Tra Cuu Nhanh L I PC 200-8

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SEN00084-06
HYDRAULIC
EXCAVATOR
PC200 -8
PC200LC -8
PC220 -8
PC220LC -8
PC200- 300001
PC200LC- 300001
SERIAL NUMBERS and up
PC220- 70001
PC220LC- 70001
10 Structure, function and maintenance standard SEN00103-00
Component 1
Fuel control dial
1. Knob 4. Ball
2. Dial 5. Potentiometer
3. Spring 6. Connector
PC200, 220-8 3
Engine controller
CN-CE01 CN-CE01
Input/ Title
Pin No. Signal name Pin No. Signal name
output panel
1 Electric power supply for lift pump 18 NC(*)
2 Electric power supply for IMA 19 NC(*)
3 Atmosphere sensor 20 NC(*)
4 NC(*) 21 NC(*)
5 NC(*) 22 Engine brake drive D
6 CAN(–) 23 Boost temperature sensor B
7 NC(*) 24 NC(*)
8 CAN(+) 25 Common rail pressure sensor B
9 NC(*) 26 G sensor (+) B
10 NC(*) 27 NE sensor (+) B
11 Lift pump return 28 Engine brake return
12 NC(*) 29 NC(*)
13 NC(*) 30 NC(*)
14 NC(*) 31 NC(*) D
15 Coolant temperature sensor 32 IMA return C
16 5V electric power supply for sensor 33 5V electric power supply for sensor
17 Oil pressure switch 34 NC(*)
*: Never connect to NC or malfunctions or failures will *: Never connect to NC or malfunctions or failures will
occur. occur.
PC200, 220-8 5
SEN00103-00 10 Structure, function and maintenance standard
CN-CE01 CN-CE02
Title Input/
Pin No. Signal name Pin No. Signal name
panel output
35 NC(*) A 20 NC(*)
36 NC(*) 21 NC(*)
37 5V electric power supply for sensor A 22 Fuel control dial (+5V)
38 GND C 23 Fuel control dial (–)
39 NC(*) 24 NC(*)
40 NC(*) 25 NC(*)
41 NC(*) 26 NC(*)
42 NC(*) C 27 NC(*)
43 NC(*) 28 NC(*)
44 Boost pressure sensor B 29 NC(*)
45 Injector #1 (+) D 30 NC(*)
46 Injector #5 (+) D 31 NC(*)
47 G sensor (–) C 32 NC(*)
48 Ne sensor (–) C 33 GND
49 NC(*) 34 NC(*)
50 NC(*) 35 NC(*)
51 Injector #2 (–) C 36 NC(*)
52 Injector #3 (–) C 37 NC(*)
53 Injector #1 (–) C 38 NC(*)
54 Injector #2 (+) D 39 Key switch (ACC)
55 Injector #3 (+) D Electrical intake air heater relay
40
56 Injector #4 (+) D drive
57 Injector #6 (+) D 41 NC(*)
58 Injector #4 (–) C Electrical intake air heater relay
42
59 Injector #6 (–) C return
60 Injector #5 (–) C 43 NC(*)
*: Never connect to NC or malfunctions or failures will 44 NC(*)
occur. 45 NC(*)
46 CAN(+)
CN-CE02 47 CAN(–)
Input/ 48 NC(*)
Pin No. Signal name 49 PWM OUTPUT
output
1 NC(*) 50 NC(*)
2 NC(*) *: Never connect to NC or malfunctions or failures will
3 NC(*) occur.
4 NC(*)
5 NC(*) CN-CE03
6 NC(*) Input/
Pin No. Signal name
7 NC(*) output
8 NC(*) 1 GND
9 Fuel control dial (+) 2 NC(*)
10 NC(*) Electric power supply (+24V con-
3
stantly)
11 NC(*)
4 NC(*)
12 NC(*)
13 NC(*) *: Never connect to NC or malfunctions or failures will
occur.
14 NC(*)
15 NC(*)
16 NC(*)
17 NC(*)
18 NC(*)
19 NC(*)
*: Never connect to NC or malfunctions or failures will
occur.
6 PC200, 220-8
Coolant temperature sensor
1. Sensor
2. O-ring
3. Connector
Oil pressure switch
1. Connector
2. Sensor
3. O-ring
PC200, 220-8 7
Rotation sensor
1. Connector
2. Sensor
3. O-ring
Boost pressure and temperature sensor
1. Connector
2. Sensor
3. O-ring
8 PC200, 220-8
WIF (water-in-fuel detection) sensor
1. Connector
2. Tube
3. Sensor
4. O-ring
Engine oil level sensor
1. Connector
2. Bracket
3. Float
4. Switch
PC200, 220-8 9
9. System component parts

1) PPC oil pressure switch
1. Plug
2. Switch
3. Connector
Specifications
Type of contacts: Normally open contacts
Operating (ON) pressure:
0.5 ± 0.1 MPa {5.0 ± 1.0 kg/cm2}
Resetting (OFF) pressure:
0.3 ± 0.05 MPa {3.0 ± 0.5 kg/cm2}
Function
q The junction block has 2 PPC oil pressure
switches.
q This sensor detects the operating condition of
each actuator by the PPC pressure and trans-
mit it to the pump controller.
PC200, 220-8 27
2) Oil pressure sensor
1. Sensor
2. Connector
Function
q The junction block has 6 PPC oil pressure sen-
sor.
q This sensor detects the operating condition of
each actuator by the PPC pressure and trans-
mit it to the pump controller.
Operation
q The oil pressure is applied to the diaphragm of
the oil pressure sensor from the pressure
intake part, the diaphragm is deformed. q The amplifier magnifies output voltage (E) and
q The deformation in the diaphragm causes the transmits it to the pump controller.
resistance of the gauge to change. This
causes a change in the output voltage, which
is transmitted to the amplifier (voltage ampli-
fier).
q The relationship between the pressure applied

to sensors (P) and output voltage (E) is shown
in the figure below.
28 PC200, 220-8
3) Pump pressure sensor
1. Sensor
2. Connector
Operation
q The relationship between the pressure applied
to sensors (P) and output voltage (E) is shown
in the figure below.
PC200, 220-8 29
Machine monitor 1
Outline
q The machine monitor has the functions to dis-
play various items and the functions to select
modes and electric parts.
q The machine monitor has a CPU (Central Pro-
cessing Unit) in it to process, display, and out-
put the information.
q The monitor display employs an LCD (Liquid
Crystal Display). The switches are flat sheet
switches.
PC200, 220-8 31
Input and output signals CN-CM03

Input/
CN-CM01 Pin No. Signal name
output
Input/ RS232C CD for communica-
Pin No. Signal name 1 Input
output tion terminal
Battery power (+24V con- RS232C RXD for communica-
1 Input 2 Input
stantly) tion terminal
Battery power (+24V con- RS232C SG for communica-
2 Input 3 —
stantly) tion terminal
3 Battery power GND — Signal GND for communication
4 Battery power GND — 4 —
terminal control
Input/ Communication terminal selec-
5 Wake-up 5 Input
Output tion signal
6 Relay output Output RS232C RTS for communica-
6 Output
7 Chassis signal GND — tion terminal
8 NC(*) — RS232C TXD for communica-
7 Output
9 Fuel level Input tion terminal
10 NC(*) — RS232C DTR for communica-
8 Output
11 Charge amount Input tion terminal
12 Chassis analog signal GND — RS232C DTR for communica-
9 Input
13 Light switch Input tion terminal
14 Key switch (ACC) Input RS232C CTS for communica-
10 Input
tion terminal
15 Key switch (C) Input
RS232C RI for communication
16 Preheating Input 11 Input
terminal
17 NC(*) —
Power GND for communication
18 NC(*) — 12 —
terminal
*: Never connect to NC or malfunctions or failures Input CH1 for communication
will occur. 13 Input
terminal status
Output for communication ter-
14 Output
CN-CM02 minal power control
Input/ Output CH1 for communication
Pin No. Signal name 15 Output
output terminal control
1 NC(*) — Output CH2 for communication
16 Output
2 Engine oil level sensor Input terminal control
3 Coolant level sensor Input Input CH2 for communication
17 Input
4 Air cleaner clogging sensor Input terminal status
5 Swing lock Input Electric power supply for com-
18 Output
6 NC(*) Input munication terminal
7 Chassis signal GND —
8 CAN terminating resistance —
Input/ CN-CM04
9 CAN_H
Output Input/
Pin No. Signal name
Input/ output
10 CAN_L
Output 1 NC(*) —
Input/ 2 NC(*) —
11 NC(*)
Output 3 NC(*) —
Input/ 4 NC(*) —
12 NC(*)
Output 5 NC(*) —
*: Never connect to NC or malfunctions or failures 6 NC(*) —
will occur. 7 NC(*) —
8 NC(*) —
9 NC(*) —
10 NC(*) —
11 NC(*) —
12 NC(*) —
*: Never connect to NC or malfunctions or failures
will occur.
32 PC200, 220-8
CN-CM05
Input/
Pin No. Signal name
output
Electric power supply for cam-
1 Output
era
2 Camera NTSC signal input 1 Input
Electric power supply GND for
5 —
camera
6 Camera signal GND1 —
PC200, 220-8 33
30 Testing and adjusting SEN00229-02
Failure codes table

User Alarm Component Category of
Failure code Trouble (Displayed on screen)
code buzzer in charge record
Electrical
989L00 Engine Controller Lock Caution 1 MON
system
Electrical
989M00 Engine Controller Lock Caution 2 MON
system
Electrical
989N00 Engine Controller Lock Caution 3 MON
system
Mechanical
AA10NX Air Cleaner Clogging MON
system
Mechanical
AB00KE Charge Voltage Low MON
system
Mechanical
B@BAZG Eng Oil Press. Low e ENG
system
Mechanical
B@BAZK Eng Oil Level Low MON
system
Mechanical
B@BCNS Eng Water Overheat e ENG
system
Mechanical
B@BCZK Eng Water Level Low e MON
system
Mechanical
B@HANS Hydr Oil Overheat e PUMP
system
Electrical
E10 CA111 EMC Critical Internal Failure q ENG
system
Electrical
E10 CA115 Eng Ne and Bkup Speed Sens Error q ENG
system
Electrical
E11 CA122 Chg Air Press Sensor High Error q ENG
system
Electrical
E11 CA123 Chg Air Press Sensor Low Error q ENG
system
Electrical
E14 CA131 Throttle Sensor High Error q ENG
system
Electrical
E14 CA132 Throttle Sensor Low Error q ENG
system
Electrical
E15 CA144 Coolant Temp Sens High Error q ENG
system
Electrical
E15 CA145 Coolant Temp Sens Low Error q ENG
system
Electrical
E15 CA153 Chg Air Temp Sensor High Error q ENG
system
Electrical
E15 CA154 Chg Air Temp Sensor Low Error q ENG
system
Electrical
E11 CA155 Chg Air Temp High Speed Derate q ENG
system
Electrical
E15 CA187 Sens Supply 2 Volt Low Error q ENG
system
Electrical
E11 CA221 Ambient Press Sens High Error q ENG
system
Electrical
E11 CA222 Ambient Press Sens Low Error q ENG
system
Electrical
E15 CA227 Sens Supply 2 Volt High Error q ENG
system
Mechanical
CA234 Eng Overspeed ENG
system
Electrical
E15 CA238 Ne Speed Sens Supply Volt Error q ENG
system
Electrical
E10 CA271 IMV/PCV1 Short Error q ENG
system
Electrical
E10 CA272 IMV/PCV1 Open Error q ENG
system
Electrical
E11 CA322 Inj #1 (L#1) Open/Short Error q ENG
system
PC200, 220-8 29
SEN00229-02 30 Testing and adjusting

Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
E10 CA342 Calibration Code Incompatibility q ENG
system
Electrical
E10 CA351 Injectors Drive Circuit Error q ENG
system
Electrical
system
Electrical
system
Electrical
E15 CA428 Water in Fuel Sensor High Error q ENG
system
Electrical
E15 CA429 Water in Fuel Sensor Low Error q ENG
system
Electrical
E15 CA435 Eng Oil Press Sw Error q ENG
system
Electrical
E10 CA441 Battery Voltage Low Error q ENG
system
Electrical
E10 CA442 Battery Voltage High Error q ENG
system
Electrical
E11 CA449 Rail Press Very High Error q ENG
system
Electrical
E11 CA451 Rail Press Sensor High Error q ENG
system
Electrical
E11 CA452 Rail Press Sensor Low Error q ENG
system
Electrical
E11 CA488 Chg Air Temp High Torque Derate q ENG
system
Electrical
E15 CA553 Rail Press High Error q ENG
system
Electrical
E15 CA559 Rail Press Low Error q ENG
system
Electrical
E15 CA689 Eng Ne Speed Sensor Error q ENG
system
Electrical
E15 CA731 Eng Bkup Speed Sens Phase Error q ENG
system
Electrical
E10 CA757 All Continuous Data Lost Error q ENG
system
Electrical
E15 CA778 Eng Bkup Speed Sensor Error q ENG
system
Electrical
E0E CA1633 KOMNET Datalink Timeout Error q ENG
system
Electrical
E14 CA2185 Throt Sens Sup Volt High Error q ENG
system
Electrical
E14 CA2186 Throt Sens Sup Volt Low Error q ENG
system
Electrical
E11 CA2249 Rail Press Very Low Error q ENG
system
Electrical
E11 CA2311 IMV Solenoid Error q ENG
system
Electrical
E15 CA2555 Grid Htr Relay Volt High Error q ENG
system
30 PC200, 220-8
30 Testing and adjusting SEN00229-02

Electrical
E15 CA2556 Grid Htr Relay Volt Low Error q ENG
system
Electrical
E01 D19JKZ Personal Code Relay Abnormality q MON2
system
Electrical
D862KA GPS Antenna Discon MON2
system
Electrical
E0E DA22KK Pump Solenoid Power Low Error q PUMP
system
Electrical
DA25KP 5 V Sensor 1 Power Abnormality PUMP
system
Electrical
DA29KQ Model Selection Abnormality PUMP
system
Electrical
E0E DA2RMC CAN Discon (Pump Con Detected) q PUMP
system
Electrical
DAF8KB Short circuit in camera power supply MON
system
Electrical
DAFGMC GPS Module Error MON2
system
Electrical
E0E DAFRMC CAN Discon (Monitor Detected) q MON
system
Electrical
DGH2KB Hydr Oil Sensor Short PUMP
system
Electrical
DHPAMA F Pump Press Sensor Abnormality PUMP
system
Electrical
DHPBMA R Pump Press Sensor Abnormality PUMP
system
Electrical
DHS3MA Arm Curl PPC Press Sensor Abnormality PUMP
system
Electrical
DHS4MA Bucket Curl PPC Press Sensor Abnormality PUMP
system
Electrical
DHS8MA Boom Raise PPC Press Sensor Abnormality PUMP
system
Electrical
DHSAMA Swing RH PPC Press Sensor Abnormality PUMP
system
Electrical
DHSBMA Swing LH PPC Press Sensor Abnormality PUMP
system
Electrical
DHSDMA Bucket Dump PPC Press Sensor Abnormality PUMP
system
Electrical
DHX1MA Overload Sensor Abnormality (Analog) PUMP
system
Electrical
DW43KA Travel Speed Sol Discon PUMP
system
Electrical
DW43KB Travel Speed Sol Short PUMP
system
Electrical
E03 DW45KA Swing Brake Sol Discon q PUMP
system
Electrical
E03 DW45KB Swing Brake Sol Short q PUMP
system
Electrical
DW91KA Travel Junction Sol Discon PUMP
system
Electrical
DW91KB Travel Junction Sol Short PUMP
system
Electrical
DWA2KA Service Sol Discon PUMP
system
Electrical
DWA2KB Service Sol Short PUMP
system
Electrical
DWK0KA 2-stage Relief Sol Discon PUMP
system
Electrical
DWK0KB 2-stage Relief Sol Short PUMP
system
PC200, 220-8 31
SEN00229-02 30 Testing and adjusting

Electrical
E02 DXA8KA PC-EPC (F) Sol Discon q PUMP
system
Electrical
E02 DXA8KB PC-EPC (F) Sol Short q PUMP
system
Electrical
E02 DXA9KA PC-EPC (R) Sol Discon q PUMP
system
Electrical
E02 DXA9KB PC-EPC (R) Sol Short q PUMP
system
Electrical
DXE0KA LS-EPC Sol Discon PUMP
system
Electrical
DXE0KB LS-EPC Sol Short PUMP
system
Electrical
DXE4KA Service Current EPC Discon PUMP
system
Electrical
DXE4KB Service Current EPC Short PUMP
system
Electrical
DXE5KA Merge-divider Main Sol Discon PUMP
system
Electrical
DXE5KB Merge-divider Main Sol Short PUMP
system
Electrical
DXE6KA Merge-divider LS Sol Discon PUMP
system
Electrical
DXE6KB Merge-divider LS Sol Short PUMP
system
Electrical
DY20KA Wiper Working Abnormality PUMP
system
Electrical
DY20MA Wiper Parking Abnormality PUMP
system
Electrical
DY2CKA Washer Drive Discon PUMP
system
Electrical
DY2CKB Washer Drive Short PUMP
system
Electrical
DY2DKB Wiper Drive (For) Short PUMP
system
Electrical
DY2EKB Wiper Drive (Rev) Short PUMP
system
a Entry order of items in table

The items are entered in the order of their failure codes (incremental order).
a User code
Attached : If the failure code is detected, the user code, failure code, and telephone No. (if regis-
tered) are displayed on the ordinary screen to notify the operator of the abnormality.
Not attached: Even if the failure code is detected, the machine monitor does not notify the operator of
the abnormality.
a Alarm buzzer
q : When occurrence of an error is notified to the operator, the buzzer sounds (The operator can stop
the buzzer with the alarm buzzer cancel switch).
e: Since the caution monitor is also turned ON, its function sounds the buzzer.
a Component in charge
MON: The machine monitor is in charge of detection of abnormality.
MON2: The KOMTRAX section of the machine monitor is in charge of detection of abnormality.
ENG: The engine controller is in charge of detection of abnormality.
PUMP: The pump controller is in charge of detection of abnormality.
a Category of record
Mechanical system: Abnormality information is recorded in the mechanical system abnormality record.
Electrical system: Abnormality information is recorded in the electrical system abnormality record.
32 PC200, 220-8
40 Troubleshooting SEN00231-02
3. Color codes table
(Table 4)
Color Code Color of wire Color Code Color of wire
B Black LgW Light green & White
Br Brown LgY Light green & Yellow
BrB Brown & Black LR Blue & Red
BrR Brown & Red LW Blue & White
BrW Brown & White LY Blue & Yellow
BrY Brown & Yellow O Orange
Ch Charcoal P Pink
Dg Dark green R Red
G Green RB Red & Black
GB Green & Black RG Red & Green
GL Green & Blue RL Red & Blue
Gr Gray RW Red & White
GR Green & Red RY Red & Yellow
GW Green & White Sb Sky Blue
GY Green & Yellow Y Yellow
L Blue YB Yellow & Black
LB Blue & Black YG Yellow &Green
Lg Light green YL Yellow & Blue
LgB Light green & Black YR Yellow & Red
LgR Light green & Red YW Yellow & White
Remarks: In a color code consisting of 2 colors, the first color is the color of the background and the
second color is the color of the marking.
Example: “GW” means that the background is Green and marking is White.
4. Types of circuits and color codes
(Table 5)
Type of wire AVS or AV AEX
Charge R WG — — — — R —
Ground B — — — — — B —
Start R — — — — — R —
Light RW RB RY RG RL — D —
Instrument Y YR YB YG YL YW Y Gr
Signal G GW GR GY GB GL G Br
L LW LR LY LB — L —
Type of
Br BrW BrR BrY BrB — — —
circuit
Lg LgR LgY LgB LgW — — —
O — — — — — — —
Others Gr — — — — — — —
P — — — — — — —
Sb — — — — — — —
Dg — — — — — — —
Ch — — — — — — —
PC200, 220-8 11
SEN00231-02 40 Troubleshooting
Connection table for connector pin numbers (Rev. 2007.4)
a The terms of male and female refer to the pins, while the terms of male housing and female housing
refer to the mating portion of the housing.
12 PC200, 220-8
PC200, 220-8 13
14 PC200, 220-8
PC200, 220-8 15
16 PC200, 220-8
PC200, 220-8 17
18 PC200, 220-8
PC200, 220-8 19
20 PC200, 220-8
PC200, 220-8 21
22 PC200, 220-8
PC200, 220-8 23
24 PC200, 220-8
PC200, 220-8 25
26 PC200, 220-8
PC200, 220-8 27
28 PC200, 220-8
PC200, 220-8 29
30 PC200, 220-8
PC200, 220-8 31
32 PC200, 220-8
PC200, 220-8 33
34 PC200, 220-8
PC200, 220-8 35
36 PC200, 220-8
PC200, 220-8 37
38 PC200, 220-8
PC200, 220-8 39
40 PC200, 220-8
PC200, 220-8 41
42 PC200, 220-8
PC200, 220-8 43
44 PC200, 220-8
PC200, 220-8 45
SEN00240-02
HYDRAULIC EXCAVATOR 1SHOP MANUAL
PC200-8
PC200LC-8
PC220-8
PC220LC-8
Machine model Serial number

PC200-8 300001 and up
PC200LC-8 300001 and up
PC220-8 70001 and up
PC220LC-8 70001 and up
40 Troubleshooting 1
Troubleshooting by failure code
(Display of code), Part 1
Troubleshooting by failure code (Display of code), Part 1 .............................................................................. 3
Failure codes table ............................................................................................................................... 3
Before carrying out troubleshooting when failure code is displayed .................................................... 8
Information in troubleshooting table ................................................................................................... 12
Failure code [989L00] Engine Controller Lock Caution 1................................................................... 14
Failure code [989M00] Engine Controller Lock Caution 2.................................................................. 14
Failure code [989N00] Engine Controller Lock Caution 3 .................................................................. 15
Failure code [AA10NX] Air Cleaner Clogging .................................................................................... 15
Failure code [AB00KE] Charge Voltage Low ..................................................................................... 16
Failure code [B@BAZG] Eng Oil Press. Low ..................................................................................... 18
Failure code [B@BAZK] Eng Oil Level Low ....................................................................................... 18
Failure code [B@BCNS] Eng Water Overheat................................................................................... 19
Failure code [B@BCZK] Eng Water Level Low.................................................................................. 19
Failure code [B@HANS] Hydr Oil Overheat....................................................................................... 20
PC200, 220-8 1
Failure code [CA111] EMC Critical Internal Failure ............................................................................ 20

Failure code [CA115] Eng Ne and Bkup Speed Sens Error ............................................................... 21
Failure code [CA122] Chg Air Press Sensor High Error..................................................................... 22
Failure code [CA123] Chg Air Press Sensor Low Error ..................................................................... 24
Failure code [CA131] Throttle Sensor High Error............................................................................... 26
Failure code [CA132] Throttle Sensor Low Error ............................................................................... 28
Failure code [CA144] Coolant Temp Sens High Error........................................................................ 30
Failure code [CA145] Coolant Temp Sens Low Error......................................................................... 32
Failure code [CA153] Chg Air Temp Sensor High Error ..................................................................... 34
Failure code [CA154] Chg Air Temp Sensor Low Error...................................................................... 36
Failure code [CA155] Chg Air Temp High Speed Derate ................................................................... 38
Failure code [CA187] Sens Supply 2 Volt Low Error.......................................................................... 40
Failure code [CA221] Ambient Press Sens High Error....................................................................... 42
Failure code [CA222] Ambient Press Sens Low Error ....................................................................... 44
Failure code [CA227] Sens Supply 2 Volt High Error ......................................................................... 46
Failure code [CA234] Eng Overspeed................................................................................................ 47
Failure code [CA238] Ne Speed Sens Supply Volt Error.................................................................... 48
Failure code [CA271] IMV/PCV1 Short Error ..................................................................................... 49
Failure code [CA272] IMV/PCV1 Open Error ..................................................................................... 50
Failure code [CA322] Inj #1 (L#1) Open/Short Error .......................................................................... 52
2 PC200, 220-8
Troubleshooting by failure code (Display of code), Part 1 1

Failure codes table 1
a This failure codes table is the same as that in Testing and adjusting, Special functions of machine monitor.
User Alarm Device in Category
code buzzer charge of history
Electrical
989L00 Engine Controller Lock Caution 1 MON
system
Electrical
989M00 Engine Controller Lock Caution 2 MON
system
Electrical
989N00 Engine Controller Lock Caution 3 MON
system
Mechani-
AA10NX Air Cleaner Clogging MON
cal system
Mechani-
AB00KE Charge Voltage Low MON
cal system
Mechani-
B@BAZG Eng Oil Press. Low e ENG
cal system
Mechani-
B@BAZK Eng Oil Level Low MON
cal system
Mechani-
B@BCNS Eng Water Overheat e ENG
cal system
Mechani-
B@BCZK Eng Water Level Low e MON
cal system
Mechani-
B@HANS Hydr Oil Overheat e PUMP
cal system
Electrical
E10 CA111 EMC Critical Internal Failure q ENG
system
Electrical
E10 CA115 Eng Ne and Bkup Speed Sens Error q ENG
system
Electrical
E11 CA122 Chg Air Press Sensor High Error q ENG
system
Electrical
E11 CA123 Chg Air Press Sensor Low Error q ENG
system
Electrical
E14 CA131 Throttle Sensor High Error q ENG
system
Electrical
E14 CA132 Throttle Sensor Low Error q ENG
system
Electrical
E15 CA144 Coolant Temp Sens High Error q ENG
system
Electrical
E15 CA145 Coolant Temp Sens Low Error q ENG
system
Electrical
E15 CA153 Chg Air Temp Sensor High Error q ENG
system
Electrical
E15 CA154 Chg Air Temp Sensor Low Error q ENG
system
Electrical
E11 CA155 Chg Air Temp High Speed Derate q ENG
system
Electrical
system
Electrical
E11 CA221 Ambient Press Sens High Error q ENG
system
PC200, 220-8 3

Electrical
E11 CA222 Ambient Press Sens Low Error q ENG
system
Electrical
system
Mechani-
CA234 Eng Overspeed ENG
cal system
Electrical
E15 CA238 Ne Speed Sens Supply Volt Error q ENG
system
Electrical
E10 CA271 IMV/PCV1 Short Error q ENG
system
Electrical
E10 CA272 IMV/PCV1 Open Error q ENG
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
E10 CA342 Calibration Code Incompatibility q ENG
system
Electrical
E10 CA351 Injectors Drive Circuit Error q ENG
system
Electrical
system
Electrical
system
Electrical
E15 CA428 Water in Fuel Sensor High Error q ENG
system
Electrical
E15 CA429 Water in Fuel Sensor Low Error q ENG
system
Electrical
E15 CA435 Eng Oil Press Sw Error q ENG
system
Electrical
E10 CA441 Battery Voltage Low Error q ENG
system
Electrical
E10 CA442 Battery Voltage High Error q ENG
system
Electrical
E11 CA449 Rail Press Very High Error q ENG
system
Electrical
E11 CA451 Rail Press Sensor High Error q ENG
system
Electrical
E11 CA452 Rail Press Sensor Low Error q ENG
system
Electrical
E11 CA488 Chg Air Temp High Torque Derate q ENG
system
4 PC200, 220-8

Electrical
E15 CA553 Rail Press High Error q ENG
system
Electrical
E15 CA559 Rail Press Low Error q ENG
system
Electrical
E15 CA689 Eng Ne Speed Sensor Error q ENG
system
Electrical
E15 CA731 Eng Bkup Speed Sens Phase Error q ENG
system
Electrical
E10 CA757 All Continuous Data Lost Error q ENG
system
Electrical
E15 CA778 Eng Bkup Speed Sensor Error q ENG
system
Electrical
E0E CA1633 KOMNET Datalink Timeout Error q ENG
system
Electrical
E14 CA2185 Throt Sens Sup Volt High Error q ENG
system
Electrical
E14 CA2186 Throt Sens Sup Volt Low Error q ENG
system
Electrical
E11 CA2249 Rail Press Very Low Error q ENG
system
Electrical
E11 CA2311 IMV Solenoid Error q ENG
system
Electrical
E15 CA2555 Grid Htr Relay Volt High Error q ENG
system
Electrical
E15 CA2556 Grid Htr Relay Volt Low Error q ENG
system
Electrical
E01 D19JKZ Personal Code Relay Abnormality q MON2
system
Electrical
D862KA GPS Antenna Discon MON2
system
Electrical
E0E DA22KK Pump Solenoid Power Low Error q PUMP
system
Electrical
DA25KP 5V Sensor 1 Power Abnormality PUMP
system
Electrical
DA29KQ Model Selection Abnormality PUMP
system
Electrical
E0E DA2RMC CAN Discon (Pump Con Detected) q PUMP
system
Electrical
DAF8KB Short circuit in camera power supply MON
system
Electrical
DAFGMC GPS Module Error MON2
system
Electrical
E0E DAFRMC CAN Discon (Monitor Detected) q MON
system
Electrical
DGH2KB Hydr Oil Sensor Short PUMP
system
Electrical
DHPAMA F Pump Press Sensor Abnormality PUMP
system
Electrical
DHPBMA R Pump Press Sensor Abnormality PUMP
system
PC200, 220-8 5

Electrical
DHS3MA Arm Curl PPC Press Sensor Abnormality PUMP
system
Electrical
DHS4MA Bucket Curl PPC Press Sensor Abnormality PUMP
system
Electrical
DHS8MA Boom Raise PPC Press Sensor Abnormality PUMP
system
Electrical
DHSAMA Swing RH PPC Press Sensor Abnormality PUMP
system
Electrical
DHSBMA Swing LH PPC Press Sensor Abnormality PUMP
system
Electrical
DHSDMA Bucket Dump PPC Press Sensor Abnormality PUMP
system
Electrical
DHX1MA Overload Sensor Abnormality (Analog) PUMP
system
Electrical
DW43KA Travel Speed Sol Discon PUMP
system
Electrical
DW43KB Travel Speed Sol Short PUMP
system
Electrical
E03 DW45KA Swing Brake Sol Discon q PUMP
system
Electrical
E03 DW45KB Swing Brake Sol Short q PUMP
system
Electrical
DW91KA Travel Junction Sol Discon PUMP
system
Electrical
DW91KB Travel Junction Sol Short PUMP
system
Electrical
DWA2KA Service Sol Discon PUMP
system
Electrical
DWA2KB Service Sol Short PUMP
system
Electrical
DWK0KA 2-stage Relief Sol Discon PUMP
system
Electrical
DWK0KB 2-stage Relief Sol Short PUMP
system
Electrical
E02 DXA8KA PC-EPC (F) Sol Discon q PUMP
system
Electrical
E02 DXA8KB PC-EPC (F) Sol Short q PUMP
system
Electrical
E02 DXA9KA PC-EPC (R) Sol Discon q PUMP
system
Electrical
E02 DXA9KB PC-EPC (R) Sol Short q PUMP
system
Electrical
DXE0KA LS-EPC Sol Discon PUMP
system
Electrical
DXE0KB LS-EPC Sol Short PUMP
system
Electrical
DXE4KA Service Current EPC Discon PUMP
system
Electrical
DXE4KB Service Current EPC Short PUMP
system
6 PC200, 220-8

Electrical
DXE5KA Merge-divider Main Sol Discon PUMP
system
Electrical
DXE5KB Merge-divider Main Sol Short PUMP
system
Electrical
DXE6KA Merge-divider LS Sol Discon PUMP
system
Electrical
DXE6KB Merge-divider LS Sol Short PUMP
system
Electrical
DY20KA Wiper Working Abnormality PUMP
system
Electrical
DY20MA Wiper Parking Abnormality PUMP
system
Electrical
DY2CKA Washer Drive Discon PUMP
system
Electrical
DY2CKB Washer Drive Short PUMP
system
Electrical
DY2DKB Wiper Drive (For) Short PUMP
system
Electrical
DY2EKB Wiper Drive (Rev) Short PUMP
system
a Entry order of items in table

The items are entered in the order of their failure codes (incremental order).
a User code
Attached : If the failure code is detected, the user code, failure code, and telephone No. (if regis-
tered) are displayed on the ordinary screen to notify the operator of the abnormality.
Not attached: Even if the failure code is detected, the machine monitor does not notify the operator of
the abnormality.
a Alarm buzzer
q : When occurrence of an error is notified to the operator, the buzzer sounds (The operator can stop
the buzzer with the alarm buzzer cancel switch).
e: Since the caution monitor is also turned ON, its function sounds the buzzer.
a Component in charge
MON: The machine monitor is in charge of detection of abnormality.
MON2: The KOMTRAX section of the machine monitor is in charge of detection of abnormality.
ENG: The engine controller is in charge of detection of abnormality.
PUMP: The pump controller is in charge of detection of abnormality.
a Category of record
Mechanical system: Abnormality information is recorded in the mechanical system abnormality record.
Electrical system: Abnormality information is recorded in the electrical system abnormality record.
PC200, 220-8 7
Before carrying out troubleshooting when failure code is displayed 1

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

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

a The solenoid power supply (F01-2) of the pump controller is used by the controller to drive the solenoids
and relays. 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 failure codes are displayed simultaneously.
q [DW43KA], [DW43KB]: Travel speed solenoid system
q [DW45KA], [DW45KB]: Swing holding brake solenoid system
q [DW91KA], [DW91KB]: Travel junction solenoid system
q [DWA2KA], [DWA2KB]: Service solenoid system
q [DWK0KA], [DWK0KB]: 2-stage relief solenoid system
q [DXA8KA], [DXA8KB]: PC-EPC (F) solenoid system
q [DXA9KA], [DXA9KB]: PC-EPC (R) solenoid system
q [DXE0KA], [DXE0KB]: LS-EPC solenoid system
q [DXE4KA], [DXE4KB]: Service current EPC system (if attachment is installed)
q [DXE5KA], [DXE5KB]: Merge-divider main solenoid system
q [DXE6KA], [DXE6KB]: Merge-divider LS solenoid system
a If the above problems occur, check the related fuse (F01-2) and inlet voltage of the pump controller.
1) Disconnect connectors C01 and C02 of the controller and connect a T-adapter box to the wiring
harness side.
2) Turn the starting switch ON.
3) Measure the voltage between each of pins C02 (116), (118), and (121) and each of pins C01 (2)
and (5).
a Pins C02 (116), (118), and (121) are the power supply and pins C01 (2) and (5) are the chassis
ground.
a If the voltage is 20 – 30 V, it is normal.
a Power supply connectors (C01, C02) of pump controller
PC200, 220-8 11
Information in troubleshooting table 1

a The following information is summarized in the troubleshooting table and the related electrical circuit
diagram. Before carrying out troubleshooting, understand that information fully.
User code Failure code
Display on Trouble Trouble name displayed in abnormality record machine monitor
Display on machine
machine moni-
monitor
tor
Contents of
Contents of trouble detected by machine monitor or controller
trouble
Action of
Action taken by machine monitor or controller to protect system or devices when engine con-
machine moni-
troller detects trouble
tor or controller
Problem that
Problem that appears on machine as result of action taken by machine monitor or controller
appears on
(shown above)
machine
Related infor-
Information related to detected trouble or troubleshooting
mation
Cause Standard value in normal state/Remarks on troubleshooting
<Contents of description>
• Standard value in normal state to judge possible causes
• Remarks on judgment
1
<Troubles in wiring harness>
• Disconnection
Connector is connected imperfectly or wiring harness is bro-
ken.
• Ground fault
Wiring harness which is not connected to chassis ground
circuit is in contact with chassis ground circuit.
• Hot short
Wiring harness which is not connected to power source (24
2 V) circuit is in contact with power source (24 V) circuit.
• Short circuit
Independent wiring harnesses are in contact with each other
Possible causes abnormally.
and standard Possible causes of trouble
value in normal (Given numbers are refer-
<Precautions for troubleshooting>
state ence numbers, which do not
(1) Method of indicating connector No. and handling of T-
indicate priority)
adapter
Insert or connect T-adapter as explained below for trouble-
shooting, unless otherwise specified.
3 • If connector No. has no marks of "male" and "female",
disconnect connector and insert T-adapters in both male
side and female side.
• If connector No. has marks of "male" and "female", dis-
connect connector and connect T-adapter to only male
side or female side.
(2) Entry order of pin Nos. and handling of tester leads
Connect positive (+) lead and negative (–) lead of tester as
explained below for troubleshooting, unless otherwise
specified.
4 • Connect positive (+) lead to pin No. or wiring harness
entered on front side.
• Connect negative (–) lead to pin No. or harness entered
on rear side.
12 PC200, 220-8
Related circuit diagram
This drawing is a part of the electric circuit diagram related

to troubleshooting.
• Connector No.: Indicates (Model – Number of pins) and
(Color).
• "Connector No. and pin No." from each branching/merg-
ing point: Shows the ends of branch or source of merging
within the parts of the same wiring harness.
• Arrow (io): Roughly shows the location on the machine.
PC200, 220-8 13
Failure code [989L00] Engine Controller Lock Caution 1 1

User code Failure code Engine controller lock caution 1
Trouble
— 989L00 (Machine monitor system)
Contents of
• Engine controller lock is detected (Factor 1).
trouble
Action of • None in particular.
machine monitor • If cause of failure disappears, system resets itself.
Problem that
appears on • Engine cannot be started.
machine
• If this failure code is displayed after machine monitor is replaced, user password must be changed to
Related infor-
one before replacement.
mation
• Method of reproducing failure code: Turn starting switch ON.
Possible causes Cause Standard value in normal state/Remarks on troubleshooting

and standard
value in normal Replacement of machine
1 This trouble may be caused by replacement of machine monitor.
state monitor
Failure code [989M00] Engine Controller Lock Caution 2 1

Trouble
— 989M00 (Machine monitor system)
Contents of
trouble
Problem that
appears on • Engine cannot be started.
machine
• If this failure code is displayed after machine monitor is replaced, user password must be changed to
Related infor-
one before replacement.
mation

Possible causes Replacement of machine
1 This trouble may be caused by replacement of machine monitor.
and standard monitor
value in normal If this failure code is displayed while machine monitor is not
state 2 Defective machine monitor replaced, machine monitor may be defective. (Since trouble is in
system, troubleshooting cannot be carried out.)
14 PC200, 220-8
Failure code [989N00] Engine Controller Lock Caution 3 1

Trouble
— 989N00 (Machine monitor system)
Contents of
trouble
Action of • Tries automatic resetting.
Problem that
appears on
machine
Related infor- • Method of reproducing failure code: Failure code is not reproduced since system is reset automati-
mation cally.

and standard If this failure code is displayed repeatedly, engine controller may be
value in normal 1 Defective engine controller defective. (Since trouble is in system, troubleshooting cannot be
state carried out.)
Failure code [AA10NX] Air Cleaner Clogging 1

User code Failure code Air cleaner clogging
Trouble
— AA10NX (Machine monitor system)
Contents of • While engine was running, signal circuit of air cleaner clogging switch detected clogging of air
trouble cleaner (sensor contact opened).
Action of • Displays air cleaner clogging monitor on machine monitor.
Problem that
appears on • If machine is operated as it is, engine may be damaged.
machine
• Condition of air cleaner clogging switch signal can be checked with monitoring function.
Related infor-
(Code: 04501 Monitor input 2)
mation
• Method of reproducing failure code: Start engine.

Possible causes Clogging of air cleaner (when Air cleaner may be clogged. Check it for clogging and then clean or
1
and standard system is normal) replace if clogged.
value in normal If cause 1 is not detected, air cleaner clogging monitor system may
state Defective air cleaner clog-
2 be defective. Carry out troubleshooting for "E-7 Caution item
ging monitor system
flashes while engine is running" in E-mode.
PC200, 220-8 15
Failure code [AB00KE] Charge Voltage Low 1

User code Failure code Charge voltage low
Trouble
— AB00KE (Machine monitor system)
Contents of
• While engine is running, signal circuit of alternator detected low charge voltage (below 7.8 V).
trouble
Action of • Displays charge level monitor on machine monitor.
machine monitor • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • If machine is operated as it is, battery may not be charged.
machine
Related infor- • Signal voltage of alternator can be checked with monitoring function. (Code: 04300 Charge voltage)
mation • Method of reproducing failure code: Start engine.

a Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
Possible causes Defective charge of alterna-
1 E12 (male) Engine speed Voltage
and standard tor (when system is normal)
value in normal Between (1) – chas-
Min. medium speed 27.5 – 29.5 V
state sis ground
If cause 1 is not detected, charge level monitor system may be
Defective charge level moni-
2 defective. Carry out troubleshooting for "E-7 Caution item flashes
tor
while engine is running" in E-mode.
16 PC200, 220-8
Circuit diagram related to preheating/starting of engine and charge of battery
PC200, 220-8 17
Failure code [B@BAZG] Eng Oil Press. Low 1

User code Failure code Engine oil pressure low
Trouble
— B@BAZG (Engine controller system)
Contents of • While engine was running, signal circuit of engine oil pressure switch detected low engine oil pres-
trouble sure (sensor contact opened).
Action of • Displays engine oil pressure monitor on machine monitor.
controller • If cause of failure disappears, system resets itself.
Problem that
machine
• Engine oil pressure switch signal is input to engine controller and then transmitted to machine moni-
Related infor-
tor.
mation

Lowering of engine oil pres-
Possible causes Engine oil pressure may be low. Check it and remove cause if it is
1 sure (when system is nor-
and standard low.
mal)
value in normal
state If cause 1 is not detected, engine oil pressure monitor system may
Defective engine oil pressure
2 be defective. Carry out troubleshooting for "E-8 Emergency stop
monitor system
item lights up while engine is running" in E-mode.
Failure code [B@BAZK] Eng Oil Level Low 1

User code Failure code Engine oil level low
Trouble
— B@BAZK (Machine monitor system)
Contents of • When starting switch is turned ON (but engine is not started), signal circuit of engine oil level switch
trouble detected low engine oil level (sensor contact opened).
Action of • Displays engine oil level monitor on machine monitor.
Problem that
machine
Related infor- • Engine oil level switch signal can be checked with monitoring function. (Code: 04501 Monitor input 2)
mation • Method of reproducing failure code: Turn starting switch ON.

Lowering of engine oil level
Possible causes 1 Engine oil level may be low. Check it and add new oil if it is low.
(when system is normal)
and standard
value in normal If cause 1 is not detected, engine oil level monitor system may be
state Defective engine oil level defective. Carry out troubleshooting for "E-2 Basic check item lights
2
monitor system up when starting switch is turned ON (but engine is not started)" in
E-mode.
18 PC200, 220-8
Failure code [B@BCNS] Eng Water Overheat 1

User code Failure code Engine coolant overheat
Trouble
— B@BCNS (Engine controller system)
Contents of • While engine was running, signal circuit of engine coolant temperature sensor detected overheating
trouble of engine coolant (above about 102°C).
Action of • Displays engine coolant temperature monitor with red on machine monitor.
Problem that
appears on • If machine is operated as it is, engine may seize up.
machine
• Engine coolant temperature sensor signal is input to engine controller and then transmitted to
machine monitor.
Related infor-
• Engine coolant temperature can be checked with monitoring function
mation
(Code: 04107 Engine coolant temperature)

Overheating of engine
Possible causes Engine coolant may be overheating. Check it and remove cause if it
1 coolant (when system is nor-
and standard is overheating.
mal)
value in normal
state If cause 1 is not detected, engine coolant temperature gauge sys-
Defective engine coolant
2 tem may be defective. Carry out troubleshooting for "E-9 Engine
temperature gauge system
coolant temperature gauge does not work normally" in E-mode.
Failure code [B@BCZK] Eng Water Level Low 1

User code Failure code Engine coolant level low
Trouble
— B@BCZK (Machine monitor system)
Contents of • When starting switch is turned ON, signal circuit of radiator coolant level sensor detected low radiator
trouble coolant level (sensor contact opened).
Action of • Displays radiator coolant level monitor on machine monitor.
machine monitor • Even if cause of failure disappers, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • If machine is operated as it is, engine may overheat.
machine
• Condition of radiator coolant level switch can be checked with monitoring function
Related infor-
mation

Lowering of radiator coolant
Radiator coolant level may be low. Check it and add coolant if it is
Possible causes 1 level (when system is nor-
low.
and standard mal)
value in normal If cause 1 is not detected, radiator coolant level monitor system may
state Defective radiator coolant be defective. Carry out troubleshooting for "E-2 Basic check item
2
level monitor system lights up when starting switch is turned ON (but engine is not
started)" in E-mode.
PC200, 220-8 19
Failure code [B@HANS] Hydr Oil Overheat 1

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

Possible causes Overheating of hydraulic oil Hydraulic oil may be overheating. Check it and remove cause if it is
1
and standard (when system is normal) overheating.
value in normal If cause 1 is not detected, hydraulic oil temperature gauge system
state Defective hydraulic oil tem-
2 may be defective. Carry out troubleshooting for "E-10 Hydraulic oil
perature gauge system
temperature gauge does not work normally" in E-mode.
Failure code [CA111] EMC Critical Internal Failure 1

User code Failure code Critical internal failure
Trouble
E10 CA111 (Engine controller system)
Contents of
• Memory or power supply circuit in engine controller is defective.
trouble
Action of
• None in particular.
controller
Problem that
appears on • Engine does not start.
machine
Related infor-
mation

and standard
value in normal Engine controller may be defective.
1 Defective engine controller
state (Since trouble is in system, troubleshooting cannot be carried out.)
20 PC200, 220-8
Failure code [CA115] Eng Ne and Bkup Speed Sens Error 1

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

and standard Connectors of Ne speed sensor and Bkup speed sensor may be
value in normal Defective connection of sen-
1 connected defectively (or connected to wrong parts). Check them
state sor connector
directly.
PC200, 220-8 21
Failure code [CA122] Chg Air Press Sensor High Error 1

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

Defective sensor power sup- If failure code [CA227] is also indicated, carry out troubleshooting
1
ply 2 system for it first.
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.
Defective boost pressure/ BOOST PRESS & IMT Voltage
2 temperature sensor [pres- Between (3) – (1) Power supply 4.75 – 5.25 V
sure signal system]
Voltage is measured with wiring harness connected. Accordingly, if
voltage is abnormal, check wiring harness and controller, too, for
another cause of trouble, and then judge.
Hot short (Short circuit with 5 and carry out troubleshooting.
3 V/24 V circuit) in wiring har-
ness Wiring harness between CE01 (female) (44)
Possible causes Voltage Max. 1 V
– BOOST PRESS & IMT (female) (4)
and standard
a Prepare with starting switch OFF, then carry out troubleshooting
value in normal
without turning starting switch ON.
state Short circuit in wiring har-
4 ness (with another wiring Wiring harness between CE01 (female) (44)
harness) – BOOST PRESS & IMT (female) (4) and Resis- Min. 100
between CE01 (female) (37) – JC01 – tance kz
BOOST PRESS & IMT (female) (3)
Connecting parts between boost pressure/temperature sensor –
engine wiring harness – engine controller may be defective. Check
Defective wiring harness them directly.
5
connector • Looseness of connector, breakage of lock, or breakage of seal
• Corrosion, bend, breakage, push-in, or expansion of pin
• Moisture or dirt in connector or defective insulation
CE01 Voltage
Between (37) – (47) Power supply 4.75 – 5.25 V
22 PC200, 220-8
Circuit diagram related to boost pressure/temperature sensor (Combination sensor)
PC200, 220-8 23
Failure code [CA123] Chg Air Press Sensor Low Error 1

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

1
Defective boost pressure/ BOOST PRESS & IMT Voltage
2 temperature sensor [pres- Between (3) – (1) Power supply 4.75 – 5.25 V
sure signal system]
Ground fault in wiring har- without turning starting switch ON.
3 ness (Short circuit with GND
circuit) Wiring harness between CE01 (female) (44) Resis- Min. 100
Possible causes – BOOST PRESS & IMT (female) (4) tance kz
and standard
value in normal
harness) – BOOST PRESS & IMT (female) (4) and Resis- Min. 100
BOOST PRESS & IMT (female) (1)
5
CE01 Voltage
24 PC200, 220-8
PC200, 220-8 25
Failure code [CA131] Throttle Sensor High Error 1

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

Defective throttle sensor If failure code [CA2185] is also indicated, carry out troubleshooting
1
power supply system for it first.
P20 Voltage
2 Defective fuel control dial Between (1) – (3) Power supply 4.75 – 5.25 V
Hot short (Short circuit with 5 and carry out troubleshooting.
3 V/24 V circuit) in wiring har-
Possible causes Wiring harness between CE02 (female) (9) –
ness Voltage Max. 1 V
and standard P20 (female) (2)
value in normal
state
Short circuit in wiring har- without turning starting switch ON.
4 ness (with another wiring Wiring harness between CE02 (female) (9) –
harness) Resis- Min. 100
P20 (female) (2) and between CE02 (female)
tance kz
(22) – P20 (female) (1)
Connecting parts between fuel control dial – machine wiring har-
ness – engine controller may be defective. Check them directly.
Defective wiring harness
5 • Looseness of connector, breakage of lock, or breakage of seal
connector
CE02 Voltage
26 PC200, 220-8
Circuit diagram related to fuel control dial
PC200, 220-8 27
Failure code [CA132] Throttle Sensor Low Error 1

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

Defective throttle sensor If failure code [CA2186] is also indicated, carry out troubleshooting
1
P20 Voltage
2 Defective fuel control dial Between (1) – (3) Power supply 4.75 – 5.25 V
Possible causes Wiring harness between CE02 (female) (9) – Resis- Min. 100
circuit)
and standard P20 (female) (2) tance kz
value in normal
state
P20 (female) (2) and between CE02 (female)
tance kz
(23) – P20 (female) (3)
connector
CE02 Voltage
28 PC200, 220-8
PC200, 220-8 29
Failure code [CA144] Coolant Temp Sens High Error 1

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

Defective coolant tempera- without turning starting switch ON.
1
ture sensor COOLANT TEMP (male) Resistance
Between (A) – (B) 0.18 – 160 kz
Disconnection in wiring har- without turning starting switch ON.
ness (Disconnection in wiring Wiring harness between CE01 (female) (15) Resis-
2 Max. 10 z
or defective contact in con- – COOLANT TEMP (female) (B) tance
nector) Wiring harness between CE01 (female) (38) Resis-
Max. 10 z
– JC03 – COOLANT TEMP (female) (A) tance
Possible causes a Prepare with starting switch OFF, then carry out troubleshooting
and standard without turning starting switch ON.
Short circuit in wiring har-
value in normal
state Resis- Min. 100
harness) – each of CE01 (female) pins (With all wiring
tance kz
harness connectors disconnected)
Connecting parts between coolant temperature sensor – engine wir-
ing harness – engine controller may be defective. Check them
Defective wiring harness directly.
4
CE01 (female) Resistance
Between (15) – (38) 0.18 – 160 kz
30 PC200, 220-8
Circuit diagram related to coolant temperature sensor
PC200, 220-8 31
Failure code [CA145] Coolant Temp Sens Low Error 1

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

Defective coolant tempera- COOLANT TEMP (male) Resistance
1
ture sensor
Between (A) – (B) 0.18 – 160 kz
Between (B) – chassis ground Min. 100 kz
– COOLANT TEMP (female) (B) tance kz
Possible causes Short circuit in wiring har- without turning starting switch ON.
and standard 3 ness (with another wiring Wiring harness between CE01 (female) (15)
value in normal harness) Resis- Min. 100
– each of CE01 (female) pins (With all wiring
state tance kz
Connecting parts between coolant temperature sensor – engine wir-
4
5 Defective engine controller CE01 (female) Resistance
Between (15) – (38) 0.18 – 160 kz
Between (15) – chassis ground Min. 100 kz
32 PC200, 220-8
Circuit diagram related to coolant temperature sensor
PC200, 220-8 33
Failure code [CA153] Chg Air Temp Sensor High Error 1

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

Defective boost pressure/ without turning starting switch ON.
1 temperature sensor [temper-
BOOST PRESS & IMT (male) Resistance
ature signal system]
Between (2) – (1) 0.18 – 160 kz
2 Max. 10 z
or defective contact in con- – BOOST PRESS & IMT (female) (2) tance
Max. 10 z
– JC02 – BOOST PRESS & IMT (female) (1) tance
value in normal
state Resis- Min. 100
harness) – each of CE01 (female) pins (With all wiring
tance kz
4
Between (23) – (47) 0.18 – 160 kz
34 PC200, 220-8
PC200, 220-8 35
Failure code [CA154] Chg Air Temp Sensor Low Error 1

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

Defective boost pressure/
1 temperature sensor [temper- BOOST PRESS & IMT (male) Resistance
ature signal system] Between (2) – (1) 0.18 – 160 kz
– BOOST PRESS & IMT (female) (2) tance kz
state tance kz
4
Between (23) – (47) 0.18 – 160 kz
36 PC200, 220-8
PC200, 220-8 37
Failure code [CA155] Chg Air Temp High Speed Derate 1

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

Cooling performance of aftercooler may be low. Check following
points directly.
Lowering of cooling perfor-
Possible causes 1 • Looseness and breakage of fan belt.
mance of aftercooler
and standard • Insufficiency of cooling air
value in normal • Clogging of aftercooler fins
state Abnormal rise of turbo- Outlet temperature of turbocharger may be abnormally high. Check
2
charger outlet temperature related parts directly.
If causes 1 – 2 are not detected, engine controller may be defective.
(Since trouble is in system, troubleshooting cannot be carried out.)
38 PC200, 220-8
PC200, 220-8 39
Failure code [CA187] Sens Supply 2 Volt Low Error 1

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

a Disconnect connector with starting switch OFF, then turn starting
switch ON and carry out troubleshooting.
Disconnect sensors Boost pressure/tem- BOOST PRESS &
and wiring harness at perature sensor IMT
right in order and
Defective sensor or wiring carry out operation to Common rail pres-
1 FUEL RAIL PRESS
harness reproduce trouble. If sure sensor
"E" of failure code
Possible causes
goes off when a sen-
and standard Bkup sensor CAM SENSOR
sor or wiring harness
value in normal
is disconnected, that
state Engine wiring har-
sensor or wiring har- CE01
ness is defective. ness
Connecting parts between each sensor – engine wiring harness –
engine controller may be defective. Check them directly.
connector
40 PC200, 220-8
Circuit diagram related to sensor power supply 2
PC200, 220-8 41
Failure code [CA221] Ambient Press Sens High Error 1

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

1
AMBAIR PRESURE Voltage
Defective ambient pressure
2 Between (1) – (2) Power supply 4.75 – 5.25V
sensor
Hot short (Short circuit with and carry out troubleshooting.
3 5V/24V circuit) in wiring har-
Possible causes ness Wiring harness between CE01 (female) (3) –
Voltage Max. 1 V
and standard AMBAIR PRESSURE (female) (3)
value in normal a Prepare with starting switch OFF, then carry out troubleshooting
state without turning starting switch ON.
harness) AMBAIR PRESSURE (female) (3) and Resis- Min. 100
between CE01 (female) (33) – AMBAIR tance kz
PRESSURE (female) (1)
Connecting parts between ambient pressure sensor – engine wiring
harness – engine controller may be defective. Check them directly.
connector
CE01 Voltage
Between (33) – (38) Voltage 4.75 – 5.25 V
42 PC200, 220-8
Circuit diagram related to ambient pressure sensor
PC200, 220-8 43
Failure code [CA222] Ambient Press Sens Low Error 1

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

1
AMBAIR PRESURE Voltage
Defective ambient pressure
2 Between (1) – (2) Power supply 4.75 – 5.25V
sensor
Possible causes circuit) Wiring harness between CE01 (female) (3) – Resis- Min. 100
and standard AMBAIR PRESSURE (female) (3) tance kz
harness) AMBAIR PRESSURE (female) (3) and Resis- Min. 100
AMBAIR PRESSURE (female) (2)
connector
CE01 Voltage
Between (33) – (38) Voltage 4.75 – 5.25 V
44 PC200, 220-8
Circuit diagram related to ambient pressure sensor
PC200, 220-8 45
Failure code [CA227] Sens Supply 2 Volt High Error 1

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

Possible causes engine controller may be defective. Check them directly.
and standard 1 • Looseness of connector, breakage of lock, or breakage of seal
connector
value in normal • Corrosion, bend, breakage, push-in, or expansion of pin
state • Moisture or dirt in connector or defective insulation
If cause 1 is not detected, engine controller may be defective.
46 PC200, 220-8
Failure code [CA234] Eng Overspeed 1

User code Failure code Engine overspeed
Trouble
— CA234 (Engine controller system)
Contents of
• Engine speed exceeded control upper speed limit.
trouble
Action of
• Stops injection until engine speed lowers to normal level.
controller
Problem that
appears on • Engine speed fluctuates.
machine
Related infor- • Engine speed can be checked with monitoring function. (Code: 01002 Engine speed)
mation • Method of reproducing failure code: Run engine at high idle.

Possible causes 1 Use of improper fuel Fuel used may be improper. Check it directly.
and standard Machine may be used improperly. Teach operator proper using
value in normal 2 Improper use
method.
state
If causes 1 – 2 are detected, engine controller may be defective.
PC200, 220-8 47
Failure code [CA238] Ne Speed Sens Supply Volt Error 1

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

Disconnect sensor
and wiring harness at
right in order and Ne speed sensor CRANK SENSOR
Defective sensor or wiring carry out operation to
1 reproduce trouble. If
Possible causes harness
and standard "E" of failure code
value in normal goes off when sensor
state or wiring harness is Engine wiring har-
disconnected, that CE01
ness
sensor or wiring har-
ness is defective.
connector
Circuit diagram related to engine Ne speed sensor
48 PC200, 220-8
Failure code [CA271] IMV/PCV1 Short Error 1

User code Failure code IMV/PCV1 short circuit error
Trouble
Contents of
• Short circuit was detected in drive circuit of supply pump actuator.
trouble
Action of
controller
Problem that • Engine speed does not rise from low idle.
machine • Common rail fuel pressure rises above command value.
Related infor-
mation

Defective supply pump actu- without turning starting switch ON.
1
ator CP3 PUMP REGULATOR (male) Resistance
circuit) Wiring harness between CE01 (female) (2) – Resis- Min. 100
CP3 PUMP REGULATOR (female) (1) tance kz
and standard Short circuit in wiring har- without turning starting switch ON.
value in normal 3 ness (with another wiring Wiring harness between CE01 (female) (2) –
state each of CE01 (female) pins (With all wiring
tance kz
Connecting parts between supply pump actuator – engine wiring
connector
Circuit diagram related to supply pump actuator (metering unit)
PC200, 220-8 49
Failure code [CA272] IMV/PCV1 Open Error 1

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

Defective supply pump actu- without turning starting switch ON.
1
ator CP3 PUMP REGULATOR (male) Resistance
Between (1) – (2) Max. 5 z
ness (Disconnection in wiring Wiring harness between CE01 (female) (2) – Resis-
2 Max. 10 z
or defective contact in con- CP3 PUMP REGULATOR (female) (1) tance
Max. 10 z
– CP3 PUMP REGULATOR (female) (2) tance
Possible causes 3
24V circuit) in wiring harness Wiring harness between CE01 (female) (2) –
and standard Voltage Max. 3 V
value in normal CP3 PUMP REGULATOR (female) (1)
state a Prepare with starting switch OFF, then carry out troubleshooting
Short circuit in wiring harness
4 Wiring harness between CE01 (female) (2) –
(with another wiring harness) Resis- Min. 100
each of CE01 (female) pins (With all wiring
tance kz
connector
50 PC200, 220-8
PC200, 220-8 51
Failure code [CA322] Inj #1 (L#1) Open/Short Error 1

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

If following failure codes are also displayed, trouble is in engine con-
troller. [CA322], [CA324], [CA331]
2 Defective No. 1 injector INJ CYL 1 (male) Resistance
3 Max. 2 z
or defective contact in con- – INJ CYL 1 (female) (1) tance
Max. 2 z
– INJ CYL 1 (female) (2) tance
Possible causes 4 ness (Short circuit with GND
circuit) Wiring harness between CE01 (female) (45) Resis-
and standard Max. 2 z
value in normal
Wiring harness between CE01 (female) (45)
Resis- Min. 100
Short circuit in wiring harness – each of CE01 (female) pins (With all wiring
5 tance kz
(with another wiring harness) harness connectors disconnected)
Resis- Min. 100
tance kz
Connecting parts between No. 1 injector – engine wiring harness –
connector
Between (45) – (53) Max. 2 z
52 PC200, 220-8
Circuit diagram related to No. 1 injector
PC200, 220-8 53

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

troller. [CA323], [CA325], [CA332]
3 Max. 2 z
Max. 2 z
value in normal
Resis- Min. 100
5 tance kz
Resis- Min. 100
tance kz
connector
Between (46) – (60) Max. 2 z
54 PC200, 220-8
PC200, 220-8 55

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

troller. [CA322], [CA324], [CA331]
3 Max. 2 z
Max. 2 z
value in normal
Resis- Min. 100
5 tance kz
Resis- Min. 100
tance kz
connector
Between (55) – (52) Max. 2 z
56 PC200, 220-8
PC200, 220-8 57

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

troller. [CA323], [CA325], [CA332]
3 Max. 2 z
Max. 2 z
value in normal
Resis- Min. 100
5 tance kz
Resis- Min. 100
tance kz
connector
Between (57) – (59) Max. 2 z
58 PC200, 220-8
PC200, 220-8 59

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

troller. [CA322], [CA324], [CA331]
3 Max. 2 z
Max. 2 z
value in normal
Resis- Min. 100
5 tance kz
Resis- Min. 100
tance kz
connector
Between (54) – (51) Max. 2 z
60 PC200, 220-8
PC200, 220-8 61

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

troller. [CA323], [CA325], [CA332]
3 Max. 2 z
Max. 2 z
value in normal
Resis- Min. 100
5 tance kz
Resis- Min. 100
tance kz
connector
Between (56) – (58) Max. 2 z
62 PC200, 220-8
PC200, 220-8 63
SEN00240-02
PC200, 220(LC)-8 Hydraulic excavator

Form No. SEN00240-02
© 2007 KOMATSU
All Rights Reserved
Printed in Japan 04-07 (01)
64
SEN00241-01
PC200-8
PC200LC-8
PC220-8
PC220LC-8

PC200-8 300001 and up
PC200LC-8 300001 and up
PC220-8 70001 and up
Failure code [CA342] Calibration Code Incompatibility ........................................................................ 3
Failure code [CA351] Injectors Drive Circuit Error ............................................................................... 4
Failure code [CA352] Sens Supply 1 Volt Low Error............................................................................ 6
Failure code [CA386] Sens Supply 1 Volt High Error........................................................................... 8
Failure code [CA428] Water in Fuel Sensor High Error ..................................................................... 10
Failure code [CA429] Water in Fuel Sensor Low Error ...................................................................... 12
Failure code [CA435] Eng Oil Press Sw Error ................................................................................... 14
Failure code [CA441] Battery Voltage Low Error ............................................................................... 15
Failure code [CA442] Battery Voltage High Error............................................................................... 18
Failure code [CA449] Rail Press Very High Error .............................................................................. 20
Failure code [CA451] Rail Press Sensor High Error .......................................................................... 22
Failure code [CA452] Rail Press Sensor Low Error ........................................................................... 24
Failure code [CA488] Chg Air Temp High Torque Derate .................................................................. 26
PC200, 220-8 1
Failure code [CA553] Rail Press High Error....................................................................................... 26

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

Failure code [CA342] Calibration Code Incompatibility 1
User code Failure code Calibration code incompatibility
Trouble
Contents of
• Incompatibility of data occurred in engine controller.
trouble
Action of
controller
Problem that
• Continues normal operation.
appears on
• Engine stops or does not start.
machine
Related infor-
mation

and standard 1 Defect in related system If another failure code is displayed, carry out troubleshooting for it.
value in normal Engine controller may be defective. (Troubleshooting cannot be car-
state 2 Defective engine controller
ried out.)
PC200, 220-8 3
Failure code [CA351] Injectors Drive Circuit Error 1

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

1 Defect in related system If another failure code is displayed, carry out troubleshooting for it.
2 Defective fuse No. 19 If fuse is broken, circuit probably has ground fault.
Defective relay for engine
3 Replace relay (R23, R24) for engine controller with another relay
controller power supply
and perform reproducing operation. If "E" of failure code goes off at
Possible causes this time, replaced relay is defective.
and standard a Prepare with starting switch OFF, then carry out troubleshooting
value in normal without turning starting switch ON.
state
Disconnection in wiring har- Wiring harness between F01-19 – R23, R24 Resis- Max. 0.5
ness (Disconnection in wiring (female) (3) tance z
4
or defective contact in con- Wiring harness between R23, R24 (female) Resis- Max. 0.5
nector) (5) – CE03 (female) (3) tance z
Wiring harness between CE03 (female) (1) – Resis-
Max. 10 z
chassis ground (T12) tance
4 PC200, 220-8
Circuit diagram related to engine controller
PC200, 220-8 5
Failure code [CA352] Sens Supply 1 Volt Low Error 1

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

Disconnect sensor
and wiring harness at
right in order and Ambient pressure
AMBAIR PRESURE
carry out operation to sensor
Defective sensor or wiring
1 reproduce trouble. If
harness
"E" of failure code
Possible causes
goes off when sensor
and standard
or wiring harness is Engine wiring har-
value in normal CE01
disconnected, that ness
state
sensor or wiring har-
ness is defective.
connector
6 PC200, 220-8
PC200, 220-8 7
Failure code [CA386] Sens Supply 1 Volt High Error 1

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

Possible causes harness – engine controller may be defective. Check them directly.
and standard 1 • Looseness of connector, breakage of lock, or breakage of seal
connector
value in normal • Corrosion, bend, breakage, push-in, or expansion of pin
state • Moisture or dirt in connector or defective insulation
8 PC200, 220-8
Failure code [CA428] Water in Fuel Sensor High Error 1

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

Defective water-in-fuel sen- without turning starting switch ON.
1
sor P47 (female) Resistance
2 Max. 10 z
or defective contact in con- – P47 (male) (1) tance
Max. 10 z
– JC02 – P47 (male) (2) tance
Possible causes
value in normal Short circuit in wiring har- without turning starting switch ON.
state 3 ness (with another wiring Wiring harness between CE01 (female) (14)
tance kz
Connecting parts between water-in-fuel sensor – engine wiring har-
connector
Between (14) – (47) Max. 10 z
10 PC200, 220-8
Circuit diagram related to water-in-fuel sensor
PC200, 220-8 11
Failure code [CA429] Water in Fuel Sensor Low Error 1

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

Defective water-in-fuel sen- P47 (female) Resistance
1
sor
– P47 (male) (1) tance kz
and standard Short circuit in wiring har- without turning starting switch ON.
value in normal 3 ness (with another wiring Wiring harness between CE01 (female) (14)
state – each of CE01 (female) pins (With all wiring
tance kz
Connecting parts between water-in-fuel sensor – engine wiring har-
connector
Between (14) – (47) Max. 10 z
12 PC200, 220-8
Circuit diagram related to water-in-fuel sensor
PC200, 220-8 13
Failure code [CA435] Eng Oil Press Sw Error 1

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

Defective engine oil pressure without turning starting switch ON.
1
switch OIL PRESSURE SWITCH (male) Resistance
Between (1) – chassis ground Max. 10 z
Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting
ness (Disconnection in wiring without turning starting switch ON.
2
or defective contact in con- Wiring harness between CE01 (female) (17) Resis-
nector) Max. 10 z
– OIL PRESSURE SWITCH (male) (1) tance
state tance kz
Connecting parts between engine oil pressure switch – engine wir-
4
Circuit diagram related to engine oil pressure switch
14 PC200, 220-8
Failure code [CA441] Battery Voltage Low Error 1

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

Looseness or corrosion of
1 Battery terminal may be loosened or corroded. Check it directly.
battery terminal
a Prepare with starting switch OFF, then keep starting switch OFF
and start engine and carry out troubleshooting in each case.
2 Low battery voltage Battery (1 piece) Starting switch Voltage
Between (+) – (–) OFF Min. 12 V
terminals START Min. 6.2 V
3 Defective fuse No. 19 If fuse is broken, circuit probably has ground fault. (See Cause 6)
this time, replaced relay is defective.
Disconnection in wiring har- Wiring harness between F01-19 – R23, R24 Resis-
Max. 10 z
Possible causes ness (Disconnection in wiring (female) (3) tance
5
and standard or defective contact in con- Wiring harness between R23, R24 (female) Resis-
nector) Max. 10 z
value in normal (5) – CE03 (female) (3) tance
state
Max. 10 z
Ground fault in wiring har-
Wiring harness between F01-19 – R23, R24 Resis- Min. 100
(female) (3) tance kz
circuit)
Wiring harness between R23, R24 (female) Resis-
Max. 10 z
(5) – CE03 (female) (3) tance
Wiring harness between CE03 (female) (3) –
Resis- Min. 100
CE03 (female) (1) pin (with battery terminal
tance kz
Short circuit in wiring har- disconnected)
each of CE02 (female) pins (With battery ter-
tance kz
minal disconnected)
Wiring harness between CE03 (female) (1) –
Resis- Min. 100
each of CE02 (female) pins (With battery ter-
tance kz
minal disconnected)
PC200, 220-8 15

Connecting parts between fuse No. 19 – machine wiring harness –
connector
Possible causes • Corrosion, bend, breakage, push-in, or expansion of pin
and standard • Moisture or dirt in connector or defective insulation
value in normal a Prepare with starting switch OFF, then turn starting switch ON
state and start engine and carry out troubleshooting in each case.
9 Defective engine controller CE03 (female) Starting switch Voltage
ON Min. 24 V
Between (3) – (1)
START Min. 12 V
16 PC200, 220-8
Circuit diagram related to engine controller power supply
PC200, 220-8 17
Failure code [CA442] Battery Voltage High Error 1

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

1 Defective battery voltage
Battery Voltage
Between (+) – (–) terminals Max. 32 V
Possible causes a Prepare with starting switch OFF, then start engine and carry out
and standard troubleshooting.
value in normal 2 Defective alternator E12 (male) Engine speed Voltage
state
Between (1) – chas-
Medium or higher 27.5 – 29.5 V
sis ground
CE03 (female) Voltage
Between (3) – (1) Max. 32 V
18 PC200, 220-8
PC200, 220-8 19
Failure code [CA449] Rail Press Very High Error 1

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

There may be air in low pressure circuit. Check it directly according
to the following procedure.
2 Air in low pressure circuit 1) Remove pressure pickup plug (outlet side) of fuel main filter.
2) Operate feed pump of fuel pre-filter.
3) Check pressure pickup plug for leakage of fuel and air.
a For check of fuel return circuit pressure, see Testing and adjust-
Defect in fuel return circuit ing, Checking fuel pressure.
3
parts Fuel return circuit Low idle running or Max. 0.02 MPa
Possible causes pressure cranking {Max. 0.19 kg/cm2}
and standard
a Prepare with starting switch ON, then keep starting switch ON
value in normal
and carry out troubleshooting in each case.
state
Monitoring code
Defective common rail pres- Monitoring information
4 (Machine monitor)
sure sensor
36400
While engine is 0 ± 0.39 MPa
Common rail
stopped {0 ± 4 kg/cm2}
pressure
a For check of leakage through pressure limiter, see Testing and
adjusting, Checking fuel return rate and leakage.
5 Defective pressure limiter
Leakage through
During low idle 0 cc (No leakage)
pressure limiter
6 Defective supply pump If causes 1 – 5 are not detected, supply pump may be defective.
20 PC200, 220-8
Failure code [CA451] Rail Press Sensor High Error 1

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

Defective sensor power sup- If failure code [CA227] is also displayed, carry out troubleshooting
1
FUEL RAIL PRESS Voltage
Defective common rail pres-
2 Between (3) – (1) Power supply 4.75 – 5.25 V
sure sensor
Possible causes Voltage Max. 1 V
– FUEL RAIL PRESS (female) (2)
and standard
value in normal
harness) – FUEL RAIL PRESS (female) (2) and Resis- Min. 100
between CE01 (female) (37) – JC01 – FUEL tance kz
RAIL PRESS (female) (3)
Connecting parts between common rail pressure sensor – engine
wiring harness – engine controller may be defective. Check them
5
CE01 Voltage
22 PC200, 220-8
Circuit diagram related to common rail pressure sensor
PC200, 220-8 23
Failure code [CA452] Rail Press Sensor Low Error 1

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

1
FUEL RAIL PRESS Voltage
Defective common rail pres-
sure sensor
Ground fault in wiring har- and carry out troubleshooting.
Possible causes – FUEL RAIL PRESS (female) (2) tance kz
and standard
value in normal
harness) – FUEL RAIL PRESS (female) (2) and Resis- Min. 100
between CE01 (female) (47) – JC02 – FUEL tance kz
RAIL PRESS (female) (1)
Connecting parts between common rail pressure sensor – engine
wiring harness – engine controller may be defective. Check them
5
CE01 Voltage
24 PC200, 220-8
Circuit diagram related to common rail pressure sensor
PC200, 220-8 25
Failure code [CA488] Chg Air Temp High Torque Derate 1

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

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

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

Ground terminal may be connected defectively. Check following ter-
Possible causes minals directly.
and standard Defective connection of • Ground terminal of machine ((–) terminal of battery)
value in normal 2
ground terminal • Ground terminal of engine
state • Ground terminal of engine controller
• Ground terminal of starting motor
Breakage of O-ring of supply
3 O-ring of supply pump actuator may be broken. Check it directly.
pump actuator
26 PC200, 220-8
Failure code [CA559] Rail Press Low Error 1

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

Fuel may be leaking to outside. Check it directly (Check visually
1 Fuel leakage to outside
while running engine at low idle).
a For check of pressure in fuel low pressure circuit, see Testing
and adjusting, Checking fuel pressure.
During cranking (if
0.3 – 1.1 MPa
Defect in low pressure cir- engine cannot be
2 {3.1 – 11.3 kg/cm2}
cuit parts Pressure in fuel low- started)
pressure circuit During low idle (if
0.5 – 1.3 MPa
engine can be
{5.1 – 13.3 kg/cm2}
started)
a For check of leakage through pressure limiter, see Testing and
3 Defective pressure limiter
Leakage through
Possible causes During low idle 0 cc (No leakage)
pressure limiter
and standard
value in normal a For check of return rate from injector, see Testing and adjusting,
state Checking fuel return rate and leakage.
During cranking (if
Defective injector (including engine cannot be Max. 90 cc/min.
4
high pressure piping in head) Return rate from started)
injector During low idle (if
engine can be Max. 180 cc/min.
started)
a For check of return rate from supply pump, see Testing and
During cranking (if
engine cannot be Max. 140 cc/min.
5 Defective supply pump
Return rate from sup- started)
ply pump During low idle (if
engine can be Max. 1,000 cc/min.
started)
PC200, 220-8 27
Failure code [CA689] Eng Ne Speed Sensor Error 1

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

Defective Ne speed sensor If failure code [CA238] is also displayed, carry out troubleshooting
1
CRANK SENSOR Voltage
Defective engine Ne speed
sensor
Breakage or improper clear-
Engine Ne speed sensor may be broken or may have improper
3 ance of engine Ne speed
clearance. Check it directly.
sensor
Breakage of rotation sensor
4 Rotation sensor wheel may be broken. Check it directly.
wheel
Possible causes 5
and standard or defective contact in con- Wiring harness between CE01 (female) (27) Resis-
nector) Max. 10 z
value in normal – CRANK SENSOR (female) (3) tance
– CRANK SENSOR (female) (3) tance kz
Voltage Max. 1 V
– CRANK SENSOR (female) (3)
– CRANK SENSOR (female) (3) or between Resis- Min. 100
CE01 (female) (16) – CRANK SENSOR tance kz
8 ness (with another wiring
(female) (1)
harness)
– CRANK SENSOR (female) (3) or between Resis- Min. 100
CE01 (female) (48) – CRANK SENSOR tance kz
(female) (2)
28 PC200, 220-8

Connecting parts between engine Ne speed sensor – engine wiring
Possible causes 9 • Looseness of connector, breakage of lock, or breakage of seal
connector
and standard • Corrosion, bend, breakage, push-in, or expansion of pin
value in normal • Moisture or dirt in connector or defective insulation
state a Prepare with starting switch OFF, then turn starting switch ON
CE01 Voltage
Circuit diagram related to engine Ne speed sensor
PC200, 220-8 29
Failure code [CA731] Eng Bkup Speed Sens Phase Error 1

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

Breakage of engine Ne
1 Engine Ne speed sensor may be broken. Check it directly.
speed sensor
Breakage of engine Bkup
2 Engine Bkup speed sensor may be broken. Check it directly.
speed sensor
Rotation sensor wheel on crankshaft side may be installed defec-
tively or broken. Check it according to the following procedure.
Defective installation or
1) Set No. 1 cylinder at compression top dead center (Match
3 breakage of rotation sensor
stamped mark).
wheel on crankshaft side
2) If center of oblong hole of rotation sensor wheel is at tip of Ne
speed sensor, rotation sensor wheel is installed normally.
Possible causes Rotation sensor ring on camshaft side may be installed defectively
and standard or broken. Check it according to the following procedure.
value in normal Defective installation or 1) Set No. 1 cylinder at compression top dead center (Match
state 4 breakage of rotation sensor stamped mark).
ring on camshaft side 2) Remove Bkup speed sensor.
3) If 2 grooves (1 crest) of rotation sensor ring are seen through
sensor mounting hole, rotation sensor ring is installed normally.
Defective timing of crank- Timing of crankshaft and camshaft may be defective. Check it
5
shaft and camshaft directly.
Ground terminal may be connected defectively. Check following ter-
minals directly.
Defective connection of • Ground terminal of machine ((–) terminal of battery)
6
ground terminal • Ground terminal of engine
• Ground terminal of engine controller
• Ground terminal of starting motor
30 PC200, 220-8
Failure code [CA757] All Continuous Data Lost Error 1

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

Looseness or corrosion of
2 Battery terminal may be loosened or corroded. Check it directly.
battery terminal
3 Low battery voltage Battery (1 piece) Starting switch Voltage
Between (+) – (–) OFF Min. 12 V
terminals START Min. 6.2 V
4 Defective fuse No. 19 If fuse is broken, circuit probably has ground fault.
this time, replaced relay is defective.
Possible causes
state Disconnection in wiring har- Wiring harness between F01-19 – R23, R24 Resis-
Max. 10 z
ness (Disconnection in wiring (female) (3) tance
6
or defective contact in con- Wiring harness between R23, R24 (female) Resis-
nector) Max. 10 z
(5) – CE03 (female) (3) tance
Max. 10 z
Connecting parts between fuse No. 19 – machine wiring harness –
connector
8 Defective engine controller CE03 (female) Starting switch Voltage
ON Min. 24 V
Between (3) – (1)
START Min. 12 V
32 PC200, 220-8
PC200, 220-8 33
Failure code [CA778] Eng Bkup Speed Sensor Error 1

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

1
CAM SENSOR Voltage
Defective engine Bkup
speed sensor
Breakage or improper clear-
Engine Bkup speed sensor may be broken or may have improper
3 ance of engine Bkup speed
clearance. Check it directly.
sensor
Breakage of rotation sensor
4 Rotation sensor ring may be broken. Check it directly.
ring
Possible causes 5
and standard or defective contact in con- Wiring harness between CE01 (female) (26) Resis-
nector) Max. 10 z
value in normal – JC03 – CAM SENSOR (female) (3) tance
– JC03 – CAM SENSOR (female) (3) tance kz
Voltage Max. 1 V
– JC03 – CAM SENSOR (female) (3)
– JC03 – CAM SENSOR (female) (3) or Resis- Min. 100
between CE01 (female) (37) – JC01 – CAM tance kz
8 ness (with another wiring
SENSOR (female) (1)
harness)
– JC03 – CAM SENSOR (female) (3) or Resis- Min. 100
between CE01 (female) (47) – JC02 – CAM tance kz
SENSOR (female) (2)
34 PC200, 220-8

Connecting parts between engine Bkup speed sensor – engine wir-
Possible causes 9
and standard • Corrosion, bend, breakage, push-in, or expansion of pin
value in normal • Moisture or dirt in connector or defective insulation
state
CE01 Voltage
Circuit diagram related to engine Bkup speed sensor
PC200, 220-8 35
Failure code [CA1633] KOMNET Datalink Timeout Error 1

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

Disconnection in wiring har- Wiring harness between CM02 (female) (8),
Resis-
ness (Disconnection in wiring (9) – C01 (female) (45), – CE02 (female) Max. 1 z
1 tance
or defective contact in con- (46), – K02 (female) (A)
nector) Wiring harness between CM02 (female) (10)
Resis-
– C01 (female) (64), – CE02 (female) (47), – Max. 1 z
tance
K02 (female) (B)
Wiring harness between CM02 (female) (8),
Ground fault in wiring har- Resis-
(9) – C01 (female) (45), – CE02 (female) Min. 1 Mz
2 ness (Short circuit with GND tance
(46), – K02 (female) (A), – N08 (male) (3)
circuit)
Possible causes Wiring harness between CM02 (female) (10)
and standard Resis-
– C01 (female) (64), – CE02 (female) (47), – Min. 1 Mz
value in normal tance
K02 (female) (B), – N08 (male) (10)
state
Max.
Hot short (Short circuit with (9) – C01 (female) (45), – CE02 (female) Voltage
3 5.5 V
24V circuit) in wiring harness (46), – K02 (female) (A), – N08 (male) (3)
Wiring harness between CM02 (female) (10)
Max.
– C01 (female) (64), – CE02 (female) (47), – Voltage
5.5 V
K02 (female) (B), – N08 (male) (10)
Defective CAN terminal without turning starting switch ON.
4 resistance (Internal short cir-
K02 (male) Resistance
cuit or disconnection)
Between (A) – (B) 120 ± 12 z
5 Defective pump controller
36 PC200, 220-8
Circuit diagram related to CAN communication
PC200, 220-8 37
Failure code [CA2185] Throt Sens Sup Volt High Error 1

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

Short circuit in wiring har- Wiring harness between CE02 (female) (22)
Resis- Min. 100
1 ness (with another wiring – each of CE02 (female) pins (With P20 dis-
tance kz
harness) connected)
Possible causes
and standard Wiring harness between CE02 (female) (22) Resis- Min. 100
value in normal – CE03 (female) (3) (With P20 disconnected) tance kz
state Connecting parts between fuel control dial – machine wiring har-
connector
38 PC200, 220-8
Failure code [CA2186] Throt Sens Sup Volt Low Error 1

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

– P20 (female) (1) tance kz
Possible causes
and standard 2 ness (with another wiring Wiring harness between CE02 (female) (9) –
value in normal each of CE02 (female) pins (With P20 dis-
tance kz
state connected)
connector
PC200, 220-8 39
Failure code [CA2249] Rail Press Very Low Error 1

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

and standard
value in normal 1 Carry out troubleshooting for failure code [CA559].
state
40 PC200, 220-8
Failure code [CA2311] IMV Solenoid Error 1

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

Defective supply pump actu- CP3 PUMP REGULATOR (male) Resistance
2
ator
ness (Disconnection in wiring Wiring harness between CE01 (female) (2) – Resis-
3 Max. 5 z
or defective contact in con- CP3 PUMP REGULATOR (female) (1) tance
Possible causes Max. 5 z
and standard – CP3 PUMP REGULATOR (female) (2) tance
state Ground fault in wiring har- without turning starting switch ON.
circuit) Wiring harness between CE01 (female) (2) – Resis- Min. 100
CP3 PUMP REGULATOR (female) (1) tance kz
connector
42 PC200, 220-8
PC200, 220-8 43
Failure code [CA2555] Grid Htr Relay Volt High Error 1

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

without turning starting switch ON. (Troubleshooting for relay
unit)
R18 (male) Resistance
Defective automatic pre-
Between (1) – (2) 300 – 600 z
1 heater relay (Internal discon-
nection) a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting. (Troubleshooting by replacement)
Replace automatic preheater relay (R18)) with another relay and
perform reproducing operation. If "E" of failure code goes off at this
time, replaced relay is defective.
2 Max. 10 z
Possible causes or defective contact in con- – R18 (female) (1) tance
and standard nector) Wiring harness between CE02 (female) (42) Resis-
value in normal Max. 10 z
– R18 (female) (2) tance
state
– each of CE02 (female) pins (With R18 dis-
tance kz
connected)
Connecting parts between automatic preheater relay – machine wir-
4
Between (40) – (42) 300 – 600 z
44 PC200, 220-8
Circuit diagram related to engine preheater/starting motor/charging system
PC200, 220-8 45
Failure code [CA2556] Grid Htr Relay Volt Low Error 1

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

unit)
Defective automatic pre-
Between (1) – (2) 300 – 600 z
1 heater relay (Internal discon-
nection) a Prepare with starting switch OFF, then turn starting switch ON
Replace automatic preheater relay (R18)) with another relay and
perform reproducing operation. If "E" of failure code goes off at this
time, replaced relay is defective.
Possible causes Wiring harness between CE02 (female) (40) Resis- Min. 100
circuit)
and standard – R18 (female) (1) tance kz
value in normal
state
– each of CE02 (female) pins (With R18 dis-
tance kz
connected)
Connecting parts between automatic preheater relay – machine wir-
4
Between (40) – (42) 300 – 600 z
46 PC200, 220-8
PC200, 220-8 47
Failure code [D19JKZ] Personal Code Relay Abnormality 1

User code Failure code Personal code relay abnormality
Trouble
E01 D19JKZ (KOMTRAX system in machine monitor)
Contents of
• Disconnection or short circuit was detected in personal code relay circuit.
trouble
• None in particular (when disconnection is detected).
• Turns output to personal code relay OFF (when short circuit is detected).
Action of
• If cause of failure disappears, system resets itself (when disconnection is detected).
controller
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF
(when disconnection is detected).
Problem that
appears on
machine
• This failure code is displayed only when engine lock function is effective.
Related infor-
• Method of reproducing failure code: Turn starting switch ON (Disconnection). Trouble cannot be
mation
reproduced on machine (Short circuit).

1 Defective fuse No. 3 If fuse is broken, circuit probably has ground fault (See cause 4).
unit)
Defective personal code
Between (1) – (2) (300 – 600 z)
2 relay (Internal disconnection
or short circuit) a Prepare with starting switch OFF, then turn starting switch ON
Replace personal code relay (R07)) with another relay and perform
reproducing operation. If "E" of failure code goes off at this time,
replaced relay is defective.
Possible causes
value in normal Disconnection in wiring har- without turning starting switch ON.
state ness (Disconnection in wiring Wiring harness between F01 (3) – R07 Resis-
3 Max. 1 z
or defective contact in con- (female) (1) tance
nector) Wiring harness between R07 (female) (2) – Resis-
Max. 1 z
CM01 (female) (6) tance
Wiring harness between F01 (3) – R07 Resis-
4 ness (Short circuit with GND Min. 1 Mz
(female) (1) tance
circuit)
Wiring harness between R07 (female) (2) – Resis-
Min. 1 Mz
If causes 1 – 4 are not detected, machine monitor (KOMTRAX) may
Defective machine monitor
5 be defective. (Since trouble is in system, troubleshooting cannot be
(KOMTRAX section)
carried out.)
48 PC200, 220-8
PC200, 220-8 49
Failure code [D862KA] GPS Antenna Discon 1

User code Failure code GPS antenna disconnection
Trouble
— D862KA (KOMTRAX system in machine monitor)
Contents of
• Disconnection was detected in GPS antenna circuit.
trouble
Problem that
appears on • GPS cannot measure position.
machine
Related infor-
mation

and standard Possible causes are defective GPS antenna, disconnection or short
value in normal Defective GPS antenna or
1 circuit in antenna cable, and defective connection of antenna cable
state antenna cable
connector (GPS).
Configuration drawing
50 PC200, 220-8
Failure code [DA22KK] Pump Solenoid Power Low Error 1

User code Failure code Lowering of solenoid power supply voltage
Trouble
E0E DA22KK (Pump controller system)
Contents of
• Solenoid power supply voltage of controller is below 20 V.
trouble
• While this failure code is displayed, detection of failure codes (disconnection/short circuit) of all the
Action of
solenoid systems is stopped.
controller
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • Since no solenoid valve is driven normally, machine does not operate normally.
machine
Related infor-
mation

Defective fusible link F04 or If fusible link or fuse is broken, circuit probably has ground fault.
1
fuse No. 2 (See Cause 3.)
Disconnection in wiring har- Wiring harness between C02 (female) (116), Resis-
Max. 1 z
ness (Disconnection in wiring (118), (121) – F01-2 tance
2
or defective contact in con- Wiring harness between F01-1A – F04 Resis-
nector) Max. 1 z
(male) (2) tance
Wiring harness between F04 (male) (1) – Resis-
Max. 1 z
Possible causes R03 tance
state Wiring harness between C02 (female) (116), Resis-
Ground fault in wiring har- Min. 1 Mz
(118), (121) – F01-2 tance
circuit) Wiring harness between F01-1A – F04 Resis-
Min. 1 Mz
(male) (2), – circuit branch end tance
Min. 1 Mz
R03 tance
4 Defective pump controller C01 (female), C02 (female) Voltage
Between C02 (116), (118),
20 – 30 V
(121) – C01 (2), (5)
PC200, 220-8 51
Circuit diagram related to pump controller power supply
52 PC200, 220-8
Failure code [DA25KP] 5V Sensor 1 Power Abnormality 1

Overload alarm monitor non-display specification
User code Failure code 5V sensor power supply output 1 abnormality
Trouble
— DA25KP (Pump controller system)
Contents of
• Voltage of 5V sensor power supply output 1 circuit is below 2.5 V or above 6.0 V.
trouble
Action of • Turns output of 5V sensor power supply output 1 OFF.
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that • Automatic gear shifting function does not work (pump pressure sensor system).
appears on • Auto-decelerator keeps working and is not reset or fine control performance of work equipment is
machine lowered (PPC pressure sensor system).
Related infor-
mation

Bucket CURL PPC
P01
pressure sensor
Swing LEFT PPC
P03
pressure sensor
Arm IN PPC pressure
P04
sensor
Disconnect sensors at right in
Defective pressure sensor order and carry out operation to Bucket DUMP PPC
1 P05
(Internal short circuit) reproduce trouble. If "E" of failure pressure sensor
code goes off when a sensor is Boom RAISE PPC
disconnected, that sensor is P06
pressure sensor
defective.
Swing RIGHT PPC
P07
pressure sensor
F pump pressure
P25
Possible causes sensor
and standard R pump pressure
P26
value in normal sensor
Wiring harness between C01 (female) (9) –
Resis-
J06 – P01 (female) (3) Min. 1 Mz
tance
[Bucket CURL PPC pressure sensor system]
Resis-
tance
[Swing LEFT PPC pressure sensor system]
2 ness (Short circuit with GND Wiring harness between C01 (female) (9) – Resis-
circuit) J06 – P04 (female) (3) Min. 1 Mz
tance
[Arm IN PPC pressure sensor system]
J06 – P05 (female) (3) Resis-
Min. 1 Mz
[Bucket DUMP PPC pressure sensor sys- tance
tem]
Resis-
tance
[Boom RAISE PPC pressure sensor system]
PC200, 220-8 53

Resis-
tance
[Swing RIGHT PPC pressure sensor system]
Ground fault in wiring har- Wiring harness between C01 (female) (9) –
Resis-
2 ness (Short circuit with GND J06 – P25 (female) (3) Min. 1 Mz
tance
circuit) [F pump pressure sensor system]
Resis-
tance
[R pump pressure sensor system]
J06 – P01 (female) (3) Voltage Max. 1 V
Possible causes [Swing LEFT PPC pressure sensor system]
and standard Wiring harness between C01 (female) (9) –
value in normal J06 – P04 (female) (3) Voltage Max. 1 V
state [Arm IN PPC pressure sensor system]
P05 (female) (3)
Hot short (Short circuit with Voltage Max. 1 V
3 [Bucket DUMP PPC pressure sensor sys-
24V circuit) in wiring harness
tem]
[F pump pressure sensor system]
If causes 1 – 3 are not detected, pump controller may be defective.
54 PC200, 220-8
Circuit diagram related to pump controller 5V sensor power supply output 1 (Overload alarm monitor
non-display specification)
PC200, 220-8 55
Overload alarm monitor display specification

User code Failure code 5V sensor power supply output 1 abnormality
Trouble
— DA25KP (Pump controller system)
Contents of
• Voltage of 5V sensor power supply output 1 circuit is below 2.5 V or above 6.0 V.
trouble
Action of • Turns output of 5V sensor power supply output 1 OFF.
Problem that • Automatic gear shifting function does not work (pump pressure sensor system).
appears on • Since no solenoid valve is driven normally, machine does not operate normally.
machine • Overload alarm monitor does not display normally (Overload alarm pressure sensor system)
Related infor-
mation

Bucket CURL PPC
P01
pressure sensor
Swing LEFT PPC
P03
pressure sensor
Arm IN PPC pressure
P04
sensor
Disconnect sensors at right in Bucket DUMP PPC

P05
Defective pressure sensor order and carry out operation to pressure sensor
1
(Internal short circuit) reproduce trouble. If "E" of failure Boom RAISE PPC
P06
code goes off when a sensor is pressure sensor
disconnected, that sensor is Swing RIGHT PPC
defective. P07
pressure sensor
F pump pressure
P25
sensor
Possible causes R pump pressure
P26
and standard sensor
value in normal Overload alarm pres-
state P46
sure sensor
Resis-
tance
Resis-
tance
2 ness (Short circuit with GND Wiring harness between C01 (female) (9) – Resis-
circuit) J06 – P04 (female) (3) Min. 1 Mz
tance
[Arm IN PPC pressure sensor system]
J06 – P05 (female) (3) Resis-
Min. 1 Mz
[Bucket DUMP PPC pressure sensor sys- tance
tem]
Resis-
tance
56 PC200, 220-8

Resis-
tance
Resis-
Ground fault in wiring har- tance
circuit) Wiring harness between C01 (female) (9) –
Resis-
tance
Resis-
tance
[Overload alarm pressure sensor system]
Possible causes
and standard Wiring harness between C01 (female) (9) –
value in normal J06 – P04 (female) (3) Voltage Max. 1 V
state [Arm IN PPC pressure sensor system]
P05 (female) (3)
Voltage Max. 1 V
[Bucket DUMP PPC pressure sensor sys-
Hot short (Short circuit withtem]
3
24V circuit) in wiring harness Wiring harness between C01 (female) (9) –
[Overload alarm pressure sensor system]
PC200, 220-8 57
Circuit diagram related to pump controller 5V sensor power supply output 1 (Overload alarm monitor
display specification)
58 PC200, 220-8
Failure code [DA29KQ] Model Selection Abnormality 1

PC200, 200LC-8
User code Failure code Model selection abnormality
Trouble
— DA29KQ (Pump controller system)
Contents of
• Model code signal for model which is not registered in controller is input.
trouble
Action of • Changes input model code to code of default model (PC200) and continues control.
Problem that
appears on • Since control is carried out on assumption that model is PC200, no particular problem occur.
machine
• Model code of pump controller can be checked with monitoring function.
(Code: 00200 Controller model code)
Related infor-
• Condition of model selection signal can be checked with monitoring function.
mation
(Code: 02201 Switch input 2)

Defective model selection
1 connector (Internal discon- S30 (female) Resistance
nection or short circuit) Between (1), (2), (4), (7) – (8) Min. 1 Mz
ness (Disconnection in wiring Wiring harness between C01 (female) (77) – Resis-
2 Max. 1 z
or defective contact in con- S30 (male) (3) tance
nector) Wiring harness between S30 (male) (8) – Resis-
Max. 1 z
J05 – chassis ground (T07) tance
value in normal iring harness between C01 (female) (40) – Resis-
state Min. 1 Mz
S30 (male) (1) tance
Wiring harness between C01 (female) (21) – Resis-
circuit)
Min. 1 Mz
Min. 1 Mz
C01 (female) Resistance
Between (21), (39), (40), (58) –
Min. 1 Mz
chassis ground
60 PC200, 220-8
Circuit diagram related to model selection connector (PC200, 200LC-8)
PC200, 220-8 61
PC220, 220LC-8
User code Failure code Model selection abnormality
Trouble
— DA29KQ (Pump controller system)
Contents of
• Model code signal for model which is not registered in controller is input.
trouble
Action of • Changes input model code to code of default model (PC200) and continues control.
Problem that
appears on • Since control is carried out on assumption that model is PC200, power or speed is low.
machine
• Model code of pump controller can be checked with monitoring function.
(Code: 00200 Controller model code)
Related infor-
• Condition of model selection signal can be checked with monitoring function.
mation

Defective model selection
1 connector (Internal discon- S30 (female) Resistance
nection or short circuit) Between (2), (4), (7) – (8) Min. 1 Mz
Between (1), (3) – (8) Max. 1 z
Disconnection in wiring har- Wiring harness between C01 (female) (40) – Resis-
Max. 1 z
ness (Disconnection in wiring S30 (male) (1) tance
2
or defective contact in con- Wiring harness between C01 (female) (77) – Resis-
nector) Max. 1 z
Wiring harness between S30 (male) (8) – Resis-
and standard
circuit) Wiring harness between C01 (female) (58) – Resis-
Min. 1 Mz
Min. 1 Mz
4 Defective pump controller Between (21), (39), (58) – chas-
Min. 1 Mz
sis ground
Between (40), (77) – chassis
Max. 1 z
ground
62 PC200, 220-8
Circuit diagram related to model selection connector (PC220, 220LC-8)
PC200, 220-8 63
SEN00241-01

© 2006 KOMATSU
All Rights Reserved
64
SEN00242-02
PC200-8
PC200LC-8
PC220-8
PC220LC-8

PC200-8 300001 and up
PC200LC-8 300001 and up
PC220-8 70001 and up
Failure code [DA2RMC] CAN Discon (Pump Con Detected)............................................................... 4
Failure code [DAF8KB] Short circuit in camera power supply ............................................................. 6
Failure code [DAFGMC] GPS Module Error ........................................................................................ 8
Failure code [DAFRMC] CAN Discon (Monitor Detected).................................................................. 10
Failure code [DGH2KB] Hydr Oil Sensor Short.................................................................................. 12
Failure code [DHPAMA] F Pump Press Sensor Abnormality ............................................................. 14
Failure code [DHPBMA] R Pump Press Sensor Abnormality ............................................................ 16
Failure code [DHS3MA] Arm Curl PPC Press Sensor Abnormality ................................................... 18
Failure code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality ............................................... 20
Failure code [DHS8MA] Boom Raise PPC Press Sensor Abnormality .............................................. 22
Failure code [DHSAMA] Swing RH PPC Press Sensor Abnormality ................................................. 24
Failure code [DHSBMA] Swing LH PPC Press Sensor Abnormality.................................................. 26
Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality ........................................... 28
PC200, 220-8 1
Failure code [DHX1MA] Overload Sensor Abnormality (Analog) ....................................................... 31

Failure code [DW43KA] Travel Speed Sol Discon ............................................................................. 34
Failure code [DW43KB] Travel Speed Sol Short ................................................................................ 36
Failure code [DW45KA] Swing Brake Sol Discon .............................................................................. 38
Failure code [DW45KB] Swing Brake Sol Short................................................................................. 40
Failure code [DW91KA] Travel Junction Sol Discon .......................................................................... 42
Failure code [DW91KB] Travel Junction Sol Short............................................................................. 44
Failure code [DWA2KA] Service Sol Discon ...................................................................................... 46
Failure code [DWA2KB] Service Sol Short......................................................................................... 47
Failure code [DWK0KA] 2-stage Relief Sol Discon ............................................................................ 48
Failure code [DWK0KB] 2-stage Relief Sol Short .............................................................................. 50
2 PC200, 220-8
PC200, 220-8 3

Failure code [DA2RMC] CAN Discon (Pump Con Detected) 1
User code Failure code CAN disconnection (Pump controller detected)
Trouble
E0E DA2RMC (Pump controller system)
Contents of • Pump controller detected communication error in CAN communication circuit between machine mon-
trouble itor and engine controller.
Action of • Continues operation with information of CAN communication just before detection of error.
Problem that
• Information may not transmitted normally by CAN communication and machine may not operate nor-
appears on
mally. (Trouble phenomenon depends on failed section.)
machine
Related infor-
mation

Resis-
1 tance
Resis-
tance
K02 (female) (B)
(46), – K02 (female) (A), – N08 (male) (3)
circuit)
and standard Resis-
K02 (female) (B), – N08 (male) (10)
state
Max.
3 5.5 V
Max.
5.5 V
K02 (female) (B), – N08 (male) (10)
Between (A) – (B) 120 ± 12 z
4 PC200, 220-8
PC200, 220-8 5
Failure code [DAF8KB] Short circuit in camera power supply 1

User code Failure code Short circuit in camera power supply
Trouble
— DAF8KB (Machine monitor system)
Contents of • Output power supply voltage (Rating: 6 V) from machine monitor to camera is below 6.0 V or above
trouble 10 V.
Action of • Turns output power supply voltage (Rating: 8 V) to camera OFF.
Problem that
appears on • Camera image is not displayed on monitor screen.
machine
Related infor-
mation

a Disconnect camera with starting switch OFF, then turn starting
Defective camera (Internal switch ON and carry out troubleshooting.
1
short circult) Disconnect camera and perform failure reproduction operation. If
failure code disappears at this time, camera is defective.
Ground fault in wiring har- (Disconnect camera and check that it is not defective in
Possible causes 2 ness (Contact with GND cir- advance.)
and standard cuit)
value in normal Between CM05 (female) (1) – CAMERA
Voltage Min. 6 V
state (female) (F) wiring harness and ground
Hot short (Contact with 24V (Disconnect camera and check that it is not defective in
3 advance.)
circuit) in wiring harness
Between CM05 (female) (1) – CAMERA
Voltage Max. 10 V
(female) (F) wiring harness and ground
If causes 1 – 3 are not detected, machine monitor may be detective.
4 Defective machine monitor
6 PC200, 220-8
Circuit diagram related to camera
PC200, 220-8 7
Failure code [DAFGMC] GPS Module Error 1

User code Failure code GPS module operation error
Trouble
— DAFGMC (KOMTRAX system in machine monitor)
Contents of • Position data is not sent from GPS module (in machine monitor) to KOMTRAX communication
trouble MODEM in 50 seconds after KOMTRAX is started.
Problem that
appears on
machine
Related infor- • Method of reproducing failure code: Turn starting switch ON (At least 50 seconds after starting switch
mation is turned ON).

and standard
value in normal GPS module of machine monitor may be defective. (Since trouble is
state in system, troubleshooting cannot be carried out.)
8 PC200, 220-8
PC200, 220-8 9
Failure code [DAFRMC] CAN Discon (Monitor Detected) 1

User code Failure code CAN disconnection (Monitor detected)
Trouble
E0E DAFRMC (Machine monitor system)
Contents of • Machine monitor detected communication error in CAN communication circuit between pump con-
trouble troller and engine controller.
Action of
• If cause of failure disappears, system resets itself.
machine monitor
Problem that
• Information may not transmitted normally by CAN communication and machine may not operate nor-
appears on
mally. (Trouble phenomenon depends on failed section.)
machine
Related infor-
mation

Resis-
1 tance
Resis-
tance
K02 (female) (B)
(46), – K02 (female) (A), – N08 (male) (3)
circuit)
and standard Resis-
K02 (female) (B), – N08 (male) (10)
state
Max.
3 5.5 V
Max.
5.5 V
K02 (female) (B), – N08 (male) (10)
Between (A) – (B) 120 ± 12 z
If causes 1 – 4 are not detected, machine monitor may be defective.
10 PC200, 220-8
PC200, 220-8 11
Failure code [DGH2KB] Hydr Oil Sensor Short 1

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

Defective hydraulic oil tem-
1 perature sensor (Internal dis- P22 (male) Resistance
connection or short circuit) Between (1) – (2) 3.5 – 90 kz
Between (2) – chassis ground Min. 1 Mz
Possible causes
and standard Ground fault in wiring har- without turning starting switch ON.
value in normal 2 ness (Short circuit with GND
state circuit) Wiring harness between C01 (female) (29) – Resis-
Min. 1 Mz
P22 (female) (2) tance
3 Defective pump controller C01 (female) Resistance
Between (29) – (46) 3.5 – 90 kz
Circuit diagram related to hydraulic oil temperature sensor
12 PC200, 220-8
PC200, 220-8 13
Failure code [DHPAMA] F Pump Press Sensor Abnormality 1

User code Failure code F pump pressure sensor abnormality
Trouble
— DHPAMA (Pump controller system)
Contents of
• Signal voltage of F pump pressure sensor circuit is below 0.3 V or above 4.5 V.
trouble
Action of • Fixes F pump pressure at 0 MPa {0 kg/cm2} and continues control.
Problem that
• Automatic gear shifting function does not work.
appears on
• Straight travel performance or steering performance lowers.
machine
a If 5V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor
Related infor- will be broken. Accordingly, take extreme care when checking.
mation • F pump pressure can be checked with monitoring function. (Code: 01100 F pump pressure)

Defective 5V sensor power a If failure code [DA25KP] is also displayed, carry out trouble-
1
supply 1 system shooting for it first.
a Prepare with starting switch OFF, then turn starting switch ON or
start engine and carry out troubleshooting in each case.
P25 Voltage
Defective F pump pressure Between (3) – (1) Power supply 4.5 – 5.5 V
2
sensor (Internal defect) Between (2) – (1) Signal 0.3 – 4.5 V
If voltage is abnormal, replace F pump pressure sensor with R
pump pressure sensor and check failure code. (If "E" of failure code
goes off at this time, F pump pressure sensor is defective.)
Possible causes
and standard Disconnection in wiring har- Wiring harness between C01 (female) (18) – Resis-
Max. 1 z
value in normal ness (Disconnection in wiring P25 (female) (1) tance
3
state or defective contact in con- Wiring harness between C01 (female) (49) – Resis-
nector) Max. 1 z
Max. 1 z
J06 – P25 (female) (3) tance
Min. 1 Mz
5
Voltage Max. 1 V
P25 (female) (2)
14 PC200, 220-8
Circuit diagram related to F pump pressure sensor
PC200, 220-8 15
Failure code [DHPBMA] R Pump Press Sensor Abnormality 1

User code Failure code R pump pressure sensor abnormality
Trouble
— DHPBMA (Pump controller system)
Contents of
• Signal voltage of R pump pressure sensor circuit is below 0.3 V or above 4.5 V.
trouble
Action of • Fixes R pump pressure at 0 MPa {0 kg/cm2} and continues control.
Problem that
• Automatic gear shifting function does not work.
appears on
• Straight travel performance or steering performance lowers.
machine
Related infor- will be broken. Accordingly, take extreme care when checking.
mation • R pump pressure can be checked with monitoring function. (Code: 01101 R pump pressure)

Defective 5V sensor power If failure code [DA25KP] is also displayed, carry out troubleshooting
1
supply 1 system for it first.
P26 Voltage
Defective R pump pressure Between (3) – (1) Power supply 4.5 – 5.5 V
2
sensor (Internal defect) Between (2) – (1) Signal 0.3 – 4.5 V
If voltage is abnormal, replace R pump pressure sensor with F
pump pressure sensor and check failure code. (If "E" of failure code
goes off at this time, R pump pressure sensor is defective.)
Possible causes
Max. 1 z
value in normal ness (Disconnection in wiring P26 (female) (1) tance
3
state or defective contact in con- Wiring harness between C01 (female) (68) – Resis-
nector) Max. 1 z
Max. 1 z
Min. 1 Mz
5
Voltage Max. 1 V
P26 (female) (2)
16 PC200, 220-8
Circuit diagram related to R pump pressure sensor
PC200, 220-8 17
Failure code [DHS3MA] Arm Curl PPC Press Sensor Abnormality 1

User code Failure code Arm curl PPC pressure sensor abnormality
Trouble
— DHS3MA (Pump controller system)
Contents of
• Signal voltage of arm curl PPC pressure sensor circuit is below 0.3 V or above 4.5 V.
trouble
Action of • Fixes arm curl PPC pressure at 0 MPa {0 kg/cm2} and continues control.
Problem that
• Automatic decelerator cannot be reset.
appears on
• Arm curl performance lowers.
machine
will be broken. Accordingly, take extreme care when checking.
Related infor-
• Arm curl PPC pressure can be checked with monitoring function.
mation
(Code: 07200 Arm curl PPC pressure)

1
P04 Voltage
Defective arm curl PPC pres-
2 Between (2) – (1) Signal 0.3 – 4.5 V
sure sensor (Internal defect)
If voltage is abnormal, replace arm curl PPC pressure sensor with
another PPC pressure sensor and check failure code. (If "E" of fail-
ure code goes off at this time, arm curl PPC pressure sensor is
defective.)
Possible causes without turning starting switch ON.
ness (Disconnection in wiring P04 (female) (1) tance
state 3
nector) Max. 1 z
Max. 1 z
Min. 1 Mz
5
Voltage Max. 1 V
P04 (female) (2)
18 PC200, 220-8
Circuit diagram related to arm curl PPC pressure sensor
PC200, 220-8 19
Failure code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality 1

User code Failure code Bucket curl PPC pressure sensor abnormality
Trouble
Contents of
• Signal voltage of bucket curl PPC pressure sensor circuit is below 0.3 V or above 4.5 V.
trouble
Action of • Fixes bucket curl PPC pressure at 0 MPa {0 kg/cm2} and continues control.
Problem that
appears on
• Bucket curl performance lowers.
machine
Related infor-
• Bucket curl PPC pressure can be checked with monitoring function.
mation
(Code: 07300 Bucket curl PPC pressure)

1
P01 Voltage
Defective bucket curl PPC Between (3) – (1) Power supply 4.5 – 5.5 V
2 pressure sensor (Internal Between (2) – (1) Signal 0.3 – 4.5 V
defect)
If voltage is abnormal, replace bucket curl PPC pressure sensor
with another PPC pressure sensor and check failure code. (If "E" of
failure code goes off at this time, bucket curl PPC pressure sensor
is defective.)
state 3
nector) Max. 1 z
Max. 1 z
Min. 1 Mz
5
Voltage Max. 1 V
P01 (female) (2)
20 PC200, 220-8
Circuit diagram related to bucket curl PPC pressure sensor
PC200, 220-8 21
Failure code [DHS8MA] Boom Raise PPC Press Sensor Abnormality 1

User code Failure code Boom raise PPC pressure sensor abnormality
Trouble
Contents of
• Signal voltage of boom raise PPC pressure sensor circuit is below 0.3 V or above 4.5 V.
trouble
Action of • Fixes boom raise PPC pressure at 0 MPa {0 kg/cm2} and continues control.
Problem that
appears on
• Boom raise performance lowers.
machine
Related infor-
• Boom raise PPC pressure can be checked with monitoring function.
mation
(Code: 07400 Boom raise PPC pressure)

1
P06 Voltage
Defective boom raise PPC Between (3) – (1) Power supply 4.5 – 5.5 V
defect)
If voltage is abnormal, replace boom raise PPC pressure sensor
failure code goes off at this time, boom raise PPC pressure sensor
is defective.)
state 3
nector) Max. 1 z
Max. 1 z
Min. 1 Mz
5
Voltage Max. 1 V
P06 (female) (2)
22 PC200, 220-8
Circuit diagram related to boom raise PPC pressure sensor
PC200, 220-8 23
Failure code [DHSAMA] Swing RH PPC Press Sensor Abnormality 1

User code Failure code Swing right PPC pressure sensor abnormality
Trouble
— DHSAMA (Pump controller system)
Contents of
• Signal voltage of swing right PPC pressure sensor circuit is below 0.3 V or above 4.5 V.
trouble
Action of • Fixes swing right PPC pressure at 0 MPa {0 kg/cm2} and continues control.
Problem that
• Automatic decelerator and swing holding brake cannot be reset.
appears on
• Swing right performance lowers.
machine
Related infor-
• Swing right PPC pressure can be checked with monitoring function.
mation
(Code: 09002 Swing right PPC pressure)

1
P07 Voltage
Defective swing right PPC Between (3) – (1) Power supply 4.5 – 5.5 V
defect)
If voltage is abnormal, replace swing right PPC pressure sensor
failure code goes off at this time, swing right PPC pressure sensor is
defective.)
state 3
nector) Max. 1 z
Max. 1 z
Min. 1 Mz
5
Voltage Max. 1 V
P07 (female) (2)
24 PC200, 220-8
Circuit diagram related to swing right PPC pressure sensor
PC200, 220-8 25
Failure code [DHSBMA] Swing LH PPC Press Sensor Abnormality 1

User code Failure code Swing left PPC pressure sensor abnormality
Trouble
— DHSBMA (Pump controller system)
Contents of
• Signal voltage of swing left PPC pressure sensor circuit is below 0.3 V or above 4.5 V.
trouble
Action of • Fixes swing left PPC pressure at 0 MPa {0 kg/cm2} and continues control.
Problem that
• Automatic decelerator and swing holding brake cannot be reset.
appears on
• Swing left performance lowers.
machine
Related infor-
• Swing left PPC pressure can be checked with monitoring function.
mation
(Code: 09002 Swing left PPC pressure)

1
P03 Voltage
Defective swing left PPC Between (3) – (1) Power supply 4.5 – 5.5 V
defect)
If voltage is abnormal, replace swing left PPC pressure sensor with
another PPC pressure sensor and check failure code. (If "E" of fail-
ure code goes off at this time, swing left PPC pressure sensor is
defective.)
state 3
nector) Max. 1 z
Max. 1 z
Min. 1 Mz
5
Voltage Max. 1 V
P03 (female) (2)
26 PC200, 220-8
Circuit diagram related to swing left PPC pressure sensor
PC200, 220-8 27
Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality 1

User code Failure code Bucket dump PPC pressure sensor abnormality
Trouble
— DHSDMA (Pump controller system)
Contents of
• Signal voltage of bucket dump PPC pressure sensor circuit is below 0.3 V or above 4.5 V.
trouble
Action of • Fixes bucket dump PPC pressure at 0 MPa {0 kg/cm2} and continues control.
Problem that
appears on
• Bucket dump performance lowers.
machine
Related infor-
• Bucket dump PPC pressure can be checked with monitoring function.
mation
(Code: 07301 Bucket dump PPC pressure)

1
P05 Voltage
Defective bucket dump PPC Between (3) – (1) Power supply 4.5 – 5.5 V
defect)
If voltage is abnormal, replace bucket dump PPC pressure sensor
failure code goes off at this time, bucket dump PPC pressure sensor
is defective.)
state 3
nector) Max. 1 z
Max. 1 z
Min. 1 Mz
5
Voltage Max. 1 V
P05 (female) (2)
28 PC200, 220-8
Circuit diagram related to bucket dump PPC pressure sensor
PC200, 220-8 29
30 PC200, 220-8
Failure code [DHX1MA] Overload Sensor Abnormality (Analog) 1

Overload alarm monitor non-display specification
User code Failure code Overload sensor (analog)
Trouble
— DHX1MA (Pump controller system)
Contents of
• Monitor which is not set to be displayed (Overload alarm monitor) is displayed.
trouble
Problem that
appears on
machine
Related infor-
Method of reproducing failure code: Turn starting switch ON.
mation

and standard
value in normal Pump controller may be defective. (Since trouble is in system, trou-
state bleshooting cannot be carried out.)
PC200, 220-8 31
Overload alarm monitor display specification

User code Failure code Overload sensor (analog)
Trouble
— DHX1MA (Pump controller system)
Contents of
• Signal voltage of overload alarm pressure sensor circuit is below 0.3 V or above 4.4 V.
trouble
Action of • Outputs overload alarm constantly.
Problem that
appears on • If display of overload alarm monitor is set, overload alarm monitor is displayed constantly.
machine
• Overload alarm pressure sensor is installed to only machine on which display of overload alarm
monitor is set.
Related infor-
mation
• Overload alarm pressure (Boom cylinder bottom pressure) can be checked with monitoring function.
(Code: 15900 Boom bottom pressure)

1
P46 Voltage
Defective overload alarm Between (3) – (1) Power supply 4.5 – 5.5 V
defect)
If voltage is abnormal, replace overload alarm pressure sensor with
F pump pressure sensor or R pump pressure sensor and check fail-
ure code. (If "E" of failure code goes off at this time, overload alarm
pressure sensor is defective.)
state 3
nector) Max. 1 z
Max. 1 z
Min. 1 Mz
5
Voltage Max. 1 V
P46 (female) (2)
32 PC200, 220-8
Circuit diagram related to overload alarm pressure sensor
PC200, 220-8 33
Failure code [DW43KA] Travel Speed Sol Discon 1

User code Failure code Travel speed solenoid system disconnection
Trouble
— DW43KA (Pump controller system)
Contents of
• When output to travel speed shifting solenoid was turned ON, disconnection was detected in circuit.
trouble
Action of • None in particular. (Since no current flows, solenoid does not operate.)
• PC200: Speed is low at High travel speed position (Machine monitor is set to High but actual speed
Problem that
is about Middle).
appears on
• PC220: Speed is low at High and Middle travel speed position (Machine monitor is set to High or
machine
Middle but actual speed is about Low).
• Operating condition of travel speed shifting solenoid can be checked with monitoring function.
Related infor-
(Code: 02300: Solenoid 1)
mation
• Method of reproducing failure code: Start engine + Set travel speed to High + Operate travel lever.

Defective travel speed shift- without turning starting switch ON.
1 ing solenoid (Internal discon-
V04 (male) Resistance
nection)
Between (1) – (2) 20 – 60 z
Possible causes Disconnection in wiring har- without turning starting switch ON.
and standard ness (Disconnection in wiring Wiring harness between C02 (female) (87) – Resis-
value in normal 2 Max. 1 z
or defective contact in con- V04 (female) (1) tance
state nector) Wiring harness between C02 (female) (115), Resis-
Max. 1 z
(117), (120) – V04 (female) (2) tance
Between (87) – (115), (117),
20 – 60 z
(120)
34 PC200, 220-8
Circuit diagram related to travel speed shifting solenoid
PC200, 220-8 35
Failure code [DW43KB] Travel Speed Sol Short 1

User code Failure code Travel speed solenoid system short
Trouble
— DW43KB (Pump controller system)
Contents of
• When output to travel speed shifting solenoid was turned ON, short circuit was detected in circuit.
trouble
Action of • Turns output to travel speed shifting solenoid OFF.
• PC200: Speed is low at High travel speed position (Machine monitor is set to High but actual speed
Problem that
is about Middle).
appears on
• PC220: Speed is low at High and Middle travel speed position (Machine monitor is set to High or
machine
Middle but actual speed is about Low).
• Operating condition of travel speed shifting solenoid can be checked with monitoring function.
Related infor-
mation
• Method of reproducing failure code: Start engine + Set travel speed to High + Operate travel lever.

Defective travel speed shift-
1 ing solenoid (Internal discon- V04 (male) Resistance
nection) Between (1) – (2) 20 – 60 z
state Min. 1 Mz
V04 (female) (1) tance
Between (87) – (115), (117),
20 – 60 z
(120)
36 PC200, 220-8
PC200, 220-8 37
Failure code [DW45KA] Swing Brake Sol Discon 1

User code Failure code Swing holding brake solenoid system disconnection
Trouble
E03 DW45KA (Pump controller system)
Contents of
• When output to swing holding brake solenoid was turned OFF, disconnection was detected in circuit.
trouble
Problem that
appears on • Machine cannot swing (Swing holding brake is not reset).
machine
• If solenoid and wiring harness are normal, operator can swing machine by setting swing holding
brake release switch in release position (Swing holding brake does not work, however, when
machine stops).
Related infor- • Keep swing lock switch in OFF position and swing holding brake release switch in release position
mation during troubleshooting.
• Operating condition of swing holding brake solenoid can be checked with monitoring function.

Defective swing holding without turning starting switch ON.
1 brake solenoid (Internal dis-
connection)
Between (1) – (2) 20 – 60 z
Defective assembled-type without turning starting switch ON.
2 diode D01 (Internal discon-
D01 (male) Digital circuit tester Continuity
nection)
Between (7) – (3) Diode mode There is continuity
Defective swing lock switch S04 (male) Swing lock switch Resistance
3
(Internal disconnection)
OFF Max. 1 z
Possible causes Between (3) – (4)
ON Min. 1 Mz
and standard
Wiring harness between C02 (female) (101) Resis-
Max. 1 z
Disconnection in wiring har- – D01 (female) (7) tance
ness (Disconnection in wiring Wiring harness between D01 (female) (3) – Resis-
4 Max. 1 z
or defective contact in con- J02 – S04 (female) (3) tance
nector) Wiring harness between S04 (female) (4) – Resis-
Max. 1 z
Wiring harness between C02 (female) (115), Resis-
Max. 1 z
(117), (120) – V03 (female) (2) tance
5 Defective pump controller C02 (female) Disconnect D01 and Resistance

connect pins (3) and
Between (101) – (7) on female side 20 – 60 z
(115), (117), (120) directly.
38 PC200, 220-8
Circuit diagram related to swing holding brake solenoid
PC200, 220-8 39
Failure code [DW45KB] Swing Brake Sol Short 1

User code Failure code Swing holding brake solenoid system short
Trouble
E03 DW45KB (Pump controller system)
Contents of
• When output to swing holding brake solenoid was turned ON, short circuit was detected in circuit.
trouble
Action of • Turns output to swing holding brake solenoid OFF.
Problem that
appears on • Machine cannot swing (Swing holding brake is not reset).
machine
• If solenoid and wiring harness are normal, operator can swing machine by setting swing holding
brake release switch in release position (Swing holding brake does not work, however, when
machine stops).
Related infor- • Keep swing lock switch in OFF position and swing holding brake release switch in release position
mation during troubleshooting.
• Operating condition of swing holding brake solenoid can be checked with monitoring function.
• Method of reproducing failure code: Start engine + Swing with left work equipment control lever.

Defective swing holding
1 brake solenoid (Internal short V03 (male) Resistance
circuit or ground fault) Between (1) – (2) 20 – 60 z
Possible causes Ground fault in wiring har- without turning starting switch ON.
and standard ness (Disconnection in wiring
2 Wiring harness between C02 (female) (101)
value in normal or defective contact in con- Resis-
nector) – D01 – J02 – S04 – V03 (female) (1), – S25 Min. 1 Mz
state tance
(female) (14)
3 Defective pump controller Disconnect D01 and
Between (101) –
connect pins (3) and 20 – 60 z
(115), (117), (120)
(7) on female side
Between (101) – directly. Min. 1 Mz
chassis ground
40 PC200, 220-8
PC200, 220-8 41
Failure code [DW91KA] Travel Junction Sol Discon 1

User code Failure code Travel junction solenoid system disconnection
Trouble
— DW91KA (Pump controller system)
Contents of
• When output to travel junction solenoid was turned ON, disconnection was detected in circuit.
trouble
Problem that
appears on • Machine is not steered easily during travel.
machine
• Operating condition of travel junction solenoid can be checked with monitoring function.
Related infor-
(Code: 02300 Solenoid 1)
mation
• Method of reproducing failure code: Start engine + Steer machine with right and left travel levers.

Defective travel junction without turning starting switch ON.
1 solenoid (Internal disconnec-
tion)
Between (1) – (2) 20 – 60 z
and standard ness (Disconnection in wiring Wiring harness between C02 (female) (110) Resis-
or defective contact in con- – V05 (female) (1) tance
Max. 1 z
(117), (120) – V05 (female) (2) tance
Between (110) – (115), (117),
20 – 60 z
(120)
42 PC200, 220-8
Circuit diagram related to travel junction solenoid
PC200, 220-8 43
Failure code [DW91KB] Travel Junction Sol Short 1

User code Failure code Travel junction solenoid system short
Trouble
— DW91KB (Pump controller system)
Contents of
• When output to travel junction solenoid was turned ON, short circuit was detected in circuit.
trouble
Action of • Turns output to travel junction solenoid OFF.
Problem that
appears on • Machine is not steered easily during travel.
machine
• Operating condition of travel junction solenoid can be checked with monitoring function.
Related infor-
mation
• Method of reproducing failure code: Start engine + Steer machine with right and left travel levers.

Defective travel junction
1 solenoid (Internal short cir- V05 (male) Resistance
cuit or ground fault) Between (1) – (2) 20 – 60 z
circuit) Wiring harness between C02 (female) (110) Resis-
state Min. 1 Mz
– V05 (female) (1) tance
Between (110) – (115), (117),
20 – 60 z
(120)
44 PC200, 220-8
Circuit diagram related to travel junction solenoid
PC200, 220-8 45
Failure code [DWA2KA] Service Sol Discon 1

User code Failure code Service solenoid disconnection
Trouble
— DWA2KA (Pump controller system)
Contents of
• When output to service solenoid is turned OFF, disconnection was detected in circuit.
trouble
Problem that
appears on • Hydraulic circuit for attachment does not change to single operation circuit.
machine
• Operating condition of service solenoid can be checked with monitoring function.
Related infor- (Code: 02301 Solenoid 2)
mation • Method of reproducing failure code: Turn starting switch ON + Set machine in mode other than
breaker mode (B).

Defective service solenoid without turning starting switch ON.
1
(Internal disconnection) V06 (male) Resistance
Between (1) – (2) 20 – 60 z
and standard Disconnection in wiring har-
value in normal ness (Disconnection in wiring Wiring harness between C02 (female) (86) – Resis-
2 Max. 1 z
state or defective contact in con- V06 (female) (1) tance
nector) Wiring harness between V06 (female) (2) – Resis-
Max. 1 z
Between (86) – chassis ground 20 – 60 z
Circuit diagram related to service solenoid
46 PC200, 220-8
Failure code [DWA2KB] Service Sol Short 1

User code Failure code Service solenoid short
Trouble
— DWA2KB (Pump controller system)
Contents of
• When output to service solenoid is turned ON, short circuit was detected in circuit.
trouble
Action of • Turns output to service solenoid OFF
Problem that
appears on • Hydraulic circuit for attachment is not does not change to single operation circuit.
machine
• Operating condition of service solenoid can be checked with monitoring function.
Related infor-
mation
• Method of reproducing failure code: Turn starting switch ON + Set machine in breaker mode (B).

Defective service solenoid
1 (Internal short circuit or V06 (male) Resistance
ground fault) Between (1) – (2) 20 – 60 z
Possible causes Between (1) – chassis ground Min. 1 Mz
value in normal Ground fault in wiring har- without turning starting switch ON.
state 2 ness (Short circuit with GND
Min. 1 Mz
Between (86) – chassis ground 20 – 60 z
Circuit diagram related to service solenoid
PC200, 220-8 47
Failure code [DWK0KA] 2-stage Relief Sol Discon 1

User code Failure code 2-stage relief solenoid disconnection
Trouble
— DWK0KA (Pump controller system)
Contents of
• When output to 2-stage relief solenoid is turned OFF, disconnection was detected in circuit.
trouble
Problem that
• Power maximizing function does not work.
appears on
• Travel power is low.
machine
• Operating condition of 2-stage relief solenoid can be checked with monitoring function.
Related infor-
mation
• Method of reproducing failure code: Turn starting switch ON + Set machine in mode other than (L).

Defective 2-stage relief sole- without turning starting switch ON.
1
noid (Internal disconnection) V02 (male) Resistance
Between (1) – (2) 20 – 60 z
Max. 1 z
(117), (120) – V02 (female) (2) tance
Between (109) – (115), (117),
20 – 60 z
(120)
48 PC200, 220-8
Circuit diagram related to 2-stage relief solenoid
PC200, 220-8 49
Failure code [DWK0KB] 2-stage Relief Sol Short 1

User code Failure code 2-stage relief solenoid short
Trouble
— DWK0KB (Pump controller system)
Contents of
• When output to 2-stage relief solenoid is turned ON, short circuit was detected in circuit.
trouble
Action of • Turns output to 2-stage relief solenoid OFF.
Problem that
• Power maximizing function does not work.
appears on
• Travel power is low.
machine
• Operating condition of 2-stage relief solenoid can be checked with monitoring function.
Related infor-
mation
• Method of reproducing failure code: Turn starting switch ON + Set machine in working mode (L).

Defective 2-stage relief sole-
1 noid (Internal short circuit or V02 (male) Resistance
state Min. 1 Mz
Between (109) – (115), (117),
20 – 60 z
(120)
50 PC200, 220-8
PC200, 220-8 51
SEN00242-02

© 2007 KOMATSU
All Rights Reserved
52
SEN00243-01
PC200-8
PC200LC-8
PC220-8
PC220LC-8

PC200-8 300001 and up
PC200LC-8 300001 and up
PC220-8 70001 and up
Failure code [DXA8KA] PC-EPC (F) Sol Discon.................................................................................. 4
Failure code [DXA8KB] PC-EPC (F) Sol Short .................................................................................... 6
Failure code [DXA9KA] PC-EPC (R) Sol Discon ................................................................................. 8
Failure code [DXA9KB] PC-EPC (R) Sol Short.................................................................................. 10
Failure code [DXE0KA] LS-EPC Sol Discon ...................................................................................... 12
Failure code [DXE0KB] LS-EPC Sol Short ........................................................................................ 14
Failure code [DXE4KA] Service Current EPC Discon........................................................................ 16
Failure code [DXE4KB] Service Current EPC Short .......................................................................... 18
Failure code [DXE5KA] Merge-divider Main Sol Discon .................................................................... 20
Failure code [DXE5KB] Merge-divider Main Sol Short....................................................................... 22
Failure code [DXE6KA] Merge-divider LS Sol Discon........................................................................ 24
Failure code [DXE6KB] Merge-divider LS Sol Short .......................................................................... 26
Failure code [DY20KA] Wiper Working Abnormality .......................................................................... 28
PC200, 220-8 1
Failure code [DY20MA] Wiper Parking Abnormality........................................................................... 30

Failure code [DY2CKA] Washer Drive Discon.................................................................................... 32
Failure code [DY2CKB] Washer Drive Short ...................................................................................... 34
Failure code [DY2DKB] Wiper Drive (For) Short ................................................................................ 36
Failure code [DY2EKB] Wiper Drive (Rev) Short ............................................................................... 38
2 PC200, 220-8

Failure code [DXA8KA] PC-EPC (F) Sol Discon 1
User code Failure code PC-EPC (F) solenoid system disconnection
Trouble
E02 DXA8KA (Pump controller system)
Contents of
• When PC-EPC (F) solenoid was driven, disconnection was detected in circuit.
trouble
Action of • None in particular (Since no current flows, solenoid does not operate).
Problem that
appears on • If pump load increases, engine speed lowers largely and engine may stall.
machine
• Drive current of PC-EPC (F) solenoid can be checked with monitoring function.
Related infor-
(Code: 01300 PC-EPC solenoid current (F))
mation

Defective PC-EPC (F) sole- without turning starting switch ON.
1
Between (1) – (2) 7 – 14 z
Emergency pump
S25 (male) Resistance
Defective emergency pump drive switch
2 drive switch (Internal discon- Normal Max. 1 z
nection) Between (3) – (2)
Emergency Min. 1 Mz
Normal Max. 1 z
Between (6) – (5)
Possible causes Emergency Min. 1 Mz
and standard
value in normal
state
Max. 1 z
Disconnection in wiring har- S25 (female) (3) tance
ness (Disconnection in wiring Wiring harness between S25 (female) (2) – Resis-
3 Max. 1 z
nector) Wiring harness between C02 (female) (115), Resis-
Max. 1 z
(117), (120) – S25 (female) (6) tance
Wiring harness between S25 (female) (5) – Resis-
Max. 1 z
Between (96) – (115), (117),
7 – 14 z
(120)
4 PC200, 220-8
Circuit diagram related to PC-EPC (F) solenoid and PC-EPC (R) solenoid
PC200, 220-8 5
Failure code [DXA8KB] PC-EPC (F) Sol Short 1

User code Failure code PC-EPC (F) solenoid system short
Trouble
E02 DXA8KB (Pump controller system)
Contents of
• When PC-EPC (F) solenoid was driven, short circuit was detected in circuit.
trouble
Action of • Turns output to PC-EPC (F) solenoid OFF.
Problem that
machine
• Drive current of PC-EPC (F) solenoid can be checked with monitoring function.
Related infor-
(Code: 01300 PC-EPC solenoid current (F))
mation

Defective PC-EPC (F) sole-
Defective emergency pump Emergency pump
2 drive switch (Internal short drive switch
circuit or ground fault) Between (2), (3) – (4) Min. 1 Mz
Possible causes
Between (2), (3) – Normal
and standard Min. 1 Mz
value in normal chassis ground
3 ness (Contact with GND cir- Min. 1 Mz
S25 (female) (3) tance
cuit)
Min. 1 Mz
Between (96) – (115), (117),
7 – 14 z
(120)
6 PC200, 220-8
PC200, 220-8 7
Failure code [DXA9KA] PC-EPC (R) Sol Discon 1

User code Failure code PC-EPC (R) solenoid system disconnection
Trouble
E02 DXA9KA (Pump controller system)
Contents of
• When PC-EPC (R) solenoid was driven, disconnection was detected in circuit.
trouble
Problem that
machine
• Drive current of PC-EPC (R) solenoid can be checked with monitoring function.
Related infor-
(Code: 01302 PC-EPC solenoid current (R))
mation

Defective PC-EPC (R) sole- without turning starting switch ON.
1
Between (1) – (2) 7 – 14 z
Emergency pump
Defective emergency pump drive switch
2 drive switch (Internal discon- Normal Max. 1 z
nection) Between (9) – (8)
Emergency Min. 1 Mz
Normal Max. 1 z
Between (12) – (11)
Possible causes Emergency Min. 1 Mz
and standard
value in normal
state
Min. 1 Mz
Disconnection in wiring har- – S25 (female) (9) tance
ness (Disconnection in wiring Wiring harness between S25 (female) (8) – Resis-
3 Min. 1 Mz
nector) Wiring harness between C02 (female) (115), Resis-
Min. 1 Mz
(117), (120) – S25 (female) (12) tance
Min. 1 Mz
Between (104) – (115), (117),
7 – 14 z
(120)
8 PC200, 220-8
PC200, 220-8 9
Failure code [DXA9KB] PC-EPC (R) Sol Short 1

User code Failure code PC-EPC (R) solenoid system short
Trouble
E02 DXA9KB (Pump controller system)
Contents of
• When PC-EPC (R) solenoid was driven, short circuit was detected in circuit.
trouble
Action of • Turns output to PC-EPC (R) solenoid OFF.
Problem that
machine
• Drive current of PC-EPC (R) solenoid can be checked with monitoring function.
Related infor-
(Code: 01302 PC-EPC solenoid current (R))
mation

Defective PC-EPC (R) sole-
Emergency pump
Defective emergency pump S25 (male) Resistance
drive switch
2 drive switch (Internal short
circuit or ground fault) Between (8), (9) –
Min. 1 Mz
Possible causes (10)
Normal
and standard Between (8), (9) –
value in normal Min. 1 Mz
chassis ground
state
3 ness (Contact with GND cir- Min. 1 Mz
– S25 (female) (9) tance
cuit)
Min. 1 Mz
Between (104) – (115), (117),
7 – 14 z
(120)
10 PC200, 220-8
PC200, 220-8 11
Failure code [DXE0KA] LS-EPC Sol Discon 1

User code Failure code LS-EPC solenoid system disconnection
Trouble
— DXE0KA (Pump controller system)
Contents of
• When LS-EPC solenoid was driven, disconnection was detected in circuit.
trouble
Problem that
• Travel speed is high at Lo and Mi.
appears on
• Work equipment speed and swing speed are high in lifting mode (L).
machine
• Drive current of LS-EPC solenoid can be checked with monitoring function.
Related infor-
(Code: 01500 LS-EPC solenoid current)
mation

Defective LS-EPC solenoid without turning starting switch ON.
1
(Internal disconnection) V19 (male) Resistance
Between (1) – (2) 7 – 14 z
Max. 1 z
(117), (120) – V19 (female) (2) tance
Between (88) – (115), (117),
7 – 14 z
(120)
12 PC200, 220-8
Circuit diagram related to LS-EPC solenoid
PC200, 220-8 13
Failure code [DXE0KB] LS-EPC Sol Short 1

User code Failure code LS-EPC solenoid system short
Trouble
— DXE0KB (Pump controller system)
Contents of
• When LS-EPC solenoid was driven, short circuit was detected in circuit.
trouble
Action of • Turns output to LS-EPC solenoid OFF.
Problem that
• Travel speed is high at Lo and Mi.
appears on
• Work equipment speed and swing speed are high in lifting mode (L).
machine
• Drive current of LS-EPC solenoid can be checked with monitoring function.
Related infor-
(Code: 01500 LS-EPC solenoid current)
mation

Defective LS-EPC solenoid
1 (Internal short circuit or V19 (male) Resistance
state Min. 1 Mz
Between (88) – (115), (117),
7 – 14 z
(120)
14 PC200, 220-8
Circuit diagram related to LS-EPC solenoid
PC200, 220-8 15
Failure code [DXE4KA] Service Current EPC Discon 1

User code Failure code Service current EPC solenoid disconnection
Trouble
Contents of
• When service EPC solenoid was driven, disconnection was detected in circuit.
trouble
Problem that
appears on • Attachment does not operate.
machine
• Drive current of service EPC solenoid can be checked with monitoring function.
Related infor-
(Code: 01700 service solenoid current)
mation
• Method of reproducing failure code: Turn starting switch ON + Set in attachment mode (ATT).

Defective service EPC sole- without turning starting switch ON.
1
Between (1) – (2) 7 – 14 z
Max. 1 z
(117), (120) – V30 (female) (2) tance
Between (97) – (115), (117),
7 – 14 z
(120)
16 PC200, 220-8
Circuit diagram related to service EPC solenoid
PC200, 220-8 17
Failure code [DXE4KB] Service Current EPC Short 1

User code Failure code Service current EPC solenoid short
Trouble
Contents of
• When service EPC solenoid was driven, short circuit was detected in circuit.
trouble
Action of • Turns output to service EPC solenoid OFF.
Problem that
appears on • Attachment does not operate.
machine
• Drive current of service EPC solenoid can be checked with monitoring function.
Related infor-
(Code: 01700 service EPC solenoid current)
mation
• Method of reproducing failure code: Turn starting switch ON + Set in attachment mode (ATT).

Defective service EPC sole-
state Min. 1 Mz
Between (97) – (115), (117),
7 – 14 z
(120)
18 PC200, 220-8
Circuit diagram related to service EPC solenoid
PC200, 220-8 19
Failure code [DXE5KA] Merge-divider Main Sol Discon 1

User code Failure code Merge-divider main solenoid disconnection
Trouble
Contents of
• When merge-divider main EPC solenoid was driven, disconnection was detected in circuit.
trouble
Problem that
appears on • Single operation speed of work equipment and swing is high in lifting mode (L).
machine
• Drive current of merge-divider main EPC solenoid can be checked with monitoring function.
Related infor-
(Code: 08000 merge-divider main solenoid current)
mation

Defective merge-divider without turning starting switch ON.
1 main EPC solenoid (Internal
disconnection)
Between (1) – (2) 7 – 14 z
Max. 1 z
(117), (120) – V23 (female) (2) tance
Between (112) – (115), (117),
7 – 14 z
(120)
20 PC200, 220-8
Circuit diagram related to merge-divider main EPC solenoid
PC200, 220-8 21
Failure code [DXE5KB] Merge-divider Main Sol Short 1

User code Failure code Merge-divider main solenoid short
Trouble
Contents of
• When merge-divider main EPC solenoid was driven, short circuit was detected in circuit.
trouble
Action of • Turns output to merge-divider main EPC solenoid OFF.
Problem that
machine
• Drive current of merge-divider main EPC solenoid can be checked with monitoring function.
Related infor-
(Code: 08000 merge-divider main EPC solenoid current)
mation

Defective merge-divider
1 main EPC solenoid (Internal V23 (male) Resistance
short circuit or ground fault) Between (1) – (2) 7 – 14 z
state Min. 1 Mz
Between (112) – (115), (117),
7 – 14 z
(120)
22 PC200, 220-8
Circuit diagram related to merge-divider main EPC solenoid
PC200, 220-8 23
Failure code [DXE6KA] Merge-divider LS Sol Discon 1

User code Failure code Merge-divider LS solenoid disconnection
Trouble
Contents of
• When merge-divider LS EPC solenoid was driven, disconnection was detected in circuit.
trouble
Problem that
machine
• Drive current of merge-divider LS EPC solenoid can be checked with monitoring function.
Related infor-
(Code: 08001 merge-divider LS solenoid current)
mation

Defective merge-divider LS without turning starting switch ON.
1 EPC solenoid (Internal dis-
connection)
Between (1) – (2) 7 – 14 z
Max. 1 z
(117), (120) – V24 (female) (2) tance
Between (89) – (115), (117),
7 – 14 z
(120)
24 PC200, 220-8
Circuit diagram related to merge-divider LS EPC solenoid
PC200, 220-8 25
Failure code [DXE6KB] Merge-divider LS Sol Short 1

User code Failure code Merge-divider LS solenoid short
Trouble
Contents of
• When merge-divider LS EPC solenoid was driven, short circuit was detected in circuit.
trouble
Action of • Turns output to merge-divider LS EPC solenoid OFF.
Problem that
appears on • Single operation speed of work equipment and swing is re high in lifting mode (L).
machine
• Drive current of merge-divider LS EPC solenoid can be checked with monitoring function.
Related infor-
(Code: 08000 merge-divider LS EPC solenoid current)
mation

Defective merge-divider LS
1 EPC solenoid (Internal short V24 (male) Resistance
circuit or ground fault) Between (1) – (2) 7 – 14 z
state Min. 1 Mz
Between (89) – (115), (117),
7 – 14 z
(120)
26 PC200, 220-8
Circuit diagram related to merge-divider LS EPC solenoid
PC200, 220-8 27
Failure code [DY20KA] Wiper Working Abnormality 1

User code Failure code Wiper working abnormality
Trouble
— DY20KA (Pump controller system)
Contents of
• When windshield wiper works, W signal of working ends is not input.
trouble
Action of • Turns working output to wiper motor OFF.
Problem that
appears on • Wiper motor does not work.
machine
• Condition of W contact signal of wiper working area can be checked with monitoring function.
Related infor-
(Code: 02204 switch 5)
mation
• Method of reproducing failure code: Turn starting switch ON + Set wiper switch to INT or ON.

M05 (female) Wiper blade Resistance
Defective wiper motor (Inter-
1 Operating range top Max. 1 z
nal disconnection)
Between (6) – (5) Other than operating
Min. 1 Mz
range top
Between (1) – (3) All range Max. 20 z
Disconnection in wiring har- M05 (male) (6) tance
and standard
value in normal ness (Disconnection in wiring Wiring harness between M05 (female) (5) – Resis-
2 Max. 1 z
state or defective contact in con- J04 – chassis ground (T05, T06) tance
nector) Wiring harness between C02 (female) (114) – Resis-
Max. 1 z
M05 (male) (1) tance
Max. 1 z
C01 (female) Wiper blade Resistance
3 Defective pump controller Operating range top Max. 1 z
Between (56) – chas-
sis ground Other than operating
Min. 1 Mz
range top
28 PC200, 220-8
Circuit diagram related to windshield wiper and window washer
PC200, 220-8 29
Failure code [DY20MA] Wiper Parking Abnormality 1

User code Failure code Wiper parking abnormality
Trouble
— DY20MA (Pump controller system)
Contents of
• When windshield wiper parks, P signal of storage area is not input.
trouble
Action of • Turns parking output to wiper motor OFF.
Problem that
appears on • Wiper motor does not park.
machine
• Condition of P contact signal of wiper parking area can be checked with monitoring function.
Related infor-
(Code: 02204 switch 5)
mation
• Method of reproducing failure code: Turn starting switch ON + Set wiper switch to INT/ON to OFF.

M05 (female) Wiper blade Resistance
Storage area Max. 1 z
Between (4) – (5)
Defective wiper motor (Inter- Working area Min. 1 Mz
1
nal disconnection) Between (1) – (3) All range Max. 20 z
Max. 1 z
Max. 1 z
and standard
value in normal Wiring harness between C01 (female) (75) – Resis-
Max. 1 z
state Disconnection in wiring har- M05 (male) (4) tance
ness (Disconnection in wiring Wiring harness between M05 (female) (5) – Resis-
3 Max. 1 z
or defective contact in con- J04 – chassis ground (T05, T06) tance
Max. 1 z
Max. 1 z
C01 (female) Wiper blade Resistance
Between (75) – chas- Storage area Max. 1 z
sis ground Working area Min. 1 Mz
30 PC200, 220-8
PC200, 220-8 31
Failure code [DY2CKA] Washer Drive Discon 1

User code Failure code Window washer drive system disconnection
Trouble
— DY2CKA (Pump controller system)
Contents of • When output to window washer drive system was turned OFF (when ground circuit was connected),
trouble disconnection was detected in circuit.
Action of • None in particular (Since no current flows, washer motor does not operate).
Problem that
appears on • Window washer does not operate.
machine
Related infor-
mation

1 Defective fuse No. 4 If fuse is broken, circuit probably has ground fault. (See cause 5.)
Defective washer motor M06 (male) Resistance
2 (Internal short circuit or
Between (1), (2) – chassis
Min. 1 Mz
ground
3 diode D02 (Internal short cir-
D02 (female) Continuity (Resistance)
cuit)
Between (3) – (7) No continuity (Min. 1 Mz)
Disconnection in wiring har-
value in normal
ness (Disconnection in wiring Wiring harness between F01 (4) – J03 – M06 Resis-
state 4 Max. 1 z
Max. 1 z
J04 – M06 (female) (2) tance
Wiring harness between F01 (4) – J03 – M06 Resis-
(female) (1), – D02 (female) (3) tance
circuit)
Min. 1 Mz
J04 – M06 (female) (2), – D02 (female) (7) tance
C01 (female) Voltage
Between (3) – chassis ground 20 – 30 V
32 PC200, 220-8
PC200, 220-8 33
Failure code [DY2CKB] Washer Drive Short 1

User code Failure code Window washer drive system short
Trouble
— DY2CKB (Pump controller system)
Contents of • When output to window washer drive system was turned ON (ground circuit was disconnected),
trouble short circuit was detected in circuit.
Action of • Turns output to washer motor OFF.
Problem that
appears on • Window washer does not operate.
machine
Related infor-
• Method of reproducing failure code: Turn starting switch ON + Turn washer switch ON.
mation

Defective washer motor without turning starting switch ON.
1
(Internal short circuit) M06 (male) Resistance
Possible causes Between (1) – (2) 5 – 20 z
and standard a Prepare with starting switch OFF, then turn starting switch ON
value in normal and carry out troubleshooting.
Hot short (Short circuit with
state 2
Voltage Max. 1 V
J04 – M6 (female) (2), – D02 (female) (7)
If causes 1 and 2 are not detected, pump controller may be defec-
3 Defective pump controller tive. (Since trouble is in system, troubleshooting cannot be carried
out.)
34 PC200, 220-8
PC200, 220-8 35
Failure code [DY2DKB] Wiper Drive (For) Short 1

User code Failure code Wiper motor drive forward system short
Trouble
— DY2DKB (Pump controller system)
Contents of
• When output to wiper motor drive forward side was turned ON, short circuit was detected in circuit.
trouble
Action of • Turns output to wiper motor drive forward side OFF.
Problem that
appears on • Windshield wiper does not operate.
machine
Related infor-
mation

1 nal short circuit or ground M05 (female) Resistance
fault) Between (3) – (1) There is continuity
Possible causes
and standard Between (3) – chassis ground Min. 1 Mz
Min. 1 Mz
– M05 (male) (3) tance
out.)
36 PC200, 220-8
PC200, 220-8 37
Failure code [DY2EKB] Wiper Drive (Rev) Short 1

User code Failure code Wiper motor drive reverse system short
Trouble
— DY2EKB (Pump controller system)
Contents of
• When output to wiper motor drive reverse side was turned ON, short circuit was detected in circuit.
trouble
Action of • Turns output to wiper motor drive reverse side OFF.
Problem that
appears on • Windshield wiper does not operate.
machine
Related infor-
mation

1 nal short circuit or ground M05 (female) Continuity/Resistance
fault) Between (1) – (3) There is continuity
Possible causes
and standard Between (1) – chassis ground Min. 1 Mz
Min. 1 Mz
– M05 (male) (1) tance
out.)
38 PC200, 220-8
PC200, 220-8 39
SEN00243-01

© 2006 KOMATSU
All Rights Reserved
40
SEN00244-01
PC200-8
PC200LC-8
PC220-8
PC220LC-8

PC200-8 300001 and up
PC200LC-8 300001 and up
PC220-8 70001 and up
Troubleshooting of electrical system
(E-mode)
Troubleshooting of electrical system (E-mode)............................................................................................... 3
Before carrying out troubleshooting of electrical system...................................................................... 3
Information in troubleshooting table ..................................................................................................... 5
E-1 When starting switch turned ON, machine monitor displays nothing ............................................ 6
E-2 When starting switch turned ON (before starting engine), basic check item lights up................... 8
E-3 Engine does not start (Engine does not turn) ...............................................................................11
E-4 Preheater does not operate......................................................................................................... 14
E-5 Automatic warm-up system does not operate (in cold season)................................................... 16
E-6 All work equipment, swing, and travel mechanism do not move or cannot be locked................. 18
E-7 Precaution lights up while engine is running ............................................................................... 20
E-8 Emergency stop item lights up while engine is running ............................................................... 25
E-9 Engine coolant temperature gauge does not indicate normally................................................... 26
E-10 Hydraulic oil temperature gauge does not indicate normally..................................................... 27
E-11 Fuel level gauge does not indicate normally.............................................................................. 29
PC200, 220-8 1
E-12 Contents of display by machine monitor are different from applicable machine........................ 31
E-13 Machine monitor does not display some items.......................................................................... 31
E-14 Function switch does not work................................................................................................... 31
E-15 Auto-decelerator does not operate normally.............................................................................. 32
E-16 Working mode does not change ................................................................................................ 33
E-17 Travel speed does not change................................................................................................... 34
E-18 Alarm buzzer cannot be stopped ............................................................................................... 35
E-19 Windshield wiper and window washer do not operate............................................................... 36
E-20 Power maximizing function does not operate normally ............................................................. 38
E-21 Swing holding brake does not operate normally........................................................................ 40
E-22 Travel alarm does not sound or does not stop sounding ........................................................... 42
E-23 Air conditioner does not operate normally (including air conditioner abnormality record) ......... 44
E-24 While starting switch is in OFF position, service meter is not displayed.................................... 56
E-25 Machine monitor cannot be set in service mode ....................................................................... 56
E-26 Monitoring function does not display lever control signal normally............................................ 57
E-27 KOMTRAX system does not operate normally .......................................................................... 65
2 PC200, 220-8
Troubleshooting of electrical system (E-mode) 1

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

a The following information is summarized in the troubleshooting table and the related electrical circuit
diagram. Before carrying out troubleshooting, understand that information fully.
Trouble Trouble which occurred in the machine

Related infor-
mation

<Contents of description>
1
<Troubles in wiring harness>
• Disconnection
Connector is connected imperfectly or wiring harness is bro-
ken.
• Ground fault
Wiring harness which is not connected to chassis ground cir-
cuit is in contact with chassis ground circuit.
• Hot short
Wiring harness which is not connected to power source (24
2 V) circuit is in contact with power source (24 V) circuit.
• Short circuit
Independent wiring harnesses are in contact with each other
Possible causes
Possible causes of trouble abnormally.
and standard
value in normal (Given numbers are refer- <Precautions for troubleshooting>
state ence numbers, which do 1) Method of indicating connector No. and handling of T-
not indicate priority) adapter
Insert or connect T-adapter as explained below for trouble-
shooting, unless otherwise specified.
3 • If connector No. has no marks of “male” and “female”, dis-
connect connector and insert T-adapters in both male side
and female side.
• If connector No. has marks of “male” and “female”, dis-
connect connector and connect T-adapter to only male
side or female side.
2) Entry order of pin Nos. and handling of tester leads
Connect positive (+) lead and negative (–) lead of tester as
explained below for troubleshooting, unless otherwise
specified.
4
• Connect positive (+) lead to pin No. or wiring harness
entered on front side.
• Connect negative (–) lead to pin No. or harness entered on
rear side.
Related circuit diagram
This drawing is a part of the circuit diagram related to troubleshooting.

• Connector No.: Indicates (Model – Number of pins) and (Color).
• “Connector No. and pin No.” from each branching/merging point:
Shows the ends of branch or source of merging within the parts of the
same wiring harness.
• Arrow ( ): Roughly shows the location on the machine.
PC200, 220-8 5
E-1 When starting switch turned ON, machine monitor displays nothing1
Trouble • When starting switch turned ON, machine monitor displays nothing.
• When starting switch is turned ON, machine monitor displays KOMATSU logo, screen to input pass-
word (if set), screen to check breaker mode (if set), screen of check before starting, screen to check
Related infor-
working mode and travel speed, and ordinary screen in order.
mation
• When the engine is started, the battery voltage may lower suddenly, depending on the ambient tem-
perature and the condition of the battery.

1 Low charge level of battery Electrolyte specific gravity
Battery voltage (2 pieces)
(1 piece)
Min. 24 V Min. 1.26
Defective fusible link F05 or If fusible link or fuse is broken, circuit probably has ground fault.
2
fuse No. 17 (See Cause 5.)
Wrong connection of connec- Machine monitor connector may be connected wrongly. Check it
3
tor directly. (Check mounting bracket plate with connector.)
Wiring harness between battery (–) – chas- Resis-
Max. 1 z
sis ground tance
Wiring harness between battery (+) – R04 – Resis-
Max. 1 z
F05 (male) (1) tance
Disconnection in wiring har- Wiring harness between F05 (male) (2) – Resis-
Max. 1 z
ness (Disconnection in wiring F01-16D tance
4
or defective contact in con- Wiring harness between F01-17 – J06 – Resis-
nector) Max. 1 z
CM01 (female) (1), (2) tance
Wiring harness between CM01 (female) (3), Resis-
(4) – chassis ground (T05) tance
and standard
value in normal Wiring harness between F01-17 – H15 Resis-
Max. 1 z
state (female) (1) tance
Wiring harness between H15 (female) (5) – Resis-
Max. 1 z
J03 – CM01 (female) (14) tance
Wiring harness between battery (+) – R04 – Resis-
Min. 1 Mz
F05 (male) (1) tance
F01-16D tance
circuit) Wiring harness between F01-17 – J06 – Resis-
Min. 1 Mz
CM01 (female) (1), (2) tance
Wiring harness between F01-17 – H15 Resis-
Min. 1 Mz
(female) (1) tance
Min. 1 Mz
J03 – CM01 (female) (14) tance
a Prepare with starting switch OFF, then hold starting switch OFF
and ON and carry out troubleshooting in each case.
CM01 Starting switch Voltage
6 Defective machine monitor Between
OFF 20 – 30 V
(1), (2) – (3), (4)
Between
ON 20 – 30 V
(14) – (3), (4)
6 PC200, 220-8
Circuit diagram related to machine monitor power supply
PC200, 220-8 7
E-2 When starting switch turned ON (before starting engine),

basic check item lights up 1
Trouble (1) Radiator coolant level monitor lights up red.
• Although radiator coolant level monitor is basic check item, it is also checked while engine is running.
Related infor- (If monitor lights up red while engine is running, carry out this troubleshooting, too.)
mation • Condition of radiator coolant level switch signal can be checked with monitoring function.

Lowering of radiator coolant
Coolant level in radiator sub tank may be low. Check it and add
1 level (When system is nor-
coolant if necessary.
mal)
Defective radiator coolant Sub tank coolant
P24 (male) Resistance
2 level switch (Internal discon- level
nection) Between
Max. 1 z
Between (1) – (2) FULL – LOW
Possible causes Below LOW Min. 1 Mz

value in normal Disconnection in wiring har- without turning starting switch ON.
state ness (Disconnection in wiring Wiring harness between CM02 (female) (3) – Resis-
3 Max. 1 z
or defective contact in con- P24 (female) (1) tance
nector) Wiring harness between P24 (female) (2) – Resis-
Max. 1 z
Sub tank coolant
CM02 Voltage
4 Defective machine monitor level
Between
Between (3) – Max. 1 V
FULL – LOW
chassis ground
Below LOW 20 – 30 V
8 PC200, 220-8
Circuit diagram related to radiator coolant level switch
PC200, 220-8 9
Trouble (2) Engine oil level monitor lights up red.

Related infor- • Condition of engine oil level switch signal can be checked with monitoring function.
mation (Code: 04501 Monitor input 2)

Lowering of engine oil level
1 Engine oil level may be low. Check it and add oil if necessary.
(When system is normal)
Defective engine oil level
2 switch (Internal disconnec- P44 (male) Engine oil level Resistance
tion) Between (1) – Between H – L Max. 1 z
Possible chassis ground Below L Min. 1 Mz
causes and
standard value Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting
in normal state ness (Disconnection in wiring without turning starting switch ON.
3
or defective contact in con- Wiring harness between CM02 (female) (2) – Resis-
nector) Max. 1 z
4 Defective machine monitor CM02 Engine oil level Voltage
Between (2) – Between H – L Max. 1 V
chassis ground Below L 20 – 30 V
Circuit diagram related to engine oil level switch
10 PC200, 220-8
E-3 Engine does not start (Engine does not turn) 1
Trouble • Engine does not start (Engine does not turn).

• Engine starting circuit has following 2 start lock mechanisms.
Related infor-
1) Start lock with password of machine monitor
mation
2) Start lock with lock lever

1 Low charge level of battery Electrolyte specific gravity
Battery voltage (2 pieces)
(1 piece)
Min. 24 V Min. 1.26
and turn it to START and carry out troubleshooting in each case.
Defective starting switch H15 (male) Starting switch Resistance
3
OFF Min. 1 Mz
Between (1) – (4)
START Max. 1 z
Defective lock lever switch S14 (female) Lock lever Resistance
4
Free Min. 1 Mz
Possible causes Between (1) – (3)
Lock Max. 1 z
and standard
Defective starting motor cut-
out relay R06 or R07 (Inter- R06 (male), R07 (male) Resistance
5
nal disconnection or short Between (1) – (2) 300 – 600 z
circuit) Between (3) – (4) Max. 1 z
Between (3) – (5) Min. 1 Mz
a Prepare with starting switch OFF (with only terminal C discon-
nected), then turn starting switch to START and carry out trou-
bleshooting.
Safety relay terminal Voltage
Between B – E Power supply 20 – 30 V
Defective starting motor Between R
6 Generation input Max. 1 V
safety relay (Internal defect) (R17-2) – E
Between S
Starting input 20 – 30 V
(R17-1) – E
Between C (R18) – E Starting output 20 – 30 V
If power supply, generation input, and starting input are normal but
starting output is not normal, starting motor safety relay is defective.
PC200, 220-8 11

a Prepare with starting switch OFF, then turn starting switch to
START and carry out troubleshooting.
Starting motor terminals Voltage
Between B (SB) –
Defective starting motor Power supply 20 – 30 V
7 chassis ground
(Internal defect)
Between C (SC) –
Starting input 20 – 30 V
chassis ground
If power supply and starting input are normal but starting motor does
not turn, starting motor is defective.
Defective alternator (Internal
8 Alternator Voltage
short circuit)
Between L –
Generation output Max. 1 V
chassis ground
Max. 1 z
J01 – R06 (female) (5) tance
Max. 1 z
R07 (female) (4) tance
Max. 1 z
Disconnection in wiring har- Wiring harness between starting motor Resis-
Max. 1 z
ness (Disconnection in wiring safety relay B – heater relay – battery relay B tance
9
or defective contact in con- Wiring harness between starting motor Resis-
Possible causes nector) Max. 1 z
safety relay E – chassis ground tance
and standard
value in normal Wiring harness between starting motor Resis-
Max. 1 z
state safety relay C – starting motor C (SC) tance
Wiring harness between F01-3 – S14 (male) Resis-
Max. 1 z
(1) tance
Max. 1 z
Max. 1 z
Min. 1 Mz
J01 – R06 (female) (5), – circuit branch end tance
Min. 1 Mz
circuit) Wiring harness between starting motor Resis-
Min. 1 Mz
safety relay B – heater relay – battery relay B tance
Wiring harness between starting motor Resis-
Min. 1 Mz
safety relay C – starting motor C (SC) tance
Min. 1 Mz
(1) tance
Min. 1 Mz
11
24V circuit) in wiring harness Wiring harness between R17 (female) (2) –
Voltage Max. 1 V
alternator L, – circuit branch end
12 PC200, 220-8
PC200, 220-8 13
E-4 Preheater does not operate 1
Trouble (1) When starting switch is turned to HEAT position, preheating monitor does not light up or flash.
• Preheater monitor lights up when starting switch is turned to HEAT and starts flashing about 30 seconds
after to notify completion of preheating (It stops flashing about 10 seconds after).
Related informa- • If engine coolant temperature is below 20°C, automatic warm-up system operates and preheating monitor
tion lights up for up to 30 seconds.
• Condition of starting switch (preheating) signal can be checked with the monitoring function.

a Prepare with starting switch OFF, then keep starting switch OFF and
turn it to HEAT and carry out troubleshooting in each case.
Defective starting switch (Inter- H15 (male) Starting switch Resistance
1
nal disconnection)
OFF Min. 1 Mz
Between (1) – (3)
HEAT Max. 1 z
Possible causes
and standard
value in normal 2
state or defective contact in connec- Wiring harness between CM01 (female) Resis-
tor) Max. 1 z
(16) – J02 – H15 (female) (3) tance
a Prepare with starting switch OFF, then keep starting switch OFF and
turn it to HEAT and carry out troubleshooting in each case.
3 Defective machine monitor CM01 Starting switch Voltage
Between (16) – OFF Max. 1 V
chassis ground HEAT 20 – 30 V
Trouble (2) When starting switch is turned to HEAT position, intake air heater mounting part does not become warm.
Related informa- • Check that engine can be turned with starting motor (If engine cannot be turned, carry out troubleshooting
tion for E-1 Engine does not start (Engine does not turn)).

a Prepare with starting switch OFF (with wiring harness connected),
then keep starting switch OFF and turn it to HEAT and carry out
troubleshooting in each case.
Defective heater relay (Internal Heater relay Starting switch Continuity/Resistance
1
disconnection) Between R15 –
OFF There is continuity
chassis ground
Between power
HEAT Max. 1 z
supply terminal – R16
a Prepare with starting switch OFF (with wiring harness connected),
then turn starting switch to HEAT and carry out troubleshooting in
Possible causes each case.
and standard
Defective intake air heater E01 Starting switch Voltage
value in normal 2
(Internal disconnection) Between terminal –
state HEAT 20 – 30 V
chassis ground
If voltage is normal but heater mounting part does not become warm,
intake air heater is defective.
Disconnection in wiring har- Wiring harness between H15 (female) (3) – Resis-
Max. 1 z
ness (Disconnection in wiring J02 – heater relay R15 tance
3
or defective contact in connec- Wiring harness between battery relay R03 – Resis-
tor) Max. 1 z
heater relay contact terminal tance
Wiring harness between heater relay R16 – Resis-
Max. 1 z
intake air heater E01 tance
14 PC200, 220-8
PC200, 220-8 15
E-5 Automatic warm-up system does not operate (in cold season) 1
Trouble • Automatic warm-up system does not operate (in cold season).
• When engine coolant temperature is below 30°C automatic warm-up system raises engine speed to
1,200 rpm.
• If fuel control dial is opened more than 70% for 3 seconds when starting switch is turned ON or after
Related infor-
engine is started, automatic warm-up system is turned OFF. (Automatic warm-up system stops auto-
mation
matically after operating for 10 minutes.)
• If engine coolant temperature is below 10°C turbocharger protection function operates to keep the
engine speed at low idle.

a Turn starting switch ON or start engine and carry out trouble-
shooting.
Engine coolant Coolant temperature
Monitoring code
temperature level
105°C 6 (a: Red)
Possible causes 102°C 5 (a: Red)

Defective engine coolant 04107
and standard 1 100°C 4 (a: Blue)
temperature signal system Engine coolant
value in normal 85°C 3 (a: Blue)
state temperature
60°C 2 (a: Blue)
30°C 1 (a: White)
If level of coolant temperature gauge is different from actual coolant
temperature, carry out troubleshooting for E-9 Engine coolant tem-
perature gauge does not indicate normally.
Engine coolant temperature gauge and engine

coolant temperature monitor
16 PC200, 220-8
E-6 All work equipment, swing, and travel mechanism do not move or
cannot be locked 1
Trouble (1) All work equipment, swing, and travel mechanism do not move.
Related infor-
mation

2
Lock Min. 1 Mz
Between (1) – (2)
Free Max. 1 z
Defective PPC lock solenoid
3 (Internal disconnection or V01 (male) Resistance
short circuit) Between (1) – (2) 20 – 60 z
Possible causes Defective assembled-type without turning starting switch ON.
and standard 4 diode D01 (Internal short cir-
D01 (male) Resistance (Continuity)
value in normal cuit)
state Between (4) – (8) Min. 1 Mz (No continuity)
Disconnection in wiring har- Wiring harness between F01-3 – S14 (male) Resis-
Max. 1 z
ness (Disconnection in wiring (1) tance
5
or defective contact in con- Wiring harness between S14 (male) (2) – Resis-
nector) Max. 1 z
Wiring harness between V01 (female) (2) – Resis-
Max. 1 z
(1), – circuit branch end tance
circuit)
Min. 1 Mz
V01 (female) (1), – D01 (female) (4) tance
18 PC200, 220-8
Trouble (2) All work equipment, swing, and travel mechanism cannot be locked.
Related infor-
mation

Possible causes 1
(Internal short circuit)
and standard Lock Min. 1 Mz
value in normal Between (1) – (2)
Free Max. 1 z
state
2
24V circuit) in wiring harness Wiring harness between S14 (male) (2) –
Voltage Max. 1 V
V01 (female) (1), – D01 (female) (4)
Circuit diagram related to PPC lock solenoid
PC200, 220-8 19
E-7 Precaution lights up while engine is running 1
Trouble (1) Charge level monitor lights up red.

Related infor- • Signal voltage of alternator can be checked with monitoring function.
mation (Code: 04300 Charge voltage)

Defective generation by troubleshooting.
1 alternator (when system is E12 (male) Engine speed Voltage
normal) Between (1) – chas-
Middle or higher 27.5 – 29.5 V
sis ground
2
Possible causes or defective contact in con- Wiring harness between CM01 (female) Resis-
nector) Max. 1 z
and standard (11) – J02 – E12 (female) (1) tance
3 ness (Short circuit with GND Wiring harness between CM01 (female)
circuit) Resis-
(11) – J02 – E12 (female) (1), – circuit Min. 1 Mz
tance
branch end
troubleshooting.
4 Defective machine monitor CM02 Engine Voltage
Between (11) –
Running Min. 7.8 V
chassis ground
20 PC200, 220-8
PC200, 220-8 21
Trouble (2) Fuel level monitor lights up red.

Related infor- • Signal voltage of fuel sensor can be checked with monitoring function.
mation (Code: 04200 Fuel sensor voltage)

Possible causes Low fuel level (when system Fuel level may be low (below about 41 l). Check it and add fuel if
1
and standard is normal) necessary.
value in normal If cause 1 is not detected, fuel level gauge system may be defective.
state Defective fuel level gauge
2 Carry out troubleshooting for E-11 Fuel level gauge does not indi-
system
cate normally.
Trouble (3) Air cleaner clogging monitor lights up red.

Related infor- • Condition of signal of air cleaner clogging switch can be checked with monitoring function.
mation (Code: 04501 Monitor input 2)

Clogging of air cleaner (when Air cleaner may be clogged. Check it, then clean or replace if nec-
1
system is normal) essary.
troubleshooting.
P23 (male) Air cleaner Resistance
Defective air cleaner clog- When normal
2 ging switch (Internal discon- (Air intake Max. 1 z
nection) resistance: *1)
Between (1) – (2)
When clogged
(Air intake Min. 1 Mz
resistance: *2)
Possible causes
and standard
value in normal
state ness (Disconnection in wiring Wiring harness between CM02 (female) (4) – Resis-
3 Max. 1 z
Max. 1 z
troubleshooting.
CM02 Air cleaner Voltage
When normal
4 Defective machine monitor (Air intake Max. 1 V
Between (4) – resistance: *1)
chassis ground When clogged
(Air intake 20 – 30 V
resistance: *2)
*1: Max. –3,430 Pa {Max. –350 mmH2O}

*2: –7,470 ± 490 Pa {–762 ± 50 mmH2O}
22 PC200, 220-8
Circuit diagram related to air cleaner clogging switch
PC200, 220-8 23
Trouble (4) Engine coolant temperature monitor lights up white.

• Signals of engine coolant temperature sensor are input to engine controller and then transmitted to
Related infor- machine monitor through communication system.
mation • Engine coolant temperature can be checked with monitoring function.

If monitor lights up white, engine coolant temperature may be low
Insufficient warm-up of
Possible causes (below about 30°C). Warm up engine.
1 machine (when system is
and standard • Lighting up white: Engine coolant temperature is low.
normal)
value in normal • Lighting up blue: Engine coolant temperature is proper.
state If cause 1 is not detected, engine coolant temperature gauge sys-
2 tem may be defective. Carry out troubleshooting for E-9 Engine
coolant temperature gauge does not indicate normally.
Trouble (5) Water separator monitor lights up red.

Related infor- • Condition of signal of water-in-fuel sensor switch can be checked with monitoring function.
mation (Code: 18800 WIF sensor condition)

Possible causes Water separator is full (when
1 Water separator may be full of water. Check it, then drain if full.
and standard system is normal)
value in normal If cause 1 is not detected, water-in-fuel sensor system may be
state Defective water-in-fuel sen-
2 defective. Carry out troubleshooting for failure codes [CA428] and
sor system
[CA429].
Trouble (6) Hydraulic oil temperature monitor lights up white.

• Signals of hydraulic oil temperature sensor are input to pump controller and then transmitted to
mation • Hydraulic oil temperature can be checked with monitoring function.

If monitor lights up white, hydraulic oil temperature may be low
Insufficient warm-up of
Possible causes (below about 20°C). Warm up engine.
1 machine (when system is
and standard • Lighting up white: Hydraulic oil temperature is low.
normal)
value in normal • Lighting up blue: Hydraulic oil temperature is proper.
state If cause 1 is not detected, hydraulic oil temperature gauge system
2 may be defective. Carry out troubleshooting for E-10 Hydraulic oil
temperature gauge does not indicate normally.
24 PC200, 220-8
E-8 Emergency stop item lights up while engine is running 1
Trouble (1) Engine coolant temperature monitor lights up red.


If monitor lights up red, engine coolant temperature may be high
(above about 102°C). Cool down engine coolant (Run engine at low
Possible causes Overheating of engine cool- idle).
1
and standard ant (when system is normal) • Lighting up red: Engine coolant temperature is high
value in normal (overheating).
state • Lighting up blue: Engine coolant temperature is proper.
If cause 1 is not detected, engine coolant temperature gauge sys-
2 tem may be defective. Carry out troubleshooting for E-9 Engine
coolant temperature gauge does not indicate normally.
Trouble (2) Hydraulic oil temperature monitor lights up red.


If monitor lights up red, hydraulic oil temperature may be high
(above about 102°C). Cool down hydraulic oil (Run engine at low
Possible causes Overheating of hydraulic oil
1 idle).
and standard (when system is normal)
• Lighting up red: Hydraulic oil temperature is high (overheating).
value in normal
• Lighting up blue: Hydraulic oil temperature is proper.
state
If cause 1 is not detected, hydraulic oil temperature gauge system
2 may be defective. Carry out troubleshooting for E-10 Hydraulic oil
temperature gauge does not indicate normally.
Trouble (3) Engine oil pressure monitor lights up red.

Related infor- • Signals of engine oil pressure switch are input to engine controller and then transmitted to machine
mation monitor through communication system.

Possible causes Lowering of engine oil pres-
Engine oil pressure may be low. If it is low, carry out troubleshooting
and standard 1 sure (when system is nor-
for S-12 Oil pressure lowers.
value in normal mal)
state Defective engine oil pressure If cause 1 is not detected, engine oil pressure gauge system may be
2
switch system defective. Carry out troubleshooting for failure code [CA435].
PC200, 220-8 25
E-9 Engine coolant temperature gauge does not indicate normally 1
(1) While engine coolant temperature is rising normally, temperature gauge does not rise from white
Trouble range (C).
(2) While engine coolant temperature is stabilized normally, temperature gauge rises to red range (H).

Possible causes If cause 1 is not detected, engine coolant temperature sensor sys-
and standard 1 tem may be defective. Carry out troubleshooting for failure codes
temperature sensor system
value in normal [CA144] and [CA145].
state If cause 1 is not detected, machine monitor may be defective.
(3) Display of coolant temperature gauge is different from actual engine coolant temperature.
Trouble (4) Display of engine coolant temperature gauge is different from display of engine coolant temperature
monitor.

shooting.
Engine coolant Coolant temperature Color of monitor light
Possible causes temperature level (a)
and standard 105°C 6
value in normal 1 Defective machine monitor Red
102°C 5
state
100°C 4
85°C 3 Blue
60°C 2
30°C 1 White
Engine coolant temperature gauge and engine

coolant temperature monitor
26 PC200, 220-8
E-10 Hydraulic oil temperature gauge does not indicate normally 1
(1) While hydraulic oil temperature is rising normally, temperature gauge does not rise from white range
Trouble (C).
(2) While hydraulic oil temperature is stabilized normally, temperature gauge rises to red range (H).

1 perature sensor (Internal dis- P22 (male) Resistance
connection or short circuit) Between (1) – (2) 3.5 – 90 kz
2 Max. 1 z
Max. 1 z
Possible causes
state circuit) Wiring harness between C01 (female) (29) – Resis-
Min. 1 Mz
4
Voltage Max. 1 V
P22 (female) (2)
Between (29) – (46) 3.5 – 90 kz
Circuit diagram related to hydraulic oil temperature sensor
PC200, 220-8 27
(3) Display of hydraulic oil temperature gauge is different from actual hydraulic oil temperature.
Trouble (4) Display of hydraulic oil temperature gauge is different from display of hydraulic oil temperature mon-
itor.

shooting.
Hydraulic oil Hydraulic oil tempera- Color of monitor light
Possible causes temperature ture level (a)
and standard 105°C 6
value in normal 1 Defective machine monitor Red
102°C 5
state
100°C 4
85°C 3 Blue
40°C 2
20°C 1 White
Hydraulic oil temperature gauge and hydraulic

oil temperature monitor
28 PC200, 220-8
E-11 Fuel level gauge does not indicate normally 1
(1) While fuel is added, fuel level gauge does not rise from red range (E).
Trouble
(2) While fuel level is low, fuel level gauge does not lower from green range top (F)
Related infor- • Signal voltage of fuel level sensor can be checked with monitoring function.
mation (Code: 04200 Fuel level sensor voltage)

Defective fuel level sensor
1 (Internal disconnection or P21 (male) Fuel level Resistance
short circuit) Between (1) – FULL 7 – 11 z
chassis ground EMPTY 85 – 95 z
2
or defective contact in con- Wiring harness between CM01 (female) (9) – Resis-
nector) Max. 1 z
Possible causes
state circuit) Wiring harness between CM01 (female) (9) – Resis-
Min. 1 Mz
4
24V circuit) in wiring harness Wiring harness between CM01 (female) (9) –
Voltage Max. 1 V
P21 (female) (1)
5 Defective machine monitor CM01 (female) Fuel level Resistance
Between (9) – FULL 7 – 11 z
chassis ground EMPTY 85 – 95 z
Circuit diagram related to fuel level sensor
PC200, 220-8 29
(3) Display of fuel level gauge is different from actual fuel level.
Trouble
(4) Display of fuel level gauge is different from display of fuel level monitor.
Related infor- • Signal voltage of fuel level sensor can be checked with monitoring function.
mation (Code: 04200 Fuel level sensor voltage)

shooting.
Reading of fuel level Color of monitor light
Quantity of fuel
Possible causes gauge (a)
and standard 289 l 6
value in normal 1 Defective machine monitor 244.5 l 5
state
200 l 4 Blue
100 l 3
60 l 2
41 l 1 Red
Fuel level gauge and fuel level monitor
30 PC200, 220-8
E-12 Contents of display by machine monitor are different from

applicable machine 1
Trouble Contents of display by machine monitor are different from applicable machine.
Related infor-
mation

a Turn starting switch ON and carry out troubleshooting (with
monitoring function).
Possible causes Monitoring code Normal display
and standard 1 Defective model code signal PC200-8: PC200-8
value in normal 00200 Controller model code
PC220-8: PC220-8
state
If display of monitoring is abnormal, carry out troubleshooting for
failure code [DA29KQ].
If cause 1 is not detected, machine monitor may be defective.
E-13 Machine monitor does not display some items 1
Trouble • Machine monitor does not display some items.

• The LCD panel sometimes has black points (points which are not lighted) and bright points (points
Related infor-
which do not go off) for the reason of its characteristics. If the number of the bright points and black
mation
points does not exceed 10, those points are not a failure or a defect.

a Turn starting switch ON and carry out troubleshooting.
Possible causes
Defective machine monitor When following switches are operated, if all LCD panel is lighted up
and standard 1
(LCD panel) (all surface becomes white), LCD panel is normal.
value in normal
state • Operation of switches: [4] + [F2] (Press simultaneously)
Defective machine monitor If cause 1 is not detected, machine monitor may be defective.
2
(body) (Since trouble is in system, troubleshooting cannot be carried out.)
E-14 Function switch does not work 1
Trouble • Function switch does not work.

Related infor- • Condition of signal of function switch can be checked with monitoring function.
mation (Code: 04503 Monitor function switch)

and standard
value in normal Machine monitor may be defective.
state (Since trouble is in system, troubleshooting cannot be carried out.)
PC200, 220-8 31
E-15 Auto-decelerator does not operate normally 1
(1) When auto-decelerator switch is operated, auto-decelerator monitor does not light up or does not go
Trouble
off.
Related infor- • Condition of signal of auto-decelerator switch can be checked with monitoring function.
mation (Code: 04504 Monitor 1st, 2nd line switches)

and standard
value in normal Machine monitor may be defective. (Since trouble is in system,
state troubleshooting cannot be carried out.)
Trouble (2) Auto-decelerator is not operated or reset with lever.

Related infor- • Set speed of auto-decelerator is 1,400 rpm. If fuel control dial is not set above this speed, auto-
mation decelerator is not operated or reset.

a Start engine and carry out troubleshooting (with monitoring func-
tion).
Monitoring code Item Normal display
Swing
Travel
When lever is
01900 Boom lower operated: ON
Pressure switch 1 Boom raise When lever is in
Defective PPC pressure sig- neutral: OFF
1 Arm curl
nal
Possible causes Arm dump
and standard Bucket curl When lever is
value in normal 01901 operated: ON
state Bucket dump
Pressure switch 2 When lever is in
Service neutral: OFF
E-26 Monitoring function does not display lever control signal nor-
mally.
If cause 1 is not detected, pump controller may be defective. (Since
trouble is in system, troubleshooting cannot be carried out.)
32 PC200, 220-8
E-16 Working mode does not change 1
Trouble (1) When working mode switch is operated, working mode selection screen is not displayed.
Related infor- • Condition of signal of working mode switch can be checked with monitoring function. (Code: 04504
mation Monitor 1st, 2nd line switches)

and standard
Trouble (2) When working mode is changed, setting of engine and hydraulic pump is not changed.
Related infor-
mation

Possible causes
Machine monitor may be defective. (Since trouble is in system,
and standard 1 Defective machine monitor
troubleshooting cannot be carried out.)
value in normal
state Pump controller may be defective. (Since trouble is in system, trou-
bleshooting cannot be carried out.)
PC200, 220-8 33
E-17 Travel speed does not change 1

Trouble (1) When travel speed switch is operated, travel speed monitor does not change.
Related infor- • Condition of signal of travel speed switch can be checked with monitoring function.

and standard
Trouble (2) When travel speed is shifted, actual travel speed does not change.
Related infor-
• If cause 1 occurs, actual travel speed does not lower when travel speed is shifted to Lo.
mation

Possible causes 1
and standard Voltage Max. 1 V
V04 (female) (1)
value in normal
state If cause 1 is not detected, machine monitor may be defective.
34 PC200, 220-8
E-18 Alarm buzzer cannot be stopped 1
Trouble • Alarm buzzer cannot be stopped.

Related infor- • Condition of signal of alarm buzzer cancel switch can be checked with monitoring function.

and standard
PC200, 220-8 35
E-19 Windshield wiper and window washer do not operate 1
Trouble (1) When wiper switch is operated, wiper monitor does not light up or go off.
Related infor- • Condition of wiper switch signal can be checked with monitoring function.

and standard
Trouble (2) When wiper switch is operated, wiper does not operate.
Related infor- • Condition of window rear limit switch signal can be checked with monitoring function.
mation (Code: 02204 Switch 5)

W03 (male) Front window Resistance
Defective window rear limit
1 When installed to
switch (Internal short circuit) Min. 1 Mz
front
Between (1) – (2)
When retracted to
Max. 1 z
rear
Defective wiper motor (Inter- without turning starting switch ON.
2
nal disconnection) M05 (female) Continuity
Between (1) – (3) There is continuity
ness (Disconnection in wiring Wiring harness between C02 (female) (119) Resis-
Possible causes 3 Max. 1 z
or defective contact in con- – M05 (male) (3) tance
and standard nector)
value in normal Wiring harness between C02 (female) (114) Resis-
Max. 1 z
state – M05 (male) (1) tance
circuit) Resis-
C01 (female) (57) – W03 (female) (1) Min. 1 Mz
tance
C01 (female) Front window Resistance
Defective pump controller
(Rear limit switch system) When installed to
Min. 1 Mz
Between (57) – front
5 chassis ground When retracted to
Max. 1 z
rear
Defective pump controller without turning starting switch ON.
(Wiper motor system) C02 (female) Continuity
36 PC200, 220-8
Trouble (3) When window washer switch is operated, window washer does not operate.
Related infor- • Condition of window washer switch signal can be checked with monitoring function.

and standard
PC200, 220-8 37
E-20 Power maximizing function does not operate normally 1
(1) When left knob switch is pressed, one-touch power maximizing monitor is not displayed.
Trouble
(2) When left knob switch is pressed, work equipment power is not increased.
• One-touch power maximizing function does not work when working mode is not power mode (P) or
Related infor- economy mode (E).
mation • Condition of left knob switch signal can be checked with monitoring function.

Defective left knob switch S11 (male) Left knob switch Resistance
2
Released Min. 1 Mz
Between (1) – (2)
Pressed Max. 1 z
ness (Disconnection in wiring Wiring harness between F01-9 – S11 Resis-
3 Max. 1 z
Possible causes nector) Wiring harness between S11 (female) (2) – Resis-
Max. 1 z
and standard C01 (female) (41) tance
Wiring harness between F01-9 – S11 Resis-
(female) (1) tance
circuit)
Min. 1 Mz
C01 (female) (41) tance
5 Defective pump controller C01 (female) Left knob switch Resistance
Between (41) – Released Min. 1 Mz
chassis ground Pressed Max. 1 z
Machine monitor may be defective. (Since trouble is in system,
Circuit diagram related to left knob switch
38 PC200, 220-8
Trouble (3) When left knob switch is released, work equipment power does not return to normal level.
Related infor- • Condition of left knob switch signal can be checked with monitoring function.
mation (Code: 02200 Switch input 1)

Possible causes and carry out troubleshooting.
and standard 1
24V circuit) in wiring harness Wiring harness between C02 (female) (109)
value in normal Voltage Max. 1 V
state – V02 (female) (1)
PC200, 220-8 39
E-21 Swing holding brake does not operate normally 1
Trouble (1) When swing lock switch is operated, swing lock monitor does not light up or go off.
• Condition of swing lock switch signal can be checked with monitoring function.
Related infor-
(Machine monitor system code: 04502 Monitor input 3)
mation
(Pump controller system code: 02200 Switch input 1)

Defective swing lock switch without turning starting switch ON.
1 (Internal disconnection or S04 (male) Swing lock switch Resistance
short circuit) OFF Min. 1 Mz
Between (5) – (6)
ON Max. 1 z
ness (Disconnection in wiring Wiring harness between CM02 (female) (5) – Resis-
Possible causes 2 Max. 1 z
or defective contact in con- J02 – S04 (female) (5) tance
and standard nector)
value in normal Wiring harness between S04 (female) (6) – Resis-
Max. 1 z
state J05 – chassis ground (T07) tance
circuit) Wiring harness between CM02 (female) (5) – Resis-
Min. 1 Mz
J02 – S04 (female) (5), – C01 (female) (19) tance
4 Defective machine monitor CM02 Swing lock switch Voltage
Between (5) – OFF 20 – 30 V
chassis ground ON Max. 1 V
(2) When swing lock switch is turned ON, swing lock does not operate. (Hydraulic drift of swing occurs
Trouble
on slope.)
Related infor-
mation

Defective swing lock switch S04 (male) Swing lock switch Resistance
1
(Internal short circuit)
OFF Min. 1 Mz
Between (3) – (4)
ON Max. 1 z
and standard Defective swing holding Swing holding brake
value in normal 2 brake release switch (Inter- S25 (male) Resistance
release switch
state nal short circuit)
Lock Min. 1 Mz
Between (13) – (14)
Release Max. 1 z
Hot short (Short circuit with Wiring harness between D01 (female) (3) –
3 Voltage Max. 1 V
24V circuit) in wiring harness J02 – S04 (female) (3), – S25 (female) (14)
Wiring harness between S04 (female) (4) –
Voltage Max. 1 V
V03 (female) (1), – D03 (female) (3)
40 PC200, 220-8
PC200, 220-8 41
E-22 Travel alarm does not sound or does not stop sounding 1
Trouble (1) Alarm does not sound during travel.

Related infor-
mation

a Start engine and carry out troubleshooting.
When lever is
Defective travel signal sys- 01900 operated: ON
2 Travel
tem Pressure switch 1 When lever is in
neutral: OFF
E-26 Monitoring function does not display lever control signal nor-
Possible causes mally.
and standard
state Disconnection in wiring har- without turning starting switch ON.
ness (Disconnection in wiring Wiring harness between F01-15 – J03 – M14 Resis-
3 Max. 1 z
nector) Wiring harness between M14 (female) (2) – Resis-
Max. 1 z
J01 (19) – P09 (female) (2) tance
circuit) Wiring harness between F01-15 – J03 – M14 Resis-
Min. 1 Mz
(female) (1), – circuit branch end tance
Defective travel alarm (Inter-
5 If causes 1 – 4 are not detected, travel alarm is defective.
nal defect)
Trouble (2) Alarm does not stop sounding while machine is stopped.
Related infor-
mation

a Start engine and carry out troubleshooting.
When lever is oper-
Defective travel signal sys- ated: ON
1 Pressure switch 1 Travel
tem When lever is in neu-
tral: OFF
Possible causes If display of monitoring is abnormal, carry out troubleshooting for E-
and standard 26 Monitoring function does not display lever control signal nor-
value in normal mally.
2 diode D02 (Short circuit with
D02 (male) Continuity
GND circuit)
Between (4) – (8) No continuity
circuit) Wiring harness between M14 (female) (2) – Resis-
Min. 1 Mz
J01 – P09 (female) (2), – D02 (female) (4) tance
42 PC200, 220-8
Circuit diagram related to travel alarm and travel PPC oil pressure switch
PC200, 220-8 43
E-23 Air conditioner does not operate normally

(including air conditioner abnormality record) 1
Trouble (1) When air conditioner switch is operated, air conditioner control screen is not displayed.
Related infor- • Condition of air conditioner switch signal can be checked with monitoring function.
mation (Code: 04505 Monitor 3rd, 4th line switches, 04506 Monitor 5th line switch)

and standard
Trouble (2) When air conditioner switch is operated, air conditioner does not operate at all.
Related infor-
mation

If fuse in unit is broken, circuit in unit probably has ground fault.
2 Defective fuse in unit
(See cause 4.)
ness (Disconnection in wiring Wiring harness between F01-11 – fuse in Resis-
3 Max. 1 z
or defective contact in con- unit – ACW (wiring side) (6) tance
nector) Wiring harness between ACW (wiring side) Resis-
Max. 1 z
(16) – chassis ground (T07) tance
Possible causes
and standard
value in normal
state 4 ness (Short circuit with GND Wiring harness between F01-11 – fuse in
circuit) Resis-
unit – ACW (wiring side) (6), – circuit branch Min. 1 Mz
tance
end
Defective air conditioner con- ACW (wiring side) Voltage
5
troller Between (6) – (16) 20 – 30 V
If above voltage is normal, air conditioner controller may be defec-
tive.
44 PC200, 220-8
Trouble (3) Air does not come out (Air flow is insufficient).
Related infor-
mation

without turning starting switch ON (coil side).
Between (1) – (3) 140 – 340 z
Defective blower relay (Inter-
1 a Prepare with starting switch OFF, then turn starting switch ON
nal disconnection)
and carry out troubleshooting (contact side).
R20 Air conditioner switch Voltage
Between (4) –
Air blow position 20 – 30 V
chassis ground
Defective power transistor
2 Fan switch If air flow changes according to
(Internal defect)
Operate between Low and operation of fan switch, power
Medium and High. transistor is normal.
Defective blower motor MB (wiring side) Air conditioner switch Voltage
Possible causes 3
and standard (Internal defect) Between (1) – (2) Air blow position 20 – 30 V
value in normal If above voltage is normal and blower motor does not revolve,
state blower motor is defective.
Wiring harness between F01-11 – fuse in Resis-
Max. 1 z
unit – R20 (female) (1) tance
Max. 1 z
ACW (wiring side) (36) tance
Wiring harness between F01-11 – R20 Resis-
Max. 1 z
Disconnection in wiring har- (female) (5) tance
ness (Disconnection in wiring Wiring harness between R20 (female) (4) – Resis-
4 Max. 1 z
or defective contact in con- MB (wiring side) (1) tance
nector) Wiring harness between MB (wiring side) (2) Resis-
Max. 1 z
– PTR (wiring side) (3) tance
Wiring harness between PTR (wiring side) (1) Resis-
Max. 1 z
– chassis ground (T07) tance
Max. 1 z
– ACW (wiring side) (8) tance
Max. 1 z
– ACW (wiring side) (7) tance
PC200, 220-8 45

Min. 1 Mz
MB (wiring side) (1) tance
Possible causes circuit)
and standard Wiring harness between MB (wiring side) (2) Resis-
Min. 1 Mz
value in normal – PTR (wiring side) (3) tance
state Wiring harness between PTR (wiring side) Resis-
Min. 1 Mz
(2) – ACW (wiring side) (8) tance
If causes 1 – 5 are not detected, air conditioner controller may be
Defective air conditioner con-
6 defective. (Since trouble is in system, troubleshooting cannot be
troller
carried out.)
If causes 1 – 5 are not detected, air conditioner system may be
Defective air conditioner sys-
7 defective. See Machine Component Volume of Shop Manual, Air
tem
conditioner, Troubleshooting.
46 PC200, 220-8
Trouble (4) Air is not cooled (Cooling performance is insufficient).

Related infor-
mation

without turning starting switch ON (coil side).
Between (1) – (3) 140 – 340 z
Defective compressor relay
1 a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting (contact side).
R21 Air conditioner switch Voltage
Between (2) –
Cooling position 20 – 30 V
chassis ground
Internal air sensor may be defective. Carry out troubleshooting for
2 Defective internal air sensor
Abnormality in internal air sensor.
Defective high and low pres- High and low pressure switches may be defective. Carry out trou-
3
sure switches bleshooting for “Abnormality in refrigerant”.
Defective compressor clutch
4 Compressor clutch may be defective. Check it directly.
(Internal defect)
Defective compressor (Inter-
5 Compressor may be defective. Check it directly.
nal defect)
value in normal
state Wiring harness between F01-11 – fuse in Resis-
Max. 1 z
Disconnection in wiring har- unit – R21 (female) (1) tance
ness (Disconnection in wiring Wiring harness between R21 (female) (3) – Resis-
6 Max. 1 z
or defective contact in con- ACW (wiring side) (35) tance
nector) Wiring harness between F01-11 – R21 Resis-
Max. 1 z
(female) (4) tance
Max. 1 z
AC02 (female) (1) tance
circuit)
Min. 1 Mz
AC02 (female) (1) tance
troller
carried out.)
If causes 1 – 7 are not detected, air conditioner system may be
Defective air conditioner sys-
9 defective. See Machine Component Volume of Shop Manual, Air
tem
conditioner, Troubleshooting.
PC200, 220-8 47
(5) Air conditioner abnormality record: Communication condition “CAN disconnection”, Communication
Trouble
condition “Abnormal”
• While abnormality in communication is being detected, “CAN disconnection” is displayed.
• If abnormality in communication has been detected and reset, “Abnormality” is displayed.
Related infor-
• If “CAN disconnection” is displayed as communication condition, communication cannot be carried
mation
out normally. Accordingly, condition of other items is not displayed.
• Method of reproducing abnormality record: Turn starting switch ON.

ness (Disconnection in wiring Wiring harness between N10 (female) (2) – Resis-
1 Max. 1 z
or defective contact in con- CM02 (female) (8), (9) tance
nector) Wiring harness between N10 (female) (1) – Resis-
Max. 1 z
Wiring harness between N10 (male) (2) –
CM02 (female) (8), (9), – C01 (female) (45), Resis-
– CE02 (female) (46), – K02 (female) (A), – tance
N08 (male) (3)
circuit)
Wiring harness between N10 (female) (1) –
CM02 (female) (10), – C01 (female) (64), – Resis-
Min. 1 Mz
CE02 (female) (47), – K02 (female) (B), – tance
Possible causes N08 (male) (10)
and standard
value in normal
state
N10 (male) (2) – CM02 (female) (8), (9), –
C01 (female) (45), – CE02 (female) (46), – Voltage Max. 5.5 V
3 K02 (female) (A), – N08 (male) (3)
24V circuit) in wiring harness
Wiring harness between N10 (female) (1) –
CM02 (female) (10), – C01 (female) (64), –
Voltage Max. 5.5 V
CE02 (female) (47), – K02 (female) (B), –
N08 (male) (10)
Between (A) – (B) 47 – 67 z
troller
carried out.)
48 PC200, 220-8
Trouble (6) Air conditioner abnormality record: Setting condition “Abnormality”

• If setting of air conditioner controller model is different from setting of machine monitor model,
“Abnormality” is displayed.
Related infor-
mation
out normally. Accordingly, this condition is not displayed.
• Method of reproducing abnormality record: Turn starting switch ON.

Possible causes
Defective air conditioner con- Air conditioner controller may be defective. (Since trouble is in sys-
and standard 1
troller tem, troubleshooting cannot be carried out.)
value in normal
state Machine monitor may be defective. (Since trouble is in system,
Trouble (7) Air conditioner abnormality record: Internal air sensor “Abnormality”
Related infor- out normally. Accordingly, this condition is not displayed.
mation • Method of reproducing abnormality record: Turn starting switch ON + Turn air conditioner (A/C)
switch ON.

Defective internal air sensor without turning starting switch ON.
1 (Internal disconnection or
THI (device side) Resistance
short circuit)
Between (1) – (2) 300 z – 430 kz
ness (Disconnection in wiring Wiring harness between ACW (wiring side) Resis-
2 Max. 1 z
or defective contact in con- (11) – THI (wiring side) (2) tance
Possible causes nector) Wiring harness between ACW (wiring side) Resis-
(27) – THI (wiring side) (1) tance
value in normal
circuit) Wiring harness between ACW (wiring side) Resis-
Min. 1 Mz
(11) – THI (wiring side) (2) tance
4
24V circuit) in wiring harness Wiring harness between ACW (wiring side)
Voltage Max. 1 V
(11) – THI (wiring side) (2)
troller
carried out.)
PC200, 220-8 49
Trouble (8) Air conditioner abnormality record: External air sensor “Unused”
• External air sensor is not used in air conditioner system of this machine.
Related infor-
mation
out normally. Accordingly, this condition is not displayed.

and standard
value in normal Since external air sensor is not used in air conditioner system of this
1 Normal display
state machine, above display is normal.
Trouble (9) Air conditioner abnormality record: Air flow sensor “Abnormality”
switch ON.

Defective air flow sensor without turning starting switch ON.
1 (Internal disconnection or
THF (device side) Resistance
short circuit)
Between (1) – (2) 100 z – 115 kz
2 Max. 1 z
or defective contact in con- (12) – THF (wiring side) (2) tance
Possible causes nector) Wiring harness between ACW (wiring side) Resis-
(27) – THF (wiring side) (1) tance
value in normal
circuit) Wiring harness between ACW (wiring side) Resis-
Min. 1 Mz
(12) – THF (wiring side) (2) tance
4
24V circuit) in wiring harness Wiring harness between ACW (wiring side)
Voltage Max. 1 V
(12) – THF (wiring side) (2)
troller
carried out.)
50 PC200, 220-8
Trouble (10) Air conditioner abnormality record: Daylight sensor “Abnormality”

switch ON.

Defective daylight sensor
1 Daylight sensor may be defective.
(Internal defect)
2 Max. 1 z
or defective contact in con- (3) – P31 (female) (1) tance
nector) Wiring harness between ACW (wiring side) Resis-
Max. 1 z
(15) – P31 (female) (2) tance
and standard Ground fault in wiring har-
Wiring harness between ACW (wiring side) Resis-
value in normal 3 ness (Short circuit with GND Min. 1 Mz
(3) – P31 (female) (1), – circuit branch end tance
state circuit)
Wiring harness between ACW (wiring side) Resis-
Min. 1 Mz
(15) – P31 (female) (2) tance
Hot short (Short circuit with Wiring harness between ACW (wiring side)
4 Voltage Max. 1 V
24V circuit) in wiring harness (3) – P31 (female) (1), – circuit branch end
Wiring harness between ACW (wiring side)
Voltage Max. 1 V
(15) – P31 (female) (2)
troller
carried out.)
PC200, 220-8 51
Trouble (11) Air conditioner abnormality record: Air outlet damper “Abnormality”
switch ON.

Defective air outlet servo-
1 Air outlet servomotor may be defective.
motor (Internal defect)
Wiring harness between MV1 (wiring side) Resis-
Max. 1 z
Disconnection in wiring har- Wiring harness between MV1 (wiring side) Resis-
Max. 1 z
ness (Disconnection in wiring (3) – ACW (wiring side) (27) tance
2
or defective contact in con- Wiring harness between MV1 (wiring side) Resis-
nector) Max. 1 z
Max. 1 z
Max. 1 z
Wiring harness between MV1 (wiring side)
Resis-
(1) – ACW (wiring side) (3), – circuit branch Min. 1 Mz
tance
end
Possible causes Ground fault in wiring har- Resis-
and standard 3 ness (Short circuit with GND tance
end
value in normal circuit)
state Wiring harness between MV1 (wiring side)
Resis-
tance
end
Resis-
tance
end
(1) – ACW (wiring side) (3), – circuit branch Voltage Max. 1 V
end
Hot short (Short circuit with (5) – ACW (wiring side) (9), – circuit branch Voltage Max. 1 V
4
24V circuit) in wiring harness end
end
end
troller
carried out.)
52 PC200, 220-8
Trouble (12) Air conditioner abnormality record: A/M damper “Abnormality”

switch ON.

Defective air mix servomotor
1 Air mix servomotor may be defective.
(Internal defect)
Wiring harness between MAM (wiring side) Resis-
Max. 1 z
Disconnection in wiring har- Wiring harness between MAM (wiring side) Resis-
Max. 1 z
ness (Disconnection in wiring (3) – ACW (wiring side) (3) tance
2
or defective contact in con- Wiring harness between MAM (wiring side) Resis-
nector) Max. 1 z
Max. 1 z
Max. 1 z
Wiring harness between MAM (wiring side)
Resis-
tance
end
Possible causes Ground fault in wiring har- Resis-
and standard 3 ness (Short circuit with GND tance
end
value in normal circuit)
state Wiring harness between MAM (wiring side)
Resis-
tance
end
Resis-
tance
end
end
Hot short (Short circuit with (5) – ACW (wiring side) (2), – circuit branch Voltage Max. 1 V
4
24V circuit) in wiring harness end
end
end
troller
carried out.)
PC200, 220-8 53
Trouble (13) Air conditioner abnormality record: Refrigerant “Abnormality”

switch ON.

Insufficient refrigerant (gas)
1 Refrigerant (gas) may be insufficient. Check it directly.
(when system is normal)
Defective high and low pres- without turning starting switch ON.
2 sure switches (Internal dis-
P17 (male) Resistance
connection)
Possible causes Between (1) – (2) Max. 1 z
state Disconnection in wiring har-
3 Max. 1 z
or defective contact in con- (4) – P17 (female) (1) tance
Max. 1 z
troller
carried out.)
54 PC200, 220-8
Circuit diagram related to air conditioner
PC200, 220-8 55
E-24 While starting switch is in OFF position, service meter is not displayed1
Trouble • When starting switch is turned OFF, service meter is not displayed.
• While starting switch is at OFF position, if following switches are operated, service meter is displayed
Related infor-
at top center of screen.
mation
Operation of switches: [4] + [1] (Press simultaneously)

When starting switch is turned ON, if machine monitor displays
Possible causes
Defective backup power sup- nothing, backup power supply system may be defective. In this
and standard 1
ply system case, carry out troubleshooting for “E-1 When starting switch turned
value in normal
ON, machine monitor displays nothing”.
state
E-25 Machine monitor cannot be set in service mode 1

Trouble • Machine monitor cannot be set in service mode.
Related infor- • If following switches are operated, machine monitor is set in service mode.
mation Operation of switches: [4] + [1] o [2] o [3] (While pressing [4], press other switches in order)

and standard
56 PC200, 220-8
E-26 Monitoring function does not display lever control signal normally1
Trouble (1) Boom raise operation is not displayed normally by monitoring function.
Related infor-
• Monitoring code: 01900 Pressure switch 1
mation

and standard
value in normal Defective boom raise PPC
1 Carry out troubleshooting for failure code [DHS8MA].
state pressure sensor system
Trouble (2) Arm curl operation is not displayed normally by monitoring function.
Related infor-
mation

and standard
value in normal Defective arm curl PPC pres-
state sure sensor system
Trouble (3) Bucket curl operation is not displayed normally by monitoring function.
Related infor-
mation

and standard
value in normal Defective bucket curl PPC
Trouble (4) Bucket dump operation is not displayed normally by monitoring function.
Related infor-
mation

and standard
value in normal Defective bucket dump PPC
1 Carry out troubleshooting for failure code [DHSDMA].
PC200, 220-8 57
Trouble (5) Boom lower operation is not displayed normally by monitoring function.
Related infor-
mation

troubleshooting.
Defective boom lower PPC Right work equipment
1 pressure switch (Internal dis- P02 (male) Resistance
control lever
connection or short circuit)
Neutral Min. 1 Mz
Between (1) – (2)
Boom raise Max. 1 z
2 Max. 1 z
and standard
Min. 1 Mz
4
Voltage Max. 1 V
P02 (female) (1)
troubleshooting.
Right work equipment
control lever
Between (14) – chas- Neutral Min. 1 Mz
sis ground Boom raise Max. 1 z
Circuit diagram related to boom lower PPC pressure switch
58 PC200, 220-8
Trouble (6) Arm dump operation is not displayed normally by monitoring function.
Related infor-
mation

troubleshooting.
Defective arm dump PPC Left work equipment
1 pressure switch (Internal dis- P08 (male) Resistance
control lever
connection or short circuit)
Neutral Min. 1 Mz
Between (1) – (2)
Arm dump Max. 1 z
2 Max. 1 z
and standard
Min. 1 Mz
4
Voltage Max. 1 V
P08 (female) (1)
troubleshooting.
Left work equipment
control lever
Between (15) – Neutral Min. 1 Mz
chassis ground Arm dump Max. 1 z
Circuit diagram related to arm dump PPC pressure switch
PC200, 220-8 59
Trouble (7) Swing operation is not displayed normally by monitoring function.

Related infor-
mation

Possible causes
Defective swing right PPC
and standard 1 Carry out troubleshooting for failure code [DHSAMA].
pressure sensor system
value in normal
state Defective swing left PPC
2 Carry out troubleshooting for failure code [DHSBMA].
pressure sensor system
Trouble (8) Travel operation is not displayed normally by monitoring function.

Related infor-
mation

Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
Defective travel PPC pres- P09 (male) Travel lever Resistance
1 sure switch (Internal discon-
nection or short circuit) Neutral Min. 1 Mz
Between (1) – (2) Travel forward or
Max. 1 z
reverse
2 diode D02 (Internal discon-
D02 (male) Continuity
nection)
Max. 1 z
ness (Disconnection in wiring D02 (female) (8) tance
3
or defective contact in con- Wiring harness between D02 (female) (4) – Resis-
Possible causes nector) Max. 1 z
and standard
value in normal Wiring harness between P09 (female) (1) – Resis-
Max. 1 z
state J05 – chassis ground (T07) tance
D02 (female) (8) tance
circuit)
Wiring harness between D02 (female) (4) – Resis-
Min. 1 Mz
J01 – P09 (female) (2), – circuit branch end tance
5
Voltage Max. 1 V
D02 (female) (8)
troubleshooting.
C01 (female) Travel lever Continuity
Neutral No continuity
Between (55) –
chassis ground Travel forward or
There is continuity
reverse
60 PC200, 220-8
Circuit diagram related to travel PPC pressure switch and travel alarm
PC200, 220-8 61
Trouble (9) Travel differential pressure is not displayed normally by monitoring function.
Related informa-
tion

Defective travel steering PPC troubleshooting.
1 pressure switch (Internal dis- P10 (male) Travel lever Resistance
connection or short circuit) Neutral Min. 1 Mz
Between (1) – (2)
Only 1 side operated Max. 1 z
2 Max. 1 z
or defective contact in connec- P10 (female) (2) tance
tor) Wiring harness between P10 (female) (1) – J05 Resis-
Max. 1 z
Possible causes – chassis ground (T07) tance
value in normal Ground fault in wiring harness without turning starting switch ON.
state 3
(Short circuit with GND circuit) Wiring harness between C01 (female) (36) – Resis-
Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON and
Hot short (Short circuit with carry out troubleshooting.
4
Voltage Max. 1 V
P10 (female) (2)
troubleshooting.
C01 (female) Travel lever Resistance
Neutral Min. 1 Mz
Between (36) –
chassis ground Only one side oper-
Max. 1 z
ated
Circuit diagram related to travel steering PPC pressure switch
62 PC200, 220-8
Trouble (10) Service operation is not displayed normally by monitoring function.

Related infor-
mation

troubleshooting.
Defective service front PPC
1 pressure switch (Internal dis- S10 (male) Service pedal Resistance
Between (1) – (2)
Forward Max. 1 z
troubleshooting.
Defective service rear PPC
2 pressure switch (Internal dis- S11 (male) Service pedal Resistance
Between (1) – (2)
Reverse Max. 1 z
Max. 1 z
Possible causes ness (Disconnection in wiring S10 (female) (1), – S11 (female) (1) tance
and standard 3
or defective contact in con- Wiring harness between S10 (female) (2) – Resis-
value in normal nector) Max. 1 z
state
Max. 1 z
Min. 1 Mz
S10 (female) (1), – S11 (female) (1) tance
5
Voltage Max. 1 V
S10 (female) (1), – S11 (female) (1)
troubleshooting.
6 Defective pump controller C01 (female) Service pedal Resistance
Between (52) – Neutral Min. 1 Mz
chassis ground Forward or reverse Max. 1 z
PC200, 220-8 63
Circuit diagram related to service PPC pressure switch
64 PC200, 220-8
E-27 KOMTRAX system does not operate normally 1

Trouble • KOMTRAX system does not operate normally.
• If KOMTRAX system administrator makes request for checking system on machine side for trouble,
Related infor- carry out following troubleshooting.
mation • Even if KOMTRAX system has trouble, it does not particularly appear on machine.
• Carry out all troubleshooting on service menu screen of machine monitor.

a Turn starting switch ON and check “Setting condition or termi-
nal” screen.
1 Defective communication 1
Check item Normal display
Communication start check Completion
a Turn starting switch ON and check “Condition of positioning and
communication” screen.
N ###,##,## (Latitude)
2 Defective GPS
Positioning E ###,##,## (Longitude)
Possible causes
In positioning
and standard
value in normal If latitude and longitude are not displayed in 5 minutes on open
state ground, notify KOMTRAX service hot line.
Defective communication Check item Normal display
3
environment Communication Zone level 1 – Zone level 3
If zone level 1 – 3 is not displayed within communication zone of
ORBCOMM, notify KOMTRAX service hot line.
4 Defective communication 2
Number of items not transmitted 0 – 9 (Normally 0)
a Select “Terminal Status” from “12 Display of a Select “GPS & Communication Status” from
KOMTRAX setting” in the service menu of the “12 Display of KOMTRAX setting” in the ser-
machine monitor. vice menu of the machine monitor.
PC200, 220-8 65
SEN00244-01

© 2006 KOMATSU
All Rights Reserved
66
SEN00245-00
PC200-8
PC200LC-8
PC220-8
PC220LC-8

PC200-8 300001 and up
PC200LC-8 300001 and up
PC220-8 70001 and up
Troubleshooting of hydraulic and
mechanical system (H-mode)
Troubleshooting of hydraulic and mechanical system (H-mode) .................................................................... 4
System diagram of hydraulic and mechanical system ......................................................................... 4
Information in troubleshooting table ..................................................................................................... 6
H-1 Speed or power of whole work equipment, swing, and travel is low ............................................. 7
H-2 Engine speed lowers extremely or engine stalls ........................................................................... 9
H-3 Work equipment, swing, and travel systems do not work............................................................ 10
H-4 Abnormal sound comes out from around hydraulic pump........................................................... 10
H-5 Auto-decelerator does not operate...............................................................................................11
H-6 Fine control performance or response is low ...............................................................................11
H-7 Speed or power of boom is low ................................................................................................... 12
H-8 Speed or power of arm is low ...................................................................................................... 13
H-9 Speed or power of bucket is low.................................................................................................. 14
H-10 Work equipment does not move singly ..................................................................................... 14
H-11 Hydraulic drift of work equipment is large.................................................................................. 15
PC200, 220-8 1
H-12 Time lag of work equipment is large .......................................................................................... 17

H-13 When part of work equipment is relieved singly, other parts of work equipment move ............. 17
H-14 Power maximizing function does not work ................................................................................ 18
H-15 In compound operation of work equipment, speed of part loaded more is low ......................... 18
H-16 When machine swings and raises boom simultaneously, boom rising speed is low ................. 19
H-17 When machine swings and travels simultaneously, travel speed lowers largely ....................... 19
H-18 Machine deviates during travel.................................................................................................. 20
H-19 Travel speed is low .................................................................................................................... 21
H-20 Machine is not steered well or steering power is low ................................................................ 22
H-21 Travel speed does not change or travel speed is low/high........................................................ 23
H-22 Travel system does not move (only one side) ........................................................................... 24
H-23 Upper structure does not swing................................................................................................. 25
H-24 Swing acceleration or swing speed is low ................................................................................. 27
H-25 Upper structure overruns remarkably when it stops swinging ................................................... 28
H-26 Large shock is made when upper structure stops swinging ...................................................... 29
H-27 Large sound is made when upper structure stops swinging...................................................... 29
H-28 Hydraulic drift of swing is large.................................................................................................. 30
H-29 Attachment circuit is not changed.............................................................................................. 31
H-30 Oil flow in attachment circuit cannot be controlled .................................................................... 31
2 PC200, 220-8
Troubleshooting of hydraulic and mechanical system (H-mode) 1

System diagram of hydraulic and mechanical system 1
4 PC200, 220-8
a This system diagram is a rough general hydraulic circuit diagram made as reference material for trou-
bleshooting of the hydraulic and mechanical systems.
PC200, 220-8 5

a The following information is summarized in the troubleshooting table. Before carrying out troubleshoot-
ing, understand that information fully.
Trouble Trouble which occurred in machine

Related
information
Possible 2
causes and Possible causes of trou-
<Contents of description)
standard value ble (Given numbers are
in normal state reference numbers, which
do not indicate priority)
3
6 PC200, 220-8
H-1 Speed or power of whole work equipment, swing, and travel is low1
Trouble • Speed or power of whole work equipment, swing, and travel is low.
Related
• Carry out all troubleshooting in power mode (P) of working mode.
information

a Prepare with engine stopped, then run engine at high idle and
carry out troubleshooting.
1 Malfunction of unload valve Control levers Unload pressure
3.5 ± 1.0 MPa
All levers in neutral
{36 ± 10 kg/cm2}
Left work equipment control lever Main relief pressure
Defective adjustment or mal- 33.3 – 36.8 MPa
2 Arm curl relief
function of main relief valve {340 – 375 kg/cm2}
If oil pressure does not become normal after adjustment, main relief
valve may have malfunction or internal defect. Check main relief
valve directly.
Malfunction of self-reducing
3 Control levers Control circuit basic pressure
pressure valve
2.84 – 3.43 MPa
{29 – 35 kg/cm2}
low idle and carry out troubleshooting at each speed.
Possible
causes and PC-EPC valve
Engine Control lever
standard value Malfunction of PC-EPC output pressure
4
in normal state valve 2.9 MPa
Low idle
{30 kg/cm2}
0.52 – 0.91 MPa
High idle
{5.3 – 9.3 kg/cm2}
Measured oil Measurement
Oil pressure ratio
pressure condition
Defective adjustment or Pump discharge
5 Swing lock switch: 1
malfunction of PC valve pressure
ON
PC valve output Arm curl relief Approx. 0.6
pressure (Approx. 3/5)
If oil pressure does not become normal after adjustment, PC valve
may have malfunction or internal defect. Check PC valve directly.
LS-EPC valve output
Travel speed Travel lever
pressure
6 Malfunction of LS-EPC valve
Approx. 2.9 MPa
Lo Neutral
{30 kg/cm2}
0 MPa
Hi Operated
{0 kg/cm2}
PC200, 220-8 7

Operation of levers and oil pressure ratio
Measured oil Travel with no load
pressure All levers in neutral (Lever operated half-
Possible Defective adjustment or mal- way)
7
causes and function of LS valve Pump discharge
1
standard value pressure Almost same
in normal state PC valve output pressure Approx. 0.6
If oil pressure does not become normal after adjustment, LS valve
may have malfunction or internal defect. Check LS valve directly.
8 Malfunction of servo piston Servo piston may have malfunction. Check it directly.
Cause may be lowering of performance, malfunction, or internal
9 Defective piston pump
defect of piston pump.
8 PC200, 220-8
H-2 Engine speed lowers extremely or engine stalls 1
Trouble • Engine speed lowers extremely or engine stalls.

Related
information

Left work equipment control lever Main relief pressure
Defective adjustment or
1 malfunction of main relief 33.3 – 36.8 MPa
Arm curl relief
valve {340 – 375 kg/cm2}
If oil pressure does not become normal after adjustment, main relief
valve may have malfunction or internal defect. Check main relief
valve directly.
low idle and carry out troubleshooting at each speed.
PC-EPC valve
Engine Control lever
Malfunction of PC-EPC output pressure
2
valve 2.9 MPa
Low idle
{30 kg/cm2}
0.52 – 0.91 MPa
High idle
{5.3 – 9.3 kg/cm2}
Possible Measured oil Measurement
Oil pressure ratio
causes and pressure condition
standard value Defective adjustment or Pump discharge
in normal state 3 Swing lock switch: 1
malfunction of PC valve pressure
ON
PC valve output Arm curl relief Approx. 0.6
If oil pressure does not become normal after adjustment, PC valve
may have malfunction or internal defect. Check PC valve directly.
Defective adjustment or way)
4
malfunction of LS valve Pump discharge
1
pressure Almost same
PC valve output pressure Approx. 0.6
Clogging of orifice or filter in Orifices or filters in pump servo devices may be clogged. Check
5
serve devices them directly.
PC200, 220-8 9
H-3 Work equipment, swing, and travel systems do not work 1
Trouble • Whole work equipment, swing, and travel systems do not work.
Related
information

PPC lock solenoid valve output
Lock lever
Malfunction of PPC lock pressure
1
solenoid valve 0 MPa
Lock
{0 kg/cm2}
2.9 MPa
Free
{30 kg/cm2}
Possible
causes and a Prepare with engine stopped, then run engine at high idle and
standard value carry out troubleshooting.
in normal state Malfunction of self pressure
2 Control lever Control circuit basic pressure
reducing valve
2.84 – 3.43 MPa
{29 – 35 kg/cm2}
Piston pump may have malfunction or internal defect. Check it by
following method.
3 Defective piston pump 1) Remove pump discharge pressure pickup plugs (F and R).
2) Crank engine at flywheel (manually).
3) If oil flows out of pickup plugs, piston pump is normal.
Pump shaft may not revolve because of defect in damper. Check
4 Defective damper
damper directly.
H-4 Abnormal sound comes out from around hydraulic pump 1
Trouble • Abnormal sound comes out from around hydraulic pump

Related
information

Lowering of hydraulic oil
1 Hydraulic oil level may be low. Check it directly.
level
Possible 2 Defective hydraulic oil Air may be in hydraulic oil. Check oil directly.
causes and
standard value Clogging of hydraulic tank Negative pressure may be generated in hydraulic tank because of
3
in normal state cap clogged hydraulic tank cap. Check cap directly.
Clogging of hydraulic tank Negative pressure may be generated in suction circuit because of
4
strainer clogged hydraulic tank strainer. Check strainer directly.
5 Defective piston pump Piston pump may have internal defect. Check it directly.
10 PC200, 220-8
H-5 Auto-decelerator does not operate 1
Trouble • Auto-decelerator does not operate.

• Carry out this troubleshooting if auto-decelerator does not operate when travel lever is operated.
Related Shuttle valve (in PPC valve) is installed between PPC valve and oil pressure switch of only in travel
information circuit.

Possible
causes and Travel lever PPC valve output pressure
standard value Malfunction of travel PPC
1 0 MPa
in normal state valve (shuttle valve) Neutral
{0 kg/cm2}
Forward 2.84 – 3.43 MPa
Reverse {29 – 35 kg/cm2}
H-6 Fine control performance or response is low 1
Trouble • Fine control performance or response is low.

Related
information

LS-EPC valve output
pressure
Approx. 2.9 MPa
Lo Neutral
{Approx. 30 kg/cm2}
0 MPa
Hi Operated
{0 kg/cm2}
Orifice of LS circuit (between pump – piping – control valve) may be
2 Clogging of LS circuit orifice
Possible clogged. Check it directly.
causes and a Prepare with engine stopped, then run engine at high idle and
standard value carry out troubleshooting.
in normal state
3
1
pressure Almost same
PC valve output pressure Approx. 0.6
PC200, 220-8 11
H-7 Speed or power of boom is low 1
Trouble • Speed or power of boom is low

Related
information

Right work equipment control
PPC valve output pressure
Malfunction of right PPC lever
1
valve (boom circuit) 0 MPa
Neutral
{0 kg/cm2}
Boom raise 2.84 – 3.43 MPa
Boom lower {29 – 35 kg/cm2}
Malfunction of merge-divider Merge-divider main EPC valve may have malfunction. Check it
2
main EPC valve directly.
Malfunction of merge-divider Merge-divider LS-EPC valve may have malfunction. Check it
3
LS-EPC valve directly.
Malfunction of merge-divider
4 Merge-divider main valve may have malfunction. Check it directly.
main valve
5 Merge-divider LS valve may have malfunction. Check it directly.
LS valve
Malfunction of boom control Spool of boom control valve may have malfunction. Check it
6
valve (spool) directly.
Possible
causes and Malfunction of boom control
Pressure compensation valve of boom control valve may have mal-
standard value 7 valve (pressure compensa-
function. Check it directly.
in normal state tion valve)
Malfunction of boom control Regeneration valve of boom control valve may have malfunction.
8
valve (regeneration valve) Check it directly.
Malfunction of boom control Lock valve of boom control valve may have malfunction. Check it
9
valve (lock valve) directly.
Malfunction or defective seal Safety valve for lock valve may have malfunction or defective seal.
10
of safety valve for lock valve Check it directly.
Malfunction or defective seal
Suction valve of boom control valve may have malfunction or
11 of boom control valve (suc-
defective seal. Check it directly.
tion valve)
Safety-suction valve of boom control valve may have malfunction or
12 of boom control valve
(safety-suction valve)
Malfunction of each control LS shuttle valve of left travel control valve, bucket control valve, or
13
valve (LS shuttle valve) service control valve may have malfunction. Check it directly.
14 Defective boom cylinder Right work equipment control
Leakage from boom cylinder
lever
Boom raise relief 20 cc/min
12 PC200, 220-8
H-8 Speed or power of arm is low 1
Trouble • Speed or power of arm is low

Related
information

Left work equipment control lever PPC valve output pressure
Malfunction of left PPC valve
1 0 MPa
(arm circuit) Neutral
{0 kg/cm2}
Arm curl 2.84 – 3.43 MPa
Arm dump {29 – 35 kg/cm2}
2
3
LS-EPC valve directly.
4 Merge-divider main valve may have malfunction. Check it directly.
main valve
LS valve
Malfunction of arm control
6 Spool of arm control valve may have malfunction. Check it directly.
valve (spool)
Possible Malfunction of arm control
causes and Pressure compensation valve of arm control valve may have mal-
7 valve (pressure compensa-
standard value function. Check it directly.
tion valve)
in normal state
Malfunction of arm control Regeneration valve of arm control valve may have malfunction.
8
valve (regeneration valve) Check it directly.
Malfunction of arm control Quick return valve of arm control valve may have malfunction.
9
valve (quick return valve) Check it directly.
Malfunction or defective seal Safety valve for lock valve may have malfunction or defective seal.
10
of safety valve for lock valve Check it directly.
Suction valve of arm control valve may have malfunction or defec-
11 of arm control valve (suction
tive seal. Check it directly.
valve)
Safety-suction valve of arm control valve may have malfunction or
12 of arm control valve (safety-
suction valve)
LS shuttle valve of right travel control valve, boom control valve, left
Malfunction of each control
13 travel control valve, bucket control valve, or service control valve
valve (LS shuttle valve)
may have malfunction. Check it directly.
14 Defective arm cylinder
Left work equipment control lever Leakage from arm cylinder
Arm curl relief 20 cc/min
PC200, 220-8 13
H-9 Speed or power of bucket is low 1
Trouble • Speed or power of bucket is low.

Related
information

Right work equipment control
Malfunction of right PPC lever
1
valve (bucket circuit) 0 MPa
Neutral
{0 kg/cm2}
Bucket curl 2.84 – 3.43MPa
Bucket dump {29 – 35 kg/cm2}
Malfunction of bucket control Spool of bucket control valve may have malfunction. Check it
2
Possible valve (spool) directly.
causes and Malfunction of bucket control
standard value Pressure compensation valve of bucket control valve may have
in normal state malfunction. Check it directly.
tion valve)
Safety-suction valve of bucket control valve may have malfunction
4 of bucket control valve
or defective seal. Check it directly.
(safety-suction valve)
Malfunction of service con- LS shuttle valve of service control valve may have malfunction.
5
trol valve (LS shuttle valve) Check it directly.
6 Defective bucket cylinder Right work equipment control
Leakage from bucket cylinder
lever
Bucket curl relief 20 cc/min
H-10 Work equipment does not move singly 1
(1) Boom does not move singly.

Trouble (2) Arm does not move singly.
(3) Bucket does not move singly.
Related
information

Possible Work equipment control lever PPC valve output pressure

causes and 1 Malfunction of PPC valve 0 MPa
standard value Neutral
{0 kg/cm2}
in normal state
2.84 – 3.43 MPa
Operated
{29 – 35 kg/cm2}
Malfunction of control valve
2 Spool of control valve may have malfunction. Check it directly.
(spool)
14 PC200, 220-8
H-11 Hydraulic drift of work equipment is large 1
Trouble (1) Hydraulic drift of boom is large.

Related
information

a Prepare with engine stopped, then run engine at high idling
Possible 1 Defective boom cylinder Right work equipment control
Leakage from boom cylinder
causes and lever
standard value Boom raise relief 20 cc/min
in normal state
Defective seal of boom Seal of lock valve of boom control valve may be defective. Check it
2
control valve (lock valve) directly.
Defective seal of safety Seal of safety valve for lock valve may be defective. Check it
3
valve for lock valve directly.
Trouble (2) Hydraulic drift of arm is large.

Related
information

1 Defective arm cylinder
Left work equipment control lever Leakage from arm cylinder
Arm curl relief 20 cc/min
Defective seal of arm
Possible 2 Seal of arm control valve spool may be defective. Check it directly.
control valve (spool)
causes and
Defective seal of arm con-
standard value Seal of pressure compensation valve of arm control valve may be
3 trol valve (pressure compen-
in normal state defective. Check it directly.
sation valve)
Seal of suction valve of arm control valve may be defective. Check
Defective seal of arm it directly.
4
control valve (suction valve) a This suction valve may be checked by replacing it with another
suction valve and seeing change of condition.
Defective seal of safety Seal of safety valve for lock valve may be defective. Check it
5
valve for lock valve directly.
PC200, 220-8 15
Trouble (3) Hydraulic drift of bucket is large.

Related
information

1 Defective bucket cylinder
Left work equipment control lever Leakage from bucket cylinder
Bucket curl relief 20 cc/min
Possible Defective seal of bucket Seal of bucket control valve spool may be defective. Check it
2
causes and control valve (spool) directly.
standard value Defective seal of bucket con-
in normal state Seal of pressure compensation valve of bucket control valve may
be defective. Check it directly.
sation valve)
Seal of safety-suction valve of bucket control valve may defective.
Defective seal of bucket Check it directly.
4 control valve (safety-suction a Safety-suction valves on bottom side and head side may be
valve) checked by replacing them with each other and seeing change
of condition.
16 PC200, 220-8
H-12 Time lag of work equipment is large 1
Trouble • Time lag of work equipment is large.

Related
information

LS-EPC valve output
pressure
Approx. 2.9 MPa
Lo Neutral
{Approx. 30 kg/cm2}
0 MPa
Hi Operated
Possible {0 kg/cm2}
causes and Malfunction of control valve
standard value Regeneration valve of control valve may have malfunction. Check it
2 (regeneration valve) [Boom
in normal state directly.
and arm only]
Safety-suction valve of control valve may have malfunction. Check
it directly.
Malfunction of control valve a This safety-suction valve may be checked by replacing it with
3
(safety-suction valve) safety-suction valve of normal control valve and seeing
change of condition. (Set pressure of safety-suction valve for
boom head circuit is different, however.)
Pressure compensation valve of control valve may have malfunc-
4 (pressure compensation
tion. Check it directly.
valve)
H-13 When part of work equipment is relieved singly, other parts of work
equipment move 1
Trouble • When part of work equipment is relieved singly, other parts of work equipment move
Related
information
Possible Cause Standard value in normal state/Remarks on troubleshooting

causes and Defective seal of control
standard value Seal of pressure compensation valve of control valve on moving
in normal state side may be defective. Check it directly.
tion valve) on moving side
PC200, 220-8 17
H-14 Power maximizing function does not work 1
Trouble • Power maximizing function does not work.

Related
information

2-stage relief solenoid valve
Possible Swing lock switch
Malfunction of 2-stage relief output pressure
causes and 1
solenoid valve 0 MPa
standard value OFF
in normal state {0 kg/cm2}
2.9 MPa
ON
{30 kg/cm2}
Malfunction of main relief
2 Main relief valve may have malfunction. Check it directly.
valve
H-15 In compound operation of work equipment, speed of part loaded

more is low 1
Trouble • In compound operation of work equipment, speed of part loaded more is low.
Related
information

Pressure compensation valve of control valve on less load side
may have malfunction. Check it directly.
Compound operation Larger load side Less load side
Boom raise
+ Boom raise Arm curl
Arm curl
Possible Boom raise

causes and + Arm dump Boom raise
standard value Arm dump
1 (pressure compensation
in normal state valve) on less load side Boom raise
+ Boom raise Bucket curl
Bucket curl
Arm dump
+ Arm dump Bucket curl
Bucket curl
Boom lower
+ Arm dump Boom lower
Arm dump
18 PC200, 220-8
H-16 When machine swings and raises boom simultaneously, boom

rising speed is low 1
Trouble • When machine swings and raises boom simultaneously, boom rising speed is low.
Related • If speed of single boom raise operation is also low, carry out troubleshooting for "H-7 Speed or
information power of boom is low" first.

causes and Malfunction or defective seal
standard value LS selector valve of control valve may have malfunction or defec-
1 of swing control valve (LS
in normal state tive seal. Check it directly.
selector valve)
H-17 When machine swings and travels simultaneously, travel speed

lowers largely 1
Trouble • When machine swings and travels simultaneously, travel speed lowers largely.
Related • If speed of single travel operation is also low, carry out troubleshooting for "H-19 Travel speed is
information low" first.

causes and
standard value Malfunction of each control LS shuttle valve of left travel control valve or swing control valve
1
in normal state valve (LS shuttle valve) may have malfunction. Check it directly.
PC200, 220-8 19
H-18 Machine deviates during travel 1
Trouble • Machine deviates during travel.

Related
information

Travel lever PPC valve output pressure
Malfunction of travel PPC
1 0 MPa
valve Neutral
{0 kg/cm2}
Malfunction of self pressure
reducing valve
2.84 – 3.43 MPa
{29 – 35 kg/cm2}
3
1
Possible pressure Almost same
causes and PC valve output pressure Approx. 0.6
standard value pressure (Approx. 3/5)
in normal state
Travel junction solenoid valve
Travel lever
Malfunction of travel output pressure
4
junction solenoid valve 0 MPa
Both sides in neutral
{0 kg/cm2}
2.9 MPa
Either side operated
{30 kg/cm2}
Malfunction of travel
5 Travel junction valve may have malfunction. Check it directly.
junction valve
Malfunction of travel control Spool of travel control valve may have malfunction. Check it
6
7 Defective travel motor
Travel lever Leakage from travel motor
Travel relief 27.2 l/min
Final drive may have internal defect. Check it directly.
8 Defective final drive a It may be checked by abnormal sound, abnormal heating,
metal chips in drain oil, etc.
20 PC200, 220-8
H-19 Travel speed is low 1
Trouble • Travel speed is low.

Related
information

Travel lever PPC valve output pressure
Malfunction of travel PPC
1 0 MPa
valve Neutral
{0 kg/cm2}
Malfunction of self pressure
reducing valve
2.84 – 3.43 MPa
{29 – 35 kg/cm2}
Measured oil LS-EPC valve output
Travel lever
pressure pressure
Possible 3 Malfunction of LS-EPC valve
causes and Approx. 2.9 MPa
Lo Neutral
standard value {Approx. 30 kg/cm2}
in normal state 0 MPa
Hi Operated
{0 kg/cm2}
4
Malfunction of travel control
Pressure compensation valve of control valve may have malfunc-
tion. Check it directly.
tion valve)
Malfunction of travel control Suction valve of control valve may have malfunction. Check it
6
valve (suction valve) directly.
Malfunction of bucket control LS shuttle valve of bucket control valve may have malfunction.
7
valve (LS shuttle valve) Check it directly.
Travel relief 27.2 l/min
PC200, 220-8 21
H-20 Machine is not steered well or steering power is low 1
Trouble • Machine is not steered well or steering power is low

Related
information

Travel lever
Malfunction of travel PPC (Steering)
1
valve (steering spool) 0 MPa
{0 kg/cm2}
2.84 – 3.43 MPa
{29 – 35 kg/cm2}
Travel junction solenoid valve
Travel lever
Malfunction of travel output pressure
2
junction solenoid valve 0 MPa
{0 kg/cm2}
2.9 MPa
{30 kg/cm2}
Malfunction of travel
3 Travel junction valve may have malfunction. Check it directly.
junction valve
4
5
Possible LS-EPC valve directly.
causes and Malfunction of merge-divider
standard value 6 Merge-divider main valve may have malfunction. Check it directly.
main valve
in normal state
LS valve
8
Malfunction of travel control
Pressure compensation valve of travel control valve may have mal-
tion valve)
Malfunction of travel control Suction valve of travel control valve may have malfunction. Check it
10
valve (suction valve) directly.
Malfunction of bucket control LS shuttle valve of bucket control valve may have malfunction.
11
valve (LS shuttle valve) Check it directly.
Defective seal of check valve
Seal of check valve of LS pressure sensing part (control valve side)
12 of LS pressure sensing part
may be defective. Check it directly.
(control valve side)
Seal of safety valve of travel motor may be defective. Check it
directly.
Defective seal of travel
13 a Motors of same type on forward and reverse sides or on right
motor (safety valve)
and left sides may be checked by replacing them with each
other and seeing change of condition.
Seal of check valve of travel motor may be defective. Check it
directly.
motor (check valve)
22 PC200, 220-8
H-21 Travel speed does not change or travel speed is low/high 1
Trouble • Travel speed does not change or travel speed is low/high

Related
information

a Run engine at high idle and carry out troubleshooting
(with monitoring function).
Monitoring
code: 01500
663 mA (PC200-8)
Lo 578 mA (PC220-8)
(* Reference)
Operated
424 mA (PC200-8)
Mi
641 mA (PC220-8)
1 Malfunction of LS-EPC valve Hi 0 mA
Possible LS-EPC valve
causes and output pressure
standard value Approx. 2.9 MPa
in normal state Lo Neutral
{Approx. 30 kg/cm2}
0 MPa
Hi Operated
{0 kg/cm2}
Travel speed shifting
Travel speed Travel lever solenoid valve output
Malfunction of travel speed pressure
2
shifting solenoid valve
0 MPa
Lo Neutral
{0 kg/cm2}
Approx. 2.9 MPa
Hi Operated
{Approx. 30 kg/cm2}
Malfunction of travel motor Speed shifting section of travel motor may have malfunction.
3
(speed shifting section) Check it directly.
*: Travel speed Lo can be adjusted with the adjusting function of the machine monitor. Accordingly, if the
initial value has been changed, the measured value varies more or less.
PC200, 220-8 23
H-22 Travel system does not move (only one side) 1
Trouble • Travel system does not move (only one side).

Related
information

Defective seal of travel con- Seal of suction valve of travel control valve may have malfunction.
1
trol valve (suction valve) Check it directly.
Seal of safety valve of travel control valve may have malfunction.
Check it directly.
motor (safety valve)
Seal of check valve of travel control valve may have malfunction.
Possible Check it directly.
causes and 3 a Motors of same type on forward and reverse sides or on right
motor (check valve)
standard value and left sides may be checked by replacing them with each
in normal state other and seeing change of condition.
Malfunction of travel motor Parking brake of travel motor may have malfunction. Check it
4
(parking brake) directly.
Travel system relief 27.2 l/min
24 PC200, 220-8
H-23 Upper structure does not swing 1
Trouble (1) Upper structure does not swing in either direction.

Related
information

Swing holding brake
Left work equipment control lever
Malfunction of swing holding solenoid valve output pressure
1
brake solenoid valve 0 MPa
Neutral
{0 kg/cm2}
Left swing 2.9 MPa
Right swing {30 kg/cm2}
Malfunction of swing control Spool of swing control valve may have malfunction. Check it
2
Malfunction of swing motor Parking brake of swing motor may have malfunction. Check it
3
Possible a Prepare with engine stopped, then run engine at high idle and
causes and carry out troubleshooting.
standard value
Left work equipment
in normal state Swing lock switch Swing relief pressure
Defective adjustment or control lever
4 malfunction of swing motor 28.9 – 32.9 MPa
(safety valve) ON Swing relief
{295 – 335 kg/cm2}
If oil pressure does not become normal after adjustment, swing
motor safety valve may have malfunction or internal defect. Check
safety valve directly.
5 Defective swing motor Left work equipment Leakage from swing
Swing lock switch
control lever motor
ON Swing relief Max. 10 l/min
Swing machinery may have internal defect. Check it directly.
6 Defective swing machinery a It may be checked by abnormal sound, abnormal heating,
PC200, 220-8 25
Trouble (2) Upper structure swings only in one direction.

Related
information

Malfunction of swing PPC
1 0 MPa
valve Neutral
{0 kg/cm2}
Left swing 2.84 – 3.43 MPa
Possible Right swing {29 – 35 kg/cm2}
causes and
standard value Malfunction of swing control Spool of swing control valve may have malfunction. Check it
2
in normal state valve (spool) directly.
Suction valve of swing motor may have malfunction. Check it
Malfunction of swing motor directly.
3
(suction valve) a Suction valves on right side and left side may be checked by
replacing them with each other and seeing change of condition.
Check valve of swing motor may have malfunction. Check it
4
(check valve) a Check valves on right side and left side may be checked by
26 PC200, 220-8
H-24 Swing acceleration or swing speed is low 1
Trouble (1) Swing acceleration or swing speed is low in both directions.

Related
information

1
Malfunction of all control LS shuttle valves of all control valves may have malfunction.
2
valves (LS shuttle valves) Check them directly.
3
Left work equipment
Swing lock switch Swing relief pressure
Possible Defective adjustment or control lever
causes and 4 malfunction of swing motor 28.9 – 32.9 MPa
standard value (safety valve) ON Swing relief
{295 – 335 kg/cm2}
in normal state If oil pressure does not become normal after adjustment, swing
motor safety valve may have malfunction or internal defect. Check
Swing lock switch
control lever motor
6 Defective swing machinery a It may be check by abnormal sound, abnormal heating, metal
chips in drain oil, etc.
Trouble (2) Swing acceleration or swing speed is low in only one direction.
Related
information

1 0 MPa
valve Neutral
{0 kg/cm2}
Right swing {29 – 35 kg/cm2}
Possible Malfunction of swing control Spool of swing control valve may have malfunction. Check it
2
causes and valve (spool) directly.
standard value Malfunction of swing control
Pressure compensation valve of swing control valve may have mal-
in normal state 3 valve (pressure compensa-
tion valve)
4
5
PC200, 220-8 27
H-25 Upper structure overruns remarkably when it stops swinging 1
Trouble (1) Upper structure overruns remarkably when it stops swinging in both directions.
Related
information

• Prepare with engine stopped, then run engine at high idle and
Left work equipment
Swing lock switch Swing relief pressure
Defective adjustment or control lever
1 malfunction of swing motor 28.9 – 32.9 MPa
Possible (safety valve) ON Swing relief
{295 – 335 kg/cm2}
causes and
standard value If oil pressure does not become normal after adjustment, swing
in normal state motor safety valve may have malfunction or internal defect. Check
Swing lock switch
control lever motor
Trouble (2) Upper structure overruns remarkably when it stops swinging in only one direction.
Related
information

1 0 MPa
valve Neutral
{0 kg/cm2}
Right swing {29 – 35 kg/cm2}
Swing PPC slow return valve may have malfunction. Check it
Possible directly.
Clogging of swing PPC slow
causes and 2 a Slow return valves on right side and left side may be checked
return valve
standard value by replacing them with each other and seeing change of condi-
in normal state tion.
3
4
5
28 PC200, 220-8
H-26 Large shock is made when upper structure stops swinging 1
Trouble • Large shock is made when upper structure stops swinging.

Related
information

1 0 MPa
valve Neutral
{0 kg/cm2}
Possible
causes and Left swing 2.84 – 3.43 MPa
standard value Right swing {29 – 35 kg/cm2}
in normal state Swing PPC slow return valve may have malfunction. Check it
directly.
Clogging of swing PPC slow
2 a Slow return valves on right side and left side may be checked
return valve
by replacing them with each other and seeing change of con-
dition.
Malfunction of swing motor Shockless valve of swing motor may have malfunction. Check it
3
(shockless valve) directly.
H-27 Large sound is made when upper structure stops swinging 1
Trouble • Large sound is made when upper structure stops swinging.

Related
information

Malfunction of back pressure
1 Back pressure valve may have malfunction. Check it directly.
valve
Malfunction of swing motor Safety valve of swing motor may have malfunction. Check it
2
Possible (safety valve) directly.
causes and Suction valve of swing motor may have malfunction. Check it
standard value Malfunction of swing motor directly.
in normal state 3
4 Defective swing machinery a It may be checked by abnormal sound, abnormal heating,
PC200, 220-8 29
H-28 Hydraulic drift of swing is large 1
Trouble (1) Hydraulic drift of swing is large (when swing holding brake is applied).
• When swing lock switch is turned ON or when swing holding brake release switch is in normal posi-
Related
tion, swing holding brake operates and upper structure is fixed with disc brake.
information

Swing holding brake
Possible Left work equipment control lever
Malfunction of swing holding solenoid valve output pressure
causes and 1
brake solenoid valve 0 MPa
standard value Neutral
in normal state {0 kg/cm2}
Left swing 2.9 MPa
Right swing {30 kg/cm2}
2
Trouble (2) Hydraulic drift of swing is large (when swing holding brake is released).
• When swing holding brake release switch is in release position, swing holding brake is released and
Related
upper structure is secured by only hydraulic pressure.
information

Malfunction or defective seal Swing control valve spool may have malfunction or defective seal.
1
of swing control valve (spool) Check it directly.
Defective seal of swing con-
Seal of pressure compensation valve of swing control valve may be
defective. Check it directly.
Possible sation valve)
causes and Defective seal of swing Seal of safety valve of swing motor may be defective. Check it
3
standard value motor (safety valve) directly.
in normal state Defective seal of swing Seal of suction valve of swing motor may be defective. Check it
4
motor (suction valve) directly.
Defective seal of swing Seal of check valve of swing motor may be defective. Check it
5
motor (check valve) directly.
Defective seal of swing Seal of shockless valve of swing motor may be defective. Check it
6
motor (shockless valve) directly.
30 PC200, 220-8
H-29 Attachment circuit is not changed 1

Attachment installation specification
Trouble • Attachment circuit is not changed.
• When attachment installation specification is employed, service circuit is changed as follows
according to selected working mode.
Related
1) ATT mode: Service circuit is changed to double acting circuit and safety valve is set to low pressure.
information
2) B mode: Service circuit is changed to single acting circuit and safety valve is set to high pressure.
• Safety valve set pressure on only B port side is changed; that on A port side is kept low.

ATT return selector solenoid
Working mode
Malfunction of ATT return valve output pressure
Possible 1
selector solenoid valve 0 MPa
causes and ATT mode
{0 kg/cm2}
standard value
in normal state 2.9 MPa
B mode
{30 kg/cm2}
Malfunction of ATT return
2 ATT return selector valve may have malfunction. Check it directly.
selector valve
Malfunction of service Safety valve (B port side) of service control valve may have
3
control valve (safety valve) malfunction. Check it directly.
H-30 Oil flow in attachment circuit cannot be controlled 1

Attachment installation specification
Trouble • Oil flow in attachment circuit cannot be controlled.
• When attachment installation specification is employed, oil flow in service circuit changes according
Related to selected user mode.
information • Procedure for adjusting oil flow in ATT mode of working mode is different from that in B mode.
For details, see Operation and Maintenance Manual.

Possible
Malfunction of ATT flow ATT flow adjustment EPC valve may have malfunction. Check it
causes and 1
adjustment EPC valve directly.
standard value
in normal state Malfunction of service PPC
2 Service PPC valve may have malfunction. Check it directly.
valve
PC200, 220-8 31
SEN00245-00

© 2005 KOMATSU
All Rights Reserved
32
SEN00246-01
PC200-8
PC200LC-8
PC220-8
PC220LC-8

PC200-8 300001 and up
PC200LC-8 300001 and up
PC220-8 70001 and up
Troubleshooting of engine (S-mode)
Troubleshooting of engine (S-mode)............................................................................................................... 4
Method of using troubleshooting chart ................................................................................................. 4
S-1 Starting performance is poor ......................................................................................................... 8
S-2 Engine does not start..................................................................................................................... 9
S-3 Engine does not pick up smoothly............................................................................................... 12
S-4 Engine stops during operations ................................................................................................... 13
S-5 Engine does not rotate smoothly ................................................................................................. 14
S-6 Engine lack output (or lacks power) ............................................................................................ 15
S-7 Exhaust smoke is black (incomplete combustion)....................................................................... 16
S-8 Oil consumption is excessive (or exhaust smoke is blue) ........................................................... 17
S-9 Oil becomes contaminated quickly .............................................................................................. 18
S-10 Fuel consumption is excessive.................................................................................................. 19
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) ........................................ 20
S-12 Oil pressure drops ..................................................................................................................... 21
S-13 Oil level rises (Entry of coolant/fuel) .......................................................................................... 22
S-14 Coolant temperature becomes too high (overheating) .............................................................. 23
PC200, 220-8 1
S-15 Abnormal noise is made ............................................................................................................ 24

S-16 Vibration is excessive ................................................................................................................ 25
2 PC200, 220-8
Troubleshooting of engine (S-mode) 1

Method of using troubleshooting chart 1
The troubleshooting chart consists of the "questions", "check items", "causes", and "troubleshooting" blocks.
The questions and check items are used to pinpoint high probability causes by simple inspection or from
phenomena without using troubleshooting tools.
Next, troubleshooting tools or direct inspection are applied to check the narrowed causes in order from the
most probable one to make final confirmation according to the troubleshooting procedure.
Questions
Items to be drawn from the user or operator. They correspond to A and B in the chart on the right. The
items in A are basic ones. The items in B can be drawn from the user or operator, depending on their
level.
Check items
Simple check items used by the serviceman to narrow the causes. They correspond to C in the chart on
the right.
Causes
Items to be narrowed from the questions and check items. The serviceman narrows down the probable
causes from A, B, and C.
Troubleshooting
Items used to find out the true cause by verifying the narrowed causes finally in order from the most
probable one by applying troubleshooting tools or direct inspection.
Items listed in the [Questions] and [Check items] and related to the [Causes] are marked with E, Q, and w.
E : Causes to be referred to for questions and check items
Q : Causes related to questions and check items
w : Causes highly probable among ones marked with Q
a When narrowing the "causes", apply the items marked with w before those marked with Q.
When narrowing the causes, do not apply the items marked with E. (If no items have other marks and
the causes cannot be narrowed, however, you may apply them.)
4 PC200, 220-8
PC200, 220-8 5
<Example of troubleshooting> Exhaust gas is black

Let us assume that a trouble of "Exhaust gas is black" occurred and we checked the [Questions] and [Check
items] and found the following 3 items to be the causal symptoms; [Exhaust gas slowly became black],
[Power slowly became weaker], and [Dust indicator is lighting red].
6 PC200, 220-8
There is a causal relationship between 3 items in the [Questions] and [Check items] sections and 5 items in
the [Causes] section.
The method of pinpointing the "cause" from the causal relationship and approaching the "troubleshooting" is
explained according to Step 1 – Step 3 shown below.
PC200, 220-8 7
S-1 Starting performance is poor 1

General causes why starting performance is poor Causes
q Defective electrical system
Leaking or clogged fuel piping, entry of air

Clogged air breather hole of fuel tank cap
Insufficient supply of fuel
Defective alternator (generator section)

q
Defective alternator (regulator section)

Defective contact of valve, vale seat
q Insufficient intake of air
Stuck, seized supply pump plunger
Defective intake air heater system

q Improper selection of fuel
Defective, deteriorated battery

a The common rail fuel injection system (CRI) recognizes the
Clogged air cleaner element
Clogged fuel filter, element

fuel injection timing electrically. Accordingly, even if the
Worn piston ring, cylinder

starting operation is carried out, the engine may not start
until the crankshaft revolves 2 turns at maximum. This phe-
Defective injector
nomenon does not indicate a trouble, however.
Confirm recent repair history

Degree of use of machine Operated for long period E E E
Became worse gradually Q w w Q
Starting performance
Engine starts easily when warm w w
Questions
Non-specified fuel is being used Q Q Q

Replacement of filters has not been carried out according to Operation and Mainte- w w Q Q
nance Manual
Engine oil must be added more frequently w
When engine is preheated or when temperature is low, preheating monitor does not
w
indicate normally
During operation, charge level monitor indicates abnormal charge w w
Dust indicator is red w
Air breather hole of fuel tank cap is clogged w
Fuel is leaking from fuel piping w Q
When priming pump is operated, it makes no reaction or it is heavy w Q
Starting motor cranks engine slowly w
If air bleeding plug of fuel filter is removed, fuel does not w
While engine is cranked flow out
with starting motor
If spill hose from injector is disconnected, little fuel spills w
Check items
When exhaust manifold is touched immediately after starting engine, temperature of w

some cylinders is low
Engine does not pick up smoothly and combustion is irregular Q Q w
There is hunting from engine (rotation is irregular) Q w Q
Blow-by gas is excessive w
Inspect air cleaner directly q

When compression pressure is measured, it is found to be low q q
When air is bled from fuel system, air comes out q
Inspect fuel filter, strainer directly q
Troubleshooting
Carry out troubleshooting according to "Rail Press (Very) Low Error (*1)" indicated by
q
code
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not q
change
When starting switch is turned to HEAT, intake air heater mount does not become warm q
Is voltage 20 – 30 V between alternator terminal B and terminal E with Yes q
engine at low idle? No q
When specific gravity of electrolyte and voltage of battery are measured, they are low q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
correct
Adjust
Clean
Clean
Clean
Remedy
*1: Displayed failure codes [CA559] and [CA2249]
8 PC200, 220-8
S-2 Engine does not start 1

a) Engine does not turn Causes
General causes why engine does not turn
Defective connection of battery terminal
Defective starting motor (motor section)

q Internal parts of engine seized
o See "S-4 Engine stops during operations
Defective or deteriorated battery
Defective starting circuit wiring

q Defective electrical system
q Problem in drive devices on applicable machine side
Broken flywheel ring gear
Defective starting switch

o Carry out troubleshooting for devices on applicable machine
Defective battery relay
Defective safety relay

Questions
Degree of use of machine Operated for long period E E

Condition of horn when Horn does not sound Q Q w
starting switch is turned ON Horn volume is low w
Battery electrolyte is low w
Battery terminal is loose w
When starting switch is turned ON, there is no operating sound from battery relay Q w
When starting switch is turned to START, starting pinion does not move out Q Q w
Check items
Speed of rotation is low w

When starting switch is Makes grating noise w w
turned to START, starting
pinion moves out, but Soon disengages again w
Makes rattling noise and does not turn Q Q Q
Inspect flywheel ring gear directly q

q
Carry out troubleshooting on

When specific gravity of electrolyte and voltage of battery are measured, they are low
applicable machine side

There is not voltage (20 – 30 V) between battery relay terminal B and
terminal E q
Troubleshooting
When terminal B and terminal C of starting switch are connected,

engine starts q
Turn starting switch OFF,
When terminal B and terminal C at safety relay outlet are connected,
connect cord, and carry out q
troubleshooting at ON engine starts
Even if terminal B and terminal C at safety relay outlet are con- q
nected, engine does not start
When safety switch terminal and terminal B of starting motor are con-
q
nected, engine starts
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Remedy —
PC200, 220-8 9
b) Engine turns but no exhaust smoke comes out Causes

General causes why engine turns but no exhaust smoke comes
Defective operation of overflow valve (Does not close)

out
q Fuel is not being supplied
q Supply of fuel is extremely small

q Improper selection of fuel (particularly in winter)
Defective common rail pressure limiter

Seized, abnormally worn feed pump

Defective supply pump MPROP
Clogged fuel filter element
Broken supply pump shaft

Insufficient fuel in tank
Defective fuel injector

Use of improper fuel
Questions
Degree of use of machine Operated for long period E E

Exhaust smoke suddenly stopped coming out (when starting again) w Q w w E
Replacement of filters has not been carried out according to Operation and Mainte-
nance Manual w E Q
When fuel tank is inspected, it is found to be empty w

Air breather hole of fuel tank cap is clogged Q w
Rust and water are found when fuel tank is drained Q E E E
When fuel filter is removed, there is not fuel in it w w
w
Check items
Fuel is leaking from fuel piping

If air bleeding plug of fuel filter is removed, fuel does not
While engine is cranked Q Q w Q
flow out
with starting motor
If spill hose from injector is disconnected, little fuel spills Q w w w Q

Inspect fuel filter directly q
Inspect feed pump directly q
Troubleshooting
Carry out troubleshooting according to "Rail Press (Very) Low Error (*1)" indicated by
q q
code
Carry out troubleshooting according to "IMV/PCV1 Short (Open) Error (*2)" indicated by
q
code
Inspect overflow valve directly q
Engine can be started in reduced cylinder mode. q
If pressure limiter return pipe is disconnected, fuel flows out q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Remedy
Add

10 PC200, 220-8
c) Exhaust smoke comes but engine does not start (fuel is Causes
being injected)
Worn dynamic valve system (Valve, rocker lever, etc.)
Defective coolant temperature sensor, wiring harness

General causes why exhaust smoke comes out but engine does
not start
Leaking or clogged fuel system, entry of air

q Lack of rotating force due to defective electrical system

q Insufficient supply of fuel
Defective intake air heater system

Improper selection of fuel
Clogged injector, defective spray

q
Worn piston ring, cylinder liner
Defective, deteriorated battery

Use of improper fuel
Clogged fuel filter

Suddenly failed to start w w Q
Questions
Non-specified fuel is being used Q Q

Replacement of filters has not been carried out according to Operation and Mainte-
w w
nance Manual
When engine is preheated or when temperature is low, preheating monitor does not
w
indicate normally
Air breather hole of fuel tank cap is clogged Q
Rust and water are found when fuel tank is drained w
When fuel filter is removed, there is not fuel in it w
Fuel is leaking from fuel piping w
Starting motor cranks engine slowly w
When engine is cranked, abnormal sound is generated around cylinder head w
Check items
If air bleeding plug of fuel filter is removed, fuel does not

While engine is cranked Q w
flow out
with starting motor,
If spill hose from injector is disconnected, little fuel spills w
When exhaust manifold is touched immediately after starting engine, temperature of
w

Inspect dynamic valve system directly q
When compression pressure is measured, it is found to be low q
q
Troubleshooting
When air is bled from fuel system, air comes out

Inspect fuel filter directly q
Carry out troubleshooting according to "Rail Press (Very) Low Error (*1)" indicated by q
code
Engine can be started in reduced cylinder mode. q
When specific gravity of electrolyte and voltage of battery are measured, they are low q
Coolant temperature gauge does not indicate normally q
When starting switch is turned to HEAT, intake air heater mount does not become warm q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Remedy
PC200, 220-8 11
S-3 Engine does not pick up smoothly 1

General causes why engine does not pick up smoothly Causes
Seized turbocharger, interference of turbocharger

q Defective condition of fuel spray

Defective contact of valve and valve seat
q Controller is controlling in derate mode (limiting injection rate

(output) because of an error in electrical system)
Clogged injector, defective spray

Improper valve clearance
Clogged fuel filter

Degree of use of machine Operated for long period E E E E
Questions
Engine pick-up suddenly became worse w Q Q Q

Non-specified fuel is being used w w w
Replacement of filters has not been carried out according to Operation and Maintenance w w
Manual
Oil must be added more frequently w
When exhaust manifold is touched immediately after starting engine, temperature of some
Q w
cylinders is low
Blue under light load w
Color of exhaust gas
Check items
Black w Q w w
When engine is cranked, interference sound is generated around turbocharger w
High idle speed under no load is normal, but speed suddenly drops when load is applied Q w
There is hunting from engine (rotation is irregular) Q Q Q

Troubleshooting
Inspect valve clearance directly q

When turbocharger is rotated by hand, it is found to be heavy q
Carry out troubleshooting according to "Rail Press (Very) Low Error (*1)" indicated by code q
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change q
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Clean
Clean
Clean
Remedy
12 PC200, 220-8
S-4 Engine stops during operations 1

General causes why engine stops during operations Causes
Seized parts inside engine
Broken dynamic valve system (valve, rocker arm, etc.)

q
Broken auxiliary equipment (pump, compressor, etc.)
Problem in drive devices on applicable machine side

q There is overheating
q Problem in drive devices on applicable machine side
o Carry out troubleshooting for devices on applicable

machine
Broken, seized piston, connecting rod

Broken, seized crankshaft bearing
Leaking, clogged fuel piping
Broken, seized feed pump

Broken supply pump shaft
Broken, seized gear train
Clogged fuel filter

Degree of use of machine Operated for long period E
Abnormal noise was heard and engine stopped w w w w Q w Q w w
suddenly
Condition when engine w Q Q
Questions
Engine overheated and stopped

stopped
Engine stopped slowly w Q
There was hunting and engine stopped w Q Q Q
Replacement of filters has not been carried out according to Operation and
Maintenance Manual w
Fuel level monitor indicates low level (if monitor is installed) w

Metal particles are found when oil is drained w w w Q
Check items
Does not turn at all w w

When engine is cranked Turns in opposite direction w
by hand Moves by amount of gear backlash w w
Supply pump shaft does not turn w
Engine turns, but stops when load is applied to machine w

q
Carry out troubleshooting
Inspect piston, connecting rod directly

on applicable machine
Inspect crankshaft bearing directly q

Troubleshooting
Inspect gear train directly q

Inspect feed pump directly q
Carry out troubleshooting according to "Rail Press (Very) Low Error (*1)"
q q
indicated by code
Engine rotates when pump auxiliary equipment (pump, compressor, etc.) is
q
removed
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Remedy —
Add
PC200, 220-8 13
S-5 Engine does not rotate smoothly 1

General causes why engine does not rotate smoothly Causes
q Air in fuel system
Clogged injector, defective spray (dirt in injector)

Defective speed sensor (Error at degree that it is not indicated)
Defective Bkup speed sensor, wiring harness

q
Defective Ne speed sensor, wiring harness

Clogged fuel filter

Q Q
Questions
Occurs at a certain speed range

Occurs at low idle Q Q Q Q Q
Condition of hunting
Occurs even when speed is raised Q Q Q
Occurs on slopes w
Replacement of filters has not been carried out according to Operation and Maintenance Manual w
Check items
Rust and water are found when fuel tank is drained Q


Troubleshooting

Carry out troubleshooting according to "Eng Ne Speed Sensor Error (*1)" indicated by code q
Carry out troubleshooting according to "Eng Bkup Speed Sensor Error (*2)" indicated by code q
Replace
Replace
Replace
Replace
Replace
Clean
Remedy
Add
*1: Displayed failure codes [CA689]

*2: Displayed failure code [CA778]
14 PC200, 220-8
S-6 Engine lack output (or lacks power) 1

General causes why engine lacks output Causes
Insufficient intake of air

q
Defective boost pressure sensor, wiring harness

Clogged injector, defective spray (dirt in injector)
Insufficient supply of fuel
Defective installation of boost pressure sensor

q
Defective drive of injector (signal, solenoid)

q Defective spray condition of fuel

There is overheating

q
Air leakage from air intake piping

o See "S-14 Coolant temperature becomes too

high (Overheating)".
Leaking, clogged fuel piping

q Controller is controlling in derate mode (limiting
injection rate (output) because of an error in
Clogged spill piping

electrical system)
Clogged fuel filter
(air leakage)
Suddenly Q w Q Q Q Q
Questions
Power was lost

Gradually Q Q Q Q Q Q
Replacement of filters has not been carried out according to Operation w w
and Maintenance Manual
Engine oil must be added more frequently Q Q
Dust indicator is red w w
Air breather hole of fuel tank cap is clogged w w
Output becomes insufficient after short stop of operation w
Black w w
When exhaust manifold is touched immediately after starting engine, w w
temperature of some cylinders is low
When engine is cranked, interference sound is generated around w
Check items
turbocharger
High idle speed is too high Q
High idle speed under no load is normal, but speed suddenly drops when
Q w Q Q
load is applied
Engine does not pick up smoothly and combustion is irregular w w Q Q w
There is hunting from engine (rotation is irregular) Q Q Q Q Q
Blow-by gas is excessive w w

Inspect air intake piping directly q
When boost pressure is measured, it is found to be low q q q
Troubleshooting
Inspect fuel piping q

Inspect spill port check valve directly q
Carry out troubleshooting according to "Rail Press (Very) Low Error (*1)"
q
indicated by code
When a cylinder is cut out for reduced cylinder mode operation, engine
speed does not change q q
Inspect boost pressure sensor mount directly q
Carry out troubleshooting according to "Chg Air Press Sensor High (Low)
Error (*2)" indicated by code q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Adjust
Clean
Clean
Remedy

PC200, 220-8 15
S-7 Exhaust smoke is black (incomplete combustion) 1

General causes why exhaust smoke is black Causes
Insufficient intake of air
Leakage of air between turbocharger and cylinder head

q

q Defective condition of fuel injection

q There is overheating
o See "S-14 Coolant temperature becomes too high

(Overheating)".
q Controller is controlling in derate mode (limiting injection

rate (output) because of an error in electrical system)
Improper fuel injection pressure

Improper fuel injection timing

Crushed, clogged muffler
Abnormally worn injector

Clogged, seized injector
Suddenly became black w w Q Q Q
Questions
Color of exhaust gas Gradually became black w Q Q

Suddenly w Q Q Q
Power was lost
Gradually Q Q Q Q
Muffler is crushed w
Air leaks between turbocharger and cylinder head, clamp is loosened w
Engine is operated in low-temperature mode at normal temperature Q Q Q
When exhaust manifold is touched immediately after starting engine, temperature of
some cylinders is low Q w
Check items

Pump relief speed is high (Fuel is injected excessively) Q
Exhaust noise is abnormal Q w Q
Engine does not pick up smoothly and combustion is irregular Q Q Q Q Q w
If spill hose from injector is disconnected, abnormally much fuel spills w

When turbocharger is rotated by hand, it is found to be heavy q
Troubleshooting
When muffler is removed, exhaust sound improves q

Carry out troubleshooting according to "Rail Press (Very) Low Error (*1)" indicated
q q
by code
When a cylinder is cut out for reduced cylinder mode operation, engine speed does q
not change
Carry out troubleshooting according to "Coolant Temp Sens High (Low) Error (*2)"
q
indicated by code
Check with monitoring function q q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Adjust
Clean
Remedy

16 PC200, 220-8
S-8 Oil consumption is excessive (or exhaust smoke is blue) 1

General causes why oil consumption is excessive Causes
q Abnormal consumption of oil
Turbocharger
Oil leakage from oil pan, cylinder head, etc.

q Long-time operation of engine at low idle or high idle
Worn, damaged valve (stem, guide, seal)

(Do not run engine at idle for more than 20 minutes
continuously)
Dust sucked in from intake system
Clogged breather, breather hose

q External leakage of oil
Worn seal at turbocharger end
Oil leakage from oil drain plug

Wear of pats in lubrication system
Worn, damaged rear oil seal

q
Oil leakage from oil cooler
Oil leakage from oil piping

Worn seal at blower end
Oil leakage from oil filter

Broken piston ring
Broken oil cooler

E E E E
Questions
Degree of use of machine Operated for long period

Oil consumption suddenly increased w Q
Oil must be added more frequently w Q
Oil becomes contaminated quickly Q Q w
Outside of engine is dirty with oil w w w w w
There are loose piping clamps in intake system w
Inside of turbocharger intake outlet pipe is dirty with oil w
Inside of turbocharger exhaust outlet pipe is dirty with oil Q w
Check items
There is oil in coolant w

Oil level in damper chamber of applicable machine is high w
Exhaust smoke is blue under light load w w
Excessive Q Q w w
Amount of blow-by gas
None w
When intake manifold is removed, dust is found inside q

When intake manifold is removed, inside is found to be dirty abnormally q
Troubleshooting
Excessive play of turbocharger shaft q q

Check breather and breather hose directly q
Inspect rear oil seal directly q
Pressure-tightness test of oil cooler shows there is leakage q q
There is external leakage of oil from engine q q q q
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Correct
Correct
Clean
Remedy
PC200, 220-8 17
S-9 Oil becomes contaminated quickly 1

General causes why oil becomes contaminated quickly Causes
q Entry of exhaust gas into oil due to internal wear
Clogged turbocharger lubrication drain tube

Defective seal at turbocharger turbine end
q Clogging of lubrication passage
q Use of improper fuel
q Use of improper oil
Clogged breather, breather hose

Operation under excessive load

q
Defective oil filter safety valve

Worn valve, valve guide
Exhaust smoke is bad

Clogged oil cooler
Clogged oil filter
Questions

Metal particles are found when oil is drained Q Q w
Inside of exhaust pipe is dirty with oil w
Engine oil temperature rises quickly w
Check items
Color of exhaust gas color

Black w
Excessive Q Q w Q
Amount of blow-by gas
None w
Excessive play of turbocharger shaft q

Troubleshooting
Check breather and breather hose directly q
See S-7
Inspect oil cooler directly q
Inspect oil filter directly q
Spring of oil filter safety valve is hitched or broken q
Inspect turbocharger lubrication drain tube directly q
Replace
Replace
Replace
Replace
Replace
Clean
Clean
Clean
Remedy —
18 PC200, 220-8
S-10 Fuel consumption is excessive 1

General causes why fuel consumption is excessive Causes
q Leakage of fuel

q Defective condition of fuel injection (fuel pressure, injection timing)
q Excessive injection of fuel
Fuel leakage from fuel filter, piping, etc.
Defective common rail pressure

Fuel leakage inside head cover
Defective supply pump plunger
Defective operation of injector

Improper fuel injection timing
Defective feed pump oil seal
Defective spray by injector

E E E
Questions

More than for other machines of same model Q Q Q Q
Condition of fuel
consumption Gradually increased Q Q
Suddenly increased Q Q
There is external leakage of fuel from engine w
Combustion is irregular w
Engine oil level rises and oil smells of diesel fuel w w
When exhaust manifold is touched immediately after starting engine, temperature of some w
cylinders is low
Check items
Low idle speed is high Q

Pump relief speed is high Q
Black Q Q Q Q
Exhaust smoke color
White Q
Remove and inspect head cover directly q

Inspect feed pump oil seal directly q
Troubleshooting
Carry out troubleshooting according to "Rail Press (Very) Low Error (*1)" indicated by code q
If spill hose from injector is disconnected, much fuel spills q
Carry out troubleshooting according to "Coolant Temp Sens High (Low) Error (*2)" indicated by
code q
Check with monitoring function q q

Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy

PC200, 220-8 19
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)
General causes why oil is in coolant Causes
q Internal leakage in lubrication system
Broken hydraulic oil cooler on applicable machine side

q Internal leakage in cooling system
Broken cylinder head, head gasket

Internal cracks in cylinder block
Broken oil cooler core, O-ring

Holes caused by pitting
E E
Questions

Suddenly increased Q Q Q
Oil level
Gradually increased Q Q
Hard water is being used as coolant Q Q
Oil level has risen, oil is milky Q Q w
There are excessive air bubbles in radiator, coolant spurts back w
Check items
Hydraulic oil on applicable machine side is milky w
When hydraulic oil on applicable machine side is drained, water is found w
Pressure-tightness test of cylinder head shows there is leakage q Carry out

shooting
Trouble-
Inspect cylinder block, liner directly q q troubleshooting

on applicable
Pressure-tightness test of oil cooler shows there is leakage q machine side
Replace
Replace
Replace
Replace
Remedy —
20 PC200, 220-8
S-12 Oil pressure drops 1

General causes why oil pressure drops Causes
q Leakage, clogging, wear of lubrication system
Leaking, crushed, clogged hydraulic piping

Defective oil level sensor, wiring harness
q Defective oil pressure control
q Improper selection of fuel (improper viscosity)
q Deterioration of oil due to overheating
Clogged, broken pipe in oil pan

Clogged strainer in oil pan
Defective regulator valve

Worn journal of bearing
Lack of oil in oil pan
Defective oil pump

Coolant, fuel in oil
Clogged oil filter

Questions
Oil pressure monitor indicates low oil pressure Q w

Non-specified oil is being used Q Q
Replacement of filters has not been carried out according to Operation and Maintenance
w
Manual
Indicates pressure drop at low idle w
Oil pressure monitor Indicates pressure drop at low, high idle Q w w w Q
(if installed) Indicates pressure drop on slopes w
Sometimes indicates pressure drop w Q
Oil level monitor indicates oil level drop w w
Oil level in oil pan is low w
External hydraulic piping is leaking, crushed w
Check items
Oil is milky or smells of diesel oil w

Metal particles are found when oil pan is drained w
Metal particles are found when oil filter is drained w Q
Metal particles are found in oil filter q

Troubleshooting
Inspect oil pan strainer, pipe directly q q

See S-13
Oil pump rotation is heavy, there is play in oil pump q

Valve spring of regulator valve is fatigued, damaged q
Inspect oil filter directly q
If oil level sensor is replaced, oil pressure monitor indicates normally q
Replace
Replace
Correct
Adjust
Clean
Clean
Clean
Clean
Remedy —
Add
PC200, 220-8 21
S-13 Oil level rises (Entry of coolant/fuel) 1

General causes why oil level rises Causes
Coolant in oil (milky)
Defective seal of auxiliary equipment (pump, compressor)

q
q Fuel in oil (smells diluted diesel fuel)
a If oil is in coolant, carry out troubleshooting for "S-11 Oil is in coolant"
Broken oil cooler core, O-ring

Worn, damaged rear oil seal
Cracks inside cylinder block
Defects in supply pump

Broken injector O-ring
Questions

Fuel must be added more frequently w w
Coolant must be added more frequently Q Q
There is oil in coolant Q Q Q Q w
Oil smells of diesel fuel w w
Oil is milky Q Q
When engine is started, drops of water come from muffler Q
When radiator cap is removed and engine is run at low idle, an abnormal number of bubbles appear, w Q
Check items
or coolant spurts back

Exhaust smoke is white Q
Oil level in damper chamber of applicable machine is low w
Oil level in hydraulic tank of applicable machine is low w

Remove injector and inspect O-ring q
Troubleshooting
Inspect cylinder block, liner directly q q

Inspect rear oil seal directly q
Pressure-tightness test of oil cooler shows there is leakage q
Remove and inspect supply pump directly q
Inspect seal of auxiliary equipment directly q
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Remedy
22 PC200, 220-8
S-14 Coolant temperature becomes too high (overheating) 1

General causes why coolant temperature becomes too high Causes
q Lack of cooling air (deformation, damage of fan)
Rise of hydraulic oil temperature on applicable machine side

q Drop in heat dissipation efficiency
q Problem in coolant circulation system
q Rise in hydraulic oil temperature
o Carry out troubleshooting for machine
Defective radiator cap (pressure valve)
Defective coolant temperature gauge

Defective operation of thermostat
Slipping fan belt, worn fan pulley

Clogged, crushed radiator fins
Clogged, broken oil cooler
Clogged radiator core

Broken water pump
Lack of coolant
Questions
Sudden overheated Q w Q
Condition of overheating
Always tends to overheat Q w w Q
Coolant temperature Rises quickly Q w
gauge (if installed) Does not go down from red range w
Radiator coolant level monitor indicates drop of coolant level (if monitor is installed) w
Engine oil level has risen and oil is milky w Q
Fan belt tension is low w
When fan belt is turned, it has play w
Milky oil is floating on coolant w
There are excessive air bubbles in radiator, coolant spurts back w
w
Check items
When light bulb is held behind radiator core, no light passes through
Radiator shroud, inside of underguard on applicable machine side are clogged with
w w
dirt or mud
Coolant is leaking because of cracks in hose or loose clamps w
Coolant flows out from radiator overflow hose w
Fan belt whines under sudden acceleration w
Hydraulic oil temperature enters red range faster than engine coolant temperature w

Inspect cylinder liner directly q
on applicable machine side
Carry out troubleshooting
Inspect oil cooler directly q

q
Troubleshooting
Temperature difference between upper and lower tanks of radiator is large

When operation of thermostat is carried out, it does not open at cracking
temperature q
Temperature difference between upper and lower tanks of radiator is slight q

Inspect radiator core directly q
When operation of radiator cap is carried out, its cracking pressure is low q
Inspect fan belt, pulley directly q
When coolant temperature is measured, it is fount to be normal q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy —
Add
PC200, 220-8 23
S-15 Abnormal noise is made 1

General causes why abnormal noise is made Causes
Abnormality due to defective parts
Deformed cooling fan, loose fan belt, interference of fan belt

q
Abnormal combustion
Defective inside of muffler (dividing board out of position)

q
Leakage of air between turbocharger and cylinder head

q Air sucked in from intake system
Improper fuel injection timing (abnormality in coolant

low temperature sensor, boost temperature sensor)
a Judge if the noise is an internal noise or an external
Broken dynamic valve system (valve, rocker lever)

Interference of turbocharger, seized turbocharger
noise before starting troubleshooting.
a The engine is operated in the low-temperature mode
Excessive wear of piston ring, cylinder liner

while it is not warmed up sufficiently. Accordingly, the
engine sound becomes a little larger. This does not indi-
cate abnormality, however.
a When the engine is accelerated, it is operated in the
Improper gear train backlash

acceleration mode and its sound becomes a little larger
Removed, seized bushing

Clogged, seized injector

for up to about 3 seconds. This does not indicate abnor-
Dirt caught in injector

mality, however.

Questions
Condition of abnormal Gradually occurred Q Q

noise Sudden occurred Q Q Q
Non-specified fuel is being used Q
Metal particles are found when oil filter is drained w w
Air leaks between turbocharger and cylinder head w
When engine is cranked, abnormal sound is generated around cylinder head w w
When engine is cranked, beat noise is generated around muffler w
Check items
When exhaust manifold is touched immediately after starting engine, temperature of w Q

Black Q w Q
Engine does not pick up smoothly and combustion is irregular w
Abnormal noise is loud when engine is accelerated Q Q Q Q
When turbocharger is rotated by hand, it is fount to be heavy q

When muffler is removed, abnormal noise disappears q
q
Troubleshooting
Inspect valve clearance directly

Inspect gear train directly q q
Inspect fan and fan belt directly q
When a cylinder is cut out for reduced cylinder mode operation, engine speed does
q q
not change
Abnormal noise is heard only when engine is started q
Confirm with INSITE or monitoring function on applicable machine side q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Remedy
24 PC200, 220-8
S-16 Vibration is excessive 1

General causes why vibration is excessive Causes
Defective parts (abnormal wear, breakage)
Improper injection timing (Abnormality in coolant temperature sensor, boost temperature sensor)
q
q Misalignment between engine and chassis
q Abnormal combustion
a If abnormal noise is made and vibration is excessive, carry out trouble-
shooting for "S-15 Abnormal noise is made", too.
Misalignment between engine and devices on applicable machine side

Broken output shaft, parts in damper on applicable machine side
Stuck dynamic valve system (valve, rocker lever)
Loose engine mounting bolts, broken cushions

Worn main bearing, connecting rod bearing
Improper gear train backlash
Worn camshaft bushing
E E E
Questions

Suddenly increased Q Q
Condition of vibration
Gradually increased Q Q Q
Non-specified oil is being used Q Q
Metal particles are found when oil filter is drained w w
Metal particles are found when oil pan is drained w w
Oil pressure is low at low idle Q Q
Check items
Vibration occurs at mid-range speed Q Q

Vibration follows engine speed Q Q Q Q
Exhaust smoke is black w Q

Inspect main bearing and connecting rod bearing directly q
Troubleshooting
Inspect gear train directly q

Inspect camshaft bushing directly q
Check with monitoring function q
Inspect engine mounting bolts and cushions directly q
When alignment is checked, radial runout or facial runout is detected q
Inspect inside of damper directly q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Adjust
Remedy
PC200, 220-8 25
SEN00113-02
PC200-8
PC200LC-8
PC220-8
PC220LC-8

PC200-8 300001 and up
PC200LC-8 300001 and up
PC220-8 70001 and up
90 Diagrams and drawings 1

Electrical diagrams and drawings
Electrical diagrams and drawings ................................................................................................................... 3
Electrical diagrams and drawings ........................................................................................................ 3
Connector arrangement diagram ......................................................................................................... 5
Electrical circuit diagram for air conditioner ......................................................................................... 7
PC200, 220-8 1
Electrical circuit diagram
Electrical diagrams and drawings PC200, 200LC-8, PC220, 220LC-8 1
Electrical circuit diagram PC200, 200LC-8, PC220, 220LC-8 1
SEN00113-03
PC200, 220-8 3
Connector arrangement diagram
PC200, 200LC-8, PC220, 220LC-8
Connector arrangement diagram PC200, 200LC-8, PC220, 220LC-8
Number Address of Number Address of

Connector No. Model Component name Connector No. Model Component name
of pins stereogram of pins stereogram
A08 SWP 12 Intermediate connector V-1 P04 AMP 3 Arm curl PPC pressure sensor N-6
A13 DT 2 Intermediate connector I-1 P05 AMP 3 Bucket dump PPC pressure sensor N-5
A15 DT 2 Intermediate connector L-9 P06 AMP 3 Boom raise PPC pressure sensor N-5
AB Terminal 2 Alternator (Terminal B) AK-9 P07 AMP 3 Swing right PPC pressure sensor N-6
AC01 8 Air conditioner unit Y-3 P08 X 2 Arm dump PPC pressure switch N-3
AC02 X 1 Air conditioner compressor electromagnetic clutch AJ-4 P09 X 2 Travel PPC pressure switch S-1
AMBAIR PRESSURE 3 Ambient pressure sensor AJ-2 P10 X 2 Travel steering PPC pressure switch S-1
BOOST PRESS & IMT 3 Boost pressure/temperature sensor AK-5 P13 X 2 Intermediate connector Q-2
C01 AMP 81 Pump controller U-8 Attachment pedal front PPC pressure switch
P14 X 2 R-2
[Attachment specification]
C02 AMP 40 Pump controller U-8
Attachment pedal rear PPC pressure switch
P15 X 2 R-1
CAM SENSOR 3 Engine Bkup speed sensor AJ-1 [Attachment specification]
CE01 DRC 60 Engine controller AK-1 Attachment pedal front PPC pressure switch
P16 X 2
CE02 DRC 50 Engine controller AJ-1
P17 2 Air conditioner high/low pressure switch V-1
CE03 DTP 4 Engine controller AK-1
P20 M 3 Fuel control dial R-7
CK01 AMP 14 KOMTRAX communication module Z-7
P21 X 1 Fuel level sensor G-9
CK02 AMP 10 KOMTRAX communication module AA-7
P22 D 2 Hydraulic oil temperature sensor AN-2
CM01 070 18 Machine monitor P-5
P23 D 2 Air cleaner clogging switch N-3
P24 X 2 Radiator coolant level switch AB-6
P25 AMP 3 F pump pressure sensor K-9
CM04 070 12 Machine monitor (Unconnected) P-4
P26 AMP 3 R pump pressure sensor K-9
CM05 070 8 Machine monitor (For connection of camera) Q-6
Attachment pedal rear PPC pressure switch
CM06 070 4 Machine monitor (GPS antenna) P-2 P30 X 2
COOLANT TEMP 2 Engine coolant temperature sensor AJ-3 P31 2 Air conditioner daylight sensor P-5
CRANK SENSOR 3 Engine Ne speed sensor AJ-1 P44 D 2 Engine oil level sensor AL-8
D01 SWP 8 Assembled-type diode O-8 P47 DT 2 Water-in-fuel sensor AN-4
D02 SWP 8 Assembled-type diode O-8 R01 Terminal 1 Battery relay (Terminal E) C-8
D03 SWP 8 Assembled-type diode P-9 R02 Terminal 1 Battery relay (Terminal BR) C-8
D10 2 Diode X-8 R03 Terminal 1 Battery relay (Terminal M) A-9
D11 2 Diode Y-8 R04 Terminal 1 Battery relay (Terminal B) C-9
E01 Terminal 1 Electrical intake air heater AK-5 R05 Relay 5 Light relay U-9
E06 DT 2 Intermediate connector AL-1 R06 Relay 5 Starting motor cutout relay (PPC lock) P-9
E08 X 1 Intermediate connector AK-9 R07 Relay 5 Starting motor cutout relay (Personal code) P-9
E10 D 1 Intermediate connector AI-6 R08 Relay 5 Horn relay W-9
E12 2 Alternator (Terminals IG and L) AL-9 R10 Relay 5 Rear light relay [Rear light specification] U-9
F01 — — Fuse box V-9 R12 Relay 5 Cab light relay [Cab light specification] U-9
F04 L 2 Fusible link (65A) C-9 R15 Terminal 1 Electrical intake air heater relay (Coil circuit) A-8
F05 M 2 Fusible link (30A) C-8 R16 Terminal 1 Electrical intake air heater relay (Contact circuit) B-8
FUEL RAIL PRESS 3 Common rail pressure sensor AM-5 R17 X 2 Starting motor safety relay (Terminals S and R) B-7
FUEL REGULATOR Supply pump solenoid (IMV) AN-2 R18 Relay 5 Automatic preheater relay X-9
H08 M 4 Intermediate connector Z-3 R28 Terminal 1 Starting motor safety relay (Terminal C) B-9
H09 M 8 Intermediate connector AA-4 R20 Relay 5 Air conditioner blower relay T-8
H15 090 22 Intermediate connector V-1 R21 Relay 5 Air conditioner compressor relay T-8
H16 S 12 Intermediate connector Z-3 R23 Relay 5 Engine controller relay (1) W-9
INJ CYL 1 DT 2 Injector #1 AJ-4 R24 Relay 5 Engine controller relay (2) W-9
INJ CYL 2 DT 2 Injector #2 AJ-4 S02 SWP 6 Light switch S-7
INJ CYL 3 DT 2 Injector #3 AK-5 S04 SWP 6 Swing lock switch S-7
INJ CYL 4 DT 2 Injector #4 AK-5 S07 SWP 6 Rotary lamp switch [Rotary lamp specification] S-7
INJ CYL 5 DT 2 Injector #5 AL-5 S10 090 2 Right knob switch R-6
INJ CYL 6 DT 2 Injector #6 AL-6 S11 2 Left knob switch W-1
J01 20 Junction connector (Black) AA-7 S14 M 3 PPC oil pressure lock switch W-1
J02 20 Junction connector (Black) Y-3 S21 — 12 Emergency pump drive switch P-9
J03 20 Junction connector (Green) Y-2 S22 — 6 Swing holding brake release switch P-9
J04 20 Junction connector (Green) Z-7 S25 090 8 Intermediate connector Q-8
J05 20 Junction connector (Pink) Y-8 S30 S 8 Model selection connector T-8
J06 20 Junction connector (Orange) Y-8 SB Terminal 2 Starting motor (Terminal B) AI-7
K01 M 2 Pump (PC) resistor P-6 SC Terminal 1 Starting motor (Terminal C) AI-7
K02 DT 3 CAN terminal resistance AL-1 T01 Terminal 2 Floor frame ground Y-3
L01 DT 2 Working lamp (Boom) F-8 T02 Terminal 1 Cab ground AH-3
L02 DT 2 Right headlamp F-8 T03 1 Intermediate connector X-2
L03 2 Room lamp AE-8 T03A Terminal 1 Radio body ground X-2
L05 2 Intermediate connector [Rotary lamp specification] AF-9 T04 Terminal 1 Revolving frame ground J-1, V-1
L09 DT 2 Rear working lamp [Rear working lamp specification] T05 Terminal 1 Revolving frame ground K-1
L15 2 Rotary lamp [Rotary lamp specification] AG-9 T06 Terminal 1 Revolving frame ground K-1
M01 PA 9 Radio W-2 T07 Terminal 1 Revolving frame ground K-1
M02 2 Speaker (Left) AH-8 T08 Terminal 1 Revolving frame ground B-7
M03 2 Speaker (Right) AG-9 T09 Terminal 1 Revolving frame ground L-1
M04 2 Cigarette lighter R-6 T10 Terminal 1 Revolving frame ground L-2
M05 M 6 Wiper motor P-3, AC-5 T12 Terminal 1 Engine cylinder block ground AL-1
M06 KES0 2 Window washer motor M-3, AB-6 TOOL PORT Communication connector AJ-2
M07 090 2 Horn (High tone) H-1 V01 D 2 PPC lock solenoid valve M-2
M08 090 2 Horn (Low tone) G-1 V02 D 2 2-stage relief solenoid valve H-8
M09 M 2 Optional power supply connector (1) Z-4 V03 D 2 Swing holding brake solenoid valve M-2
M10 M 2 Optional power supply connector (2) AB-4 V04 D 2 Travel speed shifting solenoid valve I-8
M11 M 4 DC/DC converter AB-5 V05 D 2 Travel junction solenoid valve M-2
M12 M 2 Optional power supply connector (12 V) AA-4 Attachment return selector solenoid valve
V06 D 2 I-9
M13 M 2 12V outlet AB-5 [Attachment specification]
M14 D 2 Travel alarm L-2 V11 D 2 F-PC-EPC valve AN-4
M40 2 Headlamp [Headlamp specification] AD-8 V12 D 2 R-PC-EPC valve AN-2
M41 2 Headlamp [Headlamp specification] AC-7 V19 D 2 LS-EPC valve AN-5
N08 D 12 Service connector V-9 V23 D 2 Merge-divider EPC valve (Main) I-9
N10 4 Air conditioner unit T-7 V24 D 2 Merge-divider EPC valve (LS) J-9
OIL PRESSURE SWITCH Terminal Engine oil pressure switch (Low pressure) AM-1 Attachment flow regulator EPC valve [Attachment
V30 DT 2 Q-2
specification]
P01 AMP 3 Bucket curl PPC pressure sensor N-7
W03 M 2 Window rear limit switch AG-9
P02 X 2 Boom lower PPC pressure switch N-7
P03 AMP 3 Swing left PPC pressure sensor N-4
SEN00113-03
PC200, 220-8
5
Electrical circuit diagram for air conditioner
Electrical circuit diagram for air conditioner PC200, 200LC-8, PC220, 220LC-8 1 PC200, 200LC-8, PC220, 220LC-8
SEN00113-02
PC200, 220-8 7

Tra Cuu Nhanh L I PC 200-8

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Fuel control dial

Coolant temperature sensor

Oil pressure switch

Boost pressure and temperature sensor

WIF (water-in-fuel detection) sensor

Engine oil level sensor

9. System component parts

2) Oil pressure sensor

q The relationship between the pressure applied

3) Pump pressure sensor

Input and output signals CN-CM03

Failure codes table

User Alarm Component Category of

User Alarm Component Category of

User Alarm Component Category of

a Entry order of items in table

3. Color codes table

4. Types of circuits and color codes

Connection table for connector pin numbers (Rev. 2007.4)

HYDRAULIC EXCAVATOR 1SHOP MANUAL

Machine model Serial number

Failure code [CA111] EMC Critical Internal Failure ............................................................................ 20

Troubleshooting by failure code (Display of code), Part 1 1

User Alarm Device in Category

User Alarm Device in Category

User Alarm Device in Category

User Alarm Device in Category

a Entry order of items in table

Before carrying out troubleshooting when failure code is displayed 1

Locations of fusible links

Location of fuse box and fuse Nos.

Troubles that occur when power supply of pump controller is defective

Troubles that occur when power supply of pump controller is defective

a Power supply connectors (C01, C02) of pump controller

Information in troubleshooting table 1

Cause Standard value in normal state/Remarks on troubleshooting

Related circuit diagram

This drawing is a part of the electric circuit diagram related

Failure code [989L00] Engine Controller Lock Caution 1 1

Possible causes Cause Standard value in normal state/Remarks on troubleshooting

Failure code [989M00] Engine Controller Lock Caution 2 1

Cause Standard value in normal state/Remarks on troubleshooting

Failure code [989N00] Engine Controller Lock Caution 3 1

Possible causes Cause Standard value in normal state/Remarks on troubleshooting

Failure code [AA10NX] Air Cleaner Clogging 1

Cause Standard value in normal state/Remarks on troubleshooting

Failure code [AB00KE] Charge Voltage Low 1

Cause Standard value in normal state/Remarks on troubleshooting

Circuit diagram related to preheating/starting of engine and charge of battery

Failure code [B@BAZG] Eng Oil Press. Low 1

Cause Standard value in normal state/Remarks on troubleshooting

Failure code [B@BAZK] Eng Oil Level Low 1

Cause Standard value in normal state/Remarks on troubleshooting

Failure code [B@BCNS] Eng Water Overheat 1

Cause Standard value in normal state/Remarks on troubleshooting

Failure code [B@BCZK] Eng Water Level Low 1

Cause Standard value in normal state/Remarks on troubleshooting

Failure code [B@HANS] Hydr Oil Overheat 1

Cause Standard value in normal state/Remarks on troubleshooting

Failure code [CA111] EMC Critical Internal Failure 1

Possible causes Cause Standard value in normal state/Remarks on troubleshooting

Failure code [CA115] Eng Ne and Bkup Speed Sens Error 1