAL Below 1 V
Between (37) and grounding
Swing 20 – 30 V
20-321-1 PC200/220(LC)-7
(7)
BACK
TROUBLESHOOTING E203
Electrical Circuit Diagram for Swing Holding Brake of Governor • Pump Controller
PC200/220(LC)-7 20-321-2
(5)
BACK
TROUBLESHOOTING E204
User Code Service Code Failure Code Failure Short-circuiting in merge/divide solenoid
— E204 DWJ0KB phenomenon (in governor • pump controller system)
Failure content • Abnormal current flew to the merge/divide solenoid circuit, when power was supplied to the circuit.
• Power supply to the merge/divide solenoid circuit is switched OFF.
Response from
• Even after the failure cause disappears of itself, the machine operation does not return to normalcy, un-
controller
less the engine starting switch is once turned OFF.
Phenomenon
• In L mode, the work equipment moves slowly, or the swing speed is slow in its single operation.
occurring on
(Front and rear pumps are not separated)
machine
Relative • Operation of the merge/divide solenoid (ON or OFF) can be checked in the monitoring function.
information (Code No. 023: Solenoid 1)
(Internal short-circuiting
or grounding fault) Between (1) and (2) 20 – 60 z
Between (1) and grounding Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
Assembled-type diode tion during the troubleshooting.
2 D03 defective
D03 (male) Resistance value
(Internal short-circuiting)
Between (1) and (5) Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
Grounding fault of wiring tion during the troubleshooting.
harness
3 Wiring harness from C03 (female) (17) to J06 to V03
(Contact with grounding Resistance
circuit) (female) (1), or between wiring harness between C03 Above 1 Mz
value
(female) (17) and D03 (female) (1) and grounding
a Turn the engine starting switch OFF for the preparations, and hold it running during the
troubleshooting.
Governor • pump C03 Travel control lever Voltage
4
controller defective NEUTRAL Below 1 V
Between (17) and grounding When operating one side
20 – 30 V
only
20-322 PC200/220(LC)-7
(7)
BACK
TROUBLESHOOTING E204
PC200/220(LC)-7 20-323
(1)
BACK
TROUBLESHOOTING E204
User Code Service Code Failure Code Failure Short-circuiting in merge/divide solenoid
— E204 DWJ0KB phenomenon (in governor • pump controller system)
Failure content • Abnormal current flew to the merge/divide solenoid circuit, when power was supplied to the circuit.
• Power supply to the merge/divide solenoid circuit is switched OFF.
Response from
• Even after the failure cause disappears of itself, the machine operation does not return to normalcy, un-
controller
less the engine starting switch is once turned OFF.
Phenomenon
• In L mode, the work equipment moves slowly, or the swing speed is slow in its single operation.
occurring on
(Front and rear pumps are not separated)
machine
Relative • Operation of the merge/divide solenoid (ON or OFF) can be checked in the monitoring function.
information (Code No. 023: Solenoid 1)
20-323-1 PC200/220(LC)-7
(7)
BACK
TROUBLESHOOTING E204
PC200/220(LC)-7 20-323-2
(5)
BACK
TROUBLESHOOTING E205
User Code Service Code Failure Code Failure Short-circuiting in 2-stage relief solenoid
— E205 DWK0KB phenomenon (in governor • pump controller system)
Failure content • Abnormal current flew to the 2-stage relief solenoid circuit, when power was supplied to the circuit.
• Power supply to the 2-stage relief solenoid circuit is switched OFF.
Response from
• Even after the failure cause disappears of itself, the machine operation does not return to normalcy,
controller
unless the engine starting switch is once turned OFF.
Phenomenon
occurring on • The one-touch power max. switch does not work. (The main relief valve is not set to high pressure)
machine
Relative • Operation of the 2-stage relief solenoid (ON or OFF) can be checked in the monitoring function.
information (Code No. 023: Solenoid 1)
20-324 PC200/220(LC)-7
(5)
BACK
TROUBLESHOOTING E205
Electric Circuit Diagram for 2-stage Relief Solenoid in Governor • Pump Controller
PC200/220(LC)-7 20-325
(1)
BACK
TROUBLESHOOTING E205
User Code Service Code Failure Code Failure Short-circuiting in 2-stage relief solenoid
— E205 DWK0KB phenomenon (in governor • pump controller system)
Failure content • Abnormal current flew to the 2-stage relief solenoid circuit, when power was supplied to the circuit.
• Power supply to the 2-stage relief solenoid circuit is switched OFF.
Response from
• Even after the failure cause disappears of itself, the machine operation does not return to normalcy,
controller
unless the engine starting switch is once turned OFF.
Phenomenon
occurring on • The one-touch power max. switch does not work. (The main relief valve is not set to high pressure)
machine
Relative • Operation of the 2-stage relief solenoid (ON or OFF) can be checked in the monitoring function.
information (Code No. 023: Solenoid 1)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
2-stage relief solenoid tion during the troubleshooting.
defective V06 (male) Resistance value
1
(Internal short-circuiting
or grounding fault) Between (1) and (2) 20 – 60 z
Between (1) and grounding Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
Grounding fault of wiring tion during the troubleshooting.
harness
2 Wiring harness from C03 (female) (28) to V06 (female)
(Contact with grounding Resistance
circuit) (1), or between wiring harness between C03 (female) (28) Above 1 Mz
value
and grounding
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position
during the troubleshooting.
Governor • pump C03 Working mode Voltage
3
controller defective
Other than L mode Below 1 V
Between (28) and grounding
L mode 20 – 30 V
20-325-1 PC200/220(LC)-7
(7)
BACK
TROUBLESHOOTING E205
Electric Circuit Diagram for 2-stage Relief Solenoid in Governor • Pump Controller
PC200/220(LC)-7 20-325-2
(5)
BACK
TROUBLESHOOTING E206
User Code Service Code Failure Code Failure Short-circuiting in travel speed shifting solenoid
— E206 DW43KB phenomenon (in governor • pump controller system)
Failure content • Abnormal current flew to the travel speed shifting solenoid, when power was supplied to the circuit.
• Power supply to the travel speed shifting solenoid circuit is switched OFF.
Response from
• Even after the failure cause disappears of itself, the machine operation does not return to normalcy,
controller
unless the engine starting switch is once turned OFF.
Phenomenon
• The travel speed does not turn to Hi.
occurring on
(The travel motor swash plate angle is not set to the minimum)
machine
Relative • Operation of the travel speed shifting solenoid (ON or OFF) can be checked in the monitoring function.
information (Code No. 023: Solenoid 1)
(Internal short-circuiting
or grounding fault) Between (1) and (2) 20 – 60 z
Between (1) and grounding Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
Assembled-type diode tion during the troubleshooting.
2 D04 defective
D04 (male) Resistance value
(Internal short-circuiting)
Between (2) and (6) Above 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
Grounding fault of wiring tion during the troubleshooting.
harness
3 Wiring harness from C03 (female) (27) to J06 to V04
(Contact with grounding Resistance
circuit) (female) (1), or between wiring harness between C03 Above 1 Mz
value
(female) (27) and D04 (female) (2) and grounding
a Turn the engine starting switch OFF for the preparations, and hold it running during the
troubleshooting.
Governor • pump Travel speed &
4 C03 Voltage
controller defective Travel lever
Lo + Neutral Below 1 V
Between (27) and grounding
Hi + Travel 20 – 30 V
20-326 PC200/220(LC)-7
(7)
BACK
TROUBLESHOOTING E206
Electrical Circuit Diagram for Travel Speed Shifting Solenoid in Governor • Pump Controller
PC200/220(LC)-7 20-327
(1)
BACK
TROUBLESHOOTING E206
User Code Service Code Failure Code Failure Short-circuiting in travel speed shifting solenoid
— E206 DW43KB phenomenon (in governor • pump controller system)
Failure content • Abnormal current flew to the travel speed shifting solenoid, when power was supplied to the circuit.
• Power supply to the travel speed shifting solenoid circuit is switched OFF.
Response from
• Even after the failure cause disappears of itself, the machine operation does not return to normalcy,
controller
unless the engine starting switch is once turned OFF.
Phenomenon
• The travel speed does not turn to Hi.
occurring on
(The travel motor swash plate angle is not set to the minimum)
machine
Relative • Operation of the travel speed shifting solenoid (ON or OFF) can be checked in the monitoring function.
information (Code No. 023: Solenoid 1)
20-327-1 PC200/220(LC)-7
(7)
BACK
TROUBLESHOOTING E206
Electrical Circuit Diagram for Travel Speed Shifting Solenoid in Governor • Pump Controller
PC200/220(LC)-7 20-327-2
(5)
BACK
TROUBLESHOOTING E211
User Code Service Code Failure Code Failure Disconnection in travel interlocking solenoid
— E211 DW91KA phenomenon (in governor • pump controller system)
Failure content • No current flows to the travel interlocking solenoid circuit, when power is supplied to the circuit.
Response from • None in particular (The solenoid does not function as there is current flowing to it)
controller • When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon
• It is difficult to steer the machine while traveling.
occurring on
(The right and left travel circuits are not separated from each other)
machine
• Operation of the travel interlocking solenoid (ON or OFF) can be checked in the monitoring function.
Relative (Code No. 023: Solenoid 1)
information a The solenoid detects disconnection, when power is ON. Hence be sure to check it with power ON after
the repairs. (For how to turn power ON or OFF, refer to the troubleshooting under Service Code [E201].)
20-328 PC200/220(LC)-7
(7)
BACK
TROUBLESHOOTING E211
Electrical Circuit Diagram for Travel Interlocking Solenoid in Governor • Pump Controller
PC200/220(LC)-7 20-329
(1)
BACK
TROUBLESHOOTING E211
User Code Service Code Failure Code Failure Disconnection in travel interlocking solenoid
— E211 DW91KA phenomenon (in governor • pump controller system)
Failure content • No current flows to the travel interlocking solenoid circuit, when power is supplied to the circuit.
Response from • None in particular (The solenoid does not function as there is current flowing to it)
controller • When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon
• It is difficult to steer the machine while traveling.
occurring on
(The right and left travel circuits are not separated from each other)
machine
• Operation of the travel interlocking solenoid (ON or OFF) can be checked in the monitoring function.
Relative (Code No. 023: Solenoid 1)
information a The solenoid detects disconnection, when power is ON. Hence be sure to check it with power ON after
the repairs. (For how to turn power ON or OFF, refer to the troubleshooting under Service Code [E201].)
20-329-1 PC200/220(LC)-7
(7)
BACK
TROUBLESHOOTING E211
Electrical Circuit Diagram for Travel Interlocking Solenoid in Governor • Pump Controller
PC200/220(LC)-7 20-329-2
(5)
BACK
TROUBLESHOOTING E213
User Code Service Code Failure Code Failure Disconnection in swing holding brake solenoid
E03 E213 DW45KA phenomenon (in governor • pump controller system)
Failure content • No current flows to the swing holding brake solenoid circuit, when power is supplied to the circuit.
Response from • None in particular (The solenoid does not function as there is no current flowing to it)
controller • When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon
occurring on • The machine's upper structure does not swing. (The swing holding brake is not released)
machine
• Operation of the swing holding brake solenoid (ON or OFF) can be checked in the monitoring function.
(Code No. 023: Solenoid 1)
• If there is abnormality neither with the solenoid nor with wiring harnesses, the upper structure can swing
by moving the emergency swing brake release switch to the FREE position. (In this case, however, the
Relative
parking brake does not work, when stopping the machine)
information
a While in troubleshooting, hold both the swing lock switch and the emergency swing release switch in
the OFF position.
a The solenoid detects disconnection, when power is ON. Hence be sure to check it with power ON after
the repairs. (For how to turn power ON or OFF, refer to the troubleshooting under Service Code [E203].)
Swing holding brake a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
solenoid defective during the troubleshooting.
1
(Internal disconnec- V05 (male) Resistance value
tion) Between (1) and (2) 20 – 60 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Swing lock switch during the troubleshooting.
defective X05 (female) Swing lock switch Resistance value
2
(Internal disconnec-
tion) OFF Below 1 z
Presumed cause and standard value in normalcy
Assembled-type a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
diode D01 defective during the troubleshooting.
3
(Internal disconnec- D01 (male) Digital type circuit tester Continuity
tion) Between (7) and (3) Diode mode Continued
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Resistance
Disconnection of Wiring harness between C03 (female) (37) and D01 (female) (7) Below 1 z
value
wiring harness
Resistance
4 (Disconnection or Wiring harness from D01 (female) (3) to J02 to X05 (male) (3) Below 1 z
value
defective contact
with connector) Resistance
Wiring harness from X05 (male) (4) to J06 to V05 (female) (1) Below 1 z
value
Resistance
Wiring harness between V05 (female) (2) and grounding Below 1 z
value
Short-circuiting of a Turn the engine starting switch OFF for the preparations, and hold it in the ON position dur-
Wiring harness ing the troubleshooting.
5
(Contact with 24V Between wiring harness between C03 (female) (37) and D01
circuit) Voltage Below 1 V
(female) (7) and grounding
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Governor • pump during the troubleshooting.
6
controller defective C03 (female) Disconnect D01 and connect pins Resistance value
Between (37) and grounding (3) and (7) of the female side. 20 – 60 z
20-330 PC200/220(LC)-7
(7)
BACK
TROUBLESHOOTING E213
Electrical Circuit Diagram for Swing Holding Brake Solenoid in Governor • Pump Controller
PC200/220(LC)-7 20-331
(5)
BACK
TROUBLESHOOTING E213
User Code Service Code Failure Code Failure Disconnection in swing holding brake solenoid
E03 E213 DW45KA phenomenon (in governor • pump controller system)
Failure content • No current flows to the swing holding brake solenoid circuit, when power is supplied to the circuit.
Response from • None in particular (The solenoid does not function as there is no current flowing to it)
controller • When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon
occurring on • The machine's upper structure does not swing. (The swing holding brake is not released)
machine
• Operation of the swing holding brake solenoid (ON or OFF) can be checked in the monitoring function.
(Code No. 023: Solenoid 1)
• If there is abnormality neither with the solenoid nor with wiring harnesses, the upper structure can swing
by moving the emergency swing brake release switch to the FREE position. (In this case, however, the
Relative
parking brake does not work, when stopping the machine)
information
a While in troubleshooting, hold both the swing lock switch and the emergency swing release switch in
the OFF position.
a The solenoid detects disconnection, when power is ON. Hence be sure to check it with power ON after
the repairs. (For how to turn power ON or OFF, refer to the troubleshooting under Service Code [E203].)
Swing holding brake a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
solenoid defective during the troubleshooting.
1
(Internal disconnec- V05 (male) Resistance value
tion) Between (1) and (2) 20 – 60 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Swing lock switch during the troubleshooting.
defective X05 (female) Swing lock switch Resistance value
2
(Internal disconnec-
tion) OFF Below 1 z
Between (3) and (4)
Presumed cause and standard value in normalcy
LOCK Above 1 Mz
Assembled-type a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
diode D01 defective during the troubleshooting.
3
(Internal disconnec- D01 (male) Digital type circuit tester Continuity
tion) Between (7) and (3) Diode mode Continued
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Resistance
Disconnection of Wiring harness between C03 (female) (37) and D01 (female) (7) Below 1 z
value
wiring harness
Resistance
4 (Disconnection or Wiring harness from D01 (female) (3) to J02 to X05 (male) (3) Below 1 z
value
defective contact
with connector) Resistance
Wiring harness from X05 (male) (4) to V05 (female) (1) Below 1 z
value
Wiring harness between C03 (female) (3) (13) (23) and V05 Resistance
Below 1 z
(female) (2) value
Short-circuiting of a Turn the engine starting switch OFF for the preparations, and hold it in the ON position dur-
Wiring harness ing the troubleshooting.
5
(Contact with 24V Between wiring harness between C03 (female) (37) and D01
circuit) Voltage Below 1 V
(female) (7) and grounding
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Governor • pump
6 C03 (female) Resistance value
controller defective Disconnect D01 and connect pins
Between (37) and (3) (13) (3) and (7) of the female side. 20 – 60 z
(23)
20-331-1 PC200/220(LC)-7
(7)
BACK
TROUBLESHOOTING E213
Electrical Circuit Diagram for Swing Holding Brake Solenoid in Governor • Pump Controller
PC200/220(LC)-7 20-331-2
(5)
BACK
TROUBLESHOOTING E214
User Code Service Code Failure Code Failure Disconnection in merge/divide solenoid
— E214 DWJ0KA phenomenon (in governor • pump controller system)
Failure content • No current flows to the merge/divide solenoid circuit, when power is supplied to the circuit.
Response from • None in particular (The solenoid does not function as there is no current flowing to it)
controller • When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon
• In L mode, speeds of the work equipment and swing in its single operation are too fast
occurring on
(Front and rear pumps are not separated)
machine
• Operation of the merge/divide solenoid (ON or OFF) can be checked in the monitoring function.
Relative (Code No. 023: Solenoid 1)
information a The solenoid detects disconnection, when power is ON. Hence be sure to check it with power ON after
the repairs. (For how to turn power ON or OFF, refer to the troubleshooting under Service Code [E204].)
20-332 PC200/220(LC)-7
(7)
BACK
TROUBLESHOOTING E214
PC200/220(LC)-7 20-333
(1)
BACK
TROUBLESHOOTING E214
User Code Service Code Failure Code Failure Disconnection in merge/divide solenoid
— E214 DWJ0KA phenomenon (in governor • pump controller system)
Failure content • No current flows to the merge/divide solenoid circuit, when power is supplied to the circuit.
Response from • None in particular (The solenoid does not function as there is no current flowing to it)
controller • When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon
• In L mode, speeds of the work equipment and swing in its single operation are too fast
occurring on
(Front and rear pumps are not separated)
machine
• Operation of the merge/divide solenoid (ON or OFF) can be checked in the monitoring function.
Relative (Code No. 023: Solenoid 1)
information a The solenoid detects disconnection, when power is ON. Hence be sure to check it with power ON after
the repairs. (For how to turn power ON or OFF, refer to the troubleshooting under Service Code [E204].)
1 defective
V03 (male) Resistance value
(Internal disconnection)
Between (1) and (2) 20 – 60 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
Disconnection of wiring tion during the troubleshooting.
harness
Resistance
2 (Disconnection or defec- Wiring harness from C03 (female) (17) to V03 (female) (1) Below 1 z
value
tive contact with connec-
tor) Wiring harness between C03 (female) (3) (13) (23) and Resistance
Below 1 z
V03 (female) (2) value
Short-circuiting of wiring a Turn the engine starting switch OFF for the preparations, and hold it in the ON position
harness during the troubleshooting.
3
(Contact with 24 V cir- Wiring harness from C03 (female) (17) to V03 (female) (1)
cuit) Voltage Below 1 V
and grounding
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
Governor • pump tion during the troubleshooting.
4
controller defective C03 (female) Resistance value
Between (17) and (3) (13) (23) 20 – 60 z
20-333-1 PC200/220(LC)-7
(7)
BACK
TROUBLESHOOTING E214
PC200/220(LC)-7 20-333-2
(5)
BACK
TROUBLESHOOTING E215
User Code Service Code Failure Code Failure Disconnection in 2-stage relief solenoid
— E215 DWK0KA phenomenon (in governor • pump controller system)
Failure content • No current flows to the 2-stage relief solenoid circuit, when power is supplied to the circuit.
Response from • None in particular (The solenoid does not function as there is no current flowing to it)
controller • When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon
• The one-touch power max. switch does not work.
occurring on
(The main relief valve cannot be set to high-pressure set)
machine
• Operation of the 2-stage relief solenoid (ON or OFF) can be checked in the monitoring function.
Relative (Code No. 023: Solenoid 1)
information a The solenoid detects disconnection, when power is ON. Hence be sure to check it with power ON after
the repairs. (For how to turn power ON or OFF, refer to the troubleshooting under Service Code [E205].)
20-334 PC200/220(LC)-7
(7)
BACK
TROUBLESHOOTING E215
Electrical Circuit Diagram for 2-stage Relief Solenoid in Governor • Pump Controller
PC200/220(LC)-7 20-335
(1)
BACK
TROUBLESHOOTING E215
User Code Service Code Failure Code Failure Disconnection in 2-stage relief solenoid
— E215 DWK0KA phenomenon (in governor • pump controller system)
Failure content • No current flows to the 2-stage relief solenoid circuit, when power is supplied to the circuit.
Response from • None in particular (The solenoid does not function as there is no current flowing to it)
controller • When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon
• The one-touch power max. switch does not work.
occurring on
(The main relief valve cannot be set to high-pressure set)
machine
• Operation of the 2-stage relief solenoid (ON or OFF) can be checked in the monitoring function.
Relative (Code No. 023: Solenoid 1)
information a The solenoid detects disconnection, when power is ON. Hence be sure to check it with power ON after
the repairs. (For how to turn power ON or OFF, refer to the troubleshooting under Service Code [E205].)
1 defective
V06 (male) Resistance value
(Internal disconnection)
Between (1) and (2) 20 – 60 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
Disconnection of wiring tion during the troubleshooting.
harness
Wiring harness between C03 (female) (28) and V06 Resistance
2 (Disconnection or defec- Max. 1 z
(female) (1) value
tive contact with connec-
tor) Wiring harness between C03 (female) (3) (13) (23) and Resistance
Max. 1 z
V06 (female) (2) value
Short-circuiting of wiring a Turn the engine starting switch OFF for the preparations, and hold it in the ON position
harness during the troubleshooting.
3
(Contact with 24 V cir- Wiring harness from C03 (female) (28) to V06 (female) (1)
cuit) Voltage Max. 1 V
and grounding
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
Governor • pump tion during the troubleshooting.
4
controller defective C03 (female) Resistance value
Between (28) and (3) (13) (23) 20 – 60 z
20-335-1 PC200/220(LC)-7
(7)
BACK
TROUBLESHOOTING E215
Electrical Circuit Diagram for 2-stage Relief Solenoid in Governor • Pump Controller
PC200/220(LC)-7 20-335-2
(5)
BACK
TROUBLESHOOTING E216
User Code Service Code Failure Code Failure Disconnection in travel speed shifting solenoid
— E216 DW43KA phenomenon (in governor • pump controller system)
Failure content • No current flows to the travel speed shifting solenoid circuit, when power is supplied to the circuit.
Response from • None in particular (The solenoid does not function as there is no current flowing to it)
controller • When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon
• The travel speed does not shift to Hi.
occurring on
(The travel motor swash plate angle does not turn to minimum)
machine
• Operation of the travel speed shifting solenoid (ON or OFF) can be checked in the monitoring function.
Relative (Code No. 023: Solenoid 1)
information a The solenoid detects disconnection, when power is ON. Hence be sure to check it with power ON after
the repairs. (For how to turn power ON or OFF, refer to the troubleshooting under Service Code [E206].)
20-336 PC200/220(LC)-7
(7)
BACK
TROUBLESHOOTING E216
Electrical Circuit Diagram for Travel Speed Shifting Solenoid in Governor • Pump Controller
PC200/220(LC)-7 20-337
(1)
BACK
TROUBLESHOOTING E216
User Code Service Code Failure Code Failure Disconnection in travel speed shifting solenoid
— E216 DW43KA phenomenon (in governor • pump controller system)
Failure content • No current flows to the travel speed shifting solenoid circuit, when power is supplied to the circuit.
Response from • None in particular (The solenoid does not function as there is no current flowing to it)
controller • When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon
• The travel speed does not shift to Hi.
occurring on
(The travel motor swash plate angle does not turn to minimum)
machine
• Operation of the travel speed shifting solenoid (ON or OFF) can be checked in the monitoring function.
Relative (Code No. 023: Solenoid 1)
information a The solenoid detects disconnection, when power is ON. Hence be sure to check it with power ON after
the repairs. (For how to turn power ON or OFF, refer to the troubleshooting under Service Code [E206].)
1 solenoid defective
V04 (male) Resistance value
(Internal disconnection)
Between (1) and (2) 20 – 60 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
Disconnection of wiring tion during the troubleshooting.
harness
Wiring harness between C03 (female) (27) and V04 Resistance
2 (Disconnection or defec- Max. 1 z
(female) (1) value
tive contact with connec-
tor) Wiring harness between C03 (female) (3) (13) (23) and Resistance
Max. 1 z
V04 (female) (2) and grounding value
Short-circuiting of wiring a Turn the engine starting switch OFF for the preparations, and hold it in the ON position
harness during the troubleshooting.
3
(Contact with 24 V cir- Wiring harness from C03 (female) (27) to V04 (female) (1)
cuit) Voltage Max. 1 V
and grounding
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
Governor • pump tion during the troubleshooting.
4
controller defective C03 (female) Resistance value
Between (27) and (3) (13) (23) 20 – 60 z
20-337-1 PC200/220(LC)-7
(7)
BACK
TROUBLESHOOTING E216
Electrical Circuit Diagram for Travel Speed Shifting Solenoid in Governor • Pump Controller
PC200/220(LC)-7 20-337-2
(5)
BACK
TROUBLESHOOTING E217
20-338 PC200/220(LC)-7
(5)
BACK
TROUBLESHOOTING E217
Electrical Circuit Diagram for Model Selecting Connector in Governor • Pump Controller
PC200-7
PC200/220(LC)-7 20-339
(1)
BACK
TROUBLESHOOTING E217
PC220-7
User Code Service Code Failure Code Failure Abnormality in inputting model code
— E217 DA2SKQ phenomenon (in governor • pump controller system)
Failure content • A model code signal was inputted which indicates another model that is not registered in the controller.
• The controller treats it as a default-set model (PC200).
Response from
• Even if the failure cause disappears of itself, the machine operation does not return to normalcy, unless
controller
the engine starting switch is once turned OFF.
Phenomenon
occurring on • None in particular with PC200 model
machine
• Model names (expressed in number) that the controller recognizes can be confirmed in the monitoring
Relative function. (Code No. 002 and 003: Controller Model Code)
information a Input of model selecting signals (ON or OFF) can be confirmed in the monitoring
function.(Code No. 027:Switch Input 2)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
tion during the troubleshooting.
Disconnection of wiring Wiring harness between C02 (female) (37) and C09 Resistance
harness Max. 1 z
(male) (1) value
2 (Disconnection or defec-
tive contact with connec- Wiring harness between C02 (female) (17) and C09 Resistance
Max. 1 z
tor) (male) (3) value
Between wiring harness between C09 (male) (8) and J05 Resistance
Max. 1 z
and grounding value
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
tion during the troubleshooting.
Grounding fault of wiring Between wiring harness between C02 (female) (7) and Resistance
Min. 1 Mz
harness C09 (male) (4) and grounding value
3
(Contact with grounding Between wiring harness between C02 (female) (13) and Resistance
circuit) Min. 1 Mz
C09 (male) (7) and grounding value
Between wiring harness between C02 (female) (27) and Resistance
Min. 1 Mz
C09 (male) (2) and grounding value
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position
during the troubleshooting.
Governor • pump C02 Voltage
4
controller defective
Between (7), (13) or (27) and grounding 20 – 30 V
Between (37), (17) and grounding Max. 1 V
20-340 PC200/220(LC)-7
(5)
BACK
Electrical Circuit Diagram for Model Selecting Connector in Governor • Pump Controller
PC220-7
PC200/220(LC)-7 20-341
BACK
User Code Service Code Failure Code Failure Disconnection in S-NET signal
— E218 DA2SKA phenomenon (in governor • pump controller system)
• A failure occurred in S-NET communication between the monitor and controller in the past.
Failure content
(The machine operation returned to normalcy, when the display was resumed)
• While the failure is still continuing, the machine operation is controlled by the following default setting.
1) Working mode: E mode
Response from 2) Travel speed: Lo
controller 3) Auto-decelerator: ON
4) Attachment oil flow rate: Minimum ( )
• When the failure cause disappears of itself, the machine operation returns to normalcy.
• The working mode cannot be changed. (The display changes normally in the monitor panel)
Phenomenon
• The travel speed cannot be shifted. (The display changes normally in the monitor panel)
occurring on
• The auto-decelerator cannot be released. (The display changes normally in the monitor panel)
machine
• The attachment oil flow rate cannot be changed. (The display changes normally in the monitor panel) ( )
• This Service Code No. is displayed to inform that there was a failure occurred in the past, when S-NET
communication between the monitor panel and the governor • pump controller is returned to normalcy.
Relative
• The communication has already returned to normalcy by the time this Service Code No. is displayed.
information
But thoroughly diagnose all the related equipment and circuits, and remove all potential causes for a
failure in order to prevent recurrence of failures.
: The multi-monitor specification machine only.
Grounding fault of wiring ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
harness during the troubleshooting.
2
(Contact with grounding Between wiring harness between P02 (female) and Resistance
circuit) Above 1 MΩ
C02 (female) and grounding value
Short-circuiting of wiring ★Turn the engine starting switch OFF for the preparations, and hold it in the ON position
harness during the troubleshooting.
3
(Contact with 24 V cir- Between wiring harness between P02 (female) and
cuit) Voltage Below 1 V
C02 (female) and grounding
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position
during the troubleshooting.
4 Monitor panel defective P02 (male) Voltage
Between and 6–9V
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position
during the troubleshooting.
Governor • pump
5 C02 (male) Voltage
controller defective
Between and 6–9V
20-342 PC200/220(LC)-7
BACK
TROUBLESHOOTING E218
Electrical Circuit Diagram for S-NET Communication between Monitor Panel and Governor • Pump
Controller
PC200/220(LC)-7 20-343
(1)
BACK
TROUBLESHOOTING E222
User Code Service Code Failure Code Failure Disconnection in LS-EPC solenoid
— E222 DXE0KB phenomenon (in governor • pump controller system)
Failure content • Abnormal current flew to the LS-EPC solenoid circuit.
• The controller reduces the output to the LS-EPC solenoid circuit to 0.
Response from
• Even if the failure cause disappears, the current does not return to normalcy, unless the engine starting
controller
switch is once turned OFF.
Phenomenon
• The travel speed is slow at Mi and Lo, or in L mode, speeds of the work equipment and swing are too
occurring on
fast. (The LS valve set pressure cannot be controlled)
machine
Relative • Output to LS-EPC solenoid (ampere) can be confirmed in the monitor function.
information (Code No. 015: LS-EPC solenoid current)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
LS-EPC solenoid defec- tion during the troubleshooting.
tive V22 (male) Resistance value
1
(Internal short-circuiting
or grounding fault) Between (1) and (2) 7 – 14 z
Between (1) and grounding Min. 1 Mz
Grounding fault of wiring a Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
harness tion during the troubleshooting.
2
(Contact with grounding Between wiring harness between C03 (female) (6) and Resistance
circuit) Min. 1 Mz
V22 (female) (1) and grounding value
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
tion during the troubleshooting.
Governor • pump C03 (female) Resistance value
3
controller defective
Between (6) and (3) (13) (23) 7 – 14 z
Between (6) and grounding Min. 1 Mz
20-344 PC200/220(LC)-7
(5)
BACK
TROUBLESHOOTING E223
User Code Service Code Failure Code Failure Disconnection in LS-EPC solenoid
— E223 DXE0KA phenomenon (in governor • pump controller system)
Failure content • No current flows to the LS-EPC solenoid circuit.
Response from • None in particular (The solenoid does not function as there is no current flowing to it)
controller • When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon
• The travel speed is slow at Mi and Lo, or in L mode, speeds of the work equipment and swing are too
occurring on
fast. (The LS valve set pressure cannot be controlled)
machine
Relative • Output to LS-EPC solenoid (ampere) can be confirmed in the monitor function.
information (Code No. 015: LS-EPC solenoid current)
1 tive
V22 (male) Resistance value
(Internal short-circuiting)
Between (1) and (2) 7 – 14 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
Disconnection of wiring tion during the troubleshooting.
harness
Between wiring harness between C03 (female) (6) and Resistance
2 (Disconnection or defec- Max. 1 z
V22 (female) (1) and grounding value
tive contact with connec-
tor) Wiring harness between C03 (female) (3) (13) (23) and Resistance
Max. 1 z
V22 (female) (2) value
Short-circuiting of wiring a Turn the engine starting switch OFF for the preparations, and hold it in the ON position
harness during the troubleshooting.
3
(Contact with 24 V cir- Between wiring harness between C03 (female) (6) and
cuit) Voltage Max. 1 V
V22 (female) (1) and grounding
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
Governor • pump tion during the troubleshooting.
4
controller defective C03 (female) Resistance value
Between (6) and (3) (13) (23) 7 – 14 z
PC200/220(LC)-7 20-345
(5)
BACK
TROUBLESHOOTING E224
User Code Service Code Failure Code Failure Abnormality in F pump pressure sensor
— E224 DHPAMA phenomenon (in governor • pump controller system)
Failure content • Signal voltage from the F pump pressure sensor dropped below 0.3 V or exceeded 4.72 V.
Response from • The controller controls the F pump pressure at 0 MPa{0 kg/cm2}.
controller • If the failure cause disappears, the sensor returns to normalcy of itself.
Phenomenon
occurring on • The travel speed does not shift automatically.
machine
Relative • Input from the F pump pressure sensor (pressure) can be confirmed in the monitor function.
information (Code No. 011: F pump pressure)
20-346 PC200/220(LC)-7
(5)
BACK
TROUBLESHOOTING E224
Electrical Circuit Diagram for F Pump Pressure Sensor in Governor • Pump Controller
PC200/220(LC)-7 20-347
(1)
BACK
TROUBLESHOOTING E225
User Code Service Code Failure Code Failure Abnormality in R pump pressure sensor
— E225 DHPBMA phenomenon (in governor • pump controller system)
Failure content • Signal voltage from the R pump pressure sensor dropped below 0.3 V or exceeded 4.42 V.
Response from • The controller controls the R pump pressure as 0 MPa {0 kg/cm2}.
controller • If the failure cause disappears, the sensor returns to normalcy of itself.
Phenomenon
occurring on • The travel speed does not shift automatically.
machine
Relative • Input from the R pump pressure sensor (pressure) can be confirmed in the monitor function.
information (Code No. 012: R pump pressure)
20-348 PC200/220(LC)-7
(5)
BACK
TROUBLESHOOTING E225
Electrical Circuit Diagram for R Pump Pressure Sensor in Governor • Pump Controller
PC200/220(LC)-7 20-349
(1)
BACK
TROUBLESHOOTING E226
Service Code in Electrical System E226 (Abnormality in pressure sensor power source)
User Code Service Code Failure Code Failure Abnormality in pressure sensor power source
— E226 DA25KP phenomenon (in governor • pump controller system)
Failure content • Abnormal current flew to the power source circuit (5 V) for the pressure sensors and potentiometer.
• The controller turns OFF power supply to the power source circuit (5 V).
Response from
• Even when the failure cause disappears of itself, the current does not return to normalcy, unless the en-
controller
gine starting switch is once turned OFF.
Phenomenon • Signals from the pressure sensors and potentiometer are not inputted correctly.
occurring on • The Service Code of "pressure sensor abnormal" and that of "potentiometer abnormal" are displayed at
machine the same time.
20-350 PC200/220(LC)-7
(5)
BACK
TROUBLESHOOTING E226
Electrical Circuit Diagram for Sensor Power Source in Governor • Pump Controller
PC200/220(LC)-7 20-351
(1)
BACK
TROUBLESHOOTING E227
User Code Service Code Failure Code Failure Abnormality in engine rotation sensor
— E227 DLE2MA phenomenon (in governor • pump controller system)
Failure content • A normal pulse signal is not inputted to the signal circuit in the engine rotation sensor.
Response from • The controller exercises a control equivalent to E mode.
controller • If the failure cause disappears of itself, the signal input returns to normalcy.
Phenomenon
occurring on • The machine lacks power a bit.
machine
Relative • Input from the engine rotation sensor (rpm) can be confirmed in the monitor function.
information (Code No. 010: Engine RPM)
or disconnection)
Between (1) and grounding Min. 1 Mz
Engine rotation sensor For the inspection and adjustment, refer to the section of "Adjusting Engine Rotation
2
adjustment improper Sensor" in this manual.
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
Disconnection of wiring tion during the troubleshooting.
harness
Wiring harness between C02 (female) (40) and E04 Resistance
3 (Disconnection or defec- Max. 1 z
(female) (1) value
tive contact with connec-
tor) Wiring harness between C02 (female) (29) (39) and E04 Resistance
Max. 1 z
(female) (2) value
Short-circuiting of wiring a Turn the engine starting switch OFF for the preparations, and hold it in the ON position
harness during the troubleshooting.
4
(Contact with 24 V cir- Between wiring harness between C02 (female) (40) and
cuit) Voltage Max. 1 V
E04 (female) (1) and grounding
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position
during the troubleshooting.
Governor • pump C02 (female) Resistance value
5
controller defective
Between (40) and (29) (39) 500 – 1,000 z
Between (40) and grounding Min. 1 Mz
Electrical Circuit Diagram for Engine Rotation Sensor of Governor • Pump Controller
20-352 PC200/220(LC)-7
(5)
BACK
TROUBLESHOOTING E228
User Code Service Code Failure Code Failure Short-circuiting in attachment return switching relay
— E228 D196KB phenomenon (in governor • pump controller system)
Failure content • Abnormal current flew to the attachment return switching relay circuit , when it was grounded (power ON).
Response from • The controller turned OFF power to the attachment return switching relay circuit.
controller • Even when the failure cause disappears of itself, the current does not return to normalcy.
Phenomenon
• The hydraulic circuit for attachments is not switched to the single operation circuit.
occurring on
(The switching valve is not switched to the tank circuit)
machine
• It can be confirmed in the monitor function how the attachment return switching relay circuit works (ON
Relative or OFF). (Code No. 024:Solenoid 2)
information • This error code detects abnormality on the primary side (coil side) of the attachment return selector relay
and cannot detect abnormality on the secondary side (contact side).
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
Attachment return tion during the troubleshooting.
1 switching relay defective
R20 (male) Resistance value
(Internal short-circuiting)
Between (1) and (2) 100 – 500 z
Short-circuiting of wiring a Turn the engine starting switch OFF for the preparations, and hold it in the ON position
harness during the troubleshooting.
2
(Contact with 24 V cir- Between wiring harness between C02 (female) (8) and
cuit) Voltage Max. 1 V
R20 (female) (2) and grounding
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position
during the troubleshooting.
Governor • pump C03 Working mode Voltage
3
controller defective Other than B mode 20 – 30 V
Between (8) and grounding
B mode Max. 1 V
Electrical Circuit Diagram for Attachment Return Switching Relay and Solenoid
PC200/220(LC)-7 20-353
(5)
BACK
TROUBLESHOOTING E232
User Code Service Code Failure Code Failure Disconnection in PC-EPC solenoid
E02 E232 DXA0KB phenomenon (in governor • pump controller system)
Failure content • Abnormal current flew to the PC-EPC solenoid circuit.
• The controller reduces the output to the PC-EPC solenoid circuit to 0.
Response from
• Even if the failure cause disappears, the current does not return to normalcy, unless the engine starting
controller
switch is once turned OFF.
Phenomenon
• As load to the pump increases, the engine rotation drops sharply and sometimes the engine stalls.
occurring on
(The pump absorption torque cannot be controlled)
machine
• Output to PC-EPC solenoid (ampere) can be confirmed in the monitor function.
(Code No. 013: PC-EPC solenoid current)
Relative • If there is no abnormality with the solenoid or any of the wiring harnesses, the machine can be operated
information in a working mode equivalent to E mode by turning the emergency drive switch ON.
(At that time the monitor panel continues to display service code No. [E232], but this is not abnormal)
a Turn the emergency driving switch ON during the troubleshooting.
or grounding fault)
Between (1) and grounding Min. 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
tion during the troubleshooting.
Emergency pump driving
switch defective Emergency pump
2 S25 (male) Resistance value
(Internal short-circuiting drive switch
or grounding fault) Between (3) and (4) Min. 1 Mz
Normal
Between (3) and grounding Min. 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
Grounding fault of wiring tion during the troubleshooting.
harness Between wiring harness from C03 (female) (16) to S25 Resistance
3 Min. 1 Mz
(Contact with grounding (female) (3) and grounding value
circuit) Between wiring harness from S25 (female) (2) to V21 Resistance
Min. 1 Mz
(female) (1) and grounding value
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
tion during the troubleshooting.
Governor • pump C03 (female) Resistance value
4
controller defective
Between (16) and (3) (13) (23) 7 – 14 z
Between (16) and grounding Min. 1 Mz
20-354 PC200/220(LC)-7
(5)
BACK
TROUBLESHOOTING E232
PC200/220(LC)-7 20-355
(1)
BACK
TROUBLESHOOTING E233
User Code Service Code Failure Code Failure Disconnection in PC-EPC solenoid
E02 E233 DXA0KA phenomenon (in governor • pump controller system)
Failure content • No current flows to the PC-EPC solenoid circuit.
Response from • None in particular (The solenoid does not function as there is no current flowing to it)
controller • When the failure cause disappears of itself, the current returns to normalcy.
Phenomenon
• As load to the pump increases, the engine rotation drops sharply and sometimes the engine stalls.
occurring on
(The pump absorption torque cannot be controlled)
machine
• Output to PC-EPC solenoid (ampere) can be confirmed in the monitor function.
(Code No. 013: PC-EPC solenoid current)
Relative
• If there is no abnormality with the solenoid or any of the wiring harnesses, the machine can be operated
information
in a working mode equivalent to E mode by turning the emergency driving switch ON. (At that time the
monitor panel continues to display Service Code No. [E233], but this is not abnormal)
20-356 PC200/220(LC)-7
(5)
BACK
TROUBLESHOOTING E233
PC200/220(LC)-7 20-357
(1)
BACK
TROUBLESHOOTING E238
User Code Service Code Failure Code Failure Disconnection in attachment return switching relay
— E238 D196KA phenomenon (in governor • pump controller system)
• When the attachment switching relay circuit is disconnected from grounding (power OFF), 24 V voltage
Failure content
is not generated.
Response from • None in particular
controller • If the failure cause disappears, the governor returns to normalcy.
Phenomenon
• The hydraulic circuit for attachments cannot be switched to the single operation
occurring on
(The switch valve cannot be switched to the tank circuit)
machine
• It can be confirmed in the monitor function how the attachment return switching relay circuit works (ON
Relative or OFF). (Code No. 024:Solenoid 2)
information This error code detects abnormality on the primary side (coil side) of the attachment return selector relay
and cannot detect abnormality on the secondary side (contact side).
20-358 PC200/220(LC)-7
(5)
BACK
TROUBLESHOOTING E238
Electrical Circuit Diagram for Attachment Return Switching Relay and Solenoid in Governor • Pump
Controller
PC200/220(LC)-7 20-359
(1)
BACK
TROUBLESHOOTING E245
User Code Service Code Failure Code Failure Short-circuiting in attachment oil flow rate adjusting
— E245 DXE4KB phenomenon EPC (in governor • pump controller system)
Failure content • Abnormal current flew to the attachment oil flow rate adjusting EPC solenoid circuit.
• The controller reduces to zero (0) power to the attachment oil flow rate adjusting EPC solenoid circuit.
Response from
• Even when the failure cause disappears, the EPC solenoid circuit does not return to normalcy, unless
controller
the engine starting switch is once turned OFF.
Phenomenon
occurring on • The attachments do not move. (The PPC source pressure is not supplied to the service PPC valve)
machine
Relative • It can be confirmed in the monitor function how power (ampere) is supplied to the attachment oil flow
information rate adjusting EPC solenoid circuit. (Code No. 017: Service solenoid current)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
Attachment oil flow rate tion during the troubleshooting.
adjusting EPC defective V30 (male) Resistance value
1
(Internal short-circuiting
or grounding fault) Between (1) and (2) 7 – 14 z
Between (1) and grounding Min. 1 Mz
Grounding fault of wiring a Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
harness tion during the troubleshooting.
2
(Contact with grounding Between wiring harness between C03 (female) (26) and Resistance
circuit) Min. 1 Mz
V30 (female) (1) and grounding value
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
tion during the troubleshooting.
Governor • pump C03 (female) Resistance value
3
controller defective
Between (26) and (3) (13) (23) 7 – 14 z
Between (26) and grounding Min. 1 Mz
Electrical Circuit Diagram for Attachment Oil Flow Rate Adjusting EPC Solenoid in Governor • Pump
Controller
20-360 PC200/220(LC)-7
(5)
BACK
TROUBLESHOOTING E246
User Code Service Code Failure Code Failure Disconnection in attachment oil flow rate adjusting
— E246 DXE4KA phenomenon EPC (in governor • pump controller system)
Failure content • No current flew to the attachment oil flow rate adjusting EPC solenoid circuit.
Response from • None in particular (The solenoid does not work, as there is no current flowing to it)
controller • If the failure cause disappears, the EPC solenoid circuit returns to normalcy of itself.
Phenomenon
occurring on • The attachments do not move. (The PPC source pressure is not supplied to the service PPC valve)
machine
Relative • It can be confirmed in the monitor function how power (ampere) is supplied to the attachment oil flow
information rate adjusting EPC solenoid circuit. (Code No. 017: Service solenoid current)
Attachment oil flow rate a Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
tion during the troubleshooting.
Presumed cause and standard value in normalcy
Electrical Circuit Diagram for Attachment Oil Flow Rate Adjusting EPC Solenoid in Governor • Pump
Controller
PC200/220(LC)-7 20-361
(5)
BACK
TROUBLESHOOTING E256
User Code Service Code Failure Code Failure Incorrect nonvolatile memory data
— E256 DA20KT phenomenon (in governor • pump controller)
Failure content • The data in the nonvolatile memory in the controller cannot be updated.
• None in particular
Response from
• Even if the failure cause disappears, the nonvolatile memory does not return to normalcy, unless the
controller
engine starting switch is once turned OFF.
Phenomenon
• In some cases control parameters of the machines change, resulting in increase or decrease of the ma-
occurring on
chine's power.
machine
Relative
• Recorded in the nonvolatile memory are part of the machine control parameters
information
20-362 PC200/220(LC)-7
(1)
BACK
TROUBLESHOOTING E306
User Code Service Code Failure Code Failure Abnormality in governor potentiometer
— E306 DK54KZ phenomenon (in governor • pump controller)
Failure content • Signal voltage from the governor potentiometer dropped below 0.4 V or exceeded 4.6 V.
• The controller exercises control by computing the motor position through voltage right before a failure
Response from occurred.
controller • Even if the failure cause disappears of itself, the governor potentiometer does not return to normalcy,
unless the engine starting switch is once turned OFF.
• The engine cannot attain the specified rotation at high idle. (A bit lower)
• The engine cannot attain the specified rotation at low idle (A bit higher)
Phenomenon
• The auto-decelerator or automatic warming-up function does not work.
occurring on
• There is hunting while the engine is running.
machine
• The engine stalls.
• The engine does not stop.
Relative • Input from the governor potentiometer (voltage) can be confirmed in the monitor function.
information (Code No. 031: Governor potentiometer voltage)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
tion during the troubleshooting.
Disconnection of wiring Wiring harness from C01 (female) (22) to J07 to E10 Resistance
harness Max. 1 z
(female) (A) value
3 (Disconnection or defec-
tive contact with connec- Wiring harness between C01 (female) (21) and E10 Resistance
Max. 1 z
tor) (female) (C) value
Wiring harness between C01 (female) (13) and E10 Resistance
Max. 1 z
(female) (B) value
Grounding fault of wiring a Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
harness tion during the troubleshooting.
4
(Contact with grounding Between wiring harness between C01 (female) (13) and Resistance
circuit) Min. 1 Mz
E10 (female) (B) and grounding value
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position
Short-circuiting of wiring during the troubleshooting.
harness Between wiring harness from C01 (female) (22) to J07 to
5 Voltage Max. 1 V
(Contact with 24 V cir- E10 (female) (A) and grounding
cuit) Between wiring harness between C01 (female) (13) and
Voltage Max. 1 V
E10 (female) (B) and grounding
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position
during the troubleshooting.
Governor • pump C01 Resistance value
6
controller defective
Between (22) and (21) Power supply 4.5 – 5.5 V
Between (13) and (21) Signal 0.5 – 4.5 V
20-364 PC200/220(LC)-7
(11)
BACK
TROUBLESHOOTING E306
PC200/220(LC)-7 20-365
(1)
BACK
TROUBLESHOOTING E308
User Code Service Code Failure Code Failure Abnormality in fuel dial
E05 E308 DK10KZ phenomenon (in governor • pump controller)
Failure content • Signal voltage from the from fuel dropped below 0.23 V or exceeded 4.77 V.
• The controller exercises control by computing the fuel dial position through voltage right before a failure
Response from
occurred.
controller
• If the failure cause disappears, the fuel dial returns to normalcy.
• If the fuel dial had been set at FULL before a failure occurred, it does not change to PARTIAL.
Phenomenon
• If the fuel dial had been set at PARTIALLY before a failure occurred, it does not change to FULL.
occurring on
• There is hunting while the engine is running.
machine
• The engine cannot attain the specified rotation at high idle and lacks power.
Relative • Input from the fuel dial (voltage) can be confirmed in the monitor function.
information (Code No. 030: Fuel dial voltage)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
tion during the troubleshooting.
Disconnection of wiring Wiring harness from C01 (female) (22) to J07 to E06 Resistance
harness Max. 1 z
(female) (1) value
3 (Disconnection or defec-
tive contact with connec- Wiring harness between C01 (female) (21) and E06 Resistance
Max. 1 z
tor) (female) (3) value
Wiring harness between C01 (female) (19) and E06 Resistance
Max. 1 z
(female) (2) value
Grounding fault of wiring a Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
harness tion during the troubleshooting.
4
(Contact with grounding Between wiring harness between C01 (female) (19) and Resistance
circuit) Min. 1 Mz
E06 (female) (2) and grounding value
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position
Short-circuiting of wiring during the troubleshooting.
harness Between wiring harness from C01 (female) (22) to J07 to
5 Voltage Max. 1 V
(Contact with 24 V cir- E06 (female) (1) and grounding
cuit) Between wiring harness between C01 (female) (19) and
Voltage Max. 1 V
E06 (female) (2) and grounding
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position
during the troubleshooting.
Governor • pump C01 Resistance value
6
controller defective
Between (22) and (21) Power supply 4.5 – 5.5 V
Between (19) and (21) Signal 0.5 – 4.5 V
20-366 PC200/220(LC)-7
(11)
BACK
TROUBLESHOOTING E308
PC200/220(LC)-7 20-367
(1)
BACK
TROUBLESHOOTING E315
User Code Service Code Failure Code Failure Short-circuiting in battery relay
— E315 D110KB phenomenon (in governor • pump controller)
Failure content • Abnormal current flew to the battery relay drive circuit, when power was supplied to the circuit.
• The controller turns OFF power to the battery drive circuit.
Response from
• Even when the failure cause disappears, the relay does not return to normalcy, unless the engine start-
controller
ing switch is once turned OFF.
Phenomenon
occurring on • The engine does not stop.
machine
Relative • It can be confirmed in the monitor function how the battery relay works (ON or OFF).
information (Code No. 037: Controller output)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
tion during the troubleshooting.
Battery relay defective Battery relay Continuity & Resistance value
1
(Internal failure) Between A21 (BR terminal) and A20 (E
Continued
terminal)
Between A21 (BR terminal) and grounding Min. 1 Mz
Grounding fault of wiring a Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
harness tion during the troubleshooting.
2
(Contact with grounding Between wiring harness from C03 (female) (4) to D01 to Resistance
circuit) Min. 1 Mz
J01 to A21 (BR terminal) and grounding value
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position
during the troubleshooting.
Governor • pump
3 C03 Engine starting switch Voltage
controller defective
20 – 30 V
Between (4) and grounding ON o OFF
(for 4 to 7 seconds)
20-368 PC200/220(LC)-7
(5)
BACK
PC200/220(LC)-7 20-369
BACK
User Code Service Code Failure Code Failure Step-out in governor motor
— E316 DY10K4 phenomenon (in governor • pump controller)
Failure content • There is a big difference between signals from the potentiometer and the set values in the controller.
• The controller repeats the same controlling motions (step-out).
Response from
• Even when the failure cause disappears, the governor motor does not return to normalcy, unless the
controller
engine starting switch is once turned OFF.
Phenomenon • The engine rotation cannot be controlled.
occurring on • There is hunting in the rotation.
machine • The engine does not stop.
1 Fuel dial defective If Service Code [E308] is displayed, troubleshoot that failure first.
2 Governor potentiometer defective If Service Code [E306] is displayed, troubleshoot that failure first.
value in normalcy
3 Governor motor defective (disconnection) If Service Code [E317] is displayed, troubleshoot that failure first.
4 Governor motor defective (short-circuiting) If Service Code [E318] is displayed, troubleshoot that failure first.
Refer to the section of "Inspection and Adjustment - Special Func-
5 Governor lever adjustment improper
tion of Monitor Panel" in this manual.
6 Engine fuel control system defective Refer to Engine Shop Manual.
As this is an internal failure, no troubleshooting can be carried out.
7 Governor • pump controller defective (If there is none of the failures listed above, the controller is judged
as defective)
20-370 PC200/220(LC)-7
BACK
TROUBLESHOOTING E317
Service Code in Electrical System E317 (Disconnection in governor motor Phase A and B)
User Code Service Code Failure Code Failure Disconnection in governor motor Phase A and B
E05 E317 DY10KA phenomenon (in governor • pump controller)
Failure content • No current flew to the governor motor, when power was supplied to the motor.
Response from • None in particular.
controller • If the failure cause disappears, the governor returns to normalcy.
• The engine rotation drops to low idle.
Phenomenon
• There is hunting in the rotation
occurring on
• The engine does not stop.
machine
• The governor motor steps out.
Relative • Operation of the governor motor (current) can be confirmed in the monitor function.
information (Code No. 033: Governor motor Phase A current, Code No. 034: Governor motor Phase B current)
20-372 PC200/220(LC)-7
(11)
BACK
TROUBLESHOOTING E317
PC200/220(LC)-7 20-373
(1)
BACK
TROUBLESHOOTING E318
User Code Service Code Failure Code Failure Disconnection in governor motor Phase A and
E05 E318 DY10KB phenomenon Phase B (in governor • pump controller system)
Failure content • Abnormal current flew to the governor motor, when power is supplied to the motor.
Response from • None in particular
controller • If the failure cause disappears, the governor motor returns to normalcy.
• The engine rotation cannot be controlled.
Phenomenon
• The engine rotation drops to low idle.
occurring on
• There is hunting in the rotation.
machine
• The engine does not stop.
Relative • Operation of the governor motor (current) can be confirmed in the monitor function.
information (Code No. 033: Governor motor Phase A current, Code No. 034: Governor motor Phase B current)
20-374 PC200/220(LC)-7
(11)
BACK
PC200/220(LC)-7 20-375
BACK
Service Code in Electrical System E501 ("Model Selection" function not provided yet)
User Code Service Code Failure Code Failure "Model Selection" function not provided yet
— E501 DA2AKM phenomenon (in governor • pump controller system)
Failure content • Model Code is not inputted yet.
• Model data and rated load cannot be set.
Response from
• Even when the failure cause disappears, Service Code does not return to normalcy, unless the engine
controller
starting switch is once turned OFF.
Phenomenon
occurring on • The excess load alarm does not work normally.
machine
Relative • Model names that the controller recognizes (figure) can be confirmed in the monitor function.
information (Code No. 150: Model Code)
20-376 PC200/220(LC)-7
BACK
User Code Service Code Failure Code Failure Model selecting signal fault
— E502 DA20KT phenomenon (in governor • pump controller system)
Failure content • Information on the models stored in the controller have been damaged.
• Model data and rated load cannot be set.
Response from
• Even when the failure cause disappears, the signal does not return to normal, unless the engine starting
controller
switch is once turned OFF.
Phenomenon
occurring on • The excess load alarm does not work normally.
machine
Relative • (Model names that the controller recognizes (figure) can be confirmed in the monitor function.
information (Code No. 150: Model Code)
PC200/220(LC)-7 20-377
(1)
BACK
Failure Code in Mechanical System A000N1 (Out-of-rate engine rotation at high idle)
User Code Service Code Failure Code Failure Engine rotation at high idle out of rate
— — A000N1 phenomenon (in mechanical system)
Failure content • Engine rotation above 2,350 rpm was detected for more than 10 seconds, while the engine was running.
Response from • None in particular
controller • If the failure cause disappears of itself, the engine rotation returns to normalcy.
Phenomenon
occurring on • There is a possibility that the engine is damaged, if is used continuously without adjustment.
machine
Relative • Input from the engine rotation sensor (rpm) can be confirmed in the monitor function.
information (Code No. 010: Engine rotation)
Failure Code in Mechanical System A000N2 (Out-of-rate engine rotation at low idle)
User Code Service Code Failure Code Failure Out-of-rate engine rotation at low idle
— — A000N2 phenomenon (in mechanical system)
Failure content • Engine rotation below 500 rpm was detected for more than 10 seconds, while the engine was running.
Response from • None in particular
controller • If the failure cause disappears of itself, the rotation returns to normalcy.
Phenomenon
occurring on • There is a possibility that the engine is damaged, if it is used continuously without adjustment.
machine
Relative • Input from the engine rotation sensor (rpm) can be confirmed in the monitor function.
information (Code No. 010: Engine rotation)
20-378 PC200/220(LC)-7
(11)
BACK
TROUBLESHOOTING AA10NX
User Code Service Code Failure Code Failure Air cleaner clogged
— — AA10NX phenomenon (in mechanical system)
• While the engine was running, the signal circuit in the air cleaner clogging switch was opened (i.e. dis-
Failure content
connected from grounding circuit).
Response from
• None in particular
monitor panel
Phenomenon
occurring on • There is a possibility that the engine is damaged, if it is used continuously without corrective action.
machine
• This Failure Code is recorded, when the air cleaner clogging caution symbol is displayed in the monitor
Relative panel while the engine is running.
information • Input from the air cleaner clogging switch (ON or OFF) can be confirmed in the monitor panel.
(Code No. 046: Monitor input 2)
normal condition)
a Turn the engine starting switch OFF for the preparations, and keep the engine running
during the troubleshooting.
Air cleaner clogging
2 switch defective A31 (male) Air cleaner Resistance value
(Internal disconnection) When in normal condition Max. 1 z
Between (1) and (2)
When clogged Min. 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it running during the
Disconnection of wiring troubleshooting.
harness
Wiring harness between P02 (female) (5) and A31 Resistance
3 (Disconnection or defec- Max. 1 z
(female) (1) value
tive contact with connec-
tor) Resistance
Between wiring harness A31 (female) (2) and grounding Max. 1 z
value
a Turn the engine starting switch OFF for the preparations, and keep the engine running
during the troubleshooting.
4 Monitor panel defective P02 Air cleaner Voltage
When in normal condition Max. 1 V
Between (5) and grounding
When clogged 20 – 30 V
PC200/220(LC)-7 20-379
(5)
BACK
TROUBLESHOOTING AB00KE
User Code Service Code Failure Code Failure Charging voltage abnormally lowered
— — AB00KE phenomenon (in mechanical system)
Failure content • Generation signal from the alternator is not inputted, while the engine is running.
Response from
• None in particular
monitor panel
Phenomenon
• There is a possibility that the battery may not be charged, if charging is continued without corrective
occurring on
action.
machine
• This Failure Code is recorded, if the charging caution symbol is displayed in the monitor panel, while the
Relative engine is running.
information • Input from the alternator (voltage) can be confirmed in the monitor function.
(Code No. 043: Charging voltage)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
Grounding fault of wiring tion during the troubleshooting.
harness
3 Wiring harness from P02 (female) (11) to J02 to E12
(Contact with grounding Resistance
circuit) (female) (1), or between P02 (female) (11) and D01 (female) Min. 1 Mz
value
(6), or between P02 (female) (11) and A27 (female) (2)
a Turn the engine starting switch OFF for the preparations, and keep the engine running
during the troubleshooting.
4 Monitor panel defective
P02 Engine rotation Voltage
Between (11) and grounding Above medium speed 27.5 – 29.5 V
20-380 PC200/220(LC)-7
(5)
BACK
TROUBLESHOOTING AB00KE
Electrical Circuit Diagram for Engine Start, Stop and Charging in Monitor Panel
PC200, 200LC-7 Serial No. 200001 – 250000
PC220, 220LC-7 Serial No. 60001 – 65000
PC200/220(LC)-7 20-381
(5)
BACK
TROUBLESHOOTING AB00KE
Electrical Circuit Diagram for Engine Start, Stop and Charging in Monitor Panel
PC200, 200LC-7 Serial No. 250001 and up
PC220, 220LC-7 Serial No. 65001 and up
20-381-1 PC200/220(LC)-7
(8)
BACK
TROUBLESHOOTING B@BAZG
Failure Code in Mechanical System B@BAZG (Abnormally lowered engine oil pressure)
User Code Service Code Failure Code Failure Engine oil pressure abnormally lowered
— — B@BAZG phenomenon (in mechanical system)
• The signal circuit in the engine oil pressure switch was closed (i.e. connected with grounding), while the
Failure content
engine was running.
Response from
• None in particular
monitor panel
Phenomenon
occurring on • There is a possibility that the engine may seize, if the engine is kept running without corrective action.
machine
• This Failure Code is recorded, if the engine oil pressure caution symbol is displayed in the monitor panel,
Relative while the engine is running.
information • Input from the engine oil pressure switch (ON or OFF) can be confirmed in the monitor function.
(Code No. 046: Monitor input 2)
1 ered (the system in nor- a Check the failure cause and damage to the engine, and then make repairs.
mal condition)
a Turn the engine starting switch OFF for the preparations, and keep the engine running
during the troubleshooting.
Engine oil pressure
2 switch defective E02 (on switch side) Engine oil pressure Resistance value
(Internal short-circuiting) Between terminal and When in normal condition Min. 1 Mz
grounding When lowered Max. 1 z
Grounding fault of wiring a Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
harness tion during the troubleshooting.
3
(Contact with grounding Between wiring harness between P02 (female) (7) and E02 Resistance
circuit) Min. 1 Mz
(terminal) and grounding value
a Turn the engine starting switch OFF for the preparations, and keep the engine running
during the troubleshooting.
4 Monitor panel defective P02 Engine oil pressure Voltage
When in normal condition 20 – 30 V
Between (7) and grounding
When lowered Max. 1 V
Electrical Circuit Diagram for Engine Oil Pressure Switch in Monitor Panel
20-382 PC200/220(LC)-7
(5)
BACK
TROUBLESHOOTING B@BAZK
Failure Code in Mechanical System B@BAZK (Abnormally lowered engine oil level)
User Code Service Code Failure Code Failure Engine oil level abnormally lowered
— — B@BAZK phenomenon (in mechanical system)
• The signal circuit in the engine oil level switch was opened (i.e. disconnected from grounding), when the
Failure content
engine is stopped (with the starting switch in the ON position).
Response from
• None in particular
monitor panel
Phenomenon
occurring on • There is a possibility that the engine seizes if it is kept running without a corrective action.
machine
• This Failure Code is recorded if the engine oil level caution symbol is displayed, when the engine is
Relative stopped (with the starting key in the ON position).
information • Input from the engine oil level switch (ON or OFF) can be confirmed in the monitor function. (Code No.
046: Monitor input 2)
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position
during the troubleshooting.
4 Monitor panel defective P02 Engine oil pressure Voltage
When in normal condition Max. 1 V
Between (8) and grounding
When lowered 20 – 30 V
Electrical Circuit Diagram for Engine Oil Level Switch in Monitor Panel
PC200/220(LC)-7 20-383
(5)
BACK
TROUBLESHOOTING B@BCNS
User Code Service Code Failure Code Failure Engine coolant overheated
— — B@BCNS phenomenon (in mechanical system)
Failure content • The engine coolant sensor inputted a signal of 102°C, while the engine was running.
Response from
• Response from controller
monitor panel
Phenomenon
occurring on • There is a possibility that the engine seizes, if it is kept running without a corrective action.
machine
• This Failure Code is recorded, if the engine coolant temperature gauge is displayed in the red range,
Relative when the engine is running.
information • Input from the engine coolant temperature sensor (temperature) can be confirmed in the monitor func-
tion. (Code No. 041: Engine coolant temperature)
tion)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
tion during the troubleshooting.
Engine coolant tempera- Engine coolant
2 ture sensor defective E05 (male) Resistance value
temperature
(Internal short-circuiting)
Between (1) and (2) 90 – 3.5 kz
10 – 100 °C
Between (2) and grounding Min. 1 Mz
Grounding fault of wiring a Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
harness tion during the troubleshooting.
3
(Contact with grounding Between wiring harness between P02 (female) (1) and Resistance
circuit) Min. 1 Mz
E05 (female) (2) and grounding value
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
tion during the troubleshooting.
Engine coolant
4 Monitor panel defective P02 (female) Resistance value
temperature
Between (1) and (13) 90 – 3.5 kz
10 – 100 °C
Between (1) and grounding Min. 1 Mz
Electrical Circuit Diagram for Engine Coolant Temperature Sensor in Monitor Panel
20-384 PC200/220(LC)-7
(11)
BACK
TROUBLESHOOTING B@BCZK
Failure Code in Mechanical System B@BCZK (Abnormally lowered radiator coolant level)
(Multi-monitor only)
User Code Service Code Failure Code Failure Radiator coolant level abnormally lowered
— — B@BCZK phenomenon (in mechanical system)
Failure content • The signal circuit in the radiator coolant level switch was opened (i.e. disconnected from grounding).
Response from
• None in particular
monitor panel
Phenomenon
occurring on • There is a possibility that the engine seizes, if it is kept running without a corrective action.
machine
• This Failure Code is recorded, if the radiator coolant level caution symbol is displayed in the monitor
Relative panel, when the engine is running.
information • Input from the radiator coolant level switch (ON or OFF) can be confirmed in the monitor function.
(Code No. 045: Monitor input 1)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
tion during the troubleshooting.
Radiator coolant level
2 switch defective A33 (male) Engine coolant level Resistance value
(Internal disconnection) When in normal condition Max. 1 z
Between (1) and (2)
When lowered Min. 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
Disconnection of wiring tion during the troubleshooting.
harness
Wiring harness between P02 (female) (3) and A33 (female) Resistance
3 (Disconnection or defec- Max. 1 z
(1) value
tive contact with connec-
tor) Resistance
Wiring harness between A33 (female) (2) and grounding Max. 1 z
value
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position
during the troubleshooting.
Engine coolant
4 Monitor panel defective P02 Resistance value
temperature
When in normal condition Max. 1 V
Between (3) and grounding
When lowered 20 – 30 V
Electrical Circuit Diagram for Radiator Coolant Level Switch in Monitor Panel
PC200/220(LC)-7 20-385
(11)
BACK
TROUBLESHOOTING B@HANS
1 ing (system in normal a Check the cause and damage to the hydraulic equipment, and repair it.
condition)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
tion during the troubleshooting.
Hydraulic oil temperature
2 sensor defective A61 (male) Hydraulic oil temperature Resistance value
(Internal short-circuiting) Between (1) and (2) 90 – 3.5 kz
10 – 100 °C
Between (2) and grounding Min. 1 Mz
Grounding fault of wiring a Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
harness tion during the troubleshooting.
3
(Contact with grounding Between wiring harness between P02 (female) (12) and Resistance
circuit) Min. 1 Mz
A61 (female) (2) and grounding value
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
tion during the troubleshooting.
4 Monitor panel defective P02 (female) Hydraulic oil temperature Resistance value
Between (12) and (13) 90 – 3.5 kz
10 – 100 °C
Between (12) and grounding Min. 1 Mz
Electrical Circuit Diagram for Hydraulic Oil Temperature Sensor in Monitor Panel
20-386 PC200/220(LC)-7
(5)
TROUBLESHOOTING OF
ELECTRICAL SYSTEM (E-MODE)
PC200/220(LC)-7 20-501
(11)
BACK
Failure
Phenomena occurring on machine
information
Relative
Information on occurred failures and troubleshooting
information
<Contents>
• The standard values in normalcy by which to judge "good" or "no good" about pre-
1 sumed causes.
• References for making judgement of "good" or "no good"
Presumed cause and standard value in normalcy
This is part of the electrical circuit diagram which shows the portion where the failure occurred.
20-502 PC200/220(LC)-7
(1)
BACK
Type of power
Fuse No. Fuse capacity Destination of power
supply
Governor, pump controller (Controller power supply)
1 10A Emergency pump drive resistor
Swing holding brake release switch
PC200/220(LC)-7 20-502-1
(11)
BACK
TROUBLESHOOTING E-1
Failure
• The engine does not start (the engine does not rotate).
information
• The following two engine start locking mechanisms are provided in the engine starting circuit.
Relative
1) Engine start locking by means of password in the monitor panel
information
2) Engine start locking by means of lock lever
PC200/220(LC)-7 20-503
(11)
BACK
TROUBLESHOOTING E-1
value
Resistance
Wiring harness between S14 (female) (3) and R11 (female) (1) Max. 1 z
value
Resistance
Wiring harness between R11 (female) (2) and R13 (female) (6) Max. 1 z
value
Resistance
Wiring harness from R13 (female) (3) to J04 to grounding Max. 1 z
value
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Between wiring harness from battery relay B terminal (A23) Resistance
Min. 1 Mz
to A35 to FB1-18 and grounding value
Between wiring harness between FB1-18 outlet and H15 Resistance
Min. 1 Mz
(female) (1) and grounding value
Between wiring harness from H15 (female) (4) to J01 to R11 Resistance
Min. 1 Mz
Grounding fault of (female) (5) and grounding value
wiring harness Between wiring harness between R11 (female) (3) and A27 Resistance
10 Min. 1 Mz
(Contact with (female) (1) and grounding value
grounding circuit) Between wiring harness between engine starting motor relay C Resistance
Min. 1 Mz
terminal and engine starting motor C terminal and grounding value
Between wiring harness between FB1-3 and S14 (female) (1) Resistance
Min. 1 Mz
and grounding value
Between wiring harness between S14 (female) (3) and R11 Resistance
Min. 1 Mz
(female) (1) and grounding value
Between wiring harness from R13 (female) (2) to J05 to P02 Resistance
Min. 1 Mz
(female) (14) and grounding value
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position
Short-circuiting of during the troubleshooting.
wiring harness Wiring harness between A27 (female) (2) and E12 (female)
11
(Contact with 24 V (1), or wiring harness from A27 (female) (2) to J02 to D01
circuit) Voltage Max. 1 V
(female) (6), or between wiring harness between A27
(female) (2) and P02 (female) (11) and grounding
20-504 PC200/220(LC)-7
(1)
BACK
TROUBLESHOOTING E-1
Electrical Circuit Diagram for Engine Start, Stop and Battery Charging
PC200, 200LC-7 Serial No. 200001 – 250000
PC220, 220LC-7 Serial No. 60001 – 65000
PC200/220(LC)-7 20-505
(7)
BACK
TROUBLESHOOTING E-1
Electrical Circuit Diagram for Engine Start, Stop and Battery Charging
PC200, 200LC-7 Serial No. 250001 and up
PC220, 220LC-7 Serial No. 65001 and up
20-506 PC200/220(LC)-7
(7)
BACK
TROUBLESHOOTING E-2
Failure
• The engine suddenly stopped while in operation.
information
Relative • Input from the governor potentiometer (voltage) can be confirmed in the monitor function.
information (Code No. 031: governor potentiometer voltage)
1 eter fault
Between (A) and (C) 4.0 – 6.0 kz
(Internal failure)
Between (B) and (A) 0.25 – 5.0 kz
Between (B) and (C) 0.25 – 5.0 kz
Disconnection of wir- a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
ing harness during the troubleshooting.
2 (Disconnection or
defective contact Wiring harness between C01 (female) (13) and E10 (female) Resistance
Max. 1 z
with connector) (B) value
Grounding fault of a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
wiring harness during the troubleshooting.
3
(Contact with Between wiring harness between C01 (female) (13) and E10 Resistance
grounding circuit) Min. 1 Mz
(female) (B) and grounding value
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position
during the troubleshooting.
Governor • pump C01 Voltage
4
controller defective
Between (22) and (21) 4.5 – 5.5 V
Between (13) and (21) 0.5 – 4.5 V
PC200/220(LC)-7 20-507
(5)
BACK
TROUBLESHOOTING E-3
Grounding fault of a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
wiring harness during the troubleshooting.
6
(Contact with Between wiring harness between C01 (female) (23) to J17 Resistance
grounding circuit) Min. 1 Mz
and H15 (female) (5) and grounding value
Governor • pump As this is an internal failure, troubleshooting cannot be conducted.
7
controller defective (If there is none of the causes from Item 1 to 6 above, the controller is judged as defective)
20-508 PC200/220(LC)-7
(11)
BACK
TROUBLESHOOTING E-3
Electrical Circuit Diagram for Engine Start and Stop and Battery Charging
PC200, 200LC-7 Serial No. 200001 – 250000
PC220, 220LC-7 Serial No. 60001 – 65000
PC200/220(LC)-7 20-509
(7)
BACK
TROUBLESHOOTING E-3
Electrical Circuit Diagram for Engine Start and Stop and Battery Charging
PC200, 200LC-7 Serial No. 250001 and up
PC220, 220LC-7 Serial No. 65001 and up
20-509-1 PC200/220(LC)-7
(7)
BACK
TROUBLESHOOTING E-4
Failure
• The engine does not stop.
information
• The Governor • pump controller drives the battery relay for the min. 4 seconds and max. 7 seconds from
Relative the moment the engine starting switch is turned OFF to the moment the engine completely stops.
information • It can be confirmed in the monitor function how the battery relay works (ON or OFF)
(Code No. 037: Controller output)
Assembled-type a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
diode D01 fault during the troubleshooting.
2
(Internal disconnec- D01 (male) Digital type circuit tester Continuity
tion) Between (5) and (1) Diode mode Continued
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Disconnection of wir- Wiring harness between C03 (female) (4) and D01 (female) Resistance
ing harness Max. 1 z
(5) value
3 (Disconnection or
defective contact Wiring harness from D01 (female) (1) to J01 to battery relay Resistance
Max. 1 z
with connector) BR terminal (A21) value
Wiring harness between battery relay E terminal (A20) and Resistance
Max. 1 z
grounding value
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position
during the troubleshooting.
Governor • pump
4 C03 Engine starting switch Voltage
controller defective
20 – 30 V
Between (4) and grounding ONoOFF
(for 4 to 7 seconds)
20-510 PC200/220(LC)-7
(5)
BACK
TROUBLESHOOTING E-4
Electrical Circuit Diagram for Engine Start and Stop and Battery Charging
PC200, 200LC-7 Serial No. 200001 – 250000
PC220, 220LC-7 Serial No. 60001 – 65000
PC200/220(LC)-7 20-511
(5)
BACK
TROUBLESHOOTING E-4
Electrical Circuit Diagram for Engine Start and Stop and Battery Charging
PC200, 200LC-7 Serial No. 250001 and up
PC220, 220LC-7 Serial No. 65001 and up
20-511-1 PC200/220(LC)-7
(7)
BACK
TROUBLESHOOTING E-5
Failure
• The auto-decelerator does not work.
information
• Rotation of the auto-decelerator is set at 1,400 rpm. If the fuel dial is not set adjusting to this level, the
Relative
auto-decelerator does not work.
information
• Confirm the display on the monitor panel, when the engine is running.
20-512 PC200/220(LC)-7
(5)
BACK
TROUBLESHOOTING E-6
Failure
• The auto engine warm-up device does not work.
information
• The auto engine warm-up device is activated, when the engine coolant temperature is below 30°C, and
Relative raise the engine rotation up to 1,200 rpm.
information • The auto engine warm-up device is released by keeping the fuel dial opening at above 70% for more
than 3 seconds, when the engine starting switch is in the ON position or after the engine is started.
If the display on the monitor panel is not normal, proceed to No. E-14
Troubleshooting.
value in normalcy
Engine coolant
Monitoring code Item Normal display
1 temperature signal
fault Compare with the actual
Engine coolant
041 engine coolant
temperature
temperature.
As this is an internal failure, troubleshooting cannot be conducted.
Governor • pump
2 (If the fault mentioned in the above item is not found, the Governor • pump controller is
controller defective
judged as defective)
PC200/220(LC)-7 20-513
(11)
BACK
TROUBLESHOOTING E-7
Failure • Even if the preheater switch is turned to the PREHEAT position, the preheating monitor lamp does not
information (1) light up.
Relative • Input of the preheating signal (ON or OFF) can be confirmed in the monitor function.
information (Code No. 045: Monitor input 1)
1
switch fault non (2) below.
Disconnection of wir- a Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
value in normalcy
Failure
• Even if the preheater switch is turned to the PREHEAT position, the preheater does not become warm.
information (2)
Relative • In low coolant temperature (lower than 30°C), the governor • pump controller drives the heater relay for
information 100 seconds after the engine is started and automatically warms up the engine.
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
tion during the troubleshooting.
Heater relay fault
value in normalcy
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
Disconnection of wir- tion during the troubleshooting.
ing harness
Wiring harness from H15 (female) to J02 to heater Resistance
4 (Disconnection or Max. 1 z
relay terminal (A25) value
defective contact
with connector) Wiring harness between battery relay M terminal (A22) Resistance
Max. 1 z
and heater relay terminal value
20-514 PC200/220(LC)-7
(11)
BACK
TROUBLESHOOTING E-7
PC200/220(LC)-7 20-515
(1)
BACK
TROUBLESHOOTING E-8
Failure
• All the work equipment, swing and travel do not move.
information
Relative
—
information
Assembled-type a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
diode D01 fault during the troubleshooting.
4
(Internal short-cir- D01 (male) Resistance value
cuiting) Between (8) and (4) Min. 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Disconnection of wir- Resistance
ing harness Wiring harness between FB1-3 outlet and S14 (male) (1) Max. 1 z
value
5 (Disconnection or
defective contact Resistance
Wiring harness from S14 (male) (2) to J02 to V01 (female) (1) Max. 1 z
with connector) value
Resistance
Wiring harness between V01 (female) (2) and grounding Max. 1 z
value
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Grounding fault of during the troubleshooting.
wiring harness Between wiring harness between FB1-3 outlet and S14 Resistance
Min. 1 Mz
6 (Contact with (male) (1) and grounding value
grounding (GND) Wiring harness from S14 (male) (2) to J02 to V01 (female)
circuit) Resistance
(1), or between wiring harness between S14 (male) (2) and Min. 1 Mz
value
D01 (female) (8) and grounding
20-516 PC200/220(LC)-7
(11)
BACK
TROUBLESHOOTING E-8
PC200/220(LC)-7 20-517
(11)
BACK
TROUBLESHOOTING E-9
Failure
• The one-touch power maximizing function does not work.
information
• If the knob switch is pressed while the engine is running, the symbol mark is displayed in the monitor
Relative
panel.
information
• Input from the knob switch can be confirmed in the monitor function. (Code No. 022: Switch input 1)
(Internal disconnec-
tion) Release Min. 1 Mz
Between (1) and (2)
Depress Max. 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Disconnection of wir- during the troubleshooting.
ing harness
Resistance
3 (Disconnection or Wiring harness between FB1-9 outlet and M23 (female) (1) Max. 1 z
value
defective contact
with connector) Wiring harness between M23 (female) (2) and C01 (female) Resistance
Max. 1 z
(11) value
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Grounding fault of during the troubleshooting.
wiring harness
Between wiring harness between FB1-9 outlet and M23 Resistance
4 (Contact with Min. 1 Mz
(female) (1) and grounding value
grounding (GND)
circuit) Between wiring harness between M23 (female) (2) and C01 Resistance
Min. 1 Mz
(female) (11) and grounding value
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position
during the troubleshooting.
Governor • pump C01 Knob switch Voltage
5
controller defective
Release Max. 1 V
Between (11) and grounding
Depress 20 – 30 V
20-518 PC200/220(LC)-7
(11)
BACK
TROUBLESHOOTING E-10
Failure
• When the engine starting switch is turned ON, there appears no display at all in the monitor panel.
information
Relative
—
information
(Refer to cause 3)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Disconnection of wir- during the troubleshooting.
ing harness
Resistance
2 (Disconnection or Wiring harness from P01 (female) (1) (2) to J07 to FB1-12 Max. 1 z
value
defect contact with
connector) Resistance
Wiring harness between P01 (female) (6) (7) and grounding Max. 1 z
value
Grounding fault of a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
wiring harness during the troubleshooting.
3 (Contact with
grounding (GND) Between wiring harness from P01 (female) (1) (2) to J07 to Resistance
Min. 1 Mz
circuit) FB1-12 outlet and grounding value
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position
during the troubleshooting.
Monitor panel P01 (female) Voltage and resistance value
4
defective
Between (1) (2) and grounding Voltage: 20 – 30 V
Between (6) (7) and grounding Resistance value: Max. 1 z
PC200/220(LC)-7 20-519
(5)
BACK
Failure
• Part of the display in the monitor panel is missing.
information
Relative
—
information
If all the LCD in the monitor panel light up (i.e. the screen becomes totally white) by the
Monitor panel LCD
1 following switching operation, then the monitor panel is normal.
fault
• Switching operation: [ ] + [ A ] (simultaneous switching operation)
Monitor panel As this is an internal failure, troubleshooting cannot be conducted. (If there is no prob-
2
defective lem with the above switching operation, the monitor panel is judged as defective)
Failure
• The monitor panels displays contents that have nothing to do with the model on which it is installed.
information
Relative
—
information
If the display on the monitor panel is normal, proceed to Service Code [E217].
Model code signal
Monitoring code Item Normal display
1 fault
(Internal failure) 002
Controller model code 200
003
Monitor panel As this is an internal failure, troubleshooting cannot be conducted. (If there is no prob-
2
defective lem with the above switching operation, the monitor panel is judged as defective)
20-520 PC200/220(LC)-7
(1)
BACK
TROUBLESHOOTING E-13
E-13 Fuel level monitor red lamp lights up while engine is running
Failure
• The fuel level monitor red lamp lighted up while the engine was running.
information
• If the fuel gauge shows in a red range on the monitor panel, the fuel level monitor lamp lights up red.
Relative
• (5) Input signal from the fuel level sensor (voltage) can be confirmed in the monitor function.
information
(Code No. 042: Fuel level sensor)
condition)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Fuel level sensor during the troubleshooting.
fault A60 (male) Fuel level Resistance value
2
(Internal
disconnection) FULL (Upper limit) Approx. 12 z
Between (1) and grounding
EMPTY (Lower limit) 85 – 110 z
Grounding fault of a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
wiring harness during the troubleshooting.
3 (Contact with
grounding (GND) Wiring harness between P02 (female) (2) and A60 (female) Resistance
Max. 1 z
circuit) (1) value
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Monitor panel P02 (female) Fuel level Resistance value
4
defective
FULL (Upper limit) Approx. 12 z
Between (2) and grounding
EMPTY (Lower limit) 85 – 110 z
PC200/220(LC)-7 20-521
(5)
BACK
TROUBLESHOOTING E-14
Failure • The engine coolant temperature rises normally, but the display does not exceed the white range (C).
information • The engine coolant temperature remains stable, but the display rises to the red range (H).
Relative • Input from the engine coolant temperature sensor can be confirmed in the monitor function.
information (Code No. 041: Engine coolant temperature)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Disconnection of wir- during the troubleshooting.
ing harness
Resistance
2 (Disconnection or Wiring harness between P02 (female) (1) and E05 (female) (2) Max. 1 z
value
defective contact
with connector) Wiring harness between P02 (female) (13) and E05 (female) Resistance
Max. 1 z
(1) value
Grounding fault of a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
wiring harness during the troubleshooting.
3 (Contact with
grounding (GND) Between wiring harness between P02 (female) (1) and E05 Resistance
Min. 1 Mz
circuit) (female) (2) and grounding value
Short-circuiting of a Turn the engine starting switch OFF for the preparations, and hold it in the ON position
wiring harness during the troubleshooting.
4
(Contact with 24 V Between wiring harness between P02 (female) (1) and E05
circuit) Voltage Max. 1 V
(female) (2) and grounding
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Monitor panel Engine coolant
5 P02 Resistance value
defective temperature
Between (1) and (13) 90 – 3.5 kz
10 – 100 °C
Between (1) and grounding Min. 1 Mz
20-522 PC200/220(LC)-7
(11)
BACK
TROUBLESHOOTING E-15
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Disconnection of wir- during the troubleshooting.
ing harness
Wiring harness between P02 (female) (12) and A61 (female) Resistance
2 (Disconnection or Max. 1 z
(2) value
defective contact
with connector) Wiring harness between P02 (female) (13) and A61 (female) Resistance
Max. 1 z
(1) value
Grounding fault of a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
wiring harness during the troubleshooting.
3 (Contact with
grounding (GND) Between wiring harness between P02 (female) (12) and A61 Resistance
Min. 1 Mz
circuit) (female) (2) and grounding value
Short-circuiting of a Turn the engine starting switch OFF for the preparations, and hold it in the ON position
wiring harness during the troubleshooting.
4
(Contact with 24 V Between wiring harness between P02 (female) (12) and A61
circuit) Voltage Max. 1 V
(female) (2) and grounding
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Monitor panel Hydraulic oil
5 P02 Resistance value
defective temperature
Between (12) and (13) 90 – 3.5 kz
10 – 100 °C
Between (12) and grounding Min. 1 Mz
PC200/220(LC)-7 20-523
(11)
BACK
TROUBLESHOOTING E-16
Failure • Though fuel was refilled, the display does not exceed the red range (E).
information • Though the remaining fuel level is low, the display does not drop below the green range (F).
Relative • Input from the fuel level sensor (voltage) can be confirmed in the monitor function.
information (Code No. 042: Fuel sensor voltage)
ing)
EMPTY (Lower limit) 85 – 110 z
Disconnection of wir- a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
ing harness during the troubleshooting.
2 (Disconnection or
defective contact Resistance
Wiring harness between P02 (female) (2) and A60 (female) (1) Max. 1 z
with connector) value
Grounding fault of a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
wiring harness during the troubleshooting.
3 (Contact with
grounding (GND) Between wiring harness between P02 (female) (2) and A60 Resistance
Min. 1 Mz
circuit) (female) (1) and grounding value
Short-circuiting of a Turn the engine starting switch OFF for the preparations, and hold it in the ON position
wiring harness during the troubleshooting.
4
(Contact with 24 V Between wiring harness between P02 (female) (2) and A60
circuit) Voltage Max. 1 V
(female) (1) and grounding
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Monitor panel P01 Fuel level Resistance value
5
defective
FULL (Upper limit) Approx. 12 z
Between (2) and grounding
EMPTY (Lower limit) 85 – 110 z
20-524 PC200/220(LC)-7
(5)
BACK
TROUBLESHOOTING E-17
Failure • Though the swing lock switch was turned ON, the swing lock monitor does not light up.
information • Though the swing lock switch was turned OFF, the swing lock monitor lights up.
Relative • Input from the swing lock switch (ON or OFF) can be confirmed in the monitor function.
information (Code No. 049: Monitor input 3)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Disconnection of wir- during the troubleshooting.
ing harness
Wiring harness from P02 (female) (17) to J02 to X05 (male) Resistance
2 (Disconnection or Max. 1 z
(1) value
defective contact
with connector) Resistance
Wiring harness from X05 (male) (2) to J05 to grounding Max. 1 z
value
Grounding fault of a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
wiring harness during the troubleshooting.
3 (Contact with
grounding (GND) Between wiring harness from P02 (female) (17) to J02 to X05 Resistance
Min. 1 Mz
circuit) (male) (1), to C02 (female) (38) and grounding value
Short-circuiting of a Turn the engine starting switch OFF for the preparations, and hold it in the ON position
wiring harness during the troubleshooting.
4
(Contact with 24 V Between wiring harness from P02 (female) (17) to J02 to X05
circuit) Voltage Max. 1 V
(male) (1), to C02 (female) (38) and grounding
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position
during the troubleshooting.
Monitor panel P02 Swing lock switch Voltage
5
defective
OFF 20 – 30 V
Between (17) and grounding
ON Max. 1 V
20-526 PC200/220(LC)-7
(5)
BACK
PC200/220(LC)-7 20-527
BACK
Failure
• When operating the working mode changing switch, the working mode monitor does not appear.
information (1)
Relative
—
information
Failure
• When operating the auto-decelerator switch, the auto-deceleration monitor does not appear.
information (2)
Relative
★If the auto-decelerator itself does not work, either, carry out No. E-5 Troubleshooting.
information
Failure
• When operating the travel speed shifting switch, the travel speed monitor does not appear.
information (3)
Relative
★If the travel speed does not actually change, carry out No. H-21 Troubleshooting.
information
Failure
• When operating the windshield wiper switch, the windshield wiper monitor does not appear.
information (4)
Relative
★If the windshield wiper itself does not work, either, carry out No. E-19 Troubleshooting.
information
• When operating the select switch, the adjustment display does not appear.
Failure
• When operating the LCD monitor adjusting switch, the adjustment display does not appear.
information (5)
• When operating the maintenance switch, the item display does not appear.
Relative
—
information
20-528 PC200/220(LC)-7
BACK
TROUBLESHOOTING E-19
Failure
• The windshield wiper does not work.
information
Relative • Input from the window rear limit switch (ON or OFF) can be confirmed in the monitor function.
information (Code No. 049: Monitor input 3)
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position
during the troubleshooting.
Monitor panel fault
(Rear limit switch P02 Front window Voltage
system) When installed at front 20 – 30 V
Between (15) and grounding
When retracted at rear Max. 1 V
5 a Turn the engine starting switch OFF for the preparations, and hold it in the ON position
during the troubleshooting.
Monitor panel fault P01 Windshield wiper switch Voltage
(Windshield wiper
motor system) OFF Max. 3 V
Between (9) and grounding
Between (10) and grounding Max. 3 V 20 – 30 V
ON
(Constant cycle)
20-530 PC200/220(LC)-7
(5)
BACK
PC200/220(LC)-7 20-531
BACK
Failure
• The alarming buzzer cannot be cancelled.
information
Relative • Input from the alarming buzzer cancellation switch (ON or OFF) can be confirmed in the monitor function.
information (Code No. 049: Monitor input 3)
Short-circuiting of ★Turn the engine starting switch OFF for the preparations, and hold it in the ON position dur-
wiring harness ing the troubleshooting.
3
(Contact with 24 V Between wiring harness between P02 (female) and P03
circuit) Voltage Below 1 V
(male) and grounding
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position dur-
ing the troubleshooting.
Alarming buzzer
4 Monitor panel fault P02 Voltage
cancellation switch
Release 20 – 30 V
Between and grounding
Depress Below 1 V
20-532 PC200/220(LC)-7
BACK
TROUBLESHOOTING E-21
Failure
• "Boom RAISE" is not correctly displayed in the monitor function on the monitor panel.
information
Relative
—
information
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Disconnection of wir- during the troubleshooting.
ing harness
Wiring harness between C03 (female) (10) and S06 (female) Resistance
2 (Disconnection or Max. 1 z
(1) value
defective contact
with connector) Resistance
Wiring harness between S06 (female) (2) and grounding Max. 1 z
value
Grounding fault of a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
wiring harness during the troubleshooting.
3 (Contact with
grounding (GND) Between wiring harness between C03 (female) (10) and S06 Resistance
Min. 1 Mz
circuit) (female) (1) and grounding value
Short-circuiting of a Turn the engine starting switch OFF for the preparations, and hold it in the ON position
wiring harness during the troubleshooting.
4
(Contact with 24 V Between wiring harness between C03 (female) (10) and S06
circuit) Voltage Max. 1 V
(female) (1) and grounding
a Turn the engine starting switch OFF for the preparations, start engine and carry out trou-
bleshooting.
Governor • pump C03 Boom control lever Voltage
5
controller defective
NEUTRAL 20 – 30 V
Between (10) and grounding
RAISE Max. 1 V
PC200/220(LC)-7 20-533
(5)
BACK
TROUBLESHOOTING E-22
Failure
• "Boom LOWER" is not correctly displayed in the monitor function on the monitor panel.
information
Relative
—
information
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Disconnection of wir- during the troubleshooting.
ing harness
Wiring harness between C03 (female) (20) and S02 (female) Resistance
2 (Disconnection or Max. 1 z
(1) value
defective contact
with connector) Resistance
Wiring harness between S02 (female) (2) and grounding Max. 1 z
value
Grounding fault of a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
wiring harness during the troubleshooting.
3 (Contact with
grounding (GND) Between wiring harness between C03 (female) (20) and S02 Resistance
Min. 1 Mz
circuit) (female) (1) and grounding value
Short-circuiting of a Turn the engine starting switch OFF for the preparations, and hold it in the ON position
wiring harness during the troubleshooting.
4
(Contact with 24 V Between wiring harness between C03 (female) (20) and S02
circuit) Voltage Max. 1 V
(female) (1) and grounding
a Turn the engine starting switch OFF for the preparations, start engine and carry out trou-
bleshooting.
Governor • pump C03 Boom control lever Voltage
5
controller defective
NEUTRAL 20 – 30 V
Between (20) and grounding
LOWER Max. 1 V
20-534 PC200/220(LC)-7
(5)
BACK
TROUBLESHOOTING E-23
Failure
• "Arm DIGGING" is not correctly displayed in the monitor function (special function) on the monitor panel.
information
Relative
—
information
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Disconnection of wir- during the troubleshooting.
ing harness
Wiring harness between C03 (female) (30) and S04 (female) Resistance
2 (Disconnection or Max. 1 z
(1) value
defective contact
with connector) Resistance
Wiring harness between S04 (female) (2) and grounding Max. 1 z
value
Grounding fault of a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
wiring harness during the troubleshooting.
3 (Contact with
grounding (GND) Between wiring harness between C03 (female) (30) and S04 Resistance
Min. 1 Mz
circuit) (female) (1) and grounding value
Short-circuiting of a Turn the engine starting switch OFF for the preparations, and hold it in the ON position
wiring harness during the troubleshooting.
4
(Contact with 24 V Between wiring harness between C03 (female) (30) and S04
circuit) Voltage Max. 1 V
(female) (1) and grounding
a Turn the engine starting switch OFF for the preparations, start engine and carry out trou-
bleshooting.
Governor • pump C03 Arm control lever Voltage
5
controller defective
NEUTRAL 20 – 30 V
Between (30) and grounding
DIGGING Max. 1 V
PC200/220(LC)-7 20-535
(5)
BACK
TROUBLESHOOTING E-24
Failure
• "Arm DUMPING" is not correctly displayed in the monitor function (special function) on the monitor panel.
information
Relative
—
information
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Disconnection of wir- during the troubleshooting.
ing harness
Wiring harness between C03 (female) (40) and S08 (female) Resistance
2 (Disconnection or Max. 1 z
(1) value
defective contact
with connector) Resistance
Wiring harness between S08 (female) (2) and grounding Max. 1 z
value
Grounding fault of a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
wiring harness during the troubleshooting.
3 (Contact with
grounding (GND) Between wiring harness between C03 (female) (40) and S08 Resistance
Min. 1 Mz
circuit) (female) (1) and grounding value
Short-circuiting of a Turn the engine starting switch OFF for the preparations, and hold it in the ON position
wiring harness during the troubleshooting.
4
(Contact with 24 V Between wiring harness between C03 (female) (40) and S08
circuit) Voltage Max. 1 V
(female) (1) and grounding
a Turn the engine starting switch OFF for the preparations, start engine and carry out trou-
bleshooting.
Governor • pump C03 Arm control lever Voltage
5
controller defective
NEUTRAL 20 – 30 V
Between (40) and grounding
DUMPING Max. 1 V
20-536 PC200/220(LC)-7
(5)
BACK
TROUBLESHOOTING E-25
Failure
• "Bucket DIGGING" is not correctly displayed in the monitor function (special function) on the monitor panel.
information
Relative
—
information
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Disconnection of wir- during the troubleshooting.
ing harness
Resistance
2 (Disconnection or Wiring harness between C03 (female) (9) and S01 (female) (1) Max. 1 z
value
defective contact
with connector) Resistance
Wiring harness between S01 (female) (2) and grounding Max. 1 z
value
Grounding fault of a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
wiring harness during the troubleshooting.
3 (Contact with
grounding (GND) Between wiring harness between C03 (female) (9) and S01 Resistance
Min. 1 Mz
circuit) (female) (1) and grounding value
Short-circuiting of a Turn the engine starting switch OFF for the preparations, and hold it in the ON position
wiring harness during the troubleshooting.
4
(Contact with 24 V Between wiring harness between C03 (female) (9) and S01
circuit) Voltage Max. 1 V
(female) (1) and grounding
a Turn the engine starting switch OFF for the preparations, start engine and carry out trou-
bleshooting.
Governor • pump C03 Bucket control lever Voltage
5
controller defective
NEUTRAL 20 – 30 V
Between (9) and grounding
DIGGING Max. 1 V
PC200/220(LC)-7 20-537
(5)
BACK
TROUBLESHOOTING E-26
Failure
• "Bucket DUMPING" is not correctly displayed in the monitor function (special function) on the monitor panel.
information
Relative
—
information
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Disconnection of wir- during the troubleshooting.
ing harness
Wiring harness between C03 (female) (19) and S05 (female) Resistance
2 (Disconnection or Max. 1 z
(1) value
defective contact
with connector) Resistance
Wiring harness between S05 (female) (2) and grounding Max. 1 z
value
Grounding fault of a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
wiring harness during the troubleshooting.
3 (Contact with
grounding (GND) Between wiring harness between C03 (female) (19) and S05 Resistance
Min. 1 Mz
circuit) (female) (1) and grounding value
Short-circuiting of a Turn the engine starting switch OFF for the preparations, and hold it in the ON position
wiring harness during the troubleshooting.
4
(Contact with 24 V Between wiring harness between C03 (female) (19) and S05
circuit) Voltage Max. 1 V
(female) (1) and grounding
a Turn the engine starting switch OFF for the preparations, start engine and carry out trou-
bleshooting.
Governor • pump C03 Bucket control lever Voltage
5
controller defective
NEUTRAL 20 – 30 V
Between (19) and grounding
DUMPING Max. 1 V
20-538 PC200/220(LC)-7
(5)
BACK
TROUBLESHOOTING E-27
Failure
• "SWING" is not correctly displayed in the monitor function (special function) on the monitor panel.
information
Relative
—
information
ing)
Right Max. 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Disconnection of wir- Wiring harness between C03 (female) (29) and S03 (female)
Resistance
ing harness (1), or wiring harness between C03 (female) (29) and S07 Max. 1 z
value
3 (Disconnection or (female) (1)
defective contact Resistance
with connector) Wiring harness between S03 (female) (2) and grounding Max. 1 z
value
Resistance
Wiring harness between S07 (female) (2) and grounding Max. 1 z
value
Grounding fault of a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
wiring harness during the troubleshooting.
4 (Contact with Wiring harness between C03 (female) (29) and S03 (female)
grounding (GND) Resistance
(1), or wiring harness between C03 (female) (29) and S07 Min. 1 Mz
circuit) value
(female) (1) and grounding
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position
Short-circuiting of during the troubleshooting.
wiring harness
5 Wiring harness between C03 (female) (29) and S03 (female)
(Contact with 24 V
circuit) (1), or wiring harness between C03 (female) (29) and S07 Voltage Max. 1 V
(female) (1) and grounding
a Turn the engine starting switch OFF for the preparations, start engine and carry out trou-
bleshooting.
Governor • pump C03 Swing control lever Voltage
6
controller defective
NEUTRAL 20 – 30 V
Between (29) and grounding
Right or left Max. 1 V
20-540 PC200/220(LC)-7
(5)
BACK
TROUBLESHOOTING E-27
Electrical Circuit Diagram for Right and Left Swing PPC hydraulic Switches
PC200/220(LC)-7 20-541
(1)
BACK
TROUBLESHOOTING E-28
Failure
• "TRAVEL" is not correctly displayed in the monitor function (special function) on the monitor panel.
information
Relative
—
information
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Disconnection of wir- during the troubleshooting.
ing harness
Wiring harness from C03 (female) (39) to J01 to S30 (female) Resistance
2 (Disconnection or Max. 1 z
(2) value
defective contact
with connector) Resistance
Wiring harness from S30 (female) (2) to J05 to grounding Max. 1 z
value
Grounding fault of a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
wiring harness during the troubleshooting.
3 (Contact with Wiring harness from C03 (female) (39) to J01 to S30 (female)
grounding (GND) Resistance
(2), or between wiring harness between C03 (female) (39) and Min. 1 Mz
circuit) value
A43 (female) (2) and grounding
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position
Short-circuiting of during the troubleshooting.
wiring harness
4 Wiring harness from C03 (female) (39) to J01 to S30 (female)
(Contact with 24 V
circuit) (2), or between wiring harness between C03 (female) (39) and Voltage Max. 1 V
A43 (female) (2) and grounding
a Turn the engine starting switch OFF for the preparations, start engine and carry out trou-
bleshooting.
Governor • pump C03 Travel control lever Voltage
5
controller defective
NEUTRAL 20 – 30 V
Between (39) and grounding
Forward or backward Max. 1 V
20-542 PC200/220(LC)-7
(5)
BACK
TROUBLESHOOTING E-28
Electrical Circuit Diagram for Travel PPC hydraulic Switch and Travel Alarm
PC200/220(LC)-7 20-543
(1)
BACK
TROUBLESHOOTING E-29
Failure • "Travel Differential Pressure" is not correctly displayed in the monitor function (special function) on the mon-
information itor panel.
Relative • When pressure difference is created between the right and left travel PPC circuits (in steering), the travel
information differential mechanism is turned ON.
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Disconnection of wir- during the troubleshooting.
ing harness
Wiring harness between C03 (female) (16) and S31 (female) Resistance
2 (Disconnection or Max. 1 z
(2) value
defective contact
with connector) Resistance
Wiring harness from S31 (female) (2) to J05 to grounding Max. 1 z
value
Grounding fault of a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
wiring harness during the troubleshooting.
3 (Contact with
grounding (GND) Between wiring harness between C03 (female) (16) and S31 Resistance
Min. 1 Mz
circuit) (female) (2) and grounding value
Short-circuiting of a Turn the engine starting switch OFF for the preparations, and hold it in the ON position
wiring harness during the troubleshooting.
4
(Contact with 24 V Between wiring harness between C03 (female) (16) and S31
circuit) Voltage Max. 1 V
(female) (2) and grounding
a Turn the engine starting switch OFF for the preparations, start engine and carry out trou-
bleshooting.
Governor • pump C03 Travel control lever Voltage
5
controller defective
NEUTRAL 20 – 30 V
Between (16) and grounding
One side of right or left only Max. 1 V
20-544 PC200/220(LC)-7
(5)
BACK
TROUBLESHOOTING E-29
Electrical Circuit Diagram for Travel and Steering PPC hydraulic Switch
PC200/220(LC)-7 20-545
(1)
BACK
TROUBLESHOOTING E-30
Failure
• "Service" is not correctly displayed in the monitor function (special function) on the monitor panel.
information
Relative
—
information
20-546 PC200/220(LC)-7
(5)
BACK
TROUBLESHOOTING E-30
PC200/220(LC)-7 20-547
(5)
BACK
TROUBLESHOOTING E-31
Failure
• The air conditioner does not work.
information
Relative • For the electrical circuit diagram inside the air conditioner unit, refer to the section of STRUCTURE AND
information FUNCTION - Air Conditioner in this manual.
1 Fuse No. 11 fault When the fuse is blown, there is a big possibility that grounding fault occurred in the circuit.
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Disconnection of wir- during the troubleshooting.
ing harness
Resistance
2 (Disconnection or Wiring harness between FB1-11 outlet and M26 (male) (4) (5) Max. 1 z
value
defective contact
with connector) Resistance
Wiring harness between M26 (male) (8) and grounding Max. 1 z
value
Grounding fault of a Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
wiring harness during the troubleshooting.
3 (Contact with
grounding (GND) Between wiring harness between FB1-11 outlet and M26
Voltage Min. 1 Mz
circuit) (male) (4) (5) and grounding
a Turn the engine starting switch OFF for the preparations, and hold it in the ON position
Air conditioner unit during the troubleshooting.
4
defective M26 Voltage
Between (4) (5) and (8) 20 – 30 V
20-548 PC200/220(LC)-7
(7)
BACK
TROUBLESHOOTING E-31
PC200/220(LC)-7 20-549
(11)
BACK
TROUBLESHOOTING E-31
Self-diagnosis
notice Trouble Disconnection in recirculated air sensor
E11
Contents of
• Disconnection in the recirculated air sensor system is detected.
trouble
• Fixes the recirculated air temperature for control.
Action of • When the following condition is satisfied, the operation returns to normalcy.
control panel <Completion of removal of cause> + <Deletion of self-diagnosis notice> + <Turning starting switch OFF
and ON> + <Starting air conditioner>
Related
information
1 air sensor
THI (male) Resistance
Possible causes and
(Internal disconnection)
Between (1) and (2) 300 z – 430 kz
a Prepare with starting switch OFF, then carry out troubleshooting without turning
Disconnection of wiring starting switch ON.
harness (Disconnection Wiring harness between M30 (female) (12) and TH I
2 Resistance Max. 1 z
or defective contact with (female) (2)
connector) Wiring harness between M29 (female) (11) and TH I
Resistance Max. 1 z
(female) (1)
Defective air conditioner If neither of causes 1 and 2 is the cause of the trouble, the air conditioner system
3
system may be defective. Refer to CHASSIS COMPONENT, Shop Manual, “Air conditioner”.
Self-diagnosis
notice Trouble Short circuit in recirculated air sensor
E12
Contents of
• Short circuit in the recirculated air sensor system is detected.
trouble
• Fixes the recirculated air temperature for control.
Action of • When the following condition is satisfied, the operation returns to normalcy.
control panel <Completion of removal of cause> + <Deletion of self-diagnosis notice> + <Turning starting switch OFF
and ON> + <Starting air conditioner>
Related
information
cuit)
Between (1) and (2) 300 z – 430 kz
a Prepare with starting switch OFF, then carry out troubleshooting without turning
Disconnection of wiring starting switch ON.
harness (Disconnection Wiring harness between M30 (female) (12) and TH I
2 Resistance Max. 1 z
or defective contact with (female) (2)
connector) Wiring harness between M29 (female) (11) and TH I
Resistance Max. 1 z
(female) (1)
Defective air conditioner If neither of causes 1 and 2 is the cause of the trouble, the air conditioner system
3
system may be defective. Refer to CHASSIS COMPONENT, Shop Manual, “Air conditioner”.
20-550 PC200/220(LC)-7
(5)
BACK
TROUBLESHOOTING E-31
Self-diagnosis
notice Trouble Disconnection in coolant temperature sensor
E15
Contents of
• Disconnection in the coolant temperature sensor system is detected.
trouble
• Ignores the warm-up control and fixes the engine coolant temperature at 60°C for control.
Action of • When the following condition is satisfied, the operation returns to normalcy.
control panel <Completion of removal of cause> + <Deletion of self-diagnosis notice> + <Turning starting switch OFF
and ON> + <Starting air conditioner>
Related
information
disconnection)
Between (1) and (2) 95 z – 455 kz
a Prepare with starting switch OFF, then carry out troubleshooting without turning
Disconnection of wiring starting switch ON.
harness (Disconnection Wiring harness between M30 (female) (14) and THW
2 Resistance Max. 1 z
or defective contact with (female) (2)
connector) Wiring harness between M29 (female) (11) and THW
Resistance Max. 1 z
(female) (1)
Defective air conditioner If neither of causes 1 and 2 is the cause of the trouble, the air conditioner system
3
system may be defective. Refer to CHASSIS COMPONENT, Shop Manual, “Air conditioner”.
Self-diagnosis
notice Trouble Short circuit in coolant temperature sensor
E16
Contents of
• Short circuit in the coolant temperature sensor system is detected.
trouble
• Ignores the warm-up control and fixes the engine coolant temperature at 60°C for control.
Action of • When the following condition is satisfied, the operation returns to normalcy.
control panel <Completion of removal of cause> + <Deletion of self-diagnosis notice> + <Turning starting switch OFF
and ON> + <Starting air conditioner>
Related
information
short circuit)
Between (1) and (2) 95 z – 455 kz
a Prepare with starting switch OFF, then carry out troubleshooting without turning
Disconnection of wiring starting switch ON.
harness (Disconnection Wiring harness between M30 (female) (14) and THW
2 Resistance Max. 1 z
or defective contact with (female) (2)
connector) Wiring harness between M29 (female) (11) and THW
Resistance Max. 1 z
(female) (1)
Defective air conditioner If neither of causes 1 and 2 is the cause of the trouble, the air conditioner system
3
system may be defective. Refer to CHASSIS COMPONENT, Shop Manual, “Air conditioner”.
PC200/220(LC)-7 20-551
(11)
BACK
TROUBLESHOOTING E-31
Self-diagnosis
notice Trouble Short circuit in daylight sensor
E18
Contents of
• Short circuit in the daylight sensor system is detected.
trouble
• Assumes that the daylight sensor is not installed for control.
Action of • When the following condition is satisfied, the operation returns to normalcy.
control panel <Completion of removal of cause> + <Deletion of self-diagnosis notice> + <Turning starting switch OFF
and ON> + <Starting air conditioner>
Related
information
a Prepare with starting switch OFF, then carry out troubleshooting without turning
Disconnection of wiring starting switch ON.
harness (Disconnection Wiring harness between M30 (female) (16) and P15
2 Resistance Max. 1 z
or defective contact with (female) (2)
connector) Wiring harness between M30 (female) (3) and P15
Resistance Max. 1 z
(female) (1)
Defective air conditioner If neither of causes 1 and 2 is the cause of the trouble, the air conditioner system
3
system may be defective. Refer to CHASSIS COMPONENT, Shop Manual, “Air conditioner”.
Self-diagnosis
notice Trouble Abnormality in air outlet damper
E43
Contents of
• Abnormality in air outlet servomotor system is detected.
trouble
• Stops the air outlet servomotor.
Action of • When the following condition is satisfied, the operation returns to normalcy.
control panel • <Completion of removal of cause> + <Deletion of self-diagnosis notice> + <Turning starting switch OFF
and ON> + <Starting air conditioner>
Related a Do not connect the power cables to the motor terminals directly to drive the motor. Doing so can damage
information the motor output shaft and break the motor coils.
Resistance Max. 1 z
(female) (3)
Disconnection in wiring Wiring harness between MV1 (female) (3) and M29
harness (Disconnection Resistance Max. 1 z
(female) (11)
2 in wiring harness or
defective contact in con- Wiring harness between MV1 (female) (5) and M30
Resistance Max. 1 z
nector) (female) (9)
Wiring harness between MV1 (female) (6) and M29
Resistance Max. 1 z
(female) (8)
Wiring harness between MV1 (female) (7) and M29
Resistance Max. 1 z
(female) (9)
Defective air conditioner If none of causes 1 and 2 is the cause of the trouble, the air conditioner system may
3
system be defective. Refer to CHASSIS COMPONENT, Shop Manual, “Air conditioner”.
20-552 PC200/220(LC)-7
(5)
BACK
TROUBLESHOOTING E-31
Self-diagnosis
notice Trouble Abnormality in air mix damper
E44
Contents of
• Abnormality in air mix servomotor system is detected.
trouble
• Stops the air mix servomotor.
Action of • When the following condition is satisfied, the operation returns to normalcy.
control panel <Completion of removal of cause> + <Deletion of self-diagnosis notice> + <Turning starting switch OFF
and ON> + <Starting air conditioner>
Related a Do not connect the power cables to the motor terminals directly to drive the motor. Doing so can damage
information the motor output shaft and break the motor coils.
Resistance Max. 1 z
(female) (11)
Disconnection in wiring Wiring harness between MAM (female) (3) and M30
harness (Disconnection Resistance Max. 1 z
(female) (3)
2 in wiring harness or
defective contact in con- Wiring harness between MAM (female) (5) and M30
Resistance Max. 1 z
nector) (female) (2)
Wiring harness between MAM (female) (6) and M29
Resistance Max. 1 z
(female) (4)
Wiring harness between MAM (female) (7) and M29
Resistance Max. 1 z
(female) (5)
Defective air conditioner If neither of causes 1 and 2 is the cause of the trouble, the air conditioner system
3
system may be defective. Refer to CHASSIS COMPONENT, Shop Manual, “Air conditioner”.
PC200/220(LC)-7 20-553
(5)
BACK
TROUBLESHOOTING E-31
Self-diagnosis
notice Trouble Abnormality in recirculated and fresh air damper
E45
Contents of
• Abnormality in recirculated and fresh air servomotor system is detected.
trouble
• Stops the recirculated and fresh air servomotor.
Action of • When the following condition is satisfied, the operation returns to normalcy.
control panel <Completion of removal of cause> + <Deletion of self-diagnosis notice> + <Turning starting switch OFF
and ON> + <Starting air conditioner>
Related a Do not connect the power cables to the motor terminals directly to drive the motor. Doing so can damage
information the motor output shaft and break the motor coils.
If the fuse (in the unit) is broken, the circuit probably has a grounding fault, etc.
2 Defective fuse (in unit)
Possible causes and
20-554 PC200/220(LC)-7
(5)
BACK
TROUBLESHOOTING E-31
PC200/220(LC)-7 20-555
(5)
BACK
TROUBLESHOOTING E-31
Trouble • The air conditioner does not operate. (1) The air conditioner does not operate at all.
Related
information
a Prepare with starting switch OFF, then carry out troubleshooting without turning
Short circuit with chassis starting switch ON.
ground in wiring harness Between wiring harness between circuit breaker fuse 11
3 Resistance Min. 1 Mz
(Contact with ground cir- outlet and M33 (male) (3) and chassis ground
cuit) Between wiring harness between M27 (female) (14) and
Resistance Min. 1 Mz
M30 (female) (6) and chassis ground
a Prepare with starting switch OFF, then turn starting switch ON and carry out trou-
bleshooting.
Defective air conditioner M33 Voltage
4
unit Between (2) and (3) 20 V – 30 V
If the above voltage is normal and the air conditioner does not operate, the air condi-
tioner is defective.
a Prepare with starting switch OFF, then turn starting switch ON and carry out trou-
bleshooting.
M30, M29 Voltage
5 Defective control panel
Between M30 (6) and M29 (12) 20 V – 30 V
If the above voltage is normal and the air conditioner does not operate, the control
panel is defective.
20-556 PC200/220(LC)-7
(5)
BACK
TROUBLESHOOTING E-31
Trouble • The air conditioner does not operate. (2) Air does not come out (Air flow is insufficient).
Related
information
a Prepare with starting switch OFF, then turn starting switch ON and carry out trou-
bleshooting.
Possible causes and
PC200/220(LC)-7 20-557
(5)
BACK
TROUBLESHOOTING E-31
Trouble • The air conditioner does not operate. (3) Air is not cooled (Cooling capacity is low).
Related
information
20-558 PC200/220(LC)-7
(5)
BACK
TROUBLESHOOTING E-31
PC200/220(LC)-7 20-559
(5)
BACK
TROUBLESHOOTING E-32
Failure • The travel alarm does not sound while the machine is traveling.
information • The alarm begins to sound when the machine is at a standstill.
Relative
—
information
As this is an internal failure, troubleshooting cannot be conducted. (If none of the causes
5 Travel alarm fault
listed in Item 1 through 4 above is found, the travel alarm is judged as defective)
Electrical Circuit Diagram for Travel PPC Hydraulic Switch and Travel Alarm
20-560 PC200/220(LC)-7
(5)
TROUBLESHOOTING OF HYDRAULIC AND
MECHANICAL SYSTEM (H-MODE)
PC200/220(LC)-7 20-601
(11)
BACK
20-602 PC200/220(LC)-7
(11)
BACK
TESTING AND ADJUSTING SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEMS
★ This is a system chart that has been drawn up by simplifying the whole hydraulic circuit chart. Use it as a
reference material when troubleshooting the hydraulic and mechanical systems.
PC200/220(LC)-7 20-603
BACK
2
Cause for presumed
failure <Contents>
(The attached No. for • The standard values in normalcy by which to judge "good" or "no good" about
3
filing and reference presumed causes.
purpose only. It does not stand • References for making judgement of "good" or "no good"
for any priority)
4
20-604 PC200/220(LC)-7
BACK
TROUBLESHOOTING H-1
H-1 All work equipment lack power, or travel and swing speeds are slow
Failure information • All the work equipment lack power, or their travel and swing speeds are slow.
Relative information • Set the working mode at A mode for troubleshooting.
PC200/220(LC)-7 20-605
(11)
BACK
TROUBLESHOOTING H-2
Failure information • The engine speed sharply drops or the engine stalls.
Relative information • Set the working mode at A mode for the troubleshooting.
20-606 PC200/220(LC)-7
(11)
BACK
Failure information • No work equipment nor travel and swing functions can be set in motion.
Relative information • Set the working mode at A mode for the troubleshooting.
Failure information • An abnormal noise is heard from around the hydraulic pump.
Relative information —
2 Quality of hydraulic oil bad Air may have get mixed with the oil. Make a visual check.
Hydraulic tank cap breather It is presumed that the breather in the cap of hydraulic tanks is clogged, thereby
3
clogged causing negative pressure inside the tank. Make a visual check.
Hydraulic tank strainer It is presumed that the strainer in the hydraulic tank is clogged, thereby causing
4
clogged negative pressure in the suction circuit. Make a visual check.
5 Piston pump defective The piston pump is suspected of an internal failure. Check the pump itself.
PC200/220(LC)-7 20-607
(11)
BACK
Failure information • The fine control mode poorly functions or its response is slow.
Relative information • Set the working mode at A mode for the troubleshooting.
Orifice in LS circuit
2 The orifice in the LS circuit is presumed to be clogged. Check the orifice itself.
clogged
a Stop engine for preparations. Start troubleshooting at engine high idle.
Oil pressure ratio
20-608 PC200/220(LC)-7
(11)
BACK
TROUBLESHOOTING H-7
{29 – 35 kg/cm2}
Malfunctioning of merge/divide The merge/divide valve (main and LS valves) is presumed to malfunction. Check
3
valve (main and LS valves) the valve itself.
Malfunctioning of boom control The spool in the boom control valve is presumed to malfunction. Check the valve
4
valve (spool) itself.
Malfunctioning of boom control
The pressure compensation valve in the boom control valve is presumed to mal-
5 valve (pressure compensation
function. Check the valve itself.
valve)
Malfunctioning of boom control The regeneration valve in the boom control valve or the seal is presumed to mal-
6
valve (regeneration valve) function. Check the valve itself.
Malfunctioning of boom control The lock valve in the boom control valve is presumed to malfunction. Check the
7
valve (lock valve) valve itself.
Malfunctioning of safety valve The safety valve for the lock valve is presumed to malfunction, or the seal is sus-
8
for lock valve or seal defective pected to be defective. Check the valve itself.
Malfunctioning of boom control
The suction valve in the boom control valve is presumed to malfunction, or the
9 valve (suction valve) or seal
seal is suspected to be defective.
defective
Malfunctioning of boom control
The safety and suction valves in the boom control valve are presumed to mal-
10 valve (safety and suction
function, or the seal is suspected to be defective. Check those valves themselves.
valves) or seal defective
Malfunctioning of LS shuttle
LS shuttle valves in the left travel control valve, bucket control valve and service
11 valve (left travel, bucket and
control valve are presumed to malfunction. Check those valves themselves.
service valves)
a Stop engine for preparations. Start troubleshooting at engine high idle.
12 Boom cylinder defective Boom lever Amount oil leakage from cylinder
Raise relief 20 cc/min
PC200/220(LC)-7 20-609
(11)
BACK
TROUBLESHOOTING H-8
Malfunctioning of merge/divide
2 A mode 0{0}
solenoid valve
2.84 – 3.43 MPa
Other than A mode
{29 – 35 kg/cm2}
Malfunctioning of merge/divide The merge/divide valve (main and LS valves) is presumed to malfunction. Check
3
valve (main and LS valves) the valve itself.
Malfunctioning of arm control The spool in the arm control valve is presumed to malfunction. Check the valve
4
valve (spool) itself.
Malfunctioning of arm control
The pressure compensation valve in the arm control valve is presumed to mal-
5 valve (pressure compensation
function. Check the valve itself.
valve)
Malfunctioning of arm control The generation valve in the arm control valve is presumed to malfunction, or the
6
valve (regeneration valve) seal is suspected to be defective. Check the valve itself.
Malfunctioning of arm control
The safety and suction valves in the arm control valve are presumed to malfunc-
7 valve (safety and suction
tion, or the seal is suspected of defect. Check those valves themselves.
valves) or seal defective
Malfunctioning of LS shuttle
LS shuttle valves in the right travel control valve, boom control valve, left travel
valve (right travel, boom, left
8 control valve, bucket control valve and service valve are presumed to malfunc-
travel, bucket and service
tion. Check those valves themselves.
valves)
a Stop engine for preparations. Start troubleshooting at engine high idle.
9 Arm cylinder defective Arm lever Amount oil leakage from cylinder
Digging relief 20 cc/min
20-610 PC200/220(LC)-7
(11)
BACK
Malfunctioning of bucket con- The spool in the bucket control valve is presumed to malfunction. Check the
2
trol valve (spool) valve itself.
Malfunctioning of bucket con-
The pressure compensation valve in the bucket control valve is presumed to
3 trol valve (pressure compen-
malfunction. Check the valve itself.
sation valve)
Malfunctioning of bucket con- The safety and suction valves in the bucket control valve are presumed to
4 trol valve (safety and suction malfunction, or the seal is suspected to be defective. Check those valves
valves) or seal defective themselves.
Malfunction of LS shuttle valve The LS shuttle valve in the service control valve is presumed to malfunction.
5
(service valve) Check the valve itself.
a Stop engine for preparations. Start troubleshooting at engine high idle.
6 Bucket cylinder defective Bucket lever Amount oil leakage from cylinder
Digging relief 20 cc/min
PC200/220(LC)-7 20-611
(11)
BACK
TROUBLESHOOTING H-11
Failure information (1) • Hydraulic drift of the boom is a bit too fast.
Relative information • Set the working mode at A mode for the troubleshooting.
Failure information (2) • Hydraulic drift of the arm is a bit too fast.
Relative information • Set the working mode at A mode for the troubleshooting.
The seal for safety and suction valves in the arm control valve is suspected
to be defective. Check the valve itself.
Arm control valve (safety and a Whether the seal is defective or not may well be determined by changing
2
suction valves) seal defective for other safety and suction valves. (Do not attempt to change them for the
safety and suction valves for the boom LOWER and the lock valve, be-
cause the set pressure differs)
Arm control valve (spool) seal The seal for spool in the arm control valve is suspected to be defective.
3
defective Check the seal itself.
Arm control valve (pressure
The seal for pressure compensation valve in the arm control valve is sus-
4 compensation valve) seal
pected to be defective. Check the seal itself.
defective
Failure information (3) • Hydraulic drift of the bucket is a bit too fast.
Relative information • Set the working mode at A mode for the troubleshooting.
The seal for the safety and suction valves in the bucket control lever is sus-
pected to be defective. Check the seal itself.
Bucket control valve (safety
a Whether the seal is defective or not may well be determined by changing
2 and suction valves) seal
for other safety and suction valves. (Do not attempt to change them for the
defective
safety and suction valves for the boom LOWER and the lock valve, be-
cause the set pressure differs)
Bucket control valve (spool) The seal for spool in the bucket control valve is suspected to be defective.
3
seal defective Check the seal itself.
Bucket control valve (pres-
The seal for pressure compensation valve in the bucket control valve is sus-
4 sure compensation valve) seal
pected to be defective. Check the seal itself.
defective
20-612 PC200/220(LC)-7
(11)
BACK
{approx. 30 kg/cm2}
dard value in normalcy
Hi Operation 0{0}
Malfunctioning of control valve
The regeneration valve in the control valve is presumed to malfunction.
2 (regeneration valve) - with
Check the valve itself.
boom and arm only
The safety and suction valves of the control valve are presumed to malfunc-
tion. Check those valves themselves directly.
Malfunctioning of control a For the arm and boom, whether they are defective or not may well be de-
3
valves (safety & suction valve) termined by changing them for other safety and suction valves. (Do not at-
tempt to change them for the safety and suction valves for the boom
LOWER and the lock valve, because each set pressure differs)
Malfunctioning of control valve
The pressure compensation valve of the control valve is presumed to mal-
4 (pressure compensation
function. Check the valve itself directly.
valve)
Failure information • Other work equipment moves when relieving the single circuit of specific work equipment.
Relative information • Set the working mode at A mode for the troubleshooting.
Control valve (pressure com- The seal for pressure compression valve in the control valve is suspected to
1
pensation valve) seal defective be defective. Check the seal itself.
Failure information • The one-touch power max. switch does not operate.
Relative information • Set the working mode at A mode for the troubleshooting.
PC200/220(LC)-7 20-613
(11)
BACK
H-15 In compound operation, work equipment with larger load moves slowly
Failure information • In a compound operation, work equipment with larger load tends to move slowly.
Relative information —
The pressure compensation valve for the work equipment with larger load is
dard value in normalcy
Failure information • In a compound operation of swing + boom RAISE, the boom tends to move slowly.
Relative information • If the boom moves slowly in the single operation of boom RAISE, carry out the H-7 check first.
Malfunctioning of LS select The LS select valve is presumed to malfunction, or the seal is suspected to
1
valve or seal defective be defective. Check the valve and seal themselves.
Failure information • In a compound operation of swing + travel, the travel speed drops sharply.
Relative information • If the travel speed is slow in the single operation of travel, carry out the H-19 check first.
Malfunctioning of LS shuttle The LS shuttle valve in the left travel control valve or the swing control valve
1
valve (left travel and swing) is presumed to malfunction. Check both of them directly.
20-614 PC200/220(LC)-7
(1)
BACK
TROUBLESHOOTING H-18
PC200/220(LC)-7 20-615
(11)
BACK
TROUBLESHOOTING H-19
20-616 PC200/220(LC)-7
(11)
BACK
TROUBLESHOOTING H-20
3 The travel interlocking valve is presumed to malfunction. Check the valve itself.
locking valve
a Stop engine for preparations. Start troubleshooting at engine high idle.
Travel control lever Solenoid valve output pressure
Malfunctioning of merge/divide
4 Operating both sides 0 {0}
solenoid valve
2.84 – 3.43 MPa
Operating one side only
{29 – 35 kg/cm2}
Malfunctioning of merge/divide
5 The merge/divide valve is presumed to malfunction. Check the valve itself.
valve
Malfunction of travel control The spool in the travel control valve is presumed to malfunction. Check the spool
6
valve (spool) itself.
Malfunctioning of travel control
The pressure compensation valve in the travel control valve is presumed to mal-
7 valve (pressure compensation
function. Check the valve itself.
valve)
Malfunctioning of travel control The suction valve in the travel control valve is presumed to malfunction. Check
8
valve (suction valve) the valve itself.
Malfunctioning of LS shuttle The LS shuttle valve in the bucket control valve is presumed to malfunction.
9
valve (bucket) Check the valve itself.
Check valve seal defective at The seal in the check valve of LS oil pressure pickup port is suspected to be
10
LS oil pressure pickup port defective. Check the seal itself.
The seal in the check valve of the travel motor is suspected to be defective.
Malfunctioning of travel motor Check the seal itself.
11
(safety valve) a Whether the seal is defective or not may well be determined by swapping the
motors between forward and reverse, or right and left.
The seal in the check valve of the travel motor is suspected of defect. Check the
Malfunctioning of travel motor seal itself.
12
(check valve) a Whether the seal is defective or not may well be determined by swapping the
motors between forward and reverse, or right and left.
PC200/220(LC)-7 20-617
(11)
BACK
TROUBLESHOOTING H-21
Failure information • Travel speed does not shift, or it is either too fast or slow.
Relative information • Set the working mode at A mode for the troubleshooting.
20-618 PC200/220(LC)-7
(11)
BACK
TROUBLESHOOTING H-22
H-22 Track shoe does not turn (on one side only)
Failure information • A track shoe does not turn (only on one side).
Relative information • Set the working mode at A mode for the troubleshooting.
Travel control valve (suction The suction valve seat in the travel control valve is suspected of defect. Check
1
valve) seat defective the seat itself.
Travel motor (safety valve) The safety valve seat in the travel motor is suspected of defect. Check the seat
2
seat defective itself.
Travel motor (check valve) The check valve seat in the travel motor is suspected of defect. Check the seat
3
seat defective itself.
a Stop engine for preparations. Start troubleshooting at engine high idle.
4 Travel Motor speed reduced Travel control lever Amount of oil leakage from travel motor
Travel relief 27.2 ¬/min
The final drive is suspected of an internal failure. Check the inside of the final
drive directly.
5 Final drive defective a A failure inside the final drive may well be determined by an abnormal noise
from within, abnormal heat generated or metal dust or chips contained in the
drained oil.
PC200/220(LC)-7 20-619
(11)
BACK
TROUBLESHOOTING H-23
Failure information (1) • The machine swings neither to the right nor to the left.
Relative information • Set the working mode at A mode for the troubleshooting.
Failure information (2) • The machine does not swing in one direction.
Relative information • Set the working mode at A mode for the troubleshooting.
20-620 PC200/220(LC)-7
(11)
BACK
TROUBLESHOOTING H-24
Malfunctioning of LS shuttle The LS shuttle valves for all the control valves are presumed to malfunction.
1
valve (all LS shuttles) Check them directly.
Malfunctioning of swing motor The parking brake portion of the swing motor is presumed to malfunction. Check
2
(parking brake) it directly.
a Stop engine for preparations. Start troubleshooting at engine high idle.
Swing lock switch Swing control lever Swing relief pressure
Improper adjustment or mal- 28.9 – 32.9 MPa
3 functioning of swing motor ON Swing relief
{295 – 335 kg/cm2}
(safety valve)
If the oil pressure does not return to normalcy even after the adjustment, the
safety valve is presumed to malfunction, or suspected of an internal failure.
Check the valve itself.
a Stop engine for preparations. Start troubleshooting at engine high idle.
4 Swing motor defective Swing control lever Amount of oil leakage from swing motor
Swing relief Below 10 l/min
Failure information (2) • Swing acceleration is poor only on one side, or swing speed is slow.
Relative information • Set the working mode at A mode for the troubleshooting.
PC200/220(LC)-7 20-621
(11)
BACK
TROUBLESHOOTING H-25
Failure information (1) • The work equipment overruns excessively when stopping swing.
Relative information • Set the working mode at A mode for the troubleshooting.
Failure information (2) • Swing only one side, and the work equipment overruns excessively when stopping swing.
Relative information • Set the working mode at A mode for the troubleshooting.
The PPC slow return valve is suspected of clogging. Check the valve itself.
Swing PPC slow return valve
2 a Whether the valve is clogged or not may well be determined by swapping
clogged
the right and left valves and watching the result.
Malfunctioning of swing control The spool in the swing control valve is resumed to malfunction. Check the
3
valve (spool) valve itself.
The seal in the suction valve of the swing motor is suspected of defect.
Swing motor (suction valve) Check the seal itself.
4
seal defective a Whether the seal is defective or not may well be determined by swapping
the right and left suction valves and watching the result.
The seal in the check valve of the swing motor is suspected of defect.
Swing motor (check valve) Check the seal itself.
5
seal defective a Whether the seal is defective or not may well be determined by swapping
the right and left check valves and watching the result.
20-622 PC200/220(LC)-7
(11)
BACK
Failure information • There is a big shock caused when stopping a swing motion.
Relative information • Set the working mode at A mode for the troubleshooting.
Malfunctioning of swing PPC Swing control lever PPC valve output pressure
1
valve NEUTRAL 0 {0}
Left or right Above 2.7 MPa {Above 28 kg/cm2}
The swing PPC slow return valve is presumed to malfunction. Check the
Malfunctioning of swing PPC valve itself.
2
slow return valve a Whether the valve malfunctions or not may well be determined by swap-
ping the right and left valves and watching the result.
Failure information • There is a big abnormal noise caused when stopping a swing motion.
Relative information • Set the working mode at A mode for the troubleshooting.
Malfunction of swing motor The safety valve in the swing motor is presumed to malfunction. Check the
2
(safety valve) valve itself.
The seal in suction valve of the swing motor is suspected of defect. Check
Malfunction of swing motor the seal itself.
3
(suction valve) a Whether the seal is defective or not may well be determined by swapping
the right and left valves and watching the result.
The swing machinery is suspected of an internal failure. Check the inside of
the machinery itself.
4 Swing machinery defective a A failure inside the swing machinery may well be determined by monitoring
abnormal noise, abnormal heat generated or metal dust or chips con-
tained in the drained oil.
PC200/220(LC)-7 20-623
(11)
BACK
TROUBLESHOOTING H-28
Failure information (1) • Natural drift of the swing is too big (when the parking brake is activated).
• When the emergency swing release switch is in the OFF position (this is a normal condition), the
Relative information
swing and parking brake is activated and the swing is fixed with a disc brake.
Swing motor (parking brake The parking portion of the swing motor is suspected of malfunctioning and
2
portion) malfunctioned interior failure. Check that portion directly.
Failure information (2) • Natural drift of the swing is too big (when the parking brake is released).
• When the emergency swing release switch is in the ON condition (this is an emergent condition),
Relative information
the swing and parking brake is released and the swing is retained only hydraulically.
20-624 PC200/220(LC)-7
(11)
TROUBLESHOOTING OF ENGINE
(S-MODE)
PC200/220(LC)-7 20-701
(11)
BACK
[Questions]
Sections [A] + [B] in the chart on the right corre-
sponds to the items where answers can be obtained
from the user. The items in [B] are items that can be
obtained from the user, depending on the user’s
level.
[Check items]
The serviceman carries out simple inspection to nar-
row down the causes. The items under [C] in the
chart on the right correspond to this.
The serviceman narrows down the causes from
information [A] that he has obtained from the user
and the results of [C] that he has obtained from his
own inspection.
[Troubleshooting] Causes
Troubleshooting is carried out in the order of proba-
bility, starting with the causes that have been
marked as having the highest probability from infor-
mation gained from [Questions] and [Check
items].
(a)
Questions
[A] (b)
(c)
(d)
(e)
[B]
Check items
[C]
i
shooting
Trouble-
ii
iii
20-702 PC200/220(LC)-7
(5)
BACK
tion)
the failure. However, do not use this
injec
when making calculations to narrow
down the causes.
fuel
2. Use the E in the Cause column as ref-
sive
erence for [Degree of use (Operated for
zzle
xces
nce
long period)] in the [Questions] section
n no
p (e
fere
g
as reference. As a rule, do not use it
jectio
men
timin
pum
inter
r
nde
when calculating the points for locating
le
uel in
tion
ction
er e
ger,
, cyli
the cause, but it can be included if nec-
injec
lean
ed f
l inje
char
ring
essary to determine the order for trou-
, seiz
fuel
air c
r fue
bleshooting. urbo
ton
ctive
n pis
ged
ged
rope
ed t
Defe
Clog
Clog
Seiz
Wor
Imp
Confirm recent repair history
PC200/220(LC)-7 20-703
(5)
BACK
Causes
d
hea
tion)
)
ized
der
injec
r se
cylin
fuel
nge
e, va rger and
sive
k, plu
eat
zle
xces
lve s
(rac
ction tion noz
leme nce
a
boch
p (e
re
ump
g
nt
terfe
timin
pum
r
n tu
jec
der
ance
on p
uffle
valv
er, in
el in
tion
e
n
er e
etwe
, cyli
jecti
lear
dm
ct of
injec
d fu
harg
lean
l inje
lve c
el in
ring
gge
b
conta
eize
Legend
ir
rboc
fuel
air c
of a
r fue
, clo
e fu
n
r va
: Possible causes (judging from Questions and check items) s
to
ed tu
ctive
ctive
,
n pis
ectiv
: Most probable causes (judging from Questions and Check items)
kage
hed
ged
ged
rope
rope
: Possible causes due to length of use (used for a long period) Defe
Crus
Defe
Clog
Clog
Seiz
Wor
Deff
Imp
Imp
Lea
: Items to confirm the cause.
Confirm recent repair history
Degree of use Operated for long period
Suddenly became black
Color of exhaust gas Gradually became black
Questions
Replace
Replace
Replace
Replace
Replace
Repair
Adjust
Adjust
Adjust
Clean
Remedy
20-704 PC200/220(LC)-7
(5)
BACK
Five causes
Step 1
Clarify the relationship between the three
symptoms in the [Questions] and [Check items]
section and the five Cause items in the vertical
column.
Three symptoms
Step 2
Add up the total of and marks where the
horizontal lines for the three symptoms and the
vertical columns for the causes intersect.
(1) Clogged air cleaner element:
(2) Air leakage between turbocharger
and cylinder head:
(3) Clogged, seized fuel injection nozzle:
(4) Defective contact of valve, valve seat:
(5) Worn piston ring, cylinder:
Step 3
The calculation in Step 2 show that the closest
relationship is with [Clogged air cleaner element].
Follow this column down to the troubleshooting
area and carry out the troubleshooting item
marked . The Remedy is given as [Clean], so
carry out cleaning, and the exhaust gas color
should return to normal.
PC200/220(LC)-7 20-705
(5)
BACK
TROUBLESHOOTING S-1
General causes why exhaust smoke comes out but engine takes time to start
• Defective electrical system
• Insufficient supply of fuel
• Insufficient intake of air
• Improper selection of fuel
(At ambient temperature of –10°C or below,
ASTM D975 No. 2 diesel fuel is used)
a Battery charging rate
Charging rate
Ambient 100 % 90 % 80 % 75 % 70 %
temperature
20°C 1.28 1.26 1.24 1.23 1.22
0°C 1.29 1.27 1.25 1.24 1.23
–10°C 1.30 1.28 1.26 1.25 1.24
20-706 PC200/220(LC)-7
(5)
Replace Defe
ctive
Replace Defe regu
lator
ctive
Replace Defe alter
nato
ctive r
Replace Defe or de
terio
ctive rated
Adjust Defe injec
tion batte
tive nozz ry
Replace injec
tion le
PC200/220(LC)-7
Defe
tive timin
Correct injec g
Leak tion
age, pum
Clean c lo p
TROUBLESHOOTING
(5)
20-707
S-1
BACK
BACK
TROUBLESHOOTING S-2
n
ectio
it
• Failure in hydraulic pump system
ttery
circu
conn
• Defective electrical system
d ba
ting
inal
ch
otor
e
star
lay
t
term
swit
iora
lay
ng m
ry re
ty re
g of
eter
ting
ery
ear
atte
tarti
wirin
safe
or d
star
batt
ing g
b
s
ctive
ctive
ctive
ctive
ctive
ctive
ctive
en r
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Brok
Confirm recent repair history
Questions
move out
sound
Battery terminal is loose
When battery is checked, battery electrolyte is found to be low
Remedy
20-708 PC200/220(LC)-7
(5)
BACK
TROUBLESHOOTING S-2
(2) Engine turns but no exhaust smoke comes out (Fuel is not being injected)
)
ized
r se
nge
y
nk
t, ke
el ta
k, plu
n
shaf
pisto
in fu
c
p (ra
er
g
drive
pipin
r
mp
rain
hole
n e
pum
u
i
stra
tank
ump
t
p
fuel
her
eed
d
pum
tion
ilter,
on p
l use
reat
el in
king
en f
injec
uel f
air b
jecti
feed
nt fu
r fue
, lea
brok
f
ctive
en in
fficie
ged
ged
ged
rope
ged
ed,
Defe
Clog
Clog
Clog
Clog
Brok
Seiz
Insu
Imp
Confirm recent repair history
Operated for long period
Questions
Replace
Repair
Repair
Remedy
Clean
Clean
Add
PC200/220(LC)-7 20-709
(5)
BACK
TROUBLESHOOTING S-2
(3) Exhaust smoke comes out but engine does not start (Fuel is being injected)
.)
r, etc
• Lack of rotating force due to defective electrical
k)
stuc
r leve
system
cap
y
spra
• Insufficient supply of fuel
r
rocke
nge
tank
em
• Insufficient intake of air
tive
, plu
syst
alve,
ery
fuel
• Improper selection of fuel
efec
k
liner
m (v
batt
c
fuel
t
p (ra
le in
n
aine
le, d
ter
leme
e r
syste
der
ted
r in
rain
r ho
hea
pum
p str
nozz
n
iora
i
er e
g, a
i
t
l
alve
s
y
e
e air
d
c
h
pum
tion
eter
l use
lean
filter
tion
reat
ggin
,
ken v
ring
intak
injec
or d
injec
feed
air b
air c
, clo
r fue
fuel
, bro
ton
ctive
ctive
ctive
n pis
kage
ged
ged
ged
ged
ged
rope
ctive
Defe
Defe
Defe
Clog
Clog
Clog
Clog
Clog
Wor
Defe
Lea
Imp
Confirm recent repair history
Degree of use of machine Operated for long period
Suddenly failed to start
Questions
Replace
Replace
Correct
Correct
Remedy
Clean
Clean
Clean
Clean
Clean
20-710 PC200/220(LC)-7
(5)
BACK
TROUBLESHOOTING S-3
ap
y
seat
spra
• Improper condition of fuel injction
nk c
alve
• Improper fuel used
tive
el ta
nce
nd v
efec
ger
in fu
r
fere
r line
nt
g
iner
ve a
plun
le, d
pipin
leme
inter
aine
ance
hole
nde
stra
f val
nozz
mp
er e
, str
fuel
ger,
i
lear
her
, cyl
mp
act o
n pu
lean
filter
tion
char
reat
king
lve c
u
ring
p
jectio
cont
injec
feed
air c
air b
, lea
urbo
l
r va
e
ton
fu
ed in
ctive
n pis
ged
ged
rope
ged
ged
ged
ed t
ged
Clog
Defe
Clog
Clog
Clog
Clog
Seiz
Seiz
Clog
Wor
Imp
Confirm recent repair history
Degree of use of machine Operated for long period
Replacement of filters has not been carried out according to
Questions
Operation Manual
Non-specified fuel is being used
Engine oil must be added more frequently
Engine pick-up suddenly became poor
Rust and water are found when fuel tank is drained
Air cleaner clogging monitor lights up
Noise of interference is heard from around turbocharger
Blue under light load
Color of exhaust gas
Black
Clanging sound is heard from around cylinder head
Mud is stuck to fuel tank cap
Check items
Replace
Correct
Correct
Adjust
Remedy
Clean
Clean
Clean
Clean
PC200/220(LC)-7 20-711
(11)
BACK
TROUBLESHOOTING S-4
20-712 PC200/220(LC)-7
(5)
BACK
TROUBLESHOOTING S-5
p
zzle
pum
• Air in fuel system
d no
feed
• Defective governor mechanism
p an
• Defective governor motor mechanism
and
pum
nk
a If hunting stops when governor spring is dis-
tank
el ta
k
r
l rac
feed
erno
connected, carry out troubleshooting for E
rnor
fuel
in fu
ntro
mode.
n
v
gove
een
aine
f go
twee
ner
hole
o low
of co
betw
i
p str
nt o
stra
it be
tank
n of
her
is t o
tion
stme
cuit
pum
circu
lter,
ratio
el in
reat
ir
pera
c
i
adju
uel f
spee
ope
feed
air b
air in
nt fu
air in
o
f
ctive
ctive
ctive
fficie
ged
ged
ged
ged,
ged,
idle
Clog
Defe
Clog
Clog
Defe
Defe
Clog
Insu
Clog
Low
Confirm recent repair history
Degree of use of machine Operated for long period
Occurs at a certain speed range
Questions
improperly adjusted
When control rack is pushed, it is found to be heavy, or
does not return
When fuel tank cap is inspected directly, it is found to be clogged
When feed pump strainer is inspected directly, it is
found to be clogged
When fuel filter, strainer are inspected directly, they are
found to be clogged
Correct
Correct
Adjust
Adjust
Adjust
Adjust
Remedy
Clean
Clean
Clean
Add
PC200/220(LC)-7 20-713
(11)
BACK
TROUBLESHOOTING S-6
t
men
y
eat
ragm
spra
• Improper fuel used
t
lve s
djus
nk
(if non-specified fuel is used, output drops)
iaph
tive
el ta
nce
ve a
d va
• Lack of output due to overtaking
efec
or d
in fu
er
fere
i
e an
t
g
nt
a If there is overheating and lack of output,
efec
iping
r
nsat
e, d
aine
plun
er
leme
inter
hole
e
der
valv
train
carry out troubleshooting for overheating.
g, d
ozzl
uel p
mpe
n
p str
mp
cylin
a
er e
ger,
her
lear
prin
t of
s
on n
n pu
st co
pum
f
,
filter
reat
lean
char
king
,
ntac
lve c
ring
or s
jecti
boo
air b
feed
jecti
air c
, lea
urbo
fuel
o
vern
r va
ton
c
i n
ctive
ctive
ed in
n pis
ged
ged
ged
ged
rope
ged
ged
ed t
t go
Defe
Defe
Clog
Clog
Clog
Clog
Clog
Clog
Seiz
Seiz
Ben
Wor
Imp
Confirm recent repair history
Degree of use of machine Operated for long period
Suddenly
Power was lost
Gradually
Questions
Replace
Replace
Replace
Correct
Correct
Adjust
Adjust
Remedy
Clean
Clean
Clean
Clean
20-714 PC200/220(LC)-7
(11)
BACK
TROUBLESHOOTING S-7
ifold
• Insufficient intake of air
man
d)
• Improper condition of fuel injection
on)
eize
take
• Excessive injection of fuel
jecti
seat
er s
y
nd in
spra
ve in
lung
alve
ger a
timin efective
essi
nce
ck, p
nd v
char
fere
(exc
nt
p (ra
ve a
turbo
le, d
leme
inter
ance
r
r
p
inde
uffle
f val
pum
pum
nozz
een
er e
ger,
lear
, cyl
dm
act o
tion
tion
betw
ction
lean
tion
char
ve c
gge
ring
injec
injec
cont
injec
of air
air c
r inje
, clo
l
urbo
r va
ton
ctive
ctive
ctive
n pis
hed
ged
rope
ged
rope
age
ed t
Defe
Defe
Defe
Crus
Clog
Leak
Clog
Seiz
Wor
Imp
Imp
Confirm recent repair history
Degree of use of machine Operated for long period
Suddenly became black
Color of exhaust gas Gradually became black
Questions
is stopped
When check is made using delivery method, injection timing
is found to be incorrect
Injection pump test shows that injection amount is incorrect
When valve clearance is checked directly it is found to be
outside standard value
When muffler is removed, exhaust color returns to normal
When control rack is pushed, it is found to be heavy, or
does not return
Remedy
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Adjust
Adjust
Clean
PC200/220(LC)-7 20-715
(5)
BACK
TROUBLESHOOTING S-8
rger
General causes why oil consumption is excessive
ocha
Turb
• Abnormal combustion of oil
seal
ad
e
• External leakage of oil
r he
c
stem
hose
a
oler
ken
r f
• Wear of lubrication system
al su
inde
il co
, bro
e sy
her
plug
r cyl
l, se
or o
reat
r
intak
ide)
nde
d
nd
n
ing
an o
a
rain
ine e
er e
or b
lter
, gu
e
, cyli
l pip
ar s
om
oil d
oil p
oil fi
blow
ring
stem
ther
turb
in fr
oler
ring
n re
o i
from
from
from
from
iston
brea
il co
al at
lve (
al at
ked
roke
ton
en o
n pis
t suc
en p
kage
kage
kage
n se
kage
n va
n se
ged
n, b
Brok
Clog
Brok
Wor
Wor
Wor
Wor
Wor
Dus
Lea
Lea
Lea
Lea
Confirm recent repair history
Degree of use of machine Operated for long period
Oil consumption suddenly increased
Engine oil must be added more frequently
Questions
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Correct
Correct
Remedy
Clean
20-716 PC200/220(LC)-7
(11)
BACK
TROUBLESHOOTING S-9
PC200/220(LC)-7 20-717
(5)
BACK
TROUBLESHOOTING S-10
• Leakage of fuel
• Improper condition of fuel injection
• Excessive injection of fuel
n)
jectio
n)
er
pisto
el filt
g
sprin
ive in
mp (
g, fu
r
rnor
cess
cove
er
d pu
pipin
lung
ay
gove
p (ex
timin
head
e fee
r spr
fuel
p
nt of
pum
pum
olde
ction
id
side
from
s
al in
stme
h
tion
el in
l inje
io
age
le
t
oil se
nozz
injec
injec
adju
of fu
e
leak
fu
ctive
ctive
ctive
ctive
ctive
ctive
age
rnal
Leak
Defe
Defe
Defe
Defe
Defe
Defe
Exte
Confirm recent repair history
Operated for long period
Questions
Correct
Correct
Correct
Adjust
Adjust
Adjust
Remedy
20-718 PC200/220(LC)-7
(11)
BACK
TROUBLESHOOTING S-11
S-11 Oil is in coolant, or coolant spurts back, or coolant level goes down
t
aske
k
bloc
ring
ad g
r
oole
, O-
der
, he
ting
cylin
core
oil c
ead
y pit
er h
ks in
oler
aulic
b
used
ylind
il co
crac
y d r
en o
en h
en c
s ca
rnal
Brok
Brok
Hole
Brok
Inte
Confirm recent repair history
Degree of use of machine Operated for long period
Questions
Suddenly increased
Oil level
Gradually increased
Hard water is being used as coolant
Engine oil level has risen, oil is cloudy white
Check items
Remedy
PC200/220(LC)-7 20-719
(11)
BACK
TROUBLESHOOTING S-12
20-720 PC200/220(LC)-7
(5)
BACK
TROUBLESHOOTING S-13
r
cove
al
ead
• Coolant in oil (milky white)
nt se
ide h
mp
• Fuel in oil (diluted, and smells of diesel fuel)
et
ipme
ace
gask
n pu
• Entry of oil from other component
g ins
eve
surf
ring
equ
ectio
k
d
le
bloc
hea
pipin
, O-
seal
s
iary
lder
n j
ad,
der
core
ting
i
l
om
rear
t
side
i
osta
x
le ho
p au
r he
cylin
y pit
el fr
oler
n
ged
erm
art i
nozz
nde
pum
de b
of fu
side
il co
ama
h
p
l i
t
y
s ma
ctive
ctive
ctive
ks in
ctive
en o
en c
kage
n, d
Defe
Defe
Defe
Hole
Brok
Defe
Crac
Brok
Wor
Lea
Confirm recent repair history
Questions
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
PC200/220(LC)-7 20-721
(11)
BACK
TROUBLESHOOTING S-14
re
)
ratu
pen
• Rise in oil temperature in hydraulic pump system
t
aske
aug
mpe
ot o
a Carry out troubleshooting for H mode.
pulle
g
ins
ad g
es n
oil te
ure
tor f
fan
ler
, he
erat
e
t (do
o
valv
radia
ump
worn
o
core
ting
ead
oil c
p
osta
tem
p
ure
lic p
pum
y pit
shed
er h
ing,
ator
ken
herm
ress
r
t
wate
olan
drau
b
ylind
ater
slipp
, bro
radi
, cr u
e
p
d
t
of co
in hy
en w
s ma
ctive
ctive
ctive
en c
ged
ged
ged
belt
Lack
Defe
Brok
Brok
Defe
Clog
Hole
Defe
Clog
Rise
Clog
Fan
Confirm recent repair history
Degree of use of machine Operated for long period
Suddenly overheated
Questions
Condition of overheating
Always tends to overheat
Coolant temperature Rises quickly
gauge Does not go down from red range
Radiator water level monitor lights up
Fan belt whines under sudden load
Cloudy white oil is floating on coolant
Cooling water flows out from overflow hose
Excessive air bubbles inside radiator, water spurts back
Engine oil level has risen, oil is cloudy white
Check items
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
Add
20-722 PC200/220(LC)-7
(11)
BACK
TROUBLESHOOTING S-15
ifold
e)
.)
man
, etc
engin
d)
General causes why abnormal noise is made
n)
n )
eize
ositio
lever
ta ke
o
less
t i
injec
er s
nd in
ance
t of p
cker
• Abnormality due to defective parts
liner
lung
e, ro
• Abnormal combustion
d ou
ger a
lear
ce
v
der (
essi
nce
ck, p
eren
le
(valv
• Air sucked in from intake system
boar
ve c
ch a r
cylin
nozz
fere
(exc
ash
f
p (ra
nter
f val
ystem
iding
turbo
ing,
inter
ackl
tion
mp
g
i
pum
nt o
ton r
r (div
l t
n pu
lve s
een
c
ushi
ain b
n be
ger,
tme
of pis
j
ed in
tion
b e tw
uffle
ic va
ectio
ed b
char
n, fa
ar tr
djus
injec
ide m
wear
seiz
ynam
of air
seiz
urbo
d fa
j
r ge
n
a
i
ctive
ctive
ctive
ct ins
,
ssive
rme
rope
ged
en d
ed t
ing,
age
Defe
Defe
Defo
Defe
Leak
Clog
Miss
Defe
Seiz
Exce
Brok
Imp
Confirm recent repair history
Degree of use of machine Operated for long period
Questions
stopped
When control rack is pushed, it is found to be heavy, or does
not return
Injection pump test shows that injection amount is incorrect
Fan is deformed, belt is loose
When valve clearance is checked, it is found to be outside
standard value
Remove cylinder head cover and inspect directly
When muffler is removed, abnormal noise disappears
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
PC200/220(LC)-7 20-723
(5)
BACK
TROUBLESHOOTING S-16
k)
. stuc
noise is made".
tion)
d
gne
r, etc
ion
injec
isali
General causes why vibration is excessive
cush
r leve
fuel
pm
ocke
ken
sive
• Defective parts (abnormal wear, breakage)
pum
ring
lve, r
, bro
• Improper alignment
xces
bea
ulic
m (va
bolts
ash
• Abnormal combustion
ydra
p (e
main
r
mpe
ackl
syste
ting
pum
h
rod,
e da
ain b
and
alve
oun
g
tion
shin
cting
nsid
mic v
gine
ar tr
em
injec
u
art i
dyna
f en
ngin
nne
r ge
mb
ctive
en p
ter o
n co
n ca
rope
se e
ctive
Defe
Brok
Wor
Wor
Cen
Defe
Loo
Imp
Confirm recent repair history
Degree of use of machine Operated for long period
Questions
Suddenly increased
Condition of vibration
Gradually increased
Non-specified oil is being used
Metal particles are found in oil filter
Metal particles are found when oil is drained
Oil pressure is low at low idle
Vibration occurs at mid-range speed
Check items
Replace
Correct
Correct
Adjust
Remedy
20-724 PC200/220(LC)-7
(11)
OTHERS
PC200/220(LC)-7 90-1
(9)
BACK
OTHERS HYDRAULIC CIRCUIT DIAGRAM
PC200-7 90-3
BACK
OTHERS HYDRAULIC CIRCUIT DIAGRAM
PC200-7 90-5
BACK
PC200/220(LC)-7 90-7
(6)
BACK
PC200/220(LC)-7 90-9
(6)
BACK
PC200/220(LC)-7 90-11
(6)
BACK
PC200/220(LC)-7 90-13
(6)
BACK
PC200/220(LC)-7 90-15
(9)
BACK
PC200/220(LC)-7 90-17
(9)
BACK
PC200/220(LC)-7 90-17-2
(9)
BACK
PC200/220(LC)-7 90-17-4
(9)
BACK
PC200/220(LC)-7 90-17-6
(9)
BACK
PC200/220(LC)-7 90-17-8
(9)
BACK
PC200/220(LC)-7 90-17-10
(9)
BACK
PC200/220(LC)-7 90-17-12
(9)
BACK
PC200/220(LC)-7 90-19
(6)
BACK
PC200/220(LC)-7 90-21
(6)